•
NO. 72
NOTES FRONt THE SHOP
•
Plus: Ips For Your Radial Arm Saw
$3.95
No. 72
EDITOR'S
December, 1990
COLUMN
•
Sawdust H
do you gd R pit..·., 01 w,.,d 10 bend in a g(·ntW.grru.'t:(uJ.,I1Ve? It's a task thaI doesn't seem natural. Yet lt's a 101easier than it looks - and a whole 101mc.sit·r.tu<,. One or 11,,, mO$1 popular projects 1l,.1 involves bent wood is a hall tree [or hats and coats, The I'.,.e.1 tlung about • hall I".., (., least (rom a woodworker', puinl of view) i. thai it'sa progressivetessoa in how to make bent wood laminations. The legs are 3 simple L.·bend The Coal hoo~'S gel a linlc more complicated .. ith Sbends. Then to hold the Shooks 10the posr, you have 10 make a complete cirrle, a ring. And 10 mal", the ring a liule more of a challenge. it's round in cross-seetion (3 rf'fl shaped piece fonning a ring). The basic process for making bent laou nations is
Iid,t.,.. Donald B. I'... ·hk. Dt-!O&D 1)"",'1... Ted ktalicek M:tIIllIdllKlidilM Ooull)ll.< I-Ili""" A<
RkMr
I'."""
Cordoo GrupP<' 1'ro)o,'<'I[)egjj!ll'" I",,, \tunkcl mW.trabH D3\id Kr<~1inlt
Cary <''bris(enscn RodSlookes 1..1,';H GIQ\\1K'ki Dirk \ vIf St~ e('g 'Il\:ulation Oirodor Uz Brcd, .... o
G"'I,h&-. n.... "lor Jon Snyd.r 1"',*,~SuppliL.,. t.e..lit.\no Ck'!U'burt CUSlulll"rSmic:e~Ij,'T Undn M(II'I'()W' CUStOrtltr
Sevio,
l..lad. ...JQnCtf
lWlly 801dford
&all Mod", G""'1Uc 8"",,,,," Vicki
Ed"lU'd.,
MR.: ~tI1itb J'"f1nfe E~
JIm; ee lWtlwvc Joolyn l'ro$$
J 01'1)' """dni Robo,rto Rutoh Co"""l1... Pa,,1£. GI'I'l)' &i>kk~ UndnO·l!ourl<. jl;ero'OrkAdminis1taIQr Oo,.gt:\.q M. );dsmr .~mini>on'a~A.""1SCh~1')·I.;\';"_
Sanily&um Sourt",book J.anMy"", I\ml,\. BudrtOl' SMp !'.!>nag"r SI""" Cuni.. lluiJding ~Iainldl""'", """ Grilli'"
A",-me Krn....•
SI'"'' Manage..,;: 8«1(\'1<),. (.A
P<:>M.~.li\ \Voodsmith-Q;
~1i
ttsSX Ml~.'j,pu~d b~ ,'('l. >.pnl, JUtll'. Au!.: O! ~. b)' 'l-ood"mftb. PUbUllhlb, C~mJWlY.2!OO t.nnd 01
IOQothl): .\\l'('ftut',
~e)
Dt. 'iCl'il , !L, "'-5031:! PtitltJ:i1 1ft the U.s.'-
~'oo4sm.ld:ae i~ "ft'IMl~ tndc-.trtnQ(WoocbtJuth
""lob' ' "' ' c.n"",,>: t:('t1JI)~ 1990 h)
..a~l" ..",",...,
Y,~.1'I1lIi.;J'II)lC'lfl~}"
Su.~t~)\" __ t'JO~ ~t-5.9S.1,,'1' \'t'W'lt12 ",...u,,'at: ~.9$.('.anamiff h ,p'ldd ~(IOI),".ir Us. "";Do """ $u6. .s-..d 0.,;, ""'!'.id~ I"" ~"""'.. lA...t "
lou.
~.m..<
l~tM5rnd(~orolddrtStCO
lIIt"'!l<-<,M ..... lA~).J.'"
~~Quc:Jrion1o;l'(~~~
lr~
On pal[<':l8 w ..•n · slw"ing a SlOP block lor a mdlal lIml saw. This SlOPis actually a damJllfut, attaches 10a fence. Irs simple. bul,l \\o"",weaL Even if you don't have a radial arm ...... you11find a dozen uses ror thi~ "'"p/damp on other tools, The otht-r damping device Is equally ~nlpl,. It'~shewnall pagl' 2:l as pan OftJ1C
miter jig Ior a radial arm saw ••>\gain.it would be ca,,110 mb,. bUI take a look at lt, All it is b • pit'(;< 01wo<>d"ith a kerf io it and a machine .....-.'" - no complicated mechank, BUI il "01ks great, \\1lh jusl a little im· agination. Ihi, damp can be PUIto use all over 111t>.JlOP
\1'\\ f",~~Oneoflhecomment$1 hear fn'Qu,·ntl)· about 1I'",,,I.,,,ilh is," Idon't know how you g"r' do it wilhoul advertis,n~. bUIkeep upth~ gooo work. •and don't dUlI""1 Uf>wilh ad •." glue them togl"_h~rIn a form. The1'Can'illot The kr)' In making the whole thing work of clamps, ctue is oozinJl 0111everywhere, WllhbUIadVl'rtiSlnl( involvl's the business and. in a "ford. it's a mess. Rut when the ghlt.· "'d.. 01 l,uhU,hlflSl - circulaiicn manageIllt1f.l ,"t· jol) (If .1 ,·jl"('Ul.l1ljun director is to dries.you 've got a beautiiul bentlaminntion 01 course, 'here a r"" delail, thrown in hri'lJ.: ill I1l'W "i.ubS(_·riptiun~(\lsua1l}tby sendthere. The firsl one is how 10 rip thin. ,")II ing out din...1 mail packagcsi, and ICning slstent strips of wood. 01 all uie problem'. ,,,.,..,111,"b,,-nll<:rs know when their subthis one appears to be the easiest. )'<1 I've >
I inv"lv,", • Vt'ry 111<' whol,. thing depend~ a great del ampl •. tak .., ph..,.. Oil one ruml. Ynu ba .....lo H",.Jlh. both owned by R<,ad"r'~ Dill •.,.1 in allow tim.. fur Ull'lllue 10dl)' on on.. pic"Ct! l'ewYork. before you can move 10 nexl pie<-I'. Liz ,..'as anxious 10 gel back 10 the mid· Even if you doo', waru. LObuild the ball west. and liked the challenge or .....orking for In.''l•• tb\.'tf!'s a gr('al deal of saU$raction in a magazine lbaLwas entirely dependenl on making onc S-hook - ,"ven if It·s jusl 10 circulation. For my part, rm delighled 10 hang up )'our shop aproll. work ",ilh someone .....ith Ill'S talent. el" \IPS. There an'lWoc!amping devices ~V.XT (SSt t. '[,he next issue of in this issue Ihal are easy to miss. bUI are Wood~m;/ll.No.7.!. ",11 be mailed during well worth inve,1iJr.lling . thewet:k OfJ3nUAry 1991.
•
'0
,h.,
itA,h K..i)IJ.aw(6
5.W1!tt,. CcoJ)IIlII11lmr. -~da) "
2
No. 71
•
..~
~A~~L_O~O~K~I~N~S~I_D~E~ _
Contents I 141./'\ L.:!J
Tipll Con/eli! alld lil'l' gl'eCl I Iips! roll I/l'lloll'II'OI)(llIx)rJ.:f'l'S: 1) AeUllsiable Rolle)' Stand. 2) Router Tuble PIl.~1tBlock'.• J) hllpl'ol'ed Teno» Cnltillg./ig.J,) A ChipS/inge,'. i)) Sandpaper Files.
'rips & Techniques
1
1 Bent
Lamination
L.
_\'~IC
Be'1/1Lamiuatiou
petge6
Il(;llrr ansu-er lots 'I}' quest lOllS Oil belldiug thi« strip» of uood. EI'(,I'Y'
---1 ~
Ihi 1If1/rolll "ho»: t IIirk "10 ..hou: m IIcit ".
IHall Tree
11101 Aaolnut traditional rorite, Ih I" sui id Hall Treefeatures fourdisff!
---1.
L.
Iinctirr belli
lI'ood S·hook~. Besides flu! Sshook«. the leg.~and the «ooden 1'; IIg /)rodde d ifferent bendi Ilg choilecqe».
•
1 Laminated Ring L.
.;;.._--'.
11161 d~f!irtllt JlIClkillfl laminated rillg is Il.q it .~o1tlld$.AI/d tile same
/lU! (Is
(f
technique could !lUll r OWI1
[Shop Notes _-.!. L.
"I'en
11(11/Tree
pClgeJ{J
be used to mnke
uiooden )('iled" .
11181 J)Problems. Rub 11rtll. SUI/ding Dr" ,i) Router Elise Plutcfor J)
1)1
_.J
CuHil19 Circles. J,) ~roodPlugs. 1
Fern Stand
11201 Fern ']'hebent «ood. leg~ oj litis qruceful Slcl/lc/ reucceuted by (( tool uu I (I
_.J
L.
sI"ip .•andu-iched beuceeu oak strips.
ITalking Shop ~_....!..
L.
11241 flatsau» If'e discuss the difference betweel( and qututersaum l umber.
_.J
PI us, /I'e luok at calipers and ciam ping Iill/e.
ITools & Techniques
11261 Rtldicrl A.?'I."all': A Neu: Table Top,
IFence & Stop Block
11281 «ndu A Rirop-IIIClde adjustable ao» block lIew lVood!el/('1!puilliejilli.sh-
ISouraes
11311
touches
011
OILr radial a 1'111 salc.
Harduure (Llld " roject eu pplie» neededforthe projects in ihi« issue. Fence t\:. Stop Block
No. 72
.!()
A Felice Support Ledge, A Jlitel' Jig, And A Safell! ffa ndle.
illg
•
}Juge
talk about
WooJsmlth
pa.geJ8
FROM
FELLOW
WOODWORKERS
r-------------------------------------~.
•
Tips & Tee
ques
ADJUSTABLE ROLLER STAND .1 mad" the roller stand fea- b)" 2t1·wide plywoud anchor nired in "l't.HHI.~""111No. 70C'b' across the bouem of thc'" inner ier 10 .dju>t by adding a Iwighl sleeve. After Irlu ;ng it in position, adjusunem system that works drill" hole to accept the rope. like an ('I e-vawr Now put the inner sleeve back The bask idea behind the sys- inside the pedestal, The rupetem is thai a rope r"st<'nedto the winds up around a :\!-t"-diamelec bottom or the inner SIN". winds dowel CUI th e
1 CROSS SEcnON
-
.,_-
the pedestal,
pedestal, see r\l:.l.A"the do\\ el T" bold the dowel in position, is turned. theinnersleeve .Iowly I pinned il. To do this, drill It,'' rises within th~p<>GI",taI. Then. holes throul!h thl'dowd on both once in position. itcan belocked sides 01the pedestal and insert down with the wing IIUI. short If." dowels. Also drill a To add the system to my roller holclhrough the dowel 10 attach stand. , started by removing the U,(' rope inside Ute pedestal I roller assembly and the inner also added a handle made from a cap front Lhe tal' of the stand. piece er scrap stock and a short Xext. I drilled '!ft" holes in both length 01dowel. se.. Fig. I. FinaUy. a four loot length ul sides or llw pedestal down trom th~ lOP(·dge and centered rope! ,vilh a knot on one end can on it. wiolh. Ix· threaded through the hole in To allow tlu-inner sleeve togo tho dowol and the hole ln the anupand down within Ihe pedestal, chor plate, Then Ii" it oif on Ut. CUl a W'o",'i
INN" SllIV[
',,·"WJPE SWf
..
<, '
P£O(STAL
'-..
3""'
DOW ... PIN
<,
.~
tfANDU
~¥
)
.,"
-,.
31;1"
DOWEl
I
' ,"
DOwn
.....
-ROPI. , ... OIA.
NOTE: IOUll
STANDAtOM
WOOOSMITH: No. 70
ROUTER TABLE PUSH BLOCK .1 wanted 10 roin the ends 01 moved when routing thin stock.) from the back edge of the push sandpaper along DIe front edge 101\.1{ nnrrow pleces of wood on KeXl.allach a push handle cut block, see ~ill. I er the push block. Finally.to help keep the stock my routertabl e. but the problem from a piece of 3,-l"·dianll..'lt.'r Jim limld,1I from slipping. glue a strip of Loveusvitte, \'i,yi,tin was hulding them square dowel. Position the dowel 3" in againSt the fence. To solve the SC1U:W ADDmONAl STltIP problem. I made a special push AlONG fa0t6 fOG! 1 2 block. refer 10 Fig. 2, ~,---,," To make this push block. stan \ bycuttingapicceof'l't' plywood SI! wide and 12" lonJ{. see Fig. 1. , '..... ) .... PIA. Next. to a110",me to hold a PLYWQOO DOWn SlOP workpiece firnlly against t~e tront edge 01 the push block, I [NDNfAR -r-+--!-_~ CUI out a hand-hold, see Fig. I, lIlT Then. lor more control I made the from edg<- of the push block thicker. To do this, screw a II-:!"· "ide by 8"·long strip of 31,' ply.
-+
s::::r":"
£--4
."
wood flush wiLh the froat edgeuf the block. (This piecre .... an be re-
-l
." ,
HAND HOLD
W'1<,,,bm. rh
No. 72
•
• IMPROVED IENON
.1
""'0("<1a ;.labl"jilt for cll(li~
tenons 311d htdf lap joints on my
table saw,
BUI
the jill'- l've seen
lend 10 drng ns they slide ale)llSt 11,(,nl) Ience. So Icarne up "it" n jiR" that's
stable ami Illidc$ easil)' along my metal rip tenre. """ I·ill. I """,.aabmlyco""" fmm widoninll the jig \\;111 a I \~'! X 1 V2" spacer nI1ac)1t!(110 the inside (aCt', Then 1<1 r..duc.. drag. I used 'It'!'l' round plastic furniture "fet'lor glides where the jig touches
1
t{NON
--..
CUnlNG
JIG
the rip fence, _l·-IR. la. These the space r ~" «"I arc normally nailed inlo the above the boltom bottom of furniture legs 10 help edge of Ihe jill. see heavy fumiture slide over C"dJ'- Fig. Ia. This way it I,,,,iog. nUllhe), also help my jig won't drag on the sa",' table as jl'" fllide a1on!! Ih~ renee. IVhcn buildinglhcjig.1 ripped bdng used. Ih,' '1"10"'" a bit wider than 1Ii!<~ essary $0 Icould get an exact fi; later Then. I nailed the glides iutoplace cn both the spacer and th .. in~id,' of the jig where il \""'_ _"'} touches the rip fence. Once the jil{ is asDuring assembly. I installed sembled, tbe fil on u)e rip it'ncl~1J1ay be
cumNG flG
This ume, we·.... looking (~r lips on how 10 organizectamps. Ctampscoru~inaJldiff~renl shapes and sizes, and SIOring them takes lip a tol o( ~j)ace. S" ifyou have " sp<-cialway In keep your damps organized. tell us about it. W.,1lpub6shthc best lips in UwApril 1991 issue o( IVrl(l(!.mdlh (No. 7.1).5.:nd Y(lur tip> (postmartedno lal~rlbanJanuary7,l991) 10 Shop lip>; Contest, 1\'oIl(l~", 2200 Grand Ave •• Des Moines. lowa 5(1312.\V,,'1t "111nnue tn publish other Tips and Techniques, 100.and pay upon publkauen $1510 $100 for these tiPS based on Ihe published I,,"gllt.
it".
spacer and plant" a small amount
of
wood 0(( tbe side
(If
the spacer
.-
,
PlASIIC
GllDU
SPACER
CHIP SLINGER
SANDPAPER
• Chi"" and dusl (eU down iIlto stinger slightl)' latger Ihan the lhe mOlor when 01)' rOul"r was hole in Ihe rouler lable so it pr()o nl<1ulll,,1in illYmuwr lable. So I t("('t~ lIlt" mCJtor ('\'('n '\,)l(~nIh,-. cam,' UI' \\;lh lhe idea or a chip roul~r is~h"t off."",. rig. la. slinger to pr(H<:<:t the InOlor, r", L. h'etlt'IX·J' A chip sling('r is a lf1"~thid Zel't!1,()/Jle. f'l!ll "ollyl ('t{I' IU plywood di~k lhal fit~on 111~'rouler bit 1 A, SIDE VIEW shaft. sel' Fig. 1. \ .. ··TMlCK (Nole: t:or short PlYWOOD SUN
• I usc ,andpal'er foks in my shop for e,"('"thing (rom d"li·
shank bit,uolfa pl.So
tic cut~out (rom a
coffee can lid.) Th. ~-pinning disk b:liu~
tI\vay an~1hing,hal falls lhrough Ih. hole in the table. I mad" my chip
No. 72
DISK""
l'\otv: If you haw a wide fe-nce likt" a llieselllc)'er. lrnil~nC\~or Vega "'Y$ICln. you could use lhi!\
opooshe the Illides. Then screw lh~ spacer in placeand try the fit agruu. Continue tlli ....procedure tenon CUlling jig on your teble until you jt~1a perfect fil. saw. 100. Since your jig will I maintain tltit'- perfect fil bridge. wide (cnl"'. the spacer during all S('a~)ll~I)r planing doesn't II('l~dto be II It'·wiele-. more stock oft Iht spacer when JUSI make il wide enough 10 acit expands in humid weather, commodate the nails on the back \I'ben tJl~w...aOwr drit's oul and of the g11de~.Illu:;, lit" exira ~ the spacer contraclS. I add " you can plane il fora perf,'C1fil .l/(lJ'iy 1~(J')i",~()n sllinl beNf("en the spacf'rand \Il~ Gfl'slln III. ()rt'!)Il)1 sidr D(lhe jig
,I," x ,I.,"
•
CLAMP ORGAHIJ:ER$
too tight. Til make il fit. unscrew the
~~~t.__
•
~L1ny IVMd«mith readers ba''<' gn'31 ,;olulions 10 problems, they've run into while working in their shop, \Vp"dlike you 10share those tips with other readers, So (or the n" xt ('W i<."U"". wr'lt ask (or tipson !1Olvinlr differ· entshop problems. UpIi! three ollitebe", tipsin eachcategory will be awarded ~ I~·ood.,"il},Master Try Square. Duplkalc or very similar lips will be considered in the order we rceceive them.
ROUTER TABU HOlf
c-o:!t(>'
~dill~ jol)!'>
ttl
FILES
shal"p\!ning
pend Is. To inake Ihe fiI~.I use Ihe Stikil paper nOln'aUy ";;ed on Illy palm sander. sec Fig 1 Slikil pap~r has adh""iveon the back
and
conlt"S
in mils.
....irsl. I make 3 handl~oul of V~"ply· wood. Then, press
Ihe wood handl" 01110 Ihe adhl'>'iv,'on th~back ofO,e Stikil paper and cui along Ih,' ('dge of lhe handle \\;Ih a knife. Woodsmlth
1
"(lIt ean nlake one with rf.-.....ru·
Inr sandpaper. 100.Apply sand· ing di
.lJl'di~ P.·f1"~'tyl'·a"ia Sll10T
SANDPAPER
TO -THfNTJt1M EDG£WfTH
KNIFE
5
TECHNIQUE
WOODWORKING
•
Bent Lamination B
QUESTION: WI",( ;" I}" a..1 It'ruinl! tlW'f 1/1/" .t"I".?
ent Lamination is a process of bending thin strips of wood - using lots o( )!lueand lots ofclamps. II's mESSY. but .\."W'dI'diog to v-c a ~uny bent piu:e of wood C!11I.1!Il' from a glue-encrusted form.
""'I! To
<'\II strips to a consistent thickness, and do it safely. f Ctlt
them on the table saw using a special shop-made insert with a splitter. set' opposue page, ~llli~
The process starts will. ripping some thin strips of wood
insert is made so there's no room on either side 01the blade for the strips 10 fall into the 5101. RIl'PtNG. To rip the strips. set the fence so the distance between the fence and the blade equals the deslred thickness. Using a push block. cutasmany strips as you11need plus several extras. (Some may break while
and applying glue to each strip.
TIlCD it's a matter of slarking all the strips together b'ke a sand, wich and layiag the sandwich on its side in a bending jig. Then the strips are pushed around the curves on the jig. and clamped every few inches. ,\ CH,\u.E!
beingbent)
cause the grain of each piece
nJ11~am"
tid
the bouom of the -U·.
crssnoss.
ing,
bUI
Okay, this sounds interest· like any woodworking technique,
someqncsrionscomewith the process,
I'm 'W( SI
Any wood will bend if lr's cui thin enough, But some woods bend easier to tight curves without breaking. Amoag the commonly availnble hardwoods, oak. walnut, mallOjlllny. and ash bend the best, Hardwoods usually bend beucr 'han softwood" but redwood. yellow pine. and cedar ron be used in bending projcclS. $TI(,\Ic:m'GlWN. Whalever kind or ... cod lsused, remember thai wood with grain Ihat runs in a falrlystraightline is best for bending around tighl curves. Highly figured wood. or woods like maple and birch which I,av(' unpredictable grain patterns, often break before ,hey bend. see Fig. 2. (For more on wood grain. see page 24.)
Shop :-/otc: Often when ripping a board. it'. dillkult to keep it tight against the fence. This causes a variation in the thickness of the piece. Check the piece with a squan- and joint it. ifnecessary. KEEP lS ORDER.. To minimize color variation in the laminated pieces, arrange the stnps In the order they're cut off the board. This makv, it difficult to ""'" the joint lines when the pi('C(.'" are IIlued up. Sometimes they will match SO wen. the lamination looks tike a piece of solid siock. IUP FOR~'1'R-\JGlrrGIWN. When rippiag. the goal is 10 keep the straightest grain on t1le.(/ytoftheslriptohclpprevenlbreakage when bending. So if the straightest wain is on the face of the board. just rip the strip< 10 the apprepriate thickness. see Fig. 2. However. if the straightest grain is on the <.' oCthe board. cutting the strips is a two stepprecess, first. rip. piece to the width of the finished strips (plus Vui' 10 allow for clean-up and shaping). TIleD turn lbat piece on its edge and resaw the strips with the straight grain up. sec Fig. 3, TI'is way. the st.raightestlmlin will appear on uie 0011('of
•
lhe strips,
1
IRafGUlAA GRAIN ON fOOf
•
fIRST:
RAP &lANK TO WIDTH Of' S11UP
SECOND: ROT"ff8lANK~'
"
ANDUSAW
6
W"ru,m.th
No. 72
•
QUESI10N: Hull' Ih,rk .•tumt d th. etrip«be! (On?1 J ,'.>It ,.t(JII~f~/flll ~/"'I;~l'~"'l'"'i~/lr(!r!
You \.'3J1
UI)(:
V~1')'thin
strips, but there are
some problems. First, it can be difficulllO rip very thin pieces 10 a consisn-nt thickm .....:"._ And, there's a 101or waste by all the saw kerf s, l~n.lly. it'.moreawkward 10giLle and then wrestle II large number of r~a1Il'
",,,,".'<1
thin strips around a lorm thall a small JtUI~14 ber of "il(hU), thicker 011.".. I use the thickest strip that will bcn~ around the ''''811('st radius in the jig. II's oflen "trial and error approach \\'hile bullding lI,e F~m Stand on P3ile' 2O,IIried 1<1bend an \II;"·thitk strip of walnut for a leg. and il broke. Yet a ~··Ihick ,tril). justlo:lt' of an inch I""". bent ju"l fi,,<'. ~.' rna}' nol """'m like much, but when Ihe strip i< only v." 10 begin with, 1t!tJ" is 25% or its thickness.
QUF~"ION: Tlu n .,/";,,,, on' /tal'll til I,~(·(I~U"I ('t·t'''~(l/t·l.l/.11(111' d» I((tn ~'I'(JU'it ; I(pi/'re I}'f M!/ht IJI'r~' "i'.;'(~!
•
I-lt:'rt"\;a til), ~1t.~Mlreaslack Qil}'llln, raLht*r than onp at a till'lt".l:(>r inst.aJ1 orth~ Slal'k. I also use dial calipers to a~curatcly measut(' Ih('lhicknc%ol ,;triP"- FIlrmore nn dial calipers, S('(' Talking Shop, page 25.
QllESflON: What
'f the
.Il·ill. ""/1'1
1'iF),d n totl ~Idthrj;,,.,tl IrltltQ,,1 b,"t'O].'1 i'~/?
\I'hen J don't ",anI 10 make a Slrip any thin· ncr, and it still won't bend wilhQul breaking. I lake advaOlag .. of Ihe rael thai moist wood b~nd, beltcrthan dry wood Soak th~ strips in L1pwatcr in Ih~ kitchensink. (lflheywon'l filinlhe sink, usc the bathlub.) Snaking time "aries with the wood and
RIPPING THIN STRIPS One key 1(1a SUCCCl.',iul bent lanunatlon projec t is using wood strips tllal ha... "4UIU'<' edges .. ndare uniform in thickness. ThccasiestiIJ\d tw.yI've found 10 cut them is 01\ a table saw with a "ZeTO clearance" insert
piece 01stock 1(1the exact thickness of the saw blade ked. Theil ,... t ill" high (wide) and 3"long.~nd Ih('cnd that willbecloSt''' to the blade to a point, and then lIlue tbe splluer imo the slot, ",(' Fig.a.
with aspllner, and a simple push block.
Filtally. bore a jO·di"",cl<'r hole in the insert to make it easier to lilt out of'thetable.
INSE.,. The insert on mYlablesaw has .. , IilUl'~lear3Ilfe on ~a~h side of the blade ilIOn the thin C311tfall down into the bladp ,101.'1'1,.. spliner keeps the kerf open Ihe same width ., the blade <0 ilreduces kiHckand binding on the back cdgf' of Ih., blad.,
make
insert. first resaw or plane a hardwood blank 10 tI", Ihklln~ of th.' oJ)
tanksl'
this
in""., tIl!! new insert will lie flush
('tm'"''
Now the "riginal insert from your saw and trace Ih" outline of the insert onto ti't· blank, 11I"n rouJ.!h CUIIn within t ,.;"uf Ih,· oUllill<.'.sec Fig. I. To trim Ul<' new insert to the exact shape ~rth~ original, I use the original 3, a ternplate 5tartby tapingth"original in""rt w tI", n~w inscrt hlank wilh doublc·>ided carpet tape. Then I)lQU,Ot a flush trim bil in the rouler table ancl, witl, the bearing riding on the originalln$ert. trim the new one '" sfulpe, sec ~1g.Ia. (If ),011 don't have a flush lrim hit. rOil l;'~n,;and or file the iose" until il fit.snllj{ly in Ihe QP("I.inll·)
The nm sWpislo cut the blade $10t.T
a
1
the ~pliuer rip" I[AfUNG RJD£S •
OIUOlNAL
PUSH BLOCK Of all lite push blocks in the lI'aCJ!/smit), shop. the one that II:Ork, ilesrfor riJ)pinl[!bin strips is eXIA'nwly simp"'. It suaddles the saw blade >0 the h,'C1 on the bouom «Igl' "I I he block pushes b
pu""
sawblade, SHOULD YOU SAND? After ripping the strips to thickn~ss, you might be le.mplecllO sand the strips bef"re YO!1glue Ihlffi' up.l>on'L ·lbesaw ...illC:uttll!' .triPS!l(' the l'
UWOlth rough II,e planer
2
INSERT
l _
FlUS'H
T1tIM
orr
thickness. So check the strips every ten minut<'S or so to _ how flexible they nre. Takt' a SlriP"UI oftbewaterand gently try to bend it around Ihe lighestcurveon thl' jig. If il won'l bend .round Ihe lorm. put il back in the ""ler and "ail a wbile longer 11Ie h2"· thick wainul ,trips lor the Hall Tree books
....
AIJGN FlNCf WJfH tOG( 0' ORtGINA,1. ""$t~T
\\'CJ'i" rt"a(ly to bend aftf"r soaking 20 minliles
•
in roonl ten1peraturl'" water. \\ 'ET IIl'SOrNG. When lhe wood strips are Oexibl~ pnoullh. take tI,em oul of the sink. shake off lh<- excess ","3lt:r, afl
when they'reglued up.lftlley·reslJllwel. the moislure wiU decrease the holdin/{ power of rhe glue and the workpi('(:c may delaminate.
No. 72
3
,
4
1°
lx4 PUSH &lOCK
SAND fND TO A POINT GlUE
.PtIITt1t SPllTTtR
CUl TO fn
SAWKUI
IN PUC{
""
GWlf ...• .. mTO
aorTOM or 01.0(1(
7
use them with. block or a pad 10keep from forms and ih€" outer forms, marring the workpiece. see Fig. 6. inner forms are usually anachvd to the base, and Ihe strip, wrapl",d around WEOGES. In some cases 111uSC'a wedg<' in Let's start with the tools. Youll need only a place o( a clamp. see Fig. 7 There isn't al- them. The outer forms arc not attached, iabh- saw to cut lite Lltinstrips. (The blad~ ways enough room to USC' wedges, since They hold th~ strips againsi ihe inner Iorms must be square to tho' table and in tine wirh lh~y require 3notl"'r block on Ul<'jig 10 and distribute the press ure of the clamps. To make the funns, lay nul Lh~ the fence.) 1 11<'1 a srnoorh .hap<'son the plywocel.or glue a enough cut with a combination 4 pauern onto the plywood with blad e thar lh.. strips don't have spray adhesive or rubber ccto be planed afterword s. The ment.Then cut the plywood wiLit onh .p,>dalill'd tool ill the QlJE&110N:V(J} Iw(da totoJd(""p""r ~p"{'lal toots to »IMr (I hpII( /nminntrol1!
'''1'
.;t----= (l...~~=--,,\ror"'
process is a bending jig - and
that's made in tilt' shop. Ai;. for the damp', il d..~nd.
/
on how cornplcx nr large the project is, The most clamps
you'll need at anyone tim!' for the projects in this issue is. rwd.(' (fur 1111'U:J11 Trw ring). and uwy can bea combination o( Cclamps and small bar clamps.
\
a band saw or sabre saw, I like to
...'11 to within Vl6" of the pencil fine, and U'M sand to the line with a disk or drum sander. Th;, way, I make sure the surfaces th.ttouch the strips an' smooth, ISSE~mLY.when all the
I
pieces are cut. lay them out in posaion On the base. Check thai the clamps are big enough to
G\lfAWAY lASE
,-_pas.
bridgl' across the Inner (orms, QF£STION: I rlOII" har« that manu "wedge" against. BUI they're another srreng' the thickne>~ of the Strips. and the Oilier forms, If they aren't, downsize the forms or el« mps. Aretl« rc UIIUtl'ft~rllati,'ts to 11 ~;)'{I way 10hold tbe strips in place. use larger damps Then. screw the inner C-elo U~P$" II(II'fn r rLn l1i[l$I QUESTION: HOII' mv- lI,p /wlldlllg jig. form. 10 thebast' Finally, do a "dry "In" 10test the jig. Stan Several. but I (ound that C-clamps are the it,adp! What mnlr,inl~de) the;, r"'P,ir(_? easiest and most versatile way to do laminaby genlly ~ndillK dry strips into (he form. tion. So ifyou don't have enough, try 10bor- I used A·C(inrerior grade) plywood to build Then pu( on the damps and check. for gaps. SCI there are no row some from" friend. the jiln' ShO"'" in this issue, Since lite grain Sand down allY I,igh 1.:;J>()ts <;-mAl'S,An altemative 10using Cclamps switches direction irom lay"r UJ layer, ply· W\I" between forms and the .trips. is to use metal straps. A strap applies even wood isequally strong in alldirection •. A 101 Qt "ESTlOX: I','J~U't 'lit glllr !frick '1) fhr pressure all around th., curve and h~II)Spre- 01 clamping pressure can be I)UI an a ply· vl'lIl U'" strips (rom 'lJliuiJ,)! along !b~0111· wood (orm without breaking lt. JfY 'x n utiJi,n"",. You could use a lower l!rad(' plywood 'id,' i.e,'. SC<' Fi!!.5,Slrapscan be made (rolnl pieces o( metal plumber's strap or thin di- (sudlasCI)X). but watch out fnrvoids.They To ket·p the I!luc trom sticking. rub un a mension tn,'lal bur stoek, Buill arc avnilablc can weaken t11~form Ilr('rr:'tr a rough l'1l$.!P heavy coal 01 paraffin or paste W3.X.I rtpeat at hardware :.tor(.·s, when' the (orm rOlllact< Ihe lamin'led this wa.xingsttp ~rwecn cach usc. Rub the paraffin orwnxonal!surfaccs Illat One end 01 a strap is fixed to the base. .trips. Particleb()ard a1:;<'W()rk, well. though Thl'n it bends around a curve and is pulled it'smore Iik.elyto break under pr",,-""'c than ..ill be in contact with the workpi",,'e.To gel a .mootb ,'oalof J)..raffin, I U~ a hair dryer up right on Ihe other end. A bolt go•• Ihe pl)'wood. 111\.<;£.To 111akc.t bcndingjig. ~tar1by rut· 10 melt il into lh~ iorm. 'I"is - rial. but it helps the paraffin penetrale Ih~ pnn the bendilll! piec~ and the Slrips. 11rh, 1,lywood and ~Iimlnales any ,'h,nce 01 the up dllht with a winr;: nutor a wrench. ba~ i!:- toO big. ~,t()lI11 v.ind up li~hleninJ! ;u1 gillt' >Iickinllln the jig'. C.\~,~. Canl!; are anotllt!r J,!txxi, inexJ*n· :'iotC': Thcr("s ont' tim ..' J \voultll,'l rt'Colnsive allt'malivQ lO C-clamps. Th(·)t can bt Ihe C-clamps willi half·lums ~in('t' th.> b"-das the canl is tum("dlamination. In IhlS situation. I uS(' mof<' pres.'UIl' limn you mil!ht expl-'<'1.So 4. Then:an'lwo part
')('~I'
5
6
CAMS
•
7
ffXlD
-S"ffitIPS
•
,"lOaM
-Offsn
PlVOTP¢CNT
Woodsntim
lOO$(
IUX1C
III'NT
sm.s
, .......
''' <0111><
No.72
•
•
•
Ql-ESTION: Willih. wlI",/lry 11'"1""'11 nut coward each end wrapping lhe strips buck to its urlyitluJ ~/IU'JtaJlerpitcI llll! around the curves. Yes, a liul... I!you fWdthat there's 100 much AI first. just pUI springbac:k ina laminated piece. reshapethe enough damp presforms b)' tightening the curves enough to sure on Ihe suips to make up (or the spring back. There's 0" keep them from formula (or how milch to ,.....hape the forms, moving. Tightening it ill'l takes around the QUESTION: lI'Iml kimia/ylll' .'wuM/ curves. things can gel a little tense and Il.'il>! II(/If! (If) IjIJII !If "I -1'/III,t' *t "I)X! lit' r,"s (III t:.(({ "I ,~/t',!(}(c,tt'l iglll {~ tl, in, ",r,-q if/Itt fffflf 11,'d ,..I np r.J_( rushed, so II'saguoo 111",'<1 IiIL'oolld Wooo 'UPI>I)'a Ilig/lt ",/(tp {(,yzlero 1I(/IJwll 'it.'d IfP iilit' (t prets« l. (aliphatic) glueswill also work since they fill "third hand." small g'dPS 10 some extent and dry quickly. Some ohhe strips "ill s1io~up above the U$ehlt!f the curve the w£"ater the pressure Ifthe projc<1has a 101o( "rips and ),ou'r(' resias you bend the stackarouud the curve s, $0 l leave the clamps on (j". such as the rem Sland legs. glu._·takes h)t;gcr l41 set-up. so }'{)U \\'OJ' 'I (l"el re-adjust Ihe pesiiien o! a clamp or add tht:re is less pressure 10 spring back, Itlll'i~ quite a.~rushed. another one. ,'35<1, I'll remove the clamps a(ltr six hours, For 3 project that will be outdoors, I usc a \\'hen I'm sure that all the strips are in REMOVL'IG TIlE Cl.AM1'S. \\'heo Iremove resorcinol glue or epoxy. They're water- contact with each other. I re-lighlcil all the the damps. I do it slo\\'I)'. Walch the CUIVC'S proof and will stand up 10 the weather. clamps and even out the pressure. carefully. and check (or delamination. A However. epoxies differ in how wen they fill CU:'\.\·l p.l3efore the glue starts 10set up. small amount of.pring back isuormal, BUIif gnps and how much working lime they pro- use adrypaper towelor small piece of wood Ihe strips start 10 separate• re-tighten the viele. You'll have' to experiment to dcterrninc 10wipe offa lototthe glue that hasoozed OUI. clarupsand wauarleastacouplemore hours, what you need. lt's easier to remove the glue now than later, in then remove Bent lamination uses lOIS ofglue. It's hard and reJno\'in~ the excess may shorten d.l)r. pi•xe, and stan cleaning it up, 10predict just how much you 11need. bUIit is ing time by exposing the edges ofthe strips. usually more than you expect, The legs for Don't use a wei towel thQugh. You don 'I want QUE!:>'TION: 11'/1(11'. 'hI! I,,·., 'IVIU 109<1 the Fern Stand,tor example.took more than 10add any rnoisiurc 10the strips. "JJnll 1//<1191 h"lf a 1201.. bottle. So make sure you have plenty ofglue before you start, QUESTION: Ho« /(",g dOt. il IIlkf Ji.,. Ius<' a paint SCJdpef to gel the ''lOr'S{ of rut' Al'rLYl~GruE GUrEoTu apply the glue. I tllf gl,ef' ") (/~'ll! glu~ .,!(. Bul don'l try 10get 00\\<1110bar~ us(! au illexpt·n$lVe foam bnJsh and uinl Lbe" w(lod with ~teSCralleJ'Qr you IDa), I~ar of! tip to thcwidth of the strips. TIle (oam brush TI,;' process is very differenl from gluing up some cdg(·s. can be wash(-d Oulafi('r each use. but ildel~ a panel. \I'hen gluing up a pando Ilak~ the To rcmov('lhe rcsl oftlw glue 1use cithc.' damps 0« in 10 10 30 minules. BUIwb~n a low angl~ block plane or a sanding drum. If riorates r3llidly.so have several on hand. I'clur the glut into a $malt cupordi~h.an(1 laminating slrip'. the ....'slotsof glue and nol )'ou use • block plane. make a fine ''Ill tu spread it on cmly one side of eactt striP. see much ,..-ood In soak up tIte mois.ture. avoid tear oul. Mil. 8. j\:s )'OU brush the glue onto the strips. Once the snips arein the bending jig, the S.'lDdingh also "good way to remove the nloislure in the glue can'l escape on three slack tllcm like you're making a sandwich. IaSIof lh~ glue For those pit'Ccs thai have 'n,en pick up the Slack and lay il on ilSside sid~s, The base and bending (orms are l.'l'lldual curves and will fit on my drill press in Ihe fonn. 'Yll.xed.leavlng only Ihe expo,;ed edge oftl •• table. I feed the workpiec~ bctVoeen a drum strips (orthe moislure 10 gel Oul. sander and a guide block clamlX-d 10 the 1ighl('r curvt. rcquin' longer drying labl~.• ee ~·ig.IU. QUESTION: 1I'''l!r'~ Ih' bPSI pm"f'II/II'P for ~Ja"'l}i UtI tJ(tt :"fri~? lim,'. The glue needs 1<1 bt' completely dl)' tONlU s,ol'.The pmcessisinvolved. bUI (noljust sel·uP) 10r('sisl the strips' desire 10 it's prel1Ylogical. 100.\\'bile il may be trickY Slmclamping in the lDiddle.and then move spring back 10Ih.ir .ril.~lll~ shape. And the and a lillIe me"",'. it's ah;o ju.tplaiu (w•• Hthings
stay
place,
the
work-
",1
8
10
SAND 10 UNlfORM tHlCKNlSS
$TA(l( snIPS
AS GJ.Uf
,
lS APPUEO
•
APPL,Y THIN lAYER Of GiVE ONE SLOEONLY
>J". 7~
ClAMP OUfOf BlOCK
TO Orll.L PfClSS r Atlt
9
HEIRLOOM
PROJECT
•
Hall Tree This hall tree offers three differenr bending challenges - a silnple L~bend, a more comphcored S~bend, and to top it off, bending a full circle, All you need a few shop,made jigs, and a linle rime,
E
IS
very tim. I ."" , pi'-'
10 ,lUll and Iry Iv ligun' vUI how il was mad." And whenever I think of bending wood, a classic proj.,,11ll1ll rye wanted 1(1 build comesto mind- a hall treewuh its disrmctive curled hooks. C.~O'STRlcnox I soon 10Wld out this project requJtt>s it bit Clf patience 10 glue up Ih(' IlIn',' bern paris - the legs, Ih,' ~ books, and Ille ring, I'.'l'h offe",
a dlffcrt'nl bending ,'hallenj(" The k-gs require a slnglo bend and are the simplest to make The ~.haP<"i hook. have
I""
h<:nd, and are more l'hall,'nj('
WC)()IJ, For thl s project.
selected
I
walnut
b~C3USt.: It slTt)n,g. and has 3
bends \\·('JI.is lr3onional elegance 1llRD\\ '\RJo:, Once Ill,' curved
parts are made.there's not a 101 uework toassemble the han tre" The ~h(l(J"'"Sand ria,S!are :;.(.. ''1lrt'" In Iho 110<1with brassovalhead screw s, I also used walnut pluJ,t"-to cover l~l"" flathead ..;cr(~"",:,- ill the leg holt'S. (~"tH'Nt~"t..,),
Prciect
Sttpplir:l.
is uffonos: L1w walnm plus:> and Ihe patterns (urlb,· bcndiug~", "' ... Sources un ""1« 31.)
iog. And the riog i, laminated I1NLSIl, (3('QuSt: of Ille curved using a slightly dif(ereOIIJrOCt,,;:; parts in Iht' halltree.I decided to
than the other two, (\\'e\. in, USt' a wipe-on finish. I wiped on a eluded an article on belli lam in. couple vI coals 01rung oil to protion technique'!'>on paJr"t' 6 and ~I duct a soh luster,
MATERIALS
!BENDING JIGS
WOOD PARTS A Leg SuI;»(32) B Hoo~ Stri;» (20)
hz.1'.I>'3O '1'.12x~.30
C POSl (I)
1'.~xI\.l!'~
o IlingStOtlerSlnp(1) E RlngSlfI;» elOl
'1'.12. :v.'"() ~x ~..·24
SUPPLIES • 7 6 Bel H 01.y.',the'< WO'r)tII
JC
hQodWOQd!CISWS
• (llconol
.,
"".9, a.,
,
~..... 4',' ~60" A
E ~ •• .It
i I
F
"act
10
'1
n
t
A
,
3'"," ..60· {1.5 act. ".)
.
""
I
ad..
I
"" .. ~ .." • 7fT 12
pOs!8WOX
DIAGRAM
5'."" 6O...t1.:1 Sll.'t.l
E
'I. COl'
• (6) No 8. lit.. 110"
• (' pin.) Tung 00l
~."
• (1) 3"Ion9 Iiogebol1
• (0) No 8 x 2' not' heaO\'Joodscrsws
• (8) WoIrnJtovolheod plugs • (8)No 6. t' !;l<
CUnlNG
• (nAB' ".48' $heet or ~."tnl(;l
rt.l
fT: =m·
!~,o~
:
B
:_g_
,
I i7ZZiZdJ J -,-~• ,
I
No, 72
•
•
•
BENDING JIGS I started work on the hall tree bybuildingthe three bending jigs, (Nol~: Layillj!our these
jigs may be the most difficult pan of this whole pruj""I, Allhou)!h we're shuwing drawings(or tIwsejigs on this page. you may want 10 order the jllll·xi,r patterns and detailed instn,cliun. from W""dxlllilll Prujlrl SUNlli ... ~'t'page 31.) lEG BESI)INGJIC;.The leg bcndin)!jill consiSlsohhrec pi,,,,e.;:. base, a fixed form, and n Ilivutinll P"""Uf(! block. sec Fig. I. The fixed (unn is attached 10 Ihe base bUI the pressure block piv..", on. dowel. The pressure blocknnd fixed form operate much like a hamburger press 10squeeze the strips rogeilicr.Thecndsof till' fixed fonn also act as <:lIl-off lines for lrimming the legs 10 their finished lellgih once they're glued up. CclNSTRI'cnl)S ~0'11lS.The fixed (0011 and pr.....sure block (or the leg bending jig are made by gluinillogether a double layer of :JI4" plywood. Afler the rwo pieces of pi)" wood an' glued logf'lhrr. the next step is 10 draw afull-size paperpanern ofthejig shown in Fig, I.Then glue this pattern 10 the plywood. andcut thepiecesto NJUUll shape. N~xl. damp the pieces 10 the base and drill ~'•• holes for IwO dowels - one (near the end oj the pressure block) actsas a pivol pin. and t11~other (near Ihe inside cdJ(,' ,,( the pressure block) holds the pressure block inposition uutilclampscanbe applied, Then, clri1l11i1"ll1,,1(~and S(.'f'('\\'111f>fix~ form' 10 Ihe 00"'. see Fig. I.Afl~r the holes are drilled. remove both pieces, sand 10 the
pattern Ii"es, and SCrewthe jig together, S·HOOK lIESDL"G JI(,. Although ihe S. hook jig squeezes siripstogether like the leg jig. it'sdiffcrenl in a ncmber ofways.Instead o( relying on one pressure block il uses 5\'e smaller curved pressure blocks. see Fig. 2. And it uses IWO whistle-shaped bending forms -Ihe larger one is fixed 10the base while the smaller one acts as both a pivoting lonn and a pressure block. Th.. pivoting fonn swings out and allows ihe strips 10be inserted. then pivots back so tlte)' can hi! tij!htlyclrunped in place. tOl'(STRl'cnON NOTES. 111e pivoting form also uSA.'Sa pin lik"lIte leg jig. bUIthis time I used a v," carriaze boll with the threads CUi uUinstcad of a-l'1" dowel, sec Fig. 2.Th c, -\14" boh located euhe center D(Ib" pivoting form allows room 10 drill holes for C-clamps, There are also two sets of marks on the bendiog jig - one sel shows where the shooks will betrimmed
•
10 size. sec Fig.
CUT-off
LEG BENDING JIG
s·
NOTE:
0
UN' •
--
,,-.otA.,
,t.~
lONG
___
S(t.lOING fCNtM
ANl)PJtl$WlI tI.O(fCAa, 11,..~ntIQt
,
PRUSUR£ "lOCK
PtVOTDOWEL
_M
SOlOW
61,.
4-13" r-
IENOlflm
r
TO lASE
I CIJI P.utS FROM 2l,AYERS OF lI.....mt(k Pi,YWOOD
2'"
cut..", UN'
2
HQUS
,
BENDING JIG
.o1tM
,
,
rOk ClAMPS
HOOK
flX£D
S"
...
,"
UN'
.lI....
I
.
CIJr.Qff
CUT PAftTS
'R"'"
'0"
l .. ··lHlCi(
PlYWOOD CURV(O PJtlS5URf
BlOCKS
,
SCk!W;----...-·
CUT"'«
PlVonNG
CURVED
UNl:
PRESSURE
.0"'"
MOll LOCATION - -
'lOCKS
-----
----J6'"-
3
-IAS(
RING fOltM PII.01 HOtf lOCA1K)N5 fOR HOOl(S
RING BENDING JIG
,
S""
'"1\.
Cut PARTS
fROM~."·1MICk PlYWOOD
•
13"
1, •• WlOIE SlQTfOa STARTtR STRIP
2,And
the other set shows the screw hole positions for mountJng lite Shooks. RlSI) ""'''I)INGJI( ••The ring bendingjig is compl~lely different from the other IWO. It doesn't have any pivotinKparts or pressure blocks. Instead. it consists u( a simple ring· sh.Pl'" term thal'S mounted onto a square base, see fig. 3. (For more on making this jig. see P3II" 16.)
N\,. -, I ...
...
1
S(IItEWRING
MARK fOUjt fOUAU.Y·SPACIO POINTS ON FOAM
~OAA\10 rME --
-'-1..-
fOR PIlOT MOl.(lOOATION$
_
""---\'(/oodsrmth
.., II
LEGS
4
I After complcling !he jij('S.I sand, and check fora bj!hl fiL began work on dIe four !logs. :\otc: ("\ny imperfecticns on The fir>t swp is 10 rip th< th(' jig will translate intu gap. 00 .trill'> [or the legs. To k.",p the larmnated parts. h'sbenerto the Ic~sfrom bowing under SJ)<'IlU exira lin1<' sanding nQW, heavy loads (such as winter than applying filler later, Once coals). I d••rided 10 make you're satisfied with the fil, apply them 1"wide, Each Ictg is a generous coal of pa-:,t~wax to glued 1111 from eight strips, the jig, This helps prevent theeach :V12"-thick - for a lotal strips from Slicking to the forms, thickness o[:¥,'. GU ~:IPI.E(;s.Aflerthebcnd· CUT S1·RII'S. The log ing jig is waxed, the I~g. "an be strip. (A) are cut from :\ ,". glued up. I used a f031l1 brush to thick stock in IWO SI(·PS.FIrSt. rip eleven apply an even coat of gill. onto blanks (oaNugh lenl.1h of30"3nd afinished cne stde oteach legstrip Then I width of H~'. Then. resaw each of these Slacked ~'Cstrips and damped them 10the blanksimo three h2"·tbickstrips. see Fig. 4. straighl section of the pressure block, S<'C (This will give you a lotal of 33 strips. You Fig, 5. n11i, helps keep the strips aligned.) need eighl strips [or each Icg. a 10lal of 32 Now close the pressure block and lock it strips. but vou mal want te cut extra incase in position with the dowel. see Fig. 6.111"n, apply clamps across the form and pressure any of the strips twist Orbend.) rssr rrrns«, Before ,!!lwlljtthe strips to- block about every 4" to 5". and remove the gether, there's one more important >lepdowel. see Fig. I, test fitting the bending jig. This involves Aflcrthc leg has dried lldillgjig. and it from the jig. Then clean up the jig by rech.ckingforgaps, moving an)' glue with a chisel. xow, usc th,' To check fit. swing the pressure bl,..:k same procedure to KJUt.~the remainim; legs. '1'1<1\11£';". Once all four I"R$ ar.. Rlul'tl, out and damp strips 10the ('nd of the block. see Fig. 5. Then swing the prcssore "1', thl')' need to be trimmed. Before you trim block dosed and insert the locking dowel. 111[>,111. scrape off any excess glue and handsee rtg. 6. \It"Xl. clampacross the IOml:iUJ1(1 plane each leg loa finished widthotl". Tht-n, mark any areas where there are gal>:;.see if there an- ~Inyvariations in thickness. UM.'a tig. 7, Ii necessary. disassemble the jig. re- drum sander and a rub block 10 thickness
tl,,·
~~"'t
5
ClAMP AND Glut liGHT stlUPS TO STIAWlHf
SKtlON
6
aa.oc~PAST HOlt
sand Ih,' 1.:g$IOa unifonn ~,', see p.'g" 18. Next, set each I"l( back in the Ix>ndinl!jig and mark the locations 10trim to length. Finally. cut eath 1"1(10 its finished lellj.'th. sovxn O''ER EllGF.S, Aflcr the legs have been trimmed 10 length. the edges can be rounded
QVt'T_
I routed the top ,_u!/r.rl$ of each
I(>gwith a :~t\"round-over bit in the: roult:f wble, Sec ~il!~.Then. 1used a file to round over tht' lOP' 11(/... of the legs 10 a ¥,," radius, >rt' fig, sa. \UIC: For .Iability, don't round over the bonum t'()ge, of lite l~g>, ORlU.MOI~'nX(i noiss, The linal slep in making the I<,!(sis io drill two counterbored lllounti"1Ihoi.., in each leg. see ~ig, 9, To do thi" first drill a ~,"-dcepcuunterborc with a , " drill biL Then, use a ~c"drill bit to drill the -hank hole
7
'UtST. SWlNG PIt(SSUltfc
Of' PRl:SSU1U "SlOCK
a.
APP\.YC
IN t.ASt-
.J
...,. I
THlN;.lNSlJIT DOWn TO TEMPORARJl.Y
P1lUSURI StoCk
LOCK IN PlACE
Non:
USE A. SCRAP a&.OC1C ,.,.,0--' HAIMWl J01AP STRlP$ FLUSHAT fOP BtFOIl£ ~GHJIN'Na.ClAMPS
a.
NOTE: ~•• ROUN.D.oVER ON lOP tDGlS ONLY
FlU (ND ro )aROUND'oOV'bt
ROUT~l" ON ROUTt. TASU:
12
•
•
•
S·HOOKS , .lust like the legs, the [our:-'
bending fig. I ,lipl>~d rubber <- - honks are made with .\.:It'. bandsover the bent ends ofeach "'--lL!:- thick strips, but they're only or cirr STRlf's. T" rill the rough areas on the form s, Then. book strips (B) (or tht- (our takethe jig apart and re-<'1nd as Shooks, I b'lIan by CUlling necessary until a tight fit is L-_--"."_-' IWO blank. 10' rouj'!h width achieved, 1'-"inaJly. reassemble ui 3" RI\d a length of 30" TIll11,. set the rip the bending jig and apply. Ienee to produce l-,!'·thkk strips and ripthe R~ncrouscoal of paste wax to Hili "II > O\'FR Elle ~:S. A(Ie r the S.ho"k~. re blanks 10 pro·duer Iwenty .v,' -wide ,trips. the edges ofthe forms, the pressure blocks. trimmed, lilt' t"dgl'~ can be ruunded over. ( five-trips for each S-hook. ",',0 ~ig10. and the base el.n;·I·I' S-HOOl\>,. ~ow !hOI the bending die! this t))' mounting a ~'l'itlround-over bit in """KESD' 1t(0)"S. Before tlw strips can bcglu('(!.upin Ihe b,·ndingjig.! soaked them jig is ready, the Shooks can be j!lued up. the router table and raising it 10 produce a and pre-bern them to shape. This helps pre- Start by applying an even COal olgluelo one ~16"·d,,"pcut, see Fig. 1:1. NlI'r lilt' I·dges vent the strips from brC3¥ing on the tight side of each strip. Then. ,t.'lCkthe strips and are routed, round tlw ends o( each S-hOtlk damp them in the form, just as when wet- with a file. see Fig. 14. I used a quarter 10 radius bends oflh~ bending forms. T" wet bend the the remaining sers ef strips. TRJ.\I S-HOOKS. After the Shooks arc the Shook to the post, and one to attach the Ih,' pivotarm and thefixed form, see Mit. I L Nexi. \\'orking frorn the center out, curl the glued·up. they can be trimmed. To do this, ring. To locate the holes, place the Shooks strips around one radius 81 a time, Clanll)iJlg begin by scrapingoffany excessglue. Then, on til<' bending jig and mark them. refer 10 the pressure blocks in plac .... v I"ig. 12. (! hand plane Ihl' Shooks to a uniform width, Fig. 2 iorthe hole locntions, Kext. use a :.~" drill bit to drill two shank holes in each 50 used 2. /' (·damp, for this.) N~
11
CLAMP
'Ino
FOAA\
,Nt STRIP~
_- ..------\
8E1Wt[N Axro f.OR,M AND PNOT ARM
':>_:
r
0
.;;.
~
"-
NOn: SOAK STtuPS 30 MiNUTU IN WAltR IErolt£'Wn
13
.....
~IVOl
CLAMP PAUSURt _/
~
sa Rxr
,
T......
o.
CUT·OfF UN'
.. LOCKS 1M PlACE
BASt
IIOUT£l
or-
SCUW 1101.(
-.
.~~ alNo.NG,
lOCA-noN
""'
1/
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/'"
(ut.Q" UN'
a.
HOOK ..
TRACt
RAOfUS ONTOfNOS
!
15
LotAn MOUNTlNG HOW
'IOMIMAKS ONIENOLNG JtG
111.( ENOS TO AAO'US <>fA QUARTfR
•
,~,.
~,....... "":3
SHANK-
MOll
Nv. i2
WooJSllllrh
13
•
POST ,-------,
Once the I~ and Shooks are completed, work can bt.>gin,10 lh.· I~~·-thirkPC"1. To make th,· post, I laminated two pircesof1,"-thkk stock tog.ther instead of
milog Ihicker stock for two reasons. First,1"'~hkk walnut is more commonly available, And se cond. a laminat\"Cll)lJ~thas less of a tend"oey 10twist than a piece of L-__ "!!..---' P..'.!"-Ihick stock, To make the po.1 (C) .• tart by ripping two ~""'Ihick post blanks In 3 rough width of 1%" and a rough leogth 01 iO", Then, glue and clamp II.. pieces t',gether face to face. \\'hen the glue is dry. scrape off any execs, and joint or plane the post until it's I Ii-i" square. se,' Fig, IG.Then. trim the post 10' finished length o( 68". R()LTSTOPI'ED t'I\'\."FF.JI. To giv. the po>t an octagonal shape, I routed "upped chamfers on the top two-thirds of the POSt. The chamfer starts 24" up from the bouom of the post and provides. square surface 10 attach tlw 1Log:,. To indicate the beginning of the slopped chamfer, mark reference lines around the post 24" from the bonum end. see Fig. 17. Then. draw a reference line on the router table fence that's aligned with lhe center of
16
17
,,"
Q !
POst
......
aOUttR
eorroM lNO
rENeE
a. "-,,"
...
T
POST ~
18
a:')
SAM! alT
HEIGHT AS fIG. '70.
~."
1'0\'
the router biL Aft~r tlw post and feDceIIJ'C marked. raise the chamlcring bit to CUl" ~i~wid,>chamfer
on the post. see
b.
•
~-Ig.17a.
To rouuhcchamfer.ease the postintothe routerbit so the line on the workpiece aligns with the reference line on the fence. Now. moving the post to the left. rout a chamfcron aU fouredgesofthe~t. SL~,.g. 17. CIIAMfER TOP A."O BOTJ'OM_ \\11il. ihe chamfering bit is still SCt up, rout chamfers on both ends of the post, see I·-ij(.ISa. I placed a $OPlIOrtunder one end of the long POSIwhile chamfering Ihp other, and useda router table push block (sec TIps. pag~4) to keep the post square to the fence, see rig. 18aotrr DECORAm"£ CROOI'F..After the
(SEt PAGE- 4)
19
14
- -, -;:-.
20
'i r
TOP0'
POst
endsare chamfered. decorative gTOO\'es can
be routed I" in from each end. To rout the grooves. I used a ~J"-dia. core box bit set II."-deep. see Fig. ISb. DRIU, MOI:NT1NG IIOLES. Afler grooves are routed in the post.the nC>tstepis LOdrill pilol holes to mount the kgs and S-hooks. The holes for the Shooks arc centered on the width of the POSt12"down from the lOP end. see Fig. 19. The holes for the legs are alsecentered on the post. see Fig. 20. Locate the firsl hole 7" from the bottom of the post and the second hole 4" iron. the firs~ Mer marking the holes. usc a %2" drill bit 10driU the:v,"-dcep pilot holes.
ttOUTU. fUll PUSH 6lOCX
POST
... u. "',,"·HOlU
2.'
~"·OlEP ON AU
fOUJt fACU
•
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, 7"
IOTTOM
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ON AU fOUltf4C£S
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OF POST
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No. 72
•
•
RING ,------,
The 18$101 I he bentwood
c..
components to make i:-- the
ring. 111<' ring i,buill-UP from
:>:I:/"'Ihickstripstharare bent around a found form. (~'Of step-bYoSt'1)Instructions on building the ring bendina form, see pages Hi 10 11.)
Afler ti buHdmgthebendingjil1. ripa jj ..._ ·IO",lonl(ring starter strip ST\~T£R STRIP.
.,./' \-
I (D)
trorn ~,"'lhick 'lock (The starter str ip i...cut longer than the n.~1(JIUli' strips so it'll wrap around Owring form "omp!t'lely and ov,-rlal' about aquarter-turn.) Soak lhe~lrip in water L-_--"-_.J
and damp ilto the Iorm 10 pre-bend il 10 ,h3I)<'.Then eut u-n 2~··lonRrinl!~trip~ (E) and pr....bend them, Let the strips dry over-
21
nighl. Then insert the starter strip in lite slot in tilt' Jig. clamping th~ strip as you work around me form. Nexi. apply glue where it Q''- 1'1«1)~andclamp it in place. CO)II'U'Tl'GTIIRRI\'G. Then u's a matter of adding the other strips one at • lim.. around the form, Once the thickness is built up to '¥.". the rinj! can be cleaned up and rounded Over with a ~II round-over biL !Again, this is explained on pagc", Into 17.) SCREWHOI.ES.Afwr till' ring has been made. Ihe next step i. to drill lour holes to anach the ring 10 the S-hooks. Since the !:>-
drilling the angled hoi." I bulh a drilling jig, see ~'tg.21. The jig is constructed frnm ¥~". thick plywood and is simply an angled pial, form. To hold the ring in place, I glu.'" • couple cleats to the plauorm, sec ~iJ:.21. (You could drill the hol<'1;without m,· jig if your drill press has a tilting labl{-.) llRIt.L IlOI.J;S. After the jig is m3<1,·.scuhe ring on the plaliorm.Then, position til<' platf..nn on th,' drill pres.' table until a 'l-:r!" drill bit is centered on the thickness o( till' ring. see Fig. Z'la. Now. adjusllht depth stop on lite drill press to drill ~.-d('('phow. and hooks n1('''('1the: ring atul\ angle, thc.·l101('$UJ'\.' then drill thc Iour pllot holes. drilled at 20' in fnur equally-spaced locatl~lIsH.Sinceali oftheparts ofthe hall tree an-screwed tOR,·lIter.it'srnuch easiertofin tions. To locale the holes.place theringback on the bending jig and mark where the four ish each pan before assembly. Su before going Imy Iurtlwr. I rubbed on IWO coals of hull'S "in be drilled, sec Fig. 3. ORlWXG JIG. To position th~ring lor lung OIL I,OCATt MOll POSfOON:$ 'ROM
ORIWNG JJG
RUDEN(.(
~-----------'Jr
MAUS ON &l:NOtNG JIG
a.
~... PlYWOOD
•
ORtU~ fQUAtl Y-~SpA(tD <, MOl"
"..
DR.U. PRI~S TA&lf
ASSEMBLY /If'''r tht· finish has dried on all tile parts, assemblycan begin, ,\1T"\('11 LEGS.Start by placing each leg on th. "".1 and lilting up the pilol and ~hank holes. ·111<'n. screw the leg 10 the post with II s"flatheadwoodscrcws, see ~ig. 23.Once all lour I~gs were screwed on. 1):lued oval head walnut plugs in each bole. see Fig. 233 (For more on pluK>.St.'C page 19.). .\nAC'1I "·HOOKS. After the lej!s are atiached.the m'XI step isto screw the S-hooks to the J'O'I. Todo this, position Ollt' Shook on the 1>O~'ancl screw it in placewirh a J" brass ovalh ead SCI''''''. set' Fi):. 24. r.vlake sure the large radius on thi:' Sohnok is at the bottom.) f-Jeo!Qll" {a.~ll':'njnR theremnining Shooks in place, slip the laminated ringov(>rth~honk yuu just mounted. (The ring won't filover all
•
fnur S-hook. Ol"~'IIw)"", installed.) Nnw, "ilh th(' ring 100.. ' on ihe post, (ft'CI'eW tht' rin!! to ... eh S-hook with. I" brussowlh.ad ~re".$t"e l-tK. 24a.
24
23
POST
"HOOK
PWG-
.Ox '" ~aRAS$ OYAlKfAD
sc.tw
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.0.
,
.. OVALKlAO
1- BRASS
o.
OYAlH£AO SCREW
S'HOOk
RING
PlUG
t5
WOODWORKING
TECHNIQUE
Laminated Ring Making a laminated ring is fairly simple. It's jusla matter of gl uil)g and \\'TIJPJ)iog strips around
pOinl of the jig. It fits into holes drilled in a large shop- buill
router base plate, (If you have 8 trammel peint for your router,
a ring-shaped brndingjig Okay. but i-m"t it even easier to cut a ring oul of a solid piece? It's easier. but not better (or 3 crouple 01 reason!'. 1;"jI'bl. there would be rwo ",t-a k spots where
you won't u('Cd to make a new
router base.) &\5£ NATE. So I started by
re-
placi11$: the base plate on n\)'
routerwithanew one. (Formore on this. sec P3!(e 19.) Afler it's replaced, drill thre e !,Iu;"pivot
lh~gnin cutsdirectly eCT"" the thickness, of the rinR .\nd second. a solid ring warp. with changes in humidity - but a
holes in the pial!',
1'0 locate the holes, insert a
laminated nOR won't,
v,"-straij1h1 bit in the router and measure out (rom the cUlting
Though I'm using Ille ring
irom tilt' Hall T,.,.., (shown tin
p3g"IO) asan example.thisprocedorecan beused 10 make any ,i1,(: ring or even (I wheel, Just change the ring-shaped belldingform. see photo. ,i7kohhejig andeu; shertercr longcrslrips. The trickiest part ofthis project is making the round form-e-irhas to be-a perfect circle. REI'OISGm., TIle bending jil1 I used is made (rom Iwo pieces or l'." plywood. One To dothis, Iusedarouterand aprvotpin The piece is a square basco The second piece is a pin is simply a brad driven into the center-
edze, The closest hole to the bit (:W.") is used to rout the iI/sit!' edge of the bending fonn. see Step 1.The next hole (5") is for routing the ol
'0
(
, stOT FOR STARTtJtSrtlP nPROUltR
art iNTO STOCK AND ROTATEClOClCWlSt- TO ROIJI' R1NG _./
1
r..or(ll~r( nter ti'IPil (1111/.dm.II' ('} ...('II'~ JDY tlte rirl'I(/a.· /01-/)1 Ttn:n, x("rrl(+
1)IY'rtf)(Jd 1~ln"J..'it"'f.lptllPfXO 'lit ,..rrj/t',,.UN Ift,II, '" thr 1")19" ltd ; ',)'PI" tit~li', WORK STAa1'I:R STRip AR-OUND FOAM ClAMPING
tvfJtY
6-'0.·
a )tPI(' IM.')f'
1>/lJtP t()tJII' mnter,
2 l1'il1l ":'·.I,.",ght hil. rottl III, ,,,.g. 3 ultiny.I.1,_. radii,S n"d .; ri rlga nd .4If(l(h
Remere scr(!1J's (I ltd ,~flJ(I)"nft' 1'1"9
Drc u·II,," -mide slot in (J S{~1),."~a'" .\·f,}'t, tu ""f tlie bat.e ot~rtrlldk('1'( U' r111[1 iupku» (Q/.,U (l.11d f)(lAf
~htll)fd /('1"'11
,.uditur p.t"Ut J,bl'1_(,
rllt IJ't :1/(" "'Itll
AOOGWf ON INSIDE Of Ov(RtA.P-......_
I HOlD SfAJITm SJRIP IN SLOT WITH C·C1.AMP
,
A1TDl GWlNG AOO (-CLAMPSTO HO\.D IN.PUc(
11'11," thestorur .~tnphegm~tt)ot·l'r· Iret 011.'r1J>.< mId pl1,.I"."d O""III'U Remor« ony r.J·~e15~ gll«:ai tlte ePLdof 4 funu. Ut t1r.v OI't!I·'';Uhl.7'1'1'>.,I.,U;II 5 iap il.ll,1f. apply gill' t« th~ OI'.r/
(l!l'll)I tile ktn/I, ;tlse-rtlt({1 j)'lto t Iu: ';;/(11 (Inc/ r}all1pltlg I!I·er!16· it} d"
16
tel'll.J~'t
11.eOytl'f:
$Iut. m'erlap lite strip, ami ,.,,·t!OIllP,
1]
.m1P blo
:-Jo.72
•
•
•
ro cut the slot. first unscrew the oc'nding plate is complete. work can begin on Ih,· 10m.from the base, Then. draw an ,,"'-wid .. ring-shaped bending fom. it,;elf.Sian bycut- curved slot on the form. see Stl!1'3. (I U5(.'(i a ling OUIa plywood blank and laying out cen- large coffee can lid to ~ellhe desired curve.) ter lines on it, see Step I Then, draw the :-Iex1. use a sabre <;;JW 10 cut the slot, (ann eirclesfor reference during Toutinl( ASSElIUL\', Once the slol is tilt, re-nsThe ring (ann is cut from this blank by semblerhe jig by 1l1PIlingthCbase overtoget making repeal passes with (h. roUIPT until u clean surface (no grOO\'~~ from routing) the bit CUIS Ihrough Ihe blank. To ke('11the and ""rew th,' rill.'l·shaped Conn onto tht blank in place during routing.] screwed iliO ba."l'. :,\tl·xt. If) keep the ~IUl.lofrom l:'uckin~, rut' top ()f a second pit..'-':(· nt' plywood. "t'(' apply a generous coat of pasn- wax 10 the jig. L'MIN,\TE RING.\\lth the jil( complete. Seep 1. toe.. lethe ""!'I'W"so tht'Y wont be in the path of thc' bit, Then. drive a Ii gauge work can begin on the laminated ring ilSi'lI. bra(1 U)ivol pin) into 111(·..-emerpcin; and snip Bcfore the stripscan be glued together, they need 10 be WN bent, To do this, "Oak a ,trip off the brad II,' above the surface. Rf)l T 8.~S'r)fNGF()R.\I. Once the pivot pill in water for 15minutes and clamp it to thrlsinplace, thetormcan be routed. To do this, form without glue. Keep the strip on the sci tile routerbit IU make a VI·I~et.'1Jcut and (IJnn for 15 minutes, remove it, and wei make apasswiih the base plate firsttewered bend the remaining strips, 'Own allow all the over lhc 3'\1," pivot hole.Then make a pa,,, ring strips to dry ovemigltL with the base plate lowered over Ihe 5" pivol Once the strips are pre-bent tile gluing hoi,'. NO".lowerth"bit t I"atatim~until ti,e process loanstart. sec Step 4. B<-gi n by inse ningthe ~IY'lonl(starter strip into Ihe slot and bilCUIS through the top layer, sec St~p 2. cvr SLOT, After tile top layer is routed clamp the strip 10 the form as you work through.lhe next step lstocut a slot into ihe around the (onn. When you reach the point ring-shaped lann for thl! first strip of the where tbe strip overlaps, apply glut 10 Iht lanllna1ed ri~. 'Int!-startt1T strip is an ~xlra- overlap and damp it in pia'.... ~ Step 5. As tilt! renlainjn~ 24"·\ong strips ar~ long strip tll~ll acts as a foundation layt-r for additional strips. wrapped around the (onn. tbe) aTi' bUII,'« ~L\KJXGrue FUR'IS. Once
the router base
together at the end" sec Step 6. Make sure the strips are flush at the top, And continue wrapping until the ring is at least :jI."·thkk. see Step 7. Once the ring is laminated. the top and
bol1001 edges are planed Ou,h. st'(' Slep 8. TRL'I RINC,lll4.-" next step is (0 usc a router to trim the ring to a circle. To do this, ~';n by mounting a scrap block insid.· the bending ((1mt.~""t" SIt."p9, Then, UF.t'Iht' rc.'((.l'rc:nfi" lincsou thc ring (ami 10 10<"0103 centerpoint
on the block and install a pivot pin, \\ilh the pivotpin in position.the ""t,.it!e OftllC'
ring can be trimmed to aperfoct circle.
Usc the Ilivol hole that's fanhest from the router bit (5-V.") and a t ."·straight bit.Then. slowly rout counterclockwise around the ringru llT<'\,cnttlwla.l strip (rom learing out.
=Swp9. Then. to trim the In~/(14 of tile ring. remove the WllSI~ section of the starter strfp
with a hand saw. see Step 10.Next. feather the inside of the starter strip to 10m! a smooth Cirri". ROt ND O"ER E1)(;ES.To complete the ring. use a 3rjf' round-over bil un the router table and a rub arm 10round over the edges. see Sleps 11 and 12. (For more on u~ a rub amI, SCt' Shop Notcs on pagc IS.)
Rf.M.OVl:OCfSS CWf"WTTH
StaAPat
TK(N
PLANE staR'S
RUP4 WffM IJING JORM
ADD ADDmoHAL SlRtPS CLAMPING
MAY 2" TO3"
\\'ork Ol.(t~(l~trip.~ around lit, J(lrll~. ,4ff, r t/l(;. !1tll~ rlrlrA. ~r'l'1J1~('(ltlU $rrt,'ll' ;-;I/t·,· blurk l)l:tid( bp)l(i;}(g ('111»lpingas ltftt' tt Q~))t'C"IiS(l toy it) gf'f .(n,.,'i" 1111 d"(I', (J bl'(lt1 il110 tI,t.: Cl'uft r. t ..·~·~S$ {111lt: .frtJ)'t I'te to}' uf '''te· ring (r(ipqltalt gillt' Sqllf I :e-()Itt bt'IU'~'ll'~ :o:-trilk>;, It'itlt tl ~rra.JH!r,Ti't Ii. pltl 'tl! btJtJt t;(igtIR t~r/Ilt' Lr~(pr~'l)t},oll' /rlll, .i·II..· dt.ff. tl) I,i.". IltL (',))11 i )ltlf uutil I'; U!! is (tt It'(f $:t J/ .." f I,jrk. Slr'llpt_n II1'h ~{'itl1tilt he-udi."g[()I'ln. 1(11111 )fated ri ug If} it M''fi'rl ('';r'('U,
8
7
9
faQNTOf lOUT ••
fAflll
cur
wrT14 HAND SAW TO REMOVE: WAS'rf
•
SANDOff WEOCE
rt~(!J}ro", l>eudt,'g for'11 r"ut n/fl'),l'(!$.f\ f{to ''(t'r str,p u'ilJt Jlll,ild ~(/)ulIJ'''liISidf'' (if/ht ri"9 (( Itt II it njttltes ltlstlll t)u IJ,t ,torn).
1 0 Uli o s(1«.'. TJ,eJt. Ilf~t}10."f
tl
No. 72
RUa,tJtM
DlR(CnON OF f(0)
11
C'/n)}'I'
(l
"Ilb
(1J')"
fo fh" IYJlftrr
((I bit
RQJllld ()ly~r tile t"ifldt
12 ";)10 u';lh
f·(lye.,; oft/t.
aUfl tY1/411d ()t·p,./ltt Q;IIP,id,·· ('rigj's ojlJ", ri Ilg 'f.~;tlg(J.J/~.7'()}( tid .f)I'er bil.
117.,,, l'Oltl;l!g lite inside edgfJl of lite rill!!.
S" lit .. billll rlll~"ab",'i! lit .. loblt.
rollt III a r/CKk(('i&
WU(ldsmith
tJtf' "lib Ur/)1 i), (1/(1('.('.
(l,r('('1101'
17
FRO
TIPS
SOME
Nt
SHOP
OUR
•
Shop Notes RUBARM • When making L1w laminated ring for the HallTree shown on paJ!~ 10. I wanted to llUl a '1'." round-over 011 all (our t·dges. However, I ran Into a problem
terpoirn of the workl'irrt·
i\rXI. to gt:1 lh<- rub nrm aligned wirh the bearing un ,ht' problem was that the bearing bit, tum on the router. Then, surface would be removed CO!loSJ'RVCI10". To make a slide the rub arm imo the router during the fi~trouter' pc1K:> and rub arm. cui a notch ,1iKh!ly bit until the end "(the rub ann i... using thr ~x"round-over bit in the bit would cui a shoulder on larger Ihan the diameter of the flush with 111" bearing. see Fig. 2 router bit bearing in a pi('('t' of 1\0\(. turn off the power and the router table Ihe second pass. see fig. I. The problem is the location cif ISIXG A RI'B ARM. To solve 11,' Masonite. Then. glue. base damp the rub ann to the router the IlearinK - it's too far above this problem. I made a rub ann piece under the arm. see Fig. 3. labl".rd~rluStcp 11,,"page 17 Note: For Ihe Hall Tree ring. I Once the rub arm is installed, IJlt' cUlling <'fig!' on some bits, [rom a piece of I,r," Masonite, Nonnally. illls isn't a problem The rub arm acts as a substinne cut an arc Oil the end of the rub matching round-overs can be since the bearing has pICJlt)·of bearing surface and when it's in- ann 10 allow till' ring to rotate routed without creating an un wanted shoulder. surface 10 rid" awUns~
1
&lA.ING ,1:10(5 .AlO~ W!1)lST PAin Of RlNO
BUI, on the ring I wanted to
rollt a Inating round-over The
2
1--'
RUe AJtM PROVIDES SUtFAa
TO
~ot,AGAtNST
S('(.'
Fig. 2.Thisprevent» the bil from removing 100 much stock,
3
DUllING 'KONO cIIJ
CUT8LANK INlWS
UA,Vf ROOM to tlAMPTO ~ ItOU'IU TUU
CUTNOTCH SUGHnY
-
IARG•• THA""
IIOtII'IJO ."
IKARlHG
AlC MAT(H(S AAOIOS Of RSNO
OVULAPAND
GlUtINIU.Q
SANDING DRUM PROBLEMS • I came across a problem when
pand, locking lh. sleeve in posi. SC'(' F'? lion. ,g. _. 11llClUESS SA,,(OI'C:. During press 10 thickness saud pan> of used 10 press the workpiece into the Hall Tree. I noticed the the drum sander, see fig 1. normal sanding. Lilt' drum and edges I sanded ....'(:reo·t 0.11ORI'''' COrr\STRl CT1()!\. To un- its sh""l tum at the same speed, thcy were concave, sec rig, I derstand why this causes the ilul when you thickness sand. lI'hen I examined the drum drum 10 bow. you have to look at the workpiece is inserted besander. I discovered the top and how the drum hold, L1>e"'Ulding tween the drum and a rub block. bottom of the drum were bowed sleeve in place. When the nul on 1l1i~can cause the drum to slow out. (Note.Thisonlyseemste be the drum shafl is lighl('ll('d. It down. even ",op if ennugh presa problem ",th Ihe larg,' hollow pulls th,· bouom Rangt' up. 'Ibis .u,,· i,apptlcd - bUI tlu- ,haft drums and nOI the S01aIJ<>r solid causes Ih,' rubber drum 10ex- will still be rotating since it's using a sanding drum on the drill
1
O'RUM SANDER lOWS OUT
rubber drums.) This problem arises whenever 3 rub block is
tightened iruo the drill press chuck. This over-tightens the drum, causing it to bow I'\C I"SERT.The problem is eliminated b)' slidin!: a piece (I[ PVC pipe insid« the rubber drum. This allows the drum to
tighten. bUI keeps it irOn! bowing. For my :1" drum. I CUI a piece of IVJ"·dia. I've pipe to 8 length 01 2ltl" It" exactly the right size to til inside the drum.
3
-,
I',.," PVC PiJ'£ INS:EmD IN
DaUM
18
Np.72
•
• ROUTER BASE PLATE FOR CUnlNG • To '"UI the round ,h,·I,,·, for Ill!' Fern Sianeland Wm'k~ II", ring bending jilt for the Hall free. I replaced 11... base plate on m)' rout"'rj\'itll a 1ar:g\.·r~11ol)buill bast'. The n...w base pl31<'
acts 3$ a trammel auachment ior t"Ultingand roulingdrd~s. li.bE I'L\TL Iused a tli«t> of "," Plexigl., (or ),ou could use Maserute) tor the new base. To curcircles I"orthr projf!Cl~in lhi~ issue.the new b;1~ needs It' be extra long. To make the base plate large enougb for tho ring on the Hall Tree. rul lilt' PI,·,.;' gla
•
CIRCLES "our ex
the plywood 10 my bench . To auach Illi..;.piece of Plexi- ample, on the fern Stand I To rout a circle, $t~t111(,'bit \/.1'" Rlas to yuurrouter, I)OS11100your needed 7"·dia. shelves so I deep and drop the base plate router's original base plate over drilled a hole 31-," (rom the edge over the pivot pin. then, lip tilt tit,,· n("\' platt!and use it as a tern- ,,(tJ1C bit. ~'C Fig. 2. router nt a sligh, angle sc the bil plateto locate and drillthe screw For the pivol pin I used a 17 is s)igbtly above the surface and holt." and large center hole gauge brad and drove it imc the tum on lite router. sec Fig. 2. PIVOT nOIE. The n('XI step is workpiec e. snipping it 011 ~4" (Nole: If you're u.ing a plun~ II) drill a VUi"-diamt'ler hole in above the surface. router. you won't have to tip h.) Ihe new base plate In fil oyer a ROL'TISG ('IRCUS. Once the Now, ,Iowl), plunge the bit pivot pin. see rig. 2. pin is in place, you' re ready to into the blank. Then pivot the To locale the pivOIhole. firsl start routing. To keep thl' bil router rlm'kll'i" around the mount a slr'tiight bitin the router (rom cutting InW the bench circle until you reach tile stan (I use a v,,"-srraighl bit). Then. when roulinR all th e wa) point. Repeat this process. measure from the cutting edge through thr- blank. I screwed il lowfring th. bitli," (or less) be01 the bit 10 the hulc. This dis- (in the wasl~'iCctionl 10 a piec.., tween passes until the bit cuts tance isequalto th{·radiu~ of the of piywood and then clamped l1,rough the blank. S<'t' Fig. 3. circle you want 1o cut,
of9V~tI, S<'t.·l-lg. 1.
lIP ftOl.ltlR AND LOWt•• " "'_-"'_"'NTO WORKPLKl <,
1
SCRiW .LANK TO
BASil,.. WASlt S((;TION
...,. PIVOt PIN PLYWOOD aASE
WOOD PLUGS • Wood plugs are commonly available in three styl es: flat-
head. ovalhead, and burton. see
Free, I needed a simple way to install the plugs without flatten-
piece, Ovalhcad plugs have a rounded lOPihal protrudes from the workpiece.And buuon plugs have a shoulder that keeps the head evenhighero{fth~surface.
ing the IUpS. So I made a plu![ seller that matches the plug's rounded lop. see Fig. 2. C(ISSTRl.'t'TIOS. To make the plug seller. first Cui a :]f." dowel. 11a'·long. Then. drill a shallow hole in nne end of the dowel with a 7/t6" twi,t drill bh, see Fig. 2. SETrue ru'cs. To use the plug seuer, position an ovalhead
Flathead and bunon plugs arc simple 10 insJaIlsince either the top or $houlder of the plug i< nush with the work surface. Ovalheadplugs.however. can
plug in a hole and place the Sel' ler over Ihe plug. Then. tap lb. sctterjustuntil it boUoms ou' on the workpiece. see Fig, 30. Notl.': Don'l continue tapping
be driven inion fur. And il'~easy 10Dallen their rounded lOp. Since [ used :}s" ovalhe.d
you'D leave a doughnut·shaped dent ill the work ."UriBe•.
fig. 1. And they're available in
~ .. '!.~. and 1.1" diameters. I~STAWNG pu'cs.
Flathea d
plug:; arc installed so the lOP of the plug is nush writh the work·
•
plog,;fonhc FcmStandand Hall
No. 72
1
WOOl> PLUGS
BUlTON
OVALHEAO
FLATHEAD
/--....
,
~
t.
1 '\
1
2
the SE!tterafter it bottonlS (Jut or
WooJsnll[h
\-{
I 1 DON'T
OAJU PAST
..
!
1'~l71
3
1iV[l ON I" ,,~
.IT ORW. HOll
~7~, ... lW&ST ORW.8ITroa ~." OVAlHEAD PUJG.S
PWO SmtR
,
19 I
WEEKEND
PROJECT
•
Fern Stand There are two challenges to bUikling Ihisfern stand. The first is bending the legs with a gentle curve on both ends. The second is eLLCting the shelves into /Je7iect circles, Fortuna tel)· , sinlple figs lnake both tasks a snap.
Y
wnuld
that makinll bent legs - CSI>oall)' legs with a bend on '",rh OU
t h ink
ends - ,"'"uld require a -':cI111plt. cared jig and maybe a special
technique Iha. involves steamillg tht ..wood.
Actually the bent k'j!Son this stand
arc
bent lumivatume.
They're made o( thin Strips ,,( oak with two strips of walnut in lilt' \'t"nt-..r fnr accent. These strips are laminated (glued) l()o gether and shaped on a bending jig. (For more on beut laminalion. sec page In Rf-:N')iS"G JI(;. 1·0 bend the
curves on both ends of the legs. all you need are ten damps Ihal
w(lod can be benl to shape without steaming, soaking. or an)' 'lled.1 preparation. $IIH.\'E». The bent legs are (If
attached to three round shelves.
I sized the shelves 10 hold a medium sired (6"o(]i3.) flower pol. bUI the shelf diameter can be varied to almost an)' size. Cutting the shelves into perfetl cird," i~ the second chalknl!'" on this proJed. But again. it'scasier than it might seem. All I used is a router filled with a shop-made base plate thaI bas a piVC)1 hult drilled in il. When thl' hole is SCI over a pivot pin. the router swings around it to cut perfect circle s.
open I(J allt;"d~t -1", and a ~illll11t"
"l~lStl.A-:.
•
for the-fini~ll. lh~
bending jig that's made out or
primaryrequirement isthat it re-
plywood, 111e jig is designed with gentle curves sn ttu- strips
coats or salin Jl<,lyun-thane.
sists moisture
r applied
1\\'0
~
MATERIALS
3;,..
A OokLegBlon1<&m I ,•• M (Each bioI''' YieldsItvee Sl~ Minimum of 18stopsneeded) 8 Wo "ulleg BIon1<&(3) '1-. x 1\II. XM (Each btank Y aids lrJeesll\ps. Minimum 01$ill stnpsneeded)
C WolnuISheIves(3)
~A.8.8
(Edge-gllJe these rreee blankSfrom sll( 4' .8
cseces )
~." x st.," . 48" I.' 14. f,. 001(1
{TT'T!'T~lEl c :1." .. 3',,-·
L
z,z
c .aa.
c
{1.2 ad. Ft. Wolnul}
.. ',,'
8 ..... " ..... ::tfl';%l
•
Also requ.ed for bena.ngjlg • (I) 10'.<1<1 piece
'. ·thlCkpl)lwood
• (I) 14' .2"",. p.ece ~'.f·thIc~ply\VOOO • (I) 14' .~1~· piece -InlC~MosonlteorP!ywOOd
I'.
20
,
N,l. 72
•
BENDING JIG The first slc pin building the (em sland i> 10 1V1 1de \yilh 1) ~1" space between them, make the legs. Bill before you can even start which "ill be the thickness of the legs.) on the Ic~. you have to make a bending-jig. '\fter drawing the half-circles. CUIthe blank Ilegin making 1I1Ojigby cuninga base irom in half. sec Fig. 3. Then cui out the quarter:\I," plywood, see Fig. I. circle forms with a sabre saw. 81ANKFORFOK."S.The next tepin build)'01 ~"NG11IEFOR~1S. }\fter-all the form ing the jig is to add sections 01~lr.iiJ:ht and pieces are CUI.the bending jig ran be ascurved forms lU bend the uiin strips 10 sem bled. Start by screwing thr inside shape. Since the strips are )I/u1' wide.these (smaller) curved pieces 10 the base. To align the ends of the IW(. curved forms should Ill!at least 1" thickl made the forms by gluing a piece of III" plywcod to a pieces, drdW a line down the length of the piece of·v," plywood 10 produce a blank 1-1" base. li"'2"from one edge. sec I·ig.. 1. 11''''1 by ~J1"1.". set rig. 2. mark reference lines 18" to each side of Ih... STR,\ICtrr Fo')R'IS.::-'1.x pieces are cut out ot centerline. sec Fig. 4. Now screw down Ihe this blank 10 make the bending form: four curved pieces SO the outside of the curve curved pieces and 1\\'0 ~traighl pieces, To touches the tS" reference rnarks atthe ends make the straight sections. just rip two and the line down the center. pieces I \r!' wide b)' 21"'2" long, S<'(' fig. 2. Ne:l.1.screw one of the straight pieces un ct K\!~'Of·()R~I"'.To make tilE' curved ~. the line down the center so it's aligned will' lions. scribe ("ur half circles on the remain- the ends tlf the C\U"Y~ j·it..'(es. iug pan of lilt' blank. sec F11>!. 2. (1b"", Note: The other straight piece and curved curves are spaced to produce curved forms piece.. are not screwed 10the base.They're M ....
1
B£NDING JIG
T
,
2
__-""'1 ••
fRST: RIP rwo
used 10clamp IIw strips 10 the fixed form>. Finally .10 prevent the stripsfromsiicking 10 the base and bending forms, rub paraffin
(orpasiewax) '10 thesurfacesthat willcorne in contact with the $trips during gluing. ci i'TTh'G nlE S1"'RJr·s.Now vou can start cutting' the strips for th~ leRs.. Fi""1cut S('VeIl blanks of:V·,"·thickoak and thn.'t' blanks of :!;,"·lhkk walnut 10 widths of lVItI' and lengths oj 41". Now. resaw the blanks into thin
II~~
3
WlOE STRIPS FROM .A;-v_....... \4" x 211,,"
SECOND;
.LANK
CUTOUAftft. CIR(USwtTH eA.NOSAW
•
•
ORSAA~SA.W
5(1.11f HA.t.F aRC';I.B ON ItEMAINJNG
aOANlC
4
•
1--' STRAIGHT
'o«M f
1 l a.
..
211.,.
e
"
3." I"
•
lI".. PlYWOOO
eA,$f
[ CUTl.),"·lNKK STRW$tROM\
-
•
IliANI<
\~ 4
A~D
FOR.M
, No.71
.
....... lOO~
-
'ORM 10"
"
_f -.
...____. 4·
_.J
-
,
1\i.ICKNfSS OF SlACK, $ttOULD fOUAL"',,-
21
•
LEGS After riPPinll alithe oak and walnul strips, Ihl.'next step is 10glue-up the k'1!S. GI..l.'ING TIlE ~"ffiIPS.Sian by spreading the ~IIICon on" side 01each strip. Then. a. LJu, glue is applied. slack Ille .trill" like a sandwich: Ihl'{',' oak. IWtIwalnut, and thrC<' oak strips. Now pick up this stack and lay il on its 5i(I<' aj-'llinstthe straight (~mlon the bending jill. C!.>\,\1PING. Nnw. add the other straight (orm and clamp everything together. starting in the center and working toward the ends. see l'il(. 7. Then. align the top edges of the strips flush by gently tapping them down with a hammer. 8~!'oDIN(; TIle ST'Rll'S.Nex~ the ends o( til" strips can be bent around the fixed curved pieces To do Ibis. use the loose curved piece to press the strips against the curved lorms. When they're bent a.' fur as they can be bent by hand, piu lin a clamp. centered on the curved section and tiRblen it down. see ~ig7. Ihen add twomoreclampstoeachcurved section, Now. tightco all the damps ;;0 the pressure is even along the entire leg. CLEAN·t·". After waiting about six hours (or the glu(·to dry. l\'mQ""lh~ leg from the bt'ndingjig. Then, scrape off theworsi of the dried Jduc witha paint scraper. Begenllethe paint scraper is " rough 1001and can easily tear CJr gouJ,:C the strips, Now the legs can be planed to their 6nal width of 1". To avoid tear-out. Iused a low angle block plal1~. cerro IF.NGTIt.I\s It comesout ufth~jig. the leg is too lon,l(and must be cut to length. You11 need 10 mark Ihc lOPand Ih(' bottom endsot each leg. and then rutofftheexc~ To keep all three legs a uniform length. I marked rhe cut-offlocations on the jill. Use acombination square to mark the locatlon o( the top of th.. leg ·1"in (rom the cod or th.. flXt>d curved (onn.$Cc Fig.S. Then mark the location of the leg bouom 2¥.· from the end o(the other fixed curved form, see Fig. 9. xow. put theleg' back in the bending fonn and transfer the cut-off'locations from the jil( 10 the leg. Then, cut offthe extra stock with a band saw or hand saw. ~Hi\PINC'l'Hl'. ESI)!;. When the exun !\lock
11
~ ClA,MP Sl1tAIGW'f SKnON
SECOND:
8
1--'
MAIIlno.
9
END OF LIe
IWI~ BOnOM
IN. W1rH
--
SQUARE
c,...,_
V'_"" .: r=" ••
.. ~
o.
a.
ROUNOOvtl np WI'fH'IU
CUT0" STRAlGlif wmtlANOSAW OR. SABAl SAW
ROUNO ()VI:R £ND WITH HU! OR OlSK SANJ)ER
--.-
DttAWUNE PERPlNDtCUt,A1t TO ENOIOFORM nAT fOOT-
10
UG
,.W
ItOUTlR.
ROUTmG(S 'N A stAllS oF UGt-iT PASSU
•
',.
ROUNDoOvtR Sir
is removed. round overthe lOPend o( lh.lt'g with a file, see Fig. Sa. The bottom end requires a secondcuuecreate aflat (001. To do this. use the combination square to drnw a line on the bottom ofthe leg•centered on the squared end. sec Ftg. 9a. CUIoff tht' CXc<"'" and then shape the lip with a file. SH.t\I~INGTI.F.SIOES.To soften the comers 01 the leg s. I used a ~t<" round-ever bit mounted in the roult-rlabl.- and tt,tllc a klriVS
12
ollighl P3s.""s, see Fig. 10. SCREWHOUS. Aflcr rouodinK "II"r the IPIIS. mark the localions 10 drill the holes (or the screws that attach the legs to the shelves, Here "Ilain I used the jig 10 lay oul the screw hote locanons, see Fig. 11. Finally, drill a ¥."..tJlameter counterborc V,"-deepat each oClhemarked locations. see Fig. 12. Then, drill uie shank hole with a :!ltG" drill bit. ) ... COUNTIRIORf
....
/' ' ....~DQP
I
~." COUNTtUORf ClNTlRtO IN UG \
CROSS SEcnON
22
Wood~mith
-, •N0.1_
•
•
SHELVES \\11t!l1all three tells at" complete, work can tractor and mark every 120'. see 1~1g.14.
begin on th" shelves, The circular shelves (C)areculfroUl '4" thickwalnutblankswith a router, To make them. start by gluing up three 8'1K~" :,qUatl.-:-.coc,,"fiR. I:{. IIQl'TCIf{( U:S. To ou the blanks Into perr.~t 7"-diamewr circles, I used my router filled with a 'J1('('ialbase plate. l'his bast' is slighII)'largerthan the original baseto accomodate a piv(JIhole 3t'tl! frt,nl the router 1,jL For more 011 cuuing circles, SCf.' 1>3Kt." 19. 1.J.;c. SI7Tt"IIf-".11w I,'gl\ an' screwed int" notchescut into Ihecdl!e.oflhc ~hdllt·,- 'J" mark the centers ofthese notches, usc a pro-
13
_'""'"
...... ...__
••
..............'
r~3"'" (f
"
i~
INro
~
~.
•
~ ATTACH lU.ANJt
120\
.....
•
- I~" ROUND
r /
-,
"'.
./
ROUT aUI,I.NOSl: lEFOR[
18
~-_;; ., "
'."':
~
C,"~
OANJ).AW
......
"
..
,.
SMoOTH NOTCH
wt'n4 ' ....·OIA
....
t
e-, "3
.r
QHltRUHI:
}.;,~
17 ~
r
\.
ctlmNG HOTCHtS
-e,
~)
'y
~
ROM [OGl
$HIll'
aoUTtHG SHQI"
J!j.~.,..
IN'."
I
Tl.MPLArt
.
~
sn TtMPlATl
~~
-..~
UG NOTCH
lAY our ctNtUS ""NOfCl<6 fOR1.toS
TO SCJt.All8AU wmt CAI.P£T TAIIi
(a,
tJ
",'/ /j} \J._ . . .;z:, ~.
lUOR(
r:~
'/
...
»: /'
-
...
16
"\".~=
15
~'/
GUJI: UP T'HRU :I: ..".JH1Cl(stttLl at.ANtCS
•
..
~
~SMELfC
.~.
14
~
I
tlUIUIOSE Et)()ES. Before cut ling the :<01'(;11 TE.'tPI.ATE.Each notch js cut to fit notches. I routed a bullnose edge on each the side of. leg. It'< easiest to lay them out ~helf. see fiR. 16.To do this. mount a l':!" by first making a template that's the same round-over bit in the router table,adjust ltso shape as the lew;. see Flg, 15. To do this. iI's "'Ib" above the table. and rout both the round over the edges of a scrap piece of I"· top and bottom edges, see fiR. 100. thick b) I"·wide stock, u>ing a :Vtt" roundOT OtT NOTCHES.Now the notches can over blt. Use scrap that's long enough to be be Cui OUI.see Fig 17 I used a band saw to safply handled on th,· router table, R'OlOV!! Ih.·•see ">g. 18.N"w.l<.''SIthe legs in the notches 10be sure they fit, shelt.sec FIg. 15.
,
ORU.M SANDEll ,
fo-
<,
ASSEMBLY legs.into tho shelf notches with No.lix P.'2" Oathead wood screws, see Hg. 20. Once the rem stand is as sembled, check to see thaune shelves are perpendicular 10the legs. lf tlte stand is twisted. loosen the screws- adjust the stand and then rc-tighlcn Ihe screws. I'U'Csc'·R.,,\,, 1I01.t:s.Finall) . fiUthe screw
To assemble the legs and shelves. "Ian by drilling a pilot hole centered in cad' notrl •. To do this. damp the shelf lnto a large hand screw or between two piece~ of scrap slLI",drill press table, sec Fig. 19. SCR",\'·U:C'TOSHEL\'El;. Next, screw the
~1
PIlOt HOU (N NorCH
;} "
•
,
aH'11.a .),,"
19
(T •
'1
I
/
!
f"
~'
20
\
i
~
-
'c,
cu....
.w. ...
A~~
TO•• IU. ... USfA.1l
~
~
•
j \~ood;nl1th
CJirac THAT $TAND
ts STRAIGHT effORE GI.V1NG"PlUGS fN SCIlf;WHOW
...
ItG-O
,~
~
Nott:
a,
AU. SCREW HOlESwnH OVAlHtAD PlUGS
ClAMPSf
.17 N". i2
~
o
//
~
IX~ J~ ;::'
SCUWLtGS TO Sft{lV($
l.
"It.
~ ~ fl~
holes with oVlIlheadwalrun wood plugs. see Fig. 2Oa.(Formoreon inscrtinglheseplogs. see Shop xoies, page 19.) 1·1111ISII. To pmtect the rem stand from moisture and water stains, I applied IWO coats 01 dear satin polyurethane, sanding Iightl)' between coats.
.ax
SHW
•
11'1"
fhWOODSCREW ~
.
23
COM
}vI E N T S
QUESTIONS
AND
•
Talkillg Shop FLAT OR QUARTERSAWN? I IIlll''_' tt n oi(1 tabl, Ihltt'l( 1}1(~itl)I!lnIrafnnd ! lllf,nt to rl· 11(1)1";"t. {Jut /",1 "n~'tn!laIJm/~.
1,," ,tt.,d,ltg tl" ,·;tJltl "";"d '('Clod. "l't t"t'lt (Ollillc(lt 1(IfH/II/ IX "'Iltllrlt"r"nu'il -
r'f';
GROWTH RINGS ARf
ltSS THAN 4.i· TO TK£ fAa or- TH' 80,"0
vI"
.OAltO SHAJNKS
tIlt
AS IT DalU
"
~'(il; f,'11 "ft' "'1,,,,'.;; nut qtl(,,.t",~au·)j!"'}I,·t .. due» " r",llt '''ti''l '! .l'lud ,,./,IlI'x lllf
bi,
tIlt adr« Ilta!I" tfIU.'fill!l,t)
J"illi' .II
"roo,.I!
Bill ;ttY8, "[ol,lll.llll
First oi all your problem i~o'l tindinzthe right kiud ofwoodirs finding the right rltt of...""d. lis you said. your table top W'
FLATSAWN
[:::
ers is,j1(lli)II'CJt.
quantity of u.:ablt' lumber with the fewest detects.
..
.I
,, ,• •, ,• 4, •, •, t• ,• •, ,•
('lTl1~(, U)(;S.The difference between them is in the wav
they're cutat the saw mill When log$ar~rut into lumber.the "oaJ is usually to produce the larg
...
QUARTERSAWN
FLATSAWN 80th of these methods produce
SUGMT MOViMfNT IN TH)(~HtSS
FACE (;R.-\IS~However. the direction of th~end grain isn't
111~ only dii{~""n<'ebetween flatmostly flatsawn (11r plainsawn) sawn and quarter-aw II lumber. lumber-> the mosicommon cut The face grain also changes. In 01 lumber available, woods with pronounced grain 1I0lUZO~"AL £.'''D GRAIJoi.To pauems (lik(' red oak), quarter determine if a board is flUIS3\l{n. sawing produces aJIIIOsl iridesstart by Io<'kingat the end grain, cent rays or flakes on the face of SA\\'ISG ARO~IN1) nil-: LO(~_ Ifthe growth rings arc I~ than the board, see photo. WOO]) \fO\'F.Mt:;~T. Another One way 10 avoid Lh,' I~,~ 45 10 the face oi the board, ii's desirable area in the center is to flaisawn.s~edrawing above. diifercllcc is tllC' way quartersawraround the 10g:To do this, Another sign that a board is 03t- sawn lumber resists dimena sawyer (the person who cut sawn is an 0\131 nrll·shaped face sional changes (shrinking and log. into lumber) starts with the {.trainpattern, see photo above sw~lIinl:) and cupping with b("iltlooklngsick' ,,!the log, cutt:han$ltS. in ..:ea-sonal humidit}'. QUARTERSAWN All boards expand and conting offboards until he COUll'S to a defective area, Then the log is Another method forCUtting• log tract along Iheir growth rings, turned 90' and sawn again. This imo board. is called quartersaw- On a IlatsaWtlboard thi s ca use. leaves the center portion intact. ing. With this method the log is the board 10 move and possibly which can then be made into CUtin half and then quartered, cup across its width, see drawposts or lower gradl' lumber, see drawing. Then boards are ing. On the other hand, on a TIIRfJllGII ANn TIIROl ell. If cui from each one of the quar- quartersawn board there's very the log is rather small. or has tered sections. ijU]~movemcntacrossthewidth \'t."R1lCAL ENn (;RAI:'. Cutting oi the board and virtually no many defects. the sawyer may decide it'stoo time consuming 10 the hoards Iising this method chance (If cupping. RIfT, In both iJatsawing and sa... around the log. Instead, treates a difierenl pattern on uw end. The growth rings .... ill be a~ quan~rsawing. a certain amount board$ arc cut one after another. 'Ibis is sometimes referred to a. mo.t pr:rpr:ndicularto the (ace of of lurubrtr will be r(fl.'O.Il'/f, The t"Utting-througb and through: lhe boord, see drdwing, growth rings on this lumber will
Typically.the clearest lumber comes from just beneath th~ bark, And the least desirable art-a is the vt''1' center (or pith) 01 the tree. This renter area is weaker and prone 10 cracking and checking.
24
QIlARTERSAWN I''ACE GRAIN run approximntely
•
15· to I)",
face clthe board, Here again the easiest ~rayto determine thi~is by looking at the end grain, Riftsawn boards usually have a >lIaigln grained appearance without a strong pattern or rays.
So it makes an excellam choice if you want 10 "'play down" the grain on a projt":~ AVAJIAl!II.m'. II quartersawn lumber is so gr~at, why isn't it readily availabJe? The problem with quartersawn lumber is thai il'o;:_time C011!\Uming t() mill and lt's wasteful
It take ....a large
diameter log to get boards ofan)' si1.~liticanlwidth. so many oithe pieces are toe, narrow to be uSW'" ful. TIle end result is that quarrersawn lumber is expensive and hard to find in large pieces, Finally, don't be discouraged
if your local lumber dealer doesn't list quartersawn lumber. ~:ycn• Om""wn log will have a few Quartersawn and riftsawn boards, So sorl Ihrough the boards carefully - you might just findwhal you're looking for.
No, 72
•
r
•
CALIPERS ltow fie. ),CIU art"unltt·ly rncasure clampnut Then 'h~''3IiJ)<'''' can thin ~Iril)'" of Yru«x1?'11'1... C)Ut'~ be- u ...cd 10 make rt'p"lilivt,., ti(nll"III1'(' up ,1",,1\\ ,l't-Ultjng We' IUt.~asur\·m('n1' ~lirlr. ca1ipt'r... ,uil" (or til\' Irll1llll.kd prnj{'<'ts are- available in c. ithcr II1c'I1 er rh('('k the depth of • hulc )'011 in ,hi, io:... ut· \'e'tl could 11)' to metric j!1':ldu;Jllon... 1)1\1. c.. U.D'Fft:"o..I\ dlalc. ~1I1)l I'"l'I jU!'1 drilk-d, Or (,"\'1.'» lht.·depth ul hal.11l\ l".~ 1111"'1111••
'h"
•
"Ii,.,.,.
hasa '.~'k nrclamp ynu can lock Ih.· lidi in l')()Qti{'nand remove lh. <'.Ihp"'" toread it, Oryou can n d t be dial with th.· .:alipe'" Ilgh,unlh ... orkl»'''C(' rlu-ethe ....''('('nd method b-cau-e thl'''C'~ :1
"'MOtl of error v. ben mo vinR
tIl",OlI'lo rs,, onltR t'l'. I rind my,elf r. 3d11nl: lor the dial calipe .... ml,n' allel more I iI~'t p on...nex. tel lilt 1'~Ultr (I)' ch('\.·king the
",r ~t()(;:k bet ........·Cn
thickm- ......
1'.1'''''. It', uJ"'I1l"at
for check-
illS{in ...jclc.' cibll1:n":on~. such as 'h, w,oth (II"dado, Orth. actulil ,tianll'll'f of a hoI(_" you jU~l f1rilh"flln "v.','rkpil't'l',
CLAMPING TIME ,'"" 'tl' hll 'f' I
rhflK"
.!r
(l1tJ!
lal ps (
cniltt""(lt(.1tht· \rio 00.1 )ou·r~"., Ir}:.
ItUJlutC-:.whrn tht- tempt r:a~urt'
1111l1Uh"'!1onnd~C. rilo!hl to work.
nt2"Mlh ~if\Cttltl,;\il n'3~tltl) ,..,.nh j.5 d<'gl'(~ (~tlt'!.A'Tlding 3. 'lo;.'--krfUt-C up bt>lit"\"t" thai \ our \\ood m!t) nc~ pand Ihroullh a planer is ''''liP I ol'dded:o lJ)" an "xP<'rilll< III f,r1-.. ,I.( IO"p$ol/"ONJc "I" bencarth(,"o;~lrnum 11101" lhat would cl=k ,,\lI)"U', In(ror· ).:tI.W("f" ~or) r \, ,I.!t at ka.....t (Qur le,I" '.I rorl:' tun'" \."'Ontc'n~U ... a J:IXld id(""3 \1,) matton about the rt.>Lltion,hlp h.tuf"". anellh,lf ...( nf)' i( rnl in a Jvl, r ':'1"rcld lea\'( tht· 4,~lamJ)'" I,n u Ii lIt; belW{'t>l1 tIw dryin2 tino" "I )"\- bll! hllrr),. '"nnaD,.1 prl'k..-to lOngt.':r th.aI1 Jc tf·... g<'nl'ra] ruj~ 10\\ glu(' and air ((·m.,. ·rc:l.1Ur~ wast e)\, rlligilt ,\t "q"./".,Yl !-TT, Th,· ... '\.·ol1rJ r,ln"'ldrrdtlon I p\ll dolloJ)5 f)1 yen ..", gh.,· "n t'nl III"64,'(10<'"(mt'd thallh~ l·l.lmplnJ: llnlt' dt'llt'l1rJ, on a lot of thlnj.l....ill~·ludinl.:the kind of is tht' Vwa}lllt I ....t' IJit't"C"... f)j .1 I"". pia't.'::,o(wood, lind Ih,'n lX11 ~'i01 "ill r"ll ·Ih,· pmblem is that Ilt.'IA·lv..:ll't.-djellUl'!'>"Vo·(.'U up, glut ) 011 U"(', ''If'r~ al joinl cf,m"'I"~I-'h,'r,1l1t' bt."tt~r Ont~ pi~t" in th .. n·(rigt·rattlr """111."'111111, y,.'(' u"llall~ .. USt" lh~ fil. II", I,'" dJmpIII" ,im,· b ·n,..o J watched the difllan~ or ,:and in Iht.· mJdd1c.: e,f it. Tht· RlUt, 10 tht., V.CMxtI..f1uncdi.4h.... ly. the joinl 1111' J!\ fl' 'r.tJ rult, Ilt,lll'w 1:-45 a Q, <"ak('"r~)lnl.) TE.\IPI-.A\l1 Nt· 1111'It·11IP'.:r:. the (·(rijlerator. ",hjl ....... Ullt '....lllllei lLppt"dr fine at ~ But IninUlt·.. h,r~~' ~lulnli!,and5 i:(. what thicker from th. ,·old. had runor tht' air. '.'ood. IlJUI t:lul" 1(' ,IUllutt .. a :-ot n)bl~'JOinl~. a.I1. , til.· " .. 1<1 """ a cbaoc~ 10 lik.· tOllgUt' and groCtvt'... f'''~ a}sc, ha... an affl'(1 011 ('lampiJljt 110 <;;kirl and the tt,H,ll'Ipi("'k pJit dr) out. \ou'd v.ind up ~;lh a plain,-d ).H. H~ qUK'k1) pumled timC" the ""M.lt r they U<", Iht t1tlfll)'iJ:h, d<'J>l't"'
O
'I'·
I
•
"'Ill"
,,,),
~, I ...
TOOLS
&
TECHNIQUE.S
•
Radial Arm Sa", T
he radial ann saw is tit... perlect 1001 lor cUlling kmg pieces oC stuck t(, Ill.nag... able lengths. But the problem is.
FINCIi
Ih~ tables on most radial arm ~\\'Sare too short. Il becomes a
real balancing art to cut a ~·root 1<'I1I."hIrom an 8-h)ot board. To "",1,,(·this problem. I re placed the particleboard table Chal carne on my $3\\' v. nh a new, lunl(l'r table (Bl'Si""" the uld table had zouen pretty chewed UI) over
the y('ar.;.) PROTfCTtVf SOIJIJ·H)R£l)()(lR.I iound the SORFACt perfC'('l replacement table at the SPACUtS OF ' .... local home center, It's a wUd· OF I." MASONnt MASONm core door that measures :10" ~ wide and ~O"lung. (Slight I), blemished. these doors arc SlcnON often available for about $25.) QtlAaI.l n,CS<' doors are usually H'." thickwith a solid con- ui panicleboard. They're heaw and stable -guOO for saw tables. TIn-races 01solid-cen- doors are tYI)j(all~ chipout on th~ bouom side since hardwood \'I.'"('('J. ruul even if 111t:r~':-.no :-,uPJX,rt where" the the lace i. blemished, il still blade exits, works fioC:" for a saw table To help keep the new table in :-'ote: Instead \)1IIsinl! a solid- good shape. I screwed down a cure door yoU could build uptwo protective surface of V." Malayers 01 ~," plywood lor a 111- sonite to the topofthe table. with ptacernent table. a replaceable middle section, PROTEL'1TI'ESUlFACE.i\Jlother drawing above. Now. when thing that's always bothered me the Masonite becomes 100 cut about working on the radial arm up. Ireplace the middle section saw is the way the table g~t. and start fresh with a smooth chewed up with repeated cut surface. ting.!ls the kerfs in the table gel "PACERS. As a further precauwider. sawdust builds up in the tion against sawdust build-up. I kerfs. And the workpiece can added another feature 10 the
_NT
'I'"
SOUD·CORl DOOR'-......
SPACERS
{1,S....·THlCKl
(GlUe TO fRONT
SI<\'lON OF TAlLIJ
new table, This is simply a rowof
~pac("r~attached between i.he fenccandthc front sectiononhe
table. see drawing.
These spacers produce a ser-
ness 01 your table and any protective surface. Poshlon the spacers at 7" to 8"' intervals, and glu(, them to the inside edge of the from sectlcn 01 the table.
ies 01 l(3)lS between the fence and the CUllingsurface 01 the
Shop Note: 1101meh glucworks
table, The gaps allow sawdust to fallthrough thetableratherthan accumulate on top of the table and keep. workpiece (rom but· tinlltight against the fence, Icut the spacers oUloIV." Masonite 10 a length 01 2". The width of the spacers is determined by the combined thick-
SIJPPORT. Finally. if you position the longer table very Car 011· renter (It'1l.()orighl Onthe base) you may want to support the
•
best Ior this,
heavy end with a cabinet. or
simply a 2x4 brace. This keeps the table 1I10re stable when you're cutting a long piece of heavystock.
FENCE SUPPORT LEDGE • It's nOInecessary 10PUIa 101lg table on your radial arm saw ju~t because you wam a long fen."e. BUIifyou do add a long replacement fence (like th~ one shown On pag~ 3/), you may want 10 consider adding a ledge to support 10D$!workpieces, see !'ill'. I. A ledge that extends from the end of th. tablv 10the end of the fence keeps a long workpiece from drooping over the end 01 the table. The ledge also lets you use a stop block beyond the end
26
onhe table.
_.
MAI
X
11",-
COUNT'UtSUNK Fh WOOOS(If"WS
FINe> I
•
can return it to its original
position by simply bUIUn)tthe ledge UPIOthe end oftbe.able.
\Voodsmlth
No. 72.
•
MilER JIG • AhhoUJ(hI use the radial ann saw mostly (or cross-cutung.
there III'(' umeswhcn I USC it for cutting miters. But the problem is moving the saw ann from 90 to 45' and back allain. It lakes a lot of 6ddlingaround 10 gel il reSCI to CUI a perfect 90' aner cut-
comer 011 the centerline. After it's screwed down. rut ilofLOush with rhe odf'(e of the base
tH TSIIl~; I'E:o.(F crmes.
for
Nt'Xi. screw two outside fence I{uides (e) parallel to the edges of the inside fence !(Uide. see loig. I Screw these in place with temporary spacers of +'4" stock (the same thickness as rhe
The jig consists of a base and
fence) sandwiched betwffll the inside and outside guid(_"".
ling miters, My sclution was h) build a miter jig. Then the saw arm can nlwaysbe k~ptat90' whilethejJg
is damped
10 the
saw
ta bk-
c:ulljng miters, fence RUides (ail cut (rom less than a quarter sheet Of;~/~"ply.
wood). and a pair "r removable hardwood fences. The base damps 10 the mdial arm table. and the guides fomt channels lor the remcvabl .. fenc,'l'. I1
•
one edge, see Fill. I, Align the comers of the guide with one edge of tht base. and a third
the RUide< screwed in place. work can begin on Ih,> two fences (D). TIleS(!lengths of 1'4' hardwood fit in channels formed by the FE.'1CES. 'l'ilh all
f~n<:"guidl-s, (The fencescan ""
removed when milt'ring a wid.· workpiece on the opposite side of the jig.) Once in posidon. the fencescan be lock~ in plac e, I rut lite (encc' from a 1\"!" line (that will .Iilln with the "ide >I1ip of'harrlwood. ~'CFig. blade) centered on the lenl,'lh. 2. The k·nP,thot the fenct'S isn't rl\Sllj~"'-UC~(,tI')£. '\')'4'("Ul criucru-!.hcY''3n be cui long to a square (16" x 11;") inside 3l'l'OTnmoda", ""-"',lIkpi<'Ccs. fence j!U:ide (8) and screw it The system for locking the down to the base so itoverhangs fences in place is a simph- one.
1
INSIDE h)FENCE GUIDE
16"
-
WASJ£
First drill a '." countersunk
conterhne on Ihe base aligned with the saw blade 1'" avoid CUlling Ihrough the jill. raise the blad(· 1:V""above
~ '-wide by ~·."-d~epslot, also
the table. Then cut a ,h.llowkerf tontop of 1111'inside f''''''e guide. T" CUI 11 miter. first hold or
screw
hole for a machine screw centered on the bouom "dg e of the fence. see Fig. 2. Then rip a
centered on the bouom "dlle. lightening a wing nul on Ih,· end of the screw causes the screw head II> slide up into the coumersink.As Itslides up.the $lot opens and locks the fence in ltschannel, USINGT8EJIG. Tt) use this jig. butt il again", Ihe fence on Ihe radial ann saw. Then clamp the jig down tothe saw table with the
,."
2
COuNTU:SUNK SCUWHOU CfNT'£RfO ON fHfO(NU5
16"
.,~
"." NOTE:
(UlIO DUIIlfl) llNG'ffi
damp the workpiece against the fcuce (This keeps the workpiece from creeping.) Then pull the saw t1u'ougb the workpiece. Shop Nolo, Bl damping a
stop block 1t) the fenre at U\()end of the workpiece. multiple pieces (like frame sides) can be cut to a unifonn length.
FENCE
)§J
0 ..
WING NUl
t,".W1Ot )( ~4"·D£rP lXPANsJoN SlOT (tHftftto ONTHKKNfSS
SAFETY HANDLE
•
• I get uneomfortable when I short section (3") hold, the cross-cur short pieces on lhe workpiece lightl)' a~aillst the r"dial ann saw. I jusl don 'I like felice. (I'lle short and lonll S<.'C' my fingers that close to the tions (om, a 60' angie.) blade. So I made a safety handle fly placing !.hecod of the long It)hold small pieces, section against the radial ann The boomerang-shaped saw fence. you can apply a lot of handle is cut from a 12"·lonll leverage on the workpiece piece of 1W.·lhick stock, ,ee
Finally. glue a
Fig. I. The long section (about 9") of the bandle keeps your hand away from the blade The
paper on each end (If the handle to keep it from sliding on the fence or the workpiece,
No. 72
Wo"J"Ttlith
27
RADIAL
ARM
SAW
•
Fence & Stop Block hen rulling on tl... radial arm >'II'" the re 's of len a 101of measuring and marking of a workpiece before
W
place at any point along the renee. Then, to t-tinlinalt' meas-
cuulng it to length. But this, "measure, mark. and cut" method leaves room Ior error. 1'0 vliminau- l11('~ gu~No~-urkI
the
added this fen..", and Slop ,)'Stem. 11ICf('arc IWO partslO thissystcm: a high renee and a stop block that locks onlO Ih,· renee, seepboto, Oncethe stop block is tighlen('
the
SLOP
rate
10 keep
uring before each cut, I added a self-adheslvc measuring taj)(' to (('_'11t"(>.
111(' measuromcrn is
read throur,h a P1exil!la.<"hair-
line' indicator, "Ole: The hardware 10 bllilrl
cut t hem in a ~inStlepa_" As lonlt as I was replaeinz the fence, I de-
cided to make illof1!(er,too. ITo support Ihe longer stock this rente can now handle, you mal' warn to adrl a longer table or support ledge, page ~6.)
=
block is available at or through Woods,,,,'}! ['raJert SIlI'pri....."'~ page 31 "mRS, One thing needsto Ixsaid here about this system II you ~ng the radial ann to cut miters, you'lI cui lhmuJlh the metal measuring tape on (h." new Ience. Ithinku'smore aecu-
many hardware stores.
the radial arm per-
mrull'lItly ~I at 90' anyway, To CUI miters, I use a separate jilt. STOPBLOC! The stop block is Oleheart oi see page 2T this SI'SI.m, Itrideson uie new feuce several 'L\KISG 11U, FlXfI'R.E, Since this is a fix, inche« to the le(t of Ihe saw blade «, there's ture for the- radial ann saw (though you no interference> with the motor housing. could adapt itfor a power mlter saw), I made I made the SIOI)block from J 12"·tluck it entirely on the radial ann saw, BUI if you stf)(:k ~I()Ucan U~ a eomruon zxtt _Tht,,·rc·:-. havea table saw.you might find Ir easler and a win,!!nut on top of Ih. block 10 lock il in sater to rip uic pieces on it,
•
BODY BLOCK & PINCH BLOCK The stop block consists or lWO main parts:
Then cut a notch for the-pinch block OUIof pinch blork. 11l<'SC one ~ndo(lh" blank, se....Fig. 1.Tomake this pieces act together to make the btock "stop" notch, ,"I tilt! radial sa" blade Id' above lho: along the fence. table and make a series of ,,'·.rlawing kens until yc,u've formed a 2¥,,"·\\~dl!notch. "'Ole..·ll III order to make cutting these parts with tilt: radial arm saw easier (and safer). l smooth offany ridgt.'S lut b)' the sawblack-with started out with an oversize piece of 1Vi'- a chisel, and cut the body block 13,."long, Pl:':CIlBLOCK.After the notcb is ttlt in the thick stock for each of ~ICblocks. DOD"mAX To male" the bod" block body block, the next step is to make the (A). start with a 21'2".wide by9"·longblank. pinch block (11), refer to lrolt.3. To d" this, the body block and
H
BODYBLOCK)
1
®
2
NOlt:
cui an oversize blank to width to match III" hl'ighl ofthpDol!'h in the body block (2"),
To determine the length of Ihe pinch block. position it in the notch or the body block with tbe:\'t",thkk stOl'kym,11brusinl( (or the fenre sandwiched in between. S('(' Fig, 2,Add a match book cover between the fence stock and thc pinch block 10 aCI as a spacer for clearance. No" mark th~ pinch block and cut u tu length. """ fig. 2.
3
PINCH III.OC1<
I
I
t..
I~'
1
CUfF.OM
looy &l,OC1(
11,,-
,_,-..._
•
2"• q.
BiANJ(
2'
....., 4)4"
NOlt: CUT BODY BLOCK
' .....
JaQM 9"- lONG ,LANK
28
..
~
).. 'J1iROATOf ~ STOP.lOCK frTS TKIOCNESS-
"
~
OFnNCrpws 1'MfCkNW OF SPAC(1t
W"",,!smlth
®
.... PINOi -BLOCK
No,72
•
•
ASSEMBLY With the body block (A) and pinch block (8) cuuo size, you're ready to begin assembling the ,lop block. The pinch block i.auached 10 the body block with • carriage IMJh and wing nut, sec Fig.·!.·tighl~ning the winRnut pinches the block against the fenc!·. To erealf the 'pinching" action.the pinch block is b..'Vdt>dalong ils upper end.anu hinged III the body block with a spline 0(11." Masonite. see ~-Ig.4 a, CI.TSPUNE "F.RI'S. TIlt' spline fits in kerfs nil in both blocks. see Fig. ~. To rut these
4
,"
,~. SPUN£
NOTE: I(\I(l
fXlIND,
ONlY to
$l'u."
kerfs the saute distance from the ends of
both pic"",. I buued the block. agaim,l a stopclamped 10the radial ann saw fence, see Fig. 5. Position Ibis SlOP It.J" from the saw bladeand (-ut a It."-
•
head of the bolt. drill a ;,.~.counterbore OJl ihe bottom of the pinch bl,,,..k, '>t't' Fig. 1 Then drill an oversize (~,.") shank hoie through the bod) block and pinch block for Ihe It,"x:r' carriage boll. see ~Jg. 7a. '-\.~DnlF.}Jf.:\'EI.s. Now,tocreaiethepinching action sand 3bevelon the-topedgeofthe pinch block. ,." Fig. 4a. Finally. 10 keep built-upsawdust from affecting the accuracy 01 the SLOp. sand another bevel on the lower inside edge ofthe bod)' block. see Fig. 4.
7
ASStMaLE ~N04IUXK
••
AND IIOOY BlOCK WITH SPUN! IH KtRIS
--~ ~
\
=<: ~l
-
IlVR fOll
SAWEMJ
o. }.-
DRJU.OY(lSlH
.-1".-'
COlJNTER80JtE...
HOl.[FOA
1". CAaRlAGE 8011
.--~~
IODY PINCH StoCK
"lOCK
RWE'
DRlll A '-'," COONTtHOlE
' •• OEI'P
INDICATOR BLOCK Atu-r the stop block is assembled, a triangular indicator block is glue"
Next, scribe 11 'iairline mark centered on the width of the Plexiglas using an X·Actoknife. To make il readable,fillthe scribe linewithblack inkfrom a feltup marker. SCtl£W "OLE.To anach the PIC'Xlgias. drill a 1t4" screw hole centered on its width and IV." down from the top, Note: This hole is larger than the screw to allow for adjusting the SLOp 10the measuring tape later.
UP. To prevent il from twisting as irs tightened, the hairline indicator rests on a lip (E) of \oS" Masonite. see rig. 9. ~'lSE"'H"'Y. Once the lip is CUI10 size. glue it to the front of the indicator block. Then glue the indicator block (C) 1'0 the leltsideof the body block (A). see Fig. lO. Finally, loosely screw the hairline indicator marked side down -10 the indicator block.
IWR.UNE.
O. INDICATOR
10
BLOCK
®
,
UP
No. 72
WouJsmirh
29
•
FENCE \Vilh 111.-stop block complete. work can
begin on We radialarm saw (cocc.I,.,,1 Ultfence (rum ·~~"~hil:kmaple and chamfered
11
12
CROSS SECTION ISL.. VIEW)
WI" IO~(nlllt edge 10providv a mur,' dire....1 line o( sight when rl'adinR th~ta~ measure, re (er It> Fig, 11
VAaN&SH eHAMfOt
, FENCE
fHa.OATOF STOPIUXI(
CD
RlI' TO \\ urm. 111determine tilt' width (height) oflhe (eoct' (~), measurcthetbickness o( ynnr tabh- and add th,' height of We Ihroal opening in lh,' SlOpblock (2"), see Fig. II. -.:,,'" rip the f,,"('1' 10Ihh combined widlh,
0,
,.
•
•
~
Cl TTO I..£NG'I11.Jlt'[urc.' ('tIlling 111(- fence '0 length, thC.'fl' ure S(IOlt' dt.·lision~ 1)(·
,u
WIDtH VARJU WfUI THtCKNESS OFT~
mad,' Silln' I wanted Ihe m"lurity "r the (rnet to th,' r~r} nl th,' blade, th. fir.;1 d.-.:i· sion was 110\1 tar to go to tile left, 'This i. u.!1iUaJl)" determined b)' the amount of room there i, in the shop 10 thl" leCl ul Ih" radial arm saw (before a W'.u\ or another machine). or Ill~siz(' ollhe saw tabk ,10 myshop. wen' \V3S enough room for a ~~'I f,1nrt· on rn.;-ll.'ft Then I had to d cc ide thl' le'ngth of f.. nc.. lhal will fil til thl' rl!l'" of the blade flO my C3S<;,30·), This or...de Ihe IIllallt'Ogth O(
J ... ·WIM
CHAMfEIl
flN((
CH.AMfUl
all
13
saw
Illy fvnev KO" ("ot,,: I'ar mo re 011adding a larger table to your "''' or adding a support ledRe (orth~ fence,'C'C pag,' 26.)
,.
CI"\~ffER. ,\ll<-r the tence ;«UIIO tinishro size, Ihe next step is to cut a ~Jt·wid~ chamfer alon~ thetcp edge for th(' measuring tape, see I~ll, 12, To do Ihis, I used a chamfering bit on Ole router table, see Fig.
.....
(RUfATO P. 26,
12a, butYQU <"uld !wvel·rip Ihis on the radial arm saw or table-saw (Shop '01'" lfyou saw the chamfer, plane or sand out any saw "larks so the self-adhesive measuring tape
chamfer.",
bas a snloolh surface III ,tick cu"
1i:1\:lllng tht> sel(·adh~jvt·measuring
MEASURING
~(,·XI.I 3
applied a coat (.f varnish to
Ihl'
edge of LIlt!fence. This provide>
non-porous surface (or permanently al· UJpt>
tNSf,\lL fENC£..Once the varnish dries, you (30 install the fcnre on tI", table. see Fig, 13,With the fence locked in place, cut a kt'rl Iltrough lhe [(,IIC('to the depth ol the table,
TAPE
AfI~r the fence i~ installed in the I.bl". the next step is 10attach the me,,-
"zero" the SlOPblock. AlTACU T.\P":,
•
NOTE: SUPPOI2T L£DQt MAY a( AOD£D Hllt£
To do this, firs!
fil
the stop
llS(NG TIlt:: STOI' UI.DCK. ~Ow comes th<"
We hairline for MY measurement and cut off a piece 01 scrap Then re al test. Set
measure the tess piece' against th~measur-
block ontc the (eli" e.11t~1lbutt the righl side ing tape - il should be exactly the same of th,· SLOPblock to th,' It'ft ~id~ of th. s<,w leogth a, illdkatcd by the haIrline, b1ad.'. S<'C Fig, II. Now. ";Ih Ih~ "Oil block c1nmp<'d in this posilion.lX'eJ back a couple 14 inches o( th,' paper bal'king Irom the rem eod 01 the measurU1J! ta~ I.UTf Qt.GHT SlDt-Of STOP 1'0 L(Ft Slot Of &lADE Thelllhrt'ad th~ Lapeund.>r lht' rlexiJ!!as TH[N lOCI( STOP tN PLACE indicator and position the -7£ro· point undt'l' the hairlinv, sec ~lg, 14 No'" r~IlI"vc th~ resl of the backing and prK' we tap<' 01111> the (ence. (You olay h:J\'t: to cut the 111(.'asur· iog lape to the lengw or your fence.) ~11\~ '1. 'N~,Nexi. d1(....k till' hairline in· dicalor closdy. If the hairline docs ol)l read exacLly wro wben the
There's om' more thinll to keep in mind Any time you remove th~ «ne,· or replace the saw blade with one Ih31's a different thickness (such as a thin kerf blade) re-adjust the hairline so it s&:e~anaccurate- "zero" reading (or th(' new blade.
15
PO$ITIOH HAlRUN£ OvtR
~\
/'
liIlO MARKAND T'IGH1'lN SCAm .J
~ ,"
•
1
~
30
-..,
1
~CAt()"
.LOCK
~
~
...
left side of the blad,', 100,.,0 the screw thai
Iiolds th.. PII.'Xigl3sin pl:tet,. 111"n slide the Plcxigl .., unlll the hairline is Over Ow ""ro and r"'u~hl("" the S('f('w, see Fig, 15,
,
,
.A;~ SAW
al.ADl
'"
No,72
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SUPPLIES
PROJECT
•
Sources HALLTaEEPATTEaNS \Voodsmith ProjectSuppIJesis off..,ing fuJ~siJ..epaltems with in-
structions formaking'the Ix'nding
jigs forthe Hall Tree (featured on page 10). Indudcd are plans {or the leg jig, the Shook jig' and the ringjig. HaJJ Tree Jig Patterns 772-200 HallTn!f Paut!lllS
s.~.95
OVALHEAD PLUGS \Ve used woodovalhead plugs to
cover the counterbored screws on the lIall Tree (page 10) and the Fern Stand (page 20).
Woodsmith
Project
chined from reinforced fiberglass so they're lightweight but strong. Included are a metal rod for measuring' hoi,' depth and jaws for both inside and outside measurements. The IY'!"·long jaws open 6" widt. The feature Ilike most about these calipers is the easy-te-read dial. Most of the calipers found in catalogs and sreres have adial lhal m'''''''I'1."$ in hundredths of an inch (set' Alternate Sources. below). Some of'these abo have an Inside dial that reads in Standard inch inerements of ~".
Sup-
plies is offering these plu,tr,
•
111ey will fit 8 'l'ij"..!ia. hole and are only sold inpack$of25. 0va1bead Pluj!.~ 772· 100 \\'aInut Plugs $1.65 772·110 Oak Plugs $1.55 772·120 Cherry Plugs $ 1.6S 772-130 Birch Plugs., ..".$L25 The dial calipers offered here are divided by \.tI" increments. but have another feature that's especiallyuseful. Marked on the I use dial calipers. They're also inner dial are divisions of handy for measuring stock as it eighths, quarters, and half inch. comes out of the planer and the There are also bold hash marks depth and width of holes. (For at VIS'I intervals. more on calipers. see page 25.) These marks and Increments \Voodsmith Project Sup- I find the mosl useful. \Vhen plies is offering the same dial working with wood. I don't usucalipers that we use in the ally measurcin hundredths ofan 1V,J
To accurately measure the thickness of thin strips of wood used inbent lamination projects.
ORDER INFORMATION
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MEASURING TAPE
There ate a varicty of uses for a self-adhesive measuring tape. (We're induding one in the Radial Arm Saw Stop Kil above.l Theycan bemounted on benches. row tables, and lathe beds. The \.'t'·wide self·adhesive steel tape has black numbers and hash marks against a white
background. \Voodsmith Project Supplies is offering tapes RADIAL ARM SAW STOP that read from righl 10 lefl and Woodsmith Project Supplies lefl to right. (NOte: The right to is offering a hardware kit for Iht' left tape is 6 feet long and the left Radial Ann Saw Slop shown on 10 right tape (eel 10nl1.) MeasuringTItpt.>:; page 28. The kit includes a clear Plexiglas hairline indkator. a 772·~J 0 Right To Left ~1,·a.. large plastic wing nut. a self- uring Tape, 6 fLlong .........S6.95 adhesive measuring tape, and 772-450 left To RighI Meas-
i.·,
uringTape (Reads righl 10left) • (I) 11.<' x I V." x ZI-!I" Clear
uring Tape. ·1fLloog
$5.95
LAROE WING NUTS To secure the fences on the Miter Jig shown on ~e 27. we u~ la~epla~tif winK nuts with merallnserts, Youcan bwld this jig with standard metal wing nuts, bUI we find these 3"·wide wing nuts easier to tighten. They're the same wing nuts we
Plrxigl ... Hairline lndicator. (Hairline on the back side is etched and inked) use on other jigs in our shop, \Voodsmith Project Sup• (1) 'I." x 3" Carriage Bolt • (I) Larg~ Plastic \\jnfr NUL plies is offering these wing nuts
\\itll Metal Insert. 3" Across
to fit 111«'(/ different bolt sizes,
\\·ingl<.Threaded To '\rCCllt Large \\ling Nuts 772-403 V4"·20 $L65ea. Standard ","Bolt • (I) 'I." LD. \Vasher 766·211 .. 1<;·.18 $1.65 ea. 770·110 W'·LS $1.65 ea, • (I) #6 x :V," Rh Screw • (l) R6 washer 10 or more til one-size: $1.50 ca.
ALTERNATE CATALOG SOURCES
BY "HONE To order byl1L1iI,use the form For CaSlin' service use our ToU enclosed Voith a curreat Issue Free order line. Phone orders or wrire )'our order on a Pl~o:c cal) 1xlp1~edMolldaylhrough o(paper. andsendwith a check Friday, 1j:()O k\1 to &:00 PM or money order. (lncl\lde$:l.50 Central Standard'Tlme. handlilJg and sh'JlI)ing ch3rl:e Before calling, have your with each order.) IA r<:Sl<,ents VISA "rMaster Card ready. add 4f, sales tax: CA residents '-800-444-7002 add 6.2511. sales UIX. Send In: WoodsmithProject.Supp~ Allo"~",6",,·"')J/.. d~I;'''rJ/. ~'f'f}(~, Pn·CCIf Insfbj(tct to clla"l/(' P.O.Bo" 10350 ojJ.~ F;"""_'V.I$~ Oes !\I.oines, lA 50300 '"
No. 72
read a measurement that's ea.")' to ...'Ork with. The accuracyofthcsecahpers is plus or minus .0015" and the bezel is adjuSlable. Also. there's a drill and tap cbart on the back. FinaU)' .ihecalipers are held in a protective case. Dial c..Jipers 772·300 DialCalipers ...$26.95
ihectherhardwarenecessarvtc build tbe Slop. (Note: Wood is not Included.) Radial Arm Saw Stop 772-400 Radial Arm Saw Slop lIardw-",,' Kit " $12.95 • (I) Y'!"x6h.SclJ:ildlleSiveMea ..
DIAL CAUPERS
8YMAIL
that "4'~" L...thesameas~". But by using this dial. I can quickly
S,n,ilw' Iiamu'Urt al/d $llpplie.mag be /oulld ill the/ol/(1Iuwg calalogs. Please call <=1. company/ora t%/og orin/(frmoliml.
Meisel Hardware Specialties 800-441-9870 PIII.IJ~ Trendlines
The Woodm>rkers' Store 612-128-2199 Dial ClIlipi"fS. PIIrker's Supply of NM
800-767-9999
~S-9292
Dia! C(1/ip"I"IJ. PIII.g s, Tape
Dial CO/ipn'd. Plllgs, Talle
Woodcraft 800-225-1153 Ow.! Calipers. Tape
WooJsmirh
Cherry Tree Toys
61·1-484-13113 PIU9S
31
A
LAS
T
LOOI(
Final Details Stop Block
FemStand
"{tc/ 'i$a l.t!, nltl/olrltlf
bit Uj'/l(ttr/ IVln
Hall Tree
Bent Lamination
.. r"i~ Halt Tree i.I( Yf,/(r
/,«(t.
ft'g u
I,'llrt
I/IU" a. pl.'C'1 ro l,flU!!
')t br:ltl {«",i"aliUlt 1..-ljIIUjJf!(llegJi. f:i-s/,(lJJed J,t)Ok~,u ,/~l« r;/f9.
32
.._ The grnrrJu/ ("(1'.," ...."u tltl~ Fin, Stalld art hig" li!lhr.'l( by (I "If,t Ulll ,..I MJn Tll,':driJk. "" iI.4\ Ii" If!1lgl'r oJ',·(,th It 9/t j~tll'llltC'}'f's lilt a'Ui II lit slu:J l'''';'t.
('(lJ("~(.
-
1.
,I",t
}~')'t1/',,, " fll'pd tl {(Il ul:fu"C'J! rtHJ/X ") II( 11,1 .
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