A

Note Towel bar can be mounted on either side. Vi hole 'A deep with a 32 shank hole centered inside 1 hole deep with a Ya hole centered inside mating pilot hole in end panel Va hole 1 deep 13 4 x 5Vz x 96 Maple (8 bd. ft.) 13 4 x 5V2 x 96 Maple (8 bd. ft.) 13 4 x 7Va x 96 Maple (10.7 bd. ft.) 13 4 X 5Vz x 96 Maple (8 bd. ft.)

A successful woodworker

With Materials List in hand, shop wisely When selecting stock, keep in mind which project parts a board might yield and whether the grain and color will match surrounding pieces. Both of these tasks prove much simpler if you have the Materials List with you. A cutting diagram helps as well. Most good lumber dealers won't rush you, so take your time to ensure you select the best stock available. Use your best stock for key parts of your project Use cutting diagrams to help decide how much stock...

Base Side Trim

base (Traditional-style trim shown) 5 32 shank hole, countersunk on bottom side Miter-cut the trim (P, Q) to length to fit the bottom panel. For the best appearance, maintain a continuous grain flow across the trim pieces, as laid out on the Cutting Diagram. Lay out the applicable contour on the trim. For a shaker bookcase, lay out the curve on the front and side trim (P, Q), where dimensioned on Drawing 4. For a country bookcase, adhere the remaining two copies of the base front trim pattern...

C

B* glass stops > 2Vz 17 C 4 Written by Jan Svec with Chuck Hedlund Illustrations Roxanne LeMoine Lorna Johnson x 5V2 x 96 Cherry (4 bd. ft.) Plane to thickness listed in the Materials List. 3 4 x 3V2 x 48 Cherry (1.3 bd. ft.)**Resaw, and then plane to thickness listed in the Materials List. Note We divided our display case in thirds, both horizontally and vertically, giving us nine identical niches. You can divide your case any iiiiv you wish the divisions can even be different sizes. Just...

Clothes Rack

Apply the patterns to the frieze (E) in the following order P1, P2, P3 with both extensions trimmed, P1 with its extension trimmed, P2, and P3 with its right extension trimmed. sides (C). Make certain the cleat does not bow in or out. Plug all the counterbores with short pieces of 3 s dowel. To do this, place glue in the counterbore and tap in the end of the dowel. Use a handsaw to trim the dowel slightly above the surface, and then sand it flush. Fill any imperfections with wood filler and...

D

See the instructions. Materials key 0-oak, OD-oak dowel. Supplies Double-faced tape, paper for patterns, spray adhesive, 1 brads, x2 dowel pins (16), 10x2vi flathead wood screws (8). 'Parts initially cut oversize. See the instructions. Materials key 0-oak, OD-oak dowel. Supplies Double-faced tape, paper for patterns, spray adhesive, 1 brads, x2 dowel pins (16), 10x2vi flathead wood screws (8).

Fullsize Patterns

When we last did comparison shopping at a home center, we found straight-grained, knot-free C and Better Select pine for about 4 per board foot. The No. 2 and Better Common cost about 1.35 per board foot for wide boards, and 1 per board foot for narrow stock. We found untreated Southern yellow pine at a lumber outlet for 3.70 per board foot. Pine draws a lot of unglamorous assignments window casings, garage shelves, and so on but it dresses up nice, too. The same wood you used in shop class...

Description

A combination of the two highest recognized grades, allowing only minor imperfections, including small, tight knots on the better side. Numerous small knots and blemishes that cover smoothly with paint. Small to moderate-sized knots. Takes paint fairly well, but knots may need to be sealed. Used for siding, molding, shelving, and paneling. Contains splits and loose knots. Does not take paint well. Used for crates, sheathing, subflooring, and secondary furniture components.

Door Lap Joint

For a surefire way of positioning the hinges on the doOr and face frames, see the Shop Tip opposite. Mount the hinges on the door and face frames. With the hinges mounted, and the door frames in place, center and install the library door latches, where shown 011 Drawings 3. 4, and 7. Each latch strike has one slot and one hole. Position the strike, and drill a pilot hole at the center of the slot. Secure the strike with a roundhead screw, as shown. Do not drive in the escutcheon pin at this...

Du End Section View Detail

rabbet 'A deep along sides and front rabbet 'A deep along sides and front How do you store your holiday or vacation photos We like to show ours when friends or family stop by. Because the dog-eared processor's envelope never looks good lying about, we designed an attractive solution. Resembling a book, our box looks great on the coffee table. You can even display two photos at a time in the lid by sandwiching them back-to-back between the glass panes. Cut the bottom (A) and the back (B) to the...

Tenon Detail

square counterbore Vb deep, with a vi hole centered inside 'A dowel 2 long glued into part(Q) 'A dowel 2 long glued into part(Q) square counterbore Vb deep, with a vi hole centered inside 0.1 x 4'A x 6V1 clear acrylic (2 needed) Install a chamfer bit in your table-mounted router. Rout the V t and 'As chamfers, where shown. A miter gauge and extension will help when routing across the ends of the base (A) and cap (C). Rout the 7 ib chamfer on the underside of the cap (C). (We cut the deep...

E0 Drawer Handle Detail Section View

8-32 x 3 4n roundhead machine screw Glue and clamp together the left side assembly, top and center shelves (I J), and top back rail (G). Add the bottom rails (H) and right side assembly to align rail G. Complete the case by gluing and clamping together the bottom rails (H), bottom shelf (K), and right side assembly, centering the shelf front-to-back. J 5 32n shank hole, countersunk on bottom face W groove W deep V411 from bottom edge 8-32 x 3 4 roundhead machine screw 1 4U grooves W deep V411...

E3t0p Section View

W groove Va deep Vb from edge Using 213 V'-long spacers to position the middle side rail (H) above the bottom side rail, glue and clamp the rail to the side (A). Using 213 V'-long spacers to position the middle side rail (H) above the bottom side rail, glue and clamp the rail to the side (A). Cut the bottom panel (O) to size. Next, to form the front trim (P) and side trim (Q), cut a 5x65 workpiece from W'-thick stock. Then, rout the applicable profile along an edge of the workpiece. For a...

End Of Leg Detail

Va spacer clamped to stopblock spring apart in use, ye flat for storage. Your micro' holds the key to curvin Cut and plane two pieces of stock (we selected white oak) to 4x17 8x12. Then make a photocopy of the full-size patterns (Drawing 2). Spray-adhere the patterns to the wood blanks folding over the patterns where indicated. Drill a ' s pin hole through each blank, where shown on the full-size patterns. Cut the blanks to shape using your bandsaw or scrollsaw. Also cut the long kerfs in each...

End View

Blade to 18 from vertical, and position your fence 'A away from the base of the blade, where shown on Drawing 3a. Cut the bevel on the ends of the lid first then, cut the sides. Cutting in this sequence minimizes chip-out. Using your tablesaw or a rabbeting bit in your table-mounted router, cut a 5 ifi rabbet Va deep around the perimeter of the lid (G H) on the bottom side, where shown on Drawing 3. To avoid chip-out, make several passes around the lid, raising the blade or bit a little at a...

Es Shelf Cabinet Rail Detail

Then cut 3 s rabbets Vi' deep on the ends of the rails, where shown on Drawing 2a, forming lA tongues 3 s long to fit in the side rabbets. Finish-sand the parts. Now clamp the rails (B) between the sides (C). Drill counterbored screw holes through the sides and into the rails, and drive the screws. Then clamp the top and bottom (A) in place, flush with the back edges of the sides and centered side-to-side. Drill counterbored screw holes, and drive the screws. Cut a...

Etctop View Detail

1 longer than the length listed, and miter one end of each. Mark centers on the mitered ends, and plunge slots for 20 biscuits. Glue and clamp the cap front (N) to the top of the upper cabinet, centered side to side, and overhanging 2lA, where shown on Drawings 4, 4a, and 4b. Align the miters with the front corners of the face frame. Drill pilot and countersunk shank holes through the cap front into the upper carcase top (D), and drive the screws. Position the cap sides (O), mark them flush...

Exploded View

2 shank hole, countersunk on bottom face of part , with a 3 32m pilot hole V2 deep in part (H) 'A groove 3 s deep 'A from back edge 5 32 shank hole, countersunk on bottom face of part (j), with a 2 pilot hole V2 deep in part (5) 'A grooves deep deep 'A from edge For the board feet of lumber and other items needed to build this project, see page 18. inside face of the sides (A, B) and tops and bottoms (C) for the backs (E), making sure you have mirror-image door sides. Lay out the window and...

Finished Size

A panels ' > 10V2 10 OP 2 C front uprights 2 243 i 0 2 D upper rails 33 4 101 2 0 2 E tower rails IC1V2 0 2 F* brackets Vt 2 4 0 2 G' arms 4'A ISVz 0 2 H shelf skirts 3' 42V2 0 2 I seat skirts 2 2 42vi> 0 2 J* seat and shelf 3 4 i6' i 43 EO 2 K back rails 2Vz 4216 0 2 M' fillers 3 g 5 8 3 0 18

Frame

Cut the top rail (A), bottom rail (B), mullions (C), and shelf (E) to the sizes listed in the Materials List. Cut the stiles (D) Vi longer than the size listed. You'll cut these to final length later. Using a dado blade in your tablesaw, cut 'A grooves Vs deep, centered in the top rail, bottom rail, mullions, and stiles, where dimensioned on Drawings 1 and 2. To make sure that each groove is centered in the part, turn the piece end-for-end after the first pass and make a second pass. Don't...

Fulllength Filler Strip

Left Match a scrap piece with the color and grain pattern of the damaged area. Left From your matched piece of scrap plywood, rip a filler strip with your tablesaw blade set at 2 from vertical. Right Cut a shallow groove across the damaged area with the grain using a dado blade. If you don't have a clean-cutting dado blade, use a router and straight bit. Right First, apply glue to the filler strip and groove. Then tap the filler strip into place with a flat hardwood block and hammer. Secure the...

Glass finish

For tight-grained woods, such as the maple shown in this project, sand the surface to 220 grit, and you're ready to apply the finish. An open-grained wood, such as oak, ash, walnut, or mahogany, requires the use of a matching-color paste grain filler. Pack the grain by working the filler cross grain with a wide putty knife. Let the filler dry, and then sand the surface to 220 grit. To make polyure-thane finish flow out smoothly without brush marks, add three tablespoons of paint thinner to one...

H

For every inch of length gained, you lose 7 V' in width. For every inch of length gained, you lose 7 V' in width. Clamp the scarf joint using angled clamp blocks to keep the clamping pressure perpendicular to the joint. Clamp the scarf joint using angled clamp blocks to keep the clamping pressure perpendicular to the joint.

Upright Gridded Pattern

Vs dowel holes 1 V e deep Dry-clamp one end section (A, B, C) together, using the scrap cutouts for flat edges to clamp against. Then, mark the dowel-hole reference lines on the mating pieces. Dry-clamp one end section (A, B, C) together, using the scrap cutouts for flat edges to clamp against. Then, mark the dowel-hole reference lines on the mating pieces. Unclamp the end sections. Then using a doweling jig, drill a pair of Vs holes VAc, deep where marked at each joint. Using Vs dowel pins 2...

Corporation

Copyright Mereolh Ckxpcreiior. 2036. All rights reserved. PtwHed in USA. America's Best-Ever Woodworking Projects & Shop Tips Frame favorite photos and support good reading with this pair of bookends. Build a stack of leaf-shaped boards for all the members of your family tree. Add a thermometer, barometer, and hygrometer to your home. Contrasting woods and tapered legs will grab your attention. Dollhouse and castle designs provide imaginative shelving for kids' treasures. Picture this...

Id

3A x 5'A x 96 Quartersawn white oak (4 bd. ft.) 3A x 71A x 48 Quartersawn white oak (2.7 bd. ft.) the legs (A) under the top (L), positioning them 5 s from the leg outside edges, where shown on Drawing 3. Touch up any areas that need it with 220-grit sandpaper, and remove the dust.

Info

3 4 X 9' 4 X 96 Oak (6.7 bd. ft.) (2 needed) 3 4 x 3' 2 x 96 Oak (2.7 bd. ft.) 'Plane or resaw to the thickness listed in the Materials List. 3 4 x 3' 2 x 96 Oak (2.7 bd. ft.) 'Plane or resaw to the thickness listed in the Materials List. 3 4 x 7'A x 96 Oak (5.3 bd. ft.)

Jsl

counterbore Va deep with a 2 shank hole centered inside counterbore Va deep with a 2 shank hole centered inside Keyhole hangers 16 on center, centered on the width of I Keyhole hangers 16 on center, centered on the width of I Vb rabbet W deep for the chalkboard or V2 deep for the tackboard 7 i6-diam. Va-thick self-adhesive door bumper counterbore W deep with a 5 32m shank hole centered inside 8 x 11 2 F.H. wood screw driven into the wall stud or wall anchor Vb rabbet W deep for the chalkboard...

Keepsake box

Contrasting woods and tapered legs make it a real eye-grabber. Don't let the refined appearance of this project fool you. It's not difficult to make. We'll show you how to shape the tapered legs using patterns and a sander. You may have a harder time choosing which woods to use. Select your own combination of species, or try one of the combinations shown here. In the Source on the opposite page, you'll find a handy buying guide for all of the necessary stock milled to the required thicknesses....

L

Thickness of 3A stock for parts (R) and (l). thickness of 3A stock for parts (R) and (l). W groove Va deep Vb from edge A groovy way to put the squeeze on glue squeeze-out Removing excess glue when assembling parts is messy and risky. If you leave the slightest residue, it can seal the wood and block stain penetration, resulting in a blotchy finish. Here's a simple way to avoid the problem. Cut Vb grooves Va deep Va from a part's edges on its glue surface, where shown above. Then, apply glue to...

Left Tong

With the beveled face of each piece down, push the microwaved tongs together until they overlap approximately 5. Wearing gloves or oven mitts to protect your hands, remove the paper towels. While the tong halves are still warm and wet, force them together, overlapping them about 5, as shown in Photo A. Allow the assembly to cool for one hour. Then separate the two halves, and sand each through 220 grit. Hacksaw a l-W'-long piece of ' s brass rod and assemble the two blanks, slipping 6 brass...

Leg

Even without a lathe, you can turn round legs in your shop. Here's a jig that works beautifully at your router table with a 3 t bowl bit. Even without a lathe, you can turn round legs in your shop. Here's a jig that works beautifully at your router table with a 3 t bowl bit. Position the leg on the routing jig with the bottom end of the leg disc against the right-hand stopblock. Then, rout the first past.

Leg Fullsize Pattern

Width of grooves must match width of laminated panels. 15V4 for part 391 4 for part Width must match thickness o laminated panels. Paper pattern and 1 4 hardboard template for marking the leg profile Tenon width must match thickness of laminated panels. ' -thick cherry plywood to the sizes listed. (You'll need to double the quantity in the Materials List.) For the best appearance, cut the panels so the veneer lamination line will be in the center of each panel, where shown on Drawing 1....

Lever Operated Fence

ADJUSTMENT CENTER MOUNTED FENCE 8 FACE JOINTING CAPACITY 45 ' BEVEL JOINTING CAPACITY 135 BEVEL JOINTING CAPACITY 24 H OUT Plus special features, g-1 event information 604 Full Color Pages of Woodworking & Metalworking Machines, Tools & Accessories PARALLELOGRAM TABLE ADJUSTMENT SYSTEM ALL COMPONENTS ARE

Lxyl

counterbores W deep on outside face with a 5 32 shank hole centered inside 3 4 l *Note Use the same J -J- double-curved profile iU for the shelf skirts (H). To apply paper-backed veneer, first cut the veneer slightly larger than the panel. Spread woodworker's glue on the panel with a short-nap roller. Clamp the panel and veneer between particleboard platens. Paper-backed veneers are available in the widest variety of species. Because large panels require the use of cauls to transfer clamping...

Machining

Cuts parallel to the fibers remove more woody material and lignin than cuts across the fibers, which encounter more hollow pockets. That's why rip cuts require more power. Unlike manufactured materials that have uniform strength, density, and structure (such as plastics), there's little in the makeup of wood that can be called consistent. Variations in cell density and distribution within a board are the norm, not the exception. Boards of different species will react differently during the same...

One bookcase

Simply change the wood type and trim details to suit your taste. We'll show you how. Here's a masterpiece you can build that will showcase your treasured tomes for years to come. Simply build the basic case in the wood of your choice, and then add the traditional, country, or Shaker top and bottom trim. The bookcase, which measures 333 4 wide by 13 deep by approximately 6'A' high, has a fixed shelf and three adjustable shelves to hold loads of books or display items. We used primarily oak and...

Op

See the instructions. Materials key 0-oak, OP-oak plywood. Supplies Spray adhesive, Vix5Vix7Vfe glass panels (5). Blades and bits Dado blade, W piloted rabbeting bit, and 1 Vi Forstner bits, 1 2 roundnose bit. FULL-SIZE GRIDDED HALL BENCH ARM PATTERN 3 4 x 71 4 x 96 Oak (5.3 bd. ft.) Here's a cradle that's sure to be passed on from generation to generation. Made of durable ash, the cradle features a simple rocking mechanism that offers a soothing solution to the...

P

Supplies 8x1 ' i flathead wood screws, dowel, spray adhesive. Supplies 8x1 ' i flathead wood screws, dowel, spray adhesive. Blades and bits W round-over and cove router bits, 2R scrollsaw blades. Hardware. Shaker pegs no. 04E51, 3.50 for a package of 10 single-hole keyhole hangers no. 125505, .99 for a package of two self-adhesive door bumpers no. 02S82, 7.99 tor a sheet of 56. Woodcraft. Call 800 225-1153, or go to woodcraft.com.

P 1

Materials key P poplar, H-tempered hardboard. Supplies 8x1' 2 flathead wood screws, 18x5 8 wire nails, dowel, spray adhesive. Inserting 73 i-long scrap spacers, position the shelves (E) between the sides (C). Drill counterbored screw holes centered on the shelves' thickness, and drive the screws. Materials key P poplar, H-tempered hardboard. Supplies 8x1' 2 flathead wood screws, 18x5 8 wire nails, dowel, spray adhesive. Blades and bits W round-over and cove router bits, stack dado set, 2R...

Pine much

Create this classic furniture piece for your home, and in the process, learn a super-simple way to make doors with glass inserts or raised panels using just your tablesaw. Made entirely of affordable -Vi-thick knotty pine lumber and -Vi6-thick beaded planking, this handsome piece has a classic country look that's enhanced by such details as its pegged doorframes and antique glass. You'll find helpful hints for working with pine on page 120. And, by all means, don't try to hide the knots they're...

Powersanding

Sanders can be your shortcut to success or a source of hasty headaches. Done right, power-sanding speeds your way to a silky-smooth surface. Done wrong, your impatience will haunt you with every flat spot, gouge, and burn mark your tools leave behind. Use these tips to avoid sanding's biggest pitfalls. Potential problem Figuring that finegrained hardwoods, such as walnut or cherry, require a fine sandpaper grit, you add a fresh 220-grit sleeve onto your drill-press sanding drum or a fresh disc...

Q Hingelocating

Two coats of high-gloss polyurethane followed by a final coat of satin polyurethane. Sand and remove dust between all coats. Install the hardware and fill the chest with cherished belonings. Written by Owen Duvall Project design Kent Welsh Illustrations Roxanne LeMoine Lorna Johnson Photographs Douglas E. Smith

Q Support Fullsize Pattern

Next, dry-clamp the hanger assembly against the top, where dimensioned on Drawing 3. Use the holes in the supports (J) as guides to drill mating holes into one of the aprons. Attach the towel bar assembly to an apron. Crosscut Vi' dowel stock to length, and plug the screw holes. CrosscutVa' dowel stock to the appropriate lengths, and plug the lag bolt holes in the corner pieces (D). Be careful when cutting the dowel plugs to length. You don't want them too stand to proud, as...

Rabbet The Cap For A Snug

Check over the bookend, and resand areas that need it. Slightly chamfer any sharp edges with a sanding block. Apply a clear finish. (We applied two coats of an aerosol satin polyure-thane, sanding with 220-grit sandpaper between coats.) Stick four self-adhesive bumpers to the bottom corners of the base. Then cut two 2-thick clear acrylic panes to 4x6. Smooth the sharp edges with a sanding block, and remove the protective covering. Sandwich a photograph between the panes, slide it into the...

Safeguard

Safeguards Sanders make poor thicknessing tools, especially belt sanders. When gluing up sections, inspect for workpiece slips at joint lines, and correct imperfections well before the glue sets. If a problem still surfaces, visualize an area about twice the width of your sanding pad on either side of the joint. Gradually work from the edges to the center to avoid abrupt surface changes directly over the joint. Potential problem When edge-joining pieces of exact thickness, it's tricky to glue...

Sh0ptip101

Don't assume that the color shown on a label will truly represent how the stain will look on your project. To get an accurate indication of color, sand some of your leftover stock to the same grit as your finished project, and then stain portions to see what you'll really get. If you can't find what you're after, create your own shade by mixing two or more together, recording the amounts of each. Always stir stain thoroughly before you use it to ensure even coloring. Look for shiny areas that...

Sh0ptip13

With one end of the seat assembly resting on a spacer, flex the opposite side assembly just enough to allow you to lower the seat's other end into its dado. Achieving the (almost) invisible plug When developing the design for this project, we were concerned that the end assemblies and arms with all their plugged counterbores might look like Swiss cheese. To prevent that, project builder Chuck Hedlund took great care in selecting and installing the plugs, shown in the photo. Here are some of...

Sh0ptip14

Here's a simple way to avoid tear-out when routing the openings on the back of the frame Move the router counterclockwise rather than the normal clockwise direction. With this technique, known as climb cutting, you move the router in a direction that's with the rotation of the bit rather than against it. Be sure to clamp your workpiece securely when you climb cut keep both hands on the router use a sharp bit and make progressive, shallow cuts. Practice on a scrap piece first to get used to the...

Sh0ptip15

The Cutting Diagrams found with each project shows just enough material for the pieces in the project. If your stock contains a defect or you make a wrong cut, a little extra material can save you a return trip to your lumber source. We recommend buying at least 15 percent extra for each project. Remember If you do lots of building, hardwoods are typically discounted when purchasing 100 board feet or more.

Sh0ptip1q

Low-tech trick gives solid-wood panels room to move There's no getting around it wood contracts and expands with changes in seasonal humidity. If you don't allow for that movement, wide panels of solid wood will bow, cup, or split. So, when you screw cleats to solid panels, counterbore the screw holes in the cleat as . Uj shown. That allows the screw to move back and forth as the panel moves. Never glue cleats to wide, solid-wood panels. back top trim .(N) and side top trim (O) on the chest,...

Sh0ptip28

Clear-drying epoxy best for filling knots To lock knots in place and create a smooth surface for finishing, rely on epoxy. Use the epoxy that looks clear in its applicator tube it dries clear, so the knot retains its natural look, as in Photo B. The epoxy shown in Photo C is milky white and opaque when dry. If you find a dead knot here and there after you begin your project, lock each one in place with clear, five-minute, two-part epoxy. With that done, you can saw, joint, or plane the wood...

Sh0ptip31

Apply a coat of primer to the sanded surfaces and edges of the pieces you wish to paint. Primer bonds tighter to the wood than an unprimed coat of paint and is less likely to peel or crack. After the primer dries, lightly sand the surfaces with 220-grit abrasive to knock down the little bumps caused by air bubbles and dust specks. 3 a rabbet 'A deep along inside bottom edge routed after (p), (g), and are assembled.

Sh0ptip38

Protect your bits while expanding your work surface with a 3 i plywood auxiliary table clamped or bolted to the metal table, as shown in the top photo on this page. When you need to drill several through holes, go one step further place a backer board on top of the auxiliary table. Use any handy scrap, such as the particleboard shown at right. The backer board prevents tear-out on the bottom of your workpiece by supporting wood fibers around the hole, while keeping your auxiliary table intact....

Sh0ptip40

A simple fence comes in handy when you need to drill more than one hole at the same distance from the edge of the workpiece. Make a fence by cutting two straight pieces of 3A stock to a length that matches the width of your auxiliary table. Use your tablesaw to cut a Vax' a dust-relief channel at the edge of one piece. This channel preserves accuracy by keeping sawdust and wood chips from lodging between fence and workpiece. Screw the pieces together at a right angle, as shown at left, and you...

Sh0ptip42

Twist bits can drift off course when drilling into irregular grain, especially small-diameter bits like the VW' bit shown at right. Limit this tendency by inserting the bit well into the drill-press chuck when you mount it. Leave enough of the bit exposed to bore the hole to the desired depth and make sure that it's centered in the chuck, not trapped between just two of the three jaws. You also can improve your accuracy by using brad-point bits. One of the trickiest drill-press tasks is boring...

Sh0ptip44

Potential problem You're sanding down your sealer coat of clear finish with 220-grit paper when your sander cuts through both the finish coat and the stained surface beneath. Odds are you'll need to sand down to bare wood and restain the entire surface of the damaged face. Safeguards This time, rethink the need to sand between the first and second coats. Such finishes as lacquer partially dissolve the earlier coat, and require no between-coat sanding. With polyurethane finishes, apply a second...

Sh0ptip46

Potential problem Edge-banding a sheet of hardwood plywood with matching veneer often leaves overlaps where the edging protrudes above the surface of the face. To remove this, you pick up your sander and lean it over to even out the excess. On one especially stubborn portion, the plywood hardwood veneer disappears along with the edging, exposing the layer beneath. PROBLEM LIVING ON THE EDGE SAFEGUARD Safeguards Don't tilt your sander as you cross the edge or you'll remove both veneer and...

Sh0ptip47

PROBLEM RUFFLES WITH RIDGES SAFEGUARD Potential problem You've just fed a workpiece with a long, sweeping curve through your oscillating spindle sander when you stop to admire your work and discover that your long curve has become a string of bumps and dips. Safeguards We exaggerated a bit here to make a point Always use the largest diameter drum that fits within the radius of the curved edge. A hand-sanding alternative uses the curved scrap created when your curved workpiece was cut....

Sh0ptip58

If both faces of the plywood will be visible on your project, you need to minimize chip-out on each side. Do this by making a scoring pass first, with the blade raised only about W to Va, as shown. Then raise the blade, as advised in Tip 48, and make another pass to cut completely through the workpiece. When fibers, splinters, or even sizable chunks of wood break away from your workpiece while you're cutting or shaping it, that's chip-out. Fortunately, you can avoid nearly all of that surface...

Sh0ptip72

Keep an eye out for tear-out when crosscutting Crosscuts, on the other hand, tear across fiber walls, which introduces more stress on the material. Think of slamming an axe into the side of a log The blade smashes through a few layers of fibers, then stops. Making a clean crosscut in a board requires a cutter sharp enough to slice fiber walls rather than smash through. Even sharp cutters bend the fibers ahead of and surrounding the cut. Sometimes, the wood tears before the blade cuts through....

Sh0ptip74

Try these exciting solutions to boring problems Boring holes in wood presents even more problems because the spinning cutting edge of a drill bit cuts through fibers running in multiple directions. And a bit produces a great deal of pressure on the wood fibers ahead of and around it. This can cause tear-out where the bit enters the wood in the walls of the hole and, especially, where the bit exits. The problem Drilling produces holes with rough edges and tear-out where the bit exits the wood....

Sh0ptip92

Not every part requires a measurement Every measurement introduces a chance for error. Prevent this by taking all of your measurements once (making sure they're accurate), and then transferring them to a story stick. Be sure to label each mark. Now you can set up your tools using the story stick instead of your tape measure. Chuck Hedlund, WOOD magazine's Master Craftsman, turns his tape measures into story sticks by applying masking tape to them and marking measurements on the tape. A company...

Sh0ptip94

Different tape measures will yield different results Compare tape measures from several manufacturers and you'll likely find they read differently. Prevent errors by using just one tape measure throughout a project. Also make sure that the tape you choose reads the same as other measuring tools you'll use, such as a try square or steel rule. Double-check the accuracy of your tape's 1 reading to make sure the hook hasn't become bent or stuck. If it has, start your measurements at the tape's 1...

Sh0ptkp26

Finish-sand all parts and assemblies to 220 grit. Then, set aside the planks for the backs (V, W). To give the pine an antique amber glow, brush on two coats of oil-based satin polyurethane, sanding with 220-grit sandpaper between coats. Retrieve the back planks, and apply a stain. We used Minwax Winter Moss water-based wood stain, following the instructions on the manufacturer's can. To avoid discoloring the stain, brush on two coats of water-based satin polyurethane....

Shop

Properly sealed, cutting boards will last for decades. But, if the finish wears down and moisture gets into the wood, delamination and warp-age could occur. To protect cutting boards, wash them with a warm soapy cloth instead of immersing the board in water or placing it in a dishwasher. When the finish appears to be wearing thin, brush on a new food-grade oil. If the board's appearance suffers from knife cuts, resand before applying new sealing coats of finish. Looking for a great gift idea...

Shoptip

With your display case complete, you'll need a method for fastening items to the matboard back, or if you are using dividers, securing the items to them. Secure items to the matboard back with small dots of silicone adhesive, or tie them in place with thread, monofilament fishing line, or very fine copper wire. To tie your items, first poke holes through the matboard with a sewing needle. Loop the thread, line, or wire around the item, feed the ends through the holes, and tie the thread, line,...

Side Assembly

Overall dimensions are 28 wide x 20V8 deep x 30Vz high. For the board feet of lumber and other items needed to build this project, see page 26. 1 and 1a, attach an auxiliary fence to your saw fence and an auxiliary extension to the miter gauge. Then cut a Vs tenon < A long on a rail cutoff. Test-fit the tenon in the grooves in the rails. Adjust your setup, if needed, and cut the tenons on the rails. Place the legs (A) inside face up on your workbench, and pair them together with the grooved...

Specifications

Motor 3 HP, 220V, single-phase, TEFC, 3450 RPM Precision ground cast iron tables Infeed table size 8 x 437s Cutterhead knives 4 HSS, 8 x W x 1 8 Cutterhead diameter 33 i6 Max. depth of cut Vs Max. rabbeting depth V2 Approx. shipping weight 461 lbs Grizzly is pleased to introduce our new 8x 76 Jointer, Model G0490. Check out these great features and you will know why we are so excited about it -you will be, too.

Spline Slot Setup

Fasten sides together using double-faced tape Keep that miter in line with a spline Here's a handy method for beefing up long, mitered joints in jewelry boxes and the like. You can make slots for hidden splines with a straight bit, two stopblocks, and a simple support block. Set your Vs straight bit to project 'A above the router table. Clamp an auxiliary fence to your router table fence, so that your workpiece won't slide into the bit-clearance notch. Set this fence the same distance from the...

Step

Rout partial round-over along top edge of box sides. Lumber kit. Enough vfe lacewood and Vs birch plywood for one box, 12.95 ppd., or enough slock for five boxes, 34.95 ppd. Kit no. W843. Heritage Building Specialties, 205 North Cascade, Fergus Falls, MN 56537. Call 800 524-4184, or go to heritagewood.com. Project Design James R. Downing Illustrations Kim Downing Lorna Johnson Photograph Hopkins Associates Set fence flush with pilot bearing on router bit. Vz round-over bit set W below edge of...

Storage

With the back (E) captured in the grooves in the sides (A, B) and top and bottom (C), glue and clamp the case together. Check for square. Glue the shelf (F) between the door sides (B). Screw scrap 341 2-long braces to the cases' bottoms to keep the assembly square. Create this entertaining castle-style bookcase by adding easy-to-make turret trim and quoins to the cases.

Stretchers

3A counterbore Vb deep with a 4 pilot hole Vs deep centered Inside (upper stretchers only) Vb round-overs along bottom ends only Mark the top of the leg 1 Vi from the mortised edge. Use a straightedge to extend the pattern line to the mark on the paper pattern. Cut 1-deep notches in parts B. Then raise the blade, and cut 2-deep notches in parts C. To prevent chip-out, back the cuts with an auxiliary extension. Cut 1-deep notches in parts B. Then raise the blade, and cut 2-deep notches in parts...

Upright Gridded End Pattern

Plane a thicker piece of oak to Vic thick. Cut Vs plugs Vic, long from the oak. After you plug the screw holes, sand the plugs flush. Touch-up sand if neccessary. Stain and finish the assembled rack. (We applied a walnut stain and polyurethane.) Illustrations Kim Downing Roxanne LeMoine Photographs Hopkins Associates Bob Calmer

V

3 8 counterbore 1 4 deep with a 5 32 shank hole centered inside 8 x 1< 2 F.H. Keyhole hangers 16 on center, wood screw driven centered on the width of (B) into the wall stud 7 ie-diam. Vs'-thick self-adhesive door bumper 3 s counterbore Vi deep with a 5 32 shank hole centered inside 3 s counterbore Vi deep with a 5 32 shank hole centered inside 7 ie-diam. Vs'-thick self-adhesive door bumper

1

Start with two edge-joined laminations From l3 4-thick maple (commonly called 8 4 stock), cut the lamination strips (A, B, C) to the sizes listed in the Materials List and as shown on Drawing 1. Position the strips for Panels 1 and 2 in the configuration shown on Drawing 1. Number the pieces to keep them in the correct order when edge-joining them. Edge-join the pieces to form the two panels. Use a damp cloth to remove the excess glue. (To keep the laminations manageable, we glued and clamped...

Ree

It shows up well and wipes off easily. Mark surfaces using a sharp pencil to create fine, removable layout marks just don't press too hard. Pencil marks can be difficult to see on dark woods and tough to erase from light woods. When working with those woods, place tape on the surface and write on it. Identify waste areas so you don't cut or drill on the wrong side of your line. Use arrows to designate outside faces and to distinguish mirror-image project parts....

Vv

Panels are laminated from two thicknesses of W plywood. Unclamp and sand all the panel assemblies. Then, place each assembly outside face down and, referencing Drawings 1 and 6, measure l3A down from the top edge of the side bottom rails (C) and front back bottom rails (F) for the location of the top edge of the side cleats (H) and front back cleats (G). Because the front back cleats (G) fit between the side cleats (H) when the panel assemblies are joined together, you must center the front...

W

Cut the center fixed shelf (F) to size. Then, glue it between the cases, as shown in Photo B. Cut the adjustable shelf (G) and supports (H) to size. From ' -thick poplar, cut a ' > x22 blank for the window trim (I). Set the shelf, supports, and trim blank aside. Cut the base panel (J), side trim (K), and front and back trim (L) to size. Lay out the cutout on the front and back trim, where dimensioned on Drawing 1. Jigsaw the cutouts to shape, and sand smooth. Glue and nail the trim pieces to...

Xd

13 4 x 71 4 x 72 Maple (8 bd. ft.) (2 needed) 'Plane or resaw to the thickness listed in the Materials List. 'Plane or resaw to the thickness listed in the Materials List. Note that there are no lower holes in the front face of the front legs. Raise the bit to its final cutting depth of 1 ifi. The last cut should be very shallow (about ' us) to make the 27 s-diameter leg as smooth as possible. Repeat the process for all four legs. Finish-sand all four legs. Move to your drill press, and drill...

Dowel Hole Locations

Centerpoints for dowel hole locations Centerpoints for dowel hole locations Centerpoints for dowel hole locations Centerpoints for dowel hole locations Remove the clamps, and drill -Vs holes 'Vie deep where marked. (We used a doweling jig for alignment.) Glue, dowel, and clamp the pieces together for each end panel. Once clamped, check them for flatness with a straightedge. If necessary, loosen the clamps and flatten the pieces against the pipes or bars of the clamps. Mark a centerline on one...

Grooveandtenon Details

Feel free to customize the look and functionality of the coatrack frames. Options include photographs and chalkboard (photo opposite page), corkboard, or simply the plywood frame backs as attractive wood fillers (photos at left). To make your own chalkboard, spray W hardboard with Rust-Oleum Painter's Touch Chalk Board Finish, available at home centers. 6 x 9 V F.H. wood screw Vb x 51 8 x 7Va glass 3Az pilot hole 5 e deep from back of (5) 1 V2 hole 5 i6 deep with a 2 pilot hole deep, inside 3Az...

Archcutting

Chances are good that you have a circle-cutting jig. But did you know that you also can adapt a similar principle to cut arches with a bandsaw In the example shown above, an auxiliary table fastens to the bandsaw table by way of metal channel (clamps would work, too). For these clocks, Schlabaugh woodworkers know that the left edge of the jig must be 57 i6 from the left edge of the bandsaw table to cut correctly. A paddle outfitted with a toggle clamp holds the stock to be cut and rotates it...

E

7 notch 19 i s deep initially, 1 V21' deep after trimming 5 32 shank hole countersunk W round-over 8 x 1 V4 F.H. wood screw 5 32n shank hole, countersunk 23 POST CAP & LEG DETAIL ' hole 2 deep, centered Vi round-overs 73 (Round-overs stop 1 from ends, no round-over on bottom inside edge.) -Vz hole 2 deep, centered (For footboard only when ioinina bunk beds.t Make the hole-drilling jig, shown on Drawing 3. Using the jig and a stopblock on your drill bit, as shown in Photo B, drill 'A holes 2...

Lid Fullsize Pattern

Miter-cut four equal lengths of stock (ours measured 5 long each) from the 24-long board. Transfer the side full-size pattern (Drawing 4, lower right of page 128) to the bottom edge of one of the box sides. Cut and sand the radius to shape. Use this as a template to mark the three remaining box sides. Cut and sand the three pieces. Dry-clamp the four pieces to check for tight corner joints. Then, glue and clamp the pieces. For an easy no-clamp method to adhere the mitered corners, start by...

Ci Fullsize Partial Pattern

For the dollhouse bookcase, apply adhesive to the back face of the roof trim (S). Then, using 8d finish nails, fasten the trim, with the bevel-cut ends together, to the front roof support (Q). Fill the nail holes, and touch up with paint. Place the case assembly faceup on your workbench on spacers, as shown in Photo D. Remove the braces from the assembly's bottom. Then, position the base assembly (J K L) on your workbench, and center it on the case assembly. Drill mounting holes, where...

Create Your Custom Stain

Alan's stain formula uses nonfibered roofing tar made with pure asphalt mixed with Minwax red oak stain. Minwax natural stain lightens the mixture as desired. Buy nonfibered roofing tar or you will have to strain the fibers out before mixing. A thicker tar is available in caulking-style tubes and can be thinned with mineral spirits. Sand to at least 150 grit, and then raise the grain with a damp cloth. Distilled water works best because it contains no chlorine or impurities. After the wood...

Prepare The Wood Surface

In a well-ventilated space, work the asphalt stain mix into the grain with a soft brush or rag. Work up from the bottom so that drips or spills on surfaces below will do no harm. Let the stain stand for 3 to 5 minutes, then wipe off the excess. For darker finishes like those shown at the far right, spray on light coats of the mixture without wiping them off. To make certain his mission finish matched today's aged original finishes as accurate as possible, Alan borrowed examples of authentic...