$2.50NOTES FROM THE SHOP

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NO. 44

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WOODSMITH2

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matter of I)()()rworkmanship in producinglhe 1001.Dado blades are 3 good example.\\ nether you get • stack set or one of thewobble blades. you're 8pending enoughmone~'that it should do it. job well- 'ight.ml ofth. box.The downfall onmost or the dndo blades

we've pUl'chased is lhe qualit), of sharpen­in~ - il was unacceptably poor. AlthoughIhi. '" relath'cly easy to fix (just take it to a1I00d :<harpening shop and hand over about$:.'1)1,it tffedively adds to Ihe eost er theblade. A ~n isn't such a bargain ir you1."" to add $20 JUSt to !tel it 10 work the'"8~')t'~supposed to.

I'm ,lowly beginning LO change my ap­"rUllfh tqwnn) bu~-!ngtools. [used to setahmlt on th,·eest. Sut that can lead to cheapl(lC.Jll' Hilel Irustration, Now J set a limit on'I"ollt) I 1000kfor good. to-high quality10010, 'I18Ymore. bUI I'm much happier a.I \\ork \I lth the tool.

.",. n r r~~\'&LOP&.\Vc've changed the.1. '10'"o(th"~nvelop" that's inserted in thece-nter of lhi... issue. \\'c·,·c added a few1)o:,(~8tn chl"<'k if you're OO\'1ng a problemw ith }'nur ...ubr!tr1"lloD.

Ir \·,.,r bou ...I. damaged in the mail orhi, mi"""~ ,",).."<.<;l, we'll be bappy to send~0"• rr.,,· replacement cap):AI.". Ie you're receiving duplicate

""IJll"'. 1101 U" knO\\. (This is usually thel"t~ult of K(onthn!.! In two orders (OJ'a newoul",,·ol'lion.) We periodically cheek the"nllrt' lilt· to try tu find duplicate copies.Althnul!h \\-ere pble to catcb mO!itof them.It0. h \·...1.,. IlmeoC(Jnsunling proce.~.Let us.kilO", alld \\c'lI be happy to carrect yourB'Ih1i<'nJ,lJOI\ rl'(.'()m.

On\.' Ol her 11roblem L"mis,.l~ingissues be·'-:IU.., o( • change in oddre... (\Ve get!>ulld"..],uf addl'e-"S changes each month.)Th" P",1 Offie<>will forward magazines for01,1>" l \\ 0 month. ... after ~~oumQve. Since1.... ><18'"11/1~, a hi-monthly pubtication, it'stoa."" tlJ m~ un issue.

If you change your address. or if we'vemade a m...'take or misspelling on your label.I,·t 11.' Imow. We1J OOITllCl it and send any~U"C \,ou"'e miK.~.One '!aatthing. From time to time we rent

the 1I'"ooslIIilh ~ubi;criber Ii$l w qualifiedwoodworking campauie. who send oUIcatnlogs or information on woodworkingtool' and supplies. Wescreen the .. offerswmake sure (as be.~1W~can) ""11 it is an offerof inLereSt to \\·ood\\·orkers.

HO\\·~fert if you (10 not ""ant to recE'i"ethi.; information. plea:>ccheck the box on thefronl JI'ItlCI of the envelope and ,;end it in.

N&XTII!1AILINO. The June issueofll'ood­smith (No. 45) will be maJled during theweek ofJune 23. 1986.

SAMPl.E COPIES

"you t\aV$8 fnend ,,!lQwould TOOl10 58&acopyofWoodomMh, joJSt send the names aocf odd<ess.and we'll send a sample (al no cost~

BACK ISSUESfoJ1 back Issues of _til are sIlll av_Seod for a flee boo!tIet desalbmg tI'1e contenlS andprices of tilbad< issuGs.

WOOOSMITH (lSSN 0164-4114) Is publishedbImon1I1Iy (FeI>ruaIy. ApnI. June.August. October.Decembe<) by WoodsmIII> I'IIbIisNng Co.. 2200GIlIS1dAve. Des MoInes. Iowa 50312.WOODSMITH Is a '89_ ttadematI< of tI'1eWoodsmoth PubUsIWlg CoCopyrighl 1986 by WoodsmI1h Publishing Co.

All Rights Reserved.Subscrtptlons: One year (6 issues) 510. lWo)'OOIS (12 ossues)S18 Single copy pnce. 52.SO(Car1ada aocf foreign: add 52 peryear.)Chang. Of Address: Please be sure ID"""OdDbolh your old aocf nt1N addtess.Secondclasaposlage paldat Des Moones. """'"Postma8lat: Send change of addoess I'IOIJce.Form 3579. 10Woodsm,Ih PubTfShlngCo.. 2200Gf8(IdAve .•DesMoines, 10..... 50312.

EdilorDonaldB. Peschke

DesIgn DorecIorTed Ktallcek

AssiSlant EditOrsSteve Kroh"",rOoug...o L HICksDouglas M, Udsror

TechnicalllluslratorsDavId KrayllngMlkeHeruy

SubsctipIIco Manage<Sanely J, Saum

SWscnptioo AssisIantsCIlristel Mine,Vicky RobinsonJacIde Stroud

Computer 0penIIJ0nsKeoMlner

AdministrativeA_tChetyl Scott

BuilidingMail""'""",,Archie Kr"U5e

ABOll1'nils 'SSI)£. I ."muml,..r lh.· Ii",ttime J saw burl \'pneer-I meana ~hl""_'l"freal burl veneer In its natural ~I:tl(' Inotveneer on a piece or rumitul,\" tha.t Wlll\­covered with I~y~.."or yellowed ,·on".hand years of darkening}. I ,.,1\.- am"",,1 atthe swirl. of color nnd subtle l>allen .. -cen.ain1~·untl orth~ tna.r\·eL..;of natul'\'

But a... beauuful n....thov an', J'\'t al\\"""1had a reluctance to \\o~'kwith \'t.·n'·l'h.Actually the problem is trying 10 workwith burl veneers the uld·rll..<hl l WRy

BUTI veneer COnIl'S in Ihin ·"'1",·1)'small sheets (abou; IW to I.l· "'1WU'\'1Ilw.tare dry and incl'edibly wrinkled. ,\ndthe)'-'rl' b}' no mean", ['fl.....or ernek, s, 6phlt'i.and even holes, It can be "i""","""li"~(t can also be a I()l ofwork jf )'OUwant to

veneer a large .una ee with burl "'I1,'<'rusing hide glue and a veneer prl':-..... Rifrthtin the middle, up pop. a bubhle II"'t ",m.,l),refuses to stick down,There are two changes that make work­

ing with veneers a lot easier. F~I. 1\,·become a real fan of contact cement, Iteliminates the need (or a veneer press, andit's especially nice when working "ith th"unruly waves a.nd wrinkles or burl \,e".,."·,(\'{c're sho"ing a few ti~ for working withveneer on page 15.)The other change is the introduetion of

flexible veneers. These paper-backedveneers are as ctese to perfect as you canget with anything made or wood. Th,'y·....·very eILSYto work with, (Although 1hOI(' tosay it, but they're even .a.ier than "ork­illgwith Formica.)If there'. a dra ....back. it'. that the' nt·'­

ible veneers are very, vel1' thin, Youha\'.·to be right on the money. becaust'thcl'I"galmost no chanc. to smooth thinl!" OUIhyplaning or sanding.

If you've been wanting to try a Jlroj,'<twith veneer, Ihe small box shown in thIBi.s$ue i~an ea.-y \\'ay tostart. Afit'r ,,'ol"kinJ:on t.he t.~IOboxes 5hown in the phuto Qnpage 12. I made another one out of cocobolowith a Carpathian .Im burl. Now thai ", ..,fun - and worth the elTon to Ill't to kllu"\'eneens a tittle better.

DADO!:S. Over the past couple of y,-an<we've been coUeding VarioU8 dado blad.$.t$ to geLsome experience with each ""t.The d[()'erenees among the sets are amaz­ing - and somewhat depl'eS-'ing Rt th,·Mmetime.

I'm coru;tantly amazed at the)lOOt '1uali­ty of many of the tools on Ihe market.Sometimes it's a mntter of )lOOtdCNgJ1.This is p;U'tieularly true of th_ tookaimed at the "sell it quick at n 10\\ pri","mark,·t. They're just not worth ha\-!ng,BUI mOl..,often than )IOOrdesign. il', •

Numbef44 April. 1986•SawdustI·W1.X~llli

3\VOOOS\IITH

I.d " ,\ ntt ('0 (0 t I' " goo<lMZl fl I tZ« gl It , la'1I A"

I(wi II l' U "0 .lmll.YT It, d bar 001·tO~i" 01 (/ tltt .tHQll b.,zt'S (t'(ltJ.lrtd I U ~1',,""(. JJ II ""M .. tt,bt ('0 rt "lllf./f} ( IJillNt(Jf~ ..ttlf lunl,,(urttqll,n I'r"("rtl~·tlliek·111ft01Iii, "~.#l~·'1g '(l~ ("all thIYJu'f!t<a t~·y'-q It In'l}r (l "'1 10n 1I!1)i(J .1(/(1(.-rl rtl $(rips oJ',nctJII.I.;'Jlg I(J/" ('.if "tYf ~stJl"f11K1 Ihe sid.f..:$COilI~ "ql((tltd "/1,

• you d l<e101Nr•• WOGCIWotIaloglll>wiIh_' •• d.rs of Wool/smith, send yOUf ildea 10w_.T~ & T~. 2200G..ndAve Des -. Iowl 50312w. pay a _omum 01$10 lor lops. andS1Sor

more '0' Sl>ldal lec:IlnlQues (!hal ate aecepted'or publlc8l1011).PllaM ON.a complete explana·110ft 01your odea If I sllelch IS needed. send IIalOng; we'll drew a new one

,. ..." .1h /{ (H 19'tall lUll. ~\.f" 1

f

after Ihe !du\' IlCUup. -unpl) remo'~ th~tape "ith th(· .,,, .... j.,~\I('on il.

tuN 1AP'lAlONGIHSa fOO.IOf JOt"" UNa

11'\.'\1.'lltJ~'nl;utl"tt 11\Jm~lrf)rOO\.joinl boxesthl,t ",'I" tu b.: .lain."". I found on the firotbox thotlt \\~I,...quite " Ch4)rt'lO remove an)'C'''''~glue from Ih(· inside corners o( th....,_,:., IKJ th{~il-Wlnwould take unirOlml,~ It \\ a_..e~t)('('ltlJ~'(liffictllt to ('hilJ n\\1})' on a smallIx" "here I rouldn\ ltd .•chi..el inside,

ThI,'11 10Wle upon tlK' ...tea ofu.,int! ma.....k­lJlg tape on th,· in:<i<I~, ( each box to ...aI offtht> llIu,. 110;-(...... 1.'lum;:.JU': aPl~' tht> 1"Jll'dill'll with the bottom of lhe ,Iot,.. Then.

S(ND IN YOU. IDEAS

l)J"" lhe t0l>~' Inpo."ltion.hrinJ: one oftIJto dado ,Jot.ln the \\ urkpoc.",mto the blad,·UIJtil \ • the stop, Theil mo' e it liidltly- ,,-\ ( 110 you'", ju.'U tk-anlng up thebottom of the olot Wltillt',::mooth. ilat, .....11IqlW1! ('onunu. on d..'aIlinJ! lip the ""'t oitIK' _Iou<" Ih th Nl!Il(> ted>nl<lll<'.

[N"UirriH, "",,#... \'*0".$0;'1

F:~I/.(l,.·tJ~\(,f~ Illff" ,1'JI,'t II'/t't a 'Mlllds(JI#~,(mIM" IJo" Ih'lf8(IU't lerJ"llq'lt' l(,tl, uS<lbrloMOIt' rfn" 1M fJ II ".1,, fl rYJlti('r tubf, (Sf't' ,\iJ,nJ..,IIItlt \',J. l", IHltl' .1/(If (I /'1' QI'liJs/tllillg"!MI,,.,JJ" I" CI , .. ,u/e r t(,blt), 0,. 1t....~(lllal'(l·1IIId Mhrr.sau (''''/ U Zlf'Y"!IJ(lt'tlgl S.tol'r" , ptd O("nJUi Ilff IIY"fJ,.·Jl t t~~J.f 11IQpt. 1111'/fUdtd q(rh• ."b" "", hn.'~E,lh""IOI"Ix 3' ( tl_} hit (JMflrp./ N~·I()(Jtlblad~()II,~:b~""u ~

CLlANINO UP .oX JOINT SLOTS

I u'" IId ffcn:-nt technique to oll'an uJ' th~ro\l~h bottoms of I"" joint .lo~" left by •.wlo", I ( ,~ \I ,,,,,I... th :-':0. 42.page :!III. I0.) it \\ Ith III, b;.UMt~\\,

SUI)t 1,) ('1.t"1I' lit( :.. l'lt-::tiJ(htt!CJ(e :ottlp toIh,· o.lI1.I>.a\\ lahl,· behind the blade. The~leJf'hlL' te, b.. .)(·*'~·'l(li(..ular to the sawhlad.,. To do t hL' II< t til" baJ~l;a\\ miterJ!1ll1j!' [or'~ Then put lt mth .. miter gaugc,~ (Il ';\IM. holtllt tight HilUm...t the stop whiledaml' nl! the top 10 tbe table.The ,I 101"""from the !'rom oi the .wp to

the t.....nt cull ~ edgt' (i(!lJ..>;;aw teethlIhouI<lequal till' (uD rlepth vI the box .J<lllltoW. This '" the Ihiclmt'-- o( the adjacentpll'<'<'ln the boXJ()U1l.

MASK OUT GLUE

JO<' I;n:JlI~7It(,&,".A ";(', a

tighten a "ing nUlIn from the back until it·slip Il:lUJlSt the T·nut It "ork- great f,<I'marking and tigfl\ ."ttln;: ~h with amaeross IlK,gnun.

T""" lth' dcl-lhol CUI, u-t tum the bolt IIIIh" T·nul. J'hen to 1>1\" ,,,,t It Crom mo'inj!.

lOW.cOST MARKING GAUGE

H• ...,'. An clI','ctI,. m,,,'Iung cutunl( j{'dUl.'e 1made (or the ro:\t o( a W\\ «,n~' wilh a~ bolt a T-nut. a wing nut. and a ~~ blod; of -t 4 Ilarch< 00<1.

f11'11t drill. •bole throu!lh the MItt'!' ofthe bIotk to 8Cfommod:tte. ~. ~'I'cania!rebolt Then drill 11 <'OIIntcrbore part waythouI.'IIth~ bln<k to aecepl the 'f.nut and tapthe 'f.nut lllto position.

:-':0\\ ~."ndIh"lup of the <:al'l"iage bolt fiat\\,th "di",·IUind,·r. l'hen angl" the bolt beanin ..datlllll to tI", dL...: .m" grind II be"elMoogr allll ... Wll)' ""lUnd the head. finally.sharp"n lhr «I",' on lI.harpening~tone.•

Albc,1 BPO'.\f~JI'H'll/a",/, Pru"$!/llYIlIln

:-;0\\ Ioo\!,n the n,..lIt "inlt nut on thef,·_ a...,.ve the let\ one ti!lht). pull th,·playing can! out and pcsh the fence backaj!3ll1$t the b!oclc. n,;, h:I., moved the f~lX'<!back from ItO ol"it:inal ""ttln!: a dkUUll...,pqualto the Ihk~ oCthe 1>Ia~'IIlI!card.f'inally tl&hteJl lhe wmg nUl bOIC'k '~'\\'D.

:0;0" mak,· anotl",r 1"'-_. I( the ClIt b -tillI'tftl Yo kit· enc,ul'!'h, l"t,ntlnuP on 'Uith lhL­proc...... unlil )"u 11,'13p<'n('('l fit. I(al anytlmf;' UII'nIl got'S lOr. (1("Cp. the proc...-e:s.... canI", "'\'~"'l,1b)' addinjt card, hetwecn IhehlllCkand Ihv fen,..,.

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t;1MOV'I """nNOCAItO ANO flUSH,.N(t~.IH)lSTOP'tc.OCK

PLAYING CAItDS IN THE SHOP

The", are tll1~\\h< n I """" to maze a fineadj\l"tml lit (lfthe- rl"lt.('r table fence to sneakuv on a fin",11 dimension, RUI loo;ening thefenee alwl Ir)'Ulg to tal' It over j~la hairnever fl.1."t'1lUW W\'l' me the control [tntlooklnJr for.Instead, I u playing cards as gaul!"

shims, (They'n' ,·xa<:tly L lOOth of an inchthick &0 three ut th"m equal about 101•thIckne~ s, ) Or, I use a .park plug feeler"."go (or extremely fine 1OIiju.'rn"'n.....~tart b) III:Iking a Ib, eut, Ifit'" not qune

wirle enoul!h. hold. playiJll1:card (or more if~) III:lWUIt the back right end o(tlJ..>r.nee and damp • ICI'Bp bIocl< to the tableu!lht lIj:alJIst the can!

__ T_i~s& Technigue_s__

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WOOOSMITH

•4

.\ ."'.S'....;.60

8::;;! ..:l»mll..a±_!iI

IIj It."'."Y, .. 6 ,.,'0-\ _6' •• 4',t.. ,., "', .. fitI .... 2¥.. sv.h ply. M..~,'.JCQ,dtoh,' •• 2.3""v.."Yn·S· ..'¥I•• lY..1.'.''''' •• 1y.. ".I .." pay (\If to flt~•• lV •• 12., III \l. ..011 to ",

•

........ _(21

.... w..121C ",_")D ....... (llI _SIdell!, 0.... ".(2)00....,0.., ,,(2)H-""21I _0._(2'J (01~_s_,.)1 (1)M ., ,1.N s."p,Di'f.(3)

___ R_ec_i~eCard BoxA DOUBLE-DRAWER FOOD FILE

CUTTING DIAGRAM

It- Ir1te1Wtmg """ a project can ,l('\'elopCrom a mph> id.>a. Thi.'! r't'<'l," CU'd box I:'"good """"Vie \\" ...~" unlllllal)J lhinking0(.SIDlpleonc·dl"~"rr b.. x tohoJ,l SxSClnI.<

Rut then soree or the "<coks" on OW" oI:llI"look • look al the angu::lI.k,~ ando:Udth<re .."",,\ enough room r....aD t.h<:1rn<apenonIs. So" c adderIana:hct- <In,,\( r.

:-;Pxt. u..t.oad or making Ju.<t • plain box(or the -e d .. "en wedceid .. 1tod,..... u"tIIt­co"",,, ",th nuter and dovetail kP,"jomta'.'lIlaiJl('(1 in .k>UW on Ill\I!'" 10-11 And...,.., the bo., ",..joll1 e~1thlll "aVo"1cy notmake the drawe rs with thisjOlrll'Ry th;" time the cooks """N~"I of lhe

"'",.,.,..draw. r.bUlol.<",..,1Ullklnllnboul thtW3) th,·jr ..",kbool;;o 1t,1.co, ,....-d "'ll> Oourwhen laid out un J& t'C)unk·)'\('jl. !'o \\e nddt"l'latilt-up frame to hold toclkbot,k •.

'111.. called for a ~11(1 fnUll<' IlnlUn<lth<bouom of!h<·box to I>ollln,,'orr lhl "III. elf·anee of lhe lOP fnml:(~.••t\K I M.llul, l,rujt"Cl.designs t.,KIIO developas you !(t'tmto Ihem.

But on~of the niC(>f"lIlu1'<.'"ofthi. I,n,j,'l'lit< that yQU ran leav~orr part or II" ",.,.j).~,(the Iilt-ull cookbook bolder) un<1.till have nus... ful proioct (lh,' ...",il'l' boxt, Andthat's where 1bel,'"Iln: lilt' b;lIIir box

THIIOX

To build the box. I .tnrt.'Il by "","I'"ing .nau¢> .to<'k 10 aboul v..' thickfor the lop Rnd bottom (A). lh' I""... 1"" IRI, and tho dlv~"'r «'I II\"t,:'·00 can elimina.tt'! re~,a,Y..lngIf ~CMJhave 11«0", to Iii ·thirk stoek.)

After tilt- Mock .. I'l'Sllwn... Ill\""glue one blank for the 1"1'and bottompien.~to rou.ch dimen.""'M or 7 ,­",;.to, and "!i(' 1001{ T1><:n .odl1l'"Klueanother blank for both !'ide ,,1<'<'\ andtht- eli,iIk'r 10 rough dlltl( nslons (.r... •..id..and 1G'10fIIlSi>op!\o)k: In-t.atIo( .. h,,·gluIOIt~"OUcan bortom, and ,ide piece- see Detail In fIg

u..«''' '·wi,k· -toek, ButWI«' .....icr boom. I 11>e v,,'.\\ ide rabbet aDo ... ,. a deeoratlvctend 10".rp, I think il- better I" rip tht-m .H·batk tor tbe V.·ply ...ood bsek O~downor Il.'<! naJT(J",r boanIo BJICI ,..!"u.· cvrnse nu, MfTERS. :\",'1, <lit rrouthem tOl;\'tht-r....... n aft,r tbt' ¢Ill' dries, mil" ....on thl.'~nd,of ~b >idepi.oro H ""plane tht' blanks flat and down 10..... thick. Ihal Ih.. final length i.5" from long pomt 10Ct'TT11,eTOROt:OH'Il" \\'h"n 11>., wnl( ""int of the mitered encl.__(~ ....JI8g<'

blank., lU'e Jllanl~1to V•• nl' Ih"m buth to. 10 for an ~xplanatiun on rullin~ theoeunifonn "idth of6 ....•• :>lowrutlh. lupond mi....... I I'ot(': Bp <\Ire to CUtlhe mi",,, ...bollom pieee' (A) to ",ugh I.nlllh. of II" th~y'''''"n Ihl' saml.' (ace Il.' the mbbets.from the long blank, Ami CUIorr two &',j,' Th"n mller lhe tnd~ "f the lop alld(rough I.nlllh. "des (HI from the' .h"rt t.,uum I'i..",", (Abo that tht fina!lcnglh ,.blank. Sa"e Ihe .....mainlng:; pi'~'e (ruujth 13'. Note: Thi. length ;,. b.~"""on havinglenjtth) for the divider ,(;). 1\\u elm"e .... \\~lh 3,5 tani. i".itle.

RAOO",. FOR 'nn; BACK On,'<: nil Ih(' DADOPOR DIVIDER. On"" all the mite'"pil~14 a~ cut. to rnuJ.th length. tut u ~;'''. ha\'{l b(>~n ('ut, rout a If." by 1/." dAdo 'l,,'•• 3Y1.... 36' CUSAWto '.1wide by y."·d....p rnb~1 for tb. plywood Cl'ntcrl,1 lIero.. the in.<ide(ace of the lOp an £, .:r1illElback on th~ in.lell' bark e,I!:(' or Ihl' l:":I':., :,,:.:":d~bo=I~lo:m~p::iec::e:,,:...:..,~e:....:.F~ig~.~2:::'_(~:-<~'o:t:e:..:.:.1~=======:- ..J

5

••.,

_SlOT~TUfDONWfOTH/ASL

eo.

DfJA!L"",,"7

• : Sl!ilAlGHlSn

..... &AOICEOG£

·.·.~,·ttAMP(5(:[ OOAJt.RG 1)

_,

1® /SIDEs:

J©

DIVIDER

®SIDE

,,'.

- NOTE: All S1QCIC',,' THO"sw- --,..___

WOODSMITH

originally built the box with « stoppeddado, see photo, but changed the design toa through dado LOmake it easier to eut.)

To make the dado for the divider. mounta y. straighL bit on the router table. raiseit to a height of II,". and move the Ienee soit's 6\1. from the renter of (he bit. (Note:The 6''''"lllea8urement ishalfthe la·length.)

Now .'OUt the dado ""'""SS the inside fAeeof the top and bottom pieces, see ~·ig. :tThen rotate the workpiece 180" and makeanother pass, (Thi. IWO-pa..'5 method en­sures that the dado is centered. If.okay ifthedado is a little wider than Yo". The tonguethat 61., in the dado can be 3(ijusted laten)

SACK. After the dadoes arc routed in thetop and bouom, cut the y. plywood back(0) to fitin the rabbets, Then dry assemblethe box with the baek in place.

DIVIDER. To determine the lenl,othofth.divider. measure the distance from thebottom of the center dado in the lOPpieceto the bottom of the center dado in thebottom piece. In my C<ISC this measured~'I:".seeFig. 4.

To determine the width of the divid••·.measure the distance inside the box fromthe plywOod back to the front edge of thetOP and bottom pieces. 111my case thi$measured 6"'", see Fig. -1.Arter cutting the (lh'ider to final .ize.

rout tongups on the thickness of both ends.see Fig. 4. I routed the.. LOngue. on therouter table. sec Fig. f>. sneaking upon the6naJ thickness until the tOllgue just tits inthe center dado.

ASSEMBLY. Once the tongues fit snuglyinto the dadoes. glue up the box. di,;(fe.·.and plywood back making sure the di"lderi$ Oushwith th~ Iront edge.•. Then clamp itwith a couple of bandclamps.

DOVETAIL SLOTSAND KeYS

When the box was <ir)' I added the dovetailkeys. To do thi.. I used a Yo" dovetail routerbit raised 0/,. above the table. see Detail inFig. 6. (A 0/," Or v." dovetail bit would workju_o;t as well.) This technique is shown onpage; 10-11.

DOVETAn.. SLOTS. ~'itot. position androut the center stot across all four corners.Then move the fence sothe center oflhe bitis 1Vo" from the jig and rout the next set ofslots, see slct locations in F'ig. 7.ArLer these slots are routed. don't

change the fence but iiiI' the box so theopposite face is against the front of the jigand rout theslots on the other side. Finally.move the fenee so the center of the bit is ~"from thejig and rout the remaining slots.

DOVETAILKEYS.After all the slots arerouted. make the dovetail key~ using therouter table (once again, see pages 10-11).Cut the keys about I~'Iong and then gluethem into the slo!$.J\fter the keys are dry. eut them off close

to the surface with a fine-toothed saw andthen trim them flush with a sharp chisel.

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WOODSMtTH

~ .-.,-OOWll SlOPc(N'JUfO ON0PlhlHG

OOUi-.ll!

'Ilfl DRAWERS

Aft~rthe boxIS (,,,,,pi< te, the d=~rs tanbe built to ftl In tIK·"Il(·nin~. [ beIr.m work00 tho·dnI....... by ruttmgf·iKht dra",-r,;ick",lEI (rom Y. thid< n'","n stock to a Iini.""-odwidth (.f21 ",,0). ""'gld"ngth of6v.-.

BOlTOM RA8I1t:T. lI.. for. cutting the,"!~.to final I(·ngth. cut v..'-deep rabbetson the bouem l'lg. of 1I111·iJ.:htpieces just","1" enough for th~!I. plywood drawerbottom •• ,,'t' [lOllom Delail in Fig. 8.

Lt:NtlTIf OF81Ut:S.Aner the rabbets arecut, lh~ (Irawer .,,[(., can be cut to finalk·"~'\h.Mc...~ th,' width of the drawer"I""lIng in th,' bux. "' -e FiK. 9. (In my ease,lhi i'JK"nlUgmeasured r, ....) :'\lO\\·cut crossmitt'1"!! on the cnd,iof a1lelKht pi~ <0 IheI ngth ITom pOUlt to point of the mite,.,."'I tho ,.'idth of the opening.t Sote: Thedm....,,,, an' "'11W'f'so aU e,ghl sides an!tht UlIl(' Imgth.)

1.1\ lI'l ROAIlO£.' AIl~r aU eighl draw er.00 hau been m't~"",1 t" length. routCt'l1t......od d.1d........ "", four of the pieees(the 1<1, 01 the 1.. 0 drawers. to acceptn !nO, able .11,-1."·,.. (G). see Divider DetailInFJl:N

1\()l"TC)"tIt' X'·\l. Mat the 1/.- plywood1")11""" (~') (" nllll the rabbets. Then glue

I .",11'1011111Ih, ,In ... """ with the bottoms in. "Il,,·,· Sill..., II... elnl\\""" fillightly into the4'1)('111'15::. eheek th,lt th{·)·'~ square.,,,,,\',I ,'I Kt \..; \\ hen the drawers are

d~ .,Id lb. eI", etail keysu.inl( the sametedln IU. u on th~ 1'00" ....... key loeaticnsmllMoSld \1'''. hI: s.Aft<.r tbe kr) .. are l(lued in and cut off I

o h lor plant' tbe, d('•• liglltly <0 the Idra.. I."'" 11110the """ning with about

clea.ranc »n l"arhntt'.1'1\ III. It.. 1\0" rut removable dividers

IJ) tel ItI In the darlne1i In each drawer,11("( t I~s,kI' Kt Ii' To k""11the drawer from tip­

I III ,I.... " ,U it'. pulled out. !added 8k •ke r (III to th,· baek of each drawer, see"'11( ' •. 'll1l' ki('ker 81.0"0 aets as a spacer tok'·'·I' th" drn"~r from goillg too far backlIllo 'he· bcl\,'n••h Io'nnin~ the Ihielme," of the kickerI JlU hcd the draw~r all the way into theOOX1UJ<1,"",,,,ured the set-back, In my caseIh. "" ••. I w~nted to add a V,,··thickfaL.se·,I"',.er frrmt "n" have il.tick out •frum the frunt ,-dgt> ofthl· bus. see Detail inFIg. 11.Thio m....nt Ihe kicktorwould haveto be .thkk.('ut I .. o kid,...·"to that Iluckn<.•• and to

the obape .110"n In f Ig. ~. Then. ~ue tIK:klcll' r to the cenl.t oflhe drawer back ~It'.a....h \\1tl'l th .. draw~r bo.t tom.

FALSE ORA" f:R 'ROo,;1'8. Th compl<!tcthe dra\\I· .... rut 1\\0 f81:.<·drawer front$(I) from y,- >lock. Th .. "idlh ;'~quaJ to theh"'Khl of Ih~ drn\\~r QPI'ning minus '1,,­and the length match •• the rron~ or thedr.lw<'r. "ee rill. 10.

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Q) FRONTI8ACK(II:Ju' mas1 71~ISflGURf 1'2----,..'•.-Now rout a V.round-over profile with a

0/,." shoulder around the front face of thefal"" drawer frontss, see Proftle in fig. 10.Then glue the rronl<' to the drawer sothey're flush with the sides and bottom,KNOBS.Wnen the d ....wer front. are dr~;

drill and then >,(,1"eW a porcelain knob to thecenter of each front. see Fig. 10.DOWELSFOPS.To keep the drawer from

pulling out too far. drill v. holes throughthe lOP of the box 10 accept ,>,,··Iongdowelstop'. see Detail in Fig. 11. (The"" SlOpScatch the kiekers.) Center the holes abo,'.each of the draw er openings,

THlfRAMES

0_ the drawers were complete. I added atUl'UII cookbook holder to the top and amatching frame to the bottom.crrrnxc TO ROUGH SIZE.StlU't by 1;1>­

ping aU eight frame piec-es from ~'.1 (1'1',.thick) stock to a final width of 11','. Thencut the four frontibackl- (J) to • roughlength of IS" and the four side. (K) to arougb length of8V,". see Fig. 12.RABBETTHE TOP FRAME.After the

frame pieces .re cut to rough size, cut a ~'.".wide rabbet in the four top frame pieces toaccept the \'<" plywood top panel (I.)....Top Frame Detail in Pig. 12.MITER TO LF.NGTH. Now the frame

pieces can becut to final length. Measurethe length and depth of the box and cutmiters on the end. of the frame pieces :;0

the lini.hed point-to-point length. are IV.longer than the box. see Fig. 12. (Thisallows • ,..' overhang Oneach side.) In my...se this made the fronL'ba""" 14V,"longand the sides 7¥.1II' long.

'rop PANEL Once the pieces are cut tolength. glue up the frames. Then cut the,.•" top panel (L) to fit in the rabbets of thetop frame and glue it in place.

PROFILES. After the rrames arc asssem­bled. "fie lhe router table with a fence torout profiles on the top and bottom edltes ofeach frame .s ec Pig. 14.First, roul an ageeprofile with a 0/"," point·cutting ogee bit(Sears No. !I HT 2S583). Then Oil) theframe over and rout a Y','Ouncl-ovcr on theother side, see Fig. 13.

BOOKSTOP. The next step is to add abookstop 1M) to the top frame. Begin byrouting a stopped \10' groove near the tOPfront edge .(the top frame. see t-i~. 15.Next, cut. blank for the bookstcp from

,'''·thick stock to 1V.. wide by 12' long. Cuta centered tonlt\le on the bottom edge ofthis piece to fit the grocve (see Detail infig. 17). and noteh both ends of thetongues to match lhe length of the groove.Finally. make a pattern from the g1;d

drawing in Fig. 1~ and trace it on theblank. (Make sure it's lined up with theshoulder of the rabbet. ,eo Fig. 17.) Thencut the bookstop to finnl shape. (Since it'$easier to continue \\ ork without the book­~top in place. don't j(h... it inyet.)

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WOODS,,"UTH

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""ACHING TH[ fRAMts

0.." lhe mlflW>. are complete, Ihey can beut18<h.<ltothe box, Ibegan byauachingthebuttym f.-.unt·.OOTTO" t'RAM£. Start by drilling six

slight I)" oversize ('.~') shank holes andcuunt e r s ink s for #8 x IV," Ph.woodscrews, see Figs. 18 and 19. (Note,TII~ bottom frame is nOI glued on. soeversized shank hole.~allow for expansioncentracuon of'the box-lThe box sits on four W' buttons that act

as -reet.· Drill "'I,"·deep holes for thesebuttons in the bottom frame and Itlue themin place, see Fig. 19.After the buttons are glued in, po"ition

the frame so it's centered on the bottom ofthe box and mark and drill ""'. pilot holes.Then screw the frame to the bottom.

SIJPPORTSYSTEM. Before the top framecan be attached to the box. a supportsystem (N) is added lo the back side of thetop frame. This system hold. the frame atabout 40· for a cookbook. see Fig. 23.$taJ't building the support system by

cutting. piece of 110' stork to I'Y' wide andtong enough to fit~nllgly between the !'rontand back of the frame, see Fig. 20. Thendrill a hole v.- from one end to accept a IGdcommon nail for a pivot pin.

Next, make t IVO rip CUts to slice theworkpiece into thirds with each piecemeasuring l4' wide, see Fig. 20. Then trimthe middle pieee down to a length of·Plt andround over both ends.~r rounding over the middle piece, put

all three back together. line up the hole:..andepoxy a 1Y," piece of a IGdnail into the holeSO the middle arm pivots.

Finally. glue the two <11ll8ill<'pieces to thecenter (underside) of the top frame. (Note:Clamp the outside pieces with enou¢> gapbetween them so the middle piece pivots.)

MORTISES.Once the support system isglued in plsee , locate the mortises for theIy.,·.longhinges, see Fig. 21. POSitionthehinge so the knuckle is centered on thefront edge of the box. see Pig. 22.Now mortise deep eneughso the knuckle

is flush with the lop of the box. Then drillholes for the hinge screws, and screw thehinges to the box, (Note: I had lofileoffthepoint of the '"'··Iong brass screw sinee itcame out into the box opening. see Fig. 22.)To mount the other hinge leaf to the

frame, tum the box upside down so it'.centered on the frame and mark the posi­tion of the hinge. (One way to do this is,,1th locator pins. see U'oodsmillr No. ~2.page 8.) Then drill for the hinge screws,

SUPPORT HOJ..E.When the frame is ultedup, the support arm fits into a shallow %'.dia. hole centered on the length of the boxtop, gee Pig. 23.

FI.NISIL Finally 1 glued the bookstop inand finished the project with three coals ofHope's Thog Oil Varnish.

9

tAILll'SAW

AGUIlSCROSS SECTIONS

Afu!r the first support annis clamped in place. drill pilotholes and screw it in place,Then damp the second sup­port ann down to the otherreference line, and check thelecatlon of thU, second arm\\;th a framing square, seeFig.·1. It should be exactly gooto the firs t arm. If it'. not,loosen the clamps and read,just. Once it'$' in the t'OJTeCllocation. dam,> it down tight,and then drill and screw it inplace (Note: Don' glue it Incase adjustment is needed.)

ASSEMBLY.Before assemblycould begin, I cut two pieCCllof'Yo" threaded rod to 6V? long.(Shop Note: \Vhen cuttingthreaded rod put a nUL on tnt'

nxllH1.".. cutting. After it'.cut, back QITthenul to reform ans drunaged thresds.)Toassemble the jig. use a double nul and

washer arrangement on the fronl plate, seeDetail in Fig, L (I used IVz"-dill.fenderwashers under the nut on the inside of thefront plate and under the \ling nuts on bothsidesofthe b.-.cl< plate. These lVid~rwasherskeep the plates square to the rods.)No" straddle the two plates over the

router table or table saw fence and slidethem up light against the sides of the fent"',""'-' Fig. 5. Then adjust the ollposing wingnuts up against the back plate.Finally. acljUSlthe wing nuts so the jig

slides smoothly over the fence. and check ifthe front plate i.square with the table.

'.HOU

I-C.OUHlU&OItE.e,.."'OEE:P

WOODSMITH

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• NIt

When it came time to make thedovetail key joint shown onpage 10. , gol out our .tandal'djig that ridesover the tablesawrip fence, Ifigured ilcould bemodified for the router table.

But it wouldn't fit over therouter table rence _ and to bequite honest. I've never beenreal happy with th.'U jig. Itdoom'! ride $JIlOOI.hIy along thefence since the distance be­tween thejig's two plates has tobe Ibe thickness of the fenceplus exact/y a $midgeon ror asmooth ride. \\'hat 1 neededW&8jigthat could be adjustedto ride over either a table sawor router table rence.The adjustable jig shownhere seems to solve the prob- L- -"'......._

lem, 1b b:WId the jig. begin by ~tting twoplates out of :v,. plywood to 6" wide by lb¥long, see Fig. 2. Temporarily stick the twoplates together with double-sided carpettape or tack them together with "nL.h.ingnails and retrim the bottom edges so they'reex(J.Clly BUM.

DIULL HOLES FOR RODS. With the tWOplates still stuck together. drill two l"·dia.by V.."·deep counterbores in the frontplate, see Fig. 2. And then drill ""'"-dis.holes the rest of the way through bothplates for threaded adjustment rods.

TENONS OR KEYS?The jig can be builtfor making tenons by adding one verticalsupport ann to the front plate. Or, byadding two support anns (at a right angle

,--

to eaeh other) the jig can be ~ forrutting d(}\'et:ulkey joints.

SUPP()KT AltMs. 1b locate the supportarms, firgt determine a center bottompoint on the front of the front plate. Thenuse a combination square to draw two 45'"lines up from thiS point. see fig. 3.After tbe reference lines are drawn, cut

two '"·"ide support arms to about 12"long. I cut these out of"'.. plywood so theywould stay straight.

MOI]!.'TING TIn: SUPPORT ARMS. Nowclamp one orthe support arms down so thetop edge lines up Bush with one of theangled reference lines. Locate one end ofthe ann <;0 it's \4" up from the bottom edgeof the plate. see Detail in Fig. 4.

~H3~~~~jr--~--~-aamuMU~~~~>PONTON

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__ A_djustable Holding_J!gc._____

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WOODSMITH10

6 Mou))t III~jig owr the router (ablefence. Drlen ••inr tile /<)CanOl' of the

8/ol$ by nwosuriJlg from liwf nmllact of thejig 10 the t<'I!/<Irof the bit.

.,_SUR, FIIOMcamJ

Of' lIT 10 fRONf P\A1t Of JIG

3.11..... "'"' du.tall~" beiu"J.'ll ",,«s of Ih~rohbrt ()II 8ide pieces (llld cut plyuood

1.00t"" t" fit. Cui prrciJ<dl/ ';IJU bottom1IIIliti kf"rp box BgIUl''ll dltmlg C-/Ot)tpillg.

Shop Now: l sneak up onmiters by "double-cutting: Itseems to gi,·p a cleaner,straighter cut that doesn'tburn, Start by making an initialmiter eut. Then make. se...'Undcut so only half the thickness ofthe blade (about V,.n it;cutting.see Detail, Slep l.CUTTIlt.: OTllER END.After

the first cnd of each piece ismitered. clamp a slop block tolhe ,uxilial'Y fence 110that theolher end will be cut about v,..longer than the final length•see Step 2. Cut the second

lid. and th•en move the stoll block tooI"u"I., cut the piece to liM' length (skim­l1)in~t he LlJ<>t VIG" off the. miter).Uc)1~rtl)'(llw~aU the pieces are mitered

to finAlI""J(lh, cUl th~ plywood bottom toIII ill I he nohh,·t. or l.'I'OOves. see Step a.(~hhl' :.;"".: If. frame is being made -WllhoUIa b..ttom or top - I cut Q piece of!I<''''P "Iy",,, ..d Ihnt fit.< inside the frame.Th", "'Tnl' h"I,,,, k('('11the whole box squaredunllll .....·nlhly.)

5 Gille fl"" pain; together ond .lip thebottom i"fo pia"" 10 lUfuan' lip til<' bar.

Claollp ",iUI tloo bandclamp« or "rop "'ffhoc;Ol(pI~ .'r~mgnlbIxTbollds.

2C10fllP U "(()II blrxk t" II ,rll,u,.v /rR('rQIld cut 1/11' t~thl'" I lid 4/1!Jh'111 ( ,. J

/Oltg. TI'~I'ft'UdJllxt tl" 1I/IJp JNf".4 '41 tru«l('Orl:piecr f{JJ;I/~!Ii'(111'lfll),

"o.IlOCI

. ~

,

t.)Jl('e lh_'l'oa\\ l...~l \I}I ut "X<t('ll)' t.a. \\t,tkcan h('gln on Ih. nutors, :;UIrt b) mlt~nllRone end or each box t\li-li,', ~ ... st.·p 1

of sandpal"'T 1(1lh.· l",slli"l1 (,.,,"'. \11thdouble·sicll'<lcal'!"'ll1'I"TESTCIIT Nexl. lilt th,' blatl"lu I:; and

make a tf:sl nat on tYo t) l'h"C't-S t,f8('rU,ko Hul«1thl· t \\'0 test j..Il(OCt togt tht r and f'lll,t'kthem \\ilh a ,t;qwtrt'.

THE Ml1tRS

4S,u'tad gil,,· OIl IIIilrrt!allJi hold pairafsidt pi'~tighl agai".l "'IlIlIri"g jig.

Cha "ifer rorl)tT of i.r:~jig to aUoII' tt<CO~ lorgt U~~qJ(erZ¬ ":Jfll0" In~idcconl"-

1First tip blad(' to .$.;0 (.I rId Cllt ONC<'lidThen make a $eCOIl.d cut on that end to

ski)" off a"nih..,. 'I,." (half Iileblad•• thick­,~e88).furucit'an Cl(l.

s....

Miter & Dovetail Key_Joint -A DOVETAIL THAT FOOLS YOU

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13 CuI /tPIIRab(lIItl'/,' Itnlg allll gl""the-", ;ntn flIt> ~1(Jllt.O,tc"~tIlt:.keutJarr.

drl/- rill Ihe," "(f r/o.'CItl Ilu' .•id, oftl,e ,",,.t~';tli.a.(i"p.tot,tllt'd $011:

14 .t:;/la,'e erres» (~/fJI'lsl, "'illl 11~JlalpeJlt8el. liork fro", tnrh l't'rlll'(' It)­

jl"U rei tl,f ceufpr 0.(tIle bo.r [!idt' tl.) IIY1:ty", tllf',1(J(t(tuil keys,fro"1 ("/ti,l/lillfl IJ 'f.

-

12 RIp tI,p /(IIIg ,I",~tail k.. ,. ,,0 II",,rvrkpic(-c SO they.lall uUV.l !JII""JI tl,,'

b{IZ(i,. Leovea ~'iglltsJ,ould,,. to IH' ;!tun'" tIl"k<'!lJ$ aro If·idl' t'nofqJI1.

11 T,.,'lh,·dOl~ailtollu"elo"" ,(ll]il.•ill Ih, .,[oIs r",<I.d i" litt/lOr. I( il'

)'''' 'I litlle 100 thick, slightly su,,'; mrtQlI!1"'ll to pmti-l,tt' a govd ~""g.fit,

tlPxm;OR'WORKftK[

10 .\(uhF",,' pus. Oil bolhedge.,"1011'fort' of workpiece. 7'hl''' flip pice»

il,'tV and ruut vPJI()·;~;ttface. Ij-'ou!llir is fOf)

I/"e'/i. "'01'( .(t'"rp a I,d mttt OgaIU.

9 11'ilh bit (II !1(!"" 11";9111. ro,,1 dU"floilIm'gllts (", both fflg'" of {I pi...·' of

.crop. Use o"ollter pitre 'if SM'tl/1 1<> hold,,,,,k/I,oce fight Ggawsl th«feur«.

1

8 R()/(l C'-(.)lt(tT Blot jiTf<l. Th"" t>I('U'( fllffencepJY the 'le--X( slot. S'rp J '\~itJll)"1

Iltr/J'rng "",t:e,,17;p fllf! bQ.r (I""tud (ltrd rollttI,t' ."lot 011 th» (It/1ft>' Sld('. St~/) 2.

7Hold boJ: light agoi'MI 8ide of Jig amidown in tJlf .'tI'll(KJrl. ant(.,'i' and PUMI

'''roug'' tI", bit. ('o",~r r'} 00,. ."""ltI rld(o./o)lgsurf a," ~i"'.JIltcr tubl<.

11WOODSMITH

•

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ASSEMBLY: Before a..~mbl~', test thebottom for final fit by dry clamping the boxtogether. Once it fits. go ahead and glue upthe box.On smaller boxes ( find it easier to glue

the sides up in I"'i",around ,I squaring jig,see Step I. And then I gh,. lh" llairstogether, On l"'1(('r boxes, 1 find irs easierto glue up all four at onee,Either way, slip t"" bottom (or square

"crnplin placeto hold tht' box square. Thenwrap a couple of hand damps "round thewhole assc mbl)' "lid u.,:hten, see~t."5.

DOVETAIL SLOTS

After the glu!> is dry on the miters, thedovetail ke~' <lOIS can 00 rut aCJ'O$Seachcorner, Begin by mounting a dovetail bit onthe router table. (Note: \V. used a II,'dovetail bit here but you could use • Yadovetail bit as Mown in the photo or even a"Iraight router bit for Oat keys.)JIG. To hold the box at an angle to the

router table, I built a jig that straddlesover the router table rCIl<.'C, sec page !J.\~'ith the jig straddling' the fence, deter­mine the location ofthe.lot. by measuringfrom the center of the bit to the side of thejig. see Step 6.

If there's 10 be an odd number of keys,locate the firs t slot so if.centered on thewidth of the box, see Step 8. Now hold thebox tight against the jig and push itthrough the bit. see Step 7.!tOUTCYrHERSJ.OTS.Next, move the

fence until the-next slot locRtio" i$ centeredover the bit and rout that slot. Then flip thebox (donl move the fence) so the opposite,'<Igei,again.t theji!: and roUt the opf1<>.<ite.Iot. Continuewit h this procedure to rotllall remaining slots,

THEDOVETAIL KEYS

OnC('the slots lIJ'C CUI. remove the jig butkeep the router bit at the same height tomake the dovetail keys. The key. arc mad.by finn routing dovetail tong""" on theedges of a pieee of scrap, see Step II.

Hold the workpiece against the fencewnh3 piece of scrap (see Step 9) and rout, oneedge. Then Oip the workpk",e so the oppo­me side is against the renc:ennd rout theother edge, see Step 10,Now test the tonguefor fit-it.hlluld be snug, _Step II. lfit'~~lmtoo tight. readjust the rene<> to take ofTatittle more (see tip on Jl<l1l'13).After the tongues are routed, ,imply rip

the keys oerthe btriP., see Step 12.FINISHING THEJOINT

Now CUt the keyg into I'f! lengths, apply alillIe glue to each key. and "Iide it into theslot. AJ\erthe glue-dries, trim off the ""000<'with a .6n...toothed >QW, see Step 1:1.To muk. the kuy. pericetly Dw;hwith the

!\ideorthe box. ,lulV~thtm orr"ilb a;;harpchisel, see Str·p 14. Then you can .how offyour "do,'etail" jOint.

•

~'OODSMITH

NOTE: cut IOTtOM 1'ANfl1OROUGfolSfl!"\'t;'" .'IJ·

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JOlt SIDESANOrtSr"EaSI

).,-roo\t1lattCUl-on\!. is rut on lh<tinsid(toftho '1'''' I"' -eo ' 1K,1in¥ the 00)(is assembled.""lei tho !'I(.,,~t~I..rroo\·eiscut 011 the 01ttsitieofth" box aJ\er it's assembled, refer to Fig. :1.

MOIH (;ROOYES- ikgin by routing' a +.'­wide Il1'00' e, . down fi'Om the tOP edge of"a"h workpiece, see Fig. 5. Note: Thedl'P' h o( tho groove is important - Itshould I ' close 10 balf the thickness ofIh, O!"..k , possible,cur SlOES TO LENGTH. An.er the

~roo\'(" art! routed, the sides can be cut toI"nllth. Rtart by cutting the two work­fJ1\"('_'!'Into six pieces- approximately 5"10llN (Ssve two of the pieces to use aa testl,,,,,e.later.) Now selthe saw blade to. 45-.tOUR.'

BOTI'OM HADD!.'. To ...,UI .h" "",tlnmrabbet, :ldjU'1 Ih. ("n«'~'thenlhhcl .'JUSt a hair dN'""r thall tI••combinedth'ck·ness of the sub·baJ ( ply" ood and on,'thickness ofl ... I4·rl><"""l.(Th.· f"lt (ur IIxbottom pan~1 b- ",OUI1I<'<Itu a pi.-,·" ,,(posterboanl. set> [IN:ul, Fill. :1.1

OVERt..APPINGRAII81ITS.The n,-" 61('"Involves u~inJ.tit llltl" lngC'J"Jll)< tC'.t 6t"ot llulid to lit onto tbe ba se, Th. lx..1way tu It'"a. good fit 115to n....semble thr- Ix." R.!l ft. , ..hl,It.·unit. then eut the 101'"rr to fnrm the lid.There's also • mny t",,11I1I'1""that ",ok, ...an overlapping rabbet JUIUI "h~"" Ihe 11<1and base meet, see l'ij1 II.To make lhese on· rillI'!''''!: 1·.hb.·I~,I" II

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I uk" to make tittle boxes - they let me bet~tra'''~'lI1It "'ith exotic woods and veneersthat I OOIlldn't aITord on larger projects.And. unlCtl!; I'm trying to be tricky, boxesdon\ 1"l'<luire complicated joinery - just...",ful fitling.

THEVINURfD I'ANlLS

The square box shown in the photo haswalnut sides and a tid panel made withCarpathian elm burl veneer. 'I1,e hexagonalbox has zebrawood sides and the lid panel isveneered with maple burl. (See Sources onpage 24.)

Note: The rest of this rutiele and theartWork deals with making the square box.The procedure (or the hexagonal box is thesame. except wheN noted.THE PANELS. I started by making the

veneered top panel (forthe lid) and the (e1t­tined bottom panel. (You need to havethese panels firsl in order to size the rab­bets that are used to mount the panels inthe side pieces, refer to Fig. 3.)Start by catting V.plywood panels to a

rough site of 4~" square, "eo Fig. 1. (Note:V."bircb plywood works well as a sub-has.for veneez) Then I laminated Carpathianelm burl veneer 10 both sides of the toppanel. (For more on t.bi.~veneering tech­nique, see page 15.)The plywood bottom panel isalso eat to a

rougb size of 4~" square, but the fell isn'tadded until later (so it doesn't gel tilledwith sawdust).

THf SIDES

After the panel. are made. the stock ror thesid"" is rut to size. Begin with two pieces of4148tQCk (~, .. thick) at least B"wide by IS"long. This length is longer than needed toallow extrafor test pieces. Now. resawthesepieces to get two pieces '110" thid< and planethe surfaces smooth, see Fig. 2.Then rip thetwo pieces to 8 final width of2"K.ROur RABBETS.The rabbets that hold

the top and bottom panels in place can becat on a router table. To rout the rabbetsfor the top panel, fil'St set the bit to cut V.·deep. Then adjuat the fence so the width ofthe rabbet equals the thickness of theveneered lap panel, see Fig. 3.\Vhen routing this rabbet, reed the

workpiece fI'oom left to right (instead of thenormal direction ofright to len). see Fig. 4.This "bad< (coeding"le$.."'nschip-out on theshoulder that "ill be the top edge of theside piece.Shop Note: "'hen backfeeding, the rout­

er bit wiD try to pull the workpiece. Holdonto the workpiece tightly.

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angle to cut eros. miter>; on both ends ofeach piece. (On the hexagonal box 'leI lheblade to 80" and cut the workpieees into 3"lengths.)We"'e found thul the best way to cut

miters like Ihi$ i. to u•• a double-emprocedure on each mitered end. Sec page10for details.\Vben mitering these Jlil:."~to final

length, clamp • step block 10 the auxiliaryfence on the miter pUJte 80 the point-to­point measurement 011 the aide!' is ·llAr­(2'+''' on the hexagonal box), see Fig. 6.CUTPANEJ..STO Sl2.£. After the sides

have been cut to length, dry assemble theboxwith band clamps. Thencul the top andbottom panet. to lit in the rabbets, Sneakup on these cuts untO the panels fit snugl)'in the rabbets, bUI don't "spring" themitered corners, see Fig. 7.GLUETIlE SIDES.When the lop and bot­

tom panels fit, the sides can be glueodtogether, Use the panels to keep the sidessquare. bot don't glue them in place yet. (Ifollowed the gluing procedure shown in thearticle on page 10,)

SEPARATE IlASE AND LID

Now comes the fun part - separating thebase and lid. Before cutting intO the box, Jused a test piece to set the bit height andrenee position on the router table,

POSITlON THEFENCE. The fence is SOLtorout a groove on the outside of the box thaioverlaps the groove already cut on theinside of the box. '!'he overlap should beabout Y,,,-, whicb means setting (he fence"i',," from the bit, see Fig. S.Since these two grooves overlap, they

will form the two overlapping rabbets onthe lid and base, see Fig. 3.

ADJUST BIT BEIGH'£ The critical part ofthis cut is adjll8ting the height of the bit sothe groove on the outside of the box isslightly deeper than the groove ab-eady cuton the inside. (This sets the clearancebetween the two rabbets. rf the groove istoo deep the lid will be loose. If the grooveis too shallow, the lidwill be tight.)

Use one of the pieces left over all.ercutting the sides as a test piece. Set thedepth of cut until the second groove is justa hair deeper than the finn groove. seeDetail in Fig. 8.CUTGROOVES. When the set-up works

on the test piece cut grooves on two oppo­site sides of the box. see Fig, 9. (Togive yousomething to hold outo, press the top andbottom panels in place in the box.)MAKEFILLERSTRIPS. 'lb keep the box

from collapsing when the next two groovesare routed, cut two 61lerstrips to tit in thegrooves and tape them in place, see Fig .10. With the strip" in place, cut the twogrooves on the remaining sides of the box.Remove the strips. and the overlapping

rabbets on the lid and base should slidetogether, see fig. 11.

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pad to the bottom panel, see Fig. 20,

FINAL ASSEMBLY

Alter~ing the box. Iapplied three COOlSof Delt Clear \Vood Fin;"b (Mro.oll. Whentbe finish "'lIS dry. I glue.. tbe bottom panelinto the box. Then Iglued OK'felt insert and

API'lY INLAY $TlIIP

An .... r.ho okIcs ""' _mb1ed. the box isrc..I<1\ (or tht> lilU h,n~ touches, I began by~l'ply\nj(un Inlny .tnp 10 the top panel (SeeSiwl' l\.~.~1"'1:" 23.)This strip is rabbeted,nto the t'Cigc o( r.ho' lop panel

RAII8.'"!: To rout th(' rabbet, adjust theb,t hi cut • hair shallower than the thick­n .. of the strip, see ~'jg. 13. (The strip i.",nd,-d Ou.h "ilh the lOp later,)

:-It,.. t•• ~u.st the fence to cut a rabbetC<jual to the width of the srrip, To preventthh< thin piece from sliding-into the openingin the (.~, Iclamped a plywood faciJlg tt,the fence, see Fig. 12.

MITER THE STRIPS. Alter the rabbetsare eut, giue the panel into the box', lid.Then the ends of the inlay snips aremitered with a sharp chisel 10 fit in therabbets. To guide the chisel. I made amitering bJoek from a scrap of2~4 cut off ata 45·angle, see Fig. 14.Begin by mitering one end of the .trip.

Then. position the strip with the point inone corner of the rabbet and mark theposition of the opposite point with a chisel.see Fig. 15. Now cut this miter on theblock. Alter the strips have been mitered.giue them into the rabbets.

CIIAMffR LIDfOGfS

I chamfered the edges where the lid andbase meet. This tan be done by holding thebox together and against. the renee whilema1;ing8 single pass over a V'i(roOve bit onthe router table. see Fig. 16.Note: The top edge. on this box are

square. For a softer profile. the top edg<>could be eased with. V.round-over bit onthe router table. set' Fig. 17.

MAKE TilE flLT PADS

The box has a felt liner inside and a relt pad011 the bolWm. The trick to making the feltfit properly is applying it 10 a posterboardbacking. see Fig. 18.

GLUE FEI.TTO POSTERBOAJID.1)) gluethe felt, I used spray adhesive. (SeeSources. page 24.) Spray the adhesive on apiece of (e1t large enough 10make both thebottom pad and the Urter Then mount it tothe posterboard, see Fig. 18.TRACEPATTE.RNS.Now trace the bolo

torn panel on the posterboard for the bot­tom pad. see Fig. IS. Then turn the boxup.id. down to trace the outline (or thelinm-.see Cross Section, t"ig. 18.Alter the patterns are traced. cut out

the pad and the liner with an X·Acto knifesee Fig. 19.

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ADOITIONIUDftYlNG liME

To nallen the dampened ven ee r. place itbetw ,.. n the sheers of paper and the piecesof part ,."oi)llard. see Fill. 1.Then place thebricks on top and let it sit 2-1hours.

011 lh.· """"nel day, remoisten the veneer,put in dry paper, then .'Cplaee the bricks.(In the third d8); change the paper. but

drm'l "",!.ten the veneer. By this time the"e_,' will btl almost Oat, but it should beallowed tn ory thoroughly before use.

GLUINGChung ,,",ul pieces ofveneer to a sub-basecan be c1('))4'with contact cement or vellowglue, I prefer a plywood (birch or' Balticbi...h) sub-base beeausse the glue sticks to itwell. If M."'>nitet, used, it should be rough­enod with """,,paper to help the glue formastronger be,nd.

CONTACT CEMENl: ContaCI e<>ment j,the e~iesl \\'8)'to glue \'eneer to another,

WOODSMITH

surface, The secret to a l-'1lO<1 bondis making sure there's enough cement on both surfaces.

Since figurt~1 veneer j~I)rft­dominantly end grain, it's \'(''1'

absorbent. The open wood 1""'<'"ill soak ul' the first coat of een­tnct cement. Let this first coatd.,)' thoroulthly. then apply Q sec-nnelcoal.When the seennd coat drie s.

the surface should look glossy. If......any (lull t;1)()t~ remain, apply

another coat.rontnrt C.'(l'mt,~nlha~ to be "dry"

on both surfaces beirur joined be­Core it can he used, When theeomaet ~mCI1\ no longel" rcelt>.tick>', the ven.. r ean be applied.To apply the veneer, lay a piece

of pape.· on the top of the sub­base, Then, pa~.itklnLht.·veneer.1\0"move the paper tn expose a_.strip alon)!'one edge where the

t \"0 !'UrfAl"CScan come toget her,\Vhen the two surfaces are joined along

on. edge, slowly slip the paper from be­t'\\~een the surfaces while pressing then)together. Then 1',,11the ven• er fiat with 3roller, st.., Fig. 2.

YELLOW GLUE. YeUowwood glut! i.saferto use than contact eement- especially inareas with poor ventilation. Toj!luc veneerwith )'eUo'" glue, :t small press is needed,For the .mall veneered panel on the de­eorative box, I made a press with $oCl'QI}~ofparticle board and C-elamp!'.Tolise the P""_', apply glue to both sides

of the sub-base and to the veneer. Thensandwich the sub-base between two pi""e.of waxed paper to keep the Illu. f''I)11I.tickinl: to the press and clamp it tight.Since no air can get to the glue. it dries

~lowly.Allow 8t lea~t 21 hlluY>before reomo\~jng the c1tlml)S,

DE CURL DE BURL

~INGPR£SS

I WOrkM with two different kind.>of veneer> when making the prqj.eets {OJ' this issue, TIw hn.·f...".· iscovered with pap"....backed C~xibkoveneer. The tops of th,' b\tl~de­eorative boxes an" CO\'t'n."C:J withold-fashioned veneer, (It'. 'litT.wrinkled, and asdr)' as an autumnleaf.) Gluing these two t),I"''' ofveneers to a sub-ba.-..e i....~'1lnilar.but the preparation is ditTo","\,

Ftexible veneer requires nopreparation before gluing, II'" as_y to apply Ill> plastic lruninnw.That'. because tne thin !a"...,rofveneer i. laminated to a sheet oftuugh paper, The paper keep.' theveneer Oatand prevents splitting.Old-fashioned veneer requil'el'

special preparation, This is be­cause it', rarely Oat. 10 eornpoundthe problem, iigun.'<Iveneers suchas burls don't have any real grainStrllctUl'C - it 1(00$ every whichway. I call this "nervO\ls' grain, It'. under.t;re,;o and tendo to crack under pressure. 10lesssen the chances of cracking, it should heOattened before 1L'I6.

fLArnNING

The secret to Ilattening veneer isdampeninj;it to make it flexible, then p.-...;ing it Oat.The process takes about three days in asimple flattening press.

DA~IPENlN(l.Dampen the veneer withwater sprayed from a hand mister, Dol,'tsoak it. Just lightly spray each side withoutforming droplets. With ju.st a little mois­ture it's ready to go into the Oattcninj!press.

.'LATTENING PRESS. The flat teningpress isn't fane)'. It's just two pieces or ¥..-p'""tiele board or plywood•• ix or eightbricks. and ,;orne absorbent paper (likebrown paper groeel'Y bags),

Veneers

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WOODSMITH

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RNISHEO!)lMENSIOtIS

•~·t tit.· C"'K'" 011 th~ table saw so the

di 1'''..·•·h. the out.ine of'the blade is equalto th, thicknc>,. of the veneered p8Il~1.TI....n <lIt .1;''1''0\>".en both edges of all four1''''<00;" !IN' Fig. 2. tThese grooves are JUSt1111(1., kerf -,,qual lothewidth of the saw

)11atl.Il \11"F.T PANEL. After the grooves are

cut tl ... ponti. are rabbeted to form1<1111.'11,· 1<1fit in the grooves. I did this ontho ruuh·rt"ble.;ee Fig. 3.~'ILh~ f.nce so the width of the rabbet i.

"Illal ttl the depth of the groove (0/, ..")."h~1I raise the height of the bit So thethkkll""" IIf Ihe remaining tongue Ilu, inth •• rroeve. (It helps to sneak up On this''lII, le,tinl( it on a piece ofthe scrap cut offfr..m the veneered panel. Raise the bit alilli. at 8time to get a good fit.)Nnw: ''>'hen the rabbets are cut on the

J>IUII'Is, make S~ the face you want to.ho\l on the outside of the ease is d<mm onll,.. router table.

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THI CASf FRAMI

Xext, work can bt_'gUl on th.· 1..'iI.'*. RatJlt:'Jthan makin~ it lid lint) a ba.......' t"'OIl<·"...,.h·pieces. tbe l4.'<'lm''Ilw h •.'I\- Is to mak.- th~ease as 01'" wut alld th.·" cut th~ titl ocr

So. I.<lmal", th, .'lk'<'. cut th.- rour 'kk", 10.ize. All (llur JlI,""'" ...,. ¥t" thick wid "1'1".1to a fin:11 width .,r:~8- 'l'II·lf)nK~irl{·~t ..\. tbetop and bottom 1'".....,,) .re cut 10 " rr.,~hlenj,>1hof I" ru.1 U.· ,11C1I'l.1~''SCHI a .... rulto a roul.'illcngth ..f II...,.,f 11(. :!

GROO\'-ES "'0", 1).\Nt.I",,~,StoXl. 1,'11"")\1"

are cut on the i~lrtt.·fam flf t::lrh l)it~'t'l4'hold the p"nol", 11.. trl.'k), '''1'\ IJIIC.-tlllll!the groove ...in l'Xllctl~·the "gilt 1)c~11il,n.The distanee Inlln the .<fK(· IIItho work­

piece to the (a:rthl'~' l..II{.· clf tht· gnK)~t·must be equal to the thick'..... IIf tl u­veneered panel, n·r,·,. 10 t·ij(. I elf tlli'groove is cut too clo.,,·10 lh" ...I~c. Ih,·panel will stick UJ1. Anti "UK-'C th.· v, n",''"'t i"$0 thin, it can't be >\andtod<1,.\\ n,)

A CASE FOR THE YUPPIES

16

..(~r \'CW'\I I've wanted to build a woodenbri 1<'M<l. hut one thing stood in the way: a""11"<1 Cortho hard ware. This problem has1..~'1lIOlvlod by the folks ...ho put out '!'heWoodworken;' Store catAlog - they nowIui,c • kit of the hardware (loch. hinges.W1da liner) ..s well :IS ~ leather ~ forbrlclca.'te5. see Sources, page 24,Note: All of the dimensions of this brief­

case are based on fitting it with the linerCromThe "'oodworkers' Store catalog. ThismeiIJ1S a ease that measures U y," by l5Y,'i,l8idc. (The liner is okay in quality. but it'snot a nice leather one. You could leave it out,and build the case any meyou want.)10make the case B>1llghlweightas possi­

ble, J made tbe frame out of Va"-thick stockand thepanels out of v." hardwood plywood.(Using hardwood plywood provides a light­weight panel that's also sturdy and stable.)There'. also another option for the panels,

rryou want 10 get a little fancier, the panelscan be <overed with veneer - which isn't asdillicult as it might sound, The new flexibleveneers are SO eai>J'to work wilh it almosttakes ali lhe fun out of it. Those veneerscemein sheets with a paper backing and canI be applied to a sub-base (birch plywoodworks well) ",ith eontae; cement.

VENEERED PANELS

if you want to use 1'.' hardwood plywood(",ithout ve_r) for the panels, begin bycutting them to a size of 121'. wide by IllY.long. !fyou want to apply a flexible veneer tothe panels, begin by cutting the 1',"plywoodsub-bases about 18" wide by 14"long. seeFig. 1. (These ove~ sub-base panel. aretrimmed 10 fit after the veneer is applied.)Note:The sub-base panels for the veneer

are cut so the grain runs in the l4'direction,sec Fig. 1. This is because veneer is nlw8,Y&applied cross-grain (perpendicular) to thesub-base grain.

After the sub-bases al'e cut 10 rou,gh size,abo rot four pieces of Gexible veneer 10 lhesame rough size. (The panels are veneeredon both sides.)

COi''TACI' CEMENT.10 mount the veneer,apply contact eement te the sub-bases andto the paper side or the veneer,'Vben the cement is dry to the touch, the

veneer can be applied. Support the veneerover the sub-base \11th several dowels, seeFig. I.Remove the dowel on one edge andpress down the veneer with a roller. Theneentinue to remove dowels and press the,'eneer down ~ lhe sub-ba..<:e.TRIM TO Slzt. Alter lhe panels are

wneered on both sides. trim them to IinIlIdimen..<i= of 121'. wide by 161'.lonl:.

•Briefcase

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JOINING THE CASE

After the panels are rabbeted, the four sidesof the case call bejoiIled. Here I u:-eelmiterjOints that are strengthened and deeeratedwith dovetail keys, (See the article startingon page 10.)

To join the ease with thb joint, begin bymitering one end of all four frame pieces.Then inorder to miter the opJlO"iteends wfinal length, slide the panel into tt,e groove"in one long side and one short side, see Fijl.5. Now mark the point.<where It..> rabbetedshoukler of the panel I'M- on the framepieces. see f'ig. 6. '!'hen miU'rth. end. of thepieces at these marks.Shop Note: When mitering II",,,,, end••

attach a fence to the miter gauge and clampon a stop block. AdjU$t the stop so the cut io.made right on the mark on the long pll-eee.Then miter bot" lung pieces at the NUll~setting. Move the stop block and miter th~short pieces to length.

ASSEMBLY. Afte,' all four piee es aremitered W length, the ease can be assem­bled. Apply glue to both mitered ends andthe grooves for the panels. Then slide thepanels in place and clamp lhe ease togetherwith band clamps.

DOVETAIL KEY JOINTS

When the glue is dry, the dovetail slots canbe cut on the comers ofthe case. Icut threeslots with a %" dovetail bit using the layoutshown in Figure 7. (Note: YOor 0/," dovetailbits can also be U$Od. but use the samespacing to the center of the bit as shown in~Iig.7.)

DOVE'l'AD. SLOTS.To CUt the slots. URethe jig shown on page 9 to hold the case onthe router table. Set the height of thedovetail bit to 0/." and position the jig 'h"from the center of the bit, ,... Fig. 8.(Note: By setting the bit '1'." high, il \\~IIproduce slots YI" deep as measured on theside of the case, see Fig. 7.)Now rout dovetail slots on all four cor­

ne rsofthe CMC. Then turn the case around(so the other side is against the jig) •• ndrout four more slots.The middle SlOI is routed off-center l<J.

ward the bottom of the <"-"C. This is be­cause when the box is cut apart to form thelid, there will be an y" kerf removed. Toallow for this kerf, the middle slot i. shifted\4>"lowardthe bottom of the ease - whichmeans it's centered 1%" from the bottom.see Fig. 7. This way, after the kerf is cut,the dO"elai! keys will be evenly spaced.

DOVETAU. KEYs. After all three slots arerouted on each comer. dovetail keys arccut W fil in the slots. (See the article onpage 10.) Glue the dovetail keys in theslots, trim them off. and sand them flushwith the sides of the case.ROUNDEIlCES. Finally, round-over the

mitered corners and all edges with a Y'round-over bit, see Fig. 9.

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WOODSMlTH

CUTOFF LID

:<;ow the cuts can be made to separate the lidfrom the base But before making !.hesecuts, fm;1 make IWO 'l"<hnped spacers, seeFig. 11, (Thes.cspacers ,u-e used to preventthe lid from collapsin~on !.heb.aseMthe finalcuts are made.)Thmake the spacers, eut rabbets em two

edges of a pieceof scrap (about 12"longby 2"wide), A(lju.st the size of these rabbets to1eA\'"a tongue equal to the width of !.heke,-fmade by the saw bL~dp.Then him off theedge ofthis piece and tulil inhalrto producetwo T-shaped Spac(>l'b •

OUT 0'-.' I.ID. Now bet up the AAWbyraising the blade high pnough to cut!.hrouW>the thickness of one side of theClI.'c,..ce Fig. 10. Then adjust the fence solh,' eut is made 1y,. from the renee.1\ll'tll otI Ihe lid. make a cut on one end

"f Ih,' e4!1<'. Then rotate the ease 180' and,n.,k. IIJIOthercut (Inthe opposite end ..'I,," wpe Ihe T·~h8ped~pacel'''in these

l "II cul~ArMlmake the final twocut." on the"'mammg .id~. 0«.'<1 Fig. L2.

MOUNT THl HINGESN,," the 1i,1und base are ready for all thehard Will"" Fil"l. moem hinges tojC)inthe lid.,,~I1_·. Th·,,>,In' two z- brass hingesn.,rt'!I<.1 into the ,odll'''' of the lid and bas".",.•FI~.1:1 I tilt lhemort~for!.hehingesClll th ..· rout('T t"abtl·.

HINGh MOMflHES. ~t"UJII a yo·~traighthil n,.1 .<'( .t 10• height equal to half thethll'kn. 'of lh,· knuckle ufthe hinge. Then.<-1 tit .. f.·"o<· 2" from the i>l6ide of the bitc",·, hK 11l.n"drnakcatlltatbothendsofII .. lid :m,1 thv ba-e, 1<00Fig. 15.

I{,·",'t th(· (elK'(,'::'() it's.J'" from the outsid»~.ftht, hJt (t,c. make a 2"' ..wide mortise), ~""Cn~I C. Then make another set Qf cuts and('I, :tn l.I·tlllhe waste between the euts.

'I10UI\'T ItlNGES, Mounting these hinges• .,ItHk u'ic!Q: 1had some trouble gettingIh<·hi nil"" lined up so the lid was perfectly.hj!ll,-d with the base (when it was closed.)

()Ilt· '\a~, to (10 it is to mount the centerO<'n'l\ in the leaf that attache. to tbe base.Th"11mount "locator pins' in the outsideI"" holes of the other leaf (that mounts totill' lidl. (Locator pins are described inU'"",IHlllilh No, 42. pagt'8,1\\'i!.h the locator pins mounted, hold the

lid in position over the base and press downso !.hepinsmark the location of the screws inlhe hinge mortise in the lid, Then mountthese screws. This should help alij!ll the lidand base, And continue by mounting the rest"fthe screws.

If the lid Is off a tittle from ulij!lling withthe base, fiddlo with the hinges to Il"t thealignment as close ..s, possible. Then clampthe case closed and plane the sides so the lidand base aliJ:n.

BRASS FEET. After the hinges aremounted. drill four hole> for the screws

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WOODSM1TH

used to mount the brass feet, see I"ljt. 1!3-LlDSI1PPQRT. N~xt,lhe lid supports are

mounted in.ide the ease. Drill pilot holesfor the supports as shown ill Fig. 17.Thenscrew the lid sUPI'OI'l.>'ill place,

LOCK AND HANDLE

The hardware ldtal",conuul1s two eombina­lion locks that are morused into lhe base.(While mortising in th,'lock., Inomo\'t'<) tIM?hinges, feet and supports Cromthe ether endof the case.)

~IORTISE,The mertises ror the locks an'y..0 wide by 2"10119:and .n' 1"e"t,'tI MI"Crumthe top edge oftheba.-e, R'< f'R. IK Tocutthe mortises. mark their location' 8nd drillout the waste with a ~"4"Ferstner bit. seeFig. 19. (Since the mortl_ go all th...waythrough the sides , <lampon a backin)!l.i"" ..to prevent chip-out.) Then use a ""if",1 toP""" the ~ide,of the mortise square, "''(.Fig. 20.Now, slide the lock into the mortise and

mark the location of the four holes in th,'corners. Then drill V," holes through theease sides for the brass posts, see }'-"ig. 21.(These brass posts are pins that are split atthe end and work something like couerpins.)MOUNT CATCH. Before mounting the

lock, the catch must be positioned. Re­mount the hinges and place the lock in themortise (with the posts in place, but notspread) and close the lid,Then insert the catch into the lock, and

mark the location of the two brass poststhat hold lhe catch to the lid, see rig, 22,Remove the catch and drill II.' holes for thebrass posts.

llANDLE.There's onemere set orholes todrill [or the handle. Locate the bra ssswivel plates on (he handle so they'recentered on the width and height of theease twith the lid closed), see Cross Secdcnin Fig. 2·1.Then drill pilot holes ror thescrews u...>d to mount the handle,."INISH Tin: CAS." Before the final

mounting of all this hardware, sand theease and al)ply the finish. (I used Suther­land Welles Polymerized Tung Oil, seeSources, page 24,) Let the finish dry thor·oughly before mounting the liner,

INSTALLHAROWA'RE,\Vhcn the finish isdry, remount the hinges. the brass feet. thelid support, and the handle to the case.Then secure the locks and catches with thebrass POSts.To do this, insert the posts and use •

screwdriver to spread the split end•. Thenuse a C"'L~mpto tighten the ends down,see Fig. 2!l, (Fold up a pieee of paper toweland place it on the head or the post so itlI_n't Rt't scratched by tIM? C..,lamp,)

INSTALLUN£R. The last stepis to installthe Uner, ~·Q."ten the line,.', panels insidethe case with double·sided carpet tape, seeFig. 24. Then tack the end OI\j)Sto the sidesor the case with small brass brads.

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WOODSM111i20

•STEll STACK SETS

\\·,·I,-I .. II",th hi!lh-.pood steel and carbide­"1'1"'" ."""k .. u<, evalu.1ting two differentt),I>11within l'tlch "1Wj(OlJ'

:-:01<'. 1'""", quoted in this article arc."~ 1••1n·lail. M,,"t.d,tdo sets go on salefn:~fnlim,' tel time, S(_>(' SouJ"eeS, page 24.

II •.\T Sf ..xt, ~tm!Vial .teel stack setslin' t.h"II'l••t""ftt"n.h·e. The Sears 8" set (9liT 3'~175)j. t.ypical n(thi~ type, we DetailI 11'8priced 3\ S:~1.99in the Sears 1985.'II""; ('"W(·t Md Hand Thol Catalog.Th.· cUIl~'" on this Sears set have a

'1"IJ,l(> tooth eenfignration that consists offi,,· cutting teeth, a deep gullet. then a.-. kt-r tooth to remove lb. sawdust,

Th,· cuulng teeth arc ground and ,..t inJ(rrmp.<of five. That is. 1\". teeth are\),·",Iec! and set (bent) in onc direction,Thi» group is followed by an unset rakerto<.11Iwith a nat top. Then the next group"f fiv~ cutting teeth is beveled nn<lset inthe op~it.e direction.

Thc purpose ofalternating the bevel and..,t of groups of t.eelh is to provide clear­Mt" belween the sides oC the groove beingCUl and the blade plate. There's a negative.«eet. though. Because the poinL.. of thecutting teeth extend beyond the path onhepoints ofth. raker teeth. the conler oCthegroove bottom i.nol sharp and squnre, seeo"Laiis IAand lB.The Sears 8" Oat stack sel lell. a groove

bottom that was unacceptable at the cor­Der$. And it tended to tcar the grain on theedges. The problem ~th the edges c'Ouldbe corrected with sharpening. But. theproblem with the corners of the bottom is adesign Oa\\' - it could be Je5!;eJled. but. noteliminated. \Vhile this sel might be attrac-

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able Iu cUI through t.ho ,·,.1 of. b"",,1 tnInakl"a notch rl'r box jeint ....,

t:VAI.UAl'l"(;CIUAI.ITY In "v3Iu"lilll: Ih,'qualit~·of a dildo bllttlc"I"·rfonnant't· 10 "no[t.h,,,,,· applieation», tht·I!TOO'~be,lwm ..equally (or morv) imr.II~1II\1than th,' t""edge.'. So I""kat the buttam nr>t. It~houldbe Oat and .qw.r,· \\,tlt th,' >id,,,,. Th"11lookat the~" lh"y should be .harp \\lth nosplintering. (Mak,· thi. ,,·,t aero:.., Ih,I,rrain "'here It'unnf:,! hsntf.toIllikt'ly to oeeurEven the lower quality bl1d,.. 1,·.,·" ,tw,.edge. when PloughinR with th. grain.l

A VARIETYOF DADO BlAD(S

"!'here are two basic t)'J.M.·~01dtul(~l"'I:"h."S­the stack set IIlIdthe wljw.t.lbl.·elMo bb«le.Both type., pe.fonn the ""'1(' thl'C( 1'11'1Job.That is, to cut. gl'OO"C lb,' d...\,J blu,I,·mIL.tpare the sides ImlOOthand k-,,,',' th.· l'<1~...'"clean. It mu.:,t.JlblIlC the bull....., Oat 8l~1square to the groove "d"", And. il h"" t.(1remove lbe W8.,te from lhl-groo"" It""I(.'Ve saw no purpose in Irying to teI<t ."'1")'

dado blade on the market - thCl'l'" 100much overlap \\;thin the bm;ir t)ope;<. So weselected some re'.dily availabl. models. that\\'c're already familiar with in our..hop. \\'echecked out the .tack seto tir&.

STACK DADO SETS

A $tack dado gets its name becaUJ;C a ,;et.eon.';"<t6ofsl, "rscvcn individual pieces that.are stacked togcthcron the sa\\' arbor. Actl..

DADO BLADESI'm nola KkcpticalPCI'S<ln. Since 1 assume atool ",II t\q the job it's Intended to do. I'm1"1'rit<cd when it doesn't. Before blamingU,,· "",I I ask myself t'WIl questions: Am I'L<inl( it properly? Am Iexpecting toomuchrr..m It! For the past four month. ('\'(' been.IL<;,kingthese questions over and over about,bIdo blades.~I:;eoneern \\~th the performance of

,bIdo blades beglu. with a letter from a,ubocriber. He expressed hi. di&....arisfac­lion with the Sears It'rWOlh ruijustable,Iado blade. He had purcha.'l(>(1the dadoblade and found that the bottoms oCthegrooves it all ",·(U'('.n'l square with the.ut-.;.Sears happily exchanged the dadoblade with another. assuming the fin;tblade might be faulty. The sccollli dadoblade produced the same angled groovebottmns.Before jumping to conclusions. we bought

• similar dado blade from Sears. It had thesame problem. SO I had to conclude there"11$a b3.<ieproblem with these blades.About this same time we were buJldinp:

the box joint project.> for !:,sue.J2. Anotherproblem with dado blades cropped up. Thebottoms of the notches for the box jointswere unacceptable when cut by most of thedado blades we have in the shop. We.mtch­ed to the router table to make the small boxjoints. But this wasn't an alternative for the\argel- join!:>011 the cabinet because of theamoum of waste thaL had to be removed inone pass, So we used • dano blane andcleaned up the groove bottoms by hand.

That was the last straw, Instead of,"""",bing [or more alternatives for mAkinggrooves. I asked myself what I reall)' ex­pected of a dado blade. Then I wanted toknow why tbe dado blade Oi() ofien failed tomeet my expeetatiens,

HOW '10 JUDGE A DADO BLADE

Judging a ne"" dado blade seems easyelll)Ugh.Just take it out ofthc box and makea fCIt cuts aoross the grain (ndado) and \\iththe)!nlin (agroove) ina=pofwood. Then.may"," try it on a piece of plywood. If it•phnte"". it'. 00 goOri. If the cut 1001<.<smoot.h. the dado blade is perfonning prop­.l'll\ \VoU.there's more to it than t.hat.

'TKK DAllQ BLADE'S JOB. The dado blade,lIould cut a wide kerf with dean edges, aOat boUom, and the corners where thebottom mt"ta the .ides should be sharpand "<1u~. It .hould abo make II partialcut on t.he edge of 3 boa.•'d to make a rabbetor tonl(Ue. It should be able to make mult.i­pie pas._ 8Cl't1!1S the Volin on the end of aboard to form a tenon. And. it should be

•Tools of the Trade

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ally. all of these components 5t into twocategories - a pair of outside eutters ant! acollection ofchippers,TH£ CU1"I'£RS.The euuers are the preci­

sion components of the stack dado set.Their job is to define the edges and makethe straight, v••iical side. on the grooves •Th~y look like small circular saw blades.

Tll& CIJIPP€R$. The chippers are two­toothed blades that fil between the cut­t"'~.The chippers control the width of theIll'(IOVe,remove lbe waste, and plane thebo,tto,m of the groove t1at.

\I'I>'t stack sets come with five chippers;rour l\J't' v." thick and one is v.." thick. The'\ldlh "rth~ groove being-cut is controlledby til<' number of chippers added to the"lack.~in~ eachof the cutterscuts a YI!"j!T'1"".~,tht· .t"ok oct can cut grooves from,-to' ,•• \\'lrl~in '1(1" increments.

21WOODSMlTIi

So. which set is best'! The Oldham set is •l(OO<I value. II 0061.5con:;iderably 1_ thanthe premium set", yet perform. all functionsadequately cxrept for making box joinU;.BUIfor all'around use, it's hard to beat the

Freud or Delta. Both peliorm \'et)'wellout·of·th.. bo~. Their plic'CSare high - bUIbothare often hea\;ly di!<oounled.They shouldperform excellently for a Ufetime.

tracts from the smoothness of the bottom.On th•• c premium blade~ there's just Ascore line on the outer ed~e er each groove.With a correctly sharpened set. this re­sults ina very nat bottom.The Freud and Dell' sets wit h the sin­

gle-angle grind produce ,-er y cleangroo, -es, Both fulfill all dado application s,including rabbets. tenons, and box join",.Since they're priced about the same. it'shard to give the nod to one 0" the other.

OBSERVATIONS

errect Ih,' quality oCdadoes. groove s, rab­bets, .ut( tenous, it would rt'SUll in less­than 'Ik'n,"'t bo" joints.The );"""" blade's performance is sort of

a 1(0<.1now•. bad nt'wsstory. Itmakes very~\Uln.·gr.H"'l·bouems, but tears the woodfiben- ""dly Oil cross-grain cuts. Both ofthese ImIt. re..ult from inoolTCCt.harpen·inlt. Th" mkcr (t..ll>are exactly the .. melen~>ttt," Ih(' ""'vel leeth. If the blade"were ,;harpened ".jth the rakers honedslightly lo"('r than the be"el teeth. th.tearout w,.old .-IQJl.PRE'''l'! CARIltD£.TlPPIill St.'Ts. One

slep up art the industriaJ-quality dado",t,. "'''' J)H2i1 .1. The 6· Fl'('ud (D53ooSI41;.~1and th~ 6" Delta (35·550'$165.00)are repl"'l'~nl"ljve of this category.On both sets the CUllers are unique -

they hav~ rightllnd left .ides. The teeth onone ruth·r.I'\: all ground at one an)tle andthe t<'t?thon th~ olh ..r cutt"r are ground 3tthe Ol'posit" angle.Thl' point of ca"h It>!ithis actually .eor­

ing the ,,000, '1'(' Detalhi..:.!.Aand 4B. Thesrore line '" ju.t a hair deeper than lhe full"epttt o( the rak('r tooth and the chipp"n..Thu.line kw"" the .'(!geof the groo"e cleanby pre"t'nting lhe wood fibers from tearingout J)a"tth(' line a, they're removed by lheraker:, and lhe .ttipper-,;.Thi. _ring action i. charactelistic of

tutU>ts with a1Lernate bevel leeth. too.BUl, the inner $Coremark they le""e de·

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wood,The second problem becomes apparent

when the two cutters are used withoutchippers to CUl a Il." groove. Becausethere's. space between the euuers.n smallsliver of wood is left [n the bottom o( thegroove.see Detail2A. Thl$ sliver has to beremoved either with a chise1 or by makinganother flll$.Sharpening the hoUow'g1'Ouudstack SCI

does tittle to improve its performance. Itsteeth oontinue to fill, ." burning .-email.. aproblem. And the sliver left in the groovebottom bec-omes,,;dcr each lime the dadoset is sharpened.Although hollow.grinding improves the

pel-formance of regular saw blades (andgives them a higher quality image). in thecase o( darlo sets hollow·grinding is aClual·Iy • detriment.

CARBIDE·TlPPED STACKsnsThe price jump from ~teel to carbid.,..tipped<t.'lCkdado scts is a big one. But. ,;0 i.theimprovement in performance.

CONVENTIONAl. CARI)I.o&.TlPPED SETS.The 6' Oldham (f,oo.CCD.$119.00) and theS" Sear. (9 HT 3264~.99) are typicalrepre..<entative.. of t'Onventional carbide·lipped .tack ""I~. The rotte'''' on both set.are ';milar to carbide-tipped combinationblad~$,>1lC Detail ~. Th. tutters on theOldham set have 11>teeth: there are 22 011the Sears culters. The teeth on both h"'e

• tive because it's so inexpensive, it's really an alternate top bevel, The Sears has aonly suitable (or framing and construction, raker tooth between the beveled teeth: thenot Cor <abinel-qualily joinery. Oldham does not.

HOLI,.OW-GROUNUSTt;EJ. sers, Another The teeth on both sets have a steep hookSears dado, the tr 'Smooth-cut" (9 HT angle likea rip blade. This Sleep hook angle3:!53~4.99J. I, rel'""vnt3liY, u( hollow- helps pull th,' workplct~into the blade and~ound dado,'" ,ee netail 2. Hollow- down apinsl the sa" table. lt ·Ceed.­ground .«'('1 >('1.- gel their IUI_ lx_use smoothly. And. burning isn't a problemthe cutter. plate rim i. ground !\O il'. with either of'thesc dado set a.thin",'r w"sru the plat.· '~'Il\('r. Thl, Nliof Both the Oldham and the Scars performallow,. the teeth ttl be !!Tuuml",thout any better than the steel sets, but there is aSCl and (in theory) leav ... 1,.,."...",· be- marked ditTerencebetween them. The Okl­tWeen the plate and lhe ,I~. oflhe J.,'l'U'Jve, ham.hea..,.thewondfibe.",cleanlywithoutThe CUll.."" on a hollow ground. tl«'k <<-I learingthe edges on cross-grain cuts, BUI. Aftl!l' pUlting the stack .Iano sets through

cut smoother ann cleaner than the cutters because there's no raker tooth to clean UI> their pares. [ made several observationson a fiat set, And. becau .. ' Ihe h",th a..... between the bevel leeth. a tiny ridge "' left that would iniluenee my buying decisions.unset and have a fiatt"I). the <OrI ... r ....h,·rc in the bottom n.rar each comer. see Details, srset, V8.CARBIDE. The .tccl.tack setsthe groove side and bouemmeet '" "4uart' 3'\ and 3B. While this tiny ,;dge doesn't don't perform as well as the carbide-tippedand sharp. BUI, while this r----------":---.."-:=,.,--.....,===---.....,,,.-:,,,,---, sets. The problem isn't •set euts smoolhel" than the l'::TH 2 :: 3~1t 4= matter or ~harpn(!~ (~teelnat set. it has two distinct can be made sharper thanproblems. CU1'TER 8IAI)£ carbide - it just doesn'tThe first problem is it TOOI'MDESIGN hold an edge as long).

burns badly, especially let The problem seems 10 hewhen ploughing with the ,II design. The steel btadesaregrain in dense woods [ike economy tools, They'vecherry and maple. This '/.....WIDE~OO\l£ I I 1,I U 1 n been designed with the~7~~".:"~ryrru;s;::~ c;'.:'.;t. .~ Y' _;; 'A . _~ ~!~~[:!~~'not the endThe gullets between the SUARPeNING. As (or theteeth fillwith sawdust, The ¥....-WtDE,~OOVE t1----=.Q~_~n_n ~carbide-upped sets, properaccumulated sawdust in- v -_. --_ .. 18 -- ••••• sharpcning is the keytc thecreases fric-tion, which me ~... '1 2'8 _ set's performance. Out.-,i.)f•makes the blade bum the lhe box performance prob-

lem. all could be traced back to e"""Il'SSfactory.harpening.Careful sharpening mean!'. more than

getting the carbide tips sharp. It meansgelting the tip, uniform and making surethe relationship of the Leeth is correct.The correct relauonship mean. the rak­

er teeth and the chipper teeth are exactlyth. ""m.length. Th. be"el teeth should bejUl!! a hair longer. A <'lU"bide·tippcd.tackdado sharpened to thc>respecifications willperform allof it., jobs well.SIZE.One of the other oonsidcraUon. in

buying a dado :>et i" size. Dado >eLS aregenerall~' available in 6", 7 • and 8" diame·tOTh. t.bigger better? I don·llhinktio.Tobegin "~th, the 6"dado blade "ill cut a

H:·deep g1'OOveon the Sc<u" table ,ow.Thi;; l, mol'(' than adequate for any projeclimaginable.

Considering that and the fart Ihnlthe6"dado ~lS cost les.~.\,'e see no sense inbuying an If dado set.

CONCLUSIONS

WOODS~lITH22

'n~,,\<-u,Ed!(e adjustable dado is the only11I<.1tI tl"""" that perfonlle'" properly lighto<,t (If the blll(.Thl.<isbe<'au,*,the ,nanuf.1CoIU1'<'r undel'"tands sharpening geomelr),(Th,·y ('\"en include detailed sharpening in­u-uctiUIl8,,;th the blade,)Based on (lllJ' e,,-perienoo, I prefer the

A('II,Edge of ali the adjustable dado bl.d ....Hut, any of the other blades will perform uswdllll\er _tom .ttarpenillg.Caution: \Ve f.. l the Freud 8" AD800 is

lIot safe for use on table saws. This isbc'C3lL"C the hub is too thick to allow the nutto be runy threaded on the arbor shalt,

ADoIUS1'AOt..EVS,S1'ACKSE'C"'hen mak·ing the thoioo between aclju$table dadoesand c:urbide-tippel! .tack sets, I prefer.tack sets. They cllt smoother edges lhanadjustable sets, And by placing cardboardspaoerslX'lween the chippers, it's not hardto fine·tune the groOve \\idth.

I'm willing to pay more for a tool tMtproduces the quality 1 expect - and ",illprobably outlasl me.

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•flallen.a coneave bottom. it's almost impos­sible to keep the groove depth uniform onboth sides,

DOUBLE-CONCAVE, Tb~ Sears -Ex·calibur" lelt a double·conca,·€!bouom pro­file. This is because both of the blades aresharpened like saw blades, so side-by-sideares are lell behind,

\\'e fclt the double-coneave bottom Wasthe most difficlllt prom. to Ilatten.

PROPER SH~RPlNING

AOJU5TAall DADOBLADES

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of the gl'OOvecan\ be improved.The groove bottom cut by an .dju.<tabl"

A" uht-rnall\. 1'1th,' Mack,.,t is the n<ljust. dado j_, gen(-r:tlly ""'ooth. Ane! the mon'Ihlt 1!;Wlololwll It loa> a lot of a appeal teeth it has, the smoother the bottom. Thishe'<1lI It.. -muk tool, rather than a is b<'C81lS<' each toolh cleans up th~ ('<lu''''of<Olil-dion ..( "'ml)Onen~, It can IX' adju.ted the path cut by tit" adjacent teeth.t" nit ,I(1't1O\t" lrom 'I, "ide to C)',,' wide This smooth groove bottom k'a\t·, the" til !"fin"e adjustments within this range. impressionthat tho! dadois perfonnilljl bet­.\nd tht....•"'lju.'<tmllntscall be made without ter than it "':tUy ;_, What', "'"010 roo",n'n." jill: the dado blade from the saw; important is the bottom profil.,

11<...•• the adjustable dado blade measure THEIOnoM PROFILf"1'10 tbese claims? 'Vehave live models and'Olr l"oclu,';()n L' "yell, hUI • , .- The "but-ill The bottom l'roiile <U1hy om:ltlju tnbh'dado To pruperly sharpen an adju,;table dado. asth;lt it doe"ll\ produce a Ji.rsst-rate groove. blade is ,..0-;,1)' Oal. l'.'WII1y, Il'~ 1<1'111,..1.much (or more) auention must be paid to

MODELSTESTED. OM of the fi\'e models concave,or 0011'<". The,,", prom ... "..wt j!('()me~' as to edge sharpness,we have is the dado blade ""uu, "".,.., FACTORYSUARJ'ENING.that generated this a''liele ~, Poor factory sharpening- the IS-tooth Sears (!i HT '~4\«'> was the cause of all the:1263c$34.99).Three olhe r:; MIlAI>E problems we experiencedare the Delta l2-tooth "Mi· OOUNOT woa." w ith adj u$lable dado

lACH TOOlMFClUOWSere-Set" (34·959/$3G.10), n'OWNI'AlH blades. The quality of thethe Acu-Edgt>8-toolh Jlhl_ '. G.oovE cut is almest totally depen-CIlI" ($49,951, and the S" AU''(1"0l10III<010 dent on the attention theFreud 2~-tooth (AD800 IOUAlW<G'H'IOMClHn. blade get. on the sharpen-$62.90), The firth dado ing machine. To prove thisblnd(· is one we just 1(01in: -, tomyself. I had our poorestthe Sears "Excalibur" (9 performer - the 16-toothHT321081$99,991, NOfE,,nmOf« ::;ear. blade - custom

WHAT DO THEY LOOK lOOlHONIACH_ -harpened.UK~'?All of these adjust- ~':="'~ CUSTOM SHARPENING.able or "wobble" dado 'Y,OROOVE • GROOv{ \\'hl'n I took the Scars 16-blades IO(lklike ~ carbide- tooth adjust.ble dado bladetipped S3V.· blade that's '!~~'Z~':'-' l~' uur local sbarpeningmounted to a thick hub. L __J L _:_.:..:.__:_ .J $hnl', I explained that it,,'!utt make. them unique b that the hub !h,m thl' )..~~.. -try oflh" r{;.I" hl"de .... 1hy ""' 1t'll\'UW ,.n Imilled bouom, Then Ican be turned .0 the blade tilt. at an angle the way it'- l<hal'»('llL.I, u.-k.. III,1' ,h"'1 ..',wr tOI'l'gnnd the blade 80to the arbor. Adju.LiIlI( this nn!!le ,-arie" AS(.Lf;U 1101'0'1_ n,~ s"ur.; I,;'l<.,th ,I w""I<II,,,,\'., II antbottom at ""•. (1 couldthe v.idlh of the groove cut. adju,;t.'hl" blad(, 1'".lu(' ..",,,,, anl(l<'1 hot .I"I! "lIh th~ eemer "dge that would be

HOW DO TH £.V \\10RK1 You can go torn. 'rhl~ IJ' the "'~lalll)( ('4trt."1",...~f.."Iilu.lln~ I~·I\nt nam)\\.\'r "-Ullul~.)through a lot of mental gymnastics t"ying - th~ t.<.,th "" 1111.' ""I" or th,· "lad" an> An. r .harpt'nillll, the Sean; dado bladeto figure out how a wobble dado blade ground lon~er l""n II", ol'I.""t. t«'11>,'UI cut "n..t bottomed jrt'OOveat 'Yo".The CO~tworks . But the secret is that it doesn't ling the utllt'r side urthtO )!1'tJO\ e, or re:-har]Jt:'nlD{!was $22.00.realty wobble, CONCAVERO'FIU\l,Th.·lkol",anoi I ,,'uti THE fiNAl CHOICE

'Vhat happen, i$ thi~: The blade i~ Hdjustabl., dado It"''',,,, 1",,,., " ""M·,,,.mounted between two lUll:led disk$ that j(I'oo,'c bouom, ..... F'Il, ~arc paI'l of the hub, The&' disk;, lUt the The conca'~ -lu'I" l'\",,,lIs (rum _••1"",,blnde 80 each tooth is sJufted out from the blutllt ~h"'1~'nl,.llik,' a j!8" bInd,. Th,.t to,\'ertical axis. Although it appem,; to \\'ob- th€>dh-tanc(: fnlm tht· I,.·,·ntt·rteJ tIn' lil't' I~1>1",in reality each tooth stays B $peclfic the ...me on 81tl<'cth, 'Vb"II" bl.d.· ,"IIIdi:,t.nnce OUl from the axis a.,_, it I",()t.at.e~ ('(IUlll-Jellgth tecth i..IIn~'h'(ltn Ilr,,,,lut.,(, ,I

arQund the arbor. >leurill, I. \\,id.,' cut, the gr'OO' ~ ho,U"", ",.11MH' "Note: The Sear.!"Excalibur" is unique in cur"e that'. the same IU,\,'" lhe lila".'

that it has two 2-1-toolh blades, The blades PLAT HOTl'OM The ,\<11-ErI~.·.t ..d ..are mounted on a ~inglc hub at opposite blade mak,,~" nat·bottom,,1 j!1'OO\-~ lI' th,angle, to thearboJ·. iJ, "fft-<:t, it's two dado oy.' $('lling, """ Fig, a. A t1atl...ttolU<un bo_,bl:odcsl'\Inning on the same arbor, produced at a "P"'ifi, ....dlll If th., <1:<d..

QU~llTYOF THECUT blade is 'P'dallu ~und_ !.lut!hc, bouom",11 be Ilat nnl)' at that ",'t!l1lg TIn. ISbe<'ausethe'p<.'Cjalgrindin~ 1<'8.'''' the( ....th10n!(eSlon the teeth in thp out~r palh,

CONVEXBOTTOM "'hon tht ..h'll·gdg.·clado blade i.adju.ted to mok.· a naml\\"'rgroov~,aeon"ex (ridged) bottom .o,'\Ilt._.The eonvex bottom is le~ ObJt->('"lit)n.ablc

than the conca,'~ botttlnl. It', easy tu Oat­ten \\;Ih a chisel. Basically, what y~u'r.doing i.planing duwn Ute center ridge tolhe depth at the e<>mers, 'Vhen trying to

NQm"tt~r h<Jw it wurK>-, the quality tlf theeul is still the ptimary concern. The sidewall. of a groove cut by an a<ljustable dadol,lmll' ;O'\~\·t·rtlC'.t1. I)Ul lhl' ed~ aren't a.\;.d~an .. those <-utby " .wok set. This is 8I"(",-ullof ~ach tooth havmg ita own path.

g""h tim" lh~ d;IClobblde re,·"I.es, theOUI<!nno,ttooth 011each !<ideis the tlnly one<!Uttin!(th"L~lgeufthe grtJ().". So. nomatterhowmllnyteeth the daoo blade II"", the edgt·

I'Rom .• 'h wrru OIL BUI Bob admittedlh1t the re L. a JI'""ibilit> of pcn"trati~ells tiOakln): thrtlUgh 1l thin veneer antIattackl"!: the adhesive, And \\'ateo Oil ""0'14' nf tho \\'OJ~\since it penetrates ~ fardewn al,,1 eontain ,l hi""h percentage ofw)"t'nl

1',.\1''''" ·IJACK}::» v t:.NJ-;.t;H.One solution isto U:-:.t R '''',)I'r hackt·(1Ilexible veneer sincethl' ,loaf)o')" IJr,.vlttt·.. somev vhat (If a barrierbetween the "m.h and the adhesive, (Bob~lur)!"ill'l"It.rl1(l'!'\ t-t'\'t'raJ tlexihle veneers:Bob )I"r, ..'"n\\'uo.l"urking ~upplie:-, I J:!:lBanI'tO" n 11",,,1. LouL-ville. KY 40'21101;;"J2 I;;';' 2S.11j.)\\ebb .L....n'C<>mrnl'tlll,anoth"r 1)'Pt' u(

veneer It\!.,.,.", that u...e;. a pressure­"""" 11'< ad~\ e, -I I"dn\ ""Y it', totally'"'mu .... 10 anything: he says. 'but it',;I"""'t •rou. II \( Kt I)\ • "l:•.R \\p also tallu.:d to

Glenn I~.·h.·rty al Albert Constantine ands.:Ul. InC', Hr- foUt:Jtt·..;t(-d a nell' productC:l1)\,(1 S:lnllJ), ..t It consists of veneerbacked With .lllIy,·r "f,'""l'r, then a lay"roffoil. and lillllll." alloth"r 111;I"rof paper. Thefoil uets at' a barJ1t'" tv the fini ..-h.Thv ollly di.'"""·anta~. "e,;eo ",ith San·

PI)' ..' i.~thut tht' '" ()lKI ta~·...r i~\:(ll",)'. \"1.'1")'thin. You han' tu II.· careful >0 "oU don't::-afI() thrlluch 1t •

S;onrl) I ... va.,.h't· IIInine .,Jeci ....andt"" '17.c~ I:!I .910 , .~. ,!)Ii"') (rom Albert(·o."tantme and :<On. Inc .• 21.;0 Ea;.u:h~,·ter Road, ll,,,,,,.:\\ 11)161.NJI).Z!:l-,.,...".

OIJ"t'ERE" GLt ..... o\noth('l' ;.(llution ""to u>t' a J:lu., oth~r than mnta ...t cement.Yello" I!:llIe (a1'I'Mtlc ,...,.in) I"el'bt< oilfim.hcs belter Ihan ""ntact remont. Oel­K." lI'lI. will" (Irk on a ,mall project whentht \ ,·lu,,'4.'r «."an lx.' t·Ji....ll~clamJ*<I, but i:m'­practlraJ fl)l" lar).!\' ht·,,'l \,'ork \\;thout 3\"cn.'t'r 1'1'\ '" ,lA....l.nl'(. lilt HNIIi" Th. type or

\"{"n.'t'r IIr gltl" U (10(1i!\ only half the ~tor)·..Ju"'t R" 11ItIM)rtUJ1t .... ho\\' the finish i~"",,",,1. Th rc'~,.wmptatiun to continual·I) '!.:llI c I"~" •••11.. add to th" ,h,,,,n. ButIh all \\S th, •.,I,,'nts to ""netrote th.,\lent :T &l'MI attack tht.· adhe;:;.i,,·e.It b< t t.. let the adhe,i, ...CUI'('(or at

I, I' hOIl... b< fore appl);ng the finish.'I1t<>nPUI on a couple li~ht ,...a1ing <O:d, ~r

and let them dry llaorougltly (a coupleda) before.pp!)i:...addltJOnalcoat.>.One oth.r CIlution: I( you're lini.-hinjt

'ellftr ..,th lacqu"r (including Deft Clear\\'aod ~ lO",h,. don\ I'UIon. h<-a,,)' coal ofh,l(hJ) ·thm" ..d Inl.''1ul'r ,ina: '""'" contact""ml·nl. d..... I..,· in IAcqu.. r ~r. Seal".. ith a V'·I')· lil(hl ",.at (If ~qcqu~rsanding""aiel' "I' th(' III....u('r it';(>lf.1"en when it'sdl'Y. apIII)' light tnl) ,"HI,.

23\\o'()OO~M'TH

U~('(In !o'hort )11('('4' f to ) lei limit the prob­lems ir tht'J»itO('(' ill bowed 01" twisted.TI' rut the ,"Iuyo, ol..rt by settiOj1 the

dL,tan.·,o 1,..1w'~'n th.· f"n"" :ond the bladeto '~lual th,' Ih"'.n,' w,dth of the inla): Inm,} etl. •• I !let It to cut a ;'&"-\nde strip.Then t the bl",!.- h"l~htto about 'hr.

:0;0" make a I...... and then mp the pi"".around ... the ( J>posIt.> (• ..., i,agoin." thp(,~a.xI makeanoth~r pa<s. >«Sl<~P1.Rl""'t the "" .. 110 the lhiekne....< cut is

taJuonon th,·ouliide ()ef\) ,ide ,.(theblade.",e !'tC}.2 The Ilritkne-- ,bould be a littlemoJ'C than the thick"" ..., or the veIl""ryuu·n· uclng 110It can be sanded down flu,haft~1'It'.gI".", m."'1<''' th.· I!eC<Ind <'lit •• made. the thin~lnl)S lall (,n thl' "8sl(,fO ~i(le "'here the)ran\ kirk l\lIek. And th~ .maU .Iot in Ih<woodell in'~rt P"",·(·nt.<the .ltip,; f)'om.lipping d"wlI ""In" Ih~ .IIW.

OIL ON VENEER?\\'. re(t!nlly ",,,,·I\·,,IIIl'll1l from a .ub>rcribt·rin .0000'1:)n.Ohio \\ M \,1l....plannillg to vCflC\--'rapn.j<d and tint,h It ,nth \\atoo Danish Oil.But h,' .....< """,.""", thHt th" oil nnghty ft4:'n the C'Ontact ~m-nt lim Jill the '·clll"(';r.!'lJl(e"C\\eft Jan" ~~l~'eneer ona

coupl,' pro)l'ds 10 th ' '" ..... I ",..JCaI Bob\\,bh. ""."....or Rob " \\, JWooidna:Supp1ies. if he h:taI 11<=.. (..n.o I.rob!< fIlS\lith oillinbhes on ,",nee.

..\\ on):. ~'{ta C'OfDI,!;t.1ntor t\\O t:\t.-r">

"""pie month; about '''IX'''''' hllill;! as •~u1t or fln••h: llob .... 01 ·U,u;.lIy th,"""'I,lainl Ian m11l(l<klltal",th ~•."""j(t'''- If u..n· ".". 1018o( problem...... I\\ n'llrln'\ 1)l'1n 'lll 1Ilt'68.-

2 THICKNESS.,:r \\.- I

\_ •.r'" ,""'7 I

CUTTING

11-.- "If((1

CUTnNGWIDtH

C~ITt~(. rH. ,TR.P" On..., th e in.....,rt 15inpl3«,lhe .nlaYl can be cut on tbe edge ufUp'''·'' IIf II( '.'1' with a tine-tooth"" blade. I

over the guide >11;1".AI; the planing pro­gI'I'''''{''. d. n<>1 plAll\' the bl.ripol. They willst0l' Ihll phm.·whc·nth~workpiece is planeddown to th.ir thlcknlljl••

CUllING INLAYSTRIPSThe pl'u.:.:dul'\' I u..... formaking thin (~'.thick b)' V.·" ..Ie) Inlay otoipo; i., ,-imilar tothe metfuwls "t'" C prt"\;ou.·.I~·~ho""'ll(orcutting .mall .trips. aut there ;. 0"" dill'e".onee - t~ inla) 'trip" are ,; T'JI narro"and thin. They're the kind of piereHhat MJIdown Into tOO &lot III the >II"", in.,ert plale.And )00 ha,~to dit:' tluwctt the """UuotWId .. tOO "",. to ftnd the lIInJ'S.

., .... Hl "I..AII: .toe v.--a) to _...())\·e theprob)"m 10 make • "ood.n Ill!ert",th a<maU bind 01.1 So 1\,.. ",. 1.Ih ;\0. a.'i,pagt"2:i for JOt.n l'l(lll1lllilWJL)

Cut the """'11 (I. """"" and damp ,I IIllolh..· I'\.'\"CSA III tt"." tahl(·~" nU'nral~ th,bladc toctll,ulc.1 u~wloI< u- the billd••

lHINWOODAll of the proj('cl,. in Iht, i~_ use thin stock- ~". ¥." and even V.thick. Although ~:.thick stock h ."metim;·, available at hard·wood lumber ya,,". anything thinner thanthat i.<difficult to flnd 'otTthe shelf,"Th~""Iution i.III "IR"e it down yourself.

Of ('OU""', I( you have a thickne ess planer.that'" an t.~H••")· la.-ck. 'f'heo alternative is toresaw the .tock to .. thickness that's I!.z' toV,.0\·"1'th., final thickness, Then use a handplalll' to ,"" ...th It the re!!t of the ""A):The probk-m Ifind" hen <loin!!:this is th,·

ha.ss le or ronstanll~ checlcing the thicknei--or the pi«..' .. Iillc al I • ,came time making,ure It',[(".Han eve ~ aIIlhe WA)_ the I l-a:).

On!iJIWI pl''<'I.'8.I', "orth makinj1a simp ...jig to guld. th, IIL,r,eto the proper th",k·Ill·...s. Jll"it rota pi£"Ce of plywood as a bar-eand I,lar~ the rvsawn workpiece on thl'plywood.·f11t..·n rip two l~"",\ide strips toth.· finalthiclo,c ..., ycu want (or the werk­piece. Thek lhcS('I,,,,.tril'" beside the WOI'k,piece C!<.unlt·,"';nkinl!: the brads.Nowjust "Iun.thl' workpiece down, angl­

ing the pl.~ .Iightly i'O the heel and toe are

___ S_h_opNotes

•

•

•

WOODSMITH24

•II

DADO .I.ADEs

J'ri<, (j~ m the art:i.:lc on dado blade,;"". n .....""" ,.I<d n·tail prices. Fortunately.nl(llll ..r I""'" .." ran be purchased on sale,IT "I 1< ,I~.lInlthrough mail ()rdercatalogs.

"".t·U ~ IA('K DAJ)()SET.The industrial'I, ...hl) /0',.,.",1" ,·"rl"dr·tippedStack DadoS. t (Ord"r IS... 117:lJ\2. $99.(0) is availablef""ln \\'OOCI"llrkt·r's Sllllf,l)' or Ne"' Mexico.I~)'I \\ ~I. r~~'1.\lanK,!•• NE. Albuquer·~Ul, ;0.;101Bill:l. I'I.MI-r~;,.!l'192(Catalog:t n,,)

III ItA 1)1'11>0~E"-' 111(' IIldustrial qua!i.t) ll<llo"Carb k.t Pl.roSlo'*Dodo SritOnk.,. So ar,q)), $11".50) and the INlto.Ad ,ufnbk IJcdI'I()nI<rNo.~. $36.10)are both oh.", n Ih lit< Dclta AOCl'SS01'}' Salee,;ataloi: ., .. ,bbte from "-ood"orker·. Su~I~) r :\''''' \1,1"'0. addres., above.

.\1 l • oca; IR~.ctJT_TheAn.·Edg. 1M,.( t A4j tabl, [)ado (Order No. 09T31·Hf•• ~I".•, N"l.) u. available from \Vood·•.",1\ SUI'I,ly. 1)<·1'1.WSI. -II Atlanlic A,e..1'0 ]lo, \IlOO. \\·"bun,. MA 01ll88;800-'>'2.';.II~'I (('ltwl'lj(: F",'t').OI.OIlAM ellRHIDE·TIPPED STACK

DADo. Till Oldlwm b"('arbide·tiPl~ StarkS., lOrd<r :-10.600-C(.'O.$S9.(0);"Il\·wlableIno" B.mlilll!ham Saw \\'orlul, n..PL WS4.910 North:!llth St., Binrungham. AL35201:~)04'U1·1316 (Calal ..... Fn",).

St;AR.~DADOSETS. ",., Seant dado ""Ipn ....'$ """ onler numb.." I!>ted \:do" arefrom the Sears 19"~ Po...er and Hand'IbolC.taI"!:. \\at<h for;ale pri ... ,.• -tandard-cut Stade !J<.d" Sri. 8", Oat

atcel, Order No ~ HT 3'l-17S. $34.99.~moollt<ltt Slack {Judo "'I, 8", bollow·IlJ'Oll"d 1It,...,I.Onl.r :\0. !lHT 325:1. $.I~.99.('arb,d,..li"",,1 Stllck [",do Srf. 8". OrderNo.9 HT:l:lI>1.$'<9.!I!l. Adjll.taoltdado,l6-tooth. Ord~r No. II HT 3'263, S34.!l9. ·Er·,,,bbllr' f:·Z Ad}".t Dodu. t\\in blacle, Or·del' No.9 HT827!J!!.$lJI1.00-

,

IBut (or t~ appticallon. lu.R'h.speed i!leel

_mo to lIurk fine. \\ ••u.se'" the Yodo\·et.ailbit (:-10.9 HT 2.",...~I.$4.1'9) from the 1!l8i>'86Stoan\ Power .",1 Hand TholCatalog. Blackand Deeker tds<> ,,(fera a ~,' dovetail hit (N~.59078. $<1.07)At local Rinck and Deckerdealers, A v.: l'oI1,·...Cable dovetail bit is.],,0 available (nlln'

ALBERT C(lSN1'M"INE AND SON. INC.(acIr1",'~'.00\1". Dn"'lllil Hit. If,'. Order"'. to,_"JoIl." 'J".'(1. -i1)I{lo)i7, ~).~,

line eauuon: For lh .. project. don't use a~ -JtiuIIIg' do' .WIbit - the kind with the.:xtra Cutes that creal.· an .,,,...,.ic>n .101 for"x..,.. !due. _ IIOnd.mritJ.No. 31. ~bila are ",..nabl( (rom a-b and \'ennonl,\II1l'rI<IUI). Th.-e '''''''''JOb ,lot "ould.oo..­onU",JOInt

:;0...e dccidrd tomake our o....n ;tn,,,, ootof tlCl"Rl'.""" Sbop Not .... paj{t' :!:!.

DE(:OR"TI\ Il t"I.AY" :O;tiUanother pes­!<tibilil)' \\ culd he to UM a tlt'Cf_lMl.ti\l' inla):.They're av,.. "'1>1.In a wide variety uf ffi!.:-i~..fr(Jn~Itll of th4' 6Oun:I'S lio;t(..'(1 above,

FEI.TANI)AI)III:."IVt;. WI' PUI'\·h.k«'<ithef.'ll (or th. I,.." HII~r a,"1 I"~ "I 3 loea!fabric.' l\t(Jr,,·, SliMlY 3(lhc!'oi\'~ are .\·.t~Ila.bl(·at art l"UP1,1)' stores. l~()l"~:J )o,l', lr)' to Ul44>\\1)0(1 glut' or (.vlllact (.'(_·ml·,nl TIl<-y ~rakinto th.· (I'll.)Two """10 tn"'" of. ·rayad!," ves are

.~ailablc· adhffi' "" (or ,,""nam'nt mountin~ and t"- (or t.mporary mounung. Ap._·nnanent a<Ihe"'lf' fhould be ~(_-d tomounl th., fdt \\'c used 3M :,pray.Menl3~1Photo-~Iount "wid al", ..'Ork. (3)1Spl"8~.~lount 15 al<mporvy a.lhe,,,·e and.hould ""t 00 u",-,I.)

1.'UCASt

Youcom onl"r th~ hanlwarc for the bricl''''''<efrom:Tilt: WOOIlWOIIKEKS' STORE.(add re,"

above), 11";,fN.. '· IInrdll'Ort Kit. incl\ldl'!'locl<.s, lIn~r. hing•• , 8"loUI'I)OI1.$.Order 1'(0A9J90. $:l9.tm. Gr",,;nc Lrot/ler H~"dlr.s]Xod(y Dark Bmwn (Onl('r No. D!IlAAIt orLighl Bmwn (Order Ko_ D!tioOll. $9.95.You n,-cd • "K'CCof O.xible \'enet'r thaI

l11t'1I.'u .... ' .1wI II', i2" for the briefcr.-·\\'" """'" • """"Ie bncfca....,..out o(t.u andrift <Ill IIhlle oak anrt c.tnIm.od the Y'_

f~m;AL8t:RTCO"STA."i'E A''D SOS "t'.

laddms abo,,~). f'l.'zibl.·I"",.,.. I"", ~-,Sp.'<'() Trak(OnlerNo.llrVI5Ifor$:J.l.liOor \\ n'te 0:\1<, rift rul. (Ord<.>rNo. I!FYI'1I(or $:.'7_()(j. l:-it", lhe ao.talou for other $peO.'SQyail"bll·.)FI~xibk· ""ntO(>" arc 01<0available from

Th~ 'Voodwork.r.;· Store. Bob Morgan\VC1orlwo"kin~Suppll.,. CraI\$man \\'oocIServi<'t' Company. and Arti<try in Venee'"Inc. tSM>Q<kln......·.above).\\e onlon'<l th.· lung 011Jirllih for lhe

bn('("""" (rum:(,Allllt::TT WADE COMP",,,,, 161 Av~nu.

o( Ihe Am< rieal', ;o.;~\l York. :-.,. IIM113."'l().2:!1·29~2IC..talOI( $3.001 S"I/ ...rl<lI d\I..ll•• PollI~ TU'19OilSNJ1IT.Onkr:\0.WROI.('I. ~unperquart.~lIIl!n1a,ut\I({ ",,"'olll"mud n.'go.lrLoICLtUt"OnIer!\o WRIl;!01, $1~90 ....rqaar'~

OOVOA'L _OUTERlilT\\e " ....1. • Ilu\ ctall nJUterbit tomake thenulered rI.,..etad kf?)JOUlI on the "--cit'" CIIrdI." and rlra" .... _(&...articleaMuI thisJomton "'Ij(~10). \\t' h"VI'II'tlx-en able to locate ay,' car/"," -I'II,H·t! dovetail bit. They'", aUhigh·."",·" ",,"'!.

IttCIPt CARl) lOX

'00 ran oro. I' the hamwlITe for the recipe<lIni box rrum

Illr. \\OODWORKt:RS' STORE. 21lSOi In­du.lnul Boulevard. Rogcn;. Mol' 55371;flit 1:!>I·219!ItNute: $7.5U mimmum cash01'.11'1' Cut.loll: $2.1101.I'nrrtloul KilO'" (2).I' dill.. Om.r No. 1::1702.$1.IQeath.lfill!/f'1<tl "~lr}............1Y,·lnnl(."'·openwidth.!Ii1<Tt'..... mdu<led. Onl,'r No. DI22I. $1.60JNUI' S"rro: 11,,1,HIlIt"'.~ 14t. Yo'.Oak. Order;0.;0 BIIII8. $1.70 ,"'I'm.

SMAll lOX IURl VINEEllS

Rut! ,'enet'rsroTl1e m odll·,haped piecesanrtare a\-ai1abI(ltfrom a vanetv of ~":>_

l'ht'Ck the ratalo!:& I sted belOw for spt.ocifitoI'P"CI~,w...... and pn ces , Youcan 0"""r thehurt, anrt ".",,, I'tdu<! w, U--e<1 on the .manboxe.. (nlfl1:ALBERT (;OSSTAl>'T1NEAND SON. INC..

2050 EIL'lehc"tel' Road. Bronx. NY lQ4tH·2:..'97: !ltJ().22:~0!I7(Note: $10.00 minimumca.h ~rd(·r.Cmalog: $1.(0). B."/l't>IIeer.npproK. 10"x Hr. :1sq, fl. minimum order.(\Ve u"",' ('al118thian Elm Burl for the~bo,. ()nI,,1' No. V16. :Sl.20persq. fl.,an<! Maple Rurl (or the h"x8$lOn box. OrderNt" V5:!. $1.2.; 1"'1' "'I. fl.'. \~. <w Gi,,,.1'101. Onl,r No. 12\·(.jr, f.4.IS.Albtrt Constantine and Son al.;o om,n; a

Hurl 1n..."".\....ITt"'''''t It includeo<2 "'I. fl.o( !l('\COdlfl"'''''I\1 bur',. om.·r Spt>cia1;o.;o.C\'S 2:11.~1I.2.'>(lthcr m ul on"·r ~ o( burl ","""",

includeTIIF. "'OODIIORKF.RS· STORE. <ec

addre.-..: ab.,\·C').BOB MORGA:' WOODWORKING St;P·

I·UF.S. 1123 Bant,town Road. Loub\ille.K\. IIr.!tJ.l.r,(r~·I~.(j·2045(Catalog: $1.(0).

CRAf"n;MAN WOOl) ~ERV'C£ COMPANY.11:15W Corthmd ('t .•Addisol1. IL 60101:312-62\1·:1100 (C"18101(:$1.(0).

"RTlSTIIY IN VENEERS. INC. 450 Oak'nw A\'e .•Soulh Plainfield. NJ 070b0: 21)1-66t>-I~:SO (C[\lalol(: $1 !;Ill.

ISLAY SIll'" \\"'tn It ramt> time to lind(.M _.Yo,"'" X 16 lunJZ"inJa)' ~lrip rC)fWbox, \\ e mn int.u a l)rohlem. Alben ColIn.tantlne and Son Ita- a m'nImum onkr of ad07..n , .long plc<es (.\"al~rol \1'00dS"pI let' ~ for 'jJ("""". OnIer :\ o.!to\ II ~ ()O per 12.'.The \\ .. .m.otittrs'St,......(~abo\·e),

...illaeIl one 3G'-long OlI'lPbut they ha'e aminllnum $7 60 total .... h 0"""1' ~'allm/1100<1Sln/l. th,d<,' ,,'de x 3J,-long:\\nit.· ~lal'lc, Onl"r :\ o. As12:l. $.3-1eachHInck, (lrd.r ;0.;0. A~120. $.50 each;R,,,,,·,,ood. Onl.·r ;0.;0.A);121. $.52 each;:;'It'I1,,, •• I. Onl(·],No. A8122. $..52each).

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Sources