8/20/2019 Woodsmith - 070

1/32

NOTES FROM T SHOP 3 95

O 70

8/20/2019 Woodsmith - 070

2/32

No 70

l.ong· lune .ubocrlber, know that we

h,,,,·

h,ld

a

'InlIlRk

getting

tV(If~I'''/lt/,

cut

on , ,' h( 'du lc' (I n (ao111~.flOO. h e - i s o n eo f

the (l''A O f lR ' u , : a I : \ n r f , u ( u l

\\11\ th o I>I~d•• ,I.houIN,·k? \ \' e ll . he 's

j l l'l l ;1 1 11 1 clltl l l I . , f l J,'_ .In

dSsi~,

edi tor.

\ \. h f 'l t WI' flr,1 Inll'F'\'1t

'wt'cl

Hick. il cer ta inly

1...11 ' th.t h,' \\. '1)' lllmili,,,wilh a ll the

p r l'J t , ( ,~ 1 1 1 0 1 1 1 '. 1 , ' .I Jl J · , l rt -d U\ r I ht . . y e a rs . .

IIu \ I k m - 'Y o h i  .I~I  l \ \ ( ) ( x l v . ' c ) r k e r

 II( n h. 1011 1, 1 1 Ihot a- u kid It.· u

-d

,oask

le'rlt ,1 In

11.•dofl l .\1i a t( .· t, ri . .U l \a .. '''It .O

h..1:0Ihi-

f ir5 t . .. .

  I

IOub.

Itt · bt'l1 ll modify

UlS:

hIS I'a,ml .   o r r . . . .

tabl,

S oon tht 'tt 'a ter

h looI

00'

s R d u c c d III a ruk -r.

:- ;0...

h. .

Ita

a lun

, Ompk ..., ,, ,,1, ,( lools

and Ih< 'abil i l ) 10 hd p u' pruduce our n .....

3 2

page

l X p andl . .. .

\'{ f'q o n o f

  ° o o d . > f , ,ti f J r .

\ mltH f \It:. .~' JOining uSb

(,ol'\lon

(:.ipPt·

(;ordoo

c omeo

from a back·

):round ul bruad t b()x( ...a('k( Ci on lop of ( '3C'hotht r

a ba ,,· , p t 'ndu lu l II C.>e. and h (' ad c a, ..·

Thr w a y 'lA t' dl ', ig nt- d it . lht 'rt> art

'IX

(ram,·,   ith m olded , - < 1 1 :

th aI ... .

 l;Il' atr

m\ ,

IMl ' m a in C a < . . . .a s . .

( . J )

it....

h t

C 1 ' O ' 'l l i

mold , a t th IOP

and kkkboanl;u

tht·

001

lorn So.

In (\ .\

it )

u ~

ou

c . . aJ l

ru t m o l di ng

and m akf' box .. y( )U can b uik ilh i, ( 'k ic k.

C.:lq )\ I-W .....W\llE.

\\ t

o

a r t i n

tht

pro c; .. , . . o f t:h .tn ll ln a ll o ( o ur . .ub~-ribcJ

fik·...to .t nt \\. updatn l ,} · .. .i . 'Tt1 I,', J: t. l n . : 10

t- na bl t, u . . . to d e l II If , t e l f

thing,

b t t ( l . o r an d

(a,ter wllh ),.,u r ,b 'ri ptiu n lI nd .

it

 ,ill

abo hdp w ith p rCK '.  ,i lI Ordl' (u r oo ., k

is...ul·~an(ll)mjt ('t~uppli..~~

 Ib, 1I ly llrobl~111j, Ihal U,,,re

will

  > < a

chanll(··nY~r I)(·riod. 8I 1w n no and

A ugusl 2(hll . , . w ill  I )

b t>

llbll  10 a(..,,\~t's...

)'our, 1 l 1 I 1 f r

J jt /1 , rt (()rd~inlheconlput\.-r:

Note : II

yo u

h . , c ·r ~n tJ )

placcdan ord.r

fu r bark

i ~ul

or project

~P1)li(.' '

n,m

U ' o .

th(.~

f\.....

rtl~

ttl

JC () (

afft'(1t-d . ~ •.

if

)OU

h a \ ( . a qU(- -4 jhlnR Co

C-.-nJ:ltI I KII)b v \\

ooo,mitlt

Publ).Jung

(  '.pili)'

A J l Ii R h t > . . .. . .. . .. .

-.I.

Su~ ;Ptjqn••~

)DC'

  It

Ch

l ''IJ~'

 1595.

T  ..... . • . .. .. . »27 9 i l. :anada lFor ri : ' :

> < I <

S~  U

 > .

fuocb. ~llII

C O I 1 \

Sl.95.

~ {la ...,.., ... id .. [le..~1 1liDe>.L -\

.m d

I I t

;e d . J l l I IO n ,

tI ~

r)Q~tmD I'r.~ nd( h,]n~\ uf

ddR''' ' to

,, , T l l1 1

  Il, (~xe'lilt, (~'

\'~)\~.lA5W50.

 >ubt.< riptionQu

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8/20/2019 Woodsmith - 070

4/32

A UJC iUAJ ty

Gum

HE5C ;HT

ADJUSTMIHl

 N,

\

1

No. 70

smo II.: , lid 01a pl('(' ; ., 1 . 1 . , e li n

'h e \i un i ,i n J , ra b l, ' u~ ( ) r< Iown

local,.,; Ih,' h,·i,..h l I I r Ih.,o ri ll b it

.1m.,d. 1 m

\lonl-101I

rab .·in

1 l00d.;

I

 1 : 1 1 h7 and I am

I~. ,...~Iwithlh...

an'u ,')

and

C'J-;4   ill) h ie ,h I r e in nu rou t

In()r t i . . ( ·~

 

It)\I,:C'Vt'f,I tUn tlnal]i('

t(1

rtosist

c h i c l i n s :

yC )U a he ln t a nlH hc- r

u S ( >

I r li lt ' ' l1 i ,i llll T;.bl,'   hid ,

) ()U

(;till'cl

ltl rill Iltitlll. i.t· ,

I IUr}. .

ltlnlal

bClring. ,

rt'(l'r you to

\\  I(Ir/ ,III/ \(). J 2 . in v . l l i rh ) o u

It'atun'd ,I 11t)ril.cllllal borinR:ji2

th.u

i...

-C)lllt wh. '1111ilar to lh~'

HORIZONTAL BORING REVISITED

a 

Tips

&

Tee

 : 7 a r r IS

 l Nl t R O

aE1WUN

POStS

SOlT 1lIO£SON

lXT lH StO N ST OC X

InoNOtNDOf

WOI:KPtlCt

in th t · router and mount the haw

. , 1 . 1 1 . , ~ th e b lt a li gn > w il h th e

b h,

an d iscen tered

~ 'cll)

, ·

tYol ntlu-m

It IInnmi-e

i...

equired at tht t

•nd til the stock, extend ,h('

  ,-c,rkl .II , ,\ ( t o

~VPOn Uk 

belts

b,

pull, a

pK \ .

or

stock

in

th.·

\ St II\.1fslhl·-..am(·thicknK~J.S

Ih werkpi .•~ee~i~.

 It I ard hild

\\ 11,1ffU,. \

't r

/JIll

dri ll c )\ 'e , I' rs i l. t l (JUfllc·rbtlrc·rl

11CI I I~

to mount thl' ba~

tf) yell ir

r01J1 ,..r

a nd a llow

IC tTmmor

a( 1

Ju..iments, see Fig.: b

Ihen. on the back ....tlt fl the

ba...e, drill two counn rlKJrt d

11 (,1(' '0.10 accept tht· he••d..

lIt

Ilk

• machine bult- on a line I

from th e axi....OJthl router ...hat .

dk •.

sev

tig.2.

Thenepo~}

h

boh- In

pIac

e. _11j .2a

:\( xt, insert a . ,, ....ra.q.:ht b t

•

ques

\V 0 0 D

\(1 ()

R K E R S

,

 

.

 

.

2

S om e r ou u- r b a o; t· s ,h a I ' I X

isting threaded ho i, ,, , 1 0 (lr«'I>'

m ac hi ru 1 x, 1'~ J u st ,,: n·   in ilu

b olb an d

, U

u(l ,h, 'lw , , , I ,

lr v ou r ro ut er b......• (I.,\ '...n't

havethreaded hoh«, ;

8/20/2019 Woodsmith - 070

5/32

s

SIND IN Ton

nps

IIyou v .o uld

li kl'

to ~hart' a

l ip

or idea..

j U < ; . 1

~nd

il

to

11 '.00..1  

TIp, and Tech

RI lU(  S, 2 20 0 (;ran d A \· ~• Ot:>

\I  int '5 .10  '35O O 12.

\\ ~ ...m pa y

upon publica-

li on SIS 10 ~ll~J (dc l 'nding

on I h ,' pub l i,hed I,'O JM ollhe

lip). 1 ' '''''' indude an ex-

1 ,I. lnt llill and a ,ketch or

phl)tn (W\ U d raw ant w one),

KI

iJal/t .

/ ,/ iJib 11 1 , I l , . 111 11, ' f l 10

: - < . . .

70

Illt'J.l 4'1 i t l ntc) 1 )C ) - . . i l i Q I 1n the cut·

1 ,· ,I,..ad. · n . . .

Hand i· rac k

hu ld •

II ,. .

kniv,,,

while I

lighlen

th e

FASTENER LUBE

• T n ..

void

Ill thinner

t it an n t~ '

  ,v . bl. . · hk'll al.lv., Ill,· k.,1

10

do,.

p

.1i~1I11)· after 111,

. . oocI , . .. .

s .'SII,,· blad. \1)'

lit....

,plitlt r maintain-, the exact

 idlh  f

l he .. . v .

kerf.

T il ,k,· I II ,· . .p IiO , · r. b c ei n b )

n l O lk l n j .( . 1 n t . ' \ \ i n to ; ( n

l IJ(luthi~

n· ,,, or

plane

a blank I., the

t h ick ru . .. . o r I hl ' t n~ .. rt nfX'tlinll

i n t lu -

  'lA-

t . ,b l t -~ , the nt; \\ in-ert

will

Ii.· n ,h v. ilh II , wble top,

SPLlnER INSERT

8/20/2019 Woodsmith - 070

6/32

W LLauclUT

 _5CiW

8 u., II doOd.)

1I

 I I<

IUI . As   r me clock

work s,   work ed w itb

the

 .,,' S uIl iV -d I l Company of

  \I1I,,,,,hu,, Us to put to gether a

'1>1'1.i.1 kit

of

the

high.quality

bn ,,,, dCK 'kworks (m a de in G er

m an) ) and alllhe hardware you

need to build the clock. see

Sc 'UI CI·'.

page 31.

  ''' . W hen fini shing pro

jt ct 

bk ..

th i, (v .im a lo t o (mo l d

en gl, I

6k,' to

us e 3 wipe-on o il

fim fhi time

Ihose

a

tung

oilfinl,h

(G

en

eralF misbesT wo

St 1l s.,~ll S~»tl l1l).

DOOMS. The clock pictured 31

~ thas a

gla'must

be

perllOCIIy sq ua re , and

th( y

have

10be

flat. lfyou re on larget

with these little detalls.theclock

is a 'na p 10build.

 :QI II)MJ.~ T.At   rst glance.

you miR ht als o expect mat you

would need •

lo t

of equipment ta

build a clod, like tltis - C l P < -

Timeless desig n  So lid cherry

rass clock w orks

Tru ly

an

heir loom pro ject

-

~ l

Tall Case Clock

 

HEIRLOOM PROJECT

 

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7/32

H

• Clockl( I( l)epogq31)

• (4l)

No 8 x I )' Fh

wood$C'9WS

• (20)

No

8 x 111 .A I wocx:lsctews

• (28INo./ I... FhwOOClscrews

• (30)

Yl 1X00s

• Songte  1 rQng ,~ WindOwgiOSS

• Tung o II liN. .1 I

SUPPLIES

7

,.8

x

IS

••I~ I~

.4

x 2'' '10 X JOI,.

~••2.00'0(1)

V 580tDa

Suppa<

(2)

W Sc,ew

8IociU

(2)

X t>mo B oo rd (I)

Y W.ncIOw$'op(l)

CR OW N M O LO IN G

Z (1f ,on' lldGs (I) '•• I ••

4()

Rgh

M e ' r , o o , / S i d o l

(1) o.ll.x42Rgh

88 AI . ont/Sioc >

 I ••

2 x d4

Rgn

CC

> P Ius

P>:ncI (I) '.

po ;

C... to f·

 «'

v

PE NDULUM

CASE

D O O R

 

I

M TERI LS

1w

o

 

@

 

HEA D

CA SE

D O O R

  o

o 'i

(s

,

•

CRO W N M O LDING

FRA M E

  -

HEA O CA SE

EXPLO E VIEW

8/20/2019 Woodsmith - 070

8/32

Nn.70

... ·WlOI MOItftSf

.2 ; . ..

OflP ClNTtaJD

. . . . , .2 ; ,. ON TH.t

8/20/2019 Woodsmith - 070

9/32

NOTE: -----~ ~

OMITSCRew HOLIS ON •• ONI P'lCE

Of

,ttAM( 0. IO OM Of HIADCASE

N(X1

ItOUt

I ...

ROUHO-OVIR )

: -===:::

I.

COUHlL.SUNk

 1

SHANKHOUS

.

flltSl ROUT 1

tOUNOOVtR

o.

I

AI

I ,   R O U N - D - O - V -   -   - . -   T - ~   r .

STEP

2

b .

 

f ......

C

I

STEP

1

 

- 2 .   , . -

. . .

S) , 

••~_~.~......t

2 ,- _

. . 

I

~,

. .

. . , -

1

.-- ----------, 0

,. FRAME0 •

T

It  ,

6

-

T

1

L

I

,,

1 .· ..

FRAMEC • ..,.

, .

I

I,

STRAIGHl 81f

_ 2 ,· ..

-

,.1._

ROUNDOW INSIOl (DGCSWlfH

t .~

ROUHD--OVU.,T

 . 

~~~ ~

.

  • • 1 , -

STtP

u.ln '2

.

 

0'

,

.

-

 to O Covt I 

0

 

,

. . . . . . .

I

111. *

_ 2'.- _

-

.

 

2 , , · 1   ) - ~

< -

,~  . ~ ~~~ 

_ 21.- -

-

llAvt  , 

SI4OULO'.

b.

I,·. ..

STEP

....... 2

',. COVI lIT

~

  . _

  . -

. .

- 1),.*

,

 0

•

•

1,.-SHANK

HOUWI1l4

J

f ldu ium ( '3 . .. .••

SlI.tpt: I

he tr .lnll . . ..bv

fil t

n UI~

ing tfu lit

l C.\ t

in ,(·..eral

I):-l '{_' un t i l th~ 'r t ' a ~;.r·lhK·k

. . ..lc 'uld, · ( eu\ 1hc ' (ralTlt

N t'x I r fU l1 ~tW )i. ~

deco ra

, , \ ( m ho. abel\·t· tilt· cove, , , O J

nail). ,olll'1I I ~ upper inside

\~d~cwith;Il..* round-over bit.

T h en .. dri ll tlu - c ou n te r

s un k ,Ila nk 1 1C )h ' ,.

FRAME A (1'

This frame~Il Ih kkk

board from

Ih,

10 ca...........e

Ora\\ln~.C a c t n g (t:I; t .

( 0rot Ihr

profil~

n Ih,' trom

an d ..id t . . ..( J ( t h t, t rnmc· . rou t

3 V '

cove in ~t \ ( r,,1pa....t ...unt i l

th ..

rt ,

.t

\-4 'lhic. 'k

~l luulcJ( . · r

along t) tl out...(I~·, f Ihl ( r a m

Cmllllld lh, p r o m , · by form

ins : II 1

~ ·d ' · ' · I) r . ,bb, ·1

.IO lIlh(·

J()~( f mu...klv , '( I J ,: t '. I h i . .should

1(~i1\'t·.t

~ ·thi{'k,htlUlclc' l

Prt ' -1 l r i ll tl lt 6 \ ,( , coun tersunk

. .. . ank h i , I , '' '' ' ,I'

,hc, \\

n

8/20/2019 Woodsmith - 070

10/32

I,un f

~

-~,f~-

 

a.. 11.,-

 

WOODS . s ec F ig . 9.

,\ \s~ H I\ ~LN ow rh e s id e

panels

(H )

< w , be CU i 10 final width ( IW , ) . s e e Fill. 8.

T lu -n s prea d lillie in 'id e e ac h groove. and

.Iide I he

IOngu('cI

side panels in lo the

I lr oc lV rd t rom pan .'I . (lamp the case w ith

p i p < damp' untillll j lue dries,

fIlA'WOW 1)(,10.' Aflt'r the glue dries.

roul • d otal;v,' h. chamferakmz theout

 ;cIl' ''()I t' or

lilt' Imnl

p ie< .. . FIR II

~op th,·,·h.lml(,,,. 2  from the lop a nd 0 01

 lim o f

tIM

~~

\11 \( II\ PPtW Olt,UlE. , ow SCt eW a

bull·

. , . , . . . . . ( l .

(t-dIlk' (til.Finally. screw

Ih ;, , 'm i r t· ' ui> -a ,mb ly 10 t h e lOPoiF ram~

A

o n I I , k ic kb oa rd , s ee

I tg.

10.

N o. 7 0

AIt , . . .making

al l six franw,.

I ~ work on the kick·

board The kickboard

con

 ,Is of. front(£) and (v'o

.Id s

(f)

Stan by ripping

all thre e p ie ce s to a un i-

( n n w id th of 4 . se e F ig . 5.

 lTuts. No , miter

b ot h e nd so tt he k ic kb oa rd

f ro nt ( E) so it's V longer

tha n the (ron t o( F ram e A

L

_j~-::'2..J

(I6~, '

from

long-poin 10

long-point) Then miter

th e

Iron

0 1 boll, kk kb oa rd sid es (F l. a nd

rut off

till'

b ac ks ' th ey 're ~ .· Io ng er th an

tho'  dt '

8/20/2019 Woodsmith - 070

11/32

s ou ... , u _

.OUNo(D

CORN IS w nH CHISll

10W0tCA5(

1Acx.

•

J

',. auos

 6:1t I,

f h WOODSCttlW

. .

  fl •

••~

1

_l,· __

0 6

1

11

ll.70

~

LOWER

CASE

•

141 . c . , ~ ' . . . . . .J

Non:

fWSt<

 

lAC.

....,., (J

L OW ER C ASE

D UST PANEL

I

LO W ER

CASE

BACK

.

PEN ·

D UlU M

CA SE

BA CK

lS

o(a ...

;?

Jh WOOOSCRlW$

Off MI _~.

•

PEN DUL~~' -

C A SE S ID E

FRA ME B

1

CASE

SIDE

•

FRAME

B

12 P EN DU LU M C AS t

~~~~

§ 5

;ii ~

The pendulum case co .

,,'I,oCtwosides (K) held

In plac.- between a pair of

'Il -

frame-s,

see FOg . 12 .

 IOF- -romaketheca se

sid e~

(K)

start b)

edge-

s:lulllJ{ blanks

to a

rough

width of 8 and length o(

32 . Theu

trim each 10 a

final w id th I

 

le ss than

Ih.

depth ofFrarne B

(7 t,,

• in

01)

case), and 31l';

- lonl(. «'(· I·ig. 12.

AU(, '''C, F'RA.\lbTO CA.'E SIDE.

\\ jth

the

...d pant'l, cut I.) 'il.A;, the case can

be

as

.. . -mbk-d

T.. do thi,.

stand

one of the

-B

Iram, on edge .. ,th

iI,

back (unshaped)

-ection do lAn 1 1 1 4 .n  . . . a n d one of the ( '3CO(_'

  d,..,

nn ..tI~

(I11L l:n ,,,

thatlh e back

,-d~,''''

of both I t' art flush.I ~O\\

p o c : i

lion the ,id,'

pi(-c('  

in from the shoulder

ollh lraml',

,,-,

8/20/2019 Woodsmith - 070

12/32

N I 1 _

70

2

roPOf

H(  DeAS(

lFRAMt C)

  . -

IN .SEt

=

-

ItOWN

MOLDING

FIElD

fRAME

 

-

,a.

~ , -

-

@

 . -

I .

~

1

,

. . .

 

OV£RHAHG

 

17

NOTE:

  (2AU

,. . . . .

fRONTS

COVE

fRAME

  AA

10 ....

. -

 ,

INsn

1--...- 

, . . , . . . 1

0

,

,-

0vutH.U

th\~

fraDlc,

b~

gilling

Ih ,' 1 ' 01and then th .s id , ,, ,

onloIll( tram~ bdow il.see Fig. 19a.

CROWN MOLDING

o

-

':1,  - r

l

•

•

2

,-j

I

I.

ItOUNO

ovta

IOClS a.

r

- ........_ Of

SJIUHlS 10

,IT MOImS(S

_c

:- OVOtKA.NGS

SID'S

1'l

DIAL

fRAME

STlLES

~

0

r ~

SOfTEN

' 1 0 , . . '

IHSIOf

I O G r

 

W Ill<

 

,  

tIOUND·

0

AD

a

•

A I

II.I 

RAMI 0

rh WOOosc.tw

•

PlNOUlIJ.M

(A (

~

-

,

 

,-

, e A M

ovrltHANG

FRAMEC

7

1I~h . . . ca se i s

made

up

/ 01 0 ..;d .....

(I )  'POrated

b} a dial frame. and at

(ached 10

two

bullnose

fram4 '- see f .l g. 1 7.

IIEAIlIll , Bewn b)

,'dlll'-gluing

IW O head

~ iCfl ft

t he h , . .. .1 ( n . to th e lO P of Ihe pendulum

case. -..('(-lg. 1 1 ' \ .

HEAD CASE

8/20/2019 Woodsmith - 070

13/32

I 3

22

NOTE:

.j

POSRION

 

f1:INGlS fRO,M

TOP AND 10110M

Of OOOIlS

\XlooJsmlth

PANELSTOP j.

1  __

NOTE:

LAYOUT STOP

PO IN T FOR

CHAWlR

WlfH

PENCil

,

f

•

HAMfER Bl1

(OPTIONA L

1c  WOOD PANIl)

l o   . - .Jl_

0:

PHOTO,

  I

P O . ; . . : .

-,..j

No. 70

 

O UT SIDE

fACE UP

 .  

RABBETING

Bit

iNSIDE

fA Ct UP

.j

,

 

eRAI>S_

SQ UA RE

UP (ORNERS

) J(~ 

AA8e£T

'OR GI.ASS

GL ASS

wrNDOW

WINDOW

STOP

r- CO-==~ @@

21

•

o

,

h-4----~

•

e-

PENDULUM

CASEDOOR

STILES

POSITJON CAtCH

I-PlATEIN UN

WITH PUll

(:,

  J

1

CtNTtR AND OQIll

KOUIO FIT

PUll HAROWAAt

~

8'.

~

~ 2. .. ....

(b.

,

  . . . .

4

2t.,, 

I-t....

 

• •

®

PENDULUM

CASEDOOR

RAILS

 

-

lot,

~

_21,,  _

a.

ROUND OYlR lOGES

t

Of' S9LIN(S TO

[J

mMoRmrs

2  ,,-

1  . 

t

 'l

f

~

[)

D -

2 . 

HEAD CASE

 

DOOR RAILS

f

@-

. . .

ts·

HEAD CASE

  ,. . .

~

t

(sa PlNQUl,UM

DOOR STllfS

~

, . . .. . .CA SE . DO O ••

,

,

13.

1

,

2

t ...

t. MORnU

. . .

I

.~

c·

0

.10. OEIP

,

CENTIREO ON

STOC.

r lli,The clockhastwodocrs=

• head case door that al

lows access to the elock

hands. and a pendulum

C3S

door th.1

allow>

access

to

the weigbts. The

fra m es (or

both

d oo rs a rc

made using mortise and

spline join >, and both

f rameshavca rabbet along

the in~icl('edg.' to accept a

 -_ ' I

glass

(or

wood)

panel,

 _-

8/20/2019 Woodsmith - 070

14/32

N o. iO

oodsmllh

4

 

®

SlAT·

  00

 UPPO U C : : : J ; : : t : : : : : = = = t ~ ~

DOOR

PUU

 

sql1w ,

B L O C K

® r

HEAD CASE

CROSS SEcnON

2

INSTAIJ. \\  ()RKS. ~ ()   ,

se t

ine

c lock

works

on

t i l <

K J ) < w < > d

scatboard (U).

The hand-

shaft should be ce ntered inthe di al hole,lfit

isn t,

r emove a nd re-cut

t

supports (\').

To

,l(ld

Ih., c himes , f ir st screw th e c him e

blockonto ihec hime board ( > . ) . Then sc rew

thechimeboardtothescrew bl oc k.

(IV )

an d

-eatboard ,upport. (V).see fig. I.

m'q'  ',\XlI..After you've lin   tu ned O le

movemen t a nd c himes.topotithe hea d case

with a du st panel  CC , se e fig. 1.Cut th is

IIIfil  illli t crow n m oldin g ann screw

(d on 't ~ Iu ) it in place - y ou m ay need to

remove

it to a dju st th e w o rks,

Finally,

add a

wall b racke t a s- shown

on page 6.

13

',. _

. . . .

C U T O U T W A S l l

,~.

. HOf.,E fO A C HIM E S lltN C1 NG W IA f

,

 

r

1 

SEATlIOARD ®

- ,.

CHIM(

. .. hole

n c a r o ne e n d ror a chime silencing wire

ClockWorks

CHIMES

OVEMENT

8/20/2019 Woodsmith - 070

15/32

1 5

)

Ihi' >t'nding when

running

a

, ,('II·~tllnd ''aUst' friction.

  'I'< ;all>' in Ihkk ', ... o k. S o

\\llt n u...OKl\ ~bre sa\\, you

rnay l'ilV(O to ~ 'l'ri.fi('ea ~moolh

< ul b y u.illl (

it

,·oa,. .,rb la de t ha I

r un s '' () ( ,I t. 'r - and s t. rn ighl cr .

(;t JI gf .\lclrl.u

f~ ,,~tJill,

11/111 ./11,, 01,. .

II

, , , u · , , ·

u'InJ(

a

,harp blade

lhat', d lIn~d lor Ihe la.1 (()OJ.

 . f 4 . ..abl\ . .. . . .. .\\-ill fc.lOu a

..Iraljlhl lint \ 1)' 'At'll Ct ..

p(.....

cialIy .Io n~ h nt') T h,' CUi malk·

in

lhi k

 tll k

i,

ollt'n   ..ted.

And )'uu11

hav e a hard

time

gt 1 '

ting a

Nlbr.

sa..

t o (o llow a long

( 'tIN (' w ilh f in i,hc d-q ualily re

~ull'

'lll(,'S(' ,1\ort(. onlinR~

cc:n~

• I J.,I'  t lU I

 f

n

I ,,,d ,tt

u

(J I

ifllblll,t I, It ito/,n MUtt· ::=',,111~

It,;II J(II (1'I ~;Uf II

 > ' / o o t l l (',(t~

',til (,fhl 1 1 1 J i I {II' a luggl'd~

l('(ll'U ( ,1, • \ ,

I , 11 / 1

u n

Ilt)I tt,

11t;llg / 1 , , , , / ( ) , . tR It   1~(lbr~

1U r~

. .

lOCK

(unUHlAl>  \

fnD

.ow.

SlOt

GUIOI

tHIN

Icraround 111(way a s .a br t' . ...

j,

design(c d t(, c:Ul. filth,,·,. tlliUt til,·

way

you'rlA ll...ng 1 l

SA'\'I~(;  ~SoSII( INC• ·Illt·

sabre

-.;a ....

nlakt'~u,,,autl-fII,\\ll

sawing

, 'U ; [I., U~I~) , . , I tn

tilt

s lic inll cul~ mad.· bl a

band

s aw '~ cont inu c)u ' c ) uJ )

bladlo

This m t· a n:-. o nly ilft~ 1,1lilt'

o:;abre '3' l(,·,h t \, r lou\.'h lilt'

wood . w hile a band,.. ..

bl.J,.

  , , < : 1 1 1 1

h un d, ,- .I 1 ''( 'lh Ih3 1

c ulthro u~ h th . .

 lid:.

roanl

'1. 1 ' AI.....   bn·

$3'

bladcsha 'liuk-lIr 0lI- I •

(ilia is . th e l oo lh ,- .I , -d u

tlllh.·

blade

dot·,n ',

prodUCt

a wld r

k ~ .r r t ha n t he

1'( 'lllthr

blad,'')

But b an d sa blad.,

do

h.v~

some

  I. Thi'

allow,

I h( '1 l l 1 0

make   t i l , 'UI< , ilhtlul

bind·

in g, w h ic h h (· a ts . 1 11 'ilt' bind

Nn. 70

USING A SABRE SAW

2

, -

S.lot GVJO 

,r:

IO~

,I  10(

GUID I

f

•

~

 

~

•

.  

,

~

 

liE -AT

Rllu>-n', I

think

th t',

Ih . . m ain probl 1

sian l'UUillJ(,

Ih e

b l,d .. ,,;1 1 C U I

str-ughl

UU I

bdore lonR il heat' up and

.. d cr so ff co ur se ( .... ia ll) o n

t hi -· k . . 0 0 < 1 or W I ld

J I T I i n )

Ihal

< au .., th e

blade

I n b en d

A b .

8/20/2019 Woodsmith - 070

16/32

SI tINfOUJN

RUNS

A tl tO SS JO INT

3

CU t SPUN[

SOOKTlTWS

tMAN OlPJH

U.ICWS

,

N o. 70

k.l1..

If

the

o.pIin~...ill

be

hiddl.'n

in Ih,' finrsht-d

proj

problem

11

the

bo x

OT

case b

constructed in -uch a wa y tha t

dam ps w ill reach around

it .

I

C iamPODa 2x~block f lu

8/20/2019 Woodsmith - 070

17/32

TAB lE

SAW .

TOP

nA) H R-

a O A R O

17

0 

t ....

1l

W~NU1

< : : > /

N o 70

leur

TOUNO 

AFItIt ;

l

MimiNG -NO

p

 -..___,/

= : -+~__ ~ _J

f .0----2\-..-~.j

fiRST(VI TWO30 ANGW

~ __ ---:~ ON lND OFWASTt PIKE

MITERGAUG[

S L O T

2

4

th e m ite r slo t o f yo ur ta ble saw,

se e Fig.

1 .

 O n

m y tab le saw th e

miter s lo t measu re s

: v .  

x It ,)

Once the runner is cut, the

hole for the b oll and the expan

sion slot are made in one end•

seeFil l. 2 . Thencut

th e

runnerto

a finis he d l e ng th 0(5  , se e Fig. I.

STOP B lOCK . N ex t. 1 0 m ake

th e

SlOP,

I u sed the w aste from

cutting'

th e

r u nn e r 1 0l en g th . se e

Fig. 3. C ut tw o 30 ' angles o n o ne

end. tr im th e s to p to l en ll th . a nd

glue

it

to

th e lO p of

th e

r unne r .

Finally,assemble lI,e feather

board

an d

 h e

r u nn er . se e l g.4.

As

th e w ing nu t is tig hte ne d

th e bolt head fo rc e s the sides of

theguide b ar a g a in s t th e s i de s o f

t he m ite r g au g e slo t.

In

e[f(.-.:I.

it's w e d g ed tig h tl y in p la ce .

FIRST;

DR 'LL I

 

OlA .

COUNTlISINI(

NOTE:

SIU RUNNER10

rrr MIn. GAuGESLOT

THtRD:

CUTA ,   KUF

2 '.  I .ONG CEH1tR.(O

ONHOU

SECOND:

DR ilL A I••HO L E

THROUGH CfN l tR O f-

COUNftRSINK HOt.f

RUNNER

 

. .

SPACE Alas

lVtNlY

3

, , 

. .

1

f EAtHEBBOARP

room for an adjustment slot

that s a dd e d l al e r.

SafelY Nole : When u s in g th e

table saw

1 0

cu t th e notches,

L u m

o ff t he s aw a nd wail f or t he b la de

10stop,

t he n p u ll

the stock out,

rmally . cu t

th e

fesiherboard

to i lSf inished

length

o f 1 0 .

ADJUSI M E1-T SI .( )T .

To

allow

th e f ea th e rb oa rd 1 0

be

u s ed w i th

varying widthsof stock.cu t an ad

ju s tin g slo\

near the short edge.

T o m ake the slot, cu t a ~16 · ·

w ide g roove that e x tends 5\12·

(rom the squ are end of the

fealherboard.

se e

rig. 1. 11ten

fo r added

str eng th, cu t a

smal l

f il le r b lo ck a nd g lu e it i n p la ce .

R lfNNER . 'V ilh Ihe fe ath er

board comple t e .

th e n ex t s te p is

10CUIa

li -long

r u nn er 1 0Jil in

blocktothetopottherunner. B r

mitering

th e end

of

th e

stop

30 '

each way.

t h e f e at h er b oa rd

can

b e u s ed in tw o d ir e ctio ns.

cer

ru s

BlANK. To

ma k e th e

featherboard, I star te d w ith a

  . · Ih ick b lan k. ab ou 1 14 · lo ng .

Nex~ r i p i llO a

finished

width of

: r . 1 o I l an d cu t a 30' miter onone

end, se e Fig . 1.

T he

feather

board

w ill be Irimmed II>

a

f in is he d l en g th o f 1 0 later.

B.~

T h e n e x t s t e p

i s 1 0 c u t

th e barbs. T o ke ep each of th e

barbs a u niform leng th , I

ma r k e d

a st op t in e pa ra ll e lto a nd

2 : V   from

th e

a ng le d e n d, se e

rill. 1 . Each

o(

the barbs is W '

w ide and can be cu t w ith a han d

saw . a b an d saw , o ra tab le saw .

NOle : If y ou u se a table saw .

r aise th e blade 1 0 fu ll he ig ht so

th e

e n ds o ft he n ot ch e s w ill

be

as

vertical as possible.This creates

.T o

ge t

a c c ur at e r es ult s w h en

usillj a fence on a table saw .

I

like

to

u sc a f e at he rboa rd,

A (cathcrboard is d e s ig n e d to

ap ply co nstant p re ssu re to the

sid e o f th e workpiece . This pres

sure i sc r e at ed bycuu ings eve r a l

long

n ot ch e s in o ne end of the

f e at he r b oa rd . T I,e stock thai re

mains. t he f in g e r- li ke b ar b s. a ct

lik e sp rin gs. p u ttin g p r es su r e

against the stock.

EXPANDAHI.E RUNNER.

T he

bigges t problem w i ll ' a f ca th e r

board is ( ,ding a w ay to

hold

it

in

p la ce . e sp ec ia lly on a ta ble

saw

w h er e cla mp in g is difficult

T o solve this problem. I m a de

a r u nn er th at e x pan ds to

fit

t ight

in th e mite r gau : s lo to f my table

s aw . r e fe r toHg 4 a. B u t, th i5 only

k e e ps t h e r u nn e r- in

place .

To keep the fcathcrboard

fr om tu r nin g, I g lu ed a stop

FE THER O RD

SfE flG.2

FOR DB AJl.$

_ _ _

8/20/2019 Woodsmith - 070

18/32

N o. 70 

\\ hen the roller problem

wa-,

,,11,,-.1.1

con

e er nr ate d o n

buildi1ll

e xtra s i nto th .· - ta nd

IlEJGKT\IlJ\SDIDT. The roller umt

j

mounted toa large sliding

8/20/2019 Woodsmith - 070

19/32

1

t., It

3'

  o o •

72 

.614.  t.)

1 . . . . ; . . 9 : . : : . . , , _ - - . . , .

E :.; Y , :0Yl

AlSO

RtQU'tt(O;

I,

SKIn M

a  VWOOD

~   5',,· -72· [2.1a4. ft.1

k , .,,;~=.;, I : : z z ~ . . J

 f t

I

•

~ •• :It •••

72· f3

lei.   t . ,

;

.

•••r

WOOOSCtlW

e-

CROSSBAR

. . . . .

  l  

t

OOT

\

INNER

(0, SLEEVE SIDE

N 70

WOOD PARTS

A >odeSlaIEnd (2)

e

_'aI

Sides

(2)

C ....Sleev9End (2)

0.. _ S i d o 1 C 2 >

E ~COIIGCOP(l)

f 1lI i OOrS C 2 J

G ...,. I

C 2 J

H SuPPO< Arm6(2)

I .

JI)pOrt

TlQS(3)

J ~Rob 2

SUPPUEs

• I 28d

f,

0 - IhlCkHo

8/20/2019 Woodsmith - 070

20/32

~ 70

10

\

3 I, 'V

,

0'  

INNER

SUiEV£

SlOE

'- PlYWQOO

2

7

INNER SLEEVEASSEMIIlY

PUING(

GOWN. THEN

MA,I(_(

SlVRA,t.

SH ALL O W P AS SU

WITH J . - STaAtGKT arT

CORNER JOINT

$1Ol '.

,

4

CtNIIl

art

2.~..

f tOM '.£Hel

NOTt:

CUI SlOTOH

OH\

YCHt (NO

N«

otta.L 2.

- SlUT l$ToP

HOltS

-

 DiStAl f  

(NO   l

,

PEDESTAL

END

~ •• T'Ht(_1(

HA lIOWOOO

•

I

(a)

PEDESTA L

SIDE

','

PlYWOOD

I

 

I

z

  .

_,

. . .

_

 ND

-

-

-

Hf«l

1

, .

,

 T :

. . .

,'

1

3

SIO(

AU x,

( )

 (Ne[

r

  .10.

1\

 

1

,

P ED ES TA l A SS EM B LY

THE CENTER SUPPORT

 

The fir~1 step in

~ building

th e

roller

~ .....1··..

stand is to make

the

renter ...uppon This

support consis....()(

1 1 1 0 0

patt.'.

a

p•

.'d tal

a nd a n in ner sle ev e,

T a dj u, t I h~ hp i ( hl

uf

the rollers. rhe

inner ~1t.'t·Vt·...I icl .· ..inside the pedesta and is

hel d i l1 l 't. u, :( ,'w i th a ' ill R nut

1)1.I)l'. T\1 1 'tartL)d by making lh('

 ,-d.',ttl

lui

lIlt' two

pedestal end, (A)

(rum I·Ihi 1,

h,-,'

8/20/2019 Woodsmith - 070

21/32

2 1

\; . 70

2

1

ai', , h ,  ',nflll (I

easlf rtl)

ht)ld

In  ,In ,.. tl,; .,,/, ~offl'rblu

(ro m

mam nll the ..

ood

I

pu l a lend. r ash, r and a '1andard ...,her

O\ T

lh' 1> 0,11

ltd thn'2 1 U n ~ case 1110.<

  'IngaoW'

l-nut .. oI dri1Jnl .  COUll l...

I > o . . . . .

•md 

W' hole.)

S.'xl.1 cUltapenod 'ide> (onth  band

saw)

to  lake Ihe~inKnut ~

;l Si{ r (0

mb.~ Step

2. 'J'hl'n to rt  tlU t'l)Ih t'am ount of surface-co lt·

t.,·t. 1o ind ..d a 1 Pl'r on Ihe

bot tom > ide

l Tn.1-   1 )

1 ( , . _

To m a ke th e in rx -r

..leeve,

5tar1b}

nppanRihe- two omee

sleeve

ends

(C ) 1061ins ide Ihe pedestal with 1 1

u f c k

. falln

X r- xt, c ut th e- e tw o piec

e-,

to

1 l (1h (23 ). ,N FlK t

  ~ 1'1t:tt.~.After

th~ ends

ar e

cUlnllk·I,'(f. Ih,'

next

,Iep 

to

,,,I

th e in ner

sleeve Mid . (I) Stan by m~.surinl1 th~

in,ill,' width

or Ih,' l)lode.tnl. Then subtract

I VI.... W lwl t a ,, ,,· mbl .od this w ill giv e y ou

V ,

ck - ar an c e· x·lw''

8/20/2019 Woodsmith - 070

22/32

N o. iOooJsOIlIh

 

2~·

 

-- I

~

SUPPORT

ARM

111.

OWIRscaMS

GO INTO

END P IECES

(AU.SCRlWS

II x1 . .

  i)

supp a

TI £

,

C D

SUPPORT

T

Rr

 

-®

 Nll

n1S0

SUPPO

. . . .

-

AM)

I 

RADIUS

OH(NOS

 

,

t

J

. . . .

•

3>,'

~

 

SU

N~

R T

. .

S

i~

I

•

: :

l

•

  T

 

. ;

i

I

 

9

TOP VIEW

 

\ .. ·C .... aQLT

.' tONG

 --

DRlll~.

CQUNnRSUNK

SHANK HOL £ 

RtMOvt L1VruRS

ANOASSlMW

ON

A LAl SURfACE

18

7

CtrJOAOQ

 I TWUN

\ p[Nell UHES

o.

.ax1  ...• 11

WOODSCUW ........

oruu ~ 1 . ·OUNTU·......  

SUN ) H.AHI( QtU

Having co mpl et ed

th e base. Itarted

. building tb e sup

p or ts f or th e rollers.

Beginbycutting th e

~4 ' lhick support

arms (II ) an d sup

po rt ties (I) t o t he ir

  finished

dirnen-

s ions, see Fig.

  9

Then

sand a   M

ra dius O n

II

bottom co mers o f th e s u ppo rt a rms .

  \TfACI-I

Ait\tS. ~exl center th e arms on

theumersleeve, keepingthearmsflushwith

th t' l O P edge a f th e cap < I i . Now m ark th e

location of l i te SCJ C  holes so

th e

t op sc rews

go

into

th e

edge

or liltc ap (~: )a nd t he lower

ones go in to th e e dg es o f the en d pieces   e).

see Fig . 1 9. T hen dr il l c o untersu nk sh an k

ho le s a nd s cre w th e arm s 10 th e s le ev e .

,\1T AC HTI ES.To complete th e r o ll er s u p

p or t. s crew lh e th ree suppo rt tie s (I) across

th e

lO P

edg e o f th e arm s. s ee

Fig.

193.

ROLLER SUPPORTS

 5

4  

SPAC( (QUo\UY

ONaOTK tNQS

.

  . .

(ClNTtR

 ItOSS AJtS

ONOUTb:

-....:;::---~Sll£VENDS,

fWS-HON

........  _.. eonOM

O nc e th e cen ter s up -

~ pcrt iscomplete.the

next s tep is to m ake

th e base   support

~ it

Th. base is

made up o f two

parts: the

cross

bars an d th e feet

TH £ CRO SSBARS.

Starling w ith ~ . ·th ick stock, cut two

crossbars (F)

10

their fi n i shed s i ze. seeFig .

14 .The n. p o si ti o n

th e

c ro s sb ar s s o th ey 're

c en te re d a nd O us h

with

th e

bottom

o f m e

ou te r s le ev e. Now . drill four countersunk

screw ho les in each crossbar and 5

8/20/2019 Woodsmith - 070

23/32

WuoJ.smtth

ClOSS '

®  LONG

WIDE ROlLER

vtRSION

 

T(RROD

2.2'. lOHG

)

  >

PVC ItOUlRS

  1.ONG ...

) \ ;. , . 70

C_~R.-\H ,. T he 6rsl p ie.:es

th at neeed 10 b e I nlttbl'ned ar c

the two c ,-o ,. ,b a r s   I ) In st ea d 01

11 long, cut Ih(' ,e pieces 22

IO llg.111isl'x trd Il'nlttb j needed

to

kN P

th e

I fJ3I e 31 .)

WI E ROLLER ST N

II  1

1 

WOOOSC l lW>

AnACH IUISH

WITH rHOS   TtU

J

ROWR

RAIL

SAND

,- RA DIU S

OHlHDS

•

US  TlMPOttARY

SPActRIO

AUONROWRS

DURING ASSlM  l Y

SECOND:

INSIIT

to a

A,ND

AnACH

01H0t IU Il

 

. .

 t

.1_

2 , 2-

. . . .

r r

r J

• 1

F IRST :

safW CHI

llOWlIlAJl

 

SUHOIT  S

rollerssp8Ct'CIprolX r iy I put a   'fiat ..-asher

o n e ac h

e nd

o fth e ro d. see

Fig.

2 O a

T H E R A IL S. Allthar~ left to m ake ~ the

r oD e r r ai ls

(1)

Thes e

rai ls ~

,;c re w ed t o

t he s up oor t

IJl S (1 )

an d hold th e ro llers in

p la ce . U si ng ~ . · th ic k s to ck . c ut th e rails to

th eir fini sh ed s iz e. th en sa nd a I  rad ius on

t he t op c ome rs .s ee F ig . 21.

Nex t. d rill fiv e

7 / 1 6

holes on th e insid e

face O t each m il. T hes e holes ar e :}'8 -d ee p

and centered

7

apart , se e rig. 21.

Finally , s c rew one of th e rails

(J )

10th e tO P

of th e sup po rt ti es ( ll. Then in se rt the

ro U e r

assemb ues In to th is r ai l. T o kee pth e roller s

at th e correct h eigh t whil e 1

instaOed

th e

other rail. I p lact'd a II , -th ick temporary

sp acer u nd er o n(' end . see F ig . 2 1.

h ard wo od 10 ~ ... ~

see

1' 18.20. Thes e

wh ee l. c ome p re -d ri lJ ed

to the

correct size

i or th e lII steel

ro d

that

s uppOns

the rone.-.

NOle : W e are offering these wheels

t hr ou gh 11000 . , /1

P ro J « uppl~ 

se e

p ag e 3 1. O r you can mak e your own w heels

b y u sing an ad ju5 lab le circle cu ner .

To make up for any i lTeguJari t ies on th e

insi d e of Ih e lube , or th e out sid e oi the

wheels. w rap electrician 's

tape

aro un d the

wheels b efore pushing them in flush to th e

end s of the tu bes, Then pin them in place

w ith IW O 17'lfolugew ire brad s. se e Fig.2 O a

S1Ul AXlE NODS. Nex t. lO support th e

rolle 1cu t6v e pie ce s oC lll ' S t ee l rod. Each

pletti.cut

11';

Ion gan d insertedthrougb

the hoI. '

in

th e wheel Then . to keep the

20

With the rone.-   1>

p or t c omp le te d.

 

....arted working on

th e h eart of th is p ro

it...

1-the ro llers,

E ach of the

fiye

r ol le rs i s m ad e (ro m

a se ctio n o (

2 PVC

pipe. This pi pe is

u se d ( or d ra in li ne s a nd i s s o ld by th e

fOOL

CI T

RO W 'H ,

TO U

8/20/2019 Woodsmith - 070

24/32

N ,I. 70

4

S UP P UE S

• 60  lO FI

A

INCk Vw'h .re 001(

• 2 '

J; '

A

'hICk M o :s o n:' e o r

#Y'Ief

cosebOC.

• ( 0) N o 8 . I • rn WOOOIC ' 9WS

• (.: lo 7. I , l e t > t)rasaW O O d S C t e w s

• No

Oil Fhwoooserew5

• o· 8lden lC n

spong

• l

t)ross

ChOn

• ( ll> l u R S l J ' c l l ( ) Iln'V('l1llnoisturt> f r o n t seeping in

altlng lh, '

 l°rt°\ - 

and l 'I ) lt in g the woed.)

RAt .....

r) •• \, ..

t ..

The ( ,nt of the inner bin

S :o .Qrt. ,~·d up \'-lth a raised panel, 1 1 ) 'O U

ha,'c'  Itried makinz a fr am e w ith a raised

panel. lhi...

i...

J fdirJ~l'asy approach. The

frame

I'

JO ined uh < .t ub

I~non

ture rt· ,is l.tnllll,U l t. th ,· rvami::;hC'$,)

II hardware kil   av ai lab le

for the

m ail

bo x , 'c '

 ',III't

on pa ll  31

 

d o esn  t h ave a lid . Instead,

chIs

1nailb ox

is design ed tvith a n in ner b in

thaI p ivots our. T he bin is sized co h )ld m a gazines and o versized envel  )/Jes

w) th ey d o n t ha ve

to

h e fo ld ed o r lnang led) to

get chenl In and

o u t.

Mailbox

I

WEE KEN n r R 0   E C T

  ~

8/20/2019 Woodsmith - 070

25/32

. . .

 

fHWOO

s(RIW

c

~~\..d-r~

1 \ -,.-..ux;

NOTE.

ROUT 1_- CHAMf lR ..,.;

ON AU.(DOIS lACK

~( ' ACKI OOr ~~(~OG~E_~ J

j

,. s , -

f

'.'

COUNTt.RaOU I .. '

~l.-Ol(P PiVOt

HOU

 ,

,

7-

-,

f

 

,

'. PIVOT

I

OI

•

.1•

, 1 . .-

WOOOSC:lt(W

USE IA .I t C t .AMPS

to

MOlOCASI

tOGrntO

AltON TOPAND

80 OM Of C.SI.

WITH PEN(.lL UNfS

A , NO S C R E W T O C E Tl iE R

-=-.l

~~-;;H

1O.... INQS

.t,

SIDES

G

STILE

ERAU DIMENSIONS:

4'W

Jt

14' l H. 512 0

--------

0lJU

 I,  (OUNTUIOUS

AND 1 ' •• SHANK MOlLS

PIVOT

SCI W

 

....

INN£R BIN

BOTTOM

•• a 11..

_   w o o o

SCItlWS

_.-.;

PIVOT SCREW DETAIL

OUTER

CASE

SIDE

•• x

1'....

f

WOOl).

S(R1W

s.P ft IN G

•

RAIL

PANEL

 

Wilh

t i l < r,, r

pi,....,

(o r

I I... o uter case

clamped 10g( ' II . .. r , pilolholes at all

a .. .emb ly - cr ew h l\ .· . tl in n~Then SC r t 4 ' .h~

case tng\·tllt·r. '4v · ig. :4b.

re J

cover the

screws, lout

lit

plu~...trom scrap, Glue the

plu~.n

pla,· , · .

an d

trim 1 1 1 < 1 0 f lush.

. ,,,,. \11\1'. I (J ..

tart

,, ts(·111bly.draw a line

;u:ru ' . . .. IH in..ult ' (.Ift el(t il l' .. .i(t~A)

 

in

[rum lilt· tt'll {tllclbottom ends (not th(

,·h.IIII.-,).,,~ hI ' :\;, Tlu-n.clamp the case

t ( j~c·{h\ · r (1tll ' hlJ) . t l lf lbouom pieces align

with ·ht · ' ( · IJt ·nc.1111JU S . .. .. 't·I·I~.3.

 . P W O

r

OUTER CASE

BOTTOM

©

,

J

INNER

BIN

BACK

HANGER

STRIP

'G'

..

-

INNER •

IlIN Slot

•

OUTtR \ )

CASE TOP

EXPLODED~V~I E~~~V_~~=__~ ~

.'2.1',·

lh ..... SS

WOOOSCftW

OUTER SE

I

b.~dt

u ndmg I I , m a ilb o x b ) ma kill : I ll,

 I{

o r 1 1 1 ( ' 0 0 1 ( 1 '

(3~

...11'.... IO lakt..'tll,,·outer~sides(.\).

....an by ('Ullin): I~O . ~lhlrkblanksto a

fini,lu:

d w hh

o f  > V I and ro ug h l ng Ih 0 1

1 5 T l u - n c u i a

II I

a n ~ I , · . . n e a c h e n d s e t h «

u,,· r .aIlIt·n~lh' '

8/20/2019 Woodsmith - 070

26/32

No. 70

r n ow , ro ut a ra bb et on th e b ac k

7

. . .

. .) . .

-

-

8

nONT

. ~¢

  ,

l ranl l' s l ilo's.see   tpp1 in F ill. 6 .

.: 1-

~, 

r

_ _

,

-

n ,' mo r e srepon the f ront. f rame .

'IONT

I

  -

e in ner b in to p iv ot ou t v .i thoul

•

 

¥.~

e

I c, r p lane a 10 ' be> .-e lon th e I(IP

. ,

INNER BIN

90'

. .~p2UlF  1I6,

ilh the fr on l fram e co mp lel e.

SIDES

~

I1>G applied.apply

 POX)

glue

(i t' s WUICrprc.>1 ) 1 0 th o stu b ten ens o n th e

r ai l s , and damp th e fr ame a round th e p ane l.

J () I~ PKY .Th ,' f ro n l f ram e w ill b e j o in ed to

t he s id~ . 0 1 II I< 'i nn e r bin w ith a d ou ble ra b

bc 'l jo i n l. 1 '0

edgt'ufllw

1 11( ; 0

To a 11 0 th

binding. tOU

' ' ' ' l i e . .. . . . . .St

'11) -, \V

O(·xt cut 1\\

,U1d10, II,

tapc,on

th .

t h.' b a nd o; a

Nex l. eu

,idl'S by P~ ' lC

table saw',

~'jnally.,

ra bb el a lo n

'i id e p ie ce .

INNER MAIL BIN

8/20/2019 Woodsmith - 070

27/32

  >

HANGER

ST RIP

14

13 «Nno KNOBON

TOP fROHf UJl

WI A S CRA P Of

WOOD TOLML UN 

No. 70

Th e f in al '1 'P b e fu r. h an l( in g h e ma ilb ox is

1 0mount t he h ar dwa re . -ee rill. 12.Aspring

h el ps t he i nn er bm r etu rn in to th eo utercase.

A nd a ch ain k ee

 P

th e in nc rb in f rom

pulling

OU II( H) (rtr.

L oc ate an d d rill scre w h oles to m o un t th e

< ;p ri nga nd c ha in f in th e b ac k o ft he i nner bin

a nd in sid e fn ct ; o lth . o uter ca se sid es W.

se e FIll. 12. (Youcan vary t h e sp ring tension

b )' ad ju sting w here the h oles are d rilled .)

N lcr in,lalling the spring and chain.  

moun te d I ll . b ra k no bc en te re d o n the to p

rail

 f)

o ( t h.· (ro nl r am o . s ee F ig . 1 3.

:-; ,XI.

r ip a Mnl(er strip (D ) to an

O\-eraII

height 01 1 ~ ,th a

10 '

bevel 00 the LO p

~ e, F i~

11

T he n C U Iit L Ole ng th to

m atc h th e in ,id e w id th o f th e o ute r case,

: :0 .

mount the hanger strip in the

d e< ir ed lo ca tio n o n th O' fro nl o f th e h ou se .

Then s el t he ma il box on the hange rst rip and

d rill p ilo t h olM I hro U lfh th e lo p o uter c ase

shank ho le... lor N o. 12 x l~ ' roundhead

b ra wood ..: ., .. a nd s cr ew the ma il box i n

place,   t . F ill. I I

HARDWARE

NOTE:

AlJCj.H

  O liN aonOM

tlUSHwmi 1On l4 rOOI

Of   1 tO N l .1ItAM[

. 6 .  . .

EDG E AT 10' ' SCR(W

 .~a . D O U B lE RABBETETAIl

  (1OP Vlrw)

l

/ ....a

rACt DOWNON

woaK lHOt

 , 

NOTE:

S PRING

MOUNTS IN

  ,

LOCAnON

ON

oPPOSm

 1 0

CHAtN

 

snCHA IN TO S f O P ~ ~ ~ ~ N ~ N U ; : : : : : : : : : : : : ~ ~

,N ATTH( ONT (DOl

1

Of nt, OUlU

eMf TO

~~};

~4

ltAC . PIVOTHOLI

~1~  .~ ~

 

12

inner

bin. uw m s, To determine

the

lh ickn , - of lh shun.. pooh th e inner bin

against the bo tlo m o f

the

8/20/2019 Woodsmith - 070

28/32

8/20/2019 Woodsmith - 070

29/32

NOTE:

PUSH

moe

f(A't'MOao,uO

1110'HOTI'

 t •

)

11lt biRJ. t·..1p i. tt 'n ll ai l' fc .b l l 'm ' he n ripping

un

I h, ' l ab ),' '''

I ktrk/Nlrk. Kickback 1)( .

c u r- wh ,' TII h, b t ad .· m l ,'h a p i ec e

o r

stock

a n d I hn . .. .' II bat ·k 81 IOU. S io ct ' a

t ab le ,. ., . .. .

b la c l. n on , ,, '

a i > < I U I

~OOO'JIIIl.

don',

undrr

, inaatr Ih. · ( 'n' w1 th .. h ic b a sa ' blade

< 3 1 1

h url a

J I ,, · . . f w ,'

J')

p o e ,, ) 1 ) . mo'l k it kb••:k ca n be 1 r . l < . 1 . ' d

10

c.nt>c.(tIAOl,)ll.....lbk

caliCO( ~)mt· t imesasa'4'

k rf

miKhl

d ,,'

up and pioch

thebacko( th

b lade Or Ih ,' pi,..... ~ m. ' . v.edgCu ,h the

j i S '

an d

t h e : . .

t , , thr~J ,).Il.

tk' s;.,. . .

 

I II('III C,nt r;11J.:hll-dJ,te on a

board.

1 u~ a

' 1 r .l I J(h l·hn ( ' r iPJ>ing

Jig

on

th e tabl( '   3 '.

Ev, ' il

}i,,11h.I\I ·. 

join tt' r

it

ma) , b e fa ster to

n}) a ''It.liJ, l'II'1IU('(ln tht'

table

saw,

Ql ESI10\:

S.., . rh. / I .

J;n ., , I I, ,,,llff lolI/ l ,d 01,1.:0

:\ . I 1 1 ,

'Qt'lJnn.~t,Umfiq ('tJ

.tmJ lhltdlJi' .

. . ; 1

Irl ,, rhn InJfl

tl/,r.

whal'3 ,h, ht-~t 'VI I I~tIh, bfl(J_n/,.. to tl

.. , (;,,. , K

,i h'

MO•• '{PH CJtlAft A $MOOnlEft CUT

~ . r t

t Q ; Q j lJ ~

I ~ /COMB NAno~

L/

B := :LA=D~E: -_

-- --< ::::J

29

~

.too<

  'CUltl 

'OOVI.

...uoo ....

R IP 8 LA DE

N SH TH I STOCK

AHOTHI...o

f i 1 I . wt'

don) .JK n. • J(WI'\) on Ih I .1bk , ' llU,, ,

dont

  , · , . d I> b u v o ~.e'~J oUflll1.ll1l

wt...n.~...

p, - . i b I . :

  'WGHT~UNf

.' ,'NO JIO

MUI·I\C,JI l :on d

.101. ,1

ripping.

I u'< a: , · .Ih , · a m . d ,

ri p

bbd e. ,. ., Il th

o n 1 1 , b l ad e a t( ' a n ll l.'( f l orwa rd mo r e

than

on a . {rO ~'\.Il or l·,)nlbln~ltionb l ade •

-ee

drawlll~

  k .

lb · 'lRkd

Iet'th

mak ,' •

...i....ng flit. th;lt allo , \'(JU

l' ( 4'C d

quickl) · .

T

k, 'p

Ih b L l < 1 l rum b.- in o , r l03dt :d

... h h lp , a Ih, '

'I,>(k is

k d Ih ro ug h.

th e

nUrJlbt 'r f. f

I,· th 1,

kC 'j1 1el a m in imum. BU la

b lad rwl lh h ' lI I < ' , h ,' a n I .a v a l dg j ( ,' < t :d l to .

To

 ,Ivl'Ihi,

prob lem.

I

o ften u S( ' a I

0-

bind,

nl)J' in~ I< 'dU liqu• . 1make Ih t' f i r. ;1 I I

t Ij '~t)Vi'I V,t' tl-:.inJ: ,I ril)J)i11K

b lad ,· . l 1\ (, .' n I

,unll '

b k

and dean up

I he ( 'U I IO

fini,h , ' ( f

 idlh   'lill

a c ro . .. .'l'Ut

f )rCUITlb ina tion b lad{ · .

n (

kt- HI Itl...\l, ......

/\nc••llrf option ould

be I II I I. .. .. I lu n

k r1 n p b la rl . The>< -b lades

ha\'c' narro~\-r 1 t . ' t . : L h than on ...

andard

car·

b id , o W d b LJ dt- ...

T h m e an s th ~re is I ,

rt.·.....tanc:4:·  Ill'n l Uttill~. aJld ~our mol or

,huu ldn ' l

ha 'IO

lIork

a. '

hard ( Fo r mo rt '

o n t hi n k .'f f b l3 d , ' . ,., .

1\

I.

Ii :\0.

;;3.l

Qt

E..O\: t.

,,(doro>lmylah/. ,u ,

01 I   I , , .

or tlcmll lI It

Clrt Ult

I,,.. , l

1')J ry

1 1 4 II er» (INI'

tklHq

I

('lIN

.1,) t JfI'/','

bll.~IHq

a ur»

1.'

( ( 11

,I

, A ,

8/20/2019 Woodsmith - 070

30/32

N il. 7 0oodsmirh

0

NOTE:

SAW

HAlf

ClRCI .E

PIVOT BlOCK

5  , 

WORK IIC E

CROSS

SECTION

 

ARMPAmRN

NOTE:

 

PIVOT

. .

3~ 1·

 

CUT fROM IV,  

IlOClC

n 1 IC K S T O C K

1 1 .

SKANl<

W ST 

WASlt HOU

  -

 ,

_us

 

-r -

DIA

I

- .· GRtD_

_..t_

.

,

R IP I'L G JIG. Iused thesedamps to m a ke

a straight-line rippillj jig, see p ho to . (F or

more on t hi s j ig . see page 29.)

BENCIt 1l0U).I)()WNS. They also make

greathold-downs

on

a workbench.Just

drill

W '

h oles th ro ug h th e b en ch to p a nd in sta ll

T'nuts from bel ow . O r . i fyou r bench a1re-ddy

has do g holes, slip a l on g b olt with a large

w as he r u p t hr ou gh

a

d og h ol e.

T o tigh len down he arm . you can m ake

your o wn w in g n ul o ut o f w o od . see page 21.

(H ar dw ar e f or th e d am p is available fro m

II oodsmilh   roje t

S ppIiRt

see page 31.

\ \' hen us ing ih is c lamp .th eidea

lsthauhe

two s ide s

o fth e a rm a r e d i ffe re nt

l en g th s f or

various thicknesses

01

w ood . T his also ai,

low s y o u s ome fl eldbilily inw here the end o f

th e arm i s p la ce d on t he wo rk pi ec e.

mp

PROJECTS HOP

T

hiS is a

gre t

l it tl e h o ld -d own c lamp

that can be m oun ted to a w ork ben ch ,

on . drill press t ab le , o r

as

p ar t o f

a

ripping

ji g f or t he ta bl e s a w s e e e p ho to s a t righL

The clampisdesigned

with

onesideolthe

ann shorter than the other. II pivots on a

c yl in dr ic al b lo ck to a llow a r an ge o f o p tio ns

in the th ic kn es s o f Siockyo u can damp

8/20/2019 Woodsmith - 070

31/32

3 1

.~ ,)..mllh

\...

70

\ r t to u,,.Jujilrd.l fTY

\of 1 n,. ••

lIbyd r, t httHg.

q n • Orfl~.

J dI J

BY

PHONE

J

(Jrlas ter

  ,ire

u our

Toll

In order line. Phuo  orden.

canbcplat . -ed ~Jon daylhroullh

 ·nd.y. ~:QO,,\\1 10 5:00 I M

(l rItr.ll sc:.ndard

T i_ .

Bef or e r ailing , han  )'our

\I~

r M a>t~ C ard ready

 ·800 444 7002

BY MA IL

To ord.r b) mail u...·

th e

lonn

enclost d

  ' ith •

cum .1 I )~

or v.:rit~

}our order 00 a

1 =

[ . ( f>

olpapt,r . a nd s. -nd . ..

,ha

,hock

or mon .. uni t. ,. Ho .de S 3 . S O

bandlinl an d shi_ < h a J x e

with each ordcl- .J L~ r( ,.lai

tax.

S o .

n d 1 0:

 Woodsmith P r q j < > c : t

Supplict<

P.O. Box 10350

n e ; o M oin  •• lA 6(),106

ORDER INFORMATION

1

• (1 0) N it. 8 x lit. woodsm .·

w

s•

Z inC · l'l att'd,l'hillips Fla th ea d

• (24) \(1. 6 x W' Woodscrews.

Zint·

I' lal.d.

Phillips

Flathead

. 1

\0. 12x 1 · \\ 'oodsc reVo's .

•

Bra~ SlcuedRoundhead

• ( 11Ro u nd B , Kno b. I ' D ia,

•(I

b' l~n-.jon Sprins:. fi loD,ll

I

(1   lBra Cha in

765-305

Uo,.

s k o n t

Sea~

ani (3-0. tulx-) __ 83.29

HOLD-DOWN CLAMP

IVood,mith Project Supplies

i.olf,'rill~ a hard wa,... kit and a

full· ,i1.( 'pall ern n  'eded 1om ak e

Iw lt hold-doWII cL 'Ullpsas sbown

'  ) Il aK ,· :m Earh kil inrl ud es

~ ouRh hardware to m ak e two

dam l>  an d Iw elve T ·Nuts as

mounti rtg , Ial io n \\ 000

i>

  I indudlod.)

Clamp

H ard war e

770· 300 H old·Do....llClamp

H ardware .._ $6.95

• (2) l.arll~ l a,.lic Wil1jf~ub

\1 1 th

\klalln ,rt.. 3 ~

II   '1:' . T hn '3 d,o d T o A tX e p i

S ta ndard ~~ ' Boh

• (21 •

x

b~ \1a(hin~ Boh ,

AlJ.

Thr,· ••d . H rxh cad

• (2)~ \Va,h,· ,

-(..) -,,\lut~

-  12) ~'-·r·Nuts

• (2)

I'u ll· ii/. t' Arm

Pauem s

I : < i t   S6 .95

\I

,,'n ' o t -ring

  0 kit 

oo e ki .

to build tht' ~dard size Rolk-1'

.....nd

,h uwn on

page III and

.lIw lh e r kit 10 build the .. id e

KnO t'r S la nd sh own at th e bot

rum

of page 23.

(Note:

Th e

  ,I.

flathead screws for ...

 ·fllbly.and electrician s tnpe

.tt.   includ ed in eith er kll.)

Koller S tand Hardware

77() I o Sl an dard Roller

  land lI ar dw llJ'C $.149,

• [..) Large

Plastic \\ ing

Nuls

1\ith ~1elalln..aJr)

Bra

Bull Hiug('s,

S  n llp ....2 I,,)n~xl\,. Opt n

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A LA ST LOOK

 

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