8/20/2019 Woodsmith - 071

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  3 95

OTES FROM

T

SHOP

8/20/2019 Woodsmith - 071

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t - ;

7 1

\Voodsmith (ll>SN 0104..11 141

i.

pul>

lished bimonlhll'

t r- ,· b . , AVr il .J un , ', Aug .,

OCI. O C) byW ,,, lh l 'ubli.IIIIIRCo.,

2200 Grand Ave.. O~>

Moin t:>.1A

,0312

\\ tHXIsmilh I  a rcgi~lcrl·dtrademark of

\\ '\ l U C J s t n it b 1 1 tll > lh . } t i n g C o .

~COPl'rigbt

1990 by

II 'I)O( SJnichPubtl,JunM

Company,,\ll right. I'\ ..

Stlbscript iOIlS:

(J o t y e a r (6 i : su t : : - . )

::> 15 .95.

Ty,Q)~ (J2i~.uc:t') ~ ~,. Canada/foreign.

ad dS< .O\ )/ y... .. U . S. luooo;.~1lJ

8/20/2019 Woodsmith - 071

3/32

3

o 7 1

 ontents

 T ps   Technique s

 

[±]

A Specia Tips Coutes and.

si.r

gl pal tips fromfet Imru-oodioorkere:

  COllt(}urBorinq Jig, 2) A \ i,~1Helper.

.1 } Itouter Table Douels. 4) Pilot Hole

Marker. ,S)~rillg

,Yal

H rPllrh, 6) Hillgl

,\1ol/tlting Helper.

  T o y B ox

I

WIre

b ilt th is

 l oy80:1

unth kid

mind. Tw o (ul.illswble lid

su] ]Jo 3

prerent tbe dsjronl slanllnillg dOI( 1 Iall

lilllefillgers, A lid In make

it

easyto T/lnl 1?

WI'

pili

it

0)1

casters.

I

  nd Mirror

111211 hi.~l oldpdHnlld \IiI I Ol l7lakesuJI

e/e }ClIII

oddition

to (lny

dresser,

And

the

carred initia l m o ke thi» a 1 '''11

persona gift,

Hand Mirrt»:

puge

 

SbopNotes

 

IJ Roulinqc Comer Radius.e) Pho·

tOC(1)1Iransfer. J Irouinq \ ·«lte(?l .

4) H i llg e Lo ea to r P in s .

 

M u sic B o x

: s  

~\t(lI/llllln(I / I. 1leh·

and

all

ill/aiel

(I( cplil strip highlight III lid of ihi»

cl(lssir :I/u,~ilB(),~,

I Paper ripper

 

We look a ( /(e/I OIiI the 10caIdiner

(Iud (/(miglled

 

Paper Grippertha

C(1I1/;e

bu i ll

il l

s ho rt o rd er .

I Talking S ho p

  2 4  

nrf / I( lI e i nJ (I I 1 1 1 a lio ll on a se lf -ccn -

tl l illfl hinqe bit. Ptus, Ic e look

  t

Inyi11gm il board» a lid gil e o f ei o t ip s fo r

sultdin ) 01/ lathe.

 Night Light

  6  

Bllill /1 01/1 solid then y, thi« , light

Lighl atlell ajl iellllly gloll 10

  lly

1 00111,

AlI(I 1 ; /1/0111 interrhouqeoble

panels. it will (llia7)1to almos allY mood,

l S o U J C e S

  3

Ha rdicare and project suppt iee

neededforthe project» in thi»

il1sl E ,

. light Light

lIa ge 2 6

8/20/2019 Woodsmith - 071

4/32

No.71

 . ROUND OVERalT

2

gditfJr ~

.\·nl : T II~ tterll ..

, ilt /l le 1 ; Q r k~ } 7 1 1 or 1 , . . -· iil PII, . .

te r

( IO/l n/s  II,d

I l f t I ;

r.

  )Ithin-

, ( j IJi{ ( e~,tIl t s t i j f · / . . - t·;b1l.~/(·.8(}()

 J ) lr J , a x it pl1~.ottS ; (,,. tll~

I Ofl(I T

Int.

1 0,.  

.Iiy

tl} tllJIA ,

xlita/lty

 

itt I)l( t.

l

dIJJf t I.If. f,(lf

\VOOd:; 11itlll \ O, .ttl.

AllOW lIA5T

'2 

ON tAC.k rN» 10

HOUt

fKt WORJ IIrl

-

ECOND:

SUDEAlONG

r E N C E

1

Slrt f   rrett

Knli*f l,·JI. JIUIltat,a

the router t ble and the fence.

Now tum the stock 00 a nd r ou t

1 1 1

adjacent ...de, sve F i g . 2.

T he n ro ut

the

o th er s id es

in

th e

sam e m anner. F inally . rut the

dowel 10 I( ngth

8RA ktT AD lUSTS

to . . c C O M O D A T I i

.O A ltO D m

To millr h e squar e to ck I ru o a

round

dowel. press tho stock

a ~a in l th e r ou nd ....v er b it a bo ut

2 frum the Idlend. sec Fig. 1.

Then

push

Ihe 'lock 10the Idl.

s toppir lg about   from W e r ig l1 1

end.This

leaves

a

Jlat surfan

for

 oldilll( tbe stock

.rudy against

• wh en I h av e a

projecl that

re

quire> short l engt hs of hard,

w ood dow els, I m ake my ow n on

the router table. sce Fig.

I.

II

s a v e s 1 1 1 0 1 1 C Y . a n d th e

dowels'

grain and color match the ,I 01

I } , pro j , ,

I start with a square piece 01

stock

the

CXJ IC

width

and t hi ck

II('N;. h e d e si re d d Q w e ldiarn  

u-r.

but

at least four inches

I.mger than the desired IcnJ lh

To make a :Y .· -d ia m eh ,r dowel .

( o r e x amp le . f in ;1c u t s ome

 1 ,

~ tock 10 r o ug h l en ), bra ck et 10

be

adjusttd

U I

or

down

10

suit the siz « of

the

wood

beingworked

I covered the top ~dj(e 01the

shelfbrscket with. piece ofsplit

g arde n

hose to prevent marring

th e

wood, see Fig

JollII U.•

lId} ,,,,1t/

Eltgli:1hfull· , t . •

V (

U J. , Nt  t

 

 

often

need

to hold lon.l(

boards edge up

lo r

doweling,

m . rt is in J .: . o r p la n in g .

nul

it s

hard t 1

du this with

only

a n t e

vise. So. alon~ \\ Ith the \,l::i4 a t

one end o r m v b e n c h I u se an

I ne x pen si ve mda l ,hdfhrackN

al the other end to hold U I the

lon g sto ck, se e J ·ig . I

The b racke t h ouk , im o a --hi ll

s t an d a r d t h a t . ..r n o u n u -d o n

the

VISE HELPER

lour of

till

workpiece onto the

jig. keeping

the

edge 10 be

drilled parallel  ilhthe jig',

jointed edge. see tog. I.Thencut

OUI

thecontouron

the

band

saw

:\ow place the join led edge 01

thcjigon th e drill pre s s t abl e

I

the workpiece into the cutout

a re a, a nd d ri ll, s ee

~1g.

,

  ou~ xC Jr,l llxnu

I) ,rrel l/Klrl , / f l fl

• W he n 1n eed 10 dr il l accura te

holes in contoured leg. or any

odd -s ha p ed wo r k pi ec e ,   m ake a

Jig 10 hold the workpiece S

8/20/2019 Woodsmith - 071

5/32

 

• H e re s a no th er Wlly double

sided carpet tape ca n be used

a ro un d th e shop. I u se il I h('lp

accurately

aliR'

and attach

loose-pin h inges,

First. I :;crev .. l h t 11in~t·onto

th ~ door. N X I apply a layer of

carpet ta pe 1 0II , hinlt~I ,flhal

c on ta cts t he c abine t

Then . pos it ion

~,e

o oro n th e

cabinet an d pres, o n th e h inll( '

location Once tl), tap is finniy

3ll.1l· lu:d ttl  h~ 3binl'l. gt. lIl1y

t t lltnV, OIl

llingl

pin

and l ht

door. The carpel tap h uld s th e

hinll lea f

securely in place

fo r

p ilo t h ole d ril li ng a nd o utlininl

fur mor t ising .

TIlis ICdlOiquc c an .lsC l

be

used fo r tighl pin hinge, N ler

pr(~SSiing

fin nly o n Ih l : h in ge 1 0

c at io n . v er y C:lI\'fully open Ihe

cloorand

 llPPUrt it

whi)(\

YOll

at-

tach t he h iD~C10 Ihe cabinet.

Jo/ , lI e./ ,k

11tJul r f i r. ( /ortl t ln

HINGE HELP

in

the pre-dr i lled

shank

ho le and

tap thepunc h to mark th ~ center

ofdw pi lo l ho le . s c.>Fill. ta.

H( f 1 11

S,

01

/> 1

[Joyl m OMo

\XloodstUtth

2

th e wrench with a ro uter an d a

V4

round-over bit .

This

wrench lighten

% an d

sm aller w ing nuts, IIal , work

w ell tighle ning the thumb

screw s, like th ose that lock a

fence in place on the back of

the

radial

am' saw tabl....

t Y f it C : r

E. S r / U l 't d ll t

r

$rofl.4.,.'8.11 ,s

No. 71

.).- Of., HOLE

 

,

 

wid e. A V. .w id e dado blade

centered on the thickness of th e

s to ck w i ll

cuuhe

slot in om

P.1SS

You c o uld a ls o ma ke tw o p as se s

with

a s tandar d 1 r s· ·w id rb lade .

A fte r c ullin g th e slo t, cu i th e

stock 10 a1- shape on Ih. band

saw. so the hair and ~Io l are al

th e b as e o f t he 1 .

  '1 S < 0 m uch rorq uc thar yo u

have

1

b e c ar efu l n ul lo s na p

oU

t he win l( nu ts .

T - ( . make the

wrench,   cut scme 1

:It,, ·lhick ~lotk Y ' . : '

SCluart . s rc

f·jg.

1.

3 2

NeKt. I bored a 31 .

diam cler hol~ '

ccnlcr(.~d ill

Itl ~

 lId

graill.

Iv

(I( rp.

Then I widened UIC

op

tinue to pubtish otherTlpsendTechniques

to o. an d pay upon publ katio n $ 15 10 $)0 0 fo r

tlI ,  \t ' tip  based on the pubUsh,'IIlellgtll.

rA P PU NCH

TO MARK FOR

91101 HOU;:

 RE ·OJUUlD

S NK OII

a.

large to fil through the shank

hole. a nd th in a w ls ar e 100smal l

to beaccurate. Tosolve th e prob

l er n, I u se an a lte re d mach in is t's

pin punch.

P in p un ch es arc

available

at

most

harrlwflrestorcs.andcome

in the sa me d iam ete rs as drill

 /

~ GRlND 11 TO

DlAMfTJR OF

Pll,OT HOU

  tt

B IT

/

• W hea joining tw u pieces of

wood wit l lsc rews . I l ik e t o d r il l a

shank hole in th e lop o r fr on t

p ic 'c and

a

pilol hole in th e

an

chor piece. B ut it s diffic ull to

m ark th e p ilo t h ole SA) l t' s ac cu

fa ll 'ly c en t e r ed

on w.

shank

hole. C . nttr p un ches are 1

PILOT HOLE MARKER

  'fallY W r J < ) { / i t il readers tell u s th ey 'r e

very interested in m ak ing pr jecL~for the

shop. So. for the nex t few issues, we'll ask

)'l\u Ior tips and techniquescn solvingdi{fer·

ent shop problems.

\V ell rea d } o ur tip s an d ttl them out U p

to three oith best tips

in

each ca tegory

will

be awarded a Woodtlllitif

M aster

Try

Square. Dup lica te orv ery sim ilartipswm be

considered in the orderwc receive them.

SHOP TIPS CONTEST

8/20/2019 Woodsmith - 071

6/32

No,71

oodSOlnh

re rn storth e lettersand numbersand acompletehard

ware

kit

for the

lOy

bo x. see

 oU ,.,5,

P38< 31.

HARI)WARF . .

There s actually m ore h ard ware o n

th is p ro jt C t th an me ets

th e e ye .

The

lids

ar e

a ua c h ed

to th e sides w ith pian o h in ges. an d supported with

slow-closing

l id suppor ts .

T he re s a fa ls e b otto m

that

restson adjustable sh el f s uppo rt s. A nd th e r ea l bouom

l sp os itio n ed toa ll ew ro om fo rc as te rs ( so Mom

or

Dad

c an ro ll th e to v

bo x

to w he re th e

mess

is  ,

nN SU On ~of theadvanUlgCS ofusingrnapleis th l

it p res en ts a g oo d s urfa ce

for

painting. I p ain

led

th e

boxes with br igh t p r iR l a ryco lo r s , A f te r thepa in t d r ied .

I a p p lie d tw o c o ats o f gloss poiyure l l lane varnish  

t h e e n tire toy bo x 10 protect th e

paint

from chipping .

T

iSIO) box lookss o much li ke a la ),. il m ig h l e ve n

gel used 

Apart I rom looki ng l ik e

.101 of

fun.

we

tried

10 design

it

with

kids

in

mind . T he lid s

  r

SUi>

ported with slow-closing lidsupports so th ey w on I

slam o n little fin ge rs. C urio us fin ge rs w ill a lso fin d

ro und ed

e d g e s

b oth in sid e a nd

out.

And ,

th e

bottom

re sts o n a dju sta bl e s he lf s up po rts s o il c an b e

raised

fa r

e ve n th e s h or te st a rm s 10 re ac h th e b ou om ,

CONSTRC cn O I(. T he con structio n o f th e bo x is

fairlys imple. Weus e d maple plywood l or t he s id e s a n d

added

solid

maple s tr ip s  llhe comers SOwe c ou ld

roun d th em over. The fron t and back h ave m itere d

frames with a large glued-on letter and Dumber.

 WIIO

8/20/2019 Woodsmith - 071

7/32

7

ooJ;mnho,71

ALSOUQUlRII),

I SHE.fTC4 .. 81 Of

3 ....

PlYWOOD

~.~m(l·. 4 } OfI.  MASONrrt

L :

r:::£:

E :-3

~ C oS··

4 1 1.7ad. fl.

f : · 1

:t )

0 , } .

t   If jI/.~

W OO D PA RTS

A

Sldef'onel;(2)

>

piy. 2 > re

x2Q v..

8 End_

  4PY

2 0 > , .

x 2lV;

C Edg Sin .  4)   1 .  If,K22

D Bottom(l) ol

8/20/2019 Woodsmith - 071

8/32

8

Woodsmirh

No. il

2 1·

SUOfItl

aonOM

 [ OU

/lnActUNG

cmGtNOt ANR

BOlTOM

19~. 

ND

PANEL

®

BOTTOM

CIM\P

ACROSS

ENOPANR

-

••_

@

', -

' 40'

\OIpANR

NA IL wrtH 1 T 1

flNJSH NAIlS

•

SlOf

P A l < I l . . . , , ' ; '   .   ' ' ' ' ' ' ' '4 ~ t . .

(a .

4

CROSS SECTION

SECOND:

 ·UT

AU .

fOUR

BlANKS 10 RNtSHEO

W10TM OF-, 1 1 .

,

~

 

@EDGING

,.

STRIP

3

l t e n

t fNDS

 

_

,

-

 

SIDE

PANEL

_ SIDE ENO_

PANn PANn

 .  

a

,. J

FIRST:

GLUE   ....

3-....

2

NOTE:

., -

  OWOOO lDGING

20 4  

. .. . lDGINGU9

r

 ST~IPSTOAll roUR

. , .

PlYWOOD tA NkS

 

j

 

6 

TllM

@f

l i

t

 

IDE/END SID£

®

 2

BLANK

PANEl.

END

1MAK£olntl

PANEL

Iegan buil

8/20/2019 Woodsmith - 071

9/32

L .A

ROUTCOONlUClOCKWiS ; D

r

ON OUTfi t lOGE  

SlOt:

PANn

@

No. 71

A

ra l

s e• bo uom ca n b ea dd ed to m a ke t he

toy,

accessib le {o r smal le r chi ldren ,

The

size

nf I I, ,, fa lse bottom

(I )

can be

d eterm in ed a fter th e b ox isa ssem bled . S tar t

by m e as ur in g th e in sid e d im e ns io n s, >i( t

r ig.

9.Then

< .

F ig . S .

Shop

NOI~ :

T o he lp k ee p l h~ r oo te r f nlO lli fJp inginto the

panel ,

I

placed a :V~ - thickempo ra r y space r

i ns id e 1 1 1

8/20/2019 Woodsmith - 071

10/32

No,71

V dsnuth

0

SANOlOG(S

SMOOTH

WT OUl e.rnt~ AND

R rMOV I: APEA PATTUN

5

WE l£T ItR TO

16  16- PileI

OF t _ MASONITE

lOUT ~~..

ROUND'()VUt

ONaonOM too S

ANOHANO HOlE

NOTt:

OONOT~NO

OvtalOlIOM

toot

Of :

HtNGf SntlP

 3 ttOUJ A ' 

II

8/20/2019 Woodsmith - 071

11/32

II

aoTtOM

I ..

UI

SUPPO RT

 

~

:r

f

 

l 

a

1

',

9

 

uo

 1'16 hick)

an d

2 lonll. T hen . center the

pad s o n t he en d p an elsand nail th em i np l ac e

wi ll . smal l

b ra ds . s ee F ig . lSa.

Finally, appl) '

a C031of polyurethane (0 II II' level ing pads.

ATt M:H IJI)S.One. the pad s a re in p l:.ce.

th e lid s can be screwed 10 th e h in ge s. To

mark

th e

hin ge s crew

h ole le catien s in

the

ends ofeach lid. 1used lccatorplns.seeShcp

N O les . p ag e 1 7. P ositio n Ihe lids on Ilw

h in ge s SO

the sidl'-Io-side

gaps

and the

gap

b etw e en t he p u ll s tr ip s (J)

ar e

the

sa m e.

After th e e nd h olt' lo ca tio ns a rc m a rk ed .

drill

a p ilo l h ole f or e a ch screw. Then . secu re

each lit with

IW O

No.4 x ~' woodscrews.

NexL

driU

the

remaining

pilol holcswith the

hinge

bit

a nd i ns tall the

re st

of the scr ews .

PAINT fRAME

'ACIONlY

PAINT

una

 

ANOFRAMt-

f-Ael  M\lCOlOR

No.71

CASTER

20

 

IKSTAU. un SlIPPORTS. ()ore tilt.. lids arr

fastened. the

lid

$UpJXlnS ca n be

installed.

T he lid

supports

I cho w h av e

three

fe atures

lI.al I re ally like. 1~ 1'S l,I he y e as e th e lid s

down s lo w l y S ec on d . t he l l '1 a d ju s ta b le

so

as kids gel o ld er . th e lid s c an c lo se f as te r.

Third.

the su pp orts

have

a de te nt posit ion

th at locks thl' lld s open.

1'0

ins ta l l the

sut>

pan•. I.)'nutthe

hole locations

on each

lid

and end panel

(B), S

Fi g. 19 . The n. d ri ll

pilot holes

 I

used the

hinge b it a ga in ) a nd

(a sten th e s up ports in p la ce.

c;STAU.~TE RS. Finally . 10m ak e the (0)'

box (? d~yo mov e a ro u nd .] i ns ta ll ed l-asters

on tile bouom

(1),

A tl.ach a caster 1V .l   in

from ea ch in sid e c orn er. s ee

fig.

20 .

MASK ARtA UNDO:

l£T1U. WORE PAJNTINGfAa

MASKlDOU

FIRST :

cumo

Lm 1 II

WfTHtN

~fANO

t1tAClwrrn

ptNCll

11

blue gl~ss SI> '' 'Yenamel.)

A TTA C H I- ITE R A l< ll m IMR E R , 'Vith the

painling c omp lete. remov e a ll rh e m a sk in g

materi als and lil lie Ihe lencr a nd number

on to th e en d p an els .

APPLY

po'.\'ultf;n. '~.~inally. ap p ly

IwO

co ats

of

gloss

po lvurethane

to th e

entire

lOy

box

(including

tilt

painted _»J. sa nding

1i (luJI'

between the

coats.

WHIT t

BA CKGROUN.D

6

a nd th e tcu cr er n um ber w ith a b rig ht color.

Before th e p ain t ca n be app li ed

to

the fa ce o (

t he f rames. the edges o f t he fra mes m ust be

masked 0[. se e Fig. 16.,. To do Ihis, run a

strip

o f m a sk in g

tape around the

molde d

edges of the frames. T he n, m a sk offthe en d

and side panels . Once this is d on e. p ain t ihe

raised (ace o( each frame and the leuer or

n umbe r wah th e s ameco lo r, 0 used red an d

..--HINGE

UYWNG 0,

PAD

s( A.EWMING

TO 'O X F 1R .S T.

tM:N'OUO

r.-.lEV£UNG

.N/ PAD

The

f ina l step

I s t o

atta ch

the lid s (w it h piano

hi nges), th e lid supports an d the casters,

ISSTM.l.IIIN :ES.

I

crewed

p ia no h inJ(es

on the s id e p an els (A ) a nd then atta ch ed the

lid s

to

the hlngcs.Start

by Clltting

the ) V z ·

w ide p ia no hin ges to f it each s id e p anel and

screwthem

in

place,see ~ig. 18.0 useda

se lf-centering '

hinge

bi t to drill

the

hinge

screw

holes,

S I C

Ta lk in g Shop , page 24).

1. 1-: \1- :l UDS.

T o m ak e p ositio ning of the

t ids eas ier. I fi l'$lleveled them nush with th e

lOP

of the lO y

box,

S in ce th e lid s s ito n h in g es ,

IW O leveling pa ds (K) ar e attached to the

lop

edge

of each en d p an el (B ), see F ig. IS .

To do

this. cu t the pad s the sam e thick·

n es s a s th e h in ge k nu ck le s (m in e me as ure d

H R W RE

 INIS

Before I glu ed th e le tte r a nd

number

10 th e

e nd p an els . I ap plied a

finish

1 0 th e lo y

box.

To a chie ve the took of a k id' sbuilding b lock .

the end p an els and the (aces o( the fra me>

ar c

pai nte d.s ee F ig .

16.

MASK'S :. 8< (0 the

end panels

can be

pa inted . th e lo y b ox must .

be

mas ked 0[.

S Ian

by

masking

o f feach

en d

panel (B )

where the le llcror number wi ll be located In

prov id e

an unfinished

surface

m glu e to. T o

d o this , cen ter a letter

or number

on each

endpanel and t race [ igh ll yl lt t> l Iod i t,

> <

r r g

17 .Then .

mas k

o f f a

rough

area

within

th~

traced

outline,

Next, l r na s ked o ff th e e dg e> 'and (aCl'>' o(

t he f rame pieces, an d cove red t h r es t o (l lI e

box

with

newspaper.

PAJNT PA. T.LS.

After the panels are

masked of f, p ai nt c an

be applied. I sprayed

on

IW O

c oa ts o f wh ite gloss en am el (rom an

ae ro sol can.

After th e s econd coat

is dJ)'. r e

move th e m a sk ing materials.

PA INTFIIA.'IES ASDlETTERINUM B E1 .nle

next SICPis to p aint th e (act'Sorthc f rames

THKKNtSS

Of - 2 ....

uvtuNC PAD MA1CH:ES

TH)Q(N S 01 k:rNaE KNUCJ

8/20/2019 Woodsmith - 071

12/32

No.71

.,odSllllth

1

PAnERN

>1

  .

~

 

.

ST~

- POINT

 

3·

~C E N T E R

POINT

~

7  .

3 . .

~

•

 

IEVlLlOGlA S

2),-1. .

MIRROR rrs  W

the distance between lIw bit and the pin. you can rout

IW O

conccnmc c ir c le s

Another chal 'ng~ (and Ihis nn~', optional) Is

c arv in g rb e in iliA Io n Ih .· b ac k. T o c arv o l he in iria l l

used a router and straight bi . and then textured the

backgroundb)'h~ Onpage15

we'

includedstep

by-step insrructions furthisprocedure

T

hert wert a couple   f challenges in making'this

hand mirror. First.   had 10IiRureawaytocunhe

outside lOp edge 10 u perfect circle. And then how 10

r o u t a c ir cu la r recc..... f o r a

roUI

mirror,

The so leuon

1 both

or

these-

p rob lems i s

1

u se a

pivotpm

 I n 1

3. router

  ~~Ota[j lg- th e

router around

th e p in . you c an r ou t p e rf l. .: 1circles. Then, by vllryin~

The trick co cucring m e

lOP

o f th is

mirror to a

perfec t c ircle

revolves around a siln ple p iv ot /)in. Once ) 'OU know m e secret, ie's an

e a s~ w e e k e nc l p ro je ct th at makes a g rea t gift .

Hand Mirror

PROJECTEEKEND

G.I-O

.11t ) ; -) 0 ) ~h >;lTl

11

thiR

,)fJ/./,...-t1  

fJ r

0

f Jltt

- 1

 t le d

fh

~Oit,

Tlml

ill

iI'

f}

Ih /tl ld

ill t l

ItJl lin i,d ,,'hiU   . ; g

0 right ),-r ,ljrJl' ' omb ing

I ,....

rOO'd 'lifI·luuuvd P

) , .U/

oot Il,.. pull ,. /llld

lAYO flip ;/OfI YROIJ,. ho dlrtut 1ls

ON ~

)I qlhf

8/20/2019 Woodsmith - 071

13/32

 ooJ,nllth

o.71

T1 OUGH

fOil GlUE

• • •

I,· ¢-..

J

$1 RA1GHT atT

l hen p ivo t th. ..mu ter a round

th e

c irc le unt il

y ou reach th e sto p p oim .

R C p { a l t h is p r oc e s s,

lowering

th e b it

I,I~

( or Ie ss ) b erw e e n p as ss e ' u ntil

th.. .bi t

CUb

Ihrough the hlank.se -e I ll .3a.

1{01T )IIRROR R,:CE . Next. to rout lilt'

r ec es s to rr he m i rr or , r es et t he b it ~'It; Jeep.

and , . . i ti on t hent he rp iv ct

hule

 In

ove rt h v

brad. \[0\\  ro ut a r JlitIJ[~ /t~irrk-,

sec

Fig. 4.

 This w ill rout .. groove  -;;

a

1I16 -t~p

nm a kin g th e h and m lrr or is te

rep la ce y ou r m uter b as e p late w ith a s ho p

ma de p la te . T h e n ewp la te n ee ds

 

b e larger

than the original so il ca n tw S C I o ve r a p i vo t

p in . T h en it's

u se d lo r r ou tin g

lilt circular

s ha pe a ro un d tht:- to p ()rtht~hand

mirro r and

recesses

(o r

thegl~s mirror

and

carving.

1l,.\SE . 1.A .._1

cut the

11(. \\base

ptnte from

a pic... 01 v f'ic ig l: c, ( ur u se M a so nitv ) tu

a width 016 a nd 7 '# .' lo nll. set I'il . I.

Now, cen te r

your

router's

original base

plate  v r th e ne w

pial

8/20/2019 Woodsmith - 071

14/32

\Voodsmilh

4

Glut M JRRO R D OW N

WITH THIN 8I: AD

Of  lUCON l  (A\.Am

U N IF O R M G AP ~u

AAOUNO (DOE Of MIRROR

~ 

,rvlL(O G t.A SS M IA.OR

S HO UlD .' 1ttaS SIO U GHTl 'l

1 0

(tNllR a.tV tllO

G L A S S

M J R R C H ltN

  JlfClSS

 ~

RO UNO ·OvtR

on

 

t

a  

OUTIUUHOst

WT1l i

I.., ROOHD -O VE R lIT

 

IlfMOV fROM

PI. ' rWOOO

7

WORK IN

COUN'l t l lC ,OC Irimc l(>rof

th carving   t this t ime with a s ln lig h t b iL

St... the ~t~b)' ' ' ;(cp instructions fo r

carving

on

th e

opposite

page. )

cur m SIW'F_ O nce all o f t ro utin g is

com pl e te . the h a n d le c a n be CU I LOs ha pe O n

th e

b an d s aw .

set

FIJl .7.1 slat ted by cutt ing

about l ts outs ide the L'YOUI t ine.

SAN TO FI~J\t SI-IArat..

N t > : t mount it

sa nd in g d ru m in

th e

d rill p re ss a nd s an d up

to the outl in e o nh e ha n dle . s ee F ig . 8 . D o n 't

sand

th e

circular

(top)

part

o f t m irro r o r

Y m a y g o UlJ c

it

o u t

o  

r o u n d .Ju s t

san d so

t bere 'sa smooth t rans it ion

b etw e en ~ te

mir·

ro r circle and the handle. see Fig. Sa.

III

u.. OS~ ruG :.   lter the handle

was

sanded to f in al s ha pe . I TOUlt'd3Wil

bullnose

p ro fi le a ll th e w ay a ro u nd Ut e e n ti re p ie ce ,

s e e Fig.

9.

T o d o

this,

m o u n r a ~ r o u n d- ov e r

bit in t route r ta b le a n d s et i t lY IS b o v e the

ta ble , sec F og.93 .

The n r out both the-top

an d

bouom

edges

o f the m irro r. A ile r ro uting. lighlly hand

sand the

edge 10

remove the Rat spot

at the

cen ter. but don 't round over th e edges.

Here, you w am a

crisp

line.

FIN ISII . Before rnountinz th e beveled

g ta ss m irror.

 

i n ish

8/20/2019 Woodsmith - 071

15/32

15

'ih) (1( i smnh

o . 71

f l l 1 3

C ]

£ r q : J {  

J 1 £ 9v[

  l \ P Q9 S -t u 0/ 'W X

Y

z

6

Final »,

stipple 1 1 1 /

tne bur};.

grt t

1 1.  t~

g

ft -Y .,.~~r ~l/lnIJ~T lui

sel.

Holel/lle

I la il .C I . .

/>rightll)fd Inpjirmly

1(ltl l l  

hammer.

U SE EV EN

 USSURt

5

s 80}lflllhe e d g < l 8 ofl lLe letter. To

dotili. ./II)W

I I

sidea/I' lIa.l.e  at

/1#

i l l lt ul /Ute

a

nd .. b tl le .I t I 'I ' r dg , a /,h r

le tte r I In l. 1 I hEu'ro ,roul/ tWd.

 

~ - - - -

4

R f ' 1 1 1 0 1 ~ lr1· ,111sa le 1 / . . . . , 'OI,If r

 )il..

11

nt l

/Jt(') p t

I o ff le t / t ; I IXft t . t rJt .

1 )lu911;,vJl pill hlJlp   Iitl l

~/ir'eY'fro)

t d t

of

b illllk .  4   1 1$ $

Ol'OI17fdt  lf outsid» ty/glf

a

lu letter. Cflt a.~

r lusc  til

pD. ' {s lb t l' ' fY i / I, IJ ld t l J l1 / I,ng

f lU lrf t(·r.

So

Iry

a

cUllpl~dif fe1 ( 'n lCOm binat ions

of

nail

se t si1 '~ an d depth s o n a scrap piece to SL'<

whichyou l ik e b e st. T h e tr ic kto a gc od b ac k

ground Is unifo rm do t placemen t

a n d d e pt h.

2

Alia flill~rfXIllpnl

in

cj,'t:'J(lQ)ldu

lll

lililil

r bber ce'~le'~l

r Hllmy t'lllllf '

sire.Cut a. Ul l d outsid« . d g of th»l~tl;lr

' '' il II 11017 ' t li f • . D i s ca rd bad (gTQu>td.

1

7 1 ' 0 1 1 t perimrtrr of tt» t l'rf'1fAjilr(111

initio], SCI ' bllll/}; /V

ply ,

  I I

lltY l r

.~;.(/eoen. R01~fa

~'/n:· d . r e p

rii ( (~

b y

s (f ling 1 '; '' 01/1011

 IJ

OIl 'h e1'11'011 ; > 1

lO U T IN CO U N TtR :·

CLOC WISe OUtKTKm

fir.t

d rn w a

centerline

d ow n th e back o f th e

mirror through the pivotpin . Next.press the

c en te rp oin t o f th e leite r pauern dow n o ve r

th e pivot pin.Then, align l it e center li nes on

the pattern

and th e

mirror back . N ow th e

pattern is in p o si ti on to be glu ed d ow n .

~ 'PPtJSG. To enhance the letter. I

s t ipp l ed o rdoued th e background w ith nail

s et. s ec p h ot o. I fou n d th a t b y f irm l y t app in g

a~ nail set.I created a very tlifferent look

than Ij t)(

from

ligh t ly t app ing a

Itll{'

nail

set.

C

arving

an

in itial

on the backof'the

rnir

rormakes

ita morepersonal tift-yet

the carving isn't 311that difficult. In the

steps below, l'vc done almost th e w ho le

job with a router,

Full-s iz e p atte rn s o f t h e IN t er s ai ih e bOI·

tom of the paxe are

available

from

Wood .'m ,I I, P ro je c t

i ' . lfJlp/;eo . s ee ag e

31

They

come

printed with

a centerline and

cen te rpo int.

so t )1I ,y 'r c

ea$} ' to

aliR n .

L£' TER AlJGNM  'T.

To a lig n Ih e

le ll e r ,

Routing etters

U E

ECHNIOUTER

8/20/2019 Woodsmith - 071

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No.71

-\ ~ APPLY HUlT

.....__ __UNlllOUJUNE

IS T RA N Sf t • • l D

TA PE PHOlO(OP't

0 PAntRN IN PlACL

 

SUlReN

ONHlGHlSl

KEATStmNG

COP)',

which p uts m ore toner on

th e paper.

HO\\ ro. To use this tech-

-lque. set the iron on i t's highest

setting and 13Jll the photocopy

fate do wn o n

th e

workpiece,

Then  iron th e back

of

the

photocopy

un ttl

some of

th e

loner releases (rom th e paper.

Note: This tC< 'h n iq u l'

will

pro

duce a mirror im age. For an ex

planalion o( how

L O

gel a non

mirrored image (such as fo r IN·

ters). see

l\ od.,milll

No . 4 7 .

• 'Vile ) hearne ti n It tocarve tile

tid

fo r

the Music

Box .

I wanted

to

make

a

few

practice

designs.

bull didn twant roredrawthem.

llEAT TRAl\SFER. Then I r....

membered a

ti p

that appeared in

Il uoditmilil No. 45 in olving th e

use of an iron to tr an sf er a pat

tern from a phetocopy. The

secret is the

tl Jl

oftaner phOIO

copiersuse-

it s

heat

se n sitive

By r ea p pl ying heal som e  

th e

tonertransfers

to

theworkpiece.

I fo und

it best to makea dark

1

ftACk· ROUTONE

TO tWO INCK£5

iN fROM [ND

------~~

C RA P PIECE

router can ride

along

the bottom

edge of th e sid e piece bUL st ill

needs

support te) avo id t iP I )i n ll .

SoIilascrappiecein the recess

01 th e b ottom . >1 , Fig.2.

To avoid t.he problem of

cbipout. first back-rout the

ourleed side. This involves

making the f ir s t router p a s s

across

the

I in al

inch

or

twoojthe

ounccd (rij: hL · hand)  n in a

right-to-left mo tio n. s ee Fig. 2a .

111cn. when the router is fed

across the

workpiece

in the

proper

direction

OcfHo-righl).it

won t split a ch unk o ff th e frame

. . fro ... _  J

asn esns m tne cut.see+ig.....

~.ono .

2

Sh op N ote : T o rOU Ith e ra dius

on the Toy Box. I first made a

replacement base oj   4 M.·

sonite for the router. (~1oSt

router bases aren

 

pre-drille-d  

accept a · 1 4 round-over bh.)

Tl/P~ R \MEtOIlo~~ 

o ro ut

the r ad iu s on th e

lOp

corners of

the frames. first clamp two

square-corn ered p ieces o f s crap

across 111 ~corner 

I < . C

Fig. I.

Then rmu the radius in sev .... 

Hglll passes. lowering the

bit

slightly between P3 .

1l(l1 T()~1COR. (ERS. routed

the bouom comers next, bU Id id

th em a liltlediffcrcmly .H e re t he

PHOTOCOPY TRANSFER

AOUT~ROM

lEFT TO IUGMT IN

S V[RAl PASSU

Cl ,A M p S CR AP PiECE

ONlOl SIO[S

Of

flWo\E

lOp  

1

 HtPOUT PROBL£MS. Since

th e round-over bit (in this case a

1=: 1 bill

terms

iheradiusby

culling ONYI the corner -

rather than I 1>tlll 1 lh( l corner

- there's a

tendency (or

th e

wood

10 splh away on the

ouueed

side

of th e workpiece.

Bunhere sa way to prevent this,

an d also 10 k eep th e rou ter (rom

tipping o n th e 1,lgc o f th e f ram e.

SCRAP~IND\\1Cn.  lne trick

involves sandwichin.~(he work

piece between

IwO

pieces of

scrap, S < . < Fig. 1.T he rou ter w ill

still produce chipout. bU I on th e

S C r - d P pieces, nouhe wor kpiece.

• As I w as mak ing the To), 13 0x

show n on p ag e 6 .1 had torout a

large rad iu s o n the com ers of

each side lrame. Ordinarily you

('30 usea band S;.1.W.sabre-saw, or

a rasp

to

rough cut the radius.

andrhen sandit  moath.

1.)0inl(

this

freehand workS

fine when you only need 10

radius a couple u l corners, B ut

(o r

the

To), B ox , I wanted

to

mdiu. all (our corners of both

f ramcs-s- tight radius cuts alto

getlwr.

A nd .

since I

WUl '1,'d

the

radius to

be

a perfect ar c. I de

cided to

make them

using a

round -over bi t i n the rou ter

ROUTING A CORNER RADIUS

Shop Notes

S HOPURRO MIP S

O 

8/20/2019 Woodsmith - 071

17/32

17

SECOND:

PRESS UD

DOWN TO

MAK[

IMPRlS510N

 

•

2

th e h in ge flap , se e F ig . 2 . N ex t.

Il< ,,,itionthe lid on the case and

p re s s d o w n s o the p i n s le a v e im

p re ss io ns o n the

inside

or

th e

lids. Then . open up th e lid , r -

mov e th e lo ca to r p in s, a nd d rill

the pilo t holes .

ling offmost of the threads on a

couple of extra hiogt·

screws,

Then. I ftled th e cut ends of 01<

screws to a fin e p oin t.

S Fig. I.

t

SL CTIlEPINS.To use tbe lo

cate r pin s. place on, pin in the

e nd h ol es

of

th e hing( and

do, ,

wooo-rAC£.O

\ I1Sf

I

 

Nil. 7 1

  c am e a cro ss a c ommo n prob-

10mwhile Iw~3naching the lids

10 the roy Box

case.

I had

al ·

r ea dy mount ed the b in ge s o nt o

t h e c a st . and ne ed ed t o p re -d ri ll

and screw thelids tothe hinws.

TIle probk-m

i s fUU can t

mark

LOCATOR PINS

fiRST:

POstT ION

LID

-X ACTOOR

OTttE1lSHAap

XNlfl

APPLY fYIN

C OA T O F Y tL l.OW....... ....._ 1

GlUII TO WOlUCl tt«

CUfvtNt£1t

lARGER THAN

WORKPf(CE

PI.OltCf

IAS[W1TH

AWMQIIUM f O G .

.

KtEP,ftON

MOVf~oa

VU4 J

MAYIURN

1

the hinge hole locations on th c

lid once th e lid b set inposition.

I n eed ed a way 10 locate th e ex ac t

center or Ih e hi n ll e h oles o n th ,·

li ds w ith ou t opening them up ,

,\IAI)~ FKOM SCREWS.

To do

this, I madelocator p i n s b y cut-

stan by placing the veneer on

the glut.>dworkpiece. see F ig. I

Then.

10 keep

the veneer from

moving. I p ta e e t he iron o ve r one

comer un ti lt he veneer s lays

DU I.

Now ,

w

ith th ~ corne r   tacked

down. move lb~\iron slowly

bac k an d lonh acro ss t he piece

until th e g lue

i 

et

  Ie:

 

A'avingtheircmin

pl

ac.,

may

eause

tl u - v en e er t o

bunt.

finally. Dip th e workpiece

over

and.

u~jnRa sharp knife,

tr im th v en ver flu sh with Ill<

sides,

set:

I~ (.2.

1

steam s e tti n g is turned o ff. N o te :

Tokeep (romgettinl(l:lu~ un

th e

base o lth c iro n. you may want I

co ver il w ith aluminum Joi l.

While th e i ron is wamlin. . : un ,

cu t Ih e v en eer

so

it

slightly

larger man 111ework piec e, Then

apl l) glue   th e w ork piece .

 I

u se y ellow woodworkln g glup.)

U se just e no ug h g lu e   U   butter

th e surface , so Ih grain ~1 I( m

ba re tys howsthrough,

TACK0)

8/20/2019 Woodsmith - 071

18/32

_J  .  __

 , -

t

-. . . . . .

 t 

18

No.71

X'ood and a rough length of24 .

RO L I< D O V ER E DG E.

A lte r th o

blank

is

CU I

10 size, rout a I I   r ou nd -o ve rw it h a shoulder

along

one

edge. S(. C Fig . la . A d ju st th e b it s o

a   . shoulder Is le ft on th e bot tom edge of

th e b lan k to form th e b ase of th e musk box.

SHADOW UNE. After ro utin g th e round

over, th e next

step

is to rout a shadow line

a ro un d I he / lI oul  id~ c dg~ o f t h e b la n k.

S I < .

rig. lb . T o d o th is. I u sed a   straigh t bit,

a nd a dju ste d th e b it to s tic k u p W ' ab ov e th e

rou te r ta ble .

Once

th e height is s et, a dju st

th e fe nce

>0

th e b it rou ts a  V16 ·wideabbet

on the ou ts id e f ac e o[lh. blank.

11 'SERUP.The n ex t s te p is 1 0r ou ta lip , o n

Ih e r O il

  ~idt

dge. for lhe P le x ig la s du st

covenosit on . sre F ig lc. S in ce th is lip i s t he

sa m e d ep th a s t he s ha do w lin e, th e h eig ht o f

th e rou te r b it d oesn 't h av e 10 b e c ha ng ed .

S imp ly m ove th e fe nce ove r to m ake a V~··

wide rabbet .

THE BLAN K

T

he r ea l r ea so n I

w

an te d to b uild th ls

music box wasto exper iment with two

techniques 1seldom get th e c ha nc e to try-

working with ve ne er a n d chip carving.

It

was

great fun to try these techniques on tbe

sm al l lid . a nd J didn 't have to wony about a

m a jo r e ff or t. ( Fo rr no re on th e se techniques,

s ee S ho p

NOI. on

p ag e 17.)

Another challenge   '11$trying to figure out

away to g el t he m u si c works to srartwhen I

opened

th e

lid a nd to

s to p when

I c l os ed th e

U

a .

The se ereus a small pin conn e ete d to th e

...re shut -o ff a rm o f

th e

music movement,

TIle

overall

se crm to m a kin g this project

go

'llloolhly is 10 make sure everything

works

b P

th e b ox is a ss emb le d. Iound

updry-assemblingit several ti m e. ( wi th r ub

b er b an ds) b efore a ctu all y g lu in g it up .

I

also found it best te

sand

al l the inside

surfaces   f Ort assembly . T h en . a fte r th e

box i s a s semb le d,

I

sed asp ra ycan toapply

th e f in is h r ath e r than u s i n :

3

brush.

Y o u h a ve to p la n a he ad e ven on a sm a ll b o x like ch is. T h e sid es a re 1 o u ced to

sh a p e first. T h en yo u can try yo u r hand at two d iffe re nt sty le s fo r th e lid .

Music Box

r W_E_E_K_ E _N_ D P _ R_O~J ~E_ _ T

~ 

8/20/2019 Woodsmith - 071

19/32

19

OlUE nt MfJ(RLO

CORNI;RS lOGll HlA AND

H C N D IN PlAtE WITH

RUUER UN.OS

ClNTERMOVtMfNl'

I 'IOX

Q.. SHUToO n

PIN

CHKK THAT ALL

WOtUUNG PAR1 S

Dt t-....

.MOW FREtl Y

©

BOTTOM

D fUI,l t HOlE  

rott~N

TtM--=-___

MOVlMfN1

CLUE·I

r. F inally . apply glue to th e

m ite re d e nds an d re as se m ble th e b ox

with

Ih e

bo tto m

(C l in p l ac e. s e e

F ill .

6. (M ake

su re m at th e pin and arm are connectcd.)

i ng it 1 0thewire arm. Then cen re rt he move-

men

I

n the box

and mark.the locationenne

tw o mounting' h o le s. s ee ~ ig . 4. Disassemble

th e bo x a nd d ri ll 1 6   mount ing holes .

ROUGH

-UNG YH 5 

No. 71

O nce the fro nl/back . an d sid e pieces are

m it ere d to hmgll l.

m e next

step is 10 m ake

IllC bottom

o f th e

music

box.

I301TOM .TIlebottom (C)

is

a p ie ce

otsolid

wood

that s resawn

and

planed

down to f it

t he 11 l ·w ineg rooves in Ie s id es o f me bo x.

To de te rm ine the

length

and w idm of the

bottom .

dry

assemble th e box,

holdinll

it   -

gether with nrubber band.

N ow . m easu re th e inside d im en sio ns o f

th e bo x. a nd ad d th e dep th of th e g ro ov es o n

all four

sides,

T o p ro vide e xtra

clearance

during ass embly . subtract   1 6 (rom the

length a n d w i dt h a n d cu t th e bottom 10

size.

KE\ 1ND HOlF..

Before

assembly. holes

have 10 be dr illN in the bottom and one of

th e s id e s to accommodate

th e m u sic w o rk s.

To m ak e rh e alignment of the pin and me

m ovem ent as sim ple as possible. start by

d ri ll in g a n OVCrsi7.e hole ( \ - l diameter) in

t he bo tt om (C )

fo r

th e k ey w in d s te m to

pass

through, 5(. rgtJl

o f 6 .

81;

~ig.

2 . A n d

th e

two

side piec es (B )to a rough lengm 0 5 .

TR IM TO SIZ E. On ce th e p ieces arc cut 10

t he ir r ou gh

lengths.

l il t t he

ta b le

saw

b lade

Merall theculsare made on the lo n g b la nk .

the next step is to cu t th e fr on tlb ack pieces

(A ) and sid e p ie ce s

 B)

10 their finished

lengths. BUI

th ere a re lw o p ro ble ms h ere .

rU'St. ) 'ou h av e 1 0suppor t an d guide

till

-s e

sma ll p ie ce s while mitering the ends 10

le ng th . S ec on d. e ac h p air of pieces has

to

be

I .trtctl II lh e same length.

,\t. XIlJARY FENCE.

The

solu ti on 1 0 b ot h

problems lst o a tta ch an auxilia ry f en ce to t h e

FRONT BACK SIDES

8/20/2019 Woodsmith - 071

20/32

NIl.71

. . . .

. .. . · l ttICK

puxtGl,AS

OtJ l

COVlR

10 lOCATEPILOf HOUS-,

US I CARPfT lAPE AND snoe

UO TO H INGE S ...... .- ... _--.....

  '-,oodsm

t

th

 

MARK ENDWRH KNlft

m£N

  lIT WITH

ODS-ELaN JIG

 

fAPfIN

POsmoN

CUT

CH.4HN£l

TOWIDTH

' tN

10

I

SETDlPI H

S L I  T L Y

uss THAN THiCkNESS

Qf-INU y

S f R IP

ADJUST FENCE

 

S 4lTcut h

TO/MlLK

 

• J

I ·

STRA'~

an ..

•

.

IN .lAY STRIP   .....

HOt.O INlAY STlltP

FWSH

wmt

SHQUU)la

 ND MARKW.OlH

9

8

ROtmllrABU

I NCI

TOP f ACE

DOWN

P

S H O ULD E•   ::;

,,- ROUND-

OVERIII  

.

 / ~

 

~~

7

I

T o com plete the m usic box. auacb the lid

an d drop in a dust s hie ld m a de of l lo gl. .

HIXCf.S. Th e lid isa na ch ed 1 0th e b ox w it h

two small bull hinges. To mount these

h ing es . I c h is ele d o uttw o m o rtis es in t he to p

c~orthebackpiece

(AJ.,..,.,l ig. I:l.

Each

mortise is tile same lengl l l as the h in ge a nd

as

d ee p a s

th e

h inge knuck le see F ig l :l a

t ex i. p o si ti on t h e hinge f lu s h w i th t he ill

j,/pe dg e o f th e m < )r ti . s ec F ig . 138. Mark

th e h ole loca ti ons , d r il l p ilo t h o le s w ith a n 1 8

g au ge b ra d. a nd s cre w th e h in ge s in p la ce .

To

locate

th e p ilo t h o le s i n t h e lid . fo ld t h e

hing< closed and Slick a piece o f d ou bk

sid ed c arp el ta pe o n e ac h h in ge .   F ig . 1 3.

Then pre ss t he l id down on t opo ft hl h in g es .

N ow open the lid . m ark the screw hole

lo c at io n s. a nd d ri ll t he p il ol h o le s.

nxrsn

;~\ ll

USTCO\ E R. Next,I removed

th e w orks and h inges and sprayed on

IW O

coals of a er os o l D e ft Clear   ood Finish.

Final ly. cut a ,,> ·thickdust cov er from

P le xig la s to re st o n th e in ne r lip .

FIN ISHING TOUCHES

N ext. I b egan w ork on Ihr I ,t '· l hi ck l id . Th e

li d

(I»

iSC'U1o the-same dimensions as th e

o uts id e d im en sio ns o f Ih,· box ( 31 /. w i dr

a nd 4 1 ,; .

long). > 4 Fig. 7.

I d ec id ed t o d r es s- up tilt lOll 0(1l l< 'music

box w ith burl veneer and an inlay strip .

jus l up

to

t i l <

w id th ma rk .

ATIl\~.AYS11lIl~.Afl

8/20/2019 Woodsmith - 071

21/32 

GLU   CAR VEl)

PANEllN Pt.ACI

 

r

\V od,mlth

ROUT t ....D£EP

C L O S E

tOOUTUN 

3

ClIISEI.$1~I·()RT.

Now ,

to

gN a crisp

shoulder around tile recess, 1used

3

chisel

tocut to the layout line. Ilen- again I used 1 1 1

Iayout

, g a U R t . b u t th is O rn e a s a S U I1 P C)r 1

for

the chisel.

  eO

Fig . 4. To get the insert 10

ii i

tij(hlly.

angle

th e ch isel w

undercut the

sides oflhe n)Ct SS slightly.

;\1. (

Mg. ,Ia.

ROUNDOvtR. O n ce vo u v e f in is he d c hisel -

mil' the

rN:CSS

to the li ne . rout a

V  

round·

over

with

a

\Ill: 

shoulder

a rou nd th e fou r

edges cflllc lid . see Fig. 5a.

All that's I ft is to cut the carved panel to

  t

the recess. Then pply a small amoum (II

glue 10t he b o tt om or the panel and Pr6$ it

in to p la ce . se e F ig. 5.

C HISE l

 U CKTlY

u TO

GAU Gf AS

 

U NOlRCU T

  SUP~ (OCf

 

.

Nu. il

5

C U T 1~... T H I tC

U O 1 S A M E

SlZ£ AS ao x

2

wood is

a

'Oft.

almost grainless w oo d that

ca rves ea si ly.

C.\IlC;F.. Before

 

ctually

started work on

the lid. I made a j 3UJ1e for laying out the

outline of the r ecess . s ee Fij[ I below. ullcr

I u se d lhisgauj(e

as a

support for.

chisel

W

cleanup th~t 'gcsof Ih~routed recess, refer

to Fijt

1 .

L\y()I  .Onceycuvefinis hedmaking the

gauge. use it 10lay ou t t il e recess on the lO P

o f th e If   · lhick lid

se e

Fig 2

ROl TtNG. 'Vilh the ktvuut complete. th e

ne xt ste p is

10

rou t a

~I -deep

recess

103C'

«lPI lhe c ar vin g. s ec F ig . 3 . T o d o th is . use a

\ I ,

s tr aig ht b it a nd r ou t r / o s < to th e line.

2

Tlr r  C l d cut lri/ll l lnot

8/20/2019 Woodsmith - 071

22/32

No. il

•

 

., 

- = : I = f f = = . , . . . . . . . . . = - - : ® ; : : ; : .   1   ; ; .

 I,. - __

1

ENOVlEW

KI

I>l

AT20

c o . . . .

 .

B AC K PL AT E

  M O V E  INC

tO WA ; D II A OE

AND

cu r RAl-SU

3

S E T I LA O E

AT2

W A S TE

1 2

ENOVlEW

 

,

11

.

,. i

M A R BL E H O LD E R

(ltcould

be

longt · rorshoncr. butlhislcngth

will hold a 8W x 11 piece 01paper,'

ORlI.UIOLES,

The

marbles

are

held

in~.·,

diameter holes set at an angle to the back

plate. It's easiest to drill a series of  I  g ld

holes. and then rip the workpiece at an

angle, Start by drilling ten

g'tb -dcep

hoil.,.

down

th e

length of the

work -

p iece . s ee F ig .

 

R IP T O \\1D111 .Next. rip th e

workpiece (wilh the holes

down) at a 20' angle so the dis

iance from the edg~ of the board

to th e long point of th e angle is

I . se e Fig, za.

R.>\lIBET~~JRPAf f:K. To

pro

v id e an ar ea fo r the p ap er

to

slip

into. I

Cut a

rabbet along the

angled edge, see I~g. 3. To do

this. lea ve the blade at 20' nod

lowl ril

  o:V$ abowthetablc.

see

Fig. 30 . Then move th e fe nc e

lo w ard sth e s aw blade ihe

thkk·

ness of th e blade.

BACKPLAn

After rabbeuing the marble holder, Imadea

back ptate

(8). ~

fig 

4. It's cut from a

pi \  . . ()i~

tock.

2  l  

wide and 13Vz long,

Then.

to

k eep th e m arb les fro m g ripp ing

lhl'paperloo tightly. drill a series ofshallow

 ) 1  holes in lh~back plate....eer.g. 4.

T

he idea for this project

CAA lef rom a

local

diner.

After I

ordered.

the waitress

slipped

m y order under a ho ld-

inll device for the chef, When I

looked at

the '

device I was~Ir-

priscd to find glass marbles

holdiflg

the paper  

hought

it

would be

handy

to have

one

of

these

grippers

to hold

drawings

in the shop or the grocery listin

th e

ki tchen,

The ehall~ng was designing

the gripper so it

would

ea~i1y

hold a piece of paper when

iI's

slipped into place, but not so

firmly

that the paper

rips

when

pulled out. After some trial and

error. Iw as able 10 make it work by drilling

a

shal low

pocket behind each marble.

MARBU HOLDER

I

began building Ute gripper by

CUll ing

a

marble holder

(A ) from 'o /, · ' · thicks to c k lOa

width of J   t  

a nd l en g th

of 111< '1 ',ee Fil . I.

Paper Gripper

~ O_ _N_E _  _ E_V_ E _N_ _ _ N_ G P _R_ O~J _ E~C_T ~ 

8/20/2019 Woodsmith - 071

23/32 

PUll OwN

TO REMOVE ___

 U AP R

UNO R

MARIt£S

 MARitI:

IUMOvt TApt

-AnfR ASS£MBlY

IA K PlATl-

MARll.

HOLOtR

IM.aLl HOlDER

11

GWAAU

tAPE HOLOS

MARWS IN

Pl aOURIN 

ASSlMBlY

®

 MaiL

HOI.O. .

10

MARlLE

GA UOE

.I. I fOU

 

tRIM OfF AU. toGES

  AT2 ·ANGl{

®

BACKPlAll

8

I--- @

HANGING

8AJt

1 ~OFf

W AS TE

  MAlN

 tf OutO CROP

TKROUGHHOU

 

HANGING

AtTlR atPPlNO.

SNAP

Off

SOvt.....

/ i~~~

N  .

 

I

_aAR

@

CU T CE N T EI t(O C R O O vt

IN SfRllS Of PASS s

-

CUT BAA . TO

RT IlOOV[

KRPOOYn ll

elT ATSAMt

HEiGHT

®

a  .

PtA,..

H A N GIN G B AR @

tiS' LONG)

6

HANGING THE GRIPPER

Youca n h a ng t he g ri pJ l( ron t he w all b y d r iv

ing

SCr

8/20/2019 Woodsmith - 071

24/32

No.714

ll tift j 

scuw

CAU ES HlNGE to

SH iF f P O R 1ON

 

HINOt

any of the boards have checked

e nd s, cu t o ff any defects before

sketching th e outliue.)

Next. usc the materials list to

start sketching where the pro

ject parts might

 it

onto the

board.

Since

most material lists

  ive finished

dimensions

fur

  f(f'I,t' / ~tl)lfrlld

ot lo nl

Iu ,b t r U t1 nJ I IllrA

It/)

SO, t

l ,o l d / , O O d

Ior n

p f u j t r l .

 

1 , I S

unh{ ld ,l , « rutti j Ig d i( lg ) (l m

a d

nmtrr ot»

li.,,1 1)1fJ11t I,allfi

usu

a

tos«  ~ (l. ilt 

i ,lteatllt r

Sitlce

lturtill.}(Jod

l ( nlb t r

i~

I lQ l C«II. Ull.l ) ;Jr,,, l if /l l, .O f ( 1 11 (1

J ( t l g t J '$ .

,t   «~'I ditllt lllat

t I l l

wfdp .n J   boa rds

BJ,olI Oil  ,,-If

~ tttl ltg dl(lgrl II'ti fll'/

 (I,f,/ll nl ln~le.Il'Iwllri,'ks

do

gllli

f ~r, ht, /)/lyi tg  nd

l yi tguul bo o rd

s

r

J J

P

8/20/2019 Woodsmith - 071

25/32 

J( 

,lOdsml[h

o.71

PRf.l , as

th e center 01 th e w ork, th e rim

has a grealer

vcloci

ly an d a

larger diameter. This

Illt llns

Ih e r .. w ill

be

more

w ou d in

con-

LaCIwith the s an dpa pe r in Ih~

s am e a tn Olm t o f li Olt; .

Another lime to decrea$e

spt'ed i.

when

sand ing w ork

  '1h sm all beads Q r sharp eris >

ed ges . By sl ow ing down you'lI

be

able

10 co nl To l how r3 t, id ly

tb 

wood

i>

removed.

It l

13k~

lo ng r lu s an d

ill

th is Sj)P,\J ER. Before yo u sand

3

pro ject. 1I1e fi r~1 step is 10

choo s e t h~ COIT f'C II) 'P nd   - ' T i l

sandpaper.

I

use aluminum

o xid e s an dp aper

b~c aus~

il

. tayssh3rpL'T long( 'r a nd d oe sn't

b re ak down f rom h  al ascluickly

as Ihe

other

lypeS.

I gencrally

US

8/20/2019 Woodsmith - 071

26/32

8/20/2019 Woodsmith - 071

27/32

 

CUnlNG DI GR M

A

tnt fchOngeobie P O n e I s

 4)~ 

X 4   rA

X8

8 0Mde,PoI\E l l I 4 Ir. X 8

C 8oc < Pane l

 1

lJ•• ,.   8

 

Si005 2

~.x..w.x8

E Base l

\ 5V4 6

f UdO)  1 1 5 11 4 6

GUdBtock l ~.x2.4

H Ughl

Booto  I 

ItX2

x  

SUPPUE5

•  4)No.

I

I

R >

w o o d s c r e w s

• lu n g 0 0 1

finish

• F elt c lo lh 6   x 6 ( ro l.>gh)

• Nigh, Ughll it

 see page

31)

MATERIALS

C R O S S

SECTION

 .RONT

V1 fW I

0

T

flXTVat

PtH H W f f GS O f

UGHT ftXIUIU

HO PUSH INTO

UGHTSOARD {

l~

W oodsm 1 h

@

S I D E

- I

PHOTO DETAILS

L IG H T F IX T U R E

®

LIGHT BOARD

 ---

•

• •

•~; e:

O~~

• • <

• • •   o

@

S ID E

@

INTERCHANGEABLE

PANELS (4)

LIGHT DnAIL

@

BACK PANEL

 stORAGE CHAMad

fOIt

txlllA

INttl(kANGfABli

P as

 ®

D IV ID E R .

PANel

-_/

 @/

U D

BLOCK../

D

O V l :R A U D IM E N S I O N S :

9 · Hx6 Wx5V. D

EXPLODED VIEW

8/20/2019 Woodsmith - 071

28/32

Wood,01'th

8

7

5

: : J

~

. -

lU P

1

SUDf SfDEP1Kt

. -

fINe.

AGAJN.SllNa

TOTRlMmGU

-{-   J  *

,

sa

a t A O . - h

~.  filCH -,

.

F ,

 

l

.

,

',

ROUNG-OvtR

B n

-. -  

- - . . . .

ROUNDOVlR

OUTStD(

toot

10tJf1R rABU

'[NC£'

lltlM_. ,

'RONT A,ND .,.

BACK (OCfS

Of

S tM P IE CE S T O ',,  THICK ..

  slo rag ('· c ha mb er. se e F ig. 3. Do

this

by

makin g a s er ie s of p as se s w it h t h e r ip b la d e,

O Il'S IDE EI )( ;ES .Nex t , to make th p sides

appear thinner than their

actual ~ ..

thick

n ess, I trim m ed lit fro nt an d b ac k e dg es

down to

W

t hi ck , s ee Fil . 4. To do l i tis . sel

t he t ab le s a b la d e

 o'~

(ro m th e fe nc e a nd

. high. see rig.

5.

BVtJ.NO ~I'ROf'D.£_

Aftertrimming the out

side

edges,

ro ut a bu ll nose p ro f ii t- on t hem

with 01 ¥

round-ever bit.

'1'0

do this.

first

raise the bil V. . • high and r ou nd o ve r

th

outside

edges (groove ' fac e

Itll .

~e Fig. 6.

Then ra ise the bit V.l   hi J. l l an d r ou nd ove r

the in sid e e dg es (g ro ov e dQ w . se e Fi) . t

PRf ._- \SS&\tRL ,

~OY,l

(' '1 lllI1l'

side

l)it.. '4.:t·

into f\I,'O 8'1·longsections, see Fig. 3. Then

nlue the ba ck a nd d iv id er pa nels in place

(flu ,;h a t th e ta ll a nd botto m ) be tween the

two s ide s. refer to Explo de d \'i , ·w . fl'lS 27 .

. .

2

®@®

PANrlS

tC U T SIXPtKU

J.  fHlCX)

six 8 ·lo ng p an el s. s ec Fig. 2.

S hop N ote: Instead of resaw ing solid

stock. you could useplywood (but the plies

will sh ow o n th e fin ished

pauern pane ls ).

_ .. . . _ .

 

_ - . . . .

U l L . . - - - f U F ;  

AU.GROOVlS

~l

l...I ,

I~ ':--.

<

NO TE:

USEruT PlleE

lO

8/20/2019 Woodsmith - 071

29/32

29

 t·

,,

...~

,,

COIJNTruUNK

SH ANK HOLE,S

•

t.  INSET

PILOT

HOISS

2 

SACK

RONt

,

.6 x '· 'h

WOO OSCREWS

~--4 - __

UT

--t-Tom

'

-CUT

1 m

a 

@

un

• ~ BLOCK

 

,'.... NOTE 

t _ INW

/ ON

A U.

SIDES

.

, 

H

® ~

 

_

UGHTf . l-

 

80ARD

e

2 

. .

a 

3  

/ LI GHT

( 'AMIot

D

un

of the box b)' m eans of a lid block that's

gl d tu liltuod tl '> id( ' o f w ( · l id . se e rll . 12.

To make 1I1~lid bloc k (C ). start by cut

lin g a

  y~ 

p iece of 81O< 'ko

f it

th e o pe nin g o f

th e Ughlchamber ( - .. i ha f ronlpanc l io p lacej .

W i th th e li d b lo ck c ut t o s iz e. r uu ra n a rr ow

chamfer alonJ all four edges of o s id e 0 1

th e b lo ck. (The ·t:a~·.lhi~wa.. l~ .)

Now d ri ll p il ) 1ho i,

-s Ihrough

th e sh an k

holes in lo the bottom ends of each side

1>;... .. . s ee F il l. I I a , 111enI I lu c and screw th e

00.,,'

in l'Ia'....with

Iffi

I AI woodscrews.

IJL>BUICK. The

li d

fils'nugly

o nto th ,· to p

ASSEMBLIN G THE BOX

 

,

®

8ASE  .

NOTE:

eA S E A N O U O

STAWTOUT AS

~lONG

BlANk

' ..~ X 1 ..' aA OO Vf

fOR

(lfC'1':llC

CORD

 ,

aonoMsrO £

O F B A SE

9

,..

 ,

~gin making lite

.. base and lid 01 th e

box b y cu ttin g a

b la nk to a fin al w id th

01 SII ,  , and a rough

length or 12),0 ,

Resaw, then

sand.

the

blank

10 a final

thickness, of ~  .

N o w ru t

the blank into two pieces,

each 6

0,

long.t fonn abase E) and a lid (F).

F1~C;ER

surr,

A   f inswr .101

in Ih.

base

a llows aCC lOSSo the electrical fix lure. To

make t h i s . bore tw o 1

 hok-stmhe

b a . . . . . . · .then

cu t

4JUt the

wa..; tc

between themwitlta sabre

saw.see

~1S .Sa.

(0110r .ROOI ' . :Next.forma V, .o.epwoove

for th,· ('ll'Clrl al,'OO'd in tlw bouorn oi Ih~

base using tht rourertabl«. see Fig. 9,

R()l NI)·()''}· R Er'(iF.S. After cutting this

gf ...• r ou nd -o ve r b it, T o d o

this.

mise the bi t 1 ; above' th e tab le . >

8/20/2019 Woodsmith - 071

30/32N ll .7 1

oodsm'th0

The mag ic o f t he n ; h t l ig bt l s i n the

scroll-sawn panels. Here are som e

suggestions

 or m king four

inter

changeable panels.

SCaOWNG TIPS

The patterns mown here arc half-size,

50

h av e t hem

l '1lI 'IWd

  O I l \

81

a c op y

sho p. o r s en d l or t he f ul l· s iz ep a tt er ns

from

Wood , ,;lh f t fTj  ~tSIIPJlfic; J.

see Source l lo1ge31

-';ole:The

fig/tt r

areas of tlw draw

ings a re th os et ha t s ho ul d becu t away .

 

used a : 1 0 5 ski p toolh b la de in th e

scroll s aw fo r e ach o lt he pauerns.)

A' lTACH PAl' lb-a. .

Firs t f in ish

sand

e a c h o f th e J).'IIlcl blanks. Then gluc a

p attern to th e

b l an k

using

3 M s

Sprow

MuuOlora U g hl coat otrubbercemcm,

DRflJ  HOI F ~Befo re y ou be gin 10

saw. dr il l s tart in g holes fo r the pierce

(inside) cut s, a nd f or t he o th er h il i.

ANI >II. Fin ish the

p an el s b y

dipping

th em in  shal low

pan

of

lung

oil .Then

poke out the excess finiSh from the

drill h ol es w ith a w ir e b ra d. (A ~ hO Io f

  ompressed alr works e..en beuer.)

F UING ST RS

D rill the hole, for the background

s tars f ir sl (us ing V 6  and 11l

drillbus 

The p oin ts on Ih moon and th e fai

lin g sta rs w ill

b e

shar p est if y ou fo rm

themwhh tw o inter$('Ctingl1IlS. rather

th an b y h yin g 10p ivc t a round them.

J CK O L NTERN

Drill o ul th o '13J1I (w it h 1116 nd  V J i

bits) an d

tilO I \w he n y ou r e s cr ol-

ling

between lite

leaves).

SNOWTPINI

l )r il l ho les for th e snowi lakes ( I s bil)

and the tree ornaments G rl  ) .11I1m

d r i n  

8/20/2019 Woodsmith - 071

31/32

31

'l.71

NIGHTUGHT

The hardware (or

the: Night

L ight on page:

26 b

available

from

\Voodsmith Projt'Ct Sup

plies. This package includes a

>ocket/lighl sw itch and plug

(with slx

fOOl

0 1 cord ). Iw 04 W U tl

white nighLIlghtbu lb • • adhe•

sive-backed

gn' 1

(dt. and (our

full-size .....

ol l

sawpatterrrs.

(St.

previous pa ge (or pauems.)

Night Ughtllardwure

771·.jOO  ight Ught

Hard-

war.li ckas:~ __ $9.95

• (l I S ock

e -

t/U ght S witch, S ix

Foo t Cor d and

Plug

• (2 ) 4 Wa tt \V b ll~ Ug hl

Bulb.

•(Ipe.) Adhc / l i d

• (lpc.)}'. x .I~I'·x 16   . Sidt.,;

•(I) . y , x 2 x l

tid

Block

• (I) ~ x 2 x .,  Lh rry

i'ly·

wood J. iy,htA o a . r d .

(;0.'

J S i o ·  

VIX BnS

In Simp Now,- lin Ilag.·

24 .

W(,

(liscusS(- e No.9

\fL'

b it c an ) ,. ,

used

fo r N o.8 . 9 . and 10St·....ws.

VIXBits

771·505 No.5

\ IX

Hit $8.95

77 1·509No.9\'jxBit. S9.95

771·500

Both 8it,;. $17 .95

ROUTER Bns

W, . a lS .

Woodsrnith J?rojcd:Suppli( S

P.O. Box 10300

Des ~foines,lA5()306

OR ER INFORM TION

CARVING KNIVES

\\re experimented

with B

variety

u( knives

while

chip-carving

the

top of th e MuskB ox sh ow n on

page 21. I even

called

Wayne

B arton w ho is one of tile finest

eh isx:atV lUu,t b e · cut iluri

veneer mii}  contain

pat(·hi . -

or

&'2n1$,owcre

~lpplyiRS

mort'

t han ) ouneed

MUNicBox \Yood Kit

771·350

Musl c Box \ \ . ,, 1

and In lay Kit. _....•.

SI7

 I:.

• (I) \O~.'

X

2l.,. 'x 24 '1 \\·ablut

• (I) ~.

3 1 , . 0 2 x

~l~ \ \ ,1 11 11 J1

-(I) ~ x 2~' ,' 3

i

., 11 1 \\'atllu'

PlywlKld r k> ~m.G ood 1 S ick

• (l) 4

x

12  \\'alllUI

1',11'4'(

BackedBurl\'tn 'r

.(1) ~'6 ~ 21 

Mapl,  \\

al

l lu V M a p ic I n la y :- lOp

Musk Box Chip-Carving Kit

\V l' a JS41 lJullvgt tlu-r a ki t r'1'r

chipcarvers.h s idcnticalt« thl'

veneer k it. bU I instead

(If

V-('II('('(

and th~

inlay.

W e   ,. pp ly a

10lll(

block

  I' ba'; '' 'WI KI

fo r

I~ nl)'1

p ract ic ing . , ,'e 're a l . :t l

including

a (ul l· s iz e d ch iJk, 'a n ing pa tt t m .

Musil' Box Chip-Ca,,';nll Kit

771·375Music Ilox Chip-

C a . r Y 1 I 1 J t K I l . .. . . ~

J  '.

-(I)

~tl

x2lj x

I n  

lJ,a ..

 ~ lJOd

• (1 )

t'2 x

2v-

x

2

J  \\'aln111

• (1)

\ - 2 x 3 1 1 - l x P . .'i·  'alnut

•(I) J 1 I

X

2  1 8

X

37,.,.'\I 'alnut

PI)'WlKldBottom. C,ocKI1 Sid,·

TOY BOX

All

the hardware needed

to

build

the

To), Box is available

from \Voodsmith Project Sup

plies. The package includes

hinges. lid

supports.

,Iwlf UIl

ports.casters, plus a

sheet

oHull

';7£ pauerns of letters A B. and

C

and num~rals

I. ~ . a nd

3 . Not ,, :

W'Kld and pain t ' iu

8/20/2019 Woodsmith - 071

32/32

  ,

'11/' /

II

u n

Ill,

I,d

tdJ~th;1frlllrl ,\

  , I t ,

1 'Jlll

tv ,','''1' '' ll .f t . } 'I,r xcrutl :« 1t 1~ 1A Ilf \ 11111·

 

Ptrtt

 '1

  ' fA ,ru'(IJ/

 I III/tl

f H a. -

 '(I~ I

e.

/ JO . ; , ,, ,, S 4, ~ ,~Jqlt ' f'U11l I IPJJOrlS tit hold flIt

fid~('lit' H I I I . ; -   / . 1 1

r

1 It(Ctl)/'J(i,IY

~llt

.lOpt'llt/I I

t/ri''''''fll'll,i

,1fll~u'

8'1J'

~tJ

pli'n.~n/

~:trIJ,.i~.Tilt' I,m ls lllljJ'Vm/f ,,1 tali.  p I1. ';U 1

Music Box

.. . . 1 1 , , 4 / Jlf,

I

J , I t ) . r Il f

II(i

  tlr mil   t: (l d{r:.

lirall   f

I/ '/rli ~ ,c

II. l\',fh (III

 ~IJ

,.(ierry b a . H ~

(1

t

I.*,

 'JII

t

 

r . , , , , ,/ 11 I rot If I Y)   f ~ ld II {

.. TIlt

~trt W t t I . . t

 I'I fig lJ(IINtr,,, ,1.

fnrr'

i~

.(flt' nliilflry 11'n...

 

lunrbl, .........

11~liqlll

Rli.li,IIJ

 /fJ

to

J t  ':'( /f',

  0/1/ t lu G 'P JJ e r 't u tIlt:

 VIII.

 inal etails

L .j )K

 ST