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NOTES FROM THE SHOP

O 6

3 50

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No. 63

oodsm ith

W O O D S M lT H ( IS SN

0164-4114)

is

pub

lish ed b im o nth ly (F eb ru ary , A pril, June,

Augus t, October I :>ecembe r) by

Woodsmi th Pub lish in g C o.,

2 2 00

Grand

Ave ., Des

Moines,IA50312.

oodsmlfh

is

a re gis ta te d tradem ark o f

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send us h is/her nam e

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8erI

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Ifyou d like share a ti p

with o ther s , s endin your idea

to W ood sm it h, 'l 'p s

Tech

niq u es , 2 20 0G ra ndAve. ,

D es

M o in es , I ow a 5 03 12 .

W e pay $15 for accepted

tips. P le ase send a n e x pt an a

tion and a sketch it needed

(w e' ll draw a n ew one ).

SENDIN YOURTIPS

To allow for expansion when

m ak in g ra ise d p anel s,

usually

cu t the panel a little narrow er.

Somet imes, though, th e pan el

wil l rattle in sid e th e g ro oves of

th e fr am e .

To f ix th is p roblem . I cu t nar

row s t ripso( se l i- s ti ck ing foam in

sulati on tape (V s thick). When

th e tape is stuck to the b ott om o f

th e groove in

th e fr a m e

it kee ps

th e p an el from rattling . a nd a ls o

allows

ro om fo r

expansion. insu

lation ta pe can be found in mos t

h a rdwa re s to re s.

Georg e

Seifer t

Shorev iew,

Minl1sota.

Woodsmi th

T o k eep edg ing from sliding ,

d ri ve t hin b rads about ev ery 1 2

al ong th e edge of

th e

plywood

and

sn ip

th em off

so

a p oin t p ro

trudes, Then app ly g lu e to the

strip an d

al ign

it w ith

th e

edge.

Press th e strip ag ain st th e f ir st

b ra d po in t, th en re pe atd ow n the

le ng th o f the edge.

(N 0 te :.Edging

str ips m ust

be thicker

th an the

l eng th o f t he p r ot ru di ng pointa)

Now c lamp th e s tr ip in p lace.

David Warren

A1a.tinez, C(.lifon,ia

In

WoodsmitltNo. 62 th ere's a

techniq ue on h ow to clam p th in

edging to plywood using a

c lamping boar d w ith a rounde d

edge. This works fine, but ad

pro b lemskeeping

long thioedg

iD g strips from sliding w hile

c lamp ing a nd g ll in g.

GLUING EDGING PANEL RAnLE

T o u se th e ta ble, s lip a C clam p

t hr ou g h t he ova l a nd

then

t ighten

your wo rk piec e to th e ta ble.

MikeFt .n~wli

NiagataFa/is . Ne Yo rk

No. 63

SANDPAPER CUnlNG JIG

ce r O U T W A S T E :

IN SHA PE O F OVAL

RfU TWO HOW

5 IO E BY S IO

To get the leng th, ad d 2 to

the w idth of the oval. Now

layout the ovals at the loca

tion

mark s

on th e table.

Dril l

bo les at both ends of the

ov als and cu t betwee n th e

tw o holes w ith a sa bre sa w .

C CLAMP TABLE

hav e an extra w ork bench

mad e ou t of a p ie ce o f p lyw ood

that sits on tOp of two old

sawhors es .

se this bench

fo r all ty pes of work , especial ly

sanding . But while sanding . the

workpiec etend stosli dearound.

To hold th e work - r .M A J = < o v A 1 S = ; ; . I G N O U O ; ; :H S O - - - - - - ,

piece in po s i ti on. Cl MPS C N GO IN NO

created a simple OUT NOWORK IN

: > o a r ..

m a n s c l a m p .

NY DIRETION

1 'h isidea uses

or- ~

dinary C elampstha t U ~

f it t hr ou g h ova l win-

dow s in the p ly ~

wood,

see drawing .

y

To CU I th e o va ls ,

m ark areas on the

ta ble lop w he re y ou

w ou ld m ost likely c lamp p ie ce s.

M y role ofthum b for measur

ing th e width of th e ov al is to

measure the w idth of

the

nec k

on the

Ccl am p ,

then add

1 .

gl ued ont oonecomer later. start

~ from one edge.

Now

rou t

v-groo ves ~ deep

al o ng th e la y ou t lin es to s erv e as

a cutting trough fo r th e )m if e.

Then dde d tw o s tr ip s a tone

co rn er to Iorm a stop for the

sandpaper, s ee d ra w in g. S in ce

the stop gets in the w ay of the

knife blade, I cu t a kerf through

th e stop

w ith a hand saw ,

a lign -

in gth ek erfs w ith th e V grooves.

T o use the sheet cut ter, p lace

a c ou ple of

sheets

of s andpaper

upside dow n on the base w ith a

comer agai nst the stops. Now

cu t

th rough

th e sh ee ts. Move

tbe justcut edge against the

s to p s a nd rep eat th e cu t

a:l egH i lUm u l

B eale A F B , Califlln irJ,

3 O R

6

S I

Slims

rying

to cu t uniform p ieces of

sandp ap er for an orb ital sander

is a h assle. T o m ake it ea sier ,

b uilt a s an dp ap er c utt in g jig .

The base of the jig is a sq uare

of p lywood w ith V grcoves

ro ut ed at m easured w idths to

g lide a sh op k nife. To

m a ke

th e

base. , cu t a p iece of :j 4 tllick

p lywood 1 0 12

x

12 .

Next, determ ine how

m a n y

piecesor sa ndll ap er y ou can get

o ut o f o ne sb eet fo r y ou r s and er.

The standar d

si ze

of a sheet of

sa ndpaper is

9 x

11 . M ost orb ..

ta l s ande rs u se 1 /3 0fa

shee~

of a she et o r e ve n 1/6 of a sheet.

Onc e y ou k no w theshee t size ,

la yout the position of the cut

li ne s on t he

topotthe

ba se . S ince

there

ar e two ~ w ide stops

M eivinE vc. (s

Meridian, Idaha

shank . To do this only takes

th ree hands: on e to hold th e b it

up , and the other tw o to tigh ten

th e collet w ith tw o w renches.

O r, yo u ca n slip a rubber O

ring arou nd th e shank of th e b it

T h e O rin g w ill h old the b itatthe

co rrec t h eig ht a bo ve th e collet,

an d th en y ou 'll h av e b oth h and s

fre e to tig hte n d ow n th e b it

icked

up so m e

ofthese

rub-

ber O -rings for about 20 cents

ap iec e at a loc al h a rdwa re

store.

(For a

V

shank you 'D need to

use a V O -r in g a nd t o r a

h

shan k use a lh O ring .) J llstroU

th e O ring onto th e shank u ntil

i t's a b out a ~ from the transi

t io n f ill et

d rop s a ll the w ay do wn , th e col-

l et w illgrab a ro un d th e Iilletand

no t th e whole shank .

So,

y ou r aise

th e bit

u p a lit tle,

un ti l t he co llet onl y co nta cts the

OR ING HOLD S BI T

WHllI TIGHTENING

W h en m ou ntin g a rou ter b il.you

do n't w ant th e b it to bottom

ou t in the col let . TIl e p roblem

has tod o w ith tbe t ransi ti on f il let

that's betw ee n th e cutting bead

and the shank On most route r

b it s . IT th e shan k of the b it

ROUTER B IT HOLDER

Tips Techniques

WOODWORKERSELLOW

o t I o _ _

1 /4 OJA. OR

1< l t DrA . O -R ING

FRO M

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N o. 63oodsmith

SUEI.\ ES,

O ne of the

linlt

c on sid er at io ns w he n b uy

in g the lum ber for prc ie ct lik e th is is g ettin g sto ck

th at s w ide enough (or the shelves

( 9 \ 1 1

w ide) . A I

th ou gh t ha t m ig ht

be

th e e asie st a pp ro ac h. it m ay n ot

be

th e b est. W id e sto ck te nd s to

warp

e as il y. S in c e t he

sh elves in th is b oo ksh elf a re n ot m ou nte d in to d ado es

in th e e nd tram es, they a re p a rt ic ularly susceptible 10

w arp a s tim e g oe s 011.

I prefer to glue up a couple of narrow er strips

mak e e ac h sh elf. T he d iffe re nt g ra in p atte rn s in e ac b

strip

will

he lp p re v ent w arp . W e v e sh own the CUlling

Diagram with th is a pp ro ac h o flw o strip s fo r o ne s he lf .

RADIUS

COIt ERS.

There s One feature on the end

frame s th at s ty pic al o n a lo t o ( fu rn itu re p ro je cts

a ra di us is c ut on each corner to soften it. To cut

th ese ra dii. I used a m ethod that produces a uni

form radius on every corner. C hec k ou t this p roce

dure in the tip box on page 7.

FlNISII,

I f inished this bookshelf using tw o coats

of sa tin polyurethane varnish , sanding lightly be

tw ee n eacb coa l.

T

he p rim ary desig n fe atu re of this b ook she lf is

on e y ou c an t see. T he re s n o h ar dw a re . fact.

th ere s no perm an en t join ery holdin g

U she lv es

to

the end fram es. ta ll kn ock s dow n b eca use the

shelv es can b e lilted rig ht of( the e nd fram es.

The she lv es re st 01 1 dowels in th e e nd frame s. Th is

m ak es

U te

whole unit ea sy to k nock dow n b y j ust lifting

t he sh elv e.o lH he e nd d ow e ls .

O ka y, th at m ak es it e asy . b ut

it

c an t b e v ery

SIUrdy,

righ t? Wel l. t h e s tu rdines s comes f i oms ti lf ener s th arare

added to th e back edJ{csof th e shel ves. T hese stiffeners

are cut to fit tight between th e

en

f ram es to p re ve nt

racking (sideo.-aysmovem enO.ThcyaJsoserveotherpur

p os es. T he y kee p the shelves from bow ing under

w eig ht. and th ey w ork weD as back sto ps f or boo ks so

th ey d ont slid e o flfh e b ac k

edge,

~t

7/24/2019 Woodsmith - 063

5/24

5

oodsmith

o . 6 3

EXPLODED VIEW CORNERSTIFFENER

STIF~ER

. . .

~

E . . . . . . .

~l

44 \1 4

2

~

1 .

' I

=

I

i STilE

,

1

r0

HElF

D

. e o

J

1.

2

, , &

H

8x;1Fh

SHElF

S~lF

~wOODSCRew

D

0 . 1

I

-

STIFFENER

-~

~

. .

I

. . .

. . . . .

. . . _ ,

/,

6

-'.t~R ,

W-OlA.

t

WOOD PLUG

'

-o;J

~

~

- . . . : : : : - . .

SHELF

- . . . . : : :

~

6

STIF~NER

, ] I

.

.--

STIFFENER

./

, : :

; '

STilE

~

>

I-

~

A

,

.

47

: \1 -

1 =

.

- -

,-

~-

.'t--:

S~lF

I

SHELFDOWEL

~

~?:::

SHELF .

~

~

SUPPORTDOWEL I'-

I

SHlF~ENER

\

c I'- ~

. , . , 0- E

,

STill

;

.L

I

:

-

SHELF@)

ot

sat1n polv-

urefhone.sond

i l t t v

between coots

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No. 63

SECOND: ADD GLUE

to LA P JOINts

6

FOURTH:

TlGHTfN c . .c lAMPS

T ORNfRS

5

NOTE:

FINISH 11 R,OUND OV:R

ON IN SID E EN D FR AME

Woodsmith

FIRST: fN SRt SH.ELFSUPPORT

DOWfl INTO snLlS ~ __

t o p ul l th e shoulders tigh~s sh ow n in Fig.

5 . Once th e sh ou ld ers are tight, [ added a

Cclamp on each com er to squeeze the end

laps together .

RAD IUS.A fter the glu e dries. I cut a 1

rad iu s on all c om ers. refer to the tip box on

t he o p po site page.

ROUNDOVER.A fte r c utting the radius

c om ers. fini sh ro un din g o ve r th e in sid e an d

outsid e edges of t he end fram e. s ee F ig .

Sa.

INSERT DOIIIELS .A ft er c uftin g U le d ow e ls

In length. insert them betw een tw o stiles.

(M ake sure the Ja p jo in ts o n th e stile s fa ce

the sam e dire ct io n , s ee

F Ig .

4.)

ASSMl lLY.1 0 co m plete th e as sembly of

the end fram e. lay the stile assem bly fla t

ac ross two pipe clam ps so the end lap s face

u p, se e F ig. 5 .Nextapply g lueto th e end lap s

o n Ib e ra ils (B ) an d cla mp them to the end

l ap son t he s ti le s (A ) usingthreep ipeclarnps

P

~EH SflU H

M A R K A C .A :O $S

U sruss

W IT H S QU AR .E

NOTE:

FORDOWll

L NGTH AD D

D IS TANCE

BETWEN

SH OULDRS

P L U S H O L

OE PTKS 9AI

SHELF

SUPPORT

DOWELS

c

RAIL

STIli

A fter d ri llin g h oles fo e Ib e su pp ort d ow els

(C), 1started to asse mb le th e e nd fra me s.

S ll El .I ' S U PPORT OO I ll E I. $.

First,

I

cu t th e

sb el( su pp ortdow els (C ) to le ng th . T il d e

term ine the length . m easure tile distance

betw een the shoulders of Ihe rails

9Vl ),

see

Fig . 4. Then add In th is me as ur eme nt

th e d ep th s o f tw o h ole s i n I h es ti le s. Noweu t

len W '-d ia . dow els V II'le ss th an Ib is lo ta l s o

th ey w on 't b otto m o ut.

EN D FRA ME A SSEM BLY

from one end, then every 6 . ref er to the

E xp lo de d V ie w o n p ag e 5.

CENTER BIT. Be fo r e d r il li ng the boles, I

centered the bito o th e th ic kn es s o f t he s tile .

To center the b it, insert a \ 2 bra d-point

bit in to the chuck, then clamp a 2x4 on the

d rill p re ss ta ble fo r

a

fe n ce , s ee .F i g. 3 . Now

pu t the outside face of

a

stil e

against

th e

fence. W ith th e

drill

p re ss o ft, lo we r th e b il

so th e b it'.s poin t m ak es m ark in the wood .

Flip

the

s ti le a round,

so

the olber face is

against

the.fence

a nd low er th e bi t a ga in . If

I be p oin t o n th e bi t doesn' l

exactlye n ter

th e

first m ark. ad just the fence and

try

again

u ntil y ou o nly m ake one m ar k

DRIU. ROl.S . After th e b it is ce ntered.

d ri ll f iv e ho le s:V 4 de ep in to th e ins id e edge

o f e ac h stile (A ).

la ps , s ee the a rtic le o n p ag e 20.)

ROUNDOVEREl)GJ;S. Be fo r e a s semb li ng

th e f rame, ou nded over the inside edges

o f t h e s ti le s (A ) using a Vs ro un d -o v er b it i n

the

router,

se e

Fig. 1.T hese e dg es c an 't be

rcundedafter th e frame is a ss emble d b ec au se

thedowelswillbe

in

t hew' ) ', r e fe roo F ig. 5.

1 0 ke ep [ rom r ou tin g int o th e jo in ts o n th e

stiles,

I

m ad e p en cil marks

2 fz from each

e nd fo r s to p

marks, see

Fig.

1.

LAYOUfHOl.S.Afterrow ld in g th e e dg es ,

a id o ut re fe re nc e m ark s to d rill a series o f

holes dow n the inside edge of the s ti le s

to

moun t th e

shelf.support

dowels

C)..

T o g et tile m a rk s a lig ned

onal l four

stiles,

stack them on edge so the ends are flush,

then clam p th em together. see F ig. 2 . N ow

ma ke m a rk s a cr os s th e e dg es , s ta rtin g IA

This bookshelf is

rela tively easy to

buitd -there are

only tw o en d frames

a nd th re e s he lv es .

started by m aking

th e tw o e nd

frames.

Begin

b y rip pin g

four

stiles A)

an d

(o ur ra ils

a

all to a un iform w idth of

2 .

T hen cu t the stiles

36Y l

lo ng a nd th e rails

I

long.

Shop Note: lso w ent ahead and cut

som e

extra

pieces

tha t l

used for te s tcu t ting

th e jo in ts O n th e e nd f rame.

1 10APS.

Afterculting

thestilesand

rai ls

t o s iz e ,

they re

jo in ed w ith end la ps to f orm

the end fram es. (F or m ore o n cutting

en d

STILES A ND RA ILS

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7

SP ER

8lOC~ .

~

SHElf ,

~ DIA.

WOOD

PlUG

Woodsmith

LA Y U N IT

FACE~OWN

N o. 63

~

_/_,:~~

~

OUNOO VE R

A ll ED GES ON ST IffENER

WItH I,..,. ROU N IX V ER BIT

l

SHElf

,NO

f A A f .

.... I

8 ~

CUTsnffENER TO ~

~rr

GHT BEtWEEN ~

EN D FR MES

~

~~

s e

S .ACE, BLOCK \~ , .

x

10 AUGN STIffENER .

h

UP frOM SHElf .

FASTl lNSJ11 t EN ER.l

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N o. 6 3

oodSll.lith

s h o u ld o cc u r will no t o pen a n y o f th e jo in ts o r c a u se

cracks t o d e v el o p .

JO I N E R Y . W b i l e thejoinery i n t h is pro jec t is notcom-

plicated pr e cise fits a re v e ry im po rta n t. F or m ost

p ie ce s. P re co m m en d t he y b e c u t o ve r s iz ed , a nd th e n

tr im m ed t o fil

W O O D . W h en c ho osin g w o o d fo r t he c as e. y t o l is e

h ard w o od s th at h av e b ee n k iln d rie d . N o m atte r h o w

carefully th e c a se is c o n str u ct e d , u sin g w oo d w i t h a

h ig h m o is tu re c o nt en t w i l lc au se p ro b le m s.

1 b uilt th is c a se o u t o f w a ln u t. T he b a nd ie s o n th e

c h ise ls a re lig h t c ol ore d a n d th e d a rk ba c kgr o u nd

m ak es th em stan d o ut. W a ln ut is sta ble a nd re la tiv ely

e as y 1 0 w o rk w i th .

PINISH

A f te r co m p le ti n g th e c a se , Ih e in teri o r a n d

t he e x te ri or w e re fio jsh ed w ith th re e c o ats o f h an d -

ru b be d tu n g o y ou fe el yo u n e ed a m o re d ura ble

fi n is h, p o l y ure th a ne w i l lo f fe r m o re p ro te cti o n.

a ve a fo n dn e ss fo r u ni qu e c on ta in ers . T h at s w h y

[am in t ri gu ed w i th t hi s p ro j ec t I ln o t on l y ho l d sa n d

p ro te ct s t he c his els , i t s a ls o a w o r kin g d is pla y b ox .

T he fa c t th a t w e u se d Ih is b o x fo r ch ise ls d o esn t

m e a n th at it w o uld n t w o rk e Q ua ll y w e ll fu r a se t o f

knive s , o r b y re m ov ing th e d iv id e rs, it c o uld h o ld a

s pe c ial b oo k o r h ou se th e fa mil y a lb u m .

END GRAIN

S in ce th e to le ra n ce s o n th is c as e a re

v e ry t ig h l, I h a c )t o p al c l os e a tt en ti on t o t he m o v em e n t

o f th e w o o d a s i t e x p an ds a nd c on tra ct s w i th s e as on al

c h an g e s in h u m id it y). T o p re ve nt p ro ble m s w ith th e

w o o d sp lit ti n g, t h eg r ain o f a ll th e p ie ces sh ou ld ru n in

th e sa m e d ir e c tio n.

IV b ile itm a ys e e m like a lo to fe xtr a w o r k t o d e al w i th

llo f t he e nd g ra in p ie ee s.th e re su ltis w e ll w o r t h it . A l l

o f th e g ra in in th e c a se ru ns in th e sa m e d ire c ti o n,

a lm o st as i lth ec as e w e re h ol lo w e d o u ro fa s in gl e piec e

o f w o o d . B y d oi ng th is, a ny m o ve me nt in th e c ase th at

This

case pro te cts your fa vo Tite c hisels and do ubles as a

w orkin g chisel stand Instead of com plicated joinery this p ro jec t re lie s o n

a p re c ise

t

and understand ing the natura l m ovem ent o f w ood

hisel se

PROJECT

HOP

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9

END

BLOCKS

THIRD: CUTTO FO

7/24/2019 Woodsmith - 063

10/24N o. 63

oodsmith

0

N O T E :

U N

fL U SH

ON All

IOf S

Gl ur OTToM

PANn TO DIVIDERS

A ND tND LO CK

BOTTO M

P AN EL

CU8rrOM

PANELTOffT

D~VIDER

ASSEMBlY

MUST

S Q U A R E

F LUSH EN D BLOC K

A NO D IVIDER S

No tes, page 12 . T Ile f in is he d size o f the b ot

to m panel is the sam e as

th e

o u ts id e d ime n

sio ns o t th e tra y th at y ou ju st g lu ed u p, se e

Fig . 7 . (Our d iv id er t ra y me as ur ed 9l1 ., x

12. .)

N ow glue the bo ttom panel (C )

10

th e

divider tray . U se gl ue sp arin gly to a vo id

sq uee ze out. M ake Sure

th e

edges o f the

botto m

p a n e l C)

ar e

fl u sh w ith

th e

s id e s

o f

t he t ra y div ider s B) a nd the en d blocks (A ) .

sander o r a san ding b lo ck .

ASSEMBLY.

A fter the div id ers h av e bee n

s an de d. f it ao d g lu e t he m i nto the g ro o ve s i n

th e en d b lo ck s, s ee F ig . 6 . (Make s ur e t ha t

this as se m bly is square and that it sit s f la~)

II0 IT0MJ>.~t..

A fter th e dividers

B)

ar e

gl ue d i nlC )lh ee nd blo ck s

(A ),

y ou can m ake

th e

bottom

p n l

C).

Start by edg e-g luing eno ug h

V . U l ic k

sto ck to m ake th e bo tto m pa nel . s Shop

W ith the e nd b lo ck s

(A )

comp leted yo u

can begin wo rk o n

the case div iders

(B ) :Startby ripping

V sto ck fo r th

e

dividers to

width,

R IP TO W I D I1 I To

det erm ine th e w id th

o f the di viders, m easu re the t licknes

(h eight ) o f the end blo cks (A ) an d

ri p

th e

dividers to that w id th . (I n m y case that

measurement

w a s

1. i . )

D E1E R MlN E TH E L N G I'H . Af t e r th e

pieces

have bee n

r ipped

to w id th ,

ut

all

o f th e

di viders to th e c or re ct len g th f or

my

chisels .

To det ermine th is len gth , m easure your

lo ngest chisel and add % . (The extra

: V

all ow s f or th e V g ro o ve s in th e en d b lo ck s

(A ) an d a V ofc lea rance within the case.)

lAYINGOlTl lI A R C .

A f te r t he di viders

( B ) h av e b ee n c utt o le ng th, layoulashallow

ar c t o a llo w c le ar an ce t o p ic k u p t he chisel.

B eg in b y la yin g o ut the ar c o n one o f th e

d iv id er s. To do this, mark

point s

1% in

from each en d o f th e divider alo ng the to p

edg e, see F i g. 4 .

To

draw the

are,

ta p e

th e

dividerto

ascrap

pi ece o f p ly wood an d drive a c ou ple of nai ls

alongside th e tw o m a rks o n the divider, s e e

F ig . 4. T hen bend

a

piece o f p osterboard

insidethenailsandadjusttheapexofthearc

so it' s \4 fro m the o pp osite edge o f the

d iv id er . T h en d ra w t he ar c .

C IJ l1 1 N G T HE A R C. N ext st a ck all o f the

divider s with

uie ar c

on top and

wrap

th e

st ac k w it h m a sk in g t ap e, m ak in g su re th at

theedgesandendsareflusb. se e F ig .

5

N o w

cu td ose to t he layout l inewith

t he b a n ds a w ,

and then sand up to the line using drum

DIVIDERS BOnOM P NEL

s aw f en ce

so

that it acts as a sto p fo r yo ur

next cut. A f te rc uU ing t he f ir st g ro o v e, tu m

thepieceendforendandcutanothergroove

b ef or e m o vi ng t he fe nc e. R e pe at t hi s p ro ce

du re

uotil all

o f th e g ro o ve s are c ut.

C IJl11 N G T HE G R OO V ES . A ft er th e rabbets

a re cu t. d iv ide th e spa ce betw ee n th e rab

b et s i nt o

s ix

eq u al s paces (o r th e n um b er o f

chisels in your set) with a \4 g ro o ve b e

tween

th em .

se e Fig. 3 .

N ow m ove th e table

A iter m aking the

en d b lo cks,

1 1 4

tab

bet s a nd g ro o v es

are

cut to ho ld the case

d iv id er (B ) . (Cu t t he

r ab b et s a nd g ro o v es

to m at ch the actual

th ickness o f the

dividers .)

SE T 'I H .E D A D O B U ID E .

Be g in b y s e tt in g t he

sa w to cut a

1 1

x

V

rabbet. To do this,

atta ch a w o od en fe nce to y ou r ta ble s aw r ip

fence ,

see

F ig. 2.1 also

u se d a

wo oden

ext en

sion o n

my

miter gauge. The ext ension

sup.

ports th e pi ece

and

helps preve nt

chipout,

N ow s et th e r ip fence (0 act as a stop an d CU I

a rabbet on bo th ends o f the end blocks A).

se e F ig. 2.

N ote: These rabbets (and th e g ro ov es

L ha H o ll ow )mu st b e c ut i nt o end g rain o n th e

end blocks (A l.

CUnlNG THEGROOVES

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11

NOTE: ROIIND OVER (NDS

A N D E D GE S W ITH C A SE C .L O S E D

UD S l FF ENER

cer T O F fT

G B ETW EEN

UD IO[S

stiffene r (G )

10

fit b etw ee n th e lid s id e s ( 1') .

see F ig . 1 2, F in ally . g lue O le pieces n as

sh ow n in the C ross Sec tion on pag e 9,

F INGER REOE SS.

The last step is to file a

~ wid e finger recess in th e bottom end to

m ake a lip for openin g the lid . See

Fig .

12.

Woodsm ir h

CH ISEL REST

CUTTOFfT

8 T W E I ; N

C A S E D IV ID E R S

D

1 2

to F ig , 1 . use a round-over b it a nd ro ut a

b ulln ose o n b oth ends. see F ig .

113 .

CUT TO FIT. Nter t l bu llnoses ar e

com plete . cut o ff tw o ~ Iong piec es, se e

Fig.

ll . N ow , cut th e ch ise l rests 0 to fit

be tween thecase dividers

8

.and cutthelid

N o. 63

Once the lid is co mpleted , ro und over th e

s id es ( VS ro un d- ov er ) a nd e nd s

round

ov er ). r ef er to F ig . 12 .T hen yo u ca n begin on

th e chisel rests (D) and lid stiffener (G).

ROtJJ1NC THE EOGE ,

Usin g th e c ut-o ff le ft

o ve r f rom ma kin g th e end b locks

(A )

(refer

TOOL RESTS ND LID STIFFENER

_

DONor

G L UE S lO E S

TO P O C K ET

PANEl

POCKET

PANEL

~ from ti le bottom end . See F ig . 10.Then ,

drill a

a

p il ot h o le t hr o ugh th e lid s id es (F )

a nd in to th e e nd blocks (A) . se e

FIg . 10.

Now

r em o ve tile c ar pe t ta pe an d e nla rg e th e hole

in th e lid sides F to ~ .

B e fo re s cr ew in g the lid sides (I ) to the

c as e tr ay , p la ce

a

1 . i 2

sh im behind e ac h lid

side

(1').

N ow t ighten down a No. 12 round -

h ea d s cr ew u ntil th e b ottom of thescrewslo t

is

Bush

w ith th e lid s id es

(1'),

see F ig . lO a.

ASSEMBLE 'l 'l iE UD . Next .

fit

th e r ema in

ingpartof the lid b e tw e en th e s id es, a nd trim

the end flush w ith the

lOP of

the case, see

Fig.

9 .

Then g lue the panel th e lid sid es

(I ) only . Wh e n theglueisdry.file t he s cr ew

he ad s flu sh ,

se e

F ig . lOa.

LID , r-,

PANEL

S tT S AW S lADE TO 30

2> \ 4 - TO TH E

LONG POINT

O F TI-I B EV EL

LONG

PO ,m

G l .U M O V A 6 LE S ID ES

TO TOP PANE L ON lY

Now se t your saw blade at 30 ' and cu t a

p ie ce o ff t he p an el that 's th e le ng th y ou ju st

determ ined, se e F ig . Sa.

N ex t, p lace the short p iece on tile case so

th e lo ng b ev eled point is touching the arc .

N ow m ark an d trim th e e nd Ilusb , se e F ig . 9.

UDSIDES,

T o m a ke th elid s id e s ( F) .s ta rt

by m e asu rin g th e th ic kness (height) o f the

case. T hen rip tw o pieces ofll4 s tock to th at

measurement (2 ) and cut them to the sam e

leng th a s th e c ase , see F ig .9 ,

Af t e r th e l id s ide s (I ) a re c ut, f as te n th em

to th e

t y

w ith d o uble -sid ed c arp et ta pe.

RINGE SCIlliWS.

W ith the sides n pla ce

y ou c an d rill th e h oles fo r th e h in ge sc re ws.

First d rill a ~ 3 c ou nte rb ore , V I6 deel,>and

After the lJ 'ay as-

sembly is c om p le te

you can begin OJ tile

lid pan e l

(E). Start

by g lu in g u p e no ug h

stock

to m ake a

panel that's

V

w id er an d 1 l onger

th an th e tr ay . A f te r i t

dr ies , r ip th e p an el V t6 wider th an th e t r ay .

ASSEMBLEme POCKJ o:T .N ex t, to fo rm th e

pocket and lid top, cut the pane l in to tw o

parts, see F ig . 8.To de te rm ine the le ng th o f

O le p oc ke t.m e asu re fr om th e e nd o fth e tra y,

to w here th e a rc be gin s O n th e d iv ider . Then

ada ~ to allow for tr imm in g .

LID SSEM LY

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No. 63

PU U OU T SP CER N O

__ A P}>I Y W EfG HT

ABOV[JOINT

\VEIGH DOWNTOP. Nex t s lide

th e sp acer out and lay ano th er

strip o f w ax paper o n top of th e

jo in t lin e. N ow lay a board on

to p of th e wax p ap er a nd s ta ck

a hea vy ob je ct Iused a brick)

on top o f the board.

M ak e sur e th e (W O pi ec es are

layin g

f lat,

and let the glue dry.

A fter th e gl ue d ri es . rem ove th e

nailsfrom one side before taking

th e p an el u p,

Woodsmith

pie ce s to b e gl ued ar e

t (J ~hi?lg ,

see F ig .

L

W ith bo th pieces in place,

drive seve ra l na il s in to the ply

wood alo ng th e e d geo fth e o th er

piece,

se e

F ig , 1,

GLUE T i JOINT. Vb en the

nai ls a re in p la ce both edg es ,

till one of the pa nels up an d

spr ea d a light fi lm of gl ue along

th e ins ide edge, Then gen tl y s et

th e p iec e b ac k i nto posi tion.

us e a piec e of plywood. ) A lso ,

place api ece of waxpape r under

th e pieces

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Voodsmirh

U ROUTt~

a S S

TEMPL n

TO LO lE

scaEWHOlS

2

MAKEMumPLf

PSSES WITH

THEORAIN

/4

M SONnt

WlNG

MULTIPU: PASSES.

S et th e bit

about Y a deep and rout the

workpie cew it l1 t he g rain . (Rou t

in g a cro ss th e g rain m ay c re ate

swirls on the face.) T hen m ake

another pass to

plane the

s tock to f in a l th ickne s s.

If

there

a re a ny sw irls l ef t on t he surface,

1 u se a SC ra per t o c le an th em o ff.

bottomsout

on

therightguide

s trip a nd th e

to e

b otto ms o ut o n

t he l ef t g ui de s tr ip .

If t he wo rk p ie ce is so w ide

that the plane can t bridge

a cr os s b oth g uid e s trip s, that s

okay.

Ai;

lo ng as yo u start w ith

the heel overoneguide strip , t he

toe o f the plan e will finally re st

On the far guide strip as you

work ac ro ss th e piece.

ONE MORE THING

There's

o ne other th in g

h ou ld m en

l io n h er e. [said that the final

thickness o f t he workpiece w ill

be the same as th e thick ness of

t he g uid e s trip s. T h a t s not ex -

a c t ly t ru e .

S in ce th e c uttin g e dg e o f t he

blade sticks out slightly below

the so Je of th e p la ne ,

thefinished

t hi ck n es s o fy ou r wo rk piecewiJI

a ct ua ll y b e a hair t hin ne r th an

the s tr ip s. If your thic kn ess b as

to

be xact

slightly in cr ea se t he

thickn ess of the strip s to

com

p en sa te f or t he b la de dep th.

~~~~ST

~ FaO M .

UnlNG INTOR ILS

1

No. 63

USING111EJ IG . After bul ldiog

th e

jig.

y ou're ready to p lane.

Start

b y s tic kin g t he wo rk piec e

d own on th ej ig b as e w it h d ou ble

s id ed c arp el t ap e, s ee F ig . 2.

mE art Ne xt, moun t a ny

flat

ottom

bil in t he r ou te r.

iter

SOm elesting, found a:l4 or JI, .

dia s tr aig h rb it worked the

b e s t

fortbelength,

cut iuwiceaslong

as th e w i dth o f t he jig 's

bM

N ow screw the w ing to the

ro ute r u sin g th e O rig in al b ase

p la le as a drilling guide.

Also, 10ke ep t he b it f rom

rout

ing into th e ra ils, 1g lu ed sto p

bl o ck s t o th e b otto m o f th e w in g

n ear th e e nd s.

se e

F ig .1 .

B esides planing tbin stock

w ith a h an d p lan e. I 'v e a ls o u se d

a ro ute r, m ak in g repeat.p a s s e s .

To do th is , I made a tw o-part

jig,

se e

Fig.

2.

T he 6 rst

part is a

b ase to h old the work pie ce . The

second

part

is a w ing a tt ac he d t o

th e ro ut er t hat sl ides Onth e bas e.

BASE.To m ake the base . c ut a

re ct an gle f rom

jI~

plyw ood a

li ttle longer than the length of

the workpiece , and about 3

wider th an y ou r w orkp iece.

N e xt . t o r ais e th e ro ute r u p off

the workp iece, I g lued rails

alo ng th e ed ges of the base. C ut

t he ra ils 1 4 w id er (h igher) th an

th e th ick ne ss o f th e work piece.

SUDING

WIN G.Af ter mak ing

t he b as e, I cut out a w ing to re

p lace the plastic base on th e

ro ute r. To mak e the w ing, rip a

p ie ce o f \ 4 Mason it e 2 w i de r

t ha n th erouter'splasticbase.As

PLANING WITH A ROUTER

GU IDE STRIPS

PLANE AT

S LI GH T A NGLE

dow n thin stop blocks

I

use

1/8

M ason ite) in fron t and in

b ac ko ft he wo rk p ie ce . A l so , 5 ta

c ou ple o f t h in s pa ce r b lo ck s be -

tw een the w orkpiece and the

guide s trips.

US ING THE J IG . A fter th e jig is

built, y o u ca n

begin

planing.

stan w ith the plane held at an

angle so the heel of the plane

bangs over one of the guide

strip s, see F ig.

2.

C on tin ue to

p lan e u ntil th e h ee l o f th e p la ne

tMIONG TIlEJtG.

T o m ak e the

jig.

start

by cutting a plyw ood

b ase, see F ig .

1.

Then rip two

guide strips to the final th ick

ness you want for tbe work-

piece. N ow place the

resawn

w ork pie ce o n th e b ase a nd tac k

th e strip s ab ou t 1 fro m e ac h

e dg e o f th e wo rk pie ce . ( To

k e e p

from dam aging the plane, set

t he b ra ds b elow th e s urf ac e.)

N ex t, to k eep th e w orkpiece

f rom movin g wh ile plan ing , t ack

If

you resaw stock on band

saw ,you

'refaced

with

thetaskof

smoo th in g t he rough-sawn su r

face. O n

s m a l l

pieces se a

h an d p la ne . B ut i~ s d iff ic ult to

p lane a onsi tent thickness

a cr os s t he e nt ir e p ie ce .

I 've fo un d irs w orth the tim e

t o mak e

a

jig th at h elp s sto p the

plane

a t

t he c or re ct

th ic k n e s s

(No te : F lI S t ,I re saw th e work

p ie ce a bou t VI o ver the final

thickness .

se e

page 22.)

HAND PLANING THIN STOCK

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N o. 63

oodsmith

a dju st ab le b o x j oi nt j ig f or e it he r th e t ab le s aw o r th e

rou te r table .)

HANDLE. The handle is p ro b ab ly t he mo st u n us ua l

part o f t hi s p ro j ect, T h e e as y

way

to m ak e a han dle is

to cut ito u to fa p ie ce o f~ s to c k, B u t t he re wou ld be

we ak s po ts a t th e u pp er c or ne rs w he re th e

grain

cuts

d irect ly acro ss the corner .

Instead , I laminate d t he h an dle fr om th re e pie ce s o j

V

s to ck . T he g ra in o n th e m id dle pie ce r un s a t r i gh t

a ngl es t o t h e f ac e p ie ce s. L ikep l ywood, this-strength

e ns th e p ie ce in b oth directions.

WOOD .

r

built the to olbo x fro m hard m aple . It s

s tr on g a nd will la st fo r y ea rs. u lum be r m ay be

difficultto ob ta in , s eeTa ik ingShopand Sources , pages

23 and24 . )M ap le c an ch ip ou tw hen p la n in l1 .(Fo r fips

o n p la nin g , s ee S ho p N o te s, p ag e 1 2.) P op la r o r r ed

gum woulda l sobe good cho ices. They reno ta s st rong

IS map le . but l igh te r a nd e as ie r t op l a ne .

fINISH Fo r max imum du rab il it y 1 decided to apply

two c o at s o f s em i -g lo ss p o ly u re th an e t o I be to o lb o x.

h e re a re two ma in con si der at ion s i nd e s ign ing a

t ool box :s tr eng th andwe ight It ha s tobe strong

en ou gh to sta nd u p to h ea vy u se . b u t l ig ht en o ug h s o i t

is n t a bu rd en t o c a r ry a round,

REINFORCEMENTS . The so lu tio n w as to b uild the

toolbox

bom

th in s tock

(V ,) .

bu t r ei nf o rc e t beweak

spots. F o r e xample , th e to p p an el o f th e lid is m ade

from V 4 s to c k tha t s b a cked w i th ano th er p ie ceo t V4

sto ck . T his b ac kin g lo ck s th e a ng le d lid pieces to

ge th er and p rov id e s a I f 1 1 ba se t o a t ta c h the h and le . s ee

t he C ro ss Se ct ion on the oppo si te p age .

T he b ottom o f t he c as e is c ut fr om

V 4

plywoodand

m o un te d in to ~ g ro o ve s. T o k ee p th e lip b elow th e

g roove s f rom b reak ing ou t. 1 added angl ed t rim strips

JO INERY.d e cided t o u s e box j o in ts f o r t hi s p r ojec t.

l ith e p in s a nd s lo ts m a tc h p er fe ctl y, t h er e s p le nty o f

g lu ing sur fa ce s and that create s a s tr on g j oi nt .

Th e box j o in ts a re a ls o sma l l e nough

(V i

x V ~ha t

th ey c an b e c ut o n e ith er a ta ble sa w o r a r ou te r ta ble.

(I n oo sn titk No. 42 w e show ed ho w to m ake an

H ow d o you m ake a toolbox that s both stro ng an d lightw eight?

O ur so lu tio n w as to use thin m aple an d join t w ith b ox jo in ts

We

a lso added a unique la m inated h and le on top

oolox

PROJ T

TUR

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15

o, 63

Woodsmith

c

ANGLID

R E I N F O R C f iM E N T

STR IP

low m C OM pAR TM EN T C AP AC ITY:

3'/...Dx7t'J-w' 1511;2L

L U M B E R

7 S q u G re H

V

solid m apl e

0 .7 S q u a re H 11 so lid mol l l6

24'

x

24'

plee Y 4 maple 0

blreh

ply.

HARDWARE

1Brossplonohln ge(P/ 6 X 13')

1

Bre s sb o x c c tc n

with

screws

6No. 6X :Vd'ro~ndheadWOOdSCl8WS

, See page 24 for kfflnfaClTlotlen

FINISH

Varnlsh: Solin polyur.efhone

SUPPLIES

ALSOREQUIRlD:

ONE 24.x 24 PIECEOF 1/. PLYWOOD

F OR C AS t A ND T RA Y B on oM S c, R

H H

s

~ .. x

3 . 3- 3 .7

Sq.

Ft.)

J

F

o

o

,

~

ANG lED IAC1< lNG

PIKE LOCI S lOP

S

TOGETHER

C T C H

REMOAIl

--

' eRA.

PIANO

HINGE

K

6

l

ROSS SECIION

p

p

Me

A

1 1

x 5 33 11.15Sq. Ft.Eoch

CUnlNG D IA GRA M

~ x I~ 16

V.x3-8

~ x316

'I4x4,,-16

'I.

X

4 '1.2- 15 l- 2

V.x I ll.-

15 '1 .2

V.x8-6 5pes.

FRONT

ANGLID

SIO

TOP

A Front/Bock 2

8 Ends 2

C BoHom(I)'

D

Stm,

F r/I l < Trim (2 )

E Stm, End Trim(2)

F HingeCleat< 1

G Fr,Tray

ledge (I)

H EndTrayled~(2)

1 Frant/Boc < 2

J EndS2)

K Mgled Sldef(2)

L TopO)

M

TopBocking(l~

N Hinge Cleat 1

o BoxHandle 1

T R Y

P

Front/Bock

2

'I. x 1% - 14 '~ .

Q

EndS 2 V.x Ill.- 6V .

R

BoHom(I)'

'14

X

6.

x

14''1 ,.

S Handle I

iI

x 2iii147/,e

These pieces are

V

plywood,

'I4J

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No. 63

oodsmitb

6

TltAY_/ _ I I

LlDGE --. .

CAStSIJ)E-- ;

SECOND:

MITER FRONT UbG

TO FIT INS ID E C AS E

CASE

BACK

Ll

~J~

h. ,_

END~~

P1 .YW O

jy

D

TRIM1

I IOTTOM

__.,:J,. 4 : : :

. ;_..., a.

45 ANGLE

TRIM STRJ:

MITE.

l j r-

CORNERS ' : .

I _~

TOFJT ~ 4 ~

NOT~-' t j 1

CASE

~_R~EI?~

UPSIDEDOWN

t

HINGE

C L E A

~GlUEfLUSH

4

~C~:: _

fiRST:

(UTHING

ClEAT TO 'Ii '_ '-

p ~

FI T 8ACK _

OFCAS(

I.... ~ ~

1 \

I-- .~ I ......

~ -L,3 ~

;....- FRONT TRAY

END LEDGE

TRAYLEDGE

UT twO)

THIRD:

MntR

a

ONT

' Il

01 END

.

mAY

L G S

.

TO fiT

(NJ) OF

CASE

@

~_J

fRONT/BACK

TRIM

b oth e nd s. T he se s trip s a re m ad e b y c uttin g

a \ (1 ode eprabbet

4

wide on one edge of a

piece o f W ' th iek stock, see F ig . 4b.

Then

m ite r b oth

ends

of the fron l Iray

le dge (G ) to

fit

in side th e fr on t of the case .

se e FIg . 4 . O n th e e nd tra y le dg es (H), m iter

the fron t end . but let th e back end bu tt up

against th e b in ge cleat (F).

N ow. g lue the

strips

in so the top edges

ar e 1 1 4 above

thetopofthecase ,

s ee Fig . 4b .

th e inside. Top rovide a sc re w su rfa ce fo r t he

Ji d

hinge.

I

mounted

a

hinge

cJeat(F)

t o t he

in sid e b ack o f t he case. see F ig. 4.

Cut th e h in g e c le at 1 wide and to length

to fit in side the case. T hen glue the cleat in

p la ce so th e to p e dg e is llush wilh the top o f

t he c as e back. see F ig.

40 .

TIlAY LEOGE.

T o sup po rt th e rem ovab le

tool tray . [g lued wide tray ledge slrips

an d R) in side the case on the fro nt an d

Alter the case is

dry. I

turned it o ver

and

added trimstrips Dan d E) to the bo tto m .

11U1II ~IRIPS.T o m ak e th e an gled strip s,

rip a 45 ' bev el on a piec e of ~Isto ck . T h en

s et th e b la de to 90 an d ri p th e angled.strips

of f the was te side o tth e bl ade.

Next, mite r th e strips to length an d glue

them in p lac e, s ee F ig .

3.

H I NG E C L EA T .Alter the trim is in plac e, I

turn ed th e case over an d started to work on

TRIM S TRIPS HIN GE CLEA T TRA Y LEDGE

ClAMP

l

OFF FLU SH

@

BonOM

PLYWOOD

T

lOGE

WASTE

T f

@

T s .

NOTE: CASE FRONT/BACK 4 1 1

AL LST O Ck (CUT twO

V ~~~T ~H~I C~K ~~~ ~==~ =~~~~~~~

cur 8 TTOM GROOVE D .EP

a.

CAS . ~ F~

rn rTf

@ ~

@K CUT

@ T 5

~~~=l

O P CASE END 4 r t

t EDGE (CUTtw O )

CUTGROOVE AT ' = = = = = = = = = : = = = i

THROUGHFIRSTPIN N; : ~

8

~ SCRAPPLYWOOD

KE PS C AS E SQUA RE

6

B01TO M .Ne x t, cut a n ,t deep groove fo r

th e

I I

plywood bottom (C) O n all fo ur

pieces. Position the groove so it cuts

th ro ug h th e

first

p in

en

th e c as e fr o nt) up

from th e bo ttom , see F ig .

1.

Af te r t he groove is cut in all four p ieces,

c ut th e p ly wo od bo tto m (C ) to fit.

ASSJ;AW LY . To

clam p

th e

c as e t og e th er,

I

used band clam ps and scrap clam pin g

blocks, see F ig. 2 . P ositio n th e b lo ck s just

b ey on d th e jo in ts

at

each com er. T o kee p

th e to p of the case squar e. Ilipped a scrap

p ie ce o f p ly woo d in to th e c ase .

PWG HOLE.Af te r t he ca se is assembled ,

th ere 's s till a little v oid in th ee nd s w he re th e

b otto m g ro ove C Om es throug h one o f the

b ox jo in l p in s. T o fill it , I glued in a wedge

sh aped p lu g an d cu t it o ff f lu sh , see F ig . 2a.

the bo tto m edge of each piec e a nd w ork ed

up . (The was te

a t the

topwili be c ut of f

la ter.)

The

case

end p ieces

B)

start w ith a pin at

th e b ottom ed ge an d th e c as e

front/back

p ieces

(A)

st ar t w it h

a

slot.

see

Fig .

la.

Pro ce du ra l N o te : l'I 'h ile th e jil( ' is s et up ,

you may a ls owant to cu tth e b ox j oin ts o n th e

lid an d tray p ie ce s (se e p ag es 17an d IS).

Ct rM 'OWlDTFJ.

Aftercutting th e b ox j o in ts,

Irimm ed down the case p ieces to final

w idth. First rip the case en d (B)so th e c ut

aligns w ith the to p edge o f the ni,lk p in up

tro m the bottom ,

se e

F ig. 1. Then cu t th e

casefron t

an d bac k (A) to

this

sam e width.

Note:

If

your dado b lade cu ts u tly I I

wide slo ts, then these pieces w ill be 4 1 1 4

w id e. T he im po rtan t th ing is to cui the

p ieces so th ey end w ith a fu ji p in o r slo t

1

began work on th e

to olbox by m aking

~?

the case . Start

by

~ c uttin g a

C8 e

front

an d back (both A)

an d two ends (8)

.........._ fr om

I I

st ock to

a

ro ugh width of 5 .

se e FIg. 1 .T hen cu t

th e front an d back p ieces

(A)

16 lo ng a nd

dIe en ds (8) Slong .

Pro ce du ra l N o te : Wbi leyou'reselup, you

ca n al so cut the li d pieces so they 're the

exa ct sam e le ngths, se e opposi te P 'l ll e.

B O X J O IN I'S.

A lte r th e p ie ces

are

cu t to

si ze . you ca n cu t I I box jo ints o n th e en ds

o f a l l f ou r p ie ce s.

se e

F ig .

1.

\ ' Ibeo cutting the box jo in ts J started at

CA SE

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17

ooo sm ith

NOTE:

LtD U P SIDE

DOWN

4S

ANGLE

.- - TOP

--~ BACKING

TOP

SACKING

U D H IN G E

CLfAT

\

,

.

NAMEIR

10

UD HINGE Q. CUT OFF

FWSH WITH

CLEAT

c t : ; t = = = = O = T T , O . , M , : : O f = U : : D = : : j

N OTE: C UTU DTOPTO

n

OPfN~NG

B nw tE 'N A NG lE D SIDE S

ANGLED SIDES

2 \0

lEVa.

SECOND:

CU T 22 h

EVl1SO

W10TH

MA~ES

AN GL E

ONEND ~r~..

LIDTOP

ANGLED

SIDE

9

22~

UV EL

ENDVIEW

Sn

CLAMPING

D

FRONT /BA CK

7

M AR K W HE Ri IN D

MflTS fRONT/BACK.

THENRIPUD

fRONT/BACK

AT22.,.,

CUlTO

MATC H C ASE

C U T 45

ANGLS OFF

CORNERS

CUT45

~L

.... ~-TOAUGN

WITH CO f tN rR

NOTE: UD ENDS

FRONT/lACK PIKES r_-r,,-IC _UT _TW _O _:.I.....,,-ry-FT

ST AR TW m I A PiN .

-r

THEN cu r

TW O SL OTS 0 3

o

UO N

Q

C 1

COTTO

MAtCH CASE

1------------1.-

N o. 63

Once th e lldfram eassem bly is dry, yo u can

cu i t he t op p ie ce s. Th e top ism ad e o u to ftwo

a ng le d s id e s

(K)

and o ne li d t op

(L).

ANGI, .EDS l)J;:S.1

s tar ted bycu lt ing thetwo

angled sid es (K), see Fig . 8 .

Rip

one ed ge

of e ac h p ie ce at a 22lfl angle to a rough

wid th of 3lfl .To determine th e final width.

ho ld the piec e in place and mark ih e point

w here the angled com er on the lid end I)

m ee ts th e a ng led side piece (K).

Now rip th e p ieces to width (at V: on

t he p en ci l mark and cu t them to length.

TOP . Once ihe an gled p ieces are g lued

down, th e top p iece (L) fils in like a key

stone , se e Fig . 9 . F i rs tc ut o ne e dg e a t 2 2 1't.

T hen s ne ak u po n

theother

ed ge

untilitfits,

BACKIN G. Next , I r ei nf or ced i he

to pw ith a

backing p iec e ( 1),

se e

Fig . 10.To m ake

t hi s p i ec e, firstcut it to le ng th to fiti ns id e th e

lid . Then rip the edges at 45 and glu e it in.

HINGe ClE \T.

T o pro vid e a screw ing su r

fa ce fo r t he hinge, Im ou nted a h io ge

cleat

(N)

o n th e b ac k

ins ideofthe lid. se e

Fig.

10.

R ip o ne edge at 45, and cu t the other edge

flu sh w i th t he bo ttom o f th e

lid.

see F ig . lOa .

CHA\fFER. Wilh th e clea t g lued in. rou t a

chamfer a ro un d th e isi4 e 'ellge of th e lid

front and ends to m ake the lid fit easier on

th e c ase, Y ou may also have to bevel the

outside

o f t he tra y

ledges, re fe r to Fig . 4 b.

LID TOP

LI FR ME

Tbe basic cas e is

r 5 ~

complete at tbis UD FRONT/BACK

(CUTTWO )

1.

p oi nt. N ext , YOuca n All STOCKI.. HICK

build th e lid . B eein ,-------------------------,

0

I i \ 1~.

by cu tling the lid 0

ROUGH

fro nt and back

p ie ce s I)

l:jl~

wide

a nd th e sa me length

as lh e case (16 ),

se e Fig . 5 .Then cut tw o lid end s(J ) 3 wide

and to leng th

to

mat ch th e case

(8 ~.

BOX JOJ.l(lS. W i h the pieces cut to size,

yo u c an c ut the box j oi nt s. On ce a ga in . s ta rt

from th e bottom e dg es . s ee F 1 g . 5 .

Note: Only

w

slots are cu i in th e

fro nt/back p ieces so th ere 's ro om to b ev el

th e to p edg es later , refer to F ig. 6 .

CU T O FFANGus. After th e b o x jo in ts a re

co m plete , cut a 45 angle o ff t he to p com ers

of the end piec es

0),

see Fig .

S.

To d o th is.

make th e cu ts o th e a ng le a li gn s w it h th e top

o u ts id e c omer o tth e second pin.

see

F ig . S a.

ClITOFF FRONT/IlACJ( . Next . dr y a s semb le

ti le li d p iec es . Where the an gled comer you

jus t cu t 00 th e end piece m eets the front

piece. m ake a m ark, see F ig . 6.111eo rip th e

fro nt/b ac k p ieces at22lfl so th e S h01'tpoinl

o f t he a ng le e nd s at th e mark.

ASsEMBLY. Now glue thesefour l id p ieces

togeth er. To hold them square. Ila ce d

th em

on

th e .assem b led case . se e

Fig .

7.

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No. 63

I l

GLUEHANDl

TO BOTrOM

it to len gth to f it i n side th e tray.

To form the grip , f ir st d ri ll Lwo1 h o l es 1

do wn fr om th e to p e dg e. see F ig. 12 . Then

cut betw een the holes w ith a sabre saw .

Now , cut angled sections out 01 the top

C Om ers o f the handle. see Fig . 1 2 . Th en

ro un d o ve r th e in sid e o f t he g rip an d th e L O p

e dg es w it h a

V .

r ou n d-ov er b it. see Fig . 1 3a,

A IT ACIIIIJ \NDL . A fter the edges are

rounded, glu ed the handle to U te inside

bottom of the tray, see F ig. 13 . To

s tr en g th en t he jo in t, d ri ll a

a

ho le th rough

th e en d o f th e liay and into th e hand le, se e

Fig . 13 b. T hen glue a short length o f 4 i

dowel in to U te h ole an d

trim

itnush .

,

ASE

CARm

T P E

Woodsmith

8

,.- -----, Sometimes irs h andy

to just carry a tray

filled w ith tools in

st ead ofa whole tool

bo x .

S o

I i nc lu ded a

removable too l t ray .

CUT

PI

E CE S. T o

make the tool tray.

-- --l

s ta rt b y c u tt in g a

tray

front an d back (b oth P) and tw o end s Q)

from V 4 stock to a rough w idth of 2 , see

F ig . 1 2. T o d eter mine the le,ng tb of these

p ie ce s, m easu re th e d istan ce b etw een th e

tray ledgesioside the toolbo x and th en su b

t ra ct V ' s ( so t he t ra y f it s c omfor ta bl y).

TRAY

I . . . . Jv 'T

L > ;J

TR AY FR ON T B ACK

(CUT

IWO) ,;-.'

2

.OTTO~jWA

GROOV

Ih DEEP

b

CENTtR

HANOU:

ON TRA Y

3

GLUEINPWG

'- __ THeN CUTOFF F lUSH

a

P NO

HINGE

.n.

DR ilL 8I T

T o m o unt ti le h inge, Itarted by S l lr ewiug

o ne hinge leaf to the mortise in the lid.

Then. stick a narrow str ip of double

sid ed carp et ape o n Ilte to p ba ck edge of

th e ca se. Now . set the lid on top of the

c as e s o i t's

in

th e d os ed p os it io n.

N ex t, c are fu lly o pen the lid a little

w ay s, re ac h in sid e, and pr ess the b in ge

leaf d ow n tigh t again st the carp et tape.

Then open the lid al l the way and put a

b lo ck o fw oo d unde r th e lid 1 0support it.

N ow driU ho les for th e hinge screw s by

d riU in g th ro ug h th e h ole s in the hinge

lea f and ri gh l o n th ro ug h th e carpet tape.

s ee dr aw ing . Fil\ally. re mov e t he a pe a nd

s cr ew th e le af d own tigh t.

H INGE MOUNTING

BOXJOINTS.

Aft er th e pi ec es ar e

CUl

to

siz e. you can cut th e bo x jo in ts. The proce

dure is the sam e as the ca se - start at the

bottom of each pi ec e an d w ork up .

Thei l rip the pi ec es to w id th so yo u e nd u p

with

f ou r f ul l p in s o n t he f ro nt /b ac k piec es.

BO ITOM.

Next, cut a gro ove fo r U te b ot

to m o n a ll the p ieces. T he n c ut th e p ly wo od

tray bottom (R ) to f it b e tw e en th e g ro o ve s.

IISSEMB~Y.The proce du reforassembtin g

t he tr ay is the sam e as the case.

e

sure to

plug the h oles m ad e b y t he b otto m g ro ov e.

R AN D LS . o m ake the tr ay handle (S ). I

used 1Il stock. First, cut the handle to a

fi nish ed w id th of il f. , see Fig . 12 . 'Ille n cu t

a,

AFTER.ROUTlHO

C l A N U P T O

YOUTUNf

WRHCtiJHL

CUTH INGE

ATKNUCKU

JO lNT UNE

Ot TANCf FROM SCREW

HOLE

ND OF

I-.J HI NGE SHOULD

aE UN IFOR M

AT80TH

O S

me lid . B e gi n b y l ay in g o ut th emo rti se so i t's

c en te re d o n t he bac k o f t he lid .

Io ute d th e m o rtise w ith a st ra ig hl b il o n

th e ro ut er ta ble, see F ig . 1 1 . R a ise th e b it so

the h eight o f t he bit equa ls th e th ic kn ess of

th e h in ge. see Fig . 1 1a .

To

routthemortise,

move t he li d b ac k a nd

fo rth over the bit ro uting comp letely

th ro ug h th e lid b ac k

I

and the h inge c le a t

N).

r

sto pped short of U te end lines an d

c le an ed u p t o th e l in es u sin g a c his el.

A fter the m ortise is co mplet e. you

~ a11

mount the p iano h in ge. see b ox at right .

A f te rt he l id i s c ompl et ed . it' s a tt ached to th e

c as e w it h a p ia no h in ge .

CUTIlNG

TI:IE

SINGE.I

tarted by cutting

a

1Vlsltwidepiano hinge to length . To deter

m ine t he l en g th , t hr ee t hi ng s shoul d bec on

sidered : th e len gth m ustbeshonerthan the

case; both ends should be cu t at knuckle

jo in t l in e s; an d the di s ta nc e f rom th e end of

th e hinge to th e first sc rew hole sh ould be

uniform on both ends. In my ca se . I cu t the

hinge 13 lo ng . see Fig . 11.

mNGE~IORl1SE.

Afterc ut ti ng th e h in ge t o

length , you can cut a matching m ortise in

HINGE

7/24/2019 Woodsmith - 063

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19

F IL

Off

S l W S

fLUSH wn'H

IN S ID E O F

ue

BO X CATCH

CENTttlCA1 CH

ON TOOLBOX

2

o

NOTE :

SOfTEN ll f GES

OF PIVOT BLOCKS

A N D HA ND1 .E

EDGES

FOft SMEJ Y

7

a

TODRIU HOLE

AT90

HOLD

B L A NK FLA T ON

Rill PRE S5

WITHClAI \P

Woodsmirh

NOTE :

CU T 4 5 A N G LE S

O FF CO ft N E R S

PIVOT

BLOCKS

8

4 ' ANGLE

~~DlA

H O LE S

WArn

BOX HAND LE

@

OURTH

RIPOFF 2

WID EH A N D l f

8 LA N K

H AN D LE P I E C E S

At15TOCK

V

THICK

6

1-3 -1

P IE CE S T O S Jz r

- - - - -

.

.

\

@

@ @

J

I

I

4

FIRST:C UT' lHREE

SECOND :

C UT O NE PIEC E

IN HA Lf

N o. 63

o ff t he screw s on th e in sid e of the lid.

The last part to

make is th e hand le

(0) and the tw o

b lock s that ho ld th e

hand le to the lid .

HANDLE BLANK.

S tart by lam in at in g a

b lank from three

p ie ces o f ~ s to ck ,

se e

Fig.l4.

Cuttbe th ree pieees3 wideand

6 long. Then

cu t

one of the p ieces in half.

N ow tum th e tw o

half

p ieces so th e grain

ru ns alri ght an gles to Ihe6 lon g p i ec es a nd

san dw ich (glue) th e half pi ec es b etw ee n

th e lo ng p ieces.

Afte r the g lu e dri es , ri p th e bla nk d ow n to

2 w ide fo r th e hand le and sa ve th e w aste

p ie ce /o r th e p ivot b lo ck s. B e fo re c uttin g th e

sh ap e o fthe ha nd le,

I

tr imm e d th e

blank

to

5 \ 1 2

long and rounded over the bottom

e dg es w ith a V a

round-over

bit,

se e

Fig.

l~ .

INSIDE

ClnOUT.

N ex t, to

form

th e in side

co rners o f the handle, drill two :ol -dia .

ho les, ll la from each end , s ee F ig .

I S . T h en

la yo ut th elllsid eed ges o Ctbe h and le .

B efore cu tting out the handle, ril led

2 d ia. boles in the ends of the hand le to

ho ld pivot pin s, see F ig .

153.

CU T O U T S RA PE . N ext, cu t ou t the inside

edgesoft l iehandlewith a band

saw ,

sec F ig.

16 .T o fin ish th e shape, trim 45' a ng le s o ff

the top comers .

RO UN D O VER EDGES .

T o m ake the

handle

mo re com fo rt ab le t o g ri p, ounded overthe

top edge and th e in sid e e dg es , se e Fjg.17.

PIVOT BLOCKS. Afte r the handle is

co m plete, ad e th e p ivo t b lo ck s fro m th e

s tri p c ut o f f t h e handle blank. Start by

cut-

ting th e s t rip :v , , wide, and then cu t 45

an

g les off th e top comers, see F ig.

18.

Next ,

d ri ll tw o p ilo t h ole s n ea r each e nd to a cce pt

the m ounting screw s. Then cut the lll.l

lo ng p iv ot b lo cks offbo th ends of the strip.

P fN S , The hand le is he ld to the p ivot

b locks w ith p insmadefrom No.sscrews. To

do th is, s tart by dr illing a 2 d ia . ho le

centered on the inside end of

ea ch

pivot

block. se e Fig. t~e xt, tighte n a No.6 x

: V screw int o th e hole lea ving

\ I ,

of th e

sh ank show ing. Thencu l of ft h es crew hea d .

MO t lNTlNG U HANDLE . To moun t th e

han d le , fi rst cen ter the handle an d pivot

b locks on t he to po fth e to olb ox . L e av e a b ou t

V 6 be tw ee n th e handle an d each b lo ck to

prevent b in din g, se e F ig . Z O a.

N ow , to locate the screw holes , tip th e

blocks on th eir s ides and draw lines down

fr om the tw o h ole s in t he b locks onto th e lid ,

see F ig . 20 . A fter d rilling shan k holes at

thes e po in ts , tig hte n th e p iv ot b locks down

to th e lid with roundhe ad woo d

screws

CATCH. To com plete the too lbox , 1

centered a c atch o n th e fro nt of the too lb ox

a nd s cre w ed it dow n, see F ig . 21 . T h en fi le

HANDLE

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20/24No. 63

oodsmith

20

MakerepeaUdpa8811Sover

i l I ella o f tw o test pieces

The il check Ulilfit tiltJliI out-

8 ide su r faces a rej l I sh .

Toremovethe V-cu t3 , s li de

th e

1Uo kpiece

rig ht a nd

l ef t over b lade1Uhi le

pushi l lg

it

fonoarda uf back

W h e a d tu to

se t i8 IUled

the bevel t eeth

Ott

Ut8

ld

side b la d es ma ke small

V Mlts

intheface ofUw hal/lap.

INTlaMfDt Tf UT

1. lCUT

-

FJN CUT

HOU WITH MmIt

G UGE ND USf

f[NC(AS STOP

Moun t

a dado blade and

86tUlAfettce U a s to p. U se

a 1Uorlcpice10 set the distance

bet1Ueen Uwenu and blade .

MUI;nPIJl PA

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21

oodsmith

F AC E P IEC E

JIG SHOUlD

fRictiON

m

O V E tt F tN C E

s

V E RT IC A L S T OP

M U ST B e 9 0

T O T A 8 1 1

L O A t E

S C R E W S A B O V E

8 L A D E P A T H

CROSS PIC[S

M T H F E N E

TH ICI NESS

NOTE:

C U T A L L P IE C E S F R O M

P L Y W O O D

A s th is s top is added, make

sur it's vlJrlictt/ to th saw

table . T he

on ly o th er c a ut io n

is

to m ake sure

th e

screws

a re

abo ve th e p ath

of

th e bJade.

and test tile fit over th e fence.

Then add sh im s ifnecessary,

V IlJm C A LST O P. 'V hen tltejig

s lid es e as ily but fi rm ly . add a

vert ica l stop O n the back end.

TENON

unlNGJIO

n a rr ow , t he ji g wil l bin d on th e

r ipfence.

f th e cross pieces a re to o

w ide, the jigw ill be looseon th e

fe nc e. 1 11eo irs

difficu lt to

ad

ju st w h e n s n ea k in g

up on

the face

cut.

SlUMS. How do

you get it perf ( C t? I

U yto getthe p ieces

r ighton th e m oney.

J; lu ti f l 'moff,ltryto

err by m aking

them

tO O

narrow .

Then sh im out

W ith paper or o ld

piayingcards.

ADO FACES . Aner

cutt ing th e cross

p ie ce s, c ut th e fa ce

p ie ce s a bo ut 6 by

1 2 . S crew a ll t hese

p ieces togethe r

N o. 6 3

The jig Is e t o m a ke th e fa ce

cut for an end la p is th e same

o n e u se d for culling tenons, It s

w hole purpose is to ho ld the

w orkp ie ce vertica l a s it's

gu ided th rough the b lade.

The jig is designed to

straddle th rip fence. Th is

ho lds i t.D pos it ion and a lso p r o

videsawaylo adjust i tsposition

in re la tio n to U le blad e,

CIJI PlECES.

The jig c o ns is ts

o f tw o fa ce s he ld together w i th

crossp ieces. There 'sa lso a ver

tic al s to p a t th e e nd o f th e jig .

To m ake th e jig , firs t rip tw o

c ro ss p ie ce s to w id th to m atch

th e th ic kn es s o f yo ur

rip fence ,

T his w id th is fa irly c ritica l b e

c a us e y ou wan t a good f ri c ti on

fit agalnst the fence w hen th e

face p iecesa r e added.

if the p ie ce s a re a hair to o

TENON CUnlNG JIG

8

TJ I6 seU inU8 desc ri bed : i n

Steps

5

a n d 6 1o ov6aS III.aU

eon,er 1:,~tll6siloulder flwt 8re

mooed.with

0.

isel.

Ho ld t Jl 61 I Jol k ,J ie ce i n th e

te>))~ig. Tilen grad,w.llll

m ove th e fence til the blad e

clds

halfthe

thitkne;;.~.

SECOND:

N OTE: KtfP CHfSEt CUT

ou r

sorroaFLAT WASTE

AGAINST FA CE ,

S et fen ce to c ut sh ou ld ,

equal to lo , d tho f , -a i l. Set

blade Iwight

1/16 ieee tJIIJ

)lIJlf

tite tJlukilwss oftltestock.

FIRST ....

DOWNON .

7/24/2019 Woodsmith - 063

22/24Na.63

oodsm i[h

GUID

f or c on si st ent cuts, I use a clamp the guide to t he t ab le. tail end of the piece in that

sim ple shop-m ade guide as a W ith the guid e in place, you direction and continue to push

f en ce , s ee F ig . 1. (Note:

If

the can begin cutrtng. Push the the .stock through the blade.

blade C01 t inWlUy d rif ts o r if b oa rd tig ht ag ai ns tt he gu id e, U The rad ius on the end of the

you re resow ing a number of you see the piece start to drill guide allow s you to sw ing the

l on g bo ar ds, set up an angled off the line, sim ply sw ing the piecew ithoutbi nding.

fence. For m ore information, r1~~~~~~~

ee

I f ood mW I,

No , 5 1 .)

i f - . . . :

J . . . . -

Theguidelorreeawingshort

I \

.'~~ ~~ D C U T

piecesismadefromascrap2x4

.i

C ~ ; 4 v m

a

SUGHT

clamped on edge on the band

sawtable.Cutaslightradiuson I

th e e nd o f t he 2 x4 , se e detail.

C lTI UN . Be fo re r es aw ing,

m ark a cut line on the edge of 17 _ . _ ~

the w orkpiec e, w ith a pencil

.A:. /~

a nd a c omb in at io n s qu ar e. I ; ;

/

MAKlNGTHEClTI'. Now . line ~~ . ;; ,~ 1-, The firs t s tep in resawing is to

mount a high fence on the table saw.

se a

6

hig h a ux il ia ry fence t ha t i s s cr ew e d t o t he

r ip f ence , see F ig.

L

T his fence help s

pre

venrth e

s to ck f rom t il ti ng a nd ma kes il eas

ier 10 ste ady the piec e as i~s being cut.

ROUGHcur, A ft er I'veattached th e high

fen ce to the rip fenc e, I resaw in tw o steps .

F ir st, I r aise th e b la de 11 -2 a bov e t he t ab le

Resawing

WOODW ORKING T HNI QU

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oo dsm irh

o. 63

tio n dates

011

all bot tles of

Tite-

bond ( excep lga ll ons) . Ifa glu e

bot tle isn 't la be lle d, y ou s ho uld

date it yourself - especially if

you're b uy ing a large quantity.

A f te r I'v e h ad a b ottle Jo r a y ea r.

I start to get susp icious ,

A lso, it's best to buy from a

de aler who sells a lot o f g lu e.

You 'll h ave a better chance of

ge tt ing a fr esher stock of glue .

One o th er th in g. I try to k ee p

th e lid o r c a p o n U te b ottle to p re

ve nt the glue from getting a

skim layer.

ROIVdoyou know i ta bot tleof

g lu e ma y h aver ea ctie d its tim it?

-I i

th e g lu e sta rts to th ic ke n

o r g et v er y g r ab by, t ha t's u sua ll y

ind icative of th e [act irs on its

w ay o ut, It w o n't c ha ng e color.

ll

i t separate ifit 's b ad ?

No. there is a little bit of

liqu id s epa ra tion at the top or a

dark line around the to p . it can

be stirred back together. A s

long as yo u can stir it b ack in so

it lo oks good, it isgood.

In the

r

o f 1 98 8, Franklin

Chem ica l b eg an pu tti ng e xp ir a-

Doyle , of Fran k li n's Ch emi ca l

R ese arc h L ab. W e advertise a

m inimum of one ,ear. That

wou ld be fro m th e tim e the con

su me r b uy s it, So, in reality . by

th e time ti le g lue is used itcould

be 18 m onths or m ore from the

da te o f manu fac tu re.

T ha t is s u bje ct to sto ra ge c on

di tions . H ightemperatures hor t

ens sto rage t il e. Ifit 's f rozen and

thaw ed 10 or 12 tim es, that

wou ld shorten it. Butlight(ultra

violet rays) doesn 't ha ve a n eg a

tiv e effect On it. '

S ince we u se T itebo nd brand

glue most of the tim e in the

lVoorhmith shop. I decid ed to

ca ll Franklin Chemica l. th eman

ufacturer o iTit ebond, to s ee if I

co u ld li nd t he a nswer.

S)lelf life On Titebond an d

mo st o f the ot herye llow gl ues is

vague, ' explaine d Dennis

r

th er e a s ho rt siU J /f li fe for

gl ue like th er e is for som e f in

is/rt S s u eho

s/rel/(u;?

WayneBoyd

Den ve r, Colorado

GLU SH LF LIF

is

the AP 10 pla 'le,' f , om

Ryobi. It produce a

smooth .

fin ish dmQII

to as

th in as 1/

th ic k o n l( J' wid e s to ck ,

though

th e V boa rd a ctu all y

has less

~'017'me

of lumber in i t.

T o e lim in ate th e c on fu sio n.

th e standar d practice is to list

th in lu mb er a s a su rfa ce dimen

sion (s qu ar e (e e ). ra th er Ih an

boa rd fee t

WIDTHS AND LENGTHS

Anoth er th in g s ho uld be n ote d

about t hi n l umber . It 's of tensold

on ly in random widths and

lengths. S o you should order

extra lumber to allow for

po ssible ed ge gluing, and to

c omp en sa te for short pieces.

A th fchneJlspiamer'i on e oJthe

easie st metho r pl linu

lsunber ,nooth and

t o

a con

sist em th ic klre ss . P idu redh ere

in g h ar dwoods . Its ac tually a

measure of

vol m - .

(F or mo re

in fo rma tio n o n b oa rd f ee l ref er

to Woodi, . . , itl1No. 61).

The standard practice, when

figurin g

board

fe et, is that any

thickness less than 1 i s still

Iigured a s if itwer ea full1 thick .

When d ea lin g w i th t hin l umbe r,

Ul is c al l g e t a l it tl e con fu s ing .

t means that a V .1 thick

bo ar d c ou ld be listed as h aving

the sam e num ber of board feet

as a ~4 th ick b oard that's the

sam e w idth a nd l en g th - eve n

$400 i s s ti ll a l it tl e beyond their

sh op budget .

S o on page 13 , we've de

s cr ib ed a c oup le o f in ex p en siv e

techniques{o r plarting resawn

lumber . One o f theme thods use s

a t rad it ional hand p lane. lh e o the r

is

a

low- tech j ig

th at

employs

a

ro ute r to d o a ll th e p la nin g,

hand plan ing

seem s like too m uch

wor k . th ere's a sim ple alte r

native - g et so me on e else to d o

it. \Ve checked around

and

f ou nd t ha t s ome lo ca l c ab in et o r

m il lw ork sh ops w ill pla ne y ou r

stock dow n to V 4 or lesss, The

go in g rate fo r sh op tim e in our

area isabout$30to $4 0pe r hour,

and most shops have a m in

im um cha rg eo fS 15 to $ 20.

8UY NGTHIN UIM8ER The

J ina l a l te rnative is to buy th in

lumber

th rough the mail -

w hich can be expensive. (F or a

list o j m a il o rd er s ou rc es fo r t hin

lumber, see

page

24.) Before

pl acing a n o rd er. y ou sh ou ld

k no w a coupl e th in gs ab ou t h ow

thin lumber is usua lly speci fi ed,

SQUARE~llErVS BOARD

rssr

First, lumbe r u nd er ~ hick is

us ually so ld in square fee t. no t

/lOlwd fe e t

Note : B o ard fe et is th e s ta nd

ard

unit of m easure w hen buy-

Two of the projects in thi s

is sue, th e Tool Box an d

the

Chi sel Case, use th in

(Y 4)

stoc k. That's someth ing that

you 're

no t

likely to fin d at yo ur

local lumberyard.

lllCKNESSPtANER .11 eeasi

est solution is to u se a th ic kn es s

p la ne r t o s ur face th e lum ber to

exa ctly th e tllickness you w ant.

Okay. let's be realistic. T he

cost of a p la ne r is d iff ic ult {or

m ost h om e-sh op w oodworkers

t o j us ti fy -

with

one exception .

A fe w y ears a go , ~yobi i nt ro

duced a tight-weight 10 pI-but

don'twanltospendthousandsof

dollars.

()1'H)1RMtm lOD . A lth ou gh a

th ickness p laner is a g reat m a

c hin e to ha ve la a s ho p,formany

hom e w oodw orkers the extra

THIN LUM R

Talking Shop

QUESTIONS

NOMMENTS

7/24/2019 Woodsmith - 063

24/24

Woodsmi t h P ro ject Supplies

a lso h asth ree har dware kit s for

t he L in ge rie D r es se r in

Wood,

sm ith N o. 5 3. E a ch k it c on ta in s

your choice otdrawe r pull s (see

photo) an d all the hardw are to

com plet e th e project .

753 110 K it LO A 539.95

.753120 KitLO B $39.95

.753 130 K it WC $24.95

A ll th re e o f th es e kits al so con

tain the foll ow ing:

7 )

pla s ti c r et ai ni ng buttons

(use d fo r th e dra wer st ops) .

20 fe el o f s elf adheri ng pla s

tic glide str ip fo r th e d raw er

sl ides ,

f you need extra

parts

or

w ould li ke to use th is h ardwa re

an other proje ct, w e ar e offer

in g the draw er pull s and the

glide strip ind iv id ually . (T he

glide strip comes in 10 foot

le ng th s only .)

753112 G lideStrip ..... $4 .95

.464-753 Pul iLDA . $4 .9 5 e a.

464-722 P ull L D B. $ 4.9 5 e a.

75313 i Pull L OC . $1.25 ea.

UNGER IE DRESSER

Woodsm ith Project Supplies

now has hardware for the

B lan ket Chest th at we fe atured

in

Woodsmitk

N o. 3 2. T h e kits

in cl ude your choice of pull s (s ee

photo) and . all the necessar y

har dw are for th e projec t

732 100 K it BCA $59.9 5

732 200 KitBG B S59.9 5

732 300 KitBCC SS9.9S

A ll of th e a bo ve kits in cl ude:

(2 ) 2 x 3 So lid B rass H inges

( 1) Full M ortise Chest L ock

(1 ) Sa tin B ra ss L id S u pp ort

Th is lid support fe atu res an

ad ju sta ble tensi oning rod that

le ts y ou fine tu ne th e am ount of

res is tancenecessary tokee pthe

lid in position , It al so k ee ps th e

lid from sla m m ing shut.

fyou w ould like to p urc ha se

either the lid supporter t he p ull s

individually . s p ec if y t he follow

ingord er number s:

.732 104 L id Support. $22.95

732 101 Pull B eA . $4 .9 5 e a.

732 201 Pull BCB . $4 .9 5 e a.

BLANKET

CHEST

oodsm ith P roject Supplies

is now off ering new har dware

opti ons for th e tw o hei rl oom

pro je cts shown her e.

PROJE T SUPPLY UPD TE

THIN LUMBER

Toolbox H ardware T oo lb ox T hin Stock

T LOGS

There are se veral so urce s fo r

.7 63 100Toolbox K iL . $5.95

763 200TIl in Stock .. $ 3 4 .95

T U

fo l w l u i Y I g eo,Upa91ft' Vlt'6

th in lu m be r a nd we have li st ed a

(1) 1V 6 x

13

Brass P iano (1 2 .)5 x 17P ie ce s, 1 A thick

S i1 } l - tW )

ha rdt{l 1r6

or 8 1 . p p l i e a .

fewofthematthe right Lookfor

Fnngewith B rass

S c r e w s

(2 ) 3Y 'Z x

17

Pieces , W (h jck .

Pka .6 re er to tlt .' r catalo g

th e co de

TL

af te r be address .

(1 ) B o x C atc h w i b S cre ws. 2 ) 8 x 1 7 Sh ee ts o f 4

l he

OJvmtlg

TOOLBOX

(6 ) #6

x : y

Rh

BrassScrew s. B irch P lyw ood .

A lb ert

Constantine

T I le h a rd wa re that w e used on

ORDER INFORM TION

2050 Eas tchester Rd .

th e T oo lb ox isava ll abl e t h rough

B rOIL ,N Y 1 04 61

W oodsm ith P ro ject Supplies

BYMAIL BYPHONE

TLT

or from one of the catalog

Bob .Mo r ga n Wood wo r Qng

sources li sted at th e ri gh t (see T o o rd er by mai l. use th e form For Caster serv ice use our

1123 B a rd sto w n R d .

codeTB ). on the pro te ctiv e c ov er of t h is Toll

Free

order line. Phone

Louisvi l le, K Y 4 02 04

W e are also offeri ng all the issue or w rite your order on a orders can be placed M on.

TL

th in lu m ber n eed ed to b uild the p ie ce o fp ap er , a ndse nd it with thru

Fri.,

8:30 4 :30 CST.

C raftsm an W ood ServiceT o ol bo x. T Ile lu m b er

is

al l kiln- your check or m oney order Before you cal l p l e as e f iI Iou t

d ried hard m aple . except the (please include$1.5 0 sh ipping the order fo rm co m pletely,

1735 \V . Cort land cc

plywood wh ic h is IA birch . char ge w ith each ord er). lA V J S A or M C orders only .

A dd ison. lL60101

A ll of th e m ap le has bee n s u o

res idents ad d 4% sal es tax .

TL, TB

la ce sanded on both s id es a ndall

Send ord er to :

18 444 7 2

The W oodw ork ers ' S to re

the edges are cut squar e.

\Voodsmitb Projec lSuppUes AU , ~ 6 ./or dI ll ivery 218 01 I ndu s tr ia l Boulevard

Since tbe lum ber is cut to

P . O . 8 0 ,, 1.0 350 ote PriWl ubje~Jto ClitlQ6 Rogers . M N 5 53 74

spec ial spec i fi ca tions. w e are in-

D es foines , IA50306 u t

TL,TB

e lud ing a new cu tt ing d iagram.

our es

SUPPLIES

ROJECT