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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

    Woodsmi th

    Publishing Co .

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    SubscrIptIons: O ne year

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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

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    5

    oodsmith

    o . 6 3

    EXPLODED VIEW CORNERSTIFFENER

    STIF~ER

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    E . . . . . . .

    ~l

    44 \1 4

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    , , &

    H

    8x;1Fh

    SHElF

    S~lF

    ~wOODSCRew

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    STIFFENER

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    . . .

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    W-OlA.

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    WOOD PLUG

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    - . . . : : : : - . .

    SHELF

    - . . . . : : :

    ~

    6

    STIF~NER

    , ] I

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    STIFFENER

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    , : :

    ; '

    STilE

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    47

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    1 =

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    .'t--:

    S~lF

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    SHELFDOWEL

    ~

    ~?:::

    SHELF .

    ~

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    SUPPORTDOWEL I'-

    I

    SHlF~ENER

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    c I'- ~

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    STill

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    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

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    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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    15/24

    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

  • 7/24/2019 Woodsmith - 063

    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

  • 7/24/2019 Woodsmith - 063

    21/24

    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

  • 7/24/2019 Woodsmith - 063

    23/24

    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

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