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Plus
s
Fo r Y our R ad ia l
rm
Saw
NOTES FRONt THE SHOP 3 95O 72
8/20/2019 Woodsmith - 072
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H
)
do you
gd R pit..· ., 01
w,.,d
10
bend in
a
g(·ntW.grru. ' t : (uJ
. ,I1Ve?
It s a ta sk tha I d o es n t s ee m natural . Ye t
lt's a 10 1eas ie r than it looks - and a whole
10 1mc.sit ·r . tu<, .
One or 11 ,,,
mO$1
popular
projects
1l,.1
in
volves bent wood is a ha l l
tree
[o r hats and
coats, The I'.,.e.1tlung about • ha l l I .., (.,
le a st ( rom a wo odwor ke r', puinl o f v iew )
i.
t h a i i t' sa p r og re s s iv e te s soa in ho w t o m ak e
ben t wood l amina t ions.
The legs a re
3
sim ple L .· bend T he C oa l
hoo~'S ge l a linlc m ore co mp lic ate d .. it h S
bends. Then to
hold
t he S hoo ks 10 th e p o sr,
y ou h av e 1 0 m a k e a comp l et e cirrle , a rin g.
And
10
mal ,
th e rin g a
liule
mor e
of
a c ha l
l enge. it's round in cross-seetion 3
rf ' f l
shaped piece
fon nin g a
ring).
The
basic p ro ce ss fo r m a kin g b en t la ou
na t ions is<impl ,. : rip t.hin str ipsof wood. and
glue
them togl _h~r
In a
form.
The1 ' Can'il lot
of clamps, ctue is oozinJl 0111everywhere,
and. in a fo rd. it's a mess. Rut wh en the ghlt.·
d r ie s .you ' ve
got
a beau t i iu l bentlaminntion
01 course, 'he re a r delail, th rown in
t he re . T h e
firsl
o ne is ho w
10
rip thin .
, )II
slstent strips ofwood. 01 all uie problem' .
this o ne a pp ea rs to be t he e a s ie s t. )'<1 I 've
round it th e mos t perplexing 0 'I ve,
I 'V lr ied • 101of methods 10 np
,trip<
o
w o o d. It's
l)Ue
o f
the
mO M
ba....
l ·
w~k: - .
in
w o o c 1 w o r J .. 'i ng . R i p p in g t l
th in . .. .fi~ls
n ( , t
100 ba d. Hil i ri llJ)ing lots of Ihin tri ,. a n
· () S Isl. ih(ly
t h e - s a m c . ' thh,'kn~,i~(~t::
l'asy B: . it $\, t.'m~
1 1 1 e m~lhod I lik ~ ~ >I inv lv , , • Vt'ry
s impl~ addi t ion 10your l able <3W.Thenddi
l ion
is
a < ho p om a dc m s e rt p la le w ith a .1 )ln ·
le r ( s c . C p ag e 1). 'Illc oplill<'r ; ')U,I d l i ll ie
p ie ce o f w o od lh al s lk k, up rmm th e 1,1 ,.
bU I itm.k .- s a b igdi ff t' <e f lc l' i n t h e : \C ru roe )
andcoflsislcnq' of ripcuh-.l1·
Ii
worth trying.
Nt 'w b a rk .. , t he h a ll lr <'( .· . A lt hou lt h
it'~
n Ul a com plk med p ro jo 1:l ;1 do , , la k.· a 10 1
o f tim e. Bendim th fo ur S .h oo k,. (o r ( 'x ·
ampl • . ta k . ., p h ..,. .
Oi lone ruml.
Y
nu
ba . .. ..
lo
a llo w tim . . fu r U ll'lllu e 1 0 dl)' o n
on..
pic Ct
before y ou c an move 10 h nex l pie<-I'.
Even
if
yo u doo',
w a r u .
LObuild th e b all
In.''l••
tb\ . 't f 's a g r( 'a l
deal
o f
saU$raction
in
making onc S-hook - , ven if I t· s
jusl
10
ha ng up ) 'our shop aprol l .
el \IPS.There an ' lWoc amping devices
in th is issue I ha l a re ea sy to m is s. b UI a r e
well worth inve,1iJr.lling .
On
pal[< :l8
w . . •
n ·
s lw ing a
SlOP
b lock
lo r a m dla l lIml sa w . T his S lO P is actual ly a
d am Jllfu t, a tta ch es 1 0 a f en ce . I rs s im ple.
bul,l \\o ,w eaL Even
if
y ou d on 't ha ve a
ra dia l a rm ...... y ou 11 fin d a d oz en u se s ro r
thi~
' p/damp on other tools,
The otht-r damping device Is equa l ly
~nlpl,. It'~shewn
a ll pa gl' l as
pan
OftJ1C
m ite r jig I or a ra dia l a rm s aw ••>\gain.it would
be ca, ,110 mb,. bU I ta ke a look a t lt, A ll it is
b • p it'( ;< 01 w o<> d ith a ke rf io it a nd a
m a ch in e .....-.' - n o co m plica ted m echa n
k , BUI il
01
ks great, \\1lh jusl a little im ·
a gin atio n. I hi, da m p ca n
be
PUI to use a ll
ove r
1 1 1 t > . J l O P
\1 \\
f ,~~Oneoflhecomment$1
hea r
fn 'Qu ,· n t l) · a b out
1I ,,,I.,,,ilh
is, Idon 't
k no w ho w you g r' do
it
wilhoul a dve rt is
,n~.bU Ikeep
u pth ~ g o oo work . • a n d d on't
dUlI 1 Uf>wilh a d • .
The k r) ' I n m a k in g th e w ho le th in g work
W l lhbUIadV l 'r t iS ln l ( involv l 's the bus in es s
'd . . 01l,uhU,hlflSl - circulaiicn manage
Illt1f.l t· jol) (If .1 ,·jl ('U l. l1 ljun director is to
hri'lJ.: ill
I1l W
i.ubS(_·riptiun~\ls ua1l} tby se nd
in g o ut din...
1 mail
packagcsi, a nd ICn ing
, ,, ., .. ,111 , b , ,-n ll< :rs know when thei r sub
><ripllun
is
~b ut hl end (by sendin g ou t
l \ 'u c . ,, \\ 1 1 1 n O l il 'i l o o ) .
Even
fur.
sma l l publ icalion like
l\~l}(it£t; (ltlt.
thi~
l il vo l ve s n la il ing o ut mil ·
lions
oj
pi.....,.,.of
earh
YC:ll '.
Al l~a$l. Ihm's I he <;imple exp lana t ion .
'n\,, , ,san incrediblc3mount 0 1 detail. a nd
whnll lwl ' lik.. 1 0 a ll numbel' crunching.
1 1 1 < w ho l,. th in g d ep en d~ a great de<llon
compulers-and we a ll know ho w
screwed
u p I hin gs ca n g el w ith compuleN .
T o ha nd le a ll of t hi s. a n d k e ep ll sg rC lWing
allh .. S M le l im e . we a rc f or tuna te 10 ha ve a
\'' ' ')' ta le nte d p er so n jo in uS a s circula t ion
dirt ' t:to r. illBr< deson .
was ionne rl y
d r cu l Jl ti on d i re clo r
fo r
f a ,
lIulldyt)IUIL magazine (a
1.3
mi~
lio n c ircula t ion m(lJl 87. inc).and 4m; ri ta>l
H ,.Jlh. both owned
by R<,ad r'~
Dill•
,.1
in
l 'ewY ork .
L i z , ..a s a nx ious
10
ge l ba ck
10
the m id ·
west. a nd liked t h e ch a ll e ng e or .....rking fo r
a m ag azin e lb aL w a s e ntire ly d ep enden l
on
circulation.
For
my
part,
rm
delighled
1 0
work ,i lh s ome on e .....th Ill Sta lent .
~V.XT SSt [,he next issue of
Wood~m;/ll.N o .7 . . ,11 be mailed du ring
th ewe t: k OfJ3nUAry 1991.
Sawdust
COLUMNDITOR'S
\Voodsmith-Q ;
ttsSX
01
M~. j,pu~d b~
IOQo thl):
, '('l.
> .pn l, JU tl l'. A u . :
O ~ .
~e)b)
'l-ood mftb. PUbUllhlb, C~mJWlY.2 OO t.nnd
.\\l ftut , Dt. 'iCl'il , L , '-5 0 31:
P t i t ltJ:i1
1ft t he U . s.'
~ 'oo4sm.ld:ae i~
ft'IMl~
tndc-.trtnQ(W oocbtJuth
l o b c.n ,,>:
t:( t1JI)~
1990 h) Y,~.1I1Ii.;J'II)lClfl~}
..a~l . , ,...,
Su.~t~ \ __'JO~ ~t-5 .9S. ,,'1'\ 't'W'lt12
,...u,,'a t:
~.9$.
('.anamiff h ,p ldd
~(IOI), .ir
Us.
l o u ; D o $u6.
.s-..d0.,;, - '.id~
I ~ '.. lA...t
~.m..<
l~tM5rnd(~orolddrtStCO lr~ it h
lIIt ' l<-<,M.... lA~).J.'
~~Quc:Jrion1o;l (~~~
K.. i ) IJ .aw(6
5 . W 1 t t , .
C c o J ) I I l II 1 1 l m r .
-~da)
Iid ,t.,.. Donald B. I'. .. ·hk.
D t- O & D 1) ,'1... Ted ktalicek
M:tIIllId llKlidilM Ooull)ll.< I-Ili
A<< 4anlf.dilo , TM'YJ. Sttoh:rrum
J nu.') oo ,
~1_
DolAn
R k M r< J S . I ' .
Cordoo G rupP<'
1 ro)o, < I
[)egjj ll'
I ,,,
\tunkcl
mW. trabH D3\id Kr<~1inlt
Car y
<''bris(enscn
RodSlookes
1 . .1 , ' ;H G IQ \ \ 1 K ' k i
D irk \
v
If
St~('g
' Il \ :ulatio n Oirodor
Uz
Br cd, . .. . o
G 'I ,h&-. n....lor JonSnyd.r
1 ',*,~SuppliL.,. t.e..lit.\no Ck' U'burt
CUSlu ll l rS m ic:e~ I j, 'T Undn M ( II I () W
CUStOrtltr Sevio, l..lad. ...JQnCtf
lWlly
801dford
&all
Mod ,
G '1Uc8 ,,,,,
Vicki Ed lU'd.,
M R .:
~tI1itb
J ' f 1 n f e
E~
JIm; ee lWtlwvc
Joo lyn
l'ro$$
J01'1)' dni
Robo ,r to Ru toh
Co l1... Pa,,1£.GI I l)
&i>kk~ UndnO·l ourl<.
j l ; e ro 'OrkAdminis1ta IQ r Oo,.gt:\.q M. ) ;d sm r
.~mini>on'a~A. 1SCh~1')·I.;\'; _
Sanily&um
Sourt ,bookJ.anMy ,
I\ml,\. BudrtOl'
SMp '. >nag r SI Cuni..
lluiJding ~Iainldl ' , Grilli'
A ,-me
Krn....•
S I' '' M a na ge..,;:
8«1(\ 1<),. (.A ~1i<MelDena ...
P<:>M.~.li\ KentW.l<h
Decembe r, 1 99 0o. 72
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WooJsmlth
o . 7 2
pa .geJ8ence t\ : Sto p B lo ck
}J uge . )
pClge J{ J
3
Harduure
(Llld
r oje ct e u p plie »
neededforthe projects in ihi« issue.
1 1 2 8 1 A
Rirop IIIClde
adjustable
ao»
block
«ndu
l Iew
lVood el/('1 uilliejilli.sh
illg
touches
01 1 O IL
r radial
a 1 1 11 salc .
I Fence &Stop Block
petge
6
6 Rtldicrl A.? I. all :
A Neu: Table Top,
A
Felice Support
Ledge,
A Jlitel
Jig, And A Safell ffa ndle.
I
Tools Techniques
Talking Shop 2 4
If e
d iscuss the difference betweel(
L .
~_.... ..
_ flatsau» and qututersaum l umber.
PI us, /I'e luok at calipers and talk about
c ia m p in g Il l /e.
[Shop Notes
8
J) Rub 11rtll. J) SUI/ding Dr
1)1
L . _ . . _ Problems.
,i)
Router Elise
Plutcfor
CuH
i l 9
Circles.
J, )
~rood
Plugs.
Fern Stand
2 '] 'heben t
«ood.
l eg~ o j l it is qruceful
L .
_
Fern Sl cl / l c/
(I
reucceuted by ((
tool
u u I
s I ip .•andu-iched beuceeu
oak
strips.
I
ll Tree
A tr ad itio na l
ff
rorite
I
h
I
sui
id
L . ---1.
aolnut Ha ll T reefea tu re s fourd is -
I
nctirr
belli
l I' ood S·hook~. Besides
flu
Sshook«. the leg.~
and
the «ooden ;II g
/) ro dd e d iffere nt bendi
Ilg
choilecqe».
1
Bent Lamination
Il ;llrr ansu-er
lots
'I}' quest lOllS Oil
L . 1 ~
belldiug
thi« strip » o f
uood.
EI (,I Y
Ii 1 If 1/r o lll h o» :
II irk 1 0 ..h ou : m
II
cit .
1 rips &Techniques
ont nts
I
1 4 1 . / \ _\~IC
Tipll
Con/eli
alld
lil'l'
L : J
gl'eCl
I Iips
roll
Il lloll II OI) llIx)rJ.:f l S:
1) AeUllsiab le Rolle)' Stand. 2 Router
Tuble PIl.~1tBlock' .• J) hllpl'ol'ed Teno»
Cnltillg./ig.J,) A ChipS/inge,'. i)) Sand- Be'1/1Lamiuatiou
paper F i le s.
1 Laminated Ring
6
JlIClkillfl (f laminated rillg
is
/lU (Is
L . . ; ; . . _ . d~f irtllt Il.q it .~o1tlld$.AI/d tile same 11(11/Tre e
te chniq ue cou ld I'en be used
to
mnke
l llr
OWI1
uiooden )( iled .
ISouraes
~ ~ ~~L_O~O~K~~N~S~_D~E~
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l
N o. 72
' 1 < ,, ,bm . r h
HAND HOLD
SlOP
s r -r- -- -_~£--4
[NDNfAR
lIlT
..... ....PIA.
P L Y W Q O O DOWn
SC1U:W
ADDmONAl STltIP
AlONG fa0t6 fOG
~,---,,
\
- +
s an dp ap er a lo n g D Ie f ront edge
e r
th e p ush b lo ck .
Jim limld I
Loveusvitte
\ i yi tin
m ov e d w h e n r o ut in g th i n s to c k.)
KeXl.allach
a p u sh h a nd le
cu t
from
a
piece
of 3, -l ·dianll.. lt. r
d ow el. P ositio n th e d ow el 3 in
wanted
10
r oin th e ends
01
1 0 1 \ 1 { nn rr ow p le ce s
o f wood on
my r ou te rta bl e . b ut th e problem
was hulding them square
a ga in St t h e f en ce. T o so lv e th e
p ro b lem . I m a de a sp ecial p ush
block.
refer
10Fig . 2 ,
To
make this
push
block.
stan
bycuttingapicceof 'l' t' plywood
S I w id e a nd 1 2 lo nJ {. see F ig . 1 .
Next .
to
a1 10 ,m e to h old a
workpiece
firnlly
against t~e
tr ont edge 01 th e push b lo ck, I
C U I
o ut a h an d-h o ld , s ee F ig .
I,
Then .
lo r m o r e co ntr ol I m a de
th e fr om e d g < o f th e push block
th ic ke r. T o d o th is, scr ew a II-: ·
ide b y 8 · lo ng s tr ip o f 3 1 , ply .
wo od flu sh w iL h t he fr oa t e dg eu f
th e b lo c k. (This piecre . .. .n be r e -
from the
b ack edge o f th e push
block, see ~ill. I
F in ally .t o h e lp k ee p t h e s to c k
fro m slipping. glue a str ip
of
ROUTER TABLE PUSH BLOCK
NOTE:
IOUll STANDAtOM
WOOOSMITH:No . 70
, ... OI
R O
DO
NN
-
SllIV[
. _-
,,· WJPE
SWf
31
;
<
I
. .
£O(STAL DOW...
PIN
-
,
<,
DOwn
.~ tfANDU
. . . . .
.,
CROSS SEcnON
1
) 2 t1 · w i de plywoud anchor
across the bouem
o f
t h c
inner
sleeve . A f te r I rl u ; ng
it i npos i ti
on
d r il l h o le t o a cc ep t th e r ope.
Now put the inner sleeve back
inside the pedestal The rupe
w inds up around a :\ -t -d iamelec
dowel C U I th <Iowd 10 lonl
an d sl;d ~ i t t h ro ug h th e h o les in
the pedestal,
T b o ld th e d owel in p ositio n,
I p inned il. To do
this,
drill
It
holes
th roul h
thl 'dowd
o n b ot h
sid es 0 1 t h e p ed esta l a nd in se rt
s ho r t
I f .
do wels. A lso dr ill a
holc lhrough
the
dowel
10attach
U,(
r ope
inside Ute pedestal I
a ls o a dd ed a
handle
m a de fro m a
piece er scrap stock and a short
le ngt h 0 1dowe l. se.. Fig. I.
F inaUy . a
four
lo ot len gth u l
r o p e
,vilh
k n o t o n
o ne end can
Ix·
th read ed th ro ug h th e h o le in
th o d ow o l an d th e h o le ln t h e an
c h o r p la t e, T hen Ii it o i f o n
Ut.
b o ttom f th , ' anchor plate,
Now, 3S you tum the ( ow, l
m e in n e r s j(,,(-'V 4. ·
will easily
OIOVe
lo r sma ll h~ighl adjustm ents.
J ph 1 0 0 t
E tf l- · Yi·I . f 1 . rk III U ~
m a d th e r oller stand fea
nired
in l t .HHI .~ 111No. 70C b
ier 1 .dju>t
by
adding a Iwighl
adjusunem system that works
like an ( I e-vawr
The bask idea
beh ind
the sys
te m is th ai a r op e r st< ' ne d to th e
b otto m o r th e inner SIN . winds
up o n a dow el suspended be -
tween he
two
sides of he
pedes ta l, s ee r \l :.l.A th e do \\ e l
i s turned. t h ein ne rs le ev e . Iow ly
r is es w it h in
th~
< > G I , ta I .
Then.
once i n po si ti on. i tc an
be
locked
down with th e wing IIUI.
To add th e
s ys tem to m y r o lle r
stand. , started b y removing the
roller
assem b ly and th e
inner
ca p
f ront
Lh e
tal of
th e s ta nd.
Xex t. I d r il le d
' f t
h o les in b o th
sides o r llw pedestal 3 down
t rom th ~ lOP (· d ge a nd c en te re d
on it. wiolh.
To
allow
tlu-inner sleeve togo
upand down w i th i n I h e pedes ta l,
CUl
a
W o , i < J t : b ) 7ft
-long
Sl( )1
in
bo th sides o f tile inner sleeve.
A lig n th e s lu t wilh the
,¥,
holes
in th e side ,, (t h e pedes ta l,
' 'h en . to p ro vide a plac e to
se
cure th e ro pe. Igluw a :I' . - thick
ADJUSTABLE ROLLER STAND
•
ques
ips
Tee
FROM FELLOW WOODWORKERS
r ~
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5
oodsmlth
o. 72
THfNTJt1M
EDG£WfTH
KN IFE
Sll10T
SANDPAPER
\ . . · ·TMlCK
PlYWOOD SUN<HR LARGtR THAN
DISK ROUTER TA BU HOl f
A, SIDE VIEW
stinger slightl)' latger Ih an th e
ho le in Ih e ro uler la ble s o it p r()o
t( ( t~
lIlt
mCJtor \ n \,)l(~nh , - .
roul~r is~h t
of f . , . rig. la .
r
h etlt IX·J
Z e l ' t 1 ,( ) / J l e .
f l ll
o y
( t{I
IU
• Chi a nd d us l (eU down iIlto
lh e m O lo r w he n
01)
rOul r w a s
nl<1ulll, ,1in i l lYmuwr lab le. So I
cam,' UI \ \; lh lhe idea or a chip
s lin ge r to pr(H<:<:t th e InOlor ,
A ch ip s lin g ('r is a
lf1 ~thid
plywood di~k lhal
fit~
on
11 1 ~
rouler
b i t
shaft. sel Fig. 1
(Nole :
t:or
shor t
shank
bit,uolfa
pl.So
tic
cut~out
rom a
coffee c an lid .) Th.
~-pinning disk b:liu~
tI\v ay
an~1hing
,h al
falls lhrough Ih.
h o l e i n t he ta b le .
I mad my chip
(lIt
ea n
nlake o ne with rf.-....u·
In r sandpaper. 100 .App ly s an d·
ing di<k cem enl 10 tllC handl
a nd I he n cU ll he s an dp ap erto fil.
l\ I /io.tJI (... t;I /or,
.lJl di~
P.·f1 ~ tyl ·a ia
• I
usc ,andpal'er
foks
in
my
shop for e, (' thing (rom d li ·
c - o : t (> ' ~dll~o l ) '> ttl s h a l p \ n in g
p en d Is. T o inake Ih e fiI~. use
Ih e Stikil paper nOln'aUy ;;ed
on
Illy
palm sander. sec Fig 1
Slik il pap~r has
adh iveon the back 1
and conlt S in mils .
rsl
I make
handl~
u l of ~ ly·
wood
Then,
press
Ihe wood handl
011 10
Ihe adhl '> ' iv, 'on
th~ack ofO,e Stikil
paper and cui along
Ih ,' ('dge of lhe
handle \\ ;Ih a k nife.
SANDPAPER FILES
l '\otv:
If
you haw a
w i d e
fe-nce
li k t
a l li es e ll lc )'e r.
lrnil~nC\~
or
V e g a
'Y$ICln.
you could use
lhi \
tenon
CUlling jig on y ou r
teble
saw . 100. Since your jig
will
bridge. wide ( c nl '. the spacer
d o e s n t II( l~do be II I t · w i e l e - .
JUSI m a k e il w i d e en ough 10 a c -
c o m m o d a t e t he
nails
on
th e
back
of the g11de~. llu :;, lit exira ~
y ou c an pl an e i l f o ra p e rf ,' C1 fil
.l/(l J'iy 1~(J )i
,~ )n
fls lln III. ()rt' )Il)1
O nce th e ji l{ is a s -
sembled, tbe
fi l
on
u ) e rip it'ncl~1 J 1 a y be
too tight.
Til
make il
fit. unscrew the
spacer and plant a
small amount of
wood 0((
tbe
side If
the
spacer
opooshe
the I ll ide s.
T h en s cr ew
lh~ s pa ce r i n p la ce an d
try
th e f it
a g r u u . Continue tlli ....procedure
unti l y o u jt~ 1a perfect fil.
I maintain t lt i t - perfect fil
during all S( a~)ll~)r p laning
m ore sto ck o ft
Ih t
s pa ce r w h en
it
e x p a n d s
in h um id
w e a th e r,
\I'ben tJl~w aOwr drit's oul a nd
the spacer contraclS. I add
sllin l beN f( en the spacf'rand \ l~
sidr
D(lhe
jig
CHIP SLINGER
PlASIIC
GllDU
, I , x , I . ,
S P A C E R
This um e, we· . .. . look ing (~r lips on how 10
organizectamps.
C tampscoru~inaJldiff~renl
s h a pe s a nd si zes, an d SIOring th em ta ke s lip
a tol o( ~j)ace. S ifyo u have sp<-cialw ay In
keep your damps organized. tell u s abo ut it.
W .,1 lpub6shth c best lips i nU wApri l
1 9 9 1
issu e o(
IV rl l .m dlh
N o . 7 .1 ).5 .:nd Y (l ur tip>
(postmartedno
la l~r lbanJanuary7 ,l991)
10
Shop lip>; Contes t, 1\'oIl(l~ ,
t
2 20 0 Grand
A ve • • D e s
Moines .
lo w a 5 1 3 1 2. \V ,, 1 t
1 1 1
nnue tn publish other Tip s andTechniques,
100.and pay upon publkauen $15 10 100 fo r
th ese tiP S based on Ih e published I,, gllt.
~L1ny IVMd«mith r ea de rs b a''< ' gn '31 ,;olu
lions 10 problems, they've run into while
w o rk in g in their s ho p, \V p dlike you 10share
th ose tips w i t h o ther readers, So ( o r t he n x t
( W
i < U
w r'lt a sk (o r t ip son 1Olvinlriffer·
entsh op p roblems.
UpIi threeollitebe , tipsin eachcategory
will
be awarded ~
I~·ood., il},
M as ter
Try
Square. Duplka lc
or
ver y s imilar lips will be
considered in th e order we rcece ive them.
CLAM P ORGAHIJ:ER$
the
space
r ~
above
the
bo ltom
edge o f Ih e jill. se e
Fig. Ia. T his w ay
it
won t drag on the
sa ,'
table
as
jl
bdng used.
t{NON ..
1
cumNG flG
~~~t.__
th e rip fe nc e, _l· -IR . la . Thes e
« I a rc n o rma ll y n ai le d inlo the
bottom of furniture leg s
10
help
heavy fumiture slide over C d J '
I ,, ,, iog. nU llhe), also help my ji g
fl li de a1 on Ih ~ renee.
IVhcn b u ildinglh cjig.1 ripped
Ih,' '1 10 '
a bit
w id er th an 1Ii <~
essary
0 ould
get
an
exact
fi;
later Then . I nailed the glides
iu to plac e c n b oth th e s p ac er an d
th .. in~id, ' of the jig where il \ '_ _ '}
to u c h e s
th e r ip f en ce.
Dur ing as se mb ly. I install ed
'0( <1a ;.labl jilt for cll(li~
tenons
311d
h td f la p j oin ts on my
ta ble saw, BU I th e jill - l 've s e e n
le nd 10 d r ng n s they slide
ale)llSt
11 ,(,nl ) Ience.
So arne up it n
j i R
that s
stab le ami Illid c$ ea sil)' a lo ng
m y m etal r ip tenre.
I·ill. I
, .aabmlyco fmm
widoninll
the
jig
\\;111
a
I
\~ 1
V 2
spacer
nI1ac)1t (110 t he in side (aCt ',
Then 1 < 1 r . .duc . . d r ag . I used
I t l
round plast ic f u rn i tu r e
fet 'l
or g lid es w h ere th e jig to uc he s
IMPROVED IENON CUnlNG JIG
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No. 72
fIRST:
R P
l ANK
T
W ID T H O f S U P
SECOND:
ROT ff8lANK~'
N US W
QUESTION : WI ,( ;
}
a..1
' I It ruinl tlW f 1/1/ .t
I .?
To <'\II
strips to
a
consistent
th ic kn es s, a nd do
it
s
a
fe ly. f
Ctlt
them o n th e ta b le sa w u sin g a
special shop-made insert with a
splitter.
s t
opposue page,~
insert is made so there 's no
room on
e it he r s id e
01 the b lade
fo r the strips 10 fall
i nt o t he
5101.
RIl PtNG. To
r ip t he
strips. set
th e fe nc e so the distance
be
tw een th e fence a nd the b lad e
e qu als th e desl red th ic kness.
Using
a
pu sh b lo ck . cutasmany
strips
as
yo u
need
plus s eve ra l
extras. ( So me may
b re ak w h ile
beingbent)
Sho p :-/ otc: O ften w hen rip
ping a board.
it'.
dillkult
to
keep
it tight
aga ins t t he
fence. Th is c ause s a va ri at ion
in
th e th ic kn es s o f t h e p ie ce. C he ck th e piece
w ith a s qu an - a nd jo in t it. i fnecessary .
KEEP lS ORDER To minimize co lor varia
tion in th e la min ated pieces, arrange
the
stnps nth e o rder t he y r e cu t off th e board.
This
makv, i t d if fic u lt t o '
the
jo in t lines
when th e
pi('C(.'
ar e IIlued up . Somet imes
they will
match SO
wen. the
lam ina ti on looks
ti ke a p ie ce o f s ol id siock.
IUPFOR~'1'R-\JGlrrGIWN. W hen rippiag.
th e goal is
10
keep th e s tr ai ghtest grain o n
t1le.(/ytoftheslriptohclppreven lbreakage
w hen b en din g. S o
if the
straightest wain is
on t he face o f the board. just
rip
the str ip< 10
t he app rep ri ate th ic kn es s.
se e
F ig . 2 .
However. if t he s tr a ight es t g ra in is o n th e
< . < i g >
oCthe board. cutting th e strip s is a t w o
steppre ce ss , f irst. rip. p iece to th e w id th o f
the
finished
strips
(plus
ui
1 0 a llo w fo r
clean-up
and
shaping). TIleD turn lbat piece
on
its edge
a nd resa w th e s trip s
with
the
stra ig ht g ra in u p. se c F ig. 3 , TI'is way.
the
st.raightestlmlin
will
appear on u ie 0011 (of
lh e s trips,
W ru,m.th
IRafGUlAA
GR IN ON fOOf
A ny w oo d
will
bend
if
lr's
c ui th in e no ug h,
B ut s om e w ood s
bend
e as ie r t o ti gh t c u rv e s
without b rea kin g. A m oa g the co mm on ly
availnble hardwoods, oak. w alnut,
mallOjlllny.
and
ash
bend the
best ,
Hard
woods usua ll y
bend
beucr
'han
softwood
bu t r edwood.
yellow
pine.
a nd c eda r ron be
us ed in b e nd ing p ro jc clS .
$TI(,\Ic:m'GlWN. Whalever
kind
or ...co d
ls us ed , remembe r th ai
wood
w ith g ra in I ha t
ru ns in
a
f alr ly str aig h tli ne is b e st f or b e nd
ing around tighl curves. H igh ly f ig u re d
w ood. o r w o od s lik e map le a nd b ir ch w h ic h
I,av(
unpredictable
grain
patterns
often
break before ,hey bend. see Fig . 2 . (For
m ore o n wood grain . see page 24.)
QllliSI10N: I m W SI<I'I'w/lalkllltl ~/
Il t fxJdtl)lrse r n f b 4 tllllll i ,ttr/l ou projvcf.
II? , .llu lld / look/ur?
c ause th e
grain
of
e ac h p ie ce
nJ11~ m
tid
th e
bouom
of t he
-U·.
crssnoss. Okay ,
this
sounds
interest·
ing, bUI like any woodworking technique,
someqncsrionscomewith theprocess,
6
B
nt Lam ination
is a
process of bending thin
strip s o f
wood -
u sin g lo ts o (
) lueand lot s o fclamps. II's
m E S S Y .
bu t . \ . W ' d I 'd i o g to v-c a ~uny
bent
p iu :e o fwood
C 1 1 I . 1 I l '
from a
glue-encrusted
form.
The process starts
will rip
ping so me thin strips of w ood
and
app ly ing g lue
to each
strip.
TIlCD
it's
a matter
of s larking
all
th e strip s to ge th er b 'ke a sand,
wich
and
layiag
th e s an dw ic h o n
its side in a b en din g jig . Then
th e
s tr ips a re pushed
around
the
curves o n the
jig.
and clamped
e ve ry f ew
inches.
,\ CH,\u.E <GE.
The
challenge
is th at the wood strips don't re
ally wan t
to b end around
the
form. So a s y ou w rc sd e th em in to place
th e
glue
z s
ou t a ll ove r.
And the strips
no t
o nly slid e fo rw ard a nd b ack ag ain st th em
selves, t he y . 15 ( 'w ant t u s l id e lip a nd d ow n.
Tho
payo i
comes w hen y ou remove th e
damps an d $I3r s cr ap in g o ff l h e d rie d g lu e.
The sloppy mess becomes an auracnve
piece
of
wood -
bem to th e p er fe cl s ha pe .
And
Ole
rnoreh scleaned ,
th e
beuerh
looks.
S1'RI:.'SC'n1.
T here's m ore to b en t lamina
Lionthan jus t
appearance.
It 's s t rong
as
well
as anrac tl vc , 1 t il e
it
would
be
much
easier
to m ak e a curv ed p iece b y sim ply cu nin g it
out of so li d
stock
with
a band saw or
sabre
saw . it's
nOI
always
3
g oo d id ea . C Ullin g
curves
frOID
blanks
Cr< aI~S
a 101o f waste ,
And there will be a w ea k S PO Iw he re th e
g ra in ru ns
3 ( 1 OSS the
n arro w fa ce ( fro m
<><tge
o
cdg~).,;ee
fij . l
Fl l fPxampl . . , if
y ou c ui a p ie ce o f so lid o ak
in to a
L :
sb ap e. yo u can ea sily b reak it in
IWO.
If th e g ra in ru ns eru r.lly in th e U ,
it
w ill b re ak a t th e b ou om , If it r un s ho ri zon
ta lly . i tw i ll b r eak
on
t he s ide s.
If
y ou lam in ate th in ~ 1 rip s
of
o ak In to th e
same sha p e. it's very di f ic ul tt o b re ak be -
Bent Lamination
HNI QUOODWORKING
1
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7
o . 72
Wlf ...• ..mTO
ao r TO M o r 0 1.0 (1 (
GlUE
.P t I I T t 1 t
INPUC{
SPllTTtR
CUl TO
fn
S WKUI
lx4 PUSH
lOCK
AIJGN FlN Cf
- WJfH tOG 0
.... OR tGINA,1.
t~T
2
S N
fND TOA
POINT
1°
,
a I[AfUNG RJD£S
• OIUOlNAL
INSERT
l _
FlUS H
T1t IM
orr
1
piece 0 1 sto ck 1 (1th e e xa ct th ic kn ess o f th e
saw blade ked. T heil , ... t i ll h ig h (w i de )
an d 3 long .~nd Ih ('c n d th at w i ll be cl oS t'''
to the bla de to a point, and then lIlue tbe
s pllu er imo th e s lo t, ,('
F ig .a.
Filtally. b or e a jO · di ,c l< 'r h ole in the
in
sert to
make it
easier
to
liltout of thetable.
PUSH BLO CK
Of all lite push
b lo cks in
the
lI aCJ /smit)
s ho p. the one th at II:Ork, i lesrfor riJ)pinl[ bin
s tr ip s i s eX IA 'nw ly s imp '. It suadd les th e
s aw b la de
>0 t he h ,'C 1
o n th e b ou om «Igl
I he
block
pushes
b J I i
th e II
url'pi<'('
a nd the
waste
past the
blade . se e
Fig,.1.
The p ush b lo ck is m ade fro m an 11 ·lon
pi,= I I f
2x4 . T il p ro vid l' a
lip
to
p u
Ill
sto ck, c ut o r glu. a
4
h ee l o n
the
bottom
. '<Ige of I h~ b l oc k .
13~addin.. a heel to
thellJj)
01 th e block
y oucantam the bloekoverand
us e tlw
otbe
s id e w h e n
th e
fir';
h eel g el' torn
u p b )' th
sawblade,
SHOULD YOU SAND?
After ripping the s tr ip s to th ic kn ~ss ,
yo
m igh t be le .m plec llO sa nd th e strip s b ef re
YO 1glue Ih lf f i' up.l>on'L · lbesaw .. .i l lC:utt l l
.triPS l(' th e l '<lgC<are squu re and th., t~irk
ness i s , , i fo rm . Sanding
may
ro un d (h
edgl'S an d create dellTl' ,.ion.
in the
lruck
ness
o f
Ihe
,mps.
li.H wfult
il
Ih . , are blade m ark s in I Il
fuceot tb e ,mps? USlOga combination blad
iosle'ttl o{ r ip pin g b la de
will
~liminaw
m ally 0 1 th ,' aw m3J'ks .
Or ,
if
yo u have
Ihirkn<· p laner Iha l
will
planelhin stock
ri p
the
strips :;lightly Ihick, ' ' an d
th en ru
UWOlthrough
II,
e p lane r
O ne key 1(1 SUCC Cl . ', iu le nt l an un atlo n p ro
jec t i s u si ng wood strips tllal ha.. . 4UIU <
e dge s . .nd are u ni fo rm in thickness . Thccas
iestiIJ\d<af~ >tw.yI ve found 10cut them is
01\a
table
sa w
with
a ZeTO
clearance insert
with
asp llner, an d a simple push block.
INSE.,.
Th e in se rt o n mY la ble saw h as .. , I ilU l'~lea r-
3Ilfe on ~a~hside
of
the blade i l I O n the thin
<lri]l '>C311t a ll d own i nt o
the
b ladp ,101.'1'1,..
spliner keeps the kerf open Ih e s am e width
., the
blade
<0ileduces k i<k I>Hckand
bind
ing o n the b ack
cdgf of
I h. , b l ad . ,
SltAPL IGTIW IILA, IL To
make
this insert.
first resaw or p lan e a ha rdwood blank 10
tI ,
Ihklln~ of th. i n . o J)< tn iug in th e sa w
ta nk sl' tIl n ew in se rt w ill l ie f lu s h
Now ( tm the r ig in a l i ns er t from your
saw and trace Ih outline of the insert onto
ti t· blank, 1 1I n r ou J. h C U I I n w i th i n
t .;
f
Ih ,· oUllill<.' . ec F ig. I.
To trim U l < ' n ew in se rt to th e e xa ct sh ap e
~r
h~ o r ig ina l,
I
use th e o rig in al
3,
a te rn
plate 5tartby
tapingth orig inal in rt tI ,
n ~w in sc rt hlank wilh doublc·>ided
carpet
tape . Then
I) lQU,Ot
a flush trim bil in
the
r ou le r ta bl e a n cl , w i t l , th e bearing r id in g o n
the
originalln$e rt . trim th e
ne w
one '
sfulpe,
sec ~1g.Ia. (If ),011
don't have
a f lu sh
lr im h it. rOil l; '~n,;and or file the iose until
il fit.s n ll j{ l y i n I he QP( I .i n ll · )
The nm sWp is lo c ut th e b la d e $10 t.T< ld o
this.
I p la cl .' h e o ri gi na l i ns er t
in the
saw
t.hlp ' 1exl .carc l1.UYllhgn
the r~I lt : wi lh the
e:dge 01
the orig inal
insert, , .•
Fij(.
2.
11I.n
ri p
th.
,,101.< lo ppi ng a nd tu rning off Ih ,, ,,'
3 1t
from lilt' end o (
I h e n . . . W
insel1.
E SPLl I ffiR.
Til
mak l the ~p li ue r rip
RIPPING THIN STRIPS
\I'h en J don 't ,anI 10 mak e a S lr ip a ny th in·
ncr, an d it st il l w o n 't b en d w ilhQ ul breaking.
I lak e advaOlag .. of Ih e r ae l
thai
moist wood
b~nd, beltcrthan dry w ood Soak t h~ s tr ip s
inL1pwatcr
in
Ih ~ kitchensink. ( lf lheywon ' l
filinlhe sink , u sc the bathlub.)
Snaking tim e aries with the wood and
thickness. So check th e strips ev ery ten
minut< 'S or so to _ how flexible th ey nre.
T akt' a
Slr iP UI oftbewat erand
gently tryto
bend
it
around Ihe lighes tcurveon
thl
jig . If
il w o n'l be nd .round Ihe lorm . pu t il back in
th e ler and ail a w bile longer 11Ie h2 ·
thick wainul , trips lor th e Ha ll T r ee books
\ \ C J i r t a (l y to bend
aftf r so aking 20
minliles
in roonl ten1peraturl ' water.
\\ 'E T II l'S OrN G . W h en lh e w oo d strip s a re
Oex ib l~ pnoul lh . t ake t I, em oul of the sink.
shake off lh < - e xcess , 3 l t: r, a fl <l put the ln in
the:
jig
/1,,.,,1 gilir. Ben d th ~m slowly nn d
c ar ef ull y. Once they're in p ositio n, (lU llh t
c la m ps o n. 3 ll d I t- t Ih em
dry.
If
possible. I lik e 10 le i the strips d ry o vo r
DighL I t' s impo rt an t tll al the slrip s b e
dry
wh en th ey 'r eg lu ed u p.lftlley · re slJ ll we l. the
moislur e w i U
decrease
th e h o ld in /{ p ower o f
r he g lue an d the workpi( (:cmay delaminate.
QllESflON: What fth e .Il·ill.
/1 1
1 iF ), d n
to tl
~Id
hrj;,,. ,t l
IrltltQ ,,1 b , t O ]. 1
i'~/?
I - l t : ' r t \ ; a t i l ),
~1t.~Mlreaslackil} llln
r a L h t * r
th a n o n p a t a ti ll l t . l :( > r in st. a J1 < X \
t:ight ; V 3 2
Ihick Slrip$ should < ,< ual-l', .l Ieiore ripping
) 'our w ood In iin; ht'd tllicknc SS. ri p :;onlt~
~ tr ips
OU I
1 ) 1 ra p
s l( )~k and
mea .ure Ih ~
thkkJlb> orth~ Sla l'k.
I also use di al calipers to a~curatcly
m ea su t( ' I h( 'l h icknc% ol , ;triP -FIlrm ore nn
dia l ca l ipers,
S('('
Talking Shop, page 25.
QUF~ ION:
Tlu
n .,/ ;,,,,
on
/tal'll
til
I,~(·(I~U I t·t ~(l/t·l.l/.
1 111
d»
I tn
~I (JU t
; I(p i/ re I } f M /ht IJI r~
i'.;'(~
You
\ . 3 J 1 UI : V~1 ) thin
strips,
but
there
are
some
problems.
Firs t, it ca n be
difficulllO
ri p
very
thin
piece s
10 a consisn-nt thickm ..... . _
A n d , t he re 's a 1 01
or
waste
, , , , . < 1
by
al l th e
saw
kerf s, l~n .lly . it .
moreawkward
10giLle
a nd then w re stle
II
la rg e n u m be r of r~a1Il'
thin s tr ip s a round a lorm t h a l l a small JtUI~14
be r of il(hU ), thicker
011. ..
I use the thickest strip that
will
bcn~
a ro un d th e
''''811('s t
radius
in
th e
jig .
II 's
ofle n t ri al an d error approach \\ 'h ile bulld
i ng l I,e F~m Stand on P3ile' 2O ,IIried 1<1end
an \II; · thitk strip of w alnut fo r a leg. and il
broke. Y et a ~ · · Ih ick ,tril). justlo:lt' of an
in ch I . bent
ju l
f i , , < '. ~ .' rna }'
no l
'm
like much,
bu t
when Ih e strip
i <
on ly
v
10
begin
with,
1 t t J is
2 5
or its th ickness.
QUESI10N:
Hull Ih rk .•tumtd th.
etrip«be
On?1
J , . > I t
,.t(JII~f~/flll
~/ 'I;~-
l ~ l
'i~/lr( r
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lOO$(
IUX1C
< a >
, . . . . . . . < 0 1 1 1 > <
III'NT
sm.s
7
T o ket· p
the
I lu c trom s tic kin g. r ub un a
heavy coal 01paraff in or pa ste W 3.X .I rtpeat
th is w a. xin gs ttp ~ rw e cn c ac h u sc.
Rub the paraff in orwnxonal surfaccs Illat
. .i ll b e i n con ta ct w it h th e wo rk pi , ,' e. T o g el
a .mootb , oalo f J ) . . r a f f i n , IU~ a h ai r d ry e r
10 me lt il in to l h~ i orm . ' I i s < tep i s n' t eS$ en ·
rial. b ut it h elps th e p ara ffin p ene tra le Ih ~
1,lywood and ~Iimlnales
any , 'h ,n ce
01 t he
gillt
>I ick in l lln the jig'.
:'iotC': Thcr( s ont t im . .'
\voultll,'l rt Coln-
mend wax ing lhe f o rm. l lyou 'r e n () ll t i n t o
. .a nd o r d r< ln u p
thl'
f ac t' . o f y ou r
fini h~
l am in ati on ai le r g luing.c1uo· ' U$ C 'w ax on Ihp
fn rm. P ' le wax an d paraffin ,ill p , 'cm th e
fu Us b (ro m pe ne lra Lin J.( th e w oo d o n th e
J in ish l>d lamina ti on. I n Ih lS s it ua ti on. I uS ('
axed paper II I lin,' th e form.
Qt ESTlOX : I',
J~U
lit lllr fr ick 1 ) hr
JfY 'x
) ~ I
utiJi,n ,.
Woodsntim
-Offsn
PlVOTP¢CNT
ffXlD
, -
OaM
CAMS
6
I u sed A·C ( in re ri o r
grade)
p lywood to b ui ld
th e jiln ' ShO ' i n t hi s i ss ue, Since lite grain
switc he s d ire ctio n irom la y r UJ l aye r, p ly ·
wood i sequ all y s tr on g in a ll d ir ec ti on • . A 101
01 clamping pressure
can
be I U I
an a
ply·
wood (o rm w ith o ut breaking lt.
Y ou co uld use a lower l rad(' plywood
( su dl asC I)X ). b ut wa tch ou t
fnrvoids.They
c an weaken
t11~
orm
Il r( 'rr:'tr a ro ug h l '1 l$ . P
w hen' th e (o rm rO lllact< Ihe lam in 'led
. t rips. Par tic leb()ard a1:;<'W()rk, well. though
i t' smore I ik .el yt o b reak under p r , ,- ' c than
I he p l) 'wood .
11 1\. < ; £ .To 111a k c . t bcndingjig . ~tar1by rut·
lin l a b ase . J us t m ak e il b ig e no ug h to SUI>
pnn the
bendilll piec~
an d
the Slrips.
11rh,
ba~ i :- to O
b i g .
~,t()lI11.ind u p li~hleninJ
; u 1
I he C-c lamps willi half ·lums ~in('t' th.> b <e
INSin
th e wayo f t h e C - (' lamphand l s . T h l'
se <'m s lik ~ a .m allllO im . bU I w hfn y ou' ,
~ 1d i 111al ltho<c glul11l1P. t rip . round the
( orms. }, () uwan t t h e d aml ' lo ' to o n q ui ck ly .
FOR. S, 111t'f orm s a re th e pan. o f
u , e
jig
th at th cw no dstrip sa .. bo nta ro und ._ F iJ .
4 . T h en :a n'lw o p ar t< ro th e (umt~.lh,' inner
QUESTION:
HOII'
m v - lI,p
/wlldlllg jig.
it,adp What mnlr inl~e ) the;, r 'P,ir(_?
wedge
against .
BUI
they're
another srreng'
way
10ho ld t be s tr ip s i n p la ce .
I
G\lfAWAY
,-_pas. lASE
\
form s a nd
i h €
o u t er
fo rms,
in ne r f orm s are usually anachvd to
the base, and Ihe
strip,
wrap l , d a ro u nd
them . The o uter fo rm s arc no t attached ,
They ho ld t h~ s tr ips aga ins i ih e inner I o rms
and d is tr ib ut e t he p re s s u r e o f th e c lamps .
T o m ak e th e fun ns, la y nu l L h~
.h ap< 's on th e plywoce l.o r g lue a
pauern onto the plywood with
spray adhesive o r rub be r cc
ment.Then
cu t th e p lywood
wiLit
a
band
saw
or sabre saw, I like to
. . . '11 t o w it h in V l 6 of th e p e n ci l
f in e, a nd U M sand to the line
with
a disk o r d ru m s and er. T h ;,
way , m ak e su re the sur faces
th .tto uch th e strip s a n' s mo oth ,
ISSE~mLY.when all
th e
pieces are c u t . la y th e m o u t in
posaion On
the
b as e. C h ec k th ai
the clamps
are
big enough to
bridg l' ac ro ss th e Inn er (o rm s,
th e
thickne>~
o f
the Strips.
a nd th e O ilie r
f orms, I f
they
aren't,
downsize
th e fo rm s o r
use larger dam ps T hen. screw the inner
form.
10
thebast'
F in a ll y ,do a
dry
n 10 te st t he j ig . S tan
by ge nlly ~ nd illK d ry s trips in to (h e fo rm .
Then pu( on the damps
and
check .for gaps .
S a n d down
allY
I , i g h 1 . : ;J > () ts
CI
t h e r e a r e n o
W\I b etween f orms and t he . tr ip s.
use them w ith . block or a pad 10keep from
marring th e workpiece. see Fig. 6 .
WEOGES. In s o m e c as e s 1 1 1 u S C a
wedg<
in
place o ( a clam p. see Fig. 7 T here isn't al
w a y s enough room to
U S C '
wedges , s in ce
lh~y require 3no tl 'r blo ck o n U l< 'ji g 10
.;t----=
(l...~~=--,,\ror
-S ffitIPS
S ev era l. b ut I (ound th at C -c lamps a re th e
easiest an d most v ersa tile wa y to do lamina
tion.
So
if y o u d on 't h av e e no ug h, tr y 1 0 bo r
r ow some f rom f r ie nd.
<;-mAl S,An altemative 10 using Cclamps
is to use me ta l s tr ap s. A s tr ap applies even
pressure al laround th., curve and h~II)Spre
v l 'l Il U ' s t rips ( rom ' lJ l iu iJ, ) a long
b~
111·
'id, '
i.e,'.
SC<'
F i .5,S lr ap scan be made (rolnl
pieces o(
metal
plumber's strap
or
thin di
mens io n t n, 'la l b ur
stoek,
Bui ll arc avn ilab lc
at hardware :.tor(.·s,
One en d 01 a strap is f ixed to the base.
Thl 'n it b en ds a ro un d a c urv e a nd is pulled
up right on Ihe o ther end. A bo lt go ••
th ro ug h rh r fre e
end
o f Ih e stra p a nd th en
Ih ro ug h a f ixed b lo ck. ' I e , u- al ' get pulled
up dllht with a winr;: nutor a wrench.
C . \~ ,~. Canl ; a re ano tl lt r J, txx i, i ne xJ*n ·
s iv e allt'm aliv Q lO C-c lamp s. T h( · )t ca n bt
n ic ely d es ig ne d a nd c ar elu lly r on ~C l{ 'd o r
li,e} (.:811
be
a I)iect of
w uO (1 W ill, .'0 \
r ound ,-d com, 'r .
S( .
F ig . 6 ,
11le impurtllnt
th ing i<th31 thcpivOI puini bt- off .<;II1;()more
p re \u 'e is a p p li t .. . > - d s th e canl is t u m ( < I
If yo u u;.e (anl$. rem em ber they ex~n
mof< ' pres.'UIl' l imn you mi l h t e xp l- '< '1 .So
QF£STION: I
rlOII
har«
th at m an u
el«mps. Aretl« rcUIIUtl ft~rllat, 't s t o
~; {I
e l o
U~P$ I I ( I I ' fn rL n l1i[l I
L et's s ta rt w ith th e to ols . Y o ull n ee d o nly a
iabh- saw to c ut lite Lltinstrips. (The blad~
m ust b e sq uare to tho' t ab le and in t ine wirh
the fence.) 1
1 1 < 1
a srnoorh
e no ug h c ut
with
a
combination
blad
e
thar
lh..
strips
don't have
to be planed
afterword
s. T he
onh .p,>dalill'd tool ill the
process is a bending jig and
t ha t' s made i n t il t' s ho p .
Ai;. f or t he damp , i l d . .~nd .
on how cornplcx nr large the
project is The most clamps
you'll need at anyo ne tim ' fo r
the projects in this i s sue
i s .
r w d . (fur 1 1 1 1 U : J1 1 Trw ring).
an d
uwy
c an b ea c omb in atio n o (
Cc lamps an d sma ll b a r clamps.
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9
J .
7~
C lA M P O UfO f B lO CK
TO Orll.L PfClS S r Atlt
TI,;'
process
is
very
differenl
from
gluing
up
a
panel. \I'hen
glu in g up a
pando
Ilak~
th e
damps
0 «
in 10 10 30
m inu le s. B UI wb~n
laminating slrip' .
the . . . .
'slotsof
g lu e a nd
nol
m uc h , .. -o o d In so ak up tIte mois .ture.
Once th e s nip s a re in th e b en din g
jig ,
th e
nlo is lure in the glue c an'l e sc ap e o n th re e
sid~s,
The
base
an d
bending (orms
ar e
'Yll.xed.leavlng
only
Ihe
expo,;ed
edge
of t l • •
s t rips (or the moislure 10gel O ul.
1 ig hl( 'r c ur vt.
rcquin
longer
drying
l im , '. The glue needs
bt
completely dl)'
(no lj us t s e l·uP ) 10 r( 's is l th e strips' d es ir e 1 0
spring
b ac k 1 0Ih.ir . ril .~ll l~ shape. And th e
QUESTIO N:
Ho« /( ,g dOt il IIlkf
Ji.,.
tllf
g l,e f' )
(/~ ll
nu t
coward
e ac h e nd
w ra pp in g lh e s tr ip s
around
t he c urv es .
A I
first. just
pU I
eno ugh dam p pres
sure o n Ihe suips to
keep them from
moving. Tightening
comes l at er ,
When
you
start
bending the glued·
up ,uip> around th e
curves. things
can
gel a little t en se a nd
r us hed , s o
II'saguoo
idea 10 have a f ri en d
near
b) '
10
>'UPI>I)'
a
third
hand.
S om e ohhe strip s
ill
s 1i o~up above t he
r es ia s you bend t he s ta ck ar ouud the cur ve s ,
T0keeptheedgeslush,useahammertotap
t hem down .
s e e F ig .9 ,An d roc lo s e
anvgaps,
re-adjust Ih e
pesiiien o a clam p or add
a no th er o ne .
\\ 'hen
I 'm s ur e
that
al l th e s tr ip s a re
in
contact with e ac h other. I r e- li gh lc il a ll th e
clamps an d even out the pressure.
CU: \.\·l
p.l3efore theglue starts 10set up.
us e
adrypape r towelo r small piece
of
wood
10wipe offa lototthe glue that hasoozed
OUI.
lt's easier toremove th e g lu e n ow than later,
and reJno\'in~ th e e xc es s may shorten
d.l r.
ing time by e xp os in g th e e dg es o fth e strips.
Don't use a
wei
towel thQugh. Youdon Iwant
10add anyrnoisiurc 10 th e strips.
SAND 10
UNlfORM
tHlCKNlSS
10
Ius< ' a p ain t
SCJdpef
to
gel
th e
lOr S{
o f r u t
glu~
., (.
Bu l d on 'l
try
10 get 00\\<1110 bar~
w(lod with
~t
SCralleJ 'Qr you IDa), I~ar of
s om e c dg (· s .
To r cmov (' lh e r cs l oftlw glue 1use
cithc.'
a low angl~ b lo c k p la n e o r a s and ing d rum . If
)'ou use • b lock
plane.
m ake a fine Ill tu
avo id tea r oul.
S. 'lDdingh also
good
way t o
remove
th e
IaSIof
lh~ glue For
those
pit 'Ccs
tha i
have
l.'l'lldual
c u rv es a nd will fit on my
drill
press
table. I f ee d th e workpiec ~ c t o e e n a drum
sander and a guide
block
clamlX-d 1 0 t he
l ab l~ .• e e ~ · ig .IU .
tONlU s,o l'. Th e pm ce ss is in vo lv ed . bUI
i t 's pre l1Y
logical.
100.\\'b ile ilm a y b e trickY
and a l il lI e me , ' . it 's a h;o
ju.tplaiu
w••
QUE :> 'TION : 1 1 / 1 ( 1 1 .
hI
I , , · . ,
IVIU
109<1
JJ nll 1 //< 11 9 1 1
U$ehlt f th e curve the w £ ate r th e pressure
0 l l eave th e c lamp s on ( j <m ighl .
When laminating a piece with more
grndualt'llIVe> . suc h a s the re m
Sland legs.
tht:re is le s s p r e ssu re
1 0
spr ing back,
Itlll i~
, '35<1,
I ' l l remove
th e
clamps
a (l tr s ix
hours,
REMOVL IG TIlE Cl.AM1 S. \\ 'heo emove
th e dam ps. I do it slo\\'I)'. Walch the CUIVC'S
carefully. an d check (o r delamination. A
small amount of.pring b ac k isuo rm al, BUI if
Ihe strips
start
10
separate• re-t ighten
th e
clarupsand wauarleastacouplemore hours,
th i n g s s t a y
in
p l a c e
th en r em o v e
t h e w o r k -
p i•x e, a nd s ta n c le an in g it up ,
lit' r s
(III t: { I
,~/t (}(c ,tt'l ig lll {~ t l,
in,
r - q i f/Itt fffflf 1 1 ,'d ,. .I n p r .J _(
If (Jtx/ ClIft
I,..
bt.'lIt. Th~ 1(Vt.:~~tlli( k( 1 f l / l l l / x t , · l l('il f
Hf)(lk,d r ) r ·
I li g/ lt , /( tp { ,yzlero 1 I I J w l l it. d IfP iilit t prets« l
APPL,YTHIN
l AY ER O f G iVE
O N E S LO E ON LY
TA(l( snIPS
A S G J.Uf
l S A P PU E O
Slmclamping in t he lDi dd le .a n d t he n move
QUESTION : 1 I'''l r '~ I h b P S I pm f I I/ I I P
for
~Ja'l}i U tI t J t t : fri~?
1 1 1 , < 1 IiIL'oolld
Wooo
<OIue(a yell , \w glue)
for the projects in this issue. Other yellow
(aliphatic)
glueswill also
work
since they
f i l l
sm all g dPS 10s om e e xt en t a nd d ry q uic kly .
Ifthe
projc<1has
a 101o( rips and ) ,ou 'r ( '
concerned th at y ello w g lu t· won't provide
e no ug h , v
) rk ing li me .
use wh ite
glue . \ \1't it('
g l u. _ · ta ke s h )t;g c r
l41
s et- up . s o
} { U
\\'OJ'
I
(l e l
quite a.~
ushed.
For 3
pro jec t th at w ill be outdoors,
I
usc a
r es or cin ol g lu e or e po xy . They 'r e water
proof
an d will stand up 1 0 th e w ea th er.
However .
e poxie s d if fe r i n h ow wen
they
fill
gnps
an d ho w much
work in g l ime t he y
pro
v ie le . Y o u ll h av e toexperiment to dcterrninc
what you n eed.
Bent lamination useslOIS of glue. It s hard
10 predict just ho w much you11need. bUI it is
usually
more th an y ou expect, T he le gs fo r
the Fern Stand,torexample.took more than
h lf a
1201 . .
b ottle. S o m ak e su re y ou ha ve
plenty of g lu e b ef or e y ou start,
Al rLYl~G
uE
GU
Eo
Tu a pp ly t he
glue.
I
u s( a u ille xp t·n $lV e fo am b n J s h a n d uinl L b e
t ip to thcwidth of t he s tr ip s . T I le ( o am b ru sh
ca n
be
wash(-d
O ul
afi('r
each
u se . b ut
ildel~
riorates
r3llidly.
so
have sever a l
on
hand.
I c l u r th e
glut
i n to a $malt cupordi~h.an(1
spread it on cm ly on e s ide o f e a c t t s tr iP. s ee
Mi l . 8 .
j \ : s
) OUb ru sh the g lu e o nt o th e strips.
slack
tllcm
like
you re
m ak ing a
sandwich.
n , e n
pick
u p t he
Slack
a nd la y
il
on
ilSside
i n I h e f onn.
Yes,
a
liul...
I you
fWdthat there ' s
100 much
springbac:k
ina laminated
piece. reshapethe
forms b) ' t igh ten ing t he c u rv es enough
to
make up (o r th e spring b ac k. Ther e's
0
f ormul a ( o r h ow m i lc h t o ,. .. ..h ap e t he f orm s,
it ill l
t ak es < om e x pe rim e n ta tio n . ( Nm c :
Smal l t amlnated proiec ts il l
nommlly
have
ve ry I il tl e sp r ing back .)
QUESTIO N : lI'Im l kimia/ylll
w u M /
Il.'il> II(/If (If) IjIJII If -1'/III,t' *t I)X
Ql -ESTION: Willih. wlI ,/lry 11 1 11
buck to it s urlyit luJ
~/IU JtaJlerpi tc
llll
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N o, 72
0
~ . JC
5'. 6O..1.:1
Sll.'t.l
I
I
~.... 4 , ~60
. 9
ad.. a . ,
E
A
,
~,o~
A
i 7 Z Z i Z d JF
I
~ •• .It 3' , ..60· {1.5ac t. .)
i
:
B
J
.. ~ .. • 7fT 12 act rt.l
I
f T : ·
: _ g _
-,-~-
I
1
n
,
•
,
UnlNG DI GR M
hz.1'.I>'3O
1 1 2
x~.
30
1'.~xI\.l ~
1 1 2 :v.' ()
~x ~.24
B EN D IN G J IG S
• nAB
.48 '
$heet o r
~. tnl(;l<plywood
• (1) 6' length lI. ,dlo
dowel
• (1) 3 Ion9
I
COl'
Iiogebol1
• (0) No 8 x2'
not
heaO\ Joodscrsws
• (6) No 8. lit.. 110
hQodWOQd CISWS
• (llconol pOs 8WOX
WOOD PARTS
A LegSuI;»(32)
B Hoo~Stri;»(20)
C POSl I
o IlingStOtlerSlnp(1)
E RlngSlfI;» elOl
SUPPLIES
• 7 6 B e l H 01.y. the < WO'r)tII
• (8) WoIrnJtovolheod plugs
• (8)
No
6.
t
;l<<m0ll<.lh 00SCi8W1
• (8)No 8
x
ll',' Fn
wOOd$C1eW$
• (' pin.)
Tung 00l
special aruclc o n
h<:ndinJ(
nnzs
o n p ag e 1 6,)
W C)()IJ, For thl s project. I
selected walnut
b~C3USt.:
It
bends \ \· ( 'J I. is slTt)n,g. and has 3
l r3on iona l e legance
1llRD\\ \ R J o : ,
Once
Ill, ' curved
parts ar e m ade .the re s n ot a 10 1
uework toassemble the han tre
The ~h(l(J ' Sand ria,S are :;.(.
''1lrt'
I n I ho 1 10 <1
w i th b r as s ova l
head screw s, I also used walnu t
pluJ,t -to cover
l~l
flathead
. .;cr(~ ,: ,- ill th e leg ho lt 'S .
(~ tH Nt~ t.,),
Prciect
Sttpplir:l.
i s u ff ono s :
L w
w a ln m p lu s:> a nd
Ihe pa t te r ns (urlb,· bcndiug~ ,
' .. . S o u rc es u n
1 « 31.)
I1NLSI l ,
(3( 'QuSt :of I l l e curved
par t s
inIht'
h a ll tr e e. I d e ci d ed
to
USt' a w i pe-o n fin ish . I w ip ed o n a
co uple vI
coals
01rung
o il
t o p ro
duct a soh luster,
M TERI LS
E
er y tim. I . , p i - < X 01
bentwood funutun -, I h a v e
1 0 ,lU ll an d Iry Iv ligun ' vU I h ow
il
was mad. And whenever I
think
o f
bending wood ,
a
classic
proj .,,11 ll1 ll rye wan t ed build
comesto mind- ahall treewuh
its
d is rm c tiv e c ur le d h o ok s .
C.~O'STRl
cnox
I
soon
10Wld
o ut t his p ro je ct r eq uJ tt >s
it bi t
C l f
patience 10 glue up Ih(' IlIn','
bern paris - the legs, Ih,' ~
bo ok s, and Il le ring, I' . 'l'h offe ,
a d lf fc rt 'n l bending , 'h a ll en j (
Th e k -g s re quire a s ln glo be nd
and are the simplest to make
The ~.haP< i hook. have I
h<:nd,
and are more l'hall, 'nj('
io g . A nd the riog i,aminated
us ing a s l igh t ly dif(ereOIIJrOCt,,; :;
than the other two, (\\'e\. in ,
e lu de d a n a rt ic le o n b elli la m i n .
t ion technique ' '>on
paJr t'
6 an d ~
T his ha ll tree o ffers three d ifferen r b end in g cha lleng es a
silnple
L ~be nd a
more
comphcored S ~ be nd and
to
top it off
bending
a fu ll c ir cle All yo u need
IS
a few shop m ade jig s a nd a lin le rim e
Hall Tree
ROJECTEIRLOOM
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II
'(/oodsrmth
. .
-'-1..- _
S(IItEWRING
~OAA\
10 rME --
1, ••
W l O I E
Sl QTf Oa
STARTtR STRIP
3
Cut PARTS
fROM~. ·1MICk
PlYWOOD
' 1\.
M A R K fOUjt
fOUAU.Y· SPACIO
P O IN TS O N F O AM
fOR
PIlOT
MO. -
lOOATION$
PII.01HOtf
lOCA1K)N5
fOR HOOl(S
RING
fOltM
RING
BENDING
JIG
-IAS(
3
-----
---J6 -
,
PlVonNG
.0 '
SCk W;----...-·
M O ll L OC AT IO N - -
CURVED
P R E S S U R E
'lOCKS
CUT '«
UNl:
CURV(O
PJtlS5URf
B lOCKS
0
CUTPAftTS
R
..·lHlCi(
PlYWOOD
,
lI.... HQUS
rOk
ClAMPS
HOOK
BENDING
JIG
flX£D
.o1tM
.
,
IJr.Qff
U
2
. . .
cut.. , UN I
CIJI P.utS FROM
2l,AYERS OF
lI.....m(kPi,YWOOD
___ 6
1,.
r
13 r
SOlOW
IENOlflm
_ M
TOlASE
I
. o t A .
PtVOTDOWEL
,t.~ONG
-
RUSUR£
lOCK
•
CUT-off 0
UN
NOTE:
S(t.lOING fCNtM
ANl)PJtl$WlI
tI.O fCAa,
11,..~ntIQt
,
LEGBENDING JIG
s·
. .
N
\ I
BENDING JIGS
Istarted work on the hal l t ree bybui ld ingthe
three bending jigs, (Nol~: Layillj our these
jigs m ay be the m ost difficult pan of this
whole
pruj I,
Allhou) h
we're
shuwing
drawings(or t Iwse jigs on th is pag e. you may
want
10
order the jllll·xi r pa ttern s and
detaile d in stn ,c liu n. fr om
W dxlllilll Pru-
jlrl SUNlli...
~t
ag e
31.
lEG BESI)INGJIC;.The leg
bcndin) jill
con-
siSlsohhrec pi ,, , ,e . ;: . b ase , a f ix ed f orm , and
n Il ivutinll P Uf( block. s e c Fig. I.Th e
fixed (unn is attached 10 Ihe base bUI th e
p re ssu re blo ck p iv.. , o n. do w el. T he p re s
su re b lo cknnd f ix ed f orm ope ra te much l ik e
a
hamburger
press
10
s q u e e z e
th e
s trip s r o-
geilicr.Thecndsof
till
f ixed fonn a lso ac t a s
<:lIl-off lines for lr imm in g th e legs 10 their
finished lellgih once they're g lu ed up.
CclNSTRI'cnl)S
~0'11lS.Th e
fixed (0011
a nd p r..... u re b lo ck ( or th e le g b en din g jig
a re m ad e b y g lu in illo ge th er a do uble la ye r
o f : J I 4 p ly w o o d . Afler th e rw o p ie c e s of p i
wood an'
glued
logf'lhrr. the ne xt step is
10
d raw aful l- si ze paperpane rn ofth ej ig shown
in Fig, I.Then glue this pattern 10 the ply
wood.
andcutthepiecesto U U l l shape.
N~xl. damp the pieces 10the base an d
dr ill ~'•• ho les for
IwO
dowels - one (near
the
e nd o j th e p r es su re b lo ck ) a cts as a p iv ol
pin. and t1 1~other (near Ihe inside cdJ(,',,(
the pressure
block) holds
the
pressure
block inposi tion
uutilclampscan
be
applied,
Then, clri1l11i1 ll1,,1(~and S(.'f'('\\'111f>ix~
form' 10 Ihe 00 '. see Fig. I.Afl~r t he ho le s
a re
drilled.
r e m o v e
both pieces,
s a n d 10 th e
pa tt er n I i e s, a nd SC rew th e jig toge the r,
S·HOOK lIESDL G JI(,.
Although
ihe S.
hook ji g
s q u e e z e s
s ir ip st oge th er l ik e the le g
jig. it 'sd if fc ren l i na ncmb er o fw a ys .Instea d
o(
r ely in g o n o ne p re ss ure b lo ck il
uses 5 \'e
sma ll er curved pressure blocks. see Fig . 2 .
And it uses
IW O
whistle-shaped bending
forms-Ihe la rg er o ne is fi xed 10th e bas e
whil e t he sma lle r o ne a cts a s b oth a pivoting
lo nn a nd a p re ssu re b lo ck.
T h .. pivo ti ng fonn swings ou t a nd a llow s
ih e strips 10be i ns er te d. th en p ivo ts b a ck so
tlte)'
ca n
hi
tij htlyclrunped
in
place.
tOl (STRl cnON NOTES. 111e pivoting form
a lso uSA.'Spin lik lIte l eg j ig . bUI this time I
used
a v , carr iaze boll
wi th t he t hr eads
CU i
uU in stc ad o f
a-l' 1
dowel , s ec
Fig.
2 .T h c \1 4
bohlocated euhe center D(Ib pivoting form
a ll ows room
10
d r il l ho le s for C -c lamps,
There are also tw o sets o f marks on the
b en dio g jig - one sel show s w here the s -
h o o k s
will
bet r i m m ed 10 s iz e . s e c F ig . 2 ,A n d
the oth er set s how s th e s cr ew h ole p osit ion s
for mountJng l it e Shooks.
RlSI) '''I)INGJI( ••The rin g b endin gjig is
compl~lely different from th e o th er
IW O.
It
doesn't have any p ivo tinKpa r ts or pressure
blocks. In stead.
it
co nsists u( a simpl e rin g·
sh .Pl' term thal'S m ou nte d o nto a sq ua re
base, s ee
fig.
3 .
(F or m ore o n m ak in g th is
jig. see P3II 16 .)
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12
ON
ROUTt.
TASU:
ROUT~l
FlU NDro )a
ROUND oOV bt
a.
NOTE:
~•• ROUN.D.oVER
ON lOP tDGlS ONLY
P1lUSURI
StoCk
. . . , .
Non:
USE A . SCRAP a . O C 1 C . . 0--
HAIMWl J01AP
STRlP
FLUSHAT
fOP BtFOIl£~GHJIN Na.ClAMPS
THlN;.lNSlJIT
DOWn
TO TEMPOR AR Jl.Y
LOCK IN PlACE
'UtST. SWlNG PIt(SSUltfc
aa.oc~ PAST HOlt IN t .ASt -
ClAMP ANDGlut liGHT
stlUPS TO STIAWlHf
SK tlON Of' PR l:S S U 1 U S l OC K
.J
7
APP\.YC<I.AMPS NOY 4-
TO S· AND RtMOVf DOWtL
s a nd I h ,' 1 . :g $ IOa uni fo n n ~ ,', see
p. 'g
1 8.
Next,
set
e a ch I l( b ac k
in
th e
Ix>ndinl jig
a nd m a rk th e lo c atio ns
10
tr im t o l en gt h.
F i-
n all y. c ut e a
th
1 1 (10 i ts f in ished l el lj .' th .
sovxn O EREllGF.S,Aflcr th e legs have
b ee n tr imme d 10 l en gt h. th e edges c a n be
rounded
QVt 'T_
Irouted the top
, _ u / r . r l
of each
I(>gwith a :~t\ ro un d-o ve r b it in the: roult:f
wble , S ec ~il~.Then. 1 used a file t o r o un d
over tht'
lOP
11 / . . .
o f th e le gs
10
a ¥ , , radius,
>rt
fig, sa .
\UIC:
Fo r
.Iability,
don ' t
round
o v er th e b on um t'( )g e, o f lite l~g>
ORlU.MOI~ nX ioiss, The l in a l slep in
making
th e I <, ( ss i o d ril l t w o
counterbored
l ll o un ti 1 I h o i . . , i n e a c h l eg . s ee ~ig,
,
To do
th i f ir st d r il l a ~ , -d cep cu un te rb orc w ith a
, d ril l b iL T h en , u se a ~c r il l b it to d ril l
the -hank hole
s an d, a nd c he ck fora bj hl f iL
: \otc : ( \ny im p er fe ct ic n s o n
th(' ji g wil l t ran s la t e in tu gap.00
t
larmnated
par ts .
h'sbenerto
S J ) < ' I l U exira l i n 1 < ' sanding nQW,
than a p pl yi ng f il le r l at er , O n ce
you re sa ti sf ied
with
th e
fil,
a pp ly
a generous c o a l o f pa-:,t~wax to
th e jig, Thi s helps prevent the
s tr ip s f rom S l ic k in g t o t he f o rms ,
GU ~:IPI.E(;s.Aflerthebcnd·
in g jig is w a xe d, th e I~ g. a n
be
glued up . I u sed a f031l1b ru sh to
app ly a n e ve n c oa t o f gil l . on to
c ne stde o tea ch leg str ip T hen I
Slacked ~'Ct rip s a n d
damped them
10 the
s tr a ig hl s ec t io n of t he p re ss ur e block, S<'C
Fig, 5. n i h el p s k ee p t he s tr ip s a l ig ne d. )
N o w c lo se th e p ressure b lo ck a nd lo ck
it
i n p o s it io n w i th the d owe l. s ee F ig . 6 .111 n ,
a pp ly c la m ps a c ro ss the f or m a n d p re ss ur e
b lo c k a b ou t
every
4 to 5 . a nd rem o ve
the
d ow el . se e F ig .
Aflcr thc leg h as dried <lv('might, r emove
it fro m th e jig. The n c le an up th e jig by re -
movin g a n)' g lu e w i th a c hise l. x ow , usc th, '
same procedure toK J U t . ~the remainim; legs.
'1 ' 1<1\11 £ '; . Onc e a ll four I R $
ar..
Rlul ' t l ,
1 ', thl')' n ee d t o b e t rimme d. B ef or e y o u tr im
1 1 1 [ > , 1 1 1 .
sc ra pe o ff a ny exc ess glue a nd ha nd
planeeach leg lo a fi n ished widthotl . Tht-n,
if there
a n- ~ I ny v a ria ti on s i n
thickness.
UM . 'a
d ru m sa nd er a nd a rub blo c k 10 thickness
I After complc l ing he jij('S.I
began w o rk o n dI e four logs.
The fir>t swp is 10rip th<
. trill '>
[or the legs. To k. ,p
theIc~sfrom bowing under
hea vy lo ads (suc h a s winter
coa ls ) .
I d • •r id ed
10
make
them 1 w ide, Eac h Ic tg i s
glued 1 1 1 1
from eight strips,
each :V 1 2 - th ic k - fo r a l o t a l
th ic kn es s o [:¥ ,'.
CUT S1·RII'S. The log
strip.
(A)
a re c ut fro m :\ , .
th ic k sto c k in IW O S I (· P S . F Ir S t. r ip e le v en
b la nk s (o aN ug h le nl.1 h of30 3nd af inished
w idth o f
H~ '. Then.
resaw
each
o f
these
blanksimo th re e h 2 · tb ic k str ip s. s ee F ig . 4 .
(This
will
giv e yo u a lo ta l o f 3 3 str ip s. Y o u
need eigh l strip s [o r ea ch Ic g. a 10lalo f 32
strips . b ut v ou m al w a nt te c ut ex tra in ca se
a ny o f th e strip s
twist
Orbend . )
rssr rrrns« , B efo re , lw l l jt th e s tr ip s
to
gether, there's one more important >lep
test fitting th e bending jig . T his inv olves
p la cing the strip s in the I x> ll d il l g jig. and
ch.ckingforgaps,
To check t ·
fit.
sw in g t he p r es su re bl,..:k
o ut a nd damp ~ ~ 'ttrip s 1 0 th e ('nd o f the
blo ck. see Fig. 5. Then swing the prcssore
b l o ck dosed and in ser t th e l oc kin g d ow el.
se e rtg .
6 . \It Xl. c l ampa c r os s
th e IOml:iUJ1(1
mark any areas where there are gal>:;.see
tig. 7, I i n ec es sa ry . d is as semb le th e jig. re-
4
EGS
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,~,. ~ ,...... :3
SHANK-
Ol l
13
LotAn
MOUNTlNG HOW
'IOMIMAKS
ONIENOLNG Jt G
1 5
W ooJSllllrh
v. i2
111.(
E N O S
TO
AAO'US
<>fA
QUARTfR
a.
T R AC t
R AO fU S
ONTOfNOS
o.
HOOK ..
13
I IOUT£l
T......
CUT·OfF
UN'
a
lOCA-noN o r -
S CU W 1 10 1.(
ut.Q
/' UN'
Hili II O\'FR Elle ~:S.A(I
e
r
th e
S.ho k~. re
tr immed ,
lilt t dgl'~
an
be
ruunded over. (
die this t))
mounting
a ~l itl
ound-over bit
in
th e router table and ra is in g
i t
1 0 p ro d u ce a
~16 ·d,, p
cut, see
Fig. 1 : 1 . Nl r lilt' I·dges
are routed, round
tlw
ends o( each S-hOtlk
with a file. see
Fig .
14. I used a quarter
10
strike a radiu s o n the en ds. see Fig . 14a.
I)KIu.. 'lO t :o. XC 1I0 1£S . T o comp le te th e
S -h oo ks . d rill tw o h ole <: o ne f ur moun tin g
th e Sh oo k to th e post, an d on e to attach the
ring. To locate the ho les , p lace the Shooks
on
t i l <
bendi ng jig an d ma rk th em . refer 10
Fig. 2 io rth e hole lo cntio ns, K ext. use a :.~
drill
bit to
drill two shank holes
in each 50
hook.
S( ~~ig.
5.
Fi na ll y . counl er<ink the
holes
IIvnlhead screw. w il l ,it flu,h w i t il
t t l 'ooUI;1tt:t~..r t ,E. s . . a ' ( t ll k . ( P fig.
lSa.
CLAMPPAUSURt _/
. . LO CK S 1 M P lA C E
1 1
CLAMP ,Nt STRIP~
8E 1W t[ N A xr o f .O R, M
'Ino
A ND PN OT A RM
F O A A \
> _
. .
------\
_
~o ~
. ; ; .
~
.~~
-.
-
~IVOl
NOn:
. . . . .
SOAK STtuPS 30 MiNUTU
IN WAltR IErolt£ Wn
~
alNo.NG, saRxr
BASt
lint
2 0 S TR IP S
J. , , · JH I C J C
I
be nding fig . I ,lip l>~d rubber
bandsover
th e
bent
ends
of
each
<N 10 p ,, ·v .m
i t
from Insin g ils
bEolIl
shape -as il dri ed .
TE~Trrnsc,
Now that tilt's..
hooks
ar e
p r e - bem, it s tim e
l )
ItU
b ac k a nd f ine tune
tile
bend
ing jig . C la mp
01,,
se l o r strips
in to thcjig
an d
mark
an y
gap> o r
rough a re as on th e form s, T he n.
ta ke th e jig a p art an d re-< 1nd as
necessary
until a tight fi t is
achieved, 1 '- i n a J ly . reassemble
the bending jig and ap p ly .
R~ncrousco a l o f pa ste wax to
th e e d ge s ofth e form s , th e p re s su r e blocks.
a nd th e b as e
el.n;·I·I' S-HOOl\>,.ow
hOI th e
bending
jig
is ready, th e Shooks can be j lued up .
Start byapplying an even COal olgluelo one
s id e o f e a ch strip . T he n. ,t .' lCk the s tr ip s and
damp
them in th e
form,
ju st as when wet
be n d in g
th e
Shooks , Lei
th e glue dry over
night. r emov e th e S -h ook from Ihp jig . an d
t h e n
glue,o l> th e r emaining sers ef s tri p s.
TRJ.\I S-HOOKS. After the Shooks arc
glued·up .
they
can
be
trimmed . To do
this,
begin
by
scrapingoffany excessglue Then
h an d p la ne Ih l' Shooks to a uniform w idth ,
N~<t.el e ac h S .hoo k bac k in the ndingjig
and mark Ihe ('\11-0« 1 000 l lH on at th e ~ l Id s.
I'il(. 12 Finally cui Ule ends orr each
:; 'hook
wilh
a h an d
saw
o r a ban d sa w
, . lu st l ik e th e le g s, t he [our :- '
<
honks are made with \ :It
'--lL :-
th ick
strips, but
th ey' re on ly
': . ' -w ide. T ll. 1 .k~ s
6\1(0 strips
l am i na te d l ox,-ther I Iorm
each of Ihe (otlr S-hook,.
lI 'ilh
glut bi-rw r-en
Ih .
pieces the
S-hook s
measure
about , • • th ick .
cirr STRlf 's. T rill the
book strips
(B)
( o r t ht- ( our
Shooks , I b 'lIa n b y C U llin g
L-_-- . _- IW O blank. 1 0 '
rou j' h wid th
ui 3 RI\d
a length
of 30 TIll11,. set
the
ri p
I enee to
p roduce
l-, '· th kk str ip s and ripthe
b la nk s 1 0 p ro· d ue r Iw e nty
.v,' -wide
,trips.
five-trips foreach S-hook.
, ,0~ig
10.
KESD' 1t(0) S.Before tlwstr ips ca n
bcglu( '( .upin Ihe b, ·ndingjig . s oa ke d them
an d
pre-bern
th em to s ha p e. T his
helps
pre
vent the strips from brC3¥ ing on the
t igh t
radius bends oflh~ bending forms.
T wet b end th e
<t r ips .
p lace five s tr ip s at
:1 rim e
in
wa te r f or
about 1 5
minute s T he n,
dam p the ,trips in t he bend ing j i b etween
Ih,' pivotarm and
th e fix ed f orm ,
see
Mi t . I
L
exi \\ ork i n g frorn the cen te r ou t, cu rl th e
s tr ip s a round one
radius 81 a
t ime,
Clanll)i Jlg
t he p r es sure blo ck s in plac. . . . v I ig . 1 2 . (
used 2./' (·damp, for this.)
L e t I he ~ h oo k dry ovrrnil( lu . 'hen < ak
3 1 1 d
\\ t
brnd 1 1 1 r( 'l n a i n i n J, s t ri p s i n *t.., ol
live_..
f f r
t l ltl )ving a ~l of
strip'
frUI Il thr
S·HOOKS
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. . .
,
... u.
,, ·HO lU
·
· ·OlEP
• •
ON AU
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fOUJt f CU
. .
•
7
IOTTOM
OF POST
I
_
• I
- 1 . . . . L
b
1 0\
SAM alT
a :
HEIGHT A S
fIG. 70.
Woo,Jsmith
19
- , - ; : - .
TOP0'
'i
r
POst
•
'2
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1)t(P
.
ON AU
fOUltf C£S
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t tOUTU
ll
PUSH lOCX
(SEt PAGE-4)
POST
18
_,_.±t
-,-iii ~
1
t IEiI I
~ ~I'~
~ .
POST
~
16 17
a
Q
POs t
-
orr oM
aOUttR
rENeE ,
,
lNO
. . . . . .
. . .
T
14
,-------, Once the I~ and Shooks
are
completed,
work can
bt.>gin10 lh.· I~~·-thirkPC 1.
To make th,· post, I lami-
n ated tw o pircesof1, -thkk
stock tog.ther instead of
m ilog Ihicker stock for tw o
reasons. First,1 ~hkk
wal
n u t is m ore common ly a va i l-
able, A nd se c ond. a lam i
nat\ Cll lJ~thas less of a ten-
d oey 10twist than a piece of
L-__ ..---' P... -Ihickstock,
T o m ake the
po.1
( C ) . • tart by r ip pi ng two
~ 'I hic k p ost b lanks In
3
ro ug h width of 1%
and a rough leogth 0 1 iO Then , glu e an d
c l a m p
II.. pieces t',gether fa ce to
fa c e
\\'hen the glue is dry. scrape o ff an y
e xe cs, a nd
jo in t
or
pl ane
the post
until
it's
I I i i
square. se,' Fig,
I
G .
Then. trim the post
10 f in is he d length o( 68 .
R()LTSTOPI ED t I\ \. FF.JI.
Togiv.
th e po>t
an octagonal shape, I routed upped
cham fers o n the top two - th i rds of th e POS t.
The
cha m fe r sta rts 2 4 u p from the bouom
of th e post a nd p ro vid es. sq ua re su rf ac e 1 0
a t t a c h tlw 1 L o g : .
To indicat e th e beginni ng of th e slopped
chamfer , ma rk r ef er enc e l in es a round th e
post
24
from the bonum end.
Fig. 17.
Then.
d r a w a r e f e r e n ce
line
o n
t he r ou te r
table fence t ha t' s a li gned with lh e center of
the
router b iL
Aft~r
tlw
post an d feDceIIJ C m ar ke d. ra ise
th e chamlcring bit toCUl ~i~wid,>hamfer
o n th e post.
see
~ Ig.
7a.
To rouuhcchamfer.e a se th e p o s ti nto th e
ro uter bit so th e li ne on th e work piec e aligns
w ith the r efe re nc e lin e o n the f enc e. N ow .
moving the post to th e left. rout a chamfcron
aU
fouredg es ofthe~t.
SL~
,.g.
1 7
CIIAMfER TOP A. O BOTJ OM_
\\1 1 il. ih e
chamfer ing b it is still SC t up, ro u t chamfers
on both ends of the post, see I· -ij(. IS a. I
p la ce d a $OP lIOr tu nd er o ne end o f t he long
POSIwhile chamfering
Ihp
other, and useda
router t ab le p us h b lo ck s e TIps. pag~4 ) to
keep th e p os t s qu ar e t o t he fence, s ee rig. 18-
aotrr
DECORAm £ C ROOI'F..After
the
endsare
chamfered.
decorativegTOO\ es can
b e
routed I in fro m each end. To ro ut th e
grooves. I sed a ~J -dia. co re box bit se t
II . -deep.
see
Fig.
ISb.
DRIU, MOI:NT1NG IIOLES. Afler grooves
a re r outed in th e p ost.th e n C >t ste pis LOdrill
pilol
holes
to moun t
the kgs
an d S-hooks.
The holes for th e Shooks arc centered on
th e width of th e POS t 12 d own f rom the lOP
en d. se e F ig . 1 9.
T he ho les fo r th e leg s ar e a lsec en ter ed o n
th e post. see F ig . 2 0. Locate th e f ir sl hole
7
f ro m th e b otto m of th e post
and
t he s econd
hole 4 iron. the firs~ M er m arking the
holes. usc a % 2
drill
bit 10dr iU the:v , -dcep
pi lo t holes .
POST
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t5
OVALKlAO
PlUG
-
,
RING
S HOOk
.0. 1- BRASS o.
OYAlH£AO SCREW
.Ox
~aRAS
OYAlKfAD
sc.tw
POST
24
HOOK
PW
DR.U . PRI~S
TA lf
a.
I,OCATt MOll POSfOON: 'ROM
RUDEN(.( MAUSON l:NOtNG JIG
/If'''r th t· fin is h h as drie d o n all tile parts,
a s semb lycan begin,
,\1T \('11 LEGS.
S ta rt b y
p la cin g each l eg o n
th. . 1 and lilting up the
pilol
a nd ~ ha nk
ho les . ·111<'n.c rew the leg 10 th e p os t with
II s flatheadwoodscrcws, see~ig.3 .Once
a ll lou r I~ gs w ere s cre wed o n. 1 ):lu ed o va l
head walnu t p lug s
in
e ac h b ole . s e e F ig . 2 3 3
(For
more
on
pluK>.
St. C
p ag e 1 9.).
.\nAC'1I ·HOOKS.
After the lej s are at
iached.the m'XI s te p is to s cr ew t he S -h oo ks
to th e J O I Todo th is , position Ollt' S hook on
the 1>O~ 'n c l screw
it
in placewirh a
J
brass
o v alh ea
d
SCI''''''.
set
Fi :.
24 .
r.vlake
sure
th e
large radius on t h i Sohnok isat the bottom.)
f - J e o Q l l
{a.~l l' :' njnRheremnining Shooks in
place, slip thelaminated r ingov(>r th<?~honk
yuu j us t moun ted. (Th e ring won 't f il over a ll
fnu r S -hook.
Ol ~
Iw) , in sta lle d.) Nnw ,
ilh th (' r in g 1 00.. ' o n ih e p os t, (f t'< llh e r e
maining S - i 1 < K l k s thn,ugh t he r in g and s er e'
th em to th e p os t.
~1TA(lt
RING.
The f in al s te p i$ t o con nl 'C l
Ih ,' r ing tu
the :-.ho k<.
T o d o
Ihi~. >CI'eW
tht'
r in to ... e h S -h oo kw i th . I brussowlh.ad
~re .
t e
l - t K . 2 4 a .
ASSEMBLY
~ Jr
ORtU~
fQUAtl Y-~SpA(tD
<, MOl
~ PlYWOOD
O RIW NG JJG
2
d ri ll ing the angled ho i. I b u lh a drill ing jig,
se e ~tg 1 . T he jig is c on stru cte d f rnm ¥~ .
thick plywood and is s imp ly an angled pial,
f orm . T o hold
the
ring in place, I glu.' •
couple cleats to the plauorm, sec
~iJ:.
21.
(You cou ld d ril l th e h ol< '1 ;without
·
jig if
yo ur d ri ll p re ss h as a t ilt in g l ab l{ -. )
llRIt.L IlOI.J;S. After t he j ig i s m3<1,·.scuhe
ring o n t he p la li orm.Then, po si ti on t i l < p la t
f ..n n o n th ,' drill pres.' t ab le u nti l a 'l-:r drill
b it is c en te re d o n th e th ic kn es s o ( till' rin g.
s ee F ig . Z l a Now. a dju sllh t d ep th stop on
lite drill press to drill ~.-d('('phow. an d
th en d ril l t h c I ou r p llot holes.
tl~lIsH.S incea li o ft hepar ts o f t h e ha ll tree
an-screwed
tOR,·lIter.i t 'srnuch easiertofin
ish
each pan before assem bly. S u before
going Imy I urtlw r. I r ub be d o n IW O c oa ls o f
lung OIL
n ig hl .Th en i ns er t t he s ta rt er s tr ip i n l it e s lo t
i n ti lt '
Jig. clamping th~ strip as
yo u
work
around m e fo rm . Nexi. a pp ly g lu e wh er e it
Q 1 1 « 1 ~ a n d
clamp it in place.
CO)II'U'Tl'GTIIRRI\'G. T he n u 's a m atte r
of adding the other strips one at • lim ..
a ro un d t he f orm ,
Once
th e
thickness
i s bu il t
up
to ¥ . . th e r in j
can be cleaned up
an d
ro u n d e d
Over with
a
round-over
bi L
Ag a in , t h is i s e x p la in ed o n p ag c , I nto 17. )
SCREWHOI.E S.A fw r till' rin g h as b ee n
m ade . Ih e n ex t s te p i.o d rill lo ur ho le s to
a na ch th e ring 10 th e S -h oo ks . S in ce th e : > -
hooks
n1 1t h e : rin g a tu l\ a n g le , th c. · l 1 0 1 ( ' $ U J ' \ . '
drilled at 20' in fnur equally -s pa ce d lo ca
tions.To loca le the ho les .p lace the ri ngback
on the bending j ig and ma rk wh ere the four
hull'S i n be d ri ll ed , s ec F ig . 3 .
OR lWXG JIG. To pos iti on th~ ing lor
,------, The 18$ 101
I
h e b en two od
c
components
to
make
i: th e
ring. 1 1 1 < ring
i
u i l l - U P
f rom
:>:I: / 'Ihickstripstharare bent
around a found form . ~ Of
step-bYoSt'1 )Ins truc ti on s on
building
the
ring
bendina
fo rm , s ee p ag es
H i 1 0 11.)
ST\~T£R
STRIP.
Afler
t i
buHdmgthebendingjil1. ripa
jj..._·IO ,lonl(ring starter strip
.,./ \ - I (D) trorn ~, 'lhick 'lock
L-_-- -_.J
The starter str ip i cut
longer
th an th e n ~1J I U l i
strips so it ll
wrap
a round Owr ing form omp t'lelyand ov ,-r la l '
about aquarter-turn.) Soak lhe~lrip in water
and dam p ilto the Iorm 10 pre-bend il 10
,h3I)< '.Then eut u-n 2~··lonRri nl ~trip~ (E)
and pr.. ..bend
them
Le t t he s tr ip s dry over-
RING
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:-Jo.72
Remor«
ony r.J·~e15~ll« :a i tlte eP Ld of
t / f i, ..1 81r tpaJ lt i , ,, h u tt t I lesecolfd
glued stri; 10 tht ftr.•
. 1]
ee a V;··tllick
.m 1 P b lo <k
to d am p th e b ut t jo in tt ig ,.t
5
11 '11 , thestorur .~tnphegm~tt)ot·l r·
iap i l . l l , 1 f . apply gill t« th~ OI .r /<lp·
/ li tl gMt< } . T llQ r tel ll.J~ thecla. tps 11.eOytl'f:
Iut.
m'erlap
l ite s tr ip,
ami ,. ,, · t OIl lP,
A 1T Dl G W lN G A OO
-CLAMPSTOHO\.D IN.PUc
AOOGWf ON
IN S ID E O f O v( RtA .P-......_
Remere
scr( 1J's
(I ltd ,~flJ(I) nft 1'1 9
Q/.,U ( l .11d f) (lAf Drc u·II,, -mide s lo t in
rir lga nd
rllt
IJ' t
: 1 / I t l l (J S{~1) , .
~a .\·f,}'t,
tu
t li e b a t .e
ot~rtrll
k 1 U ' r 1 11 [1
iupku»
2
.4If(l(h
a
)tPI(
I M . f
1>/lJtP
t()tJII mnter,
l1 ' i l1l : ·.I,. ,ght hil. rottl III, g
~htll)fd/ ( 1 1 1 u lt in y .I .1 ,_ .
rad ii,S n d .;
, . u d i tu r p .t U t J ,b l 1 _ (,
n R UltR
ar t iN TO S TOCK A ND
R O T A TE C l O C lC W l St - T O R O IJ I' R 1NG _. /
stOT FO R
STARTtJtSrtlP
pOinl
o f th e
jig.
It f it s
into
ho les
drilled in a
la rge
shop- buill
ro uter base plat e,
If
y ou h av e
8
t rammel peint fo r your ro uter ,
yo u
w on t
u( 'Cd to
m ake
a
ne w
ro ute r base. )
\5£NATE.
So
I started by r e
placi1 1 : the base plate on n\)'
routerwithanew
one.
(Fo rmore
on th is. sec P3 (e 1 9.)
Afler
it' s
re pla ce d, d rill thre e ,Iu; pivo t
holes in the pial ',
1 '0 lo cate the ho les, insert a
v, -straij1h1 bit
in th e ro ute r a nd
measure
out (rom the
cUlting
e dz e, T he c lo se st h ole to th e b it
(:W. ) is use d to r ou t th e i I/ si t '
edge o f the bending fo nn . s ee
Step
1 .
T he n ex t hole (5 ) is fo r r o utin g th e
ol<t.<idte dg c o tth e b ending fo rm . The th ird
hole (5'y,,,) isn't
used
0
mak e the fo rm ,
lt's
u se d a fte r th e laminated ring is Jd ued up to
t rim the ri ng
0
a perfect cir cle
r ing -s haped be ll di ng fo rm . s ee phot o.
The t ri cki es t
part
o fth is p ro je ct i s mak ing
th e round f o rm - e-irh as to b e-a
perfect
circle.
To dothis, I usedarouteran d aprvotpin The
pin is simply a brad driven into th e center-
1 6
Iret 0 11
r 1 J > < m Id p l1 ,.I . d O I II 'U
funu. Ut t 1 r v OI't I·' ';Uhl. 7'1'1'>.,I.,U;II
(l l ll)I
,( itl,
tile Jftnyt~r ktn/I, ;tlse rtlt {1 it
j lto t Iu : ;;/(11 (Inc/ r}all1pltlg I I·er 16· it } d
HOlD SfAJITm SJRIP
IN SLOT WITH C·C1.AMP
W O R K S T Aa 1'I :R S T R ip
A R -O U ND F OA M C lA M PIN G
tvfJtY 6 -'0.·
1
r..or ll~r( nter t i I P il 1 1 1 1 / .d m . II' ( '} . .. II ~
J D Y
tlte
rirl'I(/a.·
/01-/)1 Ttn:n,
x( rr l (+
1 ) I Y r t f ) J d
1 ~ l n J . . i t
f. lptllPfXO 'lit , .
rrj/t ,,.UN
I ft,I I , ' thr 1 )19 ltd ; ,) PI tit~li
Making
a laminated
ring
i s fa ir ly
s imp le . I t' s
jusla
m atte r o f g l
u
il)g and
\\ 'TIJPJ)iog
strips around
a ring-shaped brndingjig
Okay. bu t i m t i t even easier
to cut a ring oul of a solid piece?
It's
easier. but
no t be tte r ( or 3
crouple
01
reason '.
1; jI 'bl.
there
would b e
rw o
,t
a
k spots where
l h~gn i n cu tsd ir ec tl y eCT th e
th ic kn ess, o f th e rin R .\n d s ec
ond. a so lid ring
warp
with
changes in humidity - but a
laminated
n O R
won't,
Though I 'm using
Ille
ring
irom tilt' Hall T,.,..,
(shown
tin
p3g IO) asan example. thispro
cedorecan beused
10
make an y
, i 1 , : rin g o r ev en I w hee l, J ust c han ge th e
,i7kohhejig andeu; shertercr
lo ngcrslrips.
REI'OISGm TIle bending jil1
I used is
m ad e r om
I
w o p ie ce s o r
l'.
p ly wo od . O n e
p ie ce i s a s qua re
basco
The s ec ond piece is a
Laminated Ring
TECHNIQUEOODWORKING
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7
11
C'/n)} ' I ' l Ilb (1J ) fo fh IYJlftrr
I bit
a U f l tY1/411d ()t·p,./ltt Q;I IP,id,··
( 'r igj's ojlJ ,
ri
Il g f.~;tlg(J.J/~. ()}( ti d .f)I 'er bi l .
S
l it . .
billll rlll~ b ,'i
l it . .
loblt.
faQNTOf
lOUT ••
fAflll
No. 72
8
,4ff,
r
t / l ; . 1tll~
r l r l rA.
~r'l'1J1~('ltlU
t
·~~
1 1 1 l t :
.frtJ)'t
I t e
t o }
u f t e · r i n g
It'itl t
tl
~rra.JH r Ti't
Ii.
pltl 'tl b t J t J t t;( igtIR t~r Ilt
Slr 'llp t_ n II1 'h ~{ itl1il t he-udi. g [( )I ' ln .
12
RQJllld )ly~rile t ifldt
f · ( l y e . , ;
oft/t.
;)10 u'; lh tJ tf' lib Ur/)1 i) ,
(1/(1('.('.
11 7. l'Oltl;l g lite inside edgfJl of lite rill .
rollt a r /C K k ( (' i& ( l, r( '( '1 1 0 1 '
DlR(CnON OFf 0
RUa tJtM
9
rrt,'ll'
;-;I/t·,· blurk
l)l:tid( bp)l(i;}(g
.(n,., i 111 1d (I ', J b l' (l t1 i l1 10 t I t . : Cl uft r.
Lr~(pr~'l)t
},oll'
/rlll, .i·II.·
dt.ff.
tl) I,i. .
IltL
1(11111 ) fa te d ri ug If} it M''f i'r l ( '';r '( 'U ,
WU(ldsmith
to gether at the end s ec S te p
6.
M ake sur e
th e s tr ip s a re f lu sh a t th e to p, And continue
wra pp ing until th e rin g is a t le as t :j I. ·thkk.
see Step 7.
Once the
ring
is laminated.
th e top
and
b o l 1 0 0 1 edges ar e pl an ed O u ,h . st Slep 8.
TRL'I
RINC,ll l4.-
next
ste p is
(0
u sc
a
ro u te r
to trim the
ring
to a circle. T o do this, ~ ';n
by
mount ing
a scrap block
insid.· the bend
in g
((1mt.~ t
SIt . p9 ,
T h e n , UF.t'
I h t' r c . ( ( . l rc :n f i
lincsou
t hc r in g ami10 10< 01 03en terpoint
on th e b lo ck and install a pivo t p in ,
\\ilh
th e pivotpin i n p o sition .th e
t,.it e
OftllC' ringcan be trimmed toaperfoct circle.
U sc th e Iliv ol h ole tha t's fanhest fro m the
ro uter b it 5 - V . ) and a
t
. · straight b it . Then.
sl ow ly rout
co u n te r c lo c kw i s e
aro un d th e
rin gr u llT< '\,cnt tlwla.l stri p ro m learing out .
=Swp9.
Th en . to trim th e In~/(14 of tile r ing. re
m o v e
th e
WllSI~
se ctio n
o f
th e
sta rte r s tr fp
with
a
hand saw. see
Step
10.N ext. feather
the
inside
o f
the starter strip to 10m a
smooth C irri .
ROt ND O ER E1)(;ES.To complete the
ring. use a 3 r j f round-over b il un th e ro uter
table
and
a ru b arm 10 ro u nd o v er th e
edges .
see Slep s 11 a nd 12 . ( Fo r mo re on u~ a
ru b am I, SCt' Shop N o tcs on pagc IS .)
Rf.M.OVl:OCfSS CWf WTTH
StaAPat TK N P L AN E s taR' S
RUP4 WffM IJING JORM
ro cu t th e s lo t . f ir st un screw t he oc 'nd ing
10m.from th e
base, T hen . d raw
an
,, '-w id . .
c ur ved s lo t o n the fo rm. see St l 1 '3.
I
U5(.'(i a
large coffee can
lid to
~ellhe desired curve.)
: - I e x 1 .
use
a s ab r e <;;JW 1 0
cut
th e
slot,
ASSElIUL\', O n ce th e slol is tilt
re-n s
semblerhe
jig
by
1l 1PIl ing thCase overt oget
u c le an
surface
(n o grOO\ ~~
rom routing
and rew
th,'
rill.'l· s hap ed C on n o nto th t
ba. l . :,\tl·xt. If) k ee p th e ~IUl.lo r o m l : u c k in ~ ,
apply a generous coat o f pasn- wax
1 0
the j ig .
L'M IN ,\T E RING . \\ lth the jil( complete.
work can
b e g i n
on th e
laminated
ring
ilSi'lI.
Bcfore th e stripscan b e glu ed together, they
n e e d 10 be WN bent, T o d o this
O ak
a ,trip
in wate r fo r 15minu tes an d clamp it to thr
form without glu e. K eep th e strip on the
(IJn n fo r 15 minutes remove
it,
an d wei
b en d th e remaining strips, 'O w n a llow all the
ring strips to dry ovemigl tL
O n c e
th e
s tr ip s a re pre - b e n t
ti le g lu ing
process loan
start.
se c
Step
4.
B < g i
n
by
in se
n
ingthe
~IY
onl(starter strip into Ih e slo t and
clam p th e s trip 10 the fo rm as you wo rk
a ro un d th e ( on n. W he n y ou reach the po int
where tb e strip o verla ps , apply gl ut 10 Ih t
ove rl ap and
damp
it in pia '.... ~ Step 5 .
As
tilt
renlainjn~24 ·\on g st rip s ar~
wra ppe d aro und the (onn.
tbe) aT i' bUII ,'«
1
0
Ilf~t}10. f rt~( J
r o , l> eudt , 'g
f o r 1 1
tlU l i r u t n / fl ') ,l '( $ . f\ f {t o (t r str,p u i l J t
o Jlll,ild
s(1« .'. TJ,eJt.
~(/)ulIJ'''liISidf'' (if/ht
r i 9 (( Itt II it n j tt lt e s l tl s tl ll t u IJ , t ,t o r n ) .
cu r wrT14 HAND SAW
TO RE M O V E: W A S 'r f
\\ ork Ol.(t~(l~trip ~round lit,
J lrll~
( '1 1 1» lp in g as l tf tt' tt Q~)t 'C I iS ( l to y it) gf'f
(r(ipqltalt gillt' Sqllf I :e-()Itt bt'IU'~'ll'~o : - t r i lk > ; ,
(',))11 i )ltlf u ut i l I '; U is (t t
It'(f
:t
J/ ..
I, jrk .
ADD ADDmoHAL
SlRtPS CLAMPING
MAY 2 TO3
~L\KJXGue FUR'IS. On ce the
router
base
plate is co mplete. w ork can
b egin o n Ih,·
ri ng-shaped bending fom. it,;elf.Sian bycut
ling O U I a p lywood bla nk and la ying out ce n
ter lin es o n
it,
see Step I Then, draw th e
(a nn eirclesfo r reference during Toutinl(
T he
ring
(ann is cut f ro m th is
blank
by
making repeal p a s s e s
with h.
ro U IP T
until
th e
b it
CUIS
Ihrough Ih e
b la nk . T o k e 1 1t h e
blank in p la ce during routing.] screwed iliO
u t top f a second
pit. . - :(·
n t plywood. t'('
Seep 1. toe . . l et he ' I'W so
tht'Y
wont b e in
th e
path
o f
thc'
b it, T he n. d ri ve a
i
g a u g e
bra(1 U)ivo l pin)
into
1 1 1 ( · . .
-emerpcin; and
snip
o ff th e b r a d
I I
above th e surface.
Rf)l T 8.~Sr)fNGF()R.\I. Once the pivo t pill
lsinplace , t he to rmcan
be
routed. T o do
this,
sci tile ro uter bit IU make a VI· I~et. '1Jcut and
m ak e a pa ssw iih th e b ase pla te f irstt e we re d
o v er lh c 3 \ 1 , pivo t ho le.T hen m ake a pa,,,
w ith th e b as e pla te lowered o ve r I he 5 pivol
h o i, '. NO .lowerth bit
t I
atatim~until
ti,e
bilCUIS th r ou gh th e to p la yer, sec S t~ p 2 .
cvr
S LO T, A fter
tile to p layer is routed
th rough.lhe n e x t step ls to cu t a sl o t in to ih e
ri ng- shaped lann fo r t hl f ir st s tr ip o f the
lan llna1ed
ri~
Int -startt1T s trip is an ~xlra-
long strip
tll~l
cts as a found atio n lay t- r f or
ad di tiona l s t rips.
SANDOff
W E O C E
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Np.72
tightened iruo the drill press
chuck.
This
over-tightens the
drum, c a u s in g it to bow
I'\C I SERT.The problem
is
eliminated b)' sl idin : a piece (I[
PV C pipe ns « the rubber
drum .
This
a llo w s th e d ru m
to
tighten. bUI keeps
it
irOn
bowing. For m y : drum. I
CU I
a
pie ce o f IVJ ·dia.
I ve
p ip e to
8
length
01 2ltl
It e xa ctly th e
right size to til inside the drum.
I , . ,
P V C PiJ'£
INS:EmD IN
DaUM
18
O R U M S A ND ER
lOWS OUT
-,
1
3
pand, lock ing
lh.
sleeve
in
posi
. F ?
ion. SC'(' ,g. _.
11llClUESS SA,,(OI'C:. During
no rmal sanding. Lilt d ru m and
its sh l tum at th e same speed,
ilul w hen you thickness sand.
the workpiece is inserted be
tween th e drum an d a ru b b lo ck .
1l1i~can cause
th e
drum
to
slow
d own . e ve n ,o p if en nug h p re s
.u,,·
pptlc d -
bUItlu- ,haft
will still b e rotatin g sinc e it's
l
MAT(H(S
O I O S
Of
R S N O
CUTNOTCH
SUGHnY
IARG•• THA
IIOtII'IJO .
IKARlHG
rubber drums.) This problem
a ris es wheneve r
3
ru b block is
used
10
p re ss th e wo rk pie ce in to
the drum sander, see
fig
1.
ORI'''' CO rr\STRl CT 1() \. To
un
derstand w hy this causes the
drum
10bow.
you have to look at
ho w
the drum hold, L 1> e
'Ulding
s le ev e in p la ce . W hen th e n ul on
the drum shafl is lighl('ll('d. It
pulls th,· b ou om Rangt'
up. 'Ibis
c au se s Ih , ru bb er d ru m 1 0 e x-
• I
c a m e
across
a
problem when
using
a sanding
d ru m o n
the
drill
press
10
thickness saud pan> of
the
Ha ll T re e. I
noticed
th e
edges I
s an de d ....(: reo· t
0.11-
thcy were concave, sec rig I
lI'hen I examined the drum
sa nde r. I d is co v ered th e to p a nd
bottom ofthe
d rum we re
bowed
out. (Note.Thisonlyseemste
be
a probl em ,th Ih e larg,' hollow
drums and
nO I
the
S01aIJ<>r solid
SANDING DRUM PROBLEMS
2
R U e J tM P R O VID E S
SUtFAa TO~ AGAtNST
1--
DUllING'KONO cIIJ
-
1
OVULAPAND
GlUtINIU.Q
UA Vf ROOM to
tlAMPTO
~ ItOUIU
CUT8LANK
INlWS
3
n UNO~rurSSfNCf
l A.ING , 1 : 1 0 ( 5 .AlO~
W 1 lST PAin fRlNO
i\rXI. to gt:1 lh<
rub
nrm
aligned wirh the bearing un ,ht'
bit, tum on the router . Then,
slide the rub arm im o
th e
router
b i t unti l
the end
(the rub ann i
flush
with bearing. seeFig.2
1\0\(.
turn
off
th e
power
an d
damp the ru b ann
to
the router
labl .rd~rluStcp 11,, page 17
Once the r ub a rm is i ns ta ll ed ,
matching round overs can be
routed
without
c re atin g a n
un
wanted
shoulder .
terpoirn of the work l' ir rt · S .
Fig.
2.
Th isp re ve nt» th e b il fr om
removing
100
much
stock ,
CO loSJ'RVCI10 .
To make a
ru b
arm. cui a notch ,1iKh ly
larger Ihan the diameter of the
router b it b ea rin g in a pi('('t' of
1 1 Masonite . Then . glue. base
piece under the arm. seeFig. 3.
Note: For Ih e
Hall Tree
ring. I
cu t an arc Oil the end of the
ru b
ann
10
allow
till' ring
to rotate
smoothly
during rout ing .
BUI, on the ring I wanted to
rollt a Inating round over T h e
problem wa s th at th e b ea rin g
surface would be
removed
d urin g th e fi~tro u te r
p c K >
a n d
the
bit w ould c ui a s ho ulder on
Ihesecond pass. see
fig.
I.
ISIXG A RI'B ARM.To so lve
this problem. I made a
ru b
ann
[rom a piece of I r M asonite,
The r ub a rm
acts
as a subst inne
bearing surface andwhen
it's
in
<tailed.
i t r ub s
~
th e
cen-
• W hen making
L1w
laminated
ring fo r the HallTree shown on
paJ ~
10 . I wanted
to
llU l a 1 .
roun d-over 01 1 all (o ur t· dg es.
However, I ran Into a pro ble m
using thr
~x ound-over bit
in
the ro ute r ta ble
The problem i s the loca ti on c if
the
I learinK -
it's
too
fa r
above
IJ lt cUll ing < fig on som e
bits,
N onna lly . illls is n't a problem
since
th e bearing
ha s
pICJlt)·
of
su rface
10
rid
awUns~
RUBARM
Shop Notes
SHOP
UR
RO Nt
IPS
OME
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19
PW
m
WooJsnll[h
ORW.HOll
~7~,..
W &S T
ORW 8ITroa ~
OVAlHEAD
PUJG.S
DON'T
OAJU
P A S T
1Vl
ON I ~
T
plog, ;fonhc
FcmStandand Hall
Free, Ieeded a simple
way
to
install the plugs without flatten
ing the IUpS. S o I made a plu [
sel ler that matches th e plug's
rounded
lop.
see Fig.2.
C(ISSTRl.'t'TIOS.
To make the
p l ug se ll e r.
firs t C u i a
:]f dowel .
11a' · long.
Then.
drill
a sh al low
hole in nne end
of
the dowelwith
a7/
t
6
twi,t
drill bh, see Fig.2.
SETrue
ru'cs.
To use the
plu g seuer,
position
an ova lhead
plug
in a
h ole a nd
place
th e Sel'
ler
over
Ihe
plug .
Then. tap lb.
sctterjustuntil it boUomsou' on
th e workpiece. se e Fig,30.
Notl . ' :
Don'l
continue
tapping
the SE tterafter itbottonlS (Jut or
you'D le av e a doughnu t· s h ap ed
dent illth e work . UriBe.
N o. 7 2
3
1
WOOl> PLUGS
OVALHEAO
BUlTON
/ - - . . . .
~
FLATHEAD
,
t.
1
1 ~l71
\
\-{
1
• Wo o d
plugs
are
commonly
available in three styl s: flat
head . oval head , an d b ur to n. s ee
fig.
1 . And they're available in
~. .~
nd
1 1
diameters.
I~STAWNGpu'cs. Flathead
p lu g:; a rc in sta ll ed s o th e lOP
of
th e
plug
is n us h
w
rith
the work·
piece, Ovalhcad plugs have a
rounded
lOP
ihal
protrudes
from
t he wo rkp ie ce .And buuon plugs
have a shoulder that keeps th e
head evenh ighero{fth~surface.
F la th ea d a nd b un on p lu gs a rc
simple 10 insJaIlsince
either th e
top or $ ho uld er o f the plug i<
nush with the work surface.
Ova lheadp lugs.
however. ca n
be driven inion fur.And il'~easy
10Dallen their rounded lOp.
Since [ used
:}s
ovalhe.d
WOOD PLUGS
PLYWOOD aASE
SCRiW .LANK TO
BASil,..
WASlt S ;TION
P VOt P
,.
LOWt••
'_- '_ 'NTO WORKPLKl
<,
lIP ftOl.ltlR AND
1
the
plywood 10m y b en ch .
To ro ut a c irc le ,
t~t
11 (, ' it \ /. 1 '
deep and drop the base plate
over the
pivot pin.
then,
lip
tilt
router nt
a
sligh, angle sc the
bil
is s)igbtly a bo ve th e surface an d
tum on
lite
ro u te r. s ec Fig .
2 .
(Nole: I f you're
u.ing a
plun~
ro uter. y ou w on 't h av e to
tip h.)
ow
,Iowl), plunge the bit
into the blank. Then pivot the
router rlm kll i around the
circle until you reach tile stan
point. Repeat this
process.
lowfring th.
bitli, ( o r l e ss ) be
tween passes until th e bi t cuts
l1,rough the blank. S<'t' Fig.3.
circle you want
1
o cut, o u r ex
ample, on the fern Stand I
needed 7 · dia. shelves so I
drilled a hole31-, (rom the edge
, , ( tJ1C
bit.
~ C
Fig.
2 .
F or th e pivol p in I used a 1 7
gauge brad and drove it imc the
workpiec snipping
it
~4
above the surface.
ROL'TISG ('IRCUS.
O n c e the
p in is
in
p lace , y ou ' re read y to
start routing. To keep thl bil
(rom cutting
InW the
bench
when roulinR all th e wa)
through
thr
blank. I screwed
il
(in th e wasl~iCctionl 10 a piec..,
of piywood
and then clamped
o f9V~t I, S< ' t. · l -lg . 1 .
To auach Illi..;.piece of Plexi
Rlas t o yuu rr ou te r, I )OS11100you r
router's original base plate over
t i t ·
n ( \ ' p l at t and use
it
a s a t er n
plat t o l ocat e
an d
drillthe
screw
holt . and
large
c en te r h ol e
PIVOTnOIE.
The
n( 'XI
step
is
II)
drill a
VUi -diamt'ler
hole in
Ihe new base plate In fil oyer a
pivot pin. see rig. 2 .
T o locale th e pivOIhole. firsl
mount a slr'tiight bitin the router
I
u se a
v,, -srraighl
bit). Then.
measure from the cutting edge
01 the bit 10 the hulc. This dis
tance isequalto th{·radiu~ ofthe
• To
' U I
the round ,h,·I,,·,
fo r
Ill ' F ern S ian el a nd W m 'k ~
II ,
ring bending jilt for the Hal l
free. I replaced 11.. base plate
o n m ) ' r ou t ' rj \'i tl l a 1 ar :g \. ·r ~1 1 ol )
buil l
bast'. The n...w base
pl31< '
acts 3 a tr ammel a ua chm en t io r
t Ul t ingand roul ingdrd~s.
li.bE I'L\TL
I
sed a tli«t> of
, Plexigl ., (or ),oucould use
M ase ru te) to r t he n ew b ase. T o
curcircles
I orthr projf Cl~
in lhi~
issue.the new
b;1~
needs
It
be
extra
long.
T o m a ke the ba se
plate large
enougb
for tho ring
on the Ha ll T r ee . rul lilt' PI,· ,. ; '
gla<In a \\;,l1h l Ii7 a nd a l to nR ih
ROUTER BASE PLATE FOR CUnlNG CIRCLES
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N,l.
72
c
TT T T~lEl
~. x st., . 48 I. 14 . f,. 001(1
{
Alsorequ.ed for bena.ngjlg
• I
10'.<1<1 piece . · thlCkpl)lwood
• (I) 14' .2 ,. p.ece ~'.f·thIc~ply\VOOO
• I
14' .~1~· piece
I'.
-InlC~MosonlteorP ywOOd
:1. ..
3 ,,- · .aa. {1.2 ad. Ft. Wolnul}
z z .. 8 . . . . . . . . . . : : t f l ; l
A OokLegBlon1<& m
3 ; . .
I ,••
(Each
bioI'''
YieldsItvee Sl~ Minimum of 18stopsneeded)
8 W o ulleg B Ion1 <& (3)
1 - .
x 1\II. X
(Each btank Yaids lrJeesll\ps. Minimum 01
$ill
stnpsneeded)
C WolnuISheIves (3) ~A.8.8
(Edge-gllJe these rreeeblankSfrom sll(4' .8 cseces )
M T RI LS
f
w(lod can be benl to shape
w ith ou t ste am in g, s oak in g. o r
an)'
lled.1
preparation.
IIH .\ E». The bent legs are
attached
to
three
round
shelves.
I sized t he s hel ve s 10 h old a m e
d ium s ire d
(6 o(]i3.)
flower
pol.
bU I th e s he lf d iam e ter ca n be
va ri ed to
almost
an)' s i ze.
C uttin g th e s helv es in to p er
fetl cird,
~
he second chal
knl ' on this proJed. But again.
i t' sc as ie r t han
it
might s eem . A ll
I used is a router filled w ith a
sh op -m ad e b ase plate th aI b as a
piVC)1
h u lt d ril le d in il .Wh e n th l'
hole is
SCI
o ver a p iv ot p in . t he
router swings
around
it
to cu t
perfec t c irc le s .
l~lStl. :
fo r
the-fini~ll.lh~
pr ima ryrequ i rement i st hat i t re
sists moisture applied 1\\ 0
coa ts o r s al in J l< ,lyun -t hane. ~
Y
OU
wnuld
t h in k
that
m akinll bent legs - C S I >
oall)
legs with
a bend
on
, r h
ends -
, u l d
require
a - : c I 1 1 1 p l t.
cared
jig and
maybe
a special
technique
Iha.
involves
steam
illg tht..wood.
Actu all y th e b en t k 'j S o n t is
stand
arc
bent
lumivatume
They re made o( th in S tr ip s ,,(
o k w ith tw o s trip s o f w a ln ut in
lilt
\ t nt-..r
fnr accent. These
strip s are lam in ated (glued) l ) o
g ether an d shap ed o n a ben ding
jig . (For m ore on beut lamina
lio n. s ec p ag e
In
Rf-:N )iS G JI(;. 1·0 bend the
cu rv es o n b oth e nd s o f t he le gs.
all
y ou n ee d are
ten damps
Ihal
open
I J
allt; d~t
-1 , and
a
~illll11t
bending jig th at's m ade out or
plywood, 111ejig is designed
w ith g en tle curves sn ttu- strips
There are
tw o
cha l lenges
to
bU ikl ing Ih is fe rn
stand.
The first
is
b e n d i n g
th e le gs w ith a g e n tle c ur ve on b oth e nd s. T h e secon d is e t i n g th e shelves into
/Je7iect circles, Fortuna te l · s in lp le figs ln ake both tasks a snap.
ROJECT
EEKEND
Fern Stand
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-
10
2 1
~
~D . _f
FOR.M 4 -.
lOO~ ____ 4·
'ORM _. J ,
CUTl.), ·lNKK
STRW tROM\
I l i A N I <
lI ..
Pl
YWOOO eA, f
4
1--S T R A I G H T o «
f
l
1
•
1\i.ICKNfSS OF SlACK,
ttOULDfOUAL ',,-
I
SECOND;
CUTOUAftft.
CIR(USwtTH
eA.NOSAW
ORSAA~SA.W
3
5(1.11f H A . t . F
aRC ;I.B ON
ItEMAINJNG
a O N lC
2
fRST: RIP
rwo
II~~
W lO E S TR IP S F ROM .A;-v_.......
\4
x
211,,
.LANK
e
211.,.
used
10
c lam p I Iw s tr ips
10
th e fixed fo rm> .
Finally .10prevent the stripsfromsiicking
10
the base
and bending
fo rm s , r ub p ar affin
(o rpasiewax)
'10
th es ur fa ce sth at w illcorne
in c o ntac t with th e $tr ip s d uring gluing.
ci i TTh G n lE S1 'R Jr· s.Now vou can star t
cutting'
t he s tr ip s fo r t h ~
leRs..Fi 1 cut S('VeIl
b la nks o f:V · , ·th ic k
oak
a nd th n. 't' b la nk s o f
: ;, · lh kk walnut
10
widths of lVItI an d
lengths oj 41 . Now. resaw
th e
blanks
in to
thin <trips
by
sctting the rip fence ¥ . r / from
th e s aw b lade.see 1-1,1(.5 .F crmoreinfcrrna
tion on ripping IIUDstrips, see page 7.)
1
b e sur e your saw Is se t co rrecdy . tes t
it
bycutting eillhl. tripSO(S<.T3PSlOC k.Then
Slack th e strip s a nd
m e a su re th e
thickness.
see
Hg. 6. If the
:;CIting isco rr e
'CI .lI te sta ck
will b. :y , · th ick.
When th e , U ing was correct. I re s a w e d
• IO Ia I
of
20 oak
strips
A and S walnut
strips
(8).
I
cut two extra strips of each in
case som e broke
while
bending.)
1V1
M
1de \y ilh 1)~1pace betw een th em ,
which ill be the thickness of the legs.)
'\ ft er d r aw ing
th e half-circles.
CUIthe
blank
in
half . se c F ig . 3. Then cui out th e qua rt er
c ir cle f or m s
with
a s a bre s aw .
)'01 ~ NG11IEFOR~1S.\fter-all the form
pieces
are
CUI.
the bending
jig
ra n
be
as
sem
bled.
Start
by
sc rew ing
th r
inside
s m a l l e r ) curved pieces 10 th e base.
To align
th e
ends
of
the IW(. curved
pieces, drdW a line down th e length of th e
bas e. li '2 from one ed ge. sec I· ig . . 1 . 11 ''''1
mark reference lines 18 to each sid e of Ih...
centerline . s ec
F ig .
4 . N ow screw down Ih e
curved pieces
SO
th e outside of the curv e
to uc he s th e tS reference rnarks atthe ends
a nd th e line down th e ce nter.
Ne:l.1.screw
one o f t he s tra ight
pieces
un
th e lin e d ow n th e c enter so it 's a l igned will '
th e e nd s
tlf
th e
C\U Y~
j · it .. es.
No te : T h e o th er s tr aight
piece
and cu rv ed
p ie ce .. a re n ot s cre we d 1 0 the base .They're
•
__- '1 ••
3
•
1 B£NDING JIG
The first sl c p in b uild in g th e (em sland i> 10
m a ke th e legs. Bill b ef ore y ou c an e ve n s ta rt
on the Ic~. you have to make a bending-jig.
Ilegin making 1I1Ojigby cuninga
b as e ir om
: \I plywood, see
Fig.
I.
81ANKFORFOK. S.Thenext tepin build
ing the jig is to add sections
01~lr.iiJ:ht
and
curved
form s lU
bend
th e
uiin
str ips
10
shape. S in ce th e s trip s a re )I/u1 ' w ide. these
forms should
Ill
at least 1 thickl mad e th e
f o r m s
by
glu ing a p ie c e
of II I plywcod
to a
piece of· v , plywood
10
produce a blank 1 - 1
by ~J1
1 . .
set rig . 2 .
ST R ,\ICtrr F o')R 'IS . : :- '1 . xi eces are cut out
this blan k 10m ak e th e b en din g fo rm : fo ur
curved pieces and 1\\'0 ~traighl pieces, To
make the straight sections. just rip two
pieces I
\r
wide b)' 2 1 '2 long,
S<'('
fig. 2 .
ct K\ ~'Of·()R~I '.T o m ak e tilE cu rv ed ~.
lions. scribe ( u r h al f circ le s on
t he r ema in
iug pan
of
lilt' blank . se c F11> ..
(1b ,
curves are spaced to produce curved forms
BENDING JIG
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N -
• 0.1_
. . . .
Wood~mith
CROSS SEcnON
~. COUNTtUORf
ClNTlRtO IN UG
\
) ... COUNTIRIORf
/ ....~DQP
2
1 1
o llig hl P 3s . s, s ee F ig . 1 0.
SCREWHOUS. A flc r ro uod in K II r the
IPIIS.
m ark the lo cal ions
10
dr ill t he hole s (o r
the
screw s that attach the legs to th e
sh elves, Here I la in I u se d th e j ig 10 la y oul
t he sc rew hote locanons, see F ig . 1 1.
Finally, dri ll a ¥ . ..tJ lamete r c ounterborc
V
-deepa t each oClhemarked
locations.
se e
Fig. 12.Then, drill uie shank
hole with a
: l t G drill
bit.
i s r emove d. r ou nd o ve rth e lO Pe nd o ( lh.lt'g
w ith a file , s ee F ig . Sa. T he bottom end re
q uir es a
secondcuuecreate
aflat
(001.
T o d o
th is . u se th e c omb in ation square to drnw a
lin e o n t h e b ottom o ft he leg •c en te red o n the
s qu are d e nd . s ec Ftg. 9a .CU Io ff t ht ' CXc<
an d th en s ha pe th e lip w ith a file.
SH.t\I~INGTI.F.SIOES.
To so fte n t he come rs
01 th e leg s. I used a ~ t < ro un d- ev er b it
mo unted in the rou lt- rlab l. - and tt,tllc a klriVS
.
ROU NDoOvtR
Sir
ROUTmG(S N AstAllS
oF
UGt-iTPASSU
ROUNO ( )V I:R
£N D W IT H H U
O R O lSK SA N J) ER
DttAWUNE
PERPlNDtCUt,A1t TO
ENOIOFORM
n TfOOT
ROUNOOvtl
np
WI f IU
a
CUT0 STRAlGlif
wmtl OS W
OR.SABAl SAW
-
-
_ V'_
. : r= ••
W ~
BOnOM
N
W rH
S Q U A R E
MAIIlno.
1 ENDOF LIe
9
C lA M P S l 1t A IG W f S K n O N
SECOND:
. -
t O U T l R .
W
Af te r r iPP in ll a li the oa k a nd w aln ul strip s,
Ihl.'next step is 10 glue-up th e k'1 S.
GI..l.' IN G TIlE ~ ffiIPS .
S ian by
spreading
the ~IIICon on side 01
each
strip.
Then.
a.
L J u , glue
i s appl ied .
sla ck I ll e . tr ill
like a
sandw ich : Ihl '{ ', ' oak. IWtIwalnut , and thrC<'
o ak s tr ip s. N o w p ic k u p th is s ta ck a nd
y
il
on its 5 i ( I < aj- 'l l instthe straight (~mlon th e
bending jill.
C .>\,\1PI NG . N nw . a dd th e o th er straig ht
(orm an d clamp everything together.
s ta rt in g in the center and working toward
the ends.
se e
l'il(. 7. Then.
align
the to p
edges of th e s tr ip s flu sh
by
gent ly t app ing
th em d ow n with a hammer .
8~ 'oDIN(; TIle ST'R ll'S .N ex ~ th e e nd s o (
til strips can be bent around the fixed
curved pieces To do Ibis. use the loose
c ur ve d p ie ce to
press
th e s tr ip s a ga in st th e
cur ved l orms. W h e n th ey re b e nt a.'
fu r
a s
they can be bent by hand, piu lin a clamp.
centere d o n th e c urv ed se ction a nd tiR ble n
i t d own . s ee ~ig.
Ihenaddtwomoreclampstoeachcurved
s ec tio n, Now.
tightco all th e
damps ;;
th e
pressure is even alon g th e e nt ir e l eg .
CLEAN· t· . Af te r wa it in g abo ut s ix h ou rs
(o r the glu( · to d ry . l\ 'mQ lh ~ le g f ro m th e
bt'ndingjig . T he n, s cra pe o ff t he wo rsi of
th e
d rie d J du c w itha pa int sc raper . Begen ll e
the paint sc ra pe r is ro ugh 1 00 1a nd c an
easi ly tear r g o u J : C the strips,
N ow th e legs
can be
p la ne d t o t he ir 6nal
w idth of 1 .To avoid tear-out. sed a low
an gle bloc k pl al1~.
cerro IF.NGTIt.I\s I t comesout uf th~j ig.
th e leg is too lon,l(and must
be
cu t t o l ength.
Y ou11 need 10 mark Ihc lO P an d I h(' b ottom
endsot each leg. and then ru tofftheexc~
To
keep all
three leg s
a
un iform length.
I
marked
rh e cu t-of f l ocatio ns o n th e j ll Use
acomb in ati on squ ar e to ma rk the loca tl on o (
th e
top
of th .. leg · 1
in
(rom
the cod o r
th ..
f lX t> d
cu rved (onn .$Cc Fig.S . Then mark th e
lo ca tio n o f t he le g b o uo m 2 ¥.· fr om t he end
o( th e other fixed cu rv ed f orm, se e Fig. 9 .
xow . pu t theleg' ba ck i n t h e b en di ng f on n
and transfer the cu t-off 'locat ions from the j il (
10
th e le g. Then, cut o ff t he ext ra s to ck with
a
band
saw or hand s aw .
~Hi\PINCl'Hl'. ESI) ;.
W h en th e e xu n \lo ck
LEGS
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~ood;nl1th
.
i
SHELVES
\\11t l1al l three tells at complete, work can
tr ac to r a nd ma rk ever y 120 '.
1~1g.4. tlU IU IOSE Et)()ES . Before cut ling th e
b eg in o n th s he lv e s, The c ir cu la r shelves
:<01'(;11E.'tPI.ATE .Each n otc h js cu t to
f it
notches. I ro uted a
bullnose
edge on each
(C )a re cu lf roU l '4 t hickw alnu tb lan ksw ith th e sid e o f. leg . I t'< easiest to lay them out ~h elf. see fiR . 16. To do th is. m ount a
l ' :
a r ou te r, T o m ak e th em . s ta rt
by
gluing up by first m aking a template th at's th e same ro und-o ver bit in th e router ta ble ,adju st ltso
t h r e e 8'1K~ :,qUatl.-:-. o c , , f iR . I :{ . shape as the lew ;. see Flg, 15. To do this.
iI's I b above th e ta ble. and ro ut bo th the
IIQl TCIf{( U:S. To
ou
th e b la nks Into p er- ro un d o ver th e ed ges
of
a scrap pi ec e o f
I ·
top and bottom
edges,
se e
fiR.
100.
r.~t 7 -d iamewr c ir c le s , I used my router thick b) I ·w ide stock , u>ing a
: V t t
round- OT OtT N OTC HES.Now th e notches can
f il led with a ' J1 ( '( 'i albase p l at e. l'h is bast' is over b lt. U se s cra p that's long enough to be be Cui OUI.see Fig 17 I use d a band saw to
sli ghI I ) 'l arger than the or ig inal b a se to a cco -
safply h an dled o n th,· router table,
R'OlOV
Ih .· <lock,bUlajigsaworco pin gs aw
moda te a p iv ( JIhole 3 t 't l fr t, n l t he rout er 1,jL Now , 10mark the notches on the shelves . would a lso work.
Fo r more 011 cuuing circles, SCf.' 1>3Kt. 9.
c en te r th e k 'g templat e over th e 120 mar ks
Then , to sm oo th th e in side sur face or lh e
1 .J . ; c . SI7Tt IIf- .1w I ,' gl \an' screwed int 011a she IL S ct il : 1 1 . in fr om
~IC
dge. and notch. usc a : t . -d lame te r sand ing
drum
on
no tc he sc ut in to Ihec dl e. oflh c ~h dllt· ,- 'J
draw a line around the tem pla te onto the
Ihe
drill
pres>•see
> g .
18.N w.l<.''SIhe leg s
mar k th e c en te rs of th ese n otches, u sc a p ro - sh elt.sec F Ig. 15.
in th e n otch es 1 0
be
sure th ey
fi t,
13
14
.~
15
, /j}
t J
. . . . .
. . . _ _
\ . ~=
.
'/ IN ro
_ . . . . . . . . . . . . . .
\ J . _ . .
. ; z :
r~3 ~ ...
~ ~. 120\
f
I ~
i~
~ ~~
. . . . .
~SMELfC ~'/
sn
TtMPlATl
IN .
»
/
lA Y
our
ctNtUS
UG
-..~
ROM [OGl
NOTCH
-
~
•
NOfCl<6
Tl.MPLArt
fOR1.toS
GUJI: UP
ATTACH lU.ANJt
-e,
T'HRU : I : . .
. JH1Cl(-
TO SCJ t.A l l8AU
HIll'
stttLl at.ANtCS
wmt
CAI .P£T TAI Ii
•
r
. . .
lUOR( aoUTtHG SHQI
QHltRUHI:
16
(a,
17 ~
}.;,~
18
~-_;;
I~ ROUND<WUrr
r
.,
'y
SMoOTH NOTCH
~
.
wt'n4 ' . .. .OIA
t
~ C, ~
. . . .
OR U.M SANDEll
-,
' . ' :
,
J j.~
fo-
/
.
./
e-,
3
O A N J ) . A W
~
. . .
. . . . . .
,
<
.
OUT aUI,I.NOSl: lEFOR[
\. r
ctlmNG HOTCHtS
,.
ASSEMBLY
T o assem ble th e leg s an d sh elv es. Ian
by
le g s. in to tho she lf n otches with No.lix
P . ' 2
ho les w ith oV lI lheadwalrun wood plug s. see
dril l ing a pil o tho le centered in cad ' notrl •.
Oathead wood screws, see Hg. 20 . Once the
Fig 2Oa.(Formoreon inscrt inglhese plogs.
T o do th is. d am p th e sh elf lnto a large h and rem stand is as semble d, c he ck to s ee th aune
see Shop
xoies,
page 19 .)
screw o r b etw een tw o p iece~ o f s crap sl< lck she lv es a re p erpendicular 10 th e legs. lf t lte
1· 1111ISII .o pm tect the rem stand from
<0 the slw l (j~ he ld securely 0190'
II>
LI ,
drill
st and is
twisted.
loosen th e screws - a dju st
moisture and water stains, I ap pl ied IW O
pres s t ab l e, sec Fig . 19 . th e stand and the n rc -tighlc n Ih e sc rews. coats 01 dea r sa tin polyurethane, sanding
SCR ,\ ·U:CTOSHEL\ El;. Next , s crew th e
I U Csc·R.,,\,,
1I01.t:s.Final l) . f iUthe s cr ew Iigh tl )' be tween coa ts .
19
~1
H'11.a .),, SCUWLtGS
//
AU . SCREW
PIlOt HOU
,
\
TOSft{lV($
a,
o
'c,
HOlESwnH
(NNorCH
'1
l .
~
OVAlHtAD PlUGS
I
It .
;}
/
i
. w .
~
~
ItG-O
~
~
. . . . . .
~ - ClAMPSf<Rf
~ ~
fl~
P(JtPfN..
cu....
,~
;:: ~ TO•• IU. ... USfA.1l
SHW
.ax 11'1
•
Nott:
fhWOOD-
17
IX~
CJirac THAT TAND
~
SCREW
j ts STRAIGHT ef fORE
•
GI.V1NG PlUGS fN
.
J~
SCIlf;WHOW
8/20/2019 Woodsmith - 072
http://slidepdf.com/reader/full/woodsmith-072 24/32No, 72
run approximntely 15· to I) ,
face
clthe
board,
Here
again th e
easiest
~ray
to determine thi~s
by
l ooking a t
th e
end g rain,
R i ft sawn boar ds u su al ly h av e
a
>lIaigln
grained appearance
without
a
strong pattern
o r ra ys .
So it
mak es an ex cellam ch oice
if you want 10
'play down
th e
g ra in on
a
projt :~
AVAJIAl II.m'.
II
quartersawn
lumber
is so gr~at,
wh y is n't
it
readi ly ava ilabJe?Th e
problem
with
quartersawn
l umbe r is
thai
il o;:_time C 011 \ U m i ng t mill and
lt s wasteful It take....a large
diameter
l og t o
ge t boa rds
of
an )'
si1.~liticanlw id th . s o m a ny o it he
p ie c e s
a re to e,
n a r r o w
to
be
u S W
fu l. TI le e n d
result is that
quar
rersawn lumber is expensive
and hard
to
f in d in l ar ge p ieces,
Finally, don't be d is couraged
if your local lum ber dealer
doesn't list quartersawn lumber.
~:ycn•
Om wn l o g w ill h av e
a
few Q uartersaw n an d
riftsawn
boards, So so rl Ih rough the
boards carefully - yo u m ight
just f in dwha l y ou'r e l ook in g f o r.
QIlARTERSAWN I''A CE GRA IN
F CE ;R.-\IS~However. the
d i r e c t io n
o f
th~
e n d
grain
i s n t
111~nly di i{~ n< 'ebetween flat
sawn and quarter-aw
II lumber.
The
fa c e grain a ls o
changes. In
w o o d s with pronoun ce d grain
pauems (lik(' red oak), quarter
sawing produces aJIIIOsl
i r ides-
ce nt r ay s o r
f lakes on the
f a c e
of
th e
board,
s ee phot o.
WOO]) \fO\ F.Mt:;~T. Another
diifercllcc is tllC' way
quarter
sawn
lumber resists dimen-
s io n al c ha n ge s
(shrinking
a n d
sw ~lIinl:) an d cupping with
t:han ltS . in . . :ea-sonal humidit} ' .
All boards expand and co n
tract alo ng Ih eir
growth rings,
On a
IlatsaWtlboard
th i s ca use.
t he b o ar d
10 move and
possibly
cup across its width, see draw-
in g.
On
th e other
hand,
on
a
quartersawn board th ere s very
ijU]~movemcntacrossthewidth
o i the board and virtually no
chance
If
cupping.
RIfT
In b oth
iJatsawing
and
quan~rsawing . a cer ta in amoun t
o f lurubr tr w i ll be
r fl. O .I l / f ,
The
g row th r in gs o n t his lumbe r will
• • • • • • • • •
t
SUGMTMOViMfNT
INTH) ~HtSS
FLATSAWN
80th o f these methods produce
most ly f la tsawn (11r plainsawn)
lumber-> t he mo sic ommon
cu t
lumber available,
1I0lUZO~ AL £. D GRAIJoi.To
determine i f
a b oard is
f lUIS3\l{n.
start by
Io<'kingat t he e nd g ra in ,
If
t he g row th rin gs
arc I~ than
45 10 th e face o i th e bo ard, ii's
flaisawn.s~edrawing
above.
Another
sign
that a board is 03t-
s awn i s an 0\131 nrl l· sh ap ed fac e
{.trainp a tte r n , se e
photo
a b o v e
QUARTERSAWN
Another
method fo rCUt ting• l og
im o b oa rd . is
called quartersaw
in g. W i th th is m eth od th e
lo g
is
CUtin
hal f
and th en quartered,
see drawing. Then boards are
cu i from each
o ne o f the quar
t er ed sec ti ons.
\ t. R1lCAL ENn (;RAI: .
Cutting
th e h oard s Iising th is m etho d
treates
a d i fie re nl p a tt er n on u w
e nd . T h e growth
rings ....ll be a~
mo. t p r :rp r:nd icu la rto th e (ace
of
lh e b o or d, see drdwing,
QUARTERSAWN
FLATSAWN
O ltO SH JNKS
A S IT DalU
GROWTH RINGS Rf
ltSS THA N 4.i · TO TK£
fAa or-TH 80, 0
24
I IIlll _ ttn oi(1 tabl , Ihltt l(
1}1 ~itl)I lnrafnnd lllf,nt torl·
11 (1)1 ; t.
{J u t
/ ,1 n~'tn laIJm/~.
1 ,, ,tt.,d ,ltg
t l ·; t J l t l ; d v I
( Clod.
l t
t t lt (O ll illc( lt tIlt
1(IfH/II/ IX
'Iltllrlt r nu'il -
r f ; ~ il;
f, 1 1 ft' 1 , , , , .; ;
nut
i
qtl(,,.t ,~au·)j }I,·t ..
ue»
r ,l lt ti l
.l'lud ,,./ ,IlI'x
tIlt adr« I lta I
tfIU.'fill l,t)
J illi .II r o o , . I
Bil l ;tt Y8, [ol,lll.llll
F irst o i
a ll
your
problem
i~o l
t ind inz the r igh t kiud o fwood
i rs f in di ng t he r ig h t
tt
of . . .
d.
lis y ou
said.
y ou r ta ble
to p W iS
made u ing
qucrtereov«
lum
be r.
T od ay . th e
type o f l umbe r
that
is
typically
ava ilable in most
lumber ) a rds( l l ldbui ld ing
c e n t-
ers
is,j1(lli)IICJt.
('lTl1~(, U)(;S.The difference
betw een them
is in the
wav
they're
cutat
t he s aw
mill
When
lo g $a r~ ru t i nt o lumber.the oaJ
is u su ally t o p ro du ce t he larg<sl
quantity of u.:ablt' lumber with
th e
f e w e s t
detects.
Typically .th e clearest lumber
co mes fro m just beneath
th ~
ba rk, And t he le as t desirable
art-a is the vt 1 center or
pith)
01 the tree. This renter a rea i s
w e a k e r an d p r o n e 10
cracking
and checking.
SA\\ ISG ARO~IN1)
nil-:
LO(~_
One way 10 avo id Lh ,'
~~
desirable
area
in
t he cen te r
is to
s aw ra ro u nd t he 1 0g :T o d o t his ,
a sawyer
(the
person
who cut
lo g . in to lumber ) s ta rt s w i th the
b( i l t looklngsick ' , , the
log,
cut
t in g o f f bo a rd s un ti l h e
COUll S
to
a d ef ec ti ve a re a, T hen th e lo g i s
t ur ne d 90' a nd sawn
again.
This
leaves the center portion intact.
which can then be m ade into
posts
or
lower gradl '
lumber,
TIIRfJllGII ANn TIIROl ell. If
th e log
is rath er
small.
o r
ha s
m an y d efe cts. th e
sawyer
m ay
decide
it'stoo
t ime consuming
10
sa ... aro und th e lo g. I ns te ad ,
bo ard $ arc cu t
one
af ter another.
'I bi s i s
sometimes
referred to
a.
t Ut t ing- th rougb and
through:
FLAT OR QUARTERSAWN?
Talkillg Shop
UESTIONS
N D
OM }vI E N T S
8/20/2019 Woodsmith - 072
http://slidepdf.com/reader/full/woodsmith-072 25/32
,~,
,), I ...
1 1 1 1 l1Uh ' 1 o n n d~C . r il o h l t o wo r k .
(~tlt
.A 'T ld ing
3. ' lo ; . ' - -krfUt-C up
pand Ihroullh a planer is
).:tI.W( f
~or)
r \ ,
,I. t
at ka.....(Qur
h.tuf . anellh,lf ...(
nf)'
i(rnl in a
bll hl l r r ) ,. ' nnaD,.1 prl'k..-to
wast e)\, rlligilt
t'nl III 64, '(10<' (mt 'd thallh~
~'i01 ill r ll ·Ih,·
pmblem
is that
I l t . ' I A · l v ..:ll't.-d jellUl' '>
V o · ( . ' U
u p ,
W h,
n )'Utl
)II.. '
0 p ie e rs o f
YI'()od
l(j~l'lllI,r,
lll(,
nloisture in
tilt Rlu( '
i....b'ScJlbcd
into lh e
( '. Itrr :t · ,
el f 11 ,e '
w no d alo n g
lh e
Jllint.
11tt
\\ ()ud eXpoI.I. lds 'Aim
L I , ,
tI(ldiljc)naJ Iltoi 'lUfl
I f )
UII
,'re
10
t > l a n ~ or ,:and
t ht ., V .C M x t
I..f1uncdi.4h....y. th e
jo in l
' .. .. l ll le i l L pp t d r f in e
at ~ But
a. I1 . , til.· .. 1 < 1
a cbaoc~10
dr) out. \ou'd v.ind up ~;lh a
sunkenJOml r 3 > ' i J : h , d<'J>l 't '<it .n
aJ,'llJIth. JOlnlh .)
cm.t1 t t ,. 'T1c .. . . O nt' mor e
th o n g If p,u·,,· ' •
big
hurty.
Y ~In.t\ v.anllt) con oider using
.1 , .J ori<IOI: 'Ill
JlIu~
o r a
(i ...minul ' · poxy, Tb.)' ·r~
In(lrt ( xpt nsi\,t th an y ello \\<
I:hl<' . bUI the
d am pin g lim cs
ar e
x tfl 'mdy shun .
I tUJlutC-: .
whrn
th t - t em pt r :a ~ ur t'
,..,.nh
j.5
d<'gl'(~
I o l ' dded :o lJ) a n xP< 'r il ll< I I I
lhat would
cl=k ,,\lI) U', In(ror·
matto n abo ut the r t .>Ll t ion,hlp
belW{'t>l1 tI w
d ry in 2 tin o I ) \-
1 0\ \ g lu (' a nd air
((·m.,. ·rc:l.1Ur~
I
p\ll
do l l oJ )5 f)1y en .. , g h .,· n
I .
pia't.'::,o(
woo d ,
lind
Ih ,'n lX 11
Ont~ pi~t in t h . . n·(rigt·rattlr
·n , . .o
J
w a tc he d t he d i fl <f l' n l r a lt
atwhich th~.~uedollop,
dn ...1
AI l ,, :r ; \n
J lol l r .
Ih , ' t l iCf ) ' (' l lf l '
. . . . . i j oo ubvl()us. ~fhl lut 11131al I
( Imn l h , :mp c ra t ur t hat) ski111l l 'd
O\·t.
r f .. ,, (np l t t t' l) ' a n d ha, l . t J. ~joIlfl
gt1l' (.n a lOtllltlJit 'k ~tanelinJ.:UI'
in I h t. · mJdd1c. :e,f it. T ht· R lU t, 10
the (·(rijlerator. , h j l . .. .. ..
Ul l t
what thicker from th. ,·old.had
110 <;;kirl and the tt,H,ll'Ipi( 'k
pJit
t 1 t l f l l ) < d 0'1.'1'.
....lU:i.S~I GlF J()l ,
The
f inal
I.'on~id('ration on
d ' lns:
u mc (a nd t ont , . ·l n~~u h av e
m uc h c on tr ol O \'t:~ rJ-: o h o v. .. .o o n
YOIIcan pul s)lllt ...
{rt~S..
Cln a
g lut '
j()inl alter rrmoving th,'
clamps. If I plan to do <nnw
h an dw o rk o n a glu.d·up pand.1
will '('mov~Ih., damps In 30
cniltt (lt(.1tht· r o 00.1 )ou·r~ ., Ir}:.
n t 2 M l h ~if\Cttltl,;\il n3~tltl)
b t > l i t \ t th ai \ our \ \ood m t) nc~
bencarth (, o ;~ lrnum 11101
tun' \. 'Ontc'n~
U .. .
a
J:IXld
id( 3 \1,)
lea\'( tht·
4,~ lamJ) ' I,n
u Ii
lIt;
lOng t. ': r th .aI1 Jc t f ·. ..g<'nl'ra] ruj~
-TT ,
T h ,· . ..
' \. ·ol1rJ
r,ln 'ldrrdtlon
is tht' Vwa}l l t I .. . .t IJ i t ' t C . . .
f)j
.1
joinl cf,m 'I ~I-'h,'r,1l1t' bt. tt~r
lh~
fil. II , I,'
dJmpIII , im,· b
II<'CCS.sal ) '
g ( u . t t l
i.,jnt
\ t o i l l
t ...
qui~ Ic~s
gltlt, . t l .d
l('..~ s.rIUt'
mt'an$lt· ...dryill~ li'IlI' 1\colnl) )\
j o i n t n'<t11ir t . . . . n lu r c· s .. r I\ U Ote . i i I )
tht'gapsand Ih., ,· \tr.l~h 'tlk, ~
nlort'tinlt'loeir') (.. ntlrt ull n
a
Q,
< ak(' r~)lnl.)
TE.\IPI-.A\l1 Nt· 1111'
t ·11IP' . : r : .
run - o r tht ' air. ' . ' ood . I l JUI t:lul
a}sc,
ha..
an affl'(1
011( lampiJljt
t i m C the M . lt r they U< , Iht
mort' cialltplng ' lOW'S n<'CC'
53l'l' 1111'
rult·hen:
53) )df
i~o
d()ubk lb,'
fLI:nPII1j : t lnl t
fi,rt. \ef)· Ie )to l5 (It J{Tt't' d r. tp in
t emp (. 'r a tu r t· -
For
t'xanlplt· , il ~ou ~I)ulrl
1 ( 'a v e t h t ,
clamJ,. CJna 1)'1nt
l
hlr
45minutt·s wh\'n it ..7(ldt'Wt t'~.
k...
p
th~d a m p ; , ,,0 lor ltmll KI
, tl rhflK
l1tJ
lal ps (
hll f I
. r
I a/leag.oor •
liP
,ltor
IIIJ 1Wf . J (aN I
f , r 1 - . .
,I.(
IO p o l/ O NJc I
l e , I .I rorl:'
Jvl,
r : 1 rcld
,\t q ./ .,Yl
l·l.lmplnJ: llnlt' d t'llt 'l1 rJ , o n a lo t
of
thlnj.l....ill~·ludinl.:the k ind
of
glut ) 011 U (, ''If'r~ al
1 1 1 . 1 1 1 1 1 1 ,
y,.'(' u llall~ ..
USt
F ran kto n 1 11 t ' iHl1ld1 • •
1 < 1
G lu~ (a
Y l1f1w Jlh...). , I culkd
J < · f f
S h uc ' r n tl k t' l . d h 'C , 'I ) lu r r u
' I ) I ( ' i a l
j,t
In lilt, \\ ' cHKI
i\rJhl ~i\·t~)i\i~
. ..e ul l ,f
i'
r tl n k li n I n tl 'm~ l io n a L
( c , r l l i . .. . t( l \ 'i r t '
1 1 1 1 ' J \ fl 'r .tJ rult,
Ilt , l l l 'w
1:-45
IninUlt·..
h,r~~'
~lulnli ,
and5
i:(.
1(' ,IUllutt . . I ·
a
: - o t
n)bl~
Oinl~.
lik.· tOllgUt and groCtvt'... f ~
plain,-d ).H. H~qUK'k1)
pumled
I
out \hal thl'
I'
a RC nera)u . . I e and
dcx·....·' :lPl)I~'lnf·\·,~...tualion.
\1 ) Rl l fl,n
T T h ( ' 1 1
a n' r l~ ur m ain th.&ng 'lo Cftn.. .<k,-r
.. . .h .. .n
s:luill R. tn c·
f ir . . . ;:-. tb e
m o i~ 'u n . . « () nl 'nl (It tht- M)d.
1\loi..t ....l)Url
nl )
In'Jrt.:
l Jan l,)ing tilllt. btlt Yl .U fila), nOt
alway
1\
kn()w lilt' c..·);a<:lllloi~lurt
CLAMPING TIME
hasa'.~'knrclamp ynu canlock
Ih .· l id i in l ' )( )Qt i{ 'nand r emove
lh. <'.Ihp ' t o read
it ,
Oryou can
n d
t
be dia l with th.· .:alipe'
Ilgh,unlh ... orkl»'''C(' rlu-ethe
. .. .' '( '( 'n d me thod b -c a u- e thl C~
:1 'MOtl
of error
v.
ben mo v
inR
tIl ,OlI'lo rs,,
onltR t l .I r i n d my,elf
r. 3d11nl: lo r th e d ial calipe ....
ml,n '
a l l e l
more
I iI~ t
on . . .nex .
tellilt
1 ~Ult
r (I)
c h (' \. · ki n g t h e
thickm- ...... , r ~t()(;:k bet ........C n
1'.1' ' ' ' ' . It ,uJ 'I1l at for check
i l lS{ i n . .. c l c .' c ib ll1 : n : o n~ .
such
as
'h, w,oth (II dado, Orth. actulil
,tianll'll'f of a
h o I ( _
you jU~l
f1rilh flln v.','rkpil't'l',
rh('('k
the
depth of • hulc ) 011
jU ' 1 d ri lk -d , O r (, \'1.'» l ht .· d e pt h u l
a
cUd(,
o r g ro o v .
\10 1 dia l cal ipers have ,liat,
that art.' graduated In Ih u
...andth .. of an inch. which i..
pk-nty 3CCW'3le (or mo-t ,,00<1
1IIori<. ·f The) c an a ls o ,, ,Iouod
,th tI I I1 lduan, IO ' \I 'h il . · u
~
i...
i d ll M ' r s mal l i n en -me n t
on a
ruIc rora
slid, calipers, it
('3.''-)' to read on a dial
calipc rs,
or more information en wht-n
In fi nt l r Ji al c al ip er s, s ev S o u re r
nn I l 'c
31 .
1'~lXG CAUPF.R.O;.'1~()
u . . . t ·
t:ul
i IM. ' r -. .s l id l~ t I l e j a v . - - s lc lM · d fl n ;j
nrkpil ' ....TIleD.if Ih('
ali r,
c lam pn ut T hen
' h ~ ' ' 3 I i J ) < ' ' ' '
ca n
be -
u . ..
cd
10
make
r t 'p li l ivt, . ,
IUt.~asur\·m('n1'
~lirlr. ca1ipt'r...
are- available in c . ithcr I I1c ' I1 er
metric j 1':ldu;Jllon...
1 )1
\1. c. .
U . D 'F f t: o . . I\ d l al c . ~ 1 I 1 )l
I ' l 'I
difl. ,froma 'hdr
c a r
I rs in
t ha t
w .
,1idt I ' i . . 'Onnertl f t tet a
d iah n di<'3 h r . ' U P f l t 'T l ' l l li J ) < '
inph to.A,lh,·,lid mo\(.,.,th~
dial prnvid ,a d reet I't'3,Jout
that , 'd,it '1' to n - : a d than a . ide
, - e t li p t . T . . .
In
.lddiIion 10
m <ltk a nd
out
< id e m t ax ur c rn en t ... a ll I lia
fat
i )I ~
can
be
u..... to measure
depth, \11,.'0
Ih l 3lil ' ' ' ' Ja ' '
,an
op t · n r : d . • t m etal r od thllt' ,t t
t3cl't'cl to lh t' ~11(lfpr tJ tnl f i t s
rn)m h
bo no m .. I thl' < I i , . , . , .
a nd i sa
coov('ni('l1t rit'flth t:;ttlJ.t _
~ phOlf. 1111 '
(',an
I,t
, 1 . . . . .
,1
te l
lt ow fie.
),CIU
ar t unltt· ly r nc asu re
thin ~ Iri l) ' o f Yru«x1? '11 '1. . .C)Ut'~
ti(nll III1 '(' up ,1 ,,1 \
,l t-UltjngW e '
,uil (or til\' Irll1llll.kdprnj{'<'ts
in ,hi, i o : . . . ut· \'e'tl could 11)' to
hal.11l\ l .~11 1 '1111•
<urvor a
ruler
on L1II ' t 'd l . : :l ' e ll 1 ) ,4 , th in ~triP -
b U ll hi . ..
r na , ti c
1
vlcld
V I
r v a cc u
rd . l , -,\IllS Or y ou t001 11 ddo
ha, Ido - u~ a ealll .,...·
'1J1lF ( 'U I'I It'-
Th. ·
,lid<·l-a).
rp
f .
(If c, 3.hpn rul. ha.. been
tl......rl
bv
m:k'hlnl't ...10r(I nrune-.
t o mt 3o ; ,u r t' i n
I.
rnaland
I
xterna]
d im en . .. c} n .. . .. .. .. I I I Y O 'r c a l i l l t · r - .
In 1 )1 1( 1 11 ,
()nl
J 1 '4 ' I l f the-calipers
i...
i x( '(1 t e) , h i ' m ai n pan o r till
((-,ell.J\II
t lu- ,,,It ll t
~lW j
pa n o f
n ...
i ( I , ' tl , ;
n lu '(' i n o r I lu t u nt il
both jaw,
'o U d l
Ill<'workl'i.·ct.
()n(~I' in l1Cl.iliflU, th r ' l it h -c a n
h.
d:UlllWd
with
.1
kourl(od
CALIPERS
r
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N o. 7 2 .
Voodsmlth
FINe>
_. X 11 -
COUNT UtSUNK
Fh WOOOS (If WS
onhe table.
MAI<II<Gl1~I£IX: .
ut the
su ppo rt ledge Iran i I V · tJlick
sto ck to a width 0 12 . T o a tta ch
It ,
f l S l
bUll th e en d 0 1 th e le dg e
1 0th e e nd o f t h e s aw ta bl e. k ee p
ing the to p surfaces 01 the saw
table
an d
le dg e (lu sh .
Then
s cr ew the l ed g e i n p l ac e from
the
backside of t he f en ce .
yo u ever rem o ve th e fence,
} OU ca n return it to i ts o r ig ina l
p o sitio n b y sim ply b UIU n)t th e
l ed g e UP IO th e e nd o f tb e. ab le .
• I t' s nOInece s sa r y 10PUIa101 lg
ta bl e o n y o ur r ad ia l a rm s aw ju ~t
b eca use y o u wam a l ong fen. e.
BUI
if
yo u do add a long replace
ment
fence
(like th ~ o n e shown
O n p ag ~ 3/), yo u may want 10
consider adding a ledge to su p
p o rt 1 0 D$workp ie c es , s e e ill . I.
A le dg e th at e xten ds fro m th e
en d o f th. t ab lv 1 0the e nd o f th e
fence keeps a lo ng wo rkp ie c e
fro m dro o ping o ver the end 01
the table. T he le dg e a ls o le ts yo u
u se a s to p b lo ck b ey on d th e e nd
FENCE SUPPORT LEDGE
ch ip o ut o n th ~ b o uo m sid e s in ce
111t:r~ :-.no :-,uPJX,rt
where
the
blade exits,
T o help keep the new table in
good shape. I screw ed do wn a
protective surface
o V
Ma
sonite to the topofthe table.with
a r ep la ce ab le m i dd le section,
I
drawing above.
N o w .
when
th
Masoni te
becomes
100 cu t
up.
eplace
th e m i dd le s ec tio n
and start fresh with a smooth
surface.
PACERS. As
a fur ther p recau
t io n agains t sawdust build-up. I
added another feature 1 0 th e
ness 01 your table and any p ro
tective
surface.
Poshlon
the
s p ac e rs a t to
8 intervals,
an d
glu(,
them to
th e
i ns id e e dg e
of
th e fro m s ec tlc n 0 1 the table.
Sh op No t e:
1101
meh
glucworks
b es t I o r t hi s,
S IJ PPORT .
Finally.
if
y ou p osi
t ion the l o ng er t ab le very C a r ·
renter (It 1l.()orighl Onthe base)
yo u may want to su pp or t the
heavy end with a cabinet or
sim ply a 2 x4 b race. T his keep s
the table 1I10re stable when
you re cutting a lo n g p iec e of
heavystock.
new table,Th is i s s imp ly arowof
~pac( r~attached between i h e
f enccand thc f ron t sec ti ononhe
t ab le . s ee d raw in g .
These sp ac ers p ro du ce a se r
ie s 01 l (3 ) lS between th e fe nc e
and the CUlling
surface
0 1 th e
t ab le , T h e g ap s a ll ow s awd us t to
fa l l th rough the tab lera ther than
accumulate on top o f the table
an d keep. workpiece (rom but·
tinlltight
against
the
fence,
I cu t t he space rs oUloIV. Ma
so nite 10 a length 01 2 . T he
width
of the
sp acers is deter
m ined by the co mbined thick-
SPACERS
GlUe TO fRONT
S I<\'lO N O F TA lL IJ
SOUD·CORl DOOR -......
{1 S ·THlCKl
SP ACU tS
OF I.
MASONm
~
PR OTfCTtVf
SORFACt
OF ....
MASONnt
_
SlcnON
Qtl aI l
ECHNIQUE.S
FINCIi
OOLS
T
he
r ad ia l a nn
saw
i s t it. ..
perlect 1 00 1 l o r cU lling
kmg p ie ce s
o C
s tu ck t (, Ill.nag...
a bl e le ng th s. B u t the prob lem is.
Ih~ tables on most radial arm
~\\ re too short.
b ec om es a
real balancing art to cut a ~· r o o t
1<'I1I. h
I rom a n 8 -h )o t
board.
T o ,1 ,,(· t hi s p ro b le m . I re
p la ce d th e p articleb o ard ta ble
Chal carne on my 3\\'v . nh a new,
lunl(l r
table (Bl Si the
uld
t ab le h ad zouen
pretty
chewed
UI)
o v er th e y( ar.;.)
SOIJIJ ·H)R£l) ( )( lR. I iound the
perfC ( l
replacement tab le
at th e
lo cal ho me center, It's a w Ud·
core door that measures :10
wide an d ~ O lu ng. (Slight I) ,
blemished. these doors arc
oft n available forabout
$25.)
n C S <
doors
are usual ly H .
thickwith a solid con- uipanicle
board . They re heaw and stable
-guOO for
saw tab les .
TIn-races
0 1 s o l id -c en - d o o r s a re tY I) j( al l~
hardwood
\ I. ( ( J. ruul
even if
the lace i blemished, i l s ti ll
wo rk s f i o C : fo r a s a w table
:- 'ote :
I ns te ad \ )1
IIsinl
a s o li d
c ur e d o o r yoU c o u ld b u il d u p two
layers
0 1 ~ ,
plyw oo d lo r a
1 1 1 -
p tace rnent t ab le.
PROTEL'1TI 'ESUlFACE. i \ J lo ther
thing that s alwaysbothered me
about wo r ki ng o n the radial arm
saw is the way the table g~t.
chewed up with repeated cut
ting . ls the kerfs i n t h e t ab le gel
wider. saw du st b uild s u p in th e
kerfs.
And
th e
workpiece
can
Radial Arm Sa ,
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27
o J Ttlith
.
.,~
NOTE: Ul O
DUIIlfl) llNG ffi
t, .W 1O t )
~4 ·D£rP
lXPANsJoN
SlOT
tHftftto
ONTHKKNfSS
FENCE
§ J
,
OuNTU:SUNK
SCUWHOU
CfNT £RfO ON
fHfO NU
2
short section (3 ) hold, the
wo rk pie ce lig htl)' a ~a ills t th e
felice.
(I ll
e short and
lonll
S<.'C'
tio ns (o m, a 6 0' angie.)
f ly p la ci ng . he cod o f t h e l ong
section ag ain st th e rad ial ann
saw fence you c an a pply a lo t o f
le ve ra ge o n the workpiece
Finally. glue a <trip of sand
p aper o n each end
(I f
th e han dle
to k eep
it
f rom s li ding on the
fence
or the workpi ece ,
0 WING
NUl
co nterhn e o n Ih e b ase alig ned
with th e saw blade
1' av oid CUlling
I hr ou gh th e
jill. ra is e th e
blad(·
1:V above
the table. Then cut a ,h.llowkerf
to n
to p o f
1111'
inside f e guide.
T C UI 11 miter. fi rs t h old or
dam p the w orkpiec e a gainst the
fcuce (This keeps the work
p ie ce f rom c re e p ing .) The n p ull
th e s aw t1u'ougb the workpiece.
Shop Nolo, Bl damping a
stop block
1t)
th e f en re a t U\ ) end
of the workpiece. multiple
p ie ce s ( lik e frame
sides)
ca n be
c ut to a u nif on n le ng th .
16
ASJ£
First drill a '. countersunk
screw hole for a machine screw
centered on the bouom dge of
th e fe nc e. se e
Fig. 2. Then rip a
~ '-w ide
by
~·. -d~epslot, also
centered
on
th e
bouom
dlle.
lighteni ng a wing nul on
Ih,·
end of th e screw causes the
screw
hea d
I I> slide
up
into the
coumersink.As Itslides up.the
lot ope ns
and
lo ck s th e fe nc e in
ltschannel,
USINGT8EJIG.
T
t
use thi s
jig.
butt il again ,
e fence on Ihe
radial
ann
saw .
Then clamp the
ji g down to the saw
table
with the
INSIDE
h) FENCE
GUIDE
N o. 7 2
• I
get
uneom fortable w hen I
cross-cur short pieces on lhe
r
dial ann saw . I ju sl d o n 'I like
my fingers that close to
the
blade.
So
I m ad e a safety handle
It) h old sma ll pieces,
The boomerang-shaped
handle is cut from a 12 ·lonll
piece of 1W.·lhick stock, ,ee
Fi g. I.
The lon g
s ec ti on ( about
9 )
of
th e bandle keeps your
hand aw ay from the blade T he
SAFETY HANDLE
-
6
1
one edge, see Fill. I, Align the
comers of
th e
guide
with
one
edge
of
tht
base.
and a
third
comer 011 the centerl ine . After
i t' s s c rewed down. r ut
il
ofLOush
w ith rh e o df (e
of
the b as e
tHTSIIl~;I E:o.(F
crmes.
Nt Xi screw
two
ou ts ide
fence
I{ uid es
e
parallel to th e edge s
of th e in sid e fe nc e ( U id e. se e
loig. I Screw these inplace with
t empo ra r y s p a ce r s of + 4 s tock
(the same thickness as rhe
fence) sandwiched betwffll the
inside and
o u ts id e g u id _ .
FE. '1CES. 'l'ilh all th e RU ide<
screwed in place. work can
begin
o n Ih ,>
two fences
(D).
TIleS( lengths o f 1 '4 ' h a rdwood
fit
in c ha nn els fo rm ed by th e
f~n<: guidl-s, ( The f ence s can
remo ve d w he n
milt'ring
a w id .·
w o rk pie ce o n the opposite s ide
o f the
jig.)
Once
in po si don . t he
fences
ca n
be lock~ in plac e,
u t lite (enc c' from a
1\
ide >I1ip of'harrlwood. ~ Cig.
2 . T h e k · nP ,th ot the fenct'S isn t
c riu cru - .h cY ''3 n b e c u i
long to
3l l OTnmoda , - ',lIkpi<'Ccs.
The
system for
lo ck in g th e
fe n ce s in place is a simph- o n e
• AhhoUJ(h I use t he r adi al ann
saw
mostly
o r
cross-cutung.
there III ( umeswhcn I
USC
it
for
c uttin g m ite rs . B u t th e p ro blem
is movin g th e
s aw ann
from
90
to 45 ' an d back al la in. It lakes a
lo t
of
6ddlingaround
10
g el il
re
SC I
to
CU I
a per fec t 90 a ne r c ut
ling
miters,
My
sclution was h) build a
miter jig. Then the saw arm can
nlwaysbe k~ptat90' whilethejJg
is d amp ed
10
th e sa w
tab k - for
c:ulljng miters,
The jig
c o n s ists
of
a
base
a n d
fence RU ides (ail cut (rom less
than a quarte r sheet Of;~ ~ ply .
w oo d). and a p air r removable
hardwood
fences.
The base
damps
10
the m dial arm table.
an d
th e
gu id es
fomtchanne ls lor
th e
remcvabl ..
fenc,'l '.
I1 <IS E.1le1l in making t he j ig b)
cuttingthe base A to a width of
I<lW
and a length oi 21 .
set
Fig. I. Then
draw a
n·(trenee
line (that will .Iilln with the
bl ade) centered on the lenl,'lh.
rl\Sllj~ -UC~(,tI )£. \ ) 4 ( Ul
a square (16 x 11; ) in side
fence
j U:ide
8) and screw
it
down
to
th e b as e s o i toverhangs
MilER JIG
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No,72 ,, smlth
®
.... PINOi
-BLOCK
1iROATOf ~
STOP lOCK ~
frTS TKIOCNESS
OFnNCrpws
1 MfCkNW OF SPAC(1t
PINCH I II O C <
CUfF.OM
looy 11 • 2 • q.
l,OC1( BiANJ(
_ . . . _
3
NOlt:
cui an
oversize blan k to w idth to m atch I I I
hl ighl
ofth pDol 'h in th e b od y blo ck (2 ),
To determ ine the length of Ihe pinch
block.
pos it io n it
in
th e n otch or th e body
block with tbe :\ 't , thkk s tO l 'kym,11 brusinl(
(or the fenre sandwiched
in
between.
S( (
F ig , 2 ,A dd a m a tc h b oo k c ov er between th e
fence
s to ck and thc pinch blo ck
10aCI
as a
spacer fo r clearance. No m ark th ~ pin ch
block and cut u tu length. fig 2.
place at
an y
point
along
the
renee.
Then,
to t-tinlinalt
meas-
uring
before
e ac h c ut , I added a
self-adheslvc
measuring
taj)( to
th e
( ( _ 1 1 t ( > .
1 1 1
measuromcrn
is
read throur,h a
P1exil la.<
hair
l ine ' indicator,
Ole:
The hardware
10
bllilrl
th e S LO P block is a va ila ble a t
many
hardware
stores.
or
through
Woods,,,, } [ raJert
SIlI pri..... ~ page 31
mRS,
One t h ing
needs to Ix -
said
here
about
this
system II
you ~ngthe radial ann to cut
miters,
yo u'l I c ui
lhmuJlh
the
metal measuring tape on (h.
new Ie nc e . I th in ku 'smo re a ec u
rate 10 keep the radial arm per
mrull lItly ~I at
90
anyway, To
CU I miters, Iu se a s ep ar ate
jilt.
seepage T
L\KISG 11U, FlXfI'R. E, Since this is a
fix,
ture
fo r
the-
radial
ann saw
(though
you
c ou ld a da pt itfo r a p ower m lte r s aw ), I m a de
it entirely on the
radial
ann saw, BUI if you
haveatable saw.you m igh t find Ir easlerand
sater to
rip
uic
pieces
on it ,
Then
cut
a no tch
for
t he -p inch b lock
OUI
of
one~ndo(lh
blank,
se...Fig. 1.To
make
this
notch,, Iilt radial sa blade Id above lho:
ta ble a nd m ake a series o f ,,'· .rla win g k en s
un til yc,u 've formed a 2¥,, ·\\~dl no tch . 'Ole.ll
smooth of fany ridgt.'S lu t
b)
the saw black-wi th
a c his el , a nd c ut th e
body
block 13,. long,
Pl:':C IlBLOCK .After t h e no tcb is ttlt in th e
body block, th e next step is to m ake the
pinch block (11 ), r ef e r to l ro l t.3 . To d this,
1
BODYBLOCK)
®
I
t
I~
1
,
)..
4 4
NOlt:
. . . .
~
UTBODY BLOCK
JaQM 9 - lONG ,LANK
The stop block consists
or
lW O main parts:
the body
b lo ck an d H
p inch b lo rk .
11l<'SC
pieces act together to makethebtock stop
along the fence.
order to m a ke c u ttin g these parts with
tilt:
radial arm saw
easier (and safer). l
started
out
with
an oversize piece of 1 i -
th ick s to ck fo r e ach o f ~ IC blocks.
DOD mAX To male the
bod
block
(A). start with a
21 2 .wide
by9 · longblank.
BODY BLOCK
PINCH BLOCK
STO PBLOC The s to p block i s O l ehear t o i
this SI'SI.m, Itr ideson uie new feuce several
inche« to th e le( t
of
Ih e s aw blade «,
there s
no i n te r fe r enc e> with the mo to r housing.
I m ade the SIO I)block
from J 12 ·tluck
s t f ) ( : k
~I U
can
U~
a eomruonzxtt _T h t ,, · r c · : - .
a win, nut on top of Ih . block 10 lock il in
W
hen rulling on tl ...
radial
arm > II
t he r e ' s
of len a 101of measuring an d
marking
of a workpiece before
cuulng it to length. But this,
measure, mark. and cut
method leaves room Ior error.
1 0
vliminau-
l11('~
gu~No~-urkI
added
this
fen.. , an d
Slop
,)'Stem.
11ICf('arc IW O part s lO thissys
tcm : a h igh renee and a stop
block
that
locks
onlO
I h ,· r ene
e,
seepboto, Oncethe s top b lock is
tighlen <i down.vou ca n
cut
p; c
after piece to uniform length
without
measuring or mark ing .
FL CE .The new f<onc~ i<1a It~ r
than the one that com es with
m o st r ad ia l a rm s aw s T h is ex tr a
hcightgiv,, , ,you
more suriacelo
support the back edge or awork,
piece P lu s
it
I t t o ; ) OU s ta c k w o rk p ie e e s a n d
cut
t hem
in a
~inStle a _
A s lonlt as I w as re pla e in z th e fe nc e I d e-
cided t o m a ke il lof1 (er,to o . I To s up po rt I he
lo ng er s to ck t his
ren te ca n n ow h an dle, you
mal ' war n
to
a drl a l on ger table
or support
ledge, =ag e
~6.)
Fence Stop Block
SAW
RMADIAL
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WouJsmirh
O. INDICATOR
BLOCK
®
10
N o. 72
UP. To prevent il fro m tw isting as irs
tig hte ne d, th e h airlin e in dic ato r re sts o n a
lip (E) of
\ o
M asonite. see r ig. 9.
~'lSE 'H 'Y.
O nce th e lip i s
CUI10
s ize . glue
it to the fro nt o f th e in dic ato r b lo ck . Then
g lu e th e indic at or b lo ck (C) 1 0 the le lt s ideof
the body blo ck
(A).
see Fig. lO . F ina ll y ,
loo sely screw the h airline ind icato r -
marked side down -10 the indica tor block.
IWR.UNE.
N ext, scribe
11
'i ai rl in e ma rk
centered on th e width of th e Plexig las using
an X·Ac tokn if e. Tomake il readable,fillthe
scribe
lin e with
black
inkfrom
a
felt
u p marker.
SCtl£W
OLE.To a na ch the PIC'Xlgias.ri l l
a
1 t 4
screw h ole cen tered o n its w idth an d
IV . down fro m th e to p, Note: T his h ole is
l arger t han the s crew to allow for adjust ing
th e SLOp 10the measur ing tape later.
DRlll A '-',
COONTtHOlE
• • O E I P
PINCH
StoCK
IlVR
~
fOll
S A WE M J
RWE
IODY
l OCK
•
•
o
DRJU.OY(lSlH
}.- .-1 . - HOl.[FOA
COlJNTER80JtE... 1 . CAaRlAGE8011
. ~~
ASStMaLE ~N04U XK
AND IIOOY BlOCK WITH
~ SPUN IH KtRIS
--~
=
7
NOTE:
\ l
fXlIND,
ONl Y to
l'u.
~.
SPUN£
Atu-r the st op b lo ck is a ss emb led, a t ri angu
l ar i nd ic at o r b lo ck i s g lue < l10 the sid e. T his
ho ld s t he hai rl in e i nd io . .. ,. to rh a l s hows the
pos it ion o f the sto p b lo ck o n the fence.
SUlCK
,\, [J
IS'OIC ATO R.o make th e ln
dicator block (C ).
CUi3
t riangle f rom
1 0 2
stock, refer to fig. 9. Then. to make the
hairline indicato r (D). CIII a piece o f ~.. '
P1exil las
I
V .
w id e a nd 2 W 'lo ng . s ee F ig . 8.
IN D ICA TOR B LOCK
4
i th t he bo dy block
(A)
a nd p in ch b lock (8)
cu uo si ze , you're ready t o begi n assembling
the ,lop block . The pinch block uached
10 th e b od y b lo ck w ith • c arria ge I M J h an d
wing
nut sec
Fig .· . · ti gh l~ n ing t he w inR
nu t
pinches the b lo c k a ga in st the
fenc · .
To
erealf th e 'pinching acti o n. th e p in ch b lo ck
is b . .'Vdt>dalong ils upper end.anu hinged
III
the body b lo ckw i th a s pli ne 0 1 1. Masonite .
se e ~ Ig.a,
C I. TSPUNE F.RI'S. TIlt
sp li ne f it s
in
kerfs
nil
in b oth b lo cks.
see
F ig . ~ . To rut these
kerfs the saute distance from the ends of
bo th pic ,. I b uued th e block. agaim,l a
stopclamped
10th e radial an n saw fenc e, se e
Fi g. 5 . Position Ibis SlOP I t . J fro m th e s a w
bladean d
-u t
a
It. -< (-ep
kerf a cro ss th e
end
onhe
b o d)' bkx: k (A I. s ee F ig. 5 .
Then
ra ise
th e s aw b la de and ('III a h -< eep kerf on th e
p inch b l ock (8) . see ~i .
j \t . U < . e ntE SI)U.~E.\ ith th e D),ating kerfs
cut. the next step is \ . cut a spline to
fu
the
kerfs, see Fi g. 4. I Cui th e spline from
\ o
~1asonil to a w id t h o f ' ' and l eng th o f I vi
Then tempo ra ri ly assemble th e bo dy bl o ck
A) an d th e I linch blo ck B) with b e splin e
in p lace.
11RIIJ. HOLTHOI ~ N ext, 10 re ces s th e
head of the bolt. drill a ;,.~.counterbore OJl
ihe bo ttom of the pinch bl,,,..k,
'>t't'
Fig. 1
Then
drill
an oversize (~,. ) shank hoie
thro u gh th e bo d) block and pinch bl o ck fo r
Ihe It, x:r' carriage boll. see ~J g. 7a.
-\.~DnlF.}Jf.:\
EI .s . N ow, tocreaieth epi nch
in g a ctio n s an d
3
bev elon t he -t o pedgeofthe
p in ch b lo ck. ,. Fig. 4a . F ina ll y. 10 kee p
built-up sawdust f rom af fec ti ng the accuracy
01 th e SLOp. sa nd a no ther be vel o n the lower
inside edge o f the bod)' b lo ck . s ee Fig . 4 .
ASSEMBLY
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No,72
1 5 ~ \
O ITIOH
HAlRUN£ OvtR
/' liIlO MARKAND
T I G H 1 l N SCAm
~
J
1
~
,
,
•
1
. .
~
~
. . .
.A;~
~CAt )
,
SAW
'
L O K
al.ADl
I.UTf Q t.G HT Sl D t- Of ST OP
1 0
L Ft
Slot
Of
lA DE
TH[N lOCI( S TO P tN PLACE
1 4
There's o m' m ore
thinll
to keep in m ind
Any tim e you remove th ~ «ne,· or replace
the saw blade with one Ih31's a different
thickness (such as a thin ker f blade) re -ad
ju s t th e h a ir l in e s o i t
s :e~an
c c u r a t e - z e r o
reading (or
th( '
new b la d e.
tNSf,\lL fE NC£..Once th e va rn is h d ri es ,
you 30nstall the f cn re on
tI ,
table. se e Fig,
13,W it h th e fe nc e
locked
i n p la c e, cut a
kt rl
Iltrough lhe [( ,I IC( 'o the depth ol the table,
llS (N G TIlt:: S TO I' U I.DCK.
~Ow
comes t h <
real test. Set
e
hairline f or M Y m e as ur e
m ent and cut off a piece 01 scrap Then
measure the tes s piece' against
th~
measur
ing tap e -
il s ho uld
be
exactly th e s am e
leogth a, illdkatcd
by
the
haIrline,
~ ,·XI.
I appli ed a co at (.f varnish to Ihl
cham fer. , edge of LIlt fence. Th is p ro vi de>
3
non-porous surface
or
permanently
al·
1 i: 1 \ : l l l ng th t> sel(·adh~jvt·measuring U J p t >
CH.AMfU l
all
WIDtH VARJU
WfUI THtCKNES S
OFT~
•
J ... ·WIM
fl CHAM fEIl
0,
30
FE N CE
C D
..... NOTE:
SUPPOI2T L£DQt MAY
a
AOD£D Hllt£
RUfATO P. 26,
1 3
,.
~
,
•
AaN SH
eHAMfOt
2
fHa.OATOF
STOPIUXI
AfI~r the fence i~nstalled in the I. b l . th e
next step is
10
attach the me,,-<urillj(tape and
zero the SlOPblock .
AlTACU T.\P :, T o d o th is , fi rs fil th e s to p
block
ontc the
(eli e . 1 1 t~1 lbu tt
the righl side
of th ,· SLOPblock to th,'
It'ft ~id~
of th . s<,w
b1 ad.'. S<'C Fig, II. Now. ;Ih Ih ~ O il block
c1 nmp<'d in th is posilion.lX'eJ b ack a cou ple
in ches o( th,' paper bal'king Irom the rem
eod
01
the
measurU 1J
ta~
Thelllhrt'ad th~
Lape
und.>r
lht' rlex iJ as
indicator
and posit ion the -7£ ro · point undt'l'
the hairlinv, sec ~lg, 14 No' r~IlI vc th ~
resl of the backing an d
prK we
tap<' 01111>
th e e n c e . Y ou olay h :J \ t: to c ut th e 111 . as u r·
iog lap e to the lengw or you r f ence.)
~11\~1 .
N~,
Nex i. d1 ( .. ..k
till' hairline in·
dica lor closdy.
If
the hairline docs
ol)l
read
ex acLly w ro
wben
the < lO Pis louching th,'
left side of the blad,', 100,.,0 the screw thai
Iiold s
th..
PI I.'Xig l3s
in
pl:tet,. 111 n
slide
th e
Plcxigl .., un ll l the hairline is O ve r O w ro
and
r 'u~hl(
the
S( f( w,
see Fig, 15,
MEASURING TAPE
C RO SS SE CT ION
ISL.. V IEW)
1 1
Vilh 111.-
stop
block
complete.
work
can
begin onWeradialarm saw(cocc.I,.,,1Ult
fence (rum ·~~ ~hil:kmaple and chamfered
W I
IO~(nlllt edge 10
p ro v id v a mu r, ' d ir e....1
line o(sight when
rl'adinR
th~ta~ measure,
r e ( er I t
Fig,
RlI ' T O \\
urm .
1 1 1
determine
til t' w i dt h
(height)
oflhe (eoct' (~) , measurc thetbick
ness o(ynnr tabh- and add t h ,' h e igh t ofWe
Ihroal
opening in
l h, ' S lOpb l oc k
(2 ),
se e
Fig. II. -.:,,' rip the f , , ( 1 10Ihh combined
widlh,
< I~~
2.
Cl TTO I..£NG I11.Jlt [urc. ( tIlling 1 1 1 ( -
fence
0
length,
thC. fl
ure
S IOlt dt.·lision~
1 ·
mad,' Silln' I wanted Ihe m lurity
r
the
(rnet to th,'
~
nl th,' blade, th . fir.;1 d.-.:i·
sion was 110\1
tar
to go to tile
left,
'This i.
u . 1 i U a J l )
determined b)'
th e
amount
o f
room
there
i
n the shop
10 thl leCl
ul Ih
radial
a r m s aw b e fo r e a
W ' .u \
or another machine).
or I l l~s iz ('
ollhe
s aw tabk
,10
myshop. wen
\V S
enough
room for a
~~I
f ,1nrt· on
rn . ; - l l . f t
Then I
ha d to
d
cc
ide
thl' le'ngth of f ..
nc..
lhal
will
f il t i l th l ' rl l' of th e s a w blade f lO
my C3S< ;, 0 · ), T h is o r. ..d e Ih e
IIllallt'Ogth O(
Illy fvnev K O ( ot,,: I'ar m o re 01 1adding a
larger
table
to
your ' ''
or
adding a support
ledRe (orth~ fence,'C'C pag, ' 26.)
CI \~ffER.
\ ll< - r the tence ;«UIIO tinishro
size,
Ihe next
step is
to cut a ~Jt·wid~
chamfer alon~ thetcp
edge
for
th('
measur
ing
tape, see
I~ll, 12, To do Ihis, I used a
ch am fering bit
on
O le router t ab le , s ee Fig.
1 2 a, but YQU < u ld wv el· rip Ih is o n th e ra dial
arm saw or table-saw (Shop
01 lfyou
saw
the chamfer, plane or sand out any saw
larks so
th e
self-adhesive
measuring
tape
ba s a s nlo olh s ur fa ce
III
,t ic k c u
FENCE
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ooJsmirh
o. 72
The Woodm>rkers' Store
612-128-2199
Dia l C l I lip i fS. PI I< J I I.op
\Voodm>rker's Supply of N M
~S 9292
Dial
CO/ipn'd.
Plllgs,
Talle
Cherry Tree Toys
61·1-484-13113
P
IU9S
M eise l H ar dw are S pe cialties
8 0 0 - 4 4 1 - 9 8 70
PIII.IJ~
Trendlines
800-767-9 999
Dia C(1/ip I IJ. PIII.g
s,
Tape
Woodcraf t
800-225-1153
Ow. Calipers. Tape
S,n,ilw' Iiamu Urt al/d llpplie.mag be /oulld ill the/ol/(1Iuwg
calalogs. Please call
<=1.
company/ora
t /og
orin/(frmoliml.
LTERN TE T LOG SOUR ES
ME SURING T PE
There ate a v aricty of uses for a
self-adhesive me as ur in g t ap e.
(W e're induding one in the
Radial A rm S aw Stop Kil above. l
They can bem oun ted on benches.
r ow ta ble s, a nd lathe
beds .
The
\.'t'· w id e self· adhesive
steel tape has black numbers
a nd h as h marks a ga in st a wh it e
background. \Voodsmith Pro
ject
Supplies is o ffering tapes
that read from righl 10 lefl and
lefl to right. (NOte:
The
right to
left tape is6 feet
l ong and
the left
10 right
tape
i ·
( ee l 10nl1 .)
M easuringTItpt.> :;
772·~J 0 RightTo Left ~1,·a.
uring
T ape, 6 fLlong . .. .. .. ..S6 .95
772-450
left
T o R ig hI M eas-
uring Tape. · 1fL loog $5.95
L ROEWING NUTS
To secure the fences on th e
Mite r Jig sh ow n o n ~e27 . we
u~ la~epla~tif w n nuts with
me ra ll ns er ts , You c a n bwld this
jig with standard m etal w ing
nuts,
bUI w e fin d
these
3 ·w ide
w n nuts easier to tighten.
They 're t he s am e wing n uts w e
use on o the r j ig s in o ur s ho p,
\V oodsm ith Projec t Sup
p li e s i s o f fe ri ng t he se w in g n uts
to
fi t 1 1 1 « ' ( / d if f er en t bo l t s iz e s,
Large \\ling Nuts
772-403 V4 ·20 L65ea.
766·21 1 ..
1<; · .18
1.65ea.
770·110 W' ·LS 1.65ea,
10 or more ti l one-size: $1.50 ca .
that
4 ~
..
thesameas~ .
But
by using this dial. I
can
quickly
r ea d a me as ur em e nt th at 's ea. )
to...Ork with .
T he a ccuracyofthcsecahpers
is
plus o r m inu s .0 01 5 an d th e
bezel is ad juS lab le. A l s o . th er e 's
a drill an d tapcbart on th e back.
F inaU )' .ihec ali pe rs a re h el d i n a
protective case.
Dial
c..Jipers
772·300
Dia lCa lipe r s . .. $26 . 95
R DI L RM S W STOP
W o odsm ith P ro ject S upp lies
is
offering
a
hardware
kit
fo r
Iht
Rad ia l
Ann
Saw S lo p sho wn o n
page 28 . The k it in cl udes a clea r
Plexigla s ha irline indkator. a
la rge plastic w ing nut. a self
ad he si ve m e as ur in g ta pe , a nd
ihectherhardwarenecessarvtc
b uild tb e Slo p. (N ote: W ood is
not Inc luded .)
Radial
Arm
Sa w Sto p
772-400
Radial Arm Saw
Slop
lI ardw- , , ' Kit $12.95
•(I)
Y' x6h.SclJ: ild lleSiveMea. .
uringTape (Reads
righl
10
left
• I
1 1 . < '
x
I V
x
Z I - I
Clea r
Plrxigl ... Hairline lndicator.
(Hair line on th e back side is
etched a nd i nk e d )
• (1) 'I. x 3 Carriage Bolt
• I
Larg~ Plastic \\jnfr NUL
\\ itll M etal I nsert. 3 A cro ss
\\·ingl<.Threaded To '\rCCllt
Standard , Bolt
•(I) 'I.
LD.
\Vasher
•(I) 6x : V , R h Screw
•(l)
washer
Allo ~ 6
,,· ')J/.. d~I; rJ/.
~ff} ~n· f
n s f b j t c t
to cl la l / (
ojJ.~F; _'V.I ~
For
CaSlin'
ser vice u se o ur T oU
Free order l in e. P h on e orders
cal 1xlp1~edMolldaylhrough
Friday, 1 j : ( ) O k\1 to & :00 PM
Centra l Standard 'Tlme.
B efo re calling , hav e your
VISA rMaster Card ready.
800 444 7002
To order
by l1L1 i I,u se th e f orm
enclosed
V o i t h
a curreat Issue
or wr ire ) 'our order on a Pl~o:c
o(paper .
a nd se ndwith a c he ck
or money order . ( ln c l\ ld e$ :l .50
hand li lJg and sh 'J l I )ing ch3r l: e
with
each
order.) IA r<:Sl<,ents
add 4 f, s ales tax: CA res idents
ad d 6 . 2 5 1 1 . salesUIX. Send In:
WoodsmithProject.Supp~
P.O.Bo 10350
Oes \ I.o in es, lA 50300 '
BY HONE
YM IL
ORDER INFORM TION
The dia l
calipers
offered
here
are divided by \.tI increments.
but have a no th er fe atu re th at's
especiallyuseful. Ma rk e d o n the
in ner dial are d iv isions o f
eighths,
qu a rters,
a nd h alf in ch .
Ther e are also bo ld hash marks
t VIS I in terv ls
Thes e
marks
and
Increments
I find th e mosl useful. \Vhen
work ing w ith wood. I don't us u
al ly m easurcin hund re dth s o fan
in ch. A nd I can't always recall
chined from reinf orce d fiber
glass so they're lightweight but
stron g. Includ ed are a me ta l r od
fo r
measuring'
hoi,' depth an d
jaws fo r b o th
i ns id e a n d
outside
m easurem ents. T he ' · long
ja w s o pe n 6 w i dt.
The feature ike most about
these calipers is the easy-te-read
d ial. M o st o f th e c alip ers fo und
in ca ta logs
a nd sre re s h av e
adial
lhal m'''''''I'1. $ in hu nd redths o f
an in ch (set Al ter nate Sou r ce s .
b e low ). S ome o f 't he se a bo hav e
a n I ns id e d i a l that r ea ds i n S t a nd
a rd in ch in er em en ts o f ~ .
H LLTaEEP TTEaNS
\Voodsmith ProjectSuppIJesis
off.. ,ing fuJ~siJ..epaltems with in
structions fo rmak ing'the I x 'ndi ng
jig s for the Hall Tree ( f ea tu r ed on
page 1 0) . I nd ud cd a re plans {o r
the le g
jig
th e S ho ok jig' an d th e
ring j ig.
HaJJ
Tree
Jig Patterns
772-200 HallTn f Paut lllS s ~ 9
OV LHE D PLUGS
\Veus ed woodovalhead plugs to
co ve r th e co unterb ored scre ws
o n th e lIa ll T re e
(page
1 0) a nd
th e
Fer n S ta nd
(page
20).
W oodsm ith Project Sup
plies
is offering these plu,tr,<n
four different types ur wood .
111ey will fi t 8 l'ij .. ia. h ole a nd
are o nly so ld inpack$of25.
0va1bead Pluj .~
772· 100 \\'aInut Plugs 1.65
772·110 O ak Plugs $1.55
772·120 Cherry Plugs 1.6S
772-130 Birch Plugs. , . . . $L25
DI L C UPERS
To accurately
measure
the
th ic k ne ss o f thin strips of wood
used
in b en t l aminat ion p r o je c ts .
I use dial calipers. They're also
handy for measuri ng stock as it
co mes o ut o f th e planer an d th e
de pth and w idth o f holes. (Fo r
mo re on
calipers.
se e p ag e 2 5.)
\Voodsmith Project Sup
plies is offering the sam e dia l
calipers th at we use in the
V J < X k < m i th shop. They' re rn a-
Sources
SUPPLIES
ROJECT
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.. r i~ Halt Tree i . I I,'llrt
I / IU p l . C 1
l,flU
Yf,/(r
/ , « ( t .
ft'g u ('(lJ( ~(. ')t br:ltl {« ,i aliUlt -
1.
}~ t1/',,,
fll'pd
tl {(Il
ul : fu C'J
rtHJ/X )
II (
, I , t
.<I(nIJ~ fJ 1'Q( ;d.()nrr fhl 1/ ,
, ,1. ttll III' ~
Bent Lamination
.._ The grnrrJu/
( (1'., ....
u
tltl~
Fin, Stalld art
hig l i lhr. 'l ( by
(I
If,t
Ulll ,..IMJn
Tll,':dr iJ k .
iI.4\ Ii
If 1 lgl ' r
oJ ,·(,th
It
tj~tll'llltC'}'f's lilt
a 'Ui
IIlit slu:
J
l'''';'t.
FemStand
Hall Tree
• ..Iliaci, tI
s s
hop· ,,,d, .rfJp bllJCkIt) {qllr
m dia i
anll QW
tQgt t
QI .'CU
ut«
C~I3 t'l'ery f, (~ •
\1 1
tjQ,(
{tc i a l.t ,
nltl/olrltlf bit
Uj /l(ttr/ IVln
t
Stop Block
inal etails
LOOI(
S T
