Wood 162 (Apr 2005) - Clean.pdf
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Better Homes and Gardens
®
WOO
D
®
The Shop-Proven Woodworking Magazine
ISSUE 162 APRIL/MAY 2005
9
small- shop
9
small- shop
projects
projects
p. 35 and 90
clutter busters
■
garage/basement cabinets
■
workshop overhaul
■
outdoor storage bench
flatten
any piece
of
wood
– with
no tearout!
weekend projects
■
dresser-top valet
■
keepsake box
■
chamfer plane
skill builders
■
routing small parts
■
super dowels for stronger joints
■
how to texture wood
cool tools
■
12 brad nailers rated
■
5 problem-solving clamps
U.S.A. $6.99
1))
®
April/May 2005, Issue 162
p r o j e c t s
16
adjustable
miter-gauge
extension
20
picture-frame
clamping
jig
38
versatile
tool
cabinet
system
39
mitersaw
work
station
40
sheet-goods
storage
rack
41
super-simple
shop
wall
cabinet
42
dresser-top
valet
47
palm-size
chamfer
plane
53
textured-top
keepsake
box
66
basement/garage
storage
system
82
store
’n’
sit
outdoor
bench
90
router
planing
jig
92
modular
lumber
rack
93
outfeed,
cutting,
and
assembly
table
94
small-part
sawing
sled
95
mortising
jig
for
loose-tenon
joinery
82
t e c h n i q u e s
42
66
18
fast
fix
for
too-wide
dadoes
32
routing
small
parts
safely
35
reader’s
workshop
overhaul
50
texturing
wood
for
dramatic
looks
88
how
to
install
stepped
Miller
dowels
96
finishing
school:
making
dings
disappear
99
carved
masterpieces
by
Byron
Brayton
t o o l s
&
m a t e r i a l s
22
wise
buys:
shop
radio/battery
chargers
57
BONUS
POSTER:
guide
to
clear
finishes
63
five
must-have
specialty
clamps
76
tested
and
rated:
18-gauge
brad
nailers
104
three
shop-proven
products
47
76
50
35
d e p a r t m e n t s
88
6
editor’s
angle
Workbench
8
sounding
board
12
ask
WOOD
24
shop
tips
116
what’s
ahead
Mobile
belt/disc
sander
Mobile jointer
under bench
®
Versa-cab
Wall
Cabinets
This seal is your assurance that we build
every project, verify every fact, and test every
reviewed tool in our workshop to guarantee
your success and complete satisfaction.
Mobile
planer
Sheet goods rack
Bench
Versa-
cab
63
Mitersaw
station
Mobile
tool
cabinet
Versa-
cab
Lumber
rack
Mobile router
table under
bench
76
Mobile
bandsaw
Mobile
tablesaw
Mobile tool cabinet
under bench
Drill
press
Dust
collector
Overhead door
editor’s
angle
shop safety:
never take it for granted
All of us learn by our mistakes,
however painful they can be.
But you can get the gain
without
the pain when you take a cue
from the mishaps of others. In
that spirit I bring you this recent
real-life story.
I
was in a meeting with Tool Editor Dave
Campbell, discussing future articles,
when I was told that Chuck Hedlund,
our resident Master Craftsman, had injured
himself in the
WOOD
®
magazine shop.
“What?” I thought to myself, “Chuck is
one of the safest woodworkers I know; how
could he have a shop accident?”
As I soon learned, Chuck had cut his
thumb and damaged its nail on the drill
press, despite his 35 years of professional
woodworking experience. While setting the
cutting depth of a 30mm multi-spur Forstner
bit, Chuck lowered the spinning bit to a
rabbeted edge, clasping the workpiece to
the fence with one hand. The bit’s rotational
force pulled the workpiece and Chuck’s
thumb into the bit. As with most shop
accidents, everything happened in a split
second.
I later asked Chuck how he would do this
operation differently in the future. “I should
have taken the time to clamp the workpiece
to the drill-press table,” he said. “That’s
always a good idea when you’re working
with a large drill bit or circle cutter.”
As Chuck points out, clamps have
many uses in the shop beyond helping you
assemble projects. Use them with your drill
press or mitersaw, especially when you’re
machining small parts. When you can’t
clamp the workpiece, say when passing a
board through a tablesaw or jointer, employ
pushsticks and pushblocks.
Even the best of us can have a shop
accident when we’re in a hurry—just ask
Chuck Hedlund, our Master Craftsman.
Never perform potentially dangerous
operations when you’re hurried, upset,
or tired.
Machining stock with power tools
requires your full concentration.
Listen to that little voice in your
head.
If it says you’re headed for trouble,
pay attention—don’t gamble that you
might
get away with a dangerous operation. Slow
down, take a breath, and do things safely.
Respect your power tools.
You can
become
too
comfortable with a machine;
don’t forget how quickly it can hurt you.
Tune your tools.
Misaligned fences
and other out-of-whack components can
contribute to stock binding and kickback.
Stay out of harm’s way.
Know the path
that a piece will take if it kicks back, and
position yourself elsewhere.
D
ress for success.
Do
wear eye, ear,
and lung protection.
Don’t
wear loose-fitting
clothes or jewelry that can get caught in
machinery.
Never ball up oily rags.
Avoid
fire by spreading oil-soaked rags on a
noncombustible surface to dry.
Enjoy your woodworking
and be safe,
Other favorite safety tips
Although not a complete list by any means,
here are some of my favorite pointers for
injury-free woodworking:
6
WOOD magazine
April/May 2005
sounding
board
Our bulletin board for letters, comments, and timely updates
Easy-access
scrap sorter
I have a suggestion for your scrap sorter
in issue 160, page 37. The ceiling in my
shop is low and I find that when I have
to place a longer piece in the rear-most
compartment, I ding the ceiling. I
remedied this by cutting one side where
it covers the rear compartment down to
24", as shown
below
. This allows long
pieces to be angled into the sorter
easily without the dull thump that can
only mean one thing.
Don Cherry, Leicester, Mass.
CMT touts safety for its
blade and bit cleaner
Your article on blade and bit cleaners in
issue 158, page 20, makes mention of
safety precautions for the various products
but includes no tests to distinguish
environmentally clean and safe agents
from those that are dangerous to the user
and the environment.
Your readers should know that CMT
Formula 2050 measures at pH 10.5 by
litmus paper and pH 10.8 by meter,
according to our tests. [A pH of 7 is
neutral; pH numbers below 7 are
increasingly more acidic, while pH
numbers above 7 are increasingly more
alkaline.] At that pH, Formula 2050 is a
mild eye irritant; if it comes into eye
contact, rinse with water for 15 minutes.
No precaution exists for skin irritation, but
we advise rinsing with water after use.
In our tests, the review winner, Empire
Blade Saver, has pH 14 by litmus paper
and pH 13.9 by meter. Any pH 14 material
can cause eye burns as well as skin burns,
ulcers, and rashes. If ingested, a pH 14
material may cause severe and permanent
damage to the digestive tract. Inhalation
may cause severe irritation, burns, and
possible coma. Prolonged or repeated
skin contact may cause dermatitis.
In a pH test conducted in the
WOOD
shop,
we confirmed CMTs results: CMT Formula
2050 measured 10.5; Empire Blade Saver, 14.
Formula 2050 is a fast-acting pitch-
and-grime remover, as proven by your
tests, but much safer than other products
that clean as well.
James LaMuraglia, CMT USA
Editor responds
I agree that CMT is a highly effective and
safe product. Empire Blade Saver
received the “Top Cleaner” designation
because it costs less to use and removed
slightly more pitch and grime on uncoated
blades after 5- and 30-minute soaking
intervals. The products were equally
effective at removing debris from non-
stick coated blades. That said,
woodworkers must be more cautious
using the Empire product, protecting their
eyes and skin, as recommended in the
article. I’m glad Mr. LaMuraglia raised this
issue so that readers can best judge
what’s most important to them.
Dave Campbell,
WOOD
®
Magazine Tool Editor
6‹"
10‹"
6‹"
24"
Article updates
In issue 159, page 89, change the MLCS
Ltd. cast-iron router table model number
to #9593.
In issue 160, page 18, the Penn State
four-jaw chuck model C3418 has been
discontinued, replaced by model
CUG3418, shown at
right
.
HOW TO REACH US
Woodworking advice:
Post your woodworking questions (joinery,
finishing, tools, turning, general woodwork-
ing, etc.) on one of 20+ online forums at
woodmagazine.com/forums
Subscription assistance:
To notify us of an address change, or to
get help with your subscription, go to
woodmagazine.com/service
; call
800/374-9663 and press option 1. Outside
the U.S., call 515/247-2981. Or write to
WOOD magazine, P.O. Box 37439, Boone, IA
50037-0439. Please enclose your address
label from a recent magazine issue.
To order past issues and articles:
Order past issues of
WOOD
magazine, our
special issues, or downloadable articles from
issue 100 to present visit our online store at
woodmagazine.com/store
, or by calling
888/636-4478. Some issues are sold out.
Editorial feedback:
Send your comments via E-mail to
woodmail@woodmagazine.com
; or call
800/374-9663 and press option 2; or write
to WOOD magazine, 1716 Locust St., GA-
310, Des Moines, IA 50309-3023.
Updates to previously published projects:
For an up-to-date listing of changes in
dimensions and buying-guide sources
from issue 1 through today, go to
woodmagazine.com/editorial
.
To find past articles:
See our index at
woodmagazine.com/index
.
8
WOOD magazine
April/May 2005
Better Homes and Gardens
®
����
®
April/May 2005
Vol. 22, No. 2
Issue No. 162
E
DI
TOR-IN-CHIEF
BILL KRIER
Executive Editor
JIM HARROLD
Managing Editor
MARLEN KEMMET
Senior Design Editor
KEVIN BOYLE
Tool Editor
DAVE CAMPBELL
Techniques Editor
BOB WILSON
Techniques Editor
PAT LOWRY
Projects Editor
OWEN DUVALL
Projects Editor
JAN SVEC
Design Editor
JEFF MERTZ
Master Craftsman
CHUCK HEDLUND
Bill made this dresser-top valet out
of walnut. See
page 42
for plans.
Art Director
KARL EHLERS
Associate Art Director
GREG SELLERS
Assistant Art Director
CHERYL A. CIBULA
Production/Office Manager
MARGARET CLOSNER
Photographers
MARTY BALDWIN, SCOTT LITTLE, BLAINE MOATS, JAY WILDE
Administrative Assistant
SHERYL MUNYON
Marlen and his kids made 29
birdhouses for relatives, friends,
and teachers at Christmas.
Illustrators
TIM CAHILL, LORNA JOHNSON, ROXANNE LeMOINE, MIKE MITTERMEIER
Technical Consultants
DEAN FIENE, JEFF HALL
Contributing Craftsman
JIM HEAVEY
Proofreaders
BARBARA KLEIN, JIM SANDERS
CUSTOMER SERVICE: 800/374-9663
For more ways to reach us about specific matters, see
page 8
.
Publisher
MARK HAGEN
ADVERTISING OFFICE:
333 N. Michigan Ave., Suite 1500, Chicago, IL 60601
Phone: 312/853-2890 Fax: 312/580-7906
Sales and Marketing Assistant
GAYLE CHEJN
Sales and Marketing Assistant
LISA GREENWOOD
Account Executive
JACK A. CHRISTIANSEN
Direct Response Manager
CAROLYN DAKIS
Direct Response Sales Representative
SANDY ROBINSON
Account Executive
PATRICK R. TOMLINSON, SR.
Northeast, Phone: 212/551-7043 Fax: 212/551-7192
Director, Corporate Sales
RICH BERENSON
Detroit: RPM Associates,
29350 Southfield Road, Suite 31, Southfield, MI 48076
Phone: 248/557-7490 Fax: 248/557-7499
Southeast:
Lagomarsino, Dempsey & Dennis, Inc.
2951 Piedmont Rd. NE, Suite 100, Atlanta, GA 30305
Phone: 404/261-5400 Fax: 404/261-5404
Promotion Art Director
SARAH MASSIMO
Director, Corporate Research
BRITTA C. WARE
Business Manager
JOEL ETIENNE
Consumer Marketing Director
ROBIN HUTCHINSON
Consumer Marketing Manager
LESLIE SHAEFFER
Advertising Operations Manager
PAT HENDERSHOTT
Production Manager
STEVE KRIDER
Senior Vice President
BOB MATE
MEREDITH PUBLISHING GROUP
President
JACK GRIFFIN
General Manager
TOM HARTY
Brand Licensing/Operations
DOUG OLSON
Consumer Marketing/Finance
KARLA JEFFRIES
Manufacturing
BRUCE HESTON
Creative Services
ELLEN DELATHOUDER
CORPORATION
WILLIAM T. KERR,
Chairman and Chief Executive Officer
STEPHEN M. LACY,
President and Chief Operating Officer
In Memoriam — E.T. Meredith III (1933–2003)
©Copyright Meredith Corporation 2005 All rights reserved. Printed in the U.S.A.
10
WOOD magazine
April/May 2005
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