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

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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

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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

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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

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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

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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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Wood 007 (Oct 1985) - Clean.pdf (41202 KB)
Wood 006 (Aug 1985) - Clean.pdf (34156 KB)
Wood 002 (Nov Dec 1984) - Clean.pdf (42069 KB)
Wood 003 (Jan Feb 1985) - Clean.pdf (45772 KB)
Wood 009 (Feb 1986) - Clean.pdf (39142 KB)

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