WS #060.pdf

NO.60

NOTESFROMTHESHOP

$3.s0

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Sawdust

DonaldB. Pe6chke

Ted Kralicek

OouglasL Hicks

Oouglas M.Lidsler

KentA. BucKon

Ken Munkel

DavldKreyling

Ca.y Christens€n

Fod Sloakes

ChrisGlowacki

SandyBaum,Mgr.

JackieStroud

PatKoob

LisaThompson

LeslieAnnGearhart

TerryJ. Slrohman

KenMine]

CherylScotl

JeanCarey

Archie Kiaus€

A.Bor,'T THIS rssltE. Hislory repeats itself,

or so they say. I ladn't leally thousht

nuch about that in tems of Woods,'ii,

until we stafted work on rhis issue.

I/oo.lsnil/. actualy goi stafted in July

1978 when I besan work on th€ firit issue.

,A-sit tlms out, ninety-nine yeals earlier,

in May 18?9, my gr€at g?.dfather, Enil

Peschke, stafi€d his o$n compuy.

W]ly am I mentionins this now? The

compdy Emil staded was a "Manufac

ruer of all kjnds of Mouldings,Pictw

Frames and Curtain Pol€s." (I'm lucky

enough to have one of tbe busin€ss fonns

he used back ihen. We incoryorated it into

the cover photo of this issue.)

So, it's conins tull cycle, and I'm finally

getting around to making the pictur€

fi?Ines that seem to b€ part of my hei-

tase. Of cours€, l,he moldings we'r€ shos-

ing in this issu€ are not .early as oruie

as those Enil nade 100yeas !go. But

So far, w€'ve added the suppli€sfor

thr€e of lhase past pnrjects. Fil5t is the

clock novement (either brass kelvind or

quad,"6attery), dial, door slass (which is

stenciled d-s shosn in rhe jssue) and the

hrdwde for the Resulator Clock sho$n

in Woods,ril, No. 36.

As a result of a number of requests. we

ar€ otrering nore choices for the Cradle

shoM in Wood3rzil/' No. 48. The cradle

ws orisinaly shown in oak. We now offe.

the spindles (and the buttons) in oak,

If you wanted io bujki the Eurcpea.

Workbench sbo$n in Woo.ls'ritl No. 50,

you may hav€ had houble getting the

vises. It was xol the fault of Woodcraft

Supply (the rnail oder source we lisled)-

TheJ did an adnintle job of trTing to set

and ke€p the vises in stock. The poblem

was $'ith the manufactu€r.

We hale talked directly with the man-

uf&turer and hav€ received a sbipnent of

the vises for t|e Norkb€nch. You can siil

order toon Woodcrafi Supply, and we arc

also tr'.ins io k€rp some on hand.

rcco IIEMS. One of the things I didnt

mention was the addilion of ihe "logo"

itens. We nos have a shop apron, a cotree

mug, and a coxluroy Gp

PrcruRE FRAMES.W]tat wa-sso much

tun, though, was conins up wiih a variety

of tuames usins a limited amount of

machinery. We decided to lirnjt the work

to usins a router table to fom the prcfiles.

This meant we had to make aI th€ profiles

with router bits. Is this roo linitins?

At tusr, I thoushi it woukl be. But tben

I began looking at the dozensofrouter bii

profiles avanabb. Thera were actualy too

many choices.So, we took another ap-

pnrach. ALI of tbe prcfiles are made by

using onh three silndnrd router bit pro'

files (stmisht, roundover, rnd corebo\).

Using differcnt sizes of thes€ bii.s, we

were able to come up wiih seveml dozen

plofilcs. Then it became a matter of choos-

iDs which oncs to sho\r in this issue.

We settled on 10profiles. Some are very

simple, some ar€ complex. Th€ key to tbe

complex ones is that they are rcally just

combinations of ihe sinple ones. That is,

the complex moldinss s€'re showins don't

have to be one srdp of wood that's fomed

by a very complex bit.

Insi€ad, make sevenl strips with just

one profile on eeh strip. Then join them

together. Conbinations like this ar€ al-

nost endless.All that h3sto be done is to

find new ways of aranging the stdps to

oe|te new pnrfiles.It's just a mntter of

using your imagination.

PRoJECTsuPPuEs.In the lst issue,I

talked aboui the project suppli€s lbr the

p.ojects sho\rn in lvoodsntti. lve are

beginning to so bek to proj({ts sho$D jn

past issues and trying to find sources lbr

those suppli€s. (!'or sone of these past

projects, w€ sonetimes listed a source

that ha-ssince stopp€d carrying tbe items.)

TheWoodsmithStore

aI with the

tYoo{tuDill logoon them.

To be bonestabout all this, I resisted

offering this t)]rc of tbi.s for many yees.

But whai triggercd it wa^sa simple need.

I $anted a spod shop nprcn.

The typicalbluedennnonesI'!e seenin

sone caialogs ud stoies just $'eren't tbe

quality I wanted. And worse, the pockets

we.e too small and in the $mng places.

So,w€ desisDedou own. Actually,Tery

SLrchrmndesign€.liL- ..

NEw FAcEs.Te.ry joined oul Pmject

SupplJ tem this pasl fall. He worked in

the Wooik,iill Siore herc in Des Moines

for $out a year. The. we r€cruited him

to help with the "fiont

(FebruaryApril,June,Au-

gust, October, December)by Woodsmilh

PublishingCo.,2200GrandAve.,Des

Moines,1450312.

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WoodsmithPublishinqCo.

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end" work for the

tbe shopapron

and getting the other logo ilems lined up,

TeFy hLs been working on rll the details

you never ihink about . . . getting t€le

phone lin€s in for the 800 number, desisn

ing th€ foms need€d to take oders nnd

to ship then, and tryins io think of ways

to make th€ entir€ process morc efficient.

He ha-shad several hcadaches.

But things arc prcsressins. And with

Teuy's help, rve hope to offer a wider

l"nse of sewiee for all Woods,riil prcject

Postmaster: Send changeof addresslo

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lA 50312.

SAMPLECOPYWewillsendafreesample

copyof tlbodsmrti lo anyone.Just sendus

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The ne\t issu€ of Wood'

s,riih will be maileddudng the week of

lebrudJ 2?, 1989.

WOODSMITH

WOODSMrH (ESN 01&4114) is pub'

lashed

bimonthly

Ir addiLionto desigDing

NEKr MATLTNG.

s &. Techniques

stock6"long-Now. to dcicm ne ryhereto

ddll holes for the difibrent sizcd dorvels,

nark a cenl.olinealoDgtbe thicknessol

a coting salvor a backs.r1r.

To pinch the biadetighi nr the kcr{ I

usea '/," dia.machnres.reN andnut. I)iU

a rr"-din. holc, cntofeil on the width of

lhe handle % trom ihc leadins edse.

Now belel the hoDt €dgesol lhe handle

so mor€bladecaDbe used.

]RAMINq A 45' ANGLI

When I set up the table sl$' for cutting

miters, I us€ a liltle geometrv to :]djust

the miter g:uge for 45".

To set a 45' angle, I use a franring

squtu€ and fom an rsos(rlfs l.fiansle. (AI

isoscelesLrianslehas two equalsmes,and

rwo 45" nngles.)

Next nrdkernarkson this cent€rhrc 1"

and 2" fiom eachend of the block.Then

ddll the four (lo$'el holes ('r,", /,' Lld'

and 'f1") compl€telv throush the block.

(Dilling rbrcugh l.he block allows the

do$'elto be pushed thruush so oneend is

ag:insl.thc fences'hen.utting.)

In ad.lition to cultingditr€feDldiameter

dowels,I also waDtedthe jis lo cut the

dow€lsto differentlengths-To do this, hv

the block doirn on the band sas' (so the

hoiesare hori,onhl) and cut 2['lons

s.rw keds at y!" inteNals on both cnds of

TRA,'\iIINCSOUTRE AT€ EOUAIAT

MIIERGAUG! !TO'

Sinsleedgedfuors hale a smallholein

the cenler of the bl.]dclhnt nccdsto b€

enlarged to acceli the machine scrcrv-

SiDCe

To set the miter gauge to I true '15"

3ngle,set the naming squ,ueon the top

of ihc table saw. N.rw rlisn the same

measurenenis on both dms of the firm-

ing squ{e right qainst the edge oi tbe

thc metalir th€ ruor bh(le is very

b|ittle I jus! used r pan of nee(ilenose

pliers to snip oui a hg€f cenlerhole.

hrsed lhe tuof into the sarvkelt lionr

the side so tht brk ol the bladeis flush

lvith ihe botiom of the saN ke : (lle

carefulnot to tush the shalp edgeof thr

blade.)Then tishten do\vnthe bla(]€Nith

lhe machnrescre\L and nut.

\\rhen usnrs the scr.tpcr, .just push or

pull the scnper io scnrpcihc workpiece.

Ca Fei.l

( ho\'r Hill, N!|,Jtt\.ll

Ne\t loos.n Lhe miter gauge locking

knob and genUv snug the gauge up agan)si

fie fiunis squnre. Thc miter sause is

nolvsct at exactly '15'. Then,iightendo$'n

lhe locking knob ad Ioul€ r.eady t., cut J

15" mile..

To use the jis, align the lence so the

blade fiis inlo the ke|f slol. Insert the

dowelstockirto the concci dirmeter hole

unlil UrceDrlof the dowel is againstlhc

leDce. NoN holdtheiis anddos'elaDdcut

tbrough the dowcl. Slowly brck the jis

out, and push the finished dowelout th€

edgcof l.hc jis usinstheuncut dorvelsto(k.

Repeat lhc tl|ocodurc to get the same

r, S.hrtitl illtl

LoDlpoc.Cdtlbtitk!

Editots Note: This tip till r:ork orllt il

the sau bkd. is potr l.l u,ith th. ntittl

0atule slot. I.l the btkl. ;s na{ p.iall.L,

th. .t llts ate atua s xoiito to Le oll no

,ntt.r hor, r.ttectth. ,tit.r !fi lr has

beer set. Al$. <:lk(l; lo Dnkt srt. thal

ruur.[iflDti n sAtlotcis ltul! square.

SPOUTCAP

If )oule ahrars losins the snrallspoul

caps finm cont.incN of snull cans, gel

someheb lion electddrns.

I keep a larietr of the small diametef

elecl.rician's

Harcltl Sklldcr

Sktk Cal1.x., n, | | s ! lt\!| nt

t\Liston wire conneet.ors

(so'nelimes c,.Icd $'ir€ nuts) in the shop.

W}en I lose a capliom ncanorgluebottle.

I just scr€\roDoneofthese DitJ tlvist-on

RIGHI IENGIH ON sHORTDOWELS

I use quite a few short doirels fo. sluing

joinrs tosethef. And I've had morc than

just a iew problems cultins lafious sho(

lengths fmm n$ do\Lelstock.Tbc ten!,ths

are usudlv inconsistent.and sometimes,

whencuttirg the dowelson the bandsa\r,

they would be caughtbetrveenth€ blade

andthe rip lence.This not ody ruined the

dowel bul. becamea saiety hazrKt .rs \i€ll.

I rcsolved these problems by rnaling .]

verv simplejig from 2x4 stockthat can

.ul four ditr€rent sizeddow€l diameteN on

the band saw. The jis (a^s shown in the

dnwins in the niddle colmn) will also cut

otr dowels in 1l' increnents Lrpto 2" long.

To make lhjs jis, slart by cutting the

lhat I'!e beenusingfor

some time no\L s'ith gr€:rLsucccss.It's

ciled dcior bladnu and I use it tof r

va'iety of purposes- My main us€though

is to remole anX glue thrt sho$'sup \Lhile

stairing, especiallyalongl.he.dge seams

0n slued boarls or in lisht cornel.s.

The docto.bladeis a snrgb'edgedrazor

bladenount€d in a handle.The handleis

rnade 1r.rD a ,1,'r l.lrick piece of scnp

me&suing 1'l. wi{le by 6" long.

To make the handle fit comlbrtably in

your hand. d|aw a hnnd conlour on the

scmpaDdcut ii out on ihe b:lndsaw.Then

cut a 7."-deep bnnd saw ked in one end

to hotd i.hc blade. (Th€ band salv curs

abouLa %,,L$idekef.) You cu alsouse

It,rd Wrtt:tll

Da ir, Caricttit:tt

'IND IN YOUI IDEAS

tipwith other

teaderc ol Woodsnilh,send your idoa lo:

Woadsmilh,

lips & Techniqu€s,2200Grand

Ave.,DssMoin€s,

lowa50312.

We pay a hinimum ol$10fo.tips,and$15or

morelor special

Please give acohpl€testplana-

tionol youridea. lra skelchis ne6ded.ssndir

along;wo

lldraw a nsw ons.

WooDSMITH

CH'A? SCRAPER

Her€s a technique

llyoudlikeloshafeawoodwo.king

rehniques (lhat a.ea@ept€d

lor publicalion).

St"p_$too!

A STEP

IN THERIGHTDIRECTION

joint€.

EDGI€I.UETHESIOES

I besan by making the two side (leg)

piec€s.The trick to rnakingtwo miror€d

pieceiis to start with oru blanL see Fig

1. Ihen after aI the srooves are routed,

it'E cut in haf to cr€atethe two pieces.

cLUE-up.To nlak€ the blank, start by

edge-sluingthre€ pie€es of rx6 pine t

cr€it€ a blank thads musHy 16vt' wide

and29' lons.

c'ul'rt) sra. A.fterthe gluedri$, plane

or b€lt-sandthe blaDk flat. Then cut it to

a width of l4 and u" long, s€eFig. r.

IAY OUT I.INEs

Aft€r the blankis cut to size,two dadoes,

a groove, and a Ebbet are rout€d to join

the other piec€s of the stool,seeFig. r.

DADoEs.Stad by laying out a '/,Lwide

dado for the bottom step 6v;' ftom each

end.this is a stoppeddado,so rna* the

stop line Ya"ftom the ft0nt edge.

oRoovE. N€xt, lay out a Y,"-wide

gmovet hold the r;s€r. It'8 locat€d67."

from the front edge of the blank and

connects

[aTERtAtS ltsl

CUITING DIA9NAfl

fu-

OsElf Utuiiod: r/ w r lq'f d t 1{ h

A 5i& {2)

U. t 6L - re/.

H,Affi.;gw

I &tlF (r)

c sr.p 0)

L . l2'/r - r6q.

U.t, - r6L

D ldd( P.mf(l)

the two dadoes.

B cx naBBEr.Finally, lay out a rabbet

alongthe ba.k edgefor the ba.k panel.

The width of the rabbet shodd equalthe

thiclalels of your stock (%t.

ROUIERGUIOE

E ud 0)

Y.,e|A- lt

.IIO

Aft€r the layout is done, you can besin

Nuting. Tohelpalignthe cutsonthe lines,

I nade a sinple guide jig for the rcut€r.

Bud,D.[c. the jig is just a fencenailed

to an 8 -wide base of %" Masonite or

plywood, s€e Fig. 2. Rip a straight fence

and nail it to the bas€so the backedseis

Z' fton oneedge,se€Fig. 2. (Ihe z, lip is

us€dto clanp the jis to the wo*piece.)

cuT orr ErrcE.The nicepart abort the

jig is that you can use it t get perf€ct

alignmentwith your layoutlines.The key

is that the bit clrtson the edgeof the iig.

To a.mmplishthjs, mounta v1'straight

bit in the mut€r. then clanp the iig down

andlun the rcuter alongthe fen€eso th€

bit cutsthe wast€ofr the front edge. Now

NOIET

GIOOVE DETAIL

WOODSMITH

Lile is too shot. For a four year-old, that

meansyou needa stoolb€cause you're too

shortto re:ch the sinkto brush your teeth.

For an adult, it means you'r€ still using

the sane stool to re2cha[ the way ba&

on the t p sher of the kit h€n cabinets.

For this pmject, we used a basic aF

Dmach. The stepstoolis madeof cotmon

iine, which is another way of sayingit has

a "country look." The joinery is equaly

hsic tongueand groove

Y. t 11- rlL

the cut edge is exactlr" in line {'ith the path

of the bit, seeF's. 2.

ROUIING

Alicl. ihc jig js complcic,il.c:n be usedio

rout Lhetw.r dadoes,the gloove,and the

Bbb€t on the blank.

Rour D,{DoEs.Bcforc foul,ing, I

clamp€dthe sidc blank (A) on top of a

coupleof sawhoNes,see lig. :1. lheD I

clampedthe jis in place so its edse is

ilgled with lhe left edse of the lefi da.lo

iine, seeStep 1, Fig. L

S€l the depth of the router bit so it cuts

a 7" ieep groove in the blank taking into

considelaiion ihc thi(kness of the jig's

ba..e. (Shce the base of my jig wa^s '/a'

Lhick,I sel tlre depth of cut at L .)

Now set thc rcul.cragainstlhc lenccot

t}€ jig and cut the gaoove. nolirg 1r'on

the back edge of the blank lorvdrl the

ftont eilge,see Step I in Fig. L

ShopNote: Sincethe routcr bil is iulr-

ing cloch{ise, rcuting lhis directioDactu-

all)' pushes tlre muter base tight ag.rinst

NOTE:

srop THr,rDADo.This dado is stopped

'f," ftlm the front edge to keep iL nom

sho$ing on ihc frul. edgc of thc sl.ool.

Watch the la]oul lines andstop \Lhen the

bil touchcsthe stopline.

sEcoNDDADo,Nert, move th€ jig

do$n to the dado on the oiher end and

follo\Lthe sameprocedure, seeStep 2.

cRoovE. Afler these llvo dadoesafe

routed,tum lhejis90'and cinmpii sothe

edse aligns with the l.{out lirc fol the

gloole lor the riser. see Slet :. 'l'his

lroove stafts in the (lado oDthe left anil

stopsin ihe dadoon tht dshl.

ShopNote: hrsleadof trying to pluDge

the bit exaclll in the let dado,I plunged

lhe muler bii n liltle ahead (to rhe dghr)

ofthe dado.Then I hekl the muler firnlv

andmovedit back\Lddsuntilit brokeinto

5IIL3

aAcx RAaBET,The l,6t thing is io roul

th€ r.lbbel lbr the back paDel. Sinceihis

rabbel is /. u'ide,andthe bit is vJ'wide,

it hlls lo be rculed in two slels.

first, align the edgeofthe iig sith the

insi{le Layout line and rout a ,/j !vi.l€

gloole, see Sicp .1. Then mole l.hc jis

towdrl Iou about v;' aDdnrake another

p:l5sl.o clean out th€ femainjng \raste, see

Fig. 5.

CUI BLANKIN HALF

After thc fouling is complele, Jou cancut

lhe blank in half io crl.!:liclwo minored

side pieces. To do this, slait bI rough

cutting the blank in haLI\rith lhe mitcr

gauge on lhe lable sarv-

To get ih€ hvo side lieces to r.tr(:ll a lht:

sa,ie finished length. set the rip lence

13'rL"from ihe biade, see Fi!i. 6. Then

cut eachpiecewith lhc ,o?lori cdgc

against the Iip hnce.

WooDSIIITH

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