ShopNotes_019.pdf

Built-up Moldings Selecting Circul Saws

Hand Plane Jointer I nd-Held Rm1t.inrr Tins

mroa Donald B. Peschke

ULU~T~YE EMTOR Douglas L. Hicks

rawrouwc EDITOR Richard S. Peters

usocnrr~ ED~TOR Tim Robertson

usrs.rMr EDITOR Phil Totten

co*rmsunm ED~TOR Mark A. Williams

cRranvE olaEsma Ted Kralicek

urr omEerea Cary Christensen

s~~oo~~~rusrarrnn

mism of woodworkers - their

attitude and enthusiasm. Whether I

talkto someone in person, onthephone,

through the mail, or via electronic mail,

they're usually excited about some new

idea or technique.

They're also always lookingfor a way

to improve something - their shop, a

project, or a finish. Along with this

come lots of suggestions. "T3ey Don,

how about? Or have you ever consid-

ered? And I sure would like to see. .."

IMPROVEMENTS. It's no different

when you get a hunch of woodworkers

together to publish a magazine. This

desire for improvement is just as strong.

In this issue, you'll find a number of

improvements. Nothing drastic. Just

things you've been asking for - like

more tips, a special department for the

small shop, the Lumberyard, and the

Finish Room in every issue.

We've also included two new regular

features. We're calling the first feature

a Hands-On Project because it uses one

of the techniques in the issue. It's just a

quick project to give you a "taste" of a

new technique. In this issue, there's a

simpleWall Mirror. It's based on thebuilt-

up molding article shown on page 12.

SELECTING TOOLS. The second new

feature is SelectingTools. We've set out

to write articles that will help you se-

lect the right tool for your needs. But

with two important differences Ji-om

the "tool reviews" you're likely to find

in other magazines.

First, we don't receive any of the

tools as gifts. We buy them at full price

just as you would. This way we don't

owe anyone any favors.

This also assuresus of getting a regu-

lar production model and not a tool spe-

cially prepared by the manufacturer.

The end result is an honest, unbiased

look at each tool. (In this issue, we fea-

ture circular saws, see page 8.)

And second, instead of providing a

Kurt Schultz

ILLUSTR~IORS Will Niskanen

Roger Reiland

Mark Higdon

PamoaarpHEn Crayola England

oEncn DIREWOR Ken Munkel

SEwloR DEIIONER Kent Welsh

SHOP M~\II~~.ER Steve Curtis

SM(IP-.F~C~LITILS

Steve Johnson

Manager; Gardon C. Geippe . Gmphie Artist-

Cheryl L. Cynor

EORPOI&iL SEr'VICE*

Plenning Director Jon Maearthy. Contra..,..

Robin Hutchinson. Accountiw: Laura Thomas

.Bookkeeping: Julie Greenlee. Prad Manager

Cml Quijano. Info. Services Mgr: Joyce Moore

single viewpoint, we've carefully se-•

lected a team of testers with a wide

range of skills -so that you can easily

identify with one of them.

I'm excited about these new impmve-

ments. Let me know what you think.

Elect. Pub. Coodinator Douglas M. Lidster .

ApplieationSpeeialisC LindaMom.Support

Assistant Nick Thielen Admil~istrativeAssis-

tants: Cheryl Scott, Julia Fish . Receptionist:

JeanneJohnson. Bddi7Lg Mailzt.: Ken Gliffith

Manager: Mark Mattussi - Pmjeet Supplies:

LindaJones. Technical Suppo* Jeff Janes

CUSTOMER SERVICE

Sundoc Jennie Enos- Custom Server

~4s.:

STATEMENT OF OWNERSHIP, MANAGEMENTAND CIRCULATION

(Requjred by 39 U.S.C. 3685)

1. Titleof Publiestion: ShopNotes. la hibliestionNa.: 10629696 2. Date of Filing: September21,1994.3. Frequen~dissue:

Bimonthly. 3a. No. of issues published annually: 6 (sUI 3b. hualsnb~criptionprice:$19.95.4. Campletemailing address of

hown office ofpublieation: 2200 Grand Avenue, Dea Moines, (Polk County), Iowa 50312-5305.5. Complete mailing address of

theheadquarters ofgeneral husineas offices ofthe publisher 220.3 Grand Avenue, Des Moines, Iowa50312-5306.6.Full nvmes

hndeompletemaiiingaddrersofpublisher, editor,sndmansglnge&ttor:PubEsherand Editor: Donald B. Pesehke, 2200Glvnd

Avenue, Des Moines, Iowa50312;ManagingEditor: Richard S. Feters,2200 Grand Avenue, DesMoines, Iowa5a312.7. Owner:

WoodsmithCorporation. 220.3 GmdAvenue, DesMoines, Iowa 50312; Donald B. Peschke,22W Grand Avenue, Des Moines,

Iowa50312.8. Known bondholders,mortgagee~,andothersecUllty

Jennifer Murphx Joy Krause, Sara Kono,

Anna Con, Lonnie Algreen, Karla Cmnin

SHIPPINO MP.RTYENT

Supeniisor ;Nancy Johnson .Fulfillment Gloria

Sheh,ChuckC~onSyIviaCmy, LanyPline

holduaowning1percentormore oftotalamountofbonds,

mofimgesorotherrcluitie.p: None. 9. (Does not apply.] 10. Extent and natare ofe"ru1ation:

Average no. mpies Average no. eopies

ezh isme d"rhg ofsingle issue publuhed

precedingl2months nearesttofilingdate

A. Total no. copies printed (net pressrun1 . ... .. .... ... . .. .... .. .... ..... . .. .. 274,829

ShopNotenm (ISSN1062-86861is published bimonthly

(Jan., Mareh, May, July, Sept., Nor) by Woodsmith Cor-

poration, 22W Grand Ave., Des Moines, IA 50312.

ShopNotes* .anpi.twed~tweddoiW~Co,p

OCoppi&t 1995by Woodsmith Corporation. All

rights reserved.

Subscriptions: Single Copy, $4.95. One year subscrip-

tion (6issues1, $19.95. Two ye- (12 issuesl, $35.95. Cah

damoreign, add $5.W per year.

Second Class Postage Paid at DesMoinw, Wand

at additional offices.

Postmaster: Sendchange ofaddress to ShqlNoles,

Box 11204,Des Moines, iA50340-1204

SubscriptionQuestions? Cail1400-333-5854,Sam

to spm, centrai Time, weeKd~dys.

E.Mail. Prodim EWE97A, Compuserve: 75330,2301,

Intunet: 75330230l@compuseme.eom, American On-

line: Donpeschke.

B. Paid andlur requested armlation:

1. Saies thmugh dealers, street vendors an

240,970

29,032

2. Mail subsmiptions (paid andlor requested

199,697

C. Total paid andlor requested eirmlation

228,729

223,778

9,017

3,175

240,970

ShopNotes

No. 19

ne of the things I enjoy most

about woodworking is the opti-

ClREUUTlDN

Circulation Direetol Liz Bredeson Subsmip-

timManager PhyllisJessen. Direct Mail Mr.:

Troy DoweU-NezusstandSa1es:KentA. Buckton

PUBLISIIINO SERVICEI.

Art Directo~: Cindy Jackson. Catalog Produets

Manage?: Bob Baker - Iwentory ControUProd.

Contents

Projects & Techniques

Hand Plane Jointer 4

This shop-built jig produces a straight, square edge on a

workpiece by converting your hand plane into a jointe,:

Built-up Moldings 12

' A router and some ordinary bits. That's all it takes to

build up your own detailed moldings.

Wall Mirror 14

Use our simple built-up molding technique to make this

handsome wall mirror in just a few hours.

Cutting Guide

A un~que

track~ngsystem on th~s

cutt,ng gu~de

lets you use

saw orrouter toproduce straight, accurate cuts

Routing Rofile5 22

Create decoratwe profiles that are smooth and cons/stent

your c~rcular

w~tha hand-held router and our step-by-stepapproach

Departments

Buying a circular saw? Our team tests eleven popular

saws and offers practical suggestions on what to look for

Great Tips

Pipe Clamp Tips

~rdm

glu;ng up flatpaneisto keep~ngclamps from marnng

the work, here's a collect~on

of our best plpe clamp tlps

The Small Shop

Clamp 5tomge system 24

This convenient storage system organizes all of your

clamps so they're right at hand where you need them.

Readers'Tips

Shop 5olutions 28

Our readers offer their own shop-tested solutions to com-

mon woodworkingproblems. Plus two quick tips.

Lumberyard

Lumber Grain 30

There's more to lumber orain than aooearance. It also

affects the stabil~tyand cost of a projeit.

# Finish Room

Danish Oil 3 1

A natural-looking finish that" easy to apply And you can

repair it too. AN this makes Danish oil worth a closer look.

Clamp Storage System page 2;

No. 19

ShopNotes

Jointer

All it takes to get a perfectly

square edge is a small hand

plane and this shop-built jointer.

piece acrossthe plane here is the depth of the groove.

to produce a clean, Since the blade on a plane

crisp cut. Asanadded doesn't extend clear to its side,

R ecently, one of the small

benefit, we found that

the jointer worked just as well

with large pieces, refer to page 7.

So it's also an ideal project if you

don't have a power jointer.

FENCE. The jointer starts off

as a tall plywood fence (A), see

Exploded View and Fig. 1. To se-

cure thejointer, the bottomofthe

fence tightens in a vise. And the

top supports the workpiece.

GROOVE. After cutting the

fence to size, the next step is to cut

a wide groove. In addition to ac-

cepting the two wood tables, the

groove provides a recess for the

plane. The thing to keep in mind

the groove lets you '%u@ the

blade below the surface of the

fence, see Fig. la. This way, when

the workpiece is held tight against

the fence, the blade removes a

shaving across the entire edge.

TABLES. Once the groove is

cut, you can add the two tables.

Like a power jointer, there's an

infeed and an outfeed table to

support the workpiece.

hand planes in our shop

turned up missing. But even more

mysterious than its disappearance

was the place it showed up - in

this shop-madejointer, see photo.

c&:

It seems that one of the guys

,was looking for a way to get a

,..

straight, square edge on some

pieces that were too small to

plane by hand. Or pass safely

across the power jointer. So he

built a "holder" for the plane that

works like a jointer.

With two wood tables for sup-

port, you simply run the work-

Before determining the length

of these tables, you'll need to po-

sition the plane so the blade is

centered on the length of the

fence, see Fig. 1. Then the tables

are built around the plane.

FENCE

U(PLODED VIEW

OYERALL DIMEN510N5:

lO"WxS6"Lx3WD

SHORT

SUPPORT

BLOCK

OUTFEED

CARRIME

BLOCK

TABLE

BOLT

ShopNotes

No. 19

Hand Plane a

tables are made

by gluing up two pieces of 34"-

thick hardwood. (We used maple.)

It's easiest to start with one long

blank that's ripped to width to fit

the groove, see Fig. 1.

To provide continuous support

for the workpiece, the tables butt

up against the ends of the plane.

So with the plane in position, at

the infeed (B) and outfeed table

the ends of the fence to the plane.

NOTCIL Dependingonthe plane,

you may need to notch the outfeed

table to fit the adjusting mecha-

nism (The notch shown in Fig. lb

provides plenty of clearance for a

standard size block plane.)

CHAMFERS. And to keep your

hand from hitting a sharp corner

if it slips off the workpiece when

jointing a workpiece, chamfer the

exposed edges on the tables and

fence, see Fig. 1.

ATTACH TABLES. NOW

~mThe

TABLE

(W'-THICK PLY.)

CHAMFERS

it's sim-

a matter of gluing the iufeed

table flush at the end. Then use

the plane as a spacer and glue on

the outfeed table.

ADJUSTMENT SCREW. TO en-

Hard ware

(1) #4 x %" Fh

Woodsorew

(2)

sides of a plane aren't necessarily the front knob of the plane. And

90" to the sole. The screw allows ashort block (E) fitsunderthecap.

you to correct for this by tilting To provide a stable work sur-

the body of the plane so the sole face, the bottom ends of the sup-

sure that you end up with a is 90" to the fence, see Fig. 2a. port blocks rest on top of the

square edge on the workpiece, SUPPORT BLOCKS. Next, we when you tighten down the

you'll need to install an adjust- added two support blocks to keep So the blocks are cut to length

ment screw in the groove, see the plane *om falling out of the and glued in place so the bottom

Figs. 2 and 2b. That's because the jointer. A long block (D) supports ends are flush, see Fig. 2b.

No. 19

ShopNotes

!'4-x 3!'zV

Carriage Bolts

(4) v4'' Flat

Washers

(3) 1/4" Wing

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