Woodsmith W0601A PDF

Special Collector’s Edition FREE
+ CD
120
120+ SHOP-TESTED
100
In side
EXT
RA
SHOP-TESTED Tips
TIPS & TECHNIQUES
TIPS &
TECHNIQUES
By
Back
U L A R
POP !nd
Dema
Over 120 Great Tips and Techniques to Help You Get the Most from Your Shop
GET MORE:
Quick Fixes
Router Secrets
Table Saw Tricks
Clamping Solutions For More on Building
Fast Finishing Skills This Tall Featherboard,
Turn to p. 35
A Publication of August Home Publishing
USnewstand1.indd 1 10/29/2008 10:02:47 AM

+TIPS &
120
SHOP-TESTED
TECHNIQUES
President & Publisher: Donald B. Peschke

Executive Editor: Douglas L. Hicks
Creative Director: Ted Kralicek
Art Director: Doug Flint
Sr. Graphic Designers: Robin Friend, Chris Glowacki,
Minniette Johnson, Randy Shebek
Graphic Designer: Lindsay Rees
Associate Editor: Joel Hess
Assistant Editor: Christy Byers
Videographers: Mark Hayes, Craig L. Ruegsegger
Sr. Photographers: Crayola England, Dennis Kennedy
Electronic Image Specialist: Allan Ruhnke
Project Designers: Chris Fitch, Ken Munkel, Kent Welsh
Shop Craftsmen: Steve Curtis, Steve Johnson
Project Designers/Builders: Mike Donovan, John Doyle
Editor: Terry Strohman

Contributing Editors: Vincent S. Ancona,
Mitchell Holmes, Phil Huber, Randall A. Maxey,
Bryan Nelson, Dennis Perkins, Ted Raife
Magazine Art Directors: Todd Lambirth,
Cary Christensen
Contributing Senior Illustrators: Harlan Clark,
David Kreyling, Erich Lage, Roger Reiland,
Kurt Schultz, Cinda Shambaugh, Dirk Ver Steeg
Contributing Illustrators: David Kallemyn, Peter Larson
Contributing Senior Graphic Designer: Jamie Downing
Corporate V.P., Finance: Mary Scheve
Single Copy Sales: Lisa Trom, Sandy Baum
Production Director: George Chmielarz
New Media Manager: Gordon Gaippe
120+ Shop-Tested Tips & Techniques is published by August Home

Publishing Company, 2200 Grand Ave. Des Moines, IA 50312.
Canada Post Agreement 40038201
Canadian BN 84597 5473 RT
Copyright© 2006 August Home Publishing.
All rights reserved. No part of this book may be reproduced in
any form or by any electronic or mechanical means, including
information storage and retrieval devices or systems, without prior
written permission from the publisher, except that brief passages
may be quoted for reviews.
Woodsmith® and ShopNotes® are registered

trademarks of August Home Publishing Co.
For subscription information about Woodsmith or ShopNotes, visit

us online at:
www.Woodsmith.com or call (800) 333-5075
www.ShopNotes.com or call (800) 333-5854
A Supplement to August Home Publications
2200 Grand Ave.

Des Moines, IA 50312
120STTT_Inside FrontCOVrevLOGO.i1 1 10/24/2008 1:13:28 PM

®
+
120 TIPS &
TECHNIQUES
SHOP-TESTED
Letter from the Editor
T
here is no substitute for real-life workshop quality pencil is one of the most important tools you
experience. But unless you’ve worked as a can own for accurate layouts (pages 4-5).
professional cabinetmaker or built custom fur- Many of these tips can be put to use right away in
niture for a living, chances are few woodworkers your own shop. Others will hopefully come in handy
have the experience to handle each and every prob- at some opportune time in the future. Either way, I
lem that comes up. That’s why tips and techniques hope you’ll enjoy learning about some of the practi-
like the ones you’ll find in this book are so popular. cal, common sense solutions you find here.
They fill in the holes and answer the questions that
we’ve all had at one time or another.
In 120+ Tips and Techniques, you’ll find quick
tips, like the one for removing burn marks from
cherry (page 49). Some of the tips use simple jigs,
one example can be used to align your table saw’s Terry Strohman
rip fence (page 34). You’ll even learn why we think a Editor, Woodsmith and ShopNotes
Must-Have
Band Saw Blades 5 Great Baseplates — Easy Router Add-Ons SIMPLE ROUTER TECHNIQUE HASSLE-FREE ASSEMBLY
GUARANTEED!
www.woodsmith.com
®
Vol. 27 / No. 159 GET MORE Vol. 14 Issue 84 www.ShopNotes.com
FAST C LASSIC C
CLASSIC ABINET-B
CABINET -BASE
ASE
Table Saw
Makeover • Projects WORKBENCH
• SMOOTHER
• QUIETER
• SAFER
Heirloom
JEWELRY
• Tips
CHEST
Summer Sizzler
COOL
PLANTERS
• Techniques STOP SEARCHING
FOR DRILL BITS! PLUS:
TABLE SAW
JOINERY
in Every Issue
low-cost MADE EASY!
Classic THE MOST

VALUABLE TOOL
Bookcase build 1, 2, or 3
DRILL
PRESS
CABINET
FOR YOUR SHOP —
IT’S ONLY $$50
A Publication of August Home Publishing A Publication of August Home Publishing
www.Woodsmith.com ORDER ONLINE www.ShopNotes.com
SHOP SAFETY IS YOUR RESPONSIBILITY

Using hand or power tools improperly can result in serious injury or death. Do not operate any tool until you read the manual and understand
how to operate the tool safely. Always use all appropriate safety equipment as well as the guards that come with your tools and equipment
and read the manuals that accompany them. In some of the illustrations in this book, the guards and safety equipment have been removed only
to provide a better view of the operation. Do not attempt any procedure without using all appropriate safety equipment or without ensuring
that all guards are in place. August Home Publishing Company assumes no responsibility for any injury, damage or loss suffered as a result of
your use of the material, plans or illustrations contained in this book.
120STTT_A001rev.indd 1 8/14/2006 2:17:31 PM

+
120
CONTENTS
SHOP-TESTED
TIPS &
TECHNIQUES
Layout & Measuring
Pencils — Your No. 1 Layout Tool .......................................4
A look at the first tool you reach for in your shop. Learn why
pencils may be your most important layout tool.
Tips & Techniques..............................................................6-7
Workshop Techniques
Get An Invisible Plywood Edge ............................................8
How do you end up with a plywood edge that won’t be noticed?
You’ll be surprised at how easy it is to do.
Tips & Techniques..........................................................10-17
Joinery
Tips for Trimming Laminate, pg 14 5 Steps for Perfect-Fitting Tenons.......................................18
It’s really not that hard to get tight-fitting, gap-free tenons in a
short time. In fact, we’ll show you how in five easy steps.
Tips & Techniques..........................................................20-27
Sawing & Cutting

Cutting Perfect Pieces on Your Table Saw ..........................28
Learn how to get your next project off on the right foot, with four
steps for successfully cutting a perfect piece on your table saw.
Tips & Techniques..........................................................30-35
120STTT_C002-003rev.indd 2 8/9/2006 4:08:14 AM

Clamping
Must-Have Corner Clamps .................................................36
Assembling face frames, miters, and plywood cases has never
been easier, thanks to these unique clamps.
Tips & Techniques..........................................................38-39
Stay-Put Clamp Blocks, pg 39
Routers & Router Tables

Three Basic Router Bits.......................................................40
You probably already have the three router bits you need to
make a host of decorative profiles.
Tips & Techniques..........................................................42-49
Hardware
Easy Steps for Installing Brass Screws .................................50
Don’t risk ruining the look of a great project. Take a look at a
few secrets we’ve found for drilling and driving brass screws.
Tips & Techniques..........................................................52-53
Sanding & Finishing

Surface Preparation .............................................................54
Finishing doesn’t have to be a chore. To end up with a profes-
sional looking finish, start with careful surface preparation.
Tips & Techniques..........................................................56-61
Secrets of Shellac, pg 61
Glue Application Chart

Choosing and Using Glue ..............................................62-63
120STTT_C002-003rev.indd 3 8/9/2006 4:08:59 AM

Your #1 layout tool
Pencils
Y ou might not think of a pencil
as a “shop tool.” But whether
it’s tucked behind an ear or slipped
into a pocket, I always have a pencil
at the ready anytime I’m working
in the shop. In fact, a pencil is the
one tool I use on every project. And
since they’re such a shop staple,
it’s my opinion that pencils really
deserve a closer look.
Quality – A standard wood
pencil is such a common house-
hold item that few of us probably
give it much thought. But like any
other tool we use on a daily basis,
there are big differences in quality
among pencils. If you’ve ever used
a cheap pencil you know what I’m
talking about. In fact, you may be
surprised to know that the “wood”
is actually compressed sawdust and
the pencil lead is hard and gritty.
By contrast, better pencils are
still made from incense cedar
(which produces the pleasant, dis-
tinctive aroma when the pencil is
sharpened). And the pencil lead Pencil Grades – Selecting a (No. 2 is the most common.) But
(actually graphite — there is no pencil also involves making a deci- pencils that are sold for drafting
lead in pencils) is carefully manu- sion on the hardness of the pencil are available in up to twenty dif-
factured and graded. General, lead. Everyday writing pencils ferent grades, ranging from a 9H
Dixon Ticonderoga, and Musgrave are usually graded on a four-point (hardest) to a 9B (softest). You can
are a few of the U. S. manufacturers grading system, with No. 1 being the find drafting pencils at most art
still making quality pencils. softest and No. 4 being the hardest. supply and craft stores.
Shop Tips: The Write Stuff
{ White Pencil. I use a white, { Eraser. Just as important as a { Clip-On Sharpener. This pencil
colored pencil for marking dark pencil is a good-quality drafting sharpener clips onto your belt so
woods (like walnut) where an eraser. I keep one in my shop it’s always within reach, allowing
ordinary pencil line won't show up. apron for erasing layout lines. you to keep your pencil sharp.
Layout & Measuring | 4
120STTT_C004-005rev.indd 4 8/9/2006 4:10:24 AM

In the drafting pencil grading < These stainless
system, the letter H stands for hard Slots for steel rules have
and the letter B stands for black. The accurate rows of precisely
numbers indicate the relative hard- marking positioned slots
ness or blackness of the graphite. and holes that
So a 7H is harder than a 2H and a 9B are sized for the
is softer (and blacker) than a 3B. In lead of an 0.5
the middle of the scale are two inter- mm mechanical
mediate grades — HB (hard and pencil.
black) and F (fine or firm) — that Edge
roughly correspond to a No. 2 and a guide
No. 11/2 pencil.
Most of the time, I stick with an
HB or even a 2B. The leads of these
pencils leave a dark line without
having to bear down on the pencil.
90° bend
But I also like to keep a pencil with
for marking
a harder lead (like a 2H) around in
edge of
the shop. The harder lead doesn’t
workpiece
wear down as fast and leaves a
lighter mark I can erase easily.
Mechanical Advantage – Of 0.5 MM
course, wood pencils aren’t the Mechanical
only choice you have. I know sev- pencil
eral woodworkers who prefer to
use mechanical pencils. These pen-
cils typically have a very thin lead. replacement leads are available make a heavy line
(A common lead diameter is 0.5 once the original lead is used up. that’s easy to see. But
mm.) This gives mechanical pen- And like standard pencils, you can if you sharpen the
cils the advantage of being able to buy replacement leads in several pencil to a chisel-like
draw a consistent-width line, even different grades. point (see box below),
as the lead wears away. This makes Carpenter’s Pencil – There’s you can also use it to
them a great choice for precise one other type of pencil that I still draw a fine line. And { Used with a mechanical
layout work. In fact, there are keep around in the shop and that’s like other pencils, you pencil, the slots in this
even some special layout tools for a traditional, carpenter’s pencil. can buy carpenter’s rule make precise layout
use with mechanical pencils (see Although I don’t use it much for pencils with soft, automatic.
photos above and at right). layout work, it’s a good choice for medium, or hard lead.
Another advantage of mechan- less exacting tasks, like marking Finally, for some tips on a few
ical pencils is that they don’t need lumber for framing projects. other pencils and pencil accesso-
sharpening. You simply advance the Carpenter’s pencils have a wide, ries that I like to use, see the box
lead as it wears down. Inexpensive rectangular-shaped lead. So they on the opposite page.
To the Point: Carpenter’s Pencil

A properly sharpened carpenter’s
pencil should have a chisel-like tip on
the end (see main photo at right). In
the past, a utility knife was the only
way to do this. But there are now
sharpeners that make sharpening a
carpenter’s pencil a breeze.
Opposing Blades. These spe-
cial sharpeners have two pairs of
opposing blades. First, you insert the
pencil in one end of the sharpener
and move it back and forth over
the blades to sharpen the faces of
the pencil. Then you simply turn the
sharpener over and insert the pencil
in the other end to sharpen the sides
(see inset photos).
120STTT_C004-005rev.indd 5 8/9/2006 4:11:11 AM

Secrets of the Story Stick
When laying out matching 1 2 USE STICK
dadoes, I like to use a stor y MARK TO TRANSFER
LOCATION DADO LOCATION
stick. It’s simply a piece of scrap OF DADO TO WORKPIECE
ON STICK
that I use like a ruler, but it
only has marks on it where the
dadoes need to be cut.
Advantages – The real
advantage of a story stick is you
don’t have to measure anything. NOTE:
(It’s easy to make a mistake BUTT END OF STICK
AGAINST INSIDE OF CASE
when using measurements and
adding them up.)
With a story stick it’s just a matter of marking the loca- stick against the inside of the case and marking the exact
tions of the dadoes on the stick and then transferring the locations of the dadoes (Fig. 1).
locations to the matching piece. Then with the same end of the stick against the case,
Using the Stor y Stick – To use a story stick for jobs move the stick to where the dadoes need to be cut and
like transferring dadoes, start by butting one end of the transfer the marks (Fig. 2).
“Tip” for Locating Hinge Screws

It’s easy mounting hinges for 1 2
overlay doors to a cabinet. But #4 x #/4" Fh
BRASS CUT OFF FILE IMPRESSION
trying to mark the matching screw WOODSCREW THREADS TO A LEFT IN
POINT DOOR DOOR
locations in the door is a challenge.
I used a couple of shop-made
LOCATOR PIN
pins to help with this. To make HINGE
the pins, file two brass screws to 1 2 3
a point (Fig. 1). (Brass screws file
FILE
down easily.) Then trap a pin in
WOOD-FACED
each of the top and bottom hinges VISE KNUCKLE SIDE
for one door (Fig. 2). OVERHANGS
SIDE
Position the door and press it
against the pins to mark the screw
locations (Fig. 2).
A Handy Layout Tool

I like to secure my case backs with screws so they’re easy CUT SCRAP
RULE IS HELD IN RABBET TO MATCH
to remove. Sometimes I’ve used as many as twenty screws WITH DOUBLE-SIDED LENGTH
TAPE
or more, all spaced evenly around the plywood edge. OF RULE
That’s a lot of screws to lay out.
Layout Tool – To make it easy to mark all the screw 12" SHOP
RULE
holes the same distance from the edge of the plywood, I
mounted a ruler onto a piece of scrap. This eliminated the
need for a tape measure.
First, cut the piece of scrap to match the length of a 12"
shop rule (see drawing). Then, cut a shallow rabbet along
2!/2
the edge to hold the rule in position. NOTE: RULE
IS 1" WIDE &/8 !/2
Cut the width of the rabbet narrower than the rule. This
way it hangs over the edge of the scrap. The amount of CUT
RABBETS
overhang should equal the inset of the woodscrews. TO HOLD
To make it even more useful, cut a rabbet on the other RULE
#/4 %/8
three edges of the tool (see detail). This way, it can be
used to lay out screwholes that require a different inset.
120STTT_C006-007rev.indd 6 8/9/2006 4:12:04 AM

Double-Edged Spindle Turning Template
One year I made several identical projects for gifts. Each of guide has a series of cut-out notches used like a caliper.
them had ten spindles that I turned myself. When turning Pattern Side – The pattern side of the template shows
a single spindle to match a pre-determined pattern, all you where the different contours of the leg pattern are to be
really need is a ruler and caliper. positioned along the length of the workpiece. By holding
Template – But, if you’re making multiple spindles, this side of the template against the workpiece, the position
it’s simpler and more accurate to transfer the pattern to a of each contour can be marked with a pencil (Fig. 2).
full-sized template first. Then turn each leg following the Template Side – As the spindle is being turned, the
template, and they will all be identical. other edge of the template works as an indicator gauge. It
The template is a piece of 4"-wide posterboard cut the shows when you’ve reached the correct outside diameters
same length as the spindle (Fig. 1). What makes this tem- of beads, tenons, and tapers, and the correct inside diam-
plate different is that there are marks along both edges. eters of coves, fillets, and V-grooves (Fig. 3).
Along one edge is a line of “tick” marks that serve as A template like this helps ensure all spindles turned
a ruler for laying out the pattern. The other edge of the from the same pattern look identical.
1 MARK POSITIONS
OF ALL CONTOURS
2 TRANSFER ALL 3
MARKINGS TO
ROUGH-TURNED
WORKPIECE
PLACE
#/4 1 1 &/8 NOTCH ON
1!/2 WORKPIECE
#/4 1!/2 #/4 %/8 1 %/8 TO CHECK
1!/2 1!/8 1 &/8 #/4 %/8 DIAMETERS
CUT NOTCHES TO
MATCH DIAMETERS
OF ALL CONTOURS SUPPORT TEMPLATE
ON TOOL REST
One Good Level Deserves Another

If you’ver ever had to replace a broken vial in an heirloom
level, you know how hard it can be to install a new one. To
get an accurate reading, you need to check it on a known
level surface and adjust it if necessary.
But how can you check that a surface is level if you don’t
have a level? One way is to use a clear plastic tube filled
with water (see photo at right).
To take advantage of this, fit the ends of the tube into
notches in a flat piece of plywood and add water (a drop or
two of food coloring makes it easy to read the level). higher or lower. Then simply shim under the side of the
Then slide one end of the tube up or down until the level where the water is highest until the water columns
water column is flush with the surface of the plywood. are equal. (I used playing cards for shims.) Now use the
This will move the water column at the opposite end either surface to check your level.
Drawing a Simple Oval

You don’t have to be a
whiz kid in geometry CENTERLINES
OF OVAL D 1!/2 D D
to draw an oval. A B
A B A B
Points, Circles
and Arcs – First, 3!/2
C 1!/2 C C
only four points need 1!/2"
1!/2 1!/2 RADIUS TANGENT LINE
to be drawn. Then CONNECTS CIRCLES
all you have to do is
draw two “circles”
and two “arcs” using 1 From the center of the oval, Use centerpoints A and B
measure and mark the cen- 2 to draw two 3" circles to 3 Use centerpoints C and D
to draw arcs connecting
a compass. terpoints A, B, C, and D. form the ends of the oval. the tangents of the circles.
120STTT_C006-007rev.indd 7 8/9/2006 4:12:40 AM

Get an Invisible
Plywood Edge
Y ou want to hide the edges of
your plywood panels, but you
don’t want the edging to show. It’s
not as hard as it sounds.
I use plywood in my projects
all the time. It makes the job go
easier and the quality of the project
better. But there is one drawback
to plywood — the exposed edges.
To put it simply, the edges of ply-
wood can be downright ugly.
And more often than not, they need
to be hidden.
For some projects, I’ll simply glue
on a 1/4"-wide strip of solid wood,
trim it flush and not worry too much
if the edging doesn’t “blend” well.
But other times, you might want to
apply an edge to the plywood that’s
A thicker edging a little more subtle — an invisible
strip can be edge. Sound impossible? Well there
trimmed to leave are actually a number of ways to
a thin edge. } accomplish this without too much { Heat-sensitive veneer tape can be easily applied to the plywood edge with a
extra effort. warm iron. When trimmed flush, the thin veneered edge won’t be noticed.
Make It Thin tape that’s made specifically for

When your edging is thin enough, it this purpose. It comes in rolls and
becomes nearly impossible to see. is made from very thin hardwood
Edging that’s only 1/32" to 1/16"-wide veneers. You can find it in most of
won’t be noticeable except under the common wood species.
the closest examination. And there There are two types of edging
are several different “thin” options. tape and both are pretty easy to
Edging Tape – One of the apply. The self-adhesive type works
quickest and easiest options for thin just like sticky tape. It can be applied
plywood edging is adhesive veneer with just some firm pressure.
PIECE OF
SCRAP
PLYWOOD
CUT EDGING STRIP
< A thick edging piece LOOSE WITH UTILITY
KNIFE AND
glued into a rabbet in STRAIGHT EDGE
FACE
the edge of the plywood VENEER
leaves an invisible seam.
RABBET PLYWOOD EDGE

LEAVING FACE VENEER
EEdging From Plywood. To make CCut It Loose. Next, use a sharp

thin edging from plywood scraps, utility knife to cut the veneer strip
THICK EDGING first make a saw cut on the joint from the plywood panel. The
STRIP GLUED
INTO RABBET line between the face veneer and edging will be a perfect match in
the plywood core. grain and color.
Workshop Techniques | 8
120STTT_C008-009rev.indd 8 8/9/2006 4:13:35 AM

The heat-sensitive edging tape but still
takes only a little more work. It has a creates an
coating of adhesive on one side that invisible edge
can be activated with “gentle” heat. on one face of the
All you do is set it in place and use plywood.
an iron to apply the heat, as shown The trick here is
in the photo above. Both types shown in the drawings on
of edging tape are made slightly the bottom of the previous
oversized in width. Once the tape page. First, the plywood edge is
is stuck firmly in place, you trim it rabbeted so that only the thin face
flush to the surface of the plywood veneer of the plywood remains on
and you’re done. one side. When a thick edging strip
Trim It Thin – Sometimes I want is glued tightly into this rabbet,
a thin edge that will hold up to a little the joint line between the thin face { A round-over
more wear and tear than edging veneer and the edging strip disap- or chamfer
tape. So in this case I make my own pears. You end up with what looks routed onto the
slightly thicker edging, as shown in like a seamless, solid-wood edge. edging strip will
the upper example at far left. This technique involves a little more provide a disguise
The easiest way to do this is to work, but it works like a charm. for the joint line.
start thick and end up thin. By this
I mean you apply a thicker edging Disguise It
(about ¼" thick) to the plywood and Making it thin isn’t the only way to
then trim off the excess on the table hide your plywood edging. Another END OF CUT
FALLS AT
saw. A final thickness of about 1/16" strategy involves using a thicker JOINT LINE
gives you a little more durability edging piece and then disguising it.
at the edge, but it still isn’t thick The idea is to visually blend the ply-
enough to be noticed. wood and the edging piece so that
A Perfect Match – If you want to the transition from one to the other
apply a thin edge and also ensure a won’t be noticeable.
perfect match between the edging I start by gluing a standard 1/4"-
and plywood face, the two drawings thick edging strip to the plywood !/4"
ROUND-OVER
on the opposite page show you how. and then trimming it flush to the BIT
This method uses the thin, face surface. Then I add a little some-
veneer from a scrap piece of the thing extra. A molded edge that Smooth Transition. A carefully
same plywood as the edging piece. easily draws your eye from the routed round-over ending right at
When it’s glued to the workpiece, edging to the plywood face can suc- the joint line between the edging
you have both a thin edge and one cessfully hide the joint line or any and the plywood can fool the eye.
with the same grain and color as the grain or color difference between
plywood face veneer. the two pieces.
A Different Approach – Another The drawing and the photo above panel will be seen from both sides,
way to go “thin” with edging takes give you the idea. The edges of the make a second cut on the bottom
a unique approach. Here, the ply- routed molding cuts (chamfer or edge. You still have edged plywood
wood veneer provides the thin roundover) on the edging strips but you would have to look pretty
edge. A thicker edging strip is used, fall right at the joint line. And if the close to see it.
Shelves: Beef It Up
On occasion you not only need to And then notice how I borrowed
hide the edge of the plywood, but the trick shown above to disguise the
also add some extra strength and edge. A simple round-over creates
thickness. Heavy-duty bookshelves a seamless flow from the plywood
come to mind. So how do you do this panel to the solid-wood edging.
and not make it look obvious? Well, Splined Miter Edging. The
a couple solutions are shown in the second example (lower shelf) uses
photo at right. a similar idea but with a different
Rabbeted Edging. The first style of joinery. Here I applied a stout A thick edging piece
example (photo of top shelf at right) piece of edging with a carefully cut carefully joined to
shows a thick rabbeted strip applied splined miter joint. The resulting the plywood not only
to the plywood that adds both visual invisible joint and crisp edge will hides the “core,” but
thickness and a considerable amount leave anyone guessing — is it ply- also adds strength
of stiffness. wood or solid wood?
120STTT_C008-009rev.indd 9 8/14/2006 2:34:50 PM

Shop-Built Door Pulls
I like to build authentic-looking wooden door pulls for my To form the
Craftsman-style furniture. The fact is, they’re simple to tenons, you
make and all you need to do it is a long piece of scrap, a simply cut a
couple of router bits, and a 1/4"-wide dado blade. narrow dado
Start by selecting an extra-long blank for a couple of pulls all the way
(Fig. 1). (I used a piece of 3/4"-thick cherry for mine.) The around the
extra length makes the blank safer to work with. blank. I like to
The first step in shaping this style of pull is to rout a use a 1/4"-wide
chamfer around each end of the blank (Fig. 2). Next, rout a dado blade (Fig. 4).
cove around each end using a 1/2"-dia. core box bit (Fig. 3). (Or you could use a 1/4"
Now, before cutting the pulls from the blank, it’s best straight bit in a router table.)
to form the tenons that fit into mortises that are cut in the All that’s left now is to sand the pulls smooth
doors. Since the tenon is in the middle of the blank and not and cut them from the blank. Then glue them into
at the end, this cut looks a little odd. the mortises in the doors.
NOTE:
1 CUT HANDLES 2 3 ROUT FINGER 4
FROM BOTH !/8" ROUTER
RECESS
ENDS OF BLANK CHAMFER CUT TENON TO MATCH
TABLE MORTISE IN DOOR
FENCE !/4
&/8
!/8
BLANK
#/16 !/4
CHAMFER !/2" CORE !/4"-WIDE

DOOR PULL BLANK BIT BOX BIT
#/4" x 4" x 10" ROUGH DADO BLADE
Making and Using a Push Stick

Ever y table saw should hand, I rounded the handle 1 2
come with a good push with a 1/4" roundover bit. 1"GRID !/4" ROUNDOVER
stick. Most don’t — so the To prevent kickback ON ALL EDGES
EXCEPT BOTTOM
best solution is to make when cutting thin strips,
one of your own. be sure that the heel of the #/4" RADIUS
The one shown here is big push stick hooks over the 9
enough to keep your hands strip between the blade and
!/2"RADIUS
away from the blade. And the fence (Fig.3).
9#/4
it can easily be made (or When ripping wider TRIM OFF USED
EDGE TO FORM
repaired if it gets chewed pieces, center the push CUT FROM #/4" MATERIAL NEW BOTTOM
up). But most important, stick between the blade
it allows you to hold the and the fence (Fig. 4).
workpiece down tight
against the table as well as 3 4
push straight ahead.
I made my push stick
out of a piece of scrap 3/4"
medium-density fiberboard
(MDF) but you could also
use plywood. First cut it to
the shape shown in the grid
drawing (Fig. 1). The base
area is wide so that you can
recut it and create a new
bottom and heel if it gets
chewed up (Fig. 2).
To make it easier to grip
and comfortable on the
120STTT_D010-011rev.indd 10 8/9/2006 4:14:51 AM

Aligning and Clamping Edging
When I install edging onto a set of fixed shelves in a book-
case, I like to do things a little differently than normal.
Instead of installing oversize pieces that get trimmed flush FIRST: CUT
SCRAP EDGING TO
before the shelves are installed, I prefer to cut the edging BLOCKS FINISHED SIZE
to exact size and glue it in place. MASKING
The reason for doing things differently is the narrow TAPE
edge on the shelf. It’s too easy for the router and flush trim
bit to tip and gouge the edging. By cutting the edging to SECOND:
USE BLOCKS
an exact fit, only a little light sanding is needed. TO KEEP
EDGING
But one problem you run into when applying edging ALIGNED
this way is keeping it aligned with the edge of the ply-
wood. After the glue is applied, the edging seems to want
to slide out of place.
My solution to this problem is to use scrap blocks to help THIRD:
align the edging. First, I clamp the scrap blocks to both APPLY GLUE
AND HOLD
sides of the shelf (see drawing). The blocks form a slot for EDGING IN
PLACE
the edging to fit into. WITH TAPE
To “clamp” the edging in place, I’ll use masking tape to
pull it tight against the shelf until the glue dries.
Burnishing a Miter
Building a box with outside miter joints To burnish a miter CLOSES GAP
AT OUTSIDE
mitered corners looks that’s commonly used like this I simply use a CORNER OF
MITER
great. But a lot times, I on base moldings in screwdriver. The trick is
end up having a problem houses. You just “bur- to hold the screwdriver
at one or more corners nish” the corners. at a ver y slight angle
of the box — the miter When an outside to the workpiece. Then PRESS HARD
AND MAKE
joints have a slight gap miter has a 1/16" or less press down hard to ONE SMOOTH
STROKE DOWN
on the outside edge. gap you can roll both bend the fibers slightly EACH FACE
Luckily, there is a neat sides of the joint over to as you stroke down the
little trick for closing fill the gap. miter joint.
Bench Board Support

A lot of the old, heavy traditional-style work-
benches had a big, bulky support called a
bench slave for holding the ends of long boards
that are clamped up in a bench vise. They were
used mostly when jointing the edges of longer
boards with a hand plane. The problem is a
bench slave takes up a lot of space when it isn’t
being used and it’s a hassle to drag it out every a.
time you need to use it.
BUTT
Recently, I built a new, heavy-duty work- HINGE
SWING
bench for my new shop. And with my new BOARD SUPPORT
bench, I decided to use a simpler design for OUT TO HOLD
ENDS OF LONG
the support. To do this, I made a board support WORKPIECES
out of a scrap piece of 2x4 (see drawing and
detail at right). Then I attached it to the leg of
my workbench with a butt hinge. BOARD
SUPPORT
Now, when I need to clamp up a long board, MADE FROM
2X4 STOCK
I just swing out the board support. When I’m
done, it just folds back under my bench.
120STTT_D010-011rev.indd 11 8/9/2006 4:15:53 AM

Saw Your Leg Blanks Square
I like to use turning squares when I make cabriole legs face “A.” For a clean cut, I ripped this face in shallow incre-
for projects like a Queen Anne end table. But even though ments, raising the blade slightly between each pass.
they’re called turning squares, I’ve rarely seen one with Here’s where you’ll have a bit of a problem. A 10" blade
two square (90°) faces over its entire length. The easiest can’t be raised high enough to cut all the way through a
way to square one up is with a jointer. But, if you don’t own 3" turning square. So to solve this, I removed the square
a jointer, this job can also be done on a table saw. from the jig and planed down the extra lip (Fig. 2).
Squaring Jig – To cut the leg blanks square using the Next, turn the square one quarter turn (Step 2), nail it
table saw, I built a jig out of a couple pieces of scrap. The back in place on the jig, and adjust the rip fence to cut the
jig keeps the blank from rocking and twisting while it’s next surface “B.”
being ripped and also helps in squaring up the blank. Two Square Sides – Once again, make the cut in incre-
To make the jig, nail a piece of tempered hardboard at ments and plane it flat. At this point surfaces “A” and “B”
90° to a scrap of 3/4"-thick stock. The hardboard should should be square to one another.
be about as long as the blank. To make the final two cuts, the jig won’t be needed. Just
After the two jig pieces are nailed together, position the set the rip fence for the finished width and cut surface “C”
turning square on the inside corner of the jig and tack it (Step 3), and finally surface “D” (Step 4).
in place with several finish
nails (Fig. 1). 1 2
Note: Remember to tack
TACK PLANE DOWN
toward the ends of the JIG TO EXCESS LIP
TURNING FLUSH WITH
blanks where the nail holes SQUARE CUT SURFACE
can be cut off when cutting AT BOTH
ENDS
out the leg profiles.
Four Steps – Next, I
!/4"
follow a sequence of four HARDBOARD
PLATFORM
cuts until the four sides are
90° to one another. First,
place the jig on the table
saw with the jig set against 3
the rip fence and the A
A B
hardboard face down C A D B
A B
(Step 1 in Fig. 3). C
Now set the fence so the STEP 1 STEP 2 STEP 3 STEP 4
blade will make a cut along
“Trim” the Trim for a Tight Fit

The success of a great project depends on the fit of the Carpenter’s Fix – This is the same problem faced by
parts. This is especially true for trim such as case blocks carpenters who install trim molding in houses. Their solu-
that are applied to the face of a project. tion is to use molding that’s milled with a shallow “relief”
Case Blocks – These blocks add a distintive touch on a on the back side. With the relief cut the piece is able to flex
formal bookcase and are often used to hide end grain on so that it fits up tight against a wall.
the side pieces of a base or pediment. The blocks should So I cut a shallow channel across the back side to create
fit tight to the case along their edges. But if the blocks are relief behind the block (Fig. 2). Note: In order to avoid
cupped even slightly the edges won’t fit tight (Fig. 1). weakening the block, only cut the channel 1/16" deep.
1 CUPPED PIECE OF RELIEF ON BACK OF MOLDING 2

MOLDING CAUSES GAP PERMITS TIGHT FIT
AT JOINT LINE a.
CUT RELIEF
!/16"-DEEP
LEAVING
!/2"-WIDE
SHOULDER
CUT RELIEF IN
MULTIPLE PASSES
OVER DADO BLADE
120STTT_D012-013rev.indd 12 8/9/2006 4:17:13 AM

Applying Flexible Veneer
When veneering a small project, I there are any voids in the surface, use Instant Bond – But a word of cau-
typically use flexible veneer. (Other a wood filler to level them out. tion. As soon as the two cemented sur-
types of veneer are available, but they After applying a wood filler, sand faces touch, they’re stuck for good.
don’t work as easily.) the surface smooth. Then, I like to So, to avoid prematurely sticking
Paper Backing – Flexible veneer remove any dust by wiping the sur- the two pieces, first cover the dried
has a paper backing that keeps the face with denatured alcohol. substrate with a sheet of waxed paper.
thin hardwood veneer from cracking Now, cover both the veneer and the Then position the veneer.
as it’s rolled onto a project. (Don’t try substrate with two coats of nonflam- When the veneer is down, slowly
to remove this paper.) mable, solvent-based contact cement. pull out the waxed paper (Fig. 1).
Before applying veneer, clean up After the cement dries (in about 15 As you’re removing the paper,
the substrate. For the best bond, it minutes), the veneer is ready to be flatten the veneer with a roller. This
must be smooth and free of voids. If applied to the substrate. improves the glue bond and squeezes
out air bubbles.
1 2 Roll It Out – After the waxed paper
is removed, I roll out the veneer again,
NOTE: USE EDGE OF
IF WAXED PAPER SUBSTRATE TO GUIDE starting in the center and rolling
STICKS TO CEMENT, RAZOR KNIFE
ALLOW ADDITIONAL towards the edges.
DRYING TIME After rolling out the bubbles, the
veneer can be trimmed to the edges
of the workpiece with a razor knife or
WALLPAPER veneer saw (Fig. 2).
SEAM ROLLER
Note: Before trimming the edges,
inspect the grain direction on the
REMOVE WAXED PAPER
AS VENEER veneer. Then cut with the grain first
IS ROLLED DOWN
to avoid tearout.
Old-Fashioned Way To Install a Drawer

Sometimes, I’ll install drawers so that they ride on simple Now the depth of the grooves needs to be established.
wood guides. To make this work, you have to cut grooves Your goal is a tight fit with no side-to-side movement. The
in the drawer sides. And to get the drawers to slide in and best way to do this is to sneak up on the final depth (Fig. 2).
out easily, the grooves need to be sized exactly. (I started by cutting the grooves just under 1/4" deep.)
Note: Before I install the wood guides, I like to chamfer After making a pass on each side of a drawer, test the fit
their outside edges first (Fig. 1a). This prevents the cor- of the drawer in its opening. If it fits too tight (or doesn’t fit
ners from breaking with use. at all), raise the blade a hair and cut the grooves again. But
Two Steps – Getting all the grooves to fit the guides is remember, you’ll be cutting both grooves deeper, so make
a two-step process. First, I cut the grooves so each drawer blade adjustments very small.
fits tightly on its guides. Then I sanded the grooves until When each drawer fits snug in its opening, sand the
the drawers slid smoothly. bottom of the grooves until the drawer slides smoothly
A dado blade in the table saw works best to cut the (Fig. 2a). But don’t sand the full length of the grooves,
grooves. Use a scrap piece to test the width (Fig.1). Then only the high spots.
set the rip fence so the grooves are centered on the sides Finally, apply some wax to both the grooves and the
of the drawers. drawer guides for even smoother sliding drawers.
1 2
a. CHAMFER
a.
EDGES OF SAND BOTTOM
DRAWER GUIDE OF GROOVE
FOR SMOOTH FIT
GUIDE
SNEAK UP ON
DEPTH OF GROOVE
USE SCRAP
TO TEST WIDTH
OF GROOVE
120STTT_D012-013rev.indd 13 8/9/2006 4:17:38 AM

Apply Your Own Laminate
I recently finished building a bed- slippery glue. And the instant bond roller to press the laminate down as
side table with a pull-out tray. I really allows you to roll out the surface to you go (Step 1).
liked it because it provided a conve- remove air bubbles. After the dowels have been removed,
nient place to set a drink or snack. The first thing to do is to apply a use the roller to work from the center
And because the tray is covered with coat of contact cement to both the of the panel out to the edges. This will
plastic laminate, I didn’t need to worry oversized laminate and the plywood help remove any trapped air bubbles.
about a spill ruining the finish. tray panel. You’ll know the pieces are And don’t be afraid to really bear down
But applying laminate can be tricky ready to be joined when you touch the on the roller. The more pressure you
and you can quickly get yourself in cement and it feels tacky, but doesn’t apply, the better the bond will be.
trouble if you don’t follow a logical stick to your finger. Trim Flush – After the laminate
sequence. The easiest way to do it is Spacers – When you’re ready to is in place, it needs to be trimmed to
to use contact cement, a roller, and a fasten the laminate to the tray, you match the panel. This is easy to do
flush trim bit to enen up the edges. don’t want the pieces to touch until with a flush trim bit in a hand-held
Contact Cement – Many expe- the laminate is properly positioned router. Just set the bit so the bearing
rienced woodworkers prefer using over the plywood. To allow you to do rides on the plywood and rout around
contact cement to attach laminates this, set some dowels on the panel to the panel (Step 2). Then lightly sand
and veneers to a substrate. That’s serve as spacers (Step 1 below). the edges. But be careful not to round
because once the mating surfaces Roll Out – Once the laminate is over the edges. If you are adding edge
touch, that’s where they will stay. in position, start from one end and trim to the panel, you want a tight joint
There’s no sliding around on wet, remove one dowel at a time. Use a between the panel and the edging.
1Before positioning the oversized laminate, lay a series of There’s a good reason for cutting the laminate oversized.
dowels on the plywood. Then when the laminate has 2 This way, you have some “play” room when you position
been properly placed, remove the dowels one at a time and it over the plywood. Trim the laminate even with the ply-
roll the laminate down. wood with a flush trim bit in a hand-held router.
Safely Cut Thin Edging Strips

To cut thin strips safely, I rip them off the waste side of the
stock. The problem is, it’s hard to set the rip fence so they
end up a uniform thickness. So to make this easier to do, I a. PANHEAD
use a simple stop system. On the edge of this stop there’s SCREW
a “fine tuning” screw.
To use the stop system, first move it alongside the blade
and adjust the screw until the distance between the saw
blade and the screw equals the thickness of the strip
you’re trying to cut off.
USE SCREW TO
Safety Note: Secure the stop 3" in front of the blade. ADJUST STOP RUNNER
SCREW TO FROM SLIDING
Next, slide the workpiece against the screw. And then DETERMINE
THICKNESS OF STRIP
slide the fence against the workpiece. Lock down the
fence and cut off a strip. To cut strips exactly the same
width, slide the workpiece and fence against the screw
again and reset the fence.
120STTT_D014-015rev.indd 14 8/9/2006 4:18:22 AM

Label Cutoffs Invisible Cleats for Hanging
Have you ever considered how much This hanging system works great for BACK
time you waste sorting through a heavy shelves that hang on wall studs.
stack of scraps in your scrap bin, It consists of two beveled strips that DRY- WALL
WALL STUD
looking for “just the right piece?” As interlock and permit the mounting
SHELF
you know, it can be really frustrating. screws to be located anywhere.
Magic Marker – Even in a large The beveled cleat is ripped from
stack of cutoffs, it’s quick and easy to one edge of the back piece. Then the
HANGING
find the size you need if you mark the cleat is screwed to a pair of studs. CLEAT
dimensions on the ends of the stock. After it’s finished, hang the shelf on
I keep a wide-tipped permanant felt the cleat so the mating bevels interlock.
marker in the workshop to make the Note: This system can be easily
markings easy to read. adapted to just about any project.
If you have enough space, it even
makes sense to separate the scraps
by species, like you can see in the
photo below.
Preventing Vise Rack
One of the problems with vises is that CLAMP BLOCK IN END
WORKPIECE OF VISE TO PREVENT
they can rack. If you tighten down a RACKING
piece of wood in one end of the vise, CUT BLOCK TO
the other end toes in. COMMON THICKNESSES
This racking means pressure will

be applied only to one edge of the
workpiece, causing the assembly to
pivot or spin as you work on it.
To prevent this, I made a stepped
block. Then I choose the thickness
on the block closest to my workpiece { Notched Block. For workbenches
and slip it into the other end of the that have a heavy bench vise with a
vise. Once it’s tightened down, the wood face, I use this notched block to
workpiece is held tight. prevent vise rack.
Quick Tips for Attaching Brass to Wood

When I need to attach brass to wood, Shank Hole – Next, I switch to a
I like to use cyanoacrylate glue (CA) 1/8"-dia. bit and drill a 3/16"-deep shank
and brass screws. The “instant” glue hole centered over the pilot hole.
holds the brass in place temporarily Countersink – Finally, I add a
while I drill pilot and shank holes and shallow countersink to the brass
the countersink (Fig. 1). plate. The reason you’ll want this
Pilot Hole – Most of my projects countersink a little shallow is to leave
that incorporate brass inlays or over- the screw head standing just proud of
lays, are custom-made hand tools the brass strip.
that require small brass screws. So to The screws keep the brass strips
install them I start by drilling a 1/16"- attached over time. After the screws
dia. pilot hole, 1/2" deep, through the are in place, the heads are filed off
brass and into the workpiece. flush and sanded smooth (Fig. 2).
1 CROSS SECTION 2
COUNTER- FILE HEAD OF
SINK #/16 SHANK SCREW FLUSH
HOLE WITH BRASS STRIP { Perfect Fit. Using this simple
method for countersinking and filing
PILOT a brass screw results in an almost
HOLE !/8
invisible fit between the screw and
!/16
the brass strip.
120STTT_D014-015rev.indd 15 8/9/2006 4:18:54 AM

Installing a T-Nut Gluing Up a “Flat” Panel
Normally, I use a hammer to tap a T- Gluing up a bunch of narrow boards This depends on the growth rings on
nut (with prongs) into a workpiece. to make a wide panel of solid wood the end of each board. If you alter-
But sometimes there just isn’t enough seems like such a simple thing. But nate the rings, each board moves in
room to swing a hammer So I like to there’s a little more to it than first opposite directions. The end result is
use a large plastic wing nut and a bolt meets the eye. a panel that stays flat.
for this installation instead. The goal is to end up with a panel Glue Up – After you have the
Start by threading the bolt all the that looks like a single, wide piece of boards arranged, you still have to
way into the T-nut. Then slip the bolt wood. But it also has to be perfectly glue them up. Once you start, you
and the barrel of the T-nut into the flat (and stay that way). Reaching need to work quickly to get the panel
pre-drilled hole in the workpiece. this goal is a two-step process — first, flat — and to keep it that way while
Now, to seat the T-nut, just thread the boards are arranged to consider the clamps are applied.
the wing nut on the end of the bolt. appearance and movement. Then the One trick that will save some
Tightening the wing nut will tightly boards can be glued up. assembly time is to apply glue to only
draw the T-nut prongs into the work- Arrangement – The first step is to one edge of each joint (detail ‘a’).
piece (see photo). arrange your boards for uniformity. Then, to keep the panel from
This means matching the color and bowing as you tighten the clamps,
grain pattern of adjacent boards (see alternate clamps above and below the
photos below). panel every 6" (see drawing).
In addition to appearance, you’ll Finally, if the boards aren’t exactly
also need to consider how the panel flush, whack them with a mallet and a
will move with changes in humidity. block of wood (detail ‘b’).
a.
APPLY GLUE
TO ONE
EDGE ONLY
Bench Dogs SPACE CLAMPS

6" APART
b.
Bench dogs improve the versatility
SCRAP
of any workbench. Early versions fit BLOCK
into square holes and were made out
of wood. Or they can be made round
so that they fit into round holes.
A quick and easy way to make a
bench dog for round dog holes is by
cutting the threads off a large bolt and
then grinding the sides of the head at
a slight downward angle.
{ Curved Grain. With curved grain, { Straight Grain. Boards with side-
arrange adjacent boards so curved by-side, straight-grain create an
grain patterns “merge.” almost invisible joint.
120STTT_D016-017rev.indd 16 8/9/2006 4:19:31 AM

Installing Wood Plugs
Occasionally on a project, I’ll have exposed screw 1
heads that need covering. That’s when I use WOOD PLUGS
plugs. Wood plugs are usually available in three BUTTON
OVALHEAD
styles (Fig. 1). And the three most common
diameters available are 1/4", 3/8", and 1/2". FLATHEAD
Installing Plugs – Each type of plug is unique

in the way it’s installed. Flathead and button
plugs are simple to install. Ovalhead plugs, how-
ever, can be driven in too far, flattening the top.
With ovalhead plugs, you’ll need a simple
way to install them without flattening the tops.
So I made a plug setter that matched the plug’s
rounded top (Fig. 2). 2 3 PLACE SETTER ON
Construction – To make the plug setter, I PLUG AND TAP
a. DON’T
DRILL
first cut a 3/4" dowel, 11/2" long. Then I drilled a PAST
BEVEL
shallow hole in one end of the dowel with a 7/16" ON
twist drill bit (Fig. 2). BIT
Set the Plugs – Once you’ve completed the

plug setter, it’s easy to use. First, position an DRILL HOLE a.
WITH &/16" TWIST
ovalhead plug in a hole and place the setter over DRILL BIT FOR #/8"
the plug. Then, tap the setter just until it bottoms OVALHEAD PLUGS
out on the workpiece (Fig. 3a). OVAL-

HEAD
Note: Don’t tap on the setter after it bottoms PLUG SETTER MADE PLUG
FROM #/4" DOWEL (1!/2" LONG) PLUG
out or you could leave a doughnut-shaped dent SETTER
in the work surface.
Thin Strip Push Block

Sometimes when ripping very narrow stock, I don’t feel fence, plus 3/4" for the thickness of the spacer (Fig. 1).
altogether comfortable using a push block that’s designed To cut the stepped cuts on the piece that faces the saw
mainly for wider stock. And it’s nice having more than one blade, lay out and cut a stair-stepped design. Each step is
option in the workshop. So I also built a push block that 1/4" high and 1/2" wide. (I cut mine using the band saw.)
straddles my rip fence (refer to Fig. 2). Next, glue the face pieces to the spacer so their bottom
Stair-Step Notches – This version is made from two edges ride on top of the saw table and the spacer clears the
face pieces of 1/4" hardboard and a spacer. And for dif- top of the rip fence.
ferent thicknesses of stock, I cut stair-step notches on the Handle – Then, to get a secure grip on the push block,
front end of the hardboard face nearest the blade. I drilled a 3/4"-dia. hole and glued a 3/4"-dia. dowel near the
To make this push block, start by cutting a 3/4"-thick back of the spacer.
spacer to width to match the thickness of your rip fence. Using the Push Block – To use this push block to rip
Note: The width is critical because the push block narrow stock, first set it over the fence with the notch on
should fit snugly over your rip fence, but not so tight that it the push block over the workpiece.
binds when it’s being used. To help hold the stock tight against the fence, you can
Cut the two hardboard face pieces 7" long and high use a featherboard or just hold a piece of scrap against the
enough to clear any adjustment bolts on the top of the rip piece while cutting (Fig. 2).
1 POSITION SPACER CUT SPACER

2
TO CLEAR RIP FENCE WIDTH TO
FIT RIP FENCE
7" SPACER SHOULD
CLEAR TOP OF FENCE
!/4"
HARDBOARD
CENTER
!/4" #/4" DIA.
!/4" DOWEL HANDLE
!/4" ON PUSH
BLOCK
!/2" !/2" !/2" HOLD WORKPIECE TIGHT

TO FENCE WITH PIECE OF SCRAP
120STTT_D016-017rev.indd 17 8/9/2006 4:20:03 AM

5 Steps For
Perfect-Fitting Tenons
1 Cheeks & Shoulders As shown in the drawing below, make your first cuts at the end of
For many woodworkers, a perfect- a miter gauge with an auxiliary the tenon. Check the rough thick-
fitting tenon starts with a dado blade fence backs up the workpiece, pre- ness and then work back toward
on the table saw. With this method, venting chipout, and the rip fence the shoulder. The final pass along
you’re going to establish the long is used as a stop to define the final the shoulder should be very light.
shoulders and waste away most of length of the tenon. At this point, the tenon will be cut to
the material on the cheeks. With the blade set slightly low, length, but still just a hair thick.
AUX. MITER
GAUGE FENCE
RIP FENCE
WORKPIECE
WIDE DADO
BLADE
a.
END VIEW
LEAVE SMALL
AMOUNT
OF WASTE
NOTE: USE THE DADO ON CHEEKS
BLADE TO “ROUGH OUT”
THE CHEEKS AND
CUT CLEAN SHOULDERS
{ In the first step of cutting a

tenon, the cheeks of the tenon are
roughed to a thickness that just
begins to fit the mortise.
Joinery | 18
120STTT_D018-019rev.indd 18 8/9/2006 4:20:39 AM

2 The End Shoulders Use the same rip fence setup you leave score marks
Step two is where you’ll cut the tenonused to cut the cheeks of the tenon. or possibly chip the
to final width and establish the two Begin by setting the dado blade long shoulders. As
end shoulders. The drawing below slightly low so you can sneak up on illustrated in detail
shows how to proceed. the width of the tenon. Now with the ‘a,’ you want to leave
workpiece on a little material here
edge, start to to be carefully pared
AUX. FENCE waste away the away later.
material at both Once the width
ends of the of the tenon is per-
tenon. Check fect, the work at the
SNEAK UP ON
FINAL WIDTH
a. the progress as table saw is com-
RIP OF TENON
FENCE
LEAVE
you go, gradu- plete. The photo at { A sharp chisel
WORKPIECE MATERIAL ally raising the right shows where to go from here. will make a
ON END
SHOULDERS blade. With the workpiece firmly clamped quick job of
TO BE But don’t cut in the workbench vise you can pick squaring the
PARED AWAY
right up to the up a sharp chisel to complete the end shoulders.
shoulders of work on the end shoulders. Several Shallow paring
WIDE DADO
BLADE the tenon. It’s shallow slicing cuts will remove the cuts will leave
too likely that remaining material easily and leave them clean.
the blade will a clean, square shoulder.
3 A Custom Fit Start at the end of

the tenon and work
WORK ACROSS THE
CHEEKS WITH
At this point the shoulders are cut FINE CUTS
around all four sides of the tenon. back with light cuts,
The width is perfect but it’s still a removing the same
little “fat” through the thickness. So amount of material
USE SMALL SHOULDER
now it’s time to achieve a custom from both sides. To do PLANE FOR A SNUG
fit. To do this, you’re going to care- this, take a couple of CUSTOM FIT
fully trim the cheeks of the tenon passes on one side and
for a snug fit in its mortise. And for then switch faces.
this job, my tool of choice is a small With just a little
shoulder plane. work, the tenon will
A shoulder plane gives you the begin to slide deeper
handy combination of a fine cut with into the mortise. If it NOTE: REMOVE EQUAL
great control. You can work across takes more than firm AMOUNT OF MATERIAL
FROM BOTH CHEEKS
the cheeks of the tenon without fear pressure to seat the
of tearout (right drawing). So main- tenon, trim some more
taining a flat surface is easy. and test it again.
4 Undercut NOTE:
5 A Quick Chamfer
Now your tenon is a perfect match UNDERCUT Now you have a mortise and tenon
ALL FOUR
with its mortise. But you also want SHOULDERS joint with a perfect look and fit. To
OF TENON
the joint to look as good on the out- make certain that this is still the case
side as it fits on the inside. So the after the glue and the clamps are
next step involves a little fine tuning applied, plane a small chamfer onto
on the shoulders of the tenon. the ends of the tenons. This allows
You can quickly get the idea from it to slide in smoothly and provides a
the drawing at right. I use a sharp bit of relief space for glue.
chisel to slightly undercut the shoul-
ders of the tenon around all four
sides. Start about 1/16" back from
the face of the workpiece and use
the same type of shallow paring cuts
you used for the short shoulders USE SHARP UNDERCUT
CHISEL FOR SHOULDERS
of the tenon. You don’t need to cut SHALLOW ALLOW JOINT
UNDERCUT ON TO CLOSE
deeply. The small amount of relief SHOULDERS TIGHTLY
you create will ensure that the joint
closes tightly and looks seamless.
Joinery | 19
120STTT_D018-019rev.indd 19 8/9/2006 4:21:23 AM

Spacing Slats with Playing Cards Squaring Miters
When building panels for countr y When gluing up all four corners of
projects, instead of edge-gluing the mitered projects, the slightest amount
boards together, the slats are some- of extra pressure from a clamp can
times screwed to a cleat. If you use cause it to rack, creating gaps.
this method to build a panel in a dry So when gluing up miters, it’s best
shop, a 5"-wide slat may swell across to work on one corner at a time. What
its width by as much as 3/64" as the I use to keep each corner square is a
humidity increases. So you need to simple block of wood (see photo).
attach the slats to the cleats with a Be sure to square up the block and
gap between the slats. after you’ve added glue, clamp the
To space the slats evenly and consis- block to the inside of the corner.
tently, I use playing cards as spacers. Note: I also thought it was a good
the thickness of three cards is just idea to chamfer the corner of the block
about the right amount of space. to provide relief for glue squeeze-out.
Dovetail Clamping Block

The key to clamping a dovetail joint ALIGN CLAMPING FINGERS
OVER TAILS
is to apply pressure directly over the
tails. To help with this, I cut a series of DOVETAIL
CLAMPING
notches in a piece of hardwood scrap BLOCK
to create “fingers” that line up with
the tails of the joint.
Then just a couple of clamps across PINS
the assembly will provide pressure on
each of the pins, drawing them tight TAILS
to the mating piece.
Biscuits for Table Top Fasteners

Anyone who owns a biscuit joiner wooden biscuits. They can also be in a board. Next, cut the board into
knows how handy biscuits can be. Not used to make fasteners that hold small blocks. Finally, drill an oversize
only do they help to strengthen a joint, a top securely in place, while still shank hole in each of the blocks and
but they’re also great for helping to allowing the wood to move. All you glue a biscuit in the slot.
line up a panel (and keep it aligned) need to make these fasteners are a Now cut a series of slots in the aprons
during glue up. biscuit joiner, a piece of stock, and or rails of your project (Fig. 2). The
Another Use – Recently I’ve some woodscrews (Fig. 1). biscuits in the blocks fit in these slots
discovered there’s another use for Start by cutting evenly spaced slots when screwed to the top.
1 2
FIRST: CUT SLOTS OVERSIZE SHANK
IN BOARD HOLE
SECOND: CUT
BOARD INTO SLOTTED
PIECES BISCUIT
SLOT RAIL
BISCUIT
TOP VIEW
a. BISCUIT IN THE
BLOCK FITS
SLOT IN THE
APRON
RAIL
OVERSIZE SHANK HOLE
Joinery | 20
120STTT_E020-021rev.indd 20 8/9/2006 4:22:03 AM

Center a Mortise Pinning Box Joints for Strength
To center a drill bit on a thickness Instead of just gluing my box joints, CROSS SECTION
of stock, set the fence so a small bit there are times I’ll also secure them
touches the centerline. To re-check, with a dowel pin through each corner.
flip stock end for end. Then switch to It adds to the strength and can save a
your mortising bit. lot of time on large projects because DOWEL
you don’t have to use as much glue.
To do this, simply drill a hole from
the top and bottom at all four corners
and insert a length of dowel. You don’t
need to drill all the way through the
joint, just deep enough to allow each NOTE: DRILL
dowel to capture a pin from the mating THROUGH
AT LEAST
side (see drawing). THREE PINS
SO DOWEL
Cut each dowel a little longer than “CAPTURES”
the depth of the hole. Once the dowels PIN FROM
MATING
are tapped in, trim them with a chisel, PIECE
and sand them flush.
Round Tenons with a Table Saw

The easiest way to cut tenons on the
ends of dowels is to use a table saw and a.
dado blade. An auxiliary fence on both
CL
the miter gauge and rip fence helps.
The diameter of the tenon is deter- AUX. RIP
FENCE !/4
mined by the height of the dado blade.
Set the rip fence for the length of the
tenon (detail ‘a’). CENTER
To make the cut, hold the miter DOWEL OVER
BLADE, THEN ROTATE
gauge in place with the dowel against DOWEL FORWARD TO #/32
the auxiliary fence as you rotate it for- FORM TENON MITER GAUGE
AUX. FENCE
ward (see drawing).
Tips for Aligning Half Laps

If you’ve ever tried to make your own lattice for a project, Next, cut a series of dadoes across the blank. Fasten an
you know that the hardest part about them is getting the auxiliary fence to your miter gauge to help support the piece
half laps to align. The secret to making lattice screens align and to prevent tearout on the back edge (Fig. 2).
is to cut all the notches at once in a wide blank, then rip the Once all the dadoes are cut, set the rip fence and rip the
individual slats from the blank. pieces to final width. Make sure you mark one end of the
Start by cutting your 2x8 blank to final length and then lay blank so that you can orient the strips the same way when
out the positions of the notches along one edge (Fig. 1). you assemble the screens (Fig. 3).
Note: If you’re laying out a lot of lattice screens, you may This same procedure can be used when cutting the frame
want to check the “Secrets of the Story Stick” tip on page 6. pieces that surround the screens.
1 2 3
2x8 BLANK
FOR SCREEN PIECES
BLANK FOR
SCREEN PIECES
BLANK
LAY OUT MARK
HALF LAPS DADO BLADE COMMON
ON EDGE OF BLANK ENDS
Joinery | 21
120STTT_E020-021rev.indd 21 8/9/2006 4:22:29 AM

Super-Strong Splined Miter Joints
Miter and spline joints add a lot to a project. The miter hides The position of the rip fence will determine the location
the end grain. And splines are good for a couple of reasons. of the kerf (Fig. 1a). I prefer to offset the kerf toward the
Note: A spline is just a thin piece of hardwood that runs heel rather than the point of the miter (Fig. 2).
across the joint. With the spline near the heel, the tip isn’t as likely to crack
Advantages – First, hardwood splines provide more off if the joint is stressed. By positioning it there, you can
face grain glue surface. A miter joint is end grain to end also insert a longer spline to provide more glue surface.
grain, which is an expecially weak joint. Spline – Now cut the hardwood splines to fit the kerfs.
Second, miters tend to slide out of alignment as you clamp These splines are exposed, so I cut them so the grain runs
the joint together. A spline helps keep the pieces aligned. perpendicular to the joint line (Fig. 3). (If the spline is not
(For another way to keep miters together, see page 25.) exposed you could use 1/8" hardboard instead.)
Kerfs – The spline fits into kerfs cut in both workpieces. Also, to ensure that the spline won’t prevent the miter
After cutting the miters, lower the blade, but keep it tilted to from closing completely, I cut the spline a hair shorter
45°. Then move the rip fence to act as a stop (Fig. 1). than the total depth of both kerfs.
1 RIP FENCE
2 3
KERF TOO CUT SPLINE
CLOSE TO TIP SLIGHTLY LESS
THAN DEPTH
OF KERFS
a.
WORKPIECE FENCE
TIP MAY
BREAK OFF
KERF CLOSER TO HEEL

PERMITS LONGER SPLINE
MITER
GAUGE
SET SAW SPLINE GRAIN
WORKPIECE BLADE TO 45° RUNS
ACROSS JOINT
Sliding Dovetail Joints Made Easy

Sliding dovetails are a two-part joint. Even without glue, Sneak Up To a Tight Fit – The secret to the best fit-
the angled sides of the tongue fit the angled walls of the ting sliding dovetail is in sneaking up on the final cut until
groove exactly. It’s an extremely strong way to join two the tongue piece just fits the grooved piece. To help make
perpendicular pieces of wood. And they allow panels to it easier to rout, I built a tall fence to hold the tall pieces on
float independently of the frames during seasonal changes edge while routing.
in humidity. Grooves and Tongues – First, rout the grooves with a
Be Precise – Routing both parts of the joint requires hand-held router, running it against a straightedge (Step 1).
precision — a tight fit holds the project together. But the Then rout the tongues on the router table, sneaking up on a
joint shouldn’t be so tight the parts are hard to assemble. perfect fit (Step 2).
1 2
FENCE DOVETAIL
TONGUE
DOVETAIL
GROOVE
#/8
#/8
!/2" DOVETAIL
BIT
NOTE: MOVE FENCE
TO SNEAK UP
!/2 ON FINAL CUT
1 Rout dovetails with a hand-held router.

Set depth of cut, then run router against 2 The dovetail tongues are then routed
on the router table. The height of the
a straightedge. Using a straight bit followed bit matches depth of the dovetail groove.
by the dovetail bit makes this job easier. Sneak up on the final depth for a perfect fit.
Joinery | 22
120STTT_E022-023rev.indd 22 8/9/2006 4:23:00 AM

3-Step Mortise & Tenon Joints
There are lots of jigs and machines on the market that all the adjoining pieces. To cut them, set the fence of the
make cutting mortises and tenons easier. And if you have table saw to the desired length for the tenons, making sure
a lot of joinery to cut, they’re worth the investment. But to measure from the outside of the blade (Figs. 2 and 2a).
for small projects a mortise and tenon joint can easily be The trick is to use a piece of scrap the same thickness as
cut using just two power tools, a chisel, and a file. the workpiece to set the height of the blade. Make passes
All this involves is boring a series of centered holes over both faces of the scrap, and gradually raise the blade
on the width of your stock (Fig. 1). You want them to be until the thickness of the tenon fits snugly in the mortise.
slightly deeper than the final length of the tenons. Then Follow the same procedure to cut the shoulders of the
you simply clean up the cheeks of the mortise with a tenon (Figs. 3 and 3a), carefully paring away the shoulders
chisel, leaving the ends in the half-round shape. until it fits the mortise length. Then I use a file to round
After the mortises are cut, you can make the tenons on over the corners to fit the rounded ends of the mortises.
1 2 3
REMOVE WASTE a. REMOVE WASTE
WITH MULTIPLE
BY DRILLING
SERIES OF
PASSES OVER
SAW BLADE
a.
OVERLAPPING
HOLES TRIM
#/4
WIDTH OF
#/8"-DIA. TENON
BIT WITH
MULTIPLE
PASSES
USE SAME FENCE

SETTING TO TRIM
WIDTH OF TENON
#/8" WIDE, #/4"-DEEP
MORTISE CENTERED
ON STOCK CUT RABBETS
CLEAN SIDES ON BOTH
OF MORTISE FACES OF PIECE
WITH CHISEL TO FORM TENON
Stop Miter Joints from Slipping Apart

Miters are commonly used to hide the First, use the table saw to cut a
end grain on two pieces that are being shallow kerf across the inside face of
joined. It’s a joint that works well for all the pieces (parts A and B) (Step 1).
picture frames and small boxes that Then the miter is cut with the blade
won’t get a lot of handling. aligned with the kerf (Step 2). (A
But by itself, a miter joint isn’t hardboard rub strip helps to align the
that strong. So for larger projects, I blade to the top of the kerf.)
often use a variation of a miter joint Lastly, a shallow rabbet (1/8") is
— a rabbeted miter — to join the four cut on both ends of the two opposing
workpieces. (For another solution to pieces (parts B) (Step 3). Again, the
this problem, see page 22.) rub strip helps line up the cut.
ATTACH RUB STRIP THICKNESS OF

!/8" LESS THAN RIP WORKPIECE
FENCE TO WORKPIECE
RIP THICKNESS OF WITH CARPET TAPE RIP RUB
FENCE WORKPIECE !/8 FENCE STRIP
!/8 !/8
A B A B B
SET BLADE TO
45° ANGLE
1 The rabbeted miter joint starts out

the same on all four workpieces. 2 Now, cut the miter. Be sure the
blade is aligned to the kerf. To 3 Finally, the last cut is a rabbet on
the two opposing piece. Again
First, cut a 1/8"-deep kerf with a regu- help, stick a piece of hardboard to the use a hardboard rub strip, but this
lar saw blade across the inside face of workpiece. Then adjust the fence and time to help position the blade in rela-
each piece. sneak up on the cut. tion to the long point of miter.
Joinery | 23
120STTT_E022-023rev.indd 23 8/9/2006 4:23:28 AM

Plugging Mortises Frame and Panel Glue-up Jig
Recently I was working on a project Gluing up a frame and panel door so pressure and position of the clamps
that had a series of slats that fit in it ends up perfectly square can be dif- until the frame sits square in the jig.
mortises. Because of the way the ficult. The pieces always seem to slip Note: To prevent any glue squeeze-
project was designed, it was easier to out of square during glue-up. out from sticking to the jig. I brushed
apply the finish before assembling all To get around this, I built a jig that on several coats of polyurethane
the pieces. The trick was keeping the provides an accurate reference when finish to the base and cleats.
finish out of the mortises — I wanted gluing up panels (see photo).
good glue joints later on. Build the Jig – The jig con-
To do this, I plugged each mortise sists of a plywood base and two
temporarily with foam caulking rod cleats (see drawing). To pro-
(see photo). (The caulking rod that vide an accurate reference, it’s
I used was slightly wider than the important that the cleats are
mortises.) After the finish dries, just screwed to the base so they’re
remove the foam rod. 90° to each other.
A twenty foot length of 3/8"-dia. To use the jig, star t by
caulking rod purchased from my local placing each clamp directly
hardware store cost less than $5.00. over (and parallel to) the rails
of the frame. Then, adjust the
#/4"-THICK
CLEAT
SCREW FIRST CLEAT
FLUSH WITH EDGE
PLYWOOD
BASE
2"
90°
36"
24"
{ Plug the Mortise. A short strip of
foam caulking rod does a great job SCREW SECOND CLEAT
SQUARE TO FIRST CLEAT
of keeping finish out of the mortise
before glue up.
Jointing with a Hand Plane

What’s the secret to gluing up panels One of the biggest challenges with edges up and the face sides of the
so the joints are strong and nearly hand planing is getting a perfect 90° boards out (see the drawing below).
invisible? The answer lies in the angle between the edge and the face. Now plane both boards at the same
boards edges. Boards with straight, One solution is to not worry about time. Any variation from 90° on one
smooth, square edges glue up into being perfect. Instead, tighten both edge is cancelled out by the variation
flat panels with strong joints that are boards into a vise with the mating on the other edge (detail ‘a’).
hard to see.
So how do you make a straight, PLANE MATING
smooth edge? Traditionally, a long EDGES TOGETHER a.
hand plane called a jointer was the
tool of choice. (“Jointing” is the pro-
cess of preparing one board or edge
to be joined to another.) FACE SIDE FACE SIDE
Jointer Plane – A jointer plane has
a long flat sole, usually well over 20"
long. So as it’s passed over a wavy edge
the plane iron (blade) only cuts off the
high spots. (A shorter plane will ride POSITION BOARDS IN
VISE FACE SIDES OUT
along the wavy edge and won’t provide ANGLES OF MATING EDGES MATCH
a flat surface.)
Joinery | 24
120STTT_E024-025rev.indd 24 8/9/2006 4:24:06 AM

Stop That Panel From Rattlin’
In the past, I’ve had trouble the corners of the frame
with raised-panel doors before assembling the door
during dr y seasons. The (see drawing).
panels (which fit fine when Let the silicone harden NOTE: SILICONE
DOTS SHOULD BE
it was humid) contract in overnight. Then install !/32" TO !/16"-THICK
the frames, causing them the panel as normal. The FRAME SILICONE
to rattle around. silicone acts as a shock
To prevent this, I now put absorber, cushioning the
small dots of silicone near panel inside the frame.
Shop Tip
Fluting Round Tenons
Dowel Centers –
When a dowel fits tight in a hole, it Occasionally, my dowel cen-
usually scrapes off the glue as it’s a. ters fall out. To prevent this,
driven home — unless the end of the place a piece of tape across
dowel (the tenon) is fluted. I make the dowel center. The points
flutes for the bench’s dowels using an will still go through the tape
ordinary set of pliers (see drawing). and make their mark.
Checking Miters
The normal way to check a For me, it’s easiest to hold GAPS INDICATE NEED
mitered corner for square is the pieces together edge-to- FOR ADJUSTMENT
to butt the miters together edge and place the square
and place a try square on in the mitered corner (see
the outside of the corner. drawing). This also allows
I don’t. Mainly because I me to place the mitered
find it difficult to hold the pieces over the edge of my
square with one hand while bench so I can get a more
keeping the mitered work- accurate reading when TRY SQUARE
pieces tight in the other. checking thinner stock.
Undercut for Tight-Fitting Shoulders

There’s an easy way to make mortise least 1/16" untouched along the out- the chisel in toward the cheek of the
and tenons fit together without gaps at side edge of the shoulder. If you cut tenon (Fig. 2).
the shoulders — undercut them. all the way to the edge, you’ll leave a Also, to prevent the square ends of
“Undercutting” simply means gap in the joint. the tenon from pushing all the glue
paring away the end grain 1/64" deep Start by lightly pushing a chisel to the bottom of the mortise, lightly
along the tenon’s shoulders. straight into the corner (Fig. 1). Do chamfer the ends (Fig. 3). This
The trick is to undercut the area this all the way around the tenon. chamfer can be cut with a chisel or
next to the tenon cheek, leaving at Then to remove the waste, angle block plane.
1 LIGHTLY
CHISEL DOWN
2 3
LIGHTLY
ALONG TENON LEAVE !/16" CHAMFER
INTO SHOULDER BORDER BEVEL TENON EDGES
SHOULDERS
TOWARD
TENON
Joinery | 25
120STTT_E024-025rev.indd 25 8/9/2006 4:24:31 AM

Locking Rabbet Drawer Joints
I like to use dovetails for my drawers To make a locking rabbet, a groove
whenever possible. But occasionally I is cut in each end of the drawer front
use a locking rabbet joint at the front (Step 1). The tongues depth matches
corners instead (see photo). It’s much the thickness of the side pieces.
stronger than a simple butt or rabbet Then the inside tongue of the
joint, and it’s not as difficult as cutting groove is cut shorter (Step 2).
dovetails. In fact, the entire joint can Next, a dado is cut on each side piece
be cut on the table saw. to accept this short tongue (Step 3).
Note: Although I’m showing how to The distance between the dado and
cut the joint on the table saw, the same the end of the workpiece should equal
procedure can be used to cut the joint the width of the dado in the drawer
with a straight bit in the router table. front (see photo).
1 2 3
BACKER
BACKER !/4" BOARD
AUX. DADO
DADO FENCE BOARD
BLADE BLADE DRAWER
DRAWER SIDE
DRAWER FRONT
FRONT
BACKER
BOARD
END VIEW
a. END a. a. END VIEW
VIEW !/4
!/4 !/4
DADO
INSIDE BLADE
!/4" FACE
DADO !/2 SNEAK UP TONGUE !/4
BLADE ON LENGTH
OF TONGUE
1On the ends of the front piece,

cut a slot to leave a / "-wide
14 2Then to complete the tongue, it
needs to be trimmed to length. 3Finally, to hold the tongue on the
front, cut a / " x / " dado on
14 14
tongue. The tongue should be as Just sneak up on the cut until the each side piece. (Be sure to check
long as the side pieces are thick tongue is 1/4" long. the setup with a test piece first.)
Edge Gluing Thin Stock

I like to use solid-wood 1 SPACER 2 BRICK PULL OUT SPACER AND
bottom panels for boxes FIRST: DRIVE NAILS APPLY WEIGHT
ALONG EDGE OF ABOVE JOINT
and small chests, which ONE PIECE
means I often have to glue WAX SECOND:
PAPER SLIDE
the panels up. When edge SPACER
gluing thin pieces, I use a UNDER
JOINT LINE
special technique. #/4"
SCRAP THIRD: DRIVE NAILS WAX
Prepare Stock – For the PLYWOOD ALONG EDGE OF OTHER PIECE PAPER
TOP BOARD
first step, I start by jointing BRICK HOLDS
NOTE:
the two edges so they fit BOTTOM EDGES REMOVE NAILS IN STOCK IN PLACE
WHILE GLUE
1"-LONG ONE SIDE BEFORE
together without gaps. You MUST TOUCH NAILS TAKING UP PANEL SETS UP
can use a jointer for this
step, but if you don’t own
one, a block plane will also
do the job.
Work on Plywood – Now, place the two workpieces edge along the edge of the other piece (Fig. 1).
to edge on a piece of plywood. Place a piece of waxed paper Glue the Joint – Now, carefully tilt one of the panels up
under the joint line to prevent them from sticking. Then, and spread glue along the inside edge. Then gently set the
drive several finish nails into the plywood, along the edge of workpiece back in place.
one of the pieces. Weigh Down Top – Next, slide the spacer out and lay
Joint Line Spacer – Next, slide a spacer under the joint another strip of wax paper on top of the joint line. Now lay a
line. The trick is to center it on the joint line and make sure board on top of the wax paper and stack a brick on the board.
the bottom edges of the two pieces are touching (Fig. 1). Make sure the two pieces are flat, and let the glue dry.
With both pieces in place, drive several nails into the plywood Finally, remove the nails before taking the panel up.
Joinery | 26
120STTT_E026-027rev.indd 26 8/9/2006 4:26:21 AM

Simple Jig for Compound Miters
The traditional method for making edge was then supported by the aux- under the stop block and against the
compound miters is on the table saw iliary fence (Fig. 1). auxiliary fence. Then push the work-
with the miter gauge angled and To prevent the molding piece from piece through the blade (Fig. 2).
the blade tilted. This procedure can sliding up during the cut, clamp a small To miter the other end of the work-
be tricky and involves referring to a stop block to the auxiliary fence so it piece, move the miter gauge to the
chart for the correct angles to set the rests on the top edge of the molding. right slot and swing the head of the
miter gauge and the blade. Making the Cut – To cut the gauge to the opposite 45° setting.
But if the workpiece can be held molding to length, begin by rotating If the molding can be cut by holding
at the angle it will be installed on the miter gauge to 45° and place it in it against an auxiliary fence this way,
the project, the table saw blade can the left slot of the table saw. Tip the the cut is likely to be much more
stay at 90°, and only the miter gauge workpiece to the correct incline (with accurate than the old-fashioned com-
needs to be angled. I was able to use both edges flat) and bring it up tight pound miter procedure.
this simpler technique for a recent
project. Now I use it all the time. 1 C-CLAMP 2
Auxiliary Fence – To make the cut, SWITCH
TO
begin by fastening an auxiliary fence STOP LEFT-HAND RIGHT
BLOCK SLOT HAND
to the miter gauge. The fence has to SLOT
be tall enough to support the molding WORKPIECE
MOLDING
when it’s held at the desired angle.
Since the bottom edge of the
molding I used was cut at 45°, there MITER GAUGE STOP
BLOCK CHANGE
was a flat surface that could rest on MITER
TALL AUXILIARY FENCE SETTING
the surface of the table saw. The top
Check for Square Better Looking Tongue & Dado Joint

A small piece of plywood acts as a There are several ways to join a
substitute where a try square won’t shelf to the side of a cabinet. A full-
fit. Cut the plywood at exactly 90° and width dado (see upper photo at right)
trim a corner for clearance. normally works fine, but if the shelf
doesn’t fit the dado exactly, there will
SAWN-OFF
be a visible gap.
CORNER AVOIDS Tongue and Dado – The tongue
CORNER BLOCKS
and dado joint (lower photo) looks
better because it hides any gap above
the tongue of the shelf. Another benefit
is that it also covers up any splintering
along the edges of the dado. You can
also center or off-set the tongue.
Make Through Mortises with a Jig Saw

#/4"-DIA.
DRILL BIT
MARK
CENTERPOINTS #/8"
IN FROM ENDS
MORTISE CHISEL
ENDS HALFWAY
DRILL A THROUGH EACH
MORTISE PILOT HOLE SAW TO WITHIN !/16" SIDE TO CLEAN
CENTER LINE AT EACH END OF LAYOUT LINES OUT MORTISE
1 Lay out the mortise cen-

2 Drill a / " hole at each
3 Remove waste using a
4 Chisel up to layout lines.
34
terline, ends, and pilot end. Use these holes to jig saw. Cut to within To help prevent chipout,
holes 3/8" from each end. lay out edge of mortise. 1/16" of all layout lines. work from both faces.
Joinery | 27
120STTT_E026-027rev.indd 27 8/9/2006 4:26:49 AM

Cutting Perfect Pieces On Your
Table Saw
S tart by cutting the workpiece

to size. Sounds easy, doesn’t it?
But a lot of woodworkers will admit
Size As You Go – Usually, when
building a project, you’re working
on one assembly or step at a time.
to having goofed at this supposedly For example, doors, drawers, or
simple task a few times. A piece of case parts. So this is how I like to
stock ends up too short, not straight, approach cutting parts to size. Just
or out of square. Sometimes this size the pieces that you need for CHECK LONG
isn’t a big deal, but other times it the job at hand. It’s easier to keep EDGE WITH
SQUARE AND
comes back to bite you. things straight and you can make SQUARE STRAIGHTEDGE
So now I have a simple routine minor “size” adjustments as you
Workpiece cut to that I follow when cutting stock to work through a project. Reference Edge. To get started
final size size on the table saw. Cut List – Before you start cut- right, you need one straight and
ting, you need a goal. And for me, square edge to work from.
this is a cut list. I jot down a list of
the parts that I need to cut and their
dimensions (thickness, length, and Rough Cut – Once I know what
width). Even when I’m only cutting a size pieces I need, I rough-cut the
part or two, I write down the dimen- parts from the stock at hand. At
sions. It’s too easy to remember a this point, all you’re trying to do
“wrong” measurement. is get in the ballpark. It’s easier for
Workpiece If you have a lot of pieces to cut, me to work with and acccurately
rough-cut check them off the list as you go. size smaller pieces. I just try not to
from stock Then all you’ll need to do is take a skimp here. For example, if I need
quick glance at your cut list to tell if a 2" by 24" stile, I try to give myself
you have all the parts you need. You about a 21/8" by 25" piece to work
don’t want to get halfway through with. But the rough dimensions
the job and realize that you’re short you use will depend on the stock
one door rail or drawer side. you’re working with.
Starting point
(hardwood stock
from lumberyard) Sawing & Cutting | 28
120STTT_E028-029rev.indd 28 8/9/2006 4:27:24 AM

One Straight, Square Edge – With the rough-
sized pieces in hand, the next goal is to give each
4 Steps for Perfect Pieces
piece one straight and square edge. This edge will STEP ONE
guide your first rip cut. A straightline rip jig on the a. END VIEW
table saw, a handplane or a pass over the jointer will EXTRA WIDTH
do the job. Before moving on, make a quick check RIP FINAL
WIDTH
ALLOWS FOR
FENCE FINAL CLEANUP
with a straightedge and square and then mark the
straightened edge (box below left).
The Four Steps RIP CUT

Now you’re ready for the four dimensioning cuts that CREATES TWO
PARALLEL EDGES
you see illustrated in the drawings at right.
Two Parallel Sides – The first step is to rip the
workpiece close to its final width (Step One). I never iRip Close to Final Width. With the straight, square
try to hit the final dimension right on the money. The edge against the fence, rip the workpiece close to its
purpose is just to make sure that both long edges are final width. The extra width allows you to clean up this
straight and parallel. An extra 1/32" or 1/16" in width face with the final cut.
is plenty. This leaves enough material to allow you to
come back later and clean up this face — eliminating STEP TWO
saw marks, burn marks, or tearout from crosscut- a.
ting. And with straight, parallel edges to work from, AUX. MITER
FENCE BACKS
you’ll have a much easier time getting square ends UP CUT
when you crosscut to length.
One Square End – Once you have two straight
edges, begin cutting the piece to length by making a CHECK CUT
END FOR
clean, square crosscut on one end. But don’t get car- TRIM FIRST SQUARE
END TO
ried away, this is usually just a light trim cut. Be sure ROUGH LENGTH
to leave yourself enough length for the final cut.
The ends of the workpieces are often where the
joinery takes place. And the key to accurate cross- SSquare One End. Once you have two straight
cuts is control of the workpiece. For this I rely on a and parallel edges, you can begin crosscutting the
miter gauge with a long auxiliary fence (Step Two). workpiece to length. Start with a square, trim cut
This gives you a solid backing for the workpiece that across one end of the piece.
allows a controlled feed and limits tearout. A smooth,
steady feed produces the best crosscuts. Too slow STEP THREE
and the wood burns — too fast and you’ll end up with CROSSCUT TO a. TOP
a ragged or inaccurate cut. FINAL LENGTH VIEW
If I’ve got a stack of parts to cut to length, I’ll
square one end of all the pieces before cutting any
to final length. A mark on the squared end will help
keep things straight (see main photo).
Cut To Length – Now you can make the final USE AUX. FENCE FINAL
WITH STOP BLOCK LENGTH
crosscut to length. And more often than not, you’re FOR MULTIPLE CUTS
going to want to cut several pieces to identical
lengths. Door rails and stiles, and face frame parts FFinal Length. A second crosscut on the opposite end
are a good example. gives you the final length. An auxiliary miter gauge
So rather than measure and cut each piece and fence with a stop block clamped to it makes multiple
hope for the best, I set up to cut “multiples.” This cuts quick and accurate.
involves measuring and marking one piece and then
using this piece to set up the saw for cutting the STEP FOUR
PUSH
remaining identical pieces to length. A stop block on BLOCK a.
the miter gauge can be adjusted as you sneak up on END VIEW
the length of the measured piece, as shown in Step FENCE FINAL
Three. The length of the pieces that follow will be WIDTH
exactly the same.
The Final Edge – At this point your workpiece
is cut to length and has one clean, square edge. But
it’s still a little overwidth. A light rip cut removes the LIGHT RIP CUT
LEAVES WORKPIECE
extra width and cleans the final edge, as you can see AT FINAL WIDTH
in Step Four and the main photo.
That’s all there is to it. At this point, the workpieces CClean Rip. With the piece cut to length, a light rip pass on
are square and true to size. But the best thing is that the face you cut in step one, gives you the final dimension.
you can move on with one less thing to worry about. Any saw marks, burn marks, or tearout will be removed.
Sawing & Cutting | 29
120STTT_E028-029rev.indd 29 8/9/2006 4:27:58 AM

Getting Clean Cuts In Plywood
When crosscutting a plywood panel, the bottom layer of it’s splintering on the top of the plywood, raise the blade.
veneer often splinters out along the cut line. But there are Scoring Cut – The most common way to get a clean cut
some steps you can take to prevent this from happening. is to score the panel along the cut line before making the
Plywood Blade – Perhaps the easiest way to avoid cut (Fig. 1). To do this, cut through the veneer layer with a
excessive splintering is to use a special blade with more sharp utility knife. While this method works, it’s sometimes
teeth, that’s made just for cutting plywood. The more teeth difficult to line up the saw blade with the scored line.
per inch, the cleaner the cut. Scoring On the Saw – An easier way to score the panel
Combination Blade – But if you only have a combina- is to use the saw blade itself. The trick is to make the cut in
tion blade, there are a few tricks you can use to get a clean two passes. On the first pass, set the blade just high enough
cut. First, if the blade is crusted with sawdust or pitch, clean to cut through the veneer (Fig. 2a). Then raise the blade
it thoroughly. Sometimes, however, even a clean combina- and finish the cut on the second pass. To help ensure the
tion blade will splinter the veneer. workpiece stays aligned with the blade during both cuts,
There are two reasons for this. First, a combination you can clamp an extension fence with a stop block to your
blade has fewer teeth than a plywood blade, so it won’t cut miter gauge (Fig. 2).
as cleanly. Secondly, the cutting edge of the teeth may be Backer Board – Another way to keep the veneer from
pushing the veneer down rather than slicing it off. splintering is to use a backer board (Fig. 3). This is a piece
Blade Height – One way to avoid this is to change the of plywood or hardboard that’s placed below the workpiece
cutting angle of the teeth by raising or lowering the blade. when making the cut. This way the veneer layer is sup-
If your panel is splintering on the bottom, lower the blade. If ported and can be cut cleanly.
1 2 SCORE PLYWOOD VENEER 3 SCRAP HARDBOARD OR PLYWOOD

WITH SAW BLADE UNDER WORKPIECE
SCORE
VENEER
WITH KNIFE
BEFORE
CROSSCUTTING
a. CUT a. a.
THROUGH BACKER BOARD
STRAIGHT VENEER WITH PREVENTS
EDGE KNIFE SPLINTERING
DURING CUT
STRAIGHT- CUT VENEER LAYER
EDGE ONLY ON FIRST PASS
Safe Cuts With a Miter Block

To protect the mitered edges of a workpiece when cutting reset the rip fence (Fig. 3). Run the block across the blade
slots for splines, I use a scrap block with an angled slot in with the same face against the fence.
it (Fig. 1). The mitered edge fits in the slot so the wood To cut the spline kerf in a mitered workpiece, fit the
fibers won’t get crushed. sharp edge of the mitered panel into the slot (Fig. 1).
Miter Block – To make the block, rip a 2x4 to 11/8" wide Then, put the block against the fence and set the blade to
and cut it to length to match the mitered piece. Then, set the the right height (Fig. 1a).
rip fence 9/16" from the blade and cut a slot on the narrow Finally, cut the kerf in the workpiece with the block
edge of the block (Fig. 2). Next, tilt the blade to 45° and riding along the fence.
1 2 3
MITER
BLOCK a. BLOCK PROTECTS
1!/8
CUT TO FRAGILE TIP (/16
LENGTH RIP OF MITER
OF PANEL FENCE SET FENCE
RIP #/16" FROM
EDGE FENCE SAW BLADE
1!/2
#/4 TILT BLADE
TO 45°
BLOCK SITS
ABOVE TABLE TOP
120STTT_F030-031rev.indd 30 8/16/2006 3:37:04 PM

Shop-Made Outfeed Support Roller
This shop-made outfeed support roller can be secured in from two pieces of 3/4"-thick stock. The longer half of each
the jaws of a portable workbench (see photo) or clamped to bracket extends down the face of the plywood and serves
a sawhorse. And when it’s not being used, it can easily be as a stop to set the height of the support (see photo).
stored in the table saw stand. I used the roller from an old copy machine. But a
Make the Roller – The support is simply a roller typewriter roller would also work. Another option
attached to a piece of plywood by a pair of 11/2"-thick is to make your own roller using a piece of PVC pipe with
wood brackets (see drawing). I made the brackets filler pieces in the ends and a length of dowel.
2"-DIAMETER ROLLER
BRACKETS MADE
FROM #/4"-THICK
STOCK
#8 x 1!/4" Fh
SCREW
DRILL HOLE
TO MATCH
DIAMETER
OF SHAFT
#/4"-THICK PLYWOOD
Don’t Get Pinched When Cutting a Box In Two

Like a lot of woodworking tasks,
NOTE: TAPE
cutting a box into two parts looks SPACERS IN PLACE
more complicated than it is. But
with the right technique, it can NOTE: SPACERS
RUN SAME EXTEND
easily be done with just a table SIDE AGAINST THROUGH
FENCE FOR BOX
saw. All it takes is a good rip blade, EACH PASS
the right cutting sequence and
a simple trick.
Cut Opposite Sides – First, cut
two opposite sides (or ends) of the box
(Step 1). Make sure the blade is raised
high enough to cut through the thick-
ness of the workpiece and be sure to
run the same side of the box against
the fence during each pass.
Problems – Now is where you’ll
have a problem. When you cut the 1 Tofirstcutthing
a box into two halves, the
to adjust is the height 2 Once the initial cuts have been
made, you need to take the
next two sides, the saw kerfs can of the table saw blade. You want it proper precautions to avoid a kick-
pinch the blade and cause kickback. to just cut through the thickness of back accident. To do this, you want
A dangerous situation. the box sides. After the blade is set, to prevent the saw kerfs from clos-
Keep Kerfs Open – To prevent make a pass on opposite sides (or ing up and pinching the blade. Start
the kerfs from closing, slip a pair of ends) of the box. Just be sure to run by cutting a pair of spacers from 1/8"
spacers through the box and tape the the same side against the fence for hardboard and slip them through the
spacers in place (Step 2). each pass. This way, if the cuts end kerfs you cut in the box. I use strips
After you’ve made the final two cuts, up a little off-center, they will still be of masking tape to hold the spacers
simply remove the tape and separate aligned with each other. When that’s in place (you don’t want them falling
the two halves. complete, go on to the next step. into the blade during a cut).
120STTT_F030-031rev.indd 31 8/16/2006 3:37:30 PM

Cut Plywood Without Chipout Using a Circular Saw
When working on a project with a lot of large pieces of To solve this problem, cut a wide second slot centered
plywood, I like to start by cutting them down to a more on the first one (Fig. 2). Cut it wide enough to allow the
managable size from a 4x8 sheet with my circular saw. guard to move freely, but stop it 3/4" back from the for-
Normally, I always face the good surface of the plywood ward end of the blade slot (Detail in Fig. 2).
down since the blade causes chipout on the top (“up”)
side. But sometimes I want a clean cut on both sides.
Zero-Clearance Auxiliar y Plate – To prevent chipout
on the top side, I attach an auxiliary plate to the saw’s base
plate (Fig. 1). The plate has a “zero clearance” blade slot
cut in it. This backs up the wood fibers along the cut line
and prevents chipout (see photos at right).
The idea is pretty simple. Screw a piece of 1/4" hard-
board to the saw’s base plate (Fig. 1). Then, carefully start
the saw and plunge the blade through it. Now you’ve got a
plate with a zero clearance blade slot.
Blade Guard – The only problem is that now the blade { Chipout. Blades on { Clean Cut. Attaching a
guard won’t work. It’s held back by the auxiliary plate, so circular saws chip out the “zero clearance” auxiliary
the blade is left exposed. top side of the plywood. base plate prevents chipout.
1 2 CUT OUT SLOT FOR

a.
a. BLADE GUARD
CROSS
SECTION
WASTE
WIDE SLOT
ALLOWS #/4
BLADE
GUARD TO
ATTACH AUX. PLATE MOVE FREELY
CUT AUX. PLATE WITH COUNTERSUNK ZERO CLEARANCE
FROM !/4" HARDBOARD Fh SCREWS BLADE SLOT
TO SAME SIZE AS LEAVE #/4" OF BLADE
BASE PLATE BURIED IN AUX. BASE
Rip Narrow Strips Without Moving the Rip Fence

HANDLE
(#/4" x 6" -
Whenever I need to rip narrow strips
#/4"-THICK of material, I use a simple jig (see
STOCK)
photo). The thing that makes this jig
different is that rides against the rip
fence on the table saw. It ensures that
each ripped strip is identical in width.
BASE
(6" x 24" - !/4" HARDBOARD) Two-Part Jig – The jig consists of
two parts. The first part is a hardboard
NOTE: NOTCH %/16 base that has a notch sized to match
PUSHES WORKPIECE the width of the strip (see drawing).
THROUGH SAW BLADE
The second part is a wood handle that
a. gets glued to the base.
ADJUST RIP FENCE Make Your Cuts – To set up the
HANDLE TO ALIGN OUTSIDE
EDGE OF NOTCH jig, start by positioning the rip fence To rip a strip from the opposite
WITH INSIDE OF so the outside edge of the notch aligns edge, don’t reposition the rip fence.
SAW BLADE
BASE with the inside edge of the table saw Just rotate the workpiece and repeat
WORKPIECE
blade (see detail ‘a’ at left). After fitting the process.
the workpiece in the notch, push the Note: It’s best to use a workpiece
jig past the saw blade to rip the first that’s at least 3" wide so your hands
narrow strip from the blank. stay well away from the blade.
120STTT_F032-033rev.indd 32 8/9/2006 4:29:37 AM

Cut Glass Stop Cutting Perfect Half Laps
Glass stop can be cut from a larger When cutting half laps on small workpieces, I like to use a straight bit in the
blank with just two passes on the router table and a zero-clearance fence to get a smoother surface.
table saw (Figs. 1 and 2). A zero- Setup – I check my setup by first cutting a test joint on some scrap the same
clearance insert around the blade thickness as a workpiece from the project. For 1/2"-thick pieces, raise the bit
will prevent the stop from falling 1/4" above the table. Then make a pass on one end of each scrap (see drawing).
into the saw. Check the setup by fitting the pieces together (detail ‘a’). If the faces are per-
fectly flush, the bit is at the right height.
1 Cutting Joint – Using a 1/2" straight bit, I took three passes to cut the 1" width
!/4 of these joints. The first pass defined the shoulder of the joint. The second pass
is a light cut with the end of the workpiece pressed against the router table fence
and a small part of the bit exposed (detail ‘b’). This cut helps prevent chipout
!/4 as you clean up the remaining waste on the third pass.
Consistent Depth – As you make each pass, press down firmly on the
workpiece so the cuts are all the same depth.
2 a. b. ZERO-CLEARANCE
FENCE
BACKER
BOARD FRONT VIEW
ZERO-
CLEARANCE
FENCE FACES WILL
BE FLUSH
TEST SETUP BY WHEN SETUP WASTE
GLASS STOP MAKING A PASS IS CORRECT
ALONG ENDS OF TWO
PIECES OF SCRAP
Setup for 221/2° Miters Two-Step Resawing

Setting a miter gauge to exactly 221/2° can be difficult. But Although there are lots of way to do it, I like to use both a
here’s a trick to make this job easier. table saw and band saw for resawing narrow boards from
Gauge Markings – Set your gauge to 221/2° as indicated thick stock. This method is most useful with boards that
by the markings on the head of the gauge. Then make a are too wide to cut all the way through on the table saw.
test cut through a piece of scrap. Start by using the table saw to score the two edges of
Check the Angle – To check the accuracy of the setup, the board with cuts that are about 1/4" deep (see detail ‘a’).
place the long side of one piece against the rip fence. Next, Then, to finish resawing the board, switch to the band saw
place the mitered end of the second piece against the (see drawing). The scored cut lines on each edge of the
mitered end of the first (see drawing). Check the angle board act as “guides” to keep the band saw blade on track.
between the second piece and the rip fence with a plastic This method works well because it usually results in
triangle (available at office supply and art stores). An accu- boards of uniform thickness (which means there will be
rate cut creates a 45° angle. less final planing needed).
a.
45° CUT !/4"

SECOND: SLIDE IN DEEP ON
45° TRIANGLE BOTH ENDS
RIP TABLE
FENCE SAW FENCE
FIRST:
PLACE ANGLED
EDGES TOGETHER
MITER GAUGE SET

AT 22!/2°ANGLE
120STTT_F032-033rev.indd 33 8/9/2006 4:30:08 AM

Crosscutting Large Panels
Whenever I’ve needed to trim the the slot on the table saw and guide the of the panel. And the line for each
ends of a long, wide, glued-up panel, long panel so the cut will be clean and runner should be located the same
I’ve used either a circular saw or a square (Fig. 2). distance from the cut line as the saw
hand-held router. But recently, I came To do this, start by making a couple blade is from the miter gauge slot.
up with a different method using of long runners to fit in your table saw With the layout lines drawn, the
my table saw. It takes less time than slot. (I made mine out of a 3/8" x 3/4" runners can be screwed to the panel.
using a router. And by using my good strip of solid wood.) Size the runners (I used a framing square to align each
crosscut blade, I get a clean, square carefully — you want a snug fit, but of them.) And make sure the screw
cut with no chipout — much better not so tight that it will bind. And the heads are countersunk below the sur-
results than the circular saw. runners should be longer than the face of the runners.
Temporary Runner – What makes panel is wide (Fig. 1). Trim – Now with the runners in
this all work is a temporary runner Layout the Lines – Next, I laid place, simply flip the panel over and
screwed to the bottom face of the top out two lines on each end of the panel: get someone to help support it as you
panel. (That way the screw holes won’t a cut line and a line for the runner guide it over the saw (Fig 2). Then
be seen.) Like the runner on a miter (Fig. 1). The distance between the cut turn the piece end for end and trim
gauge, this hardwood strip will ride in lines should equal the finished length the other end.
1 #8 x 1" Fh
2
TEMPORARY RUNNER WOODSCREW
CUT TO SLIDE IN MITER
GAUGE SLOT
FRAMING a.
SQUARE TEMPORARY
RUNNER
WASTE CROSSCUT BLADE
RUNNER
WASTE
NOTE:
HAVE HELPER
DISTANCE BETWEEN MITER SUPPORT OPPOSITE
GAUGE SLOT AND BLADE END OF PANEL
(SEE DETAIL a)
Simple Jig for Dead-On Rip Fence Alignment

A lot of older contractor’s-style table Paper Spacer – Now slide the jig Setting the fence with a gap still
saws have a fence that rests on two to the far end and use a spacer to allow allows for straight cuts, but it greatly
rails, one at the front and one at the for a 1/32" gap (Step 2). (A few sheets of reduces the chance of binding
back of the saw’s table. If you have notebook paper works well.) between the blade and the fence.
this kind of saw, you’ve probably
noticed that you often get burn marks
when ripping stock. This is probably
because of binding. Binding on this PAPER
GAUGE
type of saw is common and usually
means you have a misaligned fence. ALIGNMENT
JIG
Adjust the Rip Fence – To prevent
this type of binding, I like to adjust the
fence so it’s slightly canted from the
miter gauge slot (about 1/32"). To make FENCE
this easier, I use a simple alignment jig
that rides in the miter gauge slot.
The jig is made from two pieces of
scrap screwed together in a T-shape,
with a small brass screw in one end.
To align the fence, simply slide the
jig to the front of the saw, move the 1Todown
align the fence, first lock it
with its face just touching 2Now slide the jig to the far end of
the fence and adjust the fence to
fence in and lock it down (Step 1). the brass screw on the alignment jig. produce about a 1/32” gap.
120STTT_F034-035rev.indd 34 8/9/2006 4:30:37 AM

A Tall Featherboard for Tall Workpieces
When making frame and panel sides
for a case, I like to use a tongue and
groove to hold the panel in place.
There are a lot of ways to this. You
could use a router table and a straight
bit, but I use a table saw when cutting
grooves in the edge of a workpiece.
Tall Featherboard – But there’s
just one problem. If the workpiece
is extra wide it’s hard to keep it flat
against the rip fence. You can use a
featherboard, but most of them are
designed to hold a piece that’s laid face
down on the saw table. So to keep tall
pieces flat against the fence and stable
during the cut, I made a “tall” feather-
board that applies pressure to the full
face of the board. !/8" HARDBOARD
Different Design – My design is STOP
a. HOLE
a little unusual and doesn’t look like
a traditional featherboard. That’s
because I use a piece of hardboard that CUT
acts like a spring to apply the pressure FEATHERBOARD SLOT IN
RUNNER
(see drawing at right). NOTE: SAW KERF SO IT CAN
CUT AT 15° ANGLE EXPAND
This piece of hardboard fits snug in WHEN
an angled saw kerf that I cut in a L- PLASTIC KNOB IS
WING NUT TIGHTENED
shaped block. Yet it’s easy to adjust
for different stock sizes.
Expandable Runner – The block
is attached to a runner that fits in RUNNER
the miter gauge slot of the table saw. DEPTH OF
MITER SLOT
Instead of using clamps to hold the
featherboard in position, the runner
!/4" x 1"
expands when a pair of wing nuts are MACHINE
SCREW
tightened (see detail ‘a’). This wedges NOTE: CUT KERFS IN
BLOCKS, THEN ALIGN CUTS
the runner in the slot so the feather- AND GLUE BLOCKS TOGETHER
board won’t move.
Safe Bevel Ripping on Right-Tilt Table Saws

Bevel ripping both edges of a narrow workpiece using the for a small table was to start by ripping a 45° bevel along
table saw is a delicate operation. In order to make this pro- one edge of each block (see left drawing). Then I ripped
cedure safer, I like to use a narrow, shop-made push stick, another bevel on the opposite edge (see right drawing).
and the eraser end of a pencil as a hold-down. I carefully sneak up on the final width until the trian-
The procedure that I used to make the corner blocks gular block just fits in the back corner of each leg.
FIRST: BEVEL RIP SECOND: BEVEL RIP

CORNER BLOCKS FENCE TO FIT
TO ROUGH
WIDTH
PENCIL
WASTE
PUSH
TILT BLADE STICK
TO 45°
WASTE
AUXILIARY AUXILIARY
FENCE FENCE
120STTT_F034-035rev.indd 35 8/9/2006 4:31:05 AM

Must-Have
Corner Clamps
I n a perfect world, assembling a
project would go smoothly. All
the parts would stay aligned and all
the joints would fit snugly. But we
all know that assembly time can get
pretty hectic. So whether it’s miter { Caption (arrow). Et
joints, face frames, or even putting autpat ullam dolorerit
together a plywood case, one way ad tinit, sequam
to avoid the juggling act is to work dolortio cor irilit,
on only one corner joint at a time. veliquam inisl endio et,
For this strategy to work, you’ll conse tet nissequam,
need some way to keep the joint commod molendiam
together. Thankfully, I found a few endre tismodo odiatue
unique, corner clamps to come to
the rescue. These unusual-looking
clamps make it easy to get tight-
fitting joints. And they keep project
parts aligned at exactly 90°.
Bessey Angle Clamp

The first clamp I took a look at is
the Bessey Angle Clamp. It’s shown
in the photos at right and below.
Notched Jaw – What sets this
clamp apart are the unique, inter-
locking jaws. The V-shaped opening
in the fixed, rear jaw provides two
reference faces for aligning parts.
And at the back of this jaw you’ll
also notice a pair of notches (or
openings). These openings do two
things. First, they provide access to
the joint for drilling holes, driving you to clamp T-joints, as in the far The pivoting action of both jaws
screws, or attaching other hard- right photo below. enables you to clamp parts that
ware. Secondly, the notches allow As I mentioned, the notched jaw aren’t the same width.
is “fixed.” But that’s only partly Front Jaw – The wedge-shaped
Bessey Plastic-coated true. Even though it doesn’t slide front jaw, like the rear jaw, is plastic
jaws resist glue up and down on the screw, it can coated to keep glue from sticking
Angle Clamp
and finishes still pivot. The advantage of this can to it. The front jaw slides along the
Jaws pivot be seen in the middle photo below. screw and forces the mating pieces
to allow for different
material thickness
{ The Bessey Angle Clamp opens wide enough to clamp three types of
joinery. The clamps can handle miter joints (left photo), as well as pieces
Notches in rear jaw let
that aren’t the same width (middle photo). Notches in the fixed jaw
you clamp T-shaped joints
allow the clamp to grip T-joints with ease (right photo).
and provide acces to
Compact clamp corner joints for drilling
fits in a toolbox and driving
Clamping | 36
120STTT_F036-037rev.indd 36 8/9/2006 4:31:49 AM

The Multi-Spanner
Gross-Stabil
together and into the reference about 13/8"). So when it comes to Multi-Spanner
clamps both corner
faces on the fixed jaw — even miter putting together larger plywood
and T-joints
joints like you see in the left photo workpieces, I’ll turn to the Multi-
on the opposite page. Spanner clamp from Gross-Stabil
Another thing I like about this that you see in the photo at right.
clamp is its small size. It easily fits Big Clamp – The first differ-
in a toolbox, so you can always have ence you’ll notice from the Bessey
one close at hand. clamp is the size. The depth of Clamp screws
the faces of the Multi-Spanner are can be posi-
Gross-Stabil quite a bit larger, almost 21/2" in tioned in two
Multi-Spanner fact. This gives it a bigger bearing locations
While the Bessey Angle Clamp surface for clamping up wider proj-
tackles frame construction tasks ects. The faces are cast zinc and
with ease, it can fall a little short in epoxy coated to resist glue and Swiveling clamp lets
case construction. The reason for finishes. Just like the other clamp you apply pressure
that is the jaws aren’t very tall (only mentioned, the faces of the Multi- right where you need it
Spanner allows it to hold
the pieces in both corner eling arm (see photo at left). With
joints and T-joints. this feature, you can apply pressure
Double Screws – directly in line with the joint. Or if
Another obvious differ- needed, you can tilt the screw out
ence is the way that the of the way to provide access to the
workpieces are secured joint for driving screws or nails.
to the clamp. Instead Both sides have a pair of holes
of a single screw, the that allow you to position the clamp
Multi-Spanner uses two screw in a high or low position. The
opposing screws. You benefit here is that you can adjust
can see these two screws the screws depending on the size
in the photo above. of the workpieces.
A pivoting clamp One screw threads Finally, check out the box below
head allows you to through the body to hold for some other corner clamping
apply pressure right a workpiece up to 11/8" options. And to find out where to
where you need it thick. On the other side get all the clamps shown here, go
of the clamp, the screw online or contact your local wood-
is mounted on a swiv- working dealer or tool supplier.
Low Tech: Sometimes, Simple Will Do

Just about everyone could use
a third hand when it comes
time for assembly. And that’s
where the two clamping
helpers you see in the photos
at right come in.
Jet Jointing Clamp – The
simple spring clamps you see
in the left photo works like
a paper clip for wood. Two
stainless steel leaf springs
grip workpieces up to 3/4"
thick and hold them against a
glass-reinforced plastic body.
Rockler Clamp-It – This
unique precision alignment
square (right photo) isn’t
really a clamp, but its thick,
polycarbonate body does
make it easy to attach a { The Jet Jointing Clamp uses { With the Rockler Clamp-It Assembly
couple of clamps and hold stainless steel spring-action leaves to Square and a pair of clamps you can
case parts at a perfect 90° for hold mating parts together at 90° quickly align and square up large
assembly and glue up. against a rigid center block. plywood cases.
Clamping | 37
120STTT_F036-037rev.indd 37 8/9/2006 4:32:31 AM

“Springs” Hold Miters Together
When gluing up frames with mitered cor- To avoid this, I clamp hardboard
ners, sometimes I use a “spring” miter “pads” to the workpieces before
clamp to hold the pieces. The strong attaching the spring (Fig. 1).
spring does a good job preventing the This way, the spring digs into the
pieces from slipping during glue up. hardboard pads instead of biting into
The problem with this type of clamp the workpieces (Fig. 2). The spring
is that the sharp ends of the spring can still applies enough pressure to clamp
leave unsightly dents in the corners of the joint, without leaving any marks
your workpieces. in the workpieces.
1 2 APPLY SPRING
MITER CLAMP
TO PIECES
a.
CLAMP CLAMP SPRING
HARDBOARD DIGS INTO
PADS NEAR PADS, NOT
THE MITER WORKPIECES
HARDBOARD JOINTS
PAD
SPRING
MITER
CLAMP
Cradles Keep Pipe Clamps Upright

Pipe clamps have a frustrating tendency to tip over when PIPE CLAMP
gluing up a solid-wood panel. Also, moisture in the glue
reacts with the iron pipes, which creates an ugly black
stain on the wood. GLUED-UP PANEL
To steady the clamps, I make several “cradles” from
inexpensive metal broom clips and plywood blocks (see
drawing). The clips have the added benefit of raising the
panel off the clamp, so there’s no worrying about the pipes BROOM
CLIPS
staining the wood (see drawing).
Use Wedges to Stop Panels from Cupping

While dry-assembling large projects, where shelves are glued on each end. Stick the spacers to the sides with
clamped between the sides, the centers of the side panels carpet tape and clamp the assembly together.
will often cup out from the dadoes (Fig. 1). Now, to force the center of the side panel tight against
I came up with a fix that uses opposing wedges. These the shelf, tap opposing hardwood wedges between the
wedges work against a clamping bar that “straddles” the clamping bar and the sides until the shelf is completely
sides (Fig. 2). This bar is simply a 2x4 block with a spacer seated in the dado (Fig. 2).
1 2 WEDGES REMOVE !/2"-THICK

CUPPING SPACER
WHEN USING CLAMPS ONLY,
SIDES CAN CUP AWAY FROM SHELF
a.
CLAMP
SHELF
CLAMPING
BAR
CLAMPING
BAR
Clamping | 38
120STTT_G038-039rev.indd 38 8/9/2006 4:33:21 AM

Spring Clamps for Hard-to-Reach Spots
Filler blocks help support drawer run-
ners inside a cabinet. But clamping a.
the filler blocks can be a challenge. TOP
VIEW “SPRING” CLAMP
The blocks are centered in the drawer MADE FROM THIN
STRIPS OF WOOD
opening and most clamps don’t have
wide enough jaws to hold them in
place (see drawing).
So instead of using a regular clamp
here, I flexed some thin strips of wood
into the drawer opening (detail ‘a’).
“SPRING”
This “spring” clamp (and a bar clamp CLAMP
in front) holds the filler block in place FILLER
BLOCK
while the glue dries.
Weatherstrip Improves Your Clamp Blocks

When edge gluing wide panels, I
often like to use scrap blocks to dis-
tribute the clamping pressure. The
blocks also help me avoid denting
the edges. But sometimes the scrap
blocks fall to the floor before I get the
clamps tightened.
To solve the problem, I made a
number of U-shaped clamp blocks
that stay right where I put them.
The secret is a piece of self-adhesive !/4"
weatherstrip attached to the “jaws” of HARDBOARD
each block (see inset photo). 2"
When you slip the clamp block GLUE UP
EXTRA LONG
over the edge of the workpiece, it BLANK, THEN
CUT CLAMP
compresses the weatherstrip (see 2" BLOCKS TO
LENGTH
drawing). This provides just the right #/4"
amount of resistance to hold the block
in place (see photo). #/4"-THICK
STOCK
To make the clamp blocks, I find it’s 1!/8" WORKPIECE
easiest to glue up a long blank. Then WEATHERSTRIP NOTE:
CLAMP BLOCKS ARE
I just cut the individual clamp blocks SIZED FOR #/4"-THICK STOCK
WEATHERSTRIP
to length from the blank.
Shop Tip
Two-Timing Clamps for Long Pieces
Tape the Pipe – You
Sometimes, projects go together can protect your projects by
without a lot of problems. But occa- applying a strip of masking
sionally, a large project (like this tape to the top edge of your
double headboard) can cause prob- pipe clamps. This prevents
lems during the gluing and clamping the iron in the pipe from
stage. In order to clamp the lower reacting with the water in
rail to the two uprights, I needed a a. the glue and staining the
very long clamp. Since I didn’t have a wood. Another solution is to
long enough clamp on hand, I ended raid the kitchen pantry and
up using two shorter pipe clamps simply cover the bars with
instead, interlocking them to get the half-sheets of waxed paper.
length necessary (see drawing).
Clamping | 39
120STTT_G038-039rev.indd 39 8/9/2006 4:33:50 AM

Make All These Profiles and More With
Three Basic Router Bits
O ver the years I’ve accumulated

dozens of different router
bits. What I call the “workhorse”
it for a special job. This finally led
me to the realization that you don’t
need a drawer full of expensive bits
truth is that many bits can produce
a variety of shapes depending on
how you put them to use. To make
bits (the ones with standard pro- to rout fancy profiles. some of the profiles above, I used
files) get used over and over again. Just Three Bits – If you have different parts of the bit or changed
By the same token, the more exotic any doubts this is true, just take the depth or height of the cut. For
“big money” bits usually just gather a look at the photo above. It illus- example, a core box bit (or cove
dust. I probably bought each one trates the point perfectly. All of the bit) can be used to create a wide,
because someone told me I needed molded edges shown (all examples shallow cove or a deep hollow.
are 3/4"-thick stock) can be made Multiple Bits – Some of the
1/2”-dia.
using just three common router simple profiles you see were made
Round-over bits. These are bits you’ll find in using only a single bit. But to
Bearing can bit
be removed just about any woodworker’s col- create the more complex shapes,
for deeper cut lection. And as you can clearly see, you’ll need to use a combination of
the possibilities for putting them to bits. For instance, a 1/2" round-over
use are pretty impressive. along with an accurately cut 1/4"
The three bits (shown at left) I cove creates a large reverse ogee.
used to make these examples are a Accurate Cuts – One of the keys
1/2" round-over bit, a 1/4" round-over to successful results is to make the
bit, and a 1/2"-dia. core box bit. cuts carefully and accurately. Two
Just One Bit, Several Cuts – The or three (or more) light cuts will
following page shows how to make often yield better results than one
1/4”-dia. a few of my favorite profiles. deep cut. This is more important
Round-over There’s really no great secret than doing the job quickly. And
bit to the process. First, I try to avoid finally, a little fine sanding is often
1/2”-dia. thinking that a single router bit needed to “blend” multiple cuts
Core box bit can only make one type of cut. The into one smooth, seamless profile.
Router & Router Tables | 40
120STTT_G040-041rev.indd 40 8/9/2006 4:34:33 AM

How-To: 7 Easy Profiles Shop Tip: Design Your Own
ONE SETUPS As you can see, the layout tools I used to design
these profiles are pretty basic. A section of 1/2"-
!/2"
ROUND-OVER dia. dowel works great as a template for a 1/4"
BIT
#/8
roundover or a 1/4" cove (1/2" core box bit). And a
1"-dia. dowel was my 1/2" round-over bit. Chances
are if you can draw it on paper, you can find a way
to make it with a few common router bits.
!/4"
ROUND-OVER
BIT !/8
!/2" ROUND-OVER
BIT WITH BEARING !/16
REMOVED
!/16
TWO SETUPS
%/16
!/2"-DIA. #/16 !/4" ROUND-OVER
CORE BOX BIT BIT WITH
BEARING !/16
REMOVED
#/4
!/2"
ROUND-OVER !/2"-DIA.
BIT CORE
BOX BIT #/16
!/4
THREE SETUPS
!/2 !/4"
!/4" ROUND-OVER #/16
!/2"-DIA. ROUND-OVER BIT
CORE BIT
BOX BIT %/16
(/16
!/4" !/2
!/4"
ROUND-OVER ROUND-OVER !/2"
BIT BIT CORE
BOX BIT #/16
!/4 !/4
Routers & Router Tables | 41
120STTT_G040-041rev.indd 41 8/9/2006 4:35:10 AM

Shop Tip Routing Small Pieces
When routing small pieces on a router
A Bit Greasy – Before table, how do you keep them from tip-
flush trimming a plastic lami- ping into the hole in the insert plate?
nate surface, I first coat the One solution is to add an auxil-
bearing of my flush trim bits iary top made of 1/8'' hardboard (see
with a little Vaseline. This drawing). To provide clearance for
prevents the contact cement the router bit, you’ll need to drill
and laminate dust from a hole in the top. And drill the hole
building up on the bearing. slightly larger than the bit.
All it takes to attach the top to the
router table is a few strips of carpet
tape. With the top in place, raise the to hold them with a rubber-bottom
Iron Out Marks bit through the hole to the desired grout trowel (see photo). This way, I
height and you’re ready to start can control the cut without getting
After rounding over an edge, there’s routing. The only other problem is my fingers close to the bit.
often a shallow “track” left by the how to safely hold a small workpiece. Note: Grout trowels are available at
router bit bearing. This means a line The best way I found to do this is hardware stores and home centers.
of wood fibers is compressed. To
restore the compressed fibers to their !/8"
HARDBOARD GROUT TROWEL
original shape, simply use a damp TOP WITH RUBBER PAD
cloth and a hot iron (see drawing).
HOT IRON
ON
DAMP
CLOTH
RAISES a. GROUT
COMPRESSED WORKPIECE TROWEL
FIBERS
CLOTHES HARDBOARD
IRON TOP
CARPET
NOTE: TAPE
SET IRON WORKPIECE
TO MEDIUM TO
AVOID SCORCHING
Auxiliary Base for Routing Inside Chamfers

If a frame and panel are 1 2
already assembled, it’s dif- LINE UP a.
FLATHEAD END OF
ficult to rout a chamfer on WOOD GUIDE
SCREWS WITH
the frame because the panel CENTER
OF BIT
gets in the way of the pilot V-GROOVE !/4"
BIT GUIDE HARDBOARD BASE
on the chamfering bit.
!/4"
Auxiliary Base – To deal HARDBOARD
with this problem, I used a BASE
ROUTING
“V-groove” bit instead to EQUAL DIRECTION
DISTANCE
make the chamfer. But to
guide the bit, I had to make GUIDE
an auxiliary router base and GUIDE

!/4"
a special 11/2"-wide guide HARDBOARD DETERMINES
GUIDE START AND
(Fig. 1). I made them both STOP POINTS
from 1/4" hardboard. OF CHAMFER
Guide Function – The

primar y function of this
guide is the same as that of the pilot on a chamfering Rout the Chamfer – To make the chamfer, just adjust
bit. It keeps the bit a uniform distance from the edge the depth of the bit to cut a 1/8"-wide chamfer. The guide
being chamfered. But the guide also stops the chamfer will maintain a uniform chamfer and stop the cut exactly
a uniform distance (3/4") from the corners. 3/4" from the corners (Fig. 2).
120STTT_H042-043rev.indd 42 8/9/2006 4:36:19 AM

Making Straight Cuts Between Profiles
The base on one of my projects has ogee profiles cut out the layout line, leaving about 1/16" of stock.
of it to form feet. In between is a straight cut that sepa- Straightedge – Then I switch to a flush trim bit in my
rates the two profiles. You might think the profiles were router table to rout to the line. But to get a straight cut,
the hardest parts to make. But making the straight cut you have to guide the bit. To do this, I use double-sided
between them turned out to be more of a challenge. tape to “clamp” a straightedge flush with the layout line
There’s nothing tricky about cutting out the profiles. (Fig. 1). Now the bearing on the bit follows the straight-
You just follow the layout lines with your band saw (or jig edge to rout the line (Fig. 2).
saw) and sand them smooth. But this won’t work when You’ll have to stop short of the profile because the diam-
cutting along the layout line that separates the profiles. eter of the bit (1/2") won’t let you into tight corners. But it’s
Here, the goal is to have a line that’s perfectly straight. If easy to finish the cut. Use a chisel to clean up the corner.
your blade wanders even a little, it’s easy to see. So I don’t Note: I left the straightedge carpet-taped in place to
cut right to the line. Instead, I’ll cut on the waste side of help guide my chisel.
1 STRAIGHTEDGE
2
POSITION ONE EDGE
OF STRAIGHTEDGE
ON LAYOUT LINE
DOUBLE-SIDED
CARPET TAPE
FLUSH TRIM
BIT
BASE FRONT STRAIGHTEDGE
LAYOUT
LINE STOP SHORT OF CORNER
AND CLEAN UP WITH A
CHISEL
Safe Routing “On the Edge”

Most routing operations should be The problem is, if you try to bal- the router (Fig. 3). The base serves as
done before a project is put together. ance the router on the narrow edge of a bridge across the case to the opposite
That’s because it’s easier to rout a a piece of 3/4"-thick stock, it will prob- side. I make this auxiliary base from a
groove or a profile if the workpiece is ably tip one way or the other and dig short piece of 1/4" hardboard.
lying flat. But, there are times when into the wood (Fig. 1). Luckily, there After drilling a hole in the hard-
it’s necessary to do some routing on are a couple of simple ways to solve board platform for the bit to come
a project after it’s assembled. A good this problem. through, I use double-sided carpet
example is when you’re routing the First Solution – If the case is con- tape to stick the auxiliary platform
rabbets for a back panel. structed in such a way that clamps to the plastic base on my router. (Or,
On this project, the rabbet had to be will reach around it, clamp on a 2x4 you can remove your existing base
routed after the case was assembled. block flush with the edge to be routed and screw the new platform directly
But this led to another small problem (Fig. 2). This provides an extra 11/2" of to your router.)
— I soon realized I was going to have solid support for the router base. Rout the Rabbet – Then, you can
trouble keeping the router level on Second Solution – The second rout as usual with the new base strad-
the sides of the case. method is to add an auxiliary base to dling over both edges of the case.
1 2 3 !/4" HARDBOARD
CLAMP 2x4
TO EDGE OF CASE
TO SUPPORT
ROUTER
WORKPIECE
EDGE TOO
NARROW TO CARPET TAPE BASE
KEEP ROUTER HOLDS BASE RIDES
STEADY TO ROUTER ON
EDGES
OF CASE
120STTT_H042-043rev.indd 43 8/9/2006 4:36:48 AM

Adding a Router Table Insert
There are two things to look for when Once the strips are in place, the 1
creating the opening for an insert plate opening can be trimmed with a hand-
in a router table: the plate should fit the held router and a pattern bit (Fig. 2). FIRST: DRILL !/2"-
DIA. HOLES IN TWO
opening like a glove and it has to be You’ll need to do this in two passes, OPPOSING CORNERS
flush with the top of the router table. since most pattern bits are only 1"
Here’s an easy way to do both. long (Figs. 2a and 2b).
Layout – To lay out the opening, Attaching Cleats – With the
start by using the insert plate as a opening complete, you can attach
template. A framing square makes it the cleats that hold the insert plate in
easy to center the plate on the table, place. To position the cleats, flip the SCRAP TO PREVENT
CUTTING TABLE
allowing you to position the insert top face-down on a flat surface. Then
SECOND: CUT AWAY
plate square with the edges of the drop the plate in the opening and glue WASTE WITH JIG SAW
table. Now hold the plate firmly in and screw the cleats in place.
place (some double-sided carpet tape
will help in doing this) and carefully 2
trace around the edges.
Roughing Out – Next use these lines
as a guide for cutting out the opening. FIRST: TRIM
AROUND
Start by drilling a couple of starter holes OPENING
on opposite corners of the waste area. a. b.
Then use a jig saw to rough out the CROSS SECTION CROSS SECTION
opening, staying about 3/16" away from
the layout lines (Fig. 1).
Trim Opening – After rough-
cutting the opening, the last step is SECOND: LOWER WASTE
BIT AND REMOVE
to trim the edges to match the size of REMAINING WASTE
the insert plate. To do this, tape down !/2"-DIA. LOWER BIT
PATTERN BIT ON NEXT PASS
some strips of 1/4" hardboard along the
lines on the top.
Routing Odd-Size Rabbets

Routing a rabbet on a curved piece bit in the router table and raise it to the leaves 3/16" exposed to cut the rabbet
isn’t difficult. A router table and a desired height (depth)(Fig. 1a). to the desired width.)
rabbeting bit with a pilot bearing will Cut Notch – Then use a piece of Next, clamp the auxiliary fence to
do the job just fine. plywood scrap as an auxiliary fence, the table. Then draw a line on the
But what if you don’t have a rab- cutting a notch in the center to make it a fence directly over the center of the
beting bit? To get around this, you zero-clearance fence (Figs. 1 and 1a). bit. (This is a reference mark used for
can use a 1/4" straight bit on the router To cut the notch, clamp the scrap routing the rabbet.)
table and a zero-clearance fence with piece to the router table fence. Then Rout Rabbet – Now rout the
the router bit partially “buried” in the turn on the router and push the fence rabbet, always routing right-to-left.
fence (Fig. 1). into the bit until 1/16" of the bit is Be sure to always keep the piece in
Adjust Bit – First, mount the straight buried in the fence (Fig. 1a). (This contact with the fence (Fig. 2).
1 2 3
COMPLETED
RABBET
!/4"
STRAIGHT
BIT
ROUT a. #/16
NOTCH IN
AUX. PENCIL MARK
FENCE INDICATES
!/4 CENTER OF
ROUTER BIT DIRECTION
OF FEED
120STTT_H044-045rev.indd 44 8/9/2006 4:37:20 AM

Backrouting for Clean Rabbets
Cutting rabbets for panels on the Make It Safe – So if backrouting
insides of door frames isn’t compli- is so great, why not do it all the time?
cated, even if it’s done after the doors The problem is that the router bit
are assembled. To do it, I just use a won’t pull itself into the workpiece,
hand-held router and a rabbeting bit. as it normally would. Instead, the bit
Scoring Pass – Whenever I rout a will bounce along the edge, trying to
rabbet though, I worry about chipout pull the router along. This can make it
along the edge. There is a way around harder to control. So whenever back-
this — by taking a light backrouting routing, take a light pass, keep a firm
pass first. This means a pass in the grip on the router, and brace your
direction opposite in which the router arms against your body.
usually runs. (This would be counter- The idea is to remove just the mate- ROTATION SAME AS
FEED DIRECTION
clockwise inside the frame.) rial at the front edge of the cut so BACKROUTING
Backrout – The reason this works there won’t be chipout when the cut
is that the bit is cutting into the work- is completed.
piece. The material behind the cut sup- Rout Rabbet – After the edge has Square Corners – When the
ports the material being removed (see been scored, you can make deeper rabbet is completed, you’ll notice the
drawing). On a normal pass, the bit passes to cut the rabbet to full width. corners where the bit couldn’t reach
cuts out of the workpiece. The unsup- But this time rout in the normal direc- are rounded. These can easily be
ported wood at the edge of the work- tion. (In this case, clockwise around squared up by paring away the waste
piece is what chips out. the inside of the frame). with a chisel.
Trimming Edging Flush

I like to trim the sides of my plywood bookshelves with
hardwood edging. And once the edging is glued in place,
it needs to be trimmed flush. To do this, I use a router with
a bearing-guided flush trim bit.
Fill the Dadoes – If the case has dadoes to hold shelves,
you need a way to keep the bearing from dropping into
them. So I fill each dado with a filler strip that is just thick
enough to fit flush with the face of the plywood (Fig. 1).
No More Tipping – Then the trick to keeping the router
from tipping when working on the thin edges is to clamp
both side pieces together. It gives a wider surface for the
router to sit on. And it lets you rout the edging on both
pieces at the same time.
To make this work, you’ll have to separate the sides to
make room for the router bit. Then I clamp 2x4 spacers
between the sides to hold them apart and make a wide
platform for the router (see photo at right and Fig. 2).
Finally, I trimmed the edging that sticks out past the
ends to length with a sharp chisel (Fig. 3).
1 !/2" FLUSH TRIM

ROUTER BIT
2 FIRST: CLAMP SPACER SECOND: ROUT 3
BETWEEN CASE SIDES EDGING FLUSH
EDGING
USE
CHISEL TO
TRIM END
OF EDGING
FILLER FLUSH
STRIP
BOOKCASE NOTE:
SIDE DIRECTION
OF ROUTER
120STTT_H044-045rev.indd 45 8/9/2006 4:37:44 AM

Routing Out for a Circular Inlay
A marquetry inlay is a nice way to add particular inlay was close to a true block over the inlay and tap it in place
a touch of class to any project. The circle, I used a circle cutter to score with a hammer. Then place a board
problem is getting it mounted. For the outside edge of the recess. on top of the inlay to clamp it down
a recent project, I used a “starburst” Then I removed a majority of the evenly. Finally, sand the inlay flush
inlay, which has a circular shape that waste in the recess with a router and with the surface of the board.
is easier to work with. a 1/2" straight bit. Set the depth of cut
Paper-backed – I bought my inlay to about three-fourths the thickness
from a veneer supply house and the of the inlay and rout to within about
inlay came mounted in a rectangular 1/8" of the score line. To remove the PROTECTIVE VENEER
piece of veneer. So the first thing I did remaining waste, I used a sharp 1/4"
was remove the inlay itself by cutting carving chisel. SCORE
CHISEL
AWAY
around it (through the paper backing) To mount the inlay, apply a coat of OUTSIDE INLAY EXCESS
EDGE PAPER SIDE UP
with a razor knife. This backing is contact cement in the recess and also
actually veneer tape that holds all the to the “back” of the inlay.
pieces of the pattern together. Note: The side with the brown ROUT OUT RECESS
When the inlay is removed, mea- paper is actually the front, or top side.
sure its diameter and cut a recess Press the inlay into the recess (with
to fit (see drawing). Because this the paper side up). Place a softwood
The Best Way to Get Edges Flush

Trying to get the edges of two work- in line with the cutting edge of the
pieces exactly flush can be close to bit. As the bearing rolls along one
impossible if you just try to position surface, the other surface is trimmed
them by hand. exactly flush with it (see drawing).
That’s why when I need two sur- For smaller pieces, you can mount
faces perfectly flush, I cut one slightly your router in the router table and
oversize and then use a flush trim bit guide the workpiece past the bit. But
FLUSH
to take off the excess after the pieces it’s not safe or practical to handle TRIM
BIT
are glued up (see drawing). large workpieces on the router table.
A flush trim bit works because it In those cases, use the flush trim bit
has a bearing at the end that is right in a handheld router.
Router Fence Alignment

When routing a dado across a wide mount the bit in the router and run it down (Fig. 2). Now rout along the
panel, I mark the location of the dado the router base against the high fence edge of the fence. The dado should
first. Then I clamp a fence parallel to to rout a dado across the scrap. match the layout lines.
the layout lines to guide the router. Using the Gauge – To use the Router Base – Since router bases
The problem is figuring out the alignment gauge, turn it over on the can be mounted off center in rela-
exact location of the fence. You have workpiece so the dado aligns with tion to the bit, always keep the router
to measure the distance from the edge the layout lines. Then butt the fence facing the same direction that it was
of the router base to the cutting edge against the end of the gauge and clamp when you routed the gauge.
of the bit, then transfer this measure-
ment to the workpiece. Somewhere 1 RUN ROUTER
AGAINST
2 CLAMP STRAIGHTEDGE
FENCE AGAINST
there’s likely to be an error. 2x4 BLOCK END OF
GAUGE
Alignment Gauge – To be a little
more accurate, I made a simple gauge.
It’s a piece of scrap with a dado cut
across it to align the fence parallel to
the layout lines (Fig. 2).
To make the gauge, clamp a piece BUTT END OF
ROUT SHALLOW ALIGN DADO
of scrap to the bench and clamp a GAUGE BLOCK
DADO IN GAUGE BLOCK WITH LAYOUT LINES
AGAINST 2x4 ON WORKPIECE
higher fence at one end (Fig. 1). Now
120STTT_H046-047rev.indd 46 8/9/2006 4:38:12 AM

Pattern Routing with a Flush Trim Bit
I just completed building a storage cabinet for my saw After cutting the bottoms oversize, you can use this tem-
blades. All ten trays on the storage cabinet have identical plate to rout all the profiles.
bottoms, made of 1/4" hardboard with rounded pulls on This template will create a uniform appearance for all
their fronts (see right photo). So I wanted a simple way to the trays in your cabinet (see right photo below), and it will
cut them all to the same profile. also save you time and effort.
Pattern Template – One of the
quickest ways to make identical parts
is to use a pattern template and a flush
trim bit in the router table.
To do this, just secure the template
to a blank with carpet tape, and set the
bearing on your router’s flush trim bit
to ride against the template.
For the pulls on the cabinet trays,
the template is made up of two parts:
a small piece of 1/4" hardboard in the
shape of the pull you want, and the
hardwood front already fastened to
each tray (see left photo).
Bevels of Another Angle

On a recent project, I wanted a 30° chamfer on an edge.
However, all I had was a 45° chamfer bit. Not wanting to a. WEDGE EXTENDS
BEYOND ROUTER BASE
buy a new bit for what was likely to be a one-time use, I
found a way to make the 45° bit work.
Wedge the Router Base – The solution was a 15°
wedge for the base of my router. To ensure a stable base,
the wedge has to be wide enough to reach the outside edges 30°
15° WEDGE
of the router (see detail). I removed the base plate and used BEVEL
it as a template when drilling the mounting holes. To ensure 45° CHAMFER BIT
an even chamfer, make sure to keep the wedge parallel to
the edge when routing.
Routing Custom-Fit Dadoes

When routing a dado in a large panel, I find using a hand- To do this, I set up a fence with a spacer strip that deter-
held router is much easier than wrestling with a large mines the exact finished width of the dado. The width of
panel on my table saw or router table. the strip, plus the diameter of the router bit should equal
Two Passes – Since lumber is rarely the exact same the finished width of the dado (Fig. 1a). After the first
thickness as the diameter of a router bit, I use a smaller bit pass, remove the spacer. Then make the second pass to
and make two passes. complete the dado (Fig. 2).
1 2 SPACER FIRST
PASS
a.
STRAIGHT
BIT
SPACER
SPACER REMOVE SPACER
TO COMPLETE DADO SECOND
PASS
TAPE WIDTH
ROUT IN OF DADO
SPACER DIRECTION
STRIP TO OF ARROW
FENCE
120STTT_H046-047rev.indd 47 8/9/2006 4:38:44 AM

Choosing Ogee Bits
An ogee router bit is simply one that has two radii (one ROMAN OGEE STANDARD OGEE
concave and one convex) that are the same size, which CONCAVE CONVEX
create a distinct profile. A standard ogee bit is similar to a RADIUS RADIUS
Roman ogee, but the locations of the concave and convex
curves are reversed (see drawing). (If an extra shoulder is
added to the ogee bit it is called an ogee with a fillet.)
Either can be substituted for the other, because it doesn’t CONVEX CONCAVE
RADIUS RADIUS
affect the size of the profile, only the style.
Routing Stopped Profiles

When routing a stopped profile on just a matter of marking the points to width so the profile routed on it
an edge, it’s easy to determine the on the finished workpiece where you lines up with the mark (Fig. 2).
end of the cut with a couple of simple want the profile to start and stop. After routing the edges, there is still
stop blocks. Then, by clamping a stop block next some hand work to be done.
To make the stop blocks, clamp to each mark, you can stop the cuts at At both the start and the stop points,
a block to a piece of scrap (Fig. 1). the correct position. the bit leaves a squared-off shoulder
Then rout the inside corner formed To make the stopped cuts on the (Fig. 3). Round this shoulder with a
by the block and the scrap. Now it’s inside edge of a small frame or box, file and sandpaper to match the rest
you may need to trim each stop block of the profile.
1 CLAMP STOP
BLOCK TO TOP VIEW
SCRAP 2 3
STOP BLOCKS CLAMPED
TO ADJACENT SIDES
STOP ROUTER BIT
BLOCK LEAVES SQUARED
ROUT IN THIS OFF SHOULDER
ROUT DIRECTION
PROFILE
USE FILE TO
ROUTER SHAPE PROFILE
Routing Direction
If you’re cutting a circle a consideration. Typically, called “backrouting” and have more control.
from a larger workpiece you would run the trammel it can be tricky to do free- The rotation of the bit
using a trammel, it doesn’t in a counterclockwise hand, as the router wants will still cause the router to
matter which direction you direction (Fig. 3). This to bounce along the edge. want to pull itself along. So
rout. Since the bit is sur- gives you the best control. But with a trammel, the keep a firm grip on it and
rounded by stock, the cut is But the cut isn’t backed up, tool is anchored and you make shallow passes.
always backed up and won’t so it may chip out.
chip out (Figs. 1 and 2). A way to get around this 3 4
When routing an outside is to move the trammel
edge, direction should be clockwise (Fig. 4). This is
EDGE BACK-
ROUTING ROUTING
1 2 ROUTER
COUNTER- ROUTING AN EDGE
STRAIGHT BIT CLOCKWISE CLOCKWISE
STRAIGHT BIT
MAKE
SHALLOW
CUT IS CUT IS PASSES
BACKED BACKED
BY UNCUT BY UNCUT
WOOD WOOD
NOTE:
WOOD IN FRONT OF
ROUTING CLOCKWISE NOTE: BIT IS SUPPORTED
ROUTING COUNTERCLOCKWISE THERE MAY BE SOME WHEN BACKROUTING
CHIPOUT WHEN ROUTING
COUNTERCLOCKWISE
120STTT_H048-049rev.indd 48 8/9/2006 4:39:13 AM

Dovetail Depth Gauge
Once you have the bit set to cut a nice, tight dovetail joint, across the width of the block (Fig. 1a).
it’s worth taking a few minutes to make a simple depth- Next, clamp the piece in a vise and rout an oversized
setting gauge. Then you can easily reset the bit the next dovetail-shaped notch across it (Figs. 1 and 1b). To do this,
time you want to cut dovetails. run the bushing against the left shoulder of the dado and
To make the gauge, start with a long piece of scrap that then back out along the dado’s right shoulder (Fig. 1b).
you cut to length later (Fig. 1). To provide clearance for Now whenever you need to set up your router for dove-
the guide bushing, use a straight bit to cut a 3/4"-wide dado tails, use the gauge to reset the height of the bit (Fig. 2).
1 2
a. NOTE:
UNPLUG ROUTER
WHEN SETTING
WHEN DEPTH OF BIT
#/4 RESETTING
&/16" !/4
RAISE BIT UNTIL
GUIDE BUSHING EVEN WITH TOP
OF NOTCH
ROUT
DOVETAIL
NOTCH IN
TWO PASSES
CUT OFF
WASTE AFTER
ROUTING DOVETAIL BIT
Using a Rub Arm for Raised Panels

Cutting arched raised panels is often It’s called a raised panel bit (Fig 1). To rout this edge, first draw a refer-
done with an expensive router bit When routing the arched top edges ence line on top of the rub arm. Then,
with bearings that follow the arch. of a panel, you’ll need to add a rub to maintain a consistent width, move
However, a less expensive bit is arm and position it over the top of the the workpiece so the edge is always
available that doesn’t have a bearing. bit (Figs. 1 and 1a). perpendicular to that line (Fig. 2).
RUB FEED
a. ROUT IN SERIES OF RAISED ARM DIRECTION
PASSES MOVING ARM AWAY PANEL BIT
FROM BIT BETWEEN PASSES
!/4"-THICK ARM,
2" WIDE
REFERENCE ARM
LINE
RAISED NOTE: KEEP HANDS
PANEL BIT CLAMP CLEAT RAISED
PANEL CLEAR OF BIT
TO ROUTER
TABLE FENCE
Shop Tip
Router Bushing Thread Lock
Burn Marks – It’s easy
When I’m routing dovetails or I have a problem with the threads of to leave nasty burn marks
following a template, I use a guide the bushing working loose due to the when routing a profile
bushing on the base plate of my vibration of the router. onto the edge of a piece
router (see drawing). But sometimes To solve this problem, I use a simple of cherry. And sanding a
fix. Before installing the routed profile is tough. I find
WRAP THREADS
WITH TEFLON TAPE
ROUTER BUSHING bushing on my router that it’s easier to remove
base, I wrap the male burn marks if you apply
threads of the bushing mineral spirits to the mark
with Teflon tape (the kind before sanding. The solvent
used with threaded pipe penetrates the glazed area,
connections). The tape and after a few minutes, you
prevents the threads from can sand if off easily.
vibrating loose.
120STTT_H048-049rev.indd 49 8/9/2006 4:39:41 AM

Easy Steps for Installing
Brass Screws
I nstalling hinges with brass
screws always makes me a little
nervous. Just one misplaced hinge
screw can affect the fit of the hinge
and therefore, the entire door. Over
the years, I’ve learned a few simple
tricks to make installing brass
screws easier.
Working with Brass – To start
with, let’s talk about the screws
themselves. When it comes to tra-
ditional hardware, that means solid
brass screws. They look great, and
best of all, they won’t rust. But for
anyone who has used brass screws,
you’ll know they have one big draw-
back — the brass is pretty soft, so
it doesn’t take much to strip out the
head or even snap it off.
Another big problem I’ve discov-
ered is that the screws that come
with some hardware can be pretty
wimpy. So I usually throw them Although slotted screws look tapered sides, which can lift out of
out and buy better-quality screws more traditional, they’re harder the slot. Instead, you should look
from the hardware store or online. to keep in good shape. If you do for “cabinetmaker’s” screwdrivers.
I’ve found that high-quality screws use them, the type of screwdriver They have parallel sides to keep
are quite a bit beefier than reg- you use can make a big difference. them in place (right).
ular screws and they usually have Mechanic’s screwdrivers (shown If the screw head isn’t critical
deeper threads. at left in the photo below) have to the look of the project, I like to
swap them out for easier-to-drive
Phillips-head screws.
Laying Out Pilot Holes – Once
I have the type of screw selected,
the next step is to lay out the screw
location. To do this, I always try to
use the hinge itself. Even a slightly
off-center hole can pull a hinge out
of alignment. So, after laying out
the hole, you’ll need to make sure
the drill bit stays on course. There
USE SQUARE
TO KEEP BIT are two ways to do this. One is to
PERPEDICULAR
TO WORKPIECE dimple the workpiece with an awl.
This gives the bit a place to start.
Or you could use a self-centering
DRILL BIT > A straight-sided screw-

SHOULD MATCH driver (right) is less likely
ROOT OF SCREW
to slip out of the slot
than the tapered
screwdriver (left).
{ Straight Shooting. For the best fit, the screw needs a perfectly
perpendicular pilot hole. Sighting against a small square keeps the
bit straight and on target.
Hardware | 50
120STTT_H050-051rev.indd 50 8/9/2006 4:40:10 AM

bit. (These bits are known as Vix this problem. Just take a look at the soft metals and wood.
bits, but that’s another story.) Shop Tip box below. Start with Steel – Oftentimes,
Picking the Right Bit – Next, A Good Hardware Fit – The I’ll need to install and remove the
you’ll need to select the right bit hinge itself plays a big role in the hinges several times when fitting
for the pilot hole. I usually pick a fit of the screws. On some hinges, doors. To avoid damaging the heads
bit that’s the exactly same size the countersink doesn’t match the of the brass screws, I’ve come up
or slightly larger than the root angle on the screw head. Although with a little trick to avoid having
of the screw. This makes driving it may not seem like much, the dif- this happen. Instead of using the
the screw easy, but still gives the ference is enough to prevent the brass screws, I’ll use steel screws
threads plenty to bite into. screw from seating properly. This for this process, as you can see in
When drilling the pilot hole, it’s can keep the hinge from closing. the photo below right.
important to keep the bit square to Weldon Countersink – To Help Driving the Screw – At
the workpiece. To do this, I use a solve this problem, I use a Weldon last, you’re ready to drive the screws
try square to align the drill, as in countersink to rebore the counter- in place. To make this easier to do,
the drawing on the opposite page. sinks in the hinge, as you can see lubricate the screws with a chunk
Don’t worry if, despite all your in the photo below left. A Weldon of wax. You’ll end up with a hinge
best efforts, the pilot hole goes off countersink has a single cutting in the right place, fastened tightly,
course, there’s a simple solution to edge that leaves a smooth surface in and looking its very best.
Steel screws can take

the place of soft brass
screws for repeated
driving and removing
while fitting hinges.
< A Weldon countersink makes quick

work of reboring the recess in a hinge
to match the screws. A poor fit can
prevent the hinge from closing fully.
Shop Tip: Adjusting Screw Holes

No matter how carefully I’ve 1 2
marked and drilled a pilot hole,
sometimes one still ends up
in the wrong place. When that THIRD: TRIM
DOWEL FLUSH
happens, there’s a simple solu- SECOND: APPLY GLUE WITH A CHISEL
AND REDRILL
AND TAP IN DOWEL
tion that will take care of the WITH A HAMMER PILOT HOLE
problem — invisibly. FIRST: DRILL OUT
First, I drill out the pilot hole PILOT HOLE
WITH !/4"-DIA. BIT
with a 1/4”-dia. twist bit
(Fig. 1). Then I apply some
glue to a matching dowel and
tap it into the hole (Fig. 2).
Once the glue dries, you can
trim the dowel flush with a
sharp chisel. Then lay out and
drill a new pilot hole. Best of
all, after you screw the hinge in
place, it covers up any evidence
of the repair.
Hardware | 51
120STTT_H050-051rev.indd 51 8/9/2006 4:40:50 AM

Installing Inset Hinges
Inset hinges can be more frustrating to install than ordi- in the opening centered up and down and also left to right.
nary butt hinges. When the door is closed, both leaves Then clamp the free leaf of each hinge to the door stile
of the hinge are inside the cabinet. This makes the screw through the opening where the glass will be (Fig. 2).
holes in the hinge almost impossible to reach. With a C-clamp on each hinge, open the door and drill
Luckily, when you use inset hinges on a cabinet with pilot holes for the screws (Fig. 3). (I use a self-centering
glass doors, it’s easy to solve this problem. I install them drill bit.) Then, screw in the screws and remove the
before the glass panes are in place. clamps to check the fit.
To do this, first screw all the hinges to the cabinet frame Now, the screws should be removed and then reinstalled
(Fig. 1). Now lay the cabinet on its back, and put the doors later, after the glass is in place.
1 2 NOTE: POSITION DOORS IN 3

CABINET, THEN CLAMP FREE
POSITION TOP AND BOTTOM LEAF TO DOOR STILE
HINGES 2!/2" IN FROM RAILS
2!/2
SELF-
CENTERING
BIT
LAY
CABINET
ON ITS
NOTE: SCREW ALL HINGES BACK TO USE SCRAP TO OPEN DOOR, THEN
TO CABINET FIRST POSITION PROTECT DOOR DRILL PILOT HOLES
DOORS FROM CLAMP FOR SCREWS
Installing Brads CARDBOARD

ADJUSTABLE PLIERS
BACKING
One way to mount the glass, picture, pliers to fit around the frame and brad,
and mat in a picture frame is to use and squeeze the brad into place. (You
1/2" brads to hold everything securely may need to adjust the pliers so the
behind the backing. A great method jaws stay parallel as the brad is driven
for doing this to use a pair of adjust- into the frame.) To prevent marring
able pliers (see drawing). the frame, place a piece of cardboard PICTURE PROTECTIVE
CARDBOARD
GLASS OR MAT
Just set the opening width of the on the outside edge of the frame.
Installing Grommets
One thing to consider when building a desk for a com- can see your layout lines. Then lay out the location using
puter is what to do with all the wires. Plastic grommets let a combination square (Fig. 1). Now, drill a hole in each
you feed the wires through the desk top. corner and cut out the waste with a jig saw. To prevent
For round grommets I use a hole saw to install them. chipout, I used a special reverse-cut jig saw blade (Fig. 2).
But for rectangular grommets I take a different approach. Finally, install the grommet and punch out tabs in the
To lay out the grommet, first tape over the area so you cover to create the openings (Fig. 3).
1 2 SIZE HOLE TO
3 GROMMET COVER
BACK CORNER FIT GROMMET
OF DESK
NOTE:
DRILL CORNER HOLES
COMBINATION WITH BRAD POINT BIT
10 SQUARE GROMMET
CL
CL
REVERSE-CUT NOTE: REMOVE TABS IN COVER

MASKING TAPE BLADE TO CREATE OPENINGS FOR CORDS
Hardware | 52
120STTT_i052-053rev.indd 52 8/9/2006 4:41:33 AM

Installing Threaded Inserts
Whenever it’s possible, I like to use my drill press to install 1
threaded inserts. It’s the best way to make sure they are
a.
straight and square in the workpiece.
Cut Off Bolt – To use the drill press for installation,
start by sawing off the head of a bolt that fits the insert.
Next, thread two nuts and the insert onto the bolt and
tighten the nuts against the insert. The next step is to
mount the bolt in the chuck.
Install the Insert – Finally, with the drill press turned
off, you can install the insert. Using the control arm for
pressure, screw the insert into the hole, turning the chuck
clockwise by hand until the insert is flush with or slightly
below the surface of the workpiece.
Installing a Magnetic Catch

Magnetic catches are generally fairly simple to install. But flush with the work surface. To do this, I guide the magnet
on a project with a narrow wooden frame surface (like a in the hole with a square, flat block of wood (Fig. 1).
small box or cabinet that’s under 3/4" thick), you need to Align the Catch – Second, in order for the door to stay
be able to install one accurately. closed, the catch must align with the magnet. To ensure
Seat the Magnet Straight – The catch I used, like it does, I place the screw on the magnet, close the door,
most, consists of two parts: a magnet and a catch plate (or and tap the door with a no-mar hammer (Fig. 2). Then
screw). To install one properly, two things must be done. when you open the door, the mark left behind will indicate
First, the magnet has to be seated straight in the hole and where to mount the catch.
1 2
USE BLOCK
OF WOOD
TO GUIDE
MAGNET
IN HOLE
MAGNET USE SCREW

TO MARK
LOCATION
ON INSIDE
OF DOOR
FOR CATCH
SCREW
MAGNET
Reverse Countersink Tip

Recently, after gluing up a number hit me. I simply reversed the counter-
of small drawers for a project, I sud- sink cutter on the end of the drill bit,
denly realized that I had failed to drill as you can see in the photo.
and countersink holes on the back Reverse the Direction – With
of the drawer fronts for the pulls and the bit inserted through the hole and
woodscrews. Drilling the holes was then chucked up in the drill, all you
not a problem, but the drawers were have to do is reverse the direction of
too small to allow my drill to fit inside the drill and gently pull back on the
to countersink the holes. bit to countersink the hole. Once the
Bright Idea – As I sat contem- holes and countersinks are all drilled,
plating my dilemma, an idea suddenly all you have to do is install the pulls.
Hardware | 53
120STTT_i052-053rev.indd 53 8/9/2006 4:42:05 AM

6 ways to get a perfect finish
Surface Preparation
A pplying a finish is like a “Catch
22.” Although it emphasizes
the color and grain of the wood,
it also puts a magnifying glass on
even the tiniest flaws.
Once you apply the finish, any
tool marks, nicks, or glue spots will
stand out like a chrome bumper on
a hay wagon. Fortunately, you can
prevent this by carefully preparing
the surface of the wood.
As a rule, I get as many pieces as
possible ready for the finish before
assembly. Take a table for instance.
It’s easier to sand the legs and
apron separately than when they’re
joined together at right angles.
Note: To ensure a tight fit, just be
sure not to sand around the areas
where the pieces join together until
after you assemble the project.
Tool Marks – Working on
pieces individually also makes it But scrapers leave a surface that It goes without saying that a
easy to see the “ridges” that often looks different than the surrounding power sander speeds up the pro-
get left behind by the cutters on a area when you apply a finish. So you cess, see photo B. But while this
jointer, planer, or router. Especially need to create a smooth, uniform works fine on large, flat surfaces,
if you shine a light across the work surface by sanding. the “give” in the foam pad tends to
at a low angle (see photo above). Sanding – Sanding is not the round over the edges. To maintain
To remove these machine ridges, most exciting job in the world, but it a crisp edge (especially on narrow
I use an ordinary hand scraper, as doesn’t have to be a chore. The key pieces), I switch to a sanding block,
you can see in photo A below. is to work efficiently — not harder. see photo C.
Step-by-Step
A. Use a scraper to remove any B. A power sander makes quick C. But on a narrow workpiece,
tool marks or ridges. Skew the work of removing material on a sanding block ensures a crisp
scraper at an angle for the best cut. large, flat surfaces. corner and a flat surface.
Sanding & Finishing | 54
120STTT_i054-055rev.indd 54 8/9/2006 4:43:02 AM

Grit – Another thing to consider ones made by the previous grit.
USE A STRAW
is the sandpaper grit. If it’s too While it’s tempting to “jump” a few TO SCRAPE
coarse, the sandpaper leaves deep grits to save some time, you actu- AWAY GLUE
IN TIGHT
scratches that take a long time to ally end up sanding longer with CORNERS
sand out. So unless the surface is very fine grits. So I aways follow up
extremely rough, I start with 120- with the next finest grit (150).
grit sandpaper on most projects The final grit you work up to
Even so, don’t waste time with depends on the finish. For a thin,
120-grit if you run across a deep oil finish where the feel of the
scratch. Switch to a coarser grit wood is important, I sand with 180
to remove the scratch. Then, to and 220 grits for an extra-smooth
ensure that the area takes the finish surface. But with a built-up finish
(or stain) evenly, go back over it like varnish or lacquer, 150-grit is
with 120-grit sandpaper. plenty smooth.
Change your sandpaper often. End Grain – One exception to
The abrasive particles only cut fast all this is end grain. Because it’s { Glue Scooper. A straw works
for the first few minutes. It doesn’t porous and soaks up more finish great for scooping away skinned-
pay to massage the surface with (or stain), the color will be darker over beads of glue that are
worn out sandpaper. than surface grain. To get around trapped in tight corners.
Direction – The direction you this, an old trick that works well is
sand is also important. The old rule to sand end grain one grit finer.
of thumb holds true here — sand Glue – Although it’s convenient to
with the grain in a back and forth sand pieces in advance, there may be
motion. The scratches left behind if problems later. Any glue squeezeout
you sand across the grain require a left on the wood surface will show FIRST:
MASK
lot of resanding to remove. up as a light spot when you apply a OFF
JOINT
The dust that builds up as you stain or finish. LINE
sand will make the surface feel The best way to remove glue
smooth. But the real test is how it is to wait until it “skins” over and a.
looks. The goal here is to get a con- scrape off the excess, see photo E.
sistent pattern of scratches. Or simply keep the glue from get- SECOND:
AFTER
But in order to check, you’ll need ting on the wood in the first place, GLUE
SETS UP
to clean off the dust, see photo D. see margin at right. REMOVE
This also picks up any loose pieces Mineral Spirits – One final TAPE
of abrasive which can leave telltale note. No matter how careful you
scratches of their own when you are, there’s always a chance of a { Mask Corners. Taping off
sand with a finer grit. stray “glueprint” going unnoticed. inside corners before gluing and
Fine Grit – Basically, the fine To make these smudges reappear, assembly reduces the time spent
grit sandpaper creates a series of I wipe down the project with min- later cleaning out the corners.
small scratches that replace the eral spirits, see photo F.
Step-by-Step, cont.
D. Remove sanding dust and bits E. After you’ve assembled the F. Wiping down the surface with
of abrasive that have fallen off project, scrape off the “skinned- a rag soaked in mineral spirits
with a shop vacuum and brush. over” glue with a chisel. reveals stray glue smudges.
120STTT_i054-055rev.indd 55 8/9/2006 4:43:33 AM

Cleaning Up Chamfers Spot Gluing
Stopped chamfers add a decorative To solve this, simply wrap a piece of If you’re screwing a shelf to a panel,
touch. But, when you rout a stopped sandpaper around a dowel and sand all you need are two drops of glue and
chamfer, its end isn’t symmetrical the end (right photo). It won’t take some hand pressure to get it set in
(left piece in photo below). One side much work to get both sides looking place exactly where you want it. Later,
ends up a little “flat.” the same (right piece in first photo). it can be secured with the screws.
Scraping and Sanding In the Corners

Normally I like using a hand scraper always push or pull the blade in the I make a sanding block with beveled
and sanding block for scraping and direction it’s angled. (This way it ends and beveled sides (Fig. 2). The
sanding. But on a glued-up frame and won’t cut into the workpiece.) pointed ends allow me to get the sand-
panel, it can be hard to get right down Beveled Block – To sand a corner, paper right up against the corner.
into a corner with a scraper or typical
sanding block. 1 2
Instead, I use two tools shaped for BEVELED EDGES ALLOW
the job — a razor blade and a special SANDING BLOCK
TO GET INTO
sanding block. CORNER
Razor Blade – To scrape out
a corner, I use a razor blade from a
utility knife (Fig. 1). It works great for
scraping away glue smudges and dried
beads of glue.
To use the razor blade, hold it at an UTILITY
KNIFE
HOLD AT ANGLE
angle and push or pull it with the grain WHEN SCRAPING RAZOR
BLADE
of the wood — just like a hand scraper.
Never scrape across the grain. And
Special Sanding Block

I usually try to avoid having exposed
dado joinery on any of my furniture
projects. If the notches aren’t smooth SANDING
and flat, you’ll notice it when the BLOCK
pieces are glued together later.
But sometimes exposed dadoes
can’t be avoided, so I created a simple
#/4" PLYWOOD
sanding block out of plywood and a a. 1
piece of 1/4" hardboard (see drawing).
Just make sure the “handle” of the
sanding block spans the notches so ADHESIVE-BACKED !/4" HARDBOARD
SANDPAPER
their depth stays consistent and their
edges aren’t rounded over.
120STTT_J056-057rev.indd 56 8/9/2006 4:45:05 AM

Simple Tips for Successful Sanding
When you’re sanding a a power sander (unless 1 2
project, sometimes what you want to round them
you “don’t” do is just as slightly). Instead, use a
important as what you do. sanding block.
Even Strokes – First, The Right Grit – If you’re
don’t sand wood like you sanding with 150-grit sand-
scrub the floor. Use long, paper and you find a deep
even strokes. This way, you scratch, stop and switch to
sand in a straight line with a coarser grit to remove the
the grain, not going side- scratch. Then work back up
ways across the grain. to 150 and continue.
Pre-Sand – Also, you End grain tends to “drink
should sand glued-up up” more stain, making it
panels (and large pieces) darker than the face grain.
before cutting them to size. To get the end grain to avoid the edges if possible. Then rip off the top layer
This keeps the thickness accept a stain the same as (Stay about 1/8" away.) It’s when it’s worn (Fig. 1).
more consistent around the the face grain, sand the end too easy to cut through the Tight Spots – Finally, to
edges, which could tend to grain a couple grits finer. finish and remove the stain. sand in tight to a corner or up
end up a little thinner. If you’ve stained a project, When using regular sand- to an edge, wrap some sand-
Avoid sanding up to be careful when sanding paper, put four layers on a paper around a dull chisel or
the edges of a board with between coats of finish. And sander at the same time. a putty knife (Fig. 2).
Block for Sanding Arcs

After cutting out an arc, 1 2
the waste makes an ideal
sanding block for finish
sanding the inside edge.
Cut out a small piece to fit
ARC
comfortably in your hand WASTE a.
(Fig. 1) and attach a thin SELF-ADHESIVE ARC ON SANDING
strip of self-adhesive sand- SANDPAPER BLOCK MATCHES
ARC ON WORKPIECE
paper to the inside edge.
The arc follows the cut left
CUT A SMALL
by the saw to smooth out PIECE FROM WASTE
FOR SANDING BLOCK
any indentations (Fig. 2).
Cove Sanding Block

The best sanding block is
one that matches the shape
to be sanded. So I make a
custom sanding block from
rigid foam insulation to
sand cove molding.
Make the Block – To
make the block, first trace
the profile on the end of the
foam (Step 1). Then cut it
to rough shape on the band
saw (Step 2). Finally, shape
the foam to the desired pro- 1 Trace the rough outline Next, use a band saw
of the cove onto a small 2 (or a hand saw and a 3 Smooth the profile by
rubbing it across a piece
file using the piece to be block of thick rigid foam file) to cut the profile to of sandpaper stuck to the
sanded (Step 3). insulation. rough shape. cove portion of the piece.
120STTT_J056-057rev.indd 57 8/9/2006 4:45:33 AM

Sanding Flush Sanding Those Rascally Rabbets
I’ve made a couple of large “country- When sanding a rabbet, it’s
style” chests that feature machine-cut easy to tip the sander and
dovetails. I always set the jig so the round over the edge.
the pins and tails both stand proud of To prevent this from hap-
the side. This way, I can come back pening, clamp the work-
and sand them flush. piece in a bench vise with
One way to get them flush is to a piece of scrap flush with
use a belt sander. However, it’s easy the top of the rabbet. This
to accidentally round over a corner. supports the sander and
To prevent this, clamp a scrap piece keeps the edges square.
across the end of the case flush with
the panel the sander is riding on.
Protect Your Hands for “Free”

If you don’t protect your hands when
staining, they’ll end up the same color
as the project.
Although plastic gloves keep your
hands clean, they aren’t free. But my
“gloves” don’t cost a penny. I just slip
my hand into the plastic bag that the
newspaper came in (see photo).
Shop Tip
Line Up Your Face-Grain Plugs
Shop Brush– I keep a
I use a lot of woodscrews in coun- brush in my shop commonly
terbored holes. So to hide the screw used by a draftsman. The
heads, I plug the holes. bristles on this brush are
There are two types of plugs — face longer and softer than most
grain and end grain. Face-grain plugs shop brushes so it cleans
are nearly invisible, but end-grain up sawdust around equip-
plugs will soak up the stain and look ment and down in cracks
too dark, so make sure you choose and corners easily.
the correct one (see photo).
Touch Up MDF Before Spray Painting

When I make a project out of medium- quite porous, they’ll wick up paint color coats (right photo).
density fiberboard (MDF) it’s usually like a sponge. So I fill them with a The thing to be aware of is that
one that will take a lot of abuse. When hardening putty first (left photo). It’s subsequent coats either need to be
that’s the case, I give it a durable available at most hardware stores. sprayed on within the hour (when the
finish with enamel spray paint. Then I apply a coat of primer paint is still tacky) or after 48 hours
Since the edges of MDF are (middle photo) before applying the (when it’s completely dry).
120STTT_J058-059rev.indd 58 8/9/2006 4:46:37 AM

Choosing the Best Outdoor Finish
When it’s time to apply a finish on alkyd primer and a couple of coats of
an outdoor project like this garden a quality latex paint. This, of course,
bench (see photo), you have several covers up all that beautiful wood grain.
options from which to choose. It all But the plus side is paint will protect
depends on what kind of wood you the wood better (and longer) than any
use to build the project. other finishing option.
Show Off the Grain – If I’d wanted Best Alternative – When it comes
to let the grain of the wood stand out right down to it, I usually can’t bring
as much as possible, I could have used myself to paint outdoor projects. But
an oil finish formulated for outdoor I was willing to sacrifice a little of the
use. This is a good choice with a more wood grain for more protection. So
expensive wood, like redwood or teak. instead of paint, I applied a semi-trans-
But there’s one drawback to this type parent stain (see photo). These stains
of finish — you’ll want to renew it are made from an oil/alkyd resin for- found that when it comes to staining
every year or so by applying an addi- mula that also needs to be renewed, but the vertical sections of a project
tional coat of oil. only about every three to five years. (like the legs) a dry foam brush was
Maximum Protection – Another You’ll want to follow the instruc- helpful for removing the excess so I
option is to paint the bench with an tions for the stain you pick out. But I didn’t end up with any runs.
Shop Tip
Finishing Baster
Hand Rubbed Look – If
On finishing jobs, I you want to give a semi-
needed a way to mix pre- gloss finish that “hand-
cise amounts of finish to rubbed” look all you need
get just the right color. is a brown paper bag (the
So I bought an inexpen- kind you find in the grocery
sive turkey baster at the store). The paper is slightly
grocer y store. Be sure abrasive so it buffs the fin-
to get one that has 1/4 oz. ish without actually cutting
graduation marks. through it.
Know Where It’s Going Before Finishing a Cabinet

Simple changes to a project can make pigmented stain. This makes the sur-
it look completely different. That’s the face of the cabinet white without com-
case with this cabinet. The finish can pletely filling the pores.
effect the look of a project as well. Now, to simulate years of wear just
For example, a towel rack makes “dirty” it up. To do this, highlight
the cabinet perfect for an informal the pores by wiping on a coat of dark
bath (photo far right). But, by stain over the entire surface and then
replacing the towel rack with Shaker immediately wiping it off (see photo
pegs and staining it with a few coats of bottom left). This leaves the stain just
oil/urethane finish, it would look fine in the pores, so the cabinet instantly
in a more formal setting. That’s why I looks much older than it really is.
always consider the style and the final
location of a project before I finish it.
Antiquing – If you’re after an
informal look, I suggest giving it an
old-fashioned antique finish. It’s easy
to do without actually distressing it
with nicks, dings, and scratches. To
do this, I take advantage of the wood’s
open pores. (In this case, I used oak.)
First, wipe on three coats of a white
120STTT_J058-059rev.indd 59 8/9/2006 4:47:04 AM

Preventing Blotchy Stain In Pine
Pine can be a stubborn First, be selective in the SURFACE grain a little more with the
END GRAIN
wood to stain. On a single boards you use. Look at the next higher grit. This will
piece of pine the pores can edge of the board for a tight fill in the pores of the end
alternate from large and and straight grain pattern. grain with fine dust. Then
open to small and dense. Avoid boards with swirling when the stain is applied, it
The grain often swirls or unusual grain patterns. won’t penetrate these areas
around so that you find Second, always sand as deeply.
end grain where you don’t the project thoroughly, Finally, brush on a stain
expect it — on the surface working through progres- end up with a lighter color, controller before applying
of the board (see drawing). sively smoother grits of use a finer grit (180) sand- the stain. The controller
These variations in the sandpaper. Areas with paper as this will seal up partially seals up the large
grain affect the way the large scratches left behind the larger pores. pores so they won’t hold as
stain is absorbed into the by coarse-grit sandpaper Next, once you’re through much pigment. The result
wood. The pigments in the trap more pigment and sanding the entire surface, is a more even stain (see the
stain settle in the pores, stain darker. If you want to go back and sand any end right side of the photo).
and the deeper the pore, Then, you can begin
the more stain it holds. So applying the stain right
some areas hold more pig- away — before the stain
ment than others. This can controller has had time to
result in a series of light and dry completely.
dark blotches (see left side Note: Be sure to stir the
of the board in the photo). { Blotches. Applying an oil stain to this piece creates a stain frequently to keep the
There are steps you can series of light and dark blotches (left side above). But using a pigments in suspension and
take to control blotching. stain controller first helps even out the color (right side). ensure consistent color.
Sanding Pad
I like to fold a quarter sheet of sand- as you sand with the outer surface. To fold the pad, first make a single
paper into a pad that eliminates the The pad is also nice when sanding cut to the center of the sheet. Then
usual grit-to-grit contact. This way, on the lathe. With four layers of insu- follow the steps shown. To expose a
the unexposed surfaces won’t wear lation, my fingers don’t get as hot. new surface, simply refold the pad.
FACE
FACE
FACE
BACK
BACK
BACK FOLD PAD SO

THERE IS NO
GRIT TO GRIT
CUT HALFWAY DOWN CONTACT
CENTER OF SHEET
Filling Gaps
Very few woodworkers can cut per- Slurr y – While you sand, you’ll
fect dovetails by hand ever y time. create a slurry of sawdust and oil. As
There are bound to be small voids no it accumulates, work this slurry into
matter how hard you try. The trick is the gaps in the joint. Keep sanding
to somehow fill these voids so they until there’s enough to fill the voids
blend into the rest of the joint. between the pins and tails.
One solution is to apply a liberal Dries Hard – The mixture will
amount of a Danish oil. Then while dry very hard, and it matches the end
it’s still wet, sand with 220-grit silicon grain of the pins and tails almost per-
carbide sandpaper. fectly filling the gaps.
120STTT_J060-061rev.indd 60 8/9/2006 4:47:40 AM

Using Shellac for an “Aged” Look
To give a project a warm, “aged” color, slowly deteriorate. So that I know it’s
I like to use an old-fashioned form of fresh, I mix my own from flakes.
finish — three coats of shellac. Shellac is mixed in “pound cuts”
One Coat of Orange – The first — the number of pounds of flakes to
coat of finish I use is an orange shellac. a gallon of alcohol. I used a 2 lb. cut.
This gives the wood a nice, warm color But I only mixed up a pint at a time
— and it doesn’t blotch like a pigment- (which requires 4 ounces of shellac
based stain will. flakes). Don’t worry about being pre-
Two Coats of Blonde – Then to cise. Just get it in the ballpark.
keep the color light, but still add even Use the Right Brush – To apply
more protection, I apply two coats of shellac, I use a natural bristle brush.
blonde shellac. Don’t work the finish too much with
Shellac comes ready-to-use or the brush. The shellac dries fast, so
in flakes that must be dissolved in you can sand lightly after about three
alcohol. Once dissolved, it begins to hours and apply another coat.
Make Your Own Custom Oil Finish Fine Sanding

I sometimes want to bring out just a Paste Wax – Finally, I like to top A small file or emery board can be
bit of color when I finish a project, so things off with a coat of paste wax used to smooth out any rough edges
I stain them using a homemade stain. applied with 0000 steel wool and buffed left behind after scroll sawing is com-
To make the stain, I mix a teaspoon with a clean rag. This smoothes the plete. It takes a little time to do this,
of burnt umber artists’ oil color into a surface and protects it. but the end result is well worth it.
quart of boiled linseed oil (BLO).
For projects that take a lot of abuse,
I’ll also use a finish that can be built
up, such as polyurethane.
Three Coats – I brush on at least
three coats of finish to all surfaces
of the tables and allow it to dry fully.
Lightly sanding with 320-grit sand-
paper between coats.
When and Where to Use Aniline Dye

When you choose a piece slightly before applying the
of highly-figured wood dye. Then lightly sand off
for a project, you usu- the “whiskers” that rise.
ally want that figure to Note: I use sandpaper
“pop out.” The solution that’s one grit finer than
that I like best is to use an that used on the project.
aniline dye. It produces A rag or brush is all that’s
a deep, rich color that won’t needed to apply the dye. To
obscure the grain. avoid lap marks, keep the
Powder – The type of workpiece surface wet and
aniline dye I use is a powder wipe off the excess before
that dissolves in hot water. it dries.
And, because it’s water- Top-Coat – Be aware the
based, it will raise the grain dye will appear chalky or
of the the wood a bit after it’s dull when it dries. Applying
applied. But there’s a simple a top-coat will restore the
trick to keep this “fuzz” to vivid color. Just be sure it’s
a minimum. oil-based — water will redis-
Just dampen the wood solve the dye.
120STTT_J060-061rev.indd 61 8/9/2006 4:48:07 AM

Glue Application Chart
Working Water
Glue Applications Temp Resist
Choosing Regular Indoor projects 50° + Poor

& Using Yellow
Glues Type II
Yellow
Type III
Indoor or outdoor
projects
Waterproof joints
50° - 85°
47°
Excellent
Excellent -
S
Yellow Waterproof
tanding in front of a shelf at the
woodworking store, I counted
twelve different kinds of glues. It
made me think back to when I started White Indoor projects where longer 60° + Poor
woodworking and there were about open time is desired
three choices for assembling a joint:
hide glue, yellow glue, or a couple of
nails. So does anyone really need all Liquid Hide Indoor projects where 70° - 90° Poor
these different adhesives? longer open time is
Just like you choose the right desired, joints that may need to
wood for a project, you also should be disassembled
pick a glue that fits the needs of the
joint. On some jobs you need a glue
that dries within seconds. The next Hot Hide Indoor projects, restoration of 140° - 212° Poor
time, you may need 10 minutes furniture originally assembled
to get the parts assembled. Some with hide glue, joints that may
joints have to resist the weather. need to be disassembled
There are even joints you may want
to take apart later.
No one glue does it all, so knowing Polyurethane Indoor projects, 50° + Excellent
the strengths and characteristics outdoor projects
of each type will help you choose
the right glue. That’s why we are
providing you with this handy ref- Epoxy Bonding dissimilar materials 35° + Excellent -
erence chart. This way, when you (i.e. metal or glass to wood), depending Waterproof
find a glue that works, you’ll know bonding oily woods, and for on formula
enough to stick with it. waterproof bonds
Contact Plastic laminates and 65° + Fair

Cement veneers to substrates
Spray Paper patterns and 50° + Poor

Adhesive fabrics to workpieces
Super Glue Repairing small cracks, chips, 50° + Very Good

securing inlays
Hot Melt Temporary bonds that 240° - 400° Fair

Glue need easy removal
Glue Chart | 62
120STTT_J062-063rev.indd 62 8/9/2006 4:48:44 AM

Open Clamp Cautions
Time Time Notes (Refer to product labels for more information)
5 Min. 30 Min. Widely available, Freezing can ruin glue.

inexpensive, strong bond.
5 Min. 1 Hr. Same as above, Freezing can ruin glue.

plus water resistant.
10 Min. 30 Min. to 1 Hr. Useful for outdoor applications

in cooler temps, water clean up,
solvent free.
8 Min. 1 Hr. Bond is not as strong Freezing can ruin glue.

as yellow glue.
10 Min. 12 Hr. Joint can be disassembled

with steam/heat.
< 1 Min. 2 Hr. Sold as granules that must be

dissolved in water and heated.
Joint can be disassembled
with steam/heat.
20 Min. 4 Hr. Needs moisture to cure. Can react with moisture in skin.
Foams as it cures. Wear gloves.
5 Min. to Varies with Two-part system that must Repeated exposure can cause
90 Min. open time be mixed before use. sensitization. Avoid skin contact,
depending wear respirator and goggles.
on formula
10 Min. to Apply pressure Solvent-based open time shorter Vapors can be extremely flammable.
60 Min. with roller than water-based open time. Do not use near open flames.
30 Sec. to None May need to mask off Do not use around open flame.
1 Min. surrounding areas to
avoid overspray.
15 Sec. to None Accelerator available Bonds skin instantly.

5 Min. to speed cure times. Fumes may be irritating to eyes.
5 Sec. None Glue sticks must be Hot glue dripped on skin can cause burns.
heated in glue gun.
Glue Chart | 63
120STTT_J062-063rev.indd 63 8/9/2006 4:49:15 AM

120+ SHOP-TESTED TIPS & TECHNIQUES INDEX
Layout & Measuring Fluting Round Tenons ................................... 25 Routing Out for a Circular Inlay ................... 46
Shop Tip, Dowel Centers............................... 25 The Best Way to Get Edges Flush ................. 46
Secrets of the Story Stick ................................ 6
Checking Miters ............................................ 25 Router Fence Alignment ............................... 46
“Tip” for Locating Hinge Screw....................... 6
Undercut for Tight-Fitting Shoulders............ 25 Pattern Routing with a Flush Trim Bit .......... 47
A Handy Layout Tool ...................................... 6
Locking Rabbet Drawer Joints ....................... 26 Bevels of Another Angle ............................... 47
Double-Edged Spindle Turning Template ....... 7
Edge Gluing Thin Stock ................................ 26 Routing Custom-Fit Dadoes .......................... 47
One Good Level Deserves Another ................ 7
Simple Jig for Compound Miters ................... 27 Choosing Ogee Bits ....................................... 48
Drawing a Simple Oval.................................... 7
Check for Square ........................................... 27 Routing Stopped Profiles ............................... 48
Better Looking Tongue & Dado Joint ........... 27 Routing Direction .......................................... 48
Workshop Techniques
Make Through Mortises with a Jig Saw ........ 27 Dovetail Depth Gauge ................................... 49
Shop-Built Door Pulls .................................... 10 Using a Rub Arm for Raised Panels .............. 49
Making and Using a Push Stick..................... 10 Sawing & Cutting Router Bushing Thread Lock......................... 49
Aligning and Clamping Edging ..................... 11 Shop Tip, Burn Marks .................................... 49
Getting Clean Cuts in Plywood .................... 30
Burnishing a Miter ......................................... 11
Safe Cuts with a Miter Block......................... 30
Bench Board Support..................................... 11 Hardware
Shop-Made Outfeed Support Roller.............. 31
Saw Your Leg Blanks Square.......................... 12
Cutting a Box in Two..................................... 31 Installing Inset Hinges ................................... 52
“Trim” the Trim for a Tight Fit ...................... 12
Cut Plywood Using a Circular Saw ............... 32 Installing Brads .............................................. 52
Applying Flexible Veneer .............................. 13
Rip Strips Without Moving the Fence .......... 32 Installing Grommets ...................................... 52
Old-Fashioned Way To Install a Drawer ....... 13
Cut Glass Stop ............................................... 33 Installing Threaded Inserts ............................ 53
Apply Your Own Laminate ............................ 14
Cutting Perfect Half Laps .............................. 33 Installing a Magnetic Catch .......................... 53
Safely Cut Thin Edging Strips ....................... 14
Setup for 221⁄2° Miters .................................... 33 Reverse Countersink Tip ............................... 53
Label Cutoffs .................................................. 15
Two-Step Resawing ........................................ 33
Invisible Cleats for Hanging .......................... 15
Crosscutting Large Panels .............................. 34 Sanding & Finishing
Preventing Vise Rack..................................... 15
Simple Jig for Rip Fence Alignment ............. 34
Quick Tips for Attaching Brass to Wood ...... 15 Cleaning Up Chamfers .................................. 56
A Tall Featherboard for Tall Workpieces ...... 34
Installing a T-Nut .......................................... 16 Scraping and Sanding In the Corners ........... 56
Bevel Ripping on Right-Tilt Table Saws .......34
Gluing Up a “Flat” Panel ............................... 16 Special Sanding Block ................................... 56
Bench Dogs .................................................... 16 Simple Tips for Successful Sanding ............... 57
Clamping
Installing Wood Plugs .................................... 17 Block for Sanding Arcs .................................. 57
Thin Strip Push Block ................................... 17 “Springs” Hold Miters Together .................... 38 Cove Sanding Block ...................................... 57
Cradles Keep Pipe Clamps Upright ............... 38 Sanding Flush................................................. 58
Joinery Use Wedges to Stop Panels from Cupping .... 38 Sanding Those Rascally Rabbets ................... 58
Spring Clamps for Hard-To-Reach Spots ...... 39 Protect Your Hands for “Free” ....................... 58
Spacing Slats with Playing Cards .................. 20
Weatherstrip Improves Your Clamp Blocks... 39 Line Up Your Face-Grain Plugs ..................... 58
Dovetail Clamping Block .............................. 20
Two-Timing Clamps for Long Pieces ............. 39 Shop Tip, Shop Brush .................................... 58
Squaring Miters.............................................. 20
Shop Tip, Tape the Pipe ................................ 39 Touch Up MDF Before Spray Painting ......... 58
Biscuits for Tabletop Fasteners....................... 20
Choosing the Best Outdoor Finish ....... 59
Center a Mortise ............................................ 21
Routers & Router Tables Finishing Baster ..................................... 59
Pinning Box Joints for Strength .................... 21
Shop Tip, Hand Rubbed Look .............. 59
Round Tenons with a Table Saw ................... 21 Shop Tip, A Bit Greasy.................................. 42
Finishing a Cabinet ............................... 59
Tips for Aligning Half Laps ........................... 21 Routing Small Pieces ..................................... 42
Preventing Blotchy Stain In Pine ......... 60
Super-Strong Splined Miter Joints ................ 22 Iron Out Marks .............................................. 42
Sanding Pad........................................... 60
Sliding Dovetail Joints Made Easy ................ 22 Aux. Base for Routing Inside Chamfers ........ 42
Filling Gaps ........................................... 60
Three-Step Mortise & Tenon Joint ............... 23 Making Straight Cuts Between Profiles ......... 43
Using Shellac for an “Aged” Look ........ 61
Stop Miter Joints from Slippng Apart ........... 23 Safe Routing “On the Edge” .......................... 43
Make Your Own Custom Oil Finish ..... 61
Plugging Mortises ........................................... 24 Adding a Router Table Insert ........................ 44
Fine Sanding ......................................... 61
Frame and Panel Glue-Up Jig ........................ 24 Routing Odd-Size Rabbets............................. 44
When and Where to Use Aniline Dye.... 61
Jointing with a Hand Plane ........................... 24 Backrouting for Clean Rabbets ...................... 45
Stop That Panel From Rattlin’ ...................... 25 Trimming Edging Flush .................................. 45 Glue Application Chart........62-63
Index | 64
120STTT_J064rev1page.indd 64 8/14/2006 2:08:50 PM

FREE ONLINE BONUS
Get More…with 120+ Shop-Tested
Tips & Techniques
Along with 120+ Shop-Tested Tips & Techniques you have

FREE access to one of our most popular downloads on the
web — 10 Best Table Saw Jigs.
With this lineup, you can't go wrong! You'll get 10 plans for
jigs that can easily be built in an hour or two with material
you probably already have in your shop.
Here's how to access

your exclusive
ONLINE BONUS
Go to
www.ShopNotesSpecials.com
and enter this access code
in the box on the form.
TIP237
NEWS_120 Inside Back cover.indd 1 10/26/2007 10:37:26 AM

+TIPS &
120
SHOP-TESTED
TECHNIQUES Plus Double Bonus!

1. Discover Our SECRETS
• 6 Ways to a Flawless Finish
• Cut Perfect Pieces on your Table Saw
• Mortise & Tenon Joints — 3 Easy Steps
• 3 Basic Router Bits — 7 Beautiful Profiles
• Clamping Tips for Exact Miters
• Plus over 100 more…
2. Get 100+ EXTRA Tips on CD Included FREE Inside
FREE • Build a Collection of PLUS!
C D IN S I D E
Your Favorite Tips &
Techniques
• Easy To Install, Easy to
Print Out, & Easy to Use
• Compatible with
Top 10
Video Tips
Windows or MAC
3.Online BONUS: 10 Table Saw Jig Plans

• Easy-to-Build Jigs Will Help You Get
More from Your Table Saw
• Make your Cuts Cleaner, Safer, and
More Accurate
• Easy Access Online
• Print Out Complete Plans
• Go to www.ShopNotesSpecials.com
NEWS_120 Back Cover.indd 1 10/26/2007 10:34:30 AM

Woodsmith W0601A PDF

Uploaded by

Copyright:

Available Formats

Woodsmith W0601A PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Woodsmith W0601A PDF

Uploaded by

Copyright:

Available Formats

Special Collector’s Edition FREE

A Publication of August Home Publishing

USnewstand1.indd 1 10/29/2008 10:02:47 AM

President & Publisher: Donald B. Peschke

Editor: Terry Strohman

120+ Shop-Tested Tips & Techniques is published by August Home

Woodsmith® and ShopNotes® are registered

For subscription information about Woodsmith or ShopNotes, visit

A Supplement to August Home Publications

2200 Grand Ave.

120STTT_Inside FrontCOVrevLOGO.i1 1 10/24/2008 1:13:28 PM

Letter from the Editor

Vol. 27 / No. 159 GET MORE Vol. 14 Issue 84 www.ShopNotes.com

Classic THE MOST

A Publication of August Home Publishing A Publication of August Home Publishing

www.Woodsmith.com ORDER ONLINE www.ShopNotes.com

SHOP SAFETY IS YOUR RESPONSIBILITY

120STTT_A001rev.indd 1 8/14/2006 2:17:31 PM

Sawing & Cutting

120STTT_C002-003rev.indd 2 8/9/2006 4:08:14 AM

Routers & Router Tables

Sanding & Finishing

Glue Application Chart

120STTT_C002-003rev.indd 3 8/9/2006 4:08:59 AM

Shop Tips: The Write Stuff

Layout & Measuring | 4

120STTT_C004-005rev.indd 4 8/9/2006 4:10:24 AM

To the Point: Carpenter’s Pencil

Layout & Measuring | 5

120STTT_C004-005rev.indd 5 8/9/2006 4:11:11 AM

“Tip” for Locating Hinge Screws

A Handy Layout Tool

Layout & Measuring | 6

120STTT_C006-007rev.indd 6 8/9/2006 4:12:04 AM

One Good Level Deserves Another

Drawing a Simple Oval

Layout & Measuring | 7

120STTT_C006-007rev.indd 7 8/9/2006 4:12:40 AM

Make It Thin tape that’s made specifically for

RABBET PLYWOOD EDGE

EEdging From Plywood. To make CCut It Loose. Next, use a sharp

120STTT_C008-009rev.indd 8 8/9/2006 4:13:35 AM

120STTT_C008-009rev.indd 9 8/14/2006 2:34:50 PM

CHAMFER !/2" CORE !/4"-WIDE

Making and Using a Push Stick

120STTT_D010-011rev.indd 10 8/9/2006 4:14:51 AM

Bench Board Support

120STTT_D010-011rev.indd 11 8/9/2006 4:15:53 AM

“Trim” the Trim for a Tight Fit

1 CUPPED PIECE OF RELIEF ON BACK OF MOLDING 2

120STTT_D012-013rev.indd 12 8/9/2006 4:17:13 AM

Old-Fashioned Way To Install a Drawer

120STTT_D012-013rev.indd 13 8/9/2006 4:17:38 AM

Safely Cut Thin Edging Strips

120STTT_D014-015rev.indd 14 8/9/2006 4:18:22 AM

This racking means pressure will

Quick Tips for Attaching Brass to Wood

120STTT_D014-015rev.indd 15 8/9/2006 4:18:54 AM

Bench Dogs SPACE CLAMPS