le

Dreiie
(Super-simple Drawers!)

Countertop Wine Rack p.62

Wall-hung Mirror p.66
Coffee Table, End Table,
Sofa Table p.54

Cut NO-gOOf Dovetails p.24

}>

THE ~ecrel 10
Airtight Dadoes
• p~6
 6rizzly InduBtrii!ll®
121f2" Portable Planer
• Motor: 1112 HP, 11OV, single-phase • Sanding motor: 1112 HP, 11 OV, Single-phase Side Handles
Double Sided
• Max, cutting height: 6" • Conveyor motor: l/lO HP, 11OV, Single-phase, for Portability!
Blades
• Max, cutting depth: 3M' variable speed 0-15 FPM
• Feed rate: 22 FPM • Cutterhead speed: 9400 RPM • Drum surface speed: 2300 FPM
• 4 column cutterhead support • Max, stock d imensions: 12" wide x 3W' thick
• Adjustable flip up wings • Min. stock length: 8"
• Side handles for portabliity • Sanding drum size: 4"
• Top mo unted return roller • Sanding belt: 3" hook & loop
• Thermal overload protection • Approx. shipping weight: 160 Ibs,
• Approx, shipping weight: 66 Ibs,
2 ADJUSTABLE PRESSURE
ROLLERS &
G0663 INDUSTRIA L-DUTY BELT
REG .~
SALE $19995 G0459 REG. ~ SALE $52500
8" X 75" Jointer 8" X 75" Jointer w/Spiral Cufferhead
• Motor: 2 HP, 110V /220V, Single-phase, TEFC, 3450 RPM
• Mo or: 2 HP, 11 OV /220V, single-phase, TEFC, 3450 RPM
• Precision ground cast iron table size: 9lfa" x 75"
• Precision ground cast iron table size: 9lfa" x 75"
• Cutterhead knives: 4 HSS, 8" x W' x lJa" .-----:----.r:z----J
CENTER • Deluxe cast iron fence size: 38"L x l lfa"W x 4"H
• Cutterhead speed: 5500 RPM MOUNTED • Curterhead speed: 5500 RPM SPIRAL
• Cutterhead d ia,: 3" FENCE
• Cutterhead dia,: 3" CUTTERHEAD
• Max, depth of cut: lJa"
MADE IN • Max. depth of cut: lJa" MADE IN
• Max, rabbeting ISO 9001 ISO 9001
• Approx.
depth : W' FACTORY! FACTORY!
shipping
• Approx, shipping
weight: 558 Ibs,
weight: 558 Ibs,

INCLUPES INCLUPES
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10" Left-Tilting Table Saw 15" Extreme Series Planer

w/7' Rails & Extension Table w/Spiral Cufferhead
• Motor: 3 HP, 220V, Single-phase INCLUPES • Motor: 3 HP, 220V, Single-phase
SHOP FOX"
• Precision g round cast iron table CLASSIC- FENCE' • Precision ground cast iron table
CAST IRON MITER &AU&[
• Extension table size : 27" x 44" • Table size: 15"x5Ws" w/extensions MADElH
• Arbor: %" (accepts dado b lades up to 13116") • Max. cutting height: 6lJa" _...,.:~: ,~Jd ___ ISO 900t FACTORY!
•
•
Cutting capacity: 8" L 54" R
Max, depth of cut: 3" @ 90°, 21fa" @ 45° 54" Cutting
Max, cutting depth : lJa" ~)A~'\::-
• Feed rate: 16 & 20 FPM /J-';' l
• Approx, shipping weight: 532 1bs, .~ I ""Capacity!

....- .....
• Cutterhead speed : 5000 RPM
-==Ii;"".
IA~'C
l' . -
• Anti-kickback fingers
• Approx, shipping weight: 640 Ibs,
G1023SLX
G1 021X2
REG, .$J2.95:OO
REG.~
SALE $1195 00 SALE $125000
Ilal
 • OVER A MILLION SQUARE FEET PACKED TO THE RAFTERS WITH MACHINERY & TOOLS
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Mini Planer/Moulder
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DECEMBER 24, 2008 r:-;:=====5
• Motor: 2 HP, 220V, single-phase Planer Knives.
• Planing width: 7"
Stand and
• Max. profile depth: %"
2 HPMotor
Included!
• Max. profile width: 6%"
• Max. stock thickness: 71/4"
• Min. stock thickness: W'
• Min . stock length: 9"
• Feed rate : 14 FPM
• Cutterhead speed: 7000 RPM
• Approx. shipping weight: 243 Ibs.

Huge selection of moulding knives

available online at grizzly. com'"

G0552
2 HP Planer/Moulder
Reg.~

$55000
Accessories
H8152 v/skit for existing ownersofG0552 Reg. ~ $295.00
H7489 Replacement straight blades $49.95
H6496 Elliptical jig for curved moulding $275.00

GO 10 GRIZZLY.COM® 10 GRIZZLY GIF1 CER11FICA1ES Gift Certificate

VIEW ALL 1HE HOLIDAY SPECIALS TAKE THE GUESSWORK
FOR A LIMITED TIME YOU WILL RECEIVE A
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·.o.· ••• ,..,..,.? 'M ..... .,.

grizzIY·CDDJ®
Circle No. 583
in this issue

)ll'SI(~~IIIJII:r ~

PROJECTS TECH NIQU ES

Shaker-style bedroom 14 Staining solid stock and plywood
These pieces complement the bedroom suite
that began in the previous issue. 16 The simple secret to perfect dadoes
· 34 Dresser 24 How to avoid dovetail-jig goofs
41 Dresser-top valet 70 Going pro: One man's success story
66 Wall-hung mirror
10 Dust-collecting floor chute
TOOLS &: MATERIALS
12 Super-simple tapering jig
29 Top New Tools for 2009
54 Easy and elegant table trio New Unisaw, power dowel joiner, jigsaw
Build any or all from the same plans- blades, self-shifting drills, more
only the part lengths change.
50 Tool test: 6" dado sets
62 Great giftable: Wine holder

DEPARTMENTS
6 Editor's Angle
8 Sounding Board
18 Shop Tips
45 2008 article index This seal is your assurance that we
build every project, verify every
74 Ask WOOD. fact, and test everyreviewed tool
in our workshop to guarantee yo ur
92 What's Ahead success and complete satisfaction.
Dec./Jan. 2008/2009 Issue 188
on the web
woodmagazine.com

MORE GREAT GIFTS ONLINE

Looking for something special to build for your
holiday gifting? You'll find dozens of ideas for all
ages and tastes at woodmagazine.com/gifts.

INSTANT ANSWERS TO YOUR

WOODWORKING QUESTIONS
Got a stumper? Don't stew about it-ask for help on the WOOD Online® forums.
When you post your question at woodmagazine.com/forums, it's like having 100,000
experts at your fingertips.
HoW to handletarge eAu,1 AUen O. , <jIt 1 minute ago by
allenworsham

what would you do? ,mbwoOdSS 16 mlhutes ago

by grandp4bear

Jewelry 80x Joinery" Need to draw on your expatiene<o Mithael the 20 minutes ago
Fledgling by gtandpab"ar

[J) A little help for a nOlilce pie.... " rnchd. dp 21 4- 40 minutes ag.

~ ~ j
by Gary 1<.
The question ... .
. Y h /
our username ere ...

"
....
o.T
The number of replies ...
r
Most recent reply

62 MAKE A DOOR,
WIN A TRIP TO
VENICE!
Build an interior door, snap a few
photos, and e-mail them to us for
your chance to win! You'll find free
video tips on doormaking, plus
complete contest entry details and
rules at woodmagazine.com/door.
 INNOVATIVE PRODUCTS

~
SHOP FOX®is one of the fastest growing machinery lines in
the country, offering an unbeatable combination of quality
and affordability to all segments of the woodworking trade.
We offer a 2 Year Warranty on all SHOP FOX® machines!

14.. BANDSAW 10" LEfT TILT HYBRID 6" JOINTER

CABINET SAW w/Parallelogram Adjustable Beds
~
1 HP, 110V/220V, ~ 1';' HP, 11 OV, single-phase motor
~ 2 HP, 11 OVJ220V, single-phase motor
single-phase, TEFC ~ Precision ground cast iron table wI ~ Precision ground cast iron table
motor wings measures 39';''' x 27" measures 55 ';," x 6"
~ 14" square precision ~ 4 knife, 4850 RPM cutterhead
~ Shop Fox· Alumina-Classic· Fence
ic.:~~!!9111"'" ground cast iron table ~ Cutting capacity: 3" @90', 2'/8"@ 45 ' ~ Rabbeting capacity: ,;,"
~ 6" max. cutting height ~ Quick adjust levers
~ Rip capacity: 30" ~ Arbor: '/8"
~ 2 blade speeds: ~ Top mounted switch
1500 & 3200 RPM
'----.............
~ Cast iron wheels
~ Ball bearing blade
guides
includes both
lllcludes blade, stalldard
felice alld miter gauge and dado inserts

W1706 W1748 W1755

12" TABLE SAW 20" PLANER

w/RMng Knife &. Extension Table w/Mobi/e Base - 5HP
~ 5 HP, nov, single-phase motor
~ Precision ground cast iron table &
~ 10" intake hole extension wings
~ Table w/wings attached measures 20" x 55'1s"
~ 0.2 - 2 micron
~ 2 feed speeds: 16 FPM & 20 FPM
filters
~ 4 knife, 5000 RPM cutterhead
~ Magnetic switch
~ Pedestal mounted
w/remote control magnetic
~ Noise reducing
safety switch
mufflers ~ 5 HP, nov, single-phase motor
~ 55 gal. steel
~ Precision ground cast iron
collection drum table & trunnions
Inellldes ~ Table w/extension measures 30%" x 78%"
steel stalld alld ~ Quick release riving knife & steel splitter
detailed illstructioll Bllilt-in locking
~ Digital bevel angle readout Mobile Base
mallllal
Inellldes 12" blade,
W1762 Jellcealllimitergauge W1754

14" SLIDING TABLE SAW 7tlz HP HEAVY-DUTY

~ 15 HP, 220V/440V', 3-phase cutting motor ~ 10Hp, 220V/440V', 3-phase main motor INDUSTRIAL SHAPER
~ 1 HP, 220V/440V', 3-phase scoring motor ~ 7';' HP, 220V/440V', 3-phase, 3450 RPM motor
~ 2 HP, 220VJ440V', 3-phase feed motor
~ 125" W x 126" L cutting capacity ~ Precision ground cast iron table measures
~ Variable speed feed control
~ Micro adjustable rip w/2 fence stops 47'14' x 35 '12"
~ 18" throat for large stock
~ Integrated overhead dust collection ~ Split micro adjustable fence
~ 8" min. cutting length (wi
~ Delivers 10'12' of travel ~ Precise dial angle scale for spindle tilt
included hold-down kit) Features Riving Knife
, and Scorillg Blade ~ 4 spindle speeds: 3900, 5000, 7200 & 9400 RPM
~ Built-in auto- ~ Front mounted spindle lock
lube system *440Voperation requires
the purchase of a
for easy 440V therma l relay &

.-e
maintenance ~~~~;~!-~3~ magneticcontactor

*440Voperation requires
the purchase of a
440V thermal relay &
magnetic (ontactor

W1803 W1806
ShowlI with optional *440V operation requires
Also Available:
D3698 Laser Guide the purchase of a D3699 Optional Fu/(r
440V thermal relay &
",,/Pedestal Mount magnetic contactor
EI/closed Blade Gllard

SHOP FOX'" VISIT OUR WEBSITE OR CALL TOLL FREE TO FIND AN AUTHORIZED DEALER NEAR YOU.
is a registered
trademark of
Woodstock
SHOPFOX.BIZ 1-800-840-8420
International, Inc.
sales@shopfox.biz WHOLESALE ONLY 10051

Circle No. 1824

 woodmagazine.com

December/January 2008/2009 Vol. 25, No.7 Issue No. 188

EDITOR-IN-CHIEF
BILL KRIER

Managing Editor Deputy Editor

Where
.... ................ MARLEN KEMMET DAVE CAMPBELL

Art Director Senior Design Editor

KARL EHLERS KEVIN BOYLE

woodworking
Techniques Editor Tool & Techniques Editor
BOB BOB HUNTER

Multimedia Editor Multimedia Editor

LUCAS PETERS CRAIG RUEGSEGGER
Marlen enjoys turning small
hollow vessels. These measure
less than 4" wide.
Design Editor
JEFF MERTZ

Associate Art Director

GREG SELLERS
Projects Editor
LARRY JOHNSTON

Assistant Art Director

CHERYL A. CIBULA
Bob demonstrates the
comes alive!
tool stand he built from
Production/Office Manager
MARGARET CLOSNER
Administrative Assistant
SHERYL MUNYON
plans in issue 182.
2008·2009
Photographers
MARTY BALDWIN, JASON DONNELLY, DEAN SCHOEPPNER, JAY WILDE
Show Schedule
Contributing Illustrators TIM CAHILL, LORNA JOHNSON, ROXANNE LeMOINE
Technical Consultants JEFF HALL, DOUG HICKS, BRIAN SIMMONS York, PA
Contributing Craftsman JIM HEAVEY York Expo Center
Contributing Proofreaders BABS KLEIN, IRA LACHER, JIM SANDERS November 7-9,2008

SUBSCRIBER SERVICE Novi, MI

Go to woodmagazine.com / help or write to Rock Financial Showplace
WOOD magazine, P.O. Box 37439, Boone, IA 50037-0439
November 21-23, 2008
Publisher MARK L. HAGEN
ADVERTISING AND MARKETING
West Springfield, MA
CHICAGO: 333 N. Michigan Ave., Suite 1500, Chicago, IL 60601 Eastern States Exposition
Marketing Manager AMANDA SALHOOT January 9-11, 2009
Advertising Manager JACK CHRISTIANSEN
Account Executive RYAN INTERLAND
Show Hours
Friday 3pm-9pm
Direct Response Advertising Representative LISA GREENWOOD
Assistants GAYLE CHEJN, NIA WILLIAMS Saturday 10am-Spm
ATLANTA: Navigate Media Mark built this Sunday 10am-3pm
DETROIT: RPM Associates kitchen island for his
-------B-u-s-in-e-ss-M-a-n-a-g-er-JE-F-F-S-T-,L-ES-------- daughter's condo.

Associate Consumer Marketing Director DAN HOLLAND

Buy your tickets
Associate Director of Marketing-Newsstand TOM DEERING
Production Manager SANDY WILLIAMS
online and save!
Advertising Operations Manager JIM NELSON For complete details about each show,
E-Commerce Manager MATT SNYDER or to receive show discounts, call
Vice President/ Group Publisher TOM DAVIS
toll-free 866-749-4988, or visit:
MEREDITH PUBLISHING GROUP
President JACK GRIFFIN
www.woodworksevents.com
Executive Vice President DOUG OLSON
Chief Revenue Officer TOM HARDY Can't make the shows?
Finance & Administration MIKE RIGGS
At the beginning of 2009
Manufacturing BRUCE HESTON
WOODMagazine.com
Consumer Marketing DAVID BALL
Corporate Sales MICHAEL BROWNSTEIN
will have online videos of the
Meredith 360 0 JACK BAMBERGER most popular seminars.
Interactive Media LAUREN WIENER Stay tuned for more details .
Corporate Marketing NANCY WEBER
Research BRITTA WARE
Chief Technology Officer TINA STEIL
At each show, make sure to stop by
New Media Marketing Services ANDY WILSON the SawDust Cafe®, sponsored by
A1~~!~ WOOD®Magazine.
President and Chief Executive Officer STEPHEN M. LACY • Chat with fellow woodworkers
Chairman of the Board WILLIAM T. KERR
• Enter your projects in daily
In Memoriam - E.T. Meredith III (1933-2003)
Our subscribers list is occasionally made available to carefully selected woodworking competitions
firms whose products may be of interest to you. If you prefer not to • Learn about woodworking clubs
receive information from these companies by mail or by phone, please
let us know. Send your request along with your mailing label to Magazine and schools in your area
Customer Service, P.O. Box 37452, Boone, IA 50037-0452.
© Copyright Meredith Corporation 2008. All rights reserved. Printed in the U.S.A.
Retail Sales
Retailers can order copies of WOOD for resale
SqwDust
woodmagazlne.com
bye-mailingjennifer.buser@meredith.com

5
Cafe
 Editor's Angle
Back by popular demand!
Annual-Article Index
Now you have two simple ways to find a past project, tool review,
or woodworking technique article: the cumulative online index at
woodmagazine.com and the printed annual index on page 45.

WOOD ack in the November 2007 issue I from the magazine easily, so we printed
MAGAZINE

Interior Door Contest B touted the numerous benefits of

the WOOD® magazine online
index (woodmagazine.com/index).
it on the heavy stock in the center of
the magazine usually reserved for
project patterns. To accomplish that, we
Among the bennies: It's cumulative moved the full-size pattern for the wine
(going back to issue 1 more than 20 rack on page 62 into the body of that
years ago!) and comprehensive (right article. The WOOD Patterns®insert will
up through the issue in your hands). return next issue.
You simply punch in a word to describe And here's a feature I think you'll
what you're looking for, click on really appreciate. We left room in the
"search," and presto, up pops any index margins for punching holes so
number of articles matching that word .. you can store it (and subsequent ones)
Clearly superior, right? Not necessarily. in a three-ring binder for easy retrieval,
Pretty soon I heard from a lot of you as shown below.
that preferred the paper version we On the back page of the index you'll
used to include in the magazine every find quick tips for using it, as well as
year. Well, we never ignore our custom- the online index (in case you want to
ers, so we set about breathing new life search issues prior to 2008) . We've
into this old concept. published great projects for nearly 25
I put the project in the capable hands years, with no two projects exactly
of Margaret Closner, our Production/ alike. I'm always amazed when I look
Office Manager. In addition to keeping back at the huge archive of past work.
our creative band of woodworking Finally, let me assure you that,
editors and craftsmen on schedule and despite all of the benefits of the
generally organized, Margaret has an Internet, we plan to continue to publish
uncanny recall of past articles- a skill an annual paper version of the index
honed from fielding thousands of into the foreseeable future. You've been
reader inquiries over the years. She put pretty clear about
that talent to work and soon came up wanting it, and we
with an index designed to help you hear you! .
find the article or shop tip you're
looking for as quickly as possible.
Next, we decided the index had to be
on durable paper that you can remove

AIIl
STEP 3: Place index in a three-
ring binder for quick access.

6 WOOD magazine December/Janua ry 2008/ 2009

Sounding Board
Our bulletin board for letters, comments, and timely updates

Teacher takes home WOOD® magazine

prize with stunning bedroom table
At the 2008 Design in Wood competi- through-tenons and breadboard ends
tion in San Diego, Brian Carnett's for joinery. His table also netted a
Asian-influenced bedside table, shown second place for Excellence in Finish-
at right, won the Excellence in Work- ing. (He used an oil/polyurethane mix.)
manship award, sponsored by WOOD The San Diego Fine Woodworkers
magazine. A former woodworking Association sponsors the Design In
instructor, Brian, 55, now teaches high- Wood c,9mpetition each summer.
school photography and social studies This year, 302 entries from 15 states
near his Escondido, Calif., home. He competed for prizes valued at more
builds furniture in his spare time. than $20,000. To see more photos from
Brian made the 14x14x30" table from the show and to enter the 2009 event,
wenge, quilted maple, and ebony, using go to sdfwa.org.

Avoid sawing steel with a I'll take my sheet goods

wood-cutting bandsaw to go, please
In your review of 14" bandsaws in issue I built a sheet-goods storage rack similar
185 (September 2008), you mentioned to the one in issue 184 Guly 2008), but
cutting steel with a dual-speed machine didn't want to simply park it against a
using the proper blade. I would warn your wall. So I added 6" swiveling casters to
readers against that for a few reasons. make it mobile, and extended the
First, the blade speed-measured in feet width to add
per minute (fpm)-of our wood-cutting clamp racks,
bandsaws is much too fast for cutting sawhorse
steel. (Typically, a steel-cutting bandsaw holders, and
runs at 75 to 300 fpm, while a wood- a bin for
cutting bandsaw runs 1,500 to 3,200 fpm. storing
You can safely cut nonferrous metals, such small
as brass or aluminum, at the slower speed.) cutoffs. Now
The heat generated when cutting steel at I've got
those faster speeds would quickly damage everything I
the teeth on even a steel-cutting blade. need within
Also, most steel-cutting blades are easy reach.
designed to run at much higher tension When I'm
settings than typically used in woodwork- finished, I
ing bandsaws. Finally, the metal chips just scoot
could become pressed into the rubber them out of
tires, thus reducing their life (unless they Some bandsaws, such as Grizzly's G0621, the way. •
have been designed for it). are built to cut wood and metal. This model -Mark Abbott,
-Bill Crofutt, Grizzly Industrial has a 150- to 3,OOO-fpm speed range. Cookeville, Tenn.

HOW TO REACH US
• For woodworking advice: • Subscription assistance: • To order past issues and articles:
Post your woodworking questions (joinery, finishing, To notify us of an address change or to get help with Order past issues of WOOD magazine, our special issues,
tools, turning, general woodworking, etc.) on one of your subscription, visit woodmagazine.comlhelp. or downloadable articles from issue 100 to present: Visit
16 online forums at woodmagazine.com/forums. Or write to WOOD magazine, P.O. Box 37439, Boone, IA our online store at woodmagazine.com/store.
50037-0439. Please enclose your address label from a Some issues are sold out.
• To contact our editors: recent magazine issue.
Send your comments via e-mail to • Updates to previously published projects:
woodmail@woodmagazine.com; or write to • To find past artides: For an up-to-date listing of changes in dimensions
WOOD magazine, 1716 Locust St., LS-221, See our indexat woodmagazine.com/index. and buying-guide sources from issue 1through today,
Des Moines, IA 50309-3023. goto woodmagazine.com/editorial.

8 WOOD magazine December/ January 2008/ 2009

Great Ideas for Your Shop
Dual-purpose
Dust Chutee all like

W making
dust in the
shop, but nobody .
likes cleaning up
afterV\lard. Here's a
handy helper that
both speeds sweep-
up and keeps chips
and dust off the
floor and work-
bench. Build this
simple project
using liz" scrap. Cut
a hole in the top to
fit your vacuum
hose or add the optional collar for a dust-
collection hose. Create the base so the
ends protrude ll/z" beyond the edges of the
sides to clamp it to your workbench. Then,
bevel the front edge of the base for ease in
sweeping debris into it for easy pick up . •
Project design : Paul Amberg

#8 x 1 W' F.H . wood screw

5/32' shank hole,

countersunk Hole sized to
fit your vacuum
hose, centered

10 WOOD magazine December/ January 2008/ 2009

Quick &Eas)' Jig
Super-simple
Tapering Jig
Tapers turn bulky, blocky
stumps into svelte and s~xy
legs. Start cutting the fat
with a·trip to the scrap bin.
n the last issue (#187, November

I 2008; p. 32), we provided plans for

an adjustable tapering jig. It works
great for cutting an infinite variety of
tapers, including those on the Basic-
Built Tables on page 54. But if you want
a simpler tapering jig to build that same
table set-one that doesn't require any
special hardware-try this one. It's not
quite as versatile, but perfect if you
value simplicity in your jig.
Start by cutting the base, guide, end
cleat, and spacer from %" MDF or
plywood to the sizes shown in the
drawing. Make the hold-down from 1/4' flat washer 1/#8 x 2" pan head screw
any piece of scrap. (We had %" poplar
in the cutoffs bin.) 5132" shank hOI~t
Glue and screw the end cleat to the
base. Then glue the spacer to the guide, W' rubb" b"moo, ~~HOLD-DOWN
but don't attach this assembly to the --- \..J,., - : 7'q1/2"
base yet. Its position depends on the 6 W'~ '-.. All stock 3/4" thick
taper to be cut.
Before completing the jig, use it to set
<
up the tablesaw for the cut. First, install 36"
a zero-clearance insert so the cutoff #8 x 11/4' F.H . wood screw
won't lodge between the blade and
insert plate. (For more about making
and using a zero-clearance insert, go to
woodmagazine.com!zeroclearance or
woodmagazine.com/zcivideo.) Next,
place the edge of the base against the
saw blade, then slide the rip fence
against t)l.e opposite edge of the base.
To use the jig, place one of the-legs
on the base with the top against the
end cleat and the taper marks on the guide. The rubber bumper on the
ends of the leg along the edge of the jig, bottom of the hold-down prevents the
as shown in the photo. Place the guide/ leg from slipping.
spacer assembly against the leg, drill To cut a taper, turn on the tablesaw
the mounting holes, and screw the and push the jig and leg past the back
guide assembly to the base. (Don't glue of the blade. Use an outfeed support to
it so you can reposition it to cut tapers keep the jig and leg from falling at the
of different lengths.) Retrieve the hold- end of the cut. Watch a FREE video on cutting
down and screw it to the spacer to hold Note: We've removed the blade guard to leg tapers with this jig at:
the leg firmly against the base and show you the operation. Use yours . • woodmagazine.com/taperjig2

12 WOOD magazine December/January 2008/ 2009

 Wood conditioner on the right side reduces
the color contrast between porous and
less-porous surfaces, helping the edge band
blend with the plywood veneer.

1 Try gel stain first

Unlike liquid oil-based stains designed .
to penetrate wood as much as possible,
the thick consistency of oil-based gel
stains helps control how much color
penetrates both solid wood and veneer.
After applying a consistent coat of gel
stain to all parts, stop short of wiping
off all the excess on areas that need
darkening. Should you accidentally
leave streaks on the wood, wipe them

Blending Banding away with a clean cloth moistened with

mineral spirits, and start over.

2 Condition the wood

Plywood's dimensional stability makes it great for many Wood conditioner works like a thin
film finish to block stain from over-
projects, but it usually doesn't stain to the same hue as the penetrating porous areas. By partially
solid-wood banding along its edges. Here are three fixes. filling pores as well as the surface, it
also reduces earlywood/latewood
contrast, as shown top left.
dhesive beneath a plywood challenge by matching the grain You can buy ready-mixed wood

A veneer can throw off stain

penetration compared with solid
wood, whether on an edge-banded
pattern of the banding to the plywood
grain, as shown below.
• Avoid smearing squeeze-out across
conditioner or make your own by
mixing two parts mineral spirits to one
part polyurethane or alkyd-resin
shelf or a bookcase made from plywood the surface during glue-up, or you'll varnish. To apply conditioner, brush it
sides and a solid-wood frame. Try these end up with light spots on top of your onto the surface and allow it to pen-
simple tricks to help your project parts other color-matching problems. etrate thoroughly. Then wipe away any
look like they came from the same tree. If you anticipate staining mis- surplus, and let it dry overnight. Lightly
• Stain helps equalize minor color matches, make practice glue-ups of sand the surface with 220 grit, wipe
differences, but it can make matters finish-sanded scrap plywood or clean, and apply stain.
worse when it highlights the pores of veneered MDF and solid wood to
mismatched grain. First minimize the experiment with these three solutions: 3 Seal, then stain
For the most consistent color, even
between wood parts of different shades,
apply stain to a layer of film finish
instead of the wood itself. Dewaxed
shellac provides a quick-drying sealer.
To mix your own, dissolve 3 ozs of
shellac flakes in 16 ozs of denatured
alcohol. Or buy premixed shellac sealer,
such as SealCoat (zinsser.com), and
thin that by half with denatured
alcohol. Avoid flakes or premixed
shellac containing wax; polyurethane
has trouble sticking to it.
Brush on or spray the sealer evenly
across all surfaces, and allow it to dry.
Scuff-sand the surface with 220 grit,
and apply the stain. One caveat: The
sealer will make it difficult to achieve
Matching the grain of a white oak edge to the grain of the oak-veneer MDF helps the two dark stain colors, but it eliminates
surfaces blend together after staining. blotching and lessens grain contrast: •

14 WOOD magazine December/ January 2008/2009

-L _________ ._~~_~___~__
 Win A FREE
Trip For Two
To Italy!
Contest Runs Sept. 15 to Jan. 15
www.woodmagazine.comldoor
for more details

Raised Panel Bit

For Making
Raised
Panel Cuts

Now you can Create Beautiful,

Customized Doors willi Strong Joints.
Imagine the Possibilities•••
Thanks to Freud's patented innovation, you now have
the ability to make door joints with precisely fit tenons
of any length. Use the bits right out of the box for high
quality stub tenons, or by simply removing the top of
the Rail bit, create extended tenons (for stronger joints) Two Piece Bit Sets Available: • Roundover Profile with Bevel
• Roundover Profile (#99-267) Raise Panel Bit (#98-300) .
at all four critical corners of your door. Combine with
• Ogee Profile (#98-268) • Roundover Profile with Cove
Freud's flawless Stile bit design, even add Freud's • Cove & Bead Profile (#98-269) Raised Panel Bit (#98-302)
award winning Quadra Cut™ Raised Panel Door bits,
you can create unique interior doors with any design
or wood species. These router bits come set up for
1-3/4" height (for entry doors) and can easily be adjust for
1-3/8" height (for interior doors). PraciseIJ the best.
Red router bits are a registered
tradeillaik of Freud Alllerrca Inc
ISO 9001
VOS'ON 2 000
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• • •
f dt I
www.reuoos.com
Workshop Savvy
The Simple Secret to

No-Fuss,
Dead-On
Dadoes
Use this technique to achieve
perfect-width dadoes in only
two test cuts. Guaranteed.

orget tedious trial-and-error becomes slightly thicker than the set your blade height for the

F testing. The trick to tight table-

sawn dadoes is to subtract-not
add-shims.
workpiece, as shown above. Install the
blades, chippers, and shims in your
tablesaw, and make a test cut in scrap.
3 finished dado depth, and make a
second test cut to confirm the correct
width and depth. Now you're ready to
To start, you'll need two scraps, about (You don't need to worry about the cut dadoes for gap-free joints like the
6" square of the same thickness. In one dado height at this point.) one shown below. •
of those squares, center a 5/S" dowel Remove enough of the dado set to
about 4" long. Now follow these three
steps anytime you need to cut a dado.
2 retrieve all of the shims, then set
them aside. Insert the workpiece end in
Finish-sand all workpieces that will the test dado, which should fit loosely.
1 be inserted into the dadoes, and lay From the shims removed from the dado
set, fit as many as possible into the gap
one on the nondoweled scrap. Stack the
blades and chippers on the doweled jig between the workpiece and dado edge,
until they're just less than the thickness as shown below left. Set aside these Watch a FREE video on how
of the workpieces. Then add shims shims and install the remaining shims to make tight dadoes at
between the blades until the dado stack as you reassemble the dado set. woodmagazine.com/videos

16 WOOD magazine December/ January 2008/2009

 US, TOO. Introducing

The Wood Tool Sharpener

NEW from the makers of

r.:; Drill Doctor.
Cutting Edge Technology for Woodworkers
Take a look at our latest project. It's the result of years of work, listening to
woodworkers like you, and then building the wood tool sharpener that you
wanted. Take a tour of the features and see what you think:

Adjustable Top Tool Rest-makes freehand

~
sharpening easier, more precise Glass Grinding Wheel-1S0mm
tempered glass wheel- provides a
•• . '. maintenance-free, always flat and true
580 rpm wheel speed- grinding surface on which to adhere
Powerful 1/5 HP Motor PSA Abrasives

Sharpening Port Lapping

Surface- "plunge-pull"
sharpening technique and Skew Cam
Sharpening Port abrasive Adjustment-controls
.increases burr removal and bevel-edge squareness
speeds sharpening

Sharpening Port-enables precise

and repeatable angles of 20°, 25°,
Dry Cooling System-routed 30°, and 35° for chisels and plane
airflow and heat sink system irons up to 2 inches wide
keeps tools cool without the
mess of a wet system

FaE
Innovative Edge-VisionTM WORK SHARP
Slotted Wheel-lets you
see the cutting edge as
Abrasives
you sharpen ! &
WOOD
MAGAZINE

Project Plans
See our insert card
in this issue for
Work Sharp is available at Sears, Rockier, Woodcraft, offer details!
Amazon.com, and wherever you buy your tools. Circle No. 1665
II11 Sho
II Helping you work faster, smarter, and safer
I'
1\
II
'I
Ii Blocked drill-press crank needs an extension
After adding an
!II auxiliary tabletop to
my benchtop drill
I. press, the new top
prevented the table-
Ii elevation crank from
II turning. Here's how I
worked around the
problem: First, I Carriage bolt, long
Telecom engineer Bob Hoffman has
enough to clear table,
I removed the crank
handle and replaced with head cut off
two places where he makes small
pieces of wood from large piece-s of
it with a threaded wood: his fully equipped 2-car garage
coupler drilled and workshop and his twice-weekly karate
tapped to accept a set sessions. Both require careful attention
screw. Next, I cut the to finger safety.
head off a long
carriage bolt and
ground a flat area to
accept the table
crank's set screw.
, I (Size the coupler and
\I carriage bolt to fit your drill-press the carriage bolt into the connector and
I
crank's shaft.) the handle, securing both ends with set
,, To stabilize the extended handle, I screws. My new extended crank works
attached a support bracket to the like a champ.
bottom of the table. Finally, I threaded -Bob Hoffmann, Sugar Hill, Ga.

Bob Hoffman will be the first woodworker

or martial artist on his block to have Freud's
new Doweling Joiner, which we're sending
Sand safer with a jointer pushstick for submitting this issue's Top Shop Tip.
While removing the
mill marks on some
lumber with my
stationary belt sander,
Top tips earn tools!
I noticed (for the Tell us how you've solved a workshop
umpteenth time) that stumper. If we print it, you'll get $100
my knuckles were and a copy of 450+ Best-Ever Shop Tips
very close to getting (woodmagazine.com/450tips). And, if
scraped as I held the your idea garners Top Shop
board's edges. I had Tip honors, we'll also
recently made reward you with a tool
prize worth at least $300.
WOOD® magazine's
Send your best ideas,
"Sure-grip" jointer along with photos or
push stick [free plan at drawings and your
woodmagazine.com/ daytime phone number,
jpushstickj. to: Shop Tips, WOOD
So, I used it to keep Magazine, 1716 Locust St., LS-221,
my fingers clear, as Des Moines, IA 50309-3023. Or, by
shown. The board e-mail: shopti ps@woodmagazine.com.
stayed on the sander Include your contact info in the e-mail.
and the skin stayed Because we try to publish original
on my hand. tips, please send your tips only to
WOOD® magazine. Sorry, submitted
-Charles Hamilton,
materials can't be returned.
Gray, Tenn. continued on page 20

18 WOOD magazine December/January 2008/2009

 20" 18" 16"
.JET.
www.jettools.com QUALITY INNOVATION SERVICE

, Circle No 1588
 Shop Tips
Easy-to-reach scrollsaw
blade keeper
Scrollsaws aren't known for an abun-
dance of onboard storage space. So I
stuck strips of magnetic tape I got from
the office supply store to a small piece
of plywood and mounted it to the
scrollsaw arm. The blades stay within
easy reach and the magnet keeps them
from vibrating onto the floor.
-Rick Hutcheson, Grimes, Iowa

Metalworkers hold the key

to deep clamping jobs
My last project, an entertainment
center, had a part that was difficult to
clamp due to its depth. None of my
woodworking clamps had enough
reach. So, I turned to my locking
C-clamps. The jaws' 11" reach, with the
aid of a clamping caul, distributed the
pressure perfectly.
-Bob Kel/and, st. John's, Newfoundland

Dedicoted to Dust Collection Since 1993.

Call Today for FREE Catalog! Order Online!
1.800.132.4065 www.oneido-oir.com 20 WOOD magazine December/January 2008/ 2009

J
Let your guard down for
eire saw safety
I added a 1/s" hardboard auxiliary zero-
clearance plate to my circular saw to
improve the cut quality, but I didn't
like that the retracted guard left the
blade exposed. Then I realized that the
workpiece really only needs zero-
Berea Brand
clearance support where the blade Pen Kits!
teeth exit the workpiece at the front of • High Quality
the cut. So I used a jigsaw to widen the • Original Designs
back two-thirds of the blade opening • Reasonably Priced
to allow room for the blade guard to Visit us at www.bereahardwoods.comor
snap back into place just as it was made call us at 1-877-736-5487 ore·mail us at
bereahard@aol.com
@@~~~W~)(V~o.lnc.
to do. 18745 Sheldon Rd' Middleburg HIS., OH 44130

-Rob Price, Watkinsville, Ga. Circle No. 2127

Shoe organizer turned

glue organizer
Don't let your shop door go unused as
storage space. I took my daughter's bId
mesh, wall-hung shoe organizer and
secured it to the door with a couple of
screw hooks. Now it holds glues,
compressed air, and spray finishes-any
small container, really.
-James Pruett, Rutherfordton, N.C.

woodmagazine.com 21
 Portability:
The JDS Cyclones have
a base with wheels that
allow the cyclones to be
transported anywhere!

I
28"
- - - - 4 0 " ______ -/
Quick Connect Drum Lever:
Disposing of collected waste is
quick and easy! Just lift up the
drum lever and slide the steel
With more performance drum out. Return the drum
and more features JDS is and lock down the lever, its
raising the bar for 2-stage that easy!

Cyclone Dust Collection!

Step 0 lift Drum Lever Step e Remove Drum

. Self Cleaning Canister: More Power:

The JOS Cyclones are Th e unique "Turbo-Fan"
equipped with a 1 micron impeller from JDS now
canister that is self cleaning. provides more CFM and
Every time the unit is turned greater performance at high
off a signal is sent to the levels of static pressure.
canister motor that activates
cleaning Nflappers" inside
the canister!
Shop Tips
World's most economical
corner clamps
Rather than buy a specialty clamp set
for mitered corners, you can make your
own like I did. Simply take some cheap
plastic spring clamps, remove the pads,
and drill holes to accept #4xl" flathead
wood screws.
To clamp up a mitered corner, drive
the screws through the clamp so the
tips will just bite into the wood, and
clamp the joint as shown. Driving the
screws a little further ensures that the
clamp won't slip.
-Mike Radcliff, Nashville, Tenn.

Available at:

Sawdust. It invades your workshop, threatening to take over. But with CleanStream Pro Filters
on your side, sawdust doesn't stand a chance. CleanStream adds true HEPA filtration to
your wet/dry vac. So no matter what kind of dust you're sucking up, 99.97% of even the
finest particles, down to 0.3 microns, are kept out of the air. CleanStream won't clog,
and it lasts longer than any other filter out there. We even have a one-year guarantee to
prove it. Declare victory over sawdust today. With CleanStream. www.cieanstream.com
Cleanstream and GORE are registered trademarks of W.L. Gore & Associates, Inc. © 2008 W.L. Gore & Associates, Inc. ~
Circle No. 2124

Scarf a snack,
save a paint roller
I hate washing out my paint rollers
when I have to take a break for lunch or
overnight. So, to keep the roller from
drying out, I store it in a discarded
potato-chip can. After cleaning out the
can, drill a hole in the center of the lid
and cut a slit from the hole to the lid
edge. Then slip the roller into the can
and snap the lid into place. The can
works great as a roller saver (and as an
. excuse to eat potato chips) . •
-Gerrit DeBoer, Grandville, Mich.

GREX
23 GA HEADLESS PINNERS

,woodmagazine.com
 Afew taps from
'7he Persuader"
should fix this.

00 they sell wood

filler in quarts?
•

ovetail joints are one of the But the fit of these eye-catching corners When you're routing multiple joints

D hallmarks of quality woodwork-

ing, and a router and store-
bought jig make quick work of them.
must be precise, as shown at left. And if
you don't use your jig often, it's easy to
forget even one small thing that results
with the same setup, make all common
pieces (drawer sides, for example)
identical in thickness and width.
in poor-fitting joints. Here's how to • Always make test cuts in scrap stock
minimize the headaches. that's of equal dimensions to your
workpieces until you achieve the
These hints will.get y'0u desired fit . Don't mess up your project
started on the right foot parts trying to dial-in a joint.
• Read the owner's manual and do • Slow your router bit speed to avoid
what it says. Proper setup heads off burning the pins and tails. Particularly
most goofs, and when you need help when routing closed cuts, such as half-
the solution often will be found there. blind pin sockets, at higher speeds,
• Use the correct router bits, guide trapped heat can build up and burn the
bushings, and jig templates. Manufac- wood; and burned surfaces don't bond
turers design all three elements to work well with glue.
together; straying from the right combi- • Finally, if you'll make the same
nation invites problems. project again, save the final test pieces
• Machine all your workpieces square to use as set-up blocks for the next
and to the correct dimensions. Inter- time. Then use those to set the bit
locking pieces don't have to be of the depth and workpiece position in the jig.
same thickness, but they must be flat
Half-blind dovetail Through dovetail and square to make a tight-fitting joint. continued on page 26

24 WOOD magazine December/ January 2008/ 2009

 PRECISION CONTROLS AT YOUR FINGERTIPS.

ACCURACY FROM A ONE-PIECE TRUNNION.

CONVENIENCE IN A WEll-DESIGNED DRAWER.

----~--- -- - -~-- ----~- -

THE NEW UNISAW GET READY FOR THE COMPLETE PACKAGE.

www.deltaportercable.com/unisaw
Avoiding Workshop Goofs
Head off half-blind errors
GOOF: You've cut tails instead of pins GOOF: Thin or unequal end tails or
on a drawer front. pins weaken a joint or leave it with an
HOW TO AVOID IT: Before routing, unattractive appearance, below.
label all components (front, sides, back) HOW TO AVOID IT: If your jig allows
near the joint for easy reference. Also, variable pin spacing, set the template
whenever possible use contrasting stock fingers so you get at least a half-pin on
for your drawer front so it stands out each end, as shown at right. If your jig
from the other parts. does not have
variable DON'T DO THIS
spacing, you'll
need to plan
your preject or
drawer widths
RIGHT:
Drawer to match the
side template
spacing. To do
this, measure
the template
width between
half-pins
closest to what
you'd like, as
shown at far
right, and
make that With a fixed template, measure from the
your work- edge stop to the right side of any finger and
piece width. make your workpieces that width.

26 WOOD magazine December/january 2008/2009

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Thwart mistakes with through dovetails
GOOF: You've cut your tails and pins GOOF: The bit tears chunks from your support the fibers of your workpiece to
with the wrong bit or the wrong side of workpiece as it exits the cut, below. prevent tear-out. When routing pins or
the template, as shown below. HOW TO AVOID IT: Sandwich your tails wider than the bit diameter, rout
HOW TO AVOID IT: Remember this: workpiece in the jig between two in incremental steps, removing the
Dovetail bits use straight template backer boards, as shown below right. waste material in three or four left-to-
fingers, and straight bits use angled Like a zero-clearance insert on your right passes rather than sim{>ly plung-
fingers . Again, labeling project parts tablesaw, these sacrificial boards ing through the workpiece. •
helps avoid confusion. Also, sketch the
joint on the end grain and mark an X
to indicate the areas to remove.

Use any scrap stock, such as this hardboard,

to back up your cuts on both faces.

woodmagazlne.com 27

Are uou buuing

lie best?
'NNOVATIVE
Unique fully Integ,."ted .off grip handle

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Value "ricad Ciampa for _ ftH11f81U11
Your Kreg Jig ®•••

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FORE ER!
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best new wood~~rking tools for the coming year. The 9.ood
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market &spite ough economic ti
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The strength of dowels;

the speed of a biscuit joiner
Combine the best attributes of dowel and biscuit
jOinery and you'll see why we think Freud's' new
Doweling Joiner will be a huge hit. A pair of spiral
carbide router bits (in sizes from ¥l6" to Yz" in diameter)
bore perfect dowel holes centered 1WI apart. Use the adjustable, retractable
pins on each side of the bits to register from a workpiece edge or another
hole. And by running the Doweling Joiner along a straightedge, you can
"This tool is so intuitive and easy to use quickly and accurately rout rows of equally spaced shelf-pin holes.
that it could be bad news for biscuits. II Freud Doweling Joiner, $350
Bob Hunter, Tools Editor 800-334-4107, freudtools.com

Extreme Makeover: Delta Unisaw edition

Delta's iconic cabinet-style tablesaw got
a from-the-ground-up overhaul _----,.i
this year, and is being fully
made in the U.S.
What's new? For
starters, you'll find
big up-front blade-
. height and bevel
~ handwheels, externally toolless removal of the safety guard,
J accessible bevel-stop splitter, and riving knife; an arbor lock for
.~ adjustments, and a clock- one-wrench blade changes; and a shroud
face bevel gauge. There's also the around the blade for improved dust
30"-deep cast-iron top (up from collection. It will sell with either a 3- or
27") with the added workpiece 5-hp motor and a Biesemeyer fence in 36"
support in front of the blade, and or 52" rip capacity.
an accessory drawer mounted under
the table extension. Of course, it also Delta 10" Unisawtablesaw, $2,800-$3,100
800-223-7278, deltaportercable.com
sports features we've come to expect
on high-end cabinet saws, such as continued on page 30 29
 Milwaukee mitersaws digitally accurate to 0
1/10
"/'d</ove to outfit Milwaukee's first foray into the 12" mitersaw category yields two models
loaded with user-friendly features. For mitering, there's an industry-first
my shop with
digital scale accurate to 0.1°, a detent override, and smooth-as-silk needle
these clamps." bearings under the rotating
table. Add to that nine
bevel stops, an effective
4"-wide dust-collection
chute, incandescent lights
on both sides of the blade,
and a bevel-gear motor that
reduces kick at startup and
shutdown.
Milwaukee 12" dual-compound
mitersaw (shown),$500;
-sliding mitersaw, $700
. 800-729-3878,
milwaukeetool.com

A jaw-dropping face-lift
for the K-Body clamp Shift gears automatically between
In the face of ever-increasing competition, drilling and driving
Bessey has redesigned the venerable K-Body Never again wonder whether your drill/driver is in the right speed range
parallel-jaw clamp. Using the same I-beam bar, for the job. These two lithium-ion-powered drill/drivers automatically
the K-Body Revo jaws are %" taller and Y2" shift gears as each task demands. They start in the high-speed range, and
wider with replaceable face pads. Easier-to-grip if the job needs more
rubber-and-plastic handles replaced the wood torque, the
ones. Each clamp now includes two saddle automatic trans-
pads to place under gluelines to support the mission switches
assembly and keep glue off the bar threads. immediately to the
Options include a sliding tail jaw (so you can low range. There's also an
Ridgid model,
center glue-ups on the bar), and a jaw adapter override to lock the tool in
$230
for clamping angled assemblies. the high-speed range. 800-474-3443
Bessey K-Body Revo Parallel-Jaw Clamps, ridgid.com
AutoShift 18-volt Drill/Driver,
$36-$72 (in 8 different lengths) Ryobi model, $200
800-828-1004, besseytools.com 800-525-2579, ryobitools.com

"Stretch" your bandsaw Oscillating drum sander sands

for resawing smoother, burns less
Adding a 6" riser block to a cast-iron A drum sander removes thin layers of material without tear-
C-frame bandsaw increases its out, but often leaves straight-line scratches from the abra-
resaw capacity, but also its ten- sives. And resin buildup on the sanding drum can transfer
dency to flex. The General burn marks to the workpiece. You then have to remove
International 90-200M1 allows these scratches or marks with a portable sander or
you to adjust its resaw height in hand scraper. Jet's 22"-wide, open-ended
no time. With a solid-steel Oscillating Drum Sander gives you the option
support shaft instead of cast iron, of switching on I" of side-to-side ___I
the head raises or lowers on a rack-' movement (like an oscillating ~_~~~'-'---'!S!~...'.

and-pinion gear. So you can set the spindle sander does vertically)
saw low and use a 93 1!z" blade for as it sands to avoid these
ripping or curve cutting, or raise it to pitfalls. And its Sand Smart
full height and install a 106" blade for feature automatically slows the
a 12" resaw cut. This model also has feed rate during demanding
ball-bearing blade guides, 16x16" table jobs to prevent bogging down
with rip fence, and flexible work light. the drum motor. :I
General International Jet 22-44 Oscillating Drum Sander,
15" Adjustable-Height Bandsaw, $1,480 $2,050
888-949-1161, general.ca 800-274-6848, jettools.com

30 continued on page 32
 MLCSwoodworking.com...
Free "Online Videos" show you how
to rout it, join it, and buila it

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Our Mitered Door Frame Kit creates
"Hide the ply" elegant Rail & Stile Doors. Includes
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The Edge Banding router bit
Router Bit, 1/4" & 5/32" Slot Cutter
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Item #1480.............. $79.95
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The Marvel 40 3-In-1 Router Kit is a
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~VIDEO Make strong Half Blind 1/ 2" Dovetail Joints. Our set
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Item #1485 .................$II4.95
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Circle No. 245

Portable cyclones offer better dust
collection for the small shop
We prefer two-stage cyclone dust collectors to single-
stage bag units because the vast majority of the debris
falls into a collection drum and never reaches the
impeller or filter. But traditional cyclones are big and
require dedicated spaces. These portable units bring
that superb separation into the home-shop realm Oneida Mini Gorilla
with small footprints and about 5' heights. Oneida's Mobile Dust Collector,
Mini Gorilla comes with a 5/1 inlet and 10' of flex- $890
800-732-4065,
hose, and specs about 600 cfm of suction. The JDS
oneida-air.com
unit has one 8/1 inlet or two at 4/1, and claims about
1,700 cfm of suction. It also has a built-in filter
cleaner that automatically beats the pleats inside the JDS 2-hp Portable Cyclone, $1,300
filter every time you shut off the machine. 800-480-7269, jdstools.com

Add a rock-solid helping hand Cut dead~on mortises

wherever you need it with your handheld drill
Two years ago Magswitch launched its powerful MagJig JessEm's Zip Slot Mortise Mills allow anyone with an electric
magnets that turn on and off with the twist of a switch. or cordless drill to machine perfect-size mortises. Bearing-
Now the company has developed an accessory hold-inl guided bushings position the high-speed-steel spiral bit in
hold-down system with interchangeable workpiece supports. the mill's slot; then you simply plunge the bit a little at a
The Universal Mounting Base kit gives you the flexibility to time as you slide it side-to-side using a lever. Each kit comes
place support right where you need it on any ferrous surface, with loose hardwood tenons, or you can cut tenons on your
using the two included MagJigs. One support is flat with two workpiece. The smaller mill makes only lJ4/1-wide mortises-
sets of roller bearings, and the other has a 7° bevel on each perfect for %/1 stock-while the larger unit makes %/1
side of a single bearing guide. Both provide unflinching mortises standard
support without the resistance of a feather board on your with optional 1;4" and
tablesaw, bandsaw, or jointer. Yz/l accessories .
available.
Magswitch Universal Mounting Base Kit, $lS0
303-468-0662, magswitch.com.au JessEm Zip Slot
Mortise Mill,
'/4" model, $100;
3Ja" model, $250
866-272-7492,
jessem.com
(Sold exclusively
at Woodcraft,
800-225-1153,
woodcraft.com)

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WOOD magazine December/January 2008/2009

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Tumcrafter™ Lathes
Shaker-styl

S
ure to become a family heirloom,
this six-drawer cherry dresser
combines classic Shaker style and
practicality. Build it alone, or add the
separate valet (page 41) and wall mirror
(page 66). The dresser and accessories
match the pencil-post bed shown in
issue 187 (November 2008). A seven-
drawer lingerie chest, coming in issue
189 (March 2009), rounds out a com-
plete bedroom set.

Start with the side parts

1 Cut four leg blanks (A) [Drawing 1] to
size [Materials List, page 40]. (You can
cut them from solid stock or laminate
them.) Mark the position of each leg on
its top (FL for front left, for example).

2 Lay out the tapers on the two inside

bottom faces of each leg (A) [Drawing
1]. Using a tablesaw and tapering jig (see
Quick and Easy Jig, page 12), cut the 1.

tapers [Photo A]. Sand the tapers to .

remove saw marks.
Layout the locations of the mortises I
3 for the front rail (F) and back rail (G) 1
on the legs (A) [Drawing 1]. Form the 1
mortises by drilling a l,4" hole W' deep at
each end of each mortise. Then drill I
evenly spaced holes between them, and 1
clean out the mortises and square the
corners with l,4" and %" chisels.

4 Cut the side panels (B) to size.

Rough-cut the panels for easier han-
dling, and then rip and trim them to

~5size on your tablesaw.

Install a W dado blade on your
tablesaw and set the cutting depth
1
to ¥S". Cut five dadoes and a rabbet in
the inside face of each side panel (B)
[Drawing 1].

6 Lay out the arc on the bottom of

each side panel (B) [Drawing 1] by
marking the centerpoint, and then

WOOD magazlrii DecemberlJanuary 2008/2009

 Groovin' and gluin' avoids
squeeze-out messiness
When gluing parts onto the f<,!ce of
a panel, glue will squeeze out from
behind the onlay onto the panel.
Removing the glue along the joint is
difficult, which could affect the finish .
A blade kerf about Va" deep, Va" from
the edge on the back of the on laid
part will catch the glue and keep
it from getting on the panel. Cut
grooves at the top and bottom of the
upper rail (C) and at the top only on
Taper two adjacent faces at the bottom of the bottom rail (D) . -
each leg (A). The straight sides face out at
each corner.

drawing a line through it and the end- out from marring the side panels, see depth so the pilot bearing rides on the
points of the arc with a fairing stick. (Go the Shop Tip, above. Glue and clamp the bottom edge of the side panel (B). Then
to woodmagazine.com/fairing for a free upper side rails flush with the top edge trim the bottom edges of the lower side
fairing stick plan.) Bandsaw slightly out- ofthe side panels; let the lower side rails rails (D) flush with the side panels [Photo
side the line, and then sand to the line. overhang the bottoms of the side panels B] . Finish-sand the rails (C, D) and
Lay one side panel (B) on your work- by ¥s". Align the rail ends flush with the touch-up sand the side panels.
7 bench, dadoed side up, and lay the edges of the panels.
6 Apply glue to the biscuit slots in two
front and back legs (A) for that side in
position, flush with the panel at the top.
Mark biscuit locations on the side panel,
5 Chuck a flush-trim bit in your hand-
held router, and adjust the cutting
legs (A) and one side assembly (B/C/
D). Run a bead of glue along the edges of

centered between the dadoes and the

#20 biscuit slot
dado and rabbet at the top [Drawing 1].
Mark the corresponding locations on
each leg. Repeat for the other side panel
and legs.

8 AdjUst your biscuit-joiner fence to

center a #20 biscuit slot on the thick-
7"

ness of the side panel (B). Plunge slots at

the marked locations on the panels.
Finish-sand the side panels to 220 grit.
Va" grooves
Va" deep
Va" from top
and bottom
16%"

~j
Make both sides, now
1 Adjust your biscuit-joiner fence to
place a #20 biscuit slot %" from the
inside edge of the legs (A) [Drawing 1]. 8"
48 /2'
'

Plunge slots at the marked locations. 43V4'

Finish-sand the legs, using a flat sanding

2
block to prevent rounding the faces.
Cut the upper side rails (C) to size
[Drawing 1]. Cut two blanks
1
lAx3lAx17" for the lower side rails (D);
the extra width facilitates trimming the
bottom arcs.
Layout the arc on the lower side rail
3 (D) [Drawing 1] with a fairing stick.
-'CW)-Quick tip! Stack-cut parts for unifor-
¥ mity and speed. Cut both parts at once: V4"
Layout the arc on one blank. Then,
-.....•.. V2"
stack both blanks with all edges flush,
and fasten them together with masking
tape or double-faced tape. Bandsaw the
arc about ¥a" outside the line.
% x 2'12" mortise

4 Attach the upper side rails (C) and

lower side rails (D) to the side panels
(B) [Drawing 1]. To prevent glue squeeze-
W'deep
#20 biscuit slot centered
between dadoes

woodmagazlne.com 35
 DTENON DETAILS

Keep the bearing on the flush-trim bit firmly Glue the legs (A) to the side (B/C/D), flush at Dust off some panels
against the bottom edge of the side panel (B) the top. Square the assembly, and clamp the
to neatly trim the lower rail (D). top and bottom. Then add middle clamps.
1 Cut the dust panels (H), dust panel
front rails (I), back rails (J), and end
rails (K) to size [Drawing 4] .
the side panel (B) , near the dadoed face
to minimize squeeze-out on the outside
face. Lay the side assembly, dadoed face
adjust the cutting depth to W'. Cut the
tenons on the ends of the rails (F, G)
[Drawing 3].
2 Measure the thickness of the ply-
wood dust panels (H), and then cut
overlapping blade kerfs to make a groove
down, on W' spacers on your workbench,
and insert biscuits in the slots. With the
mortises in the legs facing down, assem-
3 Layout, bandsaw, and sand the arc
along the bottom edge of the front
rail (F) [Drawing 2] as you did for the side
that wide centered on the edge of the
dust panel rails (I, ], K) [Drawings 4, 4a].
Quick Tip! Size grooves to fit plywood._(@)_
ble and clamp, keeping the tops of the panels (B). Finish-sand the front and Position the rip fence slightly more than V
legs and the side panel flush [Drawing 1, back rails. half the thickness of the stock from the
Photo C] . Repeat for the other assembly.

7 Cut the drawer spacers (E) to size.

Align the spacer bottoms flush with
the dadoes in the side panels (B) [Draw-
ing 2, Photo 0]. Glue them
and fasten with a pneu-
matic brad nailer, pinner,
3/,6" slot 3/4" long, countersunk
or ~" wire nails. on bottom face T~~~~~~~§§§~~~~
#8 x 0/4' F.H . wood screw
Make the rails #8 x 1 V4" F.H. wood screw -

1 Cut the front rail (F)

and back rail (G) to size
[Drawing 2].

2 Install a Y2" dado set on

your table saw and

EJEXPLODED VIEW

1" on bottom
front rail only

36
 SKILL BUILDER
Stub tenons, by the numbers
Stub tenons on the end rails must fit into
the grooves on the front and rear rails. To
determine the rabbet depth for a
centered tenon, measure the width of the
groove (.220", for example), right, and
subtract that from the thickness of the
rail stock (.750"). Divide the result (.530")
by two to determine the rabbet depth for
each face of the tenon. (For this example,
cut a rabbet .265", or ''l'64", deep.) Make
test cuts on scrapwood to sneak up on
the best tenon fit .
Cut a temporary stop from 3f4" stock, and slip
it into each dado in the side panel (B) to align
the spacers (E) for gluing and nailing.

outside of the blade (about Yli' for the the groove is too narrow, move the W rabbets that form the tenon [Drawing
dust panels). Then, cut a 14 "-deep kerf fence farther from the blade. 4], see the Skill Builder above.
in scrap stock the same thickness as the
rails. Rotate the piece end for end, and
cut another kerf. Test-fit the plywood in
3 Cut W-Iong stub tenons on the ends
of the dust panel end rails (K) to
match the grooves in the front and back
4 Attach an extension to your miter
gauge, and notch the ends of the
dust panel rails (I, J) [Drawing 4a] with
the groove, and adjust as ,necessary. If rails (I, J). To determine the depth of the the dado set in several passes [Photo E].

5 Arrange a dust panel (H) and rails (I,

J, K) in assembly order on your bench
[Drawing 4] . Apply glue in the rail
grooves, assemble the dust panel, and
clamp, checking for square [Photo F] .

Grooves to fit
V4" plywood %" deep

Stub tenon V4" long 5/S x 15/ ' 6" notch

to fit groove

The tablesaw fence acts as a stop for the Clamp the joints, and measure the dust For the shallow bottom dust panel (H/l/J/K),
length of the notch. A miter-gauge extension panel (H/I/J/K) across the diagonals. Equal rip the front (cherry) rail (I) on one dust panel
supports the end of the rail (I, J) for cutting. dimensions indicate the panel is square. to 1" wide.

wood magazine. com 37

 Clamp the spacer (N) to the dust panel (H/I/J/ Put temporary spacers between the ends of Make sure the top edge of the front rail (F)
K) with a caul. Insert wedges under the caul the dust panels (HII/J/K/N) while you glue, lies flush with the top of the dust panel front
to apply pressure at the middle of the spacer. clamp, and screw t~e divider (LIM) in place. rail (I) as you clamp them together.

Construct the remaining five panels in BTOP DUST PANEL DETAIL III DRESSER BACK VIEW
the same way.
1
6 RiP %" off the front rail (I) of one
dust panel (H/I/J/K) [Drawing 4,
Photo G] to make the bottom dust panel
" ® '1]r'/: "
~~ ¥.fTT .iJI
-

[Drawing 2]. Finish-sand the panel. -~

-~-~-
. ~ . -.- --
7 !I ~6" slot ¥4" long,
Cut the divider (L) to size and the
divider trim (M) to fit the front edge © !I countersunk

~ I~
of the divider [Drawing 2] . Glue the on bottom face
divider trim to the divider, flush on all ~. ---::=:=
edges, and clamp. Finish-sand.
1I - ®~
8 Cut two divider spacers (N) to size.
Center one spacer side-to-side on the
bottom side of the top dust panel (H/I/J/
N 1' iI I

K) and the other on the top side of the

next dust panel down from the top
[Drawing 2]. Glue and clamp [PhotoH].
low) dust panel (H/I/J/K) into the bot-
tom dado of the side assembly [Drawing
2]. Place another dust panel temporarily
6 Edge-glUe %" material to make a
slightly oversize blank for the top
(0). Rip and trim the top to size.

9 0n the bottom of the top dust panel

(H/I/J/K), drill and countersink
screw holes for the top (0) [Drawings 2,
in the middle dado.

3 Without gluing, insert the tenon of

the front rail (F) into the mortise in
7 Tilt your tablesaw blade to 37° from
vertical, and cut the bevels on both
ends and front edge of the top (0) [Draw-
5] . (For #8 screws, drill %z" shank holes the front leg (A) [Drawing 2]. Then, place ing 2]. Rout a Ys" round-over on the bev-
and ~4" pilot holes.) To allow wood the other side assembly on the rail and eled edges. Finish-sand the top.
movement in the top, enlarge the holes
in the dust panel back rail (J) to make
dust panels. Check the fit of all parts
[Drawing 2]. 8 Cut the back (P) to size. Install the
top (0) and back (P) [Drawings 2, 6] .
slots about %" long [Drawing 5] by drill-
ing through them with a ¥l6" twist drill,
and rocking the bit back and forth .
4 Lift off the top side assembly (A/B/
C/D/E), and remove the front rail
(F) . Apply glue to the front edge only of
Elongate the countersinks also. Finish- the bottom dust panel (H/I/J/K) . Then,
sand the remaining dust panels. put the front rail back in position and
replace the side assembly on top. Square
Construct the case and clamp the case, and then clamp the

1 Cut two spacers the same size as the

divider (L) from scrapwood. Then,
glue and clamp the top dust panel (H/I/
front rail to the dust panel [Photo J].

S Lift off the top side assembly (A/B/

C/D/E), the front rail/bottom dust
J/K/N) , the divider (L/M), and the next- panel assembly (F/H/I/J/K), and the
to-top dust panel [Drawing 2] , centering other dust panel (H/I/J/K). Apply glue to
the divider side-to-side on the dust pan- the dadoes and mortises in the side
els. Place the scrapwood spacers at the assembly on the sawhorses. Then, with a
ends of the dust panels [Photo I]. Drill helper, position the front rail/bottom
and countersink screw holes through dust panel assembly, the back rail (G),
the dust panels into the divider [Draw- three dust panels, and the dust panel!
ing 2], and drive the screws. divider assembly (H/I/J/K/L/M) on the

2 Lay one side assembly (A/B/C/D/E)

on padded sawhorses, dadoes facing
up. Without gluing, fit the bottom (shal-
side assembly [Drawing 2]. Glue and
install the other side assembly. Square
the case assembly, and clamp [Photo K].
Assemble the case on sawhorses to allow '
space for clamping. Clamp the assembly
evenly at the front and bac:k.
II
38 WOOD magazine December/ January 2008/ 2009
'12" dado 1/4' deep %" from back edge BTOPDRAWER

n!lDRAWER JOINT DETAIL

'See instructions.

W' dado 1/4' deep

IlIWIDE DRAWER
1/4' dado 1/4' deep
rz.~.--- :
/_/ /'
S >
~
./

~,-~-;:;::~:.:::::.:
~

l
V y 55/8" for part0{;

61fs" forpart@ '~

~~~~
" ~ 1~rpart(2)) m DRAWER GUIDE
TAPE DETAIL
\....~ ~___ ~ J /
7%" for part® .
~ ..,.*
- . .,p
"'~
331/s"
W~ ~' 77/s"
61/s" for part®
for part@

~/~
.. 6" "'- --- ~
::::--..... -"-.- ,_
--- --
" . ><~~
.,P -
.
-..~
/.

7 /18"(1 / //j ~
V1" wire nail / d
':?
~~~/ 1

33 5/8" (J :::::--.... 19"

~~~. 1/4' from bottom edge See Instructions .

. . .!P.P.IP'W'P.'....~
Build the drawers
1 Cut the drawer fronts (Q, U, X),
backs (R, V, Y), sides (S, Z), and bot-
4 GIUe the drawer fronts (Q, U, X) and
backs (R, V, Y) to the sides (S, Z)
[Drawings 7, 8] . Slide the bottoms (T, W)
toms (T, W) to size [Drawings 7, 8] . into the grooves in the sides and fronts,

2 Set up your tablesaw with a 1;4" dado

blade, and machine the fronts (Q, U,
X) and sides (S, Z), as shown in Steps 1- 3
but do not glue them. Square the draw-
ers, and then clamp the joints [Photo L].
Attach the bottoms to the backs (R, V, Y)
of Drawing 9. Change to a Y2" dado blade, with wire nails.
and make the cut at the back of the
drawer sides, as shown in Step 4. The
front, side, and back joints assemble as
S Lay out and drill mounting holes on
the drawer fronts (Q, U, X), sized for
the knobs you have chosen. Finish-sand
shown in Drawing 10. the drawers.
Cut a groove as wide as the thickness
3 of the plywood drawer bottoms (T, Complete the dresser
W) in the drawer fronts (Q, U, X) and
sides (S, Z). Locate the top of the groove
the same distance from the top edge of
1m
rails
Cut the drawer stops (AA) to size,
and glue them to the dust panel back
[Drawing 2]. Apply low-friction With the drawer glued together and the
the fronts and sides as the width of the slippery tape to help the drawers slide bottom in place, measure diagonally to
drawer backs (R, V, Y) [Drawings 7, 8]. smoothly [Drawings 11]. - ensure square. Adjust as needed, and clamp.

mMACHINING THE DRAWER PARTS

, - - - - -- - - - - - r - - .- - - - - - ,
STEP 2

39
 Materials List
FINISHED SIZE

2 Inspect the case and drawers, and

touch up the finish-sanding as nec-
essary. Stain as desired. (We stained the
Part
Side assemblies
T W l MatI. Qty.
Top drawers
Q fronts %" 6'/s" 16%" C 2

R backs 2
A* legs 1W 1W 48Y2" C 4
dresser with Minwax no. 607 Cherry-
B side panels %" 17" 43'/4" CP 2 5 sides V2" 6 'Is" 19" SM 6
wood gel stain to match other pieces in
the bedroom suite.) C upper side rails 2 T bottoms '14" 15 7/s" 18" BP 2

3 APply a clear finish. (We applied

three coats of satin polyurethane,
sanding to 320 grit between coats.)
D*
E
lower side rails
drawer spacers
'/4" 3" 17" C 2
10
Shallow drawer
U front %" 6'/s" 33%" C
F front rail %" 3" 34%" C V back '/2" 5%" 33%" SM

4 Install the drawer pulls. Then slide

the drawers into place . •
G
Case
back rail
W bottoms '14" 18" 33'1s" BP 4

Written by Larry Johnston with Kevin Boyle Deep drawers

H dust panels %" 16'/2" 32" BP 6
Project design:Kevln Boyle X fronts %" 7 7/s" 33%" C 3
Illustrations: Roxanne LeMoine; Lorna Johnson dust panel
%" 1%" 35" C 6
front rails Y backs '/2" 7%" 33'1s" SM

Cutting Diagram dl,lst panel

back rails
%" 1'/2" 35" SM 6 Z sides '/2" 7 7/s" 19" SM 6

AA drawer stops SM 6

------------ K
dust panel
end rails
%" 1%" 16'12" SM 12 ' Parts initially cut oversize. See the instructions.

l divider %" 6'14" 18W CP Materials key: BP-birch plywood, C-cherry, EC-
M dividertrim %" %" 6'14" C edge-glued cherry, CP- cherry plywood, sM-soft maple.
Supplies: #8x%", 1'14", and 1%" flathead wood screws,
N divider spacers '14" 3" 16" SM 2
#20 biscuits, 1'12" wood knobs (10)' '12" and 1" wire nails.
0* top %" 21 '14" 39'14" EC Blade and bits: 'Is" round-over bit, rabbeting bit,
flush-trim bit, dado set.
P back '14" 33%" 41 " BP

Source
low-friction tape: Slippery tape, 25U04.01, $12.50,
3/4 x 48 x 48" Cherry plywood Lee Valley, 800-871-8158 or leevalley,com.

mit ® hi
:.- ®
u@
3/4 x 7% x 96" Cherry (5.3 bd . ft.) (2 needed)
3/4 X 91/4 x 72" Cherry (5 bd. ft.)
~
~~ ® -
3/4 x 9% x 72" Cherry (5 bd . ft.)
- ::=fi
'Plane or resaw to the thickness listed in the Materials List.

1[10 t~_ -ifuF--- 3=~;;;R

J 3/4 x 91/4 x 96" Soft maple (6.7 bd. ft.)

~~-- +~ l:<$--~ =:j

3/4 x 7% x 72" Cherry (4 bd. ft.)

i®@~£~ 3/4 x 9% x 72" Soft maple (5 bd. ft.)

3/4 x 7'/4 x 72" Cherry (4 bd. ft.)

i@ - - --- r(Q)= f@-- --------~--------- I

3/ 4 X 7% x 96" Cherry (5.3 bd. ft.) (2 needed)

"(8)
_._____ ,"__> ___ ~,..__-+....l
£ ----
3/4 X 7% x 96" Soft maple (5.3 bd . ft .)
----
~® -- l-'® -£® =t®#tl
3/4 x 7% x 72" Soft maple (4 bd. ft.)

b;®--- l ®- -#3 --~+---- I

-~

3/4 x 7% x 72" Cherry (4 bd. ft.) % x 48 x 96" Birch plywood

---------1
...",/ .. _-
- -- - - ------
% x 48 x 96" Birch plywood % x 48 x 96" Birch plywood
40
 Dresser-top Valet
Here's an accessory that dresses up your dresser and adds storage space at the same
time. It goes together quickly with biscuit joinery and features a pair of easy-to-build
drawers. The valet matches the dresser on page 34, but would look great in any setting.

PROJECT HIGHLIGHTS parts to finished width, cut them cross-

cut-style, using your miter gauge.
• Overall dimensions: 2914" wide x
1614" deep x 5" high.
• Two drawers-each with a hidden
4 Tilt your tablesaw blade to 37° from
vertical, and cut the bevels along the
bottom edge on both ends, and then the
compartment-hold small items.
• Materials needed: Cherry, %", W'; front edge, of the top (A) [Drawings 1 and
soft maple, %",112"; and birch 1a] . Rout the Ya" round-over along the
plywood, W . top of the beveled edges.

Start with the case parts

5 Change to a %" round-over bit, and
shape the top of the ends and front
edge of the bottom (B) [Drawing 1] .

1 Joint and edge-glue cherry boards

7h" thick or thicker to make two Get ready for biscuits
161fzx36" blanks for the top (A), bottom
(B), sides (C), and divider (D) [Drawing 1].
-c®-Q
. uiek Tip! Glue up a panel in stages for
1 Make a story stick for the biscuit
joints [Drawing 1, Skill Builder] on the
extra side (C). Label the back edge.
V planing. To make each blank, start with
three SYz"-wide boards. The three-wide
glue-up won't go through most home-
shop planers, so edge-glue two boards
SKILL BUILDER
into a panel, and then plane it to W Here's a story you can stick to
thick. Plane the third board to the same A story stick helps you layout repetitive
thickness, and then edge-glue it to the measurements, such as the biscuit locations
panel, keeping the joint flush. on the valet, quickly and accurately. Instead

2 RiP and crosscut the top (A) from

one blank and the bottom (B) from
the other [Materials List, page 43].
of measuring and marking the locations
separately, lay them out once on a piece of
scrapwood, as shown at right.
Then position the story stick on or against
3 Set your tablesaw rip fence 3Yz" from
the blade, and crosscut the sides (C)
and divider (D) to length from the
the project part, and transfer the layout
marks to the workpiece. For the valet, we put
remaining edge-glued stock. Crosscut the sto'ry stick to work as a fence, too, when
an additional piece about the same size plunging biscuit slots in the top and bottom
as the sides; you will make it into a story [Photo B).
stick later. Then, to safely rip the short

wood magazine. com 41

 ·.
/

Biscuit
centerline
®
~ ) #20 biscuit
(-::<~
Story-stick '.
position /
m
With the back edges of the top (A) and bot-
m
The story_stick serves as a fence and locator Set the case on risers for clamping. Place
tom (B) aligned at the center, mark the biscuit for cutting the biscuit slots. Align the guide clamps at the biscuit locations on the sides
centerlines on the top. mark on the joiner with the story-stick mark. (C) and at the ends of the divider (D).

2 0n the top (inside) face of the bot-

tom (B), draw biscuit centerlines
always aligning the story stick flush with
the back edge of the part.
along the back inside edge of each side
(C) [Drawing 1].
across the middle and 1W' from each
end [Drawing 1]. S Transfer the biscuit locations from
the story stick to the top and bottom 2 Finish-sand the top (A), bottom (B),
sides (C), and divider (D) to 220 grit.

3 Draw a biscuit centerline across the

m iddle of the top (A) on the inside
edges of the sides (C), again keeping the
backs flush . 3 APPlY glue to the biscuit slots in the
bottom (B), insert biscuits, and
face . On your workbench, bring the back
edges of the top and bottom (B) together,
and align them at the center. Transfer
6 cut W' off the back edge of the story
stick. Then, align the new back edge
with the back of the divider (D), and
assemble the sides (C) and divider (D)
[Drawing 1] . Then, apply glue to the slots
in the sides and divider, insert biscuits,
the locations of the other biscuit center- mark the biscuit locations on the top and attach the top (A) [Drawing 1] .
lines to the top [Photo AJ, and layout
the lines on the top.
and bottom edges of the divider.

7 AdjUst the biscuit-joiner fence to 4 Make sure the sides (C) fit flush with
the back edge of the bottom (B) and

4 AdjUst your biscuit joiner to cut a # 20

slot. Place the marked edge of the
center slots on the edges of the sides
(C) and divider (D). Clamp each part to
the divider (D) sits W' from the edge.
Then, clamp the case [Photo C].
story stick 3fs" from the middle centerline
on the top (A), and clamp. With the bis-
cuit joiner vertical, press its base against
your workbench, and plunge the three
slots in each edge. S cut the back (E) to size. Drill and
countersink screw holes in the back.
(For #8 screws, drill %2" shank holes and
the story stick, and then plunge a biscuit Build the case ~4" pilot holes.) Set the back aside.
slot at each biscuit location on the story
stick [Photo B]. Repeat for all the biscuit
centerlines on the top and bottom (B),
1 Set up your table-mounted router
with a W' rabbeting bit or a straight
bit and a fence, and form the rabbets IEITOP PROFILE DETAIL

DVALET ®

#8 x 3/4" F.H. wood screw

Slippery tape
42 WOOD magazine December/January 2008/2009
 EJDRAWER

Measure from each front corner diagonally

to the corner of the false back; the measure-
ments must be equal. Clamp the drawers.

Build a pair of drawers

1 Cut the drawer stops (F), drawer
fronts (G), drawer sides (H), drawer
backs (I), and drawer bottoms m
to size.
1W' wood knob

'See instructions.

2 Set up your tablesaw with a W' dado

. blade, and machine the fronts (G)
and sides (H), as shown in Steps 1-3 of [Photo 0] . Fasten the bottoms to the (E) in position, drill pilot holes in the
Drawing 9, page 39. Change to a W' dado rearmost backs (I) with wire nails. sides (C), and drive the screws. Attach
blade, and cut the dado at the back of
the drawer sides, as shown in Step 4.
Make another dado, where shown for
5 Drill mounting holes in the drawer
fronts (G) to fit your knobs [Drawing
2]. Finish-sand the drawers.
the felt pads to the bottom (B). Install
the drawer knobs, and slide the drawers
into the openings . •
the second drawer back (I) [Drawing 2].
Wrap up the valet Written by Larry Johnston with Kevin Boyle
3 Cut a groove as wide as the thickness
of the plywood drawer bottom
the drawer fronts (G) and sides (H).
in m
1 Fit the drawers and touch-up-sand as
necessary. Glue the drawer stops (F)
Project design: Kevin Boyle
Illustrations: Roxanne LeMoine; Lorna Johnson

Locate the top of the groove the same to the bottom (B) [Drawing 1] .
distance from the top edge of the fronts
and sides as the width of the drawer back
(I) [Drawing 2].
2 Stain as desired. (We stained the
valet with Minwax no. 607 Cherry-
wood gel stain to match the dresser.)
Materials List
Part T
FINISHED SIZE
W L Mati. Qty.

4 GIUe the drawer fronts (G) and backs

(I) to the sides (H) [Drawing 2] . Slide
the bottoms minto the grooves in the
3 APPlY a clear finish. (We applied
three coats of satin polyurethane,
sanding to 320 grit between coats.)
Case
A* top %" 16W' 29W' EC
B* bottom 3/4" 15%" 28%" EC
sides and fronts, but do not glue them.
Square the drawers, and clamp the joints 4 Attach slippery tape in the drawer
openings [Drawing 1]. Place the back C*
D*
sides
divider
3/4" 15"
%" 14%" 3W'
3V2" EC
EC
2

E back 1f." 3V2" 26" BP

Drawers
Cutting Diagram
F stops %" %" 3" SM 2
G fronts 3/4 " 3%" 12%" C 2
H sides V2" 3%" 14112" SM 4
7/a or 11/16 x 71/4 x 96" Cherry (6.7 bd. ft.) (3 needed) 2%" 4
backs '/2" lP/s" SM
'Plane or resaw to the thickness listed in the Materials List.
bottoms V4" lP/s" 13112" BP 2
tj ' Parts initially cut oversize. See the instructions.
3/4 X 3V2 X 60" Soft maple (1 .7 bd. ft.) (2 needed)
Materials key: C-cherry, EC-edge-glued cherry,
BP-birch plywood, sM- soh maple.
Supplies: #8x%" flathead wood screws, 1W' wood
knobs (2), #20 biscuits, 1" wire nails, 112" felt pads (4).
Blade and bits: Va" and %" round-over bits,
rabbeting bit, dado set.

Source
Drawer t ape: Slippery tape, 25U04.01, $12.50,
Lee Valley, 800-871-8158 or leevalley.com.
1/4 x 24 x 48" Birch plywood

woodmagazlne.com 43
 .The Perfect Choice for Custom Cabinets and Fine Furniture
l Serious woodworkers appreciate quality
and workmanship. That's why so many of
them specify Forrest saw blades for build-
ing custom cabinets and fine furniture.
Forrest blades deliver smooth, quiet cuts-
without splintering, scratching, or tearouts.
In fact, independent tests rate our blades
#1 for rip cuts and crosscuts.
Forrest blades and dados have been the
choice of discriminating woodworkers for
almost 60 years. Craftsmen recognize that
our proprietary manufacturing process,
hand straightening, and unique grade of
C-4 micrograin carbide produce exceptional
results. They also know that Forrest blades
are manufactured in the U.S.A. and backed
by superior service.
Read what these customers say:
"Your blades are without question the best
by miles, and I have tried them all."
Bob Jensen-Fridley, MN Custom Woodworker II - It's Easy to Order
'These are the finest blades I have A specialty blade that is
All Forrest blades come with a 30-day,
owned and you should be proud of your ideal for box joints, dove-
money-back guarantee. So order today
quality product." tails, flat-bottom grooves,
in any of these convenient ways:
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• Visit one of our fine-quality
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• Call us toll free at 1-800-733-7111.
Forrest has six quality blades especially joints without bottom splin-
(In NJ, 973-473-5236) Ask about
suited for producing custom cabinets and ters. Delivers smooth cross-
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Woodworker I - For all Duraline Hi-AT - Flawlessly blade sharpening.
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• Visit our website:
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© 2008 Forrest Manufacturing Code WM
softwoods. the grain. * As seen in Fine Woodworking's 2004 Tool Guide, pg.121 .

Woodworker II Woodworker II Woodworker II Dado King Dado King Duraline Hi-AT Custom Woodworker II

•
Rne Woodworking'
M~?:Zin. e Woodshop News Wood Magazine Woodshop News Woodshop News Woodshop News
WO.Od
i';
'~.'
~-
•
e·
~ /I ;
"i~~, l'!o,,,,~ . ......"

Circle No. 205

#11
7
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 2008 WOOD"INDEX Issues 181 thru 187 For quick tips on using
this index, see page 48.

181 182 183 184 185 186 187

PROJECTS
Article. Issue: Page Article. Issue: Page Article. Issue: Page
Bed, knock-down, twin, 183:52-56 Drum sander, portable, 185:20 Remote control holder, 183:74-75
Bed, pencil-post, 187:24-31 End table, country, 186:39 Rocking chair, 183:36-41
Bench, hall-storage, 183:66-69 End table, mission, 184:58-62 Router table, portable, 187:6
Bevel sled, no-tilt, 187:43 Entertainment center and matching tables, 186:32-37 Sconces, wall, 181:70-72
Bookcase, 185:60-64 Fluting jig, 187:16 Sheet goods rack, 184:26
Box trio, 181:78-80 Gun cabinet, 185:30-38 Shelving, modular, stackable, 181:32-40
Buffet/hutch, country, 182:38-44 Hutch/buffet, country, 182:38-44 Shop cart, workbench, 185:49-53
Cabinet, display/gun, 185:30-38 Joinery jig, for tenons, half-laps, bridle joints, 187:43 Shop organizer, 183:48-50
Cabinets, modular, stackable, 181:32-40 Knife handles, 184:92-93 Straightedge setup gauges, 183:32
Calendar holder, 187:68-70 Knife holder, 184:94 Table, drop-leaf dining, 181:58-62
Chinese checker board, 186:72-76 Mission end table, 184:58-62 Table, coffee, country, 186:38
Clock, art-deco, desk, 187:74, 76 Miter sled, 187:42 Table, end, country, 186:39
Clock, wavy veneer, 182:82,84 Mitersaw station, wall-hung, 186:24 Table, end, mission, 184:58-62
Coffee table, country, 186:38 Nightstand, 187:36-39 Tables, sectional, 182:60-63
O Coin flag, presidential, 181:46-49
Coin map update, state, 184:10; 185:7
Outdoor server, bar, 184:32-38
Outfeed support, 182:24
Tablesaw blade locker, 183:80-82
Tapering jigs, 187:33-35
Crane, toy, 185:68-72 Plug trimming jig, 185:16 Tool stand, 182:76-79
Crosscut sled, zero-clearance, 187:42 Puzzle, safari, scrollsawn, 184:44-45; 185:7,47 Toothpick dispenser, turned, 182:72-75; 185:6
Display cabinet, 185:30-38 Puzzles of Perry McDaniel, 182:32-37; 185:7 Workbench, shop cart, 185:49-53
Display case, bow-front, 187:56-61 Quilt ladder, 186:62-65 Yo-yo, turned, 184:76-78

TOOLS & MATERIALS

Article. Issue: Page Article. Issue: Page Article. Issue: Page
Angle-setting gauge, MiterSet, 181 :52 Drum sander burn marks, 186:26 Portable sharpening system, Norton, test, 183:100
Bandsaw, Rikon, test, 183:96 Dust collection accessories: 185:65-67 Random-orbit sanders, test, 186:56-59
Bandsaw fences, test, 185:26 Dust collector, mini, Steel City, 181:50 Ratcheting Hex Wrench, 181:50
Bandsaws under $550, test, 185:54-59; 186:8 Dust collector, Powermatic, test,186:80 Respirator, Quicklatch, test, 184:101
Bed hardware, 187:18, 20, 22 Dust collectors under $400, test, 182:66-71 Router, trick out, 182:12-13
Belt sander, Porter-Cable, test, 182:96 Dust-collector remote controls, test, 182:22 Router base with laser guide, MlCS, 181:51
Bench grinder, Grizzly, test, 185:80 Fasteners, tabletop, 181:28,30 Router bit speed, 186:30-31
Biscuits, Fixo, 181:52 Hearing protection, test, 184:86-88,90 Router bits:
Bowl gouge, how-to-use, 186:66-69 Jig hardware, 185:42-44 Box-slotting, 184:24-25
Brad nailer, DeWalt, test, 186:80 Jointer/planer combinations, Grizzly, Jet, 181:51 Rule-joint, 181:22, 24
Clamping table, Kreg, test, 186:83 Manufactured wood parts, 182:57-59 Router bits, Freud Quadra-cut, 181:52
CompuCarve, test, 184:82-84 Mobile machine bases, 184:30 Router table, Kreg, 181:52
Dado sets, 6" vs. 8", 183:17 Molding cutter on tablesaw, 183:16 Router tips and tricks:
Digital miter gauge, Craftsman, 181:51 Oak, using and finishing, 184:40-43 Enlarge holes in two easy steps, 184:50
Dovetail dust collectors, leigh, Rockier, 181:50 Parallel-jaw clamps, Woodline, 181:52 Gauge blocks simplify bit setups, 184:48
O Dovetail jig, Chest Mate, 181:52
Drill bits, Power Bore, test, 185:79
Pen-drilling vise, Penn State, test, 186:82
Pinners, Grex, Cadex, test, 185:78
Get a grip on small parts, 184:49

Drill press, trick out, 183:18-19 Portqble clamping station, Workmate, test, 184:100 continued on page 46

45
 TOOLS & MATERIALS (CONT.)
Article, Issue: Page Article, Issue: Page Article, Issue: Page
Router tips and tricks, continued: Rout stopped cuts with stopblocks, 184:49 Skew chisel, how to use, 183:70-73
Idea you can copy, mounting holes, 184:51 Shelf-help for trimming edges, 184:49 Sliding table, Mast-R-Slide, test, 184:100
Joint boards on a router table, 184:52 Spacers divide raised panel cuts,184:52 Stackable panel clamps, R&R, test, 182:96
Master complicated curves, 184:50 Starter pin keeps fingers safe, 184:49 Stainless-steel sanding discs, Microplane, test, 183:98
Pair of paths to precise plunges, 184:47 Tape your way to tighter dadoes, 184:48 Tablesaw, how to buy, 183:62-65
Parallel passes, 184:48 Wipe out tear-out, call for backup, 184:51 Tablesaw blades, general purpose, test, 183:44-47
Reset a fence, 184:47 Routers, multibase kit test, 184:70-75 Tablesaw safety, 186:29
Rout away extra edge-banding, 184:52 Routing, computer-controlled, ShopBot, 181:51 Tablesaw setup, accessories, 187:40-43
Rout corners consistently, 184:50 Sander holder, Orbital Station, test, 184:101 Tablesaws, test, 187:50-55
Rout dead-center dadoes, 184:47 Sanders, random-orbit, test, 186:56-59 Turning chisels, LeeValley, test, 183:96
Rout precise shelf-pin holes, 184:51 Sharpening systems, test, 186:40-43 Vacuums, tool-triggered, test, 183:104
Rout round-overs, not tip-overs, 184:49 Shoulder pJanes, test, 183:90-92 Vision aids, 184:80-81

TECHNIQUES AND FEATURES .

Article, Issue: Page Article, Issue: Page Article, Issue: Page
Basic woodworking skills, 183:84-88 Paint, 183:26,28 Repetitive cuts, 182:64-65
Bevel edge, gluing, 184:98 Furniture: to build or buy?, 184:64-67 Router tearout, 184:28-29
Bowl gouge, how-to use, 186:66-69 Geometry, shop, 185:40-41 Safety, saw blade, 182:80
Box-joint jig, how-to, 181:74-76 Glue, removing from clamps, 185:74 Sanding, hand, 184:68-69
Bracket feet, crown molding 185:22-23 Glue stain, 183:16 Sanding, random-orbit myths, 186:60-61
Breadboard ends, 186:18,20 Gluing metal, 186:26 Skew chisel, how to use, 183:70-73
Car, wooden, "Splinter," 186:6, 50-55 Grooves and rabbets, cutting on tablesaw, 183:14 Splinter, wooden car, 186:6,50-55
Cherry, how to darken, 186:28 Hand-tool woodworker, 182:8 Stopblocks ensure square frame, 185:74
Dadoes and grooves, rout, stopped, 183:30-31 Health, woodworking with pacemaker, 185:73 Tablesaw, cutting wood on benchtop, 187:78
Doors, frame-and-panel, 182:46-49 Joinery: Tablesaw accuracy, 187:40-43
Doors, inset, installing hardware, 182:88 Breadboard ends, 186:18, 20 Tablesaw cuts, troubleshooting, 184:22-23
Doors, preventing warp, 185:24-25 Dovetail, hand vs. machine-cut, 182:50-51 Tapers, cutting on a tablesaw, 187:32-35
Dowels, cutting grooves in, 185:75 Dowels and round tenons, how to make, 183:42-43 Tear-out, preventing in figured wood, 186:22-23
Dowels, using, 185:76 Mitered-half laps, 182:18,20 Template transfer tricks, 186:27
Dowels and round tenons, how to make, 183:42-43 Rabbets, tablesaw, 183:34 Top Shop Tips of All Time, 187:62-67
Drilling accurate holes, 186:70-71 Stopped dadoes and grooves, 183:30-31 Veneer, working with, 181:88
Fasteners, tabletop, 181:28, 30 Table leg connectors, 181:84, 86 Virario, hardwood, 181:90
Feather boards, 181:92 Tenons, using a shoulder plane, 183:94 Water stains, alleviating, 187:80
Finishing: Joint strength test, doors and drawers, 181:64-69 Wax, paraffin, 185:73
Filled pore, oak, 181:18,20 lacewood and leopardwood, characteristics of, 187:79 Wood gravity, 182:92
Heat resistant, 186:28 Milling your own lumber, 184:96 Wood movement, 184:96
Kitchen cabinets, 183:17 Oak, using and finishing, 184:40-43; 182:90 Workbench, drawer slides, 181:88
Multi-color, spray paint, 186:76 Plywood, sanding edges, 183:14 Zero-clearance insert, how to make, 182:28, 30
Oil and varnish mix, 185:28 Purpleheart, wood, 181:90
Outdoor, 183:76-79 Random-orbit sanding myths, 186:60-61

46
 SHOP TIPS
Article. Issue: Page Article. Issue: Page Article. Issue: Page
Aerosol nozzle, cleaning, 181:16 Drill bits: brad point vs. twist bits, 183:88 Plywood shelves, trimming, 187:67
Air-filtration remote, 186:15 Drill matching holes using spacers, 182:65 Pushstick coating, 183:20
Angled stops keep miters sharp, 182:65 Drill with plunge router, 181:16 . PVC fitting for blast gates, 181:10
Bandsaw, accurate cuts with double lines, 187:8 Drilling guide for portable drills, 186:65 Right-angle driver, rachet, 185:13
Bandsaw, freehand straight cuts, 187:67 Drilling rounded objects, 185:71 Rip thin materials, 187:67
Bandsaw fence from speed square, 187:67 Drill-press accuracy from portable drill, 187:66 Ripping strips, 187:63
Bandsaw tenons, 182:65 Drill-press fence from framing square, 187:63 Router-bits: six essential bits, 183:87
Bead scraper, 185:15 Drill-press keyless chuck, 186:14 Router subbase, no tipping, 187:59
Bench clamps, 186:14 Dustpan, 185:10 Router table, dust collector, 184:18, 186:8
Biscuit joiner splines, 182: 17 Edge-gluing finished thickness boards, 185:61 Router-table fence, incremental positioning, 182:33
Biscuits, transfering locations, 187:64 Faceplate parting from workpiece, 183:20 Router-table fence microadjuster, 183:24
Bolts, starting deep, 187:29 Fairing stick for laying out curves, 186:64; 187:60,63 Routing corner radii, 181:79
Box holder, wall-hung, 186:16 Frame clamping jigs, 187:63 Routing recesses without tear-out, 186:73
Box-joint jig on routertable, 183:23 Glass, cutting, 182:1 7 Rule joint, prevent chip-out, 181:59
Bowl press from threaded rod, 187:13 Glue joints keeping them clean, 187:65 Sander stand, 184:18
Cabinet door installation, 184:21 Glue squeeze-out contained in grooves, 187:65 Spindles, drilling, 184:20
Case-building helpers, 185:15 Hardware placement use gauge block spacers, 187:64 Splinter, removal, 184:20
Chamfer stop for accuracy, 182:64 Honing guide gauge, 184:16 Square astud, 182:77
Chamfers, stopped, 187:27 Jigs, labels for, 183:88 Squaring large panels, 185:11
Circular saw, adjust blade depth, 183:85 Magnet in pocket, 187:12 Stock supports, fold-down, 184:16
Circular-saw, cleaner cuts from, 183:85 Marking your projects, 186:15 Story board for laying out drawer hardware, 185:52
Circular saw guide ensures accuracy, 187:66 Mirror for tablesawn box joints, 181:76 . Story board for tablesaw, 185:8
Clamp odd shapes with tape, 187:66 Miter mistake fix, 185:12 Story stick for multiple dadoes, 183:49
Clamping blocks, right-angle, 187:62 Miter sled, 184:14 Straight cuts with portable power tools, 183:67
Clamping flat panels on round pipe, 183:86 Miter-gauge extension and stops, 182:65 Straightener, cracked boards, 181:10
Clamping multiple panels, 185:13 Miters, perfect length, 182:14 Support table, temporary, 187:10
Clamping small pieces, 187:8 Miter-slot runners, adjustable, 181:14 Tablesaw, fence, clamps as stops, 182:65
Clamping with flexible go-bars, 183:50 Miter-slot runners, installing, 187:42 Tenon on adowel, 184:21
Compass, extension, 186:12 Mortise, making a, 186:33 Thin stock, planing, 187:66
Copper, working with, 181:72 Mortise plugs on tablesaw, 184:60 Thin-strip ripping, 182:65
Cutting large panels, 187:67 Mortising jig, 185:10 Trim router subbase, 187:12
Cutting plugs flush, 187:65 Mortising on a router table, 182:64 Turning narrow vessels, 183:22
Dado end grain on long workpieces, 183:39 Organizing shop tips, 186:16 Veneer plywood, cutting faces, 187:65
Double saw-fence stops, 182:65 Outdoor projects, seal end grain, 184:36 Workbench extension top, 182:14
Dowel center finder, 186:17 Plan storage on window shade, 187:10 Workholders, scrapwood, 187:64
Drawer slides, spacing, 187:64 Panel glue-ups, 184:61 Zero-clearance cuts without custom insert, 181:14
Drill bit holder and gauge, 185:8 Panel groove, snug fitting, 182:78 Zero-clearance plates, bandsaw, 186:12

Faceplate parting
from workpiece,
183:20

47
 HOW TO USE THIS INDEX
his annual index includes every • Projects (plans with step-by-step • Shop Tips (quick ideas you can put to

T article and Shop Tip that appeared

in WOOl)® magazine from the
December/January 2007/2008 issue
instructions) ,
• Tools & Materials (product reviews
and guidance on using tools, accessories,
use in your shop today).
Then look for the one word that best
describes the project, technique, tool,
through the November 2008 issue. To hardware, and wood products), or shop tip. Articles with two strong
quickly find the article you're looking for, • Techniques and Features (specific skills descriptors, such as a mission table,
first identify the major index category and articles of general interest, such as may be found under both descriptors-
most likely to contain the article: craftsman profiles), or "mission" and "table."

Three steps to find any article, from issue 1 to present, using the online index
You also can quickly search the III the search box under Keyword The browser now displays a list

1 comprehensive online index of all

WOOD magazine articles in one
of two ways. First, to get directly to the
2 Search, type the one word that
best describes the article subject,
avoiding plurals. For example, to locate
3 of articles related to your search
term, including the cover date of
the issue, issue number, and the page
index, type woodmagazlne.com/lndex in a tablesaw review, type tablesaw, (or numbers. If you don't have the issue, most
your Web browser. Or, click on the Article simply table) but not review. Click ,o n articles published in WOOD magazine
Index button, shown below, in the left the button marked Search. If you want to can be downloaded for a minimal cost.
column of any woodmagazlne,com page. narrow the search to tablesaw jigs, type This list indicates downloadable articles
tablesaw in the box, then click on the with the blue words WOOD STORE, which,
button next to the words: Jigs, Fixtures, & when clicked on, give you more details
Organizers under Category Search. Next, about buying the article. Otherwise, some
scroll down and click on Search under back issues are available for $7.95 (plus
Keyword and Category Search. s&h) by calling 888-636-4478.

Keyword Search1ablesaw" and Category Search 'Jigs,fixtures & organizers'

40 articles from WOOD magazine matched the search criteria you entered.

USe as an 0uIfaed BenchlTable and Assembly BenchlTable - Plans available at the WOOD
STORE

Not sure exactly what project plan you're looking for? Go window shopping!
So, you've had a request from a family member to build a
project-say, a piece of mission-style furniture. Where do you
start? Go to the WOOD Store® at woodstore.net and click
on the tab that best describes the article you want (Plans,
Techniques and Features, or Tool Reviews). Staying with the
mission furniture example, you next click on Projects, and on
the next page Indoor Furniture and Accessories, then Arts and
Crafts Furniture, Mission Style on the next page. There, you'll
find more than 30 mission-style projects.

48
 Oct. 10-12 St. Paul, MN Jan. 30- Feb. 1 Indianapolis, IN
Oct. 17-19 Portland, OR Feb. 6-8 St. Louis, MO
Oct. 24-26 Salt Lake City, UT Feb. 13-15 Kansas City, KS
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 igger isn't always better. Do the math: 6" stacked dado Most of these dado sets fared well in solid stock, but left

B sets cost about $20 to $30 less than comparable 8" mod-
els, and in most cases they'll do everything their big
brothers will. We seldom cut dadoes deeper than %", and all
significant surface tear-out on birch-veneered plywood and
melamine-coated particleboard. (In fairness to the manufac-
turers, Amana, Everlast, and Systimatic do not recommend
13 of the 6" sets we tested beat that by Yz". their 6" models for plywood or melamine; Lee-Valley cautions
Also, if you own a lower-powered tablesaw- particularly a against using its set for melamine. These companies suggest
benchtop model-a 6" dado set stresses its motor less without using different models with teeth designed specifically for
sacrificing cut quality or performance. (We tested three 8" sheet goods. Because most of us can afford just one set for
models along with the 6" sets, and found no advantage for the doing everything, we tested all sets in all materials to see how
larger sets other than one extra inch of cutting depth.) they fared against each other.)
If you use a dado set regularly to cut tenons or half-lap
Buy the right set for the work you do joints, choose a model that leaves flat, smooth surfaces, criti-
Before delving into the nitty-gritty of the test results, think cal for a glue joint. Many of the models we tested achieve that.
about the materials you use most often and the types of cuts Because each set's outer blades feature beveled carbide teeth
you typically make. For example, if you work only with solid (to shear the surface fibers) rather than all flat-teeth (that leave
wood, ignore how a set performs in plywood and melamine- smooth bottoms but increase edge tear-out), these sets all
coated particleboard. But if you frequently dado or rabbet leave tiny scoring grooves at the outer edges of the bottom of
tear-out-prone veneered plywood, select a set that excels at each cut. Such grooves don't diminish the joint's strength, but
leaving clean edges in that material. can make visible half-lap joints less attractive.

50 WOOD magazine December/January 2008/2009

Some chippers cut deeper than others on these %" dadoes, leaving We cut these dadoes with the same wear-tested set, using a regular
uneven bottoms. The beveled teeth on the outer blades cut deeper tablesaw throat insert (top) and zero-clearance insert. The results
scoring grooves in the corners. speak for themselves.

Some sets stay sharp longer than others Freud's unique Dial-A-Width set does not use shims, but the
Knowing that a dado set always cuts best when it's sharp, we adjustable hub on one outer blade allows you to incrementally
made test grooves and dadoes in all three materials to com- increase or decrease the width with each click, as shown below.
pare their out-of-the-box performance. These cut samples (You can reverse the hub for use on right-tilt tablesaws.) This
became our benchmarks for comparisons after the teeth had hub limited cutting depth to %", but cutting a relief slot in the
dulled. To put consistent wear on the carbide teeth, we used throat insert increased that depth to 11,4" without losing the
each set to cut 480 linear feet of lh"-wide, Va"-deep grooves in zero-clearance fit at the front.
melamine particleboard. After that we made more test cuts, • Blades that stay sharp save you money. Over time, all
both with and without a zero-clearance insert. (See examples of these sets will need resharpening. We checked with several
of tear-out and each set's performance results in the chart on sharpening services, and found they charge from $40 to $55
the next page.) Here are some key findings: to sharpen a 6" set. So if you're thinking of buying a set that
• These sets emerged as leaders of the pack. Four sets showed signs of dulling and tear-out in our test, be prepared
(CMT 230.020.06, Forrest Dado King DK06244, Freud Super to add this cost more frequently. By the same measure, a pre-
Dado SD506, and Freud Dial-A-Width SD606) earned near- mium set that showed no signs of dulling might go years
perfect grades for absence of surface tear-out right out of the before needing resharpening, depending on your workload.
box. Even after wear-testing, these sets earned top marks,
especially when used with a zero-clearance insert, below.
• Get zero help for clean cuts. SHOP TIP
Whether store-bought or shop- When you resharpen a set, be sure to include all the chippers
Zero-clearance made, a zero-clearance insert adds and outer blades so they maintain the same cutting depth
throat-plate insert critical support for wood fibers at after regrinding.
the pOint where the teeth make the
cut. In many cases in our test, using
an insert improved a model's tear-
out score by two letter grades, as
shown above right, even though the
carbide teeth had shown wear.
• Some sets make adjustments easy. All 13 sets come
with at least four chippers of varying thicknesses. (The top-
performing sets feature four teeth per chipper instead of two.)
You mix and match chippers to achieve the desired width of
cut. And often you'll need to adjust the width of your dado
stack in tiny increments to get an ideal fit, especially with
sheet goods that typically measure less than their advertised
thickness. Ten of the 13 sets include shims, but some proved
easier to use than others. For example, the shims on CMT's
230.520.06 and Forrest's Dado King come marked with their
thicknesses. (Forrest's shims are magnetic, so they cling to the
blades but also prove tougher to remove.)
Others color code their shims. Amana's 656030 includes a
handy chart that lists the correct combination of chippers and
shims for any size you want. Lee Valley lists the thicknesses of
its shims on the package. Freud's SD506 also uses colored
shims, but its included poster-which features tons of helpful
information-does not include info about shim thicknesses.
Oldham's set comes with unlabeled paper shims that tear eas- Turning the adjustable hub on Freud's Dial-A-Width set increases or
ily. Everlast and Systimatic sets do not include shims. decreases the set's cutting width by .004" with each click.

woodmagazlne.com 51
 Freud5uperDado5DS06
CMT Precision Dado 230.020.06

Freud Dial-A-Width 5D606 Forrest Dado King DK06244

ABSENCE OF SURFACE TEAR-OUT

NEW AFTER WEAR

RED BIRCH RED BIRCH

OAK PLYWOOD OAK PLYWOOO

Paper
I These manufacturers do not Adjustable steel hub
I recommend this model for use Magnetic
I on veneer plywood or melamine- Plastic
i
coated particleboard, Steel
I 2. C*) Actually measured 0/64" 4. Measured on the same hybrid tablesaw 6, C*) This model features an adjustable
I with a ¥a"-thick throat plate insert.
C*) Requires cutting a relief slot in the C**)
hub and does not need shims.
You must supply your own shims for
throat plate insert to allow clearance these models.
for the adjustable hub.
II
II
52 WOOD magazine December/January 2008/ 2009
I'
~
 =

You can't go wrong with these stacks

Just as we've found in other blade tests, premium-priced models
tend to rise above the field. We'd be happy to have the CMT Preci-
sion Dado 230.020.06, Forrest Dado King DK06244, Freud Super
Dado SDS06, and Freud Dial-A-Width SD606 in our shop because
they all cut clean, flat-bottom dadoes with little to no tear-out,
even after significant wear. For this they share Top Tool honors.
The Top Value award goes to the Freud SD206 Pro Dado set. Its
cut doesn't quite equal the performance of the Top Tool sets, but it
produced clean cuts in solid wood when sharp, with only minor
tear-out in plywood and melamine. If you'll use your set for jOinery
Freud Pro Dado 50206 on a handful of projects a year, this model will work well for a
modest $ 8S investment. • '

HOW WE GRADED FOR DADO CUT QUALITY

Below are examples of surface tear-out, shown in tested materials, with the grading parameters we used for a" cuts.

= No tear-out on either edge = Consistent tear-out on either edge

[jJ = Slight, spotty tear-out on either edge ~ =Significant, consistent tear-out on either edge

WITH ZERO-
CLEARANCE INSERT
REO BIRCH
OAK PLYWOOD

Melamine Birch Plvwn,nn

7. (C) Czech Republic

(G) Germany
(I) Italy
(L) Israel
(S) Singapore
(U) United States

8. Prices current at time of

article production and
do not include shipping,
where applicable.

woodmagazlne.com
 I

·nl'sn~~lnJII;'"
• D U

GREAT PROJECTS MADE SIMPLE.

Easy and Elegant

Three Table Set One design done three

ways makes this trio of
tables a perfect match.

M
ake any or all of these tables to
create a set that suits your
needs. You'll find the going
easy because for most of the parts in
these projects, only the length changes
WHAT YOU'LL NEED
~
LJ~
Q ~
.·Materials: W' poplar
boards, Y2" birch plywood.
We also used a pocket-
from table to table, but the step-by-step
process remains the same.
Whatever grouping you plan to build,
M (g) hole jig. (About $40, see
Sources, page 58.)

save time by milling all similar parts

while you have a machine set up. For the edge profiles. This saves time and for the table(s) you're building. If you
example, although the legs on the sofa creates identical pieces for every table. can't find solid stock 11,2" thick, glue up
table are longer than those on the coffee Note: If you make your tables from pine or two layers of ¥I" stock. Choose pieces
table, prepare the blanks for each set of oak, you'll find ready-made cove molding with color and grain that blend together
legs, and then cut all the tapers while for parts K and L at a home center. well at the joint line.
you've got the tablesaw set up. Likewise,
you can bevel the top edging pieces for Get a leg up 2 NOW layout the tapers on each leg
[Drawing 1a, 3a, or 4a] . First, label the
several tables at the tablesaw, then move
those pieces to the router table to rout 1 Cut four legs (A) to the size listed in
the Materials List on page 58, 59, or 60
best two adjacent faces of each leg as the
outside faces. Then, layout a 3;4" square

54 WOOD magazine December/January 2008/2009

 BJENDTABLE
LEG DETAIL
(Left rear leg shown,
right rear is a mirror image)

Taper jig
~----
Cut both short tapers on each leg. If needed,
reposition the guide to cut the short tapers
on the legs for other tables in the set.

IDJLEG BOTTOM VIEW

(all tables)
1:13/s" :y." 3/s" r
11
3/8
Inside
faces
®
As with the short tapers, align the layout
marks for the long tapers along the edge of
Outside faces the jig and reposition the guide assembly.

-. '

centered on the bottom end of each leg

[Drawing lb] . Next, mark lines on the
outside faces (the ones you marked ear-
lier) of each leg 11/2" from the top to
DEND TABLE EXPLODED VIEW
indicate the tops of the long tapers. Mark
the tops of the short tapers on the two
inside faces. Note that the short tapers Long taper 3/s" cove
are the same length on the end table and stops here.
sofa table [Drawings la and 4a] but are
shorter on the coffee table [Drawing 3a].

3 YOU'll need a taper jig to carry the

legs past the saw blade. (If you don't
have one, see the Quick & Easy Jig article
on page 12.) Align the marks for the top
and bottom of the short taper along the
edge of the jig. Screw down the guide,
secure the leg, and cut the first taper
[Photo A].
Note: Use a zero-clearance insert to prevent
the cutoff from lodging between the blade
and insert plate. Also, we've removed the
blade guard to allow you to see the opera- #8 x 1" F.H.--......'
tion. Use yours. wood screw 1

4 Rotate the leg a quarter turn to cut

the other short taper [Photo A]. Long taper
on outside faces

woodmagazlne.com 55
To secure the leg when cutting the second Clamp the upper and lower end rails (B, C) lightly between two legs (A) while positioning
long taper, use a spacer to fill the gap the rails. Spacers under the rails establish the inset. Tighten the clamps, and then flip the
between the hold-down and the tapered leg. assembly over and drive 1W' pocket screws through each rail into the legs.

While the jig is set up, cut the short

tapers on the remaining legs.
Note: The coffee table has shorter tapers
2 RetrieVe two legs (A), an upper end
rail (B), and a lower end rail (C) .
Place the legs on a flat surface with the
the lower end rails (C). To find the shelf's
width, add W' to the length of the cleat
(D) . Cut the shelf to these dimensions.
than the other two tables. If you're building
a combination of tables, adjust the place-
ment of the guide on the jig as needed.
long tapers facing up and to the outside.
Clamp the upper end rail flush with the
top ends of the legs and the lower end
6 Cut two pieces of shelf edging (G) %"
thick, 1%" wide, and the same length
as the shelf (F). Glue and clamp the edg-

5 unscrew the guide from the jig and

reposition a leg on it to cut a long
taper. As before, place the gUide against
rail 6W' from the bottom of the legs
[Drawings la, 4a; Photo 0]. On the coffee
table, this measurement is 4Y2" [Drawing
ing to the shelf with the top edges and
ends flush. After the glue has cured,
sand the assembly to 220 grit.
the leg, and screw it in place [Photo B].
Cut the first long taper; then place a
scrapwood spacer under the hold-down
3a]. Flip the end assembly (AlBIC) over
and drive the pocket screws [Photo E] .
Repeat this assembly operation for the
7 Center the shelf assembly (FIG)
between the legs and clamp it in
place [Photo H]. Drill %2" shank holes
when cutting the final taper [Photo C]. other end. through the shelf support cleats (D) and
Repeat this process to cut the long tapers
on the remaining legs. Use a sanding
block to sand the legs up to 220 grit.
3 GIUe and clamp the shelf support
cleats (D) to the inside faces of the
lower end rails (C) [Photo F].
%4" pilot holes W' deep into the shelf.
Then apply glue to the cleats and screw
the shelf to them.

Time to establish a base 4 Stand the side assemblies (AlBIC) on

their tops and position the upper Top it off
1 Cut the upper end rails (B), lower
end rails (C) , shelf support cleats
(D) , and upper front and back rails (£) to
front/back rails (£) between them. Use
light clamp pressure to hold the assem-
bly together [Photo G]. After positioning
1 Cut the top (H) to match the outside
dimensions of the table. Set it aside
for now. From %xl%" stock, cut the
size. Drill one pocket hole in each end of the upper rails, tighten the clamps to frontlback edging (I) and end edging m
the lower end rails and two pocket holes hold everything in place and drive 1Yz" about I" longer than dimensioned in
in each end of the upper rails [Drawings pocket screws. the Materials List. Make an extra piece to
2 and 2a]. Learn about pocket-hole join-
ery in the Skill Builder, opposite. 5 TO determine the length of the shelf
(F), measure the distance between
help set up the tablesaw and router table
in the next couple of steps.

Position the shelf support cleats (D) W' from Position the upper front/back rails (E) flush Clamp the shelf assembly (F/G) to the cleats
the bottom of the lower end rails (C) and with the top edge of the side assembly and (D) while drilling the shank and pilot holes
centered on the length ofthe rails. W' from the inside corner of the leg (A). and driving the screws.

56 WOOD magazine December/January 2008/2009

 ------ -~- =-~=~~-,~~=

W ' round-over with a

SHOP TIP
i---+--.,L-f,.../ 1/1 6" shoulder
mLOWER RAIL DETAIL
Two cuts for clean rabbets
To cut rabbets on the tablesaw, make
two intersecting cuts. For the edging
pieces (I, ]), set the blade 1,4" above the
table and position the rip fence 5116"
from the blade. Cut a groove the length
of each edging piece, keeping the piece
tight to the rip fence, top photo. Then
raise the blade height to 7116" and reset
the fence to make a perpendicular,
intersecting cut to remove the waste,
bottom photo. The waste falls safely to
the outside of the blade.
®

3 Tilt your tablesaw blade back to ver-

tical, and complete the edging by
cutting a rabbet to accept the top (H)
[Shop Tip at right].

BFRONT 4 Miter-cut the edging (I, ]) to fit

around the top (H) . Glue up the four
pieces of edging to form a frame [Photo
SECTION
VIEW I]. While the frame dries, finish-sand
the top with 220 grit. Then sand the
edging assembly (1/]) to ~20 grit. Use a (j),Q)
sanding block on the top and bottom

2 Tilt the tablesaw blade to 30° from

vertical and set the rip fence W from
faces and the bevel to maintain the crisp
edges of the profiles.
the blade. Rip a bevel on each length of
front/back edging (I) and end edging 0)
[Drawing 2]. Next, mount a Y4" round-
5 TO glue the top (H) into the frame,
apply a small bead of glue along the
inside corner of the rabbet. Then clamp
over bit in the router table. Rout the the frame and panel together, and allow
round-over with a lIJ.6" shoulder [Drawing the glue to cure. Now glue the top
2] on each piece of ed&"ing. assembly (H/I/J) to the base. The edges

SKILL BUILDER
Quick, strong joints come right out of the pocket
Fast, easy, and strong. That describes pocket-hole DRILLING THE POCKET HOLE
joinery. Using this method, you don't have to wait
for glue to dry, so you can keep working on parts as
soon as they're joined .
Making a pocket hole requires a special jig and
drill bit to form a pilot hole with a deep, flat-
bottomed counterbore, top drawing. For pieces that
fit together flush, a clamp holds the pieces while
you drive a pocket-hole screw into the pilot hole, No less than Va"
bottom drawing. To inset one piece from another,
use a spacer as shown in Photo D, opposite page. DRIVING THE POCKET SCREW
The broad, flat underside of the screwhead, Square-drive bit
shown far right, presses against the bottom of the chucked into drill
hole, pulling the two pieces together. Choose fine-
thread screws for use in hardwoods, and coarse-
thread screws when joining softwoods.
Apply glue to the mating surfaces if you want.
But when one of those surfaces is end grain, as
when joining the rails of the tables to the legs, the Clamp
glue adds little additional strength.

57
 r

porarily below the edging (I, J) [Drawing

2] . Next, miter an end cove (L) to length
so it fits against the front cove and the
opposite short pOint lines up exactly
with the outside corner of a rear leg.
Repeat this process for the other end
cove (L); then miter the back cove (K) to
fit between the two end coves. Once all
the coves are cut to length, glue them in
place [Photo J].

8 Finish-sand the table to 220 grit, and

apply a finish . (We used Old Masters
Dark Mahogany, and then brushed on
two coats of Minwax satin polyurethane,
Apply glue to each mitered end, then Miter-cut the cove molding (K, L) to length, buffing with a 300-grit sanding sponge
assemble the edging into a frame. A band testing the fit of all four pieces around the
between coats.) . .
clamp is ideal for drawing the corners closed . table before gluing it in place.
Written by Craig Ruegsegger with Kevin Boyle
Project design: Jeff Mertz
of the plywood panel should be flush blank. Take the blanks to the table saw Illustrations: Roxanne LeMoine; Lorna Johnson

with the outside faces of the legs. and rip away ~"-wide pieces for the
Materials List
6 Measure between the outside edges
of the legs at the front and side of the
table. Prepare two Yzx4" blanks 1" longer
front/back cove (K) and end cove (L) .

7 Miter-cut the front cove (K) to length

so the two short points match up
(end table)
fiNISHED SIZE
than each of these measurements. Rout exactly with the outside corners of the Part T W L MatI. Qty.
a ¥a" cove along each long edge of each front legs. Clamp the cove in place tem- A legs 1Vl" 1'/2" 25" P 4

B upper end rails %" 2V2" 17" P 2

C lower end rails %" 1%" 17" P 2

shelf support P
D %" %" 14" 2
cleats
upper front! %" 13" P
E back rails
2'/2" 2

F shelf V2" 14W' 13W' BP

G shelf edging 3/4
11
Pis" 13W' P 2

H top '/2" 20" 16" BP

front/back %" 1%" 19" P 2
1*
edging
J* end edging %" 1%" 23" P 2
n
K* front!back cove V2" Y2 17" P 2

L* end cove V2" Vl" 21" P 2

*Parts cut long initially, then mitered to fit.

Materials key: P-poplar, BP-birch plywood.

Supplies: #8x1" flathead wood screws, 1V2" pocket-
hole screws.
Bits: 114" round-over, 3jg" cove router bits.

Sources: Pocket-hole jigs, such as

the Kreg R3, are available at home centers and
through Rockier Woodworking and Hardware,
800-279-4441, rockler.com.

End Table
Cutting '
Diagram
~
r------+--I H

.- -.. . -~- . b$-==-~~-P® .-

. ---

R~5~---' =- --' F3~®""- ! ~._I-,I -®---.~--""

:y. x 7 % x 96" Poplar (5.3 bd . ft.) _ . _ _~ _ _ _ _ _ _ - -1-- .:::::::>

~~
= ~I{~)~~I@~G2L=fQ)
~~~J~~~~-
~-
~-~-~t&~)~~~k7~LC
~·~~~~~~~~~;:~-;; .r; ; ; ;-
; ;;;;;;;;;;;;;;~;==:::=
r ~
0/4 x 5V2 x 96" Poplar (4 bd . ft.) ' Plane or resaw to the thickness listed in the Materials List. 1/2 x 24 x 48" Baltic birch plywood

58 WOOD magazine December/January 2008/2009

 Materials List
(coffee table)
FINISHED SIZE
Part T W l Mati. Qty.
A legs 1112" 1112" 15" P 4
B upper end rails 3/4" 2V2" 16" P 2

C lower end rails %" 1%" 16" P 2

shelf support
D %" 3/4" 13" P 2
cleats
upper front/
E 3/4" 2V2" 42" P 2
back rails
F shelf 112" 13W' 42112" BP
G shelf edging 3/411 1%" 42112" P 2
,
H top V2" 19" 45" BP
front/back 11
P
1* 3/4 1%" 48" 2
edging
J* end edging 3/4" 1%" 22" P 2

K* front/back cove 112" V2" 46" P 2

IICOFFEE TABLE EXPLODED VIEW l* end cove 1/2" V2" 20" P 2

*Parts cut long initially, then mitered to fit.

BlCOFFEE TABLE
LEG DETAIL
(Left rear leg shown,
ri~ht rear is a
mirror image)

-- 1
"
11---------'"---------

Coffee Table
Cutting Diagram
'1.
"78
ill
I I
''2} 3/4"
4W'

r ~'I."
'78

@
M FA-----z
A) I -® A) A)
I(iSCiF------- ---~~
A - t--@ --- =---+®? j
¥4 x 51/2 x 96" Poplar (4 bd . ft.)

® . '--- ----
-=:.:>
II--~~ - - - - - - - - - - - :v. x 7'14 x 96" Poplar (5.3 bd. ft.)

B© 8
11 _ _ _ _ - .f--~--

-§(If>
3/4 x 51/2 x 72" Poplar (3 bd. ft.) 'Plane or resaw to the thickness listed in the Materials List.
1/2 x 48 x 48" Baltic birch plywood

woodmagazlne.com 59
 Materials List
(sofa table)
FINISHED SIZE
Part T W L MatI. Qty.
A legs 1112" 1V2" 31" P 4

B upper end rails 3/4" 21/2" 7" P 2

C lower end rails 3/ 411 1%" 7" P 2

shelf support
0 %" %" 4" P 2
cleats
upper front/
E %" 2112" 42" P 2
back rails
F shelf V2" 4V2" 42V2" BP

G shelf edging 3/l P/s" 42V2" P 2

H top '/2" 10" 45" BP
front/ back
1* %" 1%" 48 " P 2
edging
J* end edging %" 1%" 13" P 2

K* front/ back cove V2" '/2" 46" P 2

L* end cove 112" 'h

ll
11" P
II SOFA TABLE EXPLODED VIEW 2

*Parts cut long initially, then mitered to fit.

I!ISOFATABLE
LEG DETAIL
(Left rear
leg shown,
right ~ear
IS a mirror
image) V2 11

Long taper
stops here.

31"

Outside
face

""'1"
Sofa Table
Cutting Diagram

E¥
3/4 X 7 % x 96" Poplar (5 .3 bd. ft .)
®
01.
"78
"") 3/4
lit
I I
r ~ Ol. "
11 '"18
6%"

® '--
3f4 x 7 % x 96" Poplar (5.3 bd. ft.)

~F? -®
--------- I
3f4 X 5V2 X 60" Poplar (2.5 bd. ft .) ' Plane or resaw to the thickness listed in the Materials List. V2 x 24x 48" Baltic birch plywood
60 WOOD magazine December/January 2008/2009
 SM-100 QUALITY & VALUE SM-1 50B
4" Bench TOp Jointer WITH 6" Bench Top Jointer

SUNHILL
1IIIIIIIIIIIIIIIIIIIIllllllllllll llll ll ll ll1 1111 111 11111111111111111 11 111llllllllllllli1111 1111111111111111111111111

18
~ Sale$99
~ Sale$79
o 1.5HP 110V motor.
o 5/8HP 110V motor. o 27.5" x 6.25" table.
o 23.5" x 4.25" table. o 2 knives.
o 2 knives.
.. 8,000 RPM cutterhead speed .
o 8,000 RPM cutter head speed .
o 19" x 3.25" fence tilt 45° in and out.
o 19" x 3.25" fence tilt 45° in and out. o 451bs.
o 301bs.

SM-344
SM-236PM
13" Planer •••"'w ......... r
OHLINI!I 12-1 / 2" Surface Planer
www.sunhillmachinery.com
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Sanding Belts
o Available in grits, 50, 80,
100, 120, 150, 180, 220
o 6"X108", 16"X48", 25"x48",
25"x60" and 37"x60"
o Minimum 5 belts; m ix and
match, any size any grit.

~ Sale$189
~ Sale$459 2HP 110V motor.
Replacement Rollers o
o 4 post support of cutterhead to
o 2HP 110V motor. minimize sniping .
o 13" Planing,S" Moulding capacity. RO-08 80mm Dia. x 30mm w. o 2 Double edged HSS Knives.
o 6" Max th ickness. ~ Sale $14.95 o 26 FPM feed speed.
o 7" Min . length of stock. o 6" Max. thickness.
o 5,000 RPM cutterhead speed . RO-1 0 100mm Dia. x 50mm w. o 71 Ibs.
o 2 Feed speed 20 FPM and 10 FPM ~ Sale $16.95 Optional Stand $49.00 (Reg. $69)
o 1401bs.
optional stand $49.00 (Reg. $69) RO-1 2 120mm Dia. x 60mm W.
~ Sale $18.95 SM-346
SM-250A 13" Sur face Planer
10" Contractor's most brand power feeders.
Price break on purchase of 3 or more.
Table Saw
T.C.T. ATB
Circular Blades

~ Sale$249
o Heavy duty construction.
o 2HP 110V motor.
o 4 Post support of cutterhead to
10" 40T General Purpose Sale $10.95
~ Sale$299 o
minimize sniping.
2 Double edged HSS Knives.
o 1.5HP 110/220V motor wired 110V. 10" 60T Fine Finishing Sale $14.95 o Self aligned knives require no
o 10" Saw blade left tilt. 12" 60T General Purpose Sale $23.95 knife setting.
o 5/8" Arbor. o 8,000 RPM cutterhead speed.
o 27" x 44" table with extension . o Optimum Hook Angle o 26 FPM feed speed.
o precision aluminum extruded fence. o 6" Max. thickness.
o Special Tooth Design For Superior Cutting
o 12"(Left) 30" (Right) max. rip capacity. o 801bs.
Performance
o 2101bS. Optional Stand $49.00 (Reg. $69)
o 5,500 Maximum RPM
o 1.8 mm thin .

~SUNHILL MACH I NERY

Call 800-929-4321 to order or see us online at
www.sunhillmachinery.com for product details or a free catalog.
800-929-4321
1208 Andover Park East, Seattle, WA 98188 Items subject to stock on hand and some restrictions may apply.
Fax 206-575-3617. e-mail info@sunhillmachinery.com Circle No. 1753 Not valid with other offers. Call for details.
 ine Rack Want to try your hand at mortise-
and-tenon joinery? Give it a go
with this manageable project.

T
his graceful countertop rack keeps
your favorite wines at hand for
dinner parties or entertaining. It
2 Enlarge four copies each of the half-
size leg, rail, and rest patterns on
page 64 to 200%. Spray adhesive onto
PROJECT HIGHLIGHTS
• Overall dimensions: 13" wide x
has just four parts- and patterns for the backs of the leg and rail patterns and 8%" deep x 8¥.!" high.
three of them-so you'll be able to build adhere them to the blanks for the legs
the rack almost as quickly as you can say (A) and rails (B). • Materials needed: Maple, walnut.
cabernet sauvignon. Form the mortises in the legs (A) and Other contrasting species, such as

Make the frame parts first

3 cut the tenons on the rails (B) [Draw-
ings 1, 1a; Skill Builder].
ash and mahogany or white oak and
padauk, could be used.

1 Cut blanks for the legs (A) and rails

(B) to size [Materials List, page 64]. 4 Bandsaw or scrollsaw the curve on
the edge of each rail blank (B). Cut
• Holds six wine bottles.

62 WOOD magazine December/ January 2008/ 2009

i- - -- - - -
slightly outside the line and sand to the
SKILL BUILDER
line. Remove the patterns; then finish- Drilling and sawing simplify mortise-and-tenon joinery
sand the rails to 220 grit. The sturdy, reliable mortise-and-tenon joint
reigns as a woodworking standby. These
Assemble the frames hints will help you easily form mortises in the
1 Apply glue to the rail (B) tenons;
then assemble and clamp the rails
and legs (A) with the curved edge of
legs (A) and tenons on the rails (B) for the
wine rack.
Mar.k the mortise locations from the
each rail facing up [Drawing 1, Shop Tip, pattern onto the adjacent edge of each leg
below.] Lay the rails across a %" scrap- blank. Position the drill-press fence to center
wood spacer (we used MDF) so you can a 14" brad-point bit on the edge, shown at
center the clamps on the legs. (The pat- right, and drill a series of holes to the mortise
terned face will be up for one leg, down depth, 'l'16". Clean out the mortise and square
for the other.) the corners with ¥.i" and 1.4" chisels.

2 Bandsaw or scrollsaw the curved

edges of the legs (A). Cut slightly
outside the line; then sand to the line.
To cut the rail tenons, shown at lower right,
install a Yz" dado set on your tablesaw, and
lower it below the table surface. Attach an
3 Remove the patterns from the legs
(A), and then finish-sand both
frames (A/B) to 220 grit.
auxiliary rip fence, and position it for Va"
cutting width. Add a miter-gauge extension
that reaches the fence. Start the saw, and
raise the dado set Ya" above the table, cutting
Time for some rests a cove in the auxiliary fence.
1 Cut four Y2 xl14 x1214" blanks for the
rests (C).
On scrap stock the same size as the rails,
make cuts on both faces to cut the tenon

2 spray adhesive onto the back of each

enlarged copy of the half-size rest
pattern and adhere a pattern to each rest
cheeks. Keep the end of the rail tightly
against the fence.
Then, using the same saw setup, stand the
(C) blank. test piece on each edge to cut the tenon
3 Install a %" dado set on your table-
saw, and set the cutting depth to W.
Saw dadoes in the rests (C), where indi-
shoulders. Test the tenon fit in the mortises,
and adjust the setup as needed. Then cut the
tenons on both ends of the four rails.
cated on the pattern.

DEXPLODED VIEW
SHOP TIP v. x 1" mortise
7/, 6" deep, centered
Clamp first, saw second
Clamping curved parts poses difficul-
ties: You usually end up having to tape
the cut-off piece back onto the work-
piece to provide a clamping surface.
For such assemblies as the wine-rack
frames (A/B), glue and clamp the
components before you cut the curves
in the legs (A).

III RAIL TENON DETAIL

woodmagazlne.com 63
 NOTE: Enlarge these half-size
patterns to 200% on a photocopier
to make full-size patterns for the
legs (A), rails (B), and rests (C).

®
RAIL HALF-SIZE
PATTERN
(4 needed)

..
Drill screw holes through the base (D) into
Stand the frames (A/B) upside down to make
it easier to position the rests (e) against the the legs (A) with a countersink bit and
bottom of the rails (B). portable drill.

4 Bandsawor scrollsaw the rests (C) to

shape, cutting slightly outside the
#8 screws, drill %2" shank holes and 'li4"
pilot holes.)
line. Sand to the line and remove the
patterns; then finish-sand the rests. 4 GIUe and screw the bases (D) to the
rack assembly (Al BIC).

S GIUe and clamp the rests (C) to the

frames (Al B) [Drawing 1, Photo A]. S Atter the glue cures, touch up the
finish-sanding as necessary and
apply three coats of clear, satin finish, ©
Add the bases sanding to 320-grit between coats. REST HALF-SIZE
PATTERN
1 Cut the base (D) blanks to size. Lay
out the curved edge [Drawing 1] with
a fairing stick by drawing a line that
While the finish dries, raise a glass of
wine to your succcess . • (4 needed)

connects the two endpoints and the Written by Larry Johnston with Jeff Mertz
Project design:Jeff Mertz
centerpoint. (For a free fairing stick plan, Illustrations: Roxanne LeMoine; Lorna Johnson
go to woodmagazine.com/fairing.)

2 Bandsaw or scrollsaw the edge of

each base (D) slightly outside the
line; then sand to the line. Finish-sand
Materials List
Part
FINISHEO SIZE
T W L MatI. Qty.
the bases to 220 grit. A legs 3/4 11 1V2" 8V4" W 4

3 With the rack assembly (AlB I C)

upside down, center the bases side-
to-side on the bottoms of the legs (A)
B rails
C· rests
'/2"
'/2"
1V4"
1V,6"
5%"
12"
W

M
4

and overhanging the backs of the legs D bases 1/2" 2'/8" 13" M 2
by W' [Drawing 1]. Mark screw locations ' Parts initially cut oversize. See the instructions.
centered on the legs; then drill counter- 1/4 X 1"
Materials key: M-maple, W-walnut. mortises
sunk shank holes in the bases (D) and 7116" deep,
Supplies: Spray adhesive; #8x1114" flathead wood
pilot holes into the legs [Photo B]. (For screws, 3fs" self-adhesive feet (4). centered
Blade: dado set.

Cutting Diagram

1I _ __ __ _ ___ _ _ 1I
3/4 X 31/2 X 36" Walnut (1 bd. ft.)

®
LEG HALF-SIZE
PATTERN
3/4X 51/2 X 36" Maple (1 .5 bd. ft.) (4 needed)
' Plane or resaw to the thickness listed in the Materials List.

WOOD magazine December/January 2008/2009

 The only solid cast-iron
top with five square feet
of work surface
Includes a
standard miter
slot plus a
Universal Cabinet 's 4" dust port
T-track for and fence's 2W' port
featherboards provide collection above
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 Dressy •
Dresser MIrror
Graceful styling and simple construction combine to make this
wall mirror a quick and satisfying project. It matches the dresser
on page 34, but will fit into many decorating schemes.

PROJECT HIGHLIGHTS Make the rails and stiles

• Overall dimensions are 28" wide x
His" deep x 19W' high.
• Styled to match the dresser (page 34),
valet (page 41), lingerie chest (issue 189),
1 Cut the lower rail (A) , upper rail (B),
and stiles (C) to size [Materials List,
page 68] .
• Materials needed: ¥.i" cherry and and pencil-post bed and nightstand (issue
14" hardboard. 187). 2 Form the %" rabbets at both ends of
the lower rail (A) and upper rail (B)
[Drawing 1, Skill Builder].

66 WOOD magazine December/ January 2008/ 2009

.!
Use a push block or feather board and pushstick when routing the Attach a long extension to your miter gauge and cut it off at the 37°
rabbeted edges on the narrow stiles (e) and rails (A, B). angle to help you align the top (D) for cutting the miters.

3 Using the same setup, rabbet the top

back edge of the lower rail (A) and
the inside back edges of the stiles (C)
3 Glue and assemble the lower rail (A),
upper rail (B), and stiles (C) [Draw-
ing 2]. Square the assembly, ensuring
gRAil TENON DETAilS

{Drawings 1, 2; Photo A] . that the corners are flush; then clamp

1Va" rabbet

4 Rabbet the bottom back edge of the

upper rail (B) with multiple passes.
Leave the cutting depth set as before,
the corners [See Shop Tip, on page 68] .
Add bar clamps across the assembly to
pull the jOints tight. -V
'V8" deep

but move the fence after each pass until

you reach lYs" wide [Drawings 1, 2]. 4 Finish-sand the mirror frame (AiB/
C) to 220 grit.
')
1V8"
~
Assemble the frame Add the top and base
1 Lay out the arch on the upper rail
(B) [Drawing 2]. Mark the centerpoint 1 Cut the top (D) and base (E) to size _
[Drawing 2].
Tilt your tablesaw blade to 3r, posi-
'Va" rabbet
where shown; then draw an arc through
the ends and the,centerpoint with a fair-
ing stick. (For a free fairing stick plan, go
2 tion the rip fence, and bevel-rip the
front edge of the top (D) [Drawings 2,3].
'Va" deep

to woodmagazine.com/fairing.)

2 Bandsaw the arc slightly outside the

line, and then sand to the line.
3 Reset the tablesaw blade to 0° and set
the miter gauge to 37° to saw bevels
on the ends of the top (D) [Drawing 2,

SKILL BUILDER
Routing renders rabbets readily
Instead of setting up your tablesaw with a dado blade when you have a few
rabbets to make, turn to your table-mounted router. A %" straight bit chucked
in a table-mounted router lets you form a rabbet of any width. (For rabbets
wider than W, make multiple passes.) Or, you can buy piloted rabbet bits for
common widths.
Raise or lower the router to adjust the rabbet depth. (For the mirror, set the
depth to ¥a", half the thickness of the rails and stiles [A, B, C) .) Position the
fence to set the width of the rabbet. If you are using a piloted bit, align the face
of the fence with the pilot bearing . (For the mirror, set the fence to make a
rabbet ¥a" wide.) Test the setup with scrap stock before routing project parts.
When routing across the grain, as on the ends of the rails (A, B), push the
workpiece with a scrapwood backer (we used %x6x12" MDF) to prevent
splintering the edge of the rail when the router bit exits, as shown at right.

wood magazine. com 67

 EJTOP BEVEL

Rise above
clamping problems Fence
Clamps often prevent laying an
assembly, such as the mirror frame (AI Blade tilted 37"
B/C), flat for gluing. To keep the parts from vertical
Vall
in the same plane, lay the assembly
across risers, such as the pieces of 2x4
shown. When glue joints lie across
the risers, put packing tape or waxed
paper on the riser edges.

Photo 8] . Leave a W' face to match the EJ EXPLODED VIEW

front profile.
W8',--=::"- t-~~~~~_ 28"

4 ChUCk a Vs" round-over bit in your

table-mounted router, and position
the fence flush with the pilot bearing on
: :: . d", ~==--~-~
---~~-.~~~;"::~~:-over
the bit. Round over both ends of the top
(D), then the front, where shown [Draw-
ing 2]. Use a scrapwood backer to prevent
tear-out when routing the ends.
1W'
5 Change to a Va" round-over bit, and
adjust the cutting depth and fence
position as necessary. Rout the bottom
(E) across the ends, then along the front
edge [Drawing 2] . Again, use a scrapwood
backer when routing the ends.

6 Finish-sand the top (D) and base (E)

to 220 grit. Then glue them to the
frame (AlBIC) , centered end to end and
V8 X 157/8 X 23 7/8" mirror

flush at the back [Drawing 2] . Place the 3/ 8 " rabbets

assembly on risers for easier clamping. 3/8" deep

Complete the mirror

1 Sand slight round-overs to soften
the exposed edges. Touch up the fin-
ish-sanding as necessary.
3/8" round-over

2 Stain as desired. (We applied Min-

wax no. 607 Cherrywood gel stain.)

3 Apply a clear finish. (We applied

three coats of satin polyurethane,
sanding to 320 grit between coats.)
A Cut the back (F) to size. Test-fit the
6f"back in the rabbeted opening; then
take it to the glass shop as a template for Cutting Diagram
a piece of Vs" mirror. Materials List
S Install the turnbuttons, hanging FINISHED SIZE
Part T W l Mati. Qty.
D-rings, and rubber bumpers where
shown [Drawing 2] . A lower rail %" 1112" 24" c

6 B upper rail 3/4 11 2" 24" C

Place the mirror glass in the open-
ing, insert the back (F), and secure C stiles 3/4
tt
llh" 18" c 2
with the turnbuttons . Attach a length of D top %" 1Sfs" 28" c
picture wire between the D-rings, and c
E base %" P/s" 27W'
then reflect on your success while you
hang the mirror. • F back 1/4" 16" 24" H

Written by Larry Johnston Materials key: C-cherry, H-hardboard.

with Jeff Mertz Supplies: Turnbuttons (8), W' rubber bumpers (2),
Project design : Kevin Boyle picture-hanging D-rings (2), picture wire, W' mirror.
Illustrations: Roxanne LeMoine Router bits: W' and 3fs" round-over bits,
%" straight bit.

68 WOOD magazine December/January 2008/2009

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 Doug found a passion for turning, a sense of accomplishment,
and an entirely new career in his wooden bowls.

70 WOOD magazine Decembe r 2008/January 2009

To maximize his resources, Doug uses an Easy-Core pivoting tool that allows him to Doug places about 300 bowls in this kiln for six to
salvage the waste wood inside a bowl and turn those pieces as well. seven weeks, producing one-of-a-kind masterpieces.

t took 49 years, one bad trip to the thought, 'That's fun,'" Doug says, chuck- Doug took stock of his situation: He

I bowling alley, and eight days in the

hospital to convince Doug Magrath
to trade his office job for woodturning.
ling. But he'd been bitten by the bug,
and soon he began turning gifts, such as
had a mortgage to pay and two children
to support. Although he had no formal
training, he felt passionate about turn-
Now, he's a one-man business and a ing and already owned a small lathe and
model for transforming a hobby into a "Lying in bed for eight all the tools he needed. His accounting
moneymaking venture. The London, practice had served him well, providing
Ontario, woodworker turns one-of-a- days in a row, all I could an understanding of how a successful-
kind wooden bowls, and his business, and unsuccessful-business operated.
Forest City Woodturning, produces do was think: 'It would "The good thing about working as an
more than 1,000 bowls annually, retail- accountant is you have to be familiar
ing for $125-$400 each. The lessons be really great to do with all types of business to do an audit,"
Doug learned by going pro may help Doug says. "You physically count inven-
you decide whether-and how-to take something I like,' II tory and get a good idea of most of the
the plunge. elements of an operating business."
He also took full advantage of his
Weighing a turning future bud vases, wine stoppers, and bowls, for resources, drawing marketing and sell-
He never expected to become a success- family and friends, slowly refining his ing advice from his brother, Al Magrath,
ful artisan. Ten years ago, Doug was skills. He loved his hobby, but could he a director of marketing. He even met
working as an accountant for a property- really make a living from it? with noted bowl turner David Lancaster
development company. One day, during
a lunch-hour practice at a bowling alley,
he felt a twinge in his side as he bent to
tie his shoes. Next thing he knew, he
was flat on his back in a hospital, having
surgery to remove his appendix and a
nonmalignant intestinal growth.
"At the time I was a chartered accoun-
tant, and I was burnt out," he says with a
sigh. "Lying in bed for eight days in a
row, all I could think was: 'It would be
really great to do something I like.' " A
hobby woodturner, he envisioned spend-
ing his days in the shop. To make his bowls
Doug's interest in woodturning actu- profitable for retailers,
ally stirred years earlier. While building Doug wholesales
an addition onto his house, he tinkered them at 50 percent of
retail value. He also
with his ShopSmith and tried using it as wholesales wood
a lathe. "I took a slab of 2"-thick walnut, utensils made by his
turned it into a really ugly bowl, and I friend Tom Pinches.

woodmagazine.com
Each one-of-a-kind turning bears Doug's signature, hometown, the Doug takes on every step of the production process, from selecting
date it was completed, and the wood species from which it is made. his wood to packaging and hand-delivering his finished products.

of South China, Maine, sharing with hardest part in marketing is how to price The tax department will tell you that as
Lancaster his dream to become his your work when there's not a comparable well," he adds.
"Canadian clone." product in the marketplace. I worked Doug says he moved 'slowly in lining
With all the cards on the table, Doug with the retailers on the price pOint that up retail customers: "I added one store
decided to take the plunge. He and his would work in their market," he at a time to be sure that I could keep up
wife, Wendy, who was teaching at the explains. with demand." He built such a reputa-
time, agreed that he would take two With that figure in hand, and the goal tion for his work that William Ashley
years to make his woodturning business to wholesale his bowls at 50 percent of China in Toronto contacted him about
a success. Failing that, he could always the retail value, Doug had to make the selling his wares. Initially, he declined
return to work as an accountant. ultimate decision: Could he live on that due to his relationship with a retailer
amount of money? just blocks away. "I don't compete with
Work your plan Doug divided his entire budget into myself in the same market, he says. But
II

Two scenarios for making the hobby-to- quarters, allocating 25 percent of the when that retailer retired a few years
business leap stood before Doug. "You later, Doug contacted William Ashley.
can keep doing what you want to do and The company was still interested, and
figure out how to sell what you make, or his first shipment of about 25 bowls sold
you can find out what people want and "If you're only making within two days. "They fly off the
decide if you want to make it," he says, shelves," says Kara Guatto, an assistant
matter-of-factly. Doug chose the second enough to cover the buyer with William Ashley.
option: Find a need and fill it.
After examining David Lancaster's labor but not the It all turned out fine
business model and determining that Turning about 1,000 functional bowls
bowls would be a sought-after product, profit, then you aren't and 200 more decorative vessels each
Doug simply needed a second opinion. year, Doug has built his thriving busi-
Armed with sample bowls he'd created actually operating ness around quality and reliability.
for family and friends, he approached a "I just kept hearing about his wonder-
London retailer to gauge the market. a business." ful bowls," says Jill Wilcox, owner of
The first thing she said was, "How soon Jill's Table, a specialty retailer in London.
can I get them?" he recalls. "Now that I carry his bowls, they are our
"I quickly decided that the - most wholesale price to material cost. "You top sellers for special giving [weddings,
enjoyment was in the making rather can't spend more than that, or you will anniversaries, and birthdays]. No two
than the selling, he says. "When you're
II never make any money at it," Doug are alike. We consider them works of art."
selling, you're not producing." If he notes. Another 25 percent was flagged In all, Doug personally supplies nine
planned to spend a majority of his time for overhead, such as insurance, tools, stores in southeastern Ontario, using his
in the shop, he needed to leave the sell- utilities, "and all the little things that deliveries as an opportunity to get feed-
ing to someone else: So, rather than you don't notice." Then, he calculated back directly from the retailers. "When-
going on the craft-show circuit or mak- 25 percent for labor, and the final 25 ever he arrives, we always say, 'We'll take
ing individual sales, Doug opted to sell percent for profit. all of them,' but of course, he still has
his works wholesale. "If you're only making enough to other stores to deliver to," laughs Guatto,
Establishing his wholesale prices, cover the labor but not the profit, then adding that William Ashley usually gets
however, posed its own challenge. "The you aren't actually operating a business. 20 to 30 bowls at a time. "Around the

72 WOOD magazine December 2008/January 2009

Natural-edge bowls, like these two pieces, allow Doug to challenge his creativity. About "It's putting a piece offirewood on the lathe
one-sixth of his overall production currently consists of decorative pieces like these. and taking a piece of art off," Doug says.

Christmas season, we sold out of our tional bowls," Doug says. While he cur- other interests and the job demand pulls
entire stock in less than eight hours," rently produces about five times as many you away from what you want to do,
she says. functional bowls as decorative bowls, he that's unsuccessful in my mind," Doug
High demand also allows for periodic hopes to shift toward a 60-40 ratio. says. "There is an old saying about being
price increases. Doug's IS" salad bowl Dedication to his craft has brought self-employed, that you work twice as
began wholesaling at $ 75, with a retail him closer to the satisfaction he longed hard, twice as long, for half as much,
price of $150. Today, it retails at $200. for, lying in the hospital years ago. "As and it's true. But the satisfaction is a
"I'd rather sell 10 bowls at a fair price an accountant, I was solving other peo- thousand times more for me," Doug
than two at an outrageous price," Doug ple's problems," he says. "You get home shares. "At the end of the day, I look
explains. "People won't pay gallery and think, 'Okay, what did I actually over at that rack and say, 'I made those
prices unless they're in a gallery." accomplish or do today?'" today; I did that.''' •
Success also allows Doug to make time A hobby-turned-business might be
for decorative pieces. "I've reached the successful on paper, yet true success is in Written by Megan Stotmelster and Mark Spowart
max of what I want to do with func- the eye of the beholder. "If you have Photographs: Mark Spowart

Lessons Learned
As Doug's story demonstrates, there's "hobbyist." Find a stable prod uct and friends, and mentors fo r help in thei r
more to a woodworking business than stick to it. Don't take on more work than areas of expertise.
just a love for the hobby. If you 're you can handle, either. Deliver your
considering going pro, here are the big products on schedule in the manner Give yourself a deadline
ideas to take away: you'd expect from your suppliers. Starting a business is a bit of a gamble,
so know when to quit. Doug gave
Treat your business Establish a pric~ point; himself two years to get Forest City
like a business This is often the trickiest aspect of Woodturning up and ru nning, but if that
The key is isolating you r expenses. If runn ing a business: keeping prices low fa iled, he had his former job to fall back
possible, supply your workspace with its enough to stay competitive, yet high on. Set a deadline and income projection
own heati ng and power. Don't forget enough to make a profit . Calculate what from day one. If you're not generating a
about separate insurance and taxes, it costs to make your product, what you profit or even breaking even, move on to
either. If you need advice, see whether a can accept as payment, and then ask the a more stable income.
business school or comm unity college retailers if they can sell it for twice that,
instructo r can match you with a student Doug suggests. You'll qu ickly discover Be mentally prepared
who ca n help create a business model. whether your business plan is feasible. Transforming a hobby into a busi ness
requ ires commitment, long working
Select a sustainable Use those resources hours, and often an income drop. Be
product; deliver reliably Although Doug had the business skills, prepared for a significant lifestyle
"In order to be accepted as a purveyor of he pulled marketing, pricing, and change, and make sure al l your fam ily
goods to the retail trade, there has to be turn ing advice from outside resou rces. members are on board. Although you're
the business approach," Doug explains. A wealth of advice is only a conversation bound to face frustrations along the way,
The key word here is "business," not away, so don't hesitate to ask family, don't forget to enjoy your passion .
Ask WOOD HAVE A QUESTION?
For an answer to your woodworking question, write to ASK
Answers to your questions from WOOD, 1716 Locust St., LS-221, Des Moines,lA S0309-3023
letters, e-mails, and WOOD Online* or e-mail usataskwood@woodmagazine.com. For immediate
feedback from your fellow woodworkers, post your questions on
one of our woodworking forums at woodmagazine.com/forums.

Splitter or riving knife-what's the difference?

Q . I'm preparing to purchase
• a tablesaw and have been
researching the features of differ-
non-through cuts such as dadoes,
grooves, and rabbets.
Every tablesaw comes with a splitter
common because Underwriters Labora-
tories (UL) made them a UL-listing
requirement for new tablesaw models
ent models. What's the difference (it holds up the blade guard), and you introduced since January 2008.
between a riving knife and a splitter? can add an aftermarket splitter, such as Existing tablesaw models are grandfa-
-Jamie Zankel, Chesterfield, Va. the one shown bottom, without a guard. thered in until 2014, when they, too,

A•
Soon, riving knives will be just as will need riving knives for UL listing.
The goals of a riving knife,
• shown right, and a splitter, below,
are the same, Jamie. Both sit behind the
blade to prevent the two sides of a cut
piece of wood from pinching or
rotating into the blade. This, in turn,
prevents the workpiece from kicking
back at the operator.
However, a splitter typically doesn't
change height, while a riving knife
raises and lowers with the blade. Also,
the top of a true riving knife stands just
lower than the top of the blade, so it
doesn't have to be removed for most

Anti-kickback

Organization Simplified
•
All-Steel Storage System

J /

Some splitters feature anti-kickback pawls

wallcontrol.com for an added measure of safety.
888.792.5266 continued on page 78
770.723.1251
Over 10 times stronger than conventional pegboard 74 WOOD magazine Dec./jan.2008/ 2009

Circle No. 2100

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Thanks to Woodmaster
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Log on to www.WOODWorkersCenter.com Wood Magazine December 2008 77

 Casters for picnic tables:
Now you're on a roll
Q. The legs of my picnic table
. take a lot of abuse when
someone moves it across the patio.
What could I do to protect the legs?
-Joe Ales, Pleasanton, Calif.

A• A pair of carefully positioned

• casters should give your table's
legs a break, Joe. (And we mean that in
a good way.) You'll need a pair of fixed
casters with wheels at least 4" in
diameter. If you can find casters meant
for outdoor use, that's all the better.
Then, find a point on the outside
surface of the legs where the wheels
have about 1,4" clearance from the patio.
Bolt the casters to the outsides of the
table legs using washers and nuts on
the opposite side.
To move the table, lift the end
opposite the wheels until the wheels
.touch the patiO, as shown below. Then
just roll it where it needs to go.

10 Gift Ideas for the Woodworker

1. Magnetic Paintbrush Holder 67K74.02 $3.50 2. Ratcheting Micro-Tip Screwdriver
17K01.95 $9.50 3. Hacking Knife 28K02.60 $18.50 4. Lanyard Level 36N35.15 $18.50
5. Digital Height Gauge 88N90.01 $49.50 6. Japanese Nail Set 44K13.01 $8.50
7. 10 Painter's Pyramid™ 88K58.70 $6.50 8.4 Palette Knives 35K09.01 $9.95
9.4" Double Square 24N08.01 $36.50 10. Woodworker's Knife 06007.10 $7.50
To request a copy of our free 276-page woodworking tools catalog, call or visit us online.

,LeeValley&
1-800-683-8170 www.leevalley.com
ver<ftas®
Circle No. 803
Shipping and NY sales tax extra.

Ask WOOD
Look mal A no-clamps glue-up

Q . I've built small projects, such as a photo frame and a

. jewelry box, with delicate, difficult-to-clamp parts. Is
there some fast-setting adhesive that will allow me to use
hand pressure to clamp until the glue "grabs?"
-Kevin deMarco, Round Rock, Texas

A• Look to masking tape, Kevin. It makes a great helping

. hand for small-part glue-ups where clamps would be
overkill or wouldn't find purchase.
On the other hand, if you need an excuse to add to your tool
collection, you could invest in a 23-gauge pin nailer. These fine For small glue-ups, masking tape provides sufficient clamping
fasteners excel at delicate tasks, such as applying molding, and pressure to hold your workpiece together while the glue sets.
leave barely noticeable holes that virtually disappear when filled. continued on page 81

78 WOOD magazine December/ January 2008/2009

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Circle No. 284

PUT A SHOPBOT BUDDY CNC TO WORK

Dovetails
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FOR YOU
The ShopBot Buddy is the "ultimate workshop tool ," allowing you to create a
huge variety of projects and components, from simple 2D shapes to
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needs, space and budget.

With complete systems for less than

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See the Videos at 'eighjigs.com or space.

Buddy 48
Call or visit us online to learn how you can put Buddy to work in your shop.
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Ask WOOD
Spill strips toner finishes
Q. Without noticing, I spilled a
• few drops of home fragrance
oil on our hall table. When my
husband wiped up the oil the next
morning, it lifted the finish down to
bare wood. Please explain why this
happened and how to fix it. • True Parallel Heads provide reliable
uniform pressure across the full length of the
-Aprile Kohler; Des Moines, Iowa clamp surface

A•
• Durable Tool Steel Rail for years of reliable
The oil contains solvents that service
• Built In Clamp Pad eliminates damage to
• reacted with the table's finish, materials
which was probably a type of lacquer, • Reversible head for push/pull action
Aprile. Unlike varnish, lacquer can be • Built in flip-down clamp stand stabilizes for
dissolved even after it dries, and the oil multiple clamp applications
had all night to work. You're seeing PC·15 • 15" Capacity...............$29.95
bare wood because it wasn't stained. PC·27 • 27" Capacity...............$36.95
Instead, the table was finished with a
toner-a tinted film finish popular PC·39 • 39" Capacity...............$40.95
among furnituremakers. Toners make PC·59·59"
repairs harder because spraying toner
on the entire surface darkens existing
coats as it covers the bare spots.
If the table's finish comes close to
matching a commercial stain, use that
to touch up the damage, and seal the
stain with varnish thinned 75 percent
with mineral spirits. If not, make a
touch-up toner by mixing pigments,
such as Mixol (Woodcraft, 800-225-
1153 or woodcraft.com), in Vz-pound-
cut shellac, as shown below, or in
thinned varnish. To avoid future
problems, cover your repairs and the
entire tabletop with at least two coats of
polyurethane or alkyd-resin varnish. 1Opc Professional
• 3-1/4" ogee raised panel
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Mix pigments and shellac on a piece of scrap

glass to determine the right color before
dabbing it on.
continued on page 83

woodmagazine.com 81
Ask WOOD
Countersinking feeling
Q e llike to use aluminum
e T-track in jigs and projects.
However, I have a hard time coun-
tersinking the mounting screws.
If I drill the countersink deep
enough to seat the screwhead
flush, do I risk enlarging the holes
too much by countersinking into
the stock?
-Rick Shields, Portland, Ore.

A e Don't worry about overen-

e larging the hole in your
aluminum T-track, Rick. The metal-
to-metal contact of the angled
screwhead and the angled counter-
sink bottom holds the track in place,
not the shaft of the screw within the
pilot hole.
To install a T-track, first clamp the
track in place, making sure the top
of the track is flush with the jig's
surface. At the drill press, drill pilot
holes through the track and into the
jigi then countersink the screw holes
with the track still clamped in place.
We recommend Single-flute counter- BESSEY® Tools North America· 1.800.828.1004 • www.besseytools.com
sinks (no. 06J50.20, $16.20 for twoi Circle No 745
Lee Valley Tools, 800-871-8158 or
leevalley.com) . These allow you to
accurately center a smooth cut. Drill
until the upper diameter of the
countersink matches the diameter of Enjoy All the Creature Comforts
the screwhead, as shown below. That
may mean the tip of the countersink
bit cuts through the track and into
with Radiant Floor Heating
the jig, but this shouldn't create a
problemi there will still be plenty of
material for the screwhead to grab.
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wood magazine. com 83

 STATEMENT OF OWNERSHIP, MANAGEMENT AND CIRCULATION
(Requester Publications Only) 1. Publication Title: Better Homes and Gardens® WOOD. 2.
Publication Number 724-890. 3. Filing Date: October 1, 2008. 4. Issue Frequency: 7 times
a year. 5. Number of Issues Published Annually: 7. 6. Annual Subscription Price: $28.00. 7.
Complete Mailing Address of Known Office of Publication: 1716 Locust Street, Des Moines,
Polk Co., IA 50309-3023. Contact Person: Dan Holland. Telephone: (515) 284-2717. 8.
Complete Mailing Address of Headquarters or General Business Office of Publisher: 1716
Locust Street, Des Moines, Polk Co. , IA 50309-3023. 9. Full Names and Complete Mailing
Addresses of Publisher, Editor, and Managing Editor: Publisher: Mark Hagen, 333 North
Michigan Ave. , Suite 1500, Chicago, IL 60601 ; Editor: Bill Krier, 1716 Locust Street, Des
MOines, Polk Co., IA 50309 -3023; Managing Editor: Marlen Kemmet, 1716 Locust Street,
Des Maines, Polk Co., IA 50309-3023. 10. Owner: Meredith Corporation, 1716 Locust
Street, Des Moines, IA 50309-3023. The names and addresses of all stockholders owning
or holding 1 percent or more of the total amount of stock: Bank of America Securities LLC,
Attn: James Monahan, 100 W33rd Street, 3rd Floor, New York, NY 10001; Bank of New
York (The), One Wall Street, 6th Floor, New York, NY 10286; Bear, Stearns Securities Corp.,
One Metrotech Center North, 4th Floor, Brooklyn, NY 11201-3862; Brown Brothers Harriman
& Co. , 525 Washington Blvd, New Port Towers, Jersey City, NJ 07302; Charles Schwab &
Co. , Inc., Attn Proxy Department, 211 Main Street, San Francisco, CA 94105; Citibank, N.A.,
3800 Citibank Center B3-12 , Tampa, FL 33610; Citigroup Global Markets Inc., 333 W. 34th
Street, New York, NY 10001 ; Deutsche Bank Securities Inc., 1251 Avenue of the Americas,
New York, NY 10020; First Clearing, LLC, 10700 Wheat First Drive, WS 1023, Glen Allen,
VA 23060; Goldman, Sachs & Co., 30 Hu~son Street, Proxy De artment, Jersey Cit, NJ

F
National, Attn : Melissa Tarasovich, 525 William Penn Place, Suite 3418, Pittsburgh, PA
15259; Merrill Lynch, Pierce Fenner & Smith, 101 Hudson Street, 8th Floor, Jersey City, NJ
07302; Morgan Stanley & Co. Incorporated, Attn: Michelle Ford, 901 South Bond St, 6th
FI, Baltimore, MD 21231; National Financial Services LLC, 200 LIberty Street, New York
City, NY 10281; Northern Trust Company (The), Attn: Capital Structures-C1N, 801 S. Canal
Street, Chicago, IL 60607; State Street Bank and Trust Company, Attn: Paul Desharnais,
1776 Heritage Dr. , North Quincy, MA 02171 ; SSB -IBT/BGI , Attna: Tom Broderick, 1776
Heritage Drive, North Quincy, MA 02171 ; UMB Bank, National Association, Attn: Jan
Guzman, 928 Grand Blvd, Kansas City, MO 64106 ; U.S. Bank, N.A., Attn: Securities Control,
1555 N. Rivercenter Or., Ste 302, Milwaukee, WI 53212. Through some of the nominees
listed above, the E. T. Meredith and Bohen families and family foundations own, directly or
beneficially, approximately 22% of the issued and outstanding stock of the corporation. Each
nominee listed above holds stock for one or more stockholders. 11. Known Bondholders,
Mortgagees, and Other Security Holders Owning or Holding 1 Percent or More of Total
Amount of Bonds, Mortgages, or Other Securities: None. 12. Tax Status (For completion
by nonprofit organizations authorized to mail at nonprofit rates) (Check one): The purpose,
function, and nonprofit status of this organization and the exempt status for federal income
tax purposes: _ Has Not Changed During Preceding 12 Months _ Has Changed During
Preceding 12 Months (Publisher must submit explanation of change with fhis statement)
Not applicable
13. Publication Title: Better Homes and Gardens®WOOD
14. Issue Date for Circulation Data Below: November 2008
15. Extent and Nature of Circulation
Average No. Copies Each Issue During Preceding 12 Months:

--
a. Total Number of Copies (Net Press Run): 643,453
b. Legitimate Paid and/or Requested Distribution (By Mail and Outside the Mail):

_-
(1) Outside County Paid/Requested Mail Subscriptions Stated on PS Form 3541.
r.. __ .........
........
(Include direct written request from recipient, telemarketing and Internet

.............
WWW.GENERAL.CA
requests from recipient, paid subscriptions including nominal rate subscriptions,
employer requests, advertiser's proof copies, and exchange copies) : 482,630
(2) In-County Paid/ Requested Mail SubSCriptions Stated on PS Form 3541. (Include
direct written request from reCipient, telemarketing and Internet requests from
recipient, paid subscriptions including nominal rate subscriptions, employer
requests, advertiser's proof copies, and exchange copies): 568
(3) Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and Other
Paid or Requested Distribution Outside USPS>!> : 48,342
(4) Requested Copies Distributed by Other Mail Classes Through the USPS (e.g.
First-Class Mail>!» : 0
c. Total Paid andlor Requested Circulation (Sum of 15b (1), (2), (3), and (4)): 531 ,540
d. Nonrequested Distribution (By Mail and Outside the Mail):
(1) Outside County Nonrequested Copies Stated on PS Form 3541 (include Sample
copies, Requests Over 3 years old, Requests induced by a Premium, Bulk Sales
and Requests including Association Requests, Names obtained from Business
Directories, Lists, and other sources): 2,073
(2) In-County Nonrequested Copies Stated on PS Form 3541 (include Sample
copies, Requests Over 3 years old, Requests induced by a Premium, Bulk Sales
and Requests including Association Requests, Names obtained from Business
Directories, Lists, and other sources): 0
(3) Nonrequested Copies Distributed Through the USPS by other Classes of Mail
(e.g. First·Class Mail, Nonrequestor Copies mailed in excess of 10% Umit
mailed at Standard Mail>!> or Package Services Rates): 0
(4) Nonrequested Copies Distributed Outside the Mail (Include Pickup Stands, Trade
Shows, Showrooms and other Sources): 1,318
e. Total Nonrequested Distribution (Sum of 15d (1), (2), and (3). and (4)): 3.391
f. Total Distribution (Sum of 15c and e): 534,931
g. Copies not Distributed (See Instructions to Publishers #4 (page#3)): 108,522
h. Total (Sum of 151 and g): 643.453
Pinnacle is defined by Webster's as 1. Percent Paid and/or Requested Circulation (15c divided byftimes 100): 99.37%
No. Copies of Single Issue Published Nearest to Filing Date
the highest point of development a. Total Number of Copies (Net Press Run) : 644,000
b. Legitimate Paid and/or Requested Distribution (By Mail and OutSide the Mail):
or achievement. The latest offering (1) Outside County Paid/Requested Mail Subscriptions Stated on PS Form 3541.
(Include direct written request from recipient, telemarketing and Intemet
of router accessories that bear the requests from recipient, paid subscriptions including nominal rate subscriptions,
employer requests, advertiser's proof copies, and exchange copies): 490,274
(2) In-County Paid/Requested Mail Subscriptions Stated on PS Form 3541. (Include
Pinnacle@name have certainly lived up direct written request from recipient, telemarketing and Internet requests from
reCipient, paid subSCriptions including nominal rate subscriptions, employer
to this definition. Every detail of these requests, advertiser's proof copies, and exchange copies): 570
(3) Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and Other
Pinnacle@tools was engineered with Paid or Requested Distribution Outside USPse: 41 ,425
(4) Requested Copies Distributed by Other Mail Classes Through the USPS (e.g.
one thing in mind: to provide woodworkers First-Class Mail>!» :
c. Total Paid and/or Requested Circulation (Sum 01 15b (1), (2). (3), and (4)): 532.269
0

d. Nonrequested Distribution (By Mail and Outside the Mail):

with tools that empower them. Pinnacle@ (1) Outside County Nonrequested Copies Stated on PS Form 3541 (include Sample
copies, Requests Over 3 years old, Requests induced by a Premium, Bulk Sales
and Requests including Association Requests, Names obtained from Business
Directories, Usts, and other sources): 2,041
(2) In-County Nonrequested Copies Stated on PS Form 3541 (include Sample
copies, Requests Over 3 years old, Requests induced by a Premium, Bulk Sales
and Requests including Association Requests, Names obtained from Business
Directories, Lists, and other sources): 0
(3) Nonrequested Copies Distributed Through the USPS by Other Classes of Mail
(e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% LImit
mailed at Standard Maite or Package Services Rates): 0
(4) Nonrequested Copies Distributed Outside the Mail (Include Pickup Stands, Trade
Shows, Showrooms and other Sources): 1,350
e. Total Nonrequested Distribution (Sum of 15d (1). (2), (3), and (4)): 3.391
f. Total Distribution (Sum of 15c and e): 535,660
g. Copies not Distributed (See Instructions to Publishers #4 (page #3)): 108,340
h. Total(Sum of 151 and g): 644.000
1. Percent Paid and/or Requested Circulation (15c divided by f times 100): 99.37%
16. Publication of Statement of Ownership for a Requester Publication is required and will be
printed in the December/January 2009 issue of this publication.
17. Signature and Title of Editor, Publisher, Business Manager, or Owner: Jeff Stiles,
Business Manager. Date: 08/25/08.1 certify that all information furnished on this
form is true and complete. 1understand that anyone who furnishes false or misleading
information on this form or who omits material or information requested on the form
may be subject to criminal sanctions (including fines and imprisonment) and/or civil
sanctions (including civil penalties).

84 WOOD magazine December/ January 2008/2009

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CARV I NG

www.Flexcut.com
What's Ahead
A sneak peek inside the March 2009 issue Stackable storage
(on sale January 13, 2009) These versatile, easy-to-build units go one
atop another or side-by-side. You'll learn
how to make poplar look like pricier walnut.

Lingerie chest No-fail routines for jointing and planing 6" jointers
Practical and beautiful, this lithe seven-drawer chest Learn time-proven techniques for machining rough-sawn Our test of 10 mid-priced models with
completes the Shaker-style bedroom set that started lumber and even warped, cupped boards into fiat, square three types of cutterheads uncovers the
with the pencil-post bed in the November 2008 issue. project stock of consistent thickness. machine that will work best in your shop.

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Start designing in SketchUp Add slatwall tool and accessory storage
Google's free, easy-to-use design software sets your Use these tough and affordable wall panels and
creativity ablaze. See how you can visualize and heavy-duty hardware to devise a storage system that
refine projects before even setting foot in the shop. keeps pace with your changing shop needs.

92 WOOD magazine December/ January 2008/2009

Satisfy your most important client
The best projects aren't for, or about yourself. And when someone special is involved, safety is
even more critical. With an innovative torsion mechanism tested to 25,000 cycles, our new
Lid-Stay Hinges hold lids open at almost any angle so her fingers stay secure and your mind
stays at ease-another way Rockler helps you Create with Confidence.

RockIer Woodworking and Hardware - Since 1954

~ For a store near you or .free catalog visit RockIer.com 1-877-ROCKLER

Circle No. 661
DEWALT.

The straight plunge action creates

a comfortable, natural motion.

l,300-wall motor cuts hardwoods up

to 2-lfs" with ease.

The dual-edged track sets up foster

and lasts longer.

Available in both corded and

28v lithium Ion cordless models.