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Woodsmith - 028

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    TECHNIQUE:

    ~ M RQUETRY INL YS

    ~.;: : ___ STEP BY STEP

    NEsnED T LES

    W ALN U T M U SIC BO X

    ROUT

    SN AC K TR AY

    J W LRY BO X

    2 50

    O TE S FR O M TH E S H O P

    O 8

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    \VOOOS~UTH

    m ined to be

    as

    human

    I>' '..,.,llie.

    Itw a s n't u ntil

    I wanted

    to b uil d a r ea l ly

    n ic e woodworki ng p ro je ct tl u' l final ly

    l ea rn ed tha t

    attention

    to

    detail end mis

    ta kes

    are two

    differe nt th in g. s .

    I have continued

    to m ake m is ta kes . but

    no w 1 pa y a ttention to them . If a joint

    doesn' t fit qui te r ig ht ,

    ut it a ga in.

    f

    a

    p ro je ct is n't

    square, [

    do

    whatever

    i t t a ke s

    to

    correct

    it.

    The ne s tl ed t ables (shown on

    page 1 2)

    a re

    a ela ss le

    exa mple. In this

    case ,

    the

    detail ha s co do with on e o f the m os t b as ic

    ten en ts o f w oo dw ork in g: m a k in g

    sure

    th e

    a s s embl y i s s q ua r e.

    th e legs on a l l three ta bles a re not

    p erfec tl y s qu are. it

    \ \ ;

    be rea dily a ppa r

    en t when

    they're

    nest led lOgetber. l Ithe

    mitered fr ames for the ta ble tops a re not

    cu t ,;gh t on the m oney , the w hole projec t

    \\;U

    suffer. This is the kind of deta il

    that

    co mmands eonsiderable attentio n .. .

    ri ght fr om the

    start.

    T he s am e hQ ld~ tru e for mounting

    mar

    quetry in la ys 1 0a p ro ject, T he ov al inl a y o n

    th e l id of'the mus ic box (see page

    4)

    require

    hair-splitting'

    detai l , \Vi thOUI

    this

    kind of

    de ta il , the inla y \\~IIcertainly attract th e

    wrong kind of attention.

    I 'v e f in a ll y r ea l iz ed th a t a tte ntion to d~

    ta il m ea ns rec og niz in g th e m is ta ke a nd

    ta king th e

    extra

    s tep to correct it.

    CORRECtION.

    In

    the la st is s ue of

    oo

    WI

    (No.

    27)

    w e ra n

    a

    l en gth y a rticl e on

    how to

    chose

    a ca rbide-tipped s a w bla de.

    unfortunately. one

    part

    of it m ay ha ve

    been a

    little

    di fficul t to rea d

    b ec au se s om e

    o f th e text w as a pparently

    missing.

    It' U

    th ere .l l s ju st in th e wrong place .

    I 'm r cr cTnnR to p age 20 . th e th ir d o ol um n .

    The 1., . ( 17 U nes of I .e t a t the bottom of

    th i> c ol um n

    should

    be a t the top of th e

    co lumn,

    s r. \\ .. ,IC.;S AiJ; ,n the I ss t is sue [ m e n

    t lo ne d th a t

    Jeff

    Fa m. ( urncw

    eireulatien

    m a na g er ) p ro m iS n lith . ..

    Il, pin

    h 'r

    fo r abou t

    $600, Md

    S ea

    rs

    hfl ' on . for

    abeut

    S 2 O O H ow ever, w ith th~ h elp o f one of our

    readers

    (C arl Dykm an) we

    were able

    to

    a dd

    a p in ro utin g s et-u p

    to

    th. ,

    I I ull ,Ih

    touter

    table

    fo r

    about

    $5 (whi.h

    wa s me ro

    a greea ble to m y w aU et).

    O f course . to us e th is p in ro ute r auaeh

    m ent, you ha ve to bu ild the router ta ble

    first.

    But 1

    have

    to

    say

    tha t

    this

    router

    ta bl e h as p ro ved il .. .> < el ta lua ble (over a nd

    over a ga in) in our shop. The pin routing

    s e t-u p is o ne m ore i n e x p e n s i v e ) addition

    tha t m akes it

    well

    wort h bui ld in g ,

    I)ETAILS.

    A tten tio n to d eta il .

    T h o s e

    words

    have

    been echo ing in m y hea d ever

    s ince I w a s a sma l l boy.

    My

    fa ther w a s a

    s tickler fo r deta il . a nd wa s prone to offer

    th o se w ords of a d vice w henever he ha d the

    chance,

    I spent much of my young l if e try in g 10

    a vo id d eta il s - a dopting a s omewha t ha p

    h a z a r d a ppr oa ch

    to

    things , This of course ,

    led to numerous m is ta kes a nd m is

    ca lcu l a tions . But m is ta kes a re pa rt of be

    ing hu ma n: 1 re a soned . And I wa s d ete r-

    wdust

    E d I t O 1 '10hold the glass

    in pi , ,ing the waste from the center

    divider, Laler lh,~ stop ill be attached

    ith small bras brad.s to hold the glass in

    place rr

    Fig. I.

    .'''''~I:IIIII.\.Now Ih~ ba.,ic box is almo$(

    reaely 10 1 > 1 ~(mbled. But here's where

    you

    mll,\'

    huv to 81\ r these pIan.accord

    ing 10 tht WAy Ih .turt .top lever of the

    part irulAr

    mlJVt'mrnt )'OUtL.;;e

    is mount e- d

    to lh box

    flG.VtI' .,

    center uf the {mnt and back pieces, se.

    Filt.I

    (the width ofthi. dado should tnaleh

    th(' actual thicknc', of the divider).

    TRI\ITO,'11

    Al thi. point. the front .

    back ,I t 0 ...de, (bul not the center

    divider) can be tnmltlE'dto their IinaIwidtb

    of 1

    t',.,

    Be

    OUI'\'

    10 Inm th

    e

    excess width

    (rum th., ~., lhat illC cnluaJly

    become

    Ihe lop '('''''''''','' edgP inorder to remove

    any ch,pout produced when the comer

    join~

    \I,

    ere cut

    (,KOQ\I:SfllR G'.IS. To protect the

    mn\ (>mfnt,

    I 8f l rl ('(1

    a ~la~ cover over the

    m .i. rompartmpnt (~ . PI igilb also can

    be uscd - and

    i.

    eally a lot eMier to work

    ithl. 1 (1

    mllunl

    tlw IIlass.

    CUl

    a Y o groove

    (the thick ,.. of .ingl. strength glass) in

    one en d pie

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    5

    .-

    - _

    \ 'OODSMITH

    ,

    STUlGHT

    o r r

    / 2

    ~ ,. t- .

    c

    c

    H

    rKl

    WASt

    1

    /

    cu r

    GItOOVt- - DIU

    l .

    St4.t SlOf llYfl

    OftAll

    f R O U f

    . . . . .

    GlOOVE

    . .

    a

    r

    c

    .

    . . . .

    . .

    I

    ,

    -

    ~

    .J

    I

    GtOOV, .,, ....

    ClNnl or.-tOIl

    F JlON T(IAClC

    & , . .S.

    AI fO

    M O U M N G S

    JO COY,. COINU JOtH1 t

    CUI DADO~',DEI'

    CINTUlD ON fIONT,lACK

    Gloove ANDHOlt

    FOI StAnISIO lIV1 . I ~

    . .,

    I,

    -,-;--

    ~Ln~ ~ ~r-L_

    t-- 4. - I . . .

    \ .

    f 1

    c

    ~,

    )

    LwASTtPlK(

    /

    2 .

    oJ ...

    . . .

    [

    [

  • 7/24/2019 Woodsmith - 028

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    WOOOSM ITH

    J

    ___ ~ : .. PlYWOOD

    1 Hl A

    C Q J tN E R

    MOlOlHG

    _ .

    --0----

    SIDE lAS E

    ~

    HE BASE

    The base of this musie box ~. A mitered

    frame, rabbeted to accept a y. 1> I) wood

    bottom. To mak~ the

    f

    ra me, ril ~piece of

    414 steek to a width of 1\~ and -1 1 long.

    (This is enough length for all four pieces of

    the frame.) Then cut a

    -deep b)

    'Y,.-wide rabbet on the inside edge of thi~

    strip for the

    plywood

    bottom. see detail in

    riJ(. II.

    err TO LE~GTlJ. Next, the (our

    frame

    piece 0 and Ecan be mitered to length.

    To determine the finished length of the

    Iront.back pieces

    (E).

    hold the corner

    moldingll (cut earlier) against the

    bod

    of

    the music box, and measure the length

    from molding to moldin (.

    To

    get the length

    of

    the

    end

    piec

    es P.

    measure

    the di~tance from

    the front

    molding to the back of the box. No add

    :

    to

    both

    or these measurements to

    pro -

    vide for the

    two - Y l \ \ ; < ) e egee

    cut Sann

    the two '1wide

    l ips.

    see Fig. l:l.

    .'and the edge of the ogee profile

    on the

    base, see

    Fig.

    13.

    Finally. the four comer moldin ( (G and

    H) can b e cut to length (to match the height

    of the box) and glued in place.

    TilE PAilS.

    To

    improve the sound of the

    music box. 1 raised it Slightly by mounting

    four small pads (I) to the corners of the

    base, These pads are I~ xiI(,. square

    pieces ofY.-thickstock. Each side of these

    pads is chamfered on the bottom edge.

    To make the pads, cut a .tripy: thick.

    1'1. wide. and about

    long. Then chamfer

    three edges. see Fig. 10. Xext. cut off a

    IV. long piece from the end which has

    three chamfers. This produees one pad.

    To make the remaining three pads. reo

    chamfer the newly exposed end. and keep

    cutting and chamfering until you have all

    four pads eut, (At this point you have four

    pads. chamfered on only

    three

    sldes.)

    'fr)~ng to chamfer the fourth edge on

    these little blocks on the router table is

    CUT tABaEl EQUAl

    T O T K I KN U S

    OF P lYWOOD

    l I A S .

    .;.

    USET oaAlt

    FtGUIIE

  • 7/24/2019 Woodsmith - 028

    7/24

    WALHU f - /. .. . 7 , ,, .. 3.

    CUTT ING D IAGRAM

    ENT

    D1V1D[1

    \

    RGURe 19

    COU NTtWNIC BRAS S BRAD

    OF HINGE

    UO F

    MATERIA LS LIST

    A fron Sock (2)

    I. . .. 8Jj,

    a

    Sid (2)

    ~ .. . Iv. . ..

    /1

    C

    C.n or DivideI (1)

    . lC 1( .. V .

    0

    Bose- lnd, (2)

    uti .

    lIC 1 v . ..

    /,

    8oJe--FronV8Qck2

    Y l

    1/,.10

    F lid (I)

    V I.

    S-v.* ..

    9)/,:

    G

    Molding -- Front (2)

    > I ,, Jl

    Y ,, 10

    H MoldlnB - lack (2)

    I .

    x J

    1

    I Pod. (4)

    1..:11. .111.-

    J I

    Plywood8oho.. (I)

    Cut 10 F it

    11

    5

    ::

    D

    91 .

    ~~

    . .

    ~

    = R 4 J

    >I.

    .

    flNlSHED

    flOffLf

    L ,.

    _

    y SrtAlGHT an--

    UO OfTAIL

    RGUat 17

    1

    1

    tI

    .EOtAMR~

    E O G E IS E FO ,E

    cumHG NEXT

    JOOf

    \VOODSM ITH

    T HE L ID

    The lid to the music box is relatively

    simple. It's just a piece ofs tock that's cut

    to

    overhang the

    body

    of the box by

    Y

    on

    all four ~ide~. Then to dress it up a little,

    the edges are molded.

    To

    make this lid, CUl it .

    \I~del'

    and

    longer than the outside dimension. of the

    box (including the corner moldings). Then

    to g iv e it a custom lo ok, ro ut a y , . x 1 0 ,.

    rabbet on the top edge of the lid and cut a

    C O \ e \\rith a v c ore b o x bit s o it leaves a

    I .shoulder on the rabbet, see Fig. 17.

    Next rout another o cove Oil the bo t-

    tom side of the lid. The depth of this CUt ;

    se t So that the 00\'(' lea,'~ a :Yt~-\\id(at

    on the outside edge of the lid.

    TilE t:>UI.

    The lid can be

    used

    just like

    this. But that's 100 easy. I decided to

    SI .e things up by adding 3 small 0\'31

    inlay on the lid. All I really had to do

    to

    mount

    the inla)'

    was

    rout

    out

    the

    recess

    and drop it in. Unforwnatel~', it isn't per

    fectly s vm m errte el. S o there s really no

    \ \ 8,)

    to

    CU l out th perimeter or th r ss

    \l ithout

    some hand work.

    Although this sounds absolutely impos

    sible, with 3little patience, it can be done

    without

    was ting a

    lot of

    sto ck . O n

    page

    II

    th ere s a d eta ile d d esc rip tio n o n how

    tIl

    cut

    out the r ec ess and moun t the inlay.

    THE FINIS HING TOUCHES

    Arter the lid

    is

    complete, I cut small mor

    uses

    for

    the

    hinge on the back

    side

    of the

    box. see f'ig. 18. To simplify the process of

    mounting the hinges, c ut th e mortises to

    the full

    hickness of the bing .... The .

    extra-deep mortises allow the hinge to be

    nush

    mounted to the lid.

    fl)1ISII.Aller the hinge mortises are cut.

    drill ()i1otholes for the hinge screws. But

    before mounting the hinges, go ahead and

    apply

    th e

    finish.

    I

    used three

    coats

    of

    1\\0

    Ib.-cut o ra ng e s he ll s

    sc,

    101 JOI t:}lEST.Mer the music box

    is 6nished,

    moun t

    Lhemusical movement

    and

    install

    the start/stop lever. Then slide

    the g la ss o ve r the movem en t a nd se cu re it

    in place by pre-drilling and eountersinkinz

    brass brads in the hold-down strip. see

    Fig. 19.

    To

    dress

    up

    the

    pe n

    compartment of the

    box, ( cut 3 piece of velour LO cover the

    plywood bottom. And finally. 1 mounted

    the lid to the box.

    After

    the box was completed, I invited

    my mother over for dinner. And just by

    chance, tbe music box was silting right in

    the middle of the dining room

    table.

    She

    was delighled.

    ncarly Impoesible, so I chamfered the

    GU IS AGU, ,.

    fourth edge using

    a

    small block plane.

    Ana all four edges are chamfered, glue

    the pads

    10

    the bottom of the base so

    they re set

    back Y from

    the

    outside

    edges.

  • 7/24/2019 Woodsmith - 028

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    \VOODS~(ITH

    of the knife blade, see ~'ig. 4.

    Then make two or three mol'(>>;coring

    cuts to

    a

    depth approximately equal

    to

    the

    thickness of the inl;ly. These

    cuts define

    the outline of the inlay in the surface of the

    wood .

    Now

    r emove the inlay, and 1 < ,,, 1up

    the seetion or white paper . e. rig. 5.

    \\'hat remains should be an exact pattern

    of the inlay.

    ROUTING THE RECESS

    The contrast between the white paper and

    the woodmake.' it a whole lot easier to see

    the shape of the recess. Now all that re

    mains is to rout out this recess.

    Although it may sound like

    u.ing.

    2x'lto

    swat a fly. I use a router to make the

    recess,

    The router

    keeps

    the

    bottom of

    the

    inlay flat, smooth. and at a consistent

    depth. And it turned out to be a whole lot

    easier to

    control and maneuver than

    thought it would be.

    TF. rRL:

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    9

    (jlt~f (II,d r(,rl 11 tl lltlay ill pfarr

    T ,

    lighlly ,,,i.I ...

    1 I/Ir /I(I/I< r O O r l > :

    1119111111e tly . '11/) III,. / 1 1 o ff. P i a /

    Iy.

    Ro d

    I}I, IIIlflU

    j7 .h willt swflJcc.

    UGHny MOtf;(N

    tApt

    auotl SC ~G

    SCIAl Eet

    ~:: ::::~

    Of ,..O IC VI VINI~

    6

    I

    Xf (,

    1 f JJ 't lt t 1 1 , 1 (: ( ' 1 t t

    t (~I,( e,I~

    (IflflUflf '(1 tll.. /t r,,,,,tf Il,; tfelJllt

    Qt (,ftt

    .(c IItt

    rolll r lilt. Sri d.p I/ I 1 0 a lillie

    /1I fr

    ,,(1(( 11,('tlt,rk ('l(A

    IJ/ ,

    f llllI

    3

    Iar ItI,rv'lI (ItllltRilff1 or (I tlti roof nl

    Ilf.b,,.

    (4

    lt ,t lu 'fl 'f'

    a pir(,f ( J j

    ((I/,~'/f'

    I H J / 'H ' r ' I t lu .

    1f f,rJ.-I ; t t . TI,t I

    d r Y '

    f'Tfkf(1f /1 ,,11 1,I ,r IC 1( , ( , ( ,,11 t I,e i lulI_

    WIIln_.

    AfTAOtlO w n H

    '' ' AOH(SIVI

    \\lOOl)SMIlII

    9

    8

    r'~f'It, Xar/fJ knife to

    tnl1(

    (llfOY tIlt

    .11I rr II f

    '''lit( 1..1

    a ft.r ro ltli D

    l lId l lIl

    lI.t

    ,'(/gl' o f

    IItr ......

    slightll/,

    a nd

    trill

    rdg. o f ;11/1).1/10

    gft

    a good [iI..

    5

    R (ll't. Iht .,,11,,( a d petl P tIff

    PlI/. 1'hl' IIIII/illl 0) 111< wili/~/I(I r

    . / 1011111

    ill, 1111

    0 '( 1( ( IllIp li d)i f' o f Ih t

    ;lIlu ,( fh al s r( t. I( Y 1 (11 1( ,( ,I J ( ll ,I,tillg.

    2

    SW i/cil toan Xort

    kI/ift

    10 trim

    fflht

    re. 01 II,. protect; . .lIefer. Tlrell

    .a lld Ih rd gl 1 1/1 11 1lU//(I'1I 011 .Ulldlll9

    block In /1

    t

    II rdll' .U~.aslowerrl~;n~

    glue

    (lik,' Tit.,bt,,,,1 or w hite Il lue) was easier to

    work with

    AI,ply

    a lIhl coal of g lu e on the back of

    Ihe inlay and I ,olher en Ihe

    bottom

    uf

    the

    r(. (, ~M :-..J\ \ (11'>' light coat is all that'~

    n... INI. If Ihl'rl s to o much glue, the ex

    eess won't

    h Vi

    ony place 10

    Ilo

    when

    th o

    inla)' i ,

    clnmpl>d.

    and il

    may bu ckle -

    ruini 1 'n

    10 1

    fI( 'ork.

    C ~ fully

    pIal'

    lb, inlay

    in the '' ' ' are not the

    same the tapered area below the morti se

    is exactly the

    same

    on alit w elve legs.)

    TRI~I1 0

    LE:'(CTII

    Af'U>rthe tapers are

    CUt, tho la.l step on the 1 _ 1 t l ; to trim v

    ofTLhe tapered end. of the legs on the

    smallest two tables, Note: to produce a

    square end. be sure to keep the two

    straight edge.- of the leg. 011 I}/, labl and

    O ln.; t~ t

    tht

    lli t r g ll t \\ hilf removing

    the v : excess length.

    TH E APRONS

    I\'hen the le~ are complete. the next step

    is to cut the aprons for all three table s,

    Only the smallest of the three tables has

    the typital arrangemem off~ur aprons: the

    largest two tables have only three aprons.

    see

    Fig. 4.

    T

    started

    b y

    ripping enough material for

    al l

    10

    aprons

    to width. and $lighd~' longer

    vent accidently drilling angled mortises

    because of a tilting leg.

    Before the mortises are CUt,lay OUtall

    four legs for each table and label their

    position (for instance, lett front leg). and

    their orientation (front face). Then mark

    the location ofthe mortises on each leg, see

    f'ig. 1. Be SUrethatollty the smallest table

    is marked (or mortises / x o t U e e n the

    /rolll

    legt; for a front apron.

    I used the drill press to drill ~-wide slot

    mortises VII- deep centered exactly on

    the width of the I

    \I.

    thick legs.

    (SWoodJ Imi t i l

    No. 26 for a detailed descrip

    tion on how to cur a slot moruse.) Note: On

    the legs which are mortised on two sides.

    the mortises intersect to form an L-shape.

    see mortise details in

    Pig. 1.

    THt : TAI ER. ft r th mortises are

    drilled, the next step is to taper the two

    insid faces ofall twelve legs, This can be.

    very tricky process because the bases of

    lhe legs are only v wide. PUtting the jig

    (and my hand) vers dose to the saw blade.

    The tape,ingjig isset up so that it starts

    cutting the taper 16 from the bottom of

    T R IN O N

    Deciding to make a set of nestled tables

    with inlaid tops w as easy.

    The

    hardest part

    ofthis project

    W

    trying toname it. There

    was an on-going debate around the s ho p ..s

    to which name was the mOSLppropriate

    nestled tables, nested tables. or slacked

    tables.

    But the debate was seuled as soon as I

    started to build the tables'. Normally

    three progressively smaller end table. are

    just stacked on top of each other (stacked

    tables). Rut Lh. set builL is diff&ent.

    Rather than just stacking the tables on tOP

    of each other. each of the tables is

    nestled into the next larger one by

    means

    of

    a drawer-like sliding system.

    At first glance the construction of these

    tables

    appears

    to

    be rather simple.

    ow-

    ever. they have Lh~ir own unique set of

    problems. f'iT:'t of all the largesL tWO

    tables don't have a front apron. Elimi

    nating the front apron serves LWOpur

    poses:

    ~ lhttirs

    the

    tljfferen~

    between

    the size of each table can be kept to a

    minimum; andl/II eli . the tables can be

    nestted with a simple .liding system.

    But I'm ~tting ahead of myj;l l f. The

    first step is to cut the legs.

    THE LEG S

    The legs for all three table. are the same

    except for their length. They're all I y .

    square pieces ofstock CIused walnut) with

    a gentle taper cut on the tWOinside faces,

    see Fig. 2. The laller creates

    delicate

    appearanee. while allowing the heavier.

    full-thickness stock to be used where it's

    needed most - for additional strength

    around the mortises at the lop of eaeh leg.

    tt T TO SIZE. The first Step is to rip

    enough 6 4 I ,,; thick) stock to produce

    all

    twelve I \I.'xl

    I .

    square legs. Then the

    four lell on the large;t table (A) are CUL

    20 11 . long.

    However, because of the drawer-like

    sliding system used to nestle't the tables.

    the le~ on both of the /lI smaller tables

    (B and

    Cl

    clear the floorby

    v .

    But rather

    Lhancut them to their exaet length at this

    stage. they're cut ~.. longer than their

    final length ... ' if they extend to the 000 .

    This way their

    tapers

    can be cut toexactly

    duplicate Lhe tapers on the legs of the

    largest table.

    With the additional

    vo .

    the leJlJ(thof the

    le~'Son the smallest table are lSI\:' long,

    and for the middle sized table, l HSolong.

    THE ~IORTL~ES.After the leg blank are

    cut to length. they need to be both mol

    t ised

    and tapered. I decided tocut all ofthe

    mortise. before tapering the le~ to pre

    esded Tables

  • 7/24/2019 Woodsmith - 028

    13/24

    WOODSMITli

    13

    (han needed, see Fig. 3. AGUlf'

    MO mS( LAYOUT FOR

    The next step isto cut the aprons exaclly

    Non AUUGSA.E 1 , SCUAl

    TWOLAIGISt lUllS

    -r

    A ll MORT IS S Alt WlOE X . .. ... Oftr

    L f f i

    @ ]

    o the lengths shown in Fig. 3, (these mea-

    surements include the length of the tenons t

    AU M01mSES AI (fHTREP ON S1'O

    on both ends of the aprons).

    i,-t

    ESONS. Once the aprons are cut to

    t

    lAC)( ues

    lengtll, set up the table saw to cut , -,,Iong

    I

    fRON t LEGS

    tenons to fil the mortil'es in the lev. The

    L

    [9 J

    , E Q ]

    inalshoulder\o-;;houldcr measurement of

    3 ,

    I

    J

    I.~

    lhe aprons, shown in rig. 3, is extremely

    r

    critical - it must be correct in order to

    P o

    MOmSE LAYOUt

    rot

    ......usr ......

    have equal spacing bel ween the legs onthe

    .

    ~

    ]

    hree tables. Accuracy (or the lack of ill in

    ,

    ,

    .

    ,

    these measurements ill alsodetermine if,

    a

    0

    -

    -

    L . . . . . . . . , _ 1 : i J

    nd hew much, cu.

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    WOODSMITH

    4

    ~

    FIGURE.

    : ~

    THf SLIDING SYSTEM

    1AIG.TA8U

    The heart of this drawer-type sliding' sys-

    r

    ~ . :

    I---

    tern is a stepped groove cut in the side

    . . .~~

    -

    aprons of the

    tw o

    iargertables, see Fig. 7.

    b

    \Vhen the tables are nestled , the molded

    . -

    mitered. To determine the length of all

    (

    four frame members (Jand l() tor the larg-

    ,

    EXT SlAAllU

    est table, simply add l (for a

    Y:

    overhang

    FlONtfBACJt

    on all four edges) to the distance between

    I

    FlAM 'QUAlS ~

    :

    DiStANCE. '

    the outside edges of the table legs.

    To determine the length of the frontJ

    back frame members (L and N)on the two

    smallest tables, measure the distance be-

    tween the deepest point of the grooves in

    the side frames on the next larger table,

  • 7/24/2019 Woodsmith - 028

    15/24

    MATERIALS LIST CUTTING DIAGRAM

    A t9 Leg' 4)

    J / x 1/ ... 20/.

    IV, 5'

    . .

    8

    Md ....11. 4)

    1I

    x

    1'/ ... ltV.

    t

    Ii

    -

    Sm Leg. (4)

    tV.

    x tv. ..

    18/.

    il

    D

    L9 lode Apro. (I) V J 30/... 20

    Ill, 7

    E t9 Sid.

    Apro.,

    (21

    '0/,.

    )C 3V

    3

    b

    l

    J

    .~

    Mod lock Apr. (I)

    t~

    x

    27/ 17:Y,.

    J

    I

    G Med Sid. Aprons

    '',.

    x 2 7 / . . . lV,.

    H

    Sm ,rt/lk Aprons: (2)

    y,.

    x 2 .. 140/.

    I 5m Sid. Ap .... (2)

    ,. x

    2 .. 101

    ~

    t

    J

    La ,,../lk From ... (2) 1, . xlV ... 22

    t\

    lth

    I

    t.a Side Fromes (2) I .x

    l/ 1S

    I ~

    I

    I

    ~

    l M.ct rt/lkames(2 ) lt / .. 190/,.

    1

    M Med Sid. frames (2)

    '0/,.

    x 1h 13/,.

    N Sm'rtfDk frame (2) y,. x 1h - 16~

    SmSid.tl'roftMS (2)

    '0/,.

    x 1/7 - 12'/.

    A

    P

    FIII.r Strip .)

    cut

    to fit

    Q

    til Po.ol 11

    .y..

    j

    13.20

    R Mod Po.ol II

    .y..

    j /

    170/',.

    S

    0

    S

    Sm Pone' (1) -V.. 10/ . - 14.

    T loy Strips (5 )

    36 Ie:ngtht,

    5

    un

    snIP

    cooss

    -~ STlA IGHl

    UAVE:

    t.;...

    SHQUlDEl

    r

    fO AN D BOTTOM

    KNeE

    ~ .

    fENe

    wtolH Of INlAY

    -S Ttl , PW S LlNGTH

    OFrONCU

    cur

    fONGUt

    to

    F IT GROOVE

    \.OISlAlola fOUALS

    lNSlOE DlMENSI()N

    Of fUME pt us I'

    DIS tANCE EQUALS

    tNSiOf D6MlN IOH

    Of fUME US 1

    INlAY lAaatf

    C R O SS SEC T lO N

    UlE 1

    WOOD SMlTH

    and subtract Yo. .see Fig. 13.

    To determine the length of the si

    frame members on the two smaller tables

    1Mand 0), measure the distance from the

    ill3ide face of the baek apron. to th mnt

    face of the front leg and add an additional

    fQr the front overhang.

    PLYWOODPANf:I .

    After the miters on all

    three table tops are cut. measure the

    inside dimensions on all three frames. To

    find the size for the

    1 ,

    -thick plywood

    panel, add I to both dimensions for the

    Y, .longtongues, see Fig.

    15

    'fbi, is one

    place where accuracy is a must. Any error

    in the size of the plywood insert will make

    it impossible to aceurately rout a rabbet for

    the inlay banding later on.

    PLYWOOD TONGI'E Next, cut the

    tongues onthe edges ofthe plywood panc1R

    to fil the grooves in the frame members.

    see cross section inFig. 15,and Fig. 16.Be

    sure the shoulder-to-shoulder measure

    ment on the I)lywood matches the inside

    dimensions of the mitered frame.

    Note: When cutting the longue, make

    several duplicate. to use when setling up

    for the inlay banding.

    INI..AY B,, OINC. \\'hen tbe tongues are

    CUt

    on the plywood panels, the next step is

    to rabbet the face veneer on the plywood

    for the inlay banding, see Fig. 17.

    The depth of lhe router bit for the rab

    beting cut is set so that it's slightly /_

    than the thickness of the inlay banding.

    Then the fence i~ set

    to

    cut the groove in

    the face veneer eX:lollythe same idtJ as

    the inlay, see Fig. 17.

    Before euuing this rabbet, I routed a

    te..t rabbet on a duplicate piece cut earlier.

    Then (hi. piece i. slipped into a frame

    member. and the actual fit of tbe inlay

    banding is checked. Then the frame mem

    bers and the plywood panels are ) Iued

    together.

    To inlay the banding smps. I simply

    mitered the corners, and glued them in

    place, see Fig. 18. Then finally, all three

    tops can be finished sanded.

    MOLI)INC THE f:I)CE. The la5tstepbefo e

    the tops are attached to the base assembly

    is to rout the lable top edges using a ..,

    rounding over bit on the router table.

    Starting 1th the smallest table, rout the

    edge profile until it fil into the groove in

    the next larger table base, see

    }';g.

    2

    (If

    the top istoo wide to fit the groove. use the

    table saw

    to

    reduce the width in

    1/.

    inere-

    ments.) Repeat this process on the middle

    table, and the largest table.

    When the outside edges arc molded,

    glue the table tops to the base assemblies

    so they're centered on the width and over

    hang the front edge of the base by \I t

    (This will ensure that the front of the legs

    all line up when the tables are nestled.)

    Finally I finished the tables with three

    coatsof1~lb.eut shellac. and two coats or

    furniture paste wax.

  • 7/24/2019 Woodsmith - 028

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    ~IOODS~nTII

    6

    outer

    with

    a

    trammel

    point attachment

    STARrt:R HOL~S Before routing the

    curved sides. drill holes for starting the

    cuts. The fh e wedge-shaped com

    partments each

    receive

    two starter holes.

    one adjar:ent 10 the

    eutslde

    wall. and

    an-

    other next tothe outside edge ofthe center

    compartment Wall, see ~ ig. ~. Also drill

    one starter hole nest to the inside edge of

    the center compartment wall.

    A ll o

    these

    holes should be drilled so their edges just

    touch the inside of t.he line.

    TA(;K 1lO1\STEMPLATE.

    AiWr the

    starter

    holes are drilled. attach the template to a

    piece of plywood to keep it steady while

    routing out the

    compartments. (The

    ply

    wood should be large enough so it ca n be

    clamped to a work surface without the

    clamps getting in the way of the router.)

    When taCking the template 10 the base,

    drive a brad in

    each corner ofthe template.

    Drive at leasl two brads in the off-set

    center circle to keep it (and the router and

    trammel point attached to this piece) in

    place as it s cut free

    by

    the router.

    ROllTISG.

    After the template is secured

    to the plywood base, position the trammel

    point on poinL

    A (the

    center of the large

    circle). Then adjust the length of the

    trammel attachment so the ,,,, Sib edge of

    the bit cuts exactly on the marked

    line

    or

    the outside circle. (I used a carbide bit.

    set deep enough to cut romplelel, through

    the Masonite template in one p8S1 .)

    As the compartments are routed, be

    triangle to determine the angle (or

    these lines.

    TlII,KEN LJSES_

    After lhe center lines

    for tbe walls are marked, thicken each wall

    by drawing two more lines y to each side

    of the center line (making each wall

    v

    wide), see detall in Fig, 3. Note that all of

    these lines start at the outside circle and

    stop where they intersect the largest of the

    two ofr-set circles, see Fig. 3.

    CUnlNG OUT THE PAnERN

    After the pattern is marked on the Mason

    ite. the next step

    i

    o cut the template to

    shape. To cut the curved edges as smooth

    and accurate as possible, l decided to use II

    hen

    was inthe middle ofrouting out the

    wooden snack

    t r a v s

    it

    O O U I T e d

    to

    me

    t.hal.

    thi

    i. the first project toappear in oo -

    sm t

    that can be made entirely with a

    router. Every step in the precess - from

    routing the

    insides

    of the tray com

    partments, to cutting the

    tra y in to

    a

    circle,

    to routing the

    rove

    molding on the outside

    edge afthe tray - isdone with the router.

    Granted. some other shop tools arc

    needed to gel set up, but OnOOhe project

    blank

    is

    ready, the only tool these lrn) s

    require from start, to finish ; 8 router.

    MAKING THE TEMPLATE

    But before I could start

    routing

    the

    trays,

    I

    ha d

    to first construct a template. (Istarted

    with a lao x 13 square piece of

    v

    tern

    pered

    Masonite (or

    the

    template).

    The overall design for the template is

    based on a small circle that s inset, and

    off-centered in large circle. To achieve the

    wedge shaped compartments, I added five

    dividing wall. between the two

    c ir cl es . s ee

    Fig.

    3.

    I..ocATECE~TERS.

    The eenter

    orthe large outside circle (point

    A ) is located by drawing two

    diagonal lines connecting the

    comers of the square, (The

    center point is where these di

    agonal line.

    interseer.)

    The

    center of the

    smaller, off-set

    circle (point S ) is located on

    one of the diagonal lines.

    V

    rom point

    w A

    see

    ~i)t. 1 .

    IIRAW CI RCt MPERENl ES.

    After the center points are

    marked , I used a com pass to

    draw itotal of th,w circle .

    se e

    ~ ig. 2. The largest

    circle

    (which represents the inside

    edge of the outside walll uses

    point A as its center, and has

    a

    rodiu.8

    :; Y , . ..

    The IWO small inset circles represent the

    inside and outside edges ofthe center rom

    partrnent

    walls.

    and

    both use point

    B as

    their center. For the outside todge of the

    center

    ccmpartment

    till. I drew

    n

    eirele

    with a radius of

    2V.

    and for the inside

    edge. a circle with a 2radius. see Fig. 2.

    >lI ,DER WALt..~.

    Next, draw

    lines

    to

    separate the large circle into five wedge

    shaped compartments,

    AU

    five lines start

    at point

    S

    and use the line on which

    points A and B lie as n reference.

    Two divider walls are angled~5p from

    point B . two are angled 6 down f, Om

    point B and the fifth wall

    i~

    ight on the

    line, see F ig. 3. Use a protractor, or

    Routed Snack

    Tray__

    VEG ETAB LES IN TH E R OUN D

  • 7/24/2019 Woodsmith - 028

    17/24

    SA.ltt SAW

    MOUNTEOUNOI I . a

    MOUNt IIM -ATI

    TO SetA P L fWOOD

    HGUttE

    17

    'l i lac ClNTl to

    PlYWOOD lASt

    lOUt

    TO

    W,All UNES

    ItOuTOUTCINt.1t (0 , COM1UTtlY

    fIGUI

    AGUI, ..

    \ U l

    \\OO OS~UTH

    Be(Ol(u nl( the lemplate anchor it toa

    h

    plywood

    base to hold the walls steady as

    tbe pin hits them while rouling.

    sure to tak(a

    it

    , .10\\ and cas) as l OU ap

    proach the lineo for Ih, di,;de r wall

    s It ,

    better ltl

    101 .hurt of

    tbese hnes

    than 10

    take the chance of euuina inlo them.

    After Ih~ curved line, of the outside

    eirel

    e

    ar e

    :121.

    ~iIt< ethe

    sabre saw

    blade

    lta\. . , .

    a

    fau-Iy

    ragged edge. it .b e s t

    to

    cut clc(,. bul not quue touching the

    l ine T he n R Ic an cl , ; and the edges of each

    eempartment a~ smooth Q : possible ..

    HOLDER fOR WORKPIECE

    I

    1

  • 7/24/2019 Woodsmith - 028

    18/24

    \VOOOS~{JTH

    8

    ~('l

    lhl

    lr'Rmml'~ JattKchment on

    the

    roult'r

    tl) ..

    ut

    ::l

    ti ...

    radiu:-. ((or a

    12~

    diam,trr) ~lak.. ~ veral ide> of th e

    base, fonnml: a ho IC , 'r box to hold the

    , orkl'M tt. in plate.

    '4 'f

    ig......

    Kline r HI ,,~ \o the project

    hlank.seant~made b) l-dl(e -glumg tnoul(h

    stock

    t

    (c.nn

    3

    ~luare 13V,-x 131: Plant-

    and foanct but h ~ ur fa ('e l'O t

    or this

    blank

    month, anti trun It to fit in tho holder box.

    (T o huld the h lA nk in p la et', drive small

    brads at th,' corners orth~box, see Fig. 8.)

    ROUflNG TH[ TRAY COMPARTMENTS

    It tnok -.;(.m('head-scratching before I

    came UJ l , . .ith t h4 nt:ht combination of bi b

    and pm. to achit,,,,, the curved-wall effect I

    \\ : 1 Jo,}kln,: :

    rllr.

    I w anted each

    tom

    partment tn ha, .. a nat bottom which

    I Iltl)

    u'Ili :hLb it \\ith a I pin

    to ro u t

    lh,

    n:lt I ) lt(l,m ~ in ea ch co m

    partrm-nt,

    10,',)

    J.l~

    t o

    Adjust

    th., 'trai~ht b it

    so

    it rot>- about

    ,. (J''''11fin lh,~ f i f ' \ ; t pa.......Then tum on the

    r, lt{ r,

    I ) t

    JU$.' ethe ,,'nttOr of O~ of the

    ( 't mp : l r tmt ' l t . . ., 11, \\ t n the bit. and mD\'e

    lh(. lUll nl~

    tntel

    llOI-,tlllll. see

    t ig . '.

    He)'

    CCl. RT\' . f ;. To

    rout a eom

    partn'H nt, 1110\( tttt l,:ml,late so the pin

    i~

    a}..~ru.t a \\ 1 1 .nc l t t . ._n( lllI'\ a c ounte r

    cluck . . . .. I 'th ll ro u nd t he I , r il 11 ro tmrkt l

    \ urnrr .It

    th,

    nl'ltum o f t.-a ch ~um

    I l& rtm t 'rll .. It\.'h to a :- cun: b ox bit

    ('1

    , f lhl t . . . .l ,lh.1 -.d 1.;,tn1( lt>rin. ~ i-'jllr~

    111~Itttl, tll'l\lh (Ifcut C O th(' hit i....'eo:4l)

    of

    tho

    bottom al.1 .nak.' a ..... around the

    1)1,'h. tt'r Iii (>'2(hroml~nm('nt .

    11ll'1I111< ....~... the

  • 7/24/2019 Woodsmith - 028

    19/24

    19

    m ac him -s is thalthey allow e xt r (m . I~ f in e

    diamond wheels to

    be

    tf$(~I.They can \1:;(>

    wheels up to (,()O wit without ovcrhe~lIing

    a liJ,l because the precision tolerances of

    the machines arc (Ihigh that lhey actually

    super-hone lh~ tips rather than simply

    grind them. These machines 01,0 use n

    flood of coolant during the grinding pro

    cess to h~ll) pn ent overheating.

    Note: Raw blades that have an uI\1 3-

    shall) edge produced at the factory using

    an

    :lutQlnali('

    machine must

    be

    resharp

    ened on an automatic machine to J 'e.}11'1.

    duce Ihe original edge.

    One Iairlv 8CCU1 ;lle wav tc determine ifu

    shop can s-harpen H blaile correctly i. to

    check a ef.'{ing a

    sample of

    1 I

    shop's work. ther e .. , several

    thing,; to look (01'. Fir>l. exit mine Ih( fU1; h

    on the ca rbide tips. I f a ve ry lin. cliamolld

    wheel as used. the finish should be shiny

    (almost mirror-likej and very smooth, If

    coarse grindillg marks are visible, n fairly

    coarse diamond wheel

    w a s us ed ,

    and

    mos t

    likely the edge produced cannot compare

    with the original factory finish.

    Another imp01'tanl

    pee t

    is

    cons i s t ency

    from one

    tooth

    to

    thp

    n...xt.

    HO\\tp\Pf

    using the naked

    C) C

    to

    detect

    anJI

    ineon..

    sistency in the shape of the profile

    rron1

    tooth to tooth i~almost in1IKl '.eratoJ' 'enOr .

    But the real beauty of these automatic

    the amount il

    c o ns um e d s ix

    months a~o.

    So

    thenext best determining factoris a ph)~i4

    cal inspection of the cutting edge of the

    carbide tips,

    Using your own sense of touch is a Jl CL

    ty

    good

    guide.

    the Lip doesn't haveI ~

    l fl

    of

    a

    sharp cutting

    edge .

    it probably

    needs resharpening.

    Another way to determine

    dullness

    i to

    hold the blade near 0

    strong

    light. light

    reflectS Qffthe CUllingedge. it's dull. Con

    versely, sharp edj(e reflects no light.

    SHARPENIN G

    'hen

    it

    comes

    to

    sharpening, there's

    ol1l~1

    one substance hard enough to abraid tung

    sten carbide tips - industrial d i amond

    w h ee ls , B ut

    just using the right material

    10

    sharpen a carbide-tipped blade doesn't

    mean that it \ \111be sharpened eerreet ly.

    In e last issue of II lXXllfll ilil (Nu. 27)

    there was an ex tens ive article on carbide

    tipped

    saw

    blades - how they dilTel' from

    steel blades, how to choose them. and how

    well they work. In that article. we lried to

    talk about mast of the aspects concerning

    saw

    blades,

    excep t

    one: the problems

    asso

    elated with sharpening' a carbide-tipped

    blade.

    Every blade (even the highest quality

    blade) will eventually lose it> store-bought

    edge. This is when it pays lO know the

    tricks to determine when. where, and

    how

    a carbide-tipped blade is sharpened.

    The

    Ii, . l step in this process

    is

    deter

    mining

    / ~II

    O sharpen a carbide-tipped

    blade. Timing is critical. 'I'he lonj(er sharp

    ening is postponed, the harder il is to re

    produce. sharp edge.

    \Vniting tOOlong before s ha rpe nin g'

    carbide-lipped blade usually

    requires

    having to remove more carbide lhan nor

    m al 10 produce a sharp edge , This ;. a

    resu lt of the lips rounding over - exces

    sively on a very dull blade - as they b e

    come dull. The duller the blade. the

    rounder the edge - which means greater

    amount of enrbide has to be removed to

    resharpen the tips.

    On

    blade that is sharpened when

    needed. the amount of carbide removed

    ....n be little as ,005 . BUIif the blade is

    allowed to become overly dull, the amount

    oi material removed can easily be twice

    that much.

    \\'IlENTO RESlIARVEN. Oka) .sharpening

    as soon as

    it's needed

    is a

    good idea. But

    howcan you tell when the blade needs to be

    resharpened?

    n of the

    eas ies t

    ways is to

    recognize

    th e

    culling characteristics

    o f a

    dull

    bl ad e .

    The most common eharaeterlsrlc io that n

    dul l blade tak~s more power to mAkea CUI

    than a sharp blade. Thi. increased power

    requirement usually is detectable when

    Ihe motor bel(ins to

    bo g

    down. or if you

    have to apply more pushing pre>' 'UI'ethan

    normal while making

    a

    CUt

    tbat

    previously

    created nl) problems.

    (Some larj(e industrial users attach an

    amp meter to their equipment

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    \V O O O S M I T H

    0

    E D IT O R S N O TE . L as t s prin g Carl

    Dyk

    man(awoodworkingteacher at a schoolfor

    deaf and ha r d of hearing children in San

    Antonio. Texas)

    se n t

    us

    a

    lip for

    a

    pill

    routingjigthal he a d d e d tothe V t K d t l l l i t ll

    TOutertable. He built (his n ew addition to

    the router table so

    his

    students couldbuild

    and sell COllie.of projects.

    Carl's lip stmed something. After we

    spent several hours di s cus s i ng the theory

    of pin routing.

    we

    cameup with two proj

    etta (shown in this issue) La t.,,;t the prac

    tical side of this technique . _ . an d lOtry

    out the jig that makes it aUhappen.

    PIN ROUTINGTHEORY

    Pin routing is unique routing technique

    that's used whenyou want to make several

    identicalcopiesof a specificpattern. What

    makes pin routing different from other

    types ofrouling isthat itrequires a special

    mechanicalset-up.

    FlIEEHA)lDOL'11NG.Whenyou're

    rout-

    ing freehand, the router moves Oyer the for lessthanSS, Allyouhave 10doisattach sized to fit on the topof the route)' table's

    workpiece, To help control the router's a movable arm to hold the pin. fence - 16 long and equal to the

    width

    of

    path, il movement is limited in one of Besides being inexpensive (almost the fence (21'veryinexpensive tomake. triangular support C B I and lhe pin support THEPIN SUPPORTARM

    Instead of Silendingseveral hundred 1,101-arm (C). To start construction. cut the Next. the pinsupport arm (C)can becut

    lars fora pinrouter, the Wood l/lill, router fixed plate froma pieceof )', plywood. size and attached to the triangular sup

    table can be transformed imo a pin router THE fLXEDPLATF..he fixed plate (A)is port. Themaximumsize ofp''Ojeet that can

    A N A T T A C H M E N T F O R T H E R O U T E R T A B L E

    in

    out r

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    21

    ite for the templates used to make the two

    projeds shown in this issue, It's ea..y to

    work with. and holds up line if relatively

    Iew

    projects are routed. However, Plexi

    gIll

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    \\'OOOSMITH

    (Once

    the

    set-up

    pin i< centered. any

    other pin tbat's placed in the UI~rbIt.)

    A,

    Ih~piniJcentered onthe collel, mak~

    .utethe.upportatm (el r,.exa.::lyparalJo.I

    to the rouler t_ble.

    (~lea.Ul e

    the heIghtof

    th,' ,ul'Phrt arm at the f.nee and out It the

    end uf lht' ann. Th~

    (\\ 0

    me.afoun:m~nt

    .hould he ('qual.) \Vben Ihl>l'. al l you need

    i.

    holdirtjZil for th~ dl),,~I,

    1:

    F,it. 7.

    1'bi.

    jilt COll>;.b (,f top tackt'd 10a plywood

    ba. I .Then Ih,' b

    i

    clamped ,;0 the

    ~top is perptndicuhlr

    10

    th(,,' blad.

    Tomake tho rounclt,non (pinl. hold the

    dowel against th. ~loI Then lUlll on the

    .aw and Jmldunllyrn, ' th. blade until it

    cut, into Ih. dOlld about ~.' (A rip blade

    \\ork. b c : t > t fo r thi ...\'ut ) S lo w l\' ro tate th~

    d O 'el to

    tun1

    tht ,lutm (er

    ~(the OO,,;eJ

    t o the sizt.. 0 0 n ( ' ( 'W I .

    > ,

    the do d 1-helll~ .Iatt'd. p h it

    b.-u:kand forth Ih, pin i cut to a leo ,'ttt

    of ahout 'to . ITh... I 'lj 'lh

    ,,;U

    keep the

    '('Clionflhe

    work

    piece lhat ill he trimmed off later.

    MAKING lHE GUIDE P'NS

    The onlything leftto make isthe guide pin

    - which is

    the k(') to the whole

    technique '

    n(pin rooting. The heauty o(pin routing;,.

    Ih.. ability to combIne dlfTerent $Ues

    of

    pins

    and

    router blt~

    10

    achlc'

    e

    enctly

    the

    effect you want.. But W i ll means thar you

    may have to Chan~l' l h < . pin ri~l in the

    middle of the n.utinjCoperation. And that

    presents problem.

    ln order tohave Ih('abilily to change the

    guidepin, it

    must

    workoffthe

    same

    center

    poiru as the router bit. 1'hi. ay . when one

    size pin i filed. get them ..... moeth a.

    pos si b le - 'UI)'irregularities

    will

    be Il'llns

    f rrNI t< l the wo rkp ie c e.

    T. cheek the smoothne . .. of the tom

    p la it . p la ce it on a pieceof pal,..r and truN'

    the outline ith a ;;harp pencil. It', a Int

    e ,,, r

    10_

    bad spo:s on we tra,'('t out

    lin, th,onon the ttmplate it>elf

    Tt.

    \I'

    ,n:

    8.\$.

    \\ 'hen the lemplale i,

    f1ltocl

    '111IM,th .

    glue it t o a P It'< ' ( o f l~ ' ''o od

    antI uhk,mall brads along.n)thin diVIder

    atnIl-.

    Th ,

    , , ;11

    gi\'e the .. h I, lernplale

    m')I'('.uJlll(lrt > lO it doe..n't bend during the

    r ou ti ng o pc ) R li on.

    IIOf.' Nt; U(lX. If the temillate IVrl'('he

    inJl

    1....

    '(1to cut one cop),'of th(~

    f):tlt('m,

    It'lUldhe nAHt'dOrt Cl'ewed dlrt tly 1 4 > th.

    workpi

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    23

    OODSM1TH

    Spalled is

    a

    tenn used to describe

    wood

    in

    the process of decay, characterized by

    dark

    brown or black stain lines running

    randomly throughout the wood. Bruce

    Hoadley calls these lines zon. lin in hi.

    book Understanding \\100l

    3lats. I f[ue.8 ti(J ,~h I ,it(I,}II, 0.(dt1i11ghis .

    Wh.ol tID

    I

    III1Hk. i II,.. 0 good idtfl

    [ don't know or any apillicatloll$ in n

    bome shop that tan juatify the c o t of a

    plunge router (S200-300). In fact, most

    applications can

    be

    duplicated .Ither u.ln)

    a standard

    (and

    less expensive) rnuwr. or

    other common shop

    tools.

    Plunge routers differ from the common

    stationary routers in twoways, The most

    important difference is that on

    8

    plunge

    router the router bit can be lowered

    (plunged) straight down into the work

    piece while the router is operating simply

    by exerting downward pressure on the

    handles. In order to. do tbis. the router

    motor (and the bit) are mounted on spring

    loaded guide bars . Once the plunge CUt

    ;

    m ade

    lhe motor (andbit) canbe locked to

    a

    pre-set depth of cut and routing would

    co n tin ue a s u su al.

    The other major difference between the

    two

    styles

    of

    routers is

    the

    size

    of thr

    motor they use. Rather than using . to

    1~ horsepower motors found on most

    standard

    routers, plunge router.

    are

    equipped with motors in the 2 to 3 ho rs e-

    power range to handle the long term use

    associated with industrial applications.

    L Il n'1 I G=e

    Rl 'nels. IQwa

    PLUNGE ROUTERS

    I m ready to purchase

    a

    roIlier to liMOll

    myjl

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    store, bot if you can't find them , you can

    buy th em fro m:

    1r00001'uj Supply ( pII

    ~

    \tia~~tir}\I ( tl't

    I l'nm tn> . .l1.11111JJiH

    1'e/epholle. ' 1-8(I(},uJ /1.>.1

    By

    ordering part num ber 12K51 F 'T ,

    you 'l l ge t

    a package

    or 5

    inserts

    which

    are

    ' 1 :

    long. require

    n

    p ilo t h ole . a nd

    accept

    a 114-20 t hr ea de d bol t. P ri ce I... r 25 L 1.10for the j a l lo ll. ..

    MARQUETRY

    If you'd like 10 know

    more

    about

    mill

    quetry - how the decorative inserts and

    banding strips aloe made, and som e o f the

    history of the tetbnique - se veral b ack

    i ssue s o f

    Fine

    Il'fiQI/ ,,,kill l ma .'l\zin~are

    wo rt h pu rc ha si ng .

    Issues 1. 2 . 16 and 2i c on ta in in fe r

    marion about marquetry, Back issues of

    Pi ,., IV ,xl .. ,rking

    are av ailable ($3.0 0

    each) fro m T he T aunton P ress. 52 C hurch

    Hill Road, B ox 3 55. Newton, (1

    064iO.

    SPRAY ADHESIVES

    W he nev er w e h av e to t empora ri ly l l ue a

    piece of paper (for instance, the routed

    tr y'~ tem plate I,.llern o r th e pattel'll ful'

    th e m a rq ue ll'Y in la yllo s ome th in g, w e u sc

    Scotch brand Spray llounl A rtist's A d

    h es iv e (C at. N o

    6(65),

    The a dh es iv e c omes

    in

    al l

    aerosol can, i. easll)' ap plied, and is

    n ot s o s tick y th at th e p ap er c an 't b e p ick ed

    up and reposi ti oned. Spray t\10Ullt i s 3 \ 'a i1

    4

    able at most rtisl ~;,uJ)plystores.

    A s im ila r p l'O Ilu ct. P ho to Moun t, i$ u se d

    LO

    sl>l'ay-m oun t photog raphs in alb um s,

    an~ it's a ailable at p hotography .tor .

    THREADEDINSERTS

    T he th readed ( ro san ) in,ert< used in lhe

    ( 'OJlsl.t1Jctionof the pin router jig in this

    i..u e m ay be a aila ble a t a lo ca l h ardw ar e

    tells u s th ey 'v e ev en g ot th eir o wn m ailin g

    address: PO B ox 789. Porterville, Cal

    ifornia

    9 : l 2 5 8 - 0 7 l ,Q .

    INLAYS

    M arq ue try in lay . fo r p ro je cts in th is iss ue

    are

    available

    frorn

    several

    sources

    B e

    cause there are so m any

    d e sig n s a n d

    sizes,

    we can 't p ro vid e sp ecific o rd erin g in fo r

    m atio n ab ou t a ll th at

    arc

    available.

    Each o f the inln y su pp liers s ells a catalo g

    w ith c olo r pho tog raph s of their inlays. The

    se le et ion in all three of th e fo llow ing cata

    logs

    ill

    pretty m uch

    the same,

    although

    C onstantine generally offers m ore than

    either of the other tw o

    sources.

    E ach of the catalogs

    costs

    $1.00,

    an d

    when orde ring . be su re to

    request

    the 1 983

    edition.

    Cmlslantine

    lO50Eatt( e.~I~Road

    Broil . . ,

    ,vI' 1~61

    7'he

    n'oodlt'()rk~..

    Slo~

    JI801

    11IaJ(.l>ioi

    Bird.

    RogCt'8. \1 :-' lii;Ji~

    CrqftSIIlO>J.

    DC/)(1I1mem 10

    17J5 lI' e st C o rlt ulld C 'III1 1

    Addi8on , 11-60101

    WOODWORKING CLUBS

    Our

    l is t o {woodworki ng c lu bs c on ti nu es

    to

    grow,

    and the offer

    still

    stand. to help

    pub li ci ze your

    elubs. Just write

    to

    Steve

    Krohmer.

    ' are

    open to all

    interested

    w oodw or ke rs . F or

    mo re in fo rma ti on , c on ta ct Treasurer Gary

    Benuqui sto, : ;6 .57 th

    Avenue,

    S an ta C ru z,

    CA 95 () 6. ~,o r c al l ~og. .l i6 - 9 0a o.

    SAl' JOAQI'IN

    FISE

    WOODW()RKt:RSAS.

    SOCIA TION.V e me ntio ne d th is g ro up in th e

    last is.ue - but there

    \VIIS

    a n e M '( )r in th e

    addr~. The arrecl

    Hddrc

    for Pr< l$ ident

    M ark R . \V eb ~t.er is 6 70 N orth G . S tree t,

    P on en 'ille , C .lif or n~~

    932.:;i.

    T he tele

    p ho ne n umb er

    i$

    2W781-407~, an d M .ark

    our es


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