7/24/2019 Woodsmith - 042

1/24

NO 42 NOTESFROM

T SHOP 2 5

7/24/2019 Woodsmith - 042

2/24

WOODSMITH

leaf can be a tittle disconcerting .

That is, it was until I made my own little

pointers to locale the screw boles. Be sur.

to

.ee

this

tip on

page

S.

FL 1 lSK tN( ;.Dou lt R ick s

i

continuing

his

series on f in ish ing with a n artic le on fin-

ishing the finish in this issue. In

8 \\ 8 ;

we're

k in d o f g ~tlin Jt

ahead of

ourselves

with this

article.

But

we we re

fated with

a

dilemma

about

the sequence of things.

The next articles we have planned are

about applying

th e

various top coat. var

nish, polyurethane,

shellac.

and lacquer;

But the critical

part

of dealing with al l

these finishes is using the right technique

la finish the finish,

This is done

with

a collection of abra-

, ., v es : sandpape r, s te el

wool,

pum i ce , r ot

I for

1I otld. milh.

I know this i.an odd approach - nor

mally help-wanted ads don't appear as

part

o[the

editorial

o f a magazine . But wehave

a unique situation.

There

JUStisn't a largo

pool of artiSIS wlth experience at doing

artwork fo r

woodworking

magazines -

especially the

kind

of step-by-step draw

In~

e use

Now before

I

go any further, I have to

say what this job is ot II is not an ap

prenticeship for

woodworking.

\Ve've had

lol ofinquirie.< from people interested

in

working in the

WoadsmilJr

shop, But that'~

not

really what we need.

What

we're looking for is someone who

i.

qualified technical illu~trator (or has

strong drafting expericn ,,) and

a J s o

h a

love

fo r woodwork ing .

If you meet these initial

qualifications.

and would like to work at I\rlOd IIIilJ., send

us

your resume and wme photocopies of

your

r< < I.l

work. Send them to:

Ted

Kralicek, 220 l ~hn A nn

th i l \

iNlu

T he

original idea was

10

build

I

cahh ,1

for

tools. But the ,holi dc.,illl1actually hinf(ed

around the last step in Ih. ,, ... t rucuon

process. It's killd of a .halG,Y II ,tol1'

Although the cabinet w.... th~ pnrnary

goal. 1 also wanted to add a drswer unit

below the eabim-t RII1' I plamll'd

I 1 1,

boxjoincs to huild :h . rlrn . . IlK'dn.wI'r

unit ha d

t

i z t o d

to

Ut t . I lmfI1Of J. l l4

drawers with nltciy 1lAt

7/24/2019 Woodsmith - 042

3/24

OOOSM ITH

It

y o o

d

tike

0

s h are a

wooctworl I crosscut onmy table saw

without binding and burning. Finall~: I

decided that maybe the miter gauge slot

wasn't parallel with the saw blade. If this

was the case, I wouldn't gel a clean cut

even

if

the miter gauge was set

at

90 .

dowel during mos t of the

final

turning op

eration. The smaller diameter end

is .

only

in the larger hole for a short distance.

oh

Sa lter.

C/i /OII, ~solln

SEND IN YOUR IDEAS

Nuxt, cheek that the miter gauge head

i

.w t to exactly

90. 1b

check it, turn th

miter gauge upside down in the table slo

and bring it up tight against the frontedg.

of the table. IThe front edge of the saw

table should beperpendicular to the slot.

in doubt, cheek it with a square.)

Then nip the miter gauge over in it

normal position an d lower the blade. Fin

all,)\place

a

framing

s q u ar e

against the cu

end of the

b o a r d

and the miter gauge.

l O O m

T A

through the jig. The larger hole will UP-

port the OS- ibleo

hold the block and tighten the clamps at

the

s am e

lime.

The solution Iju;;t ntly diseevered is

to apply a patch of double-sided carpet

tape (see Sourees , pg . 24 to the center of

the clamping block.

__ T_i~s Technigu_e_s__

7/24/2019 Woodsmith - 042

4/24

WOOD JI.I1TH

THl lACK PLATE

l\,XI, glue up lhe

back

plate

8

(rom three pieeei of 4 4 stock to

nnl~h f t ln \l n~iDn. '

0(8 :

wide

by

25

[,>nK.Aner the glue

is

dry and the

bWtkplanl'ire. drill two I'W'-dia. hole. to allow the

sound of the ringing

to

escape th~ box.

(Thebells onthe outside are just

for

decor

ation. the actual ringing bells are inside,

refer to ~'ig. 27.) Center these holes V

from each side and :r down from the LOp.

see Fig. 1.

l 'I( '1 ' t ;K& Fi

in the actual

doon

First.

Uo;( the

straight bit to rout a

1 0 ..

li'

7/24/2019 Woodsmith - 042

5/24

fAC.' SI E U l

:l ....._

RO UT ..... 0 . ..

l

AGoU II: 6

.

,

I

DKOUllVE

IEU(F

GtOOvt

'Ja

.

BAC K P LA TE

ru CK V lWJ

r

_ . :.... ) . J4 ... ...

C D { - > t - ,

L~ ~ __~~-A

~ - - 7 . - - - - . . . .

SE ERG U tE FOIt

CAT EDU~t nEtAll

Qn; ~ ,~ fc : .AQC

4 41 ,, ) STOCK

f I G W t

. . . _

lt

,

I T

;

r

~t

~r

. . . , \4

~\

1 s

+

,

CDlTlION t

W I Of

-

lACK

P A I t

C

CA Th EDRA t TOP D ETA il

WOOOSMlTH

aonOM fOP

ClHttI 1UY\,ATr-

ON WIDTHOf

NOTE:

US ; I'.p FhWOODSCI(WS

TO A nA CH TfIoUtlATl T O f RO N T

0 0

Then mount y traight bit on the

router table and set it to make a ~'-deep

cut, Next. place the hole in the workpiece

over the bit with the bottom end of the

back plate to the right. see Fig. 6_

Now bring the router table fence up

tight against the edge ofthe workpiece and

tighten it down. Finally. tn make the

groove. turn on the router and push the

workpiece

to

the lell along the tenee until

the bit comes out lh~ bottom end.

Shop Note: 1hi. groove could also

be

cut

with a hand-held router and anedge guide.

W.'I. lIOt:''TIN(; IJOLES-To

mount the

phone on the wall.

J

drilled ~-dia.

eounterborcd shank holt.

In

each of lbe

rourcomers ofthe baek plate. see Fig. 7.l

used 2Yz-long.flat-head machine screws

with buuerf ly ta gp :k .,; to anchor the phone

to

the wall.

refel'to

Fig. 29 .1 Locate each

hol yo fromthe ~ideand 0/.- from the end,

se e

Fig. I

I OUNIII~C Till-: (ORNERS. After the

mounting holes are drilled. round all four

comer. of the door (A) and the back plate

(81 to a

z

radius (once again usc a 25.

piece as a template).

RO)I.l' 00.:,

Once

the

eorners

are

rounded. the final step is to rout the front

edges

ofboth the door and the back plate. I

used a ',,~.Roman ogre bit mounted on the

router table.

Feed lb. work into the rotation ofthe bit

tfrcm

ril ht

to

lell- counter-clockwise). I

cut this prome in three PlIlI. Cg. raising the

bit slittlr with each pass. On Uw final

pass raise the bit just. slight amount -

this ~ clean-up pass to remove an y bum

marks and geL a nice crisp edge with 3

f.deep shoulder. see Filt. 7.

7/24/2019 Woodsmith - 042

6/24

\\'OOOSMITII

1

TH E

sox

'AA M E

After the d 1 < < 1 r.... > t I . 1 0 .

KIYI'AO COMPARTM[NT

\\'jth th..: m am

be,

fro m,' c om ple te, \\o rk

can~n onthek~)l .rnpartmcnt lb

make the keyJ>OdI1d. , ,B I. c ut t \\ 0

' ' ' ' ' ' ' ' .

of

4 I M < Ic l < : I . . , , , . ' bS 5 klllt:'

lt ,(.

Tit.

\ (.I.~

~o rut the l A . , p

e nd o ffbo lh pit 'Ct . . M l

Gin

l hlc, 'hL;.22 ,

:t'(.'ltlng

on

~nle rnll('r PUJ,ft'1o).. t t

~ i . a .

11.

Set 8>topblock the I.ntrth oftlll' lon~c.\

lodge

(lh. baclc,-dl'te

of

the

k ey pa d 8 1t1 rl Is

;IV. king.

I U II BE T E A C :H .1 11&.NeM. cut. mhl)(t to

hold th. luuchton,' fe, {'pial. on Ih. lOll

in.ide edg e o[ earh pi, . ...

''I'

1- 11(_2 . ( ' Ib

makethi' rabbet, run the ,,orkl.ic(. over k

dado head \\ilh the 8Jlgk..1edlle j(ainslllw

rip [enee.)

,-

, . . ,

: IO T E I

WlDrH

DADO

EQUAlS THICKNESS Of

1..

ptYWOODaonOM

. . . .

. . . . , .

cur . .. oo

, OW

I

,

,

. . ..

.

. . . . ,

t

, , u n , . . ,

S.AHDf'AI'U

TOA.A' SltUACt

w r r w CA.mT API

~OIl0M ... 30 ...

. ,

c

@ G H T S ID E

lACK lOGE

1

. . . . .

CIA,I; HOU'

T

,

,

[

. . ,

. .

.

6

....un

sn

Mtfll GAUGI

to67\-i-

{:tl

-1 1

ftGUI(

11

AGU

t

. . . . . . .

t

NOTE-

tANG MOIflS($ CUT

to

DlPTM Of HINGE Ir:H UC lrlf

,

). . .

,

, .

Ag lDOC

.

c

IfFI SIDE

,

PIN DETAIL

,

1,

I

,

. . .

IIGUI,

7/24/2019 Woodsmith - 042

7/24

\'OODS~IITH

. . . . . . . ,

M i l .

QUAlS

OAVOI

rHlCl(NlSS

,.

f

HINGr

I(NUCkU

I i i

1

'MOl

H o o a n s l

alvtllD ffllfCl

CRQSS SECTION

./ >

_ I .

,

. . . . .

, . .,

H

kEYPAD UD

I ,

. .

f \.f1OI

4 . : . . ~

~ O V U : ; ; : K A H G ; ; = = l = _ _ : c. . .

o.:.:ssSECTION : . 3

IiiGutt I

S'

AGUIf ,.

' .U I i

'Vlt

TO ',.

,

MOUNtot

IOGI Of ,..ON

flU S .. W ITH TO

IOGIO, SlO

lOrE,

CUI 'OUQi.TONE

'A ce 'LATEro A T

IllWlH uaans

C Il l FltONY

ON .

CASt

-. o t UNlfOlM OV'JlHANG

,. fR ONT

~E Y fADt IOTlOM

. . . .

_ a . .

A1,2

,

, .

C;ROSSSE~tON

~.

....,

. . .

L,.-

,

.r

~

\

f

. .

. . . .

4

01.00_

. . .

YWOOO

ont)M

MOUNJWt .G SCJ 'l 'W

. . . .

tOUCH tONl

:l,

Act PUll

lSCUTOffOH

/

~

-

,

: o ; . an

t't'nl4't'I'cl,

''''''18t.l, T.. b i, 'g in , ,' '' 'l 'nb l ,V , d ril l hili .

through each

rOl'n.'r

1) (

lhl'

ph.. tic

f I'I'

plate

an temporarily n. '

il n u o th e

ra blO > in the .io pie

7/24/2019 Woodsmith - 042

8/24

WOOOSMITH

ASSEMBLY

After all the pieces for the keypad com

partment are complete. final assembly can

begin.

l

started byattaching the

buck

plate

(8) to the main box Crame.

llARKi'OSITIOS.Position the box frame

on

the

back

plate 0it's

centered

between

the shoulders (of the Roman egee) on the

sides and or; up from the shoulder

on

the

bottom.

se e

Fig.

2 0. O nc e rh e

box is

posi

t io ne d, ma rk the outline of the frame.

SHANK HOLlIS. 'ow locate eight holes

centered belween the two llentil lines on

the back plate (refer to Fig. 201.and drill a

VI shank hole at each point, sec Fig. 21.

CARPET

TAPf;.

After the shank holes

were drilled. I ui.d to figure out a way to

temporarily bold ihe box to the back plate

in order to drill the pilot holes. After

fumbling around

with

clamps, I finally

came upon the idea of using riouble~iclec1

carp.:t tape. (See Sources. pg. 24.)

p w

1)3leites of carpet tape over the

I 'nrillin .....(don't cover the corners). Then

pl .l . .. . I

h.

box

frame

into position. using the

e orm -r ma rl u< t o a li gn it.

f'IIAIT,\~IlI'OI'~ 'EKS'S-

Once

the box

fn,m, i in th(~correct lo catio n, nip the

&.,- mbl~'0\( so the back is up and drill

through lh,' .,ght shank holes with. No.8

counl.('I'

I f-h

WOOO

7/24/2019 Woodsmith - 042

9/24

WOODS~{ITH

aACXPUTE

Yo

5 .7T

auntltFlT

TO G G L E

B

: H I f 11

A

000, (I)

* , .

7Y 8t

8o

7/24/2019 Woodsmith - 042

10/24

WOODSMlTIi

ALSO tQUIIE-S ':. PlYWOOD

ca M

I[ 9b

c

1

. '.-. 11 4 7,.. (twO IOAItOS)

C UT TIN G D IA GR AM

..r th('lo(:l1b(

so

il alill'n~wilh the second pIn from the back

STO RAGE FOR THE SHOP

10

I've been wanung to build

lh~

cubine; for years. It':-. dC :'lign\(141 ntitxi

mize the- lUll thi.,g thal ~n t-hort :o.\1I)I )l~n

most shops: wall space, The cabinet has a

usabledepth fG deepenough10 hold.

Yari~ty of haml and power 10010.

In

addition.

Ih~ameum Q f w all spa'''' L ,

c ffee li v .l y douh led because

the

doors also

serve as SLOl'(I .'

com partm en ts. C U nth

door>;

are

1

,

dtoe '.)

l tATt RlALS. Since lhi , L i11$h()I)

calli1lttl.

)'OU can build it out of just about an)' rna

terial. Iho se 'I ~

birch for the cabinet

an d

door framp~. ami u,,

7/24/2019 Woodsmith - 042

11/24

1

1

\V OOOSM1TH

. . .

1

WAll

-S tUD

. . .

t.,.......... ~

~

. 1 < J i+

OTE: '- ,

t. , .

C. 'U TONCU. T..1

AND GROOVE 0 '1

TMIC IlN l. S O f SHEl f..... END V IEW

_foIAIlHG

SH 10 STUDS

WAU

GWtANO

SCa,EW

MANGE . S T ~

TOItYWO .

a A QC : w n w

) ( 1 1

WOOOSCU'WS

o

SHElf

..... I lYWOOO

WITH

H A R D WO O D

EDGING

, -

.

O I- IU .

~Olf- E N T E :IE O .

'~MF~T~DQ

to

SlA~GROOYi

,' W10E ,

~ . [ J E E P

GROOVE

SHflf

. jI ,

1.

1 C:I-:-- :::;~~t~

3 ,...

p-

1

OAOO

Stops

rN lACk

GItOOVE

~.. ;.iou.

, O t : E 9 tOft

sHEL f

r+

0 SU cms

,

T O f' O T fO M

t .

END V IEW

BAoe

MNEl

BA C K

(OG(

~

fC~R~O;S~S~S~E~C~TI~O ~N~~ f .

_I.

I

I I . . . l f D

HANGER

I

sr ...

(SEE HG 5

~

ftGURI.

2 ~

t

BOX JO INT DETAil

,

wLO[

NOTe,

IllA N E L

cltOOVlS

'0

W I D E

,y ~- Of

SIDE

I

NOTE,

Oit eoASSiMau

C JN~

T H t Jr o I C U T 1

iVlDtI AND lACK TORr

,

,

Y o

P lYWOOD

BACK

(0

Nn~

DIVIDER

(S

GUl f I

rom the front edge of the 10l>lOOllOrn

pieces to the front

roge

of the

WOO C

for

the back panel, see Fig. 3.

Toget th~ length. m...

'UJ'C

th~ shoulder

to-shoulder

distance

on the ~i(lc pieces.

(Thi is the distance between the bottoms

of

the box joint

s ts

on the side pieces, '

Then add .. (0 the two '-Iong tongut ..

on

the

ends .

After the divider is cut 10 .i 7A . c ut

tongue.

centered on the ends to

lit th.

dadees in the tol>,l ,uum pi,on,.

11.\(1\ 1 ,\.._el . The l a. .;t I. i( ('( n t { C l t l l (I

the cabinet is the back panel ID), A, men

tioned above.

1

mtt(Jc:

l hi :- . P O lIU 1 out of ',.

birch plywood. To

determine

the

.i..,,,rthl:

panel. measure tb. shoulder-to-shoulder

distance

on

the sides U1Ut the tOI

bottom

pieces, and .del .. to both dimensions for

th e ; I / l o n g

tOU J.,.'lIf': '11\

L h t (-cl~~.

Then cut o/ ,- w id e b ) \ :-deep 1 IIbbc ISon

the back face of n { ur ,odge,; of the panel

to produce Ionl( ba....(at ed tongues

that fit the j I 1()\'~ in lhe frame pieces.

HOU;S .'OR

~IIEI.\ t:S.

Before final

assembly I drilk-d series of V'odin. hole,

Inthe Ridesand the middle divider for~belC

support pin.'. SO i> fig. 4. The position of

these holes isoptional, r just started \\filh;\

t of bole, centered on the h~ight of the

sid.. pUo< e . Then I added holes centered

c\ (oor~

'

up ~n d dow n, see Fig.-I.

A. ;SE~l8t.:Now the ea binpt ca n he a.- .

sembled. It takes 3little time to apply glue

to a ll th e jeints, 50 ) OU m ay w ant to col;,;t

helper. Aile,' the ~Iue isapplied, clamp the

cabinet together with the back and center

divider in place. (The back panel

ill

help

pull the frame square. bttt check

w

make

U 1 e.)

ILI. GL GSYSTEM .

To

mount

lhe cabinet

tu the wall. I used beveled hanging sl1il'

se e Fig. Just cut tw o beveled ,tij) nnd

mount one strip to the wall (make sure you

hit studs), and the other to the cabinet.

8tl: L\t~~.Some of the lellover birch

plywood can he used to make a few

shelves. Although its not

nCC~I')~

I

dressed

up the edJ1l'~by adding birch ror:

in g strips, s

l - i $ ' . 6.

CIIA FE~ Et)r,ES The I..

7/24/2019 Woodsmith - 042

12/24

WOODS~UTH

THlOOOltS

1 1le d N ,,' ro l ru

(,Roc)\ . (IM IMWIR1'\

, . , t . . .

\fttr the box

J tnU an- cu t, cu t a grtJ(I

aloJ)g the

ID$ictt '

.. 11(,uf each

pll'tt

for tlk-duor p;uwb (U

I.

n. ...

tOO\ to t5 .- \\ ide b~ ..

IlL......)

and

IJI tl4In. ,11IO It'

mint

t< lgl o IS

lined up on

t.u I I=

k ~It..'t

II f the first 1)Innn the tOil

tlOttgnllII t-c ~IJt:.

M)H I \' .I~' N4,\\cut the door panels

1111111 ' 1 1 ,, 1 , '1 1 \' \\ '4 1 _ ) 1 ( 1

to

fi t

between the

hc.llClIII e lf

II,.

J,(nJUV4;'.... i n

the

dO lr

frame.

Th('11 MAt 1111,1.. nn .hl

r. ,('~

~i(ll o f ( ta ch

I~IIM

I

tu

r O I l U C f '

\U 5:Ul'- to fit

th e

~'TDO\ J Ii ,ff a

.. d h ua 1 to tlk total th.ckn.fl

nV

the

P ~

to

g

f in u;.h t:.t \\ ld tl . u ( 111 .-anei u . - - e a b an ds aV i: to

cut

IJUllht. i l l~f, i l l lhnJK. .

~l.F ijC . 1 2. Final ..

J) ,

lutr r. r aJI'ht: t (l~l~\\ ilh

Ii

IS chamfer

hit

on

th~ ruut~.'I l I,'

r.S'lsl Tot.lInlJllt'tt thl~cuhu\(>t.lcham

f~rt'dall the>

NI~,'.

Illd ppli ~ll lilts of

~t.thprl ll ll \\' 11,,, Th nK Oir

,

,. . . . ,

.

1 2

N(O.IIU ,-,

lOT HO LES

~ s

NOTE: o . t U . HOlESt St MITt

COlNIIIS, ' IN I '0 I .

WIDtH

I.A t.

wOOOSCItW S

,

ITt. C09Nt.tSAI S

~

. .

aNTII

'''\Il0(4l

fIOSlllOH (.A1CHli

A' tol lOP'.\NO

IOno~ Of(A,'Nll

MOUNt Hr,..GI to

f'ONt IO(;(

Of

~

C.AIJt.jll $101

DOOI

000t

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. . . .

O...,r

n)

0 4 . . . . . . . , 1 .

~.

. .

_IWO

.. I....

fOGfS

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-

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MACffl 11(

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. . . . .

.-

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atUlI SHOUlD('

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IDGlS OFPAN[l

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Of CA'$( ltS' 'hI

StD

PI N

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OOORIO OM ~

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OOR PANEL

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7/24/2019 Woodsmith - 042

13/24

1

,

WOOOSMIlH

IVI X

10 2

10... 7 -

~ 10-7

'In It.

9 ' ,

~,.29',

,.2~,

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~ 2 -

91

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. : I t ./t .~.

v1 to fit

wt

to fit

_ II . 72 IIWO IOAI'OSI

CUnlNG D)AGRAM

SPAC( ITWEEN

OlAWI' NolO 91D

t

IOTIOM ...

. .

1

t ,

SlAC(

2

,

,

,

SPAC(

,

,

\

1

t

END k

J ' lopIoll_ (21

k l...h(2,

t 0......

(2

M

O r o . . . , ., tUft.,...,

(6)

N5M Ow;

with the second slot down (of the box

joint),

see Fig. 9.

Since the drawers will be made with

V.-\\ide

box [oims, this puts the JrroO\'e

~ d ow n fro m the top edge. A dd to this the

amount

of

clearance

allowed above the

drawer

(.....')

and you gellhe

' t ....

spacing;

Then add the thiclOl '

ss

of the stock for the

1 1' bottom

('0/,, )

for a lol1d

of

I

K .

,e('

Fig. I.

fl'T C:R()()VES.So. se t tho fence

of

the

:oil I (rom the blade and cut a kerf on

thl'

1I ,,,le

fu~of the twu

end

pieces (K).

Then move the fence to widen the dado to

, . (I eut

thew

dadoes

fo r the

drawer

runners

I~

han 1/,' so the runners

\ \' uu l t' ln ' t l ) ln ( I IJ I the 1 ,/ . w id cg ro ov e o n th e

drawer ~(I,,-s.)

ItE llAINI~GGItOO\'ES. AfU r the lo p dado

is

CU~n both end piece . adjwst

the

fence to

eut the remain ing dadoesllO they're spaced

3'/1 ....and

5

from the top edge.see Fig. 4.

OAOOF_ ()~

mvmsss, Next cut the cor

responding

dndees

on the dividers. Thi~

I ires dlf(~rent seuings because the

tonl(Ue on the top edge of the dividers is

In ll~ 1 ttln sc, see Fig .

a

IlK_, t:R R t lONERS. Alter the d ado es a re

cut nn

the

end pieces and dividers, lhe

runners

eM ) are

cut to thickness so they

fit

in the dadoes, and to width so they stick

vr

see

Fig. 5.

Sinee the runners are mounted

cnJ83

th roin of the end pieces and dividers,

ap ply g lue only to the front

2

or 3 when

g l u i n g

them

in

place. (This ls

L O

aUowthe

ends and dividers to expandreontract.)

TRUI fRO' ' E(l(OES. Finally,

before as

sembling the

drawer unit,

I trimmed

%'

orfth. front edges ofthe ends and dividers,

see Pig. 5. Then later I added face strips

L O

cover the ends of these pieces,

ASSEMBLY.Now glue

and

clamp the ends

and

dividers

to

the

L O p

and bottom pieces.

(' \)

get

even clamping pressure on the

dividers, I used the tip described inTips

Techniques. ,;ee pg. 3.)

ADD

PACESTR II 'S .

When the glue is

dry,

cut ' 1 ' .-thiek face strip. and glue them to

the

front edges of the ends and dividers.

$00 Fig. 6.

14

lA.Gt MIDOl~DRAWE.

'CONY BAC.

2t 1KES)

-

--II~ -------

r

. .

. .

~

n

1A~Itf.IDOlf

~

DRAWfRSJ OE

4 \ 1 1 0

~

(.2 feES)

,

...-----I. ~~

+--- .---_

_---'1'.,'---

__ ~9 .

NOTE: AU . DtAwfR $TOCK

l , , -

I C I

Ol:PfH

Of-

SlOT EOUA~

J'HlCllNfSS

.. OfSrOClt ~.

r

2 -SIM U D RA WfR tO. S ~ S ' ' j - , , - , . - u -. - . . .w-n -'R -o - -, I' -A -'--;> t '- ._-=-1

~2~_~ ~ 2~~~=~~_

~~i_1_:L__

~~2~~~K~U~ ~

__r

FK;:Utt : B

to OflEltMlNf lINGTH Of

__ ~-DItA.Wn FRONTS,MfASUftE CASE

OPENlNGS AND SUlrRAO I.

j

u

T

NOTE: MU) iM

SECTlONHAS RUNNE.S

FOilONE

MEOlUM

AHOONE

tL OOuaL l S IZEDRAwElt

- : ~ : v .

CROSS SEClION

GUlf7

GlUe:

FACE StttPS

fOFlOHT

EDGEOf

ffljMANO

__ ot V tO fltS

/

EN O

' 1 1 1 \

I..

OHf.~'

EOGtS Of END S

ANOOMOfl.S

DlVtOft

IViut.

T

ctn fAC1

Srtl.-sTO

CovtR ENOSOfDI...WU

'UNNU GROOVES

CR OS SEC lION

(W f T M OR AW l- IS}

AGUkE S

HOOAoo

O N tO WER

lNSlDEMCE

OfOIVIDUS

,o~

1

,.~

j

___ S1,..

t

Non;

All DADO~

1.

DEEP

IV'.,., WiOf

7.

lNO : -

1

OMD(' 10 '

RGURl4

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C; ~Ro ss si c~T~ O~N~~~~

,S ID E V itW 'l

\

R U N N E R

-n

-= >

CAIO t>LDlIt

W rT H H ANDLE

. . . .,.. .

. .

. . .

fINSiDEDlA..

.... tJ\OfO

iN SE rt

. MASONITt

SAal ay 3

00011

1

PlAHOH:lNO

:~ 'ANEl

Ii .

l

;~ / ... CQUHTE .S .NK SC REW S

f IN~INETaonOM

CASJNETSHOWN

wnMOOO.

ItMOVEO

~ -- SAWItAOE

surr

NOTCH AGAlN.$lI(tY

rOMAKf SECOND CUT

2

.

nU OCNESS 0I- t0Cl(

EQUAlS WIDTH

OFSAWKHf-

Bun CNVlD 1

I -

AGA lNSTKY

T O C UT NOTc,H

.

9

j

)

~

1

MOVEKEY2',-

. .

. .

ROM IlAO TO

CUTCIOS$ NOTCHES

SA,W \AOE

(titS ' KEtf

. .

1

. .

fJGURE 10

lA RGE O RAW ERMALL O gAWERS

\

,.OU

,. .

~

.

. .

CRO S S S E CT IO N

/' lIOUNGO.

~ _ORAWEI t D rV I.D.JI

1

~~::i

'. ROU O'El I . . 1

.,,_ I)EP ....

OIAWl KUHNll

GRO OV E CU T TO

W'tOTH OF

siot

@

IMASONntaonoM

tcUfJOfn)

GROOVEFel DtAWO

aonOM' .Wfot

IV l . DEl I

/_ROUlA 1 _ iOUNo.OVERONTO

~~SAnlRASs Ml t

1 J

c o c

=

,taUtf9

W O O O S M ITH

THE DRAWERS

No~that the drawer unit i~ssembled,

the drawers can

be

buill. I started by

r ipping enough stock (or al l the draw ers to

8

width of

2

(except for the double-size

drawer in the center compartment, which

,411,,

wide). Then

all

of these pieces are

resawn to th ickness of 1 .

.RO~/B.\CKPII';C ;S.The drawer frontl

back pieces are CU I Lalength to equal the

width of the o ning less ~.' v... on . h

side) {or clearance. see Pig. 7.

SII)R

PIECf,s.The length of

the drawer s

side pieces is somewhat eptional, Icut

lhem all to the same leng1.has the length

of

the front/back pieces on the small

drawers.

BOXJOL''TS.The

drawers are

joined with

v.'wide box joints. (The technique for

cutting the joints on these drawers

i.

es

cribed in detail starting on page 18.)

After

the boxjoints

are

cut, the

groo e~

(or the drawer bottom and the drawer

runners are

3 1 < 0

cut. Then the drawer is

assembled,

see

Fig. 9. (All of this

is

also

d is cu ss ed i n the article on page 18.)

DI WERS\'ST:II.On some of lbe draw

ers I added an inte rlocking divider system,

(' 'his

is

handy (or

s to r in g s c rews,

brads.

and other small hardware.) Before cutting

the

stock

for the

dhiders. I

rounded

ever

the inside top edge of the drawers, see

C ros s S e ct io n i n Fig. 9.

The dividers V) can be made from

hardwood

s to ck le ft. o ve r fr om m a k in g the

drawers) or from

y,

Masonite. Either

way the dividers must

be

the same thick

n es s a s the width of the slot cut by the saw

blade.

CUTTO

SIZ& .

Cut the dividers to width

(height) to equal the distance from the

drawer bottom to whe re the round-over

starts, see Detail in Fig 9. Then cut them

to length to match the width and deplh of

the inside of the drawer.

~~TOI~ TS.10 make the interlocking

joints, start by rulling a no tc b on each end,

seeStep 1in Fig. 10. (Use the box joint jig

to make these cuts, see page 16.)Then cut

notches

z ~

from each end, see Step 2 in

Fig. 10. Alter the joinl$ an cut, it's just a

matter ofsliding the dividers togelh.,.. and

placing them in the drawer

l I Ot i l \ 1 ORAWERINn:\Vhenlh~

drawers

Were

complete, I mounted the entire

drawer unit to the bottom ofthe cabinet .

l

added 10' Ma.'lOnitespacers between the

two units to allow clearance for lhe doors

to swing open, see Fig. 11.)

Use a Port.align to drill

v

holes through

the bottom of the cabinet. stopping when

Lhebit just touche. the top of the drawer

unit. Then drill holes at these points for I..

inside dis. threaded inserts.

M ount t hr ea de d inserts in the holes in

U e drawer unit. Then fusten the cabinet

and drawer unit together with I. Ph ma

chine screws.

7/24/2019 Woodsmith - 042

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M ASON Jll

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lOUT \~. . stor

,nwUtl

j;lA.2l

STOPHOUS

.g;..

C(;NfEft Of

ROUtlN

SQUR

L OP V IE W

IGURt ..

OWE

oJ

Jtl NNfft . ~ ,

TO eASt ...

'. MASONItt

_-COUN1UlOlt

.OOfE

.SlOT

:ROSS SECTION

I

I

CAlIG

IOU

tbe slot between the

tw h'II,>o,

see

I iI :, :1 .

0.

to )1Uidethe jig ill the

the

b ase , s ee

fig.

I. Th,'n mount

the fn'hl miter ~;,U~, .Iot

in tho

table

sa ,

Rip a

fence to the

ba ck

f.m'( with .,' oarrla~c

12 1 0 ) 111 (

runner out of y ~Ia. nite so it's

bolts, wing nuts and washers, wide cnnu~h to .Iide smoothly in the slot.

ST A8 1 L1 ZL '1G STR&Tt'Ht;R\Vllen milking 'Own

\1st

Iu, ,' to align the runner 4

the box joints, the dado

blatl ,

will cut (rom tb.

I

fl

l~ll e

of thejig base, and glue

throu((h the base, ,'('ier to

-'i :. ;,. n,

make

It

in lila,'\ ,see

I - i l , 1 .

- - - - - - ~ - - - - - - - - - - - - - - - - - - - - . A G I T U ~ . ~ 2

. . .

4

. : I t

t

CARltlAGI IOtTS

4

NO TE:

U S E

4. Sloe.

ONH.NC f

K5

1

4

16

M AKE THE JIG

1b make this jig, I

cu t

the

y Masonite

ba s e

(D )

10 a

size of Ii

wide

b y

24'

long.

Aiter the base is cut. the

two-part

fence

tan

b e

added,

This fence consist. of a from fence

(A)

that slides .gairu;t a stationary hack fence

(Ii),

see Fig. I.Rip both

fe nce . to

a width

o f 4 '

oUlofj7

.rking on the projec

ts

in thi.

k ,U

e,

I had

to out lot of box joint.,. 'fo

make box joinll< accurately, you have tu

meet two eriteria; I) the pins and slots

have to be exactly the same

width,

and

2 )

a U sJot.-must be th e sam e depth

In order

(0

ml*t these criteria. I use

k

ji~ tn ~ide the workpieees. The jig we've

shown in niw rmith in the past is fairly

basie, It'sjust a fence attached tothe miler

gauge ith an indexing ke y mounted to the

bottom edge to position the workpiece.

The onlyproblem \lith this jig is that it'.

difficult to

fme-ume

the position of the

fence to g o l the right fit on the pins and

.Iols. I've also had a problem cutting the

.Iot.

e xa ctly th e s am e

depth

because

the

workp iece ( ends to rise

0

sink as it slides

over lhe

l .1ble

saw insert (the metal plate

around the sa w blade).

1 b

solve

th es e p ro b le m s I

made new

jig that incorporates

a

two-part sliding

fenee that allow. the micro-adjustments

often

necessary

to get tightfittingjoints.

I

also addeda iMasonite base

to

provide a

7/24/2019 Woodsmith - 042

17/24

VOODS~{lTH

S

7/24/2019 Woodsmith - 042

18/24

v,'OOOSMITH

8

NOJE:

~WO.K [CE

OOWN AGAINS1

IASO

I StAATWITH

,,,,,I FtOHl,$ACK

. . . . _ _ v . . . . . .

O S ,

cu,

-

ftC(

Th~ proeedure I~

t

h, stm,- ( 1

t l C ) t h .

hut

I l L 't .' f I

th. ,ut.'r tahl, on th,

drnwers bc-cause m:-.

r l a c t f J

llhto,'

(1Itlo',

rnuke 11

:oatL~fat'to~'

cut, (Set. 1~3J. l2(1 (01'

m ore on tb..i~p r ob le r n .

ssr

rae

JIG.

Th

mnke

the pin.' an'

cut io Ihp correct length. t the bit height

(or the blade height) to the exact thickness

of the sicek, Then make a

trial joint

on two

t es t p i( c( :; :. ,

.I so th e ju sl- (.'U t 5 :1 ut ~rafl..

die. the key lind

wt

Ih ne.t .Iot. Repeat

u n ti l ~ IY \. ..

h\\ ~eell

c u t - ,c r ot ;.. t ht .' ~ u r k ..

. F

)If C( ~ee Ig.-.

('l'T JOI~'TS

s

SII)F-S.Kext. cut the

s l u t . . . .

in (lJ\otl,ertest

pil ee

for thl~dr.I\\,tJ'~icl,s.

The side piece begin....\\'ith a slt.' ttl n\ut,>

ith th. pin in the fnulI ck )1'l .... 1' ,,t

the width of Ihi. slot. plac. Ih, fn.ol ha k

1)1C l lg -C I;;

8, l E ' < 1

to be .

l h ~ l O m b i n

di

nlerU.1UJlof tht ~IotstU ld pillS - lhe fin

ished joint - ~ntlsup _Iil(hlly n3m ,.,r or

wide,' tllan I 1)lnnll.~I.In this

~ ,,;e,

I bim

th~

pieC pins are wider (Jr

narrower than

lht

:-;lul~.

Th

m u k e

adjustments.

ru ove the fe nce ' ' tbe y is

closer

10

tb~ bit for. looser

fit,

or

farther

( ,m

Ih~ bil fCtr

a tighwr fil. 'Then make an

..Ihr-r triHl joim, and proeeed to rut th~

J tU J1 tS In all the pil t,- 'C.sfor the dnt\\'\ 'r,

CUT THEGROOVES

..C'tt r t h l' j () 1 11 t < o .1 1 '\ CUl. the groove; ror the

dn,y,l'r lklttfl' ean be CUton t he t .a bl ,, saw

Thes

grOQ\l' art

;de

by

v.--deep

rOT

lh(,

I

~t~~I \nit~)cllwm.

~hUl) ~t.tt.:

\ }ten

JJll.-lkJn) U

(In\\\'e:r, if

the drawer ~i{ll '_

Jel\\' (Jul

even ,lightly, the

drawer

will

bind 3(11un,1the runners. FOI'

Ihk; rea.\ c ~,

tile)' all 00\\

to\ \1l l1-d

lht>

f

ofllff

of

the- dra\ve1 Then,

\\'hen Ultt.lrd\\ (rs a..~mbled.

lh~

l a\\'er

1 )I ') tto m \\, .1 1 J '\I ~h the : : : ; icles oul\\ ani.

~tMn~hl( flinlfht~bo\\;

1' .VC for the drawer botlom isn't

\ .,illl

on

the

d l 3wer

front. ~t the

sa w ,

Ih. blad. align' \\;th the botlunl c 'g~o(

lh, bottom slot jn a

. o t i ( f l .

p i c C ' C . ~ee Fig. 4.

(T-hill

v:a):

w hetl the J rI O Ove

is

cu t in the

front pieces. il will .Iice through part of a

pin thal is onl~'\'i~ible-)n tilt

tln.\\\'{'r'::,

:-id(~.

. e e Fig. 5.)

. ..fte_r the S3\\' fence

b

po$ltiollefJ, cut

i ( 1 W e 6

in all four piec.8. (Mak~

, 1 & 1 1

the bo\\'oo : < u r l : 1 c e

i:;

to\\'am the sa\\'

table.)

ox Joint rawers

ST EP B Y ST E P T O B U ILD IN G A D R AW ER W IT H B O X JO IN T S

7/24/2019 Woodsmith - 042

19/24

OOOSMITH

tGURl 12.

S I I

CROSSSE~

OlAWtI SIDE

MAWRIOnOM ....

Slot

OIAWllt

\lNNS

GROOVE

SlIGHTlYaMl

ON. lOGE

SOUAtING

I'OtM

fIGURe 10

(HISE L O U T P lN

1NNAWE.

ItUNNflt G1tOOVE

ClAMPING

alOClS

SlUD TO

fiT fNSIDE

04MENS iONS

OFt>ftAwt.

V OID LE n

B Y BOTTOM

G.OOW: IN

f.O 'lT'IA(I( 'lea:

. AU G H W IT H

SLOT tN

SID E PileI ~

SlO(

OUTSIDE

r

CORNER

VIEW

' ltONT lACK

U 6

lI[

5

tGUl,4

IN SID E C OR NE R V IE W

' \ t:

IlR.\ \~ :ltIl()1 T().\1~.

Nr \\ eut the

bottoms out of 1/...~la. ,oniteto fit between

the bottoms the grooves. (Cut the bet

t41m just

tarlIO(.: e ,..

it clnt'tIoll't

g-t hung

up during .. .mbl~:)

J)k.-\\ .:RKt ~NBR (~K()O\

e. Before as

sembly; the il' -deep )...fTt)t,\:~~for thf*

draw er ru nn er are cu t o n the o uter t1UI

face or the sid~ pieces To cut th, ,

grooves. adju t th~ fence

the hla

Wid

~1()U;.and join both

s.illt'

,}j{>o(_ t'~

t

the

drawer's hn1,1,,, '.

\V h.h the drawci assembled. 111.< the '

squaring form in. .ide. Then draw

t.ht

d ml)~up tight. seefig. ~.

fI~.\l. TOtCH f:S.i\fter tht glul ~tIQ, tht

drawer is ready [or a fe\\

[anal

touehe-,

First, chisel out the

pin

blocking the rear or

the runner

groevo,

see fig. tu,

N~xI. fill the void in

the

side.. (created

by

the greove for the bottom) wilh wood

pulty matching the end I :rdin color.

A nd

finally.

I

rounded

o ve r t he

i id. tUI

edge of the drawer with a

1/.

round-ovt-r

bit. see Cross Section in Fig. IL

MAKE

TH E

DIVIDERS

After the drawers

were

assembled. Imacle

a

7/24/2019 Woodsmith - 042

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tunDlnH STOP

AGAINST ,.N ENDS

..llOlh{r Ilr ll]pm

with

box joints is tJ1~t

tht, hollilm u( tl lf ' : -1 1,t is n.ugh and un

~U1U't'. Thl,,,

i i

('.tu i('(1h) lhp design orthe

d.du bl.d, II ,If 1l.1)O'lldilllt on the t~1 l O r

(la(in, th.. rt' ('C luJ ,i tJ e A>\ er.tl (liJTe-f'Cllt

ba

prufil,'S

on

Ihe

bottom,

or

the ,1ut~.

< :

phto.RUIall h, . pror~ boil down

tl)

ont- Jtn.bllln, The

lJOttoms

of the

~Iot..:

are no,

I la t

RI.loqll:Ue

Ont ;

Y o

ay t.t \ 'Om t .' t th l pn}b t:'m

tIn

nar

ro~ ;.1,

ts,1j

te l flan-t th~ bottom oiLhI' iJol

WIth

a

'hng jig

nle ~1~llngigIU~

. ' 1 . ) n ; ' o i . . . l....r:1 p i , - ' \

tlf

) 0

1 . . l 4 ~ ' k thAt' ... t l IY J I f , v f d tl

a'ept

a

thnjt\IP. f{lr' thi ...tonJ.'Ue' lo a thickne:-'..~ to

mUIngu~on . h , 'I'< and u,.' a ,harp

kru

'0~hrough tIM>

anrl ... per

on both

_ u l , Ir th., lOnguu rl~ ,(' V,f th ~ , , 'c l ( ) ( l l : : - . .' t , n \.1trt lU It I , r uturnlnurn ,jell' : o . a 1 H 1 I J . : ;L p

.f 'l t t t u f 'I)():->itl~1:-

trut: \\'Ith ~urln~'e

1 1 1 1 N . t

h

t_'(urt an}'l(JI) CllOll,p.f

fini~h go

(,n,

It alN.

V llt t h4'

'-an.ling l (_I.~i

fini . :\h(os(l ' i ll( . h

H'

\'arnil h.la{ '~u~r.

anc l 'l ln1 -I

he

t'l\tlrt~ ,. ur (~ \ )Ohuul.1

tt e :' :~ lnl it'( 1

,\ ;th from

lI~ I) I ( lJ. :lill tI n

the: ' iOUl'fit('('

01'

, :nrm

lac). ,'h(., ,,'hi,)\.'

IK 'in t

(Jfthp~, finishl':'

Il'\

tu l.tflut' l~~grit. ;trld

~'t'U

nli~ht

'ant

to go minj.

\'1'

fh( Kttlulalltr. \\'ht'n

litllt> ball...(

).tlil(1

lll'

luy, ralf ,f)tJ {,t4 t t lt 'I l, R u t \ \ il h

l,( h ( .

r

It tHI(' IIUln

t im ( ~ . m { '\ 'i ng US ' to flni:- .h

nfl

c l uJ .: 'I I'

(II'

tlu'

:-..tllrJI,allt' r (NIW

la~( r . i lnl) ( ' rft '( ' t

i~lll~

n,

' k in \\.hln

) ' 1111 : ..~J(0 11

t..

,ron.

tht tt'l'

l lnll:-;

tlrt' 8 Jtp lie< I, ~ cial l , \' ' it II

,.h,llu(

J~

It'l , . a . . . .~ '

ltlrut, ....

nclpufM.r. f

l'~f,r

ltl'.-1f in i . ..h('

T H E ,tlST ST lPS id

thi~

S

\\h,nI't'(lt 'm....

nclltuE':-tlon:, Ilk. ~ r U 'II ,nrn1: h o r 1 }C,I )o'un .-thant.

begin. ma~

fotart

:t

I , l tl , - ( .. . . .~

r,

2 : , , . . . .

Jrrtt ~'r

fo\ PD

Itubbmll

aut the

10 1 'coats ISonl~.ff ''1.l\r '''HI:R. ''T ~ ' .. , Tlw

p '...

, ( C ' i f ir s fJn

t ac:h type fir f in is h \ \;11 l'oPOl;o .,)

t'1l.1.1~(;

If

you' , fIOin) ,10 use an oil I... 1 1 0 1 1 ' < 1 in ul ,mlOK lIrticle . But th su I 'Til.

1'1.11

\\'h~n sancling mO,

filli.h. othinK else hM to

be

done

to

Ih.. o, ..... U Ilnll'(~lu ...

nnel

lhe maleri.l, finishe . a '''

whi t. ..

,nning dw>t wil l

b f

wood

u rll e .

How,c,: if you want

to

U'

n< ,d ( '( 1 1 0 e lo

the jI out

o (

lh~

Finishing: The Final Touch

MATERIALS

&

TECHN IQ UES FO R A HAN D -RU BBED S U RFACE

o.at

Th.a

j < lo

lfl ....r t'.-U.tl I,.'f,.il '.

'I,lIl I, you have to use somv

Irt I,f

abra ..

l\'( til

smooth

it,

7/24/2019 Woodsmith - 042

22/24

L'ORIC'ANT.

Tohelp speed up the cutting

action of the sandpaper and keep the resi

due from building-up, I use oilor

water

as a

lubricant, The choice between these twe

lubricant. depends on how fast you want

the sandpaper to cut.

OIL. Sandpaper cuts more olowly when

oil isused because the oil c....ales a thicker

f i lm.

This

allows more control O\ ~r

he

cutling action, (\'Iith lighl p ure, the

sandpaper tends to ,Iide over th~ urr.eriodically.hake

ofr

the clolh

10

rid

it of the steel \Ilndpaper can cut through the finish

an d into the stained wood which will leave

a 1 i . 1 .pot that's almost impossible to

cL.rkenagain v.ith stain,

,SUlSG FORAIlH f:SIC);.I.

There'

s

anoth~r

reason to sand between coats. MoRt of the

new synthetic varnishes

(such as poly.

urethane)

drysc hard anti , oolh

that

the

next coat v.on'\ slick unless the previous

coat is roughened

first. It

doesn't hurt to

slighlly l'I>ughenany Iinish 10help the next

coal

adhere lallhough la..oquer

an d shellac

lend 10melt the previous coat and 'eld

to it).

7/24/2019 Woodsmith - 042

23/24

ca n be worked with a c le an , soil cloth. But

I prefer a block or rubbing felt since it

provides

a ilat surface

and allows the

abrs

sive to move within the fibers. A common

6i7.(>elt blockis I' thick and

2

by

4.

(The

last one

ought

ut down the mlddle on

the bandsaw to obtain two

v , thick

blocks

-one for pumice and one for rottenstone.

PI 'IICE. To usc tbe pumice with a felt

pad. spread a thin coat ofrubbing oil on the

surface of the workpiece. Then sprinkle

SOme FFFF pum ice around and use th~

rubbing relt to rub in long even strokes

with the grain,

Before long the pumice and oil wil l mix

together into a creamy paste, Ifthere's

too

much oil. you won't feelany cutting taking

place, and if there's too much pumice. the

felt will tend to catch ralber than glide

over

the surface .

A.~you work, cheek the progress by

removing the paste [rom different sections

of the surface. Iry to ruh all parts evenly

(o;ometimes I count the number of strokes

in each area). Pumice can

tilt

quickl~1SO

don't overdo it.

Once the fin is h is uniformly smooth,

clean all the residue uffthe surface before

continuing with finer abrasives.

Youmay like the sheen produced by the

FFFF

PUIDlce(sort of a polished satin).

But if you want more of a gloss there are

OOOSM ITH

three ways to go: rottenstone. rubbmg

compound. or an extremely fine sandpaper

called ?tilero Me.h.

RO'M'EN ST01'o '.

Rottenstone is used the

same

way as pumice. ~'irst. clean off a ll the

pumice residue and then switch to diC

ferent piece of rubbing felt and follow the

same procedure as with pumice. Lightly

cove r the surface with oil - don t use as

much

8 1

when working

with pumice -

and

sprinkle some rottenstone on the surface

h rouenstone burnishes th surface

and brings it to a

very

fine polished ap

pearance. Check this by holding a light at

very shallow angle to the work. Youshould

only se e It'll fine scra tches (or none a t all

in

the direct ion of the grain.

RUBBING (O'II'(JUNOS. Another

ap

proach is

to

use rubbing compounds for the

final phase. Rubbing compound is a semi

paste, abraslve/lubricant combinatlon that

is used r

rubbing

out

auto

l aequ e r s.

(Behlen's also makes a rubbing compound

for weod finishes, se e Sourees. pg . 24.

Depending on the brand. there

eo n

be two

grades: rubbing compound, or the fine

polishing compound.

Most rubbing compounds seem to cut a

little more slowly than pumice. but faster

than rottenstone and t ea ve a high lustez

To

us e

rubbing compound. work

a

little

in to a so ft, damp cloth or rubbing rtlt and

rub back and forth with ~mooth. even

strokes. If the compound starts todry out,

work ina little more compound. Ifthe cloth

starts to get crusty. rinse it OUt and add

some fresh compound. When you get the

sheen you want.

buff

the surface with a

clean, dry cloth.

M I{ K O n:SH . If you really want an ex

tremely fineand unifor.mscratch pattern.

Micro Mesh may be the solut lon.

(s..

Sources. pg.

24. It

consists of a series o

cushioned abrasive pads simi lar

to

silicon

carbide sandpaper, but they start at 150

grit and gO all the way to 12.000 grit.

Micro Mesh was originally developed to

rub out plastic airplane windshields, but i

gaining popUlarity with musical instru

ment finishers.

CONCLUSION

Rubbingouta finishcan bemessy an d time

consuming. Sometimes it's only worth it to

bring the to p (of a table or dresser fo

example)

to

a high gloss and just lightly

steel \\ the res t.

But what impresses me the most abou

rubbmg is it's such an immediate im

provement to surfaee finishes. Simply

taking the time torub out the dust nibs and

brush marks with steel woolbrings a good

feel to the surface.

I used to be in a rush to put. finish on

allow it

to

dry, and then get it up

to

the

living room S O everyone could admire it

No more. The extra time spent finishing

the finish produces a lot more ahhhs..

What impresses me

the most abou; rubbin g

is

it s

such an immediate -

prouem eni to tile sur fa ce

SLOppingat

~t

sandpaper; continue

onwith 600-gnt. Then, rub out the surface

with even finer abrasives sod rubbing oil.

r- ow (jERE ) AllRASI\ S. Pumice and rot

t en st on e a re the two most common pow

dered abrasives used LOproduce high-glo.. ,

and mirror-tike finishes.

Pu mic e

is

a

white-grey material

ob

tamed from the asbes of volcanic erup

tions, It's graded according to the size of

particles: f'FFF is the finest, down to FF,

the coarsest. (Note: Always cheek the

pumice for foreign matter or large grains

berore using it.)

Rottenstone i. an even finer. black-grey

substance. It 's made from ground-up l ime

stone and

gets

if.8 name from

the

odor

that'. rete ..sed when the raw material is

broken up, (Fortunately, the odor is gone

by the time it reaches the finishez )

Shop Tip: eep the pumice and rotten

stone in separate salt and pepper shakers

SO they can be shaken out onto the work.

piece when

eed them.

RllUDING FEL't

Pumice and rottenstone

A SATIN FINISH

After the top coat has been smoothed and

Ilattened with sandpaper, the appearance

can be controlled by refining the scratch

pattern. 1r you want a satin or dull finish.

rub the surface \\';th 000 or 0000 steel wool.

CONSIS'l'ENCl: S ,I wool is available in

grades from No.2 (tbe coarsest to 0000

(lhe

f inest) .

But these

grades are

no

3.'

suranee of quality.

I've

opened

up

0000

steel wool

and

Cound

coarse strands almost like N o . I inter

mixed in each pad. And some ste~1wool is

so oily that it imparts oil to the finhlh.

Ll81l0NST~~I. WOOI~For yean; Ivc,

just used whatever brand wasavailable at

the

local

hardware 8tO..... . But reeentlv

I

discovered

Liberon .tl'el wool which

is imported from England. (See Sources.

pg. 24 .)

Liberon comes in a roll (rather than

pads) Meyou can cut offju.~twhat you need.

And since it's made from long strands it .

mucb more resistam to breaking down.

But the best feature of this steel wool is

tbat it's oil e n and generally has a good

feelto it. 1particularly like the finest.grade

whieb is s o m e w h e r e between a ( )( )( )and a

0000

grade,

WOOLUIIE.I like to add Behlen's \Vool

Lube as a lubricant when I'm doing the

final

rubbing with steel wool. (It has the

same effect , as using' oil or water with

sandpaper) WoolLube is a gooey material

wit h c on si ste nc y th at S

somewhere

be

tween axle grease and Vaseline. When

used with 0000 steel wool. it

quickly

creates a hand-rubbed, satin finish.

To use it, wet a piece of steel wool and

wring it out. Then work

a

glob oflhe

\\'0 01 -

Lube througbout the steel wool an d rub

the surface of the workpiece with the

grain.

A s

you work. the \Vool-Lube and

water combination will start to foam up.

Oecasionally wipe off the foamwith a ral

and check your P QgrI S.

7/24/2019 Woodsmith - 042

24/24

piece

of S wiss che ese O C'< 1l1 L. f

all

the

various hole location.' (bat permit il to lit

just about everystandard router below 1...

H.P with

R

round base.

T be u niv er sa l b as e

plate

come>

\\;th

four

bushing. (,. ,'. '/;,. shon and long length s,

and

.y~

outside

11iam(t~~).

he set.can be

ordered from:

WOOJ)(,RAfT Sll'PL\ rOR .1I

Atlantic

A ' e.. P .O . B ox 4 00 0, \V ob um , M A 0 18 88 :

8002251153 ICatalog: Free).

ROltle

Gu,d,

BI($/tj iI Sd

jO , llllir er8< l1 BaS I

the ne\\' design 1

it's

easier to see your

workpiece

while

routing.

'The

I

is

listed

in the

I I 8 i ; - S G

Se....

T o o l

Catalog..,. order

numl,. .r 9-1{'J 2 i(182.

iA9.

IlIH'I:Rt;\T

ROlTERS.

O th e r c o mp am e s

(Black

and

Decker, Bosch . Po rte r-Cab le ,

and Makita) all manufacture guide bush

ings that fit their indh'idual

route, -s .

Some

ofthe bushings fit more than one brand of

router,

0

iI'S best to c he ek with a dealer

tho carries accessories

r

your router.

t:~I\'Y.RAAI.II,\S';PI,n:. One so lu ti on to

the problem of incompatibility between

brands

is \Tennont

American s universal

ball plate. The plastic base plate looks like

NEW SEAlS

GUIDE&uSHING

OlD SEAlS

G UID I' & U $H J NG

SEARS'IIt'SIIt~CS.Sears sells a guide

bushing set to fit their Craftsman routers.

It inc lude three different bushings with

o utsid e dia me te rs of ViI I . VI ' and ~ .

Before 1984

the

set was

made from

heavy steel plate. Unfortunatel); the cur

rent bushings are made from a th inner

gauge metal. The only ach'antage

'esee

in

OLD-fASHIONED WALL PHONE

Youcan order the hardware and electronic

package for the phone

from:

DAK OTAWOOOII'ORI\S. IN C.. 470 E lm

Street, Kindred, N 1) 58051; 800-137-47S7

ext.

333

(Catalog:

$2.00). Porty Lin

Phon Kit.

Order :-;0. 2PLB (specify' )'''

for toueh-tone or R for r ot ar y d ia l) .

Th~, kit includes al l of the reproduction

hardw . .re, electronics paekagr. iring in

structlons. and blueprints. (Note:

The

b lu ep rin ts s ho w u slightly different des ign

from the one presented

in

this issue. But

the hardware will work on hoth designs.)

The price of the kit is $124.69 plus S7.M

shipping

an d

handling.

TOOL CABINET

Youcan order the hardware for the tool

cabinet from:

THEWOOI)W()RkJ a long the side of template

following'

its shape. Since the router it

I

inside this bu,hinj , it rout. this .hal' in

the wood.

The template for the phone was jusl a

rectangular block

of

plywood, Uut guide

bushing> are a1suuS(.,.j \\;th dovetail joinl

fi.'(t.u.res(~ce

l\'OQd.~ tt(/i

No. 22). butt ..

hinge template>. and sign-making

CAItPEllAPE

Doub le - si ded C a rp e l

tape

wa s m e ntio ne d

ina couplespots in this issue. It's useful for

t empo r ar il y ho ld in g

parts

while screwing.

gluing.

or marking.

\Vcprefer the c lo th - ba ck (woven ) c a rp e t

tape instead of the plastic type.

It

hold.

tight but releases without pulling up

slivers

of

grain

or

l ea v in g g u m m y a dh esive

depoO'iw.

Note:

Should Ihere be any adhe

s iv e le ft o n

the wood il

ca n

be

cleaned

off

with l acquer thinner - whieh

must

be

done before finishing).

Double-sided carpet tape is available at

moothardware stores. \\'c recently bought

a

II -

w id e b y

12-footlong

roll

for

52 .29 .

RUBBING FINISHES

order most of our

finishing

suppl ies

from the following companies:

(:.\.RRETrIUJ)E('O~II'A. \:161Ave. oflhe

Amerieas,

N ew

York,

N Y 100J3 ;

8Q1} .221 2942(Catalog: S3.00).

Libero

Steel

Wuul

imported from England,

#0000

1#000 grade, V.lb. roll, Order No.

SIRIO.OJ. $3.36.

Small Felt Bl ,k.

I x 2-

x 4 ,

Order

N o .

99l'O9.01, 85.00.

Mit . .

,\1..-1, Kit,

18 sheets. foam block, instruc

tions, Order No. 5lP09.01, ~'l7.2S.

woon

fiNISHING SlI'I~I..

CO.

IXC. J26;

Mary Drive. Macedon, NY 14502:

:lJi;-9864617 (Catalng: $2.50).

Behlen'.

l l Ool { ub.:. pint, Order N . 8720)355

6.16. Behlen'. It IIbbill{l Compo H d n e u -

tral, pint, Order

1 0.

l I7 'J l}.OI115. 85.95.

WOOIWI~I'ntN(;

~T&RI'RtS&S, 17'2:9N.

68th St .. \Y auwaIO$a. 'I 532 13 :

111-771172-1Catalog;

Free).

Micrv . l1e.1t.

individual I' ~

6

sheets (see catalog for

grit.~). :l.oo per sheet,

Pnraffm (rubbing) oil. pumice. rotten

stone,

an d

paste waxes can

be

ordered

from

al l three

s ourc es

listed

a b o v e .

Th e 3MWoodf'ini.hing Pad ean be pur

chased from most

hardware

stores cam

ing 3M products. Lisl price: SI,5lJ.

\Vel-or-dI'Y silicon carbide sandpaper

and aut rubbing compound ca n b e pur

cha se d a t m os t

local

au to s upp ly

dealers.

Non--clogging,

ZillC

s te ara te s an dp ap er

ra n

be

purchased from many dealers who

carry 3Mor Norton products. Itcan also be

ordered in quantity from Garrelt \Vade

(address above) and from;

JA ~STOW~ OISTRIBt:TORS, 28 Nar

rsganseu Ave., P.O.80x 348, Jamestown,

RJ

0'Zl i3a;

MO-l23-003Q(Catalog:

Free).

.Jamestown

Distributors

has a wide selec

tion of sandpap,:r