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3 50OTS ROM TH SHOPO 57
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W OODSM1TI
2
'1'0~a little real ism into the shot, he
wan teil
to
ha ng the birdhouse on a tree
limb outside our shop window . W ith in tw o
days a family or wrens I)r ompt ly moved in.
' l' l\ ey work ed on th e nest, fly ing in and out,
an d
at
tim e s Jlen: hi ng on the roof. Itwould
have
be en a perfec t sh ot ,
:B ut every time he opened the w indo w
to get a clear sho t, the wrens became
came ra ~hy. The only tiroe they seemed
not
to ca re
abo ul Ted
Wid
the
earn ers
was
in th e
late.
aft.enloo n or eveui ng ,
hen the
lig ht w a s low too low for phoooJll 'apl lY
without a .JJash).
WeD Ted didn't J le~th e shot he want ed .
You'll have to use your imagination
to see
a
ca mera- shy
wren
)lOking
her-
head out
o f
th e birdhouse hole. E ven with
Our
peJiod ie
in te rruptio ns, Ole wrens se em
to
enjoy
t h e n new n o m e and \\C have enioyed
watching them
b u > i ly
build in g it.
NEW FAellS usually announ ce new
members of oun happy gnlilp in this
colum n, But- last.
year,
when Kenj W el sh
join ed US
as
manall\)r of the W l od ln ilit
tore here in Des 1I 101nO$.eornplet ely fo r.
got to mentio n him .
met Ken t as he was hel ping us w itl l
th e remo de lin g o f
an
ol d
carriage
ho use
be
h im l OU t t m a in building, H i s work was me
ti. ulo us and
caretul -
e spec ia ll y on th e con
struction o f the mail) s ta iteaSe
\\
added
to
lead to the sec ond floor. (It's a big coni.ge
house.)
Before he could comple te .h iswork 'cn the
carriage house ,
\V
were
impressed
enough
that he was hired to take on the task. of
running ow ' home -b as e s l'~. For the pas t
year he has worke d
bard
to help all who
co me in th e store. 'V~'l'e all
g I ; l < l
to hav e
Kellt w ith us.
MOMS .Four
ye dl:S
ago, Sand y, O hris tel
an d V ieky walked into my office one day
and anno un ced they we r e al l pr egnant.. 1
quickly had tests run on tile w ater in Lh.
dlillking fountain, and was relieved to
lea rn that the rest of us were safe.
Since
then, however, all
three have
added t o their ralnilles . And no w Chr istel
an d V ieky bav e dec ided
I >
leave 11 5 an d
de vote full time
tIS mom s,
e wish them
well,
ANO'I'HER NEW FACll . '1 '0 hell) fiU the
ga p, Lisa Thompson has joine d us
to
hel p
with customer se .-vice . She m ab-eadY
working on th e f ul fl ilmenL of the lO t oln e ...
that come in each aay. r th ink that witll
h ,' hel p we will be able to turn yo ur order
around \\1thin
t\\f
lays from the time \v e
l~v it
N'eXT ISSUE. Th.
nes t
iss ue of
W ood -
m itk
w i l l be mailed during the wee k of
August 2 .9 . 1988 .
WOODSMITFI (ISSN 0164-4114) Is ~b-
lis he d b imon thly February April, June, Au
gust. O ctober. )eG em ber) by W OO dsm llh
Publlshir)g Co.,
2200
Grand Ave., Des
M Oines , IA50312. .'
Woodsmitb is a regis te reo trademark 01
Woodsm ith Publishing Co.
@CopyrlghI1988byWoodsmithPub lishing
Co. Al lRiQhts ReseNed.
Subscriptions : One year (6 i ssI es) $1 2:95,
Tw oY ea ts (1 2 Issu es) S 22 .9 5. C an ada and
Foreign: add 2 R E I year. U.S. fu ndS onl y.
Sin gle c op y p rice . $3.50.
Second C lass Postage Pai d at Des
Moines, Iowa.
Postmaster: Send change 01 addres s
noU ce , 10Woodsmi th Publishin g Co., 2200
Gtan d A ve.. D es Mo in es, IA
S0312.
~ACK ISSU ES: A ll baGk issues of
Woodsmi th
are S1l11 vailable. For a Iree
bookle t dOSO' iblngthe contents and prices of
al l b ac k Issues , io st se nd u S y au r nam e and
address to th e a dd ress ab 0v e.
SAMPlE COPY: W e willb 0l1 ap py to se nd a
I re e s amp le
C O P y
01 Woodsmi th to anyone
y ou thin kw ould enjo y it Just send us his/ he r
name,
and
addres s.
J\_ B Otrr 1 RJS iSSUE. I'vealways respected
Japanese
ar chitectur e am I Cl dftsm ans hip .
'rh ,'( 's no do ubt that tr-dd itional Jap anes e
homes (an d thei r
su rr o u nd ing
gardens)
bring
man
and
nat ur e In
c lose
harmony
while at the same tim e be ing practical an d
cil 'icient.
Y et , while I adm ire the genius of Ja -
pa nes e architecture, Japanese furniture
des ign is no t so much to my lik ing. And
that
p re se n ts a p rob lem
f om th e
s tand -
po in t o f a woodwork er w ho wants
to
pa r
tic ip ste in some WlY with Japanese d'lsign.
I've been a lo ~ more int ei'\lS te d in b uild
ing a Japanese house than an y pi ece of Ja
ps nes e fumiture I've Seen. The so lution ill
sim pl e - build on ly pa rt of a house .
That is, I wanted
to
bu ild the one d es ig n
elem ent that epitomizes
Japa nese architec
tu re: shoji SCI'''S, (Thes e' are the slid ing
dC)O I'Shat allow the 'b lendi ng of arc hltec
ture with nature while still offering some
privaey.)
However, will adm i~.to feeling. Ii tU e
awkward about tak ing on thiS PlOOject.It
se ems
bes t
left to
a
lecture
fr om a
visiting
Ja pan es e master shoj i maker (tategu-shi).
'V ith a bo w to those who h av e d ev ote d
th e ir liv es to thi~ work , ( dec id ed to tlY
my ha nd at th is anc ien t trade. I decided to
build a foldi ng sc ree n made with
lb ree
sho ji
f ram e s .
i
we go t
w I >
th e ini tial design 'stages ,
my h esita tio n ab out
the
PJ:O jl'Otesurfaced.
Wha t happened was that we wanted to
mak e a couple of cha nges to th e traditiona l
sh oji ~ and I di dn 't fee l com fortabl e about
clianging a design stee ped in cradieion.
On tl lld it ional shoj i, the grid that forms
the center of the fr ame can
be
se en onl y
from One
side;
ric e
pa pe r
covers the
other
si de. But be cause of tl le nat ure of the fol d
in g sc reen, we
wtu 1 te d
to
h ave gr ids o n
both sid es .
Since the grids
are
trnditionally mo r-
tised in to the fram es, if the paper w ere
dam aged, it w au l,1 b e ne ar ly impo ss ible
to
replace w ithout disman tlin g the entire
frame.
Rather than mortise each piece of the
Wia
in to the fram e, we assem bled all en
ti re
Wid
th at
is
held into the outs ide frame
with removab le stops .
So ,
1I l'( th ese authentic shoji or are they
simply fo ldin g sc ree ns that look lik e shoji?
The'talte, is more a cc urate . But no ma tte l'
\v hat
th e
orig in or
authenticit)~
I v e en-
joyed buildi ng them .
B lt tOS.As Ted begins the task of photo
gr aphy fo)' ea ch iss ue, he's always faced
,, th th e p oblems of how to ~prop th e
pr oject. This b ec am e a 1 - e a J challenge when
he s ta rt ed wO)'ki ng on the bi rdho use.
Sawdust
Operat ions Steve K ro hm er
M a f 1 ( c i i r > g _ S te ve O o zier
l\dminisl1ative
As Christel M ine r
Slore Managers :
St lOOll\, MO Jon Behrle
B i r l e l o y CA Michael O eHaven
DesMoInes.IA Kent We ls h
The Woodsm ith S to re
W
lth
Number57
June 988
E d i t o r
D onald B , Peschke
D es ign O ire c o r
Ted Kral icek
M a n a g in g E d r lo r
O ouglas L. Hicks
Assistanl Editor O ou gla s M . L id ster
P r o j e < : t oes ;gner K en Munk el
T e d m i ca J I I IU s ll a r s
DJlvid Kreyling
Cary Chr is tensen
Rod Stoakes
C hris G lowacki
CUSlO_
S e I I c < I
S andy B aum , Mgr.
JackleS tro ud
Pat Koob
LiSJIThompson
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3
IIyou'd kkelO 'a .. I
_llg
lipwilh_
readers of Wood,mJth. send your idea 10:
WoodSlTl l th. T IJ)S & TecI1 IUqu t1$. 2200 G,and
Ave,D es _.Iowa 50312-
We
pay amrioom 01 S10 lor _ andS15 or
m ore $I>801aI 'ec t>noQueo (ilia, are _ a d
pub ieation).
PIe... g w e a C C < 1 l j1 Ie Io e x p la n a
tion 04 Y O U' Idea. If S k el et 1 I S n e ed e d. send i1
a lOng ;
welf
d raw a n ew on e.
SINO IN YOU. IDIAS
PUNCHING TIN
In lV()O(f II1 jil No. 55 we featured a
coun try p ie safe and I1 l1artic le on ho w to
punck the tin pane ls (or the do ors, After
lhe artic le appeared we heard from a
couple
,,,del'll
who
have
bu il t
p ie safe s an d
offered twe m ore t in-punching methods:
Edu,inBdl
H,,,,, . oio
mounts a
punch in a drill 1 1T l'l'i .T hen he sets th e
depth
gauge
on the drill press fo r
th e
cor
rect size bole when the punch is lowered ,
By
m ov ing the tin around on
th e
d riB p re s s
table and low erin g the p WlC h into the tin.
he punc h e s u nir nn hole&
/ Jo ll g/a s Stovall of
/Jam'iII.,
Vily-inia
uses an automatic c c . n t . . e r punch that.'s nor..
mal ly used (01 'metal I l1you l w ork. A punch
li ke th i.
ileU .
ro r abo u t $10. I t' s a sin gle
hand operatio n and can be a ciju ste d i rom
shallow to deop
pene t ra tion .
The U ps can
also
be ,. . g r ound
I. Q
ditTerent hole Sha pes.
Jitl
B61tini
Kersey, l e1l1 .I/I , 1 i
T o solv e the
Ilrcblem, 1
sI igl IUy
eoemer-
sink th e
shank
hole
on
th e
mdnside
of
the
front board.
1biI
c reate s a void ror any
raised
fibel'll to fit i ruo, Ir y ou 'r e a Jre ru Iy
se t up
to
cou nl( ,..ink the top of
th e
ho le ,
it's easy to flip the
boanI
over and eoun-
teraink the bottom .
~c_
oYT H N I C
HOt
to CIEATI Sf :
- . . . . . . . .
WOOOSMITH
STRAIGHTLlNE RIPPING JIG
In 1V Q(}(/. ' I1l1il
No.
53 a
reade r
re com
mend ed cu tt in g atrni ght edge on a
crooked bol lrd by I< mporarily gluing a
workp ie ce to a N t rn igh t ca rr ie r board w ith
ho t
mel t glu e. T he n t he c ar rie r board is
TU n
along the rip rence to cu t a stnlight
edge on th e workpie
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WOODSMITH
- ~ ~ __ -l.
10 4 .. _ ..
1 -
. .
N O T E :
A U . fl AM E . .. E C ES
STA IT OU T 1
' . . ' l o '
TtflCK.
aAJU A ItE R ES AW N L A I E .
fO
I \ niICK . SEE fIG 4 ,
f IGU R E I
4
'This fo lding screen is a seal ed-d ow n ve ... .
s io n of tra d itional J a p a n e s e shoji
p r o -
I 1 0 I l l l C e d show-gee).
In Japan.
sh o j i s
ar e
used
as sl iding doon< or room partitions
that
ru n from fl oor to ceil ing.
Our version is .horter. It ean be u s e d to
divide offa s ect io o o f a room or as a dress
ing
screen. 1 0 addition to the tdze. we ve
also made some other
c h 3 n g e s .
Jap. ' ' ' ' '
shojis have a eenter grid mortised into the
frame
with rice
paper glued to th e hack of
the grid The paper i. trtlditionaUy
changed every year before N ew Year's
Day so the
how;e
can begin th e
Y
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5
OODSMITH
NOTE:
C H E C , T H A t
A L L E G Il S t A Y
FIA I A GAl NS J C lAM I'S
ASSEMBLY
On c e all of the sptil l
r
NOTE:
A U snl l I I. l }1:lat
All RA ILS I',, THICK
S I I L E
CHAMf'1 A U
fDGfS
OF S fllI$I XCEn
WH~RfEND SWET t Ail
M IOIlI f
SPUNES
@
_
2
_~
',t' W A S T E
' '::.,.
ONO '
F E T H E R
80
_
lfAVE NeE ./
AHDIlAO[
~
SlmNOTHl
$AMI ,
Then rut two grooves on the insi edge
of all of the stiles and r:dls. On the middle
r:dl OI~Y,cut
be
groove. on
o o
edges. To
C II t
the
second
groove,
tum
the piece
end -
fOI'( nd. (Note:
If
the stites are at all
bowed, eut the grooves on the convex side
so it b o w s in toward the center of the
frame. Then be grid wiU force the pieee
8U':IighL)
END GROOV8S. NexI, to aeeept the
splines, cut matc lUng grooves in the ends
of the
r : U I s
To do this, don't change the
saw
lIett.ing,
b u t stan d
the
raiL~
on
en d
and
cut the end grooves, see Fig. 3. (Shop
Note: r supported the workpiece with a
wood block. A tenon jig would also W011< ,
but that require ,Uing the fenee.)
CUT TO TWCKl'IESS.After the end
grooves are cut, tbe rails 8 can be cuI to
final thic lmess. Traditional Japanese de-
sign C 3 l J s fer the rails to be thinner than
the sllles. To do this, cut
off ea ch rail
US i ng a
two step
method, so o F ig . 4.
First, set the rip fence 1%' from the
blade and cut
\ o l
off one side, see Step 1
in
I'~g.4.
Then move
the
fence
in
and cut
\ 0 { /
off the other side, see Step 2.
CHAMFERS
Before assembl ing the frame. ha m f e r ed
the edges. On the stiles, chantfer all of the
edges except where the end of the stile
meets the rail , see .'ig. S.
On the rails. chamfer only the top edges
of
the top
rail an d
the
beuem edges of
the
bottom rail. Oon't chamfer the inside edges
or the middle rail.
SPL .INES
The frame is held together with aplinea
thot
fit
in the grooves.
51.'111.by
resawing
stock to thickness to match the grooves.
CUT TO W Il> 'J 'f I. For strength, the grain
on the splines shou ld ' perpendicular to
the joint line. Th is
makes
the splines wider
than they are long, note grain direction in
Fig. 6.
1'01' the splines C) on the Lo p and bot-
tom joints, cut them to width to 6t from
the edge of be rail to the boUom of the
Bpline groove (1 ~ ),
00
Fig. G . Since
there are grooves 011 both sides of the
middle rail. the middle .plines 0 are cut
to fi t be tween tlte sp line g rooves (lV,t
wide).
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cumNG GRID PIECES
After the fnun are complete. work can I ~
begin on the grids that fit inside the I' :
frames, A U o f th e g rid pieces are l o w thick
tin held
together
with lap
join ts ,
Tho
border picee
nro
. t
wide and
th e
center
pieces
are
o/,,~w ide.
CUTTO wreru. Start by ripping 814(or
l .t. thick)
stock into
strips for the side
g rid plo ee s (E ) a nd
the
to p
and
bottom g rid
pieces
(F),
se e
Fig. 10.
To a llow
fo r
plan.
in g,
rip
these
strips
a tittle (1(,,) more
h an W ' thlclc, _ Pig. 8.
If
yOUTe
making
three
screens,
cu t
at
least
four Y w th icks t rips to
a
rough
length
of 4r for the Ie g rid p ie ce s (E), s ee S te p
I
ill Fig.
8. Also
cu t
four
y, -thick
strips
to a rougll length of 1 7 for th e t op lbo tt om
piece. (P), (I cu t extra strips of ever y .i,.4)
as
j < t e s t pieces
1Ift(1
so I d have
extras
in
esse lily of the strips warped.)
CUT TO '1'IUCl{Nll$S.Alter th e .t th ick
strips
are
cut, reset the rip
fence
to U ttle
more
than ....
from
the
blade,
see Step 2
in
~lg
.
Lay
the
workpiece
down
on
its
side an d
rip
tw elv e s id es
(E)
from
the four
49
strips
an d
twelve
topIbottoms
(1') from
the four 17 .trips.
Ct:l
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OODSM ITH
c ,.
_RI
@
S lO E
GIlD
kPf ACINOerrwuN
AU t DAOOlS eVEN
FlGUIE
the jig, see .Fig. 17. Again. mark lhe ends.
the jig so the blade cuts about
in
the een
te r .h e jig, W Id screw the miter gnuge
to the back fence the jig.
GUARD.To keep fingers away from the
blade. I made a guard from a couple pieces
of
scrap and
s c r ewed
it to the bad
nd
te ll o n join t.
Another choice is
a
lap joint.
Tho b ig gest prob lem with this
joint. is a ~ua1
Ol\e -
it.
aUO\\S
pari
of the
en d
gTlIin
to
he soon
o n the
edges of the fram e (refer
to F ig.
I .
How ever, b eeause the
des ign
of this fram e i n dudes molding
strips that cover the edges
and
the end grain areas of the
lap
jointa),
I decided to we
lap joints.
8UIL DING THE FRAME
To b uild the m im e, the fou r s id e s
a re c ut
to
s iz e nnd joined w ith half
la ps. B e llin
by
rippin g
4 1 4
stock
( y,, ac tu nl thickness) 1U s
w ide. Then cu t tllC fr-dIlle si des
(A )
? :IV /
lo ng an d the top an d
bottom frame I)ioccs (H) 21 '
lo ng , se c ~~g . 1
HALf I..A I'S. A Jl.er the f ram e pieces are SET HEIGHT. The second
critical
cu t to length, half
laps
are cut
00
th e end$ measurement
is
th e th ic kn es s o f each lap.
to
jo in th e co me .... o f the f ram e. There are A l of the dado b lade so it
tw o critical m easurem ents for these
lap
wiD cu t n tt y h lf w a y th ro ug h
the
stock.
joints,
First,
t he d is ta n ce from the
en d
of
( his
win tak e ... m e
trW
and error cuts on
the
workpiece to
the
shooJder must
be
some
test
pieees.)
equa l
on all
pieces,
W hen the height of the b lade is sa form
To e ' llre th is, I
used
the rip fen ce as the laps
by
m ak in g m ultip le p asse s
o'er
sto p. L ock
the
rip fenee down so it's I
y, the
blade.
(the width of the sto ck ) fro m the far side GLUE PRAM&. AJl.er l1PS are cut On
the
of the dado b lad e, see D etail. F ig . 2 . ends of a ll f ou r p ie ,:cs. the f rame can be
R~Gr nUH~I - - - - - - - - - - - - - - - - - - ~==~~~- - ~~~U ~A~N=.
. ~. . ~ ~~~
CUM
NOTE:
H....
W S
ust
~
C V l _
$lOCO
A P R OJE CT TH AT R E FLE CTSTRA D I T ION
fPT H i It
TM tc ICN(SS
Of
STOCI (
D E T A I k
HAIl...
N T
Wall
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II
QODSMITH
N On
so
fU.MI
O PlYWOO
AOC_V
_ . . . . . . . . . . . .
M O U l I t O G S
ROUTIR
TA ILE
KNQ
MfTtl HOS
TO A T
@
TOP /BOnOM
MOLDINGS
fIGURE
f. PlYWOOD BACK
anT O I
0f lH1HO -_ .-
. . . . . .
SPAaRJI i;
PUA l l
@
IN NER
SIDE
TRIM
CU I
NC
,om
_
. , .
n
tQUIU
,-
F l r o c
@
0IIfS101
~PI :E
8.QUIU iC LOml\
@
OUTSIDE
TA IM PIECE
@
OUTSIDE
TR IM P IECE
-,
AGUU,
G A U G .To kee p the rounded edge uni
fonn for
th e
l en gth o f
th e I 'r ame . I
made a
simp le g auge. The ga ug e
is tw o
strips of
~ Masoni~
gl ued together v.;th
th e
edges olL le t
about Yo
se e DeWI. Fig. 3.
MOllNT
S11Uf 'S .To mount
the
ou tside
strip
(C). apply
gl ue to the
strip an d Crnme
an d pu t
three C -e lamp loooeIy in
position.
see Fig. 3. N ext. use the gauge to align
the top (roun ded edge) of
the strip, see
Fig.
3. Then tigh~n the clamps.
TlU M
E N I)S.A ller
th e
glue
d rie s. r emove
the clam ps and tr im the en ds otT t he out
side st rip s
flu s h
w ith
lh e
to l>
a n d
bottom .
INSIDE nltIl'S.
N ow
th e inside ships (D.
E ) can be glued
to
the
inside of
th e frame.
This
is
done
in
two ~ tel ' Fi rs t. carefully
cu t the strips
to
fi t
th e inside d ime ll lj ion s
or the fr.une
w ith 45-
miters on the ends.
Next .
apply
glue
to
th e
strips
an d frame.
and usc the spooer gauge to position the
strips an d clamp
them in
place.
see Fig. 4.
BACK.Aller
th e
stJips ar e
glued in
place.
th e
plywood
back (L ) is cut to
size.
Cut
itto
wi dth
t o f it b etwee n th e out.'1ide strips
(C).
Then cut it
to
l eng th SOit 's
nush
with
th e to p
.nd
bottom
e d g e s of the
f r ame.
se e
Fi g. 4.
(Wait
until
law
to
attach it.)
MIR ROR MOLDING
The
mhTOIis held
in
th e frame with
p ro -
fi le d mokling strips F .
G .
1 made
these
m o ld i ng a o n
the
ro u te r ta b te flo m a
2 -w jde
piece
of
\O (.' ~hicktock, R eG
Stell
1. Fig. 5.
CU T
P IIOFIJ .E ,
'l'he
proHle
is cu t
w ith.
1 ( . R o m n n ogee
bi t.
Begin b y practicing
on a
piece
of \~ -th ick scrap li n d ad just th e
he igh t
O f the bit
until
the top and
bo ttom
s hou lde rs a re equa l. se e
Step 2, Then
rout
001/0e d g e s of
the 2 -w id e blank,
IU.P
MOLDINGS .
After routing
th e
pro-
~, the ~ -\l;de
molding strips
are
ripped
oil th e e dl lC'ti.see Step 3.
C UTTO SIZ E .
To fi t
the
moldings
inside
the frame. b e g i n by
mitering
the end.,
of
the
side moIdinWOF)
so
they fit
tight be
tw een the top
l ind
bottom of the Crnme,
T h e n miw
th e
ends
o f the top an d bottom
moldings 0 f or a tight
fitbetween
th e s id e
moldings.
SPA CK
> 0 1 1
MmR OR .
\Vhen
gluin g the
moldin .. in
place,
L hey
have to be posi
tio ned to allo w
for
the thi clOlIl'lSof
th e
mir
ro r. r o do t.his , I cut; s e ve ra l spacers th e
Same
thick ness as the m irror. (I
u s e d
Masoni~
or
I~ ,thickmirro r).
MOU N 'rMOWIN GS .N ow . to moun t, t he
mokUnWO.
< J t th e Inune
ov er
tb e
plywood
00ck
an d p ooillon the
s p a c e r strips
along
th e in side
trim strips
(D ). see Fig. 6. Then
app ly g lu e
to the
moldinga
a nd p re ss
them
against. th e in ~
rim strips
an d
dow n on
th e
top of
th e .pooer
strips.
N~:It Imoo;i.
impossibl e to clamp
the
moldings
in p lace, so
I
held
each pi
eee
of
moktin g w ith m y fm gt>rs until
the
glue
grabbed
(about
minute).
then instalJed
th e next p ie ee o f mok lin g.
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WOODSMITH
C U RV E D S HE ll
When
th e
I rrune
w as com pleted. I
a d d < d
a
m olded cap on
th e
to p
and
lIb elf o n th e
bottom . I started with th e s he lf.
rw o
LAYellS.
The shel f is laminated
w ith tw o
piece . . : the Lop
piece
H)
with
n
bu lln o se edge and the b ottom p ie ce
(I)
with
Roman ~ l fiIe. refer to Fig. 9 . Both
pieces
are cut from
41 4 stoek 5W
wide.
Cut
the
L op p iece (H) 24'
lo ng
and the bo t-
tom piec e I) 23' long, See Fig . 7 .
ARcs.
AllA>r the work pieees are rut IA
m e . eoncenuic arcs are struck on
th e
front
edges with
an an:
jig . T o
m a k e
the j ig , j oi n
tw o pieces of stock in a
T'
shape, see Fig.
7. Then draw a centerline down the stem
of
the T'.
The arcs are drawn
using
an ann made
(rom a thin
strip
o( scrap with three holes
in it, see Fig. 7. Drilla ho le at one end for
tho pivot point.
At the
other en d
drill two
holel l (or th e pe ncil, one 191 / fr om th o
l)ivO I ;poin t, and the other 20 from th o
p O L
point.
(Don' t
mount this ann. ye .)
AUGN JlC. A llA >r
maki n g
the
jig,
draw
n ~nterline .,,_
b oth s he lf p ie ce s
(H, I),
centered on th o length. Tho n align th e ce n
te rline on the
W I )
piece H) with
the
ce n
terline on the jig.
DRAW ARcs. T o draw
th e
an: on
th e
top
pieee (H),
mark
poi n t
on
the .. ui o(
th e
workpiece
1 .down from
the top edge,
se c
F~g.7.
Now center the 20 l)Cl1CiIhole
ove r
this
point, and drive n brad through
th e
pivot
hole
at the
to p
o(
th e
swing arm.
( M ak e s u r e
the
brad
iscentered
o n th e
reno
terline on the jig .) T hen strike an are alo ng
th e
fron~edge
of
the workpiece.
To
bl y
out
the
are on the bottom piece
I).
mark
0 P OUlt
on
th e
end of the work
piece 1% d o , , from
th e
top edge. Then
put the pencil
in
the
19~' hole
and strike
an arc using the sam e pivot position.
Note: To make concentric l U C S t it's im-
,orLant
to
ch ange the position of the pen,
ciI.
w
t it '
point. If you
ehaoge
the
p ivo t po in t,
the
l in es won 't
he
oonc:enuic.
CITr TO SHAPE.
A l l A > r sui king the arcs,
cut
the top and bo ttom sh elf pieces
to
shape
with.
sa ber .. w o r ban d saw
und
sand the
e dg es sm oo th .
ROUT EO OES. N ex t. ro ut a b uJlo ose pro
file on
the
curved edge and
the
ends o(
the
shelf top piece
H).
I did this w ith a \ o
ro und-over bit oct only
0 / .
hi gh, se e
DeUtiI
ill
Fig. 8 . For
the
shelf bottom piece
(I),
rout the curved edge and ends w ith a
z
Roman ~
bit,
see Fig. 9 .
A T l'A C R SHllLV ES . T h e ~ he lf top piece
(Hl is attached to the bottom edge o(
the
Ieume w ith
th1'Ctl
N o. 8 X llt Fh wood
sc re ws, D rill 1) lOtholes and then glue and
screw
this
pieee to the frame, see Fig. 8 .
T o m oe nt
th e shelf
b ottom p ie ce
n,
cen-
ter it on the shelf top piece
H)
with
the
rear ed ges n u.~h. The n glue and clamp it in
plaee,
12
ao u r (N OS RItST
OU T 'ACt
AN O IN O _.,..
CAP-
Q )
T O P
ROUNDOvtlt
VOTE:lEAVI Mel( EDGES
OF aoJH CAP AND
T O S Q U AR E
DE T AIL
GUI'10
C,NTt. $1191eonOM
ON SHfIl' TOP AND......../
GlUt IN PlACE
D E Te l L
(S IDE VIEW,
#81l1')''' I
' W O O O S C : . E W S
1 > -
._ )
It IJ
lit 1'II
F h w o o n S C RE W
N O T E:
CEHltI SHill Tot
ON.eoftOM
f _
GIl
BQIl ING PETAl~
tor
1 ,, -
SHElf TO P
7/24/2019 Woodsmith - 057
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1
.
A I notch
es,
To
c. ut
these
nctehea,
It
tho dildo blade to cut the same
width as the logs (in my case, %'). Next,
(l(iju st
the height of the blade to cut exactly
halfw ay through the log.
When the dndo blade
is
set. adjust the
rip fence to U S a stop so it's ~. from
the dado blade. see Fig. 2. Now, hold the
logs
tight
against the miter gauge with the
ends bulUd agail'.' the rip fence and cut
the ~ on both
ends
of the wal l logs.
CHAMfER LOGS
puntil now, the logs are just square
stock. To make them look
like
logs, I
ehamfered
the ends and the edges on the
router L l b I e ,see
Fig. 3.
C abin B irdho use
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7
WOODSMITH
CROss SECI and th e
halflaps
used on
th e lo g s o n the
walls
bec:omes
obvious.
The
main dif fe rence
is that
Lincoln
Logs
ar e truly interiocking, so
th e
ends of
the
w alls stay alig ned b y desig n. B ut w ith h alf
la p joints
the
lo gs c an sl ide, so the w alls
w o n't stay aligned o f th eir o wn 8OC01-d.
W A LL SO Il SW8.
This sliding is no
big deal
beceuse the
wall
logs
ha ve
to be screw ed
together U\Y v l Iy .
I
used 2YI ' long No .8
SC l 'OWS
o
tie the low er
four
tiers of 109> o
gether (sc rewing up from t he b o ttom ) , se c
Fig. 6. Then I sank two m ore tlC re WK
th ro u g h th e top o f the front
and b ac k
walls
to
tie the top tiers of
logs
to the
bottom.
see Fig. 6.
S ho p N o te :
The
screws
join
four logs
t < > -
getbcr.
Dril l ing
a sh an k h ole thro ug h lh e
(Irst three lo g> and
pilot
hole into th e
fourth w ould b e a
typ ieaJ
p ro ce du re . n ut
in
th ja sitnntion th er e w ould only be about
thr.e th' ead s ho lding ea ch screw in . . n .
cedar, S o I spot glued th e 109> together
fi rs t
and
drilled a 4 pi lo t hole through all
fo ur lo gs. _
C r o s s
Section. Fig. 6.
AI)D lI AV BLOCKS. T o com plete
the
walls, nail
th e angted
eave
log> to the to p
of
the walls, se e
Fig. 6.
(1
pre-
d ril le d th e
ho le to make it easier to driv e th e I > r a d s
wi thou t sp li tt ing the
wood.)
WALL ASSEMBLY
AD . JUSTar r, T o
set up the
router
table.
align
the
fro nt edg e
of
the router tab le
f n with the edge o f the pi lot o n the b it,
see
Detail.
Fig.
3 . Then , using
3 scrap 88
a test. piece, a arc
chamfered, the
ea ve
lo g> arc m ade fro m
the uncut
piece
of
seoek
(C),
see F 'ig . 5 .
T o make
these
logs ,
begin by c l l: unfe r
ing th e
ends a n d otto
ed ges o f
th e
work
piece.
Next. setthe table sa w to a 458Jlgle
and
rip one eave log o ff the outside ed.$tl>.
T he n res ct th e fence and cut IUlOther one
on the opposite
side,
se e Deta il. Fig . 5.
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WOOOS~UTH
W ith tlle wa ll s complete, the next step is
to
make the gsbIe logs 8 that form the
p e a k of
tbe
roof . ound
the e a : , W s t
way
to do
this
w as to s t.'l Ck
t .he Ulree
full.length
IOf 8
f l l ' S . , then
e ut,
th em to
a trillngu lar
sh n p e as a unit.
G I,. U E L OG S. 1 0
build up the Il1lblC ogs,
glue
three
logs tq(e t .her, keeping
til.
fr ont
f u < : e s
parallel
To do this, apply glue to L b e
fllcing edges and lay
the logs
nat. Then
clamp
th em tight ly keeping
tbe faees
an d
end s aligned , 0 1 0 0 D e t a il in Fig. 7 .
AIle,'
th e glu ed sta ck of logs is
dry,
plac e
it in the notches in t.he angled eave log s.
Then glue
and clam p
the three logs as a
unit on top of the
walls,
see Fig. 7.
Note:
It does.n tmatter
what
kind
of
glue
is
u s e d
w a te l ) ro o f O r not) b e c aus e the
gubl. log s w i ll ac tu ally
be
held together
with
n a i l s
la te r.)
R ID GE BE AM . Aller L b e
ga ble
logs are
dry,
a ridge b e a m
(0)
is made
to
oupport
the roof, see Fig.
8.
The
easie. l
W'dYto
make this beam
is
to t tbe sa w b lad e at
nd cut off one of the
edges
of n 7 .long ,
'VI ' thick pi ec e
O f
stock. (This is tl ,e same
technique used
to
cu t the e a ve IOW I,s ee
Cutting Detail
in
~ ilt..)
MOlnoT RlOOR BEAM.
To mount
th e
r i g c
beam, position it so the r comer
r .'o os u p a nd it's c entered on th e g able logs,
> I C C ~'ig. 8 . Then nllpl y a co upl e dabs or glu e
arK)
Il fti l it
in place
with 1 f inish n tu ls sec
Ridge Det.ail in f 'i g. 8 .
Cl1T GABu s Aller naiIi:ng the ridge
beam
in
place,
th e
gsbIe logs are cut 00 at
.46 an gle to form the roof line, T o (10 this,
llijO
the angled
sllrf c ,
o r
the
ridge
beam
Hnd ca ve lo gs to a li gn n b aek sa w,
Ti, .n
saw
t
the ends of tllc gable logs, see )o 'ig. 9.
N ote: W hen cutLing the gable logs,
the
saw
will
a I $ O cu t
o O 't he e nd
o f L b e top logs
on the
walls,
see Fig. 10.
This is
ob y. It
will
provide c l e a r a n c e fo r
the
ro o f.
NAIL GAI)~F. LOGS,
After the gn ble s log s
IIr
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19
DETA il
4 l1Urs .fOUlltO
--_- 1
D E T A I L
9
TWO lCU
UOOR.O KIA
MINGUS
D E T A IL
~_. IOUNOOvt. lIT
ItOUTlt
r
Uli l
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\VOODSMITH
LAY SHINGLES
Afte r a ll the sh ingles
are
cut, tb ey 're g lue d
to th e Masonite roof s he at hin g . A lth ough ~
professiona l r oof use a sh ing ti ng
hatchet
to al ig n th e shi ng le c ou rs es , cribed l ines
on the sheathing for al ignment.
IJNE SPACIN G .
The lin es
are 6)10
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21OODSM ITH
and
wor < to the right end. lW peat this
AGUlE' 17
_
. .
P I O C O S S al l the way up the roof.
1 ' 1UM RIl)CE .
' be
Wt
co urse o f
&tingles
A~
1
~nOM
CUWInS
, ; - : : ;
~~-
is applied I O
th e U lP end of
the shingles
TItlOUGI< lIDG.AfU>r
all
the sbingles
are
in
1
j
place
the ridge C lip is
put
on . Nonn ally,
J1..,7 )'
7
. 1 . 1
~~
he rid): e en p
is
mad e
o r pertions
of GALVAHIIE'O
.bi ng les . But, to kee p
Irom
having
(0
work
1 7777 \,
) P I '
with wlY ,J iC'l , , used
strips. 77. . , ....,.
1 '0
mak e ti le ridge caps, tr im th e tw o
MATERIAL S L IST cunlNG DIAGRAM
VI6' tr uck trip (m ad e when making th e
eave
boards)
to
M o
wide
and 0/,,
wide.
0,1 011 Dlmfn,j.o.ns. Slid x 8~ w It 71/th
314.115.1;2 :16
Then
glue them to the top course of
A W.II
log.
(20) Y 0/..-7
[
at i
i~tg
bingles w ith the W
strip
overlapping the
Gablo log. (6)
~
0/, trip, s e o e
Detail A in Fig, 1 6.
B I
1 -7
C e . . .
log>
(2) V.V.-7
_ F
I
r
[~
LOOR
D R- ge ......
(I )
V V.-7
C
E
E
W ith the 1 'O Ofinisbed, the
house need,
a
e
Sbiog (3001
I,.Jt v. _ 1
1/.
D
D oor for the
ne.t
To mak e h ou :< ek ee pin g
F
- (1)
V.x41 A._ 6
ALSONEEDPIta Of 1 ; . MASONITE :It t2YJ
easier, I
mad.
the D oor rEmOvable SO
old
nests
and
deb ;
(wh ieh p ro, id e
an off ,
IRDHOUSE
SICS
on home for bugs) coold b e c leaned ou t
fo r
a new
f nm it y o f b ir ds
next spring.
cor TO S1Zv. . To make
th e b otto m
(I )
Binl s
are
I>It. Sj>aJTO'' ' '
and
, t. ar ling s . .
IISU-
th e cbart below ,In ), 'UideJi ,, 'S,
not rules.
l lANO M OI INTING .To keep
the
bouse in
a l l , : ,
on
the un\\'{'lco1 le l ist,
A fam il)' o f w re ns I i l:n ore d th e
guide-
the tree
(even w hen
rocked
by
gale
force Keeping w rl;nJ (ll out is no problem - lin es an d
moved
uno our I\OU .~ - even
win ds ), .h e h an gc rH h av e W 00
finnly an-
they require an
en trance
hol e at least J :
in
though
the
ho le b
iu.t
2~' upfrom
the
chored
through
t h e r id ) :e
beam mto the
top diall 1C clw r
tv...
6'
to
s -
4 ;< 4
8
to
1 (1 ' 6'
to
20'
b ird y ou w an t to altn lcl, se e b ox a t rig hl.)
Eastern
Bluebird
lY . r :
S
S , :;-
8'
to 1 0 '
PlNJ jIL
Finally,
to
keep
the cedar
Nuthatch
V
6'toS'
4'
x
4'
If ' u> 1 (1 ' 12 to
20'
shingleo
U d
l og s f rom abs or bi ng
moisture,
TI~
lV.-
6' loS'
4,
x
4
If 'to
1 ( r
6 to 15'
I
la id o n two coal
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WOOOSMlTH
p la ne h er e, but if yo u're d oing a lot o f p la n
ing you'D probably want to use a larger
smoothing (No.4) or jack (N o.
5
plane.
ROU' f lo :R ' rAa lJo:. Hand planing ca n be
fu n , bu t the tJ lOUgl ll of planing al l lOB grid
pieces ro r th e shoj i
screen
\v as a L itt le ov er
whelming. S o I use d u different technique
similar
I . < >
II
tip
w e re ce iv ed from
Jim Ser
ra to re , o f H atboro , Pe nn sy lv an ia , J im uses
a router table tike a m in iature planer.
The trick hero ill to push the workpiece
&om left to right bdltM a tmight bit an d
the router
fence. (No te:
I C
you r router
takes ~-shank biL'. use them. They help
t
,;bration for
smooIheT . ..
t.
Sinoe II1 ' I RS.
Another m ethod uses
side runnen< and b oek pI :me. The run
n ers a re simply a c ou ple of l1CI 8ps of ~ .
t h ick . -t o ek that
r id e a lo ng
both
sides
of
the
plane . The
> I a n e
is pinched between the
runners ,Lh two bolts an d
wing
nuts. The
ad van ta ge o f th is m eth od over the sole run
ners is that you can
il < : O l o r e c l
tig ht.- gra in ed s of t w o od s. (Sometimes, the
wood
is
laequered
black.)
PONI ROSA PtNE. W.
wanted to use
Sitka spruce, but because o cost. an d
avaiL'tbility w e fin,illy se tiled on Ponderosa
pine. The key .. to choose stock that's clear
of knots and d.fecta and ha s grain that'o
ns stm ight lUI
possib le.
Also, when buying the lumbe r, don't get
u U colistn lct ion
grndc
pine
to
save m oney
- it
wiD
yield
more headaches
than
savln.gs. ' ICom lnon grades (such as No.1
or No.2) woul d work , but yo u may have
to wor k around knots and defects so extra
stock ,II be needed. 'rhe best soft;wood
lumber to get is select' grade, such as
D
and
Beuer or
C
and
Better.
(F or
more
on
pine. see IVood mi h
1 1 0 .
55.)
omER POSSlBlUTIES. What about
other woods? We'v e built. other fuIl-size
shojis Mth Sitka spru
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V OOOSM IT H
oep.e 1 1 1 1 'S . One J a . . < t note. In addition to
the Raman ogee, there are t ,o other bits
in lhu OW c frun il )r, A
lil Jxhu'tl
oft ce is
sim ilar to a Rom an ogee, bll t th e locat ion
the eo ncn ve l:l.I\dlh e convex C U I VC S ar e
,v I, top drawing.
I r
(m cx tr ..
.boulder
i< I
,kled
th e
gee
b it , i t i s. ru le d
an agee ith a lillet.
Roman agee bits have tw o rad ii
0 00n-
e av e 3 Jx i :& convex) that are the same : t i : z e .
T he n om in al size
of the
bi t
( I,, )
refers
U1esilA. of ~Ich radius rather than the over
al l cut of the bit . The re arc two com m on
$irb of Roman ogee bits: o / . r l llnd
v . . .
OTIIt-;n I)ESIONS, The : I X l l 3Jl{1
V I
radii
a re c om m on ~iJoJlS,
but
there .' other
de
siWl fNllU , on a Roman ogee bit
that
' 31 ) '
from nullluf:1eturer to nuulufacturer,
Manufucturers ususIIy Ii,t the overall
height of the cutting edge from the top of
the . hO l ll d. r s ec ti on th e b otu >m of th e
bit (1101 counting the bearing). This
nlt. 38Ul ( lnentvaries from one luanufae-
tUlCI
to unother,
ln r cu l il .y , t h is measu rement isn 't lm po r
tanto
You tun increase the slze of
the
sh ou ld er by lowering th e bit
3 , , < 1
making
repeat pa. . .ses What is important (and isn't
uswilly listed) is the location of the cem e r s
of the tw o radii in relation eacll athOl .
Some Roman ogee bits have the
\ 0
cenl('~ on the same horizon. sc U te bil on
the Io n in the
drawing
below . OU1( '1'm an
ufncult Cn\ (.Ic~igll an elongated hit. w lth the
ccnt. tl\l SI)rend apart. as on the rig llt...
'r ill. e rre ct.. t he fi nis h< :< 1app earan ce o r
th e
,'lit lind can be c r it i. ru if you're trying
to m atch an
ex i3ting Roman
ogt' < t will cut. hen I
keep it
hanging
ri gh t 11i. X~to
n,y
,, W to
C klm p tb e featberboards to th e tabl e
M d use support b locks to h old th em in
pIaoe, se e
U>p
d raw in g, T he n, y ou ',.. re ad y
to plane from left 1.0 right. AI,.).,;:;tart
\\ ith a test, p ie c e s in c e ( (( 'tUng t h e renee and
foatherboanls set up corT< cllymay take
so m e fine tuning.
SAMPLE DADO 80ARD
W hen cu tt ing
t i , .
lap jo int. for the lo g c abin
bi rdhouse
an d
th e
grid o n th e sh qji scre en .
it . important that the pi~ fit t igh tly to
((('thor.
To do this, you have to cut
an d
plan e th e pieces the
e xa ct s am e
idth
11 8the eross dadoes tha~h ey 're g oin g
to
fit in lO .
The problem
is th at
you
usuill ly
have to
cu t and pian. the pi~' 1 1 8
you cot the dlldoo.. 'rhough m ost
.tack dad o sets I\)'e fa irly accurate, you
never know exactly how w ide cu t and
plane
the
wort ,p iece until you have dado
1.0 test it in.
T h er e's a lw ay s 3dlln((( 'r of kiekbacl< an y
tim e y ou
push
a
piece of wood b etw een th e
bi ~ and the fence (that is, from left
to
right
in to the rotation of the bit), T o pre ve nt
th i. , and ho ld tll. I,i_- tight against
th e renee for a smooth CU t , I c lam ped two
fcathel'b03 l 'ds
to
the rou te r
ta b le .
the teatherboarda have to be etampe d to
the be nch in sligh t~v on : 'lC~poo ;i ti ons. The
left (infeed) fcathcrboo rd hold. the w ork
p ie c e t ig h t against the fe jll,1 b e / l Y r e the
routr bi t cuts the workpiece , The right
(outfeed) rcatherboanl is :0 little
doser
the fence 1.0 bold the fin ished workpiece
ti ,~ against, the fenee a./ltr th e cut,
N O T E :
R , .
WOlKflOM
LIlT 0 ItIGHr
bi ~ the atOO1iaey f~ equa l the
de.;i.oo stook
I.hickn~.
(Note: Don t
try
to plane 0(1 ' more tl , IW in one pass,)
7/24/2019 Woodsmith - 057
24/24
WOOOSMITH
24
S inc e th e ri ee paper on ly comes
in
11 '
w idlh, ' (an, l the g'liils are 16' w id e) , ~ou
w ill have
to
glu e the paper d ow n
to
th e
bac k of th e grid w ith joiru -un der
th e
cen
tel' v ert ic al 5U ;p,
To do thi s, sLap le the pape,. dow n to the
ba ck of Ih e 6 at the top (the sam e as fo r
$e libe ,rgiass sheet), But with the riC e
p ap e r, tine up One edge of t h o J) aper hal f
way
ove r the
ce nt , .ertlcal strip,
Then
fold th e pa pe r ba ck
a nd
sp re a d thin
I.Y81
of white glu e
dow n
the veltical center
a nd
ar oun d outs ide. Nl'x t, li,y the paper
hack dow n and press
it
in to th e glued sur
fa c e, A t'U lr th e paper is glu ed down, trim
the
e xe e ss
of f along U ,
outs ide
ed ge s W ith
a sh arp knife or ....,.,or blade.
KJ1 '
l'lUcr.s .
Th e prices listed
fO l'the
kits
include nos ta g
