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Woodsmith - 058

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    O TE S FR O M T S H O PO 8

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    WOODSM I1'H

    AB011l ' TH IS ISSUE, How high shoul d

    a

    issue.

    What

    it gets down

    to

    is th at

    the

    QheS I of drawers be? That's a good q u e s - height of the ease is actually d ete rm in ed

    tion. And one tha t's ac tu ally v ery difficul t by the draw ers, whic h a re mu lt ip le s of /. .

    to answer.

    But t

    wou ld

    be too easy

    if

    that

    were

    th e

    When you set out to build a chest of only co nsi deration,

    d ra w e rs ,

    there are two m ajor

    st e p s :

    build - In a dd ition

    to th e

    dovetai l lay out, y ou

    in g th e c he st itse lf,

    an d

    then building the have

    to

    a ll ow f or th e c le ara nc e ab ov e e ac h

    d raw ers to

    fit, So

    it would seem easy

    to

    drawer.

    MOl'

    pla n nin g a he ad. A ls o, s in c e

    say,

    W eU , I 'd lik e to b uild a c hes t 30 bigh we

    wanted to

    us e

    plastic

    glid e

    strips (to

    with four drawers. h elp th e d raw er s lid e in

    aO O

    o ut e as ily), w e

    But th e design of any woodworking pro- had

    to

    a llo w fo r the th ic kn ess o f th e strip s

    je et is

    a

    comb in a ti on o f art a nd s cie nc e.

    Th e

    in d ete rm in in g th e height

    of

    each opening.

    rt

    is the aes thetics of the design. The There's one last d etail: the th ick ness o f

    science is figu ring out how

    to

    make all the the stock. W e list the thic kness of 4 1 4 stock

    p ie ce s f it to g eth e l', as y , .

    4 /4 s

    the designa tion for lum -

    Okay, Don, sounds

    li ke you re

    about

    be l th at s 1 t. hic k

    when

    it s rough 8a \V l1.

    to get

    into

    a

    treatise on design.

    Let s

    skip

    Then

    it's plan ed down to final thicknes.

    s,

    a ll th at and gel down to the lutty gritloy, The N atio nal H ard wo od Lumber ~ ia-

    In

    a nutshell , I'm alw ays

    amaze d

    at

    th e .tion sets the

    standar d

    of v . th ick for

    amount of bas ic pla nning req uired

    to

    build most h a rdwood s. )

    what I th in k sh ould be

    a

    sim ple ches t

    of

    au t in reality , th e sto ck you use may be

    drawers. t

    seems

    like

    a never-endingser- a

    differen t cti ql th ickness - usually it's

    ies of det ail s

    an d

    decisions, so me wh ere b etw ee n

    y., and Y I , r ,

    You

    About a

    year

    ag o, we were building the have

    to

    t ak e th is

    into

    a ccoun t when ad ding

    s ev en -d raw er lin ge lie dresser fO l' issu e in the thickness of th e rails that ar e

    be

    No. 53 . 'V e w anted

    to

    use dovetails

    to join

    tw ee n e ac h

    drawer,

    the drawers,

    b u t

    sin c e th ere were so m allY , So, detennining

    th e

    heig h L of

    a

    dresser

    we de ci ded to u se a route r

    and

    dovetail jig is n ot e asy. T he d im ensio ns w e sh ow in the

    rather than cu t th em all by hand, plans m ay seem odd. PO I' e x ample , th e

    Just about

    that

    tim e w e received a tip basic

    case

    fo r th e

    dresser

    is

    25',),,,,

    high ,

    (rom W illiam

    Schultz, a subscribe r from

    an odd dim ension. But it's act ua lly ju st th e

    A lbuquerqu e, N ew M ex ico . H e had b uilt

    s u m

    of

    all

    these details .

    dovetad

    jig

    aO O

    mad e

    hi s

    own templa te

    SOUltCflBOOI\.

    you 've been

    s ubserib-

    usi ng a box joint jig. ing

    fOI

    awh ile , y ou 'll rem emb er th e

    Wood-

    D o u g

    Hicks

    d e c id e d to b u il d

    th e jig

    to Itmitlr OI,rceboi>k.W e

    b eg an p ublishing it

    se e how it work ed. fn the m iddl e of that in

    1 9 1 ,

    (b ut

    t

    d id n't c om e out last year).

    p ro c e s s , Ken s to p p e d by an d mentioned The b a si c id ea b eh in d th e Sm,roobook is

    that

    he . a l w a y s wan ted

    to

    build jig th at

    to

    provide in fo rm ation for w oodw ork ers.

    u s e d c am s in ste ad o f w in g nuts

    to

    hold t he Rather than add advertis ing

    to

    Wood

    work pieces in

    p la c e .

    Then Ted made a few

    smith,

    we decided

    to

    pu blish the

    Source

    comments

    an d

    ch anges . Soon we-had

    a new brxik.

    It's a listin g o f c om pa nie s who have

    a p p ro a c h to a

    dovetail jig . mail-order

    catalogs,

    or

    offer

    info rm ation

    0)1

    Unfortunately . we didn't ha ve enough tools and supplies for

    woodwersers.

    room in

    that

    is sue to show the jig . So we Thi~ year s So rce lXJQk, will be m ailed

    waite d until we began bua( lin g the com- free

    to

    a ll a ct iv e

    WoodS1ni lh

    subsc rib ers

    panion

    piece (the cherry

    d re s s e r

    ShOWI lin

    lIS of

    Sep tember

    (988). Pe l

    like

    to

    invito

    th is iss ue)

    to

    sh ow the dovet ai l jig . you

    1 .0

    u se th e

    Solt1 'cebook

    if you're look-

    S ince we had the doveta il jig , we wanted ing for catalogs

    01

    o th er in fo rmation, It's

    1 .0

    build the drawers fO I'th e

    dresser

    with an easy way to order

    a

    lo t of

    information,

    it , This automatically

    sets

    so m e

    parame- PltOTEcrrvS COVER.

    For quite a few

    ters

    fOI

    the

    ~ize

    of the draw ers.

    years

    w e'v e a dd ed

    a

    protective

    COvel

    to

    W hen you use a dovetail jig , the pins

    IVood.~mit1.

    U was a convenient way

    to

    an d

    so cket s

    ar e

    cut w ith a

    template

    th at's show the covers of

    back

    issues.

    b a s e d on inc re me nts o f 1 , 0 1 . (This d i m e n - But we gpt to th e point thai there w ere

    sion

    actually com es

    from

    th e V .. -< lia. m ore

    back

    i ss ue s a v ail ab le than th ere w as

    guide bushing that's u s e d

    to

    guide the r o o m

    to

    show t h e m , W ith this is sue, w e've

    route) ..) But the layout of t he dovetails has added an e x p a n d e d version of th e p r o t e c

    to

    be mu ltip le s o f v ,, because

    at tbe tive

    cover,

    and

    we were able to

    add

    an ex

    m inim um

    YOII

    need one socket

    and

    two panded order form and some

    in form ation

    balf-pin s (o ne

    On top,

    one on the bottom )

    about

    th e

    kits

    shown in the past issues.

    to

    make

    a

    joint.

    NEXT MAILING,

    The next issue of

    Wood-

    I'm getting a li tt le s ide tr acked hers.

    sm t

    (N o, 59) will be mai led tlw ing the

    Back

    to

    the design of the

    dresser

    i ll t his

    week

    o f O c tober

    3 1, 19 88 ,

    WOODSMITH (ISSN

    0164-4114)

    is

    pob

    lis hed bimonlh ly (Februal)l , Apri l,J une, Au

    gus t. Octobe r, Dece mber) by W oo dsm ith

    Publi sh ing Co ..

    2200

    Grand Ave ., D es

    M oine s, IA

    50312.

    WOOdsmi th

    is a re giS te red lrad em ark

    0 1

    WoocIsmilhPubl ishing Co.

    \tCopyrigh t

    1988

    b yWoodsmith PubUshing

    Co. A llR ights R es erv ed .

    S ub scrip tio ns : One year (6 iss ues) $1 2 .95 ,

    TwoYear s

    (12

    issues)

    22 .95. Canada

    an d

    Foreign :

    add 2

    PIl r ye ar, U .S . fundS only .

    S ing le.c op y p rice ,

    3 .50.

    Second Class Postage Paid at Des

    M oihe s, Io wa.

    Postmaster: Send change

    01

    address

    notice , to W ood smilh Publishing

    c o ., 2200

    Grand Ave., D e s M oines , IA 5 0 3 1 2,

    BACK ISSUES: A ll back issues of

    Woodsmi th

    are still availab le. For a fr ee

    bookle t desclibinglhe co n te n ts and prices o f

    a ll back iss ues , ju st se nd us your n am e an d

    ad dres s

    1 0

    th e addre ss

    ab o v e .

    SAMPLE COPY : W e willbe h ap py to send a

    free sam ple copy of WorxJsrnfth o a ny on e

    you th i nkwould enjoy it J us t s end u s his/he r

    n a m e and a dd re s s .

    wdust

    0peratOoos Steve K rohmer

    M arketingM anage r S te ve D o zie r

    SioreM an agers:

    S I. L o u is . M D J on B eh rle

    8 e rke i< ly .

    CA Mi cha el DeHaven

    Des

    M oines .IA K en t We ls h

    The W oodsmith Sto re

    Edit ,

    Dona ld B . P es ch ke

    Oe$Igij

    Direct' Ted Kra li cek

    Manag ing

    EdrtOf

    Douglas

    L.

    Hicks

    A ss istantEd ,I' Doug la s M .U c ls te r

    P ro je ct Designer K e n Munk el

    Technlcal llustrators Dav id Kreyl ing

    Cary Chr is tensen

    RodStoakes

    Ch ri s G lowack i

    Customer

    SeMce

    S andy B aum , M gr.

    J ac ki e S tr oud

    PatKoob

    L is a Thompson

    Computer

    0 p e r a1 ) O n s

    Ken M i ne r

    Admin istrativeAssIS. Cher yl Scot t

    JeanC.rey

    BuildingM ai ntenance A r ch ie K r au se

    Number

    58

    August ,

    1988

    rodsmith

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    Now , place th e

    ro uter so

    th e

    w ing is

    on

    the work

    surface and the

    bit

    hangs

    slightly

    over the outs ide o f the ed gin~ stri p. M ove

    tbe bit slow ly into th e strip kee pi ng one

    h an d se cu rely pressed down on the bl ock

    'I 'he top layer follow s the ,..

    dius

    of the

    router

    on on e end, but

    has

    a

    wing

    that

    st icks out abo ut

    6

    beyond the

    router

    on

    th e

    other

    end.

    After

    cutting

    this

    piec e to

    size,

    T

    use d th e plas tic

    I(lUW'

    bas e as a

    tem plate to mark

    the location

    of

    the

    bi t

    hole

    and

    SCrew holes. Then

    I

    glued

    a

    block

    as a

    handle to the top of the win g.

    Ne xt. c ut a su b base to shape with 9()0

    po int and glue it

    to

    th e

    top

    la ye r so th at

    ~

    stops

    short of

    th e

    b it. B y

    making

    tb e

    su b

    base

    come to a 9()0

    p oin t, y ou

    can

    easily

    work into Ute COt11er or a workpiece that,

    ha s e db ng

    on tw o

    sides.

    1 '0 u se th e

    jig,

    screw it to the bottom of

    t.he router and mount a stl'aight bit, Then

    adjust the dep th

    S O

    th e b it jus t

    touches

    the

    work

    su rface.

    B lO C K ftAN D LE

    3

    V O OD

    MITH

    If

    yo u'd lik e to sh are a w oo dw orking tip with othe r

    readers of W oodsm ;rh . send your Idea 10:

    Woodsmlth. TIp & Tec hn iques. 2 20 0 G ra nd

    Ave.. Oes Moines, Iowa 50312.

    W e

    pay

    a m in im um a 51 0 lor UpS, I I I l O S e l y

    ap -

    plied a little proud of the adjacent

    surface,

    This

    is ot ten

    th e

    case

    ,,~ th ta ble tops,

    coun

    tertops, and

    plywood panels.

    use my router

    with

    an

    auxiliary base

    to

    trim off the extra edging. To do this,

    start by

    re mo vin g th e p la stic base plate

    f i O n l

    the oute r and mount

    a

    two-lay er

    base m ade from

    1 . 0

    M as onite .

    The

    bag

    d o e s n t

    catch

    a U

    of the dust

    ( the,., , s still som e that goes out the back

    J the saw1.

    but

    it's a big im provement

    (>\ < '1 . .

    h;.t us ed to end up O n my floor.

    Mbriey H. Grt/.Ju

    Belle il/e, Ontario

    GARBAGE SAG

    H E lD T O

    R rot, ICER W ITH

    L A R G E R U f l 8 . E R

    ~NOOft

    B U N Ge E C O ftD

    o

    Then,

    visited a lo ca l b uild in g c en te r

    an d fo un d a fu nnel-shaped furnace a ir d uc t

    re duce r m ad e from sheet m eta l. There are

    a variety of

    shapes

    an d s iz es , b ut

    get

    one

    with

    a flat shoulde r that ru ns

    around

    th e

    bottom .

    Now cat an opening in th e plywood pan el

    with

    a sa bre

    sa w

    t o s ec ep t

    th e

    shee t m et

    al re duce r. By cu tting carefully , you

    , 1

    get a

    sn ug enough fit SO that the reduce r

    c a n ju st be p ushed in lo the opening a nd

    held w itho ut f as tener s. (I f neOO$$3' ) ' ,t can

    be strew ed in pla ce w ith a couple o f sh eet

    meta l

    s c re w s f ro m

    t he i ns id e .)

    ~l y

    wife

    se wed up

    a

    cloth bag w ith

    a

    drawstring \0

    catch the ch ip s, but a p lastic

    garbage

    bag and

    large rubber

    band or

    bungee cord would also work.

    TABLE SAW DUST BAG

    In order to t U~o wn o n s aw du st and chip s

    ~Io w ing all over m y

    sh op , 1

    added

    a

    dust

    bag tQ th e bo ttom of my table saw .

    ta rtro by cutting

    a

    piece of 'l(, ply

    w o od to bolt W the b ottom of

    my

    ta ble saw

    ca binet .

    __ T_i( sTechnigu_e_s __

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    W O O DSM ITH

    R IP

    HNCe

    A G U R E 2

    1 1

    DADO ES

    V ~Ollie ON INS IOE _

    F CE OF Bo m EN D P NE LS

    END DETA il

    NO

    P NE L

    E ND PA NE L

    @

    ,

    tt O U I D E R

    C OR NE R DE TAJ ,

    ED GE GL UE lYIO END

    1 f = , , J : : : : : P ~ A N ~ E l S

    lOM 41 S TOCK

    RGU~E1

    ,.

    .

    .

    - _

    ,

    _

    . ~ ~~

    .

    .

    4

    Probably th e m ost in teres tin g p< ut about

    building thi s ho pe

    chest

    is the

    corner

    joint,

    It's a

    va ri at ion o f

    a

    to ngue

    a nd g roove ,

    but

    the co rn ers are beveled an d shou lder s ar e

    added to both ends of the bev el. It so unds

    co mplicated, but it's actually easy, A nd it

    produce s a unique jo int that adds a lo t to

    th e overall ap pear ance of th e chest,

    END PA NELS

    [ began work on th e ches t b y e dg e- glui ng'

    en ough

    I

    stock 0/,. ac tu al t hi ck n es s)

    to m ake two end pan el s (A) that were

    roughly

    18

    w id e an d

    21

    lo ng. After th e

    glue dri es, p la ne

    0)

    belt san(l the pan el s

    nat.

    Then

    cu t

    the m to fi n is hed size :

    17

    wide

    by

    20

    long,

    see Fig. 1.

    Shop

    Note :

    rt:.

    im portant that these

    panels

    be

    planed 0) sa nded to a iform

    th ickn ess acro ss thei r w idth . Ifthey 're not

    perfectly uniform, the shoulder cut o n th e

    outs ide of the jo int

    will loo k wavy.

    C UT DADOES. After the e)) d panels are

    to si7 .e, y ou can he gi n work on the C O l1 I e r

    jo in t .. S tar t by cutt in g ~ w id e dadoes on

    th e in sid e fat e of the end panels . (A lt hough

    this jo in t is traditionally called a tongue

    and glWL e, i t's ac tually a

    to ngue

    an d dado

    si nce the groove runs across the grain.)

    To cut th e dad oes, set the rip fe nce so

    th e distance fr om the fen ce to th e outside

    of the saw blade equal s the th ic kness of

    your stock,

    minus

    1 1 < tq

    allow

    for th e

    shoulde r), s ee Step ~ in F ig . 2Since

    J used

    l It thick

    stock,

    I

    se t the

    fence

    lo

    fr om th e outs ide of the bl ad e, Then cut a

    ' l' Id ' deep dado at both ends of the p anels.

    R OOT

    DADO.

    N ex t,

    I

    used the router

    tab le to ro u t a ~ d ee p d ad o o n th e o th er

    face of each pan el (t he o utsid e face). 'P his

    dado will law form a shoulder alongside

    the corner angle, see C orner D etail.

    ro rou t this

    dad o, mount a o

    straight

    bi t in th e ro ute r ta ble and se t the fence so

    the outside of the bit is in line w ith the

    dado you just cut on th e saw , see S > I)2 .

    ROUTANGLE AiteJ th e d ad oes a re c ut,

    switch

    to

    a

    cham fe r

    b i e

    to

    rout a 4~

    angle

    along U le

    outside

    end of the panels, se e

    Step

    3. T o get uniform V I' shoulders at

    both ends of the cham fer, sneak up 0 11 th e

    fin al e ut b y raising the

    bit

    a li ttle at a tim e

    un ti l both shou lde rs eq ual 1 1

    fRONT AND BACK

    N ex t, work

    ca ll

    begin

    011

    the n'O nt B)an d

    back C) panels. A gai n , these panels ar e

    edge g lu ed Irom 44 sto ck, a nd planed to

    a uniform thickness.

    C UT1 ' 0

    SI ZE .

    'T he leng th of both panel s

    is the sa me (35~ >, but the w idth vari es

    ____ H_o~e

    h st

    AN HEIRLOOM FOR THE FUTURE

  • 7/24/2019 Woodsmith - 058

    5/24

    5

    R UN NE R D ET Ail

    T R lM D E TA il

    -

    ROU

    v t R

    It

    .... 0

    cu r so tONGU E

    FI TS IN

    DETA il

    GROOVE lETA l t

    SETDADOBlAM

    -l

    ~~W1DE

    .

    l

    1

    I

    I

    ]r.

    I

    END P ANEL

    @

    SHEtF

    @

    T R Y

    RU NNERS

    AVOID NAIUNG

    lltM INLOa

    OR HINGE AREA

    T OP T RIM

    ueaEl F RO Nt

    A ND aA CK EO GE S -~

    T O F OR M I ONGUES

    F IGURE 4

    GIlOOvtS

    fOil

    PlYWOODSHf11

    -

    ~

    BACK

    PANEL

    T R AY R U N NE R

    GROOV l :

    EP GE atUIl

    FRONTJaACK

    FR OM 41 4 SlOC K

    -

    FRONT

    PANEL

    ~~

    -

    FIG UR E 3

    \VOODSMITH

    si nc e a drawer fits unde r the fro nt pane l

    (B).

    First,

    cu t th e ba ck pane l ( C ) to a width

    o f ]7 ,

    se e

    F ig. 3.

    N ext, c u t the fro nt pa ne l (B )

    6V il

    1 'lSS

    in w idth tha n the bac k pa ne l, se e F ig . 8

    (T his measu re ment take s into

    consider .. -

    tion the 5 h d ra we r h eig ht, a

    v

    g dp

    above the dra wer , and a

    0/,. filler ship

    b elo w the drawe r, re fe r to F ig . 10.)

    TO NG U l: .

    AftNthe pa ne ls

    a re c ut

    to

    size ,

    cu t a ra bbe t o n the end o f ea ch piec e to

    create a 'h -I ong to ngue

    t o

    fit in the

    dadoes

    o n th e end pa ne ls .

    r

    cu t th is on th e

    ro u te r ta ble , see C orner De ta il i ll F ig . 8 .

    Sneak up on the cu t

    unti l

    the tongu e

    fits

    snu gl y in to the dado .

    RUNNER A N D SH EL F G ROOV ES .There 'S

    one mo re s tep o n the fro nt and back

    pane ls. Two v. . -w ide g ro ove s have to be

    cu t on the inside fa ce s o f these pane ls to

    ho ld tray runners and

    a

    shelf,

    se e

    Fig . 3.

    SHELF

    Once th e g ro o ve s ar e cu t, a plywood she lf

    0

    ca n

    b e m ad e,

    se e

    Fig .

    4.

    To dete rmine

    th e w idth of th e s he lf (f rom f ro n t to back),

    dr y-a s s emble the che st and mea su re the

    i ns id e d is ta n c e

    between

    the end pane ls .

    T hen add

    fl

    fo r the tw o V . . < . l e e p dadoes .

    T he length o f the she lf is equa l to th e

    in sid e w id th o f th e c as e. (T h ere a re n't any

    to ng ue s on the ends o f the she lf.)

    TO N G U E . N ow ro u t ra bbe ts on the fr ont

    a nd b ac k e dg es to fo rm to ngues ,

    se e

    D etail

    in F ig.

    4 . A gain, 'sneak up

    on this

    c u t u ntil

    th e to ng ue ju st

    fits

    th e g ro o ve .

    ASSEM BLY

    W he n the sh elf

    is

    comple te , the b as ic c as e

    can b e a s sembl ed.

    Start

    by g lu in g th e f ro n t

    (B) and back C pane ls to o ne end pane l

    A. To he lp ho ld the assem bly squ are ,

    s lide the she lf (D ) into th e grooves from

    th e o pen end.

    After

    the gl u e

    dries, glue

    the othe r end pane l in pla c e .

    RUNNERS AND TOP TRIM

    After

    the c as e

    is

    a s s embled, two runners

    E

    are

    added to bo ld

    a

    stiding tray.

    RU N NER S . C u t the

    runners

    to

    a

    wid th o f

    V I ,

    s ee R u nn er

    De ta il i ll F i g.

    6.

    Then cu t

    ra bb ets a lo ng e ac h e dg e, fo rm ing a to ngue

    c ente red on th e runne rs tha t

    fits

    th e o

    grooves in the front and back

    panels,

    Afte r th e to ng ue s

    are formed,

    cu t the

    ru nners to lengt h to fi t inside the

    case .

    Then glu e the ru nne rs into th e g ro ov es.

    S h op N o te : I t' s d i ff icu lt to

    clamp

    th e

    run

    ne rs .

    So

    1

    wedged

    a

    le ngth o f sc rap be

    tw een the runne rs to P I eS S th em in

    place

    unti l

    the glu e dri ed.

    TOP TR IM . The final

    step

    is to add

    W -

    thick trim strip

    F)

    around th e to p edges ,

    se e F ig . 5 . C ut th e trim str ip 1V .. wide

    and ro und ove r the bo ttom outs ide edge ,

    se e T rim D eta il in F ig. 5. T he n, miter th e

    pieces

    to

    length, and glu e and na il them to

    the to p o f the

    case .

  • 7/24/2019 Woodsmith - 058

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    W OODSMlTH

    THE BASE FRAME

    O nce th e case w as

    complete,

    I b e g a n work

    on

    t he b< I$C .The bas e

    consists of

    a s cr oll

    cut kickboard frame with a

    molding

    StrIll

    glued on lop o f it, ref er to Fig. 8 .

    KICKBOARD FRAM . To

    make

    th e kick

    board

    fram e , cut the fl'QntJbackpieces

    (G),

    an d

    tw o

    S id es (H)

    fI 'om

    41 4steck

    to

    a

    width

    of

    4 ,

    se e

    fig.

    6 ,

    Then m iter b oth ends

    of the front/b ec k p ie ce s so the length of

    e a c h piec e (from long p oin t to long p oin t)

    is tv. longer

    th an

    the w idth of the

    as-

    sembled ease. N ext m iter the side p ieces

    so

    they're

    V i longer than the depth of

    the case, (This creates a fram e that is

    la,-ger

    than

    th e

    case

    on all

    four sides.)

    KERF

    A. NO

    SPLINE. 1 0 help keep the

    mi te rs a li gned

    while

    clamping, 1cu t

    ker f

    in each miter and added a

    sp line, see

    Comer

    Detail in F ig. 6.

    SCROLLWORK.Be fo re g lu in g the

    frame

    to gether, I cut a SCl 'Q1 I esign al ong the

    b otto m edges. S tart b y drilling J -4 iam e

    te l'

    ho le s

    near

    th e

    end of each piece,

    J

    1/.

    up from the bottom edge, s e e Fig. 7 .

    Next,

    m a ke a

    poster board half-pattern

    fo llow ing

    th e

    dimensions

    in F ig . 7. (Or

    send for the

    patterns,

    see page 24 .) Then

    tra ce th e p attern on the w orkpiece and cu i

    it ou t w ith a sabre saw or band saw .

    ASSEMBLY, W hen the scrollwork has

    been cut and sanded , glue th e kiekboard

    frame tcgether.

    ~fOLDINGS1'RIP. 1 '0 com plete the

    base

    fram e, 1 m ade a

    m old i n g

    st rip

    (1)

    that's

    glued

    to

    th e

    top

    edg e o f the fram e, see Fig .

    8, Sta.t by

    c uttin g tw o

    p ieces

    of

    41 4

    stock

    ror the sides to a rough length o f 2 2 . Then

    cut the front

    and

    back pieces to a rough

    le ng th of

    38'.

    B efo re c utlin g tb e pieces to f ina l leu ,>th ,

    I ro u te d a

    Roman

    a g e e p ro file a lo ng th e

    lop edge, see Step 1 in Fig. 8. Then cut a

    rabbet alo ng the b ottom edge, see Step 2.

    Shop N ote: This rabbet should be I/,/

    less in \\;dth than the thickness of your

    stock

    to create

    a a shoulde r l l A t } , in my

    ea se ). s ee CI 'OSSSect ion in Fig . 8 .

    MITER M OLDING.After th e ra bbets are

    cu t, m ite r th e p ie ce s so th e sh ou ld er of the

    rab be t fits a ga in st th e in side edges o f the

    k ic kb oa rd fra m e , s e e F ig . 8. T he n g lu e the

    molding

    strips

    in p lac e.

    ASS EM BL Y .

    To attach the case to the

    kiekhoard frame, drill

    o/i.'

    shank

    holes

    co m pletely th ro ugh th e

    base molding,

    se e

    Fi g . 8. Then tum

    th e ea se u psid e d ow n an d

    position the base on top of it. Now chill

    p ilo t hole s, a nd .screw th e bas e

    to

    the case ,

    see Fig. 9.

    FD .LEllS'l'R1P . A fter the base ftam e w as

    screw ed to the ease, I ad ded a

    ont

    fi ller

    strip (J) to the bo ttom of the draw... open

    ing , see Fig. 9. I t's p o si ti on ed t o create an

    \1,;'

    shoulder where the ends o f the strip

    m eel the end panels (A ). (This co rr espond s

    with the

    V shoulder on

    the

    co m e r jO in t. )

    6

    Q)

    FRONT -

    FIlL ER STRI P

    8

    '

    WOOOSCRW -

    Kl CKBOARD

    SIOE-~ '

    :- - -

    c

    CUT1 fiT __

    O PE N IN G ' '\

    f IGUR E 9

    1 1

    1 1

    : 1 ''''lllI lf

    ~ml'~'

    stRA IGHT

    '. IT-

    STE P 2

    CROSS SECTION

    l I l J . o '-'i,

    l J I~

    r~t:;;:-JJ..

    II1 ,, -

    ; o K

    L.. 0/ . ;

    F -

    O R IU ~ H A N K

    U

    r-

    HOlES

    TO

    AnACH

    BASE TO CASE

    STep 1

    1 1 0 .

    T....

    fE N CE

    D

    / -MOLDING

    ST RIP

    f IGURE 8

    LA Y OUT

    PA rrt RN

    Am .

    ctnTlNG

    T O L E I iG i H

    FI GURE

    ORlll I ~Ol

    8 FO RE tAYlNG

    our

    PATTEItN

  • 7/24/2019 Woodsmith - 058

    7/24

    7

    ,.,.

    1 M

    fI GU R E 1 3

    .- lOMAN

    00 .. 811

    UD PANS.

    E DG E G lU E U O

    RC4 4 S T O c K

    r

    y o

    I

    . ,

    F IG U R e 1 2

    .,I..

    r

    4 1

    ~

    1 0 [

    3 ~

    ~

    -.-. 1 :::;;---,

    . . .

    B A C K T R IM

    y o

    I l IA.ICOU

    {IWf -1

    ,

    ,

    .

    ,

    l

    . 4

    ,

    ~

    -

    _

    . . .

    ~

    8...

    -

    l OI U. ,.

    -k

    . , ~.

    -

    2....

    .... HOU

    TO.

    r-

    -

    -

    S lO E T R IM

    (fULL

    ATlHN)

    .1

    .

    PlUG

    , .

    -

    SIDE

    TRIM

    @

    S E T

    aAQ( j,.

    F ltO M _ .

    .- O N

    A U .

    S I D E S

    ,

    -

    ___. .;-

    20 .-

    SIDE

    T R I M

    o

    ROOt 11

    GLUE.UIIIN .

    TO U P O N

    1NS lD E O f CASE

    K I C I C I Q A R O

    S D E

    MOtOING

    sniP

    1 D RA W ER G U ID E '\

    (ClOSS 5 E C I 1 O N )

    ~ 2_

    AGUR( 10

    :K )

    V E R T I C A L

    RU fR S TR IP

    fanTom

    { 00lN1HOI

    w,

    onSMITN

    DRAWER GUIDES

    ' 'here are a rew m ore details to take rare

    o f. F ir st .

    drawer

    g uid es a re m oo nt ed

    in

    side

    the

    ease to a lip created by

    the

    mold

    in g

    .trip:; (1) .

    see Fig .

    1 0 .

    T he se g uid es

    , sl of a run ner

    and

    a s id e g uid e,

    To make

    th e

    drawer gu ides .

    first cu t

    th e

    ru nner s I.

    lr

    id e and the side

    gu ide s

    (M)

    I Mde . Then cut both to le ngth

    to

    fit

    between

    the back

    edge

    of

    th e

    filler strip

    ( .1 ) an d the ca bin et b ac k (C ), s ee Fig. 1 0 .

    N ow

    glu e th e

    runner (L )

    to the to p

    e d g e

    of the molding

    .1til

    (I) on th e inside or

    the ki ckbo aI '( I f rame, see Fig. 1 0 . T hen

    glu e a side guide (M ) on top

    of

    the

    runner.

    M ake sure both the runner

    and

    ;de gu ide

    are glued

    t ig ht < \I fai nstthe end

    panel

    I 'lU . R S T RU '.T o complete the draw er

    opening, I g lu ed a v ert ic al filler strip (K)

    at each end

    of the

    opening see Fig. 1 0.

    (N o te that the gr.un on this strip runs the

    sam e direction as

    the

    fro nt o f

    the

    ease.)

    G l ue t he

    strip to

    the en ds

    of

    t he o pen in g

    50

    they 're nush ith the front

    panel

    (8).

    THELID AND TOP FRAMJ

    The

    li d

    fo r

    the chest is

    mad e from so lid

    s to ck . a nd to pped w it h a scroll ed fram e.

    rn~ uo, Start.by edge-gluing'

    enough

    stock to make a lid blank (N ) tha t' s

    l1 lughl y 2 8 w ide and 39 long. 'V ben the

    blan k Is dry and planed

    O at .

    cut

    it 1 1 1 -

    Iarg~r

    (in both dil 'ection. .) than th e

    ease,

    se e

    Fig.

    ROt r r P llOF I t . il . N ext. rout a Roman

    egee

    prolile

    around all four edges lea\ing

    a \I..

    ~houlder .

    see

    Edge

    Detai l

    in Fig. 1 1.

    S CROu . .E O

    FRAME.

    ' 'h e sc ro ll ed fra me

    on

    top

    of

    th e li d

    COl l -< I s t s

    of

    three

    piece,;

    that

    are m itered at the

    b a c k

    e em ers, ' 'h e

    back p ie ce (P ) i ut to a w idth of S o

    and

    the n m itered to

    length

    (f rom l on g p oin t

    to

    l on g p o in t)

    > 0

    it's 1

    V

    I~$$

    tht tn

    t he l en gt h

    of thP tid . see

    ~ ilt. I.

    T he two side pi eces (0 ) are cut

    to

    a w id th

    o f

    :r .

    S i ne (: t he se p ie ce s ar e onl y m itered

    on the buck comet, fi rs t

    cut .

    miter on

    000

    end

    of

    ea ('h

    piece.

    '' hen tr im the ot her end

    straight

    I\()

    tho di st ance from the l on g p oint

    on

    th e

    mil. the ' ron t edge is

    lil.

    les s

    than

    th e

    wirllh of the ti d , see ~ 'ig . 1 1 .

    SC II O I .L W O R K .

    A fte.

    the pieces ar e cu t

    to

    .ize.

    th e

    8 :1 011d es ig n c an

    b e

    c u t a s

    w a s

    d o n . e m the kiekboard. Drill

    ou t th e I

    holt ,

    make

    A

    pattern (see Fig. 1 2)

    a nd

    ttanl'rcr it

    to

    th.

    wo rk pie ce . T h en c ut

    out

    and .and

    th e

    d,,, ,ign.

    Al>- '

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    8/24

    WOOD SMITH

    THE TR AY

    A ll t ha t' s l ef t

    the ches t

    a re

    th e tt-.lYand

    tbe drawer . J started on the tray .

    DSS IGN .The tlllY

    is

    ac tu ally a tt-a ditional

    dovetailed drawer,

    bu t

    with a twist. On

    a

    typical

    draw er, the front fac es th e

    D.'ont

    of

    the

    case. But on this tray, I had to con-

    s tr uc t it SO th e front a ct ua ll y fac ed

    the

    side.

    The

    cr itical

    measurem en t

    on

    th e tra y

    is

    its dep th (from front to ba ck in sid e th e

    case). Since it's easier to cut a drawer front

    to a p recise length than it is to make the

    overa ll d rawer length a

    p recise

    fit

    1 jS\

    tu rn ed th e d raw er sideways in th e c ase .

    CUT1 J i 1 : I'IF;Csg. S tart building

    the tray

    by cutting. tray fron t an d ba ck

    (Q )

    (Whic

    a re re ally 0 )1 th e sides ) an d tw o tt-.lY s id es

    (R). A ll four p ieces a re cu t from ~ stock

    to

    a

    w idth of 3~ , see Fig . 14.

    To determ ine the exa ct length of the

    D'Ontiback pieces (Q ), measure the inside

    dep th of the cabinet (n'Ont to back) and cu t

    th e tray s Ji'Ontiback y , less. T hen cut

    the tray's side

    pieces

    to a length

    01' 2() .

    so ur DOV lTA U .s .A fter the pieces ar e

    cut to

    size, rout i d ov eta ils to join the

    (OUI' pieces.

    00

    pages 20

    to

    2J .

    sorroa, Now , cut groovesfOI the

    v

    p ly wo od b ottom (S) an d then cut the bot

    to m (S) to fit, s ee D e ta il in Fig. 14.

    THE DR WER

    Next I

    b uilt th e

    drawer,

    'l'h is time, it' s

    o rien ted in the traditional direction.

    I started by m aking a rabbeted d raw er

    front ('1') f rom 414stock . To determine th e

    w id th of the D'Ont, measure th e height of

    the op ening and ad d

    %

    (for tw o

    %

    rab

    bets).

    >

    subtract

    V .

    (for clearance).

    M for the length of the drawer front,

    f ir st mea su re

    the w idth of th e o pe nin g.

    Then ad d

    %

    fo r the ra bbets and subtrac t

    (for Y ,,f clea ran ce on both sides) ,

    pnOFlL E EDGE .Af ter the drawer front

    is cut to

    size, ro ut a shouldered round-over

    on all four edges, see Stell J in Fig. 15

    'Ihen

    rout.

    0/ .' rabbet aro und th e back.

    S ho p N ote: I ro uted the r abbet in tw o

    passes. First. set the fence for a shallow

    bac/aoard

    (le ft to right) sc orin g pass to

    preven t chipout , Then move the fence an d

    make a full % w ide cu t.

    CUTOTHER PIl CES. When

    the

    drawer

    front

    is

    com plete, cut the sides

    (U)

    an d

    back (V )

    to

    size from

    'h th ick

    stock.

    JOINRY \Vhen all the pieces ar e cut,

    rou t dove tail joints Oil th e COM let'S (see

    page 22). Then cut gr oo ves fo r th e drawer

    bottom (W), and cut the bottom to lit.

    1 ULl.S. B efo re as se mb ly . I d rille d shan k

    holes to mount U10carv ed (o r brass) pulls,

    see Fig . 16.

    If you 're usi ng c arv ed pu ll s, y ou hav e to

    drill c orresponding hole s in the bac k of th e

    p ull. T o d o th is, cl amp the pul l

    in

    pla c e a nd

    m ark the pilo t holes on the pull w ith an

    awl. Then dl;1I th e p ilo t holes in ea ch pull.

    V R A ET O N

    AU FOUR S iD ES

    PUllS

    CK

    D @ A W E R

    NOTE ,

    U TMean N

    TW O ASSES.

    seemr

    NOTE,

    t O J T INDS ARST

    T O P tttVEtfT

    CH1 PQUf

    STE P 2

    ST EP

    W'

    D O V E T A I L S

    TR AY 5 S FAC E F RO N T

    AND BA cte O F C HES T

    NO TE ,

    SIDE

    BOTTOM

    v,. ptYWOOO. CUT

    ro

    FIT) _

    X~R O N T

    18 /..

    SIDE

    FIGURE 4

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    9/24

    9

    \ ' : lOOSMITH

    0 T. y m. mack (2)

    y,

    X

    3

    /2 - 18/,6

    N

    T , Side< (2)

    ;;x3'h-20

    S

    1iay i ltom (I) '/4 ply. 18

    1/,6 X

    t

    9Y

    ,

    O C..... f

    t(l}

    171 '6 X

    6 - 33 1.

    N

    U

    Oro~r

    S id c tS ( 2)

    v x5 1.-19

    v

    Oro\Wt Batie

    1

    ~ X

    SV..-

    321/a

    W O n r w .

    Boltom (1)

    '/ .. p ly . 1 B V.. X 3 2

    T

    B

    A

    A

    A

    G

    H

    Fj:

    A

    A

    0

    R

    0

    0

    B

    0

    L

    N

    ,

    v z z w z z

    u

    'M.- 11 7';''' 96

    C

    p

    c

    Tro y 8olfom (S ) and

    Drawer 8oHom C W ) cut

    f r o n

    48 JC 48

    ~

    of V . ptywoocI

    u

    v

    $Mlf {OJ (:I.It fro m

    24~43 ,,, I

    01 Jf. plywood.

    CUTTING DIAGIIAM

    atmR MORTISE

    O N n U CK N E $.S

    O F F R ON T P AN E l

    R OU T O UT

    SHAUOW

    M O R T I S E

    FOR P lA TE

    R O U T

    DEE~

    M O R T ' t s 1 i

    100 l O N G U e

    o

    Ce:NTER

    U N E

    Of CHST

    Non;,

    LOC K

    MORnSE

    wla SE

    OFfSfT

    ON CH EST

    C RO SS S EC TIO N

    F I GU R E 1 7

    D E T A I L

    CENTfR P IN

    SH OULD

    ON SA CK

    O N

    fOOl OF ntlM SUGH1I.Y

    PASTW

    TOP

    1ltlM

    C f N TE R I .I D

    ONCAse,

    l A

    I It

    W

    LONG.

    ROUT MOR nSES

    O ~

    J4-

    rO N

    SuGHn y t.SS

    MOImSE

    WIDTH HINGE

    THANKALf mE

    O UT B AC K

    E N D P A N E .L

    lH I(KH ESS Of

    ED GE

    K NUC K LE

    A

    End P a ne o ls ( 2 ) 0 / 1 0

    x

    17- 20

    B

    Fron, Panel (1)

    /,6 X

    10

    1

    1._35 /.

    C

    Bad e Panel (1)

    1)/16X17 - 3SV.

    0

    S h ol f ( ')

    A N

    ply. 19

    1/.

    x

    34.

    E TroyRunners (2)

    ''1 '00 x

    0/..-

    34 ;'

    F

    Top T rim

    ,/.. xl /16-10ft.

    BA Se

    G f

  • 7/24/2019 Woodsmith - 058

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    WOODSlvUTH

    DADOS .Befo re a s sembling the fram es, end. Then three m ore dadoes are la id o ut

    r

    sw itc he d o ve r to

    \\,0. [

    flO f'

    VIEW )

    holds the face stiles

    (D ,

    E) to the side stiles

    ONOUfS,IOE ~

    FACE~S

    ;---

    ..

    -'1 'I.- 1 -

    RAaIIET fO R

    (C). This is a combination of a rabbet with

    ft .Y W O OO BA C K

    To p ~

    tongue and groove joint, see Fig. 4.

    III

    t 1

    If .:

    I.

    he first step

    is

    to cut a groove on the

    f

    ~

    --

    i-,-- c

    nside face of the face stiles

    (D ,

    E). Posi-

    ( . 1/.

    tion the lip fence S A > the distance to the out-

    1

    ~,,:.

    DETAi l

    side of the blade equals the thickness

    O f

    CU T

    'tWo

    MIRRORED

    the side stile (C), see Step 1 in Fig. 5. @

    s s r s

    O F 'A C E $ 11 lES

    (Note; Be sure this groove is cut on the

    FRONT

    ~

    ~

    1

    ~I/

    face with the foW'dadoes.)

    FAC E

    @i~

    A B B ET N EE DE O.

    The next step is to cut

    STILE

    : v , . I.

    t-

    . . .

    - - 1-- -

    a rabbet next to the groove. This rabbet

    fRONT

    OSedn the sides of the dresser,

    OUTSIDE EDGES

    FAa STilES

    To prevent this, r cut a rabbet the same

    UK<

    ?

    /J

    F I G U R . E 4

    RABBET /G ROOVE

    @

    depth as tbe dadoes on lhe inside face of

    Hl.ONJFAce

    JO INT

    @

    each face stile (D, El). The side stile (C)

    USE f liP

    sn~

    snu

    then

    fits

    into this rabbet; and hides tbe

    F iNCEA S

    c

    SlOi

    T O P

    STOf'

    t- .

    R 3 l

    adoes, see Fig. 4.

    ~

    RONT /BACK

    _':;S

    A C S S T I l E S

    -

    I~

    ClTI RABIlET.

    To cut the rabbet, ,,,ii\(

    the dado blade

    %

    high, see Step 2 in ~'ig.

    f-9--~

    I/,L

    1 . . A i

    F-~___

    ~ ii( :

    y.xv.-

    5. Then a;are cut,

    MEASutfME'NT

    ~ _ _ M A Y V A R Y

    sembled, glue

    and

    clamp them to the rails

    - 20 ,/ 5 11 GH n y

    (A and )3 ) and the plywood panel (F) to

    ~

    o r a side frame, see Fig. 6.

    ,- @---

    Shop Note; Before gluing these frames,

    CARp( TA .. A

    e-, ...-

    .

    double-check to make sure you have two

    STR IP

    Of

    WOOD

    0./

    mirrored sides and the roP label on all ONtO EDGEto

    . . . _ _ . _ _ _ ~

    four stiles is actually on the top. Once

    flRO lCT G R OOV E

    ;;

    r

    HILE ctAMPlNG

    -

    ~

    everything

    is

    lined up, glue each side as-

    M A K E S UR E S lO E ) _

    . . . . . . _

    . . . . . . . .

    sembly together with the pieces flat

    .. ~

    R A M l IS fLA t FR OM

    .

    ro d

    to act as an axle pin through the eye

    bolt, see Fig. 7. (Shop Note : You can cut

    tbis from a long rod, or nOOln the un

    th readed

    section of a ( ,boll)

    EYE BOLT.

    The eye bolt is just a stand

    ar d 0/,( X

    5' eye bolt purchased Dooma

    hardware store. After using the jig for

    awhile,

    J

    discovered that the eye section

    started to uncurl when extreme pressure

    was applied to the

    cam.

    To prevent this,

    ha d it welded shut, see Fig. 7.

  • 7/24/2019 Woodsmith - 058

    18/24

    WOODSMlTJ:

    8

    TEMPLATE

    After the jig base block and esm s were

    comp le te .l b egan

    work

    on

    th e comb

    tem

    plate

    th at g uid es th e

    ro ute r.

    N ote: W e're

    o ff er ing a p re -cut

    plastic

    template

    in

    a

    kit

    (see p a g e 24 ), bu t y ou can make your OW h

    fi'Olll ~ \ faRon i te .

    This t emp la te must

    be

    extremely accu

    rat e

    or

    t he dovet ai l jo int w on 't

    fit together

    co rrectly , I found that the most ac cura te

    m eth od o f cu ttin g th e n otches in th e

    co mb

    wa s

    to

    use a box jo in t jig . To bui ld a box

    joint jig . se e Woods ,; No.

    42.

    CI)T N01C1IES .Sta rt by cutt ing a piece

    o f M a so nite 4 w ide an d 24 long, see Fig .

    S, The next

    step

    is cu ttin g the notches.

    Since a W d ov eta il h it use s a 1 1 , (out

    side

    dia me te r)

    router gui d&

    bushing ,

    th e

    notches h av e to be ex act l\ '

    0 / 0 .

    w ide.

    (Check the w idth cut

    by

    y ou I' d ado bla de

    by m ak in g a noteh in a

    test

    piec e an d se e

    if

    your

    guide bushing

    fits.)

    W hen the notch w idth is

    C01'1 'OOt,

    raise

    the blad e 1 high and th en screw a ta ll

    a uxil ia ry f en c e to tb e m ite r gauge. Now ,

    stan d th e M aso nite o n ed ge and cu t a notth

    6 fro m O ne en d, see Fig . 9 .

    U lJ Il~G KBY.After the first notch is

    cut.

    cu t a v . . . in de xin g k ey an d glue it

    into th e notch in the f ence , see F ig . 1 0

    Once the gl ue d rie s, trim the top of th e k ey

    slightly and cham fer the edges so the

    workpiece will slil ov er it .easily.

    Then, mo ve th e fence OV ~la nd s cre w i

    to th e mitel gauge so th e key is i r J I c t l y

    1 1 . from the dado blade. (N ote: T his dis

    tance has to be extremely ac curate and

    m ay take some

    fi ne

    tuning. The

    b o x .

    joint

    jig shown in

    Woodsmill t

    No. 42 has an ad

    justable fence that makes this adju stm en t

    easier.)

    cor RIlMAIN1NC NOTCHES.Ooce

    th e jig

    is s et. up , p lace the fi rs t no tc h o ve r th e key

    and cut se con d notch in the template.

    (Note:

    I

    backed up the workpleee w ith

    another p iece of v .i Masonite 0 0 p revent

    chipout. Then contin ue this process unti

    fourteen

    n otch es are cut, see Fig. U .

    T o cheek for aeeurscy,

    measure

    the dis

    lance f ro m th e

    fil :lt

    notch to the last. Since

    t .here a re fo urte e n

    ?/j, ..

    f,, \\ id e no tches a nd

    thirteen 'I.. -w ide p ins, it should measure

    11

    Y o see Fig.

    8.

    ROUNOTHl: PINS. Once all the notches

    ar e cut, ] f iled the front en d of each p in

    rou nd, see Fig . 1 2 . (Note: The bac k end o

    the notches on m ost comm er cia l temp lates

    are also rounded, but they don 't have 0

    be to e ut d ove ta ils .)

    CU1 'TO

    LENGTH.

    To cu t th e temp late to

    leng th , p lace it

    0 1 1

    the base block w ith the

    m id dle p in

    centered

    o n the leng th , see F ig

    1 3. Then mark and cut the temp la te the

    same length as the

    to p

    o f th e base.

    BRACKET S . The tem p la te is a tt ac h ed 0

    Lhe b lo ck w ith angle bra ckets. T hese can

    be

    made from 4 x 4 s te el c orn er brack et s.

    P O S m O N

    ltM . PlA tE R U SH

    W IT H E N D S O F A S E

    COUNtQS INK HOlS

    lE M Pl A lf fOR l

    C i

    _Fh M QiINECR~S

    STUD

    D E T A I L

    V

    CUT OFf

    3

    lONG

    .. .--MACH IN SCREW .

    lfAVE A R

    lON G ' STU D

    , -

    . ; . - , , , - _

    .

    CUT T EMP lA T E

    f lU H Wlnt 910

    Of BASE

    W IO T H

    Of

    S t , O T

    SHOULD MATCH

    O lA MF ftR O F

    HOU; ~am

    CUTOff

    W A S T E

    ( wAST t em p a :t e

    t o w a r d

    yo u ..

    'ro o SHilLWW. If 110tdeep

    81Wag k, 'nU1ve t o w a r d ji g .

    roo

    LOOSE . If

    join t . 'is to o

    loose, in c r< ' < l$ 8 il d e pt h.

    roo TI;llr. lf (I 8 jo in t is

    I t ig ht , d ec re ase dep th .

    S< ttingup to make router-cut dovetails is

    always a trial and en-or effort, There's usu

    ally lots of fiddling around with trial pieces

    and l'eadjusUng to get

    perfect fit.

    roo LOOSE. the joint

    is

    so loose ehat

    the pieces wiggle around when they're put

    together, the depth of eut, is too shallow,

    see first photo below. I n c r ea s e the depth

    of cut about

    v

    and try again.

    roo 'ITGB'I'.Ifa trial cut is so tight that

    the pieces can't

    be

    tapped together, the

    router bit

    is

    extended out too fur from the

    router b a s e . D ecrease ehe depth of cut

    about

    Vd

    and

    tl

    again.

    roo DEEP. If the pins on the drawer

    sides

    go

    to o far into the SOCketson the

    drawer front, the sockets are to o deep, see

    middle photo on right. To correct this,

    move the template out (toward you) by

    turning the stop nuts on the studs counter

    clockwise.

    Be

    sure to adjust, the nuts on

    both ends of the jig.)

    Note: You may want the pins to be

    recessed from the ends ofthe sockets about

    .o t. This helps when sanding the joints

    flush later. (See T i p s page 23.)

    roo SHA/..WW. If the pins don't go far

    enough into the sockets, move the tem

    plate in (away from you) by turning the

    stop nuts cloekwise.

    OFFSET.After the joints are cut and

    tapped together, sometimes the top edge

    of the draw. Iront doesn't align with the

    top edge of U,e side, see third photo.

    If both the top and bottom edges.are off

    set equa l amounts, there could be a couple

    of things wrong. FiJost the edges o f both

    pieces have to be light against the stop

    block. There might be some sawdust b e-

    tween t.he workpiece and the stop block.

    Second, the offset on the stop blockmay

    not be exactly

    V a

    If it's a little more

    than that, you might

    try

    adding a layer or

    two

    of

    masking

    tape

    to the finger on the

    stop block.

    Note: The end of the stop block should

    be centered on the first notch of the tem

    plate, see Step 4 on page 20. If it's not, the

    top edges of the two pieces willbe a l i g n e d

    but the joint won't be symmetrical on the

    top and bottom

    e d g e s .

    OTHER PROBL.ThfS. M,ost other prob

    lems are usually caused by the pieces no

    being clamped down in the jig so they are

    flush across the top, or because they mov

    out of position as they're being routed.

    TROU L SHOOTING

    9

    FinaUy remove lie (mllpiate alld

    check (hat

    I

    of lte

    8()(Jk~ ts

    mid

    p in.5

    (, re I t iform . O ppos i 1 e . io i n t s a l' e cu t. on

    th e w il t s u ie

    of

    the ji g .

    10

    A ft e r aU jo in t s a re ro u ted , cu t bo t

    to m roov

    0 1

    S lt

    l?l t1QO

    P W; S e .

    to

    , atcl. drawer bottom

    thickness.

    Cen

    te r tire

    g l O ( J l J e

    o n

    the bottom sock~t.

    TAlII

    S W

    StO'

    eon

    SO KT

    F N

    7

    o p ..

    e l J e > I .

    c/lipout 01 1 d '' ( ~e> 'ide,

    s/art. by maicblg a li g l l t p as s from.

    1igll t to w f t . . This V groove est/,blishes

    a. clean shoulMr liM.

    Next, ..woo the router from wft to

    right 100rkinDin mut oul of th e

    1 I0 te he l l. P I< h t he r O I U e into _ ,,,,te h

    ,,, ,ti t. th e

    bushing h its tlte b o tto m of .tolelj.

    M A l < E U G H r P A :_ S S

    1 0 P RE V EN T CH IP O U T ...

    th O OV ErA ll B IT

    pass from right to left, see Step 7.

    Then gently m o v e the router in and out

    of the fingers, moving

    f rom

    left to light,

    se e Step

    8 .

    You should be able to feel the

    guide bushing stop at the beck of each

    notch. After routing, but before removing

    th e pieces from the jig, cheek that you've

    l O U l l ld each socket evenly, See Step 9 .

    ROUTING RRMA1NlNG JOINTS. At, this

    point, you've routed

    the

    joint

    at

    the left

    front corner of the drawer. (It's marked

    No.

    1

    in Step

    1

    Next rout the right rear

    corner joint,(marked No.3) using the same

    procedure.

    M o u n t

    the

    d ra we r

    side on the

    o-ont of jig, the drawer back on the top of

    jig - with the bottom edges _ ainst the

    stop on the li if and the inside. facing out.

    The other two joints (No. 2 and 4) are

    routed with the pieces tight against the

    stop block on the rigltt side of the jig.

    Again, always claml) the drawer side to

    tbe

    jhmt

    of the jig, the inside of the

    pieces facing out, and the bottom edges

    a .rinst the stops (this time on the right).

    IVben routing on the right side, follow

    the same procedure. Make a light

    p a s

    ss

    from right to left and then move the rout r

    in and out of the notches from left to right.

    BO'M'OM

    GROOVE.

    When all the joints

    are routed, aU that's left is to cut the

    grooves for the draw. bottom, see Step

    10. Cut the g.-ooveso it's centered O il the

    bottom socket of the drawer

    front

    Then it

    mil

    be

    hidden by a pin on the drawer side.

  • 7/24/2019 Woodsmith - 058

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    W O O D SM IT H

    R ETEDDR WERS

    M a kin g th e d ov etail joints f O J a drawer

    with a a b b e t e d front is a little different

    from routing a flush front draw. , You

    have

    to

    take into eonsid e r a t ion the lip

    arou nd the outside of the draw er front,

    LAYlNG 0\11 . W hen you layout the

    p ie ce s, th e w id th

    of

    th e

    drawer's back an d

    s id es h as

    to

    e qu al th e

    .hOld(ler-Io ,shm 4er

    widt h of th e drawer ll'Ont in stea d of th e

    c ve ra ll w id th , 'l ee S te p 1. A nd the length

    of

    th e back e qu al s t he

    shoulder-to-shoulder

    length of th e f ro nt, no t th e overall length,

    (I cu t th e r ab bets bej'ore routing,)

    N o te : Onc e a ga in , it s best if th e c ab i ne t

    is

    designed so the w idth of th e

    drawer

    back

    an d sides is

    a

    mu lt ip le o f 'I. ,

    SPACER. W hen clam ping the drawer

    (r(JnL to the jig, yo u also have to take into

    cons ide r. . t ion the rabbe t. '1'0 co rr e ct ly posi

    tion th e shoulder ill relation to the tem

    plate, [ pu t a s pa ce r between th e drawer

    f ront and the stop b lock, see S tep 2.

    To determine the thickness

    of

    this

    sp acer , s uo tr . . c t th e width of the rab b et

    D '9m

    V , ,

    (since a pin plus a

    notch -

    Y o ) .

    For a

    ,..

    bbet then , y ou will need y,

    s pace r, s ee

    Step ~

    END ALIGNMEI fl . O n the end o f th e

    dr awer f, 'ont. the sltouJde,' of the ,.. bbet

    (not the end ) ha s to be aligned w ith the

    (,'O ntof the jig. 1 0 'let th is u p, c ut a m atch

    in g rabbet i n p ie ce of scrap ana clamp it

    under the front pressure

    bar,

    Then bring

    t he r h. .

    wer

    front up

    ti~ht agai,,~t

    he ,

    - a b

    b et in the

    scrap, see

    S tep 3,

    ROU I ING SIDEl;, AIle,' ,'Outing th e

    drawer n'Ont (S tep 4), rem ove the front

    f ro m th e

    top

    of the jig and replace it

    ,vith

    a piece

    of S 'I'8I),see

    Step

    5.

    Then bring' th e

    drawer side up tigb t against the

    front

    of

    the jig and the scr ap , S ince tile side piece

    d oes n't h av e a

    rabbet

    in it, you can rou t it

    w ith ou t a s pa ce r,

    BACK CORNERS,The back comers

    (where th e drawer back meets th e sides)

    al-e eut with th e

    flush

    doveta i l technique ,

    s ee p ag e 20 ,

    onOM GROOVE

    T he r ab bet also has to b e c on sid er ed w he n

    locating the groove for the b ottom in all

    th e pieces, T o d o th is, I just av oid th e nil).

    b et by m aking a little fence for the tab le

    saw

    that

    fits

    1mder

    lh e rab bet, see S tep 6,

    T he n th e g ro ov e will

    be

    cu t the sam e dis

    tance f rom the shoulde r on the drawer

    5 -on t a s

    it

    is f ro m th e b otto m

    on

    th e b ack

    an d Sides, s e e S tep 7,

    W h en cu tting a gr oov e f or a

    v . r

    plywood

    bottom, r do it

    ill

    two s te ps, F ir st. a dju st

    th e f en ce IO the cu t w ill b e slightly of f

    centered 01 1 the bottom socket. A f ter

    m a kin g a p as s w ith a U th e.'pie ce s, m o ve b h e

    f en ce s lig htly u ntil th e g ro ov e is c en te re d

    on the socket and w ide enough to accept

    th e V . , bottom , T hen m ake another pass,

    8

    T ap d ra llJ CI 'sides iulo

    < / 1 0

    front

    umil I} e

    pins fit flush w ith the

    S/tollktel'. T lte b ack jo in is cuI the same

    a s for a. fill h f ro n /, d rawer,

    1

    o ,d

    the

    bottom

    { lroove on V 'C ;,..

    side

    of lite c lrcuvcr sides

    (w d

    o w ; k .

    lea ve lite rip fen ce a'ut Masm,ile , , , , , , c . . .

    in th e .a m e p osiu or:

    1 1

    R BBfTED

    OR w tR FI lO W Y

    TA P P fN S

    IN fO S O CK ET S

    U NTtl S lO IS flUSH

    L E V E F ENCE ~

    AND B lOCK IN

    SAME POSJTrON

    AS~~

    IUU l , _ )

    6

    To cu t g ro ov e f or b ot(6 1 . , a it a s tl 'i p

    o j M o so n i l e to

    the

    botU

    oj' a block

    a.ut ckmlp It)

    f e n c e .

    Theu.nm th e 'ubbe

    .h m ll de r ga i,w t t il e M a S O Il it e

    5

    nemoue 1 1 , .

    drawe r front mul

    l I P l a c e

    'willt a pi.c~ of 8 0.1', T h e n . 1'OU th e

    l)i/l8 61t tile euds of ih d'' };lool' sitl. (I,.

    . ((nU) M a ll . a

    f l ,

    fron: dllllvel ..

    1 1

    -

    4

    Cui the

    ,~(l(;ket.

    in

    I I . dra wer fron:

    ( iI mouillg TO ute r p 'Om lef t

    I

    ,igh t.

    Work il l (l'ut

    ou t

    Ih~ IIUicif & sltill{l

    bottom . ou ilt al l of tl te l/ol e.< ,

    To keep tile ..IUflddelof rabbel al ig>1e1t.

    R BB ETED

    ONT

  • 7/24/2019 Woodsmith - 058

    23/24

    However, J usually fo llo w th is secon d

    m ethod and cut the joint so the pins are

    about V,, too deep . B ut take this into

    cons id er at ion when meas ur ing and cut ti ng

    the draw er fro nt an d bac k to le ng th. fth e

    pins ate se t V., too deep , th e length o

    the draw er front and back w ill b e sh ort

    ened

    v s

    whe n b oth en ds are sand ed.

    arou nd th e pins an d also in t he s ocke ts.

    usua lly use a s mal l r uti st'~ b ru sh to d o this

    Tile problem

    is that there are

    a

    lo t o f su r

    faces

    to

    COveran d

    the

    g lu e c an s ta rt

    se

    ting

    up

    before you

    can

    get the draw er as

    sembled. It's

    a

    good id ea to h av e SOmeh el

    to spread the glue quickly

    S NDING THEJOINT SMOOTH

    T he p erfe ct d ov eta il joint should fit to

    g eth er tig ht, flu sh , an d th ere shouldn t b

    a l ot o f e xc es s g lu e s quee ze -ou t. That's th

    id eal. B ut in reality , there m ay be som

    finishing work to do on a dovetail join

    a ft er a ss emb ly .

    In fact, since I know the joint w on't

    b

    perfect, I plan tbe fit of the joint so it ha

    to be sanded down exactly sm ooth. Th

    on ly ques tion here is: Should the joint b

    cut so the

    1 ill

    stick up a little from th

    surface, or so th e

    c U li s o j l it e s o ck e/ .

    stic

    up a li ttle?

    S AND ING P INS , ff

    the joint is cut so th

    pins-stick u p, yo u have to san d th e ,q / tOl

    d ra wer sid e to k ee p it a u nifo rm th ick ne ss

    If you only sand dow n the face of the pin

    (neal

    the joint), the m id dle se ctio n o f th

    draw er sid e w ill

    be

    th ick and cause pro

    lem s w hen it's tim e to fit the d raw er in th

    cabinet.

    S AN 'D ING O R AWE B J;JNIJS. If the joint i

    cut SO the pins ar e deep, then you onl

    have

    to

    sand the ends of the sockets (the

    ends of the drawer from, and back). B u

    th is creates another problem , The fron

    and back ru- eu sually cut to leng th to fit th

    opening in the cabinet I there w i l l be

    sm all g ap on either end. fy ou s an d afte

    the d raw er

    is

    assem bled, the gaps can

    e as il y g et

    too

    large .

    However, even w ith light tapping , it's

    best to ap ply even pressure across the

    w bo le jo in t to p re ve nt th e p in s fro m sp lit

    t in g ou t.

    r

    p lac e a b lo ck o f h ard wo od o ve r

    all the pins on the drawer side and then

    tap u ntil the p in. are seated

    in

    t he bo tt om

    o f th e so ck ets .

    ST NLeY H lttMJl Instead of

    using a..

    steel hammer 01 wood en ma lle t, I'v e f ou nd

    t ha t a S ta nl ey De8(1B low hamme r wo rk s

    n ic el y for most j oin t a ss embly ta sk s. These

    h am m ers are m ad e o f b la ck p lastic a nd

    the

    head is filled w ith oil and shot They Call

    be

    used

    with

    quite so me fo ree a nd still n ot

    dent the wood. They 'r e a va il able at m ost

    h ard wa re sto re s an d h om e ce nte rs,

    NO Cl-AlIfPS . O ne advantage of having

    t igh t f it ti ng j oi nt s is that you w on't need

    cla mp s to h old th e d ra wer to geth e)' w hile

    the glue dries . (C lam ps c an so me tim es

    have the negative effect of pulling the

    d rawer o ut o f s qu ar e.) fth e jo in ts a re c ut

    w ith a tight fib,

    just

    ch eck th e draw er fo r

    square as soon as the joints are tapped

    home. Then allow the drawer to dry on a

    Oa t su rface ,

    GLUING DOVET ILJOINTS

    How much glue should be applied to a

    d ov eta il jo in t? A nd wh et sh ou ld y ou ] lu t

    it - on the pin s o r in Ille so ck ets?

    TIGHT JOINT. If th e join t f its tig hUy , y ou

    d on 't n eed m uc h g lu e. I u su ally sq uirt o ne

    d ot o f y ello w g lu e o n th e b

  • 7/24/2019 Woodsmith - 058

    24/24

    lOT IJ '>8F.D ovetail Jig Parts and W ood

    Kit

    ($54.95) includes th e p ar ts in K it l If fi SE

    plus all of the w ood (hard m ap le) needed

    to b uild th e

    jig:

    (1 pe.) 1% x 6 x IS ( Bas e to p ).

    (2

    pes.)

    1%

    x

    1%

    x

    15 (Bars).

    (I

    pc .)

    1%

    x

    1%

    x 1 6 V : .

    (Oams),

    1 pe.) y. ,

    x

    b

    W x

    2 . 2

    (Base).

    l

    pe.)

    II . x 2'4 x S

    (Stops).

    TEIIWLAr ONLY. f you want

    the plas-

    tic com b

    dov etail

    template

    only .

    Order

    Kit #58C,

    Dovetail Template,

    $24.95.

    OOVETAILorr. W e' re also

    c)ffeling

    a

    double-fluted,

    carbtde-tlpped 'A' dovetail

    bit. It's a high quality bit w ith a 1 1 . shank.

    O) d.1 Kit #58H ,

    'J ,

    Dovetail

    Bit,

    $1{ ;.75.

    O RD ER IN G IN FO RM A nO N

    To 0111erany

    0

    th e kits, w rite y onr ord er

    an d yo w ' n a m e and a d d re s s o n a piece of

    p ap er (o r,

    if

    availab le, use the order form

    o n th e p ro te ctive covel' o f th is is su e). S en d

    YOIU

    orden a nd p ay men t,

    (110

    ch arg e cards

    or phone orders, p lease) to :

    W ood .m ith K its

    P.O. B o x 10350

    nes M oin es, 1 A 5 00 06

    Please spee if y t he kit nu m ber on the out

    side of t.he envelo pe . A llo w 4 4> w eek s for

    delivery. Postage and handling are free.

    (Iowa

    residents add 4%

    sa le s ta x.)

    Plio

    es

    o f t he se

    kits

    ru... g oo d thr ough Decem ber

    31 , 1988 .

    on the hope ches t,

    Order

    Kit

    #58C,

    Hope

    Ches t Pattern, st.oo.

    DRESSER

    W()() ( ismi lh is also offering a ki~ of hard

    ware for the dresser.

    KIT

    5 8 1 > . Dresser Kit

    (~6.95) includes:

    (6 ) S olid B rass D raw er P ulls, w ith

    00

    ramie rosettes, 3 bor e .

    I)

    PI astic Buttons (drawer stops).

    15 reet of G lid e

    Strip,

    se ll-adhering;

    pressure -sensitive

    plas tic ,

    I .

    wide ,

    D O VE TA IL J IG

    We've also p ut to geth er tw o d iffe re nt ki ts

    to build th e dovetail jig.

    K IT #58 e. Dove ta il Jig Part s K it ($3 4.95)

    includes:

    (1)

    Do ve ta il C o mb Templat e. plas

    tic,

    o/ i' I

    x

    4 X

    I S / .

    (4 ) Eye Bolts , 0/ ,01 'x 5 ,

    lvith

    eyes

    welded sh ut.

    (4) Threaded Inserts,

    0 / , , , ' in sid e dia.

    (4) Com pression Springs,

    %

    x

    2 ' .

    (4) Steel Pin s, ~ x 10/. .

    (2) Pan

    Head

    S crew s, N o. 1 0 x

    Y .( .

    (2)

    Machin e S crew s, v . { x

    3 .

    (8) Hex Nuts, '/'1'.

    2 )

    'II W in g Nots w ith

    w a s h ers ,

    (4) Fh.

    Macli ine Sc rews, V x 1 4

    (4) Fender W ashers, 0 /0 , x

    10/,r

    (2) Corner Brackol. 2 )( 4 X

    tN

    aluminum with slot an d holes .

    KIT N l8B. H ope Chest K it (B rass P ulls)

    (~.95)

    include s all of the item s in K it

    #58A , ex cept the pU ,lI sare m ad e of Solid

    Brass, 2% x

    4 /.

    see ph ot:o abQ ve.

    PATTERNONLY. If

    yo u

    only want the

    fl lU-si1 .epa tt.e n1 S o f th~ scl'lllwol'k de.~igns

    HOPE CHEST

    WO O f lsm ilh is o ff eJ in g two hardwa re kits

    fo r (he

    hope

    chest. One

    has carved cherry

    pulls, the other solid b rass pu lls.

    K IT # 6 8A . Hope

    Chest K it

    (Wood

    Puil$)

    ($34.95) includes:

    l pa ir ) So li d

    Cherry

    Ha rdwood Pu ll s,

    2'~'

    x

    9 % ,

    se e photo below.

    These

    pulls are hand carved in the Amana

    Colonies in Iowa,

    (I pair) Solid B I O S S Hinges, 1 V .

    long, Z open w idth,

    \\~tJj

    screws.

    (1

    pair)

    Lid Supports.

    on e rig ht- hand,

    one le ft -hand, b l O S S plated, w i t h b l' 8 S S

    screws.

    (1 )

    Chest

    Lock,

    key, str ike plate, and

    k e y h o le escutcheon.

    (1)

    Full -s iz e Pa tt er n s of scrol lwork.

    WOO SMIT KITS

    eyes from co m ing uncurled.

    Cut four 'h, x

    1%

    steel p in s fro m

    a V i' steel rod or [rom the unt.hreaded

    part of 0 . 4 carriage bo lts .

    M ake tw o

    2 '

    x

    4

    brackets from

    4

    x

    4 C O m e r br ackets, s e e page 18.

    GUID&BUStliNG. ')'0 use

    th e dove ta il ji g

    you

    need a V , .

    outside diam et er

    guide

    b u sh in g ,

    Bush ings

    ar e

    m ad e

    to

    fit

    specific

    ro uters, so ch ee k w ith a d eal e r who carries

    accessories for your

    router. /\

    universal

    bu sh in g' set is avai lable from :

    WOOOCRAI 1' suppx,y CORP.,

    41 A tlantic

    A v e ., P .O . B o x 4 0 )0 ,

    WObUi'Il,

    M A 0 1 88 8 ;

    800-225-11 53 (Catalog : F r e e ), Rotder G uili 'ls

    (1 pai r), br 3SS

    pl ated, 6'h long, 01 1le1 ' No. 01205.

    CllIlst Lock,

    include s

    key and es cu tcheo n,

    Ord er No. 03304, Carved H art lw(I ( ) ( lP u l l s

    (2), 1% hig h, 4% wide , Chen-y, Order

    No. B12OO;'V aln ut, Order No. B

    l2oo ;

    Oak , 0111er No. B1204. AnOLhel' option

    would be to use

    brass pulls (see

    pho to

    bel ow ): Sl (W Puils (2 ),

    :r

    bore, 4%

    overall , O rd er No. Ell2.3 .

    DRESSER

    Y ou

    can

    ord er the

    dresser

    h a rd w a re I om

    W oodfnni lh se e be low ), or fr o m :

    our es


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