of 14
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3 95
O TES FR O M T S H O P
O 9
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No. 69
J .m
tr h
fo rt
is
a nal lened -out Ssh ape w ith the fronl
of th e seal cur ved down 10al low relief be
h ind yo ur kn ees, A s w e played w ith thai
s h a p e . we lound that it was most c o m
lortGbI
when th e se at
was
shaped SO the
11 ( . .. .
ure is di s tributed evenly al ong th e
back.,Cyour legs. somewhere
alonl .he (:C.
e nd .t hir d a nd fourth sla ts o n th e h ir seat.
Thh.l iV .
O nce w e
gO I
a
consen~u,
Olllhe
angle
01
t he b ac k.
we had tod.I,'rmin,'lh. III 01
t h l's ea t. Ad ir o nd a ck c h ai rs
ar e
typically d~
sig ne d w it h c on cav e ( l ' ·shaped) > TOM) J.SirOhmnn
James
~ olan
Project Iksigner
Ren Munkel
IllU>lrnlo Dovid
Rreylin~
CI l (.~n
RodStoakes
tIlri.G c k i
Grnphks
O~.rJu.
Snyder
Prni lo inO$.1A lien.Welsh
COLUMN
une.
1990
o. 69
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\Voocbmirh
o 9
3 Hardum re and pr oje ct su pp tie »
neededfor theprcjects in this issue
3
Our
s ab re s aw table alltno« YOIIto
control the workpiece - jusl like
when using a band s a.w01 scroll saw .
I
Tools
Techniques
I
Talking Shop
I f 2 I
SOllIe
s pe cia l c on sid er atio lls fo r
L __ - - = = - - _ . . : . . . . - . ~ Illakiligoutdool' nrnitul'e.
2 4 IV elook our Ad irondack chair I lid
.~tetc hed it to coni fortab ly ho ld two .
Adirondack Settee
I
Beam Compass
2 2
Til
is
shop-made r fl lnpas s
does
what
L
- - - = _ - _ _
_J a sllIal CfJll1paSS can I it d aws
very IU1 ge irc les.
3
6 Here:~olll l er[) iol
ofthetrudiiional
sltltl1llmti1ne favorite. It s /) Id ltfor
years
of outdoOI ·I·elaxatioll.
I Adirondack Chair
I
Shop Notes
4
S01l1etipsalldideasfi Olll in-side
lite
L _ - - = - 1 ~Voo(u;lnitltShop: 1 Cutting Cornel
Blocks . 2 A Thin Stock PIt.,1IB lock. 3 A
Spacing Jig . I. ROlltil lg SlItall P ieces.
I Tambours I 2 e UII wer a few ques tiOll11abo ut
L J the way t (l Il lbours work. And .~how
you
hoieto
make
YOllrOIll lllallWou)·.
I D ase I
f l Walllltl tallibour
doors
slide
L __J ~ (u Ound th e ends of this CD case to
conceal th e
28
C
D s
.~ lol·ednside.
page22
page
6
Tanlbolll S
1
f 4 1 Great tips [rom [el ltno ioood-
L.: J workers:1 Clall~pillg IUiler Jo in ts .
t Velcro Holders . .
,Uo1 ti si ng Tab le
S top s . Router Table Turning .
I TIps
Techniques
ont nts
LOOK INSIDE
Patio Table 2 6 The slaiconstrnction of this simple Adirondack Chair
L _J table is a
perfect
?natch to the
Ad irondack . c ha ir and Sette e.
I Sources
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N() .6 9
p iv otin g b as e plate re sts on the
bo lt an d po sitio ns th e bit at the
co rr ec t loca tion.
To locate the holes, mount a
v· groov~ bit in th e ro uter and
ra is e
the router untilthe
p oin t o f
th e bit is at the desi re d h eig ht.
see Fig. 1a,Then, tighte n down
th e base p late.
Now.ho ld
a
% b ra d p on u b il
und erth e b ase p late and push on
it to m ark th e cente rp oi nt o f t he
stop hole. Then raise the base
plate out of the way and drill
th ro ugh the back of the Mort is
ing Table.
One ca utio n: 111is technique
works on ly
if
the s tock iS f.> · ar li /l
Vi
: \ I
or I th ick . lt's still a
good idea to w ork w ith a
corn-
mon (front ) faceofa llyourwork
pieces down against th e table,
o
1 :
Rull i
Keltmi lg OH
\VoodSffillh
ftRST:
PO S H ~...
aR,AOPOINT
fl INTO
.ACKPANEl
ItOUTl.
o
.. - C A RR IA G E B O LT
CU T O fF T H A£A OS )
_ aAS
I'lATt
4
•
.. 3
DRILll ·
INOfXlN G
STOP HOlfS
tA B LE
I
1
has to be ... . . . :l~ r l l above
the
table
To in dex 1Ii l C positions. I
driUed
holes below
th e
router
bas e p la te a nd in se rte d a c ut- of f
~ carriagebo ll in to the desi red
ho le
as a
,;t op. '-
~ig
The
diUerenl
thicknesses
of
stock.
tarted by assum ing that
mos r of t he s to c k I would bemor-
tis .ing w ould be Vl .
: v .
or 1 ~
thick. So. to cut
a
mortise
centered o n th ese th ic kn esse s.
the center of the mort is ing b il
• A fl er b ui ld in g th e Mo rtis in g
Tab le featu red in lI ood lIIilll
No. 67 . I mad e on e simple addl
bon thai
makes
t
even
mo re u se -
ful.
By a dd in g an indexing sys
tem .I c an qu ic kl y r epo si ti on th e
b it to cut c en te re d mo rti se s in
MO RTIS ING TA B LE IND EXING S TO PS
• lv e ro un d all k in ds o f use s (o r
se lf-adhesive Velcro strips in my
shop. I bu y¥. ·w idc · strips from
a hardware store fo rS 1 :1 9 a foot.
Originally
ought the V elcro
(urkeeplngpencils w ithin reach,
W rap a sm all strip
around
th e
p, :nd l and stick a s tr ip in a co n
v ni cn l ~pot a bove your bench.
and th ~ pencil never ro ll s away.
Afwr
th e
Velcro
was
in my
shop. I found lo ts o f o ther uses
{orit.
The
mos t obvious
uscsare
{ur hulding tape measures
r ul er s, a n d
s:mallhan d tools.
B ull think the m ost v alua ble
U -4 · is when
1 0 0 1 needs 10 be
close to a machine. A push stick
on th e s id e of a tabl e sa w. Route r
w re nc he s n ea r lilt
ro ute r tab le .
Orachuck key
on
the
dri ll
pres
All
it
ta kes is
a
s tr ip rV elc ro o n
the
10 01a nd a m a tin gs tr ip on t he
machi ne. The stuff holds. I've
nev er h ad itvibrate loo se .
Gary G aitlt er
SO A,, o l ,io.
r»
VELCRO
o
o
pt u
APPU[O
ACaoS
CCNTut
It I I I I Ayull
B
nl~I·II ••
11 \
th t' clam p. w ill fo rm a line
through th e center of th e jo int.
111 cn when the hand sc rew is
tighlcne d. press ure w i l l bt ap
plied dirf: clly on th ,· jo in t.
see
Fig.la.
On a long tall) miter rom, r.
se t up two pairs of bloc ks: Ot
se t at th e top an d UII< li t th .· 001
t om o f th e jo inL
MIliltfO
CORN .
WITH
S PU NE
ClAMPING
al ) 1
use
a
hand
screw)
This
damp
app l iesp ressureacross the je im.
1cut th c w idt h otthe blocks to
ma tch t he thickness o tth e h an d
sc rew . an d ab out long.
The
o nly trick y p art is cuttin g' the
a ng le d n ot ch es in th e blocks,
To do this. I mounted a ~l
dad o
blade
in th e ta ble
s aw and
tipped th e blade to
45 .
Cut th e
notch close to one end so when
th e
blocks
are
inp lace . the t ipsof
• Her e's a c lamp in g Jig I us e to
keepmitered eomerstight
while
gluing. I I· s . met hod for pu ll ing
th e pressure w h e re it s needed
- at th e Center of the join t and
p er pe nd ic ula r to uie jo in l l ine .
SCI? F ig . l a.
The jig consists o f
two : Y t ~
thick blocks C clamped 10 th~
IWO
pi ec es th at are
being
joined.
ui
an
angled no tch in each
blockroaccepianotherclamp. (I
M ITER CLAMP
Tips Techniques
WOODWORKERSELLOWRO M
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5
.. .
69
I,. S T R A I G H T
an
STO.
lLOCt(
ItOIJT
Of' I.·
CHAMI1I I Of <
lA(MPASS
II \· o u , . . . ul d l ike to share a
tip r idea, ju~t send it to
\Ioo . nulh, TiP and Tech
niqu . .. . ..2 ' . OOCrnndAve. . Des
\loint~, Iowa50312.
\\ 'r
w
pa y upon publica
tiun S15
to
SIOO (depending
')It
th, ' publisht.'I i
length
of th e
lilll. P ica , in clud e an ex·
plana tion and a sketch or
photo (w~1Idfllwa rt cwon e) .
4
....l an A O O Yf
CINn. OFntl(ftt.S1INO
SIND IN YOUR
nps
IOTt-tWHW,5
SHOULDS[ (OUAlLY
LA R Gll t n - tA N
CNDSOF WORtc (Cl
sc.UW10
wo.l(PI.(Ct
Cut WHIrLS
WITH
AOJUSTAW
WHIrLC , 'I
HIllP'llOT
HOU
crNTtR(O
Of < I>IOS
NOT(:
2
r
OT(:
I
ItOUTU
fUll
OOIIT,I
UMrTSUNGrH OfUG
t
NC(
,
C C
ClAMP
RO UT RI( iH t
[
S TO P L O CK
10
un
f01ENCt
[i]
r~ fljt B j\ I( : 7 (1fN b l l j .( t . It t
, t , ', ' 1fJ,.,(
/ )1 ; ( ( 1 1 II /It li , P (
r l ,,'e
(/IJ lI.ifttrr •
. , t t ,
u.. .., (/
it
(/ t', n' : t rt r/ l riJ> l t-J , , ;111l lt If.
1 1 , , I , , 1 ) 1 ) , , 1 1 ,
U I , l
, 1 , , ,
l
I rl,l, t}'f
tff/ ....
, . . . t f /,.g tI, t ,, , ,, , '
t)
/JlfOlll niHIl (AII,f tnt If'g
h
I ,· t, { ,
Ix J f/ ..(I~t.J
dun-,
IIIU.lIy
thv
bi l will
have
rut around tll(,entire ra ce ofll1('
Y o ' c t r k l > i l ~ .
I l l < ' trirk t making t he wo rk
pi,'(' alnl ,1
,ll'rll'('\)}
round is
patience, Rotall' t he wo rkp ie ce
1 1 1 ,yJ.lII
between
P3'''' ' '
a n d co ntin u« to la ke stock oil'
, : 1 \ ' 1 , eorm-r .-\...you rout. you
i ll bt·
{r( dtin~morecorners
with ( 3,:11 pa . bu t lht co rne rs
' (1(\'1
be
as ,harp. l l Fill. ~
, . , ,·n tuaJl)· th,·
workpiec e
will
,Iart to I cl -mooth and round.
Then remove Ih e wheels a n d
ha nd ...uld an y of th e -mall 11 .11
nn'''' It b y Ih bit.
J ( , J , 1 I Gra l
JIIl/eall,Ah'
fe n ce so Iha t when th,' I r l :, M f
1 ) / 1 1 )
If ) 'Ou
''dill 10
make th ~ work·
pi ... round, m ov e Ih,' ft-n c~
ba ck ~.·andmak ...anoth~r '< · I ( l I
cub. 8}' rePl'ating
Ihi
pm.;.-
be sliUhtly In rgc' r th a n I II (' ,\(I of
the leg il', auached 10,wr
~il .
.
After rhe whee a re ru t 10
sise.
scr ew them
tighl to the
ends u( th,' workpi, e ' II~)'
f/O/'' '1
tum. ~O 4y ou c an ~tp
t he r o ut er table, se e ~lg. 2 .
Xote: SiIKc th e 'hed, mU'1
alwray' run on the ,utt f
t . a . b l t .
an d
along
th e
11'0(' , the
Icn~
rt
h
of your router labie a nd f ne{'
l imits the I~ngthof ''''''k)'OO ra n
turn -
\ h~n making Irg'
lon ger than 11 . I m atl,' a tern
porary rOUI~rtabk fn,m a IClng
ship o( pl) 'Woort
by ,'Ulh nR a
piec,'
of
'qu 'rl' stoc k 10 kn j 1 h Then
drill
a ,m a U p ilu l ho le a l t he
cen
u-rpomtv 01 e ac h ,'n d In moun t
th e ' h ( < 1< . 't'I·ill. 1 Now , if
you ' n '
makillR31aPl'n-dleg.li~
taper (IIIlour ,idt, ul
lh,'
work
pit'(-(.
on lht. ' l .abll sa w
The Irick h' mysystem comes
I1 ( X I -
Ih e wlweb. I
('ut
th ,~
frolll .~ , ,wck wilh an ad·
juslabl(' rird,' rulll'ron lIlt'drill
pr '
they
w oul db e l ar g er
in
din nw h'r Ih an th .. end . o( the
worklllC ,, If)
uu·,.
'1urning •
cylinder.
CU i
both w h l, the
;1l11t
III.
l\uI ir)OU I { turning
a lap
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N o. 69
oodsmith
canvas .. ( \ ~
talk
abo ut tam bo urs and ho w to m ake
them i n a n a ni c t - beginnil ]R on page
12
The tricky part w as ro uting perfectly m atched
g ro o ve s in th e lOP a nd b otto m o f t he o ute r c as e fo r t he
tam bo ur d oo rs to ride in . T o d o th is, I u se d a te m pl at . ..
an d a g uid e b ush in g o n th e ro uter. T hen, to shap e th e
lOPand
bottom
piecesso
they
matched the shapeoithe
groove . I used
the
template 8 llIin. B ut th is tim e w ith a
ru b arm o n th e ro uter tab le.
WOoO ANI Fl
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7
u,69
10',·
I
l.
,
CUnlNG DIAGRAMATERIALS
CASE
BOTTO_: )
~
'
PR IG HT
CANVAS
BACKING
DMDER .
f00....
TOP
PLATE
6'.
ItOUTINO lTMPLAn MADI
AtOM ,, _
THICK MASONITI
CASE
TOP/BOTTOM
G
ROU TIN G TEM PLATE
r . ~ T · O 1.sW·~ ;L
W OO D P AR TS
S U P PU ES
A UprigIlt.(3) ,...4 ... 9tgh
• 4 800rd F G • Illick
red 00Ic
~. A L·_C:
B DMdeti(52)
- x I . ?
4
liI6
• 31
SquoteFt 0112 nlclcw(l utlo: 'he
2•• l •20 (.4ad. ,]
C Top/BoMomPlo1es(2) ••
4. '2.
tomDoU _
and
II1edMdeIS.
) ,, · 1 2.tU.
't.}
D C erFocllO(l)
~ •• 9 -
•
.' 'hick edOOk plywoo(Hor heoock
I
Ou1erFocIngs(2)
~ x
1~. 91\
• Mod.umwelgN orl1Srsconvos
G
o c I « l
V.-PIy 9\11
x
13',
It1ickMosonIte10:templote.
'1.4·.$0 (t.S Sq. t .)_
G Cose Top/Botlom (2) ~X 712 1910
• (16) No 8X~4 F woooscrews
H Tombour SIo S(S8)
~. x 12 9 1 1
•
Dowel 10:stop pin$
',Ji4·56 (1
.5Sq.'f.
I
HOl'Idles(2)
I XIt, 2
• t~ PIntof lung o~fin
~ j
~
TAMBOUR
SLATS
®
OUTER
J •
FACING
• D lL I S
f 1
•
; -
,
BOTTOM
~
PLATE
HANDLE
0.0
0)
GUllI
auS I ING
CENTER
FA CING
EXPLODED ViEW :._.._ -,
~VEllAU DIMENSIONS :
lOS
H:It11 2 W...1 , 0
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•
W,xx1sln1rh No. 69
length.] clamped Slop block 103Uauxiliary
I t'm 'e o n th e m it er dUR~.ee rig. 4. As (o r
th e length o f t he d iv id er s. I Cu t t h~m 1 16
shorter than the w idth of the upright< 10
a llow lor expans ion and con trac tion.
cu tSG OJ~lI)ERS.Once the d iv id er s a re
U~
henext stepisto glue them in t kerfs.
Pu tad l 'O l )o fg lue in each ker f, n ea r t he f rom
e dg e o f th e d i vid er . ( l) on 'ts pr ca d th e g l u. in
t he ker f) Then set th e u prigh t o n edg e and
push th edivi de rs down a j ain st th e wo rk s ur
f ac e t o g et t hem f lu sh w ith th e fro nt ed ge 0 1
each
uprighl.
se e
rog.5.
conu
Ul'lUGHT
e ach up ri gh t. t he n CUi t o you r l ayout lines.
No mau er wh ich me thod you choos e fo r
c uttin g lh l' k err.,. y ou 11 n eed to mo un t an
aux il ia ry ( enee 10you r mi te r g auge. s ee
Fig,
2 . T his fe nc e n ot o nly p ro vid es extra sup-
p ur l. it h elp s p re ve nt c hip ou t wh en t he s aw
b la de e xit s t he wo rk pie ce o n th e b ac k
edge,
N~X1.llrimmediheuprights to length To
do th is. trim the up righ ts so th e space be -
lw ,,< ,nth e o utsid e k erfs an d th e e nd o f th e
upris:hlS Is lrl
tl
making sure each upright
has t hi rt ee n ke rf s, s ee
Fig.
la o ( I n my e as e.
th e u pr ig hts me as ur ed 8 4t< ong.
4 U~wOltKSURf «
_ .A S A S TOP 10 KfE::P-
OMQUSRU SH
......_ w l 't 'f 4 F R O N T DG
strips. I started by resewing tw o blanks to
V t t thickness, Next, cut lilt blanks
in .,
p ieces tha t rneasure- l wide by 16 lon l (.
T hen these pieces are ripped into thin
srrips, see ~ig.
3. (This method will
yield
e xtr a d iv id er s. b uI s ome won't
b o · u,,,bll )
S inc e l
didn't wanuhe
sa. . . .marks to
~IOWOil
th e strips, I c u t th em a ti ttle th ic ke r th an th e
k erf a nd th en sanded them to
fit.
~hoJ)Note: Iused a 13rge l)U~hb lock to r ip
t hc el ev eu s tr ipSo« e ach b la nk. For mon- 00
t hi s pu sh b lo ck . se e pag e 14.
crrr
m I.ENGTII.
To c ut a ll th e d iv id er s l ,
s
-WAStE
,
RIP OIVlDERS SUGHll Y
-- -THf K£k THANSAWKlAF
S A ND O ft P lA NE
to frr
Al te r t h up ri gh ts
a re k e rf ed
a nd c ut to
f in i shed leng th .
the
next S lC1>s 10make
th e d iv id ers th at fil
into th e k er fs tn s up
pon the CD boxes.
M aking the
dividers (8) is a
IWO Sltp procedure, F irs t. l . z · lhick
s tock
is
rip ped in to th in strip >. T he il th e strip s a re
cut t o t he ir f in is hed l eng th.
DI\lDE( ST1HPS.To make the divider
DIVIDERS
L
WASlI
ItOUGH
clNtta
UPRlGMf
UPRIGHTS@
ker fs i n a l lt hr ee p ie ce s for t he d iv id er s 10fi l
into .
T he cn b oxe s slid e o n a nd
a re su p
por te d by the div iders. )
I c ui k er fs e qu al 10 th e width of the saw
blade (abou tW The right and le it uprights
ar e
kcrfedonthdrinsidelacl',oll/ I. BUL th e
center
up ri gh t i s
kerfed
o n b oth sid es.
se e
1 i J : . .
K~;Rl 1SG11IEI'IECES.The mos t accurate
way 10
cu i
these V l · dl'CPkerfs
is to
u se th e
indexing
meth od sh own
in S ho p
NO le s o n
l>aI(e15.Another way would
be
t o l a) ' ou t the
.p ac in g f or
thin
ee n kerfs 3 10 ng an ed ge 01
t
S·RJGHT: . To
m ake the
uprights
(A ). s ta rt b y cU ltin g
tlm.'C~I -thickblanks
to a
widt h 01
fh'·.sct'
F ig . l.T he ntr im th es e
pieces to. rough length (,i9
Al te r t he u il li gh t pieces h ave been cut to
their r U R h
k
ngtll,
th e
n ex t s tt P is lc c ut
inner
case .
I b eg an b uild in g th e
CD ease b making
the three uprigfus
that
are pan of the
UPRIGHTS
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WooJsffi,rh
n.69
ASSEMBLING THE INNER CASE
)t
Aller all of the
6
TOP
divide are IIh ' I ~ -AUGH
t..,
I
f).CUllhe back,oi sflu~b wit)llh~topand
0UTtR ~
OUTERFAtiNG
ill
- - l . .
bonom of the rase (91,;, ·,vide).bul extends
FWSHWrn4
ACING
lOGE Of UPRlOHr
C£HTf R®
-
k beyond bolh Upris:hLS10hide III('
tanl'
FAONG 0
bour backing). Glueihe back
(I.)
in place.
. . . . . . . . . .
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N il. 6 9
0
ROUTt ..
TAat£
f H
10111
lOGES OF
CAU10P
ANo onOM
17
J-S.
10M
lOO£
M AK E U GH T PA SSES _,
SNEAKING UP ON UN f:
1..- STRAlGKJ an
R O U G H
\ T
..lANk ClOSE
roUNI ..THtN
AOUT U9 TOUHt
CROSS
a,
SECTION
id~nlkal l o a n
be a p rob lem ,
The solut ion is [0
use a template. The template lets
y ou rou l
identicalgroows,
and
ilalso h, lpsyo\l make
the case
top/bottom
(G) the same size.
111£T _\If'L~n:.~lrs1.layout
the
Il-mpiatC.
see Fig. II and the RoutingTemplate onJl ij(e
7 . ThC1 lcut
and sand it
to
si7....
SCt
r ig . 1 . 2 .
RIA. KS.
T he next Sll'l)
is
to
make
mir
rored
topand bouom blanks.Simp ly g loeup
tw o bl ank>
to width of8 and
lenRll l
of 19
T o k ee p
from g cu ing m ixe d- up . ma rk
the
inside
from
edge
of
both
b la n ks . a n d
both
sides of the template. see Fig_13_Nowcenter
th e
template
o n o ne b la n k
andclampit
down .
INDE. IlNGHOUS. To keep the template in
posi t ion when routing . f used
IWO
indexing
pins. Markthetrlocations (referto Template
on
p.'gc 7) a nd d ri ll hole.
t hr o ul1 h I he
tem
plate and
h into
tile b lan k. see
Fig. 13.
(These ho le s il l b e
h idden bythe innercase.
T o lo cate
th e
h oles o n I he othe r
bl an k . f ij p
the tem pla te over and u s e tl 1< '6 t holes as a
d ri ll in g gu ide. sec 1:-'8_13.
INOf. XPISS.
O nce the hole. are
drilled,
pu t a
114dowel pin in
e ac h h ole an d trim th e
pins Ou shw ith th e (01 oflltt remplaie.
C SElOP ND OnOM
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P 0 5. 1 1' ION CASt
l ' , flA C K 'ROM
INS IO£
O f'
oaOOVI
tl ' t .ACf TAMIOUR$
INeonoM GlOOvt
THiJIIClN1U tOP
ON INNOt
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N o, 69
2
CANVAS lACKING ~
/R .•..~
1 : < ~ ~ ~
E ?
SLA~~~ \
AROU N D A TIGHT CU RV l
a.
V.SHAPf AllOWS
- TAMIOURTO
bf NO fOAWA ItO
rL~ .'t
A
THOUGH SlAT WILL
FIT IN STllAtGHT SECTION
OF GAOOVE. n s TOO
WIDE ANDIOR TOO THICK
TO GO AROUND CURVE
B
THINf ER SlATS WIU
GO AROUND CURVE BUT
SHAJIP EDGESMAY CAUSE
THE SlATS TO BIND IN
GROOVE
C
ROUND OVEROR
cHAMFER EDGESFOR
SMOOTHER nACKlNG IN
THEGROOV£
3
S-SHAPtD TAMIO~
a 'NOSH 1WO CROSS SECTION
I / - :: _ _ . . .- :: ; ;; , ~ ~ . ~ C T l 5 ° E S ~ 9 ~ Y
10~~ :-~ : l \:~ ·
l,~~~ ~ ,
----J ~
f/ CROSS SECTION WIDE SlA )
WORKamm
WITH
A
OtNnf
URvt
Design
:-Iole:
If
yo u
need
IU
use th ick
..Jab
bU l don t want to
make
a
wide
groove ,
the
e nd s o f t h e ta m b ou r c an be rabbeted ,
A lter determi ning thewidtl lof the groove,
drawthecurve thatyou need thctambourro
folkiw Now here s where Lh ingsg l interest
m g. T o g et th e slat 1 0 fo llo w th e c urv e, y ou
have t hr ee v ar ia bl e. 1 0work w ith - width,
t h ickness , and p ro fi le ,
WIDTH,
The first v ariab le is th e width of
th ,- .Ia l •. \\1 1il y ou c an m ak e a w id e-slat
tambour lollow a l ig ht r ad iu s, i twon 't move
..,,,.,Ill])', The m' ofthumb
is :
II , narrower
the s ia l in e t ighter the curve.see A g, 2 .
nnc, ,'Xt ;S .~ , Once you'v e d et erm in ed t he
, dl h t lh ,'l '1 at -, lh c n e'XlU li ng 10
consider
is t he rhicknes of th e slats, First, Oleslals
need 10be s ligh t ly
I l a . ,
t ha n t he w id th
01the gnxj\ t , I I t he y'r e t he s ame s i? -ca s t he
gr'H'V\~
t ,toy \\un l
f i t around the curve.
see
S l o . p A i ll Fig . 3 ,
BUI,i f the Sl31$are made 100 th in they will
r ail lc a ro un d in t he s tr aig hl s ec tio ns o f t h e
g roove I 'v e f ound tha t i flh e t hi ckne ss o (l ll e
< Ia tb V t 6 le ss t ha n t he w id th o tt he g ro ov e.
it j us t a bout r ig h t f or most t ambour s,
PROFILE.
The fin al c ons id er al io n (or g el
ling the fanlbour to f ol low ti le CUlVl i it~
profile. P ro file refers 10 the w ay the sial
lookswheo v iewed from the('nd , 'n ,isisusu,
al l)' a c ham le r o r a ro ulc d ro un d-o ve r (lik e
o n t he C l) C aS
maki ng s ur e bot h p ar ts wo rk l og el l , r,
111..·
~jmplt..> l\ a~ La
do this
,
(Im\\
every th ing on pa t) t; r
fit>;t.
Stan by detennin ,
in g h ow w id e Ille groove nee' ti s 10be. SIO('O
Ihe g ro ove w ill m osl likely b e ('ul vitl, a
rouler in on( ' pa ;S,the \\ id lh o llw groov~ i s
lim it , ( t o th e s iz e o f t he r ou le r b il, So yo u
h av e to ma lc h t he s iz e o rt he sla ls to t hl'
t
01 the b i t (g roove) .
T
here '. noth in g m ag ical abo ut a tam ,
bour. I t s juS l
a
s l id ing door
t ha t s f lex
ible, This f ic -xibf ilYallows
she
ta mb ou r 1 0
s lide in 8cu rved t ra ck.
Th e \\'a)' 10make a t ambour f lex ib le is 10
j oi n. s er ic se fi nd iv idua ls la ts w it h s ome s or t
offlexible hingr- The most common method
of h ing ing t he se s la ts
i.
o g lu e Iltem 10 8
fabricbacking.
B ut. there'. m ore to m aking tam bours
than just glu in g
fabric
to wood, In C3CI,
m a lt in g t h .. t amb ou r is the 1 p art - the
t ri cky (and interes ting ) part i s de
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13
IJ.69
5
.\·jl~·t.
; C ,(
itl p
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N o. 69
GlOCK PUSH S
W ORKPIECi A N.O
WA S1
P nll O
l a~
PUSH
alOCK
2
w aste Ih ro ug h O le blade. elimi
nating Ih e l iu lc sp lin te r ,
l3yaddinga heel o n to p onhe
block lOO. you c an tu rn t he block
over ifllw first h . .1g rt s t om up .
block m ade frorn an Un· long
piec,' o f2 x4 . '~ .
F i g .
2.
CUI
out
or I lu c o n 3 v n lweI on th e
bo tt om o( th block. Thispushes
001 111l'workpiece and th e
1
tri mmed (/ff w i lh a p oc ke tk ni (r
orchlscl.Ive
come u p w ith
a s o
lution that prevents t he sp lin te r
in
t h e f lr s t
ptace.
j'l SI 1I10CK. Iusc a
push
STtONGCotNER IlOCK
14
• T yp ic ally w he n rip pin g th ln
s to ck . I u se a th in pu sh s ti ck . s ee
Fig. BUII've n ot ic ed a problem
wi th t h is t echn ique .
A s
the push stick m o ves
DIe
workpiece past the blade. the
w aste sid e o f t he w ork pie ce c an
split
off
J I before
the
C ut is
complete d . Th is le av e s a l i ll ie
tri
angular SJ)l inlCrof wood o n Ih .
waste
piece.
see
F i g .
la,
SPUNTER. Ify ou 'r e m a k in g 3
series o f th in s tr ip s (b'llch as (o r
tambour
s la ts ), th a I s p li nt er c an
k e e p
th e w ork pie ce fro m g oin g
Illlhl againsl the fence on the
next pass. (O r s ilti ng O a t on a
jo in te r t ab le ifyou ' re jo int ing be
t w ee n p a s se s .
Though the
splinter
ca n b e
CUTBlOCKS 5 curs
t
r-... F~lO~M~:bt~.,--,...-~--::.,
b olb to th e drill press tabl,'
Now e l the co rne r b lo ck
again,1 th(' renee an d slop block
....ith the longedge up-and drill
the holes with a countersink blt,
(~I.J
E
Since the s crews mighl
loosen
a s th e
furniture
is
racked,
I
glued
( he b lo c ks 00w ith c on
strnction adhesive
almost in l ine ,< 'i ll , the di rect ion
o f th e groin (see Fill. lal. This
means they can splil uff the
c or ne rs a s they'' ' 'Ughtenl'« ,
It's beucr to have I he g ra in
ru n (l( f~
th e
sc rew holes .
This
is done
by
laying outtr iangl , . ,.as
sh o w n to
fil _ I
Thi-. way the
g ra in ru ns p ara lle l
10
1 1 lung
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15
' ' I
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N ,,_ (1 9
6
ch air lo ok ed ( se e b ack c ov er). I decided
10
r na ke a n
entire out door g rouping USingdea r n il -hear t r edwOI ld
(,.,... from cover). T o I< :t the beauty o f th e redwo od
show. I u sed 1 1
clear fin ish ,
s ee Ta lk ing
Shop.
po1ge29 .
And 10 st ren gth en th e I
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W o< ldsmi lh
f
1
LAYOUT lOWlR
IA K DRACt~tnoN
../
. . . . _ ~ ~
-.--
361..
R
•
@
BACK LE G
( ;
LOWER
BACK BRACE
@-
CORNER
BLOCK
RM
@
RM
SUPPORT
S < D
t
. ~
r-
t o . . - 96 : . ;;: ; :: ~--I N--------- ---~:----
Nt),69
SUPPLIES
• (60)No 8x 1>,0. btossFhwoodsc
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1 8
N o, 69
,. .
, -
LUlAND
SCltlWWlTK
Jl 2 WOOO
S CRE WS
U SE C lA M P T O
HOlDfRONTmnCKl
- fH POSITION
WHlU SCRlWING
. ,
,ltCHT
uo
IACKUO
~
, -
3
FRONT
C
STRETCHER
- S
~-
~~
I
2
FRONTUG
rlONruo
fb.~
. ,1 ,. _
~ \ \ /1-
•
~
LAYOUT
.
,
1 tUUU.HCf . . .. .
-
, -
INntOM
ntOHT
mGt
,
i
-
f)
•
a.
•
'
, s . . ..
,
WOOD SCIIIWS
-
(
)1.-
IHStOl fACI
1 _. J.-
\
15 •
f
1((1 UG
sauAJl1
•
10 FlOOR
,
IACX 110
~
, f
S,t
orrAU h.
lACK llG
tn·'rh~·r. 1
i :~ •
\i XI.
r.pl} ....
n ·
adh iv~
III the {ronl
lid ;, 0 1 II , b;II'k
It l(
(A). an d
d a mp
th e
(ron
I ,,,.'Iritt
bt:twI','nllw I('gassemblies,
' .... F ig . 3 . 1 11 1'11
14''1''''
t he s tr et ch e r in p la ce
10the front end ..of IIII'b..ck lel('-
complcte.thr ,'xl su-p is«)m ak e th (' front
• rrercber
(C)
Ihal connects the IWI)sides.
T o do th i •• 6 't cui tit,· p iece- III lenj lh
22\1~ ) rom a Ix6. see
F ig .
3 . l1 '1 l'n
rip
it to
f in nl w id th (H', ). N nw d rill I counter
sunk s h an k h o k- s ''''31' e ach e nd o fth c fro m
CAAP 1T TAM
MASONITI
P ntltN
lOUG
a,
f
.
-
.-.
)·ouma~
.ttlt
to ow, a l,omplate from \ ....
\ ...unitt>
Then
yo u
4 . . - . u 1 u-e
the
t~mplate
wuh
a
flu,h
Inm bit in
llll'
router 10
r ou l a ll
th e back k'I':' In identical ,hal>\ll 'ut twu (runlleJI' (8) 10a finished
....Lt·
of 3V· x t l
Tlu-n
cut
two
blank s ( or
tlu- ba
8/20/2019 Woodsmith - 069
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N 69
19
Gl UI AN. - - - . . .~
SCRlWWflH II • 1
WOODSCltrwS
A L . I o C N , J t O H T E O G l
0' I tACIwnH
,~ lOG£ Of LlG
A I 'r lIlh ,,' o j th ,· b ac k b ra ce p ie ce s a re
round,,1
, . · , . lh, · l l Iw,·r back
bract'
(~1
ca n
be ;n'I II d lx IW 1I th,· back
1 t 1 r 3
on the
''<
mbk- d b as e- . ... . ., I ·i ll 7 .
To
cI
lit,,, forst 1'1l1). wad o[conSlnt('
Ililn
ar1h(osj\,· I(J tilt fll(l ...
of
tht·
Joy,er
back
br1k~c11lt~~lJl)n
thr
bra('('qthe C4)UJ}o
,,,unk h l an' Cannl(toward 'he ironl 01
Ihedellr
f 1 ( :
l a m p tht~JIt't (o in po...1 J .o n b t .: £ t \; C f n
Ih~t 1M
mark, un
Ih (nsid , 01
t h< b ac k
k·lI' n ,In 'l edl(e of Ihelol'ier bark brace
, ho lll d n . .. .· l lh ,· I P
d g ,
of ea h ba ck 10i l.
.......i~ 3
111l l u -t ~ n Xx 2 bra~..,Fb woodscrcv.-s
tu ft l Il t. l i( . ..·c·1 1 1plart' t h r C l u _ g h the hol~
al acly
,hill.-d
i n I h,· b.lck leg •. ~ Fig . 7 .
LOWER BACK BRACE
f005II1ON
ALONe LAYOUT
UNI
usr C l . . A M 1 J
0
HOlOaRACI
IN PlACt
NOT£:
PU t
fOP SCRtw INFfRST,
THENWOttK DOWN
OUNt(R.SINKS
ON 10m III)(
1
5
TIIANSmt
LAYOUTUHES
.ROMlowtR 1J,A(l(
OAC( TOUPPEI
lACKIUCE
,
NOTE :
COUNT'. SIN K 11.-SHANK
HOUi ONOPPOSJT(SlOt
\ - ; ;
~ . y o ~ U J ~ . . · ~ · ~ · . c ~ u ~ ~ ~ ~ ~ ~ ~ · T
....~... MAAK aNJtltS
lo a
SCItCW _. ..
.ITW[tN SLATS HOLESON fACH SlAT LAYOUt
_2
1.._..21-_
2....·_2..._
r ~ ~ ~ ~ . ~
f
UPPER
lACK ..RAel
@
6
1 9 . ·
.... CKA .....
.... ct
s.n
SAW .. FtNCI
. l A D (
TOU'
.
LOWEl lBACK
BRACE
f
UPP£~R~~- - - - - - ~==: : ~: : : =~: : ~- - 1B~A~C~KJ ~A~RU
BACKBRACE - - , . BRACE
- < Y
4
..quare
10
lran,I r th•• lin t '
...cRru 11m' ',·xl.
m;u:k
th < position of
the
T,,,
huk' centered on th e slat
posi
tion.. en each
pit,(l'. ot't Fig.
5. :'\ow
drill
countersunk pilol
hul.,
in
th
Io cr back
brae and IllI' UI>ll\1 ', .. :k bra..e aube
marks.
ROI~l)n\'lRfI)(.f' Wilhlhescrewhol.
drilled,
O)llt U~~
round -overon allthe edges
ollh,·lh ,· bnJl'I·inn' I .IIIIt-d the bark
,1ill 10
be Ilk'll.
, hi . ..
pn-ce
ha s 0 be bc.,\ ( l{ Cialong its trout
t:dR' to 'lJl'flt'r1lh,' t a t . . . TlC1111hi. .b c . . . ., ·l.
lihlh,
so bLwdo25 .andriplh,·back ann
brae (El _
, , 1 < 1
v, ' ~
Ig.
4a.
11)\\.1(K\lk.liH,\(t :\ 0 , \It the I O \ \ C T
back hnlcr
(I)
Inn..idlh of 51#.' 10del...·
milK Its w n s , . 1 h . fll(a Urt~Ih£' distance
be
I '~ n
tlw
bark
i< l...
at Ih, fro nt o r th e a<
. .. -mbled base (2(~~ ),'lt'rlo iK I
I.. ,,. 'I~\TIJ'I- , Afl..,.t he I f) \I ,C 1 back
h l':1 ; ' ..
ut
In ·nlllh.lay OUI th ,· pos i tion 01
Ih bark ,Ial, nil it. Fig.5.
l· iNI . t iro
ahnvcentercd
OJIlit ..
len m h o (
BACK BRACES
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No.
(>\ )
«NtH'.
1.1.0I
~
\
aAtkSlAlS
.tJt(
21.-• .))'.-
n·(t ftf)('.· nw-k .. .on the b ra ce s, ~ 'I 'is :' I C)
lI\'1\. \It'l IJR\(E.
Then the ba.:k/arm
b
rae ,
(E)
sere. . , < 1 to
the back
,I. ,
driv
jnl-:Illt'S(Tl'\\,fr()m thefront oi the-chair Te
I~K ' : l I \h e p o -u io n o r~ SC I'( '
hc,lt .....
li,...,1
ll 'lU lorll,, ' rd.·rt'J'(,(, l in es f rom t il .· b a, 'k (lr
Ih,·1....\t
IUJl s
id..•
slats
a round t o t he ( runt \ lr il h
a -qu.m-
, , 1 - 1 1 1 . I
ia.
m a ke a s ec o nd
I \ '. lr renc~ mark
1 1 , ,
dllwn irom Ih,' lines you jusl
transfern-d,
: 0 . . ..
connect Ih( '~ l 'A: 'Cond
r e( er l n .. · ma rk . .
with itp t 'm ' il li nC 'ac ross the f ron t C.(tlll' ..JOtI...
~.xt,rum the frnnt of I , chair. drill ,I
......,;( ...o( .....
JUntt. f 'Unk
-mank ho1t,
'tn
l}l.'
lint .t t'ntl nngtht' holt. §on th .......dlh of ( 3('}1
,Iat FinaUl. altach the back rm b ,,,, IE)
bc-hind Ih,' ,Ial
-c.......
ng lrum tll., I....nl
rRONT
S T R E T C H E R
conE. CORN
8lOCKON
'RONT TRfTCHER
9
R E F E R £ < - I IJ \:e:XI. draw two line-,
o n ea ch
QUL,idl '
,Ltt
II
fldif.'att>
h 1 .
location
01 Ib. . o th e r , . ... back b race -- . -ee Fig. 10 .
Draw'h~
fil l
bn.·31ll~
UJI lrom lilt'
bottom
of each slat 10ndi,'ah' the top
edge
of the
upper back br:oc. ·(I»), .. . ., . -ill. 1I
Then dra~ the 't'(,nel hilt, 17 .,. up
in)1
t he b ott om of each .Ial to ,dit-arl tlle lO P
e dg e o f t ile b ac k/ arm b ra ce (E). M~Fig. I I
(This refert'II li,lt' , h ll ul ll I , Ic\'d..rith Ih~
top of th e fronl I , ·g.)
I~SL\lJ.. l I'I'..-N
I \t
t\ tlK.\l.~.:\0 , glue
a nd s cr ew lilt·UI~ b;o. . ·kbra. . . . lUI 10Lhe
back of
th~
'A O (KlI 'lde' al§ . u l iJ( l11f l1 :i l wi lh
tlle ,..,fer...n('(' bO t· , . ' I'll. 10
Then glu< and
.J (....
,h........ 1of Ih.,back
,lab
to
boll , b ra . .. · , .
Ir~lIinlllhm' ..itll tlle
8
,. '
Glut AI«) scuw
$TR.lTCHr.
WfTHII)C 2-
WOODSC.EWS
h-~
I
,
+
\
,
CORNER
aLOCK
(,I., ' THICK }
OACKLlG
,
•
J 1 , . * $HANk
-
,
'1-
HO
:\0 it ,
tune to
make
1 1 1 1 . o c k
,tal'., 1I - r ro '1Zi:.F1t'SI,
rut Ih.,dllhl beck
slats (H)
~W'..
ide
and 3S , long. '
n . . .
n
soften
a ll l our ro~
u~i g .1 \ s round-
overbh in Ih,'n)llh'r
1)i~, 1J (ll T IIlE~IA '.
1'''lall thv
IWII
lIuhid,',lal'
fi t
see Fig. 10.Todo
thi-,
r, '1
ill'I~Yadl ...-ave 10he back >ide oIlh. 10 r
back braceI~l. lllt-n align tll.· ,~ h 10Ih,'
r(;{t'rt'rK:t:
Olark
on
lhi~
brace, nnd n u . . .h
ilh Ib , b co llomed l .
\1tt r
(11(
~ are in po: , it ion.
I(.'1'l' '\
lht ·111
in
, ,1 'Kl '
from
the
Ironl.
SC'e
~ig II
BACK ASSEMBLY
Imade cc>(llt 'r hk,< ,k,
10ht
o (p ~
Iht
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11,,(ldsmtth
@
C-CLA MP
;/
UC k S1.AT
~~
\
fiRST ,
GLUEAND StREW
~~
l\aMA'FRONT
SECOND:
SCAlWS
\
C lA MP S AC K £NO RUSH
-
W 1l 1i a AC t ( /.A ..RM BRA CE
15
;
a8 x 2
\ WOOD
SCREWS
T
~
ROUNO ()VfR
fRO,, UG
FRONTlfG
A RM
SUPPORT
~
I,
ROVND OVPt
A RM
-~
I
~
. . . . .
\1..,
f
14
3 _
_ : _ J
.
,
. .
ACK LtG
l
16- aMi
OTE:
G WE AN D SC RE W S EAT
SlAJS reBAC K U GS W ITH
fa • \'.- rh o
WOOD
SCJl£WS
·, aOUNOo
OvtRON
F IR ST S L A T
_
\ '. SPACtR
NOTCHSKOND
SlATATANOl ~ , ....
T O F IT A lt OU N D
l ij....._~
fRONTtG £ATSlAT1.1 t
~i~~
~ ,,; c e r r e rn
InwtI
fRONTUGS
CUT 1.A$T
StATfO fIT
OAC K SU oT l'
:. {b.
C~
UG
,
SPACtH
E A T S L A TS
G\
fRONT
UG
II x 11~- SECOND
W O O D S C :I t. EW S $1.A l
12
'The last step is to
add the arms and
a rm s up po rts. First
cut the two ann
supports
(1)
tofinal
length
(S )
an d
widih
1 1 < .
Then
la y
out and cut
till
angle on the sup-
p on s. se e 1 ·1g.13 . N ow
round OVerflll il the
outsideandbottomedgesof thesupports
N e xt , c en te r t he a nn s u p po rt s
011
U\(: out-
side of the
t rent
legs and drill countersunk
bank hole, from the inside. see Fig . l:l.
1 11 ~nI llu a nd sc re w th e su up crts in
pl1CC .
AJ{)IS.
Cui
the IWo arms (IporI..
see Fig. 16.
Now adjust the tilt
of rhe b ack slats se
the back en d of the arm
i s n ush
with t he r ea r
e dg e' o ( t he b ac k/ am b r a ce . C lamp the ann
inp lace . thendr il l and s cr ew l tto the b a rk / ann
s up po rt f rom
undemeaih.see F ,g . 1 5.
Hi\1)I1
'5 8.\CKsu ers , Finally. lay out and
c ut th e 16 ra diu s a rc o n th e lO P
ends olthe
b oc k S I3 1$ .
see
Exp lo d< 'd v ie w on pa ge
17.
I
used a beam com pass
(set'
page 22) 10 lay
ou t
th e
arc. an d a sab re saw
1 0m ak e th e cu t
(refer to Fig. 8onpaze 28).
ARM ASSEMBLY
•
N ow it's tim e for the. '
scat slats (I). First,
rill six ~lal~2~
wide, and one slat
2\. 1 wide. O~11his
la st sia l 1 0 f il la te r.)
To determine the
length
of
Ih e sla ts.
add 1
\.': IO
t he w i dt h
of th e b ase , fo r a:> r overhang
at
,'a dl e nd.
R Otl1 3 ~/~ round-over-on ahe'
rdg('$..
(A t, :
round-over o n th e fr nnt edgcofthe first slat .)
seRE\\ HOI..ES.
New drill countersunk
shank
holes
ce nte re d o n th e id tl. 0 1e ach
slat.andl
~t
TOln the ends,see Fig.12.
Alsodrill countersunk shank holt's alonl
the (ront edge of the firsl sIal where il at
tache« 10th e lro nt sm-rchcr, M~ Fig . 1 2 :: 1,
f1{O'T1WO ~I,\TS. CUI Ih(' first
8/20/2019 Woodsmith - 069
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. .
,
,
. . . ',
1
,
DRIll 'u·
HOtt THROU(j:H
10THPlKU
CARPrJ
''''''
OCfmta..
m tN T ll tt .'¥ \
' ' ' ' ' '
lU~
CUTBlANK
INfO FOUR
1'.-·W1M
Net
4
av.o.
C : : : : ; : : I P N C t
A,
<
SIll< blo ck trom a :~ , I
I ;r
In re on
II
< ) I...
I)ush
block, ' t ' I I( '
1U
~11(I< IIMVF,ST(Wf11I1~, \\,ilh lilt' four
Ilit ,' ,uf .....
ick t'\\o
11lnh,;tlinJ: Ilil \'( 'S
to
~l tilt
r
I
-m p -rar ilywith
dlJuhlt· · ,j(il-d carpel
L Ipt.
S( (
1-1£ .$ ,
This
k
t...} OUn11 lilt>
finger
n.-J1:,
h ( : l
sen \\
hcle-, and
d(,,(,1)rali\l.'l. OfTk'f '
mllC 'N an boll l p N - c . _ ' C o
at
Ih( ....me tune.
, . 1
neue..
:\0
you can
drill th e
('1', ~1-nt- 'llaPt--d fu12t rnt;ll·ll\. :-._10 holdth~
1 < ( ' ''; .. hil. drilling, I buill
a
,i01I I. jill,
S('('
I'IK. , 1 1
u -
JiJlconsis lsoftour :v , ,lhirkdeals
n,I.I 'cll(, O J I J i ), : o O O bas e,
()'Il l IJ't'
jig
is buil l.
-t
Ih I,llk'd 'I 'J.L t ll1tr
l rd .f ll nK 1 t' ad s in l ol h( 'j ig and
'L~·.11
orst
RI'I '
b lr t e dn ll th e
ung' 'T'HlICh
l he f io j < ' r
l1Q ({hl S ~ OW } ,~ ....id( (:at the bottom ot
thccurve), < ; , Q position tht \ Interpomt 01 the
I.IM~I· ~~~h-
or,
fOP POWnON •
Of
llANO
TOO ' '-
WA$lt
3
hot
PU'S)f
Iloa:
1--I..••......
2
I ,:-;,,11th t g rain directlon 1111 'blank
r-,
wid .,r th an il is lo ng,)
I),U,O.Af\t'r th e b la nk
i~
ut In ...
£
rout a
t
',dt~,p da do ' LTt' t lu - blan k. \\lten lit.
blank ., cut
10 il~
and 11u.' t c, 1laC'l$of lbl
tm.01111'·)
point
art
xrt \\l Ci
t('R~ther, the
dad , r. . no • motti , Ihal pulCh , around
I
. , hit k beam, ro ro ut th., dado.Lu-a-d
a I ,lr3ighl bit, , ...., f lI: la
1'1'(.111'(;ACTIO'.1\) cr..atl' tht· 1}lnt hulI:
ac:ljcln.till ' top in..
d _ ·
portion •• t'd~'hram
mel
head
has 10be
lilll lhinn.'r
than lilt
biltt/lill part. S o Itrimmed I~ on the ,,
widt,
~-'Clic 'l1of
the blank. ~., ~
I,t :
( , 'llU
'lZE.
~(·Xt.t·UIht blank
Into
tour
.-quaI-.izt'
(1
;4 i
8/20/2019 Woodsmith - 069
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W
.,,32 .-
M C H IN E
KIU W INTO
BAC
Paret
Rt·DRIll
~ l. ·
O L t -
THROUGH
fJtONT
PJEC£ONl l
7
NDSAW
lAC PIlel
tOP
PLYWOOD
Sf
NAIl. CLEAtS
TO lASl
SECOND:
ORIU 211-
S It£W HOU :S
DRIUING JIG
dr il l b i l
%
from th e ed ge of th e workpiece,
s ee F ig .
S.
W h il e t h e p ie ce s a re in th~j~.also
drill two ~ holes for
the
machine
screws,
re fer to F ig.
MrrER E
8/20/2019 Woodsmith - 069
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:': .69
4
,G
COI:NfI
'LOCK
©
fOOHT
SltCTCHU
@
lACK
llG
(QUAl
ovtIIW
fRONT
t
IACJCJAL'4
....a
\
~o
UHlI ... CIC
.ACt
3
SIT 1(Vf(
OAUG(
AT.S·
r an CUT SUGKnY
OV(IUl1[O, THIN
ftUt\
TO' IETW'U.N
fOOHI
STltfrCHU
IoHO LowtJt
aAocau.Q
r
1 uS( 1AC1CUG
l~ AnfJtH
W
CENTER
j
j J
SUPPORT..
f. ~W
BLANK i:I
'n ln l o j the fro m stretcher leIand I h . . b a ck
ollin I erback b,. ,c (1).... hR.:1 Then
glUt nod
-crew
the center t1Itl)()rtIn pIact. .
\:->0'.':when lbe scat ,I~I' III',· dddl-d.make
~Urt·
tu
screw th em
rothe
1111'
tlll.)t. K ,, , , , ,J
tIll'
lop
enhe
center S1l1l'~jn.)
nacx , A~S('mble
till'
r~
8/20/2019 Woodsmith - 069
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25
iloodsmifh
~. x 51,· ·72 (four6oord.e 3 lei.ft. loch.)
? .
8
~••• .5 ,-·96' (4Bd.A.)
l.....x 5t, •96- {4Bd.Fl.'
: 1 ;
_ - : ; > 7 , >
.:nZltt ..-/~zz -.pn?Zitt>lil
I
3
A
1
F·..
S~3 . .
UnlNG DI GR M
.
i
-,
•
CINTER
SHANKHOUS
ON SLATS
< .
LOWER BACK BRACE
II ,I .
N o. 69
WOOD PARTS
A . BockLflQ (2)
1 .
x6~·36t;.
B F.onlLflQ 2)
l••
~ 22
C FronIStrefche«I)
- \ 0 •
,111,·43'-','
D
UPP8rBockBtoce(I)~.x2~ «»'.'
E Bock/ArmBroce(l) ~.x2~ 454
8/20/2019 Woodsmith - 069
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1'0.69
,I'
StOE
APRON
•
~
LEG
.
,0
CORNER
BLOCKS
,
CLE AT
00
TOP
SLATS
Woochmllh
~.... SI,...1 1.. ... ••
d
ft.(~1
E . . . : : ~
I
.I••• 7 1 . · . . . . .
(2.614.
.J
CUnlNG DI GR M
LEG
STl tETCHER
®
CLEAT
OVERAll DIMENSIONS:
203. W 46 . l,, 16 H~
lo
x3~· 5\
bx3\;·31
~ x 3l?·17~.
~.x3\;·17 ,
~•• 2l>·47
~.x2·19h
ll
S t O l
WOOD PARTS
A leg>(4)
B SodeApfons(2)
C End
Al)tons
(2)
o
SlrelcN B (2)
E lopSials(8)
F
CIeots(2)
G Comer 8Ioc1a (41
SUPPLIES
• (32 ) No 8 x 1 I bloss Fhwoodscrew s
• 2A No 8 x 2 oross Fnwoodscr
M TERI LS
EXPLO E VIEW
~l fI.inally.
fini 'h,'d tl1 l ' r edwoo d
lable with tw o c oats 01. rIO /5 0 m ix tu re 0 1
lu nll o il and sp ar v arn ish (Fo r m ore on fin
j,h if 1l l a n d p ain tin g o ut do or f ur ni tu re . s ee
Talkon~ShOP.page29 .)
once 3l(a in , y o u c ould u $< 'I.in < ,nd
paint th e ta bl eto ma tch t l .. . o th ,'r
IW O
pieces.
To
av oid ru st sta in s o n tIlt' ta ble. I u se d
b ra , s cr ew s a nd c eu nu r su nk t hem > li ~h tl )'
b do . . t il e < u rf ac e. •
Az
buil din g t h ,\dirondack Chrur
an d
Settee,
Idecided to comp le te t h.
M ' t by bu il di ng a -mal l p at io t ab le, Lik~he
Chair and Seuee , th, ta bl~ i~ui lt u si ng
,im l.lr glu e an d sc rew jOim ' ry.
1 1 1 e a ss emb ly pmc. -du re for t he s la ts a nd
th e c utt in g p ro ce du re lo r the arcs is
a I . .
th e
ing th ic k
stock,
(All
o(
t he ' s to ck (or th e C hair, So> t , nd Tab le b
N th ick . except fo r th e comer blocks,)
To do this, ] cut th e It,'g, ~ lwid e a nd
-cre w < 1 th em to th e o ut ,id e 0 1 th e apron ,
B ecau se they 're th iv w id e, w ben they ' ,
, , .. e d from the s id t '
)'00
gt theimpres, ion
tltatthey re
made l rom th i
8/20/2019 Woodsmith - 069
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27
oodsrnuh
o. 69
6
_ .
{. J ®
STRETCHER
l op . a nd th at th e b ase o f th e ta ble is square .
Then the se rewscan be tighlened into place.
,\DDSTItP. l' CHE R .Afterh e l eg s a nd apron ,
a re s crewed t og ether, th e stretchers
(0)
ca n
be added. Start by d ril li ng c ountersunk
shank holes I V a nd 7 up from t he bo t tom
of each leg. see Fig. 6 . Center the holes on
die wid th o t t he leg.
Then glue a nd c lamp th e str etc he rs b e
tween th e legs so the bono , edge is 4 up
from the bouom of the legs. and the
stretcher is centered on the w idth of the
legs. F ina l ly . sc rew t he l egs to t he s t re t che r s
with o 8 x 2 n ath e ad brass wood screws.
•8 11/...
BRASS rh.
WOOOSc.REW
1
1 . -
I \
, J: .t '1 ,-
/ ~ . u - COUNttRSUNtC
( . ~SH.ANK HOUS
.a Jt
2
auss -
fh.WOOOKJtfWS
J
t
®
WE
APRON
NOTE:
APRONS SHOULD
t .l -f LU SM ACROS S TOP
@
IN D
_ON
END
AP~ON
1,.·_
COUNTtRStNK
SCl tOWS
C I . .AMP INO
APItON
afI WUHUGs
5
4
3
SC R .E WH OLES .After al l o f th e ed ges are
r ounded ove r.
th e n ext s te p is to
dr il l coun
te rs unk ¥ t6 - d iamet cr shank holes
0 1 1
th e
inside
foce
o f
th e
s id e a prons (B)
n ea r th e
ends. se e ~;g.
.
A S S E M B LY . Now. th e side uni ls ca n be as -
sembled.
I
glued
and
screwed
them
to
gether u si ng c ons tru ctio n a dh es iv e a nd No.
S x lV ,· f lathead b ra ss woods cr ews . s ee
Talk ingShop. page 29.
Pos it ion the topedge
onhe a pr on Du sh 1 0 th e to p o f e a ch leg. an d
keep the end s 01 th e apron I from th e o ur
sid e ed ge o f each leg . se e F ig . I.
ca n be g lu ed an d screw ed to th e en ds o f t he
side
aprons. To do
this.
first drill
two
coun-
t er sunk s hank
boles
ncar
each
en d
o f the
en d
aprons (C).
se e
I·;g.
,Ia.
Then
b e gi n a s se m b ly
by laying
one o f 't he
sid e u nits o n its sid e. see Fig. 4. S< 'l 'CW One
e nd a pr on
(e)
to the end of Ille side apron
with No .8 x 2 b ra ss wood sc rews an d con
slruclionadhesive.eh ..,kth tthepi~ Cesare
H ushac rossthetop .
Then
screw ano ther en d
apron
10
th e opposite end of the
side
unit
N ow sta nd u p b o th
side
u n it s. a pp ly a dhe-
sive. an d c lam p them together. se c F ig . 5 .
C heck th ai th e a pro ns a re H us h a cro ss tlie
Once th e s id e un it s
are completed. they
ca n be connected
w it h e nd apron s
an d
stretchers.
ClJIT()slzE.8cgjn
by CUlling two end
apro ns (e) a nd tw o
stre tcher.l(D) 1 0the
same
s i z e 3 V z
x 1 A t . . s ee F ig s. 4 and 6.
Nex t. ro un d o ver th e edges (but nO I th e
ends) o f th e aprons an d stretchers with a \ I s
round-over bi t,
S C R EWON API\ONS. Now
th e
e nd a pr on s
O. •..·ROUND-
OVERan
QUARTtR
I ..ADIUS)
aonoNi
2
J~t,.
@
L£
AUOH S lot APS tON
fLUSHWITHTOll,
NOSO
•_~ ~~ __;i
OfFSET
ONI01K
(N,DS~.....
NOTE:
DONO .OUNO
OVLRlNOSOf
A ONSOR
T OPS OF- L£G
\
SOUAlt.
UGSfO
. .. .. . 010
aprons (B ) 31rl w id e a nd 3 1 long.
RAOll' S t .E ( .i S .
A ft(:r th e p ie ce s
Y..
ere cut to
' i 7 . c . Ianded a J t 2 radius on the bo ttom
comers
of th e
legs to belp prevent the
c ome rs f rom chi pp ing i(th e lable is dragged
along a rough surface, (Shop Tap: To mark
th e
' z 0 '
radius.
tr ac e a ro un d a qu ar te rh eld a t
th e bo tt om come r of t he l eg .
SEe
Fig.2 .)
ROtrNDO\ EREf)Gf... Next, rout a ~'.
round -ove r on
al l
fo ur ed ges 0 1
th e
l egs and
aprons, and un the bottom end 01 the legs.
se c ~;g.3 . (Xo te : Don 't round over D. lops
of th e le gs o r th e
ends
o f th e
apron
s.)
•
SIDE
APRON0
3 '-
1
LEGS SIDE APRONS
I s ta rt ed bu ild ing the
labl~ by making tw o
s id e u n it s, E a ch s id e
unit consists of two
le gs c on ne cte d w ith
a s ide ap r on . se e fiR
1.
Later. tbe side
units are connected
with end aprons to
f on n th e b as e o f th e ta ble .
refer
1 0F i g . 5.
CL 'T I'IECE STOS IZE .To make a side unit,
start
bycuUing
th e
(our e gs
(A ) to a
width
of
3W
a nd l eng th
0(15\1, .
T hen cui tw o side
8/20/2019 Woodsmith - 069
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Nu.69
Iu..-~~I .•. il
~ 1 . · ~
SHANItHOli
1
lit
2
I.ASS
rh.
WOODSCUW
CR OSS SECTION
-
P'N'SII.
Bdore
atlat'hing til.· lOp. I
finidon
Ihe
w,dlh of
Ihe
lOp.S( t. Fi,lt'.to. l1 , en d r i\'~
~:()()(l~'r(.'w~hrough ear),
, (.n'(:r
b10ckand
in lo th e lOp .
S( (
fig . lOa.
IIII'
ba .... upside dow n on the slats so it's
c en te re d o n the l ength of II , l bll 'IOp. re fe r
1 0F i ll . 1 0 .Th en po si ti on I I ,d . · . ~(I,.
Jill.
.'flt
th J ( . g . . ,
onboth ('I,d,
.>.lIuth~clealsa reC
llNh0>,'
2 , - _ ,
,-
I TOI
~
. . .
SPACD.
....
-
8/20/2019 Woodsmith - 069
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oodsmlth
n.69
O nce the
spar
v arn ish an d
lU oil are-mixed, liberally
brush the
mixture
on One
see
tio n o ( t he p ro ja :t an d I t it s oa k
in to th e w o od .
The
sohredwood
w ill p ro ba bly d rin k u p m o s t of
t he f in is h. bU I w i ll i .The a dhe s ive
i s p robab ly s tr ong
e no ug h to u se w ith ou t
screws,
but
it 'seasier
to
assemble
m an y p ro je cts w ith
screws
as
w ell a s a dh esiv e. I a s s e m ble d th e r edwood
furniture w ith b ra ss screws an d counter
sunk
al lof the
screw
V I below t I , C surface.
T he b ra ss a nd re dw oo d c olo rs seem t o work
well together,
S
in ce th e A d iro nd ac k F u rn i
ture
in
this
i ss ue w i ll
su
out
s id e i n thesun an d rain.thereare
some special considerations
w hen building and finishing
these
projuyforgluingdt' t k ·
i ng to f loo r j o is ts an d paneling
10
walls.
T his adhesive is sold in tubes thlll fit
a
standard caulking gun. I buy it at a local
horne
c en te r fo r
S 2 .2 1 a
tu be. and o ne tu be
was
enou gh
10
do nil o f tile A d iro nd ac k fu r
niture
in th is
issue.There an: number
of
d if fe r en t h r andsava il ab le , bu t l ook fo r a i ube
o f a dh es iv e th at's b oth
w a r e r p r o o t
an d
de -
s ig ne d [o rw o o d.
JOI l\TllN E. \ 00
c on s tr uc tio n a d he -s iv e
le av e a th ic k jo in t
l iRe?
N o. and you don 't
have
III
spread
i toutas
you wou ld , h. 1 I
using
ye ll ow glue . U sc a new tube and cut a
W'
h ole in th e n oz zle
of
th e lu be . T h e a dh es iv e
should be creamy. about like toothpaste.
Run a sma ll b ead o rd ots o n o ne of 111('pil 'CCS
10
be joined, sUlyingabout
l/4
f rom th
e
lodge.
T hen. when (he pieces a re S queezed to
g eth er, th e g lu e
will spread
OUIover t he e n
t ir e j o in t a re a l ea v ing a n ic e. t hi n i oi nt l in e .
If
so me o f th e ad hesiv e sh ou ld
squeeze
Talking Shop
QU STIONS
NDOMM NTS
8/20/2019 Woodsmith - 069
30/32
~o.69
0
0 m ailer w hat bl_d,'
you re
u5lnll. or ,'hal material you'....
cutting, you11 almosl al ... ys
have 'J)linlerinll along Ih e
rdg
of a f re e h and ,bn: .,,,. CU I
ro Pl'l'veIllthi~Imarl a plale
(I f ~i< Masonite rn.1Iauache-, to
Ih('
base of
the
sabre
,v. with
double -s ided ca rpe t tapo,
A slO I in the
:\1. Onil,· fils
t i l lhtlr aga iOSl th e ,ides of tbe
bJad( ' 10
prev~ '(JliOl~nng. A
notch 31 the fronl of the p1ak ........
hd you
f o U o
a pc'll-
.
. . .
aosslltAQ
'
UTTON
Sabre Saw Table
TOO L S_A_N_D_T_ E C H N I Q:::.._U_E_S
- - - 1
8/20/2019 Woodsmith - 069
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31
o.6Q
Be...
m (.
UlllJllI
Illlrd\\Ute
• 74:~ 1(.)\ t· . IJU ( _(Jfllpa ,
Hard ,ln . . . ,S .~ .9S
(4)N lc'd
II ,,,
Fin ..rNut<
(.1) .1 1-: 12 . I II. MIld.. ' - · n . . . . .
(I)
Hr ....W , o J · , ,
III I Ch,,,,,,, 11.,,,,1I',,illl
I
) 1 ,·,J ,,.
Uhf
b-ad
PAmaHS
full ...
It...~11('m5
'J r
I)lt
\dw
i
d kcruir'sback~ , ...nn .II
ann - ..uppt ,n . . .
&ft.
iI\
,Iil.tbk·
t n - I f
'oodsm ith Pro ject ~pplialso
ClICering
another se t
Ihal ad ds th e bi ts need ed for No.
6scrt'ws (
I
•.,~.....(It 1)
• f JO
(lias
of II~JI
, ~'2 ,1·1a th .1Id
., .~ IIIog0f25) SI25
.
40
elias
o f
1(0)
8 3 . . .'1 5
Imt I'Llll-d K.. '1 , ,,
' 0 ~ . 114 Fl:IlI.1Id
• i69 25 ~
1 1 o I s :
o f .: ..)
• 769-250II~ 01100
:\0.~, 2 . F l,,'h , a d
·'~26 ;
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