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Woodsmith - 078

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  • 8/20/2019 Woodsmith - 078

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    D I S P J I

    C INET

    • Gun abinet

    Sewing ox

    • • ox Joint Jig

    Nl .78 NOTESFROMTHE SHOP 3.95

     

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    No. 78

      wdust

    W

    hnlkl 'll'

    ni t

    ill

    tilt

    sbop

      I t ,

    at

     YII

    IIkl'

    wllrkllll III) U'

    , op .even

    if

    night) Mos t ofu:n irsthcchal~It.· vo u t lmfl

    h . IV . · . ,

    fllm.tllll· l uJ igned I I Imak~ an mter lock ing mo ldinR ,. f \

    hen :

    an d

    the re lha t s ta rl lI ll . .. ..

      u n

    0),;.......

    and

    til,·

    Endosed you'lI

    find Ihe WMd8> i l}o

    inevilabk di 'I

    Ih('fiN i,'Ut of lI ·oo«han

    J

  • 8/20/2019 Woodsmith - 078

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    ITalking Shop 1 1 3 1   Tips on R 7 1 ~ tPrevention in the

    L _ _

      = : _ _  = ...J. S ho p. Z ) Recharqeable Batteries,

      8   T he r es ult» a re ill/01 

    r

    Sharpen

    ing Tip Contest. The I/'illllel's: Two

    jigs fOI l a,~y,

    marl'

    acrumte sha1 pl wig,

    I

    Sbarpening Contest

      7   ;esllowfechniquestolnakeslrollg

    unti oitractice bo...joints lIsing onl

    adjustabie 80.. Joint ,J ig .

    IMaking ox Joints

    I

     oxJointJig   4   Accurate bo,l'joinlS are easier than

    L _   =_ _

    .::..;= ...J. eeer, O u,. Bo ,( J oin t Jig works ali

     lOllI'table

    saw or

    router

    fable.

    I

    Sewing  ox

      8   The lop   -aus pi

    /101

    open to unco 'el'

    L -- ..J. a 10l/g case, It s a w eekend project

    wi th lot s o /s tO t age /o l sewing supplies.

    WvoJsmiln

    o, il l

    page~

      Sources

      3

    Hardware 011 / project supplies

     -- -- -------- . needed for the project»

    il1

    thi» issue. Box Join t Jig

     Shop Notes   6   J) Houito Lall Ou l Den ti l Molding,

    L _... ..

    ..J.

    2

    Ins/ailing Inset H inges.,j ) Posi-

    tiolling Shelves illa Cabirlet, 4 Cllftin{J

    HalfLap«

    01 1

    Thill Stock,

    pagel8ewing Box

    page  

    4   We slunc how to make doors tho:

    lo ok like th ey c aI n e front a cabinet

    shop -

    Ilsing t 11 0 COlnnlonrouter

    bits.

      Matched Moldings

     

    Gun Cabinet

      3  

    Sim

    p le

    mod ific atio ne c ha ng e

    the

    ..... ...J. D isplay C abinet in to a

    hand,~ollie

    case to

    store

    and

    display

    your gUllS.

    1 Display Cabinet I   l

    S h o p - m a d e

    IIloldings

    u ud y lu slS

    L _

    _ _- __ ~ ..J. ~ palled doors produce a D isplay

    Cabinet with clcseic lines,

    j l1 atched,l1 oldings

    I ~ F ire g rp at tips fro m fel/o u w oo d,

    ~ icorkers. 1 illak i IIg u   igfo r S an d,

    ing Circ le s , it Cnttillg Beve led No tche s

    /01'

    S tn oh ors e L eq s. 8 Scrapers

    /1'0111

    Ja pa ne ee S aw s, 1 Cu ttin g Odd A llg le s,

    ,j Gan gin g th e Depth of Dowell/olen,

    ITips

     

    Techniques

    Contents

      LOOK INSI E

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    Nu.71 )

    X/  dSlIltth

    CUT

    FIIONflDG'

    Of

    SlOts

    AI7S

    o f p as se s, s ec F ig . I

    Note:

    To

    kC'ep the top rail

    sq u are 10 Iht' blade. slip a 1 1 . -

    thick spacer under tile oppooile

    end oj the rail to compensate

    lor

    th e

    t hic kne ss u r

    the jiJ'r 'sbase,

     

    ST Op

     UXI(

    3

    8RACfRA t.

    ACWNSTMmIt

    OAUOl ffNa:

    2 N OTE :

    I--d. CUTNQ1 tHB

    WITH

    aEVtw) ~oGE5

    DOWNON SAW lA8U

    c.... . . . . .

    JIG

    TO fABLE

    Ihat>Pin~down. S l < e

    Fig.

    3.Then

    mount the w ork pic et a nd s lide

    Ih, ami m Ih,'groOve.

    W h<  

    he

    workpiece touches

    til< dbc, hold ti l< l ITIIl in th e .1 01

    with

    one

    h an d. T he n ro ta te th e

    workpiece with the other hand

    as you slide the arm slightly

    ch.....

    r 1 0 the

    '3llding

    disc

    unlil

    \h,.

    workp ie ce i s r o u nd.

    .Iprr}})I(

     

    JalL fA 1:

    ft, /itfl (l J:f .  ~f Hro11 yil

    stead, be built a

    simple

    jig

    10

    notch the tcp nail on

    3

    radialann

    , . .w.=rtg

    3.

    The

    jig

    consists of

    3 sland 10

    holdlh~2x6lopraiJata75

    angle

    in

    from

      the

    (enCl'

    and •

    ,;lOp

    block 10 hold the rail in the

    proper posu ion 3J' ro inS i th e

    stand •• N Fi g. ~ Both are

    mounted on a ~c t l lywuod base.

    To usc the

    ji (.

     'llh~ blade 5'

    above th e sa tab te. T hen le an

    the

    rail a , ,, , iI lSI

    the stand and

    waste out the notches ina series

    beve le d no tches on a ta ble saw ,

    To

    do

    this.

    start b)'

    ripping

    15'

    beve ls along b oih ed ge s uf Ilw

    lop

    nail, see

    Fig.

    I.

    Then. to cui the notcbes.

    sw itc h 10 a d ado blade set at   J O

    an d m ake a

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    WvoJsmllh

    o. 7 8

     e Scheiderer

    RociU . l t r,  Ifill>lC>lo ia

    L ;

    L J

    SQU~fUN£

    DOWN fRONT

    ANDaACK

    lDGnd  miti l, TIp

    a nd T e ch

    niqucs,

    2200 Grand Ave.

    D t S l > 1 o i o c S   I o w a 50312 .

    \V e w iD pal ' ( upoo pub ti ca

    tioo) .$ 15

    to

    $100 .

    depending

    lin the p ublished length of

    th e tip . P le as e in clu d e a n e x

    p lan arion an d a photo or

    s k c t c l J

    (welldra) 'Janewonc).

     

    SIND

    IN

    YO . TIPS

    • There s

    noUting

    WOJ'lW

    than

    starting to glu e u p a p roject only

    to d iscover that you r dowel

    ho le s a re n't d ee p e no ug h -th~

    dowelsare bottoming ou t be ro re

    the jo in  ~losed .

    T o avoi d th is p ro ble m. you

    shou ld a lway s double check the

    d ep th o ( th e hole s

    by

    measuring

    t hem a ft er d r ill ing. But bow do

    y ou ge t n ruler down into. dowel

    ho le w ith such a na rrow o pe n

    ing?  

    se

    a tire tread depth

    gauge 

    see photo.

    A

    tire

    tread depth g au l: '~ h as a

    u l 't 'dk -l ik e p robe tha i easi ly fils

    in to a d ow el

    hole.

    M in e is ca li

    br ated from 0 to l in

    ¥.t

    incre

    ments.  Tlretread depth gaull.

    are available atmos t a u to su pp ly

    stores nnd cost between  2.00

    andS3.50.

    N ex t, a lig n th e sq ua re dlin c ,

    01 1 th. . .workpiece to (he side o(

    th e m it er gauge slot . see fig. 1 .

    Then loosen th e a ng le lock on

    the m ite r

    l. lIug~andslide

    it

    up

    agaillsl the workpiece. Now,

    lock the miter gauRe at that

    an gle. T hen align

    th~ cu t

    line

    w ith th e b l ad e a nd m a ke th o cu L

    Do IIy C

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    No.1S

    o hmnh

    • 5pailS) Itl5eI bICs:Ihnges..,;thlCIewt

    • (~)1'.'llYeoooo~

    • (4) ,'x I • R hrno ct11rO lC GWS

    • (4)~'ooo.

    • (6) 80IICClclleS

    • (15)V, S t o e f suppotls

    • (2) LQck

    (OP1()nOl)

    SUPPLIES

    T

    h....init

    Il lln g

    }otl·r

    11 -1\°

    ttl

    nouce 300m

    thi~

    cabinet ts the upt_ r dO(..... [arll door is neatly

    dmdedint ot1I.-h'l:b II;linAndC3< hJ)iUlt'ofglassb

    surrounded b) a mold('f)

    rei

    ee llul

    thaf,

    no t  ,ball find

    th e roost in'.n~   Ill.

    dC'Ia i •

     I

    hoI the

    doors are

    constmcted

    Howare aJllhmc- p:lI1 on the door

    J iMd

    log~1her?

    Andhowdo)ou rul

    tho

    Inside corM lb. doormoJd.

    ings? There must

    b

    a 101of •

    'w

    milt·..,.er coped

    comers

    to

    cu i. Or

      II.. ,t

    an

    ., lIp' ,,,,,,..,1

    o f rou te r or

    shaper blts. ();ot at all lI·s. n....1 h .. -hn ique us ing a

    router with common

    bi1,

    \\ e n 

    l h · r i f l JC

    a separatea r -

    tid e a bou t

    th i, 1 , '( 'hniqIlC

    '>111'111'

    II and

    15,)

    TOPMow r-c;. T he dour i nHI Ih ,' I Inl) 113 ftth at

    ha s

    inleresting dew l 111cd 81 ,, - 'poonsolburnt

    umber

    .nhI·,

    oi l. mix• . . in I q uart of Iin.~-edoi l. Then

    af ter 411hours I covered il 'nth t hn -e C03Ih (S;, lin '

    Part o f th e beau ty o f th is p ro je ct

    is in

    its tr ad itio na l a l>  > carance .

    Bu t w  t you can t see a re the un iq ue ro uter technic/llcs

    th a t

    go in to

    builtlin g th e g lass and ra ised

    (> neldoors

     isplay  abinet

    r R 0

     

    _E_ (__T

    -----i

    E I RL 0 o ~1

  • 8/20/2019 Woodsmith - 078

    7/32

    7oodsmlth

    o. 7 8

      ~

    p

    . .

    if KK

    E E E E

    ~

     

    p

    L

    v

    ~.• PlYWOOD0 • 96

    F

    E

      ; I

    1

    ~4  .

    7l1t .  06- (5 lid. A.

    ICKb)

    CUnlNG DIAGRAM

    OVERAll DIMENSIONS:

    42lf.'W

    x

    16 D

    x

    777,...·H

    LOWER

    CASE

    ®

    .@

    IWJ.

    CAT K

    \

    ~. ply- 11

     

    X 37 11,

    \?   1 .? 40'1.

    . X1~·121?

     1 .ply  II I I : x 52

     1 .xl-52

    'I'.x

      7V

    :VAX1\ .1 -5 2

    ~-4

    x

    l lt

    t

    h

    : V 1. 50

     f ply -I T A t x 50

    1'/2 x 1·Il(WA

    I

    \ .I

    x I· 1 2 : VA

    :V AX

    1 /4

    -41~ .

    ~~ .1 ' , . ·13~

     AX 1 1 2 42

    V A X

    1 \ .1 1 3

    2

    \

    ( ~ : )

     @

    IW

    CATCH

    -l't.ply-14¥A' 2 1 ~

    'I-.ply-14'14x38%

    ¥.pt{-IM'ex4Q

    'l'A x l-2J'>t

    ~x

    ~A- 371;.

    ~.x4¥.-37h

    < . a x ¥ .

    7f>rgh.

    ¥.

    x

    3- «Ol'.

    ¥.x3-1()

    .vAXI?- 16rgh

     e1ves(3) ~ xOV. - 37~

    EXPLODED VIEW

    MATERIALS

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    3

    No. 78

    9

      _ _

    NOTE:

    CUTAND OW ON

    FItOH T M Ol.D lNG F IRST ,

    ntm

    GtUf ON sto I\\O\DtNG

    e-

     i)..

    ROMAN

    OGEE

    MOLDING

    WASn

    ROMAN

    OG£E DETAIL

    OGfI

    MOWING

     ~ 

    KICK80ARO

    ROMAN

    OG££

    MOLDING

      < D

    ./

    / BACK

    /-

  • 8/20/2019 Woodsmith - 078

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    N o. 78

    o :}f,·. hick, a ra bb et w ill

    be

    formed

    when th e se f ra m e pit' /bot tom

     M .

    Ailer

    th e

    to ng ue s arc f orm ed , m iter th e

    f ram e p it

     Ct. to fil the

    panels.

    St 'C

    Fig.

    6 ,

    Then c ut th e e nd s o f th e fra me s id es (0 )

    Oush

    wi th th e

    back

    edge

    o fe a ch

    panel

    TlIREADED ISSER r.>. A f te r R lu in g the

    f r ame ill

    place,

    th readed

    inserts

    can be in

    stalled in the b ouo m p anel 10 c on nect

    the

    tw o c as es . s ee 1 ' i J . Sa. To l oc ale th e in se rts .

    center the b ou om p anel en lO p o f the lo wer

    case

    while

    m akin g sure the b ack e dg es are

    f lush. Then m a r k

    through th e

    holes you ve

    d rilled in b e to p (C ) o f

    th e lowercase.

    SlIll:S.

    N o w yo u c a n s ta r t

    on th e IW Osides

     I ),

    First

    CUllWO

    p ie ce s o f

    : } f

    p lywood 10

    f inal

    d im e n s io n s , s e e Fill, 7 . C ut to ng ue s f or

    fadng

    (Q)

    o n the fro nt edge o f e ach panel.

    and. rabbet

    forthe back framc on the

    i

     •• i

    b ac k ed ge o f

    each

    panel.see

    I j~

    aand 7 b.

    .-IS. ~IB IX .

    T o a sse mb le th e c as e. f irs l

    d ri ll s hank holes 1 I1 roU) (hthe tou /bouom

    a ss em b lie s. s ee F ig . 8 ,1 'h on g lu e a nd s cr ew

    the m 1 0

    th e

    sides

      I ),

     C(

    Fig.

    Sa ,

    S IDEFACII I 'G .o rude theedgcso fthe sid e

    p an els, glu(' a

    I ·wid( face frame to the

    upp er ease, To do this, firsl cut tw o

    side

    facings

     Q

    10 ICIlRth In

    fi t

    between the

    lop/bottom

      M)

    panel s. see

    r ig. 8.

    Nex t. cu t a g ro ov e on

    the

    b ac k fa ce o f each

    side

    facinll

    (Q)

    1 0 fi t th e lo n gu e O n th e

    front

    e dg e o f th e s ides (p}.11 leng lue the r ac in g 1 0

    the

    sides. S« Fig.

    8,

    FACt: RAILS.

    Nowcut twofaee rails

    (R)

    to

    fi l b etw ee n ine

    side

    fac ing,

    sec Fig.8,

    Then

    g lu e a nd s cre w 1I1em

    in

    place.

    U PPER CA SE

    SIDE

    < p

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    Wood,;mi[h

    < ).. .Y

    R OM AN

    OGEE

    MOLDING

      _

    C AP

    - ':::::i.

    @

    ~C' . ~ ;..i'

      .~~..:::..

    11

    y ou c ou ld us c 3 s ingle piece of I \o'z ·thiek

    stock.) Lay out the dentil blocks all each

    piece and then cot the grooves. For m ore

    information. s ee S ho p N Oles . p ag e 1 6.

    A f le ryou'r e f in is h ed cut ti ng t he g roove s.

    miter th e dentil pieces t o f it a round t he front

    a nd s id es

    of

    t he c ab in e t.

    sec fig. 10.

    Then

    g lu e a nd s crew th em d ow n. s ee Fig. l la ,

    TOP MOIJ)tNG. I f ound it e as ie st to m ak e

    th e R om an og ee m old in g pieces, and g lu.

    th em to u ie s qu are e dg e caps be ro , c u tt ing

    them

    10f ina l l eng th. To

    make th e

    t he f roo t

    (Y) and ..

    ide

     Z)

    ogee trim pieces . first rout

    N o. 78

     ~  

    II

    ,8x 1- .

    . wooo~~

    I /

      CK

    P A NE L

    e

    a

    Roman

    ogee

    profile i nt o t he edge of

    lV, ·

    wide s tock ,

    see Fig. Ila.

    N ow you can cut the pieces for the front

    (AA) and

     id e

    (fiB) caps I   ft

    wide . Then

    glue

    and clam p the

    caps

    1

    the agee trim

    pieces

    with Ille

    bock

    edges R us h. '

    Fig.

    Iia

    Aftcr

    the glued-up pieccsare dry. miter

    them

    to

    f ir on t opo lt he dent il mo ld ing .

    CA BIN ET

    ASS£.\IBtl'.

    M e rlh e to p m old in g

    i s g lul '( and screwed in p la ce . s et t he u pp er

    caseontopofthe lowercase.Thenfastenthe

    tw o

    cases together

    using V machine

    screws to fit t he th readed

    inserts,

    b. •

     ~~~

     

    CK

    OMDER

    ®--...

    I

    51

    \1  Df£P

    D DOES

     

    The final step on th e u pp er c as e is to a dd th e

    mold ing t o t he lOPo ft hc c ab in et . T he mold

    i ll g i s bu il t up 01 three dilie ,nt.trips: a den-

    t il mold ing . a R om an o gc e m eld in g, an d a

    s qu are e dg e c ap . s ee rJg.ll . The t ri ck ie s t o f

    th e th ree is  

    den ti l mold ing .

    DE~ L~tolJ)DOG.w an ted th e b lo ck s in

    t he d cn til m o ld in g t o be equal inwid ih and

    cvenl ys pa ccd apa rt . I a ls o wanted full blocks

    o n b oth en ds. s ee F ig . 1 0.

    tmadetheblanksforthcdennl front (\ \' )

    and sid e  Xl p ie ce s f ro m t wo

    pieces

    of  1 4 ·

    thlckstcckgluedtogether.see rlg.lla. (Or

    MOL ING

    Sl1U

    ®I

    NOTE:

    GROOVl UT

    ON INSl mG S

     

    th e

    back

    panels (V) . se e

    Fig, 9. CUI

    Ute

    back panels M from

    \ 1 4

    plywood 1

    f inal

    d imen si on s . a nd glue

    the frame and

    panels

    together. see Fig. 9 . Then glue a nd s cre w t he

    ba ck f rame

    in

    p la ce . s ec F ig . 9b .

      CK

    STtU

    -( )

    S1\1lIn:NOSS. Nowcutstubtenonsonthe

    e nd . o f th e ra ils

      n

    and divider

    (U)

    10fit th e

    grooves,

    SO

    F'Jg. 9a.

    P,I)'/Et .

    Next ,

    dry

    damp th e f ra m e in t he

    cabinet 10

    de te rm i ne t he

    f inal

    d imen si on s o f

    O nce the top. bot

    tom. and sidesolthe

    upper case ar c as

    sem bled. the next

    part

    to

    build

    is the

    ba ck . T Ile ba ck to n

    slsts of

    IW O 1 ('

    ply·

    _ =

    wood

    panels in a

    L..t::::~_ frame.

    jo ined w ith

    stub

    tenons and

    grooves

    ~1IA.\'E.To build  lw J'rdOlC. first rip we

    stiles (Sj.rails (I). and d iv id er( U) to tinal

    widths see Fig 9

  • 8/20/2019 Woodsmith - 078

    12/32

    N o. 78

      1   _

    I....OU NOoOVfR _24 ...

      £ r +~=F:: J;

    CAPS   •• .._: __

    T

    ... 21 }- __

    c tD

    HORIZO NTAl.

    DIVIDER CAPS

    -@

    R AIL C AP

    VERTICAL

    CAP

    13

    \VooJsmlth

    2

    GLUE A.S1 RAGAL  

    lEn H ND DOOft

     

    -~

    14- ,-

    u r

     

    RAISED

    oev..tt

    PANEL

    I  OVUlAP _

    \

     ,  

    ,

     

    ROUND · OVER

    ASTRAGAl .

     

    @BJ

      @GL AS S S TO P

    I. ,_ I,,

    LOW ER STILI:

    ,. ,

    - I

    T his w ill (ann a II .

    overhang

    a nd le av e

     

    c lea r ance be tween th e d oo r and the c abi ne t

    op;tning .

    Next .

    rou t a

    II .

    round-ove r

    on

    tile

    ji  < J f edges, se e l ig .14a .

    .~ J l lAGAl..The nex t step is to add an

    ast:rag;ll

    (IJ...

    MM). Wha l s an a st ra g al ? It s

    the strip

    lh at h id es th e

    gap

    waen

    th e

    doo r s

    ar e closed. G lu e i t i n to the r abb et in th e left

    d o or . s ee F ig s. 1 4 a n d l· la .

    It A N G n O O H i. B e fo re

    i ns ta ll ing th e g la ss

    and panels

    in

    the doors. I

    posit ioned

    the

    hinges and

    dril led

    the

    hinge

    screw

    holes.

    (Fo r a tip on d oin g th is. se e p ag e 16 . ) Then.

    remove the

    hinge,

    In mount

    the ~ and

    raised

    panels .

    P ~as. STOPS.U,\RUWARl:To dress up

    th e bottom doors. I made :V l ·thick raised

    panels

    (N N).

    They re  raised on both

    (a c es

    with

    a   '. c o re box

    bit . se e

    F ig .

    15a . I

    held the panels andglass

    in

    placewith quar

    ter-roundglass SLOP (00). see rig. ISb.

    After

    th e d oo rsare

    rchuog .

    i n st al l t he knobs

    a nd d oo r catcbes,

    SHU 1- ; s .F ina ll y.g l ue upandcut sto ck fo r

    three sh elves (PP). Fo r in fo rma tion on 1 0 

    eating

    t he shel ves . see S ho p N o tes,

    page 1 7.

    RAll .SA . O DIVID£RS. T hen , to determine

    th r

    l eng th o f i h e raits

    (EE)

    and ho ri zonta l

    dividers (FF).

    l ayout

    two stiles

    w ith the

    r o u te d edges facing inas in thcf in i shcddoor

    ( I tWA apart) . see Fig, 12 . N o w m e as ur e be

    tween

    th e

    wooves.

    Nler

    rutting

    th e

    rails

    an d

    horizontal

    dividers to this l eng th . C I IIthe I on g u es a n d

    d ad oes o n ea ch a s sh ow n o n pa ge 1 5.

    VElmt AL l)l\11)£llS. To determine the

    ltngth of the vertical dividers (GG. HH).

    d ry a ssem ble the stiles

    an d

    r ails. T he n c ut

    the dividers 10 length and cu i th e tongues

    and ha l f- lap jo in ts, so . CP gl

    IS .:- lowglueand

    c lamp I he p ie ce s t oge th e r,

    CAl S. A l l

    the

    r ails a nd dlviders

    have

    a

    mold ed cap  IJ.JJ. KK) g lu ed o n lop. The

    ca ps a rc r ou nd ed o ver o n the lOP a nd c ov ed

    on

    the

    ends

    to

    match

    th e

    mo ld ed e dg es

    o f

    th e s ti le s a nd r ai ls , s e c

    Figs.

    1 3 a n d 1 3 3.T o

    det erm ine the length o ( all the caps.

    measure

    you r

    assembled

    doo r. (Again

    thi.

    is

    all explained on pages 1 1 and 1 5.)

    O 1-:R1lA. 1GAND ROONl).()\ E R. Once the

    doo r is assembled . rout a ' l o t rabbet a r o und

    tile   ck

    ed ges o f each do or .

    s ee F ill.

    1 4 .

    CtJTtOM

      Roove

    -,~

    -

    -

    111} ~

    -

    11 1. , . .

    12

    DOORS

    . . . - . . . . ' - - - ,  ID e do ors o ffered

    the biggest chal

    lenge on th e

    display

    cabinet, (For an ex

    pla na ti on o n jo in in g

    the d oo r parts. see

    pai r< 14 .)

    DOOR snLES.

    I ;  c o

    tho ugh the

    u pper do ors an d lo wer d oo rs a re cli(fc 01

    sizes, the apprc>achto

    building

    them is th e

    same.

    To

    determine

    th e

    length

    o f th e st iles

    (CC. DO). firsl m ea su re the h eig ht o f the

    door

    O)X 1l iDg.

    Then add   . since the doors

    ar e liptX. dwith a II, O V I · r a P . se c r. g.1 2 .

    Nex t, c u la g ro o ve a nd r ou nd o ver th e

    it,·

     t p

    ed ge o f e ac h s tile, se e Fig : 12a .

    OOORwnnn. To determine the knglh of

    th e

    rest

    o f t he doo r p ie ce s. s ta rt

    by

    rneasu r

    in g th e w id th o f th e o p en in g a n d d iv id e

    Ihis

    measuremen t in h alf fo r th e tw o door> (i n

    mycase .ISW ) .

    Now s u htr .lC I h alf the

    gap

    you

    want be.

    tw een the IW O doo rs (V I6 ) . 1 1 1 e nadd th e

    ov erh an g fo r the in ,. ,1 hinlll 0 ,0   ) Thls

    m ad e the width (,f a,  h doo r

    1 8 - '1 1 .  .

  • 8/20/2019 Woodsmith - 078

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    J ~

    uodsmith

    o. 78

    -

    -3 ,'. ---------~

      ... 11.. -fh.

    WOOOS UW

    l K

    DIVID

    ACt

    BACK

    5TIU

    ,-

     

    BARRfl

    ....-RAll

    BARRfL RAll

    w  

    T t l SlOG'l

    ~,------ 3 

    thick stock towidth. see Fig.

    1.

    Then,

    lo

    determine the length.

    measure

    the

    d is ta n ce be tween

    the sides in the upper case,

    Aftercuttingthe rail to length.

    c uu hre e n otc he s a lo ng th e b ac k

    edge o the

    barrel rail

    io il

    around

    th e st iles and

    divider in

    the back frame, see Fig. 1.

    The barrels rest innotchesent

    in

    th e f ro nt o f

    the

    rail. To m ak e

    ti le notches. fi t drill I holes as

    show n in F ig . 1 . N ow CUl up lO

    the holes to complete the

    notches. Then round ove r the

    top and bottom edges of each

    n ot ch a n d th e fronl edges ofthe

    rail

    with

    a V I round-over

    biL

    I s cr ew e d the barrel rail in

    place through the back frame

    aOOultwo-thirdso(lhewa)'upon

    the upper case, see Fig.2. (You

    mayneed to reposit ion yours.)

    RUU: BAS >.

    Th e rifle base is

    CUi from a piece of ll . ·th ick

    edge-glu ed stock. CUi i19 wide

    and 10 Ipl1j th to fi t in side the

    U P 1 > case

    se e

    i · J R 1  

    Aller the riOe base Is CUt10

    s ize  la y Q UL fln  1cui the slots fo r

    the rifle butts, se e Fig. 1. I

    ro un de d o ve r

    th e lO p edges of

    each slot

    and

    the fro nt

    edge o(

    the base piece with a I t round

    over

    bit

    Finally. screw (don'(

    g lue) the b ase in p lace rrom the

    bouom of tile u pp er e ase ,

    W

    llh a few changes, th e

    I > is pl ay C ab in et show n

    O il

    pag.6can

    be

    used

    In

    show

    off

    a co llection of r iOes.

    l PPElt DOORS.

    O ne major

    cha nge I made to turn Ihe cabi

    net into a gun cabinet is

    the

    u pp e r d oo rs , To offer a b euer

      te w

    used

    a single

    sheet

    of

    g la ss w iL I\ o ut d iv id e r s in e ac h

    door instead or eight panes. TI,.

    stiles and

    ra ils

    re ma in

    the

    sa me

    as on the O i.piayCabinel .

    U )C KS .Another change on

    ih ed co rs is to ad d locks. To belp

    keep the g un s a n d am m un itio n

    secure,  nstalled locks on rhe

    upper

    and

     ow r

    righl·hand

    d oo rs. s ee Fig 3. Each lo ck is

    m o rtis ed in to

    ihe back of the

    doorrail andhooksoverastrike

    plate on the bac k 01 the cabinet

    face rail, S

  • 8/20/2019 Woodsmith - 078

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    No. 78

    oodsmllh4

     

    _ l1   U 1 tt   1 - J Ol I Iut-ol t r

      t

    ill ro uter

    tab te , m w at.( j1

  • 8/20/2019 Woodsmith - 078

    15/32

    IS

     

    Apply

    a

    feu·

    spots

    of

    rilico> .

    if

    grooves . Tilt: r ur ed s il ic on»   ill

    keep 9/4 fro m m ov in g

    SIdeway

    s. Inser t

    glass alldsec ,,, lUith 1/, quarter-rOlwd.

    C RO S S S E CT IO N

    c ......

    s 'f'

    ,

    .  

    ClASS

    (1 C  OUA,ftTtR .

      l

    OUND

    1

     

    W itl,

    heig lo t of

    ro« t( J r b i t set tlte

      ioml

    J1 r l(lht ll

    1 O l l t iJ ,g

    th«

    stiles  

    IVUt

    tlu:

    pl Ojileollboll.

      d y e s of

    rite

    divid8r

    capsa71d ~ldeedg.ofeaclt rail cap.

    RAILCAP

    8

    First, gl . up

    lite dWlders

    and

    miu

    ill/o II

    grid. Tlu t l

    9lue

    ~Iile.~  UI~

    grid. T() keep the comers from lifting.

    cw.mpaj o. t

    piece

    of

    wood aC '8 U ,e . •tries.

     

    Cell iera 1 lI1flap(}>,tl leumgtltofea 1 I W e ll td g < l an.si(/(> e d g '

    o1l ly

    for rail

    raps). T I t <

    OI:t:l'hIl11I1f(fm,~a

    r a b h < ' t

    thu; }IO ' rheg/a ,' or woodpanel ill pto.ce,

     

    To

     elt

    l positiQII I Ior izol l l l1 l

    divide,.,.

    fo r

    assembly , .e

    Ihet' t11ir(l. /

    dil'idl'l'

    a s ( /.  SIO)'1I sl ick. s la rk lc x:a tio 1 l

    of

    each

    half I( lp Oil blu-k j

    I Iside edge

    of

    th e st i le.

    V[ITICAL

    OM ..

    S T l l

     

    4

    To tIlt

    tn«

    t

  • 8/20/2019 Woodsmith - 078

    16/32No,

    is

    6

    OPfNDOOCt,

    DA iU P IlOT HOUS

    IfOI;

    S C R E W S

    3

    POSmoNlOP AN.DBonOM

    HlNGf. :2',, FROM RAI lS

    ~ 2  ·

    1   i ; 

    ~-. r- -

    ,/J. - .

    1~

    V -/ .t -,

    /

    SCR[W AU HlNOf5

    to

    (A81NnfUM

    lnsel hinges. like the ones

    used On th. I);splay Cabinet on

    page 6 . can be m ore frustrating

    to install than ordinary butt

    hinges. S in c e both le av es o f t h e

    hinge arc inside

    the cabinet

    w hen che door is closed. the

    screw holes in the hinges are

    tough 10reach.

    on e ach h inge , y ouean nowopen

    th e doorsanddrillthe p ilot holes

    for the screws, seeFig. 3 .

     

    used

    a V ix bit, see pag e 31,) Then,

    screw

    i n th e

    screws

      In   1

    remove

    th e clamps 10 check each door.

    Now th e screw s can

    be

    re moved

    and then reinstalled afler th e

    gla5.~i illplatt)

    LA Y

    CAllNflQN

    I T S B A C l<

    TOPOStrtON

    DOORS

    2

    IIII>GE TO CABINET, Ta

    g~t

    around the problem . J used

    clam ps as te mpora ry screw s

    to

    hold the hinges 10 the doors

    l > Im the glass was installed

    To do this,

    firsl

    screw all the

    hinges   (he cabinet frame.

    see

    FlJ{.1. Nnw pUI the doors in the

    doo r o pening cen tered up an d

    INSrALUNG INSEr HINGES

    POSfT1ON OOOIU IN . c;AltNlT 

    THtN Cl.AMPf ltH l lA1

    TO

    D < > O a

    snlf

    down and a1sole[I ICl r ight.

    CUUIPTO 1) ) lR.Then.tohold

    the doors in this position, I

    clamped the free leaf of each

    hinge IQ the d oo r s li le Iltrough

    thewindowopenin~.

    se e

    Fix.

    2.

    This way, lh.. damps hold the

    door ill place,

    ll1NGETf lDlJ (IR ,Wi lh ac lamp

    Woodsnllth

    TO CH£AT · LA T0Ul DADO

    .....MAAJ l.lGtnLY OIITSIOl

     

    D(SlRlD lOCAnDN

    cabinet. It's nO I practical to

    divide t h e extra ~ among  

    t h~ b lo ck s 1 0

    g~l

    he m th e e xa ct

    same sil~ Jlorksjust as w e ll to

    make 'Jp

    t h e

    d itrc rcn cc o n jus t

     u u

    o f th e b lo ck s.

    For example, to com oensate

    (or a m old in g s tr ip

    thai's

     - I I ro o

    lnng ... art chealing \t.t on the

    l a S t

    eight marks, , . . ,fer10 Fig.2.

    This way, each of th e last eight

    blocks

    will

    be \t.t'

    100 large,

    bU I

    thls shouldn't be-noticeable.

    L AY OU T S Tau >

    nur~

    THEN CUT DADOES

    T O M A R KS

    1 ....

    DENm e tOQ

    ISSAMl stU

    , AS OTHlR:S

    . . , . , . . . . _ , i l n - '1.. r

    1 . . . . . . - 1

    ..__,...t.ASTDlNnl.locLK:-.....J posmo,. Of ,DADOES

    ISNAUOwtl CUT

    wmt

    fNO lCQ tCJIG

    THANOMU C4N GAINAfT(R MANYc ur s

    2

    you can usc 10 gel all t he d em i t

    blocks 10

    up r

    v e ry c lo se 10

    U  

    e same

    size .

    After you've measured and

    marked, you' ll know whether

    the la st < '1 .1 sg oin glo p ro du ce a

    den ti l block th e sa me size a s th e

    first. II it doesn't work out

    ( 'XacU y,YOIIan

     chea r 

    sl ij htly

    on th e la y ou t t o com pen sa te for

    th e d ifference

    S ay yo ur denti l m old ing s tr ip

    has to

    be

    out

     - I I

    longer- to fit the

    So.

    u se

    a tape measure lhal'~ as

    lea st as long

    AS lh(> workpiece,

    an d don  I move the tape a,

    y(,u'r~ marking

    Otherwise,

    yo u're R oin g tt) be bac k with th e

    .gain problem again.

    COlll'EJ>SAlL 1G. W hal if you

    cu t 3m olding st rip Ihnl fits your

    c ab in et , b ill

    it s nO I

    U w

    same

    length as ca lled fo r in th e p lans?

    Won't each of the blocks be

    di rferent th an ~ ificd in the

    pian '? Y es. bU I

    there s

    a Ir ic k

    .11yo u use an il1dcKinllsys tem

    like a bu.j oi nt jig

    ItJ

    cu t th e d en

    ti l m olding

    011

    th e D isp la y C 3 b~

    net, yo u Call run into a problem

    If the ji lt i,n'l  I up  .  ,{ccl/y.

    there can be a slight gain (o r

    IOS$) betw ee n each cut

    th at

    ca n

    add up.

    It

    doesn 't lake muell

    error (a lilll~a. 1 1 1 2 8 in Ihedi ...

    l an c e b e tw~n

    CULS to

    be no ti ce

    able by Ihe t ime y ou g et It) th e

    e nd o f a lo ng work piece

    If th ere' ~ a l lin o r 1 0 .

    \h

    v las t

    derail block w on 't be the sam e

    ....ze as IJlt rest,

    a n d

    Y{lU

    1 1

    beable

    to ,

    the ' difference, $4. '< ' Fig . 1.

    M EA SI  REM 'O '1AR1tT he b est

    wa) I've found to get demil

    blo ck s th at all look

    ~I~

    sante

    011

    a lollS workp ie ce i i' l o la ) ' o u r the

    position o f the d ad o es w ith a

    penci l i ns te ad o f u s ingajig . (For

    the Disp lay C ab inet. th e 1'4 

    dadoes ar c

    : v

    apart.)

    \V be you CU I 10 a m ark . it's

    important th a t the mark s (o r the

    dadoes ar c laid OU I accumld)'

    CUnlNG DENrlL MOLDING

    Shop Notes

    SI-lOPURRO M  P SOME

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    17

     (lnodSIl11th

    fol low this

    s ame s eq u en c e

    when

    cun ing tenons. )

    The

    f irs t c ut

    I make

    is the

    shoulder

    cui.

    u sin g th e fe nc e

    as

    a

    S L O P

    block. se e Fig.

    I (Since

    this isn t a through

    - c

    'UI. there ' s

    n o d an g er o f k ic kb ac k

    using

    th e

    f cn cc a nd m i te r gauge lQgethc r .)

    The

    next cut  

    m ake is

    at

    th e

    end

    u f th e w ork pie ce .

    Then I

    clean ou t th e w aste i n between

    witb successive

    cuts

    back

    tow ar d th e s ho uld er, s ee F ig . 2 .

     

    an

    inlo

    3

    common prob lem

    working on Iht vertical dividers

    fo r

    th e doo rsof t he

    Display

    Cab

    inel-

    tUliing

    lOll (

    ha lf l aps

    on

    Ih ~ e n d s o ( a t hi n workp iece ,

    \ Il le n mak i ng

     11Ch

    a cu t .the

    end of

    a

    th in w ork pie ce c an O ex

    u p an d dow n. T his m ove me nt

    < 'WI

    make th e h alfla p th in ne r a l

    the end than at

    t he shou lde r .

    The so lu t ion

    is

    to cu t th e la pin

    a sequence that prevents the

    wo rkpi ec e f rom

    Ocxi.ng.

     I alsc

    N o, 7 8

    SEQUENCEFOR CUnlNG H LF L PS

    ' lMIRD:

    JttMOvtW Sn

    POSITIONING C INET SHELVES

    • \Vben Ulcr . a rc w in d ows ou a and lOp edge of each w indow

    1 2

    I

      'K fOQ

  • 8/20/2019 Woodsmith - 078

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    N o. 7 8

    n c X  b D l i t h

    a t ra di ti on al s < w in g o r k n i l t i n g b o x . B i l l . fo r a

    box

    u s e d 1 0 b o ld o th er craft supplies, y o u may

    p r e f e r t look o f 8 ontr sting plywood top,

    W O O D A X i l H A R D W A R E .E x c e p t

    to r

    th e

    ply.

    w o o d ti d an d bottom panels I b u i l t th e entire

    sewing box romclear white

    pine.

    1 0 a ct a s s ha fts

    fo r th e

    pivol a r m s

    se d

    b ra ss r iv et s in ste a d o f scre w s - S C r e w s c a n

    w o r k l oo se a ft er a w b iJ e. T h e n. 10 m a t c h th e

    rive

    IS I

    screwed

    t he c a rr yin g h a n d l e 1 0 U 1C

    m a in c as e w ith ro un dh ea d b ra ss w c e d s e r e w s

    an d

    filed the screw

    h e a d s

    ftal.

    W o o d 8 > 1 . i ll l Pr o j r c l

    Supplies isoffering. ki t

    o f h ard w are fo r th e S e w in g B ox th ai in c lu d e s

    the rivets, brass

    w o o d sc re w s a nd b i rc h k n ob s .

     

    18

      T\ c b ig ge st c halle ng e I h ad in d esig nin g

    .1 . ; i i s S ew i n g

    Box

    d i d n l

    have

    a n y t h i n g

    10

    do

    with

    making the boxes, The challenge

    involved de.igning

    it

    S O t h e tO P

    trays

    pivot

    open and sit (Ial 00

    t he l ow e r box w ith ou t a ll

    the contents spilling out

    T h e p ivo t a r m s u se d f or a tt ac h in g th e tr a y s

    a r en t unique -

    ifs

    th e s am e sys tem yo u s ee

    on

    ta c kle b ox e s w ith a n in sid e tra y . B u t to g et

    th em 10

    w o r k

    righl in v e l v e s r wo things: CUlling

    t he p iv ol a rm s s o they re id e n tic a l a nd m o u rn -

    in g th em a ll

    in

    th e

    corre ct

    l oc a ti on s o n t he

    b o x

    UIl1 REAnlEl fS. W e r e s ho w in g IWOdiffer·

    ent w a y s

    10 complete the

    lid s th ai c o ve r th e

    Ira) >. A f a b ri c -c o v e re d lid is w h a t y o u d f iod o n

    T his S ew ing B o x

    is

    rea lly thr ee sep ar a te bo xes a ll m ad e th e sa m e w a y.

    \X /o o d e n a rm s connect th e tra ys to th e rnain ca se a n d w hen yo u pivo t o p en

    th e tr ays th er e s ro om in sid e th e ca se fo r l o n g er m a t e r ia l s.

    Sewing

      x

     

    PROJECT

    EEKEND

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    19/32

    19

    ~-

     

    SU  U S

    • (2)  - ,[ jo BlrchKnobs   . Screw$

    • (16) 1I2'Ex r

    • (2) '10. 1  lhBrossWood c1ew$

    • Itr.

    20'

    Clolh

    Fob< i c

     optloooO

    • 10 .21) PoIyesterBoItlng opHonal)

    • Genefol Flnishes 'T wo-Slap SeoIocen

    11• 2.8

     

    x

    2 8

    7

    x 7  1 :  - 1 0 . Ply

    CASE

    A CaseSldes(2) 11• 3',,>.16'4

    8 C a se End (2) 1 . x 3112x 8

    C Case

    BonomO) ~. x

    l{)\.a-

     I.Ply

    TRAY

    D TroySldes(4)

      TroyE nd s (4)

    F Troy

    Bottom

    (2 )

     

    G

    LldSides(d)

    lI.x'Y4.S

    H LldEnds(d) 11 x

    '1 '••

    8

    I lid Pone (2 ) 7:V • 7¥ . -  f.P ly

    J Lldlnse-1/, Ply

    OTH ER W O OD PA RTS

    K

    Hondle(l)

      .6 1 •• 8

    L PIVoIA rms(S ) 11x 112.5 1 '.

    M Troy D Iv id e ,. ( 12)

    It

    x 1 :V .x 7 112

    WOQDP ats

    M TERI LS

    U l>

    ~

    SIDE DET IL

    Wood .m trh

    o . 78

    OllJUlI/r m th4

    k

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    N o. 780

    US( aACKING ao....O '0 J(m

      c

    lOX

    souAltr

    G.

    ronNa

    SOAP OCI( ONlACHCOlH~

    OISTRrtUt'I CLAMPING PR[UU ••

    6

    CUTPlUGTom

    vom..,,(hIOS

     

    .oW

    7

    wood

    in

    pIac ..

    «

    ~il

    5. All

    the boxes

      . · r r

      nlbl, d,

    I Illm'd • w,l1gl $l,aped

    plu~irue

    till I

    small

      id, on th~ ends

    of

    tach b ox ,

     t

     - I II , 6 .

    Then

    I

    s anded Ihcp lugs

    and pin. Ou i 7 . e 01 the

    plywuml bottom, and lid panel>, firs dryas

    semble .11thl1'C boxes, Then, cut the

    pi),

    w.KKI bottoms

     C 

    F) and lid panels (I)

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    21

    ood,m irh

     

    ROUND OVERAU £DGS

    0 HANDli lXcarr

    .... fIOTOI(S

    flU

    sc.tW

     tAl

    LATTO

    R MOV

    S L OT

     3

    2  

    f--' RO UNl>-OVOt

     ~Y

     

    OllU.~.

    fIO..  

    ,

    YHANDlE

     

    1

    uS Mrru CAUCf

    W 1 T M

    1 AU XIU AR Y< [NCr TO

    f-....J

    SU1>PORTHANOL(

    The S< wiugbox has

    a carrying hand le

    that separates the

    tw o trays, To m ake

    th e handle  K .first

    cui a blank to w id th

    and length, see Fill.

    1  Then loy Out

    th e

    arcs on th e to p an d

    boltom ofthehandle and the hnge rope ll ing.

    A lso m ark the lo ca tio n o f the : y   holes tllat

    defi ne th e ends o f t he finger opening.

    CliTN(lTCII ;S.

    Beforecuttingthearcs.cut

    a n otc h On ea ch side of th e blank

    to

    all ow

    clearance (o r th e han dle to slide in to

    the

    case, refer to Fig . 1 3. I c ut th ese \, , .wid e

    notches

    u si ng the m i te r g aUgl : on th e table

    saw. se e Fi g.

    11

    SAWT( )SH , \P f_N owcuuhcarcaonthetop

    and bott om o( th e handle. Then bore the

    hol es at the ends of the fin ger slo t, and

    complete

    Ole slo t w ith a sabre sa w. N ex t, to

    mak e th e handle comfortable .I routed a 1 .

    round-ov eron the curved edge>. s ee f tg.12 .

    INsr

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    N o. 78

    oodsmlth

     

    NOTE :

    rHSTAt1

    RlV iTS

    fHstQUG.H lOWta fNDS

      1 mOl AItMSmtST

     Da1U 1f T

    TO MAAK LOCAnoN

    Of

    HOLES ON CASE

    AN D TRAY )OES

    •   ·HOUS

    F O R f U vt S

    , / - -- >< : :: : ___/

    lAASS

    W S ot

    aRASS

     rv

    .   .

      . .

    T T A C H C E A t

    TO£NO

     'GAUGl

    CUT l AYOUT GAUGE to Sin.

    TKfN

    MAIM LOCATION OF FOUR \ ,- HOlES

    8

    T o

    U : O C

    th e gauge . place i ta g ai n sl th e s id e

    oftho;;ewing

    bo x

    ( wi th th e tr ay i n p o si tion)

    and po ke Ih . . dri ll b il Ih ro ug h th e g llug e

    holes

    10

    le av e a m ar k th at shows the l oca ti on

    ofth~

    'II;t

    holes fo r th e r iv ets , s ee F ig . 19.

    rSSL\LLAItMS

    \VTn

    RIVETS.

     lh n al l tile

    ho les have been drill ed fo r th e ri ve ts, th e

    armscan

    be

    attached to

    th e

    bo x.

    (It 's

    easies t

    to

    do th is w ith the case lying on

    it>

    side.)

    Then th e ca ps o f the riv ets can be se t with a

    sharp

    ham mer blow fr om inside th e

    case.

    tray (o r ri vets . These h ole s h av e 10

    be

    lo

    ca ted as accurately as th e h ole s i n t he arms,

    So I

    se d  si m ple gauge to la y th em out.

    T o

    mak e

    th e loyoul gauge.

    stan

    with

    a

    pie c e of sc ra pwoodeu t t oaw id lho S \ '. I and

    a length o f 8 . see Fig . 18 . N o . .. la y o u t th e

    t o cadon of the four rivet

    h ole s o n th e g au ge .

    a nd d ri ll the ho les w ith a V J 6 b it in th e d ri ll

    PI ' l 'SS.Then , 10

    make

    it

    easier

    to lin e u p ti le

    gauge to the w orkpiece. I s cr ew e d a n ar row

    c le at o n tb ee nd o f t he g au ge . se e F ig . 1 9.

    P IVOT ARM

    0'

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    o . 78

    lonOM Of UD INSERT

    . RA1l4fA.D

      MACHIN 

    ....__ sarw

    1  FlATHEAD

    M CH l N f

    SCIItw

    cvr h SEtO TOSm;. When th~

    s him s a re cuuo '5i2 0 8 i t f

    edge

    as the en d n otch es. see F ig . 2 2 .

    \\'ilh the ce nter no tches cut on all the

    d iv id er p ie ce s. a ss em ble them to create

    each

    divider

    unit.Then.

    to

    allowclearance

    ro r

    ih e r iv et b ea ds i ns id e e ac h

    tray.

    pla ne o r

    sand the lower outside

    edge

    of the foor

    div id e r p ie ce s thOlwillcontact th e rivets.

    TR Y D IV ID ERS

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    Nn.78

    4

    RUNNER

    ....Tlti jIg r( J )1. be

    bit ill/ort:1(tting bo.

    )()l llt.J.5   t

    « router

    tab/ . By

    mOllnfillg

    { stm/ lllt bit in tht~

      I.J I , Y () I j re   l le

    I rill ..

    101.

    wilh11al

    bottom» - e.p'·'

    rmlly 'ndhes/OI3

    u .~.~ allcrhn l

    (, I (JI.I. / 'I.: , Bu .1.fur

    b T -

    } >t}lt~

    la r g e r

    thu

    n I,., ·, tIlt:

    table

    If J /I 

    a f lU

      1

    is a

    mor« i }j id ,11 ool

    ~ TIl<

    bor

    JI h lt

    ji g

    ca )( . b U t jo r use

    alla labl~8aw. lI ilh

    n

    dad. blade, bu.t

    joilJ t~l

    be cut

    qllltkill o.1Idncru·

    rillrly Alld bll

    udJII.ling thr fron

    fi

    lire, jlt

    ji g

    c n I w

    fi ue-Lu Ilt'd for a

      , .,- ,,1 f il , ill «11 1

    I< ,d, dlldQ. TIl<

    I(lhle

    . < 1 1 1 1

    olld tlado

    blade are best for

    InrgerjQillt <

    F IXED PL T li

    tN D EX PL Tli 

    To se t up fo r a p erfect fit betw een m alin g

    workpieccs, th ere are SIOISin

    th e back

    fenc e.

    This ktsyou adjusl the d is ta nc e b etwee n th e

    index

    p in a nd

    Ih e router

    bit (or

    saw

    blade) .

    U- TIiRCI lANG£Al ltEIN .The i ndex p in is

    mounted 011

    carrier

    p l te

    that

    c n be

    taken

     

    a nd r ep laced w ith anoth er p la te

    WI has

    a di ff~ll nt· si 7. eindex pin. T h is w ay, you c an

    cut io inl~

    ofvariable ilk 

    BACKING

    PLATE

    Finally, there s the re-

    p laceab le back i ng

    p l  te

     

    preven t

    chipout.

    se c Expl od ed V iew. T his is ju ,l a pi ec e of

    Ma son it e t ha t s bev eled on

    IW O

    ed ges so

    it

    slid es in

    3

    dovetailed

    rCC1SS in th e

    (ront

    fence.

     f

    o ne p la te g elS too ch ew ed u p, it

    can

    be r ep la ce d w it h a not he r.

    USt;S 

    T his b ox jo in t

    jig

    can be used on

    ei th er

    a

    table

    saw

    o r r ou tcrtable,

    see photos,

    Shop

    Note:

    To

    use lh i.jig on a rou ter table,

    th .. lo P o f the ta ble m ust

    have

    a

    SIO I

    fo r th e

    runner, O n th~ fac in g p ag e w e sh ow h ow to

    r ou r a

    slOI

    i na shop-built r ou te r ta ble.

     

    ve seen a lo t o f d iffe ren t b ox jo in t jig s

    ov er I ll 

    years, So,

    when I b egan

    to

    build

    th e S ew in g B ox fo r th is issue, I decided it

    w s

    tim e to des ig n a bo x jo in t jig

    with

    Ill.

    (eatures

    I ve

    been looki ng for,

    L n)[X

    Pt~.

    Almos t every

    bo x joinljig

    I ve

    seen use s an index pi n to keep  n equal

    s pa ce b e twee n

    th e

    s lo ts i n

    th e

    h ox juin l B ut

    it  s usually

     

    pin t hat s

    fi xed

    in p la ce on the

    jig .

    I w arned a

    j ig w i th

    an

    a dju sta bl e p in

    SO

    you c an sn ea k

    up

    all

    th e peIT t Ctjoint.

    Another tltin g ab ou t tile in d ex p ill hink

    is imponant-i l sh ould

     e

    removab le .

    U

    YIIU

    c an re place

    th e in dex

    pi n

    with

    one that s

     

    different sire, if  a lo t mo re accurate when

    cuUinglarger or sm aU cr s lo ts a nd p ins.

    C1.EAN

    cvrs , There

      115

    one other feature

     a nte d o n

    a

    boxjoinljig .lfthejig cut. box

    joinlS llc c  rollly. it s h ou ld a lso cutthejoints

    cleanil l' So.

    f o r t h is j ig.   anted a backing

    plate b eh ind the

    C\ lL

    Mer

    building

    several

    prQtot) pCs,16n;illy

    came up witlt a jig that s adjustable, work s

    fo r d ifferent·siz joints, nnd makes nice,

    c lean cu ts .

    Pius. il can

     e

    bu ilt to fi t

    eith er a

    table saw

    or a router table.

     l;\TER~\L mad e the

    J i g with

    hardwood

    an d

    Maso nite parts

    se e

    ~::X ploded

    Vi~w,

    The

    (r on t a nd b ack fe nce s

    are

    maple (to

    I. ;v~he

    j ig stabil i ty),and

    SO

    is

    t he i nd ex

    pin (to

    min-

    imize wear). The table run ner can be m ade

    from

    eith er

    hardwoo d

    or ph en olic plastic

    an d cut to f it yo ur m iter gauge S IOL (For EXPLODED VIEW

    sourcesofthe

    hardware

    n ee de d to m a ke the

    r------------::------------------

    oo xjuinljig,

    s ec p ge

    31.)

    B CK IN G PL TE < D

    HOW THEJIG WORKS

     ox oint ig

    \ . )I 21.,-

    C RRI  G

    Olt

    PROJECT

    HOP

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    '

    ROUTSlOl

    t UVf;UL

    PAS SU:

    straight bit

    M ak e

    ~ r l p a sse s . mO v i n g

    t he s tr ai gh te dge sl ightly be

    tween

    fJa. 'iSCS

    to ,;n k upon the

    final

      idLh

    oClhe sloLStopwhco

    th e m iter gauge b nra nd th e ru n

    ncr ofth e B ox Jo intJigju5t fi t O1e

    sl ot - QOI tOOtiltblortooslop1)y .

    No. 78

    . a . I Fh

    WOODSCMW

    fRONT OF ROutER tABU

    ClAMP

     TAAIGtIT.

      .

    AaAU l

    mGfOf

    TAIl r I:

    U Sl r-.au SA W  

    aAOO£ TO lOCATl-

    POS111ON

    Of

    St.OT

    IN

    R UftR

    l.uti TOP

    . -

    n

    4

    AOJUSt S tRA IGK1 lD Gl TO SN EAK

    UPON fINAl WlDnt OFSlOT

    Then draw a p en cil mm on

    Ibe t,ibl~ lOP10

    indicate both

    edges

    o f

    me sIaL

    To guille the router . 1I'm

    porariJy

    c la mp a Slra ig hle dg e to

    lh .e. to p o f your reuter table. se e

    J o i g .

    4. T h e n . to cut the s101 .I

    U $< '¢

    ti le router w ith a Jh

    I'll locate th e position of 01 11

    slot Iusedthem it er 11 'lugetroll l

    m y ta ble s aW a s a gu i~e. see

    fig.

    3.

    Set

    the

    m iter

    gauJfo io-Ironl n£

    Ih~ bit hole so the gal,lgeeka.:s:

    th e h ole an d the bar Qftlll .¢ lw r

    g dug_e

    is parallel

    to

    t i l e .

    trol l l

    ed ge oithe table.

     

    .

    &A CK ©

    f I H  C

     

    BACK  

    FENCE

    -

    T

    I   . . ·

    2

    AXEO PlATl

    To use th is Box Joint J ig on th e

    router table. Ibere has 10 be a

    m ite r ~ \lg ~ slo t

    in

    th e ta ble

    lO p

    o f

    y ou r ro ute r ta ble .

    So

    ifyour

    tabl(l -doesn'tbavc a slor.yoll w i l l

    hav e to ro u t one. ( his lot

    should al$o

    be c ; u t

    i(taL Ct I)ll'ou r

    mirergnug  )

    ROUTER TABLE SLOT

    .... .. ASDlSfANct

    at1Wt N

    MR t1t

    GAUGl SlOTAND

    tDGlO arr

    01t • .....,.

    IWN_

     

    NOTE:

    RiP RUNNlR TO MATCH

    W1DnI

    Of

    YOUR

    MITU O UGl SlOT

    I IUNNER

     JF

    _ - -

    IXED Ii

    P L A T E \Ill

    (I ,, 9 _ l H 1 C K ~

    ~

     

    started bui ld ing th e jig fro m th e b otto m u p.

    T hat is. 1 starte d w ilh lh e ru nn er. I c ut the

    runner

     A

    (rom W ' phcnolir plastic (you

    could use hardw ood) to a length 0(9 . sec

    F ig .I. HUIm e Impor tant thing a b ou t t he r un -

    ner iathe width-e-it must fitthemitergauge

    slot o f

    yallr

    tab le sa w o r ro uter table .

    AXEDPI,'''':. Once the runner is cut to

    w idth. the next step is to m ake the fixed

    pla te

     6)

    th ai th e ru nn er attaches to .

    set>

    Fig. 1.Cu t t hi s

    f rom

    V   Maso nite . t he n c ut a

    Vu; .

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    F.ON1

     Net

     ~

    Q

    10

    ,. (.R( )\ E,

    \ \1 ,, , I h( ' i nd e x p in s h av e

    ho ,

    n

    c

    u t

    to

    finlshed

    ';1.I\ ON PL

    th,'

     ,dlh of th e ind('~pin, Th~ ming locullh~ -lui' far,ourl».

    J U m l,. ~ o c e m o > 01 t h ,'

    bu.

    J o in t s loLSI cu t

    a rt ' ', '. 1~·, WO,ur ','   id ,'. I slartt 1l by

    cunillg

    a n i nd e p in I IIt ell o f Ihcsc idths,

    CUIeach

    in dex

    pin

    (G ) ~ •• long from

    hardwood ._

    Fig.

    9. · I1WII . lomake i teas ier

    fo r Ihl' workpi/ 'Cj ' II) < l id ., , I\ I\ · r t h e

    pin,

    I

    - .anol(od3

    ,Ughl

    chamf r

    o n Ihe

    upper

    l-dj('~

    srr

    SAW

     

    ,

    SAJro\I

    ANGU:

    AS

    00V'fTAlt.11T

    ,.. ..I

    a

    ,

    (lllc'r

    It s be..n used r;5~:;~; -;:;:::;::;:;:::-, ,,::, 7-;:==--::;::;::;;;:::::

    f o r cu l ling u ,l lCJ ' t' nl C H...... - 0 0 ... ,1tS - '-

    re;

    . So

    d l ~ IV,

    ..ilt

    J()ints,

    1

    e-

    10·

    cided tn

    make i 1

    n o . - -

    2 ...

    p l a< : t' ab J t. a nd s lid e .. . s, -

    In• do\ tail , ,101an (

    till'

      ' I 1 < ' e .

    1 0 r out th e 51 01in .'

    Ih ,' tro ut fence. 1

    u,, ·d

    a d ov erail b it

    on the router table,

    ...' Fi~.~.Then, 10

      ok. the backing ~ ',' lHt1AOo10 'Sl ..

    p L. . . .(F.).

    f i l ' S l

    0 1 ' 1 . . .L__ __ ~ C l H T U U > ~ ~ ~ O N ~ '~   '~ O ~ 'N U 5 ~ ~ _ : : = = =

    ubt,· ....

    w

    blade

    10

    trulcll tilt' ~ o f

    lh o d< ,1all bi l

    (u.o;ua I\'

    14)

    n cnripalol1j(~ripon,·\'aee Flit 7

    1'( , CUIsevera l

    Inl IS

    1,..1d10 t he b ac k

    f...,.,..

    by

    twO

    camajI,

    1»11-

    and

    knob ,

    Cu.

    v.ingnul5).

    ref,,

    10I,~. ~ Drilltwo counter

    bored holes for

    the

    bull,

    t I ' U I align with

    tilt'

    ,loiS in the back knn'. ' FIll. ;a_

    TIlRFMlf.'DS ~J(1', llw in

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