7/24/2019 Woodsmith - 042
1/24
NO 42 NOTESFROM
T SHOP 2 5
7/24/2019 Woodsmith - 042
2/24
WOODSMITH
leaf can be a tittle disconcerting .
That is, it was until I made my own little
pointers to locale the screw boles. Be sur.
to
.ee
this
tip on
page
S.
FL 1 lSK tN( ;.Dou lt R ick s
i
continuing
his
series on f in ish ing with a n artic le on fin-
ishing the finish in this issue. In
8 \\ 8 ;
we're
k in d o f g ~tlin Jt
ahead of
ourselves
with this
article.
But
we we re
fated with
a
dilemma
about
the sequence of things.
The next articles we have planned are
about applying
th e
various top coat. var
nish, polyurethane,
shellac.
and lacquer;
But the critical
part
of dealing with al l
these finishes is using the right technique
la finish the finish,
This is done
with
a collection of abra-
, ., v es : sandpape r, s te el
wool,
pum i ce , r ot
I for
1I otld. milh.
I know this i.an odd approach - nor
mally help-wanted ads don't appear as
part
o[the
editorial
o f a magazine . But wehave
a unique situation.
There
JUStisn't a largo
pool of artiSIS wlth experience at doing
artwork fo r
woodworking
magazines -
especially the
kind
of step-by-step draw
In~
e use
Now before
I
go any further, I have to
say what this job is ot II is not an ap
prenticeship for
woodworking.
\Ve've had
lol ofinquirie.< from people interested
in
working in the
WoadsmilJr
shop, But that'~
not
really what we need.
What
we're looking for is someone who
i.
qualified technical illu~trator (or has
strong drafting expericn ,,) and
a J s o
h a
love
fo r woodwork ing .
If you meet these initial
qualifications.
and would like to work at I\rlOd IIIilJ., send
us
your resume and wme photocopies of
your
r< < I.l
work. Send them to:
Ted
Kralicek, 220 l ~hn A nn
th i l \
iNlu
T he
original idea was
10
build
I
cahh ,1
for
tools. But the ,holi dc.,illl1actually hinf(ed
around the last step in Ih. ,, ... t rucuon
process. It's killd of a .halG,Y II ,tol1'
Although the cabinet w.... th~ pnrnary
goal. 1 also wanted to add a drswer unit
below the eabim-t RII1' I plamll'd
I 1 1,
boxjoincs to huild :h . rlrn . . IlK'dn.wI'r
unit ha d
t
i z t o d
to
Ut t . I lmfI1Of J. l l4
drawers with nltciy 1lAt
7/24/2019 Woodsmith - 042
3/24
OOOSM ITH
It
y o o
d
tike
0
s h are a
wooctworl I crosscut onmy table saw
without binding and burning. Finall~: I
decided that maybe the miter gauge slot
wasn't parallel with the saw blade. If this
was the case, I wouldn't gel a clean cut
even
if
the miter gauge was set
at
90 .
dowel during mos t of the
final
turning op
eration. The smaller diameter end
is .
only
in the larger hole for a short distance.
oh
Sa lter.
C/i /OII, ~solln
SEND IN YOUR IDEAS
Nuxt, cheek that the miter gauge head
i
.w t to exactly
90. 1b
check it, turn th
miter gauge upside down in the table slo
and bring it up tight against the frontedg.
of the table. IThe front edge of the saw
table should beperpendicular to the slot.
in doubt, cheek it with a square.)
Then nip the miter gauge over in it
normal position an d lower the blade. Fin
all,)\place
a
framing
s q u ar e
against the cu
end of the
b o a r d
and the miter gauge.
l O O m
T A
through the jig. The larger hole will UP-
port the OS- ibleo
hold the block and tighten the clamps at
the
s am e
lime.
The solution Iju;;t ntly diseevered is
to apply a patch of double-sided carpet
tape (see Sourees , pg . 24 to the center of
the clamping block.
__ T_i~s Technigu_e_s__
7/24/2019 Woodsmith - 042
4/24
WOOD JI.I1TH
THl lACK PLATE
l\,XI, glue up lhe
back
plate
8
(rom three pieeei of 4 4 stock to
nnl~h f t ln \l n~iDn. '
0(8 :
wide
by
25
[,>nK.Aner the glue
is
dry and the
bWtkplanl'ire. drill two I'W'-dia. hole. to allow the
sound of the ringing
to
escape th~ box.
(Thebells onthe outside are just
for
decor
ation. the actual ringing bells are inside,
refer to ~'ig. 27.) Center these holes V
from each side and :r down from the LOp.
see Fig. 1.
l 'I( '1 ' t ;K& Fi
in the actual
doon
First.
Uo;( the
straight bit to rout a
1 0 ..
li'
7/24/2019 Woodsmith - 042
5/24
fAC.' SI E U l
:l ....._
RO UT ..... 0 . ..
l
AGoU II: 6
.
,
I
DKOUllVE
IEU(F
GtOOvt
'Ja
.
BAC K P LA TE
ru CK V lWJ
r
_ . :.... ) . J4 ... ...
C D { - > t - ,
L~ ~ __~~-A
~ - - 7 . - - - - . . . .
SE ERG U tE FOIt
CAT EDU~t nEtAll
Qn; ~ ,~ fc : .AQC
4 41 ,, ) STOCK
f I G W t
. . . _
lt
,
I T
;
r
~t
~r
. . . , \4
~\
1 s
+
,
CDlTlION t
W I Of
-
lACK
P A I t
C
CA Th EDRA t TOP D ETA il
WOOOSMlTH
aonOM fOP
ClHttI 1UY\,ATr-
ON WIDTHOf
NOTE:
US ; I'.p FhWOODSCI(WS
TO A nA CH TfIoUtlATl T O f RO N T
0 0
Then mount y traight bit on the
router table and set it to make a ~'-deep
cut, Next. place the hole in the workpiece
over the bit with the bottom end of the
back plate to the right. see Fig. 6_
Now bring the router table fence up
tight against the edge ofthe workpiece and
tighten it down. Finally. tn make the
groove. turn on the router and push the
workpiece
to
the lell along the tenee until
the bit comes out lh~ bottom end.
Shop Note: 1hi. groove could also
be
cut
with a hand-held router and anedge guide.
W.'I. lIOt:''TIN(; IJOLES-To
mount the
phone on the wall.
J
drilled ~-dia.
eounterborcd shank holt.
In
each of lbe
rourcomers ofthe baek plate. see Fig. 7.l
used 2Yz-long.flat-head machine screws
with buuerf ly ta gp :k .,; to anchor the phone
to
the wall.
refel'to
Fig. 29 .1 Locate each
hol yo fromthe ~ideand 0/.- from the end,
se e
Fig. I
I OUNIII~C Till-: (ORNERS. After the
mounting holes are drilled. round all four
comer. of the door (A) and the back plate
(81 to a
z
radius (once again usc a 25.
piece as a template).
RO)I.l' 00.:,
Once
the
eorners
are
rounded. the final step is to rout the front
edges
ofboth the door and the back plate. I
used a ',,~.Roman ogre bit mounted on the
router table.
Feed lb. work into the rotation ofthe bit
tfrcm
ril ht
to
lell- counter-clockwise). I
cut this prome in three PlIlI. Cg. raising the
bit slittlr with each pass. On Uw final
pass raise the bit just. slight amount -
this ~ clean-up pass to remove an y bum
marks and geL a nice crisp edge with 3
f.deep shoulder. see Filt. 7.
7/24/2019 Woodsmith - 042
6/24
\\'OOOSMITII
1
TH E
sox
'AA M E
After the d 1 < < 1 r.... > t I . 1 0 .
KIYI'AO COMPARTM[NT
\\'jth th..: m am
be,
fro m,' c om ple te, \\o rk
can~n onthek~)l .rnpartmcnt lb
make the keyJ>OdI1d. , ,B I. c ut t \\ 0
' ' ' ' ' ' ' ' .
of
4 I M < Ic l < : I . . , , , . ' bS 5 klllt:'
lt ,(.
Tit.
\ (.I.~
~o rut the l A . , p
e nd o ffbo lh pit 'Ct . . M l
Gin
l hlc, 'hL;.22 ,
:t'(.'ltlng
on
~nle rnll('r PUJ,ft'1o).. t t
~ i . a .
11.
Set 8>topblock the I.ntrth oftlll' lon~c.\
lodge
(lh. baclc,-dl'te
of
the
k ey pa d 8 1t1 rl Is
;IV. king.
I U II BE T E A C :H .1 11&.NeM. cut. mhl)(t to
hold th. luuchton,' fe, {'pial. on Ih. lOll
in.ide edg e o[ earh pi, . ...
''I'
1- 11(_2 . ( ' Ib
makethi' rabbet, run the ,,orkl.ic(. over k
dado head \\ilh the 8Jlgk..1edlle j(ainslllw
rip [enee.)
,-
, . . ,
: IO T E I
WlDrH
DADO
EQUAlS THICKNESS Of
1..
ptYWOODaonOM
. . . .
. . . . , .
cur . .. oo
, OW
I
,
,
. . ..
.
. . . . ,
t
, , u n , . . ,
S.AHDf'AI'U
TOA.A' SltUACt
w r r w CA.mT API
~OIl0M ... 30 ...
. ,
c
@ G H T S ID E
lACK lOGE
1
. . . . .
CIA,I; HOU'
T
,
,
[
. . ,
. .
.
6
....un
sn
Mtfll GAUGI
to67\-i-
{:tl
-1 1
ftGUI(
11
AGU
t
. . . . . . .
t
NOTE-
tANG MOIflS($ CUT
to
DlPTM Of HINGE Ir:H UC lrlf
,
). . .
,
, .
Ag lDOC
.
c
IfFI SIDE
,
PIN DETAIL
,
1,
I
,
. . .
IIGUI,
7/24/2019 Woodsmith - 042
7/24
\'OODS~IITH
. . . . . . . ,
M i l .
QUAlS
OAVOI
rHlCl(NlSS
,.
f
HINGr
I(NUCkU
I i i
1
'MOl
H o o a n s l
alvtllD ffllfCl
CRQSS SECTION
./ >
_ I .
,
. . . . .
, . .,
H
kEYPAD UD
I ,
. .
f \.f1OI
4 . : . . ~
~ O V U : ; ; : K A H G ; ; = = l = _ _ : c. . .
o.:.:ssSECTION : . 3
IiiGutt I
S'
AGUIf ,.
' .U I i
'Vlt
TO ',.
,
MOUNtot
IOGI Of ,..ON
flU S .. W ITH TO
IOGIO, SlO
lOrE,
CUI 'OUQi.TONE
'A ce 'LATEro A T
IllWlH uaans
C Il l FltONY
ON .
CASt
-. o t UNlfOlM OV'JlHANG
,. fR ONT
~E Y fADt IOTlOM
. . . .
_ a . .
A1,2
,
, .
C;ROSSSE~tON
~.
....,
. . .
L,.-
,
.r
~
\
f
. .
. . . .
4
01.00_
. . .
YWOOO
ont)M
MOUNJWt .G SCJ 'l 'W
. . . .
tOUCH tONl
:l,
Act PUll
lSCUTOffOH
/
~
-
,
: o ; . an
t't'nl4't'I'cl,
''''''18t.l, T.. b i, 'g in , ,' '' 'l 'nb l ,V , d ril l hili .
through each
rOl'n.'r
1) (
lhl'
ph.. tic
f I'I'
plate
an temporarily n. '
il n u o th e
ra blO > in the .io pie
7/24/2019 Woodsmith - 042
8/24
WOOOSMITH
ASSEMBLY
After all the pieces for the keypad com
partment are complete. final assembly can
begin.
l
started byattaching the
buck
plate
(8) to the main box Crame.
llARKi'OSITIOS.Position the box frame
on
the
back
plate 0it's
centered
between
the shoulders (of the Roman egee) on the
sides and or; up from the shoulder
on
the
bottom.
se e
Fig.
2 0. O nc e rh e
box is
posi
t io ne d, ma rk the outline of the frame.
SHANK HOLlIS. 'ow locate eight holes
centered belween the two llentil lines on
the back plate (refer to Fig. 201.and drill a
VI shank hole at each point, sec Fig. 21.
CARPET
TAPf;.
After the shank holes
were drilled. I ui.d to figure out a way to
temporarily bold ihe box to the back plate
in order to drill the pilot holes. After
fumbling around
with
clamps, I finally
came upon the idea of using riouble~iclec1
carp.:t tape. (See Sources. pg. 24.)
p w
1)3leites of carpet tape over the
I 'nrillin .....(don't cover the corners). Then
pl .l . .. . I
h.
box
frame
into position. using the
e orm -r ma rl u< t o a li gn it.
f'IIAIT,\~IlI'OI'~ 'EKS'S-
Once
the box
fn,m, i in th(~correct lo catio n, nip the
&.,- mbl~'0\( so the back is up and drill
through lh,' .,ght shank holes with. No.8
counl.('I'
I f-h
WOOO
7/24/2019 Woodsmith - 042
9/24
WOODS~{ITH
aACXPUTE
Yo
5 .7T
auntltFlT
TO G G L E
B
: H I f 11
A
000, (I)
* , .
7Y 8t
8o
7/24/2019 Woodsmith - 042
10/24
WOODSMlTIi
ALSO tQUIIE-S ':. PlYWOOD
ca M
I[ 9b
c
1
. '.-. 11 4 7,.. (twO IOAItOS)
C UT TIN G D IA GR AM
..r th('lo(:l1b(
so
il alill'n~wilh the second pIn from the back
STO RAGE FOR THE SHOP
10
I've been wanung to build
lh~
cubine; for years. It':-. dC :'lign\(141 ntitxi
mize the- lUll thi.,g thal ~n t-hort :o.\1I)I )l~n
most shops: wall space, The cabinet has a
usabledepth fG deepenough10 hold.
Yari~ty of haml and power 10010.
In
addition.
Ih~ameum Q f w all spa'''' L ,
c ffee li v .l y douh led because
the
doors also
serve as SLOl'(I .'
com partm en ts. C U nth
door>;
are
1
,
dtoe '.)
l tATt RlALS. Since lhi , L i11$h()I)
calli1lttl.
)'OU can build it out of just about an)' rna
terial. Iho se 'I ~
birch for the cabinet
an d
door framp~. ami u,,
7/24/2019 Woodsmith - 042
11/24
1
1
\V OOOSM1TH
. . .
1
WAll
-S tUD
. . .
t.,.......... ~
~
. 1 < J i+
OTE: '- ,
t. , .
C. 'U TONCU. T..1
AND GROOVE 0 '1
TMIC IlN l. S O f SHEl f..... END V IEW
_foIAIlHG
SH 10 STUDS
WAU
GWtANO
SCa,EW
MANGE . S T ~
TOItYWO .
a A QC : w n w
) ( 1 1
WOOOSCU'WS
o
SHElf
..... I lYWOOO
WITH
H A R D WO O D
EDGING
, -
.
O I- IU .
~Olf- E N T E :IE O .
'~MF~T~DQ
to
SlA~GROOYi
,' W10E ,
~ . [ J E E P
GROOVE
SHflf
. jI ,
1.
1 C:I-:-- :::;~~t~
3 ,...
p-
1
OAOO
Stops
rN lACk
GItOOVE
~.. ;.iou.
, O t : E 9 tOft
sHEL f
r+
0 SU cms
,
T O f' O T fO M
t .
END V IEW
BAoe
MNEl
BA C K
(OG(
~
fC~R~O;S~S~S~E~C~TI~O ~N~~ f .
_I.
I
I I . . . l f D
HANGER
I
sr ...
(SEE HG 5
~
ftGURI.
2 ~
t
BOX JO INT DETAil
,
wLO[
NOTe,
IllA N E L
cltOOVlS
'0
W I D E
,y ~- Of
SIDE
I
NOTE,
Oit eoASSiMau
C JN~
T H t Jr o I C U T 1
iVlDtI AND lACK TORr
,
,
Y o
P lYWOOD
BACK
(0
Nn~
DIVIDER
(S
GUl f I
rom the front edge of the 10l>lOOllOrn
pieces to the front
roge
of the
WOO C
for
the back panel, see Fig. 3.
Toget th~ length. m...
'UJ'C
th~ shoulder
to-shoulder
distance
on the ~i(lc pieces.
(Thi is the distance between the bottoms
of
the box joint
s ts
on the side pieces, '
Then add .. (0 the two '-Iong tongut ..
on
the
ends .
After the divider is cut 10 .i 7A . c ut
tongue.
centered on the ends to
lit th.
dadees in the tol>,l ,uum pi,on,.
11.\(1\ 1 ,\.._el . The l a. .;t I. i( ('( n t { C l t l l (I
the cabinet is the back panel ID), A, men
tioned above.
1
mtt(Jc:
l hi :- . P O lIU 1 out of ',.
birch plywood. To
determine
the
.i..,,,rthl:
panel. measure tb. shoulder-to-shoulder
distance
on
the sides U1Ut the tOI
bottom
pieces, and .del .. to both dimensions for
th e ; I / l o n g
tOU J.,.'lIf': '11\
L h t (-cl~~.
Then cut o/ ,- w id e b ) \ :-deep 1 IIbbc ISon
the back face of n { ur ,odge,; of the panel
to produce Ionl( ba....(at ed tongues
that fit the j I 1()\'~ in lhe frame pieces.
HOU;S .'OR
~IIEI.\ t:S.
Before final
assembly I drilk-d series of V'odin. hole,
Inthe Ridesand the middle divider for~belC
support pin.'. SO i> fig. 4. The position of
these holes isoptional, r just started \\filh;\
t of bole, centered on the h~ight of the
sid.. pUo< e . Then I added holes centered
c\ (oor~
'
up ~n d dow n, see Fig.-I.
A. ;SE~l8t.:Now the ea binpt ca n he a.- .
sembled. It takes 3little time to apply glue
to a ll th e jeints, 50 ) OU m ay w ant to col;,;t
helper. Aile,' the ~Iue isapplied, clamp the
cabinet together with the back and center
divider in place. (The back panel
ill
help
pull the frame square. bttt check
w
make
U 1 e.)
ILI. GL GSYSTEM .
To
mount
lhe cabinet
tu the wall. I used beveled hanging sl1il'
se e Fig. Just cut tw o beveled ,tij) nnd
mount one strip to the wall (make sure you
hit studs), and the other to the cabinet.
8tl: L\t~~.Some of the lellover birch
plywood can he used to make a few
shelves. Although its not
nCC~I')~
I
dressed
up the edJ1l'~by adding birch ror:
in g strips, s
l - i $ ' . 6.
CIIA FE~ Et)r,ES The I..
7/24/2019 Woodsmith - 042
12/24
WOODS~UTH
THlOOOltS
1 1le d N ,,' ro l ru
(,Roc)\ . (IM IMWIR1'\
, . , t . . .
\fttr the box
J tnU an- cu t, cu t a grtJ(I
aloJ)g the
ID$ictt '
.. 11(,uf each
pll'tt
for tlk-duor p;uwb (U
I.
n. ...
tOO\ to t5 .- \\ ide b~ ..
IlL......)
and
IJI tl4In. ,11IO It'
mint
t< lgl o IS
lined up on
t.u I I=
k ~It..'t
II f the first 1)Innn the tOil
tlOttgnllII t-c ~IJt:.
M)H I \' .I~' N4,\\cut the door panels
1111111 ' 1 1 ,, 1 , '1 1 \' \\ '4 1 _ ) 1 ( 1
to
fi t
between the
hc.llClIII e lf
II,.
J,(nJUV4;'.... i n
the
dO lr
frame.
Th('11 MAt 1111,1.. nn .hl
r. ,('~
~i(ll o f ( ta ch
I~IIM
I
tu
r O I l U C f '
\U 5:Ul'- to fit
th e
~'TDO\ J Ii ,ff a
.. d h ua 1 to tlk total th.ckn.fl
nV
the
P ~
to
g
f in u;.h t:.t \\ ld tl . u ( 111 .-anei u . - - e a b an ds aV i: to
cut
IJUllht. i l l~f, i l l lhnJK. .
~l.F ijC . 1 2. Final ..
J) ,
lutr r. r aJI'ht: t (l~l~\\ ilh
Ii
IS chamfer
hit
on
th~ ruut~.'I l I,'
r.S'lsl Tot.lInlJllt'tt thl~cuhu\(>t.lcham
f~rt'dall the>
NI~,'.
Illd ppli ~ll lilts of
~t.thprl ll ll \\' 11,,, Th nK Oir
,
,. . . . ,
.
1 2
N(O.IIU ,-,
lOT HO LES
~ s
NOTE: o . t U . HOlESt St MITt
COlNIIIS, ' IN I '0 I .
WIDtH
I.A t.
wOOOSCItW S
,
ITt. C09Nt.tSAI S
~
. .
aNTII
'''\Il0(4l
fIOSlllOH (.A1CHli
A' tol lOP'.\NO
IOno~ Of(A,'Nll
MOUNt Hr,..GI to
f'ONt IO(;(
Of
~
C.AIJt.jll $101
DOOI
000t
-
. .
. . . .
O...,r
n)
0 4 . . . . . . . , 1 .
~.
. .
_IWO
.. I....
fOGfS
.....-.u
SlIGHTlY
~ . . . . .
-
01 ' HOUI
N CA\[ FOI
MACffl 11(
(.AJCMlI
. .
,
,
. . . .
. .
. . . . .
.-
...
000 .. ,
, GIIOOYf
. . .
atUlI SHOUlD('
\IN: WtDf IV
DE ON AU
IDGlS OFPAN[l
Ft(;UI(
ONtHAII 'MOlH
Of CA'$( ltS' 'hI
StD
PI N
,
OOORIO OM ~
.,
, . . -
OOR PANEL
All000
'-Nil G'OOV S
WIOI I\,
I
D(~
N OTE .. , ..s.......
0001 fltAMl 10
Cl(T(IM. p (-
sat
OfMNEl
'0
-
OOO R TOP
000. S'O
'ftGUI.7
7/24/2019 Woodsmith - 042
13/24
1
,
WOOOSMIlH
IVI X
10 2
10... 7 -
~ 10-7
'In It.
9 ' ,
~,.29',
,.2~,
',.2418',
~ 2 -
91
- It.
'8-':.
. : I t ./t .~.
v1 to fit
wt
to fit
_ II . 72 IIWO IOAI'OSI
CUnlNG D)AGRAM
SPAC( ITWEEN
OlAWI' NolO 91D
t
IOTIOM ...
. .
1
t ,
SlAC(
2
,
,
,
SPAC(
,
,
\
1
t
END k
J ' lopIoll_ (21
k l...h(2,
t 0......
(2
M
O r o . . . , ., tUft.,...,
(6)
N5M Ow;
with the second slot down (of the box
joint),
see Fig. 9.
Since the drawers will be made with
V.-\\ide
box [oims, this puts the JrroO\'e
~ d ow n fro m the top edge. A dd to this the
amount
of
clearance
allowed above the
drawer
(.....')
and you gellhe
' t ....
spacing;
Then add the thiclOl '
ss
of the stock for the
1 1' bottom
('0/,, )
for a lol1d
of
I
K .
,e('
Fig. I.
fl'T C:R()()VES.So. se t tho fence
of
the
:oil I (rom the blade and cut a kerf on
thl'
1I ,,,le
fu~of the twu
end
pieces (K).
Then move the fence to widen the dado to
, . (I eut
thew
dadoes
fo r the
drawer
runners
I~
han 1/,' so the runners
\ \' uu l t' ln ' t l ) ln ( I IJ I the 1 ,/ . w id cg ro ov e o n th e
drawer ~(I,,-s.)
ItE llAINI~GGItOO\'ES. AfU r the lo p dado
is
CU~n both end piece . adjwst
the
fence to
eut the remain ing dadoesllO they're spaced
3'/1 ....and
5
from the top edge.see Fig. 4.
OAOOF_ ()~
mvmsss, Next cut the cor
responding
dndees
on the dividers. Thi~
I ires dlf(~rent seuings because the
tonl(Ue on the top edge of the dividers is
In ll~ 1 ttln sc, see Fig .
a
IlK_, t:R R t lONERS. Alter the d ado es a re
cut nn
the
end pieces and dividers, lhe
runners
eM ) are
cut to thickness so they
fit
in the dadoes, and to width so they stick
vr
see
Fig. 5.
Sinee the runners are mounted
cnJ83
th roin of the end pieces and dividers,
ap ply g lue only to the front
2
or 3 when
g l u i n g
them
in
place. (This ls
L O
aUowthe
ends and dividers to expandreontract.)
TRUI fRO' ' E(l(OES. Finally,
before as
sembling the
drawer unit,
I trimmed
%'
orfth. front edges ofthe ends and dividers,
see Pig. 5. Then later I added face strips
L O
cover the ends of these pieces,
ASSEMBLY.Now glue
and
clamp the ends
and
dividers
to
the
L O p
and bottom pieces.
(' \)
get
even clamping pressure on the
dividers, I used the tip described inTips
Techniques. ,;ee pg. 3.)
ADD
PACESTR II 'S .
When the glue is
dry,
cut ' 1 ' .-thiek face strip. and glue them to
the
front edges of the ends and dividers.
$00 Fig. 6.
14
lA.Gt MIDOl~DRAWE.
'CONY BAC.
2t 1KES)
-
--II~ -------
r
. .
. .
~
n
1A~Itf.IDOlf
~
DRAWfRSJ OE
4 \ 1 1 0
~
(.2 feES)
,
...-----I. ~~
+--- .---_
_---'1'.,'---
__ ~9 .
NOTE: AU . DtAwfR $TOCK
l , , -
I C I
Ol:PfH
Of-
SlOT EOUA~
J'HlCllNfSS
.. OfSrOClt ~.
r
2 -SIM U D RA WfR tO. S ~ S ' ' j - , , - , . - u -. - . . .w-n -'R -o - -, I' -A -'--;> t '- ._-=-1
~2~_~ ~ 2~~~=~~_
~~i_1_:L__
~~2~~~K~U~ ~
__r
FK;:Utt : B
to OflEltMlNf lINGTH Of
__ ~-DItA.Wn FRONTS,MfASUftE CASE
OPENlNGS AND SUlrRAO I.
j
u
T
NOTE: MU) iM
SECTlONHAS RUNNE.S
FOilONE
MEOlUM
AHOONE
tL OOuaL l S IZEDRAwElt
- : ~ : v .
CROSS SEClION
GUlf7
GlUe:
FACE StttPS
fOFlOHT
EDGEOf
ffljMANO
__ ot V tO fltS
/
EN O
' 1 1 1 \
I..
OHf.~'
EOGtS Of END S
ANOOMOfl.S
DlVtOft
IViut.
T
ctn fAC1
Srtl.-sTO
CovtR ENOSOfDI...WU
'UNNU GROOVES
CR OS SEC lION
(W f T M OR AW l- IS}
AGUkE S
HOOAoo
O N tO WER
lNSlDEMCE
OfOIVIDUS
,o~
1
,.~
j
___ S1,..
t
Non;
All DADO~
1.
DEEP
IV'.,., WiOf
7.
lNO : -
1
OMD(' 10 '
RGURl4
7/24/2019 Woodsmith - 042
15/24
1 5
_
l
_.
::
C; ~Ro ss si c~T~ O~N~~~~
,S ID E V itW 'l
\
R U N N E R
-n
-= >
CAIO t>LDlIt
W rT H H ANDLE
. . . .,.. .
. .
. . .
fINSiDEDlA..
.... tJ\OfO
iN SE rt
. MASONITt
SAal ay 3
00011
1
PlAHOH:lNO
:~ 'ANEl
Ii .
l
;~ / ... CQUHTE .S .NK SC REW S
f IN~INETaonOM
CASJNETSHOWN
wnMOOO.
ItMOVEO
~ -- SAWItAOE
surr
NOTCH AGAlN.$lI(tY
rOMAKf SECOND CUT
2
.
nU OCNESS 0I- t0Cl(
EQUAlS WIDTH
OFSAWKHf-
Bun CNVlD 1
I -
AGA lNSTKY
T O C UT NOTc,H
.
9
j
)
~
1
MOVEKEY2',-
. .
. .
ROM IlAO TO
CUTCIOS$ NOTCHES
SA,W \AOE
(titS ' KEtf
. .
1
. .
fJGURE 10
lA RGE O RAW ERMALL O gAWERS
\
,.OU
,. .
~
.
. .
CRO S S S E CT IO N
/' lIOUNGO.
~ _ORAWEI t D rV I.D.JI
1
~~::i
'. ROU O'El I . . 1
.,,_ I)EP ....
OIAWl KUHNll
GRO OV E CU T TO
W'tOTH OF
siot
@
IMASONntaonoM
tcUfJOfn)
GROOVEFel DtAWO
aonOM' .Wfot
IV l . DEl I
/_ROUlA 1 _ iOUNo.OVERONTO
~~SAnlRASs Ml t
1 J
c o c
=
,taUtf9
W O O O S M ITH
THE DRAWERS
No~that the drawer unit i~ssembled,
the drawers can
be
buill. I started by
r ipping enough stock (or al l the draw ers to
8
width of
2
(except for the double-size
drawer in the center compartment, which
,411,,
wide). Then
all
of these pieces are
resawn to th ickness of 1 .
.RO~/B.\CKPII';C ;S.The drawer frontl
back pieces are CU I Lalength to equal the
width of the o ning less ~.' v... on . h
side) {or clearance. see Pig. 7.
SII)R
PIECf,s.The length of
the drawer s
side pieces is somewhat eptional, Icut
lhem all to the same leng1.has the length
of
the front/back pieces on the small
drawers.
BOXJOL''TS.The
drawers are
joined with
v.'wide box joints. (The technique for
cutting the joints on these drawers
i.
es
cribed in detail starting on page 18.)
After
the boxjoints
are
cut, the
groo e~
(or the drawer bottom and the drawer
runners are
3 1 < 0
cut. Then the drawer is
assembled,
see
Fig. 9. (All of this
is
also
d is cu ss ed i n the article on page 18.)
DI WERS\'ST:II.On some of lbe draw
ers I added an inte rlocking divider system,
(' 'his
is
handy (or
s to r in g s c rews,
brads.
and other small hardware.) Before cutting
the
stock
for the
dhiders. I
rounded
ever
the inside top edge of the drawers, see
C ros s S e ct io n i n Fig. 9.
The dividers V) can be made from
hardwood
s to ck le ft. o ve r fr om m a k in g the
drawers) or from
y,
Masonite. Either
way the dividers must
be
the same thick
n es s a s the width of the slot cut by the saw
blade.
CUTTO
SIZ& .
Cut the dividers to width
(height) to equal the distance from the
drawer bottom to whe re the round-over
starts, see Detail in Fig 9. Then cut them
to length to match the width and deplh of
the inside of the drawer.
~~TOI~ TS.10 make the interlocking
joints, start by rulling a no tc b on each end,
seeStep 1in Fig. 10. (Use the box joint jig
to make these cuts, see page 16.)Then cut
notches
z ~
from each end, see Step 2 in
Fig. 10. Alter the joinl$ an cut, it's just a
matter ofsliding the dividers togelh.,.. and
placing them in the drawer
l I Ot i l \ 1 ORAWERINn:\Vhenlh~
drawers
Were
complete, I mounted the entire
drawer unit to the bottom ofthe cabinet .
l
added 10' Ma.'lOnitespacers between the
two units to allow clearance for lhe doors
to swing open, see Fig. 11.)
Use a Port.align to drill
v
holes through
the bottom of the cabinet. stopping when
Lhebit just touche. the top of the drawer
unit. Then drill holes at these points for I..
inside dis. threaded inserts.
M ount t hr ea de d inserts in the holes in
U e drawer unit. Then fusten the cabinet
and drawer unit together with I. Ph ma
chine screws.
7/24/2019 Woodsmith - 042
16/24
\VOODSM11li
DfHCno.N~
Of'fED ~
c a ....
M ASON Jll
tUNNEt
lOUT \~. . stor
,nwUtl
j;lA.2l
STOPHOUS
.g;..
C(;NfEft Of
ROUtlN
SQUR
L OP V IE W
IGURt ..
OWE
oJ
Jtl NNfft . ~ ,
TO eASt ...
'. MASONItt
_-COUN1UlOlt
.OOfE
.SlOT
:ROSS SECTION
I
I
CAlIG
IOU
tbe slot between the
tw h'II,>o,
see
I iI :, :1 .
0.
to )1Uidethe jig ill the
the
b ase , s ee
fig.
I. Th,'n mount
the fn'hl miter ~;,U~, .Iot
in tho
table
sa ,
Rip a
fence to the
ba ck
f.m'( with .,' oarrla~c
12 1 0 ) 111 (
runner out of y ~Ia. nite so it's
bolts, wing nuts and washers, wide cnnu~h to .Iide smoothly in the slot.
ST A8 1 L1 ZL '1G STR&Tt'Ht;R\Vllen milking 'Own
\1st
Iu, ,' to align the runner 4
the box joints, the dado
blatl ,
will cut (rom tb.
I
fl
l~ll e
of thejig base, and glue
throu((h the base, ,'('ier to
-'i :. ;,. n,
make
It
in lila,'\ ,see
I - i l , 1 .
- - - - - - ~ - - - - - - - - - - - - - - - - - - - - . A G I T U ~ . ~ 2
. . .
4
. : I t
t
CARltlAGI IOtTS
4
NO TE:
U S E
4. Sloe.
ONH.NC f
K5
1
4
16
M AKE THE JIG
1b make this jig, I
cu t
the
y Masonite
ba s e
(D )
10 a
size of Ii
wide
b y
24'
long.
Aiter the base is cut. the
two-part
fence
tan
b e
added,
This fence consist. of a from fence
(A)
that slides .gairu;t a stationary hack fence
(Ii),
see Fig. I.Rip both
fe nce . to
a width
o f 4 '
oUlofj7
.rking on the projec
ts
in thi.
k ,U
e,
I had
to out lot of box joint.,. 'fo
make box joinll< accurately, you have tu
meet two eriteria; I) the pins and slots
have to be exactly the same
width,
and
2 )
a U sJot.-must be th e sam e depth
In order
(0
ml*t these criteria. I use
k
ji~ tn ~ide the workpieees. The jig we've
shown in niw rmith in the past is fairly
basie, It'sjust a fence attached tothe miler
gauge ith an indexing ke y mounted to the
bottom edge to position the workpiece.
The onlyproblem \lith this jig is that it'.
difficult to
fme-ume
the position of the
fence to g o l the right fit on the pins and
.Iols. I've also had a problem cutting the
.Iot.
e xa ctly th e s am e
depth
because
the
workp iece ( ends to rise
0
sink as it slides
over lhe
l .1ble
saw insert (the metal plate
around the sa w blade).
1 b
solve
th es e p ro b le m s I
made new
jig that incorporates
a
two-part sliding
fenee that allow. the micro-adjustments
often
necessary
to get tightfittingjoints.
I
also addeda iMasonite base
to
provide a
7/24/2019 Woodsmith - 042
17/24
VOODS~{lTH
S
7/24/2019 Woodsmith - 042
18/24
v,'OOOSMITH
8
NOJE:
~WO.K [CE
OOWN AGAINS1
IASO
I StAATWITH
,,,,,I FtOHl,$ACK
. . . . _ _ v . . . . . .
O S ,
cu,
-
ftC(
Th~ proeedure I~
t
h, stm,- ( 1
t l C ) t h .
hut
I l L 't .' f I
th. ,ut.'r tahl, on th,
drnwers bc-cause m:-.
r l a c t f J
llhto,'
(1Itlo',
rnuke 11
:oatL~fat'to~'
cut, (Set. 1~3J. l2(1 (01'
m ore on tb..i~p r ob le r n .
ssr
rae
JIG.
Th
mnke
the pin.' an'
cut io Ihp correct length. t the bit height
(or the blade height) to the exact thickness
of the sicek, Then make a
trial joint
on two
t es t p i( c( :; :. ,
.I so th e ju sl- (.'U t 5 :1 ut ~rafl..
die. the key lind
wt
Ih ne.t .Iot. Repeat
u n ti l ~ IY \. ..
h\\ ~eell
c u t - ,c r ot ;.. t ht .' ~ u r k ..
. F
)If C( ~ee Ig.-.
('l'T JOI~'TS
s
SII)F-S.Kext. cut the
s l u t . . . .
in (lJ\otl,ertest
pil ee
for thl~dr.I\\,tJ'~icl,s.
The side piece begin....\\'ith a slt.' ttl n\ut,>
ith th. pin in the fnulI ck )1'l .... 1' ,,t
the width of Ihi. slot. plac. Ih, fn.ol ha k
1)1C l lg -C I;;
8, l E ' < 1
to be .
l h ~ l O m b i n
di
nlerU.1UJlof tht ~IotstU ld pillS - lhe fin
ished joint - ~ntlsup _Iil(hlly n3m ,.,r or
wide,' tllan I 1)lnnll.~I.In this
~ ,,;e,
I bim
th~
pieC pins are wider (Jr
narrower than
lht
:-;lul~.
Th
m u k e
adjustments.
ru ove the fe nce ' ' tbe y is
closer
10
tb~ bit for. looser
fit,
or
farther
( ,m
Ih~ bil fCtr
a tighwr fil. 'Then make an
..Ihr-r triHl joim, and proeeed to rut th~
J tU J1 tS In all the pil t,- 'C.sfor the dnt\\'\ 'r,
CUT THEGROOVES
..C'tt r t h l' j () 1 11 t < o .1 1 '\ CUl. the groove; ror the
dn,y,l'r lklttfl' ean be CUton t he t .a bl ,, saw
Thes
grOQ\l' art
;de
by
v.--deep
rOT
lh(,
I
~t~~I \nit~)cllwm.
~hUl) ~t.tt.:
\ }ten
JJll.-lkJn) U
(In\\\'e:r, if
the drawer ~i{ll '_
Jel\\' (Jul
even ,lightly, the
drawer
will
bind 3(11un,1the runners. FOI'
Ihk; rea.\ c ~,
tile)' all 00\\
to\ \1l l1-d
lht>
f
ofllff
of
the- dra\ve1 Then,
\\'hen Ultt.lrd\\ (rs a..~mbled.
lh~
l a\\'er
1 )I ') tto m \\, .1 1 J '\I ~h the : : : ; icles oul\\ ani.
~tMn~hl( flinlfht~bo\\;
1' .VC for the drawer botlom isn't
\ .,illl
on
the
d l 3wer
front. ~t the
sa w ,
Ih. blad. align' \\;th the botlunl c 'g~o(
lh, bottom slot jn a
. o t i ( f l .
p i c C ' C . ~ee Fig. 4.
(T-hill
v:a):
w hetl the J rI O Ove
is
cu t in the
front pieces. il will .Iice through part of a
pin thal is onl~'\'i~ible-)n tilt
tln.\\\'{'r'::,
:-id(~.
. e e Fig. 5.)
. ..fte_r the S3\\' fence
b
po$ltiollefJ, cut
i ( 1 W e 6
in all four piec.8. (Mak~
, 1 & 1 1
the bo\\'oo : < u r l : 1 c e
i:;
to\\'am the sa\\'
table.)
ox Joint rawers
ST EP B Y ST E P T O B U ILD IN G A D R AW ER W IT H B O X JO IN T S
7/24/2019 Woodsmith - 042
19/24
OOOSMITH
tGURl 12.
S I I
CROSSSE~
OlAWtI SIDE
MAWRIOnOM ....
Slot
OIAWllt
\lNNS
GROOVE
SlIGHTlYaMl
ON. lOGE
SOUAtING
I'OtM
fIGURe 10
(HISE L O U T P lN
1NNAWE.
ItUNNflt G1tOOVE
ClAMPING
alOClS
SlUD TO
fiT fNSIDE
04MENS iONS
OFt>ftAwt.
V OID LE n
B Y BOTTOM
G.OOW: IN
f.O 'lT'IA(I( 'lea:
. AU G H W IT H
SLOT tN
SID E PileI ~
SlO(
OUTSIDE
r
CORNER
VIEW
' ltONT lACK
U 6
lI[
5
tGUl,4
IN SID E C OR NE R V IE W
' \ t:
IlR.\ \~ :ltIl()1 T().\1~.
Nr \\ eut the
bottoms out of 1/...~la. ,oniteto fit between
the bottoms the grooves. (Cut the bet
t41m just
tarlIO(.: e ,..
it clnt'tIoll't
g-t hung
up during .. .mbl~:)
J)k.-\\ .:RKt ~NBR (~K()O\
e. Before as
sembly; the il' -deep )...fTt)t,\:~~for thf*
draw er ru nn er are cu t o n the o uter t1UI
face or the sid~ pieces To cut th, ,
grooves. adju t th~ fence
the hla
Wid
~1()U;.and join both
s.illt'
,}j{>o(_ t'~
t
the
drawer's hn1,1,,, '.
\V h.h the drawci assembled. 111.< the '
squaring form in. .ide. Then draw
t.ht
d ml)~up tight. seefig. ~.
fI~.\l. TOtCH f:S.i\fter tht glul ~tIQ, tht
drawer is ready [or a fe\\
[anal
touehe-,
First, chisel out the
pin
blocking the rear or
the runner
groevo,
see fig. tu,
N~xI. fill the void in
the
side.. (created
by
the greove for the bottom) wilh wood
pulty matching the end I :rdin color.
A nd
finally.
I
rounded
o ve r t he
i id. tUI
edge of the drawer with a
1/.
round-ovt-r
bit. see Cross Section in Fig. IL
MAKE
TH E
DIVIDERS
After the drawers
were
assembled. Imacle
a
7/24/2019 Woodsmith - 042
20/24
\VOODSMITli
'HOUlD'.
A tTS A S
OllfH
5101'
NOll
MOvliT'
ANOWQb:Pda
TOGlfHf.
tunDlnH STOP
AGAINST ,.N ENDS
..llOlh{r Ilr ll]pm
with
box joints is tJ1~t
tht, hollilm u( tl lf ' : -1 1,t is n.ugh and un
~U1U't'. Thl,,,
i i
('.tu i('(1h) lhp design orthe
d.du bl.d, II ,If 1l.1)O'lldilllt on the t~1 l O r
(la(in, th.. rt' ('C luJ ,i tJ e A>\ er.tl (liJTe-f'Cllt
ba
prufil,'S
on
Ihe
bottom,
or
the ,1ut~.
< :
phto.RUIall h, . pror~ boil down
tl)
ont- Jtn.bllln, The
lJOttoms
of the
~Iot..:
are no,
I la t
RI.loqll:Ue
Ont ;
Y o
ay t.t \ 'Om t .' t th l pn}b t:'m
tIn
nar
ro~ ;.1,
ts,1j
te l flan-t th~ bottom oiLhI' iJol
WIth
a
'hng jig
nle ~1~llngigIU~
. ' 1 . ) n ; ' o i . . . l....r:1 p i , - ' \
tlf
) 0
1 . . l 4 ~ ' k thAt' ... t l IY J I f , v f d tl
a'ept
a
thnjt\IP. f{lr' thi ...tonJ.'Ue' lo a thickne:-'..~ to
mUIngu~on . h , 'I'< and u,.' a ,harp
kru
'0~hrough tIM>
anrl ... per
on both
_ u l , Ir th., lOnguu rl~ ,(' V,f th ~ , , 'c l ( ) ( l l : : - . .' t , n \.1trt lU It I , r uturnlnurn ,jell' : o . a 1 H 1 I J . : ;L p
.f 'l t t t u f 'I)():->itl~1:-
trut: \\'Ith ~urln~'e
1 1 1 1 N . t
h
t_'(urt an}'l(JI) CllOll,p.f
fini~h go
(,n,
It alN.
V llt t h4'
'-an.ling l (_I.~i
fini . :\h(os(l ' i ll( . h
H'
\'arnil h.la{ '~u~r.
anc l 'l ln1 -I
he
t'l\tlrt~ ,. ur (~ \ )Ohuul.1
tt e :' :~ lnl it'( 1
,\ ;th from
lI~ I) I ( lJ. :lill tI n
the: ' iOUl'fit('('
01'
, :nrm
lac). ,'h(., ,,'hi,)\.'
IK 'in t
(Jfthp~, finishl':'
Il'\
tu l.tflut' l~~grit. ;trld
~'t'U
nli~ht
'ant
to go minj.
\'1'
fh( Kttlulalltr. \\'ht'n
litllt> ball...(
).tlil(1
lll'
luy, ralf ,f)tJ {,t4 t t lt 'I l, R u t \ \ il h
l,( h ( .
r
It tHI(' IIUln
t im ( ~ . m { '\ 'i ng US ' to flni:- .h
nfl
c l uJ .: 'I I'
(II'
tlu'
:-..tllrJI,allt' r (NIW
la~( r . i lnl) ( ' rft '( ' t
i~lll~
n,
' k in \\.hln
) ' 1111 : ..~J(0 11
t..
,ron.
tht tt'l'
l lnll:-;
tlrt' 8 Jtp lie< I, ~ cial l , \' ' it II
,.h,llu(
J~
It'l , . a . . . .~ '
ltlrut, ....
nclpufM.r. f
l'~f,r
ltl'.-1f in i . ..h('
T H E ,tlST ST lPS id
thi~
S
\\h,nI't'(lt 'm....
nclltuE':-tlon:, Ilk. ~ r U 'II ,nrn1: h o r 1 }C,I )o'un .-thant.
begin. ma~
fotart
:t
I , l tl , - ( .. . . .~
r,
2 : , , . . . .
Jrrtt ~'r
fo\ PD
Itubbmll
aut the
10 1 'coats ISonl~.ff ''1.l\r '''HI:R. ''T ~ ' .. , Tlw
p '...
, ( C ' i f ir s fJn
t ac:h type fir f in is h \ \;11 l'oPOl;o .,)
t'1l.1.1~(;
If
you' , fIOin) ,10 use an oil I... 1 1 0 1 1 ' < 1 in ul ,mlOK lIrticle . But th su I 'Til.
1'1.11
\\'h~n sancling mO,
filli.h. othinK else hM to
be
done
to
Ih.. o, ..... U Ilnll'(~lu ...
nnel
lhe maleri.l, finishe . a '''
whi t. ..
,nning dw>t wil l
b f
wood
u rll e .
How,c,: if you want
to
U'
n< ,d ( '( 1 1 0 e lo
the jI out
o (
lh~
Finishing: The Final Touch
MATERIALS
&
TECHN IQ UES FO R A HAN D -RU BBED S U RFACE
o.at
Th.a
j < lo
lfl ....r t'.-U.tl I,.'f,.il '.
'I,lIl I, you have to use somv
Irt I,f
abra ..
l\'( til
smooth
it,
7/24/2019 Woodsmith - 042
22/24
L'ORIC'ANT.
Tohelp speed up the cutting
action of the sandpaper and keep the resi
due from building-up, I use oilor
water
as a
lubricant, The choice between these twe
lubricant. depends on how fast you want
the sandpaper to cut.
OIL. Sandpaper cuts more olowly when
oil isused because the oil c....ales a thicker
f i lm.
This
allows more control O\ ~r
he
cutling action, (\'Iith lighl p ure, the
sandpaper tends to ,Iide over th~ urr.eriodically.hake
ofr
the clolh
10
rid
it of the steel \Ilndpaper can cut through the finish
an d into the stained wood which will leave
a 1 i . 1 .pot that's almost impossible to
cL.rkenagain v.ith stain,
,SUlSG FORAIlH f:SIC);.I.
There'
s
anoth~r
reason to sand between coats. MoRt of the
new synthetic varnishes
(such as poly.
urethane)
drysc hard anti , oolh
that
the
next coat v.on'\ slick unless the previous
coat is roughened
first. It
doesn't hurt to
slighlly l'I>ughenany Iinish 10help the next
coal
adhere lallhough la..oquer
an d shellac
lend 10melt the previous coat and 'eld
to it).
7/24/2019 Woodsmith - 042
23/24
ca n be worked with a c le an , soil cloth. But
I prefer a block or rubbing felt since it
provides
a ilat surface
and allows the
abrs
sive to move within the fibers. A common
6i7.(>elt blockis I' thick and
2
by
4.
(The
last one
ought
ut down the mlddle on
the bandsaw to obtain two
v , thick
blocks
-one for pumice and one for rottenstone.
PI 'IICE. To usc tbe pumice with a felt
pad. spread a thin coat ofrubbing oil on the
surface of the workpiece. Then sprinkle
SOme FFFF pum ice around and use th~
rubbing relt to rub in long even strokes
with the grain,
Before long the pumice and oil wil l mix
together into a creamy paste, Ifthere's
too
much oil. you won't feelany cutting taking
place, and if there's too much pumice. the
felt will tend to catch ralber than glide
over
the surface .
A.~you work, cheek the progress by
removing the paste [rom different sections
of the surface. Iry to ruh all parts evenly
(o;ometimes I count the number of strokes
in each area). Pumice can
tilt
quickl~1SO
don't overdo it.
Once the fin is h is uniformly smooth,
clean all the residue uffthe surface before
continuing with finer abrasives.
Youmay like the sheen produced by the
FFFF
PUIDlce(sort of a polished satin).
But if you want more of a gloss there are
OOOSM ITH
three ways to go: rottenstone. rubbmg
compound. or an extremely fine sandpaper
called ?tilero Me.h.
RO'M'EN ST01'o '.
Rottenstone is used the
same
way as pumice. ~'irst. clean off a ll the
pumice residue and then switch to diC
ferent piece of rubbing felt and follow the
same procedure as with pumice. Lightly
cove r the surface with oil - don t use as
much
8 1
when working
with pumice -
and
sprinkle some rottenstone on the surface
h rouenstone burnishes th surface
and brings it to a
very
fine polished ap
pearance. Check this by holding a light at
very shallow angle to the work. Youshould
only se e It'll fine scra tches (or none a t all
in
the direct ion of the grain.
RUBBING (O'II'(JUNOS. Another
ap
proach is
to
use rubbing compounds for the
final phase. Rubbing compound is a semi
paste, abraslve/lubricant combinatlon that
is used r
rubbing
out
auto
l aequ e r s.
(Behlen's also makes a rubbing compound
for weod finishes, se e Sourees. pg . 24.
Depending on the brand. there
eo n
be two
grades: rubbing compound, or the fine
polishing compound.
Most rubbing compounds seem to cut a
little more slowly than pumice. but faster
than rottenstone and t ea ve a high lustez
To
us e
rubbing compound. work
a
little
in to a so ft, damp cloth or rubbing rtlt and
rub back and forth with ~mooth. even
strokes. If the compound starts todry out,
work ina little more compound. Ifthe cloth
starts to get crusty. rinse it OUt and add
some fresh compound. When you get the
sheen you want.
buff
the surface with a
clean, dry cloth.
M I{ K O n:SH . If you really want an ex
tremely fineand unifor.mscratch pattern.
Micro Mesh may be the solut lon.
(s..
Sources. pg.
24. It
consists of a series o
cushioned abrasive pads simi lar
to
silicon
carbide sandpaper, but they start at 150
grit and gO all the way to 12.000 grit.
Micro Mesh was originally developed to
rub out plastic airplane windshields, but i
gaining popUlarity with musical instru
ment finishers.
CONCLUSION
Rubbingouta finishcan bemessy an d time
consuming. Sometimes it's only worth it to
bring the to p (of a table or dresser fo
example)
to
a high gloss and just lightly
steel \\ the res t.
But what impresses me the most abou
rubbmg is it's such an immediate im
provement to surfaee finishes. Simply
taking the time torub out the dust nibs and
brush marks with steel woolbrings a good
feel to the surface.
I used to be in a rush to put. finish on
allow it
to
dry, and then get it up
to
the
living room S O everyone could admire it
No more. The extra time spent finishing
the finish produces a lot more ahhhs..
What impresses me
the most abou; rubbin g
is
it s
such an immediate -
prouem eni to tile sur fa ce
SLOppingat
~t
sandpaper; continue
onwith 600-gnt. Then, rub out the surface
with even finer abrasives sod rubbing oil.
r- ow (jERE ) AllRASI\ S. Pumice and rot
t en st on e a re the two most common pow
dered abrasives used LOproduce high-glo.. ,
and mirror-tike finishes.
Pu mic e
is
a
white-grey material
ob
tamed from the asbes of volcanic erup
tions, It's graded according to the size of
particles: f'FFF is the finest, down to FF,
the coarsest. (Note: Always cheek the
pumice for foreign matter or large grains
berore using it.)
Rottenstone i. an even finer. black-grey
substance. It 's made from ground-up l ime
stone and
gets
if.8 name from
the
odor
that'. rete ..sed when the raw material is
broken up, (Fortunately, the odor is gone
by the time it reaches the finishez )
Shop Tip: eep the pumice and rotten
stone in separate salt and pepper shakers
SO they can be shaken out onto the work.
piece when
eed them.
RllUDING FEL't
Pumice and rottenstone
A SATIN FINISH
After the top coat has been smoothed and
Ilattened with sandpaper, the appearance
can be controlled by refining the scratch
pattern. 1r you want a satin or dull finish.
rub the surface \\';th 000 or 0000 steel wool.
CONSIS'l'ENCl: S ,I wool is available in
grades from No.2 (tbe coarsest to 0000
(lhe
f inest) .
But these
grades are
no
3.'
suranee of quality.
I've
opened
up
0000
steel wool
and
Cound
coarse strands almost like N o . I inter
mixed in each pad. And some ste~1wool is
so oily that it imparts oil to the finhlh.
Ll81l0NST~~I. WOOI~For yean; Ivc,
just used whatever brand wasavailable at
the
local
hardware 8tO..... . But reeentlv
I
discovered
Liberon .tl'el wool which
is imported from England. (See Sources.
pg. 24 .)
Liberon comes in a roll (rather than
pads) Meyou can cut offju.~twhat you need.
And since it's made from long strands it .
mucb more resistam to breaking down.
But the best feature of this steel wool is
tbat it's oil e n and generally has a good
feelto it. 1particularly like the finest.grade
whieb is s o m e w h e r e between a ( )( )( )and a
0000
grade,
WOOLUIIE.I like to add Behlen's \Vool
Lube as a lubricant when I'm doing the
final
rubbing with steel wool. (It has the
same effect , as using' oil or water with
sandpaper) WoolLube is a gooey material
wit h c on si ste nc y th at S
somewhere
be
tween axle grease and Vaseline. When
used with 0000 steel wool. it
quickly
creates a hand-rubbed, satin finish.
To use it, wet a piece of steel wool and
wring it out. Then work
a
glob oflhe
\\'0 01 -
Lube througbout the steel wool an d rub
the surface of the workpiece with the
grain.
A s
you work. the \Vool-Lube and
water combination will start to foam up.
Oecasionally wipe off the foamwith a ral
and check your P QgrI S.
7/24/2019 Woodsmith - 042
24/24
piece
of S wiss che ese O C'< 1l1 L. f
all
the
various hole location.' (bat permit il to lit
just about everystandard router below 1...
H.P with
R
round base.
T be u niv er sa l b as e
plate
come>
\\;th
four
bushing. (,. ,'. '/;,. shon and long length s,
and
.y~
outside
11iam(t~~).
he set.can be
ordered from:
WOOJ)(,RAfT Sll'PL\ rOR .1I
Atlantic
A ' e.. P .O . B ox 4 00 0, \V ob um , M A 0 18 88 :
8002251153 ICatalog: Free).
ROltle
Gu,d,
BI($/tj iI Sd
jO , llllir er8< l1 BaS I
the ne\\' design 1
it's
easier to see your
workpiece
while
routing.
'The
I
is
listed
in the
I I 8 i ; - S G
Se....
T o o l
Catalog..,. order
numl,. .r 9-1{'J 2 i(182.
iA9.
IlIH'I:Rt;\T
ROlTERS.
O th e r c o mp am e s
(Black
and
Decker, Bosch . Po rte r-Cab le ,
and Makita) all manufacture guide bush
ings that fit their indh'idual
route, -s .
Some
ofthe bushings fit more than one brand of
router,
0
iI'S best to c he ek with a dealer
tho carries accessories
r
your router.
t:~I\'Y.RAAI.II,\S';PI,n:. One so lu ti on to
the problem of incompatibility between
brands
is \Tennont
American s universal
ball plate. The plastic base plate looks like
NEW SEAlS
GUIDE&uSHING
OlD SEAlS
G UID I' & U $H J NG
SEARS'IIt'SIIt~CS.Sears sells a guide
bushing set to fit their Craftsman routers.
It inc lude three different bushings with
o utsid e dia me te rs of ViI I . VI ' and ~ .
Before 1984
the
set was
made from
heavy steel plate. Unfortunatel); the cur
rent bushings are made from a th inner
gauge metal. The only ach'antage
'esee
in
OLD-fASHIONED WALL PHONE
Youcan order the hardware and electronic
package for the phone
from:
DAK OTAWOOOII'ORI\S. IN C.. 470 E lm
Street, Kindred, N 1) 58051; 800-137-47S7
ext.
333
(Catalog:
$2.00). Porty Lin
Phon Kit.
Order :-;0. 2PLB (specify' )'''
for toueh-tone or R for r ot ar y d ia l) .
Th~, kit includes al l of the reproduction
hardw . .re, electronics paekagr. iring in
structlons. and blueprints. (Note:
The
b lu ep rin ts s ho w u slightly different des ign
from the one presented
in
this issue. But
the hardware will work on hoth designs.)
The price of the kit is $124.69 plus S7.M
shipping
an d
handling.
TOOL CABINET
Youcan order the hardware for the tool
cabinet from:
THEWOOI)W()RkJ a long the side of template
following'
its shape. Since the router it
I
inside this bu,hinj , it rout. this .hal' in
the wood.
The template for the phone was jusl a
rectangular block
of
plywood, Uut guide
bushing> are a1suuS(.,.j \\;th dovetail joinl
fi.'(t.u.res(~ce
l\'OQd.~ tt(/i
No. 22). butt ..
hinge template>. and sign-making
CAItPEllAPE
Doub le - si ded C a rp e l
tape
wa s m e ntio ne d
ina couplespots in this issue. It's useful for
t empo r ar il y ho ld in g
parts
while screwing.
gluing.
or marking.
\Vcprefer the c lo th - ba ck (woven ) c a rp e t
tape instead of the plastic type.
It
hold.
tight but releases without pulling up
slivers
of
grain
or
l ea v in g g u m m y a dh esive
depoO'iw.
Note:
Should Ihere be any adhe
s iv e le ft o n
the wood il
ca n
be
cleaned
off
with l acquer thinner - whieh
must
be
done before finishing).
Double-sided carpet tape is available at
moothardware stores. \\'c recently bought
a
II -
w id e b y
12-footlong
roll
for
52 .29 .
RUBBING FINISHES
order most of our
finishing
suppl ies
from the following companies:
(:.\.RRETrIUJ)E('O~II'A. \:161Ave. oflhe
Amerieas,
N ew
York,
N Y 100J3 ;
8Q1} .221 2942(Catalog: S3.00).
Libero
Steel
Wuul
imported from England,
#0000
1#000 grade, V.lb. roll, Order No.
SIRIO.OJ. $3.36.
Small Felt Bl ,k.
I x 2-
x 4 ,
Order
N o .
99l'O9.01, 85.00.
Mit . .
,\1..-1, Kit,
18 sheets. foam block, instruc
tions, Order No. 5lP09.01, ~'l7.2S.
woon
fiNISHING SlI'I~I..
CO.
IXC. J26;
Mary Drive. Macedon, NY 14502:
:lJi;-9864617 (Catalng: $2.50).
Behlen'.
l l Ool { ub.:. pint, Order N . 8720)355
6.16. Behlen'. It IIbbill{l Compo H d n e u -
tral, pint, Order
1 0.
l I7 'J l}.OI115. 85.95.
WOOIWI~I'ntN(;
~T&RI'RtS&S, 17'2:9N.
68th St .. \Y auwaIO$a. 'I 532 13 :
111-771172-1Catalog;
Free).
Micrv . l1e.1t.
individual I' ~
6
sheets (see catalog for
grit.~). :l.oo per sheet,
Pnraffm (rubbing) oil. pumice. rotten
stone,
an d
paste waxes can
be
ordered
from
al l three
s ourc es
listed
a b o v e .
Th e 3MWoodf'ini.hing Pad ean be pur
chased from most
hardware
stores cam
ing 3M products. Lisl price: SI,5lJ.
\Vel-or-dI'Y silicon carbide sandpaper
and aut rubbing compound ca n b e pur
cha se d a t m os t
local
au to s upp ly
dealers.
Non--clogging,
ZillC
s te ara te s an dp ap er
ra n
be
purchased from many dealers who
carry 3Mor Norton products. Itcan also be
ordered in quantity from Garrelt \Vade
(address above) and from;
JA ~STOW~ OISTRIBt:TORS, 28 Nar
rsganseu Ave., P.O.80x 348, Jamestown,
RJ
0'Zl i3a;
MO-l23-003Q(Catalog:
Free).
.Jamestown
Distributors
has a wide selec
tion of sandpap,:r