Mission Style Table • St.

Nicklaus Carving
Included in this issue:
Jewelry Box • Kids' Bobsled • Carousel Toy • Box Dmm
Bed-and-Breakfast Tray • Towel Rack • Dancing Folk Toy
November/December 1989
 SUPER SALE!
Powerful planer is
totally portable,
with a 2 H.P. motor
that lets you handle
wor kpieces up to
12 1/2" wide and 6"
thick. Makes
16,500 cuts per
minute. Stand not
included!
NN912P
Made In West Germany
Create extreme ly clea n, flat botto m holes in thin
veneers or through end grain and knots . Sizes 1/4 "
to 2", 3 1/2" long with a 3/8" shank.
Come in a sturdy woode n cas e.
YYFB15PRT
$99 95

15 PC. ROUTER BIT SET

1/2" shank , ca rbide
tipped bits, in a
' . 1/4" shank tung sten hardwood case .
carbide bits really can Includes 3 straight
take the heat. bits, & a core box,
Includes rabbeting , vee groove,
chamf ering, laminate, dov etail, cove,
roman ogee, cove , rabbeting, roun-
roundover, dovetail, dover, roman ogee,
vee groove, combina- 45° chamf er, and
tion panel, 3 straight, flush trim with
mortising, flush trim, bearing.
and bevel trim bits. AV2025
DPARB151

$99 9 5
22 PC. BRAD POINT SET RELIANT 1" X 42" BELT SANDER

Brad point set has

11 bits from
1/8" to 1", and 11
Adjustable lock- Built rugged , with a 1/2
ing collars let you H.P. motor giv ing you
drill to an exact 1720 RPM of smooth
depth. Brad point belt or disc sanding. 7"
feat ure preve nts throat. Belt size is 1" x
walking or slip- 42". Disc size is 8".
page. 1/8"- 1/2" Table adju sts 45°, or
have 1/4" shanks. can be remo ved totally.
5/8"-1" have 3/8" Belts available.
shank. YY22 NNSGl

$29 9 5 $12995
Order Toll Free, 24 Hrs. A Day:
MONEY BACK
00·343·324 ! ::::C::JND9 GUARANTEE
Examine any item in your
n · Ie e DEPT. WJND9 M home or shop for 30 days .
Return merchandise for a
375 Beacham St., Box 6447 ,
Chelsea, MA 02150 complete merchandise
ADD $4.00 SHIPPING AND HANDLING refund or exchange.
REGARDLESS OF HOW MANY ITEMS YOU ORDER.
 VOLUME 13, NUM BER 6

c '1"'
-
l ~,
-
1 l '1"'
_'\ -
~
I~
Ed itor and Publisher
James J . McQuillan
Managing Editor
DEPARTMENTS
Thomas G. Begnal
A ssociate Editor 4 Shoptalk
David F. Pet ers
Staff Edito r 6 Letters
Thomas Clark
9 Readers' In formation Exchange
Contributing Edito r
Jim Bar rell 10 Cabinetmakers' Supplies
A rt Director Hardw ood Suppliers
Dan Thornton
Illustration/ Page Design II Events
Michael Gellatl y 46
Maria Meleschnig 21 Woodworking Basics Kids'
Mo rlising BUll Hinges
Craftsman Bobsled
Mark J. Ziobro 24 In The Shop
Circulation /Promotion Dado Heads
Lynne Streeter, Mana ger
JoAnne Finkle , Subscriptions 29 Special Techniques
Patricia Malumphy, Distribut ion Marqu etry: The Empty Window Method
Maureen Murphy-Gere g, Subscriptions
Comp uter Operations 34 Finishing
Kathy Shook, Sup ervisor Aniline Dyes
A dvertising Manager
Kimberl y Gellatly 46 Gi ft Shop
Produ ction Manager 74 Shop Tips
Jane Manley
Offi ce
Patricia McLean , Manager
Lynda Morris, A ssistant
Administrative A ssistant
FEATURE
Marie E. McQuillan
T he Wood wor ker's Joomal (ISSN 0 199-1892) is 16 Lyne s Unlimited
publi shed bi-mon thl y in January, March, May, M aking Toys in a Kansas Chicken Coop
July , Septem ber a nd Novemb er by The Madri gal
Pub lishing Co ., Inc., P .O . Box 1629, New Milfor d,
CT 06776. Teleph one: (203) 355-2694.
Copyr ight 1989 by T he Madr igal Publi shing Co. ,
Inc. No par t o f thi s publi cati on may be reproduced
by any method without permi ssion from the
publi sher .
Second class po stage paid at New Milford, cr
PROJECTS
06776 and additio na l offices.
Subscription Rates: In the United States and its
possession s - One year (6 issues) 515.00. Two 37 Bed-and-Breakfast Tray
years (12 issues) $26.00. Ca nada - One year
$24.95 (CAD), Two years $42.95 (CAD). Foreign
countries - One year $20.00 (USD), Two years 40 Mission Style Trestle Table
$35.00 (USD) .
To Subscribe, Renew or Change Address: Write
to Th e Woodwo rker's J ournal, P.O . Box 1629,
New Milf ord, cr 067 76. inclu ding mailing label
42 Jewelry Box
for renewals and changes. For gift subscription s,
include your o wn name an d ad dress as well as those
o f gift recipients. 46 Kids' Bob sled
Postmaster: Send Change of Add ress to The
Woodworker' s Journal. P .O . Box 1629, New
Milford, cr 06776. 48 St. Nicklaus Carving
Co ntributions: We welcome contri butio ns in the
form of manu scripts, draw ings and photographs
and will be glad to co nsider such for possi ble
publ ication . Co ntr ibuto rs sho uld incl ude a
54 Carousel Toy Missi on
stamped . self-addressed envelope of suita ble size
with each submission . While we ca nnot assume
56 Box Drum Style
respo nsibility for loss or damage, all materials will
be tre ated with care while in ou r possession. Pay-
ment for the use of un solicited material will be
Trestle
made upon acceptance. Address all co ntributions 59 Dancing Man Folk Toy Table
to : Edit or, Th e Woodworker's Journal, P .O . Box
1629, New Milford, cr 06776.
U.S.A . Newsstand Distribution by Eastern News 62 One-Board Towel Rack 40
Distr ibutors, Inc.• 1130 Cleveland Rd., Sandusky,
OH 44870.
Phot o Credits: John Kane/ Silver Sun Studios. 64 Secretary Desk
Cov er and pages 3 (Ta ble. Sted), 37. 38. 40. 42, 46.
64. 65: Jerry A nt ho ny. page / 6 (Train): Ellen Butz.
pages 48-53.

November / December 1989 3

 Mark's Desk just a "one-trick pony." This issue has about as rich a collec-
Early this year we had an editorial staff meeting to decide tion of project plans and in fo rma tive articles as any we've
what proje cts should be included in these upcoming winter ever done.
issues. Going into the meeting, I wanted to push for a small The oak trestle table is in response to the growing
secretary writing desk that I felt would have a lot of appeal. I popularity of the Mission style. With its beautiful dark
thought it cou ld be built of pine and given an antique painted finish, it can certainly be considered an heirloom piece, so
finish. don 't forget to date and sign it somew here under the top .
Mark Ziobro, our staff cabinetmaker, took issue with me, Who knows, it may be up for au ction at Christie's someday?
saying that such a fine desk deser ved to be built more as an Our marquetry coverage continues with the Bed-and-
heirloom rat her than a decorator piece. He proposed that Breakfast Tray. Perhaps you'll be inspired enough to make
fine cabinet woods be used with a natural finish to emphasize the transition fro m the craft of duplicating our designs to the
the beauty of the wood. At the time, Mark was a new art of creating your own compositions in wood .
member of our staff and I suspect that he wanted to show us Appropriate to the holiday season , there are plenty of
the high level of work he was capable of doing. projects that will ma ke fine gifts for your family and friends.
After thinking it over , I asked for the opinions of the rest For the kids there's an up-dated version of our old friend the
of the gang . The vote was for the heirloom treatment and Dancing Man (I defy adu lts to keep their hands off him), a
now, after seeing the finished desk, I'm glad I went along nifty old-time Sled, and for the toddle rs, the Duck Carousel.
with Mark 's suggestion. The Box Drum is as much a serious percussion instrument
It's a beautiful piece and certainly reflect s Mark ' s skills in as a toy and may well find its way into some reggae and rock
jo inery and finishing . All of us look forward to the letters bands. And we've wrapped it up with Tony Lydgate's lovely
and photographs which we hope will soon be coming in from Jewelry Box and the Shaker-inspired One-Board Towel
proud readers who have completed this project. Rack. Got enough to keep you busy for awhile?
The staff an d I wish you and yours a fine holiday season, a
No One-Trick Pony healthy and productive new year . . . and perfect miters .
The desk is something special for the winter season but as
regular subscribers know, The Woodworker's J ournal is not Jim McQuillan

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4 The Woodworker 's Journal

 the new, eledronic hand tool that accurately measures every angkt, not iust level and plumb
You r old bubble level is a thing of a one-year warranty against defects in
the past, because now youcan own a materials and workmanship.
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With the push of a button, engineersand experienced carpentersto make it "carpenter's level" you'll ever own.
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November /December 1989 5

I The Events column in your
September/October 1989 issue listed a
Letters
canceled.
Readers should keep in mind that
don't have every part available, but the
company reports that the inventory is
toll-free number to call for informa- sometimes the dates and times for an large, so there is a good chance offind-
tion on the Woodworking Across event can change after we go to press. ing what you need. Direct your call or
America show in Ventura, California. On occasion, it can be canceled letter to the attention ofBrad Morckel.
Howe ver, when I call the number, I altogether . Before making plans, it's a
can't get through. good idea to check and make sure the
It's a tedious job to punch all those
Charles White, Oxnard, Calif. event is still on as scheduled.
holes in the eight tin panels of the
We listed four Woodworking Country Pie Safe project featured in
I have a circular saw in need of
A cross America shows in our your July/August 1989 issue. To make
parts. It was manufactured by the
September/October 1989 issue: Ven- the job easier and faster, stack and
Millers Falls Company of Greenfield,
tura, California; Indianapolis, In- secure the four door panels on a scrap
Massachusetts . When I wrote to them
diana; Columbus, Ohio and Mil- pine board, then drill through all four
for information, I was informed by the
waukee, Wisconsin. All four had the at one time . Use a X2 in. diameter bit
Post Office that Millers Falls is no
same toll-free number. After receiving for the tulips, a X6 in. diameter bit for
longer at that address and that the for-
your letter, we called the number and the stems, leaves and stamens, and a Ys
warding address has expired. Can you
learned (from a recording) that it has in. diameter bit for the border and re-
help?
been disconnected and flO further in- maining large holes . Once the door
Ed Ryan, Hudson, Ill.
formation is available. We then tried panels are completed, do the same for
the regular phone number that came The Millers Falls Company has been the four side panels. Be sure to use
with the original correspondence to us. out of business for several years. safety glasses as the X2 in. and X6 in.
That number is also no longer in ser- However, their inventory of spare bits may break under heavy use.
vice. Finally we tried writing, but our parts for the electric tools was recently When finished, turn each panel over
letter came back stamped "moved - purchased by Ohio Tool Systems, 3863 and use a belt sander to lightly sand
left no forwarding address." Ap- Congress Parkway, Ridgefield, OH down the sharp edges of the holes . I
parently then, all the shows have been 44286; telephone (216) 659-4181. They know this is not the authentic way to

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6 The Woodworker's Journal

~~====================================~,
pierce tin , but for this project, it cer-
tainly is the quickest.
You specified the wrong molding-
head cutter for the Chippendale Small
sas City Woodworker' s Guild, P .O.
Box 413922, Kansas Cit y, MO 64141.
Tom Russell, Suffern, N. Y. Chest project in your September/
October 1989 issue. To cut the molded
I would like to know if the projects edge on the base front and sides (parts The Woodworker ' s Club of
in The Woodworker's Journal can be E and F), you said to use Sears part Houston has 193 members. In the last
made for sale and profit. Or is there a number 9BT2352. The part should be four years the club has donated more
restriction? 9BT3212. than $12,000 to the Make-A-Wish
Eric Belke, Stevens Point, Wis. Ed Gibson, Cleveland, Ohio Foundation. The money was rai sed by
selling items crafted by the members.
This is a question often asked by our For more information on the club ,
readers and the confusion is probably Wood working Clubs write to W.R. Hochmuth, President,
related to the copyright statement that Woodworker' s Club of Houston, P .O.
is found on page 3 of each issue. The Kansas City Woodworker's Box 34481, Hou ston , TX 77234.
Our copyright applies to the project Guild is a non-profit organization for
photos, illustrations, and written copy . woodworkers of all skill levels - from Denis LaLonde writes to tell us that
It serves to protect them from being beginners an d hobbyists to serio us the 55 members of the Durham Wood-
reproduced by others and sold as amateurs and professionals . The Guild working Club meet every second Mon-
plans. However, from our plans, you has been op erating for four years an d day of the month from September to
can make and sell as many of the proj- currently has 147 members. Meetings June. Meetings are held in the wood-
ects as you like, and our permission is are held the second Wednesday of shop of the Eastview Boys and Girls
not needed. In fact, one of the main every month from 7:00 p.m. to about Club, Eulalie Avenue , Oshawa, On-
reasons we feature the Gift Shop sec- 9:00 p.m . at the Moose Lodge, 510 tario. New members are welcomed.
tion in each issue is to provide projects North Sterling, Sugar Creek, Missouri. Write to Denis LaLonde, Pre sident,
for those readers who would like to Prospective members and visitors are Durham Woodworking Club, 221 Mit-
make a little extra money from their welcome. For more information write chell Avenue, Oshawa, Ontario LlH
woodworking hobby . to Gary E. Derzinski, President, Kan- 2V7. ~

Special Limited Offer - Expires Dec. 31, 1989

FORSTNER BITS: ~~¢Tom~YA~~N~~i~~~AST EXPENSIVE
Forstners, the only wood bits that can: POC KET HOl E

• Bore any arc of a circle at any angle

• Make entry holes in veneer, end grain, and knots
• Leave glass smooth walls and a flat bottom hole
POCj(ET I1Ol.E
Pros use them: IN EN D G RAIN

• For start ing rabbets or grooves

• To make pocket holes to attach rails to
tops , and rods , spindles and ~::>O'l:::-..u~==~=:::.
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• To make blind holes for plugs and
• Through holes for locks
3" FORSTNER BIT
Best Because: Inexpensive Because: 1/2" shank; 6112" O/A
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SALE $34. 95

II';
• Precision ground cutting edges, lifters and brad • Our sincere desire to
• Hardened to H RC 50 restore sensible prices PLUS Shlp JHnd l. $4.115
• Mirror polished head to maintain splinter free for woodwork ing tools ORDER '1 0-1322

entry holes SPECIAL INTRODUCTORY OFFERS BUY A H.·pc FORSTNER srr SET (1/4, 318, 112,
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7-pc Brad Poin t Drill Set, a $12 .00 value. a 25-pc Brad Point Drill Set In Metal Index, a ,--
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November /December 1989 7

 Professional Quality Woodworking
Machines At Affordable Prices
FEATURES :
• Parallel Rocker Arm Cutting System :
New Low Price... Drives the blade up and down, avoids blade
breakage, polishes as it cuts , eliminate s
Super 15" Scroll Saw sanding.
• "E·Z Set" Blade change system:
On Sale... $119.95 Clamps any thickness blade (down to "000"
size) easily into the "E-Z Set" pivoting blade
Scroll Saw and Accessories Price Li s t
(Co mpa tible with Penn Stat e Sup er 15" Saw and
Cut intrica te wood patterns easily with this holders mounted permenently on the saw Scroll Saw s of sim ilar design)
ve rsatile machine . Many extras, including: arm s . Sim plifies rea ttac hing blades Super 15" Scroll Saw - complete & assembled
• Accessory package now worth $ 52 .00 especially when making internal cuts. #SAW $119.95 ($10 UPS)
o New " E· Z Se t " Blade change system SPECIFICATIONS: Dust Blow er
• Construction Cast Iro n Keeps your pattern line visible at all times, Our most
: ~~~~~~~~~ ~~t 1 ~:, p~g~~r~~c.e.s.s~r~:. I~~t~[Link].o.n. i~~r~~~~~~i;(l)ded.
• Machine weight 43 Ibs Scroll Saw Stand
• Motor - Heavy du ty totally encl ose d 37" hit, drilled to align with saw, great convenience.
fa n co ole d 110-120V , UL listed , #ST ..reg $39.00, On Sale.... $ 26.00 ($4 UPS)
. . d . Scro ll Saw Blades
b a II b ea ti ng In uct ion moto r #BPK _4 dz asst (2dz Pinend, 2dz #9)..$ 14.00 (0)
• Blades - uses 5" stan da rd & pinend #BPS _2 dz Spiral blades (size #2) .......$ 10.00 (0)
• Stroke length 3/4"
C t S d 1650/ ' " E-Z Set" Blade Change System
• u pee m in (Free with purchase of saw). Includes top & bottom
• Table t ilt 0 - 45 0 to left holders, all hardware and instructions.
Options: Dust Blower & Saw Stand #RET $ 15.00/set (0)
Neptune 1-112" plastic Lettering Guide Set
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Ch 0 12 Blade Assortment $ 3.50 value case alphabet + numbers + FREE patterns.
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a;-". !~
O ·~~.(fl 0 E-Z Set blad e change system..15.00value joot S~~Ch d F h d f .
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combination of these accessories ordered separately

< . / Don't settle for less from importers selling stripped down versions of our Saw
This machine will pay for itself time
Super 125 Planer and again by planing your own
Portable with "Power Feed" • Shipped lumber. At 65 Ibs , you ca n carry this
assembled· Retail value over $600.00 P l an e r t o a job site or mo unt it
perma ne nt ly in y ou r wor kshop lik e
On Sale ... $349.95 any stati ona ry machine . You'll
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. --
~
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fo r a t radit io nal st atio na ry mode l of a
s i m i lar c apaci ty - wit h c o m pa ra b le Planer & Accessories Price List
res ults .
S~~~1 1.2~..~Ia.~~r..-..c~.~.PI:t:.~~~.~~s$~f~~~5 ($15 UPS)
SPECIFICATIONS : Extra Sel of 2 Knives - High speed steel, 12-12"
• Kn ives.... 2ea, 12-1/2" wid e, HSS #PKN $ 25.00/set (0 )
• Motor - 16 Amp , 115V , 80 00 RPM
• Auto Feed rate 26.2 FPM
D~~MhU.t:..-. f0r. V~~U.u.~.t~~~~ff.~[Link]$~~.~8s($3 UPS)
• Cutting speed 1600 0 C uts/mi n Planer stand - Heavy duty, 27-112" high
#PST ..reg. $44.00, On Sale $ 39.00 ($6 UPS)
• Thickness of stock ..... 3/16" to 6"
Ball Bearing Rollers - (Minimum purchase 2 rollers )
• Size ... 15-1/2"H X 22" W X 21 " Bed Build a roller stand, infeed/outfeedtableetc. with these
• Max Depth of cut .......... 1/8 " 13" X 2" Heavy Duty rollers. Purchase includes FREE
plans for buildingtheroller stand shownabove.
#BBR . $ 6.50/ea ( $3 UPS/per order)

DC-1 Dust Collector Add $20

UP S
Freight
( No frt chg if orderedw/Planer, otherwise add$3 UPS
0 )

On Sale ... $189.95 Penn ~ ......, ~ ,",UII" "'UIIC:III'

Our company has been in business for
Keep y our sh o p c le a n and safe from saw d ust
wi th ou r large ca paci ty , co m me rcia l style system .
over 50 years. We unconditionally
This collector has up t o 10 t imes more air flow guarantee your satisfaction with our fine
than a Shop Vac and runs much quieter.
machines. All of our machines carry a
Thirty day Money Back Guarantee and
SPE CIFI C ATI O NS: One year Warranty for Parts and Labor.
• 1h p, 11 0/220V (p re wired 11 OV)
• 61 0 CFM a ir fl ow • 6990 FPM ai r speed
·2 B ags 15"dia X 22" ·20 gallon bag PENN STATE INDUSTRIES-J
• 4" inl et • Casters on base 2850 Comly Road· Phila , Pa 19154
• Wei g ht 75 Ibs • Size - 26 "x15 "x57 "H Order Toll Free 1-800-288-7297 (Ext 90)
Free with Purchase of DC-1 For information 1-215-676-7609 (E xt 15)
20 Feet Of Duct Hose Visa , Master, & Discover Card accepted
4" To 3 " Rigid Adap tor 0 4 " To 2" Flex Adaptor Penn sylvania residents add 6% Sales T ax
Plans For 2 Stage Setup Sources For Piping & Fittings0

FREE ... $ 15 .0 0 VALUE Add UPS Sh ip ping C ha rg es as not ed

Continental U.S. only(Callfor shipping charges toother locations)
8 The Woodworker's Journal
 Readers' ~\~vrON
B( )( )f(,"i",'IIl EO S
Information Exchange ...h.\· tdJ, A\' l'urJIII ..,i:t.\C.\

from the publishcrs of

Fine Woodworking magazine

Looking for an owner's manual for an old band saw? Need a bearing for a
hand-me-down table saw ? Can't find a source of supply for an odd piece of
hardware? Ma ybe our readers can help. Send along your request and we 'll try to
list it here - and p erhaps on e of our readers will have an answer for y ou. Du e to
sp ace limitation s, we'll be unable to list all requests, but we'll include as many as
we can .

I ha ve an 8 in . Atlas tilting-arbor I have a Montgomery Ward 10 in .

table sa w, model no. 3021. It was table saw, model no . THS-2715, that
manufactured by the Atlas Pres s Co ., I need a drive belt for , no. XM-1116.
Kalamazoo , Mich . I need the pinion This belt is a flat cogged belt. Can
gear that makes the arbor tilt. I have you please tell me where I might be
A great
\ " .... lli",w:l,u,rllh'.f(
\"I'.~I""""".J .. ,1'

the parts list, but I need a source for able to get one?
the parts. Can anybody help? If an y Eugene Ny bbler
reader need s a copy of the parts list , RR 1, Box 2 7 project starts
write to me and include a stamped Rushville, NE 69360
self-addressed en velope. with plans.
w. James Otto (But we don't stop there.)
I am looking for an instruction
515 H eath er Lane
book for a Shopsmith Magna En- Want to build your 0\\11 Shaker-
Easton, PA 18042
gineering, model no . ER. style dining table? Wc' H givc yo u
Alfred R . Steuart the plans and a c hancc to watch
Can someone tell me how to use a superb craftsm an make the
174 Middle Island Rd.
spiral blades in my Craftsman 16 in. piece. You 'll also gct a wealth of
Medford, NY 11763
scroll saw, model no. 113.23611O? It solid in formati on you ca n usc on
now handles only 5 in . pin -type furniture projects time and time
blades. I have been given a Craftsman aga in. You 'll d iscove r sho p se t-up
Harold L. Behen benchtop lathe, model no. 103.23870,
tip s, how to usc a varie ty of tools
100 Rob Huf fman Dri ve and am in need of an owner's manual
and machines effec tively a nd
Co vington, TN 38019 and parts list for the same.
more. Includes bookle t. 60 m in.
Dick Heilgenstadt
438 Second Ave,
I(JClI I6
I have a Craftsman/Dunlap bench East Northport, NY lJ 731
drill pre ss, model no. 101.03541. I Risk-Free Invitation
need an owner 's manual and pa rt s I'm looking for the owner's o Yes , plea se se nd m e Build a
list. manual for a Craftsman jigsaw, Shake r Table 'with Kellv Mehler to
Tom Clark examine free for 14 davs, If I'm no t
model no . 103.0404. co m ple te ly satisfied, I ;nay return it
123 Culv ert St. H.L. Goodwin and th e plan s booklet a nd owe
Torrington, CT 06790 134 Tracy Lane, Box 242 nothing. Ot he rwise I' ll he hilled
Shelburne, VT 05482 $29.95. plus $2.50 postage a nd
handling (CT residents add 8% sa les
I have a ShopCraft 10 in. table ta x) .
saw, model no . T6700. The motor I am trying to locate a blade guard , Ch ec k o n e : 0 VIIS (#()('()()4 1)
stopped. I wrote to them and the po st owner's manual and parts list for a o Bcta (#()()()()42)
office returned my letter and said that Homecraft 4 in. jointer, model no . I prefer to pay now : D l'aym cn t e nc losed
they'd mo ved and left no address. 1-1367.
Doe s an ybody know who made the William Pike
motor? 641 Grove N.E.
William M . Volon ino Albuquerque, NM 87108
Curry Road, RD 3 AlJllitESS

Mahopac, NY 10541 I need an owner's manual and parts C ITY

list for an old Sears Roebuck table
I'm looking for a plane iron, cap saw, model no. 113.22411. STATE ZIP

and lever ca p for a Bailey no . 4 plan e. M . Christine MacTaggart

Mail to : Th e Ta unton Pr ess
E .D. Kadera P.O. Box 187 ()J S. Main si., Box J55
3041 Circle Hill Ct . N.E. Lakeside, CT 06758 l'IC \\10\\'n. CT 06470
Cedar Rapids, IA 52402 ~
November/ December 1989 9
 AMERICA
Cabinetmakers'
" Come Back to Amer ican Made Quality· Come Back To Eagle"
Supplies
ROUTER
BITS
Hardwood Suppliers
As a service to our readers, The Woodworker's Journal periodically lists sources
for various woodworking products. In this issue, we are listing companies that
specialize in mail-order sales of domestic and imported hardwoods. This is by no
means a complete listing and we hope to include additional companies in future
issues.
( \. ,j A. ,
Acacia Hardwoods East Mountain Hardwoods
<• • ,
Route 4, Box 130 Route 7
Sen d for the complete 52 page mail- Lubbock, TX 79424 Sheffield, MA 01257
orde r cata log featu ring ov er 900 diff erent Domestic, imported Domestic
route r b it s , s ha p e r c u tte rs and
accessories . American Woodcrafters Educational Lumber Co., Inc.
905 S. Roosevelt Ave. WJ P.O. Box 5373-WJ
(0- ;end me a-;-REE catalog via 3rd clas~ Piqua, OH 45356 Asheville, NC 28813
I mail. (Allow 4-6 wee k delivery.) I Domestic, imported Domestic, imported
I 0 RUSH me a co pyTODA Y via first class I Arroyo Hardwoods Eisenbrand Inc. Exotic Hardwoods
mail. I've enclosed a check for $3 .00 I 2585 Nina St. 4100 Spencer St., Suite J
I for special postage and handl ing . Pasadena, CA 91107 Torrance, CA 90503
I BONUS - Yo u will receive with your I Domestic, imported Domestic, imported
I catalog a $5.00 refund goo d I
tow ards your first purch ase. Austin Hardwoods Garreson Lumber
I MAIL COU PO N TO: Eagle America I Dept. WJ RD 3, Dept. B
I BOX 1099 CHA RDON, OH. 44024 WJ I 2119 Goodrich Bath, NY 14810
I Name I Austin, TX 78704 Domestic
Address---- _ Domestic, imported
\.fi!y'; State -=Zip _ J Badger Hardwoods
General Woodcraft
531 Broad St. WJ
Route 1, Box 262 New London, CT 06320
Walworth, WI 53184 Domestic, imported
Domestic
VISIT THE SHOW NEAR YOU! Henegan's Wood Shed
• Free Workshops Catskill Mountain Lumber Co. 7760 Southern Blvd. WJ
• 100 Exhibits· Win a Jeep 4x4 P.O . Box 450-WJ West Palm Beach, FL 33411
Swan Lake, NY 12783 Domestic, imported

* The
Woodworking Shows *
Domestic
Colco Fine Woods & Tools
K & S Specialty Lumber
P.O. Box 125
Dept. WJ Hill' s Lake Road
~
machinery 2631 Jackson Ave. Carthage, TX 75633
tools· supplies Memphis, TN 38182-0449 Domestic
Domestic, imported
See the Widest Variety of Kountry Kraft Hardwoods
Woodworking Products Maurice L. Condon Co., Inc. Rt. 1
All Under One Roof Dept. WJ Lake City, IA 51449
250 Ferris Ave. Domestic
HUNDREDS OF ITEMS White Plains, NY 10603
Machine ry· Power & Hand Tools- Supplies Domestic, imported McFeely Hardwoods
712 12th St. , P .O . Box 3
November 3-4-5 Oregon Craftwoods Lynchburg , VA 24505
November 10-11 -1 2 So. California 10921-L York Road Domestic, imported
November 17-18-1 9 San Diego Hunt Valley, MD 21030
Decem ber 1-2-3 Delaware Valley Domestic, imported The Sawmill/Woodworker's Dream
Coming in 1990...Arizona. Atlanta. Charlotte.
510 Sycamore St.
Chicago. Cleveland . Colorado , Da llas.
Croffwood Mills P .O . Box 329
Indianapolis. Kansas City. Milwaukee. No. Rt. 1, Box 14-J Nazareth , PA 18064
California , Richmond , [Link]. Salt Lake City. Driftwood, PA 15832 Domestic, imported
So. California .. .and more. Domestic
Talarico Hardwoods
Seminars by James Krenov. Roger Cliffe. Bob
Rosendahl. Rude Osolnik, Nick Cook . Ed Speas.
Croy-Marietta Hardwoods, Inc. RD 3, Box 3268WJ
Peter Good. Ernie Conover . Michael Hanley. 121 Pike St. , Box 643 Mohnton, PA 19540-9339
Luther Judt , and other Master Craftsmen. Marietta, OH 45750 Domestic, imported
1-800-826-8257 or 213-477-8521
Domestic
Wood World
Call for free brochure 8:30 - 5 Pacific Time Dimension Hardwoods, Inc. 1719 Chestnut Ave.
113 Canal St., P .O. Box 825-WJ Glenview, IL 60025
Shelton, CT 06484 Domestic, imported
Domestic ~
10 The Woodworker 's Journ al
 ~\UNTON
Events Il( x )1\,'; \ 'IIl EOS
~

from the publish ers of

Fine Wood'lJ:.'orkill4 magazine
We will gladly list as many events of interest to woodwo rkers as space permits.
Listings are f ree and may include shows, fa irs, competitions, workshop s and
demonstrations. The deadline is six weeks before publication, Nov . 15 for the
January / February issue. Please address announcements to the Events Depart-
ment. Readers planning on attending events should call ahead if possible. Schedul-
ed dates, tim es, and locations sometimes change between publication and the date
of the event.

Arizona: Guilford Handcrafts Center 11 th An-

nual Holiday Expo sition, Nov. 4 - Dec.
Arizona Association of Fine Wood- 23, Mill Gallery and The Shop, 411
workers, 7th Annual Sho w, Nov. 5, Church St. , Guilford. For more infor-
noon to 4 p.m. Los Olivos Adult
Center, Phoenix. For more informa-
mation call (203) 453-5947.
Build the
tion call (602) 246-8245.
Florida: workbench of
California: Woodworking World, The Jack son- your dreams.
ville Show , Feb. 23-25, Jack sonville If you 've ever dreamed of building or
California Woodworking 1990, Juried Memorial Hall. For more information imp roving your 0\\11 workbench,
Exhibition, Jan. 11 - Feb. 16, Brea call 1-800-521 -7623. here's thc boo k that will s how you
Civic Center Gallery, Brea. For more how. Ca lling o n t he insights and
information call (714) 526-7100.
Maryland: discoveries of dozens of ski lled
The Woodworking Shows, So. craftsme n the worl d over, Scott
ACC Craft Fair Baltimore, Feb. 27 Landis examines bench es for a ll
California, No v. 10-12, L.A. County
-March 4, Baltimore Convention ki nds of wood working - fro m a
Fairgrounds, Pomona. For more in-
Center. For more information call tradit ional Shake r bcnch to a mass-
formation call 1-800-826-8257.
(914) 255-0039. produ ced Workmatce .
The Woodworking Show s, San Diego, llurdcoce r, color, 256 pa~es, 2 78
Nov. 17-19, Del Mar Fairgrounds, Del Massachusetts: photos, 185 dm 'w illgs, 4 bench.
Mar. For more information call pililiS, 19 pages of measu red
1-800-826-8257. North Bennet Street School: An Ex- dm 'willgs, #07006 1
hibition in Craftsman ship, Sept. 28
-Jan, 4, 39 North Bennet St., Boston. " If I only bo ug ht onc woo dworki ng
Connecticut: book in 1989 , this firs t an d
For more information call (617) dcfin it lvc book on t he wo rk be nc h
Brookfield Craft Center lith An- 227-0155. wo uld bc it ."
nual Holiday Sale , Nov. 24 - Dec. 24. - Wood worker
Po st Modern Architectural Furniture Michigan:
Exhibition - David Barth, Nov. 11 1001 22
Woodworking World , The Grand
-Jan. 7. For more information contact Risk-free Invitation
Rapid s Show, Feb . 2-4, Stadium
the center at P .O . Box 122, 286 D YES, please send m c The
Arena, Grand Rapid s. For more infor-
Whisconier Road, Brookfield , CT Workbellch Hook to examine FREE
mation call 1-800-521-7623.
06804; (203) 775-4526. fo r 14 days. If I'm not completely
sa tisfied, I ma y re tu rn it a nd owe
Brookfield Craft Cent er, Weekend Missouri: noth ing. Ot hc'm;se 1 will bc billed
Workshops: Table Saw Techn iques I, ~24.95. plu s 2.50 post age a nd
Nov. 11; Table Saw Techniques II, Midwest Woodworkers' Association handlin g. (CT res ide n ts add 8%
Show , Nov. 25-26, Columbia Mall sa lcs t:LX.) # 07 0 061
Nov. 12; 18th Century Car ving I pr efer to pa y now: D Puym c n t enclosed
Techn iques with Eugene Landon, Community Room, 2300 Bernad ette
Nov. 18-19. For more information Drive, Columbia. For more informa-
contact the center at P.O. Box 122, 286 tion contact Karl Haak, P .O. Box
Whisconier Road, Brookfield, CT 7093, Columbia, MO 65205.
.\ Il Ill\ ESS
06804; (203) 775-4526.
New Jersey: CITY
Nu tm eg Wood turner s L eague
meeting, Nov. 20, 7:15 p.m. at the The Woodworking Shows, Delaware ST.\ n : ZIP
Bro ok fi eld Cr aft Center, 286 Valley, Dec. 1-3, Garden State Park , ~I ailto: The Tau nto n Press
Whi sconier Road, Brookfield. For Cherry Hill. For more information call 6.1 S. ~I a in sr., Box .155
mo re information call And y Barnum 1-800-826-8257. NC\ \lO\\1I, CT 064 70

at (914) 225-2798. (continued on page 13)

November/ December 1989 11
 CALL TOLL FREE * SANDPAPER
NO GIMMICKS - GREAT PRICES
*
1-800-523-4777 (East of the Miss.) BELTS: GRITS ASSORTED SHEETS: (9 x 11) PRICE
1-800-541-5537 (West 01the Miss.!
UNLESS OTHERWISE SPECIFIED CABINET PAPER
10" HEAVY DUTY 10" SUPER H.D. 1 X 30 $.69 ea 3 X 24 $ .80 ea 50 /pk 100 /pk
TABLE SAW TABLE SAW 1 X 42 .69 ea 3 X 27 .83 ea 40·D $16 /pk $30 /pk
1 X 44 .69 ea 4 X 213/. .91 ea 50·D 15/ pk 27/pk
2V2 X 16 .73 ea 4 X 24 .94 ea 60·D 14 /pk 25 /pk
3 X 18 .74 ea 4 X 36 1.14 ea 80·D 13/pk 23 /pk
3 X 21 .77 ea 6 X 48 2.98 ea 100 thru 150C 12 /pk 21/pk
3 X 23 3/. .80 ea 2V. X 80 2.47 ea
OTHER SIZES ON REQUEST FINISHING PAPER

NO LOAD PAPER 50/pk 100 /pk

80·A $ 9/pk $16 /pk
50/pk 100/ pk 100 thru 280A 8/pk 14 /pk
Precis ion grou nd cas t-i ron Precision groun d cast-iron 180·A thru 400·A $10/ pk $18 /pk
table and wings . 1'12 H.P. tabl e and wings. 3 H.P. WET IDRY PAPER
motor. Weighs 255 Ibs. motor. Weigh s 500 Ibs.
MODEL G1022 MODEL G1023 PRESSURE SENSITIVE 50/pk 100 /pk
Regu lar ly $345.00 220 thru 600A $13 1pk $23 1pk
ADHESIVE DISCS!
ONLY 5325.00 F.O.B. ONLY 5850.00 F.O.B.
MOBILE BASE 589.95 MOBILE BASE 589.95 6" $1 .06 ea * OTHER ITEMS * *JUMBO CLEANING STICK *
MODEL G1739 Pr epaid To You MODEL G1740 Prep aid To You 8" 1.99 ea *WIDE BELTS $8.80
9" 2.46 ea *ROLLS SEND MAIL ORDERS TO:
THE INCREDIBLE SHOPHELPER 10" 3.05 ea * FLAP WHEELS ECON-ABRASIVES
12" 4.45 ea * PUMP SLEEVES P. O. BOX B865021
A MODEL FOR EVER Y APPLlCATlONI 15" 6.95 ea PLANO, TX 75086
NATIONAL 1·800·367·4101
MODEL. G1630 - YELLOW SHOPHELPE RS
* MINIMUM ORDER $25.00 IN TEXAS (214) 377·9779
FOR TABLE-SAWS
* MASTERCARD, VISA OR CHECK * TEXAS RES. ADD 6% SALES TAX
MODE L G 1578 - GREEN SHOPHEL PERS
FOR SHAPERS *SATISFACTION GUARANTEEDII * SHIPPING CHARGES ADD $4.25
MODEL G1766 - ORANG E SHOPHELPERS
FOR RADIAL-ARM SAWS
IF YOU VA LUE YOUR FINGERS.....
YOUR CHOICE - ONLY $49 95 YOU NEED A
Prepaid To You'

MADE IN USA! 7housands sold at up to £89.95'

The RIPSTRATE holds the work tight against the fence with
Introductory Price! no hands near the blade. Makes perfect, straight cuts.
MODEL G1768 Wheels lock to prevent kickbacks. Requires no adjustment
AVOID $29 95 Pre pa id To You for stock width or thickness.
SET-UP
HASSLES TEMPLATES FOR Over 50,000 now in use in amateur, professional, school,
INCRA-JIGS government, mil itary, and corporate maintenance shops.
Make intricate dovetails , MODEL G1832 One year guara ntee, 30 day money back trial. Only $69
finger-joints , etc....with delivered. Check, M.O., Visa or M.C. Free Brochure.
this amaz ing jig. ONLY $9 95 Prepaid To You

CLAMPING Write or call our to ll free number : 800-421-0256.

MITRE-GAUGE MINI DUST COLLECTORS
Fi sh er H ill Pro du c t s, 3 Fis her Hill , Fit zwi ll iam , NH 03447
The Lowest Pr ice Dealer inqu iries invited.
IN U.S.A.!

This portable
dust collector Is
the answer to the
sm all shop mess.
Motor draws 8
amps and unit
A very handy device that weighs 77 Ibs .
holds the work-p iece
MODEL Gl031
MODEL G1822
ONLy$29 95 P repa id To You ONLY $169 95 Prep a id To You

2406 Reach Rd
1821 Valencia St .
Bellingham , WA 1' . _ 1 / ,
Will iamsport, PA
(717) 326-3806
(206) 647-0801
MON·FRI - 8:30 AM 10 5 PM
MON-FRI - 8:30 AM to 5 PM
SAT. - 8:30 AM 10 1 PM

t2 The Woodworker's Journal

 Events Free ~UNTON
B(X)KS~\'JDEOS
Continued
Subscription to ... h.\" j( ·lkJl I " l..'lJthu.";;L'it."

South Jersey Wood Carvers, 4th An- Woodworking from the publishers of
nual Fall Woodcarving Show, Nov .
18-19, N.J. National Guard Armory, Catalog Fine lVoocl-u.'orkillg magazine
Route 38, Mt. Holly. For more infor-
mation call Jack or Connie Raleigh at
(609) 829-8731. Can for
yountodayl
New York: Our new 120
page. full-color
Woodworking World, The Central catalog is
New York State Show, Nov . 3-5, The here for your
browsing
N. Y. State Fairgrounds, Syracuse. For pleasure. And
more information call 1-800-521-7623. it's packed with over 4.000
new and best-selling woodworking
Woodworking World, The Long tools . supplies. kits & books.
Island Show, Jan. 19-21, Hofstra Our advice i. free, tool
University, Hempstead. For more in- Wondering whi ch ch isel to us e for cu tti ng
deep mortises ? What's th e best hardware for
formation call 1-800-521-7623 .

Constantine Woodworking Courses:

your kit chen cab inets? Th e best finish for
decorative paneling? Our expert Technical
Reps are just a free phone cal l away. It's all
50 years of
Wednesday schedule: Marq uetry, part of the service you get from Woodcraft. woodworking
Nov. 1, 8; Picture Framing, Nov . 15,
29; Wood Finishing, Dec. 6,13 . Satur-
Call free 1·800·225·1153 in 3 volumes.
Orwrtte to: Master craftsman Tage Frid gives
day schedule: Marquetry, Nov. 4, 11;
Using Your Router, Nov. 18,25; Chair you step-by-step instruction in

.'!~!2~~!:!'
Caning, Nov. 11, 18; Furniture Resto - joinery and essential
ration, Dec. 2; Wood Finishing, Dec. woodworking technique. In
9; Picture Framing, Dec. 16. For more P.O. Box 168 6 . Parkersburg. WV 2610 I Furnituremaking he provides
information contact Constantine's, plans for 18 of his most
2050 Eastchester Rd., Bronx, NY distinctive pieces.
10461; (212) 792-1600 . " Fo r the serious (or soon to he
serious) woodworker, these arc
Or egon: the essential how-to books. "
The Woodworking Shows, Oregon, - The Old l louse Journal
Nov. 3-5, Memorial Coliseum, 1O()I I~
Portland. For more information call
1-800-826-8257. Risk-free Invitation
o YES, please send me the Tage
Oregon School of Arts and Crafts : Frid books I've indicated below. If
Holiday Show, Nov. 9 - Dec. 31, Hoff- I'm not completely satisfied with my
man Gallery, 9245 SW Barnes Road, books, I may return them within 14
days and o,,:e nothing. Otherwise I
Portland . For more information call ,,;11 he hilled ~21.95 per book (or
(503) 297-5544 . $49.95 if I order the set) , plus 2.50
postage and handling. (CT residents
Pe nnsylvania : add 8% sales ta:x.)
Tage Frid Teaches Woodworking
Olde Mill Cabinet Shoppe: Wayne o Book 1: Joinery (#070009)
Barton on Chip Carving, Nov . 11-12. o Book 2: Shaping, Veneering,
For more information contact the shop Finishing (#070019)
at 1660 Camp Betty Was hington o Book 3: Fumiturcmaking
(# 0 7004.1)
Road, York 17402; (717) 755-8884. o Saw oyer 20 % on the 3-booJ, se t
(#07.\090)
Woodworking World, The Central
Pennsylvania Show, Nov . 17-19, State
Farm Complex, Harrisburg . For more
information call 1-800-521-7623. .\ IJIJRESS

Texas: CITI'

Paxton Beautiful Woods, 2nd Annual ST.\ TE ZIP

- --
-[:]. ..,; Send your malt-In Inquiry to:
Woodworking Art Fair, Nov. 18-19, P.O. Bo x 71O·CE
Mail to: The Taunton Press
1105 6th Ave ., Carrollton. For more Xenia . Oh io 45385 63 S. Main St. , Box 355
information call Wes Guyer at (214)
245-1192. ~
--
'=:1ZtI=
,
Or call TOLL·FREE -1 ·800·533·3728
Dealer moutrtes Invited
Newtown. CT 06470

November I Decem ber 1989 13

 CABINETRY and ASSEMBLY TECHNIQUES
,,, 1!tUM ilt 11ideo 7ape I
Now you can improve you r woodwork ing ski lls for professional results .. . at home and
at your own pace.
This two-hour video is presented byJohn Parko . a woodworking expert and an experienced highschool and
adult education shop teacher. He will teach you the techniques that are used most often to build furniture .
cabinets . chests and many other popu lar wood projects - using frame and panel construction . John will
guide you through basic Cabinetry such as blade selection . gluing and clampi ng. and then on to advanced
techniques of cove and tenon cuts and cutting raised panels . using the table saw as the major power tool.
Unlike other video programs . this woodwo rking video cove rs a project from start to finish (including stain-
ing). Not only will you learn the proper techniques of frame and panel construction (by watching John build
the Blanket Chest shown) . but also all the critical woodworking know- how of assembly for professional
results . With what you 'll Ieam , you will beable to apply that knowledge to build the chest and many other
wood projects of your choice . Printed chest plans are included treel
Best indication of the production quality of this tape is the fact that hundreds ot high schools. vo-tecns and
universities are now using it in instructional settinqs,

Don't delay, send $29.95 plus $3.00 shipping

for your personal video cassette on woodwork-
ing to .. .
RaGA ENTERPRISES INC.
P.O. BOX 2743J CODY, WY 82414
LI MASTERCARD L VISA u CH ECK
Acc t . No .... __ . . Exp . •. _ _
Dealer Inquiries Signature . _
Welcome N am e _
(307) 527·6671
Address _

City Sta te Zip

QUALITY HARDWOODS
Clear • Kiln Dried • Surfaced 4 Sides • 3f4" Thick
3" to 10" Widths • 2-Ft. to 7-Ft. Lengths
20 Sq . Ft. Packs • Random Widths & Lengths

Red Oak-Plain .. . . . S45.00 Ash . . . S49.00

Red Oak-Ouarter Sawed .. ......... 551.00 Basswood . . . $31 .00
White Oak . . 544.00 Poplar . . ... ... 527.00
Cherry . ... 559.00 Aromatic Red Cedar (Tight Knots) .. . $32.00
Walnut. . 560.00 Cypress . $31 .00
Hard Maple.. . . .. . 533.00 Birch . . . $43.00

Orders Shipped C.O.D. by UPS. Shipping Charges Added.

Texas Residents Add 7% Sales Tax.
To Order Call 214·693·4735 Dr Write to:
K & S SPECIALTY LUMBER
P.O. Box 125 - Hill's Lake Road · Carthage. TX 75633

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14 The Woodworker's Journal

 1/2" Shank Carbide,Tipped Router Bits Moulding Plane Protiles
Product News
To keep our readers up-to -date, we use this column to
feature brief descriptions of tools and supplies that may
be ofinterest to woodworkers. The product descriptions
are provided by the manufacturer and are not a result of
tests or reviews by the editors of The Woodworker's
Journal.

Water Based Acrylic Enamel

The Savogran Company's new
Acrylic Enamel is a non-toxic,
non -flammable and odor-free
spray finish which adheres to vir-
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interior decorating and craft
projects, and yet is strong
enough for industrial purposes.
And because it is also salt and
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outdoors. The water base pre-
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soap and water. For more infor- SPECIAL OFFER: SET OFALL FOUR BITS
mation, contact the Savogran $99.95ORDERITEM #866. Set of fourquickly
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Plate Joining Router Attachment

A quickly installed, easy-to-operate router accessory
that duplicates precision plate joining operation (com-
monly referred to as biscuit joining) for woodworking
profe ssionals and Do-It-Yourselfers is available from
Sears. The affordable Bis-Kit is designed to fit on most
an y router. Sears Bis-Kit is complete with all the com-
ponents necessary to convert a portable router into a
plate joining system. The kit includes the Bis-Kit base
and carri age assembly, a 3-wing carbide-tipped cutter
blade , and a supply of wood joining biscuits. The Sears
Craftsman Bis-Kit (no. 25423) is available at most Sears
stores and in the 1989-90 Power & Hand Tools Catalog.
~
November/ December 1989 15
 LYNES UNLIMITED
Making Toys
in a Kansas
Chicken Coop
wo dozen small tractors fill a bench , each getting its

T own set of oak fenders. Two fully assembled in-

tricately detailed locomotives rest on a shelf, loo king
like works of art. About 20 toy pickup trucks hang in a rack
along one wall, their noses pointed skyward waiting for
finishing touches - two dabs of glue and a pair of head -
lights. Rows of tractor wheels line a shelf near the wor k-
bench . Stack s of truck cha ssis, trailer hitches , train grills and
axle yokes fill cubbyholes set into a wall.
The owners of Lynes Unlimited, husband-and-wife team
Fred Cairns and Kath y Dawson, were busy trying to make
more of their classic wooden to ys, prepare samples fo r an
upcoming craft show, supervi se the excavation for a new
shop building, and entertain a visitor. Fred drilled holes for
mounting bumpers, Kathy glued parts onto a chassis, quick-
ly working her way to the bottom of the stack of par tly
assembled tractors. They tried to stay out of the way of their
two employees. Fred and Kath y talked about how the y
started in the toy busine ss and what it's like now that the y
have become successful at it. And about what it's like to live
Fred Cairns and Kathy Dawson at work in their tiny shop in rural in rural Kansas, yet travel all over the country selling their
Kansas. to ys at craft shows, about 20 a year.

This large train set made by Lynes Unlimited takes up nearly six fee t of track .
16 The Woodworker 's Journal
 Fred said that after more than 10 years in the business he's The beauty of the area is jarred by the proliferation of
finally starting to feel comfortable with all the ins and outs. abandoned farms. The boarded-up buildings, rusting metal
The toy line is selling well; Fred and Kathy are recognized as roofs and falling-down barns are testimony to a region beset
established artists. The hours are as long as ever. The two by chronic economic ills. There are small towns with plenty
find the shows themselves to be a friendly environment. of houses, but virtually no business. A visitor to the area is
"Most of the people who do shows are our age, in their liable to see a foreclosure notice or two tacked to a locked
late 30's, early 40's. We know lawyers, teachers, professors door. The economic reality makes it imperative that Fred
who gave up their professions to do crafts," Fred said. and Kathy continue in their present work if they want to stay
Many, if not most, of the couple's friends were made on the there.
craft circuit, so each show is a renewal of old friendships. The new shop building is going in next to Fred and Kathy's
Fred and Kathy both had careers in social services, doing house. It actually will be on the site of their former home,
rehabilitation work with the handicapped, before they which was destroyed by a tornado two years ago. Luckily,
started Lynes. In fact, Fred and Kathy met while involved in there were no injuries because the family was out of town at a
rehabilitation work, which used woodworking to help show. Their old place was a total loss. The experience,
develop the motivation and manual skills of the handicap- however, reminded them of the strong bond rural people
ped. Neither Fred nor Kathy have formal woodworking share. When they returned, unaware of the destruction, Fred
training. and Kathy found the site already cleaned up and their
Lynes has turned out to be successful, but the nature of the salvageable possessions boxed up and stored. All the
craft business is that it's hard to get too comfortable. There neighbors had pitched in to help out, even though nobody
are times when the cash flow just barely keeps up with ex- could reach Fred and Kathy.
penses. The legacy of the tornado reinforced the family ties to the
"At a lot of woodworking shows, like Springfield area, and even contributed to the decision to finally move out
(Massachusetts), I may only have $30 in my pocket when I of the tiny shop, which was getting too small to handle the in-
get there. If I don't make a sale, I just moved to that town," creasing workload.
Fred said. Inside the present shop is a collection of hand tools and
"Why, oh why, do we do what we do?" Kathy asked stationary equipment that includes a drill press, table saw,
rhetorically. radial-arm saw, lathe, jointer, thickness planer, disk sander,
But despite the uncertainties, Fred and Kathy say they are band saw, portable electric drill, several glue bottles and tape
committed to making a living from woodworking. And the measures. The tools are nothing fancy or expensive, mostly
craft business is, after all, what allows them to live in the inexpensive machines made for hobbyists and homeowners.
beautiful Kansas countryside, which is central to the lives of Except for the abundant supply of toys and toy parts, the
Fred, Kathy and their two children, Jordan, 6, and Caitlynn, shop could belong to a well equipped woodworking hob-
3~. byist.
The fields outside the toy shop window extend into a far The new shop will double their available work area, from a
horizon in every direction. The shop is in a small chicken tiny 700 square feet to an acceptable 1,500. And Fred wants
coop on Fred's parents' farm. It's one of a collection of out- to buy some industrial-quality equipment. Although the
buildings surrounded by the rolling northern Kansas work has begun, Fred and Kathy aren't sure when they'll ac-
farmland. The town, Kimeo, with about 20 people, is too tually be in the new shop. They still have to work out some
small to have its own post office. The mail goes to Greenleaf, details, such as going to the bank to ask for money.
just north of Kimeo. "We've needed to move for a long time and finally we're
Fred and Kathy live in a house on a 20-acre "plot" one getting around to it," Kathy said.
mile away from the shop . The land in rural Kansas is so vast Starting a project before getting the loan or lining up the
that 20 acres does seem like a plot. A mile seems a con- money may seem strange to city folk, but it's apparently a
siderable distance in more populated areas. Here, Fred and way of life in Kansas, where much of the work is done for
Kathy's house is the first one you come to after Fred's folks', barter. The contractor, for example, may take some of Fred
who are semi-retired after a life of farming. The house rests and Kathy's toys as part payment for the work.
on a high spot in the Kansas prairie, with a view of cows graz- In fact, it's the barter system and the extended family that
ing in a far pasture, a clump of trees shading a nearby glen, helped start Lynes and that still helps to keep it going. Fred
fluffy clouds marching off into the distance, and a large mis- and Kathy's tiny shop is rent-free and utility-free. In ex-
sion church serenely occupying an open field. The stone change for the electricity, Fred supplies water for part of his
church and steeple tower over the nearby empty countryside. father's land near Fred's house. Water can be expensive in
(The mission was built in 1904 by the Catholic Church, op- Kansas, where electric or wind-powered pumps are used to
timistic about the area's potential for settlement. Recently extract the water from the huge underground aquifer.
the church suspended regular services.) (continued on next page)
November/December 1989 17
 Lynes Unlimited
1 Continued ,
One difficulty of the rural location is getting and maintain- "It's been an evolving process, and a process that's still
ing tools. There aren't any distributors for woodworking going on," Kathy said. "We'll make something for a long
machinery nearby, so Fred and Kathy have been buying tools time, and then it'll sort of dawn on you: why don't I use a
from a major national mail-order company, which they ask- smaller piece there and save some money," Kathy said .
ed not to be named because they are not happy with the ser- But Fred and Kathy also spend a lot of time making sure
vice of the tools. that they market a quality toy. If it isn't perfect, it's not a
"We don't want to give (them) any publicity if we can help Lynes toy. As Kathy said: "It's just got to be right. When
it, " Fred said. you roll it and you see only three wheels moving .. . that's
Dealing with a company that sells mainly to homeowners yeck."
presents problems to professionals. When tools break down Because they make hundreds of toys a year, with a
or need servicing, the repairmen that come aren't always well minimum of help , they do everything they can to streamline
trained. One repairman who serviced the thickness planer production. For example, many of the toys share a common
recently gave it a new and disturbing noise, Kathy said. chassis. Their shelves are filled with sub-assemblies that can
When they called to complain about the noise, the company be used for a lot of the toys, depending on what orders they
gave them the runaround. receive. There are stacks of chassis assemblies, tractor
"Their response was, 'Well, I guess that's what a two-year wheels, hoods, engine assemblies and other miscellaneous
old planer is supposed to sound like,' " Kathy said. parts. There are bins of axles, wheels and pins.
But depsite the drawbacks of the remote spot, the two If the list of toy parts sounds something like a machinery
have no plans to change their lifestyle or locale. catalog, it's by design. Lynes specializes in farm equipment,
"We're very committed to rural living and it's worked out trucks, and construction machinery. Fred seems to have tap-
for us. We like Kansas," Kathy said. "But there aren't a lot ped into a yearning for a type of toy that appeals to adults
of advantages here as far as cultural things." and children alike. One new design is a cement mixer, with a
Lynes' rural location does give the company a certain local barrel turned from laminated oak and padauk. Another
notoriety. Fred jokingly boasted that Lynes is one of the top popular design is a steam shovel, with pistons that work.
four manufacturing concerns in the county. He can be sure And there's the popular bulldozer with a track system that
of that fact even without any revenue statistics. There are ex- Fred designed. Fred is especially proud of the fully func-
actly four businesses. When the local television station wants tional track for the bulldozer and steam shovel. A lot of toys
a business story, Lynes IS one of the obvious choices. have track systems that are fixed, but Fred uses a clever
"We were on the Christmas show, as one of the four system of wood slats and leather strips to make a movable
businesses in the county," Fred said. track.
Being out in the country may help Lynes get governmental Fred and Kathy would also like to concentrate more on
assistance. Fred said that their property had recently been toys as an art form, which they believe makes their toys so
named an enterprise zone, making them eligible for special successful. Their toys are now being sold in galleries, and on
tax treatment. The state is also helping to promote Lynes and special commission, and they'd like to increase that part of
will include the firm in a special exhibition of Kansas crafts the business.
to be held at one of the country's premiere shows, The New Getting people to see toys as works of art, however, is
York International Gift Show. sometimes a struggle. Kathy said people seem to resist the
The road to New York from the first toy has been a long idea that something designed for play can also be art. And if
one. In fact, when Fred decided to leave his rehabilitation people do agree the toys are art, they often say the toys are
job in 1978, he opened up a shop doing general custom too nice to give to children. Fred and Kathy say that it's
woodworking. He started making a few toys, and that part parental expectation as much as anything else that leads
of the business seemed to take over. children to destroy toys. It may be hard for some people to
"It just evolved to the point where everything else just sort believe, Kathy said, but children can readily be taught to
of took the back burner," Fred said. respect fine toys . And, after all, the alternative to giving
By the time Fred and Kathy married, in 1982, the direction children fine toys is giving them junk.
was established: from making and selling toys locally, to sell- "You teach your kids taste when they grow up. It might as
ing wholesale, to doing small craft shows, to finally winning well be good taste," Kathy said.
entrance to the national juried craft exhibitions. At the ma- Fred is also working on designs to move in other directions
jor shows, Fred and Kathy generally sell directly to retail than toys. He and one of his employees, Don Bruna, are
buyers, as well as taking orders for wholesale accounts. working on a traveling case for gun collectors. But design
Along the way, Fred has developed unique designs . time is hard to find in the crush of day-to-day orders. It
"In order to survive in this business you've got to be uni- always seems like the time will be available next week or the
que," Kathy said. week after.
Kathy keeps the books, arranges the show dates, makes "Let's get this run over and then we'll have the time. Then
toys, keeps house, and helps organize production. The another run comes along . We never get the quality time,"
grandparents often watch the children. Life and work within Fred said.
the tiny shop is now a routine. Fred and Kathy seem to step in Editor's Note: The Woodworker's Journal has published
and out of the production line, hardly missing a beat as they plans for two of Lynes' toys. The Farm Tractor and Wagon
instinctively know what remains to be done to finish a run of was featured in July /August 1989, and the Classic Pickup
toys. Truck in November/December 1988. a
18 The Woodworker's Journal
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20 The Woodworker 's Journa l

[j~Woodworking Basics l
ven though it' s a fairly simple fatigue or the overeagerness, but we But hinges fall into several broad

E operation, mortising for hinges

often tests the patience of ex-
perienced woodworkers . It just doesn't
can help with sound technique . First,
though, a word about hinge types.
There are an extraordinary number
categories: hinges that ar e applied to
the surface, hinges that mount into
pre-drilled hole s and hinge s that need
seem fair that a slip of the hand here of hinge types on the market today. to be recessed or mortised in place. The
can ruin hou rs and hours of meticulous There are wrought iron hinges for an mortised butt hinge shown here is still
work. But slips often do occur, some- Early American look , there are rule the most common type of hinge for
times because of a rush at the end of a joint hinges for ta ble leaves, there are traditional cabinetry, although con-
project - hoping to get those doors on offset hinges for face-frame kitchen cealed pre-drilled hinges are supplant-
before calling it a night - and some- cabinets, there are concealed hinges for ing it in contemporary styles. Note that
times because of fat igue. Euro-style cabinets and there are pivot hinge dimensions are commonly given
Another reason woodworkers ma y hinges for mounting on the tops and as length by width - where length is
foul up the operation is that they just bottoms of cabinet doors. There are the measure along the joint or barrel,
plow into it without having anyone variations of all the common hinge and width is the measure of the open
show them the essential tricks of the types and there are hinges for every hinge. So the width includes both
trade. We can 't help you with the conceivable purpose. leaves and the space that the jo int ta kes
up between them.
In this article we'r e talking about
only the butt hinge. First we'll go
through the basic hand-tool pro -
cedure, then we'll discuss a variat ion
using an electric router. If you ma ster
the technique of applying thi s basic
hinge, you'll manage the oth er styles

Mortising more easily.

Butt
Hinges
Photo 1: The tools rail into three
basic categories: layout, cutting and
mounting. The layout tools needed are
a combination square, a pencil, a razor
knife and a marking gauge. The cut-
ting tool s required are chisels and a
do vetail saw. The mounting tools are a
screwdriver, an electric drill and a self-
centering drill bit called a Vix bit.
The tools here are representative in
the sense that you don't necessarily
need an identical set to mortise a hinge.
One X in. or %in. wide chisel will get
the job done as well as the two we
usually use in our shop. You can get
away without the Vix bit. A small
brad-point or twist drill will do the
trick . The Vix bit makes mounting
easier by centering the pilot hole s for
the screws.
(conti nued on next pa ge)
21
 Woodworking Basics
Continued
Il...=::::::==================================================================
method of mortismg for each leaf
separately. With either method it's best
to set the depth a little under the actual
thickness .

Photo 2: Locate the hinges on the

door. The precise location doesn 't Photo 4: Establish the mortise width
matter as long as the pair of hinges and deepen the cuts. Use the combina-
supports the door properly. Whatever tion square and the razor knife to
look s good is usually fine . Measure establish the width of the mortise. Set
Photo 6: Use the dovetail saw to
from top and bottom and lightly mark the square from the actual hinge. With
make a series of kerfs almo st, but not
the location of both hinges with a pen- the hinge in one hand and the square in
quite, to your marked depth. First hold
cil or razor knife. Just mark one end of the other hand, slide the rule until the
the handle of the saw down and make
each hinge; a light nick will do. You 'll end rests against the joint. Slide the
an angled cut from the depth line to the
establish the other end from the actual combination square along the edge as
width line. Then slowly raise the han -
hinge. shown, using it to guide the knife . First
dle as you work the saw, deepening the
make a light cut and then bear down
rear of the cut but staying within the
and deepen the score line. Also use the
mortise . Make the kerfs X in. to Ys in.
combination square as a guide to
apart.
deepen the side cuts.

Photo 3: Start scribing the hinge

profile into the door, setting the actual
hinge in position, and establish the top
and bottom mortise perimeter. Use the Photo 7: Use the corner of a small
razor knife to lightly sever the wood chisel to widen the kerfs as shown, cut-
fibers as shown. Don't set the width, or Photo 5: Use a marking gauge to set ting one side of the kerf and then the
back line, yet. (Note that the joint or the depth . The depth is taken from the other . The chisel should be very sharp
barrel overhangs the edge of the door. hinge thickness. You can either recess so you can pare away the waste without
Some craftsmen let it overhang fully, both leaves of the hinge into the door having to use excessive force. If you
others set it halfway in, deepening the (or case) and mount the other leaf have to push too hard, you're likely to
mortise a bit along the edge.) flush, or use the more common slip.
22 The Woodwork er' s Journ al
===================================================================,
best coordination, it's difficult to cut a Photo 11: Clean up the mortise with
perfectly str aight line with the ro uter . a chisel. First pare to the lines, and
Follow the steps detailed in Photos 2 - 4 then use the shoulders to guide the
above, using the knife to establish the chisel as you square the corners.
outlines of the mortise. Try to cut as
deeply as possible with the razor knife. More Mortises
Then proceed with the following steps. Once you've cut your first mortise
The mounting is also the same as with successfully, you've gone most of the
the hand procedure. Note that we use a way toward mastering the process of
laminate trimmer for the routing. It's mounting butt hinges. All that remains
lighter and easier to control than a full- is to cut the second mortise on the
size router . door, and the matching case mortises.
Photo 8: Pare to final depth. With To line up the case mortise with the
most of the waste removed, use the flat door mortise it's best to use the
of the chisel to slowly pare the mortise already-cut mortises as a guide. If you
to final depth. Work deliberately. If rely on measurement alone, small er-
the chisel starts to cut into and lift the rors can mount up and create an ill-
grain, come in from the other direc- fitting door. First, mount both hinges
tion. As you get close to the depth, try on the door and set it into the opening
the hinge in the mortise. Run your exactly as you want it to hang. You'll
fingers across the top of the hinge and probably need to use thin cardboard as
door to judge whether the two surfaces a shim. Then mark the location of the
are flush . Your fingers are a better hinges onto the front or sides of the
judge than your eyes. case. Scribe the sides and width with a
combination square and the depth with
the marking gauge .
Often it's not easy to mark the hinge
location on the case because the pin
obscures the top and bottom edges of
Photo 10: Clamp a support block the hinge leaf. And opening the door
along the workpiece edge so that you disturbs the position you're trying to
have a wide enough surface to keep the achieve. To resolve the problem, it's
router fro m tipping. Mask off the best to make a simple positioning aid.
edges of the mor tise to make it easier to From scrap stock (X in. plywood
see the line. Use a ~ in. rad ius straight works well) cut a template that's the
bit and set it to the depth of the hinge same thickness and height as the door.
leaf. Start a little off the line, and move With the hinges mounted to the actual
toward the line as you proceed. Stay door, transfer the locations of the free
just a hair inside. hinge halves to the template, and drill
through the open hinge holes into the
Photo 9: Setting the hinge. Use the template. Now you can position your
Vix bit, if you have one, to drill pilot template, called a story pole, on the
holes for the screws, using the actual case and lift off the hinge locations.
hinge as the guide. Make sure you You also use it to locate and drill the
mark which side of the hinge goes on holes.
the doo r an d which goes on the This method is especially handy if
cabinet. The holes are sometimes dif- you have a lot of doors to hang. You
ferent enough to throw off the fit of a can set a pair of hinges in the first door
door. and then use the template to layout the
Rou ter Method mortises on the remaining doors and
case sides. If you use the story pole to
You can use the router to cut the transfer the mounting holes, you
mortise without a lot of elaborate jigs. should make sure the hinge leaves have
The trick is to establish the outlines of uniform holes from side to side. If not,
the mortise as you do with the hand- use the story pole for laying out the
tool method, and use the router for mortise, but use the actual hinges for
removing the waste only. Even with the marking and drilling the ho les. a
November /December 1989 23
 In The Sho~

TWIN BLADE WOBBLE 6 ~' STACK

8 " STACK I SINGLE BLADE WOBBLE

DADO H EADS
dado head is a cutter that's based on their rotation around the cen-

A used on the table saw or radial-

arm saw to make cuts wider
than the kerf a single saw blade can
tral hub cam (Fig. 2). Most single blade
~' L....z. 'W\~ ..........A.~ 'NO_ _~
~=~"" ~ .....
make. Although it's possible to get by
without a dado head and make wide
cuts by repeatedly readjusting the rip
fence or workpiece, this is not a very
practical alternative.
Types of Dado Heads variation of the stack dado head is
There are two types of dado heads, Freud's new safety dado head, which
wobble dado heads and stack dado features a high shoulder in front of
heads. With most wobble dado heads, each tooth (Fig. 4).
models adjust to any dimension from
a single blade is mounted on a cam-like Ys in. to IX6 in., while the twin-blade
hub (Fig. 1). By rotating the blade on variety adjusts to any dimension from
X in. to IX6 in. All wobble dado heads
have a scale on them that indicates the
width of cut, but a practice cut should
be made first to check accuracy.
Stack dado heads are essentially two
saw blades with chipper blades sand-
wiched in between. The standard stack
dado head includes four Ys in. chippers
and one X6 in. chipper, or one X in.
chipper, two Ys in. chippers and one X6
the hub, the width of the dado cut is in. chipper (Fig. 3). By combining Some non-carbide dado heads are
adjusted. More wobble produces a chippers, any width in X6 in. in- still available, but we don't recom-
wider cut. A variation of the standard crements from Ys in. to IX6 in. can be mend them. Carbide outlasts steel by
wobble dado head is the Sears twin- achieved. For finer adjustments a shim at least 10 to 1, and with steel only
blade version, which features opposed set is required, or spacers can be made marginally less expensive than carbide,
blades each tilting an equal amount of cardboard, paper or sheet metal. A the money saved doesn't justify the
24 The Woodworker's Journal
============================================================-,
shorter life. Whatever type of dado of-cut than larger heads. However, this dado head is figuring out just where
head you use, keep in mind that, after isn't a problem unless you work in very the sides of the cut will fall . There's
sharpening, the width of your dado cut thick stock. Most cuts with the dado really only one way to do this. With the
will probably be a little less than the head will be at a depth of less than 1 in. saw turned off and unplugged, rotate
width the same blade produced at the Where a greater depth of cut is re- the blade by hand until you locate the
same setting before sharpening. quired you'll probably need several farthest tooth. Measure over from that
Primary Function passes to achieve the full depth, tooth to the rip fence. Don't assume
especially if the cut is wide. Your ear is that the farthest tooth at one setting
Although a dado is specifically a the best judge of your saw's power will be the same tooth for all settings.
groove that's cut across the grain of a limitations. If the saw is laboring, Mark the teeth with colored felt-tip
board, the dado head can also be used you'll not only shorten the motor's life pens to identify which is the farthest
to cut rabbets, make tongue-and- but chances are the cut will be rough. tooth for settings you use frequently.
groove joints, and cut tenons, grooves There are a number of ways to use For the distances that you use fre-
and lap joints. As is the case with the dado head. The two most common quently, cut spacer blocks to fit be-
regular saw blades, if you work mostly uses are in conjunction with either the tween the fence and the dado head,
in plywood, it's a good idea to pur- rip fence for making grooves and rab- then adjust the fence until the farthest
chase a stack dado head that's design- bets (Fig. 6), or with the miter gauge tooth for that setting just touches the
ed for use in plywood. General- for cutting dadoes (Fig. 7). As the rab- spacer (Fig. 8). Be sure to unplug the
purpose dado heads are designed for beting illustration shows, you'll need saw before making this adjustment.
both ripping and crosscutting. Dado to mount an auxiliary fence with a Always make a test cut in scrap before
heads for laminates and composition cutout for the dado head for this using your project stock. It's difficult
board have more teeth and produce a operation. Always use a pushstick for to set the width exactly using the dials
smoother cut. ripping cuts. on wobble dado heads. The dials are
The size (diameter) of the dado head there mainly as an indicator, and the
you buy will depend on the power of
your saw. Many light-duty 10 in. table
saws are not capable of powering an 8
in. dado head. To make a simple com-
parison, powering a dado head that's
been set for a % in. wide cut is like
ganging six Ys in. thick saw blades side-
by-side. The amount of wood that's
being removed in a single pass is six
times the amount that a single blade
removes in a single pass when set at an
equivalent height. A 6 in. diameter
dado head requires less power than a
larger diameter dado head set for the
same width, mainly because the test cuts are needed to check and fine-
smaller arc the blade transcribes means tune the setting.
there's less surface area in direct con- If you've opted for a stack dado
tact with the board (Fig. 5). head, you'll not have any trouble
Smaller diameter dado heads will locating the dado. Just measure from
also usually be capable of less depth- the outside face of a tooth. As with
wobble dado heads, spacer blocks
come in handy for setting the rip fence
with distances you use frequently.
However, because the chippers that
come with the cutter usually don't
allow fine-tuning the dado head width ,
You'll also need a special table saw you'll be left with two options for
insert to use with your dado head, since widths that can't be measured in X6in.
the slot in the regular insert isn't wide increments. First, you can use shims or
enough to accommodate the dado spacers to fine-tune the width, or sec-
head. You can make your own insert ond, you can dimension the board so
from scrap plywood if a commercial that it will fit into the dado you cut.
dado head insert for your saw isn't Thicknessing the board is easy if you
available. Just be sure the insert is flush own a planer or thickness sander, but
with the saw table surface and does not even if you don't own one of these
protrude above it. tools there are a few simple tricks to get
The tricky part of using the wobble (continued on next page)
November/December 1989 25
 In The Shop
Continued

a good fit. Planing or sanding just the cut, such as would be made in the side
end of the board to reduce the thick- of a bookcase to accept a % in. thick
ness a little is the easiest way. Or you shelf. We looked at the accuracy of the
can readjust the fence or workpiece dado groove width, the smoothness of
and make a second cut to widen the the sides and bottom, the profile of the
dado a little. When you are making bottom, and the tendency to chip-out
cuts wider than IX6 in., or cutting lap as the cutter exited the board. In order
joints or tenons, you'll usually need to be able to evaluate the cutting quali-
several passes to complete the opera- ty of the dado heads, we did not back
Now you can use this ONE power-feed shop
to turn rough lumber into moldings, trim, tion. Overlap the cuts at least X6 in. to up our test cuts, although in practice
flooring, furniture - All popular patterns, Rip- get a smooth bottom. crosscuts should always be backed up
Plane-Mold & Sand ... separately or in comb i- with scrap to prevent chip-out.
nation with a single motor. Low Cost ...You Shop-Test
can own this power tool for only $50 DOWN! Sears 7 in. Wobble Dado Head: This
We tested four different dado heads. model plowed a reasonably smooth
I BA~1JREE',TRIAL! I Two were wobble dado heads, the
Sears 7 in. single blade model with 16
dado in our cherry board. The sides of
the cut, although a bit rougher than the
teeth, and the Sears 8 in. twin-blade cuts produced by the stack dado heads,
RUSH COUPON TODAYl Excalibur, with a total of 48 teeth (24 were very acceptable. The vibration to
------------ teeth on each blade). The other two our Rockwell Unisaw was minimal.
Fo le y-Be ls a w Co.
~ 6301 Equ itabl e Rd. were stack dado heads: Freud's 6 in. The width measured exactly % in. on
. ~ . De pt. 91492 stack dado head that we've used in our
Kan s a s City, MO 64120 our first try. The bottom of the cut was
o YES Please send me complete facts about PLANER shop for years, and Freud's new 8 in. flat (Fig. 9) and did not exhibit the con-
-MOLDER- SAW- SANDER and details about3Q-Day safety stack dado head, which has
trial offer . cave profile that we often see from
N a me - - - - - - -- - - - - replaced the older stack dado head in wobble dado heads (Fig. 10). Finding
Address the Freud line. The 6 in. Freud stack and identifying the farthest tooth was
City _ dado head has 18 teeth per blade for a no problem with this 16-tooth blade,
total of 36, while their 8 in. safety dado which in turn made it easy to locate the
State Zip
head has 48 teeth total (24 per blade). fence. The corners of the cut produced
~---------------~ The chippers on stack dado heads each by this wobble dado head were square.
CASES and BINDERS have two teeth . Sears 8 in. Twin-Blade Wobble
Freud says that the new safety dado Dado Head: Although it costs twice as
head eliminates the kickback and much as the single blade Sears model
reduces the tendency to climb that we tested, this dado head wasn't
traditional dado heads have. This is measurably superior to the less expen-
made possible by the addition of a sive blade.
special high shoulder in front of each Although the instructions clearly
tooth. The shoulder limits to .2 mm the state that the bottom profile of the
cut each tooth can take with each dado can be controlled by the dado
revolution of the blade. It does not head's positioning on the saw arbor,
limit the depth of cut. we did not find this to be the case. We
Handsome tried several positions, but all pro-
The Sears and Freud dado heads are
binders hold 12 issues,
open flat for easy reading. fairly representative of what you might duced the same twin scoops at the bot-
Compact box cases also available. expect with wobble and stack dado tom of the dado (Fig. 11). To its credit,
Please send your order with payment to: heads when it comes to both cut the dado head produced smooth sides
JESSE JONES INDUSTRIES, Dept. WWJ characteristics and ease of setup. We'll and no chip-out. Our initial setting at
499 East Erie Ave. , Philadelphia , PA 19134 let you come to your own conclusions %in. on the dial produced a cut a little
Enclosed is $ .
Add $1 p er unit Postage and Handling.
as to what's best for you. wider than the desired %in.
Out sid e U.S.A. $2.50 (U.S. currency only). The current prices of the models Freud 6 in. Stack Dado Head: Our
PA re sid ents add 6% sales tax . tested cover a wide range. On the low old stack dado is still the favorite, even
I Size : 0 Standard 0 Oversize end is the Sears 7 in. wobble dado though some of its teeth are chipped
(Vol. 10/2 - present) (Vol. 4 /5 - Vol. lOll)
head, with a catalog price of $39.99. and it's due for a cleaning and sharpen-
Please send _ _ Binders; _ _ Case s
for The Woodworker's journal. Next up the line is the Sears twin-blade ing. There's no fussing with locating
Binders: 1 - $9.95 3 - $27.95 6 - $52.95 wobble design, with a catalog price of the farthest tooth, the sides and bot-
. Cases: 1 -$7.95 3 -$21.95 6 -$39.95 $76.47. Freud's old 6 in. stack dado tom of the cuts are smooth, and there' s
Nam e (Please Print) _
head is being discounted for about $95, no chip-out problem. The combination
Stre et _
and their new 8 in. safety dado head is of chippers produced a cut just a little
City _
$119, with the 6 in. version a little less, under %in. wide. Our only complaint
Stat e /Z ip _
$109 in a current catalog. is the small V-cuts that the two outside
Charge Orders (Mini mu m $15): Am Ex, Visa . MC . DC Our test consisted of crosscutting a blades leave in the corners (Fig. 12).
accepted. Se nd card name , " , Exp . dale.
Ys in. deep by % in. wide dado in We'd prefer a blade that leaves the cor-
~~~~~~=~~~~~~~~-~ cherry. This is a common size dado ners square. Freud says the V-cut ac-
26
, The Woodworker's Journal
commodates some of the excess glue size of the V-cuts that this dado head
when you assemble a joint. leaves in the corners.
Freud 8 in. Safety Stack Dado Head:
Safety Reminders
There are
This newest o ffering from Freud was
not heads-and-tail s above the other Although a dado head doe s not over 4,000
model s as we had expected . The sides usually protrude very far out of the money-saving
saw table throat, it is an accessor y th at
and bottom o f the cuts were smooth
requires great care in use. Don't feed
reasons why
enough, but no matter how many times
we remounted this dado head it still stock too quickly or take too deep a woodworkers
produced tear-out on one side as it ex- bite . If your saw is not capable of rely on Constantine.
ited the board. It's possible that we had powering the dado head through a % Unique products. Hard-to-find products.
a defective blade, or that one too th was in. wide by 1 in. deep cut in a single 4,000 woodwork items! Everything important
pass, then make the cut in two passes, for people who like to Build-Restore-Repair-
not machined properly, but the tear- Refinish- and like to save money doing it.
out was annoying. Another anno yance tak ing a X in. deep cut each time. Cabinet or fum iture wood? Choose from
When using a stack dado head, over 200 sizes and kinds. Beat up surface
was the fact that the blade plowed a to cover? Choose from 150 richly-grai ned
make certain that chippers and blad es veneers. Plus 500 plans ... cabinet hard-
r\a....9 are all facing in the right direction , and ware .. . 96 How-To Books . .. 118 carv-
ing tools and chisels ... 76 inlay designs

~
that the teeth of the chippers fit in the
. . . and lots more for One-Stop, Right-Price
spaces created by the gullets of the out- Shopping without leaving home!
side blade s. Stagger the chippers so
they are evenly spaced . CONSTANTINE Est. 1812
2051N Eastchester Road. Bronx, NY 10461
With wobble dado head s, check that
"\A.10 the center hub is not cracked or broken CONSTANTINE Est. 1812

~4
before mounting the dado head. 2044 N Eastchester Road
Bronx, NY 10461
With all dado head s, make certain Name _
that the blade s clear the sides of the slot
in the tabl e saw insert before tu rnin g
the saw on. Also make sure that the nut
1=\A.1 ' hold ing the dado head has been fasten-

~
ed tight. Remember, the saw should be [Link] DIRECT CLOCKS
unplugged for any and all adjustmen ts.
Never attempt to use the dado head
\1 AND FURN ITURE
-- -- or an y oth er saw blad e without the Do -It-You rself
Kits or Asse mb led
throat insert. When using the dado an d Fini shed
~\A..1Z. head in conjunction with the rip fence, • Grandfather Clocks,

~
always use a pushstick and keep your M antel and Wall Clocks
hand s well away from the blade. • Cabinets, Chests, Tables,
Chairs, Desks...and more !
Wear a dust mask , eye protection • Sol id 3 /4 " Blac k Walnut.
and a short-sleeved shirt. The se three Cherry, or Oak
• Heirloom Q ual ity
items should be routine whenever you • Solid Brass West German
~<:7\=:" 10"",11"", 12 ~E.. use the table saw, not just when using Movements and Dials
'C-XAAAe.~"""E.~
'F':::>=.. L'-f"-?::..\"Y
the dado head . • Money Bac k Guarantee
Kit Prices
Starting at $89.50.
path X2 in. greater than the desired % Sharpening
in. width. We'd pre fer that the cut was We don't advocate the do-it -your-
a little under % in. rather than over , self approach to sharpening. If blade s
since it' s easy to sand stock down, but are sharpened incorrectly, they can
very hard to grow boards thicker. A grab and tea r stock right out of your
wider cut is an even greater problem if grasp. If you crack the carbide and a
factory-milled %in. stock mu st fit into piece of tooth breaks off during use, it
the dado, since this stock usually becomes a dangerous projectile. We'd
measures a little under %in. by the time rather send our blade s to someone who
you've finished sanding. sharpens them for a living and is set up EMPEROR
(' L O CI" ( 'O:\IB\ l" Y
To their credit , when Freud designed with the right machinery for the job. World 's Large st Manut act urer ot Grandt at her Clock Ki ts
Dept. 3321, Emperor Indu strial Park
this new blade they placed safe ty high All sharpening services are no t Fairh ope , AL 36532 • Phon e 1·205-928-2316
on the list of priorities. There's no equal, and it ma y take several tries I am uuerested in
o Do -u . vou rsen Kils 0 Fini shed Cloc ks 0 FinIshed Fu rn itu re
qu estion ing th e fa ct that t h e before you find a service who se stan- Name _
shouldered design of th is blade cuts dards satisfy your s. Check the Yellow Street _
do wn on kickback and climb, especial- Pages or ask local millwork shops or City _
ly if you work on a radial-arm saw. other woodworkers for sharpening ser- State Zip _
Also to thei r credit , Freud redu ced the vices in your area . ~ (Please Ptl nt )

November/ December 1989 27

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Wood Iden""calion Handbook StO CARPENTRY Woodwork Joinls (Hayward) S9
Rouler Handbook ISpielman) SI 0.50 Adhesives and Glues: How to Choose and
Timber Frame Home (Benson) S23
The Rouler (Rosenthal) $14 WOODTURNING Timber Frame ConstruClion (Sobon) 512
Use Them (Millet ) Sll
Projects lor the Router IChall m) S9.50 Turning Wood IRollan) SI7 Building Small Borns. Sheds, Shellers SI2
Bank Saw ProleclS (Crabb) SQ.50 The Procllce 01Woodlurnlng (Dorlow) S22 Housebulldlng. Do-II-Yoursell GU ide HANDTOOLS
24 Rouler ProjeclS IBlandlord) S8 50 The Crall 01Woodlurning (Samsbury) SII (~eCri s l olor o ) SI 6 Jopanese Woodworking Tools (Odale) S23
24 Table Saw Prolects (Blandlord) S8 50 Woodturner's Companion (Roszklewlcz) 114 Carpentry (LewIS) SI 8 The Making 01 Tools {Weygers) SI 3
Scroll Saw Handbook (Spielman) SI 2 50 The Cralls man Woodlurner IChlldl S12.50 Treall se on Slalfbullding & Handrall mg 121 PlanecralilSainsbury) SIO
Scroll Saw Pallern Book {Splelmon) SI2.50 Woodlurning Projecls & Techniques The Sleel Squore (Selgele) SQ
Scroll Saw PUllie Pall erns (Spielman) S1 2.50 IBoull er) SI4 Dlcllonary 01 Tools UsedI" Woodworking
Shaper Handbook (Slephenson) S16.50 Polychromatic Assembly lor Woodlurnlng WOODCARVING and Allied Tro ~ es ISoloman) S56
Gell ing Ihe MoSi oul 01 Your Shaper IBrown) SI6 Sionley Planes 1969 P" ce Guide 15
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Turned Bowl DeSign IRall an) SI 7 Sculptrng Wood 11InqUlsl) S28
Gell ing the Most oul 01. Series Books· Award Winning Designs lor Woodturnlng Vol" e (Borlow) SI 4
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How to Choose & Use an Air Compr essor $9 IJacobson) SI2 How 10 Make Animated Toys IWakelleld) SI 2
Creative Chain Saw Projecls $9 Making Wood Decoys (Tangerman) SIO Toymoker's Wooden Vehicles (B u ckla n ~ ) SI 2
Woodlurner's Projecl Book (Jones) SI 2 Chip Carving (Barton) ' SI O
Your Choin Saw (M c~ullo ch ) SQ The Principle and Practice 01Ornamental BI,llard's Dall lmg Wooden Toys SI 2
Tool Gll ndmg & Sharpenmg Book SI Moking 01Huntmg Oecoys IVeosey) $42 Handcrall ed Wooden Toys IBuckland) SI 2
or Complex Turning IHoli l aplle l1 S22 Songbird Corving wil h E. Muehlmall S38
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Cham Saw Lumbermaking IMalool) S22 Walerlowl Pamlmg (Veasey) $44 (Plerce) SQ
Woodlurner's Bible ( B l o n ~ l o r ~ ) SI6

28 The Woodworker's Journal

 )

\U E TRY:
The Empty
Window Method
by Nicholas Mariana

he window method of mar- method for almost any marquetry pat- don 't need experience working with

T quetry is a technique where a

sturdy scrap piece of veneer,
called the waster , is used as a template
tern, but when the pattern involve s
mainly geometric shapes and straight
lines, I prefer to use a variation of the
marquetry or veneer in order to make
this sunburst. Most of the cuts are
made with either the veneer saw or
for cutting out the various shapes in a window method that I call the empty knife , using the straightedge as a guide.
picture that's made up of many dif- window. With this method no waster is
ferent pieces of veneer. By cutting used. Instead, the entire pattern is the The Empty Window Method
away a portion of the waster a window window - hence the term empty win- Step-by-Step
is created, which is used as the template dow. The marquetry picture is con-
for cutting the individual pieces of structed much like the pieces of a puz- Organize your materials before you
veneer that build the picture. With zle are put together, but you work start. Most important are the veneers.
complex shapes and curved or free- directly over the pattern. For the sunburst, I used koa fo r the
form patterns, the window enables the The empty window technique is outside border, curl y maple for the in-
marquetarian to try any number of perfect for making the marquetry sun- ner border, walnut for th e diamond
veneers and adjust them for grain or burst that decorates the Bed-and- border, lacewood at the four corners
color before the right piece is found . Breakfast Tray on page 37. This design surrounding the diamond , primavera
The marquetarian just slides various is . basically an exercise in cutting for the sun and primavera and curl y
veneers under the waster to judge their straight lines and corner miters. The maple for the rays. Each of these
effect in the window . A new window is edges of already fitted pieces of the veneers contrasted nicely with the
cut out for each shape in the picture. work-in-progress also provide a win- others and complemented the ash stock
It's po ssible to use the window dow for tracing common seams. You (continued on next page)
November/ December 1989 29
Il...==:::::::=========================================~
Special Techniques
Continu ed

% - - -- - - - - - - -- - ----
1---- - - - - - - - - - - - - - - - 10
"I

30 The Woodworker 's Journal

==================================================================-)
Z,A

to cut the first ra y (Fig. 2B). Use the

first ray as a pattern for tracing the re-
maining rays, and cut them with the
straightedge and veneer saw.

used for the tray. Many other com- measure up 1Ys in . along the perpen-
bina tion s of veneers will work as well. dicular center line from the bottom,
Ju st be careful when selecting your and mark point A. Draw a horizontal
veneers to not choose something that's line through point A.
too brittle. With long pieces like the Then using a protractor, locate the
border strips and ra ys, brittle veneers center ray by marking points 2X
te nd to break apart or crumble. degrees on either side of the perpen-
In addition to the face veneers, dicular center line (Fig. 1). This center Step 3: Now assemble the ray s on a
you' ll need a sheet of veneer to apply to line is the 90-degree point on the pro- sheet of contact paper (Fig. 3). Lay the
the reverse side of the panel. When tractor. From there mark out the contact paper sticky side up over the
veneering large surfaces, it's essential 5-degree steps that establish the re- pattern. Position the ray s facedown on
to veneer both sid es and not just the maining rays until all the rays are the contact paper using the pattern as a
face . Without the reverse side veneer to marked. When scribing the actual ray guide . By sliding the ray s up or down a
equalize stresses, the panel would warp lines, use a sharp pencil and continue little you'll get them to fit just right.
or cup . Select an inexpensive hard- the ray lines out to the border. Don't press each ra y onto the contact
wood veneer, such as birch, for the Next, from point B, 2 X in. up from paper until it's properly po sitioned.
reverse side. For the panel substrate, I the bottom, scribe a 2% in. radius for
used birch plywood . the sun. Also locate the points of the
The tools you'll need are a veneer diamond and mark out the various
saw, a sharp kn ife , a straightedge, a borders, as shown. The diamond
fram ing squ are , and either a fret saw border is Ys in. wide, the outer border is
or a scroll saw. You also need clear or 1X in. wide and the inner border is 1 in.
frosted contact paper (I use the frosted wide.
plastic sheet that's sold in hardware Step 2: Layout and cut the ray
stores as a stick-on window privacy pieces . The rays are alternating strips
panel), yellow glue, masking tape and of primavera and curly maple. It's best
a large sheet of paper for your pattern. to start building this pattern out from
Step J: Layout the full-size pattern the center, so start with the center ray. Step 4: Transfer the top lines of the
on a sheet of hea vy paper. Draw two Making the first ray is a two-step diamond and use the straightedge and
perpendicular lines that intersect at the process. First position your veneer veneer saw to cut them (Fig . 4). Note
center. These lines will center the pat- over the pattern and mark out the ray that you'll be cutting through both the
tern. Next, measure out from these lines (Fig. 2A). Then move the veneer veneer and the contact paper under it.
center lines and mark the perimeter. As to a cutting surface (% in. thick par- Step 5: Using a compass, scribe a 2%
show n , the outside dimensions of the ticleboard is a good cutting surface) in. radius half-circle on a piece of
pattern are 14Y.; in . by 20% in. Now and use a straightedge and veneer saw (continued on next page)
Novem ber/ December 1989 31
I~==============================================================-I
Special Techniques
, Continued

sharp pencil. Then move the triangles

to your cutting surface and trim along
the pencil line with the straightedge
and veneer saw. Join the triangles to
the sunburst with contact paper, but-
ting the joints as tight as possible.
Step 9: The two borders are added
last. Cut the I in. wide curly maple
border and slide it under the sunburst
(Fig. 9A). Then use a sharp pencil to
mark where the points of the diamond
overlap it. After cutting the waste on
primavera veneer for the sun. (Fig. Step 7: Cut Ys in. wide strips of this overlap with the straightedge and
5A). Then tape the primavera in place walnut to use as your diamond border knife, assemble the maple border strips
over the rays, with a waster sheet of around the rays (Fig. 7). As shown, the to the sunburst with contact paper.
veneer beneath. The waster is just a strips are cut long and overlapped at Overlap the ends and cut the corner
scrap of sturdy veneer that backs up the corners. Join the border strips to miters as before with the straightedge
the cut. Use masking tape to anchor the sunburst with contact paper, being and knife.
the primavera securely, and locate the careful to get a tight butt all around.
radius by positioning the sun with Lay the straightedge across the strips at
respect to the sun on the full-size pat- the corner and cut the miter with the
tern. Then use the scroll saw to cut the knife. Note that the knife is drawn
sun radius (Fig. 5B). Since you are cut- from the inside of the corner to the
ting through both the rays and sun at outside. This way there's no chance of
the same time, you'll get a perfect a knife slip damaging the rays. Repeat
match where they meet. this procedure at the remaining three
points of the diamond.

The 1X in. wide koa border is cut

and fitted much like the curly maple
border. Position the border and use a
sharp pencil to mark the V where the
points of the diamond overlap it. Move
the border strip to the cutting surface
and cut these relief points with the
straightedge and knife. Be sure to cut
out from the points of the V so if you
slip you won't ruin the border. Mount
the koa border to the sunburst with
Step 8: Cut four right-angle pieces of contact paper, and cut the corner
lacewood (Fig. 8). As shown, the lace- miters as before. You should now have
wood triangles are slightly larger than the completed marquetry sunburst
final size. Position the lacewood mounted on contact paper (Fig. 9B).
triangles by sliding them under the sun-
burst, using the full-size pattern as
your guide. Mark the cut line with a

Step 6: After removing the scrap

from the rays and sun, use a piece of
contact paper to add the sun to the ray
assembly (Fig . 6). Then move the as-
sembly to your cutting surface, and us-
ing a straightedge and either the knife
or veneer saw, trim the sun flush with
the outside rays. Note how the straight- Editor's Note: Gluing the veneer to the
edge is positi one d over the part you plywood substrate is covered in the
keep, so any slips with the knife or saw Bed-and-Breakfast Tray instructions.
will not ruin the ma rquetry picture. a
32 The Woodworker's Journal
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Finishing
ne problem with most wood stains is that they par-

O
water-soluble dyes will. Because of their ability to penetrate
tially obscure the wood grain, which often results in a varnish and shellac finishes, alcohol dyes are often used for
muddied look. If that is the effect you're after, fine. minor touch-up and repair work .
But if you want to color wood, yet retain as much grain detail Oil-soluble dyes are non-grain-raising dyes used primarily
as possible, try an aniline dye stain. to tint oil-based varnishes and lacquers. But they can also be
What's the difference between aniline dyes and other applied directly to the wood as a stain when mixed with the
stains? First, most stains rely on pigments to color the wood. appropriate solvent (turpentine, naphtha, lacquer thinner).
Pigments are fine, solid particles of color, suspended in a sol- Use the solvent recommended by the dye manufacturer. Oil-
vent such as water, mineral spirits or some other petroleum soluble stains aren't as lightfast as water-soluble dyes, but
distillate solvent. A binding material (usually linseed oil) is
added to make the particles adhere to the wood surface. As
the stain dries on the wood, the solvents evaporate, leaving a
thin film of the pigment on the wood surface. Aniline dyes,
on the other hand, completely dissolve in the solvent, enabl-
ing them to saturate the wood fibers with color - without
hiding the grain pattern. This same penetrating ability makes
dye stains preferable to pigment stains for use on dense, non-

ANILINE
DYES by Jim Barrett

porous woods, such as birch or the maple blocks shown in

the photo. (The pigments in stains often don 't adhere very
well to these woods).
Choices in Aniline Dyes
Aniline dyes are available in a wide variety of wood tones,
as well as pure colors such as red, black, yellow, blue, green,
orange, and many accent colors. (One manufacturer makes
over 75 colors and wood tones in water-soluble dyes alone).
And, if you're into experimenting, you can mix the dye solu-
tions to produce virtually any custom color that you want.
Most aniline dyes come in powder form that you mix with
the appropriate solvent: water, alcohol (methanol), or a
hydrocarbon-based (oil) solvent such as turpentine, naphtha,
or lacquer thinner. The dye powders are economical to use. they're more light fast than the alcohol-soluble type. The one
Depending on the color and manufacturer, one or two major drawback to oil-soluble dyes is that they will bleed
ounces of powder costs between $2.50 and $5.00, and will through lacquer and some oil-based topcoats. They generally
make about one quart of dye. Stored in tightly sealed glass or need to be sealed with a l-pound cut shellac sealer before you
plastic containers, the mixed dye has a nearly infinite shelf apply the final finish.
life. Water-soluble dyes are, in our opinion, the best all-around
Alcohol-soluble dyes are the least desirable for use by the choice for most projects. Not only are they more light fast
home woodworker for several reasons. They don't penetrate than the other types, but the colors tend to be richer and
as deeply as water- or oil-based dyes, so the colors aren't as come in a wider variety. Overall, they're less expensive than
brilliant. Many of the colors aren't as lightfast (resistant to alcohol- or oil-based dyes. This is because, although the
fading) as those of the water and oil soluble types. Their fast powders cost about the same, the solvent you use to mix
dry time makes alcohol-soluble dyes tricky to apply with a them comes from your faucet. In addition, they're easy to
brush or cloth, so they usually must be applied with a spray mix and apply, non-toxic when dry, and won't bleed through
gun to insure even coverage, especially on large pieces of fur- oil or lacquer finishes. The only drawback is that, because
niture. On the plus side, they won't raise the wood grain like they're water-based, these dyes tend to raise the wood grain,
34 The Woodworker ' s Journal
==================================================================-1
giving it a fuzzy feel and appearance. To counteract this Jell-O, Following the powder/solvent proportions recom-
problem, you'll need to take the additional step of raising the mended by the manufacturer will produce the color indicated
grain with water, then sanding it off before applying the dye on the container. Adding less powder to the solvent will pro-
(see Applying the Dyes). duce a lighter shade of the color; more powder, a darker
A variation of water-soluble dyes, called NGR (non-grain- shade. As mentioned earlier, you can mix various colors to
raising) dyes or stains, consist of a water-soluble dye pre- achieve custom colors, provided the dyes you're using are all
mixed in water-free solvents. One such dye is sold by water-soluble (you can't mix a water-soluble dye with an oil-
Behlen's under the brand name Solar-Lux Stain. These dyes or alcohol-soluble dye). Although you can mix the various
share all of the characteristics of water-soluble dyes above, water-soluble powders when these are dry, it's much easier to
mix already-prepared solutions.
One quart of dye should be more than enough for all but
the largest projects. Items needed for mixing include a
l-ounce plastic measuring spoon, a I-quart glass or plastic
measuring cup or mixing bowl, a stirring stick, and a l-quart
glass or plastic storage container (plastic lids are preferable
to metal ones). Avoid metal containers and utensils, because
the metal may affect the dye color.
Follow the general mixing instructions on the container
label. To make a quart of dye, measure I quart of hot (not
boiling) water into the mixing bowl. Hot tap water is fine,
unless the water in your area has a high mineral content.
(Minerals in the water may affect the dye color, in which case
it would be safer to use distilled water.) Next, gradually stir
in the amount of powder recommended by the dye manufac-
turer (either I or 2 ounces). Several of the Behlen's dyes we
used required the powder to be premixed with 8 ounces of
methanol (wood alcohol) before adding them to the water.
Once the powder has dissolved, strain the solution through
a cloth filter (such as several layers of cheesecloth) into the
storage container, and seal tightly. Allow the mixture to
stand I hour before using.
As mentioned earlier, you can vary the intensity of the col-
or indicated on the label by adding more or less powder to
the water. Before staining the actual project, test the dye
solution on a scrap of wood of the same species. If the color
is too strong, add more hot water; ifit's too weak, reheat the
solution and add more powder. Judge the color when wet. It
will be somewhat lighter when the dye dries, but will darken
again when you apply your final clear finish.
Applying the Dyes
Water-soluble dyes don't emit toxic fumes, so you don't
need a mask or respirator when mixing or using them (just
avoid inhaling the powder). It's a good idea, though, to wear
but won't raise the wood grain. They can also be used as tints plastic gloves, unless you want to dye your hands the same
for lacquer finishes. However, NGR dyes don't come in as color as the wood. In general, follow the same common-
many colors as water-soluble dyes, and ounce-for-ounce, sense procedures that you would with any paint or stain.
they're about twice as expensive ($5.00 to $6.00 per pint). Before staining the wood, you'll need to raise the grain
Also, because they're premixed, you can't darken the color and sand it off. Wipe the project with a wet cloth, let dry,
indicated on the label. If you want to lighten the color, you and sand lightly with 220-grit sandpaper to remove the
must add a special reducer recommended by the manufac- "fuzz." If you notice any additional raised grain after stain-
turer. Otherwise, we found them every bit as effective as ing, lightly hand-sand with 320-grit paper, being careful not
water-soluble dyes, without the hassle of mixing. to remove the stain. An alternative to this process is to go
All things considered, we recommend that you stick with ahead and apply the dye, letting the grain raise as it will.
the water-soluble dyes - at least for starters. Following are Then apply a wash coat of shellac to stiffen the fuzz, and
specific instructions for mixing and applying them. sand it off with 320- or 400-grit silicon carbide paper. In
either case, blow or vacuum the dust off the piece before ap-
Mixing the Dyes plying the final finish.
Mixing water-soluble dyes is not much harder than making (continued on next page)
November/December 1989 35
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,_
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easier to use a sponge or soft cloth for application. To avoid
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streaks and lap marks, make sure you apply enough dye to
or your money back keep the surface wet until the entire area is covered . You
• Shipped Jn I week For free brochure. wr ite or call (402) 46 4-0511
• Sohd brass head- deep cut letters don't have to worry about applying too much, as the wood
• tst line HAND CRAFTED BY - as above
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wipe over the entire surface with more dye, which will put the
dried dye back into the solution.
With most woods, the end grain will absorb mor e dye th an
the face or edge grain, and will be darker. Also, some soft-
Everyb ody talks about the woo ds and highly figured woods will ab sorb the dye uneven-
ly. Unless you like this effect, you can insure more even ab-
weather. Now you can do sorption by first sizing the enti re wood surface (or ju st the
something about it. end grain) with a mixture of 1 part yellow woodworker 's glue
to 5 parts water. After the glue dries , lightl y sand the surface
Global temperatures are rising . 1988 was one of the with 220-grit paper.
warmest years on record . Instead of talking about it, When working on a large project, such as a table , star t at
you can help by planting trees. To find out more, the bottom, and complete one entire section or part (such as
write Global ReLeaf, American Forestry Association, the legs) before moving on to the next. After you' ve dyed
P.O. Box 2000, Dep t. GR2, Washington, DC 20013. each part, wipe it with a dry rag to remove excess dye.
If you decide that the piece is too dark after you ' ve applied
G~BAL~L£M the dye, you can lighten the color by wiping over the enti re
surface with a rag dampened in clear water. This pu ts the dye
back into the solution and removes some of it. Conversely, if
You can make aworld ofdifference. the piece is too light, simply mix a more concentrated solu-
tion of the same color and apply a second coat after the first
has dried completely (12 to 24 hours). Unlike pigment stains ,
a second coat of the same solution usually won 't intensify th e
Don 't Suffer in Silence color if the wood surface is already fully saturated with dye.
We are here to help you with any subscription question as quickly Also, once you've dyed the piece, yo u can alter the color
as possible. But we can't help if we aren't aware of your difficulty. If by wiping a second color or several colors over the first. If
the following doesn't help, write our Subscription staff. you want to remove the color altogether and start fro m
NON·RECEIPT OF ISSUE: Allow 8 weeks for your first issue to scratch, use a commercial wood bleach (available through
arrive; and bi-monthly after that. If you miss an issue, let us know most woodworking catalogs or from a local lumberyard or
immediately (include order date and a copy of your label and home center).
cancelled check, if possible). We suggest you also notify your local
postmaster. After the piece is dyed to your satisfaction, let it dry over-
night before applying the final finish . Because water -soluble
DUPLICATE BILLS OR RENEWALS: Our bill or renewal may
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notice even 30 days after mailing your payment. Please disregard the alcohol- or water-based finishes may reflow the dye,
notice. However, should you get yet another notice, let us know and however. You can prevent such problems by sealing the dyed
we will check into it. piece with a light coat of shellac before applying the se
NEW SUBSCRIPTION OFFER: Occasionally we use another finishes. ~
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DUPLICATE ISSUES: Sometimes order s are duplicated or a Constantine's Mohawk Finishing Pr odu cts
renewal is processed as a new order , so that two copies of the same 2050 Eastchester Rd. (Behlen 's products)
issue are sent. If this is happening to you, send us both mailing labels Bronx, NY 10461 Rt. 30 N.
and indicate the correct address. We will extend your subscription or Amsterdam, NY 12010
cancel and refund one of the order s. Garrett Wade
161 Avenue of the America s Wood Finishing Supply Co.
But Don't Suffer in Silence! New York, NY 10013 100 Throop St.
Palmyra, NY 14522

~'s
Highland Hardware
1045 N. Highland Ave., N.E . Woodcraft Suppl y Corp.
Atlanta, GA 30306 Wood County Park #210
= = = .T ..
The _".l
Lee Valley Tools
P .O . Box 1686
P .o. Box 1629, New Milford, CT 06776 J'.[Link] P arkersbur g, W'I 16\0\
1080 Morrison Dr.
Ottawa, Ont ario , Canada K2H 8K7

36 The Woodworker 's Journal

 f you've never had the pleasure of Before cutting the stepped profile in sanding operations.

I serving or being served breakfast in

bed, then build this tray and the ex-
perience is sure to follow . The ad-
the sides (A), establish the notches into
which the supports will fit. We used the
router table for all the notches, rab-
The Yz in. diameter half-round
notches in the supports are made by
clamping the two supports face-to-
justable tray also tilts up for a writing, bets, grooves and dadoes in this piece. face, and then drilling through on-
reading or drawing surface. The bit height for these notches must center at each location with a Yz in.
Marquetarian Nicholas Mariana ex- be Ys in. Later, when you shape the diameter bit. The hole positions are
plains how to make the sunburst design sides, the Ys in. deep cutaway that's shown in the Top Elevation.
in our Special Techniques article begin- made at the bottom edge will produce We lathe-turned the handles, but if
ning on page 29. the final X in. notch depth that's il- you don't have a lathe they can also be
We used ash, but other woods such lustrated in the Side Elevation. The I made on the table saw using the Yz in.
as oak or cherry will also look fine with in. diameter holes for the handles and radius rounding-over cutter in the
the marquetry sunburst veneers. The the Ys in. deep by Ys in. wide dadoes for molding head. A Yz in . radius
base and tray are constructed of Ys in . the ends (B) are also cut before the rounding-over bit in the router table is
thick stock, except for the Yz in . thick sides are shaped. still another option .
supports (C), the 1 in. diameter The notches in the legs (E) for the Assemble the base section before go-
handles (D), and the tray bottom (0), stretchers (F) are cut before the ends of ing on to the tray section. Use screws
which is X in. thick plywood. We the legs are rounded. Tape all four legs and brads to reinforce the joints.
resawed all the solid stock from a 2 in. together and establish the notches in The tray section is made to fit the
thick by 6 in. wide by 8 ft. long board. them at the same time. If you are using base. First, you'll have to laminate the
Use about 6 n. of your 8 ft. board a X in. diameter bit in the router table, marquetry sunburst to the plywood
for resawing to provide the Ys in. thick each notch will require four passes. tray bottom (0). Start with a piece of
parts. Resawing 8/4 in. thick stock will Use the band saw to profile the sides plywood that's a little larger all around
yield three individual Ys in. thick and to cut the radius on the ends of the than the marquetry picture. Then, us-
pieces, after allowing for the resaw legs. Stay outside the radius line on the ing yellow glue, sandwich the mar-
kerfs and planing. The remaining 2 ft. legs with the band saw, then final sand quetry sunburst and a backing veneer
of your board will yield the supports to the line. The four legs should still be around the bottom. Use %in. thick sec-
and handles. taped together for the band saw and (continued on next page)
November / December 1989 37
 ------

Part Description Size

Base
A Side % x 2% x 28
BEnd % x 1% x 15
C Support Y, x 'I. x 15%
D Handle 1 in. dia . x 15% long
E Leg % x 1% x 9%
F Stretcher % x 1 x 16%
Tray
G Bottom Y. x 14% x 20%" 1
H Side % x 1Y. x 21% 2
I End % x 1Y. x 14Y. 2
J Leg % x Y, x 8Y. 2
K Stretcher % x % x 20% 2
L Hinge 1'/, x 1 in. butt hing e"" 2
M Catch as shown" 1
" The final thickness of your tray
bottom will probably diff er, as
determined by the plywood that you
select and the additi on of the
marquetry veneer .
"" Available from Constant ine, 2050
Eastchester Road , Bron x, NY 10461;
Hinge is part no. 73A15, $1.95 per
pair . Catch is part no. 64C8, $.80
each. Prices do not include shipping
and handling.

tions of particleboard as clamp blocks,

and two-by-fours to distribute the
clamp pressure evenly. You'll need at
least six bar clamps. The contact paper
will keep the marquetry from sticking
to the particleboard on the front, but
you'll need to add a layer of wax paper
between the backing veneer and the
particleboard clamping block on the
bottom side.
It's important that the tray bottom
be squared up relative to the sunburst
design before it is cut to final size. Ap-
ply masking tape all around the
The Woodworker's Journal
 I
I I
r-- J
- --1
I I
I I
I
,--1 I

- -- 1
I I
I I
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r--
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t1""---;-+----- - - ----:-- - 2.1~ - - - f- - - - - - - - +-++--f,.H

IlL

perimeter on the face of the mar- When dry, assemble the sides (H) If you made your tray for an exact
quetry. The tape keeps the delicate and ends (I) around the bottom. Note fit into the base frame, then you'll find
veneer from splintering. Then lay a that a thumb slot is cut into the inside that a gentle bevel on the outside edge
straightedge horizontally across the face of the tray side before the tray is of the tray will be needed so that it will
panel, in line with the points of the dia- assembled. Bore a series of side-by-side clear the base side after the hinges are
mond, and mark these center points at holes, then clean up the slot sides by mounted. This bevel can be hand-
the edges . Repeat for the vertical sliding the piece along the fence that planed (be sure to set the brads first),
points of the diamond. Measure out you clamped to the drill press table. or it can be made by sanding on the belt
from these center lines when marking Cut the groove for the bottom after or disk sander.
the final size of the panel. This will in- you've laminated the marquetry and Finish with two coats of Deft semi-
sure that it's centered. backing veneers, so it will be the cor- gloss aerosol-spray wood finish. Mask
The final trimming of the panel is rect width. off the marquetry panel to avoid
best done with a cutoff box on the Add the leg/stretcher assembly (J overspray. Sand lightly between coats,
table saw, using a 6O-tooth carbide and K), which is pinned in place with then rub the final coat with steel wool
blade. Remember, there's no chance clipped fourpenny finish nails. Round before waxing . Finally, mortise for the
for a graceful recovery if you make a the bottom edge of the lower stretcher hinges (L) that mount the tray to the
mistake here. Finish both sides of the so that it will fit neatly into the half- base, and add the catch (M), which
marquetry-decorated bottom with a round notches in the supports. Rein- prevents the tray from opening unex-
good-quality polyurethane to protect it force the lap and rabbet joints with pectedly. We used X in. long brads to
from spills and moisture. brads or screws . fasten the catch. ~
November/ December 1989 39
 Mission Style

TRESTLE TABLE
ere's a substantial table you'll be proud to serve a saw blade. When making these cuts, it's best to try your

H turkey on. The dark oak and simple, sturdy con-

struction are characteristic of the American Mission
style popular in the late 19th and early 20th century.
setup with some scrap to insure the tenons fit tightly in the
mortises.
Next, form the through-mortises in the legs, the matching
We made the table from 5/4 and 6/4 stock so we could tenons in the shelf, and the mortises in the shelf for the keys
achieve a 1 in. thickness for the top (A), cleats (B) and legs (G). Use a band saw to cut the profile and tenons on the ends
(E), and the 1X in. thickness for the shelf (C), spreaders (D) of the shelf. Again, lay them out carefully with a marking
and feet (F). gauge so that all the tenons are the same and they fit in the
Start by edge-joining boards for the wider parts of the mortises.
table (the top and the shelf). After the y are joined, plane or Make the cleats from the 5/4 stock and bevel the corners
sand them to the final thickness. and drill the holes as shown. Note that one of the holes on
Next, make the feet and spreaders, which are the same ex- each cleat is elongated to allow the screw to move slightly as
cept for the cutout on the bottom of the feet. After making the top adjusts to seasonal moisture changes. Also drill the
the parts to the size given in the Bill of Materials, cut the holes for the 2 ~ in. by no . 10 machine screws that hold the
mortises. Lay them out carefully, using a marking gauge to spreaders onto the cleats.
insure they're all the same. Then drill a series of holes to The keys are cut on the band saw and filed and sanded to
establish the mortises, and clean them up with a chisel. Use a final shape. The chamfer on the ends of the shelf tenons is
band saw to form the profiles. also established with wood files. Use a };6 in. radius round-
Now cut the four legs to size, and form the 1X in. long over bit in the router to soften the edges of the top.
tenons. First establish the shoulders of the tenons by cross- Give all the parts a good sanding. Start with 120-grit paper
cutting to the X in. depth all around the workpieces. Then and then use 150-, 180-, and 220-grit paper. Stain all the
use a tenon jig - or clamp the workpiece to a supporting parts with a dark stain such as Minwax Jacobean. Then glue
piece of plywood - to remove the waste pieces. Don't try to the legs into the feet and spreaders. Finish the piece with
run the workpiece through the saw on end without a support, several coats of polyurethane varnish or lacquer. a
because the workpiece can twist and pull your hand into the
40 The Woodworker 's Journ al
 ®
@ --r~ V\s.w
Bill of Materials
1-<- - - - - - - 11 - - -- - - (all dimensions act ual )
No .
Part Descriptio n Size
Req 'd .
A Top 1 x 36 x 60 1
B Cleat 1 x 1 x 32 2
C She lf 1¥, x 11 x38 1
D Spreader 1¥, x 5Y, x 24 2
E Leg 1 x 4 X 19¥, 4
F Foot 1'/, x 5Y, x 24 2
G Key 1 x 1¥, X 4'/, 4

-~- 60
"'''''
.2..... -

~6 &C"U,A~~
~"-\."'D'
\""OP"
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J-o<-I+- - - - - -"""' - - - -!-- - -t-M

f - - - - -- - - 34

November/December 1989 41
 he most important thing about 45 degrees, and check the setting by smaller than the space it fits into.

T making this box is the choice of

lumber. The finished piece
should have a truly gemlike appear-
care fully milling several test pieces.
Make sure you get a true 90-degree
angle when you butt the mitered test
You are now about ready to glue up
the box. First polish the inside faces of
the sides and ends. I use the 6 in. by 48
ance, so select stock that is highly pieces together. Mill a 45-degree miter in. belt sander, with a well-worn
figured. I use curly, tigertail/fiddle- on one end of each of the sides and l20-grit belt. A pad sander will also get
back, bird's-eye or anything else that's ends. Then set up a stopblock on your the job done. Vibrate the veneer side of
especially beautiful. It's worth spend- auxiliary miter fence, and cut the other the plywood bottom with 220-grit
ing money on the materials; you only ends to establish the 14 in. and 9 in. paper, if it needs it. Don't sand too
need about three board feet. lengths respectively. Make the bottom long, though, as many veneer ply-
Select material that when ripped in a perfect rectangle, about X6 in. woods have a flitch that is paper-thin.
half will yield two pieces, Ys in. thick by I use duct tape or masking tape for
4 in. wide by 24 in. long. The ideal Bill of Materials many glue-up operations. It's often
(all dimensions actual)
stock is about 9 in. wide by 2 ft. long. awkward to use clamps for smaller
Crosscut to yield the two sides (A) No. projects such as boxes. Put a piece of 2
Part Description Size
Req'd.
and the two ends (B). These parts in. wide tape that's about 4 in. long
should be a little oversize in thickness, Box over the miters of the two long sides.
length and width. Then joint one face A Side 1fs x 4 x 14 2 The point of the miter should be posi-
of each piece to get it perfectly flat. If BEnd 1fs x 4 x 9 2 tioned right at the center of the tape.
you're using highly figured stock, C Bottom % X 7' Y, 6 X 12' ~ 6 1 Run a bead of glue into the bottom
however, watch out - even a sharp D Rail % x % x 7% 2 groove of all four pieces, and spread an
jointer can tear the grain. If a piece is E Post 0/'6 x %6 X 1Y. 2 even layer of glue over the miters on
too figured to joint, I use a 6 in. by 48 F Border '7\6 X ' 0/' 6 X 20 ' 2 the ends only. Don't let the glue get all
in. belt sander with a 60-grit belt to G Panel %x 5% x 1lJ% 1 the way to the inner edge of the miter.
sand the face smooth. Once you have Tray With the box right-side-up, put the
established the flat face, rip the sides H Side % x % X 12~ 6 2 bottom in one side (be sure the veneer
and ends to exactly 4 in . wide. I End 7'a x % x 5 2 side of the bottom is down), and add
Mill the grooves for the bottom (C). J Bottom % x 5% X 11 1 ~ 6 1 one end. Butt the miters together,
Also, cut the groove in the end pieces K Center Divider %6 x % X 11%6 1 make sure they're true, and wrap the
to accept the rails (D) that support the L Divide r Y'6 x % x 4% 5 other half of the tape around the end.
tray . The location of the groove is 1% • Border laminat ion dimensions are at Add the second side, wrap its tape, and
in. down from the top edge. rough laminat ion stage, befo re cutting finally the other end, wrapping again
Crank your table saw blade over to and shaping . with tape. Check your box with a try
42 The Woodworker 's Journal
square laid flat on the workbench. fence. Practice a few cuts with the jig use Indian rosewood for the black ac-
Turn the box over to check that the and some 4 in. wide scrap to be sure cent trim on the lid and for the splines.
joints are tight at the bottom. If there's that the groove for the middle spline is You can use other woods, but I'd hold
glue squeeze-out, wait about an hour in the precise center of the box side. to the theme of using the same species
and then carefully chisel the half-dry The blade height setting for the mid- for the lid accents and the splines.
beads off. If you use white glue, the dle spline groove is I X6 in., while the The thickness of the spline stock
beads should be the consistency of blade height for the two deeper must be equal to the width of the
chewing gum and will scrape off easily. grooves is Ys in. If your setup for the groove that the saw blade created.
After the box has dried, mill the middle groove is accurate and on - Resaw stock to the required thickness
kerfs for the exposed splines. These are center, then you can mill both grooves on the table saw, but take care not to
both decorative and structural, since for the outer splines using the same work with anything less than a 12 in.
they reinforce the miter joint. Use the fence setting. Simply flip the box over length. Use your pushstick for this and
jig shown in Fig. I. This jig holds the so the opposite edge is against the jig. all other table saw ripping operations
box at 45 degrees to the table, and is Whether I make this box from curly outlined in this article. I use a carbide
guided against a high auxiliary rip Hawaiian koa or bird's-eye maple, I (continued on next page)

November/December 1989 43
50-tooth alternate top-bevel blade. peat the procedure for the second 20 process for the second lamination.
This blade should leave a smooth in. long lamination, taking care to keep Select the center panel from your
enough cut so no jointing is needed. the individual strips in the same order. finest figured stock. Make sure it is
Use the band saw to cut the spline When the lid border lamination has kiln dried and has been allowed to ac-
stock into triangular pieces, about Ys dried, crack it out of its cocoon of climate. A center piece of solid wood
in. larger all around than final size. newspaper and glue. Crosscut it to this size will expand and contract
Dip the splines in glue and insert them yield a side lamination and an end slightly with changes in climate. The lid
in the groo ves. This is one time when lamination, about 12X in. and 7X in. will not come apart, however, because
you want to see glue slobbering out. long respectively, or just slightly longer the center panel is edge-glued to the
Too little glue and there may be gaps than the final length and width of the laminated border, which is splined
around the splines that you 'll need to lid. Set the rip fence to about IX6 in. together. Prepare the stock for the
fill later . Let the glue dry overnight. and raise the blade to a 1 in. height. center panel as you prepared the sides
Then mill off the excess length of the With the laminations on edge, rip one and ends. Keep it as thick as possible,
splines on the band saw, and sand flush face to clean off the excess glue and ideally about Ys in. Make sure it is a
on the belt or disk sander. You should produce a smooth surface. Move the true rectangle at least large enough so
have a box that 's a perfect rectangle, fence in so that it's % in. from the that its width plus the two laminat ions
with three splines at each corner. blade, turn the pieces, and rip again to and its length plus the two laminations
The lid is a series of strips (F) clean up the opposite face. Repeat this are slightl y larger than the box open -
laminated together and then applied
around a center panel (G). To make the
lid, you'll need to first cut stock (use
the same woods that you selected for ~

T~
~
the box) into a series of strips of vary-
ing thicknesses that are all l X6in. wide.
For the boxes shown I used an outer ~
~ 1'"
border about X in. thick , followed by
alternating strips of dark and then light t
wood that are Ys in., X6 in., X6 in., Ys

~l
1
in., and X6in. thick respectively.
I start with two pieces of koa or 1--2. I~-.. -l~~ I--I~----.. --I~ 2.-.
bird's-eye maple and two pieces of In-
dian rosewood . All four pieces should ~
be IX6 in. thick by 4 in. wide by 20 in. -. '-

long. Once I'm sure the pieces are the ~I .. f17,-b .1

same size, I set the rip fence on the
table saw so that I get, to the left of the
saw blade, strips as thin or thick as I --- - - - - - - - - - -/2..!<l - - - - - - - - - - -
like. Don't try to get the strips to the
right of the blade (between the blade
and the fence) - this is difficult and
dangerous. I now Tip four strips (two -k
koa or bird's-eye and two rosewood) at
the same fence setting. Move the fence ~
a little to the left and rip four more ~
strips, and so on until the stock is too 7~
5t
thin to rip anymore. I now have strips h
to laminate lids for a series of boxes.
~
To glue up the strips, first make a
gluing jig out of a piece of % in. thick IO~ {"
plywood about 7 in. wide and 22 in.
long, and two strips of % in. plywood
about 2 in. wide by 22 in. long. Lay 1-- - - - - - - - - - ---i
newspaper down on the 7 in . wide ~~. ~ :
1"1 ~
plywood, then one-by-one laminate
the strips in the order you like, starting
with the X in. thick border strip. You
---.f-- - -+- -I

r-<7-" j I

IJ ~----------------~~~--- --------~l~
should have six layers. Add the 2 in.
wide plywood clamping strips on either
side, and clamp crossways with three
bar clamps. Place two short clamping
blocks over the top of the laminations
and clamp them to the plywood base I~

with two 6 in. clamps to keep the r~o~"", ,,\__~

laminations from buckling (Fig. 2).

Allow to dry for at least 24 hours. Re-
44 The Woodworker's Jo urnal
ing. Then rip the panel in a series of lid is beveled on the table saw. Raise just slips within the box. Then wedge
cut s, taking off only a small bit at a the blade as high as it will go and in- the lid in place with a few slips of
time, until it's just wide enough to fit in cline it 6 degrees off the vertical. paper, and drill the X2 in. diameter by
the box with the laminations all Locate an auxiliary rip fence so that 1X in. deep hinge pin hole s. It's impor-
around. you'll have the X in. thickness remain- tant that you select the proper hard-
Once the lid panel and the lid border ing at the edge. Cut the long bevels ware for this part - and spare no ex-
are cleanly milled, miter the border and first, and then the short bevels. If your pense. I use four-penny finish nails ,
glue it on. Let the assembly dry. center panel is about % in. thick , as $1. 79 for a box of 1000. Locate the
After the bevels are cut on the lid, it mine is, then you'll end up with a small hinge pin hole about I Ys in. from the
will be only X in . thick at the perim- flat at the top. back of the box (see Side View), cen-
eter. Center the lid splines on that X in. Now use the belt sander to soften the tered squarely in the middle of the
Using the table saw jig you made for sharp edges of the bevels and produce spline in the lid. The idea is to position
the spline grooves in the box, cut the the domed shape. Don't reduce the the hole so the lid tilts back at a com-
spline grooves in the lid. Glue the thickness at the edge; concentrate your fortable angle when open. That way it
splines in place and let dry. efforts toward the center. Also, round won't unexpectedly slam shut on its
Trim the splines using the band saw, the rear edge of the lid as shown so it owner 's fingers.
and sand them flush. Also sand the in- will not bind when opened. Once you are satisfied with the lid
side face of the lid flat. The top of the Fit the lid by sanding the edges till it location, remove it and cut the bevels
on the sides and end s of the box. The se
bevels are cut with the table saw blade
angled to 15 degrees. Set up your fence
so that the thickness of the sides at the
top and bottom edges is X in. Sand the
bevels, but do not soften the crisp cor-
ners . Fill any gap s with a mixture of
sawdu st and glue before final sanding.
Next, cut the two rails that support
the tray, and the two posts (E) that
support the lid. Glue these parts in
place, but test-fit the posts to make cer-
tain they stop the lid flush with the top.
1 cut the thumb radius in the box
front by roughing it in with the chisel,
and then wrapping some sandpaper
around a 1 in. diameter dowel to final
shape the radius. The thumb slot in the
front edge of the lid can be cut on an
overarm pin router, if you have one, or
by drilling a series of side-by-side hole s
with a 7';6 in. diameter drill bit. Clean
out the waste with a sharp knife.
To final mount the lid, chop the
heads off the finish nails, drive them
halfway through the box side with a
tiny punch or another nail, and plug
the holes. 1 sand some stock to a X2 in.
diameter for the plug s.
Finish the box with Watco oil. Flood
on a coat, rub with 00 steel wool, and
wipe dry . Wait 36 hours, then steel
wool to remo ve the Watco crust. Blow
off the dust and apply paste wax .
The tray is a straightforward con-
stru ction of ends (H) rabbeted into
sides (1) assembled around a plywood
bottom (1) . A velvet-o ver-posterboard
liner cushions items placed in the box .
The divider assembl y (K and L) is
mounted over the liner and is cut for a
1--- - - - - - s.!l - - - - - --". press-fit into the tray. Brads through
f--- - - - - - - -q - - - - - - - --1 the tray ends anchor it. Si

Tony Lydgate is a professional

wood worker who lives and works in
Palo Alto, California.
November/December 1989 45
 G 1FT S HOP Easy- To-Make Gift Projects

e won't make any claims fill any voids, sand the edges well and front and back cleats are glued and

W for downhill speed records

with this sled. It's strictly
for small fry and safe, gentle hills. We
then paint. We applied two coats of
Rust-oleum Regal Red aerosol.
Next, layout the various oak parts.
screwed in place with I in. by no. 8
screws. We also glued and screwed the
back stretcher, stop and runners. Use
do promise that delight will register on Contour the front and back cleats (B, 1% in. by no. 8 screws to fasten the
those little faces when they spy it under C) to match the profile of the top. The back stretcher and stop, and 1%in. by
the Christmas tree. 25-degree angles on the stop (D) are cut no. 10 screws to mount the runners . To
Our sled is made from % in. thick on the table saw. Cut the steering and avoid rust, use brass or galvanized
oak, except for the X in. thick plywood back stretchers (E, F) to size, referring screws . The glueblocks help provide
top (A). A %in. thick by 8 in. wide by 7 to the grid pattern for the profile on the rigidity.
ft. long board will yield all the oak ends of the steering stretcher. Drill the Finish the oak parts with Deft spray
parts. X6 in . diameter pull-cord holes in the polyurethane, then mount the front
The top is a good place to start. We steering stretcher. steering stretcher and runner assembly
used cabinet-grade birch plywood, The four runners (G) are made by with a Ys in . by 2X in. long carriage
which is fairly free of voids. If you use first laying out and cutting one runner, bolt. Use flat washers between the
a construction-grade fir plywood, be and then using it as a template for front cleat and steering assembly and
sure to fill the edges and sand well to marking the other three. Again,. refer under the locknut. The locknut insures
eliminate splinters. Layout the top to the grid pattern for the runner that the sled won't come apart during
profile (the grid pattern will help with shape. use. Make sure the bolt, washers and
the front) and cut out with a band saw After cutting four triangular locknut are galvanized. A clothesline
or jigsaw. Drill the carriage bolt hole , glueblocks (H), assemble the sled . The pull completes the sled. ~

Kids'
Bobsled
46 The Woodworker's Journal
 GIFT SHOP

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-.
- -- - - - - - - - - - - 3L.- - - - - - - - - - - - - -

I - - - - - - - - Ie. - - - - - -- _..

Bill of Materials
(all dimensions actual)
No.
Part Description Size Req'd .
A Top % x 12 x 32 1
B Front Cleat % x 6 X gy. 1
C BacK Cleat % x 3% x 12 1
D Stop %x 2x 6 1
E Steering Stretcher % x 3Y2 x 22 1
F Back Stretcher % x 3% x 18 1
G Runner % x 3% x 18 4
H Glueblock % x % x 3% 4

November/De cember 1989 47

 GIFT SHOP

St. Nicklaus
Carving by Rick and Ellen Biitz

This project is excerpted from the book, Woodcarving

With Rick Blitz, by Rick and Ellen Butz; Ordering informa-
tion can be found on the insert bound in the center of this
issue.
any of our Christmas customs come from Ger-

M many, among them the Christmas tree and several

favorite carols. None, though, has found a warmer
place in our hearts than St. Nicklaus.
The roots of the St. Nicklaus tradition go back several cen-
turies to a certain early bishop who, because of his legendary
acts of kindness, became the patron saint of students and
children. In time, St. Nicklaus' feast day, December 6, was
celebrated by the giving of gifts to small children in the
saint's name.

~
Grain

~
48 The Woodworker's Journal
 GIFT SHOP

As the tradition flourished in the remote Black Forest If you have a carv ing bench with a vise and some gouges,
region of Germany, small figures of St. Nicklaus, like this you can begin this carving in the same way a mountain wood-
one, were often whittled as gifts. These early carvings were carver of a small Alpine village would. In roughing out, the
usually blue or green or even brown, instead of the red we've gouges are more efficient than a knife, since they take off the
come to associate with "Santa Claus." waste wood more quickly. Otherwise, you can carve St.
I love to make these little carvings in the fall when the chill Nicklaus entirely with a knife, but it takes a little longer.
in the air reminds me that winter isn't far away. It seems that
some of the magic of Christmas is reflected in the feeling that
I always get when suddenly, after hours of patient whittling
on a block of wood, a little person appears to be looking
back at me. The carving really seems to take on a life of its
own.
Try carving St. Nicklaus and I think you'll feel the magic
yourself.
I used air-dried white pine for this St. Nicklaus. Pine is a
traditional carving wood in the mountain regions where this
type of figure was first carved. I love the fragrant scent of the
pine shavings, reminding me of Christmas trees and pine
bough decorations.

Fasten the carving in the vise and use a V-gouge, 6 mm to

10 mm wide, to mark the top and bottom of his sleeves
(Photo 3). Then use a flat 30 mm no. 2 gouge and bevel the
wood down to the level of the V-gouge cut on either side of
the sleeves, leaving them raised (Photo 4).

Begin by drawing the front and side views of St. Nicklaus

on a block of wood 2X in. by 6X in. by 1% in. thick. You'll
notice that I only drew in the feet on the side view; the rest
will be shaped with carving tools (Photo 1). Cut out the
blank on a band saw beginning with the side view. This will
leave you with a flat surface to rest your blank on when cut-
ting out the front view (Photo 2).

Turn the carving sideways and reclamp it in the vise. Then

use the V-gouge to make a diagonal cut to outline the bottom
of the arm (Photo 5).
(continued on next page)
November /December 1989 49
 GIFT SHOP

Then round off the sharp corners of the block with the no.
2 gouge (Photo 6). Continue rounding over to the middle of
the back. Do the same on the other side, using the V-gouge to
outline the arm, and the flat gouge to round the corners. The
back should be slightly rounded .

Next, shape the feet by rounding off the sharp angles

(Photo 9). Be careful not to carve against the grain . You can
tell when this is happening because your knife starts digging
into the wood, making splinters. If that happens, reposition
your hands and the wood so you're carving from the op-
posite direction.
Working with the grain is especially important around the
feet because the toes are fragile. Carving against the grain
can easily split them off. If a toe does break off, glue it back
in place with some wood glue and continue carving when it
has dried.

Now that most of the excess wood has been removed, take
the carving out of the vise. The rest of the work on St.
Nicklaus will be done while he's held in your hand.
Use the V-gouge again to outline the belt with a shallow
cut. Hold the gouge the way you would hold a pencil and
gently push it through the wood with your fingertips.
Remember, don't let the fingers of your left hand get in front
of the cutting edge of the gouge (Photo 7). Notice that I've
wrapped heavy string around part of the shaft of the blade.
The string makes the tool more comfortable to hold when
you're making this type of cut. I learned this technique while
visiting some woodcarvers in Switzerland. It really helps.
Now use your carving knife to pare the wood on either side
of the belt down to the cut. This leaves the belt raised above
the cloak (Photo 8). After shaping the boot, use the V-gouge to incise a very
Use the same techniques to make a 1; in. wide ruff around shallow line around the bottom to form the sale of the boot
the hem of St. Nicklaus' cloak. (Photo 10).
50 The Woodworker's Journal
 GIFT SHOP

Draw a line around the hood abou t X in. back fro m the
face. Then cut along it with your V-gouge (Photo 13). Next ,
use your knife to pare away the excess on the face side o f
your V-gouge cut (Photo 14). Repea t this procedure until the
face is about Ys in. wide with X in. of hood standing proud
around it.

Mark out the cuffs on the sleeves by making a shallow cut

down the center of the sleeve area , and a cut about X in. on
either side o f it with the V-gouge. Then pare away the wood
of the sleeves leaving the cuffs raised (Photo 11).

Draw a line for the eyes X in. down from the top of the
forehead, and draw another line X in. below that for the bot-
tom of the nose. Then make two notches about Ys in. deep
where you drew the lines (Photo 15).
With your knife, round the back of the head to form St.
Nicklau s' hood. Then car ve the top of the hood down so it
slopes toward the face (Photo 12).

(continu ed on next page)

Nove mber I Decem ber 1989 51
 GIFT SHOP

To shape the eyes, hold the knife in the pencil grip and in-
cise a very shallow cut (about 1J2 in. deep) around the outline
of the eye (Photo 19). Then care fully slice away a very thin
chip above and below the eye area (Photo 20). To make the
pupil of the eye, remove a tiny triangular chip of wood from
the bottom eyelid by taking the point of your knife and mak-
ing three cuts angled so they meet at the bottom (Photo 21).
At this point, you'll really start to see St. Nicklau s in the
wood.

The next several step s of carv ing the face can be a bit
trick y. You may want to practice on a scrap 0 f wood to get a
feeling for carving the detail s.
Holding the knife in the pencil grip, incise the two lines
that will form the sides of the nose (Photo 16). Then pare
away the excess wood over the cheek s (Photo 17). To shape
the cheek , remove a small triangular chip by making a ver-
tical cut between the cheek and the nose and then making a
small horizontal cut to slice the chip free (Photo 18). Then
round over the sharp angles on the cheek and forehead .

52 The Woo dworker 's Jo urna l

 GIFT SHOP

Next, holding the knife in the pencil grip, draw a line to Now that the face is done, you're ready to start the
establish the lower edge of the mustache and a second line for finishing details. Use a V-gouge to texture the long hair of
the lower edge of the mouth (Photo 22). Then use the point the beard and mustache. A little 3 mm V-gouge is perfect for
of the knife and pare away a thin chip below each of the cuts this if you have one (P hoto 24).
(Photo 23). This is similar to the technique used to shape the With the V-gouge, carve a line around the hood meeting at
eye. the beard to form the fur ruff on the hood. Round it slightly
with a knife.
Then, using the V-gouge again, make a series of short cuts
to create the fur texture on the cuffs, hem, and hood of St.
Nicklaus' cloak (Photo 25).

The carving is now done. But before you start painting,

drill a small hole at a downward angle in the crook of his
arm. This will hold the traditional good luck sprig from your
Christmas tree.
The painting techni ques used on this carving are very sim-
ple. For St. Nicklaus' white beard and eyebrows and the trim
on his cloa k, use white acrylic paint thinned with water to a
good brushing consistency. For these areas, I find acrylic
covers better than oil paint. But for the other colors, I use
oils since they have a softer look.
After the white paint has dried, you may paint the cloak
any color you choose. I like cerulean blue, because it is very
close to the azure color traditionally used in some areas of
Germany.
Squeeze a little oil paint into a saucer and thin it with
turpentine until it becomes a transparent stain. This paint
mixture will allow the wood grain to show through and add
extra character to your carving. Paint it on the carving with a
soft sable brush (Photo 26). Paint the boots and belt with
black oil paint also thinned to a stain with turpentine. As a
historical note, this style of painting is called tinting and is
seen on many of the old European woodcarvings.
You may find you rself carving several of these for friends
and family. Although some of the fine details may be
cha llenging, this type of woodcarving gets easier to do with
each new one you make. ~
November/ December 1989 53
 GIFT S H O P

version of a traditional to y,

A thi s small carousel seems

especially enchanting to yo ung
childr en. The spinning disk rises and
falls as the ducks go back and forth in
th eir merry-go-round. The effect
seems to cast a spell on the little ones.
We made our carousel from scrap
we had around the shop : mahogany
for the base (A) and spinning disk (B),
and pine for the ducks (D). Start by
laying out the two circles for the ba se
and the disk. Then cut out the circles
and drill the center holes in the ba se,
disk and ball (E). Also drill for the
screws that hold the ducks onto the
disk, and the Yt6 in. diameter hole s for
the string. Soften the edge of the ba se
with a Ys in. radius round-over bit in
the router. Cut out the ducks using our
full-size pattern s as a guide.
Next, cut the pole (C) to length and
esta blish the two X in. deep ker fs that
hold the strings in place. A do vetail
saw works well for the thin kerfs. Sand
all th e parts thoroughly be for e
finishing and assembling the to y. Th e
ba se, disk and dowel are finished with
three coats of Minwax Antique Oil
Fini sh. The du cks and ball are first
primed and then painted with enamels:
red for the ball, white for the duck
bod y, yellow for the beak, and black
for the eyes.
The duck s are screwed into the disk
with I X in . by no . 6 flathead screws.
The pole is glued into the base. The
string is inserted through the hole s and
looped over the top of the pole . We
used one continuous length of string,
rat her than four separate pieces. Ad-
ju st the length so that the disk is
suspended about ~ in. abo ve the base.
Finally, secure th e ball with a dab of
glue. ~

Bill of Materials
(all dimensions actual)
No.
Part Description Size Req'd.
A Base 6 in. dia. x %th ick 1
B Disk 7 in. dia . x %th ic k 1
C Pole 'h in. di a. x 13% long 1
rU\-\:,S\2.E ? ......~~~
D Duck see full- siz e pattern 4
E Ball 1 in . di a.·
>:z \ NL~ S'.=..c.¥::..
1
• Avail able from Cons ta nt ine, 2050
Eastchester Road, Bronx , NY 10461;
(212) 792-1600. The catalog num ber is
WB100.

54 The Woodworker 's Journal

 GIFT SHOP

1 '7 \A .
~\.--L..

\?VLI<.S 5E.""\ \N Y4
r = M OV-.s\~ E\:>'A~

"7'B. RA'v. ~'VAE.

(~

November/ December 1989

 GIFT SHOP

rego n woodworker Gar y The Head in., then the dado depth must be X6 in.

O Damaskos has built a business

selling these wooden drums.
His company, Nova Diversified,
While you are waiting for the
side/end assembly to dry, go to work
on the head. It's important that you
to leave the required %in. Note that the
side of the dado starts at about the end
of the jigsaw cuts and that the dado ex-
claims the drums are especially great select a piece of hardwood that meets tends in X in. toward the center. A
for kids, providing an outlet for three criteria. It should be attractive, plunge router is ideal for this type of
creative expression and spontaneity, thoroughly seasoned, and reasonably cut, but you can also use a regular
while developing eye/ear/hand coor- straight-grained. Don't reach for that router. Set the desired depth, use a
dination. We can say with certainty highly figured bird's-eye maple or fence, an d plunge the cutter in by tip-
that the drums are fun to play - walnut crotch. Chances are the wood ping the router slightly. Stop the router
whatever your age. will be under tension, which would be at each end, so the dado is no more
Damaskos tells us that the origin of released when the tongues are cut, than 4% in. long. You'll probably need
the Box Drum is pre -Columbian, and causing them to warp or bind. several passes to achieve the full depth.
that it was developed independently by The thickness of the head is IX6 in.
Aztec, Mesoamerican and African Start with stock about %in. thick, then
cultures. Other names for it are tongue joint flat the face that will be glued Bill of Materials
down to the box. The power jointer is (all dimensions actua l)
drum, slit drum or bongo box.
The first box drums were simply the best tool to use, although the hand No.
Part Description Size Req'd .
hollow tree trunks, with an H-shaped plane can also be used.
slit cut into the side. The H shape To transfer the tongue pattern, slip a A Sid e % x 4% x 12 2
resulted in two pitches. Combinations sheet of carbon between the full-size B End 3J. x 4% x 5% 2
of several size tree trunks were used to pattern page and your stock, and trace C Head 1Y. 6 x 6 x 12%' 1
create melodies. the tongue outlines. Damaskos uses a D Bottom % x 6 X 12Ys' 1
The drum shown is crafted in ash , jigsaw to cut the tongue pattern. Drill E Foot as shown 4
with a padauk head and a plywood starter holes as shown to provide en- F Mall et as shown" 2
bottom. While other woods can be trance points for the jigsaw blade. , Parts are sli ght ly oversize before
substituted, we recommend that you After cutting, use a belt sander with a assembly and final sanding.
stay with hardwoods for the sides (A), l50-grit belt to sand off the chip-out. " Avai lable from Nova Diversified,1104
ends (B) an d head (C). Don't get carried away with the belt N.E. 28th Ave., Portland, OR 07232.
Cost is $7.50 postpaid for one pair.
sander, though. The head thickness
The Box needs to stay within X2 in. of the I X6
Start by getting out stock for the in. dimension (not less than 2X2 in.). Next, take sandpaper strips and
sides and ends. The sound hole isn't a The next step is to rout a X in. wide sand between the tongues to remove
must, but it does improve the tone a lit- blind dado on the underside of the any loose wood fibers. If any of the
tle. Refer to the grid pattern for the head, as shown in Fig. I. It's important tongues are binding, try recutting with
heart profile. It's easiest to cut the that the depth of the dado be figured to the jigsaw to widen the kerf. In some
sound hole with a scroll saw before leave exactly % in. of material. Any rare cases, if recutting does not correct
assembly. Next cut a X in. wide by % deviation (even as little as X6 in.) will the binding, you may need to discard
in. deep rabbet on the ends of the sides, detract from the quality of the sound. the head and try a new piece of stock.
and then assemble the sides an d ends. If your head thickness is exactly I X6 If a tongue warps slightly so that the
56 The Woodworker 's Journal
 GIFT SHOP

FIe. . .1

)
II'" F't-'1WtX>D

~S"L- "FE'S ..

~I~---l ~ r- {~J'S -
l ---j ~ r-I~ ~ ~ I 1fi
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1:2- 5'13
END

(continued o n next page) 57

November/December 1989
 GIFT SHOP

kerf is not consistent, then sand as

needed to open up the kerf.
Assembly
Before you start gluing up, make
certain that the top and bottom edges
of the box are perfectly flat. Damaskos
uses a very light cut on the jointer to
true the edges. Another option is to set
up l20-grit sandpaper on a section of
Medium Density Fiberboard (MDF),
and clamp it to the saw table or some
other flat surface. Use this setup to
sand the edges true.
Then apply the head and bottom,
using yellow glue. Don't be too
generous with the glue. A lot of glue
beads running down the inside of the
box will detract from the tonal quality.
Line the head up carefully to make cer-
tain that the outside tongues, when
depressed, don't come into contact
with the sides. As you'll note from the
Bill of Materials, both the head and
bottom are slightly oversize. When
dry, use a flush-trimming bit in the
router to flush the edges with the box.
4:- Apply a X in. radius roundover all

-t-t-~+
around, and final sand the drum with
180-grit paper .
Finishing
The type of finish you use is impor-
tant. Lacquers, shellacs, polyurethanes
I and on-the-surface finishes are not
recommended. Use only penetrating
oils or oil-and-varnish mixtures that
penetrate the wood, rather than
creating a separate layer over the
wood. It's important that the wood be
free to reso nate. Flood on enough oil
to sat urate the inside surface of the
head. Both sides of the head must be
treated equally. This is messy, but a rag
will take care of cleaning up the excess.
After the finish is dry , apply the four
plastic feet (E), which are available at
most hardware stores . The feet keep
the drum from rocking, and raise it
slightly above the surface it's placed
on. This improves the resonance.
Mallets
You can make mallets (F) using
dowel stock and Superballs. Drill a X
in. diameter hole about two -thirds of
the way through the Superball. Then
cut a 12 in. .length of X in. diameter
dowel, and use epoxy to glue the dowel
into the Superball. As an option, pro-
fessional -quality oak mallets with dur-
able latex heads are available from
Nova Diversified (seeBill of Materials).
~
58 The Woodworker 's Journal
 GIFT SHOP

12. 4 - ---.-1

12.
his Dancing Man is one of our soon have him tap-dancing at a fren-

T all-time favorite folk toys. It's

an ideal hand tool project.
These toys were originally crafted by
zied pace. Rotate the dowel handle for
flips, and move him to and fro on the
paddle as he goes through his routine .
hand, and there's always a certain joy With a little practice, you're sure to
in making something without using have your audience clapping along to
power equipment. the beat.
He looks rather staid and stiff, but We've provided full-size patterns for
those wooden legs and arms are all the parts except the paddle board
capable of moves that amaze. To set and the dowel handle (B). Our man
his limbs in motion, sit on one end of and the handle are cherry and the pad-
the paddle board (A) with the other dle board is pine. While various
end extending out over the edge of a thicknesses are required, the pieces are ~p..K~-e.
table or chair, and vibrate the board small and can easily be planed by hand. J.:z. 9\A. >< i6~
\-=N~
with your fist. By controlling the danc- The torso (C) and legs (0, E) are Yz in. (continued on next page)
ing man with the dowel handle, you'll thick and the arms (F) are Ys in. thick.
November/December 1989 59
 GIFT SHOP

The handle is a length of Yz in . diameter any saw marks. Test-fit the slip joints to find locall y, bu t you can order them
dowel , the no se (G) is a short piece of to make sure there 's plenty of slop. from The Wise Company, 6503 St.
X6 in. diameter do wel and the paddle You want the joints to be loo se. Claude Ave. , P.O. Box 118, Arabi, LA
board is X in. thick. Before assembl y, drill the Yz in. 70032.
First, thickness your stock, then lay diameter by X in. deep hole in the For the legs, remember to drill only
out the various parts using the full-size dancing man's back for the handle , the through the outside cheek and the
patterns. You can slip a piece of car- X6 in. diameter by X in. deep hole for tongue of the slip joint. Don't drill into
bon paper between the page and your his dowel no se, and the two X6 in. the inside cheek. If you drill through
stoc k and trace the profiles. Cut the diameter by X deep eyeholes. Also drill the inside cheek, the pins won't grab.
pieces out with a coping saw. the X6 in. diameter holes for the brass Also on the leg joints, we set the
Next , use a dovetail saw to cut the escutcheon pins , or brads, that join the escutcheon pins and used a dab of clear
slip joints that form the knee and hip legs and arms. We used Ys in. long 18 epoxy over the heads to hold them fast.
connections. A X in. wide chisel will gauge pins with the ends nipped off to After gluing the dowel handle and
clean out the waste in the notched half get the right length (about ;;;6 in.) for nose in place, finish all parts with
of the slip joint. Sand to smooth out the slip joints. These pins can be hard penetrating oil. a
60 The Woodworker 's Journal
 GIFT SHOP

< 00
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November/December 1989 61
 I·:, ,.:. ,
G 1FT SHOP
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ere's a towel rack that's perfect successive grits of paper up to about a good idea to use a stop to make sure

H for a spot near the kitchen

sink. It has enough arms to
hold plenty of dish towels, yet it folds
150- or 180-grit. Next, layout the cuts
you'll make to establish the top, bot-
tom and six arms. Remember that
all the holes are the same depth.
While you're working on the drill
press, layout and bore the keyhole
flat against the wall when not needed. you'll need to leave Ys in. between cutouts in the back of the top. You'll
We made our towel rack from pieces to allow for the saw's kerf. You need a keyhole bit for this operation.
bird's-eye maple. The light maple want to arrange the cuts so that the With the holes cut, finish the shap-
seems to go well in a kitchen setting, towel rack parts fit together the same ing. Cut the radii on the top and bot-
and the figured grain adds interest. The way as the original board, so make sure tom, and use a tapering jig (Fig. 2) to
project is small enough so that the fan- that you letter or number the parts so establish the slight tapers in the arms,
cy wood won't set you back too much. they go back together the right way. which start 2X in. from the hinge ends.
For a mail-order source for the Next, cut the board into the eight Form the % in. radius roundovers on
bird's-eye maple and other hard- pieces. First cut off the 2 in. wide top, the arm ends with a wood file. When
woods, refer to the Cabinetmakers' then cut the six X in. wide arms, then rounding the arms, work the file a little
Supply listing on page 10. cut the 2 in. wide bottom. This cutting extra so that you reduce the total
Start with % in. thick stock for the sequence is safer than cutting off both length by about X2 in. That way the in-
arched top and bottom (A) and the six 2 in. wide strips and then ripping the % side of the arms won't rub against the
arms (B). A single piece of bird's-eye in. arms. Then cut the Ys in. diameter wall.
10 in. wide and 20 in. long will yield all dowel into six % in. long pieces to use Next, sand all the wood parts to a
the parts except the hinge components: as spacers. high sheen. We used 120-, 180-, 220-
the spacers, rods and washers. The With all the wood parts cut to size, and 320-grit papers. We finished the
spacers (C) are Ys in. diameter dowel. start boring the holes to form the parts with three coats of spray lacquer.
The rod (D) is X in. diameter brass rod. hinges. Set up a V-block on the drill Assemble the parts using a dab of
The washers (E) are common %in. I.D. press as shown in Fig. 1 to bore the X epoxy glue to hold the brass pins in the
washers, the same washer that's sold to in. diameter holes in the center of the holes in the top and bottom. Make sure
fit a % in. diameter bolt or machine dowel spacers. Also layout and drill X that the parts aren't arranged too tight-
screw. in. diameter holes in the top, bottom, lyon the pins or the arms won't swing
Prepare the bird's-eye board by and the six arms. Note that the holes in out smoothly. ~
thoroughly sanding both sides with the top and bottom are X in. deep. It's
62 The Woodworker's Journal
 GI FT SHOP

Bill of Materials
(all dimensions actual)
No.
Part Description Size
Req'd.
A Top/Bottom % x 2 x 18% 2
B Arm % x % x 16 6
C Spacer %dia . x %long 6
D Rod y. dia. x 5 long' 2
E Washer %I.D. 2
, Rod is brass (or steel) and available at
many hardware stores. Steel rod is
available mail-order from Meisel Hard -
ware Specialt ies, P.O. Box 70, Mound ,
MN 55364-0070, catalog number 7403.

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November/December 1989 63
 have a local source for hard-to-find
woods, refer to the list of mail-order
sources for hardwoods on page 10.
Most of the cherry case parts are cut
from %in. thick stock, but you'll need
a few small pieces of X in. thick stock
for the cubbyhole parts. Because you
only need a little, it's easiest to plane
down some % in. stock to get the re-
quired X in. You'll also need I X in.
thick stock for the tapered legs. We
used 8/4 stock to achieve the full I Xin.
width at the top of the legs, but you
may be able to get away with 6/4 stock
if you don't mind making the legs a lit-
tle undersized. If you buy the 6/4 stock
rough, you'll get usable stock between
I Ys in. and 1'X6 in. thick.
You'll also want some poplar or pine
for the Ys in. thick inside drawer parts .
We used pine because it was available.
Of course, you can also use cherry if
you happen to have plenty on hand.
Finally, you'll need some X in. thick
plywood for the case and desk backs
and drawer bottoms . A cherry veneer
plywood is the best choice, but you can
substitute pine or mahogany if you
want.
Getting Started
The secretary is made in three
separate pieces: the base, desk and
bookcase. For purposes of discussion
we'll treat them separately, but in prac-
tice you'll want to mill the stock for all
the sections at the same time and also
glue up stock for the wider sections at
the same time. Make the panels
carefully, being sure that all the stock is
true and that the edges are jointed
perfectly square before glue-up.
Depending on the width of your
lumber, you may need to glue up stock
for the desk top and bottom (A and B),
the desk side (C), the desk lid (E), the
bookcase top and bottom (Q and S),
and the door panels (Z). Since the desk
section is the most involved, we started
construction there. But it really doesn't
matter, so begin with whatever section
you're in the mood for.
Desk Section
Start by cutting the stock to the
overall dimensions listed in the Bill of
Materials and preparing the wider
tately yet delicate, this small pieces with dark heartwood as well as panels as needed. Make sure that the

S secretary will lend an air of

elegance to any ro om of your
ho use. The curly maple details in a
the lighter sapwood. The panel we used
is %in. thick by lOX in. wide, so you'll
need to hunt up some wide stock unless
desk lid and the case parts are flat and
true after glue-up. A little extra care
now will save you a lot of grief trying
cherry case give this tradit ional design you decide to glue up the panels from to fit the lid to a crooked case. If you
an appeal that's hard to resist. smaller pieces. Since the visual appeal find that the parts are slightly out of
The doo r pa nels, drawer fronts and of the secretary depends so much on true after they are glued up, use a hand
vala nce are cut from curly maple. For the panels, we think it's worthwhile to plane to true them.
some extra visual interest, we used find some wide stock. If you don't With the parts cut to size, start on

64 The Woodworker's Journal

the details and joinery. First, cut the Ys tail sides and then use a chisel to cut to creep off the line .
in. wide by X in. deep rabbets in the along the dept h lines. Holding the parts together with a
case parts for the back. Then establi sh Note that before starting the chisel clamp, mark the pins fro m the com-
the sloping angle on the side sections cuts, it 's best to use a knife to create a pleted tails, and extend the lines do wn
using a band saw. small shoulder to rest the back of the from the end grain to the depth lines
For the dovetails, first scribe the chisel again st. Cut down once lightly you established before. Again use the
depth of cut (the thickness of the stock with the knife at the depth line for each dovetail saw and chisel in sequence to
plus X2 in.) onto the ends of the case pin, using a straightedge as a guide. cut away the waste. Work carefully
top and bottom and onto the matching Then cut do wn again with the knife and slowly on the dovetails so they
edges of the sides . Then layout the tails angled to ward the waste portion. The come out crisp.
on the sides using the dimensions two cuts should form a thin cross-grain After cutting the dovetails, dry-fit
sho wn in the side view. (It helps to use chip. When you remove the chip, you the case together and adjust the do ve-
a sharp kni fe for the layout here.) Ex- ha ve a neat shoulder along the bottoms tails as needed to get a snug fit. You
tend the layou t lines acro ss the end of the ta ils. If you don't create the shouldn't have to whale on the parts to
gra in . Use a do vetail saw to cut out the shoulder to start with, the chisel tends (continued on next page)

7~

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November / December 1989 65

 Bill of Materials
(all dimensions actual)
No.
Part Description Size
Req'd.
Desk Unit
A Desk Top % x 8¥2 x 34 1
B Desk Bottom % x 16 x 34 1
C Desk Side % x 16 x 8% 2
D Desk Back % x 8 x 33% 1
E Desk Lid %x11x33 1
F Breadboard End % x 1% x 11 2
G Divider %x8x7% 2
H Shelf % x 8 x 10% 2
I Valance % x 1% x 11 1
J Drawer Guide %x%x7% 2
K Drawer Stop %x %x 2 2
Base
L Leg 1% x 1% x 29% 4
M Front Apron % x 6 x 32% 1
N Back Apron % x 6 X 32¥2 1
o Side Apron % x 6 x 14% 2
P Corner Block %x 3 x 9 4
Bookcase
Q Case Top % x 9% x 35% 1
R Case Side % x 7% x 28% 2
S Case Bottom %x 8% x 34 1
T Adjustable Shelf % x 6% x 31% 2
U Case Back % x 32 x 28% 1
V Rail % x 1% x 32% 1 get them to go together. joint needs to be mortised in so tha t
W Cove Molding % x % x 52% With the desk case held together half of the thickness fits within the lid
X Door Stile % x 3% x 25% 4 with clamps - but still not glued - and half withi n the bottom. (For more
Y Rail % x 2% X 12¥a 4 make the lid to fit the case. Cut the on mortising hinges see "Woodwork-
Z Door Panel % x 10% x 20% 2 panel to size and form a 1 in. long ing Basics" on page 21.) If the lid
AA Doorstop % x 1% x 31% 1 tenon as shown on each end. Mortise doesn't lie perfectly flat, you can ad-
Drawers on the breadboard ends using three just it somewhat by slightly changing
BB Drawer Front % x 3% X 10~a 2 pegs. Make slots as shown for the two the position of the hinges.
CC Drawer Side % x 3% x 7% 4 outboard pegs to allow the panel to Next, remove the lid, take the case
DD Drawer Back %x 27/ a x 9% 2 move in relation to the ends. Note that apart, and start on the cubbyhole
EE Drawer Bottom % x 75!Ja x 9% 2 the 1 in. tenon is a tad shorter than the details. The vertical dividers (G) are
Hardware· length of the groove in the ends. This notched and dadoed into the top and
FF Door Knob %dia . brass also allows for expansion. (For more bottom of the case. The horizontal
as shown 2 on making breadboard ends, see our shelves (H) also have blind dadoes
GG Drawer Knob %dia. brass January/February 1989 issue.) where they fit into the dividers and the
as shown 2 After gluing on the ends and allow- sides. The decorative valance (I), also
HH Lid Hinge % x 7 as shown 2 ing them to dr y, sand the ends flush if made of curly maple, is glued and
II Door Hinge 2 x 1% 4 needed. Then bevel the top edge and nailed in place. The drawer guides (1)
JJ Bullet Catch %a dia . as shown 2 test fit the lid to the case. Shape the X6 are screwed in place. Use oversized
KK Shelf Pegs %dia. 8 in. radius bead on the edges of the lid shank holes to allow the case to move
• As required. on the router table. Gauge off a fence in relation to the guides. The drawer
• • Hardware available from Paxton for the roundover instead of a ball stop s (K) are glued in place ~ in. back
Hardware, 7818 Bradshaw Rd., Upper bearing. The bevel cut on the top edge from the edge. Dry-fit the case and all
Falls, MD 21156 ; 301·592·8505. Door won't allow you a flat for the bearing the cubbyhole parts before final
knob (FF) is catalog no. 915, $2.08
each ; Drawer knob (GG) is no. 913, to ride on. assembl y and gluing.
$1.62 each ; Lid hinge (HH) is no. 5009 , Then use a Ys in. diameter core box When you 're sure everything fits,
$9.98 a pair; Door hinge (II) is no. 4102, cutter to cut a Ys in. deep finger recess sand all the parts thoroughly, using
$3.59 a pair ; Bullet catch (JJ) is no. in the sides of the breadboard ends. successively finer grits of 120 to 220
4426, $.50 each ; Shelf pegs (KK) are paper. It 's a lot easier to sand now than
no. 5521, $.66 for eight. Prices don 't
Again use the router table and drop the
include handling and postage. Call lid onto the core box bit. Use a high after all the parts are assembled. When
Paxton for exact shipping costs, which fence so it's easy to control the cut. you assemble the desk section, use glue
will vary with destination and parts Also mortise in the hinges, and check sparingly in the dadoes and dovetails.
ordered. the fit of the lid to the case. The hinge You want enough to hold the part s

66 Th e Woodworker' s Jo urna l
together but not so much that you have With the base unit parts roughly is rabbeted into the case, and the doors
glue squeeze-out all over the desk. shaped, cut the taper on the legs. First, are applied to the front. Two ad-
cut the two tapers on the inside of the justable shelves (T) fit inside .
Base legs using a tapering jig in the table Start by cutting the stock to size and
The base is a straightforward saw. Then set the legs in V-blocks for making the % in. wide by % in. deep
tapered leg construction. First, cut the support, and plane the secondary dadoes in the top and bottom . Then
leg blanks (L) to size and chop the mor- tapers by cutting away the inside cor- cut the corresponding %in. wide by %
tises. Then cut the tenons on the ner of each leg as shown in the Bottom in. deep rabbets on the ends of the
aprons (M, Nand 0) to fit the mor- View of Leg detail. Also cut the 7';6 in. sides. Also cut the %in. wide by ~ in.
tises. Note that there's a 7'; 6 in. radius beads on the outside corner of deep rabbets in the edges of the top ,
shoulder on the tenon sides, and a ~ in. each leg. bottom and sides to accept the case
shoulder at the top . Establish the pro- As with the desk unit, dry-assemble back.
file on the front and side aprons after everything before getting out the glue Next, cut the rail (V) to size and
cutting the tenons. bottle. When you're satisfied with your form the bead using a three bead
Next, make the corner blocks (P) work, sand up all the parts and clamp molding cutter (we used Sears cutter
and establish the %in. by %in. rabbets and glue the assembly. number 9BT2352) . Also cut the
on the angled ends. Cut the matching % molding (W) from a % in. thick by %
in. by % in. grooves in the aprons as Bookcase Section
in. wide strip of cherry using a ~ in.
shown. The blocks stiffen the base and The bookcase section is comprised radius cove cutter. Round over the
also serve as the attachment point of of two sides (R) dadoed into the case edges of the top and bottom with a X
the base to the desk unit. top (Q) and bottom (S). The back (U) (continued on next page)

November/ December 1989 67

in. radius roundover bit in the router. grooves at the same depth rather than cut the grooves for the outsides of the
Then, use the drill press to cut the hole s changing settings. fronts. Remove the dado head, replace
as shown in the sides for the adjustable When you assemble the doors, it with the saw blade and cut the
shelf pegs (KK). remember not to glue the panels in tongues back, as shown, to fit the
Dry-fit the parts, and if everything place. They float in their grooves. dadoes . The inside tongues are cut
fits, sand the parts and assemble the back X6 in. while the outside tongues
Drawers
bookcase. The rail, molding and are cut back Ys in. to allow for the X6
doorstop (AA) go on after the case The drawers employ a dado and rab- in. overhang.
itself is out of clamps. The rail and bet to hold the fronts (BB) onto the Use the dado head or router table to
doorstop are just glued in place. The sides (CC). A X6 in. lip on one side of cut the X in . wide by X6 in. deep
side molding is nailed in place with each drawer helps prevent the drawers grooves in the front and sides for the
finish nails, with glue only on the first from rubbing against the sides of the drawer bottoms (EE). The drawer bot-
few inches near the corners. The front desk and creating visible wear . The tom is slid into place and secured with
molding is glued along its entire length. drawer side instead rubs against a X in. three small brads driven through the
With the case complete, move on to thick drawer guide, which is hidden by bottom and into the bottom edge of the
the doors. Mortise the stiles and rails the lip. back.
together, leaving a X in. shoulder on Both the dado in the sides and the
Finishing Up
the tenon sides and a Ys in . sho ulder top rabbet in the fronts are made with the
and bottom. Cut the raised panel using X in. wide dado head cutter. First set Finish sand the three sections and
the table saw with the blade set IX6 in . the dado X in. from the fence and X6 apply three coats of tung oil. Then ap-
high and 23 degrees from vertical. Be in. high, then cut the dadoes on the ply the various hardware elements: the
sure to use a high auxiliary fence when front of all the sides, as well as the rab- door knobs (FF), drawer knobs (00),
cutting the raised panel. Note that the bets in the backs. You'll need to run lid hinges (HH), door hinges (II),
grooves in the stiles should allow some the back s through on end, using a bullet catches (JJ) and the shelf pegs.
room for the panels to expand and tenon jig for support. Adjust the fence Apply the back s to the sections with
contract with seasonal moisture to Ys in. from the dado blade and cut finishing nails and a small bead of
changes. The side-to-side movement is dadoes in the back of the sides. glue. Use threaded inserts to hold the
much more pronounced than the top to Raise the dado to Ys in., reset the bookcase section onto the desk section .
bottom movement. You don't really fence to X in., and establish the Screws through the corner blocks into
need to allow extra room in the rails grooves on the insides of the fronts, the desk bottom secure the desk sec-
grooves, but in practice many wood- again running the pieces through on tion. With threaded inserts, the book-
workers do . It 's easier to cut all the end. Then raise the dado to 'X 6in. and case is easily separated for moving.~

68 The Woodworker 's Journ al

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Patterns/Instruction s (wood cutouts) - " Good Wood " Pennsylvania Hardwood s.

The Classified Rate is $1.50 per word, " Santa-with-List" ; " Sleigh"; "Snow- Over 2000 sizes 12 species. Ys " to 2 " thick.
payable with order. Minimum ad length man "; "Candy Cane "t "Carolers" ; Sur faced, kiln dried. Small orders welcome.
is 15 words, and the deadline date is the " Stag"; " Doe" ; " Fawn" - $3.50 each Free catalogue: Cro ffwood Mills, RD #1
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Send copy (count each word and initial) NY 14559. Post Office Box Bron ze Doors No.1 & No.
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nal, Classified Dept., P.O. Box 1629, Full-size wooden toy patterns, unique new shipping. SASE: Hubbert Woodcrafts,
New Milford, CT 06776. designs, fast service. Catalog $1.00 refund- P .O. Box 1415, Fletcher, NC 28732. (704)
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Craftworker's Marketing Kit helps wood- PA 16232.
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Lamp Parts for Lamp Makers and Hobby- 4th Ave., #26, Yuma, AZ 85365. ty of species in several thicknesses and
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woo den jo inted dinosaurs. Great profit or parts , kits, books, supplies - Catalog Craftshops, Garages Inexpensive!
gift idea. Send $6.50 to Dakota Wind, Box $1.00 - (614) 484-4363 - Cherry Tree Catalog $5.00 (refundable) . Ashland Barns,
866WJ, Jamestown, ND 58402. Toys, Belmont, OH 43718-0369. 990WJ Butlercreek, Ashland, OR 97520.
70 Th e Wood worker 's Journal
 -
Craft Supplies: Clock movements, com- Craftsmen - Show pride in your fine Full-Size Professional Plans - Catalog
ponents, plans, epoxy; foil and art prints, work. Personalize your pieces with engrav- $3.00. Over 200 professionally designed
Shaker pegs, touch tones, door harp sup- ed brass plates. Send $1.00 for sample plate plans for building fine furniture. Furniture
plies, Bible clocks, videos, transfer art, - Handcrafted by - your name. V-B, 807 Designs, Inc., CJ -ll9, 1827 Elmdale Ave.,
stencils - over 1200 items! Wholesale East Dana St., Mountain View, CA 94041. Glenview, IL 60025.
catalog $3.00 (credited) . Steebar, P .O. Box
463-E, Andover, NJ 07821-0463. Bookcases, Entertainment Centers, Ideal Woodworking Business. Work
Waterbeds, Bedroom and Children's Fur- Home. Unusual Money Maker. Free
Toymakers - Wheel Cutters for $17.95. niture, etc. Catalog $3.75. Kraemer Fur- Brochure. Pine Shop, 897-3 Mammoth,
Send stamp for brochure. Deaton, Box niture Designs, 1350 Main St., Plain, WI Manchester, NH 03104.
22784, San Diego, CA 92122. 53577.
Over 1000 Woodcraft Patterns! Profitable
Spray-On Suede Lining. Finish any project Carousel Horse Carving (YJ standard size gifts, toys, country projects, whirligigs,
with a soft touch . Free brochure, sample and smaller), Books, Blueprints. For order household accessories, yard decorations . . .
enclosed. DonJer Products, Ilene Court, info, write to: Heritage Arts Press, 3315 more! Catalog plus sample pattern $2.00.
Bldg. 8R, Bellemead, NJ 08502. (800) Sacramento St., San Francisco, CA 94118. Accents (BJ-1I9), Box 7387, Gonic, NH
336-6537. 03867.
Use your scrap wood. Make Shaker fur-
Chair Caning Supplies - cane webbing, niture miniatures. Book shows how. Free Windowsill Cat Patterns for twelve dif-
rush, splint, ash, rawhide, cord. Catalog details/sample plan. RAI, (WIN), Box 586, ferent wooden cats to sit on windowsill,
$1.00 (refundable) . Caning Shop (WJ), 926 Alpharetta, GA 30239-0586. shelf or ledge. Send $7.00 to Dakota Wind,
Gilman, Berkeley, CA 94710. Box 866WJ, Jamestown, ND 58402.
1990 Leathercraft Catalog . 100 pages.
Stainless Steel and Brass, Screwsand Bolts. Largest selection available of genuine 300 + Plans - Build shop machines and ac-
Small quantities, free catalog. Elwick, leathers, tools, kits, books, supplies. Fine cessories. Catalog $1.00 refundable. Wood-
Dept. 757, 230 Woods Lane, Somerdale, tooling, utility, garment leathers, suedes, Met (WJ), 3314 Shoff, Peoria, IL 61604.
NJ 08083. exotics. Belt, wallet, moccasin kits and
more! Low prices, quantity discounts. Send Router Table/Cabinet Plans. Cam-lock
Fine Woodworking Program. One year $2.00 pstg/hdlg to: Tandy Leather Com- fence, large laminate top. Turns your router
course in furniture and cabinet making, pany, Dept. WJl189C, P.O. Box 2934, Ft. into an accurate, easily built stationary
design and drafting, turning, carving, tool Worth, TX 76113. machine with storage. $14.95 or SASE for
use, finishing, and more . Nationally Ac- brochure. Caranna Custom Woodcraft,
credited. Financial aid available. Free Dulcimer Builder Supplies, Precision milled P .O. Box 20585, Columbus, OH 43220.
brochure. Roberto-Venn School of and fine sanded dulcimer and hammered
Luthiery, 4011 S. 16th St., Phoenix, AZ dulcimer woods. Cherry, walnut, paduk, Real Scroll Saw Patterns - Not For Band-
85040. (602) 243-1179. rosewood , birdseye, and curly maple, Sitka saws. Seventurn-of-century antique cars -
spruce, W.R. cedar; related hardware, Chevy, Ford, Buick, etc. For gifts or profit.
Woodentoy - patterns, project books, strings and accessories. 65' stamp for Unique, very detailed. $7.00. Memory
hardwood wheels, pegs, cargo, people and brochure. Folkcraft Instruments, Box Lane, 5367-C East Mountain St. (J-l),
more. Send $1.00 for catalog; $4.00 for 807-W, Winsted, CT06098. (203)379-9857. Stone Mountain, GA 30083.
catalog plus 2 patterns; or free brochure.
Woodentoy, Box 40344-WWJ, Grand Large selection of wood parts. Free catalog.
Junction, CO 81504. Lockbit Keyless Chuck for cordless tools. K & K Woodcrafters, RD 4 Box 270A,
Only $8.00. Spors Company, 3031 Iroquois Scotia, NY 12302.
Door Harp Hardware - 50 tuning pins (W), Detroit, MI 48214.
$15.00; 250 pins $52.50; 500 pins $80.00; Live and work in Paradise! Own a pro-
1000 pins $120.00. !4 lb. No.2 wire $8.00. Informative Catalog for Woodworkers, fi table, well-e stablished furniture
Tuning pin wrench $5.00. All prices woodcarvers, upholstery, antique restorers . refinishing/repair business in Hawaii.
postpaid within the continental USA. Many unusual, hard-to-find items. Send Great family opportunity. Rainbow Isle
Folkcraft Instruments, Box 807P, Winsted, $1.00 to Van Dyke's, Dept. 83, Woon- Restoration, P .[Link] 1173, Kapaa, HI
CT 06098. (203) 379-9857. socket, SD 57385. 96746; (808) 822-5437.

I N D E X T 0 A D V ER T ISERS
Accents 70 Furniture Designs 70 McCall House 69 Singley Specialty 69
Accuset Tool Co. 4 Global ReLeaf 36 McFeely's Hardwoods 69 Taunton Press 9, II, 13
Black & Decker 75 Gold Country Wood works 69 Meisel Hardware Specialties 20 The Tool Company 70
Brown Wood Products 69 Grizzly Imports 12 Minuteman, Inc. 70 Trend-Lines 2
Constantine 27 Homecraft Veneer 70 MLCS 15,33 Turn-a-Carve Tool Co. 69
Dollar Trading Corp. 7 Horton Brasses 69 New Hampshire U.S. Saw 14,15
Dremel 19 Imported European Woodworkers 4 Wedge Innovations 5
Eagle America 10 Hardware 70 Nova Tool Co . 36 The Winfield Collection 6
Econ Abrasives 12 The Japan Woodworker 69 Olson Catalog Sales 69 Woodcraft Supply 13
Emperor Clock Co . 27 Jesse Jones Industries 26 Paxton Hardware 69 Woodmaster Tools 6
Fisher Hill Products 12 K & S Specialty Lumber 14 Penn State Industries 8 The Woodworking Shows 10
Floral Glass & Mirror 14 Madrigal Publishing 36 Rocking Dobbin Ranch 70
Foley-Belsaw 26 Manny's Woodworker's Roga Enterprises 14
Forest Street Wood Designs 69 Place 28 Sakura U.S.A. 13

No vember/ December 1989 71

 ~t\-Back Issues - t r
~ Back issues are $3.50 each postpaid ($4.50 Canadian funds) .
To order use the form bound in the center of this issue.

Vol. 9 No . 4 Jul y-Aug '85

Gate-Leg Ta ble, Computer Desk, Shaving Horse,
Stamp Dispenser, Crumb Collecting Breadboard,
Toy Trucks, Early American Wall Shelf, Pivot-
Top Game /Coffee Table, Settle Bench, Shaker
Single-Drawer Cupboard, Fold-up Workbench ,
Articles: Product Liability: Part II; Caning and
Wood Finishing Supplies; Spray Finishing; Table
Saw Basics; Making the Rule Joint; The William
and Mary Period .
Vol. 9 No. 5 Sept-Oct '85
Colonial Schoolmaster's Desk, Contemporary
Sideboard, Mahogany End Table, Victorian Hall
Tree, Cutlery Wall Cabinet, Swing-out Plant
Hanger, Prancing Horse Silhouette, Block Puzzle,
Iron Caddy, Toy Ironing Board , Early American
Water Bench, Wooden Smoot h Plane, Shaker
Sewing Box, Articles: A Craft Fair Visit; How to
UseStick Shellac; A Guide to Circular Saw Blades;
Making Bent Laminations; Country Colonial Fur-
niture.
Vol. 9 No.6 Nov-Dec '85
Moravian Chair, Dulcimer, Oak Dining Table,
Shaker Washstand, Marking Gauge, Veneered
Wall Clock, 4 x4 Off- Roader , Teddy Bear Puzzle,
Duck Pull-toy, Landscape Cutting Boards, Early
American Tall Clock, Pine Desk Organizer, Ar-
ticles: Secrets of Success; Weaving a Fiber Rush
Seat, Part I; Table Saw Ripping Prob lems and
Their Solutions; 4-Piece Book Match Veneering;
Pennsylvania Dutch Furniture .
Vol. 10 No.1 Jan-Feb '86
Freestanding Shelf System , Chippendale
Bachelor's Chest, Oriental ServingTray, Country
Bench, Antique Knife Tray, Tape Dispenser,
Vol. 8 No.3 May-June '84 Vol. 9 No.1 Jan-Feb '85 Valentine Box, Toy Tow Truck & Car, Shaker
Country Vegetable Bin, Folding Deck Chair , Early American Step Table, Oak Barrister's Drop-leaf Table, Shop-made Bow Saw, Child's
Shaker Pedestal Table, Wall Hun g Display Bookcase, Parquet Table, Shaker Trestle Table, Settle Bench, Plate Shelves, Articles: On Getting
Cabinets, Wooden Coat Hanger, Toy Car and Bandsawn Wooden Scoops, Toy Biplane, Book Paid for Your Work; Weavinga Fiber Rush Seat,
Trailer, Paper Towel Holder, Carved Hand- Ends, Contemporary Candle Holders , Necktie Part II; Table Saw Crosscutting: Techniques &
Mirror , Writing Desk, Carved Walking Stick, and Belt Holder, Keyed Miter Jig, Modular Coffee Tips; Router-Lathe Fluting: A Shop-made Ap-
Laminated Clock, Oak and Glass End Table, A r- Ta ble and Bar , Magazine and Book Rack, Con- proach; Chippendale Furniture; Special Section:
ticles: How to Lay Out and Make Circular Cuts; temporary Chest of Drawers, Articles: Toys and Back Issue Index .
Mail Order Selling; Stripping Old Finishes; Carv- Children's Articles: An Outline of The Consumer Vol. 10 No.2 Mar-Apr '86
ing tbe Ban-and-C\aw Foot. Product Safety Commission Standards; Shellac;
Not Available
Truing and Squaring Lumber; The Fingerjoint
Vol. 8 No.4 July-Aug ' 84 Spline; Suppliers of Furniture Kits; The Shakers; Vol. 10 No. 3 May-June '86
Wag-on -Wall Clock , Oak Swing, Candy SpecialSection: Back Issue Index. Victorian Whatnot Shelf, Contemporary Lamp,
Dispenser, Cof fee and End Ta bles, Tugboat and Vol. 9 No.2 Mar-Apr '85 Early American Bench, Steam-bent Clock, Pine
Barge, Lazy Susan, Early American Mirror, Col- Hutch /Cupboard, Canada Goose Basket, Toy
Queen Anne Lowboy, Television/VCR Stand,
onial Pipe Box, Sewing Machine Ca binet, Cam Early American Pine Corner Cupboard, Toy Tool Crane, Con diment Holder, Shop Workstation,
Clamp , Hamper, Articles: What Sells Best?; Set, Wind spinner, Woodchopper Whirligig, Parsons Table, Shaker Lap Desk, A rticles: An In-
Homemade Removers; Buying a Basic Set of Chinese Puzzle, Cut-off Jig, Blanket Chest, terview with Toymaker Clare Maginley; How to
Hand Tools; Kerf Bending; Suppliers of Caning & Shaker Harvest Table, Blacksmith' s Tool Tray, Flatten a Warped Board; A Guide for Choosing
Wood Finishing Products. A rticles: A Guide to Photographing Your Work; Your First Router; Supported Steam Bending;
Applying Shellac and Lacquer; Sharpening Plane Victorian Period.
Vol. 8 No.5 Sept-Oct '84 Blades and Chisels; Installing Machine Woven Vol. 10 No. 4 Jul y-Aug '86
Not Available Cane; American Queen Anne, 1715-1755; General Shaker Slat-Back Side Chair, Wall-Hung Display
Woodworking Suppliers. Cabinet, Latticework Planter, Country Bucket
Vol. 8 No.6 Nov-Dec '84 Vol. 9 No.3 May-June ' 85 Bench, Adirondack Chair, Coffee Mill, Oamdig-
Stickley Chair , Tool Cabinet, Shaker Sewing Jacobean Joint Stool, Wall Cabinet with Recessed ger's Basket, Box of Shapes Toy , Disk Clock,
Stand , Lighted Display Ped estal, Teardrop Clock, Finger Pulls, Shaker Desk, Kitchen Cart , Contem- Tenon Jig, Dictionary Stand, A rticles: Selecting
Pierced Tin Cabinet , Toy Hook and Ladder Fire porary Wall Clock, Colonial Wall Sconce, Card the Right Project for Production ; Mo re About
Truck, Busy Bee Toy, Colonial Doll House, Kit- Box, Towel Bar with Glass Shelf, Marble Race Warped Boards; All About Router Bits; The
chen Organizer, Wine Server, Grand father Clock: Toy, Cradle, Vanity Mirro r, Miter Clamping Jig, Sliding Dovetail Joint ; Furniture Kits Suppliers.
Part II, A rticles: Starting a Business: Part II; Ap- Articles: Product Liability: Part I; Restoring an Vol. 10 No.5 Sept-Oct ' 86
plying the Final Finish; The Fundamentals of Antique Mirror Frame; Coping with Wood Move- Desk with Tambour Top, Vanity Case, Stool, Cof-
Wood ; Inlays and Inserts; Gustav Stickley and ment; Making Recessed Finger Pulls; The Jaco- fee Table, Blanket Chest, Mortar and Pestle,
American Mission Furniture. bean Period. Whale Folk Art Silhouette, Toy Wagon, Cran-

72 The Woodworker' s Journal

 berry Rake, Router Bit Box, Shaker Drop-leaf
Table, Articles: Are Your Prices Competitive?;
Restoring a Rosewood Chair; Basic Router Opera-
tions; Making Tambour Doors; General Wood-
working Suppliers.
Vol. 10 No. 6 Nov-Dec '86
Early American Hamper, Cube Table, Rabbit Pull
Toy, Old-Time Sled Wall Shelf, Cassette Tape
Holder, Dog/Cat Bed, Vanity Mirror, Early
American Washstand, Router Table, Victorian
Sleigh, Articles: Wholesale and Discount Sources
of Supply; Sandpaper Abrasives; Usingthe Router
Table; The Mitered Bead Frame and Panel; Clock
Parts Suppliers.
Vol. 11 No .1 Jan-Feb '87
Shaker Blanket Chest, Glass-Top Dining Table,
Dovetailed Stool, Jewelry Box, Door Harp, Toy
Firetruck, Canada Goose Mobile, Balancing
Sawyer Folk Toy, Early American Style End
Table, Jointer Push Board, Articles: Direct Mail
Promotions - Defining the Market for Your Turned Shop Mallets, Articles: French Polishing Vol. 12 No .6 Nov-Dec '88
Work; Old Wood; The Mortise and Tenon, Part I; Made Easy; Plane Iron Sharpening; Making a Child's Carousel Lamp, Shaker High Chest, Table
Combination Hand/Router Dovetailing; Special Splayed Leg Drill Guideblock; Traditional Chip Saw Crosscut Box, Country Vegetable Bin, Whale
Section: Back Issue Index. Carving; Shop-Tested: 12 Jigsaws. Pull Toy, Colo nial Wall Sconce, Treetop
Vol. 11 No.2 Mar-Apr '87 Vol. 11 No . 6 Nov-Dec '87 Christmas Oranament, Classic Pickup Truck,
Shaker Sewing Desk, Garden Bench and Table, Curio Cabinet, Rocking Horse, Three-drawer Contemporary Cradle, Articles: Flattening Wide
Mirrored Wall Shelf, Rhombohedron Puzzle, Jewelry Chest, Tapering Jig, Rolling Toy, Folk Surfaces with the Hand Plane; Making a Cove-
Wood Sawyer Whirligig, Folk Art Door Stop, Art Silhouette, Two Towel Racks, Early American Edged Raised Panel: Core-Box Bit Method;
Kangaroo Pull Toy, Colonial Pine Wall Shelf, Style Wall Shelf, Corner Cupboard, Stacking Polyurethane; A Sander For Large Surfaces; Can-
Contemporary Hall Table, Articles: How to Wine Racks, Articles: On Glues and Gluing; Band ing and Wood Finishing Suppliers.
Create a Direct Mail Promotion; Types of Finish Saw Setup; Making the Continuous Bracket Foot; Vol. 13 No.1 Jan-Feb '89
- An Overview; The Mort ise and Tenon, Part II; Step-By-Step To A Flawless Finish On Pine (Or Shaker Wall Cabinet, Shop-Built Disk Sander,
Making Bevel-Edged Drawer Bottoms. Any Other Wood); Hardware Suppliers. Cherry Table, Pine Wall Clock, Rock and Roll
Vol. 12 No. 1 Jan-Feb '88 Toy, Contemporary Candlesticks, Merganser
Vol. 11 No . 3 May-June '87 Early American Pierced Tin Cabinet, Contem- Decoy, Child's Table and Chairs, A rticles: Buying
Display Pedestal, Kitchen Canister Set, Riding porary Coffee Table, Puss 'n Books Bookends, Hardwood Lumber: What You Need to Know;
Biplane, Contemporary Serving Cart, Napkin Cookbook Holder, Wooden Jewelry, Child's The Thickness Planer; Making Breadboard Ends;
Holder, Decorative Planter, Country Vegetable Duck Puzzle, Shaker Wall Clock, Stereo Cabinet Ebonizing; Hardware Suppliers; Specia l Section :
Bin, Pine Medicine Cabinet, Shop Drum Sander, and Speakers, Country Occasional Table, DrilI Back Issue Index.
Vienna Regulator Clock, Articles: Penetrating Press Jig, Articles: Edge-gluing; The Drill Press;
Oils and How to Use Them; The Jointer; Veneer, Vol. 13 No.2 Mar-Apr '89
Pierced Tin; Four Shopmade Finishes; General Oriental Mirror, Adirondack Settee, Cou ntry
Part I; Decorative Joinery: Dovetail Key Butt- Woodworking Suppliers.
Miter; Caning and Wood Finishing Suppliers. Village, 18th-Century Tilt-Top Ta ble, Toy Fishing
Vol. 12 No.2 Mar-Apr '88 Trawler, Two Trivets, Folk-Art Cow, Greek
Folk Harp, Oak & Glass Tier Table, Crystal Revival Birdhouse, Pine Armoi re, A rticles:
Regulator Clock, Early American Candlesticks, Transferring and Entargmg Patterns; Making
Arrow Wall Decoration, Three-Drawer Country Tripod Legs; Three Easy Finishes for Pine; The
Wall Box, Key Cabinet, Contemporary Box, Portable Circular Saw; Schools and Craft Centers.
Shaker Carrier, Articles: Use and Sharpening of Vol. 13 No.3 May-June '89
the Hand Scraper; The Lathe: Basic Setup; Jewelry Chest, Storage Seats, Ta ble Saw Gauge,
Quartered Turnings; Lacquer; Stationary Too l Oval Extension Tab le, Nessie Pull Toy, Back
Suppliers. Massager, Decorative Wall Key, Country Wall
Vol. 12 No.3 May-June '88 Shelf, Contemporary Mirror, Articles: Panel Re-
Hunt Table, Loon Carving, Early American Dry tainer Disk System; Understandi ng Circular Saw
Sink, Contemporary Dresser, Old-Time Pipe Box, Blades; Cutting Box Joints; Non-Toxic Finishes;
Antique Knife & Fork Tray, Dutch Tulip Folk-Art Massachusetts Woodworker Paula Garbarino;
Silhouette, Colonial Salt Box, Bud Vase, Miter General Woodworking Suppliers.
Gauge Stop, Articles: Spindle Turning; Selecting Vol. 13 No.4 July-Aug '89
and Sharpening Lathe Tools; Recessed Finger Pull Country Pie Safe, Shaker Long Bench, Folk-Art
Step-By-Step; Types of Stain; Clock Parts Sup- Sign, Toy Farm Tracto r and Wagon, Miniature
pliers. Flower Cart, Kitchen To ngs, Pine Wall Cabinet
Vol. 12 No. 4 July-Aug '88 with Tinsel Art, Stacking Bookshelves, A rticles:
Four-Drawer Lamp, Oak Magazine Rack, Occa- Dealing with Uneven Wood ; Tinsel Art; Coping
sional Table, Mitered-Corner Box, Heart Stool, with Your Radial-Arm Saw; Brushing Lacquer;
Decorative Cutting Boards, Kids' Piggy Bank, Tools on Display: A Visit to a Woodworking
VOl. 11 No. 4 July-Aug '87 Turned Bowl, Country Cupboard, Articles: Show; Stationary Equipment Suppliers.
TV/ VCR Cabinet, Early American Style Faceplate Turning; Workshop Layout; Cutting Vol. 13 No.5 Sept-Oct '89
Bookcase, Pine Trash Container, Sturdy Low-cost Dovetails on the Table Saw; Staining Basics; Oak Globe Stand , Country Bake-Room Table,
Workbench, Country Basket, Desk Calendar with Schools and Craft Centers. Chippendale Small Chest, Stacking Desk Trays,
Pen & Pencil, Butterfly Pull Toy, Vanity Mirror Vol. 12 No.5 Sept-Oct '88 Pencil Box, Apple Doorstop, Space Shuttle Toy,
with Drawer, Apothecary Chest, Articles: Shellac; Oak Bookcase Desk, Miter Cutting Jig, Captain's Marquetry Coasters, Ice Chest with Marbleized
The Hand Plane; Veneer, Part II; IncisedCarving; Clock, Country Coffee Tab le, Rooster Folk-Art Top, Articles: The Table Saw: Basic Adjustme nts;
Hardwoods Suppliers. Silhouette, Harvest Basket, Bird Push Toy, Pencil Cutting Full-Blind Dovetails; Marquetry: The Pad
Vol. 11 No .5 Sept-Oct '87 Post Nightstand, 18th-Century Pencil Post Bed, Method; Marbleizing: Creating a Faux-Marble
Pine Woodbox, Contemporary Love Seat, Two- A rticles: Why Worry About Wood Movement?; Finish on Wood; Mount Lebano n Shaker Village:
Drawer Oak Platform Bed, Snail Pull Toy, Joining Ring Segments; Drill Bits and Boring: The A Museum in the Making; Tool Review: Shop
Ifciuted Trivets, Spice Rack with Chip Carving, Hole Story; Filling Open-Grained Woods; Hard - Test - Four Portable Planers; Clock Parts Sup-
Joiner's Tool Chest, Shaker-style Step Stool, wood Suppliers. pliers.

November/ December 1989 73

ISho~ Ti~sl
Most work shop s have at least one in a busy work shop. To make it easier
jar or coffee can that' s filled with a to find , tr y spray painting the tape
hodgepodge of screws, nails, nuts, measure case with a coat of bright ir-
bolts, and the like. To find a part ridescent paint.
buried in the jar usually means dump-
ing the contents on the workbench. If I was forever misplacing the chuck
I designed this pushstick after suf- you 're lucky enough to find what you
fering a serious hand injury while using key for my drill press. My solution was
are look ing for, you then have the task to remove the magnet from an old
a molding head on the radial-arm saw. of getting all tho se little parts back in
I was using a length of small diameter the jar. Th is homemade tray makes the
job much easier. When you dump out
the jar, the tray sides keep all the parts

dowel as a push stick when the molding

head suddenly kicked the workpiece stereo speaker, then glue the magnet to
back at me and drove the pushstick the drill press feed handle hub. Now ,
through my hand. I feel more com fo rt- stuck to the magnet, the key is always
able with my new design. It uses a close at hand.
flang ed bicycle handlebar grip, which Pat Souders, Lake Park, Fla.
fits tightly over a 16 in. length of %in. The Woodworker 's Journal pays $25 for reader-
dowel stock. The dowel end is not ched contained, and the corner cutout in the submitted shop tips that arepublished. Send yo ur
to grip the stock. Should kickback oc- bottom makes it quick and easy to ideas (including sketch if necessary) to: The
cur, the large flange would help carry pour the parts back. The cutout also Wood worker 's Journal , P.O. Box 1629, New
the hand back with the pushstick . I cut provides a means to hang the tray. Milford, CT 06776, Attention: Shop Tip Editor.
We redraw all sketches, so they need only be clear
a flat on the flange to keep it fro m roll- and complete. If you would like the material
ing when placed on a flat surface. Th e tape mea sure is one of those returned, please include a self-addressedstamped
Harold N achlin, San Diego, Calif. tools that seems to get easily misplaced envelope.

Next Issue • • •
We've lin ed up so me grea t projects to star t your
new year otT right. The Sho p- Built Spindle Sande r is
a useful addi tio n to any sho p. It's the perfect tool
for sa nding curves ... like th ose on the apkin
Hold er. The W eaver 's Chest of Drawers, with its
milk-painted fram e and butternut draw er fronts, is
ba sed on a similar Sha ker chest in Mt. Leban on ,
New York. Th ese ar e just three of the man y proj ects
yo u'll find in the J anuary/February 1990 issu e of
TIle Woodwor·'le,.'s [ournal.

74 The Woodworker's Journal

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The only one of [Link] inthe U.S., the Elu Jointerl " ~ i,:-
Spfiner !:las amotor that swivels, so plate cutting ." "
from any position [Link]'s more, it makes ' (,
..groovesfor,flat dowels and splines,and iseven " I
I aprecision trim saw. ~aking it by far the " " ~; '-.
. most flexible tool you can own. .
-t. :' ( ' . . . . . :. . . .
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.: Solid and p.60erful;'aii Elu 'Plunge "
Routers provide perfect 90 degree
entry and exit from the workpiece. Plus,
, on two models,electronic controlled
variable speed isperfect formatching ,
, cutters toall different materials toassure
",. 'the [Link] each Router is
, 'availablewith avariety ofattachments
. to'giveyou total versatility and control.
" . .
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• ' . --Our Universal 'Planer has the power and, ' '.' ,
• . durability neededfor awide variety of materials. Its •
.... cast aluminum shoes are precision machined after ()ssem~1y , . ' .
.r..e~. ". so they're parallel tothe planing surface and rabbeting .
-. ..... [Link] itgives you asatin-Hke finish every time,
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.'., ", -Tbe Elu System. Atradition 'of painstaking crattsrnanshp a~d modern tech'nology combined tocreate
the benchmarkfor woodworking accuracy, .'. " . . ., .. . .,
" , . Every tool we build has baU and roller bearing motors, .heavY~uty housings and the latest power
transmission systems, Plus innovative accessoriesthat alloy.' you to [Link] the most grueling shop
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" E lu~ From Black & Decker.~ :" , ,

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•
Country Projects For Woodworkers Contemporary Woodworking Projects Woodcarving With Rick Butz
If bui lding the simple, sturdy furniture of Paul Levine guides woodworkers of all Learn woodc arving! With ju st a few tools
the old cabinetmakers appeals to you, skill levels through room-by-room and a few hours to spare, you can share
then you'll want this collection of the chapters of coo rdinated furniture and in the simple pleasures of carving.
best country projects from the 1980-84 accessories. The clean angles, sturdy Wander into the Black Forest of
issues of The Woodworker's Journal. 85 joinery and special techniques are made Germany with a traditi onal carving of St.
complete plans range from weekend easy to master with step-by-step Nick, or into a small Russian village with
projects like Colonial Candlesticks and instructions and illustrations. Among the a Dancing Bears folk toy. You'll enjoy a
Fireplace Bellows to more challenging 40 handsome projects are a matching chip-carved Quilt Rack, wildlife carvings ,
projects such as a Shaker Chest of Love Seat, Chair and Ottoman set, an and a Tobacconist's Indian. All 14
Drawers, a Stepped-Back Hutch , and an Oak Credenza, a Platform Bed, and a projects are fully detailed with step-by-
18th Century Trestle Table. Some plans Japanese Shoji Lamp. Children will enjoy step photos. There are also chapters on
are also found in Projects for the ir own table and chair set, puzzles tool selection, sharpening, whittling,
Woodworkers, Volumes 1 and 2. and a great box of dominoes. chip and relief carving.

BOOKS
FROM ~
You'll find the order form for these books bound in the center of this issue.
Projects For Woodworkers, Volume 1 Projects For Woodworkers, Volume 2 101 Projects For Woodworkers
Beginning and advanced woodworkers Original ly published in the 1982 issues For the eager amateur just start ing out
alike will appreciate the full range of of The Woodworker 's Journal, all 60 or the craftsman with a shop full of
styles in furnitu re, accessories, lamps , projects were chosen with a wide variety tool s, 101 Projects For Woodworkers
clocks, toys and gifts. Of the 75 projects of styles and skill levels in mind. Each features an unparalle led variety of
selected from the 1980-81 issues of The project is presented with complete classic projects for everyone. Included in
Woodworker 's Journal, plans include a instructions and thorough illust rations. thi s collecti on of plans from the 1977-80
Cabinetmaker's Workbench, Pine Shaker You'll find household accessories like issues of The Woodworke r's Journal are
Cupboard, Old-time Icebox, a Cobbler's the Desk Caddy, Casserole Dish Holder, a classic Rolltop Desk, an old-fas hioned
Bench Coffee Table and a Child 's and Breakfast Tray easy to build. And Porch Swing, traditional and
Victorian Sled. Fully detailed you're sure to enjoy the reward of contemporary furnit ure, clocks, mirrors ,
instructions, illustrations, and photos. completing more involved projects like home accessories, toys and novelties .
the Tambou r Desk, Old Danish Chest of Complete instructions and illustrations.
Drawers and Swinging Cradle.
Projects for ..
Woodworkers "/
75 Project Plans for Furniture,
Toys. and Accessories
Volume I