OUR BIGGEST ISSUE – 116 PAGES PAGES OF TIPS, TRICKS & TECHNIQUES
ANOTHER MYTH BITES BITE S THE DUST: FINISHING BOTH B OTH SIDES NOT NECESSARY OCTOBER 2004 ISSUE #143
Best $1 Best $1,50 500 0 Woodshop High-Quality Work, Low-Budget Low-B udget Tools Tools
4 Great Ways to Make Drawer Drawerss Tor ornad nado o Tab Table le 10 Dowels, 2 Boards, Boards, 4 Hours Hours – You’re You’re Done
PLUS • Ultimate Hand Plane Cabinet • Best Honing Guide is the Cheapest 6 Tricks Tricks to Make Better Cabriole Legs
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CIRCLE NO. 126 ON FREE INFORMATION CA RD.
CIRCLE NO. 126 ON FREE INFORMATION CA RD.
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Most stains are made with linseed oil. Varathane Premium Wood Stains are made with our proprietary, ultra-clear soya oil formula. Unlike linseed oil which can contribute unwanted color to stains, the clarity of
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Varathane’s soya oil formula allows the stain to reveal the beauty of your wood. The end result? All of Varathane Varathane Premium Wood Stains’ 24 colors are considerably richer, clearer and brighter. “Would you like a nice Cabernet?”
Or Traditional Cherry? Or Mission Oak? Varathane Premium Wood Stains are available in a wide range of appealing colors. In fact, Va Varathane’s rathane’s colors are preferred pref erred more than than 2 to to1 1 over the the ® ™ colors of Minwax Wood Finish . From Natural to Dark Walnut, you’re sure to find the right color for your wood finishing project.
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CIRCLE NO. 159 ON FREE INFORMATION CARD.
Log on to www.woodanswers.com and the first 5000 requests will receive a complimentary Trial T rial Size Variety Variety Pack, featuring all 24 Varathane Premium Wood Stain colors. With new Varathane stains, you’ll not only be revealing your wood’s true beauty and richness, you’ll be revealing your own sense of style and craftsmanship. For your next project, trust the name that’s been the premium wood care leader for almost five decades. And soon to to be the the premium leader in wood stains as well.
Minwax is a registered trademark of the Sherwin Williams Company. Company. *Source: Preference Test of the Varathane Line versus the Minwax Line of Interior Wood Stains, May 2003
contents IN EVERY ISSUE
14
Fix a Square that Isn’t Square Q&A
Turn your framing frami ng square into a precision cabinetmaking tool. Plus: Center your router bit bit in your aftermarket afterm arket guide bushing and the best books on wooden hand planes.
18
The Easy Way to Get Glue in Tight Places TRICKS OF THE TRADE
Vacuum pressure (from a kitchen appliance) gets epoxy into impossible places. Plus: An ancient idea extends a clamp’s reach, turn tur n a dead bolt into a planing stop and more.
18
28
Side-clamp Honing Guide ENDURANCE TEST
It’s not train training ing wheels – it’s just good sense. This guide helps you produce sharp, square edges every single time.
30
A New Feature-laden Band Saw TOOL TEST
Powermatic’s 14" Powermatic’s 14" machine has ha s all the bells bell s and whistles. whistle s. Plus: 240mm Japanese hand saw, s aw, In�nity’s Dadonator, Noden’s Noden ’s Adjus Adjustt-a-Ben a-Bench ch and the Veritas Bullnose Plane.
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30
Router-made Mortises & Tenons POWER-TOOL JOINERY
This age-old joint doesn’t require hand skills. If you need to get it done fast, fa st, use your router. We show you how. how. by Bill Hylton
42
Bottle Stoppers AT THE LATHE
Learn the tricks for this popular spindle-turning project. project. by Judy Ditmer
110
Finish Both Sides? It’s Not Necessary FLEXNER ON FINISHING
You read that right. Finishing Fini shing both sides of your tabletop won’tt reduce cupping won’ cuppin g or war ping. We show you why. why. by Bob Flexner
34
April, June, August, Popular Woodworking (ISSN 0884- 8823,USPS 752-250) is published 7 times a year in February, April,
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October, November and December by F+W Publications Inc. Editorial and advertising offices are located at 4700 E. Galbraith Road, Cincinnati, Ohio 45236; tel.: 513-531-2222. Unsolicited manuscripts, photographs and artwork should include ample postage on a self-addressed, stamped envelope (SASE); otherwise they will not be returned. Subscription rates: A year’s subscription (7 issues) is $28; outside of U.S. add $7/year Canada Publications Mail Agreement No. 40025316. Canadian return address: 2744 Edna St., Windsor, ON N8Y 1V2 Copyright 2004 by Popular Woodworking . Periodicals postage paid at Cincinnati, Ohio, and additional mailing offices. Postmaster: Send all address changes to Popular Woodworking , P.O. Box 420235, Palm Coast, FL 32142-0235 Canada GST Reg. # R12259471 R1225947166 Produced and printed in the U.S.A. ■
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PROJECTS, TOOLS AND TECHNIQUES
46
Tornado Table This may be the t he easiest table you’ll ever build. And it will surely be one of the coolest. by Steve Shanesy & John Hutchinson
ON THE COVER A cabriole leg is a classic furniture detail we all aspire to. Our template makes building them easy work.
53
Intro to the Table Saw WOODWORKING ESSENTIALS
We kick off a new seven-part series serie s about the table saw with some important information infor mation about different kinds of saws and a nd how to set them up. by Nick Engler
61
Cover photo by Al Parrish
3-D Mortising Upgrade An easily modi�ed X/Y vise will turn your drill press or benchtop mortiser into a precision machine.
DEPARTMENTS
8
Out on a Limb Send a free magazine and do a good deed.
66
$1,500 Workshop
72
Hand Plane Cabinet
80
Block Plane Basics
10 Letters
84
38 Great
72
Woodshops
112 News & Notes
A $17,050 $17,050 pencil sharpener; 109 tools for $100 and one of the world’s largest band saws.
Our list of the tools that t hat let you set up up shop without maxing out your credit card or sacri�cing accuracy. accur acy.
Hand planes are the thoroughbreds thor oughbreds of the shop. And this simple and effective cabinet is the barn.
Every project seems to require a block plane. Choos e the right tool and a nd learn to set it up properly. by Lonnie Bird
Mail from readers
Step back in time with a visit to the shop of Dana Batory, the leading expert on vintage machinery.
46
90
Steel-stringed Guitar A 25-year-old 25-year-old dream is realized reali zed when Editor Steve Shanesyy builds a guitar. Join him on his journey. Shanes
Four Good Ways To Build Drawers Drawer s The simplest, strongest and fastest ways to build this important furniture fur niture component. component.
96
Make Your First Cabriole Legs It’s easier than you think. A little work on the table saw, band saw and lathe add up to great curves. cur ves. by Glen Huey
102 10 2
3 Most Essential Tools When it comes to woodworking, woodworkin g, remember the old saying, “It’s not the arrows, it’s the India n.” by Jim Tolpin
4
POPULAR WOODWORKING October 2004
80
FLAT OUT BETTER.
A powerful 8 Amp motor offers variable belt speeds from 850 –1 –1,400 ,400 sfpm
A unique, three wheel design puts the motor between the rollers for better balance
The machined platen delivers flatness and maximum belt-tomaterial contact
A robust all-metal housing provides added durability
Dust collection system with a break-away bag is durable, efficient and easy to empty
THE DW433 BELT SANDER FROM DEWAL WALT T TAKES INNOVA INNOVATION TION AND AGGRESSIVE MATERIAL REMOVAL TO A NEW LEVEL. The DEWAL WALTT DW433 3" x 21" belt sander offers a powerful 8 Amp motor and electronic feedback to maintain belt speed under load. The variable speed dial delivers belt speeds from 850–1,400 sfpm for the proper removal rate on a variety of materials. An extra-long machined platen ensures flatness and maximizes belt contact with the material. A unique, three wheel design places the motor down in between the rollers to offer better balance, the lowest possible center of gravity and a unique automatic belt tracking system. A robust, all-metal housing provides added durability in a drop, while the innovative break-away dust collection system is durable, efficient and easy to empty. A two-position front handle, top exit cord and rubber grip provide added comfort while you work. In every way, the DW433 belt sander is more aggressive, more durable and more balanced — for a faster, flatter finish every time.
©2003 DEWALT. The following are examples of trademarks for one or more D EWALT power tools and accessories: The yellow and black color scheme; the “D”-shaped air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the array of lozenge-shaped humps on the surface of the tool. CIRCLE NO. 110 ON FREE INFORMATION CARD .
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October 2004, 20 04, Vol. 24, No. 5 popwood.com
Editorial Of�ces 513-531-2690 Editor & Publisher Steve Shanesy ext. 1238 • steve.shanesy@fw pubs.com
While these quality spokeshaves are beauties, they will actually become your favorites because they are so comfortable and easy to use.
Art Director Linda Watts ext. 1396 • linda.watts@fw linda.watts@fw pubs.com Executive Editor Christopher Schwarz ext. 1407 • chris.schwarz@fw pubs.com Senior Editor David Thiel ext. 1255 •
[email protected] Managing Editor Kara Gebhart ext. 1348 • kara.gebhart@fw pubs.com Associate Editor Michael A. Rabkin Project Illustrator John Hutchinson Photographer Al Parrish Contributing Editors Nick Engler, Bob Flexner, Glen Huey, Don McConnell, Troy Sexton
Until the end of October 2004, we are offering our new concave spokeshave at a special introductory price. For those interested in all three, we have a special price for the set. (reg.. $75. $75.00) 00) Shipping & NY sales tax extra. 05P33.11P Concave Spokeshave $65.00 (reg Spokeshaves (flat, round & concave) $149.00 (reg. $205 $205.00) .00) 05P33.13P Set of 3 Spokeshaves
Magazine Group Head David Hoguet Executive Vice President President Magazine Advert ising Jim Gleim
For more details or to request request a free catalog, visit us online or call us at:
CIRCULATION Mark Fleetwood, Group Circulation Manager
1-800-683-8170
www.leevalley.com
Lee Valley Tools Tools Ltd., 814 Proctor Avenue, Ogdensburg, New York York 13669 CIRCLE NO.136 ON FREE INFORMATION CARD.
OU’RE PROBABLY J MBITIOUS. Y OU’RE JUST A S A MBITIOUS. Whether you are a do-ityourselfer, a professional woodworker or somewhere in between, you have a world full of projects in the home or in the shop that will be easier and more enjoyable to complete when you use quality clamps, bench vises and miter boxes/saws from the Adjustable Clamp Company. Look for them under the Jorgensen, Adjustable and Pony brand names wherever fine tools are sold.
PRODUCTION Barbara Schmitz, Vice President Vicki Whitford, Production Supervisor Brian Courter, ProductionCoordinator ADVERTISING Don Schroder, Advertising Director 331 N. Arch St., Allentown, Allent own, PA 18104 18104 Tel. 610-821-4425; Fax 610-821 610-821-7884 -7884
[email protected] Advertis ing Production Coordinator Debbie Thomas, Tel. 513-531-2690 ext. 1219
[email protected] SUBSCRIPTION SERVICES: Subscription inquiries, orders and address changes c an be made at popwood.com (click on “Cus tomer Service FAQs”). Or by mail: Popular Woodworking , P.O. Box 420235, Palm Coast, FL 32142-0235. Or call 877-860-9140 or 386-246-3369. Include your address with all inquiries. Allow 6 to 8 weeks for delivery. NEWSSTAND DISTRIBUTION: Curtis Circulation Co., 730 River Road, New Milford, NJ 07646 ATTENTION RETAILERS: To carr y Popular Woodworking in in your store, call Steve Hudziak at 800-894-4656 or write Magazine Retail Sales, Steve Hudziak, P.O. Box 5014, Iola, WI 5 4945-5014. Back issues a re available. Call 800-258-0929 for pricing or visit our web site at popwood.com. Send check or money orde r to: Popular Woodworking Back Issues, F+W Publications Products, 700 E. State St., Iola, WI 54990. Please specif y publication, month and year.
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Made in the USA by the Adjustable Clamp Co., 425 North Ashland Ave., Chicago, IL 60622,
www.adjustableclamp.com CIRCLE NO. 102 ON FREE INFO RMATION CARD.
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Safety is your responsibility. Manufacturers place safety devices on their equipment for a reason. In many photos you see in Popular Woodworking, these have been removed to provide clarity. clarit y. In some cases we’ll use an awkward body position so you can better see what’s being demonstrated. Don’t copy us. think about each proced ure you’re going to perform beforehand. Safety First!
CIRCLE NO. 120 ON FREE INFORMATION CARD.
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ON A LIMB
Send a Fre Send Freee Magazine And Do a Good Deed Y
ou may �nd the following a bit off-t of f-topic opic might then start receiving un solicit solicited ed mail. compared to the usual fare found in this So let me make this pledge to you: No names space so let me start by asking your indulgence provided to Popular Woodworking under under this and telling you about a meeting I had last charity program will ever be made available winter at the headquarters headquar ters of Lee Valley Tools Tools to an outside party. and Veritas in Ottawa, Ontario. You may wonder wonder how we can afford af ford such I was talking with Robin Lee, the company a program, giving up to 25 percent of a subpresident, covering a wide ra nge of interest i nterest-- scription price to charity. The simple fact is ing subjects. At one point Robin steered the new readers who come to us via this program conversation toward corporate charitable save us the money we’d we’d otherwise otherwis e spend on giving and described a program his company advertising to go out and �nd them. started some years ago. I was thoroughly t horoughly taken We’v e’vee decided to support t wo charities by the concept. It’s one of those “everybody with the funds we will be donating. donating. One is wins” ideas, a “no brainer.” the American America n Cancer Ca ncer Society (cancer (cancer.org) .org).. We’ve adopted the idea from Lee Valley It is safe to say everyone has been touched in Tools, and a nd here’s how it’s going to work: some way by this widespread, ongoing health You help help us find a woo dworker who be- problem. We We see evidence that signi �cant comes a Popular Woodworking subscriber, subscriber, and progress is being made on ma ny cancer fronts, we, in turn, make ma ke a $5 $5 donation to a charity. but there remains much work to do. Let’ss say you have a friend Let’ f riend and you think thi nk The other charity we will support is The he or she might enjoy receiving Popular Wood- Nature Conservanc Conservancyy (na (nature.o ture.org) rg).. This orga orga-working . All you need to do is �ll out the form nization’s no-nonsense approach to preservbelow and mail it to the addres s shown or ing import ant habitat is commendable: It visit popwood.com/charity.html popwood.com/charity.html and �ll out buys land outright to protect it in perpetuity. the electronic form there. We’ll We’ll send your The Nature Conservancy also works with friend a free copy of the magazine and a note individuals and busines ses to keep private saying we were given their name by a friend. land in private hands while making sure u se (However,, we won’t say who, so it would be restrictions preserve its natural state. PW (However good to let them know to expect the free magazine.) If they decide to subscribe, all they do is complete the order form and mail it back (it will have a code so we know the orde r is from our charity cha rity program). Steve Shanesy I fully understand any concerns you might Editor & Publisher have about providing the names of friends who
Please send a complimentar complimentaryy issue of
GLEN HUEY Glen’ss motto is Glen’ i s this: “If you can’t do it on a table saw, it’s not worth doing.” Once a lover of all things Shaker, Glen has since immersed himself in the Queen Anne, Chippendale and Federal styles to produce custom furniture from his shop just north of Cincinn ati. He’s a master at �nding simple ways to tackle complex operations, such as his cabriole leg technique shown on page 96. Unlike some hobbyists-turned-ca reerwoodworkers, Glen – a professional since 1989 198 9 – still loves the craft. cra ft. “I get up every morning and a nd can’t wait to get started,” he says. He has written two books on building early American furniture and also teaches woodworking classes regularly regularly.. BOB FLEXNER For 10 years, Bob’s quest has b een to demystify finishing – long considered a “black art” shrouded in mystery and made more complex by confusing labels on �nishing products. Bob’ss landma rk book, Bob’ “Understanding Wood Finishing” Finishin g” (Readers Digest), opened the eyes of thousands of woodworkers. But Bob’s B ob’s not a chemist. He started his career in 1976 1976 building custom furniture furnitu re in Oklahoma. He eventually turned to furniture restoration, which better challenged his skills. Finishing, however, however, proved to be a problem. So he started reading book s and talking talk ing to chemists. Today, he skewers skewers �nishing myth s (such as the one on page 110 10)) through his writing and workshops.
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LETTERS
Glo lov ves at Hear Heartt of Lathe Saf Safety Deba Debate te Reader Argues that Hand Protection Is Too Dangerous – Author Disagrees I was glad to see the star t of the recurring column on woodtur ning – “At The Lathe” (August 2004) – until I saw the turner wearing weari ng a glove. I noticed that she was shown u sing a few common-sense safety devices (such as the facemask and earplugs) but thought it quite ironic and irresponsible that a glove was being worn, especially considering the article was geared toward new turners. T he American Association of Woodturners recommends not wearing gloves in the third section of its safety guidelines (woodtur (woodturner.org/resources) ner.org/resources) and for very good reason. I’ve heard heard all ki nds of justification s for wearing gloves while turning – protecting the user from heat and bark �ying of f, reducreducing vibration, using �ngerless or tight-�tting tight-�tting gloves isn’t isn’t as dangerous d angerous and, of course, says aying “I haven’ have n’tt had a problem probl em yet.” None of them justify the enormous risk of getting that glove caught on just the slightest bit of wood and pulling pulli ng it (and (and the rest of you) into the spinning piece. The tur ners, experienced or novice, that I know who have had injuries sustained sustaine d by wearing gloves at the lathe don’t think the t he risk is worth it anymore, either. either. If you feel you need to wear a glove to protect your hand during turning, you’re doing somethi ng wrong. Don’t use the glove as a cr utch to overcome de�ciencies de�ciencies in your technique or project planning. For example, you can adjust the tool position or your hand position to keep the hot shavings or shar p bark off your skin. This isn’t a situation where a blade guard is taken off t he table saw for photographic photographic purposes. purpo ses. A number of pictures pictures in this article show the glove in close proximity to the spinning wood. This is a serious and da ngerous practice that must not be perpetuated in your magazine by having pictures of it being practiced. At the very least, I implore i mplore you to make mention of the danger of wearing gloves near
CIRCLE NO. 166 ON FREE INFORMATION CARD.
10
POPULAR WOODWORKING
October 2004
a lathe in upcoming articles. a rticles. Let the public know of the risks invo i nvolved. lved. Andrew Hilton Spring�eld, Missouri
Author Judy Ditmer Ditme r responds: I often use a glove while turning to protect p rotect my hands hand s from injury. If the gloves �t well and the turner’s hands are kept entirely on the near side of the toolrest at all times – as they should be in any case – wearing a glove should present no hazard. (Note (Note that in i n the photo on o n page 77 at left and on page 78 at top-left, I moved my hands so the tool’ tool’ss position can be seen.) It is essential (whether you’re wearing a glove or not) to keep both hands away from f rom the piece while th e lathe is i s on. It’ It’s not distance, but rather a positive orientation of the upper hand to the toolrest that ensures this. Some part of this hand is placed pl aced against the rest in a way that prevents the hand (or the tool itself) from being pushed or pulled into the piece. Without this positive connection to the toolrest, there is no way to control the in-andout movement of the tool. It is the leverage and control this contact affords that keeps your hands, gloved or not, safely on your side of the toolrest. continued on page 12
WRITE TO US Popular Woodworking welcomes welcomes letters with
comments about the magazine or about woodworking in general. We try to respond to all correspondence. Published letters may be edited for length or style. All letters become property of Popular Woodworking . How to send your letter: • E-mail: popwood@fwpub
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