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NO. 41
NOTES FROM THE SHOP
$2.50
Sawdust Number 41
Sept.. Oct., 1985
EdllOf Dcmald B. Peochke
DeSign llIreclOr Ted Kran .. ~ AssIstant Ed1tars Ste'le Krohtner Doug las l. Hleks Douglas M. Lidster
If d()iJI~!'Om€!lhin~two )tear:o. in a row e.Eablbhes " tradition, then I'm happy to .ay that this i. our trndhional
Too many businesses make deelsions based on how much money is going to be made. The "bottom line" a11l'3)'sseems to dictate deeisicns and new ventures, I think I' beuer approach is to make
that \\ uulll makr- "Ire ..,nIts, 1\(1n nt the same tim!' he int,·r.,tinJ( to huild \\,,, &1,. \,"antt.'tl tu lnclude one bl~P"")J4."Cl especially fur kids, The tin. we came ul' with this year 1h an easel desk. ,
decisions based 011 the service you can provide, I try to put myself in the CU$iorner's shoes and make mv decisions from
TH\I)ITI()S.
h(lliday!!ift i»Ul·. we've (ned to rome up with projects
that perspective. . This is the approach we used from the \Vh"" IV,' l1""t ,u.rtcd th.. "roJ""t, I b
one pro} tising).:\ ow we're trying this approach TilCIlnlcallJlUslm!()f$ eet where my OP'111011 dldn't .",unt much. with the store. David Kreyl1ng \Ve docld,,,1 II) call UI ~.m.' expert, - We For the pm;Lyear; Steve Krohmer lui, Mike Henry invited some (,flh ... l'·'HxIAlll;fJ( kids to te~t been heading up the work on the store. SubscJ1ption Manager it nut. They were mort' than eager to Part of his job is to order e"c1'IIl/rillg a Sandy J. Baum answer Our (}'It lioM. woodworker would want - imported hand SubSenphon Assistants y~"the de.k top f"Jd~down okay Iwith- tool", power equipment, 3Ii species IIf\\'ooo Christel Miner out ban~nK ~'our head). The drawers ean (including exotic woods), finishing supVicky Robinson be reaehed c;u;U) II dllt'~1l'Ltil)over when plies, speciality hardware. In short. Jackie Stroud ernwlinl: "'.1' th,' dr',k to get to the cork everything, Computer OpemUons board. E''''YthinjC cheeked out. That job sounds like a woodworker'. Ken Mfnef But th~rc wns one thing we didn't an· dream, But according to Steve, it has ticipate. The longer we watched the kids turned into a nightmare of paperwork. CirculatIOn Managet 1uI\;nK" ",,,,denul Lime, the more we He'. had to order over 4,000 different Jell Farris be~.n 10 see other possibilities for this item", from all over the world. Adml,,;Stra1lveAss;S\8nt projc'<'t.\~'Ith longer legs (adult size), it But that's the approach we wanted to Cheryl Scott could bt· • m.",""ge center in the kitchen, take, and the store is well on the way to Bu.ldongMaintenance Or by mllkinp:it witheut 11'Jl>'. it could be. being the kind of store for woedworkers ArchIe Krause wall-hung'de.\\, qu('!'>tinn!'. \\'h)' dicl )'OU J!U)'~at l'tJ(H'i store m"nugcr. Woodsml1h Pub·,sIllng Co. $,).il" decide to open a store'! An> th.n, I!",itf•• lhe St. l.ouii'loeation. \\;11 there Copyrlghl 1985 by Woodsm"!> Pubhslling Co. go}n$: to be muTe ~to,.et-~ Are )"OUgoing to be Iluu-e ::-tOf'f::;'In the future? A,I AlQhts Reserved offer mail'(lrrli'rI)urchru1 question (why did We docid. to • ~"1'" II)",h:lk~ out.' theil we'll see what years (12 iSoSues) S18, Single copy pnce, $2,SO open S $10....1) g..1s ot the heart ofh"w \\e h.,'pens. (Canada and Foreign: odd 52 pa' year.) apl)ruaclt thin).,.""htrt> at "rood~l,/ill '\~h(.>n ()nco la..'1!lque:;tion eonc~rning the store: Change Of Address: Please be sure'" InclUde W(HKi.'l't"itl, st.arted !-'t','el) ~·eJtn;.aj!(I, Ctnt'Clf J)fj ~'()Upl,'n lo Lake phone Ul'tlOrs or ha"e 3: both yourold and new address, the ded.i(ons that had to bt.' marl. "':L' \\ hat m••il-urder cautlog? Second class postage paid ilt Des MoInes, the purpo:;eof the comf"ll'Y\\l.. , Ko. Thl'l'Care already several excellent Iowa. Il', popular 1I0waday. (or th(' "f.
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,,(lod.
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2
WOOOSMITH
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T_~ & Technigu_e_s__
CHECKING A 22'/,'
In order to make an octagonal (eight sided I frame. ,)'OU have to cut 22:'/:: miters on lh(, frame piece", (This type of mitered frame \\'3< used on the clock. see pg. 10.1 The only problem is how Lacut aJl tlr(./Irat. 22Y,o mitez Note: T...,hnicall~'you'", culling a 67~/ al/{/I~. But to do this, >'OU have to tip the blade to the 22u• mark on the gauge (91) -22Y,'~6",·).
However, most
58"' 1!3\Igt'S
(Jusl)' inaccurate, One
\\'8:'
to
arc :set
110lOli·
the saw
accurately is to use an ;'rti~l'::-ftlljustable
prorraeter; Or. "OU can make a {rial CUt (Inti
eASE UHf
..--'---I,!-Jl---.,-
1
tho face ofthe arm and the seecnd hole (#21 glc. put the compass at Point C UJuldraw " I_ted on the edge, an arc on each line, Point. U and E, ,..., Tt. "lake a wheel, start b)' cutling a Step 2, round wherl blank .lightly oversize with. ~Iovc the compass to these points 3nd hole saw; bandsaw or sabre .a\~ (:o\ote: If draw two more arcs in.~j(lethe anglo, ("I,n- euu ing witha bands.... nw or-sabre sa", dlilJ 3 neet. t.he pt)lnl where th..-se Ul'\.~inlt·~(.'(.·t axi" hole III the l"i!IIU'r.' tPl)int ~..) to Point C nn(1 )oIOU'\>(> bisected STEP 1 iIOIJJ
MITER
-t-I
6ISI-:(I 15 .\.~GLf..Repeal this process to
b;,;,'Ct onc of the 45 angle:- to get a 22'. angle, ."" Step 3,
rH~('K)IIT~NTo check
the mlter; urn...a another line (Lin,·.1) perpendicular (90' Ito th" base line, (1'(ote: A, mentioned above. you QI"e technically checking a 67'h' angle, 1b get the S7Yi anl[l", you have t" draw this perpendicular line. ) Now make It trial cut on a 2.x4 scrap. (Thick stork gives more surfaee to check the miter, refer to rig. 7 on 1'1(. 11,) Slide the trial piece along Line ,I until th. cut lodge aligns with the angled lin." TOY WHEEL flXlURE
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'2 /
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4S' ANGLE
C
I·
lIST &LOa IN THtS
COmt.
t
3
For years I've U$,' fixture to clean and dress them up with 8 disc sander, The base of the fixture '" a piece of , pl>'wood that's clamped down to • disc
three ""3!Oht!X"S and a \\ing n\lt over a ~... carriage bolt. The ~It run, in a 1/'- slot in the plywood bas e,
•
j~JUSta
matter of u!rinJ(
th. blgh $chool l!'eomClry you thought you'ri lIever need. A 2"11>'angle ii; half (a biect$ this line al 90'" by placing th~ "harp point of the ~ompa.sson any two poinbon the bas'" line (Points A and B) and draw two IltCl\ that intersect ahove ""d below th. line. Then conne<:tlhe inten;l!<:tion I>oil'!.> to farm the perp;;ndicular line. \\'OOOSMITH
STep 2 CHAMRRING
..,-
HOlf/
Onee all the whee». tin! uruform, turn the pivot ann en edge .0 Hole #2 fit,; un th~ pivot pin. see Slep 2, Nu" adju"t tlw .10]1 w'_"""", until a thamfe.. \\~IIbe lake" off th. <-dge oj the wheel and pivot the "rm into the spinni,,!!:diS(",
then cheek the cut enel again>! n 22,,,' 16i\l£') anJ(le drawn on a piece of paper, I like t hb seeond way because you're checkinll' the aCIIL..J cut on the workpioce. Now the problem i" How do you dt:", "
22V:c angle? Thi$
Then "lace a washer over the ,,'hl'l'!
"axle" on tbe Pl\'ol arm, and place a whe...! blank over the washer. Xext, fit Hole #1 011the pivot pin so the pivot .tIII IS flat on the plywood base and arljlL...t tht.·<.ttll) washers and \\'in~ nut until the "lank j, just touching the ""nding disc, sec Step I, Th1"11 on the sander ami ,..,tal~ lh. bh..ik by hand until if. round,
tl'jll;(1111E, 7Ilrk G""t"n BtlY. '\';$(()UN"ltl SEND IN YOUR IDEAS
If you'd hke10_.
To make the pil'Qt arm, cut a piece or stock to 211,' by IS" and trim a l~'c1eanmce ,'tit "IT one end, Then add a wheel -axle" made Ii'om a machine bolt. CUl oIT the thread,andepoxJ itin. holcneat the end. Nexl, dnl) t wo "--din. hO)"$in the pivot arm, The rlt$t hole (IFI) is drilled lhrllUgit
a woodwork'ng up WIthotho,
readers of Woodsmilh. send your Idea to: Wooosmlth, Tips & Techniques. 2200 Grand
Ave.. Des Mcjnos,Iowa50312 We pay a """,mum of $10 fot I 1>$. end :;150' more for speclallechniQUos (Illat are aCCled
forpUblicatIOn).Plaase gIVe a compiele exlllana· Ifon of your Ide. If a skatcilis needed. sand ,t along: we"il draw 8 new one.
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Kid's Easel/Desk ---------------A KNOCK-DOWN ART CENTER
I rI...,rled 10 try I!Oml1hinll:n~\\ on Ih proJ""t I.,.l..ad of u nil:1".,11110.,,1JOIll' ery methods. 111~ ","",k·.I ..wn litlln~'" The eonneetor 1 usc 1to make the J ml>1 l-of a boh thalJ ,,"'lhrou!;tl('Il<' (f the p,eces the Ullli~hl In lb. ,,,amp" ,oho,,"n In fill. I be t IOlICn we I Utto. metal do,,~l th3t'. mounted Into tb, 8CCond P'("« (the .helr t, ~ t'll :! The jenu t..... ted hJ thi... ",n,'dor .' ,urpn-m~"~' strong y, t, ~Oll can take It
nw.
apart ",th an Allen "f\'!I(h KNOCK·DOWN flnlNGS
Silk"e thl- ('f.nu("(:tol' is u~('lllll)',Innil t be major pieces of tht PI'(' eet, 1 ~lartt"tt b~' experimeniinz with mounung tht'I-c.' con nt.'C\.(J~to the i'n,i 1)[a tt·~t I'it...·,·f.lln'la,' to one of the ,heh"'~ ",,,Ion thi. "n'J"ct
The
[if'!-it
fol('P j" to U:o-t'a square
If' mark IlI'lt·(1 to
the centerlines of thv htllt>8. I \, in!-llstl l \\'0 i'OI\rl¥l'lllr" 1)('1° "')'lllr, ..c, 1
marked l \\ f) lines Ul·r(.t:'i" lhi' l'11CI ;11\(1(Ul'{' of the workpi ecv, "',' Xt<')1 I in Fill. :1. Then I marked the eento ...lOint. uf II total of four hfJlcl'i. '1\,,(, h(JI(.·:o< nl',' l'('ltlt"'"."cl
•
on the \hirkllt·:o,!--at the "nd of the \)(1:\1"(1 tel
accept tho bolt. Th.. r,·nh·.,."nt" other
of th,·
LV.'Qholt!8 at" on the fUt'l' ("I' thc'
metal cro .....dO\'l·I~, "('''' ~ll'J' I)KII.LI't;
Til ... flc)r.f:-.
1 111 t
i),:,
Aflt'l' lht,
,I.
111,le
Iocanons we rv mark .. l. [ ,,*111 dO'H'hng jij! (".,. SoUR"'" ~,IIto tlnll • ~Iu. hol(~ on the l'("I... sec ~t"-'I)2 in Flg :1, Then I switched to the,ln11 press to tlnll intt;~~tjn~ ,a--(Ila.h(,tt"$ In th~ fat"'" for tbe ere ........ dowels, H't" ~lc'I' :~ Shop :\nl<'. The ,,·tru<(lono th3t came with tb~filtin~ ('31...i for lh .. Ie) tl(t a "1....-dia, ho!~.but I (olund that to I", a liul. til!ht. A .. .,113..hul, ali"" 8 mol'< pla) for .....,·('r lIIlju,tment.
"Il'.
,
ClOSS SECTtON " HOU
~
I.
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... IOUGH
An.r dnUin" the Iwle., ,t', ..ml'ly a matter or mounung the metal .10".13 and
OO:t- 1>1.'"fig. I). and ul!htemnjl them "nug an AI),.n w.........h
,,"h
fUT
aoss
.....
, I+OlI
,
00wtt "-.01,/
Once I lI"l th~ hanll' "r how
I" mount th, 1 ht~rall work OJI thl' t'aMI desk, ~tan b.\'glum~ tl}joC(·thl·rt\\{1 fJi{'<'f11 ()(-14 ( •• fll'ltlal, ~tex:kto rrulkll {'ach (tKlt (A1. "", Fig. 4. Th do thb. cut four l'i,...... '5 3", wide by III lonl( and IIlu(' thelll tOji{t'lher in t\\'O paiNo. ,-\fttlr th,·y'ri' (I~', trim them lO:{ - "'ide b)' 1,." lilng. llIULL JOt~T l'U".:( TUNIIUI r.S. Th,· feet 3rt! held to th~ upright .. Ill) ,"th th.· knock-
COkNIClOI
DQUQCnIrfl
connectors.
4
DRIllING PROCEDURE
1
2
ORIU If. HOlES ". Oft,
3
\VOODSMI fH
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these eounterbores (In the thickness of the foot and located 2V" and 7" from the back end. see ~'ig. 1. ~ow drill a hole for the eonneeicr bolt the rest of the way through.
RG"'••
UPRIGHTS
,
v.-
fl ~-
lAMINATE1wo PlEaS
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+ ¥"
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SHELVESAND STRETCHER Now lh~ shelves (C, D.El and stretcher (FI can be cut to size from ~'4 stock. Rip the three shelve. to 3 width of and the stretcher 10 " \\;dlh of 3W'. Then trim aU four pieces 32" long. see ~'ig. 6. IlRILL UOI,':~ FOR BOLTS. Afte r the shelve, and stretcher are cut to size, drill two holes in th,· ,'ncb fc,l' the connector bolts, (Note: Set ""id~ the middle shelf since it won't have any holes in it.) Center the holes on the thiekn~"" of both ends of the top $helf. bottom shelf. and the stretcher, refer to Fig. (;. DRILL>JOI.1iS '-ORfRO,iSI)()II'ELSFinalIy. drill the holes for the cross dowels on the bottom ,.jde of the tep and bot lam shelf and on the IJack side of the stretcher; (These holes are posiuoned so they intersect with the I.'. holes in the end, see Fig. 6.)
r.
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Next, cut four uprights (Bl from 4'4 stock -fF;" co~N.cro~~i '. IADlVJ ON 4 fOOT ~ HOlE " All COR e:IS to finished dimensions of wide by 41~~' .. I' , J'. ~ . /. (ASstMStl tWOl long. see Fil(. O. .- (OUJ'"lIUO.( BOLESTO \TT-'CU.. ~:t .. 'T. To attach the i,_.'t'!i T I upright. to the feet. start by drilling 8 v.. • ", •• 140,. ~ ~ hole, 11'" deep in the bottom end of each FRONTVIEW 4 ~ -7 upright for the connecter boll. Center tbe hole all the width and thickness of the .""' •• > OAC' RONT upright, s.. Detail in Fig. D. TOPCORNERDETAIL UPRIGHt UptiGHt Then drill a I~··dia .. IV,.-r1ee" h()l~fOI' r r l~,. ,... the cross dowel on the inside face centered r y. up from the bottom edge. r' J c: SUELf,\;';DSTRf;'1'('Ut:R III)L£s' A1\er the UPRlllHTSi' holes are drilled on the bottom end. of aU I. ~'. IOUND-OV£t C-ORNfRS upright. lotating them 17" and :38'1" up HOllS FORTO' SHElf from the bottom edge, see "'ig. 5. PIVOTHOLEDETAIL To connect the stretcher (F), I wo mOI'C 1'" holes are drilled on the back uprights, 21'1. '(VOl HO\! ON Center them on the wielth. 5'1, antl7~:· up FROm Ul"lttGHTS ONLY' from the bottom. see Fig. 5. "", pn'OT HOI.~:S.There's still one more hole '-' to drill in each/roll' uprighl (the uprights 4"" .. 'IVOI HOll fSEE DETAIL} .cith",.t the stretcher holes). This hole ~ serves as the drop-front pivot hole. MArkthe 1II8id~faces of lhe uprights so ',. HOlf. ~~. ott, \ FOR mOT"N -r you have a mirrored set. Then drill a I ~,..·-dia., ~·-deep hole on the inside face of fOOl CONNECTORPffAIL CONNECtOR HOLES each upright, refer to the Pivot Hole Detail FORBono,-\ SHIt' orlU. HOlt OH in Fig. 5. INSJDff~Cf Of vnrGHT ..... ._ c RDt:: 2'. 10a~, radius. see Detail in Fig. 6. I Shop l\ ote: J used a quarter (2S~ piece; SfE DETAil ,~ t· as n template. Then I eased over aU the • sv. CONNECTOR ~ HOLE. 1'.. DEE-fl' edge, on the reet and uprights (except the +! bQlt",,, end. of the uprights) with 8 V,' 3" round-over bit. J'~
aI',
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1
1
1
OF4'4 Sloat TOGtlHtlit
,
ENDVIEW
ON All l-OGfS
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4
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., ItOUNO·OYEa
lOP VIEW
WOOOSMITH
I
NOTe,
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f·~'.tHlc~1
(cur !WO .,£as
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_to.
NOTE!
:. HOlf
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-J1 5b
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6
«",..£0£..= lotllH'Cr,m
MIDDLE_SHelF !..
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32
NO HOUS OIJW:O IN MIOOlt SHELf
,II:
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0
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&ACtl: EDGE
"I-
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&AQC.lDG£
TO!UJl_OnOM SHElf
T 1
AU STOCk.
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OE[I"
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.. M'DDU !HElf
-
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SI(fIG • fOI G~
~S
110""'" SHIll
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rHKIC;~(U Of
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Now the drs"..-r umt conn be built l'hL'"unu • I..;,made h)' j()lJlin~ ttlt' .nill1l1l'11l' or the tOj)'botlom Aheh '''' ... ,e t Ii: 7 .JUN)&'" ."CtR ['1\ Iltt.N'" ~·l'\t.rot the four • ·.. lde by .-d.'Cp d.d,~ for Ih, d"id~",(.Il tlw , ~od (ar< of thl bottom anti middle .""Iv~" ~'" f II': s. To cut th(':-.\ dsdoe -, !"It t th~· (11"t"I'«~ bf·t ....t.:1,.'O the ..··\\lcl( ,laclfl blad, arwt thl" rip fence to 1 •• , 311rt mal« a II,,1.AAon 1~llh shelves, Then flip the board .-nd (on·,,,1 tu make dA(I:-.lh\· NU11\' l)uolan("I'(t .) I rom lh(;t other enci. :\(,\1. r,·~t Lhi (\'h\'l' (or 12V;" anll cut \\'(1 nl(Ifa) rlallu("s oll "ach board.
,,
DIVIDER
01""'01 NOTt lOCAJION Of aoss OOWll ttOUS ,.. tli.ArlON '" I'OSI'_ Of ......
•• (CUT FQIJ. "(CIS
.. ......,
aaca
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-~. . .....
n. •
UNIT
DRAWIR
"
...
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1". -
NOTE 4U GIOOV(\ ... wlDl a, . 0(1'
Ant>r lhll (littltlt·S ,II't' I,.....'m I,Jclc, cut four drawt-r Cll\'lflt·rl'l (4;J (I'Clll1 1 1 ••1\ I I)""Its
stock
lQ U
finil'>l,c() width le, Inal('11 lht
width of the middlo' shelf. and til" h'n~"h uf 31r;!'" see }-'iK ti. '" IOUNI).OVIR ON TOP ,.ON' EOGEAND
aonC*
-
ll"
fRONJ fDOE
~C:RO::S:S:;S:E:CT~'O~N:,_...,...
otAWl.
DIVIDE. G
.onQA4 SHIt' o ~
OIVlOlIS ftUSM
WI'"
,.lOm IOGl Of'SHnvtS
..,. -~.
~
MASONIJI SPAUI
3
TOP SHIV:
•
•
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tK;l-;~_
""to
Tht.·r'(".t_&
';"'(.'Uor. 111FiJ= \I.
n h.
n '"
krep lhe .1",,, en; (rom II
SlOW
o
:w. 1'.' ' ;
C)\ ..
shelfand only 0111' (n.1l1 "I~,' o(lh., mid.II.-
... ... ''''''''
..._,
~I DfYIDf_1
R()I"I'
•
and bottom shelf with U V,,- r-OUlu-"()\'t\f bit, rt>(er to the C ' ",-octiollin Fijt' !l. 1", 11,._ft~ \lltl.\ SU\' ~IUl'th" (Ii, ut· eno III the .1.dOl rlt('('kinl[ In make sure I~'", Oll.h .. ith th.· (ronl and th., ,nd art' -quare, see f Ig 9 1'1( \~ .. H. ",'\( •. k ... \\'hell the 01\ lfil'r 11111 '" ,II'): C'Illlwo • \''''
uu to
•
An",-
more :-olel}beI()n- a:'~lnblinJ: the ctl~.\\t·J· unit. ER.."'l'over both Iront ,..lg\~~of thl' t~)f)
UVfl RONT fOG( -,
C
1St;Tilt: "i't•.sl;( 1:.'.
dividers to size, cut lon,I(Ut."b c('·lll(·r('~1 UI\ bolh end, 1(. iii Ih.· d(lfloe' in Ill(' ,h<'ln' .., ...x- Fi.:. !I.
21) (k("..,
tie.'
gluing the ~ll.I«"" In•
Ih(' fToJlt edge- 1(1 make> It f-a.,'llf'r (II kid.lo iii th~draw.", Into Ih., "I... nm~. be\it
•
JOINT DETAILS
'-,.... 't8Ll. """1na11~u..(· :r ronnf'C'tor ...tt)
.."" mble Ihe f.ocl 10 the UI'rij:h15 .nol ~ COnnl",lol"> 10 fa-It'n Ihe helf Ulilt Mild tn·teller tn th(· UI,rij!'hl'. "of' ~"j!'. IU
caoss
DOwn
DROP fRONT
the ba...ic: cfc...k unit j~as! j·mt.l(ocl. \\"Ol"k can bt'gin c)n thl' oro}, [runt 'l"h, ;\'0\\' that
100'
•• ,A'
6
t ht· tfl)' 'l"
sht.'lf
to allo,," acte!'.." to IhI:'(IrA\\'t·~ t'\'('n \\·h(·n il'.clo,,,d, see pholll on 1'1:' I, In Ih,' ••hOlO il hI\> a ~'onni"a"'O\"'I'('d lJ3'I('I. bUI ulhl'r
SIIITCHt. f (IOUNOOyrl AU FOUllOGISl <001
fram£'" fit!' hc-l "'('P"
, JOINT CONNfClOI (fOOl TO UHIGIfT ONlY,
option.. are di""u>",~1 ill
HcIUI'\'(''',
"K. 21.
('l'T t'RAJlIEl'tt:('~S. Th "llIk~ lh~ (1,.111('.
start by clIlling lWO .Wes (0 lInd IlOO1'1111. \VOOJ)SMI'lIi
•
•
•
(.II (",m 1~ .t6<'k 10 1 _ .. ide, "Then trim I~ ,II, 10finl:'h,'CIk>nJllhto equal the d'-'ant(' (rom the top oilh~ top -Iklfto tbt· bottom ,,( the bottom .helf. see F, •. 11. 'ron th< rails to len:gtil ~ Ib,· iram, fib between tb~ uprilCbl~. Tbt-, makes th,· mil. 2' .".,,, lhan 1M wi
sruaT(~
...
:S.",
tht' desk width
f1IWi'nlng.
tThu; 2
"r hc,lh .1I1~" the
fl-
allows
(llr
-
--
...... ,..
...... I
~
RAIl
1
,....
J
thf>
, •
l.nl.'lh o( stub
STILE
DRO~ FltONT PANEl •
tt"nllnlt, ;tu(1 ~ • :-.pa(·irl~t I. ,\1 I x vn: rue l-l)I(\11(.·'" Before as~('Inl)ling thr- r''i''lll', laminate a piece of
t.AMJNATI 10rM 'S'DiS Of
CROSS SECTION
coo
I·'flrlnil;'~ltn ,'uri, ..jt)", (,( a 17 x :11" pi(-,\·t> fir ~... ~1"H"lIIh·.(It "ill be trimmed to filial (Iimf'n~iclI\~ later )
MASONIlt WI'" '<)tMJCA
,.,
AU G'fOOYIS(I~Tla(O ON SToc.lC
• DI('
(-t T (;nIK)\ t:!' .soy. cut ,b.'TOO\'e-!'" on thto in j.)t l"ft~~ of thl' frame I)i("('tl... ",. nt>t'fl ancl JU~l ,\j,lt.' l'll0U~h to accept lht'
l-·()nnK"a"("O\ ered l13n..-1, see Cross &"C'lit n In f II! II sn .i TJ. \:()'~ Aft. r the gnwJ\.\.-....an: cut rut stub II nons on thce",I",,(the rails to tit th. grooves, oc<' t '1::. I~. SI'\I t.N ,TRII' \\'h('n the frame I' "'mb ,·,1. Ihe bottom rail ha. to ",. ",,-1uoned FI the rlr3v.l·l~ can be fl:."m(,vt1i when th,- (ramt. Ii' til tht! ~:lf.:-t'rl posirien, Til elnthis ••t()(1 n flat't'Y :-.lnp in the gtVu\(.. on tlu- l eunm ,,( paoh stile, ~'(. FiJZ.la. This ,I nl' b cut to Icnlrlll to equal tll(' dislllllc(' w",·IIII1. bottom of the bottom ,1101(1"th. bottom 111'111,· middle shelf. 1'111, Itt f(lr eh-arnnce, sec "·ig. 12. (l T THEP\'.:I .. :\c.,\\: dry' as...... semble the (ntml. to ):'l'{ the ln~ldt.dimensions (If) tllt_' bottoms of the ~'I"OOq...) an
'--1
u.·t
•
to
RAlt
.All
oaT A"IIUU MAIl( I"'SIOt COthtl
J
STill I
3'.
el\ f:l, •. IM.":''''': Bt'i re 1inal4L..~( mbl-: round 0'" the In- de edJr'" of tbe fram, "lll.a .... und-over bit. The reund-
1«11'HI'(;
TIlE ("OR~t.KS. On~" th~
0'
•
-
_.CIKI 101lOM .... 11
•
SlU, I
CUT SJ'AGU m# TOAt GtoOVf .. .. POSmON
TOP COINER DUAlt
OH'r • rout",1 alon!! 1he cntirv Iength uflh. rails, but I'" Z'tulJpetJ on the stues, 1m' a.-.,,·mbl, tIK- frame and mark the inside eorners. Then ch,,,,".mblp ancJ rout th,· ,atu .karol)('< (QrP 'oUDg. fln-t file the oollom ,n
MIDOlt
SHIll-
fit RC)l 'I'
1
1
PlYOT PIN DETAil I
".
"'
.. '" SIIU
,
C
aOUNOOVU EHOSWITM flL[
N08.1', WOODscllfW
"' •• OIUS ON TOfl OUTSID(COIN(IS
CUT HEAD OfF AfT£R SCR(W1NG INTO mlf
01 Slilts
!GUlf It
000.(l'
mOllnt mll~"lC'tic."teho, to hold Ih" drop (rllnt 10 thc' 1o," .h,'lf. "eo ~·il!".17. \VtX)J)~MI, 11
7
-
,. .
GUill.
I
THE CHALK 'RAY
~
,
)'
C"A~l.AY
'CUlllOM"
.) STOCJc
lOUT OUt GROOVE ,_ Dl1P IY 1 .. W'OI
..... trwo
_.A'" ....., .-_;_
....... ...... :::.::=r::,'U;._I:=.::. .:..:.:.=--...:"'=''!=;;;
N.S~ISto
..... ,--'-1.j--'--- -----
C~
lOX lIT
AGU.I 19 SClEW Af'oIOGWt
"'CU' 10f"IAY' OOnOM::::::"iO::f' SIDE OF I'OSITlON TaAY ' • '
flo.... IOlTOM Stfftf
1t. '.
NOlxt.fh. WOOOSCREW
NOTE.
..
SCREW CHAUt flAY 10 IOtTOM SHIl, (DO NOT ClUJ,
,5'.
• 11 ••
fIG WIDrH Of OlAWl1
OII'(N,,..O llSS
"~.
SJAmWl1H
AStOt
,
• GIOOYf
I.
.. I ''''
fRONT 8ACK
,..
N
(CUtfOOl "'CIS)
.le'lj(I1\,1 '" Ihp
I.'
and rruLke a "'<'roM pa..... Then mo' e tbe f,nee oJ,ghtl~ 1IlllJ/i from tbe bit and "'I ...at the prothe fence bark: 80the bit is l1.~ttll'~on the fmnl of lh,' j!TOO\'l' ) TI) comptr-te th(' l-'I'c.I(~'t-, rout a cove on both ~j{Jt,_>g(,f th v• grfJ(t\
~ \\
hh 8
l'tII't.,lwlx
bit. Locate tfu Ienee ..o that lhll ""'Itl'r (,r the bit i, 'Lli~"ll'd with th,' shoukh-r "f Ih,' gJ'OO'·e.:-('(>!-'ig. 1~, Si'l('t'1nC)~t~ ..eerv bil. rout only to "d"l'th "f about " •. make lhe cut in two tm!-'~c~to I(l'l It (Il'lllh "f ¥,,". flOl \"1>1)1(; Til>; ('()It\"I;It~.Aftol' IIu-
.I'('X
groove is routed. round nil four ".nll"'''' to 1':" radius. Then c:,~t' UVl1r all thf' tOfI):(·,. \,-ilh a 1.' fr'lln(}·U\'\'I'tlit •
CHALK TIAY
SUPPORT 8RAC~Er •
ea-el
(and
SIDE 0
,
J
NOTE AU OIAWf. sroa:
OffP
ISU ,-.oss SKttOH
l'
down the- t~ ~.th,· dIalk lr ..~·loal.IN.'un sc:n-v.:t.",J .nd removed.I
US .... N TO .. THlC.aHHS
J
$lot
o
I
or
StAllS Wll" A PtH
,CUT fOUl P1.fUS
S'-f~."i)Jt·r HR.\( " ..:n;. '1'0 m41U11\' tht, truv to the bottom ~hl·)(. make t \\·'1 ~Ur}pc,,; brackets (~rl jnll (If ,,_,'raJl.t 1..tIH,'k. J'l·(t·t' tu : fig, H' Th.·" ,,'re" und IIlu,' th,' hrlll·k.·\< 10 th,' bouom lhe chalk tnt.> ~ 0\\ center thl' chalk tnt\ on the bottom 6h~1(and t!C1'f'" tbe bn"'kel& W Ih... ,h.·lf. ...,f~r to .'11': 1:\011' [xm'l gil,.. the brackets to the helf If you \I ant 1.. 1,,,',,k
THE DRAWERS
'TIw two dra....""" ..... made OUI of '-th,,·k stork Itnd Joined ,.,lh 1><" JUlhl$. t ITn'1; nn; 1·ll;lt;. ... To mak, the four dra""r fronUback I"~'C'(:\1. ('ut I"" pll~ of 1 .a ...tock to a ""rlt h flf 2 .- and a rollgh ["\gIh of 10 ., Th(n ~I 1,.0 mo.... pst_'('(".. 2 .·b~'i ,·{orlheCourclrA\\tr ties II
R..... w th ..,... f'OJrbL,nk.. 10
.1
hick·
ncs.~to prudu('(' the ('I.:ht ,Ira" tor Illt"('I'" To dett'nnin,' Ih.. fin"h.~1 h'nlZ1hof th,· (ronllback pi""" •• Oleasun> lh,· dra\l """nln" and .ublnt,1 ... lin my ......• lhlS
"r
carne out to 91
•,
~. l :: .-
fl'Vu. ONflONT
S'O£
80' JU",.", flU VOIDS lEfT
IY eonOM GlOOVl
•
CROSS SECTION
b
((Ntl'
WI'" rum
I.
MASONI"
CORNER DETAIL80nOM
1.-, f.1~1';"" 2(,.)
A& ('JI"lhc
"de pie«'>. th .. l.. n~'1h .huul,1 ',<)11011 Ih .. rl.plh of the ol"'"ing.
An.,· the drn\l "r p:u18 art'
cuI to length. th,' box jlllnh <0" tit ,·ut. (I-~or a fitep ..b~'-st(·I)arlitll" (In ho\\· t(, l'tal box J0inl8, t\('t> l~!(~r~/~"liIJt. Nt), SZ,,) Cut y... !II; Y.- IJil\~ Mill :,lfll~ rnr tht1 tXtX joint> on the end of ell~h Iliec". Tho front back piece. (Nl hove five pin. und sl:.,.1 \VOOOSMITIl
•
•
•
with a 1Il0! on III<' top colge while the 41., cO; ha\ t ~\ 11In." and Fotart with a pin uri tlk,·
top
nu"
TI. tiT
.......
:\v" test the width or a
dno".r piece n III<'0l"'run~ lOU may M, e 10 trrm JU t 0 '"ud~,'()11 off the 101' anti bottom .. I~.. until II Iit s, UUTT.,,, (.MIHH t.. When Ihe drawer plt.'Ct'!o\fit th~· cll"lning. cut 11 ~ (.-wide b)' y,·.dt·I·1' alo'\I: th~ bot~om inside ,,11(' IIf ('lII('C(' 10 hold a~, ~t.""nrte d.lI\\,·r bottom IP). Ltll:"t~th.. groove in li",' with tht· .. •cond pinlSlol up from th~ bottom t·cI~l·........ Detail in rig. 20.
•
r---;l
IOtJ·NO
...
OVII
BACK STOP
~
1, MOUNTllltG
PACKI'
~COUSllC4LCDUNG 'IU
Kl""''''
(liT' .'(Jm)\,
--
BACK PIN· UP BOAR!! OETAIt
see t la;. :!i'
l'1li'{t I
• MASON,rfI.C.
IACIt STOf'
•
•
SHIETCotl(
"'Of 000
~E!lKL£..To
determine th,·.ilW ofth e dr.\\ or bottom (1'), d,,· a....~·mt'1l·t:.at'h draw er. measure th4?> in~ifl(> clinltlL"IOIl'and alt" ,. (or the combined (i"llth (If t t ,I "''''_)fl\ (". The n cut the bottom leI fit al I J: LJ\ rbe dra\\('r l(l~thcr. "I)
J
ACOUS'1CAL CEIUNG
nu
.,. '.
o
MAS
...c<
,
III'tII t" Final". in-tall Ihe handle, c\,' o1'·n-t1 on thl' rro;,l. of each drawer lACK PIN·UP BOARD
SUPPOl;l AlM
\llI.n tht' drawer- " cre eornple te, ( eut th,· back to fil and m"d~ 3 pin-up boartl to fil een Ih~ 101' :",d middle shelves. II KJo. Cut th« back \(1) from v.. ~Ia."'nilt· 10 fil ,",i",· the ul)liJ(h~and betweenthe rnbl"'l. in Ihl' 101>and bottom shelves. I·'~·II· II()AIIlJ.Then 1 made the pin-up board fl~.m H l>it'Ceof V. -thick cork glUM 10 the -mooth (back) .ide of an acoustical
m'l"
•
('t~iliJlj{(ilp
I. (()',
()th(,I'
pg. 21, Onc,' it', inK. -
rl". cui it 10 fillh.
open-
•
To h"ld Ih~ 1'''''UJl ho...nl in place, cut I we
.tolh(RI from I I ,'.)('k and serewthem to Ih.· ul,ri~h". """ Detall in Filt. zt. "inal": lIl.'l'rt Ih"I,in'up board Ifrom the back "I(I~)und Krt.'\\ tht" )1~.rule ~'l'"k to t~
fO!'
...
.. •
options, see Sources,
...
SCkEW'AC~ INtO .AllaS WITH HO
MOUNTING
S .. I Fh
aU'K£T
••
Q'
WOOOSCREW
•
n
, ~
"fOs.,,,
12. ~ MlOOtI SMIU
woooscwfw
.. -..
,h<'!"... HARDWARr FINISHING
•
~
The 1•• 1 .ttl' i,to in-tall the hardware to ,t,. NYlON GUDI ....0 SUJlIKlrt Ih,· dn111front. (S(.", Sources. pg. :!-I. fctr in(~)I-mnlitln about lhi~ hardware.) L----MA...:.::..:'r.::R.::IA::.l:.:S=U:.S-T ------Ididn't follo\\ the lnstructicn« Ihat came with Ih,' drop-Iront support. Instead, \() Ov.,oll Ofmtn,lon.! 3. w Jt 30" d • 48" h mount Ih~ t\V1Isupports. fi''lll lower the A FHI (4) ,.",. x 3~•• 18 drop Iront into. horizontal position. Then • Upnsht. (4) ''II. x 3',4 • 44', >ere" Ihe lOp mounting brackets to the C Top SM" (1) It.-,. Ji 1·32 fronl ul'n~ht". refer lu Detail in Fig. 21. o Bo"o", She" ttl Il". a 7·32 No" If)\\ l'r thl' :-.Ji(Jjn~head tn the lo\\·t:....t E M.clcfl. SMlf (1) ''"',•• 6' •• 32 l~),illf'n anft attach th(" IO"'{_T mounting F S'mchoH (1) " a J'~- 32 hrack~I'10Ihe uprights. \\llh th" .Iiding G Orow.r Dn...den (4) l.).ll X 6"-. - 3' .. Iw.d MiIIsJ.:llul! I th. (0" ~r hracket. in.-tall H Otowe, $poe.,. (2) 1."- 6"'•• 9 I. lhe '"I>port ann b.,..,"eILo the drop front. I Drop hen. S".... (2' '-'I,. l' J - 22 1I."III.r. ...,,, (;Ln.£:i. To romplcte lhe J Or.p ","" lo.b (2:) ''';' xl', -~ • •__',I...k.mount I~ handle on Ihe OUI·
CROSS
•
1'f'C~..ing
the sete\\"'S
",·1"" th,· .urface on the ""jde. Also. al· Ulth nl'lon 1>.. ", IIhd.·s 10 each foot I~, frum Iht· ~n,I,. see F,g. :.!O. t'I'ISIl I found II ea.,jc.t 10 take the whol(· lhin~ allart for finishing. Then I appli~d 1"'11ooat. of .atin polyurelhane. lel .t t1r)\ nnd ""RAAembl ..d it.
K OropFrom'onoe'(I, L (hotk T.rvr(1)
' ... ·lS·.-.29.). , • :a 3';'. 2a~.
M Svpport iko(k., .. (2)·· t, 'I :a 1... 5'" N Ota~, F,ont'lolIaGJ (4)· I. :a 2",,1• 9J.J ',. o Drow., S'd... (4)· 1/..' .. 2"A, _6){.. , Orawe, Bottom. (2) " 6~ x 9·/,.
o toek
(1) R aoc.k $t0l» (2)··
,~
':V"
21 I/, It 32 )( tIJ • 16¥..
DIAGRAM
A'llOA,IOS '.'1\0
I.
:-i(lt" of the frame.
SECTION CUnlNG
•
•
It
7'.- • 72'
8
e
--"'.
c
•
L J
•
A150 lEOU'11S • MASONITE" .,. \19< H.K.P'Q) ONE 'tECE Of fORMICA36 • 36·
-'ort. N ond 0 produe. two 1.....thickpiK" when Nwrwn from .'4 ('" I.· octuol) "'ock. "Port, M ond R can be (ul from % terap.
------------------
Woons~IIIH
9
Desk Clock
•
A MITERED TIME FRAME Sometimes It's hard to imagine how little wood it lakes to build n clock, Th,>ca..... for this desk cluck ran be mad e from a few small .CTlIpS of hardwood, and the movement j~ an inexpensive battery-powered quart,l( model.
(~
Sourees, pg. 2
The case for this clock is based on making part of an octagonal (eig!lt-sicled) Il-ame. It starts out as one piece oi 4·4 stock ripped to a width uf2VtaJld about 22" long, see Fig, I. (This is loneer than needed to provide a "handle" for cutting the mite,." on th~ small case pieces.) The inside surface of the clock case has two grooves lhal hold lhe fronl and back panels. However, before these grooves can be cut, Idid the preliminary work of laminating the stock for tho panels so I could determine th~ final ------' width needed for thc panel grooves. TlI& r~\-"&LS.The easiest way to make the panel, is 10 use Yo hardwood plywood. But I wanted to add a lillie color to the clock. so I made the panels by laminating a 5 by 10' piece of ~'o.-micato a piece (If '" ~la.'Qnite using ""ntact cement. PA. ...ELGROO\·ES.Now the YI"-dceppanel ~OO\'e$ can be cut so they're .et in Y? from the front and back edges of th~ C1iS('. Th do this, a(liust the fence se it's '" from Ihe blade, see Fig. 2. Then pia" a groove down one side of the workpiece. Swap ends and plow a second groove on the opposite edge, Since must blades CUl a kerr about y." wide, \'cry tilli. acljU$cment is
passes to widen the inla)' ,l!l'OO\'. to its final width of '1'w , CUTTING THE INLAY
Mer this eenier groove is CUL, an inlay strip is ripped (from eontrasting wood) to fit thv groove. RIP 1-"1..\): Start b)' ripping n piece of ~'4 stock the same length as the case workpiece 8JKl just a hair ever Y,' thick (so when it's in the groove it will stick above the surface of the workpiece). Shop Note: \Vhen ripping pieces thi. thin. I use • push jil! that rides on the fenee of the table saw, see Fig. -1. (For more on building thisjig, seeThlking Shop in II'oo to the width of the !!''OOve,see Fig. o. To maintain a unifonn width, I us~d a small push stick to press the strip again'L the fence just ahead of the blade. neee.. :u·y to widen the groove to fit the INLAYTHE STRIP. After the inlay 511;1>is Formica, Masonite lamination. tlf using cut to lit the groove, glue it in place. \Vhcn plywood, tho groo\'. would be widen) the glue is dl1: plane the inla)' flush with THf: t~l.A) C:ROO\"E.After the grllO\'CS the surface of the workpieee. Next, round for the panels are cut, a "'-\\'idc by V,"_ over all four edges with a ,." round-over d""I' groove is cut centered on the outside bit. see Fig. 6. Then cut the ends square, surfaee of the case for an inlay strip. To cut CUTTING THE MITERS this centered groove. adjUSt lhe fcnw ,;0 the blade is almost centered on the work- Now the five small section....for the clock piece, see fig. 3. ease run be cut orr lhi. workpiece. Each of Then plow a groove the length oi the thc:--t ,)if>C('$ 1"t"qUlrt"!' 22l,tj miters, workpiece, Swap ends and make a second SF.TTII~;.\~(:LE. Adjust the blade to • pass. This will produce a gt'OO\'C exoeLly :l2', angle and make a teSl rut on a scrap centered on the width of the workpiece, 2.1. (S!n,'c all of t he case pieces will be cut Then it's just a matter of mo\ing the fell''<' on thl' "\\'IISle side," check the angle on rhe lowal'd the blade anel making two Iharl' pi"," Iltul i. off)
Y'
t
or
•••
ROUtE 2
CUmNG 'ANEl GJOOY(S
so alADf ' •• H1Gtt
flNCt
,,,I
eurnNG INLAY G.OOV( Of" aLADE I~."HIGH
_"'r-I " ..
SECON,'AS' /
cur
GIOOV( TO MATCH:
W:.oJlj~f
CROSS SECTION
.. '-.t--
,~r[J":"-;
1
-'ur-~--' •
l:{ ',"... 10
,N,OTE:.UN 0""'"£
EDG£
AOAlNSr flHCt fO«: 2nd ANO 4,1-1PASS
¢
-FIRSt 'ASS
NotE: RUN OPI'OSlTt EOOE AGAIHST ffNCE roa 2nd AND -Cth PASS
.-------1 .:~
~.
rn fOURTH PASS
AWAY
~
~'HttDPASS
-
,"£ItO PASS
\),'OOOSMITIi
•
To help eheck the blade anb~e. I drew n 22~' angle on a piece of paper ami cheeked the miter on the 2x~cul-off, see Fig. 7. (For infonnation on how to draw lh._ angie.• ee Tip> & Techniques on PI!".:1.) ~ET U' TifF.~\\\. Once the blade angle is sei.] used the following set-up tc mner the pieces to length. First. I clamped a s 10p block 10 the Ienee to gaul(\' the lenj!(h ufthe segment. see fig. 8. Shop Kote: To prevent any chance of kickback, IK- sure lhe step block b in front of lh,' blade far enough that the workpiece can't eontact the block and the bladeal the same time. Abo. 10 help hold the workpiece ,"ead;' when cutting the"" small pieces, I added an auxiliary fence to the miter gauge. CUI this fence 1(1length .0 it extend s about I beyond th • saw blade tso it .u1'I'0rt, both the workpiece and th" "ej!"menl being CUI off on the far ,ide of the blade), One other tip: To prevent the workpiece from "Uding tluring the CIlIJl. glue a ;LJ;II of ,andpaper to the fat... of the renee, SJ::T('\'T-(W>' t.t:SGTH Now the two uprights for the cluck ease can be cut to a length of 3". (mea.
flip the workpiece around and CIII off the second upnght from the other end. (Be
RQUIf 4-
FlGUU S
..
~
t!m. RiP A • -·WIDE
(
STilt.' ~
. WOOOSCIAP PRESSURE snCK
,(}
••• ,.•• 1 STOCK
AGUR£ 6 GLUt INLAY
'NTO GROOVE -
-
'.
ROUHD.oVER
sn
IOU'ER TAalf
Uf"'-E
J
'Y'
IS(£ nit JIG
SAW SlADE
FIGURE: JO
ROUtE l'
lE ..rllM tNO 01 WORKPIECE
sure to keep lhe inlay side up.)
ro COItR£CTTHE ANGlf
TRI\' Til!; ESDS. Ane.· both upright.
have been cut. the mitered end. of the workpiece have to be recut to get the miters l(oillg in the right direction to cut the three top segments. 'fum the workpiece over (1;0 the inlay side faces down) and trim both ends. see Fig. 11. (XT THESHORTSEG:IlS~'TS. No\\ follo\\ the same procedure .... on the upright., tc CUt the three top segments to a length of 211.. ' (from long point to long point of tho mitered ends). sec Fig. 12. Adjust the fence .0 the 2¥,. mark is aligned with the reference kerf in the auxiliarv miter fence. Then cut a segment off eaeh end of the workpiece. Before cutting the third piece. flip the workpiece inlay-side down and trim one end to gel the miter I(oillg in the right direction. see Fig. 13. Then position the workpiece inlay-side up and cut the third segment from the just-trimmed end. WOODSMlTH
'WORKm-CE
SAWDUSt
.ruiF
',NLAY
S'DE
SA.W II,.AD£
AGUJt! 1
ooWN flGUIf
",.
SfGMENT
R[.SET STOP BLOCK TOWAID BlADE TO CUT SM.A.lU1it ",eelS
INLAY SIDE
"''',
13
__
r---.
2',.-
Itl-TllM
~
(NO TO CORRtel
y
THE ANGlE
\
'NLAY SlOI!
00_
11
ASSlMIll
Aft~r the Ih,'case "'b'l'l1 -nt-,have been rut to knl!lh. t h
..... 101'
SfGoYotHl TOONf
1
S
2
THl eASl
3 •
, t
(;It ~ l ,·'tl(;"T ro St:(;\It:,'T The ~e·
quence us v·(1
CASE ASSEMBIVSEQUENCE
r-
.,._
I
ll'
'Cmbl(.· the (rame- In-
.~lijlTlm~nt Ig
HOl.O 00_ RAJ AGAiiNSl
- "\(\
til
\ elves Joirun~ tach upright to on. angll'd top M:J111l<'1l1 1in;1. ".(. ~t('p I in Fig. II. here difficult since you're ...-oriong witb round",1 l-d~C'.[ did it b) carefully align>ng the ,.. ""I grOU\'(>; on the JJ..f( d~surtaees, IW\' ,,"jg. 15. \\'hen th.. I",,, 1'1('('(" are ali),'llt.'d, p""" them lil[hll)' 10g.lh.·,. (ur about a minute while !K,!dlllj[th" ""'mb!y flalaj!3in.Jlthe case i;4.~nL~ from ,Iickinjl.) Gil E TII~:ro,' SM;M~;~'T. When the glue i. dry 01\ th,· uprighl :111{1 angled :l('~>'JT\~III. {lWIIIII (Ilur hours), the lop piece can b<' glu,·t! to om- th,' pairs, S(>~ :;tep 2 in Fig. 11. JO'~ TILET\\(j~lJ)~;, Then the Ja_
',,"fAa
'.....
WAJ[[O
jmn('<1 or
SAN-Qf'APE:R
•
;I
Cram e-,
~lt'I':! In FIll 1·1. S
.nd. nat
''''",In.'CI oH'm'ghl on Ibe as-emhled ease, the oCtile UI)r.~hto can be squared 10 ....,.1 on I.... do..-k ba.se, Todo this. tape a .Jxo"t, f """,I,,"pe r I". fl31 -urfate and rub the C'JIN' bac:-k"",I forth no 1:3P>' an> I, n, .... ~ 11( '10. Ii(, elIl'\·Jul not 10 Sire!', IlK
~"'.",IJOIIIIS
MAKl THE PANELS
PANel
.st,"
IfWO '*f(.ISI
AUG'" lOP Of'
ClOCK'ANII WI'"
r..;
fRACtO
OUTUHI Of CASl
,
cut til ElZ,,·, l~(")!in b~' cutting 1\\'0 5" "'I"un'" Then measure the distance be· I"t','n Ih" Ih~ I(I't>Ilve,;in the "I'n~ht., and CUIIh,' I';III('lsto fit. It T nu, (·OR'~;Il.~:-;CXI.the corners of th,· panel, art cut 10 match the angles in tIK'<"-'" . Slid~ thv panel inln the ca: .li~'l1,~1with th.. an(rlur~m~nl n Crom each upper rorner on Ih~ .. de to( th~ pan~l.
until
--
4'
• I
ttu Furmiea-covered panels can be
boltom.o(
_
_.
,
~ 1 •• ~
•
va.,..1
XU,\ cut ocr lh«· l"':tn£·)corners at a 15" or' O.,U
t
'M MOttS
tHROUGH lACK SIOf OF tA,fVR
=============:::::~===::;;;;::;;;;========~~!x>=I:lo:m::..or 12
,
t
d""
, TAACf INSfOi Of CAS' ON lACK OJ ClOCK'ANlt
•
until
5111111:.' AkGUS
,IOM IIOfM MAIk"S
nlST JOINT llN(
"'l'
3111(1,· ,lartinl{ at th,· mark,_ After the cornerg ha\'~bt,,'n rut .• lid(· the ~lIels back into th,' c,...... Th~n lIIark where the upnghts end, and Irion the exee~s off the t he panel, .e(' Fig. 17.
\VOODSMITH
•
•
• r
t
MAKE THE FACE
When the panels fit the frame. I mad" the clock face by drillinJ! holes for the movement and hour markers, I'OSITI():< Til.: •• '('F.. I wanted to make certain the face was centered even thou~h the panel might be cocked in the case. So I slid the face panel into the ease and tra ced the inside of the case on the back ,ide of'the panel, see Fi!l:. 18. The cluck hands are attached to a threaded stud that projects from the clock movement through the face panel. I marked the location for this stud 2\~" up from the bottom and centered between th~ tmced lines, see Fig. 19. After marking th. location for the stud, the posiuons of the hour marker!' are 10-
cated b)' using a compass to draw H l!.-· radius around the center hole. Then use a square to mark the location. of the hour markers on Ihe circle. DR11.1.rue 1I01.f!S. Aner the IlOllitionK of the hole. are marked, drill a hole for the movement's threaded stud. (I drilled from the back to avoid marring the face.) HOLR ~1ARK£R$. I wanted to have bra ss hour markers. SOI made them out of No. 14 bra" s roundhead screws inserted from the back, see Sum" es , pr;. 24. Drill '%, holes
•
(for a tight friction fit) and epoxy the screW$ in place . After these screws are inserted, cut them to uniform length by USU11ta .pacer jig made out of V,.- ~1a:. sonue. see f~ig.20. Drill four hoIes in the jig to match Ih~ positions of the screw s, Place the jij'( over the screws and cut them off flush with a
RGUIitE 20 SJ'ACflt JIG
VActl
JIG
CLOCK PANEL ftGURE '2
SAW OFf SCltCW
2 SAND SClfWS flUSH wnH SPACE. J1G
HOUIf
,.
r
ACC-EN.l stltlf' ...
ROUlt 25
- •• ",ll.Fh WOOOSCR£W
lRACi lOCAnON
Of
POSIOONING BLOC«: ONTO lASE
hacksaw, see Fi!.'S. 21 and 22. Then "lind the end. smooth. (Brass "ill sand e.,ily.l MAKE THE BASE
f'inally, the bas" is made. It's a sandwich of the same wood used to make the ease and the inlay strip. sec Fig. 23. FOJ·th. IWO outside pieces, rip two pieces or.J,'4 stock to a width of lV,., and about 7" long. Laminate these two pieces to a "' rip that's the width of the inlay sUip on the ca.-e frame. When the glue isdry, plane the surface and trim the base to a length of6". Then round over the top edges, POSITIO:< OLOCK. The case is mounted to the base with a small block. Thi. block is as "ide as the space between the front and back panels and as long as the distance between the uprights, sec fig. 24. 'Iraee the outline of the block on the base. Then glue it in place, When the glue Is dry. hold t he dock frame to the base and dnll two holes (for No.8 X IY,' screws) through the base into the bottom of the upng. hts, see F'''19. _v_ GI\'E IT TilE WORKS. :-low mount the movement to the face panel and CUL the
hand" 00l'ize, see Fig. 26. Finally. I applied two coats of tung 011to the CMe. WOODSMITH
C(NTEa
SCltW$
ON
L.__ -~ AUGN INLJ.Y ml' WITH ACtE-Nf STRI' qNr(RfO ONaASE-
INLAY STRIP /'
CROSS SECTION
NOTE:
CUt HANDS TO leNGTH WITH SCtS.SOI:S
b.>l
t...
t--
o
Je
o
4
1'~"
l::-
o POUitONING •.
1-......
.IOCK
.-
MlNlItE
HAND
-
HOOR HANO
DIMENSION OF HANOS
I;.. -
,
~/ ~l'1 3' ••
-
13
Round Trivet
•
A CRISS-CROSS SURFACE SAVER )lakmg n round trivet like the one beneath the teapot ~ an interesting challenge. This lli"cl ha.' grooves routed til lighl angle> on (11>po.srite side....ofthe workpiece to create a unique lattice pattern, \\'ben J IiIOI :;8,. une of tbese trivets, I couldn't helpwonrlerlnj! how ttl hold a round workpiece in place to rout parallel jlTOO"e., Then il dawned on me - rout the ~'TOO"es while the workpiece is squnrc.theu cUIII to the round shape. A" J began experirnenung with making tnvets. r found lhnl the thickness of Ih. stock plnyt'd. bigpart in the overall appear· ance of the lattice pauern. Ueing stock that's ,to ',. thick seems to look best.
•
:SO. to start. Iresawed (ripped on edg~) ""me stock 10 a thickness of '",., Then tu make an l:f'·dia. round trivet, I glued up enough ~. stock to form a g' square. see Detail in Vig, 1. ROUTER TABLE SET·UP
The Iattiee pattern i~ formed by l'Oulinjt double-stopped grocves all both {ace. of this square, To•• t up the router table tocut lhe gro,)\'es, mount a ~. carbide-tipped core box bit, Shop :':ole: r experimented with bulh straight bit' and core box bits, A
• stnp of 'Y' wood, When the"" spacers art" mounted. the ~l~nit(' strips are placed again:':t Utestop block., ~ the grooves stop ~."shorter than the eemer p''Oo"e. see Fig. S. The ]"·\\"d. 'pacer is placed against the fence to ,hilt the groove~ I" to each $ide of the center zroeve. (Cut this spacer long enough 10iiI .nlljtly between tbe V'-space,'>' "" it holds them up a~'l!inst the stops and keeps them from tipping, see Fig. 8.) Shop Note: J found thal labeling the
14
S.. ..\C·.:KS"'OM GK()()\...:s • t
t'--'U
",j.
TIle
spacers used for grooves #,1 and 15 consist of \~'U strips 7J. wide lhal go agailltit the stop, and a ,trip 2" ";de that goe,. aj.rainst the fl·nte. see Fig, 9. I labeled these with an x .ymbol, ~j.\('y'tt.~ "'OR CHOO\ I;~S_6 \4'i1) .;_
>'JliII used for grooves
The
#6 and #7 consist
of two strips 1%" wide lhal go against the ~0l's.and n strip 3"wide that ~s against the fence, see Fig, 10. I labeled this set with ~pace~'\ithP'8phic~~rmbolsma(lejtea:-it'I 10keel) the sets togelberduringthe routmg .. [' .ymbol, ~
9'
..
MAKE POSITION SPACERS
At this point, the router table is .ct up to rout. the center grooves, But, before you begin routing. YOIIhave to make three se~ of spacer blocks for the additional grooves. The ide. is to use the spacers to rout progressively shcrter grooves that "iU fit 'he final round shape of the trivet, refer to Detail in f'ig, L SPACERSFOR GROOVES .2 AND '3, The spacers used to cut gJ'OOYCS In and #3 on either side of the center groove consi~1of two strips of ~. Masonite and a j"·\\;de
steps. J marked the set for grooves #2 and "':1 with th~ symbnl
,
r----.. NC!
r
'<~ stO'
810CK
4',,- ~ ~.
.,..
;;-*
Po':.-
~
•
MEASURE10
ClNl'fJ Of
arr USE A \? CORl' lOX lin
WOODSM1TH
•
I""U" 2
THE ROUTING SEQUENCE
IVhen aU the spacer; have been cut 10 size. the grocvescan be routed. The depth of CUI must bealittlemore than haJfthethiclrness of the stock to produce the lattice pattern. On I',".lhickstock I found the bestdepth for the grooves was o/Ili • For a smooth cut. it's. best to make two passes. On the first pass aU groove, are
•
$TOP
routed to half depth (about ¥to'). Then the entire sequence is repeated to deepen the graO\'''S to the full depth of '" • Tll~ ,'IRS!'I' \55. Now the routing ean begin. Thel'outinll'sequence:rtartswilhapa...<,; on each side of the workpiece to create the center grooves. Position lhe \\o.·kpiltCC in the upper right-hand corner created by the
fence and the right stop block, see Fig. 2. Theil lip the workpiece down 01110 the bit. To roUt the stopped groove.jusIslide Ih~ workpiece from right to len keellingthe top edge tight ~gajnst the fence. Next. flip the workpiece over 10 rout H center groove on the other 'ide. However, be sure to position the workpiece so the
1"00.' s ,.,. .J..
-
_
-
just-cut groo\'e i~ 11e'7J('1,dir"laT to (point-
•
ing toward) the fence, see f'ig. 2. Shop Note: I found that the grooves arc such a strong image all the tap of the workpiece that I kept wanting to tum the workI>i.."c$o the gJ'Oo\'('ontheIOp$idl!(lhe$id~ I was looking at) ran parallel tu th,' fcnt'e-
10 the fence. TilE SK(.·O'iI) J'ASS. The second :>t't o( cuts
F;WOHIIJlfCE
OVU TOtOUl GROOVE 1
ON $IDE .. •
*~
•
I
•
'~U'E•
....Un,
creates the two groovescn both .idl.,. "ith. center groove (grocves #2 and #3). This sequence is shown in Figures :l thru Ii. The pcsition of these gl'OO\'C'iS i~ eontrelledby the Ospacer set. see Fig. 8. \\1th the threespacers in position.place thestoek in the upper li),(hl·halld corner and rout 1,"1'00\'(' #2, see Fig. 3. Then keep the same Iaee up but 1'O18ll' the square 180" and cut groove -#3 on the other "ide of the center groove. see Fig. ~. Anel' these two grooves are routed. nip the square OVCI'and repeat the process Oil the opposite side, see Fi~. 5 and 6. THE TOIRJ) PASS. The thil't! set of cuts requires the x s-pacers to rout groove;, and fiG, see t·ig. 9. It's repemlve, but just make sure the visible grooves (on the top side of the werkpleee) art' pointing toward the fence when the cuts are made. TH.: FOliRTIl P.\SS. Finaltv, the fourtb set of CUl$ u_theLsPHcersct, and followsthe
"Gun .~,
\:::
the same way 1was mf.';0fr the workpiece. The trick is to concentrate finkeeping the visible greoves always pointing' toward the fence even though the workpiece L, moved
parallel
.
~
fIR~T PASS
SjCONO PASS
NO S'AGtRS
GtOOVES_2 AND If3 ,. WlO( SPACI.
'11"
1/· ..· ~
u
I
..
* f1 ,
..... WID!- Sl'AC·f.S
,
,1""•••
fQURTH PASS GlOOVES:
,.. II
11-6 AND .7
3'WII>'"ACU
o
AAlIIeprocedure as before, REPEAT\T .·VLL 1>':P1'8. After all seven
jm)O.e~ have been routed on each side to approxim~lelyhalf depth, adjust the height
of the bit so it cuts to full depth ('Y,.'). Then repeat the entire sequence ofpasseson both sides of the workpiece. \VOOO$MITH
" .. WIDE SPACflS
IS
flOu.r 11 WORJ(PIECt
MAKING 'T ROUND
. ~
I DlU,l HOtE fOt flAMMEl POtNt C£NTUlO C»< _.GOWU
( ..
SPACE'., DOWfLS TOCa..ESf()ND WITH HOlE'S rN WOa1C"KE
a ~,' slnlighl bit anda trammelauachment, rTM ~
!-
I
11 rr;;~
• maua)
(1 I ! I
'lI"c-tl' TOP VIEW
SCRAP 2_4
t· OWIEItR
x:t:LL15
at I I I I I D
"." ,.LOf HOU: fOlt LOWEIING
an
lOP ¥IEW cROSS seCTION
POINT
looft.--
-
WORXPlEa
Bho!, Xote; When u~ing routers with a rigid trammel base, it may be necessary to drill. starting how to get the bit in ,,,,,,ition before turning on the router, Make t,(!l'lUinthe edge of the holejust toucbes the c)ut~id(>edge of the trivet circumference.
y,
rout the circumference in three
,,<'tting the bit deeper :uteI' each oomplN< I"'SS, WORKe(,..CH
•••
FIGURE 14
/
'.
.OOND-.OVER
art
,,
MAKE !'ARtIAl CUT WITH ' .....ROUNo.ovt ... r ro PIOOOCl -auu NOS'"
flGUlf 14
RGUlt 17
~..oowa .......
L..........·SAHDPA".
ROUND THE EDGES
\\1,,'n the trivet i;. routed free, remove it frqmth,'ji~;,"d round ever the edges, I did thi> on th" router table using a -11." roundover bit 1"ise'<1 to Ie..'" than full height to pruduCl: a bullnose edge, see Fig, I·L Although the round-over bill used has a ball-bearing pilot, I didn't reel this gave optimum CODlJ'Ol when rounding' the edj(e, S<., 1added a sUlbilizinl"brace, sec Fig, Ir" To position this brace. place the trivet so the edge is firmly against the fence and of ""Jill Uluching the bearing on the router bit, Then clamp the braeeso it', perpendieulartotherencewithoncedgcincontnct with the edge of the trivet. \\'hen the brace is in place, roundover the edge of the trivet by rotating it eounterclockwise , t'I"ISHI"G, Ati.el' the edges are rounded, I sanded the triv.l smooth and finished it with Deftoil ShoPNote:f!astraightbitisuscdtorout. tbe grooves, the ends will probably bum. Sand of( th. bum marks with sandpaper mounted in a slotted dowel on a drill press, see Figs. 16 anel 17, \VOODSMITH
•
,
12,
1""'"'' VISE
•
,,!.
!'O\\'
PLYWOOD
16
Tilt: ROt,.,,,!: J 1<:.To hold the workpiece in place while routing, it's mounted 10 ajig. The jig consists of a piece of ".. plywood wnh a2x4 scrap fastened to the bottomso it can be held in a vise. see fig, I L Next, three Yi'-dia, holes are drilled in the plywood for the dowel pins that hold tne werkplece steady during the routing operation. First drill a I'ihole at the center of the plywood and Itlue. length of dowel in the hole so it project. just less than the thickness of the workpiece, Then place the workpiece on the plywood .... 1he dowel goes through the hole created by the intel'l!e(:ling center groove., No" mark th,' location of the two end holes, Remove the workpiece and drill these t\VII bole.. to accept ¥"·-dia, dowels. Finally, drill 8 small h"I,' in th. end of the center dowel t~accept th,' trammel point. ~£T U' TRUIMI;:( .. The pattern of the routed gTOO\'t':'; ts designed for tin 8'" diameter trivet, Til rout 10 this diameter, set the distanee bet ween the trammel point and the inm r t'(lge of the router bit 10 ,J". see L" r IJ!,
'RAMMEl
,.....
After the groeves are routed, the trivet can be CUt to the round shnpeusing areueerwlth
•
•
Sguare Trivet ------------------
The round trivets (in the previous article)
Arter this groove i< cut. carefully tip the workpiece up and Il.waytrcm thl' bit, Then rotate the square 18(t' anti repeat the cut t« make the second gJ'Wve. To rout the groove.; on the OPIJO.itl'~id", nl11lhe ~U1lJ"e ever And position it against th e ,top and the fence, Make certain the f..""JC)\'("~on the top surface are p' rp« 1I~/i'·II· iarto(ptlinting toward) the fence, The" cut th... jIrOtI\'CS on this side, P\s.'''~~T\lOAl'II)THR££,Tos('\ up [a"the second set ofcuts. place the I'-wide spacer tlbtaill.."!t the fenceand repeal the~(Ioquen(.'i!o( four ,,"-s"'. see Fig. :1, Finally. "lace the 2"-Willt'spacer against the fence and ,'Out Ih,· four outer grooves. see F'ijl', ~, II 'h,,".Il.ixgl'uovei- have bee" routed Oil t!-<:'('h ..ide, r\"f.;,·t the router bit to a Yi(;" depth and ,'ejJ<'.,tthe routing sequence to take the grl'l"\,~' \0 full depth,
present somewhat or a challenge far la)·jog out the groove, and cutting the cireumference, but a square trivet ilt even easier to make and just as attractive, The square trivet shown here starts OUl as a 7- square
•
made of :,-thick stock, ROUTER TABLE SET-UP
Unlike the round trivet, the square one
doesn't have a center groove. Instead, the router table ls set up to rout a pair of " ',
•
wide grooves that straddle theeenterline or the trivet. Todo thison the 7"Slluare trivet. position the fence 2''4'' f"'Omthe ttJ~lrof the bil. see Fig, I. ShQ,' Note: I switched loa I'.r' ,<'roil/III bit (which produces flar-boucmed grooves as shown in the photo). and resolved to deal with the inevitable burn mark>; IUler. All slx grooves step 11.. from the edge of the trivet, To control these cuts. damp plywood stops to the router table", the inside edges arc ;;. .' from the edge of the bit. ~'(' Fig, 1. >'OSITtO\ $1' '(,~:RS, This set-up on thE( router table is used to rout the inner pail" of groove.Qneith.!,.~ideofthecent.rline, Th. posuion of Iht· ne~t pair of gro:, i> enntrolled by a spseer th8~ i,placed between the fence and the workpiece. Cut thisspaeer '" widealidlon!!~II(>ul1hI" fit betw •• n the stops, see Fig, :I. Theil fo,' the third pair of grooves. cut D spacer 2"' wide. sec Fig, 4,
ROUND THE CORNE~S AND EDGES ROUTING SEQUENCE
Aflerthe spacers have been cut to size. the routing sequence can start, This is a series of cuts 00 each side of the trivet to produce Ilro",~.',,·deep, However. I found the cut was smoother if the bit starts al half depth
(about v,.;, TDE FlIIST1',\55, Beg," by pl'lcing the \\ "rkpi""e so it fits tightly;" the upper right-hand corner between the fence and the stop block, Fig, 2, Then. tip the workP'~ down. and slide it to Ihe lert,
After all the groove< were cut to full depth. I uscda 'luartcr(251' piece) 10 mark an arcon tht· .. >nler". nnrl sanded them to the line. Then I rounded tbe edges with a 'I. roundover b,t 011 Ih,' router table, R~;ll(l\ I, illftS 'IARKl>.Te remove the bun, mllrJph.d I WII coals of Deftoil,
r.,~tG",u.... nrr--------~~--R-R-ST--PA-S-S------------~r-r-, HNCf
not'
StOO
MtASUIlE FROh\
OUTSIDE fOG! Of 8ff lout
liGHT TO un
RGU E-.
SECOND PASS 2~SPAClR
BtOO('
•
•
•
C= \VOODSM1TH
17
___
'E_oy Bank Truck
•
MONEY ON THE MOVE The bil!Kcst problem with toy bank. is bow t(~J,.'l'l your
money out when
)'("U \\'~llll
it.
Th.· usual seluuon on most banks i. tu drill a h'JI~on the bottom and use a cork stop. Pull out the stop and out comes your tllOnC)', But that's lOOeasy, I thought the chullcnl1l' of building a lOY bank would be to figur~ out n "".''CI. hidden release to gel the money out. That was the idea behind this bank truck.
-----
THE CHASSIS
To build the truck. I started by oultU)Kthe chassis (A) frern " piece of 11 .I"ck (' v,,· thick> !I'.· long and til n rough width o( 2;,". A\I.t: II\1K)~. Then I cut two dadoes on the bottom to hold the axle s. Both of the'. dadoes are V, wide by V:deep. The front dado is positioned Vz" from the front of the chassis, and the back dado L"2' (,.om the back end of the· chassis, .e<' Side View in "ig. I. ('All IIAIJO. There's another dado 10 cut on the lop side of the cbassis where the cnh \\ilI be mounted. Thi. dado i> Yo deep. and the width is equal 10 the thickness of two pieces of YI stock. (The cab that fits in this dadu is made by laminating I WI) pk'C(>; of ~'4 stock togethcJ:) Shop Note: Although these three dadoes (and the groove lhal follows) can be cut with a dado ""I (I wo bl.ri~. and chippers), it leave; a ~tightly Irregular bonum. Instead, I cut these dadoes on the "outer table using' a Vi' slnlight bit to get a smooth bottnm. To cut the dadoes on the MITt'" workpiece needed for the chassis. first clamp an auxiliary fence over the router table's renee to cover the sawdust hole, see rig. :1. Then use a push board (a piece of ply· wood works well) to guide the workpiece through the bit, see Fig. 2. TRIM TO WIDTH. After the three dad""" (for the two axles and the cab) are routed. the chassis can be trimmed 1(1 a final width uf 2". m;m off both edges to clean up any ehipout caused when cutting the dadoes.) C''';STt:R GR()O"E. Finally.. a groove is routed down the center of the ehassis 10 hold the engine compartment and also the secret sliding mechanism, This !D'OIJ\'e is deep by 1',,. wide. see Fig. I. To rout thls groove .0 if. centered, I used a two-pass procedure, refer 10 Fig. Start b)l setting the fence on the router table so the bit is near the cent ..r of the workpiece, Now make one pass with one edge of the workpiece against the fence, and then flil' the piece around to make
0/,
v,
• another pass with the other edge again::;t I~ the fence were positioned so the bu the fence. wen' routing the shoulder nearest Ihe 1'0 widen the gl~,o\'e. move the fence fence, the rotation of the bit would be the away from the bit and continu .. with thl~ same '" the ,Ii.-.c'<'tiunof f.'<.od. This can Iwe-pass cutting procedure until the ,>1"1"" th .. bit to grab the workpi eee and ~\'e is Ih' wide, see Fi!t. 3. "run with it." rl1w effect is like kick-back Note: When routing a "...joe grd the workpiece from ril!'hl !(lIen 01 \lln.R sxn. Aner the center is routed, cut a v," -deep 450 chamfer on the and adjust the fence SO the biti.cullinglhe shoulder of the groove that's [arthes: from 1'C"rend "flh. chassis. see Chamfer Detail the fence. This way the shoulder being cut in }-·lg. 1. ('m" RE310IAI.Il()Lf:. 'Ihen the last step is fed 119(1;.'1 the roiauon of the bit.
gM'!)".
AGUU 1
-
....
2~
...
...
,
Li' --.__~.L=rr "..Lr-<: , I SIDE VIEW .- ~.~--~-----.. 1"'·..... ·-.
- AXlIOA~S
DElr
OADO JOt AXlf
..
,.
CHAMfER DETAil
a.
18
~ DADO fOR CAB
~
lfAlOf
CHASSIS
OAOO fOR AXLE
WOODSMlTH
•
•
on the ehassis is to cut the coin removal hole. Drill IWo }"-
mUlt :J
RGUli2
_our
if
l' ,-.WIDE ( GROOVI CENTEIiD
ON CHASSJS
IrT CUTS ON
SHOIJI.IlEI FAtl'H£Sr FROM FfNCI
-'--I I
1lIE ENGINE COMPARTMENT
..I\t this point, tht.·chassis is complete. Xow it's just a matter of adding piece. 10 n, 1 started ,1\ the front. adding the engine
compartment
(8)• eee
1I0U'U
CHASSfS
Fig .. j.
ROUtU
The engin() ooml)";'lrtm~l\tstarts out as a
block of two pieces of 4 4 stock laminate-d together, Cut two piece. 2<, wide by about 6' long. (This is oversize to make it easier to work with.) Glue the-se (\\'0 pieces tOj(.tb~r and then trim them to width to equal the widlh oj the th assis. RABBE'I$.Next, cui rabbets on the bot, tom edges of this block to produce a lOllgue that tits .nuj(ly in (he center groove in the chassis. I cut the se rabbets on the router
table using a v." straight bit. see Rabbeting Detail in Fig. ii. CIi.U••'EK TOI' To complete the engine compartment. I used n ~5°chamfer bit on the route" table to shape the top edlle;<.
These chamfers are Detail in Fig. 5.
•
y.
ftOUU<4
''''Ill T9P VIEW
,.. t'...,. , rtr--~lr----;-l
,
I .OIA. kOlE
I"I
JJ.~t__
FIGURE 5
'"...
$tRAJGHT
-
..
==--====ll,-
0-
.'.
_L_~
COIN REMOVAl HOl£
T'.
_
-}-
-
___
~~~-!J..
.-
RABBETING DETAIL
,.eam I.'
Oft'
• . WrDoE
deep, see Chamfer
)IU(.'ST 1'(, CILI.'lSIS, After the M1bbct. lind chamfers are CUl. the engine com,
.S CHAMftIl
.11
partmem call be glued and clamped to th" chassis, The only tlifficully here i>that the block tend!' to slide on thl: glue 3. it',
.., ;
$l .... GHT
clamped in place, Th make thi. alignment easier; I cut a
>Cntp piece to widt h to lit in the cab dado (,pr Fig. 6'. $0 lhE' engine block could he hutted "ltainS! this block lL' Ih. clamp is tightened. (Note: Once lh~ engine bloek i. clamped in place, remove the.crdp hl",,~ in ease any excess glue has seeped out which might glue it in the dado.) When the glue is dl,),. slice orr the front end of the engine eomparunem so it's Hush with the front of the chassis. see Fig, 7, ORII.I.HOLES.The last step on the engine compartment is to mark the position of the bole. needed for the headlights, the radiator cap, and the front bumper, The headlights are yo' screw hole buttens and need Yz-,dia. hole. "bout v,,· deep, see Fig. S. The radiator cap is a dowel thaI fits in a !4-,dia. hole on the top of the engine block. And finally. the from bumper (e) is eut to size "" it'~ v.·thick. V,·,,,ide by a" long. It', mounted with two bumper support pin>(which are axle" pegs). Mark these hole. on the front en,l of tl'" chassis and while they'..., drilled, make sure you don'l drill into the axle dad". see Cross Section in Fig. II. Shop ~ow:AAer marking th<·positien of these holes for the«' piece•• I damped the workpiece in a bench vise and used 3 Portalign to drill them . ..". Fig. 9.
RGUltf 6
CUT SCIA'
::; ro FIT CA. 0
GlUE A,ND ClAMP ENGINE IN C(NftR GlOOVE
GU.~•
fRONT VIEW
..
'
V.
WOODSMTTH
GUREq
••
S.DE VIEW OIlU
KOLES WlIH PO.TAlION
Y'
•
lua
r ", . T- . '.,' ~@
L
~••
" ( .- r~
:0. ......
J
ED 1
MOUNT FlU$.H -Wtn4tOl mGf O,"Vl$('
<.l»
r
19
,-
...
RGU'110 10·
TOP VIEW
ftGU.E" 11
THE CA8
• r,
,
o j
I'
01\006 AilE ''J.
oa, l
2
,
-<>1"
HOUS
f
FtGUJlE II
FlOURE 13 c.LAMPrifCfS AND DItIU. HOltS fOR .PINS
CO!'ING
SAW-
/
Olttt.l. ~ HOllS AND cur Out
..,~-i,I-.___
wrkoow WllH C09tNG SA
•
fFGUlf '4
NOTE:COf 8EVELSto lU"" ''4~. WIDE SHOVI.OEfI:ON EACH
FIGUU 15
SlOE OF WINDOW
,
.
m $A.W AT 22·
~-4.,7'-," , ..~
"
'
,',
FIGUII£ 16
(
SIDE VIEW
o
i WID'>! Of lANK BOX
EQUAL
to
HaGHT OfCA8
r-
f
I.·.
CA. KAS WID£. SHOULOl. ON lACH SIDE Of ENGINE
r ~. oown
FOI GASCM
20
The challenge in building the cab is how to make th~ windows. The solution turned out to be kind of like the theory behind carving - )'OU lout away everything that doesn't look like a window. The basic procedure is to CUt dadees in two pieces (D) of ·1'4 stock and laminate these two pieces together, see fig. II. Howevez , I found It WII> easierte start bv .' wO"king with one longer pleee rather than t "'0 short pieces. I !>tatted "it hone piece of J ·1stock cut to a rough size of3Y' wide b~' 10' long. see Fig. 10. Cl'TI)AOOES.Then t eut : 11:"-wide darloc~ v". from hath ends of this workpiece. This can be don" on the router table (refer to I"ig. 21, or on a table saw with the use of an auxiliary f.,K't' on the miter gauge. Clamp R $t0l' block at one end of ibe auxiliary fence nod use the rip fence at the other end 10 cernrul the width of CUt for each dado. >'00 Detail in Fill. 10. CIT'TUSIZE. Aftt'r lh" d:ld_ are cut, trim the workpiece 10 a final width of3 ..... (Trim offbolh edges, removing any chipout caused when the dadoes were cul.) Then cut off the two blocks (D) fot the cab, cUlting 2' below the dado to produce blocks I" long, see rig. II . ..II(IxT wl~rl()\\.These dadoes produce the ,id" windows when lhe blocks are laminated. Rut 10 produce the front window, hoi.., have In be drilled in one oi Ih" pieces, see rig. I!. Mark the centerpoints for fourY' -dia, holes at the corners of the fronl window. Then drill out the holes and CUI OUllhe window wiLha ('Oiling saw, sec I"L'·Ig 1'> _. 1..\.I1IS.\1'E "It;('ES. When the f"ollt window is complete. laminate the two hili."" log,·lh.r. To prevent the blocks from ,Iiding on the glued surfaces, Idry. clamped the two piece. together and drilk-d hole~ for two alignment pins lY' "owo)$l. "Ole Fig. 13. After the hole, are drilled, apply glue, lap the pins in place. "nd damp the pieces LOgether; H.;' .:1. tDGES. \Vilen the glue is clry. bevel rip tile edges at a 22' angle. Notp: If all has gone aecording to plan. these bevel euts will leave a v.. -wide pillar on hath ,itl"" of the front window. see F·ig. 1<1. AI,o, the front of the cab \\;11 have a -,'·"ide shoulders on each side of tile enWile compartment. refer 10 fig. 16. "Qt:~,. CAli. After the bevel. IIl'I! CUt, sand the cab and glue it in the dado in the chassis, see Fig. 16. GAS1:\.'iI\S. Next, cut the gas tanks ( E) to ,Jzc (see f'ig. 16) and clamp them to the chassis so they're flush with the top of the chassis and y,.... from the back of the cab, Then driU a 't,'-dia. hole (fol' lhe gas cap) through the tank and into the chassis, Glue and clamp the 8'3." tanks in place with the dowels sticking out II,',
II"
WOOOSMITH
• •
•
•
•
,
•
•
OUll1l
BANK COMPARTMENT
" • ..I
NOTE:
11, ',l
The bank compartment i.a box made (mm •·-thick "lock. ITo IlCl pieces lhi, thin. resaw t -4 stoek (I(i\\n tc"!"'iz4!.' Cl'T 1'0 SIZ£. Then np the stock for Ihe sides (F) and front. bark (Gl lO a width of 31'" . see Fig. 11. ITh;" width mu.t match the dist.ance between the chnss..;:-, and the top of the cab•• e,· Sirl. View in Fig. 16.1
r,
. ..;fr
G.
--i
1 CORNER JOINT TOP VIEW
.'.
PIN STRIPE
9PT10N:
cut rwo KERFS , •• ~ Dt£P ON $IO(S
3',
,
Next. CUl the 1Cide~to lenb-rth ::;0 they're
'." lunj!(!l' IhM Ih" distance bel ween the cab and the end (If Ihe cM".L<. JOINEk\.111l· box ~itll':'are joined to the front back with ~lml'l. rabbet joints by cutting , ..-O'·ejoint. 1b make this joint. cut a y;, -widc gruove • d,·,·., the imide face of the sides and fronLb,«k JliPCtlS. sec Detail in Fig. 17. ll()1"TtI'1 Nt)\\ to gel the final size of the bottom. dry·a.,-"(:mble the box lind UJ~a~Ufi'lh,' lll,icJl' dimensions, adding ,~. for the ton"'lIe~. '1'11<'11cut rabbets on ail (ollr (.-d~>iO tu Il'.I\ t." l~)I.gu.·$to fit $I\ugl~t in the groove-, xt't_· lJ.cl:\llll' ~·iR.17. ('(II' H."I'" II 11(l1..~.The la$t step bC4 fo", "",,·mhl v ,. tu drill two I't-dia. helos
AU rtEelS ' ," rHICk
09
'IONr
I
$11'(
-
l
or
, ...
.
WIDi GROOVE ~"." DfEP
•
for the
hole.
eOlI11·;·n1Ilrltl
RJKl
CUT' i ·DiEP KERf
ON &At. PiKl TO 51.""Wt.A1E'OOOIS t(
1
Ihnn th,' I"", ~",I to .1 ."ugh limgtb of 10 . TMn th. ecru 1,,1can be CUt. Set "I' t h. toblo· saw to cut. slot centered on Ih, "1~lh and length of the piece f'c.t'til! It'l' S,)t,· oroI.rct the blade approxlmnu-ly '·'·nl.·...·" on the length. place the .-Illt 0[(1... "orkvi~tlgllinst the hlade anti I I h, h"11:111 of the blade Ulllillill.' 1"'101 \\ h,,·. the billde enters and the WI'r"'. "r t h,' "ood are about 1 .. apart.'1t hj: II' Then mark this
"I)'"
Ie"'·...,.
1.,:-ilic)11 em
'tl 1..1.1
l.ov.'.'r llll' hla.).
the
\\t1r.,lIl"('l
011
M~\
~tOftU~ a
I h..,
btock to clamp
tnarkA, ~
1
t(1
nl
•
2" long 1'<> It""11
:-;,'XI.tU! the top to
1~II~h .. , Ih.. com .101 I_ ....111<''''<1on th~ length, ~'1'I·'it{.I!" ~\Ilkl. rhn,lnfc)'the fronl edge RIle) nUl1111tlu· (I'tilit ("()I"l'n- ttl a 1" radius. ~'CFill 20 )llIt"TTUI\ Fill:lll~·.til, . and clamp Ih. t"JIIll "lace. VJOODSMITH
J
,
fAlSi !lA,0£ TO CUT COIN SlOT 1',~
t
-
..,
~I
'0 lll'GI'lI Af'" SlOT 1$ Cut
"I
C
...
I
-
10' 04 1 "......
TO 2' LONG
t
AGURl20 <,'
r
TOP VI~W
._L
"1
1
t,,,. 0
0
-- ....
r( ,~ o
CHAMfER DEl All r
•
I
. -'r ..
ItOUND
CO_Ntl'S TO
1 RAO.US
f I',
tt-
fo~ig.18.
:\0Y. lUl'n un tlu' sa~ lllMlral!'4. th(* blade. st"!IJJ}IIJ: \\ 111Il ll" )1..... 1 1$ ~tPltnlximateJ.\·
, ~i"'"
...
-
I'
NOTE, • "iM, fO"
•
saw to cut \,ul this hfj!..·,see Fig. 17. 'S!W'IIH.I :-;.. w Ih., FI.I,·,and fl'ontJbnck
am he 1(1u<~1alMI c amp ..,1 tu the bouom. rue rru- To "uml,1l'1l tht· 00>", the piece for the toV (11'" cut to ..j7A;· so it's V," wider
I.•• ~
GUlfl'
use a coping
Lf
~-!-
ON SIDES AND FRONT &AC.
0"
BonOM JQINT
SLOTCEHTEUD ON lfHGTH
0.,0.
t
•
3'.' ,
NOTE:
'I ""EMIlUD
I
trw0
IlAN' IS ... I'IfDll • JHAN lACK
'lllOX ~
~~
",
..
,
Of "'.
..B
21
u~:, CUT
"((I' lOll
rc tOUGH
THE AXLES
JUIU' ItOCII$
L(NGfH
Refor<:mounting the bank box to the
MOON'
AX'"
""OCt( IN NOJot
.....
s-
fQ DIIU
AXLE BlOC.!Cj • •
Hot..
»«:
Eh
HOI.E~ FOR AXLE PEGS. In errler AXlE
11<00<
WH(n
'. lOUNoova
en ON ItOUfEI tABU flGUlE23
Sj,JPING TONGUE AND 8UMPE@
-
lONGUE • tONGflt TKAH .... NK aox
•
...-
•
DOW£L\
~7,J
BUMPER
DETAIL
CUT .. OM "feE Of SCit,Ap
GlUE AXlE
BlOCI(S
Amy WAJ( TO GROOVe so TONGUE
~JO DA.DOfS
SllOES EASilY
mUlE 14
DltU ·11 HOtf Off' ENOUGH TO
1 (I"
CROSS SECTION
' .• OI'U
'. DRIU It,
on
HOlD SPRING AHD
ttlAO Of NAil
-----f---,
/
lfAR
AX",
1t0Cl<
,,; MOll:
rot act
f.rNI:SttHAJl--' flGUlf 25
-0'" HOLl ~..- OlEP'
I'..
TONGUE
~
I'AI
AXU elQO(
.,.
,. ('
22
______
1ONGl/£ IN C(OSlO ~SlttON
au""",
til
mount the wheel. to the-se block S, ;, "-
ft ,
!'
•
TIle S("i.'r,,·tto g..,tlin)t .,Ollr money out (If thi> bank (n,ck iI' the ,Iidi"~ tongue IKI that covers 'he coin ·"ot (In the bottom of the chassis ThJ!O\flngue is housed in the center groove ill th" chassis and is pulled out by u,ing the ...,!IT bumper Il>' a handle ITT 1'('"a t; m SI7.E. CUI the tongue to width :illlllh iekness so it slides easily in the woo,"e in the chassis, The lenJ!;thshould be • IUllllcr than the bank box. Sl "PER. After the tongue is eut to .ize, tho bum""r eL) can be added. Start with a pit<" of 4 I SCTliI' S"long and wide enough to work with comfortably. Then CUt a dado al'rh:-;':-o.lht! center of lhi~ piece to accept the end IIr the tongue. see ~"i~. ta. Arter Ih~ dado •• cut •• lice oIT a "t -thick I"'''''' tor th.· hump"r and glue it to the enel ~)rt ht: lf~I)~e\\ ith the aid of two ",/' dowel ~lIll:;.t;""l" Fig. 2:i, HU.t:.\.,t I"S The tongue " held in lh~ chl,.....'~ )rnJO\'l" with a spring-release pin thaI II'''''' lhflllgh the rear axle. (Befnre drilling' the bole...for thi.- pin. if. lwt
•
M'.
\VOODS~UTH
•
• •
...,
the "('Jo~I' position on the. chassis, and I)u.h an StJ nail thfQugh the hole in th~ axl. block. "e<' Fill. 20. Tap th~ nail to mark the position oi'the catch hole. Thenremove the tongue and drill a ' .. -di a. hole ~. deep at thLs point. arrrox. After the catch hole is drilled. CUt the 8d nall ro length so it extend" " below the axle block. anti epoxy a button to the end of th. nail, see Fig. 26. Shop Note: In order (0 drill the hole in the button, drill a ""-hole in a piece of scrap to hold the but ton. Then it's rdath'ely easy to drill a hole to fit snugly around the Sd finish nail.
M f~NDER
., MAkt-F'''Sl CUT AlOfliG 8OnOMEOG(
,1.-1t
Of ItUNNING
--------~. ,
\'.'"1
BOARDS
•
fUU SIZE PATTERN
'.
THE fRONT fENDERS
•
•
:-;ext, the front rend.!'>' I~II 81'(' cut to shape (0 look just like real fenders. (J know this shape 100"-, fragile. but they're Ii lot stronger than they leck.) The fenders are made b)' marking a 1\'. -radius arc and a I'Y,"·rndiu. arc on A piece of tq scrap, see Fig. 27. Then use a quarter (2eland the enn of the axle block, see t',g. 31. (tut • slit in the 1'0.1erboard to fit around the axle peg.) ~tOt::
GoUtl 2q
DlUM
SANDEl
NOTE, 4nACHfEND'. SO" CLU.I'$ WHEn
I
AGUltf 3-0
CROSS SECTION c.lAMP saAP
to CKASS1S
'0 TlS' SUOING lONGU,
ANO Sf&JNG RELEASE!,IN
~
fhe-1
SUDING TONGUE
FtGUlf 31
use: POSIE.IO .... O AS -S'Aal WHEN GLUI-HGtN
GUI£ 31
!=ROSS SEq10N
"" sas
HO,."
1'.
""W$
~w
23
Sources hardware store, In fact. we were surprised al 1m, \""('I~ uf spnllj.'" a' iJabk>.
D[SK CLOCK
\
I,..,
KID'S [ASll
DESK
,,, I can order tnt, ha1"d'\lln: {or the kill's " •• l,II. -k from:
lit.; \\tH)IJ\\OIlK":K~' Sl'C}I'.:, 21t'l..l1 In· ,1\I..trial Boulevard, I(oj.:!t'rs. \1:\ ;,:,."71. (61~1 .t:!;-.:·21!t9 tt'atnlog :-..! fI') J(lf rt (um«lorHoi'a,dC I), I l~i!C!I , .!', Ord er :"0. (~:;r~JO$ I.. r set, ,; 00 p('l'onJ:.. Ol( as II" .. \ 10 and, 'h~ lIowl-It. Th~ .!londanl [1"",1·11and a tit uxt: model "lttl r...-:'In,,\n.llll~ ...ttt \\·In \\ -UJJnpcnt elf ",nl;.III1tI\IIJ" lI,n CJVPl'fl'uln "'lI b''lInll. Xo. II·m \\hi',· II1HII~ tinbh II (tlfft'relJlj<,b:;, 'rh{,\' \\{'I"C'Ulllrt" than hal'IJ~ ('(, t :$1;.1(1(Sl.!HII~'r ~IU;U'l'roOt), r (II to ~t11them _tt a f(·:L"flft.ltlli(l ("(.:-l ($1 !"() per mon' :n(Ornl.allUJl all11•.Jt hU)·lng oiff(·rt'llt """p' oi Fomuca, ..-, the pardgl'al'" "'Iuarc f" I). 1.8tl'1' "e d ,;ro\ .......llhal SOme lumber under the I.)e,k I'I000k abo,< \1\Rt\l~, There are a '\\lilt. \-:u-it"t)j ( ~anl< and bulldlnl! «'nto r, that earn ronm<3 (or olh,r bl1l,d I r 1,1a."icI,nm lI1ark~,.,.a\aitable I hat \\111 "'nl .... n pia.st Il.3tt') ha\(' a i"j)('CUlI rtlt:k (1111{Ir a .....'lrtt'1l lammal~. Eaoh has ,', rICh antag~, anti .. hfJr\3" nnt} !oO('nll~ It'll U\'('r ft')m tar)!'I' 1h:-.:ltlv3ntage.. .... fll ,ll'I~. The IlnCc.'" ~l,t'IIlI.'(1 rlur unci thl' 'J'h£t brighte:-o.l rnlfll'H nr(_' Jl1UtIL' \\'Ith {)ur l,tlCal 1.:anf:tt)·c,fe"!{II"Sllllht·, ,l'ks "\I'1'I;"'vtl u , hl"u;ul~J Itllni clt1-~t·r:t.'!(· 111;tI'K{'I"!". supply ,ton' <'lIrrl.. 1Sanford', E"JIO TOY aANK TRUCK brnnd In • ",nely o( col. r fo,., 1:,0 ~ \ au """ erd, r th paru r the •ruck from Th, • '""rke ....\\ '1>r Chf,il't '\\'(lul11 t,t \\'atf:r-l,n «n.,rk.·",. They aN' ....."hl) .\lllJabl ... It I ~ u,le hole> • l 'rd, r :\0. '1"1'112.~.14 ":lch /J'JI, H ,Ito 3. "~I.lo Ord, r anUl'pl) ~Ion \\'e fOlln' also (IiUnd'd' nntt.·:r) (tlrtht· If1Il"k.ln~pin can tHo' "twa\ t,Jt~t'(1 (rum all f,lel ()\ t'rheDfl Proj"'clor I',·n'" al\·;.tiJabJe to l,.tll~l"'llntpen (tIll' "~lu'k,ulI" t~'PCJ.aUl \\c tJroa(t or fine Pf)iut arul It \ :ll'lt'l:-' of rolurs rnulltl the stmt· "))I'ltlJ,." 1•.\ ,u.:kin~at d ltK1tl (or S!f\J e3ch,
J."....
f~,
•
"t~,,
.""ill
00"""'"
om"
r.
O
.'MY
24
The \\ ater-ba ..to nlArkf'f'S rvquire a
• \\'t"t
~I..,nl!'·or cloth to" 'I"' th. Of oil and thf' colon t~ndto water 6"otl thou~h the 0\ er-
head proJectDr
pens an' much bri¢tter
or
than
the Crayola brand t. SUIIl" the wau-r haSi markers caution that lh(')' rna)' stain clothmg; but most of thvm wnuld pl'ob"bl) \\'a....h out ea_...ier than thv dl) t'I'L"l'markt·J":o', .JI...-\('l\NOAKI), In ..tt'''41 "I Ulin)!, ."nrml(·:t tand marke~ on tht easel, another OJltl"11 "ould be t. 11.."," bla~kbo.'lnl \\e iuund a .!·~a·blackboard at a to, .to re that could 1>< rul to fit the ''''''' 1111 to be ut least 16"' ,,/!t ,.). The eost \10 114$11 .•)11. $inct' blaekbeanl ...art" llolU:tlI)' In,t(ll· from a .)14..-'(."(' I,f • _'t,L"'lllit, I ) OU l'f''Jlfllamirulle 3 secfInd "11""(.' (,f t·1Jrmil",t·e'I\"·Yl"(l Y.... )1a. ..t)nitt" to tho hack to mnkvthe J~\lll·t.('fhi:-;. \"ll)' .)OU \\oulet ha\t- t rmiea on the ciet.'K :-oJ,lt, and • hlac:kboarrl on thP elL"" .. de.) ~:a....U,t>" 2',,3
•
"'I
I.
ta
pnn! of $t;.tJ.5. JK·r'1II,art In l)iaeK ancl $10.1 i I'"r qunn In J1I''('n 1'1"" t' 8(j,\RI)- \\t' fl)\4"I't."(J the back .Jf
1he (1.~k,{,'1."I('1\\ ith
l'.11L
r If,
R
l'lll·UV lMJanI and a
rl'qUlrt~
I"
a hulJelin bt)
• X 32"'. To mak( our nJ;!lnal board .. e bou~t "Ihick .-hoel rork alld!wl pwnned Ul~It directly to th" M.,oml. back lIut th n "" I"l'aliu>d lhal mo,t thumbtar'" are ... long thaI lin'), \10111<1Im,h rli:ht Ihroul!b Ihe eork hut chulrlo"L I,,· ),n'j! l,l Into the hnnl ~IU.l'iflllitl!, So ,\\',-" Jdued I he cork to 8 ;t.·xI' IJll'\'C of 1i(..'Otll'otical
Thi::- \\clrkl ..I ....,-.at. llUt tl)' thl' "e bad pUrdlll.......! Ih,' ."rk. the ....'1·
('("1Ins: tll~ Ill<
~. aDd the curkboard adhe''''e, "" had 'pcJ1t more molK'\' than \\ e u'antell \ belter ,dtv.. might "" 10 Ju.-t bu) a
at a t~,~. di:--eoWll. clr CJrjj~ F;uPJ.ll~'stor,", t.:lk,· off thl' f11l01e. "rut l'ut it to fit. S(~n~('url-n':l a l!'x:J' bullf'1 in I... rd ror $IO.!I!I(0,,10" :-;,•• 1\"('-6& II .). N-:t.r.- at.." can·i.· .. futt\lntl (lark brf,"'n ,~
trlJ.atlt.!uulletln
}III],tnl
··thick ('f.rk :o"Otrip!i
~\'e
' ' }III 8QUKt\,~ WIth atl ..
bac.-king.A packa", of four ,tnp.' nch ,trip mea,u ... ' 12"x ti") ;. $1!1.l!'1 ~nnler :-;". I!i.K\·.".,U· A 1",C"kaKcof • (our !Cquare~(each t',1)uare m("a!-l.urc~ l:.t"xl2"'llS, S7,~1 t()I'flc'r S.,. l!f..K..'(Q>4-11 ,~C)U\\ill
neccl l \lit') rNtl'kKJott'!oo hf lhe~c small "'1un,.... 1'01' Ih. hlllh'lin holt"l, \VOOn.,\IITH