Make a Pirate Chest

. Plus
PuliOut Plans
Colonial Shelf
Rocky Duck
08

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to the sma ll shop MODEL G1834 $
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Make intric ate dovetails , yo ur part are eliminated!
construct ion with quick
finger-joints, etc . . . with Set of 6 templates for Enlarge or reduce images right on the wood
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this amazing jig. making dovetai ls and accurately.Comes with a scri be point & lead.
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CALL TOLL FREE (FOR ORDERS AND CATALOG REQUESTS ONLY)

EAST OF THE 1-800-523-GRRR +- (For Orders & Cata logs Only) -+ WEST OF THE 1-800-541-5537
MISSISSIPPI: (7 17 ) 326-3806 +- (For Inquir ies & Customer Service) -+ MISSISSIPPI (206) 647-0801
89-106
 0 iCfjill&J,
>

il_
AugusVSeptember 1989

A Popular Woodworking Project

Laminated Bracelets and Napkin Rings
by Devore 0. Burch 29
Unseen Creations by Kathy Hackleman 34
A Popular Woodworking Project
Colonial Shelf by John A. Nelson 53 29
A Popular Woodworking Project Q;
e
0
0..
Rocky Duck by Howard V French 54 s:
~
0
LJ
y
'"
0
A Popular Woodworking Project
Make A Pirate Chest by Warren Asa 56
A Popular Woodworking Project
A Sleek Mahogany Table Set 60
by Hugh Foster
53
A Popular Woodworking Project
Decorative Carved Screen by Amy D. Shojai 66
Focus on Carving
Carving Carousel Animals-Part 3
by William H. McMaster 71
A Hand-Rubbed Oil Finish by Thomas Wisshack 76
60
The Turner's Page
Egg Cup by John A. Nelson 83
4 Clear Cuts
12 Book Reviews
_M.t1!iITff@iilJHWfMmJilW IM1f11''M$ ;,;ml.W'PWmmrtwlit@$J!B!f11'&On-theIit0 Gverdl.!liillB 16 Videoscene
20 The Business End
~ 24 Tried and True
Warren Asa smoothes the top of his . 86 Out of the Woodwork
oak pirate chest with a spokeshave. This ]j .-. ~ .
delightful project isn't as difficult as it i
looks. Improvisation is the key to bevelling
the slats for the top. You'll find a full- size
pattern for the end pieces bound into 6 Letters
the center of this issue (that's right, you 10 Tricks of the Trade
don't have to send away for it) and 22 Tests & Comments
complete instructions for the project on
page 56. 80 Calendar
84 Classified Market
85 Index to Advertisers

A ugust/September 1989 3

I was watching Norm 's show on PBS (one of the best things on
televi sion ).They were showing a closeup of a certain table saw
procedure. It's a dramatic shot, actuall y. The camera starts out
high, sort offollowing Norm around at shoulder-level. Then , as the
wood make s smooth contact with the table and fence, the camera
swings over and drops-zooming in on the front edge of the blade
ju st as the material make s conta ct. Then , as certain as his cut is true,
the bright message com es crawlin g across the bottom ofthe screen:
"Guard removed for photographi c clarity . Safet y guard s should be
used. "
Ah , the thing s we do in the name of photographic clarit y. Never
mind that it would be impossible to make that particular cut with
the guard in place.
PW should probably run such a disclaimer with some of the
photos we publi sh. We should do so for safety purpo ses, just
like they do on The New Yankee Workshop: to cover our as...
...selves. We prob abl y will.
My high schoo l shop teacher kept the table saw guards hand y:
next to the machine with the wrenches and blade s. He jokingly told
us to put them on the mach ines only if someone from the
administration buildin g was on their way over. And, that was really
only if they were bringing a lawyer with them .
He said the guards themselves were a safety hazard . Speak ing
for those guards and those machines, he may have been right. I
know I never saw an injury that resulted from the absence of a
guard.
I do not mean to say that PW is recommending you not use your
table saw guard. We can' t say that.
I'd like to hear how you feel about the subject, though. I'd
especially like to hear from those who swear by the guard. Are there
aftermarket guards that are as worthwhile as aftermarket fence s?
Any shop-made ver sion s that do a better job? Write in and let us
know . It goes without saying that shop safety is an essential
concern-even to big-time TV stars.
Random Notes: If you're looking for Part 2 of Alan Marks'
feature on computer-aided furniture design, stay tuned; you'll find
it in the October/November issue.
I'd like to welcome Assistant Editor Phil Fischer to our staff.
Phil's been messing around with wood for years, but his previou s
dayjob was as a high school English teacher. He had planned to add
a second story to his house during summer break this year but
decided to forgo tho se plan s to come join us at pw. I'll be teach ing
him my loooong-term remod eling approach.
Welcome also to Ginn y Pruitt and Sue Fullmore. Ginn y helps
with pasteup and illustrations (see pages 66-70), and Sue helps
with circulat ion and advertising chores. Both brighten the offices
considerably.
4 Popular Woodworking
Popular Woodworking Staff
Editorial
David M. Camp Editor
Wien Chad Managing Editor
Phil Fischer Assistant Editor
J.A. Newell Editorial Assistant
Contributing Editors
William H. McMaster
Alan Marks
Hugh Foster
James Barrett
Don Kinnaman
Art Department
Ginny Pruitt
Circulation
Suzanne Eriksen, Sue Fullmore
Customer Service
May Fayne
Advertising
Debra Nowak Advertising Manager
Tel. (4 15) 67 1-9852.
Pop ular WoodH'o r/';inK (lSSN 0884-88 23) is published
bimonthl y by EGW Publish ing Co. 1320 Galaxy Way.
Concord . CA 94520 . Second-class postage paid 31
Concord. California and add itional mailing offices .
POSTM AST ER se nd address c hanges 10 Popular
w ood working , 1320 Gal axy Way. Concord. Ca lifornia
9452 0.
SU BSCR IPT IONS :
A year' s subscription (6 issues) is SI 7.00; two years' worth
( 12 iss ues) is $30 .00; o utside of U.S.A. add $5.00/year . Send
all subsc riptions , adve rtising inqui ries and co rrespond ence
to :
Popu lar Woodw orkilll{
1320 Ga laxy Way
Co nco rd. CA 9452 0
Please allow 6 10 H wee ks for deli very .
All rights rese rved . Rep rodu ct ion without prior perm issio n is
proh ibited. Co pyright 1989 by EGW Publishing Co .
Unso licited man uscri pts. photographs. art wo rk and ot her
materi als are accepted . but Popular Wood~ 'orkin l{ can not 3.\ .
sume respon sibility for these materials. Wri ters who subm it
articles do so w ith the understanding that the work.is origi nal
and done by them. Th e autho r warrants that submi ssions and
subseq uen t printi ng of any materials in Popular Woodwork
i"K magaz ine dono r infringe upo n the rights of any third party
and agrees to be totally liable for such claims . Subm issio ns
mu st be accompa n;oo by a self-addressed. stamped en velope
for retu m .
Th e op inions expressed by the auth ors do not necessari ly
refl ect the po licy of Popular WondKorkinx . Editori al corre -
spo ndence is enco uraged . and may be ed ited for publicat ion.
Ad vertisers and age ncies assum e com plete lia bility for the
co py in their ad vertise ments and warra nt that it does nor
infrin ge on the copy rig hts or tradem arks of othe rs. Ad verti s-
ers and age ncies agree to hold publ isher harml ess from any
liabil ities arising o ut o f s uch infri ngeme nt and to reimburse
publisher for any and all ex penses and costs incurred by
publisher by reason of such infringement.
Co rpo rate of fice rs: Wayne Lin. Preside nt
Prod uced and printed in U.S. A.
 CARBIDE - TIPPED ROUTER BITS
TENS OF THO USAN DS OF OUR ROUTER-B ITS ARE IN USE IN SHOPS ACROSS THE CO UNT RY.
W E USE HIGH. INDUSTRIAL GRADE CARBIDE WHI CH IS PRECISION GROUND TO EXACT ING SPEC S.
PRICES ARE PREPAID TO YOU & WE SHIP FAST !

RAISED PANEL BITS STRAIGHT BITS SPIRAL - FLUTE RABBETING BITS FACE MOULDING BIT

25 SET OF 5 I' ~ CUTTING I '12" SHANK

. I
DIA .

~~ ~
1- 114" 15'16" Cutting dia.
ONLY ALL
~

~
!I"J 1-3/B" Cutting
$22,95 I
'14" SHANK '14" SHANK length
'14" SHANK
" 4" SHANK. 1-5IB" DIAMETER MODEL CUTTING PRI CE
~

it~ ~
MODEL G15B9 CUTTING LENGTH
MOD EL DIAMETER PRICE
112" SHANK. 1-5IB" DIAMETER 114", 5/16",3/8" , '/2", & 5/S" G 1409 1 S" s 995
MODEL G1590
G 1797 1 S'
3 -16"
$ 1500 G 14 1Q 1 4' $1095
'.~.lf> MODEL G136 7
MODEL G1587 SET G 1798 $ 15.00 G 1411 3 S" $1095
ONLY $19.95
G 1799 732" $ 1875 G14 12 12" $ 1250 529"95
SLOT CUTTERS GI800 1 4' $ 15.00
THISSETCOUNTS AS I PIECEFOR DISCOUNT} '12" SHANK
n DEPTH OF '12" SHANK BULL-NOSE
I
I CUT 5/ S" FACE MOULDING BIT MODEL CUTTING
LENGTH
PRICE
RADIUS BITS
I
CUTTING 1 S" s 995

~{E3
MODEL PRICE G 1413
'12" SHANK DIAMETER
G 1414 1 4" $10.95
G l80 1 $26 00
G 1415 3 S" $10 95
.-r'-=~b-.., 15 ' 16" Cutting dia. G1802 3 S' $3795 BUYANY
G1 4 16 12" $12 .50

(
~
(J ~;~~~ cuttlng ~~~~~~~~
G 1803 1 2" $39 95 10BITS
'I4" SHANK AND
MODE L CUTTING
THICKNESS
PRICE
THUMBNAIL BIT CHAMFER BITS DEDUCT to'1e

II
G135S 1 S" $16 50

G 1359 $17 .50 : .v, MODEL G136B 'h " SHANK 'h " SHANK
45
G 1360 1 ' 4" $17 .50 L:::J 529.95 2- I 12" Cutting dia .
MATERIAL

~
MOD EL THICKNESS PRI C E

'h " SHANK G1G04 1 S" $1195

curnse PRI C E STRAIGHT BITS . . '14" SHANK G 1G05 3 16- $11.95
MODEL THICKNESS
A G I606 1 4' $ 12.75
G136 1 1 i 8~ $ 16.50 MO DEL CUTT ING
DIAM ETER
P RICE G1G07 3.- $13.25
GI608 1 2" $ 1395
G I362
G 1363
3 16"
1 4"
$ 17.50

$ 17.50
I BUYANY
10BIT$
G1401

'12" SHANK
I" $ 12.95
G1609
G1610
5 S"
3 4 0
$1495
$1495
AND
G 1611 I" $ 1595
DEDUCT10"" FACE MOULDING BIT MOD EL CUTTING
A
PR ICE
V-GROOVING BITS DIAMETER

~ '12" SHANK 1 '12" SHANK

' - 1116"
G1402
G1403
1 3 16"
1-58"
$ 13.50
$ 1450
CLASSICAL BITS

+
G 1404 1-34" $ 1850
Cutting dia .
90 ANGLE

~)
I MO DEL CUTTING
DIAMETER
A
PRIC E 1-5 ' B" Cutting VERY
COVE BITS

~m
length

i POPULAR
G1371 l f4- $5 .95
G 1372 5 '16- $5 .95
3 S" UYANY

~
G1373 $595
'14" SHANK G1374 3 S" $595 Momo"" 10BITS
A G1375 716- $595
D AND IMODE~ ~~~~~~N~ylS~9~5~~~P~JDEfo I YOU
MODEL CUTTI NG
DIAM ETER
PRICE G1376 1' 2" $5 .95 ' 32.50 DEDUCT 10,,"
I 1 'l' SHANK. 1- 1 7 DIAMETE R
MODEL G15980NLY $19.95 PREPAID TO you I
I
G 1395 3'- s 995 G 1377 1/2" $9 .95
. '14" SHANK
1,2" $11.95 G1378 9 16- $625
G 1396
G1379 5 S" $625 ROUNDING BITS ,
G 1397 5 S" $ 12.95
STRAIGHT BITS

..W
G 13S0 3 4" $695 MO D EL RADIUS PRICE
'h " SHANK G1381 7 'So $6 .95 G 1405 3 S" $12.95
A GI382 I" $895
MODEL CUTTING PR ICE
G1406 12" $ 1395 WITH
DIA METER
G139S 3 '4~ $ 13.95
'14" SHANK '12" SHANK
G1399
G14QO
7 S'
I"
$ 15.95
$17.50
MO D EL CUTT ING
DIAMETER
A
P RIC E M OD el
,
RADIUS P RICE
r~ BEARING GUIDE
'14" SHANK
~ J
G1663 1 14~ $595 G 1407 3 S" $ 12.95
G1664 5 '16" $595 r '14" SHANK
DOVETAIL BITS Gl665 3 S" $595
M ODEL RADIUS PR IC E G 1408 12" $ 13.95
-
G1666 3 S" $595 G 1417 14 0
$ 1295 A
M O DEL CUTTI NG
G1667 7/16" $595 G 1418 3.- $ 1650 ROMAN OGEE BITS DIA METER
PR tCE

BUY ANY G1668 112" $595 G 1419 1 2" $1850 G13B3 $595
10 BITS GI669 1' 2" $995 G1364 3 S" $695
'h " SHANK

i
AND G1670 916" $625 BUY ANY Gl385 12" $595
DEDUCT 10% G1671 5 S" $625 t 10BITS G l386 12" $695
M ODEL PRtCE
"1 G1672 3 '4~ $8.95 RADIUS G1387 1 2" $695

~ ~ '14" SHANK
G 1420 1 4" $ 1295 OEO~~~ lOot.
G142 1 3S" $16.50
A OGEE FILLET G 1422 12" $ 185 0
FACE MOULDING BIT
MODEL CUTTING PR IC E
DIAMETER
RAISED PANEL BIT '14" SHANK r= '14" SHANK
G I388 3.- $495
DOUBLETONGUE ,
Gl389 $495 MO D EL PR I CE

'1
'12" SHANK RADIUS 15116" Cutting dia .
& GROOVE LOCK MITRE
'12" SHANK G1423 532" $15.50 5 !B" Cutting length
G1424 1 4" $1650
A 2-5 IB" DIAMETER 5 ' 16" Bead
MO D EL CUTT ING
DIA METER
PR ICE
-""- '12" SHANK
'12" SHANK
G1390
G1391
G 1392
1'2:" $495
$5 .95
$6 .95
~ JIi _

l?"'" 1 ~~ODELG1679 MO D EL
t
RADIUS PR ICE
Dlr
~~ MODEL G1369
G 1393 7 .'8"
I"
$7 .95
$8 .95
MODEL G15BB I ~ ONLY 53 4 09 5 G 1425 5 32" $15.50
519.50
G1394 G1426 1 4' $ 16.50
ONLY $22 ,95

CALL TOLL FREE (FOR ORDERS AND CATALOG REQUESTS ONLY)

EAST OFTHE 1-800-523-GRRR .- (For Orders & Cataloqs Only) -- WEST OF THE 1-800-541-5537
MISSISSIPPI : (717) 326-3806 .- (For Inquiries & Customer Service) -- MISSISSIPPI (206) 647-0801
 Popular Woo~~orking welc'OrAes
your comments;' pro or con , about
articles we publish. Send your letters
to: Ediff! r, Pop~J1lr Woqdworking,
1320 Gblaxy wa)', C~i/(;ord, CA
94520. [ etters he editedfor pu}/-
lication.
Interest in Boring Tools
I have long been a subscriber to Popu -
lar Wo odworking, and I especiall y enjoy
the articles on old tool s by Graham Black-
burn. However, I couldn 't help but notice
a few errors in his article on boring tool s
in the December/January 1989 issue.
They are :
I. While bit s for the Stanley push drill
rotate in both dir ections, they cut (and
sho uld be gro und with clearance to cut)
on the pu sh stroke onl y. There is little
pressure on the bit on the return stroke,
and no cutting ac tion .
2. I have never seen a nut au ger with a
flange or bol ster, and could not find one in
any books or catalogs. If the sq uare shank
of a nut auger is even slightly loose in its
wooden handl e, it will soon ream out the
handl e. The way to prevent thi s is with a
tapered shank that is alw ays pulled tightly
into the handl e by the nut ; a bol ster would
not allow this.
3. I have never seen a boring machine
with a feed mech ani sm . They usually
have withdrawal mechanisms , but not
feed . Blacksmith s' post drill s hav e feed
mechanism s.
4. The beech -and-brass brac e illus-
trated is a plated brace, not a framed one.
Th e term s are not interchangeable. In the
brass-plated brace, the bra ss plat es
stren gthen the wooden fram e. In the
brass-framed brac e, the frame is of cast
brass, and the wood infill is mainly deco-
rative.
While talking about hand and breast
drill s, I was surprised he didn 't ment ion
the more complex ratchet drill s, such as
those by North Brothers. The se allow the
handle to ratchet in either dire ction, lock
the chuck to make bit changing easier and,
in the double ratchet setting, will turn the
bit in one direction regardless of which
way the handle is turned. Still, it was a
good articl e.
John Martin
Cumberland, ME
6 Popular Woodwork ing
The au th or replies: Whil e it is true
that there is little pr essure on the hit
during the return stroke of a Stan ley pu sh
drill , the cutting edge of the hit is f orm ed
hya simple flu te gro und along both side s
in such a way that , in effect . there is
indeed a cutting edg e on hath sides and a
certain amo unt of cutting does occ ur. If
the hit wer e ground so that only the lead-
ing edge cut , it wou ld he very diffi cult to
keep the hit cent ered in any hole-with
the result tha t the hit would tend to hind
and turn with diffi culty.
Your points co ncerning the nut au ger,
horing machin e , and plated bra ce are
tru e and well tak en . Of the several nut
au gers l awn. the single example with a
holstered shank has indeed had the inside
of the handle ream ed alit and shows evi-
dence of past own ers having made at -
tempts to refill the hole and tighten the nut
and washer ever mor e sec urely to the
point where they are now deep ly embed-
ded in the top of the handle. This was
obvio usly not as succ essf ul a design as the
commo ner f orm you de scrihe.
By f eed mechanism on the horin g
ma chin e , I meant to refer to the beveled
gears on the cra nks and the hit holding
mechanism that dri ve the hit. It is, of
course. only the pit ch of the lead screw on
the tip of the auger that determines the
rat e of f eed of the hit . The conf usion
hetween fr am ed and plated bra ces de-
serves to have been pointed out and, as
mentioned at the end of the article. war-
rants a separate article cove ring this
enormo usly interesting area of old tools.
Graham Blackburn
Rio del Mar , CA
The Shop File files
I read with int ere s t Hugh F.
Williamson ' s S hop Filing S ystem
("Tricks of the Trade, " PW #4 8, April/
Ma y 1989).
I use a loose-Ieafbinder with the nam e
of the magazine label ed "project s" and
another labeled " how- to." I use the tabs
you can purchase at any stationery store,
making it easy to find each publication ' s
projects and how-to.
Abov e all e lse, it's nice, on a co ld
winter ' s night to grab a bunch of maga-
zines , a large cup of hot chocolate and
enjoy going throu gh them again. You
may even find something you overlooked
before.
David Eckel
Syracuse, NY
Rega rd ing Hugh Williamson ' s
"S hop Filing System," I have a sugges -
tion: Why not have your adverti sements
physically se parate yo ur article s so the
tail end of one does not fall on the same
sheet as the start of another?
That way when articles are removed
for filing it saves us shop nuts from mak-
ing a spec ial trip to the photocopier.
Todd Effren
Brooklyn, NY
Th ere are several reas ons why this
wou ld he impractica lfor us to do. First of
all . we ar e limited in term s ofthe locations
of co lor pa ges because of the way the
magazine is printed ; if we want to use
co lor. we can only use it on certain spe-
cifi c page s. Getting color ads and color
edit orial pages to all wind up in the right
p lace wou ld he almost impo ssible ,
Secondly. the ad pages are firm ed up
at the very last minute. It tak es a f ull two
months f or the editorial department to
prepare its materia l. so we lump it all
together in the middle of the magazin e ,
then wh en ad sales are finalized we put
togeth er the front and hack of the ma ga-
zine .fi lling in the space betwe en the ad s
with our departments (Book Reviews ,
etc.) . Th ere j ust isn' t enough tim e he-
tw een the ad closing dat e and the issue
deadline to allow f or rearrangin g every-
thin g .
Edit or
HighTech Pragmatism
Peter Good seems to have a problem
with the word "Technology" ("Truly
Low-Tech Woodworking," PW 4 8,
April/May 1989).1, too , have been tinker-
ing with woodworking for severa l years,
and altho ugh I haven 't achieved
museum-di sp lay quality, I certainly be-
lieve in the axiom " use the right tool for
the job." My workshop is not a high-tech
factory, but I make furn iture and other
useful and marketab le prod ucts with the
"proper tools." Mr. Good seems to derive
a sense of arrogance from his insistence
that he can do it ju st as well as someone
UC202 3/4Inch 415/ 16" 5/s"

UC209 3/4Inch t
415/ 1 3/4"
UC210 3/4 Inch 415/ 16" 3/4"
UC211 3/4Inch 415/ 16" 31t
UC212 3/4 Inch 415/ 16" 3/4"
 letters
continued
with more modem equipment. I find it
diffi cult to believe that a busine ssman/
woodworker would tie his hands ju st to
prove that " what works, works."
Yes it works, but just how efficiently?
Every tool in my shop is there for a pur-
pose. I can't afford every high-tech
gadget that's on the market, but I use each
too l the way it was de signed to be used.
Tool s are nothing mo re than a method to
achieve a singular goal: 10 produce a fin-
ished pro duc t that is useful and, at the
same time, provide a se nse of satisfaction
e th~~
u'd like to see
.'lIIe nice'round numbers
you get with these Delta saws.
Here's achanceto cut yourself
a $100 rebate check from Delta
when youbuyeither our 18"Elec-
tronic Variable Speed ScrollSaw
or 14" Wood Cutting Band Saw.
The 18"ScrollSaw allows you
to lockin anyspeed from 40 to
2,000 CS/M. Work in areas as
tight as Y6/ diameter, on stock
up to 2" thick.
The 14"Band Saw, with
its 6 ~" capacity
and micrometer
adjustable blade
8 Popular Woodworking
to its creator.
I agree with Mr. Good in that " it' s not
so much the equipment you use as the
technique:' That' s very satisfying to the
pragmatist who satisfies his primal need s
by crea ting orna te furniture with a butter
knife and a screwdriver (and maybe a
large box of bandaids). But I find it hard
to believe that as a craft sman who ma nu-
facture s custom doors. he would be satis-
fied to produce his ware s on a "hobbyist"
scale. Where is the entrepreneurship, the
busine ss acumen and part icular ly the
1.
guides , is perfect for contours,
straight cuts and resawing.
If you're ready to cut it with
the best of them, calltollfree for
the name ofyour nearest Delta
dealer. Delta International
Machinery Corp.,
800/438-2486
(in PA, 800/438-2487) .
Offer good on 18" Scro ll Saw!
Model 40601 and 14" Band Saw!
Model 28 283 only from
part icipating dealers in
continen tal U.S.. Alaska
and Hawaii from July 1 to
December31 ,1989.
Building
On Tradition
CELTA A Penta ir Company
common sen se? So-called "high- tech"
equipme nt wou ld provide him the luxury
of producing his ware s in far less time
than by his antiquated method s. The
mac hines would surely pay for them -
selves in very little time and give Mr.
Good the extra time to figure out more
way s to use his father' s screwdriver.
[ don't have any problem with Mr.
Good's basic premise, but I have a big
problem with a businessman that won 't
wake up to modem produ ction tech niques
that wo uld increase his ability to man u-
fac ture more a nd s ti ll pr odu ce
high--qual ity merchandi se. Somew here
along the way yo u mu st put into perspec-
tive the essentia l idea of product and
pragmat ism.
Thank yo u for lett ing me get this off
my chest. I take a lot of pride in my
avocation. Perhaps it's "pride" that is
lacking wit h Mr. Good?
Gar y L. Ward
Phoenix, AZ
Th e author replies: Perhaps I sho uld
start hy say ing that I don 't actually
"tinke r" with woodworking. I've heen a
su ccessful professional wood .....ork er for
19 years. I also take great pride in my
.....ork and have many devoted custome rs
.....ho will readily attest to the quality of my
.....ork ,
The "right too l for the job" is some-
times a matt er of opi nio n. which in tum
may he based on experience . Many proce-
dures in woodworking can he do ne by
several I'ery different methods. Ten ons .
for example. can be made using f our cuts
on a hand saw .four cuts on a tabl e sa w. a
series ofcuts usin g dado blades on a table
saw. a ro uter with a straight bit. a router
with a sp ira l hit. an indu strial tenoning
ma chine . or hand chise ling . In the right
hands. all of these tools .....ill produce
results of nearly eq ua l q ua lity . in nearly
the same am ount of tim e. and all will he
perfe ctly fun cti onal. Bill different pe ople
use different meth ods. and that' s OK . I
ro utine ly cut hin ge mortises in do ors with
a ro uter , hill I know another "door man "
who does the same opera tion with a
hammer . chisel. and mortising p lan e with
eq ua l res ults in the same am ount oftime.
I' ve al so been in the shops ofa nu mber
of renowned woodworkers and have wit-
 nessed their use of some tools and meth-
ods which you would . no doubt . be ap-
palled by. I'm talkin g about homemade
machinery and tools that bear a close re-
semblance to randomly f ound objec ts.
Th e d ean of wood turn ers , Bob
Stocksdale's prin cipal piece of equip-
ment is a homemade lathe which he
rigged up partly by using spare parts. His
fi rst lathe was operated by a washing
machine motor. Bob's turning is done
almost exclusively using a single uz"
gouge. and his tiny basement shop has
ceilings that are so low you have to duck.
and part of the floor is dirt . Sam Maloof s
overcrowded shop. where you have to
pick your way around disorderly piles of
miscellaneous material s. looks more like
a garage before a garage sale.and a piece
of f olded- over sandpaper is one of his
most important tools. Using what many
people would consider low-tech tools
and methods. these craf tsmen, who are at
the very top of the fi eld , produce stun-
ningly beautiful pieces ofwoodwork with
reasonable effic iency and without a great
deal of effo rt. In the case of Roy Under-
hill ,auth or and star ofthe highly success-
f ul "Woodwright's Shop" series on PBS.
a whole career (and a very good one at
that) was built on low-tech tools and
methods.
Don't get me wrong; I certainly advo-
cate the use oftools and methods that do
a good job . safe ly. efficiently and in a
timely manner. For example. I am a great
fan of air-operated tools and use them
da il y . I ope ra te in ~ premium
5.000-square-foo t shop equipped with.
among other things. a 12" table rip saw. a
12" rolling-table crossc ut saw. 10" table
saw. /2 " jointer. 12 " planer . 24" planer.
very large band saw . 16" disk sander.AS"
edge sander. large drill press and a cen-
tral dust collection system . all of which is
industrial- grade machinery.
Many woo dwo rkers , particularly
those who arej ust starting out.may not be
able to afford some ofwhat you refer to as
the "proper" tools and equipment and .
out ofeconomic necessity. may have to do
the job in a lower-tech way. There may
even be an advantage to this because to
make the lower-tech tools and methods
produce a quality result . you have to
develop a greater degree of skill and a
August/Septemb er 1989
more sensitive f eel f or the material to
BARTLEY
PASTE STAINS & VARNISHES
make up fo r the lack ofprecision or effi -
ciency in the tool. Quite possibly. this Nooffensive odor Recoatin 4 hours
makes a more prof icient craf tsperson.
Nobrushes No sags or bubbles
Bear in mind that much ofthe woodwork-
Nosanding between coats
ing machinery in use today-particularly
at the industrial level- was developed so Dries to touch in minutes
that consistently high-quality results
could be produ ced rapidly by operators Call today and ask about
with lower levels ofskill and experience. our sample kit! You'llbe
Some ofthe best machinery works so well glad you did
that any klutz can obtain good results
using it. In this case. is the operator a
woodworker. or ju st a button-pusher DEALER
with little or no skill? INQUIRI ES
l 'm not a woodworker who. as you put INVITED
it. "creates ornatefurniture with a butter
knife. a screwdri ver and a large box of
bandaids." I'm not quite that good. But I 1-800-BARTLEY
can. if need be, pr odu ce a fi ne (In MD 301 820-7722)
f rame- and- panel entry door with mor-
tise and tenon jo ints. raised panels with
beveled or coved edges and raised deco-
rative mouldings around the panels using
nothing but a table saw. belt sander .
orbital sander. a half-dozen pipe clamps
and a hamm er. Startin g with rough lum-
ber . I could complete the proj ect in less
than a day. With no additional equipment.
I can also make the panels with arched
tops (think about that one f or awhile). I
don't usually do it with this little equip-
ment, but I can.
Stop in at my shop sometime. We' II
have a beer and maybe I can show you a
couple of nifty tricks. For instance, I
could tell yo u about how I make
one-piece laminated elliptical mouldin gs
and picture fram es. I get pe rfect results
using any old table saw and router table.
a hammer and a f ew nails. You'd be
shocked.
Peter Good
Oakland. CA
Let us introduce you and your family
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Appr ov ed by Co m m . of Ed . Sta te of South Caro lina
9
 iii?

"Tricks ofthe Trade " shares readers' tips f or making wood-
working tasks easier and safe r. If you've come up with a trick
that would help other woodw orkers, send it to "Tricks ofthe
Trade " c/o Popu lar Woodworking, 1320 Galaxy Way, CO l/-
cord, CA 94520. Include any photos or sketches that help il-
lustrate your idea (we 'll redraw them ). We pay $25 fo r each
trick we publish.
Planer Tricks
Eve n the planer can be jigged for spec ial opera tions . If yo u
wa nt to plane stock thinner than the bed will allow, make th is
"s lave board" fro m a plastic-l aminated sink cutout. Cut it to the
width of the feed tabl es and lon g eno ugh to reach at least to the

Vise Arrangement
In my fir st (tiny) sho p I built a 6'- long wo rkbe nch and
mounted a ca rpe nte r's vise on the left end. Ho wever, besid es 5/itve Beam
wo odwor king I did so me woo d carving and also work ed in bon e
Clt::al;
and met al. so I need ed a ma c hini st' s vise . I mounted a heft y
mod el on the right side , po sitioning it so that the perm anent jaw
would be in perfect ali gnment with the ca rpe nte r's vise. It wa s
one of the smartes t mov es I eve r made . Ico uld cl amp long board s
in both vises pro viding g rea t sta bility for sawi ng. planing,
drillin g and ca rving. I padded the ja ws of the machinist' s vise
when necessar y. So me may arg ue that a mac hinis t's vise has no
place in a woodworki ng sho p, but my wor kbenc h had to provide
faci lities fo r all of m y inter est s and thi s arra nge me nt wo rked
pe rfec tly for me. I'm still usin g thi s bench in the sa me way in my lilted.
.- -- 5lctve &xr.-d
larger shop 40 yea rs later.
Warren Asa f e-tce
G lendo ra, CA

Plywood Transport
Th e passage of tim e has mad e it inc reasi ng ly diffi cult for me
to lift and ca rry large shee ts o f plywood aro und the shop . I ca me
up with thi s de vice to rem ed y the probl em. As show n. it is a
simple ca rt w ith a hin ged rack that tilt s up to balance the plyw ood
hori zont all y and s wings do wn to eas ily move the mat erial
around the sho p.
Th e only dim en sion that real ly matt ers is the 24" wid th of the
c:
rack . Hinge it to the upright portion of the ca rt in suc h a way that :;
r-------------------------,~
r- 4 2-" iii
2" -4" v-swt
r > _ _- C1 ~ t
fb::;~~;:;;::;::====--i1 ~
\ ~
D
'"
c
o
.~
;;;
~ L---- ....J

it wi ll be flu sh with the top whe n in the hor izo ntal posi tion. W ith
the weig ht of the plywood bal anced on its ce nter. it requires very
little effort to lift it up or do wn . ow I s lide the material o ut o f
its rack and onto the ca rt. tip it down to ro llover to the tahl e saw,
and tip it back up again to present it to the ma ch ine at the right
he ight.
John E. Leed s
Ojai , C A
outfeed rollers, and apply a c lea t to the bottom to stop it agai nst
the infecd table . W ith thi s se tup, yo u ca n make yo ur ow n veneers
do wn to abo ut 1/16" th ick .
A slave board made fro m a 2 X 4 with a V-groove c ut in the
top and a cleat on the bott om makes it possibl e to mi ll a flat
surface onto roun d stoc k for use as dr awer pull s. etc.
On e time. I had to duplicate so me tap ered hou se sid ing that
was no longer manufactured. I made a slave board that was the
width of the siding and had mat eri al und er one edge to tilt it up
into the c utter head at the proper angle . A fenc e alon g the othe r
edge kept the stoc k from slid ing down as it wa s bein g mill ed .
Don Kinn am an
Phoeni x, AZ

10 Popul ar Woodwor kin g

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 W;Book .Reviews
by Hugh Foster
The T AB Hand book of Hand and
Power Tools by Rud olf G raf & George
Wh alen, 1984 (T A B Book s, lnc.,
Mo nterey Lane, Blu e Ridge Summi t, PA
172 14) 50 1 pp ., pap erback. $ 17.95
T his bo ok m ak e s a n exce lle nt
one-stop g uide for novice crafts persons
who are choos ing their first tool s. The
introdu ct ion to the hand tool sec tio n is
one of the most se ns ible two-page essays
I have read. Besid es describin g what's
ahea d and advis ing that few project s will
be described, it gives a qui ck history of
hand tool s po inting o ut that thei r use has
co ntinua lly increased human s ' ability to
think.
Hu gh Foster is (//1 English- teaching
woodworker in Manitowoc. w isconsin.
12
Before taking a look at the tools
them sel ves, the autho rs discu ss several
points abo ut the attitude that lead s to safe
wo rk. Taking this sec tion to heart and
applying it to o ur ways and wo rks could
po ssibl y put man y doct or s o ut of
busin ess. Sinc e Chapter O ne wise ly
admo nishes us that sharp tools are the
safest tools. Chapter Two takes up
meth od s o f sharpening. Th en the rea l
business of the book begin s: twent y- si x
more chapters d iscu ss eve ry co nceivable
type of tool. Woodw ork ing tool s are
exa mined. to be sure, but so are tools for
shee t metal wo rk, e lec trica l wo rk,
masonry, plumbing, se wing, kitchen, and
even yard work. Th e book wo uld
represe nt an honest va lue eve n if it
incl uded only ha nd tools, but it ranges far
beyond the wo rkbe nch.
Mos t of the book is devoted to power
tool s. T he auth ors des cr ibe which
features are he lpful and which are just
fluff in co mmo n workshop tools. from
simple drills to much more complex
devices. Besides woodworking tools,
devices like we lders are discussed.
Bran ching o ut from strict ly shop tools.
the boo k co nside rs cha in saws. lawn
mower s, cultiv ators, and even snow
blower s. Prop er use of these items migh t
ge t us more sho p tim e! Ju st abo ut the on ly
power tools not covered are the orb and
sce pter. but then those are used on ly by
re ign ing roy a lty.
T he seco nd half of the book, like the
first. co ntains a harvest of information.
Ever a g lutto n, thou gh , I wanted even
more da ta abo ut tool main tena nce. Even
thou gh I try to be co nsc ientious about
mainten an ce, I don 't know how, where.
or wit h what to lubricate and adj ust my
mach inery. As much as I like this book,
I'd be eve n more del ighted with one that
sha red that info rma tion.
Scroll Saw Handbook by Patrick
Spielman, 1986 (Sterling Pub lishing
Co., 2 Park Ave .. New York, NY 100 16)
256 pp.. pap erback , $ 12.95
So man y types of scro ll saws are
ava ila b le tod ay th at a prospective
purch ase r mi ght find it hard to know just
where to star t shopp ing. I have found
myself in that situation more than once,
and have thu s far always give n up on the
not ion of scroll sawing in my sho p. Now
I'll know how to shop for one the next
tim e I'm sm itte n by the urge. Spielman
takes us throu gh the vario us kinds of
scroll saws, both by type and by brand.
Over half the book consists of thoro ugh.
info rma tive. we ll-illust rated product
revie ws. T his book does n't tell yo u which
type or brand to buy, but Spie lman's
exp lana tions of the di fferences make it
possible for you to make an informed
j udg me nt.
The second hal f ofthe boo k is devoted
to saw ing techn iques. Som e of the jo inery
that ca n be sc ro ll saw n after a bit of
practi ce is nearl y incre dib le. I like to use
dovetail s in my wo rk , and Spie lman
shows here a fine way to qu icken their
Popu lar Woodworking
cutting.
A sec tion on " Ma rquetry Basics" is
very entertaining, es pec ially the photos of
Silas Kop f' s ve ry non-basic marqu etr y,
which alone make the price of admi ssion
worthwhile .
Scroll Saw Pattern Book by Patrick
& Patricia Spi elm an , 1986 (Sterling
Publ ish ing Co ., 2 Park Ave ., New York ,
NY 1001 6) 256 pp., paperbac k, $12 .95
With ove r 250 pages of scroll saw
pattern s and photographs of scroll saw n
items, this boo k sho uld be the scro ll
sawyer's del ight. While there are only a
co uple of pages of ac tual text, those pages
prov ided this reader with an insight into
why most of my atte mpts tocopy a pattern
by the "grid" method have failed-and
why my next effort won' t. Th e c raft
item s that he provides pattern s for are the
type that se ll like hot cakes in my area . If
you' re wond ering why you have that
ex pensive scroll saw, this book may
answer the question.
The Fru gal Woodworker:
Woodworking for the Beginner on A
Budget by R ick Liftig, 1986 (TA B
Books, Inc., Mont erey Lane, Blue Ridge
Summi t, PA 1721 4) 227 pp., paperback ,
$ 12.95
This boo k ca ught my eye because it
looked like the sort of thing I love to hate.
I had a visio n: I wo uld look at it for a few
min utes and then pan it. My first
impress ion was wro ng, however, as I
d iscovered while read ing the bri ef
biography of the author. Liftig is a denti st
who loves wood wor kin g because wood
does n' t bleed, no r does it mind when he
slips. I like a fe llow who can look at
himself with a wry sense of humor. Rick
Liftig is also a fe llow who has done so me
pretty dece nt woodworking in a pretty
Spartan sho p. His introd uctio n shares the
secret of his success: having a positive
attitude.
Chapter One reminds us that we ca n
go bankrupt buyin g tools. Dem onstrating
the trut h of this, he point s out that
bankrup tcy auctio ns are among the best
places to buy woodworking tools. The
most importan t too l in the shop, says
Liftig, is the be nch, and he adv ises you to
save a bus he l by making your own. He
August/September 1989
shows a bench plan that features a Black
and Deck er Workm ate as its main
fea ture.
The onl y place he wouldn' t have you
skimp is on your woo d. That makes sense.
He says to learn to like plywood in the
right places for the right reason s. Stud y
the great designs of the past, and study
Lift ig 's designs, too-they aren ' t bad.
Th e book includes fine des igns for
attrac tive computer furniture. You may
not find anything exc itingly new here, but
the book ' s refreshin g tone sets it apa rt
from the ordinary .
The Complete Book of Portable
Power Tools by R. J. DeCri stoforo,
1987 (Ste rling Pub lishing Co., 2 Park
Ave ., New York, NY 10016) 258 pp.,
paperb ack , $ 14.95
The author knows as well as yo u and I
that this book is far from "complete," but
novice woodw orkers will appreciate his
co llec tio n of cl ear , easy to read ,
well-i llustrated material. DeCri stoforo
covers safe use of co mmo n tools,
including the circular saw, saber saw,
reciprocating saw, electric drill, router,
belt sander, pad sander, disc sander/
polisher, power planes, flexible shaft
tool s and o the r gr inde rs, va rio us
batter y-powered too ls, and some unu sual
tools as well. In addition, he tell s us how
to fabricate stationary work stations for
portabl e tools. For those with access to a
fully set-up shop, whateve r that is, this
sec tion won 't mak e much difference, but,
then, neith er will the rest of the book. For
the novice, however, these setups will
help to ease the transition from beginn er
to ex pert tool ow ner.
The book also discusses lumber, panel
m at er ia ls, o ther woo d pro d uc ts ,
abrasives, hardware, and shop math.
These ap pend ices consume nearl y the last
third of the book. Wh ile some of the
coverage may see m superficia l, the
sec tio ns on hard ware and shop ma th
fasc inated this reviewer, who found
himsel f say ing, " I didn 't know that" so
ofte n that maybe the author sho uld
co ns ide r w rit ing " DeC ris tofo ro 's
Co mplete Book of Shop Math ."
Ca binetma king and Millwork, 5th
Ed itio n by John L. Feirer, 1988
(G le ncoe Publ ish in g Co., 153 19
Cha tswo rth St., M ission H ills, CA
9134 5) 992 pp., hard back, $39 .95
Thi s book, in its fifth edition, is still
laid out like a text book, and, like most
textb ooks, it regul arly waxes d ull. But
that dulln ess isn' t really much of a
handi c ap , fo r th e bo o k is very
co mprehensive. I' ve had a copy of the
1977 revised edition since it came out,
and it's one of the few book s that lives in
my shop, where it will, no do ubt, be
supplanted by the new edi tion . As is
always the case with a gigantic wo rk,
there are parts-s-even of this ne w
edition- that look outdated, but that is
pretty easy to forgive. When I know so
much that I don ' t have to refer to
Cabin etmaking and Millwork a co up le
dozen times a year, I' ll wri te a new o ne
with all new photos.
Feirer 's text is so fine that it's not
like ly to become ou tmoded in our
lifetim es. If there ' s a copy of an older
edi tion in your shop, yo u don 't reall y need
a new one, but if yo ur sho p doesn 't have
one, it probab ly sho uld.
Fasten It! by Charles R. Se lf, 1984
(TAB Books, Inc. , Mo nterey Lane, Blue
Rid ge Summit, PA 1721 4) 293 pp.,
paperback, $ 14.95
More than half of Faste n It! applies
more or less directl y to woodworkers.
The author opens his disc ussio n with
kind s of woods and plywoods, and the
best methods for fas tening eac h. He
concl udes that wood -to-wood joints
with appro priate adhes ives are the bes t
wood faste ners. He remi nds us that joints
mu st be tight because it is the join ery, not
the glue, that hold s our projects togeth er.
A lengt hy chap ter shows eve n novice
woodworkers how to make strong joints
precise ly and q uick ly. Eve n more
interesting are rev iews of var ious glue
types, ofte n by bra nd name.
W het her we are woo dwor kers
beca use we are fairly handy, or vice versa,
is as old a question as whet her the
chicken precedes the egg . My friends
and relatives are co nvinced that I can
fix anything; of co urse , I ca n't, but I' m
forever trying-if on ly to keep fro m
disa ppointing my lo ved one s. For this
reason I fou nd the rest of the book
13
tHWM1itt B
'00kReVleWS
,8
continued
more interesting . I know of two fire places
tha t wi ll be safer because I have read
Self's disc uss ion of mortar , and that sa me
discussion wi ll permit me to lay so me tile
in a long-put-off proj ect.
Th e cha pter on met al fas te ni ng bears
some resemblance to the ca talog of
Mi nnesota mail order hard ware ve ndo r,
DRI Inc., but Self' s descripti on s of the
various fas te ne rs are more co m plete.
Rem aining chapters hi ghli ght so lde ring
and we ldi ng, tap es, and othe r flexibl e
fas tene rs ran ging fro m hin ges to ro pe .
These closing cha pte rs are little more than
curso ry treatments of the ir subjects.
Where it is good, thi s text on fasten ers is
abso lute ly fine, but its weak nesses stem
from the very fact that it is an am bitio us
work. T hey are fo rgi vable because they
merel y represent instances of the w rite r 's
reach exceed ing his grasp. If yo u read it
thou ght full y, a grea t deal ca n be learn ed
fro m thi s book, regardl ess of yo ur
fastening ex pe rtise .
Picture Framing Made Easy by
Pe ne lo pe S to kes, 19 86 (Ste rl ing
Publishin g Co., 2 Park A ve ., New Yo rk,
NY 100 16) 128 pp. , pap erback , $9.95
I wo nde r as I look at ye t ano the r book
abo ut pictur e fram ing why an yon e wo uld
need a book that says basicall y, "Cut a45
ang le on eac h end of four pieces the right
len gth and fas te n them togeth er." Of
co urse, every author elabo ra tes furth er,
but still.... And then there ' s Ms. Stok es'
book . Far and away the most co mplete
book on the subject I' ve see n, th is one
treats the wh y and whe refore of picture
frami ng as we ll as the how. A fter dealin g
with the diffe re nt typ es of fra mes fo r
different types of art, St okes tak es up
ma tti ng, g lass i ng , mountin g,
three-dimen sion al art, mak ing the fra me,
asse mbling the work , and appl yin g the
backi ng.
Most im po rtantly, howe ver, she
teach es us wha t to do wh en we screw up
so me part of the pro ce ss. A mu sic ian
friend of mine once told me that he pla ys
qu ite a few wro ng not es, but hi s
professiona lism perm its him to " hide"
them . The noti on app lies directl y to
Sto kes' book . What se para tes it fro m
others abo ut fra mi ng is that she shares
wit h us the " tricks" that make her fra mes
14
bett er than average .
Industrial Drafting: Principles,
Techniques, Industry Practices by John
D. Bies, 1987 (Mac m illa n Publi shin g
Co., 866 T hird Ave .. New York, NY
10022) 530 pp ., hardback, $2 4.9 5
Th e publi c ati on d at a o mi t a n
im po rta nt fact about thi s book-the trade
nam e AU DE L. That nam e alone sho uld
be sufficient to recommend it. Thi s highl y
resp ected series has been around for
decad es, but thi s yo ung autho r man ages
to brin g new light to his subject. Rath er
than open with a rehash of basic drafting,
Bies ove rviews profession al drafting
ro om pr act ic e s , e q u ip me n t, a nd
techniques. G uide lines fo r lettering ,
s ke tc h ing, and in strument dr aw in g
fo llow, as does a review of geome try and
trigon om etry. In treating the various
types of projection, he di scu sses the
theory as well as the pract ice , so that we
ca n und erstand wh y thin gs are drawn as
they are .
A dva nce d topi c s i nc l ude
dim en sionin g, tol erances, nonthreaded
mechani cal eleme nts, springs , thread
sys te ms, mech an ism s (ca ms, ge ars,
bearin gs), working dra wings, jigs and
fixtures, axo no me tric proj ections, and
more. Th e text cl oses wit h a useful
discu ssion of co mpute r-aided drawin g
and design (CA D D). Appendices detail
drafting standards.
Thi s is a fine instru ctional text useful
to learn ers with so me bac kgro und, and to
woo dworkers who would like to spend
th ei r p rojec t plannin g tim e m ore
efficiently.
Woodwo rki ng and Cabinet-
making: A Basic Gu ide to Working
with Wood by F. Rich ard Boll er, 1986
(Mac m illan Publi shing ce., 866 Third
Ave., New York , NY 10022) 353 pp.,
hardback , $ 18.95
Thi s A UD EL manu al is a 353-page
hardbac k at a paperback price. Its
inform ation is so lid and basic but not
flas hy-which may be precisel y wh y
AU DEL manu als are such a go od buy. In
clear, simple, and acc ura te terms , Boll er
covers mat er ials, design , hand and pow er
tools, basic co nstruc tion, and se tting up a
hom e work shop . Onl y the chapter on
project s disapp oint ed me . Much of the
e lec tric a l equipment in the ph ot os
a ppe a rs antique , and th e p roj ect s
illu strat ed look as though they were made
in the 195 0 ' s. I reall y wo nder ho w mu ch
more ex pe ns ive it would have been if the
autho r and ed itor had incl uded projects
and photos cap abl e of dazzl ing neoph yte
woodwo rke rs into wanting to produ ce
their best. In sho rt, thi s is a good referen ce
vo lume, but its low interest value means it
won 't be pull ed from the shelf often.
Making Cabinets and Built-Ins:
Techniques and P lans by Sam Allen,
1986 (Ste rling Publ ishin g Co., 2 Park
Ave., New York , NY 1001 6) 384 pp.,
pap erb ack , $ 16.95
Thi s book has a more modem feel to it
than the A UD EL manual review ed
above . It ' s better illu strat ed with both
photos and drawin gs, the writing is
friendlier, and its proj ect, a kitch en, is
more attrac tive and interes ting. Som e
time ago I bou ght new kitch en cabin ets
bec au se I thought the project was bigger
than I co uld handle . If I'd had this book
then , the new kitchen would have cost a
third of its pric e , wo uld have been be tte r
looking, and would have taken only a
co uple of we eks to build.
Th e bo ok is not ju st for beginn ers- its
most inter esting feature may be the ninet y
pages of bill s of material for vario us
sty les and typ es of modul ar cabinets. Full
use of thi s book co uld change yo ur hom e,
or at least provid e yo u with an interesting
and even profitabl e project.
Furniture Repair & Re storation:
Over 100 Methods & Projects by
Len and Ka y Hilt s, 1981 (Creative
Homeo wn er Press, P. O. Box 527,
24 Park Way, Upper Saddle River ,
NJ 0 7458-23 11) 160 pp. , paper back ,
$7 .95
Althoug h this volume has been aro und
since 1981, I ran across it only recentl y,
and the penalty for m y lack of vigilan ce in
cruis ing the book stores has been at least
a couple of pieces of thrown- away
furniture. Th is is the book that shows yo u
how to salvage tho se pieces that yo u
thou ght were beyond repair. Highli ght s
incl ude fixing ca ne sea ts and back s,
repl acin g cas ters, fix ing "alliga tored"
finis h, c igare tte bums, dent s and go uges,
Popular Wood working

dowe led jo ints, broken comers, edges,
tenons and veneer. warped jo ints and
surfaces, and water rings, among othe rs.
The full-color illustrations really help in
the finishing sections. At $7.95, this one's
a steal!
C a binet ma k ing: T he Profession al
Ap pr oach by Alan Peters, 1986
(Macmi llan Publish ing Co ., 866 Third
Ave., New York, NY 10022) 197 pp.,
hardback , $29.95
In the broad est sense , this is a ho w-to
book, but not as in " how to build twent y
proj ects." Pete rs te lls us how the Arts and
Cra fts Movem ent go t to where it is today,
ho w to learn woo dwo rking, how to set up
a shop, and how to run the finances of a
sma ll business (in Eng land! I say, mate.
be certain to collect you r value-added
tax!) Fortu nate ly. Peters moves away
from these things q uickly and gets to
"Design-Thinking. Techniq ues a nd
Inspiration," and how to ge t
commissions, ba tch production, and
This Could Have Been
advance d trai ning. As a bonus of so rts,
Your Ad
Peters throws in exce llent drawi ngs of For information about advertising in
seve ral of his best designs. Since I got the Popular Woodworking, contact:
book, 1've gone through it four times , and Debra owak
it gets better eac h time. Popular Woodworking
1320 Ga laxy Way
C rea ti ng Sma ll Woo d Obj ect s as Concord, CA 94520
F unc tio na l Fu rn iture by Donna Z. (415) 671-9852
Me ilach , 1987 (Crow n Publishers, lnc. ,
225 Park Aven ue Sou th, New York, NY
10003) 288 pp., paperback , $14 .95
Although I co uldn' t remember see ing
the 1976 edition of this book , I had a
strange sense of deja \ '11 as I peru sed it-
I had see n it all some where before,
somew here else. The newest item in its
" up-to-da te" b ibli ograph y was
pub lished in 1975 . Appare ntly there have
been no good woodworki ng book s
pub lished since then. Well , there have
bee n so me , but th is co llection of
"cu t' n'paste" certai nly isn' t one of them .
This book is lovely to look at in a dated
sort of way, but be sure to look at it very
carefully befo re you buy . ~

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August/September 1989 15
~ideoscene a ~~_.m
by Alan Marks
Ta b le Saw & Accessories:
Operation & Safety
Radial Arm Saw: Operation and
Safety
Band Saw: Operation & Safety
Jointer/Surfacer & Accessories:
Operation and Safety
Wood Lathe & Acce ssories:
Operation and Safety
From the se ries Woodwork ing Power
Tools, 1987 by Meridian Ed uca tion
Co rp., 236 E. Front St. , Bloom ington , IL
6 170 I, $89 .00 eac h, eac h 14 minutes in
length .
This series co nstitutes what co uld be
defi ned as standa rd seconda ry schoo l
training fare-straig ht o ut of the high
schoo l audio/v ideo department.
Co nsidering the stress they place on
avoi di ng acc ide nts, these are the so rt of
videos all shop instructo rs and anxious
begi nners sho uld know abo ut. Blinking
red text flashes on sc reen to ca ution
students whenever the possib ility of
dange r appea rs during a dem on str ation .
Use of guards and guide lines for persona l
safe ty are point ed o ut. All tapes detai l
basic operati ng procedures. A teacher ' s
gu ide co ntaining an o utline of the
mat e rial plu s a li st of suggested
disc uss ion question s is incl uded with
eac h tape.
I have no critic ism of the materi al
itself. I do have a number of reser vations
concerni ng the way in whic h the
present ation is made.
Every video in the se ries is narr ated by
an ove rdu bbed vo ice, the ow ner of whic h
never appears on scree n. Thi s anonymo us
voice gives instru cti on in profession al,
well- modulated, we ll-artic ulated tones
rem iniscent of what might be expec ted
from a gra duate of the Co lumbia School
of Broadcasting.
The Meri dian Ed uca tion Co rpo ratio n,
wh o produced thi s tap e, mark et s
hund red s of videos and fi lms tri ps
cove ring eve ry co nce ivab le fie ld,
incl uding rob ot ics, e lectro nics, design ,
d rafti ng, a uto mo t ive me ch ani c s ,
welding. metallurgy, home imp rove-
ment, and the building trades. It is
A lan Marks is a cabinetmaker ill Carme l
Valley . California, and a contribu ting edito r
to PW.
16
~~;~.~~
in te res t ing to not e how th e
long- accepted. standardized approach to
filmstrip ed ucation by the audio/v isual
indu stry now seems ineffectu al compared
to the way more modern video instru ction
handl es it.
Years ago, when the ex pense of film
and the cos t of processing necessitated
getting things right on the first or
second take, visual portions of the
instru ction were don e separate ly from the
so und. Expensive mikin g and mi xing on
stage were avo ided. Overdubbing was
easi ly done in a so und studio. If the
narrator fluffed his lines it cos t noth ing
to re-record his voice on the magnetic
strip.
Today, most mod ern video instruc tion
is done with an instru ctor who is miked
di rectl y. It cos ts nothin g to re-do a scene
because with magneti c video tape all that
is needed is to record directly over the
unacceptable material. Modern mikin g
techniques redu ce expense as well. A
co ncea led min iatu re lap el mik e
broad casts an FM signal to the recorder,
thus e liminating boom s and cables.
Rece ivin g ins truc t io n fro m a n
o n-sc ree n in struct or in st ead of a
disemb od ied voice mak es a presentation
more personal and more engagi ng. Had I
co nti nua lly been forced to revie w
narrated video s for this co lum n, the
intense boredom would have ca used my
dem ise long ago.
I ex perienced other problem s with the
presentations as well. Modem teachin g
methods employ a few trick s which the
producer of this series would do well to
acq uaint himself with.
A prim e obj ecti ve in v is ua l
instru ction , or any instru ction for that
matter, is to raise question s in the
stude nt's mind. His ment al faculti es
attuned to ge tting answers, the student
grasps eage rly at the information supplied
by his instru ctor and retain s it. To
acco mplish this goal in a practical way, it
might have been useful, for exa mple,
to begin by showing a uniqu e operation
or a uniqu e object created using the
power too l to be discu ssed . Thi s would
pique the stude nt's interest and raise a
few intern alized question s, like: " How
was this acco mplished?" or "How can
I take adva ntage of this in my ow n
proj ect ?"
A second tenet of modem education
hold s that a student should have some
idea of what material is to be prese nted
before he is ex posed to it. Th is may take
the form of an introductory outline-easy
to accompli sh in the video format, usin g
supe rimpos ition of text. Along with this a
consc ious effort ca n be made to keep the
student appraised throu ghout the tape as
to where the instru ction is leading and
what ground has already been cove red, as
a so rt of revi ew. Such orientation
enco urages wand ering mind s to stay in
the groove.
The above comme nta ry applies
equally to all tapes in this series. I also
have ob ser vations concerning a few of the
tapes in parti cular.
Regarding the band saw tape, I was
surprised they didn 't use diagram s to
illustrate how adju stments are made.
Often there were fleet ing references to
parts and pro cedures never explained
full y. There see med to be more narration
than actua l demonstration. Of course,
how mu ch information can yo u really
stuff into fourt een minut es of instruct ion?
The machine used by the student did not
appea r to hav e a foo t brake- to my mind
an important safety feature. And why
didn 't they sho w how to change the
blade? I guess this was the instructor ' s
res pons ibility . Th e emphasis, as in all of
the tapes, was on danger and safe ty. I
know du st collec tion systems are usually
standa rd in secondary school shops. but
dust itse lf is a hazard and should be
point ed out as such.
In the j ointer/shaper tape, students are
told that stoc k should be jo inted "with the
grain," but this term is not defined. If I
were a beginning student, I think I would
get co nfuse d when told that "e dge
jointing is used to make an edge stra ight
with the face. "
Th e lathe tap e was ve ry well
o rganize d and outlined and is an
exception to the genera l criticis m I fee l
applies to the other tapes. Th e part s of the
lathe are adeq uately discussed, and both
spind le and facepl at e turnin g a re
dem onstrated . Si x types of turnin g tools
are menti oned but the use of eac h is not
d emon str at ed-the m yster iou s
fo urteen-minute time limit again.
Popular Woodworking
 TUNGSTEN CARBIDE
ROUTER BITS
Ment ion is made of the ball bear ing
dead ce nte r and the cup, or co ne, dea d Heavy duty industr ial Qual ity
1 4 by 1-1 4 in c h l o n g shafts

center, but the d iffe rence s between them Enc losed Ball Bearing Gui d e s
are not ex plained. Wh y not tell stude nts Too ls exceed AISI standa rds

the reason for lubri cating when using the

dead ce nter (to keep it fro m burning and ~ CO,"., Round-o ve r
. Rad ius Pr ice
digging into the wood)?
1 /4 " $12 .50
A dem on strat ion of scraping is g iven,
3 /8 " $13 .75
but the turning tool used is not named . Th e 1/ 2 " $14.50
tool rest used in facep late turnin g was
different from the one used for spind le
~ Co B;I,
Rad ius Pr ice

+
turnin g, but it wa s not nam ed either. I 1 /4 " $14.50
would h a ve lik ed a littl e more 3 /8 " $15 .50
completeness in this video . 1 /2 " $17.00
T he info rma tio n these tapes conta in is 45" Cham!er Bit,
of critica l importan ce to any woodshop Diame ter Pr ice
begin ner. T he y sho uld be required 1" $12.00 78 full -colo r pag es of exclusive . inn ovative
view ing by students before they are 1- 1/4 " $14.00 tools and accessories for the w oodwo rker .
1-1 /2 " $15 .50 do - it-you rselfer an d ho bbyist. all guaranteed!
permitted to use mach iner y and, in my Mail in the coupon today...or call toll-free
1 DO '\, Money Ba ck Guarantee
opinion, the instruct or sho uld also give a
800-654-7817 ( Dept. 114)

(---------- -
dem onstrat ion afte rwa rds, as sugges ted Order now - Toll free
in the teacher ' s g uides. 1-800 767-4747 Anytime ) Please ru sh my FREE catal og!

Th e Meridian Ed uca tion Corp orati on Visa - Master Charge Ok

I Name _

also mark ets a co mplete series of six Or mai l c h eck to : I Address - - - _

films trips each covering both the rad ial SK YCROFT TOOLS , INC . I Ci ty I
P.O. Box 418P1 State Zip _
arm saw and the tabl e saw in greater
Myersville, MD 21773-0418 I Mail to: Leichtung Workshops. De pt. 114 I
detail. ~ L 4944CommercePky. .:....Cl eve land .OH441~...J

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5371-1 Heavy-Duty Magnum 5007NBA 7 1/4" Circular Saw $119 .77
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~
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N80C1 Nailer Coil4D-12D Be.mn $299.77 9850 Cordless 3/8" Driver
N70SB1 Nailer Stick 6D-1OD Be.mn $229.77 Drill Kit $139.77
N12B-1 Nailer Coil Roofing 7556 1/2" 2 Speed Reversing
7/8" to 13/4" $368.77 Right Angle Drill Kit $169.77
N60FN-2 Nailer - Rn ishing 659 Reversing Drywall Driver $79.77
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August/Sept emb er 1989 17

 MLCS Ltd.
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ITEM BEST CUT ANGLEDEPTKRADIUS LARGE CUTTING SHANK PRICE ITEM BEST CUT DESCRIPTION ANGLErDEPTHiRADIUS LARGE CUTTING SHANK PRICE
NO. BEST PRICE DESCRIPTION CIRCLE DIAMETER DIA. LENGTH ~ZE NO. BEST PRICE CIRCLE DIAMETER DIA. LENGTH SIZE
11400 1r.- d _ 1 l1f4' Classical $10.00
11491 jlf.!' Classical $11.00
m2 l 1f.!' Class~al $14.00
$15.00
l1f4'
jlf! $18.00
jlf.!' 1f4' ~4' $7.00
'!f16' l' $7.00
118' R
'!is' I' $7.00
1/4' R If! I' $7.00
'!is' R If! '! $14.00
If.!' R if,6" I' $7.00
~4' R
Sfa' I' $8.00
118' R If! ~4' l' $10.00
:16" R If.!' l' jlf! $12.00
1/4' R If.!' $7.00
'!It R Sfa' $ 7.50
If! R ~4' $ 8.50
~4' R 7Je' $ 9.00
I' R l'
1f4' $30.00
mo '!is' Rabbeting ~8' Deep If! $30.00
mo lB:" ~~~i!9. _ -~ ~~ 1/4'
If!
$30.00
~366 118' Slot Cutler ~s' Deep $3000
~368 1f4' Slot Cuner '!fs' Deep ~4' If! $11.00
Il403 '!It Dovetail 9degree 718' If! $11.00
Il405 If.!' Dovetail 14 degree l' If! $13.00
Il409 :4' Dovetail 14 degree jI/a' If! $14.00
~709 :4' Dovelail l-L~r~_
11/4' '# $15.50
11402 - ~'-DoVetai-- 8degree jlf! :4' $17.00
1!404 If.!' Oovelail 8degree '# jlf! $15.00
~708 11M Dovetail 8degree 7Je' 17Je' $2300

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To order by Master Charge or Visa Call Toll Free, 7 Day - 24 Hour Order Service
18005339298 or send check to: MLCS Ltd., P.O. Box 4053 PF, Rydal, PA 19046
 We're Not Tool Snobs, But ...
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'- I- L...-
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Ie---: v'- ',
L....-- L....--

Laminated Steel Chisels are just not for every-

one. As with much of life, owning and using the
very best appeals to only a small select group of
people, even when, as with chisels, the cost IS
clearly affordable.
For hundreds of years, traditional Japanese
chisels have been forged by Masters and their
journeymen. The blades, of high carbon steel,
hardened to Rockwell C 64-66, are supported by
an upper layer of iron that absorbs the shock of
mallet blows. The very hard steel takes an
exceedingly sharp edge and holds it far longer
than any Western chisel. These are lifetime tools.
Combination Tang and Socket construction for
added strength. g" Overall , 2-1/4" long Blades.
Sizes: 1/8", 1/4", 3/8" , 1/2", 5/8", 3/4", 7/8" , 1",
1-1/4" ,1 -112".
ORDER #02-0731 set of 10 Laminated Steel
Chisels only $89.95 plus $4.00 ship/handle.

WHY PROFESSIONALS USE

BRAD POINT DRILLS
Brad Points are engineered espe -
cially lo r wood - soft wood or hard.
The cenler point (brad point) of the
drill is pushed into the ma rked
location for the hole. It lock s into
position and will not slide out. Then
the motor is turne d on . The hole is
drilled ~ where it is wanted .
This is the most important part of
doweling, after proper measuring .
CLAMP 'N

W
The two outside spurs cut clea n

...,rt1DJ.J.J-'
entry holes. There is no tear out
(splintering) - not even in Oak or
TOOL GUIDE
Curly Maple - so that if the hole is to
be later plugged to cove r a screw, ALL-IN-ONE.. .
the periphery of the hole will be
almost invisible. Bar Clamp Straight Edge
These spurs provide smooth hole Fence Power Tool Guide
walls and almost flat bottoms . A
dowel shou ld touch bottom to glue properly. Metal working drills As a FENCE or GUIDE, it attaches ten times faster
leave a tapere d bott om.
than 'C' clamping and won't surface mar wood. As a
It is best to own a com ple te 25pc set and have every size from l iS BAR CLAMP, the unique low profile jaws enable you
to 1/2 in increments of 1/64ths (.0156) because commercial
doweling is seldom sized exactly . Dowels that are too loose don't to clamp butt-jointed corners (down to Y2" material)
cut it; those that are too tight don't fit. and also allow edge clamping. These clamps always
WHY DOLLAR'S BRAD POINTS ARE BEST: Our drills are milled
lay flat for easy assembly set-ups. World's fastest,
from the solid; others are only roll lorged. Our brad points and most versatile bar clamp!
spurs are first milled then ground lo r accuracy . We use high
carbon , alloy steel. Many others are made from plain carbon steel. TWO SIZES AVAILABLE:
Our drills are heat trealed and hardene d to Rockwell C4S-52 . They 24" Grip , , , .. . . . ... . . . . . . . . .. . . , , , $22.95
are tough, sharp and long lasting . Most companies that sell drills
do not know what they are made of, or what the hardness is. 50" Grip (panel size) ... . . , . , , . , , , $32 .95
AS FOR PRIC E, YOU BE THE JU DGE.
ORDER TOLL-FREE! SHOllT J/IINS~
These drills will fit any 31S or larger chuck. EDGE ClAMPING
FREE met al index included. 1 800 428-3809 (Inside California)
1 800228-1806 (Outside California)
ORDER '1 0-0100 as-ee Brad Point Drill Set only $29 .95 ea. Mas ter Ca rd, Visa , Check or Money Order. In California, add 6% sales tax .
20< mo<e sets 10 one address only $26 .95 ea.
ShipIHandling $3.00 10<I , $5 .00 10<2 0< mo<e to one address . WE PAY FREIGHT within Continental U.S.A.

CALL TOLL FREE: 800-447-7770 ' VISAiMC,AMEX

Dollar Tradin~ Corp, (Est 1953); P.O Box 8433. Grand Rapids MI 49518
Dept PW 08 Sales Tax MI 4%; CT 7-1/2% 965 W. VENICE BLVD.
NO HASSLE, 30DAY MONEY BACK GUARANTEE
RODMAN &COMPANY,INC.
LOS ANGELES, CA 90015

Augu st/September 1989 19

 the BusinesS:ihEnd
by Peter Good
Wou ldn' t it be nice if every meeting with a potent ial clien t
ac tually resulted in a sa le? I ca n' t make promi ses, but perh ap s I
can give yo u so me new insight s into the process of e ffectiv e
se lling that can s ubs ta ntia lly increase the return s on yo ur e fforts .
An imp ort ant gro und rule in co mmercial dea lings is that yo u
mu st get out of yo urse lf and learn to relate to the customer on
thei r level. You mu st learn to read betw een their lines, and wh en
they spea k, it' s imp ort ant that yo u reall y hear wha t they say . A
big probl em that man y of us have is tha t we' re rather
self-centered and tend to tak e a g lorified view of our produ cts
and abi lities . Whil e the re 's not hing inherentl y wro ng with this,
we some time s becom e preoccupied wi th such noti on s, clouding
our abi lity to es tablish a mean ingful and producti ve sales
relation ship with a potenti al buyer. So, the first thin g we have to
do is to be ab le to ment all y put o urse lves on the she lf- secure in
the kno wled ge that o ur se lfwi ll still be there whe n we co me back
for it-and devote o ur full atte ntio n to the potent ial buyer.
A good way to get used to this type of attitude is to practi ce
it on the pho ne. Thi s is part icul arly important when so meo ne
ca lls yo u for the first time in regard to yo ur business . Wh en the
phon e rings, before yo u pick it up, be sure that yo ur m ind has
finished deal ing wi th whate ver yo u were do ing befo re the phone
As the owner of Grand Openings in Oakland. California, Peter
Good manufactures doors. He also gi ves seminars at national
woodworking shows on business aspects of running a small shop.
Effective Selling
rang . Put that ac tivity, thou ght , or wha teve r, mentall y on hold.
It' s crucia lly impo rtant in the sa les proc ess for you to "b e there"
whe n yo u mak e initial co ntac t with a potent ial custome r. Don 't
be sha ring any part of yo ur atte ntion with anythin g e lse. If yo u
do , yo u' re likel y to mi ss so me of the subtleties of the ca ller ' s
message, and perhaps eve n mak e some glaring errors, lik e
failing to catch their nam e the first tim e. If, at any other time in
that co nversation, you ha ve to ask them to repea t their nam e, yo u
weren't there whe n they sa id it the first time; yo u we re
so mew here e lse, ment all y. And if yo u ' re only half there now ,
they may reaso n, will yo u co ntinue to be only half there?
Rem ember that the ca ller is co m ing to yo u for help in some
way . Th ey may be tim id and, in all likelihood , harbor man y fea rs
abo ut co ntac ting yo u. Will yo u und er stand what they need? Do
yo u do that so rt of thin g? Do yo u have the tim e? Ca n they afford
it? Will yo u treat them fairly? Do yo u do goo d work? Ca n yo u
reall y provide wha t they wa nt, o r are yo u ju st another se ller of
empty prom ises?
In talking to yo u. the potent ial customer may not ex press
their fears. but yo u need to und erstand that those things are
present , eve n if they are not spo ken . We all have fears when
co ntemplating the pur ch ase of nearl y every thing . We often fear
that the produ ct or serv ice will be too ex pe nsive, will not do wha t
we hop e it will do, or anyone of a hun dred othe r thin gs.
(Re me mber yo ur last major tool pu rchase?) We have these fea rs

WOODWORKER " best on TABLE SAW WOODWORKER I Best onRADIAL SAW For TABLE and RADIAL SAW
With this ONE ALLPURPOSEblade 40 Teeth and1/8kerf. (tablesaw too) This ALL PURPOSEbladegives scratch free (very good on chop saw too!) STOP SPliNTERING
SMOOTH RIP & CROSSCUT 1" - 2" ROCKHARD Sand POLISHED cuts on all materials RIPor CROSSCUTup to 2". those SPliNTERY OAKS . HARDWOOD VENEERS and
SOFTWOODSwith smoothassanded surface. AII 60Tand 3132" THIN kerf20' ATB and5' face hook. thin 2 SIDELAMINATES ONPARTICLEBOARD.
PLY-VEN EERS oak/birch crosscut Wi th NOBOTTOM DOUBLE HARDER and 40% STRONGERcarbide.
SPLINTER. FOR FASTER FEED RATES AND MORE ABSOLUTE
THIN KERF:
Mostly 1/8 kerf 150 ATB and 200 face hook(easyfeed). SPLINTER CONTROL.
saves1/3wDod less on eachcut. radial or table,
DOU BLE HARDER and40% STRONGER CARBIDE. Feeds easy whenused for moderate rip and crosscut on DURALINE HI-AT
Ends blade changing (doesrip. combo and crosscut). table saw. Note: Fine Woodworking
Ends scratchy saw cuts (for therest of your life). Reduces " JUMP IN" greatly for better" PULL-CONTROL" .
Ends secondstep finishing (jointing and sanding). Editorial Nov.lDec. 1988
Practically elinlinates bottom splinter on RADIAL No. 73pg. 65 S.N.
Ends cutt ing l hS " oversize to allow for RESURFACE . CROSSCUT .
Buy and sharpen ONE blade instead of 3. 24Trip. 50T Totally stopsALLbottom and top splinter on ply veneers recommends !!JIJ!!.
Combination, BOT Crosscut. in push-cut mode on RADI AL. alternating top bevel(ATB)
Strongly recommend our .00 1 flat large stillener OurSTIFFENERSTRONG LY RECOMMENDED AGAINST !!ll!J kerfs andg blade
dampener against outside of blade for smoothest, Quietest. outsideof blade only for best cuts. stiffeners for smoothest
cuts bythis and anyotherblade.
Madeandserviced in USA for your benefit.
cutson RADIAL SAWS , JIm Forrest. President and de signer ,
Use30T if ripping mostly 2" - 3" hardwoods. etc. microscoptng cut1lngedge.
Side wobbleheld .001- others .004/.010is common ! List Safe
RAISEfor THICK woods. LOWER for THIN woods and 12" x 60T x ror SI8" 5198 51 19 Ali s/a" hole. Boring up to 11/4" $7.50 extra
perfect cuteverything' 10" x 60T x 5/8" 162 97 - Larger holes - time basis.
List Sale List Sale 9" :60Tx.518" 156 94 Shipping $3.50.
12" x 40Txl " 5183 5109 8" x 40TJI32" 51 36 582 8- x 60T x 518" 150 90
12" x 30Tx l " 162 97 30T3I32" 11 5 69 New 8 114" x 40T x 518" 136 B2 HI-ATPriceList
10" x 40T 156 94 71/4" x 30T3132" 112 49 RY0 81 RA200 TS200 MAKITA 5008 N8A
30T 135 81 7"x 30T 3132" 112 49 8" x BOT 5202 14" x 80T 5232
HITACHIPSM8 PORTER CABLE 36Bl
9" x m 1~~ ~~ :18~r~6~b~~ ~~~I~ ~'~;50
ALSO help your SEARS blade. FREUD. PtRANHA , JAPANESE
Lasercut DADO KING MULTITOOTH dado setcuts ALL114" -13116"
9" x BOT
10" x 80T
12" x 80T
207 l OOT
207 16" x 80T
212 l OOT
266
262
294
THIN SAW. DML. LEtTZ, etc. U~~~~~D~L~Soo~6wa~T~rR~~8~~~~DA:~,~'~;gf~~~~~ lOOT 253
FOR BETTER CUTS I fillersand 24T outside saws. NOTHtNG LIKEIT IN THE USA tI All CARB IDEIS THE HARDESTOFTHE C-4 grades
Useour large'18" DAMPENER

o
and 40%STRONGER, NOT WEAKER' !
STIFFE NERS . aqarnst one Side For 50% 10300% longer life!
6" - 525 Parallel and flat to .001 FREE dampeneror S10.00 off with any

o ~
. i{, 2nd blade.
5" 24 Stops vibration. flutter. 8" x 24Tx 4Tx 8TIIl1ers 13/16" set 5299 5:e" set 5209
cuttmg norse and blade 8" x 24Tx4T 3/"''' set 249 1/2" se t 179 ." CHOPM ASTER SERIES FOR MITE R SAWS fo r

o nng .
4" - 21 Tryableand RETURNABLE
Full cash refund.
FREE di mpene, 0' 1 10.00 011with any 2nd bl ade .
10" x 24T x 4T x 8T fillers

FOR MCP ME LAMINE

13/16" sel 362

s LOWPRESSURE LAMINAT ES
8" Neg-shear24T )( 21 or 4Tfillers 5259
" .'
tiqht. smooth. splinter-tree mtter-joints. NEW
AVAILABLESIZES .
Hilach,8112" DeWalt 81/2"
Delta
8112" x 60Tx 5/B"
9" x 80T x Sle"
List
5179
204
Sale
5 89
99
10" Neg-shear 24Tx 2TDr 4Tfillers 314 RYDbi-Maklta 10" x 80T : SlB- 207 109
5/S"holes boreto 11/4" 57.50 extra. Others
available. Add 52.00 ShiPPing .
5,," holes- bonnqextra - SHIPPING55.50 RyDbi-Maklta
Hrtactu
14- x l OOT
15" x l00Tx l "
x," 266
277
160
164

~
WERECOMMENDOUR FACTORYSHARPENING 23DAYS ON THESE ANDALL MAKESOF CARBIDE TIP SAWS SHIP INUPS Usesmall stiffener wherepossible.
(500 grit microscopedl 10 x 40T 51425.60T$16 83 Add return UPS 53D' 2ndDay A" $5
NOW ORDER the one blade that will outlast you' (10-20 sharpemnqs cess.ore) I
~....~:_.
,
I
We honor Amex, Visa & MasterCard. ~
Money Orders . Pers?nal Ch.ecks an? COD's . . . . . ,
ffi
SATISFACTIONGUARANTEEDORFULL CASHREFUND. Dealer Inqu i ries Welcom e. I To order BY MAIL clip ad, Circle choice s and
40 years ol line Ame rican saw making & sharpening enclose payment. Specify Dept. PW when ordering.
FORREST MANUFACTURIN G CO MPA NY. IN C. PHO NE TOLL FREE!
250 De law anna Ave.. C lifto n . NJ 070 14 1-800 -526-7852 (In NJ : 201-473-523 6)

20 Popul ar Woodworking
beca use we have been let down , ripped off or disillusioned so
many tim es that we ca n scarce ly believe it when eve rything
works out ju st fine . You will have an incredible selling
adva ntage if yo u ca n let a potenti al custome r know ea rly in the
process that yo u under stand that they have fears , and let them
know that yo u will not repeat the things that brought on the ir
fears in the first place. Then, of co urse , you have to be sure not
to repea t those things, once you make the sa le.
We have been co nce ntrati ng on the co nce rns of the custome r,
which is as it sho uld be . Most ofus like attention and ca ring from
others and if we ge t it, we will co ntinue to go back to the so urce .
Isn 't it grea t whe n yo u find a ga rage that reall y know s how to fix
your car right and does a good job, on time, with a sm ile, at a fai r
you are showing respect for their abi lity to se lect among several
things.
Puttin g togeth er a sa les procedu re which encompasses all of
these issues will es tablish yo u as someo ne who care s abo ut the
customer and is responsi ve to the ir needs. [f you a lso corne
through wit h a qu alit y prod uct or service tha t doesn ' t let the
buyer do wn, you' ll have a winning co mbination that, in the fina l
analysis, may ca use you a probl em of a differen t sort: How to
deal with success. All woodwo rke rs should have that problem .
Popu lar.
Pocket-size
that the mois ture content of wood is
MINI L1GNO
crucral. Moisture related de fects such as

price? And isn ' t it g rea t when the repair proves to be properl y
$110 surface checks . warpage , cracks , loose
Only [omts . fogg y finishes , etc " can ruin
the bes t piece ever built.
and reliabl y don e? Most peo ple wo uld go co nsiderably out of
their way to patron ize such a busi ness and will never go
elsew here. Good bu sinesses are so hard to find that when we do, mo istur e de fec ts are irreversible .
The refore don 't waste money and
we never let go of them . T hink of your business the same way. time on wet wood . Use a moisture
Incl. Case . meier 10 be sure you work
Conce ntra te o n the cu sto me rs and their needs, and they' ll kee p Battenes only with dr y woo d.
and Prns
co mi ng back to yo u. Rem ember in your co nversations with for Ul-and '/'6-
Measuring Depth. Ask for E t~ on
customers or pote ntial c ustomers to use words like " yo u" and mo isture mete rs (ra nge 430%.
4-60 % ) a nd accessories to
"your" frequ entl y, and use "me" and " I" only when necessary. morntor air or kiln d rYing .

T his same thin g holds true for any kind of adve rtising. Keep in
min d that an im portant ingred ient in successful se lling is to
crea te a bond be tween the buyer and yo ur produ ct or service . As k
you rself. " W hat ca n I say to this person to make them fee l
emo tiona lly draw n to my product or service?" 1/2" Shank CarbideTipped Router Bits Moulding Plane Profiles
What abo ut reading between the lines ? This is a little more
tricky because mos t of us tend to not say exactly what we mean ,
beca use to do so m ight not be socially acceptable, and so we tone
it dow n a bit -may be a lot. You r job, therefore, becom es that of
interp reter to determ ine the full importance of the buyer's
words . The inter pretive process is further co mplicated by the
fact that what that person is sayi ng is ofte n deepl y influenced by
either posit ive or negative emotional ex periences from their
dista nt past, which they may not eve n be consciously awa re of.
Listen ca refully for indications of resistance to certain materi als,
proced ures or desig ns. Such resistance , although mildl y stated,
may be the result of so me trau matic past ex perience . [fthi s is the
case (and you' ll probab ly never know ), it cou ld be d isastro us,
from the standpoint of making a sa le, for you to ignore their
resistance or wo rse ye t, insist that their resis tance is ground less
or without merit. Instead , it wo uld ge nerally be mo re producti ve
to accept the resistan ce an d offer alternative so lutio ns. If yo u try
to j ustify the origi na l idea , even if yo u think it' s bette r, it may
ca use the buye r to take a defensive posit ion (perha ps not eve n
knowi ng why), which wi ll grea tly reduce yo ur chances of
making a sale.
Speak ing of alternatives, a good selling practice is to present
seve ra l d iffe rent solutions , if pos sib le, and ex plain the
adva ntages and disadvantages of eac h. T his allows the customer
to make an informed decisio n. More importantly, it indicates to SPECIAL OFFER: SET OF ALL FOUR BITS
them that you are sensitive to the fact that they may have needs $99,95ORDER ITEM #866.Set of four quickly
or desires whic h may no t have been fully exp resse d and that to produce classictraditional mouldings. Bits are shown Full Size 2 Flute Carbide Tipped.
Order by VISA / MasterCard,7Day / 24Hour Service,Call 18005339298
accommoda te such things, yo u are giving the m some op tions. or send check to: MLCS Ltd., P.O. Box 4053 PO, Rydal, PA 19046
Also, if you ex plain the pros and con s of alternatives or cho ices,

August/Sep tembe r 1989 21

 "T ests and
by Hugh Foster
CommentsV' Tru-MatchEdge Joining System '
jm'~, mi,mm, "';"m) vrZ*'XiKW":W

The toughest part of gluing boards

edge-to-edge the o ld-fas hioned way is
linin g up the faces flush to eac h other. A
sha per with the right c utte rs ca n crea te a
sca rf joint that interlocks the two edges so
the faces line up; th is also result s in a
stro nge r joint with more gluing surface
area. Well , now there ' s an easy way to ge t
sim ilar result s with a rout er.
Port er- Cabl e ' s T ru-Match Edge
Joining System wo rks by way ofaspecial,
co rruga ted ro uter bit and a ste pped ro uter
sub-base. Th e bit and base are ava ilable
individuall y, togeth er as an accessory kit
for ce rta in Port er- Cabl e rou ter s, or as a
co mplete sys tem that includes their
model #6 90 2 router fitte d with a 1/2"
co llet.
Th e stepped sub- base allow s you to make
both cut s with th e same depth setting .
Th e Tru-Grip Clamp 'n ' Tool Guide is a straightedge
fo r guiding routers or portable circular saws that can be secured
without C- clamps or hand scre ws; it can also work as a bar clamp.

The corrugated profile on the edge of on e

board is offset just enough to match the
profile on the other board so the two
sufa ces line up flush .

To use the tool. c lamp a straig htedge
3- 1/4" back from the edge to be joined.
What ca me to mind for th is straig htedge
was the Tru-G rip Clamp 'n ' Tool Guide;
interes ting ly eno ug h, these Tru - Gr ip
cla mps in 24" and 50" len gth s are
avai lab le at Port er- Cabl e Se rvice Ce nters
as we ll as fro m Trend -Lines, Rodm an ,
and other tool so urces . Th e clamps ca nnot
be recommen ded too highl y.
Se t the depth of the bit to the thickn ess
of yo ur material. plus I/x". Put yo ur
hear-muffs on: the tool run s at 92d B, not
Hugh Foster is a pari -time furni ture
dcsignertbuilder in Manitowoc. Wisco nsin
and the aut hor of The Biscuit Joiner
Handbook (Sterling Publishing Co .. 387
Park AI'l'nue SOli/II. New York, NY 100/ 6 ).
bad for a rout er , but loud enough that
protr acted use is sure to dam age your
hear ing; better safe than sorry!
As with most router operations,
always run the tool from left to right. If
yo u have the layout right , the only thin g
yo u' ll have to rem em ber is to turn the
router 180 0 for oppos ite sides of a joint.
Routin g half the joi nt on the " high" side of
the router base and the other half on the
" low" side is what permi ts the two halves
to mate flush.
T his tool is such an easy opera tor that
it m ight make biscuit joining as irrelevant
as bisc uits have made dow elin g for this
kind of application. It makes for fast,
easy, and supreme ly acc urate wo rk. ~
Wher e to Get Them
Porter-Cable ' s Tru-Match Edge
Joining System #692 specially fitted
router and bit, or #692 I sub-base and
bit accessory kit for routers with
#42186 or # I 0695 sub-base : contact
Porter-Cable Corporation, P. O. Box
2468, Jackson, TN 38302-2468, (90 1)
668-8600.
Tru-Grip Clamp ' ri ' Tool Guide
available from Porter-Cable; Rodman
and Company , Inc., 965 W. Venice
Blvd . Los Angeles, CA 90015 , (800)
228 -1806 : or T rend-Line s 375
Bea chham St. Chelsea, MA 02150,
(800) 343-3248.

22 Popular Woodworking
 Offering a complete line of fine
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SPINDLE SHAPER
DRUM SANDER
DUST COLLECTOR SK-30SPA..$799.00 Double drums. Dustchute. 1/4 HPfeeding
lH P Motor - UFO-90 $199.00 I" and 3/4" Spindle3HP 15" 3 HP - SK-15DS $1795.00
2HP Motor - UFO-101 $339.00 28"x30" table FIR Switch 20" 3 HP - SK-20DS $1975.00
3HP Motor - UFO- l 02B $465.00 SLIDING TABLE SK-35ST.....$199.00 25" 5 HP - SK-25DS $2355.00

TRUE VALUE &TRUE QUALITY ,..

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(213)949-3747
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12/1 Jointer
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20B1 Laguna Canyon Road. Laguna Beach, CA 92651 .714-494-7006
 Tried and True
by Graham Blackburn
I moved my shop rece ntly and, as is
usual when this happen s, was fo rce d into
a co nside ration of all the ex tra stuff that
see ms to acc um ulate bet ween moves. It' s
hard for me to wo rk in a di sorgani zed
envi ronme nt so m y sho p is ge nerally
prett y neat. I think I kn o w what's what
and where eve ry thi ng is- but it's
astonishing how much ex tra cree ps in and
ge ts sec reted aw ay, quite forgott en unti l
some thing as dr astic as a move fo rces it
out into the open.
Now it' s easy to und er stand ho w tha t
extra screwd river that yo u picked up at a
yard sale and thr ew into a drawer was
quickly forgotten, and ho w you soon lost
track o f num erou s othe r sma ll item s
acquired here and there , but a workben ch
is anothe r matt er. Even sma ll ben ch es are
subs tantia l objec ts a nd di fficult to
ove rloo k, but I had become o blivious to
the fac t that my shop no w hou sed an ex tra
full-sized antiq ue ca bine tma ke r's ben ch ,
fully eig ht and a half feet lon g ! It so unds
imp ossible, es pec ially when yo u conside r
that my oid sho p was not mu ch bigger
than a two-car ga rage, but so me how the
bench had di sappeared from view-at
least as a ben ch- and I was qu ite taken by
surprise whe n I began the move and
uncovered this lar ge beh em oth lurking in
the shadows.
Uncove red is, of course , the ope rative
word here. Thi s ex tra bench had been
acq uired a whil e ago as a potenti al project
for restoration and incorporation into my
regular work spa ce. Th e usual press of
da y-to-<lay busin ess had delayed the
prop o sed re storation, a nd in th e
meantime, the ben ch had begun to be used
first as an ex tra wo rksu rface , then as an
ex tra storage surface . Eve ntua lly the
wo rkbe nc h had di sappeared under a
we lte r of boxes co ntai ning paint ing
supplies , c a rv ing sa mp les , specia l
hard ware , scales, gl ue co ntainers, ca ns of
Dani sh o il, lacquer th inner , bo xes of
roofi ng nail s, a big shop fan, and my
eme rge ncy e lec tric heater. I had erec ted a
" temporary" she lf above the ben ch for
ja rs of asso rted nut s, bolt s, was hers, and
sc rews, and had rapidl y filled the space
Graha m Black burn is a fu rniture des igner!
ma ker ill Rio del Ma r. Califo rnia and the
author of many hooks Oil woodwo rking and
home maintena nce ,
24
The Workbench
below with box es o f rags and other
finishing supplies. One end of the ben ch
had becom e co mpletely obsc ured with
the aut omoti ve equipme nt that I am
forced to keep in the sho p. and the oth er
end had been pressed into se rv ice as a
co nve nient pla ce to rest a bun ch of
woode n sas h c ra m ps that had
unexpe ctedly com e my way . Th e result of
all this was that the bench had literally
disappeared from sight.
Now I have alway s loved tools for
their own sake , but have nev er admitted to
bein g a too l co llector, so I try and ab ide by
the se lf-imposed rule that if I haven' t
used something in the last two years it's
time to get rid of it. I am very happy with
my reg ular ben ch-a larg e European
model of c lass ic d esi gn whi ch I
peri od ically resurface and refini sh-and
the fact that I had co mpletely forgott en
abo ut the ver y existence of the antique
ben ch seemed adequ ate proo f that it was
not reall y need ed and sho uld be disposed
of. Thi s decided. I we nt abo ut the awful
busine ss of packing eve rything e lse into
boxes, and for got about the ben ch for the
mom ent. I felt sure that whe n the tim e
ca me, I'd be abl e to find an eager home for
suc h a desirabl e item .
The days passed, and the old shop
grew gradua lly emptier since I was not
moving far, and could effec t the mov e
bit by bit. Slowl y, the antique bench
was revea led un til fina lly it was the only
object left in the now vaca nt space. It
stood there, magn ificen t, its anc ient
patina glowing in the desert ed shop,
looking larger than ever, and I could not
avoid exam ining it more clo sel y than I
had before. As its presen ce grew more
powerful, it becam e more difficult to
do any thing about disposin g o f it. Thi s
was no o rd ina ry ben ch, no mere
co nve nient extra work surface for the
occasiona l help er or stude nt who find s
his or her way into my sho p; this was
a king among ben ches, and I rem em -
bered my exciteme nt when I had first
come acro ss it.
It had been one o f those se rend ipito us
find s that occur now and then whe n one is
not acti vel y looking for anythi ng in
parti cu lar. I had been he lpin g a friend
mov e, and the bench, which had bee n in
the house when my friend had bought it,
had had to go as part of the ge ne ra l
clearing out for the new owner. It had not
meant more to my friend than ano the r
cumbe rso me objec t to be dealt with , but I
had seen it not only as something to do
w ith woodwo rk ing (whic h always
arou ses my int erest) but as some thing
ob viou sl y ver y old and of great potenti al
use in my own shop. At the time there had
been no time to do more than qui ckl y
move it; and its subseq uent fate, afte r a
couple more mov es on my part, has been
explained above.
Now I look ed at it mo re carefully. It
wa s, as already menti oned, eight and a
ha lf fee t lon g. Aside from the extra labor
involved in the res urfacing of such a large
bench that is nec essar y from time to tim e,
a large ben ch is much to be preferred ove r
a smalle r one. It pro vides not only goo d
working space and suppo rt for planin g
lo ng and wid e board s, but is also
invaluable for assembl y--especiall y of
thin gs with legs that mu st all be
referenced off the same flat surface .
C abin etm ak er' s ben ch e s ha ve
evolved o ver the last two hundred yea rs
into a fairly standa rd form eq uipped with
a pair of vises-one at the right-hand end
(as yo u stand in front of the bench ), and
on e on the front of the bench, towards the
left-hand e nd. The fo rmer is known as a
tailor end vise , and the latter is a face vise
or, if it e xtends a ll the way from the top o f
the bench to the floor, a leg vise. Thi s
bench was fitte d wi th a massiv e tai l vise ,
nicely dov etailed and operated by a large
wooden sc rew . and a full-length leg vise,
also o perated by a large wooden sc rew,
and complete with a bored adju stment bar
at its foot.
Ben ch es ha ve not always had vises,
and man y of the holdin g devises that were
used before they became co mmo n may
still be incorporated to goo d e ffec t o n
mod ern ben ch es. Thi s bench had its sha re
of these, too, but before describing them
in grea ter detail, I' d like to say some thing
abo ut the woo de n sc rews used in ea rlier
vises suc h as tho se on this ben ch . Mo st of
the tim e whe n they are found toda y, they
are in such a sad state of rep air that it can
be diffi cu lt to believe that they ever
functioned ver y efficiently.
A rec ent Tried and Tru e column (PW
48, Apri l/May 1989 described the root s
Popular Woodworking

----"---
'& !Jide AYYYL5 c;love b;J. j(ed
iY10 side t7F ViSe
,I
" .-Guide ArM.5 wwY'bi;ed.
ivtlo fc;{ce o-f V ise
E" before they will slide throu gh easi ly.
something very simple. fixe d to the
underside of the bencht op or to the
supporting frame. Co mmo n faults are that
the guide block is loose in its fixi ng. the
slots or c utouts for the guides are
excessively worn and perm it too much
play. or that the block and guides are
misaligned-makin g a wide r. and hence.
too sloppy adjustmen t necessary if the
vise is to be opened and closed to its full
ex tent.
It may be necessary to replace the
guide block if it is too worn or brok en . or
it may simply be a question of resecuring
it firml y to the bench. Once the g uides are
rigid ly fixed to the face of the vise . they
should slide through the block with as
little slop as possible. Th e fit sho uld be so
tight that waxi ng the g uides is necessary

~ The second part that may need

~. attention is the garter. The garter keeps
~ the screw attac hed to the face of the vise.
:T
:c and at the same time allows it to tum . It
L..- -----' ~ may be simply made out of wood. or it

that were once commo n for makin g the

woo den thread s that were used on a
variety of objects. including the large
F!1.2 Wood eV\ti1 Mettil L GtfYtevs
woo de n sc rews co m mo n on
ca binetmaker's benches. When adjusted ---:::;;-~ Gu Ld e Arm s
prop erl y and kept in good repair. these
screws mak e possibl e vises that have
great holding po wer combined with a
Wm.5cve w
nicene ss of g rip--capable of firml y (tWV/5 rvi: rtlfp&t block.
holdin g a thin pie ce of .pa pe r . 5eCVYed to be.Vl.-ch-
Unfortunately. such old vises have often
been terr ibly abu sed and it is sometimes
difficult for them to sec ure ly grasp even a
two-by-four. Th ere are. however. really
only two part s that need atte ntion to keep
these vises working effic iently: the guide
arms and the screw ga rte r.
Regardl ess of the co ndition of the
bencht op and the matin g surface of the
vise (w h ic h can be im proved. if
necessary. later ). the first thin g to see to,
if yo u co me into possession of one of
these vises (or a bench ). is the pro per
operatio n of the guide arms. They must be
rigidly fixe d in the woode n face of the
vise itself. Thi s may have been effec ted in
various wa ys. as show n in Figure I.
Furth ermore. they mu st run smoo thly and
trul y in whate ver form of guide block has
been provided for them . Thi s is usuall y

August/Sept ember 1989 25

 Tried and True
continued
may consist of a two-pa rt cast iro n piece.
as show n in Figure 2. On ce yo u locate it.
it is usuall y qu ite obv io us how it is (or
ought to be ) atta ched. A ll that is usuall y
nee ded is to see that it too is sec ure ly in
place and wi IIall ow the sc rew to tum with
a m inimum of pla y. possibl y wi th the hel p
of a little lubri cati on (g rease in the case of
a me ta l ga rte r. and wax in the case of a
woo de n ga rte r).
The above holds true for al l vises-
tail. face . and leg vises-but leg vises.
beca use of the ir ex tra size. are usuall y
provid ed with an add itiona l adj ustme nt at Beved Bar
their foot. Th ere are va rious ways in
which the foo t o f the leg vise may be held
sec ure ly. so that the face rema ins parall el
to the face of the ben ch no matter how
wide ly th e vise is opened. T he
commo nes t meth od is a simple bar or
bea m. fixe d to the face of the vise like the
guides. whic h runs throu gh a slot usually
forme d in the leg o f the bench . T his beam
is bore d wi th a se ries o f holes so that a pin
may be insert ed at the appro pria te point D

(see Fi gure 3). .~

O nce the vise is run ning pro pe rly. its ~ Ffj.3
top s urface mu st be mad e perfectl y flush ~ L- ....J

-rail Vise - __

l1J

Deilld v>IW' held

vVt TVl-i [ v ise

F[1. 4

26 Po pular Wood wor king


F~. 5
with the top of the be nch. This is a ll part
and parcel of prop erl y dress ing the
ben cht op . Flatten ing of the bench may be
accomplished wi th the j udic ious use o f a
pair of windi ng sticks in co nj unctio n with
a po wer hand plan er . a joint e r plane. a
smoo th plan e. or j ust a sc raper-i n that
o rder. de pe ndi ng o n the degree of
tla tte ning and refinish ing necessar y. I
wo uld lik e to cor rec t th e ofte n
erroneo us ly held beli ef that refini sh ing
a ben cht op as o ld as the one und er
disc uss io n is wa nto nly des troyi ng
va lua ble patin a. If th e ben ch had
remai ned co ns tantly in the hands of a
d iligent crafts person from the day it
was made. it would never have been
allowed to deteri orate into a shameful
August/September 19H9
Hz; Ie5 fl;v-
5JPptJYtlM3 Pivv
Detlld V\I1aN1
" pa t ina " in th e firs t pl ace . Su ch
re finishin g is not the sa me as sa nd ing the
surface clean and app lying a coat of
pol yureth ane- as is so often done by
mi sguided and ove rzea lo us ant iq ue
shops. Sandpaper sho uld never touch a
benchtop for fear of loose grains of
abras ive damagin g fine ly sharpe ne d
cutting edges. and pol yureth ane is a
hideou sly inappropriate fini sh .
The insid e surfaces of the vises. and
the matchin g surfaces of the ben ch (o r its
legs or wherev er the vise mat es) should
also be maintained in smoo th and closely
mating cond ition. A badl y abu sed vise
may need to ha ve its insid e face bu ilt up
with additional wood to rend er it correctly
plan ar. I find it also help s to glue thin
pieces of card to these surfaces . T he card
is ea si ly repl aced when it de teriora tes.
and not only protects the jaws of the vise
but also help s avoi d de nting or damagi ng
so ft pie ces clamp ed in the vise . For rea l
protecti on of a fres hly finis hed wo rkpiece
it so metimes help s to glue pieces of baize.
felt . or eve n ca rpet to the inside of the
jaws.
T he antique ben ch in my shop needed
a little of all the above described atte nt ion,
but basically its massive tail vise and
hand some. full-leng th leg vise were as
effec tive as the day they we re made.
More over , as ment ion ed earlier. there
were additiona l holding bo nuses. of
which the most impressive was a slidi ng
deadm an .
A deadman is an upr ight that is ofte n
freestanding or held in the tai l vise .
provided with a peg that ca n be posi tioned
in anyone of num erou s holes bored in its
face to support the end of a lon g board
held in the face vise , as show n in Figure 4.
A more so phis ticated versio n is a
dea dm an made integral with the fro nt of
the bench . and not need ing to be
supported in the tail vise. So metimes.
such a deadman ca n be mo ved c loser to. or
furth er from. the face vise in order to
support varyi ng len gth boards at the most
co nve nient place along the ir len gth . T his
bench had such a deadm an . whose top and
bott om ends were grooved to run on
matchin g project ion s und er the front of
the bencht op and on top of the bott om rail.
as show n in Figure 5.
Th e top was also provid ed with a
se ries of mortises fo r the inserti on of
ben ch dogs to be used in co nj unc tion with
a cas t iron ben ch stop se t in the top of the
tail vise-whic h had a mate se t in the
hencht op itsel f at the othe r end. Modem
repl acem ents. made of potent iall y less
tool-damagin g alum in um. m ight be
prefe rable to cas t iron o nes, but these
were possessed of s uch a hand some
nineteenth ce ntury qu alit y- they we re
obvious later repl acem ent s for woo de n
bench stops-tha t it was impossible to
co ntemplate replacin g them.
There we re eve n several holes bored
in the top fo r iro n holdfasts- sim ple
ang led pieces of iron with a small
tlatt ened face at one end design ed to ho ld
anything sec ure ly to the top of the ben ch
27
I "--!~'.~e~ -and True
simp ly by being wedge d int o the hole (see
Fig ure 6).
All these accommodation s were mad e
in a very profession al manner. T he vise
sc rews and ga rters, while handmade.
we re not the least bit ama teur ish. Th e
dovetail ing of the vario us members of the
tail vise. and the finis hing detail s of the
leg vise. together with the regul ar. neat
way the dog morti ses had bee n mad e.
were every bit as good as those in a
fac tory- made ben ch migh t have been. It
was still obv ious for a co uple of reasons.
ho we ver. that this was a handmad e ben ch ,
and this lent an even grea ter cha rm to the
piece.
Firstly, altho ug h the bac k piece of the
top was thinner than the two massive
pieces wh ich co mprise d the main surface,
28
there was no tool tray. And secondly, the
undercarri age o f the workbench appea red
to have been built from parts that mu st
origina lly have form ed part of an ea rly
bed frame. since they were bore d in the
mann e r typ ical of the co rde d beds
co mmo nly used in eig htee nth ce ntury
New England. Such beds were held
togeth er by rope which for med an
inter woven base upon which the ma ttress
and bedding rested . T he bedc ord was
woven through hol es bored in the sides of
the fra me . T hese frame members were
also co mmo nly given a sma ll bead to
brea k the edges- j ust like the bo tto m
members of my benc h.
I had found th e be nc h in
Co nnec ticut-w he re rope bed s had once
bee n very co mmo n-and it was tempting
~ Ttilil V,se
.BeV1ch <t p
<,
BeYld1 D! j Muvbsr:s
to spec ulate that so me ente rprising joiner
back at the end o f the eig hteen th ce ntury.
had traded a newer bed that he had been
commissioned to make for the older
rope bed it was repl acin g. and used the
part s in the co nstruction of his new
work be nch.
By th is point in my assess me nt of the
bench . I reali zed I was too attached to the
quality. the wo rkm an shi p. and the
roma nce of it to be abl e to ge t rid of it.
So me how I wo uld have to find roo m for it
in my new sho p, and I secretly promi sed
mysel f that this time I wo uld see it put
back into service. and no t allow it to once
agai n becom e a mere g lor ified she lf or
storage fac ility . I wo uld have to be nd my
rule abo ut usability a litt le, but then wha t
e lse are rules for '? ~
Popular Woodworkin g

by Devore O. Burch
I first becam e inte res ted in lath e turn -
ing bac k in 1935 . whe n I wa s takin g
woo dworking co urses at Pol ytechn ic
High Sc hoo l in Fo rt Worth . Texas. Eac h
yea r. when the school held its "ope n
hou se" to di spl ay the stude nts ' accom-
plishme nts. the wood sho p see me d to
dr aw the largest crowd. No t only did the
stude nts ge t to show o ff their work . but the
shop instru ctor wo uld have severa l live
dem on strat ion s go ing on, On e of the real
crowd-pleasers was turning woode n
br a c el et s o n seve ra l of t he o ld
line- sh aft-dri ven lath es.
Devo re Bu rch is a woodworker ill Fort
Worth , Texas.
August/September 19R9
In retrospect . those bracelet s were
prett y crude. Mak ing on e involv ed push -
ing a woo d blank with a pre-cut insid e
diam eter onto a tapered mandrel. then
turning the outside into va rio us design s.
(So me of yo u old- time rs may recall thi s
meth od .) Non eth eless. the girls wo uld
sta nd in line to ge t one (they wer e free. of
co urse).
Sever al years ago, my wife overheard
an old schoo l friend and I rec alling these
shop ex pe riences and insisted that I make
so me bracelet s for her. Well . on e thing led
to anothe r, and I eve ntua lly developed the
techniques show n on these pages . I'v e
mad e and so ld thou sand s o f these brace-
let s. and have give n awa y an eq ual num -
ber as gifts. I' ve ma de them from all the
dom estic hard woods, and practica lly
eve ry exotic spec ies from amarant h to
ze brawood .
Because a boa rd foo t wi ll yie ld up to
20 bra celet s, depending o n the width yo u
mak e them , yo u can indu lge in exotic
hard wood s witho ut ba nkru pting the fa m-
ily bud get. (I've found that the ladi es wi ll
" ooh " and " ahh" over the wide bracel et s
but usuall y end up bu yin g the narrower
ones .) Also. one blan k will yie ld bo th a
bra ce let and a sma ller napkin rin g, as
you ' ll see later. You ca n make the brace -
lets in a woo d shop with mod est eq uip-
ment - lath e, band saw . drill press, and
tabl e saw-but yo u wi ll need to mak e
severa l simple ji gs and fixtures.
It 's best to make these bracelets in
batch es to save se tup time on the various
machines and fixtures. Start with a sma ll
batch - say. 5 or 10, to hel p wee d o ut the
initia l "uh-oh 's " as yo u learn the process.
My mass-producti on techniques ce n-
ter around a very precise. three-hol e ref-
ere nc ing sys tem that locates and hold s the
blanks for drilling , and attac hes them to
the mandrel for turn ing. In orde r to use
1/4" rods for reference pin s, the hol es that
fit ove r the pin s need to be eve r so slightly
larger. You can ge t a se t of drill bit s that
are designed for j ust thi s kind of preci -
sio n. Th e sizes of the drill s are ide ntified
by letters of the a lpha be t. and the " F '
d ri ll ' s s ize is .257 ", o r seve n
one- tho usandths larger than 1/4" . It is
made spec ifically to drill holes that fit
over 1/4" stee l rods.
Ma king the Blanks
Fir st, glue up a " log" (from which
yo u ' ll slice off the blank s). using a co re of
hardwood that co ntras ts with the ex terior
wood yo u've chosen . Th e core wi ll not be
included in the bracel et s, but w ill be a part
of the napkin rings that yo u ' ll mak e fro m
the same blanks. Ama ra nth over a mapl e
co re. or vermillion over a walnut core, for
ex amp le. mak e es pec ially prett y rings. If
yo u don 't wa nt to mak e the napkin rings,
use any inexpen si ve lumber. suc h as pine
or fir, for the co re.
I g lue up the logs in two stages as
sho wn in Figure I. Start by cutting a
1-3/4" X 2" core (the len gth will dep end on
the number and thi ckness of blanks yo u
wa nt). Nex t, cut two 3/4" X 2" str ips of
exotic woo d to the sa me len gth . Wipe
the surfaces to be g lued with den atured al-
co hol or ace to ne to rem ove the oi ls. the n
29

Figure 1. Gluing Up the Log
dress excess to trim size
r
2"
-- r- - +- - - - -
core
-
L
-- -- - - - --
!..
First Stage
L..-
glue and clam p the strips to each 2" side of
the core , usin g a good g rade of clear
epoxy adhesive. (O rd ina ry wood glues
don 't always give yo u a reli abl e bo nd on
exotic woods.) I use G-2 br and epoxy,
avai lable fro m Headl and Intern ati on al.
Inc. (see So urce List o n page 33). T his
prod uct is spec ially fo rm ulated for use on
"o ily" exo tic woo ds, such as teak, rose-
wood, coco-bo lo, and ebony. Wh en the
epoxy has c ured, dress the 2" di me ns ion
to 1-3/4" and apply 3/4" X 3- 1/4" boards to
the ot her two co re sides .
Wh en the epoxy has cured , sq uare up
the ends of the log, find dead center at
each end, and bo re an " F" hole abo ut 3"
deep.
Yo u ca n make yo ur brace lets fro m o ne
type of wood, but yo u' ll ge t a more strik-
ing appearance if yo u lam inate them from
Figure 2. The Drilling Jig
I insi de the sa w) as yo u're cutting .
rtl/"e-
tl~
base plate
thickness of your scrap
30
Second Stage
--' =
two or more co ntras ting woo ds, such as
rosewood and ve rm illion with thin maple
fea ture stripes (made from scra ps of ve-
neer) sandw iched bet ween the exotic
woo ds. Just glue up a log for eac h spec ies
yo u wa nt to use, slice thin wa fers fro m
eac h, and lamin ate these to mak e yo ur
blanks. The co mbinations of woods and
designs yo u ca n ac hieve are virtua lly
unlimited .
I use a car bide-tipped Freud 80-too th
com binatio n blade to slice off the wafers;
it leaves a surface smoo th eno ugh for
g luing witho ut further surfac ing . Afte r
yo u've cut off all the blank s wi th ho les in
them from one end of the log, go back and
dr ill agai n so that all yo ur wafers end up
with that ce nter hole.
I usuall y g lue up about 10 wafe r as-
se mblies at a time, usin g the simple stac k-
bushings
sized for
"F" drill
j L
ing fixture shown in the pho to at bottm
right, page 3 1. To make the fix ture, cut a
wooden base 1-1 /2" X 6" X 10", dr ill an
"F" hole in the ce nte r, and insert a 1/4"
stee l rod that is abo ut 10" to 12" long into
the ho le (do not fas ten the rod pe rma-
nentl y to the base). Cu t a top block the
sa me size , wi th its ow n hole dr illed
throu gh the ce nter, to put over the top of
the stacked blanks. Coa t the matin g sur-
faces of the wafers with epox y, and stack
51 the assemblies over the rod, placing
j pieces of wax paper bet ween eac h brace-
~ let "sand wich." Apply the top block and
~ cla mp , then wi thdraw the rod so it wo n' t
.~ becom e a perman ent part of the stack .
~ After the epoxy has cured, clean out the
ce nter holes with the drill.
Preparing the Blank
for Turning
Nex t, mak e the dr ill jig show n in Fig-
ure 2; it is used to bore the hole pattern
required for mounting the blanks on the
lath e fixtures. I mad e the base plate formy
ji g from stee l; yo u can make yo urs fro m
tempered hardboard , or hard wood. Steel
bus hings fo r guidi ng the " F" dr ill ca n be
orde red fro m Manh attan Supp ly Co. (see
So urce Lis t on pa ge 33). Drill the holes for
these bu sh ings on 1/2" cente rs, and use
yo ur ben ch vise to press them into the jig
base plate.
To use the j ig, place it ove r the blank
as show n in the top photo on page 32, then
inse rt a 1/4" pin through the center hole.
Bore one of the o uts ide holes, insert the
second pin , and then bore the thi rd hole.
Th e blank s ena ble yo u to make one of
two bracelet sizes: 2- 1/2" inside diam eter
(sma ll) or 2-3/4" insid e diameter (reg ular).
T hese two sizes will fit the hand s of most
g irls and wo me n (if yo u intend to sell the
bra celet s, it ' s a good idea to make some in
eac h size) . I c ut these out with a thin-wall
hole saw . Keep the saw sharp, and clean
off acc um ulated o ily sa wdust (es pecially
Mak e a holding jig for the blanks by
drilling the hole patt ern from yo ur drill jig
into a piece of two-by lumber lon g
eno ugh to clamp to yo ur drill press table .
Positi on this j ig in line with the pilot bit of
the hole saw, then press a 1/4" stee l pin into
eac h of the two o uter holes. Th e pin s
sho uld ex tend abo ut 1/2" above the sur-
face of the two-by.
Place a blank in the holding j ig and
bore abo ut 1/3 of the wa y throu gh the
blank; flip it ove r and repeat on the othe r
Popul ar Woodworkin g
 ~---~---- s:o
:;

"'"
,.,
D

'"
~
s:
a.

Glue the hardwood around a core of some

other species (above left ). Drill a hole in
the exact center of the log (above). Set a
stop- block for the thickness of the wafers,
and remove the throat plate to allow them
to fall clear of the blade (center).

Cut wafers of different thi cknesses for

bracelets of different width s (left). Put wax
paper between layers to keep the individual
assemblies from sticking together (above).

August/September 1989 31
r-----------------------------------, ~
~
lathe face plate E
~
hardwood >.
LJ
<Il
c
threaded inserts .Q~
"F" hole
(1 /4" X 20) ~
r---

~;-;;
r ---- - - - - - - - - - -
---- - - # - - ---
..... _- - --- - -- - - - - -
r-r- -:

4=-==
\ ~: ::

k-~:o:-.- r_--- 4" to 6" - -- .1 (A bove left ) Use the center pin to locate the
drill hole pattern jig; drill on e hole, then pin it and drill the
from drill jig oth er. Two pill s hold the blank in place

3/ "
7
plywood
while you sa w partway through with a hole
saw (above right). In stall threaded inserts
4 ill the mandreli and lise Allen screws to
Figure 3. The Turning Fixture hold the blank ill place during turning
(above and below).

side (do n' t bore co m plete ly throu gh the

blank at this time). Now, rem ove the
blank and saw the rough o uts ide dia me ter
of the bracelet (about 1/2" la rge r than the
insi de dia meter) on yo ur ban d saw or jig
saw . I use a simple template di sk wit h an
"F" hole in the ce nter to mark the 0 0 for
cutt ing.
Turning the Bracelet
Nex t. build the turning fix ture sho wn
in Figure 3. I use 1/4" A llen ca p sc rews to
attac h the blanks; the screws fit into
threaded inserts in the fixture. Mo un t the
fix ture on the lath e face plate. then pin the
blank throu gh the ce nter hole in the fix-
ture (yo u ca n use one of the 1/4 " pins from
yo ur drill jig. or the shank of a 1/4 " tw ist
drill ). Install the screws. and remove the
ce nter pin . You 're no w read y to turn the
blank into a brace let -let yo ur imag ina-
tion run wild. Fo r the profile. I' ve used
templates. mould ing cutte r shapes, etc..
but I like a simp le design because it

32 Popu lar Wood wo rking

 Figure 4. The Finishing Mandrel
scrap rubber \
remove head
from 3/ s" bolt
J..r--------,+--j
I
a
3/ "
S
washer
nut
I
' /s" plywood
Figure 5. The Napk in Ring Fin is hing Mandrel
hardwood adaptor for spur center
<[- - - -fIIW"'I--i I
doesn 't detract fro m the natural beaut y of
the woo d.
Afte r turning the brace let with a sharp
skew chisel, I sand it on the lathe, usin g
progressively finer gr its from l2o-grit to
600-grit pap er follo wed by crocu s cloth;
then poli sh w ith a soft c loth-the exotic
woo ds po lish lik e a ge ms tone. No w, put
the bracelet back on the sa me setup yo u
used with the hole saw and ge ntly feed the
saw throu gh the bracelet to cut out the
plu g. (The brace let wi ll sta rt spinning on
the sa w whe n yo u've cut through it.) Be
s ure to save the plu gs, becau se yo u' ll be
makin g yo ur napkin rings fro m them .
The fina l ma chining pro cess on the
bra celet is to sa nd the inside diam eter
with a drum sa ndi ng attac hme nt on yo ur
drill press. Thi s ma y see m aw kwa rd at
first, but yo u' ll soon ge t the han g of it.
Hold the bracelet with thumbs and fin gers
of both hand s and let it slowly rotate as
you apply light pressure on the sanding
drum.
Finishing
First, appl y two co ats of sa nding
sea ler to the insid e of the bracelet only;
wh en dry, rub lightly with #0000 stee l
woo l. Use yo ur favorite finish on the
II August/September 1989
L ~
slip-fit inside bracelet
-+-
1'/2" diameter wood space r
from core of napkin ring
out side of the bracelet. Th e fini sh ing
mandre l shown in Figur e 4 makes it ea sy
to apply a traditional French poli sh , using
your lathe or drill pre ss. Except for the
1/2" closed-cell neoprene rubber pads that
hold the bracelets, all the part s are readily
ava ilable at mo st hardware stores . I
bou ght the rubber for my pad s from Texas
Rubber Supply, Inc. (see Source List).
Here ' s how I fin ish my bra celets: fir st
apply two co ats of sanding sealer, sanding
between coa ts with #4000 aluminum
ox ide paper. Th en apply six to e ight coat s
of bru shin g lacqu er , such as Deft Clear
Wood Fini sh , following the label direc-
tion s. Afte r the fina l co at cures (in a da y or
so), I mount the bracelets on the fini shing
mandrel , chuck the mandrel in the lathe,
and po lish the lacquer fini sh with fin e
pumice and rubbing oil, then rott en ston e.
Finall y, I wax and buff the bracel et to a
deep, lustrous fini sh .
Na pkin Rings
The procedure for mak ing the napkin
rings is sim ilar to making the brace let s.
You'll mak e them from the plu gs re-
moved from the bracel et blanks. Th e
rings have an inside diameter of 1-1/2" and
an out side diameter of about 2" . Bor e the
--
Sand the insides of the bracelets with a
smaller diameter sanding drum chucked ill
the drill press.
10 abo ut 1/3 through on each side, as you
did the bracelets. To turn the rings, I was te
one of the plugs to make an adapter for the
turn ing fix ture in Fig ure 3. Mount it to the
fixture and turn it down so its sma ller than
the 00 of the rings, then attac h a napkin
ring blank using lon ger Allen sc rews .
After you've turn ed the rings and
bored out the ce nter plugs on yo ur drill
press, save these plu gs for use as space rs
on the napk in ring finis hi ng ma ndrel
show n in Fig ure 5. C huc ke d between
the centers of yo ur lath e , the mandrel
enables yo u to pol ish or fin ish six rings
at once. ~
Sou rce List
G-2 Epoxy:
Headland International, Inc.
2020 - 124th Avenue, N.E., Suite CI02
Bellevue. WA 98005
Drill j ig bushings:
Manhattan Supply Co.
151 -A Sunnyside Blvd.
Plainview, NY 11 803
Neoprene rubber
for finishi ng mandrel pads:
Texas Rubber Supply, Inc.
217 Beach 51.
Fori Worth, TX 76 111
33
........;;:_ _
 Unseen Creations
by Kat hy Hackleman
As Dale Reif look s back ove r his life ,
there are few thin gs that the Ne wto n,
Kansas, man wo uld do differentl y, but he
does wish he had spent more tim e study-
ing woo dworking ma gazin es while he
co uld still see . Reif, wh o has bee n blind
for ove r ten years, took up se rious wood -
wo rking about thr ee yea rs ago. He now
spe nds several hours a day, six days a
wee k in his backy ard work sh op.
" I don 't think there is one word that
describes prop erl y what I do, " Reif
laughs. " It's the shaping and c utting of
hardwood s. It' s the und esigned art of
machining and cutting of woo d," he says ,
searching for the right co mbination of
words to describe his craft.
Basicall y what Reif does is g lue di f-
fere nt types of wood together , c ut a sha pe
from the g lued block and then sand it into
the shape he "sees" in his min d. Th e end
produ ct is one that an y sig hted craft sma n
wo uld be deli ght ed to claim.
Reif', who is 50 yea rs o ld, suffers from
retiniti s pigmentosa , an inherit ed disease.
Fro m the 20/2 0 vision he had when he
graduated high schoo l, he suffered a grad-
ual loss of vision ove r the next seve ra l
yea rs. He retir ed from Hesston Co rpo ra-
tion, in 1986 afte r working there for
nearl y 30 years. Hisjob was wo rking with
metal, and in his free tim e, he stud ied
metalworkin g magazin es. " At that tim e, [
had no interest in wood," he rel ates, "Now
I wish I had spent that tim e on woodwo rk-
ing magazines."
After retiring, he bou ght a woo d lath e Dale R ei! po ses with h is favorit e mantel clock,
and started " play ing around" with woo d-
wo rking. His wife enco urage d him to
build a work shop , and soo n his hobby taken to buy the right tools and then mod- hard woods native to ce ntral Kansas
turn ed into a full -time job. ify them to meet his needs. "I f your too ls (mos tly walnut , birch and cherry) .
His goa l in woo dworki ng is perfecti on are Mickey Mouse. they ' re not go ing to It is that same love of a challenge that
and acc uracy-a go a l he says he is usu - cut it," he ex pla ins. keeps Re if from usin g a co py lathe. " l
a lly able to meet because of the ca re he has Deciding that there was not enough don't want to make one piece and then
cha llenge in wor king with so ft woods, 100 mor e ju st like it. It' s more of a
Kathy Hackleman is afreelance writ er ill " because I co uld do that with my pocket- cha llenge to make eac h one different ," he
Mcl'he rson, Ka nsa s. knife," Re if chose instead to foc us on sa id. For exa mple, eac h of the dozens of

34 Popular Wood workin g

 rolling pins he has mad e is different in the
types of wood used , the length , the diam e-
ter and the handles.
Likewise, he doesn 't like to make
something so meo ne else has design ed.
Each of his creatio ns has co me fro m his
imagination combined with the mem ories
of how he think s the fini shed product will
look. "If you can' t bu ild so me thing out of
your imagi nation, I can't see any chal-
lenge to doing it," he sai d.
Reif rememb ers the cha rac teristic
co lors of the wood he uses, which he ca n
identify by feel and sme ll, and he puts
them together in co lor patterns he thinks
would be effective.
Ha ving mastered the "easy" items
such as bowl s, rolling pin s, trays and lazy
susans, Reif has gone on to grea ter cha l-
lenges. Some recent projects have in-
cluded matchin g sets of end tables, m usi-
ca ljewelry boxes, and clock s, all of which
he has designed him self.
In addition to the basic probl em s of
cracks, warp s, and splits that face any
wood craftsman, Reif also faces pro blems
and dan gers that are unique to him be-
cau se of his blindness. Spl inters are a
con stant source of discomfort becau se he
Reif uses a homemade disk sander to shape his pieces.
must spend so much time fee ling the
In his special setup at the lathe, Reif has wood to ident ify it, and he can not see a
incorporated a machinist's vise to hold and move the tool.

August/September 1989 35
ro ugh splinter until he jams his finge r into
it.
More dan gerous, however, are the
power tools that he must wo rk with to ge t
the basic shape before hand sandi ng . To
avo id getting c hips of woo d and saw dust
in his eyes, Reif a lways wear s a face
shield that protect s his face and neck . But
that still lea ves the problem s of the saw
and grinder them selves. As he ge ts read y
to saw, he measures his wood fort he exact
length he needs, using a rul er with raised
ma rkings or one of several pre-cut iron
pieces that se rve as measurement g uides. ~
Alwaysleaving hisleft handon the wood. :f
he brings his right hand up to gauge the .~"
distance to the blade before turning on the U
machine. " Yo u know the saw will always
co me straight o ut. My left hand is always
Thi s walnut candy dish is inlaid with aftller of maple.
A walnut candle stick

Thi s square clock with a round fa ce is made

out of walnut.

safe. Th e only time' wo uld have trouble

is if the blade is du ll, it has a tendency to
grab the woo d instead of sawing straight
thro ugh," he said.
T he only time he makes allowances
for his blind ness is when sawing a piece
that is less than one inch. "That's getting
too close," he sa id. For the tiny pieces, he
clamps the piece to be cut to another piece
of wood be fore cUll i ng .
When sanding, he is j ust ca reful to
keep his fingers away. '" always know
exactly where it's at," he said, adding '"
wo uldn' t tell the next blind guy to do this,
but it wo rks for me."
amed "Unseen Creations:' Reif s
wor ks wou ld be wort h having for their
beaut y alone, but as rem inders of what we
ca n accomplish if we choose to do so,
the ir value is imm easur able. ~

36 Popular Woodworking
PullOut Plans
Popular Woodworking #50
August/September 1989
Pages 37-52
 '\
'\
,-,
, ,
, '\@, ,
, ,
'\ I ,
,. \
'\
Rocky Duck ,,
Cutting List
Rough Size
Qty Part T W L Piece
1/
2 A 1 2" 11 ' // 27" wings
1 B 1" die meter 13' /2" support rod
1 C 1'/2" 11 '/4" 17" seat
2 0 3/4" 11/ 2" ]3/,6" tail feathers
1 E 1' /2" 107/ s" 11 ' /4" head
1 F 3/4" di meter 63/4" handle
1 G '/2" 11 '// 105/S" seat back
1 H 1/2" 11 1/ " ]3/;
4 leg rest
1 I '/ 2" 11 ' // 7' /2" foot rest
leg rest
1 J 1'/2" 2'/ 4" 11 '// support

1 K 11/ 2" 2'/4" m; bumper

Supplies
4 #12X 3'/2" flat head wood screws
2 #12 X 4" flat head wood screws
2 #10 X 2' /2" flat head wood screws
finish nails
~ ~ N f'- _ ..
-- --~.I

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APopular Woodworking Project

Colonial
Shelf
by John A.Nelson
Our forefa thers were very imag inative when it came to the
design of wall shelves. Their sense of proport ion was superb,
and through the yea rs. the graceful and beaut iful lines of their
ea rly shelves have rem ained unsurp assed . Eve n tod ay. with o ur
computer-ass isted design ca pability, we have not imp roved
upon their lines and designs.
Th is ea rly shelf design , datin g from the eighteenth ce ntury,
was found in Maine. It is fairly small, and is per fec t for holding
a clock or other sma ll objec t. I was attrac ted to it becau se of its
smoo th, graceful lines. It ca n be made of any kind of wood. soft
or hard . Hard wood makes a more impressive project and can be
-g. finished much more beautifully.
*
.!{
Begin by transferr ing to wood the PuljOut" Plan s for the
it four pieces-two sides (A), one brace (B) and one shelf (C). Cut
C'
3 out and sand the two sides together so they will be an exact pair.
~ After cutting out the brace. countersink two I/S" ho les in it for
L -1 ~ mounting the fini shed shelf on the wall.

Glue the brace to the notches in eac h

side piece and check to be ce rta in that all
pieces are sq ua re before the glue
sets.Once the shelf is glued and nailed .
c round the edge s very slightly with sand-
paper.
Prepare the proj ect for fini shin g by
sanding all over with a fine grade of
sandpaper. Stain the shelf, if you wish,
with a color of yo ur choice, and com-
plete it with any goo d grade of low- gloss
finish. Apply a coa t of paste wax. and
your shelf is no w rea dy for the next
cen t ury . ~
10111I A . N elson is a woo dwo rke r and the
author of 26 hooks . ineluding W ood w ork er 's
Jackp ot (lA B Books , Monterey Lane, Blu e
Ridge Summit, PA 172/4 ).

Colonial Shelf
Cutting List
Finished Size
5
s:
'5 Qty Part T W L Piece
.,'"
= 2 A 3/ "
a 43/, " rt; sides
.c>-

See the PullOutT M Plans section for full-size patterns. i

V>
c 1 B 3/a"
3/ "
2" 12" brace
L- _ 1 C a 5'/2" 14\" shelf
~

August/Septembe r 1989 53
APopular Woodworking Project

Rocky Duck by Howard V. French

Rocky Duck is a sturdy, inexpensive
and easy-to-ma ke riding toy that will
del ight the pre- school set. Exce llen t
rockin g surfaces are provided by the
curva ture of the wings. Two-by-twe lve
material makes for wide "tread" and easy
operati on on ca rpe ted floors . and also
eliminates any need for cross-brac ing
bet ween roc kers. The "tai l feathers" nea r
the wing tips prevent even the most
energe tic little rockers from tippi ng over
backw ard.
Sta rt the project by transferring to
wood the wing pattern from the full-scale
PullOuf l M Plans in the center of the
magazine. Cut out one wing (A) anduse it
as a pattern to lay out the other. Stack and
cla mp the two wings toget her secure ly.
"0
15 and smooth them with a belt sander.
0'
.!J: Since the left and right wings are
5'----,---,--::----,-.".----- - - - - -
: Howard V. French lives in Abeline, Texas
5- where he spends his tim e dreaming lip
Q woodworking project ideas.

Figure 1. Assembly Diagram

~
:
s
iil
.!J:
d
3
See the PullOuFM Plans section for full-size patterns . r-

'--- '~"
...J :J

54 Popu lar Woodworking

iden tica l until the holes are dril led.
choo se the best surface of each for the
outer sides. Drill I" holes to a dep th o f
1-1/8" for installing the suppo rt rod (B)
later. (A Forstner bit comes in handy
here .) T he n co unterbo re holes for the
3-1/2" flat head wood sc rews which will
later attac h the wings to the seat (C). Now
make the tail fea ther s (D) as sho wn in the
Pu ll'Out" Plans. To ensure that the
curved surfaces o f wi ng and tail fea ther
pieces meet prec ise ly. lay a wing on the
stoc k. trace the curve and cut. Align the
ce nterlines of the tai l and wing pieces and
attach the ta ils with g lue and a finish nail
throu gh each.
ex t, lay out the patt ern for the head
(E) from the PuljOut" Plan s and cut it
out. Locate and dri ll 1/8" pilot ho les
throu gh fo r the eye and for the handl e (F).
Foll o w the pil ot holes with a I" paddle
blade bit for the eye and a 3/4" paddl e
blade bit for the handle. drilling to a depth
of abou t I ". Then turn the head ove r and
follo w the pilot holes unt il throu gh . Th is
pro cedure lea ves a clean hole on both
sides of the ma teri al.
Cut the se at (C) to the ro ug h
di men sion s in the cutting list, and bevel
the back edge as show n in Figure I. After
rippi ng the be vel. cut the seat to its final
shape (see Figur e 2). Align the head with
the seat and counterb ore holes for two 4 "
flat head woo d sc rews . T he n fasten the
head o nto the seat.
Round both ends of the handle (F) and
insta ll it throu gh the head piece as shown
in Fig ure I. Lay out and cut the seat back
(G) from 1/2" plywood and sc rew and glue
it to the seat.
Cu t the leg rest (H) and the foot rest (I)
from 1/2" plyw ood and bevel the back
edg e of the leg rest. Whil e the saw blade
is tilted, rip the edge of the leg rest support
piece (1) to the ang le show n in Figure I.
Make the bumper (K) fro m the pattern in
the Pullfr ut" Plans: then g lue and
finish-nail these pieces tog ether as a
sub-assembly.
ext. attach the le ft win g to the se at
with glue and two 3-1/2" screws . Chamfer
the ends of the suppo rt rod (B), apply g lue
to one end. and insert it into the I" deep
hole yo u dr illed ea rlier in the left win g.
ow fit the foo t rest and bumper
sub-assemb ly into place. With the leg rest
(H) and the leg rest support (1) firm ly
aga inst the botto m o f the sea t, co untersin k
holes for 2 - 1/2" woo d sc rew s throug h (1)
and into (C). App ly g lue to the mati ng
surfaces and ins tall the sc rew s.
Apply glue to the remaining e nd of the
s uppo rt rod and install the right wing.
T he n dr ive two sma ll fini sh nai ls throug h
the foot rest and into the support rod .
Sand all ex posed corners and fini sh
the completed assembly as desired.
Rock y Duck is now read y for ye ars of
fai thful service. ~

Rocky Duck
Figure 2. Dimensions of the seat
Cutting List
Rough Size
Qty Part T W L Piece
2 A 1' /2" 111/ 4" 27" wings

1 B 1" diemeter 13' /2" support rod 2" R

holes for attach ing head
1 C 1'/2" 11 '/4" 17" seat

2
1
0
E
3/. " 1' /2" 73/ , 6" tail feathers

1' /2" 107/ 8" 11'/4" head 11 ' /4"

~-------:>",---~----,
-- -------- ----- - -- -4w-
.:.t./ ---- -1tu---
<I,' -
-+1 ' /2"

1 F 3/
4" di meter 63/ 4" handle
1 G '/ 2" 11' /4" 105/ 8" seat back
1 H '/2" 11' /; 73/." leg rest
1 I '/2" 11' /; 71/ 2" foot rest
leg rest
1 J 1\ " 2'/; 11' /; support

1 K 1' /2" 21/; ' 73/ 8" bumper

I:
- - - -7"- - ---
- - - - - - - -17"
L3 "-"0+1.....-
3/
16
4" ---i
Supplies
4 #12 X 3'/2" flat head wood screws
-,---------,
2 #1 2 X 4" flathead wood screws
2 #10 X 2' /2" flat head wood screws
finish nails

August/Septembe r 1989 55
 Ma/(f a Pirate Chest
Screw th e sides tu th e ends, and fill the holes with plugs.
by Warre n Asa
Eve n as a boy I liked pi rate ches ts. I had no gre at interest in
things nautical , but a pirate ches t had such rakis h angles and
c urves with rea l !lair that I found them thin gs of wo ndro us
beauty . Wh y pirates hit on thi s unique design I have never
kno wn . Perh aps the sha pe adde d streng th or discouraged stac k-
ing, or perhaps pirates had a greater apprecia tion of aest hetics
than we im agin e. I made Illy first pirate ches t some yea rs ago and
liked the wa y this useful ches t dominated a roo m and becam e an
instant co nversa tion piece. Making one is rather a diffe rent so rt
of project, but it' s goo d so lid woodw or king throughout, so if yo u
like that you will enjo y making on e.
The chest show n und er co ns truction here was made o f red
oak that had been sa wn and planed to 1-1/4" X 5 ". You can use
any cabinet-g rade woo d that yo u hav e or ca n acq uire. Now.
don 't do yo ur sho pping fro m the cutting list, j ust ge t 37 board
feet of 6/4 materi al, and ge t it in len gth s that arc multiples of30"
so you 'll have ex tra len gth for trimming. O f co urse you don 't
have to build yo ur pirate ches t thi s size . Cons ide r a smaller one
for a child's toy box or an eve n smaller one for jewelry. If yo u
ma ke a larger one, I sugges t it be for a big room becau se a pirate
ches t can see m to take ove r a roo m.
Most of the co nstruction isjust butt join er y but the curved lid
is a little trick y. Not that it' s all that difficul t; itj ust requi res so me
acc urate mea surem ent s and sa wing , and some planin g and
Warren A.l'a has beell wlu'lIlillg and woodcrafting since his
scouting days. lie specializes in native A merican folk craft .

56 Popular Wood working

 ....,..,,,.,,...~-------------. -g. r------------------------,
'en0
~
Figure 2. Key Dimensions
5'
.,c:
11l

5'
g
3"

L t

r
trim ends
to compensate
for saw kerf

12"

z:
L .--0-t--
IL _ _
- --'----'---+ r
-i
__J
riP bottom
to be flush
with the ends

See the PullOuFM Plans section for full-size patterns.

Determine the width and the angle of the bevel by measuring fro m
your actual end piece.

scraping to smoo th down the finished product. The key to
de signin g a pirate ches t is to make a full- size template of the end
piece in ca rdboard; yo u' ll find a pattern for this in the PultOut"
Plan s sec tion in the ce nter of the magazine. Thi s size end piece
will be appro priate for chests that are from 28" to 34" long.
Start the ac tua l co nstruction by gluing up the pane ls for the
ends (A), sides (8), and bottom (C). Your end panel (A) ca n be
quit e a bit shorte r than the length given in the cutting list if you
alte rna te the layout of the pattern as shown in Figure I. Use a
port able circ ular saw to cut the sloped sides of the end pieces,
then band saw the top profile. Finish-shape the two pieces as one
unit , so they wi ll both be the same . When yo u cut the lid portion
from the en d, yo u' ll need to trim a bit fro m its ends to acco unt
for the saw kerf (see Figure 2.)
Dress the panels and cut them to length , and while that stop
is set up, cut the materi al for the lid to length , too. Cut more than
you think yo u will need because there is some waste invo lved in
makin g the lid.
To rip the panels to width set your table sa w blade to 78 , or
better yet, the ac tual slope of your fin ished end pieces (on paper
they're 78; what are they in reality?). Rip o ne edge of the
bottom panel (C), then tum it end for end and rip it to the width
that matches the bottom of your end piece (see Figure 2).
Use the same blade angle to trim one edge of eac h side panel
(B). Measure the width you need to go fro m the rim of the box
dow n over the bottom , and flip these pieces over to rip to that
final width. You want both edges parallel. Rip the-two lid sides
(D) to width in the same manner.

You can use clamp s to hold the fi rst several strips, after that you 'll
need to screw them to each other and to the ends.

Figure 1. Flip the pattern end-for-end to use

less wood.

August/Sep tem ber 1989 57

Cut each pair of strips to match the situation and rough-shape Some of the tools used for shaping the lid, clockwise from the top:
their bottoms to fit the curv e of th e ends. a scorp, a spokeshave, a spoon- bottom carving plane ,
and a bench plan e.
Use a scorp, a carving plane or just a gouge to smooth the concav e surf aces, and follow up with a curved scraper.

"

58 Popul ar W oodwork ing

 the edge of the strip as close to it as yo u ca n. Then ju st take a
Pirate Chest
plane to the bottom of the board and shape the ends to fit the
Cutting List curve. Don't worry about round ing the who le len gth of either
surface at this point; ther e will be plent y of time for that. Ju st get
Rough Size
the edge s to fit pretty good , and shape the str ips as need ed .
Qty Part T W L Piece At this point you run into one of the odd thin gs abo ut makin g
1 A 11/ 4" 21 " 32" end panel
the lid, namely that when yo u clamp these wedge-s haped pieces
the y have a tendency to creep. Clamps can help with this for a
2 B 11/ 4" 14" 29" side panels while. I continue to sa w, glue and clamp in this mann er until the
1 C 11/ 4" 11 " 29" bottom panel clamping becomes diffi cult . At that point , I use fla t head woo d
screws to fasten each subsequent strip to the piece next to it.
2 0 11/ 4" 41/ 2 " 29" lid sides
[Editor' s Note: For best results, attach a single strip in the
20 E 11/ 4" 2" 29" lid strips center and work your way down both sides to meet the strips
you've already applied.)
1 F 11/ 4" 11/ 2" 23" handle
Build up the entire lid always striving for tight joints. Wh en
Supplies you finish this gluing, the top is prett y rou gh lookin g; lots of
elbow grease will be called for to work it do wn. At the very apex
2 3" butt hinges
of the lid is a convex curv e which ca n be tackl ed with spokes have
2 brass handles and block plane. On each side, however , is a co ncave c urve
1 roll top desk lock set
which requires an entirely different approach . My favorite tool
for this is a spoon-bottom carving plane (see the so urce list at the
Sources end ). Thi s small tool can be used with one or two hand s and
Spoon-BottomCarving Plane #OBJ03 or
allows you to sculpt ju st the curve yo u want. It provides yo u with
100'/, Hollowing Plane #02831 from:
Woodcraft Supply Corp. the freedom of cut of a gou ge but with the co ntro lled cu t of a
P. O. Box 4000 Dept. PW89 plane. A hollowing plane will also work. Lackin g eithe r of these,
Woburn, MA 01888 a large gouge, scorp, or small, curved adze would see m the bes t
Brass Handles # 06902 and bet. Curved spokes haves are of no value becau se the handl es ge t
Roll Top Desk Lock Set #06804 from: in the way. Do the final work on the lid with curve d and straig ht
The Woodworkers' Store
21801 Industrial Blvd., Dept. PW scrapers. Naturally, all of the curves are j ust the re verse when
Rogers, MN 553749514 you work on the underside of the chest lid.
Sand the outside of the chest, and fasten the hinges and lock .
Sand the ins ide surfaces of these pieces before you asse mble I used 3" butt hinges. Because of the ang le on the front panel you
the chest. I fastened it all together with 3" round head shee t metal may have to be a bit crea tive to make yo ur lock mech ani sm fit.
screws, and of course , glue. The screw head s were recessed 1/2" On this che st I rever sed the lock and catch plate. I also drill holes
in 1/2" diam eter hol es. I filled the holes with black walnut plu gs for the handle hardware at this time but don 't fas te n it until afte r
because I like the co lor co ntrast betwe en the dark wood and the the fini sh is applied. All of the fittings on thi s ches t are standard
oak. Use any conveni ent spacing. commercial hardware in brass. The larger pir ate ches t sho wn in
Assemble the lid frame consisting of the lid sides (D) and the one of the photos has c ustom- made hard ware of black stee l.
two c urved-top ends , with glue and scre ws. Make sure this If you use a hasp to lock your chest it provid es a co nve nient
fram e is square or at least lines up with the box . handle to raise the lid, but this design utili zes a built- in key lock .
Now comes the fun part of buildin g a pirat e che st. Con struct - So the que stion I faced was how to lift the lid. I so lved it in a way
ing the c urved lid is a true woodwo rker's challenge, but don 't be that doe sn 't alter the raki sh lines. I added a strip of oak partway
intimidated becau se it is not that tricky. Think eac h step through acro ss the front of the lid. Thi s strip was left over from mak ing
before you act, measure twice before yo u cut, and yo u will be the keystone piec es for the lid. I ca rved a groove on the lower
OK. side to provide a good fin ger grip. It works quite we ll and is not
My approach to fo rm ing the lid is to view it as a complex obtru sive, but a bra ss handle on either side wo uld have do ne the
arch. Th e key to buildin g an arch from an arch itectural point of job equally well.
view is a keystone and so I make a series of keyston e- shaped I finished this ches t with Dani sh oi l, but yo u ca n decide what
pieces to cover the ches t top. After makin g my first chest, I fini sh you prefer. The larger chest was finished with polyur e-
wond ered if perhaps I was doin g thin gs the hard way. I thou ght thane . The final jobs were attachin g the handl es and esc utcheo n
abo ut preshaping piece s for the lid like barr el staves , or of plate for the keyhole, and attac hing a cord to keep the lid from
build ing up the top with very thin strips. But after serious con - opening too far. If your chest is as large as this one , be sure to use
sideration, I rejected all of these as being impractical forthi s job. heavy-duty handles. I also put a layer of cedar in the bott om for
I measure the angle for the first piece, set the table saw and arom a and moth prot ect ion.
cut two pieces-t-one for eac h side . I rough-shape the bottoms of The days of the pirate were long ago and, happil y, their needs
these pieces to fit the curve of the ends, and then glue and clamp have largely been forgotten ; but they did leave us one positi ve
them in place. legacy, their unusual chests. If you want to share in this bequ est,
Th e sec ret is to eye ball the angle with your T- bevel, and rip this is the project for you. ~

August/September 1989 59
APopular Woodworking Project

A Sleek Mahogany Table Set

by Hugh Foster
Honduras mahogan y lend s itself well
to the simple, clean lines of man y co ntem-
pora ry furniture pieces, such as th is e le-
gant coc ktail table/end table se t. I chose
the wood not o nly for this rea son , but also
becau se it was ava ilable in wide plank s,
which enabled me to make all the table
tops from a sing le piece of 20 "-wide )
stock. If yo u ca n' t get material this wide,
you' ll need to glue up rand om widths to
make yo ur top s. Of co urse , yo u ca n make
the tables fro m wa lnut. mapl e, or any
species yo u like. They're designed to
emp hasize the natural beaut y of the wood
itself, unhindered by orna te detail s. Also,
the simple design enables yo u to eas ily
alter the length, width , and height to suit
Hugh Foster is a part -time furni ture
dcsignerlbuilder ill Manit owoc,
Wiscoll silllllld the author af T he Biscu it
Jo iner Handbook (Sterling Publishing
Co . , 38 7 Park A " 1'1/111' So uth, New York.
NY / 00/6 ).

18"
1 16"

~---------------52"
I..
Figure 1. The Shape of the Top
---------------IJ
60 Popul ar Woodworking
 your particular need s.
When I made the tabl es shown here, I
had ju st acquired an antique beading
plane, which I used to pro vide some vis-
ual interest to the aprons. Individual tastes
differ , how ever, so you ma y not want to
add the beading, or you might even want
to 1- 1/4" thick X 20 " wide X 52" lon g. If
you start with rough 5/4 " stock , the thi ck-
ness after plan ing will be slightly less.
Thi s is okay , but try to kee p ma terial loss
to a minim um. If you don 't have a planer
wide enough to surface the face s (few of
us do) have it done by your lum ber dealer

\ . to add oth er detail s of your own.

The Cocktail Table
or a local cabi net shop. The top for the end
tabl e is mille d to the same basic width and
To make the top for the cocktail tabl e, thick ness as that of the cocktai l table. If
yo u' ll need a pan el that is cut and surface d yo u're makin g the co mp lete set (with one
cr-----------------------------------,
51
j Figure 2. The Apron to Leg Joint
E
(3.
0>-
r>

'"
c
a 1" ~
~
; ~~ I -

-g.
a
<;
'" .z'"
or
"
III
C
~
_ _ _ __ _ __ __ ~ ...JQ

August/Sept em ber 1989 61

 or two end tables), just buy a longer piece
of top material and cut all the tops from it.
Thi s not only saves time and money, but
assur es a clo ser match in wood color and
grain pattern.
Once yo u' ve milled the top (A) to
rou gh size, taper the sides. as shown in
Figure 1. Although the initial width is 20",

~ 2"
I
I
I
I
2
,
r-
3
/ "
4
I
I
I
I
t
3"
the fini shed top will measure 18" wide in
the center, tape ring down to 16" wide at
each end. The ex tra margin not only fa-
c ilitates cutting the taper, but also
matches the widt h of the end table tops. if
~
I I

~
I I
I you 're mak ing these from the same stock.
The best method for cutting the tapers is to
@ use a portab le circular saw with a straight-
edge clamped to the work.
Pla ne and sand the sides and ends of
the top to remove saw marks. Nex t, de-

Cocktail Table
'133/ 8 "
Cutting List
Finished Size
19' / 2 "
Qty Part T W L Piece
1 A 1'/4' 20" " 52" top
4 B 2" 2" 133/ 8' legs
2 C 3/: 23/ 4' 401/ 4' side aprons
2 D 3/
4" 23/ 4' 123/4" end aprons
4 E 15/ 8' 15/ 8" 6" corner braces

-I I I.. Supplies
1" 8 table clips with screws
16 #10 X 1\ " flat head wood screws

-I I I.. 4 furniture glides

Figure 3. Mortise Layout on Legs 1" "Finished width after cutting tapers will be 18".
See text.

62 Popul ar Woodworking
cide whic h side will be the top surface,
then place the tabletop bott om side-up on Figure 5. Installing the Crossbrace
your bench and bev el both end s, as shown
in Figure I. I used a drawknife and spoke-
shave to rough-cut the 3" bevel s, then
smoothed the beve lled surface with a
plane and cabinet scraper.
Flip the top back over , and use a cabi-
net scraper to remove mill mark s from the
surface. On thi s project , I found that I o
didn't need to sand the top ; after scraping, @
I scrubbed it with its own shavings, bur-
nishin g the surface until it literally shone. g
I then appli ed a coat of medium- walnut .
E

Watco Dani sh Oil , followed by six coat s ~
of natural Watco, and finally, a good ~
waxin g. I started my fin ishin g schedule .9
c

for the top before building the base be- ,g~
ca use the top required additional coat s to L . . . - - - - ---!._ _---"'-- .!-. ---I

build up a durabl e fini sh. on each side . usin g most of the same proce d ures de-
To mak e the base , cut the legs (B) to Disassemble the table and apply a coat scribed for the coc kta il tabl e-mortise
size indic ated in the cutting list, then mark of medium walnut Watco oil to the base. and tenon join ery, tapering the legs, ap-
and cut mortises for the aprons as shown Rea ssemble and apply two or thre e coats plying an oil finis h, and so-forth. On e
in Figure 2. Ne xt, tap er the legs, as sho wn of natural Watco to the entire tabl e. Note major difference is the addi tion of a
in Figure 3. You can c ut the tapers on a that the initial coat of medium walnut o il dra wer and the e limi nation of the co mer
tab le sa w, using a simple taper ji g. If yo u yo u applied to the top and base simulates blocks to allow clearan ce for the dr awer.
don 't have a taper ji g, now is a good time the deep , rich appearanc e of mahogan y Th e height of these tabl es is 20-1 /2", but I
to mak e one (yo u ' ll find instruct ions in dark ened with age, wh ich it will do natu - stro ng ly sugges t that yo u adj ust it
the Jun e/Jul y 1986 issue of Popular rall y after a period of time, anyway. After (length en or shor ten the legs) to accom-
Woodw orking ). Aft er cutting the tapers, the final oil coat is dry, appl y a good paste modat e the height of the arm rests on yo ur
plane and scrape or sand the legs to re- wa x, and your table is read y to grace the sofa or easy cha ir.
move an y saw mark s or other surface livin g room . C ut the top (F) to size, smo oth to
defects. Matching End Tables remove mill mark s, and break any sharp
Now, cut the aprons (C and D) to the To mak e the end tables, yo u' ll be edges with sandpaper. As with the cock -
sizes indicated in the cutting list. Th e (;r - - - - - - - -- - - - - -- - -- - - -- - - - - -- - - -- ---,
len gth includes I " at both ends to allow 5
for tenon s. Mark and cut the tenons, then ~'"
test them for fit in the morti sed legs. Mak e
any needed adjustments for a perfect fit
(the top side of the tenoned aprons should
be flush with the top of the legs), then
scrape or sand the aprons smooth. Now is
also the time to add any decor ative fea -
ture s to the aprons, such as the beading I
put on mine. You sho uld also cut a kerf at
1/2" frum the top ed ges of the aprons for
the tabletop fasteners (see the list of sup-
plies).
Glu e and clamp the base assembl y
togeth er (see Figure 4 ). A framin g clamp
facilitates thi s nicely . Before you attac h
the top , cle an up an y g lue squeeze-out on
the base, sand or scrape it smooth, and
burni sh with wo od shavings. Cut and
insta ll the four co rne r braces (E) to the
base, as shown in Figure 5. Then, car e- The finished drawe r f ront is wider
full y position the base on the underside of tha n the apron s to create a lip
the top , and attac h it with tablet op fasten- for pu lling open the drawer.
ers and screws , two on eac h end and two

August/September 1989 63
 Figure 6. The Drawer Support Structure

tail table, start yo ur finishing sc hedule o n the base and attach it. End Table
before building the base. Cut the legs (G) No w, measure and cut the drawer
to size, then cut 1/2" X 1/2 " X 3" long supports (L), and attach them to the bot- Cutting List (for one)
morti ses in the legs to accept the back tom edge of the filler strips with glue and Finished Size
apron (H) and side aprons (I ) as show n in finish nails. Make sure the tops of the
Figure 6. Next, c ut a 1/2" wide X I" long supports are perfectl y flush with that of aty Part T W L Piece
stop--dado, 1/2" deep to acc ept the front the front support (1), so the drawer will 1 F 1' /4 " 20" 28" top
draw er support (1). Th e bottom surface of rest squarely on all three.
4 G 2" 2" 191/ 2" legs
the dado should be exac tly 3" below the Next, cut the draw er sides (M) and
top of the leg. Mark and cut the leg tapers ends (N) to size and cut the 1/4" X 1/4" 1 H 1" 3" 14'/2" back apron
as sho wn in Figure 3 usin g yo ur tapering grooves in them to acce pt the plywood 2 I 1" 3" 24" side aprons
j ig on the table saw. Cut the ten on s on the bott om (0). Cut the bottom to allow a
e nds of the aprons (Figure 6), and bead the slight amount of mov ement in the frame front drawer
1 J 1/ "
2 1" 14' /2"
support
edges. (do not glue it in place, or the drawer may
Test- fit the base assembl y and make warp or stick). You ca n either assemble 2 K 3/ "
4
21/2" 23" filler strips
any needed adjustme nts, then glue and the drawer fram e with simple butt joint s,
clamp the base together (see Figur e 7). usin g glue and fin ish nail s, or, if you 2 L 1// 13/ 4" 23" side drawer
supports
After the glue has dried , cle an off any have a router and dovetail jig, with
2 M 1// 2' // 20" drawer sides
squeeze -out and sand or scra pe smooth. half-blind do veta ils. If you do the
Flip the base upside-down on yo ur bench latter, adj ust the lengths of the pieces to 2 N ' / 2" 2' /4 " 123/ 8" drawer ends
and measure the distan ce bet ween the co mpensa te for the dovetails. Cut the 1 0 1// 12 3/ "
193/ 8" drawer bottom
4
front and back legs at the side apro ns. Cut finished front (P) to size and ap ply it
filler strips (K) to fit between the legs, and to the draw er so it clears the underside of 1 p 1" 3' /2" 133/ 8" finished
drawer front
plane Ih em 10 a thickn ess that makes them the tabletop by abo ut 1/8 ". The ove rhang
flush with the legs ' inside co rne rs. Th e at the bottom will enabl e yo u to ope n the Supplies
bottom edges of these strips sho uld line drawer without knob s or pulls.
8 table clipswithscrews
up with the top ed ge of the front draw er Appl y fini sh to the end table and
support (J) so that the side dra wer sup- drawer face, following the same pro ce- 4 furniture glides
port s (L) will be flush. Cut the groo ves for dur es as for the cocktail table. As a final Sources
the table iron s in these filler strips; the touch , you can add furn iture fee t to the Table Clips #09500 and
draw er sides will ride low enough to clear bott om of the legs (see the list of sup- Furniture Glides #C1724 from:
the table iron s. G lue the strips to the side plies). If you've made two end tables, yo u The Woodworkers' Store
21801 Industrial Blvd., Dept. PW
aprons, flush with the apron top. Aft er the now have a hand som e se t to arrange Rogers. MN 553749514
glue has dried, carefully position the top around your favorit e co uch. ~

64 Pop ular Woodw orkin g

 Figure 7. Assembly of the End Table

August/September 1989 65
Decorative
Carved Screen
by Amy D. Shojai
Thi s fold ing wood sc ree n is co m-
prised of six ind ividu all y ca rve d and
hinged panels that po rtray , on one side , a
stylized fruit tree and on the other, a
peacock in full di spl ay. Agate stones hav e
been mounted in the sc ree n for "eyes" of
the peacock feath ers on one side, while
shining through as " fru it" of the tree on
the othe r.
A my D. Shojai is a woodcarver and writer
living in Sherman . Texas .
66
I mad e my sc ree n out of one by twelve
knott y pine she lving plank s with dim en -
sions 01'3/4" X 11-1/4" X 54". T he kn ots
are incorporat ed in the design, ac ting
alon g with the agate stones as the many
eyes of the bird feather s on one side and
the tree ' s fruit, knot s, and burl s on the
oth er. If yo u choose such woo d, dra w
yo ur design to give yo u as little carv ing of
the knots as possibl e since the wood in
these places is of unpredi ctabl e grain and
den sit y.
Th e de sign may be as simple or intri -
cate as yo ur ima gination des ires . Th e
pattern s in Figures I and 5 are provided
ju st to get yo ur creative jui ces flowing;
you 'll have to cu stomize them to acc om-
modate the knots in your wood . Ali gn the
plank s on a large work space , and , with an
eye to the size and po sition of the knot s,
pencil in the de sign . Rem ember that when
carv ed eac h individual plank mu st full y
align with the next. Th e pen cil lines will
be ca rve d away so , at this stage, keep the
Popular Woodworking
 de sign simple. Detail should be add ed
later.
The first stage is roughing out the
design by cutting an outline and then
removing the " background." For useful
information on this and every stage . read
William H. McMaster' s "R elie f Carving:
An Introduction" (Popular Woodwork -
ing #39. October/November 1987).1 used
a very basic co llec tion of carving tool s
including a straight blad e knife. a chise l.
shallow and deep gouges. and a V-tool.
Use the straight blade to outline the entire
desig n. Cut at an angle. leanin g the handl e
of the kn ife toward the de sign . Then cut a
second o utline. parallel to the first with
the blad e handle tilted away from the
design . T his procedure sho uld result in a
thin. wedge-shaped groove completely
outlining the pattern.
Now. keeping in mind that the deeper ~
the backgrou nd. the more contrast the i '''' '
Figure 1. Make the knots in your material the fruit in the design.

'"5
D:
c
c:
i3
>-
D

'"
c
o
.~
~ L- -' L --' '-- -' L JL ---1'-- --.J

Augusl/Scptembcr 1989 67
 ~~
~/~ Figure 3.
Carve clusters of leaves as
receding layers.

Figure 2. The three stages

of shaping a surface.

carving will sho w, decid e what porti on s

of the design will stand out the furth est.
Thi s sec tion sho uld be atta cked first, or
later the ca rv ing may need to proceed
nearl y through the woo d in order to ga in
the right co ntras t. You want to "boas t" the
high areas by rou gh ing down the low
areas.
I ca rve d the trunk and branches of the
tree first , incorporating the ex isting grain
and idiosyncrasie s of the plank right into
the design. Knots in the plank becam e
knots and fruit of the tree; grain in the
plank was ex aggerated and stylized, be-
co ming gna rled limb s and bran ches. Af-
ter using the stra ight blad e to outl ine .my
portions of the trunk not roughed o ut
previou sly, round and smoo th the ove ra ll
tree shape (see Figure 2). Then add indi-
vidua l burl s and details- again, by
roughing first and then round ing and
smoo thing. Use this same roughing,
round ing and smoo thing routine throu gh -
out the project.
Ca rving the leaves of the tree is very
simple and rep etiti ve, yet when finished
they look ex treme ly impressive. At first
they are nothing more than .ro ughed o ut
ci rcular areas where individual leaves
will later be formed. Each circle is
rounded and smoothed to a co nvex
mound whose edges see m to " disa ppea r"
into the plank. Leav es are then pencil ed
in, starting a lways at the high est point of
the mound and und erlapping as yo u pro-
ceed out to the edges of the circle (see
Fig ure 3) .

68 Popul ar Wood wo rking

 Figure 4. Use the V-tool to detail the feathers.

Figure 5. The knots and the agates are the "eyes" in the feathers.

August/September 1989 69

Usin g the straight blad e. cut a protec-
tive outlining groove (a stop-c ut) around
the top-most leaf. Round and smooth the
next underl ying leaves so that the high est
leaf app ears to stand out from the mound .
Continue with the imm ediatel y und erly-
ing lea ves. deciding which is topmost
and cutting protective groo ves aro und it.
Each time the gro ove is ca rve d, the next
underl yin g le a f is round e d a nd
smoo thed---only then is its own stop-cut
carved . Onc e all the c ircles of leaves are
completed, eac h indiv id ua l leaf may be
scored down the middl e with the V-tool
to create a vein or stem, g iving furth er
detail and texture to the finis hed carv ing.
Carve the peaco ck by following the
same pro cedure. C ut a protect ive groove
that outlines the bird first. Rou gh out the
back ground and smooth it; then deter-
min e th e topm o st porti on -th e
peacock ' s head and neck-and carve and
round it appropriately. I achi ev ed an in-
terestin g "feather" texture here by using
70
the sha llow go uge ve ry carefully.
T he sweeping tail feathers are layered
m uch the same as the leaves (sec Fig ure
4). Pencil simple oblong sha pes onto the
woo d, crossing to adjacent plan ks to en-
ha nce the illusion wh ile be ing careful to
kee p the plank s and d rawings lined up and
true. Once the oblongs are roughed in
wi th the straight blad e and rou nded
smooth, ca rve a ce nter quill in eac h. Ac-
comp lish this by cutting alo ng eac h side
of the quill with the V-tool when wo rking
with the grain, or by cutting two para lle l
o utlines with the straig ht blade whe n
wo rking agai nst the grain.
Ca ref ully smoo th the line of the q uill
and round the bod y of the feathe r down to
meet it before carving the ma ny met icu -
lou s parall el grooves with the V-tool. T he
eyes of the peacock fea thers sho uld be left
alone, whethe r o r not they co inc ide wi th
knots.
Fo r acce nt, ca rve inset s through the
plank s to hold agat es. which then se rve as
"C
zr
o
g
0-
'<
5'
'"
ll>
C
5'
f -- - -' Q
peacock fea ther eyes while show ing
thro ugh o n the othe r side as sty lized
apples . Stained g lass ca n also be used , or
the wood itself w ill do j ust fine.
Th e co mplete d panels hinge in an ac-
cordi on fas hion so that the screen ma y be
fo lded for easy mov em ent. Depending on
the design , the six pan els co uld also be
hin ged in two three-panel sec tions. I
stai ned the kn ott y pine to a cherry finish,
wiping off the first coat with a clean ,
lint-free c loth, allow ing the deepl y
carved recesses to reta in more of the stain.
Th is crea tes all effective co ntrast and adds
to the appea rance of depth in the carving.
Finish the wood before inst allin g the ag-
ates . I anchored them in their pre-carved
inset s with ce ram ic tile ce ment.
Since its size, compos ition and fini sh
can be determined in ad van ce to comple-
ment ex isting interi or design , the decora-
tive ca rve d sc reen can mak e an attractive
and dramati c woode n acce ssory for virtu-
ally an y roo m. ~
Popular Woodworking
 by William H. McMaster anima ls. Some of them carved a
In this artic le we will round out yo ur co llectio n of large se lection of anima ls, while
carouse l anima ls by giv ing yo u a few pattern s for others on ly offered the lion
men ager ie anima ls. With the increasing popularity of and tiger-the favo rites wi th
the carouse l, the figures eve ntually began to incl ude the ridi ng publ ic. The
anima ls other than the horse. Although the horse carvers often used his-
was by far the most popular, most manufacturers torical sc ulpture for their
(exce pt Stein and Go ldstein) offered mena gerie model s. Mu ell er used
the pro cession al lions
William H. McMaster is Chief of the Education
Di vision of the California Carvers' Guild. on the Lion Wall of the
His "Focus Oil Carving" is 6th Century BC Babylonian
a regularfeature ill palace of Dariu s I. The lion s
PW .
ca rve d by
~ Loo ff a re

"\
\ llt'~ s imi lar to
the six lion s
ca rryi ng s uppo rt
pill ars fo r
th e o rna te
pulpit of the
13th Century
Ca the d ra l at
Ravello, Italy. Many Dent zel
lions are co mparable to the tradi -
tional standing lion used in heraldic pageantry and co mmo n on
many coats of arm s.
Th e lion was traditionally placed on the outs ide row
Full- Size Pattern with his natural pre y (ostrich, deer. giraffe, zebra) mounted
on the inner row s ju st ahead ofhim to sim ulate his stalking
of the weaker animals as the caro use l revol ved. Th e tigers
were generally placed on the opp osite side of the carouse l from
the lion to indicate that these two predators do not share the same

August/Se ptember 1989 71

 habit at.
Men ageri e anima ls first appea red on Europ ean caro use ls
" during the late 18th ce ntury and became popul ar in
-..........:::::::-,J1_~ Am erica after their intro duc tion by Charles Loo ff in
187 6. Wh en Ch arl es I.D. Loo ff arrive d from Denmark in
1870 at age 18, he was cha lle nged by immi gration offic ials to
give a middl e nam e as a positiv e " ID." No t having one, he re-
so urcefully told them that his middle initi als were " I.D." On ce
in Ameri ca he began wo rking as a woodca rve r in a furn iture
fact ory and carved ca rouse l animals at hom e in his spare tim e.
He was ve ry successful and soon began carv ing carousel anima ls
full tim e. In 1910 he moved his fac tory to Ocean Park , CA, and
laterto Lo ng Beach . His carouse l in Lon g Beach was recentl y re-
stored and is now ope rating fo r the enjoyme nt of all.
T he most popul ar men agerie animals we re carve d by
Dent zel, and his carvers ac hieved a great deal of real ism whil e
producin g thei r fant asy fig ures. How ev er , when the Mu eller
broth er s left the co mpa ny in 1907 , Dentzel stopped produ cin g
menageri e anim als.
Here we present two patterns fronm Dent ze/ : the ca t and the
giraffeand also the came l produced by the Phil adelphia Tobog-
gan Company. For referen ce photos of the or iginal carved ani-
mals, yo u ca n use the fo llo wing three book s: The Art of the
Caro usel. by Cha rlo tte Din ger, shows a picture of the head of
the cat and its paws on page 6 1, the g iraffe on page 64 , and
the came l on page 144 . Th e second book is The Encyclo pe-
dia of Collectibles (Buttons to Chess Sets) by Tim e-Li fe
Books. In this book the ca t is on pa ge 43, and the giraffe on page
69. A goo d reference for the ca me l is again shown on page 80 of
Painted Ponies by William Manns and Peggy Shan k. These ref-
erences will help yo u with both the carving and the paint ing of
these figures. It' s go od to learn to use photograph s as referen ces
whil e you ca rve . For co ntinuing information on caro usels and
carousel animals, yo u might wa nt to subsc ribe to the qu arterl y
magazine, Caro usel Art (P .O. Box 992 , Garden Grove, CA
92642).
Before yo u start carving, it is es pec ially help ful to first mak e
a clay mod el of the head , so yo u have a ve ry goo d idea of how
it is form ed . T he main charm of these fantasy anima ls is in the
faces, so that is where yo u sho uld spe nd most of your effort.
I placed the hold ing tab s for the ca me l and giraffe on the
bottom o f the two hind fee t as sho wn in Fig ure I . When working
on the animals, leave the carving of the hind legs until the end.
You don 't wa nt to break these hind legs. Wh en the tab is re-
moved , yo u can hold the anima ) in a vise bet ween two pieces of
hard spo nge to protect the ca rvi ng yo u have already done.
Dentzel Cat
Th e firs t carouse l ca t wa s created by Sa lvatore Ce rn igl iaro,
an immi grant from Sicil y. who was one of Dent zel ' s mo st
talented carvers. Eve ry Dent zel ca t had some small anima l in its
mouth representing its newl y ca ught prey. Th is pre y was usuall y
either a bird or a fis h, and in our patt ern we use the fis h. Th e head
of the caught an imal was alw ays fac ing the left side , away from
the outside of the ca rouse l, to spare the onloo ker of looking di-
rectl y at the dead anima l.
Figure 1. Holding Tabs Th e ca t in thi s pattern has a rea listic bod y ca rved in a running
pose. Use the phot ograph s referred to above and those that
acc ompan y this articl e to guide yo ur ca rv ing . Fi gur e 2 gives
eng ineeri ng-style views of the ea t's head to help you with this

72 Popular Woodworking
 0' - - - - - - - - - - - - - - - - - - - - - - --,
.c
'5

'">-'"

s:J

'"
c:
.2

Figure 2. Details of the eat's head

most import ant part . The value of this style of pattern is that it
makes sure that all views are consistent with o ne another. Thi s
is acco mplished by the guide lines drawn to each prominent
feature. Th e side and front views are coo rdi nated through the use
of a reflec tion line. The views can then be co nside red to lie on
three sides of a rect angul ar block. You would do well to first
block out the wood to this shape before starting to carve. Then ,
by first rem oving the shaded areas as shown in Figure 3, yo u can
ge t the co rrec t sha pe of the head. I find that whenever I ca rve
heads of any kind , this method produces the best res ults. Do the
ot her anima ls in the same fas hion.
Since the ca t is in a suspe nded pose, it is the only one of this
set that req uires a po le for support. Locate the ea t's holding tab
behind the pole, and remember to dri ll a hole for the pole once
the wood has been bandsawed and before you beg in carvi ng.
The body is textured using a sma ll U-tool to simulate fur. It
is useful to shape the cutting edge of this go uge as a bull- nose
to give better control in the scoo ping motion used in texturing.
Also, in order to get clean cuts, the tool m ust be super sharp.
Keep it polished on an 800D-grit water stone with stro kes par-
allel to the cutting edge.
Dentzel Giraffe
Our giraffe patte rn is of an early versio n of a Dent zel outside
stander which was carved in 1895. It is real istically posed with
its head lifted high as though it was abo ut to graze on the leaves
of a tall tree. The origi na l giraffe stands approx imately six feet
Figure 3. Blocking out the eat 's head
tall and is the largest animal on the caro use l. It is now in the
Charlo tte Dinger co llec tion, one of the finest in the country.

August/Septembe r 1989 73
 Fig ure 4 gives you three views of the head. In this case we
have cha nged the orientation of the front view so that you ca n see
more of how the fea tures are shaped. Note the way the reference
lines and the reflection line are positi on ed for this changed view.
As you ca n see, this meth od of creating pattern s is very versat ile.
The protrudin g ears are ve ry delica te, and you must be ca re-
ful not to brea k them off while ca rving. Su pport them with the
fingers of yo ur left han d whi le ca rving with the go uge in the

with only one hand .

Philadelphia
Toboggan Company
K
right. I find that the penc il- grip sty le of go uge works best fort his
type of carving since it is very versa tile when carvin

Camel
This co mpany was fo unded
by Henr y Auchy an d Ches ter Al-
bright in 1903. Th eir carousels are
know n for the ir su- perb craftsmansh ip
and design. T hey ca rve d ma ny armored
horse s w hic h we re adorn ed with rep licas
of armo r and weapons from the 13th to
17th Century. T he P. T . C. caro use ls were
e s p e cia II y kno wn for their fine chariots
which were based on class ical
them es and intrica tely ca rved .
During the ir thirty years of op-
eration, they had the serv ices of
so me of the best carvers and pro -
d uced man y menagerie ani ma ls.
T his ca me l pattern shows one of
the ir o utside row stande rs carved in
1903 . The bod y has textured fur
carved in the same manner as that of
the cat.
T here were many other menag-
er ie anima ls on the caro usels. They
were carved by most of the maj or
carouse l ma ke rs. Here are some notes
on some othe r anima ls that you may
wan t to add to your co llection: T he most
co mmo n mod el of the goat fo r the
carouse l carvers see ms to be the Spanish
Ibex, whose horn s form an open spiral
ris ing in an upward direction, the n
fla ring o utward and backwards. A
wooden Den tzel caro usel goa t has a
Full-Size Pattern perma nent hom e at the U.S. Naval
Acade my, where it serves as the
symbo lic mascot for the Navy.

I
Roosters were liked because of the ir
co lorfu l plum age; how ever, no hens
were made by the Am er ican carvers.
All carouse l deer had rea l an tlers
lam inated inside the top of the head .
T his made them stro nge r, and they
we re eas ierto install than wooden
ones . T he frog was only carved
by th e Her sch ell - Spillm an
Co mpa ny. T heir leaping frog

74 Popul ar Woodworking
...----------- - - - - - - - - - - - - - ,-g.
~
'c.:":>
C
~
~
s
ill
!{
or
<D

'or"
C

footm an in a bow tie and cutaway was modeled afte r Sir

Figure 4. Details of the giraffe's head
John Te nner's illustratio ns for Alice in wo nderla nd. It is the
only carousel fig ure that was carve d wea ring hum an sty le
clothing.
With the co ncl usion of this series of articles on the ca rving
of carouse l anima ls, you sho uld have the begi nnings of a nice
co llec tion of these wo nderful fantasy ani ma ls. Learn to lise the
engi neeri ng style of crea ting pattern s and yo u w ill have much
better result s in produ cing well - proporti oned figures. ~

Full-Size Pattern

August/Se ptember 1989 75

A Hand-Rubbed Oil finish
by Thom as Wisshack remov e the scratches from yo ur previous sanding and begin the
The use of oi l on woo d is par t of an anc ient trad ition. An oi l polishing action.
fini sh is a good cho ice for objects which won' t be exposed to In a short time you will not ice the grai n and color of the wood
liquids or getting a lot of hard use. It ' s an o pen- po red finish, one comin g into sharp focu s. Further the effect by switching to
that will enhan ce the color and grai n on both traditional and 400-grit paper. Compl ete the sanding by burnishing with a worn
contemporary furniture and develop a beautiful pat ina over piece of 400-grit paper. Gentl y round all sharp corners. Check
time . I like to think of it as an ongoing, living finish because you for imperfections, first with a strong light ,
can renew it by adding a coat of oi l at any time. With eac h then with your fingertips. Your fin gers
application , it seems to get rich er and ga in more depth . True , it will tell you if your project is
can take several week s to produce a good oi l finish, but the time ready for fini shin g.
and labor payoff in the end with super ior results.
To crea te a hand -rubbed oi l finish, begin with a flaw less,
glass-smooth wood surface- an essent ial foundation
for the coats of oil you will apply later. Begin
by removing machine mill
mark s and other
flaws

with
sharp cab inet
scraper. Don 't rely on
sandpaper alo ne to take out
. the dips and valleys in your
work- sandpaper can
even make the problem
wor se. Next, rai se the
grain of your wood with a
sponge dipped in hot wa-
ter. This force s any imper-
fections to the surface so
that you can more easily
sand them off. It also
makes your piece less
tro ubl esome to repair
later, if it come s into con -
tact with water.
When the wood is dr y, you 're .
ready to sand . Stock up on 220-, 320- and
400-grit silicon carbide wet-or-dry sand -
paper. You'll find that it cuts better, stay s Although
sharp lon ger , and per- form s the final a number of oi I
polishing that ordinary abras ives can 't. finishin g product s
For large, flat areas attach a piece of220- grit on the mark et will gi ve yo u
paper to your orbital sander. For hard to satisfactory result s, I encourage
reach spo ts use a rubber sanding block or a you to mak e your own oil solution. Be-
piece of softwoo d covered with shee t cork, cau se the ingredient s are so sim ple and inex-
and sand with the gra in in lon g , e ve n pen sive, and becau se the sense of acco mplish me nt
strokes. Vacuum your piec e before going in making yo ur own wood finish is so stro ng, every
on to the next grade of abrasive to pre- woodworker should ex perie nce it. Begin by mi xing three parts
vent loose grit from ruin- ing the work. Re- Thomas Wisshack is a furnit ure make r. restorer. and fini sher in
peat the process with 320- gri t paper to Galesburg , Illinois.

76 Popular Woodworking
 "in
"8
o
~
~
1>
'"
o
15
-a. L-- - - - - - - - - - - - - - - - - - - -- - - - - --'
The author rub s down the first coat of oil 01/ this wail/lit writing
table with rotten ston e and a pad of steel wool. Above, the finished
piece.

August/September 1989 77

'--
boil ed linseed oil to one part pure mineral spirits. Add a few
drop s ofJapan drier (ava ilable at mo st pain t stores), about 5% by
volume.
For the first coat , get maximum penetration by warming the
jar of oil in a double boil er or e lectric glue pot co nta ining about
an inch of water. With oil , yo u needn 't worry about absolut ely
du st-proof conditions. Flow on a liberal am ount with a natural
bri stle brush. Cover ea ch area quickl y to avoid uneven absorp-
tion, and work the oil into the pores of the wood. Let it soa k in
for twenty or thirt y minutes and then sprinkle the surface with
rottenstone abrasive powder. Giv e your project a vigorous rub
with a piece of burlap or some stee l wool. Be sure to work with
the gra in of the wood , since the burl ap and rott enstone can leav e
fine scrat ches if used carelessly. Put plenty of energy into
rubbing down your first coat of oil-it should provide a
gla ss-smooth foundation for the remaining applications. Re-
mov e all traces of oil from yo ur work with soft rags and dispose
of these highl y flammable item s immediatel y, preferably by
submerging them in water and removing them from the shop.
There are vast differences of opinion on how long to let an oil
finish dry between coat s; overnight see ms to be the minimum ,
and two weeks the maximum drying time used by various
finishers. I prefer waiting from one to two weeks betw een coa ts
becau se a shorter drying time leave s a greasy look to the wood ,
espec ially after many coats. With oil , you're not ju st lettin g the
coats dry, but beginning the process of curing- harde ning the
finish. When matching antique pieces, I wa it an es pec ially long
time between coats in ord er to impart a hard , cured shine that
matches the old fini sh.
You can adju st the drying tim e by adding Japan drier to your
oil solution. The drier not only forces the evaporation of the
78
Th e classic lin es of this
mahogany lowboy are
accentuated by a hand-rubbed
oil finish,
iii
~
o
~
~
>.
.c
~
'"
- ' s:
0.
min eral spirits, but it force s the evaporatio n of the oil as we ll.
Even if yo u choose to use one of the commerc ial oil finishes, try
experime nting with small amounts of drier to be abso lutely
ce rtain it will dry properl y. In this way you safeg uard against
unforeseen cha nges in hu m idity and pec uliarities in wha tever
wood yo u are working with. In short , yo u wan t to obta in a tough
film of o il in the shortes t time poss ible.
For the seco nd coa t use a brush as be fore, but skip the burlap
and rottens tone and simply wipe the surplus off with rags. After
another wai ting period, add a third coat by simp ly dipping a soft
rag in the o il so lution, applying it and w iping off the surplus. In
time yo u will ge t a fee ling for ho w man y coa ts it will take to get
the look you want on yo ur project. T he beaut y of oil is that there
is no lim it to the number of coats yo u ca n apply, and if do ne
prop erly, eac h will give your work more depth than the last. At
the very minimu m, I suggest yo u apply fo ur coa ts. The lowboy
in the photo above was finished using six coat s of oil.
On e reaso n why oil fin ishes appea l to so many craftsmen is
that there is no thick acc um ulation of varnish or lacq uer to
scratch and chip off. When a sp ill or minor scratc h does occ ur,
it ca n usuall y be repaired simply by dipp ing a pad of 0000 steel
wool into the o il so lution and rubbin g ou t the dam aged area . For
slightly hea vier dam age, "wet-sand ing" with a worn piece of
400- grit silicon ca rbide paper usuall y does the trick . Remem ber
that the surface of your piece will cha nge co lor in time, so use
this last sugges tion with some ca ution-s-don' t sand too dee ply
and reveal the inner co lor of the wood . In the photo at the
beginnin g of th is article , the top ofa wa lnut wri ting tabl e is being
revived with a pad of stee l woo l dipped in oil. Adding a small
amo unt of rottenstone powder will make a paste to help restore
the original shee n. ~
Popular Woodworking
The Turners r Page

Egg
Cup
by John A. Ne lson
A lthoug h th is egg cu p is a sim ple
turni ng proj ect , it m ak es a great gift for
those who ha ve hand-erafted decor ati ve
eggs to d ispl ay. o r fo r those who j ust like
to eat the ir hard -bo iled eggs in sty le. It ' s
turn ed fro m a solid piece of hard wood Q;
two inch es in diamet er and abo ut fo ur 15
"-
inc hes lon g. A ny nic e piec e of hard wood ~
w ill do , like th e spa lte d m apl e I used . Its ~
fu ng i-i nd uced m arkings pro vide inter- li
es ting a nd unusu al detail beyond the ~
mapl e' s c lassica lly s im ple gra in pattern. c.L- ---.J

Secure the block to a turning plate by ~ r------------------------------...,

first g luing it to a piece of sc rap wood that ~
is about 3" in di am eter. For eas y se para- "
oS
li 2 0 I A .- ~---~--.....,..,. - - ----r---.-
tion late r, insert a piece of paper be twe en .:5,
. \ I
the g lue surfaces, o r use a hot g lue g un to ~ \ I
join the block and the scrap. Aft er turn ing ~
I
I /T I
11
the o utside surface to sha pe . care full y c ui
\ 3/4 R
l / ;'
IS DIA .
o ut the inte rio r sha pe . A sa fe and easy way
to begin is by drill ing a 1" di am eter hole
'~ 2
a bo ut 1" deep . Then sta rt w ith the o utside <,
.... ;'
/ ~
9 -- --
wa ll of the hole yo u ' ve drilled and work
yo ur way o utward. T o ge t the exact size 116 0 I A. t ::::;:::::;::::::;:::; ::::==::;:::=7 ~I/ 4
and sha pe of the int eri or space. yo u mi ght
3 f
wa nt to use a lar ge egg o r. if the c up is for 1 IA . 9 /16
d ispl ay. wha teve r yo u plan to put in it. 4D
Sand the c up a ll over with a fine sa nd- I 3/16 DIA .- '-
pap er a nd fin ish it wi th two or more coats
I 1/2 DIA.- _ _ __ 3/ 16
of a sa tin va rn is h. Finall y, cut a piece of
5/ 16
fe lt to size and g lue it to the bottom of the
c up. Now find an egg- and don 't forget
to hard boil it! ~
J ohn r1. Ne lson is the author of numerous
hooks and (J Contributing Editor 10 Popu lar
Woodworkin g.

August/Se ptember 1989 79

 Calendar
Events of Interest to Woodworkers
working.
If your group is having an event For information, contact: Eric Nelson,
youwou,ld likeother woodworkers Museum Curator, at (707) 579-1500, or
it o hear about, please send usall Thomas Stockton, Show Chairman, (707)
' pertinent' information at least 795-8618.
three months beforethe opening
date. We will publish it for you in Date: October 2-6
Calendar free ofcharge. Event: Afive-day reliefcarvi ngworkshop
with William H. McMaster
California Location: Lighthouse Art Center, 575US
Highway 101 S. CrescentCity
Date: August 9-13 Techniques covered include creating
Event: The Pacific States Craft Fair an illusion of depth through foreshort-
Location: Fort Mason Center. Bay & ening and the illusion of distance
Laguna Streets. San Francisco through depth perspective. The class
Threehundred artists. newand estab- will emphasize advanced design tech-
lished, all producing high quality hand- niques.
madecrafts. have been selected forexhi- For information, contact: the light-
bition. All mediaincluding clay, basketry, house Art Center, 575 US Highway 101
fiber, jewelry, metal, mixed media, paper S., Crescent City, CA 95531. Tel. (707)
and wood, will be ondisplay. 464-4137.
For information, contact: American
Craft Enterprises, Inc., P. O. Box 10, 256 Date: October 6-8
Main Street, New Paltz, NY 12561 . Tel. Event: Northern California Woodwork-
(914) 255-0039. ing/Home Improvement Show
Location: Cow Palace, Geneva Avenue
Date: August 25-0ctober 29 & Santos Street, Daly City
Event: Artistry in Wood '89 Machinery, tools, supplies, demon-
Location: Sonoma CountyMuseum, 425 strations and workshops for beginning,
Seventh Street, Santa Rosa advanced and professional woodwork-
This annual juriedshow presentedby ers, turners, carvers, homebuilders and
TheSonomaCounty WoodworkersAsso- rernocelers.
ciation features work by leading amateur For information, contact: Michelle
and professional woodworkers in Son- Troop, 1516 South Pontius Avenue, Los
oma County, andincludesweekenddem- Angeles, CA90025. Tel. (213) 477-8521
onstrations of various aspects of wood- or 1-800-826-8257.
12 SHOWS IN FALL 1989!
Free Workshops * 100 Exhibits * Win a Jeep 4x4
Connecticut
Date: August 18-20
Event: Summer Crafts Festival
Location: Berlin Fairgrounds, Berlin
All shows are juried, with 200 to 250
exhibitors and 15,000 to 25,000 public
attendance per show. Indoor ($180)
and outdoor ($200) spaces available.
Submit five product slides and one
booth display.
For information, contact: Arts & Crafts
Festivals, P. O. Box 412, Canton, CT
0601 9. Tel. (203) 693-6335.
Illinois
Date: October 6-8
Event: WoodworkingWorld
Location: Metro Center, Rockford
Close to "Little Switzerland," an early
immigrant settlement, the show will in-
cludedemonstrations of Swiss chipcarv-
ing and Swiss cabinetry teaching tech-
niques.
Forinformation, contact: Woodworking
Association of North America, P. O. Box
706, Plymouth, NH 03264. Tel. 1-800-
521 -7623 (Monday-Thursday) or (603)
536-3768.
Maryland
Date: October 13-15
Event: The Baltimore/Washington
Woodworking Show
Location : Festival Hall, 1 West Pratt
Street, Baltimore
Machinery, tools, supplies, demon-
strations and workshops for beginning,
when it will travel the rest of the year to
galleries and museums throughout the
cou ntry. Entrants will benotifiedof accep-
tance by November 6.
For information, contact: The Worc-
ester Center for Crafts, 25 Sagamore
Road, Worcester, MA 01605. Tel. (508)
753-8183.
Michigan
Date: September 22-24
Event: The Metro-Detroit Woodworking!
Home Improvement Show
Location: Cobo Hall, 1 Washington
Blvd., Detroit
Machinery, tools, supplies, demon-
strations and workshops for beginning,
advanced and professional woodwork-
ers, turners, carvers, homebuilders and
remodelers.
For information, contact: Michelle
Troop, 1516 South Pontius Avenue, Los
Angeles, CA 90025. Tel. (213)477-8521
or 1-800-826-8257.
Minnesota
Date: August 13-19
Event: Sixth Annual Villa Maria Wood-
carving Workshop
Location: Frontenac
Classes planned include caricature
carving, relief carving, stylized carving,
songbird & waterfowl carving, carousel
horse & fish carving, and marquetry.
Classes will be available forexperienced
and beginningcarvers.
For information, contact: Villa Maria
Workshop, P. O. Box 37051 , Minneapo-

* The
Woodworking Shows *
advanced and professional woodwork-
ers, turners, carvers, homebuilders and
remodelers.
For information, contact: Helen Fill-
lis, MN 55431.

Date: September15-17
Event: The Twin Cities Woodworking
man, 1516 South Pontius Avenue, Los Show

~
Angeles, CA 90025. Tel. (213) 477-8521 Location: St. Paul Civic Center, 143
machinery or 1-800-826-8257. West Fourth Street,St. Paul
tools supplies Machinery, tools, supplies, demon-
Massachusetts strations and workshops for beginning,
advanced and professional woodwork-
SEE TH E WI DEST VARIETY OF WOODWORKING Date: September & October ers, turners, carvers, homebuilders and
PRODU CTS UNDER ON E ROOF Event: One-week workshops in House remodelers.
Renovation (September 11 -15), Finish For information, contact: Helen Fill-
Hundreds of Items
Carpentry (September 18-22) and Cab- man, 1516 South Pontius Avenue, Los
Machinery Power & Hand Tools > Supplies inetmaking(October 2-6) Angeles, CA90025. Tel. (213)477-8521
Sept. 8-9-10 Greater Cincinnati Cincinnati Conven tion Center Location : Heartwood School, Johnson or 1-800-826-8257.
Sept. 15-16-17 Twin Cities St.Paul Civic Center Hill Road, Washington
Sept. 22-23-24 M etro-Detroit Cobo Hall, Detroit For information, contact: the Heart- North Carolina
Sept. 29 - Oct. 1 Western Washington Seattle Center wood School, Johnson Hill Road, Wash-
Oct. 6-7-8 "No, Calif ornia Cow Palace, San Francisco ington, MA 01235. Tel. (413) 623-6677. Date: September 22-24
Oct. 13-14 -1 5 BaltimorelWashington Festival Hall, Baltimore Event: Woodworking World
Oct. 20-21-22 Pillsbu rgh Tri-State Pillsburgh ExpoMart, Monroeville Date: September 22 Deadline Location: M. C. Benton Convention
Oct. 27-28-29 Central Florida Curtis Hixon Conv. Ctr., Tampa
Nov. 3-4-5 Oregon Portland Memorial Coliseum Event: Woodturners of the Northeast Center, Winston-Salem
Nov. 10-11-12 So. California Los An geles County Fairgrounds 1990 The show will include router master
Nov. 17-18 -19 San Diego Convention & Perf. Arts Center Location: Worcester Center for Crafts, Brad Witt who will share his knowledge
Dec. 1-2-3 Delaware Valley Gard en State Park, New Jersey 25 Sagamore Road, Worcester and techniques.
The Center for Crafts and the Central Forinformation, contact: Woodworking
'Specia/ Woodworking/Home Impro vement Show
New England Chapter of the American Association of North America, P. O. Box
Seminars by Ian Kirby - Roger Cliffe - Bob Rosendahl Associationof Woodturners invite turners 706, Plymouth, NH 03264. Tel. 1-800-
Rude Osolnik - Nick Cook - and other Master Craftsmen from the northeastern states to apply 521 -7623 (Monday-Thursday) or (603)
1800-8268257 or 2134778521 for entry to an exhibition. Juried by 536-3768.
Call for free bro chure , 8:30 - 5 Pacific Time p Vermont turners Alan Stirt and Michelle
Holzapfel, the show will be on view at Ohio
Save $1 off reg. $6 admission with this ad the WorcesterCenterfor Craftsfrom Feb-
ruary 10, 1990, through March 17, 1990, Date: September 8-1 0

~o Popu lar Woodworking

Event: The Greater Cincinnati Wood-
workingShow
Location: Cincinnati ConventionCenter,
525 Elm Street, Cincinnati
Machinery, tools, supplies, demon-
strations and workshops for beginning,
advanced and professional woodwork-
ers, turners, carvers, homebuilders and
remodelers.
For information, contact: Michelle
Troop, 1516 South Pontius Avenue, Los
Angeles, CA 90025. Tel. (21 3) 477-8521
or 1-800-826-8257.
Oregon
Date: October 15
Event: A seminar in Precision Wood-
workingon a Small Scale
Location: Oregon School of Arts and
Crafts, 8245 SW Barnes Road, Portland
The instructor willbe Ken Altman and
thefee is $33.
For information, contact: Becky Ban-
yas, Oregon School of Arts and Crafts,
8245 SW Barnes Road, Portland, OR
97225. Tel. (503) 297-5544.
Pennsylvania
Date: October 2022
Event: The Pittsburgh Tri-State Wood
working Show
Location: Pittsburgh ExpoMart, 105 Mall
Blvd., Monroeville
Machinery, tools, supplies, demon-
strations and workshops for beginning,
advanced and professional woodwork-
ers, turners, carvers, homebuilders and
remodelers.
For information, contact: Michelle
Troop, 151 6 South Pontius Avenue, Los
Angeles, CA 90025. Tel. (213) 477-8521
or 1-800-826-8257.
Tennessee
Date: September 9
Event: One-day seminaronsmalldrykiln
technology
Location: Log Home Guide Information
Center, Cosby
Air-drying, kiln types, and kiln drying
techniques willbepresentedby technical
experts, and should be of special interest
to people interested in drying from 1 to
5,000 board feet of lumber per month.
Jointly sponsored bythe Tennessee Val-
leyAuthority, Tennessee Valley Dry Kiln
Association, and Log Home Guidemaga-
zine.
For information, contact: Bill Parrish,
TVA Forestry Building, Norris, TN 37828.
Tel. (615) 632-1656.
Vermont
Date: August19
Event: TheSixteenthAnnual Wood Carv-
ers Exhibit
Location: Peoples Academy Gymna-
sium in Morrisville
Exhibits, sales and carving demon-
strations willrun from 9 am to 4:30 pm.
For information, contact: C. A. Brown,
Exhibit Coordinator, P. O. Box 268, R. F.
D. 1,Waterville, VT 05492.Tel. (802)644-
5039.
Washington
Date: August 3-September 3
Event: Dark Dancers
Location: Northwest Gallery of Fine
Woodworking, 202 First Avenue South,
Seattle
New works in exotic woods by Jon-
athan Cohen willbe showcased.
Forinformation, contact: Cheryl Peter-
son, 202 First AvenueSouth, Seattle, WA
981 04. Tel. (206) 625-0542.
Date: August 12-13
Event: Artwood exhibition and demon-
stration
Location: Artwood, 1000 Harris Avenue,
Bellingham
Artwood,aco-opgalleryofwoodwork-
ers, will displayfine furniture and acces-
sories of textiles, glass, ceramics and
painting. On August 12, Vernon Leibrant
will demonstrate lathe turning.
For information, contact: Artwood,
1000 Harris Avenue, Bellingham, WA
98225. Tel. (206) 6471628.
Date: September 2
Event: Artwood exhibition and demon-
stration
Location : Artwood, 1000 Harris Avenue,
Bellingham
Artwood will displayfine furniture and
accessories of textiles, glass, ceramics
andpainting. OnAugust 12, Len Zeoliwill
demonstrate lathe turning.
For information, contact: Artwood,
1000 Harris Avenue, Bellingham, WA
98225. Tel. (206) 647-1628.
Date: September7-0ctober 1
Event: The Artof Chairmaking
Location: Northwest Gallery of Fine
Woodworking, 202 First Avenue South,
Seattle
ChairsbyNorthwest woodworkerswill
bedisplayed.
For information, contact: Cheryl Peter-
son, 202FirstAvenueSouth, Seattle, WA
98104. Tel. (206) 625-0542.
Date: September 29-October 1
Event: The Western Washington Wood-
workingShow
Location: Seattle Center Coliseum, 305
Harrison Street, Seattle
Machinery, tools, supplies, demon-
strations and workshops for beginning,
advanced and professional woodwork-
ers, turners, carvers, homebuilders and
remodelers.
For information, contact: Helen Fill-
man, 1516 South Pontius Avenue, Los
Angeles, CA 90025. Tel. (213) 477-8521
or 1-800-8268257.

This machine will pay for itself time

Super 125 Planer and again by planing your own lumber.
Portable with "Power Feed" Shipped At 65 Ibs, you cancarry thisPlaner to a job
assembled Retail value over $600.00 site or mount it permanently in your
workshop like any stationary machine.
On Sale ... $349.95 You'll spend hundreds of dollars less
for this 12-1 /2" power feed Planer thanfor
a traditional stationary model of a similar
capacity- with comparable results.
SPECIFICATIONS:
Knives.... 2ea, 12-1/2" wide, HSS
Motor - 16 Amp , 115V , 8000 RPM
Auto Feed rate 26.2 FPM
Cutting speed 16000 Cuts/min
Thickness of stock ..... 3/16" to 6"
Add $15 Size ... 15-1/2" H X 22"W X 21" Bed
UPS Max Depth of cut 1/8"
Freight Machine Weight 65 Lbs
Planer & Accessories Price List
s~~c;..~.~.~..~Ia.~~r..-..c.o.~.P.I.:.t.:..~.~.d..~.~~~~~I~d349.95 ($1 5 UPS)
Extra Set 012 Knives - Highspeed steel, 12-1 2"
#PKN $ 25.00/set (. )
D~~bhU.~~.:.~~~.~a.c.u.u.~..t.~.~~~~.~~.~.~.~his24.00 ($3 UPS)
Planer stand - Heavy duty, 27-112" high
#PST ..reg. $44.00, On Sale $ 39.00 ($6 UPS)
Ball BearingRollers - (Minimumpurchase2 rollers )
Buildroller stand, infeedloutfeedtableetc. w/lhese 13-x2- Heavy
Duty rollers. Includes FREE plansforbuilding roller stand shown
above. #BBR $ 6.50fea ( $3 UPS/per order)
( ) No freight chg ifordered wlPlaner, otherwise add $3UPS

DC-1 Dust Collector Add $20

UPS
On Sale ... $189.95--------.... Freight

Keep your shop clean and safe from FREE

sawdu st with our large capacit y, with Purchase of DC-1 PENN STA TE IND USTRIES-P
commercial style system. This collector 20 Feet Of Duct Hose
has up to 10 times more air flow than a 2850 Comly Road Phila, Pa 19154
4" To 3" Rigid Adaptor
ShopVac and runs much quieter. 4 " To 2 " Flex Adaptor Order Toll Fr ee 1-800288-7297 (Ext 90)
SPECIFICATIONS:
Plans For 2 Stage Setup For information 1-215-676-7609 (Ext 15)
Piping & Fittings Sources Visa. Master. & Disco ver Card acc ept ed
1hp, 110/220V (pre wired 110V) Free $15 Value Penn sylvania resident s add 6% Sal es Tax
610 CFM air flow
6990 FPMair speed 2 Bags 1S"dia X 22" 20 gallon bag Add UPS Shipping Cha rges as noted
4" inlet Casters on base Weight 751bs Size - 26"x15"x57"H Continental U.S. only (Callfor shippingcharges toother locations)

August/September 1989 81
WZL22 ORDER YOUR BACK ISSUES OF POPULAR WOODWORKING TODAY! ~
~ ~
~ ~
~ Check out our exciting woodshop plans and techniques. ~
~ You're not just ordering a magazine, ~
~~0 you're ordering 4-6 sets of plans you can use! ~
~
~
~
i/1
#1 0 May 1981
Sound and Its Effec ts
$ 1.00 #28 0 Dec/Jan 1986
Cedar Hope Chest
$2.95 #38 0 Aug /Sep 1987
Dovetail Join ery
$2.95 ~:
'
v.i Good will' s Contract ShOI} The Sham isen Process Connecticu t River Valley ~.)
~ #2 0 July 1981 $ 1.50 Blind-Wedged Peg Joint Desk on Fram e ~

~
~: Assembly Furn itu re #29 0 Feb/March 1986 $2.95 #39 0 Oct/Nov 1987 $2.95 ~
Solar-Heated Wood Dryer Making a Pian o Bench Reli ef Carving ~
~ #6 0 April/May 1982 $ 1.50 Signaling Sailor Whirligig Make Your Own Handscrew ~
~ Makin g Wooden Boxes Carving the Human Head Clamps V:1
, '
~ Abrasive Belt Cleaner Test Report #300 April /May 1986 $2.95 Tall Ch est of Dra wers fa
~ Tabl e Saw Hints Mortise ana Tenon Joinery #400 Dec/Jan 1988 $2.95 ~
', ),
~
V #7 0 June/July 1982 $ 1.50 Teak Serving Cart Making Box Joints on the ~
V) Interview with Sam Maloof Trestle Tahle and Stool Tab le Saw i'/',
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~ Mak e a Mal oof Tabl e Pedestal #31 0 June/Julv 1986 $2.95 Biplane Walker ~
~
~ Create a Mal oof Finish Make YOUI' Own Solar Kiln #41 0 Feb /Marchl988 $2.95 %
~ #8 0 Aug/Sept 1982 $ 1.50 Making a Watch Clock Makin g a Jewelry Chest ~
~ Starting a Wood working Business Penultimate Patio Chair Wooden Buckets ~
~ Tabl e Saw Maintena nce #32 0 Aug/Sep 1986 $2.95 DI}' Sink 7V Cabinet ~
~ Rockwell Speed Block Sander Mart ha Thompson' s #420 April/May 1988 $2.95 e8
~
~
#9 0 Oct /Nov 1982
Staining Wood
$ 1.50 Magical Mirrors
Power Carver's Tool Cabinet
Designin g for
Dim ensiona l Change
fa~
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, a' Quest fo r the Thinn est Blade Building a Wine Rack Ga rden Cart ~
V) Ma rketing #33 0 Oct /Nov 1986 $2.95 Diamond Hones Review ~
~ #10 0 Dec/Jan 1983 $ 1.50 How to Make a Serving Bowl #440 Aug/Sep 1988 $2.95 ~
~ Selecting a Portable Sander Home Entertainment Cente r Baby Dresser 0
, ',
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V) Sealace ll Wood Fin ish Art ofSandblasting Wooden Signs Peeled Branch Settee ~
(~
~ Test Report #340 Dec/Jan 1987 $2.95 Mari onette rd
~ Evolution of an All-Wood Universal Tahle Saw #45 0 Oct/No v 1988 $2.95 ~
~ Box Design Veneered Vertical Tambours Corner Pewter Hutch ~
~ #11 0 Feb /March 1983 $ 1.95 Build- It-Yourself Co untry Sco nce ~
~ Model Ma king with Laser Backgammon Board Ma ssach usetts Lowboy ~
~ Techn ology #35 0 Feb/March 1987 $2.95 #460 Dec/Jan 1989 $3.75 ~
v:i Estimating and Bidding Building a Burcher Block Wa lnut Dining Table :1")
~ Wood Finishes Work Center Chi ld's Cupboard ~
~ #250 June/July 1985 $2.25 Ladder-Back Rocker Japa nese Handsaws ~
'~ Octago nal Pedestal Tabl e #360 April /May 1987 $2.95 #470 Feb/March 1989 $3.75 ~
r... ., In-The-Round Ca rving Folding Picnic Table Bendi ng Wood ~
~ Buildin g the Strip Canoe Carving an Arabian Duck Basket ~
~ #270 Oct /Nov 1985 $2.95 Stallion-Part I A Tilting MIrror ~
~ The Compu ter Desk #370 June/July 1987 $2.95 #480 April/May 1989 $3.75 2:1

~
"V) Alternat e Bow l-Turn ing Techn iques Interview with James Krenov Victori an Table~ ~~,
Cradle Tabl e with Ma gazine Bin Plate Join er Test Report Decorative File Cabi net ~
~ Koa Dinner Table Carving Carousel Animals ~

a~ #490 June/Julv 1989

Co lonial f ootstool
$3.75 ~
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~ ~~ ~
~ Wa ll Cab inet ~
~,, Y All available back issues for ' 1----------------, ~
~ only $70.00. Plea se send my back issues to: I ~
~ Thi s price includes postage and handling. Name I ~
, (Add $8 .00 postage fo r foreign countries .) Address I ~
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~ If :,~~:.~:~::';:::;,~::~~~:~;:'$~P'::;:; ,:~~;:~". I DPm ona' Check D Visa/Mastercard : ~
~ I Card# Exp. Date I ~
~ L -.J ~
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Se nd your orde r and payment to:
Popular Woodworking Back Issues, 1320 Galaxy Wa y, Concord, CA 94520.
~
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!2zLZ7~LZ!ZUZZTb7J..LL7ZZT..._:'7....mr..._:'7_LZ227'Z/222Z27J.L2LZ2Z?27~J7Z72?'ZZ720?Z27~~L0'LLZ227ZT&
 PACIFIC BRASS
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Vict or ia . S .C . Ca nada \' 8
RockiQg Horse Iiit .. Catalogue $2.00
Build th is beautiful 38 " rocking horse yourself . and have a family
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Phone: ( 8 13) 251-6583

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Our unique Lettering Guides are available in many
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Send $1.00forbrochure and pricesto:
1414 Cranford Drive Balls. Knobs
IEYCO
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P. O. Box 472749
Garlan d, TX 75047
1045 N. Highland Ave, Dept P50
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Au gu st/S ept ember 1989 83

I CLASSIFIED MARKET
FREE ILLUSTRATED CATALOG of books for HOMESTEAD HARDWOODS: Kiln-dried ash ,
I TOOLS woodworkers: instructions, scaled drawings, pat-
terns for furniture, toys, house carpentry, duck
basswood,butternut,cherry,chestnut,curly maple,
oak, poplar, sassafrass , walnut. Send
decoy, bird and figure carving, chip carving, wood self-addressed, stamped envelope for price list.
sculpture, lathe work, more. Most $4.00 to $6.00. 2111 Messick Rd., N Bloomfield, OH 44450, (216)
Write: DOVER PUBLICATIONS, Dept. A226,31 E. 889-3770
2nd Street, Mineola, NY 11501
RT. I BOX 14A OE PT. PW
RHINEBECK. NY12572
(914) 876-7817
SEND $1.00
FOR CATALOG
LEATHERCRAFT GUIDE-NEW 54-PAGE
WHOLESALE CATALOG. $2. (Refundable!)
I PLANS AND KITS
ATIENTION WOODWORKERS! Shaker Pegs,
MAKE YOUR OWN LUMBER-band saw mill. Leather Unlimited, PW0589, Belgium, WI 53004- Toy Parts, Candle Cups, Sawtooth Hangers, Spe-
Horizontal traversing, power feed, power-loading 9990 cialty Wood Products. Wholesale Prices! Satis-
winch, 5-20 hp. Build/$1800. Literature/$3.00. faction Guaranteed. Free Catalog. Craftmasters,
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E. Hartford, CT 06108, (203) 289-6151 (0058989) $2.00. Little Shepherds, Dept PW, 9658-E W.
CHILDREN'S FURNITURE plans and instructions.
Chatfield Ave., Littleton, CO 80123
Introductory offer 5plans for$4.95:desk,table and
STAINLESS STEEL AND BRASS, SCREWS
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el&nt'""
' ~15
SEND S1,OOFORCATALOG TO
COVER POSTAGE & HANo...lNQ
WESTERN HARDWOODS, figured lumber, burls,
squares, slabs, whole sample kits, SASE list: Eu- DINOSAUR PATIERNS, 6 full-size patterns for
reka Hardwood Supply, 3346 0 Street Eureka, CA wooden jointed dinosaurs. Great profit orgiftidea.
BOOKS.& CATALOGS 95501 (707) 445-3371 Send $6.75 for "dinosaurs"toDAKOTA WIND, Box
866pw, Jamestown, NO 58402
88 EASY-Te-MAKE AIDS FOR SENIORS. Use QUEEN ANNE TABLELEGS,pedestals, feet, and
only inexpensive sewing or woodcraft materials. finials in walnut, cherry, and mahogany. Send SIMPLIFIED PLANS for wooden-gear,
Great Christmas gifts. Details: AWE, Box 1150, $1 .00 toSouthern Country, Box6,Sharpsburg, NC weight-driven, pendulum regulated clock. $10.00.
Chino Valley, AZ 86323 27878 for brochure BOB MEYER, Rt.1 , Box 275, Elgin, MN 55932

X4 Popular W ood workin g

I
ROUGHED OUT BLANKS, 35 different 80%
CLASSIFIEDMARKET
SPRAY-ON SUEDE LINING: Finish any project PICTURE FRAME MOULDING 25 CENTS PER
roughed out basswood blanks of birds, animals, with a soft touch. Free Brochure with sample. LINEAR FOOT, FOB Pensacola, Florida. C, Stan-
and characters. Also supplies. Free brochure with DonJer Products, Ilene Court-Bldg. 8G, Belle- der, 932 Springmier Place, Pensacola, FL
SASE to West FallsWoodcarving P, 7458 Ellicott mead, NJ 08502, (800)336-6537 32514,(904) 968-6424
Road, West Falls, NY 14170, (716)662-3648 POST OFFICE BOX BRONZE DOORS;No 1 & No BUSINESS CARDS printed especially for the
SUPER WOODCRAFT PATTERNS windmills, 2-4 for $21 .00; No 3-$8.00 each Post Paid, woodworker. Free samples, Mercury Press, Box
wells, vanes, whirligigs, bird houses, jigsawing for Lewis, 1649 McDowell Rd" Jackson, MS 39204 51-W, Broadway, NJ 08808
fun orprofit. Catalog $1. CRAFTER'S,11840 North (601)372-2725
U.S. 27, Dewitt, Ml48820 CLASSIFIED MARKET INFORMATION :
18 NOTE REUGE MUSICAL MOVEMENTS and
ClassifiedRate: 95cents per word ; 15-word
WOOD accessories. Send SASE for information to:
WOODSMITHS, 128 Henry Road, Enola, PA minimum; Classified Display: $60,00 per
TOY 17025 inch for 1issue,$50.00 per inchfor6-time rate
* Patt erns Part s Wheels (6 consecutive issues). Payment must accom-
.. Executive Toys INFORMATIVE 192-PAGE CATALOG forwood-
t oys and joys * Se nd 51 for new ca ta log workers, woodcarvers, upholsterers, antique re- pany all Classified ads (not commissionable).
Box 628-P and receive coupon for
lynden. WA 98264 wh eels & axle peg s . storers, including many unusual, hard-to-find Deadline for Issue 51 (Oct./Nov. 1989) is Aug.
items, Send$1 .00 to Van Dyke's, Dept. 50, Woon- 1, 1989, PopularWoodworking, 1320Galaxy
ADIRONDACK CHAIR & MATCHING BENCH
Attractive, durable, perfect for yard/patio. Full-size socket, SO57385 Way, Concord, CA 94520, (415) 671-9852,
patterns PLUS woodcraft catalog $7.00. AC- POST OFFICE BOX BRONZE DOORS; No. 1
CENTS (AR-69), Box 7387, Gonic, NH 03867 $5.00; No.2 $5.00; No.3 $9.00, plus $1 .00 each
Index to Advertisers
nL'OODC~RA~FT
shipping. SASE : Hubbert Woodcrafts, P.O. Box
1415, Fletcher, NC 28732. (704) 687-0350

Door Harp Parts

WI'~~W~Gl~~
aii t~ i~ljii,,~!t':~ti:ill:ti~;t.];,f.j :ll.
Same Day Service
Tun ing Pins : 1 00 for $18 .00 , 500 fo r $75 .00
W ire : 25 fl. for $ 2 .50, 350 ft . for $15 .00
Bart ley Coll ection
Brown Wood Products 83
9

10 20 0 patt ern pack et for sc ro ll. band & jigsaws I Wood Balls 3/, " 100 fo r $8 .00, 500/$30 .00 Clayton Enterprises II
'0 " Co unt ry Critters"-100 pa tte rns . uniq ue proj ect s I V isa & MC ( 5 1 6 ) 4626228 Catalog $1.00 Daniel ' s Discount Tool s 17
:0 6 enjoyable "W ind-Ac t io n" Whi rligigs I Sh ipping charge $2.50 ...... NY Res. add t ax
10 "Count ry Classic s" - be st se lling c ount ry projec ts: ARMOR Box 445. Eas t Northport. NY 11731 Delta International Machinery 8
:0 100 yar d o rna me nts , animals, bird s and more I
Dollar Trading Corp. 15,19
10 17 ' Show Stopp er s" - c raft sho w best selle rs :
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: Send 57 .00 p e r packet or 3 FO R O N LY 514.00.: Econ-Abrasives II
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Tra nsl uce nt Stick s 1/2" Diameter
\. _C:~ ~~ ~f ~ ~~!'~t~e:n: ~:O_O~ ,:.,,:.e_w~l~ ~r~:;I~ _.J 4" or 10" Length. Grizzly Import s 2,5
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100 FULL-SIZE WOODCRAFT PATTERNS: SUPERTACK XO'J STIC KS PRO-90 TRIGCER GUN High land Hardware 83
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Windmills, Birdhouses, Toys, Etc, $4.50. Catalog IOl b
aste
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alone $.50 Hayes Patterns 6E Willow Street, 5O11. 518250 7.l2
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114 00 each
Leichtung Workshops 17
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PREMIUM QUALITY DISCOUNT PRICES FREEFREIGHT mosl ere
Lobo Power Tools 23

I
M
BELTS: BEST RESIN OVER RESIN, " 1 WEIGHT10 80 1
Ix 42 $ .70 ea 4 x 24 SI. OOea
3 x l8 .75 4136 1.25 Klockit 9

I
3 x 21 .80 6 x 48 2.80
3 x 24 .85 Pflces qu oled 80 g rit. ot her g u ts av o lla ble Makita 88
ADHESIVE CLOTH DISCS: BEST RESIN OVER RESIN, " X" WEIGHT
5" Dtcme ter $ .SOeo 9" $1.65 eo MLCS Ltd. 18,21
~ _~ IW 1.85
MAKE MONEY WITH YOUR WOODWORKING. 8" 1.30 12" 2.25 Old ham-United States Saw 11,12
Pnce s quoted 80 g u t. othel gu ts av a ila ble
Book shows you how. Covers different kinds of GARNET PAPER - ORANGE WATERPROOF PAPER - BLA CK
Pacific Brass Hardware 83
A..'OCABI NET PAPER - BROWN 180 thru 1200 100 PK $23 00
selling, pricing. credit,getting started. $5.00 Satis- 40 Gnl 50 PK $16.00
NO LOAD PAPER - WHITE
Penn State Industrie s 81
60 G w so PK 14.00
faction Guaranteed. In Print, Box 687PW 80 G n t 50 PK 13.00
180 thru 400 100 PK $20.00 Rodman 19
100.120.150. 100 PK 22.00 Also Sho p Roll . , C lo.h Sh....' . On. m.

Farmingdale, NJ 07727 180.220 100 PK 19.00 School of Clock Repair 9

CLEANING STICKS S3 50 SmaU $6 50 Large
RED HILL CORP.. P.O. BOX 1234, GETIYSBURG. PA 17325 Seyco Sales 83
IDEAL WOODWORKING BUSINESS. Unusual CAll TOll FREE - 1-(8001822 .0030< 17111 337, ' . ' 9 FA.X 17171337-3936
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I
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ticeship, Box 539P, Rockport, ME 04856 (207) The Woodworking Shows 80
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SrAINED GLASS
If yo u work wi th staine d glass, this mont hly maga zine
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Professional Stained Glass
245 Wes t 29t h si., Dept. o-s, New Yor k, NY 10001 PW, Woodville Road, Mansfield, OH 44907

August/Se ptember 1989 85

!8%
4w
O u t of
by Jeff Taylor
the
rN
W
oodwork
So much to do , so mu ch to do...
My wife' s in town, sho pping. I'm on
my ow n, with the blah s closing in.
Looking at all the projects und erway in
the vas t j umble of my sho p, [ desp air; the
eno rmity of the wo rk ahead makes me
tired. That cha ir ca n be undamped ; af ter
a week, the glue's surely dr y. No wo nde r
ou r hou se look s so empty; the darn
furniture mu st all be o ut here, under
co nstruc tio n or rep ai r. Th e floor need s
sweeping. A lot of the too ls bestre wn on
ben ches co uld use a goo d putting- away,
too.
But you know how it is; sunny wea ther
is the mother of procrastin at ion. And to
me , ge tting th ings don e is only a
byp rodu ct of doin g them enjoyably; [ try
to bal an c e acco m p lis h me n t w ith
relaxati on . Wh en I'm in puttering mod e,
1 usua\\y put peaceful classical mu sic on
the tapedeck.
Today, it look s like we ' ll have to pick
up the pace with some coffee. In my
yo uth, an old, wise wo odworker once
J eff Taylor continues to earn a hare
subsistence as a woodworker/writer in Burnt
Woods. OR.
"You are at your best when you lamin ate a sandwich."
86
The Caffeine Machine
admi tted, " I always take a full pot of
co ffee out to the sho p." A full [Jot ? I
mar veled then . Wh y, yo u' d twan g like a
banj o. " No , yo u need that mu ch whe n yo u
ge t o lder ," he laughed . " Wai t. You 'll find
out."
He wa s right. My tolerance for
caffei ne is still low, but a lot higher than
when I was a kid . Putt ing awa y three cups
of co ffee no lon ger mak es me wa nt to
part y all night and go drag rac ing. [ need
three cups, eve ry morning, j ust to co me
fully awake . As my mind starts to wa nde r
and my bod y break s down , I'll need five
cups j ust to pull me out of the rocking
cha ir. I'll be 40 any yea r no w.
Another wea riso me fac t co mes to
m ind : our old plastic coffee mak er
gurg led and died yes terday , unable to get
the water up to a boil. In hum an yea rs, it
was prob abl y my age.
I rummage throu gh the cupboa rds.
After some searching , I run across o ur old
es presso machine. Wh at was that old
expression?-Far out, man.
Now this brin gs back mem ori es:
Dr ivin g hom e afte r class in my oId
Vo lkswagen starship, after a few tin y
cups of es presso: my highly caffeinated
yea rs as a ca rpe nter, leadin g to my job in
a giant hom ebui lding corpora tion, and
mornings sipping the sca lding black j uice
before the commute in the BMW ; and ,
af ter the birth of our first child, those
fam ily picnics in our Honda Civic, wit h a
little T he rmos bottl e of es presso on the
sea t. Back then. we always seemed to be
drink ing it and go ing somew here .
My decision to stop rat-rac ing and
ea rn a bare subs istence as a woodwo rker/
writer cha nge d all that. We put away the
es presso machine and bought an old
pickup . Life is slowe r and simpler now, in
my sunse t yea rs . Ah, yes terdays .
It tak es a lon g tim e to make even a
small pot of espresso. But I can 't find
those ridi cul ou sly teen sy cups. Out in the
shop, I fill m y trusty old china mug with
the bitt er ebo ny syrup and take a fe w slugs
as I wo rk.
The infinit e number of jo bs qu ickly
dwindl es to a fe w thou sand. In fact, after
the second cup, Bizet and Beethoven ooze
out of the speakers like cla bbered varnis h.
So I slap in a different tape; something
loud, hard, and thumpy by Mick Jagger-
at full vo lume .
My hand s start to move in a blur,
plan ing, sa nding, staining, organizi ng,
and gr ind ing blad es to the mu sic.
Boomboom boom , wugga h...
Afte r my wife dr ives up, I hear her go
in the sho p, ca lling my name. She co mes
in the hou se to find me resting in a
co uc h-coma , but still popeyed and
tw itching .
" Gos h, yo u ' re am bitio us!" she
exclai ms . " I've never see n yo ur shop so
clean! And look at our furniture! Inside
the hou se. ye t! Th anks, honey. You mu st
be t ired. " S he be st o w s a
we ll-done-my- hero kiss on my sweaty
fore he ad.
My eyes whip up, and I start talking
in a fas t staccato. "T ired? Tired? Nope,
j ust ge tting warme d up. Go t a lot done,
all right , for sure; eve ry tool cleaned,
oi led, sharpened , and hun g up, too. Hey.
let me take a qui ck shower, and we' ll go
out for supper, a splatter movie, and
maybe some dancin g, OK ?" I snap erec t,
bon es creaking , rea dy to boogie. The
caffe ine sho uld bum off by tom orrow
morn ing . ~
Pop ular Woodworkin g
 No other mach ine has eve r attempted t o do w h at
th is mach ine does. This u ni q u e mach ine makes it
easy to do accurate boring , mortis ing , tenon ing ,
dovetails, carving duplication and more.
Us ing a table that moves i n two d irections and a
cutterhead that moves i n a th ird direction , many
convent ional (and some not so conventional)
joints can be cut qu ic kly and accurately (w ith-
i n .005" ).
By simultaneously co ntro ll i ng the pos itions of
the Table and Power Unit, the operator makes the
stylus-follower follow the template w h i le the cut-
ter is shaping the wo rk p iece to match the tem-
plate. The Tab le and Power Un it are moved w ith
very light forces resu lt ing in smooth and effort -
less operation.
Not only is each cut made quickly, but the chan ge-
over time (ti me needed to change from one cut-
ting operat io n to another) is much faster than
you 'd expect from a mach ine w ith so much versa-
til ity. For example , if you were cutting tenons and
wanted to chan ge over to cut the matching mor-
tises, the changeover t ime would be about 2
m inutes . That's fast for any mach ine , but the rea l
k icker is that tenons (ten o ns that take a tenon ing
j ig and 8 passes on a tab le saw ) take on ly a few
seconds on the Matchmaker":
Powered by a 2'1. to 3 HP plu nge router , the
Matc h maker? is small enough to f it i n any wood -
Patent #4,S93,73S, other patents pending shop . gO-da y mo ney-back guarantee.
Invented in USA Made in USA

SINGLE TENON TEMPLATES TABLE ever is less

Thickness Width Size: 17'/," x 12" Maximum tenon size: 10"
1/4 " 1" $21.50 In-out travel: 6" wide x S" high
1/4 " 1-1 /2" $21.50 left-right travel: 12" ACCURACY
1/4 " 2" $21.50 Force required to move: Stylusto spindle movement:
3/B" 1" $21.50 less than 4 oz. less than .004"
3/B " 1-1 /2 " $21.50 POWER UNIT Free table movement: less
3/B " 2" $21.50 Spindle RPM: determined than .003" (guide rollers
1/2 " 1" $21.50 by router used are on adjustable
1/2 " 1-1 /2 " $21.50 Drive: Bosch, Ryobi, Makita eccentri cs)
1/2 " 2" $21.50 or Hitachi 2';. to 3 HP Table motion deviation from
3/4 " 2- 1/2" $21.50 plunge routers straight li ne over full travel:
3/4 " 2" $21.50 Vertical travel: 6" less than .OOS"
3/4 " 3" $21.50 Force required to move: Typical overall duplicati on
less than 6 oz. accuracy (with stylus and
CAPACITIES bit of same diameters):
Maximum depth of cut: within .0 10 "
li mited by bit extension WEIGHTS
beyond collet or 6". which- Net weight: 30 Ibs.
I D E ~ ~~~~~ for ~ ~~ ~ e r'~--1
o Enclosed is my $2 .00 for a l- year subscript ion to your
catalog (eight issues).
NAME _

AODRE SS _

Cutting Edge CITY STATE Z iP _

Length. Overall Length
95- 860 3/4 " 2-3 /4 " $ 9.50 CATALOG TOTAL
95-861 1-1 /4 " 3-1 /4 " $10.50 QTY. NUMBER DESCRIPTION PRICE PRICE
95-862 1- 1/ 2'" 3-1 /2 " $13.50 8S2 00A Matchmake," to r u with $S48.00
95-864 3/4 " 1-1 /4 '" 3-1 /4 " $32 .50 BOlch . 1611 rouler
'W III cut deeper than this length with multiple passes. 95- 200B Matchmake,' tor u with $549 .00
Ryobl, Hllochl or Mokllo

BITS OR LARGE DOVETAI 802-02 1 BOlch 11811 120V routor 8239.95

132-012 1/2 " x 14 Dovetail bit $11.90 802-0 22 Balch 11811 220V ro uter 8264.50
132-063 3/4 " x 7 Dovetail bit $24.50 802088 Ryob l I R-500 ro uter 8189.00
132- 115 1" x 14 Dovetail bit $49.95
Us e addition al shee ts if ne eded .
TOTAL f - - -
Dept. PW 10 NEW M EXICO TAX 5.5% I - - -
o CH ECK EN CLO SEO GRA ND TO TA L ' - - -
O M.C .
o VISA

EXPIRAT IO N DATE

~
~
 Geauga Lake Park, Aurora, O hio Photo Ae rial Perspective , Lititz, PA

Dinn Corporation of Cincinnati, Ohio, depends on

quality Makita Power Tools to build exciting roller coaster
rides all over the United States. When you're working on
wooden structures hundreds of feet in the air, you've got to
have faith in the tools you use.
That 's why more tradesmen use Makita tools than
any other cordless. And tha t's why more and more
do-it-yourselfers and home craftsmen are turning to Makita.
Makita offers two complete cordless tool systems, each
with its own inte rchangeable battery. Choose from the
extensive 18-tool, 7.2 volt system , or the powerful 9.6 volt
system with 12 tools.
But don't forget that Makita also offers over 100 corded
power tools in its extensive line.
All our power tools, whether corded or cordless, bear
ITS ALL ll-IE POWER You NEED
the Makita trademark. Quality and durability. 14930 Northam St. La Mirada, CA 90638-5753 (714) 522-8088