Woodsmith 167 - MetosExpo - Free

' I #ow to Rescue Your Router Bits! '2
J www. woodsmith .corn
Vol. 28 1 No. I 67
jointer technique;
- -3u
t6 know
,able
~echlf~~~e
for supel itrung
.?I
\
7
% W +A
Cabinet, -

9
Table
from our imders
Tips & Techniques ..I...m.......
project!@w&sf
.4 - ..--
weekend project
all about
Curved~Fretnt Buukcm, a ,.,
Router Bit Revbal .............. .8 w wtly cwiw si&s af thii bmbw give k13
Don't toss thme old, sorry-looking router Mts,
itasophirtlcatgdLodG~utpu'llbepWanily 3
We'll show you how to make them cut lik new.
mpr'id at haw easy it goes qether, Y/ ;.
,A . ,.
tools of the trade
designer series project
SketchU b~Google**~~*~*~~~~.10 TallflfchenT&b ............
If you # ought a computer design program was
22
out of reach, check wt this offering.
techniques from our shop
Quick & Accurate Mortises. ..... .I
the msnpamrrd 5tyEirh dew d&ia pt~jm k
w h am ~ vw a&hth. kit &h4t ~Wiobk: &E
g~&oo;hvaking that peer into
2 heirloom project
Dbplay ~bjwt
, , , , , . . ,
Power and hand tool5 work side-brideto give
you perfect mortises - fast, MthaMgKthatk taQitliilandpafl
jigs and fixtures
EZ Smart Guide.. ,............
This innovative guide sysbm turns your circular
saw into a precisian tool for cutting she& stock.
r
contmgamy, puJ Ild thb psnjett will W 'in
about anywh~re in your hme.
J.4 6

Now> you ran have the best, timesaving secrets, solutions,
and techniques sent directly to ytlur computer. Just go to
~.Woedsmihmm and click on "FREE lip by hail" to
sign up. You'll receive a new tip by email each week.
I
These two symbols let you know there's maw ifdomati&
online at www.Wmdsmith.
videosr technique nmjecQ ,

I
I
hlLR0aarn-w
FoztbtramdonwhIuse ~ ~ L o t f a t l ~ r n e %&lspetQsit~@Btod%
t o ~
~ ~ g ~ u g ~ d f s h n & cw e s ~ f ~ - e k . a s h d m ~ b & w ~ , ~ t ,
er~myroutat~-$ettingthe T Q ~ ~ ~ l & Imdeawadlehrfhebewntu
t $ w
kce to align wetly dght has a& h the miW dot: at om wd sB@.i&m~@ I d a 'af),% WOdmjsbema~fmme-
~~bffie.tolb~~~I~ethebeam
phecratdkismadetaiititujgiy'
W f s , ~ I W ~ a l i ~ nf ht
e m d k m f i l i t inthemibdW.Inthe~pat
~
pdepepu~h.
t&ekncdf&~&hb dthe~i=ide,l&kdh-W
Thegaugeisjustahardwood p~Ididethegaq&to~~ iasertmdathumhs~~.
beamthatfikint~mad~~le enddlfthetabfetomaleesure&e Analumbum "dl& fib in a
cmdk.Thecta$IesUdeein& kq&the~disiaw~~ rroltclhIslthetapprt~fthecra-
&.Urhentheth~~i$
Ic
A
mp*m&'&wb
"-3
c l l & ~ h ~ t & y m
F
-.- - ---
SUBMlr8t@llR.. FIB6
WhWwd Mmw.
&W Rmb
ib&&mH~@fS, ofrio

more tips trom our readers I ;.
mrn&time&; that .exha stor$-@ is'
s q pu right in the'hce,
FO; mveral years, I've had a
large ~toard' pand abh&e$
to my shop wall. tt hag BT,&
me weu aver the pars, £mJdhg
&@&
-&ta M.wIsr;w,m
,- ,

pmjw hi@-
) p h p t q 8 U U f e ~ ~ ~ w
holm. But tapping tkF$ p1#@.-m
~ h ~ l e s w i t h a h m m ~ ~
&ip&mtapofthephJ@.
'Ib.wive @& p~blpm, I d-zr
~ ~ ~ p u ~ ~ ~ & w -
ingkltaakapiaeoflJidia.rlawd I
md &iW.sa "&pW b ~rte md
tbm&htbdWn&~d&p&
as pu can s i h ~ d&d 'a.'
Now1 set the plug in
ietbd ho4eI p b the plug setk
t~lp~p~~&e.ko'le. NDmm
&t*@
on theplug@.
J---J
t FFMd
Cdg
The Winner!
C$mgtatulations Thomas
Edwards bf Pullyallup,
Wsahiffgtom. His hardwars
a &edeqste~ wa~3e1-d as.
,'+,qfw. HF Wign uncl,wers
.7$bLwrw while wine
-.va
, :. Pi& lpr&qqwq-ganized-
W,Bn$ pw'hvii.rotl wid
1wIK a F%@r~mbla !awiable
.i&e@d rdutwJ 4Wck aut the'
,- infarmatian & the
h

"'A i

**t*'m-
'. W ~ w ~ y ~ ~ r n W ~
-.
r ~ J W &,Qf d-ine ao
b @ w ~ k ~ ~ q y W &
&&Wtrlwrn*mwbk
Yw&f II**M&W
3&&it.~Wtw&&~#n ~~~
$ WMg$L&Btl1l~a@
7 ~ ~ ~ ~ ~ y ~ t~ hi t e ~ * ~ & m ~ WM ~ e ~ a . ws a a ~
' r n @ ~ b ~ o~ r % ~ p ~ y ~ w -&b&hemw*d&
b £ t
*p& d*htj. wd8"-ilreaex~.*%~ helashargtotbew
-TQ @& up *%bpu*a fiutpb & %mvwqwwwgm?a
The tau& carbide cutting edges on rout- Pmket stones are lexi expensive. You
er bits mean ordinary Hes and stones can hold them in your hand or clamp
won't do the job. Instead, I turn to dk- them to the bench for shmpenktgbits.
rnond stones. They come! in fhree styles. I€ you'^ honing small bits, you'll need
TIIE small diamond bench stone is p i to use a needle file. They m e in difkrtt
for larger bits. Its atended h@ allows shapes to meet your needs. Sources far all
wu to make longer passes.
th~s~smlrefudonpage4~.
,mne

is sdp2t the rig@ drill Kt. ybuY $tiwed. Yq11 e m seWg
kdit~4b~if~rmupzf~ &eI~satheblt~~m
k1'ahaw.t fRi' nanWef+tl mm the dtbdyrnbyaxat-th,
@mth&width'dthemW, This lbq slide the pWe $6 +he biW
wap ymll hveephty of fwm to At tha h€t end d fhe.layout mafic,
square up the sdm without ktbq
Now you can c1mpa stopbhk to
the Pmk get tQa wide.
tile h, %'box eplaim
I prefer b we FarsAhr $i@ be- Itow to wpIete the ddkgopuse
* lmve & l4xJ s4r* m&n by wing a s p a bW.
bMwh In the wtk. But brad SQURRE II WIKL & pQu{ve
g.& bi& will wak tod, Yau just Whed ddlwghut & holm, t.h~
med to tkw twhiqw Wt's next Wp is fo &or bp,d qm'
15#t for 4he type of bit you de. tke mo& For %&I) I begin by
ThE iuu&dms Qn the opib
phc,hg the wmkph in e vise
pw*k'-t-.
or searing it @ the hch wi&
Ifypuu%aFmhabfi,~ dam#$. I like toweik&~@tly~~er
M dm d m the2q4 d tRe drill tl-@rnortiw& 1~ emgrbndp
~~mrk~bttinandsllt w~gbttopud~dwxt&ii~~.
~ ~ ~ meavb&kr @ v B
~mlRbBtKhwthb~Bi~ V@W&&BW&
~ F ' m ~ d y b ~ d f lI~ssp*a%fi~d&&bdem
-
hgmt&zwaefhdiihdpk .. .
up!h~rn,T$ew'~apvi&e
wide Cw$a* %"I. The wad:-
~ ~ ~ t ~ & ~ ~ ~ ,
w
move the &amKS vvm a wm
u r m
a n
the top mtn% rW&&
HI&&,€& mm m a
t~tiwf up i@ wt t& M~bm
SrnMMW*
Side and ends
" &fmii-e
stmuid be
smooth and
square
A ,>
*'
is fa UE the ~h&d MI

tor your clrcu~ar s,. ..

I
I
M ~ H E The . EZ Smart has
some other nice features as well.
For one thing, the guide rails are
available in six Merent lengths.
~ uvou t can connect .. two or three ..
,'
sections to make a longer guide
rail. The rail sections are lhked Vs::
together by short, aluminum con- ,
rtectors (see first photo at right). So ,,
you can make up a guide raiI that
is just as long as you need.
U P S . A lot of strai&tdge
guides use hand damps to hold
them in place. The problem with You can make a longer guide rail by simpty
this is that the clsmps can get in the connecting two shorter lengths of rail.
way of your saw when mahg a
cut. But the clamps on the EZ Smt
slide in a slot on the underside of
the w e , so they're always out of
the way (second photo).
AHIKHlP FEWURE. Ta combat chip
ping, the EZ Swrarl b w comes with
two styles of replaceable, zero-dearance
inserts - one for use with the
guide rail artd one for bhand
cuts. And both edges of the guide
rail are fitted with a replaceable,
antidp edge strip. Thtw reduce
e chipping by supporting he workpiece
right up to the blade.
ACCESSOIES. AU these features are
great, but what makes the EZ Smart
really stand out are the accessories
availabIe for it (see box below).
After taking a look at these, you
quickly realize that this isn't just
a saw guide - it's a precision cutting
system for the circular saw.
BOTlOM UM Overall, I didn't find
much about the EZ Smart to &ticize.
The fit and finish of some of
the parts Ieft a little to be desired,
but ~s didn't affect tlw functionality
of the tool. The EZ Smart will
Adding Versatilitv: EZ Smart Accessories
:lamps fit into a slot underneath the
rail, where they won't get in the way.
work with most right-blade circular
saws, but be prepared to drill
some holes in the base of your saw
to attach the base. You may also
have to enlarge the opening in the
EZ Smart base to accommodate the
blade guard of your saw.
Depending on which "package"
you order, the EZ Smart starts at
$135 (see page 49 for sources). Although
this may seem hgh for a
sbaightedge guide, if you do a lot
of work with sheet goods, I ttunk
it's money well spent I
The basit EZ Smmf Gu& ~arks pat h accessories allow you to use dle, take a look at the videos on the EZ
for cutling plywood and lumber to size. the E Z Srotttrt for a lot more tkan just S d website: www.~mexom.)
But what really mkes the EZ Smrt simple cuts in plywood. You can use it Like the EZ S m t itself, most of the
system so ap-g are &e acrmmries for cutling parts to length, squasing up arxdes are u£fd In different sizes
that are available, wake a look at the panels, or muting joinery (For mare on and packages depending upan your
phofns below to a few.) all the tasks that the EZ Smvt cart hm- spdc needs (see page 49 for murces).

curved-front
ofstorage in just a little space.
As much as I ejq a challenge, I
have to admit that every now arid
then it's nice to huild a simple,
straightforward pro]*&. And with
it's clean Iines and basic design,
that's exactly what this b m k is.
The ronstmdion is a h straightforward.
It uses quick-connect
fastmersp m there's no complicated
joinery to deal with. And it's made
almost entirely out of plywmd, so
you don't have to spend a lot of
time gluing up solid-wood pm&.
But in spite of it4 simplicity, this
project will still thrrrw you a m e
-two mesIinEdCt. If you U e a
look at the photo, you1 see that the
sides of the bookcase have a graceful
curve along the front edge.
While these curves add visual
appeal to the bookcase, hey create
a chanenge when it comes to edging
the plywbod. Here again, fhe
solution is simple - flexible, itonon
edge b&g (photo below).
s
banding is fast and
easy to apply, even
to the curved edges
of the bookcasle
sides. See page 21
for more details.

IF- -
I
FIRSZ Place nail:
location pohh r
dboa rd temg
I,

#endon to the p v e that runs
slZong the bad edge of each side. first job 4 to drill the hob for
These grooves will hold the back the c~mector hard-. Each
panel. Eecause the 4k" plywood connector is made up of two
used for the back panel is clowr parts: a cam and a pin. The pin
to %6" thick, I cut the groove by is installed into he side of the
making two pasw on my table bookcase, W& dm cam fits into
saw to get a snug fit.
aFMG M EllnrL At Ibis poht* all
aholeintPLeshelf.
Theresiitrickis~ttLe holes
that's left to complete the sides is in fhe shelves ahped with th@
to cut the curved &ape. You can holes in fhe sides of the bkcase.
seehowtofinishuptheairvein To help me with this, I d ajig
the +wo drawings Mow.
THkSHEWCS. Now, it's time: to fmus
lihtheoneahowninthebaxat
right. Shq Notebook on page 30
on &*elves. As I saidbefore, the shows huw to make the jig.
topl bottom, and middle ahelves
are fixed. In fact, they're holding
tOE KKR NO TOP IWIL To provide
extra suppoft and give the
thebookcase trJgeh with quick- boobase a more fhbhed look,
connect hardware. The other two you cm add a toe kick to the
shelves are adjustable and will
TES~ on shelf pins. (Sources are
lisfed on page 49.)
bottom shelf and a back pad to
the top. Both are rabbeted to fit
into wves (see details 'a' and 'c'
A f t e ~ ~ ~ ~ s &n h the e ppposite l ~ & page). ~ ~ The panel
(remmbm that the fixed she£veg
a~ three Writ widths), you can
set the adjustable shlves aside far
now WW you mtinue wmlung of the battom &If.
qn the thee fbed shelves.
TOP M L NOTCH& You'Il notice in
~ I W I stmkd ~ by , detail 'a' (top of oppposik page)
Wng the upper and lower fixed that the t ~p panel has notb in
shelves over to my table saw.
These shelves need grooves to
hold the Yfl plywood for the back
panel, as shown in details W ahd
'c' at he top of the opposite page.
Qnce the grooves are cut tab
these tw~ shelves and the middle
shelf over to the W press;#&e
is "trapped" In t?ae paves in the
sides, while fie toe kick is glued
in the pwe onthebottom side
its uppa corners. The mtdw fit
mund blocks that will be addd
to the grooves during assembly to
prokt the dge ban*.
With all fhis dme, the next step
wilI be to add the edging and put
the bookcme together*
Dr9UIng the a m Holes* Orill the holes for the cams
fm the b&m side of the sheh. Take are so you
don? drill through theshe/= (&tail 'a>
Route and Flip Rotate th3 shelf and flip the ji'g81
drill the cam hob in the back of the s heh. A sup
pofi bJOdc kwp the shelf /MI,
Ddi- the Comer Hdes, Ling the j$ up &A
the am t~ &U the hob for the btmmrs
into the idg~ sf t&&hk,
spacer bl
behveen
edge of shelf
Middle H&~WiwMWe& Add a ipcef to &dl fie
hob id &i mtWe Shelf to account for the back
pnel tht i@&@@a$aim.

Material
4 Cw$&
B UppwPi
C MlMb F h

oekc&e And since WI mad@ h e & € ( ~ .place ~
edge Banding are an iron, a TrSrnmitlg
fatly with fh@ pmfeKt. mtlrem&ngt#
The edge band- is just a law y mmf scmchhg* Thkn sbpljr
narrow ship of %$'-hick venm. iron th banding ontdtb edge af
(It's said b a fm dikrmt widths .the plywood (phuto 2):
and.~sofw~,~%ur~sr~n I~thatI~the~tfesu~ts
page $9.) me side of the banding by &aning a shm- ofbidis
mv- wjth a heat-activated ing at a time. FWm W 30 se~snds
@~.~y~tkhZivEt~d@k~@~flyi~ b&ud~e~~~t$&t&e#~
lvbci-

tall Kitchen Tab!?
WMhH yw*m =ding I& ~ y ~ ~ M e til bh e m
mmhg mwpapx over b d - m&~W* kQut &the way
imt -ur 21 mhag dWC (* p ~ ~ ~ ~ w ~ ~ p ~ g ~ ~ *
tw &t&m set fit r@t:h n .m*

sL-7 TF-: Aligning and Drihg Mortises

HwTa Rout Stmeed Mortises
Rpurer Tgbk S u p 5@ &:'fp-nce I?&' fwfrr the hic .pkcnge Rout, && *e rnw!&e EmW Ga mi% @&WeY'e adthe w&+
firznm r ~$mdIbfied with the ciMip&m of t& p i e &l& the ma* &ow aaijd p;hr@;&-Wp&&, hut unfit M
bir* ma&sM ahd mp mads an ?b:%e. op- mW hi We i3~
,ha&:oh tfkY&e.

I
4
making the TOP
W1th the base complete, it's time to
start building the bp. I glued up
the top from narrow maple stock
to give it a butcher-block look that
fits In with just abwt any kitchen
decor. It's a little more work than
some of the alternatives, but this
arrangement means the top will be
mose stable. It will stay flatter and
mt expand and contract as much
with seasonal changes.
aJlTM THE STRIPS. I stated by
jointing and planing a few pieces
of maple stock. 1 took extra care
to make sure every- was perfdy
flat and parallel dm@ this
step, because the planed surfaces
will actually end up being the glue
joints I've ripped the W s
into mwer strips. (The box k-
low explains how to pmpare and
lay out the strips for a flat top).
Next, set up your table saw with
a god rip blade and dwble-check
the fence to make sure it's parallel
to the blade. Then you can rip the
maple into strips. For the best glue
joinis? I like to ca~fully joint each
strip, Then you can move on to arrmging
them for glue-up.
Urn OUT TOP. Ifs a goad idea
to ixlspect each piece for straight-
ness. When you cut long, narrow
p i e you can get some bowing.
So now is the time to detwmh
which strips are bowed and in
which direction so you cnn take
that into account during assembly.
The box Mow explains how to do
this to get good results.
HUM IT UP. Now, you can glue
up the top. I first glued the strips
into s m a h &~fls (about 8"
Cuttin! and Assembling the Top
. .
wide) so I could run them through
a planet. Take a look at the box on
the next page fax details m making
a fIat and smooth tabletop.
BBW DEWILL Now, you can trim
the top to size and rout the rounclover
on the comers and top edge.
Then sand everything smooth.
After painting the base and applying
a finish to the top, you can
attach the top with Zfasteners, as
shown In the drawing above. Then
you can hun to makmg the stools.
mi
81 '
I
1
I
j
Ripping the Stock. Ch& to make sure your fence is parailel to the Lay Out the Pieces To compensate for bowing,
blade to avoid saw mark and burning, Then rip the strips and flip them lay out the strips as frown above. This waj you'll
an their side. This edge grain wili become the top of the tabb A quick get a bemr glue h d and you won't have m wony
pend mark to identify them will save time hte~ about cracks appearing in the future. I
4
26 Woodsmith
No. 167
-

How-To:
Flatten The
Tabletop
~~g a glued-up tabktop begins
during & asmbly stag.
Chping up the individual strips
on a perfectly flat surface and tapping
them in place with a mallet
is pmbably the best way to get
dl in he. You can a h use
cauls mnnbg perpendicular to fie
strips to keep them from ddhg
underclampiq pmsure
f UT AMD TRUE. When the dries,
it's tempting ta try and ff atten h
pane1 by running it thmugh a
planer. A p h will pmduce n flat
surface, but if the-opposite si& is
uneven, the surfaces won't he parallel.
You1 get an unwen panel
-
that won't sit fiat un th~ base. The
solution is to flakken ane Bide first.
If you've dm everyfhingyoucantQkeep~flat
during the glueup, it% nut hard to
knock down the remaining ridg~.
You'll want to begin by mrnoving
the glue squeezeout. An old chisel
wo& great for this.
#EaFORFUTNE%Istartby~
a straightedge to check the surface
and make a se~es of penal ma&
an the high spots. Then you can
turn to the belt sander and a W
grit belt (see box at n@). It
shmt work of the the.
The goal
duringthis phase is to move only
the Mgh spob. 8. angle th~ sander
or yw can even sand acrows the
gain. Skap hquently and recheck
the surface with a straightedge.
When alI the high sp& are
smoothed out, you can switch tn
a 120+€ belt and s a d with the
@, moving fmm slde to side
mid you have a nice, flat surface.
W SMOOTH, Then you can run
the panels through the phr, hking
light cuts. Stay a little shy of
the finat c h i b s - yauzl sand
the top to final thickness after you
glue up the pads. Give the top a
final sandmg far a smooth finish

P'-ty asad ~~* 'ke
lower spin* Mek their rmrnded
dp@veyaurf&a~Ie
rwing qotwhiled~.
llEm. me &.table, &e -1
top a& gluerd up hm m w
~ p s . I ~ t h C F ~ ~
t0asmnble;utdfkttkn~asI
did for tke table Q. A d hy'm
atkhd to ttPe base with z-fastenem,
jm lik~ the table.
d y diWl in the
'sblkp b ~slight.IwLuld~ I
ZidtH-dhQd~b
ybuvH be sinp;tm k, 1 E iit
h d p ~ ~ a l i t t b m o ~ e ~
WbEftheedgeia-
A~~0~1woEpa#da~,
d&u~m*fQP$&pu%e
d&I&I'~~~W~wOn
Mve my'd.,%m@ a gmd
$putfor mh&dpliltle t&lemd
s ~ h ~ ~ . u l
No. 167

,A,,
.
Materials, Supplies .& Cutting Diagram
,,,
,<
TABLE
A l,%s-I4
I3 . Upp,er Etrd .Aprons Q) j4 x 2'~~ - 2Q
C,>91jp.w Side Aprpns (23 % x 2 V! - 32
D',' LQWW E-nd Aprohs (2) 3Lq x ?! - 20
,
-
D-' 8
H Center Stretches 41)
-, .
(8) Tabletop.2-fwteners
(8)#8x2%" Fh Wmdscrws
, ~(8)#8x3~"PhW\lood~~~
. I
Island Worksurface
Thi6 tall tabb abo makm w handy standalone
workeurface for the kitchen. And by addlng a
~oupla mom s$retckew ~C~OSG the bottom,
you can crm~
a tihslf for swvlng large itema.
There am onb two thing6 you need to do be-
fore wssambling the base. Fbt, you'll add Wo
&ra mort;ls@e in the end mile (see drawing
below). But $ha nim thing IG you can use the
same routlng technique that I used for the
table [see the box al; the bott~pn of page 25).
The other thing you'll new4 t~ do i6 make
ma mom ce~ter straher~. The tkk hem I6
'co make sum the spaclng between them is the
Bama when you msrnbla the base,
i
1
20 -

t
- -
t;>:,'

. , > . , I
> 7 .-
6kns Stop ', > . C
When yau @ &y tu hidl the
@w*ina,edbp~a~ mona*.~tW~QEl M%&ewy*
an 32, p'11nml mal Wbppd&&ge9~~%hvea%* RrPa piem of tndrfing bani
~ o f ~ & - r n d ' ~tmter&onbo&e$p
~ ~ ~ d
the oi%e~&ed the wmkp&e, Just
~ ~ h p ~ ~ € ~ W Ai K e4 Y i l % ~ ~ ~ turnZhern~kpi~owr,re&the
s ~ g
caten~~Ietofindmqld~
md mau& to do he j&. Fa 1 trim 219e mlbg *ips fwm the thebhka&kfmL
mademylowrrqwrtm-mundflas5 w~F~.3~.Ta&ahisfgiQt~ W ~ y o w ~ d ~ ~ ~ , ysur p wow l l &$
&p mokfing. It onlp tab a few raise the bls*fe chvethew&kp-, need to miter Ule quarter-round rtop moldibq:.:-. ,?;
~~~pit.o&itjW.theW ~ ~ ~ t ~ f e n w t g ~ ~~len@t,~paucmseam t h e ~ d l
. ,.v.;r;.,L2 ,L,, ;.,yef
. -> ,la:
yau~-TRephato~tri@t~ piamofmold@hhdpd dw&win~tiortby~or
., . .: - i
> );:>:&
how it Emkf at h eompMon of ths wmkpbad cut bike* glkng~~psin~e.
.

Heirloom Project :-
g lass-panel
Display
a
Cabinet
You won't believe how quickly
this project can be built. The
key is simple, traditional joinery.
@
Shuwingortisjwtwhatthiscabinetisall
about. And t k are ~ enough htemtlng
detaibbtmdeitjwqtothetopofthe
-- I *
list of p&& h t I wmtedb build. , , . ' 'I
Mowmu&pmpk~~fheabpb "' .
displayed in tkre "ghed-in"upper sectirn
Or hmv the cabinet offers both "hidden"
and~~.Andfhefzlrtthatithasa
emalz~~~roucantuekitinjust
abwt&t~,@vkgitalotof~tB;
But woadww will W notice rrf the
details an8 strafghH~rw?rxd cmstmctim
that makes thisdiner a~stad+ut
FRAldE AND PANE. Just kause a project
isc~in*doesn"tmewnym~
.*pm-kthe-krn&v
Qfmqgp~.&meamdpd - ..
~ ~ . ~ ~ f o
~ t h e j a n q ~ b & ~ ~
~DSIE~~RLU. %aM-rw&f+o
mti&*t&thebe~thavetodowith
~~~thatkeepthe~Wfrorn
hdag bov. sming at the bowmF
thecabinetr&scm&pfhatr&eitoff~ .--
~Tkis~a~aPhInWlower
e
keep a &m l&Wg bomm heavy.
Tha?&dMisa*@*tu
e a ~ ~ m m m oFdy, f ~ afthe ~ ~ .
top, I Ugsd a pmmdecwe mokhg~to~add
one last eyecaw

M a & t?&vk~
rnoitvn makm it wy
m add &ad to s@nr,en
FRONT
SEmIOW
vlEW
For hadware
mKes, turn to
PVm
are made with
A
she I in lower
part of care is
made from
mQd
I
Mdse and
tenon face
frame adds
Saiditv to
- Y t

uild the
SIDES &
I mentioned Wore that the case
is made up of three hame and
panel amanbeS and an open face
hamc What's surpcbbg abut
this is just how quicliiy khese
&$embb go iqvthr.
SIMPLE Jmw: me reasan Eox
this is the johry that's used on
the back and sih. Here, I chm
a stub t m ami pve. Besides
quick assembly, this joint
has another hg advantage:
yw can cut it enMy an fm
table saw. And afk adding
W1 plpwd panels, the's
phfy of glue surface to ae
ate a strong, rigid asmrhly
Befm getting started on
the frames, there's one ather
thing I'd Uke to mention.
And this has to do with
working effieimtly. 'She
joinery for both the side
versatile guide to and back assemblies is identical.
rout the dadoes So you can save some -time by
in the sides. Turn cutting it & at one he.
to page 30 for When you're ripping the parts
details, to width, be sure to note the different
sizes af both the sacs
and rails (drawing at right). The
low rds will get a" arc cut on
the bottom edge later. But for
now, I leftit square to mh cutting
the joky simpler.
WTHElldtC Orwe the pinery
is mnpkte, ~rou can go ahead
aRdcutthearcontPlelo+verrails
[dd 'c'). A trip to the band saw
I1
I
makes quick work of row cut-
! tingthew. Thenthe edgeanbe
cleaned up with a dntmdm.
t
No. 167
1

2 .,
-
. .
. - .
.
- . ?.Y2= ,:- 2-,' ' -. --
-
-
.--I- - k.;1;
9; -15 m. - .-:
:..?; . -
m
bdbm rail to &ch h c m s
Qtt the db
and hack.
nm, rn 0- %and, khe
ba&bs J W a& bn be
taped just H k m the
sides-& back. NOW, glue up
facefmmhkmg-tohep
i t ~ a s ~ ~ m ~ '
MM removing the damp,
h last thing to do on the face
frame is tb rut a rabbet m the
'track hce of each stile. W mbbet.
will capture the side hmes
and make assembly easier,
cnst Assam GlUiTlg the fBCe
hame in p w is *try amght-
£omad. h d like the d*
assembly, ifs a pd idea td ror~
cmtr&emadqgat&htjdnt
line.- the sfde &m-md
tXpRra+b~~tirt~fam~.
All that's left JO cb on the caw.
is to rout astopped&amhm
the front corn&. And you can
kam how the best mdts
in the boxat right.
.
~ m E ~ ' I O P
w&h**oftfrea~
complete,ywmm gets&
m~tcwp,'mekq~5n~w-
~ a t # ~ . ~ ~ j W a p l ~ u d
pd W1521W-widElHli~ edg-
*. Bide9:'lfie &g&g i's
mikmd Wih a 'rig m-< 88
hy9ucrulmindetailY;a'
~tqp~is.~sitarpLy
~ ~ b u l . i e ~ a f t l w ~ . h
~ ~ w i n g ' r ~ ~ c a n ~ ~ ~ ~
@timed. Ifi cam&& side WA
sideand 11wh with the back,
mlrourrmk'fhe~~ista
add a ~ ~ o ~ ~ MDW l dthe
m g
t c p . ~ T ~ a p ~ ~ v e
matding &at's lxlked to wrap
;rfmmdthebt: ai~ d&

make the
Wi& the t w mplete, &re
areodllyawqde~thhgsto
&amdd,WWorku\riilk
~dup.mrtextstepiett0
build the two doors. And since the
mtru&m&ea& one is a Bide
twkmt, I'll tah ym drrw& the
pmmeat aae.
Infhednwing atright, yotl>m
web'tiheupdmwillhse
a glass pard Wif will match the
panels you% inst& in the sides.
IOIMRX 'Since a @ panel
dm't add &m@h to a dmr, the
~ ~ nwds to rbe strong n
and rigidtomakeupforit Thfs
mttkesita~~&farmortise
and jainerp. In detail 'a,'
you11 find the dimension% you'll
need to complete the jojnery.
WE?, hthdmrfrmhas
~ @ ~ ~ * p u ~ ~
r o u t n r a b b e t ~ ~ ~
to hold the glass panel, as illustrated
ia detail %.'
lie @B pmek are held in
place with some simple stop I
made at the table saw and mu*
table. You can see the stepby-step
proas on page 31.
ollentl# ows, At the same h e
youq* ord* the glass for
the dm and sides, you can also

I....
-..
mt a join- in my 9%. But me like a contradiction that such big bfifa. Number one is that
" t I o w n m 1 a b h tool can be so usz- you can put a smooth, strd ",
xtqwhg stock% &me&. h memIt'sesmWyapairaf~ rn~thefaceafabuardebigp't
b e it takes to think abaut narrowt b n Wb sephrzted and flat, or fate jQinting. Each
out a hand $am nr a belt by a horizontal cutterhead. The it$ awn techruqae.
you can joint a hard for infeed Wle is mi& or lowered to
-1
by the Mw And an adjmt- Edge
ablefmcec~utbeusedto~~ mms
L
wifhevmasimpfetmllha jainthgastrnight,
~ ~ a l abdforetpl
i ~ ~ -
how4 But k leaning TZre p- B
faward. Y u run
a s d amount Of material. The

. . :,.
4
:'/ ,
*t spot while a h I&#&@'&
wwkpiwmqa* h-
at*^ d*
**w@m-ed
~*Ykww"~'brtmw~k
h m ~ ~ ~ m
&eJmW&
be dimbing up and away a
&-h&&~8-.&
wer hMwt mure
:clthqou--w Qmpq*P -
-
-/--=====
: s ~ ~ b a ~ d ~ d h

When you wmt to make me face
ofa~td~amsits~and
~ d m g i t s ~ , t h e ~
ef iB your bmt Optim. And &Ice
Wtbg theficeqareb atn dge
way isn't a concan, this cm be
a bit cask than edge jointing.
mE Just like jointing an
+,face jointing starbby iakmg
alaakatthelmm&Ybpwantko
d!zmhine the grain dimdon and
wh* the hard tras arty -us
cupping acmw its width or tww
or Wt along its leng!h Agam,
pull have an easier h e getting a I
strqiht, at workpiece by joinkg ?:33=
-... .. :
withthehollowsidedows~ ....*.-. .'
A wm Bm When face iointing,
k with mul-
Elimina?e ~JI
push down o

. I
sqare edp# the caw might be the cut (called snipe) or tke hives
Outfeed Height.
that €he knives not in8t;luBd atap mfAQ halhay throw a W can US a
cody. All ihe hives 5ftould be pass, the outfeed babk is too low or sttaigh9eB'g.e fo
at he same Mght and perf&ly too hgh. lk &odd be setBwhwifh check the height
pivahl to the tables (m rniddle the topmost arc d the kniw flow pf the auW
drawing at right). A knife that's a $rp sight bwiqg). Too high and
Wehighonsrnesideofthekible ~ugetsrdpe,~~awandywget &&@c rhe hi&
will joint a bevdd edge. If this is
the case, just reset h knives.
a 'klbx~b" rut. A straightedge is id
you need to hd
the @ hdW
Shop Tip: Sho~Made Pushblock
me & the ChaIllagH to he
j&&&&ia$pIr;flg firm, steady
&md.pmmwe while at the
m.w.h.* w
k&m*Mmf%
C
&add Flake Very
I
I

-
'- ;
ScabbIeSbr~
; me $22 thing &at
the cwhhefs shown at right is
pu c".w ~~~c~~
but size them ta hold pt ab6*
anydun#. Far inEm~e$ Z 'm&.a
kw to hold screws d hardware,
axrd w,larpr ones t9 hold #he
wlBld-ies, ~&u-&, wdkg 5-
* , m d ~ t ~ ~ k P m
W- wfi~kllg W h I@&.
AU p heed f9 build thise
bdy cmiain&a'i$ Somz wordI
hqdhkd, and glue. %q'j;e
- wemble;8 wie eimgle dado
jw. For the' @la sk#, .pu
my wmt t@ Mild the. s&bk
. iw?@ UQ .hold@rn.@rnirrrn

k & easy steps for
Antiquing
The hardwarn br a project
is just as important as the,
#
~n md finish. Here are e
fewhardwa~"fini&e3~t~
give your pi~jed the right look.

. ,
>-.
Blades h r
the T ab
Saw
A Mend told me I
should be using
thin-kerf blades on my
table saw. They don't
7 A %jwkerf bl& lo& much different to
amI and a full- ma. C the any slgnifk
kerf blade. mnf mwmiagse?
u r -
rn 'Rwwbzw ~ m &c;
W$ WU& &#$ && Ji@#a ~ dlY d - We
e dVwrn& JR $a?$ IBnvmliMm~ @I@&J 'FWQJ&&
*dhMdaWU&
*by
Yj&e

There's no question that using
your computer to design p~ojects
.can be & real timesa,ver,
However, mest dwign p-mgmms
run a lM1e-bit on the expensive
side, Gaugle's SkeEhUp softwsm,
faatu red an page 10, is
free. You wn dawnload it ahd
try it for yburself by checking out
~.s~hug.sam.
ROUTER 11181I5108aTIOH
If you'm as hard on router bits
as I am, you'll appreciatethe tip
far dining and honing them on
page 8. kls easy lo keep-them in
good shape with just a Ikjs TLC
and the right d s . The diamond
bench stone, needle files, and
pocket stones I used rare made by
EZE-LAPDiamond Products. You
can find eontact infarmatiori for
Ei'E-LAP retailen, in the margin.
These items are also mailable at
ths Woodsmith Stow.
EZ SMMT 6WDE
Whethef itfa cutting plywbbd fo'r
Rome canstructian or a furnituw
project, the EZSrnart Guide
shown an pzr~e 14 is a handy
way ta g@t more out of your circtslsr
saw. The basic system and
optional a ~wari~s are a l I available
from Eumkm~n&, See
thk margin far deteils.
HARDBOUND
VOLUMES
This set includes five hardbound volumes
Being able to add a custom patina
tb d-thd8.b hadwarn awns up
a lot of mibilh fm y~ur pmj- pan&
mls. The ammonia, murk a&,
and lacquer thinnei you might
need am' a~ailab~s at pwr local
home center ar hardware Hare.
The dahning solution I used was
feomths bbmithStwI4E5mJ.
I atso found rlerkgning sqILltians
art ~anwawtt~~~~rnm14
& 02001547). Informatian far btk
$QU~C&S~S shm at fight
BOOKCASE
For the bookcase featured on
page 16, I used Minifix connsGtQrs
(22161), and some Y$
shdf support pins (227651 from
Ro&t.
I atso dmided that this
was a gaud projmt to use Ironon
edging (916851 to cover f h ~
plywood. The chefry veneer
edging is also available Prom the
Wwa'smith Sore.
TALL TABLE AND STOOCS
The tall mbte and tita~ls profect
ferurd on page 22 doesn't
require e lot & supplie~ other
than t h wood, ~ but I did use
some tabletop fasteners, &en
cerllqdZ+lips, tu am& the top to
rhrp.tram. I turned ta Lee Vale$
~13U1,01) for these hahdy and
easy-m-use f astenar~,
1 mads a trip tp my local glas
supplkr for thesh~lvss and &or
in the display cabinet
on page. 32. You nsn mer the
chr'me, UalCtippid butt Piiriges
(01HP8.20) snd the chromeplated
utilify catches (01 L85,02),
fram Lea Vafle y. 1 faund the, '4'
nickel-plated shelf supports
(338601, and the rubber su$hions~
(33928) that keep the shelves
from rerttling at Rackler.
HARPWARE STORME
Moat of rha hardware starage
ideas on page $4 can be built
from scrap hardwood, MDF, or
h~rdbaard. One of the projects,
however, uses handy, glasstspperd,
aluminum watch me!&&
cases (27K50.751 from Lm kMey
I ohmetbe 2%"-dia. cases for this
project, but they eym in a wide
variety of other sires, as WQII.
f heir contact information is in
fbe margfi at right.
zm-w vbld
M8hrEE&%
PMsm
amdcd
Each volume inch
or Call 1-800-444-7527 To

-
de w* ,a, iikT -,
uw- &p&dy ha door.
I ONLINE mm - i , Wen it 6 -dm to it.,& pwW
video workshop 1 jet isn't &J mu&.moy
a bupjoint goqd news &,
fiw?~ a j %yw h t amhw&qlaQk&a*m&
, ,
< - ,.%* - -
c ,>- >:,.>:
!
'
$hq@tifif-a W-lap jaf.
11WH4r trL You s& hbw

_
MITERED-END

. - - -
L-- :
- -
- ' ----- - - -
tr-, - -,
2 . - - -
w-
-
looking inside
' -
-
L.. I.
Final Details - - -
7, - -1
-
-
Drsplay Wne,
This beautiful cablnet&&
mightdraw
#mi attantion than
what's on display
Mtk It combins
A Tutt Kitchen Tabfe. Whether it's with stools you
chase
adaatic-n and
(tibwel or ones that yw build, this table
great placeto enjoy your momlng coffee, Complete
I plans for the table and stools start on pger 22.
instrudms
-
: ! *
-
Cumed-Fmnt Bookc~se. From the louk of it, you might think )
that this elegant bookcam would be a bit of a challenge to
build. But that's certainly not the caM, Plywood construction,
quick-connect hardware, and iron-on edge banding make it a
breeze. Turn to page 16 and you'll s& what 1 mean.
.- - -
- - -
- -
- - - - - --
-
- - - - --
- - --
- - - -
- - ----. -
- - - -
- - .-- -
-
- - . -