•

Ine 00-.-1

TAUNTON'S

October

2002

No. 158

•

Ing

Gel stain user's guide Router jig for floating­ tenon joinery Installing a bench vise Compound­ angle joinery without math New midi-lathes make turning affordable Top

10 rules

of woodworking

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Shaping and joining curved drawers

Whether you're a professional or a hobbyist, Delta has a lathe to meet your needs. If you're new to the world of turning, turn to Delta's Midi-Lathe and start creating decorative projects like pens and small bowls. Looking to turn larger stuff? Turn to the Work Shop Lathe. Need even greater capacity to turn heavy spindles and very large vessels? Then turn to Delta's Steel Bed Lathe. All offer the features you want. Plus the versatility and stability you need. For the name of your nearest dealer, call Delta Machinery at (U.S.)or (Canada). Or visit deltamachinery.com.

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SEPTEMBER/OCTOBER 2 0 0 2

3

Fine Woo dWork ing'€� � Departments

__-=::::� :: ;;;_.

6 Contributors 8 Letters 14 Methods of Work

Adjustable overarm blade guard with dust collection; Spline slots with a biscuit joiner; Bench stop for planing

22 Notes & Comment

Awards from coast to coast; Turning

trends; Learning from a master

28 Tools & Materials

Laguna 12-in. tablesaw; Low-angle

smoothing plane from Veritas; Shop Test: Antivibration gloves

76 Current Work

A gallery of our readers' woodworking

84 Rules of Thumb

Top 10 unavoidable truths of woodworking Gel stain user's guide, p.

60

88 Questions & Answers

What causes curl in cherry?; Opengrained wood doesn't absorb water-

based stain

96 Master Class

Laying out compound-angle

dovetails

109 Finish Line

A versatile 18th-century stain

On the Cover: Contributing editor Mario Rodriguez smooths a curved drawer front made using one of his two methods. Seep. 40 Photo: Erika Marks

Midi-lathes, p.

68

Knockdown bookcase, p. 32

Articles

32

Bookshelves in a Day Knockdown unit is engineered

BY STEVE LATTA

60

for stability and speedy assembly

36

Floating-Tenon]oinery Jig works with a plunge router

BY LON SCHLEINING ON OUR WEB SITE:

to make quick, strong joints

Watch a video clip of the author

Gel Stain User's Guide Easy to apply, these stains are forgiving, even on

BY TERI MASASCHI blotch-prone woods

63 Many many brands shades ofof gelcherrystains, 64 Compound Angles Without Math

using the jig

Simple set-up block dials in

40

tablesaw settings for accurate

BY STEVE BROWN

Two Ways to Make Curved Drawer Fronts

butt and miter joints

Choose a technique that fits

BY MARIO RODRIGUEZ

your tooling and work habits

45

Soup Up Your Spokeshave

BY BRIAN BOGGS ON OUR WEB SITE:

from good to better to best

Video tips on using a spokeshave

Wine-Glass Cabinet Tapered stiles and glass panels

BY SCOTT GIBSON

lighten an ash cabinet

56

TOOL TEST

Midi-lathes This new breed of small lathe

Three-step process takes the tool

50

68

Wine-glass cabinet, p.

50

offers several features found in bigger machines

BY ANDY BARNUM

at a more affordable price

74 A

Life Built on Bookmarks

A modest woodworking business

BY JONATHAN BINZEN

thrives on efficiency and ingenuity

Installing a Cast-Iron Vise There's more to it than sinking

BY TOM BEGNAL a few lag screws

Installing a cast-iron vise, p.

\'isit our web site: www.finewoodworking.com

56

Contributors Raised on a farm in Kentucky,

Fine

David

Salisbury (Finish Line) originally wanted to be a farmer, but when his father sold the farm, that plan fell through and he turned to woodworking. Hired by Colonial Williamsburg

27

years ago, he completed

WqqQWorking PUBLISHER Timothy D. SchreIner EXECUTIVE EDITOR Anatole Burkin

ART DIRECTOR Michael Pekovich

MANAGING EDITOR Matthew Teague SENIOR EDITOR Asa ChrIstiana

his apprenticeship and has worked in the cabinetmaker's shop ever since. Salisbury finds it deeply ironic that his grandfather was a cabinetmaker in Germany, but when he came to this country he couldn't earn a living in that profession and so became a farmer. When not woodworking, Salisbury enjoys saltwater fishing, except between December and March, when his Kentucky Wildcats

ASSOCIATE EDITORS William Duckworth, Thomas G. Begnal, Timothy Sams, Mark Schofield SENIOR COPY/PRODUCTION EDITOR Thomas McKenna COPY/PRODUCTION EDITOR Julie Rlslnlt ASSOCIATE ART DIRECTOR Kelly J. Dunton IMAGING SPECIALIST William M. Godfrey

college basketball team takes priority.

SHOP MANAG ER John White EDITORIAL ASSISTANT Christopher

Andy Barnum ("M idi­

components from McMaster-Ca rr. These mod ular,

lathes") lives with h i s

adj u sta ble parts allow him to design and debug

wife and two daughters

his machine as he builds it. But more importantly,

in Carmel, N.Y., where he

he sa id, "They're a blast:

maintains an active woodworking busi ness.

Scott Gibson ("Wine-Glass Cabinet") does what

He also teaches wood-

many of our readers wish they could do: make

turning cla sses at the School of Art and Design at

furn iture and write about it. He i s a career

Purchase College in Purchase, N.Y., and at the

journa l i st who has spent the last 10 years writing

Brookfield (Co n n .) Craft Center. Barn u m makes

and editing magazine articles about furniture

many of his own hand tool s and fi nds it especially

making and home buildi ng. A former staff editor

satisfying when he uses them to build furn iture.

at Fine Homebuilding, Fine Woodworking and

Now, however, after accu m u lating hand tools for

Ho me Furniture, he i s now a contributing editor to

several decades, he i s thinking that it might be

Fine Homebuilding and writes for several other

time to downsize his collection. Anyone need

publications. Gibson and h i s wife, Susan, returned

200 planes?

to Maine last yea r, where they are renovating a house near the Saco River.

Brian Boggs ("Soup Up Your Spokeshave")

makes chairs and rockers in Berea, Ky. While he

Steve Brown ("Compound Angles Without Math."

is always working to refine the Appalachian chair

Master Cla ss) is the head of the cabi net- and

style, he's j u st a s interested i n refi ning his

furn iture-making program at Boston's North

production processes. His curiosity and

Bennet Street School. After graduating from the

inventiveness extend from the jigs and tools he

same program in 1990, he

uses to the process of ha rvesting and m i l l i ng

worked as a fu rn itu re

h ickory bark for chair seats. His latest

maker with Philip C. Lowe

engineering venture is a n

for almost n i ne years

improved version o f h i s

before retu rning to North

X.

Baumann

CONTRIBUTING EDITORS Tage Frld, R. Bruce Hoadley, Christian Becksvoort, Marlo Rodriguez, Gary Rogowski, Mike Dunbar, Lon Schlelnlng, Garrett Hack CONSULTING EDITOR Chris Minick METHODS OF WORK JIm RIchey INDEXER Harriet Hodges G ROUP PUBLISHER Jon Miller ADMINISTRATIVE ASSISTANT Mary Lou von der Lancken MARKETING MANAGER Karen Lutlen CIRCULATION MANAGER Christine Rosato ADVERTISING MANAGER David Gray SENIOR NATIONAL ACCOUNTS MANAGER Linda Abbett NATIONAL ACCOUNTS MANAGERS John Dyckman, William M. McLachlan WOODWORKING BOOKS

&

VIDEOS

EXECUTIVE EDITOR Helen Albert

Fine Woodworking:

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AUSTRIA 7

SEPTEMBER/OCTOBER 2 0 0 2

Letters Practical use for faux fin ishing­

outdoor jobs like storefronts and signs. If

Peter Gedrys' Finish Line "The art of faux graining" ( #157, pp. 1 14-1 16)

you skip tl1e expensive woods and don't labor the joinery, you can give a client a

doesn't mention one very practical use

project that costs less and lasts longer

for faux finishing, one I discovered on a

with a false wood finish. Faux bois, by its

trip to Paris.

nature, can cover a lot of problems.

FWW

To list all the pleasures of walking

-Robert Braczyk, New York,

around that glorious city would take

The Taunton Press Inspiration for hands-on living'·

I

D EP E ND E

NY

T PUBLIS H E RS SINC E TAUNTON. INC.

Founders, Paul and Jan Roman

pages; but as a woodworker, I zeroed in

Dia mond stones deserve mention­

on the many heavy, oak, raised-panel

The comparison and evaluations of nine

doors that are used at street level in older

different honing systems ("Sharp and

buildings. Light colors seem to prevail,

Sharper,"

yellows and oranges mostly. Though

done and nicely written. We here at Dia­

Publisher, Magazines

many are set deep in masonry walls,

mond Machining Technology were

Publisher, Magazines

most get some direct sunlight each day.

pleased to see the DMT DuoSharp includ­

Some get baked all day. The thing that

ed in your evaluation.

sUl..Ick me was that, in general, tl1ese light

FWW #157, pp. 36-4 1 ) were well

More directly to the point of my letter, there seems to be widespread mention of

someone who has worked on boats, I

virtually every manufacturer of each

know the short life of clear finishes in light. As a

ew Yorker, I've been

UV

heartbroken to watch thousands of dollars of excellent woodworking and

product that was used in your article; however, Diamond Machining Technology is conspicuously absent. Now, I would anticipate that the

material on Madison Avenue storefronts

readership of Fine Woodworking is able

turn shabby in a year or so. So I was particularly interested in these

to correlate tl1e distinctive polka-dot interrupted cut pattern pictured and be

Parisian doors. Though the work was

able to say unequivocally that product

uniformly at a high level, many of the

was made by Diamond Machining

best-looking doors were faux bois-there

Technology; however, an editorial

was usually some small chipping at an

mention would have been appropriate. In

edge-and often many years old. The

this way, the readership could be assured

trick was, as far as I could tell, that the job

that the "diamond stone" was truly of tl1e

was done entirely in pigmented paint: no

highest-quality flatness with precisely

glazing and no clear topcoat.

micronized monocrystalline diamond and

It seems to me that this insight could be highly valuable to woodworkers who do

not a cheap imitation. Thanks again for a tl10ughtful, well­ written article on what we base each and

Fine Wqqc}Working

. . around the country

If we're in your neck of the woods, come by a nd see us

every day of operations on at Diamond Machining Technology: "Sharp and Sharper"! Diamond Machi ning Technology

and executive editor Anatole Burkin

F

?

Plywood instead of M D In reading the Methods of Work "Replaceable insert

-

FWW #156, p. 22), I

top for a radial-arm saw. Over 30 years I have used two radial­

Finanu Director

Publisher, Books

Creative Director Human Resources Director Controller uchnology Services Director Promotion Director Fulfillment Director Associate Ad Sales Director

John Lively T homas Luxeder Timothy Rahr Jon Miller Sarah Roman James Childs Marc Vassallo Susan Edelman Carol Marotti Wayne Reynolds Edward Kingston Steven Turk Patricia Williamson Jeff Dwight

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e Roman

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will be in tl1e Fine Woodworki ng bootl1

arm saws, and botl1 saws came with l-in.­

at tl1e Mid-An1erica Industrial

duck medium-density fiberboard (MDF)

Knorr,Donna Capalbo. Renee Pagelson. CllStom�r S�rviu:

Woodworking Expo in Columbus,

tops. When I replaced my original saw,

Ellen Grassi, Bonnie Beardsley, Katherine Clarke, Frances

Ohio. The show takes place at tl1e

tl1e only part that I was able to salvage

Greater Columbus Convention Center.

from the earlier saw was the top because

For more information on the show, visit

when I bought that earlier saw, I put

their web site at

a piece of \4-in.-thick fiberboard on tl1e

www.tsishows.com.

top and let that piece take all tl1e

8

CEO

LeanneDian, Deborah Greene, Linnea Ingram. Frederick

was surprised to see plywood used as a Nov. 21-22: Publisher Tim Schreiner

&

Chief of Operations

Business Office: Holly Smith.Deborah Cooke, Gayle

-Stanley A. Watson, technical direct01;

for radial-arm saw" (

THE TAUNTON PRESS

President

Editorial Director

finishes were in great condition. As

1975

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READ

ER SERVICE NO. 144

SEPTEMBER/OCTOBER 2 0 0 2

9

Let t e r S

(co nt i n u e d )

cuts. Not only d o I crosscut, but I also

committees composed of scientists,

perform a lot of cutting at different angles

engineers and industry experts who work

20 nunutes, and use either a brass or ny­

and frequent dado cutting on my radial-

in insurance, human safety and

lon brush to scrub the blade. Oven clean­

arm saw.

woodworking and equipment

er, however, may cause the body of the

manufacturing consistently agree that

blade to tarnish and may remove writing

Manufacturer warning-Fine Wood­

plastic pipe should not be used in

and labeling information.

working published a quick tip in its Meth­

material conveying wood waste.

-PauIJacklin, Corona, Calif.

ods of Work department that suggested using Rain-X on glasses to prevent fog

FWW #156, p. 18).

and dust buildup (

Rain-X is designed for external

automobile glass only. When used on plastic surfaces, such as safety glasses or

Static sparks arcing internally or

to get in touch with instructor Peter

mixtures inside or outside the pipe, not

Gedrys, author of last issue's Finish Line.

linlited to wood dust mixtures. Static sparks arCing from the pipe can jolt, injure or startle personnel working on dangerous equipment.

-Mike Maddox, national manager, tech­ nical service, Pennzoil-Quaker State Co.

ction-Several .years ago,

Addendum-Some readers asked us how

externally can ignite combustible

directions clearly state: "Do not use on manufacturer of the plastic to be treated."

-Tom Begnal, associate editor

Some of the reasoning is as follows:

goggles, damage may occur. Our product plastics unless preapproved by the

harm the carbide teeth. Linlit exposure to

The danger of duct fires: Plastic pipe

He may be reached at Architectural Fin­ ishes, 112 Mt. Parnassus Road, East Had­ dam, CT 06423; [email protected]. Corrections-Because of an editing er­

itself is combustible. It cannot contain a

ror, the origin and current home of the

fire starting in a duct. It's easy enough to check your dust bin or bags for

Shaker clock reproduced in issue #157

smoldering material, but sparks or

lived in the Mount Lebanon, N.Y., commu­

were incorrect. Isaac Newton Youngs

embers can also ignite residual sap

nity and built this clock as part of a group

when I was introduced to the World

coating or dust anywhere in your

of 22.

Wide Web, I surfed right to your web site.

ductwork. Running the collector for a few

Hancock, Mass., dwelling house.

Cyber satisfa

An original is now housed in the

I was sorely disappointed and quit visit­

minutes before shutdown can help, but

ing until several weeks ago.

not all ducts are designed efficiently, and

"Sharp and Sharper" (

some material may remain in the duct.

41) had a reference to ceranlic stones,

What a difference! I really like the

Also, the article on honing systems,

FWW #157, pp. 36-

format that you have now. It is clear and

Smoldering materials inside the pipe are

which in the published version were

well laid out. Keep up the good work

out of sight and inaccessible.

eliminated due to space constraints. We

staying in touch with your readers. I'll stay in touch with

FWW.

Limited choices of pipe size: PVC fittings are not designed for pneumatic

-Steve Shank, Bend, Ore.

apologize for any confusion this may have caused.

conveying, compronusing efficiency and good design.

PVC pipe dangers not debunked-In

The above incidents do occur in the

the article "PVC Pipe Dangers Debunked"

woodworking industry. Fire loss is much

FWW #153, pp. 4 8-49), Rod Cole surmises

Assistant Art Director

(

less likely in a small woodworking shop,

that PVC pipe for home-shop dust­

but the hazards are still present. Rod

graphic designer with three-plus

collection systems is safe. I feel strongly

Cole's research is impressive and

years of magaZine experience and

that metal pipe is safer than PVc.

relevant. It provides much needed

knowledge of woodworking to assist

additional information in risk assessment,

in developing technical illustrations

Historically, plastic pipe has been taboo in the woodworking industry. Panels and

About your safety: Working wood is inherently danger­ ous. Using hand or power tools improperly or ignoring standard safe­ ty practices can lead to permanent injury or even death. Don't to perform operations you learn about here (or elsewhere) until you're cer­ tain they are safe for you. If sometlung about an operation doesn't feel right, don't do it. Look for another way. We want you to enjoy the craft, so please keep safety foremost in your nlind whenever you're in tlle shop. -Anatole Burkin, executive editor

try

precisely because many woodworkers

and article layouts. Must have strong

use PVC drainpipe for air handling

drawing skills, be proficient on the

applications. However, the research is

Mac (Quark), understand the produc­

linlited in scope and done by one person

tion process and be able to meet tight

working outside his field of expertise.

deadlines. Photographic abilities are a

Although generally more expensive,

plus. Send letter and resume to: Per­

metal pipe is still a far better choice for

sonnel Department, The Taunton

woodworking applications.

Press Inc., 63 S. Main St., P.O. Box

-Robert Witter, Oneida Air Systems Inc.

Another household cleaner for shop use-A number of readers suggested oven cleaner as an alternative to the blade

& FWW #154, pp. 30-

cleaners reviewed recently in the Tools Materials department (

31). We conferred with Tony Ferrato, a

30-year veteran at Forrest, who said that oven cleaner is okay to use and won't

10

FI

E

W O ODW ORKING

Fine Woodworking is looking for a

5506, Newtown, CT 06470.

Writing an article Fine Woodworking is a reader-written magazine. We welcome proposals, man uscri pts, photo­ graphs and ideas from our readers, amateur or professional. We'll acknowledge all submissions and return those we can't p u blish. Send your contributions to Fine Woodworking, Box 5506, Newtown, CT 06470-5506.

P.O.

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Methods of Work

EDITED AND DRA WN

BY JIM RI CHEY

Adjusta b l e overarm b l a d e g u a rd with d ust collection Cei l i n g attachment

Alu m i n u m tubi ng, 1 in.

���

Steel tubi ng, 1 i n .

S u spension leg

Alum i n u m bar stoc k

Steel tubing i s bolted together to provide height· adjustment.

Dust-collection hose

Kno b s lock the head a bove the

±

H eight_ad "" a rm

Lexa n guard head

'ct

Maintain approximately 7ls-in. gap for efficient dust collection.

.so well that there is virtually no dust generated when ripping a board and very little when making crosscuts. The blade guard consists of three main parts: the head, the height-adjustment arm and the suspension leg. For the guard head, I chose 3,s-in.-thick Lexan plastic because I wanted a clear material that would be almost bulletproof. I cut the Lexan pieces on my tablesaw and assembled them with screws, which allows me to replace one piece at a time if it gets damaged. I made the height-adjustment arm with l-in.-square aluminum tubing and l-in.-wide aluminum bar stock. The arm locks in place When I decided to build a blade guard for my tablesaw, I wanted

with T-knobs to hold the head at the right height over the saw­ blade. The parallelogram-shaped mechanism keeps the head level

one that not only would protect my fingers but also would provide

with the table at any height, and it easily can be raised several

excellent dust collection. I believe I achieved this in the design

inches when changing blades or cleaning the tabletop. To remove

shown above, and for a cost of less than $ 100. One important safe­

the head from the adjustment arm, I simply have to remove a

ty feature is that during use the guard head is locked into position just in. above the workpiece. In my opinion, this feature pro­

couple of cotter pins.

vides more protection than a guard head that can be lifted by the

steel tubing. These sizes fit inside each other, telescoping to allow

workpiece during the cut. The dust-collection component works

gross height adjustments and quick removal of the entire unit, if

\-16

I made the suspension leg from Ph-in., 1 \-ii-in. and l-in.-square

A rewardJ. for the best tip

Woodworking is not rocket science, but Gordon Sampson brings the talents of that discipline to his hobby. Sampson currently works at NASA in Houston, Texas, as an electrical engineer on the International Space Station program. He took up wood­ working as a serious leisure pursuit only three years ago. Sampson's design for an overhead blade guard for his tablesaw is both sturdy and elegant. Send us your best tip, along with any photos or sketches (we'll redraw them), to Methods of Work, Fine Woodworking, Box Newtown, CT

P.O.

14

FINE W O OD W ORKING

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ER SERVlCE NO. 16;

S E PTE M B E R/ O C TO B E R 2 0 0 2

17

M et h o d S

0 f W0 r k

( c o nt i n u e d )

frame. The maximum opening between the blocks (determined by

form and to control the length of the mortise cut. TIle jig, which is

the location of the pivot holes) should be a little more than the thickness of the stock to be joined. A 7,s-in. opening is about right

used with a fence on the router, can be set to make just about any length of mortise on any thickness of wood. Best of all, you can

for 3A-in.-thick stock.

put it together from scraps in no time.

-Jeffrey

P Gyving, PointArena, Calif.

Each jig section consists of a stop screwed at a right angle to the

Router m o rtising jig Ra i

top edge of a rail. For smaller mortises, %-in.-thick by 3-in.-wide stock will work fine for both the rails and the stops. You may want

l

to scale up the jig for larger mortises or use thicker stock to pro­ M o rtise layout

vide a wider platform for mortiSing thinner workpieces. When siz­ ing the jig, just be sure the rails are long enough so that the stops overlap when the rails are clamped to the workpiece. You also can chamfer the bottom edge of the stops to aid iri clearing debris. Before using the jig, clamp it to a piece of scrap and rout a short mortise by bumping the base of the router against each stop. Use the ends of the mortise to mark a square pencil line across the top of each rail. This line will register the distance from the router baseplate to the outside edge of the bit, and you can use it to align the jig quickly with your mortise layout lines. The registration lines work only for one size of router bit, but the jig is so easy to make that I have a separate one for each bit that I use to cut mOl1ises. To use this jig, mark out your mortise on the workpiece. Align

Registration l i n e

Workpiece

the registration marks on each jig section with the mortise-length layout lines and clamp the two jig sections to the workpiece, mak­ ing sure that the rails are flush along the top. Set the router fence to locate the mortise laterally and rout the mortise to depth. If the

1.

Clamp jig sections to both sides of the workpiece, aligning t e registration marks with the mortise layout.

mortise is near the end of a workpiece, it's a good idea to add a

� � �

piece of scrap the same thickness as the workpiece to provide a longer clamping base.

-Rob Sterling, Boise, Idaho

•

Benc h stop for p l a n ing

Bench stop

2.

. .�,'..�,.... 'l-...'...'-. � '- .. -

Rout the

�-"-

PIYWOOd, �

3A1

"-'

in.

thick

My bench has no dogs or other accessories for securing a work­ piece to the top of the bench for planing or scraping. So I came up with a modified bench stop that performs this function quite well. This simple router-mortising jig has two sections that are clamped to

To make one, screw a generously sized piece of %-in.-thick ply­

both sides of the workpiece to provide a wide, stable routing plat-

wood (mine is 14 in. wide by 18 in. long) to a 2x4 scrap. The 3,{j-in.

18

FINE WOODWORKING

DEWALT.

M et h o d S

0 f W0 r k

(conti nued)

plywood i s thin enough that it won't interfere with a plane coming

produces not a gouge but a high spot. This can be corrected by run­

off the end of a %-in.-thick workpiece. The jig is wide and long

ning the piece through again. It is not possible to cut too deeply be­ cause the fence keeps the workpiece a fixed distance from the blade.

enough to keep the board from moving sideways when planing at an angle to the board's grain. Pressure from the plane usually will keep the workpiece firmly against the jig. -Justin Smith, Gustavus, Alaska

It's easy to creep up on a perfect cut with this method. The method works especially well at beveling long workpieces lying flat on the saw table, such as cutting octagonal posts from square blanks. But by adding a tall fence you can easily and safely

Quick tip: To compress a biscuit swollen with moisture, lay it on a

use this setup for raising panels. When shaping raised panels, it is

solid surface and strike it a few times with a carpenter's claw ham­

best to define the panel field with a scoring cut before making

mer. Test it in the slot and strike again, if necessary. The biscuit will

the bevel cut to produce neater edges. -Tom Lathrop, Oriental,

swell for a tight fit as soon as glue is applied. -Jim MiUer, Milan,

Ill.

NC

Fifteen-m i n ute vise

Safer bevel cuts o n t h e t a blesaw Notch for wedge removal

Auxi l i a ry fence

J

Spacer for hol d i n g thin stock

Ta b l esaw fence

Ta l l face atta ched to a ux i l i a ry fence

R a i sed-pa nel workpiece

�

Batten s serve as v i se jaws.

Here is a handy little device that is beyond simple to make. I origi­ nally made it to hold a door upright so that I could plane the edges. Since then I've used it in practically any way you might use a vise. The device is portable, and it's a great tool to have on installations. If you lose it, you can make anotl1er with scrap in only 15 minutes. To make tl1e vise, rip two 2x4s to make four 2x2 battens about All references to cutting bevels on the tablesaw that I've seen have

12 in. long. Choose tl1e best of the four battens and cut it into a 3°

the sawblade tilted away from the fence with the workpiece be­

or 4° wedge shape with a notch in the top of the thick end as

tween the fence and the blade. I think this arrangement not only

shown. Choose two of tl1e otl1er battens as tl1e jaws of the vise.

increases the possibility of burning or gouging the work, but it

Affix one of the jaws to a %-in.-thick plywood base with glue and

also poses a risk of kickback. To avoid those problems, I moved the rip fence to the other side of the blade, made an auxiliary fence as shown above and began

screws. Use the fourth piece as a temporary spacer and set the wedge next to it. Place the second jaw against the wedge, and glue and screw it to tl1e base as you did the first one.

cutting bevels in a different way. There are several advantages to

To use the jig, place the workpiece between the jaws and tap the

this setup: First, it is safer. The offcut falls into the large space un­ der the auxiliary fence where it cannot bind and kick back. Sec­

wedge into place. To release, tap the notch on the tluck end of the

ond, any wayward movement of the workpiece during the cut

20

FINE WOODWORKI

G

wedge. If you need to hold a thin workpiece, just add another -Albert Kauslick, Burlington, spacer, sized as needed.

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Notes & Com ment Awa rds fro m c o a st to c o a st

B o o k rev i ew

M a ryland woodworker wins FWW awa rd Robert Ortiz, a Chestertown, Md., furniture maker, won the Best New Artist in Wood award at the 2002 Philadelphia Furniture and Furnishings Show. The award is spon­

AUTOMOT IVE

WOODWORKING

sored by Fine Woodworking and includes a check for

1,000. Woodworkers in their

first or second year of exhibiting at the show are eligible for the award. Ortiz, whose furniture combines Shaker and Asian influences, was drawn to wood­ working in 19 84, when he came across a copy of George

akashima's book, Soul oj

a Tree.

Having been a musician, Ortiz finds that building a piece of furniture is not unlike making music. "Measure upon measure, one builds a piece, one note, one joint at

Automotive Woodworking: Res­

a time," he said. "With patience and dedi­

toration, Repair and Replace­

cation, the goal is to achieve a well­

ment

Robert Ortiz of Chestertown, Md., who won

arranged and orchestrated piece, perhaps

P ublishing Co., St. Pau� Minn.,

the award for best newcomer in woodworking at the Philadelphia show.

even a work of art."

$24.95

Fine Woodworking. This chair was made by

by Roland Johnson. MEl pape rback;

160 2001. pp.

-Tim Schreiner, publisher

RolandJohnson describes himself as a professional woodworker and a hot-rodder at heart. Two dozen

Marq uetry table wins Best in S how at San Diego

articles for Fine Woodwork ing con­ A round tilt-top table with traditional mar­

self. The table is 42 in. dia. by 30 in. high

firm the former, and I can certainly

quetry, a sculpted base and cast bronze

and is finished with oil and varnish.

attest to the latter, having been

feet won the Best in Show award at this

A woodworker for more than three

whipped around the back roads of

year's Design in Wood competition at the

decades, Schurch has been working pro­

Minnesota by Johnson in his half-fin­

San Diego County Fair. Fine Woodworking

fessionally since 1980 and has been fea­

ished hot rod.

sponsors the award, which is the top prize

tured in many magazines, including Fine

This book is aimed at the car en­

Woodworking and A rchitectural

thusiast who has limited knowledge

at the show and includes a $ 1,000 check and a plaque for the

of woodworking. It gives a good in­

Digest.

winner.

He

Paul Schurch of Santa

has

trained

Switzerland,

Barbara, Calif., won for

in

troduction to the hand and power

England

tools you'll need to work on your

and Italy, and he re­

''woody,'' plus a guide, including col­

his "Charles X" break­

turns annually to Re­

or photographs, to different solid

fast table, which is

monti lntarsiatori in

woods and veneers suitable for use

made of Pollard ash

Italy

he

in or on a car. The book covers re­

and is graced with in­

learned advanced

finishing and restoring wood, as well

inlay

as bending and shaping the complex

tricate inlay,

purpleheart and

bronze,

The

Most of the photographs are black

exhibition

is

and white, and although chiefly tak­

held annually in con­

en by the author, they clearly convey

Wood

F I N E WOODWO R K I N G

more

replacement parts needed on cars.

in

junction

22

mar­

Design

that Schurch cast him-

with purpleheart and cast­ bronze, three-toed griffin feet.

and

quetry techniques.

three-toed griffin feet

Best in show. Paul Schiirch 's table features Pollard ash inlaid

where

San

the information. My only quibble is

Diego County Fair. It attracts

with his method of applying a finish:

than

360

with

the

woodworking

pieces from around the nation and several foreign countries.

- TS.

Get a good natural bristle brush, Rol­ lie, and toss those foam ones! -Mark Schofield, associate editor

WOOlen,

Photos, except where noted, Mark Schofield; this page, top left Michael courtesy of Robert Ortiz; bottom left: Lynn Rybarczyk and Andrew Pauerson, counesy of the San Diego Fine W'oodworkers Association

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available, the cost o f connecting may be

horsepower of the motor by about a

it generates three-phase power to run

financially prohibitive.

third and has difficulty starting air

other machines. More expensive than a

compressors, dust collectors, large

static converter, a rotary converter costs

Short of mnning three-phase power, there are a number of options available to

bandsaws and other machines with

around 600 for a 3-hp unit but doesn't

get a three-phase tool running on single­

heavy starting loads. The reduced

have the starting and reduced-power

phase power. The first and most obviolls

horsepower often isn't a problem and

problems that occur with a static

option is to replace the machine's motor

can be compensated for by reducing the

converter. If you expect to own several

with a single-phase unit. But this may not

feed rate or by taking lighter cuts. But

three-phase machines, buy a good-sized

be possible on some machines because

overloading or stalling a motor hooked

rotary converter, which will be more

the original motor has special mounting

up to a static converter will cause

economical in the long mn.

brackets or the drive shaft has custom

deSU"LICtive overheating of both the

threads or splines. Unfortunately,

motor and the converter. A hard-to-start

An electronic converter is more properly called an inverter for technical

specialized motors are fairly common on

machine can be run by first starting

reasons, and most catalogs will list this

tablesaws. If the tool's manufacturer is

another lightly loaded machine, an "idler"

device under that name. An electronic

still in business, you may be able to

that serves as an electrical flywheel to

inverter transforms single-phase power

obtain a single-phase motor from them.

start the second machine. A surplus

into direct current and then uses

three-phase motor can be used as a

microchip-guided controls to simulate

will allow you to run a three-phase

dedicated idler that runs continuously to

three-phase alternating current. The

machine on single-phase power. There

improve both the starting and the

electronics in an inverter allow you to

are three basic types of converters: static,

mnning of other motors hooked up to

control the motor's speed, torque and

rotary and electronic.

a static converter.

direction of rotation, and often allow

Another option is to use a converter that

Of the three, the static type ·is the least expensive. A static converter has no

A rotary converter, which looks like a heavy-duty electric motor with an over­

for a soft start to bring the machine up to speed gradually. Most of the added

moving parts and needs to be sized for

sized junction box attached, functions as

control offered by an inverter would be

the motor it's running. Unfortunately, a

both a motor and a generator. As a rotary

wasted on a tablesaw but would be a

static converter reduces the available

converter is spun by single-phase power,

great advantage on a lathe or possibly a

READER SERVICE NO. 149

92

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84 S E PTE M B ER / 0 C TO B E R 2 0 0 2

93

Q &A

(co n t i n u e d )

bandsaw. Because i t must be

blade without loading it in a

programmed, an inverter typically is

plane and taking a cut?

dedicated to running only one machine,

-Bill Woodson, Peoria, III.

but with some compromises, it can be used to run several tools. The price of

Aime Fraser replies: You can check

inverters has been dropping steadily

for sharpness quickly by holding the

over the last few years.

tool lightly between your thumb and

Choosing the right type and size of

forefinger and lowering the edge gently

converter and hooking it up correctly

onto the thumbnail of your other hand

can be complicated. You should do

(see the photo at right). A sharp blade

some research and get more advice

will catch on the nail immediately. A not­

before investing in a converter or an

quite-sharp blade will skid a little and

inverter. (Manufacturers of converters

then catch, but not very solidly. A dull

and inverters offer extensive literature

one will slide. If your iron fails the

and phone consultations.) You'll find

sharpness test, go back and start at the

a list of expert sources on our web site:

beginning of your honing process. I

Uohn White is the shop manager for

recommend using a honing jig for quick, consistent results. Spend plenty of time

Fine Woodworking.]

on the coarsest stone until you feel a fine

Testi n g for s h a r p n ess

Then go through the abrasives again, one

www.finewoodworking.com.

burr along the entire back of the blade. I enjoyed the recent article on honing

by one, lapping the burr off the back after

systems (USharp and Sharper,"

you finish witl1 the finest grit. Try the

FWW

comes to mind: Is there any way to test

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and writer.]

#157, pp. 36-41), but one question

will skid across a thumbnail. A sharp edge will catch.

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S E PTE M B E R/0 CT0 B E R 2 0 0 2

95

Master C ass

B Y

S T E V E

B R O W N

Layi n g o u t co m p o u n d - a n g l e d oveta i l s

START WITH A P R ECISE BUTT J O I NT

Brown s i mplifies the process of making compound-angle butt j o ints o n pp. 64-67 of this Issue. Here h e offers an easy layout tech nique that opens the door to doveta ils.

If you can cut an accurate butt joint on a compound angle (see

to locate the scribe line on the other. Mark the face that has the

pp. 64-67), then you can cut compound-angle dovetails. The rest is

sharper corner, because this is the edge that a marking gauge can

basically a layout lesson. Done well, these specialty dovetails be­

be used on. Then carry the line across the edges using a square,

come an attractive design element in themselves. Cradles and trays

keeping the line parallel to the beveled edge and the blade of the

are just a few projects that require them. The drawers on a bomb€:­ style chest are another example.

square flat on that edge. Last, use a straightedge to carry the shoul­

Fundamentally, compound-angle dovetails are the same as nor­ mal dovetails. The shoulders of the pins and tails are parallel to the ends of the board, and the lines for the pin faces are parallel to the top and bottom edges of the board. The angle for the flare of the tails still needs to be appropriate to the overall grain direction.

der line across the other face.

r prefer to cut pins before tails, but going tails-first also would be

feasible here. Lay out the rise and run angles the same way to get the two bevel-gauge set­ tings

needed;

then

And spacing the pins is still a matter of strength and individual taste. The challenge is to figure out specifically what these an­ gles are when you factor in the compound angle, and also how to work with the awkwardly shaped boards. By the way, with the exu'a angles involved, hand-cutting is probably the easiest way to form these joints. I suppose a tablesaw or bandsaw could be used, but only with a number of ramps or jigs. And as far as I can tell, a router set­ up simply is not possible.

Scribe the s h o u l d e r The shoulder (the length o f the pins and tails) i s still deter­ mined by the thickness of the adjacent board. However, be­ cause these boards connect at an angle, the dimension of the

Projects like this Shaker cradle

shoulder line is not the actual thickness of the adjacent board but the width of its edge when cut at an angle. Sounds complicat­

depend on compound-angle dovetails. The angled sides make

ed, but all you have to do is use the angled end of one board

the interior more accessible.

96

FINE WOODWORKING

Photos. except where noted: Asa Christiana; this page: Lance Panerson (bonom), Kelly J. Duman (top right)

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READ

ER SERVICE

NO.

132

S E P T E M B E R/0 C T0 B E R 2 0 0 2

97

Master eIass

(conti n ued)

Use the marking gauge on the inside face (with the sharper edge). Rub the beam along the face of the board to keep the gauge in proper alignment.

t

board. P i , , " ,, p", II" to the top a n d bottom of the boa rd .

Carry the lines across the edges. Using a square with its blade laid flat along the beveled edge of the workpiece, scribe the lines with a knife.

transfer those angles to the face grain of the tails boards, rather

Connect the

than to the end grain of the pins boards.

lines. Last, use a straightedge

R ise-run tech n i q u e s i m p l ifies layout

and marking knife to connect

Start by laying out the pin spacing along the inside face of the board. Just as with regular dovetails, use the centerlines to mark

the scribe lines

the edges of each pin. The difference here is that the pencil lines

along the out· side face of the

used to lay out the sides of the pins should be parallel to the top or

board.

bottom edge of the box, not square to the end of the board. The key point with compound-angle dovetails is that the flare of the pins (and tails) is not a single angle as it is with normal dove­ tails; both the direction of the grain and the centerline are parallel to the top and bottom edges of the box sides but not square to the ends of the boards. So the top and bottom of each pin are at dif­ ferent angles. To find the two necessary bevel-gauge settings, set up a rise-run ratio on the face of one of the boards. To get a u'ue 6: 1 dovetail an­

Brown prefers doing pins

gle, don't take the rise dimensions as measurements up the face of the board. Instead, take them as elevations, with the board in its

first. Along the

sloped position. To do this turn again to the indispensable set­

of the board, mark the spac­

up block (see p. 65). Lean the board against it, and then use the top face of the block and two box sides laid on top of it to make three evenly spaced marks. ow set up the run. Draw a line through the center mark, paral­ lel to the top and bottom edges of the box. Measure the thickness

outside face

ing. Set the blade of your sliding bevel gauge parallel

of the box sides and use that increment to make six marks along

with the top and bottom

that long centerline. That's the run for a 6: 1 ratio. Last, connect the

edges of the

sixth point with the top and bottom rise marks you made earlier. These are the correct angles for the top and bottom of each pin (or

board and lay out the sides

tail). Lay a sliding bevel gauge along the end of the board and take

of the pins.

the top setting. Lay out all of the top sides of all of the pins on the

98

FIN

E \'if

0 0 0 \'if 0 R K I N G

Photos. this page, KellyJ. Dunton (top left). lichael Pekovich (top right. middle right)

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ER SERVICE NO. t76

S E P T E M B E R/ O C TO B E R 2 0 0 2

99

Master eIass

(contin u e d )

A R I S E - R U N R AT I O D E T E R M I N E S T H E A N G L E S

-------,

M A K E A L A R G E S ET-U P BLOCK

Make it like the one on p. 65, with its sides cut at the slope of the box sides. Then use the block and two of the actual box sides to lay out three equal divisions on another side of the box.

Center­ --�-

Layout board

(

l i ne of p i n

T h e centerlines o f t h e p i n s (and tails) run parallel to the top and bottom of the box. Therefore, the top and bottom of each pin

Set-up block

and tail a re at different angles to the end of the board.

box before changing the setting and laying out the other side of each pin.

Saw, chop a n d tra nsfer Once the pins have been laid out, the sawing, chopping and par­ ing to the lines are basically the same as when making conven­ tional dovetails, except the shapes look different and might be a bit awkward to reach. You can rip an extra block while cutting the butt joint and use it as a paring block when cutting the shoulders, clamping it onto the workpiece to guide your chisel. Transferring the layout of the pins onto the face of the tail board is similar to the regular process, but holding the boards is a bit of a challenge. Lay out the tails with a sharp pencil (a marking knife will bruise the nonwaste portion of the wood). Last, transfer the marks across the end of the board with a bevel gauge set at the ap­ propriate angle. Don't try to mark the tails on the other side of the board. Saw, pare and fit the tails in the standard way. S ET T H E BEVEL G A U G E A N D M A R K T H E P I N S

0

Mark out six divisions of the same thickness as the sides to create a 6:1 dovetail angle. Use those lines to set your sliding bevel gauge. There will be different gauge settings for the tops and bottoms of the pins.

_____________________________ Cut the pins or tails and transfer their loca­

Take the two settings from the layout board. Lay out one of the angles on all of the pins or

tions to the mating board. It's no easy feat to keep these angled boards in perfect position

tails, then reset your bevel gauge to the other angle and finish the layout.

during this step.

1 00

FINE WOO DWORKING

Drawing and photo, this page (top left} Kelly J. Dunton

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