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Fine WqQQWorkingo

Departments 6

Contributors

8

Letters

14 22 30 88 96 102 110 118 130

Methods of Work A safe r c ro ssc ut sled ; Ed ge-joi nti ng l o ng bo ard s wi th a ro uter

Shop Design A sho p in the b ac kyard

Tools

&

Materials

Batte ry-powered nai l e rs; Spo tl i ght on the late st too l s

A shop inspired by school memories, p. 46

Current Work A gal l e ry of o ur re ad e rs' tool s and benc he s

A Closer Look How an i nd uc ti o n mo to r wo rks

Rules of Thumb Work at the right hei ght

Reviews T he l ate st woodwo rki ng books

Questions

&

Answers

The scoop on Jap ane se c hi se l s; How to fl atte n w avy ve ne e r

Cutoffs Co nq ue ri ng cl utte r

On the Cover: Contributing editor Lon Schleining puts the finishing to uc hes on a robust workbench. For plans, see p.

38.

Photo: Asa Christiana

A clever tool case, p.

75

Roll-away garage workshop, p.

70

W I N T E R 20 0 3 /20 0 4

N O . 16 7

Articles 38

46

66

The Essential Workbench Wo rkho rse be nc h co mbi ne s the be st of the old and the new

T hi s shopmade c abi ne t sc rape r w i l l tame the mo st diffi c ul t wood s

BY LON SCHLEINING

BY STEPHEN SHEPHERD

A Shop Inspired by School Memories

70

Thi s we l l-l i t wo rksp ace fe ature s an open floor p l an o rganized fo r e fficie nt wo rkflow

TO L T E S T A TABLESAW P R I M E R

9 Midsize Tablesaws

How co ntrac to r-style saw s and hy brid s me asure up

A Clever Tool Case Bui l t-i n stand s keep an e sse nti al tool ki t at the re ady

BY YEUNG CHAN

Ripping and Crosscutting

Soundproof a Basement Shop

BY MARK CORKE

Watch a video of the author

using a crosscut sled

82

Mobile Bases Fo r sho p s l arge o r smal l , mo bil ity o ffers conve ni e nce, as l o ng as the base i s stable and rol l s smoo thly

BY CLIFF COLLEY Protecting Surfaces in the Shop M ac hi ne s, ji gs, and be nc he s all be nefit f ro m bei ng se aled and w axed

BY CHRIS A. MINICK Mobile bases, p. 82

Visit our Web site:

Ripping and crosscutting on the tablesaw, p. 56

Two-p ro nged attac k arre sts bo th ai rbo rne and vi brato ry noi se s

T he p rope r tec hniq ue s he lp e nsure acc urate and safe c uts

62

75 78

BY ROLAND JOHNSON

BY KELLY MEHLER ON OUR WEB SITE,

With w heel-mounted tool s and c abi ne ts, a two-car garage e asily transfo rms into a ve rsati le wo rkshop

See the rolling workshop in action

Take a virtual tour

of the author's shop

56

Roll-Away Workshop

BY BILL ENDRESS ON OUR WEB SITE,

BY MARK BELLONBY ON OUR WEB SITE, 50

Make a Wooden Scraper

finewoodworking.com

Protecting surfaces in the shop, p. 62

Contributors

Fine WqQQWorking

The unique hand-drawn illustrat ions found in Fine Woodworking convey not only concepts and

EDITOR Anatole Burkln

construction but the beauty of woodworking as well.

Bob La Pointe 15

more than

ART DIRECTOR Michael Pekovlch

has been illustrating for us for

MANAGING EDITOR Matthew Teague

years. In this digital age, he still

SENIOR EDITOR Asa Christiana

relies on markers and color pencils to render

ASSOCIATE EDITORS William Duckworth

his masterpieces (see "The Essential

Thomas G. Begnal, Mark Schofield

ASSISTANT EDITORS

Workbench"). La Poi nte lives on Cape Cod

Matt Berger, Karen E. Wales

SENIOR COPY/PRODUCTION EDITOR

(Massachusetts) with his wife and daughter.

Thomas McKenna

When not parked in front of the drawing board, La Pointe is likely to be knee­ deep in Wellfleet harbor tending to the acres of clams and oysters that he cul tivates for restaurants both in New England and across the country.

COPY/PRODUCTION EDITOR Julie Rlslnlt

ASSOCIATE ART DIRECTOR Kelly J. Dunton ASSISTANT ART DIRECTOR Rodney Diaz SHOP MANAGER John White EDITORIAL ASSISTANT Christopher

X.

Baumann

CONTRIBUTING EDITORS Cliff Colley

("Mobile

Tom LeRoy

(Rules of Thu m b) is a physical

Bases") is a shop

therapist i n Bru nswick, Maine, who travels

i nstructor at Plymouth

throughout the state to provide safety tra i n i ng to

South High School in

companies, to treat injured workers, and to mod ify

Plymouth, Mass. A

employee work habits and workstations. LeRoy

graduate of North Bennet

uses these same safe work habits in his

Street School's Cabinet

woodshop, a converted Boy Scout ca m p building.

and Furniture Making progra m , he has publ ished work i n Design Book

Mark Bellonby

Seven (The Ta unton Press, 1996). Although his

Memories"), an arch itect, came to the profession

woodworking and teaching ski lls may be

by way of woodworking, studying i n the late 1960s

impressive, he is most proud of his new role as

under Karl M. Pacanovsky at the H i l l School i n

( "A Shop I nspired by School

Tage Frid, Christian Becksvoort, Marlo Rodriguez, Gary Rogowski, Mike Dunbar, Lon Schlelnlng, Garrett Hack, Roland Johnson

CONSULTING EDITOR Chris Minick METHODS OF WORK Jim Richey INDEXER Harriet Hodges PUBLISHER Tim Schreiner SR. MAR KETING MANAGER Alan Whitney MARKETING MANAGER Karen Lutjen SINGLE COPY SALES MANAGER Mark Stlekman CI RCULATION MANAGER Jeanne Todaro

father to his three stepch ildren, Sarah, Pa u l (with

Pottstown, Pa, T h e school's strong woodworking

ADVERTISING DIRECTOR David Gray

Colley above), and Olivia.

program emphasized

ASSOCIATE ADVERTISING MANAGER Linda Abbett

design and drafting skills Rick McCaskill

(Shop Design) has been a

woodworker for more than 35 years. He is vice

SENIOR NATIONAL ACCOUNT MANAGER

in a setting that

John Dyckman

encouraged close

NATIONAL ACCOUNTS MANAGER

president of business development and

collaboration among the

William M. McLachlan

ma rketing for a biometric company and lives i n

fine a rts, metalworking,

ASSOCIATE ACCOUNTS MANAGERS

S i m i Val ley, Calif. He spends a lot o f his spare

and woodwo rking studios.

time enjoying his new woodshop, especially the

Bellonby cu rrently is a

times he gets to help his grandchildren assemble

design partner in a

their own projects on a child-size workbench.

Washi ngton , D.C., a rchitecture firm, design ing

Kate Kelly, John Lagan

ADVERTISING SALES SUPPORT ASSOCIATE Christina Kryzanskl

built their fi rst home. Now

present career as a furniture maker and is well

they spend their spare

known for his handmade tools. A line of Veritas

time remodeling a 1901

deta i l ch isels modeled after Chan's set is available

& Fine Woodworking: 0361·3453) 06470-5506. 203426064708171.#123210981. $59.95 $83.95 $34.95 $104.$7.959$41.9. 95 $73.95 $8.99. 5506, 06470-5506.63

bungalow in Seattle.

from Lee Valley Tools (www.leevalley.com).

Printed in the USA

office and apartment buildi ngs, condomini ums, Barry Wixey

(A Closer Look) has been design ing

and hotels.

(ISSN:

Yeung Chan

( "A Clever Tool Case") escaped

His company has designed products for a n u mber

Com m u n ist China in 1968, avoiding armed patrols

of manufacturers, including Delta and DeWalt. His

and negotiating rugged, icy mountains to get to

interest in woodworking

Hong Kong, and eventua lly la nded in New York.

started as a child and

After a few years on the East Coast, Chan moved

pea ked when he and his

to San Francisco, where he took a job with a

wife, Cora, designed and

furniture manufacturer. In 1989, he began his

6

FIN E W O O D W O R K I N G

VIDEOS

EXECUTIVE EDITOR Helen Albert

is published

bimonthly, with a special seventh issue in the winter, by

tools for more than 20 years and woodworking machinery i n particular for more than 15 years.

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READ

ER SERVICE NO. 217

TOOLS

&

SHOPS 2004

7

Letters Elongated holes made easy

In his article "Anatomy of a Chest of # 163, pp. 36-43), Will Drawers" ( Neptune recommends using slotted screw holes. I've never shied away from using them, but you must admit they are a lot more complicated than popping in a drill hole. Apart from the fact that I don't keep router bits around that fit the shank of a #8 or #10 wood screw, on some occasions I have to use flat-head screws. The solution to this problem is to chuck up a countersink in the router, but setting the stops is a pain. In most cases, I use round-head screws, drill two holes, and cut out the waste between with a coping saw, then take the piece back to the drill press and run it back and forth along the sides of the drill bit. Maybe on occasion I'll touch that up with a file. How does Neptune cut his elongated screw holes?

FWW

-Robert Braczyk, New York,

NY

as the screw shank, allowing movement in one plane while keeping things aligned in the cross direction.

The Taunton Press Inspiration for hands-on living"

A view on editorial content

I

I've never written to a magazine before; however, I felt compelled to respond to Duane Yoder's letter, "A disgruntled # 163, pp. 8-10). reader" ( I'm in my early 50s and have just taken up woodworking. Your latest Tools # 160) was of Shops issue ( enormous help to me. Several things occurred after I read the issue. First, I realized that I would need both a jointer and planer to improve my box-making attempts. And second, your reviews allowed for making a much better­ informed purchase. People start various challenges and interests at different times of their lives. I for your most would like to thank positive attitude in including articles that reach across the broad spectrum from the beginner to the most experienced.

FWW FWW

TAUNTON. INC.

TH E TAUNTON PRESS

President

"Sloppy" screws are a quick and effective way to connect parts and allow for seasonal movement. First, drill a regular hole and countersink it. Then, on the inner face (where the movement is), drill two more holes, angling them so that they are aimed at the bottom of the countersunk recess. Chisel away any waste left between the holes, and it's done. The goal is to have the screw head fully supported by the countersunk recess, but allow the shaft of the screw to tip back and forth in the angled slot. The slot is kept the same size

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 try to perform operations you learn about here (or elsewhere) until you're cer­ tain they are safe for you. If something 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 mind whenever you're in the shop. -Anatole Bw'kin, editor

8

FINE WOODWORKI

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John Lively

Editor In Chief Sue Roman Chief Marketing Officer Chief Financial Officer Chief of Operations

Sarah Roman Timothy Rahr Thomas Luxeder

Publisher, Magazine Group Jon Miller Publisher, Book Group

James Childs

DIRECTORS

Creative Director Human Resources Director Technology Services Director Controller Marketing Director, Magazines Promotion Director Fulfillment Director

Susan Edelman Carol Marotti Edward Kingston Wayne Reynolds Diana Allwein Steven Turk Patricia W illiamson

TAUNTON TRADE COMPANY

Director, Kathleen Davis

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TAUNTON DIRECT

A ustralia

WILL NEPTUNE R EPLIES:

1975

Founders. Paul and Jan Roman

&

FWW

DENT PUBLISHERS SINCE

DEPE

President. Sarah Roman TAUNTON NEW MEDIA

Oemystifying cover lines

Director, Leslie Kern

For all the years I have subscribed to your magazine, I have intended to write and relay my satisfaction to you for such a great magazine. I have saved them all and have many boxes of them. In addition to the praise I have preserved for you for several years, I have a complaint that has been with me in receiving each issue you publish. But your magazine is not the only one that does this; it's rampant in most magazines. My complaint is this: Why not tide your feature items inside the magazine the same as you tide them on the cover? -Jim Norwood, Charlotte,

NC

The headlines we write for d1e inside of the magazine don't always fit in the space allotted for the cover lines (or vice versa). But you raise a valid point: Finding an article should not be a struggle. We'll try harder to make d1e connection between the cover lines and the articles less Clyptic. EDITOR R EPLIES:

TH

E

TAU NTON STAFF

Books: Marketing: AllisonHollert, Audrey Locororondo.

Editorial: Maria Taylor, Helen Alberr, Perer Chapman, Robyn Doyon-Aitken. Maureen Graney, Carolyn Manclarano, Jennifer Renjilian Morris, David Palmer, Jennifer Peters, Amy Reilly, Erica Sanders-Foege, Timorhy Snyder, Karhleen Williams, Marilyn Zelinsky-Syarro. Art: Paula Schlosser, Joanne Bisson, Nancy Boudreau. Wendi Mijal, Lynne Phillips, Carol Singer. Rosalind Wanke. Manufacturing: Thomas Greco, Laura Burrone. Business Office: Holly Smirh, Gayle Hammond, Pacricia Solomon. Legal: Carolyn Kovaleski. Magazine Print

Production: Philip Van Kirk, Nicole Anastas. Distribution: Paul Seipold. Sergio Colon, Leanne Furlong, Deborah Greene, Linnea Ingram. Andrew Lowder, Frederick Mannes, Raymond Passaro, AJice Saxcon. Finance/Accounting: Finonu: Kathy Wonh, Andrea Henchcliffe, Susan laclaro)a, David Pond. Accounting: Patrick Lamontagne. John Vaccino, Irene Arfaras, Lydia Krikorian, Elaine Yamin, Carol Diehm, Margaret Bafundo, Dororhy Blasko, Susan Burke, James Post, Lorraine Parsons, Priscilla Wakeman.

ulfillm

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ent: Diane GouJart. Client Services: Jodi Klein, Nancy

Knorr, Donna Capalbo, Renee Pagelson. Customer Service: Ellen Grassi, Bonnie Beardsley, Michelle Berry, Katherine Clarke, AJfred Dreher, Monica Duhancik, Margaret Hicock, Barbara Lowe, Eileen McNulry, Patricia Parks, Deana Parker, Patricia Pineau, Betty Stepney, Marylou Thompson. Data

A turner's delight

I enjoyed Andy Barnum's "Midi-lathes" # 158, pp. 68-73) and found the ( FWW

Entry: Melissa Dugan, Anne Champlin, Joanne Lefferrs, Debra Sennefelder, Andrea Shorrock. Human Resources: Linda Ballerini, Christine Lincoln, Dawn Ussery.

ORTISE &&TENON JIG

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ielsen. Linda Reddington. Lawrence Sullivan,

tcEonabinlecsu,tmcwhoartthrisaenpdlutaegbnloenrcsouatnesdr.uIocdwtioeanl.jfoirnts

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•• ••• •

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Dorothy Simpson, Suzanne Sylvester, Ward Willis.

T

One set·up lor both mortise and tenon giving perteclly litting joints. Cuts mortise

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tenon sizes

01 W 'is'. to

Fully adjustable lor compound angle joints up to 45'. Reversible templates to produce round and square end tenons. Templates can be used lor accurate dowelling applications. Template guide bushes are included but router bits are required.

Room:

Michael Louchen, Geraldine Benno. Anna Pendergast. orma-Jean Taylor. Maimeno.nce: Susan

erich. Alvin Jack,

Jennifer Licursi. Lincoln Peters. Promotion: William Brady, Mary Beth Cleary, Michele

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Diana Mackey, Paul McGahren, Eve Pison, Elizabeth Quintiliano. Single

Copy So"'" Mark Stiekman, Valerie

Droukas.

trend'

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about the interests you enjoy, converse with fellow

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ER SERVICE NO. 139

TOOLS

&

SHOPS 2004

9

Let t e r S

(co nti n u e d )

comparison to be very helpful. Recently, I bought a Nova Mercury midi-lathe based on that article-a beautiful machine even though the lathe witll bed extension apparently amounted to only 20 in. between centers. However, it may be of interest to your readers that additional 12-in. extensions can be bolted on to increase the bed length even more for long spindle turning. -Julian Hamel; Ashland, Ore.

A better way to remember

Gary Rogowski's article "How to Get # 165, pp. 32Straight, Stable Stock" ( 37) covers a subject that I have struggled with on many an occasion. In the article, Rogowski talked about his FEE system (Faces, Edges, and Ends) for the proper sequence during final milling. I mounted a sign on the walI'near my planer with FEE written boldly. When I went to use the acronym, I found that I had forgotten which E stood for Edges and which E stood for Ends. Short-term memory loss is something I sadly suffer from; just ask my wife. I solved the problem by changing the last E to an N. Instead of FEE, my sign soon read FEN, which of course stands for Faces, Edges, and Ns (eNds): Now that I can remember.

FWW

-Joh n

H

DeRosa, West Dundee, Ill.

Removing glue squeeze-out

I found JeffJewitt's Rules of Thum\ "No­ # 165, pp. 86-90), mess glue-ups" ( quite interesting. I would like to add one tip that I have found useful when removing glue squeeze-out. Instead of using a toothbrush like Jewitt suggests, I use a 2-in.- to 3-in.-wide flagged end brush with artificial bristles. First dip the brush in a pail of water, then shake off the excess. Remove the glue while it is wet, and rinse and

FWW

the process. The flagged ends will get into sharp corners and down into tlle grain without leaving behind much water. Be sure to use a good-size bucket of water, and change it often to avoid making a glue wash. This process has eliminated glue stains for me. -Robert Geers, Cedar Key, Fla.

Demise of the old ways

I was fortunate enough to attend an engineering high school tllat required two years of woodworking shop. Some of our shop work occasionally would be interrupted by a crusty old instructor storming out of his office to berate a student who left a plane blade down on the bench, a chisel bevel up, or was storing away a file witll0ut wire-brushing tlle teetll clean. It seems to me that at least one of these shop rules is now ignored routinely. In # 165), I see the October 2003 issue ( two planes on the front cover that are blade down, as well as other instances on pp. 30 and 56. Have many folks forgotten that a blade dulled by any reason requires time to sharpen it, or is this just one more old shop tradition that is dying out?

FWW

-Wallace

C

Knapp, Ellicott City, Md.

EDITOR R EPLIES: Okay, I'll take the bait. Ask two or more woodworkers, and you'll get into an argument on this subject. As for me, I have found that a plane lying on its side is a waiting target for other tools (or bare skin) to bump into tlle exposed iron. When sole-side down on a clean piece of wood, whetller bench or workpiece, a plane iron is protected­ unless you inadvettently lay it down on another tool or piece of hardware. I keep my bench uncluttered when planing for that very reason. But do what works best for you.

shake off the brush frequently during Clarification

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 Fin e Woo wo k g, PO Box 5506, Newtown, CT 06470-5506.

d r in

10

F I N E W O O D W O R K I, G

A few dimensions were omitted from the article "Chair Making Simplified" by Garrett Hack ( # 166, pp. 80-87). The lengths of the seat rails are as follows, measured from outside shoulder to outside shoulder, along the top edge: front rail, 15% in.; side rails, 15�6 in.; rear rail, 11 \.2 in.

FWW

High Transfer Efficiency. Wood finishing has improved with the new MSHTE stain gun. • •• • • • Even distribution of body stains, wipe stains Low fluid pressure

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Specifications 3hp 1ph 220V 3hp 3ph 2301460V 12'/13' Blade Capacity Automatic Brake 24' Crosscut Capacity Auto Return Device Complete Guarding, Table. Frame Legs

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READER SERVICE NO. 195

MSHTE spray gun

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Industrial Finishing

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Industrio™ Pocket-ProTM Routing Joinery ���, System System Two great tools in their own right. . , . or put them together to make your own pocket hole workstation.

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For fast, easy cabinet

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F I N E W O O D W O RKI N G

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CiIIIMIaII ---. ----� _

Methods of Work

ED I TED A ND DR A W N

BY JIM RICHEY

A safe r crosscut sled

Middle fence is installed Base of sled,

24 in. wide by 32 in. long

square to the sawblade.

Extra weight at the back end keeps the sled from tipping at the end of the cut.

Sled stock, 3f..-in.­ thick MDF Blade is buried within the block of MDF at the end of the cut.

I once saw a beginner in our shop using a cutoff sled to crosscut a heavy workpiece. As he neared the end of the cut, with the far edge of the sled hanging over the back of the saw table, the sled reared up on him. Luckily, someone else was nearby and kept him from flopping the sled back onto the table and into a spinning blade. After that, the first thing we did was to build an outfeed table for that saw. I also decided to make a new, safer crosscut sled as shown in the drawings above. I chose to make the new sled of %-in.-thick medium-density fiberboard (MDF) because it's inexpensive, it's about as hard as soft maple, and it's very stable. I milled some scraps of hardwood lumber for the runners and cut a 24-in. by 32-in. piece of MDF for the base of the sliding jig. I laminated two pieces of MDF for the front and back fences and three pieces for the middle fence.

Hardwood runners ride in miter-gauge slots.

I secured the runners with glue and screws because I didn't want to risk any possibility of them coming loose during a cutting operation. After installing the nmners, I sealed and lubricated them with several coats of paste wax. Before attaching the fences, I cut a kerf into the base of the sled to give me a reference edge to which I could square them. Last, I added a block of MDF (three pieces thick) to fit between the middle and back fences. That block of MDF makes it virtually

A reward for the best ip Joe Santapau was inspired to design a safer tablesaw crosscut sled after realizing the inherent dangers in typical shop-b uilt sleds. With his sled (above), the blade is buried completely at the end of the cut. Santapau constructs high -end millwork (doors, moldings, wainscot paneling) for a living, but for fun he spends time turn­ ing small boxes on a lathe. For his winning tip, Santapau will receive a set of hand-forged chisels (www.barrtools.com). Send your best tip, along with any pho­ tos or sketches (we'll redraw them), to Methods of Work, Fine Woodworking, Box 5506, Newtown, 06470-5506.

CT

14

FINE

W O O D W O R K I:\l G

PO

The

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IXJIlJJJJ!§Mark Quality. Quali ty tools, education , se rv ice and v alue. Expect this and more from the leader in Pocke t Hole tec hnology.

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A better way to join wood. Ftult:e litronge Screws •'lDpler. . ssembly workpiece clam assembly onge Bett2rl ewer headaches. it today _.kregtDol.coRl READ

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