5/26/2018 Wood #128 2000.pdf

1/76

5/26/2018 Wood #128 2000.pdf

2/76

5/26/2018 Wood #128 2000.pdf

3/76

another great

How about these terrific-lookingclocks still can'tbelieve ow manygreatentrieswe had n our "lt's AboutTime"ClockContest.

4W

tIWOODamagazinereadersdonate242incrediblelocksWhen I announcedhe "It's About Time"Clock Contestn the December1999issue, reallydidn't haveany dea howyou would react o it. A fter all, we hadn'tdoneanything ike this before,and aswithanythingnew, here'salwaysan elementof risk involved.

But I did know two things hatmademefeel a bit moreconfident that the contestwould work. First,I know that mosteveryone asa fascinationwith clocks.And second, fter 16yearsat the editorialhelm of this magazine,Iknow you pretty

weIL WOOD magazine eadershaveprovento be someof the most generous(andgenuine)people 've ever met, and knew I couldcount on you.

As the first entriesarrivedsometimen mid-December, could ell that hecontesthad captured he maginationof manyof you. A few more clocksarrivednearlyevery day, and as we unpacked achof them, could sense hat he restof the WOOD staff wascatchingclock fever, oo.By the time the ast 15 clockswere delivered o us on April 3, 2000(the inal dayof the contest),we hadpeo-ple from all around he building coming by to take a look at your handiwork.

Yes, hese locks are ha tgood I've neverseenmorecreativityexpressednanyof thecontestswe've sponsored.To all of you who took the time to makea difference or the MarineCorps

Reserve oys for Totsprogram, hankyou, thankyou, thankyou.And a bigroundof applauseor TitebondGluesandAdhesives or theirgenerous upport.

For a look at the five top prizewinningclocks, see age 14. To view severalofthe otherCertificateof Accomplishment wardwinners,please urn topage 16.And checkout www.woodmasazine.comor evenmoreof the entries n theclockcontest. guaranteehatyou'll beimpressed. know we are.i

success story

*l #d

the editor'sffiil?ff*#

Customer Service Information: For serviceon your subscription, ncluding changeof address, ontactwww.wood-magazine.com,/service or call 800/374-9663. Subscription mailing address: Better Homes and Gardens WOODmagazine,P.O. Box 37439,Boone,IA 50037-0439. Pleaseencloseyour address abel rom arecentissue.Editorial mail-ing address:The Editor, WOOD magazine,1716 Locust Street,GA3l0, Des Moines, IA 50309-3023.For questionsfor our editorial staff, questions about how to reach an advertiser,or to place an advertisement n our magazine call8001374-9661 To order back issues call 800/346-9663. For article reprints, write to editorial addressand enclose$5per article.

WtoOtI{0VEMBER000 Vol.17.o. r lssue

EditorARRYLAYI0NManagingditorIMHARB0LDAssistant anagingditor/FeaturesETER. STSenioresignditorAMES.D0WNProjectsditor ILL RIERProiectsditorAN AIE VECProductsditor AVEAMPBEIITechniquesditorIMP0LL0CKShopManageriProjectesignerHARLES. HEAssistantesign ditor/Proiectuilder EVINProduction/OfficeanagerARGARETL0AdministrativessistantHERYTUNYArtBusinesslfice ecretaryARBARAEReader-ContactoecialistEN 0NRUDlllustratorsIM 0WNING,0RilAOHNROXANNEeMOINE,ARSONlOEConsultants()B cFARIII,I,AVEENDEContributingraftsmanIMHEAVECreativeireclor AtllELASINIAssociatertDirector0HNW.MEEKAssistantrtDirector HERYL. CIBUI

PublisherARKAGENAdvertisingirectorlLtMURPHAncillarvales nd nternet anaoer ARTENAdvertisingffice: 33N.Michiganve., uiteChicago,L60601 hone:12853-2890M:3125Direct esponsedvertisingAROtYl,lAKAccount xecutiveUWEIEEAccountxecutive()N OLMINASAdvertisinganagerIMHUGHESMarketinganager ERALLIEEGASPSales ssistant ARGARETRAVIS

PublishingirectorWlLtlAM .REEDAdvertisingervicesanagerAT ENDEBConsumerarketingirectorIZ REDAssociateonsumerarketingirector ATHAssistantonsumerarketinganager AVEBusinessanagerRAIGEA RSeniorroductanaoerICK R0W

MEREDITHUBLISHII{GR(lUPPresidentHBIST0PHER.LITTLVice residentublishingirectorERRYCreativeervicesttEN ELATH0UManufacturingRUCEEST0NConsumerarketingARTAEFFRIGrouoales ERRYAPLAN0oerationsEANPIETERSFinancend dministrationAX UiICIzft"mlt*WltLlAM .KERR.residentndChief xecutE.T.MEREDITHll, Chairmanf heExecutiveo

OCopyrightMeredithCorporation 000All rights eserved. rintedn theU.S.A.Better Homes and Gardenss WOOD@magazine ISS894X) is publishedninetimes a year n February,MarMay/June, July/August, September,October, NovemDecemberby Meredith Corporation,1716 LocustMoines, IA 50309-3023.Periodicalspostage paidMoines, owa,andadditionalmailingoffices.BetterHGardens rademark egistered n Ca-nada nd AustralRegistrada en Mdxico. ONE-YEAR SUBSCRPRICES: U.S. and its possessions,27; Canada,countries, 47. CanadaPost PublicationsMail SaleAgreementNo. 1369350.CanadianBN 12348CANADIAN RETURN ADDRESS: Better HoGardens WOOD magazine, 2744 Edna Street,Ontario,N8Y 1V2.POSTMASTER: Sendaddress Better Homesand GardensWOOD magazine,P.O. BoBoone, A 50037-0439&

WOOD magazine Novem

5/26/2018 Wood #128 2000.pdf

4/76

hithis issue'sWOODo mdg?zine

woed\M_orkingptoiectsgreat deas: rill-press ocket-holeigBore dead-onscrew holes for your pocket-holeointswith this easy-to-makeig.elegant crollsawnwallshelfRely on our full-size patterns o ensureyour successwhen making his ornatehome accent.well-composedompoteServenuts, candy,or other asty reats n this attractivewood turning. We madeours rom threeseparate iecesthat glue-assemblento the glowingly handsome aiseddish aboveright.musicon file cd cabinetStore as many as 160 cds in this well-organized, ive-drawer furniture piece.Luge brasspulls and traditionaldesigngive it a look that will work with just about anyhomedecor.bentwoodaccent ableLearn how to work with forms while shaping he legsof this clean,unaffected able design.empirestatestreamlinedrainRelive the days of luxury rail travel by craftingauthenic-looking 940sdisplaymodel.

hli htsns60

6l

74

78

November 000 ssue128

this Page 4

68gtl

toolsPffii&ialsbig-timeablesawsYou'll be pleasantly urprised y the quality and costs .found n this roundupof sevenshop-tested achines.productshatperform

Continued on pa

www.woodmagazine.c

page 0

page 4

page 8This issue's coverwood grain: poplar4

Cover photograph: D.E.WOOD magazine November 2

5/26/2018 Wood #128 2000.pdf

5/76

this issue'shighlights Continuedfrom paWOODo mlgozine

tmiquesa pro's ips or matching rainDiscover six surefire ricks for achieving he bestlook from the boardsyou select or projects.how o flusha mounted oorFollow our seven-step rocess or creating evenrevealswhenhanging lush-mountedabinet oors.tips fromyourshop(andours)how o getstartedn biscuitoiningBecome ands-onamiliarwith thisquick-and-easymethodor oining woodaswe cover hebasics.

features2 the editor's ngleI talkingbackl2 WOODONLINEol4 top clocks romourcontestMarvelat thewinners rom our It's AboutTime contesthatincludedhunrlreds f imaginative ndwell-crafted ntries.24 hot off the nternet34 be safetysawy around our ablesawBeforeyou cut your nextpieceof wood, run throughour checklistto ensure our tablesaw afetyhabitsare n goodorder.46 whatmakeswood rareWhy are somewoods so difficult or impossible o gethold of? Thereasonsmay surprise ou.5l master f timeandspaceWhen Minnesota craftsmanJamesBorden builds a clock, itbecomessomethingmore-an expression f art and philosphy ngrandstyle.

askwoodfinishingouches

November 000 ssue128 www.woodmagazine

page 5

page 4

r08tl2 page 1

WOOD magaz ine Novembe

5/26/2018 Wood #128 2000.pdf

6/76

tmlking &-**rcmkWe welcomeour omments,riticisms,suggestions,nd es, ven ompliments.Weselect ndpublishnlyetters f hegreatestenefito our eaders. riteo:

I t ts deer season;keep 'em standing upWell, it's Christmasime and herearemorewhite deer nfront yards haneverbefore.The problem s, aftera storm,

many of themare lat on theground.The ones hataren'thaveunsightlywiresor polesholding hemup.Mine havenever allen; he drawingshowsmy simpleandalmostinvisiblemethod. ustuseaneyebolt whose ye s smallerthan heheadof the gutternail, andpushor pound henail into theground.

As an added ouch,whenpainting he deer, sprinkleon glitterwhile thepaint sstill wet. t givesa niceeffect.-Rob Kuttz, orain, hio

Gutterspikedriventhrougheye-boltintoground\_.

STAKINGDETAIL

3/ro ye-bolt11/+ on g

3/ro ut andwasher

WOODmagaz ine Nov em

TalkingackW00Dmagazine1716ocustt.,GA310DesMoines,A50309-3023

Thanks from The l lomesteadfor help ing the aut is t icThanks or including he story on The HomesteadnI l9's FINISHING TOUCHES column.Woodworfrom acrosshe UnitedStates ndseveralrom Canatactedus.Dan Long of Jacksonvi lle each,Florida,e-mailedus to see f we were nterestedn some oofew weeks aterwe received rom him seven andsa(five of thembrandnew),severaligsaws,sawbladerechargeablerills, a package f new bits, andotherlaneousools.Your willingnesso shareThe Homesstoryhashelpedus reachnew friends.Thanksagain-Steve Muller, xecutiveirector,heHomestead,un

PIunge- rou tr i ig a le r tAn importantpieceof informations missing rom theplunge-routerig article n Issue123.Building o thedsionsgiven n theBill of Materialsesultsn a ig thattheDeWaltroutershown n the article.To make he igany other outer,modify theends A, B) and ence ailasshown n thedrawins.

Widthof routerbase+ 4 (widthof @ and@ )+ 3/8(halfof adjustment lot)15lgz 1s/sz

R=3/q3/e hole'l-I o 11lsz

t1 ' ,Alignwith i+dadoesin par l@.t11/a holes

Continuedon pag

)1l4u-' ,

I rnomrvtEWI

5/26/2018 Wood #128 2000.pdf

7/76

ffmffikffitrTffiffiCorrtinuedfrornpage 8

A cor rec t ion and an add i t ion to the keyho le- rou t ing i igIn Issue 123, page59, you show a key-hole-routing ig. The length of the rab-beted side rails is indicated as, Lengthof router base+ %r . This is not theoverall ength; t is the nside ength.The overall length is the length of therouterbaseplus 37s .

-Charles Krauss, ugusta, an.

You are rigltt, Churles. We apologi:.efor the ntistake.Luther Willicunsott,who helped cle,-elop he ig, wrote toalert us to the error und pctssctlonganother suggestionas well. He clrilledmore holes in the rails ancl offset theinsert in the nrcveable stop, os sltow'n irtthe drawing. This allovvshim to centera ket,hole in the top ntentber of a nar-row frante. Luther also aclvises lcunpirtgtlrc ig to tlte workpiece.

1/+ deepLength f router ase+ 33/e'

KEYHOLE.ROUTINGJIG Widthofrouterbase1ia machine screw11/4 ong

-?-----=t-I1 lqu--.--.-

. s\E{EEIE

More on the wor ldwide supp ly o fPeterStephano's rticle n Issue124,page84, WoodWorldwide, mademe proud o be a subscriber .Who saysahobby magazine annotpractice esponsibleournalism?

For those nterestedn more nformation, he UN releasedthesummary indingsof the report, A Guide o WorldResources000-2001: eople ndEcosystems:he FrayingWeb of Life. Copies f the summary anbe downloadedfrom www.wri.org/wri/wn2000.

Also, note he correctspellingof taiga, definedas amoistsubarcticorestdominated v conifers.-o)via R.Cory, ake swego,hre.(David s a consulting rborist or Pruett Tree &Landscapen Lake Oswego.)WoodWorldwide n lssue124overlooked n organrza-tion thatmakesan mportantcontribution o sustainableforestmanagement:he AmericanTree Farm System.TheSystem asestablishedn 1941, ndhasgrown o a U.S.membership f over 70,000private,non-industrialorestowners. he organization's ission s to promotehedevel-opmentof renewableorest esources n private ands,whileprotectingheenvironmentnd ncreasingublicawareness f the benefitsof productiveorestry.The Tree

countersunk#8 x 2 F.H.woodscrew1/+ hreadednsert5/sz shank hole,countersunk 3/e hole

FarmSystem ontinuallymodernizests standards, lignthemwith other nternational ertificationbodiesandnational rograms, uchas he U.S. orest ndustry'sSustainable orestry nitiative Program.-Mickey Hallum, ayettevilleMickey s the chairmanof the Tennessee ree FarmCommittee. heAmericanTreeFarm Systems aprograof theAmericanForestFoundation, I I I l9th St.NW,Suite780, Washington, C 20036.Call 888/889-4466 rvisirwww.treefarmsystem.org.

IT t3/8 rabbet

wood

Widthof router=-\-1./ll.base + 21 q,' -------=r1'z : /21/q -=-=->z | 7MovABLEroP )rtz '

1 0 WOODmagaz ine Nov ember

5/26/2018 Wood #128 2000.pdf

8/76

Home Depottsgood deed noticedOn March 8. a tornado oucheddownin St . Franc is ,Wisconsin nearMilwaukee).Within hours.HorneDepot had a truck in the areawith freeplywood and tarps or peoplewh oneeded heni o prevent urther damasefrom rain iind snow. Our thanks oHonie Depot.

-KenJaeger, ilwaukee, is.

T imberK ing sawmi l li m provementsThanks br the art icleon low-c ost sawmillsin Issue 2-5.We felt that the review wasfair in reflectinga brief experiencewitheachsawmill. I would like to point out thatsinceApri l l , we have equipped heTimberKing 1200with a l5 hp, electric-start Kohler motor. This motor has theintegratedclutch and throttle, and pull-startorelride tavoled by your reviewer.

The reviewer had some valid criticisms.most of which are addressed y chan-eeseff-ective u-eust l : hinged blade covers.cr,rttin_uead 'eedsystemdisen_9a-eesnretllrn. hairline depth ndicator,and a _euideroller moveable rom the operatingposition.

-Will Johnson,President, imberKing,nc.

THE IGHTTOOLWoodworkingClompsndAccessories

I"u ,o[ru

333Rocetreet,oidwoter,l49036lst7l278-6121ox517}78-ss23800-67r-0838

ffioRIHEro&, GermonModg,eI,F :'z Superioruolity, frs" s*$ qf#drt\ -f;c

ri: r,: 'It

t rclwGrosr5iobll 2000

CircleNo. 2230

%#'\ , , ,uiM

#*

Justaska &,9HAn4f6errrrs w ownVd-aMeetDanny errington ho useshisHawk ocreateoneof a kind guitarsor starslike Waylon ennings, mmy ouHarris,EddieVanHalenandEric Claptano namea few. DonTetyour ools imit you n creatingyourprojectof a lifetine. Learnwhycraftsmen ike Dannychoose hg Hawk Scroll Saw or their shap.

) Variable utting ctiongivesmore ontrol) Smooth ibration-free erformance) Cuts o smooth, o sanding equired) Blade hangesn seconds) $avemoney uyingfactorydirect) 3 modelso rchoose rom

[lTtrlmr+ICall ahaut urNo Eiskin the hapfi Day Trial

l-800-497-2623RB ndustriesP0 Box 369Harrisonville.M0 6www.rhiwoodtools.coml 1OODmagaz i ne November 2000 Kl14

5/26/2018 Wood #128 2000.pdf

9/76

EilJ@@rucrr\rLrNrewww.woodmagazine.comWith his reechart,youtll never guess aboutpilot-hole size

Well-designedndinformation-packedreference hartscanreallyhelpyouou tin the shop.Forexample,he screwreference hartat/e/r shows he head-boreand shank-holesize or allpopulargauges fwoodworkingscrews.t even ists

separate ilot-holesizes or hardwoods nd softwoods, nd he screwlengths vailablen various auges. he editors t WOODomagazinerefer o this charteverydaywhenpreparingproject nstructions.

You candownload ndprint this chart,aswell asothers overingdrill-pressspeeds nd umbersizing,absolutely reeof charge. ustgoto thepage istedhere.www.wo o drnagazine. co m/woodb as cs p agesaboutscrews.htm

Want a freewoodworking plan?Just ubscriberrenew nlineWe love onlinesubscriptions.hey saveus money n paper, ostage,andhandling, ndyou oftencanget your irstcopyof themagazine ooner.

In fact, o showour appreciationor youronline usiness, e ll provide ouwithaccesso five freemini planswhenyou sub-scribe r renew hroughour nternet ite.Within minutes f getting ourorder,we lle-mailyou theaddress f an nternet agewhereyoucan equesthe reeplans. t seasy, ndordering nline s 100percent afeandsecure.www. wo o drnagazine. com/ subs c ript/12

ln searchof themissingarticleIt happenso all of

We seem o rememseeing narticle, erhaps earsago, hath

just the information weneed to build a project

today. But how on earthwe find the article? Now

there s elp-a single, pto-date, omprehensivendexof all WOODmazinearticles. ou ll f ind projects,echniquesreviews, ndeverything lse hat sbeen ubliss incessue o. l .

And f thearticle ou re ooking or is n anissue ou don thave,we most ikelycanhelpythere, oo.Many of the back ssues f WOODmagazine restill availablehrough he onlineWOOD STOREo-but only until the imited splies un out.www. wo o drnagazine. com/sc gil index/wdindex.html

Signup now or our renew-and-improuenewsletterIt canbe a challengerying o keepup with all the current rojectplans, ools,andothergoodgivenawayat WOOD ONLINE, aswell as helatest pecial rograms,ool sales, ndseminaTo helpyou out, we ve comeup with a newsleter thatwill be e-mailedo you automaticallyeverymonth.All youhave o do is registeror at the web page istedbelow.You canunsub-scribe t any ime.

Thenewsletter ow hascolorgraphics,ncluding photosand llustrations,o go alongwith thshop ips hathavealwaysbeenpopular. hethousandsf readers ho already eceive t tellus hey ove t. We thinkyouwill, too.www.wo odmagazine. com/members/index.html

WOODmagaz ine November 0

5/26/2018 Wood #128 2000.pdf

10/76

fromover200entrieshereare he,t0eclodksouwouldneverbelievehe fantasticanayof clever ime-pieceshat showedup in WOODamagazine's ear2000

"lt'sAboutTime" lockcontest. ake ookat hewinnerc.he WOOD staff never quiteknows what to expect after anew contest announcement.

Eleven years &Bo, readers respondedwith hundredsof wonderful, handcraftedentries in the first-ever toy contest.Although the entry numbers fluctuatedlike river levels from then on, the quali-ty andcreativity never did. What wouldhappenwith a clock contest?

February of the new millenniumbrought a trickle of entries. By mid-March they grew stream-size.April 1markeda deluge.

And what clocks there were Tinyclocks cased n burl. Wall clocks in all

shapesand sizes.Mantle models, bothcarvedand machined.Desk-topdelightsin a hostof woods.You sentclocks hatchimed, buzzed,and ticked. A few fea-tured animation.All provedamazing.

The clocks now have new homes.Soldat auction during the fall, they generatedfunds to benefit the U.S. Marine CorpsReserye's oys or Totsprogram.That'llmean lots of happy kids at Christmas.Thanks to all of you who entered and toTitebondGlues and Adhesives or spon-sorship.Now for a look at the winners.(See hehonorablementionson page 16,and view all the entry finalists atwww.woodmagazine.com.)

GrandPrize $S,OOODavid German of Grand Rapids,Minnesota,umbfoundedhe udgeswithhis ingenious, 4"-tall, ed oak grandfa-ther clock.Why was it so special?Davidcleverly ngineerednd craftedhishingedclock to fold and nestleone part intoanother.Closed up, it easily it insidea2x2x2'box (asshown eft), s required ycontest ules,To assurenon-breakage,he craftsmanandhiswifepersonallyeliveredhe entryto DesMoines.Andsuchcarepaidoff.1 4 WOOD magazine November 20

5/26/2018 Wood #128 2000.pdf

11/76

First Prize $+,000But which way is up? Kentwood,Michrgan'sCharles Bowman had astory to tell with his 24x24 intarsiaclock. His timepiece represents hemoment when his grandpa'spocketwatch plopped into the old fishinghole.The reversedaceon the bottomwatch is a reflection n the water. Heusedpurpleheaft,maple,and walnut.

SecondPrize $3,OOOWoodworkerMikeJagieloromAlmond,Wisconsin, might have named hisanimatedclock Row, row, row, yourboat. When running, he oars moveand he ishpop rnand out behind heclock face. Mike fashioned the21x15x9 clock from cherry,walnut ,mahogany,basswood, curly maple,pine,and balticbirchplywood.

Gontest JudginThere's othingbetterabouta ctest hanwatchinghe udgingAnd our udgesweregreat un tobserue, heysmiled, rownedlaughed, nd grimaced s heywent room o roomand clock oclockmakingheirselections.

Entries in the contest filled two roomthe Des Moines offices of WOODa mazine.Shown is just a partial room fuclocks that were entered.

Contest judges Scott Mitchell Titebond and assistant design edKevin Boyle scrutinize a clock heldeditor Larry Clayton.

Cfock conlest judges, from ieft ShMunyon, administrativeassistant; Usergeant Searcy Hollis; Jeff SeivTitebond; Kevin Boyle, assistant deeditor; and Scott Mitchell,Titebond.

Third Prize $2,OOOChr is topherKroup of Fr iendsh ip ,Tennessee, eld the judges' interestwi th h is black widow spider clock.When its articulated egs were spreadout to fu l l crawl ing osi t ion,Chris 'creation measured 32' in diameter.The paintedspider's egs were madeof balsa,and the case of an unidenti-fied hardwood.

Fourth Prize $1,OOOIt was simplebeauty, se of wood, anda fine finish that drew applause forJames Peluso's 4 -tallmantleclock,Inlaidwith cardinalwood, the figuredmaplecase was satin o the touch,TheRowlandHeights,California,raftsmanprovidedaccess o the clock's batteryby making ts op slideup likea drawerby pul l ing n the handle.Continuecl on page ,)0

,$-

www.woodmagazine.com

5/26/2018 Wood #128 2000.pdf

12/76

stillmorearnaztnclockshese inalistsdeservea round of applause\tr/ten the five "It's About Time" Clock-Building ContestY V judges finally selected he prize winners, hey had a fieldof 46 finalists remaining.Although the contestwas setup for only25 honorablementions, he judges said, "So what? These are allgreat, wonderful clocks. Let's award all of them CertificatesofAccomplishment."That's how the decisionwas made,and udges'decisionsare always final. The following clock-contest inalistswere so awarded:

Shirley Mensch of Center Ossipee, New Hampshexhibitedhercarvingskillswith "FatherTime."Herhacrafted clock measures14" tall with a face enclosmimicking tonework.

This chest-of-drawers lock of figuredmahoganybuilt by Larry CardingleyofMaridian, daho, was a unique design.Standing23Vq" igh, it featuresdrawerslinedwith red abric.

Shiraz Balolia, Bellingham,Washington. Ebonytrimmedroundbearclock.Bruce Boyd, Garbondale, Kansas.Sculpturewith suspended lock.Roy Braley, Brcntwood, NewHampshire. QueenAnne-footedmantel lock.Gene Buehrer, Cornville, Arizona.Pocket-watch lockwithstand.Larry Gardingley, Maridian, ldaho.Chest-of-drawers lock (shown efi).Jim Gaughran, Lodi, Galifornia.Laminated ircular lockwithstand.Raymond Ghampine, GlintonTownship, Michigan, Walnut-hullclock(seepage 78).Jimmy Glark, Brcwn Summit' NorthGarclina. Log cabin ireplace lock.Howard Glements, Knox,Pennsylvania. "MarkTwain" tern-wheel iverboat lock.

Richad Gox, Nolwich,Gonnecticut. Roundscrollsawn locAdam Gunha, Graveland,Massachusetts. Wood beam-boxemantel lock.Jack Dalton, Jackson, SouthCarclina. Brassand aminated-wopedestal lock.Dan Demmer, Fairfax, lowa.Carriage oltwallclock.Ralph DiAmore, Queens Village'New York. Padlockwall clock.Robert Drumm, San Antonio'Texas. Marquetrymantel lock.Kathleen Escobar, West Jotdan'Utah. Segmented gg clockwith baHenry Frcidenbetger, Jr., RockyFord, Golorado. Scrollsawncenewallclock.James Gauntt, Arkville' New YoCarouselmantel lock.

Continued on page

1 6 WOOD magazine November

5/26/2018 Wood #128 2000.pdf

13/76

Continuedfrom page 16arn&m gclocks

Henry Schulz, a woodworker fromBurnaby, British Columbia, also hap-pens to be a mechanic. That's whY hebuilt this 10" wenge clock as a model ofa magnetic dial gauge, with a quartzmovement replacing the gauge.

I , : ' - : ' , : '

There's no doubt about the materialthat Raymond Champine, a reader from ClinTownship, Michigan, used for his mantel clock. Walnuts Ray gathered-countblack walnut hulls, and epoxied them together for his 1g1/z"-lall lock's fascinacase. Unopened hulls form the pillars.

Mel Gullickson,Hancock, Wisconsin.Relief-carvedicturewallclock,Donald Halden' Wyerhaeuser'Wisconsin. Fishingod and reelclock.Rod Hilldahl' Brooklyn Park,Minnesota. C-clampmusic-box lock.Lowell Hudson, Jacksonville'Florida. Classicmantel lock.GeoryeKempf, Seattle'Washington.Square,ovetailedteapotclock.Glenn Kerr, Grand Rapids' Michigan.Turn-of-the-centuryrainstation lock.Robert Lamson, Leesburg, Florida.Teardropearviewmirror lock.Sam Lay Baker Gity, Oregon.Sculpturallock.Steve Leonald, Palatine Bridge'New York. Rusticbirch-bark lock.Leland Margan, Tucson, Arizona.Sculpturalurpleheaftlock.

Neal McAfee, Sunlmerfield'Florida. World imezonewall clock.Paul McFadden, Rock SPrings'Wyoming. Mantel lockwith rout.Shirley Mensch, Genter OssiPee'New Hampshire. "FatherTime"carvedclock(seepage 76).Gharles Myers, Glinton'Tennessee. Laminated all clock.Mario Padilla, Plainfield' lllinois.Squaremantel lockwith our aces.Kenneth Parker, West Palm Beach'Florida, Saltwaterishing-reellock.Victor Pasturczak, East Moline'lllinois. Victorian allclock.Glenn Poole, Wnnipeg, Manitoba.Mantel lockwithweathergauges.Gindy Radle, The Woodlands,Texas. Built-uprianglemantel lock.William Roskop, Austin'Minnesota. Arched-topmantel lock.

Dennis Roussel, Delta, GoloradLog cabinclockwith urnishednterioJim Rubach, Waterfold, WisconsRoundturned lockon Pedestal.HenrySchulz,BurnabY'BritisGolumbia. Magnetic ial-gaugel(shownabove left).Glenn Schworm' MillersbulgtOhio, Pulley-and-beltlockGil Steele, State Gollege'Pennsylvania. Intarsiarog clock.Michael Vander Wall' WilliamstoMichigan. Carued/scrollsawnlockJohn Willis' Savannah, MissourHorsefly-shapedlockand micromedeskclock.Wayne Wollersheim, Fond du LWisconsin. U.S.Nar4yestroyerloTo seeall tIrc innlists' clocl

5/26/2018 Wood #128 2000.pdf

14/76

a pro's ips orffiwffiffimffi,ruffiwreffififf.ffiffiwruI've met a lot of woodworkerswho havea good handleonthe mechanical artof theircraft.Theybuildprojectshataresquareand sturdy,with parts hat fit precisely.Yet,manywoodworkersoverlook he moresubtlear1ofmatching raindirection nd color.As a result,heirwell-machined nd finely astenedprojectsall short n theappearance epartment.Whilebuilding he CD cabineton page64, and he accenttable on page 74, the importanceof grainmatching eallyhi thome.For both projects carefully elected, ut, and oinedworkpieces or best appearance.

In thisarticle 'l l sharesome ips for grain-and color-matching. ou can use hesesame rickswhenbuildingmany of your own projects chuckedtund,hop anager/projectesigner

-d Single out one board for small proiectsffi Wh.n selecting tock or a smallproject,saya keepsake ox or pictureframe, ry to usewood from the sameboard.Although grainand color canvary even n a singleboard,with care-ful selection ou shouldbe able o cutparts hatmatchclosely.

For large work, choosecompatible stockFor largerprojects, like to use

boards ut from the same og. Andthat'spossiblef youhaveyourowntreecustom awn.Becausemostof ushave o buy woodfrom a lumberyardor homecenter,here'show I go aboutfinding matchingboardsat theseout-lets. t takesa little time, but paysoffin good-looking rojects.

First, cull theboards hatare ree ofwarp andhave as ew defectsaspossi-ble.Then, stand hemup side-by-side,and akea stepback.Next, I reshuffletheir order or bestcolor match.

Finally, I select he boardswith similarcolor thathavegrain hat I can envisionbeingmatched s build theproject.

Grain refers o thepatternof linesonthe surfaceof a boardproduced y theorientationof thewoo.d'sannualgrowth rings. look for boardswithgrain ines spaced quallyapartandoriented n the samedirection.

Go straight when look-ing at grain patternFormostproject arts, speciallythose cut from oak,ash,or hickory, Ilike to use straight-grainedoards.That'sbecause avygraincangiveaproject,particularlya tall one ike the

For he bestgrainmatch,ChuckHedluoften cuts workpieces t a skewedangto the boardedge.

CD cabinet, nunbalancedeeling.Wavy graincancreate n optical llu-sionwherea perfectly onstructedpieceof furnitureappears ut ofsquare r plumb.

To get straight-grained ieces orprojects, choosehe widestboardsavailable.Why?Most boards reflatsawnat the mill today,meaningthey typicallyhavecathedral-grainfigure toward heir center,andstraight-grainigure toward heiredges sshown elow.It 'sbeenmyexperiencehat wide flatsawnboardyield a higherpercentage f straightgrainedstock hannarrowboards.

Continuedon page 2

Straight rain

20 WOOD magazine November20

5/26/2018 Wood #128 2000.pdf

15/76

&m#ktrtr*ffiContirtued.frorn oge 20

* ;;,i 'n,, t t : .1r *'*r P*,i ;***d n-ru'*{s s fr qi ' ; 1 { ; { , i . + , { i q i I * * { : , i ] . . - r , $ ' t t f f i S r : d$ave cathedral-grainstock for hidden partsAfter eadinghe ast ip,you

may be wonderingwhat I do with theleftover athedral-grainedtock. 'm asfrugalas henextguy,so cathedral-grained tockgoes nto parts hataren'tvisible,suchas nternal omponents.

Try this angle forwavy-tigured woodsCertain oods,uch scherry,walnut,andmaple,don't havea lot ofstraight rain.Much of theirbeautycomes rom wavy-figured rainpat-terns.That'swhy mills saw hesespecieso yieldasmanywavy-grainedboards spossible.

When workingwith thesewoods,usechalk o mark he ocation f pro-ject partson theboards. orient hechalk marks or the bestgrainmatchasshownonpage20. Doing this, he

pieces ftencomeout of the stockat anangle o the boardedges. cut outthesemarked ieceswith a handheldcircularsawor igsaw, hen oint oneedge.The remainingmaterial oes orparts hat aren'tconspicuousn the in-ishedproject.

Cut your drawer fontsfrom large glue-upThere rea number f differ-ences etween he architectural -gradeprojects hat we feature n WOODamagazineand the factory-grade urni-tureyou find in stores. or example, nthe CD cabinet ou'll see hat hegrainseemso flow withoutvisual nterrup-tion from one drawer o another.Onthe same urniturepiecemade n a fac-tory, hegrainof onedrawer ikelywon't match he oneadjoining t, andasingledrawermay haveboth cathedral-andstraight-grain.

To makea series f matching rawefronts, glueandclampmatchingpiecesnto an oversized anelasshown n Step1 of the drawingbelowIts ength measured ith thegrain)shouldbe I longer han he engthofthe drawers o allow or trimming.Thewidthof thepanel acrossts grain)should qual he combinedwidthsofthe drawers, lus t/x or eachsawkerfplus 1 for trimmin-e. crosscuthislargepanel ntodrawer rontsasshowin Step2, below.

Thisprocedure ot only makes orgreat-lookingrawer ronts,but youcaneconomize y usin,e arrowpiece(thatmight otherwise nd up as scrapto make hepanel.Forexample,mostof the drawer rontson the CD cabinearemadeof two or threepieces fwood,someas narrowas I .?Photograph: a ldwin Photographyll lustrations: im Downing,Brian Jensen

2 Steps to matchingdrawer fronts(rip 6l

Length= lengthofdrawer ronts+ 1Width= numberof drawersx width of drawers+/e saw kerfs + 1

Edge-join panelwith ieces

22 W OODmagaz i ne November 00

5/26/2018 Wood #128 2000.pdf

16/76

ffiwre&wtrffirumffiNote:We ave dited ll entriesn the nterest f brevity nd laritywhile reservinghe ntent f theoriginal essage.pinionsexpressedere re hose f ouronline articipants.

top o f she l lac?hat f in ish works onlAan I successfully pply\rpolyurethane or lacquerover a sealercoat of shellac?-Ben Licata. ew rleans.a.O There'sno problemputting acquer

over shellac. ut polyurethaneustplainwill not stick o shellac hathaswax n it. For that,you needa dewaxedshellac.Do not trustany shellaclabeled s dewaxed ntil you areabsolutely ure.Someshellacs ay heyaredewaxed, ndall thatmeanss thattheyhave akenout someor mostofthe wax. Some s not goodenough.Completely ewaxing hellac s notdifficult,but t takes ime. t is worththe effort.

-Jim Kull,SanRamon, alif.

Glu ing a through tenonI am a novice woodworker,andlwant to know the best way toglue a mortise-and-tenonointthat goes completelythroughthe leg of a chair. s thereaway I can do this without dis-placing he glue as I push thetenon through the mort ise,especiallywhen the fit needs obe so tight?-BillVanGilst. arwinton.onn.O The tenonshouldnot be a ham-

mer it. Goodmilling, igging,cut-ting, andpracticewill make or con-sistent slop of 2 to 4 millimeters njoinery.Paint he mortiseand enon

with yellow glue,andyou'll getauniformglue ine.You'll geta mess,too, but a wet ragwill clean hat up.-Pat Warner.scondido.alif,OAnotherway to get the ook of athrough enon s to cut themortiseapproximately alfway hrough hepiece, hen on the opposite idemakea mortiseabout /s deep.Thewood eft in the middle will holdglue n the oint, andyou can makeit even strongerwith a hiddenwoodscrew.Thenglue a short enonplugin the other side. like to usea con-trastingwood.-Mark Metko. arsen. is.

O The raditional ewaxingmethodis to put theshellacn a clearglassjar and et the wax settle o thebot-tom. This can akeplaceovernight rin a few weeks, epending n temperatureand other actors.Thensiphonor pourout he clearshellac,akingcarenot o stirup thewax at the bot-tom. Or you might ry the methodusedby WOOD ONLINE regular imFrye: Place hree egularcoffee iltersin the basket f an old iced eaor cof-fee maker, et hebasket n a glassjar, pour he shellacnto the ilters,cover he basketwith its orginalcoveror someplasticwrap o slowthe evaporation f alcohol, nd et tdrip all night. -W00Domagaz

Continuedon page 2

24 WOODmagaz ine Nov ember 0

5/26/2018 Wood #128 2000.pdf

17/76

Continuedfrom page 24

Wil l shel lac fu l ly prote1'm almost eady o finishsomeI mission nd ables.Usingsome whiteoak scraps, founda combination f orangeshellacoveranilinedye hatgivesmeagreatcolor. 'm wonderingf justsprayingon the shellac sdurableenough o handle pillsandnormaluse.Or should justgo with the dye and apofvurethane'":;:, in*, ctovis,.M.

OPolyurethanevarnish s moredurable,but shellacwill handleocca-sional spills. A coat of pastewax afterthe shellachas cured s good nsurance.If the shellac s freshand the wax hasbeen emoved, he level of resistance owater damage s raised significantly.-DaveMacfee,opeka,an.OCommenting n Dave's eferenceothe water resistance f shellac,accordingto Michael Dresdner, f shellac s com-pletelydewaxed t is completelywaterresistant. found this very interesting.-Gretchenllen. harlotte..C.OYes, shellac s resistant o water f itis dewaxed,but resistances subjec-

t end tables?tive. It offers far less resistance hanlacqueror any varnish finish. A wetglasson it will quickly leavea ring. the glasshasscotch n it and thescotchgetson the finish, the shellacgone.Also, literally any commerciacleaningproduct will harm it. Forexample, many cleaning servicesusWindex as a generalcleaner.Theammonia n it will destroy a shellacfinish. Most dishwashing detergentswill harm it. Shellac has a wonderfuplace in finishing, but I do not feel itisagoodenerarinisli;,fr ,1)irOFor anotheropinion on this topic, wturned o Bob Flexner, author ofUnderstanding Wood Finishing. Herewhat Bob had to say:

"Almost all furniture made rom the1820s o 1920swas inishedwith shlac, usuallywith its wax still includeand the finish has held up quite wellfor many decades.Shellac s a perfecly appropriate inish for end tables aslong asyou don't abuse hem.

"Pastewax reducesscratchingbutgives ittle or no protectionagainstspills. The shellac s quite resistant ospills, even highly diluted alcohol ikethat in alcoholic drinks.

"Though condensation n a cool glawill eventually work its way throughshellac ilm and cause t to peel, hewater won't causewater marks on shlac that is only a few yearsold. Veryhot water,or a very hot coffee cup,may do damage hough, as they alsowill do to lacquer.

"Dewaxed shellac s more resistantthe penetrationof water than shellacwith the natural wax still included,buit isn't more resistant o heat. haveconfirmed all of thii manv timesthroughtesting."i

TililT'S |IUIIITYGRIFIS]IIAIIlN P||WTRilsTrlillrc001I0s01ff tt0sTltYPn0fGT

Craftsman Ggauge 2 I/2- in. finish nailerwith case. deal or installing indow, oortrim.Drives ails3/4to 21-/2-in.long.150 nail capacity. 1.844L.149.98

Craftsman 8-gauge rad nailerwithcasedrives5/8 to 2Jn. brads.ldeal or molding nd inished rimwork.110 nail capacity. 18433 99.99

Craftsman &gauge /4-in. crownstaplerwith casedrives r-/2 o L L/2-in.staplers.13O-staple apacity. 1.8434 99.99

Ent$"et

SEARSHE GOOD LIFEATA GREATPRICEGUARANTEED'"26 WOOD magazine November20

5/26/2018 Wood #128 2000.pdf

18/76

ffiffiffiffiffi ffiMffiffiffi

NT needor a store-boughtig withI \ this hop id.Webuiltours utof 3A plywoodanda few pieces fsolidstockcut to the dimensionsshownon the ExplodedView drawing.

Build andassemblehe ig as shown.Mark the hole-locationenterline nthe aceof theworkpiece, ndplacetheworkpiece gainst he angledence.

Slide heguideassemblyirmlyagainsthe workpiece, s shown n theFrontSectionView drawingbelow,aligning he centerline n theguidewith the onemarkedon the workpiece.Theslots n theguideblockallowyouto adjust he guide or different hick-nesses f wood.Slide hestopblock pto the edgeof theworkpiece, nd ight-en t in place. Because oststilesandrails equirea pairof pocketholes,wedrill the irst setof holesat one setting.loosen he wing nut,move he stop-block,anddrill the second etof holesat the next settine.)

Chuck a 3/s rad-pointbit into yourdrill press longerbits allow moreclearance). lign the-7/s ole n theguidewith the /g bit. Clamp he baseof the ig firmly to yourdrill-presstable.Drill thehole nto,but notthrough he stock,asshownon theFrontSectionView drawing.Once herightdepthhasbeendetermined, etthe stopon yourdrill presso drill tothe exactdeptheach ime.Later, useaportable rill andaVs bit to drill a

pilot hole hrough he center f theangled7s counterboreo finish creaing thepockethole or the screw.?Note: Weusedour ig on a heavy-dutbenchtop rill presswith a spindle ravel of 3t/n .But, we ound t wouldn'twork on a smallbenchtopmodelwith a2 spindle ravelor modelswith imiteclearance n thesidewhere hedrill-pressstoputs out.ProjectDesign:Robert Taugherl l lustrations: im DowningPhotograph:Hetherington Photography

FENCEslqx61/zx91l+ encetilted15 rom vertical3/+ lywood

,-11+ x 131t arriagebollEXPLODEDIEWSTOPBLOCK1lzx33l+ 63/e, '1/+ lot15/a ong

1l+'llalwasher ndwin

@*

#8x 11 lz ' .H .wood screw

1',)

GUIDE LOCK3 l + x31 l + x91 l +plywood

51rc 4 carriagebolt 3/a ole.with a 3/+ ounterbore1/+ eepcentered n bottomside

I z'r 5/t| , / ' ' 1s/(11 l zx31 l qx91 l +made trom 2x4

11lz'

$ \f r r *u \ _ B#8x2 F.H. / ' --L^.,^.^

Dril l-oresshuck

FENOE \ \ \ W,r-3/4 rad-Pointit

FENCE / \ \ \ Y l 3 /q , , hn roGUIDEsuPPoRrs--J \ \ \ YA . slides pSetstopon dri l lofworkpiece. ,, \ nN\ ti-{t| GUIDELocK

FRoNrEcfloNrEW f;'3[ftll? ?3'ff?W OODmagaz i ne November 0

5/26/2018 Wood #128 2000.pdf

19/76

develcrp ysurshop skills7 steps to perfectly f i t ted,

dHffT$enyou install a flush-mounted oor,you simply placeonerec-tangle nside another, ight? Well, we all know that ookscandeceive n theworld of woodworking.Door installationcanquicklyzoompast simple andgo all the way to frustrating.Ideally,your carcase asperfectlysquare orners, o doeseachdoor,andyou fit them ogetherwith a perfectlyevengap,or reveal, all theway around.But don't counton t. Almostalways, ou'll have o com-pensateor small laws that can add up to big problems.Here'show tohandle he all-too-typicalproblems n a common wo-door cabinet.

I First,build he doors o the exactII size of the carcaseopening.I Thatgivesyou someextrawood

to work with n thefittingprocess.Set he cabinetup on yourwork-

bench, f possible, nd makesure t' ssitting evel.Measure t carefully nd,usinga crosscut led on your able-saw, rim one door o a length /ro essthan he height f the opening. owset he door n place,as shownabove.Does he hinge-side tilesit ightlyagainst he carcase? f so, you'reoff oa greatstart.But if you see space atone end,use cardboard r foldedpaper o makea shim hat its he gapan nch rom he end of the stile.You'lluse hisshim n the nextstep.

Go to the tablesaw o shaveabit off the bottom ail at a veryslight ngle. hiswill et yo u

align he hinge tile, ut won't uin helookof the door as longas you don'thave o trim otf oo much.To get heright rimangle, lace ourshimaninch rom he end of the door hatdidnot showa gap,as shownabove.Test-fit he door again,and rim somemore f necessary.Be careful oremove ery ittlestockwith each rim.

Place he door n heopeningpennies s 1/ta pacers n thbottom,as shownabove.Trim

top railuntilyouhavea'r/'re eveal htoo.Thensticka pennyalong hehinstileandmark he knobstile's ocatia pieceof maskingape,alsoshownthe drawing.Now ollow hese irst hstepsagain or he seconddoor.Whyoumark he seconddoo/s knobstithemaskingape, t probably ill allslightly eyondhe irstone.Markhalfwaybetweenhe two to locate hcenterof the carcase pening. he dshouldmeetat thatpointbefore oumake he inaltrim n he knobstile

Continuedon pa

30 WOOD magazine November

5/26/2018 Wood #128 2000.pdf

20/76

Establishhe ocationsor yourhinges, hen cut mofiises n yourcabinet oors. nstall he hinges,

as shown above.Here again,you wanta 1/te eveal,so set yourmortisedepthsaccordingly.he surestmethodis to mortisea coupleof piecesofscrap, nstall ne of yourhinges, ndcheck he resulting ap.Caution:Eventhough ou've ound he perfectmor-tisedepth or one hinge, hatdoesn'tassure he same result or every otherhinge.The dimensions anvary slight-ly, especiallywith handmadehardware.

To find he correcthinge oca-tionson the carcase, ut he doorin placeagainwithpennies

underneath.Mark ightlywith a sharppencilat bothends of both hingebar-rels, as seen above.Remove he door,holda loosehingeat eachsetof marks,andmarkaround he hingeplate.Usingthosemarksas guides, ut mortises ndinstall he doorwith ustone screw ndachcarcase-sideeaf.Repeatwith heseconddoor. f everythingooksperfect,add he restof the screws.

Sometimes, fterall thatcarefulwork,you stillmight indyour-self ooking t imperfect eveals.

lf the gap s too largeat one end,you'llhave o chisela thin ayerof wood outof the nearestmortise, s shownabove.When a reveal s too slight,loosen he screw n the carcase-sidehingeand slip a piece,of aper, and-paper,or cardboardrlto he mortise obump he hingeout usta bit, asshown below.Tighten he screwandcheck he revealagain.

Another ommon roblem:herevealurns ut ine,but heplane f hedoordoesn'tineup

with the face frame, as shown above.Loosen he singlescrewplaced neachcarcase-sideeafand placescrewsas shown n the inset.To shiftthe doorout,puteach screwagainstthe outeredge of its hole,To pull hedoor n, put he screwsagainst heinneredge.Once he door s linedup ,remove he original crewentirely,il lthe holewith oothpicks nd glue,anddrilla pilotholeafter his plugharden

Finally,when everythings linedupjust right, rim he knobstiles o pro-duce a l'ra evealdown he middle.Take he same amountoff each door,usingyour ablesaw r a handplane,and bevel hem slightly oward heinside.The bevel ets hem swingopeand shutwithoutbanging ogether ttheir nside dges.iWrittenby Jim Pollock with Charles l. HedlundPhotograph:Baldwin Photographylllustrations: rian Jensen

32 WOOD magazine November200

5/26/2018 Wood #128 2000.pdf

21/76

where safety begins

Of the T2OrOAOniuriesper year associated withwoodworldngr 42 Percenthappen at the tablesaw.Yet common sensetpnoven practices, andtried techniques will keePyou out of harmts waY.

hat tablesaws ank high as hecauseof many woodworkingaccidentsshouldn't be surprising.Whatwoodworkerdoesn'thaveone?Andit's probably the most frequentlyusedpower tool in the shop.Becauseof thatuse, t'll pay you healthydividends oalwaysbe on guardaround his indis-pensablemachine.

A multi-toothedbladewhirling at8,000 pm shouldspura sense f cau-tion andrespect. t shouldn't nstillfear. Armed with the advice, ules,andtechniques ou'll find here,you'llhave he confidence o get the best outof your tablesaw, ndsafely, oo.Begin a habit-formingchecklist to followbeforc sawingCalifornia Polytechnic nstitutehasdevelopeda Codeof SafePractice or anumber of woodworking machinesasaguide for operatorsand supervisorsnthe industry.We've added o it, andsuggest ou always ollow the check-list beforedoing any cutting with yourtablesaw n the shop.. Remove rom the sawtable all scrapmaterials, ools, fasteners, ndotherdebris.Also cleara 2'perimeterall

besarevos?#tablgsaw

around he saw(more whereyou'llstand f ripping ong-stock).. Use the bladethatbest suits he ob(nevera crosscutbladefor ripping orvice versa),and makesure t's sharp.Check he arbornut for tightnessandthe blade tself for chipped eeth,cracks,and otherdefects.Do all of thiswith the machineunplugged.. Set he bladeheight.Flat-groundbladesshouldextendno more than% above he wood. Hollow-ground orplanerbladesmustbe raised ashigh aspossibleo avoidbinding.. Inspectall of your saw's safetydevices thebladeguard,splitter, andanti-kickbackdevice, f present) orproperoperation.The bladeguardmustmove up and down freely to accommo-datedifferent wood thicknesses.. Double-check he location andcondi-tion of the on/off switch.

. Realign the electricalcord to avoitripping over it.. Set he fence o align parallel to thbladeat the width of the cut.. Have safetyglasseseadyto wearif cutting material hat tends o chipfull-faceshield.

Becausea tablesawgetsso much uin woodworking, turning it on to ma cut becomesasautomaticas lippion a light switch.But it shouldn't.Ponder his advice:. Never run your tablesawwhen yotired. Fatigue eads o errors n judgment andmistakes. n fact, studieshave shown hat many serious ableinjuries occur to woodworkerswhemost otherpeoplearegetting readya goodnight's sleep.Also staYawafrom the saw f you're on medicatior havebeendrinking alcohol.. Don't rush.Plan all your cuts.

Continued on pa

34 WOOD magazine November

5/26/2018 Wood #128 2000.pdf

22/76

ffiruffi#*ffimffmRH'Con tinr rct/./)'ottt lxtge -11

| -^ n- f^ f r / (\. . \ \uu )d, ru ty >crVVarcufld our. When ippingstock,alwaysanticipatethepossibility f kickback.Plan ominimizeany damageiom it to you ortheworkpiece. or nstance,on'tstand irectly n line with theblade,but off to thesideof it. To makesureyourpushing andwon't accidentallyrun nto theblade,hook he smallandring fingersof theyour pushing andover he -enceo slidewith thewood.. If you're planning o rip boardslonger han3',geta helper o supportthewood after t passeshrough heblade or usean off'-f-eedableor roller).. All cutsshould ncorporate ither hefenceor themitergauge.Neverattemptreehand awing. urning hestockon the bladeevenslightlycausesit to bind n thewoodandkick back.

On theotherhand,neveruse hefenceandmiter qau-qeogether.f youtry to crosscut ith themitergaugeusing he enceas a stop, or example,the cutoffpiece rapped y the blademay ly backat you.. Don't remove hebladeguard romyoursawunless bsolutelyecessaryomakea specific ut.. Makesure ouhavea pushstick andyfor anycuts hat equireyourhand o passwithin 6" of theblade.Seedesigns tright for two tried-and-trueushsticksyoucanmakeeasily.. If youhavedoubts boutmakinga cut,don'tdo t.You've thought itthrough, now get inposition to sawYou'vegoteverything n hand. ou'vegone hrough he checklist ndyou'vethought hroughall yourcuts.You'reset o saw.And asyou do,keep he ol -lowing n mind.. Standwith yourweightequallybal-anced n both eet. f the boardshould

suddenlygive, you don't want to runinto the blade.. Be absolutely sure hat the bladenever comes between your body andyour hands,either front to back or sideto side.. Use a featherboard o hold stockagainst he fence. And make sure youhave a firm pushinggrip on it.. As you saw, don't reach over theblade to push stock. Always keep yourhand as far away from the blade aspractical. f needbe, use a pushstick.

. [f you'remakin,eepetitive uts,stofrequentlyo takea break.Many accdents appen fterboredomulls a peson nto carelessness.. After completinghe cut, et theblacome o a complete topon ts own.Don't pushscrapwood againstheblade o stop ts rotation.. Whenyou've inished awing,ur noff the ablesaw nd ower ts bladebelow ableheight.dlDrawings: oxanneLeMoinePhotograph: aldwin Photography

TWo do-it-yourselfpushsticks

MDF shoe-stylepushstick(Enlarge 53% or ull-size attern)Length 14 "Thickness 3/4"

TDToEToIc@I@{ox@-FomIU'+

t-mcU'Eo=ox

Baltic birch pushstick(Enlarge 530/"or ull-size atteLength 12"Thickness 1/2"

N

ID0)^'d=o

36 WOODmagaz ine Nov ember

5/26/2018 Wood #128 2000.pdf

23/76

ffiffiffiffilmprove your gripwith a little forethought

Allen bellwillmakebeautifulmusicwithhis new DeWalt 2Vcordless drill andworksite adio.Theycomewithourkudosfor sending n thisissue's opShop ip.Attaboy, llen

Here's urTopShop ipwinner,Allen Abell,showing ff hisprize-winning ip anda fewof his avori te rojects,

While watchingTV one Saturdaymorning,Allen Abell sawa guyusingC-clamps hat had a knob where hedogbone-shapedighteningpin shouldbe.Our Top ShopTip winner houghttheknob might give bettergrip andleverage han hepin, andpromptlyfiled the dea n the back of his head.

Then one day, he wasputteringaround he shopwhenhe stumbledonto a box of old golf balls. One hingled to another, ndbeforehe knew t,Allen hadcomeup with this ssue'sTop ShopTip, shownat right.

Perhaps ou, too,have ound a practi-cal use or sportinggoods n your shop.Or maybe ou've ust comeup with asimplesolution o a shopproblem.Either way, your idea s worth $75 fwe print t. And, f we deem t the best ip of the ssue,

we'll also hrow n a tool prizeworthat east$250.You canpostyour suggestionso our WOOD

ONLINEo Top ShopTips discussionroupatwww.woodmagazine.com.Or send hem,alongwithdrawingsor photographs ndyour daytime elephonenumber,o:

Tips From Your Shopand OursWOOD Magazine

1716LocustSt., GA-310Des Moines, IA 50309-3023Sorry, but we can't return your submissions.And,

because we try to print only original shop tips, pleasesend them only to IVOOD magazine.Thanks

^ ,-)WUry4WOODWORKINCRODUCTSDITOR

After bending the flimsy metal tightening pin on aC-clamp or the umpteenthime, decided o geta gripontheproblem. o replacedhepinwithanoldsolid-coreolfba

I started y cuttingoff thepin with a hacksaw. thenmeasured hediameter nd engthof theremaining haft, ndboreda holeslightly argeranddeepern the center f a goball.Finally, epoxiedheball onto he shaft, sshownbelo

The ball-grip its n thepalmof my hand,andgivesmemore orque han couldgetwith theold pin.Plus, t 's easto make argechangesn clampingdepthby holding hebaandspinningheclamp.

I like to sandmy small urningswhile they'restill on thelathe,but with sandpaperlone hepaper eats p quickly.And if I back hepaperwith padding, can't control hesheet f abrasive.t invariablyendsup on the loor behindmy latheor getssuckednto my dustcollector.

So, boughtan extra-fine M sanding pongepartno.9l6NA). But nstead f sanding ith thepad tself, use t tbackmy sandpaper,s shownbelow.Thegrit on the spongegrips hepaperandkeepst from flying away,while thespongetself nsulatesmy fingers rom the heatgeneratedysanding. nd, although ou'll still wearout a lot of sandpaper, he spongewill last orever.

Cotttinued on Dope 4

-S-'{5

-Allen Abell. Lilburn, G

Cooler hands prevailwhen sanding small turnings

-Bruce Hoover, Bloxom, V

IilT

3B W OODmagaz i ne November 0

5/26/2018 Wood #128 2000.pdf

24/76

it?ITi:ql ' l

:r

T'- i

>odworker,hobbyistor home improver?perienced he precisionond speedofailingond stopling?Professionolsserstening n opplicationsrom smsll birdrcIion o cobinet building and finish andlow SENCO,'the brand of choiceofs, hos a new lineof fools, ostenersondust or you Checkout AccuSef' brand;, brod noilersond stoplers rom theiO. They're ooded with power,greotI hoveo lwo yeor worronty- the besf n Tofind the retsil outlet neoreslyou,2W, or clickon fhe deoler locotoryexpondedwebsite:y4ggggcuset.com

YOU NEED FONIHEWORKYOU DO.

t-888-222-8t44Visit our newly expondedvebsifer w w w.a c cusef.cornk| fu 6 d @t[ilr3D

t* tt*5 tu &ForPdffi

g one of Anerlc{s most prclerred woodworking loois.85 Broodell Rood, Cincinnoti,ohio 45244-1 699 Sobty Fi6t. 0 The only woy to work.''2

\ reyouowLloveyou excneumoticrneumotic iFeeder rodrtrimwork. lrcrofessionof.rccessoriesFinish oilerucrosof SEN([eofuresonclhe businesscoll -888-2tn our newl

/

&* tllftlllJir,qllrarrilill"-,"

-T':,.-.;;.:=Iott t i t tued .f i t t t t r tuge -1 8

Fin ish your pro iec tsback less or bo t tom lessWhen builddrawers r cabinets ith plywood acks, finishthedrawer ottoms r case acks eparatelyefore ssemblyWhether prayin-rr brushing,have etter ccesso all sideof theworkpiece. nd rever ave o worry about rnishcol-lectin-un three-sidedorners.-Don Eisenhardt,rom heWOOD NLT|

TopShoPiP iscussionrou

Do- i t -yourse l f c rown mold ing :R ip , rou t , and beve lI l ike to make my own moldin-es sing a fLrll-profilemoldingbit. For crown moldin-9, first rip rny blank /+" wider than

the final width. then routthe profile on nty routertablewith the bit raised/s" above he tabletop,asshown at left. The squarecorners and a pair ofteatherboards)keep thestock snu-9 -uainsthefence and tabletop hroughthe cut. Finally, t 's backto the tablesaw.wherebevel-cr"rthe waste away.

-Dick Rose, ortland,Main

40 WOODmagaz ine Nov ember 00

5/26/2018 Wood #128 2000.pdf

25/76

Glamps f rom househo ld ob iec ts ,Whilebuildinga doll house ecently, needed bunchof smallclamps, o fashioned y own rom wirecoathangers. builtthebending, 1shownbelow and n theFull-Size attern) utof scraps f ;:, plywoodanda shortpieceof 3A dowel.Eachfinishnailsrr -lsabout /+ roudof thebendingig.Cut a piec, rf coathangerwire (or % welding od)aboutl4-18 on-e,. 1 wrap t aroundhedowel,startingrom themiddle.Ther .'rapeach oose ndof thewire around heform.as sho' l in the Full-Sizepattern.The wire will want oflex backor :')u, so inisheach endwith a pliers.

dowel-''--___

rev i s i tedWhile the armsof theclampare still separated,ut the ends

to length,andgrindor file the ips lat. (Forclampingmiteredcorners n small rames, rindeach ip to a point to pull thejoint together sshown.)Onceyouhave he ig built,youcancrankout asmanymini-clamps syou ike at no cost.-lan Beaton, amloops, . C.

I n l

Shop ptn {u iz : Gan you draw theBy itself,my t i-riesaw'sfenceust sn't reliablewhen tcomes o lock'.'ig t parallel o the blade.So transfenedhegraduations f a ruler to the ront andbackedges f thetabletop, s sb ;v. in the drawin at ight.Here'show.

I attached rr .iliary fence o the mitergauge,hencut akerf in the en.,*' Jsing his ndexingkerf, I scribed zeromarkson my tetopat the ront and earedges.(Remember,h ) are zeros or both sidesof the blade.)

Next, stret,,:f.-dtripsof masking apealong he ront andrearof the abl. and ransferredhegraduationsrom a steelrule to the ape. usedmy engravero trace hrough hegraduations,h removed he apeand ightly sandedhesharpedgese by the engraver.

Now, can rign my fence arallelo theblade, ront andrear,withouta ot of fussing nd est-cutting. s a bonus,the markswork even f I havean auxiliary aceattachedomy fence.

-BarryBrigmon, adsden,Ia.

6n

FULL.SIZEPATTERN

points or usewith miteredcorners.

para l le ls?

Continued on page 42

WOODmagaz ine Nov ember 000

5/26/2018 Wood #128 2000.pdf

26/76

t$pmContinued rom page 4l

Dont t fence your bench topLike a ot of woodworkers,insetmymitersaw ower nto my benchtop ocould use he benchas stocksupport.wanted o be able o usea workstop orrepetitive uts,but didn'twant o sac-rifice usable enchspace y runningafencedown hemiddleof it, sohere'swhat did.

Instead f a fence, routeda t/+"slot3/s" eepwhere he encewould havebeenandplaceda self-sticking,eft-readingmeasuringape n thebottomofit. For a workstop, tightenmy table-saw's eatherboard-the kind thatclampsnto themiter-gauge lot-in thefenceslotas shownat right. On thoseoccasions hen needa fence, simplydrop a 3/q"-thickence n the slot.-Larry Niehus,ioux ity,owa

Miter-slotfeather oard

Continuedon page'AIIny toolsshoulile hisTheAccu-MitePis aprofessionalmiter augehatmakes ertectangles asily.Shot-pinctionassurdsead-onaccuracvort 'commonangresptusa prec6eprotractorscaleoreveffiing inbetvveen

Optional accessories:manualclamypneumatic lamy3/6'"x 3/4" miterbar-

OUr ree 800Dutch quarelvd., uite00,Columbia,C 9210brochure.1-800-382 2637/ SC803-798-1600www. hej dscompany.com

Wedo not ecommendperatingithoutthe w blade uard,ssshown ere.USPatent 5,038,486

il PillJ

/a

/'z-

ReetoGoodHorneAccept o mitationsBuy hePerformax6-32Plus rum ander,heindustry'sriginalrumsander,nd eceiveheaccessoryacKageabsolutelyREE

Packagencludes:Infeed/outfeedables

Conveyorelt rackeretBoxof ready-to-wrapsandnanerizedo it

$131 ccessoryackageFREEThe oweroshapeour dea,tnfORM4(

JET,Performax nd Powermatic A FamilyOf BrandsOffer ffective eptember 2000 hrough ,4arch1 2001 800-334-49] . www.PerformaxProduct

W OODmagaz i ne November

5/26/2018 Wood #128 2000.pdf

27/76

Continued rom page 42Mini-scrapergetsright to the pointFor removing glue squeezeout rominsidecornersof your projects,makeamini-scraper.Remove he blade fromyour hobby knife, and eplace t with atriangular glazing point, as shownbelow. They renormallyused o holdwindow glass n placebefore glazing.)

Because he manufacturerstampsthem rom sheet-steel,ne aceof eachpoint has a small burr around theedges. Scrape with that face down.With three edges on each point anddozens f points n a box,onebox astsa mighty ong ime.-Mark Williams,ockford,ll.

A ewmoreips rom urwoodworkingros.Need o scrollsawa piece ha t s solargeyou can t spin t completelyaroundon your saw withouthittingtheupper-arm upport?Seehow weworked around hisproblem n thescrollsawn-shelfnpage56..When you need o clamp the centerof an assembly ut don t haveadeepenoughclamp, urn to yourdrill pressor lathe,as shown n thephotoon page 63.8

44 WOOD magaz ine November 200

5/26/2018 Wood #128 2000.pdf

28/76

thestoryofwood

,l,,',

'-

,i,,Somestock costs a bundle.Someyou can hardly ind at all.Yetscarcityresults or many reasons.

ink voryhas beencalled he world's arestwood.It 's never been available n commercial uantity.That'sbecause he relatively mall rees hat pro-

duce t growsparselyn theirarid,SouthAfrican ange. t 'salsobecausehe Zulu ribeholds he treesacredand onlya chiefcan ellone.As a result, itt lepink voryevergot ou tinto he rest of the world.Today, hancesare hat any pinkivoryyou'll ind comes roma numberof treescleareddecadeor so ago duringa majordam construction.Because hat limitedsupply has dwindled,you'llpaydearly or any of it. That's ust one of the sto-riesbehind arewood.

Endangered trees don'tSome tree species have beenovercut to near extinction.Endangered speciesof trees, such as

fall ' ' '- ' i l =

the ones hat produceBrazilian rose-wood andpernambuco,nd up on alist generatedy the Convention n nts

.,g#.);"I'

Trees bow to expansioAs populations row and owns and cities spreahumanityencroaches n the land until few trees remaWild pear reesoncegrew throughoutSwitzerland.But the smallcountry'spopulation xpanded,he pearbegto disappear.t happenedn GreatBritain, too, with tEnglishyew. If you can ind any wood rothese reesat all, it will be n smpieces ndquitecost

F-"q:' Ft lr f

nternationalTrade n Endangered &J tSpecies CITES).Signedby 144 ?i;ro.i.countries,he CITES treatybansalistedspeciesrom world trade.Sorry no boardsaVailable cou"rnmentestric-tions often can limit the supply of \-.:..'*certain woods in world trade. *..ni&n#*.Indian osewoodsn't allowed oleave ndia n boardor log form.Before he wood enters he worldmarket,value has o be added hat eco-nomicallybenefits he country.That "valueadded"may consistof sawing he umber ntopartblanks or musical nstruments r some :other orm of machining hat createsmore obsfor thenation'speople.Somegovernments lso control all logging andpricing. ndonesia,or instance, resently asse thigh prices or teak.Buyers hengo elsewhere.

46

)4;

"a "'--\; 'tfn;; ,i 'f'

WOODmagaz ine Nov ember 0

5/26/2018 Wood #128 2000.pdf

29/76

thestcry f woodQuality not quantityExtensiveprocessing o get perfectstock reducesavailability nd drivesup the cost.Gaboonebony,at about$70 perboard oot, may be the most \expensivewood dealers egular-ly carry.And its pricedoesn't .reflect any scarcityof the treefrom which t comes. t growsplentifully in Gaboonand Nigeria.The reasont costsso much:Usersdemandet black,densewood.Anything ess,although till goodstock or many uses,hasbecomeunacceptableor projects,at least oAmerican woodworkers.

Sometimtrees succuAt times n history manor governhas had nothing o do with the disap" ance of a wood from the marketp. In the United States,he m

"-t' - from the nation's orest..,,*.-^.-. byways n but a few decades.tcumbed o thechestnut light.:., althoughscattered xamplesostatelyAmericanelm still exi.''.: ". sweeping estruction y Dutcdisease esan n the 1

lmport not export a countchoose o allocate ts wood or nationaJapan asmuch well-managedorest and,anwood rom it has ime-honored ses.HowevJapan's onsumershe costof nativewood, suchaured amo,a species f ash hat requently is"peanut" igure, unshigh. To satisfy he demandoften s sliced nto very thin veneer nd henapplimportedDouglas ir or othersoftwood.Uses ikeexplainwhy the Japanesemport 70 percent fwoodandexport ittle exceptextremely hin ve:1.r, Top dollar gets the logs A ype r

"4 mayowe its rarity to temporarypopu,,' i" Sometimes, woodyou'd ike to use ust;..,,'1-. availablen any argequantityasboards', ', not?When he "look" of a certainw,.gi;r, becomes opularwith designers nd arch:: loesof thatwood head or veneermills r,'i' than sawmills.And the veneers ndarchitecturalaneling nd otherprodu. demand.Becaur. ih.y get so much productthem, heveneermills canpay 10 o 20 tmore or logs han sawmills.That's he case,writing, with quartersawn nigre rom A

World banking stops the flA country sometimesquits exportingwood wheInternationalMonetaryFundputs its foot dWhen the InternationalMonetary Fund discoversdeveloping ation t's planning o fund s sellingoff naresources,ncluding ogs, estrictions o into effect.Anwood species rom that country vanishes rom the marketWrittenby Peter J. Stephano with Keith Stephens, PresidWoodworkersSource,Phoenix,Arizona. l lustra tions: rianJen

,.s*rf.a,f ,*4{

o'.,.bfi*f*"s,,,.,

*'**fi&..,,$

i

Victims of war Givir arand other nternalunrest imit log-gingand slow world trade.Wengecomes romZaire. Indianebonyand Ceylon satinwood rigi-nate n Sri Lanka.But unless hosecountries' ivil warscome o an endbeforeyou read his, thosewoodsare n limited supply.What there scarriesa hefty price tag.

*"4

48 W OODmagaz i ne November 0

5/26/2018 Wood #128 2000.pdf

30/76

5/26/2018 Wood #128 2000.pdf

31/76

time spaceumbrota, Minnesota, lies 29miles to the north of bustlingRochester.home of the world-renowned medical facility, the MayoClinic.There's ittle of greatnote n thistypicaltown of 2,000people. t seemsgreatplace o live and raise a family-tidy, quiet,and with just enoughbusi-nesseso supplydaily needs. o clock-maker JamesBorden. its small-townpaceperfectly eflectshis view of time."Time isn't a cold calibrationof thepassage f seconds,minutes,hours,days, andyears,but a progressionromoneevent o another," ays im,his boy-ish face flashing a smile. "That's whymy clockshaveonly hands.No face.Nonumerals. think of them as livingthings, a type of creaturesculpted ofwood that happenso tell time."

A big creaturelives on the lawnJim calls his clocks "Timeshapes."Craftedof solid woods or the mostpartnative to Minnesota, hey first captureyour eye with size and form, then mes-menze you with graceful movement."The clocksare strictly my design,andtheprocess've developedo make hemis more that of a freehandwoodworkerthan that of a precisionmachinist,"hecomments. Right from the beginninghad a problemkeeping he works boxedin like a traditionalclock. I'11showvouwhat I mean."Although Jim storeshis clock invento-ry in a oft galleryon the secondloor ofhis converted-barn orkshop,he umpsfrom his workbenchand motions out-side.He stridesacrosshe vast awn to awindmill-type structure ising 26' intothe air."This was an experiment hat I builttwo years [rgo,"he almostexclaims nexcitement.I wanted o seehow a clockwould work outdoors,unprotected. t'sall madeof white oak, with a gearwheel10' in diameterand a 5' escapementwheel. The pendulum weight is 70poundsof castconcrete."Jim clambersup the weathered truc-ture, intending to start the mechanismmoving.Thenhe stops o call down,"I twon't run for long. Too windy. A sud-dengustcatching hependulumwill stopit dead."And aftera few moments.onedoesexactly hat.

52

Backon he awn,Jimputshis hands nhis hips, ooksup at the clock,andsays,"I think 'm on a scalehatno oneelse sdoing. I startedmaking clocks small,then hey got la rger and arger.But thismay be the imit, for now."Fromhumanitiesto timepiecesRaisedn Rockford, llinois,Jim did li rtle actualwoodworking as a youngster.It wasn't until he was enrolledat Blair,Nebraska'sDana College in the late1970s hathis latentcraftsmanshiptart-ed icking."I was a humanitiesmajor," he starts oexplain. "But there, you were alwaysencouraged o do work outside yourmajor. So one semester,a classmate,Tom Kendall, and I took independentstudyand built a tall clock with woodenworks.An old man in the areagaveusadvice. t was pretty tough.Because fmoney constraints,we used salvagedwood, and spenthours iling gear eeththat we'd cut on a bandsaw.Finally,though, we had a towering lz'-tallgrandfather lock built in kind of a clas-sicalGreekstyle."To this day," Jim continues, I creditthat school for communicating o methat anything s possible. t was hat ypeof study hat helpedme to arrive at theconnectionbetween timekeepingandwoodworking art. That clock back incollege ot heball rolling."After the first timepiece,Jim startedpicking up old clocksat garage ales otinker with, fix up, and resell. "I hadplans o go to the seminaryafter collegegraduation, ut I becameobsessed ithclocks,"he recalls. So the summeraftergraduation,Tom and I tried to go intoproduction from my parents'home inRockford. We thought we could getcommissionsor clocksfrom large cor-porations n the Chicagoarea.Well, wenever got any. And in retrospect, 'mglad that we didn't becausewe reallydidn't know what we weredoing "Not discouraged, im continued tobuild clocks alone. In 1981, t seemsthat madeclocks12 hoursa day,sevendays a week, I was so inspired," heremembers.But I didn't sell many ofthe ones made."Finally,Jim decidedo shelve is toolsandpursuehis originalplanby enrolling

A clock begins as a pile of wheels aboards on the shop floor because Jdoesn't sketch his designs on paper.

in a Lutheran seminary in DubuquIowa.For a few yearshe had ittle to dwith clocks.But he couldn't keep hmind off of them,andeventually tarcollectingantiqueonesand working othem.Then he met Barbara,alsoa seinarian, and they married."We movdowntownand openeda clock shopa historic ouristdistrict,"Jim recoun"I had maybe 100 antique clocks fsale,and did repairwork. It becamemfull-time occupationas I was finishiup my classwork."When n 1988 im'swife wasofferejob as pastor in Wykoff, Minnesothey moved.Because he mostly ruarea wasn't conducive to an antiqclock business, im once againbegcreating his own. "The sand shiftfrom antiques o my own ideas,"says. I didn't sell much there,but fotunatelyBarb had a steady ncomean

WOOD magaz ine November20

5/26/2018 Wood #128 2000.pdf

32/76

Much like decorating a Christmas tree,Jim hangs sculpted bits of wood to aclock in progress to properly balance it .

had the opportunity o follow my ownthoughts. ome f thedesigns'm work-ing on now are heresultof that ime.Events that shaped timeZumbrota beckoned n 1992. Barbarabecame he town's LutheranpastorandJim continued his clockmaking. Thistime there was a new twist. His clockswereactuallybeginning o sell.At an AmericanCrafts Council showin St. Paul that year,Jim sold a 2s'-talltimepiece o a medicalsystems ompanyfor display n its corporate eadquarters. It hadan 8' gearwheel, hesays. I hadto take t there o install,andgo back afew times. t needed lot of adjustmentbecauset was surrounded y windowsin an atrium. so the wood had somemovement. Jim sold three other clocksat that show,which markedhis first realentry nto commercial rafts.www.woodmagazine.com

As consumers egan aking noticeofJim's timepiecesculptures, o did theexperts.Entries n two clock-buildingcontestssponsoredby the NationalAssociation of Watch and ClockCollectors (NAWCC) Museum inColumbia, Pennsylvania, esulted nback-to-back first-place awards. In1994,some of Jim's clocks formed aspecial, half-year-longexhibit at theNAWCC Museum hat drew raves.Even though he's mingled with theexperts,Jim admits to litt le knowledgeof the languageof horology (timekeep-ing science). There are a lot of termsthat I don't know or use much.Clockmaking has its own jargon, hesays. Yet, it doesn't matter about theterms,as ong as understand hat theydescribeand how a clock works. AndI've always beenpretty good at under-standingmechanicalhings andphysical

Timeshapeswooden clocktures start atAllfeaturepenand someself-laws. With a calculator can figthe gear ratios and the numberon agear.Knowinghow o applrealchallenge.Woodshop horologyMost of the wood for Jim'scomes from the hardwood fosoutheastMinnesota.He buysfrom a mill that custom-sawsAnd he often visits there o findright stock.In storage, ou'll find ash,cherory, maple somecarrying he dof spalting),walnut, and a smatred and white oak and otherwooMany of the rough-sawapproach20 rn width, and thexplanation. I don't like edgwood, says he clockmaker. Somake each part in a clock oupiece of wood. And for that p

C

At his bandsaw, Jim freehands stockthrough the blade to rough-shape a newpendulum for a clock.

5/26/2018 Wood #128 2000.pdf

33/76

time space

To make his own dowels, Jim invented asimple jig that mounts to his stationarybelt sander. Pressure rom the adjustablewooden platen holds the wood againstthe belt as he turns it with his fingers.

Jim's clocks never have numerals because helikes the simplicity of telling time only by theposition of the hands.

In this clock, built n theearly 1990s,Jim used amix of walnut, maple,and cherry for contrast.

weightsize, usea slowpendulum. ousee, he engthof a pendulum, ependingon type, can determine ts speed.Mycompounded nes un from a second nda half to four secondsper arc, like ametronome.The weight above he pen-dulum hub, in the escapement,ends oslow he pendulum own.And whenyou slow t down, hereareso many fewer ticks per minute hat thegear atiodoesn't ave o be so high andyou only needonemaingearwheel, hefurtherexplains,pointing to the mecha-nisms on the wall. That decreasesheamount of power needed to run theclock,and akesawaya ot of the rictionyou'd otherwise ave.There'sa trade-off, though.A slow,compounded endu-lum, is less accurate. nd with wood,you have to consider humidity. Whenwoodpicksup moisture,t addsweight.So dependingon humidity, a woodenclock canrun alternatelyast andslow.To Jim, though, imekeepingaccuracyisn't foremost.t's the wav t's viewed.

Shaping the gear wheels' faces adds tothe sculptural effect of the clocks.say t's a curvingpendulum, 'll use aboard with sweep. It's strongerandmorestable hat way.Jim evengoesso ar as o makea clockfrom the wood of a single og, f possi-ble. I don't usuallywolry aboutdimen-sional hange ecause'm mostlywork-ing with lengths,and shrinkages lessalong he grain, he adds. And I leaveenoughspacingbetweenparts o allowfor swelling without binding up theworks. The hand shaft, where one rodgoes hroughanother, s about he onlyplace worry aboutchange. he wood Iuse there-usually ironwood-has toexpandandcontractat the same ate.Most of the challenge im faceswithhis timepiecess balance.He explains,A traditionalescapement ill be muchsmaller han hose build. Becausemyclocksare so arge,I'm alwaysbattlingto decrease riction by balancing t asperfectly spossible o hat don't haveto use 50 poundsof weight o get theworks moving. To help reduce the

54

Cutting teethin timely fashionNot long after building his first woodeclock-and filing all thegear eeth-Jimdeviseda faster, more precisemethodWith the indexing jig shown centeoppositepage,he canshape he teeth(othe slots or teeth)on a wheelup to 8' indiameter.Wheels over 4' in diametealwaysget separateeeth,usually of acontrasting ood. I normally out 12 to 15 wheelsat atime, Jim notes. All I have to do isslide he routeralong ts track to cut thesameooth n everywheel. t takesaboua minute, hen I shut off the router,andturn the wheels to the next toothUsually, 'll have o stopabouthalfwathroughall the teethand sharpenhe bitBut I grind my own profiles n highspeed teel, o 'm used o it.In addition o his ndexingig, Jim hacome up with another dandy deviceBecausehis clocks require dowels ovaryingsizes,madeof woodsnot read

WOOD magaz ine November2000

5/26/2018 Wood #128 2000.pdf

34/76

At the lathe, Jim drills out a dowel that thehand shaft will pass through. He prefers iron-wood for those parts.

A mantel-size lock li ke this one ofmaple that stands about 24 highrequires more work to make than alarge one. lt sells for $8,000.

ly available, e fashioneda doweling igthat clamps to his stationarybelt sander. My clocks are doweled together, andthey use dowels for hand shafts. foundthat I couldn't buy the right sizes n th ewoods hat I needed, o I built this, Ji msaysas he demonstratesmaking a dowel(see fop, oppositepage). If I'm makinga thin dowel, I can do it in one pass.The clock a month clubAlthough he time spentworking on aclock can vary with its size and com-plexity,Jim estimateshat he averagesone clock a month.And everyonegetsthe same inish. I 'vecome o rusta mix that came pwith several earsago, says he crafts-man. It 's a mixture f polyurethanendlinseedoil. After the last fine-sandingwith 400-grit, wipeon a threepart in-seed oil, one part polyurethanemix,wipe off the excess,hen et it dry for aday or so. For the final finish, I use a50/50mix, andput on two coats.

www.woodmagazine.com

A router mounted on a slidingtrack cuts the teeth for gearwheels. The fixture will take awheel up to 8' in diameter.

Jim's f inish gives the wood a satinglow. At one time, I mixed the woodsI'd use n a clock, such as maple o con-trast with walnut. But now I want a uni-form look, so except for the teeth oflargegear wheels, usually use only onetype of wood in a clock, he says,

His customers, ow mostly individualsrather than companies because hisclocks are now of a size that fits in ahome, seem to appreciate he look, too.Customers are interested n what theysee in front of them, he observes. lguess that 's why I 've not had anyrequests or clocks made in an unusualwood. If I do get a commission, t 's nor-mally for a larger size. And thank good-ness people seldom ask for a smallerversion.Making a clock smaller s hard-er than making one larger because t getsvery complex. And I don't need an ymore complexity than I have. QWritten y Peter . StephanoPhotographs:Layne Kennedy

How a clockwork worA clockwork s a train of intermeshed eapinions-a transmissionmachine-set inmotionby the kineticenergy of a fallingwAt the top, the escapementmechanismdthe weight's ong all o the floor nto inyments as a swingingpendulum egulaweight's rate of fall, stretching he enerbrief,uniform, ndcountable its,Whileyou can trace oothedwheelsback

ancientGreekswhoused hem o computive positionsof the sun, moon, and pclocksas we know hem didn'tappear n Euntil he 14thcentury,when monksdevweight-driven locks to signal prayerClock aces with hour handscame abou16th century.They were not accurateenthough, o havea minutehand.Clocks baccurate only when the pendulumwas100years ater.The swingingpendulum ttracts he mos

tion, but t performsonlyas a regulator.Algy comes from the falling, suspendedwThe wheel train transmits his kineticenethe time-computingmotionworks or dispthe hands, and also to the escapemenenergy going to the escapement ndurelease/relock equence which relays rimpulses o the pendulum o keep it swEach swing ets the escapementunwinding a tick.

GearwheelPinion

ESCAPE

HourwheelTIMETRAIN

SpindlePendulumob

PENDULUM

5/26/2018 Wood #128 2000.pdf

35/76

5/26/2018 Wood #128 2000.pdf

36/76

Let's cut theparts to shapeI From % mahogany ut all of theI parts isted n theBill of Materials nthenextpage.Usea stopblocko cut heshelves B), bottom apron C), and topapron (E) to the same ength.(See heExploded iew on page 59.)f) Makeand adhere wo complete ideI paterns o the sides A), using theFull-SizeSide Patternand instructionsin the WOOD PATTERNS@nsert.Withsprayadhesive,mount he otherpatternsfor the bottom apron C), top apron E),and op trim (F).

How to cut workpieces tooThe sidesof this shelf measure 6V2long-significantly longer than thethroat depth (the distance rom theblade to the cutting-armsupport) ofmost commonlyavailable crollsaws.This situation presentsa challengebecause or most of the cuts in thesides(A) you can't spin the work-piecesn a 360'circle.

Note: You may be tempted o stack-cutthe sides A),meaning ouonly needonecopy of the pattern. We tried this, butdidn't find much titne savings n doingso. Wealsodiscoveredhatscrollsawingth.e sides individually yielded more-accuratecutsand essburning.Q Drill all startholesand saw hepat-L,l terns to shape. Chances are thethroat on your scrollsaw s not deepenough o allow you to swing he sidescompletelyaroundwhile cutting.As wediscovered, ou can ackle hisproblemin one of two waysas described n theboxed nformationbelow.

long for your saw's throatNevertheless, ith a little ingenuity,you can make these cuts with any

scrollsaw.Hereare wo methods.First, you can make a seriesof cutslike those shown in the CuttingSequence or Sides drawing belowleft. This canprovea little confusing,to say the least, for the beginningscroller.And, stoppinga cut midway

Time to assembleyour top-shelf projectI Mark the backedges f the sidesI for the locationsof the shelvesas ndicatedon the sidepattern.Di'lguideholesat eachof the hole ocaton the sidepatterns.Designate neof the sidepiecesorright side of the shelf. On this picounterboreand drill shankholesthe pattern ace at the guide-hole otions. On the other sidepiece (forleft side of the shel0, counterborface hat's opposite he pattern acein doubt, arrange the pieces in t

Contin

along a line often leaves a telltalinegularity n the cut.We had our best resultsby makinpart of the cut in the typical fashiowith the teeth facing forward, thereversing he blade so its teethpoinaway, as shown below right. Gettinuse o pulling the workpiece hrougthe blade akesa little practice.

CUTTINGSEQUENCEFORSIDESYou can make the cuts in the sides bsawing a part of the pattern with thteeth acing forward, hen finishing thcut with the teeth facing backward.

www.woodmagazine.com 5

5/26/2018 Wood #128 2000.pdf

37/76

scrollsawnwall shelf

Af gn the shelves with a square, clamp them in place,and drill lheT/aq ilot holes usingthe shank holesas guides.

Space he top lrim'r/q rom the back edge of the top, and position the top apron 1/2 romthe front edge of the top.58

assembled ositions-the countermust be on the outside aces ofsides.)Removeall patternsand asive.Sandsmooth.l^) With a square lign he shelveL at their marked locationsonsides A). Dry-clamp hem ogethedrill pilot holesusing he shank olguides. (See the photo at left, Screw he shelvesn place.Q Appty glue to the straightedg\J the bottom apron (C). Positibetween he sides,and clamp t tobottom shelf. Dril l pilot holesscrew n place.A Counterborenddrill shank olT the top (D), according toExploded iew drawing.A Apply glue o the straight dgt*,/ the top apron(E) and top trimClampE andF to D, where hownnTop SideView detailanddepictedphotoat left, bottom.ft After the glue dries, positioL/ D/E/Fassembly top he sidespilot holes, ndsecurewith screwsJ From scrap mahogany,cutI plugs.Glue heplugs nto hecterbores,being careful to match gcolor and direction.Saw off the explugsand sand mooth.Q Appty he inishof yourchoice\J stained ur shelf with Minwaxmahoganyno. 225, and used a coswab to work stain into the cuareas.Then, we applied a topcoMinwax satinpolyurethane.Add wall hangersike thoseshotheExploded iew.You'redone

'/2D top

A sides Yzo 51/z' 26Vz' MB shelves 15 MC bottom pron z' 31/a' 15' M

17^ ME topapron Yz' 25/e' 15n MF top rim V2' 53/e' 16' MMaterialey:M-mahoganySupplies:all angers2),#6xt/2anheadoscrews2),#8x1 flathead ood crews2stain,learinish.Buying uideHardwoodit.All he ndividualiecesut lily oversizedbutnotscrollsawn)rom%'-tHondurasahoganynd wowallhangerW128,64.95pd. eritageuildingpecia205N.Cascadet., ergusalls, N 653call 00/524-4184oorder.

WOODmagazine Novembe

2

5/26/2018 Wood #128 2000.pdf

38/76

EXPLODEDvtEw7a counterboretA deep,with a7gz hank holecentered nside#8 x 1 F.H.wood screw #6x lz P.H.wood screw

Wall hanger6u

z/e+ ilotholeg/q deep (a,\

.i.*

Written by Bill Krier with Charles l. Hedlundlllustrations:RoxannE LeMoine; Lorna JohnsonPhotographs: Baldwin PhotographyDesign:Dirk Boelmanvwnr.woodmagazine.com

1Yz'3/t'

7/u pilot hole Ta deep

7/u pilot hole 7+ deep

See heWOODPATTEFTVSonsertfor the full-sizepatterns.

Ta counterbore/+ deep, with as/se hankholecentered nsideT.#8 x 1 F.H.wood screw

-rr-'))7a plugs

\r f\ rr

#8 x 1 F.H.wood screw\ r r )-_r(

\rrg/scounterboteVc deep, with a7sa hankholecentered nside

5/26/2018 Wood #128 2000.pdf

39/76

November2

5/26/2018 Wood #128 2000.pdf

40/76

Bui ld a blankfor the top bowlLocate the center on the bottom faceof a lVzx8t/zx8t/2 blank.

(We made all parts of our compotefrom cherry. If necessary, you couldedge-glue or laminate stock to makethe blank.) With a compass,draw tw ocircles around the center, one 8t/+ rndiameter and the other 3t/+ .

Locate the center on the bottomface of a lx3t/zx3t/2 blank of th e

same wood. Draw a 3t/+ circle aroundthe center. Drill a pilot hole of the sizerequired for your screw chuck throughthe center.

Bandsaw around the 8/+ -diameterc i rc le on the I % - th ick s tock.

Bandsaw the 3/+ disc from the l -thick stock.

Glue the smaller disc inside thesmall circle you drew on the largerdisc. Orient the grain on the small one

to match the grain on the larger blank.IYote: A lathe scrw-chuck vvill hold thestock to turn the contpote bowl cmdbase. Tttrning the center post calls fo ra spur-\)pe drive center and a rotatingtail center.Turn the bowl firstMount the screw chuck on yourlathe.Thread he hole in the smallface of the blank assemblyonto thechuck.Mark a center or a screw-chuckpilot hole on the larger face of theblank.You can do this by bringingupthe tailstock and marking the woodwith the tail center's oint. Then, dis-mount he blankanddrill thepilot hole.Don't drill any deeper han he depthofthe bowl.If youhavea drill chuckandan arborto mount it on your lathe's ailstock,you candrill thepilot hole on the athe.After drilling the hole to depth, dis-mount he blank.

Rechuck he blank with the large. face against he chuck. Install arevolving cone center n the tailstock,andslide t up to support heworkpiecefirmly for turning.True the edge of the larger disc,and turn it to 8 in diameter.Truethe smallerdisc,and urn it to 3 . (Weuseda t/2 gouge or this.)

' Draw a guideline aroundthe edgeof the arger blank Vq rom the top(the surface hat's against he chuck).You can draw the line accuratelybyholding a pencilagainst he edgeof theturning with the lathe unning.Draw a similar line on the edge ofthe smallerdisc, t/q rom theglue oint.Draw a It/2 diameter ircle on the bot-tom of the smallerdisc.Turn the exteriorof the top bowl to, shape, eferring o the full-sizehalfpatterns.Grab a Vz bowl gouge o cutthe curveseasily.For ncreased tabili-ty, you can bring the tailstock up forsupport during most of the operation.Maintain a flat surfacewhere he bowlmateswith the stem.That guaranteestight-fitting,almost nvisible oint.Continued

COMPOTE ULL.SIZEHALF PATTERN

33/a dia.

63/+ ia.

EXPLODEDVIEW

1112 ia.

21/z'

r 11/2\ BOWL\

I s/to et' \i

3/a enon

2 dia.111/ rod ia .

www.woodmagazine.com

31/2 ia.

5/26/2018 Wood #128 2000.pdf

41/76

compote

,-r''-S*,rr**# -. e. -iRemount he bowl on the screw chuck to turn the inside.Take ight cuts with a sharpgouge to prevent knocking the workpiece off the chuck.

62

Finish-sandhe exteriorwith pgressively iner sandpaperfrom I 20 to 220.Takecare o keepsquare dges risp.You can applya lathe inish toexteriorat this point, or wait uthe compote s completed nd inisall at once. f you inish hebowl noleavean unfinishedspot about Adiameter n thematingsurfaceor ging. (For on-lathe inishing,we lBriwaxOriginalor French olish,bavailable rom Craft SuppliesUS800/55-8876.)Dismount he turning,and reveit on the screw chuck. Turnbowl interiorand olled op edge.Tthe bowl to about 1/+ wall thicknFinish-sand he interior and edgeyou'vealready inished he bowl exrior, finish the inside now. Dismothe urning.Another blankbecomes the base

Locate the center on a lx4xblank of the same wood. Draw a

circle around the center, and bandsthe blank. Drill a pilot hole forscrew chuck all the way throughblank at the center.

BASE PARTIALLY URNE

Finish he outside of the bowl on the lathe before eversing t on the chuck to turn the inside.

WOODmagaz ine Nov ember

5/26/2018 Wood #128 2000.pdf

42/76

fl] Mount the blank on the lathe,plac-t ine the surface hat will be the bot-tom Jf the base against the chuck.Bring up the tailstock to support theworkpiece.True the edge,and turn theblank to 3Vz diameter.dft Draw one guideline around thet**i edge VB from the bottom andanother one Vz rom the bottom. Turnthe portion between he second ayoutline and the tailstock face of the blankto 2 rn diameter.Draw a line % from the shoulderofthe resulting tenon. That line will bethe top of the undercut feature shownon the pattern. See he BasePartiallyTurned llustration.)y$ Turn the base o shape,eaving heY undercut feature for last. To formthe undercut feature, first shape thecurve from the top of the tenon to theguideline,using the bowl gouge.Thencut in at the baseof the tenon (shownon the illustration)with the tip of a3Aor 1 skew chisel.True the top surface,which will matewith the stem.ffi Finish-sand he base, taking careqJ not to dull the sharp features. Ifyou're finishing as you go, apply thefinish to the base.ffi Enlarge the pilot holes in the bot-LJ tom of the bowl and the top of thebase to 3/e diameter. A twist drillchucked in a drill press will do thismost accurately.Drill each hole to adepth of e/rc .Now turn a spindlefor the stemJ Replace the screw chuck on the$ lathe headstockwith a standardspurdrive center.fl} Locate the center on each end of a{ Vr*tVzx|Vz pieceof stock.Q Mount the stock between centers,LJ and ound t down to lVt diameter.I Mark guidelines3/q and t/q from*f the tailstock end of the blank. Atthe headstockend, draw Iines 2Vq and23/q rom the end.Turn a t/s -diametertenonbetweeneachpair of marks. SeetheTurning the Stem llustration.)ffi Luy out the stem features on theu Fblank.Turn the stem o shape, ely-ing on a Vz spindle gouge and a 1skew chisel.Finish-sand he s tem. When sand-ing a turning betweencenters, hut

off the lathe after sanding with eachgrit, and sand in the grain direction.This will help minimize circumferen-tial sandingscratches. pply finish tothe stem. Part or saw off the wasteends, eaving he tenonsVz ong.Put the parts together{ Dry-assemble he bowl, stem, and$ base o test he enons' it and deter-mine the best orientation for eachpartin relation to the others.{*} Glue theparts ogether, nd emovet glue squeeze-out.To clamp theassembly,irst mark the centeron a flat3/cx9x9 piece of scrapwood. Thenhold the scrapwood's enteragainst hepoint of the lathe drive center.

TURNINGHESTEM

Next, engage he hole in the copote'sbaseon thepoint of the tail ceter. Slide the tailstock up until the rof the bowl contacts the scrapwosquarely. (If you've already finishthe bowl, put cardboardbetween trim and the scrapwood.)Extend ttailstock am to clamp the compote,:T If you haven't already finished t-cJ compote, o so now.After the incures,apply pastewax and buff it. Afelt to the base bottom. (We presdouble-faced ape to the felt, cut itshape, henpressedt onto the base.)Projectdesignedand turned by Ray Wilberlllustrations:Roxanne LeM