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NO 9

3 50

OTES FROM T SHOP

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W O O D SM ITIi

W O O D S M ITH (TSSN 0164-4114) Is

p ub

lishe d b im o nth ly (FebruB l ) \ Apri l, Ju ne, Au

gu st, O c1ob er, D ec em b er) b y W oodsm ilh

Pu blish ing C o., 2200 G ra nd Ave.. D es

M oines, IA 5 0 31 2 .

Woodsmilh is a re g istered tradem ark of

Woodsmilh Pu b lishing C o.

C o p yr lg ht 1 98 8 b y W oo ds m l1 h P ub lishing

C o . A ll R i gh t s R esetVed.

Subsc rip tions: O ne ye ar ( 6 is sues) $12.95,

Tw o Year s ( 12 ISsues)

$22.95. C anada an d

Fore ign: add $2 p er

yea r

U .S . fu nds on ly .

S ing le copy price. $3. 50.

Second C lass Postage Paid at D es

M oines, Iow a.

Po stm a ste r: S end ch ange of address to

Woodsmi lh, Box 491 , M t. M orris, IL61054.

S U BS C RIP T IO N Q U ES T tO N S? C a ll to ll

tree8()()-43S-0 715

(il l ino is residents cali

800-

892-0753). H ou rs: 7 :30 AM to 8:30 PM ,

Cen l,ra l TIm e, wee kdays only.

BAC K ISSUES: For a fre e b o ok le t describ

ing a llofthe back is su es, se nd to

Woodsmith

2200 G rand Ave .. D es M aines,lA 50312 .

SAM P LE C OP Y: W e wil l se nd a tree sa m p le

co p y of Woodsmi th to any on e. Ju st send U

his/her nam e and addre ss.

OperaJ lonsS te ve K ro hm e r

M ark etingManager S t e ve D o zie r

S to reM an agers;

St . tools,M O Jon B ehrle

Berkeley,C A M ich ae l D e Ha ve n

D es

M oines,

IA K en t W elsh

The Wood sm ith S to re

Edifor D on ald B . P e sc hk e

OesignO keefor

led

Kral icek

M anagingEdito r Doug las

L

H icks

AssistantEdfton; D ou g la s M . Udster

Kent A. Bu ckton

ProjectDesigner K en M u nk el

Ted1nicalll.,_ ton ; D av id K reyling

Cary

Christensen

RodStoakes

C hris G lowack i

C u stomer

Service

S an dy B au m , M gr.

J a ck ie S tr ou d

PatKoob

U s a T ho m p so n

Pro jectSuWl les L e slie Ann G e ar ha rt

C om p u fe rO pe rationsKen M ine r

Admlnist ratJveAssls. C he ry l S cott

J ea n C a re y

Bu iklmgMaintenanceA rc hie K ra u se

these old er projects. (F or more o n this . se e

Sources, page 24, and the l'1 'O jec t i :> 'upplies

lisU ngs on the p ro te ctiv e e over. )

800 NUMBER, In

th e past we

have Ol~y

accepte d o rder s

b y m ail fo r th e project sup

p lie s

and bac k is su es .

N ow w e

hav e an 800

(to ll free) phone number to accept M as te l'

C ard and Visa ord ers.

Ifyou wou ld like to order an y of th e b ac k

issues 0 project supplies, just give us ,I

~a1 1at 800 -444 7002 .Jacl de , L is a. or Pat ,,';0

be haPl)Y to ta ke your order. However,

ordering by phone is o nly v aila b le 8 :30 to

4:80 Central Time, M onday through

Fliday.

FCUILUlIENT SERVlCF:S-

For the past

ten years w e handled all of the subscrip

tion orders here at Woot lsm itl But the

circulation has grow n IlOmuch that it Was

taxing our abiliby

to

ha ndle it erf iciently .

Th is

past

summer w e began ta lk in g to a

subscription f,dfillmeni co mpany, Kab le

New. of M ount M O'1 is , lL I he fo lks there

have a very profe ss io na organiza tion , yet

they also o ffer personal servie.. and have

been delight.ft~

to

work w ith .

II I short, K able N ew s

is now han dling

al l

o r our

subscription and renew al

re

ques t. (We still process the b ack iss u e and

project supplies orders. )

If

you IlR VC 3

question about your subscrip tion (or re-

newal), yo u ca ll ca ll them a t8OO-43J ;-0715(I n

Il l inQis , 800$.2 -0753). Just tell them you

wan t information about

W O t > < i8 l r 1 i l l t .

and

they'll get

you to

tb e

righ t p erson.

NEWFACES.As w e began the

search

for

another editor to help with the w.iting

chores

rO)

WoodsmiJl it bec ame clea r th a t

we were looking for someone w ith a par

ticular mix of talents. W e needed someone

w ho loved woodwork ing ; knew ItO\\ to do

te chn ica l writing , an d cou ld work co mfol' .

ably on a variety of computers. (All of the

w.iting

is

done

on eom p uters.)

We

found

Kent

Bu ckton, In add itio n to

being an avid w oodw orker, K ent has the

w ritin g s kill s w e w ere looki.ng for, O ver

the past

10years,

Kent has

produced man;

tech n ica l rublieations on su b jects ranging

from co mpute r software to diesel engines .

Kent adapted quick ly to ou. mix of

wOQ I\\IOIkillg

and writing. H is fir st morn

ing here, we put him

.ight

to work on a

pr oject, fo r th e n ex t iss ue, He had quick

ill u'Q dlletion to the hop (where he b u il l

the 1) ''Q jec t). By lh e next day he WlIS back

in fro nt o f a .OIU jlu t eJ ,

v~itingh article,

I t's g oo d to hav e Ken t here, I'm sure it

will hel p speed th ings al~ng in our que \t

to get back on schedule an d stay the, e.

NEXT MAILING. The next iss u e of

W ood

smi th w be mailed dUl ' il lf , 'I,e w ee k of

D ecembel ' 26 , 1988 .

AIl0U TTmS ISSUE . 'Ve hav e tried to make

i~ a tl dition to devote one issue of Wood

811';/1 , to small pro jec ts - especially as

Chr istm as nea l'S . The cha llenge is to C Ome

up

w ith

idea s that m ake nice

g i f u <

ye t. a r e

fun

to

build

too.

The projects I like belt are those that

offer a cha lle nge

1

hav en 't tried

before,

Since I'm not a sk i ll ed (01 fl 'equent) tu rn er,

the

om am ents

in th is is sue caught

m y e . y e .

immediately . As soon 8. Ken (OIU Pl'o ject

designer) show ed me his prototypes, I was

in fr ont of the lathe, re al ly to try my han d

at them.

It

was ( l- us tra

tin l; at first.

My

hands d id

not fo llow the curves and sh apes I saw in

my mind's

eye. But

that chan ged faster

than T thought it would. In short ord er, I

IVa.

cl1In)

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3

OOOSMlTH

The inside diameter of the tu bing bas to

00

th e same as the o ut sid e d iamete r of the

OCCASIONAllY

CLE AN l P AND

IN S ID E O F fU BI N G

It

yoo d like 10sh ere a woodwotkin gli p wi1llo lh e

read er s of oodsmithsend your idea :

Woodsmith. Tips Techniqu es , 2200 G rand

A v e., ( )e s M oines , Io w a 5 03 12.

We pay e minimum01 10 lo r

t ips.

aIldS15 or

more lor special lechnlques Ihal ar. accepted

fo r pub lica lio o ). P l ea s e g ive . co mple le exptana

ti on01your idea.

I f

a skelc h is n ee de d, sand il

along w e l d r a w a

new one.

Sf

Nil IN Y OU R ID EA S

US E

I ,

I N$ IOE

DIAMETER V INY l

TU BrNG 1 LO fIfG

Nail

a

sc rap piec-eof

edge

strip (the same

thicknes s as the edge you want to sand) to

a

lI at b lock N ext gl ue or

carpet- tape

sand

pap er

to

the Irshaped s an din g block.

Then

sa nd

the edge strip w ith th e

sanding

block

\;d ing on th e

front

fac e until

it s

l Iu sh w i th

the.

plastic

lamina te or plywood.

Ja ck. C . 'f IU ymP. '01'

8; ghamlon, Neui Ymok

GLUE BOTTLE STOPPER

1~

seem s the stoppe rs th at come

w ith

most

gl ue b ottle s e ith er g et los t, fal l on the 000)

01

ge t

stepped on. I

so lv ed th is

problem

by

maki ng my Own

stoppers out of

vin yl

tub in g a va ila bl e

at

most hardware stores

or building centers.

IIiscovere< 1anoth er s olu tio n to

clamp-

in g the molding inside th e fI-a

II1

e, As yo u

explained in th e same iss ue (page

23),

Roman

oge e

bi ll; ha ve two

radii (a

concave

an d a co nvex ) lhat ar e th e slim e. So iftw o

pi eces of the m olding

ar e

reversed

an d

put

togeth er, th ey nest into one another.

By culling some

m011

scraps of the

moldi ng an d snugging them against the

molding on the inside of t.he frame, you

ha ve a w ide clamping surface 9n the ba ck

sid e of the SC II)

mol din g. Then ho ok y ow '

clamps a ro un d

to

the outside of th e

f,..me

to hold the mold ing tigh t.

BC M O >t A . Bow ditch

Ccm w ay , M as .'J (I.(')I ,,~et I

fIaroul l, SI Jlcle

SW M C olle ge, Pennsy lvania

EDGESTRIP SANDING BLOCK

10 the Shop Notes sectio n of W oods>n i t lt

N o. 56 you presen ted a m ethod for bring

ing

an

edge strip

flush

with

a

plastic

lami

na te

01 '

plywood to p. N o m atte r how

care-

fu l you are

r

think there is alw ay s some

risk

of

h arm ing th e surface

from

ei ther

p laning or scrapin \t.

Here 's wha t I fee l is a saf e w ay to b rin g

th~

edge strips

flush . A fter glu ing the

strips

so th ey 're above the surface

a very

stight

amount , Imak e a

sanding bloc k to

sl ide along tl)e fr ont

face

of th e edge stJi}> .

glue b ottle n oz zle. (In m ost cases,

0 /

in

side diam eter tubing works fine). C ut the

tubing to a length of

2:.

Then stic k a short

len gtb of matching (~') d ow el in to the to p

end of the tubing.

To keep the stoppe flvm getting sepa-

rated from the glue bo ttle, drill a smal l

h ole th ro ug h the dowel. Then

thread

nylon

fis hin g tine, suing ,

01

some tig ht w ire

through the ho le

an d

tie it

around

th e

botlle to p .

CLAMPING ROMAN OGEE MOLDING

ln

Wood$mUh N o.

57

th ere w ere

plans

for

a

w all m irror that ha(l R om an ogee m old

ing

around

t

he i ns id e. You men tio n ed

tba t

th e molding prof i le makes it almost im

possib le to clamp the moldings in place so

yo u held each pi ece w ith yo ur fin gers u ntil

th e glue grabbed.

J

A.

J e s s 6 >

0001'/ , , ,(1 , M is .jol t l-;

Ed i t o r ', No u: L ik e a U o j

lU J

t ip s ,

print ,

I

, , , , , , , t e d

to

try this m le O1,t in

Olir

MQ p -

but w e d id ,,' t. ha ve ,

Ip

, ,, d d i e

se t.

So I

we t

to ,.

l o c a l

hardw(1J . store ,u/

, , ; a .

S l t > p . - i s e d to

. w , d , Ih at a bwric lap am l die

se t

is, , ' I . tl l .QJ,e>:/xmsive. Sear.. hM

a

~

piece ho m eo um er s et

J i ?

wu/cr

JIt .

t

l io U k m U l wil h

qJtite

a J e w lOre sizes c f

u p s a 'll(/'

Itie

FIr I t lu /cr tzo. t t ll l i lJ i .dl t1

dM s c o s

alma

rt to .~.

And lit e

tl wf i \

beg an .

In .

addu ;on 10

threading pegixKtr lltooks, il : 1 i g l - e a t

to

be

ab le

iiI add

nih ,. . t hr eo d 10 Itca ,,i.age

bolt

or

cle(1J~up som e d am aged threa d . An d

ux '-uc even trie d wp p ing in lo hard uood.

will s om 8

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WOODSMITH

2 .

2\.-

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~

-

~

~

2

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-

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I'

. . . .

l~i .

-

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t

t

II

1'VI ...

,

j,

,t

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I,

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~I.1/ 4)~.

l//

Y . . .. , .~ . . . ,

v .. ,;

Ii..

h ,

.t.

, ) ,

1\l) lIillg

Ul('

ornaments is only

h,, 'f the

lim. I d~'Cidcdto wid

II

liltle dee ora tiv o

carv ing ) 1 \ th cc - or th e ornaments , see

p age

7. \V h . 1 1

th e

omameuts were

finished. I .o l( wC ( 1II smal l sc rew ey e in

the 101 button to hanl( them . Then th e or

nam ent. eun he 1) i t..< I , O J' ju st s prn ye d

with

dCaI'

Deftto

1)I Ow

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5

OODSMITH

Ste~.-By.-Ste~

'K

TUlNINO

/~Il

' :' [\., GOUG': 1

M E A ? ]

1

4>

~

STOOC

~rOCK

V

r-

[i.

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7

SaOULOE .R ll ,O COVE. Ornament

begins

as a cylincll r w ith a cove at

th e

wais t. Then

a sh ou ldered cove is cut at

th e bo ttom . (T ip: Sine-e I'm

right-handed,

1 fo un d it e asier to

turn

th is c ov e w ith

the

o rnamen t moun te d upside down -

so

th e

cove is on th e righ t.) Com plete the om a

ment by parting o ff a sh ould er belo w the

c ov e and turning the large button. Then

c u t V - g ro o v es and a bu tton on top.

4

SMALL COVE.

Ornaments

an d ~'

have

a

small

c ov e at th e

wais t th at

is cu t with a small v. ) gouge. The mo

tion is th e same as shown in Stell 2 . Stick

the gouge straigh t in the center o f the

cove. To cu t th e left side, ro ll th e cutting

end counterc lockwise (to th e le ft ) and move

tb e handle f rom 6 :00 to about 5:00 . F or th e

light side, go bac k to 6 :0 0 and roll c lock

wise

while moving th e bandle

to

7: 0 0 .

I

OUGE

W OOOSMITH

8

FINAL STEPS. Ml ornaments ar e

turned

down to abou t a W

diame-

te r

at bo th

end s (enough

to hold

it on the

lath e). T he n san d with 150 and 240 grit

sandpaper. R em ov e th e o rnam ent fro m

lathe

an d saw waste o ff ends. I u se d kn ife

to c om pletely shape the ends and sanded

them

smooth, Thl~

ornaments hav e

carv ing (see next page). Then

to

protect

tb em , 1 sp ra ye d

on

a coat o f c le ar D e ft..

5

SANOIN G COVE. I don' t have

any

reservations about using any too l

th at \\1 11g el th e job d one. In the ease of

lhe eove, I found it d ifficu lt to ge t su ch a

smal l c ove symmetr ieal- c- Lh.,.. 's no t much

room to p la y a ro u nd an d c orrec t mistakes.

So [ turned it down to rough shape and

fi ni shed it w ith a strip o f -s3ndpapel'

wrapped U'OW1(l

a /., dowel.

T his g av e

me Lhe exact shape

wanted.

'l'UlININC A BALL,PARTINGTOOL.

B o th M the previous methods are

awkward when t \l l' l1 ing the lef t en d (if

you 're

right-handed).

If all else fails ,

grab

a parting too l. (In fact, 1 find it m uch eas

ier to use a parting tool

on

both ends.)

Strut at

th e waist,

wi th ju st a

hairline

cu t.

Th en push the parting tool around the

c u rv e p re ss ing

its

side aga inst the stock.

a nd g ra du ally increasing Lhe wid th of cu L

TURNING A BALl., SC RA PING. A n

ea sier

app roach is

to

use a scraper

to sh ape th e ba ll. Or, you ca n lise a skew

in a sc rap in g p osition . Tum the skew on

its si de an d ho ld it fia t on th e tool re

st

with

th e lon g point

leading

around

L h e e nd

o f

th e

stock.

Slide

th e

skew

around th e en d,

while keeping the

center of

the

cutting

edge

on

th e

cur ve . It's

slow ,

bu t

1es.... isky

than using a shearing cut.

,

~

~

~

\

-1

/ }

.

S K E W

:

..

6

SROl)J. .DERE O B EA DS. Turning r-

nament E is d ifficu lt becau se yo u

have

to

get a p erf ec t sphere. As

the

left.

si de is tu rned , stop short to create th e

angled shoulder at the bottom o f the OL I1a-

men t. Sin ce I u se d a p ar tin g tool,

(his

dec

o ratio n starts rigbt w here the parting too l

le av es o ff. Then tw o m ore shoulders ar e

turned at successively steeper angles

(abo ut 4:30 the n 3 :3 0 p ositio ns).

3

SMOO ni BALL.PAfING TOOl. It s

-ather

easy

to rough out

tile

basic

shape of the ball with a parting tool. The

to ol is very forgiving so you don't have to

worry to o m uch abo ut technique, W Id c an

c on centrate on vi~uatizing

the

shape of a

sphere. (Look at tile to p edge.) Thell to

get th e f inal shape, [ro ll t lte parting tool

on its si~ an d us e it as a scraping tool to .

sm oo th th e bal l to shape .

1

0

TURNINGA BALL ,SHEARING.On.

o f th e m ost d if fic ult s ha pe s

to

turn

is one of th e s imp le st -

b all. B e sid es

d ev elo pin g th e ac tu al tec hn iq ue, y ou have

to develop an eye fo r the shape. The

fa ste sb way to tu rn a ball is to use a

1

skew

with

shearing action.

This

is m ore

diffi

cult than

it lo oks. Y ou h av e to

keep the

bevel

riding

~nst the

stock nn(

rotate

th e to o l so you don' t c atc h a c orn er '

I -

-

,~

P

,

~

R i

,

m :

rn

f i

, .

~ \. \)._ s

~

.

=.iI-

~

~

ARnNG

\

~ , GOUGE

100

11 3J:h Fh

W O O D S C R E W

,-:- TlJ R : N a u no N

BACK PANft

DETA IL

WVIDe

WR O S

G UR E 8

SECOND : )

A D D V 1 H IC K v at :r. C A . l _

O U T SID E P IECES

DETA IL A

I M P f E N CE

J

~ I

21

1 , .

f

v

i

HOR IZ ON TA L P IE CE S

c u r O N E

w

T H I C K ) C U T T W O ,,,r TH IC K )

VERT IC A L P IECES

C U T T W O ~H IQ ) C UT T W O / T H t c K )

IlESAWTO T1UCKNESS.Now

resaw

th e

s to ck f or th e d iv id er s

to

thickness

to

match

th e

kerf,

Resaw enough for tw o

vertical

di viders (D ) ( ro ug h s iz es 2\4 x 7 ) and

one horizontal divider (E) (2\4j x 8'1.

S h O P Note: To allow for p laning and

sa nding , it s belIt to resaw th ese p ie ce s

slightly th icker than the kerf. T hey should

fit th e test kerf a f t , e l sanding.

l lESAW OUTSID E

PJ)::CEl;.

The fow ' out.

sid e pieces (F,G) o f th e e gg -c ra te r u- em ad e

th ick er 1 1 . 0 ) b ec au se h alf o f their thickness

is hidden b ehind the If, rab b et on the

fr ame . (When

viewed

from the front of th e

ca .

se, only ~. thickness

will

appear.)

CUT TO

s ize ,

0

make

t he se 'I , th ic k

o utsid e p ie ce s, s ta rt

b y

c uttin g tw o v erti

ca l outside pieces (F ) to ou ghly

2\1, '

x r

an d tw o ho rizontal pieces (G ) 2 '(' ' ' x ft.

To determine the fiu l lVUl t of a ll the

dividers, measure tlte depth of the b ox

Iro m the b ottom of th e p to the b ack ed ge

2 Y . ? 1 1 1 e n sub tract the thick ness o f the

glass (~ ') and the thickness of the back

v . . ) .

In my case th is m eant cuLt in g t he

dividers 211.i ide, see Fig. 5.

LENG1'H.

Now (,/I t he p ie Ce s can b e cut

to final length so they fit snugly i, side the

fram e, refer to Fig. 8. T his is 6 f or t he

vertical piece. (D ,F ) an d 7 V 1 fo r tI . hori

z on ta l p ie ce s E,G) .

END NOTCHES . Next , 1

c ut n otch es in

al l

of the pieces t assem b le them . T hese

notches are

cu t exactly half way up

the

width of

e ac h p ie ce .

Stal l by

cutting

1 1

w id e e nd n otch es in all th e p iec es

to

match

th e

thickness

o f t il e o uts id e

pieces (F,G).

To cut

t he se e nd n otc he s,

set th e

fence

a s a s to p 1 1 . . o o m th e

out si de

of th e b lade

and the b lade height equal

to

half the

w idth (height) of the pieces l l:~.ee

Detail A in Fig. 6. Then

m a k e

a pass at

the end of the pieces. (Note: Y ou can cui

a num ber of p ieces at once.) To fin ish the

notcb to '; - w ide, push the ends against

th e fe nc e and

make

another pass.

CEN TER NOTC I lES .

Next, I cut the e'en '

te l' n otc hes o n th e o pp osite e dg e o f t he en d

notches. That is, the pieces should b e

tu rned 0 the end notches ru... on the top

edge when th e c en te r n otc he s a re cut.

O n th e sh or te r v ertical p ie ce s (D ,F ), c ut

a notch centered on the lengtb (in m y c a s e

3\1,.. from

th e

end, see

Fig. 5). 0 )1

th e

horizonta l pie ce s ( E,G ) . cu t a notch

2 1 1

from each end , see Detail II in Fig. 6 .

FIN L SSEMBLY

Before

putting

all of

th e p ie ces

togethe,

~':,._ '

ini sh ed th em w ith tw o coats of tung oil.

Then 1 cu t a piece of g lass to

fit

the fram e.

N ow , slid e in the egg-crate pieces. If ~~~~~~:::

the th ickness of the stock m atches the ,,7

width

of the notches. the p leees shoul d V -

GiASS

J

:

P :US:'h~t:oge~t:her~\:~~lh:O:U:t~gI:u:e,~s~'e~e~F:~ _'_7_.)_

~ = = = = ~ = = = = = = ~ / ~ / = = = ~ = = = = = = : = = < = = = = = = = = = = = = = =

o hold the b ack panel

in

place, I _

SCl...

wed two

metal

turn b uttons in to the

b ack edge of the

f rame. se e

Fig. 8 .

V

7/24/2019 Woodsmith - 059

10/24

WOODSMITH

RESAWTO' ''

CUT FROM ONE

o i

36 DOWEL

1 1 . x 6 6

1\ 71/. _ .4

1/,

2 _ 2OY .

:Jh, x 140/

IA

a ,_

(2)

a c...u_2

c eo,SIa(6)'

D Dowol. (2)

c

cunlNG DIAGRAMATERIALSLIST

dra ing I l ddiu., circles, Locate

the

front

circle a nd low er rea r circle

tight

a t

the

corners

of t h 4 . >

wo rk pie ce , ~

F i g . I .

Next, to

Inc aw lh ~ u ppe r

rear

comer ,

mea,..ure il l t frorn the end and square a

tine dow n ( n

th e

lop edge. Pla ce

the

point

of a

t O ll 1 l l U -

on th is tin~

a n d

dra w

I I

I' l 'l ldill>circ le

1 1 0 il

tou ches the

to p

edge

u fthe workpiec e. Then II I' l lWa l ine tangent

to tbe lI ppe r : t n c l lower circle s, W hen the

wa st e is cu t 00' , the :I ng le o f the rear end

of the runner wil l be bou t

45'.

fonn th e a t. I oog n by cu tting the run

ners r un ,- 1 ( .- to 10/,. actual)

brown

a sh, 6 widl' by 3C j

long ,

se e Fig.

RUNNERS.

T he ru nners

A

form the

sides

r til(' sled.

To cu t them

to

shape,

begin ~Ilylng

ou t the

p ro fi le , < ee F ig . 1.

Sinc e th ~ p itio n o(the, 45 angl ed cu ts on

th e r~a l' of Ih t' l 'U nn el 'S is det erm ined by

the ll l 't' or the ti l 'C lc. tha t form the 001110''5,

I

dr ew

the cil'll ies fi l 't.

CORNt:RS. The two lC~UCOI11el'S,as

well

the nooc of the ru nne r. a re mnd e by

BUILTFOR SNOW , SHOW AND GO

A 1 .'00< 1Ied i$ like a fine sport, ca r. You

fe e l l ike it'~

part

of yo u a s you slide down

hil l. Eve n U lou l( h O u r le d does n' t ha v e a

fancy slee lin g mec han ism or fl ex ib le run

ners , U\C 'kid. wlll find it

1S

li ke a

Sj)OIt~

ca l'

for

fllt maneuvering down

the slo pe s.

'J 'hi~g u b jc'c t of

speed

brings m e to .

topic

th u t

1 '\l~'C ivcclome discu ssion

in the

Wood

.mill,

o f f i c i S , Given the

li gh t

bill and

th e

light

nOW con ditions,

th is sled

is

fa st.

D av e's kids (ou r lo w -bu dget tel l pilo ts)

praised

i ts speed ,

Dave,

forgetting

bis 0 1'1

youth a s a thrill seeker. g ot th e

ehiIls.

W . M nl .11

7/24/2019 Woodsmith - 059

11/24

I

, .

,

SlOTcunE'

8 1 '

CROSS

SECTIO,N

S Q UA ll U P S lG E S

A N D C O RN ER S

WITH CHISEl

MORnSE '. DEI '

- _

N O T E,

ROV' COUNlEJtClOCKWISE

AROUND aUNNER

,

'

Slot

1lOU11HG

l C 1 l O N

NOTE

QNI NNN(1

OOWNWOI

lIOUTlHG

ftGlJlf S

MOI11SI _ IOUAlS

1 M I C J C N I S S

STCIQ

3 .

--2.,, ---

9',,,

I

~GURE2

. .

. .

5...

,

. . .

.

.. . . .

. . . . .

,

17.-.

.

,

Sl[O

RUNNER

PRORl[

FlGUIf ,

W O O O SM IT lf

fRONT BI lGY_The

c urve at

the

fro nt o f

th e

runner

i.

I. by

d ra w in g a n a rc

with

a IT radius,

The

center

point

of th i,

ar e

i'NIiRSLOTS. \\'hiIe

ha d

the

router

out. I cut

th e

s lo ts fo r

the

T ,molding

tha;

goes

,uwIVI the

per imeter

of

t he r unne rs ,

To do

this I used

I..

s lo t cut te r

bit.

Rcgin

by

p mc lic ing on a sc ra p p ie ce th e

s a m e

th ic kn e.;.. a s th e ru nn er s to ck , Ad

just th e bit uutil it cult; slot exnct/y

( ( 'nu'l 'I 'd all

the edge,

T hen cut W e g ro ove

al l

thp

way around

th e runne r, se e

Fig. 6.

Snop

N ote:

T he p ilot

011the

slot

cutter

,m l.c)mut iclI lly makes a 'It ,d eep gr oove,

7/24/2019 Woodsmith - 059

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WOODSMITH

,2

A fter th e ru nn ers

n

fin ished, the cross

braces

(B)

th at support the seat slats

can

be m ade. T hese

bra ces

also

are

4 1 4

brown

as h,

3

w ide by

14'

lo ng.

TENONS.

To join the cross

braces

to th e

ru nn er s, s im ple tenons are formed by cu t

ting

v

by V o n otc he s on the top an d bot

tom e dg es p ro ducin g 2 ~N -w ide te nons to

fit th e mortises in th e run ners, see F ig.

7.

Icu t these notches on the table saw

using tlte m ite r g u g e for sup port. Since

the fence is used as a stop, T fastened a

scrap of

o / , N

plywood to the side of fue

fe nc e to protect it fro m th e blad e.

IQoIOCK.ooWN fASTENER S

Aftel' cutting th e tenons, the cross braces

aloe ready fo r th e k no ck -d ow n fasteners,

see Fig . 8 . To do this, three sets of holes

have to be drilled .

HOhES 1 :N lU1NNBRS. The fu'St set of

ho les goes thro ugh th e ru nnel'S for the

body of the bo lts ,

se e

Fig.

8.

T o lo ca te

th es e h ole s, s qu are a lin e from th e ce nte r

of the m ortise. N ex t, m ark th e hole

posi

tio ns i and ~down from the top

ed ge of the runners. Then drill

,.

holes

1i-01O

the outs ide into the mortise.

1 :ND BOLE S. Now the holes for the

shanks

of the bolts can be Al>OES.o help hold the sled squar e

an d lig id , the seat slats ha ve dadoes on

both ends that fit o ver (he cross b races.

You have to make sure thes e dadoes

n

spaced

to

match t he d is tanc es b etw een the

two Cl'()SS bra ces , To do this, I cut the dado

on ly on one en d of all th e p ie ce s first,

SETDADOBLADE.To cut the dad o es , se t

up the dad o blade

to

ma tc h th e th ic kn es s

SE AT S UP PO RTS

14 \4

.

DOWEl

AGURE 11

ROUND BO rrOM

ED GES O NLY

t

ROUNOO VER

BIT

S E T

l I f T

A .

O f P

NOTE:

TOP IDGES

stA Y S QU AH

~R O

ASS .... . .

C RO S S B RACES

TO RUNNERS

NOTE :

u

HO lES

T H R O < J O H

RU NN eRS T O

P OS IT tO N B IT

RGUR

CROS S S ECTI ON

F IGURE 9

,

U NN JI

PORrAllGN

I

T O P

fOOt

. H , . MOtE

S T R A l G I f T

C R O SS B R AC E

1,

. .

fll

8fT

NOTE:

TH IC KN ESS OF

CROSS

BRAC E

ST OCK

EQ UAl S MOR ns.; W IDTH

S H O U L E R S -

AlE ~-

V..

D EfP~ ___/

,/ ..- LONG

( SE E D E T AI L)

1l :NON

DeTAIL

CROSS

BRACE

RGURE 7

7/24/2019 Woodsmith - 059

13/24

13

OO1)SM l't'li

,

f MOLOING

TO MA I BENDS

A T EN DS

~8

UA5S

S C R E W

SEATlAl-._

DETAIL

RO SS S EC TIO N

PRE .T H RAS HOLES

WITH STEELsatEWl;

NOTE: C U T S CR EW S ON

FliS T A N D lA S T S lA TS

S1:ECROSS S tenOH . 'LC1W )__I

U T T Mot OING

T O 8 UT T E N O S

I,

CROSS

~Eglo.~

OUTtR

TAB tE

F E M e : l

blocks, 1 cut the ea rs off tw o sid es o f the

tr ia ng le w ith the band saw .

DRAWRADI I . Nex t, th e r ound corners

ca n

be

I O O d out b y drawing l adii on each

block. T o do th is , I taped al l four bJ1X:kso

gether and drew two c ir cl es ( re fer to Step

;; on page 19). First, draw a 2 1 . < outside

ra dius. 'I 'hen, draw the inside ra dius so the

thick ness of the co rn er equals the th ick ness

of the stock you plan to use for the fram e

p ieces

of the clock.

S inc e

my

Irame,

stock

w as

v

th ick, 1 m arked an in sid e r ad ius

of 10/,. ,see Fig . 1.)

FltAMI PIECES

Before

c uttin g tb e

co rners

to th eir final

rounded shape, I cu L th e fo ur fra me p ie ce s.

T he w idth of th ese pieces must equa l th e

th ick ne ss o f th e sq ua , .. co rne r blo ck s, s ee

F ig . 1 . A f te r c uttin g th em

to

will th,

cu t

all

four pieces

to

a uniform length of 7:.

G R E A T F R AM E A R O U N D T H E C L O C K

W all C lock

7/24/2019 Woodsmith - 059

21/24

2

CU I

IN S ID E

RA D IUS

8EFO RE

A S S .E M a\ Y

DETAIL A

KEfPSPUNES

F lU S H W l T H-

BorrO M E DG E

j iECOND ,

Gl U e FRAME S ID E S 8 E TW f EN

TO P;8 on O M S E CT IO N S

P T E R

ASSEM8UNG

CUT O U tS ID E

RADIUS RUSH

W IT H fR AM E

Pi taS S E E:

DETA il

a

~r

1 .- :0 ;

1

7

~PllN e B LA NK

:U T fJl:OM 41 4 S tOCK

\ _ EQU ALS ~'J1DTH

Of

GR O O VE tV .1

a r t r = i l

t , - , < : -

WOIH1uAlS

2

t.. C O / A B IN E D O E PJ H

~ O F 80TH G R O O vtS

CU nlNG SPLIN ES

F lGUR E 4

TRANSFE ill OC AnON

0 GROOVETO

C9 AN ER BlOCI

~ORNatl ac

;

:;y

iX(

R IP

FlNeE

AUGNStDE

W I1 1i C ORN E R

l AYOUT UN ~

DEIAlb

AUGN

SAW

BLA O E

W ITH LA YO UJ M AR KS

RG ua e 3

CENTER SA W

S LA O E O N

THtcK NE S S O F

WO l ( , flEeE

~

J.

IP

F E N C

RAM

PIE CE

DETAIL

F IGURE

C U T C EN T WO

G RO OV E O N

B OTR e NO S

WOODSMITH

A S S E M B L Y

There s

one

mo .

s tep

before

assemb ly .

B and saw

the

S u i b

ra dius on ea ch eo rn er

b lock , s ee D etail A

ill Fig.

6.

GLUE UP ENOS.

N ow the (tame call

be

assemb led. S ta rt by glu ing and cl .mpu.g

two corner b lo cks to a frame p iec e. T hen

glue an d clamp the O PI>O.~iteide an d con -

nec t thes e two s ectlcn s

co mp lete the

Frame. W hen th e glue is dry, p lan e the

sp lin es off f lus h w ith the top o f th e fram e.

C U T O IJ1 SIO ERAmU s. To co mplete the

basic frame, cu t o f( the outs ide mdii

O il

the

row' co rn er

b lo cks (see D etail B ), an d then

sand

the in s id e and outs ide radii sm oo th .

G R O O V E S

N ow the jo in ts ca n be cu t

to

jo in th e Iram e

pieces to th e roun d co rn ers . 1 u sed a sp li n e

and groove jo in t here. T his re qu ire s c ut-

t in g gro oves in the m illing ends o f ea ch

piece and w.ring a sp lin e in the grooves .

C U 1

ClRO O V E S.

To cut the gI 'OOV C 8 in th e

fram e p ieces, m ise the b lade to a height o f

W . se e D etail in l;'ig. 2. T hen p os itio n the

ri p fence so th e saw b lad e is centered on

the thickn ess o f the

frame

p iece.

Once

th e b lade

is

ce n tered , cu i a

grceve

in b oth ends o f al l fOUl (ram e p i ec es a lwa ys

kcep in g common race agains t th e fence,

see

Fig, 2.

(W hen

making th is cut,

I

backed up the workpiece with

II

2x4 block,

or

Y O U

co ul d use a tenoning j ig.)

G RO OV E 8 LO C KS.The grooves in Ihe

corner

block.

have

to

match the grooves in

th e

fram e pleees. T o do this,

hold

a f rame

p iece again st the en d o f O O I 1 c r p ie ce s o

i t a li gn s with th e radii li ne s d raw n. Then

tran sfer the groove locat ion on to tne

co rn er b lo ck , s ee

Fig.

:1.

N ow , move the tab le saw ip fen ee so

th e

saw

b lade

lin es up

with

th e

groove

li ne s. T h en

cu t

t l.e g rooves in each co me.'

block, see D etail in F ig .

3 .

(No t e :

If

th e

gro oves are cut s lig htly o ff c en ter, yo u can

always redraw the co mer 1 1Id ii.)

S P L I N E S

N ext, I cut s plin es to

t

th e g ro o ve s,

FOl

the ~tm ngest jo in t, Lhe grain in the sp lin es

should run th e same dh ct ion as th e grain

in the

frame

p ieces.

When

malting

the

spl ines , 1 used Ih e sam e kind o f

wood,

but

yo u

could

use a con tras tin g w ood

to am -

phasize

the

splines.

cur

SPLINES.

To make the splines,

set

Ih e .ip fence SO th e d is lnllce fro m t ile b la de

is equal to the w id th o f the groo ve, see

StCI I ill F ig. 4. N ow make two cuts on

o th en s o f a 4 w ide b lo ck .

T hen , to

Clll lhe

sp li n es

o f f, s et

the fe nee

so

(h e distanee 1 i'O , the ou ts ide o f the

b lad e to the

workpiece

end eq ual s

0 / ;-

(t hat is , Ihe comb in ed dep ili

o f

the two

grooves). s ee S tep 2 i n. Elg . 4. Fl11alJy,tr im

the

sp li n es to a ''O 'lgh w idth o f 1% wi th

a ch isel.

7/24/2019 Woodsmith - 059

22/24

WOODSMITH

FIN IS H IN G UP THE FRAME

B efore you beg in work on the face, there

are a couple more steps on t.he fram .

ROUND OVER FRONT EDGES. F irst ,

round over both II-ont edges of the frame

with a v . round-over bit, see F ig. 6 .

RABlIET BACK. N ext, rout out a

1 0

l-ab

bet 1 deep on the bac k inside edge of the

frame

t o

a cce pt the

fat...

To do this, 1 used

a p in -rou ting jig o n th e ro ute r table, se e

~ ig. 7. (For m ore on the jig, see page 23.)

CLOCK FACE

After the

rabbet is rou ted, the clock rat..

c a n

be

m a d e a n d

cut to

6 t

MAKETH E FACE . I

made

on e face

out of

v . . plywood, then ried a couple more

with plasuc laminate 0 bu rl veneer glued

to 1 1 . Ma.~onite. (N ote: Lam inate or

veneer c al l b e g lu ed to t he Ma s on it e either

before

01

a fte r t he face is cut to

fit

th e rab

bet,

se e

Shop N otes, page 23.)

The

onlY thing cri tical

hel e

is

~hat

toh

c o m p le t e d

f a ce ma ter ia l

m u st

b e

l

ss

t l n

% thick.

I h is a l low s tbe stem on the clock

m ovem ent to stick

Ollt

th e front and

the

- thick movement to fit behind the face.

~lAnK AND CU' 'OU' 'FACE.

O n c e

th e fa ce

material

is

cu t s light ly oversize, p la ce t he

clock fram e on the face and m ark the out

line Ofthe rabbet, se e P i g

8:

N ow cut the

face to

wid th

and length on

II

tab le sa w,

Theil sand the

c o r n e r s

round

O n

a disc

sander until they Jll the

rabbet

CEN1'Elt HOLE AND MARKeRs.

Before

mounting th e

face, I laid out a c en ter

hole

and the leeatiouof th ~ how markers, se e

F ig. 9. (Note: If you ord er th e d ock parts

from

Wood rmit l t

a face template is

in

cluded, see page

~t

o lay

Ollt

th e f ac e,

start

by

I li jd in g t he center point, Then

draw a 4 Y . i radius circle with

a

compass.

N ext, m ark the locations of the 12, 3, G

a n d 9 o dock m a r k e r s o n th e circle, se e F ig.

9. 'l'hen, use a protractor to mark out the

rest of the m a r k e rs at 30 intervals . After

the how m ar ker s a re laid out, d rill a \Ii

center h ole for th e stem .

FIN'ISFf.

B efore fasten ing the face int o

th e rabbet, finished the frame

and th e

face

if

it s not plastic) w ith tu ng o il.

ASSEMBLE FACE TO FRAME

When

the finish i~ d ry

you can mount the

face in to the fram e w ith cleats, see F ig . 10

GIVE

IT THE

WORKS.

Aftel'

s cre win g th e

cleats dow n to hold the face in . m ount the

works in th e b ack w ith th e h an gin g b ra ck et

between the m ovem ent and the face.

M ARKERSAND HA DS .The only thing

left, is te add the hour m arkers and the

hands. O n

p~e

24 we.e g iv en s ourees fo ,

gold.oo lored markers in both dots and

clashes You c ou ld a lso m ak e h ou r m ark ers

from dowels , plugs, or screw hole buttons,

Now , add the ha nds and the cap nut.

T hen it s tim e to hang up your n ew c lo ck

M O OR M A RK E R

ctEAT ~

h

n W O O O S C R E \ V

p

T

DETAil

C L O C K

F AC E L AYOU T

iG U R E 9

B RASS W AS HE R

ANDNUT

P NUT

R U 8 8 : A

W AS H 1 R

H O U R

M A R K f R S

H NGING

B R A C J E r \

C L O C K )

M O V E t.\fNl

AGU.RE- 10

M A R K O U TU N I

Of

RAUnON-

C L OC K fA CE

f iGURE 8 :

NOTE;

CUTMB n IN twO

V ,.: W ID E P A SS E S

/4

R O U N D

O V ER 8lT

MOW fft M FROM

, T O R t G J W I o 4 E NR O U T I NG

lt~

F F AA M E

MOVf FR MEfROM B J Q I :f t

TO \HI W H E N R O UTIN G

JJl~

O F R AM E

NOTE;

~OU~OV ft

m O N T E D GtS

O NL Y

F IG U R E.

7/24/2019 Woodsmith - 059

23/24

1 0

cut the ~. rabbet in the back

of

tb e

clock fram e, I m ounted a

h

s tr ai ght , b it

in th e ro ow ,'

table

and raised it rbove

th e

table,

Th en :u \ju .,t th e pin ( by mo vin g

the fcn h i l U l

the bit, you have to

pnl

th e clo ck fram e ag ain .< t th e p in

an d

then m ov

th e

frame Irom left to right

( c lo ckwi.

0 10 thaI

d i d .

(Since th e

o p en ing s h ave

vl corners, sometimes

it

take; couple

piee...

to

get a

good fit.)

Once you get lh~ substrate to

fit per.

f ec tly , g lu e a n

OVCOOY.c

p iece o f

Iaminat .e

01 ' veneer 10

th e

(01), Then mount a flush

uim

bit o n the router (ab le and set th e

ball

bearing on thl' bit to rub against the M a

s on ite , s ee d ,w in l(, T he c utter will trim

th e laminate 0 V~l( Nperfectly fl ush w ith

the t.1a.~nit,cand leaves a smooth surface.

fiN R UB S

A G A J N S l

N S I D E

Of

WO.I

7/24/2019 Woodsmith - 059

24/24

CRADLE ( 48)

T he spin dles and butto ns fo r the cradl e are

n ow av ai la bl e

in

oa k, walnu t or cherry.

Each package in clu de s mapl e k no bs.

C radle Parts, O ak , O rder No.

748-

11 0, $4.').95.

Cradle Parts, W aIJ,>ut, O rder No.

748-120, 59.95.

Cradle Parts, Cherry, O rder No.

748-130, 54.95.

WORKBEI'ICH (50)

Front V ise and Handle, O rder No.

750-110, 114.95.

End V ise and Handle, O rder No.

750-120,

$4 4 .95 .

W ooden Bench Dogs, O rder No.

750-

130, 10.95 per pair.

Oak Drawer Pulls, O rder No.

750-

Wood. , mil l . i. now o f(e lin g supplies for

so me of Lh ep l' uj ec t. -;l ha t h ave app ear ed i ll

e ar ti er i ss ues.

1 01'

a complet e

description

o f wh a t's in cluded (wood

is

no t in chided

Ull

less $pee if ie d) , s ee lh e p ro te ctiv e c ov e) ' on

thi s ; ssue. I f it's n ot a va ila ble , c all lhe toll -

n . . .

number or write the ad dre ss abev e.

REGULATOR CLOCK (36)

Regulator C lock,

Quartz

Clock

M ovem ent, O rder No.

736-110, $74.95.

Regulator C lock, B rass Keyw ind

C lock M ovement, O rder No.

736-120,

$9 9.95 .

Sled H ardware Red) , Order No.

759420,

$14.95 . This

bas

a ll t lle same

com

po nents as No.

759410

(m ention ed

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