Woodsmith - 071
Transcript of Woodsmith - 071
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3 95
OTES FROM
T
SHOP
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t - ;
7 1
\Voodsmith (ll>SN 0104..11 141
i.
pul>
lished bimonlhll'
t r- ,· b . , AVr il .J un , ', Aug .,
OCI. O C) byW ,,, lh l 'ubli.IIIIIRCo.,
2200 Grand Ave.. O~>
Moin t:>.1A
,0312
\\ tHXIsmilh I a rcgi~lcrl·dtrademark of
\\ '\ l U C J s t n it b 1 1 tll > lh . } t i n g C o .
~COPl'rigbt
1990 by
II 'I)O( SJnichPubtl,JunM
Company,,\ll right. I'\ ..
Stlbscript iOIlS:
(J o t y e a r (6 i : su t : : - . )
::> 15 .95.
Ty,Q)~ (J2i~.uc:t') ~ ~,. Canada/foreign.
ad dS< .O\ )/ y... .. U . S. luooo;.~1lJ
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3
o 7 1
ontents
T ps Technique s
[±]
A Specia Tips Coutes and.
si.r
gl pal tips fromfet Imru-oodioorkere:
COllt(}urBorinq Jig, 2) A \ i,~1Helper.
.1 } Itouter Table Douels. 4) Pilot Hole
Marker. ,S)~rillg
,Yal
H rPllrh, 6) Hillgl
,\1ol/tlting Helper.
T o y B ox
I
WIre
b ilt th is
l oy80:1
unth kid
mind. Tw o (ul.illswble lid
su] ]Jo 3
prerent tbe dsjronl slanllnillg dOI( 1 Iall
lilllefillgers, A lid In make
it
easyto T/lnl 1?
WI'
pili
it
0)1
casters.
I
nd Mirror
111211 hi.~l oldpdHnlld \IiI I Ol l7lakesuJI
e/e }ClIII
oddition
to (lny
dresser,
And
the
carred initia l m o ke thi» a 1 '''11
persona gift,
Hand Mirrt»:
puge
SbopNotes
IJ Roulinqc Comer Radius.e) Pho·
tOC(1)1Iransfer. J Irouinq \ ·«lte(?l .
4) H i llg e Lo ea to r P in s .
M u sic B o x
: s
~\t(lI/llllln(I / I. 1leh·
and
all
ill/aiel
(I( cplil strip highlight III lid of ihi»
cl(lssir :I/u,~ilB(),~,
I Paper ripper
We look a ( /(e/I OIiI the 10caIdiner
(Iud (/(miglled
Paper Grippertha
C(1I1/;e
bu i ll
il l
s ho rt o rd er .
I Talking S ho p
2 4
nrf / I( lI e i nJ (I I 1 1 1 a lio ll on a se lf -ccn -
tl l illfl hinqe bit. Ptus, Ic e look
t
Inyi11gm il board» a lid gil e o f ei o t ip s fo r
sultdin ) 01/ lathe.
Night Light
6
Bllill /1 01/1 solid then y, thi« , light
Lighl atlell ajl iellllly gloll 10
lly
1 00111,
AlI(I 1 ; /1/0111 interrhouqeoble
panels. it will (llia7)1to almos allY mood,
l S o U J C e S
3
Ha rdicare and project suppt iee
neededforthe project» in thi»
il1sl E ,
. light Light
lIa ge 2 6
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No.71
. ROUND OVERalT
2
gditfJr ~
.\·nl : T II~ tterll ..
, ilt /l le 1 ; Q r k~ } 7 1 1 or 1 , . . -· iil PII, . .
te r
( IO/l n/s II,d
I l f t I ;
r.
)Ithin-
, ( j IJi{ ( e~,tIl t s t i j f · / . . - t·;b1l.~/(·.8(}()
J ) lr J , a x it pl1~.ottS ; (,,. tll~
I Ofl(I T
Int.
1 0,.
.Iiy
tl} tllJIA ,
xlita/lty
itt I)l( t.
l
dIJJf t I.If. f,(lf
\VOOd:; 11itlll \ O, .ttl.
AllOW lIA5T
'2
ON tAC.k rN» 10
HOUt
fKt WORJ IIrl
-
ECOND:
SUDEAlONG
r E N C E
1
Slrt f rrett
Knli*f l,·JI. JIUIltat,a
the router t ble and the fence.
Now tum the stock 00 a nd r ou t
1 1 1
adjacent ...de, sve F i g . 2.
T he n ro ut
the
o th er s id es
in
th e
sam e m anner. F inally . rut the
dowel 10 I( ngth
8RA ktT AD lUSTS
to . . c C O M O D A T I i
.O A ltO D m
To millr h e squar e to ck I ru o a
round
dowel. press tho stock
a ~a in l th e r ou nd ....v er b it a bo ut
2 frum the Idlend. sec Fig. 1.
Then
push
Ihe 'lock 10the Idl.
s toppir lg about from W e r ig l1 1
end.This
leaves
a
Jlat surfan
for
oldilll( tbe stock
.rudy against
• wh en I h av e a
projecl that
re
quire> short l engt hs of hard,
w ood dow els, I m ake my ow n on
the router table. sce Fig.
I.
II
s a v e s 1 1 1 0 1 1 C Y . a n d th e
dowels'
grain and color match the ,I 01
I } , pro j , ,
I start with a square piece 01
stock
the
CXJ IC
width
and t hi ck
II('N;. h e d e si re d d Q w e ldiarn
u-r.
but
at least four inches
I.mger than the desired IcnJ lh
To make a :Y .· -d ia m eh ,r dowel .
( o r e x amp le . f in ;1c u t s ome
1 ,
~ tock 10 r o ug h l en ), bra ck et 10
be
adjusttd
U I
or
down
10
suit the siz « of
the
wood
beingworked
I covered the top ~dj(e 01the
shelfbrscket with. piece ofsplit
g arde n
hose to prevent marring
th e
wood, see Fig
JollII U.•
lId} ,,,,1t/
Eltgli:1hfull· , t . •
V (
U J. , Nt t
often
need
to hold lon.l(
boards edge up
lo r
doweling,
m . rt is in J .: . o r p la n in g .
nul
it s
hard t 1
du this with
only
a n t e
vise. So. alon~ \\ Ith the \,l::i4 a t
one end o r m v b e n c h I u se an
I ne x pen si ve mda l ,hdfhrackN
al the other end to hold U I the
lon g sto ck, se e J ·ig . I
The b racke t h ouk , im o a --hi ll
s t an d a r d t h a t . ..r n o u n u -d o n
the
VISE HELPER
lour of
till
workpiece onto the
jig. keeping
the
edge 10 be
drilled parallel ilhthe jig',
jointed edge. see tog. I.Thencut
OUI
thecontouron
the
band
saw
:\ow place the join led edge 01
thcjigon th e drill pre s s t abl e
I
the workpiece into the cutout
a re a, a nd d ri ll, s ee
~1g.
,
ou~ xC Jr,l llxnu
I) ,rrel l/Klrl , / f l fl
• W he n 1n eed 10 dr il l accura te
holes in contoured leg. or any
odd -s ha p ed wo r k pi ec e , m ake a
Jig 10 hold the workpiece S
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• H e re s a no th er Wlly double
sided carpet tape ca n be used
a ro un d th e shop. I u se il I h('lp
accurately
aliR'
and attach
loose-pin h inges,
First. I :;crev .. l h t 11in~t·onto
th ~ door. N X I apply a layer of
carpet ta pe 1 0II , hinlt~I ,flhal
c on ta cts t he c abine t
Then . pos it ion
~,e
o oro n th e
cabinet an d pres, o n th e h inll( '
location Once tl), tap is finniy
3ll.1l· lu:d ttl h~ 3binl'l. gt. lIl1y
t t lltnV, OIl
llingl
pin
and l ht
door. The carpel tap h uld s th e
hinll lea f
securely in place
fo r
p ilo t h ole d ril li ng a nd o utlininl
fur mor t ising .
TIlis ICdlOiquc c an .lsC l
be
used fo r tighl pin hinge, N ler
pr(~SSiing
fin nly o n Ih l : h in ge 1 0
c at io n . v er y C:lI\'fully open Ihe
cloorand
llPPUrt it
whi)(\
YOll
at-
tach t he h iD~C10 Ihe cabinet.
Jo/ , lI e./ ,k
11tJul r f i r. ( /ortl t ln
HINGE HELP
in
the pre-dr i lled
shank
ho le and
tap thepunc h to mark th ~ center
ofdw pi lo l ho le . s c.>Fill. ta.
H( f 1 11
S,
01
/> 1
[Joyl m OMo
\XloodstUtth
2
th e wrench with a ro uter an d a
V4
round-over bit .
This
wrench lighten
% an d
sm aller w ing nuts, IIal , work
w ell tighle ning the thumb
screw s, like th ose that lock a
fence in place on the back of
the
radial
am' saw tabl....
t Y f it C : r
E. S r / U l 't d ll t
r
$rofl.4.,.'8.11 ,s
No. 71
.).- Of., HOLE
,
wid e. A V. .w id e dado blade
centered on the thickness of th e
s to ck w i ll
cuuhe
slot in om
P.1SS
You c o uld a ls o ma ke tw o p as se s
with
a s tandar d 1 r s· ·w id rb lade .
A fte r c ullin g th e slo t, cu i th e
stock 10 a1- shape on Ih. band
saw. so the hair and ~Io l are al
th e b as e o f t he 1 .
'1 S < 0 m uch rorq uc thar yo u
have
1
b e c ar efu l n ul lo s na p
oU
t he win l( nu ts .
T - ( . make the
wrench, cut scme 1
:It,, ·lhick ~lotk Y ' . : '
SCluart . s rc
f·jg.
1.
3 2
NeKt. I bored a 31 .
diam cler hol~ '
ccnlcr(.~d ill
Itl ~
lId
graill.
Iv
(I( rp.
Then I widened UIC
op
tinue to pubtish otherTlpsendTechniques
to o. an d pay upon publ katio n $ 15 10 $)0 0 fo r
tlI , \t ' tip based on the pubUsh,'IIlellgtll.
rA P PU NCH
TO MARK FOR
91101 HOU;:
RE ·OJUUlD
S NK OII
a.
large to fil through the shank
hole. a nd th in a w ls ar e 100smal l
to beaccurate. Tosolve th e prob
l er n, I u se an a lte re d mach in is t's
pin punch.
P in p un ch es arc
available
at
most
harrlwflrestorcs.andcome
in the sa me d iam ete rs as drill
/
~ GRlND 11 TO
DlAMfTJR OF
Pll,OT HOU
tt
B IT
/
• W hea joining tw u pieces of
wood wit l lsc rews . I l ik e t o d r il l a
shank hole in th e lop o r fr on t
p ic 'c and
a
pilol hole in th e
an
chor piece. B ut it s diffic ull to
m ark th e p ilo t h ole SA) l t' s ac cu
fa ll 'ly c en t e r ed
on w.
shank
hole. C . nttr p un ches are 1
PILOT HOLE MARKER
'fallY W r J < ) { / i t il readers tell u s th ey 'r e
very interested in m ak ing pr jecL~for the
shop. So. for the nex t few issues, we'll ask
)'l\u Ior tips and techniquescn solvingdi{fer·
ent shop problems.
\V ell rea d } o ur tip s an d ttl them out U p
to three oith best tips
in
each ca tegory
will
be awarded a Woodtlllitif
M aster
Try
Square. Dup lica te orv ery sim ilartipswm be
considered in the orderwc receive them.
SHOP TIPS CONTEST
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No,71
oodSOlnh
re rn storth e lettersand numbersand acompletehard
ware
kit
for the
lOy
bo x. see
oU ,.,5,
P38< 31.
HARI)WARF . .
There s actually m ore h ard ware o n
th is p ro jt C t th an me ets
th e e ye .
The
lids
ar e
a ua c h ed
to th e sides w ith pian o h in ges. an d supported with
slow-closing
l id suppor ts .
T he re s a fa ls e b otto m
that
restson adjustable sh el f s uppo rt s. A nd th e r ea l bouom
l sp os itio n ed toa ll ew ro om fo rc as te rs ( so Mom
or
Dad
c an ro ll th e to v
bo x
to w he re th e
mess
is ,
nN SU On ~of theadvanUlgCS ofusingrnapleis th l
it p res en ts a g oo d s urfa ce
for
painting. I p ain
led
th e
boxes with br igh t p r iR l a ryco lo r s , A f te r thepa in t d r ied .
I a p p lie d tw o c o ats o f gloss poiyure l l lane varnish
t h e e n tire toy bo x 10 protect th e
paint
from chipping .
T
iSIO) box lookss o much li ke a la ),. il m ig h l e ve n
gel used
Apart I rom looki ng l ik e
.101 of
fun.
we
tried
10 design
it
with
kids
in
mind . T he lid s
r
SUi>
ported with slow-closing lidsupports so th ey w on I
slam o n little fin ge rs. C urio us fin ge rs w ill a lso fin d
ro und ed
e d g e s
b oth in sid e a nd
out.
And ,
th e
bottom
re sts o n a dju sta bl e s he lf s up po rts s o il c an b e
raised
fa r
e ve n th e s h or te st a rm s 10 re ac h th e b ou om ,
CONSTRC cn O I(. T he con structio n o f th e bo x is
fairlys imple. Weus e d maple plywood l or t he s id e s a n d
added
solid
maple s tr ip s llhe comers SOwe c ou ld
roun d th em over. The fron t and back h ave m itere d
frames with a large glued-on letter and Dumber.
WIIO
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7
ooJ;mnho,71
ALSOUQUlRII),
I SHE.fTC4 .. 81 Of
3 ....
PlYWOOD
~.~m(l·. 4 } OfI. MASONrrt
L :
r:::£:
E :-3
~ C oS··
4 1 1.7ad. fl.
f : · 1
:t )
0 , } .
t If jI/.~
W OO D PA RTS
A
Sldef'onel;(2)
>
piy. 2 > re
x2Q v..
8 End_
4PY
2 0 > , .
x 2lV;
C Edg Sin . 4) 1 . If,K22
D Bottom(l) ol
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8
Woodsmirh
No. il
2 1·
SUOfItl
aonOM
[ OU
/lnActUNG
cmGtNOt ANR
BOlTOM
19~.
ND
PANEL
®
BOTTOM
CIM\P
ACROSS
ENOPANR
-
••_
@
', -
' 40'
\OIpANR
NA IL wrtH 1 T 1
flNJSH NAIlS
•
SlOf
P A l < I l . . . , , ' ; ' . ' ' ' ' ' ' ' '4 ~ t . .
(a .
4
CROSS SECTION
SECOND:
·UT
AU .
fOUR
BlANKS 10 RNtSHEO
W10TM OF-, 1 1 .
,
~
@EDGING
,.
STRIP
3
l t e n
t fNDS
_
,
-
SIDE
PANEL
_ SIDE ENO_
PANn PANn
.
a
,. J
FIRST:
GLUE ....
3-....
2
NOTE:
., -
OWOOO lDGING
20 4
. .. . lDGINGU9
r
ST~IPSTOAll roUR
. , .
PlYWOOD tA NkS
j
6
TllM
@f
l i
t
IDE/END SID£
®
2
BLANK
PANEl.
END
1MAK£olntl
PANEL
Iegan buil
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L .A
ROUTCOONlUClOCKWiS ; D
r
ON OUTfi t lOGE
SlOt:
PANn
@
No. 71
A
ra l
s e• bo uom ca n b ea dd ed to m a ke t he
toy,
accessib le {o r smal le r chi ldren ,
The
size
nf I I, ,, fa lse bottom
(I )
can be
d eterm in ed a fter th e b ox isa ssem bled . S tar t
by m e as ur in g th e in sid e d im e ns io n s, >i( t
r ig.
9.Then
< .
F ig . S .
Shop
NOI~ :
T o he lp k ee p l h~ r oo te r f nlO lli fJp inginto the
panel ,
I
placed a :V~ - thickempo ra r y space r
i ns id e 1 1 1
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No,71
V dsnuth
0
SANOlOG(S
SMOOTH
WT OUl e.rnt~ AND
R rMOV I: APEA PATTUN
5
WE l£T ItR TO
16 16- PileI
OF t _ MASONITE
lOUT ~~..
ROUND'()VUt
ONaonOM too S
ANOHANO HOlE
NOTt:
OONOT~NO
OvtalOlIOM
toot
Of :
HtNGf SntlP
3 ttOUJ A '
II
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II
aoTtOM
I ..
UI
SUPPO RT
~
:r
f
l
a
1
',
9
uo
1'16 hick)
an d
2 lonll. T hen . center the
pad s o n t he en d p an elsand nail th em i np l ac e
wi ll . smal l
b ra ds . s ee F ig . lSa.
Finally, appl) '
a C031of polyurethane (0 II II' level ing pads.
ATt M:H IJI)S.One. the pad s a re in p l:.ce.
th e lid s can be screwed 10 th e h in ge s. To
mark
th e
hin ge s crew
h ole le catien s in
the
ends ofeach lid. 1used lccatorplns.seeShcp
N O les . p ag e 1 7. P ositio n Ihe lids on Ilw
h in ge s SO
the sidl'-Io-side
gaps
and the
gap
b etw e en t he p u ll s tr ip s (J)
ar e
the
sa m e.
After th e e nd h olt' lo ca tio ns a rc m a rk ed .
drill
a p ilo l h ole f or e a ch screw. Then . secu re
each lit with
IW O
No.4 x ~' woodscrews.
NexL
driU
the
remaining
pilol holcswith the
hinge
bit
a nd i ns tall the
re st
of the scr ews .
PAINT fRAME
'ACIONlY
PAINT
una
ANOFRAMt-
f-Ael M\lCOlOR
No.71
CASTER
20
IKSTAU. un SlIPPORTS. ()ore tilt.. lids arr
fastened. the
lid
$UpJXlnS ca n be
installed.
T he lid
supports
I cho w h av e
three
fe atures
lI.al I re ally like. 1~ 1'S l,I he y e as e th e lid s
down s lo w l y S ec on d . t he l l '1 a d ju s ta b le
so
as kids gel o ld er . th e lid s c an c lo se f as te r.
Third.
the su pp orts
have
a de te nt posit ion
th at locks thl' lld s open.
1'0
ins ta l l the
sut>
pan•. I.)'nutthe
hole locations
on each
lid
and end panel
(B), S
Fi g. 19 . The n. d ri ll
pilot holes
I
used the
hinge b it a ga in ) a nd
(a sten th e s up ports in p la ce.
c;STAU.~TE RS. Finally . 10m ak e the (0)'
box (? d~yo mov e a ro u nd .] i ns ta ll ed l-asters
on tile bouom
(1),
A tl.ach a caster 1V .l in
from ea ch in sid e c orn er. s ee
fig.
20 .
MASK ARtA UNDO:
l£T1U. WORE PAJNTINGfAa
MASKlDOU
FIRST :
cumo
Lm 1 II
WfTHtN
~fANO
t1tAClwrrn
ptNCll
11
blue gl~ss SI> '' 'Yenamel.)
A TTA C H I- ITE R A l< ll m IMR E R , 'Vith the
painling c omp lete. remov e a ll rh e m a sk in g
materi als and lil lie Ihe lencr a nd number
on to th e en d p an els .
APPLY
po'.\'ultf;n. '~.~inally. ap p ly
IwO
co ats
of
gloss
po lvurethane
to th e
entire
lOy
box
(including
tilt
painted _»J. sa nding
1i (luJI'
between the
coats.
WHIT t
BA CKGROUN.D
6
a nd th e tcu cr er n um ber w ith a b rig ht color.
Before th e p ain t ca n be app li ed
to
the fa ce o (
t he f rames. the edges o f t he fra mes m ust be
masked 0[. se e Fig. 16.,. To do Ihis, run a
strip
o f m a sk in g
tape around the
molde d
edges of the frames. T he n, m a sk offthe en d
and side panels . Once this is d on e. p ain t ihe
raised (ace o( each frame and the leuer or
n umbe r wah th e s ameco lo r, 0 used red an d
..--HINGE
UYWNG 0,
PAD
s( A.EWMING
TO 'O X F 1R .S T.
tM:N'OUO
r.-.lEV£UNG
.N/ PAD
The
f ina l step
I s t o
atta ch
the lid s (w it h piano
hi nges), th e lid supports an d the casters,
ISSTM.l.IIIN :ES.
I
crewed
p ia no h inJ(es
on the s id e p an els (A ) a nd then atta ch ed the
lid s
to
the hlngcs.Start
by Clltting
the ) V z ·
w ide p ia no hin ges to f it each s id e p anel and
screwthem
in
place,see ~ig. 18.0 useda
se lf-centering '
hinge
bi t to drill
the
hinge
screw
holes,
S I C
Ta lk in g Shop , page 24).
1. 1-: \1- :l UDS.
T o m ak e p ositio ning of the
t ids eas ier. I fi l'$lleveled them nush with th e
lOP
of the lO y
box,
S in ce th e lid s s ito n h in g es ,
IW O leveling pa ds (K) ar e attached to the
lop
edge
of each en d p an el (B ), see F ig. IS .
To do
this. cu t the pad s the sam e thick·
n es s a s th e h in ge k nu ck le s (m in e me as ure d
H R W RE
INIS
Before I glu ed th e le tte r a nd
number
10 th e
e nd p an els . I ap plied a
finish
1 0 th e lo y
box.
To a chie ve the took of a k id' sbuilding b lock .
the end p an els and the (aces o( the fra me>
ar c
pai nte d.s ee F ig .
16.
MASK'S :. 8< (0 the
end panels
can be
pa inted . th e lo y b ox must .
be
mas ked 0[.
S Ian
by
masking
o f feach
en d
panel (B )
where the le llcror number wi ll be located In
prov id e
an unfinished
surface
m glu e to. T o
d o this , cen ter a letter
or number
on each
endpanel and t race [ igh ll yl lt t> l Iod i t,
> <
r r g
17 .Then .
mas k
o f f a
rough
area
within
th~
traced
outline,
Next, l r na s ked o ff th e e dg e> 'and (aCl'>' o(
t he f rame pieces, an d cove red t h r es t o (l lI e
box
with
newspaper.
PAJNT PA. T.LS.
After the panels are
masked of f, p ai nt c an
be applied. I sprayed
on
IW O
c oa ts o f wh ite gloss en am el (rom an
ae ro sol can.
After th e s econd coat
is dJ)'. r e
move th e m a sk ing materials.
PA INTFIIA.'IES ASDlETTERINUM B E1 .nle
next SICPis to p aint th e (act'Sorthc f rames
THKKNtSS
Of - 2 ....
uvtuNC PAD MA1CH:ES
TH)Q(N S 01 k:rNaE KNUCJ
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No.71
.,odSllllth
1
PAnERN
>1
.
~
.
ST~
- POINT
3·
~C E N T E R
POINT
~
7 .
3 . .
~
•
IEVlLlOGlA S
2),-1. .
MIRROR rrs W
the distance between lIw bit and the pin. you can rout
IW O
conccnmc c ir c le s
Another chal 'ng~ (and Ihis nn~', optional) Is
c arv in g rb e in iliA Io n Ih .· b ac k. T o c arv o l he in iria l l
used a router and straight bi . and then textured the
backgroundb)'h~ Onpage15
we'
includedstep
by-step insrructions furthisprocedure
T
hert wert a couple f challenges in making'this
hand mirror. First. had 10IiRureawaytocunhe
outside lOp edge 10 u perfect circle. And then how 10
r o u t a c ir cu la r recc..... f o r a
roUI
mirror,
The so leuon
1 both
or
these-
p rob lems i s
1
u se a
pivotpm
I n 1
3. router
~~Ota[j lg- th e
router around
th e p in . you c an r ou t p e rf l. .: 1circles. Then, by vllryin~
The trick co cucring m e
lOP
o f th is
mirror to a
perfec t c ircle
revolves around a siln ple p iv ot /)in. Once ) 'OU know m e secret, ie's an
e a s~ w e e k e nc l p ro je ct th at makes a g rea t gift .
Hand Mirror
PROJECTEEKEND
G.I-O
.11t ) ; -) 0 ) ~h >;lTl
11
thiR
,)fJ/./,...-t1
fJ r
0
f Jltt
- 1
t le d
fh
~Oit,
Tlml
ill
iI'
f}
Ih /tl ld
ill t l
ItJl lin i,d ,,'hiU . ; g
0 right ),-r ,ljrJl' ' omb ing
I ,....
rOO'd 'lifI·luuuvd P
) , .U/
oot Il,.. pull ,. /llld
lAYO flip ;/OfI YROIJ,. ho dlrtut 1ls
ON ~
)I qlhf
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ooJ,nllth
o.71
T1 OUGH
fOil GlUE
• • •
I,· ¢-..
J
$1 RA1GHT atT
l hen p ivo t th. ..mu ter a round
th e
c irc le unt il
y ou reach th e sto p p oim .
R C p { a l t h is p r oc e s s,
lowering
th e b it
I,I~
( or Ie ss ) b erw e e n p as ss e ' u ntil
th.. .bi t
CUb
Ihrough the hlank.se -e I ll .3a.
1{01T )IIRROR R,:CE . Next. to rout lilt'
r ec es s to rr he m i rr or , r es et t he b it ~'It; Jeep.
and , . . i ti on t hent he rp iv ct
hule
In
ove rt h v
brad. \[0\\ ro ut a r JlitIJ[~ /t~irrk-,
sec
Fig. 4.
This w ill rout .. groove -;;
a
1I16 -t~p
nm a kin g th e h and m lrr or is te
rep la ce y ou r m uter b as e p late w ith a s ho p
ma de p la te . T h e n ewp la te n ee ds
b e larger
than the original so il ca n tw S C I o ve r a p i vo t
p in . T h en it's
u se d lo r r ou tin g
lilt circular
s ha pe a ro un d tht:- to p ()rtht~hand
mirro r and
recesses
(o r
thegl~s mirror
and
carving.
1l,.\SE . 1.A .._1
cut the
11(. \\base
ptnte from
a pic... 01 v f'ic ig l: c, ( ur u se M a so nitv ) tu
a width 016 a nd 7 '# .' lo nll. set I'il . I.
Now, cen te r
your
router's
original base
plate v r th e ne w
pial
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\Voodsmilh
4
Glut M JRRO R D OW N
WITH THIN 8I: AD
Of lUCON l (A\.Am
U N IF O R M G AP ~u
AAOUNO (DOE Of MIRROR
~
,rvlL(O G t.A SS M IA.OR
S HO UlD .' 1ttaS SIO U GHTl 'l
1 0
(tNllR a.tV tllO
G L A S S
M J R R C H ltN
JlfClSS
~
RO UNO ·OvtR
on
t
a
OUTIUUHOst
WT1l i
I.., ROOHD -O VE R lIT
IlfMOV fROM
PI. ' rWOOO
7
WORK IN
COUN'l t l lC ,OC Irimc l(>rof
th carving t this t ime with a s ln lig h t b iL
St... the ~t~b)' ' ' ;(cp instructions fo r
carving
on
th e
opposite
page. )
cur m SIW'F_ O nce all o f t ro utin g is
com pl e te . the h a n d le c a n be CU I LOs ha pe O n
th e
b an d s aw .
set
FIJl .7.1 slat ted by cutt ing
about l ts outs ide the L'YOUI t ine.
SAN TO FI~J\t SI-IArat..
N t > : t mount it
sa nd in g d ru m in
th e
d rill p re ss a nd s an d up
to the outl in e o nh e ha n dle . s ee F ig . 8 . D o n 't
sand
th e
circular
(top)
part
o f t m irro r o r
Y m a y g o UlJ c
it
o u t
o
r o u n d .Ju s t
san d so
t bere 'sa smooth t rans it ion
b etw e en ~ te
mir·
ro r circle and the handle. see Fig. Sa.
III
u.. OS~ ruG :. lter the handle
was
sanded to f in al s ha pe . I TOUlt'd3Wil
bullnose
p ro fi le a ll th e w ay a ro u nd Ut e e n ti re p ie ce ,
s e e Fig.
9.
T o d o
this,
m o u n r a ~ r o u n d- ov e r
bit in t route r ta b le a n d s et i t lY IS b o v e the
ta ble , sec F og.93 .
The n r out both the-top
an d
bouom
edges
o f the m irro r. A ile r ro uting. lighlly hand
sand the
edge 10
remove the Rat spot
at the
cen ter. but don 't round over th e edges.
Here, you w am a
crisp
line.
FIN ISII . Before rnountinz th e beveled
g ta ss m irror.
i n ish
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15
'ih) (1( i smnh
o . 71
f l l 1 3
C ]
£ r q : J {
J 1 £ 9v[
l \ P Q9 S -t u 0/ 'W X
Y
z
6
Final »,
stipple 1 1 1 /
tne bur};.
grt t
1 1. t~
g
ft -Y .,.~~r ~l/lnIJ~T lui
sel.
Holel/lle
I la il .C I . .
/>rightll)fd Inpjirmly
1(ltl l l
hammer.
U SE EV EN
USSURt
5
s 80}lflllhe e d g < l 8 ofl lLe letter. To
dotili. ./II)W
I I
sidea/I' lIa.l.e at
/1#
i l l lt ul /Ute
a
nd .. b tl le .I t I 'I ' r dg , a /,h r
le tte r I In l. 1 I hEu'ro ,roul/ tWd.
~ - - - -
4
R f ' 1 1 1 0 1 ~ lr1· ,111sa le 1 / . . . . , 'OI,If r
)il..
11
nt l
/Jt(') p t
I o ff le t / t ; I IXft t . t rJt .
1 )lu911;,vJl pill hlJlp Iitl l
~/ir'eY'fro)
t d t
of
b illllk . 4 1 1$ $
Ol'OI17fdt lf outsid» ty/glf
a
lu letter. Cflt a.~
r lusc til
pD. ' {s lb t l' ' fY i / I, IJ ld t l J l1 / I,ng
f lU lrf t(·r.
So
Iry
a
cUllpl~dif fe1 ( 'n lCOm binat ions
of
nail
se t si1 '~ an d depth s o n a scrap piece to SL'<
whichyou l ik e b e st. T h e tr ic kto a gc od b ac k
ground Is unifo rm do t placemen t
a n d d e pt h.
2
Alia flill~rfXIllpnl
in
cj,'t:'J(lQ)ldu
lll
lililil
r bber ce'~le'~l
r Hllmy t'lllllf '
sire.Cut a. Ul l d outsid« . d g of th»l~tl;lr
' '' il II 11017 ' t li f • . D i s ca rd bad (gTQu>td.
1
7 1 ' 0 1 1 t perimrtrr of tt» t l'rf'1fAjilr(111
initio], SCI ' bllll/}; /V
ply ,
I I
lltY l r
.~;.(/eoen. R01~fa
~'/n:· d . r e p
rii ( (~
b y
s (f ling 1 '; '' 01/1011
IJ
OIl 'h e1'11'011 ; > 1
lO U T IN CO U N TtR :·
CLOC WISe OUtKTKm
fir.t
d rn w a
centerline
d ow n th e back o f th e
mirror through the pivotpin . Next.press the
c en te rp oin t o f th e leite r pauern dow n o ve r
th e pivot pin.Then, align l it e center li nes on
the pattern
and th e
mirror back . N ow th e
pattern is in p o si ti on to be glu ed d ow n .
~ 'PPtJSG. To enhance the letter. I
s t ipp l ed o rdoued th e background w ith nail
s et. s ec p h ot o. I fou n d th a t b y f irm l y t app in g
a~ nail set.I created a very tlifferent look
than Ij t)(
from
ligh t ly t app ing a
Itll{'
nail
set.
C
arving
an
in itial
on the backof'the
rnir
rormakes
ita morepersonal tift-yet
the carving isn't 311that difficult. In the
steps below, l'vc done almost th e w ho le
job with a router,
Full-s iz e p atte rn s o f t h e IN t er s ai ih e bOI·
tom of the paxe are
available
from
Wood .'m ,I I, P ro je c t
i ' . lfJlp/;eo . s ee ag e
31
They
come
printed with
a centerline and
cen te rpo int.
so t )1I ,y 'r c
ea$} ' to
aliR n .
L£' TER AlJGNM 'T.
To a lig n Ih e
le ll e r ,
Routing etters
U E
ECHNIOUTER
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No.71
-\ ~ APPLY HUlT
.....__ __UNlllOUJUNE
IS T RA N Sf t • • l D
TA PE PHOlO(OP't
0 PAntRN IN PlACL
SUlReN
ONHlGHlSl
KEATStmNG
COP)',
which p uts m ore toner on
th e paper.
HO\\ ro. To use this tech-
-lque. set the iron on i t's highest
setting and 13Jll the photocopy
fate do wn o n
th e
workpiece,
Then iron th e back
of
the
photocopy
un ttl
some of
th e
loner releases (rom th e paper.
Note: This tC< 'h n iq u l'
will
pro
duce a mirror im age. For an ex
planalion o( how
L O
gel a non
mirrored image (such as fo r IN·
ters). see
l\ od.,milll
No . 4 7 .
• 'Vile ) hearne ti n It tocarve tile
tid
fo r
the Music
Box .
I wanted
to
make
a
few
practice
designs.
bull didn twant roredrawthem.
llEAT TRAl\SFER. Then I r....
membered a
ti p
that appeared in
Il uoditmilil No. 45 in olving th e
use of an iron to tr an sf er a pat
tern from a phetocopy. The
secret is the
tl Jl
oftaner phOIO
copiersuse-
it s
heat
se n sitive
By r ea p pl ying heal som e
th e
tonertransfers
to
theworkpiece.
I fo und
it best to makea dark
1
ftACk· ROUTONE
TO tWO INCK£5
iN fROM [ND
------~~
C RA P PIECE
router can ride
along
the bottom
edge of th e sid e piece bUL st ill
needs
support te) avo id t iP I )i n ll .
SoIilascrappiecein the recess
01 th e b ottom . >1 , Fig.2.
To avoid t.he problem of
cbipout. first back-rout the
ourleed side. This involves
making the f ir s t router p a s s
across
the
I in al
inch
or
twoojthe
ounccd (rij: hL · hand) n in a
right-to-left mo tio n. s ee Fig. 2a .
111cn. when the router is fed
across the
workpiece
in the
proper
direction
OcfHo-righl).it
won t split a ch unk o ff th e frame
. . fro ... _ J
asn esns m tne cut.see+ig.....
~.ono .
2
Sh op N ote : T o rOU Ith e ra dius
on the Toy Box. I first made a
replacement base oj 4 M.·
sonite for the router. (~1oSt
router bases aren
pre-drille-d
accept a · 1 4 round-over bh.)
Tl/P~ R \MEtOIlo~~
o ro ut
the r ad iu s on th e
lOp
corners of
the frames. first clamp two
square-corn ered p ieces o f s crap
across 111 ~corner
I < . C
Fig. I.
Then rmu the radius in sev ....
Hglll passes. lowering the
bit
slightly between P3 .
1l(l1 T()~1COR. (ERS. routed
the bouom comers next, bU Id id
th em a liltlediffcrcmly .H e re t he
PHOTOCOPY TRANSFER
AOUT~ROM
lEFT TO IUGMT IN
S V[RAl PASSU
Cl ,A M p S CR AP PiECE
ONlOl SIO[S
Of
flWo\E
lOp
1
HtPOUT PROBL£MS. Since
th e round-over bit (in this case a
1=: 1 bill
terms
iheradiusby
culling ONYI the corner -
rather than I 1>tlll 1 lh( l corner
- there's a
tendency (or
th e
wood
10 splh away on the
ouueed
side
of th e workpiece.
Bunhere sa way to prevent this,
an d also 10 k eep th e rou ter (rom
tipping o n th e 1,lgc o f th e f ram e.
SCRAP~IND\\1Cn. lne trick
involves sandwichin.~(he work
piece between
IwO
pieces of
scrap, S < . < Fig. 1.T he rou ter w ill
still produce chipout. bU I on th e
S C r - d P pieces, nouhe wor kpiece.
• As I w as mak ing the To), 13 0x
show n on p ag e 6 .1 had torout a
large rad iu s o n the com ers of
each side lrame. Ordinarily you
('30 usea band S;.1.W.sabre-saw, or
a rasp
to
rough cut the radius.
andrhen sandit moath.
1.)0inl(
this
freehand workS
fine when you only need 10
radius a couple u l corners, B ut
(o r
the
To), B ox , I wanted
to
mdiu. all (our corners of both
f ramcs-s- tight radius cuts alto
getlwr.
A nd .
since I
WUl '1,'d
the
radius to
be
a perfect ar c. I de
cided to
make them
using a
round -over bi t i n the rou ter
ROUTING A CORNER RADIUS
Shop Notes
S HOPURRO MIP S
O
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17
SECOND:
PRESS UD
DOWN TO
MAK[
IMPRlS510N
•
2
th e h in ge flap , se e F ig . 2 . N ex t.
Il< ,,,itionthe lid on the case and
p re s s d o w n s o the p i n s le a v e im
p re ss io ns o n the
inside
or
th e
lids. Then . open up th e lid , r -
mov e th e lo ca to r p in s, a nd d rill
the pilo t holes .
ling offmost of the threads on a
couple of extra hiogt·
screws,
Then. I ftled th e cut ends of 01<
screws to a fin e p oin t.
S Fig. I.
t
SL CTIlEPINS.To use tbe lo
cate r pin s. place on, pin in the
e nd h ol es
of
th e hing( and
do, ,
wooo-rAC£.O
\ I1Sf
I
Nil. 7 1
c am e a cro ss a c ommo n prob-
10mwhile Iw~3naching the lids
10 the roy Box
case.
I had
al ·
r ea dy mount ed the b in ge s o nt o
t h e c a st . and ne ed ed t o p re -d ri ll
and screw thelids tothe hinws.
TIle probk-m
i s fUU can t
mark
LOCATOR PINS
fiRST:
POstT ION
LID
-X ACTOOR
OTttE1lSHAap
XNlfl
APPLY fYIN
C OA T O F Y tL l.OW....... ....._ 1
GlUII TO WOlUCl tt«
CUfvtNt£1t
lARGER THAN
WORKPf(CE
PI.OltCf
IAS[W1TH
AWMQIIUM f O G .
.
KtEP,ftON
MOVf~oa
VU4 J
MAYIURN
1
the hinge hole locations on th c
lid once th e lid b set inposition.
I n eed ed a way 10 locate th e ex ac t
center or Ih e hi n ll e h oles o n th ,·
li ds w ith ou t opening them up ,
,\IAI)~ FKOM SCREWS.
To do
this, I madelocator p i n s b y cut-
stan by placing the veneer on
the glut.>dworkpiece. see F ig. I
Then.
10 keep
the veneer from
moving. I p ta e e t he iron o ve r one
comer un ti lt he veneer s lays
DU I.
Now ,
w
ith th ~ corne r tacked
down. move lb~\iron slowly
bac k an d lonh acro ss t he piece
until th e g lue
i
et
Ie:
A'avingtheircmin
pl
ac.,
may
eause
tl u - v en e er t o
bunt.
finally. Dip th e workpiece
over
and.
u~jnRa sharp knife,
tr im th v en ver flu sh with Ill<
sides,
set:
I~ (.2.
1
steam s e tti n g is turned o ff. N o te :
Tokeep (romgettinl(l:lu~ un
th e
base o lth c iro n. you may want I
co ver il w ith aluminum Joi l.
While th e i ron is wamlin. . : un ,
cu t Ih e v en eer
so
it
slightly
larger man 111ework piec e, Then
apl l) glue th e w ork piece .
I
u se y ellow woodworkln g glup.)
U se just e no ug h g lu e U butter
th e surface , so Ih grain ~1 I( m
ba re tys howsthrough,
TACK0)
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_J . __
, -
t
-. . . . . .
t
18
No.71
X'ood and a rough length of24 .
RO L I< D O V ER E DG E.
A lte r th o
blank
is
CU I
10 size, rout a I I r ou nd -o ve rw it h a shoulder
along
one
edge. S(. C Fig . la . A d ju st th e b it s o
a . shoulder Is le ft on th e bot tom edge of
th e b lan k to form th e b ase of th e musk box.
SHADOW UNE. After ro utin g th e round
over, th e next
step
is to rout a shadow line
a ro un d I he / lI oul id~ c dg~ o f t h e b la n k.
S I < .
rig. lb . T o d o th is. I u sed a straigh t bit,
a nd a dju ste d th e b it to s tic k u p W ' ab ov e th e
rou te r ta ble .
Once
th e height is s et, a dju st
th e fe nce
>0
th e b it rou ts a V16 ·wideabbet
on the ou ts id e f ac e o[lh. blank.
11 'SERUP.The n ex t s te p is 1 0r ou ta lip , o n
Ih e r O il
~idt
dge. for lhe P le x ig la s du st
covenosit on . sre F ig lc. S in ce th is lip i s t he
sa m e d ep th a s t he s ha do w lin e, th e h eig ht o f
th e rou te r b it d oesn 't h av e 10 b e c ha ng ed .
S imp ly m ove th e fe nce ove r to m ake a V~··
wide rabbet .
THE BLAN K
T
he r ea l r ea so n I
w
an te d to b uild th ls
music box wasto exper iment with two
techniques 1seldom get th e c ha nc e to try-
working with ve ne er a n d chip carving.
It
was
great fun to try these techniques on tbe
sm al l lid . a nd J didn 't have to wony about a
m a jo r e ff or t. ( Fo rr no re on th e se techniques,
s ee S ho p
NOI. on
p ag e 17.)
Another challenge '11$trying to figure out
away to g el t he m u si c works to srartwhen I
opened
th e
lid a nd to
s to p when
I c l os ed th e
U
a .
The se ereus a small pin conn e ete d to th e
...re shut -o ff a rm o f
th e
music movement,
TIle
overall
se crm to m a kin g this project
go
'llloolhly is 10 make sure everything
works
b P
th e b ox is a ss emb le d. Iound
updry-assemblingit several ti m e. ( wi th r ub
b er b an ds) b efore a ctu all y g lu in g it up .
I
also found it best te
sand
al l the inside
surfaces f Ort assembly . T h en . a fte r th e
box i s a s semb le d,
I
sed asp ra ycan toapply
th e f in is h r ath e r than u s i n :
3
brush.
Y o u h a ve to p la n a he ad e ven on a sm a ll b o x like ch is. T h e sid es a re 1 o u ced to
sh a p e first. T h en yo u can try yo u r hand at two d iffe re nt sty le s fo r th e lid .
Music Box
r W_E_E_K_ E _N_ D P _ R_O~J ~E_ _ T
~
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19
OlUE nt MfJ(RLO
CORNI;RS lOGll HlA AND
H C N D IN PlAtE WITH
RUUER UN.OS
ClNTERMOVtMfNl'
I 'IOX
Q.. SHUToO n
PIN
CHKK THAT ALL
WOtUUNG PAR1 S
Dt t-....
.MOW FREtl Y
©
BOTTOM
D fUI,l t HOlE
rott~N
TtM--=-___
MOVlMfN1
CLUE·I
r. F inally . apply glue to th e
m ite re d e nds an d re as se m ble th e b ox
with
Ih e
bo tto m
(C l in p l ac e. s e e
F ill .
6. (M ake
su re m at th e pin and arm are connectcd.)
i ng it 1 0thewire arm. Then cen re rt he move-
men
I
n the box
and mark.the locationenne
tw o mounting' h o le s. s ee ~ ig . 4. Disassemble
th e bo x a nd d ri ll 1 6 mount ing holes .
ROUGH
-UNG YH 5
No. 71
O nce the fro nl/back . an d sid e pieces are
m it ere d to hmgll l.
m e next
step is 10 m ake
IllC bottom
o f th e
music
box.
I301TOM .TIlebottom (C)
is
a p ie ce
otsolid
wood
that s resawn
and
planed
down to f it
t he 11 l ·w ineg rooves in Ie s id es o f me bo x.
To de te rm ine the
length
and w idm of the
bottom .
dry
assemble th e box,
holdinll
it -
gether with nrubber band.
N ow . m easu re th e inside d im en sio ns o f
th e bo x. a nd ad d th e dep th of th e g ro ov es o n
all four
sides,
T o p ro vide e xtra
clearance
during ass embly . subtract 1 6 (rom the
length a n d w i dt h a n d cu t th e bottom 10
size.
KE\ 1ND HOlF..
Before
assembly. holes
have 10 be dr illN in the bottom and one of
th e s id e s to accommodate
th e m u sic w o rk s.
To m ak e rh e alignment of the pin and me
m ovem ent as sim ple as possible. start by
d ri ll in g a n OVCrsi7.e hole ( \ - l diameter) in
t he bo tt om (C )
fo r
th e k ey w in d s te m to
pass
through, 5(. rgtJl
o f 6 .
81;
~ig.
2 . A n d
th e
two
side piec es (B )to a rough lengm 0 5 .
TR IM TO SIZ E. On ce th e p ieces arc cut 10
t he ir r ou gh
lengths.
l il t t he
ta b le
saw
b lade
Merall theculsare made on the lo n g b la nk .
the next step is to cu t th e fr on tlb ack pieces
(A ) and sid e p ie ce s
B)
10 their finished
lengths. BUI
th ere a re lw o p ro ble ms h ere .
rU'St. ) 'ou h av e 1 0suppor t an d guide
till
-s e
sma ll p ie ce s while mitering the ends 10
le ng th . S ec on d. e ac h p air of pieces has
to
be
I .trtctl II lh e same length.
,\t. XIlJARY FENCE.
The
solu ti on 1 0 b ot h
problems lst o a tta ch an auxilia ry f en ce to t h e
FRONT BACK SIDES
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NIl.71
. . . .
. .. . · l ttICK
puxtGl,AS
OtJ l
COVlR
10 lOCATEPILOf HOUS-,
US I CARPfT lAPE AND snoe
UO TO H INGE S ...... .- ... _--.....
'-,oodsm
t
th
MARK ENDWRH KNlft
m£N
lIT WITH
ODS-ELaN JIG
fAPfIN
POsmoN
CUT
CH.4HN£l
TOWIDTH
' tN
10
I
SETDlPI H
S L I T L Y
uss THAN THiCkNESS
Qf-INU y
S f R IP
ADJUST FENCE
S 4lTcut h
TO/MlLK
• J
I ·
STRA'~
an ..
•
.
IN .lAY STRIP .....
HOt.O INlAY STlltP
FWSH
wmt
SHQUU)la
ND MARKW.OlH
9
8
ROtmllrABU
I NCI
TOP f ACE
DOWN
P
S H O ULD E• ::;
,,- ROUND-
OVERIII
.
/ ~
~~
7
I
T o com plete the m usic box. auacb the lid
an d drop in a dust s hie ld m a de of l lo gl. .
HIXCf.S. Th e lid isa na ch ed 1 0th e b ox w it h
two small bull hinges. To mount these
h ing es . I c h is ele d o uttw o m o rtis es in t he to p
c~orthebackpiece
(AJ.,..,.,l ig. I:l.
Each
mortise is tile same lengl l l as the h in ge a nd
as
d ee p a s
th e
h inge knuck le see F ig l :l a
t ex i. p o si ti on t h e hinge f lu s h w i th t he ill
j,/pe dg e o f th e m < )r ti . s ec F ig . 138. Mark
th e h ole loca ti ons , d r il l p ilo t h o le s w ith a n 1 8
g au ge b ra d. a nd s cre w th e h in ge s in p la ce .
To
locate
th e p ilo t h o le s i n t h e lid . fo ld t h e
hing< closed and Slick a piece o f d ou bk
sid ed c arp el ta pe o n e ac h h in ge . F ig . 1 3.
Then pre ss t he l id down on t opo ft hl h in g es .
N ow open the lid . m ark the screw hole
lo c at io n s. a nd d ri ll t he p il ol h o le s.
nxrsn
;~\ ll
USTCO\ E R. Next,I removed
th e w orks and h inges and sprayed on
IW O
coals of a er os o l D e ft Clear ood Finish.
Final ly. cut a ,,> ·thickdust cov er from
P le xig la s to re st o n th e in ne r lip .
FIN ISHING TOUCHES
N ext. I b egan w ork on Ihr I ,t '· l hi ck l id . Th e
li d
(I»
iSC'U1o the-same dimensions as th e
o uts id e d im en sio ns o f Ih,· box ( 31 /. w i dr
a nd 4 1 ,; .
long). > 4 Fig. 7.
I d ec id ed t o d r es s- up tilt lOll 0(1l l< 'music
box w ith burl veneer and an inlay strip .
jus l up
to
t i l <
w id th ma rk .
ATIl\~.AYS11lIl~.Afl
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GLU CAR VEl)
PANEllN Pt.ACI
r
\V od,mlth
ROUT t ....D£EP
C L O S E
tOOUTUN
3
ClIISEI.$1~I·()RT.
Now ,
to
gN a crisp
shoulder around tile recess, 1used
3
chisel
tocut to the layout line. Ilen- again I used 1 1 1
Iayout
, g a U R t . b u t th is O rn e a s a S U I1 P C)r 1
for
the chisel.
eO
Fig . 4. To get the insert 10
ii i
tij(hlly.
angle
th e ch isel w
undercut the
sides oflhe n)Ct SS slightly.
;\1. (
Mg. ,Ia.
ROUNDOvtR. O n ce vo u v e f in is he d c hisel -
mil' the
rN:CSS
to the li ne . rout a
V
round·
over
with
a
\Ill:
shoulder
a rou nd th e fou r
edges cflllc lid . see Fig. 5a.
All that's I ft is to cut the carved panel to
t
the recess. Then pply a small amoum (II
glue 10t he b o tt om or the panel and Pr6$ it
in to p la ce . se e F ig. 5.
C HISE l
U CKTlY
u TO
GAU Gf AS
U NOlRCU T
SUP~ (OCf
.
Nu. il
5
C U T 1~... T H I tC
U O 1 S A M E
SlZ£ AS ao x
2
wood is
a
'Oft.
almost grainless w oo d that
ca rves ea si ly.
C.\IlC;F.. Before
ctually
started work on
the lid. I made a j 3UJ1e for laying out the
outline of the r ecess . s ee Fij[ I below. ullcr
I u se d lhisgauj(e
as a
support for.
chisel
W
cleanup th~t 'gcsof Ih~routed recess, refer
to Fijt
1 .
L\y()I .Onceycuvefinis hedmaking the
gauge. use it 10lay ou t t il e recess on the lO P
o f th e If · lhick lid
se e
Fig 2
ROl TtNG. 'Vilh the ktvuut complete. th e
ne xt ste p is
10
rou t a
~I -deep
recess
103C'
«lPI lhe c ar vin g. s ec F ig . 3 . T o d o th is . use a
\ I ,
s tr aig ht b it a nd r ou t r / o s < to th e line.
2
Tlr r C l d cut lri/ll l lnot
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No. il
•
.,
- = : I = f f = = . , . . . . . . . . . = - - : ® ; : : ; : . 1 ; ; .
I,. - __
1
ENOVlEW
KI
I>l
AT20
c o . . . .
.
B AC K PL AT E
M O V E INC
tO WA ; D II A OE
AND
cu r RAl-SU
3
S E T I LA O E
AT2
W A S TE
1 2
ENOVlEW
,
11
.
,. i
M A R BL E H O LD E R
(ltcould
be
longt · rorshoncr. butlhislcngth
will hold a 8W x 11 piece 01paper,'
ORlI.UIOLES,
The
marbles
are
held
in~.·,
diameter holes set at an angle to the back
plate. It's easiest to drill a series of I g ld
holes. and then rip the workpiece at an
angle, Start by drilling ten
g'tb -dcep
hoil.,.
down
th e
length of the
work -
p iece . s ee F ig .
R IP T O \\1D111 .Next. rip th e
workpiece (wilh the holes
down) at a 20' angle so the dis
iance from the edg~ of the board
to th e long point of th e angle is
I . se e Fig, za.
R.>\lIBET~~JRPAf f:K. To
pro
v id e an ar ea fo r the p ap er
to
slip
into. I
Cut a
rabbet along the
angled edge, see I~g. 3. To do
this. lea ve the blade at 20' nod
lowl ril
o:V$ abowthetablc.
see
Fig. 30 . Then move th e fe nc e
lo w ard sth e s aw blade ihe
thkk·
ness of th e blade.
BACKPLAn
After rabbeuing the marble holder, Imadea
back ptate
(8). ~
fig
4. It's cut from a
pi \ . . ()i~
tock.
2 l
wide and 13Vz long,
Then.
to
k eep th e m arb les fro m g ripp ing
lhl'paperloo tightly. drill a series ofshallow
) 1 holes in lh~back plate....eer.g. 4.
T
he idea for this project
CAA lef rom a
local
diner.
After I
ordered.
the waitress
slipped
m y order under a ho ld-
inll device for the chef, When I
looked at
the '
device I was~Ir-
priscd to find glass marbles
holdiflg
the paper
hought
it
would be
handy
to have
one
of
these
grippers
to hold
drawings
in the shop or the grocery listin
th e
ki tchen,
The ehall~ng was designing
the gripper so it
would
ea~i1y
hold a piece of paper when
iI's
slipped into place, but not so
firmly
that the paper
rips
when
pulled out. After some trial and
error. Iw as able 10 make it work by drilling
a
shal low
pocket behind each marble.
MARBU HOLDER
I
began building Ute gripper by
CUll ing
a
marble holder
(A ) from 'o /, · ' · thicks to c k lOa
width of J t
a nd l en g th
of 111< '1 ',ee Fil . I.
Paper Gripper
~ O_ _N_E _ _ E_V_ E _N_ _ _ N_ G P _R_ O~J _ E~C_T ~
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PUll OwN
TO REMOVE ___
U AP R
UNO R
MARIt£S
MARitI:
IUMOvt TApt
-AnfR ASS£MBlY
IA K PlATl-
MARll.
HOLOtR
IM.aLl HOlDER
11
GWAAU
tAPE HOLOS
MARWS IN
Pl aOURIN
ASSlMBlY
®
MaiL
HOI.O. .
10
MARlLE
GA UOE
.I. I fOU
tRIM OfF AU. toGES
AT2 ·ANGl{
®
BACKPlAll
8
I--- @
HANGING
8AJt
1 ~OFf
W AS TE
MAlN
tf OutO CROP
TKROUGHHOU
HANGING
AtTlR atPPlNO.
SNAP
Off
SOvt.....
/ i~~~
N .
I
_aAR
@
CU T CE N T EI t(O C R O O vt
IN SfRllS Of PASS s
-
CUT BAA . TO
RT IlOOV[
KRPOOYn ll
elT ATSAMt
HEiGHT
®
a .
PtA,..
H A N GIN G B AR @
tiS' LONG)
6
HANGING THE GRIPPER
Youca n h a ng t he g ri pJ l( ron t he w all b y d r iv
ing
SCr
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No.714
ll tift j
scuw
CAU ES HlNGE to
SH iF f P O R 1ON
HINOt
any of the boards have checked
e nd s, cu t o ff any defects before
sketching th e outliue.)
Next. usc the materials list to
start sketching where the pro
ject parts might
it
onto the
board.
Since
most material lists
ive finished
dimensions
fur
f(f'I,t' / ~tl)lfrlld
ot lo nl
Iu ,b t r U t1 nJ I IllrA
It/)
SO, t
l ,o l d / , O O d
Ior n
p f u j t r l .
1 , I S
unh{ ld ,l , « rutti j Ig d i( lg ) (l m
a d
nmtrr ot»
li.,,1 1)1fJ11t I,allfi
usu
a
tos« ~ (l. ilt
i ,lteatllt r
Sitlce
lturtill.}(Jod
l ( nlb t r
i~
I lQ l C«II. Ull.l ) ;Jr,,, l if /l l, .O f ( 1 11 (1
J ( t l g t J '$ .
,t «~'I ditllt lllat
t I l l
wfdp .n J boa rds
BJ,olI Oil ,,-If
~ tttl ltg dl(lgrl II'ti fll'/
(I,f,/ll nl ln~le.Il'Iwllri,'ks
do
gllli
f ~r, ht, /)/lyi tg nd
l yi tguul bo o rd
s
r
J J
P
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25/32
J(
,lOdsml[h
o.71
PRf.l , as
th e center 01 th e w ork, th e rim
has a grealer
vcloci
ly an d a
larger diameter. This
Illt llns
Ih e r .. w ill
be
more
w ou d in
con-
LaCIwith the s an dpa pe r in Ih~
s am e a tn Olm t o f li Olt; .
Another lime to decrea$e
spt'ed i.
when
sand ing w ork
'1h sm all beads Q r sharp eris >
ed ges . By sl ow ing down you'lI
be
able
10 co nl To l how r3 t, id ly
tb
wood
i>
removed.
It l
13k~
lo ng r lu s an d
ill
th is Sj)P,\J ER. Before yo u sand
3
pro ject. 1I1e fi r~1 step is 10
choo s e t h~ COIT f'C II) 'P nd - ' T i l
sandpaper.
I
use aluminum
o xid e s an dp aper
b~c aus~
il
. tayssh3rpL'T long( 'r a nd d oe sn't
b re ak down f rom h al ascluickly
as Ihe
other
lypeS.
I gencrally
US
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26/32
-
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CUnlNG DI GR M
A
tnt fchOngeobie P O n e I s
4)~
X 4 rA
X8
8 0Mde,PoI\E l l I 4 Ir. X 8
C 8oc < Pane l
1
lJ•• ,. 8
Si005 2
~.x..w.x8
E Base l
\ 5V4 6
f UdO) 1 1 5 11 4 6
GUdBtock l ~.x2.4
H Ughl
Booto I
ItX2
x
SUPPUE5
• 4)No.
I
I
R >
w o o d s c r e w s
• lu n g 0 0 1
finish
• F elt c lo lh 6 x 6 ( ro l.>gh)
• Nigh, Ughll it
see page
31)
MATERIALS
C R O S S
SECTION
.RONT
V1 fW I
0
T
flXTVat
PtH H W f f GS O f
UGHT ftXIUIU
HO PUSH INTO
UGHTSOARD {
l~
W oodsm 1 h
@
S I D E
- I
PHOTO DETAILS
L IG H T F IX T U R E
®
LIGHT BOARD
---
•
• •
•~; e:
O~~
• • <
• • • o
@
S ID E
@
INTERCHANGEABLE
PANELS (4)
LIGHT DnAIL
@
BACK PANEL
stORAGE CHAMad
fOIt
txlllA
INttl(kANGfABli
P as
®
D IV ID E R .
PANel
-_/
@/
U D
BLOCK../
D
O V l :R A U D IM E N S I O N S :
9 · Hx6 Wx5V. D
EXPLODED VIEW
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Wood,01'th
8
7
5
: : J
~
. -
lU P
1
SUDf SfDEP1Kt
. -
fINe.
AGAJN.SllNa
TOTRlMmGU
-{- J *
,
sa
a t A O . - h
~. filCH -,
.
F ,
l
.
,
',
ROUNG-OvtR
B n
-. -
- - . . . .
ROUNDOVlR
OUTStD(
toot
10tJf1R rABU
'[NC£'
lltlM_. ,
'RONT A,ND .,.
BACK (OCfS
Of
S tM P IE CE S T O ',, THICK ..
slo rag ('· c ha mb er. se e F ig. 3. Do
this
by
makin g a s er ie s of p as se s w it h t h e r ip b la d e,
O Il'S IDE EI )( ;ES .Nex t , to make th p sides
appear thinner than their
actual ~ ..
thick
n ess, I trim m ed lit fro nt an d b ac k e dg es
down to
W
t hi ck , s ee Fil . 4. To do l i tis . sel
t he t ab le s a b la d e
o'~
(ro m th e fe nc e a nd
. high. see rig.
5.
BVtJ.NO ~I'ROf'D.£_
Aftertrimming the out
side
edges,
ro ut a bu ll nose p ro f ii t- on t hem
with 01 ¥
round-ever bit.
'1'0
do this.
first
raise the bil V. . • high and r ou nd o ve r
th
outside
edges (groove ' fac e
Itll .
~e Fig. 6.
Then ra ise the bit V.l hi J. l l an d r ou nd ove r
the in sid e e dg es (g ro ov e dQ w . se e Fi) . t
PRf ._- \SS&\tRL ,
~OY,l
(' '1 lllI1l'
side
l)it.. '4.:t·
into f\I,'O 8'1·longsections, see Fig. 3. Then
nlue the ba ck a nd d iv id er pa nels in place
(flu ,;h a t th e ta ll a nd botto m ) be tween the
two s ide s. refer to Explo de d \'i , ·w . fl'lS 27 .
. .
2
®@®
PANrlS
tC U T SIXPtKU
J. fHlCX)
six 8 ·lo ng p an el s. s ec Fig. 2.
S hop N ote: Instead of resaw ing solid
stock. you could useplywood (but the plies
will sh ow o n th e fin ished
pauern pane ls ).
_ .. . . _ .
_ - . . . .
U l L . . - - - f U F ;
AU.GROOVlS
~l
l...I ,
I~ ':--.
<
NO TE:
USEruT PlleE
lO
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29
t·
,,
...~
,,
COIJNTruUNK
SH ANK HOLE,S
•
t. INSET
PILOT
HOISS
2
SACK
RONt
,
.6 x '· 'h
WOO OSCREWS
~--4 - __
UT
--t-Tom
'
-CUT
1 m
a
@
un
• ~ BLOCK
,'.... NOTE
t _ INW
/ ON
A U.
SIDES
.
,
H
® ~
_
UGHTf . l-
80ARD
e
2
. .
a
3
/ LI GHT
( 'AMIot
D
un
of the box b)' m eans of a lid block that's
gl d tu liltuod tl '> id( ' o f w ( · l id . se e rll . 12.
To make 1I1~lid bloc k (C ). start by cut
lin g a
y~
p iece of 81O< 'ko
f it
th e o pe nin g o f
th e Ughlchamber ( - .. i ha f ronlpanc l io p lacej .
W i th th e li d b lo ck c ut t o s iz e. r uu ra n a rr ow
chamfer alonJ all four edges of o s id e 0 1
th e b lo ck. (The ·t:a~·.lhi~wa.. l~ .)
Now d ri ll p il ) 1ho i,
-s Ihrough
th e sh an k
holes in lo the bottom ends of each side
1>;... .. . s ee F il l. I I a , 111enI I lu c and screw th e
00.,,'
in l'Ia'....with
Iffi
I AI woodscrews.
IJL>BUICK. The
li d
fils'nugly
o nto th ,· to p
ASSEMBLIN G THE BOX
,
®
8ASE .
NOTE:
eA S E A N O U O
STAWTOUT AS
~lONG
BlANk
' ..~ X 1 ..' aA OO Vf
fOR
(lfC'1':llC
CORD
,
aonoMsrO £
O F B A SE
9
,..
,
~gin making lite
.. base and lid 01 th e
box b y cu ttin g a
b la nk to a fin al w id th
01 SII , , and a rough
length or 12),0 ,
Resaw, then
sand.
the
blank
10 a final
thickness, of ~ .
N o w ru t
the blank into two pieces,
each 6
0,
long.t fonn abase E) and a lid (F).
F1~C;ER
surr,
A f inswr .101
in Ih.
base
a llows aCC lOSSo the electrical fix lure. To
make t h i s . bore tw o 1
hok-stmhe
b a . . . . . . · .then
cu t
4JUt the
wa..; tc
between themwitlta sabre
saw.see
~1S .Sa.
(0110r .ROOI ' . :Next.forma V, .o.epwoove
for th,· ('ll'Clrl al,'OO'd in tlw bouorn oi Ih~
base using tht rourertabl«. see Fig. 9,
R()l NI)·()''}· R Er'(iF.S. After cutting this
gf ...• r ou nd -o ve r b it, T o d o
this.
mise the bi t 1 ; above' th e tab le . >
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30/32N ll .7 1
oodsm'th0
The mag ic o f t he n ; h t l ig bt l s i n the
scroll-sawn panels. Here are som e
suggestions
or m king four
inter
changeable panels.
SCaOWNG TIPS
The patterns mown here arc half-size,
50
h av e t hem
l '1lI 'IWd
O I l \
81
a c op y
sho p. o r s en d l or t he f ul l· s iz ep a tt er ns
from
Wood , ,;lh f t fTj ~tSIIPJlfic; J.
see Source l lo1ge31
-';ole:The
fig/tt r
areas of tlw draw
ings a re th os et ha t s ho ul d becu t away .
used a : 1 0 5 ski p toolh b la de in th e
scroll s aw fo r e ach o lt he pauerns.)
A' lTACH PAl' lb-a. .
Firs t f in ish
sand
e a c h o f th e J).'IIlcl blanks. Then gluc a
p attern to th e
b l an k
using
3 M s
Sprow
MuuOlora U g hl coat otrubbercemcm,
DRflJ HOI F ~Befo re y ou be gin 10
saw. dr il l s tart in g holes fo r the pierce
(inside) cut s, a nd f or t he o th er h il i.
ANI >II. Fin ish the
p an el s b y
dipping
th em in shal low
pan
of
lung
oil .Then
poke out the excess finiSh from the
drill h ol es w ith a w ir e b ra d. (A ~ hO Io f
ompressed alr works e..en beuer.)
F UING ST RS
D rill the hole, for the background
s tars f ir sl (us ing V 6 and 11l
drillbus
The p oin ts on Ih moon and th e fai
lin g sta rs w ill
b e
shar p est if y ou fo rm
themwhh tw o inter$('Ctingl1IlS. rather
th an b y h yin g 10p ivc t a round them.
J CK O L NTERN
Drill o ul th o '13J1I (w it h 1116 nd V J i
bits) an d
tilO I \w he n y ou r e s cr ol-
ling
between lite
leaves).
SNOWTPINI
l )r il l ho les for th e snowi lakes ( I s bil)
and the tree ornaments G rl ) .11I1m
d r i n
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31/32
31
'l.71
NIGHTUGHT
The hardware (or
the: Night
L ight on page:
26 b
available
from
\Voodsmith Projt'Ct Sup
plies. This package includes a
>ocket/lighl sw itch and plug
(with slx
fOOl
0 1 cord ). Iw 04 W U tl
white nighLIlghtbu lb • • adhe•
sive-backed
gn' 1
(dt. and (our
full-size .....
ol l
sawpatterrrs.
(St.
previous pa ge (or pauems.)
Night Ughtllardwure
771·.jOO ight Ught
Hard-
war.li ckas:~ __ $9.95
• (l I S ock
e -
t/U ght S witch, S ix
Foo t Cor d and
Plug
• (2 ) 4 Wa tt \V b ll~ Ug hl
Bulb.
•(Ipe.) Adhc / l i d
• (lpc.)}'. x .I~I'·x 16 . Sidt.,;
•(I) . y , x 2 x l
tid
Block
• (I) ~ x 2 x ., Lh rry
i'ly·
wood J. iy,htA o a . r d .
(;0.'
J S i o ·
VIX BnS
In Simp Now,- lin Ilag.·
24 .
W(,
(liscusS(- e No.9
\fL'
b it c an ) ,. ,
used
fo r N o.8 . 9 . and 10St·....ws.
VIXBits
771·505 No.5
\ IX
Hit $8.95
77 1·509No.9\'jxBit. S9.95
771·500
Both 8it,;. $17 .95
ROUTER Bns
W, . a lS .
Woodsrnith J?rojcd:Suppli( S
P.O. Box 10300
Des ~foines,lA5()306
OR ER INFORM TION
CARVING KNIVES
\\re experimented
with B
variety
u( knives
while
chip-carving
the
top of th e MuskB ox sh ow n on
page 21. I even
called
Wayne
B arton w ho is one of tile finest
eh isx:atV lUu,t b e · cut iluri
veneer mii} contain
pat(·hi . -
or
&'2n1$,owcre
~lpplyiRS
mort'
t han ) ouneed
MUNicBox \Yood Kit
771·350
Musl c Box \ \ . ,, 1
and In lay Kit. _....•.
SI7
I:.
• (I) \O~.'
X
2l.,. 'x 24 '1 \\·ablut
• (I) ~.
3 1 , . 0 2 x
~l~ \ \ ,1 11 11 J1
-(I) ~ x 2~' ,' 3
i
., 11 1 \\'atllu'
PlywlKld r k> ~m.G ood 1 S ick
• (l) 4
x
12 \\'alllUI
1',11'4'(
BackedBurl\'tn 'r
.(1) ~'6 ~ 21
Mapl, \\
al
l lu V M a p ic I n la y :- lOp
Musk Box Chip-Carving Kit
\V l' a JS41 lJullvgt tlu-r a ki t r'1'r
chipcarvers.h s idcnticalt« thl'
veneer k it. bU I instead
(If
V-('II('('(
and th~
inlay.
W e ,. pp ly a
10lll(
block
I' ba'; '' 'WI KI
fo r
I~ nl)'1
p ract ic ing . , ,'e 're a l . :t l
including
a (ul l· s iz e d ch iJk, 'a n ing pa tt t m .
Musil' Box Chip-Ca,,';nll Kit
771·375Music Ilox Chip-
C a . r Y 1 I 1 J t K I l . .. . . ~
J '.
-(I)
~tl
x2lj x
I n
lJ,a ..
~ lJOd
• (1 )
t'2 x
2v-
x
2
J \\'aln111
• (1)
\ - 2 x 3 1 1 - l x P . .'i· 'alnut
•(I) J 1 I
X
2 1 8
X
37,.,.'\I 'alnut
PI)'WlKldBottom. C,ocKI1 Sid,·
TOY BOX
All
the hardware needed
to
build
the
To), Box is available
from \Voodsmith Project Sup
plies. The package includes
hinges. lid
supports.
,Iwlf UIl
ports.casters, plus a
sheet
oHull
';7£ pauerns of letters A B. and
C
and num~rals
I. ~ . a nd
3 . Not ,, :
W'Kld and pain t ' iu
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32/32
,
'11/' /
II
u n
Ill,
I,d
tdJ~th;1frlllrl ,\
, I t ,
1 'Jlll
tv ,','''1' '' ll .f t . } 'I,r xcrutl :« 1t 1~ 1A Ilf \ 11111·
Ptrtt
'1
' fA ,ru'(IJ/
I III/tl
f H a. -
'(I~ I
e.
/ JO . ; , ,, ,, S 4, ~ ,~Jqlt ' f'U11l I IPJJOrlS tit hold flIt
fid~('lit' H I I I . ; - / . 1 1
r
1 It(Ctl)/'J(i,IY
~llt
.lOpt'llt/I I
t/ri''''''fll'll,i
,1fll~u'
8'1J'
~tJ
pli'n.~n/
~:trIJ,.i~.Tilt' I,m ls lllljJ'Vm/f ,,1 tali. p I1. ';U 1
Music Box
.. . . 1 1 , , 4 / Jlf,
I
J , I t ) . r Il f
II(i
tlr mil t: (l d{r:.
lirall f
I/ '/rli ~ ,c
II. l\',fh (III
~IJ
,.(ierry b a . H ~
(1
t
I.*,
'JII
t
r . , , , , ,/ 11 I rot If I Y) f ~ ld II {
.. TIlt
~trt W t t I . . t
I'I fig lJ(IINtr,,, ,1.
fnrr'
i~
.(flt' nliilflry 11'n...
lunrbl, .........
11~liqlll
Rli.li,IIJ
/fJ
to
J t ':'( /f',
0/1/ t lu G 'P JJ e r 't u tIlt:
VIII.
inal etails
L .j )K
ST