Fixing mistakes

Bandsaw tires

Precise angle setups

Low assembly table

DEPAR

TMENTS

4 12 22

Letters Methods of Work Questions

&

Answers

Events Books

mment

Notes and Co

ARTICLES Cabinetmaker's Assembly Table

by Charles Davis

Torsion-box construction and a wooden brake make this mobile work surface strong and stable

94 98 100 38 42

Dealing with Woodworking Mistakes by Sandor Nagyszalanczy

Building a low, mobile assembly table, p.

And strategiesfor aVOiding slipups

mns from Shaped Staves

Reeded Colu

by Tim Carr

Bandsawn and routed segments simulate carving

How to Install Bandsaw Tires

by Robert M. Vaughan

Getting them on is only part of thejob

Routing Tapered Flutes in Flat Panels

by Malcolm Vaughan

Jigs make short work ofa magazine rack'sfan-shaped ends

Choosin2 the Grain Pattern for Curved Parts

by Peter TisChler

38

47 50 54 58

Endgrain orientation determines surface pattern

Simple Instrument Sets Precise Angles

by Tom Rose

A shopmade sine-bar and basic math yield accurate miters and bevels

Curvaceous Carcase Construction

by John Eric Byers

Slats dress up bendable-plywood sides

Build a Bent-Plywood Kayak

by Chris Kulczycki

Stitch-and-tape construction can put you on the water in less than a fortnight

Double-Blade Tablesaw Teno

nin

g

by Mac Campbell

Spacers and shims between blades make setupfast and accurate

Threaded-Lid Boxes

by Steven Gray

Shop-built device simplifies threading wooden containers

Arm

Molding on a Radial-

Saw

by Dick Willford

Auxiliaryfence and tableprovide safety and versatility

Cutting Sheet Goods Down to Size

by Charley Robinson

Alternative rigsfor sawing and routing large panels

Flocking a Box

by Spider Johnson

Simple, inexpensive methodfor adding a velvety lining

Fine Woodworking 0361-3453) cr 06470-5506, (lSSN

postage paid at Newtown,

PostMaster:

60

Mounting bandsaw tires, p.

50

Setting upfor angle cuts, p.

60

64 67 72 76 80 82 86

On the Cover:

Cutting tenons with a double-blade setup increases accuracy and production. Mac Campbell tells how to cut tenons safely with his unique aux­ iliary fence on p. Photo: Alec Waters

72.

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seeds -Hurray to Fine Woodworking for publishing the articles by John Melhuish and Warren May #93) about paulownia trees as a source for high-quality hardwood. John and I have worked together for over 13 years researching and experimenting with paulownia. We had a vision that blossomed into a mission -a global mission. We have en­ deavored to introduce this incredible tree to the public for its ecological, economical and wood-utilization virtues. We asked Warren to help shape the direction of the mission by working with the wood to demonstrate that the raw material does have a confirmed use. The excellent photos in the article of the finished products only touch on the real beauty of these items. John left his job with the U.S. Forest Service, and I left my professorship at the University of Maryland, and we set up the National Paulownia Center. We have provided information, start­ er kits, seeds, growing instructions and economic data to over 9,500 tree growers, woodworkers, industries, conservation groups, the Peace Corps, Native American tribes, and state, feder­ al and private agenCies in the United States and 66 other coun­ tries. If you are interested in receiving high-quality seeds, grow­ ing instructions and other information about paulownia, send $1 and a SASE to ational Paulownia Center, 4303 Kenny SU-eet, Beltsville, MD 20705; or call (301) 937-4635.

smoked a little, but I wasn't too surprised because I knew this was a very deep cut to make, especially in hard maple. After the cut, I checked the cheeks of the tenon-and they weren't burned-so I set up for the next cut. But when I made the final check of my setup, much to my dismay, I noticed a red glow inside my tablesaw. Since I had left my dust-collection system running, I had not noticed the smoke coming from the fire developing in the sawdust below the blade. A spark, fanned by the dust collector, had now developed into quite a blaze. I quickly shut the blast gate to the tablesaw and grabbed for the fire extinguisher that I keep near the enu-ance of my shop. Luckily, the saw was not damaged and the burning sawdust had not been sucked into the dust-collection system, but if the fire extinguisher had not been close at hand, a minor mishap could have cost me my tablesaw, if not my house. I had never expected to use tllat fire extinguisher on a fire ignited by my tablesaw. Since tilen, I have changed my work habits to include a cooling off period after I done working, and I always check my work­ shop before I go to bed. I hesitate to what might have hap­ pened if tile spark had ignited on the last cut of evenings' work.

-Peter Beckjord, PhD., Beltsville, Md.

Se g a loose dust bag- I've come up with a tool modifica­ tion inspired by Sven Hanson's article in #92 on orbital sanders. When I used my Bosch orbital sander ( model #3283DVS), I ran into tlle same problem that Hanson described in the article-the dust bag came loose. Hanson had also re­ marked that Bosch's right-angle model (#1370DEVS) uses an a-ring to hold its dust bag in place. This gave me the idea to modify my sander. I filed two slots on opposite sides of the dust

Source for pauIo

(

FWW

Where there's smoke

am

curin

-I'm writing to relay an experience that occurred in my woodshop recently. I was cutting an open mortise and tenon for an end vise on a maple workbench using my tenoning jig on the tablesaw. Because the tenoning jig held the workpiece vertically, I had to cut a full 2% in. into the end­ grain of the workpiece. When I made the first cut, the wood

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ER SERVICE NO. 97

July/August 1992

5

Letters

(continued)

chute to receive an O-ring that would secure the dust bag. I used a 1 V4-in. by I-in. O-ring with a 1/8-in. cross section (a standard size available at most hardware stores), and filed the slots about V8 in. wide by V2 in. long and about % in. in from the edge of the chute. The O-ring provides a cheap tension clamp to hold the dust bag in place. -Callan Campbell, Chicago, Ill.

A

Mis

- uts-

placed T n I found the article by Lyle Kruger about his shopbuilt tenoning jig #93, p. 66) both interesting and disconcerting. I would like to direct your attention to the place­ ment of the T-nuts in the drawing that accompanies the article. The T-nut on the lower half of the sliding portion of the j ig should be installed on the bottom of the piece, not on top, as shown. When the threaded shaft of the locking knob is tight­ ened, the T-nut should be captured, so the two parts of the slid­ ing jig are clamped together. drawn, the four small prongs of the T-nut's flange are all that are holding the parts together. The same goes for the four T-nuts on the jig's face that hold the clamping assembly. -Kenn Van-Dieren, Rochester, N Y

(

FWW

As

EDITOR'S NOTE:

Good catch, Mr. Van-Dieren. You're right about the mispla­

cement of the I-nut that receives the locking knob. In fairness to Lyle

Kruger, whose jig the article describes,

I

should point out that the error

was only in the drawing, not on the actual jig. However, the I-nuts on the jig's face (which Mr. Van-Dieren also mentions) are located correctly on the drawing. Ihese I-nuts are installed in the back side of the jig's face, and then walnut caps are inlaid over their flanges. Although no one would ever put a regular hex nut on the wrong side

ration. All the tools are in my small backyard workshop and are exposed to the same humid, Florida weather conditions. None of the tool distributors or electric-tool repair shops seemed to know if neoprene was better than rubber wire, or if there was a specification code to evaluate the best material for the jacket covering. I suggest that woodworkers periodically give all the cords in their shop a close inspection. By the way, would you call it superior engineering when a product fails right after the warranty expires? -Daniel Angert, Orlando, Fla.

than uart

-a-q er col - Thanks for Mac Camp­ bell's excellent article on quarter columns in #93. Inset quarter columns are a handsome, classic alternative to square corners on all sorts of case goods and allow for considerable variety of design. But after using quarter columns on a number of commissioned pieces, the results began to look flat, as if the column curvature was too shallow, and the case corners above and below stuck out too far. An alternative is to use partial columns with greater than a 90° arc, cut to a right angle behind the axis of rotation. This isn't as preposterous as it seems at first glance. For example, if the plan calls for a quarter column of 1 % in. radius, I can turn a column of 1 1/2 in. radius and then lay out a right-angle section whose maximum width is 1 % in., as shown in the drawing below. The included arc in this case is about 1 1 0°, giving the column a much rounder, fuller appearance. A-bit-more-

Standard quarter column

of two parts when bolting them together, it is not uncommon for people to mislocate I-nuts. Ihis error can be avoided if you remember that even

umns

FWW

Quarter column with more than a arc

90°

though the I-nut happens to fit into a hole, it still functions like any other nut-it must be on the far side of the parts to be bolted together.

If you're self-employed, don't forget to work for yourself­

Occasionally, you print articles and letters about the pros and cons of running your own business, and I have something to add to that discussion. For the past five years, I have been designing and building furniture and restoring antiques in my own shop. I learned this craft from my father, and I can understand a person's trepidation and frustration with the craftsman vs. businessman dilemma. Al­ though you probably won't get rich as a craftsman, there is something else to consider. When I go home, I open the door to a house full of furniture that I made. I would have to make three to four times more money than I currently make to be able to purchase this furniture. When you work in wood, you can't judge your wealth by your checkbook, so don't try. Some months you will make money, some you won't. But if you don't build for yourself, you'll always be in the red! -Paul Saporito, Orange, Nj.

rds

eye on tool co -Almost every woodworker knows, and is continually being reminded, to use saw guards and hold­ down fixtures and to wear face shields, respiratory masks and proper clothing. The old-timers know about safety from experi­ ence, and the neophytes read about it in owner's manuals and woodworking magaZines. The warnings are well-indicated and constantly repeated. However, the silent, sneaky, unobtrusive danger I have run into in my shop is multiple electric cord rots in the original cord furnished by the manufacturer. My Makita router developed 7 separate splits in a 1 5 month period even though it was not used very often. In fact, it was mounted in a homemade router table, not dragged around from job to job. The cord on my Skil 51/2 in. heavy-duty trim saw rotted out in almost the same amount of time - 13 months. Interestingly, my cheaper orbital sanders and electric drills are over 12 years old and have shown no signs of cord deterioKeep

6

an

Fine Woodworking

I turn the column from a square section long enough to leave a few inches of the square intact at each end. After turning, I screw a straight edge across the square ends and rip the corner section on the tablesaw. After removing the straight edge, I trim the column to length. This method is inconvenient to the extent that only one quar­ ter column can be obtained from a single turning. But turning visually identical columns is not particularly difficult, and be­ cause the corners on most case goods are separated by a fairly large distance, small variations, even on highly detailed classic columns, are of little consequence. -Joseph Beals, Marshfield, Mass.

amiliar (

fini

shes may become hard to find-There's more to the issue of regulating volatile organic compounds (VOCs) than first meets the eye. In his sidebar "Will new VOC regulations affect you?" #92, p. 82), Michael Dresdner speculates that they won't. Compliance, he tells us, will be voluntary for small shop owners. And while he urges us to be environmentally re­ sponsible, he leads us to believe that we can go on using our old, familiar varnishes and lacquers if we so choose. I have just completed a finishing book and, after interviewing several finishing manufacturers, I find that Michael Dresdner is only partly right. While compliance for small shops may be voluntary in theory, eventually, we'll all be dragged into a brave, new low-voc world, whether we want to be or not. ConF

FWW

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C lAM PING & VENEERING TOOLI

NEW $9 .0

� �It' fonu.0>(lJe.rfj(1/0&0-'" iIIu.rLl'atir& QualityVAKu m Products- LongmeadowRd. - Uncoln, MA. [l/arckl:ecLlUYlb Complete Kits from

reruiert1ft.r ollr /lClU'

Increase Production

The Best Value on the Market

Add New Capabilities to Your Workshop

Powerful air-powered VAKuum Pump that generates 1

of

VYldaonaband tWwoaLiot7 ideas" to-art:; Olifo/v homlUll?IWIuw

Catalog

115

Design Portfolio Available

-

ear

800 #/sq.ft.

CALL 1-800-547-5484 ANYTIME

strong

! • 5' J6 OR 8UVFORCWLY AU. n-t M.�ct..AMPS Incl ud •• : 6'. ..eh. ,,'. OTHER PROOUC'TS ·VACUU� DISCS-SLEEVES AQU.S-F\AP P.PlaO.no.BoxTX 75086 F865021 'SANDERSVISA. Of Ecan-Abraslves \.(214)377-9779 Nooks Hill Rd. Box Cromwell, CT U.$5.50 CALL FOR FREE 1992 CATALOG! NATIONAL send for a catalog ERVI 3

ORDER TOll FREE

(800) 241 -6748

800

I OO ttuu '.soc

14.00 13.00

25.00 23.00

3X23314

3:36 X

3.104

2 114Xeo

2.94

00c

... .

II

OO-6O Grit - 5 - 3 per

SI3.87... SI4.34 ... SI5.17 ... 17.65 18.2" 1 9.1 4

25

25 . 75

2328

20.87 24.19

37

30.48

31.f.O

60

37 . 75

ANTIQUEHARDWARE

$19.

1 00 SHEETS

GRIT· '

1 9 . 48 25 . 48

READ ER SERVICE NO. 94

$11.00

.87

3:ele wl1·1/2 HP molor & ...... ..... . ........ .. .. .. . 812 615 34-444 Saw ..lh 30' unifenee ...... . 1200 815 34-446 34-444 Table Saw complete wl3O" Unifence and 32·010 EMS syslem. . . . Sale 839 28·283 14' Band Saw wlenclosed sland and SO·274 mobile base ............................. 910 729 22-662 13' Planer wilh 2 HP motor. stand, and 32·01 1 EMS system ........................... 1436 1169 17·900 16·1/2' Floor Drill Press ....................... 441 389 1 18' Scroll Saw wlstand and blades ...... 942 729 34-080 10' Mitre Box. . Xlra Special 198 34·761 10' Unisaw 1-1/2 HP . . .. .. ...... . .. . 1715 1325 33-990 10' Radial Arm Saw............................. 818 585 37·280 6' Molorized Jointer . . . . .. . 395 50-179 314 H P 2 slage Dust Collector 335 50-181 2 H P Dust Collector ............................. 885 615 7G-200 Roor DMII Pross . . .. . .. . .. 1049 37·154 DJI5 6·Jointer ""lh 3l4 HP motor . . 142O 1079 33-055 8·1/4' Sa wbuck COmp "lh tegs ........... 865 579 34-330 8·1I4· Table Saw I 3 amp . .. .. . . . . . 34-670 10' MOloMzed Table Saw ..................... 511 385 32·100 S a on Plate Joinler.. . . .. .. . . . .... 645 275 8-1/4' Compound Mitre Saw................ 224 165 34-915 30' Unifenee ........................................ 385 239 �97 SO' Della Unifence ............................... 525 279 36-755 10' TIlt Arbor Saw .............................. 1264 895 HTC Mo ile Bases for above Machines HRD·l0 fits Della 34·444 table saw ........................ 88.SO HRD·l0X fils Detta 34·445 table saw with fence ....... 132.00 HAUl·5 fils Detta 28·283 bandsaw ......................... 88.SO

4ll-60

....... . . . . . . . . . . . . 488483 20' . . . . . . . . . 798 . . . . . . . 343 229 t t i . . . . . . . . 36-040 b

p

AMERICAN CLAMPING CORP Bessey "K" Body Ctam s hem

K3.512 K3.524 K3.531 K3.54O K3.550 K3.560

Throal

3-1/2" 3-1/2" 3-112" 3-112" 3-112" 3-112"

Opening 12" 24" 31" 40" SO" 60"

Jaw Lenglh Lisl

5" 5" 5" 5" 5" 5"

44.35 48.65 52.85 56.95 60.65 64.SO

Sale

30.99 33.99 36.99 39.79 42.39 45.09

NEW DEWALT TooLS DW364 7·1I4· Circ. Saw wlbrake. 13 amp . .. 245 DW946KI2 volt cordless 318' Hammer DMII Kif....312 DW306K8.0 amp Recip Saw w/case var. .. 254 DW610 1·1/2 HP 2 handle Router .. ..... .. .. . 2SO DW41 1 114 sheet Palm Sander, 1.7 amp .............. 87 DW705 12' Compound Mitre Saw.......................555 DW704 12' Mitre Saw.......................................... 480 DW100 318' DMII, 4 amp, 0·2500 rpm, rev ........... 1 1 0 DW2SO 4.5 amp Drywall Gun. 0·4000 rpm. rev ... 146 DW254 4.5 amp Drywall Gun. 0·2500 rpm. rev. .. 146 DWI24Kl/2' joisl & slud Drill w/case, rev .. . . 504 DW102 318' DMII, 4.5 amp, G-1200 rpm, rev ........ 154 DW103 DMII, 5.0 amp, G-1200 rpm, rev .. .... 189 1707 8-1/2' Slide Ccmpound Mitre Saw.......... 815

148 179 159 139 54 339 289 65 89 89 295 92 115 439

.... speed . . . .. . .. .. . 318' . . . . . . . . . . . . 263 n ..lh 60DMve carbide. . bl. ade. . . . . 23O 229 35-04 35-04 .. . . 34003330 3380 BeI1\6' . . . . . . . . . . . . .

SKIL SIZZLERS 3810 10' Mitre Saw. . . . . . . . . .. .. . 3810K 3810 toolh 7·1I4· Worm DMve Saw. . . . .. . 6-1/2' Worm Saw........................255 5825 27 12 voll cordless Drill Kif........................ 210 27 X 2735-04 wilh keyless chuck.................235 1605-02 NEW Biscuit Jointer with case.............200 7584 NEW 5' Random Ormt Sander ............ 160 5510 5·1 /2" Circular Saw ............. ........ ... 1 65 5660 NEW 8·1/4" 60' Circular Saw.......... 225 5860 NEW 8·1/4" 60' Worm Saw ............275 6·1/2" Circular Saw . ............ ...........210 5625

199

144 159 135 137 123 104 114 145 179 139

New Ski I Bench Top Tools 10· Table Saw ...................................... 2SO 179 16' Scroll Saw...................................... 200 135 8' DMII Press .. . . . . . . . .. 200 135 4' Disc Sander.......................... 200 135 3370 Receive FREE #2210 SKtL SUPERTWIST Screwdriver of any SkU Bench Top Tool !

with purchase

AEG POWER TOOLS VSRE500KNEW v/spd 5' Random Sander wiese 279 VSRE600KNEW v/spd 6' Random Sander wiese 264 HBSE75S3 x 21 vaMabie Bell Sander ....... 299 ABSEI5S1/2' cordless 12V Drill com!Jete w/case389 FSPE100Barrell Grip variable speed Jig Saw ...... 265 BSPE100KTop Handle variable speed with case 275

speed

I

149 155 169 235 149 159

HITACHI TOOLS Model Des ion list Sale 7·1/4' Circular Saw.............................. 214 109 C7SB OTC10 7.2 volt cordless DMII ................... 138 78 C7BD 7·1/4' Circular Saw "lh brake . .. . 127 M12V NEW 3 HP v e Rooter ....... 447 225 TA12 Ptunge RoUler 3 HP . . .. . 169 FlOOOA 12' Planer/6" Jointer . . . .. . .. .. 2835 1535 Cl0FA 1 0' Deluxe Milre . . . .. . . ... 274 C12FA NEW 12' Mitre Saw ............................. 632 299 C8FB 8·1/2' Slide Ccmpound Saw................ 899 449 FREUD LU91MOO88·1/2· carbide blade tooth . 68 43 C15FB 15' Mitre Saw ...................................... 745 FREUD LU85M01515' carbide blade 108 1ooth ... 180 105 F20A 3·1/4" Planer 3.4 amp . .... .... . . 172 99 G1 2SA 4·1/2" Grinder 6.9 amp ................... 147 79 M8V Var. speed Router 1/4" collel ... ... .... 278 155 DS10DVAK NEW 12V Cordless OMII Krt with 2 batteries ...... . . . . . . 385 199

cript 318'

. . . . . . •. . . . •. •. • .• . ariabl speed .Saw.. .. .. .. .. .. ... ... ... 354538230 48 384 . . .. . . ... .... ' .

JORGENSEN ADJUSTABLE HANDSCREWS Opening Jaw 11eml

Length

2' 2·1 12 3' 3·112' 4·1/2' 6" 8·1/2' 10' 12'

4'

5'

#4/0 #310 #210

6'

8' 10'

'I

12' 14" 1 6'

JORGENSEN STYLE 37 2·1I2"Throat 1 /4"x3l4" Box of 6 Iteml Jaw Lenglh Lisl Sale 6.49 9.86 36.55 6' 3706 3712 39.75 12' 10.92 6.99 7.75 42.99 12.05 18' 3718 13.16 47.75 24' 3724 8.39 9.55 14.70 54.45 3730 30' 10.39 16.05 57.95 3736

36'

JORGENSEN STYLE 45 5" Throal 1·318" x 5/16" hem

Jaw Lenglh

4512 4518 4524

Lisl

12' 18' 24'

Sale

30.07 31.73 33.55

19.39 20.45 21.75

PONY CLAMP RXTURES Model

7224 7236 7248 7272

"I"

24' 36' 48' 72'

BAR CLAMPS List Sale

31 .46

37.12 42.71

LOIS

ELU BY BLACK DECKER 2·1/4 HP vaMabie Plunge Roufer427 1 HP va speed �unge RoUler .... 292 3375 3-1!8· Univ. i>aner 7.2 amp . .. .. .. .. 313 Biscurt jointer "lh case ....................... 542 3 x 21 variable Sander....... 322 4024

33383304 3380

&

BLACK 1166 2600 1703-1 4011 79-034 1349·09 1180 2037 2038 3157 2665K 5045K S071 S073 2054

2660

2700 1321 27SO 2694 2695

speed speed BeI1

..... .

249 164 155 249 164

DECKER 318' Drill 0·2 rpm 4 amp................. 100 65 318" Drill 0·1200 rpm 4.5 amp .............. 142 89 10' Mitre Saw with 73·770 blade......... 313 179 1/4 sheet Palm Sander.......................... 82 59 Workmate 400 ..................................... 175 105 1 2 Timberwolf OMII 2 speed ..... . . 489 279 318' Drill rev. 0·1200 rpm 5 amp ..... 182 104 Drywall Gun 0·4000 5.0 am .......... 175 97 Drywall Gun 0·2500 rpm 5 amp .. .. 175 99 l var spd Jig Saw 4.5 amp ..... 220 145 NEW 318' cd� 12V Cyclone DMII .... 280 165 MACHO Rotary Hammer DMII.............. 742 Hammer Drill w/case .................... 239 144 1/2' Hammer OMII w/case .................... 282 163 TekGun G-25OO 5 0 amp. . . .. .. .. . 269 152 Drywall Gun 0 4.5 amp............... 142 88 7·1/4· Worm dMve Saw I3 amp........... 2SO 149 1/2' Spade hdle Drill 450 rpm 7 amp ... 292 165 4·1/2·GMnder 10,000 rpm 6 amp ...... 149 83

500

/" Orbifa 318'

.. p .. -4000. . . . . . . ..

409

.

7·1/4' Super Sawcat Circular Saw ...... 248

8·1/4' Super Sawcat Cricular Saw ...... 271

Above Saws come with FREE metal case

142 153

&

Piranha by Black Decker Carbide Tooth Saw Blades Modet #

Diameter

# Teeth

73-718 73-716 73-717 37 73-757 73-759 73·719 73·769 15 73·704 73·740' 73-770' 73·711

8 6·112 7· 1 4 7· 1 4 7·1/4 8· 1/4 8· 1/4 9 5· 1 2 7·1 /4

22 18 lB 24 40 40 22 60 16 18 32 60

73-7 73-7

1/ /

10 10 10

50

READ ER SERVICE NO. 70

I .� m.kertbe.·nscbon,"AnII h•'C: II� If;lraAsm:l... -Of"km:IuIO nlOl!ouU:ler:I100dlUIltoOls1�!lhc1l� IsI00)'�5lon�m•MOrIcoUrt1tlon.�'()(Jd 0 s:lli ..-.::1 a.. 39 ..,.lonftII.l'le.. 190manduon.0 ?'Aru)' lnJ::md bC"1 of OI'olOl-oodoo1rkJ� Innglur.dOtool,,"lr.lSCI:aan1ll":IS h-.::fll!cln9�c�nl o10r " 19M $!lC700I.nCb lheil. A a lr:td.. e� It ..00111�c mdlf.'ItII from lOol_the 111 �.insplrin8_ In an ;'-0