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1

1981 No. 30, $3.00 INDEX TO ISS� 1 THROUGH 30

BER/ OCTOBER

orking

Butlding Stairs

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n set dow au. o info�m (Ufn e[S, S [ e Useful , inetllla from ert cab lected byexp he[S, se flnis . d h an throug ca(\,e[S ne os. z.i N a g es a u m iss of

Ptn. e W '

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tV'o odwork'

Fine Woodworking • spent a year coverIng the infornlation that's now available in Techniques 3.

Techniques 3 Fine Woodworking

is here: Sixty-seven articles by fifty-two craftsmen-all the technical articles that appeared in magazine during And all preserved in durable, hardcover form. You'll find practical information about wood, tools, cabinetmaking, turning, coopering, carving, veneering, laminating and finishing. T here's even a section on architec­ tural woodwork.

1979.

Reprinted in full-along with selections from the magazine's "Methods of Work" column­ and grouped into sections for easy reference, these articles offer you a rare opportunity to learn from the masters. Our authors are all serious craftsmen, and the methods they share are the product of long hours in the shop. Tage Frid, Bruce Hoadley, George Frank, Peter Child, Ian Kirby-experts like these not only discuss their techniques, but also show you, with the help of detailed photos and drawings, how to do the work yourself.

FineVl.lUhl 1e�. g L-I.: ng Wxxh \\rT� Wxxhul'l\...J.l\J.I :ng r r. TECHNIQUES '!l TECHNIQUES 2 TECHNIQUES 3 Fil�

To order

Techni q ues 3 1-13TechniFiqnuese Woodworking),

or either of

the previous

$1752

ing issues

books (cover­

..--.-.--.--.

1110 P'l'"woodworiu: of hods,tS �ed ook andfrom matalp. Safetl{ locAccommodat k 1'0eprevent ac:c\ den starts. es all 10"" arbor List blades.

C

and '30·.

$284.29 Sale t233.%"33

$14.

52 355, 06470. 1:DUPLI 1 CATING MACHINE

RIDGWAY

-6510LVR Makita 3/8"ng Dril . Vari a bl e Speed . Reversi 0-Wel1050 RPM, 3.3-all1bballs. bearings. dede reducti �matute Ihlbl on qearinq with i Chuck..

--

ri al Sale $ 77. Il Linduit s't.99.22

"-3/8" 6010Re-versibl DWK Malcita Con:Hess e Ori \I Ki-r 600 RPM, 7.2V one hoUr Fas1 with removable batt'b.charge er,!.construc:ri 2..if on. Battery. charger holSTerwitharestorage � Salet9S. .23 ' .: Glenn wI ng Salwhiele � utjA.lI"i

balanCAlld ,

CB5estLisat�rt'and2dAeq. @uipmenT. . ;" �

.-

. Rockwell

last.

pr i ces 8Pp l 4

1437

s.

=���

l5

WOOd

quantities

Wr,te lor II Rockwell clIl�log on PortllOle and

S 2 • • • • Birmingham, Michigan 480 1 1 (313) 644·5440

Stanley

Bosch

$6,0000

S'II" onll'Y rools Enclose our comple/e clllliog II/

M i lwaukee

lor postage or

mcludmg pos/llge

Makita

29

Exhibitions

1I

MARQUETRY SHOW AND fuRNITURE CONTEST

Of the 290 items in competition at the National Marquetry Exhibition held last M a y at St. A l b a n s , E n g l a n d , " Steamboat Race " (right) won the premier award, the Rosebowl , for woodworker Tom Harrison. The prize­ winning piece, measuring 1 2 'h in. by 1 4 \1z in. , is surprisingly realistic. The variety of facial expressions, the full­ ness of the light through the windows and the detailed folds in the clothing all combine to make Harrison's work look three-dimensional. In the class of applied marquetry, P.) . Bennett's chest of drawers (far right) won first place. Its main surfaces are paneled with hun­ dreds of walnut oysters into which deli­ cately sand-scorched roses are set. This meticulously crafted piece measures 3 2 in. by 2 8 in. by 20 in. ; Bennett spent two years making it. The annual exhibition is sponsored by The Mar­ quetry Society. E nthusiasts can obtain more information about the Society through its pu blication , The Marque­ tanan, 63 Church Lane, Sproughton, I pswich, Suffolk I P8 3AY, England. Photos: Ernie Ives.

I":r:J!I'IPI!�

The National Stanley Tools Furniture Con­ test encourages student creativity and the development of woodworking skills, attract­ ing vocational education students, grades 9 through 1 2 , throughout the countty. Stu­ dents su bmit project plans requiring the use of woodworking tools and wood or wood derivatives for at least 50 of the project. This year's grand-prize winner, J oseph S . Iannuzzi, a 1 2th-grader at Everett Vocational High School in Everett, Mass. won $ 2 ,000 for his Duncan Phyfe mahogany table (right). Iannuzzi plans to become a finish carpenter. Photo : The Stanley Works.

Surprising How M uch Hand Sanding can be Saved with a

SANO-O-FLEX8 CONTOUR SANDER

%

B U TTE R N UT. WALN UT, R O S EWOOD. P I N E, CHERRY. B U CKEYE and about a dozen other woods, in boards, slabs and freeform cut ovals. Pieces up to 6 " thick, 3' wide and 16' long in some species. We specialize in coffee tables, benches. bars, carving stock. clock ovals and movements, accurately cut for you to finish. We sell by m a i l a n d from o u r fantastic wood "museum," except Sunday. Send for brochure. W E I R D WOOD. Box 190FW Chester, Vt. 05143.

9-5

802-875-3535

50'

14.000 "Sanding Fingers" per minute, eliminates tedious hand sanding.

o , ��6� ��

Manville, P.O. Box 5447 Compton, California 90224 ORDER BY MAIL If nol available at your hardware or home center 201 W.

I., $2595F W I' �-------------�, SANDER KITNo.4S 8 brushS"x l " wheeland3 abraf S dritl c Includes postage handling.

1�i��:�6t���f���u3:3��ra��� " carrying and storage case. &

30

$255

( i n c l u d i n g movement and d i al)

• Do-it-yourself case kit, parts p re-cut • Finis hed cl ocks • S o l i d 3/4" hard­

woods: b l ack waln ut, cherry, oak

Firm cushioning brushes gently force slashed abra­ sive strips over any shape and will not harm or gouge fine detail o r veneers.

Build Your Own Grandfather Prices Starting Clock Under

• Heirloom q ual ity • Factory d i rect prices • S o l i d brass West German c h i m i n g movements

FREE

Our Model 3010 Duplicator Attachment will make identical wood turnings from either round or flat patterns. Send for literature on our whole line of wood turning accessories including:

- Lathe - The

SAFETY

SHIELDS

U-TOOL WOODSHAVER

- The

UNI-CENTER SYSTEM

Toolmark CO.

Shinigls,eMiCreek Parkway Mi6840 nneapol nnesota 55430 (612) 561 -4210

• M o n ey back g u a rantee • P ro m pt s h i p m ent MASTERCARD and VISA ACCEPTED

*w!�[�� g�:k � OF GRANDFATHER CLOCKS Dept. 932 Emperor Industrial Par Fairhope. Alabama 36532

POWER TOOL SALE EXCELLENCE IN WOOD WORKING SHOW SPECIALS

FR E E 30 Honda Generators

board feet of either oak, maple, ash, h ickory or elm with each purchase : of a major stationary power tool . shipped freight collect.

First & foremost in portable generators. From a 40 I b , 500 watt 1 15 volt AC/12 volt DC generator to a 216 Ib, 4500 watt 1 15/220 volt/1 2 volt DC, electric start generator. Honda has a generator for every need from camping & boating to heavy duty construction. All Honda generators run on gasoline or for permanent installations; L.P (bot­ tled) gas. Honda also makes super water pumps & outboard motors . Send one d o l l a r for a l l Honda information booklets.

Powermatic ur'

ES 4500 G E N ERATOR 4500 watt, 39.1 am p,

1 1 5/230 volt AC 1 00 watt, 8.3 amp, 12 volt D . C . , 4 . 6 gal fuel tank (approx 5 hrs running time) 216 I b s , transport wheel s , reco i l & electric start , d i mension s 1 9 . 8" x 2 7 . 3" x 28.2", auto throttle control, auto frequency control, auto voltage control, circuit b reakers & fuses, cables & tools. Sale $1 350

S.le $1450

Ta b l e Saw Accessories B i esemeyer T­

ress, 1 1 24-F NW 40th Ave. , GainesVIlle, 32601. W O O D E N R O C KI N G H O R S E . Easy, full-size pattern, tot size they 'll love. $4. By Design, Box 2 1 502 -f9, Concord , CA 945 2 1 . PROFITABLE CABINETRY. Spiral­ bound shop manual with compre­ hensive text. Fully illuStrated with di­ agrams and proven professional step­ by-step procedures. Tool, hardware and materials list, pricing and bid­ ding hints, professional tricks and se­ crets. Ind ispensable to contractors, i n d i v i d u al c r a ft s m e n , o w n e r ­ builders and cabinet shops. Includes tack-up shop print with all key infor­ mation. $ 1 0 postpaid, $ 1 0 . 60 in Calif. , $ 1 2 U . S. in Canada. Artisan Woodworkers, 2 1 4 1 5 -A Broadway, Sonoma, CA 95476. New catalog listing hundreds of books about woodworking. Send $ 1 t o BOOKS ABOUT WOOD, RR # 3 , Owen Sound, Ont . , Canada N 4 K 5N5.

HARP HARDWARE and Strings. For b r o c h u re w r i t e : Caswell H ar p s , 14690 Carrier Lane #30, Guerneville, CA 95446. Walnut and oak FLOORING PLUGS in 4 diameters. Insulation plugs. Odd Ball Supply, Box 1 3 3 , N o . Attleboro, M A 0276 1 . SHARPENING SERVICE. Steel and carbide. Write TRU EDGE, 2 3 1 Old Annapolis Rd. , Severna Park , MD 2 1 146 for price list.

ood PO(60') 464·5058 662.

Fine hardw

lumber, including Curly Maple.

Birdseye Maple, and other hard to find varieties. Anlrim Road.

Box

FREE GUIDE to beautiful wipe-on wood finishing. General FinIshes, Box 14363FC, Milwaukee, W1 5 3 214. FINE WOODWORKING SLIPCASE. Magazines fit into cases to become valuable reference volumes. Blue front embossed in gold. One case ( 1 2 issues) $ 5 . 2 0 , 3 o r more, $4.63 ea. T he Highsmith Co. , Box 2 5 FW, Fort Atkinson, WI 5 3 5 3 8 .

WOOD&TOOL EXCHANGE For Sale A large quantiry of brand new dental cutters available-to settle estate. Box of 6/ $2. Write to: P. Selter, PO Box 24, Warren, MI 48090.

Send SASE for list of old hand tools for sale or trade. D. Truesdale, 101 E . Main, Middleton, D E 1990 1 . (302) 378-4787. Stanley, mint cond . : # 5 5 , 5 3 blades and accessories , $ 2 7 5 . # 5 0 , 1 7 blades, $85 . #7 1 , 3 cutters, $ 2 5 . Jim N agy, 49 M i d w ay D r. , McKees Rocks, PA 1 5 1 3 6 . (4 1 2 ) 7 7 1 -6459. Walnut lumber for sale, 4 qtr. and 8 qtr. flitch cut and planks 20 in. to 34 in. wide. FAS. $2-$3 / bd . ft . Call Gerry Grant, Gettysburg, PA. ( 7 1 7) 3 34-6020. A few very fine redwood burls and walnut slabs, 1 703 Jumper Ct . , Vi­ enna, VA 2 2 180. (703) 2 8 1 -425 1 . Hawaiian koa flitches - 2 in. , 3 in . , 4 in. , 6 in. thick up to 3 0 in. wide. Select for curly figure, quartersawn. Send SASE to Sylvanworks, I nc . , Rt. 1 , Box 2 1 3 , Sagle, I D 83860 or call (208) 263-9363.

ft.,

Wormy chestnut, 4/4 and 8/4, used. Rough and dry. Up to 4,000 bd. $ 2 / ft . , 500 ft . min. U-Look, U-Like, U-Haul, D. Stover, 1 4 1 1 E . King, Boone, NC 28607. (704) 262-5030 days.

ft.,

Native cherry 8-in. to 1 2 -in. widths, 4 / 4 and 5 / 4. Ap proximately 2 ,000 bd . 80..j 36Y,

2

9 Stock rail, 2%

�

The pitch board-Back at the shop, the first things to make are a pitch board and

Run, 9

---+t

two stair gauges . The pitch board is a right-angled triangle sawn from plywood, whose sides are the rise of one riser and the run of one tread . The stair gauges, one for the closed stringer and one for the open stringer, are used to position the pitch board when laying out the stringers , as shown below. You 'll refer to the pitch board throughout the job, so make sure it's accurate.

1

A Z'I.-in. allowance permits closed stringer and base molding to meet neatly at top and bortom. A 5Y.-in. allowance leaves just enough room under the stairs for a 2x4 . on edge to which Sheetrock can be nailed. the underside will be plastered. the allowance is increased.

Sta i r gauges

TT'I.

Rise,

If

Standard gauge for closed stringer

For Sheetrock,

y,

Stair gauge with pitch board 2Y.

Butt to base molding of floor above.

The closed stringer-The closed stringer, also

called the housed stringer, anchors one side of the stair to the stairwell wall . It starts out as a 5/4xlO board (1 �X9Y4) of pine or poplar. To find its rough length, measure the long side of the pitch board ( 1 2 in. in our example) and multiply by the num­ ber of steps, then add a foot or rwo for waste . Nor­ mally, for 14 risers , you ' ll need a 1 6-ft. board . Layout begins at the top, using the pitch board and the closed-stringer gauge to establish a line that will be the vertical end of the stringer in the finished stair. Next, shift the pitch board 3 in. to allow foe the landing nosing, then trace around the pitch board to locate the outside faces of the first riser and tread . Proceed down the board. At the bottom, add the thickness of the finished floor (usually % in . ) to the height of the last riser. Good stairs rest on the subfloor, with the finished floor fit around the bottom step and newel post. Thus the floor holds the stairs in place. If the floor's already installed, you must chop it out to fit .

50

Stair gauge with pitch board

/

Standard gauge for open stringer

�

Laying out the closed stringer

Butt pitch board to stair gauge.

Trim on site to fit molding..

r - - - - ..J I

I

Waste

�\ �

in . for nding nosing utt stringer to base molding. utt landing nosing to floor.

Waste

Nosing is supported by header

y,

After laying out the closed stringer with pitch board and stair gauge, above, the router template, nght (oversize for various size stairs), is used to rout the step housings.

Routing the closed stringer- The zig­

zag housing is routed !f2 in. deep into the closed stringer, to accept the ends of the treads and risers, plus the wedges that lock them in place. You can make a router template for use with a guide bushing (photo, top right) , or you can develop the housing layout from the pitch-block lines and excavate the waste with saw, chisel and router plane. Routing done, finish up by chopping small recesses to receive the end of the cove molding that covers the joint be­ tween the tread nosing and the riser below. Production shops merely butt this molding against the stringer.

Typical wedge

--1 �J/1 6

10

r

I�

Router template for closed stringer

Thickness of tread plus wedge

, .1)/

!I(

� 7/. �

The open stringer- The open stringer supports the other side

of the stair; treads rest on it and risers meet it in a neat miter: At the bottom it rests on the subfloor, at the top it is housed in the landing newel . Thus it is shorter than the housed stringer by the amount of the top riser and the 3-in . nosing allowance. It's also wider, being cut from a 5/4x 1 2 board of pine or poplar. Use the pitch board and the 5 Y4-in . gauge to lay it out as shown , starting with a full tread at the top and allowing for the finished floor at the bottom . It can be cut out on the table saw and bandsaw, but not easily. Stairbuilders saw it by hand at the bench , using a leg vise that rises several inches above the bench surface. First make a relief cut above the line of each tread, then saw all the treads , then saw the miters for the risers . The miters should be accurate , although they can be undercut by about the thickness of a pencil line to make a neat fit certain .

Laying out the open stringer

Stair gauge

The completed stn'ngers, below.

51

Treads-It's usual to buy pre-milled tread stock of white or red oak , 1 2 in . wide and 36 in. or 42 in. long, planed to 1 in. thick, with the nosing molded on one edge. The tread depth in our example is the 9-in. run , plus 1 Y4 in . for the nosing, plus Y4 in . for the tongue, a total of 1 0\12 in. Rip the stock to this width. The measuring stick gives us the length of each tread, 36\12 in. This includes the half-inch that's housed inside the closed stringer, but you must still add 1 Y4 in. for the miter that meets the return nosing on the open side, plus Ys in. in order to have a place to start sawing this miter. Thus the treads must be crosscut to 377/s in . long; this requires purchasing 42-in. stock. Using the table saw, router or shaper, make the Y4-in . tongue on the back edge of each tread , and the %-in . groove on the under­ side where the riser fits . The spindle shaper is the right machine for these operations, and is essential in the small stair shop because it will also produce moldings, nosings and handrails. Lay out the nosing miter. On the table saw , crosscut to within 2 in . of the miter, cut the miter itself, then re­ move the waste .

Section through step

T 3/. Architects often specify a rabbet-and-groove joint between riser and tread. Because there is usually a space between the top of the riser and the bottom of the groove, this joint is weak, and the nosing is likely to crack in use.

Rise, 7'/.

�oC(o;----___________ ___."...,.� ( �

i.

Return nosing

Plan of tread

Ton ue,

1 Y. \