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3 50
OTES FROM
T SHOP
O 64
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Woodsmim
W
h at's th e m ost diffic ult th in g a bo ut
bu ild in g a c ha ir?
The joinery? M aybe , .. because you're
fa ce d w ith a lot of menise an d te non jom ts ,
Although they 're not th e easiest join t to
mak e. th ey 're not lhat diff icu lt ei th er. Uyou
C 3 J l
drill a se ri es
O f
hole s, youve just about
go t a mort ise mad e, A nd
you ca n cut a
ra bbe t on th e end of board. you're hal fway
to
fo rm ing
a
tenon.
\V ell, how about the curved p ie ce s on a
chair? M ost ch airs hav e curved back legs or
curved staison th e b ack th at c on form to th e
shape 01 the occupant. A ny th in g th at's
curved isalittle m ore difficu lt to m ak e. And
th ere 's a lso th e im ag e o f b e nd in g
thep ieces
10
th e
curved
shape . BUIcurvcdpieeesdon 't
have
to b e
bn l
pieces,
T h e cu rv e d p ie c e so n
th e c hairs sh ow n in th is issu e are e a si ly cu t
on
a
band
saw.
O kay, you can cut a curved back le g On a
b a n d saw b u t i ts an es
u
ye ar (usuaUy on
Thanks
giving. Chr is tm as . an d far nlly reun ions) .
h eresto fthe tim eyou have tocon tcnd w ith
th at crack in tile middl e of the tab le.
The so lu tlom Build a tab le w ith a so lid top
(n ot cu t in ha ll) and pul tile lea ves on r u n -
ner s so th ey can be pulled out al tile end of
th e ta b le to extend it s size.
This sy ste m is nO lhing new . B ut it is so rt
o f a m in d tw iste r to e xp la in .1 1le id ea
is
that
Ib e e xte nsio n le a e s
ar e
O n ru nn er s. T he se
r unner s a re m ounted at an angle under the
lable top . 'V ben )'ou lin up the top (it
just
lIoats
on th e 1 t R S a nd a pr on s) .
the extea
s ion leafcan
bepulled
out . S in ce t he r un ne rs
ar e mou nte d a t a n a ng le . tile le af w in raise up
10b e lev el w ith th e s ur fa c e o tt he t ab te top.
lralso
mea ns th e le av es
ar e
always
part
of
the lable - not S iored in the closet w here
th ey m igh t
warp
o r c o uld b e sc ra tc hed. Al l in
all. this
extension
design makes a nice
dinin g roo m lab le fo r the 362 days. yea r
when
th l v s r
lot exte nd ed .
NEw P,ICES, There co mes time when a
busines s nee ds financial guida nce . If noth
in g else, you ha ve to know wh ere y ou stand,
and predict w h er e y ou 'r e g oin g , Thauneans
accounting .
P au l G ray has joined us as ou r co rpo ra te
controller. Fortunately, he's also a w ood
wo rk er (a ndw 3sa su bsc rib er 1 0 l oodsmit ir
ev en before he was hired), so he has an un
del'S Wlding w hy w e spend so m uch m on ey
wood and p ow e r to o ls .
S \ TISSUE .The next
tssue
of Voodsmit ir
(N o. 65) w in
be
maile d d ur in ) th e w ee k o f
October30, 1989.
Sawdust
COLUMNDITORS
WOODSM rT H
(ISSN 0164-4114)
is pub-
l ished btmonth ly (February. Apnl. June ,
August. October, December) by
Woodsmith Publishing Co 2200 Grand
A ve D es MoInes, IA 50312 -
Woodsmlth Is a registered
trademark
of
Wo o dsm ilh Pub lIS h ing Co.
Ii: Copyrfght
1989
by Woodsmtlh
Publislr
ing C o. All
Rlghls R esolVed,
Subscriptions: One year
(6
issues)
$15 .95 , Tw o Yea rs (1 2 Iss ue s) 527.95.
Canada and
F ore ign:
add
S2
per
ye ar , U ,S .
fu n ds o nly , S in gle
copy
price, 53 .SO .
Secone Class Postage Paie
at Des
Molnes,
I o w a
Postmaster:
Send C h a n g e o f address
10
WoodsmIth. Box
491. t
Moms. IL61054.
S U B SC R I PT IO N Q U E SllO N S ? caJl8OC).
43 Hl715
(IL residents:
8QO.892 ' ( )753),
7 :30 A M
10
8 :3 0 P M .
CST.
weeI
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3
oodsmith
o. 64
you'd like to shar e a tip
with others. send in
your
idea
t o Wcodsrnhh. Tips .Tec h
niques, 22 00 Grand A ve,,Des
M oines , Iowa 50312 .
\Ve pay $15 for ac ce pted
tips,
Pl ea se s end an exp lana
tion an d a sk etch il needed
we ll
draw -a new one) .
SEND IN YOUIrTIPS
Placing clam ping blocks be
tw ee n p ads on a C
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4
W oodsmith
No. 64
i ng t hi s t ab le is very s tra igh t
forward.
The j oin er y is n't
com plicated and the only hardw are you Deed is lo ur
hanger
bolts
an d
a few screws.
CI1T11NG1HTOJ .
Thetopand th e le av es on th is table
a re cu tf rom a si ng le s he et o fo ak pJ yv . o od . T o make
th e
g ra in o f t h e
plywood t P
match
up
wit lt the
leaves.
laid
ou l
mycutsasiflbe leavcs
were p rto lth e to p.
see
th e
CutlingDiagram.
Since
th e l ea ve s f it
unde r
th e ta ble to p
w h e n
in
th e
s to re d p os it io n) . t he y are
slightly
smal ler (narrower)
than
the
top.
see
th e Detail
in
the Exp lo ded \rlCw.
11IELEes. One o th er interest ing {eatoreon this table
ismeleg s,a od bo wlh ey rem ow >ted to th eap ro ns. T he
leg s
are
mounted
so
they stand at a
5
angle
They re
mounted to the table's aprons w ilh corner blocks and
ha nge r bo lts . Thisroakesthemremovableand
theycan
also be tighlened if th ey loosen ove r tim e .
FINISH. T o provid e th e table w ith ex tra
pro tect ion
use d
two
co ats o fp olyurethane,
sanding
between coats.
he
b i gges t
problem w ilh this table is
Iry ing
10
ex plain h ow work s. had such a hard lim e
explaining
m e design 10 everyone. mal
inally
went
d ow n 1 0me s ho p a nd JU SI bu il l i l.
When in ished. everyone said. ' Tha(sniceDon.bul
I thought you said m is table h ad l ea ve s? I couldn'1
r es is t s ho w in g o ff
a
little; imp ly l if te d one end 01 m e
free Oooting
lOPand
pul led the
l .aHrom
Imdn-Ih~ blt.
I
didn 'l
evengerachanee
10pul lou l theothcrleaCbcfore
someooe f iRedme tab le 101>011o see ho w worked.
HOW rrwORXS .
O n m ost exten sio n tab les th e la ble
t op i s c ut in h al an d eac h h aln s atta ch ed to so me so rt
o f r un ne rs . T o e xt en d
Ihe tableyou
pull Olehalves
81
and the leavcsdropin-on top e f t he r un ne rs .
Wi th thi s tabte th e
leat C
a re a tt ac he d t o Ole runners.
W h en y ou
wanuocxte nd the
ta ble. lift uponeend
ofth e
top and pun out a leaf. W hen the lea f is lu lly exte nde d
me top d ro ps d ow n an d
rests
on tO l'
of
th e ru nners.
O nce y ou
unders tand
ho w the ru nn ers w ork .
bui ld-
loo ks like a stand ard D an ish M od em table B ut b eneath the to p
are
tw O
extensio n tvin gs that
ad d
another
43 to
th e o v er aU le ng th
B u t
wait
a m in ute ho tv do tho se
exrensions
a ctu a lly tv o rk?
ining able
FE TURE PROJECT
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W.oodsmith
N
N
N
N
~LSONEDlD ONE 4
x
8
OF~.& tYWOODFOR TA U
TO P N D Lf VE S
M
~x ~64 5.8 8d. Ft.
M
13 . )
s
100 6.9
ad.
Ft.)
J
L
o
I
a
J
~~xS60
2.18d.Ft.
I J
CUnlNG DIAGRAM
SUPPORT A R M G U ID ED
SU PPO R T C R R IG E
5O ,G 4
G U ID ES K EEP TO P
CENTEREO
ON
B SE
UfTfDGf
OFTA8lt
--
._--_
---~
~
TOP
TABLETOP
@
TOP EDGING
These pleclil$
9 e
0/, P ywbGd,
d X
MV,,
5 A :
x~~ ~33
,,., x
1~~56gh
., x
1 -36
rgh,
Il
x AI,
35
rgh,
I . ,
A I - 22 rgh,
~.,lt31 '-4W,
x
3., - 27%
1x3-'
If,) ,2 -
2 1
414 2
V~
~ . x
2 1 - 2 - I W ,
10/,
x
2\(4- 9 >
10/ ,
x
3 - 2 7 1 - 2
'4x2'h-6
A TGP(l)'
B leaves 2)
C S I d T1) E d g l< lg 2
o EndTol) Edging (2)
E
Eod
leal edging (4)
F
S t < f e
leo Edging (4)
G Side'AplOns(2)
H EndJ\prons(2)
I CGmer l l o < : I < . S (4)
J Top Bloce.(2)
K LowerBloce l)
l Crosssroess (4)
M
SUj)portArmo(4)
N LegS 4)
o
GuldG (2 l
M A TERIA LS LIS T
PUll. lEAf
ST RAlGHT O U f
LEAFEXTENSION DETAIL
1
EXPLODED VIEW
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Woodsm i[n
The next phase is to
make
the four
aprons th at hold the
j eg s t og et ll er. The
sideapro ns(G) ar e
very easy -
just
cu t
tw o
pieces of
: tI _
th ick stock 3 Ii l
w ide b~ 47. lo ng.
The end aprons H) ar e al so 3 1 i l w ide, bu t
only 2 1 0 / lon g.
i o O T C H
E~APRONS.
Alter th e
end aprons
ar e cu t to length, you have
to
la you t th e
locationoltwo not ches . Tbesenotchesal low
Ihe le afs I\P po r1 s to b e p ull ed out. re fe r to th e
Explod ed V iew .
Tbe notches in each end apron are in
diff e l en \ positio ns so th aI th e leaf sUPPOr1S
w ill b ypass each other under the ta bl e. To
mak e th e no tches , ra is e th e blade on th e
table saw to cut 10/ 16 deep. The n make re
petitive pas se s to waste 6ut th e notches
A lter th e not ches hav e be en-cu t, use a rasp
N CHESfOR
S U PP O RT A R MS
l~~ I)E(JI
,.
DG EGUIDE
No. 64
(0fo rm a slightbevelon the bottom ofalHour aprons. These k erfs m atch liP w ith k erfs
n
no tches. This bev el should slop e tow ard th e the corner bl ocks
(I )
so splines can be use d
im ide a ce 0 1 th e end ap ron s (H). se e Fig . 5 . t o a l ig n t he a pr on s to th e com er b lo cks. Cut
KllRfS fOR .SPLINES. T o c omple te O le these kerfs 1\ I from the end of each apron ,
aprons,
kerfs
are
cu t
at
bot h ends
o r
al l four
V 4
dee p .
se e
Fig. 4.
4
ROUT
CON1 Ql
ClOCKWIS
NOTE'
TRIM[OGING RUSH
RIP FtNCE
R IP F E NC E
3
edg inj1 p ie ce s ( C,D ). a ls o r ou t
a \-i n
ro und
over on th e i71 sW bottom edge, se e Fig . 2.
APPLY EDGING .N ow tb e edging can be
g lue d and clam ped to the plywood. M ite rth e
endsoffuetopedging pi e ce s (C .D ) an d glu e
th em to the ta ble to p (A) . (F or some tips on
th is.
se e
page 11. ) Al so m it er an d glue the
leaf
edging
< E . I
tothe
lea ves
(8).
Whe n the g lue is dr y . tr im the edging
fl ush w ith the p lywood .
0
used a Dus h trim
ro uter jig . s ee IVoo dst it il N o . 6 2 .) 1 11 e e dg
ing on th e le av es (B ) is trim med 6ush
with
both th e to p and
the bortom face
of each leaf .
ROUN I) OVER EOGING .1 0 complet e th e
top edgi ng, usea If. round-over bitan d rout
the
O il/side to p an d
bottom
edges.
see
,, t g .
3.
EDGLNC
After the
longue is
routed,
yo u
can cu t th e fou r top edging p iece s (C,D).
Th ese pieces are
re s awn ro l ; : J thick
an d
thenripped to 1W' w ide. see F ig. 2.They re
cuttc
rough
length
ab out2 lon g er th an
the
sides and ends of th e p lywood top. A ls o c ut
th e eigh t ?lstw ide lear edging piece s (E,F),
se e F ig .
2.
GROOV ll N EJ)(;ING .
The
ed ging is j oined
to the plywoodpieces by cutting a ~ -w ide
groove (to match th e to ngue) on th e in side
f ac eo f e ac h piece. The g roov e is positioned
sowhen theedging isrnounted.thetopedge
sticks up ab out V t6 above the topface of the
plywoo d. (It's tr imm ed flu sh later.)
ROUNDIlJ )GE. Bef ore mounting the
top
TOP AND LEAVES
11\c table begins
by
making the.top.I cu t
th e p ly woo d (or th e
top A an d the tw o
leaves a to size
re fe r to th e Exploded
View on
page
5
RQfJJ TONGUE.In
order to mount the,
edging pieces thatcovertheplywood edges,
I
routed tong ue on
al l
the edges of each
plywood piec e. T o do th is, m ount an edge
gui de and li t straJgbt bi t in the ro ute r, s ee
F ig . 1.
Then
rout a ra bbe t on the tOP a nd
bo ttom fac es 01 tile plYwood to produ ce
vs -thick tongue, see F ig. 1a.
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oodsm ith
o. 64
GlUECoaNEQ:
8 OtKAND
SPUNEnuSh
wmt
TOP OF APROm
MAS )NfTt
PUNE
Pilot iO~
NT~~ N
ntJCKNESS
Of ltG
1 ;. a
W S H E R _
NONtn
_16
x
5
KANGEll80LT
10
ORJU~6
PI\OTHOlf
TQAOfPrt-l
Of
21n
LE G
H O LO C O R NE R
8LOCt :nGHT
AGAINST
F NCE
bl oc k isse r backfr om the ends of the ap rons,
refer
10 F ig .
8a .
SUANKItOIJ . Later. the leg s are mou nted
to
the
corner bloc ks with
:Vs -&a.
hanger
bo lt s. To prepare lor mou nting thes e bolls.
d rill a -& a .
sh an k h ole o n th e
driU
pr ess .
Cen ter the ho le On lb e in side lace of ilte
comer bloc k.
see
Fig .
8.
ASSEMBlE T IlE APRONS.Now tile aprons
ca n be assembled by g luing and cl amping
th e
COmer blocks
inp la cewi th
l1i
M asoni te
splines,
see F ig .
Sa. (used
a clamping bl oc k
to su pp ort theCdamp and ho ld the comer
square.
(See
S ho p NO les
on page 1 0
fo r
mor e on th is
techn ique)
saw
blade
a t 45
an d cut
a
bevel
o ff o ne
end
of each leg blank, se e F ig .
6.Now tum
IbeJeg
bla nk o ver an d
cut
ila g ain to form a trlal1 gu
lar-shaped, piec e so one corner has
3 l) t
w ide f iat face . see Fig .
S a.
KEJ .t FTHE BLOCKS .
T he co rn er blocks are
kerf ed to ac cept
1 1 1
Masonite splines . Thes e
sp lines
align
the corner blocks to the kerfs
ill
th e
apr ons (G.H ).
Start by po sitio nin g the .saw fence lk
from the blade , an d settin g Ute blade he ig ht
to
V 4 se e
F ig . 78 . Then cur
a kerf in both
beveled
s ideso f
th e
co rn e r
blocks.
see -F ig .
7.
Note: The kerfs in the apr ons ar e only
IV4 from the end oHheap ,n so Ih ecomer
The next step is
to
cu t an d, shape the
leg s
(N).
F irs t,
ut
the m to a fini shed
length
of27 W '.
CliM1PER UGS.
The in side edg es of
each leg (N ) are
chamfered so
the
leg can butt a g ain st t he apro nsa ta4S ' an g le.
Begin
by
setting the bla de to
45
an d
po si
tio n
thesawfence
fromtheblade,
se e F ig
9a . Now . cu t a ch am fer on one edg e. th en
tum the
pl ecea roun d
an d
cbam fe rth e o th e r
edge. TbisshouJd leavea-V. w ide n at on Ihe
in side fac e o f t he le g. se e F ig . 9.
ROUND EDGES.
Arte r the leg s are
chamfered. routed
both
oul$ideedg es w ith
a
roun d-over bit; see F ig . 9.
Pll..OTHOl.ES.
The leg s are joine d to the
comer bloc ks
wit l,
a % '< Iio.hanger bolt.To
d o this. d r il l a pilot hole 1
down (r om the
to p
an d
cente re d
on th e
\ 1 1
na t on
th e
inside
(a ce of
theleg,
see F ig .lO .
N ow . a tta ch I he loglo the co mer block by
sc rewing in a hang er bo lt, se e F ig . 11. (F or
details. see S h op No te s. pag e 11.)
LEGS
BL NK
6
The T:able apr on s
a re h eld togerner
at
each corner
with
a
co rn er
block (1).
-S ince
the
COtner
blocks ar e cut from
tbe sam e sjze
stock
as the legs (N ).
m ad e th e leg blanks
4 long erthan needed an d cu t a c omer block
(I) tthe end of each l eg b la nk.
ClTI TRE ~I..OCKS.
So-star t by cutti ng four
leg blanks from 1:v , th ic k stock. Cut the
blanks to. w idth 0 3 an d a le ng th o f31:.. .
The n to make the comer bloc ks. s et th e
CORMER BLOCKS
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ENDVJEW
No. 64
'''.
ROUND
OVrR
SU PPORT ARM
W oodsmith
15
th ee nd close st 10 th e notch, see Fig . 14.The
ta pe r s ta rt s 1 ' 2 in front of the no tch and
ta pers 10 th e end so irs 10/,,;, ' w ide. see Fig.
15. Shop Note:
J
use d Ih e ta pe r jig fea tu red
in lVoodsmithNo 6
SOFrEN 1 HE E ND . N e xt, file th e b ott om
co mer of e a c h arm to a
0 / ,
r ad iu s, se e F ig .
14 .Thenfinish t he s uppo rts by ro uting a II i
reundover on bo th bottom edges.
i
~ 9 ~
SUPPORT ARM
NOTCH _DETAi l l COA~ R
TO A :f RADIUS
TOP
curNOTCAF.S.llach arm isnolched so th e
edging 0) on the ta ble lO P can fit into it,
(See
Detail in Explode d
View.)
Loca le th e
l - de ep n o tc he s 2 O Y z in F ro m the end of th e
support a rms. se e
F ig
14 . To cut th e notch.
use th esam e methodason the a pr on s ( refer
10Fig . < t) . but lea ve th eiboucm flat
TAPER SUPPORT ARMS. After (lu ttin g the
n otch , tap er the lop of ea ch SUPP9rt an n at
TAPER S TA AT S 11h
IN F RO NT O F N O TC M
SUPPO) T ARM
14
Thefour support arms (M) ar e thekey to
making Ib is ta ble wo rk . S in ce y ou w a nt th e
leav es to
slide
up 10 be level w ith the mai n
to p, I tapered the lOP edg e o [ each arm so
tha t th e lea ves ar e le vel w ith the lOPwh e n
extended.
cur I1IE BlA N KS .T o m ake th e support
arms (M )'i>eg in by cu ttin g l:V. t h ic k s tock.
V 4 w id e by 4 9lh . long.
SUPPORT RMS
~ CR _OSS RACE
< D
br ace s (L ).seeFig.13a.
TOP BRACES. Nowturn the ta ble over-an d
screw uie tw o top b ra ces 0 to the to p o f t he
ap ro ns. T he y should be f lu sh w i th
the out-
sideofthe aprons a nd th eir ed ges Jlush w ith
th e end s of
th e
c ro ss bra ces (L ). se e Fig . 13 .
Next slide the
remaining
two cross
braces (L) betw ee n th e to p braces
0
an d
th e
lo w er b ra ce (K )
andsc rew
th em in place.
I -TOP
BRACtS
_ -
'~.
TOP8RAC E
J
NDVI~W
CNTt:R CROSS RACtS ON
LfN GTH Of S IO A PR ON2
A ITACB CRqSS BRACES.
W he. n all the
pieces arecutto size, screw twoo thecross
braces
L)
to th e ins ide fa ces of the si de
ap rons (G ). se e F ig . 1 3. C e nter th e li ra ce o n
the length of Ihe apron and screw it to th e
a pr on s ot he lo pedgesare flus h, see F ig.12a .
.OWER SIM CE. W ith the c ro ss b ra ces at
tached. tum
ihe table
over and screw
the
low er brace (K ) to (he ce nt er of the cross
W ith the legs (N ) attached to the ap ron as
semblY,1 sta rted w orkingon thesupportcar
r ia ge wh i ch g ui de s t he s up po rt arms
(M).
cu r l'I .C Ii S TO sIZE U th e pieces (or th e
support carriage ar e m ad e
from
:v. thick
stock.S ta rt b y cuntngfourcross braces (L)
2lh. w ide by lo:Y.i long . N ext, cut tw o
top
br ace s
J
2
w id e by ,29. long . Then cut a
low er brace K 2 w id e by 28\1., long.
SUPPORT RM C RRI GE
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oodsm im
GUIDE
( Tt::
NOTE: GUIDEPRfV[NTS TABU TOP FROM SHIftiNG
~
N GT M O F 1H I T Ae u:
8
placing a piece of dou ble-sided c ar pe t ta pe
O n the
g uid es and
checking ihefit,
Exceptfo r apply ing the finish . th e ta ble is
complete. T he table
le avesshculd
sl ide
out
easily when li te ta ble top is l if ted.
si de lo p edging (C ), mar k lines 3
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1 0 N o. 6 4oodslllith
a CLA MP lf < fO P Rl S 5U R I
CI. AMptNO
(IOCI K_-;;
u f s T
1
fo
-
C U T M O C K
t
R O M . 2 1 i1 4
. . . . J - _ _ - _
I
6- ...
SECOND:
UT UT_
~
AtiAW11l .r il l a % hole in
a piece o f
~
plywoo d an d in se rt a sh o rt
len gth o l% o ([ i. dowel. N ow . c lam pthe ply.
woo d 1 0 th e d rill p re ss S Oth e dowel is 1/16
b ehi nd th e b ack
e d g e
01 the bit .
se e
Fig .
3 .
T oa lign the S lo p . m a rk
a
referenee li neo n
th e p lywo o d s tra ig hl o u t
f r o m
th e ce nter o f
the dowel. A s th e p ly wo od b a s e is c l amped
down. al ign th e ce nte r 0 1the b it o n th is line.
ORJ U i\IORl1S~
ow the rn o rt isescan be
roughed cut on the drill press. (F o r m o re
in fo n na tio n o n d rillin g mort ises, s ee S ho p
N otes . page 10. )As ea ch ho leisdrilled , kee p
the fr o nt edge o f the temp l a te a ga in st the
s top
pin.
a nd the back edg e 90 ' to the refe r
e nc e lin e o n th e p ly wo o d b as e. see F ,g . 3 .
CUT OIIT LEG . W hen Ihe t empla te is
completed . y ou ca n b e g i n work o n th e back
leg) (A). I
w a s ab le to get tw o b a ck le gs OUI
cr one IVt6 blank
Ih81
m easu red
Sv ..
by 3 9
(see lb e C u tti ng l)illgnlJll Onpage 13 ).
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Sfl fUl1
.
OUND-
V l rT
4
O PP O S ITE
( es
Woodsmith
12
15
NOTE:
MAKEFRON T trGS
A M IR R O R E D S E T
N o. 64
2 x 4 as a fe nc e to the lop of the drill press
table
W hen you
drill
O ut (he m ortises on adja
cent sid es, th e b otto ms w ill b reak th ro ug h
v er y s li ghUy
into
each other, see
F'tg. 11.
111arS
okay , the t enonswiU
be
c ut ba ck la ter
wh er e U t eyme e t.
R O U N D
OVER
ED C F 5 After squaring up
O le mo rt is es w itb
a
ch isel. I ro unded over
the edges and ends of the (ront tegs on the
ro ute r ta ble . F ir st , r ou nd o ve r th e tw o e dg es
nearest th e mortises w i th a
round-over
bi t
se t : V , 6
hig h, s ee S te ps
1
an d
2
in Fig.
12.
T hen .. . ise Ihebitlo [out a full
1 4
round
overon Ole insid e ed ge (S te p3 ) an d b oth top
and bottom ends. F inally . sw itch to a
round -over b it a nd rouuheoutsideedge.see
Step4 .
CUT ~ORnS
1 tI 6
FROM 00110
( 5
11
(8) asthe tw o m ortises on th e b ac k leg
(A).
No te thatthemcrtlsesareeet c en te re d o n
the thickness. but '/1 6 from (he
outsi
e dg e o fe ac h leg. (H ere's w here you have 1 0
start t lt ink ing o f
the
tw o
front legs.as arnir-
ro re d s et .)
A fter U te m ortises are layed out on the
b ac k face o f each te g. lay ou t a 1% .lon g
mo rt is e o n th e
inside
face o f
each
le g t ojoin
to U te Iren t seat rail
(I ),
s ee F ig . 1 1 . L oc ate
t h e s e mortises
1 4 1 1 1 6
up from th e bottom
e n d o f th e le gs, ? l 1 6 fr om the out si de e dg e.
A nd be sure they fac e e a ch o th er , ( /\g ain . so
you end up w ith a m irrored set Q l egs.)
cu r MOtmSES
N o w you
can
drill
ou t all
t he ~ 6 -d ee p mo rtis es o n th e drill press. (As
before , to h elp p ositio n
U w
mo rtis e i n
re la -
lion to the edge o f Ute leg. c l a m p a straight
SC RA P
UN O R
MORTIS5 TO lVtL lfG
At
th is point. the
back legs
C A )
ar e
com plete. N ow you
can begin w ork on
the froo t leg s B .
It's critical lbat the
m o rtis es in th e
front
l eg s a lig n w it h
t h o s e
in th e
back
legs.
CuTtING Tl\E PlEeES Start m ak in g th e
front legs by cutting out two blocks J W
s q u a r e
b y 1m l on g.
MOROSE
l YourO nce the blo ck s a re cut
to size. layout two v. . \videmortises on the
ba ck face of each leg to iOln t o t he side-rails
(C , 0), see F ig.
n.
T hese m ortises are lo
cated
th e sa me
distances (1 2:V t6 and
J 5 J G )
f r o m
t he b ot tom
e n d o f th e f ro n t
leg
nUSHNDS
, ,
scrap block under the m ortise locations to
r ai se t he leg up.o ff th e d rill p re ss t ab le . s ee
Fig. 9 . ( S tic k th e blo ck t o t he legwith doub le
side d c ar pet tape.)
N o w , d rill ~ 8 - d ee p mo rtis es . m o vin g lb e
s p a c e r
b lo ck a lo ng with the leg as you driU .
C om plete the m ortises by squaring up lbe
e n d s
w ith . ch isel.
ROUND OVER EDGES
W hen all U te
mor-
t is es a recu i in t he b ac k leg , th e o nly s te p le ft
is-to round over U te edges and ends. To do
this. u se a
W I
round-over bi tset
: V i 6
high in
Ute rou te r
t ab le , s ee .F i g. 1 0 .
N o w m easure up 1 2 1 1 1 6 a nd 1 50 )'1 6 rom
the end of the fram ing square to m ark the
bottom of
th e
mortises.The
low er mo rti se is
W 'long and th e upper one 1% Ion g.
DR Ill o u r MORTISES .
T o drill out these
mortises start by c lamping a s traig ht pie ce
o f 2 x4 to th e d rill p re ss taille a s a fe nce, see
Fig.
9 .
Po~ ition
th e
fen ce so
th e
\ I ,
b it
is
c en tered o n th e th ic kn ess o fth e le g.
S in ce th e b ack of th e le g is c ur ve d. th ere
isn ta longenough flat sp oto n it to allow the
leg to sit dow n flat on the drill press table. I
solved this problem by putting a 5 '.long
BACK LEGS
C O N n N U E D
A fter d rim n~ o ut fiv e m ortises fo r th e slats
an d
o ne fo r th e b ack rail. y ou
can
b eg in l ay
ing out
th e
mortises
01 1
th e
J mt
edge of
e ach b ack leg . T h ese m ortises w ill h old th e
side seat rail
(C)
an d lo wer sid e ra il
(D).
MORTISE IAYOl1 l'. The trick is to l ay ou t
the mort ises so they w i llbeatthe e xa ct s ame
lo ca tio n o n b oth
legs,
B egin by laying one
leg dow n on its side at the end a b ench .
Then lay
d o w n
a
f ra rn in g s q ua re s o
one ann
of t he sq ua re is Ilu sh w ith th e e n d o f th e
b en ch an d
the
other arm rests against the
ilatsectiOQ o n th e fro nt o f th e l eg . s ee Fig . 8.
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N o. 64
oodsm ith
6
ROurV. --
~OUNQO, fR
U FOUR t: DGts
DONT ROUND
OvtR tENONS
lOCAlE
ffl
NAIL S1U IG HT D OWN
FROM CENnR or TOOLATt
r
SQOA.t TtMPLAT
TO C(NTERUNf
FA lliN T EM PL AT E
TO N
7/24/2019 Woodsmith - 064
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\Voodsmith
I ~
SPACE -
ATCORNRS
17
,
THAN DISTANCE
8FTWEtN RAllS
SEAT
_ < D
I . . . . .
-- 8E1WEN SEAT _
A ND S lO E R AILS
_
23
)~8xlin
S(lI:W
I
No. 64
ASSEMBLY AND SEAT
I s tar ted assembling th e eba i by gl,\ ingan ci
~ ~ - ~ ~ ~ : ~ T ~ o ~ P ~ V ~ ~ E W ~ = = = : : - 1
lamping each
side
independen tl y. Connect ~
th e fronl an d ba ck le gs w it b t ile s id e ra il s
checking Ib at th e assembly is sq uare.
A ilerthe side un it s a re Jl ry ,glue
tile
fron t
andback r a ils and the ba ckslatsbetw ee n th e
si de units t o c o m plete th ec hair. (S hop Note :
I as sembled the cha ir on to p of my tab le saw
since it s th e flatte st s ur face in m~ shop.)
CLEATThe plywood sea t is m ounte d to a
bac k cleat (H) th a t's glue d t o t h e fr ontface
o th e ba c k s ea t
rail (E).
se e F ig. 23 , To al
ta ch th e s ea t, d ri ll s crew h ole s t hrough U le
b ac k c le at a nd
thefront
se a t rail
( 1 , ) .
SEA T.
The last piece
10
m ake is Il le ~ .
plywoo d ..t(l). se e F1g.22.rt'scultoover
bang I l l on th e fro nt) but leave space
be tween th e sid es a nd c om ers oftheseatfor
the upholstery . (For more on the
uph olste ry , s ee th e a rticl e on p ag e 1 9,)
Bef ore up holstering th e seal rout a
r t
roundove ron th e to p and bo tt om edges and
;,,1~
ound ove runderthe ro n t e d g e s e e F i g
24. Finally , a f te r f in i sh in g th e c ha ir, screw
the upholstered s ea tin place.
~
~
1
j
21
~
8ACKlfO
f
NOTE: AllllAflS t a o THICK
a. 1 -
.~
f I
161~
-.
J . . . , .
1_
. r
B AC K S EA T R AIL
r
~~ 2
0 , '1 [1
r
f~
1.s1~.
0
fR ON T SE AT R AIL
~
jONf PlfC)
. _U
.--
1/4' J/-
P ~
I
j~.~'
il
14~
d
.....?
, . 0
S EA T S ID E R A IL S
..,,j; ~
T WO P IE CE S)
~J ~~
f
,
I.;
lJ:
14 \0\ .
[
J6 _P;
J'-~.
I
a
0
NOTE:
t
@ L OW E R S ID E R AilS
1/... ROUNDOvtR
TWO PIECES)
ON AU
FOU R
lOGES
NOTCH80nOM OF.sIDlsrAI
RAJI. TtN ON WHOtt ff MOTS
lA CK SE AT RA IL TNON
w ith a V rouud-overbircn Ole router table.
refe r t o F ig,
19
NOTCH
.\N O
CFlt\,\r ER ttN ONS.
There
ar e
a
couple
m ore thin gs th ai
ha ve
10 be done
before assembly .
When
the ra il s are
mounted into the leg s. th e
te nonsonheseat
side rails
(C) will
ru n in t o t he ba ck and front
seat.rai ls
(E,F),
se e F ig, 21 .
To solve th is problem at th e back leg . I
notc hed th e bottom olthe tenons Onthe se al
sie le m ils , S in ce th e o verlap at ti le front is
ve ry
slight
you only need
10
chamfer th e
tenons o f the-sid e a nd fro nt s ee
t
rail s.
The b ac k s ea t
rail
(E) is cut th e sam e
length as
th e
bac k sl als
(l6W ),
Since
rh e
fr ont legs are th icker. th an the b ack legs , th e
fr ont-seat rail
(E)
is 0 / 1 1 ; shorter (15 1l. ).
ecrrexexs.
M er
ali ofthe
pieces a re cu i
to l eng th, nextcut~'' ' . long tenons ce ntered
on nee nd so fall ti le ra il s. se c Fig 20a. CU i
the t enons to thickn es s an d w idth t o fi t th e
mortises in lh ele gs (l% w id etenonson the
s ea t rai ls an d
%(l~w ide _
tenons on the low er
side m ils) ,
ROUND OVE R EDGES. Next, round over all
fou r edge s of e a ch ra il ( but not th e te nons)
N ext. you ca n make
the seat- rails and
side
ra ils.
I
started
by resawing. enough
wood
for the four
seat rails and two
lower side rails to
B
Ulick.
cerro
SIZE.No w,
cu t all o f th e s ea l r ail s 2 w ide-and thelower
si de ra ils 1 w id e. se e F ig.,20,Asfo r length.
th e seat sid e raiJs-(C)
an d
the lower si de
ra ils
(D)
a re b oth C uI14W':lo ng,
SEAT RAILS
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18
N o. 64
I.OwOt t
~
TRIM Off SHOU LD ER
WITH ECQN'I) dJT
FIRS T C UT lE AVES '0
SH O U L D 1 l O N BOTTO M
ClAMP
W O RKPttCI
BI;AN K
8ANOSAWN ,
.OG .
1/1- OVQs.Zf)__.,.....
lUSH
T R M T
NOli: KEEP1tMPlAlt
PARAlliL TO SlADt:
Woodsmi rh
1C IIP flNGIRS
( lEASt a r T
2
;. MASONITt
R
.
MASONITtl
TlMPiATIi
ANOS'AW
s o it s ra ised up h igh enough to rub aga ins t
th e
templ te
no t the rough
edge
o f the
w o rkp ie -ce . The tr ick to th is an n is to rou n d
th e en d. an d th en cut a no tch fo r yo ur blad e
toJilin.
I
cuta
%
notch fo r the
V .
band saw
blad e
se d.) N ow clam p the guide 3rDl1O
th e tab leso
th e
bladeis
V s
Jromthe
outside
ed ge o fih e cu rv ed e nd , s ee F ig .la.
To cut out
Ute
le g. push th e
leg blank
so
the temp lat e rub sa, gain so th cg uid e arm , s ee
F 1 8 .
2 .
As y ou 're c uttin g, m o ve th e r ,a il
e n d
o f
th e blank to th e rig hl o r left to k eep U te tem
p la te p ar al le l t o th e blade.
ROlTI1NGTO f'tNALSHAPE.
After
t he wo r k
piece is cut overs i ze, y ou c an ro uto ffthe las t
V.ls'twtrh a flush trim bi t on ihe router table .
I o r s o u r e e s o tf lu s h
trim
bits,
seepllge24.)
W i lb t he t em p la te still taped to lite to p o f
theworkpie ce , r ai se ti\ e bitup untilthe bear
io g r id es O il lite edge o f the tem plate, se e
S tel) 1 ill
Fig.
4 . Then
rout
in
a
clockwise
directio n around the bit. see F ig. 3.
Since the O ush trim bit u se d o nly hasa
1 Io ng cutting ed ge aod Ute le g is IV ;
thick Ihad
to
lowerthe bitto
m a ke a s ec on d
cu t. see Step 2 in Fig. 4 . (Note: You hav e. to
use a
v
s hank H us h
trim
bit
when
routing
a pi ec e I bis th ick . T he
s ha n k
o f a ~ s ha nk
b it wou ld
mb
a gain st th e w ork piece on lite
f il Stc ut) Th eO u s h tr im b it
will
c ut th e l eg to
the exactshape ofthe template
GU lO.tARM MU f .
STfCKAaoVE
Using empl tes
Ne >..1,cu t th e sh a pe again, b u t th is tim e
carefully-so it s\ l16 o v ers iz e . ( S in ce thenext
step is to rout the leg to exact size , there s
le ss ch ip ou t w hen o nly rou ting o ff
116 .) A l
th ougb yo u
ca n
m ake th is cut freeh and ,
c lam pe d a g uid e 311n 10 the band saw to
make a mo r e pre ci se c ut.
The
arm ls
m ad e fro m
a
p iec e o f
V M a
so nite glued to ihe top o f . l~ th ick blo ck .
s ee F ig .}, T he
mi
is m ounted to th e blo ck
TECHNIQUE
T
he trick to m aking unifo rm curved
b ac k le gs f O ril le c ha ir s ( sh own i n li tis
issue) is to use a template. the templat e
m ak es cu lling o ut lite pieces
a
simple t w o -
s te p o pe ratio n on a band saw and router
ta ble - a process that produces all the
piecesyou
want w ithth ee .x ac ts am e s hap e.
E~lPlAmu s e d
V 4
Ma so n i t e to m a k e
li te tem plate.
t s
an inexpensiv e.
hard
m a te ri a l that d o e sn t 1 13vevo id s o r kn o ts ,
and you can easily work a
SD100th
edge on
it.
lA Y 0111 ' PATl 'ERN .
Start
by lay ing
out
th e
pattern o f the chair leg o n the M a so nite.
(U se th e pro jec(s grid d r ,w io g. see pag e
l3 A n o t h e r
m eth od is to
e ut a
full-siz e pat
tem out o f pap er and glue itri ghtto the M a
so ni te , Then cut o ut t he .s h ap e s li ghUy o ver
s iz e . a nd care fully file righ t up to
th e
line.
1V 0RKcwtEFUILY.Any notchesor gouges
on theedgeottheternplatewillshowup
later
o n the
fi nis hed
pi ece s .
SO
it's i m po rta nt to
t a ke-th e tim e to w ork th e ed ges sm oo th .
Ir s
no t c ri ti ca l you r
templateisexactly the
same
a s t he p a tt er n.
Ifth e c ur ve is slightly
different. th at's okay . All yo r legs w ill he
identical- U leywil lma tch
you
template ,
CI lI 11N& ' l' O SHAPE . Af le r t he t emp la te is
made , a tt ach it to t he le g
blankwifh
doubl e
s id ed c ar pe t ta pe. T hen, ve.ry roughly
band
s aw I be leg o ut o f iheblan k so it's about 14
la rg er th an th e tem plat e.
WOODWORKING
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19
9
lI ith th t lalla .Ia p/td d o .... , . t reW>
th .
maill ing
fabric m ()lLnd Ihe
f ron ta>od back of thoplll~oood.S14pledow lt
fabric
w form (}
c r e a a t Ih e
r l ler .
6
CellI('/'
tI .I (/ (lm and t he p lywood
on
110 .back . i
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No. 64
Oldof gl l id ,o ,. , . TI l l
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Wooosmith
R om ul. ove r a U < YW' e d ullS o f / le I .
b a c J ; slat
1.it
a V s /'(>I ,dove,bitoil.
I re roiaer roble Rout1Uil liz.
pieayrom
tIL_
bit.
A/I6r allsi bMk .urt8 are.cut , sand
ofinaUJricknes.
/)yfeedin{j thembe-
tween
l
d) lt n sa ud er a 1z d
a
guide block
c ia.mpedto the drill >ress t ab le .
r
Sto
G i
11.3 S.d.
J
ALSO NfED 24
x
24 P IECE.Of ~~.. PLyWOOD FOR SlAl
H
: I
11A x 6V. . 60 f 3.3 3d. Fr.}
I
~ ~
CUnlNG DIAGRAM
OVIRAU DIMENSION S:
17 ~ I\Y .lC 3a H
FRONT UGS
K
I
BACK
SlAT
,
l= -
i
\ r
~K
//
l v l
CUA T
8A C K
S f A T R AIL
BACK SLAT
RAIL
CROSS SECTION
.
F R ON T
SlAT RAil
21o . 64
o cu; a 8IatofltltiforrJ~thickness
owmp J lt ideb lock 1))itkapointed.end
'/16
o : w q y from
i U
aatl l blade. TI ll{ / trim
of f
sfqJ,
o o l e gil/Weblock and blade.
K E E P
8W>'
P A R A L I l L W f TH
fRONT fACE OF StAT
9 J I 6
fROM
GUIO
8UXK
A IkK:klegs (2) r l t . x 4 39 rgh.
B Fr tLegs(2) l~x 1~17~
C SeatS/deRol~(2)%x2-14\'2
D LowerSide
Ra ils
(2)%
x 1 ld\'.
E BockSeotRolIl ~.x2-161~
F FrontSeatRoll~n x2 15'~'.
G Boc1
x 1'/16
- :20.
I
BOCkCf
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NOTE:
WOR.KONA
FlA T SURFACe.
THIRD:
ASS tM8Lf BA CK
UNIT aETWEtN
SIDE UN ITS TO
C O M PI ETI CH AI R
No. 64
FIRST:
ASSfMLf
10(uNns~-...
SECOND:
DRY ASEMau;
BACKSLAlS
IN TO R AC K
RAIls
11
C R Q SS S EC TI ON
13
121
i s
NOleH
.~ PLYWOOD , '.,,
A ROU N D t.GS SPA CE;
1-
-
14 ...lit OYfRHANG
i~
5 <
l,. L tSS
~N,04STANCE
BawtEN Slot RAIlS
14 ?1i
9 ROU
AU
fOUR
_s
NOTE:
DO NOt SQ .UARE
UP ENDS OF MORTISE S
Wooosmith
m ortises w ith a
W
bit on th e-drill press.
Sin ce th e backseat rai l
E)
i s s t ra ight. clamp
a
straightedg eto th e.drill press tab leto keep
thernortisescentered on theworkpiece. But
on
thecurved
to p r ail
C
yo u
w iU
ha ve to run
th e workpiece against a dowel stop pin as
when mortising the b ac k le gs, se e Fig. 8 .
ROUND OVER
.DGES.
M ter the mort ise s
are drilled (don 't sq uare them up), rou nd
overthe edgeso flboth
rails
w ith a
V ,,
round -
over bit,
see
Fi g.
9.Then
fit t h e sla ts in to t he
moruses.Ittbeyre
too
tight,
you may hav e
to
slighUy shave th e end s, se e Fig. 10.
BA C K S E A T R A IL
AND SACK
lO P. R A fl
ALIGN EN OS
O F R AIL S A HO
LAYOUT
MORlISS
W r TH S Q U A Rl
Wbenal l
Ule
jack
s la ts f it i nt o l he mo rt is es ,
th e c b. ai r ca n beassembled.
ASSEMBLY .Start by glu in g a from leg , s ide
ra ils . and back leg to (o rm a side unit . After
assem bling the other. si de unit, set b oth
units aside to dry .
Next, dry assem ble the ve rt ic al b ack sla ts
H
in to th e b ack rails{G,E). Theslatsarent
g lue d in sinc e Lhe re isn t anywhere they ca n
g o o nc e- th e c ha i{ is a ss em bled .
N ow fit
th e b ac k
assembly
an d
front
sea t
ra il
(F )
between
the
side
un its , s ee
Fig . 11.
To
keep lbe
chair
Silting
a.at I placed
th e
chair on to p o fmy ta ble s aw .
U, \CK CL> \T.
After the chai r is assembled,
gl ue.
back
cleat
I
to th e fr ont fa ce o ( th e
back seat rail
E),
see Fig. 13. Position th e
cl eat so it 'sJ, l. jdown (rom thetonedgeofthe
back seat rail.
SEAT.
Si nce the plywood
seatJ
on t hi s
chai r has to fit
lll.side
th e back sla ts, i\, s cut
shorte r (1 4%'1) th an th e ladder-ba ck chair
an d re sts o n th e c le at; se e F Ig s. 12 and 13 .
A fte r th e . > air is fin ished and the. se al
upholstered , the seat can be screw ed dow n
10 the clea t a nd fro ot ra il .
A SSEMBLY A ND SEA l
BACK
SE AT RA IL
to p rail
G)
follow ing the same procedure
used
fo r
the
back slat s Oil
the ladder-back
cha ir (refer to page 16) .bUI mak e it th ick er
by settin g the
pointed
blo ck
I~G
rom
th e
band
s aw b lade. M te r fil in g il sm ooth , th is
will m ake th e bac k lOP ra il abou i : y th ick,
se e Jlig.
7.
lA Y
our
M ORTISES.
A fte r th ese tw o ra ils
are cut. Iay out th e mort is es fo r th e v ertical
sl ats. To do this, al ign
the
tw o rails an d use a
square to m ark th e m ortises directly acro ss
f rom each
other.see
Fig.
7.
ORlL l. .\O R't1SES.
Now d ri ll out V.~'~l ee p
To mount
th e
bac k
slats, th e bac k rails
have to be made
a
lit tle th icker than
those on U te ladder
b ac k c hair.
BACK SEAT RAIL-
FITSt,
cut the
back
seat rail (E) 2 w ide
an d
long.but
leave it
a full
l 4 thick.
s ee F ig . 7 .Then cu t ~4 lo ng teno ns o n both
ends
o f t he
rail.
BACKTOPRIJ.L.
Nex t. c ut the curved
back
BA CK RA ILS
7/24/2019 Woodsmith - 064
23/24
Xloodsmith
o. 64
does n t s eem to
h e lp
p r e v e n t
i t
It
t h e r e s a Situation
where
it
seems
w o r s e
it s
w h e n yo u h a v e
a cut-off
piece about 6 long.
Then it w eighs enough so ifs
Ih ro wn o ut w ith so me fo rce .
S O l.lJ l1 0N S. Th e re a re a
few
s im p le s olu ti on s to th e problem.
A s we s a id
in
th ea rtic le in N o . 6 0,
ie s a g oo d idea to sta rt by rough
cutting your pieces straight of f
o n ly 1
oversiz e b e fo rem itering,
A lso, w hile cu ttin g, stand to
lheleftofthe
blade.And
do n t let
scrap pieces collect nea r
the
bla de . T his just provides mor e
c lu tte r f or
u ie
waste
oieceto
ge t
ca ught u p on a nd kick ba ck.
T he b es t so lu tio n is to a tta ch a
plywo od p la tf orm t o th e
ight
of
the blade, see Fig. 2. The plat-
form shou ld be
th e s am e th ick
n ess a s the jig ba se.
l ~
s th e
w as te p ie ce s a re cu t a wa y they
won tfall
d own o ff th e jig.
T o
hold
th e
plywood in
p os i
tion on top of the saw table (it
doesn t slide with the jig), I
screwed
a
ru nner u nder the ply
w o od l or
a
li gh l f ri ct io n f it i n
th e
ri ght n liler ,gaugeslot.
...ol PLATJORM
KffPSWASTE
PI CE FROM FAWNG
A N D tU CkiNG BACK
th ere s very tittle supp or t b eh ind
the w aste pi ec e
at
th is poin t. th e
100Ul
doesn t cu t the triangu la r
splin ter
0 1
Cle an .
A s
th e bl ade
c o m e s.a r o u n d ,
one of the teelh can hook onto
0\0 1 lillie splin te r.H It ca tches it
j u st r igh t, it ca n throw th e waste
~iece downaga instthe table and
then U .e pi e ce ca n b ou nce ba ck
kickback), see Fig. 1.
K1CKBACKVARtEl).
\Ve vetried
to pro duce th e kickb ack on a ll
kinds
orwoods,
saw blad es, a nd
mold in g p ro fi le s. S om etimes l
kicks back, sometimes it
d o e s n t ,
Cha ng in g th e
f ee d r at e
ta ble saw wiU . a hardwoo d ru n
ner in the m it er ga u ll
5 1 0 1 .
It
runs
on the lefl side . 0 1 th e saw
bl ade and the waste piece falls
aw ay to th e righ t .o f lhe blade.
WHY TilE KJ C){8ACK?
The
p ro ble m se em s
\0
come w he n
cutting th e second m ite r a t th e
backofthejig,
S ince
thefinished
piece is on tile jig . it s alw ay s cut
o ff c le an . Bu t th e
w a s t e
piece
doesn t have any su pport.
W ha t happens is
this-There s
a
u tt le t ri an gle S j)lin te r o r
w o o d
on t h e t ra i li ng e d g e of th e waste
piece that never gets cu i
completely
o ff .
seel ig. la . S ince
nWo~ ,itl N o. 60 we fea
t oted a shop -made m ite r jig U,.I
was a Iiu le diffe re nt f rom other
miter jigs we ha d seen . S ince
Iha t a rt ic le a pp ea re d la st w in te r.
w e v e rec eiv ed a n u m be r o f le t-
te rs a nd calls-a b o u t tbejig , and
weve h a d h e opportunity 1 0 u se
itin
ou r s h o p
fo r o veray ear.
Th e g en e ra l
c o n s e n s u s
is th at
it s o n e o f the e a s ie st a n d m o st
accurate jigs for cu tting m iters.
Bu t w e ve a lso hea rd a p ro b
le m: occa sion ally a w aste piec e
W i ll kickbackas itfaJ lsolfthe jig.
The ji g c on sis ts o f a : v 1 ply
woo d base tha t s gu ided on the
MITER JIG REV ISITED
arr
CONCJ;:RJSS. Pin a lly,
mOSI
s t a nda r ds t r a i g h t r o ut e rb its
(ex
ce pt spira l e nd m ills a nd sp ecia l
mo rt is in g b it s) are made to c u t
on the.ide of the bit , not O .e
n
li ke a
d r il l b it.
T h is
means
th a t
the plu nging opera tion can be
especially hard
o n th e
bit,
SO M lITL lES t DO
s o u r ,
Okay ,
w ould y ou ever consider usi ng a
route r to
cut
mo rtise s?
H
the
mortise is shal low enough (V4
o r le s s ) to ro ut in
one
pass . an d
Im w o rking
w i t h
a number o f
p ie c e s which n e e d m o rtis e s in
e xa ctl y th e s am e locauons, yes ,
r ob ab ly w ou ld u se the router
ta ble. Because th en the lim e of
se ttin g u p start and S lOP blocks
iSjllSlilied.
This happens w ith some
routers because there s s o mu c h
play io the depth tightening
mechanism . A s y ou in cr ea se th e
depth of
ui
a nd retigH le n the
base
c e lla r
a rou nd
th e
motor .
thebitwon t be in theexactsame
position and, cuts at a slightly
differenl poin t. This doesn t
happe n with aplunge router.)
ItIDDEN
c u r ;
Also . w he n mo r-
tis ing on a ro ute r table you have
to plu nge the workpiece down
over
the
bit.
You cant see
whether
y ou are routing
exactly
w here y o u want
til e
mortise.
O ne solu tion is to cl amp st rt
a u tl stop blocks
10
you r rou te r
ta ble , bu t this ca n be tim e con
suming to
geuhescaccurate.
ta ble and save a ll th e
trouble?
T he re a re a n um b er o f p r o b le m s
y o u n e n o u n t e r w hen cu tting
mortises o n th e r ou te r I, l -
sidered C1 /U i l J} them O tt t
>1tiertable by plunging t
l :ood
piecedoum .
011
t r
b i t ?
Jolm H. Righi
Onek ama , M i c hi ga n
Wi th ou t a
d o u b t , i t s e as ie r
t og e l
.a
c l eo
n ~mortise
w ith
a route r
bit . B u t
I sliU
usually dri li lhem
ou t
b y
making
a
s er ie s o f h ole s
with
th e
m ortise bit and tech
niqu e shown on page 10 o f
this
iss u e. Then I clea n up the
e h e e k s c n h e m o r u s e b y m e k i n g
r e pe ate d c u ts with th e mort ise
bit.
o r
I
use a
sharp chi se l .
So. why not use the router
MORTISING : ROU TER VS. DRILL PRESS
Talking Shop
QUSTIONSNDOMMNTS
7/24/2019 Woodsmith - 064
24/24
24
W oodsrn ith
N o. 64
Van Dyke's
P.O . Box 278
Woons ocke t, SO 57385...cr
Wood.craftSupply
P.O . Box 4000
Woburn . MA Ol888 ... M B, RB
Woodline
1731 ClemenlA ve.
A lameda . CA 94501.. .RB
Gri zz ly Impo rts
P.O . Box 2069
J3eUingharu ,
\VA98227.. .RB
M.L .C .S.
Limited
P.O . Box 4035
Rydal., PA 19046 ... RB
The S ource
7305 Boudinot Drive
Springfiel d .
VA221S0..RB
Simi/al'/141viwal
an ti -s upp li es ma l l b e fr n , d
inl follt lwll ' t{JcaUl/ODS.HO l)qvers l J les al 'ih izes-mayvary .
P le ae er ef er tc e ac lt c a t l og f0 1' orcleringinformation .
PROJECT SUPPLY
UPDATE
T he Old Fashioned W all Phone
fe ature d,i.
Woodsmi t
N o. 4 2 is
now available th rough Wood
sm ith P rojectSupplies.
The kit in cl udes : th e . r epro
duc tio n ha rdw are.th ee lectrcnlc
parts
00
th e insid e o fth e phone
as well as all
the
w ires and
plug s. (Wood not in cl uded) In
c Iud ed a re in structions lor build
in g and w ir in g th e p ho ne.
Note: W e're otlering the
phone in to uch-tone only .
742 100 Phone Kit ...$139.95
ALTERNATE CATALOG SOURCES
BY M AIL
To orderby m ail . use th e form
on th e pr otective co ve r ofacur
rent issue o r w rite your o rd e r
on
a
piece
of
pap er , a nd s end
it
w ith your chee k or money
or der (please inclu de $1.50
shipping Charge wilh each
order). fA residents.add 4
sales
tax .
Send ord er to :
WoodsmithPrqjcctSupplies
P.O . Box 103 50
Des Moin es, IA 50306
B Y PHON E
Fo r laster service use our
roll Free or der line. Phone
or derscan b ep la ce d Mon. H'nJ
E r i S::SOAM 4:30 PM CSf.
Be fo re
you c all p le as e f il lout
the or der forO compl etely .
VISA
or
MC ord ers on ly.
1 8 444 7 2
AIIo,.4 106 jL~ek.f ' l di if1iectt o c ha u e
oft ~89
ORDER INFORMATION
Chair Pattern
'764 300 Chai r
P a tte rn ,
$3.95
MOR ISING BI S
The
Vennont
America n mort is
ing bits
th a t w e
t al ke d a bout on
page 10
a re
available as a set or
ind iv id ually tlirough \Vood
sm itb Project Suppljes, or
ROUTER BITS
\Voodsm ilh Project Sup plie s
is o ff er in g a co llection
01
high
quali ty router bi ts needed to
ma ke th e chairs an d table in th is
issu.e.
Al l 1
these
bits
have
car
bide c utte rs an d s tee l bea rings,
Rout er Bits
2 7 1 88 5 Flush T rim .. . $16 .95
' Th is
bit has a I
cutte r
length
and a
V o .
shank.
.2 7.1 -8 ,1 l Is Rndover.$23.95
v. . Shank
271 821 lis Rndover ,$26 .95
I ' l Shank
2 7181411< ndover.$23 .95
1I. Shank
271-82311. Rndover.S24 .95
I'l
Shank
764200
Rndover.S26 .95
y, Shank
764250
Rndover. $28 .95
Shank
Router bits are
also
available
fro m s om e o f th e supp lie rs l is ted
below.
e e
code
RB.
CHAIR UPHOLSTERY
add iti on to the. lumber. p ly .
w oo d. an d screw s, the o nly su p
p lie s n ee ded fo r Ib e ch airs
are
fo r th e u ph ols te ry . ( Fo r m o re
in -
formatioa , see page 19.)
When upholste red the
chairs s ed p rof es si onal qual
ity m aterials. T he co st of these
mat er ia ls may
seem
a lit tl e high
in
the
be gin nin g, b ut
Ifeel that
it s worth
in the end .
1 H E FOA~t.The
poly
ur ethane foam th at [u se d fo r O le
SC8llladd ing i s so ld
0 1
a standard
sheet
size
o r 2 4 x 108 .That's
en oug h lor
s ix ch a i rs
an d it c os t
il at
local upho lstery shop .
THE AJlRlC. The re are so
many d if fere nt fabrics to choose
from th all ha d ahar d t ime dec id-
ing
which
to use. W hen I fm aUy
dec ide d on the fabric. [
fo u n d
out
itcost$25 a yard .
I iho ugh t Ibat p ric e s eemed
awlully high until it w as ex-
plained
10
me.
Upholster y fa bric comes in
a
s ta nd ar d w idth 0154 . Sin e. . th e
fabric I lik ed wa s 54 w ide. (only
nee ded
2
yardso flength recover
si x
chairs,
T h e total fo r my uph olstery
s upp li es c ame 10 about $80, or
(a s
I
like to th ink of it) a
li ttle
under $13 .50 pe r ch ai r.
We hav e lis ted a m a il o rd er
sour ce lor foam padding. se e
Flanger Bolts
764-1
00 BoIl5 $3.95
(4 ) x 5 H anger B o n s with
nuts
and washers.
Some lo ca l h ar dwa re . stores
may c ar ry h ang er bo lt s. bu t t hey
may only be 4 long . You can
counterbore the
hole on the
back of the corn er block
10
a
de pt h o il . T h e n you wi ll ge l th e
same threads
into
th e leg .
from the source listed below .
(VCl1) lOnt
American
cal ls
these
b itsa F orsm er 'Type' tbit .) Loo k
fo r th e
code MB
after th e su p
pli er 's
ad dr ess.
Mort isin g Bits
2 78 6 54 llitSet
$25.95
1)
1 I
Mortis in g B it
l)
V a Mortis in g B it
l
I'l
Mertising
Bit
Individual ly p ri ced Mor ti se btts,
278.647
\ I . . Bil $7.95
2 78 6 50 % Bil. $8.95
2 78 6 53 \.'~ Bil S9.95
HANGER BOLTS.
TIle ha nge r bol ls t ha I I used on
the D ini ng Tab le arc 5 lon g.
These S bo lts are availab le
th rough \Voodsm ith Project
Supplies.
CatalogSourcesbelow . Look lo r
code
Cf
after the
address.
CHAIR PArrERN
W ood.sm ith Projec t Supplies
is of fer ing a luU sjm pa ttern fo r
the cha ir p arts. tile p atte rn in -
cl udes
a
l eg p rof il e with
a U
the
mortise
locat ions
m a r k e d , p lu sa
pattern lor both the h ori zonta l
ba ck slats and the vertica l bac k
sl al s.
our es
SUPPLIES
CT
RO