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  • 7/24/2019 Woodsmith - 064

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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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    7

    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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    9

    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

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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

  • 7/24/2019 Woodsmith - 064

    19/24

    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

  • 7/24/2019 Woodsmith - 064

    20/24

    No. 64

    Oldof gl l id ,o ,. , . TI l l

  • 7/24/2019 Woodsmith - 064

    21/24

    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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    22/24

    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

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    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

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    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