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\_
4
_
f t t
350
O TES FR O M
T
S H O P
O 6
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oodSll1ith
WOODS M I T H (ISSN 01644114)
pu b
lis hed b lmonlh Jy (Febru ary , A pri l, June .
August, O ct obe r, O ecem ber ) b y
WOOdsm lth PubQ sh lng eo ., 2200 Grand
Ave., Des Moines, lA 50012.
Woodsmith
is a re g is tered trad em arlt of
Wo o d sm ilh P ublish ing C o.
,~ CoPyri9ht 1989 by Wocxfsmllh PU blish
ing Co . A ll Rig hts R eseNed.
Subscr ipt ions: O ne year tssoes)
$15.95,
Tw o Y ears
(12
issues)
$27.95.
canada
and
Foreign: lld d $ 2
pe r
year,
U .S .
funds on ly , S ing le C opypn 'ce , $3.50.
Second C lass Postage Pa id at D es
M oines, Iow a an d a la dd ilionaJ offlC< S .
Pcsrm aster: Send cnange of addres s to
W o o d sm i lh , B o x 491, M t. M orrts,lL 61054,
S U B S C R IP T IO N Q U E S T IO N S ? O all800
435-0715 (IL re sid ents : 800.892-(753).
7:3 0 AM 108:30 PM . C ST. wee l\JN.Th e fu n part of th e ' toy Tra in
w as mak i ng th e track . The t ra ck i sdes ig ned
so i t's easy to m a ke-a nd so mere se ctions
c an b ea dd cd a ny tim e in th e f ut ur e. O n c ew e
des igned it, Ute hardest pan w a s w a lk ing
through th e office a s n ew s ec tio ns o f tra ck
found th e ir w ay in m ore nm azing pauerns
and
stretching 10
n ew pa n s. of
th e building.
O YA L H O X.
There are two re as on s to bu ild
the O va l BOl< sh ow n in ti llS is su e. F irs t, it
makes a oic e .g iit . B ut t he r ea l reason, is th aI
it u ses a tec hn ique that s ju st p la in { un fro m
awoodworker s standpo int .
The box is based
O n
Ihe
s ha pe of
a bev
e le d-edge ov al m irr o r. It requires transfer-
rin g th e sh ap e o f { his m irro r to a template.
The n t lt e t em p la te is used w ith a route r to
rout ou t the recess in the lid fo r the m irror
and .a c om ple m en ta ry re ce ss in
w e
b a se f o r
jew elry .
[b e id ea is th e sa me n o m atte r w ha t th e
sha pe . I f y ou find an intriguing l>alle rn ofany
shape, you c an m a ke a t em p la te f ro m it a nd
r o ut o u tt ha lsh a p e.
CAlIl lC,)S . I want to po in t ou l the note o f
c au tio n w e 'v e P ul o n th en e.,[ p ag e u n de r th e
Sawdust
COLUMN
DITOR S
ctober L989o . 65
-
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1 f you'd like to ~ ha rc
Ii
ti p
w ith o ther s, s en d in y ou r id ea
to \VoodSlllith, ' 'ips Tec h
D iques. 22tJQGrand Ave ., D e s
Moines . Iowa 5 031.2 .
\V e pay $15 for accepted
ti ps Please send an explana
ti o n an d a sket ch if needed
(we'll draw a ne w o ne ).
SEND IN YOUR tIPS
VACUUM
H 5 I ~8,36'-long
2 0'
piece
O f 1.
dowel
(32)%'wOOQscrewhQIeplugs
8 x I/.',
x 2 woodscrehordware kil,see psQe
24.
CUnlNG DIAGRAM
fOO fPa:G HO I.
: :
fRONT/BACK LEG PAmRN
T~
FRONT
LEGS
1 24~ .;
..1..__11.--_ .; ----,- ; ,---:~ 1
MA IN BOD Y PATTERN
GRI:O D IV ID ED IN TO 1 M QU A IU S
531f2 l
~
piUG
l.
_8 114 - j
w OOOSCIUWS
N o, 65
WOOD PARTS
A MClinBody I) 1 < 1 x 11 /. 38
8 Le~Wedges(4) ~x7h-1O
C Fronl
Legs
(2)
See
below'
D Reorl l9s
2
See below'
E S < d e s 2 ,) 1
Y
x 11 If. I d
f HeodSidePcs.(2).x7/.-11
G Nec~ Pieces (2)
1 .
x ;; ~ - 7
H Roc1
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SNOOur ALl SAW
M KSwtfH_
DRUMSANOER
8
W()odsmith
L Y OUTlGS
US ING GRfD
P mRN
I OUP
IN FRONT
. fGONLY
4
RJU PEGHOLI
10 be cut 10 final shape while a u ac he d to th e
leg .
BUI.
beca use
th is
creates
a
rath er
awkw ar d
culting an gle,
ad
to
cu t the
legs
an d
wedgesin
tw o steps.
First, draw
a
line
across the pattern 10
down fr om the top o f the legs, s ee F ig . 6 .
N ow cut out Ibe lower part o f ea ch le g
(w ithout th e wed ge attached), exiting
t h < :
boarda t
th e
10 mar k .
N ex t, atta ch the wedges to the
i ~ul f
the leg w ith
carpet
tape, see
Fig . 7.
The n
p lace
the w edge-side
down
on the band sa w
table, an d cu t th e rema ining sh ape . s ee F ig.8 .
When one frO )tleg (C ) a nd one rear leg
I
have
bee n
culo utand sand ed,
use
UIC OI
as patterns
(0
la yout an d
CU I
the o th er tw o
leg s. (B e su re the ho les on th is second se t
m irr o r tho se
On
th e
first)
PosmON TILEU>GS.N ex t. you can p osi
lio n the leg&on th e bo dy (A).The problem
her e is
1
de te rmme
8
reference po in t t o get
MAIN
BODY
6
CU T LOWER .
P RTO UG
rOSH PE
UP TO THE
10 MARK
LEG
WEDGES
4 TOTAL
5
. . .
1 8 , ( ;
,
COUNT t
i t B O R
WOODSCREWS
.
1.1;
SCREW
t
HOLE
l
DETAIL
. ; ; : ; ; ; . 1 ~
SH NKHOl
th e legs at th e co rr ect ang le ( st ance ). se d
Ihe joint
line
(from
making
the Lshaped
body , refer to Fig. 2) as
a
reference
line .
1 '0 d o th is,
place
a
straightedge o n
th e
jo in t
line
so it exte nds 18
beyond
the
ho r se 's b e ll y, se e Fig. 9 . N ow positi o n t he
rear
leg
0
so the top of th e leg
isflush
w ith
the horse's back and the ho of is
~
rom
thestraighted ge , se e Fig . 9 . Then s cr ew (bu t
don 't glue) the le g a nd wedge
10 U IC
body .
W ith the
rear
le g in plac e, po s itio n t he
fro ntleg (C ) so the top o f the I~isnush w ith
the horse 's back . N ow aci jusl the front leg
until
there's
22\. . betw een the hoo ves and
6 betw een the top o f the legs. see Fig. 9 .
The n scr ew (b ut do n 't glue) the fronlleg
do wn to the m ain b lldy.
TRL'L\IING TIlE WEpGES.
\V hen both
legs
are mounted
In
one side, the re 's a s ec tio n o f
wedge under the ho rs e that n eeds to
be
tr immed, Tum the ho rse o ver and trac e th e
CUT HOR SE
SHAPE TO THE UNf .
THEN Fill A ND S AN D S MO OTH
2
3
Alte r the body (A ) is
san de d, I beg an
wo rking on th e leg& .
To
give the horse a
naturdl stance , I
add ed
wedges be-
hind ea ch leg .
I.E C WEOCES .111.
leg w edge's
B
are
fo rm ed by g lu inl ; : f ive sm aller wedges
to -
gether, se e Fig. 3 .(F o r mo re on cutt ing
wedge s. se e pag e 13.)
lAYOUTntE
lE GS.A lter th e wedges
8
are
glued up, lay out the fro nt leg (C ) an d
rea rteg (D ) on a pi ece o f
l -2t'sl ock ,
se e Fig.
4.
Also mark ;
Ih~
sc rew and foo lp eg ho les,
Now
rough)y CuI
apart
the tw o l eg s, s ee
Fig . 4 .
111eo
drill a Io o tpeg ho le in the fronl
leg w ith a I forstner bit. A lso
drill ho les (o r
th e mountin g screws in bo th leg s, se e Fig. 5 .
co r IN t wo STEJS . he
wedge s
(B ) have
LEGS
The firs t srep in
building the horse is
to make a n Lshaped
bla nk
for
Ihe
body
(A) from a 38 Jong
pie ce o f2 x 12 (lW'
x
11 V
actual
size ).
To do thts.square
up one edg e o f the 2
x.
12 to
a
fi nal w id th o f
1 1 .
The n
cu t a
I Z O l
lo ng piec e o ff one end, an d glue il to the
other
piec e to fonn an Lsh ap e, see F ig . I.
Transfer the body sh ape from the
grid
drawingo n page 5 , o r se nd fo rthepattem , se e
p ag e 2 4.
(For mo rc on
gr id drawings , s ec p age
13.)
111en
cutout th e
body
an d sand thcedges,
MAIN BODY
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7
ooosmith
o. 65
11
14
muOWCIUD
15
TRAct
16
R MOVE fRom LEGS
PAnRN
OUTUN
AN D R OU T lh
MAK~JAW
Of NE~,K
RouNO-OVER
O ONTO
PAP ER
T
PI ES SO
,
SUD PAPER
\
JHtYR E
~ D A E = j ~ ~ :
FLU SH
G LU EH EA D
A ND N ECK
TRACEB OtH ~
WrrH
. ~ SID E PIecES
B ODY
~ ' \ *
P IE E S
INTO
P LA C E
SIDE-S Of H,EAO
~
~
0N10 1 x
STOCK
~~
the y're O ush
'U I
th e m ain head.
an d (hen
c lam p (but don 't glue ) the m in place .
NECK .Nextcomes th e neck . Forthe neck ,
follOW the s am e p ro ce dure a s wh e n making
t he s id e s ( O ) . see Fig. 15 .Once th eneck (G )
p ieces
Iit,
glue the head pieces and neck
p ie c es to th e
main
body .
sour HEAD, IND NECK .
\Vhen the g tue is
d ry . re move the 6 'ont legs and rout a til
round-ove r
o n t he o u ts ld e
edges
or
th e h e ad
and ne ck. see fig . 16 . (Note: D on 't rou t the
ne ck where it m eets the
leg .
Final ly . g lue
a nt i s c rew th e le gs in p lac e.
S E C O N D :
M AR K L EG S
WHER t THEY
M T H amy
gl\l~
it to
a
p iece
0 1
\I -th ic k
stock, see
Fig .
12.
(S ince
the shap e may vary , make a se pa
ra te pat tern (o r each side .)
SA N D TO
rrr, T o g et a good fit. I cu t
th e
sides o v e rs iz e . a nd t he n s an de d to ti le lines .
O nce the side s
fi t.
rout
a
i
ro und-over
on
a ll
( ou r o uts id e e dg es. a nd g lu e
th e
side s to
th e body, se e F ig 13.
T1lACETll I lE A O .T he
ne xt
step
is
1 0 c u t
the head 's si de pieces
(1 ).
Start by tracing
each side o f th e m ain head onto a pie ce of
1x8stock .
an d d ra wth ejaw line . se e F ig . 14 .
N ow . cu t out and sand
t hese
tw o p ie ce s so
idn't
wanta
skinny
horse,
sodded
th e
rw e s id es
E .
M A J< 'EA P A TI'RN .
To determine the
shape of th e sides . I
made a
paper
pa t
t e rn .
Begin by
un
screwing th e le gs o n
one side of the
horse
ju st e no ug h to slip
a
p ie ce o f pape r und er them , se e Fig . It. N ow
trac e tbe o utline ofthe bac k, be lly . a nd b oth
legs onto the pape r. C ut o ut th is shape an d
1----22~_-_-I
SIDES HE D ND NECK
le g . s ee F ig. 10 .T he n remov e th e w edge and
ro ut u p to
th ese m arks,
Repeauhe same procedure for th e legs on
th eotherside . Then sc rew all four legs tothe
horse 's b od y,
a ll th e way ar ound. (N ote : Don ' t rout th e
b o ttom on he hool.) H oweve r. th e rounding
on th e
i si l iee ge
stops auhe wedge . T o do
( h is , p la c e th e w edge in position on the leg
and m ark w here it m ee ts the edges of the
fOO Pf
HO LE
AnACH t[GS TO
C OY WITH .8 )It 2-
WOOOSCREWS
9
LEGS
CONT INUED
horse's be lly O nto e ach wedge . see F ig. to .
N o w u ns crew -t he le~ .
pull
o fflh e w ed ge s.
and cu t to
the.line.
RO \ .lND OVER I.C5. To comple te
th e le gs .
I routed a W ' ro ondove r on lheo ll ts ideedge
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oodsm ith
1 ' lMPORARllY
- SH IM HO OF I' N ECES SARY
ROCKER
eut.)
N ow
us e fine
tooth han d
sa w to tr im
e ac h h o of along th e scribed lin e.
SCREW DOWN 1I0HSE. Wh.en th e hooves
h a ve b e en
cut.and
th ey sit
fla t, the norse
ca n
be auac hed to the tw o o uts tdc cro ss bars, To
do
th is, m ark the
center
ea ch h oo f o n th ~
bo l ton l 0
f
th e c ro s sba rs, Then drill and coun
tersink
a :V I I ; shan k hole.
US ing
one N rocke rs Iollows a
- large radius . r mad e
a s ix -
[001
b eam com
pass to
lay
th em-ou t.
MAlff iACO MPASS .o make th e b e am co rn
p a s s. s ta r t
with
a
78 ' l ong
strip
o f
wood
an d
nai l d own one e nd, s eef lg . 17 .No lYmeasure
down fr om th e n ail 69l' l and 72 . and drill
ROCKERS AND CROSSBARS
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\
,
$TAPli 3
C-\.UM'S
CWYAI \N
t. APA,RT
enough. DICIt usio g 8 sm all fe nci ng staple,
attach th e yam in
dum ps
of
15
piec es.
S ta J
I
above
th e base o f t he neck
an d
ce nter
th e
staple over th e m id po in t o f Ihe p ie ce s of
yarn. se e
r~g.
7. Note: To prevent a bald
spot at the top of th e head . 1st apled in extra
c lumps o ya rn .
'filE TAlL
The finals tep is LOadd the tail.
The tai l i m ade Ih e sam e \ ya y a s ri le mane
except the yarn pieces ar e 28~() n~ and
th ere are 34 pieces in each of the three
clumps, see Fi g. 28 .
[fyau
w ..
nLIOmake
thesa(ldlc
a nd b ridle
sh ow n in the photo.see Sourc es on page 24.
K
FOOTPEG
1\1 \
, FRONT
UOI
I
DOW ll.
.
, P IN 'OOWI l
wnH
, 4 d F INISH NAIL
_ rAOM~ACK
O F L EG I
2S
W oodsm ith
15 StRANDS
Of l'''lONG
Y R
U sing the grid drawing as a reference, 1
drilled a I hole. V s de epon either sid e of
th e head. Then I sim ply g lued th e eyes in
placewith epoxy,sec Fig.26.
AAMS.The ears are
l it
from tw o
smal l
piec es of 'Ill -lh ick leathe r. Tom aketh e ears.
cui
th e leather in to fo otb all-shaped
pi ec es
th at are 2 -w id e and 4 loog. Then fold the
t wo p ie ces
in ha lf leng1)lY,;se
and nail them
t o e it her sid e o f the hea d, se e fig. 26.
ru s M ANE .WI1al's ahorse withoul a D ow
in g m an e? To m ake th e m an, cu l4 -p ly y am
into Ill lengths . There are
ov er
200 s tr ands
o f ya rn
ll
Ute mane , so m ake su re LOmake
No. 65
o
lOC ATIO N O F
EYE SAND EAR S
,p-
DfTtRMINEO
ONGRJD
DRAWING ,: ' . J
I .
J ) ; O , l
.:;.:?
FOlD liAlloIER
EARSIN H~U:,
TH EN N p, 'L
IN PlAC
,. HOJ,E,
/I DEEP
6
NOT:
'TI le w ooden parts of
the
horse
are
complete at this
point. Since th is
horse is bound
10
lake som e abuse, I
w an ted th e finish U >
be as durab le 8S
possib le . I used tw o
coat s o f s atin p olyurelhane . s and ing l ig h tl y
betw ee n c oa ts .
EYES.
The
finishing to uches are the eyes.
ear s,
man e,
an d
ta il.
The
eyes I used are
cal led g las scr a ft eyes that are 1 in d iameter.
EYES EARS MANE AND AIL
/
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T
BACI(ING
BOAAO
1I 4 OIA .
FO~ER
OE l SP E
s rr
_
Woodsmich
0
aOTTOM
KEP EDGES F 1.USH
WHEN C lAMPING
Next , resaw tw o sid e pieces 8 : ti6'
thick. ( Th is t hi ckness w ill p ro duct' a b lo ck
1.t thick -
\ 1 i
m o re th an the h eJg ht o f a
lO
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I
00< lsm ith
o. 65
EDGES
IRONTWGlS
D O f o IT
LIGHnY
S AN D S T AM P
HOlD tR F OR
fRtC'TION
fff
Ul
t o t
ROU NOo
OV ER 8IT
ON AU.
OU 'rSl0E
EDGES
EXCEPT
ONT
EDGES
NOTE:
PLA CE A R Oll O F 100
ST A MPS IN TO
H u E~,
TH N suee INTO cASE
7
8
CU T-E ND OFF
SE NOkOlDER
O R ll_ t 1 )I A.
HOltrnOOYGH .
60 TH stD E IICES
S E
S IDES
NOTE: n~~~~
STAMP
BLOCK
M U ST
Ge110KT
AGAlttsr
IN S ID E
S O TTO M A N D
8ACKO f eMf
8Ef ORE CUITING
~~THIC:K
6
R IS AWTWO PJECES
W hat you w ant is a fr icti on fi t be tw een tlt e
holde r a nd o uts ide case . T o ge l th ls , r pu l led
e u t th e bold e r and sanded lI1es id e s . l igi l t tg ,
T h e bes t w ay to do th is is to ru b th e s tam p
h olde r acro s s ap iece of s andpape rt h ars la y
in g on a Bat s u r face , s ee f ' ig. 7 , K eep ch e ck ,
ing un t i l th e h olde r fi t s l oo se enou gh to pu l l
ou t eas il y , bu t norso loose it fa l ls ou t,
R O U N D EDGl lS . Finally , round over th e
edges of th e
cas e ,
s ee Fig . 8 .
C lJ rOFF..'1D .Mer lhe h old e r fi ts in to th e
case, s and th e
lop
and bottom bandsawn
edge s sm ooth .T h en s li de th e h olde rall
t l
/ Ja g i n t h e case , an d pu sh it down so the re ' s
a s lo t for s tam es at th e top . Now cu t off th e
f r o nt o f th e a ss em ble d p ie ce s . s ee Fig . 6 .
CORNER
RWIUS.
Next. cu t a Y $ rad iu s o ff
th e top back co rn e r of th e case and san d th is
c omer sm ooth , s ee Fil l: 6 .
FlU CI1 0N FIT .N ow com e s th e tr icky par t .
A(ter th e two piece s are cu t apar t . u ie ease is
co m ple ted by glu ing : V I S
-th ick ca s e
s id e s
C
to
th e ou tsi de o lth e U .s h ap ed case .
CIIfTO SIZE. S tart b y cu tt ing tb e s id es to
th e
s an te w id th
(2 )
an d le ng th
(3 ',)
as th e
case . (For th e s e
par t s , s e d
th e sam e wood
as th e cen te r p iece on th e case .)
DRIll HOLE .To prov ide a fi ng er re ce ss (o r
pu ll ing ou t th e s ta m p h olde r. r dri ll ed a I
d il l . h o le th rough both s ide p iece s (C), s ee
fig.
5 . (La t er th e s e h ole s w ill be
cuLin
ha lf re f e r
to Fig . 6 .)
c: ;tV EON SIDES. Now you ca n
g lu e and c lam p U te s id e s 10 th e
case w ith Ote h ole s tow ar d th e
open end of t he U , s e e
Fig . S .
Here 's th e fl rs t poin t w h e re
you h ave In be care fu l or th e
s t amp h old e r
wont
h av e a p e r
fe ci fit in (h e case . First app ly
th e g lu e s p a r i n g b y . Any glu e
squ eeze -ou t inS ide th e case wil l
pre ven t th e h older fr om f i t t ing .
And don 't pu t too m uch pre s
su re on th e c lam ps.
RE tNSERTROLD ER .Once th e
g lu e dr ie s , rem ove the c l amps
and pu sh th e S t am p h ol de r back
in to th e case . It w ill p ro bab ly be
a very tight
f i L
f il doesn 't '1 i tal l
th e w ay aga ins t th e bac k o f th e
case . ch eck fo r an y dri ed g lu e
th a t
m igh t
be in th e w ay.lf i ts t iU
doesn 't fi t , you m ay h ave to
lightl, /
s an d th e s ide of th e
s tam p h olde r, s e e Fig , 7 . D on 't
sa nd too m uch - you w ant a
very: t igh t
fit
at th is poin t
FIN IS HIN G THE D IS PEN S ER
NOTE:SfOP
POwat AfTtR CUnlNG
THEN B AC K B LA NK O UT
S I CONO
CUTfUJI
Bl H
ova so
SOITOM EDGE
IS A G AIN S t -fE NC E
NOTE:
u s H A I [ < >
pfleI
IICOMES
OtmllCIIS
R E M O V E
S T AM P H OL D E R :
Jr _
~ :
.. ..
a
4
blad e to u ch e s th e st op line .
THIRDcor To com ple te th e U , firs t tum
off th e pow er and rem ove th e fe nce , T h en
fe e d th e b lad e bac k th rough th e li rs tcu t u n ti l
i t' s in U t e h ol e a n d nex t
to
th e p enc il
li ne .
T u rn on th e pow er and cu t a long th e pend l
l in e d ow n to th e s e cond cu t. and rem ove th e
h olde r. s ee Fig
,I.
Once th ey 're cut
apar t.
s ave both of
th e
piece s .
t h e f ir st c ut, s et the topdgeofth c laminare d
b la nk agains t th e
fe nc e a nd
s tart th e cu t on
fh e ron
I I d g o
c u tti ng u n ti l th e blad e ju s t
b re a ks in to th e h ole , se c fig. 3
SECON D
c or, B efo re
m aking
th e
s econd
an d th ird cu t s , m ark s top line s 14 fro m th e
b ac k e dg e on both s id e s , se e Fig , 1 . T h en
p lace th e p iece
so
th e
bottomedil .
i s a g ai n st
th e fence and m ake th e s econd cu t u n ti l th e
Me r d ri l lin g th e h ole (or th e ro ll o ts tam ps ,
I u s ed th e band saw to cu t th e s tam p h old e r
ou t of th o cen te r ofth e b lock .
S t . UP FENc e . S t ar t by c la m ping th e ri p
fence (or a s tr a ig h t p iece o r plywood ) 1 0 t h e
top of th e band saw table V fr om th e 1 8 U 1 8
o r th e b lad e .se e
Fig.
3 a.
F I R S T
cu r
Th ere are actu a lly th ree s epa
ra te c ut s th atproduce
a
U
s h ape .
To m ake
C U nlN G O U T THE STA M P HO LD ER
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oodsmith2
SH lM C AN N OT
_STtCKOUT
66 tONDUG
NOTE:
HOLD PINCll TiGHT
AGAINST S lOCK
ANO SC.RSE
ROUND
AU . F OU R .
lfG
2
~
,
e,
SHORT
~
lfG
.'
8lOCK
THtCKNtSS
sr r
StOOL EQ,U/ll.
ON FL T
..
~
DISTANCE
SURfCE
~
U N O E R
SHOflTUG
lr ;::l~
~
SKIM t..
~
SCl.8E
SHORTST~
BLOCK
SHIM
LE G IS,
penc il pq in tl igb tagainst th e lo p
o f t h e b lo c k.
Then
m ove th e pen
cil and blo ck aro und each o f th e
legs.
se e lig 2
A l l t ha t' s lC (l lo level the stoo l
(o r Ho rse) is to cu t each leg on
the
s cr ib ed lin e.
CRIBI; SCRIBE. To
t ha tpasses th r ough t he cente rof
the legs. This a(ijustil ig rod
al
lows th e com pass to be set
ea sily . ' Theo the r b en efitto u sin g
this
type or co mpass is the legs
w o n't m o ve
as
you 're sc ribing .
SCRI81NGACABINcr.
A l P ica l
e xa mp le o f s cr ib ing w ilh
a
com'
passwould
b e w he n fi llin g a ca b
inet ro an uneven w all. see fiJr.
I.To do
th is.
se tth c
distance
be .
tween he c om p as s po in tand th e
pencil
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13
o.65
SEITO
INSfD[
8J.A1
5PACER
s tOCK
1
~ . n
~
C
ttWliNS~~~R
a l.O .
The
le gs o n th e H ock in g
Horse
are splayed out w ith w ide
wedges see page 6 ). To m ake
th ese
wedges
th is
w ide.
I
started
w ith narr ow w edges and glued
them together,
cu:r1llE BlANK. 1 0 m ake the
narrow wedges start with 8
blan k the same length as you
wan t th e w ed ge s to end up.
S incei needed a 10L
of
wedges
for th e R oc kin g H ors e. Ilued
CUnlNG WEDGES
sr r MJnR G VG
TO AHG t. O F IOARD
block to the blade equals th e
It id
e /d
o f
the w edge ( ~
fo r
th e horse , se c Fig. I.N ow m ove
back
the block and
d amp
it to
th e fence
injhm
oflhe
blade .
Then put a m ark on o ne e dg e
of
the w orkpiece lhal'S half of
the w ide end (l/ts''). see Fig. 2.
N ow , an gle th e w ork piece.so
the m ark al igns w ith ib e
i 'idl
o f th e b la de and t he a dj ac en t
edge touches the block. Then
Woodsmirh
AUXiLIARY
fENCE
RdjuSI
Ih e m ile r g auge
to
(it t ight
againstlheworkpiece,
se e
rtg.
2 .
Cl11TlN(;WEIlIIES . After
th e
sa w
is se t
up. m ake a
pass 1 0 es
ta blish the
angle.The cut-off
piece 6'001 th is first CUIis w aste,
Then
flip
the blank over and
m ak e a no th er pass . see Fig. 3 .
T h e c ut- of f
f rom
th is p ass is th e
co rrect ly
tapered
wedge .
To cu t
m o re w e dg es, c ont in u e f li ppin g
the piece be tween cuts.
I
X ttCH \
CURltD lINES \
tnwt fN
X POINTS
STRAIGH T
X
UNES
DON~FlOW
grid . To keep from losing my
place . Ihin k
of
th e grid
a s a ser
ie s o f h er izont at b ands.
Within each band there ate
points w he re U te ou tli ne i nle r
seers th e grid, trs th ese po in ts
th a t are transferred from the pat-
te nt t o t he g lid .
To lo c ale these points , r men
ta lly divid e
each
llenglh of gA d
line into fourt hs. T his w ay J ca n
es timate the intersection points
easier. see P ig.
t a o
After marking tbe points , ifsa
m a tte r o f- co nn ec tin g th em w ith
n cu r ved lin e. To do th i s. lo ok at
th e s ha pe. th en ske tc h t he cu rv e
b etw ee n the
poin ts .
se e
Fig.
2 .
The
outline
doesn 't hav e to
match th e pattern exactly. It s
more import an t ihauhe f in ished
shap e looks an d feels smoo th .
2
together pieces of I thick
stock to form a blank
10
tong
a nd 2 2 w id e. (N ote g ra in dire c
l ion in F ig . 3 .) T he e xtra w idU t
al lows
you 1 0 suppor t th e p iec e
with th e m ile r g au ge.
SE'l IIS.~w .SeUingup th e ~W
t o cut t h e w e d ge s takes nu m -
ber
o f s t ep s . f ir Sl, p la ce a spacer
block between th e rip fe nc e a nd
th e blade. T hen lock down the
fence so the distance from (he
GRID
UNES
Then
connect
th e
marks.
H
~le
grid
i s sma ll.
I
use aemm ing
square t() lightly pencil in
the
titles. If th e gl id i s l ar ge, 1 use
a
s Iight board ordrywan sq ua re ,
DRAWING TItE SHAPE.
Once
the grid ti nes are drawn, the
s ha pe c an
00 t rans fe r red
to
th e
OIVloFINTOI
MALLER
INCREMENTS
OQONt HORIZONTAL
_ - BAND AT A TiME
1
don 't w ant to usc a g rid , get the
fu ll-s iz e p lans for th e Horse ant
trace them. s ee page 24.)
ACCURAT. ; .'t,\..~URME \'1 S.
To mak e the grid . first mark
~( )inl,; l apart around the ou t
sid~edges of the board you 're
going to c ut the horse out of
T he problem w ith lay ing out a
proiec t like the Rocking Horse
page
4
is th e la ck o f S Qu are
edges. There s noLhin g 10di-
m ension from . T hat's why we
u se agrid
to hel p w ith th e
lay out ,
T here a rc a f ew tricks
t ha tcan
m ake u sin g a grid eas ier.
(If
you
TR NSFERRING P nERN FROM GRID
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oodS01 ith
o pp os it e p ag e). th is sy stem allow s lh e cars 1 be ar
ra ng ed in an y
ordertoflt
th e n ee ds of th e e ng in ee r.
lR,\Cl\.
Arter
I
f in is he d b uit di ll lt t he
t ra in , I d e clded
to m ake som e track for the tra in to run on . T h e a rt ic le
o n p a ge s 18 to 1 9 shows h o w
to
b u il d b ot h s tr ai ghl an d
c urv ed s ec tlon s.I t hi nk t hi s is w h ere th e fu n b eg in s. f
YO\I m ake enough track sec tions. k ids c an u se th eir
imaginati ons to bu ild all kin d s o f d if fe re nt layouts.
M ATERlJI lS .
I buil t L he train and track from ha rd
maple . (J1 hard m aple is d ifficu lt to find in your area.
w e re offe rin gth ew co d a nd th e o th er
p art s t o b u ild
th e
train and track , see page 24.) But you could make th e
e nt ir e t ra in Q uI of p in e o r a ny o th erw oo d.
FINlSIL 111e
train and track w ill u nd ou bte dly g el
banged upso itm ay be best tosonen allthe edges and
to leave the w ood
unfinishedUycu
wan fin is h it.
I
w ou ld re com m en d a n oil f in is h th at f l o w s in to t he tight
spots. [ th e tra in is
to
be used by very sm all
ch ild ren ,
use
a
finish
that s
non-tox ic . s ee pa ge
24 .
1 4
sign ing a lO y lik e th is tra in c an q uic kly g el O UI
0 1 h an d. T h e q u e s tl on y ou r e u su al ly f a c e d with
isw ho are you designing it for: a child 1 p la y w ith or
a n a rlu ll to b uild ? F rom m y e xp erie nc e, k id s w an t toy s
that mov e a ro un d. b u t. d o n t b r e ak . A n d th ey w a nt l oy s
th at aUow them 10 IISC t h ei r imag in a tion .
A dults, on the other hand . w ant 10 b uild toy s lh al
loo k a u t h e n t i c (often 10t h e f in e s td eta iO . T I le p r ob l em
is
that
e xt re m el y d et ai le d t oy s
are
usually
builttosit
on
a s he lf, K ids wo ul d d e s t r o y r h e m .
In designing
this
tra in , w e trie d to comp r om ise . It
h as e nou gh detail to be interesting and not look
c lu n k y . But at th e sam e tim e, it s buill rugged s o e v en
t h e y ou ng e st
k id c an p la y w itll il
w ithou t
breaking il .
tlNIF )lt\l CHi\. SSIS.
Build ing ea c h of lI e five cars
sta rts lhe sam e - Y Ou build the chassis. Then it s a
m a tte r o fa dd il lg p ie ce s so it looks lik e a specif iccar.
Since a l lof th e chas si s a re b ui lll he s am e , an d int er
connect
w itb
a
u niq ue c ou pl in ll s ys te m (refer to the
A ll the ca rs for th is m in iature railro ad sys tem sta rt w ith the sam e ba sic
ch a ssis a nd a u n iqu e cou p lin g system T hen yo u add to p p ie ce s to p ro du ce
in d iv id u al c a rs A nd do n t fo rg et
to
la y som e
track
u n d er th e tra in
Toy Train
FOR KIDS
US T
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oodsmith
6
----- 4~~4
---- .....l -.,
and the
(WO
end walls (H)
10 fi t
between the
sid e walls . se e 1 ' ,g .7.
. '\SSE~tln.Y .N ow . glu e th e box toge th er.
an d glu e
it
down to the chassis. se e Fig . 7 .
SECOND: TRIM01 1
ROOF SEalON FOR tNGtNE
RIP
.. NC E
ROOF BLANK
IA THIel(
END WAllS ~
crrr PIECllS
1 0
S IZE. Beg in by
resewing
a
13 long blank I il' th ickfor
O le
wa l ls . Then
ri p th is blank 1w id e.
Next. cui the Iwo side walls(G) ~Y. t ong
,,
rnr BlADE
TO 1S
4
OWER BLOCK
3
D IUU. :l1~
HOltS
THROUGH
aLOC K fRO M
BO lK sro ES
GLUE PIEce S
TOGElH.e~
Af\ lOOOWN
TO CHASSIS
~ TAIMOFF
~KN08
SPACEM1DD lW HEt l l.-l:
FROM . : HAS54S
. . . . j 1
., th ickto p s ec tio n (0 ) 3
long . and
ro u n d o ver
th e
from end
an d s id e s.
see F ig . 5 . N ow drill ho les (o r th e
smoke-
s ta ck , f ill er
ca ps,
and headligh ls. se c F igs. 1
an d 5. Then glue down. the bo il er pa r t s.
CAl l .
N ext, m ak e th e ca b
(E)
ou t o f a small
Since th e engine p u ll s t he res t o f t he t ra in , I
built it first. i 11~ ch ass is (A ) for th e engine
requires few m o dif ications. F irs t, cur th e
to ngueo f fU lcu 'on tend . see
Fig . 2 .Then dri ll
anothers et o f h o les fo r th e ta ndem whee ls.
L O W E ll B L O C K .
S lar tadding
to p
pieces by
cu tting a lower block
(B)
from
: ,, -ul (c k
stock
that's
th e sa m e w id th as the chass is .
T hen trim an lS ' bev el o f f t he fron l end an d
glu e
lh e b l
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1 7
Voodsmith
WINDOW DETAIL
..-- WINDOW SECTION
~4)t 11n x 4);t)
CUTTWO [ .. LO NG
ROOF PIis
CAB@
f~ X 11
1 -
x 11 \
WASTE
BARRELRACK BLANK
11
A. )5EMIl~Y.Now.
glue the pi eces
to the
chassis
so ihey 're
parallel to
ea ch o ther
an d
0 8
apart.
This a llo ws the
ribs
on the barrels
to rest
betw ee n
th a racks.
BOTTOM BLOCK
(~. -1~. X4~;4)
12
GLUEOOWN
1J.. f ROM
-FRONT OF
CHASS1S
l/ .. ..-THICK
STOCK
__
.65
\Vhal
W Ould
Ille end of a t rain be w ithout a
. :aboose? A ll the parts
fOI
Ih e c ab oos e
are
similar-to piec es
m ade
for
the
other cars ,
UI ITO~IBLOCK.Startby
cutting
a
bo ttom
hlock(L ) th e
s ame s ize es o nthe passe nger
c ar a nd glu e i t to the cha ssis. se e Flg.12.
\\l:o( en barrels. (S ee page 2'1 fo r
urce s 01 the barre ls. )
\lt
To make the barrel ra ck
(1
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ct MP CU VE O
FE NC E
2.~.
fRQMlL
you use th e p lywood base boa rd . drive a nail
through the hole in th e piv ot b o ar d a n d into
th e baseboard .
(B esu relo aJign
th enai lwi th
th e front g of th e blade.
\V ith a Cu rv e b la nk in place On th e jig ,
sw ing th e pivotboard th rough the blade an d
cu t o(f lhe outside a rc of th e cu rv e, see fig .
4 . (S ave th e w aste piece from the end of the
pivot board, It's used
On
th e n ext s te p .)
c;lltINS1D ; ARt S. Af te r cuttinglhe outsid e
arcs on all th e c urv ed p iece s and sa nd in g o f(
th e to oth m ar ks, you can cm t the in sid e arc s,
To do this I use d the curved w aste p iece
that
w as c ut o(f the end of th e pivot board)
as a fence. sec F ig , 5. Posidon the curved
piece 2% fr om the insi de o fth e b la de. (This
w i l l
cut a curv e section
VIS
overs ize .
After
s an d in g, the cu rv es should en d IIp~ \e sam e
width
a s the
straights - 2 :t t6 .)
Go ahead and cu t a ll the c urv e se ctio ns to
width .Then sand thein sld eedge (rem oving
at leas t V16~so th e curved sections m atch
th e w id th o f the straightse cuons,
W @0< .1 snlith
N ex t. drill. I ll p ivo t h ole cente red on th e
width of tile board and I [r om th e end. To
help
pos ition
the blank s on the jig . nai l a
I071f j longenceto thejig so thejin edge of
th e fence is 1 2v.. fro m the p iv ot ho le.
N ow set one of the curv e bla nks on I,Q po{
th e jig and align the en ds-of th e b lan k w ith
tile fe nce , seeFig, 4. Dri ve smal l nai ls atboth
ends 9f the blank
to
ho ldit
in
place.
USING
tEJIG
To
cu t the ou tsid e
cu rv e. I set the jig on
top of m y circle jig
(s ee W oor( 1 iI I lNo.
51. O r, ju st c lam p a
piece of:v.. p lywood
to your band saw
table. S('e fig . 4.
I f you 're using-the
ci rc le
jig . positio n
th e pivo t poinl16
[r om the blade,
If
CUT INSIDE ~~
5
\
S fT Mll tA
G UOE T
2 : 2 :
1 8
Ct MP ~ PlYWOOD B Se
CJRCL JIG TO aAN D SAW
rRACKa~K
A fter th e m iters are Cu t on the ends ufaH th e
curve blanks B. you can se t up to cut th e
in sid e
an d ou tside arcs .
PIVOTJIG.
To
accu rate ly cut th e outside
arcs, I m ade a p ivot jig that sits on top of t he
band
saw . Beg in m a king the jig b y c uttin g .
1 4
x
18
p iv ot board from a piece of V .
plyw ood or M ason ite.see F ig . 3,
CUnlNG THE CURVES
CURVED TllACK
}
ClAMP
~NGLtO
22n
SToP BlOCK TO
AUXILIARY
ENC( ~
NOTE:
All StOCK
I,, THICK
m erg er w ith a not her railroad line),
cvr
IUANKS.
Begin m ak ing the track by
cu ll ing blanks fro m
1 2
stock
fo r
th e
stra ig hts A an d cu rv es 8,$ee Fig. I.
~llTER CURVES.Before cutt ing the cu rve
pieces (8 ) to their ro unded s ha pe . I m itered
th e ends ofthe b la nks . s ee
F ig . 2 .
To
do th is ,
attach an au xili a ry
fenc te t o the m iter gauge and se t
the miter liduge at
Vl
The n
m iter m end of a ll th e b lanks,
T o se t up tocut th e other end ,
tu m on e of th e b la n ks e n d- fo r
e nd and c lampas top
b lo c k t o tile
auxi l iary
fence , s ee F ig . 2 .
Adjus t
Ih e stop to trim of t th e b la nk s o
it's
l 0 7 i 1
long on
t h e
shortslde,
se e F ig .. T hen cu t a ll th e c urve
blanks
B
t o lh is
leng th .
The train can opera te O n its ow n, or you Can
m ak e a tr ack fo r it. By m a kin g b oth curve d
W Id straightse ctionsoftrack, YO Ilc an create
aw i de
var iety of interesting lay outs.
PREP_RING STOCK
A good way to start is to m ake ~ight
s tr a igh t s ect ions
~ I.
an d eig ht curv ed s e c -
tio ns
B .
(EighrcuI'V esa re needed to
make
a
com plete
circ le.) This
makes
a good s iz e
la yout , and you can add m ore se ctions la te r
< as long as the government approves your
Train Track
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~ P US H
SHOUl.D R
0 RAaen UP
l iGHt ro SPACER
T A A C 1 blocks,
and the
fence
is
fr om the po in t o f t he bit.
ORlLLTliECO )' 'NEC I'ORS .N o w d rill % d ia .
holes ,
~ 6 '
decpon bo th
edgesof theconnec
tors
(C),
se e P ig. 1 0. W h en d rill in g, p ush th e
c on n ec to r tig ht a gain st th e fence.
ORlL.LT I IE
T R A C K .To drill th e
ni.tehing
holes in t he tr ack. us c the sam e set-u p, ex
ce pt yo u ha ve to add a 4 th ick space r to iii
un der th e rabbet in the end o f t he track, se c
Fig.
11.
The
tri ck here
is
to cut the spacer
1i6
w ide (w hich is
V I~
wider than the
length ofthe rabbe t On the end
o f
the track).
Wben
thet rack
i s pu shed again st
th e
spacer .
(h e hole
will
be po sitio ned to create a gap
b etw e en th e en ds o ( th e
track. Again,
th is is
to
make i teasier
to
assemble. )
DO W ELPII'o 'S.he last step in m aking the
connectors
is
to c u t W ' long d o we ls a nd glue
them in to
the
h ole s in th e co nn ecto rs, see
F ig . 9.
TRACKSl lAPES .he
track
c an b e lay ed o ut
in a vari ety o f shapes, espec ially if m ore
65
1 0m o f t he ra bb ets o n
tile edges,
see F ig. 7.
Afte r th e sa w w as S C Iup , I r ab be te d b ot h
ends
oitlle
straight track W
USing
a
miter
g au ge to
support
t he w o rkp iec e .
On th e c ur ve d track B), I
backed
up th e
wo rk pi ec e w i t h c u rv ed pu sh
blocks. se e Fig .
8.
T o .
m ake the blo ck s. trace the shap e
o f
t he cu rved tr ac k o nto p ly w o od.)
t ra ck . r ef er to p ho to b elo w .
To
se t
up ( or c ul lin g t he se
r abbe ts . f ir s t
moun t a
I lVJ6 wide
dado blade on the saw
and
auach
an
auxil ia ry fen ce to th er ip f en ce ,
se e
F i E t ,
7a. Then bury the blade in to the
auxiliary
fence
so
0/4'
is
exposed ,
Now
r ais e th e
blade
up to
cu t
a
rabbet
exactly deep en ough to align w ith
th e b ot-
Join the pieces of track together. small
,n,, < I t
together. connectors
a re m ad e
that
fi t
Wl
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~I \RK~IIRROR .Now you c an uSC lhe fo ld s
in the paper to mark th e points whe re the
axis
lines
m e e t
th e
e d g e o f
th e m ir ro r.
se e
S te p 3 .
tA y
OlIT TEMPI_lJE ....
Jt er m arking ' th e
axis lines en tbemirror. th e te mplate can be
cu t rolll a p ie ce of 14 Mason ite . (T he te m
p la te s hown
in Step
is sized
to accept the
ovalrnirror.)
After
< ,u ttin g t he
templa te to
size.
mark
tw o
cross
lines.
see S tep 4.
Now align
th e
marks on the
edge
o( th e m irro r w ith th e
cross lin es o n th e te mp late , see S tep 5 . To
ho ld the m ir r o r s te ady , use pieceotdouble
sid ed c arp et ta pe to a tt ach uto the tem plate.
GUI E USHING
The id ea o r a lllh is is 1 0 us c th e oval shape of
the m irror to m ake a guide tem plate ro r a
route r. Th is template is then use d ,v illl a
guide
l~ hillg
h at's m o unted to the base o (
the
ro uter,
see S tep 6.
Woot.1sm irh
o nly ro ut th e o va l ins id e the base.Thisgives
yO U
a
few m o r e o p ti on s (o r add ing a :Dlving
or inlay the lid o r the box. .
MKING TH T MPL T
O k ay , b ack to the m irro r and tem plate. T il
m a ke a te m plate to rout a recess for t hem ir
ro r, th e first step is to tra ce th e s ha pe o r t he
m irro r o n a piece o p a p e r, s e e Step 1 .
FO W O N A XE S. In
o rd er to alig n th e oval
sh ap e on a tem plate .yo u have to determ ine
th e tw o
a xe s o f
th e
ov a l. T h e re s
a n ea t tr ic k
to do th is , JU St hold th e paper up to a light.
sec S tep 2. 1 1 l ~I ighl allow s yo u to see th e
o va l curve on both S id es r th e p ap er, Adjust
th e p ap eruntil th e curves align , and (o ld th e
sh ee t in half.
T h e (o ld l inc in dic ate s o ne a xis ofthe oval.
Fo ld the sh ee ti n h al flh e ot hel'way to get the
o ther ax is , (Ih ese axis lili e s a re p a rt ic u la rl y
impo rt an t t or a li gning t oval in a r ee ta ngu
la r box. )
20
v als are p le'a sin g shapes - bU I v y
difficult to draw . W hen
ec ide d 10
m ak e
an ov al
b ox . I b ad rw o
choices. could
get all
oval
temp late from all art Sl()re.
Or. I
co uld trace so mething that already had an
ov al shape.
The cho ice was easy when I ran across a
source
( o r a b e au ti (ul beve led-edge
o va l m ir
ro r. s ee soerceson ]lIlll~24. W i lh th e m ir ro r
i n h an d.I m ade an ov al bo x th at m a tc he d its
shap e. 'ln is inv olv es m ak ing a tem plate to
cu ta
recess
in th e lid fo r
th e
mirror.
While I
was at it .I u se d th e sa me te mp la te to
ro ut
a
malch ing oval recess t he ba se.
Des ign
Note : I f you don 't w an t to use (he
mirror. bu t still want to m ake a box w ith a n
ov al recessinthebase.ju st
gel
an o val tem
plaiefrom an artsto re and tr ace the shape On
a p iece or~M aso nite . The n cu t it o ut a nd
sand
it
as s h ow n in S lep 8 on th e n ex t p a g e ,
T here's ano ther option . to o. Y ou can
m ake a rectangular bo x On the ou tside and
he beau ty of th is ova l box is the be veled eclge
mirror
tha t inspired
t
h e cha llenge w as to figure ou t a w a y m a ke
th e bo x fit th e exa ct shape o f the
mirror.
Oval Box
PROJECT
F T
7/24/2019 Woodsmith - 065
21/24Z l
9
T o l tl l the (,(mt.plat~,dJ'ili -Y '8-dia .
index ho l.esOI . /lO lk lind. of the l O l lY
a~is
ente)' th e
i1ldl1>.
o le. 1 , . 1 > ' 0 ' the
e d g e oj' t l le ' i , el e> ' f
the firro;loith
)~(1i Ppenci],
w ith a dl1l111 sander mounted iu your dri l l
p ress, see S tep
8.
INDEX HOI.ES.
This tem plate
w ill
be
m ou nted to th e
l id,
and the n to the ba se to
routouttheoval
shape. T oa lign
thetemplate
on both pleces.l dr ill ed
t W O I G
index holes .
seeStep 9.
These holes
a re a ls o u sed
taterto
loca te and
drill
holes in the
lid
and base for
in dc~ pins to kee p th e lid from slid ingoffthe
base. refer to F il . 14.
FlN tSH .l f in is he d ( he l id a n dtheo utsid eo f
the ova l box w i th G en er al l~nish~ ' T w o
Step Sea la ce ll syst em . After fi n ish ing, 1
added a piece of fe lt to U I ., in sid e b ottom o f
ti le box.
bu shing ,
se e
Deta il illStept; .
f
you w a nt a n
. (lct fit
make t he t emp la te
~ Ia rgerth.n the mlrror .However. l made
t he t empla te
/s
la rger than the m ir ro r.
This
creates a I > : r l space areund the edge 01 th e
m irror to a llow f or e xp a nsion of lhe w ood
a round th e m ir ror . se e
SICP 7 .
Shop Note:
I us ed a
pie ce o f c ar db oa rd to
tra ce the line
v
outsid e the per im eter of
the mir ror .
See
$h bp Notes
On
page
12
fo r
m ore on th is tec hnique.
cm-ro SIIAPE.
T o compl et e th e template,
cu t out the insid e to rough shape w ith eith er
sabre saw or a coping sa w , T hen sa nd the
edg es sm ooth r ig ht u p
to
the m a rked line
T R C E
ROUND
P E R I M E T E R
OF M IRROR.
HOlD
MIO.
ON
TRACING
P A PE R
A lmost
a ll
router m anu fact urers offer
a
gu id e bush ing (o r templa te guide) tha t fits
on the ba se. of th eir route r. T his gu id e bush
in g ex tends below the base of th e rou te r so
it can nib a ga in sttheedge of a templa te. T he
idea
is
for the guide bushing to follow u i e
shape the
t~mp la tc whi le the router b it
(t ha t fi ts in sid e th e guid e bu sh ing) actual ly
does th e cut tin g .
T here 's one consid eration her e, T he
router bit cu ts a pa th tha t's i ,(si
7/24/2019 Woodsmith - 065
22/24
NOTE:
TO-C U T FU ll
OPTHMAK
SEV ERAlPASS{ . S
wide
lip in sid e th e e dg e
o f th e
template.
se e
Fig . 6, T he m irror sho uld fit inside lh is lip
w ith a bo ut 1 0:3 2p ac e a ll a ro und.
ROllf S ,I SF .,N e xt r ou t o u t t he base o f t he
box the sam e w ay, bu t to a dep th of 1 .1 did
th is by m aking a series of passes about V .
deep each lim e, se e
fig.
7.
Woodsm ith
Tt M PL Tl
lRJANG~
INUPWAlto
POsmON
4
a c s s
INllO
~~l WU>E
UP
6
the
(ac e o f
the
mirror
will be
6ush
with
th e
edge of th e lid (about a :V J2 deeprecess).
Remove the w aste by plu ng in g th e r ou te r
into the center of the lid and m oving it in a
c lo ck wise p attern u ntil y ou rea ch
U lC
per
im eter o fth c tem plate. see fig,S .
W hen yo u're d on e, there sh ou ld b e 3% 2
1NDEXING
PJNSMUSl
SETBilOW
TO P O F
T E M P L A T E
U SE
MA SkiNG TAPE
fO KElP Pf lCl ,
LIG NE P W Hl l
DR aW NG H OLE S
S
A14GN Slots
OF TftlANGl.I
N o. 65
M K E N D W rT H
CAJtPfNltA S
TRI N U
LIG N lOGE S
OFAUPK6
2
O R . .. .
3 , - 0
ttO U
I. DO
.
ltMPLArE
NOTE:
Gl Ut AND ClAMP
aonoM TO A SE
A ~
BOTTOM
BJ.ANK ....
, 1
~
B A s e
BJ.ANK
The index holes are used first to align
th e
temp late to the lid to rout a recess r th e
mirror, see F ig , 5 , Tap in d ex dow els ~t6 '
d ia ) in to th e h oles , b utd on'tg lue them in.
ROl lI 'UD RCf .$ , To rout ou t the recess
in th e tid , use a 11.1 traight bit and R 1/ ,0;
g u id e b u sh in g, S et th e b it deep enough so
R O U T R E C E S S
The nex t
step
is to d rill holes in th e
lid and
b ase Io r
th e in dexin g pins .
HOLES
uo. Sta rt
by l if ti ng
the
lid an d
tem plate off the
base, Then
Bip
th ese tw o
p ie ce s o v er
so
the t emp la le is
fac ing
u p a nd
la pe th em to geth er. see Fig , 3.
Now with
:.6 -d ia. bil,
drill
holes
I ' . ' l
deep in to th e lid a t.e ach end US ing the holes
in the templa te a s a gu ide.
HOl.ES IN B AS E.
Repeal th is pr ocedure on
th e ba se.Justptace th e template O n t he ba se
so
th e sides of
the
carpenter's tri an gle al i,,,
properly,
S L > C
Pig ,
< I .
D R ILL IN D E X H O LE S
I slat ted b uild in g th e b ox b y cu ttin g a b lan k
fo r
th e lid (1\) from ~ stoc k to m atc h
th e
size
th e te m plate, see F ig,
1,
The base is
made by glu ing ijp tw o pieces a :v.1 thid aonOM
OFeASt
ONA
ST ArJONARY
ElT SANDEa
IAS
SETUD
ONTO
10s hap e. p lac e il on
th e
ba se using the index
p in s t o a li gn th e lW Opieces , see F ig . 9 . N ow
useth e lid asa templateto trace tlr e o va l on to
th e base . and
Cui
it
ou t 10 rough
shape on a
band saw
S. N I ITOUNE.
To gel th e
base
10
th e
sa m e
shape as th e li d . sand them together with a
dru m sander ore n a
bel l sander.
se e
F ig .
to .
10
12
If
RO UN O
OV~Ran
11
No.6;
111e oval box is complet e ar th ls poin t -
ex cep I r rouLing p ro file s on th e L O Pedge of
th e Ii d and the bouorn edge of the base .
SHA I}OWLIN E . H o w ever. before I d i d th at.
I ad ded a shadow line be tw een the li d and
th e base . If eiLherp iccc w arps. th is lin e adds
enoug h depth So th e cra ck be tw een the ti d
and bas e is
nO lSO
visible.
A U X IU A R V F EN C E .
T
ro uL th is
shadow
l ine.
mount
a
i t l sl ra jllht blt to
th e
ro u te r
table and se t th e b it
h2 high .
se e
r i g .
na.
Then I c lamp ed a n a u xi li ar y fence (a p iec e of
: v . t
plywood)
0
th efront of the r ou te r t ab le s
r eg u la r f en c e.
N ow 111 m 01\ ti le
ro uter and
slid e th e
auxi l-
iary
fen ce in to the b it
to
rou t
an
open ing th e
w id th
of
the b it .
To reu t thesha dow lin e tum the r ou te rou
and ad ju st the fen ce so th e b it extends h2
o u t.
see
Fig .
ll a . Then
ro u l
a ra bbet
on the
to l out8 ide d ge
of
th e
base on ly to produce
th e shadow line . r ef er loYig . 14a.
~OUNO OVllR 111151000 After rOulin
the shadow line. 1 s witched to a
\/,j
ro und
over bit and rounded the insid e edge o f the
base , see F ig . 12.
O Im JU F.IROAt.S.11lC outs ide edges of
th e bas e.and th e lid ca n be ro uted to severa l
shapes. [ used a
A t
round-over b it. to
ach ieve a s imp le and
grac efu l lo ok. ( Be fo re
USin g
other b its , check rha t their p rofiles
w on t curinto Ihe holes fo r the in de x p ins.)
INDEl
7/24/2019 Woodsmith - 065
24/24
\Voodcra fl Supply
P .O . Box 168 6
P ark ersburg. \VV26102.T1.
NT
Bridge City Too t Works
11 04 N .E . 28th. Ave.
P o rtla nd . O R 9 7 23 2 NT
Tandy Leather
1 .0.B ox 791
Fort \V orr n . TX7610 1 .. .. .... 8H
Sbopm ith , Inc .
393 lltn age D rive
D ayto n. O H
45414..........T1~
NT
S i m ii m / w 1 '( J .w a . 'I I a> ld SIIp JUes nuty be jm ,.td
i n l it e j 'o l /m / li ? IU c a tl li ogs .
Htnseuer
st l ies a11dl l i zes ? )W ,IIva ry .
PIdJ .se ,-e el ' to eackc(J. ia/t: lufol 'orde iU ;> lf n)'m ati.m~
VanDykes Rest o rers Cherr y TreeToys, Inc .
P .O . B ox 278 P .O . B ox 369
Woo nsc cket, SO 5738 5 .. .... . Rli B elm ont, OR 43718 ...... .
T T
NT
LTERN TE T LOG SOUR ES
OVALBOX
T he m ateria ls n ee de d 10 build
the O val B ox am availa ble (r om
\Voodsmith P ro jeetSupplies.
T he ov al m irro r and si li co ne
se ala ntc an b e o rd ere d u sin g th e
num bers below '. (W e recom
m en d u sin g Dow s silicone se al
ant to attach the m irro rs sin ce
s om e o th er silic ones m ay da m
a ge the si lvered backs)
765300
(1) 3 x 5 Beveled
Ova l M i n 'O r $5 .115
0765-305 (3-0z.tube) Dow
Sil ic o ne S e al an t (enough to al
tach
8()
to
10 0
mi rr or s) . ..
$3.29
Al so ava il abl e
ar e
lu m ber kits
in your cho ice o f s ev e ra l d if fe r
en c hardwood .species, Each kit
includ es th e fo llow in gil cO ls:
(1 pc.) 4~
x 6I; i ;
l thick
lum ber (to m ake the lid )
(1pc.) 4~ x 6 1 2 ; t 'Vu; thick
lumber (to m ake the base )
l : V I Dowel. 4 lo ng
'765310 Oval6Q x . K it o f
Lum ber - O ak $7_95
765320
Oval B ox . Kit o f
I , .umber- W ainul .. .. ... .. $8 .95
765-330
O val B ox . K it 01
Lum ber - Cherry ...... .. . 5 8 .95
0765-340
O va l
B ox .
Kit
o f
Lumber - P adauk ..... . , .$12 .95
(Padauk
is
an
exo tic ,
red-
o range hardwood that turns
deep m aroon on exposure to
sunlight, P adauk 's saw du st can
be irritaling . so using a dust
mask
i s adv ised.)
NONtOXI FINISHES
You
w i ll wan t
to use a non-toxic
fi n ish on
the Toy
T rain and
Track project.
Ordinarily. I
li ke
to use a salad bow l finish OJl IOY
projects, bru (o r the train I d i:;
c ov ere d this fin ish w as ju st 100
thick 10 se~f in and around all
the sm all parts o f th e tr a in . In
s tead. w e used a finish called
P re se rv e N U LO il a nd fo un d illO
bean ideal I in is hf or fh e t ra in s et.
P re se rv e is a blend of natural
o ils (rom ex otic nu t meats an d
provides an excel lent .
no n-toxic
fi n ish (o r toys as w ell as bow ls
81ld wooden kitchen utenslls.
T here are o th er fin ishes ~ la l
will
als o p ro vid e
a n on -to xic fin
ish and are still th in enough to
no w
o ver th e sm all tra in parts.
TwoO flhese-General l ' inishes '
Two-S tep Seal ae ell System and
\ValCo's D anish O il - arc bo th
non-toxic
when < ' ti red : (Accord
ing to th e ir manufacturers, this
can take
from IW O 1 0 (ourwceks . )
N on-tox ic f in is h es f or th e toy
train p ro je ct are availa ble (rom
\Voodsm ith P rojectSuppli es.
orf rom
t he SOu rces l is te d
below .
L oo k (o r m e
code
NT (oliow illJ(
thesupplier'sname.
0765-275 Preserve
NUl Oi.1
F ln ish , o z
$8 .95
51j ..203
General l ' inish ,, '
Tw o-S tep System $10 .95
l > ' l P int Step Ifl
(Sealer)
~ P in t S tep 2 (Finish
Coal )
A I J o w , ~
lo o e J , : t 1 / o J '( i f ' / f o o '7 1 .
;V ri f> : 1 - '4 'c t J
*~(b ier. t
c J la . 1 g (
jl.,' 9/90.
Y PHONE
F o r fa s te r : serv ice use o u r 1 9 1 1
Free
o rd er
lin e, Phone
o rders
can b e placedM onday th ro ugh
Friday . 8 :0 0 A M to 5 :0 0 PM
csr.
B efo re you call . have your
V IS A o r M a ster C ard ready .
18 4447 2
T M IL
To order by m ail. U$~ form
on
th e
pro tec tive
co ver o f
$
cur-
re nt issue o r w ri te your o rd er
on a piece o f p aper. and send il
with your check o r m oney
o rd er. (P lea se inc lu de $1 .5 0
shipping
charg e
with each
order.) IA
residents
add 4%
Sal es la- x . Sendord er Ill :
oodsmi th ProjectSupplies
P .O . B ox 1 0 35 0
Des M oin es, IA 5 '0 8 0 6
ORDER INFORM TION
TOY TRAIN
\V oodsmilb
Project
Suppl ies
is o ffering the m aterials and
hard ware needed to build the
f lv e- ca r'Toy 'T r al n and
Track
r e a -
tu red in th is is su e
O th e r
su ppliers w ho c arry toy
tra in p arts are lis te d b e lQw .Look
(or th e code 7 1 (o l lowing the
s u pp li er 's n ame.
.765-200 Flve-CarTraln,
P arts O nly $6 .95
The k il a bo v e in cludes all th e
par ts (bill no lu mb er) n eeded 10
build five train cars:
(2 2 ) I
. t i l
x
7/ 1
6
Wheel s
(2 4 ) I I. W lleel A x le P e gs
(1) % x I
1ft'
S mo ke S ta ck
( te n on f il S v . ho le)
(1 ) 1 1 . 1 Dia . Dowel. 6 lo ng
(4 )
Oi l Ba r r el s
.765225 Five-CarTrain ,
Parts Lum ber $18 .95
11l is k it con tains all the part s
listed above. p lus the
lumber
(m a ple ) to m a ke fiv e c ars:
(1
pc.)
3~. x 17 : : f. j lhick
(2 ,p t $ .)
3 i Y 1 I
x 17 :~ . th i ck
I
pc. )
I 'r . x l ll : 1 I . lh ic k
.765-250Train
Track P a rt,
.
Lum ber $39 .95
Th is ki t conta i
llS
enough
m aple to produ ce eight curv ed
and e igh t s tr a ight t rack s ect ions.
(81)