Fixing mistakes Bandsaw tires Precise angle setups Low assembly table

108 Pages·2008·16.91 MB·English

Fixing mistakes
Bandsaw tires
Precise angle setups
Low assembly table

DEPAR TMENTS
&
Letters 4 Events 94
Methods of Work 12 Books 98
mm
Questions Answers2 2 Notes and Co ent1 00
ARTICLES
Cabinetmaker's Assembly Table by Charl3e8s Davis
Torsion-box construction and a wooden brake 38
make this mobile work surface strong and stable
Dealing with Woodworking Mistakes 42
by Sandor Nagyszalanczy
Building a low, mobile assembly table, p.
And strategies for aVOiding slipups
mn
Reeded Colu s from Shaped Staves by4 7T im Carr
Bandsawn and routed segments simulate carving
How to Install Bandsaw Tires by Robert5 0 M. Vaughan
Getting them on is only part of the job
Routing Tapered Flutes in Flat Panel5s4 by Malcolm Vaughan
Jigs make short work of a magazine rack's fan-shaped ends
Choosi2n the Grain Pattern for Curved P58a rts 50
by PetTeirs Chler
Endgrain orientation determines surface pattern
Simple Instrument Sets Precise Angle6s0 by Tom Rose
A shopmade sine-bar and basic math yield accurMaotuneti ngm biantdesarws tir esa, pn. d bevels
Curvaceous Carcase Construction by Jo6h4n Eric Byers
Slats dress up bendable-plywood sides
nin
Build a Bent-Plywood Kayak by Chris Ku6l7c zycki
Stitch-and-tape construction can put you on the water in less than a fortnight
Double-Blade Tablesaw Teno g by Mac C72a mpbell
Spacers and shims between blades make setup fast and accurate
Arm
Threaded-Lid Boxes by Steven Gray 76
Shop-built device simplifies threading wooden containers 60
Molding on a Radial- Saw by Dick Wil8l0f ord
Auxiliary fence and table provide safety and versatility
Setting up for angle cuts, p.
Cutting Sheet Goods Down to Size by 8C2h arley Robinson
On the Cover:
Alternative rigs for sawing and routing large panels Cutting tenons with a
double-blade setup increases accuracy
and production. Mac Campbell tells how
Flocking a Box by Spider Johnson 86 to cut tenons safely with his unique aux­
Simple, inexpensive method for adding a velvety lining 72.
iliary fence on p. Photo: Alec Waters
Fine Woodworking cr
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Letters
(
wnia
Source for pauIo seeds -Hurray to Fine Woodsmwookrkeidn ga little, but I wasn't too surprised because I knew this
for publishing the articles by John Melhuish and Warren May was a very deep cut to make, especially in hard maple. After the
FWW
#93) about paulownia trees as a source for high-quality cut, I checked the cheeks of the tenon-and they weren't
hardwood. John and I have worked together for over 13 years burned-so I set up for the next cut.
researching and experimenting with paulownia. We had a vision But when I made the final check of my setup, much to my
that blossomed into a mission-a global mission. We have en­ dismay, I noticed a red glow inside my tablesaw. Since I had left
deavored to introduce this incredible tree to the public for its my dust-collection system running, I had not noticed the smoke
ecological, economical and wood-utilization virtues. We asked coming from the fire developing in the sawdust below the blade.
Warren to help shape the direction of the mission by working A spark, fanned by the dust collector, had now developed into
with the wood to demonstrate that the raw material does have a quite a blaze.
confirmed use. The excellent photos in the article of the finished I quickly shut the blast gate to the tablesaw and grabbed for
products only touch on the real beauty of these items. the fire extinguisher that I keep near the enu-ance of my shop.
John left his job with the U.S. Forest Service, and I left my Luckily, the saw was not damaged and the burning sawdust had
professorship at the University of Maryland, and we set up the not been sucked into the dust-collection system, but if the fire
National Paulownia Center. We have provided information, start­ extinguisher had not been close at hand, a minor mishap could
er kits, seeds, growing instructions and economic data to over have cost me my tablesaw, if not my house. I had never expected
9,500 tree growers, woodworkers, industries, conservation to use tllat fire extinguisher on a fire ignited by my tablesaw.
am
groups, the Peace Corps, Native American tribes, and state, feder­ Since tilen, I have changed my work habits to include a cooling
al and private agenCies in the United States and 66 other coun­ off period after I done working, and I always check my work­
think an
tries. If you are interested in receiving high-quality seeds, grow­ shop before I go to bed. I hesitate to what might have hap­
ing instructions and other information about paulownia, send $1 pened if tile spark had ignited on the last cut of evenings' work.
Christ
and a SASE to ational Paulownia Center, 4303 Kenny SU-eet, -David ianson, Brighton, Mich.
Beltsville, MD 20705; or call [phone].
... curin
-Peter Beckjord, PhD., Beltsville, Md. Se g a loose dust bag-I've come up with a tool modifica­
FWW
tion inspired by Sven Hanson's article in #92 on orbital
Wh
ere there's smoke -sI'amn dwerristi. nWg htoe nr eIl ayu saend emxpye rBieonscceh orbital sander (model
that occurred in my woodshop recently. I was cutting an open #3283DVS), I ran into tlle same problem that Hanson described
mortise and tenon for an end vise on a maple workbench using in the article-the dust bag came loose. Hanson had also re­
my tenoning jig on the tablesaw. Because the tenoning jig held marked that Bosch's right-angle model (#1370DEVS) uses an
the workpiece vertically, I had to cut a full 2% in. into the end­ a-ring to hold its dust bag in place. This gave me the idea to
grain of the workpiece. When I made the first cut, the UNTOwood modify my sander. I filed two slots on opposite sides of the dust
� N anlSO ttern xanulfilnlm &
The Taunton Press: Servi
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gmerr-t;un/ancllyst; Arthur n, Roben Nielsen, rzaimnmeer"sS);;) .T racie Pavlik, secretary. P nnel: Carol Maroni, manager;
CirCNlIItlon MII_ger Brenda Htoamiln
Kinnear, teeb. services admin. SheriU Kolalkionwdsak iB,a lcloemrpiuntie,r Chsruips Lincoln, personnel assistants. Video: Craig Uman­
Mllrketing Coordi_tor Susan Roman ician. Folkwear: Cheryl Clark, manager; Gaorffo,l vGiedee, o(lt lcmoiolrdli.llcl taOsrs,t .T;h omas Menard, asst. vicleo producer.
Adminlstrlltive Se�etllry Susan M. Clark
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4 Fine Woodworking
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ER SERVICE NO. 97
July/August 1992 5
Letters
(continued)
chute to receive an O-ring that would secure the dust bag. I used ration. All the tools are in my small backyard workshop and are
a 1 V4-in. by I-in. O-ring with a 1/8-in. cross section (a standard exposed to the same humid, Florida weather conditions.
size available at most hardware stores), and filed the slots about None of the tool distributors or electric-tool repair shops
V8 in. wide by V2 in. long( and about % in. in from the edge of the seemed to know if neoprene was better than rubber wire, or if
chute. The O-ring provides a cheap tension clamp to hold the there was a specification code to evaluate the best material for
- -A
dust bag in place. -Callan Campbell, Chicago, Ill. the jacket covering. I suggest that woodworkers periodically give
u
all the cords in their shop a close inspection.
Mis ts
placed T n I found the article by Lyle KrugBeyr tahbeo uwta hyi, sw ould you call it superior engineering when a
FWW
shopbuilt tenoning jig #93, p. 66) both interesting andp roduct fails right after the warranty expires?
disconcerting. I would like to direct your attention to the place­ -Daniel Angert, Orlando, Fla.
umns
ment of the T-nuts in the drawing that accompanies the article.
than uart
The T-nut on the lower half of the sliding portion of the jig A-bit-more- -a-q er col -Thanks for Mac Camp­
FWW
should be installed on the bottom of the piece, not on top, as bell's excellent article on quarter columns in #93. Inset
shown. When the threaded shaft of the locking knob is tight­ quarter columns are a handsome, classic alternative to square
ened, the T-nut should be captured, so the two parts of the slid­ corners on all sorts of case goods and allow for considerable
As
ing jig are clamped together. drawn, the four small prongs of variety of design. But after using quarter columns on a number
the T-nut's flange are all that are holding the parts together. The of commissioned pieces, the results began to look flat, as if the
same goes for the four T-nuts on the jig's face that hold the column curvature was too shallow, and the case corners above
clamping assembly. -Kenn Van-Dieren, Rochester, NY and below stuck out too far.
An alternative is to use partial columns with greater than a 90°
EDITOR'S NOTE:
Good catch, Mr. Van-Dieren. You're rairgc,h ctu t atob ao uritgh tt ahnegl e mbieshipnld ath­e axis of rotation. This isn't as
cement of the I-nut that receives the locI kipnrgep okstneorobu.s asI int sefemais rant feirssts g latnoce . LFyorl eex ample, if the plan
Kruger, whose jig the article describes, shcoaullsl fdo r pa oqiunartte r ocuotlu mtnh oaft 1 %t ihne. r aedirurs,o Ir can turn a column
was only in the drawing, not on the actual joifg 1./12 Hino. wreadvieusr ,an dt hthee n Ila-ynouutts a roignh t-tahngel e section whose
jig's face (which Mr. Van-Dieren also mentions) are located correctly on
maximum width is 1 % in., as shown in the drawing below. The
the drawing. Ihese I-nuts are installed in the back side of the jig's face,
included arc in this case is about 110°, giving the column a much
and then walnut caps are inlaid over their flanges.
rounder, fuller appearance.
Although no one would ever put a regular hex nut on the wrong side
of two parts when bolting them together, it is Sntoantd arud nqcuaortmemr coonlu mfno r peoplQeu arter colum9n0 °w ith more
to mislocate I-nuts. Ihis error can be avoided if you remember that even than a arc
though the I-nut happens to fit into a hole, it still functions like any other
nut-it must be on the far side of the parts to be bolted together.
urs
If
you're self-employed, don't forget to work for yo elf­
Occasionally, you print articles and letters about the pros and
cons of running your own business, and I have something to add
to that discussion.
For the past five years, I have been designing and building
furniture and restoring antiques in my own shop. I learned this
craft from my father, and I can understand a person's trepidation
and frustration with the craftsman vs. businessman dilemma. Al­
though you probably won't get rich as a craftsman, there is
something else to consider. When I go home, I open the door to I turn the column from a square section long enough to leave
a house full of furniture that I made. I would have to make three a few inches of the square intact at each end. After turning, I
to four times more money than I currently make to be able to screw a straight edge across the square ends and rip the corner
purchase this furniture. section on the tablesaw. After removing the straight edge, I trim
When you work in wood, you can't judge your wealth by your the column to length.
checkbook, so don't try. Some months you will make money, This method is inconvenient to the extent that only one quar­
some you won't. But if you don't build for yourself, you'll always ter column can be obtained from a single turning. But turning
be in the red! -Paul Saporito, Orange, Nj. visually identical columns is not particularly difficult, and be­
an r
caamiliaruse the corners on most case goods are separated by a fairly
ds
Keep eye on tool co -Almost every woodworkelra rkgneo dwiss,t ance, small variations, even on highly detailed classic
and is continually being reminded, to use saw guards and hold­ columns, are of little consequence.
down fixtures and to wear face shields, respiratory masks and ( -Joseph Beals, Marshfield, Mass.
proper clothing. The old-timers know about safety from experi­
fini
ence, and the neophytes read about it in owner's manuals and F shes may become hard to find-There's more to
woodworking magaZines. The warnings are well-indicated and the issue of regulating volatile organic compounds (VOCs) than
constantly repeated. first meets the eye. In his sidebar "Will new VOC regulations
FWW
However, the silent, sneaky, unobtrusive danger I have run affect you?" #92, p. 82), Michael Dresdner speculates that
into in my shop is multiple electric cord rots in the original cord they won't. Compliance, he tells us, will be voluntary for small
furnished by the manufacturer. My Makita router developed shop owners. And while he urges us to be environmentally re­
7 separate splits in a 15 month period even though it was not sponsible, he leads us to believe that we can go on using our
used very often. In fact, it was mounted in a homemade router old, familiar varnishes and lacquers if we so choose.
table, not dragged around from job to job. The cord on my Skil I have just completed a finishing book and, after interviewing
5/12 in. heavy-duty trim saw rotted out in almost the same several finishing manufacturers, I find that Michael Dresdner
amount of time-13 months. is only partly right. While compliance for small shops may be
Interestingly, my cheaper orbital sanders and electric drills voluntary in theory, eventually, we'll all be dragged into a
are over 12 years old and have shown no signs of cord deterio- brave, new low-voc world, whether we want to be or not. Con-
6 Fine Woodworking
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. 84"
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ER SERVICE NO. 16 READER SERVICE NO. 109
July/August 1992 7
Letters
(contillued)
sider the following facts: The EPA and other regulatory agencies saw blade with his tie hanging loose, literally would have his
have not outlawed just finishing substances but also many man­ face cut in two if the tie moved into the rotating sawblade.
-F
ufacturing processes that were found to be polluting. For exam­ Reed Estabrook, Jr., Dedham, Mas.s
ple, the high temperature reactions needed to create certain cam
Which firs -
hard resins are forbidden, and manufacturers have to fill the e t? How come it seems that all of the wood­
gaps with more benign processes. These regulations have workers pictured in your magazine have a slightly stupid expres­
changed, and they will continue to change, the chemistry of off­ sion, a bit of a pot belly and wear terribly tasteless clothes?
the-shelf finishes. Since this description fits me somewhat, I would like to know­
Medical research continues to identify health risks associated does the craft make people like this, or do people like this
with certain widely used finishing materials. Several years ago, do the craft?
-An Anxi
the use of benzene was prohibited because it was shown to ous Reader (fohn Kennaughj, San Francisco, Calif.
cause cancer. Soon, the availability of toluol, turpentine and ani­ I
EDITOR'S NOTE: circulated this letter around the office, and the consen­
line dyes may be restricted for this same reason.
As Assanu s was that if the tasteless clothes fit, you should wear them, John.
VOC regulations force industrial users (shops that use for the "chicken and egg" question, perhaps other readers have
more than 1 gal. of finish per day) to buy less-organic, solvent­ opinion about which came first-the board that was cut too short, or
based finishes, the demand will drop. And sooner or later, so the stupid expression.
mm
will the supply. Although the regulations don't directly affect
Wha in
small shops and individual craftsmen, the familiar finishes will t do wedges and opera have co on?-I'm not sure
become increasingly scarce. One finishing manufacturer I talked which adage is appropriate, "necessity is the mother of inven­
to estimated small users to be less than 10 percent of the tion" or "poor folks have poor ways," but after reading
FWW
market-not nearly enough for him to keep stirring his lacquer Percy Blandford's article "Clamping with Wedges" ( #93,
and varnish pots. -Nick Engler, West Milton, Ohio pp. 63-65), I was immediately reminded of my early days of
I
woodworking. have friends with thousands of dollars invested
thin chin -
Loose clo g does not belong near ma in cleamrpys -a Isit uawtiaosn a Ip'm­ sure that we would all prefer. Howev­
palled by the pictures from the Anaheim Woodworking Show on er, economics sometimes disallows this approach, and we fall
FWW
p. 93 of your April 1992 edition ( #93). There webraec kth orene c ost-saving measures learned through years of trials and
people in the area of rotating machines with loose neckties, tribulations practicing our craft.
which is about as dangerous as you can get. I have seen what can My first encounter with field expediency was some 15 years
happen when loose sleeves are worn around these machines ago, when I found myself in charge of four Mexican brothers.
and have had near nightmares about a loose tie getting caught in These braceros had learned their skills from their father and
a circular saw. Michele Letendre, who is demonstrating a table- grandfather. They sang opera as they worked and carved
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ER SERVICE NO.8
ER SERVICE NO. 74
8 Fine Woodworking
THE CO:\OVER LATHE
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INNOVA TlVE PRODUCTS FOR WOODWORKERS
READ
ER SERVICE NO. 31 READER SERVICE NO. 57
July/August 1992 9
Letters
(continued)
wooden roses while on break. Althought iIo n watso t"hiins cphraorbglee,m" is to always use a nylon washer under the
there was never any doubt about who wsacsr etwh eh esatdu.d eIn'tv ei nf otuhnids that for flat-head screws you can cut a flat
association. They shared many tricks woafs hetrh eo uttr aodfe aw iptlha stmiec milk carton and countersink a little deep­
including how to make scrapers from ae r ditsoc aarcdceodm mhoadnadtse awt he added thickness. After tightening the
and how to make jigs that would turn sac recwh,e aups et aab lcehsiaswe li nttoo pare the washer flush with the screw head.
a precision instrument. The plastic from the milk bottle will creep enough to absorb the
One day, when we needed to glue up stsroemses f(rtahmee st,h iwcek er the washer the better).
found ourselves short of clamps. One oAfl stoh,e ibtr'ost heirmpso rptiacnkte dt o keep hydrocarbon-base materials away
can
up an extension cord, sized it to one forfo mt hpeo lfyrcaamrebosn,a tteise.d 1ah iksn oitn cludes Loctite, oils, cleaners and even
in the cord so that the cord stretcheds oaapss .i tA bwoaust ftohrec eodn layr oculneda ner that be used on polycarbonates
the frame and then inserted wedges froims tahlceo hcoeln.t eOrt hoeurtwwiasred, solvent attack will cause crazing or cracking
As
on both sides of each corner. the glaute ploiinnetss offo rsmterde- sFos]n.. Getrmhean owski, Pittsfield, Mas.s
jOints, we knew that the corners were in solid contact. (I recom­
Anah
mend substituting rope to extend the liCfoe rroefc ty opurh onexet ennusmiboenr cfoorrd s.) eim Woodworking Fair-:In
I still use variations of the tricykosu r I Aplreialr niesds ufer,o mC hatrhliesy Robinson wrote a great piece on the
Woodwo &
brotherhood, and the sounds of their arias rwkiilnlg ,f oMraecvheirn erreys ouFnudr niture Supply Fair in Anaheim, Ca­
in my memory. -Kennan Bowden, Cleveland, Texas lif. Thanks. Unfortunately, the article listed our phone number in­
vs.
correctly. Our correct phone number is [phone].
Polycarbonate acrylic-I've noticed that a lot of woodwo-Erlkle­n Schwartz, Los Angeles, Calif.
ers use polycarbonate (such as Lexan) for router bases. I've had
the opportunity to work with both polycaAbrobuotn aytoeu ra nsda faectryy:l ic ma­
terials since the mid 1960s, and I avoiWdo ruksiinngg wpoooldy ciasr bionnhaetree nitfl y I dangerous. Using hand or power
can use acrylic instead. Acrylic is chetaopoelrs ainmdp rompoerrel yf oorrg inveignlge,c ting standard safety practices can
and polycarbonate's biggest advantage-itl ewaildl n ott oc repeepr-miasn eanlts oi njury or death. So don't try to perform
its downfall. Because polycarbonates areo pseor asttiaobnlse yoaun d lecarrene p abroeu­t here (or elsewhere) until you're
sistant, they are susceptible to crackincegr taoinr t hact rthaeyz airne gsa few fhore yno us atnrd eyosusr shiosp situation.
applied, such as around attachment hardWwea rwea.n tI ty oius tpoo sesnijbolye ytoou r craft and to find satisfaction in
buy polycarbonate that has been properly stress relieved, but
the dOing, as well as in the finished work. So please keep
not all of it has been, so crazing could be a problem.
safety foremost in your mind whenever you're in the shop.
When using screws to hold polycarbonate in place, you -John Lively, publisher
should play it safe and not use excessive torque. The easy solu-
EREAD R SERVICE NO. 55
10 Fine Woodworking