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7/24/2019 Woodsmith - 059
1/24
NO 9
3 50
OTES FROM T SHOP
7/24/2019 Woodsmith - 059
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W O O D SM ITIi
W O O D S M ITH (TSSN 0164-4114) Is
p ub
lishe d b im o nth ly (FebruB l ) \ Apri l, Ju ne, Au
gu st, O c1ob er, D ec em b er) b y W oodsm ilh
Pu blish ing C o., 2200 G ra nd Ave.. D es
M oines, IA 5 0 31 2 .
Woodsmilh is a re g istered tradem ark of
Woodsmilh Pu b lishing C o.
C o p yr lg ht 1 98 8 b y W oo ds m l1 h P ub lishing
C o . A ll R i gh t s R esetVed.
Subsc rip tions: O ne ye ar ( 6 is sues) $12.95,
Tw o Year s ( 12 ISsues)
$22.95. C anada an d
Fore ign: add $2 p er
yea r
U .S . fu nds on ly .
S ing le copy price. $3. 50.
Second C lass Postage Paid at D es
M oines, Iow a.
Po stm a ste r: S end ch ange of address to
Woodsmi lh, Box 491 , M t. M orris, IL61054.
S U BS C RIP T IO N Q U ES T tO N S? C a ll to ll
tree8()()-43S-0 715
(il l ino is residents cali
800-
892-0753). H ou rs: 7 :30 AM to 8:30 PM ,
Cen l,ra l TIm e, wee kdays only.
BAC K ISSUES: For a fre e b o ok le t describ
ing a llofthe back is su es, se nd to
Woodsmith
2200 G rand Ave .. D es M aines,lA 50312 .
SAM P LE C OP Y: W e wil l se nd a tree sa m p le
co p y of Woodsmi th to any on e. Ju st send U
his/her nam e and addre ss.
OperaJ lonsS te ve K ro hm e r
M ark etingManager S t e ve D o zie r
S to reM an agers;
St . tools,M O Jon B ehrle
Berkeley,C A M ich ae l D e Ha ve n
D es
M oines,
IA K en t W elsh
The Wood sm ith S to re
Edifor D on ald B . P e sc hk e
OesignO keefor
led
Kral icek
M anagingEdito r Doug las
L
H icks
AssistantEdfton; D ou g la s M . Udster
Kent A. Bu ckton
ProjectDesigner K en M u nk el
Ted1nicalll.,_ ton ; D av id K reyling
Cary
Christensen
RodStoakes
C hris G lowack i
C u stomer
Service
S an dy B au m , M gr.
J a ck ie S tr ou d
PatKoob
U s a T ho m p so n
Pro jectSuWl les L e slie Ann G e ar ha rt
C om p u fe rO pe rationsKen M ine r
Admlnist ratJveAssls. C he ry l S cott
J ea n C a re y
Bu iklmgMaintenanceA rc hie K ra u se
these old er projects. (F or more o n this . se e
Sources, page 24, and the l'1 'O jec t i :> 'upplies
lisU ngs on the p ro te ctiv e e over. )
800 NUMBER, In
th e past we
have Ol~y
accepte d o rder s
b y m ail fo r th e project sup
p lie s
and bac k is su es .
N ow w e
hav e an 800
(to ll free) phone number to accept M as te l'
C ard and Visa ord ers.
Ifyou wou ld like to order an y of th e b ac k
issues 0 project supplies, just give us ,I
~a1 1at 800 -444 7002 .Jacl de , L is a. or Pat ,,';0
be haPl)Y to ta ke your order. However,
ordering by phone is o nly v aila b le 8 :30 to
4:80 Central Time, M onday through
Fliday.
FCUILUlIENT SERVlCF:S-
For the past
ten years w e handled all of the subscrip
tion orders here at Woot lsm itl But the
circulation has grow n IlOmuch that it Was
taxing our abiliby
to
ha ndle it erf iciently .
Th is
past
summer w e began ta lk in g to a
subscription f,dfillmeni co mpany, Kab le
New. of M ount M O'1 is , lL I he fo lks there
have a very profe ss io na organiza tion , yet
they also o ffer personal servie.. and have
been delight.ft~
to
work w ith .
II I short, K able N ew s
is now han dling
al l
o r our
subscription and renew al
re
ques t. (We still process the b ack iss u e and
project supplies orders. )
If
you IlR VC 3
question about your subscrip tion (or re-
newal), yo u ca ll ca ll them a t8OO-43J ;-0715(I n
Il l inQis , 800$.2 -0753). Just tell them you
wan t information about
W O t > < i8 l r 1 i l l t .
and
they'll get
you to
tb e
righ t p erson.
NEWFACES.As w e began the
search
for
another editor to help with the w.iting
chores
rO)
WoodsmiJl it bec ame clea r th a t
we were looking for someone w ith a par
ticular mix of talents. W e needed someone
w ho loved woodwork ing ; knew ItO\\ to do
te chn ica l writing , an d cou ld work co mfol' .
ably on a variety of computers. (All of the
w.iting
is
done
on eom p uters.)
We
found
Kent
Bu ckton, In add itio n to
being an avid w oodw orker, K ent has the
w ritin g s kill s w e w ere looki.ng for, O ver
the past
10years,
Kent has
produced man;
tech n ica l rublieations on su b jects ranging
from co mpute r software to diesel engines .
Kent adapted quick ly to ou. mix of
wOQ I\\IOIkillg
and writing. H is fir st morn
ing here, we put him
.ight
to work on a
pr oject, fo r th e n ex t iss ue, He had quick
ill u'Q dlletion to the hop (where he b u il l
the 1) ''Q jec t). By lh e next day he WlIS back
in fro nt o f a .OIU jlu t eJ ,
v~itingh article,
I t's g oo d to hav e Ken t here, I'm sure it
will hel p speed th ings al~ng in our que \t
to get back on schedule an d stay the, e.
NEXT MAILING. The next iss u e of
W ood
smi th w be mailed dUl ' il lf , 'I,e w ee k of
D ecembel ' 26 , 1988 .
AIl0U TTmS ISSUE . 'Ve hav e tried to make
i~ a tl dition to devote one issue of Wood
811';/1 , to small pro jec ts - especially as
Chr istm as nea l'S . The cha llenge is to C Ome
up
w ith
idea s that m ake nice
g i f u <
ye t. a r e
fun
to
build
too.
The projects I like belt are those that
offer a cha lle nge
1
hav en 't tried
before,
Since I'm not a sk i ll ed (01 fl 'equent) tu rn er,
the
om am ents
in th is is sue caught
m y e . y e .
immediately . As soon 8. Ken (OIU Pl'o ject
designer) show ed me his prototypes, I was
in fr ont of the lathe, re al ly to try my han d
at them.
It
was ( l- us tra
tin l; at first.
My
hands d id
not fo llow the curves and sh apes I saw in
my mind's
eye. But
that chan ged faster
than T thought it would. In short ord er, I
IVa.
cl1In)
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3
OOOSMlTH
The inside diameter of the tu bing bas to
00
th e same as the o ut sid e d iamete r of the
OCCASIONAllY
CLE AN l P AND
IN S ID E O F fU BI N G
It
yoo d like 10sh ere a woodwotkin gli p wi1llo lh e
read er s of oodsmithsend your idea :
Woodsmith. Tips Techniqu es , 2200 G rand
A v e., ( )e s M oines , Io w a 5 03 12.
We pay e minimum01 10 lo r
t ips.
aIldS15 or
more lor special lechnlques Ihal ar. accepted
fo r pub lica lio o ). P l ea s e g ive . co mple le exptana
ti on01your idea.
I f
a skelc h is n ee de d, sand il
along w e l d r a w a
new one.
Sf
Nil IN Y OU R ID EA S
US E
I ,
I N$ IOE
DIAMETER V INY l
TU BrNG 1 LO fIfG
Nail
a
sc rap piec-eof
edge
strip (the same
thicknes s as the edge you want to sand) to
a
lI at b lock N ext gl ue or
carpet- tape
sand
pap er
to
the Irshaped s an din g block.
Then
sa nd
the edge strip w ith th e
sanding
block
\;d ing on th e
front
fac e until
it s
l Iu sh w i th
the.
plastic
lamina te or plywood.
Ja ck. C . 'f IU ymP. '01'
8; ghamlon, Neui Ymok
GLUE BOTTLE STOPPER
1~
seem s the stoppe rs th at come
w ith
most
gl ue b ottle s e ith er g et los t, fal l on the 000)
01
ge t
stepped on. I
so lv ed th is
problem
by
maki ng my Own
stoppers out of
vin yl
tub in g a va ila bl e
at
most hardware stores
or building centers.
IIiscovere< 1anoth er s olu tio n to
clamp-
in g the molding inside th e fI-a
II1
e, As yo u
explained in th e same iss ue (page
23),
Roman
oge e
bi ll; ha ve two
radii (a
concave
an d a co nvex ) lhat ar e th e slim e. So iftw o
pi eces of the m olding
ar e
reversed
an d
put
togeth er, th ey nest into one another.
By culling some
m011
scraps of the
moldi ng an d snugging them against the
molding on the inside of t.he frame, you
ha ve a w ide clamping surface 9n the ba ck
sid e of the SC II)
mol din g. Then ho ok y ow '
clamps a ro un d
to
the outside of th e
f,..me
to hold the mold ing tigh t.
BC M O >t A . Bow ditch
Ccm w ay , M as .'J (I.(')I ,,~et I
fIaroul l, SI Jlcle
SW M C olle ge, Pennsy lvania
EDGESTRIP SANDING BLOCK
10 the Shop Notes sectio n of W oods>n i t lt
N o. 56 you presen ted a m ethod for bring
ing
an
edge strip
flush
with
a
plastic
lami
na te
01 '
plywood to p. N o m atte r how
care-
fu l you are
r
think there is alw ay s some
risk
of
h arm ing th e surface
from
ei ther
p laning or scrapin \t.
Here 's wha t I fee l is a saf e w ay to b rin g
th~
edge strips
flush . A fter glu ing the
strips
so th ey 're above the surface
a very
stight
amount , Imak e a
sanding bloc k to
sl ide along tl)e fr ont
face
of th e edge stJi}> .
glue b ottle n oz zle. (In m ost cases,
0 /
in
side diam eter tubing works fine). C ut the
tubing to a length of
2:.
Then stic k a short
len gtb of matching (~') d ow el in to the to p
end of the tubing.
To keep the stoppe flvm getting sepa-
rated from the glue bo ttle, drill a smal l
h ole th ro ug h the dowel. Then
thread
nylon
fis hin g tine, suing ,
01
some tig ht w ire
through the ho le
an d
tie it
around
th e
botlle to p .
CLAMPING ROMAN OGEE MOLDING
ln
Wood$mUh N o.
57
th ere w ere
plans
for
a
w all m irror that ha(l R om an ogee m old
ing
around
t
he i ns id e. You men tio n ed
tba t
th e molding prof i le makes it almost im
possib le to clamp the moldings in place so
yo u held each pi ece w ith yo ur fin gers u ntil
th e glue grabbed.
J
A.
J e s s 6 >
0001'/ , , ,(1 , M is .jol t l-;
Ed i t o r ', No u: L ik e a U o j
lU J
t ip s ,
print ,
I
, , , , , , , t e d
to
try this m le O1,t in
Olir
MQ p -
but w e d id ,,' t. ha ve ,
Ip
, ,, d d i e
se t.
So I
we t
to ,.
l o c a l
hardw(1J . store ,u/
, , ; a .
S l t > p . - i s e d to
. w , d , Ih at a bwric lap am l die
se t
is, , ' I . tl l .QJ,e>:/xmsive. Sear.. hM
a
~
piece ho m eo um er s et
J i ?
wu/cr
JIt .
t
l io U k m U l wil h
qJtite
a J e w lOre sizes c f
u p s a 'll(/'
Itie
FIr I t lu /cr tzo. t t ll l i lJ i .dl t1
dM s c o s
alma
rt to .~.
And lit e
tl wf i \
beg an .
In .
addu ;on 10
threading pegixKtr lltooks, il : 1 i g l - e a t
to
be
ab le
iiI add
nih ,. . t hr eo d 10 Itca ,,i.age
bolt
or
cle(1J~up som e d am aged threa d . An d
ux '-uc even trie d wp p ing in lo hard uood.
will s om 8
7/24/2019 Woodsmith - 059
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WOODSMITH
2 .
2\.-
~
~
-
~
~
2
~
-
. . .
I'
. . . .
l~i .
-
-
~~
J.
t
t
II
1'VI ...
,
j,
,t
.,
I,
I
~I.1/ 4)~.
l//
Y . . .. , .~ . . . ,
v .. ,;
Ii..
h ,
.t.
, ) ,
1\l) lIillg
Ul('
ornaments is only
h,, 'f the
lim. I d~'Cidcdto wid
II
liltle dee ora tiv o
carv ing ) 1 \ th cc - or th e ornaments , see
p age
7. \V h . 1 1
th e
omameuts were
finished. I .o l( wC ( 1II smal l sc rew ey e in
the 101 button to hanl( them . Then th e or
nam ent. eun he 1) i t..< I , O J' ju st s prn ye d
with
dCaI'
Deftto
1)I Ow
7/24/2019 Woodsmith - 059
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5
OODSMITH
Ste~.-By.-Ste~
'K
TUlNINO
/~Il
' :' [\., GOUG': 1
M E A ? ]
1
4>
~
STOOC
~rOCK
V
r-
[i.
7/24/2019 Woodsmith - 059
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7
SaOULOE .R ll ,O COVE. Ornament
begins
as a cylincll r w ith a cove at
th e
wais t. Then
a sh ou ldered cove is cut at
th e bo ttom . (T ip: Sine-e I'm
right-handed,
1 fo un d it e asier to
turn
th is c ov e w ith
the
o rnamen t moun te d upside down -
so
th e
cove is on th e righ t.) Com plete the om a
ment by parting o ff a sh ould er belo w the
c ov e and turning the large button. Then
c u t V - g ro o v es and a bu tton on top.
4
SMALL COVE.
Ornaments
an d ~'
have
a
small
c ov e at th e
wais t th at
is cu t with a small v. ) gouge. The mo
tion is th e same as shown in Stell 2 . Stick
the gouge straigh t in the center o f the
cove. To cu t th e left side, ro ll th e cutting
end counterc lockwise (to th e le ft ) and move
tb e handle f rom 6 :00 to about 5:00 . F or th e
light side, go bac k to 6 :0 0 and roll c lock
wise
while moving th e bandle
to
7: 0 0 .
I
OUGE
W OOOSMITH
8
FINAL STEPS. Ml ornaments ar e
turned
down to abou t a W
diame-
te r
at bo th
end s (enough
to hold
it on the
lath e). T he n san d with 150 and 240 grit
sandpaper. R em ov e th e o rnam ent fro m
lathe
an d saw waste o ff ends. I u se d kn ife
to c om pletely shape the ends and sanded
them
smooth, Thl~
ornaments hav e
carv ing (see next page). Then
to
protect
tb em , 1 sp ra ye d
on
a coat o f c le ar D e ft..
5
SANOIN G COVE. I don' t have
any
reservations about using any too l
th at \\1 11g el th e job d one. In the ease of
lhe eove, I found it d ifficu lt to ge t su ch a
smal l c ove symmetr ieal- c- Lh.,.. 's no t much
room to p la y a ro u nd an d c orrec t mistakes.
So [ turned it down to rough shape and
fi ni shed it w ith a strip o f -s3ndpapel'
wrapped U'OW1(l
a /., dowel.
T his g av e
me Lhe exact shape
wanted.
'l'UlININC A BALL,PARTINGTOOL.
B o th M the previous methods are
awkward when t \l l' l1 ing the lef t en d (if
you 're
right-handed).
If all else fails ,
grab
a parting too l. (In fact, 1 find it m uch eas
ier to use a parting tool
on
both ends.)
Strut at
th e waist,
wi th ju st a
hairline
cu t.
Th en push the parting tool around the
c u rv e p re ss ing
its
side aga inst the stock.
a nd g ra du ally increasing Lhe wid th of cu L
TURNING A BALl., SC RA PING. A n
ea sier
app roach is
to
use a scraper
to sh ape th e ba ll. Or, you ca n lise a skew
in a sc rap in g p osition . Tum the skew on
its si de an d ho ld it fia t on th e tool re
st
with
th e lon g point
leading
around
L h e e nd
o f
th e
stock.
Slide
th e
skew
around th e en d,
while keeping the
center of
the
cutting
edge
on
th e
cur ve . It's
slow ,
bu t
1es.... isky
than using a shearing cut.
,
~
~
~
\
-1
/ }
.
S K E W
:
..
6
SROl)J. .DERE O B EA DS. Turning r-
nament E is d ifficu lt becau se yo u
have
to
get a p erf ec t sphere. As
the
left.
si de is tu rned , stop short to create th e
angled shoulder at the bottom o f the OL I1a-
men t. Sin ce I u se d a p ar tin g tool,
(his
dec
o ratio n starts rigbt w here the parting too l
le av es o ff. Then tw o m ore shoulders ar e
turned at successively steeper angles
(abo ut 4:30 the n 3 :3 0 p ositio ns).
3
SMOO ni BALL.PAfING TOOl. It s
-ather
easy
to rough out
tile
basic
shape of the ball with a parting tool. The
to ol is very forgiving so you don't have to
worry to o m uch abo ut technique, W Id c an
c on centrate on vi~uatizing
the
shape of a
sphere. (Look at tile to p edge.) Thell to
get th e f inal shape, [ro ll t lte parting tool
on its si~ an d us e it as a scraping tool to .
sm oo th th e bal l to shape .
1
0
TURNINGA BALL ,SHEARING.On.
o f th e m ost d if fic ult s ha pe s
to
turn
is one of th e s imp le st -
b all. B e sid es
d ev elo pin g th e ac tu al tec hn iq ue, y ou have
to develop an eye fo r the shape. The
fa ste sb way to tu rn a ball is to use a
1
skew
with
shearing action.
This
is m ore
diffi
cult than
it lo oks. Y ou h av e to
keep the
bevel
riding
~nst the
stock nn(
rotate
th e to o l so you don' t c atc h a c orn er '
I -
-
,~
P
,
~
R i
,
m :
rn
f i
, .
~ \. \)._ s
~
.
=.iI-
~
~
ARnNG
\
~ , GOUGE
100
11 3J:h Fh
W O O D S C R E W
,-:- TlJ R : N a u no N
BACK PANft
DETA IL
WVIDe
WR O S
G UR E 8
SECOND : )
A D D V 1 H IC K v at :r. C A . l _
O U T SID E P IECES
DETA IL A
I M P f E N CE
J
~ I
21
1 , .
f
v
i
HOR IZ ON TA L P IE CE S
c u r O N E
w
T H I C K ) C U T T W O ,,,r TH IC K )
VERT IC A L P IECES
C U T T W O ~H IQ ) C UT T W O / T H t c K )
IlESAWTO T1UCKNESS.Now
resaw
th e
s to ck f or th e d iv id er s
to
thickness
to
match
th e
kerf,
Resaw enough for tw o
vertical
di viders (D ) ( ro ug h s iz es 2\4 x 7 ) and
one horizontal divider (E) (2\4j x 8'1.
S h O P Note: To allow for p laning and
sa nding , it s belIt to resaw th ese p ie ce s
slightly th icker than the kerf. T hey should
fit th e test kerf a f t , e l sanding.
l lESAW OUTSID E
PJ)::CEl;.
The fow ' out.
sid e pieces (F,G) o f th e e gg -c ra te r u- em ad e
th ick er 1 1 . 0 ) b ec au se h alf o f their thickness
is hidden b ehind the If, rab b et on the
fr ame . (When
viewed
from the front of th e
ca .
se, only ~. thickness
will
appear.)
CUT TO
s ize ,
0
make
t he se 'I , th ic k
o utsid e p ie ce s, s ta rt
b y
c uttin g tw o v erti
ca l outside pieces (F ) to ou ghly
2\1, '
x r
an d tw o ho rizontal pieces (G ) 2 '(' ' ' x ft.
To determine the fiu l lVUl t of a ll the
dividers, measure tlte depth of the b ox
Iro m the b ottom of th e p to the b ack ed ge
2 Y . ? 1 1 1 e n sub tract the thick ness o f the
glass (~ ') and the thickness of the back
v . . ) .
In my case th is m eant cuLt in g t he
dividers 211.i ide, see Fig. 5.
LENG1'H.
Now (,/I t he p ie Ce s can b e cut
to final length so they fit snugly i, side the
fram e, refer to Fig. 8. T his is 6 f or t he
vertical piece. (D ,F ) an d 7 V 1 fo r tI . hori
z on ta l p ie ce s E,G) .
END NOTCHES . Next , 1
c ut n otch es in
al l
of the pieces t assem b le them . T hese
notches are
cu t exactly half way up
the
width of
e ac h p ie ce .
Stal l by
cutting
1 1
w id e e nd n otch es in all th e p iec es
to
match
th e
thickness
o f t il e o uts id e
pieces (F,G).
To cut
t he se e nd n otc he s,
set th e
fence
a s a s to p 1 1 . . o o m th e
out si de
of th e b lade
and the b lade height equal
to
half the
w idth (height) of the pieces l l:~.ee
Detail A in Fig. 6. Then
m a k e
a pass at
the end of the pieces. (Note: Y ou can cui
a num ber of p ieces at once.) To fin ish the
notcb to '; - w ide, push the ends against
th e fe nc e and
make
another pass.
CEN TER NOTC I lES .
Next, I cut the e'en '
te l' n otc hes o n th e o pp osite e dg e o f t he en d
notches. That is, the pieces should b e
tu rned 0 the end notches ru... on the top
edge when th e c en te r n otc he s a re cut.
O n th e sh or te r v ertical p ie ce s (D ,F ), c ut
a notch centered on the lengtb (in m y c a s e
3\1,.. from
th e
end, see
Fig. 5). 0 )1
th e
horizonta l pie ce s ( E,G ) . cu t a notch
2 1 1
from each end , see Detail II in Fig. 6 .
FIN L SSEMBLY
Before
putting
all of
th e p ie ces
togethe,
~':,._ '
ini sh ed th em w ith tw o coats of tung oil.
Then 1 cu t a piece of g lass to
fit
the fram e.
N ow , slid e in the egg-crate pieces. If ~~~~~~:::
the th ickness of the stock m atches the ,,7
width
of the notches. the p leees shoul d V -
GiASS
J
:
P :US:'h~t:oge~t:her~\:~~lh:O:U:t~gI:u:e,~s~'e~e~F:~ _'_7_.)_
~ = = = = ~ = = = = = = ~ / ~ / = = = ~ = = = = = = : = = < = = = = = = = = = = = = = =
o hold the b ack panel
in
place, I _
SCl...
wed two
metal
turn b uttons in to the
b ack edge of the
f rame. se e
Fig. 8 .
V
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WOODSMITH
RESAWTO' ''
CUT FROM ONE
o i
36 DOWEL
1 1 . x 6 6
1\ 71/. _ .4
1/,
2 _ 2OY .
:Jh, x 140/
IA
a ,_
(2)
a c...u_2
c eo,SIa(6)'
D Dowol. (2)
c
cunlNG DIAGRAMATERIALSLIST
dra ing I l ddiu., circles, Locate
the
front
circle a nd low er rea r circle
tight
a t
the
corners
of t h 4 . >
wo rk pie ce , ~
F i g . I .
Next, to
Inc aw lh ~ u ppe r
rear
comer ,
mea,..ure il l t frorn the end and square a
tine dow n ( n
th e
lop edge. Pla ce
the
point
of a
t O ll 1 l l U -
on th is tin~
a n d
dra w
I I
I' l 'l ldill>circ le
1 1 0 il
tou ches the
to p
edge
u fthe workpiec e. Then II I' l lWa l ine tangent
to tbe lI ppe r : t n c l lower circle s, W hen the
wa st e is cu t 00' , the :I ng le o f the rear end
of the runner wil l be bou t
45'.
fonn th e a t. I oog n by cu tting the run
ners r un ,- 1 ( .- to 10/,. actual)
brown
a sh, 6 widl' by 3C j
long ,
se e Fig.
RUNNERS.
T he ru nners
A
form the
sides
r til(' sled.
To cu t them
to
shape,
begin ~Ilylng
ou t the
p ro fi le , < ee F ig . 1.
Sinc e th ~ p itio n o(the, 45 angl ed cu ts on
th e r~a l' of Ih t' l 'U nn el 'S is det erm ined by
the ll l 't' or the ti l 'C lc. tha t form the 001110''5,
I
dr ew
the cil'll ies fi l 't.
CORNt:RS. The two lC~UCOI11el'S,as
well
the nooc of the ru nne r. a re mnd e by
BUILTFOR SNOW , SHOW AND GO
A 1 .'00< 1Ied i$ like a fine sport, ca r. You
fe e l l ike it'~
part
of yo u a s you slide down
hil l. Eve n U lou l( h O u r le d does n' t ha v e a
fancy slee lin g mec han ism or fl ex ib le run
ners , U\C 'kid. wlll find it
1S
li ke a
Sj)OIt~
ca l'
for
fllt maneuvering down
the slo pe s.
'J 'hi~g u b jc'c t of
speed
brings m e to .
topic
th u t
1 '\l~'C ivcclome discu ssion
in the
Wood
.mill,
o f f i c i S , Given the
li gh t
bill and
th e
light
nOW con ditions,
th is sled
is
fa st.
D av e's kids (ou r lo w -bu dget tel l pilo ts)
praised
i ts speed ,
Dave,
forgetting
bis 0 1'1
youth a s a thrill seeker. g ot th e
ehiIls.
W . M nl .11
7/24/2019 Woodsmith - 059
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I
, .
,
SlOTcunE'
8 1 '
CROSS
SECTIO,N
S Q UA ll U P S lG E S
A N D C O RN ER S
WITH CHISEl
MORnSE '. DEI '
- _
N O T E,
ROV' COUNlEJtClOCKWISE
AROUND aUNNER
,
'
Slot
1lOU11HG
l C 1 l O N
NOTE
QNI NNN(1
OOWNWOI
lIOUTlHG
ftGlJlf S
MOI11SI _ IOUAlS
1 M I C J C N I S S
STCIQ
3 .
--2.,, ---
9',,,
I
~GURE2
. .
. .
5...
,
. . .
.
.. . . .
. . . . .
,
17.-.
.
,
Sl[O
RUNNER
PRORl[
FlGUIf ,
W O O O SM IT lf
fRONT BI lGY_The
c urve at
the
fro nt o f
th e
runner
i.
I. by
d ra w in g a n a rc
with
a IT radius,
The
center
point
of th i,
ar e
i'NIiRSLOTS. \\'hiIe
ha d
the
router
out. I cut
th e
s lo ts fo r
the
T ,molding
tha;
goes
,uwIVI the
per imeter
of
t he r unne rs ,
To do
this I used
I..
s lo t cut te r
bit.
Rcgin
by
p mc lic ing on a sc ra p p ie ce th e
s a m e
th ic kn e.;.. a s th e ru nn er s to ck , Ad
just th e bit uutil it cult; slot exnct/y
( ( 'nu'l 'I 'd all
the edge,
T hen cut W e g ro ove
al l
thp
way around
th e runne r, se e
Fig. 6.
Snop
N ote:
T he p ilot
011the
slot
cutter
,m l.c)mut iclI lly makes a 'It ,d eep gr oove,
7/24/2019 Woodsmith - 059
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WOODSMITH
,2
A fter th e ru nn ers
n
fin ished, the cross
braces
(B)
th at support the seat slats
can
be m ade. T hese
bra ces
also
are
4 1 4
brown
as h,
3
w ide by
14'
lo ng.
TENONS.
To join the cross
braces
to th e
ru nn er s, s im ple tenons are formed by cu t
ting
v
by V o n otc he s on the top an d bot
tom e dg es p ro ducin g 2 ~N -w ide te nons to
fit th e mortises in th e run ners, see F ig.
7.
Icu t these notches on the table saw
using tlte m ite r g u g e for sup port. Since
the fence is used as a stop, T fastened a
scrap of
o / , N
plywood to the side of fue
fe nc e to protect it fro m th e blad e.
IQoIOCK.ooWN fASTENER S
Aftel' cutting th e tenons, the cross braces
aloe ready fo r th e k no ck -d ow n fasteners,
see Fig . 8 . To do this, three sets of holes
have to be drilled .
HOhES 1 :N lU1NNBRS. The fu'St set of
ho les goes thro ugh th e ru nnel'S for the
body of the bo lts ,
se e
Fig.
8.
T o lo ca te
th es e h ole s, s qu are a lin e from th e ce nte r
of the m ortise. N ex t, m ark th e hole
posi
tio ns i and ~down from the top
ed ge of the runners. Then drill
,.
holes
1i-01O
the outs ide into the mortise.
1 :ND BOLE S. Now the holes for the
shanks
of the bolts can be Al>OES.o help hold the sled squar e
an d lig id , the seat slats ha ve dadoes on
both ends that fit o ver (he cross b races.
You have to make sure thes e dadoes
n
spaced
to
match t he d is tanc es b etw een the
two Cl'()SS bra ces , To do this, I cut the dado
on ly on one en d of all th e p ie ce s first,
SETDADOBLADE.To cut the dad o es , se t
up the dad o blade
to
ma tc h th e th ic kn es s
SE AT S UP PO RTS
14 \4
.
DOWEl
AGURE 11
ROUND BO rrOM
ED GES O NLY
t
ROUNOO VER
BIT
S E T
l I f T
A .
O f P
NOTE:
TOP IDGES
stA Y S QU AH
~R O
ASS .... . .
C RO S S B RACES
TO RUNNERS
NOTE :
u
HO lES
T H R O < J O H
RU NN eRS T O
P OS IT tO N B IT
RGUR
CROS S S ECTI ON
F IGURE 9
,
U NN JI
PORrAllGN
I
T O P
fOOt
. H , . MOtE
S T R A l G I f T
C R O SS B R AC E
1,
. .
fll
8fT
NOTE:
TH IC KN ESS OF
CROSS
BRAC E
ST OCK
EQ UAl S MOR ns.; W IDTH
S H O U L E R S -
AlE ~-
V..
D EfP~ ___/
,/ ..- LONG
( SE E D E T AI L)
1l :NON
DeTAIL
CROSS
BRACE
RGURE 7
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13
OO1)SM l't'li
,
f MOLOING
TO MA I BENDS
A T EN DS
~8
UA5S
S C R E W
SEATlAl-._
DETAIL
RO SS S EC TIO N
PRE .T H RAS HOLES
WITH STEELsatEWl;
NOTE: C U T S CR EW S ON
FliS T A N D lA S T S lA TS
S1:ECROSS S tenOH . 'LC1W )__I
U T T Mot OING
T O 8 UT T E N O S
I,
CROSS
~Eglo.~
OUTtR
TAB tE
F E M e : l
blocks, 1 cut the ea rs off tw o sid es o f the
tr ia ng le w ith the band saw .
DRAWRADI I . Nex t, th e r ound corners
ca n
be
I O O d out b y drawing l adii on each
block. T o do th is , I taped al l four bJ1X:kso
gether and drew two c ir cl es ( re fer to Step
;; on page 19). First, draw a 2 1 . < outside
ra dius. 'I 'hen, draw the inside ra dius so the
thick ness of the co rn er equals the th ick ness
of the stock you plan to use for the fram e
p ieces
of the clock.
S inc e
my
Irame,
stock
w as
v
th ick, 1 m arked an in sid e r ad ius
of 10/,. ,see Fig . 1.)
FltAMI PIECES
Before
c uttin g tb e
co rners
to th eir final
rounded shape, I cu L th e fo ur fra me p ie ce s.
T he w idth of th ese pieces must equa l th e
th ick ne ss o f th e sq ua , .. co rne r blo ck s, s ee
F ig . 1 . A f te r c uttin g th em
to
will th,
cu t
all
four pieces
to
a uniform length of 7:.
G R E A T F R AM E A R O U N D T H E C L O C K
W all C lock
7/24/2019 Woodsmith - 059
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2
CU I
IN S ID E
RA D IUS
8EFO RE
A S S .E M a\ Y
DETAIL A
KEfPSPUNES
F lU S H W l T H-
BorrO M E DG E
j iECOND ,
Gl U e FRAME S ID E S 8 E TW f EN
TO P;8 on O M S E CT IO N S
P T E R
ASSEM8UNG
CUT O U tS ID E
RADIUS RUSH
W IT H fR AM E
Pi taS S E E:
DETA il
a
~r
1 .- :0 ;
1
7
~PllN e B LA NK
:U T fJl:OM 41 4 S tOCK
\ _ EQU ALS ~'J1DTH
Of
GR O O VE tV .1
a r t r = i l
t , - , < : -
WOIH1uAlS
2
t.. C O / A B IN E D O E PJ H
~ O F 80TH G R O O vtS
CU nlNG SPLIN ES
F lGUR E 4
TRANSFE ill OC AnON
0 GROOVETO
C9 AN ER BlOCI
~ORNatl ac
;
:;y
iX(
R IP
FlNeE
AUGNStDE
W I1 1i C ORN E R
l AYOUT UN ~
DEIAlb
AUGN
SAW
BLA O E
W ITH LA YO UJ M AR KS
RG ua e 3
CENTER SA W
S LA O E O N
THtcK NE S S O F
WO l ( , flEeE
~
J.
IP
F E N C
RAM
PIE CE
DETAIL
F IGURE
C U T C EN T WO
G RO OV E O N
B OTR e NO S
WOODSMITH
A S S E M B L Y
There s
one
mo .
s tep
before
assemb ly .
B and saw
the
S u i b
ra dius on ea ch eo rn er
b lock , s ee D etail A
ill Fig.
6.
GLUE UP ENOS.
N ow the (tame call
be
assemb led. S ta rt by glu ing and cl .mpu.g
two corner b lo cks to a frame p iec e. T hen
glue an d clamp the O PI>O.~iteide an d con -
nec t thes e two s ectlcn s
co mp lete the
Frame. W hen th e glue is dry, p lan e the
sp lin es off f lus h w ith the top o f th e fram e.
C U T O IJ1 SIO ERAmU s. To co mplete the
basic frame, cu t o f( the outs ide mdii
O il
the
row' co rn er
b lo cks (see D etail B ), an d then
sand
the in s id e and outs ide radii sm oo th .
G R O O V E S
N ow the jo in ts ca n be cu t
to
jo in th e Iram e
pieces to th e roun d co rn ers . 1 u sed a sp li n e
and groove jo in t here. T his re qu ire s c ut-
t in g gro oves in the m illing ends o f ea ch
piece and w.ring a sp lin e in the grooves .
C U 1
ClRO O V E S.
To cut the gI 'OOV C 8 in th e
fram e p ieces, m ise the b lade to a height o f
W . se e D etail in l;'ig. 2. T hen p os itio n the
ri p fence so th e saw b lad e is centered on
the thickn ess o f the
frame
p iece.
Once
th e b lade
is
ce n tered , cu i a
grceve
in b oth ends o f al l fOUl (ram e p i ec es a lwa ys
kcep in g common race agains t th e fence,
see
Fig, 2.
(W hen
making th is cut,
I
backed up the workpiece with
II
2x4 block,
or
Y O U
co ul d use a tenoning j ig.)
G RO OV E 8 LO C KS.The grooves in Ihe
corner
block.
have
to
match the grooves in
th e
fram e pleees. T o do this,
hold
a f rame
p iece again st the en d o f O O I 1 c r p ie ce s o
i t a li gn s with th e radii li ne s d raw n. Then
tran sfer the groove locat ion on to tne
co rn er b lo ck , s ee
Fig.
:1.
N ow , move the tab le saw ip fen ee so
th e
saw
b lade
lin es up
with
th e
groove
li ne s. T h en
cu t
t l.e g rooves in each co me.'
block, see D etail in F ig .
3 .
(No t e :
If
th e
gro oves are cut s lig htly o ff c en ter, yo u can
always redraw the co mer 1 1Id ii.)
S P L I N E S
N ext, I cut s plin es to
t
th e g ro o ve s,
FOl
the ~tm ngest jo in t, Lhe grain in the sp lin es
should run th e same dh ct ion as th e grain
in the
frame
p ieces.
When
malting
the
spl ines , 1 used Ih e sam e kind o f
wood,
but
yo u
could
use a con tras tin g w ood
to am -
phasize
the
splines.
cur
SPLINES.
To make the splines,
set
Ih e .ip fence SO th e d is lnllce fro m t ile b la de
is equal to the w id th o f the groo ve, see
StCI I ill F ig. 4. N ow make two cuts on
o th en s o f a 4 w ide b lo ck .
T hen , to
Clll lhe
sp li n es
o f f, s et
the fe nee
so
(h e distanee 1 i'O , the ou ts ide o f the
b lad e to the
workpiece
end eq ual s
0 / ;-
(t hat is , Ihe comb in ed dep ili
o f
the two
grooves). s ee S tep 2 i n. Elg . 4. Fl11alJy,tr im
the
sp li n es to a ''O 'lgh w idth o f 1% wi th
a ch isel.
7/24/2019 Woodsmith - 059
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WOODSMITH
FIN IS H IN G UP THE FRAME
B efore you beg in work on the face, there
are a couple more steps on t.he fram .
ROUND OVER FRONT EDGES. F irst ,
round over both II-ont edges of the frame
with a v . round-over bit, see F ig. 6 .
RABlIET BACK. N ext, rout out a
1 0
l-ab
bet 1 deep on the bac k inside edge of the
frame
t o
a cce pt the
fat...
To do this, 1 used
a p in -rou ting jig o n th e ro ute r table, se e
~ ig. 7. (For m ore on the jig, see page 23.)
CLOCK FACE
After the
rabbet is rou ted, the clock rat..
c a n
be
m a d e a n d
cut to
6 t
MAKETH E FACE . I
made
on e face
out of
v . . plywood, then ried a couple more
with plasuc laminate 0 bu rl veneer glued
to 1 1 . Ma.~onite. (N ote: Lam inate or
veneer c al l b e g lu ed to t he Ma s on it e either
before
01
a fte r t he face is cut to
fit
th e rab
bet,
se e
Shop N otes, page 23.)
The
onlY thing cri tical
hel e
is
~hat
toh
c o m p le t e d
f a ce ma ter ia l
m u st
b e
l
ss
t l n
% thick.
I h is a l low s tbe stem on the clock
m ovem ent to stick
Ollt
th e front and
the
- thick movement to fit behind the face.
~lAnK AND CU' 'OU' 'FACE.
O n c e
th e fa ce
material
is
cu t s light ly oversize, p la ce t he
clock fram e on the face and m ark the out
line Ofthe rabbet, se e P i g
8:
N ow cut the
face to
wid th
and length on
II
tab le sa w,
Theil sand the
c o r n e r s
round
O n
a disc
sander until they Jll the
rabbet
CEN1'Elt HOLE AND MARKeRs.
Before
mounting th e
face, I laid out a c en ter
hole
and the leeatiouof th ~ how markers, se e
F ig. 9. (Note: If you ord er th e d ock parts
from
Wood rmit l t
a face template is
in
cluded, see page
~t
o lay
Ollt
th e f ac e,
start
by
I li jd in g t he center point, Then
draw a 4 Y . i radius circle with
a
compass.
N ext, m ark the locations of the 12, 3, G
a n d 9 o dock m a r k e r s o n th e circle, se e F ig.
9. 'l'hen, use a protractor to mark out the
rest of the m a r k e rs at 30 intervals . After
the how m ar ker s a re laid out, d rill a \Ii
center h ole for th e stem .
FIN'ISFf.
B efore fasten ing the face int o
th e rabbet, finished the frame
and th e
face
if
it s not plastic) w ith tu ng o il.
ASSEMBLE FACE TO FRAME
When
the finish i~ d ry
you can mount the
face in to the fram e w ith cleats, see F ig . 10
GIVE
IT THE
WORKS.
Aftel'
s cre win g th e
cleats dow n to hold the face in . m ount the
works in th e b ack w ith th e h an gin g b ra ck et
between the m ovem ent and the face.
M ARKERSAND HA DS .The only thing
left, is te add the hour m arkers and the
hands. O n
p~e
24 we.e g iv en s ourees fo ,
gold.oo lored markers in both dots and
clashes You c ou ld a lso m ak e h ou r m ark ers
from dowels , plugs, or screw hole buttons,
Now , add the ha nds and the cap nut.
T hen it s tim e to hang up your n ew c lo ck
M O OR M A RK E R
ctEAT ~
h
n W O O O S C R E \ V
p
T
DETAil
C L O C K
F AC E L AYOU T
iG U R E 9
B RASS W AS HE R
ANDNUT
P NUT
R U 8 8 : A
W AS H 1 R
H O U R
M A R K f R S
H NGING
B R A C J E r \
C L O C K )
M O V E t.\fNl
AGU.RE- 10
M A R K O U TU N I
Of
RAUnON-
C L OC K fA CE
f iGURE 8 :
NOTE;
CUTMB n IN twO
V ,.: W ID E P A SS E S
/4
R O U N D
O V ER 8lT
MOW fft M FROM
, T O R t G J W I o 4 E NR O U T I NG
lt~
F F AA M E
MOVf FR MEfROM B J Q I :f t
TO \HI W H E N R O UTIN G
JJl~
O F R AM E
NOTE;
~OU~OV ft
m O N T E D GtS
O NL Y
F IG U R E.
7/24/2019 Woodsmith - 059
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1 0
cut the ~. rabbet in the back
of
tb e
clock fram e, I m ounted a
h
s tr ai ght , b it
in th e ro ow ,'
table
and raised it rbove
th e
table,
Th en :u \ju .,t th e pin ( by mo vin g
the fcn h i l U l
the bit, you have to
pnl
th e clo ck fram e ag ain .< t th e p in
an d
then m ov
th e
frame Irom left to right
( c lo ckwi.
0 10 thaI
d i d .
(Since th e
o p en ing s h ave
vl corners, sometimes
it
take; couple
piee...
to
get a
good fit.)
Once you get lh~ substrate to
fit per.
f ec tly , g lu e a n
OVCOOY.c
p iece o f
Iaminat .e
01 ' veneer 10
th e
(01), Then mount a flush
uim
bit o n the router (ab le and set th e
ball
bearing on thl' bit to rub against the M a
s on ite , s ee d ,w in l(, T he c utter will trim
th e laminate 0 V~l( Nperfectly fl ush w ith
the t.1a.~nit,cand leaves a smooth surface.
fiN R UB S
A G A J N S l
N S I D E
Of
WO.I
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CRADLE ( 48)
T he spin dles and butto ns fo r the cradl e are
n ow av ai la bl e
in
oa k, walnu t or cherry.
Each package in clu de s mapl e k no bs.
C radle Parts, O ak , O rder No.
748-
11 0, $4.').95.
Cradle Parts, W aIJ,>ut, O rder No.
748-120, 59.95.
Cradle Parts, Cherry, O rder No.
748-130, 54.95.
WORKBEI'ICH (50)
Front V ise and Handle, O rder No.
750-110, 114.95.
End V ise and Handle, O rder No.
750-120,
$4 4 .95 .
W ooden Bench Dogs, O rder No.
750-
130, 10.95 per pair.
Oak Drawer Pulls, O rder No.
750-
Wood. , mil l . i. now o f(e lin g supplies for
so me of Lh ep l' uj ec t. -;l ha t h ave app ear ed i ll
e ar ti er i ss ues.
1 01'
a complet e
description
o f wh a t's in cluded (wood
is
no t in chided
Ull
less $pee if ie d) , s ee lh e p ro te ctiv e c ov e) ' on
thi s ; ssue. I f it's n ot a va ila ble , c all lhe toll -
n . . .
number or write the ad dre ss abev e.
REGULATOR CLOCK (36)
Regulator C lock,
Quartz
Clock
M ovem ent, O rder No.
736-110, $74.95.
Regulator C lock, B rass Keyw ind
C lock M ovement, O rder No.
736-120,
$9 9.95 .
Sled H ardware Red) , Order No.
759420,
$14.95 . This
bas
a ll t lle same
com
po nents as No.
759410
(m ention ed
first),
except
the T
-Illold ing is re d
color,
Sled W ood