fine woodworking 202 january 2009.pdf
TRANSCRIPT
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
1/81
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
2/81
wtNTER
008/2009
tssuE202
48
36
Best-Ever
Outfeed
able
Versatile
workstation
stores
all
your
tablesaw
gear
and then
some
B Y J O H N
W H I T E
44
Brighten
our
Sho
Withan
Epoxy
lo
Revitalize
your
old
concrete
floor
with durable,
easy-to-apply
epo)ry
paint
B Y
T I M D e K O R T E
Who sGot
he
Bes
Riving
nife?
Finally,
this safety
feature
is
required on
tablesaws,
but manufacturers
approach
it differently
B Y R O L A N D J O H N S O N
74w|sxa JXE .
Cover
photo:
.fohn
Tetr
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
3/81
69|rffiigft',*
4
Bench
igs
for
Handplanes
Accurate
handwork
is
easier
with
these
clever
jigs
B Y N O R M A N
I R O L L O
Forget
What
You
Know
About
Workbenches
Simple
system
of beams
and
bases
does
everything
a
traditional
bench
can.
and
more
B Y J O S H U A
I N N
Stop
Suffering
for
You
Craft
A veteran's
tool
choices
make
woodworking
easier on the body
B Y
A R T
L I E B E S K I N D
6 On
he Web
8 Contributors
10 Letters
16 Methods
of Wor
Knock-down
orkbench
holds
wo tool
chests
Magnetic
pring eeps
benchdogs
n
place
22 Tools
Materia
Mini-lathe
as
extra
ap
and
power
lmproved
ountersink
i
New
igsaw
blades
re
smooth
cutters
28
A
Closer
Look
Not
all carbide
s
created
32
Fundamentals
Pencil
nd
paper:
Work
precisely
y
using hese
si
tools n
unconventional
a
84 Readers
Gallery
90q A
Trou
leshootig
he
oi
nt
Why
use
a
tablesaw
molding
ead?
How
o sharpen
hisels
with
non-parallel
ides
101
ShopDesign
Hand-tool hopsaves pac
Back
Cover
Just
a
handful
f
tools
The
Thunton
P
Inspiration
for
hands-on
56
62
74
68
80
,ii'^Hg
8
1-5
ips
or
Basement
Workshops
FWWs
online
audience
weighs
in
on
muffling
noise,
stifling
dust,
adding
light,
and
reducing
moisture
B Y T H O M A S
M c K E N N A
6-in.Random-Orbit
Sanders
Do
these powerful
machines
have
the finesse
to finish
the
job?
B Y
M A R K
S C H O F I E L D
A N D B O B
N A S H
6z
siN;,*,
FineWoodwork
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
4/81
free
online xtras:
Avaiable Novem er 19 at
www.f
newoodworking.com/extras
THrs oNTH
ru
FineWoodworking.com
Fine
\M\
brking"
EDITOR
Asa
Christiana
ART DIRECTORMichael
Pekovich
MANAGING DITOR
Mark Schofield
MANAGING DITOR, NLINEDavid Hei
SENIOREDITOR
homas McKenna
ASSOCIATE
DITORS
Thomas G. Begnal, Steve Scott,
Anissa Kapsales
ASSOCIATE DITOR, NLINEGina
Eid
ASSISTANT DITOR
Matthew Kenney
SENIORCOPY/PRODUCTION
DITOR
Elizabeth Healy, Julie
Risinit
ASSOCIATE RT DIRECTOR
elly
J.
Dun
ASSISTANT RT DIRECTOR ohn
Tetrea
SHOPMANAGER obe* Nash
ADMINISTRATIVESSISTANT etsy Eng
CONTRIBUTINGDITORS
Ghilstian Becksvoort, Gary
Rogowsk
Garrett
Hack, Roland Johnson, Steve La
CONSULTINGDITOR onathan
Binze
METHODSOF WORK im
Richey
PUBLISHER natole
Burkin
SENIORMARKETING ANAGER
Melissa Robinson
ADMINISTRATIVESSISTANT hristina Gle
CONSUMER
MARKETING IRECTO
Beth
Reynolds,
Pro0irc
VICEPRESIDENI,
INGLE
COPYSALES ay
BUSINESSMANAGER avid Pond
ffi
vroeos
Why a RivingKnife Matters
Dramatic
ootage with
contributing
editor RolandJohnson
("Who's
Got the
Best RivingKnife?") hows how a riving
knife can virtually eliminate
potentially
ethal kickback on a
tablesaw.
NEWWEBFEATURE
You're n Charge
in OurNewReaderGallery
Our
new online
gallery
s a community where
you
can easily
share
photos
of
your
work
and
get
design
deas and comments
from fellow
woodworkers.
Shop
Tours
Visit he shops of ChrisGochnour,
Garrett Hack,and FWW
publisher
Anatole Burkin-plus a shop that a
Canadianhobbyistburied underground.
^ l . . ^ .
ptu) .
READER OOLREVIEWS
GLUE UBE:VIDEOS YWOODWORKERS
DESIGN. LICK.BUILD:HOWTO USE
THESKETCHUPD DESIGN OOL
onlinexclusives:
Become
memberand accessmore han 30
years
of Fine
Woodworhint
articles,
how-tovideos,
and exclusive
Web
content.
h
vroeoPRoJEcr
Build
a SmallFrame-and-Panelabinet
Only on FineWoodworking.com:Watch Tim Rousseau,an instructor
at the Center or Furniture Craftsmanship, build a small cabinet
that would work well
as a
nightstand
or side table.
You'll earn how
to construct a drawer, how to hang a frame-and-panel door, and
how
to create tapered legS and other design refinements. See every
stage
from
start to finish and download a
project plan.
fr
vloeo
Gopeandtick Basics
Online contributing editor Andy Rae shows
you
how to make a
strong
and easy cope.and-stickdoor, rom router-bit setup through
assembly and
glue,up.
plus:
-
GURRENTSSUEONLINE
*,
ARGHIVES
F
1,300+
ARTICLES, ND PROJECT
LANS
MORETHAN
5OOSKILL-BUIIDING
IDEOS
ASK THE
EXPERTS: eter Gedryson ftnishin
*-----:
DIRECTOR F ADVERTISER ARKETI
Kristen Lacey
ADVERTISING
ALES
DIRECTOR eter Ba
SENIOR
NATIONAL CCOUNT ANAG
Linda Abbett
NATIONAL CCOUNT ANAGER ohn La
SENIOR D SALESSUPPORT SSOCI
Mariorie Brown
wooDwoRKrNGooKs&
vtDEos
EXECUTIVEDITOR elen Albert
Flne
Woodwo*lng:
(ISSN:
0361-3453)
s
publishe
bimonthly, ith a specialseventh ssue n the winte
by The TauntonPress, nc.,Newtown,CT0647G550
Telephone O342ffiL7 . Periodicals
ostagepaid
Newtown,CT 06470 and at additionalmailingoffic
paid
registration
t232tO9AL
SubscrlptionRates:
U.S and
Canada,
$34.95
for o
year,
$59.95
for two
years,
$83.95
for three
years
U.S.dol lars,
lease).
anadian ST
ncluded.
uts
U.S and Canada,
41.95
for
one
year,
$73.95
for tw
years,
$104.95
for three
years
(in
U.S.dollars,
plea
Singlecopy,
7.99.
Singlecopiesoutside he U.S.a
possessions,
8.99.
Postmastel: Send address changes o.
Fine Woodw
The TauntonPress, nc.,
63 S.
Main St., PO Box
550
Newtown.CT 0647G5506.
Canada Post: Return
undeliverableCanadian
addres
FineWoodworking,
/o
WorldwideMailers, nc.,2835
Drive,Windsor. N N8T3B7, or email o mnfa@taun
F I N E
\ T O O D \ T O R K I N G
Prlnted ln the USA
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
5/81
HOW
TO
CONTACT
S:
FIneWoodworklnT,
The
Taunton
ress,63
S. Main
St.,POBox
5506,
NeMown,
CT
0647G5506
203*42ffiL71-
www.fi
newoodworking.com
Editorial:
Tocontributenarticle, ivea tip, or aska
question,
ontact
FineWoodworkr'ng
t
the
address
above
or:
Cal l :
Fax:
Emai l :
80009955
203-270-6753
Customer
Service:
For
ubscription
nquiries,
ou
can:
.Click
on he
Customer
ervice
ink
at :
www.fi
newoodworki
g.com
.Emai l
s :
.Call
ourcustomer upport enter:
To
eport
an address
hange,
nquire
about
an order,
r
solvea
problem,
all:
8004778727
Tosubscribe,
urchase
ack
ssues,
books
or videos,
r
give
a
gift,
call:
80G88&8286
Advertising:
To
ind
out
about
advertising:
Call:
8O009954
Email [email protected]
Member
Audit
rn
rh e
Bureau
f
Circutation
tD #fl1
Retail:
lf
you'd
ike
o carryFine
Woodworking
n
your
store,
call
he Taunton
rade
Company
t:
86&5054674
Mailing
List:
Occasionally
e
make
our
subscribers'
ames
and addresses
vailable
o responsible
cornpanies
hose
products
or
services
we
feel
may
be of
some
nterest
o
you.
Most
of
our
subscribers
ind
his
o be
a helpful
way
to learn
about
useful
esources
nd services.
lf
you
don't
want
us o
share
our
name
with
other
companies,
lease
ontact
ur
Customer
Service
Department
t:
800477A727
he
Taunton
uarantee:
lf at
any ime
you're
not
completely
atisfied
Frne
woodworking ou
can
cancelyour
ubscription
nd eceive
full
and mmediate
efund
of
the entire
subscription
rice.
No
sked.
008
byThe
aunton
ress,
nc.
No
eproduction
ermission
f The
Taunton
ress.
Inc.
*
Pocket,
abinet
Finish
crews
*
Yellow
inc
Screws
'
-
14'
*
Lag
Screws -112
12
*
Stainless
teel
-1l4 4
*
ACQ
Comp.
Exterior)
-114'
6'
*
Trim
Head
tainless
teel
-518'
4'
*
New
Star
Drive
GufterScrews
*
New
1-314
omposite
ence/Fascia
crews
* NewGement oardScrews Since1999t
READER
SERVICE
NO.
98
READER
SERVICE
O.94
READER
ERVICE
o.67
T O O L S
& S H O P S
2 O O 9
7
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
6/81
contributors
Tim DeKorte
yerighten
Your
Shop With
an
EpoxyFloor")
was
introduced
o woodworking
nearly40
years
ago
by
his
brother-
in-law, .E.Beacham ll,a well-known lockmaker. eKorte, ho
calls woodworking
the
perfectpastimej'
iveswith his
wife
on the
centralcoast
of California,where
he is
a sales representative
for
an
industrial
aint
and coatings
ompany.
On he subjectof furniture
design,Norman Pirollo
(4
Bench
Jigs
for Handplanes")
s an
open book ...well, blog.
Keen o
share his
insights,
Pirollohas
a
weblog
at wwwrefinededge.com,
eaturing
projects
rom
drawers o antique-car
ashboards. his hand-tool
enthusiast, ho specializesn
boxes
www.fineboxes.com)
nd studio
furniture,
wnsa
woodworking
usiness ear
Ottawa,Canada.
The Thunton Press
Inspiration for hands-on livingo
I N D E P E N D E N T
P U B L I S H E R SS I N C E I 9 7
Foundcrs, Paul and Jan Roman
President
Suzanne Roman
EW 6
CFO
Timothy Rahr
SVE OPerations
Thomas Luxeder
SVP Creatiue & Editorial
Susan
Edelman
SVE Technohgl
Jay
Hardcy
SW & Groap Publisher,
Home
Paul
Spring
SW & Publisher Booh
Group
Donald Linn
SW Aduertising
Sales
Karl
Elken
SW Enthusiat
Group & ConsumerMarheting
Janine
Scolpino
VP, Hutnan Resources
Carol
Marotti
W & Controlhr
Wayne Reynolds
VE Fulfrllment
Patricia
\i4lliamson
VB Finance
KathyWorth
VE Thunton
Interactiue
Jason
Revzon
W
Single
Copy Salzs
Jay Annis
THE TAUNTO N
PRESS
Books: Marhuing
Audrey Locorotondo. Publicity:
Ja
Noblin. Editorial: HelenAlbert,
Peter Chapman,
Shau
Devlin,
Jessica
DiDonato,
CourtneyJordan, Catherine
Levy, Carolyn Mandarano,
Jennifer
Russell,Erica Sand
Foege,
Sharon Zagata.Art: Alison
7ilkes, Kary Binder
Nancy Boudreau,
TeresaFernandes,
Nora Fuentes,
Amy
Griffin, SandraMahlstedt, Lynne
Phillips, Brooke
Ran
Carol Singer. Manufactaring
Thomas
Greco, Laura
Burrone.
Business
Office Holly
Smith,
Parricia
Marinl Legal:
Carolyn
Kovaleski.
Magazine
Print Produaion: Philip
V
Kirk, Nicole Anastas,
ennifer
Kaczmarryk.
Disribution:
Paul Seipold, ValterAponte,
Frank Bus
David
DeToto, Leanne Furlong, Deborah Greene, Fra
Melbourne,
Reinaldo Moreno, David
Rodriguez, Mich
Savage, lice
Saxton.
Finance/Accounting:
Finance: Brett Manning,
fuchar
Rivellese. 4erounting Patrick l,amonragne,
Priscilla
Jennings,
Lydia lGikorian,
Michelle Mendonca,
Judith
O'Toole, Elaine Yamin,
Carol Diehm, Dorothy Blasko
SusanBurke,
James
Foster,
Lorraine Parsons, arry
Ric
Fulfillment Diane
Goulart. Fulfllment
Systems:
Jodi
Klein,
Mindy Ko&, Donna
Capalbo, Andy
Corson,
Nanry Knorr, lnrna
McAllisrcr. Customer
Seruice:
Kathleen Baker,
Bonnie Beardsley,
Deborah Ciccio,
Katherine
Clarke, Alfred Dreher,
Paula Ferreri, Eileen
McNulry
Patricia Parks,
Deana Parker,Patricia Pineau
After
John Nesset
(Shop
DesiSn)
eganwoodworking
n 1978,
he
usedan apartment
bedroom
and a foureason
orch
as shops.
Today,
e
sharesa communal
workshop n
Minneapolis.
is
bench,
"f
Am Naturej'
was featured
on the
back cover
of FWW#155. He's
at
work
on a
commissionor
a
large
dining
able,but he
still
works
part
time as a meat
cutter o subsidize is
woodworking
abit.
You never
know where
you'll
ind
Art Liebeskind
(Stop
Sufferin{,for
Your
Craft).
He ravels
he world or his
logistics
onsulting
business
and has
been known
o
go
cagediving
with
great
white
sharks.
f
he's
home,
he'll
be in his
Baltimore
woodshop,
ursuing
a
craft he'senjoyed
tor 45
years.
His
work has helped
urnish
several omes, ncluding
ne
he
built or
himself
on a barge
n Baltimore'snner
Harbor n
the 1960s.
F I N E
\ T O O D \ O T O R K I N G
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
7/81
Betty Stepney. ata
Entry: MaryAnn
Colbert, Caryne-
Lynne Davis,
Maureen Pekar,
Debra Sennefelder,
Andrea
Shorrock,Marylou
Thompson, Barbara' (/'illiams.
Human Resources:
Christine
Lincoln,
Vendy Tita,
Dawn Ussery.
Information
Technology
Servicest App
icatio ns
Deuehpment:
Heidi
W'aldkirch, Roberr Nielsen,
Linda
Reddington,
John
Vaccino,
Daniel \(oodhouse.
Deshtop
and Networh Support: Adam
Gregory PetreCotofana, Paul
DelPadre,
Michael
Lewis.
Operations:
Joseph
Morits,
RobertaCalabrese,
John
Gedney,Marc
Imbimbo,
Jennifer
Licursi,
SusanNerich,
Amy
Reilly,SandySchroeder,
im
Sizemore
Denise
Zor. T Room:
Michael Louchen,
SarahJeffrey,
nna
Pendergast,
nne
Scheurer.Maintenance:
Lincoln Peters.
Promotion:
Jane
Weber, Promotion
Creatiue:
Jennifer
ti7heeler
Conlon, Kirsten
Coons, David
Grosso,Michele
Mayernik,
Sandra
Moryka,
lVilliam
Sims.
Promotion
Operations:
Kate Krentsa.
Taunton
Creative: MichaelAmaditz,
Lucia
Coccoli,
Sarah
Opdahl, Kat Riehle.
Photography:
SconPhillips. Video:
Dariusz Kanarek,
Gary
Junken,
Michael
Dobsevage.
Publishing
Services: Deborah
Cooper. Prepress:
Richard
Booth,
Tilliam Bivona,
David Blasko,
Richard Correale,
Villiam Godfrey, Brian Leavitt, Chansam Thammavongsa.
Aduertising
Prodttction:
Laura Bergeron,
Lisa DeFeo,
Patricia
Petro,Karhryn
Simonds,
Martha Stammer.
TA UNTO N
I N T E R A C T I V E
Matthew Berger,
Jodie
Delohery,
David Hall,
Robert
Harlow,
Christopher
Casey,Ruth Dobsevage,
Lisa
Durand,
Erika Foreman,
Mary Kate
Grant, Shahul
Kodakkadan,
Geoff lGajeski,
SteveLombardi,
Sharna
Sattiraju,
Michael
Stoltz,Dawn Vglione.
T A U N T O N
T R A D E
John
Bacigalupi,
Brett DeMello,
AllisonHolleu.
Single
CopySales:Valerie
Droukas,
Mark
Stiekman.
TA UNTO N
MA G A ZINE S
Fine lVoodworhing
.
Fine
Homebuilding
Threads . Fine Gardzning . pirt Coohing
Our magazines
re or
peoplewho arepassionate
bout
their pursuits.W'ritten
by practicingexperts n
the field,
Thunton Press
magazines
provide aurhenric, reliable
information
supported
by
insrructive
and nspiring
visuals.
T A U N T O N
B O O K S
Our booksare illed
with in-depth
information
and
creative deas
rom the finest
aurhors
n rheir fields.
'$Thether
you're
practicing
a craft or engaged
n
the creation
of your home,
Taunton
bookswill inspire
you
ro discover
new levels
of
accomplishment.
TWW.TAUNTON.
COM
Our website s a place
where you
can discover
more about
the interests
ou enjoy,
converse ith
fellow enthusiasts,
shop
at our convenient
on-line
storeor contact
customer
service.
E M P L O Y M E N T
I N F O
R M A T I
O N
To
inquire
about career
pportunities,
please isit
our
website
at careers.taunton.com.
You may also
write
to
The
Thunton
Press,
uman
Resources,63
. Main
St., Box
5506,
Newtow
n,
CT 06470.
C U S T O M E R
S E R V I C E
'W'e
are here
o answer
any quesrions
you might have
and to
help
you order
our magazines,
books
and videos.
Just
call
us
toll-free
at 800-477
8727
.
TheThunton
Press, nc.,
Taunton Direcr, Inc., Taunton
Tiade,
Inc., and Thunron
Interacrive,
Inc., are all subsidiaria
ofTaunton,
Inc.
Mortise
Pal*
Turn
our lunge
cubr
nto
a
prccision
lotmofiiser
LmseTenon
oinerv
Sj$pl',1 g$_:o
'///
lHii*?i[iY,**i^
Mad'enu.s.A.
V
/,
READERSERVICE O.
1OO
9
O O L S
& S H O P S 2 O O 9
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
8/81
Spotlight
tssuE 0.201
November/December
008
p . 3 6
STRUGGLING
ITH
A
SKILL?
THE DOCTOR
S IN
I found
"A
Trip
o the
Dovetail
Doctor"
o be really helpful,
t filled
in the
gaps
...
so
to speak. I'tl
bet mistakes
and
bad
habits
"r"
.orron
among
self-taught
woodworkers,
nd I wouldn't
mind seeing
hat type
of article
as a regular
eature. By
the way,
f
you
need a
struggling ookie
on, well,
any
subject, 'm
your
guy
-SCOTTADGER,ackson,.H.
Editor
replies:
You'renot
alone,
Scott. We've
had
a
lot
of
positive
eedback
on that
article,
and
on the video
of that
troubleshooting
ession.As
you
sugglest,
we are
planning
o repeat
he formula,
sending
other frustrated
eaders
o our favorite
teachers
(and
teachers
o readers
n
some cases) or
similar one{n-one
clinics,
while
we record
he
action
and highlight
he discoveries.
So listen
up,
desperados:
Like
the
producers
of TV reality
shows,we're inviting
you
to send
in
your
audition
apes. Whether
you
can't
get
your
handplane
or
bandsaw
o
work
right,
or have
rouble
milling umber
straight
or dialing n
a
furniture
design, et
us know.
we'll choosea few
guinea
pigB
and line them
.
up with
a tailor-made
utorial.This
should
be fun.
:1.
Send a letter,
email,
or
short
video
hat explains
which
skill
or
technique
you
are
struggling
with
and where
thingS
seem
to be
going
wrong.
nclude
photos
if they
help
to
illustrate
he
problem.
-Asa
Christiana
Direct
our
eary-eyed
ntreaties
o:
Fine
Woodworkin{,,
Doctor
s In,
63
S. Main
St.,Newtown,
T06470,
or email [email protected].
How to sharpen
mortise
chisels
The
articles rn FIX/W
#198
("Grind
Perfec
Edges
tVithout
Burning")
and
*199
("Cu
Your Honing
Time
in Half") were perfec
companion pieces.
However,
thick morti
chisels
pose
a
problem.
A
hollow
grind
with
a
3-in.
radius
(6-in.-dia.
wheel)
on
such a long bevel creates a shockingly
deep hollow
and a
perilously
thin
edge
on a tool
that needs a
chunky
profile
to
withstand pounding
and
prying.
Do the
authors
have any
suggestions?
_STEVE
AWYER,ivon ia .
Joel Moskowitz
replies:
On regular
mortise
chisels,
grind
the
primary
bevel a
22"
to 25; the
hollow will
make it a little
shallower. This will give you
the
penetratio
angle
you
need. Then
grind
and hone a ti
secondary
bevel
at
35
to add
the necessa
toughness. You can also just hone the
secondary
bevel
without grinding
it.
On
thinner
sashmortise
chisels, wou
make
the
primary
bevel a
bit steeper-sa
30"-and
then
add a
5o
secondary
beve
to arrive
at the
35o
effective
cutting
edge.
Grind t 25"
Hone
t
35 '
Hendrik
Varju replies:
I agree with
Joel,
and I would
add that
the smaller
the
grinding
wheel,
the
more severe
the
hollowing,
especially
on
a thick tool.
So
switching
from
a
6-in.
wheel
to
an 8-in.
even a 10-in.
wheel
will help
a lot.
Tip
on
zeroclearance
inserts
When I make
zero-clearance
inserts for
tablesaws, I do one thing differently from
Tom
Begnal
("Get
Safer, Cleaner
Cuts
on Your
Tablesaw,"
F\tr/W
#200).
When
making
the final
cut through
the
blank
insert,
instead
of holding
it
down
with
a
' : j ] i ,.
tr ii'r.
a
t -
J
About
your
safety
Working
wood
is inherently
dangerous.
Usinghand
or
power
ools
improperly
or ignoring
standard
safety
practices
an lead
to
permanent
injury
or even
death. Don't
perform
operations
ou
learn
about here
(or
elsewhere)
ntil
you're
certain
hey are
safe for
you.
f
something
about
an operation
doesn't
eel right,
ind another
way.We
want
you
to
enjoy he
craft,so
please
keep
safety oremost
n
your
mind.
1 0
F r N E
\ 7 o o D \ r o R K r N G
Drawing:
Kelly
J.
Dun
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
9/81
lgttefs
."., ued
push
stick as he does, I
slide the rip fence
over the insert, staying clear of the line
of
cut. The
fence holds down
the
insert
safely
and
securely as I raise the blade.
-JlM
BARRETT,
est
pringfield,
ass.
Rule oints need clearance
I was interested
n Michael Zuba's
article
on using a router to
cut rule
joints
("The
Rule
Joint
Done
Right,"F\VW
#200),
not
least because wrote
on the same subject
28
years
ago
(FWW
#80).
I
agree with
Zuba
on
just
about every
point,
but I
would
add a footnote
on hinge
placement.
Over the
years,
even the
most
well-
cured wood
can develop a wiggle.
If the
rule
joint
is
laid out as Zuba suggests,
with little
or no clearance, t
can begin
to
bind as the leaf is raised and lowered.
This can produce a squawk worthy of
a haunted house,
stiffness n the action,
and, after a while, rub-throughs
in the
finish. My
suggestion s to follow
Zuba's
layout
precisely,
hen move the hinge
toward the leaf
slightly. For most woods
29Y,
26%
2%
2%
2I%
Separate
ui ld ing
rc%
Detached
arage
Which
hrase
est escribes
your
hoppace?
Attached
garage
Basement
2%
A roomn myhouse
Sharedor rented
shop
Other
2%
None
In
our eletter, we
poll
readers
on new
questions
achmonth.Signup or he
free newsletter
t FineWoodworking.com.
and climates, moving the hinge
rAe
in.
will produce plenty
of space between
the thin edge of the leaf
and the
tableto
when the leaf is lowered,
but
will retain
the snug fit when it is raised.
-MAC
CAMPBELL,ake eorge,.B.,C
Gollect dust at
its
source
Although I agreewith the headline,
"Protect
Yourself From'Wood Dust"
(FW
#z}t),
the subtitle is incorrect:
"Masks
and
respirators
are the best defense
against
harmful
dust." It is a well-known
industrial-hygiene
principle
that
the
bes
defense s to collect the
dust as
close
to
source as
possible.
Masks and respirator
are acltally the last line of defense.
-PAUL
RAMER,.D., vansvi
Editor replies: Don't blame the author
on this one.
Editors
attach headlines o
articles,
and as
you point
out, we
goofed
You are absolutely
coffect.
That's why
an effective dust-collection
svstem s so
important.
Tlend
Airshield
Pro
o
A built-in
uiet
ankeeps constantlow
of iltered
iracrosshe
ace
o
Provides
xcellent
rotection
from nhalation
f harmful ust
with win ine
dust ilters
o
0ptimum
enter f
gravity
for balancend omfort
r
8 hourN|-MH
atteryncludesharger
Airuvare
America
Call us or visit
our
website
today
80()-32A-1792
www.ai
nrvareamerica.com
Personal
ervice Fast hipping
Keeping oodworkers
afe or over30
years
READERSERVICE
O.71
EADERSERVICE O.69
Built n
Multi-P
Sysf
Variable Fe
Mo
GS1 Gui
Sysfe
Vaiable Fe
Control
WMagne
Dropout Sw
SteelWelded
Sta
Heavy Duty
Co
ct)
o
tu
rlr,
G
o
o
o
L
lL
lntroducing
he
Quick
Release
by CarterProducts
Our
new
gtaOe
Gage bandsaw
lade ensionmeter.
Lenox Pro Master
carbidetippedand Bimetal
blades
Bandrollers, rip
and
re-saw
fences, improved tension
springs, ires,
able nserts, ircle
igs,
and much
more.
History
and comparison
etweenDelta and JET
bandsaws.
CALL
1
866-883-8064
r
1
904-3713998
7 Year
Warranty
READER
SERVICE
O.
115
t2
F I N E \ T O O D \ T O R K I N G
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
10/81
methodsof
ork
Center
panel
outed
out after
assembly.
7a-in.- th
ck
cleats
make
pocket
for one
set
of legs.
holds
wo
ool
chests
For
rnany years.
my wooclworking
shop was
locatecl
in
an
unheatecl gzlrage
n Micliigan.
This
2lnangement
workecl
fine
until winter
colcl
fc>rcecl
ue
to lnove
try
entire shop
insicle
he
house.
To
rrake
the
anntral
rnove
easier,
I ltuilt
tl-risknock-clown
workbench.
The bench consists of six parts: two tool chests
(with
clrau'ers
ancl built-in
carrying
hanclles),
two
leg
sets,
a stretcher
that
connects
the
legs,
ancl
the
top. Insicle
tl-re eg
sets
are pockets
for
the
stretcher
ancl
tl-re
wo tool
chests.
The
unclersicle
of the
top
has pockets
that
flt
the legs
ctn
one
encl
ancl weclge
blocks
on
the other
encl. \{hen
the
top is
pushecl
clown,
tl-re
weclge
blocks
lock
it
in
place.
To ltreak
clown
the ltench,
just
remove
the
top,
slicle
tl-re
ctol
chests
np
:rncl out
of
their
pockets,
then
loosen
tl-re tolts
that
attach
tl're stretcher
to
E D I T E D
A N D
D R A W N
B Y
J I M R I C H E Y
C l e a t s ,%
i n .
h i c k
Cleats
provide
extra
support
for
tool
c h e s ts .
Leg
s e ts , a m in a te d
f rom
three
pieces
of
7a-in.
p lywood
Hardwood
dowel
h a n d l e s ,
i n . d i a .
Vert ica
s, 7a-in.- th
ck
hardwood,
screwed
to
too lchest
Su
pport
b lock
tl-re
egs.
It 's
all clone
in rninutes.
Tl-re
bencl-r
s
quite
eflcient
and
sturcly.
use it
to store
tny large
collection
of
hancl
tools-all
6iO llt.
of
rhern.
-J0HN
CAVERLY,
oca
Raton.
@fortheBestTip
Send riginaltips
o Methods
f Work,
ineWoodworking ,
PO
Box
5506,
Newtown,
T06470,
or emailflrumow@
taunton.com.
f
published,
e
pay
$50
or
an unillustrated
tip;
$tOO
or
an llustrated
ne.The
author
f
he best
ip
Nu t
an
wasne
Sd
for.
an
00t t
)
To p ,
wo
p ieces
o f
% - in . - th i c k
MDF
So l id -wo o d
dg ing ,
7 + n .
th i c k
Pockets
upport
tool
chests.
Stretcher.
wo
oieces
of
3/+in.
plywood
0o\
LEG
POCKETS
RE
UNDER
TOP
TOP
VIEW
it
f i
FRONT
IEW
When
op s
pushed
own
ver
he eg
sets,
the wedge
lock ocks t securelyn place.
Tip
Knock-down
orkbench
JohnCaverfy vas
bitten
by
he
woodworking
ug
almost
5
years
go,
when
he
ook
a shop
class n
school.
Now
retired,
e
spends
gOod
ealofhis
ime
building
urniture
and
oolsat
hishome
in
sunny
lorida.
Tool
hest,
%-in. - th
ck
plywood
L6
F I N E
W O O I ) W O R K I N G
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
11/81
methods
of
work c.n,nued
Magnetic
pring
eeps
enchdogs
n
place
Benchclogs
are
shop helpers
that
sit in holes
in
a
workbench
top.
The
dogs
are raised
above
the
benchtop
so
that a
board
can be
secnred
against
them for
handplaning,
for instance.
'When
not in
use, the
dogs
slide
down
below
the benchtop.
Most dogs are held at the correct height witl-r a metal or
woocl
spring
built
into
the sides.
When
I was
rnakinl
*d*fidj*:r11fl$***
1,
the dog
at the
desired
height.
My
solution
was
to inset
two
rare-earth
magnets
into
the side
of each
rectangular
dog. I
arranged
the pair
to repel
each
other,
which
callses
the outer
magnet
to
press
against
the
side of
the
dog hole,
holding
the
dog ar
the height yolr
wanr.
Don't pull
the
dog out
too
far, though,
or the
magnets
could
pop
ollt.
It helps
to locate
the
magnets
as
low
as
possible,
so
yolr
can maximize
the
height
of the
dog.
-J lM SHAPIR0,anFrancisco
Rare-earth
magnets,
alignedwith
opposing
polar i t ies
To
prevent
work
from
slipping,
used
o
glue
sandpaper
o
the face
of my
miter
gauge
and to
other
jigs
and fixtures.
Now
I
use
skateboard
grip
tape
instead.
t
is
'
tough,
ong
asting,
and
comes
with
a
self-adhesive
acking.
You
can
ind
this
abrasive
ape
at any
skateboard
shop
or
online
at www.tactics
.com.
Jessup
nd
Shorty'sBlack Magic
(under
$5
for
a
33-in.
roll)
are
two
good
brands.
- J O I I N
A . H A S S E ,
Fort
Gollins,
Colo.
Nesting
rames
elp
with
glue-ups
nd
more
These
nesting
square
frarnes,
which
I call
multitask
shop
helpers,
take
up very
little
space
but
pack
several
functions
into
a
small
package.
The
frarnes
are
great
for
both panel
and
carcase
glue-
ups. They
are
notched
to
hold
bar
clamps
on
one
side
and
pipe
clamps
on
the other,
which
makes
them
handy
for
panel
assemblies.
And
the
frames
can be
used
to help
keep
a
carcase.
a box.
or a
drawer
sqllare
during
assembly.
The
frames
are handy
for
cutting
stock,
too.
I
use
two of them to elevate a
board
above
my
bench
for
crosscutting.
In
addition,
each
frame
is
the same
height
as my
miter-saw
bed,
so
they
can
be
r-rsed
as outfeed
sllpport
there.
- S E R G E
U C L O S .
Delson,
ue.,
anada
The
hree
f ram es , 2
22- in. ,
nd
24- in.
qua
nest nsid
one
anoth
for storage
Notches
or
p ipe
lamps
3/+-in.- th ick
MD F
Frames
help keep
a s s e mb l ie s
a t
r ight
angles.
Magnets
us h
against
ideof
mort ise
o hold
do g
at
desired eight.
18
F I N E
\ 0 f l O O D \ T O R K I N G
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
12/81
methods
f work c.n,nue.
Space-saving
ork
able
olds lat
against all
I have
replaced
he
paper-towel
ispenser
at my
workstation
with
a napkinholder,
the kind
diners
use o dispense
apkins
one
at a
time. This
approach
s more
economical
han
paper
owels
when
wiping
up
glue
and
spil ls.
The napkins
dispense
easily,
ven
f
you re
wearing
rubber
gloves,
nd the holder
akes up
less
space
and
can be
brought
o the
work
spot
or mounted
on a wall.
You ll
find them at restaurant-supply ouses.
-J0E
ESP0SlT0,
oster ,
. l .
Oolor-code
our ower-tool
ords
I plug
many
of rny tools
into
a six-outlet power
strip in
the
center
of my
shop.
At any
given
time,
I have
several
tools plugged
in wirh
the cords
invariably
tangled.
In
the
past,
when
I needed
to
unplug
a
tool to
plug
in
something
else,
I
would
trace
the
cord
through
the rangle
all
the way
back
to the tool-a hassle, to say the least.
I
eliminated
this problern
by buying
a
package
of five
different
colors
of electrical
tape.
For
each tool,
I wrapped
a color,
or
combination
of colors,
near
the
plug
and
wrapped
the
same
color where
the
cord enters
the
machine.
Now,
if I want
to unplug
a tool,
I
check its
color
code
on the
tool.
and then
unplr,rg
he rnatching
cord
at the
power
strip.
U
_/?
is
much
quicker
and
safer.
- J IM
B U C K N E LL ,
ow , as h .
F I N E \ 7 O O D \ T O R K I N G
Table
n
router
mode
My shop i.s
a one-car garage
where
wooclworking
has
to
coexist with
motorcycling,
bicycling, ancl other farnily
interests.
I needecl
a sl-rop
worktzible
tl-rat
could
double
as
a
router
table and
disappear
when
not in use.
The
clesign shown
is
made
of tlrree
glued
layers
of
3/+-in.-
tl-rick plywood
with
a
plastic-
laminerte
op
and a solid-wood
eclge.
I installed
a router-
support
plate
in
the rniddle
of
the table
ancl a wooclworking
vise
along
tl-re
ront
edge.
Tl-re table is
attached
to the
wall
via
a
cleat with
three
hear,lz-ch-rty
-ence
hinges.
The
legs pivot
and
unfolcl on
th e
same
type
of hinges.
Folded
up,
the table
is helcl
in place
with
a slicling
cloor lock
that
fits a hole
in
the front
apron.
To
protect
tl ie lanrinate
snrface while
I m
using
it as
a work
table,
I
cover it with
a slreet
of
r/+-in.-thick
l-righ-
density
fiberboarcl.
_ D A N I E L
U C E P P E ,
Sherbrooke,
ue.,
anada
Table ocks
in
p lace
wi th
s l id ing
door bol t
l ock .
4x4
legs
swing
on ence
h inges .
Heavy-duty
fence
hinges
Color-coded
ords make i t
eas
to f ind
the matching
plugs.
:)
D
-T
i
I
Colored
electr ical
ap e
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
13/81
tools&materials
I
Mini-lathe
as
extra
capacityndpower
Mini in name
only.letb
new mini-lathe
weighs
725
Ib.,makin , it more
of a midi-lathe.
GRAMERCY
OOLS
AS NTRODUCED
new
line
of hand-cut asps.
Unlike he evenly
spaced eeth
on machine+ut rasps,
he
barbs
on hand+ut rasps
are randomly
spaced.When
it comes
o rasps, andomly
spaced teeth
cut smoother
and faster.
Gramercy
offers seven
cabinetmaker's
rasps
and a handle'maker's
asp.The
handle-maker's
asp
(top
right) s unique:
RECENTLYESTED NEW
MINI-LATHErom
Jet,
the model
7220VS.It
eaturesa
3/'-hp
variable-speed
motor
(270
rpm
to 4,200
rpm), a 7-in. by
8-threads-per-inch
tpi)
spindle,
and No. 2 Morse-taper
centers. t also has a 72-in.
swing
over the bed
(9Vz
n. over the tool
rest) and a 20-in.
capacity befween
centers.A sister
mini-lathe, model
7220,has a six-speed
500
rpm to
3,900
rpm) motor.
A 24-position ndex pin doubles as
a spindle lock, a real
time-saver
when
removing faceplates
and chucks.
Jet
has also included
a
plastic
tool caddy,
a flexible work lamp,
and both a 6-in.
and a 10-in. ool rest.
Other standard
equipment includes
a faceplate, a
spur center, a knock-
out bar,
and a
live
center. All that
good
stuff adds weight;
the 1220VS s
about
I25 lb., so it won't
be
portable
for everyone without
help.
Options include
a bed extension that increases
he
capaciry
berween
centers o 48 in. and
a steel stand that
adjusts
rom 43 in.
to 45 in. tall. Both were
sturdy and well-made.
I
$ * . $ $ * #
E # # t , S
Hand-cut
asps
work
smoother
nd aster
The
blade s curved
along ts length
and has
teeth
only on its half-round ide (the back is
smooth). Those eatures
make it ideal
for
sculpting
he
inside
edgesof closed
pistol-$rip
ool
handles.
All
the
rasps
have nicely
shaped
ash handles.The
bladesare surgical-
grade
stainless
steel,so
they are tough
(the
teeth won't
break), ong-wearing
(the
teeth stay sharp),
and won't rust.
Stainless steel doesn't
take
quite
as
Accessories
add capacity.An optionalbed extension
llows
onger
turnin$s,while
a sturdy tand s heightadjustable.
Once fired
up, the 7220YSwas
a
pleasure
o use. I turned
spindles
and bowls with very
good
results.
t ran
quiet
and
smooth, with no
noticeable vibration.
And it had
plenty
of
power
throughout
the entire speed range, with no
drop-off in
torque at the lower speeds.
The 7220YS
ells or
around
$550;
he 7220 or about
fi445.
For
more information,
check out www.jettools.com.
-Andy
Barnum
teacbeswood turning at tbe
S
Uniuersity of New York
at Purcbase
Random,
not rows. Rasps with
hand+ut te
have
a random
pattern.As
a
result,they
cut
faster
and smoother than tfiose
with machine-cut teeth
set in rows.
keen an
edge
as carbon
steel.
Evenso, I was more
than
satisfied
.
with
the
performance
of the rasps.
The
cabinetmaker's rasps
range in
pr
from
$54
to
$110;
the handlemaker's
rasp s
$5O.
More nformation
can be
had
at www.toolsfonrorkingtrvood.co
-Chris
Gochnouruilds
ustom
urniture
teaches
oodworking
n Murray,
2 2
F r N E \ r o o D \ r o R K r N G
Photos:
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
14/81
tools
matenal
.n,,n,".
lmproved
ountersink
its
COUNTERSINK
ITSARE
GREAT
IME-SAVERSecause hey drill
a
pilot
hole and countersink
(or
counterbore
f needed) in
one step. These bits typically include depth stops, oo.
On
the
downside,
they tend to clog
quickly.
If
you
don't
stop regularly to clear the chips,
you
can
burn the
wood
and
Set of
four. The bits come
in four
sizes,so
you
can drill
holes for the common screw
sizes
of #6, #8,
#70,
and #72.
stays
ixed in
place,
so
there's no burning.
After
giving
the bits a workout, I concluded they
have exce
chip-clearingcapability. was able to drill deep holes
without
having to
withdraw
the bit to clear
heavy clogs. Every hole w
drilled
cleanly n one shot, and the non-marring stop
collars
didn't char the workpiece surface.A four-piece set sells
or
$5
Bits also are available ndividually. Go to
www.woodworker.co
-Mario
Rodriguez teacbesa
Pb lade
ph
a Furniture
Works
No more burn marks.The depth
stop stops spinningwhen
t
con-
tacts the workpiece, so it won't
leave
a burn
mark in
the
wood.
overheat
the bit. Also, since
most
depth
stops spin
with
the bit, they can create a disk-
shaped burn on the
wood.
'Woodworker's
Supply
has
worked to solve those
problems
with its new
CleanStopCounter-
sink Bits. Large lutes
on the countersink
cutter
help keep clogging to
a
minimum. The depth stops
have a couple of channels to
allow chips to exit
freely. At
the same time, the depth stop
acts like a bearing, allowing
the bit to spin
while
the stop
ffifi
I
Fresh hellac n he cheap
GROWINGUMBERS FWOODWORKERSave discovered he benefitsof shellac. t seals
n
almost
anythingand, when dewaxed, s compatiblewith almost any subsequent inish.
But
shellac
must be fresh,or it won't
dry
properly.
So
a lot
of
finishersmake their own, dissolvi
shellac lakes in denaturedalcohol.One drawback:You must remember o dissolve he
flake
day or two before
you
use them.
A new companycalled Shellacfinishes laims o havesolved he dissolve-time
ssue. t
imports
shellac
lakes directly rom India
and says
hat its flakes
are
fresher han those offe
elsewhere.
Fresher lakes, they
say,dissolve
aster,
and the
finish dries faster.
In
an informal est,
we
compared he dissolve ime
for
garnet
shellac
lakes rom
Shellacfinishes
ith the J.E.Moser br
sold by Woodworker'sSupplyand Jeff Jewitt'sHomes
.
Finishing
brand.
We began
at
midday,and despite
swirling each
ar
about once an hour,none of the
samples
had
completely
dissolvedby 10
p.ffi.,
,-
*
aithougn he
Homestead
and the Shellacfinishes
samples
were
close.
Both
dried
hard
equally
ast w
a
drop
was
put
on some
glass,
another
sign of freshn
Shellacfinishes ells
ive
types of dewaxedshellac,
plus
a
four-type
ampler
pack.
Prices an
from
$12
to
$21
per pound,
ower
han
most
other online sources
www.shellacfinishes.biz)
-Mark
Schofields he managing
dissolvin ,,
lowe.r
cost.
;
Sheflacfinislres
shellac flakes dis-
solved
and dried as
fast
or faster
than other
quality
flakes,
and
cost
less, too.
2 4
F r N E \ r o o D \ r o R K r N G
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
15/81
Much
fess
tearout.
A
recenily
introduced
jissaw
btade
rom
Bosch
made
clean
cuts
in
a
variety
of materials.
New
igsaw
blades
aresmoothcutters
BoscH
ls Now
OFFERING
JTGSAW
LADE
wirh
some
fearures
that
make
it
an
especially
smooth
clltter.
Traditional
jigsaw
blades
cllt
only
on
the
upstroke,
so
the
top
surface
of
the
workpiece
is
more prone
to
chipout.
This
new
blade
from
Bosch-the
T308B
Xtra-Clean
for
\Wood-is
designed
to
cut
on
both
the
upstroke
and
downstroke,
and
th
helps
to
reduce
chipout
on both
faces.
Also,
unlike
most
jigsaw
blades,
which
are
made
on
a sram
ing
machine,
the
T308B
Xtra-Clean's
teeth
are ground.
That
makes
them
much
sharper;
all
else
being
equal,
sharp
teeth
c
faster
and
produce
less
chipout.
I
used
the
Bosch
blade
and
a
typical
stamped
brade
to
mak
straight
and
curved
test
cuts
in
oak,
walnut,
cherry pine,
birc
plywood,
and
melamine.
The
Bosch
consistently
produced
cleaner
cuts.
A
package
of
five
T30SB
blades
sells
for
$14
(it's
available
only
with
a T-shaped
shank).
Look
for
the
blade
at
Lowe,s
an
woodworking
speciality
stores.
For
more
information,
go
to
www.boschtools.com.
-Tont
Begnal
is an
associate
edit
Mix
and
match.
This
sample
box
makes
ft
easy
to
choose
awood
for
a
project,
or
combine
woods
gracefully.
I
Wood
samples
good
eference
woNDER
WHAT
uMAc
LooKS
L|KE,
r chinkapin,
lippery
elm,
or
hackberry?
A
company
rom
Maine,
cailed
wood
smart,
can
help.
They
seff
sample
boxes
of 46
North
American
wood
species
commonly
used
to
make
furniture.
Each
unfinished
sample
measures
Lhin.
thick
by
3 in.
wide
by
6 in.
long.
As
we
discovered,
hat's
enough
room
to
test
a finish
or
two
on
the
back
side.
Each
sample
is labeled
with
the
common
and
botanical
namesof the wood.Also noted s informationon weight (shownas
specific
gravity)
and
shrinkage
characteristics.
n
addition,
he
box
includes
a table
that
allows
you
to
determine
how
much
a
board
will
expand
and contract
due
to
seasonal
changes
n
retative
humidity.
The
set
sells or
$fgO
and
is
availabte
rom
Lie-
Nielsen
Toolworks.
For
more
informatior,
go
to www.
lie-nielsen.com.
2 6
F r N E
\ r o o D r o R K r N G
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
16/81
acloser
ook
m
l ?
'Eg
Not
all
carbide
iscreatedqual
THE
HARDEST
AN-MADE
ATERIAL
HAS
REVOLUTION
ZED
WOODWORKI
G,
BUT
QUALITY
ARIES
B Y
M A R K
S C H O F I E L D
et used
to honing your
bits
each
time
yoLl
use
them,
as
dull
ones
tend
to
chip,
splinter,
and
burn
the work."
This
advice,
from
the first
issue
of
Fine'Woodworking,
is
a reminder
that
some
things
have gotten
a lot
easier
over
the last
30
years.
The
author
was
referring
to
steel
rollter
bits,
and
the
reason
tl-ris
advice
is
no longer
needed
is
sumrned
up in
one word:
carbide.
Invented
in
Germany
in
the I92Os,
ungsten
carbicle
is
a
dense,
hard,
wear-resistant
material
that
now
is
everywhere
from giant
mining
tools
to
the rolling
ball
of
your
pen.
In
woodworking,
it
has
revolutionized
sawblades
and router
bits,
increasing
exponentially
the
length
of
time
between
sharpening.
It's
easy
to take those carbide tips for granted, but after doing
soffle
research
I've gained
a
new
respect
for
them.
There's
a lot
of technology
in
each
tip.
-
F
rp
IP
C
e2'
w|
unfortunately,
not
all
carbide
is
created
equal,
and
there
is
national
or international
standard
for well over 5,000 differen
carbide
grades.
But
there
are ways
to increase
yollr
chances
o
buying
tools
with premium-qualiry
carbide.
I
also learned
how
to
prolong
the
life
of carbide-tipped
blades
and
bits,
and
how
to
tell
when
they
do need
sharpening.
Garbide
varies
by
quality
and
type
Tungsten
carbide
is the
hardest
man-made
rnaterial
known,
wit
wear
resistance
about
100
times
that
of
steel.
In
addition,
it has
21/z
times
the
rigidiry
of steel,
is
dimensionally
stable,
retains
its
hardness
at high
heat,
and has
an
impact
resistance
similar
to
hard
tool
steels.
In
short,
it is pretfy
amazing
stuff.
You
may
have
seen
tool
rnakers
refer
to
their
carbide
as bein
C7, C2, etc. These gracles,originally developed for classifying
carbide
by its
ability
to cut
metal
(they
run
from
Cl to
CI9),
a
clefined
not
by
its
chemical
makeup,
which
can
vafy
widely,
p
il;
o
Molded
under
pressure,
M
etal-i
njection
mol
d ng
(MIM)
is
used
to
form
the
powder/binder/wax
mix-
ture
into
more
complex
shapes.The
equipment
s
similar
to
that
used
or injection
motdin{,
of
ptastics.
Attached
as teeth.
Carbid
tips
are
brazed
onto
the
ste
plate
of
a sawblade.
Repair
broken
teeth
are
done in
the
same
way.
From
i
ne
powder
o
power
ools
C A R B ID E
S
MA D E
IN
THREE
STAGES
Carbide
egins
as
a mixture
of very
inely
ground
ungsten
and
carbon
black
1).
After
a
binder
uch
as cobalt
and some
waxareadded, he mater ia l s
molded
nto
ts
rough
shape
an d
g iven
an in i t ia l
bak ing .
Known
as
green
carbide,
he
material
at
this ntermediate
tage
s
soft
and
crumbly
2) ,
which
a l lows
t
to be
machined
easily.
inally,
it
is baked
a second
ime
at
high
emperature,
hich
causes
the
material
o
shrink
L8o/o
o
24o/o
o create
he hard,
dense
carbide
used
on tools
3) .
F I N E
\ 7 O O D \ T O R K I N G
Photos:
\' ltl lti-Metals
(this
page.
botton.r
center):
Case \{' 'estern
Resen.e
University
(nticroscope
imag
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
17/81
but by the
style
of work it
can
do. C3 is
defined
as finishing,
C4
as
precision,
for
example,
but
there is
no
agreement
on what this
means.
Like
steel makers,
carbide manu-
facturers
face
a
trade-off
between
toughness (the ability to resist
fracfure),
and hardness
(wear
resistance).
There
are two main
ways
to vary
the
properties
of carbide:
the
size
of
the
grain
and the percentage
of
binder
mixed
in.
Grains:The
trend is
smaller-You'll
often
see
carbide tools
listed
as having
submicron
carbide
or micrograin
carbide.'This
means the
individual grains
of
carbide are less
than
L
micron
in diameter.
Fine-grained
carbide
is listed
as being
1-2
microns,
medium
as 2-5 microns,
and coarse
as
over
5
microns.
\fith
the
exception
of fine-grained
carbide
found
on
construc-
tion-grade
tools
such as
circular-saw
blades
or cheap router
bits,
most woodworking
carbide
is submicron
because t gives
greater
wear
resistance.
Unfortunately,
this
also decreases
he
toughness
of
the carbide.
To
try and
reach
the sweet
spot
of
greater
lon-
gevity
without
excessive
chipping
or
cracking,
some
manufac-
turers
change
the
composition
of their
carbide
by adding
boron
or
titanium
carbide.
Binder:
the
trade-off-The
percentage
of cobalt
binder
for
most woodworking
products
ranges
from
3o/o
o l0o/o.
As
you
in-
crease
he
percentage,
he
hardness goes
down,
decreasing
wear
resistance,
but strength goes
up for
better
fracture
resistance.
Manufacturers
use this
to adjust
the
carbide's properties
for
dif-
ferent
uses.
Freud,
alone
among
the woodworking
tool
makers,
manufacturesall of its own carbide and makes 22 grades.lt
might use
an
ultrafine
grain
(less
than
0.5 micron),
high-cobalt
carbide
for
the
exposed
sawteeth
on a high
top-bevel
blade,
Used In
solld
form,While
some
bits
and
blades
have
carbide
pieces
attached
to a steel
plate
or
shaft,
oth-
ers, such
as
this
spiral
cutter,
must
be
machined
from
solid
carbide.
Tale
f
2
bits:
hard
s.ough
We were
curious
o see and
compare
he wear
on two ro
bits tested
in FWN
#191
( Tool
Test:
Router Bits ).
David
Matthiesen,
a
professor
n the
Department
of Materials
Science
and Engineering
t CaseWestern
Reserve
Unive
placed
he winning
and losing
bits in
a scanning
electron
microscopeand lookedat the damage o the straight ed
on each, irst
at
350x resolution
and
then at 2,500x.
We
noted
the finer
sharpening
ob
on the better
bit.
Hardqyearl
n
but brlltle.
Some
gpes
of carbide em-
phasize
hardness
and wear-
resistancg
but they
tend to be
more
brittle
and can chip
away.
This
bit was
still cutting
cleanly
despite
the microchips.
louh
but malleable.
This
carbide
esisted
racture
better
than
he bit
shown
above ut
$ot
blunt aster.The
ounded-
over
edgemade
poorguality
cutssoon
after he
eststarted.
2 , 5OOx
2 , 5OOx
www.
f inewoodwork
i n
g.
co m
T O O T S
&
S H O P S 2 O O 9
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
18/81
acloser
ook
con,nued
Brush
yow
teeth
rctulaily. lf
pitch
and residue
are allowed
to
build up on the
sawteeth,
they will
increase
friction.This
extra heat
will shorten
the
Iife
span
of the
carbide.Apply
a mild
household
cleaner or
bladeand-blt
cleanen
allow t
to
sit
for
a few minutes,
and then
scrub
the teeth with
a
brass-or nylon-bristlebrush.
but on a
triple-chip grind
blade
designed
to cut
more abrasive
melamine,
more
wear-resistant
carbide
is used.
What
to look
br
As one
manufacnrrer
of high-end
blades ruefirlly
explained, you
can't
tell
good
carbide
from
bad with
the naked
eye.
you
have
to rely
on the
old
saying
You
get
what
you
pay
for. There
is
plenty
of
cheap
carbide
around,
much
of which
contains
recycled
mateial,
but most
professional-quality
tools
use
only
virgin
carbide.
\[hat
you
can see with
the
naked
eye is
how finely ground
the carbide is. A tooth or flute with visible coarse grind marks
will
be less
sharp
than
one with
a more polished
appearance.
A manufacturer
trylng
to
cut costs
by using
cheap
carbide
is
unlikely
to invest
more
than
the bare
minimum
sharpening
it.
\fhen
comparing
similar
types
of blades,
choose the
one with
thicker
carbide
because
t
probably
will
be
more durable
and
can
be resharpened
more
often.
The way
the
teeth
are
brazed
to the
sawblade
or router
bit
.
is also
important.
Steel's
hermal
expansion
during
brazing
is
two
to three
times that
of carbide.
so with
conventionalbraze
alloys,
as
the steel
cools,
it
shrinks more
than
the
carbide
and
wants
to
draw
the latter
into
a
bow shape,
creating
stresses.
ff
possible,
choose a
tool
that
claims to
be made with
tri-metal
brazing shim using silver-copper-silver braze, as this reduces
the
joint
stress
caused
by brazing.
Last,'go
t6 a manufacturer's
\7eb
site
and look
around for
information
on the
carbide
it
uses. f
the
site
goes
into
detail
about
the carbide,
there
is a
better
chance
the company
is
concerned
about
quality
and
matching
the carbide
specs
to
the tool's
use.
How
to make
it last
longer
High
levels
of
pitch
and residue
buildup
should
be avoided
because,
as
the residue
is pulled
away,
t can
take small
microchips
from
the
cutting
edge
with it.
Eventually
this
will
3 0
F r N E
r o o D \ r o R K r N G
blunt the
comers
and cutting
edges.
Also,
buildup increases
friction
and
heat,
shortening
the life
of the
carbide. To
overcom
this
problem,
clean
your
carbide regularly.
There
arc many
recommended
dos and
don'ts when
it
com
to cleaning
sawblades
and router
bits. Freud
recommends
soaking
the
blade in
kerosene
and then
removing
the
buildup
with a
bristle
brush. Products
the
company
has found
that
attack
carbide are
those very
high
or low
on the
pH
scale.
Forrest
Manufacturing
recommends
cleaners
such as
Formula
409
or Fantastik
in conjunction
with
a brass-
or nylon-bristle
brush such as an old toothbrush. Don't use a steel wire brush
as
this will
damage
the
carbide. Forrest
doesn't recommend
oven
cleaner
because
t tarnishes
the
steel
plate
of
the blade
and.removes
any
plastic
film
including
the logo.
Last, t is
mu
easier
to remove
slight
buildup
on the
blade
or bit frequently
than it is
to wait
until a
thick layer
of residue
is
baked
on.
Materials
that
wear
doqm cadrid{arbide
is
strong
stuff,
but
there
are one
or two
uses that will
shorten
its life.
Anv
wood
high
in
phenolic
acid will
corrode
the
cobalr
binder. Fornrnately
this is
mostly
found
in green
or wet wood,
and in
particular
ce-
dar-not
something
fumiture
makers
are likely
to
encounter
ofte
\foods
containing
silica
or salts,
such
as teak,
also are
more
abrasive,
as are
man-made
materials
such as
medium-density
fiberboard and plywood. If you are going to be cuning large
amounts
of
plywood
or teak,
put
on
an old
carbide blade
and
save
your
best
one for
less-abrasive
cuts.
'-
When
to
sharlren-How
can
you
tell when
it's time
to shar
en
your
carbide?
Bumt cuts
is
one waming
srgn;
increased pre
sure required
to
make
the cut is another;
deteriorating.
cut
qua
such
as chipout
when
crosscutting
plywood
is a
third.
Finally,
should
you
sharpen your
own
carbide
tools?
n alm
all cases,
t is
better
to let
a
professional
sharpening
service
d
the
job;
after
all,
you
no
longer
need to
sharpen
these tools
each
time
you
use
them.
Photos, except where
noted:
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
19/81
frindamentals
fi
Pencilndpaper
WORK RECISELY
YUSING HESE
SIMPLE OOLSN
UNCONVENTIONALAYS
B Y H E N D R I K V A R J U
ou don't need to be high-
tech to achieve
high
precision.
Vhether
you
need to move
your
tablesaw
few thousandths of an inch or craft a
perfectly
fitted
mortise-and-tenon
oint,
you
can see and control
nearly invisible
differences by using two
of
the most
a.
o t
r rtl ot
iey
t
n
lzt,
tt
l;
7r1
t u
177
r,
b:,
*q$r
rr,
rar
h:{
.rLX;#J,l?,
corrunon and ancient
tools around-a
pencil
and
paper.
The
next time
you
want to dial in a higher level
of accuracy,
don
reach
for
your
credit
card
to
buy the
latest
alignment
gadget
Instead,pull
a few businesscards rom
your
wallet and a
pe
from
your
tool belt.
Pencil
trokes
ighlight
our
rog
Whether sharpening,
planing,
or routing, sometimes the amount
that
needs
to b
removed is
so little i t's hard to
see
with
the
naked
eye. Drawing
pencil
lines on t
workpiece
or the tool can make
your progress
easily visible.
G E T A W A T E R S T O N E
TRULY
FLAT
A waterstone
needs to be
per-
fectly flat
to
work well,
but it
is
hard to tell when this has been
achieved.To rack
your proS-
ress,draw li$ht
pencil
strokes
on the
face
of the stone before
flattenin ,
it.
(A
number
of abra-
sives can be used;
pictured
at
right
is
silicon+arbide
lapping
Srit
on
grass.)
The marks will
disappear first
on the hish
points,
so keep rubbing,until
all
pencil
strokes are
gone.
Photos: Mark Sch
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
20/81
A V O I DT A P E R I N G
TOO
FAR
A jointeror handplane
is used to refine
table-
sawn
tapers on a leg,
with
each
pass
extend-
in$ the
taper farther
up
the
Ie{,.
But stray
into the
desiSnated
flat
area,
and
you'll
see a
Sap
when
the
apron is attached
to
the
Ie ,.
A few
pencil
strokes near
the start
of the
taper hihliht
when
to stop
planin{,.
F I T A M O R T I S E
A N D T E N O N
When fittinS
a tenon
to its mortise,
it
can be
difficult
to
assess where
the
tenon s too thick.
Pencil
strokes
on
the tenon
cheeks
will rub
off where
the fit is
too tight,
showin(, where
to
pare
the tenon for
a
proper
fit.
S E E W H E R E Y O U ' R E
P L A N I N G
lf
you?e
flattenin ,
a
Slued-up
panel,
start by findin{,
all of the
hiSh
areas usinga strai{hted{e
and
marKin{,them
with
pencil
strokes. This way
you
can concentrate
on the areas that need
the
most wood
removed.You'll
also be able
to track any
places
you
missed.
Usea different
pattern
of
pencil
strokes in the low-
est
spots as a
warnin{,to
avoid
planing
these areas.
S E T A R O U T E R ' S
D E P T H P R E C I S E L Y
When
brin$in$trim or
a
plu{,level
with its
sur-
roundin{s,
you
need
to
set a strai$ht bit
to cut
exactly
level with
the
sufface.
Mark
a
piece
of
plywood
with some
heavy
pencil
strokes,
then
gradually
lower
the bit until the
pencil
marks
$et
liShter but
are
just
visible.While
this mi$ht sound dif-
ficult
to attain, a
good
microadjust
system on
your
router will
easily
allow
you
to dial in
just
a couple
of
thousandths
of an inchat a time.lf
you
So
too deep,back
off, draw some
more
lines,
and try a{ain.
www.
fi newoodwork
i n
g.
co m
T O O L S & S H O P S 2 O O 9
3 3
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
21/81
fundamenta\s..n,n, o
Paper
hims
I
constantly
need
o adjust
a
setup, ence,
or workpiece
by a few
thousandths
of an inch
o
achieve
perfect
accuracy.Paper
s
a
great
way
o make
precise
adjustments.
A non-embossed
usiness
ard s
typically
.011 in.
o 0.012
n.
hick,standard
4-tb.
printerpaper
s
0.OOSn.,and phonedirectory aper0.002 in. o 0.003 in .
lf
you
need
to widen
a dado
or rabbet
by
a
very
small
amount
(7),
movin{,
he
tablesaw
ence
a few
thou-
sandths
of
an
inch
isn't
an
easy ask.
Clamp a strai{,ht
piece
of milled
stock
behind
the fence,
but with
a few
business ards andwiched
between
hem
(both
at the
front
and back
of the fence
to keep
t from
racking)
(2).
After
making
a test
cut, re-
move
or add
business
ards
or
paper
shims
to move
the
fence
one way
or the
other
by
precise
mounts,
nd
make
the
cut
(3).The
width
of the
dado
or rabbet
will
be
perfect
(4).
Adjusting
he tool
resf
to a
specific
anfle
on a
Srinder
can be an
ex-
perimentaltask.
Now
change
he
ang,te
y
ptacingshims
etween
the
tool
rest
and
the tool.
On my
6-in.
grinding
wheel,
,ve
found
that
addinf
seyen
business
cards owers
he
{rindinS
anSle
by about
2.5..
I have
my
tool
rest
set at a
standard
30
angle,
but when
need
25.
for
my low-angle
block
plane
iron,l
simpty nstalt
14
business
ards
and
ti{hten
the clamping
mechanism,
and the
ob
is
done.
- - . . t
,
- . , .- i :
Youneed
a space
tween
he chisel
a
its matinS,
uSerb
Place
business
ca
between
he top
o
the mortisin{
bit a
its holder
when
in
in{,
both
au(er
bit
chisel.
With
the
au
secure, release
he
chise/ holder,
emo
the business
ards
and raise
he chis
before reti(,htenin
it.
Use hree
cards
for
the /z-in.
chise
two for
the
3/a-in.
s
and
one
for
the /t-
chise/.
7,
3 4
F r N E
\ ' ; , o o r ) \ \ , o n K r N G
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
22/81
-l
F L U S HJ O I N T S
S T A R T W I T H S H I M S
Where
he
face
of one
board must end up flush
with the end
grain
of an-
other,
place
a couple
of
businesscardsunder
the
face-$rain
board when
cutting the
joint
either
with biscuits or
dowels.
Thiswill
$uarantee
hat
the end
{,rain
ends
up
frac-
tionally
proud.
Now
lush
the
joint
using a low-ang le
block
plane.
S N U G - F I T T I N G A P J O I N T S
A lap
oint
must be
cut to
precisely
the width
of its matin{,
part.
Set
a stop
block on the
auxiliary
miter
Eauge
so
that the
cut
will
end up fractionally
wide, but then placea number of paper
or business-card
hims n front
of the
block
so that the cut will be
too
narrow.
Remove
he
shims one at a time until
the cut matches
the
desired
width.
J
i ly:
*-$F
:\{itl
Basic
7
pc.
Router Bit
Set #401
Tested#1,by
Fine Woodworki
$,
Magazine
in
a head
to head router
bit
test
of L7
different brands.
"American Made for
the
American
Woodworker"
READER
SERVICE O. 103
www. f i n e wo o d wo r k i
n
g .
co m
lnnouatiueeailres
.
2 Pocket-Hole
igs
n I
complete it
Benchtop
nd
Portable
igs ncluded
.
Dust
Collection
hroud eeps
ou r
workspace
learof woodchips.
.
Front
SideClamping
reatly
peeds
thedrilling
rocess.
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
23/81
ffi
fu* H
&{' -ila
b
Versatieworkstation
tores
allyourablesawear
and hen
some
r
B Y
J O H N
W H I T E
Shefve
your
sled.
A dedicated shelf
keeps he
crosscut
sled out of the
way
but easily
accessible.
l\lo wasted space,
Youcan do {,lue-ups nd
other bench tasks on this
table,
so
you'll
need
tools
and supplies earby.
Blades
at the
ready,
The bottom
drawers are
deep
enou{,h o sfore
blades vertically,mak-
in{them
easier o
identify
and
pull
out.
F i N I . ]
W O O D \ f l O R K I N G
Stow
your
fence. A well-
placed
rack
keeps the rip fence
closeat hand.
36
l ) l to tr>s. xccpt
u 'hc lc
r. to tcc l :Nlett I ienncr ' : t l t is
p lrgc :
. fo l tn
Tct
-
7/25/2019 Fine Woodworking 202 January 2009.pdf
24/81
good
outfeed
table
is
essential
for
safe
woodworking, because
it
al-
lows
you
to control the
work-
piece
as
it
moves
past
the blade and
off the back of the
tablesaw.
\Without
it,
you'll
have to
push
down
hard on the back of
long
boards,
which makes t difficult to
guide
them safely
past
the
blade.
An outfeed table
also naturally
doubles as a
work
surface
for
assembly
and finishing.
B