Popular Woodworking November 2007

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Learn How. Discover Why. Build Better.NOVEMBER 2007ISSUE #165We Test 6 Top Hybrids & Find the Best World-Class Finish From a Home CenterSexy Results With Common MaterialsTable Saw Shootout18 Ways to Become a Better (and safer) WoodWorkerWorkbench Upgrades11 Easy Ways to Ease Your WorkShaker Oval Music BoxAn Instant Heirloompopularwoodworking.com popularwoodworking.com Learn How. Discover Why. Build Better.NOVEMbEr 2007Features38 HybridTableSawsAre hybrid saws the answer for the small shop, or are they a compromise? We test six premium models in a working shop to fnd the best. by trOy sExtON45 ABetterWaytoWork:SkillsforSafety woodworking essentialssafety is not a set of rules, its a way of working. this new manual will develop the skills you need to work accurately and safely. by MArC AdAMs57 UpgradeYourWorkbenchEleven easy additions increase the capability of any workbench, allowing you to hold work of almost any size or thickness. by rOb POrCArO62 Greene&Greene:AMysteryTableExactly who designed this library table (that was later cut down to make a coffee table) is unclear. but its lines and proportions are excellent. by dArrEll PEArt70 FromConcepttoCompletion,Part2How to take your completed prototype into the shop and create the fnished piece. by tEd brOWN74 ShakerMusicBoxthis simple project, based on a traditional oval box, makes an easy and wonderful gift. by J OHN Wi lsONNumber 165, November 2007. Popular Woodworking (ISSN 0884-8823,USPS 752-250) is published 7 times a year in February, April, June, August, October, November and December by F+W Publications, Inc. Editorial and advertising offices are located at 4700 E. Galbraith Road, Cincinnati, Ohio 45236; tel.: 513-531-2222. Unsolicited manuscripts, photographs and artwork should include ample postage on a self-addressed, stamped envelope (SASE); otherwise they will not be returned. Subscription rates: A years subscription (7 issues) is $19.96; outside of the U.S. add $7/year Canada Publications Mail Agreement No. 40025316. Canadian return address: 2835 Kew Drive, Windsor, ON N8T 3B7 Copyright 2007 by Popular Woodworking. Periodicals postage paid at Cincinnati, Ohio, and additional mailing offices. Postmaster: Send all address changes to Popular Woodworking, P.O. Box 420235, Palm Coast, FL 32142-0235 Canada GST Reg. # R122594716 Produced and printed in the U.S.A.45 70 576274 Popular Woodworking November 2007NOVEMbEr 2007regul ars12 ItsAlmostAlwaysUserError oUtonaliMB by CHri stOPHEr sCHWArZ14 HornsonDoors letters FrOM OUr rEAdErs20 VersatileAssemblyBench triCksoFtHetrade FrOM OUr rEAdErs26 PeriodDetails arts&MYsteries by AdAM CHErUbi Ni30 13"RidgidPlaner tooltest by OUr stAFF36 ShakerStepStool iCandotHat by MEgAN Fi tZPAtri Ck80 GreatWorkfromASmallShop greatwoodsHoPs by glEN HUEy86 BenchHook JigJoUrnal by CHri stOPHEr sCHWArZ96 HomeCenterFinishing FleXneronFinisHing by bOb FlExNEr Projectno.3er,Projectno.4 oUtoFtHewoodwork by CHri s HEdgEsHybrid table saws look like a cabinet saw but have the heart of a contractors saw. is this style of hybrid machine a good cross or will it just make you cross? Page 38.COVEr PHOtO by Al PArrisHON tHE NOVEMbEr COVEr3626 86 30100popularwoodworking.com Contact Customer servicepopularwoodworking.com/customerservice Free Project Planspopularwoodworking.com/projectplans Article indexpopularwoodworking.com/articleindex tool reviewspopularwoodworking.com/toolreviews Magazine Extraspopularwoodworking.com/magazineextras Editor blogspopularwoodworking.com/blogs Writers guidelinespopularwoodworking.com/writersguidelines Contact the staffpopularwoodworking.com/contactus Popular Woodworking November 2007NOVEMbEr 2007Onli neVideo GalleryHybridSawFeaturesJoin us as we take a look at our likes and gripes of the six table saws tested in this issue.HoldingWideBoardsrob Porcaro, author of Upgrade your Workbench, demonstrates the use of some of his unique workholding solutions. youll fnd these free videos online atpopularwoodworking.com/videoProject PlansMarthasVineyardCupboardthis hanging wall cabinet with two doors is a perennial favorite with readers.popularwoodworking.com/projectplans24-hourWorkbenchyou can have a rock-solid bench for less than $200 in materials and just 24 hours of working time in the shop.popularwoodworking.com/projectplansMastertheMortise&TenonFrank klausz shows three ways to create this traditional joint and make a small stool.popularwoodworking.com/projectplansAnd More!Visit popularwoodworking.com/nov07 to fnd a complete list of all the online resources for this issue including videos, additional drawings and photos.On the BlogsPWEditorsBlogExclusive tool reviews, the latest news, works in progress and more. Find out what were up to between issues.popularwoodworking.com/blogs WoodworkingBlogEditor Christopher schwarz maintains a blog for our sister publication, Woodworking Magazine. woodworking-magazine.com/blogOnline ExtrasGreene&GreeneTableAdditional text, drawings and step photos for making the router jigs shown in the article, building the fnger-joined drawers, shaping the handle and cutting and ftting the ebony plugs are available in pdf format. in addition, there is a slide show of detail photographs from the original table.popularwoodworking.com/nov07HomeCenterFinishingWeve expanded the fnishing section of our web site even more this month, including half a dozen new articles from bob Flexner.popularwoodworking.com/nov07 Blogs Blogs Plans Plans Video VideoLearn How. Discover Why. Build Better.ContributorsMarc Adams has been a professional woodworker for almost three decades, during which hes won numerous awards, worked with the U.S. government on woodworking-related issues, and been featured in several books and many magazines. Fourteen years ago, Marc was the sole instructor when he opened the Marc Adams School of Wood-working in Franklin, Ind., to 160 students. Now, every year more than 2,500 students choose from almost 100 classes, all taught by world-renowned instructors. Needless to say, with so many people using the facility Marc is concerned with safety and accuracy. He shares his rules and procedures for achieving both in a new seven-part series.Darrell Peart began his woodworking career mak-ing small wooden items to sell at Seattles Pike Place Market, and worked for many years in various high-end custom shops throughout the Puget Sound, Wash., region. In 1989, he discovered the American Arts & Crafts movement and was captivated by the work of Charles and Henry Greene. His frst book, Greene and Greene: Design Elements for the Workshop (Linden), was published in 2006.Troy Sexton A long-time profes-sional cabinetmaker, Troy is in the mid-dle of rearranging his shop in Sunbury, Ohio. He says hes going to get rid of one of his fve (fve!) table saws and replace that with a panel-saw system. But before he does that, Troy has more pressing business: A trip to Canada to fsh for pike and walleye.Rob Porcaro has been a wood-worker for more than 25 years. You can see his work online at rpwoodwork.com. Rob is a doctor of optometry by day and a masters track competitive sprinter. He lives in Medfeld, Mass., with his wife, Julie; son, Mark; and daughter, Stefanie. In this issue, he writes about workbench upgrades on page 57. Chris Hedges A former college sociology instruc-tor, Chris decided to leave academia and recently completed a two-year furniture-making program at the University of Rio Grande in south central Ohio. The fourth woodworking project hes ever built, a near-faw-less Philadelphia-style secretary, won the Best of Show award in the Fresh Wood competition at the 2007 Asso-ciation of Woodworking & Furnishings Suppliers show (AWFS). He now plans to build furniture full time.10 Popular Woodworking November 2007NOvEMBER 2007, vOL. 27, NO. 6popularwoodworking.comEDITORIAL OFFICES 513-531-2690PubliSHeR & GRouP eDiToRiAl DiReCToR Steve ShanesyeDiToR Christopher Schwarz X1407 chris.schwarz@fwpubs.comART DiReCToR Linda Watts X1396 linda.watts@fwpubs.comSenioR eDiToR Robert W. Lang X1327 robert.lang@fwpubs.comSenioR eDiToR Glen D. Huey X1293 glen.huey@fwpubs.comMAnAGinG eDiToR Megan Fitzpatrick X1348 megan.ftzpatrick@fwpubs.comPHoToGRAPHeR Al ParrishConTRibuTinG eDiToRSAdam Cherubini, Bob Flexner, Troy SextonF+W PUBLICATIONS INC.CHAiRMAn & Ceo David H. StewardCfo John SperidakosexeCuTive vP, inTeRACTive MeDiA John LernervP, MAnufACTuRinG Barbara SchmitzDiReCToR, iT Mike KuehnF+W PUBLICATIONS INC. MAGAZINE GROUPPReSiDenT Colin UngarovP, ConSuMeR MARkeTinG Sara DeCarlo buSineSS PlAnninG DiReCToR Tom Wiandt ConfeRenCe DiReCToR Sara DumfordCiRCulATion DiReCToR Linda EngelnewSSTAnD DiReCToR Susan RoseDiReCToR, DiGiTAl MeDiA SoluTionS Michael KushnerPROdUCTIONPRoDuCTion MAnAGeR vicki WhitfordPRoDuCTion CooRDinAToR Katherine SealAdvERTISINGADveRTiSinG DiReCToR Don Schroder331 N. Arch St., Allentown, PA 18104tel. 610-821-4425; faX 610-821-7884d.schroder@verizon.netADveRTiSinG PRoDuCTion CooRDinAToRNancy Miller, 513-531-2690 X1228nancy.miller@fwpubs.comCopyright 2007 by f+W Publications, Inc. all rights reserved. Popular Woodworking is a registered trademark of f+W Publications.SubSCRiPTion SeRviCeS: Subscription inquiries, orders and address changes can be made at popularwoodworking.com (click on Customer Service). Or by mail: Popular Woodworking, P.O. Box 420235, Palm Coast, fl 32142-0235. Or call toll-free 877-860-9140 or 386-246-3369. Include your address with all inquiries. allow 6 to 8 weeks for delivery.newSSTAnD DiSTRibuTion: Curtis Circulation Co., 730 River Road, New Milford, NJ 07646ATTenTion ReTAileRS:to carry Popular Woodworking in your store, call 800-894-4656 or write Magazine Retail Sales, P.O. Box 5014, Iola, WI 54945-5014.bACk iSSueS are available. Call 800-258-0929 for pricing or visit popularwoodworking.com. Send check or money order to: Popular Woodworking Back Issues, f+W Publications Products, 700 e. State St., Iola, WI 54990. Please specify publication, month and year.12 Popular Woodworking November 2007Out On a Limbb y c h r i s t O p h e r s c h wa r z , e d i t O rLearn How. Discover Why. Build Better.Its Almost Always User Error powered dovetail jig. I thought Id be making everything with dovetails. And it would be so fast. And easy. And cheaper than buying the tools to cut them by hand.It took three agonizing days of work to make my frst drawer with that jig. Let me be clear about one thing: Theres nothing wrong with dovetail jigs, its just that some of them are better suited for producing drawers for an entire kitchen (or sub-division). Making one custom drawer with a jig like that is not so smart.Frustrated with my sideboard, I trudged upstairs and picked up Charles Haywards Woodwork Joints. This out-of-print book is flled with drawings of how traditional cab-inets are supposed to be built. And it isnt a simple, fast or easy process. Good furniture is a lot of work.I looked up Haywards rules for sizing tenons, then returned to the shop. I disas-sembled my undersized joints and used the ultra-modern Domino to cut joints that obeyed the rules that were laid down long before I was born. I reassembled the carcase and braced it against my bench to complete the operation that destroyed my frst attempt.After 10 strokes, I knew Id done the right thing. Then I vowed to write this experience down so I wouldnt forget it. And so here is, a note to myself. PWCustomer ServiceHow can I contact customer service with questions regarding my subscription, including a lost or damaged issue? Visit popularwoodworking.com/customerservice. Or write to Popular Woodworking, P.O. Box 420235, Palm Coast, FL 32142-0235. Or, if you prefer the telephone, call toll-free 877-860-9140 and a customer service representative will be happy to help you.When does my subscription expire?The date of your subscription expiration appears on your magazine mailing label, above your name. The date indicates the last issue in your subscription.Can I get back issues of Popular Woodworking?Back issues are available while supplies last. Visit popularwoodworking.com/backissues. Or if you know the exact month and year of the issue you want, call our customer service department toll-free at 800-258-0929 to order.What if I want more information about the projects and tools I read about in Popular Woodworking? For all editorial questions, please write to Popular Woodworking Editorial, 4700 E. Galbraith Road, Cincinnati, OH 45236. Or e-mail popwood@fwpubs.com.Does Popular Woodworking offer group discounts?Group discounts are available by special arrangement with the publisher. For more details, send an e-mail to Debbie Paolello at debbie.paolello@fwpubs.com or call 513-531-2690 x1296.Our Privacy Promise to YouWe make portions of our customer list available to carefully screened companies that offer products and services we believe you may enjoy. If you do not want to receive offers and/or information, please let us know by contacting us at:List Manager, F+W Publications4700 E. Galbraith RoadCincinnati, OH 45236Safety NoteSafety is your responsibility. Manufacturers place safety devices on their equipment for a reason. In many photos you see in Popular Woodworking, these have been removed to provide clarity. In some cases well use an awkward body position so you can better see whats being demonstrated. Dont copy us. Think about each procedure youre going to perform beforehand.So I have the assembled carcase of a side-board braced against my workbench and Im planing the top edge of the aprons fush with the top of the legs.After 10 strokes, things go all wrong.The front apron of the sideboard comes loose, and the carcase sways like a drunken sailor on my shop foor. At frst I cant bear to look at the problem (like when you cut your-self) but then I exam-ine the damage.The Festool Domi-nos I installed in the apron have come loose from the leg. Now, the natural thing to do is to blame the newfan-gled tool that Im test-ing. But I cant.While the Festool Domino is an engi-neering wonder, so is the machine that injects cream flling into a Twinkie. Its not the technology thats the problem; its how the technology gets used that determines if its a sensation or a scourge. Too many of our tools, books and maga-zines encourage us to take shortcuts. We get excited when anything seems easy, fast or inexpensive.Its human nature, and I fell for it.I had ignored the basic rules for sizing mortise-and-tenon joints. Specifcally, that your tenons width needs to be two-thirds the width of your stock. Because the Dominos ft so perfectly in the holes, I beguiled myself into using two of them in each leg I really needed three.I can remember the same giddy sensa-tion I got when I frst used a biscuit joiner (with a similar stupid error). And the time when I became enamored with my router-14 Popular Woodworking November 2007Lettersf r o m o u r r...