• Step by Step constructioninstruction.

• A complete bill of materials.

• Exploded view and elevationdrawings.

• How-to photos with instructivecaptions.

• Tips to help you complete theproject and become a betterwoodworker.

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WJ054

“America’s leading woodworking authority”™

Scroll-Sawn Nightlights

Published in Woodworker’s Journal “Woodworking Classics: Skill-Building Projects for the Home Woodworker”

WOODWORKER'S JOURNAL ©2007 ALL RIGHTS RESERVED

138 HOME PROJECTS WOODWORKER'S JOURNAL ©2007 ALL RIGHTS RESERVED

These nightlight projects are a lotof fun and simple to complete, and theymake great gifts. You can make yoursfrom scrap wood or even metal. Stacka few of the same designs togetherwhen cutting them out to really speedup the process. If you are introducingkids to the shop, we recommend start-ing out with 1/8" plywood. As you mightguess, kids love this sort of project,particularly since they get to actuallyoperate a power tool! (Scroll saws, ifapproached properly and with adultsupervision, are one of the safest powertools around.)

Even if a child does not do theactual cutting, they can paint or deco-rate the cutouts as they choose: from asingle color (like the flocked frog) orpainted with a lot of detail. If you havesome attractive leftovers from otherprojects, you could use a clear finish toshow off the wood grain.

SCROLL-SAWN NIGHTLIGHTS 139

Scroll-Sawn NightlightsLooking for something to interest the kids when they can’t sleep or to reassure them

during a late-night thunderstorm? These simple scroll-sawn nightlights are also a

good project for introducing older gradeschoolers to the basics of woodworking. Tighten

up a fresh scroll saw blade and let your imagination go.

Here’s what you’ll need to round up to create these nightlights:

• Scroll saw

• No. 2 or 5 skiptooth blade (optional)

• Five-minute epoxy

• 3/4"-wide masking tape

• 1/8"-thick plywood

• Aluminum roof flashing (optional)

• Nightlight kit (National Artcraft Co., part #393-256-03; phone 888-937-2723 or www.nationalartcraft.com)

Planning Ahead: Scroll-Sawn Nightlight Project

Starting OutUsing one or more of the full-size

patterns shown on the next two pages,get started on your nightlights by mak-ing copies at a local library or copy cen-ter. (Permission is hereby granted foryour personal use.) Select your materialand cut the metal, plastic or 1/8"-thickplywood to overall size. If you are goingto stack-cut the parts (as shown in thephoto on page 141), carefully tape threeor four pieces together along theedges. Do not try to cut stacked piecesthat add up to more than 1/2" thick asa group—it’s too much for a scroll saw.If you want to make your nightlight outof a thin metal such as aluminum orcopper, simply sandwich three to foursheets between two pieces of 1/8"thick plywood and cut out as usual.

Take your paper pattern and attachit to the top piece of the stack withspray adhesive. (Take care to apply

adhesive to the paper pattern, not the wood.) If the pattern has interiorcutouts, drill a 1/8"-diameter starterhole for the blade at each interior cut.Make all your interior cuts first. Then,starting on one edge, form the piece’soutside shape by following the pattern.If you’re cutting stacked pieces, it’s veryimportant that you keep everythingtogether as you cut. Don’t hesitate tostop and re-tape if necessary to keepeverything properly aligned. Once yourpieces are cut, use a block of woodwith sandpaper wrapped around it tolightly sand away any burrs or splintersfrom the front and back surfaces.

Finishing UpIf you are going to leave the wood

looking natural, simply brush or sprayon a topcoat of a clear satin or glossfinish. If you are going to paint yournightlight one color (such as black),

WOODWORKER'S JOURNAL ©2007 ALL RIGHTS RESERVED

Full-sizePatterns

Clip Location Clip Location

140 HOME PROJECTS

QuickTipMagnetic Blade OrganizerHere’s a simple organizer for scroll saw blades. Whenever you installa blade, attach the relevant number tag to your saw. Then it’s alwayseasy to tell what size blade is in the saw. When you change blades,stick the used blade to the magnet in front of the correct hole, so itdoesn’t get mixed up with brand new blades.

using a can of spray paint is an easyapplication method. For fancier paintschemes, apply a light primer coat andhand-paint to suit. Finish up by addinga light, clear topcoat of your choice toseal in the paint.

Attach the plastic clip to the backsurface of the project (five-minute epoxyworks well) where indicated on each ofthe patterns above. Snap the clip ontothe nightlight, add a bulb, and you’redone! A wonderfully simple project.

One final tip: On the cat, horse andboat patterns, you might want to hidethe lightbulb by gluing a piece of non-stick baking liner paper (parchmentpaper) across the back surface. (Referto the photo on the next page.) You canget this liner from a grocery or kitchensupply store. This hides the bulb andlends a nice “glowing” effect. Do notuse regular paper, as it could overheat.

WOODWORKER'S JOURNAL ©2007 ALL RIGHTS RESERVED

Clip Location

Clip Location

Stacked cutting is a greatway to speed up the processof creating these nightlights. For best results, don’t stackparts thicker than about 1/2".

Use epoxy to attach the nightlight’s clip to the scrollsawn design. Five-minute epoxy will do fine.

Use parchment paper to line the back of see-through lights to help hide the light bulb.

SCROLL-SAWN NIGHTLIGHTS 141WOODWORKER'S JOURNAL ©2007 ALL RIGHTS RESERVED