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Desk Clock • Tower Bookcase • Small Box
Stub Tenon & Groove Joinery • Quick Finishing Fixes
EASY'TO-BUILD COTTAGE
FRAME & PANEL DOOR
TWO DESIGN OPTIONS
AND A SPECIAL
FINISHING TECHNIQUE
No. 99
June, 1995
EDIT OR ' S COLUMN
Sawdust
Editor
Executive Editor
Managing Editor
Assistant Editors
Donald B. Peschke
Douglas L. Hicks
Terry J. Strohman
Jon Garbison
Mark A. Williams
Ted Kralicek
David Kreyling
Cinda Shambaugh
DirkVerSteeg
Erich Lage
Crayola England
Chris Glowacki
Ken Munkel
Kent Welsh
Steve Curtis
Steve Johnson
goes for woodworking projects too.
Don't get me wrong — I like large projects.
But sometimes small projects can be just
as satisfying to build as large ones. After
all, they don't take much time, mistakes
aren't costly, and it gives you a chance to
try a variety of woodworking techniques.
COTTAGE WALL CABINET. A good exam-
ple of this is the cottage wall cabinet
shown on page 6. It's not a large or compli-
cated project to build. But it does provide
an opportunity to try a number of wood-
working techniques.
Dadoes and rabbets are used to hold the
cabinet together. There's a raised panel
door with stub
tenon and groove
joinery. And the
cabinet is top-
ped off with built-
up moldings that
can be made
with a router.
project intimidate you. It's not a difficult to
build. Basically, it's just a narrow, plywood
box with a few adjustable shelves and
some simple molding.
DESK CLOCK. But my favorite project in
this issue is also the smallest: the desk
clock on page 14. It requires the smallest
amount of material and the least amount of
time to build. But what I really like best is
that it has a nifty little solution to a
big
problem. Let me explain.
Most small clock movements require a
big
bit to drill a rather large hole. (In my
case, 2
3
/s" diameter.) But who wants to
spend a lot of money for a drill bit that gets
used so seldom? The solution is simple. In-
stead of drilling
a hole in a block
of wood, the
body of this
clock was built
in sections. This
allowed us to cut
_____________ the opening
with a band saw
before
we assembled the different parts.
FINISHING FIXES. I know you're prob-
ably getting tired of all this "small talk," but
thinking small also applies to the finishing
article on page 22. With most finishing arti-
cles, I'm in the shop completing a new pro-
ject. This time, I decided to try something
different: repairing a damaged finish.
I know what you're thinking — refinish-
ing a project is a big job. And I couldn't
agree more. But you don't need to refinish
a project just because it has a small scratch
or dent. There are some simple techniques
you can use to repair the damage. These
techniques won't take a great deal of time,
money, or skill but will make the scratches
practically invisible.
NEW FACES. Recently, we've had a cou-
ple of new people join us. Holly Lucas is
our new bookkeeper. And Paige Rogers
has joined our circulation department.
OPEN HOUSE INVITATION
I mentioned last issue that we've finished
remodeling our offices, and we're getting
ready for issue No. 100. To celebrate both
events, we thought we'd have a little open
house. It'll take place on Sunday, July 23,
from 1-5 PM. So if you're in the neighbor-
hood, please stop in and say "hi."
Creative Director
Senior Illustrators
Illustrator
Photographer
Electronic Graphics
Design Director
Senior Designer
Shop Manager
Shop Asst/Facilities
CIRCULATION
New Business Manager.:
Sandy Baum •
Renewal
Manager.:
Paige Rogers •
Direct Mail Manager.:
Troy J. Dowel! •
Direct Mail Assistant:
Julie Greenlee
•
Newsstand Sales:
Kent A. Buckton •
Circulation
Analyst:
Shane Francis
PUBLISHING SERVICES
Mgr:
Gordon Gaippe •
Graph. Artist:
Cheryl L. Cynor
CORPORATE SERVICES
Planning Director:
Jon Macarthy •
Controller:
Robin
Hutchinson •
Account.:
Laura Thomas •
Bookkeeping:
Holly Lucas
'Production Mgr.:
Carol Quijano •
Info.
Serv. Mgr.:
Joyce Moore •
Elec. Pub. Coord.:
Douglas
M. Lidster •
Network Adm.:
NickThielen •
Admin.
Assistants:
Cheryl A Scott, Julia Fish*
Receptionist:
Jeanne Johnson •
Build. Maint:
Ken Griffith
The projects in this issue
prove that "good things come
in small packages.
"
There's even
a couple of design options to choose from.
The cabinet can be built with a towel bar or
Shaker pegs. Whichever you prefer.
We're also showing a couple of options
for finishing this project. For the cabinet
pictured on the cover, I used a traditional
wipe-on oil finish. But for the one shown
on page 6, I tried something different.
What I wanted was the look of a painted
cabinet — but I didn't want to hide the
grain of the wood.
The solution was to apply several coats
of white stain. Then to bring out the pat-
tern of the grain, we rubbed on a light coat
of dark stain. The end result is a project
that looks like a painted "antique."
SMALL BOX. The small box shown on
page 26 is another small project that gives
you a chance to use almost every tool in
your shop. Before you're done, you'll use
the band saw, table saw, drill press, hand-
held router, and the router table. It's a lot
of woodworking for a "small" project.
TOWER BOOKCASE. Another small pro-
ject that has gone over big here is the
tower bookcase on page 18. Small project?
Okay, it's over six feet tall, but it takes up
less than two square feet of floor space.
That's quite a bit of storage for such a
small space. But don't let the height of this
wooDSMrra MAIL ORDER
Art Dir.:
Cindy Jackson
'Catalog Prod. Mgr.:
Bob
Baker •
Inv. Control/Prod. Mgr.:
Mark Mattiussi
•
Proj. Supplies:
Linda Jones •
Tech. Supp:
Dave Stone
•
System Operator:
Tammy Aldini
CUSTOMER SERVICE
Manager: Jennie
Enos •
Team Leader:
Karla Cronin
•
Customer Service Reps.:
Jennifer Murphy, Joy
Krause, Sara Kono, Anna Cox, Lonnie Algreen,
Adam Best, Kristi Andrews
SHIPPING DEPARTMENT
Supr:
Nancy Johnson •
Fulfillment:
Gloria Sheehan,
Chuck Carlson, Sylvia Carey, Larry Prine
WOODSMITH STORE
Manager:
Dave Larson •
Assistant Manager:
Paul
Schneider»So(es
Staff:
Wendell Stone, Pat Lowery
•
Office Manager:
Vicki Edwards
Woodsmith® (ISSN 0164-4114) is published bimonthly
(Feb., Apr,, June, Aug., Oct., Dec.) by Woodsmith Corp.,
2200 Grand, Des Moines, IA 50312.
Woodsmith® is a registered trademark of Woodsmith Corp.
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Printed in U.S.A
Woodsmith
No. 99
B
igger isn't always better. And this
_____________
A LOOK INSIDE
Contents
FEATURES
Cottage Wall Cabinet 6
This is a project with lots of options. It can be built with a
towel bar or Shaker pegs. And depending on the type of
finish you choose, it'll look great in a bathroom or kitchen.
Stub Tenon & Groove
page 12
Stub Tenon & Groove ......................... 12
Use this joint whenever you need a quick frame. Our step-
by-step instructions will show you how to cut both the stub
tenon and the groove easily and accurately.
Desk Clock 14
An inexpensive clock movement and a few scraps of wood
.
are all you need to build this weekend project.
Tower Bookcase.................................. 18
If you're short on storage space, this tall bookcase may be
the answer. There's enough room to hold a small library,
but it takes up less than two square feet of floor space.
Desk Clock
page 14
Finishing Fixes 22
If there's a scratch or dent in your furniture, you don't have
to completely refinish the piece. There are some simple
techniques for quickly repairing minor finish damage.
•Small Box.............................................26
The appearance of this box isn't the only thing that makes
it unique. The construction is unconventional as well. The
body is built from a single block. Then it's "scooped out" like
a pumpkin — but you don't need carving tools.
DEPARTMENTS
Tips & Techniques
............................. 4
Shop Notes 16
Reader's Jig...........................................30
Sources................................................ 31
Small Box
page 26
No. 99
Woodsmith
FROM FELLOW WOODWORKERS
Tips & Techniques
FINISHING SUPPORTS
SCREW REMOVAL
• Nothing is more frustrating
and time consuming than trying
to remove a broken woodscrew
when assembling a project. If
you're lucky, there's enough of
the screw left so you can grab it
with pliers. But when it breaks
off below the surface, it's a chal-
lenge to remove it without dam-
aging the wood around it.
Rather than drilling out the
wood around the screw, I'll drill
out the screw itself. All it takes
is a block of hardwood and a drill
bit a little smaller than the di-
ameter of the screw.
•When applying a finish to a
project, it can be difficult getting
it on every surface. Especially
the areas next to the work-
bench. So I lift my projects up off
the workbench with small, trian-
gle-shaped blocks.
The shape of the blocks keeps
them stable under heavy loads.
And since only a small point on
each block actually touches the
wood, I can apply finish to the
entire project.
The blocks are simple to
make. Just tilt your blade to
30° and cut as many as you need.
Note: Using a hardwood (like
maple) works best. The sharp
points will last longer and won't
get crushed under the weight of
a heavy project.
To remove the broken screw,
I start by drilling a hole (smaller
than the diameter of the screw)
through a block of hardwood
(like maple). I'll use the drill
press to make sure the hole is
perfectly straight. Then position
the block over the broken screw
and clamp it in place.
When drilling the hole, it
works best to keep your drill
pressure fairly light. You don't
want the bit to wander off the top
of the screw and into the wood.
John Dykstra
Calgary, Alberta
Al Hannas
Summit, New Jersey
It
Ir
Hard wood
block
-I
Tilt blade to 30° and
crosscut blocks
Position hole
over screw
-"-"•
_^~*
l
r
,J'" ^~^^~*^
\
Vft \ \VV
Hinge
mortise
J
Hard wood
block
Hard wood
block
prevents
drill from
wandering
CARPET TAPE
• I like to use carpet tape when
working on a project. But it can
be difficult trying to remove the
paper backing once the tape is
stuck in place. So I use a little
trick that works every time.
First, cut off a small piece of
tape and stick it to one corner
(sticky part to sticky part), see
Fig. 1. Then cut a piece like nor-
mal and stick it in place. Now lift
up on the small piece on the end
and fold it back to form a small
crease (like opening a pop-top
on a pop can), see Fig. 2.
This crease will separate the
sticky part of the tape from the
paper backing so the backing is
easy to grab, see Fig. 3. Then
pull the small piece off the end
of the tape and remove the pa-
per backing, see Fig. 4.
George Johnson
Foster City, California
Attach small
piece to corner
of roll
Bend
small piece
back to form a crease
Woodsmith
No. 99
WOOD PADS
BEESWAX
•The legs on outdoor furniture
always present a problem. The
end grain on the ends of the legs
sucks up moisture like water
through a drinking straw. To
prevent this, I add wooden pads
to the ends of the legs.
These pads are nothing more
than blocks of wood the same
size as the legs. They're per-
mantly attached with glue and
screws. Shop Note: Both con-
struction adhesive or exterior
glue can be used.
But the trick here is installing
the pads so the face grain (not
end grain) sits on the wet sur-
face. Face grain doesn't draw up
the moisture so the pads "block
it" from the legs.
Stanley Walsh
Baton Rouge, Louisianna
• I like to coat wood-
screws with beeswax to lu-
bricate them. But my bees-
wax cake is hard to keep track
of. Plus it's usually covered with
chips and dirt.
To keep my wax handy and
clean, I made a wooden dis-
penser. It's a block of wood with
a hole drilled in it. Just fill the
hole with melted wax, see Fig. 1.
Best of all, when you use up
the wax towards the top, simply
cut off part of the block to ex-
pose fresh wax, see Fig. 2.
Jerry Minnick
Truro, Iowa
ut off part
of block to
expose fresh
Glue
and
screw pads
to bottom of
legs
BRAD HOLDER
•A magnetic paper clip dis-
penser makes a great place to
store small brads. Just give it a
light shake, and the brads stick
to the magnetic ring around the
top. Then it's easy to grab one
when you need it.
Ron Weichel
Santa Rosa, California
MAGNETIC PUSH STICK
• Using a push stick is always a
good idea. Especially when
you're cutting narrow pieces.
But if you're like me, the push
stick ends up on the workbench
just when you need it most.
To keep mine handy, I came
up with the idea of making it
magnetic. That way I can stick it
on the rip fence within easy
reach whenever I need it. Note:
Make a couple extra to stick to
the jointer or band saw.
It's not difficult making push
sticks magnetic. First, cut out
the push stick to the size and
shape you need. Then cut off a
piece of magnetic tape (avail-
able at most hardware stores)
and attach it to one side of the
stick. The magnetic tape is eas-
ily cut with scissors and comes
with a self adhesive tape on one
side so it's ready to use.
George Scharg
Deland, Florida
Push stick attaches to
rip fence to keep it
handy
SUBMIT YOUR TIPS
If you would like to share an
original
shop-tested tip, send
it to
Woodsmith,
Tips and
Techniques, 2200 Grand Ave-
nue, Des Moines, Iowa 50312.
Or if it's easier for you, FAX it
to us at: 515-282-6741. Or use
our E-Mail address: 75330,
2301 ©compuserve.com.
If we publish it, we will send
you (upon publication) $30 to
$150, depending on the pub-
lished length of the tip. Please
include a brief explanation and
sketch (or photo). And don't
worry about sending in a
rough copy. Well rewrite the
tip and redraw the art if neces-
sary. Also,
please
include a
daytime phone number.
No. 99
Woodsmith
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