WS #065.pdf

NO. 65

NOTESFROM THE SHOP

$3. 50

No.65

October1989

EDITOR'S

COLUMN

Sawdust

Editor

DesignDirector

ManagingEditor

AssistanlEditors

DonaldB.Peschke

TedKralicek

DouglasL. Hicks

Douglas M.Lidster

KentA.Buckton

TerryJ. Strohman

Ken Munkel

DavidKreyling

Cary Christensen

RodStoakes

ChrisGlowacki

LindaMorroq Mgr.

PatKoob

LisaThompson

LeslieAnnGearhart

PaulE.Gray

KenMiner

CherylScott

SandyBaum

JeanCarey

ArchieKrause

T\on', showthisissueto anyoneunder

LJ theageof 10. . . unless you'vegot

some shoptime blockedout.

I can't remembertwo projects that have

hadsucha gleefulresponsefrom our collec-

tion of Woodsmith kids as the Rocking

Horseand theToyTrain in this issue.

The RockingHorsewasaninstanthit.The

only problemwasdealingwith thechorusof,

"It's my turn." The Toy Train was just as

much fun. I was only disappointed

heading "nouriNc DIREcrIoN."

We try our best to show woodworking

techniquesthat are both safeand yield the

best results.But safetyshouldalwayscome

first.Readthe Owner's Manualthatcomes

with thetoolsyou'reusing.FollowtheSafety

Instructions.

No matterwhatyoureadin Woodsmithor

anyothermagazineor book,or whatsome-

onesays,youhaaetodecidewh,at'ssafe for

you.Think aboutwhatyou'redoing.If you

ever feel any hesitationaboutdoing some-

thing, don'tdoit.

NEwMcEs.Aswegetmoreinvolvedwith

offering ProjectSuppliesthrough the mail,

customer serviceis becomingmore impor-

tant. In fact, the wholereasonfor thisdepart-

mentis to providethe bestservicewecan.

To help accomplish that goal,I've asked

LindaMorrow to manageour customer

service department. (Linda has actually

beenworking here with Steve Krohmerand

the WoodsmithStores for thepastyear.)

Now I've askedher to takecharge of ful-

fillment of the ProjectSupplies. This means

shehasto get our newcomputer systemup

and running, train new staff,and work day

and night to make sure everything runs

smoothlyandall our customers arehappy.

"No problem," she said, looking a little

wearyalready.I toldher shecouldtakeaday

offnext springto restup.

By the way, SandyBaum who used to

manageour customer servicedepartment

(when it was mostly subscriptionmanage-

ment)is nowworking asmy assistant.She's

helpingmewith the businesssideof things

- circulation,renewals,direct mail. It's

greatto haveher help.

EDIToRNEEDEI.We'relookingfor atleast

onegood editor to join our staff.The prob-

lemhasbeenfindingsomeonewith theright

mix oftalents.

Most magazines requireeditorswith

editing and writing skills. At Woodsmith,

we'relooking for someonewith a first-hand

knowledgeofwoodworking,andaninterest

in passingthatknowledgeonto others.

If you're a woodworker and have some

experience with writing, or at leastasincere

interestin learninghowtowrite,maybe this

is the job for you. Pleasesend your resume

to: DougHicks,ManagingEditor

Doug and I will send you a packageof

informationaboutthe job and the responsi-

bilitiesinvolved.

llnrff Issun.The nextissueof Wood,smith

(No. 66) will be mailedduring the week of

December18,1989.

ProjectDesigner

Technical

that I

couldn't get through my discussionof how

theconnectorsare usedto join thesections

of track.Abouthalfwaythroughmy explana-

tion, theselcgo-wise kids alreadyhad the

trackassembled.

Well, that's the whole idea behind this

issue: giftsfortheChristmasseason

CustomerService

ProlectSupplies

Controller

ComputerOperations

Administrative

thatwill

soon beuponus.

RocKING HoRSE.The RockingHorse

turnedouttobe moreofachallengeto build

than I expected. It's more sculpture than

cabinetry,and requires a sequenceof as-

sembly that I had to stumble my way

through the first time.

Fortunately,we got allthe details worked

out,andthendecidedto add moredetails.

First, we addeda mane and tail. Then we

addedarealleather saddleandabridle,too.

Although the horse could be built without

theseextras,I think it addeda lot from my

"adult" point of view.Kids will loveit either

way.

TIIErRArN.The fun part of the Toy Train

wasmakingthetrack. The track is designed

soit's easyto make - andsomoresections

canbeaddedanytimein thefuture.Once we

designedit, the hardest part was walking

through the officeas new sectionsof track

found their way in more amazing patterns

andstretchingto new parts of thebuilding.

ovRr uox. Therearetworeasonsto build

the Oval Box shownin this issue.First, it

makesanicegift. But the realreason,is that

it usesa techniquethat's just plain fun from

awoodworker'sstandpoint.

The box is basedon the shapeof a bev-

eled-edgeoval mirror. It requirestransfer-

ring the shape of this mirror to a template.

Then the templateis usedwith a router to

rout out the recess in the lid for the mirror

andacomplementary recessin the basefor

jewelry.

The ideais the same no matterwhat the

shape. Ifyou findanintriguingpatternofany

shape, you canmakea template from it and

rout out that shape.

cAUrroN. I want to point out the note of

cautionweve puton thenextpageunderthe

Assts.

Sourcebook

BuildingMainlenance

WOODSMITH STORES

GeneralManager

MarketingManager

StoreManagers:

St.Louis,MO

Berkeley,CA

DesMoines.

SteveKrohmer

Steve Dozier

JonBehrle

MichaelDeHaven

KentWelsh

WOODSMITH

(ISSN 0164-4114)

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August,October, December)bY

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Ave.,DesMoines,

lA 50312.

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ingCo.AllRights Reserved.

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lToodsmith

No.65

lllustrators

lishedbimonthly

Woodsmith

SUBSCRIPTION

FROM

FELLOW

\7OOD\YORKERS

Tips & Techniques

GLUING ON A HANDTE

How do you glue ahandleinto a I solvedthis problem by cut-

hole without smearing glue on ting a trough for the glue in the

the endof the handleasit goes centersectionof thehandle. As

in the hole? (Editor's Note: We the dowelis turned in the hole,

faced this probLem ott the the troughdistributes

DRUftI SANDERVACUUM

Mounting a drum sanderon a

Nowassemble

thebox.First,

isagreatwaytosand center the plywood bottom

the edge of a workpiece.But it under the front andback frame

produces very fine sawdust pieces. Then,to provide a lip so

that'sa nuisanceandunhealthy the box canbe clampedto the

to breathe.To cut

down on the saw-

dust, Ibuiltabox

that works with my

shop vacuum.

To make the

vacuum box, rip

enough 3/4"-thick

stock to form an H-

shaped frame. I cut

all the frame pieces

3Vz"w\d,e (hieh).

The two cross

membersare cut to length so

they're172il

ttre glue

lmndle .for the Rocking Horse around the insid'e of the hole,

sltctwnhtthis issue.)

CUT INSERTHOLE

seedrawing.

To makethe glue

trough, I drilled a

seriesof small over-

lappingholes in the

dowel.The drill size

and hole depth are

relative to the

diameter of the

dowelyouuse.I use

Tarrholes %" deep

ona lrLdiadowel.

SMAITHOIEs,

THENf ItI TROUGH

ROTATE DOWETTO

SPREADGLUE

AROUND

If the glue is spreadaround

theinsideo{thehole,theendof

the dowel gets smeared with

glue as it's inserted.If glue is

spreadon the centersectionof

thedowel,it'susuallyscraped

Fill thetrough with glue, then

insert the dowel through the

hole (trough-side up).After cen-

tering the dowel on the work-

piece, quickly rotate it a few

times to smearthe glue around

the hole.

lessthanthe depth

(front toback)ofyour drill press

table.The front andback frame

pieces are cut to length so

drill press,gluethe crossmem-

bersinabout2rrfromeachendof

the plywood bottom.Finally,

gluethe top downto the frame.

I alsocut a setof insertsto fit

the variousdrums I

have.The inserts

are cut from .l/41'-

thick plywood to fit

the squarehole in

the top of the box.

Then drill holes in

the center of the in-

serts74rr

off

asthe dowelis pushed through

the hole. Either way, it usually

makesamess.

CUTHOIE

7e'IARGER

IHAN DRUM

Stanle'ySttipling

Stoekbridge,Georgio

ROUTTNGDIRECTTON

In WoodsmilDNo. 64 we

showed a drawing of how to

rout a V+ttround-over on a

chairslat (Fig. 6 on page 21).

I want to say this bluntly:

this drawing could be misin-

terpreted and could be very

dangerous.

The original drawing (Ieft,

below) showsa router table

with a V+tt round-over bit. The

chair slat is being pulled

through the bit to round over

the edge.We left out two im-

portantdetailsonthis drawing.

l. The guard, shou\d be in

pLaee wheneuer the bit is er-

posed,.Typically we don't show

the guard in the drawings so

you canseethe relationshipof

the bit to the wood.Neverthe-

less,when you make the cut,

the guardshouldalwaysbe se-

curely mountedon the router

tableto protectyour fingers.

2. You should, feed, against

th,erotation of the bit. The

arrowshowingthe directionof

feedwasleft outofthedrawing.

It maylook like the workpiece

is being pushed(right to left in

the drawing). The proper

directionoffeed is left to right,

asin the newdrawing,below.

CTAMP BASE

TO DRIIT

PRESSTABTE

largerthan

the sandingdrums.

This will leaveextra

they're abouttwice as long as

your drill press table.

After the frame pieces arecut

to size,cut a holein oneof the

crossmembersto acceptthe

hosefromyourshopvacuum.It

shouldbe afriction fit.

Nowrip apieceof 3/+'r plywood

towidthtoequalthedepth (front

to back)ofthe drill press table.

Thispieceiscutintotwolengths

forthetopandbottomofthebox.

Thebottomisthesamelengthas

thewidth of the drill presstable,

andthe top is cut to thelengthof

the front and backframepieces.

Beforeassemblingthe box, I

cutasquare holerightin thecen-

ter ofthe top to accept sanding

drum inserts.Then, to keepthe

inserts from dropping through

the hole, I addedcleats under

theholeatthesides.

in the hole.

To use the box, clamp it to

your drill press and lower the

sandingdrum soit's just inside

the hole. Then lock down the

quill and you're readyto sand.

Atr,thonyBorsi\l,i

StatenIsland, NeLuYot'k

SEND!N YOURTIPS

If you'd like to sharea tip

with others, sendin your idea

to Woodsmith,Tips & Tech-

niques, 2200GrandAve.,Des

Moines, Iowa 50312.

We pay $1S for accepted

tips. Pleasesendan explana-

tion and a sketch if needed

(we'll drawa newone).

ROUNDOVER

EDGEs,KEEPING

fINGERSCUAR

IA"ROUND- ,/

\CHAIR

FEEDDIRSCNON

OVERBIT

BACKSIAT

No.65

Woodsmith

drillpress

DRIITSERIES

INSIDEHOLE

area for the dust to be pulled

through andallowsspacesothe

drum doesn't have to be per-

fectlycentered

JUST FOR KIDS

Rocking Horse

Remember

resist

the pure delight of rockingat full speedl

Thls isa project that cre&testhosegreat memories.

f am alwaysamazed at the interestand opinions

l- aduLtshaveconcerning children'stoys.I've wanted

to makea rocking horsefor a long time, but trying to

comeup with a rocking horsethat all the adultsliked

wasalmost impossible.

MATERTAL

can be traced to the importanceof making accurate

measurements and identicalcuts,but the challenges

of this project are different.As I was working on the

horse,I realizedthat I didn't have to be soconcerned

about exactmeasurements - rather exact fils.

It'snotsoimportant that parts matchoui measure

ments exactly.It's moreimportant theyfit togetherwell.

After I hadbuilt thehorse's body,I wantedit to look

evenmorerealisticsoI addedafewextras - twoglass

eyes,ears,mane,and a tail. All the extraslooked so

good, I couldn'tresistadding a leathersaddleand

bridle. (We likedthese extra parts somuchwedecided

to offerthem asakit, seepage 24.)

stock.

The thick materialgives the horse a natural appear-

ance andmakesthe backwide enoughto sit on com-

fortably. I usedponderosapine for the horse shown

above,but any pine construction lumberwill work.

Normally much of the challenge in woodworking

\-r'

Woodsmith

No.65

when Jou werea kidandcoul.dn't

I knew from the start, that a rocking

horse shouldn'tlook thin or spindly,so I madethE

bodyandthelegsofthe horse outof 1V2il-thick

EXPTODEDVIEW

HEADSIDE

PIECES

NECK

PIECES

HANDLEBAR

#8 x2"

wooDS€REWS

3/9"

PtUG

MAIN

BODY

/la' ;

i'i^

7s"-\

PruG t

LEG

WEDGES

1li'r

REAR

TEGS

MAIN BODY PATTERN

GRID DIVIDEDINTO I' SQUARES

#8 x 11/t"

wooDscREWS

ji),'h\

ROCKERS

FOOTPEGS

FRONT

tEGS

26"

fnAtERlAts

CUTTTNGDIAGRAM

WOOD PARTS SUPPIIES

A MqinBody(l) lVzx\1t/q-38 c (2)2x12's,72"long

B LegWedges (4) 7/ax71/z-

Seebelow-

o 20"pieceof l"dowel

11/2x111/a-14 . (32)3/e'woodscrewholeplugs

E Sides(2)

(2) ahx71/a-11 r #8xl1/a",#Sx2"woodscrews

G NeckPieces(2) 3/ax71/a-J

F HeodSidePcs,

fencingstoples'

H Rockers(2) 3/ax2Vz-53V2 . (l)skein4-plybrownyorn-

I Crossbors

c smoll

(5)

s/ax 3 - 17

o (l)2"x4" piecesof leolher (eqrs)'

J Hondlebor(1) l"-dio. - 10"

. (2) l"glosseyes.

- Ae/a" . Sotin polyurethone.

K Footpegs

(2)

1"-diq,

i pint

'Cut o froniond reorIegfrom

These

itemsoreincludedin

24"-long blonkof 2 x .l2.

the hordwqre kit, see poge 24.

No.65

Woodsmith

ruh

\\il q(."

'}))

lO . (2) I xB's,72"1ong

C FrontLegs(2) Seebelow- r 11) 1x8,36"-long

D ReorLegs (2)

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