Woodcraft Magazine TruePDF-August September 2019 PDF

Table of Contents
August/September 2019 | Issue 90

Projects 24 Build a Beautiful, 3-Top Box
Take your box-making skills to the next level with an elegant
design that makes the most of vertical grain Douglas-fir.
34 Modern Plywood Workbench

Transform a few sheets of hardwood plywood into a traditional, fully-
functional European-style workbench. The strip-by-strip assembly
process speeds things along and simplifies any tricky joinery.
51 A Box-Maker’s Sled
Get double duty from a single jig designed to make perfect 90° and 45° cuts.
Tools &
Techniques 30 The Art of Seating
Few types of furniture have as many design permutations as the chair. Here a peek
at American chair design from James Monroe’s reelection as 5th president to now.
44 Inset Pulls
If you have ever searched for commercial recessed pulls, you know
how elusive and expensive they can be. Here are 4 classy designs
you can make yourself for a small fraction of the cost.
24 34
51
2
Departments
30
04 Contributors
06 Getting Sharp
08 Profiles
• Gregory Paolini
10 News & Views
14 Reader Showcase NEW
16 Hot New Tools

• Clifton Bench Planes
44
• General Finishes Stain
Blocking Primer
• Leigh VRS1200 Vacuum
& Router Support
• Jet JWP-15B 15" Helical
Head Planer
• Seal-Once Nano Guard
Wood Sealer
18 Tips & Tricks

• Well-behaved bench dogs
8 56
• Roundabout scribing
• Precision plunging
• Drilling on the level
56 Famous Furniture
• Shaker Candle Stand
58 WoodSense
• Vertical Grain Douglas-Fir
60 Great Gear 64
• Stanley #92
• Rolair AB5 Air Compressor
64 Expert Answers
69 Buyer’s Guide/
Ad Index
72 Outfeed
• Kidding in the Shop
Cover photo: Ralph Lee Anderson Aug/Sept 2019 | woodcraftmagazine.com 3

Contributors
The workbench on page 34 was designed by Andy Rae, an instructor at Making

Whole (MakingWhole.com), an apprenticeship program for men recovering
from addiction. Andy (atop bench) supervised the construction of the bench
with the crew of Making Whole (shown with shop dog Daenerys) as part of a Matt Kenney just might be the
program built on the idea that the growth opportunity in building objects by world’s most prolific box maker.
hand is the perfect platform for rebuilding lives. The shop makes studio-quality Not long ago, he designed and
furniture in wood, metal and architectural concrete, not so much for the outcome built 52 boxes over the course
of the project, but for the process. The men find that as they search for solutions of a year, blogging about the
to the problems they encounter during a build, they discover themselves. experience on his website
(mekwoodworks.com). The blog
“I like watching people work,” says David Heim, who attracted such a large audience
contributed two articles to this issue (pages 8 and 56). that Matt decided to document
He’s been keeping a close eye on talented furniture- the adventure in a book, 52
makers and woodturners for fifteen years, highlighting Boxes in 52 Weeks (published by
their work in magazine articles, books, and how-to Taunton Press). When he’s not
videos. David has also written and illustrated two of building boxes like the beauty
his own books, SketchUp Success for Woodworkers and featured in this issue (p. 24), Matt
Woodturning Patterns, both published by Spring House teaches woodworking around
Press. An avid woodturner (and a board member for the world, writes about the craft,
the American Association of Woodturners), David and hosts The Matt and Joe
also enjoys making small pieces of furniture. Woodworking Fun Hour podcast.
On the Web
Free stuff! Helping You Make Wood Work
Just a friendly reminder that we are always adding new Join Chad Stanton as he helps
totally free content at woodcraftmagazine.com. Swing by you make wood work in a new
and check out our exclusive onlineEXTRAs, Patterns, and skill-building video series from
Videos. As an added bonus, subscribers get access to every Woodcraft. Chad will share step-
project we’ve published all the way back to issue one! by-step instructions on specific
techniques that will grow your
woodworking knowledge. All you have to
do is tune-in to YouTube.com/woodcraftmarketing and then take
your new-found talent to the shop and make some sawdust.
4
Getting Sharp Share your ideas.
We love hearing from readers! And there are all
kinds of reasons to get in touch with the crew at
Sharing woodworking’s rich history Woodcraft Magazine. Check out the details below.
General information:
4420 Emerson Ave., Suite A
W oodworking may well be the

oldest human craft. Not long
after our ancestors climbed down
many generations. Today there are so
many ways to learn—from a family
member or friend, at a woodwork-
P.O. Box 7020
Parkersburg, WV 26102
800-542-9125
from trees, they began utilizing them ing club or Woodcraft store, via Share a slick tip to win cash or a prize.
Here’s your chance to help someone become
to make things. From these primi- online videos, or by reading a maga- a better woodworker and get rewarded for the
tive beginnings, woodworking and zine like this one. For more positive effort. The winner of next issue’s Top Tip award
humans evolved together. It’s a history thoughts on the future of craft, check will receive a Woodcraft Gift Card worth $250.
All others will receive $125 for a published illustrated
rich in crafted objects of all sizes and out Rick Hanish’s writing on p. 72. tip or $75 for a non-illustrated tip. Published tips
shapes, for purposes that range from Every project we take on is an become the property of Woodcraft Magazine.
purely practical to total frivolity. But opportunity to make a little history Email us at tips@woodcraftmagazine.com and
the story of woodworking isn’t only in our shops. Our workbenches are put “Tips & Tricks” in the subject line or visit
about what we make; it’s the knowl- birthing tables for much of what woodcraftmagazine.com, and click on Contact.
edge we share and the many tools we create. Every ding and dent is a Important: Please include your phone number,
as an editor may need to call you if your
that get passed from one genera- testament to the tales we tell. Build- trick is considered for publication.
tion to another, accumulating their ing your own workbench is a rite of
Have a tough woodworking question?
own special history along the way. passage for many woodworkers. In We’ll do our best to find the expert and provide the
Long after their communities began this issue, you’ll find a fresh take on answer. Email us at editor@woodcraftmagazine.com
to decline in the mid-1800s, the Shak- this age-old tradition, with guidance and put “Expert Answers” in the subject line.
ers place in woodworking history provided by professional wood- News & Views:
This catch-all column is where we do our best
continues to show its staying power, as worker Andy Rae and his friends
to correct mistakes, publish feedback from readers,
evidenced by the candle stand on page at the Making Whole community and share other noteworthy news items. It’s easy to
56. The Art of Seating (30) demon- shop in Asheville, NC (p. 34). participate in this discussion. Just email us at
editor@woodcraftmagazine.com and
strates how American chair design Get in your shop and make his-
put “N&V” in the subject line.
evolved over time. Each era developed tory with techniques for inventive
Submit an article idea:
its own brand, and different regions pulls (44) or build a small box (24) Do you have a story idea? We’d love to hear about it.
offered their take on how things for future generations to enjoy. No To find out how to submit an article, email us at
were made—the style, ornamenta- matter what you craft, if you do it editor@woodcraftmagazine.com and put
“Submission” in the subject line.
tion, symbolism, and significance. well, you can give a tree another 100
As modern woodworkers, we carry or more years, and your story will be Share photos of your projects:
We’d like to see what you’re building. To show off your
on a tradition that never runs out heard, and your lessons learned by work send your photos to editor@woodcraftmagazine.com,
of new ideas, even as we continue the next generation of craftspeople. or find us on social media.
to improve basic skills with hand
tools that have changed little over
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Aug/Sept 2019 Vol. 15, Issue 90 (800) 542-9125 ©2019 by Woodcraft Supply, LLC. All rights reserved.
Woodcraft Supply, LLC allows the purchaser of this magazine
Chief Editor: Chad McClung
Woodcraft Magazine (ISSN: 1553.2461, USPS to photocopy the included projects and techniques solely for
Senior Editors: Paul Anthony, Joe Hurst-Wajszczuk, Tim Snyder
Contributing Editor: Ken Burton personal use. Any other reproduction of these projects and
024-953) is published bimonthly (Dec/Jan, Feb/Mar,
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April/May, June/July, Aug/Sept, Oct/Nov) by Woodcraft
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6
Profiles
Gregory PAOLINI A man with a plan
B
eginning in 2007, Gregory Paolini and I
worked together on several magazine articles
and books. With each collaboration, I came
away impressed by Greg’s woodworking ingenuity
and drive. He has a knack for dreaming up clever
router templates, ingenious ways to cut dovetails,
and different ways to work more efficiently. When
we first met, Greg was building Arts & Crafts fur-
niture out of a small garage. He always seemed to
have his sights on better tools, more commissions,
and a bigger workspace. These days, he and his staff
make custom furniture and cabinetry in a large
commercial shop located near Asheville, NC. As
if that’s not enough, Greg also offers a full schedule
of woodworking classes for students who range
from beginners to experts. We spoke by phone for
this interview.
—David Heim
WM: What got you started WM: How did you decide to focus GP: My wife Mona’s best friend had
in woodworking? on Arts & Crafts furniture? moved to western North Carolina,
and we visited her several times.
GP: I grew up in Buffalo, New York. GP: Buffalo has a huge Arts & On one visit, in late October, the
When I was 11 or 12, I inherited Crafts presence, including several weather couldn’t have been more
a set of woodworking tools from houses by Frank Lloyd Wright. perfect. Mona and I looked at each
my grandfather. I had no clue Even the house where I grew up, a other and said that we could live
how to use them, so I got every farmhouse built in about 1893, had here. So we put together a three-
woodworking book in the library quartersawn white oak woodwork. year plan. Two and a half years
and started experimenting. I was In the late nineties, I got involved later, we were in North Carolina.
trying to make the tool in my hand with the Roycrofters At Large
do what the book said it could do. Association; it’s an organization WM: Tell me about your first
My first real piece of furniture that recognizes artisans who work shop in North Carolina.
was a trestle table. I made more in the Arts & Crafts style. But
things for my family and friends, after about seven years I realized GP: In Buffalo, the entire lower
and before I knew it, I was that I needed to make a name for level of our house was my shop.
making things for people I had myself, and that I didn’t want to be Our house in North Carolina only
never met. I kept experimenting known just as a Roycroft artisan. had a 11/2-car garage, so I went from
and learning techniques. Worst 1100 square feet to 400 square feet. I
case, I knew, was that I’d make WM: What brought you spent the next year building a larger
some expensive firewood. to the Asheville area? garage that I could use for the shop.
8
Homage. Greg modeled this Details make the difference.
coffee table after a piece by A master furnniture-maker,
Charles Limbert, one of the greats Greg favors Arts & Crafts and the
in the Arts & Crafts movement. Greene & Greene styles (above).
WM: How did your business— WM: So you moved out of the WM: What’s it like being a supervisor
and your shop—grow? garage into a shop with a crew, then instead of a furniture-maker?
into a bigger shop. What’s next?
GP: It took some time, but my work GP: There are days when I miss the
became accepted. Several architects GP: We’re just finishing an addition solitude of working alone—when no one’s
in the area asked if I could bring that will bring the shop to 9000 calling and it’s just me and the board.
the level of detail in my furniture square feet. And I’m about to take Being a supervisor has been a learning
into cabinetry. So I shifted the focus delivery of a CNC machine. The process for me. My goal is to have a
of my work away from furniture. Arts & Crafts guy in me hates that. successful woodworking business that I
I had opportunities to take on Deciding to incorporate CNC work don’t have to show up for every day. I want
more jobs when I was working into our business was a three-year- to be sure that if something did happen to
alone, but I had to turn most of them long struggle. I finally decided that me, the guys could continue to pay their
down. I was afraid of moving to a there’s a difference between work mortgages, my wife would be all right,
level where it was more than just that’s truly meaningful and work that’s and the business could keep going. Some
me. Fortunately, I had a student who merely essential. Is it meaningful of the area colleges with woodworking
was the business manager for his for a man to spend time cutting big programs send their students here. They
wife’s dental practice. He became my squares of plywood into little squares? always ask what it takes to make it in the
business mentor. We put together a No. It’s better to let the robot cut up woodworking business. I tell them to ask
plan to grow while minimizing risk. the plywood and have the artisans the question again but take out the word
Then we landed two big jobs. That make doors or drawers or something “woodworking.” There’s nothing magical
gave me the confidence I needed. that gives their work meaning. about making it as a woodworker. n
Photos: Courtesy Gregory Paolini Aug/Sept 2019 | woodcraftmagazine.com 9

News & Views
Faceplate fixes Plastics projects

I liked the Top Tip in the June/July 2019 issue, but have I enjoyed the articles on plastic lumber in your last issue.
an even better method for faceplate mounting. I use a Since I live in Houston with its wood-destroying climate,
piece of kraft paper cut to the same size as the mounting my outdoor projects haven’t done well, even with no
block and glue them to the blank using Titebond II. ground contact. It looks like the solid-color HDPE
When finished, I wedge a wide chisel between the block mentioned in the article is just what I need.
and blank. The paper splits, and the blank pops free. —Frank Griffin, Houston, Texas
—John Crouse, via email
Contributing Editor Ken Burton replies: For more info on plastic lumber,
I’ve tried your approach but found that the paper can shear see How Good is Plastic Wood?,
if your tool catches, potentially resulting in catastrophe. June/July 2019, Issue 89, p. 32.
This is especially true with beginners. I’ve taught basic bowl
turning for years, and my students see more success with the
added security of wood-to-wood contact between the blank
A must-see for carvers

and the mounting block. Since I switched to this method,
I haven’t had any bowls come off the lathe prematurely.
But as with so many things in woodworking, there are
several solutions to the same problem. You have something The recent editorial about travel with your family reminded
that works for you, and I hope it continues to do so. me of a neat little carving museum I visited some years ago.
The Earnest Warther Museum and Gardens is home to
the intricate steam engine creations of the “World’s Master
Carver” Ernest “Mooney” Warther. Located in Dover, Ohio,
the family-run museum welcomes visitors every-day from
9:00 am to 5:00 pm, with the last tour leaving at 4:00 pm.
—Evan Pinesworth, Tallahassee, Florida
And the winner is…

Bruce Kuveke is
the Grand Prize
Shopping list
winner in the “Build
It! with Jory and
John Sweepstakes”
Thanks for always including the Buyer’s Guide sponsored by
in the magazine. The list of tools helps me to Woodcraft, Jory
tally the cost of materials before starting a Brigham Design Studio, and SawStop. Bruce is a retired
project. And I often learn about new tools. veteran and postal worker from Boulder City, Nevada.
—Victoria Louise, Louisville, Kentucky Randomly selected from over 26,000 entrants, Bruce
will be awarded the Grand Prize package valued at
$10,000. The prize includes a SawStop Professional
Buyer’s Guide Saw and a three-day training class in Paso Robles,
See page 69 for tools and California with Jory Brigham and John Malecki.
supplies used in this issue. To learn more about Kuveke and the other
winners, check out woodcraft.com/pages/blog.
10
How to reach us
Email
editor@woodcraftmagazine.com
Direct Mail
Woodcraft Magazine, 4420 Emerson Ave., Suite A,
Box 7020, Parkersburg, WV, 26102-7020.
Please include your full name, address, and phone number.
Published letters are edited for length and clarity.
Aug/Sept 2019 | woodcraftmagazine.com 11

Reader Showcase
DENNIS CAUFIELD,
COLLEGE STATION, TX
Cedar slabs. “Happiest when
BILL MADER, FOND DU LAC, WI making sawdust,” Caufield
Cheers. Armed with only a photo from our Dec/Jan 2019 issue harvests eastern red cedar logs to
and cherry wood harvested from his land, Mader made this build sturdy benches (above) for
liquor cabinet as a wedding gift for his niece. The crotch wood his friends and family. Caufield is
on the drawer face and the lighter sap wood add visual interest. pictured at right with a 2"-thick
cedar plank that will soon be
a coffee bar in his cabin.
RUSSELL SVENDSEN, OLEAN, NY

Bathtub caddy. For this project, Svendsen combined elements from
the Serving Tray (Dec/Jan 2019) and his own Adjustable Trivet (Feb/
Mar 2017) as a gift for his daughter. He used engineered flooring for
the plank, mahogany for the sides, and curly maple for the handles.
Show off your work!
Email Direct Mail

TIM LAMBERT, BEALETON, VA editor@woodcraftmagazine.com Woodcraft Magazine,
4420 Emerson Ave., Suite A, Box 7020,
Butternut boxes. Using butternut gifted from his uncle’s Parkersburg, WV, 26102-7020.
farm, Lambert built this Tansu Box from our Feb/Mar 2009
Go to woodcraft.com/gallery for submission instructions.
issue. The drawers pull out to reveal curly maple sides.
14
Hot New Tools
arlier this summer, nearly 100 manufacturers gathered at the

Woodcraft Vendor Trade Show to share their latest offerings
in hand tools, machinery, finishes, and accessories. Here are
just few of the items that caught our eye. For more details go to
woodcraft.com, or check them out at your local Woodcraft store.
British invasion
A few years back, Thomas Flinn & Co. (a UK-based saw maker since 1923),
acquired Clico, the maker of Clifton hand planes. This merger has resulted
in a new line of bench planes (3, 4, 41/2, 5, 51/2, 6, 7) and a block plane to
complement their existing offering of shoulder planes and spokeshaves.
These premium planes incorporate the best attributes of both Stan-
Clifton #41⁄2 ley and Record (many of the employees apprenticed at Record Tools),
Smoothing Plane coupled with exceptional fit and finish. Based on the Stanley Bedrock
#166421, $404.99 design, the bench planes sport machined frogs that rest on matching
machined pads in the body. The frog can be moved to close or open the
mouth of the plane without removing the blade. The soles and sides are
ground to the British Standard for bench planes (0.003") for optimum
performance for standard planing and for use in a shooting board.
The most noticeable difference between the new Cliftons and
vintage planes is the heft. Thicker castings mean more mass;
granting greater momentum for gliding through tough grain.
The O1 steel irons are 0.125" thick (more than 50% thicker than
the industry standard of .080"), and are hardened to HRC 60-62.
Clifton Low Angle They are also cryogenically treated to improve edge retention.
Block Plane If you’re serious about hand tools and interested in taking
#166429, $374.99 the next step, go to woodcraft.com for more info.
Super powerful primer

The folks at General Finishes don’t hyperbolize, so a
description that includes words like “strongest” and
“revolutionary” warrants special attention. This water-based
interior sealer sticks to almost everything and creates a
barrier that prevents stain, dye, and tannin bleed-through.
Having tested the product in my shop, I was impressed by
the primer’s self-levelling abilities (the brushed-on samples
looked almost as good as the sprayed boards). After two
coats, the samples looked as if they didn’t need a top coat.
Innovation doesn’t come cheap, but based on this
Typical primer primer’s ability to handle the problems associated
with painting over other finishes, it’s a reasonably-
priced insurance plan for tough paint jobs.
Stain blocker General Finishes Stain Blocker Primer

Quart, #166814, $41.99
16 Prices subject to change without notice.

Leigh VRS1200 Vacuum & Perfect partner for PC dovetail jigs
Router Support Porter Cable’s dovetail jigs may be some of the
#166417, $79.00 most popular dovetail jigs on the market, but
users discover that routing the parts for a drawer
or two produces a prodigious amount of dust
and chips. With the Leigh VRS1200 Vacuum &
Router Support, PC 4210 and 4212 jig owners
can now enjoy almost dust-free dovetails.
The vacuum box is the key to cleanliness. This box
clips onto the guide bushing and slides in tandem
Sliding
vacuum with the router to collect chips when cutting pins
box and tails. In addition to supporting the vacuum box,
the beam keeps the router from tipping and offers
Support
beam a safe resting spot when making board changes.
Hello, helical. See ya’ Snipe.

Jet’s newest helical head planer deserves to be seen and heard. Compared to
straight-blade machines, the JWP-15B’s 48-tooth carbide insert, helical head planer
not only delivers a superior finish, but does so with a lot less noise. The planer is
powered by a 3-HP, single-phase, 230V motor with V-belt transmission to reduce
vibration and running noise. A two-speed gear box—operated by a push-pull
knob—provides dual material feed rates of 16 fpm for a smooth finish, and 20
fpm for quick dimensioning. The motor is operated by an easy-to-access magnetic
switch, which has a green safety light that illuminates when the planer is powered.
The most interesting innovation is JET’s Precision
Air Strut System (PASS™). This pair of heavy-duty gas
struts exerts upward pressure on the cutterhead with
upward pressure, preventing it from dropping and causing board snipe. 2-speed
gear box
Precision Air
Invisible guardian Strut System
Tired of the annual exercise of applying top coat sealers to your
Magnetic switch
outdoor projects? Maybe it’s time to step up to 21st Century with light
technology. Made by the folks who also make Anchor-Seal, Seal-
Once is a non-toxic, non-film-forming “inner sealer.” Based on its
track record in the log home and decking market, it might be your
best weapon in the fight against Mother Nature’s weathering forces.
According to the manufacturer, Seal-Once penetrates the wood’s
surface and then coats the wood fibers with nano-polymers. The
polymers allow water vapor to escape, but restrict water intru-
sion that leads to mold, mildew, rot, warping, and splitting.
Seal-Once can be used under other paints or finishes, or tinted
and used as a stand-alone stain. The coating lasts up to ten years
on vertical surfaces and six years on horizontal surfaces. n
Seal-Once Nano Guard Wood Sealer Jet JWP-15B 15" Helical Head Planer
Quart, #164465, $26.99 #722155, $2,599.99
Photos: Manufacturers except Stain Blocker samples: Doug Loyer Aug/Sept 2019 | woodcraftmagazine.com 17
Tips & Tricks
Well-behaved bench dogs

Conventional bench dogs are usually outfitted with
sprung metal or wood strips to hold them in place at
your desired working height. They work well enough
at an inch or so above the benchtop, but lack bite when
standing tall to hold higher work. This dog relies on
1/4-20 × 1/2" nylon-tipped set screws (available at
McMaster-Carr.com; item # 94115A537) to keep it
precisely where you want it, even when projecting 4"
above the work surface. To make a good dog like this, saw
your stock from a dense hardwood like maple, sizing its
body to suit your benchtop’s dog holes. Then drill a series
of 3/16"-diameter holes through the back of the dog (there’s
no need to tap them). Drive the screws through until
their nylon tips protrude from the opposite face and bear
lightly against the inside of the dog hole. It will then sit
where you want it to without further commands to “stay!”
—Andy Rae, Asheville, North Carolina
2°
Nylon-tipped
1
⁄4" set screw
11⁄4"
Drill 3⁄16"
through-hole
2" for screw.
9" Use Allen wrench to

adjust screw so that
nylon tip projects
2" at front of dog.
Size dog body to suit

bench dog holes.
18 Illustrations: Christopher Mills

Tips & Tricks
Precision plunging
I’ve found that the depth
gauges on some plunge
routers are tricky to read.
For the kind of precision
needed when routing inlay
recesses, for example, I use
as a depth gauge a drill bit
whose diameter matches my
desired depth of cut. With
the router bit zeroed out
on the workpiece surface,
Lock depth rod
I trap the drill bit between against bit.
the router’s turret and its
adjustable depth rod, and
Use drill bit as spacer Bit tip touching
then lock the rod. Remove to set up depth of cut. work surface
the drill bit, and go to work,
plunging with precision.
—William Keith, Turret
San Diego, California
20
Roundabout scribing
When installing wall cabinets some time back,
I needed to scribe a face frame to fit against
an irregular wall surface, but couldn’t find the
compass I normally use for the job. Fortunately,
Wall
I remembered that an old finish carpenter once
showed me how to scribe using regular flat
washers, which I happened to have in my toolbox. Face frame
Here’s how it works: With the cabinet braced plumb
and level, and with the face frame abutting the Flat washer
wall as closely as possible, select a washer whose
ring width approximates the widest section of
the remaining gap. Pressing the washer against
the face frame and the wall, insert a pencil tip in
the washer hole as shown, and drag it the length Ring width =
widest section
of the area to be trimmed to create your of gap
scribe line. Cut to the line, check your
Scribe line
fit, and repeat if necessary, using a
smaller washer to refine the fit.
—Mark Latimer,
Florissant, Missouri
Share a Slick Tip.
Win Cash or a Prize!
Here’s your chance to help someone
become a better woodworker and
get rewarded for the effort. The
winner of next issue’s Top Tip award
will receive a Woodcraft Gift Card
worth $250. All others will receive
$125 for a published illustrated
tip, or $75 for a non-illustrated
tip. Published tips become the
property of Woodcraft Magazine.
Send your ideas to:

Tips & Tricks, Woodcraft Magazine,
P.O. Box 7020, Parkersburg,
WV 26102-7020
-or-
visit woodcraftmagazine.com, and
click on “Contact”.
Important: Please include your

phone number, as an editor may
need to call you if your trick is
considered for publication.

Tips & Tricks
Drilling on the level

A recent job required drilling a couple Large flat washer will
of large holes in the walls of an installed remain in place when
spinning drill shank is level.
cabinet to accept the ends of a large dowel
rod. For the rod to span the two holes,
they both needed to be horizontal in order
to align with each other. Unfortunately,
it’s hard to gauge level with a spade bit,
which is the tool I had for the job. After
some head-scratching, I realized that I
could employ the same sort of balancing
principle used by a toy I had as a child. I
strung together a couple of washers, which
I then hung from the shank of the bit as Lower washer serves
shown. When drilling, the shank-hung as a stabilizer.
washer would “walk” as a result of any drill
tilt, providing a great leveling gauge. The
side-to-side perpendicularity wasn’t too
difficult to maintain, gauging it by eye with
the help of a small square placed nearby.
—Bill Shapwell, Fargo, North Dakota n
22
Build A Beautiful
3-TOP BOX
A distinctive design combines

grain-matched sides, handcrafted
Order of Work handles, and painted accents.
• Mill rabbets in sides and divider stock, By Matt Kenney
then cut sides to finished length.
• Mill stopped V-grooves in sides.
W
• Miter the sides, then assemble. hen making small boxes, I ously around the square perimeter.
• Make the bottom panel. usually design a box first, The grain display continues at the
• Cut dividers to fit, then layout and rout then select the wood I’ll use top of the box, with three different-
through V-groove in long divider. to build it. But this box is different. sized lids that nest in rabbeted sides
• Prefinish dividers and inside faces of sides. When a friend gave me some beau- and dividers. Green paint accents
• Glue bottom and dividers in place. tiful, vertical-grain Douglas-fir, I the handle recesses and the edges
• Make lids and handles. worked on a design that would allow of each lid. The handles themselves
• Add paint accents to lids, then the wood to be the most striking are made from cocobolo. Inside the
glue handles in place. feature. My box has mitered corners box, the bottom is lined with a quilt-
• Apply finish to lids and box exterior. that allow the grain to run continu- ing square.
24 Photos: Randy O’ Rourke; Illustrations: Frank Rohrbach III

4 sides, 3 lids, 2 dividers, 1 bottom
All parts except for the bottom a single board if possible; that’s the prepare some extra stock (milled to
and handles are made from clear, best way to achieve uniform grain 1/4" thickness) to use in setting up your
vertical-grain Douglas-fir. Cut sides, and wood tone, along with grain- table saw and router table for precisely
dividers, lids, and veneer stock from matched sides. Also make sure to milled rabbets and V-grooves.
HANDLE Rabbet LID

¼ × 3⁄8 × 2" 1
⁄16 × 1⁄2" 1
⁄4" × CTF*
Drill centered hole for V-groove, Stopped V-grooves
handle, 1" dia. × 1⁄16" D.
1
⁄4" W. don’t show on
bottom of box.
SHORT DIVIDER
¼ × 15⁄8" × CTF
LONG DIVIDER
¼ × 15⁄8" × CTF
2"
Locate V-groove
2" after assembling
sides (see p. 28).
Rabbets
1
⁄16 × 1⁄4"
Cut 90° point on

divider ends to
fit in V-grooves.
Miter joint
SIDE PLYWOOD BOTTOM

¼ × 17⁄8 × 6" ⁄4 × CTF
1
VENEER
1
⁄8" T.
QUILTING SQUARE *CTF = Cut to fit
How to prepare grain-matched sides

1. Prepare a blank that’s flat, square, and large enough to be resawn into
pairs of adjacent sides, as shown in the drawing. You might need to work
with a longer blank (as I did), in order to run it through your planer.
Resaw
2. Resaw the blank and swing the matching pieces around, so that
both freshly sawn surfaces face outside.
3. Mark the miter cuts to divide the two pieces into four sides,
then write matching numbers or letters on the joints that need to
match up when gluing up the sides, as shown in the drawing. Make sure
to transfer your numbers to surfaces or edges that won’t be planed. Resawn
surfaces face
4. Plane your two boards to finished thickness. outside.
5. Complete joinery work on the sides, then cut
their miters and glue up the box.

Building the box frame
Start with a blank that can be resawn you get more solid registration stick” clamping method before, do a
to yield grain-matched sides, dividers, against the table saw’s fence. dry run of clamping the box frame so
lids, and veneer for the bottom. Leave the bit in place on the you can get a feel for how the technique
Also prepare some extra 1/4"-thick router table after V-grooving works. Basically, the tape holds the
stock to check joinery setups. It’s the sides. You’ll need it later for miter joints together, while the cauls
better to have longer workpieces V-grooving the long divider. clamp with increasing pressure as
when rabbeting edges, because If you haven’t tried my “string-and- you move them toward the corners.
Auxiliary
fence Side stock
Mill rabbets in dividers and sides. Attach a wood
auxiliary fence to the table saw’s rip fence, and set
up a stack dado to cut at least 3⁄8" wide. Position the
auxiliary fence to expose just 1⁄4" of the cutter, and
set cutting height at 1⁄16". Test your setup on scrap
stock and adjust if necessary. Then mill rabbets,
Divider using a push block to protect your fingers.
stock
Hold down
Fence
Cut sides to length. Clamp a stop block to the

crosscut sled fence, 6" from the blade. Butt a square-
cut end of each side against the stop to cut the sides
Stop block
to finished length. The sides still need their ends
mitered, but the square-cut ends will provide more solid
registration when routing V-grooves–the next step.
Backer board
Rout V-grooves in sides. Adjust the height of a V-groove bit so

that finished grooves will be 1⁄4" wide, then set the fence 2" from
the bit’s point. Mark the bit’s location on the fence so you can rout
Bit location
a stopped V-groove in three of the four sides (see drawing, p. 26).
Use a backer board to guide these cuts, as shown in the photo.
For two of the stopped grooves, you’ll need to lift the side up
V-groove stops shy of
side’s bottom edge. before the bit exits the bottom edge. Make the final stopped groove
by lowering the side onto the bit and routing through the top edge.
1
⁄4"
Top edge
26
Zero-clearance
kerf Finishing details
Prefinish the inside faces of the
box sides. You can do this before
gluing up the sides (keeping finish
from mating surfaces), or after
the sides have been glued up.
Also take the time to prefinish the
dividers again, avoiding mating
surfaces. I like finishing small
boxes with 1 lb. cut shellac. I apply
several coats, sanding with 800-
grit sandpaper between coats. For
painted accents, I use milk paint
(see Buyer’s Guide, p. 69).
Related Articles
Cut miter joints in sides. Make these cuts with a stop block clamped to Flip to page 51 to build your own
the fence. To position the block, align the top corner of a side (already cut to version of the sled shown here.
finished length) with the zero-clearance kerf in the jig’s fence. The correct See WoodSense p. 58 for
cutting set-up will create a sharp miter without shortening the side. more on Douglas-fir.
Clamp with tape, string,

and sticks. Working on a
flat surface, apply glue on
the miter joints, and tape
the box frame together by
applying painter’s tape at the
corners. Tie some common
household string to loop twice
around the frame, with just
enough slack to insert a pair
of rectangular cauls near the
center of each side. Carefully
move the cauls toward the
corners, aiming for symmetrical
placement on all sides. Don’t
force it; stop when the string
is taut and joints are tight.
To equalize pressure,
set the cauls the same
distance from the corner.

Add the bottom and dividers
Cut the plywood bottom panel slightly oversize, glue veneer
to one side, then cut the bottom to final size before gluing on
the fabric. The finished thickness of the bottom allows it to sit
slightly proud of the sides. This elevates the sides, creating a
delicate shadow line that gives the box a floating appearance.
Use your mitering sled to cut the pointed ends on the
dividers. For the long divider, point one end by making two
symmetrical miter cuts with the opposite end butted against
a stop block. Before removing the workpiece, make a vertical
mark on the fence, upward from the miter shoulder, as shown
in the drawing. Then mark the piece to fit, as shown in the
photo below. To set up to point the remaining end of the long Fabric goes on fast. Adhere the cloth by spritzing the
divider, align your mark on the workpiece with the mark on the plywood with spray contact adhesive, then pressing an
fence, and clamp a stop block to the fence against the previously oversize quilting square in place. After the adhesive dries,
cut end of the divider. Make the two remaining miter cuts, trim the excess with a craft knife or rotary cutter.
then use the same technique to complete the short divider.
Cutting pointed ends on dividers
Align shoulder mark on
Zero-clearance kerf workpiece with line on fence.
SLED FENCE
WORKPIECE
Blade Zero-clearance
edge in BASE
Mark to fit. After cutting the point on one end of the long divider, tuck it
in one of its V-grooves, and mark the shoulder of the point at the opposite
end. Align this shoulder mark with the vertical mark you’ve made on the
sled’s fence, then set up a stop block to make a pair of symmetrical cuts.
Mark and rout the

last V. Set the center
divider upside down in
the box and use a square
to lay out the location
of the final V-groove.
After routing, reinsert
(right-side up) and trim
the short divider to fit.
A perfect fit. To complete the short divider, repeat the

same cut-to-fit technique used on the long divider.
28
Finish up with lids and pulls
After cutting the lids to fit in their rabbeted openings, mask
both faces of each lid with painter’s tape. Then lay out a
centerpoint for drilling a 1"-dia., 1/16"-deep handle hole in the
top of each lid. Use a sharp Forstner bit, and clamp each lid
firmly in place before you start to drill. Remove the tape when
the paint dries, and lightly sand lid edges to soften corners.
I use my crosscut sled to make the cocobolo handles. After cutting
three handle blanks to finished dimensions, set the blade height to
1/16" above the sled, and clamp a stop block 1/2" from the far edge of the
blade. With the bulk of the blank on the opposide side of the blade, set
an end against the stop to cut the shoulder, then shift the piece away
from the stop to nibble away the rest. Be sure to use a hold down.
Repeat on the other end, then clean up the notches with a chisel. n Touches of color. Coat all handle holes and lid edges
with milk paint. Painter’s tape masks the unpainted
sections and reduces the chance of tearout when
drilling the stopped holes for the handles.
Tiny, T-shaped handles. These handles are cocobolo,

but other dark hardwood is equally suitable. Cut notches
for a snug fit, mark a centerline on the lid to align your
installation, and attach each handle with CA adhesive.
The finishing touch. The

dividers and the inside
faces of the sides have
already been finished with
several coats of 1# shellac.
Once the box is assembled
and the lids are complete,
I apply several coats of
shellac to all remaining
surfaces, sanding with
800 grit between coats.
As a final step, I buff
on some paste wax.
woodcraftmagazine.com 29
The art of
SEATING
200 Years of American Design
By John Blackford
s in biology, chair design has undergone The following bit of chair design history,
its share of evolutionary twists and which features a few of my favorites, is only
turns, with any particular design car- a taste of what the show has to offer. I caught
rying stylistic DNA from its forbears while the exhibition just before it closed at The
adapting to its specific regional environment. Michener Art Museum in Doylestown, PA.
A traveling exhibit titled The Art of Seat- If you get a chance to see it at a future venue,
ing: 200 Years of American Design presents a don’t miss it. It’s likely you’ll never look at
fascinating look at the evolution of chairs in chairs the same again.
our own country over the course of the last
couple of centuries.
The exhibit’s 42 chairs are presented
chronologically in four groupings. The
first reflects the invention and technological
development spanning the 1820s to the 1880s.
This is followed by the Arts and Crafts move-
ment that continued into the 1930s. The third
group represents a period of advanced materi-
als and production that extended through the
1960s. Finally, the show wraps up by exploring
the adoption of alternative materials used in
various present-day chairs.
Fancy Chair
Philadelphia, PA; unknown maker
One of the earliest chairs in the exhibit, the Fancy
Chair could easily be mistaken for a more modern
piece—an indication of how far chair design had
already progressed by the time American chair 1820
makers got to work. The chair was intended to
meet the demand of an emerging middle class
by imitating costly inlay and carving techniques
Designers as
used in Europe. By painting on wood, American ILLUSIONISTS
designers created a trompe l’oeil that was more
affordable than it appeared. In fact, 200 years
ago, the word “fancy” meant something closer
to “fantasy,” referring to things born of illusion.
30
Shaker Ladderback Rocking Chair 1840
New Lebanon, NY; unknown maker
By the mid-1800s, furniture designers in the Shaker religious Elegance
community were producing simple but elegant chairs that
are still prized today. The Shaker design philosophy is one in simplicity
of prioritization, and the main priority is to be necessary and
useful. It is thus not surprising to find that Shakers invented such
modern tools as the circular saw, the washing machine, and the
flat broom. The underlying principles of Shaker design inspired
some of the finest makers of modern furniture, and the Shaker
ladderback chairs influenced a generation of modern designers.
1857
The official arm chair of
THE HOUSE
House of Representatives Chamber Arm Chair
Philadelphia, PA; designed by Thomas Ustick Walter
Like later chair designers Frank Lloyd Wright and Frank
Gehry, the designer of the chairs used by the U.S. House of
Representatives was also an architect. In fact, Thomas Ustick
Walter is recognized for the construction of the U.S. Capitol in its
present form. He designed this Classical Style chair for the House
of Representatives in 1857, with two manufacturers producing the
262 chairs needed. The federal shield on each chair features carved
oak and olive boughs, representing strength and peace, and the legs have
deeply carved laurel leaves. President Lincoln was photographed
in one of the chairs by the Mathew Brady Studio in 1863.
McKinley Arm Chair

Grand Rapids, MI; designed by David Wolcott Kendall
Anxiety about industrialization may seem a modern concern, but it
stretches back to the 1890s. That worry gave rise to the Arts and
Crafts movement, which represented not so much a particular
style or location, but a preference for hand-crafted items made
of natural materials. One adherent, David Wolcott Kendall,
helped popularize making furniture of oak, a wood that
was plentiful but considered coarse. Kendall’s most 1894
popular armchair became known as the “McKinley A backlash to
Chair,” after it was presented to President William
McKinley. It became so popular that numerous copies
industrialization
flooded the market, forcing manufacturer Phoenix
Furniture Company to secure a patent in 1887.

Johnson Wax Chair
Grand Rapids, MI; designed by Frank Lloyd Wright
In 1936, S.C. Johnson Wax company asked 69-year-old Frank
Lloyd Wright to design its corporate headquarters. At the time,
1938
Wright was among the most renowned architects of the 20th
century. Johnson Wax asked him to design not only the
buildings and grounds, but all furniture to be used by
Furniture reflecting employees. Wright’s building design incorporated open
architecture
space, tapering columns and circular patterns to suggest
a cathedral-like effect, and incorporated some of the
architectural elements into the design of the office
chairs. They were originally to have three legs, with
two in front to encourage good posture. However,
after Wright himself fell over in one, the design was
altered to include four legs, perhaps underscoring the
old furniture making axiom “form follows function.”
1945
Molded plywood
meets mass
production
Eames Chair
Exhibition Information Grand Rapids, MI; designed by Charles and Ray Eames
The Eames Chair, one of the most famous chair
The Art of Seating: 200 Joslyn Art Museum (joslyn.org) designs of the 20th century, was the culmination of
Years of American Design is Omaha, Nebraska over a hundred years of development in using molded
organized by the Museum June 2, 2019 – September 8, 2019 plywood for chair design, starting in Germany in
of Contemporary Art, 1830. Research during the war years advanced ways
Jacksonville, Florida in LSU Museum of Art (lsumoa.org) to use resin bonding and to form bent and laminated
collaboration with the Thomas Baton Rouge, Louisiana wood. Then, in 1945, husband and wife team Charles
H. and Diane DeMell Jacobsen July 9, 2020 – September 27, 2020 and Ray Eames developed a process to bend three-
Ph.D. Foundation. Thanks to dimensional plywood, named LCW (Lounge Chair
The Michener Art Museum Georgia Museum of Art (georgiamuseum.org) Wood). The separate seat and back were cushioned
in Doylestown, PA for help in Athens, Georgia by rubber grommets. Until the Eames separated the
putting together this article. October 17, 2020 - January 3, 2021 main parts, bent plywood furniture tended to split.
32 Exhibit photos from the Jacobsen Collection of American Art by photographer Michael Koryta
High Stool
Los Angeles, CA; designed by Frank Gehry
Starting in the 1960s, alternative materials began to
appear in chair design. Frank Gehry’s minimalistic
high stool from 1971 is made from corrugated
cardboard, Masonite, and wood. Gehry moved
on to a minimalistic “Superlight” chair with
1971 brushed aluminum surfaces attached to a simple

aluminum frame designed to carry 750 pounds.
Cardboard Gehry, an architect, got into chair making
almost by accident after becoming inspired
takes a seat by qualities in the cardboard he was using to
make land contours for architectural models. He
eventually perfected 17 designs and filed a patent
for making cross-laminated cardboard into furniture.
Though his foray was successful, Gehry eventually gave
up designing chairs to focus on his architectural work.
2003
Math, music, and
Synergistic Synthesis XVII sub b1 multiple materials
Oakland, CA; designed by Kenneth Smythe
San Francisco-based designer, artist, and
scientist Kenneth Smythe went Gehry
one better in using exotic materials.
His “Synergistic Synthesis XVII sub
b1” chair is made from Finn birch
laminate, Formica ColorCore ®,
latigo leather, Sunbrella® acrylic,
top grain leather, foam rubber,
steel, and maple dowels. Smythe’s
designs are not only materially
extensive, but also often derived
from complex evolutionary models
of nature. Inspiration for this 2003
chair comes from the mathematician
and philosopher Bertrand Russell,
the music of Frederick Delius, and the
Fibonacci sequence, in which each number
is the sum of the two previous numbers.
When graphed, the sequence produces spiral
shapes, such as that of the nautilus shell. n

Modern Plywood
WORKBENCH
A simple & super-sturdy bench built from strips
By Andy Rae and the crew at Making Whole
A
truly useful woodworking bench serves a lot of
needs. It secures all kinds of workpieces for opera-
tions ranging from rough stock prep to detailed
handwork. It offers a flat planing and assembly surface,
and provides a suitable platform for a wide variety of hand
and power tool operations.
As an instructor at Making Whole (see page 4), I share
space with a bunch of fellow woodworkers, mostly nov-
ices, who’ve become enamoured by my European-style
joiner’s bench, despite the fact that we have plenty of other
benches and work surfaces. To keep what’s left of
my sanity, it was time to build a similar bench
with even better work-holding capabilities.
We designed our new bench so that it could be
built by budding woodworkers like my junior
colleagues. Thus began a collaboration of many
student hands to build a bench that would serve their
further education.
The most obvious departure from tradition is the choice
of building materials. Despite some initial reservations, I
discovered that plywood offers several noteworthy advan-
tages here over solid wood. For starters, the material cost
for this bench is less than half the price of one made from
maple or beech. You’ll also save considerable building time.
Because most of the components are made from ¾"-thick
strips, the intimidating joinery that would be involved in
solid-wood construction (big tenons, deep mortises, and 28
dog holes) becomes a simple matter of cutting and stacking
to create the joints. Aside from the expedited construction,
the biggest benefits reveal themselves when you put this
bench to work (see photos, top right).
This strip-built workbench has become the new workshop
favorite. As a matter of fact, I’m thinking that I might build
another to supplant my old bench in my corner of the shop.
Important: The 5"-thick components ensure a super-sturdy

bench, but this thickness exceeds the depth capacity of most
saws. Even with a 10"- or 12"- sliding compound miter saw,
you’ll need to cut in from both faces. If you use 71⁄4" circular
saw, you’ll need to complete the cut with a handsaw.
34
Clever features that lend a hand
A sliding board jack works in tandem with A pair of quick-release, leather-

the shoulder vise, supporting workpieces padded end vises sport wooden dogs
for a variety of edge work chores. for clamping work to the bench top.
The removable centerboard enables
workpieces to straddle one of the top’s
twin planks, while providing an additional With its pivoting jaw, the
toehold for clamps when necessary. shoulder vise can easily
clamp odd-shaped work. Not
having a guide bar (like metal
vises) makes this vise ideal
for holding wide boards.

A strip-built bench REAR PLANK
5 × 12 × 781⁄4"
Large holdfast
We used seven sheets of 3/4" × 4' × 8' LONG END CAP CENTER BLOCK
11⁄2 × 5 × 411⁄4" 5 × 12 × 6"
Blondewood plywood, sold at home
centers, but any 3/4" hardwood Threaded rod
plywood will work. Bear in mind 1
⁄2 -13 × 24"
that nominal 3/4" plywood
SHOULDER BLOCK
isn’t exactly 3/4" thick, so 5 × 12 × 71⁄2"
your assembled parts may
not precisely match the final 13⁄4"
overall dimensions shown.
The actual plywood thickness 1
⁄2"
SHOULDER VISE JAW
doesn’t matter, but take care 11⁄2 × 5 × 181⁄4"
to obtain all your sheets 10 ⁄4"
1
Bullet dowel FRONT PLANK
from the same batch. If the 1" dia. × 21⁄4" long OUTER FACING
thickness varies from one sheet to 20"
ARM BLOCK DOG BLOCK COVER
the next, the parts might not fit. 33⁄4 × 3 × 24"
The strips are easy to handle, but
the subassemblies can get quite heavy. Blind hole
Make arrangements to have a few extra 105° Rabbet 11⁄2 dia. × 21⁄2" deep
1
⁄4 × 3⁄4" 11⁄2"
hands on deck when thicknessing and
sizing the components and during UPPER LONG RAIL
assembly. Note also that the adhesive 33⁄4 × 5 × 40"
used in plywood dulls bits and blades
more quickly than solid wood. Plan
Bolt
on replacing your planer knives (and 3
⁄8 -16 × 6"
having your saw blade resharpened)
before starting your next project.
3
⁄4"
Order of Work FRONT RAIL

• Rip six sheets of plywood into 33⁄4 × 5 × 641⁄8"
strips and make dog blocks. (See detail) SHELF
⁄4 × 223⁄4 × 631⁄8"
3
GROOVE
• Build gluing platform. 1
⁄8" deep
• Cut strips to make front and rear planks,
center blocks, shoulder block, and arm
block, and assemble each component. Notes:
• Thickness-plane components to 5", • Assembled Components indicated in ORANGE.
finish, and cut to final length. • For strip dimensions, refer to the Strip Cutting Guide,
• Assemble top. available at woodcraftmagazine.com.
• Cut strips to make legs and rails,
and assemble each component.
• Thickness-plane components to 5", Vise Screw Housing Detail Dog Block Detail
cut to length, and assemble base.
Drill holes 6" in from end of vise arm.
• Add vises and end caps. ⁄4"
1
• Make and install shelf, and

Stopped hole 11⁄8" 13⁄4" 88°
set top on base.
11⁄2" dia., 11⁄4" deep 15°
• Rout rabbet in top, and
5"
make centerboard.
. • Make and install board jack. Mortise Through hole
Drill a 5⁄8" dia. hole
in one block for 88°
2 × 2 × 1⁄2" deep 11⁄8" dia.
. threaded rod.
5"
. 36 Illustrations: Christopher Mills
REAR PLANK
INNER FACING
LEATHER
BENCH DOG Add a 2° angle to faces
(See p. 18) of end vise dogs.
Rabbet
⁄4 × 1"
1
2" dia. CENTERBOARD SHORT END CAP
1 × 61⁄2 × 541⁄2" 11⁄2 × 5 × 30"
END VISE JAW

3 × 5 × 12"
Cut a 3⁄4 × 1⁄4" through dado,

then chisel a 11⁄8 × 1⁄4"
stop cut for dog head.
DOG BLOCK
(See detail)
FRONT PLANK
5 × 12 × 781⁄4" SHIM
Cut to fit LEATHER
Peg BOARD JACK
(See detail) (See detail)
Cut notches
to fit vise.
Holdfast UPPER SHORT RAIL
33⁄4 × 5 × 30"
(See detail)
UHMW plastic
⁄4 × 11⁄2 × 8"
3
Hole
onlineEXTRA
1" dia. × 11⁄4" deep Each main component
is made up of a stack
Tenon of strips. Notching and
21⁄4 × 5 × 3⁄4" drilling the strips before
assembly creates holes
and cavities for the vises,
dogs, and other hardware
more easily than cutting
Blind hole the joinery later. Go to
11⁄2 dia. × 31⁄4" deep woodcraftmagazine.com
for a complete Strip Cutting
Board Jack Detail MID RAIL Diagram used to make
33⁄4 × 5 × 30"
the top, base, and vises.
⁄16"
7 13⁄4" Tenon
21⁄4 × 5 × 5"
2"
1113 ⁄16"
3
⁄4"-dia. hole LEG
33⁄4 × 5 × 31"
Upper Short Rail Detail (Front Plank End)
Notch for Rear Plank End Vise starts 51⁄2" in from end of rail.
12 ⁄16"
11
51⁄2" Lay out vise notches after dry-assembling the side.
33⁄4" 53⁄4"
1
⁄2"
61⁄2" 11⁄4"
1 ⁄4"
1
Peg Detail
⁄16"
3
11⁄2"
⁄8"
7
⁄4"
3
4"
8"
Prep the parts
The workbench starts as a stack of strips. Have
a shopmate help you rip six sheets of plywood
into 51/8"-wide strips. From one of the strips,
cut the dog blocks to length, and then saw the
dog head notches on the table saw as shown.
Referring to the drawing on p. 36 and the Strip
Cutting Diagram (see onlineExtras), cut the
strips needed to make the twin planks, center
blocks, shoulder block, and arm block.
Although glue is strong enough to join
most of the main components, the shoulder
vise requires additional reinforcement. To
prepare the front plank components for Strips from the sheet. You’ll get nine strips
the 1/2"-dia. threaded rod, drill the holes from a single 4 × 8' sheet of plywood. To
in its 13 inner strips, two facings, and ensure clean-edged strips, trim away the factory
dog block cover strip, as shown. (Drill the edge before ripping the strips to width.
holes in the arm block after assembly.)
Assemble the top

Gluing the strips together isn’t difficult
if you have an assembly jig like the
one we made for this project. You can
assemble each section in stages, and
use brads or pins to keep smaller parts
in alignment until you apply clamping
pressure. To ensure that the clamps
exert even pressure, use removable
plywood spacers to fill in any cavities,
masking or waxing them to resist glue. Rear half of rear plank
(upside-down)
Assemble the two planks,
shoulder block, and center blocks. Spacer block fills
end vise recess.
For safe machining, make the (Masked on underside
center blocks from a single, to resist glue.)
longer glue-up. After planing
this workpiece to final thickness,
crosscut the assembly in two.
Once the individual top
components have been glued together,
Trim to
plane them to 5" thick. If you plan length after
to seal the top with epoxy (see glue-up
Sidebar, p. 41), do that next, before
cutting the components to length.
After cutting the parts to
final length, glue the planks to Glue up the planks in stages. Stack a half-plank’s worth of strips upside down in the
the center blocks. Work on a assembly jig, with glue-resistant plywood spacers filling any cavities. After rehearsing
flat surface to keep the sections your assembly procedures, apply adhesive with a thin-nap paint roller to the strips,
aligned as you apply the clamps. and clamp them to the jig. Wipe or scrape off the wet excess glue immediately.
38
Arrow
indicates
orientaton.
Top edge
15° Stop block
Top
Angled stop for dog edge
Make 26 dog blocks. Set the blade to 15°, stand the dog block with its inner edge Ready the top strips for the rod. An L-shaped
against the fence and cut the angle for the notch. Then, flip and rotate the block stop block ensures that the access holes in
90° and make the long notch cut by first removing a saw kerf of material (inset, top) the strips used to make the front plank line up
and then butting the block against the fence to complete the cut (inset, bottom). for the threaded rod. Lay out and drill a hole
in one dog block using the same drill bit.
Assembly Jig
The jig helps keep assemblies flat and square. Build the platform from a 4 × 8'
ANGLED SUPPORT BLOCK SHORT FENCE sheet of 3⁄4" melamine-coated particleboard (MCP), which is flat and wood
3
⁄4 × 43⁄8 × 5" ⁄4 × 51⁄8 × 24"
3
glue-resistant. Make sure to assemble the fences so that they sit at 90° to the
base. After assembly, set up the jig on a flat surface (a floor will work if you use
shims to level the area), and raise the base on blocks for clamp access.
12"
SHORT BASE
3
⁄4 × 5 × 24" LONG FENCE
3
⁄4 × 51⁄8 × 84" SUPPORT BLOCK
3
⁄4 × 43⁄8 × 7"
CLAMPING CAUL
3
⁄4 × 51⁄8 × 84"
LONG BASE
3
⁄4 × 7 × 84"
Assemble the shoulder in MOVABLE BASE

stages. Glue together the wide
3
⁄4 × 18 × 96"
and narrow strips (shown)
separately, and then join
the two halves. Set a waxed
plywood spacer in the rod slot
Spacer for
rod slot to equalize clamping pressure.
Clamping caul
Project Photos: Andy Rae Aug/Sept 2019 | woodcraftmagazine.com 39

Plane the planks, then glue up the top
End vise
recess
Shoulder Spacer leg

block
Down to size. When planing

the bench top sections, take
light, equal cuts from each
face in turn to ultimately
create 5"-thick sections.
Install a spacer ‘leg’ in the
shoulder block slot to stabilize
the work for the cut.
Make the base Base Alignment Blocks

Assembling the legs and rails for the These alignment 1
⁄4" Chamfer
base takes the same “cut, stack, and glue” blocks serve as
approach used for the top, but you’ll need stand-ins for the rails
a way to establish the mortises and tenons. and legs, ensuring
To accomplish this, we made a set of five that the parts fit
alignment blocks, as shown at right. together immediately
To make the base components, first cut the after assembly. The
parts to the sizes shown in the Strip Cutting chamfers on the inner
2" Screw ×1
Diagram, adding a few inches in length. Then layers allow you to
arrange the strips on the gluing platform, inserting make sure that the
the appropriate spacer(s). Apply light clamping ends of all the strips
pressure, tap the ends of the parts to snug them are in contact with LONG BLOCK SHORT BLOCK
against the blocks, and then tighten the clamps. the block as you apply
3
⁄4 × 5 × 6" 3
⁄4 × 5 × 5"
Remove the blocks and allow the glue to dry. clamping pressure.
Once you’ve assembled the legs and rails, plane
and cut to length as before. Then drill the holes in
the legs and the blind holes in the front and back 1"
rails for the bolts. Next, dry-assemble the mid
and upper rails into the legs, and then lay out
and cut the notches for the end vises in the upper
×1 ×1 ×2
short rail as shown on page 37. (Note that the
notches extend into the legs.) Now, glue up the
side assemblies as shown. Finally, insert the front
and back rails, and drill the 7/8" holes for the bolts.
40
A little extra work for a smooth, hard top
Rear Masked plugs

plank
Front
plank Center
blocks
Shoulder
block
Front
plank Arm
block
Board Jack slot

Most types of plywood have small voids between the veneer layers. For a solid,
seamless work surface, treat the benchtop to polyester body filler (like Bondo)
followed by a coat of epoxy. Begin by adding dyes (see page 69) to the filler to
match the tone of the plywood, and note your recipe proportions. Then, working with
small batches, apply the filler with a wide putty knife. Once the filler sets, plane the
Joining the planks. To create the main body of the parts at the same machine setting as before. Then use a card squeegee to apply
bench top, glue the fully assembled planks to the a thin coat of epoxy, let it cure overnight, and plane, again at the same setting.
center blocks, which you have cleanly cut to length.
Alignment
blocks
Clamp cauls Notches for end vises
End game. Glue up the end assemblies, using a hefty block to pound the
joints home and clamping over the open bridle joints with cauls to spread
pressure evenly. Check for square before setting the assembly aside to dry.
Blind bolt-and-nut joint.

7
⁄16" bit Dry-fit the long rails into the
Trim excess
after glue-up. end assemblies and drill the
11⁄2" dia. counterbores. Then drill the
blind hole clearance holes partway,
Block-made mortises. Assemble the legs and rails using remove the end assemblies,
alignment blocks at each mortise location before tightening and continue drilling until the
the clamps. Remove the blocks once the clamps are on. bit reaches the blind hole.

Vises and finishing touches
A bona-fide bench is starting to emerge. Dry-fit the shoulder
vise parts and check that the threaded rod has access through
to the center block. Next, drill and rout the arm block to accept
the vise screw and housing plate, and then glue and clamp the
shoulder and arm blocks to the bench. Once the glue has set,
add the threaded rod and cinch it tight with nuts and washers. 11⁄2" stopped hole
Next, attach the end vises to the top, and then glue on the 11⁄4" deep
short and long end caps. Make the end vise jaws, cutting the
two-step groove in each jaw part with a router and straight 11⁄8" through hole
bit on the router table, or with a stacked dado blade on the
table saw. Chisel the angled stops for the dogs at the base
of the stepped groove before gluing the parts together.
Now, rout the rabbeted ledge in the center of the bench
top, and then make the centerboard to fit. Next, drill holdfast 1
⁄2"-deep mortise
Inside face
holes in the top, using a shop-made drilling guide. of arm
The heavy top registers onto the base via a pair of
short “bullet” dowels. To ensure matching holes, create Screw housing
a drilling guide from a plywood strip. Use the jig to drill
mating holes in the upper rails and top, then insert the
dowels and set the top on the base. Now make a board
jack as shown on p. 37. After turning a board jack peg Install the vise screw housing. After drilling a stopped hole
and vise handle from rosewood or other dense wood and for the shoulder vise screw housing and a through hole for the
attaching a power strip, the bench is ready to work. screw, rout a mortise and then square the corners with a chisel.
Cut a center ledge. Rout a 1⁄4 × Guide your holdfast holes. Drill a 15⁄16" hole in
1"-deep rabbet around the perimeter a scrap block on the drill press, and then use
of the interior for the centerboard the block and the same bit to drill perpendicular
using a bearing guided rabbeting holes part way through the bench top for a large
bit, taking two or three successively holdfast. Remove the block and finish drilling
deeper passes. An oversized through the top by hand, clamping a board to
baseplate steadies the cut. the bench’s underside to prevent blowout.
42
Keep it flat. Glue and clamp
the shoulder and arm blocks
to the bench, checking that
both components are level
with the bench top.
Set the vise height. Install a couple shims

under each inverted end vise to locate the fixed
jaw about 9⁄16" from the top surface of the bench.
Then secure each vise with four lag screws.
Shoulder block
Arm block
Clamp on the cap. Glue the short end cap over the vises’ fixed
jaws, using a single clamp and the vises themselves fitted with
scrap plywood to clamp the cap tight to the end of the bench.
Bullet dowel
Aiming for a bullet. Make a drilling guide by boring a

1"-dia. hole in a board with a Forstner bit on the drill
press. Clamp the guide flush with the front of the end
assembly and use the guide and the same bit to drill a
11⁄4"-deep hole for the bullet dowel. Use the guide again
to drill the hole in the other end assembly, and two
matching holes in the top’s underside. Insert the dowels
in the base, and then then lower the top in place. n

Inset PULLS
Four shop-made handles that lay low
By Andy Rae
W
hat do you do
when a typical
cabinet handle
or knob doesn’t suit an
application because, for
example, its projection
prevents an adjacent
door or drawer from
opening fully? Another
challenge arises when
trying to suit pulls to a
pocket door or perhaps
shoji-style panels that
slide past one another.
In that case, projecting
hardware impedes door
travel. But you still need
some way to grab the
door to pull it sideways.
And there are times
when you just want
a simple unobtrusive
look and feel to your
hardware. An inset, or
flush, pull can solve all
these problems.
In this article, I’ll
share with you four
cleverly made inset
pulls: two by a couple
of fellow furniture
makers, and two of
my own design. You’ll
find that they’re not
hard to make using
some smart shop-made
jigs to ensure repeat-
able accuracy. Best yet,
they will let you adorn
doors and drawers with
handmade pulls that
whisper “cool.”
44
Bisected pull
Architect and designer Ric Hanisch’s brass-and-wood
pull offers a pleasing grasp for doors or drawers, and
works well along the edge of a sliding or pocket door
as long as the surface area is 21/2" or wider. Because the
Forstner bit used to drill the blind hole leaves a divot,
a circle of walnut veneer is glued to the hole bottom, Brass divide. This bisected pull works equally well
which hides the divot and creates a nice visual contrast. on drawer fronts and doors with wide stiles.
Epoxying a strip of wood to the backside of the brass
bar also dresses things up both visually and tactilely. Stopped flat. With
the work clamped
to the drill press
Brass bar Walnut
1
⁄8 × 1⁄2 × 3" ⁄8 × 1⁄2 × 2"
1 table and a 2"-dia.
Forstner-style bit
located above
⁄8" R
1
Walnut veneer the center line,
2" dia. bore the 5⁄8"-deep
blind hole.
Blind hole
2" dia. × 5⁄8" D Bar recess
1
⁄2 × 1⁄8" D
Tape protects
against compass Line the bottom.
point damage.
Lay out a circle on
Centerline 1
⁄32"-thick veneer,
and cut it out with
scissors, removing
3" triangular sections
Bit centerpoint divot at a time to
avoid splintering.
Then glue and
clamp or weight,
using a caul.
Screw, then trace. Center the brass bar over the hole, A nice touch. Scuff-sand the back of the brass bar,
screw it to the surface, and trace its outline with a knife. spread 5-minute epoxy onto it, and clamp a
Then chisel out the recess so the bar sits flush. 1
⁄8 × 1⁄2 × 2" strip of wood to its rear surface.
Opening photos: Andy Rae and Paul Anthony; Project photos: Andy Rae; Illustrations: John Hartman woodcraftmagazine.com 45
Narrow pull
Paul Anthony’s three-door liquor
cabinet presented a challenge in
that a projecting pull on a side
door would prevent the center door
from fully folding back against
the front of the case. His solution
was this sleek, slim, recessed
pull that can be used on narrow
frames as well as drawer fronts.
A shallow pocket cut in the face
of the stile leaves space for fingers,
while a 1/8"-thick brass bar (see
Buyer’s Guide, p. 69) inset atop the
pocket provides grip for pulling
the door outward. Construction is
straightforward, but careful layout of
the centerlines is key. Two shop-made
jigs guide a plunge router outfitted Slim design. This pull fits
with a guide bushing and a straight narrow frames while offering
bit to cut the pocket and bar recess. a brass touch of class.
Pocket
Bar recess
centerline
Rout the bar recess. Align the bar Stop that chamfer. Set a bearing-guided
recess jig with the layout lines on chamfer bit for a 3⁄16"-wide cut, and then
the stile, reset the bit, and rout the rout a bevel around the three walls of the
3
⁄32"-deep recess for the brass bar. pocket, being careful to stop at each edge
Chisel the ends square afterward. of the bar recess to avoid beveling this area.
46
⁄8" upcut
3
spiral bit
Door stile
3
⁄4"-thick
1
⁄2" guide Pocket 111⁄16"
bushing centerline min.
Bar recess
centerline
Panel groove Door panel
Pocket Stop chamfer
centerline at bar recess.
Pull height Pocket

centerline 15⁄16 × 31⁄8 × 5⁄8" D 7
⁄16" offset
allows for
3
⁄8"-deep
Pull height panel groove. 1
⁄4"
centerline
Drill and
countersink
for screws
Bar recess
3
⁄32 × 3⁄8 × 4"
Brass bar
1
⁄8 × 3⁄8 × 4"
Pocket-cutting setup. With centerlines laid out on both 3
⁄16"-wide
the template and door stile, set your router bit depth to chamfer Ease top edges
5
⁄8" plus the jig thickness. Then clamp the jig atop the and finger-
contact area.
door with the centerlines aligned, and rout the pocket.
Pocket jig
Panel
1
⁄2 × 4 × 16" Align centerlines with
layout lines on door.
31⁄4"
Spacer
1
⁄2 × 15⁄16"
Bar recess jig

Panel
1
⁄2 × 4 × 16"
Centerlines
41⁄8"
Slightly proud. Lightly ease the upper
edges of the brass bar using 400- and then
600-grit carborundum paper before screwing
the bar into its recess. It should project Spacer
about 1⁄32" above the surface of the door. 1
⁄2 × 1⁄2"

Notched pull
My own version of an inset pull works
well whenever you want to locate a pull
on the edge of a door or drawer. When
made in pairs to suit the juncture of
two doors or drawers, the effect can be
strikingly reminiscent of mid-century
modern design. The pull is essentially
an L-shaped recess that includes a
mortised cavity that allows fingertip
access for pulling the door outward. On the edge. This notched pull
offers easy finger access from the
edge of the door. Paired pulls display
a rectangular design motif (above).
Panel
1
⁄2 × 6 × 18"
Pull location
centerlines
13
⁄16" 5
⁄8" O.D. guide
bushing and
1
⁄2" straight bit
31⁄4"
Pull location
centerlines
3
⁄4"
5
⁄8"
31⁄8"
Mortise Notch first. To set up for the cut, outfit a

1
⁄2 × 31⁄8 × 3⁄4" D plunge router as shown, and clamp the jig to
the workpiece with the centerlines aligned.
Then rout the 5⁄8"-deep notch (inset).
1
⁄2" upcut
spiral bit
Mortise second. Adjust a router edge guide to locate Smooth for the hand. Use a chisel and fine
the bit perimeter flush to the bottom of the notch, and sandpaper to smooth any irregularities left by routing
then rout the 3⁄4"-deep mortise in 1⁄4" increments. and to soften all sharp edges for a nice touch.
48
Pivot pull
Here’s a cool pull for sliding doors
or a pocket door. Essentially a 7
⁄8"
wooden lever recessed into the Wooden
button
edge of the door, it sits demurely
in waiting until a gentle push
of the finger pivots it outward Round
for grabbing. I make the lever over
top of
from figured wood for a “wow” button.
factor, and inlay a raised button Hidden
of contrasting wood to serve handle
as a fingertip target. A bamboo
skewer from the supermarket
serves as a pivot pin. n
Push n’ pull. This pivoting pull consists of a wooden lever
fitted inside a mortise and hinged on a bamboo pin. Push
the “button” with a finger, and out pops the pull.
Depth stop set

1 square= 1⁄8" for 11⁄8"-deep cut
1⁄8"-dia. 15°
through-hole
for pivot pin.
⁄2"
1
Drill 1⁄4"-dia. ⁄8" hollow
11⁄2" 3
hole for plug. chisel
Glue 1⁄4" dia. × 1⁄4"

end-grain button
into counterbore.
1⁄8"-dia.
bamboo Lever
pivot pin 3⁄8 × 13⁄16 × 4" Drill and chisel. Using a hollow-chisel mortiser,
Mortise
3⁄
8 × 4 × 1 ⁄8" D
1
plunge the ends first, then remove the remaining
material with a series of overlapping cuts.
Angle one end. Set a bevel gauge to 15° as Pin drilling. Clamp the shaped, sanded lever in its mortise with its edge 1⁄16" proud
a visual aid, and use a stout chisel to chop and parallel to the stile edge. Drill a 1⁄8"-dia. hole through both, insert the pin, and test
an angle in the top end of the mortise. the fit. Fix any binding by increasing the mortise angle or easing the top of the lever.

A Box-Maker’s
SLED
Precise crosscut and mitering
capability make this table
saw jig twice as nice
By Matt Kenney
I
enjoy making small boxes. Coming up with different designs is just as
challenging as the actual construction work. One thing that doesn’t
change is the requirement for precise cuts. A tiny gap may not be an
issue in a large project, but it can be painfully noticeable in a small box.
I rely on this table saw sled for making perfectly square and mitered cuts
in small parts. The sled has a single runner that can be used in both table
grooves. In one groove, you’re cutting at 90°. In the other, you make 45°
bevel cuts. In both applications, the jig’s base and fence provide zero
clearance with the saw blade. In addition to reducing tearout, this feature
makes it easier to align precise cuts.
My table saw has a right-tilting blade. If your saw’s blade tilts left,
you’ll need to relocate the runner to slide in the saw’s left groove when Two cuts, done right. With its runner in my saw’s
making the first cut. Be sure to make the initial 90° and 45° cuts in right-hand table groove, the jig makes an exact 90°
your jig with the same sharp, finish-cutting blade you’ll have in the crosscut. Repositioning the jig so the runner slides in the
saw when putting the jig to use. left-handgroove sets me up for a 45° bevel cut (inset).
Photos: Randy O’ Rourke; Illustration: Greg Maxson Aug/Sept 2019 | woodcraftmagazine.com 51

Start with a base, then add rails, runner, and fence
When making your jig, use dead-flat The runner’s location on the underside of
plywood, and make sure to mill your the base depends on the distance between
rail and fence stock straight and square. your saw table grooves and the blade.
This jig will work just as well if made Position it to extend the base an inch or so
smaller, but a larger size might put too beyond the blade for your first 45° miter
much torque on the single runner. cut (see bottom photo, facing page).
The fence that I’m using here is quite You’re supposed to attach the Miter
a bit longer than you need for cutting Slider with machine screws that are
small parts. The extra length makes the installed through the top of the base.
sled more versatile by enabling me to But I’ve found that it’s easier and no less
cut longer parts to uniform length. effective to mount the bar by driving pan-
The runner for this jig is an 18"-long head screws through the mounting holes Flat head screw
Miter Slider from Incra (see Buyer’s Guide, and into the underside of the base. #8 × 11⁄2"
p. 69). Like other aftermarket runners, Zero-clearance kerf
this one can be adjusted to slide easily
but without slop in the table groove. Adjustment
screw
Make sure base

extends far enough
for miter cut.
Begin with the bar. With this adjustable Miter

Slider bar, you fine-tune the fit by turning a pair of
screws with an Allen wrench. Make sure your bar
slides smoothly, and without any side-to-side slop.
Attach the runner. Glue the front and rear rails to the plywood
base, then attach the bar with #6 × 3⁄4" pan screws.
FRONT RAIL
Position the bar with enough material on one side so
that the saw blade can create the mitered edge.
Insert wood
strip in kerf.
Make the first

cut. Raise the
blade no more
than 11⁄2" above
the table for this
initial cut. (With
a right-tilting
blade, the sled’s
runner should
be in the right-
hand groove.)
52
FRONT RAIL
1 × 13⁄4 × 22"
FENCE
1 × 13⁄4 × 30"
BASE
3
⁄4 × 18 × 25"
(before miter cut)
Position fence 3⁄4" - 1"

ahead of front rail.
Zero-clearance kerf
REAR RAIL
1 × 13⁄4 × 22"
NOTE: Replace the fence if the zero-clearance kerfs

become inaccurate due to long-term use or a blade
change. Alternately, you can attach a strip of wood to
the old fence and make two new zero-clearance cuts.
MITER BAR
Pan head screw ⁄8 × 3⁄4 × 18"
3
#6 × 3⁄4"
Install the fence. Insert a

snug-fitting strip of wood
in the kerf, then register a
drafting triangle against the
strip and the fence while
clamping the fence in place.
Here I’ve clamped both ends
of the fence to the base.
Once the fence is clamped,
flip the jig over, and secure
the fence with a screw near
each end. Make a test cut in
some straight-edged stock
Drafting to confirm that the fence
triangle is square to the blade, and Make the miter cut. Raise the blade about
fine-tune the fence angle 11⁄2" above the table and tilt it to exactly 45°
FENCE if necessary. When you’ve to make this cut. When you’re done, you’ll
got it right, anchor the fence have a zero-clearance edge in the base,
by driving two screws on and a zero-clearance kerf in the fence. It’s
each side of the kerf. time to make some boxes (See p. 24). n

Famous Furniture
ShakerCANDLE STAND
By David Heim
T he Shakers have been a presence in

the U.S. since 1774, when the first
nine Believers in this religious sect emi-
piece of furniture illustrates the Shaker
union of grace and form better” than the
round stand shown here. It’s Becksvoort’s
The bottom end of the post is ever so slightly
narrower than the curved section, creating
a thin shoulder for the legs to rest against.
grated from England. Industrious and faithful reproduction of an original made The top edge of the leg follows an S-curve
always striving for perfection, the Shakers in about 1850, most likely at the Shaker that blends smoothly into the curve of the
believed that work was a form of worship. community of Mount Lebanon, New York. post. The already-thin top has a bullnose
They made things that were practical, effi- Similar stands can be seen on display at profile that makes it appear even thinner.
cient, and beautiful. the Hancock Shaker Village museum, in On the underside of the top, a crosspiece
By the 1850s, in their so-called Classic western Massachusetts. adds stiffness and is drilled at its center to
Period, Shaker woodworkers had attained Today, we’d call a piece like this an occa- hold a round tenon turned on the top of
high levels of skill and perfected their sional table or an end table. At first glance, the post. Typical of the subtle detailing that
unique designs. Christian Becksvoort, the stand seems very simple: curved legs characterizes many Shaker pieces, the ends
Simplicity, unity, and functionalism

merged to form outright works of art.
author of The Shaker Legacy (Taunton) and fit into a turned post with a round top of the crosspiece are curved, and broad
Shaker Inspiration (Lost Art Press), offers attached. But as you look more closely, chamfers disguise the piece’s thickness.
this summary: “The concepts of simplicity, small but important details emerge. The The candle stand’s cleverest feature isn’t
unity, and functionalism merged to form legs (known as spider legs) are not just cutout apparent until you turn the piece upside-
outright works of art.” He adds: “No single shapes; they taper gently along their length. down. That’s when you’ll discover the join-
Leg-to-post joinery
fastFACTS Top of leg rounded Legs butt against
• Shaker artisans were skilled to complement shoulder on post.
innovators. Among their many enduring curve of post.
inventions: the circular saw, devised
in 1810 by Sister Tabitha Babbitt.
• Prior to the Civil War, the Shakers
had as many as 4,000 followers.
Today, only two remain.
• Decades before architect Louis Sullivan
wrote that “form ever follows function,”
the Shakers followed a similar rule:
“All work done...ought to be faithfully
and well done, but plain and without
superfluity. All things ought to be made
according to their order and use.”
• Today, Shaker life and lore are preserved
at eleven different museums, spread Flat areas on each
side of socket support
out from Maine to Kentucky. dovetail shoulders.
56
ery detail that makes
this piece as strong as
it is beautiful (see drawing).
Each leg has a long dovetail that slides
into a matching socket cut in the base of
Bullnose profile softens
the post. Small flats cut on each side of edge and makes top
the socket provide a firm resting place appear thinner.
for the dovetail shoulders. These sliding
dovetail joints terminate at a shoulder on
the post that creates a subtle shadow line
while also strengthening the leg-to-post Post broadens at
top to form shoulder
connection. It’s impressive joinery work, surrounding round tenon.
hidden from view.
The stand shown here is made from
cherry, but the Shakers were happy to
use any wood that was readily available Curve at top of leg
and easy to cut and carve. Their favorites blends smoothly
included pine, birch, cherry, maple, ash, into shape of post.
and walnut. While built-in cabinetry and
case pieces were often painted, furniture
like this stand was typically finished with
varnish or shellac. n
Dovetail joint anchors

Faithful reproduction. leg securely to post.
This stand is Christian Becksvoort’s (See drawing at left.)
reproduction of a Shaker original.
You can see similar stands at
the Hancock Shaker Village, in
Massachusetts. Like the original, Legs taper along
this is made of cherry. It’s their length.
25" high, 18" in diameter.
Photo:Dennis Griggs, courtesy Christian Becksvoort; Illustration: Dan Thornton Aug/Sept 2019 | woodcraftmagazine.com 57
WoodSense
VERTICAL GRAIN
DOUGLAS-FIR
Quartersawn
Light, strong, and pin-striped Loose grain
By Ken Burton
D ouglas-fir is one of the United States’

most plentiful softwoods. Due to its
excellent strength-to-weight ratio, it has
Where the wood comes from Selecting the best stock
In truth, Doug-Fir, Pseudotsuga menzie-
sii, isn’t a fir, at all. It’s genus (Pseudotsuga)
Unlike many of the exotic species dis-
cussed in previous WoodSense columns,
long been the go-to species for carpentry translates to “false hemlock.” Doug-Fir CVG Douglas-fir can be found at big box
and construction projects. Construction forests grow in the Pacific Northwest and hardware stores, although the sales staff
2×4s designated as SPF (spruce, pine, up into British Columbia. Mature trees may not know exactly what you’re asking
fir)—are often Douglas-fir. But before can be 200 feet tall and 6 feet in diameter. for. My local place, stocks what they refer
you dismiss this species as simply fodder The dense stands in which they grow to as “tongue and groove fir flooring”
for framing walls and floors, take a closer cause the trees to self-prune, yielding (above, right) in the aisle with the pre-
look at the photos and the title of the straight-grained logs free of knots. As of mium quality pine boards. While not all
article. We’re talking about CVG (Clear, this writing, the plentiful Douglas-fir is the pieces in the bin are vertical grain, you
Vertical Grain) Douglas-fir; boards that considered far from endangered. can usually sort through and find those
are more processed and quarter-sawn— that are. This material is meant to be used
cut so the growth rings are relatively per- History in woodworking for porch flooring and has a groove on
pendicular to board faces. Ever since the Oregon Trail opened up one edge and a tongue on the other, so
the Northwest to settlement, Douglas- you’ll waste a little of it if you just want
fir has been valued as a prime building square-edged boards. These 1×4 pieces
material. Architects, carpenters, and cab- sell for about $6/board foot. You can also
inetmakers have long valued the wood find the wood online. CVG Doug-fir is
for its stability and uniform appearance, quite uniform in appearance, so, seeing
and have used it for doors, window
sashes, paneling, trim, and cabinetry. Vertical Grain
Douglas-Fir Quick Take
DENSITY 32 lbs./cu. ft.
Medium (hard as far
HARDNESS
as softwoods go)
STABILITY Very Good
ROT/INSECT
Moderate
RESISTANCE
TEXTURE Coarse
Low. Although rare,
skin and nose irritation
TOXICITY
and nausea have
From dawn to dusk. been reported.
While pinkish-red when Doors, window frames,
freshly cut, CVG (Clear, Vertical paneling, flooring,
USES
Grain) Douglas-fir ages to a beautiful, cabinetry, furniture,
warm reddish-brown with darker stripes. boxes, plywood
58
Riftsawn Right angle grain.
With true vertical
grain (quartersawn), the
growth rings are oriented at
Earlywood 90° to 60° to the face. The rings
Tight grain Latewood on riftsawn board are at 30° to 60°.
before buying isn’t as important as

when buying lumber with prominent
CVG Douglas-Fir in the shop
figure. But do note whether the grain My most recent experience with CVG
is described as “tight” or “loose.” The Douglas-fir came in the residential
tighter the grain, the closer together construction class I teach as one of
the growth rings are, creating a more the Technology Education electives
uniform texture and making it easier to available to my high school students.
work. With some old-growth lumber, (There are still a few of us teaching
the ring spacing can be 1/16" or less. “shop” in America’s public schools.)
As part of a renovation project,
Working CVG Douglas-fir our gym was updated with ADA-
Doug-fir is one of the harder softwoods compliant seating. I convinced the
on the market and features a distinct dif- demo crew to save me the lumber
ference in the hardness of the earlywood from the old bleachers—most of it
(the lighter colored areas) and the late- CVG Doug-fir. Those boards were
wood (the darker stripes). You’ll feel this just as flat, straight, and sturdy as
distinctly when bandsawing across the when they were installed over 50 years students another use of the bandsaw), I
grain. The harder areas can also cause ago, though with more chewing gum. installed a fresh blade and sliced one piece
small drill bits to drift off course. The With my lumber rack overflowing, I set into some veneer. Just like the resawn
wood can splinter easily, and is tough to about designing a project my students pieces, the veneers stayed perfectly flat.
work with hand tools. Folded sandpa- could tackle that would teach valuable The students learned the importance
per can slip beneath a splinter, angling woodworking lessons and utilize this of grain direction when edge jointing.
it right into your finger. Do yourself a beautiful reclaimed wood. We built a version Doug-fir’s flatsawn edges tore badly when
favor and use a sanding block. of the tool tote (shown here). I also wanted run against the grain. Given the board’s
The wood machines well, but use them to have a bit of school history to take uniform face grain, ascertaining proper
very sharp cutters, and employ backer home (although I doubt that will matter orientation for jointer feeding was tricky. It
blocks when crosscutting to minimize much to them until they get a little older). was essentially a coin toss to decide which
exit tearout. Climb-cutting when rout- The fir was harder and more prone way to first run the board over the jointer.
ing profiles greatly reduces splintering. to splintering than the pine the students I also found using fresh router bits
The wood glues without a problem and were used to working. They also learned made a big difference in how cleanly the
holds both nails and screws well, but the value of drilling pilot holes before boards cut. While cherry can be routed
drill pilot holes to prevent splitting. nailing through the thin sides and of with a bit that has lost some sharpness
using a backup board when crosscutting. (albeit with some burning), Doug-fir
Finishing (Or crosscussing, as they named it). splinters badly when using dull cutters.
Doug-fir has a warm, reddish-brown I was impressed with the wood’s I’m pleased with the results and
hue that deepens with age. It accepts stability. When I resawed the pieces for look forward to using the rest of my
stains readily and can be finished the sides of the tool tote, I expected the stash with next year’s class. And I’m
with any number of different top- pieces to cup and bow, but they stayed planning a project to use the T&G pieces
coats, but soaks up oil. flat. Out of curiosity (and to show the I picked up from the home center. n
Photos: Ken Burton Aug/Sept 2019 | woodcraftmagazine.com 59

Great Gear
Joinery finesse
When I first started to get serious about
woodworking, one of the first good-quality
tools I purchased was a Stanley #92 shoulder
plane. Now, more than thirty years later, I
still use it almost every time I’m in the shop.
The plane offers finesse not easily found in
machines; it’s indispensable for trimming
tenons, tweaking rabbets, and cleaning up
dadoes. A few years ago, Stanley updated
the design of the tool to make it look more
streamlined. I bought one of these new
models for the facility where I teach evening
classes. I was pleased to discover that the
new model works just as well as the original.
With a sharp blade, the #92 makes a dramatic
difference in how easy it is to make the
precise cuts necessary for solid joinery. Stanley #92 Shoulder Plane
—Ken Burton homedepot.com, $78.27 Prices subject to change without notice.
60 Plane photo: Ken Burton

Great Gear
Capable and quiet

The Air Buddy AB5 is the lightest and quietest
compressor I’ve ever used. Thanks to its light
weight (under 25lbs) and protective roll-
cage design, the tool is comfortable to carry
and reassuringly stable in use. Whether I’m
assembling a jig in the shop, pumping up my
car’s tires in the garage, or installing trim in the
house, the AB5 goes where it’s needed. With a
1/2 HP-motor providing .7 CFM at 90 PSI, this
handsome little guy is never underpowered
for any task I throw at it. And man is it quiet.
At 68 decibels, I can stand right beside the
running unit and hold a normal conversation
without raising my voice. The 1 gal. tank might
cycle on a few times during use, but I barely
notice. Quick, quiet, compact, capable, cost-
effective - clearly one of my favorite tools. Rolair Air Buddy AB5
—Chad McClung n #160167, about $170 Prices subject to change without notice.
62 Compressor photo: Doug Loyer

Expert Answers Ken Burton
woodworking teacher
and author
Avoiding splits with wedged tenons
I was making It’s a good bet that the split in your seat Take care to size your wedges properly. I make
a three-legged was caused by orienting a leg tenon slot all the wedges for a seat from a single strip of wood
stool with round parallel to the seat’s grain, rather than as wide as the tenon’s diameter and long enough for
through-tenons attaching perpendicular to the grain. Consider the difference all the wedges you need plus about 6". Resaw the
the legs to the seat. between driving a chisel with the grain in a board, piece so its thickness is about twice the width of the
When I drove a wedge and driving it into the wood at a right angle to slot (typically a heavy 1⁄8"). Taper both faces on both
into one of the slotted the grain. It’s a similar principle here; wedging ends of the strip using your disk sander, going from a
tenons, the seat split. I slots in through tenons should always be oriented near-knife edge to full thickness at a point along the
was able to repair it, but perpendicular to the grain, as shown in the drawing. strip equal to the length of the tenon. This will yield two
I don’t want to risk more There are a few other details that deserve close wedges. Cut them off and repeat until you have enough
damage. How do I get a attention when installing through-tenons in seats, wedges for all your joints. Apply glue to the tenons and
tight wedged joint without benches, and stools. For starters, make your tenons slip the legs in place with the slot perpendicular to the
splitting the seat again? 1
⁄8" – 1⁄4" longer than the seat thickness. Drill a grain. Then apply glue to the wedges and tap them
3
⁄16"-dia. hole through the tenon where the slot will home. A wooden mallet is less likely to split wedges
end—usually 1⁄8" – 1⁄4" from the tenon’s shoulder. than a metal hammer. Drive the wedge until moderate
Then cut the slot (I use the band saw) from the tenon hammer blows no longer advance it. When the glue
Carl Benson end to the drilled hole. The hole helps to dissipate the dries, cut off the protruding tenon and wedge with
Casper, Wyoming wedging action and keeps the leg from splitting. a flush-cut saw and sand everything smooth. n
64
2× slot
width Have a tough woodworking question?
Tenon dia.
Ask an
Tenon length WEDGE
EXPERT
Orient leg with slot
perpendicular to
seat’s grain direction.
We’ll do our best to find the expert

and provide the answer.
SEAT
Email us at editor@woodcraftmagazine.com,
and put “EXPERT ANSWERS” in the subject line.
Make tenon 1⁄8"- -Or-
LEG TENON 1
⁄4" longer than Mail your query to:
seat thickness. EXPERT ANSWERS
Woodcraft Magazine
SHOULDER Drill 3⁄16"-dia. hole P.O. Box 7020
at 1⁄8"-1⁄4" from Parkersburg, WV 26102-7020
shoulder tenon
Illustration: Trevor Johnston Aug/Sept 2019 | woodcraftmagazine.com 65

The Market
Advertise in
THE MARKET
68
Buyer’s Guide
Hot New Tools (p. 16) 7. WoodRiver 9" Quick Release Vise (2 needed) ................................... #162795, $149.99
1. Clifton Low Angle Block Plane .......................................................... #166429, $374.99 8. 3

⁄8 × 3" Hex Lag Screw (8 needed) ......................................................lowes.com, $0.67
2. Clifton #4 ⁄2 Smoothing Plane ........................................................... #166421, $404.99

1 9. Freud 4-Piece Rabbeting Bit Set with Bearings, 1⁄2" shank ................... #828851, $42.47
(For more Clifton planes, visit woodcraft.com) 10. WoodRiver Large Holdfast, (2 needed) ............................................... #145479, $35.50
3. General Finishes Stain Blocker Primer, qt.............................................#166814, $41.99 11. WoodRiver Small Holdfast, (2 needed) ............................................... #145480, $18.99
4. Leigh VRS1200 Vacuum and Router Support .......................................#166417, $79.00 12. Shoulder Vise Screw (#70G01.51).................................................leevalley.com, $32.50
5. Jet 15" Helical Head Planer ...........................................................#722155, $2,599.99 13. Shoulder Vise Handle (optional) (05G12.03) ....................................leevalley.com, $8.95
6. Seal-Once Nano-Guard Wood Sealer, qt. ............................................#164465, $26.99 14. 1⁄4-20 × 1⁄2" Nylon-Tip Set Screws (pack of 10) (#94115A537)McMaster-Carr.com, $7.23
15. 3⁄4 × 11⁄2 × 12" UHMW Polyethylene Bar (#8702K113) ........... McMaster-Carr.com, $7.98
Build A Beautiful 3-Top Box (p. 24)
16. Waterlox Original Satin Finish, quart ................................................... #142450, $42.99
1. 3M General Purpose Spray Adhesive .......................................... homedepot.com, $5.77
17. Saddle Skirting Leather, Tan (#9047-08) .............................. tandyleather.com, $149.99
2. WoodRiver 1" Forstner bit ................................................................. #125935, $10.49
18. Globe Electric 3-Outlet Power Strip with 2 USB Ports .........................lowes.com, $14.98
3. Milk Paint, Bayberry Green, quart ........................................................ #811181, $14.99
19. General Finishes Winter White Glaze, pt.............................................. #825779, $15.99
Modern Plywood Workbench (p. 34)
Inset Pulls (p. 44)
1. Bondo Patching Compound, 28 oz. ....................................................lowes.com, $12.98
1. Brass bar stock ................................................................................ McMaster-Carr.com
2. TransTint dye, Honey Amber, 2 oz. ...................................................... #128481, $20.99
3. West System 105A epoxy resin (1 qt.), A Box-Maker’s Sled (p. 51)
206A slow hardener (.43 pt.), and mini metering pump set .............amazon.com, $74.95 1. Incra - Miter Slider, 18" ........................................................................ #14V59, $20.99
4. 1
⁄2 -16 × 72" Threaded Rod (24" needed) ........................................... lowes.com, $11.48 Great Gear (p. 62)
5. 3
⁄8 -16 × 6" Hex Bolt, 2 pack (4 needed) ...............................................lowes.com, $3.99 1. No. 92 Sweetheart 73⁄4" Shoulder Chisel Plane .......................... homedepot.com, $78.27
6. 3
⁄8" Coarse Hex Nut, 25 pack (4 needed) ..............................................lowes.com, $2.99 2. Rolair AB5 Sir Buddy, 1⁄2 HP, 1 gal. Compressor ................................. #160167, $170.00
Items above available at Woodcraft stores, at woodcraft.com, or by calling (800) 225-1153, unless otherwise noted. Prices subject to change without notice.
Ad Index
ADVERTISER WEB ADDRESS PAGE ADVERTISER WEB ADDRESS PAGE
The American Woodshop .......................wbgu.org/americanwoodshop ............................23 Northwest Bamboo................................nwbamboo.com ................................................68
Arbortech .............................................arbortechtools.com ...........................................66 Oneida .................................................oneida-air.com............................................ 11, 70
Axiom...................................................axiomprecision.com .................................... 12, 13 PS Wood ..............................................pswood.com .....................................................68
Berea ...................................................woodcraft.com..................................................65 Rikon ...................................................rikontools.com .................................................IBC
Bessey Tools .........................................besseytools.com ...............................................22 Robert Sorby.........................................robert-sorby.co.uk.............................................18
Blokkz ..................................................blokkz.com .......................................................68 Satellite City .........................................caglue.com ......................................................62
Carter...................................................carterproducts.com .............................................1 SuperMax Tools ....................................supermaxtools.com ...........................................60
Connecticut Valley School of WW ...........schoolofwoodworking.com ................................64 System Three........................................systemthree.com ................................................7
Forrest Mfg...........................................forrestblades.com .............................................11 Tanos ...................................................woodcraft.com..................................................61
Freud ...................................................woodcraft.com/Freud ....................................... IFC Thomas Flinn & Co................................flinn-garlick-saws.co.uk ....................................64
Harbor Freight.......................................harborfreight.com .............................................19 Touchstone ...........................................touchstonehomeproducts.com ...........................62
Howard ................................................howardproducts.com ........................................21 Wagner Meters .....................................wagnermeters.com ...........................................20
King Arthur’s Tools ................................katools.com......................................................23 Whiteside Machine................................whitesiderouterbits.com ....................................55
Kutzall ..................................................kutzall.com .........................................................5 Woodcraft Franchise .............................woodcraftfranchise.com ....................................63
Laguna Tools ........................................lagunatools.com ............................................ OBC Woodcraft Magazine .............................woodcraftmagazine.com ................. 15, 54, 61, 68
Lake Erie Toolworks...............................lakeerietoolworks.com.......................................68 Woodcraft Supply ..................................woodcraft.com............................................ 67, 71
Lignomat ..............................................lignomat.com ...................................................23 Woodpeckers........................................woodpeck.com .................................................50

Looking Ahead
Here’s a sneak peek at our next issue.
Arts & Crafts

MIRROR
Make a
CIRCLE-
CUTTING JIG
Stain with
ANILINE DYE
70
Outfeed
in the SHOP
Tooling around with the future
By Ric Hanisch
and a “product” as a goal that awaited off-limits, which are up for grabs, and
on the other side of many botched where they all live. And whatever tools
efforts. A stubborn kid, I guess I was are in play, make sure they’re sharp,
determined to make every mistake tuned, and in good shape, or they’ll be
myself before I realized that when useless for skill-building. Don’t forget to
Dad said “That’s not going to work”, keep a close eye on li’l cutter-wielding
he knew what he was talking about. newbies to gauge their developing
Fast-forward about 60 years, during motor skills and mental readiness
which time two daughters, a couple before they advance to the next step.
of their cousins, and sundry other It’s a beautiful thing, watching kids
kids found their way to my own grow the kind of skills that will help
bench. And now my grandson Kai them make the most of a world that
has joined their ranks. It’s been fas- can be cut up, put together, reshaped,
cinating to watch each recent arrival taken apart, and reassembled to
to the world develop tool skills that your liking if you know how. Once
will help arm them for their future. you slip past the tiger, that is... n
It’s not hard to help kids get comfort-
s a kid, I never let the ankle-biting able with real-world tools. For example,
tiger lurking in the shadows to encourage hand-eye coordination,
beneath the cellar stairs deter me from you might set up a youngster with a ball
getting to my dad’s workbench. With peen hammer, a can of miscellaneous
its top of 2 × 10’s and its steel pipe legs, nails, and a section of log standing on
the bench was simply outfitted with a end. Show her how to hold and tap a nail
tool pegboard, an old machinist’s vise, to start it before letting go and pound-
and a hand-cranked grinding wheel. ing away into the friendly end grain.
Nothing fancy, but it was just the thing To develop dexterity, let a kid have
when there was work to be done. a go at disassembling an old fax
Early on, I mostly needed to change machine. Or clamp a 1 × 1" stick
the shape of stuff. You know, maybe in a vise and demonstrate cutting
squash a bottle cap in the vise or grind off an inch with a small, stiff back
some nicks in an old file, which made saw. Let a kid try it, and see how
great sparks! I eventually moved on quickly that stick disappears into
to defunct radios and clocks that a pile of pieces. Before you know
begged to be taken apart. While learn- it, he’ll be using a spokeshave!
ing to wield pliers and screwdrivers, While you’re at it, teaching shop
I also picked up an idea of how these etiquette is important for every-
devices worked. As I got older, proj- one’s safety and happiness, so make
ects often involved advance planning sure it’s understood which tools are
72

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Table of Contents

August/September 2019 | Issue 90

34 Modern Plywood Workbench

10 News & Views

14 Reader Showcase NEW

16 Hot New Tools

18 Tips & Tricks

Cover photo: Ralph Lee Anderson Aug/Sept 2019 | woodcraftmagazine.com 3

The workbench on page 34 was designed by Andy Rae, an instructor at Making

W oodworking may well be the

Gregory PAOLINI A man with a plan

Photos: Courtesy Gregory Paolini Aug/Sept 2019 | woodcraftmagazine.com 9

Faceplate fixes Plastics projects

A must-see for carvers

And the winner is…

Aug/Sept 2019 | woodcraftmagazine.com 11

RUSSELL SVENDSEN, OLEAN, NY

Show off your work!

Email Direct Mail

arlier this summer, nearly 100 manufacturers gathered at the

Super powerful primer

Stain blocker General Finishes Stain Blocker Primer

16 Prices subject to change without notice.

Hello, helical. See ya’ Snipe.

Well-behaved bench dogs

9" Use Allen wrench to

Size dog body to suit

18 Illustrations: Christopher Mills

Send your ideas to:

Important: Please include your

Aug/Sept 2019 | woodcraftmagazine.com 21

Drilling on the level

A distinctive design combines

24 Photos: Randy O’ Rourke; Illustrations: Frank Rohrbach III

HANDLE Rabbet LID

Cut 90° point on

SIDE PLYWOOD BOTTOM

QUILTING SQUARE *CTF = Cut to fit

How to prepare grain-matched sides

Aug/Sept 2019 | woodcraftmagazine.com 25

Cut sides to length. Clamp a stop block to the

Rout V-grooves in sides. Adjust the height of a V-groove bit so

Clamp with tape, string,

Aug/Sept 2019 | woodcraftmagazine.com 27

Mark and rout the

A perfect fit. To complete the short divider, repeat the

Tiny, T-shaped handles. These handles are cocobolo,

The finishing touch. The

McKinley Arm Chair

Aug/Sept 2019 | woodcraftmagazine.com 31

1971 brushed aluminum surfaces attached to a simple

Aug/Sept 2019 | woodcraftmagazine.com 33

Important: The 5"-thick components ensure a super-sturdy

A sliding board jack works in tandem with A pair of quick-release, leather-

Aug/Sept 2019 | woodcraftmagazine.com 35

Order of Work FRONT RAIL

• Make and install shelf, and

END VISE JAW

Cut a 3⁄4 × 1⁄4" through dado,