Popular Woodworking No 148 - June 2005.pdf

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BOX JOINTS: THE JIG THAT MAKES THIS JOINT A SNAP
LIE-NIELSEN VS. VERITAS: WHICH HAND PLANE IS RIGHT FOR YOU
JUNE 2005
ISSUE #148
Build Better
Bookcases
One Easy Plan,
4 Great Styles
Real World
Shop Storage
PLUS
A Fisherman’s
Ingenious Solution
• 6 Chisel Tricks
You’ve Never Seen
• Bowl Turning
For Beginners
• Williamsburg
Game Table
DISPLAY UNTIL 5-30-2005
contents
IN EVERY ISSUE
14
How to Sharpen Odd
Or Curved Blades
Q&A
A dowel, a couple small scraps and sandpaper can
sharpen almost anything. Plus, get our new recipe
for a one-step Arts & Crafts finish and learn to make
small veneer patches.
18
14
Setting Perfect
Miter Gauge Angles
TRICKS OF THE TRADE
A single scrap of wood fine-tunes your table saw’s
miter gauge with fewer test cuts. Plus, the best wind-
ing sticks ever, one more great use for lipstick and a
quick fix for inaccurate table saw sleds.
25
Hitachi’s Digital Miter Saw
TOOL TEST
25
The Hitachi C12LCH sets your cuts with half-degree
precision – plus a laser guides the blade. Also, an
Australian jig for people who can’t saw straight and
aftermarket helical cutterheads for many jointers.
28
Box Joints
POWER-TOOL JOINERY
Build this jig for your router table or table saw to
make accurate box joints – perhaps the strongest
machine-cut joint in the arsenal.
by Bill Hylton
77
28
77
82
Turn Your First Bowl
AT THE LATHE
Learn the tools and strategies for turning a bowl,
an enlightening introduction to faceplate turning.
by Judy Ditmer
Popular Woodworking
(ISSN 0884-8823,USPS 752-250)
is published seven times a year in February, April, June,
August, October, November and December by F+W
Publications Inc. Editorial and advertising offices are
located at 4700 E. Galbraith Road, Cincinnati, Ohio 45236;
tel.: 513-531-2222. Unsolicited manuscripts, photographs
and artwork should include ample postage on a self-
addressed, stamped envelope (SASE); otherwise they will
not be returned. Subscription rates: A year’s subscription
(7 issues) is $28; outside of U.S. add $7/year Canada
Publications Mail Agreement No. 40025316. Canadian
return address: 2744 Edna St., Windsor, ON N8Y 1V2
Copyright 2005 by
Popular Woodworking.
Periodicals
postage paid at Cincinnati, Ohio, and additional mailing
offices. Postmaster: Send all address changes to
Popular
Woodworking,
P.O. Box 420235, Palm Coast, FL 32142-0235
Canada GST Reg. # R122594716 Produced and printed
in the U.S.A.
■
■
■
Advanced Chisel Techniques
ARTS & MYSTERIES
Chisels are good for more than just tuning up joints
and removing dried glue. We look back to the 18th
century to discover how astonishingly useful this
simple tool can be – when wielded in a very old way.
by Adam Cherubini
82
popwood.com
3
PROJECTS, TOOLS
AND TECHNIQUES
32
ON THE COVER
Use similar construction
techniques to build book-
cases in four popular and
good-looking furniture
styles. We show you the
tricks to make one book-
case (or 100) as easy as
possible in a home shop.
Cover photo by Al Parrish
Learn to dress up an easily built bookcase
with simple moulding to make it fit in with
Shaker, contemporary, Arts & Crafts or
formal furniture styles.
Build Better Bookcases
42
Sawbench &
Shop Stool
This simple one-afternoon project will
come in handy at every stage of project
construction, from sawing rough lumber
to installing your finished cabinets.
by John Wilson
32
45
Special Techniques
On the Table Saw
WOODWORKING ESSENTIALS
DEPARTMENTS
Find out how and why you should use a mould-
ing cutterhead in your table saw. Plus, learn to
cut accurate tapers, and the tricks to frame-
and-panel doors.
by Nick Engler
8
10
74
90
Out on a Limb
On the Cutting Edge
Of Enlightenment
53
53
Letters
Mail from readers
If you have lots of little bits and pieces in your
shop (and who doesn’t?), find out the secret
that allows you to organize everything with-
out building a single drawer.
by Troy Sexton
A Practical Shop Cabinet
Great
Woodshops
Take a tour of Editor
Steve Shanesy’s shop.
56
Flexner
On Finishing
The Many Faces
of Varnish
by Bob Flexner
Lee Valley Tools and Lie-Nielsen
Toolworks make world-class hand planes.
Learn the real differences between the
two brands. Also, meet Wayne Anderson,
who hand builds fine custom infill planes.
Two Plane Makers
96
Out of the
Woodwork
66
Farewell Fractions
– Hello Bob
by Robert Dunstan
Based on an original from Colonial Wil-
liamsburg, this traditional demilune table
unfolds to reveal your joinery, inlay and
veneering skills.
by Glen Huey
Baltimore Card Table
66
4
P
OPULAR
W
OODWORKING
June 2005
®
June 2005, Vol. 25, No. 3
popwood.com
Editorial Offices 513-531-2690
Editor & Publisher
Steve Shanesy
ext. 1238 • steve.shanesy@fwpubs.com
Art Director
Linda Watts
ext. 1396 • linda.watts@fwpubs.com
Executive Editor
Christopher Schwarz
ext. 1407 • chris.schwarz@fwpubs.com
Senior Editor
David Thiel
ext. 1255 • david.thiel@fwpubs.com
Senior Editor
Robert W. Lang
ext. 1327 • robert.lang@fwpubs.com
Managing Editor
Kara Gebhart Uhl
ext. 1348 • kara.uhl@fwpubs.com
Assistant Designer
Susan L. Smith
ext. 1058 • susan.l.smith@fwpubs.com
Project Illustrator
John Hutchinson
Photographer
Al Parrish
Contributing Editors
Nick Engler, Bob Flexner, Glen Huey,
Don McConnell, Troy Sexton
F+W PUBLICATIONS INC.
William F. Reilly,
Chairman
Stephen J. Kent,
President
Mark F. Arnett,
Executive Vice President & CFO
F+W PUBLICATIONS INC.
MAGAZINE DIVISION
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President
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SAFETY NOTE
Safety is your responsibility. Manufacturers place
safety devices on their equipment for a reason. In many
photos you see in
Popular Woodworking,
these have
been removed to provide clarity. In some cases we’ll
use an awkward body position so you can better see
what’s being demonstrated. Don’t copy us. Think about
each procedure you’re going to perform beforehand.
Safety First!
O
UT ON A
L
IMB
On the Cutting Edge
Of Enlightenment
A
while back I was cruising an Internet
discussion forum and read through a
thread that began with this question:
“I’ve just finished stage one of setting up
my shop. I have a bench and some tools, but
I don’t have the money for a table saw. Can I
start making projects without a table saw?”
Other woodworkers chimed in with advice:
Get a miter saw for accurate cuts. Use a circular
saw and a straightedge. Don’t use a circular saw
and straightedge. Buy an inex-
pensive benchtop table saw.
This got me thinking. How
do people think furniture,
buildings and bridges were built
before power tools? It reminded
me of something I once read:
The typical suburban garage has
more tools than were available
in 1800 to clear the forests and
build the cities between the
Atlantic Ocean and the Mis-
sissippi River. What if those guys had waited
for the table saw? We’d still be sending our
taxes to London!
Why do so many woodworkers, the Nor-
mites, equate the craft with power tools? And
why, for that matter, is there a growing number
of hand-tool enthusiasts, the Neanders, who
reject any tool with a cord attached?
The point here is not to take sides but to
circle back to the original question about hav-
ing a table saw. More fundamentally, how best
to get started in woodworking and build skills
leading to good craftsmanship.
The answer, I’ve concluded, is you really
must learn both hand- and power-tool skills.
Knowing both makes you a well-rounded
woodworker, a “double threat” who can call
on either skill set to deliver the best result.
I was not an early adopter of hand tools
and I still have much to learn. For years my
experience with planes and chisels resulted in
frustrating, unsatisfactory results. The reason
was a basic inability to produce a truly sharp
edge. How was I to know what was sharp if
I didn’t know what sharp really was? Oh, I
knew when my carbide saw blades or router
bits were dull. And I knew exactly how to fix
them – send them out to be sharpened!
I had a moment of enlightenment recently
on a visit to Joel Moskowitz’s Tools for Work-
ing Wood store in New York City. Joel loves
hand tools, but he’s even more passionate
about the earliest woodwork-
ing “how-to” books, forerun-
ners of today’s woodworking
magazines. Joel mentioned
in passing the total absence
of any early writing about
sharpening. Then it hit me.
Before the advent of power
tools, sharpening skills were
as common as driving skills are
today. If you wanted to shave,
cut down a tree, butcher a hog
or even slay an enemy, you had to know how
to produce a sharp edge. Your life depended
on it, literally! To a woodworker, sharpening
was second nature.
As power tools replaced hand tools during
the Industrial Revolution, once-commonplace
sharpening skills were lost, and much of the
hand-tool know-how that built our country
then slipped into obscurity.
If I could turn the clock back to the earliest
days of my learning to work with wood, I’d
learn to sharpen edge tools just like I learned
many other skills. I would have been a better
woodworker these past 25 years. And it would
have given me something productive to do
while saving up for a table saw.
PW
CONTRIBUTORS
ADAM CHERUBINI
During the day, Adam Cherubini works with
cutting-edge technology as an aerospace
engineer. But at night, he builds baroque-
style furniture with antique hand tools in
an 18th century-style
woodshop in his 1950s
New Jersey home. This
dichotomous lifestyle
brings balance to his
life, he says. Apart from
raising three children,
Cherubini has devoted
much of his life to researching early wood-
working techniques. He shares what he
has learned with others by volunteering at
Pennsbury Manor on Historic Trades Days
(pennsburymanor.org) and by writing our
new series, “Arts & Mysteries.” His latest
article, “Advanced Chisel Techniques,”
begins on page 82.
BOB DUNSTAN
Born in England and trained to make harp-
sichords, Bob Dunstan moved to Wyoming
with his wife when he was 25. Discovering
few demands for harpsichords, Dunstan
spent the next 10 years
building period furni-
ture by commission out
of a converted tractor
shed on the banks of the
Snake River, and raising
two children. In 1987,
he started Whitecha-
pel Ltd., a catalog of fine furniture-grade
European hardware. By 1990, Whitechapel
kept Dunstan so busy that he had to quit
his furniture business. Today, his catalog is
managed for him, allowing him to return to
furniture making and to create a new form
of measurement – the “bob.” (See “Farewell
Fractions – Hello Bob” on page 96.)
Our Privacy Promise to You
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us know by contacting us at:
List Manager, F+W Publications
4700 E. Galbraith Road, Cincinnati, OH 45236
Steve Shanesy
Editor & Publisher
8
P
OPULAR
W
OODWORKING
June 2005

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