Woodsmith No 226 - August-September 2016.pdf

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GUILD
EDITION
®
Woodsmith.com
Vol. 38 / No. 226
WOODWORKING
CHALLENGE
P
UZZLE
B
OXES
Also:
Every Shop Needs
Simple, Accurate Jigs
Custom Details for
Tips &
Tricks
for:
Better-Looking
Projects
• Cleaner Router Cuts
• Top-Notch Mortises
• Smooth, Accurate Tenons
A Publication of Cruz Bay Publishing, Inc.
®
CREATIVE HOME GROUP
GENERAL MANAGER
Donald B. Peschke
EDITORIAL MEDIA DIRECTOR
Bryan Nelson
MANAGING EDITOR
Vincent Ancona
SENIOR EDITORS
Wyatt Myers,
Phil Huber
ASSOCIATE EDITOR
Robert Kemp
EXECUTIVE ART DIRECTOR
Todd Lambirth
SENIOR ILLUSTRATORS
Harlan V. Clark,
Dirk Ver Steeg, Peter J. Larson
SENIOR GRAPHIC DESIGNER
Bob Zimmerman
GRAPHIC DESIGNER
Becky Kralicek
CREATIVE DIRECTOR
Ted Kralicek
ASSISTANT DESIGN DIRECTOR
Chris Fitch
PROJECT DESIGNER/BUILDER
John Doyle
CAD SPECIALIST
Steve Johnson
SHOP CRAFTSMAN
Dana Myers
SENIOR PHOTOGRAPHERS
Crayola England,
Dennis Kennedy
ASSOCIATE STYLE DIRECTOR
Rebecca Cunningham
SENIOR ELECTRONIC IMAGE SPECIALIST
Allan Ruhnke
PRODUCTION ASSISTANT
Minniette Johnson
VIDEO EDITOR/DIRECTOR
Mark Hayes
Woodsmith®
(ISSN 0164-4114) is published bimonthly by
Cruz Bay Publishing, Inc., 2200 Grand Ave, Des Moines, IA 50312.
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from the editor
Sawdust
As summer begins turning to fall, my thoughts
shift from outdoor
activities to those inside — like spending more time in my shop. This yearly
change provides another opportunity to reinvent my shop, by looking for ways
to improve it just a little bit more. I’ll take a look at things like storage, my tools,
and where everything is positioned in an effort to get the most out of the time
I spend there. Unfortunately, quite a bit of that effort ends up being a trial-and-
error process to get things just right.
ONE-WALL WORKSHOP.
To help you avoid some of that frustration when you’re start-
ing out (or even wanting to add to your shop), check out the one-wall workshop
that begins on page 26. It has everything necessary to complete a wide range of
woodworking projects. In this issue, we’re starting out with the “bones” of any
shop — a workbench, a combination miter saw center and auxiliary workstation,
and easy-to-build wall-mounted storage cabinets.
Then in the next issue, we’ll finish things off by adding some really handy
roll-around carts that store neatly under the workbench and workstation. One
is a must-have assembly center that makes working on any project a snap. And
the other two carts provide homes for your thickness planer and router. All in
all, this one-wall workshop has everything you need, right where it’s needed.
THERE’S MORE.
Already have the workshop of your dreams? Then check out the
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other projects in this issue. I know I’ll be starting on the puzzle box on page 20
pretty soon. I’ve always been fascinated by this type of box. It features unique
design elements that keep all the parts together. Yet they still allow things to
move just enough — and in the right order — to open up the box and remove
the lid. I plan to make several as gifts this year.
Another project that I and many other woodworkers have on our project lists
is a wall clock. But the challenge of designing a clock around a purchased clock
movement intimidates a lot of us. Well, if that’s been the case for you as well,
you can relax. Just turn to page 44 to take a look at our heirloom wall clock. It
has a classic look that will fit in great anywhere. Plus, the etched design in the
glass door offers a new technique to try out.
Finally, if you, a family member, or a friend enjoy playing music, take a look
at the stand on page 36. It’s the perfect project for letting everyone know that in
your world, both woodworking and music are serious business.
SUBSCRIPTIONS
Customer Service
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Des Moines, IA 50304-9961
subscriptions@augusthome.com
EDITORIAL
Woodsmith Magazine
2200 Grand Avenue
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woodsmith@woodsmith.com
CHAIRMAN
Effrem Zimbalist III
PRESIDENT & CEO
Andrew W. Clurman
EXECUTIVE VICE PRESIDENT &
CHIEF FINANCIAL OFFICER
Brian J. Sellstrom
EXECUTIVE VICE PRESIDENT, OPERATIONS
Patricia B. Fox
2
Woodsmith / No. 226
contents
No. 226
August/September 2016
20
26
Projects
weekend project
Puzzle Boxes . . . . . . . . . . . . . . . . . . . . . . . . . .20
Boxes are always a popular project, but this one has its own
unique challenge — a specific sequence of moves is required
to unlock it and access the contents inside.
36
44
shop project
One-Wall Workshop . . . . . . . . . . . . . . . . . . . .26
Everything you need to build woodworking projects is
designed into a workshop that fits along a single wall.
Tuck-under carts provide versatility and a compact footprint.
designer project
Music Stand. . . . . . . . . . . . . . . . . . . . . . . . . . .36
Do you have a future rock star or budding maestro in your
family? This elegant music stand is the perfect accessory to
help them build their musical talents.
heirloom project
Walnut Wall Clock . . . . . . . . . . . . . . . . . . . . . .44
We all hope to find the “time” to build a clock someday. This
version features an arched top, a decorative glass panel door,
and great woodworking techniques.
Woodsmith.com •
3
Departments
from our readers
Tips & Techniques . . . . . . . . . . . . . 5
all about
Choosing Clock Components . . . . 10
router workshop
Backrouting for Clean Cuts . . . . 12
great gear
Tools Made in America . . . . . . . . 14
10
woodworking technique
Better Results with MDF . . . . . . . 18
woodworking technique
Custom Details with Bevels . . . . . 54
working with tools
Top-Notch Mortising . . . . . . . . . . 56
in the shop
Sharpening Drill Bits . . . . . . . . . . 58
woodworking essentials
Shop-Made Edge Guides . . . . . . 60
14
mastering the table saw
Smooth, Accurate Tenons . . . . . . 62
tips from our shop
Shop Notes . . . . . . . . . . . . . . . . . . 64
58
4
Woodsmith / No. 226
62
m our
fro
readers
Tips &
Techniques
“Smart” Box Joint Jig Helper
Making box joints at the table saw calls
for the use of a specialized box joint
jig that often has a tall auxiliary fence
to support the workpiece. The prob-
lem with having a tall fence is that it
requires you to bend over the table saw
after every pass, straining your neck
and back to see the workpiece and
index it over the key. This can really
take its toll on your comfort when
you’re making multiple box joints.
To avoid this situation, I decided to
let technology help me out by using my
smartphone’s camera to aid in position-
ing my workpiece. But I couldn’t just
set my phone on the table saw without
some kind of support. So I made the
cradle shown here to hold the phone.
SIMPLE BUILD.
The cradle consists of a
piece of plywood sandwiched between
two pieces of hardboard and glued
together. A couple of rare-earth magnets
epoxied into holes in the bottom hold it
in place. My phone is also in a protective
case, so I sized the cradle accordingly.
Min-Hao Kuo
East Lansing, MI
a.
SIDE SECTION VIEW
Side
!/8
!/2
1!/2
Center
!/8
Magnet
NOTE:
Size
cradle to
fit your
smartphone
case
#/8"-rad.
1!/4
#/4
SIDE
!/2
1!/2
1
!/4"-rad.
!/2"-
rad.
SIDE
6!/4
NOTE:
Sides
are made from
!/4"hardboard.
Center is
made from plywood the same
thickness as phone case.
(#/4"plywood shown here)
#/4
CENTER
#/8"-dia.
rare-earth
magnet
NOTE:
Notch in center
accommodates
phone buttons
Win This Kreg K5 Jig
Simply send us your favorite shop
tips. If your tip or technique is selected
as the featured reader’s tip, you’ll win
a
Kreg K5 Jig
just like the one shown
here. To submit your tip or technique,
just go online to
Woodsmith.com
and
click on the link, “SUBMIT A TIP There
.”
you can submit your tip and upload
your photos for consideration.
The Winner!
Congratulations to
Thomas Little, the winner
of this
Kreg K5 Jig.
To find
out how you can win this
jig, check out the
information at left
.
Woodsmith.com •
5
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