Popular Woodworking No 144 - November 2004.pdf

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A RULER (YUP, A RULER) SLASHES YOUR SHARPENING TIME
RADICAL REPAIRS: A SECRET WEAPON TO FIX YOUR DAMAGED FINISHES
NOVEMBER 2004
ISSUE #144
33 BIG MISTAKES
TO LEARN FROM
Avoid Problems That
Plague Your Projects
Classic Shaker
Tripod Table
A Simpler Joint
For Sturdy Legs
PLUS
• Build a Welsh Stick Chair
• Why You Need a Rasp
• $10 Table Saw Tenon Jig
popwood.com
$5.99 U.S. $7.99 CAN
Lonnie Bird’s Tips for
Better Glue Joints
contents
IN EVERY ISSUE
16
How Best to Store Handsaws
Q&A
Graham Blackburn explains the simple and effective
ways to keep your saws at the ready. Plus: How to choose
premium plywood and the lowdown on bullnose planes.
22
22
Router Guide for Straight Cuts
TRICKS OF THE TRADE
A foolproof jig for routing dados and cutting sheet goods.
Plus: Make stronger buttons and mix shellac fast.
30
Veritas Low-angle Jack Plane
TOOL TEST
Massive and well-made, this new Canadian plane can plow
through most workshop tasks with ease. Plus we review a
new miter gauge from Kreg and an ingenious splitter.
30
32
Testing Your Layout Tools
FROM THE BENCH
Testing your straightedge, try square and miter square are
fundamental skills for any woodworker. Here are the best
ways to accomplish this quickly and accurately.
by Don McConnell
94
32
Table Saw Tenon Jig
POWER-TOOL JOINERY
Efficiently cut tenons and slip joints on the table saw with
an easy-to-build jig that rides on your saw’s fence.
by Bill Hylton
94
97
Sharpening for Woodturners
AT THE LATHE
Recognizing a dull tool is essential to good turning. Learn
the basic moves to sharpen your set of lathe tools.
by Judy Ditmer
102
Fixing Finish with French Polish
FLEXNER ON FINISHING
French polish isn’t just for bare wood. Refinishing pros use
the technique for repairing worn or damaged finishes.
by Bob Flexner
97
Popular Woodworking
(ISSN 0884-8823,USPS 752-250) is published 7 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 2004 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.
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102
popwood.com
3
PROJECTS, TOOLS AND TECHNIQUES
38
Gluing up a project is a basic skill that is often
botched. Learn the tricks that make project
assembly satisfying instead of stressful.
by Lonnie Bird
Better Glue Joints
ON THE COVER
Good glue joints are
essential to a durable
project. Lonnie Bird
gives you the facts on
where you should
apply glue, how much
you should apply and
what to do with the
squeeze-out.
Cover photo by Al Parrish
42
49
Build a Welsh Stick Chair
A week in the Canadian wilderness with David
Fleming offers a glimpse of the chairmaking
renaissance that has thousands swinging adzes.
Using the Saw Blade
WOODWORKING ESSENTIALS
Our series on table saws continues with every-
thing you need to know about buying, using and
maintaining blades.
Second of seven chapters.
by Nick Engler
42
61
Queen Anne Table
by Glen Huey
Having built the cabriole legs (October
2004), now it’s time to complete this classic
piece. Detailed finishing steps are included.
DEPARTMENTS
10
12
108
Out on a Limb
Buyer Beware: Tool
Prices Heading Up
68
A Bit of Heaven
Get unbelievable amounts of torque with
an auger bit (plus a brace). The only trick is
learning how to sharpen the bits. We show
you how a quick tune-up works wonders.
by Samuel Peterson
Letters
Mail from readers
Out of the
Woodwork
To Rip or to Split?
73
61
Return of the Rasp
Almost extinct, rasps are poised for a come-
back. Here’s why you need a few for your tool-
box and which ones you should buy.
76
82
88
Build this classic without the sliding dovetails.
Simple tenons are easier and less fragile.
by Kerry Pierce
Shaker Tripod Table
You’ve never seen this one before: A $5 steel ruler
will radically reduce your sharpening time.
by David Charlesworth
The Ruler Trick
We make some mistakes unwittingly every day.
Here’s an eye-opening list of what you’ve been
doing wrong without even knowing it was wrong.
Insidious Mistakes
73
6
P
OPULAR
W
OODWORKING
November 2004
®
November 2004, Vol. 24, No. 6
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
ext. 1348 • kara.gebhart@fwpubs.com
Assistant Designer
Susan 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
Magazine Group Head
David Hoguet
Executive Vice President Magazine Advertising
Jim Gleim
CIRCULATION
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Group Circulation Manager
PRODUCTION
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Vicki Whitford,
Production Supervisor
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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
Buyer Beware: Tool
Prices Heading Up
oodworkers have enjoyed relatively sta-
ble prices on almost the entire range of
woodworking tools, be they electric powered
or hand tools, for years. But all that’s about to
change – and in some quarters, the change
has already begun.
So let this serve as a warning: Those plan-
ning a power tool, hand tool or machine pur-
chase in the near future would
be well advised to act now, cer-
tainly before year’s end.
Don’t blame manufacturers
for the price increases. They
have all worked hard to hold
the line on prices, absorbing
increased production costs or
the price imbalances caused by the sagging
U.S. dollar compared to foreign currencies,
most notably the Euro.
Another culprit is the increasing cost of
raw materials and oil. The price of metal has
been on a steady and constant climb. And I’m
sure the price of gasoline hasn’t escaped your
attention lately.
So if you can, treat yourself to an early
holiday gift. It’ll be worth it.
CONTRIBUTORS
DAVID CHARLESWORTH
It’s hard not to be impressed when you see
David at work with a hand plane. During his
more than 30 years as a professional wood-
worker (and more than 25 years of teach-
ing), David has devoted
a lot of energy towards
understanding exactly
how these tools func-
tion. And he’s devel-
oped a series of simple
(but some would call
non-traditional) ways
of coaxing astonishing results from even
meager tools. One of his favorite tricks for
setting up a plane iron begins on page 82.
When he’s not writing or building furniture,
David teaches small classes of students to
build finely detailed furniture in his shop
in the historic village of Hartland, which is
near the north coast of Devon, England.
W
“More Shop Drawings for Craftsman Fur-
niture,” and “Shop Drawings for Craftsman
Interiors” (all published by Cambium Press).
They’re available through Bob’s web site at
craftsmanplans.com. He’s currently finishing
two more books, “Shop Drawings for Crafts-
man Inlays & Hardware” (to be published
this fall) and “The Complete Kitchen Cabi-
netmaker” (which is scheduled
for publication next year). He’s
also contributed articles to
Woodshop News, Woodwork
and
Fine Woodworking
magazines.
Adding Bob to what I already
consider the best woodworking
magazine staff in the business
means even more depth to the articles we
send your way each issue.
KERRY PIERCE
Although Kerry specializes in post-and-rung
chairs and Queen Anne-style furniture, he
doesn’t do slavish reproductions. Rather he
blends period elements and takes advantage
of modern technology.
By replacing the tradi-
tional sliding dovetail
leg joint with a tenon
in his “Shaker Tripod
Table” (see page 76), he
avoided unnecessary
labor but still produced
a sturdy joint. A high school English teacher
for more than 30 years, Kerry has combined
his passions for writing and woodworking
in his 10 woodworking books and numer-
ous magazine articles. A recent battle with
cancer kept him out of the shop for months,
which “just drove me crazy,” he says. But
today, he’s making sawdust again.
A Charitable Reminder
In my column last issue (October 2004)
I introduced you to a new program we’ve
undertaken that pledges us to make chari-
table contributions when you help us find
new readers. Let me first say thanks to those
who already have the ball rolling. For those
who missed the column last issue, here’s how
the program works:
In a nutshell, when you provide us with
the name and address of a person you think
might enjoy receiving
Popular Woodworking,
we’ll send them a free issue. If they elect to
subscribe, we’ll set aside $5 to be split between
the American Cancer Society and The Nature
Conservancy. You can read more about the
program or send along names to receive a free
issue by visiting our web site at popwood.com/
charity.html. You will find printed forms to
submit names in future issues as well.
PW
Welcome Bob Lang
I’m pleased to introduce a new staff member.
Robert (Bob) Lang is now working on the
editorial team as a senior editor and we all
are thrilled to welcome him aboard.
Like most of the
Popular Woodworking
staff,
Bob comes with more than a strong passion
for woodworking; he also has many years of
professional woodworking experience. Over
the years he’s built furniture and cabinets, and
produced architectural millwork. He’s worked
in big and small shops alike, and for years ran
his own shop and marketed his woodworking
on the craft fair circuit. As you can see, Bob
has real woodworking “chops.”
But that’s not all. Bob also has authored
a number of woodworking books – notably
“Shop Drawings for Craftsman Furniture,”
Our Privacy Promise to You
We make portions of our customer list available to
carefully screened companies that offer products
and services we believe you may enjoy. If you do not
want to receive offers and/or information, please let
us know by contacting us at:
List Manager, F+W Publications
4700 E. Galbraith Road, Cincinnati, OH 45236
Steve Shanesy
Editor & Publisher
10
P
OPULAR
W
OODWORKING
November 2004

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