# 1 0 I , J u l2y0 0 3

BasicHVLP
SprayTechniqu
l"jfil,'H:T:fjji"
28
sprayingfinishes.

TVCabinet
40
Cleverdesigndetailsin a cabinetthat
can showcase(or hide!) your 36-in.TV.

Staining
Pine52
Work magic on economicalpine
with this step-by-stepmethod.

HVLPTurbine
Sprayers
56
We chosethe best sprayersfor less
than $600.Seewhat featuresmatter.

3-Year
Index69
Threeyearsof.American Woodworker,
sortedand grouped for your reference.

lo

=o page 56
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(J
Contents
DEPARTMENTS
&Answer
10 Question
's
#

16 WorkshopTips
6#
:"1i

22 TheWell.Equipped
Shop I

64
91
92
94
page10
e6w!

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 Subseription Questions? Seepage5

Works cp
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o AddonToolDockunitsasyourworkshopgrows. CHICAGO CarlBenson(312) 540-4802,
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The Modular Workshop CLASSIFIED ADVERTISING TheMcNeillGroup,lnc.
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E D I T O RI N C H I E FK C NC O I I i C T
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O F F I C EA D M I N I S T R A T I VM
T E C H N I C A LM A N A G E RS h a n n o nHooge

The PRODUCTION

ADMI N ISTRATIVE
ShellyJacobsen
ARTISTLisaPahlKnecht
R E A D E RS E R V I C ES P E C I A L I S RT o x i eF i l i p k o w s k i
ASSISTANTSLOriCAIIiStET,

C H A I R M A NC, H I E FE X E C U T I VOEF F I C E R

Cutting Thomas0. Rydel

W O R L D W I DC
JohnKlingel
EIR C U L A T I O D

V I C EP R E S I D E N T
DomRossi
N IR E C T O R

E,X E C U T I VPEU B L I S H E R

V I C EP R E S I D E N T / C FNOO R T HA M E R I C A N

tdge MAGAZINES A N D B O O K S&

H O M E E N T E R T A I N M E NSTt e p h e nSimon
D I R E C T O RU,. S .A D V E R T I S I NRGE S E A R C H
Britta Ware
V I C EP R E S I D E NATN D C I R C U L A T I ODNI R E C T O R
U . S . M A G A Z I N EG R O U PD a w nZ i e r
V I C EP R E SD I E N T ,C IR C U L A T I O N / O P E R A T I O N S
ReneeJordan
f inally,a saw you can dependon with a name M A G A ZNI E O P E R A T I O ND SI R E C T O R
I vou can trust.Our new MM seriesbandsaws CathelineMerolle
featurehuge resawcapacities,loadsof cast iron, CIRCULATIOM N A R K E T I N GD I R E C T O RL o uS a s s a n o

and per hapsm os t i m p o rta n tl y ... a c o m p a n yth a t lssue#101.American Woodworker@, ISSN1074-9152,

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P l e a s ei n c l u d ea c o p yo f y o u ra d d r e s lsa b e l .
 uyJan Carf
Edited

Oue$lon&
Anwer
Stripping0ptions
favoritetable,but its top is a mess'ls there an
Q. My grandmothergaveme her
easierway to strip off the old finishthan usinga messypaint remover?

A. For surefiresuccess, go straightto aliquid stripper.It will quickly cut

through any clearfinish and take lesstime and createlessmessthan
semi-pastestrippers. Look for one with methylene
chloride,the activeingredient in the fastest
working removers.
If you want to do some exPeri-
menting,stripPermay not be Your
only answer.Many old finishes
will literally melt awaywith alcohol
or lacquer thinner. Alcohol dissolves
shellac,and lacquerthinner removesmost
old lacquer.Furniture refinishersmight
also be effective.The problem is that one
might be more effectivethan another on a
given finish, sincetheir chemicalcompo-
srtlon varles.
Pour some of the solvent or stripper
into a dish.Wipe it over small sec-
tions of your piecewith steel
wool (0 or 00 works well) or z
U

a synthetic abrasivePad if
E

=
you will be finishing the z

table with a waterborne =

product. Scrub away, o
keeping your work @- I

area wet by redip- F o

ping the pad.A gar- 5

a

z
dener'sspraybottle o
a
z
is a handy applicator, I

especiallyfor vertical
-
z
surfaces. lrJ

A f t er t he fi n i s h
beginsto break down,
wipe awaythe slurrY
with paper towelsor
a r ag. Repea t th i s
(L
process until your a

piecehas an even,consis- Caution: Work in a well-ventilated =

tent appearance.DamP rags area.Outdoors is bestWear gloves,
E
tossedin a pile area fire hazard,sohang them goggles and a respirator with an
organic vapor cartridge. o
outsideto drybefore you throw them away. trJ

10 American Woodworker J U L2Yo o 3

Q u e s t i o n& A n s w e r

BetterBrushGleaning
Along with mineral spirits or paint thinner, you ll usea
Q. I bought an expensivenatural-bristlebrush for var-
nishing,but I cant seemto get it completelyclean.Thebris- solventcalled"brush cleaner"($8 per qt.) or lacquerthin-
tles are stiff after the brush dries.What can I do? ner ($4 per qt.).Youll alsouse"brush conditioner"($7 per
A. Pros cleantheir brushesin stages,often with special 6-oz.tube).Ordinary mineral oil works aswell ($+ for t0
solventsand conditioners.This techniquewill keep your oz.).Finally,you ll needa specialbrush comb ($8).All are
brush soft for years. availableat paint stores,or seeSources,page92.

Rinseyour brush in mineralspiritsuntil most tracesof varnishare Repeatthe sameprocesswith brush cleaneror lacquer
gone.Pour the mineralspiritsbackinto the originalcontainer.You thinner.Comb the brush to straightenthe bristlesand remove
can reuseit severaltimes,becausethe varnishsolidswill sinkto all varnishresidue.Let the brush soakfor l5 to 20 minutes,if
the bottom. Dry the bristlesthoroughly with a rag. time permits.

Vigorouslycleanthe brush with dishwashingliquidand hot Wipe the brush dry with a lint-free rag and applya smalldab of
water. Go through at leastfour to five wash cycles.Turnthe brushconditioneror mineraloil.Work it in,then straightenthe
brush upward eachtime so water runs directly into the bristlesonce more with the comb.Wrap the brush in its original
,bristles.Comb the brush when you're done. containerand hangit to dry.

t2 American Wo odwo rker . t u L2vo o 3

 swer

StickyDrawerSlides
Q. t built a set of kitchen drawers with ball bearingslides l0 years ago.Today,
some of the drawers are sticking.Can I relubricatethe slidesl

A. Yesyou can, with white lithium greasefrom an auto parts store.

' Assuming you haveruled out mechanicalproblems (loose screws,overloading,
etc.), first clean the slide'sball bearings with a cotton-tryp.d swab. Use a plain
household cleaner,such as 409 or Fantastik. Scrub the bearings clean with an old
toothbrush. When you're done, wipe the slide with a dry rag.
White lithium greasecomes in truo convenient forms at auto supply stores.Youcan
buy a small tube (about $2) or an aerosolcan with an applicator (about $4.50).If you
usethe tube, dab a little greaseon the bearings with a clean cotton-tipped swab and rub
it in with your finger. Work the slide back and forth a few times to distribute the grease.
Wipe off any excessgrease,and your slide should be good as new.

WhenShouldI SharpenMy Blade?

Q. How canI tell whenmy carbidetablesawbladeneedsto be sharpened?
A. Therearethreesignsthat a bladeis gettingdull burning on both sidesof
the cut,moreresistance whenripping a board,andworn teeth.
Burning. If your bladeconsistentlyleaves burn markson only onesideof a
cut,your fenceor splifferis probablyout of alignment.If you seeburning
on both sidesof the cut,the bladeis gettingdull.
Feed resistance. If it takesa lot of pressureto push a board
througha rip cut,eitherthewoodor bladeis to blame.Boardsmay
spreador closeup whencut,bindingagainstthefenceor spliuer.Try
testingthe feedresistance with plywoodinstead.Is it the sameas
whenthe bladewasnew?
'Worn
teeth. Rer4ovepitch buildup with a blade cleaner(see
Sources,page92) and examinethe teethwith a magnify-
ing glass.A 10X works best,but any magnifier will do. If
any of the corners of the blade havestarted to wear away,or
if you seeany rounding over of the tops and sides,the blade
slrouldbe sharpened.Cleaningthe blade can alsoimprove
its performance.Pitch build-up wont dull the blade,but
it can affect the quality of your cut.

SOUTeS seehsee2
American Woodworker JULv2oo3 13
Q u e s t i o n& A n s w e r
Need
DoesPolyurethane
Sanding?
Q. I've usedsolvent-basedpolyurethanefor years,and have ,,,i,111',,
alwaysbeen carefulto sandbetweencoats.I havebeentold .{S
sandingisnt necessary.ls that true?

Lt*urn ptasTF
A. lolyurethanes for floors orwoodwork are often
formulated so they dont have to be sanded,but i,,ih,ffi,f
polyurethanesfor furniture generallyshould be
sanded.
Sandingremovesunevennessand dust
in a brushed surface.If you want a silky,
smooth feelto your finish, you must sand
between coats no matter what kind of poly
you use.
By abradingthe surface,sandingalsoimprovesthe
mechanicalbond betweencoats.Sandingscratcheseffec-
tively increasethe surfacearea,so one coat adheresbetter to
another.Somekinds of polyurethanedon't needto be sandedto
bond well,but only if you re-coatbeforethe finish hardenstoo much.
The window is usuallyabout 12hours. If you wait longer,you should
alwayssand. IW

t4 American Woodworker J U L2Yo o 3

 ",.#B'
"f-' t\
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AngleSledRunners
Aluminum z

If you've had a problem with the wood runners on your spacer.You mayhaveto adjustthe thicknessof this spacer.You
o
tablesawsledshrinking or swelling,make new runners from want the angleto ride abovethe T-slot in the miter gauge.If F
o
T

1/8 in. x3l4-n.aluminum angle.Theserunners will fit most your miter gaugeslot does not have a T-slot, use a thicker
miter slots and will not shrink or swell like wood. wood spacer.lustleavea little clearancebetweenthe bottom lrl
J
O

Here'show I built mine: First I fit the angle to the miter of the miter slot and the bottom of the angle. z
'a
gaugeslot in my tablesaw.Youmay need to file the angle a lir Now I setthe sledon the tablesawwith the first runner in z.
-
-o
tle to get a good fit. The angle should glide smoothly in the a miter slot.t pulled the sledback a bit and put anotherpiece z
E
mitergaugeslotwithoutbinding,with minimum sideto side of anglein the secondmiter slot,carefully marking the loca- lrl

tion for the sawkerf. I cut the kerf and attachedthe second 2
Pray. F
Next I cut a sawkerf in the bottom of the sled base.The runner.IVe usedmy sledfor yearswith perfect alignment and (J
U
E
kerf makesrunner alignment automatic.Turn the sled over smooth action year round.
F
and fasten the first angle to the base with a 1/4-in.-thick IohnRhodes E,

16 American Woodworker JULY2oo3

WorkshopTips

DrawerSlideTracingfig
I recentlyneededa jig to tracelatheturnings.I tried a variety of
designsbut none producedthe accuracyor easeof operationthat
I wanted.
While rummaging around my shop, I discoveredan extra
setof 10-in.ball bearingdrawerslides(seeSources,page92) Ieft
Light
MobileMagnetic
over from anotherproject.I attacheda singleslideto a bracket My shop has poor light. I've found a magnetic-base
and attacheda pencil to the slidewith a notchedwood block and work light (seeSources, page92)to be a realgodsendon
Wing Nut. The bracketfits in a dado in the jig's base.The lathe my bandsawand drill press.I liked the light so much I
turning is held betweena coupleof sharpenedmachinescrews. figured out how to useit an1.r,''rhere
in my shop.I brought
The right holder is attachedto a T-track with a T-bolt and knob home a handfulof metalelectricalbox covers(about50
so I can move it for differentpart lengths.To usethe jig I move centsapiece)from my local hardwarestore.I fastened
the slidein and out againstthe turning while I slidethe bracket one whereverI neededadditional lighting, over my
left or right. The pencil doesthe drawing and I end up with avery workbench,sharpeningstation,/ou name it. Now I
accuratetracing of the part. can grab my light and stick it any,nrhereI needit.
Don Posto SteveJones

LongTenoning
Sled
Here'sa tablesaw-tenoning jig that
combinesthe light weight of a miter
gaugewith the support of a wide
tablesawsled.I madethis sledfor use
on the right sideof my blade so my
saw'sright-sidetablesupportsthe
sled.I alsoaddedan auxiliarywood
fenceto my rip fenceto act asa stop
guide and to protect the fencefrom
beingcut by the dadoblade.The tog-
gle clamp (seeSources, page92) holds
the work flat when cutting the facesof
my workpiece.When I cut the sidesof
the tenon,l just hold the part up
againstthe sled'srear fence.
JoyceHanna

18 American Woodworker J U L2Yo o 3

 W o r k s h o pT i p s

HandyDandyGraftSticks
A $3box of 1,000craftsticksis the best w o o d en sti cksfor everythi ngfrom stainand dabbingputty.
bargainI've found in a long time (see spreadingglue to shimming cabinet If you want to usea craft stickto stir
Sources,page 92). I use thesesmall doors.Theyalsowork greatfor mixing your coffee,iustbe sureit'.sa fieshone!

ShannortHooge
rW

Just0ilf ToolForAII
Your Rab[etingNeeds!
INsEnr SUPERABBET,
JR.* +nc-4e3ss
. 4-sided replaceable
carbide
knives.
t 13diflerentdeptfswilhoneloolusingoptional collars.
e Maintain exact
lolerances. -BASICTOOL
. Choose lrom4 different
dilferent
ffi AMA-12
applications:
(wood,
gradeknives
carbide for
o,4tquru,
plywood) H M A2- 1( s o l i sdu r l a c e / S S V ' / M D F )
llY-ll Smn-tz(softandhardwoort)M F A - 1( a2 l lp u r p o s e ) '**'*:." '--'"
..,,e*#

#
tr' ?
"dr\
:* I .",**

INSEnT
re
-BASICTOOL
SUpEnaBBET*
#RC-49360
o2-sided replaceable
caftide knives. If you have an original'Workshop
t 18ditlercntdepttrswithonelool Tio, send it to us with a sketch or
using oplional collars. photo. If we print it, you'll get
r Maintain exacl
tolerances. $ 100. Send to: W'orkshop Tips,
. Choose American Woodworker,
from3 different
earbide 2915 Commers Drive, Suite 700,
gndeknives lordilferent E"g*, MN 55121 or e-mail to
applications: workshoptips@readersdigest.com.
SSV@is a reqistered
m RCK-30 (wood/plywood) trademak of Submissions can't be returned and
"
ll I SRK-30 andhard
{soft wood) nI_ become our property upon accep-
(solid WILSONART" tance and payment. \We may edit
llo fl HnK-30
[---ll surface/SSV;7M0F) submissions,and use them in all
print and electronic media.
*ensrctoor,6b-+seoo, Rc-49355)
includes bit and one set of RCK-30
or AMA-12 kniv'es."
Helaiio ouq'nevraaialog AM-r-02
Amanafool'
FOR,OUN,NEW CAIALOG OR,A DEALEN,
' : NEARESTYOU CALL t-800-tw5-(n7z
FF$es {6 &'47 for more details !rvi"i,
ou, web sia ot www.amqnalool.com
 The
Price-Gutting
Saw
Got $100?That'sabout all it takesto buy Delta'sMS250 compound
miter saw-a sawthat recentlysold for ashigh as$170.Miter sawsare
greatfor the shop and asfix-stuff-around-the-housetools,and com-
pound miter sawsprovide evenmore versatility.On a compound saw
you can angle and bevel the blade. This is especiallyuseful when
installing crown molding.
With its 10-in.blade,the MS250will cut through2x6
and 4x4 (nominal) lumber at 90
E

E
degreesand at only 28 lb., this o
l
UJ
F
machine is a breezeto move a
tr
= o
z around. z
U
L A 13-amp motor powers the U'
o}!,

MS250.This will getyou through

=
U UJ
E I
:) hardwood, but more expensive F

machineshavemore powerful 15-ampmotors. a

?r ( trJ
J
The tableangles47 degreesleft and right with z
l

positivestopsat0,22-ll2 and 45 degrees. The blade E

trJ

tilts from -3 to 48 degrees.This is an areawherethe

E
l
F

MS250falls short. Many miter sawsoffer a greater

span of angles,up to 60 degrees,as well as more z.

positivestops,though not at this low price. Lr

a
t!
F
E.
l

l$nk-Free,Lightweight
Air Hose
I
o-
t

Do you ever feel like the conven- It's amazinghow easyit is to work -
L
ienceof usingair tools is ounveighed your way around a cabinetwith the a
E
u
by the rubber air hose python you Flexeelhose,and evenmore amazrng F
z
haveto drag around?Let that snake that it doesn'tcostmuch more than -
f

:<
hibernateand havea look at the new a good-qualityrubber hose.A Flex- E.
F
Flexeelpolyurethane hoses from eel hose weighs lessthan half of a o_

Coilhose.They'relightweight,flexi- rubber hoseand it doesntmar like a 2

F
ble and easyto coil, but resistkink- rubber hoseif you happento drag it (J
U
E
ing. They come in cool colors,too. acrossyour work. o
F
E
CoilhosemakesFlexeelhosesin a All the Flexeelhosesare trans- '.4

rangeof diametersand lengths.The parent,soyou canwatchfor problem E.

L
ll4n.x21-ft.coil hosecosts$18;the moisture or oil migrating from the a
(J

straighthoseis $l9,without fittings. compressorto the tool.

c;
o
o
U

Sourc€Sforallproducs Seepage92

22 American Woodworker JULY2oo3

Dp$d,,$hpp?.gv-dk
TOGGLE

Rock-Solid CLAMP

GopingSled
When you make doors on the
router table,the tricky part is cop-
ingthe end grain of the rails.You
need a darn good grip on the
material and a backerboard
to preventblowout. Eagle
America has you cov-
er ed on bot h c o u n ts
with their new coping sleds.
Choosefrom the Original, $40 or
the Pro model, $60.
The toggle clamp grips your material, and a
replaceableguide block of high-density poly-
ethylene (HDPE) plastic backs up the cut to
eliminatetear-out.With tr,vostout handles,hold-
ing the sled and feeding across the cutter is a
breeze.Sure,you could build one of these,but
when you roll in the price of the toggle clamp and
time spent to do it, thesesledsare a great value.
The Pro model has a slightlywider basethan
the Original, and includesa"keeper"on the front
to help hold material against the guide block.
Maximum width between the keeper and the
guide block is 3-314in. Both models use a self-
adhesiveabrasivetape to help keep your work-
piecefrom slipping.
With adequatepressurefrom the toggle clamp,
a sharp bit, and smooth feed rate, the Original
sledworks fine, but if you're brand new to door
making and want a little extra insuranceagainst
rail slippage,you'll get it from the Pro model.
After using the sled once,yott've got a set-up
gaugefor your next door. fust usethe cope pro-
file that'sbeen cut into the guide block to setthe
height of the bit.

American Woodworker J U L 2Yo o 3 23

 Shop
TheWell-Equipped

Gyclone
Space-Saving System
Dust collectorswith balloon-like filter c a rtri d ge fi l ters i nstead of bags.
r
bagshave away of eating up precious Cartridgestake up lessspaceand filter
shop space.A new 2-hp cyclonic col- better than bags. Oneida filters are tr
lector from Oneida Air Svstemsoffers made of high-quality filter material z.
=
a
U

and capture over 99.9 percentof test

material between0.2 and 2 microns.
This new collector comes in two
versions.The one with an internal fil-
ter, $882,has a footprint of 24 in. x 24
in. The other version,with an external
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with a 55-gallon drum, it's 99-in. tall.
The external cartridge is a lot easier
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which mustbe removedto be cleaned.
The efiernal cartridge can be blown
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24 American Woodworker JULY2oo3

 T h eW e l l - E q u i p p eSdh o p
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downloadedfrom the Websiteand printed.The instructions
#tilHKb
are clearand include good photos,not sketches. However,
AE ,"t rtotto
it maytakeyour computera while to digestthe photos.The '
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with dial-up connections.
A paid membership($ZSper year)getsyou accessto a
greatervariety of techniqueslike sharpeningand finishing,
aswell asmany additional carving projects.The member-
ship also includesa CD with the free tutorials, so you
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 BasicHVLPSPR
TECHNIOUES
How to succeed
at sprrying
owaterborne finish
hen it comesto finishing, we're all looking for easyanswersthat give pro-
fessional results.Yearsago, I switched from brushed and wiped-on fin-
t

ishes to shooting waterborne finishes with a high volume, low pressure m

-
(HVLP) turbine sprayer,and I've neverlooked back.Now my finishesare quick, safeand
:<
z
durable,and they look like a thousand bucks.
B

I made a lot of mistakesalong the way,however.Sprayingis a whole craft in itself, and z

I had to learn on my own, the hard way.If you'veneversprayedbefore,or arejust learn- E
a

inghowthis step-by-stepguidewill helpyou avoidthe most common pitfalls.Wdll cover J

-J

how to set up your shop,how to adjust the spray gun and how to go about spraying a lrJ
Y
-t
I
basiccabinet.Obviously there are a lot of fine points that we wont cover,but this is really lrJ

all you need to get going. )

J

6
A good HVLP systemcan cost $600or more (seeour tool test on HVLP sprayerson
E
page 56), but if you want to take a test drive before buying, or simply want to get one
o
F

big project done quickly,you can rent an HVLP systemat a paint store. T

E
lrJ
F
Waterborne Flnishes Are User-Friendly z.
?

:<
Waterbornefinishesareclearlythebestchoicefor sprayingin a home shop.Yougetmost C)
E
F
of the benefits of sprayed lacquer or polyurethane without needing an explosion- tr
;o
proof exhaustfan or explosion-proof lights. Warcrborne finishes generallydry to the tr
UJ
touch in 3 to 10 minutes, and you can re-coat in lessthan an hour, building up 3 or 4
o
coatsin a day.The quicker a finish dries, the lesslikely dust will contaminate the sur- so

face.Clean-up simply requireswarm water. q

a
Be sure to buy a waterborne finish that is labeledfor spraying.Waterborne finishes
=
for brushing are too thick to successfullyspray,and generally can't be thinned. See
o
SprayableWaterborne Finishes,page 38, for a representativelist of manufacturers. =
lrl

American Woodworker JULY2oo3 29

 ;,,:l:
"-: i J ,

Before You Staft

Beforespraying,do somehousekeeping
in your shop and practice how to hold
'$ the spray gun.

€
:# PrepareYour Shop
Sprayingin a smallshop is a constantbaale
with dust and overspray.(Overspray is the
fine mist that bouncesoff or missesyour
project.) Outfit your shop with plastic
sheetingon the walls,a canvastarp on the
floor,a halogenlightand a Wndow fan (about
$ 150total). Dust kicked up by the'gun can
ruin a finish.Thetarp and sheetingeliminate
the dust hazard and keep overspray from
settlingon your tools,floor and wallsVacuum
AT-e50
your project before you spray.
P
Ventilateyour shop with a window fan
behindthe project,blowing to the outside.
Crack open a door or window on the other
side of the shop to supplyfresh air.Weara
Thisworkhopsetupisdesigned
Caution: onlyforspraying not
waterbohefinishes,
finishes,
solvent-based andpolyurethane.
suchaslacquer respirator with an organicvapor cartridge
when you spraywaterborne finishes.

Strainthe Finish
Waterborne finishesmay containsolid clumpsthat will clog the
gun or spoil a finish.Solidpiecesof finishor dust mayfall into the
finish can, too. When you pour finish into the sprayer'scup,
strain it through a smallnylon anklet sock.Youcan rinsethe nylon
with water and use it over and over.
For the steps ahead you'll need a large disposablesurfaceto
practice on.We used builder'srosin paper,availableat a home
center for about $ l4 a roll, but plain brown paper or cardboard
would work.

PracticeHolding the Gun

There'sa right way and a wrong wq, to hold the gun,and)rou must
be familiarwith the right way before adjustingthe gun'scontrols.
The first step is to turn on the HVLP turbine to pressurizethe
cup.Pressurekeepsfinishfrom travelingbackup the pressuretube
and dribblingout of the gun.
Pick up the gun and hold it at 90 degreesto the surface.Dont
let the gun droop, particularlywhen you adjustthe gun'scontrols
in the steps ahead,becausethat will create an uneven spray
pattern. Hold the gun 6 to 8 in. awayfrom the surface.
Lock your wrist and move the gun backand forth with your arm.
The speedof your arm movementdetermineshow much finish
you apply.Move too slow and the finish will pool. Move too fast
and the coat will be too thin.You'llfigureout the right speedafter
you set the gun'scontrols.

30 American Woodworker J U L2Yo o 3

 FAN PATTERN
CONTROL
Adjust the Gun
Settingthe controlson the gun can be a complicatedprocess
of trial and error, but there is an easierway.We'll take you
through an orderly processthat will work each time you
readjustthe gun for different situations.

Know the Gun's Controls

Every HVLP system has three basiccontrols: the volume of air
flow the volume of fluid flow and the type and size of the fan
pattern.Thesecontrols may be located in different placesthan on
the gun shown at right. lf you're in doubt, check the owner's
manual.
An HVLP gun uses air to break up a fluid finish into tiny
droplea. lt's called"atomization." Once atomized,the droplets are
formed into an adjustablespraypattern,calledthe "fan."Thetrick
to adjustingthe gun is to get the right atomization,or balanceof
air and fluid volume, acrossthe entire width of the fan pattern.
But before you tackle that problem,the first controlto adfust is
the fan pattern itself.

Setthe Air C"p for FanSize

A small detour here. lf you have the type of gun that has an
adjustableair cap,set it now.Turn the cap so the nozzle is flush
with the face of the air cap.Asyou become better at sprayingyou
can readjustthe air cap to changethe sizeofthe fan pattern.For
now,leavethe nozzle flush with the air cap.

AIR CAP
FLUSH WITH
NOZZLE
Selectthe Fan Pattern

All air caps can be set in three positions. Each position these settings.
creates a different fan pattern. For learning how to set the air and A vertical fan is good for tops, or any time you move the gun side
fluid volume controls in the steps ahead,set the air cap to make to side.A horizontal hn is good for sides,or any time you move
a vertical pattern.Air and fluid volume settingsare about the same the gun in and out, directly awayfrom you.A round fan is used in
for vertical and horizontal hns. Round fans require readjusting specialsituationsto concentrate the finish in a small area.

American Woodworker JULY2oo3' 31

 l
Adjust the AirVolume

Regulate the air flow from the turbine too little just right too much
by'turning the knob on the air hose.
Make this adjustment beforetacklingthe To start out, turn down the Slowly increasethe air lf you turn up the air
fluid volume, below. Increasingthe air air control most of the volume until the fan is volume too much,you'll get
flow creates tinier droplets of finish,or way. Pull the trigger and evenlyatomized and has spraythat looks like a fine
more atomization.Thick finishes need make a pass.lf finish spits clearly defined edges, mist, plus an excessive
more air;thin finishesneed lessair.Hold out of the gun or if you see without splatter. amount of overspray.
the gun 6 in.fiom the surfaceand pullthe splatter at the edge ofthe Reducethe air volume and
trigger back only hr enough to create a hn pattern, turn up the air test again.(lf the air volume
6-in.-wide fan pattern. a little bit. is at the mar<imumand the
gun is still spitting finish,
use a thinner finish.)

Adjust the FluidVolume

Regulate the fluid volume by turning

too little just right too much
the knurled knob at the back ofthe gun.
This knob controls how far you can pull Begin by adjusting the lncreasethe fluid volume Back offthe fluid volume
the trigger. As you pull the trigger, the trigger for a minimal pull. until the fan is 6-in.wide. if your surhce is flooded
volume of finish increasesand so does the As you move the gun,the Tirrn the knob to stop the with finish,or move the
size of the hn pattern.Your goal is to set hn should be smallerthan trigger at this point. Now gun at a faster rate.The
the trigger so it automatically stops at 6-in.wide. Some spraying you can simply pull the fan will be too large when
the ideal size hn for the work you're situations,such as spraying trigger all the way bac( like you pull the trigger back
doing.To start out, stop the trigger at a a narrow hce frame, call an on/off switch, to spray too far.
6-in.-widefun. for a small fan in order to the same size fan.As you
minimize overspray. move the gun,you should
get an even,wet coat of
finish,not a mist and not a
flooded surf'ace.

32 American Wo odworker J U L 2Yo o 3

Spraying Techniques
Practicemakesperfect. Rather than start right in
on an actual project,build a disposablecabinet to
try out the following techniques.For construction
details,seePracticeCabinet,page38.

SprayingInside a Cabinet
Always beginwith the inside of a cabinet.A general
rule of thumb of spraying is to start with the least
visiblesurfaceand end with the most visiblesurface.
This minimizes overspray from settling on and
spoiling a surface that really counts. Overspray on
visible areaswill be covered by the final coat.
Fill your cup 3/4 full with finish.This preventsthe
fluid nozle insidethe cup from beingstarved of finish
whgn you tip the gun to get into corners.
Adjust the air cap to make a vertical hn.Increasethe
air flow to create a light spray Pattern and minimize
overspray. Light coats are fine inside a cabinet.
Reducethe fluid volume to make a 6-in.-widefan.
Next, follow the steps as shown: Spray under the top, moving from the back to the front.The hn Pattern
should just reach the edge ofthe cabinet back

Spray the back, overlapping each passby 50 Spray the sides, moving from back to fronq away from the overspray.
percent. Position the edge of the fan pattern to
just reach the inside corners. lf you spray directly
into the corner,finish will run down the inside
edge or overspray will bounce back toward you.
On an actual cabinet, remove the back if you can
and finish it separately.

Spray the botrtom, tipping the gun as close

to 90 degrees as )tou can to create an ideal
hn pattern.This is the most visible part of
the cabinet'sinside.Sprayinghere last blends
. in overspray from previous steps.

American Woodworker J U L2Yo o 3 33

 Spraying FaceFrames
and Small Surfaces
Switch the air cap to a horizonal fan pattern. Reduce
the size of the fan pattern to about 3-in. across to
minimize overspray.You can reduce the fan by
reducing fluid volume, reducing the air and fluid
settingstogether,or movingthe gun slightlycloser to
the surhce.Alwaystest on paper before sprayingyour
cabinet.
When you first pull the trigger to sprayany vertical
outside surface,such as this face frame, dont aim
right at it. Instead,aim the gun at a point above the
faceframe,as indicatedby the yellow oval at left.Then
pull the trigger and work your way down.'Dont
releasethe trigger until you're past the bottom. Do
this in one fluid movement,alwaysholding the gun
perpendicularto the face frame.

Spraying
Vertical
Surfaces
Adjust the air cap for a
horizontal fan pattern.
Adjust the fluid volume
and the air volume to
make a 6-in. fan pattern
on a piece of paper,as
shown on page32.

Start spraying at the top.Aim the gun at a point Return at the bottom and work your way up,
abovethe cabinet and pull the trigger.Then move overlappingthe first passby 50 percent.Once
down the cabinet,just as you did with the face again,use the sametechniqueof aimingat a point
frame above. underneaththe cabinetwhen you first pull the
trigger.Repeatan up and down sequenceuntil the
side is covered.

34 American Woodworker J U L2yo o 3

Spraying Tiops
Set up your light at a low angletothe toP so you can
clearly see your spray patterns.
The edge of a top deservesspecialattention. lt gets
three coats for even/ one coat that goes on the top
itsell in part because edges inevitably get extra
wear.In addition, it's easyto sand too deep between
coats on a narrow edge.Extra coats will help prevent
accidentallycutting into a stain layer under the finish.
Set the air cap for a vertical 6-in. fan pattern for
bottr the edgesand the top surhce.lt's not necessary
to reset the air caP to a small fan for the edges,
becausethat will slow you down.
Waterborne finishesdry very fast.Your goal is to
keep the gun moving at all times. Eachpassshould
blend into a previous passwhile it's stillwet.

Spray all four edges, all the way around the top. Hold the gun at 90
degrees.Some oversPra),will land on the toP, but that's okay.You'llcover it
up later.

Spray the top edges. Hold the gun at 45 Spray the top. Hold the gun at 90 degrees,and spray acrossthe front. Use
degrees.Again,dont worry about oversPray onto the sametechnique of handlingthe gun'strigger as you did with vertical
the top. surhces on page34.As you move the gun from side to side,pull the trigger
before you reach the top and releasethe triSSer only after you've passed
beyond the top.

Overlap each pass by 50 percent.Alternate

direction back and forth to keep the gun moving
quicker than the finish can dry. Sprayingfrom front
to back directs overspray toward the window hn.
. Stop sprayingwhen you reach the back.

American Woodworker J U L 2Yo o 3 35

Runs,Drips and Errors Missed Overlaps
Mistakesare inevitableas you
learn to spray.I've madesome
I'vecometo con-
whoppers,but
NOT
siderthemasopportunities,not ENOUGH1
'\
FINISH
failures!With eachopportunity'
I
you'll becomemore familiar
with fine-tuningthe gun's
adjustmentsand holding the
gun while spraying.
- r.t;l:
', :1"+i Fortunately,most mistakes
to be careful,I moved the gun Cheapskate! What was I thinking? That I'd
Yucl<.Trying a r e e a s yt o f i x b y s a n d i t g . at all?lt's
t o o s l o w w h i l e s p r a y i n gt h e s i d e o f a savefinishby hardlyoverlapping
cabinet.Or maybe my fluid volume was Waterbornefinish dries very not worth it, becausehere I'vegot a rough
too high,ldon't know.ln anycase,I let the looking texture between the spray coats.
messdry,shavedoff the excesswith a utility
fast.Whenyoumessup,waitan Actually,I just couldn'tsee where the fan
patternhit the surface,so I couldn'tiudge
knifeandthen sanded.Next time l'll check hour,sandand sprayit over.
my adjustmentsby sprayingon a pieceof the overlapsproperly.What I reallyneed
paperfirst and make sure I l<eepthe gun next time is a bright,low-anglelight.
moving.

Bubblesin the Finish Pools of Finish at the Ends Clogged Needle

TOO MUCH
FINISH
t-rurrr.

I told everyoneI reallywantedthe finishto There'sa wadingpool-sizepuddleat the Now what?My gun quit on me after I tool<
l o o l <l i k e M a r s ! U n f o r t u n a t e l yn, o o n e end of this top.What happened? | must have a coffee breal<!No, the gun'snot at fault.
bought it. Bubblesmean the coat is too startedthis passby aimingright at the end, While I was relaxing,finishdriedon the cap
thick.Airgot trappedbelowthe finishasthe and then pulledthe trigger.I know that'snot andformed a hardbubbleover the needle.
s u r f a c ed r i e d .l w a i t e d u n t i l t h e f i n i s h the right technique,
so l'll repeatto myself No problem,I can cleanit right off with a
hardened, then sandedout the offenders.To as I move my arm,"aimat a spot just beside toothpick.Now I alwayscheckthe capfor
spraya lightercoat,l'll eitherincrease the air the top, and then pull the trigger."In fact,I dried finishif I put the gun down for a few
flow,decreasethe fluidvolumeor movethe vow to keep practicinguntil it becomes minutes.lt'sas mucha habitastakingcoffee
gun faster. secondnature! breaks!

36
SprayingRaised-PanelDoors
Edgesare everywhereon a raised-paneldoor!The
secret to successis to follow a systematicplan.
To set up the gun,turn the air caPto a vertical fan
pattern. Then increase the air flow a bit beyond
where you set it in "Adiust theAir and FluidVolume,"
page32.Thisincreasesthe atomization of the finish,
producing a finer spray and lighter coat. Finally,
reducethe fluid volume (the trigger setting)to make
a 4-in.-wide fan pattern. Now you're set to 8o.
Placethe door on some 2x4s to elevateit abovethe
table.The best setup,though, is to make a turntable
to support the door.Then you can rotate the door
as you go, alwayssprayingtowards the window fan.

Spray alt four edges, all the way around the door. Hold the gun about 6 in.
away.

Spray the outside top edges. Hold the gun at 45 degrees Spray the inside top edges. Again,hold the gun at 45
and make a second passall the way around. degrees.Keep the gun moving to Preventfinish from building up
in the corners.

Spray all the top surfaces. Hold the gun at 90 degrees.Spray

Spray the bevels of the panels. Continue to hold the gun at
two continuous coats for full and even coverage.Sprayfrom
45 degrees.lf your panel is prefinished,naturallyyou'd skip this
side to side,then rotate the gun and sprayfrom top to bottom.
steP.

American Woodworker J U L2Yo o 3 37

Cleaning the Gun Practice Cabinet
At the end of a day of spraying,take 15minutes to cleanthe
Build this partial cabinetto practice spraying.lt's better to make
gun. If you skip this step,the gun may not spray properly. mistakeson a throwawaypiecethan on your pride and joy! Make
Empty the cup and fill it with warm water.Adjust the air the cabinetfrom a half sheet of 314-in.MDF (medium density
cap to make a round fan pattern, reducethe air volume and fiberboard) and assemblewith a brad nailer or drywall screws.
increasethe fluid volume. Then follow thesesteps:

Spray warm A
water into a
bucket until the
water is clear.This
cleansthe internal
fluid passages inside
the gun.Empty
the cup.

Disassemble the
gun, removing
eveD/ Part )rou can.
Clean off dried
D 1-114'
x 16'
finish with warm
water and a brass
brush.Make sure
the holes in the air
cap are clean and
free of finish.Poke
them with a dull
sewingneedleor
toothpick.

Lubricate the
gun. Wipe
petroleumjelly on
all threadedor
movable parts.
Reassemble the
gun. IW Sprayable Weterborne Flnlshes EF Pro-series
These waterborne finishesare specifi- www.ge neralfin ishes.com
cally formulated for sprayingwith an (800) 783-60s0
HVLP system.Thisis just a sampling; EnduroWat-R-Base
there are many others on the market. www. compliantsprq/systems.com.
(800) 696-06ts
ApollocoatAquaClear
www.advmachinery.com Hydrocote
(800)727-6ss3 www.hydrocote.com
(800) 22e-4937
Crystalac
www.crystalac.com PianoLac
(63r) 207-0328 www.pianolac.com
(84s)8ss-0ee6

38 American Woodworker JULy2oo3

 lovemy new 36-in.TV The double-hinged doors fold expect to pay about $ 600 in
but my wife hateswhat flat against the sides to open up materials for this project.
the glassand plastic the cabinet for unobstructed
viewing. Plus, they're a whole lot
Ventilation and
monolith doesto the Wire Management
look and feel of our family cheaperand easierto install than
Big TVs kick out a lot of heat, so
room. To avoidmarital strife pocket doors. The adjustable,no-
adequateventilation is a must. The
we went looking for some- mortise,partial-wrap hinges(see
cabinet is designedto let the heat
Sources,page 92) make these
thing to housethebehemoth. escapethrough a series of vent
doors a snapto hang.
No luck.Soundslike ajob for holes(Fig.A).
the familywoodworker!I love Cost and Materials
it when I get a chanceto jus- I chose pine for its
tify my sometimes-contro- rustic feel.Plus,I love
versialinvestmentin the shop. the smellof fresh-cut
A cabinetlargeenoughto pine in myshop.
accommodate a 36-in. TV Pine plywood is a
could look like an oversized special-orderitem
shippingcrate.But I used a and comes w i th
designwith angledcornersto either knotty or clear
easethebig-boxlook. veneers(seeSources,
Note:Thereareafewextra- page 92). Y ou can
deep 36-in. TVs that may
requireyou to cut a hole in
the back for the TV to poke
through. You could make a
deepercabinetbut youd have
to buy an additionalsheetof
plywood.Playit safe;buyyour
TV first,thenadjustthe depth
if necessary.

Television

American Woodworker J U L2Yo o 3 4l

 Holesat the bottom of the uppercrosspiece
and at the You'll Need aWell-Equipped Shop
back of the TV shelfallowboth wiresand heatto pass To build this projectyou ll needa tablesaw,a stackingdado set,
through.All thewiresfunnelout of an 8-in.-dia.holein bandsaw,biscuit joiner, screw gun, router table, router,
the back (Fig.A). The removablebackallowseasyaccess pneumaticbrad and finish nailer,planer,miter saw and at
to the snake'sden of wires behind the TV and its leastsix 6-ft. pipe clamps.
components. Checkyour router bit collectionfor a ll2-in.Roman ogee,a
ll2-in. cove,a ll2-in.round over,a flushtrim (top or bottom
bearing),and a chamferbit. If you want to makeyour own bun
feet,you ll alsoneeda 1-in.round-overbit (seeSources, page
e2).
Build some knee-high sawhorsesto support an oversized
assemblytable.
All set?Let'sstartbuilding.

AA /.\
45 DEGREES

Double-hinged doors fold flat against the sides,

leavingthe screenwide open for optimal viewing.
Becausethe doors are doublejointed,they can be
operatedwith as little as l4 in.of side clearance.

* uoRuAttyAPPLIED
TO RIGHT-HAND
DOOR
A conveniently located drawer with full-extension
slidesallows easyaccessto a treasuretrove of movies.

Detail I
Door Moldings
DOOR
TRrM(X)
DOOR
ASTRAGAL(Y)

..
r-2
7112"
l3.r \rtaf
DOOR PANEL
rRtM (z)
, \
COLUMN
TR|M (AA) n
Round over top of
door trim (X) with
sandpaper
:aF*")'.)lJl-L---i
\ -'L.'

114,,/
f. tVl-
r/16"r'.,{-------l
f ;--
*
1t4"
l-t"--*l lgtl,.l I 1"+l t
l<-3l4"+l

Ameri can Woodworker JUL2

y003
Fig.A
View
Exploded

#8x2"
l"-

The "double-jointed"doors are

much cheaperand easierto
installthan pocket doors.
American Woodworker JULY2oo3 43
 ll Make all the Build the Cabinet
I shelves 1.Cut the 3/4-in.plywood partsA through J
identical by using (seeCutting List and Cutting Diagram,Page
one shelf as a
template. Cut the
sl).
angledcorners on the 2.Cutthe shelfblanks(B,C and D) to size.Lay
other shelvesa bit out the angledcornerson one shelfblank by
oversize.Clampthe making marks 4-in. from the corner along
rough-cutshelvesto the side and front edges.Connect the marks
the template,and trim
and rough-cut the corner on the bandsaw.
flush with a router.
3. Clamp a straightedgealongyour layoutline
and usea flush-trim bit to finish the corners.
Usethe finished shelfasa templatefor making
the other shelves(Photo l).
4. Glue up the double-thickTV shelf (C) and
r) Glue edging the centerdivider (F).A coupleof brad nails
3 to the cabinet
will keepthe halvesfrom shifting under clamp
parts. The angled
corner edgingon Pressure.
the shelvesis done 5.Add the 1/4-in.edging(QQ and RR) to all
first. Use a notched the angledcorners(Photo 2). Then add the
block to apply front edgingpieces(NN and RR) to all but the
clampingpressure.
bottom shelf(it'llbe addedlater).
Let the edging
overhangalongthe
6. Cut the semicircularhole in the back of the
front.Then trim it TV shelf.Add 1/4-in. edging to the drawer
flushto the plpvood openingdividers(l) and the centerdivider.Cut
on the tablesaw. the notch at the top of the drawer opening
dividers(Fig.A).
7. Cut through dadoesand rabbetson the
sides (A) accordingto Fig. D. Glue on the
solid-woodedging (PP) and
sandflush.

G l u eU p
Gluing up this cabinetis a big
job. Dry clamp the cabinetas
a dressrehearsalfor the real
t h i n g . M e a s u r et h e e x a c t
distancebetweenthe TV shelf
and the componentshelfand
cut the centerdivider (F) to fit.
ScrewtheTV and component
shelvesto the center divider
and disassemble.

cabinet
Q Assemble the
tJ with cauls and shims.
The shimshelp put pressure
in the center of the cabinet
sides.Fastenthe center
dividerto the two center
shelvesbefore assembly. Use
screws for the bottom shelf:
moldingwill cover them later.

44 American Woodworker J U L2Yo o 3

l. Assemblethe cabinetwith glue (Photo 3). i Create a ledge
-J below the doors
Make sureit's square!
with solid wood
2. Cut the upper (G) and lower (H) fastened to the
crosspiecesto width. Cut the wire and vent underside of the
archesin the upper crosspiece. Add the screw component shelf.
flanges(GG) to both. Use a 7|8-in.spacer
3. T\rrn the cabinet on its side and reach in block to keep an even
reveal.
from the back to screwin the uPPerand lower
crosspieces (Figs.C and D).

Apply the CabinetTrim

The cabinettrim is applied to nailer boards
fastenedto the subtop and the comPonent
and bottom shelves.
of
Beforeyou cut your trim stock,selectthe E Add a row
t nailers below
best-looking,straight-grainedpine for the
the ledge to create a
column doors (N), column bases(P), door surfaceto nail moldings
frames(R, S and T) and drawerfront (Q). to.The nailer is flush
1.Rip the nailerstock(DD).Cut and fit nailer with the ledge in front
boards under the componentshelf (Photo 4 but is recessedat the
angledcorner where
and Fig.F). The tops of theseboardscreatethe
the column basefits.
ledge under the doors, so use defect-free Determine the
stock. setbackfor the
Note: Before you add the nailer to the recessednailer by
front of the component shelf, slip the two holdingthe column
basein placeand
drawer opening dividers into the opening.
tracing the back edge
You won t be able to get them in once the onto the ledgeabove.
nailer is in place.Dont screwthem in place
Justyet.
2. Double up the nailer board
along the front edge of the
c om ponent s he l f. T h e n a i l e r
board at the angledcornersis set
back to accommodate the
column base(Photo 5 and Fig.F).
3. Cut, glue and nail the column
basesin place.
I Screw dividers
4. Attach the drawer opening lJ into the case to
dividers (Photo 6 and Figs. A create the drawer
and C) . opening. A 35-in.long
s. Add shelf edging (MM) and spacer board keeps
the dividersparallelas
nailers to the bottom shelf (see
they are screwed into
Fig.F). position.Tip:Mount
6. Machine the ogee (KK) and the drawer slidesto
round over moldings (LL). Glue the dividers before
them together to make a single they're fastenedto the
cabinet.
m o l d i n g . N o t e : R e m o v et h e
bearingfrom the round-overbit
to createthe double fillet (Fig.
D).Cut and fit the two bands of
molding around the lower
portion of the cabinet(Photo 7).

American Woodworker J U L2Yo o 3 45

 I Attach the T.Addnailersto the top of the cabinet(Photo
, moldings 8 and Fig.E).
with nails and
8. The angledcornersof the top (E) are cut
glue.We used
specialmolding in the sameway asthe templateshelf except
glue insteadof you measureback 4-314in. from the corners
traditionalyellow insteadof 4 in. Glueon the top edging(HH).
glue.Thethick- Then rout the ogeeedge(Photo9).
bodied molding
9. Attach the top, keeping about a 1-in.
gluewont drip
or run while
margin on the front and sides.Apply the
positioningthe covemolding (Photo 10).
molding.
Doors and Drawer
The double-hingeddoors may look like a
nightmare to hang,but theyte really a snap.
Adjustable,partial-wrap,no-mortisehinges
are the key.
Be carefulwhen screwingthe hingesonto
the bevelededgeof the column door (N).
Q Fasten nailer
I boards on top The hingescomewith li2-in. and 5/8-in.-
of the cabinet. These long screws.Playit safeand nip 1/16-in.off
nailerboardscreatean the ends of the Ll2-in. screwswith a side
overhangabovethe cutter so they won't poke through.
doors and providea
1.Make the column trim (AA) (Fig.A, Detail
surfacefor applying
the cove molding.Start 1). Glue and clamp it flush to the outside
with the angledcorner edgesof the columns(no nails,please). Then
naifer.Use a l-l l4-in. cut the bevelededges(Photo 11).
spacerblock to set the 2. Attach hinges to the cabinet side of the
overhang.Attachthe
columns. The point of the beveled edge
remainingnailersand
screw them down should butt right up againstthe barrel of
securely. the hinge.Attachthe columnson the cabinet
(Photo12).
3. Assemblethe door frameswith biscuits.
Removethe column doors and attachthem
to the door frames(Photol3). Put the door

A Rout the
I ogee edge on
the top.Just glue
on the edging,sand
flushand rout.Then
screw the finished
toP onto the
cabinet.

10*"?i1"'r"""
under the top and
against the edge of
the nailers. Hold
the moldingin place
with springclampsas
you go. Fastenthe
moldingwith glue
and pin nails.

46 American Woodworker JULY2oo3

 :W
qA Attach the door to the column. Make
Itf sure the columnand door frame are even
at the top by butting both piecesagainsta board
clampedto your bench.Put some short 2x4s
underthe hingedjoint so you can get to the
screw holes.

Rip the 45-degree bevels on the columns. To avoidkickback, make

44
I I sure the bladetilts awayfrom the fence.That'seasyon a left-tilt saw;on
a right-tilt,move the fenceto the left side of the blade.

4A Nail panel molding to the back of

It the door frame to hold the l/4-in.
panelin place.Miter the cornersof the molding
to giveyour door a finishedlook insideand our.

qt Hang the column on the cabinet. First,fastenthe hingesto the al tr Cut the door trim on the bandsaw.
lG column.Thenuse shimsto positionthe columndoor on the cabinet.The lrJ Tilt the tableto 20 degreesand securea
half-wrap,no-mortisehingeswrap aroundthe insidesur{aceof the cabinet;all guidefence.Use a sharp,high-tooth-count blade
you haveto do is screw them in place.Removethe columnsafter you're (6 to 8 teeth per inch) for a cleanercut that
satisfiedwith the fit. won't requirea lot of sanding.
Arnerican Woodworker JULy2oo3 47
 16il;lJi;in"'
drawer box. Shim the
drawer front so the gaps
will be even.A pieceof
duct tape stuck to the
inside of the drawer acts
as a temporary pull.
Open the drawer and
screw on the drawer
front from insidethe box.
The holes left by brad
nailsare tiny and easyto
disguisewith filler.

+':

J,a Cut the bun feet Fig. B Circle-Cutting

Jig
af on a bandsaw using
Machinethe solid-wood strip to fit
a circle-cutting jig. Set the
the miter slot of your bandsaw.Screw
blank onto the pivot point of
the strip to a piece of plywood and
the jig.Thenslidethe jig onto
slide the jig onto your bandsaw,
the bandsawand cut halfway
cutting a slot to about the halfway
through the blank.Clamp the
mark.Makea line perpendicularto the
jig in placeand spin the blank
end of the cut.To set the pivot point,
to cut the bun foot.
mark the radius of your circle from
the saw kerf to a point on the line and
pound in a finishnail so the head
protrudes I in. or so. Nip off the head
and your jig is ready to go.

48 American Woodworker J U L2Yo o 3

assembliesback on the cabinet. Apply the
astragal(Y) to the right-hand door. 18;l;?:in""
router table with a
4. Drill ll2-in. holes in the edging of the
l -in. round-over bit.
subtop and component shelf for the four With the subfences
rare earth magnet cups (seeSources,page wide open,set the
92) that keep the doors closed (Fig. A). fence over the bit so
Removethe door assembliesand hinges for the blankjust makes
sanding and finishing. contact with the
bearingand the
5. Make the panel trim (Z) (Fig.A, Detail 1)
subfencesare just shy
and add the panels (L) (Photo 14). Make of the blank.Thiswill
the door trim (X) (Photo 15) and fasten minimizebit exposure.
with glue and nails inside the door frame
opening(Fig.A).
6. Build the drawer box (Fig. C), add the full
aA Measure
extensiondrawer slidesand install the drawer lY how much
in the cabinet.Attach the pine drawer front your floor dips
(Q) (Photo 16). Add the iron pulls (see away from the
Sources,page92). wall. This cabinet
must be level so the
doors will stay open.
The Bun Feet Simplysubtract an
1. Make the four 7-in. blanks (BB). Run amount equalto the
diagonal marks from corner to corner to dip in your floor
establisha centerpoint and drill a 1/16-in. from the thicknessof
the foot blocks for
hole at the center of eachblank.
the back feet. Now
2. Cut the bun foot blanks into 6-in. dia. there'll be no
circles(Photo 17).Round over the edgesto unsightlyshims
finish the bun feet (Photo 18).(For ready- under the feet after
made feet,seeSources,page92.) your cabinet's
installed.
3. Machinethe foot support blocks (CC) so
they compensatefor any sag in your floor
(Photo 19). Screw them to the bottom of
the cabinet. Screw the bun feet to the foot
blocks(Photo20). lln Screw the
4V bun feet to
The Finish the foot blocks.
The thinner foot
I have to confess,even after 20 years of
block in backallows
professionalwoodworking experience,my the cabinet to sit
kneesshakewhen it comesto finishing pine. level on a sagging
Blotching is so hard to control if you want to floor.
add any color. For this project, I kept the
blotch monster at bayby sprayingthe whole
piecewith a shellacsealer(seeSources,page
92). Then I sprayeda color layer of toned
shellac.I made the toned shellacby adding
Il2 tsp. of Trans Tint Golden Brown Dye
(see Sources,page 92) to 1 qt. of shellac
sealer.Itopped it all offwith a couplecoats
of satin,waterborne poly.
For more on finishing pine from someone
who knows what he's doing, see"Staining
Pinei' page52,bythe incomparablefinishing
wizard,Tim Johnson.

American Woodworker J U L2Yo o 3 49

 Fig. C Fig.D
Horizontal Cross Section VerticalCross Section
Through Drawer and Dado Placement
114"X 112"RABBET

1
8 -1/9" D

firl
t
rGG
I *--*-L;
le
1.r U
I J
It. ooj
I

\\. )
,r(Z-
PP \ //r
P

Fig. E TopNaiter
Positionthe angledcorner
pieces(EE)so that one
22-112
mitered end runs directly over DEGREE
the corner of the subtop and ANGLE
the other mitered end runs
over the outside
corner of the
cabinetside.

LL
#8 x 1-114"
(rYP.)

Fig.G
ClampingJig

45 DEGREES

50 American Woodworker J U L2yo o 3

 Cutting List overaf
l dimensions
60" x 47-112"
x30-718"
Paft Name otv. Dimensions Notes
Sides 2 23-3/4^x56-1/2" add 1/2 edqe
a
b Subtoo/ComoonentShelf L 26-7/8" x 43" add 3/4 oine edoe to front
C W Shelf 2 26-7/8" x 43" add 1/4" pine edqe
D BottomShelf 1 26-7/8" x 43" pine is addedto the cut corners,then add 1-1/2" edqeto front
E Top 1 2 9 - 1 / 2x" 4 4 - 3 / 4 " measureback4-518'from the corneralonqboth edqesto createanqledcorner
F C e n t e rD i v i d e r
a
Z 1 1 - 1 / 2x"1 8 " qluetoqetherand add 114"edoe',don't cut to finalwidth beforethe dadoesarecut
Upper Crosspiece 1 1 1 - 1 / 2x"4 2 - 1 / 2 " add screwflanqes;cut a littleoversize,
then trim to fit aftercabinetis assembled
H LOWerLTOSSOTeCe 1 9"x42-1/2" add screwflanqes;cut a littleoversize
then trim to fit aftercabinetis assembled
J D r a w e rO o e n i n o D i v i d e r s a
Z 9 "x 1 8 " add 1/4" edqe;cut a littleoversize
then trim to fit aftercabinetis assembled
K Back 1 4 3 - 1 / 2x" 5 5 " screwbackto cabinetto provide accessfor wirinq
s5 Door Panels a
1 3 - 1 / 4x' 4 0 - 3 / 4 "
>o- L L

M DrawerBottom 1 4 - a t A
t/-J/+ x5z
i l a ^ t l

N C o l u m nD o o r 6-1/4'x45-3/4"
Z add column trim before cuttinq anqled edqes
P C o l u m nB a s e z 6-1/4'x9-3/4"
o DrawerFront 1 7-1/4'x35-1/4" trim to fit
R Stiles + 2-1/2'x 45-3/4"
A

S L o w e rR a i l s 2 3"x 12-1/2"
T U o o eR
r ails 2 2 - 1 / 2x' 1 2 - 1 / 2 "
U DrawerBoxSides 1 / 2 "x 6 - 3 / 4 x" 1 8 "
a
L

DrawerBox Front 1 1/2" x6-3/4"x32"

DrawerBox Back 1 1 / 2 "x 6 - 1 / 4 "x 3 2 "
X D o o r T r i mM o l d i n q Z+ 1 / 2 "x 7/ 8 " miterto fit insideof door frame
Astraqal 1 5 / 1 6 "x 1 " x 4 6 " trim lenqthto fit as required
Z Door PanelTrim 20' 1 / 2 "x 3 / 4 " add1/4" x 1/4' rabbet;bevelinsideandoutsideedqes;miterarounddoor panel
AA ColumnTrim 4 1/4"x1"x48' bevel inside edqe
B B B u n F e e tB l a n k s A 2"x7"x7" g l u eu p 2 l a y e r so f 3 / 4 " s t o c kp l u so n e 1 / 2 ' - t h i c kl a y e rf;i n i s h e d
f o o t i s 6 - i n .d i a
FootSuooortBlocks +
A
6 x6 varythickness
to levelcabineton floor
D D Nailers/LedqeBoards 26' Z - I / Z keepthe clearnailerstockto makethe ledoeunderthe doors
EE T o p A n q l e d C o r n e rN a i l e r 2 2-1/2'x 6-314" 6-3/4"lromlonqpointto lonq point;22-1/2-deq.
measure miteron both ends
FF Angled CornerLedge Board L 2 - 1 / 2 x' 6 - 1 / 4 " measures 6-1/4" from long pointto long point;45-degreemiterat cabinetside,
22-1/2-deq.miteron the otherend
G G S c r e wF l a n q e 4' 3 / 4 "x 1 - 1 1 2 ' qlue or screwflanqesto backof crosspieces
H H Too Edqinq
'r0' 3/4"x 1-3l8" rout oqee edqe after edqinq is qlued on and sanded flush
JJ Cove
'10' 3 / 4 "x 5 / 8 " rout cove on wide piece of wood, then rip on tablesaw
KK O g e e 1 B ' 3/4"x 1-3/8"
tL R o u n d - O v eM
r oldinq td 3/4" x3/4" rout profileon two edqesof a wide board,then rip on the tablesaw
N/M B o t t o mS h e l fE d o i n o 1 1 - 1 / 2x" 3 6 " cut to fit betweencolumnbases
N N O t h e r S h e l fE d q i n q 6 ' 3/4" x3/4" trim lenqthto fit as reouired
PP S i d eE d q i n q 2 1/2"x3/4"x56-1/2"trim lenqthto fit as required
Edqino 4', 1 / 4 "x 3 / 4 " trim lenothto fit as reouired
RR W i d e E d o r n o o 1 / 4 "x 1 - 1 / 2 " trim lenqthto fit as requred
/w
Fig. H ety*oodCuttingDiagram
I

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i
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3/4" PINE PLYWOOD 3/4'' PINE PLYWOOD 3/4" BIRCHPLYWOOD 3/4" BIRCHPLYWOOD 1/4'' PINE PLYWOOD

A m e r i c a n W o o d w o r k e r J U L2yo o 3 5l
 ffil
/l)'",,

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iix
 ntique pine often has a dark, mellow color.
Unfortunately,when woodworkers try to duplicate
BEF()RE Y()U STAIN
that color on new pine by using stain,the resultsare
usuallydisappointing.It's easyto end up with mega-
blotchesand it's hard to avoid"grain reversall'a peculiareffectthat
makesstainedpine look unnatural (photo below).lt doesnt haveto
be that way,though.If you follow the processpresentedhere,you can
give pine deep,rich-looking color without losing it's natural
aPPearance.
Pine is hard to stain for a couple of reasons.First, its grain is
unevenlydense.Typicalwood stainscausegrain reversalbecausethey
color only the porous earlywood;they can't penetratethe dense
latewood.Second,pine'ssurfaceis usually loaded with randomly
occurringfigureand super-absorbent pocketsthat suckup stainand
look blotchy.
Ai FILLGAPSand stabilizeloose
Our stainingprocessincludesfour ingredients,water-based wood &*-\l knots with epoxy.Tapethe back
conditioner,water-soluble wood dye,dewaxedshellacand oil-based ofthe knot so the epoxy cant leak out.
glaze(seeSources,page92).Our processisrit fast,becausethereare
severalsteps.But it isn'thard,and it'shome-shopfriendly.Youdon t
needany specialfinishing equipment,just brushesand rags.
In a nutshell,the conditionerpartially sealsthe wood'ssurfaceto
controlblotching.Dyespenetrateboth the earlywoodand latewood,
so theyminimize grain reversal.Shellacandglazeadd color in layers,
creatingdepthand richness.This coloringprocessworkson all types
of pine,althoughthe end resultvariesfrom one speciesto another.

[i:! SAND WITH A BLOCK angled

LP-) acrossthe growth rings.Because
of the differencein hardnessbetween
the earlywood and latewood,bridgingas
many rings as possiblehelpsto keep the
surfacelevel.

EARLYWOOD

'r'1.' -r'' ,
j' '"
1-"'u Staining usually
(;':, PREEMPTIVE GRAIN-RAISINGiSA
,'i causesblotchesand
\:) must-do for all water-basedfinishes.
alwaysmakespine'sporous
earlywood darker than its After you've finishedsanding,dampenthe
denselatewood,just the opposite surface,to raisethe grain.Thensand it
of unstainedpine (inset).This again,with 400-grit sandpaper.
transformationis called"grain
reversal."
American Woodworker J U L2Yo o 3 53
 Look Before You Leap
Beforeyou touch your projectwith a brush or
rag, get familiar with the materialsand the
processby practicingon good-sizedpiecesof
scrap.Experimenton end grain, facegrain
and veneeredstock. Practiceuntil you're
comfortablewith the processand know what
to expect.

Fix Loose Knots

Beforeyou sand,stabilizeany looseknots by
dribbling epo)ryinto the gaps(PhotoA, page
53). To make cleanupeasier,keep it off the
surrounding wood surfaces.After the epoxy
has set,sand it flush with the surface.Clear
BRUSHON two generouscoatsof water-basedconditioner.
STEP 1 With eachapplication,keep the surfacewet for three to five epo)rytransmitsthe dark color of the knot.If
minutes,then wipe off the excess.Let the conditionerdry thoroughly,then sandit with your epoxy cures milky-white, touch it up
400-grit paper.Go lighdyon contours and edges,so you don't cur through. later,afteryou'vedyed the wood and sealedit
with shellac.

Sand Thoroughly
A good-looking finish alwaysstartswith a
thorough sandingjob, especiallywith a soft
wood like pine.Herearesomeguidelines:
Sandwith a block. Orbital sandersleave
swirl marksthat makethe stainedsurfacelook
muddy.After power sanding,alwayssandby
hand,usinga block,beforeyou go on to the
next gri t (P hoto B ). S andi ngw i th f inger
pressurealonewearsawaythe soft earlywood,
creatingan unevensurface.
Changepaperoften.Pinegumsup ordinary
sandpaperwith pitch-ladendustthat quickly

sr EP 2 lin::Y:
::#, .[:,HTJ.Ym:::
"?:ill?'""til
container and let it cool.
rendersit useless.Dull papermashesthe wood
fibers insteadof cutting them, which also
createsa muddy appearancewhen you stain.
Stearated sandpaper lastslonger(seeSources,
page92).
Sandup to 220 grit. First,levelthe surface
with 100-gritpaper.Then work through the
grits to createfiner and finer scratchpatterns.
220-gritscratchesarefine enoughto disappear
when you stain,aslong asthey don t go across
the grain.

Raise the Grain

Invariably,sandingleavessome fibers bent
over.Water-basedfinishesswell thesefibers
so they standup,leavinga rough surface.For
smoothresultswith thesefinishes,raisingthe
(PhotoC).
grain prior to finishingis essential

Two Goats of Conditioner

BRUSHON a liberalcoat of dye and keep the surfacewet.
STEP 3 Water-basedwood conditioner (seeSources,
Wipe the end grain occasionally
to check its appearance.
After'the surfaceis uniformlycolored,wipe offrhe excessdye and let the wood page92) makesthe water-baseddye easyto
dry.Thenrepeatthe process. apply.Itlimits the dye'spenetrationbypartially

54 American Woodworker JULy2oo3

sealingthewood,like a thin coatof finish. Two
coatsarenecessarytocontrol blorching (Step1).
It's important to keep the surface wet until
youwipe it, and then to wipe thoroughly.Any
conditioner that'sallowedto dry on the surface
will sealso well the dye won't penetrate.

Two Goats of Dye

We used Transfast"antique cherry brown"
water-solubledye powder (seeSources,page
92). Water-soluble dy. from other
manufacturers will work just aswell, although
the color will be different. Dissolvethe dye at
the label-recommendedratio of 1-oz.powder
to 2-qts.hot water (Step2).Be sureto let the
solution cool to room temperaturebeforeuse. STEP 4 SEALTHE SURFACEwith two coats of 2-lb.-cut dewaxed shellac
(see Sources,page92). Sandafter each coat with 400-grit paper.
. On the conditioned surface,the dye acts
like a liquid oil stain (Step3).Let it penetratefor
a couple minutes before wiping. The second
coat of dye imparts a deepercolor and a more
uniform appearance.
It's tough to get uniform penetration on
end grain. Fortunately,youcan minimize any
unevenappearancelaterwith the colored$azn.
When you have a large surfaceto cover,use
a spraybottle to apply the dye and a brush to
spreadit. Simply re-spray previously worked
areasto keep the entire surfacewet until you're
readyto wipe it dry. Sprayingandbrushing also
works great on vertical surfaces.Start at the
bottom and work your way up.
MAKEYOUR
OWN GLAZEbydissolving
artist'soil into
TVvo Coats of Shellac STEP 5 glazemedium (see Sources,page92).Youdont haveto be
Shellacprepares the dyed surface for glazng scientificabout the ratio as long as you use only one color. Dont go overboard
(Step4).It alsokeepspitch sealedin the wood. with the amount you mix-a liale glazetoes a long way.

Without shellac,pine'spitch can bleed into oil-

basedfinishes,leavingfissuresor shiny spots
that remain tacky, especiallyaround knots.

Apply Glaze
Glazeis nothing more than paint formulated
for wiping. It's easyto make your own pro-
quality glaze(Step5). Artist's oils contain high-
quality pigments for pure, clear color. Glaze
medium makesthe artist's oil easyto spread
and quick to dry (within 24 hours).
Glazingaddsa second,separatelayer of color
that reallymakesthe pine come alive (Step6).

Topcoats
Youneedto protect this layeredfinish with clear
topcoats.Anytopcoatwill work aslong asyou
wait until the glaze has completely dried. To
check, wipe the surface gently with a cotton STEP 6 GLAZEACTSASATONER on the sealedsurface,resultingin a
deep,rich color and a uniform appearance.Just
brush it on and
rag. If it picks up any color,wait another day. wipe it off. Blend unevenareasby varyingthe amount of glazeyou leaveon the surface.

,vv
American Woodworker JULY2oo3
 TOOLTEST
\ High
I/ Volume
Low
Pressure

TurblneSprayers
ou've probably brushed and wiped cal l ed H V LP becausei t produce s high
on gallonsof finish over the years. volumesof air (50 to 100cfm) at a low pressure
But have you ever dreamed of the (4 to 8 psi). For comparison,a conventional
Advantages
of
luxury of spraying on a fast, silky- high-pressurespraygun runs on 6 to 12 cfm of -
HVLPSprayers
smooth finish?If you'rereadyto wake up and air at 50 to 70 psi, which is supplied by an air E
I
Less Overspray start spraying, read on and we'll help you comPressor.
Lessoverspray make the best choice of HVLP sprayersfor :<
z
meansmore finish
your shop. Three Basic Models
d
|!

goes on your project

HVLP turbinescome either as 2-,3- or 4-
;
and less is wasted E
going into the air. How an HVLP Turbine Works stageunits and range in price from $1OOto E
a
Some manufacturers An HVLP sprayeruseshigh-speed turbine $1,000or more. For your money you get a f
J

claim a transfer rate (spiral-finned) fans to compressand blow air :

turbine unit, a hoseand a gun (Photo 1).For a

that's double conven- (Photo3).Eachfan is calleda"stage"and rotates this tool testwe looked at 22 svstemsfor $600 UJ
F
tional high-pressure
sPrayertuns.
up to 20,000rpm. That'sasfast asa router! It's or less. o
z
U
U''
Dry, Clean Air A Big Word of Caution =
TURBINE E
Moisture and oil in Sprayingcan be dangerous.The overspray
U
T

the air supply,which

can wreak havoc with
createdby sprayingcan presenta serious </)
U)
Llj

your finish,are com- health risk to you and a fire hazard to =

SPRAYGUN =
mon problemswhen your shop.You can protect your lungs by |!-
L

usingcompressorair wearinga respiratormask appropriatefor s

a

with a high-pressure the kind of finish you are spraying.Over- T

o_
spraygun. HVLP-tur-
coming the fire hazard can be accom-
bine suppliedair is
totally free from plished by using a waterbornefinish F
o
-
moisture and oil. rather than a solvent-basedfinish. o

This is what we recommend.Ifyou E

lrJ

Portable z
chooseto spray solvent-basedfin- :l
-
HVLP turbinesare
i shes,i nstal l an expl osi on- pr oof v
compactand easily E.
exhaustfan and lights,which will cost you
stored in a cabinetor
under a table and are
easilytransported.
1
A turbine,hose and spraygun make up an HVLP spray
severalhundred dollars or more. Check
localbuilding codes,too, sincethey'll prob-
k(L
2
F
U

system. ably requireadditionalsafetyprecautions. o

LemmerT_55,gwe_5trgs;$420.

56 American Woodworker J U L2y o o 3

 Features thatAdd
Convenience
The up-front switch
and hose connection
ONBOARD
TOOL KIT makethem easily
accessible.The
power cord should
be mounted out of
the way of the
switch and hose.The
gun holster is a
handy placeto store
the gun between
usesand the
onboard tool kii
holds spare parts.
GracoHVLP2500,
two-stage;$525.

REAR.
MOUNTED
POWER
CORD

How aThree-Stage HVLP

TurbineWorks
Air travelsthrough the inlet into the
first fan and then down the first
finned baffleto the center ofthe
secondfan.Thesecondfan then
forcesthe air down into the second
finned baffle,which directsthe air to
the center of the third fan where
the air is finallyforced out through
the outlet.

58 American Woodworker J U L2Yo o 3

 Anatomy of an HVLP Spray Gun
The spraygun,with controls for fluid and
air flow, is the working end of an HVLP
spray system.Thegun shown here is from
the CapsprayCS5100 system and has a FLUID
built-in air control valve.Some guns use an CONTROL
air control valve on the hose instead.The
Capspraygun also has an external lever that
is used to rotate the position of the fluid
pickuptube.

LEVER FOR
We Used Waterborrne Finishes . ROTATING
It's important to use a waterborne finish that is FLUID
PICKUP
formulated specifically for spraying (see Basic TUBE
HVLP SprayTechniques, page28). Manywater-
borne finishesareformulated for brushing and are
too thick to spray with an HVLP turbine sys-
tem. This is particularly true with the two-stage
sprayers.Somebrushablefinishes can be thinned,
but ybu must be careful not to thin them too
much becausethis can adverselyaffectthe finistfs
performance.

3-Stage Turbines Haye

Plenty of power
A three-stageturbine producesabout 50 percent
more pressurethan a two-stageturbine. This efira
pressureatomizesfinish better.The extra airpres-
sure also allows a wider range of adjustments for
the fluid and air settings.This in return provides
better control over the shapeand sizeof the spray
patterns.The most e4pensivetwo-stagesystemsdo
an acceptablejob of atomizing sprayablewater-
borne finishes,but apply them at a slowerrate.A
four-stageunit provides 25 percent more air pres-
sure than a three-stageunit but this additional
pressure is not needed for applying sprayable
waterbornefinishes.

Fig.A Howan HVLPSprayGunWorks

An HVLPgun haslargeinternalairways. Theyalloweasy
passage for the highvolumeof air that is usedfor atom-
ization.Someof the air travelsdowna pressure tube
and pressurizes the materialcup.Whenyoupull the
trigger,
finishingmaterial ii pushedup the pickuptube
andout the nozzle.As the fluid leavesthe nozzleit is
atomized by aircomingfromopenings in the aircap.

lan ffiFLuD
American Woo dworker J U L 2v o o 3 59
 OutstandingFeatures
We found severalfeaturesthat make pattern sizeand overspray.
an HVLP turbine systemeasierto Metalgunswith insulatedhandles
useand adjust.Somecan affecthow Some metal guns have a plastic
well your finish turns out (Photos2 cover over the metal handle,others
through 6). use a plastic tube inside the han-
Easy-to-change air filters dle.This is a particularly good fea-
AII machineshaveair filters that need ture to look for in a gun that has a
to be cleanedregularlyfor peakper- bottom air hose connection.The
formance. Machines with easyto hot air producedby the turbine can
remove and replacefilters scored make an all-metal handle uncom-
pointswith us. fortably warm.
Easilyaccessiblecontrols Top and bottom hoseconnections
We alsoliked units that haveswitches We prefer guns that have air hose
and hose outlets that are conve- connection points at both the top
niently positioned and power cords andbottom of the gun. Connecting
that aremounted out of the way. the air hose at the bottom givesthe
gun a balancedfeeland works great
Gun holster
for most spraying.Connectingthe
A few units havea gun holster for
air hoseat the top of the gun allows
storing the gun betweenusesand
you to run the hose up your arm,
during transportation.Sprayguns
over your shoulder and out of the
areeasilytippedover and dam-
way. This is useful when spraying
aged,so a holster is a valuable
The flexible self-adjusting pickup inside cabinets or a wide flat area
accessory.
tube on theTitan spraygun such as a tabletop.
automaticallyswingsto any angleyou Non-bleeder guns
tip the gun.lt's a great feature,but Easy-to-adjust fluid pickuptube
When you let go of the trigger, air
cleaningthe ribbed tube is a pain.Titan This featurereally caughtour atten-
completelystopscoming out of the
includesan extra flex tube with the gun. tion. The Titan usesa flexible tube
nozzleof a non-bleedergun. On a
(Photo 5) that is self-adjusting.The
bleedergun, air continuesto come
Capsprayusesan externalleverthat
E
U out.We preferthe non-bleederstyle
E
rotates a rigid pickup tube that
becauseyou don t have to worry
l

tr rotatesforward, backward,and left

l
z about accidentallyblowing dust into
(Photo 4). Being able to keep the
L
the air when you point your gun
bottom of the fluid pickup tube in
U
awayfrom your project between
F the finishing material when tipping
= sprayingpasses.
the gun at various anglesis a great
F

I
Easy-to-adjust air cap feature.It's especiallyvaluablewhen
L
The air capcontrolsthe shapeof the the spray cup gets half empty and
spraypattern from horizontal to ver- you need to tip the gun to the side
tical to round. An air cap should or backward in order to spray that
rotateeasilybecause it is common to hard to reachspot.Pickup tubes on
readjustit severaltimeswhile spray- other guns requireyou to open the
OUICK-CONNECT
COUPLER ing a project. Someair capsrequire cup and then turn the tube by hand
you to loosen and retightenthe cap or with a wrench,which is not very
A 20 ft. hose is usefulbecauseit has ring to make adjustments.Others practicalwhile spraying.
enoughlengthto work around your
rotate roughly or arehard to turn.
project,while keepingthe turbine at a A 20-ft.air hoseprovides
distanceso the filter doesnt pick up Finelyadjustable fluidand the best reach
excessoverspray. A quick-connect air controls We found thatyou needat leasta 20-
coupler is usedto connectthe hose to
Fluid and air controls that can be ft. hose to provide enough length
most tuns.The hose'sair valveis used
for gunsthat don't havea built-invalve.
preciselyadjustedmake it easierto to work around most projects.
control fluid atomization,the spray

60 American Woodworker J U L2Yo o 3

Recommendations zffi
forfinishing
If youwantanHVLPturbinesprayer
ffudft
'::::,:;:JffH b6g
ilTjffi*ffi;::1ffiril:
Our Editors' Choice and Best Buy tools are both
three-stageunits and have almost all the features
we liked.

Other Recommended Tools

The Graco HV-2500 and the Capspray CS5l00
havemany of the featureswe liked but they areonly
two-stageunits.They areboth however,availableas
three-stagemodels,but at a pricehigherthan $600.
In fact,youcangetthree-stagemodelsfor most of the
two-stageunits represented in our test.

Wagner Softspray 2500; $475

3-stagemachine
This systemhas everythingwe liked exceptthe power cord
is mounted right next to the switch so it gets in the way when
turningthe machineon and off and the fluid pickuptube cant
be adjustedwhile spraying.

Conveniently
Mounted
Switch, Hose
and Power
Cord

(800) 279-4441
(866) 247-6e37

247-6937
(800)328-82s1 FinecoatPlus

(8oo)s61-6908
Accuspray (8oo)46s-232s

AmericanTurbine
(800)443-4s00
Lex-Aire 539-2473
(888)900-48s7
(866) 247-6937
(800)328-82s1

Turbinaire M i n i P r o11 3 5
247-6937

Titan - Editors'Choice ) s26-5362

(800)328-82s1
* seeSources.page 92 for street-pricevendor list

American Woodworker JUL2

Yo o 3
 You ShouldAlso
Know About
There are HVLPspray guns
that are desiqned to run
off regularcompressed
air. k6*
They'recalled HVLPcon- j;
version guns and they offer "ffi

i-*f the same low-overspray

h i g h - t r a n s f e ra d v a n t a g e s
of a turbine svstem. One ',

'f
JE
,fi
advantage these guns
have over turbine-powered ""elw#-il, ;
j1 HVLP guns is that conver- Lynx-3HVLP
sion guns hook up to a reg- ConversionGun.
ff'
u l a r s m a l l - d i a m e t e rh i g h -
pressureair hose.This is easierto pull aroundthan
t h e l a r g e rh o s e o n a t u r b i n e u n i t . S o m e o f t h e s e
guns are availablefor lessthan $200 but most cost
twice that, or more (seeSources,page 92). Some
r u n o n a 1 - o r 1 - 1 / 2 - h p c o m p r e s s o rb u t m a n y
Titan TS40;$600 r e q u i r e a 5 - h p c o m p r e s s o ro r b i g g e r a n o y o u
3-stagemachine s t i l lh a v e t o b e o n g u a r d a g a i n s tm o i s t u r ea n d o i l
This systemhasalmosteveryrhing we liked:anonbleedergun, in the air supply.lf you have an appropriate com-
self-adjusting fluidpickuptube,fronr-mountedswitchand hose pressor,and a way to extract the moisture and oil,
connection,rear-mountedpower cord and onboard tool t h e n g o i n g w i t h a H V L P c o n v e r s i o ng u n m i g h t
kit. lt only lacksa gun holster. save you some money.

Finely Adjustable
Non- Easy-to- Adiustable Metal Insu- FluidPickup
Bleeder Adjust Fluidand Air Gun lated TwoAir Hose TubeWhile
Gun Air Cap Controls Body Handle Connections Spraying
N Y N N n.a. Top onlv N Hasno air controlvalve
N N N N n.a. Too onlv N
N N N N n.a. Iop onlv N
N N N N n.a. Top onlv N Hassmall
built-in partVtoolbox
spare
N Y N N n.a. Top onlv N Hasno air controlvalve.
N N N N n.a. Top onlv N
N Y Y N n.a. Top onlv N
N N Y Y N Bottom onlv N
N Y Y N Y Bottom only N Hasa shorthosebecause
theturbineisdesioned
- to be
hunqfromoperator's
shoulder
viaa strao.
Y Y Y Y Y Bottom onlv N Hasburlt-in
N Y Y Y Y Bottom onlv N
Y Y Y Y Y Y Y Hoseandswitchmountedon oooositesidesof the turbine
N N Y Y N Bottom onlv N
N Y Y Y Y Y N
N N N N n.a. Top onlv N
Y Y Y Y Y Y N Switchand powercordmountedtoo closetoqether
N Y Y Y N Y N
N Y Y Y N Bottom onlv N
N Y Y Y Y Y N
N Y Y Y N Y N
Y Y Y Y Y Y Y Hasbuilt-insparepartVtoolbox
Y Y Y Y Y Y N Switchand powercordmountedtoo closetoqether.lW
n . a . : N o t a p p l i c a b l e b e c a u s eg u n h a s o n l y a t o p a i r c o n n e c t i o n

A rncri can Wooclr.l'orkcr J U L y2 o o 3 63

 a
a
LrJ
I
z.
f
Iri
:<
J
T

Finishes
SprayBoothfor Waterborne
U
l
N
J

o
Fiftybucksand a fewhoursis all it takesto put togetherthis finishingbooth.It keepsover- t
T

sprayoff my tools and dust off my projects.SinceI usewaterbornefinishes,I'm ableto E.

usea regularbox fan in the window to vent the fumes.A furnacefilter overthe fan keeps F
o
oversprayoffthe fan blades.BeforesprayingI thoroughly sweepmy shop floor, put down I
rL
a

paperand crackopen my garagedoor severalinchesto make up for the air being blown z
a
outsideby the fan. z.
-
I built the booth by first staplingan 8-ft.by 8-ft.pieceof plasticto the ceiling.Then I sta-
z.
pled the top edgeof the plasticwallsto 2x2s,whichI screwedto the ceilingrafters.Oncethe t
t!

plasticwallswerehung,I stapled2x2stothe bottom edgeof the plastic.I cut a hole in the 2

backplasticwall for the fan.To storethe plasticwallsI roll them up and hangthem on loops F
t!

of rope that hook onto screwheads.This booth alsoworks greatfor brushed-onfinishes.

E.
NOTE:This setup is for spraying o

waterborne finishesonlY. F
t
Brent Greer
American Woodworker JULY2oo3
S m a l lS h o pT i p s
TubularStorage
Here'smy solution for storing skinny
things like wood trim and edgeband-
ing.I boughta 12-in.-dia.by S-ft.-long
cardboard concreteform at a home
center for about $14. I slid plywood
dividersinto the tube and addeda few
screwsto hold the dividers in place.I
hung it from the ceiling in my base-
ment with plumber's strap. Get
plumber's strap at a home center for
about$2 for a lO-ft.roll.It took one roll
to hang my storagetube.
GeorgeR. Hoffman

SprayGanStorage
I'm a greatfan of aerosolfinishes,especiallynow that
many of them haveadjustabletips that make much
lesssplatter.But my shopgot so clutteredwith half-
used cans that I had trouble finding the color I
wanted,so I built this simplestoragerack for all the
cans.Now I can instantly find just the color I'm
looking for.The shelvesneedto be 5-in. deep,butthe
angleisnt critical.Anything between45 to 75 degrees
will work. Mine is 70 degrees.
Tim ]ohnson

Tablesaw
ToolDrawer
It seemslike I m alwaysmisplacingmy push sticks,
bladewrench,featherboardsand other small table-
sawaccessories. To solvemy problem I addeda shal-
low drawerunder the sidefeedtable.I simplybuilt a
wood box that wasopen in the front and screwedit
to the bottom of my side table.Then I installeda
drawer using a set of 22-in. full-extensionheavy-
duty drawerslides(seeSources, page92).The slides
costme $14and I usedleftoverplywood.Itdidnt cost
much but it sureprovidesa lot of convenience.
TbmCaspar
/W

If yog hlve an original SmallShopTip, sendit to us with a sketchor photo. If we print it, you'll get $100! Sendyour tip to:
Small Shop Tips, Arnerican Voodworket,29l1 Commers Drive, Suite 700, Eagan, MN 55f 2f or e-mail to
smallshoptips@readersdigest.com.Submissions cant be returnedand becomeour property upon acceptance and payment.
\7e may edit submissions,and usethem in all print and electronicmedia.

55 American Woodworker JUL2

Yo o 3
 I I #78,Febnrary2000
ThisindexcoversAmericanWoodworkerissues

I n q €)K,-I"ftT::i1i.;11[sJ:;h'Hff:;,?lsfl
3-vear ;is3;?:JJr;*"'o'"
n
Acid-free paper, sources,
guide blocks,88:90
disposable,88:24
grading,8l:3 |
sources,8 l:33
molding,86:59-60, 85:6 I,
86:65
oscillatingspindle sanders
reviewed and AWrated,
phenolic,9l:42 working,S l:32-33 from plywood carcase,9 l :86 82:82-85
79:38
guide blocks of Bird's mouth joinery installing,88:82-83 power miter saws
Adjustable chucks,
s h i m s . 8 5l :8 bits for plywood reviewed by other
advantagesof 83:82
ocagons on,88:22 reviewed,92:32 parts,88:8 | magazines,S3:58
Air compressors
outfeed tables for Biscuit joiners safetychains,9l:60 slidingcompound-miter saws
station for
drill-pressas,88:94 clampingiig,79:.17 simple plywood, 95:76-86 reviewed and AW rated.
portable,9l:ll4
parts sources,9 l:45 mini-biscuits.85:54 toe boards,9| :62,91:65 84:9&-109
buyer'sguide,83:9 | -94
recommended 200 l, 92: | 04 routers as,85:53 two-part, 82:56-63 routers, 83:85-89
developmentsin,83:93
recommended 2003, 97:26 Biscuit joinery valances,9 I :62,9 | :65,9 | :66 reviewed by other
easy-drainadaptation,S0:| 3
resawing for table rails,94:62, 94:63 Bookends magazines,S3:89
features and types, 83:92
bladeselection.8l :4748 slots,94:80 lead-filfed, 87:82,87:86-57 shop vacuums
settingup an air line,83:94
on,88:23 techniques,79:73 Bowl turning reviewed and AW rated.
size and capacity,83:93
squaringcuts on,92:27 Bits beautiful bases.79:22 80:69-73
Air fi lters, cleaning,89:20
table for as gauges,94:63 Bowls, turned tablesaws.83:72-76
Air filtration systems
temporary,89:25 bird's mouth.92:32 blanksfor reviewed in other
capacityguidelines,80:44
table for brad-point,9l:78 preparing,S5:99 magazines,83:76
filters, source.80:47
auxillary,9l:42 bullnose natural-edge,85:98- | 03 thickness planers
shop-madefrom kits,
shop-made,8l:103-104 s m a l l , 9 3 : 2 39,3 : 1 0 8 primavera,99:102 benchtop,reviewed and
80:4347
tapers with carbide Boxes AW rated.79:83-87
when to clean,80:46
wide,89:89 sharpening,92: |7 ABC boxes,84:75 vises reviewed and AW rated.
Allergies
sensitizerspecies,99: | 8
tensioner for chamfer,93:108 clamping,93:86 82:92
to wood. 99: | 8
Aluminum
quick-crank,9l:42
replacement,86:24
cove
source,93:| 08
dividers.93:90
installinghingeson, 79:20 I
tires of, cleaning,89:| 6 depth gaugesfor iewelry,93:8G-90 Cabinetmaker's triangle,
cutring 79:75
tool holder for making,92:8 | sources,93:| 08
with chop saw,86:l0 Cabinets
magnetic,9l:42 dovetail lids.93:88
Aluminum tubing, source, assembling,95:7l-72
types ol 90:23,90:25 care with.85: l4 magic-coi n puzzle,87:82,
78:82 bathroom
upgrading, S l:5 | drawer-lock. 92:60-61 87:8&€9
Angles fiom plparood carcase,9| :86
zero-clearanceinserts,source, drill Brad nailers, hoseless,95:30
gauge for
8 3 : 12 as depth gauges,92:79 Brad setters box frames, 98 :77, 98:8 | 42
making,92:8| display
Banks for "recoverable" beads for nail removd,93:26,93:108
shop-made checker for lighted,98:7647
magic-coin,87:82,87:88-89 reviewed,87:26 Brass hardware and pulls
sharpening, 82:79 dividers for
Barrel bolt connectors, Forstner pullsand handles
stop block,98:56 vertical,96:l7
sources.T9:38 s p e e d , 9 3|:2 source.82:23
Anti-sag powder for glue, entertainment
Baseball bats, making,78:l2 hole-saw Brass rod stoch source,80:38
source,S | :69,81:72 home theater. S4:4U63
Bases chip clearance, ST:l8 Breadboard ends
Antique tools walnut, 78: | 7 correction
concrete weighted, 98:5f59 hollow screw-remover.85: | 0 Greene and Greene sryle,
books about, source,83:50 face frame
Batteries lock-miter,source,79:59 78:26-28
collector and restorer buifding,9l:74-86
disposal,83:69 pattern, 93: | 08 Brown, Molly ("Unsinkable"),
profiled,83:46-50
maintenancetips, 83:69 pfug-cutteri87:64,87:65 79:56 face frames.89:62
restoring,83:4&-50 fitting, 9 l :80, 9 1:82
nickel-cadmium(NiCad) removing rust from, 82: l0 Brushes
Arches filler strips,88:83
compared to (N|MH) (nickel round-over.93:| 08 90", creating,39: | 4
plywood,86:46,86:4&49, 86:5 |
meal-hydride),83:59 router brass,sources,79: | 2 flammables.82 122-124
Arcs for drill press,78:I l9-120
rebuilding,93:l0 anti-kickback,90:| 6 Bubinga, qualities of, 9 | :126
describing,92:80 for router table, 99:,4| 42
recycling,87: | 4 core-box,85:85 Builder's paper uses of,99:23
l a r g ed, r a w i n g , 9 l : 1 8 hanging
types of,90:17 flushtrim,87:65,87:80 Bulletin boards
Armchairs solo.92:20
Beadboard, making,95:22 panel raiser,86:34,86:43 making,95:69,95:75
Greene and Greene ioinery, Hoosier style,79:14
Beading, adding,93:23 rail-and-stile,86:8,86:32-34, Bureaus
78:3G-32
Beds 86:43,87:26 restoring, 96:70-78 correction
Arts and Crafts style installingbuilt-in,78:56F{|
assembling,85:67-69 slot-cutter vs. plate Burgess Edge System
bookcase.9l:5&-72 joiners, ST:8 kitchen
basic design,8l:4G-45 router bits
chair in.93:6G-72 carving,89:24
hardware,S5:59,85:69 spiral up-cutting,87:63,87:65 reviewed,99:29
hall mirror lights,98:84
headboardsfor vertical molding,85:83 Burls
making,85:7&-8 | material,9l:75
making,85:66 with insert cutters, 94:34 centering on a lathe faceplate,
plansfor
mattresses.85:59 router slot-cutter,99:50 8l:16 over-desk.95:6S-75
book of 94; | 8 pie safe,79:70-77
rail fasteners,sources,8 | :45 screw pilot,87:37 mesquite,8T:46
Ash, source,82:77 guick plywood, 96:60-67
stock, 85:59,85:69 self-centering Butcherblock
Assembly table, 8 l :62-65, rollingshop
turned-post source.93:I 08 quartersawn,89:53
84:74-78
making,85:56-69 spiral-up-cut,85:5 | Butterfly inlay from ptywood carcase,9| :86
Auger bits
Belt sanders stop collars,9l:78 kit, 99:6 l-63 scribingallowance,78:59
ship,source,80:76
buyer's guide tongue-and-groove,95:75 Butternut shop,9 l:88-96
Awls, sharpeninglig,80:32

nBacksplashes
reviewed and AW ratec.
79:66-69
features and types, 79:66-69
adjustable
reviewed.92:3|
undersized
canker of.96:96
finishing,96:94-96
qualities of,96:90-96
sink
making,87:33-43

shelves,S5:92,85:94
storage
curved, 89:60,89:64,89:65 B e l t s , l i n k ,9 l : 3 9 ,9 l : 4 | for plywood dadoes,85:5| Buyer's Guide
Bench dogs, making,89:43 Blade cleaner, air compressors,83:9 l-94 building,87:36
Bamboo skewers, T8:22
Benches reviewed,34:24 block planes,83:34-40 wall mounting, 95:72-7 3, 95:75
Bandsaw blades
garden Blast gates, modifying,79:l6 cordlessdrills web frames, 95:62, 95:64-69,
sources,T9:56,8l:50
building 8 l :66-72, 86:45-5 | Blemishes reviewed by other 95:75
storing,34:46
Bevels touch-up,95:24 magazines,S3:70 wide
Bandsaw jigs
angleblock for grinding,32:80 board feet, how to calculate, dovetail iigs,reviewed and building,87:36
duplicator reviewed,82: | 0 I
Bandsaws angle, calculating,82:79 82:12 AW rated.84:66-73 Cabriole legs
throat plates,95:5l, 95:57 Bocce balls drills, cordless,83:66-70 step-by-stepinstructions,
| 4-in. heavy-duty
with tablesaw 94:56 rules of the game,8l:22 dust collectors 80:55-5 |
reviewed,9l:24
Birch turning,Sl:|&-23 reviewed and AW rated. Calculators
bladesfor
finishing,89: 120- 122 Bolts 80:8l-85 for construction math,98:3|
2001 recommended,92:104
for other-speciesmatching, locking jointer-planers Calipers
center-finderlig,86: | 4
89:l 17,89:122 making,93:77,93:79 reviewed by other dial,reviewed,83:33
dust collection,88: 16, 90:25,
gradesof,89:l 16 Bookcases magazines,83:65 using,82:45
9l:42
plywood,39:l l8-l l9 Arts and Crafu style, jointers,83:6l-65 Carcases
features of , 90:24-25, 97:21--24
sources for Baltic,80:47 88:76€3 lathes,83:7&€3 plate-joined,98:5 I
for resawing
speciesol 89: | | 5 Arts and Crafts style knock- miter gauges reviewed and plywood, 89:56-67, 9 | :74-86
blades,9l:104-105
v s .m a p l e , 8 9 : 1 2 3 down,9l:58-72 AW rated,8l:8l-83 Carts
recommended,90:26-27,
Bird's eye maple floor pins,86:63 mortisers rolling-cabinet
, 90:l18
buying,8l:30 formal built-in,86:58-66 benchtop,reviewed and building,87:35
reviewed, S8:84-9 |
characteristicsand uses, materials list.85:5 | AW rated,Sl:73-77 workshop, 9 6:52,96:56-57
guide bearings,source,S l:50
8l:2&-32

American Woodworker J U L2Yo o 3 69

I
3-Yearlndex
Carving parallel-jaw with router,9l:91 to length recommended 2003. 97:38
replacingmissingparts, small.96:29 with tablesaw,89:86, 92:50-5 I, jig,87:84 rims of,86:70,86:73
79:8-10 PiPE 92:53,92:56,92:57 Dowels and cylinders round stock with,98:72
Case construction expandable,S0:| 3 Dents, steamingoug 8l:92 gluing into blind holes,80:24 sandingon
large cases,84:55-57 guards,78: | 8 Depth gauges hardwood, sources,78:45, caveats,86:7 |
Case-hardening, detecting, Quick-Grip reviewed,83: | 04 bits as,92:79 8l:69 sharpeningsystem with,
79:14 sources.T9:77 for bits storage, T8:20 98:62-74
Cauls, shop-made,79:74 racks,98:44 making,92:8| turning, T9:28 sizesol 86:69
Cedar, working with, 98:54 rubber bandsas,85:26 Design Downdraft dust collector speeds,86:69,86:70
Center finders small strong proportion calculator;92:83 Delta model reviewed.83:l4 storage,92:98
bandsawlig,86: | 4 making,93:22 Desk accessories shop-made,80:66 switches on, 86:7 l, 86:74
making,87:l6 spring,96:25 file holder,80:36-38 Drawers table for
Center finding squaringblocks,89:72 Desks assembly,TS:20 extended-reach,93:94
with squares,92:77 stands,89:72,89:74 building,95:6G-75 biscuit joinery, 95:62-44, 95:66 tables
Chairs toggle cord-hiding backboards, ceilinghung,78:49 auxiliary,94:20
Adirondack source,78:82,8l:6 l,85:43, 95:73-74 dividers,92:5G-57,92:59 bottom boards.94:29
all-weather: 87:6G-65 93:| 08 Detail sanders, shop-made, q u i c k , 8 9l:0 tables for
disassembling, 92: l4 Clothespins 80:32 dovetailed.84:9 l-94 making,86:||l-l14
outdoor sling clampsfrom,93:22 Disc sander designdetails,84:92 materialslist,86:I l4
making,93:60-72 Cocobolo Delta reviewed,8l:86 file, 95:60-66, 95:70 taps with,98: | 4,98:72
Rieweld style, 79:60-65 qualities of,94:6G67 Discs, twist-andJock, fit, checking,84:87 types of,90:3|,90:32
seats for Collets 98:&4-7 | fronts for variable-speed,98:34
frbric sling,93:.7l-72 removing rust from,82: l0 Door jacks f a l s e , 9 l : 7| vibration with
Chalk marking pencils, Colors, artists',93:56,93: 108 roller standas,92:35 ioint construction reducing,9l:39
sources,79:56 Columns Doors Greene and Greene style, Drilling
Cherry tapered, 88:76-77, 88:7840 exterior 78:32-34 stop block, 94:7 |
figured Commodes wood.88:57 lipped,making with a dove- straight
sciurce,88:| 04 q u i l t e dm a p l e , 8 6 : l l 6 flip-up,95:60,95:5l, 95:69, tail iig, 84:9 l-94 jig,89:26
finishing,93:52-58, 93: | 08 Compasses 95:7l-72 lock rabbets,92:60-43 Drilling jigs
sapwood ol 93:52,93:57-58, improvised,92:80 flush-fit, 79:7&-81 making, 89:64-65, 9 | :70-72, for centered holes,84:| 4
93: | 08 making,86:48 glasscabinet,98:84€5 92:5l. 92:58 for pocket holes
sources, 78:45,79:77 Concrete, stains,86:8 glass,98:87 plate-joined,98:50 Kreg K2000 reviewed, 84:22
Chests Containers glass-panel quick and easy,87:4f43 Drills
blanket gaskets for bits,92:32 q uick pfywood, 9 6:62,9 6:65-67 cordless.9T:| 6
frame-and-panel, tape,99:23 glazed restoring, 96:70-78 features of,97:29-31
Mission,99.4L59 Corbels "recoverable" beads,87:26 runners.S9:62J3 recommended 200 l, 92: | 04
78:,3745 for top overhang,99:56-57, hanging,89:65,98:85-€6 runners for easy-slidin g, 9 | :21 recommended 2003, 97:32
hope chest 99:58 hingesfor smelly,96:77 reviewed,39:92
frame-and-panel, Cordless drills from inside,87:38 spice-rackinsert, 96:26 cordless l8v
78:3745 accessories.83:70 installing,88:62-{3 stops,96:67 reviewed,9l:28
chests of drawers buyer's guide,83:66-70 making,89:65 magnet, 92:58,92:59 cordless compact,95:29
Shaker sewing cabinet, developmentsin,83:68 mortises,88:58 tool cordless mid-sized
84:82-89 features and types,83:67--68 plywood flat-panel,9 | :62 dividers,96:68 featuresof,9 |:48-5 l ,9 | :53
Chisels Corner joints plywood shop-cabinet tray-qrPe reviewed, 9l:47-54
angle gauge for sandingtool, shop-made,82: 17 hanging,9l:94-95 making,85:92,85:95 handlesfor
making,92:8| Countertops raised-panel wear away problems,84:l2 interchangeable, 98:3 |
bevel-angle,8l:14 holes in anti-rattle snakes,86:4 | Drill bits spacerjig,86:62
an$e block for ginding 8280 cutting,85:93 assembling,86:40 sharpeningand grinding Drive belts
flatteningthe blade back 82:8 | Cracks designing,86:4243 brad-point,78:65 link type compared toV-
hollow- butterfly inlay,99:6 l-63 making,86:32-43, 95:3440 Forstner. T8:67 belts.83:24
for mortises,S5:80 Credit card fraud, buying para o(85:32-39 spade,78:66 sources.33:24
new via the internet and,83:| 8 plywood,9l:67 techniques,78:63 Drum sander
dullnessol 85:8 Crosscut sleds and tables screen panels,88:58 twist,78:64 dust collectori shop-made,
protectors for for tablesaws storm panels,88:58 sources 80:64
glove-finger;87:20 slidingstop,80:24 storm-screen,88:56-64 | 4 mm brad-point, 79:,34 Drying wood, air-,8 l :50
sharpeninghollow 78: l0 sIiding,shop-made,78: | 7 twist prevention,98:85 half-inchbrad-poing79:34 Dust bags
Chop saws correction.S2:ll0 Dovetail jigs taper-point,8 I :69 shop-madehangers,82: I 8
dust collection,92:24 Crosscutting for comfortable work Drill presses Dust collection
station for s l e d ,9 l : 7 6 position,S0:24 -sandercombo,97:38 books and booklets about"
wiring,95:20 crown molding recommended,90: I l9 -sanders 80:67,80:85
Circles cutting reviewed and AW rated, reviewed,39:96 for drill presses,86:| | I
describing,92:80 with a compound miter 84:6G73 abrasivedisks,98:62,98:64-7 | for scroll saws,87:70
router iig,94:72 saw.84:57 setting the bit,84: | 0 as outfeed tables, 88:94 protective clothing, 80:65
without lathe,98:69,98:7 | Cupboards using with a routenffi:92-94 backer boards for tips for better, 80:62J8
Circular saw blades Amish lelly,89:56-67 for making slidingdovetails, sacrificial,86: l3 Dust collectors
teeth, types, 78:lGl7 Curves 84:86 basesof, improving,9 l :39 bags
thin-kerf.80:68 describing,99:59 Dovetails belts of,86:70,86:72 selection guidelines,80:82,
Circular saws iig for clamping,TS:20 clamps,89:7 | cabinegshop-made, 80:83
cordless
' r e v i e w el8v
d.9l:28 l a y i n go u t , 8 l : l 2 jig for 78:ll9-120 sources.S0:85
on router table,99:47 reviewed,35:34 center finding on,94:62 blast gates,modifing, 79: l6
Clamping routing, ST:79 jigs,92:59 chucks of buyer's guide
cauls,93:66-67 s- recommended 2001,92.|U improving,9l:39 reviewed and AW rated,
jig,for curves,78:20 describing,
92:82 on router tables,87:62,87:63 chuckson,86:7|,86:74 80:8l-85
of angles router jig,99:28
blocks,93:69
of boxes,93:86
D
Dado blades
saws.90: l9
circle-sandingjig,98:69,98:7 |
depth stops on, 86:72, 86:73
capacity
size required,80:84
sliding features of, 90:32-34, 97:35-38 chip and offcut separation
Clamps size for contractor saw,8l: l0 easing,92:22 fl oo r, reviewed, 86:68-7 5 accessories,sources,80:62
3-way dado heads iig,99:29 for wood techniques,80:62-63
edging,87:57 height-setting tool reviewed, router jig,84:86 remodeling,90:32 downdraft table
band 8l:86 with router. 85: l4 handlesof Delta model reviewed,83:l4
source,93:| 08 Dadoes with plywood,93: l5 improving,9l:39 shop-made,80:66, 82:54
bar angled,94:76 Dowels hold-downs,86:20 features and types, 80:82
choosing,94:32-33 blow out, preventing,80:77 drilling hole-sawswith filters,80:82-83
caul for 98:57 for plywood iig,87:84 chip clearance,ST:| 8 for routers.80:66
centering,cauls,89:7 | undersizing,35:5 | hardwood key holder for grounding duca,80:26
corner, for miters, 94:24 on router table.96:83 source.87:89 retractable, 87:20 leaks,sealing,S0:83
making,89:69 on tablesaw,85:94,85:95, jig for levers,86:70,86:72 mounting,S2:38
extenders,89:70,89:72 88:58,96:62 as saw stop,93:20 lights on,86:75 pipe fittings and connectors
for dovetails.89:7 | on tablesaws.9l:76 iigs,94:62,94:63 mortisers, 86:70, 86:74, 97:37 for,80:67
for miters,88:52,99:55,99:55 router base plate for notching mortising attachments,90:37 remote control,
hand-screw graduated,85:52 jig,87:8'1-85 parts sources,9 l:45 80:ll4-ll6
'
vises from.99:27 router jig, 96:22, 99:29 splitting recommended,90:36-37, single-stage,anatomy of,
pads for throat plates,95:5l, 95:57 for test fits.89:70 90:ll9 80:82
plywood, 78: l8 recommended 200 l. 92: 104 sources,S0:85

70 American Woodworker JULY2oo3

3-YearIndex
two-stage cyclonic, anatomy Glazes
of,80:82
- fumed oak, 85:79-80, 85:8 |
lacquer colors,93:52,93:56,93: | 08
in plywoodend,93:78
Fabric stopped,88:58
Dust masks and helmets spray-on,93:55 vs.dyes,93:57 V-
for chair seaa, 93:7 l-72,
National Institute of Occu- mixing with shellac,93:56,93:57 at plywood-wood
93: | 08 loin,
pational Safety and Health cups,98:22 Glazing 99:48,99:50,
99:5I,
velvet self-adhesive, 93: 108
recommended,80:68 nontoxic. ST:80 muntins with 99:53-54,99:54,99:58
Face frames
sources,80:68 oil glued-on,88:83
Dust, health risks from, 80: 104
Dust-collection systems
for cabinets
aligning,79:75 applying,93:54
spottint with,90:128
Gloves, lint-free,88:53,88:55
Glue blocks, adding,89:62
IHandles
mitered, Sl:7L79
bags,90:43,90:47 pipettes,99:27 Glue-up crank
with plate ioinery, 98:47
sealing,9l:43 polyurethane dowels.80:24 for vises,85:l8
Fasteners
upgrading, 9l:43 rubbing out, 88: | 6 of mitered joints and sements, rubberizing,85:20
tabletop, shop-made,80:26
control for spray-on,93:55 8l:14 Handsaws
Featherboards
remote,9l:43 toxiciry of 94: l5 rub-joint gluing,82:8 flush-cutting,sources,78:45
for router tables,85:82,
features of,90:4243, pre-assembly,99:54 techniques,S2:8 Hardware
85:83,92:26
97:4749,97:50 removing,96:78 Glues brass
for tablesaw,92:64, 97: | 4
filters,97:50 screw props,99:56 and wood-surface age,96: | 4 aging,93: | 4, 93: | 08
making,99:46
fine-particlecollecting,96:28 shellac bottle,99:32 escutcheon-plate,93: | 08
plastic
for bandsaws,SS:16, 90:25, spray-on,93:55,93: | 08 ePoxy Heating ducts, installing
reviewed,98:38
9l:42 with glaze,93:56-58 source.87:65 cabinetsaround,78:61'
with rabbets.96:83
for lathes,9l:44 sources,93: I 08 excess Hide glue, sources,79:77
Feet
for router ables, 88:95,92:66 spray-on,93: | 08 kerf catchment,S9:74 Hinges
bracket
for routers, 92:.| 0, 9 6:27 stripping,78:| 8 removing,89:l0 bits.93:108
making,93:86-€7
for tablesaws testing,85: | 06 extended-open-time, European,characteristics
brass
overarm.88:34 touch-up kit for sources,7917,82:63 and uses,82:64-67
source,87:89
impellers of portable,86:76 for exterior use,88:57,88:6| installing,9 l :67
for furniture
upgrading, 9l:43 varnish gap-filling,9l:l6 installing
sealingend grain for out-
parts sources,9 l:45 drip removal,85:108 holder,98:22 bua,79:8G{l
door use,84:30
portzble,92:24 straining,85: | 06 hot-melt center punch,sources,8l:65
round
recommended,90:41'|'7, wire hangers,36:78 heavy-duty,9l:26 European,32:64-67
installing,89:60,89:63-64
90:ll9 Finishing loosening,92: l4 su rface-m ou n ted. 79 :20
Fences
recommended 200 l, 92: | 04 avoidingdrip shadows,S l:90, with heat,86:65 jewelry-box,93:108
auxillary dust-collecting,88:95
recommended 2003, 97:50 82:104 open time of mortises for
choosing,96:42
sizing,90:42 end grain,8l:90 extended,9 l:128 with tablesaw 93:84
commercial,95:43
switches for final rubout,82:8 rubber tips,98:27 piano
easy-adjust,99:40, 99:.4'115
tool-actuated.92:24 flooding and wiping technique, spreaders instalfing, 89:67, I | :94-95,
for router table.88:95
two-stage can-toP 78:106-ll0 unorthodox, 78:20 93:78
magnetic micro-adjustable,
reviewed,9l:30 levitating your workpiece stains from positioning,with tape, 93:88
97:16
types of, 90:39-4 | fon 80:100 avoiding,89:70 sources,T8:45
micro-adjustable,9 | :40
upgrades,96:32 pad sponges,8 l:90 white, extended-time,87:28 bun,79:56,79:77
on new tablesaws.96:5|
Dyes raised grain white vs.yellow,93:86 continuous with barrel
router,92:65-67
bleaching,82: | 08 as a prefinishingstep,78: | 06 Gluing up bolt connectors,T9:38
layout,85:54
for figured wood,93: | 04 Fire hazards brackets.9 l:93 European,32:67
router-table
source,93: | 08 flammablescabinet for finish- face-to-hce,98: | 2 wrap-around,99:57,99:58
making,92:87-91
vs.glazes,93:57 ing supplies,82: | 22- | 24 glue blocks,98:59 Hold-downs
router-table iointer: 85:38-42
water-based
sacrificial,9l:78 Flashlights miter jig,96:8G47 for drill presses,86:20
removing,32:108 cordless l8v of carcases,99:54 for plate joinery, 98:56
for miters,93:83
reviewed,9l:28 of miters,93:86 for workbenches,9T:| 6
spring boards,92:26
- sub-,92:66,92:67, 99:40,99:44 Floors with tape,89:7 | plastic
Ear protection concrete of tapers,89:74 reviewed.98:38
T-tracks, 99:40, 99:43
and eye,92:92-95 staining,S6:8 squaringjig,89:59 router-table,86:33, 86:37
Ebonizing, tall,99:47
Fiberboard mappinguneven,78:57 stands,89:73 Holes
with Indiaink.86:76 Flush-cutting saws, third hand,96:25 in end grain
Ebony, sources,8l:6| cabinetsfrom. 87:33-43
split, repairing,87:38 sources for,78:45 Gouges centering,85:63
Edge banding Flutes sharpening routed
widths of
shop-made clamp,8 l : 12, with router, 85:82,85:85 custom strop,82:80 enlarging,85:63
for cabinets,ST:38
8 3 : 9 & 1 0|
Fiberboard, medium-density Food safe, deailing gouge,80:2 l -23 shelf
Edge gluing portable,82:20-23 spindle-roughinggouge,
for jigs,98:66 iig,9l:78
clamp racks,78:5| Food-safe finishes, 78: | 04 80:20 spacerjig,86:62
laminating,98:67-48
Edge ioinery, marking,92:77 Frame-and-panel technique,80:| 7-l 8, straight
Fibral, abrasivewool, 98:36
Edges construction 80:22-23 jig,89:26
File cabinets and holders
roundingwith a router;78:20 doors,79:76-77 tools and jigs,80:l6 Holes (defects)
desktop,80:36-38
Edgings for cabinet backs,98:79, sources,80:23 repairing,88:82
Files
applying,96:62 98:82-83 Grain, sefecti ng, 99:52, 99:54 Hollow-chisel mortising
auger-bit,source,78:65
clampsfor,87:57 for chest,99:50-54 Greene and Greene attachments
auger-bit,using,78:65
disguising,87:56 reversiblestile and rail joinery techniquesof, sharpening,78: | 0
Fillers
for miters,98:49 cutters, 78:72-74 78:24-34 Honing
ePoxy
for plywood, ST:54-58 Frames side table in the style of, machinesfor
painted filled,87:57 source,86:5|
for plywood edges,87:57 mini-biscuia,85:54 8 l:52-{ | reviewed, 39:76-8 I
planing wedges,85:8| Grinders process of , 89:76, 89:77
in tubes,98:30
marking,87:56 Framing squares adjustable-speed with strop,82:80
Finials, ball,source,86:5|
router bits for markings on reviewed. ST:29 Honing guides, using,82:80
reviewed.99:29 Finish
in tight spots,89: l4 repainting,85:24 buying,90:| 2 Hoosier cabinets
trimmer for truing,82:| 0 Grinders building,79: l4 correction
Finishes
router,87:58 Furniture shop-made,80:| 3 Hoosiers, plywood, 88:36
with plate joinery, 98:47-48 adhesion,testing,80:98
applicatorsfor maneuverabilityof swing-up housing,8 | :39 Horizontal boring
Electrical outlets testing,90:I 28 Grinding drill press vertical support
lintless,93:24
installingcabinets around, period conical stones,sources,78: | 0 fon79:17
cherry-aging,93:58,93: | 08
78:61 society,8S:8 gauge for Horsepower,
Electrophysics colors,93:55,93:108
rustic,99:6 making,92:8| peak vs. rated, 78: | 4
moisture meters contaminating
machinesfor
recommended.94:8&€9
End grain, sanding,79:54
with tack cloths,86: l0
ebonizing U
Gaps
reviewed,89:76{ |
process of , 89:76, 89:77
Humidors
wood selection,78:l0
Hygrometers
stain,86:76 and
Epoxy disguising Grinding wheels moisture meters
specialty,sources,8 | :69 exterior
water-based, 94:36 withV-groove,9l:84 aluminum oxide, character- pin type vs. pinless,79: | 4
Extension cords Gauges istics,80:l6 sources,79:| 4,8 l:50
flammablescabinet,
organizers,98:32
Extension-cord holders
shop-made,82:| 8
82:122-124
food-safe, 78: I 04, 94:l 5
for exterior doors. 88:58
thickness
shop-made,80:30
Glass
dressing,80:| 7,82:79
sources, TS:64
Grooves
n
lnfeed/outfeed aids
Eye protection curved for box bottoms,93:83 swivelingrollerl 80: | |
for figured wood,93: I 04
and ear,92:92-95 cutting,85: | 2 for frame and panel,99:52, lnlay
for mahogany,93:90,93:| 04,
93:| 08 for cabinets,98:87 99:57 bunerfly, 99:48,99:5 l, 99:54,
Glasses gang-cutting 99:63
for restorations. 96:78
prescription safety,94:| 2 on tablesaw.9l:93 Internet, buying tools on the
web. 83: | 6- | 8
72 American Woodworker J U L2yo o 3
3-YearIndex
r
Jam chucks, shop-made,
Knobs and pulls
draweranddoor,sourcefor,
marking system, 92:78, 94:75
rounding oven94:64
quilted big-leaf,86:I l6
Marking
miscut
fixing,87:57
8l:19 79277 screw props,99:56 lines for perfect
Shakerstyle,source,84:89 tapered darkening,92:80-8| testint,88:49
Japanese planes Knots, removalof, 89:22-23 making,92:5G-5l, 92:53
pull rype, reviewed,S l:89 symbols,92:76-83 splined,99:7F75
Koa,curly,89:124 uneven Marking tautes tablesawsled,96:8F85
ligs
centering,for drilling or
marking,34: l4
dowel-drilling
rLacewood, qualities of ,94:96
fixing,94:65
Levels, accuracy as a straight-
edge,83:| 28
beveled-edge wheel
reviewed,93:37,93: | 08
knife
testing,93:83,93:86
Moisture meters
choosing,94:87-88
Ladders Lid supports sharpening,92:79 recommended,94:8&€9
source,82:77
rolling sources.T8:45 making,88:54 types of,94:86-87
for clampingcurves,78:20
tenoning, on router, 84: | 6
source,86:66 Lighting using,92:79 Molders, -pla ners, 97:72
Lamination for displaycabinea, 98:79, Mat Moldings
Jigsaws bent 98:84 "recoverable" beads,87:26
base plates for board
process of,86:49 for shops cutting,88:5f55 assembled,86:59,86:60,
zero-clearance,89:20
for veneer,87:86 designing,87: l2 cutters 86:65-66
tool-free blade changing
gang,95:78 under-cabinet,95:6 l, 95:69 using,88:5f55 cove
reviewed,93:34,93: | 08
press,89:73 Locks, cam,sources,8l :65 Materials list small,86:66
Joinery Lap joints
edge-to-edge,87:| 0 Logs care with.89: l5 with router table. 93:8648
plate-joined,98:48 test cuts.85:79 cuttint and drying, 8 | :49-50 MDF curved
with tablesaw 92:56, 92:57 Louisville Slugger bats, for machinery tables,92:67, making,99:7{78
knockdown.9l:63
Lapping dimensions, TS:l2 92:88,92:90 dentil
stamps,92:82
machinesfor Lumber Measuring making,86:65
with drywall screws,87:37
reviewed. 39:76€ | amounts of systems,92:7643 fluted,85:85
fointers process of , 89 :76, 89:77
-planers,90:52,90:76, 97:55, aflowances,89:48, 89:49 Measuring tapes for picture frames, 96:82-83
Laser guides, 83:26 board-foot formula, 89:47 board-foot computing, 95:29 making,89:63
97:72
Lathe chucks bowed,89:5 | stick-on,93:20,93:| 08 with routen 85:82-85
8-in.
rim chucks,78:102-104 calculatingboard feet,82: | 2 Mesquite reed,78:8f82
reviewed.99:35
Lathe tools case hardening of , 94:54, 94:55 about,87:4f53 routing, 95:7 l, 95:73-7 4
features of,90:52-53,
gouge certified source,95:32 barbecuingwith,87:53 sandingblock,85:84
97:53-56
using,85:62,85:64,85:65, checkingin,84:32 dimensions of.87:48 small
long-bed
85:100-103 color of.89:53 dust of,87:52 making,93:82
reviewed. 39:94
partint tool construction-trade hardnessof,87:50 method,85:83
planesas,94:26
using,85:62 preparing, 98: | 0 sapwood ol 87:50 trim
recommended,90:54-56,
skew chisel crooked,89:5 | sources,ST:53 over gaps,88:83
90: | 20
using,85:62-63 cupped,89:50 stabifity o1,87:49 Morse tapers, fitting, 86:74
recommended 200 l, 92: | 04
Lathes figure in,89:53 Metal Mortise and tenon
recommended 2003, 97:56
| 6-in. variable-speed for exterior use,88:57 for machinery tables,92:67 fit ol 88:10
router-table
reviewed.9l:32 grades of,89:4&49 tapping,98:14,98:72 correcting, 93:67
making,85:38-42
bed height of grzding,&4:3*42 Metal detectors for doors, 98:79,98:80,98:85
straightedgesening aid,85:22
raising,9l:45 grain direction in, 89:52,98:8 reviewed, SS:30 haunched,88:5&-6 l, 88:64
troubleshooting,9 I : | 2
bowl heavy-duq,96:32 marking system,94:75 Methylene chloride lrlortisers
types of,90:5 |
buyer's guide,83:7&{3 planed characteristicsand uses,79: | 2 benchtop
Jointers mini lathes reviewed,
adjusting,maintaining,and hit-and-miss,89:49 Mineral spirits recommended,90: l 2O-12 |
78:68-71 pre-milled,89:52 disposing,84:28 reviewed,8T:24
tunint
buying advice,83:78-80 quarter measurements, 89:47 reusing,84:28 reviewed and AW rated.
checkingfor square,83:| 30
centers for rifuawn,89:52 Mirrors 81273-77
pulleysand bela,83: I l8
live,9l:44 selectingand buying,84:3f assemblyof,85:80 souping up,78:41
table alignment, correct-
chuck for 84:42 hall oak drill-press,97:37
i n g , 8 3 l:2 G - 1 2 2
4-iaw,9l:44 sources,96:92 making,85:7&€ | discussed,90:37
tuning,83:l8-130
cushions.9l:45 sticker stains on. 94: | 6 Miter gauges features of,90:69-71
waxing the table, 83: 126
developmentsin,83:81 twisted,89:5 | accurate,95:31,95:48 hollow chiselsfor
buyer's guide,83:6 l-65
direct-drive.95:33 warped,89:50 features and types,8 l:82-83 reviewed. S9:98
developmentsin,83:63
dust collection.9l:44 Lumber racks precise recommended,90:72-73
features and types,83:6 l-63
dust collectors,shop-made, shelf shims,87:94 reviewed, SS:32 recommended 200 l, 92 | 04
fence alignment methods,
80:65
83:| 26-l 30
fence features and size,83:64
faceplates
centering on burls,8l : | 6
U
Machinery
precision,9l:4|
recommended,90: | 08, 90: | 20
recommended 200 l, 92: | 04
Mortises
cutting,93:62,93:54
for pegs
settint knives on
features ot, 97:6043, 98:88-94 | 20v x 240v 95: | 6 reviewed and AW rated, with hollow-chisel,85:80
methods, 33: | 22-126
height,98:93 American-made.95: l4 8 | :8 l-83 making,88:70
lointing live centers.99: | 2 basesfor
on router table.92:89 slots for on legs
mini- mobile,88:92,9l:4 | tightening,93:24 marking system,92:78
on router tables.89:| 3
router jig,78:5 | recommended,90:| 20 modular stations for stop for plugging
reviewed, T3:6&7| reviewed,9l:33 quick-action,87:24 for turning, 35:6 |
wide boards,78:8
motors of outfeed rollers for Miter joints router jig, 92:50,92:52
with a routeri 8 | :8, 82:70-7 |
with router iig,89:58,98:2|
by brand,98:90 on jacks,86:28 lock-miter,79:57-59 splines,ST:63
pars sources,9l:45 portable Miter saws squaring,85:6|
with tablesaws,9T:12
recommended,98:95-97 storage,98:42 laser-guided,96:30 stopped,88:58
foints recommended 200 l. 92: | 04 tables for
knock-down recommended,90'61-64,90: I l9 through
reviewed,98:88-97 material, 92:,67,92:68 slidingcompound squaringup,85:80
bolt-and-wing nut, 85:24

n
Kerf bending
sliding-headstock, 97 : | 4
small
recommended 2003, 97:64
Magazines
filing tips,95:7
magnetic switches, as a
features of,90:59-62
Miter saws, compound
features of,97:67-49
with plunge router, 87:62,
87.'63
with routen 87:77
process ol 86:48 speed and poweri 83:80 safety device,83:28 fences for bits,85:51
Kerfs, jig, 93:83 stabilizing,98:9| Magnetizer wall-hinged,92: l0 | jigs,85:5G-5|
Keyhole hanger steadying,85:| 00 for smallnails,93:23,93: 108 recommended 200 l, 92: 104 Mortises and mortise-
sources.S0:34 weighg9l:45 Magnets, rare-earth recommended 2003. 97:69 and-tenon joints
Keyhole slots Lattice source,86:| 3 reviewed,97:8 routing,Sl:7Hl
making,89:84,89:86,89:88 building,86:46,86:47 Magnifiers station for techniques,78:37-45
screws for Layout visor-type,97:7 portable, 93:92,93: | 08 Motors
installing,89:89 tools for Mahogany Miters brushesof
Kilns storing,8S:96 finish,93:90,93: | 04, 93: | 08 biscuit joinery,94:80 replacing,S5:8
making,94:42-55 Layout tools quilted clamping electric, sources,8 l :50
operating,94:52-55 TriScribe reviewed. 82:98 features of. 93: | 04 with tape,89:7 | power of,96:3&-39
Knives, sharpening,82:80 Lead source,80:54,93: | 08 clampingblock,99:55, spark from
Knobs embedding Mantels 99:56.99:58 diagnosing,S5:8
attaching for weight,87:86-87 Arts and Crafu style, clamps,88:52,89:69, 94:24 understanding horsepower
with Tnuts.86: l6 Legs 88:7G43 for little boxes, 93:82-€3 ratings, 78: | 4
drying rack, 85: | 08 exterior building,88:7&80, 88:82-€3 gluing-up iig,96:8647 Mulch, from workhop, 92: l2
star water-proofing,86:49 Maple jig,88:5| Musical instruments
source,87:94 laminated birdseye,96:98 long turning a whistle,78:l7
T-style making, 94:60-6 l, 94:64 curly plate-joined, 98:49 correction
source,93:I 08 leveling,98:57,98:86 bed ol85:56-{9 mini-biscuits,85:54 Myrtlewood
lumber:89:52 finish.85:69 quafities of,92:'102

74 A m e r i c a n Woodworker JULY2oo3
3-Yearlndex
r
Nail sets
miters of,88:49,88:5 |
oval
Plunge routers
Bosch l6l9EVS, review,
Powermatic
bandsaws
Red oak
decay resistance compared
magnetizing making,99:72-78 83:| 04 revie*ed, 88:88{9,9o.2F27 to white oak,8l:8
painting,96:88 buyer's guide drill press | 170 Reed moldings, T8:8G€2
for smallnails,93:23
rustic-style,8 l :2f26 reviewed and AW rated, reviewed,86:68-75 Refinishing
rectangular
splines,88:49-50 78:7G79 drill presses glue-up for
making,9l:20
supplies,88:54-55 Fein,review 83: | 04 reviewed.90:36-37 before stri pping, 86:76
Nailers
Planenmolders Plywood jointer PM 54A Repairs, fillers,9 l : 128
brad -wood attachment, 98:48
buying,90: I 4, 90:76 reviewed,89:94 Resawing
cordless-compressor,9 | :29
Planers ApplePly,source,80:38 iointers avoiding warp after,79: l4
Nails -jointers, 90:52,90:76, 97:55, Baltic birch, source of void- recommended,90:56 bandsawsfor
and staples
97:72 free,80:47 planers recommended,90:.2F27,
combo gun,86:22 -molders,97:72 camouflaging,83:44 reviewed,90:79 90:l l8
brads
benchtop carrier,39:26 abfesaw 64 4,95:46 for bookmatching 88:78, 89:53
bobby pin holden 84: l6
reviewed,93:28-29 chip-out protection, 95:8 | tablesaw 64A, 96:38, 96:48, on a bandsaw,S l:45-5 |
compared to finish nails,
79:45 dust collection for cutting,9l:76 96:5G-5 | accuracytips,8l:4F50
pusheri88:50 built-in.98:30 cautions,9l:77 Primavera trick 88:23
plier-holding,9l:9| features ot, 90:7G77,97 :7 | -7 3 guide,89:38 qualitiesol 99:102 Respirators
knot removal, E9:22-23 tearout Protection, 87:56 Profile shaping organic-vapor cartridge
removing
portable with a circular saw 78:50 with disc sander,86:l3 storing,8l:90
brad setter,93:26
small recommended,90:122 dimensionsof Proportions Restoration
recommended200 l, 92 | 04 true,85:5 | calculating of bureau,96t70-78
magnetized starter, 93:23
recommended 2003, 97t74 drilling device,92:83 Roller stands
Noise
room insulation,99: l4 snipe-preventionsleds,99:25 gang,89:38 Protractor/depth gauge, double-duty,95:88
stands,95:88 edge banding,89:58,95:63, source,78:64 folding
Notches
taper sled,9 l :69,93:68 95:6,{-66,95:82 Pulls supports, 89:22-23
with tablesaw 89:88

n
Oak
types of,90275-76
vs. sanders,90:| 8
Planes
jointing,89: | 3
edge trimming, 9 | :62,9 | :64
edgebanding,96:62 .
brass
source,87:89
calculator, 92:83
pivoting
reviewed,94:39
with vise
curly red, 95:106 block edges of carving, 39:24 reviewed,92:35
finish for buyer's guide,83:39 filling,87:57 from aluminum stock, 96:6 I, Roller supports
fumed, 85:79-€0, 85:8 | sources,S3:36 edging 96:67 drawbridge-type, 87 :94
quartersawn "old-growth," types and features, Europly launched,84:26 installing,92: I l6 suppliesfor
85: | 20 83:3,1-36 router bits,99:29 Push blocks, right-angle,85:52 source.87:94
Ocarina, turning an, 78: l7 cufting angles,83:40 edgings,87:5f58 Push blocks and pads Rolling pin, turned,
correction flattening the blade back,82:81 fi nishing,88:46,89: | 2F | 22 from concrete float pads,82: I 6 79:24-34
Octagons, method, 88:22 irons of for dovetails,98:l6 sources,79:59 Rosewood, allergiesto, 99: l8
Oil finishes sharpening,38: | 2 high-density,98: l6 Push sticks Rotary tools
uPturned jigsawing fastening with magnets,8 l :37 base for
applying, 78:106-107
sources,78:54,79:62 as jointers,94:26 sanssplinters,89:20 pictured,85:83 routen94:22
Oscillating spindle Planing laminating,95:78 Puzzles Router bits
sanders figured wood,93: I M notched joint,96:64 knog 87:82-€5 bushings, sources,S l:6 l, 8 l:69
buyer'sguide of curly wood,92:44-45 red-oak magic coin, 87:82, 87:8&€9 flush-trimming
reviewed and AW rated. wetting before,92:45 choosing,88:3!44 scrol f-saw 87: 66, 87:72, 87 :73 withTeflon bearing
82:82-85 without jointing,84:9 ripping,86:59 reviewed, 34:24
Grizzly reviewed, 82:97 Plans rotan/-cut vs. plain-sliced, - reversiblestile and rail cut-
Porter Cable hand-held for Mission furniture 88:36-44 Rabbeted joints ters, using,78:72-74
reviewed, S2:96 book ol 94: | 8 sguaringup,89:58 locking ficr draryers,84:9 | -94 sources,78:45,8 | :6 l, 82:77
outfeed rollers period supports for Rabbets lock-miter,79:59
swiveling,80:| | sources,SS:8 board,99:82 for glass,88:8| point-cutting round-over
Ovals, mat cutters, 99:78 Plant stands l-beam,9 l :60,9 l :6 l, 9 l :62 for round frame,99:78 bits,78:82
nine-pot Pneumatic brad and lock radius type,84:89
- making,94:7V72 finish nailers with router,92:6f63 reversiblestile and rail
Paint Planters anatomy of,79:44 on tablesaw,89 :58, 96:62 cutters, TS:74
and fasteners patio shingled bfowout, avoiding,79:47 on tablesaws,9 | :77,9 | :9 | Router jigs
bleed-throughwith, 86:49 making,94:7840 bfowout, repairing, 79 :47 trimming for dado cutting, 78: | 8, 78:48,
for exterior doors. 88:58 Plastic laminate features and types, 79:43-49 with router, 9 l :82, 9 l :83 80:28
on damp wood,86:49 applying,99:43 impact mark, avoiding,79:45 with router, 88:6 l, 98:8 | for diagonal routing,
over pressure-treated samplesof sources,T9:49 with tablesaw 94:66 78:8G{2
wood.86:48 uses.99:25 Pocket-hole joinery Racks for dovetails
removing from pores,79: I Plate joiners c l a m p s , 9 7l 6
: drawer,96:26 slidingdovetails,84:86
sPray-on biscuitsfor Pocket-screw ioinery drying for jointing, 78:5 |
rack,96:88 making,87: l6 without aiig,82:17 for knobs,85: | 08 tenoning,34: | 6
strippint,79:| 2 edge-to-edge alignment Polyurethane finishing,88:52 Router tables
Panels with,87: l0 creating a custom sheen,78:8 for damping,9S:42 "recoverable" beadswith, 87:26
assemblyol 85:80 features of,90:82 waterborne for portable tools, 98:42 -router combo
bits for recommended,90:83,90: l 2 l addingcolor,80:102 for tablesaw blades,85:44 reviewed,99:30
reviewed,92:32 recommended 200 l, 92: | 04 best brush,82: | 04 for turning tools, 96:20 adjustments, 92:66, 92:68
Patterns rypes of, 90:81-82 sources.80: | 02 knife bases,92:69
gridded vs. slot cutters, ST:8 Posts making,85:92-93 benchtop vs. fl oor, 92:64-65,
enlarging,8T:65 Plate joinery turned two-part lumber 92:66
transferri ng, 82: | 4, 82 | 6 anglejig,99:20 making,85:58-65 with under-slungdrawers, bit storage,85:46
Pegs, decorative, 9 l :65 biscuit exposure in, 99: 104 Power miter saws (conven- 85:44 bit-height adiuster, 85:89
Pencif holder,84:14 biscuit sizing,98:5 l, 98:52 tional and compound) painting,96:88 Bosch folding table
Pencils carcaseswith.98:5 | accessories,33:58 Radial-arm saws reviewed, S4:26
carpenter's cut gauging,9S:5| buyer's guide compared to power building 99:39-45
sharpene499:36 drawers with,98150 features and types, miter saws,83:55 cove with,93:8648
chalk marking,sources,79:56 edge joinery with, 98:48 83:54-56 recalled,8S:32 curve-routint iig, 99:47
multiplying edgingwith,98:47 Ryobi reviewed,83:l4 Rags dadoes on,96:83
quickly,92:80 Paceframes with.98:47 capacity,determining your hazards of oil-soaked, 78: | | 0 dust collection,SS:95
Perf-board hold-down.98:56 needs.83:55 overhead dispenser;82:36 end-grainjig 86:34,86:35,86:36
extending the hooks on, miters with,98:49 compared to radial-arm what makes a good, featherboards,85:82,85:83,
8l:38 shelveswith.98:50 saws,83:55 78:| 06-107 85:85
shelving,S0:8 technique,98:52 dust collection Random-orbit sanders features of,99:40
Phenolic top attachments with, 98:48 after-marketsolutions,83:57 dust collection tips, 80:64 fences,92:65-67
for machinery tables,92:67 with slot-cutter bits, 87:8 laser cutting guide,83:26 Rasps sub-,92:66,92:67
Picture frames Plate turning, 78:9&-l fi Power tools sandpaper for tablesawextensions,92:73
assembling,88:53 Plugs caddy,79:| 00 making,92:22 gaugesfor
fasteners for source,87:80 storage devices,82:34,82:36 sources, S0:6 | set-up,85:53
quick-change,88:53 tapered,sources,8 | :69 technologicaladvancesin Reclaimed lumber guard for
fi4ishingrack,88:52 trimming portable, S3:30 checkingfor embedded meal, freehand.99:47
hangers,38:49 router jig,89:25 understandinghorsepower 8 4 : 18 inserts
making,96:80-88 ratings of, 78: | 4 Excalibur EXRT2
reviewed, 34:25

76 A m e r i c a n Woodworker J U L 2Yo o 3
 3 - Y e a rI n d e x
joint-making,92:73 jointingjig,89:58,98:2| belt Screwdrivers Sheet goods
jointer fence,85:3&-42 lever locks,85:75 features ol 90:8&49 right-anglebattery-driven, crosscutting,ST:37
lointingon,87:54-55 mid-size recommended,90:89-90, 98:32 dolly,86:26
knock-down,89:3| reviewed,85:70-76, 89: 100 90:l18 Screws ripping,87:37
miter mini-biscuitswith, mid-sized random-orbit broken sawingrack,80: | |
85:54 reviewed,90:122 recommended,90:8G{8, removing,35: l0 storage,8T:96
moldingson,96:82-83 moldingswith, 85:82-85 90 122 broken-through Shelf supports
moldingswith, 85:82-85 fluted, 85:82.85:85 types of,90:85-86 Fix,88:82 brass,sources.T9:77
on tablesawextensions,88:95 mortiseswith. 92:50.92:52 Sanders, random-orbit coarse-thread usingbiscuits,32:59
olatesfor mortisingwith recommended200 l, 92:| 04 loinery with,87:37 Shellac
advantagesof,85:86J7 jigs,85:5G-5l, 85:60,85:6| Sanding drivingin tight spots,78:22 dewaxed
angled,85:89 stop blocks,85:60 blocks extractors for applying,78:107
mounting,85:9G-9 | new improved,96:30 profiled reviewed.9l:34 instant,80:98
perfect.85:88 noise ol 85:73 making,85:84, 95:39 galvanized source,92:34
recommended,g0: | 23 plug-trimming jig, 89:25 sources.T9:56 source,93:| 08 Shelves
reviewed,85:8&{9 plunge end grain,79:54 makinggood joina with,79:62 cleats,87:38
pull-out,79:104 for tables,96:28 hand.78:23 paint bleed-throughwith display,89:84€9
push-blockfor reviewed,92:30 insidecorners,32:| 7 fixing,86:49 glass,98:79,98:85,98:87
right-angle,85:52 power of,85:72-73 Dads pilot holes,86:48 heavy
raisedpaneldoors on,86:32-43 rabbetswith,88:6| flexible,sources,79:56 pocket, 89:59-42,9 l :65, 9 l :66, supports,99:84
recommended,90:| 23 recommended,90:96 scratchesfrom 9l:79,91.81 installing,78:56-61
roundingover with, 93:65, recommended200 l , 92:104 exposing,88: I 4 predrilling,94: l4 metal upside-down,98:40
93:70,93:88 recommended 2003, 97:86 smallpieces,80:32 removing,SS:l8 pinhofes,9l:67,91:79
routers. 97:7.99:28 reviewed, 99:64-7 | Sandpaper sheet-metal pin-hole iig,98:80,98:83,98:84
safetyfeatures,92:68 roundingwith a,78:20 dispenser,T8:22 lor grip,9l:94 plate-joined,98:50
shaper-like safetywith,90: l6 file storage,32: I 4 stainless sink-cabinet,85:92.85:94
reviewed,89:92 sizesol 90:92-93 folding,85: 109 s o u r c e , 8 6 : l5, 8 7 : 6 5 stiffening
sleds.99:47 sparks from high-quality,96:29 wax, 86: l4 with edging,87:58
slots on.88:49 diagnosing,S5:8 mounting,93:68,98:70 Scribing support holes,drilling
springboards,92:26 speed chart, 92: | 7 overhead dispenser,82:36 adjacent edges,78:60 accurately,T9:74
tablesaw-mount speed controllers, 86:8 reinforcing,9l:20 cabinets between walls.78:60 wall
reviewed,35:30 soeeds
. of saving,98: I7 cabinetsto walls,78:59 display,78:52-55
tabletops, 92:67-69 variable,85:7l-72 sources,T9:56 Scrollsaws free-form,80:34
template routing on, 87:6 l, squaringup with,99: l6 for "short" rolls. 78:22 blade changing,87:68-69 Shims
87:63,87:64,87:78, 87:79 table-mounted,vs.shaper;83:22 unclogging,8 l :92 bladepainting,94:26 aluminumtape,93:24,93:| 08
feed direction,8T:79 table plates for Sawblades blade-threadingslots,95:26 source,87:94
templates,93:70 recommended 200 1,92:104 bandsaw bladesfor Shingles, laying
tested.92:64-73 template guide bushings,85:73 features of, 9 | : | 04-l 08 choosing,ST:74 on box,94:80
Routers Rubbing out, recommended,9| : | 08-l l0 controls, 87:69-70 Shop vacuums
basesfor process ol 88: | 6 reviewed,9l:ll0 dust management,87:70 buyer'sguide
dust collection,83:89 Rulers, storage,88:96 setting,9S:28 extending the useful life of, reviewed and AW rated,
removable.83:88 Rust t y p e so f , 9 l : 1 0 3 - 1 0 4 79:16 80:69-73
shop-made,8l:37 Preventing combination features oi 90: | 0 l-l 02, features,80:70
"body-grip" with corrosion inhibitors. sources,95:28 97:91-93.97:94 muffling noise from,
reviewed, 92:28-29 8 6 : 10 dado m u l t i p l e sw i t h , 9 l : l 8 7 9 : ll 5 - l l 6
3-HP with dehumidifiers, 86:l0 carrier,93:96,93: I 08 recommended,90: | 02- | 03, plastic liner,source,80:64
reviewed,90:123 with silicagel,86:l0 recommended200 | ,92: 104 90:123,92:104.97:94 recommended,90:.124
accessories.85:73.85:75 dado stacking reviewed,ST:66-74 tool-actuated,97:8
as biscuitjoiners,85:53 - choosing,S6:56 speeds,87:70 switches.80:7 |
base plates for Safety recommended,90:|'24 tables,87:70 Silicon putty, sources,T9:l0
making,85:20 dust hazards reviewed,86:53-56 types of,90: | 0G-l 0 | SL I E, defined,82:70
basesof health effectsol80:104 for aluminum,86:l0 vibrationwith,87:69 Slats, spacing,ST:80
removable.S5:7l. 89: 100 Uniform Mechanical for melamine.9T:l2 Scroll work Sleds
bearingsfor Code standards.80:67 jointer-quality,97: | 2 finishingbath,92:27 crosscut,93:66
graduatingwith,85:84 Prevenringstatic electricity stabilizers, 95:l0 Sealers gang,93:64
bit acceptanceof , 85:72 sparks,80:26,80:67 stiffeners,95: | 0 shellacas.92:34 for router tables.99:47
brushesof Sanders tablesaw sources,79: | 0 small-piece, 93:82,93:84
replacing,S5:8 -drill-presscombo,97:38 setting,9S:28 Sectors, making,92:83 taPer
buyer's guide,83:85-89 disc tightening,95: l2 Sewing cabinet, for planers,93:68
MakicaRD | 100 reviewed, templatesandingwith,86: l3 Sawdust. as mulch.92:l2 Shaker.84:82-89 for tablesaws.93:66
8 3 : 12 drum Sawhorses Shafts, mounting,98:7 | slidingcompound-miter saws
reviewed and AW rated. discussed, 93:39-45 flip-top,93:l8 Shaker style advantagesol 84: | 00- | 04
78:76-79 double, 93:48,97:42 knockdown and folding,79:102 sewing stands,desks,and buyer's guide
circle iig,94:72 features of,97:.4143 making,96:52,96:54-55 cabinets,84:82-89 reviewed and AW rated.
climb-cuttingwith, 99: l0 paper savingwith,98: l7 nestin8,8 l:38 tools and supplies,84:89 84:9&-109
colletsof,85:72 qualitiesof, 90: l8 stacking,39:30 Shapers features,34:l0l-102
self-releasing, 85:75 recommended,93:50-5| making,94:9| compared to table-mounted Slots
cordless reviewed,93:38-5 | Sawing, of multiples,9l: l8 routers, S3:22 on router table, 99:52,99:55,
reviewed,89:90 single-drumclosed-end,93:47 Saws with router 99:75
crosscuftingwith, 78:48 single-drumopen-end,93:46 dovetail.90:l9 reviewed.S9:92 on router tables.88:49
dado baseplate,35:52 vs.planers,90:| 8 edge protection,94:29 Sharpening Smoke alarms,
dado iig,96:22 drum frugality,39:24 Japanese-sryle, 90:l9 edge tools,82:78-8 | dust and,80:| 04
d a d o e sw i t h , 9 l : 9 | oscillating-spindle sanders veneer gauge for Snipe, eliminating, 79:85
angled,94:76 reviewed,90:l2 | source.87:89 making,92:8| Solvents
depth gauges,92:79 random-orbit Saws, compound-miter hollow-chisel mortising choosing,96:| 6
depth-of-cut adjustments features of.97:77-78 a l u m i n u mw i t h , 8 6 :l 0 attachment.78: l0 Sound Safety Products
for,85:73-74 recommended 2003, laser for lappingplates,98:62,98:64, Optimuff
developmentsin,83:87 97:7&-79 reviewed,SS:30 98:65,98:68 reviewed, 92:92,92:95
dovetailswith spindle stand for machinesfor Spanish cedar
s l i d i n g8, 5 : 1 4 , 8 5 : 5 3 and drill press,89:96 building,87:36 recommended200 | . 92: I M preferred for cigar
dust collection,92: | 0, 9 6:27 Sanders, belt Scrapers reviewed,89:76-€ I humidors,78:l0
dust collector for -polisher,97:80 burnishing, 78:104 of carbidebits,92:l7 Spires
reviewed,35:36 detail,97:80 cabinet of marking-gaugeknives,92:79 pyramidal
features of,78:76-77. features of,97:-79 sources,30:61,80:68 scrapers,S0:| 07 making,94:76
83:85-86, 90:93-95, finish,97:80 edge protection,94:29 system for Spline joints
97:83-85, 97:88, 99:64-67 recommended200 l, 92:| 04 sharpening,80: | 07 drill-press,98:62-74 for drawer runners.92:58
feed direction,90:l6 recommended 2003, 97:79 sources,S0:6|,80:58 testing for sharpness,S2:8| making,93:83,93:84
flush cutting with, 9 l :82,9 l :83 Sanders, drum squaringedge,82:79,82:8 | tool holder,98:64-73 on router table, 99:.74-7 5
flush-trimming jig, 87:58 cleaner for storage,33:96 Sharpening machines Splines
for router tables.97:7.97:85 reviewed,94:40 Scratches, minute recommended,90:124 jig,88:50
from roary rcols,94:22 Sanders, oscillating spindle exposing,88: | 4 sharPeningstones Spokeshaves,
in end grain recommended2001,92: 104 Screw extractors waterstones sources,30:6 |
centering,85:63 Sanders, portable hollow flattening,82:8| Spray painting and finishing
u s i n g , 8 5| :0 holders.82:79 techniquesand equipment
for,8l:92
78 American Woodworker t u L v2 o o 3
 3-Yearlndex
Spring boards Stools for glue,96:l4 shelves.94:65 storage under
as fences,92:26 nested,78:47 for stains,88:46 side trays,87:98
Squareness Queen Anne footstool, Switches Greene and Greene-style, switches,95:48
by feel,92:83 80:4&-54 combining,95:20 8l:52-6 | table insert for
by fol fowi ng kerIs, 92:27 Stop blocks magnetic stretchers,94:62, 94:63,94:64 tape temporary,S5:22
checking,9l:56 workbench safety o( 96:39,96:40 trestle taper jig,88:78,89:86
drafting triangles,92:78 from old deadbolt 79: l6 Sycamore how to size,82:3G-32 tapers on,92:50,92:53
for large pieces,99: 16, Stops qualitiesof, 98: I l4 utility tenon jig, 88:6G-69,88:7 I,
99:4243 doweling jig as,93:20 knock-down.86:30 88:73
Squares for angles,98:56 - Tablesaws throat plates,95:29,95:50-58
buying,90: | 4 for dadoes,98:69 T-nuts | 20v x 240v 95: | 6 zero-clearance,9 l:4 |
storage,88:95 for routers.99:46 for drawer pulls,85:l6 240-volt.96:4 | types of, 90: | 05- | 06
Stains quick-action Tables 120-volt vibration with
applyingbright-colored reviewed, ST:24 aprons,92:54-55 reviewed,96:36-5 | reducing,9l:4 |
stains,82:106 Storage Arts and Crafts style accessory storage, T9: | 00 wrenches,95:46
chemical behindstairs,95:90 small,94:5&{7 arbor-washer fl attening, 96:24 Tabletops
for cherry,93:58,93:| 08 drawers for assembly bases for attachment methods,94:64,
ebonizing,S6:76 between studs,87:94 folding,85:48 m o b i l e , 9 l : 4| 94:67,98:84
for blemishes,95:24 for lumber,85:44 buifding,87:7640 mobile storage,9l: I l2 fasteners for
for concrete. 36:8 for small para,98:25 materials list.87:79 benchtop,95:49 metal,94:64
gel in bottles workstation, 8 | :62-65, blade guards fastening,80:26
corner removal,39: l2 for the shop 84:74-78 sources,83:74 for router abl e, 99:4 l, 99:4243
on plywood,88:46 carts and caddies,79: | 00 coffee bladetilt.83:76 making,92:49-50
over figure, 89: | 20- | 2 I drawers, rolling,80:8 two-d rawe red, 92:48-59 bevel gauge,94:66 slots and buttons, 87:78,87:80
Stamps, source,92:82 lumber racks.84:44 dining blade spacers,88:67,88:70 slotted, 9S:55,98:57
Stands overhead,34:46 how to size.82:24-32 blade storage, 35:44 squaringup,99:| 6
garden weighted,98:54-59 power tools, 79: 100, 82:34, farm style,82:6&-77 bladesand cutters Tack cloths
Staples 82:36 folding shop, 93:74-7 9, 99:80 dust volume and,80:68 fi nish contamination with.
and brads hanging,89:32 kitchen work bladesfor 8 6 : 10
combo gun,86:22,80:67 rack-hung drawers,85:44 building,87:76-80 dado,86:53-56 Tambours
Stave construction shelvesfor materials list,87:79 bladesof replacing
bird's mouth joinery, 92:32 upside-down,98:40 legs angle setter,85:32 t i p , 9 3 :I l 6
Steel, rod stock source, 80:38 tool "book," 79:100 factory-turned, sources,82-Z squaring,92:78 Tape
Steel wool under bench.95:92 mortising tapered,8 l :60 buyer's guide,83:72-76 acid-free,88:55
life of walls for quick utility legs,78:23 cabinet clampingwith, 89:7 l, 89:74
prolonging,88:2| reviewed.9l:35 turned.82:4246 reviewed,SS:28 double-faced
steel-free.98:36 Straightedges outfeed cabinet left-tilt for hinges,93:88, 93:| 08
Stippling tool, holders,85:22 drill-press,88:94 reviewed,93:30,93: | 08 source,87:65,93:88,
shop-made,82:16 shop-made,83:128-129 parlor,79:5G-56 choosing, 96.,3642 93: | 08
Stock preparation sources,33: | 29 pedestaf,80:74-78 crosscut sled,87:37,87:4243, Tape
marking,92:76-83 test,83:| 30 picnic,80:74-78 89:58 double-stickinS,sources,
process ol 98:78 Surface preparation rails, crosscuttint 78:54,79:56
curved,87:.78-79 tables,78: | 7 correction Tapering legs
dadoes on, 85:94,85:95,89:86, on a iointer,84:126
9 l :76, 92:5G-5l, 92:53, Tapers
98:6&-69 clamping,89:74
developmentsin,83:75 jig,89:86

ffi dust collection,S0:66

impact of blade selection,
80:68
jointer techniques,84:
on bandsaw.39:89
on planers,93:68
| 26

lineof"Pin-Free"
A Superior Moisture
Meters features of,83:72-73,
90:9 l,:90: 107, 97:98-100
grooves on
on tablesaw 93:66
jig,88:78
planing,9l:69
gang cutting,9 l:93 tablesawjig, 92:50,92:53
stopped,88:58 with circular saw.98:57
guards for Taps, using,98: | 4, 98:72
dust-collecting,88:34 Taps and dies, metal-
Ittc 2t0 easy-mounting,95:47 threading, sources,80:38
overarm.9l:4 | Templates

fl ftiHffi
hybrid,95:44-45, 97: l 0 tape,87:6l, 87:65
inserts for toggle clamps,93:70
zero-clearance,88:67,93:84 Tenons
kerfing jig,93:83 angled,93:62-65
lap joina with,92:56 fitring,88:73,88:74
left-tilt,95:46 haunched,92:50,92:53,
miter gauges,sources, 83 :74 92:54-55
mobile base,87:94 loose,99:5l,99:52-53
tffi tfltg tfitt7 notches with mortising,85:6|
safely,87:80 mitered,ST;77
llewFeatures
Include., . octagons on,88:22
parts sources,9 l:45
on router.84: | 6
on tablesaw.8T:77
prices of,95:47 jig,88:6G-6|
* Selectable
&clas $atttngs rabbeting iig,94:66 round
rabbets on, 89:58,9 l :77,9 1:9 1 cutter.99:6
* Ptass/,loldBeadlngsFunctlon raised panelson, 95:34-40 shoulders,88:7 | -72, 88:74
recommended 2003. 97: | 0 I tablesawjig, 88:66-69, 88:7 I,
* to NanualConectlorcRcqulrrd resawingsplitteri 96: l0 88:73,92:53
rip fence-mitergaugeuse,87:77 turned,85:64
Wagner's Proven rippingjig,9l:84 Thickness gauge
* Earyto BeadDlglFrlDWef router tables on.85:30 shop-made,80:30
moisture meter router-table extensions,92:73 Thickness planers
* Exfr;nded SpeclasBangetor Erotlc, technology is virtually SawStop saleq,97:6 benchtop (also called
Iletmr lladund $pactas unaffected by wood sleds for portable)
gang-cutting,93:64 reviewed and AW rated,
temperature miter.96:84-85 79:83-87
or surface moisture. small-piece,93:82,93:84 dust collection improvements,
splineson 80:62-63
iig,88:50 features and types, 79:83-€6
splitteri 97: l2 Thompson'sWater Seal
splitters,9l:40 Advanced Wood Protector.
squeaking 94:36
silencing,9l:14 Threaded inserts
wffin www.moisturemetets.com F storagerack,9l:41 drivers,86: l4
EL.Fr(Jcs roll Frce:
l-800-e44-7078
Tcl: Fax: 582-4138:
(541)
ffi.tffjl1 M6doin ths USA

82 American Woodworker J U L2Yo o 3

 I
What's
ComlngUpI inAW #l0z,Sept.2003

ArtsandGraftsTable
Jon Stumbrasis assemblingthe piecesof a small round table,
e
perfect for putting next to your hvorite big chair.lt's got U

contemporary lines,but is actuallya scaled-downversion of a

hidden gem from the American Arts and Crafu movement, f,
z
made 100years ago by the Limbert Company in Holland,
L
Michigan.
U>
u
F

BradNailerToolTest
o

T
c
What's the reol differencebetween a 950 and a 9300 brad
nailer?Tim Johnson hasvowed to find out in our next tool
test. He's poking and prying into virtually every l8-gaugenailer
on the market.

SimpleKitchenUpgrades
Dont you wish you had designedyour own kitchen cabinets?
U
Think of all the cool ways you could make them more roomy
F

and useful.MacWentz has three simple projects that turn

6-
=
U
ordinary kitchen cabinetsinto custom-built problem solvers.
an
=
E
UJ

,$
U
.
GoAnywhere
DrillGaddy
Bits,drivers,countersinks,extra battery:where is all that
4

s stuff when you need itl Jan Carr is putting the final touches
o
on a small carrying box that organizesall the essentialsfor
-
t
drillingand driving.
E
o

!
L
a
E
U

z.

-
Foolproof
Scraper
Sharpening
Does it feel like your card scraper only works half the time, and you
E.
s
F
cant figure out why?Tom Caspar is taking the mystery our of how to
2 sharpenthis incredibly usefultool, usingwhat he callsthe worrd's
tr simplestjig. He saysthat any woodworker can make shavingslike those
U

d
pictured here the first time out of the gate.
E

American Woodworker JULy2oo3 91

 Sou rces arthe
tobuy
Where stuffwe used.

www.labsafety.com Dick BlickArt Materials

Half-maskrespirator,3M 6000 series,# | 5255; (800)828-4548, www.dickblick.com
Better Brush Cleaning
Wilson-lmperialCo., (800) 332-6050 $ l2 (availablein small,medium and large) VanDykeBrownartistl oil
www.wilsoni mperial.com
Organic vapors/P| 00 fi lter cartrid ge,#34770; 0046| -83| 3 1.25oz.tube;$5
$21 Liquinglazing medium
Rapid Brush cleaner;$8 per qt.
Northern Tool and Equipment, 00445- 1004250ml.Bottle;$9
Wooster Brush Co., (800) 392-7246 (800) 556-7885,www.northerntool.com Norton Abrasives
www.woosterbrush.com Halogen light,500 watt, with stand,# | 60982- (800)55l-44| 5,www.nortonabrasives.com
B r u s hc o m b ; $ 8 8226; $20. Stearated sandpaper
Flood Co., (800) 321-3444 3X HighPerformanceAbrasive Paper
www.floodco.com $4 ea.
| 00-, | 50-,220-grit3-packs;
Brush Stuff brush conditioner; $7 per qt. LeeValley &Veritas
(800) 87 l -8 158, www.leevalley.com
When Should I Sharpen My Blade? Accuspray 22SP;
TWo lron PendantPulls,01A60.30;$6 ea. $470
Woodworkerl Supply,(800) 645-9292 Two lron Oval Pulls,0lA60.40;$7ea. (800)696-0615,
www.woodworker.com Twelve PartWrap lron Hingeswith Minaret www.compliantspraysystems.com
Oxisolve blade cleanen#828-418;$9 per 8 oz, Tips,0 | H3 1.50;$4 ea. AmericanTurbine ATI950;$530
One 18" BlackFull-ExtensionDrawer Slide, (877)434-395
l, wwwmikestools.com
02Kll.l8;$l6ea.
Apollo A700;$600
Drawer Slide Tracing Jig Four 3/8" x l/10" Rare Earth Magnets,
(800)727-6553.
www.advmachinery.com
Woodworker's Hardware, (800) 383-0 | 30 9 9 K 3 2 . 0 3 ; $ 0 . 5e
0a .
www.wwhardware.com Four 3/8" Cup for Magnets,99K32.52;$0.50ea. Campbell Hausfeld
10" drawer slides,#KV8400-B l0; $ | 3 pr. Four 3/8" Washers,99K3262;$0.40 ea. H V l 0 0 0$; 1 7 2| H V l 5 0 0 ; $ 2 1/ 5H V 2 0 0 0 ; $ 2 2 1
One l/2"-high RomanOgee Bit, 16J33.51 HV2500; $32| / HV3000; $430/ HV3500; $594
Rockler,P00) 279 -444l, www.rockler.com
( 16J33.01 for | 14"shank);$27 (4 | 0) 692-6300, www.jackssmallengines.com
36".#21746,T-slottrack; $ l0 ea.
One l/2" radiusCove Bit, 16J29.58 (16J29.08 CapsprayCS5| 00;$575
l 8 - 5 / 1 6 ' x l - l / 2 " T - s l o t b o l t , # 8 3 3| l ; $ l e a .
T - k n o b , # 7 1 5 1 4 ; $ le a . for l14" shank);$29 (888)385-9969, www.o-geepaint.com
One l/2" radiusround-overbit, 16127.58
Mobile Magnetic Light Fuii
(16J27.08for | 14"shank);$28
Woodcraft, (800) 535-4482 FujiSuper; $500
One f " radius round-over bit, l6)27.66;$57
www.woodcraft.com (94l) 6 | 3-l0 | 7,www.cheyennesales.com
One l/2" flush-trimmingbit, 16J09.58; $ l2
Magneticwork light,#09L06; $25 FuiiQ3;$600
One 45-deg.chamferbit, 16J30-58( | 6J3008for
(800)645-9292, www.woodworker.com
LongTenoning Sled l/4" shank);$2|
HighlandHardware,(800) 24l-6748 Graco HVLP2500; $525
Public Lumber Company, (3 | 3) 89 | -7125,
www.too Is-for-woodwo rki ng.com www.o-geepaint.com
www.publiclumber.com
Toggleclamp,# | 66 105;$7 (888)38s-ee6e
Two 3/4" birch plywood;$50 ea.
Handy Dandy Craft Sticks Two 3/4" clear or knotty pine plywood;$70 ea. Lemmer T-55;$425
(800) 788-5250
Gramco SchoolSupplies,Inc., One l/4" clear or knotty pine plywood; $40 ea. www.lemmer.com
www.gramcoonline.com 50 bd.ft. pine ;$4 per bd.ft. (800)s6r-6e08
#2499;$3 for 1,000 Adams Wood Products, (423) 587 -2942 Lex-Aire LX-30C;$595
www.adamswood p rod ucts.com, (800)539-2473, www.lexaire.com
Four 5" Maple Bun Feet,A0554-DS;$8 ea. Rockler HVLP1000; $ 100
Price-Cutting Saw Woodworker's Supply,(800) 645-9292 (800\279 -444l, www.rockler.com
Delta MachinerX (800) 438-2486 www.woodworker.com Titan TS40;$600
www. deltawoodwo rki ng.com One pintTitebond wood moldingglue, (800)338-| 042,www.jnequipment.com
MS250,10" Compound Miter Saw;$100 921-971;$7
Turbinaire MiniPro| 135;$550
Kink-Free, Lightweight Air Hose One gal.sealcoat(shellac),I l9-459;$23
(800)225-| | 53,www.woodcrafc.com
Coilhose, (732) 390-8480,www.coilhose.com
Woodcraft, (800) 225-l 153
| 1 4 "x 2 5 ' c o i h $ | 8 Wagner
www.woodcraft.com 2600;$475
l 1 4 "x 2 5 ' s t r a i g h u $ 1 9 2900,$580/ Softspray
Softspray
OneTransTintGolden Brown Dye, 128482;$l7 / FinecoatPlus;$255
Rock-Solid Coping Sled 2000;366
Finecoat
EagleAmerica, (800) 872-251|
(228)863-3942,
www.gleempaint.com
www.eagle-america.com
Minwax
OriginalCoping Sled;$40
(800) 523-9299,www.Minw.x.com TablesawTool Drawer
ReplacementGuide Block;$ l0
n Wood Conditioner | -qc; $8
WaterbasedPre-Stai Woodworker's Hardware, (800) 383-0 I 03,
Pro Model Coping Sled;$60
U
Klingspor's Woodworking Shop www.wwhardware.com
F
z ReplacementGuide Block;$ l5
(800) 228-0000 22" drawer slides,#KV8400-B22;$ l2 pr.
f
T Space-Saving Cyclone System
:< Oneida Air Systems,(800) 732-4065 www.woodwo rki ngshop.com
E. www.oneida-air.com Tranfastwater-solubledye, HS3266,antique
k cherry brown;$9 per I oz. bottle GilmerWood Co, (888) 667-3979;
$882; $977
2 Online Carving Classes Wood Finishing Supplies.com www.gilmerwood.com,$ I 7/bd.ft.for Plain
F www.2carve.com (866) s48-1677 stock, $25 and up for figured stock; Note: $ 100
ul
www.woodfi nishingsuppIies.com minimum order on lumber.
Zinsser Sealcoatdewaxed shellac(2-lb.cut);$8
Lab Safety Supply,(800)356-0783
Per qt.

92 American Woodworker J U L2Yo o 3

 Wood andWhere to Get lt
Spectacular b y D a v e l ' 1 u n l < i t tcr l <

Great
od! Geylon
Beeswing
Satinwood
Loc-rkbe,vondthe striking becsn'ittgftrlLrrcitt (lcvlcltl sirtitl-
n ood and xrLr'llflnd scln-rethingelsevcry spccial-the colclr.
Cevlon sartinu,ctodhas a beautifirl pale ycllotv to solt'lctlvcllorv
c o l o r o f i e n a c c e n t e dr v i t h d a r k e r s t r c i r l i s .I l t r t t h c c t l t l l e s t
t h i n g a b o r - r tC l e v l o t .st a t i n r v o o d i s t h . r t i t t c / r r i ; t , .i t s c o l o r ,
c h a r r s i n F\ ',c r ' \l' i t t l c t t v c rt i r t t c .
Tl-rccollrbitlaticltlof stablecolor ancl sprgtllcltltlrflgLrrei:
u,hitt rlade (levlorrsatinwood one of thc "qrcat n,('rodS" ctl-thc
Earlv cabittetrttaltcrsr-tscdsatitltvooci
I8tl-r-centuryt-t-tilstet's.
effects.(,evlorl satillvclod is still
veneersto cretttestr-tttt-tit-tg
largel,vused as it \/crlccr.llLrtsolid n'oocl is alstt itt dctrli.tncl,trot
onlv for cdging to nratchthe vcttect'[rlrt also for btlx n-raliittq'
tr-rrningsancl as t'irredetail in largcr priccc's.
Nanred tor its ntrtural satin-lil<esheetl,Ceylcllrsatitln'ooc1
is ofien figLrred;A wavv,narro\\rribbort figureis Illost colllllloll.
I l u t , a n v t h i n g t r o n t I t r o t t l e ,r o e , r i b b o t r ,b r c t k e t st t r i p e t o t h e
here calt bc fbr.rrlditr atly sivctl trce.
bccst,ing figr,rref-etrtr,rrcd
bttt vcrv flrlc rllottlcc-i
Ilecsn,ingsintplV retbrsto rt prrot-tot-tltcecl
f r g u r c .L i k c t h e r a y f ' l e c ki n n ' h i t c o a k , t h e b c c s n ' i t l si s I l l o s t
pronollncec'ln,hen the n'ooc'lis c1rtarterstru'rt
(,e1'lorrsatitlvcrocl(CltloroxS'lottsn'ielctlirl)grcltysirl tIe
c l r v d e c i d t i o u sf b r e s t so f S r i [ - a t t k i r( f b r r t t c r l vC e v l o r l ) a r l c l
S o r - r t h c r Inn d i a .
Ce,vlonsatirlvooclis as hard as eboltt',u'ith a speciticgra\'-
i t r , o i . 8 0 , s o i t ' sa b i t o f a b e a r t o I n a c h i n co r u , o r l <r v i t h h a r l c l
tools. li-rt, Ceylon sartinrvoctd is u,ell behavedotr the lathc.
"Beeswing" is a great way to describe the (levlon sartintvoocl gltresartcltlrtisl-res ivell. llecar-rsc oi its
figur.e in this piece of Ceylon satinwood.The bcautifr,rlcolor, it's r-rsualh, givcn a Ir;,rturetl flrtish n'itholtt i.rttt'
shimmering "wings" combine with a deep
s t a i no r d v e .S a n d i n gt o 4 0 0 g r i t u ' i l l v i e l c la g l a s s - l i l i cs t t t ' f a c c
yellow color and a soft, silky smooth
appearance to create a truly stunning visual t h a t a l n r o s t d o e s n ' t n e e c -al f l r t i s h .A l t a t t r r a lo i l f l r l i s h r ' r ' i l l
effect. Z,
dceper-r thc,vellor,r'color to prctducetl wilrltt, atttbcr tclllc./W
Ceylon satinwood's unique look comes at a =
e

prelty stiff price. Figured Ceylon,satinwood m

r
like this runs about $25 a bd. ft. Y SOUTeS Seepagee2
e
O
F
o
r,.--
I N n o w o *;;;;, *;;.'*;'"* abor-rtit.

t____v
r
& i t e t o u s a t g r e a t w o o d @ r e a d e r s d i g e s-olll
t.c .

94 American Woodworker luLY2oo3

 E d i t ebdyT i m f o h n s o n
/

Hair-Raising
Finish
r. ]p f\
I had just built a -.-._: )
lazy Susan for
my in-laws. It was
made from walnut
tliat had lots of senti-
mental value,hav-
ingcomefrom \;
r.r)
a magnifi- .-:t*-
c ent t r ee --4;IiF{F
t hat onc e
stood on
their family
farm.I wanted
the wood to look
really special,so I
chose an oil finish, the kind you Unfortunately,the oil saton the surface made a perfectbed! My specialfinish
brush on generously and allow to so long it gottacky.Panicked,Igrabbed wasa tacky,furrymess.
soak in. Then you just haveto wipe the nearestrag-from the old laun- Fortunately,more oil, followed by
offthe excessoil before it dries. dry basketwhere I store them-and wiping with cleanrags,savedthe day.
|ust after I'd slatheredon the oil,I beganwiping furiously. Only then did My inJaws were thrilled with thelazy
got distracted by a lengthy phone call IrealizethatAbby, the family cat,had Susanand Abby has lived to achieve
(from a fund-raiser, of course!). discovered that the laundry basket a ripe old age.
DavePrasuhn

MasterPlanner z
My two boys, Steven and Daniel, and I enjoy doing table.Wealsohad a number of oak piecesthat appeared =
:<
E
woodworking projects together.We'recurrently making to go to the coffeetable that we were not making. -
o
(D

oak end tables and a walnut sofa table from a set of Tomorrow I'll to go to the lumberyard for more oak UJ
lrl

plans that I bought. The plans are for three tables- and walnut. Next time, we'll highlight the parts we need F
a
2
we'renot making the coffeetable that completesthe set. on the plans and check all the parts after rough machin- o
F

As project organizer,I decipheredthe instructions and ing, to make sure theyte correct, before we spend the F
a
assignedjobs.We laboredmany hours making legswith time on joinery!.
=
hand-cut mortises and tenons. Unfortunately, during Gary Arvan a

z
assemblywe noticed that we had two walnut legsfor one M a
o
.z
of the oak end tablesand two oak hgs for the walnut sofa -
-
z
E
t4

2
I
If you havea woodworking blunder you'rewilling to share,sendit to us.Youll receive$100 for eachone we print. Sendto: F

AV Oops!, American Voodwo"k"t, 29li Commers Drive, Suite 7OO, Eagan, MN 55121, br e-mail 'W'e to
lrj
E

oops@readersdigest.com. Submissionscant be returned and becomeoru properry upon accePtance and Payment. may 6
edil submissions,and usethem in all print and electronicmedia. E

American Woodworker JULY2oo3