Woodsmith - 031

NO. 31

NOTES FROM THE SHOP

$2.50

PROJECTS: • ADJUSTABLE DESK • ROLL-AROUND CADDY • TVVO-TRAY IN/OUT BOX

A BUYER'S GUIDE: WHICH ROUTER IS gEST?

Wcodsmith Number

Jan/Feb, 1984

31

Editor DonaJd 9. Peschke esslgn Director Ted Kralloek Assistant Editors Sieve Krohmet Michael P. Scott

AsslstaQI An D1reC1or Kay Mulder

r echnfcal Illustrators Oavid Kreyling

Mike Henry

SUbscription Manager Sandy J.

aeem

Subscription ASSistants Christel Miner

Vicky Robinson Jackie Stroud Shirley Fe11man Ann Williams

Compule, Oper'alloo1$ Ken Miner

Circulation Manager Jeff Far'l'ls

AdminIStrative Asslstant Cheryl SOOIf

Building Ma1ntenanOQ Archlo Krause (ISSN 0164-4114) Is published bfmonlhly (January, Maroh. May, July. Sep· tember, November) by Woodsmith Pubfishing WDDDSMITH

Col' 2200 Grand Ave" Des Moif\_9~.lowa503 t2. WOOOSMlT'H is- a registered trademark or tl"le Woodsmilh Publishing Co. ye.r (6Issue§) $10. Two yeals (12 iSSU.5) $18. Single copy price. 52:50 (Canadaand Foreign:~dd 52 per y.ar.) Change Of Address: Please tie sure 10Include both your old and new add(ess and a' maifil19

label from a racen1 issue. Second class postage pald at Des Moines.

Iowa.

Sawdust eluding this envelope is to provide an easy way to let- us snow of any problems you may have with your subscription. If you haven't received an issue, or ifi1!s torn or damaged. or if your name is misspelled on the label, or if you've changed your address .. , if there's auy problem ali all, please let U$ know, We want-to provide the best service we can. If there's a problem, just let us know and we'll fix it. NE\" F..\CES. Ann 'Villiams has just. joined the Jl(ood~mi1k group to help with all of the problems ljust mentioned. Uyou happen to call US, Ann's voice is probably the first one you'll bear. .PUULlsuelt'S S'rA·rE~lf;NT. Ever)' year in the J anuary/February issue of lVoodsmit,. we're required bl' the Post Office to 1>1:il1t. the Publisher's Statement shown below. Last year this statement showed ow' circulatlon at about 74:.000. This year ,vc've grown a bil- to over 151,000. Although numbers are nice, I always try to keep lit mind what, the)! really mean. When I'm working on a project 01' article for Wood.'IIIitlt, I like to think that I'm working' for 150,000 friends who enjoy woodworking. That's the only way .l cal' make any sense out of the numbers thau

Altom THIS Issue. Two of the projects in

(Jr

this issue were kinel exciting to build. Not because of the projects themselves, but beeause of the [oinery technique used to build them. The joint we used is a dovetail tongue and groove - but not your typical dovetail tongue and groove. The adjustable desk (shown on page 4) uses a slitlillg version of this joint .in the leg,.. What fascinates me about this applicaLion ts that the IOlts (and tit. joint) nave to be stu"ly enough to support the desk tOI>, yet the joint also h as to be flexible enough to slide up and down to change the height of the desk top. \Ve used-another version of the dovetail tongue and groove on the infout.. box (shown on Rage 12). This time a dovetail key took the place. of the dovetail tongue. AJ}(l 01100 again. it had to serve two pur",

poses. 'Phe ~e~''\'3S, in part, a decorative bandingstnp. but it also served as a corner joint to hold the t••ys together. It's not often ajointhas to be so versatile - but it was fun to "put it through its paces" for the projects in this issue. INllEX. You may notice that this Issue is a little thickel' than usual. That's because

we've include-d a special four-page index 'to all the articles. projects, and information shown in the first 30 issues of lVoQdsmitil. I hope it. makes tin(iitlg information in the

seem to grow so fast.

back issues

a more timely schedule for mailing out (he issues. The next issue (,\Voodsnlitlt No. 32) will be.in the mail during the week of AIII'il lOth. (Since it's mailed second el asss postage, please allow \;'\'0 weeks for delivery.) Again, thank you for your patience.

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N&XT lIAILING. Along

little. easier.

S~",,'EI_.()'pE. We've .also inserted an en-

velope in this issu e. Fe.1 fr."" to usc it to

renew you)" subscription,

order a gif't...sub.-

for a flielld, 01' order back issues. But the most important l'eaS011for in-

~C:liption

STATEMENT OF OIVNERSHIP, MANAGElMENT AND ClIlCUI.ATION (RtqlllM 1.1)' a9 0.$,(:. 31*.) 1,Tlt!.. ~f~btIt.lotlOrn! \\'~JI. 111. PubUcaUon N~: 01t$1-l114. !!. l>.1l e of tll1n~(.>dbbc, I, 19S1.(I, ..~ftq~QrUMI~O!.lllly. 311.XQ, Ilf11"i'lI(!1f:t.1lnl»1lf.f!tttt). ~b. ~,.ntW lUl.~(II.rl)Q ~~ $10,00.~. ComqI)(!tl! uWlilljt IlIfdmlorkDIJ"..., otrlCt' af IlUbllnttion!: '22OOtir.lld A\~~. tJre.\ )((,1""". (Potit CoOCI"'cy1.Ifl.......r"oo;I\t ~ CqmPll.·t.(!ngllllljt iId~(lfthil ~'od"r...rt.._'ftilf1;(Onenl bu:dM:.lo oITK"C'Wo1' lhl.!pI,l"l~r.:2200 CrtllIl j\'·('I'W.(k',\( ~1(lll1f11.JII'II:IL:-(l31!.•. C"",pk1;".lldl\·4$"rJlnbli~, I'di'l~, and naN:ci1ltC ed,l1>l'f'l Nbl;..b<+r: ~ B. -P~(" 22OO(;r.\nd A\~I\J", tIrcI ).I~~ (OwfI;$Q;Jlt. P.d;!tor:(:QI1If'ftIlpol,)ti;otMrJ,. ~Gl'aI1Il A\'cl)I;I(>.~ Mill., 10"" S(Olt: 'niOOd(lrt "I. KRIlmk. tll») ~rillII.IA\'t1I1It".Ot..)lofMII,10.....qroi!. it K0MI11btI~ho!d¢",- IlIl!rtWctfJ ~1 {WI' M(Uril)' ho1del'lCo"'11iA.~ 1 f*ft+.lIlur ll¥.o1'I:o(to,*I~1l1 {Irb<:
Postmaatt!t: Send ch~llQo of addl8:;:S notfce. POfm3519. to Woodsmlth PubliShing Co., 2200

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A Ils.l QI the eonlenl. 01 Sll bac~ issue. awe"", on the wrapper 01 lhis issue. h \h8 \-vtaRper is missing. you can send for a bookie! describIng the cont~l$ ~ndprices of all baCk issues. SAMPLE SDPIES

If YOU'have a mend who would like (0 see 8 copy OfWood.smlth, lust send Ih&nameand address. aJ1dwe'lI send a sample. (at nOleost).

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V(OOOSMITli

T_i~s& Technigu_e_s __

__ CUnlNG

RADIAL ARM DENTIL

Arter reading how to cut dentil (using the table saw) for the Curio Cabine~ in Woo,£' ,mill, No. 26, r decidecl to come up with a method that would also work on my radial

arm saw. Using my method, ehe first step is to attach a (ence to the saw that's slightly higher than the Ihickness of the dentil itself. Then make a shallow cut through the fence wtrh a "ado bladesel-oo cut a !to' ~erf. Finally, m'!Oka pointon the renee \4" to the

REVISED ROUTER TABLE

1 changed the material used for the top surface of your router table- it may be of SOmehelp to your readers. 1used "". cabinet grade 7-ply exterior plyweod that has t\VO extremely thin layers of plastic adhered on both races. This material is ccmrnenly known as MOO (Medium Density Ov~rlll.v). USing

this material sa ved me the Lime and trouble of bonding a separate piece of Masonite to the surface. And since the color of the surface is fairly light, penciled stop lines re~lIy stand out.

Bob Framci« ,11i1l"01•. To.ta. GLUING

As I

WaS

Stereo

Cabinet in l~/(Xxls))I,ilII.No, ]7. everything

was ~ing according to plan until I dry clamped tlie case together to spot any problems (before it's too late). len ofthe dado, and additional marks in %' increments for 4 OJ' 5 inches aloJlg the length of the rence. Afler adjusting the deplh of cut on a scrap piece, make ~he firsLcuLon the workpiece. Then line up the right shoulder of the dado with the first line, and make the seoond dado cut. Each successive cut is made by srmply lining up the .ight Shoulder of each dado with tile penciled marks on t~e fence as shown. Because "lining up" the cuts with the marks is an ey~-ball procedure, il

works beet if you line up as malty lines as possible for each cut.

Sf.elJe emmIT/ton

WI<.e«tRidge, Colorado DISC SANDERS FOR SHARPENING

TOOLS

I've been re~ding Ihe lI'ood811tith back

issues, anti came across your areicle on sharpening' in II'q()(lsmith No. 20. But [ was disappointed because tbe article didn't mention m~favorite method of sharpcuing: u.sing a vertical 8" disc sander freehand (with no tool rest). One thing that makes this method work so well is that you can sight down the race of the plate to assure that the bevel is in constant, contact- with the disc. All(1 I've been par~icularly pleased with the results achieved when llSiJlg this method for sharpening lathe tools.

Ed'IXl'ti llosen/eld Gu1'ley, Alaba,,,a

WOODSMITH

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DEEP CABINETS

building the Tambour

careful I am, the height is never quite righL J l,hink I've fill'llly come up with the answerto Illy problem. I designed a quick and easy jig Ihat uses a Sliding dovetail joint. To use fhe jig, the ftoating block is 1>05ilionedOn top of the blade (or bit) $0 it can ride up and down the base as the depth or cut is adjusted. The key to this system is to be sure that lhe'block is free floatulg, so it \\'ill adjllst to even the ,;Iigbtes 1ehange in the position of the blade. WAX OO\lETAlll0t~ fOR ROAllNG EfK SASE,.~."

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1 To make the jig slide easily, r used the Bosch \4" dovetail glue joint bit (see Source. on l'age24). This bit is .a little different than a normal dovetail bit - it produces squared off COI'l1Ol'S on the dovetail. This squared corner keeps the two halves from catching as they slide back and forth. And with the addition of a good coat of'wax, the sliding block ,,;11 truly "Iloat," To keep the sharp edges on the top edge

of the carbide ..tipped router bilS (rom cutAs in the past, r found that simply positioning clamps on the fron~and back edges of the cabinet sides won't pull the center of the cabinet sides tight against the shelf (0.' web frame). This seems to be • problem ever>' time I use plywood foal cabinet

construction.

ting into the sliding block, I glued a small piece of plastic laminate (Formica) to the bottom face of the block, To calibrate thejijf, I rabbeted the edge of the base and attached a brass scale Off an old wooden folding rule. I also positioned the rule I" above the bottom edge or the base to make It easier to read, Then mark a pointer on the sliding block so that it corresponds with the exact height settings 'on the brass scale.

The best method 1\,.found to .keep the center of the panel snug against the shelves is to use a clamping board that has a convex edge. By positioning the convex Kenneth Gyldclwa1la. face against the side of the cabinet (di· rectly IIcrOsSfrom the shell), and clamllillg Des ilfoi-~le8.Imoa. only the ends of the board, constant pres- 1----------------1 SEND IN YOUR IDEAS sure can be applied against the eentler of the cabinet side. I----------------i CI,,'u, Stu.rt.

J\1u11ieca, Cali/arniCA DOVETAIL GAUGE

I've a!\V;_1"Yshad a hard time tJ'lfing to use a ruler to set the height of a blade 011 Lbe table saw, or the height of a bit on the router

table, It. seems.that no matter

how

If you!d liRe to share a woodwori
Woodsmllh, Tips & Technique., 22tlO Grand Ave" Des Motncs, Iowa 50312 W~pay a minimum oJ S 10 for Ifps. and $15 or more fOf specfat techniques (thet ace accepted for'J)ubltcalion). I?lease give e complete exptaneIlcii1 01 yotJrkfea. If • sj
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A_djustable Desk A DESK FOR ALL SIZES

Mostofthe time whenwe setout to build a piece of furniture, we try to build it to a standard size. Tab1es- and desks, fot' exam})le, are supposed to be 29" high. But the problem with standard-size furniture is that people don't come in standard sizesespeeially kids. We wanted to build a desk that would

as the pCJ'S011 grew. The solution was to make the height of the desk adjustable. To do this, we decided to use a sliding hg1'O\V"

dovetail joint on the desk's leg assembly (shown in the detail photo, below I.ft.).

This way l,he whole desktop can be raised to suit the person using it. While we were at it, we also decided to make the desk top adjustable. That is, provide a way so the lop coul~ be lilted up for coloring (or draftlhg woodworkirig plans), but also so it could be laid nat for doing homework (or paying bills). To accoml>tish this requirement, the top or t.he desk is h,inged on a "rachet' frame that can be raised in merements (shown in the detail photo, below right). It became quite a design challenge to get these two adjusl.ablefeatures to work, and not interfere with each other. But once the design was worked out. the fun of building the desk could begin. r started with the desk top assembly. This consists of a web frame that supp<>rtsthe solid o""end caps, the tilting desk top, and the drawers. THE WEB FRAME The key to this whole desk top assembly is the center web Irame. All the other parts are attached 00 it. I built the web frame by cutting two long rails (A) and fOUl' stiles (8) 10size, see Fig. I. First, cut the rails to-a length of 48%" and the stiles to a length of 17%11. Then rip all six of these. pieces to a common width of 21/,1"'. JQINERY,

These six I)ieee.'; are joined

with stub tenons and'grooves, see Detail in Fig. J. To make these joints, cut. V.<-\\ide by 1f5"~deepgroove centered on the inside edge of each piece. Then CUt stuh tenons on

the ends of the foul' stiles to filtthe grooves. (For more information on this l)'pe ofjojnery, see lVoodsmiU, No. 29.) Next, Y.'cNMasonne panels are added to the outside two upenings in the web frame. (These outside I>Al)ei$ COVe.!' the areas above the drawers. The middle opening does not have a. )>anel because it has to 00 open to allow space for the "rachel" frame used to tilL the desk top up.) PJ\NEJ.s.

To ge.t the measurements for tl\e

L\VO

panel", dry-assemble ~he rrame so the two inside stiles ure lOr,' f"om the outside

4

stiles, sec Fig. 2. (This should leave an 18"

opening between the l \\'0 inside stiles.) Then cub V,," ~lasonite panels to fit the groove ..to-groove measurements in the frame.

After these panels are cut, glue and clamp th~ frame together (gluing the panels in the frame openings). END CAPS AND APRONS

'I'he basic desk 101' is formed by adding solid oakcaps to the ends of the web frame, ami 'I""US along the front and back edges, ref." to Fig. 4. €SO (:;\PS, Tlle two end caps (J) are cut

from 5/4 stock (lV,.·-thick) so theY"'e 2.1!(,' long and &~"wide, Then two Y-t""-\\';
To.rout the first groove

I

clamp on a fence to guide the router 10cut a groove I,," fi'om the top eage of the cap, sec Fig, 3. (Note: This groove is positioned to allow for the thickness of the web frame plus the thickness ofthedesk top, which is

added 10«>1'.)

Y.

Mark the start and Stop points for this groove I from the (ront and back edges of the cap. ('l'he disw.nee between these

WOODSMITH.

two marks should equal lb. width of the web frame. plus 14-.) Then plunge the router in a~ the start point and rout to the stop mark. The second groove 0\1 t.he end caps starts at the bottom edge of the cap and stops in the horizontal groove, HO\VeVel', to ensure the grooves en both caps arc in-exactly the sameposluon. I clamped the caps together (bottom edge to bottom edge) and routed

one groove across both pieces. Again, use a fence to Il:',ide the router, see Pig. 3. FRONT AND BACK APRONS

Af"tcz'the grooves

aJ.'C-

routed on the end

caps. Ihe front and back aprons (C and D) are cut to size, The width of'the-baek apron is \'1". and t·he width of the front, apron is I~-. 80th aprons are cui, to length to equal the length of the web frame. IIOUT' GltOOVt-;5. Te attach the aprons to

FIGUAFl

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the web frame. a v..~··\\·idegl'OQVC is routed on the inside face of each apron. Thi~ groove js positioned so the distance to the bottom edge of the groove is equal to t,he thickness of the web frame, see Fig. 5. (If

the groove is in this position, the top or the web frame will be flush with the top edge of the apron when these pieces are assembted.)

241(,Q)IENOS- CUT MOMS}" (111'••·, SJ()(!'I(

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ROUT TONGUES

-1!4· STOP

GltooVE

Aner the grooves are cut in the end caps

, .3~'."

and the aprons, rabbets arc cut. Ql1 all four ed~s of the web frame. These rabbets actually produce tongues to fit the grooves in the caps and aprons. sea Fig. 6. r used a route" (band-held) with a rabbeting bit and pilot to rout these rabbets. It's best 1.0 sneak up on the: depth of cut. of lhe rabbets. \'1ith each successively deeper pass, check the filofthe tongues in the grooves. They should lit snugly. ,I]'O:SGUES ON' APJtON. Next, set up the router table to rout rabbets on the encl. of the back apron (D). Again. th,e rabbets are cut to form tongues to fiL the ve''tical

grooves in the ends cap, see Fig. 6. A.fu!r the tongues are cut. they have to be.trimmed to fit the height-or the vertical groove. Simply trim oft the top section of the tongue above the groove, see Steps 2 and 3 in Fig. 6. 'l'ltl.\J .'RONT ~\rRON TO LENGTJ~.The front apron (C) docs not have tongues on the ends. Instead, it's trimmed to final length to match the shoulder-to-shoulder length of the web frame, refer to l"ig. '1. ASSEMBLY

lit tile grooves, round the four comers ofihe end ",.p~ to a o/!" radius, (I di
Then round over the outside edges of the end caps with a y,," rounding-over bit. ASSE'''IlLY. Finally, the e"d caps and aprons call be glued and clamped to the edge. or the web frame. WOODSMITH

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USf ROUTER ANO f~C.E TO CUT GROOVE

(OG£l5 JOGElNESt

WE8 FRAME

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II:OUND O""(R All Of ENOS WITH '/4" COJlNl:ft [lOU~O

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AUGH TOP OF WEB FRAME WtTH TOP OF APJlON

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THE TRESTLE LEG ASSEMBLY

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CUT OOVf1An KEY TO feT OOVETAlt GlOOVIi ON UPRIGH'

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clIfOIt/lWEIt tUNNElS TO fir SNUGO\Y flfTWffH fRONT AND BACK APRONS

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10) IACI( A'ItON ,

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The desk tOP i. mounted to a trestle leg assembly which can be adjusted in height by means of • ,Iiding dovetail, ~PRIGHT ,,~l) tUSE. To build the 1"1:>. I started with the uprights (Kland the hoses (Ll, see rig. 7. Cutthe uprights 10size and locale the po.ition for the dowel holes. (Later. pegs are inserted in the se holes as stops to hold the de.k at the height you want.) 0,,11 the V," dowel holes y,' deep, spaCing them 1loft'" apart, as shown in ~"'ig. 7. (It'S best to USC" Forstner bit to drill flat-bouomed holes.) JOII("ln·. To join the upright to the base. out a mortise in the base, see Detail in }'ig. 8. a]1(1then CULIImatching tenon 011 the end of the upright. OO"RTAt~ CROO'·E. Befol'" joining the UprighLand base together. a wide dovetail groove is rout(od on the inside face of the upright. tThi.I(I'oO'·' will hold the sliding' dovetail key.) I routed thi~ grocve on the router table, starting \\ith a 4'." I'.itraight bit to clear out most orthe waste .see rig. 9. Set thefence on the router IlIble to cut" I(I'oOvece ..I.rtd on the width of the uplight. The bottom (depth) of this ltl'Ooveshould be flush "ilh the face of the tenon. Move the fence lind milk. 1'.,;$•• on both sides of the center groove, until It.'s 2¥.0' wide, Then 6\vil.eh to n ~" dovetail bit to I'OUL l.he half·dovN:lil profile on the outside edges so the final width (from point to point) i.3'Y,o·. ROt,);Jlerx.es. Aftet· the dovetail groove is rout.ed. glue and claml' the upright and base together. Then CUta 0/,.' radius on all eerne rs, and round over the edges with • Y," rounding-ever bit. -ee ~'ig. 10. O()\'ETAIL !iF-V. Next. a large sliding dovetail key (F) is cut to fit the dovetail groove in the upri!!ht. Cut this key 1(,.wider than the "~(Ie~ldimension or the groove. Then rout the h31f-do"etail profile on both edges of the key. sneaking up on these cuts until tho k"y slides smoothly in the groove, see fill. 1I. The top end orthi. key is attached to the end ca ps on the desk tOil ass embly, To do this. cut" halr.lap to the depLh of the dovetail lit tho top MU,e key. AILet·it's cut. the shoulder of the half lap should rest firmly on the bottom edge of the elld cap. and the top end should butt .gains~ the bottem oft.he web frame, refer 00Figs. 12 and 13. DRAWER RUNNERS

c , f«ON' A"ItOH

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B.fON; attaching the leg assemblies to the desk top. the drawer runners (C) have to be eut. The-e runners serve t\\'O purposes: they support and guid~ the drawers, and the l\\IO outside runners also support the dovetail key. This was th~ biggest design problem we WOODSMITH

had with this-desk. Th.e large dovetail keys (that ride in the uprights) bad to sUllllOrl lhe entire desk top assembly. Since lhe weight of tbe desk top is not centered on the legs, there is bound to be an undue amount of racking pressure. To solve this problem, we built the drawer runners around the keys to support them and prevent racking.

'The drawer runners are cut lo/ir." wide 31Id long enough to fit OR.\,\\'Elt RUNNERS.

tight between the front and back apron,

see Fig. 12.Then %"..wide gJ'QO\'~Sate cut

y,.'

from the bottom edge of each runner. (These groove. will interlock with gl·OO\[es on the drawer sides.) After 811four runners are cut. the t.\\IO outside runners also have wide notches cut in them 10 male with the half lap on the dovetail key, see Fig. J3. (1 cut these notches on the table saw, making multiple passes to clean out the waste.) Then screw the outside two drawer runners to the 0n(1 caps. countersinking and screwing through the grooves, see Fig. 13. ,,$SEam).Y. To mount the dovetail key,
*'"

'i''lount. the dovetailkey itt the notch in the runners and mark the position of the two pilot boles in the end cal). Remove ohe key and drill %" holes, %" deep 'in the end cap for threaded inserts, (Threaded inserts are used here so the keys can be mounted and removed to complete the construction of the trelitre leg assembly.) To mount the two inside runners, drill countersink hole. through the top of Ihe web frame and into the runners. then screw the runners in place, see Fig. lil,

f -tS"

0:-

..

I

1~

HOLE fOR G

MORTIS£,;

t

....L

,7

~

.,0

(!)

1-.,-- -''''-~

FIGURE 1

W DEEP

,

,<>

HOLES FOR

OOVElAtllCty SHOULD $UOE AlEflY

fiGURE 17

TRESTLE ASSEMBLY

@

To complete the trestle leg assembly, • stretcher (E) is added between the two sliding dovetail keys. Measure the disranee between the keys to get the length of the stretcher. (Make sure the keys are

FIlOjoIT ~'~()N

®.

.

&ACXAPJl:ON PANEL

(j)

exactly perpendicular when this mea-

END CAP

surement is taken.) 1'hen add 1Y,' to this measurement to aJIO\\Ifor the t\VO %" ..long tenons on each end of the stretcher, JOINERY.Cut thestl .. tcher to length and

sra£teHEJI:

width, Then cut %"-deep slol! mortises in the keys, and cut matching tenons 011 the ends of the stJ.. tcher, See Fig. J6. Also, (hill a y,' hole in the dovetail key for the pog that's used to adjust the height of the desk. (To make this peg, I chucked a 14"dowel in the drill press and used a file to "carve" a knob on the end of the peg, see Detail in Fig. i6.) AliSE"UbY.F,nally, mount the stretcher between the dovetail keys to make su re it'. the .ightlength (so the legs don't splay in or cut). lJ this cheeks out, glue and clamp

$l@gSiHfR

DETAil

ROUND OVER TfNON TO m SlOT MOStTIS!

I/.~eORNESt flOUND

the stretcher intothe mortises in the keys. WOODS~.lJTH

7

"GUO. 1_'

-

,.._.,

13',11

.--

'.I ir---- -'.

10 OITEJlMIN( WlOTH 0'

DRAWl.,

~

0100'11$

•

Ill]

- .iT

wla FRAME

.

I, '.

~

;

'..::J FRONT APRON

,.I--t-f..,r.-'---:-:.::._----rT-,~--I

Olf' ,

MEA$UItl'OlirAHCf tOWIIN A.NO SUltlACl '.

'<'

Q}~Y{"~YNN' •• !!All

.UNNI.

tJ~. 1-

'0) O!tAWljII

t

.... Wlt" SIOf

L....

(,_.IL,~ ~.

',.

<,'

I

.,.

I,~

I',

• _~-I

""!-r~ ,

ALthiS point the d~$k is almo.t complete. All that's needed are the drawer" and the desk top. I started with the drawer •. ORA\vtk fRO_'iT.

To get the

mC3I'UI'C"

mems for the drawer front (H). measure

the distance between the t)utsidt lodgel'!of

1'.~ , .]\( 1~1o·

Ir~'Of"

THE DRAWE~S

,

•

•

•• ' MASOHITl DRAWl' aonOM RGlJItE 18

, the runn ers, see Fig. 17. Then cut the drawer front to mi. length. and to a width of3~·. D.... WER SID~ I u>'cd dovetail tongue and groove joints to assemble the drawer sides (P) and back (Ql. (A detailed d.....,ripbon ef this type ofjoinery;'; gh-en on page
on the inside face or the drawer fronts \0 attach

the drawer

sides. The dovetail $0 "'hen the drawer sides are attached. the distance between the olC,ttide faces of the drawer sides is Vtll" less than the distance bet ween the botto",~ of the grooves on the drawer runnel'S. see Fig. 17. After the dovetail grooves are eut on I he drawer front, cut the (iJ"a\\I4l1' sides to tIoite. Then cut y," grooves on the outside faces of the drawer sides to mate "lith the long-tieR

grooves are posltioned

,,'

i-..

....

_

'IQU" ,.

on the runners, see Fig. 17.

I ""'." I

BACK ANIl UOTIO~t.

DISTANCI!TO BOnOM OF GAOOVE (QUAlS

lH!C!I(NfSS OF 'ARTICLE 10.10

"'''~.

,

PlUS fORMK:A

..J -------....,.,,dl_,_ 'lY."

:.....::=:=::;;&;;:=~T fi '." O.OO\lf, '. 01('

10' "

After the side. are

cut,joiil the back between them \vith dovetail tongue and groove joints, unci CUl the

,

Masonite bottom to slse, see FiJi. J8. DRAWI-:tIIlANDL~, Before assembllng thc drawers, I made a notched "handle" on the drawer fronts, see fig. 19. Cut out the notch and smooth the edgeswith u ~(\nding drum on the drill )rCI:iS. rfhen cut n :YII" radius on the four corners of the drnwer front, and round overall theedge8 with a Yo'

rounding over bit. i'-"iSE~IULY. No\\·the drawers can be

;tg ..

sembled and mounted to the runners,

('Ur STUa 'IHON TO 'IT ClOOVt -

THE DESK TOP

After me drawers are installed. Ihe desk

top is built. The top consists or a particle board panel with formica laminated to it.

@fORMKA

8

and an oak frame around me edges. FRAME. I started by building Ihe" J o.1k frame. The rails (~1)and stiles eN) for Ihi. frame are ripped to a width of 2't.·. _ Fig. 21. as for me length of lhese pieees. metre wI to fil me desk top a..,,-~mbly. (This assembly consist>, of the web frame. end caps. and aprons, ref er to f'iSt. 17.) The top frame's rails (M) are cut to length so metre y.' It'" than the dlstanee between me end caps (J). Then the .til es (N) are cut to length so when Ihe f"ame" assembled me size from front to back is 1v,'/a'l'lqr man the web frame and aprons. see Fig. 21. f"O(l)IICA I)A.sEL. Before culling the joinLS to a•• emble this frame, I made the Formica panel insert. 1'0 do this. laminate a piece of Formica (I used dark henna. \VOOI)SM1T~1

#935) to a piece of%" particle board that's cut to a rough size of 21" x 45". -ApJ)ly a coat of contact cement, to both the Formica and the particle board. When the cement is dry to the touch. lay dowel rods over the particle board and put the Formica on top of the dowels, see r'ig. 22, Then slowly pull the dowels out, and press the F ormica in place. GROOVES. This laminated panel is used to locate the position of the V"'-wide by 'Yo"·deepgrooves on tbe inside edges of the foul' framemembers, The bottom edges of these grooves should align with the bottom of the J>ru~icleboard panel, see P'i\,:' 20. After the grooves are cut, cut *tub tenons on the ends of the stiles (N) to fit light in the grooves, see Fig. 2]. TONCUES. Dry-assemble the f"ame members to get the measurements for the panel, and cut the: panel to this final size. Next, "out rabbets on the edges of the Formica panel to create tongues that lit tight in the greoves, see F·ig. 22. (Sneak up on the depth of these ra bbets so the tongues fit snuglyin the grooves.) ,\55£"OL Y. Before final assembly of the frame, I routed a pencil groove on the·face of the back rail of the frame, see Fig. 23. Then glue and clamp the n.. me members to the edge. of the panel. Aft.1' the desk top frame is assembled, it's mounted to the web frame with IJh" hinges, see r'ig. 24.l'osltion the front.edge of the desk top sc it's Ilush with the fronts of'the drawers. refer tol'ig. 27. 'Phen i:out

fIGUru: 23

y,- ..

FtRST ROU) CENTER WItH -\'t" STIIAlGKT BIT

a",4'!!,'l!Jf:;:;;:;; fI' _~ ,y."

\

PENClt G~OOVIi

fLUSH

\

KNUCklE ClNfEII:(,D

{

ON (RONT (,OGt ~

I"

\

I.l

~-

r''''~\

I";" HINCt

MOUNtED ON lO"

SECOND ROUT EDGES WITH .,," C;:O~EBOX BIT

I.

~ ~

ROUSIE 2"

fi UNI:'E!-'U""''''''Il"o,!, ..~/J SHOUlDE·RS Of. GROOVE -GROOVE- $I'UNS END1'O END

fiGURE 25

"

r.} ,

I.ii:. L"

,<~,

.','

CUT MORTISf ro ~~'~"-._/

THICKNESS OFHU~GE /ON WE' FJlAME .--./'

.7

l --.., END C:AP

_r_

FIGU'E 26

Ih~OOWEl

I~

KEEP FRAME SQUARE

0

~~1 J,

nUSH M.OUNT KING~S....__ FIGURE 21

_.../

~

€£. _

I

I

._r-.V.' !'., ~

_HI,ES

nusa

MOUNTED
out mortises for the hinges in the web frame, (Th~

mortises should be as deep as the total thickness of tbe hinges so the top frame rests nat On the web frame.)

._.,,_

8ASE

RACHEl ASSEMBLY The last step is to make the rachet assembly that's used to tilt the desk-top up. Tll\S frame consists of t\VO notched arms (0) that fit OVerdowel pegs, see Fig. 26. Cut the arms Irom one piece.of5l4 stock. see Fig. 25. 0 r-;1114"holes along the edge, band SA\V out. the notches, and resaw this

piece to get the two arms, Then join the arms at the bottom with a V!'!" dowel rod, and a crosspiece (I) half-lapped at the top, see Fig_ 2G. Q'hen the rachet frame is hinged to the bottom side of the desk top and W' dowel pegs are mounted to the inside drawer runners, sec Fig. 27. FINAL STEPS To complete the desk, r added a "pencil catcher" to the f,'Ontcdge of the desk top so pencils or paper don't slid. orr when the desk top Is tilted up, see Fig_ 29. Also, I -added adjustable pads to the base Of the leg assemblies, see Fig. 28. The last step was to finish all lhe wood parts of the desk with Sutherland Welles Tung OilWOODSlvllTH

CENTER~G lEYElEfI;S I"IN ~OM 80lU &ND~....er

I

MATERIALS LIST OvOf'Q1IOimcnflon SOy,"w x 24¥,,"d)f 26"·34~h A Web From!!Rail. (2) 1.1/i. x 2'/. . 48'1.. 8 W~b FtCU""~Stiles (2) '¥I. x 2'1•• 170/.0 C D £ f G H

"Front Aprof'l (1) Bock Apron (1) StretMer (1) Dovetail Ke)' (2) Drower Runnel'$ (4) Drawer Fronts (2)

I J

Ralchel Ftome-Top (l) End Cops(2) Uprights (2) Base-{2} Top Frame Roils:(2) Top Frome.Stiles (2) Ratchet Frome Arms

K

l M

N 0 P Otawer Sides (4) Q Drawer 8oc".. (2) R Web Frome Ponels S Drawer Bottoml (2) T Top F"ornePanel U Fon'pica

1:J/i. x ,Ih • 48 '0/,,. x 4 • 480/. 1:J1i~x S~/ •• 4a~/,,. 1:V,,. It 3Y.i. 16'/a: x llt/ ••• 20ilY'. 10/1. x 31h • 1S 10/',. x 1'/•• 17"1. 1'/,. x $l/,• 240/.

CUnlNG

I I I

DIAGRAM

" J

•

1- B Ilm I • I. ."M 'I .' ~u~~ ~!"'!I'_I

~

L

D

'0/1,.

"/,. x 50/•• 17% lY,.x3Vi·19 I '/,. ~ 2'/ ... 47"1"/,. )t 2'/" • 20Y-i lV,.x Iy... 15 'h x 2'/•• 16 'Ill x 21/ •• 13V,t

Y.· Mcs\onilo r-;..~ Moionifo

'II" x $'1.1" • 48"

H"I,~

IB!d

x 20'.4 • 44't. 20'1" x 44~ V,

9

In/Out Box THE INS AND OUTS OF SLIDING DOVETAILS "'Th;-.-re-;-'s-an-o""ld;--"'tim-e""jo-:i;-n-tl"h-.-:t';-. not u~ed much anvmore: a I dovetail groove and·key. Thi, joint was used to hold several I boards togelher, edg'l·t ...edge , (as on a table top), But Ted Kralieek (our Design Director) ""'" dlseove re'"

same depth of eu; II. on the grooves, rout the half-dovetail profile on the edges of Ih. support arms by making shallow passes on both edgeo, see

!

Fig. 2. Sneak up on these c."Ut!" and the fit umil the .upport ann slides t'n\oolhl~' but not too loosely in the J1'OO\·e.

,e,;'

a new applicarien (or thi~

joint. The do"etail key ean be used to make a joint to hold 'he .ides of a box to.

("Qr,,"

PEG SI-I)"ORl'S. To complete

the support arms, round over the outside edges And ronan)" to keep the l.oJ>Ira>' in position (refer to Fig. 8), mount pel(>' centered 2)1.· from the lop of

gether, Maybe tha,',

no big deal,

but building this inloul box was kind of exciting because I got to useajoint that l 'dnever

the support arms, see Fig. 2.

even seen 00[01'0, We also used anorher variation on this jolnl (a .liding dovetail key) to hold the ."1" port arm on the sides tho upper and lower traytl. All in all, this i,\{out box

FRONT/BACK

Next. I worked on the front and back pieces, Thi. io where a dovetall key is used to make

or

turned out to be quilt> projeet ...

a CQ1'nCt'[oint.

ROU1' ouooves.

0'1 i1t\cr("\NtillJ{

at leust from a woodworking

standpoint. THE SIDES 1 started this project by .uUinl( Vt oak stock to size for the .ide piee.:., 'fh."" pieees are 0111to u final length of 13Y,' and to width 80 they're a lillie mere than double wide, see Fig, I. (It', much easier to cut the dovetall grooves on these picc.'C~ if they start OUI wider.) DOV£TJ\II. csooves. The duvetnit grooves that hold the support ann, in Ih. tray's ~ide pieces are routed first. t used the router table with a ".. ",mighl bil 10 clean out most of the waste ill lhiti groovc, Adjust.. the router table'to r(lnC\' t'O the straighl bil is crlllrrnl on the length ofth. sid~. Then roUt ;t 1,.'1"" (Icep dado ac~ the-

center W'oove by moving the fence toward

the bit abeut Vi' and make another pass, Then nip the workpiece end for end and rout an cClunlamount off the opposite. side of the center greovc. Keep moving the renee and routing until the groove is lo/l""

wide. Next. in!\t,ulln Y:/' dovetail bit {also set rout the edges of the groove to it~finnl width of2'1~",see Detail 2 in Fig. I, Then the double wide side pieces can be ripped in half - 10 a final width of 2'y....

f"r d<'Cpl.nd

SUPPORT ARMS

Next, the support arms are cut 6~" longand v,," wider than the widest part of the do\·("tail groove in the si(le pieces. see Flit, 2, Th.n, \\;,h the dovetail bit at tbe

'ro

milk.

this joint, the first step is to ,'<)utdovetail grooves Oil the face the n'<)nl and back

or

pieces. However, since cluvet.ail l.il$ eun not. be raised in increments

to rout n

groove.I started with a V••' straight blt to

a,

clean out most of the waste, see I"ig, For the flrst pass, set the Ience to cut u Y.!"..wide grOO\'C celli(','ea ~"" fl'0111 ~h(' edge, For this cut, the slmighl bit's depth should be slightly le... tban Ihe finiohed depth greeve 50 the final J)M~with the dovetail bit will create a reaUy clean eut. After the straigh; groove is routed on one edge. turn the piece end-for-end and rout a second straight WOO\''!on the 01)0pesite edge, Then convert the 1\\'0 $trailtht gtOO\'C"

or

into dovetall grooves. Leave the router

v,

table's fenee in the same Im-ition, and in.talI a dovetail bit set for. 'Y•• depth of AGUII2

O(tAJl 1

1',

.,.

entire \\'i(lth of the side piece, see Detail I in ~'ig, I. After the first pass, widen 'his

lour SH"OfD

I '.

S'

.t...

.......sa..,GHr

"" "

'. - -

-_

~.

,t, ~

1\ ISTPASS 2ND PASS

f[Ne[

r,-,---.,---.-J

l alP TO FINAl WIOTHAfftR AOUl1NGG~OOVE

'.'

aourta

TAllE:

~..,.ooVltA.l "r

10

WOODSMITI1

cut, and rout, the dovetail prom" on both grooves. DO\'ETAJl. $(.OJ(f:TS. \Vith this same setup on the router table, "OUtthe sockets

RGUR'E 3 6L._OCKGUlDf sloe PIECE

in the cllcf!$ of the side pieces, see Fig. d. rro _SUI>p0n.the side pieces and prevent chip out while they're on end, use a scrap 2x4

/

fENCE:

block behind the workpiece,

/

DOVETAil KEYS

(

Now the dovetail keys are cut't<) fit the groovesln the f,'onVback pieces, The keys

are ,nla
thicker than necessary, Then later.

CUT kEYS f-ROM

tONTfj:ASnNG

,

.,,<1 .,~ ..") srocs ,-_,

OOVfTAll k,EY STOCI(

FfNce ,

F1GURE S

;rresve

SUVER

f.OR S'AND1NG

I

ROUTEA' fABLE

RIP "E'( OfF SOARD

UNCE

the

whole assembly can be sanded flush. After the first fOIl,1' keys are cu~ off the two strips. ''eIJe.t this whole process to get four more keys. Then 'appl)' glue to the grooves and tap the keys in place. (Tap qUickly here because the keys absorb moisture from the glue and swell.) Tap the keys in place until ')I.- extends on bott. ends, see Fig, 6. (Be sure to clean off any excess glue from the ends of the keys.) CUTOI'ENlN(;S. Before r assembled the

'II" OOVE:TAI_l BIT

.lAO.

SAW TAa",

fiGURE 6

trays, 1 cut openings in the fl'ont pieces. Dri]] t\VO II' holes 4" on center and %" up from the bottom edge. see Detail in Fig. 6, OJ\ a band saw, and smooth "I) the opening with. small sanding drum on the
Then cut out the waste

ASSEMBLE TRAYS

After the openings in the front 'Pieces are smoothed out, glue the t\VO sides and the front/back pieces together, Then trim the excess off on the ends of the keys so the corners can be rounded over later. R~WO.xrFOR aOT1'O~t.Next, rout 3' rabbet on the bottom of each tray for the plywood bottom, see Fig. 7, (I did this 0.\ the router table with" rabbeting bit and pilot.) Then cut the plywood bottom to fit the rounded corners of the rabbet. Before gluing the bottom in place, finish sand the top side of the plywood. (It's easier to sand before it's installed.) llOUN,D O\'ER

CO;RNEI~S. Finally.

RGutE 7

fiGURE 8

I

rounded over the four' outside corners on each ll"ay with a ~ rounding over bit on the router table. Then I switched to a 11.rounding-over bit to round over all the edges of each tray. FINISH,To finish the trays, I sanded all surfaces smooth. and then applied Sutherland Welles Tung Oil (lIledium Luster). WOODSMITH

rA,lM ENO$ Of OOVfTAJlKEYS AFlf'R ASSEMBLY

r.!lJo,-

USE ~ .. ROUNOJNG OVER 81f ON

AU fOOlS

\ ¥•. RADIUS ON All OutSIDE CORNERS

I1

Two.-Drawer Caddy__ THE BEST PARTNER A DESK CAN HAVE As ...ve were "'orking on the design of the adjustable desk (shown on page 4), we knew there would be a problem with storage. Rather than try to build a lot of extra storage drawers into the desk, we thought the best solulion would be to build • "1>orate, roll-around storage
To build this ca ddy. I .wrt",1 with the solid-wood sid.. (A). Both sides lII\! made o( ;;'4 (1Yo. thick) oak. To make the sides, np .i!!ht pieces of steek i) x IT' and edge-glue the pieces to form two sides with rouR'h (limension~ of 20- wide by IT long. Ane r lhe side. are glued up, plane them 0.1. (Note: The "inside" (a.. o( the sides should be M Oal :J8 possible so the drawer .. operate 611l00thly.) Then trim the sides to their On,,1.iw of 1S" x 16". (1'0 avoid expansion/cont"action problems, the grain on the sides milo, run the 16" direction, which means it will be horiZ(lntal when the caddy I. assembled,

sec photo.) HOU" GROOVE. After both side. sre trimmed to size, three V......wtde gr'oovcs are routed on the inside (acc to attach Ihe top, bottom and back, f'in!t, I marked each piece to indicate which edge would be (or the lop, bottom and back, Then I marked the start and stop points o(the grooves 00 I could eas lly see where to begin and end the routing pMS. To guide the router. clamp a fence to the side piece. I started with the groove for the lop, then moved the (ence to rout the groove [or the bottom, and finAlly, rout",1 the groove for the back so it start. and stops in lh~ first t\\'"O grooves. see Fig. I. Each time a groove i~ routed. make sure the dire
a compass to mark a ¥~.radiul' at each eomer, and carefully round the eomerll off. Then round over aUthe edges (on bolh the inside and outside (aces) using a Yo- rounding over bit. THE END CAPS At this point, the sides are complete, Tho next step is to build the caddy'. top alld bottom (C). Both or these piee•• lire mad. out, o( W particle board wilh 614 (I

y,,'

12

thick) oak capa (B) 011 the front and back edges. The top also has a piece of F ormien laminated to it. CIlT PARTlel.': BOARD, Start by cutting two pleces of particle board to a rough size of II x 12".Then laminate a piece ofFormiea to the piece (01' the top. (I used Formiea brand Iaminate. The eolor is Dark Henna '935, matte finish.) ESOC.'PS. Next. the end caps are cut and added to the front and back edges. Rip four

caps 2Yc" wlde

16"IOI1g. Once agnin, so [ eould keep things straight in late,' steps, I marked each end cap's po!!ilion (toplfrollt and back, bottom/front and back). GROOI'£S ix CArs. The end cap$ are joined to the particle board with tongue and groove joints. To keep this joint O""h. the location of the groove. in the end cops is critical (especially on Ihe top). The cops on the top have to fit so they're perf""Uy Hush with Ihe sunace o( the For· CUnlNG

MATERIALS LIST

DIAGRAM

20"

Ow.roll Oimen"CH"I~ 17V."., x 16"" x A Side (2) ,1/'6 x 1. - 16

• End CoP' ,.) C D E F G H I J K

Top' 8ottom (2) O.rowo.. tunners (6) 19. Dtow., Front el} Sm.Dto~,Front(l) 19. Dmw., Sid" (2) Lt. Drawer Boc.k(I' Sm. Orow" Sid" (2) Sm. DtOwor Bock {I' Dl'Ow.r Bottoms (2)

L Coddyloclc(l' M Formi(O Top (1)

l' ,.~ .. S·..,". 72'

11/•• x 2Y.. x 15'h

-n x

I •

1,·/. _15'.r.

V. x If... 13"1. ·~'I •• 12'/. - 15 'lY,.x3V,.IS I/) • 9 • 131Y'. 'h lt 9· 13Y.. 'At • 3 • 13% v,. 3· 13Yt 'I." ply. (wi to Fit)

1;'''.15'''.161,4 lilA x 15'/.

• ! •

I

• •

• I • I

1''',."' '" 5' ..,," • 4,"

e

'-. • 5'h- • CI' I

tit" II 111'/." • 48'

•

•

K

WOOOSMITH

Index of Contents Thib index cove... all of the articles tinclllding projec" and techniques) contained in the fin-t 30 il":--ut.:-. or l,°ood$)),itp. The numbe.. (ollowlOgeaeh listin!(l"<)ierto the issue and I"'g~~ where you can find informarion 011 tbe Ii"ted subject.. Fer example, 20:4·7refers to infol'mation in I\'oodsmitll issue No. 20 on l)tlg~s·1through 7_

I"

Angle Cutting odel20:211 DrlJlinl(,1:10 Antique Willi mllTOr26:18-19 Band saw Blade 10::1 Cutllnj( duplicates 2ll:3 BlIlTistcr'. bookca....,29:16-21,2-1 Bead ouuing jig 16:3 Bed·.ide stand Usc·I-7 Belt buckle 10:6 Belt sander 1;':7: 10:10 Bench Garden :1:8·9:27:12·13 Trestle 2:1:24 Bevel/rip 3:3; 7:5: 25:8-9 Bind.. ·, WOOCINI I"""cle.f 7:4 Bil.!!,morti.ing 2(;:20·21 Blanket ChCKt16:12·15 Blind dOl'ctnil 12:7 Bookcase 7:6·7:29:16-21,2<1 Bookrack 7:12 Boring jig. hori1.ol1taJ12:13 SO\\' saw 6:5 Bowl fruit 21:18-21 Popeorn ~:2-I Box Ch;_'el2.1:20-22 Display 9:11 End f[Tllin15:18 Jewetrv 9:;;: 2-1:20-2'2 Ml1$ic6:6-7:28:·1-7,2-1 Recipe 10:8 Routed 13:12·13:28:10-11 Shop storage 1;;:1·1-15 Slide-top (flngel'-joinledJ 17:14-15 Ti~suc 2:5; 19:24 ~r()y 29:~J·tI.24 Box col1.11'UcliQn 3:0; ,1:1-5:26:4-6 BoxjoinI2:,1·5: 17:12·13 Drawer. 17:16·19 .Jig 2:4 Branding Iron. 10::1 Bread beard 20:2-1 Bread box, roll-top 4:6-8 Buckle. belt 10:6 Buffet tablc,ll8ll~I"K 2O;U·17 Bullel catch 19:12,17 Butler', lray table 1·1:10-11.16:16:3 Cabinet Banister'. bookcase 29:16-21,24 Bed-side 'land 18:·1·7 Caned-panel cabinet and hutcl122:18-22

I~

WOODS~lITII

Cabinet, roPiI. Chair-side 2.1:11-17 Colonial dry .ink 18:12-15 Colonialwall hutch 18:16-19 ContcmpI.y!):Il: 26:4-6 Europenn cabinet lind hutch 22:18·22 ~'I'l"ne and panel 8:S-11 Modular 8tOI"1(0H)'Hlem22:12·15 Raised-panel door 8:7 Shop gtol'l'gc 25:,1·7 SpocI26:,j·6 Tambour stereo 17:6-9 'Tambour 'TV 25:11·19 Tambour wall 17:11).11 Cabinet sera""r J 1:12·13:15:7 Camp 61.001 3:7 Candle .tand t.bl~ 11:6-7 Caned-panel cabinet and hutcl122:I8-22 Canister, turned 14:1·1-15;25:8-12: 27:3: 30:23 Car, loy 1'lIC(' 6:12 Carbide-tipped Router bit 21:S-!!:2.~:23 Table saw blade. 27:11;'21,2'1;28:19,23 Carpenter's lI'ianglp 1:1;:15:6 CllrI, mierowav~J8ervinj(23:8-11

Clock. rout. OttajtOnaI12:8-9 Round 3:10-11 SChoolhouse 21:·1-7::1O:2.~ Clubs, woodworking 27:2·1:28:2-1;29:24: 30:2-1 Coffee table 19:14-17;25:20·2'Z Coin sorter Columns 16:9 '111'.Y10:6 Colonial Dry sink 18:12·15 Wall hutch 18:16-19 Compass 7:3: 26::1 Cookbookirecip"shelf 8:·1·5 Cootingrack 1:2 Corner I Joint, plywood 22::1 ' Template 29:~ ; Cove outting 12:16:2It23 Curio cabinet 21;12-1S:26:12·17 Cul-off jig. rudi;tl :tnn gO'" 22:8 Cutting board 1:1 Dado b4,de, "tlju.'table 17:20:23:23 Danish oil finish•• 1IO:12·15 Deck Chair 3:6-7 Squares 3:10 Ohair Dentil 2G:J2-IIJ.22:29:a ConlemllOl'(lI'Y 2:6-8, 16:8-11 Denis 15:3 Dcck 3,6·7 Desk Oak, dinilll( 15:8-11 Lap 9:6 Patio 27:8-11 Shaker-style wriling 12:.1-7 Scat 25:23 Diamondstone. 2·1:7 Chair·side cabinet 2.1:14·17 Dining table Chest Circular with leaf :10:11;"21,24 Blanket 16:12·15 Contemporary oak 15:·1·5 Six-drawer (boxjoint drawers) 17:Ui--19 Drop-leaf 11:8-10 Sweater 9:8-9 Picnic 27:4·7 Toy 29:·1·9.2-1 Trestle 1::1-.;:23:12·15 Cheval mirror 30:4-8,2.1 Di.play case 9:11;26:1-6 Cbi>.eiJ;19:5:20:8-11:25:3 Door Chisel ease 24:20-2'.1 Caned'panel23:I!t-2'Z Chri$tmas OTlI"IO,'nIS 6:10-12 Glass 13:1l·9; 22: lM-22; 24:9; 25:19: Circles. routing 20:13:21:I(J.II; l)O:9 26:15·17:29:19·20 eil-culn' Hinges 13:8-9:25:19 CIoek 30:10-11 ~funtins 1:1:1l-1) [nlay I'outinl( 26:22 R.i~C(I.pllnoI2:1O.11:18:4·19:24:1"·17 Mi""or frome 12:10·11 Techniques 1:1:8·9:29:2(J·21 Tabl. tOI'19:3; :10:12·15 DOvetail Clamping Blind J2:7 Stops 9:12 Drawers 19:1G~18 Table top 15:7 Fixtures 2'l:6-10: 2:1::1:27::1 Clamps GnJO"~ 11:6-7 Hand 15:7;211::1 Half-blind 22:·1-9 Hold-down 1:6 Hand-cut I;&p22:·1·5:23::1 Pipe 15:3,7;2l!:3 l.amp 2:!:Z,1 Table lop 17::1 llachioc-<:ul 1,,1' 22:6-9 \Vedge ';:3 Plywood 22:8-9 Clock Rabbeted 21::1 Circular' 30:10·11 Routed 22:1;'9 Desk 10:4 Saw. 19:5 Manlel24:8·11; :10:2.3 Through 12:7;(i.,uo I!J)

'CI~""

Dovetail,

t;Q'll.

Frame, cout, Rabbet routing 26:22 Round clock :)0:10-11 W(.b constructlon s.s.n: 14:10-11: 22:I~-22; 2-1:101-17:25:14-17: '~-I'17'. .07. ..u..... ·"'··I-?I _ Frame and p:Jnel eonsrruction 8:6,8-11: 16: 12·1;;; 18:·1-19; 24:14.17.20-22:

Tongue and grC>O"e 9:7; 20:20-22.2·$ Dowels ChamfeMng 10:~ Cu~ting 16:3 Groov"" 16:~ llaking 19:3 Sanding 9:12 Use 24:23; 29:16-21; :~:2 Callery clock :)0:11).11 Orower Con.lnlttion ·1:5: 6:3; 15:11-15; 17:11-9_ Gatl,leg bulTet table 20:1·1·17 16-19: 18:7.19-22: 19: 15-19: 20: I~: C;!a_<.< Cutting 13:16: 17:20 21:15: 22:11-15.21-22: 2.:1-7: Door 13:8-9: 22:18-22: ~:9: 25:19: 29:5-9.14-15.2-1 6:15-17; 29:19-20 Plywood 22:H-I'; ~Iountinj! 11:3 Routed Cront 21:3 Sanding 13:3 Drill bits, morti>inlt 26:20-21 Gluinl( 7:3; 9:3: 10:;l,9; 15:7: 11:4"';: 18:3: Drill guide. ('orlaligll 12::1.1:1 19:2:1:20:23: 21:9; 23:22; 24~.l3:26:1l: Orin prc:-..... 27:23: 28:9.:M c<>net chuck 12~1: 26:28 End grain 2,1:2:1 Cuidu 1:6 Frame 26:11: :)0:9 Hole boring jig 22:3 Inlay 28:9 Morti>e. 18:23 Jig 25:18 Morti$ing bits 26:20-21 Mil;'n; 21:9; 30:9 f're$lt"Ulle table elevator 16:20 Tnrnbou rs 17:4-5 Route.' chuck 12:3 Goblot s, turned 23:4-7: 24:23 Table "uPPOl~ 19:3 Grinde.' 1001 res~20:1; 24:3 Drilling G.inding wheels 20:4-6,12: 23:23 Guide 1:6

Jig 25::1 Horizontal bo.ing 12:13 SIIOI"/IIilir Mnrk V 2!i::l ,.eml)latc 22:12-13 Drop-leaf Hinge 11:10; 14:8 .Joint 11:10: 14:7·8 Pembroke table 14:4-8 Table 11:8-10 Ellip'll!6:8: 1·1:3:16:3: 19:3: 2-1:a End board. 9:7

End grain Box 1.:13 Gluing 24:2:1

Sealing 9::1 f-il. cabinet 7:8-9 Filler Nail hole 1.::) Sawdust glue 17:3 Finger joint 17:14-1'; Fini.'\he~

N"on-loxic 19:23: 25:~:28:2J

Oil ;)0:12-15.24 Outdoor 27:14·15 Turning 20:23

Finishing techniques 11:9: 28.1: :10: 12-15

Fixtures l)o\·etail22:6·10: 23:3: 27.1 Nailing 15,1

Frome Ci~ular 12:11).11::10:11).11

Callery clock 30: 10-1I Gluing 26:11: 30:9 Molded edge U:R-17.20-22: 29:2()-21: :)0:4-8 Mortise and tenoll'$:7·11 Octagonal clock 12:8-9; 21:-1-7 Octagonal. jig 21:17

Ov.1 b:9

Holf-blind dovetail 22:4·9 Halr.lttl> 1:4,7.8: 2:11: 15:8-11; 16:6-7; 22:18-22; 27:4-13.22; 29:23 111111mil'"'' 21:) 6 Hand-cut, dove(jlils 22:4-1); 23:3 llnnd RCI'C\\!:; If>:7; 2S:S Hexagon 16:8-9: 18:8 Hinges Butler's tray table 14:16: 16:3: 20:23 Dado 18:8 1)001' 13:8-9 Drop-leaf 11:10; [.1:8 CIMS door 2,;:19 Knife 1:1:11-9 Wooden (issue 14'9) Hold-down jig 28:3 Holding' jig. vise 29:3 Hole bOling jig 22:3 Horizontal horin, jig 12:13 HUl
Joinery Blind dovetail 12:7 Box 2:4·5: 17:12-13.16-19 Corner. plywood 22:3 Dovetail 19:6-11; 22:4·9: 2:1:3 Dovet ail tongue and groove 9:7; 20:20-22,24 Drop-leaf 11:10: 14:7-8 Finger 17:1-1-15 Frame and panel 8:6.8-11: 16:12-15: 18:4-19: U:U-17.20-22: 29:4-22 HaIr-blind dovetail 22:4-9 Half.lap 1:4.7: 15:8-11: 16:6-7: 22:18-~; 27:4·13.22: 29:23 Hand-cut dovetail 22:4"';: 23:3 Haunehed mortise and tenon 14:11).11: 18:4-19 Keyed mortise and tenon 1:4 Lap dovetail 22:4-9 Locked miter 9:10 Locked inngue and dado 13:7 Machinc-cut dovetail 22:6-9 )liter and spline 1:11; 21:8-9,12-16: 22:20-22: 30:2.4-11.16-22 Mitered half-hlp 2:11 Mitered mortise and tenon 16:16-17 Molded rnortlse and tenon 24:12-13.24 Mortise and tenon 1:<1; !!-:3-5: 12:4-7.12; 13:10-11; 11:5.10-11: 15:8-12: 16:4-7.12-17; 17:16-18; 18:4·19.2'1: 20:14-17; 21:12-10: 22:18-22; 24:9.12-13.18-22.24; 25:22; 26:7-11 Open mortise and tenon 24:18-22 Parallel spline 9:9 Plywood dovetails 22:8-S Rabbet and groove (also called ,·.bbeV dado 01- rabbeted tongue/d"do) 6:8; 10:9: 13:'1-7: 18:12-15,19·21: 21:4-7.16; 22:12-15: 26:<1-6

Routed dovetail 22:6-9 Rule 1l:10: 101:7-8 Sliding dovetail longue and groove 20:20-21 Stave eonsrruction 20:8-9: 27:3: 30:23 Stopped dodo 2:6.11 Stub tenon and greeve 29:22 Through dovetail 12:7: 19:6-11 Tongue and groove 1:5: 13:-1-7;18:12-19: 24:1-1-17 Jigs. COlli. Miter 12:15: 24;12·13

Molding 26:22 Mortise cutting 16:IS: 18:23 Octagonal frame ~1: 17 Panel cut~1T2O:13; 27::1:21<:3 Panel eutting 18:23: 22: II

Pin-routing 28:20-22 Radial arm saw cut-olT 22:3 Radial ann saw router 20-.3 Raised panel 20:3 Rcsawing6:9 Ripping 20:13

Router-cut mortise 26:3 Routing round blanks 21>:3 Shelf support 18:3

Taper 1:6: 5:4: 11:3 Tenon 16:18; 24:18-19: 28:3 Vise holding 29:3

WOODSMITH

Joiner)". ('0111. Twin tenon 12:12 \Vedged mortise and tenon 15:8--12 Knife

Hinge. 1:1:8-9 Holder 10:7 Lamp Dovetail 22:2-1 Hangin)l2:9 Lap De.k 9:6 Dovetail 22:'I-!I Lazy Su~"" 21:10-11

Open 21:18-2"2 1\\;" tenon 12:12

Leg'S 'I'apored 11:11; 1,1:4-8; il8:12-13 TUJ'ue<1 12:6

Letter opener 10:7 Light bracket. swivel 9:4 Linseed oil finish 30:12-15 Locked miter 9:10 Locked tongue and dado 13:7 ~18chin~-cutdovetail 22:&.9 )Iantel clock 24:8-11; 30:23 ltarking gauge 19:12-13; 21:3 Marquetry. inlay 20:17: 26:6.22; 28:8-15.24 lIemo board 18:24 llierowa\'.,,,,,,,·ing cart 23:8-11 ltirror Antique wall 26:18-19 Cheval :lO:·I-8,24 Circular- Irnme 12:1()..U Hal! 21:16 \'anitl' lO:5i ~1:24 Mite,' Cutting 21:8-9,17; 28:S; 25:23; 30:9 Gauge, table MaW 2J;:8, 27:22; 29;23 Gluing 21:9; 30:9 Jig 12:15; 2-1:12-1:1 Locked 9:10 Mathematic< 12:14-15 lUter and .pline join.ry 7:11; 21:4·9.12-16: 22:20-22; 30:2.·1-11.16-22 lUt.red half-lap 2:11 lIitered mortL,. and tenon 16:16-17 lloduJar .torage system 22:12-15 Molded edlte frame 2-1:8-17.20-22;29:19-20: 30:4·8 )Iolded meruse and tenon 24:12-13 Moldings 24:10·13; 26:12·19.22; 28:4·7; 29;3,17·20 Mortise

Anglt~115;8-1l Bits 26:20·21 Cutting Jig 16:18: 18:23 Double dado 16;7 Dril! press 18;28 Roulel'clIl, jilt 26:S; 30:22 Slo( 8:,1; 10:3; 13:IQ-)I: 14:5,10·11; 16:4·5: 26:8-9 Through 15:8-11 'r\\;n 14:5; 18:·1.7,12.15; 20:14·17 Slortise and tenon 1:4: B:a·;;: 12:4·7.12: 13:11).11: 11:5; 15:8-12; 16:-l-'i.12-18: 17:16-18; 18:4-19.24; 20:14-17; 21:12· 1.-' 2.'18·.'" ""9 19.13 18·9? 9" 2J;:22: 26:7·11 ~lort_l!!ieand tenon Fnun,' 2G:7-11 •

....

\VOODSMll'U

__

I

_ ...•

Mortise and tenon. fOnt Haunehed J.I:IO·II; 18:·1-19 KevL'<11:·1 ~Iojded 24:12-13.2-1

'"

1

--.~.

\\'ed"ed 15:8-12 Muntin. 13:8-~ Music box 6:6-7; 28:·1-7.2-1 Nailing fixture 15:3 Nestled table. 28:12-1. Nole board 18:201 Oetallon 12:8-11;16:10; 21:4-7 ~'r.me jil( 21:17 Oil Jinil!hes :)0:12·15,211 Ornaments. Ch,·i.tmus 6:11)·12 Outdoor Furniture (i•• ue *3); 27;,1-13 '-inisheN 27:1,1·15 Panel cut-on' jig 25:13; 27:3; 28:3 Panel cutling 8:12: 11:3; 18:23; 2'1:11 Parallel spline 9:9 Patio chair 27:li-1I Pembroke table 14:·1-8 Pencil and card holder 2:12 Picnic table 27:·1-7 Pictur. frame router bit 9:3: 10:3 Picture and Ill..... mounting II:S Pin routing 28:10·11.16-18,20·22 Pipe clamp» 1&.~.7:28:S Plane Adjuslments 2:1:2()·22:25:28 Bench 23:16-22 ,'lnUeninA' 28:22: 25:3: 29:23 Jack 11;:7 Sharpening 211:18·19 Planer, \VIIgIIC" S.fe·T· 10:10; 15:7 Planing. table lop 2:1:21 Planter

Cedar plllars 3:-1 Rangin)l3:12 Redwood tub 3:3 Tapered -side. W: 10-11

Plunge routers 28:23 P*'wood Buying tips :lO:t) Comer joint 22::1 Dovetails 22:ti-9 Drawer construetiou 22:14...15 Splintering 22:11 Popcorn bowl. turned 25:24

Poria/i9"

D,;I! guide 12:a,l$ Shaper bit 12:10·11 P''68$lI1ate drill press tnble clevntor 16:20 Rabbet und groove joint (also called rabbet/dado or rnbbetcd tongue/dado) 6:8; 10:9; 13:'1-7; 18:11).21; 21:·1·7.15; 22:12·15: 2(;:4·6 Rabbeted Dovotail.21::1 Drawer (ront 22:9 Frame. routed 26:22: 36:9 Radial ann Cut..,fl' jig 22::1 Router jig 20:3

~a'"

Tabl.20:3

Technique" 15:1G; 16:16-18; 17:3;

arm t""hniqu", 18:11.23 I Radial Raised·p"n.12:1~11; 8:7; 18:·1.19.2:1:20:3; 23:23; :J.I:I·'·17 "3W

<0111.

Rasp 26:23 Recipe box 10:~ Resewing 6:9: 28:4-7 Rip/bevel 16:8 Ripping jig 25:1:1 RoIl·lop brt'lld box ·1:6-8 Resan inserts 22;11.11·15; 24:3: 27:24: 28:24: 30:3 Routed Box 13:12-13; 28:10-11 Dovetails 22:6-~1 Drawer front 2J :!i Snack tray 28:11;·18 Router Bit. catbide tipped 21:~·9; 23:23 Bit. mortising 26:20-21 Bit. picture from,' 9::1: 10:3 Bit, raised panel Z:l:2:~ Case ~:3 Chuck with drill p",', 12:.1 Debris 24:21 Dovetail flxturvs 2'1:6-9: 2:1:3 Guide. multi-purpose 17:20 Jig. centered j..ITOOV(.'N :~:22 Jig, dentil molding 29::1 Jig, mortise cutting 26:3 Jig, radial :\I'DI saw 20:3 Jig, round blanks 25::1 Pin 28:10·11.16-18.20·22 Plunge :lS::!:! Technique. 10:11-12; 13:3; 20:13; 21:S. 8-11; 26:la; 26:22: 28,10-11,16-18.

20·22; :lO:4-11.1G·22

Trammel attachment 80:4-8.10-1 ~.16·21 Reuter tabl. Cunstruction 2O:18-HJ:22:16-17 I nserts 3O~1 Pin·routing attachmenl 28:20-22 Planing on 18:3 Sabre ,,"W setup 30:3 Stand 22:16-17 Table N\'''' l'xwnl'llon 2-':3 Rule joint 11:10; 11;7·8 Safety 15:3 SaIe-T·Planer. Waf/tier 10:10; 15:7 Sander

Belt 15:7 ROCKwell S""cclIJIO<' orhil
Scrap weed projects :1:12: (;$'u. #10): 14:1'I-l~ Scraper. cabinet 14:12·13: 15:7 Screws

Brase 18::1 Sheet reek 18:~: 19:23 Serv ing Cart 23:S-1! 'i'ra,)' 19:19 Shaker-style

Pelt rack 2:3 Step :'!Ulnti 19~)..22 Table. (l",,"e .. I!) Writing de$k 12:4-7 Shaper-

Bit 12:3.10-11 Guide.- 19:23 Sharpening Aids 20:7 Carbide-tipped table saw bladt. :!II:!!I Cbi.el. 20:8:11: 26:23 Diamond .wne. 24:7 Japanese water stones ~:·1-6;26:i!3 Plane irons 23:18-19 Scraper blade I·I:I:! Stones 20:4-7.1:l-1~: 21;2:1 Table sow blad cs 28:19 Shelf Aligning brackets 1I:3 wsn 20:20·21 Shooting board 13:3 Shop storage Box 16: 14·15

Cabinet 25:·1·7 Cart )3:)<1-15 Side table 11:4·5 Sliding do"etail lonl(ue and gl'oo"e 20:20-21 Snack tray. routed 28: 16-18 Spalted wood 28:23 Spice box 6:3 Spindle turning 26:3 Spline Cutting 10:3: 15:·1·1)::!I~ll ParaDe19:9 Routed groove 21 :s.n U>e 23:22 Spool di>play case $:·1·6 Stave eonstrucuen 2.;:8-9.2·1; 2'7::J: ;W:2;{ Stereo cabinet .... mbour 1;:609 Stones

Diamond 2·1:7 Japanese \\ arer 2.l:-I..6: 2f_;;2:~ Sharpening 20: 1-, .It·!!l: 21:2!l Stool Camp3;i Shop 4:11 Stopped dado 2:5.11 Storage ;\1oriular system 22:12·1.')

Shop 15:14-15 Tabl,· saw 13:11-1.; S,,'eat(')" chest 9:8-9

$\\'l\,.:lliJrht

bracket

11:·'

Table RtlffCllt"Ie-le~:I·I-17 Butler's tray 14: 10-11.Hi Candle stand II :6-7

Tnbl e, C,'l)lIi. Coff~e 19:11·17: 2,,:ZO-Z!

Contempol'aryoak 1;;:·1-;; Uining aO:I(;'21.2·1 rx.uble·duty 1:7 Ol'1ll>'lear 11:8-10; 1l:·I-8 Gall,-II·I\' buffet 20:1-1-17 1.(·M !lO: 18-1\) N,·stl.d 2><:12-15 Picnic 27:4·7 Pembroke 11:4-8 Radinl.rm saw 20:3 Router 20:18-19: 22:1(;,17: 24:3 Shaker-style side 11:·1-5 Top 15:6·1; li:3: 19;3: 20:17: 21:23; 2:~:1:!·15.21

Tn->lle 1:3-5; 2.3:12-15 T\' t ....y 16:4-7; 17:20 Table
27:16-21,24:

2I!:I!I.2:l

Dad. blade. adjustllble 17:20 Miter !(auge 25:3 S<>IUP 20::1:23:3 S"'I1\I(" 1:1:14·15 Techniques 15:15: 12;16: 16:8.10·11: 1~:I1.2.~: 20:2a Tambour noll·wp bread box 4:6-8 S\(>"Co cabinet 17:6·9 'I'('' ll:lI; 1.1:4.8;28:12-IS Template, C4)I'n(tI' 29::3 Tenon Culling 2(i:IO-11 Huunehed 11:10-11 Jig 2-1:1S-1\1;28:3 Mit"red ,I>oulder 16:13.16-17 Rttpniring round 2:3:3 Stal(ger<:
Trestle table 1:3-;;; 2:3:12·15 Trivet, tiled 21:24: 22:23 Timg cil Iinish 30:12-15 Turning

Bowl 21:18-21: 25:2.1 Canister H;14-15: 2.';:8-12: 27:3: :10:2:1 Fruit bowl 21:18-21 Gauge 21:3 Goblets 23:4- i: 24:22 Gouges 21:22: 24;23 Legs 12:5 Popeom bowl 25:2-1 Scraper 21:22; 22:22 Spindle 26:3 1'001$21:13-22: 22:23: 24:2!l n' rrav tabl es 16;4-7: 1i:20 v anitv'mirror 24;24 Veneer 14:10·11 Yeneer tape 17:8: Z!:11-14 \'is.e Dogs z,;:3 Holding jig 29;3 Waglwr Safe·T·PJ8ner 10:10 Wall shelf 20:20·21 'VaSte basket 7:. \,rater stones .. Japanese 2<1:4-6; 26:'23 \Veh frame construction 8:8-11: 1·1:10·11: 22:18·22: 24:14·17: 25:).1·17; 26:12-17; 29:4-21 Wedge clamps 5:3 \VQod Dimensions 22:23 Movement 9:7 'Outdoor use 3:11;27:1·1-15 f:ipalted 28:23 Storage 19:2.1:30:3 Wooden hinges (issue ;(19) Woodworking clubs 27;24: 28:2·1; 2~:2-1; 30:24

Through dovetail 12:7

11. r:«k 1:2 Til':' and techniques (issues 7.-30:page 3) Ti"l'Iu(" bcx 19:24 Ti-sue box cover 2:5 Tungut_~ and groove joint 1:5: 9:7: 1:l:4-1~ "':12-19: 20::.'0-22.24: 24:14-17 Tool rest, grinder 2O:i; 24:3 Tool.torag,· 1:9.12 'rO\'

('he>! 29;1·9.2-1 Race car :):1~ Train &: Ill-II 'l'rav C~)insorter 10:6 l(out,~1snack 28:16-18 S<-r"ing 1!r.I!i SImekU:IIl-IS T\', tables It1:·t~7:17:20 'rl't:~tl("bench 23:24 WOOOSMITH

mica. (If the cap is too high, it'. difficulL to sand down without ruining the Formiea.) To get this perfect alignment, 1 didn',

nOURE 1

a ruler or measurement. Instead, J used the actual laminated piece to ~ot up US{"

the router table to rout the groG"e. Hold the laminated piece agllillSt the fence of the router table and adjus; the fence until the full thlckncss of the piece touches the outoidt edge of a ~. straight bit. (This same preeedure ean be used on a table saw.) Then rout a. ~"'~d(!_('p groove in both C:~IPS for the top. When completed. the bottom of the groG"e should meet the bottom of the particle board, see cress section, Fig. 2. ("II'S "Oil flO'I'J·OM.Although the bottom piece of particle board is actually thinner (because it'to not laminated with Formica), J used the sume set-up on the router table to rout the groove. for the bottom caps. (These ca"" will be completely hidden from ,tit"" b)' the bottom drawer, Perfection here is not so importnnt.) I'£NCII. (:ROO'·fo:S.The <:3)$ could be added as they are now. but I though! it would be nice to rout peneil grooves in the caps on the top. Il takes three passes on the router table \\;th two different bits to create this wide groove profile, First, use a 'VII" :\traight bit LOrout a ~",IIf~(leepgroove down the center of the caps, see Detail! in Fig. 3. 'Then swltch to a Yl:" core box bit, center it on one of the shoulders created by the straight bit, and rout the eeve profile V,,r deep, see Detail 2, Then repeat, this proet.1AA on

TONGUES fOR END CAPS

After the .nd cap> are complete, cut the 0/." particle board for the top and bottom to finnl si?..eof 16"x II~". see I-'ig. 5.

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that fit the groove. it's best to slowly of the rabbet. until in the grooves. S.\:-/OENI)(·APS. Because the face of the end caps "ill be butted again st the Formica to), finish sand the two LOPenps before gluing them to the top. ATrACY tSJ) CAL'S. Pinally. glue and clamp the end caps to the tOP and bottom. When the glue is dl'Y, (lim the two edges that will he joined to the caddy'. sides. and reduce the total width to 15'1".

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cnoovss FOR BAt'K. Before the caps are joined to t he top and bottom pieces, I routed the ~'1'00\'''used to hold the caddy's plywood buck in place. rrhcse V,"..wkle grooves are located ¥,." from the back edge of the ea .... see Fig. ~. Then one last stop. The bettcm/front eJl(1cap is to be trimmed to u width or llA" (see Fig, I) to allow space for the front of the bottom drawer.

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To join the top and bottom to the ""ddY'8 ",.1 sidos, a rabbet is routed on the edges orthc top and bottom to produce a tongue to fit the grooves in the sides. see Det"il in Fig. 6. The fit here should be .nug. Al(8in.

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tongues fit the groove s, Also, the bottom side o[ the end caps must.be routed nu.;h with the bottom o[the part ide board. see Fig. 6. When the thickness oft he tongue filS the groove. trim about V. the front and back edges so the length o[ the tongue fiLS the length of the groove, see Fig. 6.

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round over the edges on the end caps with a ~- rounding over bit. (Shop Note: I saved this rounding-over step unul last to remove any evidence of chi pout that might occur when the tongue. are routed on the edges of the top and botlom.) Round over the edges on both .01" on the lop, but only the bl'ck cal>on the bottom. (The front "I' on the bottom will b