Info

One of the best ways to improve the quality of my cuts is to shine some light directly on the subject. A versatile work light, like the one shown at right, fills this bill nicely. This light has two nice features. The first is a strong magnetic clamp that allows you to quickly attach it to the band saw cabinet. Then you can use the multiple swivel points to direct the light right where it's needed. For 30, you can't go wrong. 5 link belt. Vibration is the enemy of smooth cuts. A good way to...

Dado Blade Method

When cutting rabbets, the key is to remove as much waste as quickly as possible. And that's why my method of choice is to use a dado blade. A good-quality stack dado blade will cut rabbets quickly and accurately. And I find this method makes it easier to fine tune the width and depth of the rabbet. AUXILIARY FENCE. The key to cutting rabbets with a dado blade is to use an auxiliary fence. Basically, this is just a narrow strip of wood or plywood that's clamped to your rip fence. The dado blade...

Specialized Router Bits

Several companies make the router bits featured in the article on page 40. Amana Tool makes the tambour bit set (54314). It's available at Toolstoday.com. The straight bits for undersized plywood measuring 1 4 (90330), 31 64 (90528), and 23 32 (90627) and the locking miter bit (22627) were purchased from Rockier. The three-piece glue-joint bit set (8357) and box joint bit (7860), came from MLCS Woodworking. The Woodsmith Store sells the Amana dado clean-out bit (45489), the T-slot cutter...

Making the

Seat is attached with 8x3 Fh woodscrews Of course, no bench is complete without a comfortable seat. This seat is just a glued up plank with beveled sides, screwed to the legs through mortises in the top. False tenons cover the screws. After gluing up the seat blank, I cut it to size with bevels on all four edges. I also softened the sharp corners of the seat with 220-grit sandpaper. As I mentioned earlier, there are four mortises cut in the seat to hold the false tenons detail 'b' . To create...

Tray Back Rail

Band Saw Wood Patterns

So, using the oversized workpiece and a standard saw blade, I cut a W'-wide groove V4 deep detail 'a' and then cut the workpiece to final size. ASSEMBLE THE BOX. The box goes together quickly. First, just attach the stretcher across the bottom with screws. Then the back is screwed into the rabbets, flush with the bottom of the sides as shown in detail t.' Finally you can add the tray back rail. Once the box was assembled, I stained it a dark color as shown in the main photo. Let it...

Tips Techniques

Auxiliary Baseplate

When it comes to breaking down sheet goods, I rely on my circular saw and a straightedge. But because the edges of the baseplate are offset from the blade, locating the cut line involves some measuring and a little guesswork. To solve this problem, I added an auxiliary base to my circular saw, like you see in the photos. What makes it really handy is that the distance from the blade to the edge of the plate is the same on both sides. That means that I can start the cut from either end and...

Oil Based Varnishes

In the past 20 or 30 years, polyurethane varnish has come to dominate the varnish market. Most of the oil-based varnish products you'll find on the shelf are labeled poly. The reason is that polyurethane varnish uses a resin that produces a harder, more durable film. A polyurethane has unbeatable moisture, stain, abrasion, and heat resistance. It's a great choice for tabletops, kitchen cabinets, floors, or other high-traffic areas. A polyurethane doesn't have quite the warmth and clarity of an...

Mortise

Zero Clearance Insert

This new precision jig makes routing clean mortises with a plunge router virtually foolproof. The compact Mortise Pal offers easy, accurate, and versatile performance. A plunge router can cut a clean slot mortise in the blink of an eye. The only catch is you need an easy to set up and reliable way to guide your router and accurately position the mortise in the workpiece. Without a foolproof jig, routing mortises isn't always an attractive option. If you've been searching for a solution to this...