Fender Washer

I drill the recess for the washer with a Forstner bit and make the recess deep enough so the washer will bear against the backing board to hold everything snug. 16 American Woodworker JANUARY2004 The Leigh Dovetail Jig has it all. Hobbyist or professional, the Leigh D4 Dovetail Jig will ensure you create your best work. Versatility, precision and superb value make the Leigh Dovetail Jig better than the rest. Rout through and half-blind dovetails up to 24 wide in...

Bearing

5 Rout super-deep mortises for the stretcher and arm from the steps, Rout the leg to its final shape with a 2-in. flush- so a functional mortise remains when you cut away the waste. Rough-saw- ' trim bit. Before you rout, rough-saw the blank and ing the slope beyond the steps makes it easy to clamp on stop blocks. affix the template with heavy-duty double-faced tape. you can rout the seat rail and stretcher mortises. Make stopped tablesaw cuts (on the outside edge of the pattern line) from the...

Carriage Side

6 If the box rocks, level the feet on a sheet of 80-grit sandpaper.The top of the box can be leveled in the same way, if it needs it. Follow up with finer grits. 7 Build a carriage to support the box while cutting the corner slots for the keys. Screw temporary 90-degree blocks to the carriage sides and use the blocks to position the seat boards so their beveled ends just touch. Remove the 90-degree blocks before using the carriage. glue is dry you can level the feet (if they need it) on a piece...

Clamp Rail

(1-1 8 x 1-3 4 x 20) flush with the top. A rail attached to the back of the fence allows you to clamp the jig securely to your workbench. Variations of this jig, depending on the thickness and width of the workpiece, allow you to rout all of the end-grain mortises. You can use the same fence for all the variations, just change the cleats. You'll need four pairs of cleats to complete the chair. If you plan to make more than one chair, it's a good idea to make a separate jig for each pair of...

Info

A s the holidays approach, my thoughts turn to how I can weasel out of gift JL JL shopping. And this year I have the perfect scheme While the malls are jammed with poor saps, I'll be in my shop blissfully building these boxes for everyone on my list. When they marvel at the elegant keyed joinery at the corners, I won't mention how fast and easy these boxes are to make. Making the jigs and resawing lumber takes a few hours, but once you're set up you can churn out three or four boxes in a day....

Hole For Lamp Base

If you have an original Small Shop Tip, send it to us with a sketch or photo. If we print it, you'll get 100 Send your tip to Small Shop Tips, American Woodworker, 2915 Commers Drive, Suite 700, Eagan, MN 55121 or e-mail to Submissions can't be returned and become our property upon acceptance and payment. We may edit submissions, and use them in all print and electronic media. C4 carbide teeth are precision ground for an exceptionally smooth finish U-ltra-sharp cutting edges dramatically reduce...

Extralong Pilot Hole

36-255L, 12 Compound Miter Saw Accurate, Fast, Heavy Duty The world's first TwinLaser' system makes this the fastest, most accurate saw available. Great for precise bevel and compound cuts. The same saw Norm uses. MS450, 12 ShopMaster Compound Miter Saw An Unbelievable Value Built for power (15 amps) - yet affordably priced Low price includes full features like fences, clamps and extensions For your nearest dealer, visit deltamachinery.com rebate. Rebate valid 11 1 03 through 2 15 04. 36-312,...

Mdf

MDF and particleboard are extremely flat. They're perfect for veneering because there are no lumps or ripples to show through extra-thin sheets of veneer. Glue veneer on both sides to keep the panel from distorting. It may be flat, but it's not stiff. Look familiar MDF and particleboard shelves are notorious for drooping, even from their own weight, unless they have additional support. Shelves that are 10-in. deep should be no more than 24-in. long. MDF's thickness is usually right on the...

Front

I Make templates so all of your duplicated parts will be identical. Cut the templates' long, straight edges on your tablesaw, using a sled. First, set the fence and rip the sled to width.Then tack the template blank in place and run the sled through the saw. 2 Locate the leg mortises. Marking both blanks simultaneously guarantees that the mortises will line up. Use the top of the front leg to locate the bottom of the arm on the back leg. Squarely-cut blanks are essential for sound joinery and...

Foot

3 Create feet on the sides and end by using a 3 4-in. straight bit in your router table. Set up a pair of stop blocks to limit the length of the cut.To prevent the grain from chipping out at the feet, make three passes, raising the bit about 1 8 in. after each pass. Built Crosscut Sled, AW 75, October 1999, page 38 (for reprints, see page 3). Cut the parts for the ends and sides and make an extra set to test your machine setups later on. Next cut the dadoes in the ends and sides for the bottom...