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Square spindles, round tenons

Making the spindles round in a PVC pipe jig on the radial* arm saw is faster than using traditiona machining square tenons.

CUTTING ROUND TENONS ON SQUARE STOCK. S p two pieces of PVC pipe over a spindle. Carefully rotate the spindle aga • -? the radial-arm saw's fence and a stop block while moving the cutter-head. fitted with a dado blade, to remove the waste. ■

maple finished in .1 lnjht tone gives the tjMe a more feminine, lighter presence.

Birds-eye maple was my customers wood of choice. But I knew it would be nearly impossible to find birds-eve in the large dimensions required 8/4 in. thick and 10 ft. long. We settled on curb maple. Birds-eve was selected as a secondary wood, and its use was limited to the spindles.

Buying Lumber by the Log Allows Book-Matching binding 200 bd. ft. of curlv maple in the lengths 1 needed also proved to be difficult, so I sought out a timber broker and sawyer. I decided to buy whole logs and have them resawn. which would take extra work and time. But it was worth the trouble because I was able to tell the sawver just how I wanted the logs .111. Using wood from tinsame tree guaranteed that I would be able to match the figure and color.

My customer told nit. tii.it she didn't want her table to appear "too bossy." that is. she didn't want it too wild with figure. So I had the h>gs flitchsawn sawed completely through in successive layers . This method yields a combination of flat or tangential grain and quartersawn or radial grain. I ended up with boards that had a lot of curl in the quartersawn areas and calmer grain in the llatsawn areas. The areas of greatest curl were on the outside edges of the log.

I like to use air-dried wood because it machines cleaner, w ith less tearout. But air drying. I was told, wasn't an option with the curly maple. Curl is actually an abnormality to maple, and ir causes stress in the wood. Kiln dr 1 mg ! w is t< Id w uld help st.ibili/i the maple. Well. I hate to imagine what that stack of lumber would have looked like if I had air dried u. Curlv maple was an apt description of the lumber's condition after kiln drying tor more on flattening lumber, see pp. 56-57 .

Variations on a Stickley Theme

The grain—ra\ s or flecks—found in premium quartersawn oak adds visual interest to Stickley's rather simple furniture. I used curb maple to achieve a similar effect by matching up the most-figured planks and gluing them up for the massive top.

Stickley was a stickler for uniform figure on his work. Because lees made of solid stock onh show quartersawn figure on two sides, he solved the problem hi making legs Irom four mite red quartersawn sections. Some people solve the problem by simply gluing quartersawn veneer on two faces. Because this table has an altogether different look and feel from standard Sticklev. I laminated two pieces of 8/4 book-matchcd stock for the legs and left it at that.

The spindles are best machined after vou have dry-fit their matching components, which I use to mark off the location of the t* mi 'lis. 1 n: u' line round ten in u- ends of the spindles using a radial-arm saw. a dado blade and two short sections of PV( pipe that allow me to rotate the stock evenly.

Using the assembled rails as a marking guide. I lav out the tenons on a piece of scrap spindle stock to set up my radial-arm saw. I fit the radial-arm saw with a dado blade and position a stop block to establish the tenon's length. Before cutting, I slip a piece ol plastic pipe over each end ot a spindle, keeping the ends exposed. Be sun-there is no slop in the fit. I place the stock against the stop block and back fence and make a cut see the photos on p. 54 . Then I rotate the spmdle about 90* and make successive cuts to all lour sides to remove most ol the waste. I round over the tenons by carefully spinning the spindle/pipe fixture against the stop block and fence while moving the dado head back and forth.

Hidden beneath the tabletop is a subtop, i piece ol .-m. plywood with solid maple edges cross tics on two sides. A subtop has several purposes: It houses the mortises for the spindles attached to the stretcher, keeps the long side rails from flexing and helps ; eep the top ll it. The subtop ts s<n wed and glued to the rabbet in the long upper rails see the photos a bene .Two vertical sup-iwts. which an- mortised into the stretcher, are screwed to the cross ties of the subtop.

I he subtop, as well as rails, arc drilled out for sen v\ s to fast it! e top. "I hi Iarg< top will move considerably with seasonal changes in humidity, so I make the screw holes wide enough to allow the screws to move with the wood. I drill I-m.-dia. holes in. deep from the top ol the aprons with i I orstner bit. From the bottom of the i. I drill tow nd the I -in. holes using a #8 countersink bit.

Subtop keeps the base from racking

The subtop. a piece of )*-in. plywood with solid edges glued to two sides, tits into a rabbet cul into the long upper rails of the table's base. Four large holes in the subtop house screws that hold the table-top in place. The holes are larger at the top than at the bottom to allow the screws to move as the tabletop adjusts to sea sot ' in lily.

Woodworking Tools and Installation Tips

Woodworking Tools and Installation Tips

There are a lot of things that either needs to be repaired, or put together when youre a homeowner. If youre a new homeowner, and have just gotten out of apartment style living, you might want to take this list with you to the hardware store. From remolding jobs to putting together furniture you can use these 5 power tools to get your stuff together. Dont forget too that youll need a few extra tools for other jobs around the house.

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