Gluing An Octagon

But since the ends may be off, position the half-frame so the two long corners extend beyond the edge of the plywood and the two short corners are flush to the edge, see Fig. 2a. making the curs. Next, run the plywood carrier through the table saw, trimming off the long corners of the half-frame. Repeat the procedure on the other half-frame. Now the two halves can be glued together without a gap. When cutting miters for an eight-sided frame (such as the Oval Mirror on page 18), there's...

Removing Screws

One of the most frustrating problems you're likely to face as a woodworker isn't really woodworking at all it's removing broken screws. Fortunately, there is a way to remove screws that can make the job a lot less frustrating using a screw extractor. There are two kinds of extractors spiral flute extractors and hollow bit extractors. Each of these tools works differently.

Screw Extractors

On page 30 we talked about two different types of screw extractors. The spiral type is available from many hardware stores. Sears also has a five-piece set in a plastic case No. 67322 available at their retail stores. The Sears Tool Catalog also offers a ten piece set No. 20616 that includes both screw extractors and matching drills. The hollow bit screw extractors are available in three sizes W Vie, and Vs from Trend-Lines, see below. Woodsmith Project Supplies is offering these extractors in...

Spiral Flute Extractors

Wood Turning Arms Chair

Using a spiral flute extractor is a two-step process. First, drill a pilot hole into the damaged or broken screw. Next, hammer the extractor into the pilot hole. Then grasp the extractor with a wrench and turn it counterclockwise. Since it's tapered, the spiral flutes quickly jam in the pilot hole. As you continue to turn the extractor, it backs out the screw. The hollow bit extractor removes screws in two ways. If the broken screw fits inside the bit, then the extractor drills a core with the...

Cracks Splits

Homemade Tenon Jig Plans

Sometimes a crack will develop on a glue joint after the project is complete. Wood filler isn't the answer there's a better way. Sometimes a crack will develop on a glue joint after the project is complete. Wood filler isn't the answer there's a better way. It's not unusual to see an edge-glued table top or any project split apart because of wood movement caused by changes in humidity. Here's how I handle the problem. First I cut the split panel apart right through the crack. This relieves any...

Chair Seat Scooping

To make the Oval Cutting Jig shown on page 22, yqull need a variety of hardware thafs commonly available at most home centers and hardware stores. Woodsmith Project Supplies has also put together a kit of all the hardware needed to build the Oval Cutting Jig. Note The wood is not included. W784-200 Oval Cutting Jig Hardware Kit 5.95 2 V4-20 x 36 Threaded Rods 2 W x 2W Carriage Bolts 14 V4 Washers 2 V4n Lock Nuts 8 V4 Nuts

Shim Saver

Rocking Chair Pattern

I bought some brass shims from a woodworking mail order catalog to put between the blades of my stack dado set. They allow me to make very fine The only problem with this technique is that when trimming the pins off the first side of a corner, the tails on the adjacent side get in the way. There isn't a flat surface for the router to ride on. To create a flat surface, I use a piece of V amp -thick Masonite. But I soon discovered a problem. The shims are so thin they fall into the threads of...

Trammel Platform

When designing this jig, a major consideration was the size of the frame to be routed. The trammel platform has to be small enough to fit inside a glued-up blank, see photos on opposite page. But it also has to be large enough so there will be plenty of track for the guide blocks C to travel in, refer to Exploded View. The following measurements are for the Oval Mirror on page 18. They will also work for similar sized frames. platform. The trammel platform A is cut from a piece of W'-thick...

Arm Rests

When the back and front assemblies are connected, the project is almost a chair. But it wouldn't be a very comfortable chair without a pair of arm rests. arm brackets. To support each arm rest at the front, I added an arm bracket. The arm brackets J each start out as a rectangular blank of W-thick stock, see Fig. 13. tenons. The next step is to cut a tenon along one side and one end of the blank, see Fig. 13a. The tenons are more like tongues they don't have very wide shoulders. I used a dado...

Back Slats

The five back slats have the same curve as the upper part of the back legs. lay 01t shape. Start by cutting oversize blanks from lW'-thick stock, see Fig. 3. Three blanks are needed two slats can be cut from each, giving you one extra slat Then transfer the curve of the top of the back leg front edge only to this blank. lay out shape. Now transfer the leg pattern to one of the blanks. Enlarge the grid pattern to actual size, or, for a set of full-size patterns, see Sources on page 31. lay out...

Suppliescutting Diagram

Overall Dimensions 37 H x 25W x 1Vi6T 1 Vfe'x2VS'x 10' Masonite for splines 1 Vtf x 25' x 37 Oval Mirror cut to fit frame 1 ' 16 x 32 x 40 Standard Mat Board 16 7 Glazing Push Points 8 5 x V5 Fh Woodscrews 1 20 lb. Braided Wire -10' rgh. 2 1 Vfc Wall Hangers with Brads C Masonite Splines 8 Vfe x - 2Vt gt I Vi6 x 5 x 60 2.6 Bd. F . _ 1 Vit x 5 x 60 2.6 Bd. Ft.

Chair Seat

Antique Rocking Chair Diagram

The seat is just a plywood platform that rests on four cleats inside the chair opening. The platform is upholstered with fabric-wrapped foam, see Fig. 23. cleats. To make the cleats, start by ripping four strips of 34 stock to finished width 34 . Then cut all four seat cleats M to the same length 15 . Before installing the cleats, drill six countersunk shank holes in each cleat four for the screws into the rails, two for the screws into the platform , refer to Fig. 23b and the Exploded View on...

Tenon Jig That Angles

Tenoning Jig

When you want to use a mortise and tenon joint to join two pieces at an angle, you have a choice to make cut an angled tenon or bore an angled mortise. I would always choose the angled tenon. The challenge is figuring out the best way to cut the tenons at an identical angle at botk ends of the workpiece with the least amount of fuss. So I came up with a jig for the router table. For the Oak Rocking Chair on page 6, the tenons at each end of the side rails have to be cut at a 3 angle. The...