103 woodsmith 1996.02 roll top desk, Woodsmith
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Roll-top Desk· Cherry Desk Organizer. Fretwork Picture Frame. Extension Wing
Router Table
VoL 18/ No. 103
No. 103
February, 1996
SAWDUST
Publisher
Editor
Associate Editors
Donald
B.
Peschke
Terry
J.
Strohman
Jon Garbison
Mark Williams
Todd Lambirth
David Kreyling
Dirk Ver Steeg
ErichLage
O
ver the years it seems that
Art
Director
Senior Dlustrators
do with the illustrations and photos.
To make the artwork stand out
more, most of the illustrations now have
a white background. And we made the
box numbers more prominent, so you
can locate them quicker when working
on a project
Another big change has to do with
photos. Basically, youll be seeing larg-
er photos and more of them.
MORE
PAGES.
For the last six years
Woodsmith
has been a
32
page maga-
zine. But that's changing too - we're
adding four more pages.
Of course this means that we'll be
able to present you with more infor-
mation and projects. But we did
more
than just increase the number of pages.
We also increased the quality of the
paper as well. Now we're using an extra
heavy-weight paper to print the front
and back cover. This means that
Woodsmith
should stand up even bet-
ter to being used in your shop.
NAME
CHANGE.
The only other change
here at
Woodsmith
is Don is now the
publisher (a role he has been moving
towards for some time), and I've picked
up the responsibilities of editor. And
while the name at the bottom of this
page has changed, I assure you that
Woodsmith
will
continue to bring you
the high quality wQodworking projects
and step-by-step instructions that you've
come to expect.
As you can tell, I'm very excited
about all this. But I'd like to hear from
you. So drop me a line and tell me what
you think. I always enjoy hearing from
other woodworkers.
Dlustrator
February has become a month for
improvements here at
Woodsmith.
In
February 1989 we changed our graphic
presentation. And in February 1990 we
increased the number of pages.
Well, in keeping with that tradition,
we've decided to make some changes
starting with this, the February 1996
issue of
Woodsmith.
As I said before, it has been seven
years since we've done a major over-
haul to the graphic presentation (the
look and arrangement of art and text).
And while we have often made gradual
and subtle changes, we all felt that it
was time for something new.
NEW
LOOK.
We spent a lot of time dis-
cussing what changes to make and
why.
After all, I didn't want to
fix
anything
that wasn't broken. What I really want·
ed to do was make some refinements.
Our goal
was
to give
Woodsmith
a fresh
look and make it easier to read and use.
To make
Woodsmith
easier to read,
we basically made three changes. First,
the page color has changed. I've
always
felt the bufkolored page was easy on
the eyes. But we decided to make it a
bit lighter, which makes the text even
more readable. Next, we increased the
size of the type. And finally we put a lit-
tle more space between the lines to
make them less crowded.
Besides making
Woodsmith
more
readable, we also wanted it to be easi-
er to use. To do that, we've made a num-
ber of changes to headlines, typefaces,
and page layout But the changes youll
probably find most noticeable have to
CREATIVE RESOURCES
Creative Director:
Ted Kralicek •
Executive Editor:
Douglas L Hicks •
Assistant Editor:
Vincent S. Ancona
• Project Design Director:
Ken Munkel •
Senior Project
Designer:
Kent Welsh •
Shop Manager:
Steve Curtis •
Shop Craftsman:
Steve Johnson·
Senior Photographer:
Crayola England •
Electronic Publishing:
Douglas M.
Iidster •
Electronic Comunication Coordinator:
Gordon C.
Gaippe.
Associate Graphic Design Director:
Susie Rider •
Senior Graphic Designer:
Chris Glowacki •
Graphic
Designer:
Cheryl
L
Cynor
CIRCUlATION
Circulation Director:
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Director:Troy
j.
Dowell •
SubscriptionManagm:
Sandy
Baum,
Paige Rogers •
Assistant Subscription Manager.
Julie
Greenlee·
Newsstand Manager:
KentA Buckton
CORPORATE SERVICES
Vice Preside"t ofPlanning and Finance:
Jon Macarthy •
Controller:
Robin Hutchinson
Sr. Account.:
Laura Thomas
• Bookkeeping:
Holly Lucas •
Production Dir.:
George
Chmielarz •
Production Mgr.:
Carol Quijano •
Pro. Dev.
Dir.:
Joyce Moore·
Network Administrator:
Nick Thielen
• Admin. Assistants:
Cheryl
A
Scott, Julia Fish •
Receptionist:
JeanneJohnson •
Building Maintenance:
Ken
Griffith
WOODSMl11I MAIL ORDER
Operations Director:
Bob Baker.
Art Dir.:
Cindy
Scarpino •
Materials Manager:
Mark Mattiussi •
Customer Service Mgr.:
Jennie Enos •
Warehouse Supr.:
NaJ.!CY Johnson •
Buyer:
linda Jones •
Systems
Operator:
Tammy Aldini •
Team Leader:
Karla Cronin •
Tech. Support:
Dave Stone •
Cust. Servo Reps.:
Jennifer Murphy, Joy Krause, Sara Kono, Anna Cox,
Adam Best, Kristi Andrews, Margo Petrus·
Warehouse:
Gloria Sheehan, ChuckCarlson, Sylvia Carey, Larry Prine,
Scott Gilliam, Cathy Steiner
WOODSMl11I STORE
Manager:
Dave
Larson •
Assistant Manager:
Paul
Schneider •
Sales Staff.
Wendell Stone, Pat Lowry •
O/fiee Manager:
Vicki Edwards
Woodsmith® (ISSN 0164-4114) is published bimonthly (Feb.,Apr.,
June, Aug., Oct., Dec.) by August Home Publishing Company, 2200
Grand, Des Moines,
IA
50312.
Woodsrrtitb@isaregisteredtrademarkofAugustHomePublishing.
CopyrigbtC 1996 Angust Home Publishing Company.
All
rights
reserved.
Subscriptions: Single copy: $4.99. One year subscription (6 issues),
$19.95. Two years (12 issues), $35.95. (Canada/Foreign add $5 per
year, U.S. funds.)
Second
Class Postage
Paid
at Des Moines,
IA
and at additional
offices.
Postmaster: Send change ofaddress to
Woodsmith,
Box 10718, Des
Moines,
IA
50350.
Subscription Questions? Call1-8OQ.333-5075, 8:00 am to 5:00 pm,
Central Ti s.
E-Mail:
Pr :
ED]E97A, Compuserve: 75330,2301. America
Online: Au orne, Internet augusthome@aol.com, World Wide
Web: http: /augusthome.com.
Printed in V.SA
2
Woodsmith
No. 103
CONTENTS
Features
Roll-top Desk
6
Classic shape. Simple design. Both come together
to
make this
roll~
top desk a rewarding project that's easy
to
build.
Desk Organizer 14
Slide this desk organizer into the
roll~top
desk. Or build
it
as a
sepa~
rate unit that looks good from any angle. Either way,
it
helps
orga~
nize all your writing materials.
RoH..top Desk
page 6
Building Tambours
20
Understanding how a tambour door works takes the mystery out of
building one. By using a few basic designs and changing the profile of
the slats, you can build a tambour door
to
fit most any application.
Fretwork Picture Frame
24
The intricate fretwork
on
this picture frame
is
only half the story. It's
hinged
to
another frame that holds a standard 3x5 photograph. This
freestanding frame makes a great weekend project.
Scroll Saw Techniques
26
There's a trick or two
to
using a scroll saw
to
cut fretwork panels.
We show you the best blades
to
use and how
to
reduce chipout
so
you
don't spend a lot of time cleaning up the panel after it's cut out.
Desk Organizer
page
14
Extension Wing Router Table
28
This router table replaces the extension wing
on
your table saw.
Besides saving space, there's a unique fence system that attaches
to
the existing rip fence
on
your saw.
It
features a
built~in
storage
com~
partment for router bits and a dust collection
hook~up.
Picture Frame
page
24
Departments
Tips
&
Techniques ..
Shop Notes .
Reader's Jig
.
4
.
18
.
.
34
Sources
-'~
..
~
35
Router Table
page 28
No. 103
WOOdSffilth
3
TIPs
&
TEcHNIQUES
Rip Fence Adiustment
The rip fence on my con- screws to the head of the
tractor-type table saw was rip fence, see Fig.
1.
They
always frustrating to use.
It
let me "fine tune" the fence
never lined up square with position. By turning either
the blade after itwas locked the right or left screw, the
down in place. fence swings a little in the
To correct this problem, same direction until it's per-
I added a pair of adjustment fectly aligned and parallel
with the blade, see Fig. 2.
Adding the screws is
simple. Just drill and tap
two holes in the head of the
rip fence, see Fig. la When
a screw is installed, it con-
tacts the table rail and
moves the fence a little with
each turn of the screw.
Tightening a lock nut on
the screw keeps the screw
from moving once you
have the fence set where
you want it, see Fig. Za.
WaltNeu
Naples, Idaho
a.
CROSS SECTION
o
or
right screw
in swinf/s the
fencem the
same direction
a.
Drill and tap
holes in head
of
rip fence
#10-32
machine
screw
Adjust screws
to
align fence
Studded Knob
Sanding Station
Adding studded knobs to a
jig makes it easier to use.
But longer lengths aren't
available so I make my own
with a regular plastic knob,
a carriage bolt, and a cou-
ple nuts, see drawing.
Just thread both nuts on
the carriage bolt, screw on
the knob, and lock it in
place with one nut. Now cut
off the head of the carriage
bolt and remove the sec-
ond nut to clean up the
threads at the end.
Larry
Heinonen
Union City, Michigan
Hardboard sheet
blocks
off
air holes
FIRST:
_/
Add
two
nuts
to
carriage bolt "
SECOND:
Tighten one nut
against knob
A large sanding table, with
a few modifications, is the
perfect place to carve and
sand small parts. I simply
add a small "sanding hood"
that sits on top of the table.
It
concentrates the airflow
to one small area.
This hood is nothing
more than a few pieces of
plywood glued together,
see drawing above. And I
used a clear piece of plastic
for the back to let in light.
But the secret to increas-
ing airflow is covering the
rest of the table top with a
piece of hardboard. This
blocks off the other air
holes so the dust and chips
are drawn in through the
sanding hood.
Remove one nut
to
clean threads
Ben
Meller
Whitewater, Wisconsin
4
Woodsmith
No. 103
Turning the left
Biscuit Fasteners
small blocks. Finally, drill
an oversize shank hole in
each of the blocks and glue
a biscuit in the slot.
Now cut a series of slots
in the aprons or rails of
your project, see Fig. 2.
The biscuits in the blocks
fit in these slots when
screwed to the top.
Michael Niziol
Cortland, New York
Bench Hold'ast
Sometimes, the only way to
clamp a project to a work
bench is with a bench hold-
fast. But you don't need to
go out and buy one if you
make a small alteration to a
regular bar clamp.
Just remove the fixed jaw
by drilling out the rivet that
holds it to the clamp bar,
see Fig. 1. Then install a
small metal strip with a
machine screw and nut, see
Fig. 2. Note: Crimp the
threads of the screw at the
end to help "lock" the nut in
place, see Fig. 2a.
Now swivel the metal
strip to fit through a dog
hole in the bench and swiv-
el it back to hold the clamp,
see Figs. 3 and 3a.
Michael Marinello
Tempe, Arizona
a.
oversize~le
a.
f
Oversize shank
hole
Dovetail Cauls
Clamping cauls help pull
dovetail joints together. But
cutting out the face of each
caul to fit around the pins or
tails takes a lot of time.
Rather than cut out the
cauls, I hot-glue small,
hardboard pads to the face
instead, see drawing. The
pads fit arotmd the tails and
can be removed easily to fit
different-size dovetails.
WaltNeu
Naples, Idaho
---------
SUBMIT YOUR TIPS
~--
IT
you would like to share an
original
shop-
tested tip, send it to:
Woodsmith,
Tips and
Techniques,
2200
Grand Avenue, Des Moines,
Iowa
50312.
Or
if
it's easier, FAXitto us at 515-
282-6741. Or use our E-Mail: 75330,2301@com-
puserve.com.
IT
published, you'll receive $30
to
$150,
depending on the published length. Include
a briefexplanation and sketch or photo. We'll
rewrite the tip and redraw the art,
if
needed.
Also,
please
list a daytime phone number.
--~
---
Install pads
to - .--- _
_----
fit around the
_- ---
__ •
pins or tails
---
No. 103
Woodsmith
5
Here's another use for
wooden biscuits. They can
be used to make fasteners
that hold a top securely in
place and still allow the
wood to move.
All
you need
are a biscuit joiner, a piece
of stock, and some wood-
screws, see Fig. 1.
Start by cutting evenly
spaced slots in a board.
Next, cut the board into
th~:Js
to
lock
nut
on
screw
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