02. February 2000.pdf

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IGGEST
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UYERS
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Must Know
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PROJECTS
What First-Time Finishers
INSIDE!
Popular
February 2000 #113
Woodworking
The Skill-Building Project Magazine for Practical Woodworkers
T
OOL
R
EPORT
2000
Your must-have
buying guide
to
249
tools!
Pennsylvania
Stepback
Classic Colonial
Cupboard
4
Great Ways
to Build a Table
Router Fence
for your Table Saw
www.popwood.com
®
www.popularwoodworking.com
22
22
48
38
In This Issue
22
Pennsylvania
Stepback
This Colonial cupboard has got it
all: traditional joinery, excellent
proportions and the opportunity
to put your woodworking skills to
the test.
By Glen Huey
30
62
Router Fence
for Your Table Saw
Use the fence on your table saw as
the foundation for a highly accu-
rate router table system. This
quick fence attaches to your table
saw’s fence and gives you must-
have features such as dust collec-
tion and storage for your bits.
34
54
Should You Buy
Professional Tools?
What’s the difference between a
$50 router and a $150 router?
We take you inside to show you
how the things you can’t see can
sometimes affect the price.
By Randy Caillier
2
P
OPULAR
W
OODWORKING
February 2000
America’s
BEST
Project Magazine!
In Every Issue
6
8
14
18
20
56
Out On a Limb
Choose Wisely
Letters
Mail from readers
Cris Cuts
Circles Without a Band Saw
Tricks of the Trade
Great uses for a clothes pin; coffee
cans aid dust collection
Projects From
the Past
Modern Chair
66
70
74
82
84
86
88
Tool Test
Veritas’ new low-angle block
plane; Bosch’s detail sander
Flexner on Finishing
Advice for first-time finishers
38
Tool Report
This is the only way to buy a new
tool: First find out which features
are important (and which aren’t).
Then look at all the products on
the market and compare their
features and prices so you get the
right amount of tool for the right
price. This year we examine cord-
less drills, biscuit joiners, 14"
band saws, dust collectors and
10" cabinet saws.
56
Four Ways to Build a
Tavern Table
Learn four great ways to build this
table: from totally traditional to
quick and dirty. Plus, get the final
word on the rules you must obey
when designing tables.
By Troy Sexton
Wood Types
Buying Submerged Lumber
Classifieds
Caption the Cartoon
Win a set of Quick Grip clamps
Endurance Test
Fein’s random-orbit sander
62
Shop-Built
Air Cleaner
Save yourself a few bucks by
building your own air cleaner
using a squirrel cage fan and
readily available materials.
By Michel Theriault
Out of the Woodwork
Coffin Confession
48
Handmade Hardware
Step inside a darkened black-
smith’s shop, where custom cabi-
net hardware is made almost
exactly as it was 200 years ago.
On the
Cover
Check out this
year’s Tool Report
for the gospel truth
on the must-have
features for wood-
working tools.
Cover photo by Al Parrish
54
Limbert Waste Box
This faithful reproduction of
Limbert’s #255 waste can will
look great in your modern Arts
& Crafts home.
www.popwood.com
3
®
February 2000, Vol. 20, No. 1
www.popwood.com
Editor & Publisher
Steve Shanesy
Senior Editor
David Thiel
Managing Editor
Christopher Schwarz
Associate Editor
Jim Stuard
Art Director
Amy Schneider
Contributing Editors
R.J.DeCristoforo
Nick Engler
Bob Flexner
Glen Huey
Troy Sexton
Technical Advisers:
Bill Austin
Makita USA. Inc.
Scott Box
Delta International
Chris Carlson
S-B Power Tool
Dale Zimmerman
Franklin International
General Manager
Jeffry M. Lapin
Editorial Director
David Fryxell
Creative Director
Matthew Small Gaynor
Magazine Art Director
Nancy Stetler
CIRCULATION
David Lee,
Director
Mark Fleetwood,
Single Copy Sales Mgr.
Terry Webster-Isgro,
Direct Sales Mgr.
PRODUCTION
Barbara Schmitz,
Director of Manufacturing
Martha Wallace,
Magazine Production Dir.
Matt Walker,
Production Assistant
Ruth Preston,
Studio Manager
ADVERTISING
National Sales Representative
Bill Warren,
Five Mile River Assoc. LLC
RR1 Box 1400, Stockton Springs, ME 04981
Tel. (207) 469-1981; Fax (207) 469-3050
Advertising Sales
Joe Wood,
Tel. (513) 336-9760
Fax (513) 336-9761
Classified Advertising Sales
Joan Wright,
Tel. (513) 459-9298
Advertising Production Coordinator
DebbieThomas,
Tel. (513) 531-2690, ext. 219
SUBSCRIPTION SERVICES Subscription inquiries,
orders and address changes can be made at
www.popwood.com (click on Subscriber Services).
Or by mail: Popular Woodworking,
P.O. Box 5369, Harlan, IA 51593 or call
(515) 280-1721. Include your address with all
inquiries.Allow 6 to 8 weeks for delivery.
Popular Woodworking
(ISSN 0884-8823, USPS 752-250) is
published seven times a year in February, April, June, August,
October, November and December by F&W Publications, Inc.
Editorial and advertising offices are located at 1507 Dana Ave.,
Cincinnati, OH 45207; tel.: (513) 531-2222. Unsolicited
manuscripts, photographs and artwork should include ample
postage on a self-addressed, stamped envelope (SASE);
otherwise they will not be returned. Subscription rates: A year’s
subscription (7 issues) is $19.97; outside of U.S add $7/year.
Canada Publications Mail Agreement No. 0546232. Canadian
return address: 2744 Edna St., Windsor, ON N8Y 1V2
Copyright ©2000 by
Popular Woodworking.
Periodicals postage paid
at Cincinnati, Ohio, and additional mailing offices. Postmaster:
Send all address changes to Popular Woodworking, P.O. Box 5369,
Harlan, IA 51593 Canada GST Reg. # R122594716
Produced and printed in the U.S.A.
ATTENTION RETAILERS:
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Woodworking
in your store, call
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Publications, Inc., 1507 Dana Ave., Cincinnati, OH 45207.
Woodworker’s Book Club:
1507 Dana Ave., Cincinnati,
OH 45207; (513) 531-8250
Audit Bureau of Circulation membership applied for.
4
P
OPULAR
W
OODWORKING
February 2000
O
UT ON A
L
IMB
Choose Wisely
Job-site machines don’t always measure up in the woodshop.
Contact
Information
Steve Shanesy
Editor & Publisher
Specialties:
Projects,
techniques, article and
project selection
(513) 531-2690 ext. 238
steves@fwpubs.com
W
hile I’ve never spent much time on
a new home building site, I do re-
call the days when carpenters and finish
carpenters would show up hauling a trail-
er that had some serious machinery
strapped to its stake bed sides. Particular-
ly, a big old radial arm saw and a “con-
tractor-style” table saw. Where I grew up in
the Midwest, they’d set up these machines
in the garage as soon as it was under roof
to keep them out of the elements.
These tools passed for “portable” ma-
chines then. Portable enough for a couple
burly guys to hump off the back of the trail-
er and drag them in place. They ran on
110-volt power, standard fare for a con-
struction site.
The contractor-style table saw was
quickly adopted by the home woodwork-
er as a less expensive alternative to the
cabinet saw, but still featured a 10" blade,
a horse-and-a-half motor, sturdy rip fence
and reasonably sized cast iron top. It’s the
kind of saw I bought when I started 20
years ago (and just recently retired when I
finally upgraded to a cabinet saw). I had
noticed a contractor saw in one of the
books written by veteran woodworker Tage
Frid and figured it had to be good enough
for me.
Today, you won’t find a building site
with a radial arm or contractor saw in sight.
They’ve given way to a new breed of ma-
chine that’s much more portable. The
compound miter saw and benchtop table
saw. In the case of the compound miter
saw, its features are superior in nearly every
way to the radial arm saw. The new breed
of benchtop table saw has many advan-
tages over the contractor saw — if you’re
working on a job site.
These past few years, many wood-
workers have once again adopted these
job-site machines in their home wood-
shops just as their brethren did a generation
earlier. While I applaud the arrival of new
miter saws, the table saws are another story.
In most cases, I think it’s a mistake. I have
a theory when it comes to buying machines
that’s pretty straightforward. If you don’t
have to pick it up and move it during the
course of a day’s work, it ought to have two
key ingredients: cast iron and an induc-
tion motor. Benchtop table saws with alu-
minum tops and universal motors should
be the exclusive domain of job-site car-
penters. That’s what they’re made for. But
I’ve yet to encounter one of these saws that
could be classified as a wise investment for
home woodworking.
One of the problems is the universal
motor. This motor is lightweight and pow-
erful, but it is built to run for short periods
of time because it generates a lot of heat
—a motor’s worst enemy. Universal mo-
tors are also much noisier and have a short-
er lifespan than induction motors. Bottom
line: these motors are good for tools you
turn on for short periods of time (such as
routers) but not those that you run all day.
Also, saws with aluminum tops vibrate
more than those with cast iron tops. The
place where the motor and table are at-
tached is more susceptible to stress and
twisting in a benchtop saw than in a con-
tractor saw. Finally, the fences on bench-
top saws are rarely sufficient for quality
woodworking.
I’m not a tool snob, believe me. I just
want a machine that delivers the goods
until I give out rather than vice versa. I
want a machine that will stay in reason-
able adjustment, that can be pushed when
called on without begging or babying.
The table saw, band saw, jointer and
planer are the cornerstones of a well-
equipped woodshop. Among these ma-
chines, the prices difference between an
average benchtop with a universal motor
vs. a cast iron model sporting an induc-
tion motor is just a few hundred dollars.
Invest the extra money because you’ll al-
most certainly get it back the day you de-
cide to sell it. Invest, even if it means
delaying your next purchase for a year.
You’ll be glad you did, I promise.
PW
David Thiel
Senior Editor
Specialties:
Projects,
new products and tools,
tricks of the trade
(513) 531-2690 ext. 255
davidt@fwpubs.com
Christopher Schwarz
Managing Editor
Specialties:
Author
liaison, website, projects,
photography.
(513) 531-2690 ext. 407
chriss@fwpubs.com
Jim Stuard
Associate Editor
Specialties:
Projects,
carving, turning, project
illustrations
(513) 531-2690 ext. 348
jims@fwpubs.com
Amy Schneider
Art Director
Specialties:
Magazine
and cover design, photo
direction
(513) 531-2690 ext. 471
amys@fwpubs.com
Got Questions or Problems
With Your Subscription?
To report problems with your subscription
visit our website at popwood.com, call our
subscription offices at 515-280-1721, or
write to
Popular Woodworking,
P.O. Box
5369, Harlan, IA 51593.
Our Privacy Promise to You
We make portions of our customer list
available to carefully screened companies
that offer products and services we believe
you may enjoy. If you do not want to re-
ceive those offers and/or information,
please let us know by contacting us at: List
Manager, F & W Publications, 1507 Dana
Ave., Cincinnati, OH 45207
Safety Note
Safety is your responsibility.
Manufacturers place safety devices on their
equipment for a reason. In many photos
you see in
Popular Woodworking,
these have
been removed to provide clarity. In some
cases we’ll use an awkward body position
so you can better see what’s being demon-
strated. Don’t copy us.Think about each
procedure you’re going to perform before-
hand.
Safety First!
6
P
OPULAR
W
OODWORKING
February 2000

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