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Part 2 ebook present the content: windsor chair, anatomy of a sack back windsor chair, making the spindle, making the bow and arm, assembling the chair, a milk paint finish, queenanne secretar, anatomy of a queen anne secretary, making the desk unit, building the pigeonhole unit, glossary, acknowtedgments.
I I I I I I I t t I I I I I I I I I I I I I I I I I t t I I I I I I t I I I \AINDSORCHAIR T I n Windsorchairis a incontrasts study Origi- the seat at whateverangles suit its user.All of the chair's parts are joined with round mortise-and-tenons-afairly simplejoint to produce.Some woodworkerscontend that one of the benefitsof making a Windsor chair with green lumber is that you can take of the hygroscopic, advantage moisture-absorbing characor By ter of wood dryrngthe leg tenonsprior to assembly and "wet" morfitting them into tisesin theseat,a snugjoint will becomeeventighter.Oncethe joint is assembled, the tenon will absorbmoisturefrom the woodsurroundingthemortise, swellingthetenonandshrink- nallydesigned asan artless furnishing,it is now consideredto be a sophisticated of modernchairmakexample ing.Thesimpleelements of a Windsor-the sculptedseat legs, and the hand-shaped stretchers, arm posts,and spindles-beliethe precise engineering required to assembleit Anddespiteitsrelatively lightweight components, the Windsorchairis verystrong Thetop of a Windsorchairseatis traditionally anddurable Firstmadein ruralsouthsculptedby hand With shapingtoolslike Windsorchairs thespokeshave, inshave,and drawknife,it is ernEngland, possibleto customize theseatfor its user cameto NorthAmericain the Perhaps mid-18thCentury as choose instead to useseaOtherchairmakers design andunsophisticated construction, ingthemortise aresultof itspractical pioneerhome- sonedwoodfor theseat,whichwill belesslikelyto crackasit with America's thestylequicklyflourished Thejointsin the the dries,andreinforce thejoineryin otherways Thefoundation of allWndsorchairs-whether steaders with chairfeatured in thischapteraregluedandmanyof themversion featured in thischapter, thecomb-back sack-back joints-are furtherstrengthened by type-is thesolid- suchastheleg-to-seat its highbackest,or thecontinuous-arm "green"(or inserted in kerfscutin theendof thetenons freshlyfelled) wedges woodseat.Traditionally cutfroma A finaladvantage of buildinga Windsorchairis thatthe log,theWindsor's seatrepresented animportantinnovation canbedonewith handtools.Althoughthelegs in chairmaking.In earlierstyles, thebackof thechairwasan entireprocess canbeturnedonalathe(page89),theycanalso of thelegs.Thismeantthattherearlegshadto be andstretchers extension (page a drawknife withthespindles-using seating andwereattached to the beshaped-along bentto providecomfortable (page joinery horse 7B).Theseatcanbe 76)andashop-built shaving complex seatframewith relatively (page84),thenshaved andadzed to itsfinThelegsof a Windsorchairarenotbent.Instead, theback cutwithabowsaw ishedshape anchored separately to andlegassemblies areindependent, Thesack-back Windsorchairshownat left wasfinishedwith milk paint, a traditionalfinishfor AmericanCountryfurniture.,fuailablein powdered milk paint reflects form and mixedwith waterto a paint-likeconsistency, thesimplicityof the Windsorchair;it is bestappliedby brush 7T ANATOMYOF A SACK-BACKWINDSORCHAIR anyof the round mortise-andtenonjointsthathold a Windsor chairtogetherarereinforcedby wedges As the illustrationat right shows,the top endofthe legs,armposts,andspindlesareallkerfedprior to assembly;the wedgesthat fill the kerfsexpandthe tenons,ensuringthat theyfit snuglyin theirmortises Buta Windsorchairis morethanthe sumof its parts.Forstrengthandcomfort, it alsorelieson the interactionof The legsand its variousassemblies for example,work against stretchers, eachotherto supportthe weightof its with its bow, user.The backassembly, functionsin a similar arm,andspindles, manner.Thelegssplayout to the sides and arerakedforwardandbackwardprovidinga broad,stablebasefor the chair.As with all enduringdesignsthe seatis tilted back slightly,making the chairmorecomfortable The threeviewsof the sack-back on page73 provide Wndsor presented spacings, you with the criticalangles, and dimensions.More dimensions appearin the cuttinglist belowand throughoutthechapterwhereeachpart of thechairis made As you prepareyour stock,keepin mind that you will not be ableto cut someof thepartsto theirfinishedlength Thespinuntil youbeginfinalassembly dles,for example,shouldall be left at their maximum possiblelength-22 inches-until youhavebentthearmand against thespindles bow,andtest-fitted them.In thesameway,sizethestretchers only after test-fittingthe blanks betweenthe legs I I I I I I t I t I I I I I I t I I I I I LIST CUTTING t PIECE OTY THICKNESS Arm Armposts I %' Bow I Legs Seat Longspindles spindles Small Middle stretcher Sidestretchers 2', W.ORDIAM 2', 44', IYo' 11', %u ARr !3/o' 17' 20' 16' 3/ou 22', 3At T%' II%' 17' Ivi' I4Yz' I I I I I I t I I I WINDSOR CHAIR I I I I I I I I I I I Side view Front view t I t I I t I I I I I I I I I Top view thort apindlee apacedequally betweenlon1 opindleand arm poet 1ocketa in arm for lonq apindlee apaced 2'/o incheoapart MAKING THE SPINDLES indsorchairmakingstartswith a freshlycut log Becausegreen woodis swollenandlubricated with moisture, it iseasy to cleave andbend.It isalsolessworkto shape Splittingwood fromalogoffersotheradvantages First, it is stronger, because thebreakfollows thewoodfibersratherthanshearing them,asa sawmilldoes.And second, woodseasons betterif it isshaoed while stillgreen A chairspindle, foiexample, will season morequicklyandbe less proneto cracking thana board,which maycupor check Ifyou haveaccess to a woodlot,you canfellyourowntreesusinga chainsaw youmaybeableto obtain Otherwise, greenlogsfroma sawmill,a localfirewood supplier,or your local roads Youcanmakean entire department chairfromhardwoods likehickorywhite ash,or oak;butmanywoodworkers also usesoftwoods suchaspoplarandpine for theseat,whichareeasierto shape with handtools Theprocess described onthefollowing pagesfor riving,or splitting,a log into spindleblanlscanalsobeusedto producearm,leg,andstretcher blanks Oncea loghasbeencut into manageablelengths,it is time to split it Driving an iron wedgeinto theendof thelogwith a sledgehammer, asshown at left,will separate thewoodftbers alongthegrain Weareyeprotection whenyou strikemetalagainstmetal PREPARING THESPINDLE BLANKS a boltintoquarters Splifting I Onceyouhavefelleda logand trimmedoff the branches, sawit into workable lengths, calledbolts.Forbest results, usea chainsaw.Splittheboltsin hall (photo,abovd,usinga sledgehammerandironwedges; wearsafetygoggles throughout theoperation Tocleave the halves intoquarters, standthe pieceup, markthe centeron the endanddrivea wedgeintothe mark.Continue driving thewedgetighl untilthe boltsplits I I I I I I I I I I I I I I t I I I I I I I I t I t I t 74 I I I t I t WINDSORCHAIR I I t I I I t I I t I I I t I I I I I I I I I I I I I I I I r) Rivinga quarterboltintoblanks h a v es p l i ta b o l ti n t oq u a r t e r sr i,v ee a c hp i e c ei n t o I Onceyou s p i n d l eb l a n k sO u t l i n e t h e b l a n k so n t h ee n f t h e b o l ta n ds p l i t iI (above,left),thenrivethe blankswith a froeand a f roeclub m a d ef r o ma n B - i n c hl e n g t ho f d e n s eh a r d w o o sdu, c s m a p l e , -) Debarkins theblanks < h i c k o r yd, o g w o oodr e l m H o l d i n g t h e f r o ei n o n eh a n dw i t ht h e bladeoffsetfromtheoutline,strikethe bladewiththe club (above, ilghil.fwislthe froebackandforth,anddriveit in deeper.0nce t h e w a s t eb r e a k so f f, r e p e atto m a k et h e r e m a i n i ncgu t s r - J R e m o v eb a r kf r o my o u rb l a n k su s i n ga d r a w k n i f o en a i n b o t hh a n d sw i t ht h e b e v e dl o w n ,p u l l t h et o o lt o w a r dy o u h o r s e( p a g e/ B ) S e c u r e s h o p - b u i sl th a v i n g t h e w o r k p i e cbea r k t o s h a v eo f f t h e b a r k( a b o v e )T u r nt h e p i e c ea r o u n dt o d e b a r k s i d eu p u n d e rt h e h o r s e 'csr o s s b aTr h e n ,h o l d i n gt h e d r a w k n i f e t h e o t h e re n d I I I I WINDSORCHAIR SHAPING THESPINDLES ANATOMY OFSPINDLE -/,." dta +i i )/ l: ' ) i t t I I t I I I I I I I I t I t I t 'l '/ " dia '>i !Long epindle Rough-shaping thespindles I Secure a s p i n d l eb l a n ki n y o u rs h a v r nhgo r s ea n d u s ea d r a w k n i fteo s h a p e t h e s t o c ki n t oa t a p e r e dc y l i n d e rF o rb e s tr e s u l t st,h e g r o w t hr i n g so n t h e e n d g r a i no f t h e b l a n ks h o u l db e r o u g h lvye r t i c aS l t a r tb y s q u a r i nagn ds i z i n gt h e b l a n k Holding t h e d r a w k n i foen t h e b l a n kb e v esl i d ed o w n ,p u l lt h e t o o lt o w a r dy o u , a l w a y sf o l l o w i n tgh e g r a i n( a b o v e )K e yd i m e n s i o nasn d d i a m e t e rfso r t h e s e v e n l o n gs p i n d l eas n df o u rs h o r ts p i n d l eyso u n e e df o r a c h a i r ep r o v i d eidn t h e i l l u s t r a t i oant l e f t T u r nt h e b l a n ke n d - f o r - e nadn d r e p o s i t i oi nt i n t h e s h a v i n g h o r s ef r e q u e n t lsyo y o uc a ns h a p ei t u n i f o r m l yP e r i o d i c a cl l hy e c kt h e p i e c e ' s k e yd i a m e t e rwsi t hc a l i p e ros r a s h o p - m a dgea u g el i k et h e o n es h o w no n p a g e7 ( l f y o up r e f e ry, o uc a nt u r nt h e s p i n d l e o sn a lathea , s s h o w no n p a g e8 ) I I I t I t t I t t I I I WINDSORCHAIR t I I I I I I I I t I I I I t t I I I I I I t I I t I I I r) Evening outthe spindles L O n c ea l l t h e s p r n d l eas r er o u n d e d a n dt a p e r e du, s ea s p o k e s h a vt oee v e no u t t h e i rs u r f a c e sA d j u s t h e s p o k e s h a vf oer a v e r ys h a l l o w c u t H a n d l et h e t o o la s y o u d r dt h e d r a w k n i f ea,l w a y sw o r k i n gw i t h t h e g r a i n( a b o v ea)n d r e p o s i t r o n i tnhge w o r k p i e c ea s n e c e s s a rF y o r mt h e t e n o n sa t t h e b o t t o me n d so f t h e s p i n d l e w s i t k n i f e , r e f e r r i ntgo t h e a n a t o m yi l l u s t r a t i oonp p o s r t e jiiilIi ffi dr{il ffi tulil tiJill, iiiji$ ,u{lr,itrjdi d, 1HO?Tt? ,r: ShoV-madesizinggau6e // A ehog-made oizingqauge -'// alloweyouto meaeure trhe diamelersof chaireVindleeae youohapethem Soreholesinlo a wood ecrap,eizingLhemaccordinq to NhesVindleo' keydiameters Dnlla '/,.,-inch-diameLer holeinto the qaugeLo -/ -)t {,r-,2 checkNhetenon aI Lhe boLLomend of Lhe e p i n d l e ea, n d a / , , - i n c h - d i a m e t h ea r l ef o r t h e f , o Ve n d o f l h e o p i n d l e s Y o cua n a l s o c h e c ka k e y d i a m e l e r a l o n gL h e l e n q l h o f t h e e p i n d l e ob y b o r i n q a h o l et h r o u g h L h e q a u q ea n d e l i p p i n gI h e b l a n k introf,he hole.Ihe blankis lhe correcl diamet,erwhen iL j a m e i n N h eh o l ea I L h e a p p r o p r i a t ep o i n l a l o n qi t o l e n g f , h S m o o t h i nt hges p i n d l e s Q r - U s ea h a n ds c r a p etro g i v et h e s p i n d l e sa s m o o t hf i n i s h G r a s p i ntgh et h i c k e n d o f t h e s p i n d l ei n o n eh a n da n d , bracing t h e t h i n e n n a w o r ks u r f a c e , u s ey o u ro t h e rh a n dt o d r a wt h e s c r a p e r o r kr n t h e a l o n gt h e s u r f a c e( a b o v e )W d r r e c t i o on f t h e p r a r na n d r o t a t et h e spindle f r e q u e n ttl oy k e e pi t u n i f o r m I I I I WINDSORCHAIR I t Eridge 2" x 10"x 35" I I t Eench 3"x10"x72" I I t t Foot bar Adiuetment hole Pivoting arm aeaembly Erace 1'1"x3'/2"x13" Pivoting lag bolt Leg 2"x4"x19/2" I t I t I A SHAVIilG HORSE Theshaving horsegripsstocksecurely in placewhileit isshaped withdrawknivesandspokeshaves Simpleto horse features build,thetypicalshaving a bench, an inclined bridge, anda pivBystepping otingarmassembly down ontheassembly's footbar,youcanlock yourworkpiece in position between the bridgeandtheassembly's crossbar To buildtheversion shownabove, with bench, which canbe start the from half log 10 12 inches hewn a to in diameter, from rough orcutto length 3-by-10lumber Makethelengthof the benchto suityourneeds Next,cut the legsfrom2-by-4 stockandattachthemto the bench joints,reinforced T half-lap withangled byscrewsandbracestighil CutIhe twobracestrom2-by-4stockto fit between the leg'soutside edgesand screwthemto the legs.To bevelthe of the legssotheysit flat and bottoms level,settheshaving horse on a flat surfaceandbutta squareboardup against all foursidesof eachlegto markcuttinglinesaroundthem(page 79, above,/eft).Sawthe bottomsof the legsflat,thencutthetopsof the legsflushwiththebench Next,sawtheriserandthebridge to size;therisershouldbecut andbevis inclined eledsothatthebridge at an angleof about15'to thebench Locate the riserabout30 inchesfromthe backof thebenchandscrewit in place fromunderneath Thenscrewthebridge to the riser(page79, above,right)and thefrontof thebridge io the bench t I I I I I I I I t t I t I I WINDSORCHAIR t t I t I I I I t I I I t I I I I I I I I I I I I t I I I N e x tb, u i l dt h ep i v o t i nagr m T h e bly.Cutdadoes in thefootbarto match a s s e m b cl yo n s i s tosf t w oa r m s a, thenotches in thearms,fit thepieces notchedcrossbar,anda footbar together, andreinforce thejointswith (right)Thecrossbar is joinedto the screws Withthefootbarattached slio armswiththrough roundmortise and thearmassembly undertheshaving tenons, whilea bridlejointconnecis horseandscrewit in placewiththe thefootbarto thearms.Cutthearms from2-by-4stockandboretwocountersunk holes through eachoneforlag PIVOTINGARMAS?EMELY screws Makeadditional holes through the armsaboveandbelowthe f irst soyouwill beableto adlustthe positionof the assembly laterto accommodate thrcker stock.To oreoare the armsfor the bars,cut a roundmortisethrough themat thetopendand a notchat the bottom Next,cut thecrossbarto length, making it about3 inches longer than width the of the bench.Cutround in bothendsanda V-shaped tenons notchin themiddleof thebottom edge to holdyourstock.Setthecrossbar asidefor now.Next,cut thefootbar, m a k i n igt s l e n g t h t w i c et h a to f t h e crossbar to provide anoctagonal-shaped footrestoneachsideof thearmassem- 79 lagscrews Donottightenthescrews immediately; leave themloose enough soyoucanslipthecrossbar in place Do notglueor screwit, butleavethebar freeto pivot.Onceit isconnected to the arms,f inishtightening thelagscrews Lag screw I t QUEENANNE SECRETARY ASSEMBTING THECARCASE upthesides, bottom, andrails Gluing pieces I Cuttheremaining of thebookcasecarcase to size-the bottom,the rails,andthe backpanel.Next,sawa rabbet alongthebackedges of thesides andbottom forthebackpanel Cutblind tenonsat bothendsof the backrail (page 59 anddrilla matching mortise(page58) o n t h e i n s i d ef a c eo f e a c hs i d ep a n e l Witha platejoiner,makeslotsfor biscuits in thefrontandbottom rails,andmating onesin thesides Usehalf-blind dovetails (page109)Iojointhesidesto thebottom of thebookcase, cuttingthe pinsin the sidesandthetailsin the bottom Then glueon the contacting spread surfaces of all thepieces, inserting woodbiscuits whereappropriate, andf it themtogether Protecting the stockwithwoodpads, installtwobarclampsacross eachside, positioning theclampjawsonthefrontand backrails,theninstall twomoreclamps across the backandbottomrails.Tighten (left)untila thinglue theclampsevenly beadsqueezes outof thejoints.Finally, nailthebackpanel(page115)in place I I I I I t I I I I I t I I t I I t I I I I I I I I I r) Routing a groove forthetoppanel L to attachthetop panelto thebookcaseusingwoodbuttons, asshownin t h i ss e c t i o ny,o uw i l l n e e dt o r o u ta groove forthe buttons alongthetopof thecarcase Fityourrouterwitha piloted three-wing slotting cutterandsetthe tool'scuttingdepthto locatethegroove aboulYzinchbelowthe top edgeof the guide carcase Starting nearonecorner, the routeralongthe top edge(right) Movethetoolin a clockwise direction, keeping the baseplateflatandthe bit's pilotbearing pressed against thestock r32 t t I I t QUEENANNE SECRETARY I t t I t I I I I I I I I I I t t I I I I I t I I I t I I I Making thebuttons c u t o f f t h e b u t t o n sa b o u tI I i n c h e sf r o mt h e e n d s( i n s e f ,T) o m a k eh o l e si n t h e b u t t o nfso r i n s t a l l a t i ouns, ea n L - s h a p ecdo r n e r ^-^ j i g f a s h i o n efdr o ma s c r a po f I - i n c h p l y w o o a : c i n o p h n : r d m : L p t n p i h i c k n p c q n f t h p s r n a k e- lful o' I- r +L ^U r1fi,l ^t r E d n dt w o p i e c e so f OP l a m pt h ej r gt o y o u rd r i l lp r e s st a b l ea n ds t e a d tyh e b u t oetweerLnebottonof the grooveand Lie top edgeof the carcase w o o dC e t e a c he n f t h e n a d ef r o ms c r a pw o o d D r i l t h r o u g ht h e t o n sw i t h o l d - d o wm l e s sI i n c h C u ta r a b b etto f r t t h eg r o o v a s n t h e u n r a b b e t epdo r t i o nos f t h e b u t t o n s( a b o v e ) b o a r dt,h e nr i p t h e b o a r dr n t o1 - r n c hs t r i p so n y o u rb a n ds a wa n d c e n t e r o Vn, rinrill nppd tn n l : n p , ru u i n n d h r t t n n e v p n r i n r - h p s a l n n o t h p P'uuu t n n p c p e n f ' h e c a r c : s eC r r ts e v p r a l h v - l - i n r : hb l t r o n s f r o m Attaching thetop C l t h e b o o k c a steo p t o s i z e ,t h e t s h a n ei t s e n d sa r d e d g e so n a r o u t e r I a b l e( p a g eJ J ) , u s r n ga d e c o r a t t v e m o l d i n gb r t S e it h e t o p o u t s i d e - f a c e e n dp o s i t i o n tie d o w no n a w o r ks u r { a c a c a r c a soen l o n F i t t h e r a b b e t eedn f a w o o db u t t o ni n t ot h e g r o o v ei n o n eo f t h e s i d en a n e l a s n di r s e r ta n o t l e r r t ot h e p r o o v ier t h e b a c kr a i la b o u t inches a w a yD r i l la p i o t h o l et h r o u g thh eh o l e i r t i e b u t t o n di r t o t h et o p L h e ns c r e w a lt h e b u t t o n si n p a c e ( l e f t ) l,e a v i n g r n c hg a pb e t w e etrn e l i p p e de n d so f t h e b u t t o n sa n dt h e b o t t o no f t h e g r o o v e I n s t al t h e r e m a r n r nbgu t t o n ss.o a c ; n g t h e me v e r y6 i n c h e s QUEENANNE SECRETARY MAKING ANDINSTALLING CR()WN MOLDING 'l t Making themolding andattaching theframe - I F i x e dt o t h e u n d e r s i doef t h e b o o k c a steo p a n d f l u s h a g a i n stth e c a r c a s et h , e c r o w nm o l d i n gc o n s i s tos f t h r e el a y e r s ( i n s e t )C u tt h e m o l d i n gf r a m ep i e c e st o l e n g t hm , i t e r i n gb o t h e n d so f t h e f r o n i e c ea n dt h e f r o n te n d o f e a c hs i d ep i e c e C r e a t teh e b u i l t - u p m o l d i no g n t h e r o u t etra b l ea sy o ud i dt h e b a s em o l d i n g( p a g e1 ) ,u s i n gt w o d i f f e r e not g e eb i t sf o r t h e narrow a n dw i d e rp i e c e sC u tt h e m o l d i n gt o l e n g t hm , itering t h e p i e c e as sy o ud i d t h ef r a m eS t a r tb y i n s t a l l i nt g h em o l d i n g f r a m eF o rt h e s i d ep i e c e sd,r i l la n e l o n g a t ehdo l et h r o u g e c h b o a r dn e a rt h e s t r a i g het n d ;t o a l l o wf o r w o o dm o v e m e nst ,p r e a d g l u eo n o n l yt h e f i r s t2 i n c h e so f t h e t o p f a c ea t t h e m i t e r e d e n d N o w ,s e tt h e b o o k c a st eo p - d o w o n n a w o r ks u r f a c e and positioo n n es i d ep i e c eo n t h e u n d e r s i doef t h e t o p i n s t a l al b a rc l a m pt o s e c u r et h e m i t e r e de n d a n d d r i v ea w o o ds c r e w t h r o u g ht h e e l o n g a t ehdo l ea n d i n t ot h e t o p t o f i x t h e b a c ke n d ( l e f t ) R e p e afIo r t h e o t h e rs i d e ,t h e ni n s t a ltl h e f r o n i e c e s p r e a d i nggl u ea l o n gi t s e n t i r el e n g t h I I I I I I t I I t I t r I I I I I I I t r ) A p p l y i ntgh em o l d i n g f - l l e c r o w nn o d r n gr sf a s t e n e tdo t h e b o o k c a sien t w os t e p s : T h ew i d e rs t r i p sa r ea t t a c h e fdi r s t ,f o l l o w e d b yt h e n a r r o w e r p i e c e so n t o p S p r e a da t h i n l a y e ro f g l u eo n t h e b o t t o mf a c eo f t h e w i d e rs t r , p s t, a k n g c a r en o l L og e t a n yg l u eo n t h e e d g e s s i n c et h e m o l d t n sg h o u l n l yb e f i x e dt o t h e m o l d i n fgr a m e , a n d n o tt o t h e c a r c a s eS e tt h e s t r i p so n t h e m o l d i n gf r a m e , e d g e sf l u s g a i n stth e b o o k c a s em, a k i n gs u r et h a tt h e m i t e r e d e n d sb u t tt o g e t h ecr l e a n l yb e f o r ec l a m p i n g t h e m o l d i n gi n p l a c eO n c et h e a d h e s i vhea sc u r e dr, e m o vteh ec l a m p sa n d r e p e a t h e p r o c e s fso r t h e n a r r o w em r o l d i n gs t l p s ( r i g h t ) C u t t i n gw o o dp a d sw i t h c o n v e xc u r v e sm a t c h i n tgh e c o n c a v e p r o ifl e o f t h e m o l d i n w g i i l n o to n l yp r o t e ct th es t o c k b, u ta l s o h e r pd i s t r r b u ct e, a n p i n gp r e s s u reev e n l y 134 I I I I t t I I I I I I I I MAKINGTHEDOORS t I I I I I I I I I I I I I I I I I I I t I I I I I I I t An escutcheon isfastenedto oneof the shownat left.On doorsof thebookcase are thispiece,thekeyand escutcheons purelydecorative Thedoorsareactually catches heldshutbyspringJoaded on the inside installed facesof thestiles bottom of the doors nearthe DOORS MAKING FRAME.AND.PANEL thetenonin therails Gutting on the doorsof the bookcase in a testmortise(step4), thenrepeatthe process I Startmaking theframe-and-panel bycuttingblindtenonsat theendsof all therails.To dothe otherendof the boardandontheotherrailshbove,left).To jobon yourtablesaw,installa dadoheadslightly setthecuttingheightat about% widerthan cutthetenonshoulders, the mitergauge woodfenceandnotchit inch.Then,withtherailfaceflushagainst Attachan auxiliary thetenonlength thefence,feedtheworkpiece andtheendbuttedagainst by raising thedadoheadintoit Setthewidthof cut equal thecut on the intothe blades Turntherailoverandrepeat to thetenonlengthandadjustthecuttingheightto about right).Cutthe restof the tenonshoulders therailflush otherside(above, of thestock.Holding one-third thethickness molding ontheinsideedges integrated against the mitergaugeandthefence,feedthestockface- thesameway.Fashion Turnthe board of the doorframeson a routertable(page129) usinga pilotdownintothe blades to cut onetenoncheek e d m o l d i nbgi t overandmakethesamecut on theotherside.Checkforf it 135 QUEEN ANNE SECRETARY r) Preparing therailsforglueup Z- me corners of thetenonshoulders mustbe mitered to mateproperly with thestiles Remove theauxiliary fence from thetablesawfenceandinstall a crosscut or combination blade Settheblade angle to 45",makea testcut in a scrapboard, andchecktheresult witha combination s q u a r eA.d j u stth ef e n c ep o s i t i oann d b l a d eh e i g hst ot h ec u t i s a sw i d ea n d d e e pa st h ew i d t ho f t h ee d g em o l d i n g (Thebladeteethshouldjustprotrude beyond thetenonshoulder.) Tomakethe cuts,holdthepieceflushagainst thefence andmitergaugeasyoufeedit edgedown i n t ot h eb l a d eR e p e at ht ec u t so nt h e endsof eachmolded edgeof theremainingrails(left) I t t I t t : I I I I t I I I I T I I I I I I I I I Notching thestiles L e a v et h e t a b l es a wb l a d ea n g l e da t " , m e a s u rteh e w i d t h the45" cut andeachendof thestilewitha bandsaw(above, of eachrail,andmarka lineonthemolded edgeof itsmating stilea conesponding distance fromtheend.Cutintothemolded edgeat theline,making certain thatthecutwillnotmarthe faceof thestile.Sliceoff mostof thestripof molding between /eff).Smooth thecutedgeusingthetablesaw.Leaving therip fencein place, holdthestileflushagainst themitergauge, and slidethestockbackandforthacross the blade(above, righD Repeat theprocess forallthestiles r36 t T T I I I I I I I I I I I I I I I t I I I I t QUEEN ANNE SE,CRETARY mortises inthestiles Cutting youcutinstep1 Useoneofthetenons a s a g u i d et o o u t l i n i n gt h e m o r t i s eos n ihp pdops of thp stiles pacipr l:mn Tn m:kc thp ioh a l l i h p c t i l p s t, n o p t h c r f a c p t o f a c ew i t ht h e i re n d sa l i g n e dI.n s t a lal mortisina g t t a c h m e notn y o u rd r i l l p r e s s a n dc l a m po n es t i l et o t h e f e n c e c, e n t e r i n gt h e m o r t i s o e u t l i n eu n d e tr h e c h i s e l a n d b i t M a k et h e d r i l l i n gd e p t hl i n c h ; a k ea c u t a t m o r et h a nt h e t e n o nl e n g t hm e a c he n f t h e m o r t i s eb e f o r eb o r i n go u t t h e w a s t ei n b e t w e e n( / e f t ) R e p e at h e p r o c e d u rteo c u t t h e r e m a i n i n m g ortises t I I I I I I I I I I t I I Gluingupthe doors f, r - , 1T e s t - a s s e m btl he e d o o r sa n d u s ea c h i s e lt o p a r ea w a y s o m ew o o df r o m a n y o v e r l yt i g h t j o i n t O n c ey o u a r es a t i s f i e d w i t h t h e f i t , s a n da n ys u r f a c etsh a t w i l l b e d i f fi c u l tt o r e a c h g l u eo n a l l t h e w h e nt h e d o o r sh a v eb e e ng l u e du p ,a n ds p r e a d c o n t a c t i nsgu r f a c eosf t h e l o i n t s R e a s s e m btlhee d o o r sa n ds e t e a c ho n eo n t w o b a rc l a m p sa, l i g n i n g t h e b a r sw i t h t h e r a i l s U s i n gw o o dp a d st o p r o t e c t h e s t o c k ,t r g h t e nt h e c l a m p s ( a b o v eu) n t i la t h i n g l u eb e a ds q u e e z eosu t o f t h e j o i n t s t37 t I QUEENANNE SECI{ETARY I INSTALLING THED()ORS 'l I Preparing thedoors forglass I C i a s sp a n e l sl i e i n r a b b e tasn da r e h e l di n p l a c eb y t h i ns t r i p so f m o l d i n g C l a m po n ed o o rf r a m et o a w o r ks u r f a c e , t h e ni n s t a lal p i l o t e d - i n c hr a b b e t i nbgr r i r y o u rr o u t e ' a n o s e tt h e d e p t ho f c u tt o t h ec o m b i n etdh i c k n e sos' t h e g l a s sa n d t h e m o d r n g H o l dt h e t o o lf i r m l yw i t h b o t hh a n d sw h i l er e s t r ntgh e b a s ep l a t e o r t h ef r a m en e a ro ec o r n e rt,n e ng u i d e the hit into lhp insidpedsp of lhp dnnr M o v et h e r o u t e cr o c k w i s ae l o n gt h e e d g e si / e I l ) ,k e e p i n g r h e p i l o tb e a r i n g p r e s s eadg a i n st th es t o c kS q u a r teh ec o r n e r sw i t c h r s eal n da w o o d e n mallet R e p e af to rt h e s e c o n d o o r I I I I I T I I I r I I I I I I t I r ) M a k i n gt h em o l d i n g L C u ta o o a r dl o n g etrh a ny o l w i l l n e e d f o r t h e m o l d i n gt ,h e ni n s t a lal : / , - i n c i c o v eb i t i n y o u rr o u t e n d m o u n t h e t o o l i n a t a b l eA l i g nt h e b i t b e a r i nw g i t ht h e f e n c ea n d a d j u s t h e c u t t e rh e i g h t o s h a n et h e b o t t n mr - n r n eO" f L h es t o c k M o u na t f e a t h e r b o aorndt h et a b l ei n l i n e w i t ht h e b i t t o s e c u r et h e s t o c kd u r i n g t h e c u t T u r no n t h e t o o la n df e e dt h e s t o c k f, i n i s h r ntgh e p a s sw i t p u s h s t i c k S h a p et h e o t h e re d g eo f t h e b o a r d r pt h e m o l d i n g t h e s a m ew a y ( r r g h t )R f r o mt h e s t o c ko n t h e t a b l es a wa n dc u t t h e m o l d i n tgo l e n g t hm , i t e r i ntgh e e n d s a t ' C u La n df i r o n ep i e c ea t a t i m e I t I I I t t I I r38 t I I I I QUEENANNE SECRETARY I I t I I I t I I I I I I t I I I I -) Installins thedoorcatches < r J B e f o r ei n s t a lnr g t l ' e g a s s m o u n t h e d o o r so n t h e b o o k c a s ea , t t a c h i ntgh e mw i t h h l n g e st h e s a m ew a yy o uf a s t e n etdh e f a l l - f r o ntto t h e d e s ku n t ( p a g e1 ) f t i s e a s i etro i n s t a ltlh e s i t h o ut h e g l a s si n p l a c eT h eb a l lc a t c h e s h o w n d o o rc a t c h e w a b o v ef e a t u r ea c a t c hf a s t e n etdo t h e b o t t o mp a n eol f t h e b o o k c a s ea n da s t r i k eo l a t es c r e w e tdo t h e i n s i d ef a c eo f t h e d o o r t h es t r i k e s t e s ;t w o s p r i n g - i o a d b ea d l l si n t h e c a t c hc a p t u r e p a t ew h e nt h e d o o ri s c l o s e dA s s e m b lteh e c a t c h e sh, o l n e i n p o s i to n a g a i n sitt s d o o rs t i l e ,t h e nm o v ei t t o w a r dt h e b a c k n a n ehl v i n c r a n dm a r kt h es c r e wh o l e sD r r lal n i l o th o l ea t e p e atth e m a r k i n g e a c hm a r ka n ds c r e wt h e c a t c hi n p l a c e R (above, process for the othercatch.To install left) andfastening i L w i t ht h e c a t c h ,a n d t h e s t r i k ep l a t e i n s e r itt s s c r e w se,n g a g e s r l r n a r kr m p r e s s ' o trsn c o s et n e d o o r t: h e t i p so f t h e s c r e w w t h e d o o rs t r l e D r r l la p i l o th o l ea t e a c hm a r ka n df a s t e nt h e c t r r k o n l : t p t n t n p d n n r P\ C^ ^p g^o^t + +l U^l - +L lLl g^ U^ L+I hC^l - ^p ltO^L, g^ (t rau hv vnwv, p rt it tot ht Ll ) t I I I Securing theglass Unscrew t h e d o o r sf r o mt h e b o o k c a s e a n ds e to n ed o o ri n s i d ef a c eu p o n a w o r k crrrf:np Cardboard cam i n t h e d o o rf r a m et o p r e v e nt it e g l a s sf r o m ralllinq I I Spl lhp ol:c.c.:nd rhp mnldino in p l a c ea n d s t a r n L g r n c h efsr o n I h ec o r n e r sd r r l nl i l o h - o l ea s t6 r n c h , n t e r v a l s t h " o r r pt h e r r o l d i n a p n di n t ot h ef r a m e T a c kd o w "rrh e r r o l dr g w t h b r a d su s i n g I : nipnp nf e:rdhn:rd tn nrntpei thp oL:cq f r o mt h e h a m m e(rl e f t ) I of i n i s ho f f t h e t q p r p ' : ' r r r' up, i n, JsL tu ," r l ltL h" Lc d u un g J ' I I I Spr : drnn of clp:r olstins n n r r n d p v p r v f p r n ri n e h p q : l n n o i h p r : h h p i 139 GLOSSARY A-B-C.D Adze: An ax-like tool with a curved blade used to carve out concave surfaces,such aschair seats Auxiliaryfencs A wooden attachment screwedto the rip fence of a table saw or other machine,to prevent damage to the metal fence Basemolding: A decorativeframe made from molded stock that supports the bottom ofa desk Bead: A rounded, convex shapecut in wood, usually for decorationi seecove Bending form: A jig used to bend steamedwood Bookmatching: In veneering,a decorative pattern in which successive veneers cut from the samelog are arrangedsideby-sideso as to mirror eachother's image like pagesof an open book Bow: The curved upper rail of a sackback Windsor chair Brad-point bit: A drill bit featuring a sharpenedcenterpointand two cutting spurs on its circumference;produces cleanerholesthan a twist bit and does not tend to skateon the surfacewhen starting a hole Carcase:A pieceof furniture with a boxlike construction;madefrom solidpanels Caul: Used in veneering or gluing up carcases,a board placed between clamps and the workpiece to distribute clamping pressure Chamfer: A bevel cut along the edge of a workpiece Clearancehole: A hole bored in a workpieceto allow free passage of the shankof a screw Corner block A triangular block of wood screwedto an inside corner of a table'sleg-and-railassemblyto reinforce and squarethe joint Counterbore: To drill a hole so the head of a screwor bolt will sit below the wood surfaceand be concealedwith a wood plug Countersink: To drill a hole so the head of a screwwill lie flush with or slightly below the wood surface Cove:A concavedecorativeprofile cut in wood, usuallyalong an edge;seebead Crown or cornice molding: Molding attachedto the top of a pieceof furniture Cuttinglist A list of the dimensionsof the lumber neededfor a specificproject Dado.:A rectangularchannel cut into a worKplece Dovetailed halfJap joint: Used for joining the top drawer rail of a table to the legs;the half-lap at the end ofthe rail is cut in a dovetail shapeto lock the joint in tension Dovetail joint: A method of joinery using interlocking pins and tails; the name derivesfrom the distinctive shape cut into the endsofthe joining boards Drop-leaf tabls A table with a narrow top and hinged leavesthat fold down when not in use Dust frame: A flat frame used to support deskdrawers CheelcIn a mortise-and-tenonjoint, that part of the tenon parallelto the wood grain and perpendicularto the shoulder E-F.G-H-I-I Escutcheon:A metal plate installed around a keyholefor decoration and protectionof the surroundingwood Falsefront A pieceof wood installed over a drawer front, usuallyto conceal the end grain ofthe sides Featherboard:A board with thin, flexi"feathers" ble fingersor along one end, clamped to the fenceor table of a stationary tool to hold the workpiece securely Fillet In a rule joint, the short, flat surface at the top ofthe rounded-overportion of the joint; the pins of the rule-joint hingesare alignedwith the fillet Finial: An ornament-usually turned or carved-projecting from the upper cornersof a pieceof furniture Flyrail A short wood piecethat swings out from a table side rail to support a drop leaf Froe: An L-shapedtool with a beveled blade that is struck by a club to rive, or split,greenwood Glass-stopmolding: Decorativestrips of wood usedto hold a pane of glassin placein a door Green wood: Freshlycut, unseasonedwood Half-blind dovetail: Similar to the through dovetailjoint, exceptthat the pins are not cut through the entire thicknessof the workpiece,thus concealingthe end grain of the tail boards Inlay A decorativestrip of metal, hardwood or marquetry that is glued in a groove cut into a workpiece I I I I I t t I I I I I I I I t I I I I I I r I t I r 140 I I I I t I I I t I I I I t I I I I I t I I I I I I I I I I I I I I I I t K-r-M-N-O-P-Q Kerf, A cut madein wood by a sawblade Kickback The tendencyof a workpiece to be thrown back in the direction of the saw operator by a moving blade or cutter on a woodworking machine or tool Knuckle joint: A joint consistingof interlocking fingersfixed togetherby a wooden pin; enablesa fly rail to pivot awayfrom a table side rail Lamb's tongue: On a pencil-postbed, the shapeat the bottom ofthe octagonal portion ofa bedpost Loper: On a slant-top desk,a board that slidesout of a housing to support the fall-front in the horizontal position Mortise-and-tenon joint A joinery technique in which a projectingtenon on one board fits into a mortise on another Mortise: A rectangular,round, or oval hole cut into a pieceof wood to receive a matching tenon Neoclassicism:An l8th-Century design movement inspired by the estheticprinciplesof classicalGreeceand Rome Pigeonhole: A framework of small dividers and drawersin a desk:sometimes removable Pilot bearing: A cylindrical metal collar either aboveor below the router bit's cutting edgethat rides along the workpieceor a template,guiding the bit during a cut Pilot hole: A hole bored into a workpiece to accommodatea nail shaft or the threadedpart of a screw;usually slightly smallerthan the fastenerdiameter.The hole guidesthe fastenerand preventssplitting Pocket holq An angledhole bored into the faceof a workpieceand exiting from its top edge Steambending: The techniqueofsoftening wood for bending by subjectingit to steamand heat,and then bending it around a curved form Pommet A rounded shoulderproduced on the lathe;servesto separatesquare and cylindrical sectionsof a workpiece Stile: The vertical member of a frameand-panelassembly;seerail R.S Rabbet A steplike cut in the edgeor end of a board; usually forms part of a joint Stopped dado: A dado that stops before crossing the full width or thickness of a workpiece RaiL A board running alongthe bottom edgeof a tabletopto which the legscan be attached;also,the horizontal member of a frame and panelassembly;seestile Substrate:A piece of plyr,voodor solid wood used as the foundation for veneeror leatherthat coversthe surfaceof a desktop Rake angle: The angleat which a chair leg or post deviatesfrom the vertical when viewed from the side of the chair: see splayangle T-U-V.W.X.Y-Z Reveal:The gap betweenthe outside surfacesofa table rail and the adjoining legs;servesa decorativepurpose Tenon: A protrusion from the end of a board that fits into a mortise Riving: The techniqueof splitting wood from a freshly felled Iog with a sledgehammer and wedgesto separatethe wood along the fibers Rule joint A pivoting joint commonly usedin dropJeaf tables;featuresmating concaveand convexprofiles cut into the edgesofthe tableleafandtop Shoulder: In a mortise-and-tenonjoint, the part ofthe tenon perpendicularto the cheek.In a dovetailjoint, the valleys betweenthe pins or tails Sliding dovetail joint A joinery method in which a dovetailedslide on one oiece fits into a matchinggroovein the oiher Splay angle The angleat which a chair leg or post deviatesfrom the vertical when viewedfrom the front of the chair: seerake angle Template A pattern cut from plywood, hardwood, or particleboard used to produce multiple copiesof a part Tester: A light framework that joins the tops ofthe bedpostsin a four-posterbed, often usedto hang a canopyor drapery Through dovetail joint A method of joining wood at the cornersby means of interlocking pins and tails,both cut through the thicknessof the workpiece Travishen A type ofspokeshavedesigned for smoothing concavesurfaces Urn: A decorativeelementturned in spindle work; often part of a finial Veneer: A thin layer of decorative wood usedto dressuD a more common speciesofwood Wood button: A small, square-shaped block with a rabbet at one end that is used to securethe top of a piece of furniture Wood movemenfi The shrinking or swelling of wood in reaction to changes in relative humidity Plate joint A method of joining using oval wafersof compressedwood that fit into slotscut in mating boards t41 t I INDEX in italicsindicatean Pagereferences illustration of subjectmatter.Page references in bold indicatea Build It Yourselfproject Cutting lists Pembroketables,25 Secretaries, 108 Windsor chafts,72 A-B.C Adzes,backendpaper Americancountry/colonialstyles, 16-19 SeealsoFour-posterbeds;Shaker style;Windsor chairs Armoires,19 Arts and craftstables,21 Beds.SeeFour-posterbeds Bendingjigs,82 Biscuitjoints, 109 Blanketchests,20 Block-frontchests,l3 Board feet,front endpaper Bookcases SeeSecretaries Build It Yourself Pipesteamers,83 Pocket-holejigs,47 Shavinghorses,78-79 Veneerpresses, 125 Cabriolelegs,12 Card tables,12, 14 Chairs Americancountry/colonial,16,18 Chippendale,l3 Federalperiod, 14 Missionstyle,2l QueenAnne,12 Shaker,20 SeealsoWindsorchairs Chair tables,16 Chests Chippendale,13 Shaker,20 ChineseChippendalestyle,I3 Chippendale, Thomas,23 Chippendalestyle,13 Commodes Chippendale,13 Continuous-armchairs.18 Cornercupboards,17 Crown molding, 134 Cupboards Americancountry/colonial,17,19 Piesafes,20 D-E-F Desks Federalperiod,15 Mission style,2l SeealsoSecretaries Drop-leaf tables,20 135,front endpaper Escutcheons, Federalperiod style,14-15 SeealsoPembroketables Finishes Milk paint, 70, 103 Four-posterbeds,16,48-50 Canopies,49 End boards,59-62,64 Gluing up,64 Posts,51,52-56,64 finials,51,57 mortises.58 pencilposts,66-69 tang joints,49,56 Siderails,62-63 Testers, 51,65 Tools,52 usingpresetcalipers (ShopTip), 54 Frame-and-panel construction doors,135-1i9 Glass-panel Frenchprovincialarmoires,19 Furniture styles Americancountry/colonial,16-19 four-posterbeds,48-69 Windsorchairs,70-103 Chippendale,l3 Federalperiod, 14-15 Pembroketables,15,22-47 Mission style,21 QueenAnne,12 secretaries 104-139 Shaker,20 G-H Germansawbucktables,19 Greene,Charles Chairs,2l Greeneand Greenechairs,2l Half-blinddovetails.109-1 11 r Hardware,fr ont endpaper Bedbolts,59 Escutcheons, 135 Locks,127 Highboys QueenAnne,12 Hutches Americancountry/coloniaI, 17 I-I-K lnlays,front endpaper veneers.29 Commercial Pembroketables,27-29 Inshaves,backendpaper Iigs Bendingjigs,82 Drill presspocket-holejigs,47 Routers,119-120 Shop-madeshelf-drillingj igs (ShopTip), 131 Shop-madesizinggaugesfor spindles(ShopTip), 77 Tablesawtaper jigs,26 Ioinery Half-blind dovetails,109-1I Knucklejoints,25,30-31 Platejoints,109 Rulejoints, 43 Tangjoints,49,56 Throughdovetailjoints, l16 Kassay, lohn,6-7 Keyed-tenon stools,l6 Knucklejoints,25,30-i1 L-M-N.O Ladder-back chairs.l6 Langsner,Drew Windsorchair,18 Locks 127 Secretaries, Logs Splitting,74 Lumber Board feet,front endpaper SeealsoCutting lists Milk paint, 70, 103 Mirrors Federalperiod,15 Missionstyle,21 Neoclassical style.SeeFederal periodstyle New Mexicanchairs,19 Oval-backchairs,l8 I I I I I I I t t I t I r r t t I I I t I I I r I I I t42 t r I I I I I I I I I I I I I I I I I I t I I I I I I I t I I I I I P-Q Paint,70, 103 Pembroketables,15,22-25 Cornerblocks,40 Cutting lists,25 Drawersr23r 4l falsefronts, 42 runners,4l Endrais,34-36 drawerrarls,34,35 veneer,36 Gluing up,37-40 Joints knucklejoints,25,30-31 rail-to-leg,25 Leaves, 23,44-45 Legs,23,26-27 doublemortises,35 dovetailsockets,34 inlay,27-29 rail mortises,37,i8 Siderails,30-33 fly rails,32 tenons,33 Tops,43-46 rule joints, 43 using steeltabletopfasteners (ShopTip),46 Phyfe,Duncan, 14 Phyfearmchairs,14 Piesafes,20 Pipesteamers,83 Platejoints,109 QueenAnne style,I l, 12 SeealsoSecretaries R-S.T-U Riving greenwood,,74-75 Rocki-n[chairs Mission styLe,2l Shaker,20 Roll-topdesks,2I Rulejoints,43 Sack-back Windsorchairs SeeWindsorchairs Sawbucktables,l9 Secretaries, 12,104-105 Bookcases, 107 assembly, 132-133 crown molding, 134 doors,135-139 shelving,130-131 shop-madeshelf-drillingjigs (ShopTip), r31 Cuttinglists,108 Deskunits, 106,109 assembly, 113-115 bases,128-129 drawers.116-118 dustframes.I 12 fall-fronts,105,121- 124,126-127 half-blinddovetails,109-1 11 leathertops,121 locks,127 lopers,l15 platejoints, 109 throughdovetailjoints, Jl6 veneer,105,122-124,125 |oinery,105,109-I 11, 116 Pigeonholeunits, 105,119-120 14,18 Settees, Seymourdesks,l5 Shakerstyle,20 Sharpening, backendpaper Shavinghorses,78-79 Shelves Bookcases, 130-131 shop-madeshelf-drillingjigs (ShopTip), l3l ShopTips,46,54,77, 131 Spindles Shop-madesizinggauges (ShopTip),7Z SeealsoWindsorchairs Spokeshaves, backendpaper Steambending,S0 Bendingjigs,82 Pipesteamers,83 Stickley,Gustav,2l Stickleyrocking chairs,21 Stools Americancountry/colonial,16 Shaker,20 Styles.SeeFurniture styles Tables Americancountry/colonial,16,17 Chippendale,13 Federalperiod, 14-15 Germansawbuck,19 Mission style,2l QueenAnne,12 Shaker,20 Tangjoints,49,56 Thverntables,17 Teatables,l3 r43 Through dovetailjoints, 116 Tools Adzes,backendpaper Inshaves,backendpaper Sharpening, backendpaper Spokeshaves, backendpaper Turning bedposts,52 usingpresetcalipers(Shop Tip),54 Vacuumpresses, 36, 123-124 Trestletables,I Z v-w-x-Y-z Vacuumpresses, 36,123-124 Vandal,Norm, l0-11 Veneers lnlays,29 Patterns,122 Vacuumpresses, 36,123-124 Veneerpresses, 125 Weidman,Gregory,8-9 Window seats,14 Windsorchairs,18,70-73 Arms,80-82 posts,88-89,97 spindlemortises,98-99 Bows,80-82, 100-102 Cutting lists,72 Gluingup, 94,95-96,99,102 Legs,88-89 splayand rakeangles,73,91 stretchermortises,94 stretchers, 88,92-93 trimming,94 Milk paint, 70, 103 Seats,7l,84-87 legmortises,90-9I Spindles blanks,74-75 installing,98-102 shaping,T6-77 shop-madesizinggauges (ShopTip),7Z Wood Board feet,fr ont endpaper Green.74-75 SeealsoCutting lists Zoar chairs.19 ACKNOWTEDGMENTS Theeditorswishto thank thefollowing CLASSICAMERICAN FURNITURESTYLES Winterthur Museum,Winterthur, DE PEMBROKETABLE AdjustableClampCo.,Chicago,IL; Albert Constantineand SonInc.,Bronx,NY; AmericanTool Cos., Lincoln, NE; Black& Decker/EluPowerTools,Towson,MD; CMT Tools, Oldsmar,FL; Delta InternationalMachineryiPorter-Cable, Guelph,Ont.; GreatNeckSawMfrs Inc (BuckBros.Division), Millbury, MA; LesRealisationsLoeven-Morcel,Montreal, Que.;Sears,Roebuckand Co., Chicago,IL; StanleyTools,Division of the StanleyWorks, New Britain, CT; Tool Trend Ltd., Concord,Ont.; Vacuum PressingSystemsInc., Brunswick,ME; WainbeeLtd., Pointe Claire,Que./DE-STA-CO, Troy, MI; The Woodworker'sStore,Rogers,MN FOUR-POSTERBED AdjustableClamp Co., Chicago,IL; AmericanTool Cos.,Lincoln,NE; CMT Tools,Oldsmar,FL; Delta InternationalMachinery/Porter-Cable, Guelph,Ont.; GreatNeck SawMfrs Inc (Buck Bros Masse,Montreal,Que.;PackardWoodworks,Tryon, NC; RecordTools, DMsion), Millbury, MA; Jean-Pierre Inc.,Pickering,Ont.; RyobiAmericaCorp.,Anderson,SC;Sears,Roebuckand Co.,Chicago,IL; Stanley WV Tools,Division of the StanleyWorks, New Britain, CT; WoodcraftSupplyCorp.,Parkersburg, WINDSORCHAIR AdjustableClamp Co., Chicago,IL; Anglo-AmericanEnterprisesCorp., Somerdale,NJ; Mike Dunbar, Portsmouth,NH; GreatNeck SawMfrs Inc (Buck Bros.Division), Millbury, MA; Drew Langsner, Marshall,NC; LeeValleyTools,Ltd., Ottawa,Ont.; Olde Mill CabinetShoppe,York, PA; StanleyTools, Division of the StanleyWorks, New Britain, CT QUEENANNESECRETARY AdjustableClamp Co., Chicago,IL; Albert Constantineand Son Inc., Bronx, NY; AmericanTool Cos., Lincoln,NE; CMT Tools,Oldsmar,FL; DeltaInternationalMachinery/Porter-Cable, Guelph,Ont.; GreatNeckSawMfrs Inc (BuckBros.Division),Millbury, MA; David Keller,Petaluma,CA; LeeValleyTools, Ltd Ottawa,Ont.; LesRealisations Loeven-Morcel, Montreal,Que.;Sears,Roebuckand Co.,Chicago,IL; Steiner-Lamello A.G Switzerland/Colonial SawCo., Kingston,MA; Tool Trend Ltd., Concord,Ont.; Inc.,Brunswick,ME; WainbeeLtd.,PointeClaire,Que./DE-STA-CO, Troy, MI VacuumPressing Systems Thefollowingpersonsalsoassisted in thepreparationof this book: LorraineDord, SylvieGirard, SolangeLaberge,GenevidveMonette,David Simon PICTURE CREDITS Cover RobertChartier 6,7 Ron Levine 8,9TomWolff 10,11RobertHolmes 14,16Courtesyof The HenryFrancisdu PontWintherthurMuseum 18 Martin Fox t44 I I I f I I I I I I ; t I I I t I I t t I I I I I I t I I I I r I I I t t I t I I I I I I I I I I I I I I I I I I I I I I I I t W O R K S H OGPU I D E SHARPENING SP()KESHAVES Sharpening thebladeof a woodenspokeshave R e m o vteh e b l a d ef r o mt h e h a n d l eb y p i n c h i n g t h e t a n g st h a t p r o t r u dteh r o u g h t h e h a n d l ea n dp u s h i n tgh e md o w n w a r dF.o rs h a r p e n i ntgh,e b l a d ei s h e l dw i t h the tangsfacingdown.To preventthe tangsfromcatchingon yourworksurface, setyoursharpening stoneatopa woodblockto provide the necessary clearance H o l d i n tgh e b l a d eb yt h e t a n g ss, e ti t s b e v efll a to n t h e s t o n eB e c a u steh e b l a d e i s l o n g etrh a nt h e w i d t ho f y o u rs t o n e h , o l dt h e c u t t i n ge d g ed i a g o n a l a l ys y o u s l i d et h e b e v e bl a c ka n df o r t ho n t h e s t o n e R e p e awt i t ht h e b l a d ea n g l e dt h e o t h e rw a y R e p e aat g a i nw i t h t h e b l a d eh e l ds t r a i g hbt b o v e ) n c e t h es h a r p e n i n g i s c o m p l e t et u , r nt h e b l a d eo v e n d h o n et h e f l a t s i d et o r e m o v teh e b u r r f o r m e db y t h e s h a r p e n i npgr o c e s s Honing thebladeof a metalspokeshave To removethe bladefromthe spokeshave, l o o s e tnh es c r e wi n t h e m i d d l eo f t h e h a n d l e Set up a benchstoneon a worksurface;a w a t e r - l u b r i c a tdeida m o n ds t o n ei s s h o w n a b o v eI.n s t a l l t h e b l a d ei n a c o m m e r c i a l h o n i n gg u i d e L u b r i c a t teh e s t o n ew i t h w a t e n dt h e n ,h o l d i n tgh e h o n i n gg u i d e , s l i d et h e b l a d eb a c ka n d f o r t hf r o me n dt o e n da l o n gt h e s h a r p e n i nsgu r f a c eA p p l y m o d e r a tper e s s u rwei t ht h e b e v etlo u c h i n g t h e s t o n eT h e nr a i s et h e a n g l eo f t h e b l a d e a f e wd e g r e easn dc o n t i n u eu n t i ly o uf o r ma s e c o n d a rbye v e l - o rm i c r o b e v e l SHARPENING ANINSHAVE SHARPENING ANADZE H o n i na gni n s h a v e C l a m pt h e i n s h a vteo a w o r ks u r f a c seo t h ec u t t i n ge d g ei s f a c i n gu p ,a s s h o w n above.Usea slipstone to honethe edge.Startwith a rough-grit stoneand progress t o a f i n e ro n e W o r kw i t c i r c u l am r o t i o nu n t i la u n i f o r ms h i n ed e v e l o posn t h e b l a d eG i v et h e f l a ts i d eo f t h e b l a d ea f e ws t r o k etso r e m o v a e n yb u r r O n c et h e b l a d ei s s h a r pp, o l i s ht h e b e v ew l r t l e a t h esrt r o pa n dp o l i s h i ncgo m p o u n df i,n i s h i n gw i t f e wp a s s eosn t h e f l a ts i d eo f t h e b l a d et o r e m o v teh e b u r r l f t h e inshavehasa knife-edgebeveled on bothsides-honebothsides H o n i na g na d z e S e c u r et h e a d z ei n a b e n c hv i s e ,a s s h o w n a b o v eW r a pa s h e e to f e m e r yp a p e r o u n d a d o w ew l h o s ed i a m e t ecr l o s e l ym a t c h e s t h e c u r v eo f t h e a d z eb l a d eH o n et h e c u t t i n g e d g eu s i n ga b a c k - a n d - f o rmt ho t i o na l o n g t h e l e n p t ho f t h e h e v e l H o n et h e f l a t s i d e o f t h e b l a d ew i t h a s l i p s t o n teo r e m o v ea n y b u r r l f t h e a d z eh a sa k n i f e - e d g eh,o n e bothsides ... above,/eft).Sawthe bottomsof the legsflat,thencutthetopsof the legsflushwiththebench Next,sawtheriserandthebridge to size;therisershouldbecut andbevis inclined eledsothatthebridge at an angleof about15'to thebench... together-at thetop endsof thelegs ,the to start drilling theholestraight bottomsof the arm posts,and at both I the inch before tilting the endsof the stretcheri-are taperedto for first'/ lock the. .. thebench Locate the riserabout30 inchesfromthe backof thebenchandscrewit in place fromunderneath Thenscrewthebridge to the riser(page79, above,right)and thefrontof thebridge io the bench t I I