02. April 2002.pdf

THE ONLY MORTISING JIG YOU’LL EVER NEED

6 SIMPLE STEPS TO MAKE YOUR JACK PLANE WORK RIGHT

APRIL 2002

ISSUE #127

TOOL

CABINET

Built for a

LIFETIME of

Woodworking

CRITICAL

RULES

for Buying

a Compressor

$30

LUMBER RACK

Super-sturdy

Weekend Project

www.popwood.com

$4.99 U.S. $7.99 CAN

PLUS Outdoor Morris Chair

Shaker Storage Cabinet • Knockdown Bookcase

04>

71486 01355

ULTIMATE

Actor Dan Haggerty

with Ben, Stars of

“Grizzly Adams”

PURVEYORS OF FINE MACHINERY ™ – SINCE 1983

MODEL G8794

12 1 ⁄ 2 " Portable Planer

MODEL G1021Z

15" Planer w/ CABINET Stand

• 3 H.P., 220V, S INGLE -P HASE M OTOR

• P RECISION G ROUND C AST I RON B ED

• C UTTERHEAD S PEED : 5000 R.P.M.

• R ATE OF FEED : 16 F.P.M. & 20 F.P.M.

• M AX . C UTTING W IDTH : 14 7 ⁄ 8 "

• M AX . C UTTING H EIGHT : 6 1 ⁄ 8 "

MODEL G1033

20" Planer

• 3 H.P., 220V, S INGLE -P HASE M OTOR

• T ABLE IS P RECISION - GROUND TO A M IRROR - LIKE F INISH

• C UTTERHEAD S PEED : 4833 R.P.M.

• R ATE OF FEED : 16 F.P.M. & 20 F.P.M.

• M AX . C UTTING W IDTH : 20"

• M AX . C UTTING H EIGHT : 8 5 ⁄ 8 "

• M AX . C UTTING D EPTH : 1 ⁄ 8 "

• N UMBER OF K NIVES : 4 H.S.S.

Actor

Dan Haggerty

• 2 H.P., 110V

M OTOR , 15 A MPS

• C UTTERHEAD S PEED :

8,540 R.P.M.

• F EED R ATE :

25 F.P.M.

• N UMBER OF PUTS PER

I NCH : 57

• M IN . B OARD

T HICKNESS : 3 ⁄ 16 "

• M AX . C UTTING

W IDTH :12 1 ⁄ 2 "

• M AX . C UTTING H EIGHT : 6"

• M AX . C UTTING D EPTH : 1 ⁄ 16 "

• A PPROX . S HIPPING W EIGHT : 85 LBS .

• M AX . C UTTING D EPTH : 1 ⁄ 8 "

• N UMBER OF K NIVES : 3

• A LL B ALL B EARING

C ONSTRUCTION

• A PPROX . S HIPPING

W EIGHT 540 LBS .

• H EAVY -D UTY C AST I RON

C ONSTRUCTION

• A PPROX . S HIPPING

W EIGHT : 785 LBS .

4 B LADE

C UTTERHEAD !

1999

ONLY

$ 995 00

$125 S HIPPING

A NYWHERE IN L OWER 48 S TATES

“I love dealing with

Grizzly Industrial.

They have excellent

products and stand

behind everything

they sell.”

ONLY

$ 289 95

$30 S HIPPING

A NYWHERE IN L OWER 48 S TATES

FREE STAND

I NCLUDED WITH G8794 P LANER

( 700 LB . C APACITY )

FREE STAND

ONLY

$ 1,295 00

$150 S HIPPING

A NYWHERE IN L OWER 48 S TATES

MODEL G1182HW

6" x 47" Jointer

with Handwheels

MODEL G1182ZX

6" x 47" Heavy-Duty

Jointer

MODEL G1018HW

8" x 65" SUPER

Heavy-Duty Jointer

• 1 H.P., S INGLE -P HASE , 110/220V M OTOR (P RE - WIRED TO 110 V)

• H EAVY - DUTY O NE P IECE S TEEL S TAND W /B UILT IN C HIP C HUTE

• P RECISION G ROUND C AST I RON B ED

• S UPER H EAVY -D UTY , C ENTER -M OUNTED F ENCE - P OSITIVE

STOPS @ 45º & 90º • 3 K NIFE B ALL B EARING C UTTERHEAD

• T ABLE SIZE : 6" X 47" • 1 ⁄ 2 " R ABBETING C APACITY

• A PPROX . S HIP . W EIGHT : 215 LBS .

• 1 H.P., S INGLE -P HASE , 110/220V M OTOR (P RE - WIRED TO 110 V)

• H EAVY - DUTY O NE P IECE S TEEL S TAND W /B UILT IN C HIP C HUTE

• P RECISION G ROUND C AST I RON B ED

• R E - DESIGNED F ENCE S YSTEM - P OSITIVE STOPS @ 45º & 90º

• 3 K NIFE B ALL B EARING C UTTERHEAD • T ABLE SIZE : 6" X 47"

• 1 ⁄ 2 " R ABBETING C APACITY

• A PPROX . S HIPPING

W EIGHT : 235 LBS .

• 3- KNIFE CUTTERHEAD IS 3" IN DIA . AND RUNS IN

SHIELDED , PRE - LUBRICATED BALL BEARINGS

• P OWERFUL 1 1 ⁄ 2 H.P., 220V SINGLE PHASE MOTOR

EASILY PLOWS THROUGH HARDWOODS

• M AXIMUM DEPTH OF CUT IS 1 ⁄ 2 " AND

INFEED TABLE HAS RABBETING LEDGE

• S UPER HEAVY - DUTY CAST IRON BED

• A PPROX . S HIPPING W T . 450 LBS .

FREE

P AIR O F S AFETY

P USH B LOCKS

FREE

P AIR O F S AFETY

P USH B LOCKS

FREE

P AIR O F S AFETY

P USH B LOCKS

ONLY

$ 325 00

$55 S HIPPING

A NYWHERE IN L OWER 48 S TATES

ONLY

$ 475 00

$55 S HIPPING

A NYWHERE IN L OWER 48 S TATES

ONLY

$ 695 00

$75 S HIPPING

A NYWHERE IN L OWER 48 S TATES

MODEL G1035

1 1 ⁄ 2 H.P. Shaper

MODEL G1026

3 H.P. Shaper

• 3 I NTERCHANGEABLE S PINDLES : 1 ⁄ 2 ", 3 ⁄ 4 " AND 1"

• 3" S PINDLE T RAVEL

• H EAVY -D UTY 3 H.P., S INGLE -P HASE , 220V M OTOR WITH

R EVERSING S WITCH

• T WO S PINDLE S PEEDS : 7,000 AND 10,000 R.P.M.

• S PINDLE O PENINGS : 1 3 ⁄ 8 ", 2 3 ⁄ 4 ", 4", AND 5 1 ⁄ 2 "

• P RECISION -G ROUND C AST I RON T ABLE

• T ABLE S IZE WITH S TANDARD

W ING A TTACHED : 30 1 ⁄ 2 " X 28 1 ⁄ 4 "

• F LOOR - TO -T ABLE

H EIGHT : 34"

• A PPROX . S HIPPING

W EIGHT : 353 LBS .

MODEL G1019Z

14" BANDSAW

• 2 I NTERCHANGEABLE S PINDLES : 1 ⁄ 2 " AND 3 ⁄ 4 "

• H EAVY -D UTY 1 1 ⁄ 2 H.P., 110/220V M OTOR

• T WO S PINDLE S PEEDS : 7,000 AND 10,000 R.P.M.

• S PINDLE O PENINGS : 1 1 ⁄ 4 ", 3 1 ⁄ 2 ", AND 5"

• P RECISION -G ROUND C AST I RON T ABLE • 3" S PINDLE T RAVEL

• T ABLE S IZE : 20 1 ⁄ 4 " X 18"

• F LOOR - TO -T ABLE H EIGHT : 33 1 ⁄ 2 "

• A LL B ALL B EARING C ONSTRUCTION

• M AX . C UTTER D IAMETER : 5"

• A PPROX . S HIPPING

W EIGHT : 220 LBS .

• C UTTING CAPACITY / THROAT : 14 1 ⁄ 4 "

• M AXIMUM CUTTING HEIGHT : 6 3 ⁄ 8 "

• O VERALL SIZE : 66"H X 26"W X 22"D

• T ABLE HEIGHT ABOVE FLOOR : 42 1 ⁄ 2 "

• T ABLE TILT : 45° RIGHT , 10° LEFT

• W HEELS : F ULLY BALANCED CAST

ALUMINUM WITH RUBBER TIRES

• M OTOR : 1 H.P., TEFC,

110V / 220V SINGLE PHASE

• A MPS : 12@110V / 6@220V

• B LADE SPEEDS : 2500 & 3350

F.P.M.

• B LADE SIZE : 98" ( 1 ⁄ 8 " TO

“Please, can we buy

it, honey?”

G1706

EXTENSION WING SHOWN

NOT INCLUDED

3 ⁄ 4 "

WIDE )

• A PPROX . S HIP . W T . 165 LBS .

ONLY

$ 425 00

$55 S HIPPING

A NYWHERE IN L OWER 48 S TATES

ONLY

$ 825 00

$75 S HIPPING

A NYWHERE IN L OWER 48 S TATES

ONLY

$ 335 00

$55 S HIPPING

A NYWHERE IN L OWER 48 S TATES

CALL TODAY FOR YOUR

FREE 468 P AGE

C OLOR C ATALOG

MEDIA CODE

AD1304

1-800-523-4777

CUSTOMER SERVICE:

(570) 546-9663

FAX: (800) 438-5901

3 Locations: Bellingham, WA • Springfield, MO • Muncy, PA

395001658

Circle #108 on information card.

FREE

WE SELL DIRECT TO THE USER! NO DEALERS AND NO MIDDLEMEN!

BUY DIRECT & SAVE!

• FULL 1-YEAR WARRANTY ON ALL MACHINES • MOST ORDERS SHIPPED THE SAME DAY

• HUGE PARTS FACILITY WITH OVER 1 MILLION PARTS IN STOCK AT ALL TIMES

• WE HAVE 2 OVERSEAS QUALITY CONTROL OFFICES STAFFED WITH QUALIFIED ENGINEERS

NEW TABLE SAWS FOR 2002!

MODEL G1022SM

10" Heavy-Duty Table Saw

• T ABLE S IZE W / E XTENSION W INGS : 27 1 ⁄ 8 " X 40 5 ⁄ 8 "

• R AIL D IMENSIONS : 44" X 1 3 ⁄ 8 " • M AX . R IPPING C APACITY : 24"

• C UTTING C APACITY AT 90˚: 3 1 ⁄ 8 " • C UTTING C APACITY AT 45˚: 2 1 ⁄ 8 " • 1 1 ⁄ 2

H.P., S INGLE -P HASE , 110/220V M OTOR ( PRE - WIRED TO 110V)

• A PPROX . S HIPPING W EIGHT : 220 LBS . • P RECISION G ROUND C AST I RON

T ABLE

MODEL G1022PRO

10" heavy-duty table saw

with Shop fox ® classic fence

MODEL G1023SL

10" LEFT-TILTING SUPER

HEAVY-DUTY TABLE SAW

• 2 H.P. MOTOR

• P RECISION GROUND TABLE & WINGS

• W IDE & STABLE STAND

• 5 ⁄ 8 " X 1 1 ⁄ 4 " BALL BEARING ARBOR

• 37" TABLE HEIGHT

• 3 1 ⁄ 8 " CUTTING CAPACITY AT 90°,

2 1 ⁄ 8 " AT 45°

• S EE THRU BLADE GUARD

• T ABLE HAS BEVELED EDGE & T- SLOTS

• 27 1 ⁄ 8 " X 40 5 ⁄ 8 " TABLE SIZE

• P RECISION S HOP F OX ® F ENCE

• C AST IRON MITER GAUGE ADJUSTS TO

ELIMINATE ANY PLAY IN MITER SLOT

• M ACHINED STEEL PULLEYS

• P OWER T WIST ® DRIVE BELT

• 4" DUST PORT • 25" RIP CAPACITY

• S MOOTHER ACTION HANDWHEELS

• S HIPPING WEIGHT APPROX .: 290 LBS .

• 3 H.P. SINGLE - PHASE , 220V MOTOR

• S OLID CAST IRON TABLE

• T ABLE HAS T- SLOTS SO YOUR MITER

GAUGE WILL NOT FALL OFF THE TABLE

WHEN RETRACTED

• T ABLE SIZE ( WITH 2 SOLID EXTENSION

WINGS ATTACHED ) IS 40 1 ⁄ 8 " X 27"

• E XTRA - LARGE HANDWHEELS

• C UTTING CAPACITY : 8" LEFT AND 26"

RIGHT OF BLADE

• M AXIMUM DEPTH OF CUT @ 90°: 3"

• M AXIMUM DEPTH OF CUT @ 45°: 2 1 ⁄ 8 "

• 5 ⁄ 8 " DIAMETER ARBOR IS LONG ENOUGH

TO ACCEPT DADO BLADES UP TO 13 ⁄ 16 "

• O NE - PIECE STEEL CABINET - TYPE STAND

• M AGNETIC SAFETY SWITCH IS STANDARD

• A LL SEALED BALL BEARING CONSTRUCTION

• T RIPLE V- BELT DRIVE

• P OWDER COATED PAINT

• S HIPPING WEIGHT APPROX . 430 LBS .

I NCLUDES

SHOP FOX ®

C LASSIC

F ENCE !

ONLY

$ 325 00

$55 S HIPPING

A NYWHERE IN L OWER 48 S TATES

F ULLY

A DJUSTABLE

C AST I RON

M ITER G AUGE

ONLY

$ 550 00

$75 S HIPPING

A NYWHERE IN L OWER 48 S TATES

INTRODUCTORY

PRICE

$ 895 00

$75 S HIPPING

A NYWHERE IN L OWER 48 S TATES

MODEL G7947

12 Speed 17"

floor Drill Press

• 1 H.P., S INGLE P HASE , 110V/220V M OTOR

• 12 S PEEDS : 210-3300 RPM

• O VERALL H EIGHT : 64 1 ⁄ 2 " • S WING : 17"

• D RILL C HUCK : 5 ⁄ 8 " • D RILLING C APACITY : 1" S TEEL

• S PINDLE T APER : MT #3 • S PINDLE T RAVEL : 4 3 ⁄ 4 "

• T ABLE S IZE : 13 5 ⁄ 8 " S Q .

• P RECISION G ROUND C AST I RON T ABLE

• T ABLE T ILT : 90˚ IN B OTH D IRECTIONS

• A PPROX . S HIPPING W EIGHT : 275 LBS .

MODEL G1066

24" Drum Sander

• 5 H.P., 220V D RUM M OTOR D RIVES 2 A LUMINUM S ANDING D RUMS

• 1 ⁄ 4 H.P. C ONVEYOR M OTOR GIVES AN 11 FPM R ATE OF F EED

• 2 B UILT - IN 4" D UST P ORTS FOR E ASY H OOK - UP TO C OLLECTION S YSTEM

• A LL S TEEL AND B ALL B EARING C ONSTRUCTION

• S TATE - OF - THE -A RT C OMPUTER B ALANCED D RUMS • A PPROX . S HIPPING

• H ANDLES S TOCK UP TO 23 1 ⁄ 2 " WIDE X 4 1 ⁄ 4 " THICK

MODEL G9983

15" wide-belt sander

(open end)

• O VERALL DIMENSIONS : 61 3 ⁄ 4 "H X

32 1 ⁄ 2 "D X 35"W

• C ONVEYOR S PEED 13 & 16.4

F.P.M.

• B ELT FEED MOTOR : 1 ⁄ 4 H.P.

• S ANDING BELT MOTOR : 5 H.P.

• R EQUIRES SINGLE - PHASE , 220V

ELECTRICAL AND 50-70 PSI AIR

• I NCLUDES EXTENDED SUPPORT

BAR FOR WIDE BOARDS

• A PPROX . SHIPPING WEIGHT :

1,000 LBS .

W EIGHT : 430 LBS .

B UILT -I N L IGHT ! ( BULB NOT INCLUDED )

ONLY

$ 375 00

$75 S HIPPING

A NYWHERE IN L OWER 48 S TATES

ONLY

$ 1095 00

$75 S HIPPING

A NYWHERE IN L OWER 48 S TATES

MODEL G1029

2 H.P. Dust Collector

ONLY

$ 2,795 00

$200 S HIPPING

A NYWHERE IN L OWER 48 S TATES

• M OTOR A MP D RAW : 12 A MPS (220V ONLY )

• 2 H.P., 220V, S INGLE -P HASE M OTOR

• R.P.M.: 3450

• S TANDARD B AG F ILTRATION : 30 M ICRON

• P ORTABLE B ASE S IZE : 21 1 ⁄ 2 " X 33 1 ⁄ 2 "

• A IR S UCTION C APACITY : 1550 C.F.M.

• S TATIC P RESSURE : 12.3"

• A PPROX . S HIPPING W EIGHT : 130 LBS .

1997

MODEL G9922

Oscillating Spindle Sander

MODEL G1071

Oscillating Spindle Sander

• 1 H.P., S INGLE P HASE , 110/220V, TEFC M OTOR

• P RECISION G ROUND C AST I RON 25" X 25" T ABLE T ILTS TO 45°

• S TROKE L ENGTH : 1 1 ⁄ 2 "

• 1 ⁄ 2 H.P., S INGLE P HASE , 4.6 A MP , TEFC M OTOR

• G ROUND C AST I RON 14 1 ⁄ 2 " X 14 1 ⁄ 2 " T ABLE T ILTS TO 45°

• S TROKE L ENGTH : 1"

• B UILT - IN 2" D UST C OLLECTION P ORT

• F LOOR - TO -T ABLE H EIGHT : 35 1 ⁄ 2 "

• B UILT - IN 4" D UST C OLLECTION P ORT

• 1725 R.P.M. S PINDLE S PEED

• S PINDLE O SCILLATES AT 72 S.P.M.

• 10 T APERED AND T HREADED S PINDLE S IZES

• P ERMANENTLY L UBRICATED

B ALL B EARINGS

• I NCLUDES 100 G RIT S LEEVE FOR

E ACH S PINDLE , M ITER G AUGE AND

W RENCH S ET

• A PPROX . S HIPPING W EIGHT : 300 LBS .

F REE C YCLONE S EPARATOR !

• F LOOR - TO -T ABLE H EIGHT : 39 1 ⁄ 2 "

• 3450 R.P.M. S PINDLE S PEED

• S PINDLE O SCILLATES AT

64 S TROKES -P ER -M INUTE

• S HIELDED & P ERMANENTLY

L UBRICATED B ALL B EARINGS

• I NCLUDES 80 G RIT S LEEVE

FOR S PINDLE , M ITER G AUGE

AND W RENCH S ET

• A PPROX . S HIPPING W EIGHT : 95 LBS .

ONLY

$ 249 95

$55 S HIPPING

A NYWHERE IN L OWER 48 S TATES

ONLY

$ 175 00

$30 S HIPPING

A NYWHERE IN L OWER 48 S TATES

ONLY

$ 525 00

$75 S HIPPING

A NYWHERE IN L OWER 48 S TATES

OVER 10,000 PRODUCTS AVAILABLE ONLINE!

RECEIVE A FREE GIFT WITH EVERY ONLINE ORDER

(LIMITED TIME OFFER)

Circle #109 on information card.

SHOP FOX ®

C LASSIC

F ENCE !

content

TOOLS AND TECHNIQUES

16 Sturdy Fold-Away Sawhorses

TRICKS OF THE TRADE

We like plastic folding sawhorses, but they get expensive. You can build your own using this clever

idea sent in by a reader. Also, learn to set up your dovetail jig to become a precision dado machine.

18 HTC Rip Fence Improves the Venerable Biesemeyer

TOOL TEST

By adding a micro-adjustability feature and easy-to-remove fence faces, HTC has reﬁned the classic

Biesemeyer fence system found in most commercial woodshops. We tell you if it’s worth upgrading.

We also test Milwaukee’s BodyGrip router and Bosch’s 1619EVS plunge router.

22 Multipurpose Sled and Tenon Jig

INGENIOUS JIGS

Instead of purchasing an expensive aftermarket miter gauge, try this shop-made cutoff sled with a

smart tenoning attachment. The whole rig is simple, inexpensive and highly accurate.

By Nick Engler

25 Grizzly 1023S Cabinet Saw

ENDURANCE TEST

This cabinet saw — with the price tag of a contractor saw — has turned the table saw market for home

woodworkers upside down. After two years of hard use in our shop, we tell you how the 1023S fared.

38 Air Compressors in the Shop

The right compressor can transform your woodworking by giving you access to spray ﬁnishing and nail

guns. With prices dropping every year, here’s what you need to know to buy the right machine.

By Rick Peters

48 Metal-bodied Jack Planes

Many woodworkers do everything in their power to avoid using hand planes. And no wonder: Bench

planes are tricky to set up and use. Here’s a complete lesson on how to buy, set up and use a metal-

bodied jack plane — one of the most useful all-around planes.

70 Mortising Jig for a Router

You can make highly accurate mortises using your plunge router and a simple jig made from shop

scraps with some simple hardware. Here’s how to build and use one of our favorite jigs.

74 Using a Cutting List

A properly organized cutting list can help you avoid costly and

frustrating mistakes, and make your work on a project feel

much more under your control. Here are the tips from a

lifelong pro.

By Lonnie Bird

76 $30 Lumber Rack

Most people buy expensive brackets or build

bulky shelves to store lumber. Here’s a third way.

It’s inexpensive, ﬂexible, cheap and takes up

little space in your shop.

P OPULAR W OODWORKING April 2002

PROJECTS

30 Ultimate Tool Cabinet

If you’ve got the tools, the time, the wood

and the skills, then we’ve got the project.

This father-and-son tool cabinet is your

ﬁnal exam in case construction. If you’re

not ready to take the test, you still can

learn a lot about designing tool storage for

whatever type of tool cabinet is on your

drawing board.

By Glen and Malcolm Huey

42 All-Weather

Morris Chair

Armed with $40 in pine, a saw and a drill,

you can build this fall-asleep-in-it outdoor

Morris chair. Start in the morning, and

it’ll be ready by nap time. Our personal

best time for construction: four hours.

57 A Child’s Double

Dulcimer

This Appalachian folk instrument is easy to play and build (no curves here). Our version

is designed so two people can play at the same time.

By Claude Crowley

62 Shaker Storage Cabinet

Whatever you’ve got to store, this face-frame cabinet can probably take it.

Two different shelving systems help you pack away stuff that’s either heavy or light.

By Troy Sexton

ON THE COVER

Built in a garage using

machines found in

most home shops, this

tool cabinet is one

ultimate woodworking

project. Father-and-son

team Glen and

Malcolm Huey joined

forces to show you

how to build enough

storage space for

almost any set of tools.

Cover photo by Al Parrish

IN EVERY ISSUE

6 Out on a Limb

Feeling Set Up

8 Letters

Mail from readers

12 Q & A

We answer readers’

most difﬁcult questions

66 Knockdown Bookcase

This unusual and useful Arts & Crafts

bookcase can be taken completely apart

with four raps of a hammer.

80 Seedling Shelter

This simple “cold frame” helps nurture your

spring plantings during winter.

By Jim Stuard

26 American

Woodshops

Scott Phillips visits the

shop of dulcimer

maestro Warren May.

28 Deltagram

Roller supports

Popular Woodworking (ISSN 0884-8823, USPS 752-250), is published six times a year in

February, April, June, August, October 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 (6 issues) is $24.96; outside U.S. add $7/year ® Canada Publications Mail

Agreement No. 40025316. Canadian return address: 2744 Edna St., Windsor, ON N8Y 1V2 ®

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. Ride-along enclosed in polybag version 52000.

83 Caption

the Cartoon

Win a Freud

FJ85 jigsaw

88 Out of the

Woodwork

Woodworker meets

wordworker

by Philip Leon

www.popwood.com 3

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