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1/24

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4

_

f t t

350

O TES FR O M

T

S H O P

O 6

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oodSll1ith

WOODS M I T H (ISSN 01644114)

pu b

lis hed b lmonlh Jy (Febru ary , A pri l, June .

August, O ct obe r, O ecem ber ) b y

WOOdsm lth PubQ sh lng eo ., 2200 Grand

Ave., Des Moines, lA 50012.

Woodsmith

is a re g is tered trad em arlt of

Wo o d sm ilh P ublish ing C o.

,~ CoPyri9ht 1989 by Wocxfsmllh PU blish

ing Co . A ll Rig hts R eseNed.

Subscr ipt ions: O ne year tssoes)

$15.95,

Tw o Y ears

(12

issues)

$27.95.

canada

and

Foreign: lld d $ 2

pe r

year,

U .S .

funds on ly , S ing le C opypn 'ce , $3.50.

Second C lass Postage Pa id at D es

M oines, Iow a an d a la dd ilionaJ offlC< S .

Pcsrm aster: Send cnange of addres s to

W o o d sm i lh , B o x 491, M t. M orrts,lL 61054,

S U B S C R IP T IO N Q U E S T IO N S ? O all800

435-0715 (IL re sid ents : 800.892-(753).

7:3 0 AM 108:30 PM . C ST. wee l\JN.Th e fu n part of th e ' toy Tra in

w as mak i ng th e track . The t ra ck i sdes ig ned

so i t's easy to m a ke-a nd so mere se ctions

c an b ea dd cd a ny tim e in th e f ut ur e. O n c ew e

des igned it, Ute hardest pan w a s w a lk ing

through th e office a s n ew s ec tio ns o f tra ck

found th e ir w ay in m ore nm azing pauerns

and

stretching 10

n ew pa n s. of

th e building.

O YA L H O X.

There are two re as on s to bu ild

the O va l BOl< sh ow n in ti llS is su e. F irs t, it

makes a oic e .g iit . B ut t he r ea l reason, is th aI

it u ses a tec hn ique that s ju st p la in { un fro m

awoodworker s standpo int .

The box is based

O n

Ihe

s ha pe of

a bev

e le d-edge ov al m irr o r. It requires transfer-

rin g th e sh ap e o f { his m irro r to a template.

The n t lt e t em p la te is used w ith a route r to

rout ou t the recess in the lid fo r the m irror

and .a c om ple m en ta ry re ce ss in

w e

b a se f o r

jew elry .

[b e id ea is th e sa me n o m atte r w ha t th e

sha pe . I f y ou find an intriguing l>alle rn ofany

shape, you c an m a ke a t em p la te f ro m it a nd

r o ut o u tt ha lsh a p e.

CAlIl lC,)S . I want to po in t ou l the note o f

c au tio n w e 'v e P ul o n th en e.,[ p ag e u n de r th e

Sawdust

COLUMN

DITOR S

ctober L989o . 65

-

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3/24

1 f you'd like to ~ ha rc

Ii

ti p

w ith o ther s, s en d in y ou r id ea

to \VoodSlllith, ' 'ips Tec h

D iques. 22tJQGrand Ave ., D e s

Moines . Iowa 5 031.2 .

\V e pay $15 for accepted

ti ps Please send an explana

ti o n an d a sket ch if needed

(we'll draw a ne w o ne ).

SEND IN YOUR tIPS

VACUUM

H 5 I ~8,36'-long

2 0'

piece

O f 1.

dowel

(32)%'wOOQscrewhQIeplugs

8 x I/.',

x 2 woodscrehordware kil,see psQe

24.

CUnlNG DIAGRAM

fOO fPa:G HO I.

: :

fRONT/BACK LEG PAmRN

T~

FRONT

LEGS

1 24~ .;

..1..__11.--_ .; ----,- ; ,---:~ 1

MA IN BOD Y PATTERN

GRI:O D IV ID ED IN TO 1 M QU A IU S

531f2 l

~

piUG

l.

_8 114 - j

w OOOSCIUWS

N o, 65

WOOD PARTS

A MClinBody I) 1 < 1 x 11 /. 38

8 Le~Wedges(4) ~x7h-1O

C Fronl

Legs

(2)

See

below'

D Reorl l9s

2

See below'

E S < d e s 2 ,) 1

Y

x 11 If. I d

f HeodSidePcs.(2).x7/.-11

G Nec~ Pieces (2)

1 .

x ;; ~ - 7

H Roc1

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SNOOur ALl SAW

M KSwtfH_

DRUMSANOER

8

W()odsmith

L Y OUTlGS

US ING GRfD

P mRN

I OUP

IN FRONT

. fGONLY

4

RJU PEGHOLI

10 be cut 10 final shape while a u ac he d to th e

leg .

BUI.

beca use

th is

creates

a

rath er

awkw ar d

culting an gle,

ad

to

cu t the

legs

an d

wedgesin

tw o steps.

First, draw

a

line

across the pattern 10

down fr om the top o f the legs, s ee F ig . 6 .

N ow cut out Ibe lower part o f ea ch le g

(w ithout th e wed ge attached), exiting

t h < :

boarda t

th e

10 mar k .

N ex t, atta ch the wedges to the

i ~ul f

the leg w ith

carpet

tape, see

Fig . 7.

The n

p lace

the w edge-side

down

on the band sa w

table, an d cu t th e rema ining sh ape . s ee F ig.8 .

When one frO )tleg (C ) a nd one rear leg

I

have

bee n

culo utand sand ed,

use

UIC OI

as patterns

(0

la yout an d

CU I

the o th er tw o

leg s. (B e su re the ho les on th is second se t

m irr o r tho se

On

th e

first)

PosmON TILEU>GS.N ex t. you can p osi

lio n the leg&on th e bo dy (A).The problem

her e is

1

de te rmme

8

reference po in t t o get

MAIN

BODY

6

CU T LOWER .

P RTO UG

rOSH PE

UP TO THE

10 MARK

LEG

WEDGES

4 TOTAL

5

. . .

1 8 , ( ;

,

COUNT t

i t B O R

WOODSCREWS

.

1.1;

SCREW

t

HOLE

l

DETAIL

. ; ; : ; ; ; . 1 ~

SH NKHOl

th e legs at th e co rr ect ang le ( st ance ). se d

Ihe joint

line

(from

making

the Lshaped

body , refer to Fig. 2) as

a

reference

line .

1 '0 d o th is,

place

a

straightedge o n

th e

jo in t

line

so it exte nds 18

beyond

the

ho r se 's b e ll y, se e Fig. 9 . N ow positi o n t he

rear

leg

0

so the top of th e leg

isflush

w ith

the horse's back and the ho of is

~

rom

thestraighted ge , se e Fig . 9 . Then s cr ew (bu t

don 't glue) the le g a nd wedge

10 U IC

body .

W ith the

rear

le g in plac e, po s itio n t he

fro ntleg (C ) so the top o f the I~isnush w ith

the horse 's back . N ow aci jusl the front leg

until

there's

22\. . betw een the hoo ves and

6 betw een the top o f the legs. see Fig. 9 .

The n scr ew (b ut do n 't glue) the fronlleg

do wn to the m ain b lldy.

TRL'L\IING TIlE WEpGES.

\V hen both

legs

are mounted

In

one side, the re 's a s ec tio n o f

wedge under the ho rs e that n eeds to

be

tr immed, Tum the ho rse o ver and trac e th e

CUT HOR SE

SHAPE TO THE UNf .

THEN Fill A ND S AN D S MO OTH

2

3

Alte r the body (A ) is

san de d, I beg an

wo rking on th e leg& .

To

give the horse a

naturdl stance , I

add ed

wedges be-

hind ea ch leg .

I.E C WEOCES .111.

leg w edge's

B

are

fo rm ed by g lu inl ; : f ive sm aller wedges

to -

gether, se e Fig. 3 .(F o r mo re on cutt ing

wedge s. se e pag e 13.)

lAYOUTntE

lE GS.A lter th e wedges

8

are

glued up, lay out the fro nt leg (C ) an d

rea rteg (D ) on a pi ece o f

l -2t'sl ock ,

se e Fig.

4.

Also mark ;

Ih~

sc rew and foo lp eg ho les,

Now

rough)y CuI

apart

the tw o l eg s, s ee

Fig . 4 .

111eo

drill a Io o tpeg ho le in the fronl

leg w ith a I forstner bit. A lso

drill ho les (o r

th e mountin g screws in bo th leg s, se e Fig. 5 .

co r IN t wo STEJS . he

wedge s

(B ) have

LEGS

The firs t srep in

building the horse is

to make a n Lshaped

bla nk

for

Ihe

body

(A) from a 38 Jong

pie ce o f2 x 12 (lW'

x

11 V

actual

size ).

To do thts.square

up one edg e o f the 2

x.

12 to

a

fi nal w id th o f

1 1 .

The n

cu t a

I Z O l

lo ng piec e o ff one end, an d glue il to the

other

piec e to fonn an Lsh ap e, see F ig . I.

Transfer the body sh ape from the

grid

drawingo n page 5 , o r se nd fo rthepattem , se e

p ag e 2 4.

(For mo rc on

gr id drawings , s ec p age

13.)

111en

cutout th e

body

an d sand thcedges,

MAIN BODY

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ooosmith

o. 65

11

14

muOWCIUD

15

TRAct

16

R MOVE fRom LEGS

PAnRN

OUTUN

AN D R OU T lh

MAK~JAW

Of NE~,K

RouNO-OVER

O ONTO

PAP ER

T

PI ES SO

,

SUD PAPER

\

JHtYR E

~ D A E = j ~ ~ :

FLU SH

G LU EH EA D

A ND N ECK

TRACEB OtH ~

WrrH

. ~ SID E PIecES

B ODY

~ ' \ *

P IE E S

INTO

P LA C E

SIDE-S Of H,EAO

~

~

0N10 1 x

STOCK

~~

the y're O ush

'U I

th e m ain head.

an d (hen

c lam p (but don 't glue ) the m in place .

NECK .Nextcomes th e neck . Forthe neck ,

follOW the s am e p ro ce dure a s wh e n making

t he s id e s ( O ) . see Fig. 15 .Once th eneck (G )

p ieces

Iit,

glue the head pieces and neck

p ie c es to th e

main

body .

sour HEAD, IND NECK .

\Vhen the g tue is

d ry . re move the 6 'ont legs and rout a til

round-ove r

o n t he o u ts ld e

edges

or

th e h e ad

and ne ck. see fig . 16 . (Note: D on 't rou t the

ne ck where it m eets the

leg .

Final ly . g lue

a nt i s c rew th e le gs in p lac e.

S E C O N D :

M AR K L EG S

WHER t THEY

M T H amy

gl\l~

it to

a

p iece

0 1

\I -th ic k

stock, see

Fig .

12.

(S ince

the shap e may vary , make a se pa

ra te pat tern (o r each side .)

SA N D TO

rrr, T o g et a good fit. I cu t

th e

sides o v e rs iz e . a nd t he n s an de d to ti le lines .

O nce the side s

fi t.

rout

a

i

ro und-over

on

a ll

( ou r o uts id e e dg es. a nd g lu e

th e

side s to

th e body, se e F ig 13.

T1lACETll I lE A O .T he

ne xt

step

is

1 0 c u t

the head 's si de pieces

(1 ).

Start by tracing

each side o f th e m ain head onto a pie ce of

1x8stock .

an d d ra wth ejaw line . se e F ig . 14 .

N ow . cu t out and sand

t hese

tw o p ie ce s so

idn't

wanta

skinny

horse,

sodded

th e

rw e s id es

E .

M A J< 'EA P A TI'RN .

To determine the

shape of th e sides . I

made a

paper

pa t

t e rn .

Begin by

un

screwing th e le gs o n

one side of the

horse

ju st e no ug h to slip

a

p ie ce o f pape r und er them , se e Fig . It. N ow

trac e tbe o utline ofthe bac k, be lly . a nd b oth

legs onto the pape r. C ut o ut th is shape an d

1----22~_-_-I

SIDES HE D ND NECK

le g . s ee F ig. 10 .T he n remov e th e w edge and

ro ut u p to

th ese m arks,

Repeauhe same procedure for th e legs on

th eotherside . Then sc rew all four legs tothe

horse 's b od y,

a ll th e way ar ound. (N ote : Don ' t rout th e

b o ttom on he hool.) H oweve r. th e rounding

on th e

i si l iee ge

stops auhe wedge . T o do

( h is , p la c e th e w edge in position on the leg

and m ark w here it m ee ts the edges of the

fOO Pf

HO LE

AnACH t[GS TO

C OY WITH .8 )It 2-

WOOOSCREWS

9

LEGS

CONT INUED

horse's be lly O nto e ach wedge . see F ig. to .

N o w u ns crew -t he le~ .

pull

o fflh e w ed ge s.

and cu t to

the.line.

RO \ .lND OVER I.C5. To comple te

th e le gs .

I routed a W ' ro ondove r on lheo ll ts ideedge

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oodsm ith

1 ' lMPORARllY

- SH IM HO OF I' N ECES SARY

ROCKER

eut.)

N ow

us e fine

tooth han d

sa w to tr im

e ac h h o of along th e scribed lin e.

SCREW DOWN 1I0HSE. Wh.en th e hooves

h a ve b e en

cut.and

th ey sit

fla t, the norse

ca n

be auac hed to the tw o o uts tdc cro ss bars, To

do

th is, m ark the

center

ea ch h oo f o n th ~

bo l ton l 0

f

th e c ro s sba rs, Then drill and coun

tersink

a :V I I ; shan k hole.

US ing

one N rocke rs Iollows a

- large radius . r mad e

a s ix -

[001

b eam com

pass to

lay

th em-ou t.

MAlff iACO MPASS .o make th e b e am co rn

p a s s. s ta r t

with

a

78 ' l ong

strip

o f

wood

an d

nai l d own one e nd, s eef lg . 17 .No lYmeasure

down fr om th e n ail 69l' l and 72 . and drill

ROCKERS AND CROSSBARS

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9/249

\

,

$TAPli 3

C-\.UM'S

CWYAI \N

t. APA,RT

enough. DICIt usio g 8 sm all fe nci ng staple,

attach th e yam in

dum ps

of

15

piec es.

S ta J

I

above

th e base o f t he neck

an d

ce nter

th e

staple over th e m id po in t o f Ihe p ie ce s of

yarn. se e

r~g.

7. Note: To prevent a bald

spot at the top of th e head . 1st apled in extra

c lumps o ya rn .

'filE TAlL

The finals tep is LOadd the tail.

The tai l i m ade Ih e sam e \ ya y a s ri le mane

except the yarn pieces ar e 28~() n~ and

th ere are 34 pieces in each of the three

clumps, see Fi g. 28 .

[fyau

w ..

nLIOmake

thesa(ldlc

a nd b ridle

sh ow n in the photo.see Sourc es on page 24.

K

FOOTPEG

1\1 \

, FRONT

UOI

I

DOW ll.

.

, P IN 'OOWI l

wnH

, 4 d F INISH NAIL

_ rAOM~ACK

O F L EG I

2S

W oodsm ith

15 StRANDS

Of l'''lONG

Y R

U sing the grid drawing as a reference, 1

drilled a I hole. V s de epon either sid e of

th e head. Then I sim ply g lued th e eyes in

placewith epoxy,sec Fig.26.

AAMS.The ears are

l it

from tw o

smal l

piec es of 'Ill -lh ick leathe r. Tom aketh e ears.

cui

th e leather in to fo otb all-shaped

pi ec es

th at are 2 -w id e and 4 loog. Then fold the

t wo p ie ces

in ha lf leng1)lY,;se

and nail them

t o e it her sid e o f the hea d, se e fig. 26.

ru s M ANE .WI1al's ahorse withoul a D ow

in g m an e? To m ake th e m an, cu l4 -p ly y am

into Ill lengths . There are

ov er

200 s tr ands

o f ya rn

ll

Ute mane , so m ake su re LOmake

No. 65

o

lOC ATIO N O F

EYE SAND EAR S

,p-

DfTtRMINEO

ONGRJD

DRAWING ,: ' . J

I .

J ) ; O , l

.:;.:?

FOlD liAlloIER

EARSIN H~U:,

TH EN N p, 'L

IN PlAC

,. HOJ,E,

/I DEEP

6

NOT:

'TI le w ooden parts of

the

horse

are

complete at this

point. Since th is

horse is bound

10

lake som e abuse, I

w an ted th e finish U >

be as durab le 8S

possib le . I used tw o

coat s o f s atin p olyurelhane . s and ing l ig h tl y

betw ee n c oa ts .

EYES.

The

finishing to uches are the eyes.

ear s,

man e,

an d

ta il.

The

eyes I used are

cal led g las scr a ft eyes that are 1 in d iameter.

EYES EARS MANE AND AIL

/

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T

BACI(ING

BOAAO

1I 4 OIA .

FO~ER

OE l SP E

s rr

_

Woodsmich

0

aOTTOM

KEP EDGES F 1.USH

WHEN C lAMPING

Next , resaw tw o sid e pieces 8 : ti6'

thick. ( Th is t hi ckness w ill p ro duct' a b lo ck

1.t thick -

\ 1 i

m o re th an the h eJg ht o f a

lO

7/24/2019 Woodsmith - 065

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I

00< lsm ith

o. 65

EDGES

IRONTWGlS

D O f o IT

LIGHnY

S AN D S T AM P

HOlD tR F OR

fRtC'TION

fff

Ul

t o t

ROU NOo

OV ER 8IT

ON AU.

OU 'rSl0E

EDGES

EXCEPT

ONT

EDGES

NOTE:

PLA CE A R Oll O F 100

ST A MPS IN TO

H u E~,

TH N suee INTO cASE

7

8

CU T-E ND OFF

SE NOkOlDER

O R ll_ t 1 )I A.

HOltrnOOYGH .

60 TH stD E IICES

S E

S IDES

NOTE: n~~~~

STAMP

BLOCK

M U ST

Ge110KT

AGAlttsr

IN S ID E

S O TTO M A N D

8ACKO f eMf

8Ef ORE CUITING

~~THIC:K

6

R IS AWTWO PJECES

W hat you w ant is a fr icti on fi t be tw een tlt e

holde r a nd o uts ide case . T o ge l th ls , r pu l led

e u t th e bold e r and sanded lI1es id e s . l igi l t tg ,

T h e bes t w ay to do th is is to ru b th e s tam p

h olde r acro s s ap iece of s andpape rt h ars la y

in g on a Bat s u r face , s ee f ' ig. 7 , K eep ch e ck ,

ing un t i l th e h olde r fi t s l oo se enou gh to pu l l

ou t eas il y , bu t norso loose it fa l ls ou t,

R O U N D EDGl lS . Finally , round over th e

edges of th e

cas e ,

s ee Fig . 8 .

C lJ rOFF..'1D .Mer lhe h old e r fi ts in to th e

case, s and th e

lop

and bottom bandsawn

edge s sm ooth .T h en s li de th e h olde rall

t l

/ Ja g i n t h e case , an d pu sh it down so the re ' s

a s lo t for s tam es at th e top . Now cu t off th e

f r o nt o f th e a ss em ble d p ie ce s . s ee Fig . 6 .

CORNER

RWIUS.

Next. cu t a Y $ rad iu s o ff

th e top back co rn e r of th e case and san d th is

c omer sm ooth , s ee Fil l: 6 .

FlU CI1 0N FIT .N ow com e s th e tr icky par t .

A(ter th e two piece s are cu t apar t . u ie ease is

co m ple ted by glu ing : V I S

-th ick ca s e

s id e s

C

to

th e ou tsi de o lth e U .s h ap ed case .

CIIfTO SIZE. S tart b y cu tt ing tb e s id es to

th e

s an te w id th

(2 )

an d le ng th

(3 ',)

as th e

case . (For th e s e

par t s , s e d

th e sam e wood

as th e cen te r p iece on th e case .)

DRIll HOLE .To prov ide a fi ng er re ce ss (o r

pu ll ing ou t th e s ta m p h olde r. r dri ll ed a I

d il l . h o le th rough both s ide p iece s (C), s ee

fig.

5 . (La t er th e s e h ole s w ill be

cuLin

ha lf re f e r

to Fig . 6 .)

c: ;tV EON SIDES. Now you ca n

g lu e and c lam p U te s id e s 10 th e

case w ith Ote h ole s tow ar d th e

open end of t he U , s e e

Fig . S .

Here 's th e fl rs t poin t w h e re

you h ave In be care fu l or th e

s t amp h old e r

wont

h av e a p e r

fe ci fit in (h e case . First app ly

th e g lu e s p a r i n g b y . Any glu e

squ eeze -ou t inS ide th e case wil l

pre ven t th e h older fr om f i t t ing .

And don 't pu t too m uch pre s

su re on th e c lam ps.

RE tNSERTROLD ER .Once th e

g lu e dr ie s , rem ove the c l amps

and pu sh th e S t am p h ol de r back

in to th e case . It w ill p ro bab ly be

a very tight

f i L

f il doesn 't '1 i tal l

th e w ay aga ins t th e bac k o f th e

case . ch eck fo r an y dri ed g lu e

th a t

m igh t

be in th e w ay.lf i ts t iU

doesn 't fi t , you m ay h ave to

lightl, /

s an d th e s ide of th e

s tam p h olde r, s e e Fig , 7 . D on 't

sa nd too m uch - you w ant a

very: t igh t

fit

at th is poin t

FIN IS HIN G THE D IS PEN S ER

NOTE:SfOP

POwat AfTtR CUnlNG

THEN B AC K B LA NK O UT

S I CONO

CUTfUJI

Bl H

ova so

SOITOM EDGE

IS A G AIN S t -fE NC E

NOTE:

u s H A I [ < >

pfleI

IICOMES

OtmllCIIS

R E M O V E

S T AM P H OL D E R :

Jr _

~ :

.. ..

a

4

blad e to u ch e s th e st op line .

THIRDcor To com ple te th e U , firs t tum

off th e pow er and rem ove th e fe nce , T h en

fe e d th e b lad e bac k th rough th e li rs tcu t u n ti l

i t' s in U t e h ol e a n d nex t

to

th e p enc il

li ne .

T u rn on th e pow er and cu t a long th e pend l

l in e d ow n to th e s e cond cu t. and rem ove th e

h olde r. s ee Fig

,I.

Once th ey 're cut

apar t.

s ave both of

th e

piece s .

t h e f ir st c ut, s et the topdgeofth c laminare d

b la nk agains t th e

fe nc e a nd

s tart th e cu t on

fh e ron

I I d g o

c u tti ng u n ti l th e blad e ju s t

b re a ks in to th e h ole , se c fig. 3

SECON D

c or, B efo re

m aking

th e

s econd

an d th ird cu t s , m ark s top line s 14 fro m th e

b ac k e dg e on both s id e s , se e Fig , 1 . T h en

p lace th e p iece

so

th e

bottomedil .

i s a g ai n st

th e fence and m ake th e s econd cu t u n ti l th e

Me r d ri l lin g th e h ole (or th e ro ll o ts tam ps ,

I u s ed th e band saw to cu t th e s tam p h old e r

ou t of th o cen te r ofth e b lock .

S t . UP FENc e . S t ar t by c la m ping th e ri p

fence (or a s tr a ig h t p iece o r plywood ) 1 0 t h e

top of th e band saw table V fr om th e 1 8 U 1 8

o r th e b lad e .se e

Fig.

3 a.

F I R S T

cu r

Th ere are actu a lly th ree s epa

ra te c ut s th atproduce

a

U

s h ape .

To m ake

C U nlN G O U T THE STA M P HO LD ER

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oodsmith2

SH lM C AN N OT

_STtCKOUT

66 tONDUG

NOTE:

HOLD PINCll TiGHT

AGAINST S lOCK

ANO SC.RSE

ROUND

AU . F OU R .

lfG

2

~

,

e,

SHORT

~

lfG

.'

8lOCK

THtCKNtSS

sr r

StOOL EQ,U/ll.

ON FL T

..

~

DISTANCE

SURfCE

~

U N O E R

SHOflTUG

lr ;::l~

~

SKIM t..

~

SCl.8E

SHORTST~

BLOCK

SHIM

LE G IS,

penc il pq in tl igb tagainst th e lo p

o f t h e b lo c k.

Then

m ove th e pen

cil and blo ck aro und each o f th e

legs.

se e lig 2

A l l t ha t' s lC (l lo level the stoo l

(o r Ho rse) is to cu t each leg on

the

s cr ib ed lin e.

CRIBI; SCRIBE. To

t ha tpasses th r ough t he cente rof

the legs. This a(ijustil ig rod

al

lows th e com pass to be set

ea sily . ' Theo the r b en efitto u sin g

this

type or co mpass is the legs

w o n't m o ve

as

you 're sc ribing .

SCRI81NGACABINcr.

A l P ica l

e xa mp le o f s cr ib ing w ilh

a

com'

passwould

b e w he n fi llin g a ca b

inet ro an uneven w all. see fiJr.

I.To do

th is.

se tth c

distance

be .

tween he c om p as s po in tand th e

pencil

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13

o.65

SEITO

INSfD[

8J.A1

5PACER

s tOCK

1

~ . n

~

C

ttWliNS~~~R

a l.O .

The

le gs o n th e H ock in g

Horse

are splayed out w ith w ide

wedges see page 6 ). To m ake

th ese

wedges

th is

w ide.

I

started

w ith narr ow w edges and glued

them together,

cu:r1llE BlANK. 1 0 m ake the

narrow wedges start with 8

blan k the same length as you

wan t th e w ed ge s to end up.

S incei needed a 10L

of

wedges

for th e R oc kin g H ors e. Ilued

CUnlNG WEDGES

sr r MJnR G VG

TO AHG t. O F IOARD

block to the blade equals th e

It id

e /d

o f

the w edge ( ~

fo r

th e horse , se c Fig. I.N ow m ove

back

the block and

d amp

it to

th e fence

injhm

oflhe

blade .

Then put a m ark on o ne e dg e

of

the w orkpiece lhal'S half of

the w ide end (l/ts''). see Fig. 2.

N ow , an gle th e w ork piece.so

the m ark al igns w ith ib e

i 'idl

o f th e b la de and t he a dj ac en t

edge touches the block. Then

Woodsmirh

AUXiLIARY

fENCE

RdjuSI

Ih e m ile r g auge

to

(it t ight

againstlheworkpiece,

se e

rtg.

2 .

Cl11TlN(;WEIlIIES . After

th e

sa w

is se t

up. m ake a

pass 1 0 es

ta blish the

angle.The cut-off

piece 6'001 th is first CUIis w aste,

Then

flip

the blank over and

m ak e a no th er pass . see Fig. 3 .

T h e c ut- of f

f rom

th is p ass is th e

co rrect ly

tapered

wedge .

To cu t

m o re w e dg es, c ont in u e f li ppin g

the piece be tween cuts.

I

X ttCH \

CURltD lINES \

tnwt fN

X POINTS

STRAIGH T

X

UNES

DON~FlOW

grid . To keep from losing my

place . Ihin k

of

th e grid

a s a ser

ie s o f h er izont at b ands.

Within each band there ate

points w he re U te ou tli ne i nle r

seers th e grid, trs th ese po in ts

th a t are transferred from the pat-

te nt t o t he g lid .

To lo c ale these points , r men

ta lly divid e

each

llenglh of gA d

line into fourt hs. T his w ay J ca n

es timate the intersection points

easier. see P ig.

t a o

After marking tbe points , ifsa

m a tte r o f- co nn ec tin g th em w ith

n cu r ved lin e. To do th i s. lo ok at

th e s ha pe. th en ske tc h t he cu rv e

b etw ee n the

poin ts .

se e

Fig.

2 .

The

outline

doesn 't hav e to

match th e pattern exactly. It s

more import an t ihauhe f in ished

shap e looks an d feels smoo th .

2

together pieces of I thick

stock to form a blank

10

tong

a nd 2 2 w id e. (N ote g ra in dire c

l ion in F ig . 3 .) T he e xtra w idU t

al lows

you 1 0 suppor t th e p iec e

with th e m ile r g au ge.

SE'l IIS.~w .SeUingup th e ~W

t o cut t h e w e d ge s takes nu m -

ber

o f s t ep s . f ir Sl, p la ce a spacer

block between th e rip fe nc e a nd

th e blade. T hen lock down the

fence so the distance from (he

GRID

UNES

Then

connect

th e

marks.

H

~le

grid

i s sma ll.

I

use aemm ing

square t() lightly pencil in

the

titles. If th e gl id i s l ar ge, 1 use

a

s Iight board ordrywan sq ua re ,

DRAWING TItE SHAPE.

Once

the grid ti nes are drawn, the

s ha pe c an

00 t rans fe r red

to

th e

OIVloFINTOI

MALLER

INCREMENTS

OQONt HORIZONTAL

_ - BAND AT A TiME

1

don 't w ant to usc a g rid , get the

fu ll-s iz e p lans for th e Horse ant

trace them. s ee page 24.)

ACCURAT. ; .'t,\..~URME \'1 S.

To mak e the grid . first mark

~( )inl,; l apart around the ou t

sid~edges of the board you 're

going to c ut the horse out of

T he problem w ith lay ing out a

proiec t like the Rocking Horse

page

4

is th e la ck o f S Qu are

edges. There s noLhin g 10di-

m ension from . T hat's why we

u se agrid

to hel p w ith th e

lay out ,

T here a rc a f ew tricks

t ha tcan

m ake u sin g a grid eas ier.

(If

you

TR NSFERRING P nERN FROM GRID

7/24/2019 Woodsmith - 065

14/24No.65

oodS01 ith

o pp os it e p ag e). th is sy stem allow s lh e cars 1 be ar

ra ng ed in an y

ordertoflt

th e n ee ds of th e e ng in ee r.

lR,\Cl\.

Arter

I

f in is he d b uit di ll lt t he

t ra in , I d e clded

to m ake som e track for the tra in to run on . T h e a rt ic le

o n p a ge s 18 to 1 9 shows h o w

to

b u il d b ot h s tr ai ghl an d

c urv ed s ec tlon s.I t hi nk t hi s is w h ere th e fu n b eg in s. f

YO\I m ake enough track sec tions. k ids c an u se th eir

imaginati ons to bu ild all kin d s o f d if fe re nt layouts.

M ATERlJI lS .

I buil t L he train and track from ha rd

maple . (J1 hard m aple is d ifficu lt to find in your area.

w e re offe rin gth ew co d a nd th e o th er

p art s t o b u ild

th e

train and track , see page 24.) But you could make th e

e nt ir e t ra in Q uI of p in e o r a ny o th erw oo d.

FINlSIL 111e

train and track w ill u nd ou bte dly g el

banged upso itm ay be best tosonen allthe edges and

to leave the w ood

unfinishedUycu

wan fin is h it.

I

w ou ld re com m en d a n oil f in is h th at f l o w s in to t he tight

spots. [ th e tra in is

to

be used by very sm all

ch ild ren ,

use

a

finish

that s

non-tox ic . s ee pa ge

24 .

1 4

sign ing a lO y lik e th is tra in c an q uic kly g el O UI

0 1 h an d. T h e q u e s tl on y ou r e u su al ly f a c e d with

isw ho are you designing it for: a child 1 p la y w ith or

a n a rlu ll to b uild ? F rom m y e xp erie nc e, k id s w an t toy s

that mov e a ro un d. b u t. d o n t b r e ak . A n d th ey w a nt l oy s

th at aUow them 10 IISC t h ei r imag in a tion .

A dults, on the other hand . w ant 10 b uild toy s lh al

loo k a u t h e n t i c (often 10t h e f in e s td eta iO . T I le p r ob l em

is

that

e xt re m el y d et ai le d t oy s

are

usually

builttosit

on

a s he lf, K ids wo ul d d e s t r o y r h e m .

In designing

this

tra in , w e trie d to comp r om ise . It

h as e nou gh detail to be interesting and not look

c lu n k y . But at th e sam e tim e, it s buill rugged s o e v en

t h e y ou ng e st

k id c an p la y w itll il

w ithou t

breaking il .

tlNIF )lt\l CHi\. SSIS.

Build ing ea c h of lI e five cars

sta rts lhe sam e - Y Ou build the chassis. Then it s a

m a tte r o fa dd il lg p ie ce s so it looks lik e a specif iccar.

Since a l lof th e chas si s a re b ui lll he s am e , an d int er

connect

w itb

a

u niq ue c ou pl in ll s ys te m (refer to the

A ll the ca rs for th is m in iature railro ad sys tem sta rt w ith the sam e ba sic

ch a ssis a nd a u n iqu e cou p lin g system T hen yo u add to p p ie ce s to p ro du ce

in d iv id u al c a rs A nd do n t fo rg et

to

la y som e

track

u n d er th e tra in

Toy Train

FOR KIDS

US T

7/24/2019 Woodsmith - 065

15/24

7/24/2019 Woodsmith - 065

16/24N o. 65

oodsmith

6

----- 4~~4

---- .....l -.,

and the

(WO

end walls (H)

10 fi t

between the

sid e walls . se e 1 ' ,g .7.

. '\SSE~tln.Y .N ow . glu e th e box toge th er.

an d glu e

it

down to the chassis. se e Fig . 7 .

SECOND: TRIM01 1

ROOF SEalON FOR tNGtNE

RIP

.. NC E

ROOF BLANK

IA THIel(

END WAllS ~

crrr PIECllS

1 0

S IZE. Beg in by

resewing

a

13 long blank I il' th ickfor

O le

wa l ls . Then

ri p th is blank 1w id e.

Next. cui the Iwo side walls(G) ~Y. t ong

,,

rnr BlADE

TO 1S

4

OWER BLOCK

3

D IUU. :l1~

HOltS

THROUGH

aLOC K fRO M

BO lK sro ES

GLUE PIEce S

TOGElH.e~

Af\ lOOOWN

TO CHASSIS

~ TAIMOFF

~KN08

SPACEM1DD lW HEt l l.-l:

FROM . : HAS54S

. . . . j 1

., th ickto p s ec tio n (0 ) 3

long . and

ro u n d o ver

th e

from end

an d s id e s.

see F ig . 5 . N ow drill ho les (o r th e

smoke-

s ta ck , f ill er

ca ps,

and headligh ls. se c F igs. 1

an d 5. Then glue down. the bo il er pa r t s.

CAl l .

N ext, m ak e th e ca b

(E)

ou t o f a small

Since th e engine p u ll s t he res t o f t he t ra in , I

built it first. i 11~ ch ass is (A ) for th e engine

requires few m o dif ications. F irs t, cur th e

to ngueo f fU lcu 'on tend . see

Fig . 2 .Then dri ll

anothers et o f h o les fo r th e ta ndem whee ls.

L O W E ll B L O C K .

S lar tadding

to p

pieces by

cu tting a lower block

(B)

from

: ,, -ul (c k

stock

that's

th e sa m e w id th as the chass is .

T hen trim an lS ' bev el o f f t he fron l end an d

glu e

lh e b l

7/24/2019 Woodsmith - 065

17/24

1 7

Voodsmith

WINDOW DETAIL

..-- WINDOW SECTION

~4)t 11n x 4);t)

CUTTWO [ .. LO NG

ROOF PIis

CAB@

f~ X 11

1 -

x 11 \

WASTE

BARRELRACK BLANK

11

A. )5EMIl~Y.Now.

glue the pi eces

to the

chassis

so ihey 're

parallel to

ea ch o ther

an d

0 8

apart.

This a llo ws the

ribs

on the barrels

to rest

betw ee n

th a racks.

BOTTOM BLOCK

(~. -1~. X4~;4)

12

GLUEOOWN

1J.. f ROM

-FRONT OF

CHASS1S

l/ .. ..-THICK

STOCK

__

.65

\Vhal

W Ould

Ille end of a t rain be w ithout a

. :aboose? A ll the parts

fOI

Ih e c ab oos e

are

similar-to piec es

m ade

for

the

other cars ,

UI ITO~IBLOCK.Startby

cutting

a

bo ttom

hlock(L ) th e

s ame s ize es o nthe passe nger

c ar a nd glu e i t to the cha ssis. se e Flg.12.

\\l:o( en barrels. (S ee page 2'1 fo r

urce s 01 the barre ls. )

\lt

To make the barrel ra ck

(1

7/24/2019 Woodsmith - 065

18/24No. 65

ct MP CU VE O

FE NC E

2.~.

fRQMlL

you use th e p lywood base boa rd . drive a nail

through the hole in th e piv ot b o ar d a n d into

th e baseboard .

(B esu relo aJign

th enai lwi th

th e front g of th e blade.

\V ith a Cu rv e b la nk in place On th e jig ,

sw ing th e pivotboard th rough the blade an d

cu t o(f lhe outside a rc of th e cu rv e, see fig .

4 . (S ave th e w aste piece from the end of the

pivot board, It's used

On

th e n ext s te p .)

c;lltINS1D ; ARt S. Af te r cuttinglhe outsid e

arcs on all th e c urv ed p iece s and sa nd in g o f(

th e to oth m ar ks, you can cm t the in sid e arc s,

To do this I use d the curved w aste p iece

that

w as c ut o(f the end of th e pivot board)

as a fence. sec F ig , 5. Posidon the curved

piece 2% fr om the insi de o fth e b la de. (This

w i l l

cut a curv e section

VIS

overs ize .

After

s an d in g, the cu rv es should en d IIp~ \e sam e

width

a s the

straights - 2 :t t6 .)

Go ahead and cu t a ll the c urv e se ctio ns to

width .Then sand thein sld eedge (rem oving

at leas t V16~so th e curved sections m atch

th e w id th o f the straightse cuons,

W @0< .1 snlith

N ex t. drill. I ll p ivo t h ole cente red on th e

width of tile board and I [r om th e end. To

help

pos ition

the blank s on the jig . nai l a

I071f j longenceto thejig so thejin edge of

th e fence is 1 2v.. fro m the p iv ot ho le.

N ow set one of the curv e bla nks on I,Q po{

th e jig and align the en ds-of th e b lan k w ith

tile fe nce , seeFig, 4. Dri ve smal l nai ls atboth

ends 9f the blank

to

ho ldit

in

place.

USING

tEJIG

To

cu t the ou tsid e

cu rv e. I set the jig on

top of m y circle jig

(s ee W oor( 1 iI I lNo.

51. O r, ju st c lam p a

piece of:v.. p lywood

to your band saw

table. S('e fig . 4.

I f you 're using-the

ci rc le

jig . positio n

th e pivo t poinl16

[r om the blade,

If

CUT INSIDE ~~

5

\

S fT Mll tA

G UOE T

2 : 2 :

1 8

Ct MP ~ PlYWOOD B Se

CJRCL JIG TO aAN D SAW

rRACKa~K

A fter th e m iters are Cu t on the ends ufaH th e

curve blanks B. you can se t up to cut th e

in sid e

an d ou tside arcs .

PIVOTJIG.

To

accu rate ly cut th e outside

arcs, I m ade a p ivot jig that sits on top of t he

band

saw . Beg in m a king the jig b y c uttin g .

1 4

x

18

p iv ot board from a piece of V .

plyw ood or M ason ite.see F ig . 3,

CUnlNG THE CURVES

CURVED TllACK

}

ClAMP

~NGLtO

22n

SToP BlOCK TO

AUXILIARY

ENC( ~

NOTE:

All StOCK

I,, THICK

m erg er w ith a not her railroad line),

cvr

IUANKS.

Begin m ak ing the track by

cu ll ing blanks fro m

1 2

stock

fo r

th e

stra ig hts A an d cu rv es 8,$ee Fig. I.

~llTER CURVES.Before cutt ing the cu rve

pieces (8 ) to their ro unded s ha pe . I m itered

th e ends ofthe b la nks . s ee

F ig . 2 .

To

do th is ,

attach an au xili a ry

fenc te t o the m iter gauge and se t

the miter liduge at

Vl

The n

m iter m end of a ll th e b lanks,

T o se t up tocut th e other end ,

tu m on e of th e b la n ks e n d- fo r

e nd and c lampas top

b lo c k t o tile

auxi l iary

fence , s ee F ig . 2 .

Adjus t

Ih e stop to trim of t th e b la nk s o

it's

l 0 7 i 1

long on

t h e

shortslde,

se e F ig .. T hen cu t a ll th e c urve

blanks

B

t o lh is

leng th .

The train can opera te O n its ow n, or you Can

m ak e a tr ack fo r it. By m a kin g b oth curve d

W Id straightse ctionsoftrack, YO Ilc an create

aw i de

var iety of interesting lay outs.

PREP_RING STOCK

A good way to start is to m ake ~ight

s tr a igh t s ect ions

~ I.

an d eig ht curv ed s e c -

tio ns

B .

(EighrcuI'V esa re needed to

make

a

com plete

circ le.) This

makes

a good s iz e

la yout , and you can add m ore se ctions la te r

< as long as the government approves your

Train Track

7/24/2019 Woodsmith - 065

19/2419

~ P US H

SHOUl.D R

0 RAaen UP

l iGHt ro SPACER

T A A C 1 blocks,

and the

fence

is

fr om the po in t o f t he bit.

ORlLLTliECO )' 'NEC I'ORS .N o w d rill % d ia .

holes ,

~ 6 '

decpon bo th

edgesof theconnec

tors

(C),

se e P ig. 1 0. W h en d rill in g, p ush th e

c on n ec to r tig ht a gain st th e fence.

ORlL.LT I IE

T R A C K .To drill th e

ni.tehing

holes in t he tr ack. us c the sam e set-u p, ex

ce pt yo u ha ve to add a 4 th ick space r to iii

un der th e rabbet in the end o f t he track, se c

Fig.

11.

The

tri ck here

is

to cut the spacer

1i6

w ide (w hich is

V I~

wider than the

length ofthe rabbe t On the end

o f

the track).

Wben

thet rack

i s pu shed again st

th e

spacer .

(h e hole

will

be po sitio ned to create a gap

b etw e en th e en ds o ( th e

track. Again,

th is is

to

make i teasier

to

assemble. )

DO W ELPII'o 'S.he last step in m aking the

connectors

is

to c u t W ' long d o we ls a nd glue

them in to

the

h ole s in th e co nn ecto rs, see

F ig . 9.

TRACKSl lAPES .he

track

c an b e lay ed o ut

in a vari ety o f shapes, espec ially if m ore

65

1 0m o f t he ra bb ets o n

tile edges,

see F ig. 7.

Afte r th e sa w w as S C Iup , I r ab be te d b ot h

ends

oitlle

straight track W

USing

a

miter

g au ge to

support

t he w o rkp iec e .

On th e c ur ve d track B), I

backed

up th e

wo rk pi ec e w i t h c u rv ed pu sh

blocks. se e Fig .

8.

T o .

m ake the blo ck s. trace the shap e

o f

t he cu rved tr ac k o nto p ly w o od.)

t ra ck . r ef er to p ho to b elo w .

To

se t

up ( or c ul lin g t he se

r abbe ts . f ir s t

moun t a

I lVJ6 wide

dado blade on the saw

and

auach

an

auxil ia ry fen ce to th er ip f en ce ,

se e

F i E t ,

7a. Then bury the blade in to the

auxiliary

fence

so

0/4'

is

exposed ,

Now

r ais e th e

blade

up to

cu t

a

rabbet

exactly deep en ough to align w ith

th e b ot-

Join the pieces of track together. small

,n,, < I t

together. connectors

a re m ad e

that

fi t

Wl

7/24/2019 Woodsmith - 065

20/24N o. 65

~I \RK~IIRROR .Now you c an uSC lhe fo ld s

in the paper to mark th e points whe re the

axis

lines

m e e t

th e

e d g e o f

th e m ir ro r.

se e

S te p 3 .

tA y

OlIT TEMPI_lJE ....

Jt er m arking ' th e

axis lines en tbemirror. th e te mplate can be

cu t rolll a p ie ce of 14 Mason ite . (T he te m

p la te s hown

in Step

is sized

to accept the

ovalrnirror.)

After

< ,u ttin g t he

templa te to

size.

mark

tw o

cross

lines.

see S tep 4.

Now align

th e

marks on the

edge

o( th e m irro r w ith th e

cross lin es o n th e te mp late , see S tep 5 . To

ho ld the m ir r o r s te ady , use pieceotdouble

sid ed c arp et ta pe to a tt ach uto the tem plate.

GUI E USHING

The id ea o r a lllh is is 1 0 us c th e oval shape of

the m irror to m ake a guide tem plate ro r a

route r. Th is template is then use d ,v illl a

guide

l~ hillg

h at's m o unted to the base o (

the

ro uter,

see S tep 6.

Woot.1sm irh

o nly ro ut th e o va l ins id e the base.Thisgives

yO U

a

few m o r e o p ti on s (o r add ing a :Dlving

or inlay the lid o r the box. .

MKING TH T MPL T

O k ay , b ack to the m irro r and tem plate. T il

m a ke a te m plate to rout a recess for t hem ir

ro r, th e first step is to tra ce th e s ha pe o r t he

m irro r o n a piece o p a p e r, s e e Step 1 .

FO W O N A XE S. In

o rd er to alig n th e oval

sh ap e on a tem plate .yo u have to determ ine

th e tw o

a xe s o f

th e

ov a l. T h e re s

a n ea t tr ic k

to do th is , JU St hold th e paper up to a light.

sec S tep 2. 1 1 l ~I ighl allow s yo u to see th e

o va l curve on both S id es r th e p ap er, Adjust

th e p ap eruntil th e curves align , and (o ld th e

sh ee t in half.

T h e (o ld l inc in dic ate s o ne a xis ofthe oval.

Fo ld the sh ee ti n h al flh e ot hel'way to get the

o ther ax is , (Ih ese axis lili e s a re p a rt ic u la rl y

impo rt an t t or a li gning t oval in a r ee ta ngu

la r box. )

20

v als are p le'a sin g shapes - bU I v y

difficult to draw . W hen

ec ide d 10

m ak e

an ov al

b ox . I b ad rw o

choices. could

get all

oval

temp late from all art Sl()re.

Or. I

co uld trace so mething that already had an

ov al shape.

The cho ice was easy when I ran across a

source

( o r a b e au ti (ul beve led-edge

o va l m ir

ro r. s ee soerceson ]lIlll~24. W i lh th e m ir ro r

i n h an d.I m ade an ov al bo x th at m a tc he d its

shap e. 'ln is inv olv es m ak ing a tem plate to

cu ta

recess

in th e lid fo r

th e

mirror.

While I

was at it .I u se d th e sa me te mp la te to

ro ut

a

malch ing oval recess t he ba se.

Des ign

Note : I f you don 't w an t to use (he

mirror. bu t still want to m ake a box w ith a n

ov al recessinthebase.ju st

gel

an o val tem

plaiefrom an artsto re and tr ace the shape On

a p iece or~M aso nite . The n cu t it o ut a nd

sand

it

as s h ow n in S lep 8 on th e n ex t p a g e ,

T here's ano ther option . to o. Y ou can

m ake a rectangular bo x On the ou tside and

he beau ty of th is ova l box is the be veled eclge

mirror

tha t inspired

t

h e cha llenge w as to figure ou t a w a y m a ke

th e bo x fit th e exa ct shape o f the

mirror.

Oval Box

PROJECT

F T

7/24/2019 Woodsmith - 065

21/24Z l

9

T o l tl l the (,(mt.plat~,dJ'ili -Y '8-dia .

index ho l.esOI . /lO lk lind. of the l O l lY

a~is

ente)' th e

i1ldl1>.

o le. 1 , . 1 > ' 0 ' the

e d g e oj' t l le ' i , el e> ' f

the firro;loith

)~(1i Ppenci],

w ith a dl1l111 sander mounted iu your dri l l

p ress, see S tep

8.

INDEX HOI.ES.

This tem plate

w ill

be

m ou nted to th e

l id,

and the n to the ba se to

routouttheoval

shape. T oa lign

thetemplate

on both pleces.l dr ill ed

t W O I G

index holes .

seeStep 9.

These holes

a re a ls o u sed

taterto

loca te and

drill

holes in the

lid

and base for

in dc~ pins to kee p th e lid from slid ingoffthe

base. refer to F il . 14.

FlN tSH .l f in is he d ( he l id a n dtheo utsid eo f

the ova l box w i th G en er al l~nish~ ' T w o

Step Sea la ce ll syst em . After fi n ish ing, 1

added a piece of fe lt to U I ., in sid e b ottom o f

ti le box.

bu shing ,

se e

Deta il illStept; .

f

you w a nt a n

. (lct fit

make t he t emp la te

~ Ia rgerth.n the mlrror .However. l made

t he t empla te

/s

la rger than the m ir ro r.

This

creates a I > : r l space areund the edge 01 th e

m irror to a llow f or e xp a nsion of lhe w ood

a round th e m ir ror . se e

SICP 7 .

Shop Note:

I us ed a

pie ce o f c ar db oa rd to

tra ce the line

v

outsid e the per im eter of

the mir ror .

See

$h bp Notes

On

page

12

fo r

m ore on th is tec hnique.

cm-ro SIIAPE.

T o compl et e th e template,

cu t out the insid e to rough shape w ith eith er

sabre saw or a coping sa w , T hen sa nd the

edg es sm ooth r ig ht u p

to

the m a rked line

T R C E

ROUND

P E R I M E T E R

OF M IRROR.

HOlD

MIO.

ON

TRACING

P A PE R

A lmost

a ll

router m anu fact urers offer

a

gu id e bush ing (o r templa te guide) tha t fits

on the ba se. of th eir route r. T his gu id e bush

in g ex tends below the base of th e rou te r so

it can nib a ga in sttheedge of a templa te. T he

idea

is

for the guide bushing to follow u i e

shape the

t~mp la tc whi le the router b it

(t ha t fi ts in sid e th e guid e bu sh ing) actual ly

does th e cut tin g .

T here 's one consid eration her e, T he

router bit cu ts a pa th tha t's i ,(si

7/24/2019 Woodsmith - 065

22/24

NOTE:

TO-C U T FU ll

OPTHMAK

SEV ERAlPASS{ . S

wide

lip in sid e th e e dg e

o f th e

template.

se e

Fig . 6, T he m irror sho uld fit inside lh is lip

w ith a bo ut 1 0:3 2p ac e a ll a ro und.

ROllf S ,I SF .,N e xt r ou t o u t t he base o f t he

box the sam e w ay, bu t to a dep th of 1 .1 did

th is by m aking a series of passes about V .

deep each lim e, se e

fig.

7.

Woodsm ith

Tt M PL Tl

lRJANG~

INUPWAlto

POsmON

4

a c s s

INllO

~~l WU>E

UP

6

the

(ac e o f

the

mirror

will be

6ush

with

th e

edge of th e lid (about a :V J2 deeprecess).

Remove the w aste by plu ng in g th e r ou te r

into the center of the lid and m oving it in a

c lo ck wise p attern u ntil y ou rea ch

U lC

per

im eter o fth c tem plate. see fig,S .

W hen yo u're d on e, there sh ou ld b e 3% 2

1NDEXING

PJNSMUSl

SETBilOW

TO P O F

T E M P L A T E

U SE

MA SkiNG TAPE

fO KElP Pf lCl ,

LIG NE P W Hl l

DR aW NG H OLE S

S

A14GN Slots

OF TftlANGl.I

N o. 65

M K E N D W rT H

CAJtPfNltA S

TRI N U

LIG N lOGE S

OFAUPK6

2

O R . .. .

3 , - 0

ttO U

I. DO

.

ltMPLArE

NOTE:

Gl Ut AND ClAMP

aonoM TO A SE

A ~

BOTTOM

BJ.ANK ....

, 1

~

B A s e

BJ.ANK

The index holes are used first to align

th e

temp late to the lid to rout a recess r th e

mirror, see F ig , 5 , Tap in d ex dow els ~t6 '

d ia ) in to th e h oles , b utd on'tg lue them in.

ROl lI 'UD RCf .$ , To rout ou t the recess

in th e tid , use a 11.1 traight bit and R 1/ ,0;

g u id e b u sh in g, S et th e b it deep enough so

R O U T R E C E S S

The nex t

step

is to d rill holes in th e

lid and

b ase Io r

th e in dexin g pins .

HOLES

uo. Sta rt

by l if ti ng

the

lid an d

tem plate off the

base, Then

Bip

th ese tw o

p ie ce s o v er

so

the t emp la le is

fac ing

u p a nd

la pe th em to geth er. see Fig , 3.

Now with

:.6 -d ia. bil,

drill

holes

I ' . ' l

deep in to th e lid a t.e ach end US ing the holes

in the templa te a s a gu ide.

HOl.ES IN B AS E.

Repeal th is pr ocedure on

th e ba se.Justptace th e template O n t he ba se

so

th e sides of

the

carpenter's tri an gle al i,,,

properly,

S L > C

Pig ,

< I .

D R ILL IN D E X H O LE S

I slat ted b uild in g th e b ox b y cu ttin g a b lan k

fo r

th e lid (1\) from ~ stoc k to m atc h

th e

size

th e te m plate, see F ig,

1,

The base is

made by glu ing ijp tw o pieces a :v.1 thid aonOM

OFeASt

ONA

ST ArJONARY

ElT SANDEa

IAS

SETUD

ONTO

10s hap e. p lac e il on

th e

ba se using the index

p in s t o a li gn th e lW Opieces , see F ig . 9 . N ow

useth e lid asa templateto trace tlr e o va l on to

th e base . and

Cui

it

ou t 10 rough

shape on a

band saw

S. N I ITOUNE.

To gel th e

base

10

th e

sa m e

shape as th e li d . sand them together with a

dru m sander ore n a

bel l sander.

se e

F ig .

to .

10

12

If

RO UN O

OV~Ran

11

No.6;

111e oval box is complet e ar th ls poin t -

ex cep I r rouLing p ro file s on th e L O Pedge of

th e Ii d and the bouorn edge of the base .

SHA I}OWLIN E . H o w ever. before I d i d th at.

I ad ded a shadow line be tw een the li d and

th e base . If eiLherp iccc w arps. th is lin e adds

enoug h depth So th e cra ck be tw een the ti d

and bas e is

nO lSO

visible.

A U X IU A R V F EN C E .

T

ro uL th is

shadow

l ine.

mount

a

i t l sl ra jllht blt to

th e

ro u te r

table and se t th e b it

h2 high .

se e

r i g .

na.

Then I c lamp ed a n a u xi li ar y fence (a p iec e of

: v . t

plywood)

0

th efront of the r ou te r t ab le s

r eg u la r f en c e.

N ow 111 m 01\ ti le

ro uter and

slid e th e

auxi l-

iary

fen ce in to the b it

to

rou t

an

open ing th e

w id th

of

the b it .

To reu t thesha dow lin e tum the r ou te rou

and ad ju st the fen ce so th e b it extends h2

o u t.

see

Fig .

ll a . Then

ro u l

a ra bbet

on the

to l out8 ide d ge

of

th e

base on ly to produce

th e shadow line . r ef er loYig . 14a.

~OUNO OVllR 111151000 After rOulin

the shadow line. 1 s witched to a

\/,j

ro und

over bit and rounded the insid e edge o f the

base , see F ig . 12.

O Im JU F.IROAt.S.11lC outs ide edges of

th e bas e.and th e lid ca n be ro uted to severa l

shapes. [ used a

A t

round-over b it. to

ach ieve a s imp le and

grac efu l lo ok. ( Be fo re

USin g

other b its , check rha t their p rofiles

w on t curinto Ihe holes fo r the in de x p ins.)

INDEl

7/24/2019 Woodsmith - 065

24/24

\Voodcra fl Supply

P .O . Box 168 6

P ark ersburg. \VV26102.T1.

NT

Bridge City Too t Works

11 04 N .E . 28th. Ave.

P o rtla nd . O R 9 7 23 2 NT

Tandy Leather

1 .0.B ox 791

Fort \V orr n . TX7610 1 .. .. .... 8H

Sbopm ith , Inc .

393 lltn age D rive

D ayto n. O H

45414..........T1~

NT

S i m ii m / w 1 '( J .w a . 'I I a> ld SIIp JUes nuty be jm ,.td

i n l it e j 'o l /m / li ? IU c a tl li ogs .

Htnseuer

st l ies a11dl l i zes ? )W ,IIva ry .

PIdJ .se ,-e el ' to eackc(J. ia/t: lufol 'orde iU ;> lf n)'m ati.m~

VanDykes Rest o rers Cherr y TreeToys, Inc .

P .O . B ox 278 P .O . B ox 369

Woo nsc cket, SO 5738 5 .. .... . Rli B elm ont, OR 43718 ...... .

T T

NT

LTERN TE T LOG SOUR ES

OVALBOX

T he m ateria ls n ee de d 10 build

the O val B ox am availa ble (r om

\Voodsmith P ro jeetSupplies.

T he ov al m irro r and si li co ne

se ala ntc an b e o rd ere d u sin g th e

num bers below '. (W e recom

m en d u sin g Dow s silicone se al

ant to attach the m irro rs sin ce

s om e o th er silic ones m ay da m

a ge the si lvered backs)

765300

(1) 3 x 5 Beveled

Ova l M i n 'O r $5 .115

0765-305 (3-0z.tube) Dow

Sil ic o ne S e al an t (enough to al

tach

8()

to

10 0

mi rr or s) . ..

$3.29

Al so ava il abl e

ar e

lu m ber kits

in your cho ice o f s ev e ra l d if fe r

en c hardwood .species, Each kit

includ es th e fo llow in gil cO ls:

(1 pc.) 4~

x 6I; i ;

l thick

lum ber (to m ake the lid )

(1pc.) 4~ x 6 1 2 ; t 'Vu; thick

lumber (to m ake the base )

l : V I Dowel. 4 lo ng

'765310 Oval6Q x . K it o f

Lum ber - O ak $7_95

765320

Oval B ox . Kit o f

I , .umber- W ainul .. .. ... .. $8 .95

765-330

O val B ox . K it 01

Lum ber - Cherry ...... .. . 5 8 .95

0765-340

O va l

B ox .

Kit

o f

Lumber - P adauk ..... . , .$12 .95

(Padauk

is

an

exo tic ,

red-

o range hardwood that turns

deep m aroon on exposure to

sunlight, P adauk 's saw du st can

be irritaling . so using a dust

mask

i s adv ised.)

NONtOXI FINISHES

You

w i ll wan t

to use a non-toxic

fi n ish on

the Toy

T rain and

Track project.

Ordinarily. I

li ke

to use a salad bow l finish OJl IOY

projects, bru (o r the train I d i:;

c ov ere d this fin ish w as ju st 100

thick 10 se~f in and around all

the sm all parts o f th e tr a in . In

s tead. w e used a finish called

P re se rv e N U LO il a nd fo un d illO

bean ideal I in is hf or fh e t ra in s et.

P re se rv e is a blend of natural

o ils (rom ex otic nu t meats an d

provides an excel lent .

no n-toxic

fi n ish (o r toys as w ell as bow ls

81ld wooden kitchen utenslls.

T here are o th er fin ishes ~ la l

will

als o p ro vid e

a n on -to xic fin

ish and are still th in enough to

no w

o ver th e sm all tra in parts.

TwoO flhese-General l ' inishes '

Two-S tep Seal ae ell System and

\ValCo's D anish O il - arc bo th

non-toxic

when < ' ti red : (Accord

ing to th e ir manufacturers, this

can take

from IW O 1 0 (ourwceks . )

N on-tox ic f in is h es f or th e toy

train p ro je ct are availa ble (rom

\Voodsm ith P rojectSuppli es.

orf rom

t he SOu rces l is te d

below .

L oo k (o r m e

code

NT (oliow illJ(

thesupplier'sname.

0765-275 Preserve

NUl Oi.1

F ln ish , o z

$8 .95

51j ..203

General l ' inish ,, '

Tw o-S tep System $10 .95

l > ' l P int Step Ifl

(Sealer)

~ P in t S tep 2 (Finish

Coal )

A I J o w , ~

lo o e J , : t 1 / o J '( i f ' / f o o '7 1 .

;V ri f> : 1 - '4 'c t J

*~(b ier. t

c J la . 1 g (

jl.,' 9/90.

Y PHONE

F o r fa s te r : serv ice use o u r 1 9 1 1

Free

o rd er

lin e, Phone

o rders

can b e placedM onday th ro ugh

Friday . 8 :0 0 A M to 5 :0 0 PM

csr.

B efo re you call . have your

V IS A o r M a ster C ard ready .

18 4447 2

T M IL

To order by m ail. U$~ form

on

th e

pro tec tive

co ver o f

$

cur-

re nt issue o r w ri te your o rd er

on a piece o f p aper. and send il

with your check o r m oney

o rd er. (P lea se inc lu de $1 .5 0

shipping

charg e

with each

order.) IA

residents

add 4%

Sal es la- x . Sendord er Ill :

oodsmi th ProjectSupplies

P .O . B ox 1 0 35 0

Des M oin es, IA 5 '0 8 0 6

ORDER INFORM TION

TOY TRAIN

\V oodsmilb

Project

Suppl ies

is o ffering the m aterials and

hard ware needed to build the

f lv e- ca r'Toy 'T r al n and

Track

r e a -

tu red in th is is su e

O th e r

su ppliers w ho c arry toy

tra in p arts are lis te d b e lQw .Look

(or th e code 7 1 (o l lowing the

s u pp li er 's n ame.

.765-200 Flve-CarTraln,

P arts O nly $6 .95

The k il a bo v e in cludes all th e

par ts (bill no lu mb er) n eeded 10

build five train cars:

(2 2 ) I

. t i l

x

7/ 1

6

Wheel s

(2 4 ) I I. W lleel A x le P e gs

(1) % x I

1ft'

S mo ke S ta ck

( te n on f il S v . ho le)

(1 ) 1 1 . 1 Dia . Dowel. 6 lo ng

(4 )

Oi l Ba r r el s

.765225 Five-CarTrain ,

Parts Lum ber $18 .95

11l is k it con tains all the part s

listed above. p lus the

lumber

(m a ple ) to m a ke fiv e c ars:

(1

pc.)

3~. x 17 : : f. j lhick

(2 ,p t $ .)

3 i Y 1 I

x 17 :~ . th i ck

I

pc. )

I 'r . x l ll : 1 I . lh ic k

.765-250Train

Track P a rt,

.

Lum ber $39 .95

Th is ki t conta i

llS

enough

m aple to produ ce eight curv ed

and e igh t s tr a ight t rack s ect ions.

(81)