Wood Magazine 141 2002
Wood Magazine 141 2002
Wood Magazine 141 2002
WOODamagazine April2002,lssue141
46 contemporaryW stand
Letthisprojectprovidea handsome
homefor yourelectronics.
50 model speedboat
Expectwavesandraveswiththis
runabout.
rubber-band-powered
60 build-to-suitpergola
Shadeyourdeck,patio,or yardwith
c
thispleasing structure.
architectural
E
6
E 66 how to installposts
C
- Learnthe tricksbuildersuseto locate
E
co
andset postsin the ground.
=
E
(L 68 arbor/swingcombo
o summer
Planfora relaxing withthis
o
freestanding
outdoorproject.
72 deluxe deck-railing system
Planter-boxcolumnsand tough mate-
I rials make for lasting beauty.
,i.,ir I
d;is;#.
80 on-wall trellis
Combine 2x2sandlatticeto createa
greatframework
forclimbing plants.
96 10waysto tablesawsuccess
Make your tablesawthe best it can be
with these shop-smarttricks.
50
www.woodonline.com
contents
April2002,lssue141
TOOL REVIEW
U 7lq" circularsaws
We test the power, performance,and
featuresof eight competingmodels.
4 wood close-up:baldcypress
il how to craft cutlery handles
Checkout the resultsof threestaffers
who usedmail-order knifekits.
90 who built LadyLiberty?
See the role wood playedin the con-
structionof our most famous statue.
DEPARTMENTS
6 editor'sangle
I talkingback
12 greatideas:rip-fencesaddle
Machinebridlejoints, open morlises,and
tenonswith this handyjig.
14 short cuts
1 6 shopskills:step-building
Learnthe guidelines
whenworkingon
outdoorprojects.
2. joinery:mark with precision
24 talkingshop:glassshelving
Seewhatyouroptionsare,andhowthey
impactprice.
26 how dry shouldwood be?
32 askwooD
36 shoptips
42 WOODONLINEo
100 outdoorproductsrcsourceguide
101 prcductsthat perform
111 wood anecdote:coffeetree
112 what'saheadin our next issue
Better Homes and Gardensa (ISSN-0743-894X)is published
l-OOOa- magazine nine times a year in
'November,
I:!r,rly,Jvlarch...April,_May/June, ^July/Auqust,seplemlg1 octo'ber,
Meredrth,Corporation.
and oecem'uei uy
l7l6 Locust St., Des Moines, IA 50309-3023.Periodicalspostagepaid at Dei
Moines, Iowa, and additional mailin_g_offices.^Bette_rHomes
and Gardenstrademarkiegistireb in Canada
tr4arcaRegistradaen M6xico. ONE-YEAR SUBSCRIPTION pnICnSi U.S. and it, por-
ild,tY:,Tl'3
sessrons, $2E;Canada,$41; other countries,$49. CanadaPostPublicationsMail SalesProductAgreement
No. 40049562.CanadianBN 12348 2887RT. CANADIAN RETURN ADDRESS: Better Himes and
Gardens WOOD magazine.2744Edna Street,Windsor, Ontario, N8Y 1V2. POSTMASTER: SenauOOr.ri
changesro Befter Hotnesand Gardens wooD magazine,p.o. Box 37439,Boone, IA 50037-0439.
editortsanete w0CID.
April2002o vol.19,No.3 o lssue
No.141
Editor-in-Chief
BILLKRIER
Executive
EditorJIMHARROLD
ManagingEditorMARLEN KEMMET
Features
EditorDAVE ST0NE
ProductsEditorDAVE CAMPBELL
Projects
EditorJANHALESVEC
Senior
Editor0WENDUVALL
TechniouesEditorJIMPOLI0CK
DesignEditorKEVIN B0YLE
P-,"f; f'.:'sxsi
EndandCenterMountsdrawingon the centermounts.Seethe drawings,
page44 impliesthat the below and ight for the corrections. HB E
;d Y',?B
bottomends of both the end
No screwsin shadedareas
mounts(l) and the center 411q" 613/ro 6 1 3 / ro 41|c" ,,
Bottomrail@ 1 holes
mounts(J) have a 15o L 21/q"deep,drilled
bevel.Only the end mounts 41/q"on center
needthe bevel,The center
mountsare cut square.
Asidefrom thesetwo Center
rail@ No screwsin shadedareas
items,your instructions
and 45"
Buying guide revised Not untilrecently.Some good friends Wehopeso too, John,and thanksfor
for the arched-top clock of mine were aboutto move intotheir writing. Just to underscoretlrcpoint,
Pleasenotethe revisions. indicated dream retirementhome,whichwas stainingragsaren't the onlypotential
belowin red type,to the almosttwo years in the buildingand on problem. Ragssoakedwith drying oils,
BuyingGuidefor the whichthey were puttingthe finishing suchas boiledlinseedoil and Danish-oil
arched-topclockin touches.The weekendbeforethey were finishes,arejust asprone to spontaneous
i s s u e1 3 8 . to move in, fire totallydestroyedtheir combustionif not handledproperly.
Brrying Grride new home.The cause?A pile of wet Don't takechances.Neverrellt on "air-
trrass KnoDs n0. stainingragsaccidentallyleft on the tight" containers.Lay out (or hang up to
39500, $1.25 each(4); wood floor. dry as shown,left)any ragsor paper
5%"-diameter press-in
clockmovement no, I hope this letterwill hit home with towelsyou've usedto apply thesefinishes.
15343, $11,95.Order your readersand save someoneelse
fromKlockit, P,0.Box from such a tragicaccident.
636,LakeGeneva, Wl -John R. Good,Kewanee,
53147, orcall800/556- lll, Write Us!
2548,orgoto Doyouhavecomments, criticisms,
sugges-
www.klockit,com. tions,or maybe evena compliment specifically
relatingto an articlethatappeared in
W00b magazine? Pleasewriteto:
Don't fet youS drearn home TalkingBack
go up in s'moke W00Dmagazine
1716LocustSt.,GA310
l'ma regular
readerof WOODa, andI Des Moines,lA flX109-3{f23
havereadyourfrequent cautionsabout
ore-mailusattalkingback@mdp.com.
therightwayto storepotentially
com- Dueto the volumeof lettersande-mailswe
bustible
stainingmaterials
andsupplies. receive,wecanrespondto andpublishonly
Butyourgoodadviceneverreallyhit thoseof thegreatestinterestto ourreaders.
homewithme.
rip-felilce
saddfe
An inerq)ensive,shop-built jig for
top-notch machining and joinery
Tablesawrip fence
to rip fence
RIP.FENCESADDLE
simple
steip builtrrrg
Get off the ground one step at a time with a
framing square and these tricks of the trade.
deckbuilt closeto the ground,like Measurefrom the top of the deck sur-
the one shownabove,givesyou faceto the ground.This numberis the Step building
an excellent chance to learn the total "rise" of the steps. by the numbers
skills of stepbuilding.You'll usethe same Now, you needto makesurethat each Here'san exampleof how to figurea
principlesthat apply to any run of steps, of the individualstepshasan equalrise. stair run for a low deck.In this case,the
but you canpracticethemwith small,eas- If one or more are off, vour feet will top of the deck is 26" abovethe ground.
ily handledpieces. feel the difference. 1. Dividethe total rise by your chosen
We'll showyou how to build stepswith Divide the total rise by the preferred riserheightof either6" or 7" (26 divided
openstringers,which supportthe treads rise of eachstepin inches---cither6 or by 6 = 4.33).
from underneath.Laying out these 7 will give you a comfoftablestep.The 2. Roundup or downto the nearest
stringersrequiresaccuratemeasurements resultprobablywill includedecimals, wholenumberto get the actualnumber
and a bit of arithmetic.After that, it's just so round it to the nearestwhole number of steps (4).
a matterof making basiccuts. to determinehow many stepsyou'll 3. Dividethe total rise by the numberof
build. Now, dividethe overallriseby stepsto get the actual rise per step (26
Figrrre the rise the numberof stepsto get the actual dividedby 4 = 6.5, or 6V"').
Take a look at the drawingsbelow to get rise per step.Seethe box at right for a You can add or subtracta step and
familiar with step-buildingterminology. typicalcalculation. dividethat numberintothe total rise if
Now let's get to the constructiondetails. you're not satisfiedwith the riserthat
Figrrre the run you calculatethe firsttime. lf you end
The total "run" is the horizontaldis- up with a risernumberthat'snot a
tancefrom the edgeof the deck to the wholenumberor standardfraction,one
bottom end of the stringers,as shownin riserwill be slightlydifferentthan the
t" the drawing.The run of an individual rest. Make it the first one at the bottom
.1 stepequalsthe width of the tread-l 1"
Stringer-_.//2 end of the stringer.
is typical. As for treadwidth,consider11" the
Continuedon page 18 standard.As you makeyour plans,
allowfor one lesstreadthan the num-
ber of risers.Becausethe stringer
The total run of a set attachesto the deck joist belowthe
of steps equals the
distance from the level of the deck surface,the deck itself
edge of the deck to servesas the top tread.
the point where the Beforeyou buy or rough-cutstringer
stringers rest on a
pad. The total rise is boards,calculatethe approximate
the distance from lengthyou'llneed.Add up all of the
pad to deck top. tread widthsto find the total run of the
Each step consists
of a riser and tread. steps. Use a tape measureto mark that
pointon the ground,then measurefrom
thereto the highestpointwherethe
stringerwill contactthe deckjoist.This
numberis the stringerlength.
The treadcanbe one wide boardor severalnanowerboards morecommonto fit thatriserboardunderthe tread,leavinga
with equalgapsin between.We useda pair of lV+xl%" com- 1" overhang.
positedeckingboardsto makeeachtread,or you canusepres- Figurethe approximatelengthof your stringers,asdescribedin
sure-treated2x lumber.To matchthe deckdesign,we attacheda the box on page 16, andmark the spotwherethey will sit on the
boardto eachsetof risercutsso that its top edgeservesaspart ground.Installa 4"-thick concretepadon a 4" gravelbaseto sup-
of the tread,as seenin the lower right photoon page20. lt's
@:inJ:::,,'
gauge on the out-
side edge of the
square's long leg at
the number equaling
the run. The other EDrawasecondsetofriseandrun|ines,withthe
gauge goes on the lEflrise the previousrun lineat the
line intersecting
outside of the short
edgeof the board.Drawa third rise line,markits end point,
then extend the line across the board.
leg, at the number
equaling the rise.
@::1T?#T::f,:
your framingsquare
use
to mark the rise and
run. This will be the
top end of your
stringer.
Thicknessof bottomplate
Thicknessof tread
@ il Hffi
:'3.?,lll J[i,:ffi,s'ili"l[*:"8;
:llr""ol
the first tread. Then, mark the stringer's bottom end. Write
@li'"";:lli'?31,:fi
xxl'";fi i:
ifliffiiSii,Il??:f
to mark the waste areas, shown here in a lighter color.
"pattern" on your first stringer, and trace around it to lay out
each of your other stringers.
Continuedon page 20
"
@$:"',tli"'J::,'"?=#i:;.?'ix,?:"xo""i5
For open steps, let the treads overhang the stringers by
about 1" at each end. We made each tread with two boards of
G#ICUT THE STRINGER: Mount a coarse-toothed
the same composite material that covers the deck. Attach
Ebladeinyourcircu|arsaw,thencutcarefu||ya|ong
your layout lines. Always keep the blade on the waste siOe of each board with two screws in each stringer.
the line. At the inside corners, stop when the leading edge of
the saw blade reaches the perpendicular line. Use a handsaw
or jigsaw to finish the cuts.
rnark $zitfr O O
Measure by holding your rule on edge, and fit the pencil point into the
incised line. This method eliminates the slight inaccuracy that can result
from looking across the thickness of a rule lying flat on your workpiece.
lrrrying gfass=
aclearview
Size,price, options-
what you need to know to be a smart shopper
II
hen we designedthe televi- Keep in mind, also, that thick-
sion standonpage 46,we er glassalwayscostsmore than
wanteda glasstop to comPle- thin glass.We could haveused
3/s"glassand savedaboutI0Vo Ogee
ment its clean,crisp lines and to highlight
the beautifulmapleand mahogany.Once of the cost, but we felt the Vz"
glasslookedbetter.Glasstable-
-r
that decisionwas made,a whole rangeof
issuescameinto play. tops are also availablein V+",
3/+", and 1" thicknesses. Tell
Design with price and your supplier what weight the
1" Bevel
availabitity in rnind glassmust hold and the span
In our original plan, we sizedthe glass betweensupportsto determine
to fit the project. But, we were surprised the proper thickness.
by the almost$100 price tag from our
local supplier for the Vzx26x36"top Hold your
piece that the TV restson. We also ternper
plannedto make the stand'sadjustable Glass,of course,canbreak,and Chamfer
shelf from %" glass.Though smaller, the thoughtof a televisionor Grandma's
this piecewas almostas expensive.The china smashedatop shardsof broken glass
high price, we learned,was becauseboth isn't pleasant.That leadsmany peopleto "standard" profile for a tabletop. Most
pieceshad to be custom-cutto size. believe they needtemperedglassfor a supplierscan producethe custom edge
We turnedto a mail-orderglasssupplier tabletop.Temperedglassis four to five designsshown,and sometimesmore.
that offereda Vzx24x36"pieceof glassat times sffongerthan standard,but more Expectto pay at least50Vomorc for a
a much lower price: $66. So we modified expensive.Standardglasswill beara sur- customedgethan the standard-edge cost.
the standfor the 2"-narrowerpiece.The prising amountof weight-aVz" piece Ottr Vzx24x36"piecewith a 1" bevel
lesson:Justas with hardware,it's critical supportedevery two feet will bear about would havebeen$118.
to determinethe glassyou'll usebefore 80 poundsper squarefoot. SeeAsk Dependingon where your tabletop will
finalizing the designor cutting wood. WOOD in issue#137 for more informa- be located,you may want to consider
Norm Levine of WholesaleGlass tion. Also, tabletopsseldomare subjectto radiusedor cut corners,like thoseshown
Brokers(seethe Buying Guide below) heavyimpacts,so usestandardglass.Save below.Most suppliersoffer this service,
saysmany local glasssuppliersstockrel- the temperedglassfor doors,room with or without a customedgeprofile, and
atively small glasssheets.Often, the cut- dividers, and areassubjectto impacts. can ffim the cbrnersanywherefrom 1" to
offs from thesesheetsare too small to 6" for addedsafety.
be usedastabletops,so you maYend Add life to the edge If theseoptions aren't enough,
up essentiallypaying for the waste. Glassedgescan be finishedin a variety of round and oval tops are avail-
Lar:geglassretailers,suchashis, ways. Someof the common profiles are able,too. For a price, you can
buy very largeglasssheets.This shownabove.We chosea flat-polished get glasscut in almostany
resultsin lower cost,as one edgefor our televisionstand.This style, shapeimaginabte.i zu
sheetcan yield many small- or a flat-groundprofile (similar but lllustrations:
er pieceswith lesswaste. with a frostedappearance), is often the Tim Cahill
Buying Guide
Formore onglass
information write
tabletops,
WTwelve
19785
GlassBrokers,
Wholesale Ste.357,
MileRoad,
Ml48076,
Southfield, orcall800/288'6854,
WOOD magazine April 2002
wide world of wood
industrygenerallydry wood to a moisture face,or cut a few inches hardwood species heartwood sapwood
Ash, white 95 113*
contentslightly lower than it will finally from one end and check the Hickory 70 52
encounter.This practiceassumesthat the end grain.Ask first; suppli- Maple, sugar 65 72
wood will take on somemoistureduring ers may frown on poking Oak, red 80 69
Walnut, black 90 73
furtherprocessingand consffuctionstages. holesin their stock.Pinless
metersare also available. softwood species heaftwood sapwood
for proiects that last, Always let your wood Gedar, red 58 249*
Fir, Douglas 37 115*
care io- yorrr wood acclimateto the relative Redwood 86 210*
If you're suspiciousof the moisturecon- humidity whereit will be
* Becausemoisturecontentis definedas the weightof the
tent of the wood you arebuying, askthe used,rememberingthat dry
supplierto checkit for you. It might pay wood will pick up moisture water expressedas a percentageof the wood's dry weight,
not the total greenweight,it oftenexceeds100 percent.
for you to buy a moisture meter (from $70 from the atmosphere.If it's
to $150),especiallyif you buy air-driedor for your home,stickerthe
rough-milledstock.With a meter,you can wood (stackit with wood spacers)for a into a project.As relativehumidity
checkwood's moisturecontentbeforevou week or more in an areawith the same changes,wood still absorbsand sheds
buy, and then track it at home. relativehumidity beforemachiningit. moisture.The bestway to minimize this
Most moisturemeterswork by passinga (Checka pieceof furniture in your home is to sealall surfacesof the completed
small electricalcunent betweensensor and compareit to your stockfor a bench- project,notjust the exterioror exposed
pins insertedabout Vq"into the wood. mark.) You alsocan storestockstanding parts,with a few coatsof finish. aF
More moisture ffansfersmore current, straightup, but neverput dry stock
Written by Peter J. Stephano
resultingin a higher percentagereading. directly on a concretefloor. lllustrationinformationprovided by the
For the most accuratereading,checksev- Don't think that wood movementstops U.S. ForestProducts Laboratory
Photograph:Baldwin Photography
eral locationsalongthe board'sedgeor onceboardsare machinedand assembled
Creator.SkilledHobbyist.
Thlented
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askwood
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Answers fromletters,
andW00DONL|NEo
e-malls,
I
Uariable Speed hntrol for . l/4 H.P, Motor for heavy
unlimited air flow settings duty performance
t Highest Maximum air flow in t Antimicrohial I lWicron
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I recommends limitingwooddustexposures. TheJDSAir-Tech 2000will
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ask wood
We've heardthat too, Ron, but ings on one portion and used320 paper
To brrrnish or it's an old-timemethodthat's on the rest. "The resultswith sandpaper
rrot to brrrnish . . . beenmadeobsoleteby today'smateri- were far superiorto the shavings,"Alan
1|i Some woodturners
talkabout als. ProfessionalwoodturnerAlan Lacer reports.He found that the shavingscut
Y usinga handful
of shavings to says,"Turnersusedto do that to give the little groovesin the pine.They didn't
burnishtheirworkon the lathe.I've wood someluster,but that was before groovethe mapleas noticeably,but they
justfinisheda spalted-maple bowl,and we had 320-gritsandpaper."Out of didn't do much to improveit, either.
l'm wondering,whatarethe prosand curiosity,Alan experimentedwith a cou- If you really wantto burnisha turning,
consof thattechnique? ple of samples,onepine and one hard you couldusea roundbar of steel.
-Ron, yr,a
W00DONL|NEo maple.On eachpiece,he rubbedshav- However,Alan pointsout that anybur-
nishedlook disappears the momentyou thengo aheadwith staining-if you're : wood afteryou applya smooth,consistent
applya liquid finish."And if you burnish seton usinga stain.(Skippingthe stain ot* finish to the table'
'take' and going directlyto a cleartopcoatof -vv00Dmagazine
it reallyhard,somestainswon't
very well," he says.Our advice:Forgetthe varnishor lacquerwould eliminatethe ,
burnishing,andjust concentrate on doing risk of a dark spot.) : Got a question?
a thoroughjob of sanding. When sucha spotappears, it's difficult ; lf you'relookingforananswertoa woodworking
-W00Domagazineto eliminate.You would haveto sandthe , question, writetoAskW000, 1716Locust
St.,
. GA310,DesMoines, lA50309-3023orsendus
entiresurfacebelow the extentof the Forimmedi-
i ane-mailat askwood@mdp.com.
damage,or hide it with fairly sophisticated; atefeedback post
fromyourfellowwoodworkers,
Didntt like the dent, touch-uptechniques. The goodnews, i yorrquestion groups
ononeofourdiscussion at
really hates the spot accordingto Bob, is thatthe spotwill : www.woodonline.com.
1|ri Whilebuildinga tableof hard appearto be a naturalcharacteristicof the
!| dentedthe
maPle,I accidentallY
top.I ironedout the dentwitha warm
ironanddampcloth,sandedthrough
all the gritsagainto 220,andsawno
evidence of scorching.ButwhenI
applieda colonialmaplestain,a black
spotappeared wherethe denthad
been.I'vetriedsandingandbleaching,
but can'tgetthe spotout.Whatcaused
this,andis thereanything elseI can
do to fix it?
-Ed Cloonan,
Cincinnati
g/
Spindle
-l ll t' - l
| , - ?
11/2"
cabinetsfor our kitchen,Samantha
punchedthe brassinsertsfor the upper
i
Carriage I cabinetdoors."Tom seemsto have
Cross 13/q"
Section beena prettygoodcatchhimself,judg-
),,L"1
./r'li Spindlecarriage ing from his Top ShopTip, at left.
;6;'- '
ffq:,
i
, For sending this
issue's Top Shop
- S
Continued on page J8
37
shop tips
Need a tern1rorary
table? Pipe up!
I havea smallshop,so benchtopspace
is alwaysan issue,especially whenit
comestimeto finishmy projects. To gain
the extrarealestate,I makea temporary
tableout of a pieceof plywoodand four
3' pipeclamps.Whenassembled, as
shownat right,it's at a perfectworking
height,and whendisassembled, it only
takesup as muchspaceas the plywood.
-Darin Wallace,
viaW00D)NLlNEo
No-bandsaw rnethod
to crrt corrrers
I lovedthe Arts and Crafts-style family-
room makeover in WOOb magazine
issue132,and incorporated the platerail
and bracketswhen I put togethera room
for our firstchildlastfall.However,I
don'thavea bandsaw,and cuttingmore
than 30 of thoselittlebracketswitha
copingsaw wasn'tat all appealing.
Instead,I turnedto my drillpressand
fit'.i;
a 5" holesaw,as shownbelow. Atter
aa
removingthe half-moon-shaped waste
piece,I cut the bracketblankwhere
shownand nettedtwo brackets.This
techniquesure madethe job go quickly,
and I was surprisedat how littlesanding
I had to do on the curves.
-MatthewWhite, lnd.
FortWayne,
Continued on page 40
wrvrn woodonline,com
shop tips
3" butt
hinges
1x6 stretcher
TOPVIEW
I
I
I
I
1x4 apro\n
w
I
,
I
I
(\ 2x4 rear
t \ \ \-1 apron
\ attached
t)l to wall
r-!
I
Slide leg I 3" butt
assembly I hinges
right and , on bottom
fold down' side of top
top to I
store. I
I
h\ \
'\ Y-
" electricalconduit
Er+\
* *'K,,tityng
3/e"access hole
www.woodonline.corn
od online.
youbenefit
bygoingtowww.woodonline.com
Rockler.com
\^/OOD\^/ORKING SUPERSTORE
@HJeg"
,l
i4
1r
The buttressed
belle of the bayou* : i:...,:j
i;4i?*"1:he
, rI-
lust rcnraininu speciesol' an
:5 ancient trcc l'antilv that oncc
.',t!'. t-angcclover Norlh Anrerica ancl
northerrr ELu'o1tc. tlte lralclcypress
( T i t . u x l i u r t td i . t t i c l r t r n ri)s t r r - r l vu n i q u e .
This tree is classifieclus a conif'crancla
solirvt'roclbecause it has ncc-cllesrather
t h a n l e a v e s . B L r t . b a l c l c v p l e s si s n ' t a n
e v c r - ! : r e el ni k e o t h e rc u n i l ' e r sI.t s h e c l si t s
firliagc as ckr clecicluor-rs (harclrvoocl)
;e*
trecs. a trait shareclonly by the larch.
Ancl. balclcypressf'eelseqLrallyat hortre
grou ing in r,r'ater'or'on clr'1,lancl.
, i,,
ii:.
:il
In its SoLrthern raltgc. balclcl,;trc-ss
di r
i' o n c e g r e \ \ ' t o i n - r u r c n ssci z e s .T r e e s l - 5 0 '
{ .r t a l l u , i t h l 2 ' c l i a r n e t e rw s eren t Lrncorrr-
r . n o r tI.n t h c L o u i s i a n as w ' u l n l l sa n c lo t h c r
places r,r'lrere it gron,s in stancls.itn lrcre
of olcl-_cror,r'th lralclcypl'esstrees coLrld
vielcl 100.0(X)btxrrclf'eetof' lLrnrber.By
thc I930s. trccs o1'tl.rosc_ulancl propor-
t i o n s h a c la l l l ' a l l e nt o t l i e s a w ' .l ' u r n i s h i n - u
c l e c a v - r e s i s t a n tl r o a r c l s a n c l t i r l t r e r s
firl countless ckrcks. rvarchctuses.ancl
otherstnlctures.
Frorri Floriclato castcnt Tcxas thcrc's
no\\' rur abnnclant sLr1tpl1, o1' seconcl-
gro\\,'thbalclcyprcss. Althorrgh it isn't as
Growth range
resistant to clecay as thc- olcl-growth
w ' o o c l .i t ' s s t i l l a n e x c c l l c n t c h o i c e l i r r
olrtckror' prcr.jects. SaIvage o1terat ions aIscr
contribLrtcto tlrc-sLrltplv.They provicle
"sinkcr cyllress" olcl-sl'orvth logs
clrcclgccl fkrrn lakes.rivcrs. anclswnn.tlts.
"1";
Too. as clccrcpit facturics ancl wiu'e-
il holrscsarc rcplacccl.stnrctlrraltintbcrsof
/o'r
K olcl-gnrwthwoocl retltnt tcttlte saw.
-.r
r.-l
i-- Finding the tree afield
n'
i-)11 S w a n r l t f i t r c a si n t h e b a l c l c y p r e s sr a l t g e
r;. p r o v i c l e t i r c b c s t c n v i n t n r t r e l t tl o r t h e
www.woodonline.corn 45
lean lines,sleekstyling,and a touch of
flair make this televisionstand the ideal
placeto set your set. Buildit as a stand-
alone piece or as paft of a matchinglivingroom
ensemblewith the futon sofa/sleeper and modular
knock-down shelving set, both shown at right. The futon sofa/sleeperabove
All three piecessharethe same designstyle and (issue 139)is great for sitting or
snoozing.The modular shelving at
simpleapproachto construction. lelt(issue 143)can be configured
to match most any space or task
thanks to special hardware.
46
#8 x 11/qF
' .H.
screw
Il ense 3"
I--wood
t
- 11/2"
Tse"shank hole,
countersunk
21/z'
#8 x 1Yz'F.H.
wood screw
3/+"
lt7"
t/a"chamfers
Staril at the base
3/c" milrogany, cut the z/o+"
pilot hole
I From s/q"dee?
I stretchers(A), foot bodies (B), 1
and foot faces(C) to the sizeslisted in Tse"shank hole,
countersunk 2V4"
the Materials List. Laminate the feet
(B/C), as shownin Drawing1. Once the t/e" chamfer
glue dries, use a chamfer bit in your
router to rout a %" chamfer around the
boffom of eachfoot. Then clamp the feet blies (A/B lClD), then drill the pilot and ffi Glue and clamp the panels(K) to the
to the stretchers,and drill the pilot and countersunkshank holes, where shown *# frame assemblies(VJ). Make sureto
countersunkshank holes where shown. in Drawing 1. Drive screwsto join the apply one shelf-pin-drilled panel to each
Glue and screw the stretchersto the feet. assembliestogether. assembly and check that the panel's
edgesare flush with the frames.
$ Cut the lower reveal trim (D) to
&r2v2x20". Then notch each piece Add tlre ernds f, Cut the top/bottom trim (L) and end
where shownin Drawing 1. This can be I From
3/4" poplar, cut the frame f# trim (M) to width and about I "
done using a jigsaw or bandsaw.Just I tops/bottoms(I) and frame ends (J) longer than dimensionedin the Materials
make sure the edges of the notch are to size. Glue and clamp the frames (VJ) List. Fit the trim aroundthe panel assem-
squareand straight. together,keeping the ends flush, where blies (VJ|K), miter-cutting each piece to
{} Finish-sandthe lower revealtrim (D) shown in Drawing 2. ,Measure the length. Glue and clamp the trim pieces
*) and the foot assemblies(A/B/C) to frames' diagonals or use a framing in place, where shown in Drawing 2.
220 gnt. Then glue the reveal trim to square to check each for square, and After the glue sets, finish-sand the end
each foot assembly to create two base place them on a flat surface while the assemblies(I through M).
assemblies (A/B/C/D), leaving a V+" glue dries. Once the glue sets, remove ff Cut the upper reveal trim (N) to size
reveal on the sides,front, and rear edges, the clamps, drill pilot'and countersunk * from t/q" mahogany.Finish-sandthe
where shown in Drawing 1. If you wish shankholes, and drive in the screws. pieces,then stainthe top face, edges,and
to stain the base assemblies(AlBlClD), {} Cut the four end panels (K) to size ends with the same stain used earlier.
do so now. We useid Bartley's kfrom 3/q" maple plywood, making Don't stain the bottom face. Glue the
PennsylvaniaCherry gel stain. sure they match the length and width upper reveal trim to the end assemblies
of the assembledframes. Chuck a VB" (unstained face down), leaving a Y4"
if Cutthe bottompanel (E) to sizefrom
\t/q" maple plywood. From 32" solid rabbetingbit in your router and rout %" reveal on all sides.
maple, cut the bottom panel edging (F) rabbets V+" deeparound the perimeter of
to size,aswell. This is a good time to cut the good faces of all four panels,where
the adjustableshelf (G) and shelf edging shownin Drawing2.
(H) to size,too. Q Choose two panels (K) to be the
f Glue the edging (F) to the front and rlinsides of the end assemblies.Then
iJback edgesof the plywood bottom lay out and drill the shelf pin holes in
panel (E). Sandthe edging flush with the these two panels, where shown in
faces of the bottom, taking care not to Drawing2.
sand through the plywood's thin veneer Note: The dimensions shown for the
layer. Also glue the shelf edging (H) to shelf pin locations are measuredfrom
the shelf (G), sand them flush, then set the edge of the panel, not from the edge
this assembly (G/H) aside. Once the of the rabbet.
standis assembled,you can perform one accentuatethe reveal formed by
'*ATo
last operationon the shelf to help keep it ttre rabbets around the end panels,
in position. Seethe shop tip on page 48. stain the bottom of the rabbet,as shown
Mask the edge of the rabbet to keeP
f, N"*t, glue and clamp the bottom in Photo A. Use the same stain you stain from accidentally bleeding onto it
lJ assembly (E/F) to the base assem- applied to the mahoganyparts earlier. or the panel's surface.
www.woodonline.com 47
television stand
21/z'
261/z'
t'/4
13/q"
7+"-diameter
7sz"shankhole, rubberbumper
countersunk @ \ -1'(-
71/2"
I
I
t/e"chamfers
(insideand out)
7 g z "s h a n k h o l e ,
c o u n t e r s u n ko n i n s i d e f a c e
F=-1g"
't/q"
hole
t/2" dgep
(inside
OE \NI
@
\
@
1/a
l
face only)
v
'=-"
OE
I-r-\ \:2i
6" 3" F Va
-->l F--
3"
F R O N TV I E W S I D EV I E W
Miteredends
Rest the stand on cardboard to protect
that the back assembly is positioned /+" Clear View" on page 24. Finally, insert the finish. Use clamps to keep the pieces
forward of the rear edges of the end shelf-support pins and position the aligned as you drill and drive the screws.
assemblies. Temporarily clamp these adjustable shelf. Now you're ready to
install your television and components, Writtenby David Stone with Charles l. Hedlund
assembliestogether. Projectdesign:Kevin Boyle
Place the base assembly on the ends and sit back to watch the tube or at least Roxanne LeMoine;Lorna Johnson
lllustrations:
jl Photographs:Baldwin Photography
and back, aligning it so the feet are admire the stand it sits on.
flush with the outer faces of the end
assemblies, as shown in Drawing 2a.
Note that the rear edge of the back bot-
mnaterials list
tom cap (Q) should be flush with the rear
edge of the bottom panel edging (F). A stretchers Y4" 3" 19" MY I frametopsi
bottoms 3/cu 11/z' 19"
Once you have everything aligned, use B footbodies 3/t' 3" 2Vq' MY 12
J frame ends 3/q' 11/z' 131/z' P
the countersunk mounting holes you C footfaces 3h' MY
drilled through the base assembly as K endpanels 3/q' 1 9 " 1 5 " MP
D*lowerrevealtrim 3/qu 21/z' 20' MY
guides. and bore'%:" pilot holes into the trim
L. top/bottom 3/tu 3" 201/z' M
panel
E bottom 3/r' 163/q' 30"
back and end assemblies.Then drive in M-endtrim 3L' 3 161/z' M
panel
F bottom
the screws, as shown in Photo B. Using e0grng 3/q' 3/qu 30" N upper revealtrim3/qu 21/z' 20' MY
the shank holes in the back sides (P) as
guides. drill pilot holes into the end 3/c' O backpanel 3/q' 26Vz' 15" MP
G adiustable
shelf 15', 263/s',
assembliesand drive those screws. 3h' 1V4" 15"
H shelfedging 3/4' Yi 263/a' M P backsrdetrim
Remove the clamps and turn the
-Parts
initially Seetheinstructions.
cutoversize. Q backtop/bottom
stand right side up. Adhere clear rub- caps 3/4u 21/2" 261/z' M
ber bumpers to the upper reveal trim (N), Key:MY-mahogany,
fl,{aterials MP-maple plywood,
M-maple, P-poplar. Buyirrg Gr.ride
where shown in Drawing 2.
Position the Vz" glass plate on top of Supplies:#8x11/2"flatheadwoodscrews #Bxlt/o'
(38), Glass.
%x24x36" glass withflat-polished
tabletop edge,
flatheadwoodscrews (11),#Bx2t/q"
flatheadwood $66plusshipping.
WholesaleGlassBrokers,19785
the stand. For more information on screws (6),spoon{ype pins(4),
shelf-support WestTwelve Ml48076;
MileRd.,Ste,357,Southfield,
the types of glass available and pur- s/a"-diameter clearrubber
self-adhesive bumpers(4), 800/288-6854.
chasing options, see "Buying Glass: A polyurethane
stain, (gloss
finish andsatin).
mxn**frnnEctffmgitrffitr**
wrrtrv.woodonline. c om 49
ome toys arefor play,othersfor
display.With this snaz4yrub-
ber-band-powered speed-boat,
you haveboth.Modeledaftera 1930s
hydroplaneracer,this fully-functional
boat can whirlacrossa bac(yardpool
or sit handsomelyon its stand. STEP 4
Constructedwith scraps of cedar Gluedeckto hull.
2x6, straight-grained pine,and brass STEP 1
CulaVa" groove
rod,tube,and sheet,it requiresonlya th" deep centere{ '
on Uottomot tiutt@. F,--.-r'
smallinvestmentin materialsto com-
f5-"_-j*:
plete.Happymotoring!
Tii,---',*F*
Note: Thebrassrod, tube,andsheetwe
used in this project are available at
hardware and hobby stores, or see the
Buying Guidefor our source.
Forrn the hrill first (C). Edge-glue the deck halves (B) to 3"-wide cockpit, shown in Step 5. To
.$
Cut a 20"-longpieceof cedar2x6for both sidesof the center strip (C), shown avoid chipping the blank's side,back the
#* the hull (A). Cut a centeredgroovein in Step 3. With the glue dry, plane this cuts with an auxiliary extensionattached
the bottom of the hull, where shown in deck blank (B/C) to V+"thick. to your miter gauge.
Step 1 on Drawing1. ,ff Ctue the deck to the hull, shown in
*ffiStep ffi Copy the deck from the WOOD
ffi Chuck a V2" straight bit in your 4, keeping the ends and edges &#paftf'RlUso inserr.Adhere it to the
#* table-mounted router, and, using a flush. To spreadthe clamping pressure deckftrullblank with sprayadhesive.Tilt
stopblock clamped to the fence to con- evenly, lay down waxed paper, and your bandsawtable 15o, and cut along
trol the groove's length, rout a 3t/c"-long clamp the assembly, deck down, to a the pattern lines, shown in Step 6. Save
stoppedgroove, shown in Step 2. piece of 3/q"plywood. Remove any glue the cutoffs. Sandthe saw marks from the
ffi From a 2O"-long piece of dark, that squeezesinto the Vzxs/e"gloove. hull assembly.
%#straight-grained cedar 2x6, resaw
ffi Scrape any excess glue from the ff Select a piece of wood with straight
two 3/s"-thickbook-matchedpieces for q# sides of the hulVdeck assembly. S grain, and resaw and plane the
the deck halves (B). Rip them to the Sand the stern so the deck and hull are planks (D) to the size listed, book-
width in the Materials List. Cut a flush. Install a 3/+"dado blade matching the two sides.Glue and clamp
Vsx3/sx20"pine piece for the center strip in your tablesaw, and cut the the planks, one piece at a time, to the
hull, shown in Step 7. Use the hull
II ronurNc THEHULLANDDECK
51/z'
#3 x 7a"brass
7o+"shankhole, F.H.woodscrews
STEP5 countersunk t/e" slot \
Cut a 3"-widedado on back 1t/+" long ll
17a"deepthrough
hulland deck. .,,
t))
STEP8
Formthe transom.
)
t/a
STEP7
---d<- Glueplanksto
STEP2 VA STEP6 bandsawn
Rout a t/2"groove7a"deep, Tilt bandsawtableto 15', and hullassembly.
stopped3gZ"from end. cut hull/deckto shaoe.
TRANSOM
7%+"
shankholes,countersunk
cutoffs as clamp blocks. Make sure the the protruding planks flush with the
planksprotrudebeyondthe edgesof the transom.Mark the screwhole locations,
hull all around with at least 3/to"over- where shown on Drawing 1a, and drill
hanging the stern. Trim the first plank Vro"prlot holesthroughit, into the stern.
where it overhangsthe bow before glu- Remove the transom,enlargethe holes
ing and clamping the second plank. to 1/oq"for the screw shanks,and coun-
When the glue dries, use a block plane tersink them. Install a Vs" stratghtbit in
and a sandingblock to trim the planks your table-mountedrouter. Using your
flush with the deck and the bottom of the miter gauge fitted with an auxiliary
hull. Do not trim the stern. extensionand a stopblock,cut the lVq"- Now, outfit the cockpit
Cut a Vsx2x43/q" blank for the tran- long slot in the transomfor the rudder, Cut a lV+xIzAxlO"blank for the seat
som (E). Use your bevel gaugeto whereshown.Setthe transomaside. (G). Make the two cuts shown on
transfer the planking's angle onto the Sandan angledflat at the bow where Drawing2a to form the back and bench.
transom,and trim the endsto shape.Fit the planks come together,as shown Match the compoundcuts at the seat's
the transom between the protruding on Drawing 2. Cut the bow stem (F) to endsto the insideof the cockpit. (To get
planks (D), and sand it flush with the size,and glue it to the hull, holding it in a good fit, we angledthe miter gauge3'
hull at the top and bottom. Then trim placewith maskingtape.When the glue and tilted the blade 15".)Make the cuts
and sand dries. carefullv sand it flush with the on scrapto testthe fit. After making any
planks,deck,and bottom. necessaryadjustments,cut the seat to
finished length. Sand the round-overs,
whereindicated.Set the seataside.
Cut a Ixlt/axl}" blank for the wind-
shield(H). Bevel-ripthe 45" angle,
shownon Drawing2b. Angle your miter
gauge30", tilt the sawblade30o,andcut
the windshield to final length. Set the
windshieldaside.
Cut the rudderblock (I) to size,and
II test-fit it in the rectangularhole
I formed in the sternby the t/zxs/c"groove
lw f :y.i$415+S-
and the deck.The fit shouldbe snug,but
still allow easyremoval.Hold the block
with a handscrewclamp, and drill the
51
rubber-band runabout
:.
'..''''..":
I
i *
. ;^
^ " - 1€€
_-*6qe,dl
\l
#3 x t/2"brass
F.H.woodscrew
;?*\\ 7
4te 7/a+" 1 1/s'
E hole,countersunk
9
KJN
rudder block, and cradle with gloss E EXPIODED
VIEW
polyurethane. To make sure the parts are
well protected, we brushed on the first
coat, sandedwith 220 grrt, then finished
up with two light coats from a spray can.
Prime and spray-paint the seat red and
the windshield black.
n
Cut a 3"-long piece of sAt" brasstub-
@J
CRADLE
ing for the propeller shaft sleeve. Cut
a 2t/+"-long piece from a .025x2x12"
strip ofbrass sheet for the sleeve bracket.
Bend it to fit around the sleeve,as shown Bend and thread your own pro-
on Drawing 2. Solder the tube to the peller shaft, or use a brasstoilet tank
bracket so V2" protrudes at each end. scrollsaw the propeller to shape. stopperlift rod. (We found one at the
Polish away any discoloration from the File the edges smooth. Holding hardware store, threadedon one end
soldering. Put a dab of silicone sealanton it with a small C-clamp, shape the pro- with an eye on the other.)Drive a brass
the keel's bottom edge, and slide the peller, as shown in Photos A and B. screw eye into the keel at the bow, and
sleeve/bracket assembly onto the keel. Removethe pattern. string up a couple of sturdy rubber
Make a copy of the propeller from Slide the propellershaft throughthe bands. We used loops of rubber strip
the pattern insert, and adhere it to the sleeve,and assemblethe washers, from a hobby store(SIG ContesrRubber
brass strip. Drill the center hole and nuts, propeller,and cap nut, as shown. no. CR-825).
IELD
Twist each propeller blade, pushing Now, maintainingthe twist, bend an
I
1t/t
down on the short lobe, and pulling up
on the long one.
upward curl in each blade. The side with
the pattern is the back of the propellel.
$
H TOPVIEW
fl 30"
,
W,,
E N DVIE W
FRONTVIEW
1 RUDDERASSEMBLY
t/e"brass rod
8/+"long^,r4 /f A pair of clothespinsholdsthe rudder
centeredon the shaftwhileyou solderit
in place.
To wind the propeller, pull the rudder
shaft out of the transom slot, and swing
it out of the way.
ffi 51/q
W
tip of the shaft with a hammer just
t/e" hole
enough to keep the washer from sliding
f'\-spring from off the end. A hull 11/z' 51/z' 20'
pen
ballp,oint
\ Slide the rudder assembly into the B-deckhalves 1/t' 211Aa"20'
#6 brassflat washer sternrecess.Fushthe rudderblock in 1/t' 20"
C-centerstrip V8
.025"-thickbrasssheetfor to compressthe spring Vt", anddrive the D planks l/su
rudder.solderedto rod 21/4' 21'
screw through the deck hole. Screw the E*transom 1/s, 13/4' 4sAa"
transom(E) in place. Glue the seatand l/zu
F bowstem 1/," 21/c'
Make a copy of the rudder from the windshieldin placewith a coupleof dabs
G*seat 11/q" 13/4" 4s/s-
pattern insert, adhereit to the brass of silicone sealant.Wind the propeller,
'er tip. t H-windshield 1" 11/4" 415f16" c
strip, scrollsawit to shape,and file the as shownin Photo D, and let
I rudder
block f2 5/a' 17/s' P
edges smooth. Bend an 8/+" length of
Written by Jan Svec J- keel 1/sn 2sAa"191/t" P
%" brassrod for the rudder shaft, shown Projectdesign:JamesR. Downing; Jan Svec
K-cradleframes 1/t' 41/z' 7u BP
on Drawing2c. Clamp the shaft in your Kim Downing; Lorna Johnson
lllustrations:
Photographs:Hetherington Photography; 1/tu
vise,and solderthe rudderto it, asshown Baldwin Photography
L*cradlestretchers 1u 101/+' BP
in Photo C. Slide the shaft through the -Parts Seetheinstructions.
cutoversize.
initially
rudder block (I), spring, and washer. Materials P-pine,
Key:C-cedar, birchply,vood,
BP-Baltic
Compressthe springwith the washerand 4r/2"-long
Supplies: brasstoilettankstopperliftrod,#6
(3),6-32brass
flatwashers
brass nuts(2),6-32capnut,
crrtting diagranr l/qx 6 x 12" Baltic birch plywood
eye,%2"'1,D,x1"
screw
%0"-1,D,
headwoodscrew,
spring,
#3x%"brassflathead
#3xt/2"brass
woodscrews
flaf
(8),
(2 needed) rubber
solder, bands, glue,glosspolyurethane,redand
black
spraypaint, sealant.
silicone
Brrying Guide
Brass.,025x2x12"brassstripno.G7669,
$2.40;
.125x12"brassroundrodno.G7646, 5/ezx12"
$0.88;
11/2x51/zx 48" Cedar (2x6) brassround no.G7612,
tubing $t,OO. Industrial,
Grizzly
4777
Call800/523- , or goto www.grizzly.com.
www.woodonline.com 53
the WooDolfangcnfts
"i,o createtheir cutlery pieces, masking tape. Without the taPe, the and feel of the handle, I completed the
paper sheathstill tended to slide down sandingusinga palm sander,progressing
accidentally as I worked, leaving the from 120-to 220-gntpaper.
'r' ' '
" itemsfrom mail-ordersup- sharpblade exposed. BecauseI prefer a satin finish on a
Becausethe fillet knife's tang had a work knife, I didn't buff the handle,
pliers.In eachcase,they received
nice handle shape,all I had to do was although Dymondwood can be brought
bladeswith pre-drilledtangs(the por- match the two Dymondwood(a "plasti- to a glass-like sheen.Plasticized wood
tion that fits into the knife's handle). cized" wood madeof birch veneerlayers requires no protective finish, and holds
impregnated with resin) up well to the abusea fillet knife faces.
Two of the builders orderedkits that scalesto it. I did this by trac-
camecompletewith scales(the handle ing the shapeof the tang onto
each scale,then bandsawing
slabsthat fit on eithersideof the blade eacha bit oversize.
tang).Eachof our intrepidbuilderstook In my kit, the holes for the
threebrassrivets were already
their own path to completion.
drilled in the blade tang and
the scales.I just glued the
scales in place with cyano-
A fillet knife acrylate (instant) adhesive,
in a flash making sure the holes lined
By Marlen(Perkins) up. Next, I used a hammer
Kemmet,Managing andnail punchto settherivets
Editor
in the handle. Buying Guide
Prior to any work on I sandedthe scalesto rough Filletknifekit:7"polishedandhoned bladepre-
vanadium'steel
shape using a 3"-diameter drilled twoprebored
forrivets; andcountersunkDymondwood handle
the handle, I taped handle,
forattaching Kit,
blanks (rosewood threebrassrivets
color),
the suppliedcardboard drum sanderin the drill press $30including postage.Leathersheath,
$14,
sheath to the blade, and a I" spindlesander,both Easley Knives,638 N.14thAve., NE68008.402/426'2481.
Blair,
then I wrapped the with 8O-grit paper. When I crickettoms@aol.com,SendSASE forfreebrochure.
entire sheath with was satisfiedwith the shape
BuYringGuide
KnlfeSupplies. Blades:
hollow ground stainless
forpins,withsatinfinish:(6ea.)
steel,pre-drilled
49rq"
bfadewilh2t/2"ofserrationsattip,9"-long'
#8L477,
overall, Mosaic t/ex12",
$5.25; pins:
brassandstainless #MPP200-12,
steel, $16;
t/ax6",
brassandstainless steel,#MPP200'06,
$9;Scales:Dymondwood, pair,eachapprox.
#DW41S,
{ax11/zx5u, $3.25.Shipping and
handlingextra,
TexasKnifemake/s Supply,1062t9Haddington,
Predrilledholesin the tang guidethe drill The pins help hold the scalesto the #180,Houston, TX77043. 888/461-8632
bit to createholesfor pins that, along tang, and add decoration,with stainless (orders).
www.texasknife.com, Catalog,$6.95.
with epory, attachthe scalesin place. rods arrangedinsidea brasstube.
Grrt-above crrtlerv
m ByJan(Ginsumafi) Jan's cook's knife
Svec, Projects
Editor
I needed.I saweda tang slot in
Rather than follow- this blank. then used the hardboard
ing the traditional template to trace the individual handle
method of letting outlines onto the blank. Next, I cut the
the shape of the blank into individual handles, and
tang dictatethe han- sawedand sandedthem to final shape.
dle profile, I made Using the rivet holes in the tangs as To finish the ::i-
my handlesfrom z/q"-thickblanks glued guides,I drilled all the way through the handles, I soaked
up from granadillo and redheart scraps. handles, as Kevin did. I counterbored them in tung oil for an
This allowed me to make a handlewider each hole so the rivet headswould pro- hour or so, as shownin Photo D.
than the tang, a design inspired by the trude just a hair from the surface, then I let the finish dry, then buffed each
fins on a late 1950sChrysler. drilled holesfor the rivets. Next, I routed one with a cotton cloth. al
a partial round-over on the handles'
Greating a prototype edges.To avoid chipping, I sandedthe Photographs:Baldwin Photography
I beganby tracing the outline of the knife end-grainround-overs.
blade's tang on %" hardboard,then drew After dry-fitting the bladesin the han- Buying Guide:
the handle design around this outline, dles, I masked the blades where they KnifeSupplies.Blades, pre-punched
heaftreated, for
keeping the top edgesof the handle and met the handles.To install the handles.I polished,
rivets, andhollowgroundfrom440-C stainless
tang flush. I cut out this hardboardtem- appliedslow-setepoxy,making surethe steel:8" cook's,
#SS821, cook's,
$10,02;6" #SS820,
plate, and traced the pattern onto 3/q"- epoxy filled any void at the slot's $6.50; 5%"boner,#SS823,$6,58;8"carver,
#SS822,
$7,43; carving
fork,SS825,
$6,49; s/roxt/2"
Rivets:
thick scrap,which I cut and sandedto the bottom. With that done, I inserted the brass,(pkgof25)#RV125, %ox7e"
$3.95;
patternlines to act as a prototype. rivet halves and drove them together brass,(pkgof25)#RV325, $3.95,Plus
When I was satisfied with the feel. I with a hammer. shipping andhandling.
installed a thin-kerf blade and a zero- When the epoxy cured, I filed and JantzSupply, 309W,Main,Davis, 0K
clearanceinsertin my tablesaw,and cut a sandedoff any excess,then refilled any 73030. www.jantzsupply.com,
groove in the prototype's top edge to voids. I let the epoxy again cure, then 800/351-8900. e-mail:
jantz@brightok.net.
Catalog,
$5, I
acceptthe tang, as shown in Photo C. sandedthe rivets flush with the handles. i
Unlike the two-part handles of most Soaking the handles lets the tung oil
knives, Jan's one-piece design allows penetrate deeply, beautifying and pro-
for more grip area (prototype shown). tecting the wood.
Ft.rrr
r'lttl Fancifrrl fencingr
ffi issrre
iq':r.'
lrrnefirrly
tlltl
-t This fence defines the boundaries of your yard while
llrll enhancing your landscaping.Whateverthe size or
llllll
contours of your outdoor spaces, you can build the
fence to fit, with its pressure-treated posts and pan'
els made of cedar and plastic lattice. Construction
goes quickly, but the beauty lasts for years.
,\?
- tt-t"-.' -- 1:-rl =-t-
-.r*'-l
+a- i.:
.-, -, -: j:::: ::: -- l
.: ,-1-.-:'r:,---
t'l ; i
-"
il i:,::I I
:'rl i-:;-:';i,
A pergola lit
for a swing,
Page 68
This scaled-down
version of the large
pergola makes the
perfect place to hang a
swing. To build the
swing, follow the
instructions available
from WOOD PLANSo
(no. WP-OFS-I002,
$10.95).To order go to
www.woodstore.wood mall.com
or call 888/636-4478.
www.woodonline.eorn 59
I
\ t?
:
Add elegiance to )rour out-
door living wittr this airy
p on.Easilysi 6'to frt
qrryqpace,this versttile
pe will errh e ]rour
-
patioor :tard.'
hecfr;,
o two of us havethe sameoutdoorlivingSpaces,So we designed
adaptable.
this pergolato be infinitely Theoneshownhereoccupies
a 111x148""footprint,"but you'lllearnhow to increaseor decrease
How to plan y_our
its dimensions as needed.Youcan buildit as a freestanding structureon an perfect pergola
Usingthese instructions and the draw-
existingdeck or patioor set its postsin the ground.To shrinkit to the sizeof
ing belowas a guide,Youeasilycan
an arborand add a relaxingswing,seethe articleon page 68. customizea pergolato fit your needs.
No matterwhich way you go, you'll appreciatehow your pergolagoes H ere' show .
Startwith your pergola'sfootprint.
togetherlike LincolnLogs.You startwith a pileof machinedparts,raisethe to
Thi s i s si mpl ythe outsi de- of - post
posts, construct the frames, then fit the slotted canopy subassemblies outside-of-post lengthand width.
B ecause16' i s the l onges com
t m onlY
together.lt's that easy.
availablecedar2x6, and the girders
and joistsextendbeyondthe footprint
by 10" at each end, your footprintcan-
Grrt the parils not exceed 172x172".
for yorrr pergola kit Althoughyou can orientthe mainjoists
Cut four 6x6 (5 t/zx\t/z" actual) posts and sidegirders(D, E) in eitherdirec-
(A) to the length in the Materials tion,for planningpurposeswe'llreferto
List. To get a square cut, mark your cut-
line on all four sides. Using a crosscut
guide, cut all around the post to the full i
depth of your portable circular saw. -. t i
ct/2-
Finish off the cut with a handsaw. Sand {
the posts to 120 grit, and set them aside. 24"t
For the post caPS, start bY cutting i
four 1Vzx5l/zx5t/2"cap tops (B) and 51/z'-
61
rwnur.woodonline.com
pergola
ASSEMBLY
@ unruJorsr/BLocKrNG
,-1,1,t/'" 23s/a"
c,/2 | , -/
11/2"-, ) l'f -4
MMINGTEMPLATE
MARKING/TRI
151/2" th" hardboard
614"
3" deck
l/"""1"n^nkr'or",
\
3" deck screw countersunk
/
( 3" deck screw
83/a" 11/z'
Rout t/a"round-overs
R=31/2" on theseedgesafterthe
end profilesare shaped.
.,:'' and edgesflush. In the samemanner as mate with the notchescut in the bottom
i' router (to matchthejoists' before, use a handsaw and chisel to edgesof the sidegirders.As with the two
factory edges), and rout the deepenthe notches to 23/q"(or half the sidegirders(E), extendthe notchesin the
end profiles' edges. actual width of your 2x6s). Mark these end girdersto23/c"deep.Sandthe partsH
'Turn
the joists and girders as the side girders (E) that, along with and I to 120 gnt, and set them aside.
upside down on a pair of the end girders (H), form the pergola's ;, '. Cut eight 2x8 blanks 417/8"long for
sawhorses,and clamp them together outer frame. Sandthe parts (D, E) to 120 ' - the brackets(J). Using your circular
with their endsand edgesflush. Using a grit, and set them aside. saw or tablesawand miter gauge,make
square,draw lines acrossthe parts' bot- Cut the blocking (F) and upper
,,,,,: the angled end cuts, where shown on
tom edges(now facing up) for the IVz"- ',.,,,ibracketcleats(G) to size.Sandthem Drawing 4a. Mark the centerpointof the
wide notches, where dimensionedon to 120 grit, and setthem aside. curve on one blank. Bend a narrow strip
Drawing2. Using your portablecircular Cut the end girders(H) and the stub of hardboardto join the centerpointand
saw,a straightedge, and a I" chisel,form joists (I) to size. As with the main ends, and draw the curve. Jigsaw or
the notches,asshownin PhotosB andC. joists and side girders,usethe template, bandsaw,then sandto the line. Use this
(These photos show cutting similar jigsaw, and router to mark and form the completedbracket as a templateto trace
notchesin the swing pergolajoists. See end cutouts,where sho'rvnon Drawing3. the curve on the other bracket blanks.
page 68 for this project.)Checkthe fit of ' Following the same procedure as Saw to the waste side of the lines. Then
your I Vz" stock in the notch. For good , with the main joists and side girders, clamp the template bracket, in turn, to
appearanceand easy assembly,you'll form the notchesin the end girders (H) eachof the sawnblanks,and usea flush-
want a closebut not tight fit. and the stubjoists (I), where shown on trim bit in your handheld router to
.' Take two of the partsjust notched, Drawing 3. Note that the notchesin the smooth the curves.Finish up by routing
' and clamp them together,with ends end girders are cut in their top edgesto %" round-overswhereshown.
Cut the lower 8Y2"
bracket cleats 1Vz'
(K) to size.Rout the Vq"
23/q'
cove. and drill three
shank holes counter-
sunk from the back and
six shankholescounter- 131':
sunk from the front in each
piece, where shown on Drawing 4.
Sandthe cleatsto 120 gnt.
Note: The 4/4 cedar that many lumber-
yards carry is about 7/a"thick and rough-
sawn on one side. To get smoothfaces
and edges,we planed a lx6x8' board to
Set your saw to c.tl2t/q" deep. Clamp a Use a chisel and hammer to clean out s/t" thick and ripped and jointed it to
straightedge to the joists, and cut a the notches, smoothing their bottoms to
series of kerfs to define the notches. a uniform depth. 31/2"wide beforecutting the 10" lengths.
Screw together main joisUblocking (D/F) Screw together the two main joisUstub Lay out your pergola's footprint, and
subassemblies,where dimensionedon joist (D/l)subassemblies,where dimen- lag-screw four post bases to the deck.
ffir*wlng *. Fasten the upper bracket sioned on Orawing 3. Fastenthe upper Take diagonalmeasurementsto check
cleats (G) to the subassemblieswhere bracket cleats (G) to the main joists, your layout for square. The post bases
shown on Srawings ? and 5. where shown on the drawing. allow you to fine-tunetheir locations.
For the cove caps (L) and base trim Prime all the pergola parts with an Prrt it all together
(M), plane two lx6x6' cedar exterior-grade latex primer. Apply and voili, pergota
boards to 3/+"thick, as noted above. Joint two coats to the end grain and the notch- Now that you have all your pergola
one edge of each board. Rout a th" cove es. When the primer dries. lightly sand parts made, primed, and painted,
in the jointed edges,and rip off a 7-r"-wide with 220-grit sandpaper.Finish the parls you're just an afiernoon away fiorn
strip for the cove caps (L). Joint the sawn with two coats of exterior transforming your yard's personality.
edges of the remaining boards, and rip latex paint. Refen'ing to the nine-stepsequenceof pho-
them to 3t/+" wide fbr the base trim (M). tos that starls cbole and ends on page 65,
Sand the base and cap stock to 120 grit.
You'll miter-cut the cove caos and base
trim to fit aroundthe postsafter
168"
the pergolais in place.
I enncrETMouNTrNc
3" deck screw
-ls"ro"
51/2"
1 , / r " 1 ,(
151/2"
16s/a"
d < / t l
J'/2
21/q" 114a" I
il
,\ r
1r/r' 361/4' c'/2
W
B1/2"
R=31/2"
p ururuJorsr ANDENDGTRDER
1t/z" deck screw
-{ 2"
@ \
I
I
4s/a" f-
-R=31/2"
417/a"
wwur.woodonline, com 63
pergola
How to assemble the pergola (continued)
Lag-screw each end girder to two posts, Slip the end notches of the side girders Hoist the main joisUstub joist assem-
where shown on Drawing 4. Stand these (E) into the notches of the end girders blies (D/l) into place, slipping the stub
assemblies up in the post bases, plumb, (H). The tops of both girders are flush. joist and main joist notches over the
and brace them in place. Screw the bases Drill th" pilot holes, and lag-screw the side girders (E) and the end girders (H).
to the posts, as shown on Drawing 1. side girders to the posts. Fasten with deck screws. as shown.
rllr
3" deck screw
f---7 4" deck screws
21h'
\__t
\
e/e"lag screw
4" long
Ta"washer
1lz" deck
--)
1r/2"deck screw
e/a"lag screw
4" long
7e"washer
148"
111"
a
2" deck screw
EI CXPIODED
VIEW
make up the subassemblies,erect the Finish off your pergolaby driving 3" rrlaterials list
posts and girders, and assemble the deck screwsthrough the side girders
canopy and braces.All you'll need is (E) and the end girders(H) into the upper A posts 51/2, 51/z' 1073/q', c
some basic hardware:deck screws,lag bracketcleats(G). Removethe temporary B captops 11/2. 51/z' 51/2',
screws,and steel post bases(Simpson bracesfrom the posts.Drill countersunk C capbases 3/q' 41/2', 4r/2',
StrongTie no. ,4.866).To give us secure shankholesthroughthe post caps(B/C).
D mainjoists 11/z' 51/z' 168'
anchoragefor the post bases,we added Apply constructionadhesiveto the bot-
E sidegirders 11/z' 51/z' 168"
blocking underneaththe deck. When toms of the caps,and screw the capsto
F blocking 11/z' 51/2' 22' 30
lag-screwingthe girders to the posts, the tops of the posts.Touch up the paint
drill counterboredshank holes through where needed.Jl G yppqr
cleals
DracKet 11/z' 51/2, 83/a',
the girders and V+" pllot holes into the H endgirders
'
11/2" 51/zu131
posts. When fasteningparts with deck Written by Jan Svec with Kevin Boyle
Projectdesign:Kevin Boyle;James R. Downing I stubjoists 11/z' 51/z' 151/z' c 20
screws, drill only countersunk shank lllustrations:Roxanne LeMoine; Kim Downing; J- brackets 11/z' 71/q',403/a' c
holes. The deck screws drive into the Lorna Johnson
K lower
cedarwithout pilot holes. Photographs:Baldwin PhotograPhY cleats
bracket 3/t' 31/z^ 10" C
L- covecaps Vtu 3/q' 7' C 16
crrtting d ragrarnr M*base trim 3/qu 31/q' 71/a', c lo
.Partsinitially Seetheinstructions'
cutoversize,
MaterialKey:C-cedar.
51/zx 51/zx 120" Cedar (6x6x10)(4 needed)
Supplies: 1/2"deckscrews, 3"deck
2"deckscrews,
screws,4"deckscrews, %"lagscrews 3"long,3/e''
lag
(2x6x14)(10 needed) screws 4dgalvanized
4"long,%"flatwashers, finish
1 1 / 2 x 5 1 /xz 1 6 8 "
steelpostbases
nails, (4),construction
adhesive,
primer,paint.
1 1 / 2 x 5 1 /xz 1 6 8 Cedar(2x6x14)
x 192"Cedar(2x6x16)(3 needed)
1t/zx51/z
168"Cedar(2x6x14)(2 needed)
11/2x51/zx
e --.,:.)1.:.'.'---
11/2x51/z
"."e "'/ -.o_-..::)1.:.'-"---._
,:: a._.1
s/+x51/2x72"Cedar(1x6x6)(2 needed)
www.woodonline.com
65
bea
5. Dig, alignt
arrd finish the iob
Dig an 8"-diameter hole at least 6" deeper than your
area's frost line for each 4x4 post, using a power auger'
hand auger, or post-hole digger. A 6x6 post requires a
1O"-diameterhole. Shovel a 6" layer of gravel into the
hole to provide drainage. Now, put the strings back on I
the batterboards,but move them toward the outside of
the layout by one-half the post thickness. Set each post
in its hole, and move it until the outside edge lines up I
67
www.woodonline.com
Tlris freestanding shrcture lets you
venture be,yondthe deck.
l=i> 4,,deckscrews
e/ro"shank hole,
countersunk 3/e"nut
3/au
11/2' ---1
t ( 31s/+" WAShETS
-. svr'lI
he construction method
used in the previousarticle
for the deck pergolais very
versatile.With a little imagination
and planning,it adaptsto any num-
ber of outdoorapplications.
\' 3/e"washgr
We combineda porch swing from \
\ ./r" rag screw
our libraryof WOODPl-ANSowith a 4" long
reconfiguredpergola.The resultis a 1" counterbore1/2"deep with a
great place to relax and watch the 7a"hole centeredinside
world go by. See the BuyingGuide
for the swing plan. (We made our 953/4"
69
arbor/swi ng
I ururu
Jotsr
106"
E cnossJorsr
Y
Grrt the parts for togetherwith their endsand edgesflush. shank holes through the crossjoists at
tlre overhead grid Lay out the notch locations, where eachnotch.Drive 4" deckscrewsthroueh
',,.
Cut the main joists (D) to the length shown on Drawing3. Form the notches, the crossjoists into the main joists.
''' in the Materials List. Form the end
as explainedin Step4 on page 62. ..*Hpritt /s" holesfor the eye bolts,cen-
cutouts, shown on Drawing 2, as Note: Check the actual dimension of ";,*1;teredbetweenthe posts and in the
explainedin Step3 on page 61. Drill the your 6x6 posts. The spacesbetweenthe thickness of the cross joists, where
counterbored32" holeswhereshown. paired notches in the cross joists (E) shownon Drawing1. Touch up the paint
''
Cut the crossjoists (E) to the length must match this dimension. whereneeded.With the paint dry, install
. in the Materials List. Form the end the eye bolts, and hangthe swing.rl
$ Sandall your pergolapartswith 120-
'.ffigrit
cutouts, shown on Drawing 3, in the sandpaper.Prime the parts, Written by Jan Svec with Kevin Boyle
samemanneras thosein the main joists. including the posts, with an exterior- Projectdesign: Kevin Boyle; James R. Downing
'
Turn the crossjoists upsidedown on grade latex primer. Take special care to lllustrations:
Roxanne LeMoine;Kim Downing;
coat the end grain and the notches.When Lorna Johnson
Photographs:Baldwin Photography
the primer dries, lightly sand with 220-
grit sandpaper.Finish the parts with two
coatsof exteriorlatex paint.
crrtting diagrarn
A
51/zx 51lzx 144"Pressure-treated
lumber(6x6x12)(4 needed)
11/+"deck screws
eplacewimpy corner
posts with shingled
columns,and give 7sz"shank hole.
countersunk
your deck a solidstructurallook
and architecturalflair.Then,add
planterinsertsin the columns'
2" deck screw
tops to brightenyour deck with
floweringgreenery.
Constructedwith pressure-
treatedplywood,PVC lumber
(seethe sidebaron page 74),
and fiber-cementshingles,
thesecolumnsand railingswill
give you yearsof maintenance-
free enjoyment.And for added tr
tl
Distance
to the
grouno
m i n u s1 "
3" deck
SCTCWS
\r.-tl
strength,we builtthe railing's
top memberaround1Yz"galva-
2" deck
nizedsteelpipe.
wrvrv.woodonline.com 73
deck railing
VIEW
E TXPIODED
1t/2" 1/2" schedule
deck screw 4 0 g a l v a n i z e d s t e e l p i p e
1 1/2"
-\.-
deck screw
Zt/z"deck screw
7e"rabbet
t/e"deep
3t/z"deck screw
.1'
V-groove mraterials list
/e" dgep %r"shankf
@ hole,
countersunk
31/2" onfront A sides 3/q' 153/q' t PTP 4
1154a
I hole B insert
cleats 3/4' s/tu 14Vt' A
i 1/2" schedule 61/q"
C deckcleat1 1Vz' 3Vz' 15" PT
i40 galvanized
steelpipe %r"shankI D deckcleat2 11/2" 31/z' 111/2', PT
hole,
countersunk E deckcleat3 11/z' 3Vz' B1/z' PT
onback F narrow
battens 3/qu 1t/z' t
t G widebattens 3/q' 21/t' t
41/q"
strrps
H.starter 7/,16" 3/q' 54"
LOWERRAILBRACKET
1/z"cove J upperrailsides 3/tu 23/q' t
1" r- 1"
K upperrailtop 1u 3t/z' t
iltl
s/e"rabbet
/a" deep L upper
21/2" stringer 1u
baluster 21/a' t
'rI -?-r
i i '.o,' li
i M lower
stringer 1
baluster 31/q' t
,/
7sz"shankhole. 21/2" rail
N lower 1u 31/z' t
on back
countersunk 0 balusters 13/t' 13/q' 26'
P
LI
/ t l
2 1/2
@ @- P railbrackets 1u 41/t' 6t/t'
E
B
countersunk on front
_i R sides Vc' 113/q"14' A
I .._.. E
S bottom Vq' 133/c'133/q' A
v @\ I"labricate
T trimbase
U trim
3/tu 23/4' 171/2"
3/c' 3Vz' 163/q' A
A
I
I coves in the lower baluster stringer,
where shown on Drawing 3 Set the
4dgalvanized
1"roofing
finish
nails;
polyurethane
4dgalvanized
nails;
1/2"schedule
constructionadhesive;
boxnails;
40galvanized steelpipe;
maskingtape;
latexwoodfiller;acrylic latexprimer; latexpaint;
acrylic
packing peanuts; potting
soil.Forthebaluster'spacing
jig,you'llneedtwo1/cx4x5" pieces of hardboard
and
E!,,, eighlshxe/ox7t/2"woodcleats.
'bb Buying Guide
Bits,%"covebitwithtzb"
shank,no.8643,$16;1rslr6"
bitno.9228,
Forstner $13.95.MLCS, P0 Box4053,
Rydal,PA19046-6053.Call800/533-9298,orgoto
mlcswoodworking.com.
PVC.ForAzekTrimboards
Cellular information,
ca,,
Vycom at 800/235-8320,or goto www.azek.com.
- * , ;N
, "w anddeckcomponents,
Forbalusters
www.deckandporchsupply.com.
goto
wwwwoodonline,com 75
deck railing
AssermJrle
a strrrdy balrrstnde (We purchasedthe prefabricatedAzek evennumberof balusters).Drill pilot and
I To figure the number of balusters balusters mentioned in the sidebar on countersunk shank holes, and cement
I tOl you need, make a "story pole" page 74. Seethe Buying Guide to find an and screwthe first balusterin place,cen-
about I' longer than the length of your Azek dealernear you.) tering it on the widths of the stringers.
railing, and mark it off in 53/q"intervals. S fo make baluster spacing/centering Then use the jigs to position the rest of
(The maximum allowable spacebetween #*iigs, cut two Vqx4x5" hardboard the balusters, as shown in Photo D,
the 13/+xlz/+" balustersis 4".) Shift the spacers and eight tAx/cx7v2" cleats. cementing and screwing them in place.
pole back and forth on one baluster Glue and clamp together the upper and In the finished rail, the railing cap's rab-
stringer until you can locate balusters lower jigs, as shownon Drawing5. beted sides fit over the top baluster
equally spaced no more than 3" from {} Mark the upper and.lower baluster stringer,housing a length of 1/z" galva-
eachend.(3" plus the 1"-thickrail brack- tlstringer (L, M) centers(if you have nized steel pipe, as shown in Photo E.
et equals the 4" maximum spacing.) an odd number of balusters),or 27/e"to The cap will be cementedin place after
Count the number of neededbalusters. one side of the centers(if you have an the balustersectionis installed.
Clamp 2x2" scrap blocks between the Use the spacing jigs to maintain 4" The hollow space formed by the railing
upper rail sides (J) to keep them proper- spaces between balusters and keep cap and upper baluster stringer houses
ly spaced and parallel. them centered on the stringers. a fength of 1lz" galvanized steel pipe.
'F--15/8"+-
--------------------
Guided by the hole in the upper bracket, A hole in the column face opposite the To prevent sagging install 4"-long
hole through the column.
drilf a 115/rs" railing facilitates the installation of the pieces of baluster stock between the
Repeatat the railing's other end. 1lz" galvanized steel pipe. deck and bottom rail assembly.
www.woodonline.corn 77
deck railing
E PUlrER INSERT
2" deck screw
1 13/q"
,"ffi
"i .r"I
for a climbing
background
plant.But the realbeautyis
in its simpleconstruction.
n@t
Lay orrt and shape the
rrprights and crossbars
, \ o t e : B c , q i t.tt r t t r t 1' t t ' r t .li tt' tt l l l t t ' l t t t t t l t c r -
t'ttrtl itt' .sclct'titrg .stockt'ru't'titllt.,'\ll tltc
ltttt'l.s Irtt'tItc trcIIi.;.lt'(un(,('()tn(, .ft'()tntv ()
l0'-lortq t ttlttr 2x1.;. Lrxtk lltr ltottnf.s
t t ' i t l t . s t t ' t t i , q l,tqt r u i t t ; r ' i t l t n o r ' ( r r po t '
1 r l i 1 , ' t u t l i l ' i t l t r t t t k t t r t t .ost ' . s t r r u l lt.i , q l t t
l r n r ) l sl l t t t l r r o t t ' t 1 t o 1ott t l . , \ l . s ol t i t ' k t t l tt t
- --ru J' t'cdur 1x.1.urttl tt 21x18" slrcetof ltrt-
ticc. (II/c tt.sadltlu.stiLlultit t' irt Lr.stlLtttt't'
I t , ' 2 "1 1 1 111' 1 t tt1.n,u i l u l t l c i t t l t o n t t '( ( ' n l ( ' t ' .)\ .
Rin trio l0'lx-ls into Ii,:xlf':"-riiclc
ffi
rq
s t r i p s .T h c n c r o s s c L tr ht c s t r i p st o t h c
l c n s t h s l i s t c c li n t h e \ { a t e r i a l s L i s t a n c l
D r a w i n g 1 a t 0 c r c u t ct h c u p r . i - u h (t A s . Bt
a n t l c n r s s b l r r (- C s - .D ) .
L a r o r r ta r r cnl r a r l it h e l o c a t i o n so l ' t h e
cllrclocsin cach 1-riccc. ri hc-r'cclinrcn-
sioneclin Drawing 1a. N'larktlrc arei.rto
b c r c r l o r c c l n i t h a n " X " t o l ) r ' c c\ n t c o n -
t'Lrsion uhcn vou nrr.ichinc thc-clrcloes.
l n s t l l l l " + " c l l c k rb l a c l ei n v o r t rt a b l c -
sW s r l \ \ ' . l t n r l c l l t n t p a r . + ' - t h i c l ' s. c t t t l t
i'1 "G% b l o el . 1 ol l r c f ' c i r c ca. b o L ril' a h c a col l ' t h c
_i
b l u c l c ., \ l s o . a t t i r c ha n a L r r i l i u r ' \c \ t e n -
s i o r .tro r o r . l rn r i t c r g i . r L r St oc l t c l p \ u l l l ) ( ) r ' t
%' rqI
I
thc long ri orl.,picccs.
N o u c u t t h c I ' i r s tc l a r k ri n o n c o f t h c
-l'o
I o n u L r p r i r h t s( A ) . do this.position
t h c l c r r c cs o t h c s c t L l lb) l o c k i s t h c u p p r o -
l " r r i u trcl i s t u n c cl l ' o r nt h e t r l u c l c( 7 " l i r ' p l r t
, \ ) . F l L r ti h t c c n c lo l ' t h cr i o r k p i c c cu g u i n s t
t h c s c t L r lb- lro c k .t h en n i l t k co n c l l l s s o \ c r '
'#F
""*iFf *, ."*'e{iw:
WOOD magazine
,Lrj \*,
1/2" dadoes 3/4"deep
oc
631/2"
l[ onooLAYour
1t/q" deck
SCTCW
,1'/?"
11/2"
kr 11/2"
31/2"
J,,,
561/2" Tsz"shankhole,
countersunkon back side
1 281/z' I
7sz" pilot hole t/2"deep 25
1/qx157/ax157/a"
lattice panel I
g/0"shank hole
561/z
___l
'/4
a / l l
-T
|'t/q" deck screw
_) II
t/qx157/ax1St/a" 25
latticepanel
-l
t/2" rabbets't/+" deep
81/z'
1/2"-1.Dx .1 " 31/2"
copper pipe coupling
1tl2" dadoes
-_12"_4 s/+" deeP
L F-7"--1 |
/;;v'
1t/2.
T
1 1/2u
wwur.woodonline. corn
one terrific trellis
tltese pieces consecutively 7o eliminate dadoesfacing up. This will be the back
ertra fence setups. The dadoes irt the side.Lay the shorluprights(B) just out-
short uprights (B) und the short cross- side the long uprights.Now spreadan
bars (D) nmtc'h one another as well. exterior-grade glue in the dadoes.Join
the long and short crossbarsto the
Assernble, add lattice uprightswith the dadoesfacingdown to
panels, and rrlourrt lock the piecestogether.Usingthe shank
Predrill7r:" countersunk shankholes holesin thecrossbars asguides,drill-7::"
through the long crossbars(C) and pilot holesinto the uprights.Then secure
shortcrossbars(D) befbregluing them to eachjoint with a | /+" deck screw.
the uprights.Centertheseholes in the Chuck a t/2" rabbetingbit in your
dadoes,whereshownin Drawing1. handheldrouter,and setit to make a
Lay the long uprights(A) on a flat t/t"-deepcut. Rabbetthe squareareasof
surface,about 16" apartand with the the trellis frame to receive the lattice
panels, where shown in Drawing 1.
Squareup the cornersusinga chisel.Cut
mrlcE/sroP TNSTALLATToN lattice panelsto fit the rabbetedopen-
B
s/oq"pilot hole ings,but don't installthem yet.
r/z"rabbel Use your handheldrouter,equipped
t/q"deep with a chamfering bit, to rout a
t/1" chamfer along each edge of the
Attach all four mounting screws loosely
#6 x 3/q" 4'-long lx4. Then rip a l"-wide strip at first, then snug them down to hold
panhead from each edge of the board. Chamfer the trellis firmly to the wall.
t'-tfi;it"t"l
and rip one edgeof the remaininglx4
SCTCW
againso you end up with threetAxlx49" Hold the spacers between the trellis and
s/0" shank hole
chamferedstrips.Miter-cutthe stripsto wall, and secure the trellis with 4" deck
length to create the lattice stops (E). screws, as shown in Photo C. JP
Attach the stops to the trellis frame
Writtenby DavidStonewithCharlesl. Hedlund
1/qx157/ex157/a"
using 4d galvanizedfinish nails, where Projectdesign:Charlesl. Hedlund
latticepanel shownin Drawing2. lllustrations:
RoxanneLeMoine;LornaJohnson
Stain or paint the trellis as you Photographs:BaldwinPhotography
prefer.(We paintedoursto matchthe
exterior trim on the house where it is
installed.)Then mountthe latticepanels
to the frame,whereshownin Drawing2.
4d galvanized To mountthe trellisto the wall, first A- longuprights 11/z' 11/z' 631/z' C
f i n i s hn a i l dnll sAt" countersunkshank holes B-shortuprights 11/z' 11/z'561/z' C
throughthe long uprightsfor the mount- C*lonocrossbars 1l/zu 11/z' 42' C
ing screws,whereindicatedin Drawing1.
D-shorlcrossbars 11/2' 11/z' 35' C
Temporarily position the trellis, then
E- latticestoos 3/qu 1" 15' C
pushan awl or long nail throughthepilot .Parts
holesto mark the locationsof pilot holes initially Seetheinstructions.
cutoversize.
on the wall. To hold thetrellis awayfrom MaterialKey:C-cedar.
the wall, we used spacersmade from Supplies: woodglue,
Exterior paint
exterior orstain,
157/ax157/a" panels
lattice (2),4dgalvanized
finishnails
standard copper plumbing-pipe cou-
(16),1/+ deckscrews(24),4' deckscrews
(4),#6xth"
plings (t/:" inside diameterx 1" long) panhead sheet-metal
screws (12),
%"-1.D.x1"
copper
purchasedat the local hardware store. pipecouplings(4).
/4,
\D/
1 1 / 2 x 3 1 /xz 1 2 0 " C e d a r ( 2 x 4 x 1 0 )
1 1 / zx 3 1 / zx 1 2 0 " C e d a r ( 2 x 4 x 1 0 )
With its motor shaft perpendicularto the blade arbor, rather than parallel to it, a worm-drive saw (rightl is longer and
narrower than a helical-gearsaw (/eff).
www.woodonline. corn 85
circ saw tool test
F I R S T T O T H EF I N I S HL I N E
Rip-cutting speed reveals power
2x pine)
of 3 cutsin pressure-treated
(average
3.4
seconds
perfoot
4.7
seconds
perfoot
Depth-locking leverslocatedbetween
4.7 the handleand bladeguardare awkward
seconds to operatewith the left handwhilehold-
per foot ing the saw in your right.
Porter-Cable(Photo D). And, although
you can adjustthe 0' bevel stopon all of
4.7 the saws,only two-Makita and Porter-
seconds
per foot Cable-provide calibration screws for
the 45' stops.
As for the bevellocks,we preferlevers
4.3 to thumbscrews,which often put your
MAKITAsOOTNHK seconds fingers into tight spots.Bosch,DeWalt,
per foot Makita, and Milwaukee uselever locks.
,Stnmpedfoot.The baseof a circular saw
is called its "foot" (or sometimes,
3.4 "shoe"),andmostof thesefeethavegone
seconds high-tech.Only Ryobi still uses a steel
per foot foot, while the other modelssport a foot
of stampedaluminum, cast aluminum,
magnesium,or compositeplastic.
4.7 When dropped, a stamped foot may
seconds bend,but a castor compositefoot is more
per foot
likely to break. A bend can be straighr
ened; a broken foot must be replaced,
which could meandowntimeon a project.
5.8
RYOBICSB1SOK seconds
per foot
If you useyour circularsaw day in and dle and the upper blade guard, as shown
day out, you'll eventuallyneedto replace in Photo B.
the motor's brushes, and the Hitachi Most of the sawshave a depth-of-cut
C7BD, Makita 5007NHK, and Porter- scale,but some are easierto read than
Cable 347K allow you to change the others. See the model-by-model sum-
brushesfrom the outsideof the casewith- maries for specifics,but Ryobi's depth
out disassembling the saw. scale(Photo G) readseasierthan any of
,Easy cutting-depth adjustments. the othersin the test.
Although all of the testedmechanisms .Convenient beveling. All of the saws
worked smoothly, we found plenty of will bevel at least45o, and most can go
differencesin the ease of using them. beyond. Getting past the 45o stop, on
First, the locationof the depthlocks var- those saws that have them, can be as
ied. We gavelower marksto the Hitachi, simple as slipping past a ball-bearing
Clearly marked graduations make set-
Makita, and Ryobi CSB130K,wherethe detent on the DeWalt DW369, or as ting the correct cutting depth easy with
locking lever is betweenthe saw's han- clunky as the bevel-stopsleeveon the the Ryobi CSB130K.This saw also had
the most marked graduations.
www.woodonline.com 87
circ saw tool test
,^ />
t6
IFl g l{ IF
r/s? tg tlu
/o* ld, tzt
ls tFt
'lfrli
s
x It,/,i tg
t€t! s l .r- lfrl,
'"*
'/f/ft
F/"rtl
- /t*i-
lul-
ffiffi
;/s"/^€
tfts I
5
u
,N
url
s=/
rd/
.Qli n*/rs
I
tf/ft
o*-/d*d,
61/zx 111/z
61/z x 11/q
6lzx 1|Vq
6s/s x 113/a
6/a x 11/e
61/z x 121/z
6 1 / zx 1 1 / c
#F
t4t
o
e
rRlr/s/i working outdoorson breezydays.
The 347K is also the only saw in the
tracking,and a boatloadof performance-
enhancingfeaturesat a reasonableprice.
e6
F
q
c,R 1 yr.
f/=-.
U 12.3 $1s5 N/A
testwith a bypassable stopat 0o bevel,as
well as the typical 45' stop. With the
bevel stoprotatedout of the way, you can
DeWalt's DW369 trades a little power
for bevel stops at 22.5o and 45o, and
doesit for about$20 less.
c,D 1yr. 1 1. 9 1 0 0 N/A back-bevelasmuch as-3o,or bevelup to If you don't think you'll use a circular
48'. Although similar in function to the saw often enoughto justify the cost of
c 1 yr. U 1 1. 2 1 3 5 N/A
stopon the Makita, it's lessintuitive and the DeWalt or Milwaukee, the
D,R 1 yr. J 1 1 . 1 165 N/A
requires2t/z tums of the locking thumb- Craftsman27108will fill the bill nicely
c R 1 yr. U 1 1. 2 1 6 0 r007NLl($160
for you. For occasionaluse,we canover-
screwto rotateit in or out of position.
R LIFE U 1 1. 6 1EE 6391-21l$155
All of the tested saws have spindle look the thumbscrewlocks.i
c,D R 1 yr. U 1 1. 1 1 3 0 743Kl$130 locks for changing blades, but the
c Writtenby Dave Gampbellwith Kirk Hesse
C,D 2 yr. 1 1. 5 80 N/A 347K's is in a tight spot between the Photographs:Baldwin Photography
front handle and the upper blade guard,
making it more difficult to accessthan
8. (U) UnitedStates
(C) China the others. However, we'll give P-C Visit wur,',w.woodonline. cofir to
(S) Singapore
credit for including onboard storagefor talk about circular saws with
9. All saws weighedwith identicalbladesinstalled. other woodworkers.
the bladewrench.
10. Pricescurrentat time of article'sproduction.
www.woodonline.corn 89
the vyoodrruorkers
whobuilt
Hy
Look beyond the Statue of Liberty's metal exterior and
you'll find the handiwork of skilled woodworkers.
'?
"#
ffi
t{
fr-
W
r;p
Some 310 huge sheets of copper were hammered into shape against intricate wooden
molds to shape the skin of the Statue of Liberty.
www.woodonline.corn 91
^_
dorned- -r' ^_
\
--/ \/ \ -*/ \/\-
Senrecheese and
crackers on this terrific
turned tray.
Materials
'ltl2"{hick
Supplies: face-
stockforauxiliary
plate,
hotmeltglueordouble-faced
tape,
woodworke/s glue,finish,
epoxy.
BuyingGuide
Turning blanks,1shx121Ax121/t" mahogany
(edge-joined
fromcolor-blended stock);
3/4x61 maple; 1x1x8"bird's-eye
/4"bird's-eye
/4x61
maple. Kitno.W-141, $19,95 ppd.,Minnesota
residentsaddsalestax.Heritage Building
Specialties,205N,Cascade, Fergus Falls,MN
56537. Call8001524-4184.
Conecenter. Conecenter no.914-0001 (#1
Morse taper)orno,914-0002 (#2Morse taper),
Q finisn-sandto 220grit. $39.99 ppd,CraftSupplies USA,1287E.1120
S.,Provo, UT84606. Call800/551-8876, orgo
towww.woodturnerscatalog.com.
Domeandknife.6"glass domeno,011-0120,
$7,99;deluxe cheese knifeno.199-1001,
@rorm thetopknotbutton t CraftSuppliesUSA.
as youpartoffthepiece. ll $6.50.
(DCut in as closeto conecenteras Finishes. Mylands FrictionPolish(4oz.)no.
- oil(16oz.)no,
possible without it,
disengaging 949-400,$5.50; butcherblock
076-0830, $6.99.CraftSupplies USA.
W00Dospecialkit.Glass dome, knife,
friction
polish,
butcher blockoil,kitno.900-9000,
$26.99 ppd.CraftSupplies USA.
95
. t
,.*tM
96
aDAdd function to the fence. For some operations,such as
Jll*hen cutting tenons with a dado blade or cutting with the blade
Vagainst the rip fence, you'll appreciatehaving an auxiliary fence
face. Easy to make, this accessorypreventsdamageto the fence, and can
support a tall face for cutting wide workpieces on edge.
For generaluse, cut a z/q"plywood face 4"-wide by the length of your
fence. How you attach the face dependson your fence. If your fence has
holes through it, attach the face with bolts. Just counterborethe holes in
the face so the bolt heads sit below the surface. Or make a "saddle" that
slips over the fence,
^a Gover the angles. To ensureaccurate as shown at right.
frcrosscuts, make sure the miter gauge is Clamp it at the out-
Iaccurate at 90' and45'. Restone edgeof a feed end, or mount
plastic drafting triangle on the blade body-not on a pair of T-nuts in
the teeth. Loosen the miter gauge knob, stde the the saddle's back
head against the ffiangle, and lock the knob, as "legr" and use short
shown above.Do the same at45o. Thesetriangles bolts as setscrewsto
are available in artist's supply stores and are very securethe saddle.
accurate.Adjustablemodelsalso are available.
www.woodonline.corn 97
tablesaw success
o[Ittu@c
Plastics ResearchCorp.
810/235-0400
www.tuffbilt.com
re guidc FASTElIERS
ProMax Optimized
Gomment:
Thread Length
Thissquare-drive
screws
ftstenerotfers
greatholdingpowerwith shanklengths
sizedto matchwoodthickness.
McFeeley's
SquareDriveScrews
hen we designedand built 8001443-7937
the projectsfor our out- vvww.mcfeelys.com
door living areafeatured
SYTITHENG STOI{E
on pages 58 and 59, we selected Tehema WaterWashPatioPavers TC-3407
products that met our rigorous criteria. Comment: Providinga real-stonelookwitr
We combed the market for materials bettercolorconsistency,this lighter-weight
buildingmaterialis easyto installdueto ib
and hardware that are maintenance- consistentthicknessandflat bottomside.
free and resistant to weather's worst Cultured
StonrA Division of Owens-Coming
abuses.We also chose products that 800t255-1727
offer convenience, ease of installation, www.culturedstone.com
and great looks. Now let's review IOW.UOITAGE tIGHNilG
these nationally available products and Malibu Architectural
GradeC1900 andC1902
recessed lights;
C1l31floodlights
how you can learn more about them.
Comment: Easyto install,theseenergy-
efficientlightscomein manystylesand
CEDARTUMBER featureprotective, durable,metalhousings.
WeyerhaeuserCedar0ne Western
Redcedar Intermatic,Inc.
CommentCedaris a rot-,warp-,andcrack- 8151675-2321
resistantwoodthat holdsup well in above- www.intermatic.com
groundoutdoorapplications.
WeyerhaeuserBuilding
Products STEREOSPENGRS
866/233-2766 MA905 panelspeakersandoneMS15010"
vvvvw.cedarone.com subwooferwaterproofspeakers
Comment: Waftib high-fidelitystereosound,
DEGKIIIG this waterproofaudiosystemattachesto
WeyerhaeuserChoiceDek Plus yourhome'saudiosystemfor convenient use.
CommentThesewoodfiber/plasticcomposi- Poly-Planar,
Inc.
tion boardswon't rot,crack,or warp;they 215t675-7805
neednofinishandoffergreatwet-traction wvvw.polyplanar.com
dueto theirgroovedsurface.
WeyerhaeuserBuilding Products GOI{CRETE A]ID FORMS
877/235-6873 10x42"Quik-Tube concrete
formsandQuikrete
wvvw.choicedek.com 5000Concrete Mix
CommentWhilethe easy-to-use formsgive
PUG
TUMBER shapeto yourfooters,the quick-mixingcon-
AzekExpanded RigidPVC cretemixfills theformswiUrlastingstrength.
GommentThisplastic-based product TheOuikrete Companies,Inc.
machines likewoodandlookslikeit once B00t2B2-5828
painted;it's impervious
to rot andinsects. vvvvw.quikrete.com
VycomCorp.
5701346-8254 GASGRItt
vvvvw.azek.com Weber GenesisPlatinumgasgrill
CommentThismaybe the lastgrill youever
sHtltGtEs buy.lt haslong-wearing stainlesssteelcom-
ShinglesideHeritageSingle
Shingle ponenb,anda 12' quick-disconnect hose
Comment: SingleShinglewon'trot,split,or that leb you hookup to yourhome'sgas
curl.lt takespaintwellandcomespre-primed supplyso youneverhaveto run outto fill a
with a 30-yearwarranty. propanetank.
JamesHardie Building
Products,
Inc. Weber-Stephen Products,Co.
8881542-7343 800/446-1 071
wvttw.j
ameshardie.com rrvww,weber.comI
www.woodonline.corn
inuour
lFaile
E0at I tiE
CMT's N
fora$lto[ilron.
CaIl us, we'L teII you how!
This system
combinesthe
performanceand
A;;is";fi't'ip.'
with the versatility
of a router.
Professional
30-Piece $el 5'PieceCoveSet This 1rair of diartronds
Includes: 1/2'Shank
1/4"R,
Router Eits
3/8"R,1/2"R,
wins hands dourn
bils
5 Straight
3 Dovetails flt-*n r 5/8"R'
3/4'R Monocrystallinediamondsare a cutting
3 CoreBox f ${9 rrt tool's bestfriend. Virtually wearproof,
3 GoveBils WL-2015OURPRICE
OXIV
6 Roundovers they impart a consistentlyflat, sharpedge
2 FlushTrim
1 PanelBil (Gore
Roundnose
5-Piece Box)$et on chisels,knives,or evenothersharpen-
2 Boman 0gee 1/2"ShankRouter Bits ing stones.But that precisionusually
2 SlolCutlerc
1 "V" Grooue ;illl? 3/8"0,1/2'0,3/4"0,1"0,11nO
wL-2012 comeswith a high pricetag.That'swhy I
0llt $f9 set
1 Chamfer
1 BevelTrim Bil 'rU'*n OuRPRICE did a doubletake when I saw DuoSharp
monocrystalline stonesfor under$100.
WL-2010 OUR 0lltV$l0l set 13-Piece
PRICE Set rlf 13 nn
Dovelail DuoSharpstoneshavedifferentgrits on
1/2"ShankRouterBils eachsidewith color-codeddots on each
1S-Piece
1/2"Shank
$et lncludes: 3 Straight
bils
Chamler 10Dovetail[ils stoneto give a quick visual referenceto
Cove -
1/?'R,3/YR,1/4'F
Roundover - WL-2014OUR 0Itf $49 srt
PRICE which grit is up. Using the fine/extrafine
1/2"8,3/rR,1/4"R 8" stone(shownin the optionalmolded
H o m a nO g e e ' 6-Piece
Bullnose
$et base,below),I tunedup my benchchisels
1l4i'R
Straight Bils-
3/{',R,l/?tR,1/4"R
Roundover
r/nn,3/8'R,
-
1/4"8
ililf*rffi
t rflfS s
12" ShankRouterBits
114"0,318"D,1|?',D,
5/t"0,3/4'0,l*D
and found the fine grit aggressive,but not
grabby.I then flipped the stoneto extra-
1/2.Dovetail
112"Roundover
OtllY$81 set
WL-2013OURPRICE fine and,with a few strokes,honedit
wL-2022 razor-sharp.
1"CLFlusft Trim
0lltl $59 set
OURPRICE Rabbet Bit 3-Pieee
',n
Cabinet
DoorSet rfll After sharpeningeverythingbut the pen-
; I l2'ShankRoulerBits|lt cil over my ear,I simply rinsedthe
15-Piece
1/4"Shank
Set lf,fffr Z-fieceBoman0geeRait&Stlte
DuoSharpstonecleanwith water,and
s-f*Yif"'#la 2 3/4"OgeePaneiRaiser
sameasWL-2922
excepll/4" shank
WL-2021 0ttv $59 set WL-201sOUR
OURPRICE 0llf $65 mt
PRICE wiped it off. The diamondcrystalsare set
in a nickel surfaceto preventrusting.
5-Piece 0oor$et
Gabinet 5-Piece
Moulding
$el Flatnessis alwaysa concernon sharp-
rtlf m 1/2"Shank
Router
Bits eningstones,and again,DuoSharp
lncludes: I
3/4"BoreShaper Cutler
1-pcBail& Stile(Roman Ogee)
ril?3 nn excelled.I checkedthreedifferent stones
Otw s99 set using a surfaceplate and found them to
s,
4 5/8'Panel
Raiser (Ogee) WL-2011 OURPHICE
DoorLip vary lessthan .003" from perfect.
GlueJoint
DrawerLosker -Tested by GarrySmith
oogtH
WL-1505 OUR 0ttv$l?9 str
PHICE
6-piece
Cabiner
Door
Ser srire
fifH:i&
(Roman 0gee) 5-Piece
Garbide-
2 3/4"D Panel
Haiser (Ogee) TippedForslner
BitSet
DoorLip forDrillPress
3/8"Shank
,,"m,Ttffhm; w-e Sl:ijl'i;.", 35mm,1 114",1",3/4",5/8"
wL-ztlzo ouC-FnlcE $l
otlv f 9 ser Ont $39 set
PRICE
8-Piece
Classical
Set ril$ fi; Dovetail
5-Piece Set
lncludes: 1/2"$hanlRouler
Blls DMTDuoSharp
2 Glassical-
582'R& 1/4"R,1 Wavy Sharpening
System
2 0gee- 582'R& 1/4"R,
2 Roman
r* f$S{ft l"o:l{i,.,
1 Filel
0gee- 582"R& 1/4"R
ltz*,stsn,st4, Performance *****
(1/2"$hankRouler
Bits) ;i rllm Price $ 8 0 , 8$" ;1 1 0 , 1 0 " ;
wL-2016 0ttY$99 set WL-2017 OURPHICE
PRICE
OUR ottf $f 9 set $18,molded base
Value ****rt
s the only species of its genus the beans of the Kentucky coffeetree
in North America, the sparsely as a stimulating replacement. The
appearing Kentucky coffeetree result was a bitter imitation at best,
(Gymnocladus dioicus) was a welcome but they made do.
sight to eady explorers and pioneers Reachingheights of 100'and diame-
tmveling into the wilds west of ttre ters to 4' in its range from southem
Allegheny Mounains. Not that it's an Carradato Kentucky and west to
attractive tree-it leafs out in late spring Nebraska,the Kentuclry coffeetree has into fumishings and
and sheds early, causing it to stand so wide a distribution and so single a other necessities.
naked for at least half of the year. In growth pattem that it has never reached Today, if you are able
fact, becauseit often looks so stark, the commercial importance. Although, to find the wood of the
French called it chicot or "dead tfee" farmers always have used the coarse- Kentucky coffeetree, its
while to Southemers it became "stump grained yet durable wood for fence known as coffeebean.
tree." Rather than its eye-appeal,the posts and barn timbers. Light brown to Be sure to build some-
attraction was its bean-ladenpods. reddish brown in color, the heavy and thing of it, but leave
Iacking coffee beans for their trav- hard wood machines easily and takes a the beans behind. .l
els, frontiersmen ground and brewed high polish. Pioneers no doubt crafted it Illustration: Brlan Jeosen
www.woodonline.com
1€0G542-gLr5
Visit oncof our stores located nationvide! Call us for the store nearestyou.
Proudsponsorof "The
AmericanWoodshop"
hostedby ScottPhillips
on PBS.
lnrhatts ahead
intheJune/July
issue
Projects
Heirloom
chest
Buildthisasa gift,andyou'resureto makesomeone's
woods
day.Contrasting lendanairofdistinction
to
itstraditional
design.
It'sa ringer
Iimelesstoolbox Thiseasy-to-make
Lookingfor a placeto storeyourtoolsthatshowsoff yourwoodworking skills?ThisArts& Crafts- horseshoesetwillgivekids
inspiredchesthastwo drawersanda pull-outtooltray,all withprotective
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