03. June 2003.pdf

SAM MALOOF’S BRAND NEW SHOP: AN INSIDE LOOK

WRIGHT AIRPLANE: WOODWORKING PROJECT CHANGED THE WORLD

JUNE 2003

ISSUE #134

HOME OFFICE

Computer Cabinet

Organizes Everything

You Need

Euro Band Saws

Are these sexy

foreign models

worth the money?

PLUS

• CAD: Easy, Mighty & Cheap

• We Test 7 Shop Aprons

• 5 Tricks to Finish Walnut

• Traditional Jewelry Chest

popwood.com

$4.99 U.S. $7.99 CAN

Use Smoothing Planes

Instead of Sandpaper

06>

71486 01355

ALL-IN-ONE

PURVEYORS OF FINE MACHINERY ™

12 SPEED 17" FLOOR DRILL PRESS

2 HP DUST COLLECTOR

OSCILLATING SPINDLE SANDER

• 1 HP, S INGLE - PHASE , 110V/220V MOTOR

• P RECISION GROUND CAST IRON TABLE : 13 5 ⁄ 8 " SQ .

• S PINDLE TAPER : MT#3

• S PINDLE TRAVEL : 4 3 ⁄ 4 "

• S WING : 17"

• D RILL CHUCK : 5 ⁄ 8 "

• 12 S PEEDS : 210, 310, 400, 440, 630, 670,

1260, 1430, 1650, 2050, 2350, 3300 RPM

• D RILLING CAPACITY : 1” STEEL

• O VERALL HEIGHT : 64 1 ⁄ 2 "

• T ABLE TILTS 90˚ IN BOTH DIRECTIONS

• A PPROX . SHIPPING WEIGHT : 275 LBS .

• M OTOR SIZE : 2 HP, 220V S INGLE - PHASE

• P ORTABLE BASE SIZE : 21 1 ⁄ 2 " X 33 1 ⁄ 2 "

• S TATIC PRESSURE : 12.3"

• A IR SUCTION CAPACITY : 1550 CFM

• S TANDARD BAG FILTRATION : 30 M ICRON

• M OTOR AMP DRAW : 12 A MPS (220V ONLY )

• A PPROX . SHIPPING WEIGHT : 130 LBS .

• 1 HP, S INGLE - PHASE , 110/220V, TEFC MOTOR

• P RECISION GROUND CAST IRON 25" X 25" TABLE TILTS TO 45°

• S TROKE LENGTH : 1 1 ⁄ 2 "

• F LOOR - TO - TABLE HEIGHT : 35 1 ⁄ 2 "

• 1725 RPM SPINDLE SPEED

• S PINDLE OSCILLATES AT 72 SPM

• I NCLUDES 100 GRIT SLEEVE

FOR EACH SPINDLE & GROUND

STEEL TABLE INSERTS

• 10 T APERED & THREADED SPINDLE SIZES

• P ERMANENTLY LUBRICATED BALL BEARINGS

• B UILT - IN 4" DUST COLLECTION PORT

• A PPROX . SHIPPING WEIGHT : 300 LBS .

FREE

CYCLONE SEPARATOR!

G1071

ONLY $ 525 00

G7947

ONLY $ 375 00

G1029

ONLY $ 249 95

10" HEAVY-DUTY TABLE SAW

10" LEFT-TILTING SUPER

HEAVY-DUTY TABLE SAW

24" DRUM SANDER

WITH VARIABLE SPEED

• 1 1 ⁄ 2 HP, SINGLE - PHASE , 110/220V MOTOR

• P RECISION GROUND CAST IRON TABLE

• T ABLE SIZE ( W / WINGS ATTACHED ): 27 1 ⁄ 8 " X 40 5 ⁄ 8 "

• C UTTING CAPACITY AT 90°: 3 1 ⁄ 8 " AND AT 45°: 2 1 ⁄ 8 "

• 5 ⁄ 8 " X 1 1 ⁄ 4 " A RBOR ACCEPTS DADO BLADES

• M AXIMUM RIPPING CAPACITY : 24"

• 3 HP, S INGLE - PHASE , 220V MOTOR

• P RECISION GROUND CAST IRON TABLE

• T ABLE SIZE ( W / WINGS ATTACHED ): 40 1 ⁄ 8 " X 27"

• E XTRA - LARGE HANDWHEELS

• C UTTING CAPACITY : 8" L & 26" R OF BLADE

• M AXIMUM DEPTH OF CUT @ 90°: 3"

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

• 5 ⁄ 8 " D IAMETER ARBOR

ACCEPTS DADO BLADES

UP TO 13 ⁄ 16 "

• A PPROX . SHIPPING

WEIGHT : 467 LBS .

MOTOR COVER

& DUST HOOD

INCLUDED

• 5 HP, 220V DRUM MOTOR DRIVES 2 ALUMINUM SANDING DRUMS

• 1 ⁄ 4 HP C ONVEYOR MOTOR : V ARIABLE SPEED

• C ONTROL PANEL WITH AMP LOAD METER

• H ANDLES STOCK UP TO 23 1 ⁄ 2 " WIDE AND 4 1 ⁄ 4 " THICK

• H OOK AND LOOP SANDPAPER INSTALLS EASILY ONTO THE DRUMS

• I NDUSTRIAL RUBBER CONVEYOR BELT

• 2 - 4" DIA . DUST PORTS

• A PPROXIMATE

SHIPPING

WEIGHT : 495 LBS .

• A PPROXIMATE SHIPPING

WEIGHT : 220 LBS .

G1022SM

ONLY $ 325 00

G1023SL

ONLY $ 895 00

G1066Z

ONLY $ 1595 00

THE ULTIMATE 14" BANDSAW

17" HEAVY-DUTY BANDSAW

19" HEAVY-DUTY BANDSAW

• M OTOR : 1 HP, TEFC, 110V / 220V SINGLE - PHASE

• P RECISION GROUND CAST IRON TABLE : 14" X 14"

• 2 SPEEDS : 1500 & 3200 FPM

• C UTTING CAPACITY / THROAT : 13 1 ⁄ 2 "

• M AXIMUM CUTTING HEIGHT : 6"

• Q UICK CHANGE BLADE

RELEASE / TENSIONING

• T ABLE TILT : 45° RIGHT , 10° LEFT

• F ENCE : D ELUXE EXTRUDED ALUMINUM

• W HEELS : F ULLY BALANCED CAST

ALUMINUM WITH RUBBER TIRES

• B LADE SIZE : 92 1 ⁄ 2 " ( 1 ⁄ 4 " TO 3 ⁄ 4 " WIDE )

• B ALL BEARING BLADE GUIDES

• 4" DUST PORT

• I NCLUDES ONE 3 ⁄ 8 " BLADE

• A PPROXIMATE SHIPPING

WEIGHT . 210 LBS .

• M OTOR : TEFC CAPACITOR START INDUCTION ,

2 HP, SINGLE - PHASE , 60 H Z , 110V/220V

• P RECISION GROUND CAST

IRON TABLE : 17" X 17" X 1 1 ⁄ 2 " THICK

• C UTTING CAPACITY HEIGHT : 12"

• C UTTING CAPACITY LEFT OF BLADE : 16 1 ⁄ 4 "

• W HEELS ARE FULLY - BALANCED CAST

ALUMINUM WITH RUBBER TIRES

• D ELUXE EXTRUDED ALUMINUM RIP FENCE

• B LADE GUIDES : E URO - STYLE ROLLER DISC

• B LADE SIZE : 132" X 1 ⁄ 8 " - 1" ( STANDARD 1 ⁄ 2 ")

• 2 SPEEDS : 1600, 3300 FPM

• 4" DUST PORT X 2

• T ABLE TILT 10° LEFT , 45° RIGHT

• Q UICK CHANGE BLADE RELEASE / TENSIONING

WITH BLADE TENSIONER INDICATOR

• H EIGHT FROM FLOOR TO TABLE : 37 1 ⁄ 2 "

• A PPROXIMATE SHIPPING WEIGHT : 321 LBS .

• M OTOR : 2 HP, SINGLE - PHASE , 60 H Z , 110V/220V

TEFC CAPACITOR START INDUCTION ,

• P RECISION GROUND CAST IRON

TABLE : 19" X 19" X 1 1 ⁄ 2 " THICK

• C UTTING CAPACITY LEFT OF BLADE : 18 1 ⁄ 4 "

• C UTTING CAPACITY HEIGHT : 12"

• 2 SPEEDS : 1700, 3600 FPM

• B LADE SIZE : 143" X 1 ⁄ 8 " - 1 1 ⁄ 4 "

• Q UICK CHANGE BLADE RELEASE / TENSIONING

• W HEELS ARE FULLY - BALANCED CAST

ALUMINUM WITH POLYURETHANE TIRES

• D ELUXE EXTRUDED ALUMINUM RIP FENCE

• B LADE GUIDES : R OLLER DISC

• B LADE TENSION INDICATOR

• M ICRO ADJUSTING GEAR TABLE

• 4" DUST PORT X 2

• T ABLE TILT 10° LEFT , 45° RIGHT

• A PPROXIMATE SHIPPING

WEIGHT : 383 LBS .

G0555

ONLY $ 375 00

G0513

ONLY $ 750 00

G0514

ONLY $ 950 00

MEDIA CODE

AD1709

CUSTOMER SERVICE: 570-546-9663 • CSR@GRIZZLY.COM • FAX: 1-800-438-5901

3 INCREDIBLE SHOWROOMS: MUNCY, PA • BELLINGHAM, WA • SPRINGFIELD, MO

CIRCLE NO. 122 ON FREE INFORMATION CARD.

3 INCREDIBLE SHOWROOMS:

• 2 OVERSEAS QUALITY CONTROL OFFICES STAFFED WITH

QUALIFIED GRIZZLY ENGINEERS

• HUGE PARTS FACILITY WITH OVER 1 MILLION PARTS IN STOCK

• 830,000 SQ. FT. PACKED TO THE RAFTERS WITH TOOLS & MACHINES

• TRAINED SERVICE TECHNICIANS AT ALL LOCATIONS

• MOST ORDERS SHIPPED THE SAME DAY

• FRIENDLY & KNOWLEDGEABLE CUSTOMER SERVICE

• FULL 1 YEAR WARRANTY ON ALL GRIZZLY MACHINES

NO DEALERS , NO MIDDLEMEN – BUY DIRECT & SAVE!

12 1 ⁄ 2 " PORTABLE PLANER

15" PLANER

20" PLANER

• 2 HP, S INGLE - PHASE ,

110V M OTOR , 15 AMPS

• M AX . CUTTING WIDTH : 12 1 ⁄ 2 "

• M AX . CUTTING DEPTH : 1 ⁄ 16 "

• 2 HSS KNIVES

• F EED RATE : 25 FPM

• O N / OFF TOGGLE S WITCH

• M AX . CUTTING HEIGHT : 6"

• M IN . BOARD THICKNESS : 3 ⁄ 16 "

• C UTTERHEAD RPM: 8,540

• 57 CUTS PER INCH

• A PPROX . SHIPPING

WEIGHT : 85 LBS .

• 2 HP, 220V, S INGLE - PHASE MOTOR

• P RECISION GROUND CAST IRON BED

• C UTTERHEAD SPEED : 5000 RPM

• R ATE OF FEED : 16 FPM & 20 FPM

• M AX . CUTTING WIDTH : 14 7 ⁄ 8 "

• M AX . CUTTING HEIGHT : 6 1 ⁄ 8 "

• M AX . CUTTING DEPTH : 1 ⁄ 8 "

• N UMBER OF KNIVES : 3 HSS

• A LL BALL BEARING CONSTRUCTION

• A PPROX . SHIPPING

WEIGHT : 440 LBS .

• 3 HP, 220V, S INGLE - PHASE MOTOR

• 25 3 ⁄ 4 " X 20" P RECISION GROUND CAST IRON TABLE

• C UTTERHEAD SPEED : 4833 RPM

• R ATE OF FEED : 16 FPM & 20 FPM

• M AX . CUTTING WIDTH : 20"

• M AX . CUTTING HEIGHT : 8 5 ⁄ 8 "

• M AX . CUTTING DEPTH : 1 ⁄ 8 "

4 BLADE

CUTTERHEAD !

I NCLUDES

STAND !

• N UMBER OF KNIVES : 4 HSS

• D UST EXHAUST HOOD

HAS 5" DUST PORT

• A PPROX . SHIPPING

WEIGHT : 785 LBS .

700 LB .

CAPACITY

STAND

W/ PURCHASE

OF G8794 PLANER

G8794 WITH STAND

ONLY $ 299 95

G1021

ONLY $ 795 00

G1033

ONLY $ 1295 00

15" WIDE-BELT SANDER

(OPEN END)

1 1 ⁄ 2 HP SHAPER

3HP SHAPER

• M OTOR : H EAVY - DUTY 1 1 ⁄ 2 HP, 110/220V

• 2 I NTERCHANGEABLE SPINDLES : 1 ⁄ 2 " AND 3 ⁄ 4 "

• T WO SPINDLE SPEEDS : 7,000 AND 10,000 RPM

• T ABLE SIZE : 20 1 ⁄ 4 " X 18"

• S PINDLE TRAVEL : 3"

• S PINDLE OPENINGS :

1 1 ⁄ 4 ", 3 1 ⁄ 2 ", AND 5"

• F LOOR - TO - TABLE HEIGHT : 33 1 ⁄ 2 "

• M AXIMUM CUTTER DIAMETER : 5"

• A PPROX . SHIPPING WEIGHT : 220 LBS .

• H EAVY - DUTY 3 HP, SINGLE - PHASE , 220V MOTOR W / REVERSING SWITCH

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

• T WO SPINDLE SPEEDS : 7,000 AND 10,000 RPM

• 3" S PINDLE TRAVEL

• S PINDLE OPENINGS : 1 3 ⁄ 8 ",

2 3 ⁄ 4 ", 4", AND 5 1 ⁄ 2 "

• P RECISION GROUND CAST

IRON TABLE

• T ABLE SIZE WITH STANDARD

WING ATTACHED : 30 1 ⁄ 2 " X 28 1 ⁄ 4 "

• F LOOR - TO - TABLE HEIGHT : 34"

• A PPROX . SHIPPING WEIGHT : 353 LBS .

• S ANDING BELT MOTOR : 5 HP

• B ELT FEED MOTOR : 1 ⁄ 4 HP

• R EQUIRES SINGLE - PHASE , 220V

ELECTRICAL AND 50-70 PSI AIR .

• C ONVEYOR SPEED 13 & 16.4 FPM

• I NCLUDES EXTENDED SUPPORT

BAR FOR WIDE BOARDS .

• O VERALL DIMENSIONS : 61 3 ⁄ 4 "H

X 32 1 ⁄ 2 "D X 35"W

• A PPROX . SHIPPING

WEIGHT : 922 LBS .

G9983

ONLY $ 2795 00

G1035

ONLY $ 425 00

(S HOWN WITH OPTIONAL WING )

G1026

ONLY $ 825 00

6" X 47" JOINTER

WITH HANDWHEELS

8" X 65" SUPER

HEAVY-DUTY JOINTER

WITH HANDWHEELS

8" X 75" JOINTER

WITH 4 BLADE CUTTERHEAD

• 2 HP, 110V/220V, SINGLE - PHASE MOTOR

• 8" X 75" P RECISION GROUND CAST IRON TABLE

• M AXIMUM DEPTH OF CUT : 1 ⁄ 2 "

• 3" DIAMETER CUTTERHEAD RUNS IN

SHIELDED , PRE - LUBRICATED BALL BEARINGS

• 4-HSS CUTTERHEAD KNIVES ARE 8" X 1 ⁄ 8 " X 1"

• C UTTERHEAD RPM: 5,500

• C UTS PER MINUTE : 22,000

• M AGNETIC SWITCH WITH THERMAL OVERLOAD PROTECTOR

• A PPROXIMATE SHIPPING

WEIGHT : 461 LBS .

• 1 HP, 110/220V, SINGLE - PHASE MOTOR

• 6" X 47" P RECISION GROUND CAST IRON TABLE

• R ABBETING CAPACITY : 1 ⁄ 2 "

• M AX . DEPTH OF CUT : 1 ⁄ 2 "

• 3-K NIFE BALL BEARING CUTTERHEAD

• S UPER HEAVY - DUTY , CENTER MOUNTED FENCE IS 4" X 29 1 ⁄ 4 "

• I NFEED & OUTFEED TABLES HAVE HANDWHEELS FOR CONVENIENT

TABLE HEIGHT ADJUSTMENT

• P OWDER COATED PAINT

• S TEEL STAND HAS

BUILT - IN CHIP CHUTE

• A PPROX . SHIPPING

WEIGHT : 215 LBS .

• 1 1 ⁄ 2 HP, 220V, SINGLE - PHASE MOTOR

• S UPER HEAVY - DUTY PRECISION GROUND CAST IRON BED

• 3-K NIFE CUTTERHEAD IS 3" IN DIA . AND RUNS IN

SHIELDED , PRE - LUBRICATED BALL BEARINGS

• M AX . DEPTH OF CUT : 1 ⁄ 2 "

• I NFEED TABLE HAS RABBETING LEDGE

• H EAVY - DUTY CENTER - MOUNTED FENCE

• A PPROX . SHIPPING

WEIGHT : 450 LBS .

FREE PAIR

OF SAFETY PUSH

BLOCKS

G1182HW

ONLY $ 325 00

FREE PAIR

OF SAFETY

PUSH BLOCKS

G1018HW

ONLY $ 695 00

G0500

ONLY $ 795 00

R ECEIVE A FREE GIFT

WITH EVERY ONLINE ORDER!

( LIMITED TIME OFFER )

2003 GRIZZLY CATALOG!

500 FULL-COLOR PAGES OF

HIGH QUALITY WOODWORKING

& METALWORKING

TOOLS & ACCESSORIES!

CALL TODAY FOR YOUR

FREE COPY!

OVER 12,000 PRODUCTS ONLINE!

CIRCLE NO. 122 ON FREE INFORMATION CARD.

FREE

8" jointer delivers a 2 HP motor, a 4 blade cutterhead for super smooth

finishes, an extra long 75" bed, handwheel controlled table adjustments and

a 4" dust port. If you are a demanding woodworker then you must put this one

at the top of your list. We guarantee you won’t be disappointed!

4 BLADE CUTTERHEAD

FOR FINER FINISHES

PRECISION GROUND CAST IRON

BED & FENCE

75" BED – THE LONGEST

ON THE MARKET !

FREE

PAIR OF SAFETY

PUSH BLOCKS

RABBETING LEDGE

HANDWHEELS FOR

PRECISE CONTROL

MAGNETIC SWITCH

DUST HOOD INCLUDED

FEATURES:

• POWERFUL 2 HP 110/220V,

SINGLE-PHASE MOTOR

• 8" X 75" PRECISION GROUND

CAST IRON TABLE INCLUDES

5" EXTENSIONS (PRECISION

GROUND AND FITTED AT FACTORY)

• BEDS SLIDE ON DOVETAIL WAYS

• 4 BLADE CUTTERHEAD

• CUTTERHEAD DIAMETER: 3"

• MAX. WIDTH OF CUT: 8"

• MAX. DEPTH OF CUT: 1 ⁄ 2 "

• 22,000 CUTS PER MINUTE

• HEAVY-DUTY CENTER MOUNTED FENCE

• APPROX. SHIPPING WEIGHT: 461 LBS.

POWERFUL 2 HP MOTOR

WITH TWIN BELT DRIVE

POWDER COATED ,

ONE PIECE

CABINET STAND WITH

BUILT - IN DUST CHUTE

G7314

SHOP FOX ®

T HIS PATENTED BASE IS THE MOST STABLE

ON THE MARKET WITH OUTRIGGER - TYPE

SUPPORTS . A DJUSTS FROM 19" X 20 1 ⁄ 2 "

TO 29 1 ⁄ 2 " SQUARE . 600 LB . CAPACITY .

REG . $ 69 95 $

SPECIAL OPTION

HEAVY-DUTY

MOBILE BASE

MODEL G0500

INTRODUCTORY

PRICE

$ 795 00

49.95

WHEN PURCHASED WITH THIS JOINTER

selection of jointers! From a compact bench-top model to the

massive 20" model with spiral cutterhead, you would be hard pressed

to find a jointing application that a Grizzly jointer can’t perform.

Receive a FREE GIFT

with every online order!

(Limited time offer)

CUSTOMER SERVICE: (570) 546-9663 • FAX: 1-800-438-5901

493702658

3 SHOWROOM LOCATIONS: BELLINGHAM, WA • SPRINGFIELD, MO • MUNCY, PA

• 24 Hour ordering by phone or online

• Our huge parts department is stocked

with over a million parts at all times.

MEDIA CODE

AD1710

CIRCLE NO. 123 ON FREE INFORMATION CARD.

W e have really outdone ourselves this time! For under $ 800 dollars, this

$ 795 00

W ith 18 different models, no one comes close to Grizzly in size and

• 2 Overseas quality control offices staffed

with qualified Grizzly engineers.

• Most orders shipped within 24 hours.

3 SHOWROOM LOCATIONS: BELLINGHAM, WA • SPRINGFIELD, MO • MUNCY, PA

contents

IN EVERY ISSUE

18 Perfect Runners for Miter Slots

TRICKS OF THE TRADE

Add accuracy to jigs that run in miter slots with these

adjustable runners. Plus, a better way to crosscut small

pieces safely, and make a marking knife from a spade bit.

26 Two Unsung Heroes

ENDURANCE TEST

Without good glue and decent clamps, woodworking

would be a lot more difﬁcult. Titebond II and Bessey

Tradesmens have never failed to keep things together.

28 Fein Turbo III Vacuum

TOOL TEST

Finally, a shop vacuum to get passionate about. Also

reviewed: the Akeda dovetail jig, Veritas’s apron plane,

Makita’s newest jigsaw and Shapton sharpening stones.

32 Legendary Rocker

GREAT WOODSHOPS

Get an inside look and personal tour of Sam Maloof’s

new shop, which was moved to make room for a highway.

Now 87, Maloof still works in the shop every day.

36 Drill Press Mortising Chisel

INGENIOUS JIGS

There’s a better way to square the holes left by chain-

drilling your mortises. Your unplugged drill press and a

modiﬁed mortising chisel makes neat, square holes.

By Nick Engler

38 Four Good Ways to Cut Rabbets

POWER-TOOL JOINERY

Cutting accurate rabbets is one of the fundamental skills

every woodworker needs. Learn four good ways to make

this joint safely, easily and – signiﬁcantly – accurately.

By Bill Hylton

Popular Woodworking (ISSN 0884-8823, USPS 752-250) is

published seven times a year in February, April, June,

August, October, November and December by F&W

Publications Inc. Editorial and advertising ofﬁces are locat-

ed at 4700 E. Galbraith Road., Cincinnati, OH 45236; tel.:

513-531-2222. Unsolicited manuscripts, photographs and

artwork should include ample postage on a self-addressed,

stamped envelope (SASE); otherwise they will not be

returned. Subscription rates: A year’s subscription (7 issues)

is $28; outside of U.S add $7/year ■ Canada Publications

Mail Agreement No. 40025316. Canadian return address:

Popular Woodworking . Periodicals postage paid at

Cincinnati, Ohio, and additional mailing ofﬁces. Postmaster:

Send all address changes to Popular Woodworking, P.O.

Box 5369, Harlan, IA 51593 Canada GST Reg. # R122594716

■ Produced and printed in the U.S.A.

42 Why Use Hand Tools?

FROM THE BENCH

Our newest columnist has spent his career using hand

tools to outﬁt expensive homes. Find out why adding a

few hand tools to your arsenal makes good sense.

By Don McConnell

Depth =

1 / 2 to 2 / 3

of width

Width

popwood.com 3

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