Money
Maker
Article
JAN/FEB
2003
Volume 46/Issue 1
IN
THIS ISSUE
Project
Articles
•
Classic Rolltop Desk
• 16-Drawer Apothecary Chest
• First Class Letter Box
DEPARTMENTS
•
Ask Smitty
• Owner’s Gallery
• Letters from Owners
Academy Notes
Should
you have a Thickness Planer in your shop?
Service Pointers
MARK
V Service Pointers
Safety Tips
Hearing
Protection
What's
New
When
accuracy counts Incra Rules
EDUCATION
• Find
A Shopsmith Woodworking Academy Near You
• National
Woodworking Academy in Dayton, OH
ONLINE
CATALOGS
• Online Accessory Catalog
• Request
Printed Accessory Catalog
• Online
Replacement Parts Catalog
MARK
V INFORMATION
• Find
A Shopsmith
MARK V Demo Near You
• Request
MARK V Information Package
LINKS
•
Links Worth Visiting
•
Free Woodworking
Tips
FEEDBACK
Contacting
Shopsmith
Copyright
2003.
Shopsmith, Inc.
All Rights Reserved
The First Class Letter Box
4: Use regular masking tape or High Adhesion, Double-Stick Tape to fasten a number of pieces together in preparation for “pad sawing”, where you cut a stack of several pieces at once to save time. If you're cutting outside shapes, you can use your Bandsaw and make your stack up to 5-1/2" thick. If you're cutting internal shapes (such as the heart cut-out in our example), use your Scroll Saw and keep your stacks under 2" thick. Pad sawing is just one more technique that will save you loads of time. Again, see the “Making Multiples” article for a full explanation of this technique.
5: Split your pad sawn pieces into 3" high stacks, in preparation for drilling and sanding. This is necessary because your Drum Sander and 1/4" Brad Point Drill Bit won't handle stacks of pieces that are higher than about 3".
6: Drill 1/4" holes in the sides (B) using a Brad Point Bit and a stop attached to your rip fence. You can use a small handscrew clamp , a block of wood attached to your Rip Fence, or a Flip-Up Rip Fence Stop to help you get all of your holes positioned identically in your pieces. Again, the “Making Multiples” article offers some alternative choices.
7: Sand the pieces using your Disc Sander (for straight edges) or your Drum Sander (for curved edges).
8: Separate your stacks of pieces and assemble with wood glue and small brads. Insert the 1/4" dowel into the sides (B) before attaching them to the back (A). Finish sand the project by hand, then apply the stain and sealer of your choice.
Suggested retail price: $15 to $20
Printer
Friendly PDF copy of Instructions
List of Materials
Assembly, Back
Pattern, Bottom Pattern, Side
and Front Pattern
View
Plans &
Assembly Drawings
Assembly
Back Pattern
Bottom Pattern
Side & Front Pattern
List of Materials
Printer Friendly PDF copy of Instructions
