Major
Project
Article

NOV/DEC 2004
Volume 47/Issue 6

IN THIS ISSUE
Project Articles
• Poor Man's Hall Butler
• Holiday Hurricane Lamp
• Old-Fashioned Toy Cars

DEPARTMENTS
• Ask Smitty
• Owner’s Gallery
• Letters from Owners
• New Baby Workshop Calendar
 
Academy Notes
Hardwood Information You Should Know - Pt 3
 
Service Pointers
MARK V Rip Fence

Woodworking Technologies
Stepped Dowels
 
Safety
Safety Lessons I've Learned

What's New
Rip Scale Upgrade Kit

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 2004.
Shopsmith, Inc.
All Rights Reserved

The Poor Man's Hall Butler

2. Use a hand-held sabre saw to cut the mirror opening in the Back Panel (G). We chose to cut a simple oval, 22-1/2" wide by 34-1/2" tall. However, you can make the opening any size or shape you like.

Drawing the oval
Turn your Back Panel (G) over and draw your oval layout on the back side. Begin by drawing perpendicular horizontal and vertical centerlines for your oval as shown in Fig. 1. These lines will be your minor (A/B) and major (C/D) axes.

Set a large compass to the distance CX (in our case, this should be half the width of our mirror opening or 11-1/4"). Position the compass point at location A and strike an arc across the major axis line at points #1 and #2.

Take a long piece of string or heavy thread and tie it into a continuous loop that will be equal to the distance between points “C” and “2”, when the loop is pulled taut (In other words, if your push pins were inside your tied loop at points “C” and “2”, the loop would be taut.)

Drive your two push pins lightly into the back side of the Back Panel at points #1 and #2 on your layout. Slip your tied loop over the outside of you push pins. Position the point of a pencil or marker inside your string loop at location “A” and begin moving you pencil or marker point around the layout in a clockwise manner...dragging the string loop with you as you finish drawing your oval.

3. Use your Bandsaw to cut the Lid out of the Seat (K).

4. The joinery for this project is a “snap” - most of it consisting of simple butt joints and rabbets, all reinforced with wood glue and countersunk wood screws. The one difficult joint - a stop rabbet in the Front Stiles (B) - is made by carefully lowering your stock onto the Dado Blade and cutting the rabbet to a pre-determined mark on your saw's worktable surface. CAUTION: Always use Push Blocks when performing this operation to keep your hands out of harm's way. Make several passes, taking a little more stock off with each pass. Square the ends of your stop rabbets with a bench chisel.

5. Use a 1" Forstner Bit or Brad Point Bit to drill the holes for the turned Pegs (Q, R) in the Back Stiles (A). Assemble the Back Stiles (A) to the Back Panel (G), build the Storage Box and attach the Seat/Lid (K) to the assembled Storage Box.

6. Screw the Front Stiles (B) to the assembled Storage Box, then dowel the Arms (C) to both sets of Stiles (A,B). Add the Shelf (M), Trim pieces (P, T) and Rails (E, F).

7. Cover the inside edge of your Mirror opening with matching veneer tape (available at your local Home Center). Turn the Pegs (Q, R) and glue them into the Back Stiles (A).

8. If you choose to build this project from standard fir plywood, be sure to apply a light coat of “plywood sealer” to help even-out your stain finish. Be sure to finish with something that won't be affected by wet raincoats. We recommend polyurethanes or spar varnishes.

9. Attach your mirror to the Back (G) using screws and nylon washers.

10. Collect all your coats, jackets and other clothing off the furniture and cover your new “Poor Man's Butler” with them.

List of Materials..