17. the art of woodworking - shaker furniture

7/27/2019 17. the Art of Woodworking - Shaker Furniture

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PIE SAFE

J Gluingownhe ockbeading


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PI E SAFE

O Installinghe opL Set he op panel ace own n hes h o p loor nd os i t ionhe a fe ps idedown n op of t . Align he back f hecabine t i th he back dge f he op andcenter he safe etween he panel dges.Start ing ear he corners ,i t he abbetedends f he wood uttons nto he groovesin h e op ails ; pace he buttons bout6 inches pa r t nd eave %- inch apbetween he bot tom f he grooves ndt he ipped nds f he bu t tons o a l lowfor woodmovement. rive crews o as -ten he buttons n place right).

INSTALLINGROWN OLDING

1 CuttinghemoldingI Fi ta moldins ead i th evel uttand mount he head n your able awInstall ndnotch n auxiliary ood en

(page 00), nd positronhe ence orthe des i red rofile . ecurehe tockwilluse o make he molding ith wofeatherboards,lamping ne o he enabove he blade, nd second o he atab le . l amp s u p p o r t oa rd t a 90angle o he second eatherboard. aithe cut te rs nch bove he able; ono tmake u l l -dep th u t n one a sPress he tock ga ins t he ence s yoslowlyeed t into he cut te rs ; nish hcut with push t ick . eversehe boaand epeat he cut on he other dge leMake smany asses snecessary,aing he cut te rs nch t a ime, nti lhave eachedhe desired eoth f cutInstall r ip blade n he saw nd ut hmoldingrom oth ides f he workpias epresented y he dotted ines n hi l lus t ra t ion .

02


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PI E SAFE

r) Install ingtheidemoldingI FasIen ne ide molding rs t , henthe ront iece, nd nally he emain-ing ide iece. ut he molding iecesto ength, i teringheir nds. preadsome lue n h e ontactingurfacesbetweenhe irs t ide iece nd he oprail f he ide nd et he oiece nposit ion. oalloworwoodmovement,do notapply ny lue etweenhemolding nd he op of he safe. lampthe ront iece o he ront ail-withoutglue-to help ou lignhe side ieceproperly.nstallwobar lamps longthe op o secure he side iece nplace, ighteninghe lamps raduallyuntil hin bead f glue queezes utfrom he oint; sewood ads o protectboth he molding nd he op above).

Q Installinghe rontmoldingr.J 0nce he srdemolding as eensecured,emovehe lamps oldinghefront iece n place nd pply lue o tand o he ront ail f he pie afe. lsospread ome dhesive n he miteredends f he molding. se andscrewsoclamp he ront moldingo he abinet,spacinghe lamps bout inches part(left). inally,nstall he emaining id epiece s ou id he rs t ne.

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PI E SAFE

r) Installinghe orner trips

L and helf upportsSpread ome lue n he con tac t ingsurfaces etweenhe corner trips ndthe t i l e s f he p ie a fe , nd os i t ioneach trip, making ure hat he dadoesface he nterior f he abinet. oclampthe trips n place. se hin wood crapsslightlyongerhan he gap etweenhestrips above). or he shelf upports(representedydotted ines n he llus-tration), easurehe distance etweenthe ront nd ack t i les f he safe nd

c r r t he n ieces o i t Ensure ha t hesuppor t s rewide nough o ho ld heshelves ecurely.

Q Preparinghe helves\ , All our orners feach helfmust eno tchedo i t a round he o rne r t r ips .Measure ndmark ach he l f c lamp tface own o a work urface, nd ut outthe corners it ha backsaw lefD.


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TIN-PANELDOORS

-f h. doors of the pie safe re oinedI with the open version f the mor-

tise-and-tenon loint used o assemblethe cabinet. he reinforcing egs willprevent he oints from racking, evenunder he heaviest se.As shown below,you can make he oint on your able awwith a shop-made ig. Once he doors reassembled, hey are abbeted o acceptthe tin panels page 0B). As shown onpage I 1, a variety of special unchesare available or piercing he panelsthemselves. nce he panels re nstalled,the doors can be mounted o the safewith simple butt hinges page 114).

The doors f the pie safe re assembledwith mortise-and-tenons, einforced ywoodpegs. The in panels it n rabbetsalong he nside edges f the doors ndare held n place by strips of molding.

MAKINGHED(IORS

1 Cuttinghe enon heeksn he ailsI Cut penmortise-and-tenonsnyour able aw sing he shop-madeigshowthe nset. efero he dimensions uggested, aking ur e he hickness f he spaand width f he brace nable he ig o slide long he ip ence i thout obbCut he body ndbrace rom /uinchplywood nd he guide nd pacer romwood. aw noval ole ora handle n he ig body nd ttach he guide o he bodfront f he handle. c rew wood locko he body elow he handle nd t tactoggle lamp o he block. inally,asten he pacer ndbrace n place. o ut he echeeks n he door a i ls , u t t he workpiecegainsthe guide nd lamp t n plSet he cutting eight o h e enon ength, ositionhe ence o align ne f he ctingmarks n he ail wi th he blade nd l ide he igalong he ence o make hebbove). ur n he ail around o cut he other heek, hen epeat he cuts t he otend f he ail nd t both nds f he emaining ails ,

106


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PI E SAFE

r) Cuttinghe enon houldersZ- Screw board o the miter gauge san ex tens ion . hen , o ld ing ne f he doorr a i l s ga ins t he ex tens ion , d lus t he b ladehe igh t o the dep th f t he enon hou lder.A l i g n h e s h o u l d e r i t h h e b l a d e , u t t ano tched top b lock ga ins t he s tock , ndc lamp he b lock o he ex tens ion ;he no tchin the stop blockwillprevent awdust ro maccumulating etween t and he workpiece.Hold inghe a i l u sh ga ins t he ex tens ionand he stoo block. eed he stock with hem i t e r a r r p en c r r i h e r s t h o u l d e r. os a w h e o p p o s i t e h o u l d e r,u r n h e a i lover right). epeat o cut he enon houl-der s t he other nd of he a i l and n heremain ing a i l s . Cau t ion : l ade uardremoved or clarity.)

-) Cuttinshemortisesn he tiles


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PIE SAFE

Gluing p hedoor ramesD r y - ft h e r a i l s nd s t i l e s f t h e d o o r s n d

u s e c h i s e l . f n e c e s s a r y ,o i n e - t u n e n y l l -f i t t i n g o i n t s . p r e a d l u e n h e c o n t a c t i n g

s u r f a c e s f t h e m o r t i s e s n d e n o n s , h e n u s eb a r l a m p s o s e c u r e h e o i n t s , l i g n i n gh ebars with he ra i ls . Use wood ads o protec t hes t o c k n d i g h t e n h e c l a m p s n t i l a l i t t l e l u esqueezes ut of the lotnIs bbove).

f , Prepar inghe door rames or panelsr- ,1 0nce he adhesive as ured . emovehe clamps

and ecure he ames nside-face p on a work ur-f a c e . o c u t h e a b b e t s n h e r a m e s o r h e i np a n e l s , n s t a l l p i l o t e d ' / a - i n c ha b b e t i n g i t n ar o u t e r. l t h o u g ho u r i n a l e p t h i l l e q u a l h e o m -b i n e d h i c k n e s s f h e p a n e l s n d h e m o l d i n g o uw r l l e n s t a l l i n g y p i c a l l y/ e n c h a d j u s t h e b i tto cu t he abbets n wo or more asses . out her a b b e t s o v i n g l o c n w i s er o u n dh e n s i d e d g e so f h e p a n e l p e n i n g s , e e p i n gh e b i t ' s i l o t e a r -ingpressed gains t he s tock hroughout ach u t( r ight) . nce ou each our ina l epth , quare hecorners f he abbets i th a ch ise l .


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PI E SAFE

4i Preparing he door rames or he alse mullion\, 1 To enable he pie safe doors o close properly, ut a rabbeta long he ns ide ace of bo th door s t he i r on tac t ing dges ;wood t r ip , nown s a fa l semul l ion, i l l be g lued n to the abbe tof the ef t -hand oor o he doors wi l l rest lush when losed(page 10.fhe t/e-inch ap between he right-hand oor nd heedge f he mullion i l l prevent he doors ro m binding hen heyare losed, s shown n he end-on iew n he nset. or he rab-

bets, nstall dado ead nyour able aw nd adjust ts widthto 1/znch nd tsheightto /ronch. t tach nauxiliaryfencetoyour able aw ip ence, ositionhe ence or he cutting idth,an d notch he woodenence ith he blades. osupporthe doorframes. lamo eatherboardo he ence bove he dado ead.Feed ach rame nside-face ow nwith both hands above),keepingt laton he able ndpressedlush gainst he ence.

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PI E SAFE

J Peggingthe ortise-and-tenons/ Mark eg oles t all our orners f each oor rame, en -tering hem n he ront ace f he ails r/z nches rom he sideedge f he door. nstall 5 / ro- inchrad-pointi t nyour ri l lpress , lace backup anel n h e machineable o minimizetearout, nd etone f he door rames n op, entering drillingmark nder he bit .Adjusthedril l ing epth o about wo-thi rdsthe hickness f he rame. utt board gainst he rame nd

MAKINGHE INPANETS

1 Securinghepatterno he panelI Tinpanels nd he ools sed o punchholes n hem re vailablerom olk-artsupply ouses . he est ay o punch heholes n he panels o hey re ll he ameis o use pattern sa template. everalcommon atterns re llustrated n page111; use photocopier i th nenlarge-ment eature o oroduce vers ion f he

des i red atternhat s he same ize syour anels . hen etone f he panelsins ide-facepon a backup oard , enterth e pattern n he panel, nd ix he paperto he in withmaskingape. osecure hepanel o he backup oard , se ush ins ,tapping hem nto he board very ewinches roundhe perimeterf he panel.

clamp t n place sanedge uide. hen, olding he rame gthe guide, rill he hole above,eft).Bore he emaining oin both rames he same ay. Cuta peg oreach ole rom piofsolid tock, aking t s l ight ly horterhan he depth f hholes, he pegs hould ecut square, apered t he bottomand witha slight ha mfer t he op. Ta p ach eg nto ts hwitha hammer above,ight),lellingt protrude bout /r on

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PI E SAFE

TRADITIONATINPANEL ATTERNS COMMONINPUNCH OOLSANDTHECUTS HEYMAKE

Basbpunchldeal or makin4 qeomet-ric patterna becauae Lproducea olea f uniformerze; hts punch eaveea amooth edqe on botheidee of the panel

Lamp maker'a chiselFroducea emooth, elon-4aLed hole; raditionallyuaed n lanLern maktnq

Curved chiaelMakea creacent moon e h a pedcute; tradittonally ueed whenti4htinqwao pootttoned ehtnd

the panele

Star punchTraditionally ne of the moatcommonly oed ohapeo

Diamond punchldeal for Lhe edqee of patterne;a traditional choice when Iiqh'L-tn4 wao uaed behind Lhe panele

Pineapple punchFroducee he burra onpineapple aLterno

l l l

Courteey f Country Accents. MonLoureville.A


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PIE SAFE

r' ) Punchinghe holesL t J s ea h a mme r n d h e a p p r o p r i a t epunch r chise l or he ype of hole ouwish o produce. o ld inghe punch er t i -ca l ly n one of the pat tern oles , t r ikethe tool with he hammer righil.A mini-mum amount f force s needed o punc-ture he panel ; he harder oustr ike hep u n c h , h e a rg e r he h o l ewi l lbe . Pu n c hal l he holes he same way, hanging o adifferent unch rchise l s necessary. fyouare using meta l ther han in fort h e p a n e l s , u c h s mi l d t e e l , o uwi l lneed o f i le he sharp dges f the holeso n h e o u t s i d e a c e f h e p a n e l s . i t ht in , i l ing s not necessary.

Insta l l inghe in panels ndmoldingMake o u r t r i p s f m o l d i n go reach ane l sy ouwo u l d

for the glass doors of a wall clock page 125). hen set hedoor rames u ts ide-face ownon a work urface nd placepanel nd molding n posi t ion . he sharp dges f he punchedh o l e s h o u l d e a c i n g o wn .Bo r e i l o th o l e s o r i n i s h i n g

n a i l sh roughh e mold ing nd nto he rame v e r y i nthen r ive he n a i l s s i n g b r a d r i v e r. o u se h e d r ii n se r t n a i l n t o p i l o t o l e , hen o s i t i o nhe a ws nt igh tenh e o c k i n g u t .Ho l d i n ghe ame t eady, quth e aw s o set he nail above).

, o b ; 0 0 0 - 0 6 " 0 0 " ? ' - r . .

"" '""""'""^""-.3: * - ' " " :


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PIE SAFE

INSTATTINGHEDO()RS

ili, llj ltl ililll lli lll liljlt lj ljJlit ll rilltll ilijjj lll1 Installinghe hinges n he doorsI Secure ne of the doors inge-edgeu p n a b e n c h i s e . O u t l i n e n e h i n g eleaf bout inches rom he op of thedoor nd another inches rom he bo t -to m.T h e n . o ld rn g c h r s e l e r t i c a l l y.score he out l ine ndcut t s l ightly eep-e r han he h ickness f he h inge ea f .H o l d h e c h i s e l e v e l p o p a re h ewaste rom he mortise above). ncey o u h a v e le a r e d u t h e r e ma in in gmortises n bothdoors , e t he h ingesin h e i rmo r t i s e s , r i l lp i l o t o l e s , n dscrew hem n place .

1HO?Tt?Making butterfly hingeeWiLh heirwing-shapedle ves, utLerflyhinqee

were ommonly eed n3h aker urniture. od y,they ar e exVeneive nAditri ult Lo find. l, ow v r,t ranof rming eNandardbutlhinqe nho buLterflyhinqe o a oimplemalter,Grind he opo an d bolloms of butt hinqe eaveoonyourbench rinder nLi lyouuI away noughmela l lo Vroducehe characterieNichape.

6

I I J


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PIE SAFE

O Installinghe hinges n he safeZ- Po s i t i o n n e o f t h e d o o r s n t h ecabinet , l ipping woor hree heets fpaper nder he door s spacers , se abar lamp o hold he door n place , henmark he ops nd bot toms f he hingel e a v e s n h e n s i d e d ge f h e r o n tf rame t i les above) . emove he door,s l ip he pins ut of he hinges , ndout-l i n c th p f r p p h i n s p l p : v p c n n t h p s : f p

using he marks oumade o determinethe height f he out l ines . ake ure hehinge inswil lprotrudear enough romthe safe o as not o b ind agains t hec o c k b e a d i n g h e n h e d o o r s o p e n e dand losed. hise l u t he hingemort iseso n h e c a b i n e t t i l e s s y oud i d o n h edoors page 13) and screw he hingeleaves n place . epeat he process i ththe other oor.

Hanginghe doolOnce l l thehinge eaves re nsta l led ,t is ime o hang he door. i f t one of h

doors nt oposition o h e hinge eaves n he door nd he safe ngage above). lieach inge in n place o oin he eaves . ang he other oor he same ay.

TI4


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PI E SAFE

R Instal l inghe door ullsr . / Make pul l o r each dooron yourl a t h e , u rn in g r o u n d e n o n t o n e n d ,o r buy he pul l s eady-made . a rk po in tin he middle f he con tac t ing oor t i lesabout wo-thrrds f he wayup he doorsa n d d r i l l h o l e h e s a me ia me te r s h etenons t each mark .Spread ome lueo n h e e n o n s n d n s e r t a c h r r l l n totls hole (right).

, { Instal l inShe a lse mull ionT C u t h e mu l l i o nro m - in c h - th i c ks t o c k ,ma k in g t a s o n g s h e d o o r s .S ize he wid th f he mullion qua l o hegap between he shoulders f the rabbetsyou cut in the doors page 09), ess' /"i n c h . h e g a p b e t w e e n h e ig h t -h a n ddoor nd he edge f he mull ion i l lp re -ven t he doors rom bind ing hen heyare losed . p read ome dhes ive n herabbe t n he ef t -hand oor nd on hecontac t ing urfaces f he mull ion, ndse t he s t r ip f wood n p lace . lamp hemu l l i o n g a i n s t o t h h e e k n d h o u l d e rof he rabbe t hile he g lue ures /eft) .

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i S i l

ff i he same rinciplesha t$ guided he Shakers n

their daily l ives-pur i ty,wholesomeness, nd useful-ness-are eflectedn every-thing hey built.Each f thesrnall Shaker rojects ea-tured n thischapter-a wallclock,a step stool, an ovalbox, and a pegboard-is ac lassicxample f his ingle-minded philosophy.

To he Shakers, o house-hold it em, no ma tter howsmall, ould be consideredfrivolousor simple adorn-menl The erm "knickknack"

had no placen heir exicon.Whatever hey made ad obe strong, urable, nd with-ou [ ault. t also ad o beper-fectly uited o the purposefor which t was designed.

Wall clocks, ike he oneshown n page I B, and all, reestanding randfather lockswere ssential o the Shakers'disciplinedives, ut he Shakersdesigned ther ypes or special eeds. he homely wag-on-

the-wall" lockha d no case, ut only a small rame o pro-tect he mechanism, nd simply ung rom a peg. hey alsomade asic locks or theirbarns hat had onlyan hour hand.Even ess rnate was he "tower clock"at Sabbathday ake,Maine. his imeuiece ad no face r hands t all. ts main

feature was an 80-poundbrass ngine ell hat sound-ed oudlyon he hour.

Oval boxes, ike thoseshown at eft,were used ostore variety fdry goods.With their distinctive wal-lowtail ingers, traight ides,an d smooth inish, he box-es were elevated y Shakercraftsmanship rom merevesselsnt o things f beau-ty .That he Shakers adethese oxes y he housandswhileholding o a high stan-dard of excellences emark-able-and typica lof theircreed nd craftsrnanship.

The al lcabinets uilt bythe Shakers reated he needto access ighshelves. hestep stool shown on pageI29 nswered h i s equ i l e -nent , becoming mobile

but sturdy taircase. lthough ts reads ere ftendovetailedinto he sides, trength, ather han appearance,ustified heattractive oinerv.

The pegboard page 35)s an example fhow the Shakersstretchedhe usefulness f a hurnble te m untilit became nindispensable art of their ives.Pegs ined he wallsof mostShaker omes, anging ve rything rom bookshelves ndkitchenmolements o clocks nd chairs.

SreRCLASSICS

Made fi"ontquartersawn herry verteer, he band for thebox shown above s bett oroLffid drying fonrr after first

ltehry onked n hot water nnd softerrcd. he band sseuu'ed n its bent shnpe y copper acks.

The rttils, stiles, nd divider of the f'urrc for a Shnker wnllclocknre beingglued tp, seared by bnr chmtps The railsand stiles howtt at left orc oitretl with rabbets, whilethe divider sirrryly rts tto dndoes ff across lrc stiles.


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WALLCLOCK

T h. Shakers ed very disciplined,I structuredives. hey ose t4:00

a.m. n the summer, llowinghemselvesto sleep n an hour ater n winter. heystopped orking at7:30 .m.on sum-mer evenings ndat 8:00 .m. n thewinter, ne-half our before veningworship. hey lso te heir meals tpre-cise imes. Shaker lder rom Ohioonce aid, The clock s an emblem fthe Shaker ommunity ecause very-thinggoes n ime.Promptness, bsolutepunctuality,s a sine ua nonof a suc-cessful ommunity."

In theearly,lean ears f heirmove-ment,Shaker ommunities onsidered

themselvesortunate o own onework-ing "alarum"clock.As he sect ros-pered, ndas clockmakersoined hemovement,he availabilityfthe ime-pieces pread. heShakers ever arriedpocketwatches, owever. hese ereconsidered nnecessaryndulgences.

The mechanisms f originalShakercloclsweremade rombrass r wood. Ales mstlyandmore eliable odem lter-natives o buya quartz lockmovement.These an e ordered omplete ithmet-aldialandwithorwithouta pendulumfrommany obby upply tores. he ol-lowingpages how ow o assemblecase or a Shaker-style allclock.

Isaac Newton Youngs as oneof the ew Shaker lock makersto design nd construct ases ohouse is timepieces. he clockshown belowwas nspired byone hat he buib n the springof 1840 t the NewLebanoncommunity n New York State.

ANATOMYFA WALL TOCK Top rim4" x 1O3A"Caee top

panel5" x 9%"

Top-dooretile'lt/o"x 10"

Top-doorrail (2) -1%" 10" Baakboard

9%"x 32t"la"

Divider1'/o" 10"

Eottom-door

Caae aidepanel3" x 3O"ail (2)

2" x 10"

Eottom-door atile2"x '19%"

Bottom,iTtr;?;f

Thewall locks assembled ith he same reci-sion ha tShakers roughto heir aily outines.The our panels f he case re lued ogetherwith abbets, nd he ails nd tiles f he doorsar e oined ithopenmortise-and-tenonoints.The backboardits ntoa rabbet utalong heback f he case anels, nd s na i led n place .The ri mpieces re imply lued o he op andbottom anels f he case. hedividers gluedinto topped adoesn he sidepanels f he case.Us e%e-inch-thicktockorall but he doors nddivider, hich re made rom%-inch-thickood.


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SHAKERCLASSICS

BUILDINGHE ASE

1 Rabbetinghe side panelsI P repare he case ieces orassembly

by abbe t inghe ends f he s ide pane lson your ab le aw. ns ta l l dado head nth e s a w n d a d j u s t t s w id th o %u n c h .S e t h e c r r t t i n p e ip h t t I i n c h .S c r e wa w o o d e n u x i l i a ry e n c e o th e i p e n c eand notch t w i th he dado head . o he lpyou eed he long tock across he sawt a b l e n d o min imiz e e a ro u t , c r e wboard s an ex tens ion o the miter auge .Then , u t t ing ne s ide pane l ga ins thef e n c e n d h e e x t e n s i o n ,e e d t a lo n gwith he miter auge o cu t he rst ab-

beI (right).Repeat t the other end of theb o a rd n d a t b o th e n d s o f t h e s e c o n ds ide pane l . o prepare he s ide pane ls ort h e b a c k b o a r d , u t a r a b b e t l o n g h eback dse f each oard

r) Preparinghe side panelsL tor he divider0u t l ine he dado n he ron t dge f eachs i d e a n e l h a t w i l l a c c e p th e d i v i d e r .T h e e n g th f t h e d a d o h o u l d e a b o u tone-ha l fhe width f he d iv ider.nstal ls traight i t he same iamete r s he dadowrdth n a router, ut tone s ide pane l n awork urface gainst backup oard, nda l ign he b i t over he ou t l ine . u tta boardas an edge u ide ga ins the ou te r asep la te ndc lamp he se tup n p lace .Withthe base late lushagainst he edge uide,p lunge he b r t n to he backup oard ndg u i d e t i n to h e s id e a n e l , t o p p i n gh ecu t a t your nd ine /eft) . ou t he dadoin h e s e c o n d i d e p a n e l , h e n s q u a r ebo th adoes i th a ch ise l .

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SHAKERCLASSICS

Q Preparinghe divideror nstallationr - , 1 Le a v i n gh e a u x i l i a r y e n c e n dmiter auge xtension n your able aw,n o t c h h e e n d s f h e d i v i d e ro f i t i n t ot h e d a d o e s o uc u t n h e s i d e a n e l s .Po s i t i o nh e e n c e o c u t a %u - i n c h - wi d en o t c h n d s e t he c u t t i n g e i g h t f h ed a d o e a d o % n c h .Ho l d i n gh e d i v i d e ro n e d g e n d l u s h g a i n s th e e n c e n dextension,eed he miter auge nto heblades . urn he board round nd notchthe other end (right).

Roundingverhe dividerRound v er he ron t dee f he

divider n a router able . ns ta l l p i lo t%-inch ound-over i t n a router, ount h e o o l n a t a b l e , n d a l i g n h e e n cwith he bi t ' sp i lo tbear ing. osupportd iv ider, se hree ea therboards ,

lamping wo o the ence , neon each ide ot h e b i t , a n d o n e o t h e a b l e . Br a c e hsecond eatherboard it ha support oarsecured o the able . Note : he ea therboard n he outfeed ide of the fenchas been emoved or clar i ty. ) ow usepush t ick o feed he divider cross hetable (left). Make wo passes o roundover ach ace of the s tock, ta r t inga s h a l l o w u t a n d a i s i n gh e b i t s l i g hf n r i h p c p e n n d n : c c

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SHAKER LASSICS

f, Cuttinghe backboardr- , / Use a p iece f solrdwood or hebackboard-a haker u i lder ou ld yp i -c a l l v a v e r s e d i n e To ma rk u t h e

a r c h t t h e o p o f t h e b a c k b o a r d ,i r s tma rk c e n t e r l i n e e a r h e o p e n d o f h es tock nd use compass o ou t l ine cir-c l ew i tha r a d iu s f 2 l i n c h e s n h e mid -dle of he s tock , en te red 1 , nches romt h e o p e n d . N e x t ,ma rk s t r a ig h t in eacross he s tock ' inches rom he ope n d . D ra w w o p e r p e n d i c u l a ri n e s ss h o w n o a c c o m m o d a t eh e n o t c h e s nt h p n n n a n p l q p n r r b a n d a w o c u to u t h e a r c h .S e t h e s t o c k n h e s a wta b le n d e e d h e p i e c e i thb o t h a n d s ,making he straight uts rs t and hensawing he semicircle /eft) .

f ,Dril l inghe pegholen he backboard

L , l To ensure he c lockwillhang eve l ,-he nes ho lemrrst e cen te red e tweent h e e d p e s f h e b a c k b o a r d . a r kd r i l l i n g o in t ny o u r e n te r l i n e Z n c h e sf ro m h e o p o f h e a rc h , h e n b o re h eh o l e n y o u r r i l l r e s s . n s t a l i / - i n c hb ra d -p o in tr t n h e m a c h i n e n d l a m pa b a c ' < u p a n e l o l ' e a b l e o h e lp i n i -mize ea rou t . os i t ionourmark irect lyu n d e r h e b i t , l a m p h e b a c k b o a r dnplace, nd drrll he hole rrght).


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SHAKERCLASSICS

J Preparingthe op panel and opI t t impiece or he backboardYo uwi l ln e e d o c u t a n o t c h n he bedge f the op panel nd op r im pof the c lock ase o accommodate hbackboard .u t l ine he notch n he miof the edge f each piece. eave he dahead nd miter auge xtension n ytable aw, u t move he ence u t ofwa y. o c u t h e n o t c h e s , l i g n h e dh e a d i t h o n e n d o f h e o u t l i n e , at h e b l a d e s o t h e h i c k n e s s f t h e b ab o a r d , n d u s e h e mi t e r a u g e o fthe panel nt o he cut. Then, lide he wpiece long he extension y he widtthe kerfand make another ass /effl,ct inuing nt i l ou each he other nd ofout l ine . se he same e tup o prepartop r impiece or he backboard .

Assemblinghe aseS m n n t h h c c a s p n i e r ^ e 5 p l l l g

backboard , s ing rogress ivelyiner and-paper, in ishing i th 220-gr i t . ssemblethe case n wosteps , ta r t ing i th hefourpanels nd he divider. pread lue nal l he contact ing urfaces f the piecesand clamp he oints ecure ly, s shownin the color hoto n page 16. Checkthe corners or square y measur ing hedis tance e tween iagonal lypposi te or-ners f the case . he wo measurementss h o u l d e h e s a me ; f n o t ,a d j u s t h eclamping ressure nt i l hey re . nce heglue has ured, emove he clamps, e tthe assembly ac e down n a work urface,a n d i t t h e b a c k b o a r d n p o s i t i o n .t i ss e c u r e d i t h n a i l s ; o n o t us e a n yg l u e ,s ince he boardmust be ree o move sthe wood wel ls ndcontrac ts i thhumid-i tychanges . ore i lo tholes or n ishingnai ls hrough he backboard nd nto herabbets long he back edges f the casen a n e l s Sn a c e h e h n l e s b o u t i n c h e sapar t , hen dr ive he nai ls n place r ight) .

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S H A K E R L A S S I CS

MAKINGHE OORS

1 Cut t inghe enons n he ailsI U s e o u r a b l e a w o c u t h e o p e n

mo r t i s e - a n d - t e n o n sh a t o in h e r a i l sand s t i les f he doors . aw he p ieces os i z e , h e n n s t a l l c o mme rc i a l e n o n i n gl rg o n h e s a w a b l e ; h e mo d e l h o w ns l i d e s n h e mi t e r lo t .C l a m o n eo f h era i l send-up o the ig , us ing wood adn n r n t p n t t h o c t n r k l \ / l : k p t h c r r r t t i n o

he igh t qua l o the s tockwid thand pos i -t i o n h e i p s o h e o u t s i d e a c e s f h eb l a d e n d h e w o r k p i e c e r e a l i g n e d .Push he ig orward o feed he rail ntot h e h l a d e r ip h t ) h e n u rn h e s to c kr r b , r ! / t ! ' i v i i

a r o u n d n d e o e a t h e c u t o n h e o th e redge. Move he ig oward he blade lightlyso he h ickness f he enon willbe eoua lto a b o u t n e - th i rd h e s t o c k h i c k n e s sa n d m a k e w o mo re a s s e s . e p e a t h eprocess o cu t enon heeks n he o there n d o f t h e r a i la n d a t b o th e n d s f t h er e ma in in g a i l s .

r) Sawing he mortisesI Clamp ne of the door tiles nd-up othe ig ,pos i t ronhe rg o cen te r he edgeof the workpiece ith he blade, nd eedthe stock nto he cut (left).Then move he1ig ery l igh t ly way om he b lade oe n la rg e h e m o r t i s e . a k e n o t h e r a s s ,turn he st i le round n he ig ,and eed tinto he blade gain. ext , est-f i t ne ofthe a il enons n he mortise . f the it istoo ight, move he ig away rom he bladeslightly nd make wo more passes, ontin-u in g n t i l t h e e n o n i t s n u g lyn h e mo r-t i se .Use he same procedure o cu t themor t i ses t he o ther nd of he s t i le nda t bo th nds f he emain ing ti les . ou^ ^ - ^ r ^ ^ , , ^ ^ ^ L ^ ^ * ^ r p i i o f n n r r i h i cd I d t 5 u u 5 t r d 5 i l u p - i l t d u - r , o . -

joint , s shown n page 06 .


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SHAKERCLASSICS

Q Gluing p he a i ls nd t i lesr- ,1 Drv-assemblehe two door rames o check he i t of thejoints. f they ar e oo ight, us e a chisel o pare way xcesswood; f any of the enons xtends eyond he outside dges fthe s t i les , and t f lush . hen pread lue n he contact ing ur-f a c e s f h e a i l t e n o n s n d s t i l emo r t i s e s , nd a s s e mb l e h e

frames. se hree lamps o secure ach ssembly, l igninwitheach a i l and center ing thirdbetween he st i les ; ro tethe s tock i th wood ads . ightenhe clamps l i t t le t a t imuntila thin glue bead queezes ut of the

loinIsabove), he

ing he rame or square s yougo.

/ Preparingthe oor rames orglass anels- t Each oor wil l have glass anel hats i ts n rabbets u t a long he nside dges fthe rame; he glass s held n place ystr ipsof molding. nce he glue has ured, emovethe c lamps nd cut he rabbets n a routertable . ns ta l l ' / . inch op-pi lo tedtra ight i tr n a r o u t e r n d mo u n t h e o o l n a t a b l e .Ad j u s t h e b i t h e i g h t o t h e c o mb i n e dh i c k -n e s s f t h e g l a s s n d mo l d i n g o uwi l lb eusing.Remove he ence nd se t a door rameon he able . urn n he ool and press heins ide dge f he rame gains t he bi t nearon e corner, hen otate he stock lockwise oc u t h e r a b b e t s l o n g h e r a i l s n d s t t l e s( r ishf l Keen he ramp at on he able as" b " ' / ' 'yo u ee d t into he bit. Square he corners fthe abbets i th a mal le t nda wood hise l .Repeat he procedureor he other oor.


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tri Makinghe lass-stopolding\ , f Cut he mold ing ha t wil lsecure he g lass n he doors roma s ing le%-inch-thick oard . ta r t y ounding ver o th dgesof he p iece s youdid o r he drv ider page 20) , hen rp hemold ing rom he board n your ab le aw, eed ing he s tockwitha push t ick above) . aw he mold ingo f t in to he rab-b e t s n h e d o o r s , a k in g 5 ' mi t e r c u t s t h e e n d s f e a c hp i e c e . u ta n d i t o n e p i e c e t a t ime , ma k in g u re o a l i g n h emiter uts wrth he corners f he rabbe ts .

f, Mounting inges n he doorsr- ,1 The doors re hung n he c lock ase withbu t t h inges : heh inge eaves re oncea led n recesses u t n to he ns ide acesof he doors nd he ront dges f he case . os i t ion ach oor

in urn on he case nd out l ine he h inge eaves n he doors ndthe case . o cu t he ecesses n he doors , lamp he rame o awork urface ns ide- face p .Cuteach ecess i th a ch ise l n wosteps. tar t y ho ld inghe ch ise l e r t ica l ly n your u t l ine i thth e b e v e l a c i n g h e w a s t e n d a p h e h a n d le i t h a ma l l e t ,mo v in g h e c h i s e l l o n g o s c o re h e e n t i r e u t l i n e . h e n a rea w a y h e w a s t e n h i n a y e r s , o ld in gh e c h i s e l o r i z o n ta l l y,bevel-side p (left). estJit hinge eaf n he recess eriodically,s topp ing hen he ecess s about%o nchdeeper han he h ick-ness f he ea f . With he h inge eaf n pos i t ion , a rk he screwholes n he ecess , o re p i lo tho le t each mark , ndscrew hehinge eaf o he door.Use he same rocedureo cu t he ecess -es n th e rontedges f the case.

ISecuringhe glass

I Have lass anels repared or he door, utting hem %inch hor te r nd nar rowerhan he i r pen ings . h iswil l eavea %o- inch ap around he glass o a l low or woodmovement .Apply our n ish o the door rames, et t d ry, hen se t hedoor rames nd g lass n a work urface nd p lace he mold-ing n pos i t ion . o re i lotho les or in ish ing a il s h rough hemold ing nd nto he rame very inches , hen drive he na i l susing brad r ive r. o use he driver, nsert nail nto a p i lo th o l e , h e n p o s i t i o nh e a w s n d ig h t e n h e o c k i n g u t .H o ld in gh e r a m e t e a d y, q u e e z e h e a w s o s e t h e n a i l(above). se a piece f cardboard o protect he glass.

Tuah etick

l t J


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SHAKERCLASSICS

FINATSSEMBLY' l Gluingn he rim iecesI Cut he op and bottomrimpieceso

size, hen ound ver ne ace f heir ideand ront dges na router able sing9%-inch ound-overit @age 20. To n-stall he pieces, et he clock ase n tsback n a work urface nd pread lue nthe contactingurfaces f he rim piecesand he op and bottom anels . osi t ionthe r im pieces o he i r ack dges reflushwith he back f he case nd ecurethemwithbar lamps paced very to 6inches. ighten he clamps right) nlilalittle lue queezes utof he oints.

r) Preparinghe ase or he dial nd lockmechanismL me dia land lockmechanismre t tachedo a hin ply-wood acking oard, hich n urn s screwedo cleats lued oth e nside f he case. ut wo leats o t along he nside ac eof he case ide anels etweenhe op panel nd he divider.Cut h i rd ne o run lone the n s i d eac e f he oo oane l

betweenhe side anels. ohelp oumark he positionsf cleats,est-fithe clock n he case, ememberingo allow othe doors. nce he cleat ositions certain, pread lue ncontactingurfaces etweenhe cleats nd he case, nd lthe cleats n place above).

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SHAKERCLASSICS

Assemblinghe lockmechanismAssemblehe clockmechanismollowinghe manufactur-

er 's di rec t ions. or he model hown, osi t ionhe dialonthe backing oard rovided ndoutl inehe shaft ole n heboard. emove he dialand bore he shaft ole hroughheback ing oa rd n your r i l lp re ss . i x h e d ia l o he back-ingboard ith epoxy, aking ure he dial s centered etween

the board's dges. o attach he clockmovement lnsef),nsertthe shaf t hroughhe shaft ole nd he dial , hen ighten henut on he shaft by hand hbovd. f the shaft protrudesoo arfrom he dial , oosen he nut, emove he movement nd l ipon eor more ashers etweenhe movement nd he backingboard. number fwashers re upplied ith mostmodels.

Securinghe lockassemblyo he case

Positionhe backing oard n he clockcase nd ri l l o i lo t olesor%-inch o .6 wood crewshroughhe board ndinto he cleats. ore hole t each or-ner, hen drive n he screws /eff).

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f l Hansinshe oorsr\r- , / Set he clock n r t sback nd posi-t i o n h e o n d o o r n h e c a s e .Wr t h h eh , n o o n i n n o n i o r p d h c i r n r e p n h p p d o o c

of he door nd case , mark he h ingeleaf crew oles n the case . Bore heholes nddr ive he screws, hen epeatthe nrncess or he hottnm aoor above).l r e i t h e r o o r i n d s g a r n s t h e d i v i d e r,t r ys a n d i n gh e b i n d i n g a i l No w p p l ya f i n i s h o h e c l o c k a s e .

Insta l l inghe endulumMostpendulum eights ave brass

f i n i . h r h ^ r ; ^ ^ ^ " , 1 , , ^ ^ , ^ + ^ h o d . i h p u r o i o h il l l l l ) l l L l l d L ) U d ) l l y ) L l d t L i l L u , L r r Lv y u r b r r

i c r r c ' r : l l v n r n t o n t o d h v 2 n l : c t r a a n \ / A r -

i n o D n n n i r p m n r i p i h p e n v p r i n s r r n l i l l h p

p e n d u l u m a s b e e nmo u n t e d . l i d e h ep e n d u l u m o du n d e r h e c l o c k a c e o t st on e n d - a t c h e s n he h o o k n d e r h emo v e me n t . h e c l o c k a n n o wb e h u n go n a wa l l r o m a h o o k r a Sh a k e r e g -b o a r d i k e h e o n e h o wn n p a g e 3 8 .

1 2 8


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STEPSTOOL

f n their quest or orderand efficienry,I the Shakers uilt chests f drawers ndcabinets hat made good use of availablespace, ftenstretching rom floor o ceil-

ing.Step tools ike he one shown elowevolved o enable ousehold embersto gain access o the uppermost helves.Depending n individualneeds, hestoolswere made n two-, hree-, andfour-step ersions. he aller stools ften

ANATOMYF STEP TO(IT

featured teadying ods screwed o theside o provide a hand hold.

Althbugh hese tools ppeal o themodern eye,usefulness as he Shaker

builder's ole oncern. hrough dove-tailswerechosen o attach he reads othe sides ecause he nterlocking ointsgave he stools trength nd stability.Step-by-stepnstructions or cutting hejoints by hand, much as a Shaker rafts-

man might have done, are providedstarting n page 30.

The stoolswere raditionally ut rom%-inch-thick herryexcept or the X-inch-thickcrosspieces. nce ou have utyourstock or the sides fthe stool, sea pen-cil to mark he op, bottom, and rontand back edges f each iece. hiswillhelp you avoidany confusionwhen youcome o cut he pinsat he sides'top nds.

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CUTTINGHE OVETAILS

1 Notchinghe ides or he rosspiecesI "I Th e s i d e s r e ma d e r o m wo b o a r d sp l r r e d

n p e t h e r f t e r h e n o t c h e s n dt h e p i n so f t h e d o v e t a i l o i n ta r e c u t nt h e m. Ou t l r n e h e n o t c h e s n h e e d g e so f e a c h r d e i e c e . h e n u t h e m o ny o u r a b l e a w. n s t a l l d a d o h e a d nt he s a w n ds e t h e c u t t i n g e i g h t o t h en o t c hwi d t h .Sc r e w b o a r d o t h e mi t e rgauge s an extension. ake everal assesto cut each notch r ight) , eeding hec t n n k r r n n n o d o p r n r i t h h p m i t p r s : t t o e

l l c p t h o r i n f p n c p , r c , q r r r d p o r c r r t t i n ov i v v ! ! i I b

u p o t h e n o t c h n d i n e .

r) Laying ut he pinsL S"ta cut t ing auge o he s tock hickness ndscr ibe l inearound he op end of each rde iece o mark he shoulderineo f h e a i l s . Ne x t , s e d o v e t a i l q u a r e o o u t l i n e h e p i n s nt he s a me n d ; h e wi d e a r t f h e p i n s h o u l d e o n h e n s i d eface of the s tock. ta r t wi tha half -p in t each dge nd addo r r o n l v c n a n e d n i n c i n h o t u r p p n T n c n m n l p t p t h c m : r k i n o s p a t t r p

the piece n a vise nd use t ry square nd penci l o extend hel ines n he board nd o he shoulder ines bove) .Mark hewaste ec t rons i th Xs as vou qo.

Q Cutting in sr .J Leave he piece n he vise nd use a doveta i l aw o cua l o n g h e e d g e s f he p i n s ,wo r k i n gr o mo n e s i d e o f t hb o a r d o t h e o t h e r. o r a c h u t , a l i g n h e sa w b l a d e u s tthe waste ide of he cut t ing ine .Use mooth , ven t rokal lowinghe saw o cut on he push lroke above) . ont ins a wi n g rg h t o h e s h o u l d e ri n e ,ma k i n g u r e h a t h e b l a do e r o e n d i c u l a ro h e i n e


133/148

SHAKER LASSICS

Chiselingut hewasteSet he s ide p iece ns ide ace up on a

work urface nd c lamp n a gu ide lock ,a l i g n in g t s e d g e w i th h e s h o u l d e r in e .U s i n g c h i s e l o w i d e r h a n h e n a r r o wside of the was te ec t ion , utt he la ts ide of the b lade ga ins t he gu ide lock .H o ld h e e n d o f h e c h i s e l q u a r e o h efa c e o f t h e p i e c e n d s t r i k e t w i th aw o o d e n a l l e t , c o r in g l i n e a b o u t %inch eep . hen urn he ch ise l oward heend of he pane l bou t% nch be low hesurface f the wood nd shave ff a thinlayer f wasle abovd. Continue havingaway he was te n his ash ion nti l ouare about alfway hrough he hickness fth e piece, hen move n o th e next ec-tion.When ouhave emoved ll he wastefrom his side. urn he p iece ver, ndwork rom he other ide left)until hepins re omple te ly xposed .

1 3 1


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SHAKER LASSICS

Abhough the Shakers id not haverouters nd conmtercinl ig sat their

disposal, he tools' efficacy or cuttingdovetail oittts quickly nnd precisely

would certainly have nppealed o thent.The jigshown at right consists f twotenrplatesfastened o backup boards.

The workpiece s seun'ed o the jiganda stop block helps with positioning for

repe(lt Ltts. ere, a router fitted withn dovetail bit nroves n and out of the

slots f the tail board template.

f, Layingut he ailsr,l Se t a tread ottom-face pon a work urface. old ne fthe ide ieces ins own i th ts nside ace l igned i th heshou lde rine f he read . s e penc i lo o u t l i n eh e a i l s teach nd of he read bove) ,hen xtend he ines n heboard s ing trysquare . ark he waste i thXsand epeatt he p r o c e s s i t h h e e m a i n i n gread .

f, Cuttinghe ails nd emovingasteV Use dovetai l aw o cut he a i l s he same ay outhe pinsGtep ) . Angl inghe board above) ,ather hath e saw,makes o reas i e r u t t i ng . aw mooth lynd ves topp ingu s t hor t f he shou lde ri n e . ou an a l so ut h e a i l s nyour a nd aw. emovehe wa s t e i t h c h ias n steo .


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SHAKERCLASSICS

7 Testinghe itof he oints/ Before luing p he stool , ssemblei t o check he i tof al l he oints. tandone f he ide ieces nend, hen l igna tread ith t. Press he oint ogether yhand s ar as t will go (right),hen use amalleto ap he read he est f he wa yinto lace . heboards hould t snugly,requi r ingnly ight apping; void s ingexcessiveorce . f any oint s c lear lyootight ,mark he spot here t binds, hendisassemblehe boards nduse chise lto pare away little morewood, est-f i t he o in t ga in nd d jus t t u r the r,as necessary.

GLUING PTHESTEP TOOT' l Gluingp he ides

I Set pair f bar lamps na worksurface nd ay woboards ha t make pa complete ide iece n hem. preadglue n he ontac ting dges f he boards,a l ignheir ot tom nds, nd ighten heclamps nti l here re nogaps etweenthe boards nd thin bead f adhesivesqueezes utof he oint left).Glue pthe other ide iecehe ame ay.

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SHAKERCLASSICS

r) Relievinghe ide iecesL g V u t t i n g s e m i c i r c l e u to f hes i d e i e c e s ,eav ingwo egs n eachside , he stool i l lbe more table nuneven urfaces. djust compass o arad ius f3% nches ndmark semic i r-c leon one f he ide ieces, lac inghecompass ornt t he bottom nd of hesidesmidway etweenhe edges. ut hesemicirclenyour and aw right),eed-ing he stock cross he able wi thbothhands . henmake he ame u t on heother ide iece . ou an hen moothaway he marks ef tby he saw lade ne q n i n d l o c a n d p r

? Installinghe readsr- ,1Spread n even ayer fglue n he contac t ingurfacesbetweenhe pins nd a i l s , hen ssemblehe tool , et t ingthe reads n he side pieces abovd. ecurehe ointswithbar lamps, l igninghe bars i th he ide ieces ndusingwood ads s ong s he read idth o dist r ibutehe clamp-ingpressure .

Attachinghe rosspieces

Set he step tool nts

back dge nd applylue

ocontac t ingurfaces etweenhe crosspiecesnd he sidand reads. lace he crosspiecesn he i r o tches nd lamthem ecure lyn place . ear ach nd f he rosspieces,a counterboredole ora wood crew hroughhe crosspand nto he ront dge f he side iece . r ive screw neach ol e bovd. For perfect atch, se plug utter nyour rillpress o cut plugs rom he waste ood eft by eling he ide ieces tep ).Spread lue n he plugs ndthem nto hei r oles , nsur inghat he gra in i rec t ionferuns n he same i rec t ion s he crosspiece . se chise lt r im he plugslush i th he urface, hen and hem mo

Croeapiece

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SHAKE,RBOXES

BUILDINGB()X ITFirstproduced n tlrc 1790s, lnker toxeswere tnde rr grndunted izes o hold

houseltold oor/s; wherr urrpty, heycotildbe tested rrside rre rrotlrcr. heovsl boxes entoirt optrlar odcry, tu lcort be nnde easily.frottr orrtttterciolkits.The box showtrut right wos rrttdeby craftsnratr ohrt \lilsortoJ'Chnrlotte,Michigarr. He trdded .few hmrn'iotrsrefulenrcttts o tlrc utilitsrintt yet elegntttSlnker desigtt, rtch s usingltird's-eyetrrapleJbr he box torrds ru ln wsltuftburl verrcer.fbr lrc op .

1 Cuttinshe inserst -

I To make Shaker ox rom a commerc ia l r t , rrs t repareth e stock or he wo bands-one or he box and one or he op.The bands re ypicallyesawn rom hardwood tock o a th ick-neSS Of / ,0 inCh . FOf 95 { locr l tc r rco ctra ioh t-o rr ino r l , qg3;[g;52yy11

stock ir-dried o a mois tu re on ten t f 15 o 20 oercen t . ncethe bands ave een ut o size, se he proper-sizedinger em-plate o outline he ingers n he box band above),hen markt h e a c k h o le s i t h a n a w la n d d r i l l h e m w i tha X , , - i n c h i t .


138/148

SHAKERCLASSICS

r) Bevelinghe ingersL Cla p the bands o a backup oardand bevel he ingers i th a u t i l i ty nife .Holdinghe knife i rmlywithboth ands ,cut a t an angle f 10" around he ingershbovd. Then aper he outside ac e ofthe opposi te ndof each andusingbelt sander, tarting he aper about Y,i n c h e s n r o m h e e n d . h i swi l le n s u r ea smooth ver lao nduniformhicknessonce he bands re bent.

Q Markingheoint

r- , f Soak he box and id bands n boi l ingwater n t i l hey are sof t - typica l ly bout2 0 mi n u t e s . e mo v e h e b o x b a n d o mthe water nd wrap t a round he proper-s ized oxcore o he beveled ingers apover he apered nd. Make referencemark cross he edges f he band wherethe ends overlap right).Keep he beveledf ingers ressed rght ly gains t he core opreventhem romspl i t t rng .

36


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Tack-nailingheboxWo rk in g u i c k l y, l r p h e b a n d f f

t h e c o r e , e b e n d t s o h a t h e p e n c i lma rk s in e u p , a n d a c k - n a i l t t h ro u g hthe holes oudri l led n s tep us ing heappropr ia teopper acks . o c l inch het a c k s n s i d e h e b a n d , s e a l e n g th fi ro np ip e l a mp e d o y o u r e n c h s a nanvil above). nce the box bands aret a c k -n a i l e d , l a c e w os h a p e - h o l d e r sin s id e h e b a n d - o n e a t e a c h n d - t omaintain he ova l ormas t dr ies .

f , Shap inghe id bandr- ,1 Shape nd ack-na i l he op band orthe box id as described bove, ut use hed ry in g o xb a n d s a b e n d i n g o rm a n dshape-holder s t dries lef). he f ngersf o r h e o p a n d h e b o x h o u l d i n eu pevenly. llow wo days or he bands o dry.To comple te he box , u t a l id and bot tomfromouar te rsawn tock o f t inside hebands , eve l ing he edges t 5" to prov idea t ight i t l ike a cork n a bott le . hen ri l l\ r tnch p i lo tho les nd use oo thp icks soess o secrrre he nieces. he boxes an bef nishe d i th milkpa in t r a c lea r acquer.

r37


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PEGBOARD

'A placefor everything nd every-thing n its place"werewords he

Shakers ivedby, and many house-hold tems n Shaker omes ung

from assigned egs.

-|a h. pegboards a fitting ymbol fI theShaker's pproacho both dai-

ly ifeand craftsmanship. swithotherShaker-made tems, he clean, un-adorned ines fthepegboard eflecteditshumble unction ather hanany on-cernwith appearance. ut he simpledesign elied he pegboard's ersatility.Theboards id not ustholdhats ndcoats. ining he walls f Shaker omes,theywere n ntegral artofhouseholdlife-convenient, rganized, nd idy,hangers or everything rom book-shelves, ipeholders, nd owel acks ocandle conces, hairs, lothes angers(a Shaker nvention), ndwallclocks(page 18).

MAKINGPEGBOARD

1 Shapinghe back oardI Cut he back oard o size rom %-inchthick tock; ake tswidth %inch-es and ts ength ependent n he numberof pegs ou willmount. hape he boardon a router able sing wodifferent its.Start y ounding ver he ront ace fth e board t he edges nd ends page120,Ihen swi tcho a pi loted ead i t .Alignhe ence ith he bit 'spilot earingan d adjust he cutting eight o he beadswillbe about% nch rom he edges f heboard. o help ou eed he workpiece ,clamp featherboardo he able, racedwitha support oard. eed he back oardinto he bi ton edge , eeping he rontface ressed gainsthe ence. hen ur nthe board ver nd epeat he procedureorout he bead n he opposite dge righil.

For the modern woodworker, hepegboards lso eveal he Shaker evo-tion to craft. The simple mushroom-shaped egs were accorded he sameattention o detail as he finest cabi-net. For this reason erhaps, Shakerpegboards ere emarkably onsistentin design nd construction o matterwhen or where hey were made. Thepegs were ypically ashioned rommapleor cherry and averaged nchesin length.Theyweresecured o 3-inch-wide back boards usually mount-

ed 6 feet above he floor. The spaof the pegs aried according oboard's use. n New LebanonHancock, he pegs were sometithreaded nd hen screwed ntoback board. Normally, however,were attached with a friction fitdescribed n this section.

You can buy pegs eady-madturn them on your athe. n either cthe base f the pegs will need okerfed o accommodate he wedthat secure hem n place.

1 3 8


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SHAKERCLASSICS

Q Tapping n he pegsr- . f To make he pegs as ie r o instal l , se a sand ing lock oshape smal l beve l round he base f each ne . Then awakerf o r a wedge c ross he base f the peg ; o avo id pli t t ingthe woodwith he wedge , ake he cu t a t a r igh t ngle o thegra in .Once he pegs re eady, pread lue n he i r bases ndtap he pegs nto he holes above).

r) Preparinghe back oard or he pegs. a ^ ,Z- Start ing ear ne edge f he backboard , a rk he peg holes long he mid-d l p n f f h p q t n n l r ( T h c n o o a n n t ho h n a r r J

s h o w n t l e f tw i l lb e s p a c e d i n c h e sapart . ) ns ta l l Y- inch rad-po in t i t nyour ri l lp ress nda t tach backup ane lto he machine ab le o min imize earou t .S e t h e b a c k o a r d n h e p a n e l o h ef r s tm a r k s d i r e c t l y n d e r h e b i t a n dc l a m p b o a r d s a g u i d e e n c e o t h etab le lush ga ins the workp iece . hen ,bu t t ing he back oard ga ins t he ence ,dri l l h e holes /eff) .

Drivingn hewedgesForeach peg , u t a Z , - inch- long edge rom scrapwood

Spread lue n the ker fs nd on he wedges , et he pegboardface down n a work urface , hen ap he wedges n wi th ahammer above) . vo id s ing oo much orce ; h is may ausea peg o spli t . r im he wedges lushwi th he back ace f theboard . as ten he pegboardo the wal lby counte rbor ingcrewholes nd dr iv inghe screws ntowal ls tuds . oncea lhe as -teners with wood plugs page 34).

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GLOSSARY

A-B-CAuxiliaryfenceA wooden ttachmentto a tool's rip fence hat serves s ananchor or accessories nd preventsaccidental amage o the metal ence.

Blank A piece of solid or glued-upwood used o create furniture part,such as a turned eg.

Bridle oint A type of open mortise-and-tenon oint in which he tenon sas ong as he width of the mortisepiece nd he mortise extends crossthe entire width of the board.

Candle sconce: candlestick older.

Chamfer: A bevelcut along he edgeof a workpiece.

Cheek The face of the projectingtenon n a mortise-and-tenon oint.

Clearance ole:A hole drilled in aworkpiece o accommodate he shankof a screw.

Cleat: A strip of wood fastened o onefurniture part to support another, uchas a shelf or a tabletop.

Cockbeading: Narrow proj ectingmolding surrounding he nside edgeof the door opening f a cabinet.

Compound-angle ole: A hole drilledinto a workpiece with the bit present-ed at angles ther han 90o elative othe face and edge ofthe stock.

Corner strip: A notched wood blockfastened o the stile of a cabinet or therail of a table o hold up a shelf sup-port or drawer lide.

Counterbore: Drilling a hole hat per-mits the head of a screw or bolt to sitbelow a wood surface o hat t can beconcealed y a wood plug.

Countersinlc Drilling a hole thatpermits he head of a screw r boltto lie flush with or slightly below awood surface.

Cross-doweftAwood dowel or metalcylinder hreaded cross ts axis oaccommodate screw or knockdownfastener; suallyused o provide ong-grain strength when screwing ntoend grain.

Crown molding: Decorative riminstalled round he perimeter of apieceof furniture ust below he op;also known as cornice molding.

D-E-F-G-H-r-lDado: A rectangular hannel ut intoa workpiece.

Edge gluing: Bonding boards ogetheredge-to-edge o form a panel.

End grain:The arrangement nddirection of the wood fibers unningacross he he ends fa board.

Fiber rush: A natural iber made romthe wisted eaves f cattails sed ofor seatingmaterial n chairs; morecommonly used alternative s madefrom twisted kraft paper.

Finiah An ornament-usually turnedand carved-projecting rom theupper corners of a furniture piecesuch as a chair.

Glass-stop molding: Decorative tripsof wood used o hold a pane of glassin a door frame.

Half-blind dovetail A dovetail oinin which he structure of the oint iconcealed y one side; ommonlyused o join drawer ronts o the side

K-r-M-N-O-P-QKerf:A cut made n wood by the wiof a saw blade.

Kickback The tendency of a work-oiece o be thrown back n th edirection of the operator of a woodworking machine.

Kicker:A board astened crossdrawer opening and positioned bothe drawer o keep t from tiltingdown when opened.

Knockdown hardware: A fastenerthat allows he quick assembly nddisassembly f a pieceof furniture.

LeafiA panel hat is extended oincrease he size of a table andretracted when not in use: t canbe hinged or sliding.

kdger strip: A short, narrow piecof wood used o support he top orbottom ofa cabinet.

Listing: Canvas r woven wool clottape used or weaving hair seats; lsoknown as Shaker ape.

Miter gauge A device hat slides n aslot on a saw or router able, providing support or the stock as t movepast he blade or bi! can be adjusteto different angles or miter cuts.

Molding: Decorative trips of woodused o embellish pieceof furnitu


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Mortise A hole cut into a piece ofwood to receive tenon.

Mortise-and-tenon oint: A joinery

technique n which a projecting enoncut in one board its nto a matchinghole, or mortise, n another.

Mullion: A slim vertical memberdividing sections f a frame; alsoknown as a muntin.

Panel-raisingplane A hand planewith an angled sole used o bevelthe sides f a panel n frame-and-panel construction.

Pilot hols A hole drilled nto a work-piece o prevent plittingwhen a screwis driven; usuallymade slightlysmallerthan the hreaded ection f the screw.

Pilot bearing: A free-spinning metalcollar on a piloted router bit that fol-lows he edge f a workpiece r a tem-plate o guide he bit during a cut.

Pommel The square ection eft on aturned furniture eg; allows oom formortises eeded o receive ails.

Push block or stick A device sed ofeed a workpiece nto a blade or cutterto protect he operator's ingers.

Quartersawn umber: Wood sawn sothe wide surfaces ntersect he growthrings at angles etween 5o and 90o;also known as vertical-grained umberwhen referring o softwood.

R-SRabbet oint:A method of joining

wood n which the end or edge fone workpiece its into a channel, rrabbet, cut along he edge or end ofanother workpiece.

Rail In a table, he rails oin the egsand support he top; n a chair,one offour boards hat rame he seat. lsothe horizontal member of a frame-

and-panel ssembly. ee tile.Raised anel In frame-and-panelconstruction, cabinet or door panelwith a bevel cut around ts edges,decorative ffect hat "raises"the cen-ter and allows he panel o fit into thegroove ut in the frame.

Rake angle The angle at which achair eg deviates rom the verticalwhen viewed rom the side of thechair; see play ngle.

Rocker: he curved unners of arocking chair oined o the chair egs.

Roughinggouge A turning tool usu-ally used o shape square lank ntoa rylinder.

Rule oint A pivoting oint commonlyused n drop-leaf ables; eaturesmat-ing convex and concave rofilescutinto the edges f the able eaf and op.

Shoulder: n a mortise-and-tenonjoint, he part ofthe tenon hat s per-pendicular o the cheek.

Sliding dovetail oint Similar to atongue-and-groove oint, except heslide,shaped ike the pin of a dovetailjoint, is held by a mating groove.

Splayangle: he angle at which achair leg deviates rom the verticalwhen viewed rom the front of thechair; see ake angle.

Stile:The vertical member of a frame-and-panel ssembly. ee ail.

Stopped dado: A dado hat stops

before crossing he fullwidth orthickness f a workpiece.

Storypole: A shop-made measuringgauge sed o determine he dimen-sions nd he ocation f the oints na project, such as a chair.

T-U.V-W-X-Y-ZTearout The endency f a blade orcutter o tear wood ibers.

Template A pattern used o guide a

tool n reproducing dentical opiesof a piece.

Tenon: A protrusion rom the end ofa workpiece hat fits nto a mortise.

Through dovetail oint A method ofjoiningwood by means f interlockingpins and ails, which pass ntirelythrough he mating piece.

Tongue-and-groove oint A joinerymethod eaturing a protrusion rom

the edge or end of one board hat fitsinto the grooveofanother.

Tiestle: n a trestle able, a board run-ning along he underside f the top towhich he egs are attached.

Wood button: A small,square-shapedblockwith a rabbet at one end hat fitsinto a groove; sed o secure he opof a piece of furniture.

Woodmovement The shrinking or

swellingof wood n reaction o changesin relative umidity.

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INDEX

Page eferences n italics ndicate anillustrationof subjectmatter. Pagereferencesn bold indicate a Build ItYourself roject.

A-BArchitecture, 0, 15, 7Band saws

IigScircle-cuttin jigs,79

Baskets,22Benches

Dining room benches, 8Meetinghouse enches, 9, 5, 48

crest ails, 54-55cutting list,49legs,52-54

seats,4& 0-52,54-55spindles, 0,54-55Blanket chests, lBlind mortise-and-tenon oints, 90,

91-92Boxes, -9, 17 ,117, 135- 37Build It Yourself

Band sawscircle-cuttin jigs,79

Pie safespanel-raising igs for the

table saw,96Butterfly hinges

Making butterfly hinges(ShopTip), 1lj

C- DCabinets,20Candlesconces, 3Candle tands, & 78

Columns, 8,81,84-85Legs,78, 82-84, 85Rails, Z& 80,84, 85Sliding dovetail oints, 57, 78,

81-83Tops,79,80

Canterbury community, 10Chairs.25Dining room benches, 8

Enfieldside chairs, 2, 19,25,26-27back slats, 0-i1, 32, 33cutting ist,27

joinery,26, 28, 31-i2, 33legs,27, 8-29, 1-33railsand stretchers, 0,32-33rush seats, 4-37

Listing, 4,44-47Revolving hairs, 19Rocking hairs, 19, 4,25, 38-39

arms,41, 2-43assembly,42backs,24cutting ist, 39legs,40, 43rockers,4l, 43

tape seats,44-47Rush seats, 4-32Splint-seat ining chairs, 9See lso Benches

Circular cutsCircle-cuttin jigs,79

Clocks, 7, 23, 116, 17, 118Assembly, 26-128Cases,119-122Dial and clock mechanisms,

126-127Doors, 23-125Pendulums, 28

Clothes hangerc,23Cockbeading, 00- 01Crown molding, 102-103Cupboards

Cabinets,20Sill cupboards,2lSee lso Pie safes

Cutting istsEnfieldsidechairs,27Meetinghouse enches, 9Pie safes, 9Rocking chairs, 39

Dining room benches, 8

Dovetail ointsSlidingdovetails, 7,78, 81-83Through dovetails, 29, 130-133

DrawersDrop-leaf ables, 69, 74-76

Drop-leaf ables, & 56, 57, 68Drawers, 9,74-76

Legs,69,72-73Ptails,69,70-73Tops,76-77

Drying racks,22

E-F.GEnfieldside chairs, 2, 19,25,26-2

Back lats, 30-31, 2, 33Cutting ist,27foinery, 6,28, 31-32, 3Legs,27, 8-29, 1-33Railsand stretchers, 0,32-33Rush eats, 4-37

Finishes, ron endp perFootstools,22Greaves, harles, 6

H-r-l-KHinges

Making butterfly hinges(Shop ip), 113

IigSBand saws

circle-cutting igs,79Pipe steamers, ackendpaper, 0Rocking chairlegs,40

Routersdovetail igs, 1j2sliding dovetails, Z 8l

Thblesawspanel-raising igs or the able

saw,96foinery

Blind mortise-and-tenon oints90,91-92

Enfield ide hairs, 6,28,31-32, 33

Mortise-and-tenon oints, 106-1 0 7 , 11 0

Sliding dovetail oints, 57, 78,81-83Through dovetail oints, 129,

130- 33

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L-M-N-O-P-QLamb, David,6-7Lee,Ann, 0,14Listing,24

Rocking chair seats, 4- 47Meetinghouse enches, 9, 5, 48Crest ails, 54-55

tapering crest ails on a planer(Shop ip),55

Cutting lists, 49Legs,52-54Seats,4& 0-52,54-55Spindles, 0,54-55

Milk paint, /ro nt endpaperMortise-and-tenon oints, 106- 07,

1 1 0Ovalbaskets,22

Ovalboxes, -9, 17, 117, 135-137Paints,front endpaperPanels

Glass,124-125Raised,94-95

panel-raising igs for the tablesaw 96

Tin,87, 110-112Pantries. ee ie safesPegboards, 3, l7, 138- 39Pegs,front endpaperPie safes, 0, 86-87,88-89

Assembly, 7-103

Blindmortise-and-tenon oints,90,91-92Cockbeading, 00- 01Crown molding, 102-103Cutting lists, 89Doors, 89,106

frames, 106-110installation, 13-114making butterfly hinges Shop

Tip) ,113mortise-and-tenon oints, 106-

107, 10pul ls , l15

ti n panels, 7, 110-112Floating panels,93, 7panel-raising igs for the table

saw 96raising panels,94-95

Frame tiles.90-91

Rails,92-93Shelving, 04-105

Pipe steamers, 0, back ndpaperPlaners

Thpering rest ails on a planer(ShopTip), ssPulls,front endpaper

R.SRaised anels, 4-95,96Revolving hairs, 19Rocking hairs, 19, 4, 25, 38-39

Arms,41, 2-43Assembly,42Backs

listing,24Cutting ist, 39

Legs,40,4jRockers, I, 43Tape seats,44-47

Routers, 4IigS

dovetailjigs, 32sliding dovetails, 7, 8I

Raising panels,94Rush seats, 4-37Sewing esks,20Shaker oxes.See oxesShaker ulture, 0, 13-17Shaker tyle,6,16-17

See lso ArchitectureShop ips, 55 , 113Sill cupboards,2lSliding dovetail oints, 57

Candle tands, 7, 78, 81-83Spinning wheels, 3Splint-seat ining chairs, 9Sprigg, une, 10-llStep tools, 2, I7, 129

Gluingup,133-134Through dovetail oints, 129,

130-133Stools

Footstools,22Step tools,22gluing up,133-134through dovetail oints, 729,

130- 33Storypoles, 8

T-U-V-W-X-Y-ZThbles. 7

DropJeaf tables, & 56, 57 68drawers, 9,74-76

legs,69, 72-73rails,69, 70-73tops,76-77

Trestle ables, 18,57, 8feet,61, 64, 66legs,62-63, 5, 66rails,63, 66, 67tops,58, 9-60,64,67

See lso Candle standsTable saws, 6

Raisingpanels, 95panel-raising igs or the able

saw 96

Tape seats,44-47Through dovetail oints, I29, 1 0- 1 33Tin panels, 7, 110-112Tin punches, llTools,16

Band sawscircle-cutting igs,79

Pipe steamers, ack endpaper, 0Planers, 5Routers

dovetail igs, 132sliding dovetails igs,57, 81

Storypoles, 8

Table aws, 6,95,96Tin punches, 11Trestle ables, 18, 7 58

Feet,61, 64, 66Legs, 62-63, 65, 66Rar7s,63, 6, 67Tops,58, 9-60,64,67

Yarnish, front endp p erWashstands,2lWells, reegift, 6Wilson, ohn,8-9, 135Workbenches,2lWork stands,20

Yarn reels, 22Youngs, saacNewton, 16, 118

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ACKNOWLEDGMENTSThe editorswish o thank he ollowing

SHAKERDESIGNfames Archambeault, exington, KY; Elizabeth itzsimmons, ancock Shaker illage,Pittsfield,MA;

Paul Rocheleau, ichmond, MA; June Sprigg,Pittsfield,MA

CHAIRSAdjustable Clamp Co., Chicago, L; American Tool Cos., Lincoln, NE; Black& Decker/Elu Power Tools,

Towson, MD; Connecticut Cane & Reed Co., Manchester, CT; Delta nternational Machinery/Porter-Cable,Guelph, Ont.; Mike Dunbar, Portsmouth, H; General ools Manufacturing o., nc.,

New York, NY; Hancock Shaker Village, Pittsfield, MA; Hitachi Power Tools U.S.A. Ltd., Norcross, GA;Ian Ingersoll, West Cornwall, CT; Jean-Pierre asse, Montreal, Que.;Ryobi America Corp., Anderson, SC;Sandvik Saws nd Tools Co., Scranton, PA; Stanley ools, Division of the Stanley Works, New Britain, CT

TABLESAdjustable Clamp Co., Chicago, L; Black& Decker/Elu Power Tools, Towson, MD;

Delta nternational Machinery/Porter-Cable, uelph, Ont.; Great Neck Saw Mfrs. Inc.(Buck Bros. Division), Millbury, MA; LesRealisations oeven-Morcel, Montreal, Que.;

Ryobi America Corp., Anderson, SC; Sandvik Saws nd Tools Co., Scranton, PA; Stanley Tools,'Division of fhe StanleyWorks, New Britain, CT; Tool Trend Ltd., Concord, Ont.

PIE SAFEAdjustable Clamp Co., Chicago, L; American Tool Cos., Lincoln, NE; Robert Bourdeau, aval, Que.;

Country Accents, Montouriville, PA; Delta nternational Machinery/Porter-Cable, uelph,-Ont.;Great Neck SawMfrs. nc. (BuckBros.Division),Millbury, MA; Jean-Pierre asse,Montreal, Que.;

Stanley ools, Division of the Stanley Works, New Britain, CT; Tool Trend Ltd., Concord, Ont.;Wainbee td., Pointe Claire,Que./DE-STA-CO, roy, MI

SHAKERCLASSICSAdjustable Clamp Co., Chicago, L; Atelier d'Ebdnisterie R6jean Guerin Enr., St-Rdmi, Que.;

Delta nternational Machinery/Porter-Cable, uelph, Ont.; Great Neck Saw Mfrs. Inc. (Buck Bros.Division), Millbury, MA; The Home Shop, Charlotte, MI; David Keller, Petaluma, CA; Murray Clock

Craft, Willowdale, Ont.; Sears, oebuck nd Co., Chicago, L; Tool Trend Ltd., Concord, Ont.

The ollowingpersons lsoassisted n the preparation fthis book:Lorraine Dor6, Solange aberge, Genevidve onette, Tim Reiman,

David Simon. Diana Von Kolken

PICTURECREDITSCover Robert Chartier

6' 7 Steve Lewis8,9 Ed Homonylo10, l Steve ewis

12 James rchambeault13 Courtesy Hancock Shaker Village14, 15 James rchambeault both)

16 Courtesy Hancock Shaker Village17 Courtesy Hancock Shaker Village rop)

17 James rchambeault boxom)19 Paul Rocheleau hotography

20,23,39,4 Courtesy Hancock Shaker Village

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ASHOP-MADEIPE TEAMERUs e he igshown elow o steam hairparts, uch s slats r ea r egs. he co-nomical nd urable ood teamer llus-

trated an be ashioned ron 2-by-4sand - inch-d iame te rBS ioe nd t -t ings. he eviceeatures upport acksinside he pipe nda removableap teach nd or easy ccess . he teamsource s a water an onnected o hesteamer ya ength f plastic ose; hewater n he can s heated y a propane-fired ooker.This etup hould nly eused utdoors,) he team ource houldhave removable, crew-typeap .

To build he steamer, tartwitha

length fSchedule 0 ABS ipe ongerthan he piece fwood ouwish o bend.Cut t in half ndbore series fholesthrough oth ieces o accommodate -inch inc-coated achine olts nd utsas shown. hese olts il l uooort oodinsidehe teamer nd revent t romlyingn condensed ater. The inc oat-ingwillpreventhe bolts rom tainingthewood.) ri l l he holes elow he en-terline f he pipe o provideoo m or hewood. nstallhe bolts , s ing oth teel

WORKSHOPUIDE

and ubberwasher s n bo th s ides om a k e n a i r t i g h t e a l . N o w l u e b o t h

halves f he pipe o an ABS T-connector.D r i l l % - i n c h r a i n o l e t o n e e n d ore l ease o i s tu r e nd preven t xcesspressure. he n lue a connector ip e utf rom 1%- inch BS pipe o the spou t fthe T connec to r. ex t , u t a l eng th fplastic ose hat wrllconnect he steamerto the water an; he it t ings equired orth e water an end are shown bove.(The i t t i ngs or he s t eamer nd of thehose r e den t i ca l , xcep t ha t an ABSend cap s used nstead f the water an

T connector

cap.)Make ure he t t ings re irt ight.Lastly, uild 2-by-4 ame o support

the steamer. ail small upport lockat one nd o he steamer il l est nas l igh tnc l ine ndwa te r i l l un u t fthe drain ole.

Touse he steamer, arefullyonnectth e ga s ookero a propaneank. ill hewa te r an , ea l t i gh t ly, nd e t t onthe cooker. ecure he emovable ndcaps n he steamer, ight he cooker,and e t he t eamer u i ld o s team.(Caution: onot et he steamer rsteamsource ecome ressurized.)

Kemovableend cap

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17. the art of woodworking - shaker furniture

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