Rough Cut--Woodworking with Tommy Mac 13 All-New Projects from Season 2

178 Pages·2012·36.42 MB·English

by  Tommy MacDonald

WOODWORKING TOMMY MAC
WITH
13 ALL-NEW PROJECTS FROM SEASON 2
From the
EMMY® AWARD-
NOMINATED
Public
Television
Series
Tommy MacDonald
with Laurie Donnelly
ROUGH cUt
WOODWORKING tOMMY MAc
WItH
13 ALL-NEW PROJECTS FROM SEASON 2
Tommy macDonalD
wiTh laurie Donnelly
t
Chapter Name
Text © 2012 by WGBH For Rough Cut—Woodworking with Tommy Mac television show
Photographs © 2012 by WGBH
Illustrations © 2012 by WGBH Host: thomaS j. macdonald
Executive Producer & Director: laUrie donnelly
All rights reserved. Senior Program Producer: anne adamS
Producers: thomaS j. macdonald, laUrie donnelly, anne adamS
Technical Advisor: eli cleveland
Pp
Editorial Consultant: Steve brown, cabinet and FUrnitUre makinG
department, north bennet Street School
Director of Photography: john baynard
Audio: john o’connor
The Taunton Press, Inc., 63 South Main Street, PO Box 5506 Online Editor: dave allen
Newtown, CT 06470-5506 Assistant Editor: joe headrick
e-mail: [email protected] Music: david maSher & crit harmon
Graphics: brUce walker, aliSon kennedy, david maSher & inverSion media
Make-up: elizabeth moon
Editor: Scott GibSon National Marketing: peter panaGopoUloS, tara raFieymehr pettinato,
Copy Editor: candace b. levy jeSSica hartzell
Indexer: jay kreider Station Relations: nancy bocchino, victoria yUen
Interior design: nick carUSo © wGbh edUcational FoUndation 2011
Layout: amy bernard rUSSo
Illustrator: chriStopher millS
Photographer: anthony tiUeli, wGbh
Photographer’s Assistant: lUcio lecce
Library of Congress Cataloging-in-Publication Data in progress
E-Book ISBN 978-1-62113-695-8
Printed in the United States of America
10 9 8 7 6 5 4 3 2 1
aboUt yoUr SaFety
Working wood is inherently dangerous. Using hand or power tools improperly or ignoring safety practices can lead to
permanent injury or even death. Don’t try to perform operations you learn about here (or elsewhere) unless you’re
certain they are safe for you. If something about an operation doesn’t feel right, don’t do it. Look for another way. We
want you to enjoy the craft, so please keep safety foremost in your mind whenever you’re in the shop.
To everyone who has ever been inspired to pick up a piece of wood and
make something beautiful, memorable, and meaningful to you.
ACKNOWLEDGMENTS
Taunton Press David Bernstein, Margaret Drain, Melissa Martin,
We’d like to start with a double shout out to The Ariam McCrary, and all of our marketing and station
Taunton Press and the Fine Woodworking team, relations team who help make our vision a reality.
whose shared vision, hard work, and dedication help
make our Rough Cut companion book possible. This With us in the sawdust trenches are Eli Cleveland,
includes thanks to editor Scott Gibson, art director Steve Brown, John Baynard, John O’Connor, Dave
Alison Wilkes, photo editor Erin Giunta, photographer Allen, David Masher, Elizabeth Mood, Ken Fishkin, and
Anthony Tiueli, photography assistant Lucio Lecce, Jay Fialkov, who keep things looking great and running
layout artist Amy Russo, and illustrator Christopher smoothly. Thanks also to all of our special on-air
Mills. And an extra special thanks to senior managing guests who have shared their talents, even under the
editor Carolyn Mandarano, whose vigilance helped most extreme conditions (as when the shop reached
take our series from the television screen to the 110°F and everyone continued to keep their cool).
pages you are now reading. We’re proud to be
associated with such a talented and dedicated group To Tommy’s alma mater, the North Bennet Street
of people. School, thanks to those who help guide the integrity
and accuracy of all of our projects.
Thanks also to all the Fine Woodworking magazine
staff, including group publisher Anatole Burkin, editor And to those who were the focus of our Rough Cut
Asa Christiana, art director Michael Pekovich, and Road Trips, thanks for sharing your unique worlds and
senior editor Matt Kenney, who have been supportive expertise with audiences all across the country.
of Tommy since he started his woodworking career.
Our Families
Our Funders Finally, thanks to our families. Tommy wishes to thank
We also extend our deepest gratitude to our funders, his entire family for keeping his feet on the ground
without whom there would be no Rough Cut— and his ego in check. He also thanks his in-laws,
Woodworking with Tommy Mac. Topping the list is especially his mother-in-law, Marsha, and his better
Woodcraft. Many thanks to Sam Ross, Jeff Forbes, half, his wife Rachel, who is a source of inspiration
Jody Garrett, Dawn Knowst, Liz Byers, Vic Lombard, and unwavering support.
and Woodcraft’s extended corporate team.
Laurie wishes to thank her ever-patient husband,
We also wish to thank all of the independent Bill, and daughters, Katherine and Lydia, who have
Woodcraft franchise owners who have graciously learned that if you marry or are born into the life of
invited us into their stores and made us feel at home a television producer, things are never dull, are ever
everywhere from Boston to Seattle. changing, and are a good source of comic relief.
Laurie also wishes to remember her late dog, Baxter,
Our Show Team the basset hound who was always there for her, even
They are many people behind the scenes who help on the most challenging days.
bring a show to air. A special thanks to our WGBH
family, whose endless commitment and dedication Thanks team! Onward and upward.
is truly the driving force that makes our series an
ongoing success. Among them, hats off to Anne Tommy and Laurie
Adams, Melissa Hench Adams, Karen Carroll Bennett,
contents
introduction 1
Dressing Mirror Standing Mirror
2 82
Technique: Making Finger Joints Technique: Cutting Dovetails
on a Tablesaw
Veneered Coffee Table
94
Arts and Crafts
Technique: Working with Veneer
Armchair
16
Technique: Laying Out and Cutting Laminated Coat Rack 108
Curved Parts
Technique: Stack Laminations from
Precise Milling
Pie Crust Tray
30
Technique: Learning to Carve Console Table 120
with the Grain
Technique: Making Curved Parts
Serving Cart
44 Sand-Shaded Clock
132
Technique: Culling the Best Material
Technique: Shading Veneer
from Oversize Stock
Simple Bookcase
146
Drop-Leaf Table
56
Technique: Building a Router Jig
Technique: Making Hinged Fly Rails
Potting Station
158
Turned Floor Lamp
70
Technique: Ripping Stock with
Technique: Learning the Basics
a Circular Saw
of Turning
Metric equivalents 170
index 171
IntroductIon
Woodworking satisfies the soul. It allows
you to make something out of nothing,
whether you are creating a project for
yourself or to give as a gift.
The projects in this companion book
to the second season of Rough Cut—
Woodworking with Tommy Mac were
designed specifically to help you continue
growing as a woodworker. You can build
these projects just as they are or make
them your own, as we say on our television
show. We strongly suggest you work from
the plans, but adapt them to make the
project fit your home, your style, and your
tastes. You’ll find a few design options
throughout this book to help you get
started thinking about the projects in
different ways.
As with the companion book to the first
season of Rough Cut, tips and techniques
are scattered throughout the book, all
to help you develop your skills and get
comfortable in the shop. The projects here
have been designed to get you in the shop
and have some fun. As always, be safe and
remember that we encourage you to play
around with these projects. Change them
however you like to make them your own.
1
Chapter Name
dressing
P
R
O
J
E
C
T
mirror
TECHNIQUE
Making Finger
Joints on a Tablesaw
T his cherry dressing mirror was technique developed by Steve Brown
inspired by the work of two broth- of the North Bennet Street School will
ers, Charles and Henry Greene, allow you to make the joints quickly and
who were among the leaders of the Arts accurately on a tablesaw.
and Crafts movement in the United States. We chose to make the dressing mirror
They were not only architects but also out of cherry and the accent plugs out
talented furniture designers, known for of ebony because Greene and Greene
the unique details they incorporated into commonly used the two woods together.
their work. We learned from our Rough Cut Road
Several of their most noted details Trip, though, that they were open to using
are focal points of this project: the all species of wood, so feel free to use
interlocking finger joints featured on the whatever strikes your fancy.
case and the drawer; the cloud-lift pattern To complete this project, you’ll also
accentuating the top of the mirror; and need a few hardware store supplies,
the black ebony plugs. Together, these including a mirror, a length of threaded
details contribute to the overall feel rod, drawer knobs, and a small piece
that people have come to associate with of 1⁄4-in. cherry plywood for the back
Greene and Greene design. of the mirror.
The finger joints are the real technical
challenge of this project, but a simple
Chapter Name 3
Dressing Mirror
Rails
Stile
Knob
2227⁄32 in.
Post
Case top
Case side
Drawer Detail
41⁄2 in.
31⁄32 in.
31⁄32 in. 83⁄4 in.
3⁄8 in. 31⁄32 in.
1⁄2 in5. in. Case bottom
9 in. 1 in.
4 Dressing Mirror
Mirror Frame
25⁄8 in.
1⁄4 in. 1⁄4 in. 17⁄16 in. 1⁄2 in.
1⁄8 in.
2 in.
5⁄8 in. 3⁄16 in. 17⁄16 in. 13⁄16 in. 21⁄64 in.
1⁄4 in. 3⁄16 in.
3⁄8 in.
Rail and Drawer Pull
Frame Tenon
3⁄4 in. 1 in.
1⁄2 in.
1⁄4 in. 1⁄4 in.
1⁄4 in. 1⁄2 in.
1⁄4 in.
2 in. 213⁄16 in.
1 square = 1 in.
Dressing Mirror Dressing Mirror 5