Untitled - Wood Tools

i+*
vo[uME59
NUMBER
5
EDIT0RTnn Robertson
SENI0RDESIGNEDITORJinr Downing
SEI{|0REDFOR Bill Link
A!iS|STAI{TEDITORIiSusn Jesscn,Wyatr
Myers
COtlIRIBUnilc EDITORJoel Hes
PROIECT
BUIIDER Mike Donovan
ASSOCIAIE
ARf DIRECIORKiur Downing
SEl{l0R ITLUSIRAT0RErich Lage
GOilIRHflNG GRlPlllG DBIGNER Chris Glowacki
GRAPHICll{TERI{ Nathan Robertson
CREAflVEDIRECTORTeclKralicek
SR, PROIECT
DESIGNERS
Ken Munkel, Kent Welsh
Chris Fitch,l{yan Minrick
SH0PCRAffiMEI{ SteveCurtis,SteveJohnson
SEl{lORPHOT0GRAPHER
Crryola England
ELEC.PUB.DIREGIIR DouqlasM. Lidster
PRE-PRESS
IMAGESPECIAUSISTroy Clark,
MinrrietteJohnson
PREiIDEI{I& PUBIISHERl)onald B. Peschke
- MARXETII{G
DIRECTOR
GROUP
ANDSATES
J. Fritz Craiuer
EDITOR'S
NOTES
ADVERNSIilG
SATES
MANAGERi
MaryK. I)ay (515)1J75-72(X)
G e o r g eA . C l a r k ( 5 1 5 ) 1 3 7 5 - 7 1 { X )
vertheyeors,lrveknownquite
o few woodworkerswho hove
setup shopin theirgoroge.
Somehoveoctuollyconverted
theirgoroge into o permonent
shop,
bonishing
thecorsoutside.
Mostthough
do whotwoodworkershovebeendoing
for yeors- lettingthecorsond bicycles
shorespocewith toolsond lumber.
Of course,thotmeonshyingto mointoin o peocefulcoexistencebelween
shopond goroge. In porticulor,orgonizingthe shopto occommodote
tools
ond cors,providingodequotestoroge,
ond controllingdust so it won't get
hockedintothe house.
Workbench Home Woodshop Which bringsmeto thefeotureproiect
in this issue- the WorkbenchHome
Woodshop.lt'so fully-functionol
woodworkingshopthot'ssetup in o two-cor
goroge.And whot'siustos importont,
thisshopcon be quicklyond eosilyconvertedbock intoo gorogeot theend of
the doy. In short,it trulyis o shopond
o goroge.
lf you'd like o sneokpeekof the
goroge shop, turn to poge 42. Then
to seehow the
iustopenthecenterfold
projects,
tools,ond ideosin thisshop
con be usedto mokeprocticolimprove
mentsto your own shop.
One finolnote- there'snotenough
roomin one issueto tellyou oll oboutthis
shop.Sowe'll feoturemoreproiectsond
ideosfromtheshopin upcomingissues.
Woodsmith Siore - While we've
beenworkingon our shop,the folks
hereot AugustHomePublishing
{publisherof Workbench,Woodsmith,ond
ShopNofesmogozines)hove hod
onotherexcitingproiectgoingon. The
new WoodsmithStorehosiustopened
its doors in Des Moines.lowo. This
retoil woodworkingstore hos over
20,000 squorefeetof floorspocethot's
pockedwith woodworkingtools,disploy shops,lumber,ond supplies.
lf you'rehovelingin the oreo,Desure
to stop by ond visit the store.Trovel
directions
ondo debiledmoooreovoibbb
ot www.WoodsmithStore.com
ADVERNSI
iIG COORDI
I{ATOR
N i c o l l e C a r t e r ( 5 15 ) l J 7 5 - 7 1 3 5
Audit Bureau
of Circulations
W()ILKBENCH
0SSN r)(r{3 8(r57) $ fublillcd bnno.rliy
(l:.b ,Afril.JuD..Aus . ().r.. | )c..) bv Ausu{ }lon,. l\l'li{hnu (lnDprn}
l:l)(J (lnnd Avr.. l)fs Moin.s, l 5o3| 2.
l lirlfur,n r r trrienmrl ot Ausr{ l]onr' lUi'ilii,)g. (iryylght fa':l)of
Ausu* Ho,ne hrtiid)in{ (intrpr)}
All rishs r.!.r!.d.
Subscri$ioD ..rcs: sr)sl. {oFr54.e(). (h. \r.tr {[\.riptnnr
(6 r\{,.\),
$2linvo vrxr{,b,Slljd,r.c rc$nrb,gl{.(lNidixn/lntl..rJdSl{l
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Pritcd h U.S.A.
SubscriptionQuestions?
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P h o n c :f 8 { r ( }3) | l - 3 9 9
Online: www.WorkbenchMagrzrne.com
EditoriolQuestions?
WorkbadtMarrazine
2200GrrndAvc..l)es Moines.IA 50312
enrail:Editor@Workbenchmaq.conr
AucusrHoME
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Se|ultz,. larrrrr Rarnt//r': M.rB) I)etrils, fnlr.rru
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(lhrricl.rrz,Stv.r,.-1,/,r,ri$in.r:
(lri\ Sch\',nrct]cck, PC,\htiltodilt
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Kim Bles\nrg, Ilil,.S.iP'
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KirsrcD Koele, Olii(.ltrir(.l
Nrmlif Lonntrle. ,.1,,/,x,...lsr. /Rfttftr,nri
JerDne John$n, Jldi//D,rirr),
Clrl, Lou Wcbb.r. nriinrs l/Lr: KurtJohnvnr...lJId.. s4'h Dtr l{fbcccr
. Circulation: Sil/,r.ril,.r.S,r,i.,1 Diftr./r S.udI ll.nun. \iil
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Krir Scblcnucr, Irrul,r M. I)r'Mrrrris,
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l{urs.{{cr..lJrirrilr
A/irdr Joel Hcss,.i, r)iri^rr I)oughs A. Flinr. &r'(y
(;itt,i
l)$ir"mr (lltris (;kNr.ki, M.trk A. Hiyc\,Jr.. Ilobir Frjerd, Cr{,i,i
D,Ji(,.rijon.(h.u
A. Erkc . Producrs Groop: ()lddrDrr Duc,nrr llob lhkcr.
clvd,!r.\inlii
ll,rtsf:JcnDn'
EDos. ||irkiiiln sll,,inur
NrDcyJohnson,
Arf/r LrnJrJon.\,-ll,ri,rarr/ir','lrlirn/:
Nm.! l)oNDcli.Sr (lrrrrilff
(lox.April l(ftrll. I)fbof.rh
.\.r1:, lt,Ir,lrildrillr,T.nnnrvTnr.kenbrod.AnDr
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.s47: Svlvir C,,rcv. Woodsmirh Sroro: ll,d$ri
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Lrror. .lJiirdrr .\ l,d(.ri Tun Th.lcr, l fry./orli! .1/,r(rrrrt J fur :John
sibcrcll. Ari, l)qt..\r{:Jrmcs
Ho.knN, sdi,r Siy'iiWeildell Sronr, Lirry
Morivr).MrkJohDson.(;.uorv
K.u,lrrich.BrirD McCrllun:. John
wlrrcn. Stle AD(icrm. t).M Frcnnnr.
Stephen l)un.,ur. Dri.nr Si'nnroDs,
(Iii,".\r,,,rr(rjVi.ki
Ed$ituls
WORKI]ENCH
!
OCTOBEI\
2OO3
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W O R K B E N C H ' October 2003
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Questions
& Answers
T i p s& T e c h n i q u e s
ToolClose-Up
Reoder's
Workshop
WorkbenchShopTips
C u t t i n gE d g e
Tools& Products
A r o u n dT h eH o u s e
Croftsmonship
t:\\ () ti ti 1lI N (
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ANSWERS
toolmotorfune-up
PUttEYUPGRADE
I replaced
the lJtp lnotoron oneof thetoolsin my
shopwith a 1.5-hpmotor.Sincethen,thepulley
keepscomingloose.
Did I makea mistakeaddinga
biger motor?
Jim Komar
Via theInternet
From the soundof things,your new motor isnt
the problem,as long as it doesn'texceedthe
manufacturer's
recommendationsfor roms. If
the pulley is loose,chancesarethe key stock that holds
it in placeis worn and needsreplacement(seelllustration).
Replacement key stock is rypically availablefrom the
manufactureror hardwarestores.
As long as you're replacing the key stock, you may
want to think about upgradingthe pulleysaswell. Many
shop tools have cast pulleys,
which you can recognize by
their rough surface.The problem with these pulleys is
they're not always balanced,
which sometimes can cause
them to wobble.
One solution is to install a
machined steel pulley. These
pulleys are turned on a lathe,
\V-belt
so they are balanced to run
true. Identified by a smooth,
machined surface,the pulleys
are available at most bearine
supply stores.
with keywoy
Severolreqdershoveoskedoboutthepurposeof the shollowrecessmochinedon
thebockof boseboord
molding.lt'sthere
for onemoiorreoson.
Therecessollowstheboseboord
to flex
of
iusto littlewiththeopposingpressures
fie topondbotomfinishnoilsduringinsftrllotion.Thiswoy, if thereoreonyirreguloritiesin thewoll,thetop edgeof theboseboordwill stillfit tightlyogoinstit.
I
I
I
t
HOWTOSEI{DYOURQUESTIOI{S:
Email:editor@workbenchmaq.com
Forums:forum.woodnet.net
Mail: WorkbenchQ&A, 2200GrandAve.,
Des Moines,IA 50312
lndude
fullnomg
oddress,
ond
phone
doylime
number.
You'll
lereive
oneofour
hondsome
Workhench
ctps
your
ifwepublhh
lefier.
III
WORKBENCH
!
OCTOBER
I
T
I
t
{
2OO3
ANSWERS
qvoidcrqck-upswhen
DRILLING
HOLES
IN TILE
I want to replacemy shouer curtain with slidiftg doors.Tbbegin the
installation, I'Il need to drill someholesin the ceramictiles.Any tips
on drilling theseholeswitlnut uacking tlrc tile?
BobSchffir
NV
Reno,
Tile usuallycracksduring drilling if too much pressureis applied
when trying to break through the glaze.Fortunately,there areseveral things you can do to prevent that from happening.
The first thing I d suggestis buying a spearpoint bit like the one shown
below. If you can't find one at a hardware store, check with a tile store.
To prevent the bit from wandering, place a piece of masking tape over
the areayou'll be drilling and mark the hole locations on the tape.Then
using a punch, tap the trle lightly at each centerpoint to cre-
Drill in reverse
to stort hole
ate a dimple in the glaze (seeFig, 1). Be careful not to
tap too hard,asthis could breakthe tile.
Now carefully align the tip of the spearpoint bit with the dimple (Fig.2),set the
drill to reverse,
and drill iust a Gw rev-
Switchto forword
onddrill throughtile
olutions to make a small starter hole
A Thisspeorpoint
bit hos
no flutes,so it cutso cleoner
holethroughceromictilethon
o stondordmosonrybit.
(Fig.2a).Then,with the drill set
to the forward drilling position,
drill throughthe rile exercingan
evenarnountofpresure 8A 2U.
Is thereany advantageto replacingthe
mctal.guideblockson my bandsaw uitlt
plrcnolicplastic blocks?
Jason l-amberti
EI Paso,TX
Band saw guide blocks have one nrajor
purpose - to prevent the blade from wanderir-rgoffcourse or rwisting asyou make a cut.
Metal guide blocks work fine in this capacity with most
blades.They can be set very close to, but not touching the blade,
which providesplenty of supportfor the blade
during the cut. Plus, since I usually set the
blocks slightly behindthe blade teeth, there'sno
concern about the metal blocks damaging the teeth.
'With
narrow band saw blades, though, the rnetal
blocks don't provide enough lateral support.The blade
is just too narrow. Phenolic guide blocks, on the other
hand, are ideal when working with blades 1/s" or narrower. Since phenolic is a hard rype of plastic,you can
actually set the guide blocks against the sides of the
blade without damaging the teeth. Of course,the blade
will chew up the blocks, but they can be resufaced by
holding them againsta stationary disc sander.Phenolic
blocks are available in woodworking stores and catalogs.
t0
WORKBENCH
tr OCTOBER
2OO3
THENAILER
GETSTHENOD
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I l ' l t i i l t t n r trI , l ) ' t t t i t . t t t I I t ( ' t t l
Finishnoil
hole
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[ : r , t , lt t , t t l t rt ) t , t i 1 , u ] u n t,'ut t J
l i t r i t l tt t t i l s ?
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\ l ) r ' r ' t l(. ) r t ' i ' t l r t ' i r s n r . r l l r ' ri z' . ' . l l r i . l r l e . r er s . r s r r . r l l t ' r '
l r o l t ' t o l r e l l l l t , l i n , t n o t l ' 1 , i e t el s r ' r/ ) / i , r 1 ,I,t/t.. t , 1 . l r t t o n .
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t o : p l i t t l r t ' r r o o t tl l r . r nl l n i : l rn , r i l s .
\ \ , l r i l e l l n i t l r l r . l i l \, l l e 1 1 ) u n r\l\ i t l r , r r o L n r Lilr . ' . r t l .
l , t . t t l . . n . ' r ' r ' r ' t , l n g u l . rl r i t l r . r l : l r . r I e , 1l r e . r , l u. l r i , l r
. r l l o u' l r o t l r t l l n i n g . r r L l. t ' t t i t t gu i r l r . r : i n g l t ' r l r o t
l i o n r t l rt n , r i l t .' r
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i r r r ' r ' t ' , l r t l' r t ' i i o r r ' t . r I Ig l i I I 1 1t I t e r r o r ' ] . 1 . i t r ' t .
Red0ak,easy-to-wofk
Traditional
l\{aple
in a wide
Poplar;
andselect
- all reacli'variet,v
of convertient
sizes
available
athome
to-use
andieadily
imnrovement
andhaLdlvare
cer'rtefs
fiom
cozrst
t0
coast.
Get\orif
stoies
lrandson (lhriice\\(rocl
haruhioocl,
:rnd
(lilalitlirt\r)Lrffinuertips.
putheirkrorn
Weyerhaeuser
ChoiceWood"
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P r o d u c tI n f o r m a t i o nN u m b e r2 1 0
6"
/
TECHNIGIUES
odiustqble
ongle
TAPER
SIED
Like a lot ofwoodworkers, I usea tablesawand a shopmade jig to make tapered cuts. But unlike many jigs
I've seenthat are meant for cutting only one angle,my
taper sled is adjustablefor a wide range of angled cuts.
The basicprinciple of this sledis simple.Theedgeof
the sledis a "referenceedge"that indicatesthe path of
the saw blade. So to set up the cut, you just align the
layout line for the taper with the reference edge and
VIEW
CONSTRUCTION
Heel
atll'x2,,1
1t10,,
v
I
FIRSI Routo
Adiud,oble
Fence
P/l'x2" x2V/z"l
s16f'slol
SECOND:Routo
3/4t'recess,
h"-deep,
on the botbm
ND
then setthe fenceagainstthe workpiece.Asyou slidethe
sledacrossthe sawtable,the bladecus preciselyon the line.
The sled starts off as an extra-wide basemade of
3/a"plywood.Then, after attachinga hardwood runner
that's cut to fit the miter gaugeslot, a single passis all
it takesto establishthe referenceedge.
To make the fence adjustable,you'll need to rout a
slot at eachend ofthe base.Then,to provideclearance.
for the carriagebolts that securethe fence,add a shallow recessaround that slot (seeSlot Detail). A small
"heel" glued to one end ofthe fencehelpsto hold the
workpiecein placeduring the cut.
Allan Bushman
Coleta.CA
Wx 2W)
re Bolt
Runner
(3/g,'
x 3/a"x30nl
,-l
#8xl"
FhWoodscrew
notched
poil
PIPECUTTING
PARTNER
I neededto cut some PVC pipe
recendy,but lackeda holder to steady
the pipe during the cut.To remedy
this,Ijust cut rvvoV-shapednotches
on oppositesidesof the top rim of a
plastic pail. Lay the pipe acrossthe
pail, nest it in the notches,and it
staysput while you cut it to length.
A decent-sizednotch accommodates
a varieryofpipe sizes.
WayneL. Smead
Minneapolis,
MN
1,4
IT
Theitemsabove
arejustpartoftheRUSTOTEUM
Paint& FinishKit(valued
atover$400)wonby
AllanBushman
forhisfeatured
tip!
MailyourShopTipsto:
Workbench
Tips& Techniques
2200GrandAvenue
DesMoines,
lA 50312
Emaih editor@vorkbenchmagazine.com
WORKBENCH
!
OCTOBER
2OO3
TECHNIGIUES
hong'emup
BINS
STORAGE
I've always kept several of those plastic small-parts bins
handy while working on shop prqects. But they often
end up getting knocked off onto the floor, scattering
pieces everyr,vhere. So much for organization.
To remedy this, I added the plastic bins to my pegboard setup, where everything is up off the work surface but instantly accessible.
It was an easy addition. Since the bins each have a lip
on the back for hanging, all you have to do is cut a
length of aluminum bar stock and add several screw
holes that align with the holes in the pegboard. Place
a couple ofwashers behind each hole to allow clearance
for the lip of the bin, and drive a #14 sheet metal screw
through each, directly into the pegboard hole.The result
is a sturdy mounting bar to hang your parts bins.
Jim Downing
WestDesMoines,IA
flushmounting
DISPTAY
CASES
Traditional picture hangers don't allow picture fratnes or display casesto
hang perfectly flat against the wall. My solution is to use r.railsir.rstalledin
the back ofthe case (or franre) at an angle.
First. cut the headsoffseveral 6d finish nails.Then drill holes in the back
of the caseupward at a 45" angle. Push the nails,"head end" first, into the
holes (scelllustration).Now hold the display case against the wall at the
desired spot and push in and dou,nso the nails penetrate the drywall. For
heavier display cases,simply add additional nails.
Maruin Clore
Cut Bank, MT
6d finishnoil
Tool Brqke
Mobile tools are great- unlessthey insiston
being mobile while you'reusingthem.One way
to remedythis is to make a chock block.Takea
piece of 3/+" plywood and drill a hole in it (see
Illustration).Make
angledcutsfrom the hole to the
edge and chamferthe edgesof the cutout.The
result is an angledV-notch that works with a
wedgethe chock tightly
varietyof castersizes.Just
under the caster.Thepressureof the wheel on the
notch holds the chock in place.
CeorgeE. Moyer
Myerstown,PA
6d finishnoil
pressesdown inlo
dryrvollonddoes
nol hoveto hit stud
€oseSide
fits different size cosbrs
Drywoll
t6
woIIKtsENCH
tr OCTOBER
2OO3
_l
Crqfismon
LASER
TEVEL
Not too nrany yearsago,laserscould
be for.rr-rdin two places: George
Lucas fihns ancl professional construction sites.
O n t h e c o n s t r l l c t i o n s i t e s ,t h e
necd fcrr ptccision offset the prohibitive cost of hser levels.Therypical DIY'er, unfortr-rnately,was still a
slaveto his 4-ft level rnd chalk linc.
About two ye.lrs ago, howevcr,
laser technology beglansl.rowine up
in consur.ncr-priced ploclucts fi'onr
slurlers,and it sellsfor thc incredibly
low price of $39.99.
TI.re LaserTi'ac is powered by rwo
AA battcriesanclprojectsa linc tl.rat'.s
lccllratc' to phrs or nrir-rusI/+" at 30
severalmanufacturers.As renralkable
as th:rt was,it'.sevelt ntore renrarkable
to see how nruch tl're lasers hlve
inrprovecl in just those 24 rtronths.
f,rce-nrount basc lets you place the
l:rser on jr,rst about any flat surface
rnd levcl the unit up (PhotoA).The
tripocl rrrount ldapts the laserto irny
starrcJaldcrnlera tripod (PIroto B).
Finally,r rvall-nrount baseallows you
feet.The linc can be castverticxlly,
horizontllly, or xny angle in
to xttach the laser clirectly to ltrost
betwecn. It cln cven be prqectcd
w:rlls (li-scf ,llroto).
onto nrultiple or irregr.rlarsurfirces
The kit rlso conres witl.r a pair
Tl-re best exanrple of that is the
w i t l r o u t i r r t c l n r p t i o r rH
. : r r r g i r rp
qi c of llser-cnhancir-rg elasses.
Wear-inu
new Lasertac Level flor-r-rCrlftsnran.
turcs,instrllins wrinscotinq and ch:rir tlrese nrakes it rtttch ersic.rto see
This is the nrost versxtile,etsy-to-Ltse rail, or c'ven setting fence posts at r h c l r r s c ri n b r i s l r r l i g h t s i t u a t i o r r s ,
laser level I've conre lcross fbr conidc'nticalheiehts arcjr,rstr fcw cxarrr- such as outsiclein tl-resunshine.
ples of how this lasercln bc usecl.
Everything included with the kit
What I rcally rppreciatc abor,rt s t o w s c o n v c r r i e r r t l yi r r . r s o f t . z i p *
tl-risllscr, thoush, is that it cnn be percd clrrying cuse.The LaserTt-ac
l i l o u n t ( ' r li r r s o r r r . r r rpyo s i t i o r r us s i r r q Level is available in Searsstores or
the basc'sthat conre with it. A sur- online' at wlvw. Sears.corti.
llE
r
L
#
ii':n:liffii"g:
[",':'"T
A Usingthesurfocemount
bose,whichhos
threeodiusloble
feetfor leveling,turnsonythingfromthisordinorystoolto o stockof ottochtheloserto thewoll witho
booksintoo mokeshift
triood.
woll-mount
bose (right).
18
wolr.KBENCH
!
ocToBEr{
2003
H
WORKSHOP
shop-built
COMPRESSOR
CADDY
Hauling rrry "portable" air compressor from one place
to another used to be a two-trip experience - one to
r-novethe compressor,another to get the air hose and
tools I needed. But Chris Levan's handy compressor
caddy has cLrtmy haul time in half.
The compressor caddy is a thick block of wood
mounted to the compressor'shandle. It holds fittings
and accessories,an.dit does double dury as a mounting
surface for a hose reel.
The caddy is made up of two 3/+"-thick hardwood
blocks with dadoes that "sandwich" the compressor
handle. Iti irnportant to cut the dadoesso their combined
depth is just a hair lessthan the diameter of the handle
(seeDado Detail).That way, the two halvescan be bolted
tightly together, pinching the handle and keeping the
caddy in place.The top of the hose reel is securedto rhe
lower half of the caddy using those sarne carriage bolts
(secDado Detail). A simple seriesof various-sized holes
Sizedodoesto pinch oround
in the caddy accommodate all the gauges,fittings, and
attachments.
a
Air Compressor
Hondle
n
h"x2Vz"
CorriogeEolt
Drillholesto
glroreoccessories
\"
o
%" Roundover
Dodoes,sized
trofit oround
hondle
I{OTE:Coddvis modeup
of two blocksof
3/e'-thickhordwood
'r/t"Flol
Wosher
ondNut
wORKBENcH
tr oCToBER
2OO3
threodmebl rods
STRAIGHT
& TRUE
For many shop projects (like the
Precision
RouterCuideon page56),
you'll need to use a die to cut
threads around the outside of a
metal rod.A die is a hexagonalsteel
device with sharp teeth made for
cutting threadsin metal (seeInset
Photobelow).
This techniqueis often trickier
than it looks.The problem is the
rod sometimesdoesnt start straight
into the die, and the thread that's
cut will be crooked and unusable.
Fortunately,the solution is as
closeasyour drill press.It holds the
rod straight, so the thread can get
offto a good start (seePhoto).
To usethis technique,set a scrap
piece of wood on the drill press
A Toensureo stroight,precisethreodon o melol
rod,usethedrillpressto threodtherod intoo die
centered
on o pieceof wooddirectlybelow.
table. SecurEthe die holder to the
wood scrapwith four woodscrewsso
that it wont spin around (seelnset
Photobelow).
Now chuck the rod in the drill
pressand center the die in the die
holder directly below the rod. At
this point, clamp down the wood
scrapso it will remain stable.Then,
simply attach a pair of locking pliers to the rod and lower the rod
down into the die.
Use the locking pliersto turn the
rod clockwise in the die with one
hand, and at the sametime, place
firm pressureon the hand feedlever
with your other hand. This will
ensurea clean,consistentthread.If
the rod binds in the die. back the
thread out about a half turn to
removebuilt-up metal filings.Note:
Use oil asa lubricant while cutting
the threads.
I only usedthis technique for the
first %" of thread. Once I had it
started,the threadswere straight
enough that I could finish them the
usualway-by clamping the rod in
a machinist'svise and cutting the
threadswith the die holder by hand.
Forthe Precision
Router
Guide,I olsohod to top o numberof holesin theoluminum
ongleusedbr thehnces.To fop theseholesquicklyond occurotely,I chuckedo
fop in mycordlessdrill ond usedthedrill to guideit inb o pre
drilfedhole (ree lllustrolionJ.
Byodiustingthedrill clurcho o
low selfing,he clubh slipsrotherhon ruiningthethreqds.
OncEfie clubhissetpropefi holdthedtllsquoretrcfie metol
qnd drivehe |op slowlyintothehole.Hereogoin,useoil qs q
lubricont.lf the|op binds,swihh fo reversE
ond bockit out to
removethebuilt+pmeulfilings.Continue
drillingslowVuntilthe
threodsore cul oll thewoy through.
22
WORKBENCH
!
OCTOBER
2OO3
Youn'GRnRGE
TIPS FROM THE
IS YOURGASTLE,
Giveit theroyaltreatmentwith
a
$:f0,000
MAKE0VIR.
It'sAmerica's
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Contest.
garage
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makeover
courtesy
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garage
a
makeove6andwhatmakes
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lncluded
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q no-slipsolution
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GLUINGWOODSTRIPS
Asseurtrhnqthc fl-r>nt
cclgingrrnclsuppolt pilot holc'sto kec;-rthe nvo prcccs:tliqnecl
fbr tlrc ParrclOtrttitt.qllitrkstatiort
on pagc (sL'L'
Ilhrstrntitttt).This
u,rq rvheu thc picccs
5 0 p r e s c n t s : r r r i r r t c r c s t i n g c h l r l l c n g e . r r r c p u l l e d r r p l r - t ,u l u e c : r n b c l p p l i e d
Thcvl'c crrchnr:rclcup oiincliviclull strips b c n v c c n t h c n r .T I t c u , r r ' h e n t h c p i e c c s
of n,oocl,rvhich n'ill tcucl to slip :rr-ouncl :trc clenrpeclb:rck toscther, thc flnish nails
clur-insslrre-trp.Tirpr-cvcntthis fionr l-rep- kccp thc' pic'ccspcrfcctly :rlienccl:rsthc
1 . . ' l t i r t SI .t r . t . l t l r r i s l r t ; r i l .. r r r r ' g i r t r : r t i o r r qluc cL'ics.
To nrlke' this rvolk, I lr:rclto consiclcr
Pirtsto kccp thc picccs :rliqrrccl.
The blsic iclca hclc is to cl-y cl:rnr;r :r tcrv thrngs rvhile settinq up thc :rsscnrtnrr picccstoqctlrcr,drill :r fcu, pikrt lrolcs, blr,,.()nc is thlt I clicln'tu'nnt the nlils to
r r n t lt h c n i n s c r t t h c f l n i s h n l i l s i n t o t ] t c
shorv on top, so I assenrblccl
thc picccs
r-rpsitlctkx,vn. I did thc top trvo l:rvcls
O]{EGRAilD
PRIZE
tirst,drillirre rhc pilot holcs :urtlirrscrtins
thc rr:rilsthnrugh tltc rrrirlcllcl:rverirrto thc
top (.r11','l
-1.s1'11
tltIy l r',,,,r',,r'r',.
I onlv nccclcclrrbor"rtl/-1"of crrchnlrl
O]IESEGOilD
PRIZE
tt>bc stickinqinto t]tc top,just cnouqh to
grllLrit ilnd kccp it rrlrerrctl.So I clippcd
off thc tips of the rrrrils.For r/1" st()ck.I
$10,000
Garage
Makeover
Tripto a continental
UScity
Frcnt 9upport---_..
trsccl3cl n:rilsrvitlr thc tips clippcd off .
()ncc the ti-st nvo luyers urc trrkcn
Edqlng -\
25 SEMIFIIIALIST
PRIZE
PACKAGES
curc of-,rcpcrrt thc proccss firl thc bot
t o r r r l . t v c t/ { ({ . \ t ( r P. l t .T l r i . t i : r t t ' .r t . r q q r . r '
I5{I i1t;i5itii,*J,f*
EP0XYShield
Garage
FloorCoating
Kits
Lenglh of naill/+"
lonler than lhiakneao
of otook
51E? 1
Drill pilot hole through
m i d d l ea t r l p a n d l + "
deep lnto top otrip
i
n
Finish Naile
@lip tipo off)
ll'
I! RUST.OIEUM'
s t o p p i n gr u s t i s j u s t t h e s t a r t l "
Nopurchase
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Conle$
isopen
August
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15,2003,
tolegal
lJ.S.
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ages
1Bandover.Enter
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at epoxyshield.com,
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ormailenlries,
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Mailerrtry
ina
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prohibiled.
where
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visiteporyshield.com
0r
lbr can dolC
homedepot.com.
frcar
hc!:
5rE? 2
lneert autoff nallinto pilol
holeloralignment
5fE? 3
Repeatbolh 6lep6
for bottom 6tri?
w()l{
t { I I F . NC I I
!
()cT()tJ h lr. loo-l
TIPS FROM THE
for cleoncutsin oluminum
TAPE
DOES
THETRICK
Cr"rttingalunrinunr or-rrt table slrv isn't l problenr, aslong asyou havc a car'bide-tippecl bhde. tsr-rtit does ter.rc'l
to lerve a jaggecl edge (-scclrtsd Photo).
In the past,nry solution w:rsto filc thc.eclgesnrooth.IJut while cuttirrg
the :rlurrrinr-unanqle for the Prcci-siori
RorttcrCrridc
fenceson pagc 5(r, I inrclvertently cut through rr
tnanufacturcr'.ssticker on the workpiccc. ()nce
the cut was conrpletccl,I noticecl thc eclec unclerneatlr tlre stickcr was perfectly stnooth (srcPltoto).
Intrisucd, I rrn a strip of electricirltapc clown
the lc'neth of the next piece of alunrirrunrlngle-.
Then I r'an the urgle rigl.rt tl.rror,rshtlre blacle,tapc
A T o o b t q i n o s m o o t h ,c r e o n
c u t o n q l u m i n u mo n g l e e v e r y
time, run o strip of elechicol
tope down the cut line.
anrl rrll.The tlpe elinrinatccl burrs on tl'rc ec'lgc,
rcsultingirr a snrooth,clcan cut. Norv, I no ktnqcr
hrtvcto spcnclv:rlu:rblcshop tinre filing the edgcs
clcln after cuttinsrllunrinunr stock.
Morepower.
M
H
H
H
o
-c)
l=
F
Product Information Number 288
EDGE
tips& tricksfor using
BAND SA'\I
BTADES
To get the mostfrom your bond sow, get
sovvy obout bond sow b/odes.Here'sorocticol
o d v i c ef r o mo u r s h o pt o p u ty o u i n t h e " k n o w . "
lhree Blcdes - Three Culs
t 4t/2tt-widebloderesists
flexing,so it'sideol
for resowingthick stock.A hook tooth pottern
with 3 teethper inch(tpi)cleorsoutwostequickly.
Band saw bladeslook sir.nple- a thin band of metal with teeth. But the
nunrber of blade choices is a bit bewildering. So which blades do you need?
First of all, no single band saw blade can do everything well.As we build
prqects inthe Workberrlrshop,we've found that three di{Ierent rypes ofblades
will handle nrost any job (seePhotosat left).
Having said that, keep in mind that the narrower the blade, the tighter the
radius it can cut (seclllustrationsbelow).lf a blade is too wide for the task at
hand, the back of the blade will rub
against the side ofthe kerf, so you
cant rrrake a tight turn (Kef Dctail).
Bockof Blode
Touches
Sideof Kerf
l
7a"-wide
\..>
ilsfl
A Fortightcuryes,useon |/s" stondordblodewith
l4 tpi. lt produces
o smoothcut,butwith itshigh
tpi ond smollgullets,it requires
o slowerfeedrote.
28
Vz"-wide
Minimum
Minimum
Minimum
Rodius- 3/ro" Rodius- 5/s" Rodius- 272"
A To mokegentlycurvedcuts,o l/a"-wideskip
toothblodewith4 tpi workswell.Thesmollnumber of teethond wide gulletsmokefor fostcuts.
-)-
7a"-wide
One woy to get o smoolher
curvedcut is to round the
bockedgeof he blodewith
o "funing"stnne[oroilobleot
Rodder.orn
or W?J94A411.
With o roundedboclqthere
oren'l ony shorpcornerslo
get hung up on. Plus,it
decreoses
weor on theblode.
Stortby grindingon ongle
on both bock cornerswhile
thesowis running.Thencqr+
fullyroundthebock.
WORKBENcH
tr ocToBER
2OO3
EDGE
how muchis enough?
BTADE
TENSION
A bancl saw blade has to be tensioned properly to rLln trlre.
Even a ncq sharp blirde will crerte a barrel-shapedcr,rtif it's rrot
stretcl.redtightly betwe'en the wheels.Although most band saws
have a te'nsion gaulie, it'.snot always accurate.
So how clo you know if a bhcle hasthe correct amount of tensior.r?
As r rulc,:r properly tensioned bhde should cleflectapprorintatclyt/q" rvhcn the gr-ridepost is raised all the wly up.
Simple Tension Gauge - An ersy way to check tl-rc tcnsiorr is to usc a conrbinrtion squ:rre.lsJ q:lLrqe.First, sct the
squareso l/q" of thc rulc is cxposed.Align the end of tl-rerule
witl.r the cuttins ec'lgcof the bhclc md clarnp it in placc , asshown
in Plttto 1.Thcn prcss thc bhcle sideways (Plroto2/. If itis corlcctly tcnsionecl,you shoulcl fc'el cirritc I bit of rcsist:ulcc:rsyoLl
push thc blacleagainst tl.rebocly of thc squrre.
Too Much Tension - It is possibleto over-terrsion n bnncl
sew.Atworst.this can c:ruscthc sh:rftof the wheel to bend or brclk.
At best,it shortcns thc lifi' of thc bhcle. My cxpcriencc thousl.r
il
lt.
si"
',1
is that nrorc pcoplc uncler-tcnsionthln ovcr-tcr.rsionthcir blaclcs.
"breqk in" new
Blode StorcAe
To preventrust,coil
the blodeond sioreit
in o seolobleplostic
bog.As insuronce
ogoinstmoisture
hot
mightstillforminside
thebog,giveit o
quickshotof WD40.
!ubricotion
Theheotfiot buildsup
whenmokingo cut
condomogeo blode.
Sympfoms
oregulleb
cloggedwithdustond
o dry, rospingsound.
Foro coolerrunning
blode,wipe on o
sproyvegelubleoil os
o lubricont,turningfie
upperwheelby hond.
30
BTADES
A new blncl s:rwblaclcis extrerrrelysharp.In
fact, sontetinrcsit'.sftroslrarp.If you nrount
a ncw bl:rclcrnd nrrke r heavy cut right off
the bat, thc tips ofthe teeth crn chip, prcnraturcly dulling the bhcle.
Tb urtcicrstandwl.ry this l.rappens,think
of thc teetl'ras being like the tip of r freshly
sharpencd pcncil. If yor-rpress the pcr.rcil
down too harcl,thc tip will brcak. If yor-rease
Lrp though, the tip wears dowr.r :r bit so you
can pressharder withor.rt bre'aking it.
Break-In Period - The sanre thing
applies to a band saw blade.To get thc nraxirnunr lifc fionr a new blacle,it neeclsa short
"break-in"period.Thc icleais to slow down
thc fccd rate,rpplying only about one-third
the pressurefor the first ten nrinutes of sawing.This r-educesthe initial sharpnessof the
teeth, but the blade will stay sharp longer.
This break-in period is especiallyinrportant for l/s" and 1/+" bladeswith a higher
number of teeth per inch and a standardtooth
pattern (teethat 90o to the back ofthe blade).
WORKI]ENCH
tr OCTC)BEI\
r1
'il
2
divide& conquer
EDGE
INSIDECUTS
'IfuAKING
Usually,making an inside cut on a workpiece is the job of a scroll saw or jig saw.But if
you're working with thick stock,thesetools aren't up to the task.That'swhere a band
saw comesin handy.The idea is to rip the workpiece in half to exposethe inner areas
(Photol),make the inside atta (Photo2), and then glue the piecesback together (Photoj).
For best results,make the initial rip cut with a narrow blade that has a large number
of teeth per inch. (I use an 1/s" standardblade with 1a tip.) This createsa smooth surface that makesfor a virtually invisiblejoint line when the piecesare glued together.
A Tomokeinsidecutson o bondsow
on l./s"blodeond o
stortby instolling
rip fence.Thenusingo slow,steody
feedrote,rip theworkpiecein holf.
A Usingthesomeblode,go oheodond
moketheinsidecuts.Tomokeit eosyto
(Fig.3), don'l
clompthepiecestrcgether
moketheoutsidecutsiustyet.
A Now glue ond clompfie pieces
(Spring
clompskeepfie ends
together.
oligned.f
Whenthegluedries,mokethe
outsidecutsond removethepottern.
YOI,TREPROMBTYA
LITTTELESSAMBITIOUS.
Itllhefterpu ae a doit-yomelbr, a goEssimd
woodrcrker or sqnelrrherein bdwen, 1ou hanea
rlorld full of peiects h the horneor in the sfiop ttd
will b6 ecfer ard more€njqpble to comple when
)ou useqrJalrtydarnps,benchvise and miter
bores/sarc frornfie AdjrctableClampCompary
took br fi€rn mder the Joqensen,Adrsbble and
Ponybrandnarn6 whs€r,trfine toob arc sold.
lAft anrnabsteaN rWNq forour
100tHArnivelsruy
rcO-@ Mrp,
miFrsnwaldvissefgiveailW,
"
&liustable
- ".Jo€gnggd'Eb,Lg".
Madein the USAby the AdjustableClampCo' 421N. AshlandAve.,Chicago,lL 60622, www.adjustableclamp.com
ProductInlormatlonNumber218
A NE\V SLANTON
SHEVING
Now I know, cutting and fitting dovetailjoints can
shelf focuses yottr attention on
$ sually,:r displ.ry
1 ,t.r. itenrs that are on, well, display.But with this be a bit intimidating even for a seasonedwoodworker.
$'
slent-lront shelving prilject, that'.snot necessarily Because of that, we've conle up with a nifty techthe case.With its angled desigrr,contrasting woods, nique that rnakesit considerablyeasierthan it looks.
Dovetail Keys - The secretis a set of dovetail
ancl exposeddovetailjoints, the shclving unit itsclf is
"keys" that are machined on a rcuter table.Thcsekeys
onc of the star attractiott:.
'arescrawedto a wedge-shaped block at the top and
still have to be sturdy
Appearance rsicle,tl.resl.relves
to the shelf supports, and then fit into dovetailenough to kecp your valuablessafe and sccure.To
:rccorrrplishthat, they'rc supportecl by tall, A-sl.raped shaped dadoes in theA-franres (seeDovctailJoincry
fiarnes ancl thick shelf supports .rsscnrbledwith strong Dcrail).Besidessimplifiiing the joinery, this hides
the screws,producing a strong, attractivejoint.
clovetriljoir.rts (sccl)hoto at riqht).
.
VIEW
CONSTRUCTION
m
lll ro
A-Shopedfrome
suppoits shelves
I ll Reor
f,lo
ll'o''rt'
ft
A Strengthond good looks
- two reosonsI useddovetoilsto ioin the AJromesof
thisslontedshelfunit.
!lfl
Shelvesore screwed
to supportsfor
loterol rigidity
H
( -#8xlVz"
j,r/ FhWoodscrews
\l-c
DoveroirKey
35
buildingthe
A-FRAMES
One thing that eives this prgect its distinctive look are
the two A-shaped fi'ar-nes.
Each frame has a vertical rear
upright and an angled front upright (sceA-Frcme Errd
tl/t I
,\. I
t:-
I
131/n'
12"
Zcrr,).Notice too that therei a seriesof dovetail dadoes
in erch upright to hold the shelf sr-rpportsand a wedgeshapedtop connector block.
An in.rportantconsiderationin building the A-frames
is to rrr:rkesure thrt cacltpair of dadoesis accuratelyaligned.
To :rcconrplish th:rt, I r.rsed:r process that involves layrng
out the dadoes in two extra-wide blanks, routing the
c'hdoes,l.rd then ripping the blanks to widtl.r.
Prepare Blanks - The first step is to prepare two
'l
blanks fionr "-thick h;rrc'lwood(l used r.naple.)Rip thc
blanks extrr-wide (rt least 6") so you can laet rwo rear
A The key to buildingthe AJromesis to
occurotelv
tronsferlocotionsof thedodoes
fromthe reor to the frontuprights.
upriE5l-rts
f}om one and two fiont uprigl-rtsfiicn-rthe other.
Top
Conneclor
II
TAYINGOUTDADOES
SIXTH:
(seesidebor,
p. 37),
Cutdovetoil
dodoes
lrl"
I
then rip
II
'if
I'i
tl
|'r'
tl
FIRST:
Mork the centerline
of eoch ..- ReorUprights
dodo locotionon reor upright
lseeA-FromeEnd View for locationsl
!
2Vz"-wlde
Fronl
Uprights
,/
SECOND:
Clompblonkstogether
withiop connector
in'ploce
FOURTH:
Usingo squore,
tronsferdodo locotions
lo frontuprighl.
FF;:
/
Usescroppieceos
o guideto morklength
ond bevelongle
of frontuprights.
THIRD:
Clompscropsquoreto the
reor upright,ond flushwith
its bottomedge.
SupportBlock
Centerlines
A.FRAME
ENDVIEW
L
I
4u3"
tt
-tb
w()l{KBENCH
!
()CTOIIER
2003
As for length, go ahead and cut
the blank for the rear uprights to
length (75"). But let the blank for
the front upright"run long" for now.
One thing to note is that the top
end ofthis extra-long blank is beveled
at 12", which will match the angle of
the front uprights. Later, the bottom
end will be beveled at this sameangle.
Lay Out Dado Locations -The
next step is to lay out the locations
for the dovetail dadoes. Start by laying out the centerlinesofthe dadoes
on the blank for the rear upright only
(A-FrameEndWeu).
These centerlines will be transferred to the blank for the front
uprights. But first, you'll have to
position the blank at the same angle
as the front uprights will be once
the project is assembled,specifically
at a 12" angle to the rear uprights.
easyway
Top Connecgel -f,n
to establish that angle is to make the
wedge-shaped top connector that
joins the uprights.
Ultimately, you'll need two top
connectors (one for each A-frame).
But for noqjust make a single block
thatt long enough for both of them.
This block is made by gluing up nrvo
1"-thick pieces of hardwood, and
then bevel-ripping it (see the Top
ConnectorDetail).
Now you can go ahead and clamp
the beveled block between the blanks
for the uprights.This is what establishesthe angle of the front upright.
It's also a good idea to clamp a
scrap piece of wood acrossthe lowel
ends of the blanks (seeLaying Out
Dadoes).Thrs"fixes" the width at the
bottom of the A-frame.
At this point, simply use a square
to transfer the locations ofthe dadoes
from the rear blank to the front (see
Photoon page36.)
The scrap piece comes in handy
for something else too.You can use
it to mark the final length of the
blank for the front uprights.
Routing the Dadoes
Laying the dadoes out accurately is
half the battle.The other halfis routing the dovetail dadoes.To do that,
I used a hand-held router, a 7o dovetail bit, and aTlsquare fence to gr"ride
the base ofthe router (seeSidebar).
After routing all the dadoes,itt
just a matter of bevel cutting the
bottom end ofthe blank for the front
uprights.Then rip the front (A) and
rear uprighs (B) to width (seeRipping
Detail).FinalJy,trim the r'vvotop connecrors to length (2t /2").
A I purchosed
o
32" dovetoilbit
lZ"f to routthe
dodoes.lt'sovoiloblefromRockler
(#91l1!ot
or
80G233-9359
www.rockler.com
An eosywoy lrcensureconsisbntresults
whenroufing
thedovebildodoesislrcclompo T*quorehnce lo fte
ond useit b guidetheboseof lhe roubr.
workpi€ce
Thedodoesorecutin firee posses:
lwo successirrely
deeperposses
wih o t/2trshoightbit Figs. I ond loJ
ond o finol posswith o 3/andovetotbit (Fig.2l.To
sovelime, mokeo/l he culsof one setling,reposilioninghe bnce br eochsubsequent
setfing.Then
repeotthe processbr theotherlwo setups.
Thismeqnsyou'llhoveto positionfie bnce sothe
roubr bit is olwoyscenleredoverlhe previouscul.
Todo hot, clompthebnceb o scroppieceond rout
o dodo in the "hEod"of the bnce. Thenusethot
dodo os o rebrencewhen lining up lhe bnce, os
shownin FiguresI and2.
Routo Tz"dodoin
Auxiliory
heodof fence,thenolignit with roubr boie
loyoutmorks%"on eilher ,;..qra'*
)
wORKBENcH
tr oCTotsER
2OO3
Routo dovetsil dqdo in
heod of fence,ond olign it with
37
"k"ys" to
SUCCESS
One of the most interesting parts of this project is the
use of dovetail "keys."Attached to the ends of the shelf
support and the top connector, these keys provide the
strength and classicgood looks ofdovetailjoinery.
Shelf Supports - Before making the keys though,
turn your attention to the shelf supports.They span the
opening behveen the uprights like rungs on a ladder.
Altogether, you'll need five shelf supporrs for each Aframe.They're made from 1"-thick hardwood (maple)
and ripped to the same width as the uprights (21/2").
Before cutting the supports to length, the thing to be
aware ofis that one end ofeach support is beveled at a
12" angle to match the front upright.The other end is
A Toossemble
theA-fromes,
opplyo thinfilmof glue
to the leodingedgeof thedovetoilkeysond top the
shelfsupportsinto ploce.
left square to fit against the rear upright.
With that in mind, you'll need to cut each shelf support to length to fit between the uprights.To produce
a good fit, dry-clamp thc A-frame together, as shown
in the lllustratiorz
below.Then, working with extra-long
pieces,cut a bevel on one end, hold the piece in place,
and mark the opposite end (seeLayout Detaik at left).
lhe Key Elernent
After trimming the shelf supports to length, it's time to
get started on the dovetail keys.As I lnentioned, these
small wedge-shapedblocks are machined separatelyand
then fastened to both ends of the shelf supports and
SIZING THESHETFSUPPORTS
FIRST:Foreochsupport,
cul o I 2o bevelon one end of
o l "-thick,extro-long
blonk
SECOND: Setbeveledend ogoinsl
front upright(seedetoilol
ReorUpright
Supforts
FrontUpright
Scropblock
for support
NOTE: Tooccurolelydetermine
lengthsof shelfsupports,
clomp
A-Frometogetheros shown
ScropBlock
3tl
wol{KTJENCH
tr ocroBEli
2003
tl-rewedge-shapedconnector blocks.Thc keys rre urade
using a router t:rble rnd the srure 7o dovetail bit used to
cut tl.re dadoes in tl're uprighrs (seeSidebarbclow).That
way, the anglcd sides of thc keys and the dadoes are
certxirl to nratch.
To avoid working with small pieces,it'.sbest to nrake
the keys by routing both edgesofatr extra-lorrgpiece
of 3/+"-d.rickstock.TI.renaftc'rtrinlning offthe "keyed"
part of tlrat workpiece, thc inclividr-ralkcys (l) are crosscr-rtto their final 21/2" lengtl'r.
Attaching the Keys - Once the keys are nrrde, it'.s
just a nuttcr of attachins theur to the shelf supports.The
idea hc'r-cis to center the kcys on the //tirA,rr-$of the suppt-:rts(S/rirrrDetail).Todo tl.rat,I used two angled sl.rinrs,
ls shown in thc' P/roftrabovc.
Tl're shirrrsarc easy to nrake.Sirnply rip a strip frortt
sonre cxtla key stock on the table srw (Dctailsa atrd b).
Notice that there arc two difterent table saw setups,
one to nrake the shinr ft>r the rear kcys ancl the othcr
for thc front keys.
To prevent the shirttsfronr slipping around, attach
thcrrr to tlre bench with doLrble-fircetape.Therr butt the
the :rppropriateshitn, sct
end of a shelf support :rgrir.rst
l key in place, lncl drill holes for thc tnoutrtit-tgscrcws.
After iastening tl.rekeys to tl.rc shelf supports, you'll
also r-recdto install kcys on the top conllectors. Here, I
luligncdtl-rekeys to u ceuterline otr thc top connectors.
Assemble A-Frames - At this point, you're rerdy
to assenrblethe A-franrcs. I fourrd it easiestto start with
the top connector, applying a thin fihrr of glue to thc
keysand then tapping the block into placc.Thcn I'epcat
the process frrr tbe shelf supports, working yoLlr wty
Zerc
Cleoronce
Inserl
clown, as slrowt.tirt the 11roloon plge 3tl.
There'snothingcomplicobdoboutmoking the dovetoilkeys.But it doestoke
gellingthemto fttiustright.
somepofience
RoutKeys- Stortby mountingthe
dovehilbit in theroubrftrble.Theexoct
heightof he bit isn'tcriticol,it justneeds
b be higherfton thedephof thedodoes.
(l setthebit ot z/s".)
Nor odiustthebncesohe bit "gmzes"
theworkpiece{osshown)ond mokefwo
po$ies,oneoneochsidefFlgs.I ond loJ.
Thencheckthefttof thekeyin oneof the
doretrildodoes.lf needed,nudg firebnce
owoyfromthebitqndrepeotheprocess.
TrimKeys- Onceyou get o snugftt,
ifs justo motbrof usingthebble sqwic
Fimfie kry*ockfiomthe blqnk,osshoum
in Frgs.2 ond 2o.
woRKBENcH
tr ocToBER
2OO3
3/n"-thick
blonk
for keystock
A Twoongled
shimsmokeit
eosyto center
the dovetoil
keyson the
of the
thickness
shelfsupports.
SHIANDETAIT
I
Shimfor
front keys
I Blode
-+4 nrr"a
, Hl
to7"
NOTE:Moke two
posses,one
on eoch side
3/d,
Doveloil
Bir(7'l
-: 'o'f-
cherryon top
5 SHELVES
A A set of five progressively
wider shelvescompletesthisslont-front
shelvingunit.They'resimply
screwedto the shelfsupportsfrom below.
SHETF
CONSTRUCTION
@
@
Front Edging '
l3/t"xl/t" x 48"1
(mitertrofitl
Shelf
(%" x voriousvidths x 4V/z"l
(seeMoieriolslist for widfil
Toinsbll shelvis,slipfront
edgein plocefirsl,'lhen
fit cleo-'tbetriveenreor uprights
lO x lVz"
40
The shelvesin a project are usuallymore functional
than anything.But thatt not the casewith this slant-front
shelvingunit. To createa distinctivelook, I made the
shelvesfrom cherry to contrastwith the mapleA-frames.
Sizing the Shelves - The five shelvesare identical in length. As for width though, they "follow" the
shapeof theA-frames.Thatis,they'renarrow at the top
(the upper shelfis 3ll+" wide), and they get progressively
wider towardthe bottom (thelowestshelfis15"-wide).
Regardlessof their size though, all of the shelves
3/+"plywood panelswith thin
0, K, L, M, and N) are
stripsof solid-woodcoveringthe front edgeand both
ends (seeShelfConstruction
lllustration).Thisedging (O)
is simply mitered to length and glued in place.
All thatt left to completethe shelvesis to attacha
hardwoodcleat(P) to the back edgeof eachshelf.The
purposeof thesecleatsis simple.lVhenthe shelvesare
installed,the cleatsfit snuglybetweenthe rearuprights,
addingside-to-siderigidity to the unit.
Install the Shelves - After gluing the cleatsin
place,itt time to installthe shelves.
I found it easiest
to
do this with the shelfunit restingon its back (seeFig.1).
Startby slidingeachshelfthroughits respectiveopening in theA-frame and then tipping
the front edge into position first.
Then lower the back edge of the
shelf in place, fitting the cleat
between the rear uprights.Finally,
fastenthe shelvesto the supports,as
shown in rhe Photoabove. M
A ( 2 ) FrontUprights(mapte)
l" x2r/2" x7643/aq"
B ( 2 ) RearUpriglhtslmaptey
,u ^2t12,,X75,,
c (2) Top Connectors(mapre) Le/sz"
\21/z'x2L/z'
D ( 2 ) Shelf Supportslmaptel
tu ,2r1r,'x 4,'
E ( 2 ) Shelf Supports(mapte)
!" x2r/z'ix63/a'
y2112"
y9t/s''
F ( 2 ) Shelf Supportslmaptel
1,,
G ( 2 ) Shelf Supportslmaptel
t" X27/2',
x t2r/+',
H ( 2 ) Shelf Supports(mapte)
,,, ^2t1r,,x 16,,
r1r"yt/2" _ 10 lin.ft.
| ( 1 ) DovetailKeys(mapte)
z1o"x3r/t, x 477/2',
pty.)
J ( 1 ) Shelf (ctreny
3/4,xS!/2, x47t/2',
pty.)
K ( 1 ) Shelf (cherry
t1o"vgr14ux47t/2"
pty.)
L ( 1 ) Shelf (cneny
3/+';xtlt1r" x 47r/2"
pty.)
M ( 1 ) Shelf (cneny
,t1o"xt5"x47L/2"
pty.)
N ( 1 ) Shelf (cnerry
t1o'iv3g'- 4o lin.ft.
o
Edginglcnenyl
s14"x l,' x31,,
P ( 5 ) Cleatslcnenyl
HARDWARE
. (20)#10x IL/z'FnWoodscrews
. (48)#8 x 1"FhWoodscrews
WORKBENCH
tr
ocroBER
2003
G.I
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o
'ag
\t
'\b.
\I
,)*_
fr
il
<errfr-;
Hovingo gorogeshopoftenmeonshovingto choosebetweenoneor
t h eo t h e rl.t ' se i t h e or g o r o g eo r o s h o p ,b u tn o tb o t h .B u tw i t ho b i to f
p l o n n i n gt,h e r i g h tt o o l s ,o n d o f e w c l e v e rp r o i e c t sy,o u r e o l l yc o n
hoveo shopin yourgoroge- wifhoulexiling
yourcorsto thedrivewoy.
WORKSTATION
T h e s es p o c e - s o v i nsgt o r o g ec o b i n e t sh o v eo h i d d e ns u r p r i s e - o s t u r d y
,(
|
|
supportormthotextends
ouTror cunng torgeponetsto stze.
n tlrc pl:urnine pl'r:rse
of tlris girlilgc
shop,trvo thinus to1-rpccl
rny rvislt
list-stor:tgc firr tools :rncl su1.r
plics and :r rvorkstrrirr'clurgc enouqlr
to l-rlnclleshcct goorls.
six"uppcr"c:rbincts:rt:lhourc ccntel.
A look rt thc Col-rfrtrctittrr
ViL'rt,
Thcsc cebincts :rrc r>nly 12" clccp on p:lgc 51 shorvshorv c:rchpuir of
(corrr;rrrrerl
to 20"-clccpblsc cabiners). cabine'ts is connectccl. Notice that
This kccps the rvorkstrtion fron
tlie lircc fi'auresof thc cabiuetsar-e
cro'uvclingthe garlqc-,yet the slilllo',v screwed tosethcr (CdbinctAssurful1,
T h c p r o b l c n r n ' : r sb o t h t h i n s s cabirretsotlcr plenty of storrse.
Illrtstratiorr).
Orr nry clbiners,thc-[rcc
coulcl qobblc up lots of sp:rcc.So tcr
Asscmble Cabinets Thc
fi'aruesextenc-lcci
prst tl-resiclcsof tl'rc
ect thc bcst of both rvorlcls,I rnstrtllccl :rclvlrntugeof instrllinq storc-bought crbinets Lry I/q", crenting a 1/2" qap
rrsct of conrplct stor:lqcc:rbinctsancl c:rbinetsis otrvious
it'.scprick,:rncl betweerrtl-rcsicles.
So I nracler l/2',lclclecl:r top with :r pr-rll-out :u'n) to
it's easy.Four crbinets, lrrrlngecl in
tl'ricksp:rccr-,insertccl
it between the
sltpport hrqe prltels (su' Pltotttahout'). p:rirs,support the worksr-rrdrce.
Thc
cabincts,and screweclit in place.
Space-Saving Storage - To
othcr two c:rbinets:u'cnrounteclto
Build a Base -'With the c:rbacldrcssthe stor':rgcissue,I prtrchasecl the wall rrbovethe station.
inetsjoincd toqethcr in pairs, I set
5i)
w()l{KBENCH
!
()cT()llF. I{
2003
Consfruction View
W x 295/e"D x 353/a"H
OverallDimensions(withtop extended):73112"
CobinetTopAssembly
(seepoge52)
NOTE:The"upper"
cobinetsshown
hereore
12" deep,
36" wide,
30" inchestoll.
@
FillerBlocks
SpocerStrip
l/2" x lVz" x 30")-
Sz
in cobinel
#8 x2Vz"
Fh Woodscrew
Cobinet
,- #8 x2Vz"Fh
Woodscrew
{
T shz"shonkHole,
-V
|
upe
,Countersunk
@
BoseFrontond Bock
(3A"x3Vz" xllVz,'l
@
FillerBlock
( 1 "x 3 " x 9 3 h " l -
i
Ol
Mou-nting
iio.['t.,
3h" Dodo,'72" deep
'|
11
,
|
\\
t' l"recess
under
cobinet
F.,,
FillerBlock
34" Robbet,
Vz" deep
)
\\
#8 x l7z" Fh
NOTE:
Dimensions Woodscrew
CenterDivider
l3/t" x3Vz" x ld/a")
moy cnonge
bosed on size
of cobinets
x3rhtt x ldZ")
131a,'
:rbout br.rilc'lingr basc for thetrr tcr
sit on. Iti nudc fronr 34"-thick harclwood (urapleto rlratch the cabinets).
The b.rsers sct in r/1" frorrr thc flec
of the cabinets,and the sides rrncl
four rnounting blocks (l)) are
screweclto the base as r surftce for
sccuring tl-rec:rbinets.
Install Cabings5 - To install the
cabinets, start by attaching filler
brck fit flush.
One thing to keep in nrind
when sizins the baseis the joinery.
The fror.rtand back (A) rre rrbbeted
to hold the ends (B) and a centerecl
dado acceptsa divider (C).After cutting all these pieces to size, they're
glued and screwed together. Then,
blocks (E) to the recessttnc-lerneatl't
the cabinctswith double-sidcd tape.
Then set the cabinets on the base
:rnd screrv down throush the cabinets into the nror.rntingblocks (Bn-v'
MorttttittgDctail). For a penuanent
w()l\KttENcH
fl ocrT()BEl{
installation,screw throLlgh the backs
of the cabinetsinto the wall studs.
2003
51
mqkeq multipurpose
GABINETTOP
In addition to creatinga flat, durableworksurface,the top of this
worksation hasa slide-out arm that providesextra support for large
workpieces(seePhoto).Phts,
a setof metalT:tracksinstalledin the
top hold accessories
for clamping a workpiece securelyin place.
Thrde Layers-The top is constructedfrom three layersof
3/+" medium-density fiberboard (MDF). As you can see in the
Tbp ConstructionView,
the middle layer consistsof three evenlyspacedpanels (F), which are sandwichedbetween the top (G)
and bottom panel (H).The spacesbetween the middle panels
form openingsin the top for the sliding rails of the support arm.
Dadoes for?tacks-After
cutting all the panelsto size,the
next step is to rout dadoesin the top panel to hold theT:tracks.
I sizedthesedadoesfor some aluminumT:track that I purchased
&om Rockler.com (800-279-4441).If you build two tops like I
did, you'll need two 4-ft. lengths of T:track (Item#21753).
Top Assembly-The top is held together with glue and
A Themostuniquefeotureof thissturdy screws.I didnt want the screwsto be visible,so I assembledit upside
top is o support
ormthotslidesin ond
down using the assemblysequenceshown on page 53.
out,doublingthesizeof theworksurfoce. Start by laying the top panel face down on a flat surfaceand
setring the three middle panelsin place.To createthe openings
TOPCONSTRUCTION
VIEW
32"'wide
dodo,h" deep
lvtebl T-Trsck
CenbrthiSdodo
on lengfi
of bo
' NOIE:Frontedoino
is modeupof fiie
%"-thickstripsof hordwood
a
ronoPpsLr
PZ"MDFx 16"x72"1
SupportAnn
Assembly
lseepoge541
#20 Biscuits
Roils
EndCop
Ph" x2rh" xl&h"l
52
inb openings
in iop
3316"-wide
opening
hr roilson
supporlorm
woRKBENCH
tr ocToBER
2OO3
fbr the rrrils,tl-re nricldle purels rre
scpill:rteclby r set of tetnponry s1'rrtcers clurinq assenrbly.I nrade thcse
spacersl/s" tt,iricrth:rn the rrrilson the'
support lnn.Thrt wly, otlce tl-retop
is lrssenrblecl:rnci the sprccls rlre
the rails woll't bincl wllell
renrovec'1,
you slicletl-resupport iurtr ilt :rlld otlt.
Anothcr thing to be :tw:uc ofis thc
locatiou of thc sct'ews.Yotl'llw:rllt to
rnrrkc'surc they c{on't line up with
fbr tl-reTln'rrcks.
thc clrrcloes
Aftcr gluing urcl screwitrs thc
t ( ) F . l n d r n i t l d l r ' [ 1 : l t l e l st o g c r l l c r .
rclllovc the spnccrsencl scrrpe ofF
luny ulttc' thut sclucczeclottt, ns this
cor,rlclinterfere' with the nlovelllcnt
of thc support ilrlll.Then, :tpply rt
/iglrrfihrr of gluc' to tl.rcnriclcilep:tnels unrl rrttrrchthe bottout p:rnelwith
gluc urcl scrcws.
cover the exposccl
Edging-Tb
hrrtclfr-ont eclgeof thc to1'r,I :rclclccl
woocl eclsing (l). Itls cortrpriscclof
fivc l/+"-thick stlips that flt rnruncl
thc openiuus in thc to;r, cssclltirlly
fbrnring "nrortiscs" in tl-rc'eclqinq.
locute thcsc "trtorTir :rccr.rt'lttely
tiscs,"I uscclthc top, with thc sprtccrs,likc a sluc-up tenrplntc.Thc iclcrr
is to flt thc spncclsinto tlrcil rcspcctivc clpeuirrrsrtnclthe'rtclry-:rssenrble
thc ecigingstrips rttottucltltettt.
Ti; help :rlien thc strips cltrrinu
this clry :rsscnrbly,rncl to kccgrthcttr
t i o r r r s l i p p i r r q: l r - ( ) l . r nd(tlr r i r r gr - { l u e rup.I rrscdlirrislrrr.rils;rslcrristnriott
pirrs.(llclir to pauc21.litr utoft'on tltis.)
Oncc thlt's clonc, rctrrovc tlrc
strips rurciglue theut togcther ott tlte
bench. Whcn tlre glue cfi'ics,clerrn
rupthc edging nuclattrrchit to the top
with biscrrits rrnclqltre ( I3isn ri tJoi rtt'ry
THETOP
ASSEMBTING
NOTE:Topossembly
is shownuosidedown
#8 xl7a" Fh
FOURTH: Removespocers
ond cleonup glue squeeze-out
..{'i}
NOTE:Don't
locote ony
screws over
dodoes (indicoted
here by red lines)
FIRST:Lirytopponel
foce down on flot surfoce
SEGOND: Usesoocersottoched
topeto
THIRD: Glueond screw with double-sided
positionmiddleponels
middleponelsto lop ponel
FIRST: Align botiomponel
so it's flushwith top pone
oll oround,thendrill screwholes
#8 x l7a"Fh
Woodscrews
Usesquoresf,o
corefully
olign ponels
before glue-up
ToP
NOTE:Don't locote
ony screwsover
openingsfor roils
(indicotedhere
by red lines)
SEGOND:Glueondscrew
ponelto middleponels
bottom
THIRD: Scrope
ondsondedging,
FIRST: Inse*
thenottochit to top
SECOND: Remove
spocersinto top,
withglueondbiscuits
edgingslripsond
thendry-ossemble
Detoil)
Joinery
gluethemtogether (seeBiscuit
edgingstrips
oroundthem
EndCop
on bench
Topond Botf,om
EdgingStrips
x3/tt x
13141
Temporory
sPocers
Dttail). I rrlso rrclc.lecl
two cttcl crps
with biswhich
:rre
nlso
:rttrchcd
fl),
cuits rrnclgltre.
Now all
Install T-Tracks thnt'.sleft is to instrrlltheT-tr:rcks.lf
you look at the ?1Tllrf Dcrnil on
plge 52, you crln see thnt the nlr.rnrir.rur.r.r
trrrck is set in fl'onl tl-rcback
ecigc of tl.re'top.This setback :rllows
y ( ) r . lr. ( )i r r s c r t t l r c c l l r r n p r r t t:{t t ' , ' c s s o r i c s . W i t ht l r . r ri r r r r i r r d ,c r r t t l t t ' T trrck sectionsto lenlth ancl screw
EndCop
NOTE:Use
finishnoils
to keepslrips
oligned(seepoge 24)
FOURTH: Attoch
end copswith glue
ond biscuits(see
BiscuitJoineryDeloil)
thenr into thc c'ladoes.
w()llKrJEN(i Il tr ()cT()BEIr
2003
53
SUPPORT
One of the handiest featuresof this prqect is a pull-out
support arm. It consistsof four rails that slide in and out
of the openings in the top and a long front support.
Ready for Rails -To
prevent the arm from binding, the rails have to slide smoothly without much play.
To accomplish that, I planed the rails (K) 11,/16"-thick
(1/16,"lessthan the height of the openings) and ripped
them 1/s" narrower, ending up with 31l.1"wide rails.
The next step is to rout a shallow stopped groove ln
the bottom of the rwo rails that will be used for the outer
rails of the assembly(seeDowel StopDetail).These grooves
are one part ofa "stop" system thatt added later.
I usedfinish
noilsto olign
stripsfor the
frontsupport,
both in the
dry ossembly
(Photoabove)
ond for glueup
(lnsetPhoto).
Front Suppoll-\qw
you can turn your attention to the front support (L). Like the edging, iti made
of hardwood strips. Only this time, the railsare inserted
in the top, and the strips are dry assembledaround them,
forming the "mortises" for the rails (seePhoto above).
One thing to note is the thicknessof the middle strips.
To produce a tight-fitting joint, these strips match the
thickness of the rails (11ltc").The upper and lower strips
.-t/s" dowet,
-I9.I'Pti:
^'nuPsroe
.t
-
,o
vvrrer,
I " long
I
BotbmPonel
are thicker than their counterparts on the front edging
(2s,/32").Thisway, when you glue up the front supporr
(InsetPhoto),it will match the height of the edging.
When the glue dries, glue the rails into the mortises,"pin" them with finish nails, and install the arm.
Stop System - Now all that's left is to add the second part of the stop system- a dowel installed underneath the top.The dowel fits into the groove on the rail
(StopDetail).This way, when you slide out the arm, the
ends of the grooves in the outer rails contact the dowels, preventing the arm fron-rpulling all the way out.
Vz"-wldesbpped
grq)ve,3/g" deep
SUPPORTARIU ASSEMBTY
Upper/lower Strips
of FrontSuooorl
l3/4"xE/32" x
NOTE:Test-fit
supportorm
in top before
finolglue-up
25/32"
e
FrontSupport
N
\-
pt1r5,'
x 3V4,,
x lV/2,,1
Dowel stop
(seeDeloil obove)
EndStrip
l3/4t xtyr6n x7/snl
54
ll/'16"
MiddleStrips
xtl/tott x 195/e"l
1314tt
Stopped groove
(seeDebil obove|
wOI{KBENcH
tr ocToBER
2OO3
;>r
BENCH
Accessories
Shop-ftlerde fhini-Clcrmps
routir-rg,or planing, it',sa nuisanceto have
When yor-r'resar-rdir-rg,
to keep rnoving the clar.npsthat hold tl-reworkpiece so tl.rey're
not in the way of the tool. These nrini-clat.npssolve th:rt problenr.They're only 1/2" tall, so they sit belotuthe surface of 3/+"thick material. which is what I work with r.nost often. With
tl-reir1ow profile design,the clamps won't interfere with the tool.
Eacl-rclanrp consistsof two snrall wood blocks:a clanrp head
tl'rat slidesalor-rsthe T:trrck and a pressureblock that, like its natne
slrggests,applies prcssure against the edge of a workpiecc.
-fhe
lllustratiorrat risht will give you an ider of l.row the
clan'rpswork. Notice that a nr:rchine screw passesthror"rgh l
hole in the clanrp hcld anc'linto a threaded hole in :r srnall
nretal blr.Tiglrtening the screw pincl.resthe bar aeainstthe Ttrack,"locking" the clanip in place (Htd Vicu,Dctail).
The actual clanrpine prcssnrcis prodr-rcedby nvo nrore nr:rchine
screwsthat thleld into the clarnp head and into counterborcs in
thc presstrreblock (Tp Vicrt,Dctail).As you tiehten thcsc screws,
7sz"ShonkHole,
Countersunk
ClompHeod
lO'24 x3/r" Fh
\
lf-li'""('
\
/\
I
Sondpoper
strip
they pr-rshrsainst thc block, which
pressesagainst the workpiece. To
keep tl-retwo blocks fiorn conring apart,one last nrachinescrc'w
passcsthrough l cor,rntcrborein
thc ;rr-cssurc
block anc'lthreaclsinto
l l.rolcin the clanrp hcacl.
Firr:rlly,sanclp;rperis attacl'rcclto
thc' lace of thc pressureblock to
i r r r p r o v et l r e g r i p o i t h c . l : r r r r p .
'-qF;
Auxilicrry Support Block
SerurSlrelf
Sonretinresa workpiece is too narrow to fully support the fence.
That'.swherc this auxililry sllpport cor.r.rcs
in. lt l-rolclsthe llr-srrppttrtcdprLrtof the fence level with the sulface of the workpiecc.
Tl-re opening between
thc crbincts is iderl for
Tl.re support is a hardwoocl block with r bolt thrt sliclcsin
tl're T-track (Errd Viur,).To
nse the support,sinrply fit r
l"rolc in tl'rc'fencc ovc'r thc
bolt.Thcn clarrrptlrc fencc
rvith n nrctal hold-rlown
t,g"
crosscntting boards t<r
lcngth.To kecp rrry circnlar s:nv witlrir-r crsy
rcrch, I installecla sirnplc shelf in thc openine
anclsct:r tmsh cartbckrw
it lirr cr,rtofti (srcPlrcto).
Tl-re sl'relfis nothins
*,
;"
s'
|
rnolc thrn a pic'cc of
3/+"-thick Ml)F that's
cut to fit between tl-recabinets.A notcl-r for the blade ancl the
blaclc guarcl al1owsthe saw to sit flat on the shelf.And r strip of
hardwoocl covers the fror.rtedge of the shelf.
A11tl-r:rt'.s
needecl to support the shelf is a couple of cleats
r-nounted to the cabinets.Just be sure to locate the cleats far'
enough down so the saw is below the top of the cabinets.
55
'$rxhir
ROUTERGUIDE
profiles
ore oll stondord
Custom-fit
ioinery,iointededges,ond decorotive
routerguide.And duringeochof these
forefor thismicroodiustoble
occurocyis outomotic.
operotions,
,"'stdrc.outers are frequently praised as the most versai; tile tool in any woodshop.And I wouldn't exacdy
1fr!#;i
rn disagreewith that. But it seemsthat routers get
lrl
:' a lot of credit thatt actually due the accessorres
t
that truly stretch the capabiliry of the tool. Without the
even the best router is little more than
right accessories,
match dadoes and grooves perfectly to any thickness of
stock.Also, once the guide is "fine tuned," you can make
identical cuts over and over - without having to change
the setting. (For more about how to use this microadjustable router guide, see page 61.)
'What's
more, the fences in this system double as
a good tool with untapped potential.
This shop-made guide and fence system is a perfect
example of what I'm talking about.Whether you use a
plunge router (seePhoto at left) or a fixed-base router,
edge guides for your circular saw.This makes this system almost as versatile as the router itself.
this system can quickly and easily transform your router
into a handheld edgejointer (Fig. 1),rabbeting and dadoing machine (Fig.z),and even a shaper (Fig.3).
More importantly, it performs all of these functions
with pinpoint accuracy.
Adjustable Guide & Fence - To guarantee that
kind ofaccuracy, the router is attached to an adjustable
guide that slidesalong a metal fence.As you d expect, this
fence ensures a perfectly straight c:ut.But theret more to
it than that.The guide itselfhas a built-in mechanism that
lets you customize the width of cut. This way, you can
* EDGE,OINTING
BOARDS
i:.:.-,..---
- DADOES& RABBETS
Hereoneof the
long fences
serves os on
edgeguidethot
letsyou ioint o
stroight,squore
edge- perfect
for gluing up
solid-wood
ponels.
" FLUTES,GROOVES,& SLOTS
Routingshelfdodoesto the exoct thicknessof the Adding shop-modestop blocksto the fencemokes
plywoodshelvesthot will fit in themis no problem it on ideol setupfor routingoll klndsof decorotive
profilesond functionol
detoils.
guide.
with thefenceond microodlustoble
WORKBENCH
!
OCTOBER
2OO3
57
ilu --ffi
tfti?
Blocksof hordwood,foced
with superslickplostic,stroddle
on oluminum
fenceto guidethe
routeron its woy.
ROUTERGUIDE
At the heart of this system is an
adjustable rolrter quide. At first
slance,it nray look as though thc.re'.s
a lot goir.rg on here (Construction
Vial.tsut when you break the guide
down into its basic parts and under-
CONSTRUCTION
VIEW
/a" Polycorbonof,e
(Jsls"x 6"1
pieces in the left side of the
ConstntctiorrViau).The purpose of
this asser.r-rbly
is to connect the guide
to the metal fence and keep the
rvholc works nrovinq in
,^\
( )
V
#8 x3/t,Fh -'---\
woodscrews
g
standwhat each ofthose partsdoes,
it all starts to beconre clear.
Let's start with the guide rail subassembly (that's the collection of
I
a straight line. It
dors
thilt
IZ*-----..
+=_ \
x 1,,
V4,,
Thumbscrew
SmollGuideRoil
x 6"1
1s7r"1il46"
with two hardwood rails that straddle the fence. These guide rails are
faced with a strip of UHMWThis
is an extrer.nelyslick plastic.It allows
you to literally "pinch" the fence
between the rails, but still have it
slide freely.The guide rails are connected with a piece of polycarbonate and sonre woodscrews.
The secor.rdpart of the gride is :r
rod asser-nbly.
Notice that there are
two steel rods that run throu€ih the
baseof the router (sccPhotoaltouc).At
the end of theserods is rnother block
of hardwood - the adjusnnentblock.
This block "tr:rps" the router on the
rods.To tl'ratend, the rc& arc threaded
lnsert
The UHMW
plosticusedfor
the routerguide is
ovoiloblein 3/s" fhick blocksfrom
Rocklerot
80G233-9359 or
(-
Notchfor thumbscrews
(seeNotch Detoi0
Adiustment
Block
(1"x3l4"x6")
5116"
x9" sf,eelRods
UHMW
plosticblocks
5/e,,
(3/e,'x
x 6,'l
lorge GuideRoil
(1"x2l/4"x6"1
www.rockler.com
58
w()l{KBENcH
D oCToBER
2003
STEPS
CONSTRUCTION
GUIDEASSEMBTY
bottom of -1 ii:--------------sI lboseto
cenfer
Meosurefrom
of holes
cenlerfrocenlrer
STEP3
DrillTs"holes
Blonk
11"x27/s"x6"l
for threoded inserts
[o mokh
f-
SIEP
Cut7a"x l%"
robbet
to accept nuts for tightening the adjustment block againstthe router base.This
is also what gives the guide its microadjustabiliryas I'll explain later.
The critical steps in building this
guide are getting the holes for the rods
lined up perfectly between the adjustment block and the large guide rail,
connecting the guide rails so they fit
RiPsz"-*tr".ntt
"
brm odiuslment
block
278,'--____=-F
Smoll Guide Roil
STEP5
MokeSmoll
GuideRoil
5/s"
1i--l
l_
,rro,)
the large guide block and adjustnrent
block from a single piece ofstock afrr
drilling the holes for the rods (srcCuidc
AssamblyConstructionStcps).
The sn'rallguidc rail is cut fron'r a
separatepiece of stock.Then the guide
rails are assembledin two stcps.The
first step is to install thc UHMW faces
and threadedinserts.
The second step is to conncct thc
guide rails with a piece of polycarbonate.To ensure that thc gr"ridcswill slide
snloothly along the fencc,you'll nced to
5/gy''Shonkhole,
counlersunk
to cut the threads to accept thc adjustment nuts.A sin'rpletechnique for cutcing tl.resethreads accurately is explained
on pa.ge22.
Finally, slide the adjustn.rentblock
onto the steel rods and thread on a pair
#8 x 3/r"Fh
Woodscrcws,-SIEP
6
Instoll%"
|nsfoll
/4"
/
#
sW
fireoded inserts
%"Chombr
STEP7
AfiochUHMW
plostic blocks
P
shinr the g.ride rails so the llap bctween
them matchesthe thicknessof the fence
exactly.The sin'rpleway to do this is
into the large guide ratl (seeNotch Dctail
on page 58).The second modificrtion is
5/rC'holes,ts4"deep
(seeRodSpocrngDetoil
for locotion)
*l r/a,'l
over the fence snugly,and threading the
rods to accept the adjustnrent nuts.
Building Blocks - The secret to
aligning the rod holes perfectly is to cut
with a scrappiece of alurninunr angle
and sonre maksing tape (sccStcp8).
steelrods nced
RodAssembly-The
a couple nrodifications beforc assenrbly.
First, cach rod needs a notch filed near
one cnd where thumbscrewswill lock it
,l STEPI
loy od onddrill
=l--|-
|*
routerbose
7u" Shqnkhole,
g
%"xl"
Ihumbscrew
couniersunk
#8 x 3/r'Fh--1
Woodscrew
g
ha'Chomhr-\
%" Pokqrbonoie
STEP8
Clompguideroilson scroppieceof t/e"oluminumongle
ond oftochpolycorbonole
7on"Pilot hole,
Vt'dep
9/ry''holes,cenlered
over lhreoded inserts
Ts"Aluminum ongle
Use mosking bpe os shim
of lock nuts.
roBER 2003
59
FENGESYSTEM
Three fences (sccPlroto at l(i) xlapt the ronter
guide to jr.rstlbout any inr:rginablejob.A 30"longTlsquare fence is perfect fbr routins d.ldoes
in cabinet sides.And 60"- lncl cXr"-long ver-
Seconcl,the alunrinunr fence needs to be
clrillec'lancl tapped to accept nrachille screws
fionr nnclernelth.This proviclcsa secure conllection berr,veenthe hardboard ancllluntinunr
without the hlrclwale gettills in the' wry of
the router quicle.
siorrs(witl-rout?squares)rllow the glricleto be
used with full-size sl.reetsof plywood.They're
extr:r long to overhang tl-resl-rectgoocls.
Note': See the techniques we useclto trinr,
c.lrill,arrcltap the fbnce in WorkburcltS/rrpT4r-s,
beginning on paee 22.
The harclbolrclb:rseconresllext. It dso serucs
ls :r saw"tr:rck" so the fencescln be used aseclge
guidcs with a circnhr saw.To flt the brses fbr
yor,rrsrrw,lerrvcthc lurc'lbolrcl extra wicle rs yotr
:rsserrrble
the gr.ride,theu trinr it to wicith with
your circular srw fbr a cnstonr fit.
The nrake-r.rpof tl.rcfbncesis quite sinrple
(sccIllrtstratiott
[c/ol,/.Alunrinunr :rngleservcsls
tl-re"fence" and I/.1"harclboarclnrakestl-rebase.
Tl-rereare n few inrportallt llotes about tl-re
constructioll of tl-refences.First is tlut thc vcrtical leg of the ah.rnrinr.rnrlngle ueeds to be
trinnred. If left :rsis,it would be too trll fbr the
uuide systenrto ric'leon.
#6 xvz"/''--------\
Bose
02" hordboord,
6" rgh.x 30"!*
FhWoodscrew
Fence
|/e" oluminumongle,
3/4"x lV2'tl'
T-SquoreHeod
fl2"x3"xl6"f
E.
Cutupright"leg"
3/a"high
(seepoge221
sh2,,hole
topped for
l0-24 mochine
SCrew
-
10-24 x3/8tl
Fh MochineScrew
*Nole: For olher lwo versions,
moke60"- ond 96"-long
bosesond fences.
STOPBLOGKS
Moking fencesof vorious
lengthsodoptsthissystemfor
onythingfrom crosscutting
wide
ponelswith o circulorsow to
routinggrooYesin o full sheet
of plywood.
Attaching stop blocks to l'ry of the fences is a foolproof way of routins identical flutes or stoppecllrooves
:rnd dadoes.Each stop block consistsof two prrts: rl
clanrp herd l-rd a pinch block.
To lock the stop blocks on tl.refence,:r l.randleknob
pxssesthrough the clamp
held lnd threlds into m
i r r s e r ti r r t h e p i r r c h b l o c k
(srclllustratittnat riglt).The
pinch block is beveled on
the top edge.sors thc handle is trghtened.thc pinclr
block gets wedged rgrirrst
the alunrinunr fence t<.r
lock the assemblyin place
(scc Stop Dctail dt riglt).
60
ClompHeod
lll/2"x2"-1,)
-I
3/t"
l" x ltt
I'
I" h 7/s"
Vs'!--)
Noich
ll" x3/4" x2"l
w()l{KBENCH
!
h"
Threoded
lnserl
()CT()llEll.
2003
Routing Gustom-FitDadoes
The value of an adjustablerouter guide is that it allows
you to rout a rabbet or dado to perfectly match the
thickness of stock you're using.This comes in particuiarly handy when working rvith sheet goods where non-rinal thickness 13/4" for instance) is different than actual
thickness (more like lll16,") and planing isn't an option.
By equipping your router with a bit thatt smaller
than the actualthickness of the stock (a 1/r" bit would be
a good choice for 3/a" material) and using the adjustability ofthe guide, you can cut a perfect rabbet or dado
in two passes.Andbecausethe guide is microadjustable,
it's relatively easyto dial the guide in perfectly afterjust
a couple of test cuts.The three-step processfor routing
perfect joinery is shown in the Illustratiorsbelow.
islideboseof rouer
i ogoinstodiustment
ASTEPI
ASTEP
2
ASTEP
3
Moke the firsl posswith the rouferogoinst
the lorge guide roil. The spoce between
fhe roufrgrbose ond fie odiustmentblock
equolsthe difbrence betweenthe bil
1tl2")ond thewidth of the dodo (0/a").
Whenyou reochtheendof thefirst
poss,slidethe routersidewoyson the
rodsond butttheroulerboseogoinstthe
block.Thenbeginthesecond
odiustment
possin theopposite
direction.
Holdtherouterfirmlyogoinsttheodiustmentblockosyou mokethesecond
poss.fn thiscqse(cutting
o3/t"-wide
dodowitho 1/z' bitl,thebitwill onlybe
cuttingonotherl/a" of width.
GompactGut-Off Fence
Aftermokingond usingthethreehnceson thefocingpoge,
we thoughtit wouldbe niceto hoveonemorefencespecifin dimensionql
icollyfor mokingoccurofe
crosscuts
lumber
witho circulqrsow {Phofoor righrJ.
We keptthisoneshort
(l8n) so we coulduseit in coniunclion
with the T-frocks
ond miniclompsin thetop of theworkstotion.
Thishnce olsohoso hqrdwoodT-squore
b keepit peri.t.".,' ' *,,
pendiculorto theedgeof theworkpiece.
'*{*l&|,
Aportfrombeingshorbnedto fit in thespoceovoiloble
qt the shollowworkbench,the construction
detoilsof this
bnce qrelhesomeos itslongercomponions.
Theoluminum
onglehnce hosone himmedleg ond is toppedlo occept
mochinescrewsfromunderneoth.
Thehordboordboseis
exhowideto sfortondthenhimmedto o perbctfit withthe
circulorsowofterthebnce is instolled.
woRKBENCH
!
oCToBER
2OO3
ondot
mogine
spending
on entiredoyworkingin yourwoodshop
theendof thedoyyoufindvirtuolly
no dustto cleonup.Moreover,
you reolizethotif there'sno dustcoveringtheshop,thenthere's
toogoodto betrue,butmony
nodustcloggingyourlungs.lt sounds
in mind,
ond builtwithdustcollection
of todoy'stoolsoredesigned
mokingdust-free
woodworkingmorereolisticthonyou mightthink.
In thefollowingpoges,we'llshowyoufiveoreoswhereyoucon
improvements
to thewoyyoucontroldust
mokesimplebutsignificont
in yourshopfseethe Sideborat rightfor o quickoverview).
l. IooFActuoted
Vocuums
Plugyour ficolsinlo high-powervocs
thol turnon when the tool does.
2.(ollecing
Duslol theSource
with
Sbp dustbeforeit spreods
toolsdesigned
for thebsk.
loollfits
3.Dusl-Busling
Usetoolsdesignedto "tog-teom"
your dustconholchollenges.
4.(emingtheAmbient
Air
lffiUms
Breothe
eosyin yourshopwith
thelotestin oir purifiers.
5.Inprove
Yourlxisling(ollector
Moke o good dustcolleclorgreol
with thesesimpleoddons.
AI.JTOMAilC
EXTRACflON
One of the simplest and most affordable methods of dust control is a toolacruated vacuum.A tool-actuated vacuum is one that has a power outlet to
plug a tool into.When the tool is turned on, the vac comes on automatically.
Beyond the convenience of turning on each time you use the connected tool, these vacs also offer power, filtration, and easeofcleaning that
surpasseslower-priced conventional wet/ dry vacuums.
Bosch's model 3931 vac is one of the newest offerings in this category
rnd has some of the best available features.
One of the standoutfeaturesis a dual-filtration
systemthat includesa dust bag and two pleated
filters (Frg.1).Together,the bag and fi"lterstrap virtually 100%of particles3 micronsor larger.
This vac alsofeaturesan exclusiveself-cleaning mode.By switchingthe vac to Pulse-Clean
(Fig. 2), it automatically shakesdust loose
from the two pleatedfilters and collects
it in the bag.
An 11-ampmotor,130cu.ft./min.
of airflow. and 100" of static water
lift (water lift is a measurementof
the strength of the vacuum produced by the suction motor) make
this one of the most oowerful
tool-actuated vacs available.
Suggested retail is
$429.For more information,
visit
Bosch's website at
BoschTirols.com
or call1-877-2672499.
woRKBENcH
!
oCToBER
2OO3
ATheBosch's
pleotedfilterscombinewith o dusl
bog to coptureneorly100%of porticles
3 microns
ond lorger.
<A Pulse
Cleonmode
outcmoficolly
cleonsfie
pleotedftlters.
Alsoshownis
theoutletbr
icohcfiro|ed
operolion.
63
C)Collecring Dust
ZATTHESOURCE
DEWATT
ROUTER
A Theboseof DeWolt/s
DW62l funnels
dustdirectly
intrcthe lorgeinletportot fie
botkrmof fte column.
Through-the-column dust collection on DeWalt's
DW621 hasmade it the industry standardfor effective,integral dust collection for routers.A big part of
the successof this systemhasto do with the design
of the base,which funnels the dust into the column
where it is extractedby a vacuum (InsetPhoto).
This is a tried-and-true systemthat other companieshavefailed to match. For years,this featurewas
only availableon the DeWalt. However,a very similar systemis now used on Black & Decker plunge
routers aswell.
Suggestedretail for the DeWalt DW621, is $370.
For more information, visit DeWalt.com or call 1800-433-92s8.
CRAFTSMAN
& DEWATT
PLANERS
Planersarenotoriously messymachines,and previouseffortsat controlling their untidinesshave
been mostly ineffective.Now, however,there'sa new crop of planersthat usetheir own internal fansto direct debris into integral dust ports.
Pictured at left is Craftsmant 15" planer that usesa common garbagebag or trash
can for dust collection.This is a remarkablyeffectivesystem,and the internal
fan meansthere'sno need for a dust collector.Craftsman's72" and
13" planersalso utilize this system.Suggestedretail for the 15"
\ planeris $799.Call 1-800-549-4505or visit Craftsman.com.
A slightly different approachis offeredby DeWalt pelow).
This 13" planerstill usesan internal fan,but currently requires
a dust collector ifyou intend to gather the chips and dust
sornewhereother than the floor. Suggestedretail for the
DW733 is $379.VisitDeWalt.com or call 1-800-433-9258.
Rx
A A convos"holf bog" with o snopring
occeplslypicolgorhge bogs,os shown,
or o 30gollon troshcon br collectingthe
dustfromtheploner.
64
A A snoponporton theDeWoltDWZ33ollows
fie plonerto connectto o dustcollecficr
with
eifiero 21/z'-or 4ndio. hose.An inlernolfon
keepsdebrismovingthroughthe port.
WORKBENcH
D ocToBER
2OO3
BO$ffIi SANDER
Bosch discingrishcstheir 5" randont orbit sanderfron1 others on thc rrr.rrketby equipping the tool with a genuinely
eflbctivc tllrcr system.In place of the porous cloth baEp
Bosch uses a
thrt .rrc colrurlon on other such s:rnclers,
N'licrtr-Filter dust canistel'that crrpturesparticlesassmall
itr rtsuruch x a 120%o
increase
.r. .r h.rlirnicron.This rcsr-rlts
in rr.rpped dust and r noticcrblc reduction in the dust
clond that rypically fllls thc :rir while you're s:rnding.
into the llltel in tl.refirst place is the
Gettins the clr,rst
job ofthe nrotor inrpcllcr, rvhich crextesa nrild vacuum
to draw the dust through thc cight holes in the sanding
disc and direct it to the canister.In concert with the filter,this nrakesthe Bosch one ofthe clcrncstsandersgoing
having to connect it to rn extel'nalvacuur-nsource.
rrrit/roal
retril is $213. Call llosch ^t 1-877-2O7 -2499 or
Sr.rggestecl
visit l]oschTixrls.cor.nfor more infornratior-r.
A Bosch's
thebulkof the
slrcres
MicroFilcrsystem
The
dustin thebottomof fie conisfer.
collec|ed
pleobd
finestdustis troppedin he
filcr bebre it
conescopeintctheoir.
JETDISCSANDER
establisheditself as truly one of the
Jet'.s12" disc sanc.ler
all-starsof this tool review. Before using the tool, I figr.rredI d be satisfiedif it picked Lrpmostof the dust it created.Aftcr all, disc sanderscan kick up a lot of dust.
So, after sanding a chunk of MDF as fast as I could,
I was pleasantly surprised to find only a smattering of
dust on the sander'stable and no dust hanging in the air.
The secretto the successof this tool is fwofold. First,
a larg5einrpeller directly behind the sanding disc creates
an enomrous anlount ofair{ow to pull dust from the outer
edge of the disc and direct it into the onboard filter.The
filter is part two of the dust collection equation. This
canister-srylefilter traps dust particles assmall as2 mcrons
and nviss offeasily for cleaning or replacement.Suggested
retail is $396.Visit TetTools.comor call 1-800-274-6848.
< Jel's
2-micron
filter
conister
lwistson ond
off thesonder
quicklyfor
ond
cleoning
replocement.
wOIIKBENCH
!
OcToI]EI{
2OO3
Microns ore
the units of
meosureusecl
to indicotethe
size of dust
p o r t i c l e s .S o
how big is o
micron?Well,
the period ot
theendof this
sentence is
somewherein
the neighborhood of 400
microns.
65
FEIN
> Fein'scloth
ftlcr bog is
eftdive, but
mokesbr
messy
empfying.Pick
up the
optionol
cortridgefilcr
ond poper
dustbog b
get thebest
outof thisvoc.
I
At the heart of Fein'ssystemis their
line of Turbo Vacs (the Turbo II in
this case).Along with incredible
pulling power and super-quietoperation,this vachasthe unique capability to power two
tools simultaneously (Fig.1).
'While
many of
the vacsin this article provideadequatesuction for multiple tools, Fein is the
only vac with a high enough amp
rating for more than one tool at a
time (20 amps for the Fein comparedto 6,7, and 10 ampsfor the
other vacswe tested).Surprisingly,
the vac can handle a 20-amp draw
from the tools plugged into it, but
the vac itself can be powered by a
15-ampoudet.
One improvement we would
make to this vac is the filter (seeFig.
a).lt's an effective filter (rated at 5
microns), though not terribly easy
to clean ahd maintain.
Two key playerson Fein'sdustbusting team are a 6" random orbit
sanderand a 3%-hp plunge router.
The sanderis especiallyeffective
becauseof additionalports on the
outsideof the sandingdisc that pick
up dust that sftaysftom underneath
the tool (seePhotobelout).Feinclairrls
98% extractionusing this system.
On the router, a clear shroud is
attachedto the baseand createsan
enclosedareafrom which dust and
debris can be drawn awayfrom the
bit.As simpleasit sounds,the sh-roud
works remarkablywell.
One at a time or doubling the
tools up, Fein'ssystemof dust control is incredibly effective.Beyond
that, the tools areindividually among
the best in their respectiveclasses.
Suggestedretail for these tools
are: Turbo II Vac $387, 636-1
Random Orbit Sander $758,
RT1800 Plunge Router 9473.For
more information,visit FeinUS.com
or call 1-800-441-9878.
Flexiblecoupling
< Whenyou instollo
"Wy"" connecbr (from
Feinfond powership (from
fie hordworestoref,the
TurbollVoc providesthe
necessory
omPerogeond
oir fow to hondletwo tools
simultoneously.
A Portsin the perimeterof the
sondingdiscgrobdustthot
escopesfromundertheedgeof
lhe sonder.
WORKBENCH
tr OCTOBER
2OO3
I
t
I
I
I
II
i
I
t
I
i
FESTOOT
Festoolt CT22 dust extractor (at right)
provides the pulling power in this system and alsoboastsGaturesnot found
on the other vacs we evaluated.
First is a variable speed feature.
This is one of those ideas that makes
you wonder where ith been all these
years.After all, not every job requires
the full power of the vac to keep the
dust corralled. So why listen to the
motor at full volume?
Another novelty is the hose.
Seemingly an innocuous component of the system, Festool'sis something special.The hose is graphite
impregnated to resist static buildup
caused by dust rushing through it. If
you've ever seen a "dust beard" grow
on the outside of a vac hose, you'll
immediately appreciate this thoughtful touch.
A two-stage filter system keeps
dust from being reintroduced to the
Filbr cleoner-'-----.r
alr once 1r reaches
the vac, and a
cleaning
lever makes
clearing the
pleated filters
quick
and
easy(Fig.1).
"m
II
\r-
The {lagship tools of this system
are the modelATF 55 E Plunge Saw
and the model RO 150 E Random
Orbit Sander.
A fully-enclosed blade shroud on
the saw (shown aboue)and unique
hole pattern on the sander (shown
of this hole to keepdust
moving toward the nine collection
holesand to preventthe sandpaper
from clogging up. One final piece
of dust control technologyon this
sanderis a copperground in the dust
port that works with the graphitebelow) are key to the dust collecting
impregnatedhoseto el-iminatestatic
performance of these tools.
buildup (Fig.2).
The enclosed shroud traps the
Suggestedretail pricesfor these
dust so it can be collected instead
tools
are:CT 22 E Dust Extractor
with
the
open
blade
of broadcast,as
saws.
guard on most circular
$375,RO 150E 6" Random Orbit
pad,
Sander$395,ATF 55 E Circular
in
sanding
Nine holes
the
PlungeCut Saw$375.
of
the
disc,
spaced near the edge
For lnore inforrnation visit
greater
opporallow the vacuum a
or call 1-888-337Festool-USA.corn
before
it
tuniry to capture the dust
to visit one of
Also
be
sure
8600.
sander.
escapes from under the
distributors,
Festool's
leading
U.S.
in
center
of
the
There's another hole
call them
or
SoecialwTools.corn
a
the pad, but this one is actually
'Jet."
1-800-669-5519.
directly
at
out
That is, air blows
V Portsneorfte edgeof the
pod collectthedust.A cenler
"iefl' keepsthedud movingin
therightdirection.
I A coppergroundond
A A filbr cleonermokesmoinbnonce
cleoning
Formorethoroughcleoningor rePloc- grophibimpr€nold hoseelimiconvenient.
chorging.
noteeledro€totic
menl,lheftlbrssnopouteosily.
woRKBENcH
tr OCToBER
2OO3
ilffi
ffillflHltturAr
ffitr$"f,A
AfiffiCLNANER
Deltak 50-875 Renrote Air Pr"rrifierhas all the features
you shoulc-lwlnt in an air cle:rner:three speeds,remote
control operation, tinre-de1ayshut-off, and, ofcourse,
awesorlrefiltration (tr:rps99% ofparticles over 1 nricron).
Where this unit distinguishesitself is in making it easy
to uronitor its e{hciency.In the past,climbing a stepladcler to inspect the fllter w:rsthe only way to know when
a rephcenrent wrs due. l)c.ltl has added rn airflow ir-rdicator that lets you see at a glance when the filters have
become dirty to thc point of inrpedine perforntance
(Pltotrtat lcfi).'lbat nrakesit nruch more likely that you'11
rephce and clean the filters in a tinrely fashion, ensuring the hiqhest level ofeflectivenessand avoiding undue
weilr olr the motor.
Thc thrce-speeclblower provides airl'low of 540,630,
anrl 1,200 cu. ft./urin. - enongh to recycle the arr rn a
20-ft. x 20-ft. shop 13 to 1fJtinres per ho::'r (InsetPlrcto).
A tinre-del:ry:rllowsyou to set the nr-ritto continue cleln-
r A quickglonceot theoirfow indicoircr
tellsyou
if thefilterneedsto be cleoned.Remote
operotion
letsyou setthecleonerfromonyrrherein fie shop.
ing tl.rerir Lrpto 7ll: hours rfier you leavethe shop.
Sr-rggested
ret:rilis $333.Visit l)cltlWooclrvorkirrg.conr
or crll 1-il(X)-43U-24u6for nrore infornration.
BHN(HT#PAIffifffi-ffiAruffiffi
ShopVact Air (lleirnel is rr portable, rrflbrclrble,and renr:rrkably caplble
sohrtion to airborne clust.l)hce this unit on l bench oL r.ven on tlre
floor near your work, rurclit will gobblc up rrqoocl shrre of tl-rec'lustbcfor-e
it ever has r clr:ince to get airbortrc (Pltotoldort).
Operatine at 235 cr-r.ft./nrin. of rirflow, this comprcr ur.ritwill recycle' the rir in a 15-ft. x 15-ft. roonr
every 10 nrinutes.
Tlre two-strec filter (hrstt Plrcto)
'@,
grabspllticles ls srnallas5 nricrons.
Ar-rdthe filters :rre easilyaccessiblefor
cleaning or repllcement by renroving tl-reend glill. Sugeestedretail is
or call 570$'129.Visit Sl.ropVrc.cor.n
Jl6-3557 fol rrrortirrtbrrrrrtion.
> TheporirbleShopVocAir
Cleonerletsyou|okedustconhol
rightto thesource.Thetwostrrge
filcr is efhctiveondoccessible.
68
nl
-,
-
-
lmproveYour Existinq
CDUSTSYSTEM
FILTERS
JETDUSTCOTLECTOR
1
Cleoner
hondle
Conisbr
filcr
Adding a Jet canisterfilter is the best thing you can do for your existing dust collector.Thesefilters haveup to six times more filter areathan standardbagsand trap
particlesdown to 2 microns (versus30 microns for most standardbags).Cleaning
is alsoeasier- just twist a handle at the top to shakethe filter clean(Photobelow).
The looseneddust fallsinto the collection bag below.Canistersareavailableasaddons to most popular
brands of dust collectors
and are standard issue on
models.
several J.t
is
around
retail
Suggested
$200.VisitJetlob=esnr
4-6848.
or call1-800-27
'FH:
<Tumingo hondleon
trcpof fie conisbrrokes
Mo cleoningfinsover
theinsideof theftler,
knockingdustloosetrc
collectin thelowerbog.
ECO.GATE
For a dust collector to be truly effective, it must be running anytime a tool is running.Yet most of us will make
"one quick cut" or"one quick passover the router"without turning the collector on and opening the appropriate blast gate. An automatic system from EcoGate will
guarantee that the dust collector is on and the gate is
open anytime you run a tool.
The system works with sensorsthat mount to the tool
motor (Inset Photd.The sensor tells the "brain" of the
system, The Green Box, which tool is running. The
Green Box, in turn, starts the dust collector running
and opens the corresponding blast gate.
A basic system includes gates and sensorsfor four tools,
along with the Green Box. Suggestedretail is $499.Visit
EcoGate.com or call 1-888-326-4283 for more info.
< Sensors
otlnchedlo thetool motortell the
GreenBoxwhichtool is running.TheGreenBox
turnsthedustcollectoron ond openslhe corre
spondingmolorizedblostgote.
woRKBENCH
tr OCTOBER
2OO3
69
(t,
PRODUCTS
./elei g
FirstAlert
TATKING
ALARM
Imagine being awakened in the rniddle of the night by a blaring smoke
alarm. It'.sa terrifying thought, made
all the worse when you consider that
you have no way of knowing where
the danger is. Is there a fire in the
kitchen? The basement?The bathroom down the hall?
'Without
knowing the source of
the danger, it's impossible to forr-nulate a safe escape plan for you
and your family. First Alert solves
that problenr with their new talk-
ing smoke and carbon
monoxide alarm.
< Any household
remote(notincluded)
will progromFirst
Alert'stolkingolqrm.
With
a prerecorded
human voice, the FintAlert will
tell you which room the alarm has
been triggered in, and whether the
danger is smoke or carbon monoxide.
The voice warning is accompanied
by a beeping alarrn.
The alarnr can be conveniently
prograrnnred, tested, and silenced
using any household TV or VCR
relrl()te control.
The First Alert model SC07
ConrbinationThlkingAlarrnis poweredby rwo AA batteries.Suggested
retailis $39.95.Tolocatea retailerin
your area,visit www. FirstAlert.con-r
or call630-851-7330.
KrylonFusionFor
Fisch
Pricing
In the August2003 issueof
Workbench we inodvertently
listedthepriceof theFischBTM99 Benchtop
Morliseros $185.
This price wqs for lhe l/z-hp
versionof themortiser,
whichhos
beendiscontinued.
There{uilprice
of ihe 3/a-hpmortiseris $250.
PAINTING
PLASTIC
ln 19(tT,accordingto a popular film
of tl-retirtre, the future was plastics.
Well, the future is now. Plastic is
everywhere.A perfect exan-rpleis the
plastic shutter pictured here, which
likely went on nty house about the
time that r-r-rovieI mentioned was
opening at theaters.
Plastic being what it is - nearly
indestructible - the shutter is still in
decent shapeexcept for is faded color.
But now thanks to Fusion paint
'for plasticsfron.r Krylon, just about
anything made of plastic can be
returned to its original glorious
color. Or you can change the color
altogether, if the original was never
all that glorious to begin with.
The Pftoto,right, shows the shutter before and after Krylon Fusion.
A bit of cleaning with an ammonia-basedcleaner and a few coats of
Fusion, and the shutter looks new.
Fusion costs about $6 per can at
hardware stores.For more information, visit wwrv.Kr]rlon.com or call
1-800-457-9566.
70
WORKBENCH
tr OCTOtsER 2OO3
PRODUCTS
Hole-ln-One
DRY-\AAII
REPAIR
Door knobs and drywall dont mix.A carelessly
opened
door can easilyresult in an ugly hole like the one pictured at right.This makesfor a chdlenging repair.
Fortunately, a simple solution is availablefrom a
company calledMighty Good Notions...A Holein-One Company.The company'sEZ Dryr,vallRepair
Kit works inl/2" or s/8" drywall to repair holes up
to 3" in diameter.
In the caseofa"door dittg" m shown here,the first
stepis to lay out and cut the hole to fit the 3trplug (Flgs,
1 and 2), After cutting the hole and cleaning up any
rough edgeswith an included wedge saw,usethe pullT to insert the hole-in-one disk with a liberal coat of
construction adhesiveFiS. 3).
Now lock the disk, pull-T, and plug together as
shown in Figure4 and give the construction adhesive
24 hours to harden.
The next day,you can patch the hole *ith drywall compound.A{ter the compound hashardened,
sandand paint the patch for an invisible repair.
The EZ Drywall Repair Kit sellsfor $5.95 and
includesthe disk,plug, pull-! and wedge saw.You'll
need to supply a pencil, keyhole saw,drywall compound, and putty knife for thejob.To order a kit, call'
l-801-7 56-9330 or visit www.ezdrywallrepair.com:
ATheEZDrywollRepoirKit
mokesit simpleto fill o "door
ding" (left)so theholecon
be potchedwifi drywoll
compound(obove).
LevelWind
HOSEREEI
Crafeman'snew LevelWind Hose Reel is lightweight, portable,and keeps
hose neady wound when not in use.It can be mounted to a wall or ceiling,and by simply removing apin fiom the mountingbracket,the polypropylene reel can be carried nearerthe work areawhen necessarv.Thenon-meal
housing also eliminatesrust and corrosion.
'When
mounted on the bracket,the reel
can swivel freely or lock in one of seven
positionsbasedon your needs.Hose retraction is smooth and even,thanks to a layering
mechanism that ensuresthe hose is evenly
wound onto the rcel (InsetPhoto).
The reel is availablewith either 50 or 75
feet of 3/a" hose or 50 feet of 1/2"hose.The
reelsrangein price fiom $150to $165and are
available in Sears stores or online at
www.Sears.com.
WORKBENCH
E OCTOBER
2OO3
HOUSE
newlifefor on old
FLOOR
hris and BobbyJo Andreasen's
dining room floor
had seenbetter days.Originally installedin 1910,
- even
a persistentonslaughtofstains,scratches
plaster and tile at one point - had gradually contributed
to the old floor's current condition.
The Andreasent floor was in such bad shape,in fact,
that the folks at Rust-Oleum (the makers of Varathane
finishing producs) named it the winner of their recent
"America's Most Flawed Floor" contest. As a prize, this
Des Moines,lowa, couple received a complete floor refinishing courtesy of Varathane.
Uslng the Scndsr
TheVarathane crew got to work using their ezV sander
(seePhoto aboue).This sander, available for rent at many
home centers and hardware stores,is designed to be a
uniquely DIY-friendly tool.
Unlike a large drum sander,the ezV wont gouge the
floor if you leave it running in one place. Plus, theret
no need to worry about following the grain direction
when sanding. In addition, the ezV is much more effective - and much lesstime-consuming - when compared with the averagepad sander.All of this is possible
A To ovoid gougingthe floor,
the ezV sonderhosthree
rondom€rbiting
heods,likethe
heodson on electricrozor.
Estimoted
cost for
refinishing
o 224-sq. ft.
room/ Slarl
to finish:
lAfter o thoroughsonding,this
diningroomfloor,originolly
'19.|0,
instolledin
wos reody
for o finish (seepage 76).
SonderRentol
(ovg.ldqy@nlatfuezYl
SondingDiscs
ffelnS1rrclcot$5.00errii
Finish
$40
$50
$zo
!2golbns,W.a$35adl
Applicobr
(oplicrlnr,2 rcfills,and hondleJ
Totcl Cost
$to
Stto
because of the ezV sander's three unique randomorbiting heads, which are similar to the heads on an
electric ruzor (seeInset Photo at left).
Sanding with the ezV is actually a three-step process.
First,36-grit sandpaperis used to remove the old finish
and flatten the floor.This is an important step,as cupping is typical in old planks.Then, two more passesare
made over the floor using progressively finer grits (50and 80-grit).The sanding discs adhere easily to the heads
with a "hook and loop" system.
Sanding with the ezV is remarkably dust-free thanks
to onboard dust collection and a powerful built-in
vacuum. Dust is collected into a dust bag in a canister
mounted on the handle.
The one area that the ezV can't sand is right around
the edgesand into the corners.This is such a small area,
though, that it can be done using a portable power
sander from the shop. A 5" random orbit sander with
60-grit sandpaper works particularly well.
Once sanding is completed, cleaning up the floor
takesjust a couple ofpasseswith a shop vacuum.At this
point, the floor is ready for a new finish to be applied
(seepage 76).
woRKBENCH
Lt ocroBsn
2003
Applying Finish
Once the floor was sanded, the
horrreownershad to decide whether
to Lisea water-based or an oii-based
flnisl-r.
Water-based finish gives a lnore
tr;rnslucent look that exhibits the
n:rturalgrain of the wood. It requires
fbur coats,with a 2 to 3 hour drying
period between each coat.An advan-
A Vorothone
floorfinishes
ore ovoiloble
in bothwoterond oil-bosed
versions.
tree of water-basedfinish is no strong
odor while the finish is curing.
Oil-baseclfinish offers a w:lrnrer,
" . l . r s s i c "w o o d l o o k , r n d i t i s r r r o r e
durable than water-based.Oil-based
finish needs three coats with a 3 to
.l hour drying tirne between coats.
Afier weighing the options, tl-re
honreowners chose oil-based.The
<After
touching
up
theedgesof
thefloorwith
o pointbrush
(left),o coot of
on oil-bosed
finishis put
down usingo
lqmb'swool
opplicotor
(oboveleft).
first step is finishing the edges and
conrers with a snrallpaintbrush (lrrsct
1lioto).Then,a snrallpuddle of finish
rs poured and pulled srnoothly and
evenly acrossthe floor with an applic:rtor (.serPhoto).The floor is sanded
lightly before the final coat.
KLINGSPOR'S
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Hexli/fendt tor Collar
Sq|m DriveScrem
6" SqBro DdveBit
TAKE
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Product Information Number 241
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C R A F T S ] \ 4 A N SI H
P C L O SE - UP
DESIGN
truwffi#ffi
, " , l ! i . i i l l i [ . i fo i c r
. i)iil:j ii:rrr l"ii,
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,...5t '(
,l
tidded Jor Pete
Compbell
Inhicotelocework"flows"with the groin of this
cocoboloior.Turnedto shopeon o lothe,thishollow
vesselond its ebonyspireore true mosterpieces.
.u*I
\s
vr
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fl:
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Holl TobleJesse
Cook
r Sonlq Cruz loungelr JoredRustrgn
Thiswolnutond mopleloungerfeotures
groce
fullycurved,bentwoodormsond slots,os well
os wedged,through-mortise
ond tenonjoinery.
Thecurlymopletop of this
holl tobleoppeorsto "floot"
oboveon orchedwolnur
bose.And itsfoldedcorners
odd o whimsicol
touch.
Workhench's"Excellen(e
inDesign"
Aword
Winner
Reclongulor
shopeswithin
shopes- o simple,pt shiking ideo- chorocferizes
the
geomehic
designof thisdisplcy toble built by Terry
Holzgreen.Conslructed
of
moplewitho redqnilined)€
sfoinond ebonizedpoplor,
this finely crofted proiect
gotheredtop honorsot fie
foir, winningthe Excellence
in Designorord sponsored
mogozine.
S Wofu6
woRKBENcH
tr ocToBER
2OO3