Professional Documents
Culture Documents
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the problem
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of our
designers,
page 24
hands-on technique
in the shop
Motor Wiring
Preventing Kickback
Gffilao
great gear
OaA
-
Sou rces
ShopNotes.com
ShopNotes.com.
'f-ri
will
ShopNotes.com
J
Tins for
Vdur Sho
1/+"-2O x'lVz" Fh
MACHINE SCREW
realized that I
NOTE:
rosrrou ror
TOP 19 LAMINATEP
gIOE CLEAT
---.-.--
(3/+"
x1%"'3512")
END CLEAT
xll+"'2412")
HARDWOOP CLEATg
Fh
MACHINE gCREW
V+',-2O x11/2,'
plywood
TO7
(3/+"
It starts with a
#8 x1V+" Fh
wooD9cREw
set
#8 x 1V+" Fh
wooo1cREw
1LOlfED OA9E
ALLOW9 FOR A
%-20T-NUT
WDE RANGE OF
CLAMPING OPTION9
NOTE:
nrr sLorsvz"woL
A?ARI
Work Sharp
Disk Storage
Since purchasing
Work
tem,
lssue 105
it rarely leaves my
May/June 2009
PUBLISHER Donald
see
HANDLE
will be aligned
(57/6" x75/o")
V Clark,
Harlan
3/a" RAO.
Dennis Kennedy
Ralph Okonieski
Stotu, Ohio
SHARPENIN6 DI5K9
ShopNotes3 (ISSN
1062-9696)
nll rnrrs
li.ltll -HANDLE
auo (ro
'a
l'rl lllu" l^l"l' jft,l" ln"lv,lz.lv,l't-l+
sh
4-z6--1
copies to:
#Ox1lz"
'
Fh
at
additjonalmailing offices.
500117,2103
wooogcBew
Shopltlotescustomerf,en ice,cmrct
ShopNotes,com
and click on the link
SUBMIT A TIP
There, you'll be able to describe your tip in detail and upload
photos or drawings. Or you can mail your tip to the editorial
address shown in the right margin. We will pay up to $200 if
we publish your tip. And if your tip is selected as the top tip.
you'll also receive the Bosch lmpactorshown on the right.
ShopNotes.com
LA 50312.
ShopNotesG is
NOTE:
tohn Doyle
before assembly.
s,/a--t
A. tVaxey
k-
peschke
e-mail address
su
ug
sh
At"""#,"tfrHo-W
Printed in U.S.A
..-'11**;g
To get plans for
the originaljig from
lssue 94, go to:
ShopNobs.com
drilling a counterbore
in the back of the jig's
Next comes
the
FOR WORKPIECE
5/s"-OlA. x3/a"'DEE?
THICKNE9S
COUNTER90RE
LOCK NUT
lffiey Kounlski
14"-2O
THREADEP
IN9ERT
LOCK NUT 19
TRAPPEP IN
COUNTER6ORE
Plano,Illinois
V+"-2O
x2"
sTUDDED KNOB
CA?
(11Aa"
#b xl"
Fh
wooDScREw
MICRO.APJU9T
?LAlE
k",.,-Y
woooscREw
-',,1116-.,
'r{i::,i,i'':i.r:.,
s\
Clirttort, Iozttn
linr Reqnolds
Clizte.
Qwfrck T*ps
IctzLtn
Workshop
mostering
lock
Miter
Bits
t
a small amount
-jointeven
won't close tightly.
A Stronger
Miter Joint.
The interlocking
tongue and
groove profile
creates a selfaligning joint.
the
Flipped
piece
with two
'i.!]-..:a
Ci:;t:t!;rt;"::7
BITTOO HIGH
Flipped
piece
;>v
::,8 :,-,'.=l
Set Bit Height, First. To sef fhe bit height, rout a profite on two
test pleces held face down on the router table.
Flipped
piece
BITTOO LOW
things mixed
up while
To download a free
rotrting
troubleshooting 3-D
model, go to
ShopNotes.com
will
Fence $led
FENCETOO CTOSE
Flipped
piece
.:Notch prevides
't
,",
'
clearance:
for clamp
{photo at left)
Eacker prevents
\
Fine-Tune Fence. Rout a pair of test pteces
vertically to adjust the fence setting.
ShopNotes.com
Clamp workpiece
FENCETOO FAR BACK
to runner
,.
'
fr
building
uncomfortable to use, it
will only
En$0No*ilcs
of torque for a
lot of clamping
pressure.
Y Torque.
Wing
lead to fmstration.
<
Common.
Four-star
knobs are
commonly
available in a
wide range
of sizes.
..)-"
-/a
Studded
knob
Threaded
,.rFr lnsert
"h.,
EW
an
lnsert
knob
,/'//i
"!_
-.
r6)
'*'
*
T-nut
u!-
is
one downside to studded knobs.
anv aoolication in
t# sh;; A
rnoking custom-length
Studded Knobs
l:,
Hex bolt
fits into
recess /n
knob
ShopNotes.com
,, tt.:,
;.,
A Snap ln.
Choose from
a variety of
shapes to
create your
own studded
knobs.
';r,r-:;;,
iii:
.J"
.j
-metal-threading
taps. These
How
It
T-handle
wrench for
need
Tapered end
t2
#10-24 tap
-18 tap
<
my
"set"
the hole.
TAPPIIIS THREADS
restoring domqged
Thresds
A tap cuts threads on the inside of
Die handle
accepts
hole.
round stock,
a
ShopNotes.com
Chamfer. A
slight chamfer on
the edge helps
center the tap in
most die
sizes
Cutouts in die
clear shavings
',a.
.a.
I:::\r.. lF.'
shrop lr]9
)ll
gJJl Y c
uiir
-,
few
tips and techniques to get
Jr-r.t
rI
if,
ii:
Leal'n a
easy
a perfect radius or a smooth roundover.
T
To download a free
radius dimension
chart, go to:
ShopNobscom
dimensions
find
SIIAPING CURUES
ner of
Tff
If
LayoutTools, Lots of common items like the ones
shown at left work well for laying out a radius. The
radius of a quarter is close to 1/2" (photo above).
t4
Roundovers
;:,
'....:'
i,,:.
,. f
.(
small
tay-
ACTUAL 5IZE
el
r*
BINPING ON RIVET
3/+"-DlA.
foP
Leg
s/zz"-DlA.
HOLE
Leg
\___
%"-otA.
HOLE
7/zz"-DlA,
HOLE
Vzz" CHAMFER
ON ALL HOLEg
EXCE?7
Sdgdg
TA??ED HOLE
3la"-OlA,
HOLE
ON COMPA5SLEG
5/zz"-olA.
COMTA51 LEG
9HORT
(67+qLON FLANK)
HOLE
',l
t/--T
TI
o-3zIHREAO5
6M";;*;*;;"
1U4
tt
I
"/b
s/sz
sAzx3/q-
s4zx3A- 8Vt
Required
for
542x17/e-
8h
6Ya
OUT1IDE
54zx3A- 8Vz
sAzx3/q-
CALIPER LEO
(a3l4LLONG BLANK)
83/a
Each Tool:
NOTE: t-oNo
COM?499 LEO
I5 THE gAME
A5 DIVIDERLEG
1/6
)v,i-
IN9IDE
CALI?ERLEG
(67zqLONG ELANK)
OIVIDERLEA
(a74'LLONO ELANK)
ShopNotes.com
t7
3/c"'DlA,
10?
making a basic
DIYIDERg
Leg
DIVIDER
LEG
mild
steel blank.
gLANK
(5b2" x2" - bl+")
Vzz" CHAMFER
ON ALL HOLE9,
60TH 5tOE3
is an accurate layout. To
accomplish this goal, I used blue
layout dye to color one face of the
steel blank (upper photos at left).
The dye provides a nice contrast
for the layout lines you scratch in
with a shalp scribe. This leaves
you with clean, crisp lines to work
to when drilling and shaping.
Centerline Reference. The first
mark I made on the blank was the
L Cutting to
with
a slight chamfer
countersink (inset).
1B
using a
Shape. Use
'\
r't
ftnish,
lii
Practical.
Dividers are a
DtSC
9PRINO
(<=>/
Assembly. You're
almost
ORA99
WAgHER
DIVIPER
LEGS
CUT FROM
SHEET 1TOCK
G
NOTE:
ell
FouRrooLo
Shop-Made Washer.
hole
(aRJNO%
OFF
END BEFORE
u9rNG)
ORA55
3/+"-DlA,
10?
buildino the
Compass &
Ca'lipers
/
c:"ffi
(B/sz"
NOTE:
roxo
ELANK
x2" 'OV+")
9LANK-
COMPA55 LEA
19 THE gAME
A5 DIVIDERLEG
coM?As9,
20
rN9tpE
CALITERS
L
CAUPEN$
est curve
It
it
will give
3/+"-DlA.
OUTjIDE
CALIPER LEG
Outside. Ihese
(5/zz"
ShopNotes.com
Inside. Take
the guesswork
out of measuring
pipe and hole
diameters.
before
10?
to have near a
lathe to check
your progress
on turnings.
x2" - O3/+")
OUT9IDE
CALIPERS
2T
Our Shop
$hop
$hort
Cuts
-::--
Moking o
Feotherboord
When it comes to ripping a very
thin workpiece, I like the added
control a featherboard offers. But
good idea to locate a con-
miter gauge. After fitting a removable index pin into the kerf, \'ou're
it's not
it to final
THIRD:
FAgTEN AUXILIARY FENCE TO
MITER OAUGE, 9LIDE FENCE
50 PIN 19 KERF.WIDTH
9LANK
AWAY
(35/s" x511A6")
FROM 9LADE
(poN'T 6LUE)
AT BAND 9AW
I
3
NOTE:
REMOVE
INDEX PIN
TO 5TART
INDEX PIN
(1"
22
CLEAT AND
FENCE ARE MAPE FROM
/ryr',
ib ,/ /,/
t,
,/./r",",
1,2,
/,//47
/,,/,/,/
ffi.Sw$9&-
ffiwrpm$ffi
Paintin
Tffi
Ber SIed
as iliustrated
in Figure 2. (Mine
MDF
extra
ShopNotes.com
Croove.
There's one
OPENINO IN T.TRACK
storage soluticrns
modular
Garage
Storagq
lnexpensive and
easy to build, this
wall-mounted
system is a great
way to add
versatile storage.
T
24
start with a
Benchto
Although you can start building
this storage system with any of the
componenb, I decided to begin
The
nice thing about doing this is
that once it's complete, you can
instail the ben&top and have a
solid worksurface as you com-
.-/-
gtoB
NOTE:
prvrpER t9
-#6x1lz"
CENTERED IN
OPENING
Fh
wooo5cREw
in Figure
1a. Finally,
&
Bottom.
a.
glrrlvtEw
12" FULL-EXTEN9ION
PRAWER 9LIDEg
CENTER 9TILE
(1V2"
PRAWER,9LIDE9
ARE CENTERED
VERTICALLY IN OPENING,
FLUgH WITH FRONA
EOGE OF 5IDE9
x5lz")
NOTE:
FACE FRAME
PARTg ARE
s/+"'THICK HARDWOOD,
BACK t9 %',?LYWOOO
rror*t
i,i-i.:.i1;
,1]-*_.
til:r}
rlir'
_:rll
NOIE: pnrl
gcREW HorEg
SIDE
(5" x 15")
4'DRAWER
#b
?ULL
CENTERED ON
x 1V+" Fh
9taE5 0F
wooosCREW
PRAWER
FALgE FRONT
(3%" x2O%")
AND FLU9H
WITH FRONT
(3" x 19")
2.
bets
NOTE:
PRAWER
9LIPE5 ARE
completing the
+-'.E'Tn-
rrsune
?-'-#b x11h,' Fh
t{.;#**
Bench
17'x46"9HEET
(5EE OOx 9ELOW)
7a"
i I
II
CLEAT
(1" x13F/+")
NOTE:
BENCHToP
nNp aeNcFr
SHELF AREs/a"
MPF, CLEATg
ARE 5/+'-THICK
HARPWOOD,
AND 6HEET
24" EHELF
9TANDARD
13'SHELF
sUPPORl
24 AAUOE
LOCAIE CLEAT1 10
CENTER 9HELF
gTANPARDS AND
FRACKETg OYER
WALL gTUP9
10"
SHELF
5U??ORT
FA9TEN 9HELF
9TANDARDg TO WALL
5TUO5,?OgtltON gENCH,
THEN FAgTEN CLEATg
IN PLACE
BENCH 9HELF
SturdyTops. Rolling
the bottom edges and
tacking the corner
creates a clean look for
<
Wrap Around.
For the shelves, the
metal wraps around a
beveled rabbet for a
smooth transition along
the bottom edge.
I found
shelves
a local heating
evervthinq in its
a.
ToP yrEw
b.
srne ugw
Plbce
The bench is a great addition to any
9IDE
(6"
TOFVTEW
x24')
d.
9ACK
(27lz" x25vz")
before assembling
the cabinets is to drill
the holes for the shelf pins
. gt'tp wrw
(6" x23Vz")
fasten-
SIDE
Without doors, a
the wall cabinet
fon60TToM,
HANGING
CLEAT
CLEATg ANO
9TILE9 ARE
3/e"-fHICK
HARDWOOD
(A" x23Vz")
5lILE
(t"
t?6")
(23lz" x35vz")
ShopNotes.com
NO[E: etpes,
aAcK r9
%?LYWOOO,
ANP HANoING
Lll
(4" x36")
AND gHELYEg
ARE'/+" MOF,
r- fr-
29
OpenAccess.
provides quick
and easy access
to the contents.
J
I
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I
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n
,t
44
Detaitrs
oooRs (cc)
56'' LONG
ARE
MAONETIC
000R
(1O7/o"
CATCH W/9TRIKE
x24")
?LATE
1%" x1%"
9URFACE.MOUNT
HINGE
--1
"
NOTE: poone
AREs/+" MDF
33/+
#8 x3/+" Fh
WOOD9CREW
NOTE: apptrtoruRl
HINGE FOR TALL
CAFINET I5 CENTEREP
VERTICALLY
30
TO7
(6" x25
tb
x 1lz" Fh
wooo5cREw
NO[E: srprs
AND
rop
ARE1/+" MDF,CLEAI?
ARE 3/+LTH ICK H ARDW O OD,
--l't,
9IDE
(6" xza")
t'
0-
HANGING CLEAT
(2" x22lz")
,F
HANOING ROD9
(22V2" LONG)
a.
glDE vrEw
e/+"'OIA.HOLE,
V2" OEE?
HAN6ING
ROD
\O
for the conduit, you can cut rabbets along the top ends of each
side to accept the top. The top is
cut to length so the overall width
of the cabinet is 24". (To allow you
to hang items from the lower rod,
there's no bottom.)
store everything.
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
Sides
Unit)
(2)
Top,zBottorn
Divider (1)
(2)
(l)
Stiles (2)
Top Rail (1)
Bottom Rait (1)
Center Stile (l)
5 x14 -3AMDF
1334 x 43 - Yc UOf
3Vz x133A - 1y2 MDF
Back
Drawer Front,/Back
Drawer Sides
Drawer Bottoms
5 x 43
lc x|A
% x3/q - lZy2
%x1/q
(4)
- a2Vz
% xlVz - 3Vz
Vz x 3 - 19
(a)
lz xl - 13
(2)
127zx19 -%ety.
False Fronts (2)
3hx2Oh-/c|/rOf
Benchtop (l)
17 rgh. x 48 rgh. - 34MDF
Bench Shelf (l) ]2 rgh. x 44 rgh. -/q l/.Or
Cteats (4)
%x1 -1334
P
Q
-hPly.
ToplBottom
(2)
ShopNotes.com
-%|/'Or
R
S
T
U
V
Shelves (2)
%x2-22V2
23Vzx23h-%ety.
5/zx22Ye-34MDF
Vqxl-24
Stiles (2)
Doors (2)
1o7Ax24 -3/aMDF
TAtt WALI
X
Y
Z
Top,zBottom (2)
Hanging Cleats (2)
Back (l)
AA Shelves (3)
BB Stiles (2)
CC Doors (2)
8x23h-laM.Of
lqx2-22Y2
2lVzx35Vz-%ety.
7/zx22t/a-%uor
Yqxl-36
1O74x36
-lqt/'Of
EE Top
FF
(1)
To download a free
cutting diagram for the
Storage System, go to:
6x2lh-tAl/.Or
Yqx2-22Y2
Yq-Dia.x23Y2
StropNotes.conr
6x23Vz-lq l/rOf
31
I)-"
clsS?rnollrle
process.
,\
'\ii.
'
' 'iS.*'
'l i-.'., \:>
..1
Grooves in frame
pieces sized
to hold panel
nRY S$SEWlgtY
in
grooves? A
plywood panel has an annov-
the lower right photo on the previous page. This eases the fit of the
panel into the grooves. And it prevents the face veneer from splintering. The gap it creates provides
a
glue in the right places and assembling the frame and panel in a logical order. But before you begin, it's
a good idea to clear your workstuface and "preset" your clamps to
the width of the door.
Spreading Glue. The two photos at the top of the page show
how I apply glue. A brush allows
you to spread a thin even, layer on
there's no
<
u:ii:
'x.:
\\
':."1{t
i.\
'\_
Check
for Square.
Lightly tighten
the clamps
and make sure
the assembly
1i1,;^
:i
is square.
@P
{ Across
the Middle.
Compare the
middle to the
ends to see if
the stiles are
bowed.
&
ShopNotes.com
...'/
$,/
JJ
f,
l-l
lJ
Iiln!,l
{i::s
@
r cl
,J
,,t^
Some
of the other
features
I replaced my
with a 40-tooth,
the blade.
standard blade
ShopNotes.com
has
35
micro-adjusting
Rip Fence
ff*,$ rtcunr
& l**
,{hv4#
KEY
l+"-2ox1"
eruDDED KNOB
(Uo"
FIXED 9ASE
x!z"
- 1%")
NOTE:
srr
together
lr-lhfqK
(:
\SEEFIGURE4b
a small
glrptN6 AAgE
(eEEFICURES)
fence.
these
Since
this could be a
little
sHr
(33/i'x29" '5/i'?tv.)
fr.t-dr:-i:
rlcune
:::li$-_*
,.4-i('- i
#O xVz" Fh
wooDsCREW
ON ANOLEP EIOE OF
9LrDINO
OA5El0
FIT T-TRACK
of the fence
onoase22.
,/
\sulu
DETAIL \ \,
FEATHEREOARD
'1
FEATHER9OARD
(1/2" x3!2" - 6")
l+"iti-,l
Y4"-2O
THREADEP
t/+"
- 20 x1"
FLANGE EOLT5
FENCE FACE
SLIPING
6AgE
FIXEP
BASE
ShopNotes.com
lndicator
At this point, the two sections of
the rip fence are essentially complete. VVhat's left is to connect
them so the fence can be locked in
position to make a cut.
see
how
7.
a hardwood runner.
The plate is attached to the fixed
base and the runner hooks into
the T-track in the sliding portion
of the fence, as shown in the photo
at right. Aflange bolt, washer, and
knob hold everything in place.
The trick is that the runner in the
plate sits in an angled groove. This
allows it to mate with the tapered
fence. The good news is that you
c.u:r use the same taper sled you
used earlier to cut the groove. The
details are on page 23.
\,Vhen sizing the groove, the goal
is to match the width to the slot in
the top of the T-track, as shown
in Figure 7a. Then you can cut a
hardwood mner to fit and glue
plate with
#8
x 1V+" Fh
FENCE RUNNER
L Adjusting the Fence. A ruler and indicator help you fine-tune the
position of the sliding fence. Then lock it in place with a knob.
it in place. The last step is to drill
a hole to accommodate the flange
feature
- a hairline indicator. I
use it as a gauge to adjust the position of the fence face. The tapered
fence design gives you finer control for adjusting the fence. The
ruler allows you to move the fence
in precise, small increments. For
example, an Ve" of movement on
the ruler moves the fence 7o+" closer
or farther from the saw blade.
small oarts
\- Crosscut Sled
The platform and rip fence allow
you to make precise, small-scale
rip cuts. For crosscutting a small
part, you need an altemative to a
miter gauge. There are a couple of
challenges. The first, of course, is
cutting the piece accurately. The
second
Figure
provides
A Crosscut
Hold-Down. The final thing to
make is the hold-down. It consists
(Figure 9a).
square
solid controlwhile
making an accurate crosscut on
a small part.
l+"-2O x1"
9TUOOED
HANDLE
HOLD.DOWN
FACK
W FLAI-
WASHER
V4" FLAT
WAgHER
1/4"-2O
THREADEP
IN9ERT
HOLD-DOWN
FRONT
OLADE OUARD
x5" 's/+'?ly.)
(3/+"
115A,
A Platform(1)
B lnserts (2)
C Splitter(])
D Miter Bar (1)
E Fixed Base (l)
F Keys (2)
G Sliding Base (l)
H Fence Face (l)
I Featherboard (l)
J Ptate (1)
K Fence Runner (1)
L lndicator (l)
CROSSCUT SLED
M Sted Base (l)
N Fence (1)
O Blade Guard (l)
P Runner(l)
a Hold-Down (l)
R Hold-Down Back (1)
5 Hotd-Down Front (1)
.
20x29-t/aply.
2x29 -hHdbd.
Ysrgh.x2-Ya
lz x3A - ZS
33Ax29 -3/a ply.
%x/z-1h
-% ety.
-% ety.
3hdx29
2/+x29
Vzx3Vz - 6
3Yqx12-% ety.
5/dxsld-12
lVzxZ- 76 plastic
6x12-hHdbd.
Vzx3A -'tZ
3/4x5 -3/e ply.
Ycx6-hHdbd.
Va, x11s4e
x7,ts
. (21h"-zot-slot Nuts
. (1O)h-2O Threaded lnserts
. (5)h"-ZO Star Knobs
. (z)h"-ZO x l" Studded Knobs
. (l)%"-ZO x l" Studded Handle
. (l) 12" Ruler
. (1)1y2" x2" -ys" Plastic for tndicator
ShopNotes.com
-Y4" Hdbd.)
-4
%xYq-1tsAe
. (5)Y4"-2o
SLED aASE
Sled.
. (9lyo" washers
. (10) #8 xVz" fh Woodscrews
. (4) #8 x 1%" Fh Woodscrews
39
(L)
-'lts4.
r'
it
?'!='rl:i
= OEilO
-3
receptacle
,_*;;;;,fE
l-F
E.
i.9
40
If your
shop already
i.
^y
either voltage.
shown at left.
to 110/220,175/230, or 120/240.
Once
HP 1 L/2
volrs
L20 / 240
low voltag
INSUL.
TIME
FACTOR
CLAS5
PIug Change.
When converting
a motor to 240-volt
operation, you'll
need to change the
plug on the cord, as
lf
shown below.
1.0
MAX. AMBIENT 40 " C
RATING CONT.
L"
<
itr
ENC. -DP
KVA CODE
would
h voltag e
RPM 3450
AMPS L2.8/6.4
PH 1
SERVICE
e / h ig
power
LETTER
convert
to
Once
comes
ROTATION CW-OPE
BROWN
RED
---_=(^
-:
LOW
VoLTAGE
BLUE-----)--
LINE
e-urur
HIGH
EEBE-:Z@VOLTAGE
--{O
BROWN
@-LINE'l
O- ltrvr z
SAFETY NOTE
ll you are not
electrician.
move, converting
is easy.
rA
comtortable
performing
electrical work,
consuft with
a licensed
f Extension. You
can easily make an
extension cord for
your 240-volt tools.
usc
clav, so
eclikrrs.
a couple of pieccs of
scri,rp
.rbout
jr-rst
of the
ivorkout to
BOX BTANKS
9ECTION yrEw
t/32
I
11/2
example,
two of the patterns show an extrathick base with a band-sawn cutout. The thick base raises the stone
up a bit making it easy to use the
stone in the box if you choose to.
The third pattem can also be cut
with the band saw, but I decided
it would be easier to mill the two
"feet" on an extralong blank, then
6A1E
BLANK
NOTE: eLaNr
DIMENSION9 ARE
FOR A 1" x 5'- A" STONE
But,
little about using the box. I occasionally use mine to hold an oilstone while I do some honing. After
stone.
the
will
leave plenty
of room for just about any stone. I
ish Looks
DOUBLE-FEAD
g-,ul
85/a"-RAD.
ROUNDOYER
43
S@{otes.conn
FIF{Hr
FIGLIRf
EDGES
FOURTI-ir
CUT
211/zz"
-W|OE
OVERLAP THE
tsA5E BLANK
91RlP5
Template
Since there's
no joinery,
these
layers of
V+"
1]
OOOOLE.SIDED
TATE
,"//
z' ,/ ,''tHlR.D:
'.,,'tocroase
STR!?5
IOAETHER
WITH DOUELESIOEO TATE
\\
FIRST:
-Y^:-
?fiG::;\[i.6+:
wrDrH oF ELANK
NOTE:
cur
\-V
-SECONFT
?LU) 4")
,riFrk,
rrurL-,qres,qee
MADE FROM
1/+"
-<
HARD9OARQ
all around
NOTE:
ROUT IN MULTIPLE
1/r"-DEE?
FIR9T:
rllr
9ECOND: nour
44
CORNER9 OF RECE1g
WITH CHIgEL
b.
I
u"i-kio.l
I areorrue
completed,
1/+"
ROUT EEAD
MOLPING PETAIL
ON OOT|OV EDGE
OF LID BLANK
ffi
c.
ll
lr
ffi
acrylic (Plexiglas).
LAR6E ROUNDOYER
All
ffi
(bottom
Base Details.
Lid Details.
provided above or
come up with your
own molding style.
(detail'd').
used a band
nrcune
ffi_*
9ECOND:
cRo99CUT
FEETlO
LENOTH
NOTE: nour
ROUNPOVER IN
TWO OR MORE
PAg9E5
BE guRE To coNgtDER
DEPIH OF RECE55 WHEN
LAYING OUT AND CUTTING
aASE DETAILS
NOTE:
9ECOND
PA55
OASE
BLANK
THIRD:
GLUE FEET TO
UNDERgIDE OF
EA9E ELANK
ShopNotes.com
45
4-.tti
t..
ll
ll 9)
Learn a few easy steps that
will help you rip stock safely
and accurately.
il
Another consideration
SECOND:
ROTATE THE
ilH
il il
il il lt ll
I
ALI6NED, CON9ULT
YOUR OWNER'5 MANUAL
TO FIND OUT HOI,VTO
ApJU9TTHEM
46
U L_
the
11
FlR9fr UeE A
COM6INATION
9AUARE TO
MEASURE FROM
THE MITER 9LOT
TO A TOOTH
AT THE FRONT
is
NOTE:
GULLEI I9 JUST AOOVE
WORKPIECE
sofe ripping
Techniques
To make safe, accurate cuts you need to maintain
constant control of the workpiece while moving it
past the blade in a smooth, steady motion.
in the
three
<
Splitter. When a
IF PO9SIOLEUSE
BLADE GUARP
ASSEMFLY
DURING CUTTING
FEATHERBOARD
AHEAD OF
gAW OLAOE
To see a video on
how to build your
are a few additional safety accessories you can use. These include
a good featherboard, outfeed support, and a push block.
Featherboards provide extra
control.It's likehaving a third hand
to hold the workpiece up against
the rip fence. Ttie best thing about
a featherboard is that the "fingers"
only allow the workpiece to move
ShopNotes.com
decreas-
il llffia
IitH
STEP
l: rerr ll
JUI
ll,r
'ii-"Tl
ll
9TEP 2t use
RI6HT HAND TO
PUgH WORKPIECE
INTO BLADE UgINO A
SMOOTH,STEADY
lTo*
lt_J t_J
EASY REACH
9TEF5:
END OF
ns
WOR,KPIECE
REACHE9TAaLETOE
U5E RIGHT HAND
BLOCK.
I
I
fo
?UaH
WHILE
PtcKU?
PU9HING WORKPIECI
'Ilru!
9lE?
gHOULD NEYER 60
PAgT THE'NO PA99'
ZONE INDICATEP
EY REP LINE
Forlow
9TEP$: pouor
LET GO OF THE
WORKPIECE UNIIL IT
HAg COMPLETELY
CLEARED THE ELADE.
TURN OFF gAW AND I
47
{::r:-
i$
Hn
a
gr
f\
teeth.
lf
with
Xtrn-Clesn
the new
Wood
for
blade from Boscl1.
TEIGH H{}ID.BOWN
f;tAMPS
clamps
Surface Mount
Bench Mount
Versatile
cam-action lever
offers quick
Non-marring
pad
ZA12 alloy
and glass-filled
nylon provide
superior strength
operation
Non-marring pad
Bench anchor
can be screwed
or bolted in place
Speed nut
allows for fast
up to
installation
as
thick. (You
can even use it on your drill press
table.) And the clamp works with
that's
41A"
removed in seconds.
ShopNotes.com
through hole
(see detail).
^51.'
Bencfi Use.
if the quick
A long threaded
rod and a speed
nut allow you to
use this clamp on
any surface with a
Bond
[: I
Thick
Wffiffi@ffi
A Family of Adhesiyes
49
questions from
Our Readers
sonding
Metals
r
t-
When
it
rye-'
Kennis Riley
mild
shape and grind metals
- quite
steel, brass, and aluminum
often on my sander. Today's abrasives are certainly up to the task.
(I typically use 80-120 grit.) It's a
great way to smooth up an edge,
grind a bevel, or create a shape on
these common metals.
I don't
A Straight Edges.
50
Technique.
With the
house-
photo at left. Again, the downward direction keeps the workpiece tight to the table.
nilAtt
Sources
Most of the materials and sr.rpplies you'll need for the projects
The
Woodsmith Store
aoo-444-7527
r Reid Supply
PrillHntdles.
ORDER
SOURCES
"MistctlFcni'
SMAtt
.....482
Enco
800-873-3626
T-Trnck
36"
1fi"-20lrtserts
.. ..12K79.24
I/+"-20 T-SlotNuls. . . . . . 05J21.15
1/"t"
Reid Supply
..
Knb
zu/
..
-20
Thpercd
. DX-100-4
"
..00M90.01
Shd..
. 00M51.02
Rockler
Miter Bit . . .
Freud Lock Miter Bit .
45" Lock
22627
35810
o Woodsmith Store
Annrn
Locl<
Mitcr Bit
KN0BS
...
272118
fp.lo)
You'll find
..
. . . . . 5382
149059
.....
749060
Valley
Ieevalley.com
McFeely's
mcfeelys.com
MLCS
800-533-9298
Woodsmith Store
lig
he
800-871-8r58
mcmaster.com
Woodcraft
Bosclr
freudtools.com
McMaster-Carr
330-342-61 OO
. Lee Valley
Freud
aoo-334-4107
aoo-443-7937
MLCS
Dntlo ClcntrOut Bit.
use-enco.com
hnert . . . 00M51.01
o Enco
Benjamin Moore
benjaminmoore.com
Lee Valley
1/+"-20
Rockler
800-279-444L
rockler.com
McMaster-Carr
....KHO-5
mlcswoodworking.com
Snitt Blades . .
.. .
269097
Reid Supply Company
r Rockler
aoo-253-042r
reidsupply.com
800-225-r r53
woodcraJt.com
r5,
i!,,fi'!i, ,z
#i,f;
HARDBOUND VOTUMES
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(Volumes 9 through 16). Eoch volume includes o yeor of
issues,
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51
modular
Garage Storage
X Top/Bottom (2)
8 x 231/2 - 3/4 MDF
3/ x 2 - 221/
Y Hanging Cleats (2)
4
2
Z Back (1)
231/2 x 351/2 - 1/4 Ply.
AA Shelves (3)
71/2 x 223/8 - 3/4 MDF
3/ x 1 - 36
BB Stiles (2)
4
CC Doors (2)
107/8 x 36 - 3/4 MDF
HANGING ROD CABINET (Per Unit)
DD Sides (2)
6 x 24 - 3/4 MDF
EE Top (1)
6 x 231/2 - 3/4 MDF
3/ x 2 - 221/
FF Hanging Cleats (2)
4
2
3
GG Hanging Rods (3)
/4-Dia. x 231/2
CC
G
I
W
U
FF
CC
DD
DD
EE
BB
B
Z
M
C
AA
AA
AA
L
C
A
A
Page 1 of 1
K
D
Radius Chart
RADIUS CHART
(dimensions are approximate)
1. DIME
!!/32"
2. PENNY
#/8"
3. NICKLE
&/16"
4. QUARTER
!/2"
1!/8"
1%/16"
2!/8"
2#/8"
9. ROUTER BASEPLATE
2&/8"
3!/2"
PAINT CAN,
GALLON
ROUTER
BASEPLATE
The radius of a
quarter is just a
little under 12".
FINISH CAN,
1 QT.
PASTE WAX
CAN, 16 oz.
2!/4" O.D.
VAC HOSE
SPRAY CAN,
1112 oz.
PENNY
DIME
Page 1 of 1
QUARTER
NICKLE
Design Options
Page 1 of 2
SIDE VIEWS
END VIEWS
CL
LID
9"
RADIUS
LID
!/2"
RADIUS
BASE
!/2"
RADIUS
8#/4
1#/8
!/4"
RADIUS
#/4
!/4"
RADIUS
120
3#/4
!/8
#/8"
RADIUS
2!/4
#/4
!/2
#/8"
RADIUS
8#/4
1!/4
3#/4
OPTION: CAN
CL
ENLARGE SIDE
VIEWS 235% TO
USE AS PATTERN
2!/2
#/16"
RADIUS
!/2"
RADIUS
#/8"
RADIUS
%/8"
RADIUS
&/8
%/8
1"
RADIUS
2!/4
!/4"
ROUNDOVER
!/4"
RADIUS
1&/16
3#/4
1!/4
8#/4
!/2"
ROUNDOVER
BASE
NOTE: DIMENSIONS
&/8
!!/32"
RADIUS
2!/4
8#/4
3#/16"
RADIUS
!!/16
&/16
!/2"
RADIUS
2!/4
#/8
#/16
3#/4
#/16
!/4
2!/4
!/16
!#/16
#/4"
RADIUS
1!/2
8#/4
3#/4
!/2
!/16"
RADIUS
#/4
#/4
2!/4
#/4
!/4"
RADIUS
8#/4
!/8
Page 2 of 2
1!/4
3#/4
thin strip
Ripping Jig
Improve accuracy and get
consistent results with this
handy ripping jig.
Ripping multiple thin strips to a
consistent width at the table saw
is tricky at best. Its hard to reset
the rip fence after every cut for the
exact thickness you need. The jig
you see here solves the problem.
Details. As you can see, this jig
locks into the miter slot to the left of
the saw blade. A rub bearing fixed
to the end of a sliding top is used
to gauge the thickness of the strips.
!/4" - 20 T-KNOB
(need two)
!/4" WASHER
(need two)
!/4" - 20 x 1!/4" Fh
MACHINE SCREW
(need two)
Page 1 of 1