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Our
SHOP-BUILT Biggest
MORTISING Issue Ever!
More
MACHINE Projects,Tips
& Techniques
Mortises Made Easy!
INSIDE:
Tips & Tricks on
Installing Drawer Slides
Tuning Up Your Drill Press
Using Bar Gauges
Editors Top Picks
Table Saw Blades
WS217_001.indd 1 12/8/2014 10:08:31 AM
Printed in U.S.A.
20
26
30
Projects
shop project
Scissor-Lift Workbench . . . . . . . . . . . . . . . . . . 20
Built around a foot-operated lift cart, this workbench is easy to
set to any height. Plus, great clamping options and a dust
collection system make it the perfect solution for any shop.
weekend project
Spice Carousel. . . . . . . . . . . . . . . . . . . . . . . . . 26
Keep your most-used spices close at hand with this rotating
carousel. Youll find a lot of woodworking packed into this
project along with finishing options for creating a unique look.
shop-built machines
Router Mortising Machine . . . . . . . . . . . . . . . 30
Youll be creating precision mortises with ease using your
routers motor and this shop-built machine. The secret to
its smooth operation is ordinary metal drawer slides.
heirloom project
Stylish Cherry Hutch . . . . . . . . . . . . . . . . . . . . 40
With its elegant look, this tall hutch will add style and some
40 much-needed storage to any dining room. And youll learn a
lot of great techniques and tips as you build it.
Woodsmith.com 3
Departments
from our readers
Tips & Techniques . . . . . . . . . . . . . 5
all about
Working with Bamboo. . . . . . . . . 10
54
router workshop
Milling Bits for Mortising . . . . . . 12
great gear
Creating a Custom Plane . . . . . . 14
woodworking technique
Installing Drawer Slides . . . . . . . . 18
in the shop
LED Lighting Retrofit . . . . . . . . . 58
woodworking essentials
Choosing & Using Bar Gauges . . 60
mastering the table saw
Saw Blade Preferences . . . . . . . . 62
tips from our shop 60
Shop Notes . . . . . . . . . . . . . . . . . . 64
4 Woodsmith / No. 217
Tips &
Techniques
Cleaner Circle Cutting
Faced with the challenge of creating mul-
tiple wood discs for coasters, I needed a
way to cut them out without making a
center hole in the workpiece. I came up
with a simple solution using a circle cut-
ter and a scrap block.
To do it, adjust the drill bit on the circle
cutter so its higher than the depth of the
cutting blade by the thickness of the work-
piece, plus 18", as shown in Figure 1.
Use a scrap block of wood thats at least
the same thickness as the workpiece from
which the circle is being cut and shorter
diagonally than the diameter of the circle.
Locate the block in the center of the circle
and use double-sided tape to hold it in place. 1 2 Circle
To keep the parts from moving as the Circle cutter
cutter
blade makes the cut, clamp the work-
piece to the drill press table. The block
stabilizes the circle cutter without drill-
ing into the workpiece blank. The disc is Drill
completely cut out when it starts to spin. bit
Blade
After removing the scrap block, youll Drill bit Blade
Woodsmith.com 5
QUICK TIPS
Multi-Tool Sander. Bill Wells of Olympia, Washington, Band Saw Table Pin. Bill Huber of Haslet, Texas, got tired
found the sanding accessory that came with his multi-tool of looking for a wrench to remove the table pin every time
too large to get into tight areas. So instead, he wraps strips he changed his band saw blade. Instead he drilled a hole
of adhesive-backed sandpaper onto an old flush-cut blade. in the head of the table pin and installed a solid steel pin
This allows him to sand the tight spots. that provides enough leverage to remove it by hand.
Woodsmith.com 7
a. b.
%/16
TOP VIEW SIDE VIEW #8-32 x #/4" HANDLE
Ph machine 2!/2 NOTE: Drill
screw center hole
5!/4 NOTE: Base is made in handle
from !/2" plywood. at drill press
Dowel is #/4" -dia.
#/4
HANDLE !/8" -dia.
2 BASE
BASE
#/4" -dia. !/2 BASE #/8
!/2
!/4"-20 x 2"
hex bolt #/4
Dial 1#/4
indicator
#/8
BODY
7!/2
!/4"-20
threaded knob
Tee Woodsmith.com
and click on
WOODSMITH TIPS
PVC
Pipe
NOTE: Size PVC pipe Youll receive one of our favorite tips
Snap to accommodate your each and every week.
tee support stand
Woodsmith.com 9
working with
Bamboo
Over the centuries, bamboo has been used for every-
thing from walls and roofs to cooking and eating uten-
sils. However, until recently, availability was limited to
the regions where it grows. Using modern processing
methods, bamboo has become more widely available
throughout North America in products such as floor-
ing, countertops, and cutting boards. But bamboo is
also a great material for woodworking.
BAMBOO CHARACTERISTICS to those of red oak. (See the box on the extremely fast. Plus, it regrows from the
Bamboo is actually classified as a mem- opposite page.) Compared to red oak, root stock, meaning the plant doesnt die
ber of the grass family. Most commer- bamboo is harder but lighter, and has when the bamboo is harvested.
cially grown bamboo is a species called a finer texture. However, a large part Even though raw bamboo has to be
Moso and is primarily imported from of what makes bamboo so desirable transported from overseas locations, its
Asia. It has several characteristics similar as a building material is that it grows often touted as a green, sustainable
material. But to be made into lumber
Horizontal grain Vertical grain products suitable for furnituremaking
(natural) (natural)
and other uses, it requires extensive pro-
cessing. Bamboo stalks are segmented,
hollow tubes with thin walls. They have
to be cut into strips and laminated into
boards, panels, and veneer using adhe-
sives under high pressure.
VARIETIES. The strips can be glued
together edge-to-edge (horizontal grain)
or face-to-face (vertical grain) as shown
Horizontal grain Vertical grain in the upper photos at left. As you can
(carbonized) (carbonized)
see, horizontal grain exhibits the unique,
interesting grain patterns by which bam-
boo is typically identified.
Carbonized bamboo (lower photos at
left) is darkened by the application of heat
during processing. This process actually
caramelizes the sugars in the fiber.
Bamboo is extremely easy to machine
{ Whether sold in its natural state (upper left photo), or with a darker, carbonized look (lower with common woodworking tools,
left photo), horizontal-grain bamboo has the characteristic nodes most associated with although it tends to splinter some when
traditional bamboo. Vertical-grain bamboo (right photos) has a more uniform look. cutting across the grain. In addition,
Woodsmith.com 11
WORKING WITH END MILLS. If youve ever cut should go smoothly without burning, the upper right photo. It all comes down
mortises with a router, then using an end although some burning at the ends of to the type of work you do or would
mill will be a pretty familiar experience. the mortise is normal. If all goes well, like to do. I suggest starting with a 14"-
Even so, it pays to run through a few you can set up to take a deeper cut (14") dia. bit. This is a common size for many
pointers. And if youve never routed for subsequent passes. furniture-making tasks. The second bit
mortises, this is a good place to start. The bits do a pretty good job of pull- to get is a 12" roughing/finishing bit.
Since mortises are deep cuts, you cant ing chips out of the cut. But on a deep This bit creates a heavy-duty joint in
rout one in a single pass. Its just too mortise, you may need to vacuum out the larger workpieces.
much material to remove. Instead, you debris to limit heat buildup and bit strain. From there, you can pick out some in-
want to nibble away at the mortise in a For larger diameter bits (38" and 12"), between sizes like 516" and 38" bits. These
series of progressively deeper cuts, as Ive found that slowing down the router give you flexibility to match the mortise to
you can see in the photo above. (if your router is equipped with vari- the size of the workpiece. A good rule of
How deep of a cut you can take depends able speed) helps it cut more evenly. On thumb is that the mortise should be about
on the material. Dense wood requires a my router, that meant slowing down to one third the thickness of the workpiece.
shallower cut than softer wood species. 16,000 RPM (the halfway setting on the Be aware that these two bits require some
With this in mind, I like to set the router to dial). Remember, end mills were origi- additional hardware for your router. Take
take a 18"-deep cut on the first pass. nally designed for cutting metal at slower a look at the box below for details.
USE YOUR SENSES. Listen to the router and speeds. So a slower router setting will You can depend on your router to cre-
notice the condition of the cut to help help it clear wood chips more easily. ate accurate, smooth mortises. End mill
you gauge your progress. The router WHICH BITS TO GET. Speaking of bit sizes, bits offer you a way to get those results
shouldnt sound strained. And the cut you have several options, as shown in without spending a lot of money. W
Woodsmith.com 13
creating a
Custom Bench Plane
In the fall of 2014, Lee Valley introduced
Veritas #4 Smoothing Plane
a line of Veritas custom bench planes
with the claim that they could be made
Lever cap Cap Blade carrier Tote nut in over 9,000 different combinations.
iron
As you can see in the photo above, the
Norris-style styling is sort of a blend of modern
adjuster
and retro looks. But I was more curious
about how these planes can be custom-
ized and, more important, how they
Tote perform on the workbench.
TRADITIONAL SIZES. You can order a plane
in the following sizes based on the con-
Blade ventional Stanley/Bailey bench plane
numbering system: 4, 412, 5, 512, and 7.
Prices range from around $270 to $380.
Frog
Once you choose the size of plane you
Knob want, you have a number of choices to
make to design your custom plane.
Body
FROG ANGLES. The cutting angle of the
Mouth plane blade is one of the most impor-
adjustment tant considerations to make. And the
screw
Tapped frog of the plane dictates this angle. A
hole frog is simply the bed where the blade
Blade set
Toe screw rests. Its shown in the illustration at
plate Tapped
hole left. Lower frog angles are great for
trimming end grain. Higher angles can
55o Frog
45o Frog
{ A high-angle frog positions the blade { On most traditional and antique hand { A low-angle frog places the blade at an
to provide more of a scraping action for planes, youll find a 45 bed angle thats angle that slices through end grain more
smoothing figured grains. suitable for general planing tasks. easily for a smooth surface.
Woodsmith.com 15
Woodsmith.com 17
When attaching the slides to the slides wont get in your way. And you seem like overkill, but without these
drawer box, its a good idea to drive can just cut the spacer down to line up screws, the slide mechanism will likely
screws through the vertically slotted the next pair. Here again, use the slotted creep out of alignment over time.
holes first (far right drawing). This gives holes (running side to side). This will If you pay attention to these few
you room to adjust the position up and allow you to fine-tune the front-to-back details, youre guaranteed to get the best
down for the best performance and look. position of the drawer in its opening. performance from full-extension slides.
CABINET COMPONENT. Attaching the slides Completing the installation process The result is drawers that you can rely on
to the drawer boxes is pretty straight- means youre ready to put the drawer to carry a heavy load and operate
forward. Installing the other half of the into place and fit the two components smoothly year after year. W
hardware is a little more involved. Thats back together. Carefully line up each part
because youre working inside a cabinet and slide the drawer box in. Youll feel a
where things may be a little cramped little resistance here. Dont be surprised.
and dark. In addition, you need to make Thats just the way the parts reengage.
sure each pair of slides are installed con- Once the drawer is installed, it should
sistently side to side. operate easily. If it doesnt, take a look at
Drive screws
The method I turn to for this task is the box below for two remedies. into fixed holes
to secure slide
highlighted in the three photos above. DONT STOP NOW. Once both parts of the in place
The secret is an MDF spacer. This sup- slide are installed and youre satisfied
ports the slide and guarantees that each with the fit and movement, theres one
part is aligned. Then its just a matter last step thats easy to overlook. Thats { Complete the installation process by
of starting at the top and working your to add screws to the round, fixed holes driving screws into the fixed holes in both
way down. This way, previously installed in both components of the slides. It may the drawer (shown) and case components.
Woodsmith.com 19
Scissor-Lift
Workbench
With this multi-use, compact workbench, you can raise any project to a
comfortable working height easily and safely.
For years Ive had a scissor-lift cart in The mechanical advantage provided design and dust port allow it to also
my workshop. Ive primarily used it for by the hydraulic cylinder is incredibly function as a downdraft sanding table.
loading and unloading heavy items from convenient. But by adding the additional Best of all, building this workbench
my truck. It wasnt until recently that I workbench (complete with vise, tool tray, wont take you more than a couple of
decided to take my cart to the next level and magnetic tool holder) its easy to turn pleasant days in the shop. Turn the page
and make it even more useful by adding a one dimensional cart into a must-have, to get started on this Swiss Army knife
the auxiliary top you see above. multi-use workhorse. The hollow-body of shop accessories.
Locking swivel
casters keep cart
from moving
during use
Fixed
{ A dust port on the side of the casters Hydraulic lift makes
benchtop allows it to function raising and lowering
the workbench a breeze
as a downdraft sanding table.
{ A magnetic tool holder along the { Holes and slots in the benchtop { A wire mesh auxiliary tray keeps
edge of the workbench provides allow you to conveniently clamp often-used items close at hand
easy access to tools. a workpiece in place. without collecting sawdust.
Woodsmith.com 21
BENCHTOP 3
5&/8
2!/4
Benchtop
Transfer centerline of
holes to edges of
dog hole template
Dog hole
2!/4 7!/4 2!/4 template
Dog hole
template #/4" Forstner
4!/2 bit
2!/4 Align centerline of
template holes with
#/4"-dia. through layout lines
hole on benchtop sides
TOP VIEW
19 5!/8
a.
Forstner 5!/8
bit
Template
Backer
B 7#/8
Drill into Benchtop p
prevents 7#/8
backer
board ttearout on First holes drilled
tthe lower with template flush
fface at end and sides
Backer
END SECTION VIEW
Benchtop
2!/4
B SIDE EDGING
37#/4 a.
21!/2
C 1"-rad.
roundover B
END EDGING
C
NOTE: Edging is made
from 1!/4"-thick hardwood.
Dimensions shown are TOP VIEW
before rounding over corners
DOWNDRAFT BONUS. The bench dog holes weight) of the top, I found it much easier edges with the benchtop edges and
also serve another purpose. They allow to drill the holes with a hand drill rather clamp it in place. Be sure to have a
the top to double as a downdraft sand- than taking the top to the drill press. backer board in place under the assem-
ing table when a hose is attached to the To keep the bench dog holes evenly bly to prevent tearout. After drilling
dust port in the skirting. spaced during drilling, I made the sim- the holes, add a chamfer to the top
Drilling the holes in the benchtop isnt ple template shown at the bottom of edge of each hole to reduce chipping.
difficult. But because of the size (and the opposite page. Align the template CLAMPING SLOTS. To make the four slots
in the benchtop, I used another tem-
plate and a three-step process. Shop
NOTE: Size opening in Notes on page 64 explains how to make
vacuum end skirt to fit 18 VACUUM
dust collection hose END SKIRT this template and walks you through
F the process of creating the slots.
29!/2
#/4 BENCHTOP EDGING. With the holes and
5 slots completed, I added the hardwood
D 1!/2 edging to the top, as shown above. Cut
Dust hose these pieces a little long, miter the cor-
hook up
%/16"-dia. ners, and attach them to the top using
5 through holes glue and clamps. I also rounded the
E D
VISE SIDE
corners of the edging (detail a) using
END SKIRT a coarse file and sandpaper.
SKIRT #8 x 1!/2" Fh
woodscrew SKIRTS. The boards that make up the
6#/4
skirting create an opening that is
3
4!/2 sized to fit over the tabletop of the
cart. Cut the side skirts to size first,
and then form the rabbets on each
end using a dado stack at the table
NOTE: Benchtop
and skirts are shown saw. The end skirts can then be cut to
bottom face up length to fit between the sides.
The vacuum end skirt has a hole
a. b. #/8 drilled near the center to accept a hose.
D The vise end skirt is notched to provide
!/4 D
#/4 clearance for the vise rods. I made this
notch at the band saw. With the parts
NOTE: All parts
E #/4 are made from made, use a little glue and screws to
#/4"-thick hardwood Drill and assemble the four pieces. But hold off
countersink
TOP VIEW for a #8 Fh SIDE VIEW on attaching them to the underside of
woodscrew
the benchtop. Youll do that later.
Woodsmith.com 23
G
1!/2
#8 x 1!/2" Fh Vacuum
woodscrews end G
skirt
4
3
BOTTOM
VIEW Side
skirt
28
b. SIDE SECTION VIEW
Side skirt
!#/16 Side
#/8 skirt
Vise
I assembly J #/4
VISE END
BLOCKING
End
edging NOTE: Benchtop Vise installed tight
assembly, vise blocking, against benchtop and end
and vise assembly are edging with lag screws
shown bottom face up
1!/4"x 5" - 60" Hard Maple (3.1 Bd. Ft.) #/4"x 6" - 60" Hard Maple (2.5 Bd. Ft.)
B C J J J
E F
B C
Woodsmith.com 25
Kitchen
Spice Carousel
Solid-wood construction and interesting drill press techniques put an
attractive new spin on your spice collection.
While woodworking is my primary containers dont stack easily and end up the seasoning you need. Best of all, the
hobby, I also enjoy spending time in the lost in the back of the cabinet. woodworking is simple, but interesting.
kitchen. Im not a chef by any means, but The spinning rack you see above is a I made two versions of the carousel.
my family enjoys some traditional dishes welcome solution to any kitchen coun- One was stained (above) and the other
I manage to cook up. tertop. Angled slots display eight jars to was painted (refer to back cover). If
One frustration with working in the keep your most often-used spices read- youre painting yours, you can use an
kitchen, however, is digging through ily available. And a lazy Susan bearing inexpensive wood like poplar. For the
the cupboard to find spices. The various allows you to spin the carousel to select stained version, I used soft maple.
A
BASE
Scribe a
10"-dia. circle Drill #/8"-dia.
shank hole
after drilling
Base counterbore
blank
Layout. Strike lines across the diagonals Rough Shaping. Use a band saw to Centered Hole. A counterbored hole is
and centered on the edges. Scribe a cut the rough shape. Staying close to used to mount a bolt for smoothing the
circle before drilling a pilot hole. the line means less cleanup work. edges and later to assemble the body.
Smoothing the Edge. Use a file and Transferring Lines. To help with Routing Roundovers. Use the bearing
a sanding block to true up the edge of aligning the body of the carousel on the roundover bit to guide the work-
the base and make it smooth. later, extend the lines to the edges. piece to profile the top and bottom.
Woodsmith.com 27
Bumper #/16
C
Alternate 1
grain direction
of layers A
1!/2
Top a.
Wedge
Pin rests spacer !/16
Base 12 on base
8!/2
Base
Bit
centerpoint
12 SIDE SECTION FRONT VIEW
VIEW
Spacer inset 1" from base edge
Woodsmith.com 29
Router
Mortising Machine
Most projects I build have at least a few machine plans. This design has a keep- a snap. Common T-nuts and studded
mortise and tenon joints in them. And of it-simple philosophy. Its mostly built knobs round out the hardware list.
the two parts, the mortise causes the big- from plywood parts that are glued and POWER SOURCE. This mortising machine
gest headache. If thats the case for you, screwed together. The moving compo- uses a medium-sized router motor as
then maybe its time to upgrade from the nents the router carriage and sliding the power source. I find that a variable-
drill press and chisel method. A dedicated table operate with heavy-duty, full- speed router gives you more versatility.
mortising machine may be just the ticket. extension drawer slides. A no-nonsense But even with a single-speed router, this
EASY TO BUILD. Complexity is the big stop system and a commercial toggle machine will make creating accurate
obstacle to most shop-built mortising clamp make cutting identical mortises mortises a quick and easy process.
Upper table
adjusts in and out
to position workpiece
in relation to router bit
Sliding table
rests on
full-extension
drawer slides for
smooth operation
Woodsmith.com 31
#/4"-dia.
22
B 6#/4 C
A
A B
2"-rad. D
C
12
TOP VIEW A
!/2"-rad. BASE BOTTOM
(all corners)
26
#8 x 3" Fh woodscrew
#8 x 2" Fh woodscrew
G G
I H CARRIAGE
SIDE
1!/2 F
CARRIAGE
BACK
C 10
%/16"-18 x 5!/4" 1#/4 #/8
threaded rod 10
NOTE: Cutout in
router mount and
Threaded rod will cut clamp should
threads in router mount. match diameter of
Add epoxy to hole router motor
for a secure hold 4!/8
9!/2 E
2#/4
G G A
H %/8
C !/2"-dia.
F
4!/8 3!/4
6&/8
H
!/4 !/2
2%/8 2%/8
B
2!/8 2!/8
B !/4 1#/4"-rad.
TOP 2!/16
SECTION I
VIEW
The upper drawing and detail b on the ROUTER CARRIAGE. Your work on the fixed the depth of the mortise. Both pieces of
previous page have the dimensions you parts of the mortiser is over. Now its the router holder have a half-circle cut-
need for this. Then I reached for files time to tackle the moving parts. The first out on the inside edges. Like I mentioned
and some sandpaper to straighten and of the these is the router carriage assem- before, I sized this for a mid-size, Porter-
smooth the sides of the slot. bly thats shown above. Cable 892. You may need to alter the size
Creating a mounting point for the This assembly is made up of two sec- of the cutout to match your router motor.
springs is the other detail on the post tions. The U-shaped carriage and the Two short pieces of threaded rod, knobs,
face you need to address. The springs router holder. The carriage is the simplest and washers apply the clamping pressure.
are attached to a pair of eye bolts that are to make. You need to size the parts care- I drilled the through holes in the clamp
anchored to T-nuts. The lower drawings fully to wrap around the post and a pair first. To mark the holes in the mount, I
on the facing page show where to locate of drawer slides. The goal is a smooth used a brad point bit through the clamp.
the through hole and counterbore. sliding action on the slides. The back and These holes are sized so that the rod cuts
The sides of the post are glued up from sides are joined with a tongue and groove threads into the mount for a stronger con-
two layers of plywood. Take note that the joint to align for assembly (detail c). nection. I backed out the rod and applied a
front edges of each layer are offset to cre- The router holder takes a little more little epoxy to the rods as some insurance
ate a rabbet sized to accept the post face. explanation. The holder consists of a before driving them in for good.
When youve completed cutting the taper mount screwed to the carriage and a The router mount can be screwed to
along the back edge of the sides, you can clamp that secures the router motor to the carriage, as in details a and b. The
glue up the post assembly. the carriage assembly. These two parts carriage assembly is attached to the post
The post and base are joined with long are made from three layers of plywood. with full-extension drawer slides (detail
screws driven from the bottom, as shown Detail d above shows a through hole c). For the most stability, the slides are
in detail a and Top View drawing on the near the back edge of the mount that arranged to be in the closed position as
previous page. forms part of the stop system to control the carriage is lowered.
Woodsmith.com 33
HANDLE !/8"-rad.
a. b.
FRONT G F
POST BLOCK VIEW
J
#/4
1!/4 D
3
%/16"-dia. CARRIAGE 7#/4 K &/8
!/2"-rad. K
#/8" hex POST BLOCK
nut K SIDE
VIEW
#/8"-dia.
#/8"-18 x 3" hex 4
head bolt #/8" flat J
washer G
1!/4
#8 x 2" Fh
woodscrew #/4"O.D. x
2!/2 #/8" I.D.,
NOTE: 1!/4"O.D. x 1" nylon
All parts #/4" I.D., bushing
washer 1!/2
made from
hardwood H
%/16"-18
push-button
nut, hex nut
& washer
DEPTH
ROD BLOCK
L #/4
L
< Quick-Set Stops. Drill (/32"-dia. !/2
pilot hole 1!/2
Push the button in block 2
for fast adjustment.
Turn the nut to fine- 3
tune its location. !/2"-rad.
5!/4
#8 x 2!/2" Fh
woodscrew
9%/8
ARM NOTE: Turn to
!/4"-rad. page 66 for
M
M
THIRD: Secure M instructions to 1
with washers make handle shaft P
and nuts
1 %/16
N
ARM SPACER P
HANDLE SHAFT
%/16
O
ARM CAP
N
threaded rod. To fine-tune the depth of detail b. Two spacers and a cap piece are
d.
cut, simply turn the nut as needed. glued to the main handle piece. Whats FRONT
HARDWOOD HANDLE. With all the pre- important here is the width of the spac- SECTION
M VIEW
liminary items crossed off the list, you ers. They should be just a hair wider than J
can make the handle. The long, front- the bushing. This allows the bushing to
mounted handle is easy to use with move freely but without any slop.
%/16"x 3"
either hand and provides good leverage The arm has a hole drilled at each end. lag screw
for plunging the router bit into the work- One is used to attach it to the post. The w/ washers
piece. The handle is made up of three other is to join the arms to the handle
components two arm assemblies that shaft, as shown in detail b.
sandwich a shaft and threaded rod. SPLIT SHAFT. I was concerned about Creating the channel for the threaded
Each arm incorporates a slot that screw threads holding in the end grain rod is easier than it looks. Shop Notes on
houses the nylon bushing you installed of a solid dowel. To eliminate those page 66 covers the technique.
on the carriage. But rather than cutting worries, I made a two-piece shaft that You need to assemble the handle
a slot, I built it up from smaller parts, as captures a section of threaded rod. in a specific order. Fit the slot over the
you can see in the drawing above and This is illustrated in details a and c. bushing and drive lag screws to secure
each arm to the post. Then slip the shaft
P
a. between the arms and add the washers
C and nuts, as in detail c.
%/16"-18 x 2"
eyebolt RETURN SPRINGS. Two extension springs
w/washer #/4
%/16"-dia. are the final elements you need to add.
drill bit E D
As I said earlier, these springs lift the
C
F router carriage and hold it above the
BACK VIEW
workpiece. This gives you plenty of
room to move workpieces around and
F M
set up the sliding table. One end of each
5.625" x .563"
b. spring is attached to one of the eyebolts
F C E
M OD extension on the back side of the post.
springs H
Springs The two springs meet at a single screw
eye threaded into the back of the carriage
J J (detail b). You can see in detail a how
SIDE SECTION Screw eye
%/16"x 2!/2" to locate and drill the pilot hole for the
screw eye VIEW
screw eye in the back of the carriage.
Woodsmith.com 35
!/16 R !/4
Several details help accomplish those
SIDE SECTION Q tasks. An aluminum strip in the bottom R
c. VIEW Aluminum bar
face mates with the kerf in the sliding table
(detail d). And the slots shown in detail
and right, you need to attach the slide a line up with the T-nuts in the sliding
components to the machine base and table. Studded knobs and washers com- to keep a workpiece from creeping out of
sliding table so theyre offset. So when plete the task of securing the fence base. alignment while making a mortise.
the table is centered, the mechanism is Take a look at the extension tab in the TOGGLE CLAMP. The final piece of the puz-
half-open, as shown in the drawing and front of the fence base. It holds six more zle is the toggle clamp you see in the
details a and b on the previous page. T-nuts that are installed on the bottom drawing below. Its attached to a mount-
As you install the slides, its important face to anchor a toggle clamp that pins the ing base, so you can adjust its position
that the slides are installed parallel to each workpiece against the fence, as in detail depending on the thickness of the piece
other and square to the face of the router c and the drawing below. youre working with. The clamp sits in an
carriage. To install the table, you need to A STOUT FENCE. The next layer of the table angled dado to apply slight downward
remove the post and fit the drawer slides assembly is the fence. Its glued up from pressure in use. Turn to page 66 to see
together. Then reattach the post. hardwood and beveled on the back how the dado is cut. I glued a wide clamp
FENCE BASE. Moving up from the sliding edge. I installed a length of T-track in the block to the swivel head of the clamp to
table, you come to the fence base shown face to hold an adjustable stop, as you distribute the pressure more evenly.
above. The base does a few things: It can see in detail b. The fence is glued The mortising machine is now ready
supports the workpiece, serves as the and screwed to the fence base. to be put into action. The straightforward
mounting point for the fence, and deter- One more thing: I applied strips of design helps keep this a simple process.
mines the front to back position of the adhesive-backed sandpaper to the face You can read about it in the step-by-step
workpiece in relation to the bit. of the fence above and below the T-track instructions on the next page.
#10 x %/8" Ph
sheet metal screw a.
NOTE: SIDE SECTION VIEW
Clamp block is
glued up from CLAMP BLOCK
two layers of X
!/2"-hardwood. 4!/4
Clamp base is Toggle L
#/4" plywood clamp 1
!/2"-rad.
Woodsmith.com 37
Lay Out Mortise. Draw a complete mortise on one of your Set the Depth Stop. I mark the depth of the mortise on the
workpieces. You use this to adjust the table and set the stops end of the workpiece. Lower the router bit to the line and
on the mortising machine. position the nut on the depth stop at the post.
3 4
Align Table & Fence. With the workpiece against the fence, Set Right End Stop. Slide the table so the bit is directly over
use the mortise layout to adjust the table so that the bit is cen- the right end of the mortise. Move the pushbutton nut on the
tered on the mortise. Dont forget to lock the table in place. right side of the machine so its against the side of the post.
5 6
Set Left End Stop. With the bit over the left end of the mor- Position the Stop Block. Chances are you need to rout the
tise, set the stop nut on the left side in the same way. Now you same size mortise in multiple parts. Set the stop block on the
dont have to worry about overshooting your lines as you rout. fence to simplify and speed up the process.
Secure the Workpiece. After following the steps Routing Mortises. Starting at one end of the mortise, plunge the bit
1
to set the stops and adjust the table, you can slip 8" to 14" deep into the workpiece and slide the table to the other end
the workpiece into place against the fence and stop. of the mortise. Lower the bit slightly and make a second pass. Repeat
The toggle clamp presses the workpiece against the this process until the carriage contacts the depth stop. Remove the part
fence and prevents it from shifting during the cut. and install another to continue making mortises.
U U U V
ALSO NEEDED: One 60"x 60" Sheet of #/4" Baltic Birch Plywood
Woodsmith.com 39
Upper cabinet
doors built
similarly to
the side assemblies
Upper shelves
incorporate a plate
rail and thick
glass panels
NOTE: Refer
to page 67
for hardware
sources
Drawers feature
half-blind dovetails
and full-extension Bullnose molding
drawer slides for adds a decorative
easy access detail to bottom
Base cabinet doors of hutch
have cherry
plywood panels
captured in grooves Edged plywood
in the rails and stiles shelves rest
on shelf pins
Cabinet face
frames assembled
with pocket screws
Woodsmith.com 41
b. A !/2 #8 x 1!/2" Fh
#/4 woodscrew
6#/4 B
5!/2 B
SIDE !/4 FRONT
SECTION !/8" SECTION
C VIEW chamfer VIEW
Build the DADOES & DRILL. The rest of the machining youll drive pocket screws through these
Upper 3
rail 5!/2
L 5!/4 4!/2
BACK 16
!/4" MIDDLE RAIL
ply. 12#/8 Q
P
WIDE O NARROW
PANEL BACK PANEL !/8" chamfers
LOWER STILE
Upper
panel 33 5!/4
16 c. TOP VIEW
SIDE 27!/8 #/4" !/2
VIEW NOTE: ply.
Panels J
are !/4" NOTE: !/2 #/8 Rail
Middle J
plywood. Bevel !/4" ply.
rail profile
All other parts BACK LOWER RAIL
are #/4"-thick M faces
inside 3
hardwood
the face frame. This is pretty Its made of solid cherry rails and the upper and lower stiles (refer to
straightforward, although and stiles with 14" plywood panels. the left drawing below). After that, use a
I did use a few spacers sized to match Like the face frame, start by cutting the rail to set the sticking bit for cutting the
the openings in the frame as I screwed outer stiles to size and rabbeting the edges grooves and bevels in all the parts (right
it together. In addition, I cut two keys (detail c). Clamp them in place and mea- drawing). Note that the middle rail and
and put them in place in the groove in sure for the three rails, accounting for the upper and lower stiles receive grooves
the lower rail and the dadoes in the outer stub tenons added to the ends of the rails. along both edges.
stiles to ensure theyd line up with one Then cut the rails and other stiles to size. COMPLETE THE BACK. As with the face frame,
another (refer to Shop Notes on page 65). COPE & STICK. The back assembly is joined youll cut a taper on the outer stiles and
Once the assembly was complete, I routed with cope and stick joinery. This joinery rout a chamfer on the edges. Theres
a slight chamfer on the outside edges and is formed using a pair of bits at the router also a small notch to accept the bullnose
bottom ends of the outer stiles. Then I table. The box below gives you the basic molding (detail b). After cutting the ply-
glued and clamped it to the cabinet and overview of the process. Its valuable to wood panels to size, assemble the back
drove in pocket screws to secure it. make some test cuts first with both bits with glue and clamps. Then all thats
BACK ASSEMBLY. The cabinet back is a frame until you get the settings just right. left is to glue and clamp the assembly to
and panel assembly designed to look Youll want to set up the coping bit first the back of the cabinet, and drive in the
great when the cabinet doors are open. to cut the tenons on the ends of the rails pocket screws to lock it in place.
Sticking bit
Backer
K L
a. a.
M N
END END
O VIEW VIEW
#/8 #/8
Coping bit
(Sources, page 67) Rout groove in
all rails and stiles
(outer stile shown)
Sticking
Coping Bit. Use the coping bit to cut the ends Sticking Bit. After setting the height of the sticking bit
of the rails and upper and lower stiles. A backer bit to cut a mating groove, rout the groove and
holds the pieces square as you cut them. bevel on the edges of all the parts with the bit.
Woodsmith.com 43
19%/8 16#/4
U 4!/4
W T
T
NOTE: Inside S 21!/8
face of drawer
supports are 1!/4" knob
flush with edge Center slides T
of stiles on drawer sides T
DRAWER
5
NOTE: Drawer fronts and SIDE
S
supports are #/4"-thick DRAWER
hardwood. Drawer sides 4 FRONT
and backs are !/2"-thick DRAWER
hardwood. Drawer bottoms BOTTOM V
are !/4" plywood (16!/2" x 19!/8") c. !/2
FRONT
Drawer VIEW
side !/2
can set about adding some of the details mon task for a dovetail jig. !/2
that finish it out. And that starts with The first step, of course, is cutting the !/4
two drawers that fill the openings at the drawer fronts from cherry and the backs
top of the cabinet. and sides from maple. Theyre sized to
DOVETAILED DRAWERS. As shown in the accommodate the sides and create a the drawer parts, cut a groove near the
drawings above, the drawers are small gap above and below the drawers. bottom edge of all the parts to hold the
assembled using half-blind dovetail Then youll want to rabbet the perimeter drawer bottoms (lower middle draw-
joints. These joints are an easy task of the drawer front to form the lip, as ing). The groove is located on a tail on
using a dovetail jig and a router. But indicated in the lower left drawing. the sides, so its hidden once the drawers
theres an added wrinkle to the process After that, its a matter of cutting the are assembled. While youre at it, set up a
with these drawers. As shown in the dovetail joints using your jig. The jigs roundover bit in the router table, as shown
drawing below, the drawer front has a manual should walk you through the in the lower right drawing and rout the
lip around it, and then the dovetail pins process of routing the dovetails. Once decorative half-bullnose around the
are cut behind this lip. This makes the youve achieved a nice, clean fit between perimeter of the drawer fronts, as well.
!/2
Groove for Bottom. After cutting Half-Bullnose. Form the profile on the
the dovetails, set up a dado blade to drawer front by routing with a roundover
&/8
cut a groove in all the drawer parts. bit around the perimeter.
#/4
Y X Y 1
Edging
Edging Veneer
!/2"
roundover
bit Riser block !/4"
Side Front roundover Veneer
edging edging bit
SIDE VIEW
Center
EdgingFrame& Veneer.
& Cleat.After
Gluegluing
up on the edging Top Profile. With the top facing up, rout Bottom Profile. Flip the top
thestrips,
centercutframe
a veneer
and cleat,
sheetthen
to rough size and adhere the sides, and then the front edge, using panel over and complete the
additthem
to thetotop
thepanel
frame.
using contact adhesive. a 12" roundover bit in a hand-held router. profile with a 14" roundover bit.
Woodsmith.com 45
9#/4 a.
!/4
BB 2!/2
LONG DD Shelf
SHELF
(11#/4" x 30&/16") DD 9#/4
1!/4" SIDE VIEW Edging
knob EDGING
(cut to fit) 19
HH 14!/2
b. SIDE
2!/2 SECTION
BULLNOSE 2!/2 CC VIEW
HH
MOLDING 11 Bullnose
(miter to fit) molding #/4
3
AA
F F !/2
#/8" overlay DOOR
hinge GG LOWER RAIL
DOOR STILE
AA HH
DOOR PANEL
with the same cope and stick joints used
c. Face frame on the back. Each door features rails
Hinge lower stile
with coped ends joined to stiles with a
mating groove. A plywood panel fits in
NOTE: Shelves are #/8 the groove. The difference here is that
#/4" plywood. Panels
are !/4" plywood. Edging the bevel profile is on the outside face.
is !/4"-thick hardwood.
Other parts are NOTE: Cut rabbet #/8 After cutting the door parts to size, you
#/4"-thick hardwood around perimeter
of door to fit opening TOP VIEW can create the joinery using the same pro-
cedure shown in the box on page 43. Then
assemble the doors with glue and clamps.
Install the DOORS & SHELVES The last cuts to make on the doors are
rabbets along the back edges to fit the
Youre just about finished with the base left drawing). After that, simply rip the openings in the face frame and a rounded
cabinet. The mating dadoes and grooves molding strips to width. Measure and profile on the front. These steps are shown
near the bottom of the cabinet are filled miter the molding strips to fit around the in the lower left and middle drawings
with decorative strips of hardwood cabinet, as shown in the main drawing. below. Then youre ready to mount the
molding. The molding features a bull- SHELVES. Perhaps the simplest parts of doors into the face frame on no-mortise
nose profile on the outside edge. this cabinet to make are the two shelves. overlay hinges (refer to detail c above).
To make the molding, youll want to Thats because theyre nothing more FINISHING TOUCHES. At this point, youre
thickness stock to fit the dadoes and than pieces of plywood with solid-wood just about ready to turn your attention to
grooves, and then cut some blanks edging strips glued to the front. They sit the hutchs upper cabinet. But you can
that are extra-wide and extra-long. The inside the cabinet on shelf supports. take some time now to apply stain and
next step is to head to the router table, DOORS. After building the cabinet back finish to the components of the base cab-
where youll rout both edges to form assembly, the three cabinet doors should inet. Youll find all the finishing informa-
the bullnose profile (refer to the lower be familiar territory. Theyre assembled tion you need on page 67.
Waste Align
top of Door
cutting edge
w/centerline #/8 Door
Bullnose. Two passes along the bullnose Rabbet. Rabbet the door with a dado Profile. Use a roundover bit at the
molding blank take care of the profile. blade buried in an auxiliary fence. router table to rout the door front.
F
#/4"x 7!/2" -96" Cherry (5 Bd. Ft.)
H
W W W W ALSO NEEDED: One
FF FF FF 48" x 96" Sheet of
#/4" Cherry Plywood,
K E One 48" x 48" Sheet
of #/4" Cherry Plywood,
#/4"x 6!/2" - 96" Cherry (4.5 Bd. Ft.) and One 48" x 96" Sheet
J L of !/4" Cherry Plywood
O
J G
DD
!/2"x 5" - 48" Hard Maple (1.7 Sq. Ft.) !/2"x 5" - 72" Hard Maple (2.5 Sq. Ft.)
U U T T T T
Woodsmith.com 47
47!/4
11!/2
UPPER CABINET B
14!/2
a. SIDE
TOP
RAIL
B
B C
Chisel
Center bearing D
on edge of groove
Rout clockwise !/2
using a rabbeting bit a.
Waste
Rabbet. After gluing up the side assemblies, youll need to rabbet the frame to accept Chisel. After the rabbet is complete,
panes of glass later on. This is easiest to accomplish with a hand-held router equipped use a sharp chisel to pare the rounded
with a rabbeting bit. Set the bearing to run along the inside edge of the frame. corners of the frame square.
#/4
43#/4 Face
G 13!/4 3!/2 frame
FACE
FRAME 1!/4" pocket
RAIL screw
E TOP
SECTION
42 39!/2 VIEW NOTE: Bevel profile
1!/2 I
F L faces inside
FACE BACK
FRAME 1!/4 MIDDLE Back
OUTER STILE
STILE !/2
E
L
b. BACK SECTION
F VIEW
L 2!/4
FACE FRAME 3
3 MIDDLE STILE BACK Face frame
G PANEL outer stile
Case
42 bottom
13#/4 !/2
Face frame
lower rail
Woodsmith.com 49
a. #/16 !/4
M !/16
M O
#/8
SIDE SECTION
N VIEW
O NOTE: Shelves SHELF
are identical BACK RAIL O
M 14#/8
3
Stacking
plate 1%/8
with 46#/4
screws
O
SHELF
b. Connect
SIDE RAIL N cabinets with
(2" Wide Overall) stacking
SHELF plates
FRONT
RAIL
BACK VIEW
SHELVES & DOORS and side rails for each shelf to size, the
first order of business is to cut a rab-
bet along the inside edge of each rail to
With the basic framework of the upper GLASS SHELVES. The solution I arrived at hold the glass. This was easy to accom-
cabinet complete, the shelves are the is shelves with glass panels surrounded plish by burying a dado blade in an
next order of business. And since the by wood rails on all sides. The glass auxiliary rip fence. The dimensions are
upper cabinet is a decorative space to allows the light from the top to filter shown in detail a above.
display fine dinnerware, it needs a little down through the entire cabinet. Next up, you can move to the router
different treatment for the shelves than table to transform the back rails into dec-
just simple plywood panels with hard- 3 orative plate rails for displaying plates.
wood edging strips. To do this, youll use a core box bit, as
!/2 shown in the far left drawing. Carefully
Woodsmith.com 51
49!/4 CORNICE
BOTTOM
At this point, the dining room hutch bottom and routing the profile on the Y
W 2!/4
is nearing completion. All thats left front edges. (Its the same as the profile
!/4
is a three-layer cornice assembly that on the bullnose molding thats shown
tops off the upper cabinet. Then youll on page 46.) Then miter the pieces to fit !/2"-rad. V
(refer to
be ready to add lighting and move the at the front as shown above, and cut the page 46) 3
hutch into your dining room. back piece to size to fit between the sides.
CORNICE ASSEMBLY. A project this involved Drill countersunk holes in all the parts That just leaves the cornice molding at
needs a worthy crowning touch at for attaching them above the cabinet, and the top. Theres nothing too complicated
the top, and the cornice assembly fills then glue and clamp the frame together. here, but its important to note that the
this role nicely. Its a three-layer sand- Next up is the cornice wall, which roundover on the bottom edge of the
wich made up of a bottom, wall, and is made up of three pieces that are molding is different from the roundover
cornice molding at the top. mitered to fit above the cornice bottom. on the top. Also, youll want to make the
You can start at the bottom of the cor- Simply cut them to size, miter them to cuts with a hand-held router after assem-
nice and work your way up. Begin by fit, and glue and clamp them in place bling the three parts, so the roundovers
cutting some extra-long pieces for the above the cornice bottom. transition smoothly between them. The
drawings at left show you how its done.
F F
#/4"x 7" - 96" Cherry (4.7 Bd. Ft.)
V P P
V P
1" x 7" - 60" Cherry (3.6 Bd. Ft.) !/8"x 5" - 36" Cherry (1.3 Sq. Ft.)
X S S
Y Y T T
!/4 "x 4" - 48" Cherry (2 Boards at 1.3 Sq. Each) ALSO NEEDED:
U One 48" x 48" Sheet of #/4" Cherry Plywood,
One 48" x 48" Sheet of !/4" Cherry Plywood
Woodsmith.com 53
tuning up your
Drill Press
The drill press is one of the unsung much about it. But like any machine in The bearings can be checked by remov-
heroes of the workshop. You expect it the shop, a little maintenance goes a long ing the belt and turning the shaft of the
to excel at its main function of drilling way to help ensure consistently good motor by hand. If you notice any side-
straight, clean holes in wood and metal. performance. Fortunately, a drill press is to-side play or if the shaft doesnt rotate
When everything is working just right, a pretty simple machine. A motor drives with a smooth motion, the bearings may
you get great results and dont think pulleys, which in turn spin a shaft inside be worn. You can usually replace the
the quill to rotate a bit in the chuck. Here bearings yourself. If youre not comfort-
are some tips for keeping those parts able doing it yourself, another option is
humming along year after year. taking the motor to a repair shop.
START WITH THE MOTOR. It goes without say- While youre having a look at the
ing that the hardest-working part of a motor, take some time to use a shop vac-
drill press is the motor. Now, theres not uum to remove any dust and debris. Its
a lot that can go wrong with a motor, so important to keep the cooling vents clear
its usually not a concern. But there are a of dust. If a vacuum doesnt do the trick,
couple of things to be aware of. try using compressed air.
First of all, pay attention to how much CHECK THE BELTS & PULLEYS. With the belts
noise the motor is making. It should run removed, give them a once-over too.
smoothly and quietly without complain- Check for any cracking or fraying, as
ing. If you notice excessive noise like rat- shown in the photo at left.
tling or grinding, however, its time to Theres something else to watch for
{ Check the drive belts for wear and tear. If investigate the cause. It could be a sign when inspecting the belts. Some old
you see any signs of cracking, fraying, or that the bearings are worn or one of the V-belts can develop a memory if left
splitting, its time to invest in new ones. pulleys is damaged. tensioned on a pulley for extended
{ To ensure the table is square to the quill, use a bent wire. Rotate the { After removing any rust with an abrasive, apply a protective coating
chuck by hand to ensure the wire contacts the table all around. For of rust inhibitor or wax. This is especially important if youre shop is
a more high-tech solution, refer to the bottom of page 8. unheated or you live in a humid climate.
periods of time without being used. The automotive parts supplier or hardware I like to shoot for about 12" of flex, as
belt conforms to the shape of the pulley store to ensure you get the right size. shown in the middle photo at left. On
and loses some flexibility. This can cause LINK BELTS. If you want the ultimate in most drill presses, adjusting the tension
a thumping sound as the belt rotates smooth operation for your drill press, means sliding the motor and its mount-
around the pulleys. The result is vibra- invest in link belts, as you can see in ing plate forward or backward.
tion that ultimately translates to rough the main photo on the opposite page. The mounting plate is attached to two
drilling. If you find any signs of exces- Theyre more expensive than traditional rods that slide into the drill press casting.
sive wear, its time to invest in a new V-belts, but go a long way to smoothing Loosening a clamp lever allows you to
belt. Take the old one with you to an out the vibration. They wont develop a make this adjustment (lower left photo).
memory as they age and they can If you find the motor doesnt budge, tap
be made any length you need. the mounting plate with a rubber mal-
1
2" deflection CHECKING THE PULLEYS. Before you let or a block of wood. This would be
is ideal
install the belts, inspect the pul- a good opportunity to wipe or spray a
leys for damage. Make sure each light lubricant on the rods to allow them
of the flanges on the stepped to slide easily any time you need to make
pulleys are straight. Any bends, adjustments to the belt tension.
cracks, or nicks in the flange will On drill presses with three pulleys, the
wear the belts prematurely. center one moves slightly to allow ten-
If you find that the pulley is sioning of the front belt. As you tighten
damaged, you have a couple of the rear belt, check to make sure the front
choices. You could simply avoid one also has the right amount of tension.
placing the belt on the damaged SQUARING THE TABLE. Now that youve
area of the pulley. The problem addressed any issues with the drive
with this is that it limits the adjust- train, you can close the housing over
ments available for setting the the belts and turn your attention to
speed of the drill chuck. the table. The first order of business is
Another solution is to replace adjusting it square to the quill. In the left
the pulley. You can usually find photo above, Im using a stiff wire bent
parts from the manufacturer into a Z shape. With it chucked in the
online. Just make sure that the pul- drill, rotate the shaft by hand and check
ley diameters on the new pulley that the bottom end of the wire contacts
match those on the old one. the table in all positions. If not, adjust
PROPER TENSIONING. After inspect- the angle of the table and recheck it by
ing the belts and pulleys, re- rotating the chuck 360.
install the belts. When doing this, CLEANING THE TABLE. While tending to
its important to have the right the table, spend some time cleaning it
amount of tension. Too much (photo above). Remove any rust with
tension and you can strain the an abrasive and apply your favorite rust
{ Adjusting for proper belt tension (upper photo) bearings on the pulley shafts. Too inhibitor. This is especially important if
means sliding the motor mount forward or back. A little tension and the belt can slip you use an auxiliary table, which can
clamp lever (lower photo) allows this adjustment. on the pulley. trap moisture underneath.
Woodsmith.com 55
The next few tune-up tips I want to talk bit, sometimes called runout. The first In the photos above, Im using a dial
about go a little deeper into the mechan- and most obvious place to check is the indicator for this task.
ics of your drill press. This includes bit itself. If the bit isnt straight to begin The first thing to do is chuck a straight
making sure the chuck and drill bit run with, youre better off tossing it and buy- object in the chuck. Here, Im using a
straight and true without wobbling. And ing a replacement. Simply switching bits short length of drill rod. After making
you can give the rack and pinion gears on in the chuck can tell you if the problem sure the rod is centered and tight in the
the table mechanism a little attention, too. is with the bit or if theres a deeper issue. chuck, rotate the chuck slowly by hand
CHECK THE BIT. A drill press isnt much use If switching out the bit doesnt seem to and watch the needle on the dial indi-
if it cant drill a precise hole. If the end fix the problem, check to make sure that cator. Anything less than 0.005" of total
of the bit is wobbling from side to side the bit is centered in the chuck. Some- runout is acceptable for a woodwork-
as the chuck spins, it can be difficult to times, as youre tightening the chuck, the ing drill press. If theres more than that,
accurately start the hole. Plus, a wob- bit will get caught between two of the its time to take a closer look at the drill
bling bit often results in an oversized jaws instead of being gripped by all three. chuck. (Note: Youll want to place the
hole, especially in wood. CHECK FOR RUNOUT. If you know the bit dial indicator close to the chuck to avoid
Fortunately, its fairly straightforward is straight, then you need to dig a little exaggerating the error.)
to track down the cause of a wandering deeper to find the source of the runout. REMOVE THE CHUCK. As simple as the
mechanics of a drill chuck are, they can
Replacement Chuck: BY THE NUMBERS still wear out over time. And this may
lead to inaccuracies when drilling. To
eliminate the chuck as the source of
Finding a replacement chuck for runout, you need to remove it from the
your drill press may be as simple as arbor. How you do this varies with the
looking at the numbers. Most drill make and model of drill press, so youll
chucks are stamped with a model want to consult the owners manual or
number, Jacobs taper number (33, in contact the manufacturer.
this case), and the capacity. There are two common methods used
With these numbers in hand, you for removing a drill chuck. Theyre
can find a suitable replacement. shown at the top of the opposite page.
You can find replacement chucks One method makes use of a tapered,
online or at a well-equipped hard- steel drift pin. This procedure is used for
ware store or machinists supply. a chuck that is mounted to an arbor that
has a taper at each end. The chuck fits
< The numbers stamped on your old drill onto a short Jacobs taper. A No. 33 Jacobs
chuck should give you enough taper is a common size.
information to get a replacement. The opposite end of the arbor fits into
a Morse taper socket in the quill. You can
Woodsmith.com 57
upgrade to
LED Lighting
Its my opinion that you cant have too OUT WITH THE OLD. The lighting in my HOW THEY WORK. LEDs are solid-state
much light in a workshop. When set- shop is a mix of bare light bulbs in por- components mounted to a circuit board.
ting up and using tools or doing layout celain fixtures and inexpensive fluores- This means there are no burning fila-
work, ample lighting makes these tasks cent shop lights. Since the phase-out of ments that eventually break, as in con-
easier on the eyes. One way to ensure old-style incandescent light bulbs, I had ventional incandescent bulbs. You can
adequate lighting is to upgrade to LEDs. been using compact fluorescent bulbs see the rectangular-shaped LEDs in the
They have a lot of benefits in the shop. (CFLs). But they contain small amounts photos at left and below.
of mercury and should be recycled LEDs dont produce a lot of heat
Plastic properly. Theyre not the best solution. on their own. However, the circuitry
shroud Instead, Ive been replacing some of the required to transform your household
bulbs with LED lighting. current to the low voltage required for
IN WITH THE NEW. While browsing the LEDs can get pretty warm. Thats why
aisles of my local home center, I real- some bulbs incorporate a heat sink to
LED
array ized that LED bulbs are becoming more dissipate some of that heat (left photo).
prominent. And for good reason. Light-
emitting diodes (LEDs) are super-bright
and very energy efficient. So much so
that some manufacturers are shifting
Base away from fluorescent bulbs and tubes
to producing LED lighting instead.
Heatt sinkk
Low voltage operation makes LEDs too (photo at right). Theyre just start-
much more efficient than other forms of ing to appear in some home centers but
lighting. For example, to get the 60-watt you can also order them online. Theyre
equivalent, an LED bulb will only use pricey, at between $30-40 each, so you
about 10 watts. Thats a pretty significant may want to replace the tubes in only
energy savings. one fixture at a time.
Another benefit to LEDs is their long You can buy replacement LED tubes
life. Some LED bulbs are rated for a life- that plug right into a fixture that has an
time of over 20 years, assuming that instant-start ballast. Other LED tubes
youll use them for three hours a day. require you to rewire the fixture to
THE COST. LED bulbs cost more than your bypass the ballast altogether. But this { The result of replacing fluorescent tubes
traditional incandescent bulbs. But the means you wont have the buzzing and with LED tubes is brighter and more
fact that LEDs are more efficient helps to flickering that you may have experienced efficient lighting in your workshop.
offset the higher cost. Even better, in the when turning on the light.
few months Ive been looking at them, The process I used to make the conver- DAYLIGHT FOR THE SHOP. When shopping for
the prices keep dropping. sion to LED tubes is shown in the pho- bulbs and tubes for the shop, I look for
FLUORESCENT REPLACEMENTS. Switching out tos above. Some suppliers provide new the brightest (higher lumens ratings).
light bulbs is one thing, but what about tombstones youll need to use for the And I prefer daylight, or cool white.
replacing the fluorescent tubes in your new tubes. Other tubes have a wire pig- Its the best, cleanest light for shop tasks.
shop lights? Believe it or not, there are tail that you simply tie into the wires that For other shop uses for LED lights, check
LED replacements available for those, supply power to the fixture. out the box below. W
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simple,
accurate
Bar Gauges
Ive always enjoyed learning traditional WHAT THEY ARE. In short, bar gauges are CHECKING FOR PARALLEL. One use for bar
woodworking tricks and techniques. basically two sticks held together to take gauges is checking for parallel. This
Especially if that old trick helps me do or transfer a measurement. I want to talk comes in handy for cabinet work, as
the job more quickly and accurately. about a few commercial ones, as well as shown in the photo above. Its helpful
One of those basic techniques Ive come a few shop-made versions, and explain to make sure cabinet sides are parallel
to appreciate is the use of bar gauges. how you can put them to use. and not bowed in or out before attach-
Theyre deceptively simple, but once For any bar gauge, you size the length ing a face frame or installing a door.
you get in the habit of using them, of the strips or rods to suit the task at I made the bar gauge shown in a little
youll find your tape measure remains hand. Its convenient to have a few differ- over an hour using a block of wood with
in your apron pocket more often. ent lengths on standby to keep you from a threaded insert and a thumbscrew to
having to stop and make a special set in hold a pair of 38"-dia. dowels.
the middle of a project. Whether theyre NO TAPE MEASURE REQUIRED. Taking a mea-
shop-made or purchased, bar gauges will surement and transferring it to set up a
find many uses around the shop when tool is another great use for a bar gauge.
building projects. For example, you can obtain the length
{ Two wood strips held with a binder clip { The bar gauge can be used to transfer measurements to set up the table saw for accurate,
make it easy to obtain an inside dimension repeatable cuts. In this case, the bar gauge is used between the blade and a stop block
to size the length of a door stile. attached to an auxiliary miter gauge fence to cut door stiles to precise lengths.
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woodworkers
Blade Preferences
One of the first and best pieces of advice ripping to crosscutting, and even for cut- be overwhelming. To help you make the
I received when I bought my table saw ting joinery. For some, its the only blade best choice, I asked a few woodworkers
was to buy a high-quality combination they use outside of a dado blade. around here about the blades theyve
blade. This one step worked like an While a combination blade carries the added to work hand-in-hand with their
instant upgrade to help my benchtop lions share of the load, most woodwork- combination blade. Their experiences
table saw make smooth cuts. ers have at least one other blade in their will allow you to invest in a blade that
Just as its name implies, a combination kit. But with all the choices available, youll turn to often and wont just end
blade works well for a variety of tasks from deciding which other blade to get can up hanging on the wall gathering dust.
} A traditional rip blade with 24 teeth and a flat-top grind make JOHN DOYLE, DESIGNER/BUILDER. Theres much
quick work of cutting grooves and tenon cheeks. The teeth more to table saw work than crosscut-
leave a crisp, square corner at the bottom of the groove. ting and ripping. Like many wood-
workers, John turns to his table saw to
cut joinery. And for tasks like cutting
grooves or tenon cheeks with a tenon-
ing jig, he employs a 24-tooth rip blade
(Freud LM72R010). The key features of
this blade are the 18" width and the flat-
top grind on the teeth.
In addition to ripping hardwoods effi-
ciently, a full-kerf blade means John can
cut grooves for a stub tenon and groove
joint to match the thickness of a plywood
panel in just two passes (right photo). The
flat-topped teeth leave a crisp flat groove
instead of the pointed bat ears a com-
bination blade leaves. Plus, fewer teeth
keep the saw from bogging down. W
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Template
!/2" -rad.
9!/2
Position template
flush with edges 1
of benchtop
8&/16 3
2 a. 3 a.
Cut slot to inside
of template edge END
SECTION Waste END
Bearing SECTION
VIEW against VIEW
template (first pass)
Template
Benchtop NOTE: Use
template to
make first
pass b.
Spacer Waste
block
Bottom
Waste surface
of benchtop
!/8
Upper
cabinet END
door VIEW
frame
2!/2
NOTE: Cut
shown on door
bottom. Cut on
top is 2" wide { Filler strips add
Rip strength to the
blade
hutchs doors.
#/4"-thick
key aligns
groove with dado
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