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WORKSTATION?
@ Simple To Build,
Nan el
ey
‘
if |Contents ,
Features
ream shop project
Carved.Lid Tool Chest__ ES 14
‘Discover an al new joer ectrique —
“eurvos? box ania Wei saw you now 0
‘rsa an assem ther er a perec it
nealoeie
Better Box Joints DEE
Lawn hei ge deacon acouraeomite
fenkecene tie ery wcrc
bec os tier
Benchtop Miter Saw Fence KEES 25
Tur any surface into precision miter saw
\warkstanon Al you need are 3 couse of
Saas
Fold-up Worktable.
Departments
Readers’ Tips 4
pees)
Routing Grooves on the Router Table _8
ast ete pe nd enon
eee Sa peereey he
tr Barve
Knock-Down Fasteners. 10
Looking for fast and wasy assembly wih
‘sol esuls? We have te arsiver
tandeontecnique
Using Contact Cement 2
Tips ad techniquos to make your nex give
Ln go ogeineauick ana 2655.
Shop Short Cuts __4
‘Stop tosied tie ana techniques to hole you
‘solve your wocawarkng rabions, o
‘ShopNotes No. 98rae)
inthe shop
7 Must-Have Files. a2
Welt show you the fools you need to get super
‘smoot shapes nal atria
root wie
5'Small-Shop Finishing Tips 4“
ackipe ad ca rag Ria ove
xpath
saving taal sow
Resawing on the Table Saw. 4
erin scp as ease ao
Soran bat rane ou a
grt gu at:
New Leigh Dovetail Jig
(ee en eee ean Fe
Trac Gots acd coro bot
aan
Q2A 50
Sources _ St
won ShopNotes com
Lee viens
fo bung rast or ep
eee
oth Bu hats cy what we etd or
the Wb aed om ge 3 Ae
Pee a i,
eee ace er
“Ebay fh eg ties oe minal
‘ih ightw ates i py
rel eee Nee ee
ee ereyeg ae Cea
ce Then al ee ger Cs
Fath Ser Pt aig) rind
eg rneraste erie tie hes
sro remove nog tera mae
Wie wht ang in
Wal wended up witha ops le
ing thle sapped by ur Ugg
Pion Pinan te poet
sain abi oer 15
Ceili butt sudo
ctr cal oa Wo caet
IS al lorena eer
t= on lo ite photo sbowe} Now
mrt oing fo mem ha os
ee eee eee
ale seem rao ietvohess an
——
‘nto ot
wn Sopot com
a-
While building. a TY wall unit,
hd to find 0 way to accurately
snachine flats i log clus.
‘The lating jg shown hee ia my
arawer What ike about the igs
thatiemakesitexy eo routstaight,
moot fists ang the leg of
the workpiece Its worked 0 Well
Router Fluting Jig
‘in my chop, I ako use i © rout
roves ae dacoes
“The ig made rom "Bale
bik plywood and cass oF a
‘ise and two siding fences These
fens butt against he ges he
‘workpies ehh keep the cite
rice and sight
Balding the fg stats by euting
snextng worpce o ith
[Next cit the grooves fr the
henna runner then cut the
two ens fs rom the Bank.
"ou can we your router's base
plate o mark an dl he moun
fg holes and it opening in the
‘hee, Used the ror able to
rout the wo lt fo acting the
fenoas A canteline dean across
the top face and two edges Peps
poston thei curing use,
"Nexteome the 9 fences Fist
the hardboard runners are ghia
fnto grooves Aol, washer, and
ob ae teed 10 tighten dove
the fenes. The thre counter
Ford oles allow the fences to
bo adjusted to it a wise range af
workpiece widths A litle paste
wax helps ther slide smoothly
slong thebase
“This has proven very handy
and Tharp finding mere and more
seesforitintheshop,
‘Sony Varia
Yelm ‘Cone Springs, Flora
Shop Notes No. 98Cam Clamping Table
Clamping small and ode-shuped paces “radius isaghnat the projet Ths way,
Js somelines 2 challange Bul Tve as youtunthedisk itsam action ight
found an effective yt simple clamping ens against the projet. The great hing
method involves using crcular cams aboct this that you can postion the
ba deatsonapiywoow bse ‘aright where you eed hem,
‘As you can see inthe phote teow, 1 Forsmall ame ke you sea below, 1
eed Fain plywood deka dried a fasten wo cleats atrightangs, Youn |
“sill hoe sed fora WS screw that was _netle ane comer of the fre aginst
‘ct abot’ fom the centr ofthe the clas ard se the cams 9 apply
Sk: This offer hoe i wht tars amping prea fan easy tern
{be dino acam forcamping acon. tha’ prevented a oto ruseation,
"To use the cams, | just fasten them ey Grant
toa piece of plywood 50 the shortest agua, Masacusets
‘Submit Your Tips
Hf yu have an original shop tip we would ike to hear from you and consider
publishing your tip In one oF more of our publications. Just go online 0
fur wab so at w.ShopNoteacom and clk onthe ink, “SUBMT A TP.”
‘ryeucan mai your te: ShopNotes Tips forYourShop, 2200 Grand Aven,
Des Moines, IA 50312, Plane include your name, adders, 40d daytime
hone number in caso wo hae any austin
‘We wl pe up to S200 we publ Your tp
Pees eens {
‘ing 9 sown on te ponte page. Reames
Sas
eee
Senet
‘router, out eet
98 Marctvpi 2008
cn nes
{si Rr ay
Camco Srey cm
soner enue De
Sor eENN Soe Ca Seah
bic ae
“qacuccbacr seat noche
oer
1 Gade yas mag emai
1 stone yar aber
eee iseloe
Seren serve” ees
ee eke
cat ee
5‘Keeping all my camps organized
andemalyaccosble sa chalonge,
Butte simple cmp rack shown
akove helps beep ther within
any reach in my ner ar,
“Apethe thing Fike about ths
nck i that is versatile enough
to hold all types of clamps And t
Conduit Clamp Rack
did't bak the bank buying dhe
prt Ie ost 9 couple of 6 ong
Paces of inexpensive dia EMT
onda ew od laps
‘mounted or wood suppers.
T stated by seal) attaching
the supports to my shop wale
Afr that i was jt a mate of
sitaching theconduillampa tothe
Suppo and adding the lengths
of eon fo storing the damp
‘Mike Real
Dogs KanesWire Shelf Bin Rack
1k yng mal pastie storage bins keep things
cngized in the shop. Butt doesnt ake long bsfow:
S erehtops and workaurfces are veriowing with
them his andy storage rack wes «simple fs foe
set thu ost the way.
“The ac just wie lost shel fastened to sips
of wood (or exposed stds) on the workshop wail
(ou have tout off the font po the shal ist)
‘When you ag the el ithe wie nig bois
zara the plas ip onthe back o the storage is
fe ver der perfec. Dries hing about i
tom sot thebins an the hes comin vary
‘sizes — so there's bound tn hea combination fe
jnstabout every sorage need
Charey Scerson
Set Pal, Mista
Vac Accessory Rack
hte ar what my op wel te
eee ee eet car
uel ifr stim one nigra
Siiantciny endeociacevonans
ee ieee eery ae
mv bheuer caqretatia st veace
Sind toe Then tech sane ePIC ripe
Sheba winger Te P¥C ine fore
foes RS tu metre ok
rae eacecte es
nee eiemeracaan ete yak
Peeniceis inte siucentew te
eee lia cert
ib Lon
Leconte Vihar
pists
BY EMAIL
rf ae
enon
See sete
eae e I)
Merci cee
Thc
Sa ed at
470 protect ns fingers. Randy Wotle of You can use a Tut m9 block of
\ Owensboro, Kentucky uses Caben sel wood asa simple guile ora hand tap.
‘achorent wrap tom 3M. He also wrans tI ko@ps things square when tapping
“around Nis chisels fo protect ter cating holes, as Paul Fossey of Wesiicid,
‘kgs wile tho raver Massachusots aecoveted.
_worw Shop Notes com 7secrets for
Perfect
Grooves
ge
meerce 860
‘nen it comes io making snugfting grooves, [only have two,
requirments: Tho groove must be sized acutally ae he eges
Should be crip and square: Mary tes, tun to the veut ble
to gt tho jb dane. The main rsson i even an ordinary sah
biti gv you erp, fat bottomed zone,
‘On ts pgp, youl one the setup
seas well a sone essen tips for
sting top roten results, And onthe
fest page, youl find techniques
for cater and ceeCustom Grooves
Youtl find the stup ips on the
‘ppt page wil give you gest
‘ls for routing just shout any
‘ypeotgoove: However ereare
a few spect stations tht call
Toralitle more xplnatn.
Wider Grooves, Making a
groove wider seems like «simple
fas All you noe todo is adjest
‘he force and make anor pes,
right Wel alms.
“There's a eneh, You want to
make suet atthe fence
the ight crecton. A good mle ot
‘humbistoalway kp the mate
‘haya’ routing othe outside of
thebitand ene, Yuin sce what
“imeanin the upper pots.
“To widen a groove, be sue t9
move the ence ay fom he Bt
‘This way, youl fed the woke
iw no the aati ofthe bt
“When the fences moved dose
to the bit the waste is trapped
Teton the bitand fence, which
‘beclaouting operation. And the
sth me foe set naar he bt
‘bit wl try to pall dhe workpiace
utofyour hands.
‘Cenlered Grooves, Another
contom cit (often fn myst
making is « ceed groove, 1
{eed to try and mess fo got
‘it perfect centered on the werk
ane But the results were never
A Avoid Trapped Cuts. Move
| CustomStzed Grooves. To mia a gicove the fence away fm the bt io
wider than your bi, start by making @ single pase increase io siz ofthe groove in
to or mare passes,
ute aca. Thalys
reser ony tot ome ware
essing al fw oas
eae Ss
ack aere
hc, yout wh ats
eee ee oe pala
ithe poor yr met fo make
Nesgpesun de feces tab
lightly off center. Then simply fol- |
ioc ati enews
ee meas |
Boe ere see
Se ears
Tele ape adam wt
CSnmcsbup on ease
shee
fg Tats al es ogee,
ih pores retPP ee
Hardware
great
knock-down
| Any cscusion of knock-down hardware almest
{mediately conjures up images of venere, press
‘board future iva bo ros he hme enter Ad
‘ts te that many ofthe fasteners shown here are
{uiteohn seen that contest.
“he’s a goo remem manblatoren ey
these fasteners They‘ ey to ital and they‘
stron Thisllows them told nexpemsive fan
tre ming. a Weak mater Hho pata and
sill povice supesingy strong parts
‘But they’ not ie to particebord ite
‘You ean take advantage of thse great uals
‘nd put them to work in your shop as well. Many
ofthe jigs benches, and worksurfaces that you ese
‘very day can alo be coasirted using knockdown
‘asters for more converses
ven heavy-duty pieces that wort be disasem:
bio ke the workbench shown above an bei
from the strength and eave of we knockdown fas
twee offer Sometimes the bt arse
“The following common examples of knock own
hngware may Spur your creativity to come up wth
some ides, Thee are othr types, as wel bu! these
roth onc we make sure kaep on nd
CSS TT TS
YY Cross-Dowel. Crosedowelfastoers and bench with considerable fore This to be put to the test under Iara
Forbut jens nat dea bolts av an easy way 10 makesthemanescllnchokc for frees (ike had planing large
‘wan? be under connect to pices that meet ata makinganend rin connection, _workpiewe mounted on 2 bench).
Afotol stain a tightange The ilustration below Crosedowelbelisaregreatiora The age ft can be ighlened
cross-dowel cot showshow they both employ the varieiyoffuriturebuilding tasks, eal to hep the bench slid.
werk very well same prinaple — ace or bot pecially atachingastrecherto a The ne fing about tis design
‘reads into bometshoped nut le. The devesldets that the heeds theese of use. To prepare your
embeded In a hole In the cos ofthe belt emains vise (W you project pieces for bench bls, stat
necting piece By tightening the coverit with plug, you won't be bylaying outtheline forthe shank
Trl the two able tighten tate) hole fr the bl. Then, dill hole
pecsae Asthoramelmplisbanchbots on thelne foe tho bara. The Bar
pulled are ideal for eswy-dutyapplica- elshavea sot foraerewdriverto
fogether tans where the jnery & Hkely help align the hole with the al
# = Draw Bott
Forheayay
“appicaions,
Dbenen araw
bol
proviso
leny of
‘rangi\SConnator bls area great che
CONNECTOR BOLTS m
‘when comes to attaching face
‘yon can ose thom even in places
‘whee theyll be vibe
Inthe lst and photo a
‘ight you can se that connector
it is ed wit a matching ap clamp the parte you antl jie The other thing to be aeave of
‘ut. you's shopping fr thon together Than della holethrough is that these fasteners rut an
elie beste to oer both parts both pieas You can even counter- Alken wrench to tight and the
“Ty'oltencokd separately. bore thule you wane the ad si is wally metic YOU ind
Unt conneccr Bol Dulin’ tobefish withthe satice Fira, dht mast eanrector ols rye
te simpler All you need to do just screw the bot inthe cap not. either nox Sm wrench
TITS
Traded mans are ne of the cays or removal (ape Al ou nef do ie dl ole
ros uf ples of Panwine eal yo went owe rab rine wre. Th lo ed
‘Sevier Doesthlsnundite sdjstten) these le wonders cn the hee ales yo se
Sones? Wall maybe a area malsaer them if the tle vt ew
Uttebutwtnticonmstomaking The rice Wing abo hexded driver. But whenever pose, 1
figs oaything eke tot ute ens howeay uy aro ie, ey delprestomake nthe
Sv ta tat ft be
inst IS ft he bead. Then
‘Send to aut aed the rset on
then fhe ba ond gen he
rie agate incr. Now fst
Iount he Rl in he chk od
Fem tio he hol ming fhe
Sick nd Using ths me
Sou wat ea opt st be
ead you based our
T-NUTS fe
“Taulsaresinatovendedinses
Jn tat dhoy/re dina w accem
‘mexate a mating bolo cove But
‘athe than eying on thes or
the ouside, Tras ar anchored
‘lange onthe apps feof
inser but theyre a bit
cheaper (hout halt the pice) So, sethacrews Etheway.heyseon"t Fac some ppheations, you may
inadiion future, Tutsawea tum ssyou ighen the bolt. wart tse the flange as To do
‘woh feshop appliaion. —Insemneharder woods, thebarbs this fst dil a shallow courte.
‘As the photo at Aght shows, can bend break orsplitthe work borondiesurface winga Forster
some Fruts have batts tat dig pice. fitlooks ike thas thecace, bit Thon drill dhe trouser
tint the werkpiee, ethers atach THLusotheserew-on ype of Fut the shaft the rat
‘we ShopNotes.com a
cr sorews prevent
the nut hem ar
ing as you tighten
‘amatcning bat*~ top-notch results with
Contact Cement.
| Less waiting, instant bond — contact cement takes
the hassle out of gluing up large assemblies.
BE | Ter’s no qustion ut plain old ithusalong working imeancyou Several Types Therwareseveal
yellow glusis number one in my dot read to mess around with types of contact cement avalable
Shop. But there ae ms when ft lmps Sineit'sso diferent from The most common type sslvent-
It won't wk In tee es yelow gl using onc cement eB oul ako find ay
tne of the cer adhesive tat may neem intimating, Although and wstersnaed versions
ie a iate oer wea eae wes yao cal ena
of the main reasons contact complkated Andaneyougetthe thebox onthe opposite page
‘cet aks ge glueups hang of youl be wching for No mater which ype you use,
ss ‘ontactecment mareotenton. i will ony bond s another ayer
a Soo
‘TREE-PART PROCESS
“nd septa rek down the
process of using contact cement
Into ie stages: application
scembly, and sting, Ard there
cag ea fe things wane point out
= Fghtol tebat youre werking
sh seventies te
‘ShopNotes No. 98appropiate repirstor to pret
‘Sounel fom Ue tang fame
“Application, mented aor
shar eanact cement will ely bond
to-anather ayer of cement, So the
thing to doe apy a oat
‘ich pete you be banding.
‘Contact coment can get tacky
fas so you want 1 work quick
to get it spread evenly I star by
‘cating in” the edges with
‘brush a you can ae inthe main
photo on the previous page. Then
{pour asl paddle of cement in
the middle and speed it aroun
with plastic scape: The sraper
‘wll eave thick speaks. But you
‘on sce the ot im 9 gk
pass with ri rller
"Second Coa. Th ist contris
in about 15.2 inate (Tknow
when is dy tke a Took at the
photos onthe baton ofthe ecing
age) ind hiscoat usally sks
fn thesurtce avg oly thin,
patchy fm This often reals fo
‘weak band. So i's gd ie to
‘apply a sscond cont
‘The same process wad 10
apply the vend coat You notice
{scoot will goon loteasier and
vont ruin as mich cement.
Working Time. When the scx
‘nu cot 16 dy, you's rey to
‘semble the two plese. But you
‘dont need tobe na hry In nt,
the cement hes working tne of
12 hors. Sa you have plenty of
tinea ge things done. And dot
‘wore Hf you can ge boc tothe
task Youcan ctv the cernent
by rang ona thin skim oat.
“Assembly. thers any part of
sg eta coment tats chal
lenge the asembly. The re
sr the cement sticks intonily
Gad sly as som ay if touches
nother cemented pice
Soto getthe plecvalgned. use
spacers ke the hardbead strips
yo seein the photo above, When
cverthing is lined up pall oxt
the epicure one at time, work
Ing fom the centr out AS you
remove them press the pieces
teeter Bly
Setting the Cement The last
stage of the press sting the
fmt coment tenure 4 good
ona You cn do this with hard
ruber roller Get pho above)
Low-Odor Alternatives:
Spray or Water
“The fumes given offby solvent based conte cement are
prety song. you wank a small shop, his might nok
beyourbestoption Trankflly you hve some choices.
‘Witerbased Cement. One option 10 use water
Ise contact cement (polo aight I has wally
‘no oxor anes applied ist eis solvent-ased coun
Best ofall clap require just coop and water,
‘Spray. An ewen quiche allemative is spray contct
‘coment fright photo). After spraying thin lyr on
fexchmuting piece youcnly need eat aminate rte
‘cement ody I's pert or small projets or oesional
‘we And ve found it's joss songs the ype.
sworaShop Notes com
‘A Assemble
‘and Rll. tor
removing be
spacers use
‘aruboer aioe
to guarartee «
strong bond,
1 asd to think this step ony
for ling cut ac bubbles and
Jumps. Bt theresa more impor
‘unt purpose: Contact eament oly
develops fal sength after pres
‘sure hs been applet the it
‘And be sure to give the edges
‘xtra stent This lp seal he
‘edges 0 avoid the possi of
the piers dlaminating later on.
‘The itn joint tog and
resistant fo Both het and water
Pas, youca hep working on te
asset without wing fort tn
‘cure That's reson enguh five
contact cement ry
a1 | Teitonally bo ints are used o make bores with
Classic box joints and a sagt sides and amet. $0 how do you make
coopered lid combine to create | stim ‘seminpe tert iam
a stylish home for your tools. Sg eeioarei oe eee cae oe
(eeu tye ie lest weree
iDindotaseualvoe
“ ‘ShopNotes No. 98
eebox-jointed
Case
“The ay to bling the tol chet
fs hing an acura, repeatable
setup for cuting box joints. The
rile on page 25 wil help you
Sviththes And there aea few other
‘hinge Lwantto po out.
‘Accurate Joints. The fis thing
1 want to mento is hata lot of
‘he dimensions. shown on the
rowings ave Based on the size
Materials & Hardware
and spacing of the box it pins
And sows. You can see what ean
in Figure la This maans you en
tse the dimensions shown in the
-awings asa guideline but you
[pt the eat ll i you ene the
pins and sos efeenc point
Don’ worry if your dimensions
aren't exact As lng a5 the box
Jit fi egeter, yu be fine
‘And there's another reson fr
having an accurate setup. Cut
ting and iting box joints on nar-
row workpiece ike the drawers
yon bud ater) doesn take aot
Y amare Bm 0) Ath Hy
W Uy Dror Frnt /Bax(2) 2M
X Lepedrawer sides) Yen
1 ipe raver orem) $4411
2 wr Drawer froct Bak) 43
‘As Lover rer sides}
18 Lowe Dine! Brim) 04 -V Pt
Ce Laren) Yasin,
Lda 2) 854
HE Lad Wecpes (6) ath
FF Lastea) Wa
+19 96092 th Woodsoens
Styles Prades
S1s6 115 Pe voodirems
ewer Boyde) Han sHg2h, + 10)4847 Fh Wedron
Sal Drawer Fon/ack@) Yonth-4%
—Atworpnce ular fee aytem that can be et yp
pictsize Icaneailysetituponabenchiocutpartstojustas quickly os hesiter sie.
length ard iow taway when don'tneed it Unfor These to, shor ences have bigtime advange
tunately is izes ale one ofits biggest drawbacks. Rist they quickly and wily ck into a rw of aks
lock n he photo above, you cin we my solution: fen on ithe seo the saw to suit your news
8 ‘ShopNotes No. 98Exploded View Details ses
ro
eesmake a pair of
Fences
ulling «fence that sets up
glean is ot ok solid and
tjustble sounds ike a tal order
Dut the solution is actualy pretty
oles provide eioranee for the
fence ack o ove ilo bo
{heave asin Figure.
‘Your Work Space. Bore get
ting into the proces of building
this fence syste, youl need to
cnaier the sar and workbench
frangement. I made 9 recessed
hell for my mtr saw thts
mounted betwen fo ibn
‘The bel othe nae Mas wei
be worksuace. (You ean se this
Inthe photo on page 28) This ts
sme “bern” the aacent work
race ae outoand sp pore
‘this kind of reangsrent n't
going to warker you dont wor.
You cansiltiakeadvaniageofhe The free back she pet pce
feneesjstm with asimple medi- up from the hase (Figure 1), And
feation Formore tort page 32. youl notice i lok very similar
Getting Stared. There arent tothelnse. The arejusta ew di
‘many pat © ech ental se ferencesto point out Fist Uheback
fon. So ite lift bul, wider to creste a gap betwen |
“The be ofthe fence srs out the fence face and the bose, This
‘sn nario stp 2a you can see allows you align the face with the
{in Figure fs ere at the fence Sene aceon the iter a
moet the workssface I dill a Another difrence between the
pairefholesneareach end to fold base and boc ae the holes you
fhcexpandingpestethatae added ocd to dnl. Centered ove enh
Inter Tao sned the Bock cor
ats witha geile curve
Fence Back. The Tshaped
pperasembly aed about oar
lepmatson the hae And wl te
se ein place bythe pnts,
the upper portion sadhstabl,
| Centered Holes. After citing
<3 fole ra std clamping block
ia Forsne (appar, sec
‘es. Then secure the dome the
‘lock ana dru he ote (ower)
ShopNotes No, 98pst oe inthe base sles
hole he backs hold machine
sre that rans through the post.
Tako dried hee ne3ch cor.
ner Stews and washers ve hen
Used to Be the postion of the
Upper assambly the base, as in
thssde view en fing page.
oats, Al hat’ le to complete
the Bottom portion of te fence is
‘make and install dhe pst Each
post made up of two plces of
Nida dowol and afew rubber
washer Whe you tighter own
‘inthe ba these compares
the Sandwiched washer, foreng
‘hom aginst the sas ofthe hae,
sa shown in the ower se view
torte oppo page
"Tha posts are simply short sac-
tine of dowel with hole dalled
doventhe center Drilinga aight
holeenaety athe center emt
techy Batifyoutolow the process
showin he photos onahebotom
ofthe opposte page, youl have
‘hej donein no me.
Fence Face. The. lost hak
wood plese of the fence vo make
Ie the face, as shown in Figure 2
‘The only detall o point out here
1s the snl ale along he bot
tom edge I acts oo ret area
saw dus and chips ca build
“pagans the fnce an spoil the
accuracy of your cut
Along the top ey ofthe once
fac, attache length of Trade
‘Adjustable stops are positioned
Jin the tack 10 antke' maliple
Great Gear from Kre:
Identical cas (You can find out
‘morein the boxteon)
“Then’s one final thog I want
to mention, The Tack comes in
2 lengths. | simpy cut the pce
in he center wih a hack sae and
filed the eis. This each se
tion abi shortest mich, 80
‘wont bw he fence works,
‘Thefencesdoagratjobefprovid-
Ing suppor fr long workpass
Bur the Ftack and fp tops are
‘ha ke Hi pte ane! out
‘(Forsoures, tur fo page 5)
This Track ystems amount
ing fn along the botom edge sot
canbescred see theterce
face And her flat tae for
atachng a measuring ape
‘Thocurved sephseatew handy
featues2s well Thecurved shape
lest de over the top ofa woek=
piece so yo den’ ave to ip it
‘taf the way to ipa workpiece
‘underneath formugh eating. And
4 ton the Bato can be used
to alla amie stop (et photo).
ial allie iaicator makes
accurate paement aap,
“wwe ShopNotes.com
4. Miter Stop. The ingers onthe iter
‘Stop prot theta of the workoece
‘tom going crushed,fence
Alignment
A his point the contraction of
‘Ge ters Feces eo
‘et, Whats ft st tal the
fences on your workserace
“To do tat youl rec 2 ino
(er to) of es. Once you have
this done, you can then gn the
ences wi your mie a fence
‘The drawings on thi pose give
sou. god overview ofthe sep.
1 pote out a few highs 20
oul Rave no problem geting
Sourfences set just gh
Postion the Miter Saw. The
‘ist thing to do bot the iter
sa he shal Tis way youcan
set bakin the same spetif you
tik ito a jobate When you do
this, make sure the sn fence is
‘arallelt theft ge your
‘wotksurice Tis wil make dl-
tng the aks ad aligning the peste of he he, sn igure
fences much easier 4 (Min were 2m bock ofthe fees are placed im the hole,
“The gl you's shooting fr tine) To dil the hakes accurately, you'e rey to double check the
to have the fence facs precy [used the driling guide shown in aignmnt ere agait, you'd
fhoh with he fees onthe ow. Be boxenthefadiy page. the rightdge (Figur 5. Fist
othe lcs nea obo purl) Ther'sanemore hing Twantto loss te adjust ser on
{he ence oo Her’s whore along__mentionaout ding the hoes. 1 the fence backs in Figue 5.
stmightedge vl come in handy. wed a spade Bio dri the holes Then whole ence oce
oid it garth ence and gue. Now, you might fd at _apninal the sighed, ug op
aw aliweon the wexksutlace on the pons aa washer area ithe testes cn th ck Now they
sithr side ofthesaw Figue3). sug. Inorder to get smoot sip shuld rein in ne no mater
‘Locate Holes. From ths wf ftyoumay rend tosandorfthe whi bleh replace
Tolesiomikethemabiclarer. rel is « preckion cscuting
and miter station that's there
‘when you needit andy toateDrilling Guide
‘When citing the dog holes for the fence system,
9 thee ace two things you need to aesount for The fit
Is spacing the toes co that the fence setons wil Sk
‘xl i any to bole The second things Lote
Aer 30 the fences ne aligned with he fence on the
ier sae. The deiling ge you ss Blow solves
both these problems
“To mak use one of the fre backs to locate
the guide holes asshownin the dawingbelow. Then
attaches 2 fence a the font edge of the guide to
make ste the holes wot died in the ight cation
‘rom ho front edge ofthe worksurtace (etal 0),Our Shop
Shop
Short
Cuts
Tapering Jig
| Toco he wage he cre
Talon the eho age ts» Second Out Fin
malnteney hed feaily "ihe worpice oer
Cmolewagsmolicum. ads he aate
Thecmpl peri you ste _Blce © ponion Pw
terbvutlameupmintfsan Gknk oro ina ou
Morbo ae an all
top Uockon op we paon be vlc tense autzutly snd ie. bolddown
veripace athe comsctange. A fom aZ2vangl limp nd inet gue
Town sei te worpie Rat Toc ling cats Tu et toe wate, ct
{othe me Te drawings Below thefesnetheeatine shown bak eh apn Oh ea
thowyoutowlallgstgetic’ inPlmetisngete Then und Potion he op fees he fs
Tiwteyonaihg eject anceagicrwciyblakiolap baxjat pave by tbls
tig bu Coot atta ret togle postion fh ualstp Hock Fig: un) an mabe anc No
Tielurwatgstorteadcolthe re 2 shows ho 1d ts asi the br reed wate wa
dnecioadieptom Tweriad tecourineotihevnkfrlent_ cata hlp postin the werk
tal done shay blog ing sop Hock Fly Ieled_ pce agar! oop Bc ee
Roe oe a tertaicdete Vetere raFolding Table Templates
Routing the openings in he web he you se Belaw ade
‘webrandcrasbooms omthofola” 5 hardboard template wth to
Ing ole (ge 30) 8 ensy > do openings. To out he other open
‘witha fuss im Bit an afer gs all you ned odo ip the
‘late me from hardbont. The template ver and eet the pox
lave below show Bur (vo ces Wh the apg one
tempi Lat seb cutout eas stent
For the cous inthe webs, I make a dupe wed.
made a tempat Wil epee Forall fe caus, ied
{bya Ths vay 1 id have to Pokal heendsasa sting pi
repsen dhtenpate sole foe wating And ele ah
tthe emai opens And ig he rtrd sae he
‘ones youvecatal heoperings in mpi wan ecu with double
‘ne he webs, you can we at Se tape. Ae sanding all
pe ax empl for ng all you need to dot fish up
thereat wes
Tins he sae pri ehen
routing the cuous ithe Log
‘When building projet with inst drawers lften want
theta edie ft nah he smog
Seam The too hes an page 14 presents this oppor
niywith ttm er ua inkyou shace
fomakesome tricky cue, but there's an easy way tore
toa perfect math. alin how you cut ean
“The draveng shows you how to create the drawer
foot ror an oversize blank Fis make to ip cuts ©
sie the heght ofthe drier font. They tim an eu
mount of ofeach end to sze te drawer rn sing
‘the cutis. Now forthe “magic” Just glue the eutos
‘ek ono the maining strips to crest the final drawer
‘opening, Finish up by taming 9 ite oo he ends
‘andesprsof he nme, keeping the opening nie.
worn ShopNotesomDesigned with
this portab!
up under herock-solid I-beam
Tabletop
Most ofthe tabletops ima inthe
shop are just At aero sup-
pore by a simple fame. Since
thas top is made of thin, ight
wet plywood and edge with
2 solo frame, ante 19
tmoke sure provided litle add
‘ira suppor underneath.
‘As you ca tein the photo at
righ, id this by aking shop-
rmase"Tbeams" dell undertne
top, Now don’t wom makingthe
‘eel that fica ere
teal prt and simple awembly
make the overall constuction a
fay cay take
‘amLeTo
As mentioned, I waned 0 ae
the overall woriabl ightight
Sol stare by making the top out
D6 plywood! asin Figure
‘Top & Frame. Alter cating the
top sie, Lae a soled
frametothe underside. This frame
hes sifen the plywiod tp and
ids to the overall stably of
{he abit, Yer tie thatthe
oe
~
ese fr the sides ofthe fame
fea ite wider than the ends
‘Tne accomplishes two things
First i provides a wider lamp-
ing ace along, the ecges where
Youte mest key w use las.
‘And second tao ensures there's
‘enough material to form a handle
teary the worktabe
[Aller the fame is glued tothe
plywood, yout easecachcaener
‘ofthe wep. Hound teasest to
Knock of the sharp comers with
Jigs and then snd each comer
{0 fal shape
Handles The nex sep is 16
form thea that allo you to
cary the tbl. You cans in Fig
tie 1 how id this | rte by
ling out tbe ends of the ope
Ing with a Ica spade bit To |
rovidecupportalong these
led, Latched apiece of cap
With some doublesided tape he
Jovsein igs Land And
‘backer bound unde the Handle“
fara helps reduce tarot, a las |
tone in Figute b
‘Once the en for bth hanes
ware died, Tid a fi st
‘ShopNotes No. 98eve the waste and rough cut
theses, A litesanding wasallt
took to smooth everything out
‘BEAMS
“The plywood tabletop and fame
alight soto makelt stu
ic; added shop-mado beams
to the underside (Figur 2). The
beams have three main pars. 8
Single web, apa of top and bo
fom caps and filler Docks which
{itt the ends betwem the cps.
‘Web, Tho webs are made with
‘tots long, her eg 0 esp
the abllighweght without sar
Sistine. Thethinpycoed
fs Ugh but withthe openings in
tech ploce, sakes fe an ever
Tighior beam. Routing the web
openings expained i det in
Shop Short Caton page 38
‘Beam Caps. Thecapson the top
and bot of the wabs are what
aly odd strength to the overall
‘eam. Plus, they provide a lot of
snc aes for hang he bears
fothebettom af the ableton.
Toad thecapstothe web youl
eed te cut 2 entered groove in
win ShopNotes. com
‘one egeof each ap Juste sure
to see the groove to match the
acta tides of your plywood
‘es, whic may Bese han
‘After the aps are gle tothe
“ebs, you ean ad he ile locks
teach endothe bea (Rgore2)
“The blocks hep the bums stable
and add strngth, Ps, the cor
rer filler blocks provide @ solid
mounting point wen you atch
the lg aceemblis ater
“Altaching the Beams, With the
teams complete, yout ready 20
‘asic them 1 the botiom of the
tabletop. IF you look at the End
‘View in Figure 2 yes that the
eas are evenly pact
‘Chmping the ctr beams with
asctofontinary dampsisesy but
you'ineed tase ets told te
two inner ems in pace A exul
'S nothing more han ong sp
wth slight curve sind in it.
‘ours tho! adequate pressure
appli m the inner beams.
‘Support Mates The final sep
‘5 atachag the supper late, a8
Shown in Fgure 3. Then's ane
‘Mlahed to ech end of the ube,
hos with the ends of the bean
“The support plates rot ony hold
the beams in place but provide a
resting pnt the leg asebes
ner Ate cating ther length,
they‘ glued and sewed in placeadd a set of
Legs e
‘wth he top compte al tats
left so a te leg aserhies
“he eg aerblin fe ee
Uke he be — ihre but
sturdy Theweingand seekers
inthe center of th eg ames
stealth together bt
‘add tegth ae stably
The wating ad cbr care
Sinan atk a shock borer
Alun He ad onthe le cay ate a topped groove {the ble Spaying she ps es
top throughout the leg asen- ctthe groove helenghoftheleg, the table moe sabi
‘iy The tethers rest une the andthe ut lerstrps atthe top Pre. One the anges ave
‘support pte whch tanfers the sndbotom. alien tose be cut you con mark ar del he
Weg tothelagisembles. groove your pywons the sane hake forthe bls ht hl hee,
5 you did forthe beam wets assembles You can sce we the
START WITHTHELESS yo takoa ook at gure youl hae locate in gure you
Sipe the webbing finn e best ene the ile tis ae _predrllthelegs ove youve
LEG BLANK soppedgovemttelg saned intl, ces a stopped starting pom ter when te
+>; by mokingthefourlge Afr you groove forthe web. {6 dl the hoes nthe Boa to
ve the legs ctf fin enh Leg Angles Before you shape atach the lg assembles
| tnd wii, You ready to cat athe es youl want ocut the 0" Shaping The tx step fc the
ffuove on onesie lech ig fr anlesonthetopandbtom at hgp BW shape te Wop ove
theweebbing gue) Tomaieit_ slow the Ings to spread under clge Folly the gee peed
(ie ese ontouche weight t= ind
Brettanor fel ek.
Teebbing th he ig shoe,
‘ou cantar yur attention oe
Inge ha coc each pa of
Jeg Figur). You nd every
‘Bing you eed fo know lo make
the eg webs ming rp in
‘Sphere pages.
Steichen, The eg stars
are acter ky othe og asa
Bie since they stmngthen be
‘ete ste, Bl they ply
tightorvardpare
“Te tp scr as a ered
prove cit nthe eget he
i rcting and e bevel em he
ptomatchinbotometteley
“The top bevel nat agate
support plat onthe unto
the bbe Thebes sether
1s Heflin be, ut tes no
Pecdiocaltheber
‘Assembly. Now tht al the
pare Mh, youre dy ©
‘ie the og sated a
Faget Once tarecomplet you
Can Gris wpa fr al etal
“Theft ep kt rer he bs
en ore
yeast er olckthe
Sean oper sy dn
inden tester noc.
‘Leg Spacers. Atthispoint,theleg.
scr fl ft oy betwee
‘Poendsol te bleep othe
Topside) Yer
Hen) 31sm on
to coe the gap. And by adding the legs and rst agua the tp
‘ach spacer opposte comers of stretcher ofthe leg asembly.
‘ach log assembly, you can easly Attach Assemblies. The leg
fold hem fltagsinetthe tabletop. assembles ore installed with a
‘You can make the spacers as tle Gearance between the tp of
shown in Figure 4 This pieces thelegs and he abletopasshown
inFigureSb. This gap ensure hat
‘ho srs placed directly on the
top of th eg, Ph allows each
Jeg assembly toswingeasly when
Tep() APY sys Hecheadsots ——_yeuropenand coset
Eotadramet) | Mal 8 yD ernediels | Asjudohyouvanbese
1/2 Wahere ‘hot the ppc pte ret ety
4 the upper weer. (| wed a
Hewes) YaST
a Ta) Ter yo on al gh
Sipprtits() “Von 10H Sa
‘lesan he bars ig)
Wet ‘he fn step i fo the attach
1 Gagwesa thelegasembies wing the bol,
1, deen leek washers and lock aus. TAS
teresting) rteor
he reraasn) WoO
6) Fr Woodscrems
Se) 1847 Woodsen
“vor ShopNotes com.
setup allows the leg assembles to
rove rely, bu stay sng 0p
tosfone th asin the foie pose
ton, st ine up the hoes, fen
tebe and our be may
forearydury ue
a=) Woodworking 9" Rome. hv ae just wo EY 10" Mange, Competing
oer woodworking fils EA the rund ie theta
AZ Halted think every nt Td ecommend for 3 good, fle you see inthe ight phot
stop would. benefit fom exert set around or “rt tail” below The lat aes of he Wrz
Iavingall the fies shoyrnon these file and rangle fe An if you ile ac ike sal at fies fr ge
‘page: But iff o choowons «thick abot it these fo are ist inginto mow spaces
aroun fleweuld beatthotop exteriors of he Palfround flo But Taio Hk this Ro fr
ofthe ist (rain phot) Is ally talked about earlier. shaped Theyallow me ore
twofiesinane:Thefasideworks Here's what I mean. The ound ate dean sharp comer. Cen @
thesame ssa Hat ile While the fis tigterradion means get tit of wate or sae math fin
rpundsidetkescarefany curves ny and smooth auteurs Ut athe corer aid this ile mae
{ou kly to encounter ‘round le cana cesy to remove the blemish and
‘Shaping. ard. smosthing. can Talowsearundfleforincmas lee tight rp sla
sometimeste rious work Todo ing the sie ofhles ane rating One final thing Tcl hee my
thepb fistandwcurtelyLpreer sobs foriererscx ther hander, “woudworking” fs, but 1 we
long, caunecuting “Chastard” as you cn se in dh ket pote them for smoothing. ane shap-
cutor “bine” file These hive teow. 100g le gives mest ing any non-metal aterm my
Tag teeth andar es key tothe right balance of fast ating shop rom plywood tO MDE, hand
ligwith wood shavings aad ood cont in ight spaces and past lana,
sess)
aster ou)
omaiton
A 10" Tangle. Tre shara anges fa trangle fie
‘ot you clan up corre and eter fine details. na
‘ncn, tacts ke a smal a le 8s well
‘SbopNotes No. 98Metalworking
TEFL Youmightbetemptd
to just use your wood.
tng files for metering a8.
But metal dls fea quicker 50
make my woodworking es lst
longer and eat smoothly Ihave a
separate metalworking =x A 12"Flat.A big Bois youtako A 10° Round. A eoarse-cuting
TF youte like me, mest ofthe long, oven e7oKes To anacin out rund le makes quick work OF
ialworkingyoudosontatwu- sau mas ard square an edge. shaping cures inmost metas
fas. Then hss fe on your Tat
shouisbealog frie (stphoio FW" Round. Nostofthe curves} 12° Kalle Edge. The sverth
atrghd.Theone use isabasand LD yout deal within meta are LA and last fle onthe “must
‘ut The wide, Aatfacscanbe aed either dled bees or rately ave” fit na smooth hfe edge
with Jong, weeping atobes 40. stall Ughteurves.Solcontiders AU nt plance it doen Hook
‘qukky werk down yourlayout round flea mst for cutting and much dierent oma flat le But
lines Follow ths witha daw fle smoothing curves, aslsrated in ithae afew important fares.
stroke to smooth edges that have the zhoto right above ‘The rs she thin tapered pro-
been witha hacksaw ‘Atrakofsoundinglkeabroken file. As you can see fm the ght
recor a sacnd cut version i a photobelow,sthincuting edge
10" Square. The next fe on good balance Between fst cuting Can be used to shape ie ines and
the ist sa thick sturdy file and getingsmooth surfaces. dealsina workpiece,
with 2 are crs section Like" Togiterthe at lenge file, Another thang 10 noice 6 the
the tangle efor woodworking, and round fle form the "Thewe snow Dat spine ofthe Se. Ths
thisonetacKsalltheshap delay Musketeer” of metalworking. “sale” edge lets you wor right,
tnd comin, And since is meant ‘They handle the Hon's share of int.a corm witht morrng the
for detailed work in meal, I want _ your metalworking needs dacentsuroce. &
2 smoother fished
Sula So send cut
leagnodehoice,
‘The ren 1 ike a
squire fe inatnd of
(he tangle isis a nae
rl frevating oquate
ener a5 in the fst
Photo atright-Tocreste
uate slo Etat by
Alig out most ofthe
waste Then Trach for A 10" Square, Tn 2 round Nie Square. k 12% Knife Edge. A rarow cuting odes
the fle and work up to in just few stokes, yout ave nie, crs perfect fr acing five dal io meta wrk
‘he layout ines ‘corners anal, soc eget, [A ato" cage protects ajacentsutaees
Make Them Last:
Cleaning & Care
‘es are tough, simple took, Dut that doesnt mean you should ste
hm i cote can Keeping them citing fe onl harp ie
Star by string them so they cat bag arcund, The rack you see it
"he phot at ight keeps ech ane apart al easy to grab Nestle
‘curd withnylon and meats willelp keep your files clan and free
tba (vod shavings atc moisture and Tend ton). Forme
working ils [go am exe step and rbschalk long th before use
‘This prevents the etl shavings from geting pack into the teh.
‘wrsShopNotes.comarr...
small sho}
Finishi
Tips & Tricks
No room to finish in your shop?
Try these simple solutions for
top-notch results
I would be nice whave a dada rom
for finishing. But ina smal shop that’s ot
always possible These smpletips will bap
{ould mom when ifs tmets apply fish
{o your next project.
FINISHING EASEL
ining! doce nd ther large pane
takes up alot of ace And bending Ove
‘bend an eve you with an aching back,
“The achutable ene you see shove ses
‘hoe probly feng up yourtench and
lacing the work sta comfortable height.
‘A siding upright on ths enc Has you
jermine the with of the work me. Ts
Limited only by the width of yoursaeherse.
“As the drawing at et shows, he aie
parts of the easel ara par of pigs
‘made from "wo by” stock that are set up
onasahore Ancchin ebotomfach
"upright fis over a stretcher (eft drawing).
‘Anangled notch inthe back of the aps
determines the ope ofthese.
“To keep the upeghts steady, I delat
‘bea holesnench one told pecs of
VC pipe. The PVC pees are ied to ane
‘peg with sce amet deasing above)
‘Theotherupeghtis ee tosldesdinrosice
to adjust for pecs of diferent width.
"The workpisce rests on small dowels
Inserted in the font edge of each upeight
(eran drawing) And a pico of PVE pipe
that cat nha lege ad ere ©
‘he uprightanises the workpsce to prevent
itfrom siking othe easel rset drassing).
‘Youle this ensel sors a compact
space and is quik and easy to vet up when
you need room to apply a fish
‘ShopNotes No. 98LAZY SUSAN
Working around a muliaded
pret fo apply nish canbe 2
Isle, Sometimes is easier 10
“mor the project to gtatall he
nooks and crannies
“has where the turtle you
see In tbe drawing at ght can
ome in handy 1 oats 38, 0
as you're ishing a projet, you
dof thave tole moving around
foreach every side
‘Twoidetial pieces of plywood
make upthebase and thetop. And
‘zy Stan bering nthe mide
ets he top pce urn in place
[Nowapolying nish toany part
ofa poets usta matter of plo
ringitght where you ead ie
ANGING PARTS
Someties I find casier fish
Invi parts of projet ore
assembly. But fic a place for
hemody can proses problem.
Chair eps ils stiles. o ay
pare that wil be vile on all
Sides can be finshed by twisting
A sceweyeinto a hidden area of 2
rtand hanging from 2 hook
‘sual inset a Ranger the end
‘of tenon or the bo of,
‘The paris can. be hang to ay
{rom atoard with aserisof hooks
“atch as hover at at &MASTERING THE Table Saw
‘A Io of woodwork:
ing. proces call for
commonly avalible Wy
thik sock buts pretty
tltely tht every par of
Prject wil ua it So you need
Stock ina variety of theless
$ourhavea few hoes Youcan go
to tele amberyard ard rst
‘ely pay a premium pice or you
can plane down theker tock
‘at this wastes lot of wood. The
‘optin Tike ses to enc
‘sock nt hin bd
‘Todo tis, you d typically think
of using 2 hand sa. But if you
slot own cme and the pisces
syow'e resnwving_ arent to
Pr "vide just over) 'satask
ag You can accomplish on
Lyon tables
essing on the lable
‘naa of the board
Tying sacs
re with ease
using these shop-tested row s2ev-