Documenti di Didattica
Documenti di Professioni
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P
P RR
Winter 2006
PRO
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Cove-cutting Jig
Horizontal Routing Table
Cove-cuttingJig
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Ultimate Dado Jig
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Dual Router Table
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Dual RouterTableTable
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SIP_WP2.02 10/20/05 3:08 PM Page 2
SIP_WP2.03 10/20/05 3:08 PM Page 3
6 Editors Note
By Larry Stoiaken
Its winter ... time to get in the
workshop zone.
16 Workshop Classic:
A Bench You Can Rely On
Page 28 Multi-functional
28 Routing System
36 Sandpaper Caddy
Page 8
48 The Ultimate
Clamping Station
56 Trapped Wedge
Layout Gauge
Page 16
Page 64
Page
Page 36
72
Page 60
4
SIP_WP2.05 10/20/05 3:09 PM Page 5
R ING Ti
TU C
o
FE
MADE
HI-
E
EN
D
I
D
S ITY CARB
Lifetime
Guarantee
Install blades face to face for 3/8" box joints To find a dealer near you visit: www.freudtools.com (US) 1-800-472-7307 (Canada) 1-800-263-7016
SIP_WP2.06 11/3/05 9:53 AM Page 6
WINTER 2006
woodworkersjournal.com
6
SIP_WP2.07 10/21/05 10:03 AM Page 7
Taking
Takingtablesaws
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ured.With
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w ww ww w. .l la ag gu un na at to oo ol ls s. .c co om m
SIP_WP2.08 10/21/05 4:48 PM Page 8
T
o a non-woodworker, a bin of scraps or coffee
can full of odd hardware is probably fodder
for next weeks trash. But these sorts of tidbits
are like gold nuggets to a woodworker
theyre the stuff jigs are made of. While its true that our
woodworking machines are chock-full of helpful fea-
tures, they only take us so far. Once you move beyond Ten minutes of set-up time and two sticks of scrap can turn your table
saw and standard blade into an effective shaper for making cove
basic machine operations, jigs are virtually indispens- molding. Heres a job thats impossible to do on a router table.
able. Most projects involve at least one unusual or
advanced operation that requires a bit of modified
technique or machine use. When these instances come many jigs as you do projects (maybe even more!).
up, its time to reach for a good jig. Thats because jigs serve numerous purposes. For one,
jigs improve tool accuracy. T r y cutting a circle
Improving Accuracy and Repeatability freehand with a router, and youll learn quickly that
If youre just starting out as a woodworker, welcome without a jig to guide the tool, you wont have a fighting
to the world of jigsyoull probably cobble together as chance. Mount the router to a long piece of scrap, use a
A piece of scrap and a nail turns a router into an accurate circle cutter
by limiting the tools cutting path.
8 Workshop Projects
SIP_WP2.09 10/28/05 1:55 PM Page 9
Action
is forward thinking
Form follows function with the exclusive ergonomic design of PowerShot Forward
Action staplers. PowerShot staplers, patent
protected worldwide, put the power over the staple where you need it!
PowerShot's design makes stapling easier by providing more control and less user
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requires only one hand to operate.
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A piloted flush-cutting bit and a notched template make hinge A shop-made tenoning jig offers multiple advantages: it stabilizes end
mortising a breeze with a router. The jig builds repeatability and cuts on long workpieces, improves accuracy and keeps your hands out
uniformity into the process. of harms way. Nothing makes tenon-cutting easier.
nail to pivot the jig on one end andvoila! Perfect measurement errors to flub the process up. Your drill
circles every time with a stone-simple jig. Need to rip a never measured so well.
straight line across a sheet of plywood with a circular Machine-made joinery is an exercise in futility unless
saw? Its tough to do guiding the tool by eye, but clamp each step of the machining process can be carefully
a piece of flat-edged stock on top and suddenly your controlled and repeated. All it takes is a registration pin
circular saw has a reference edge to follow. It will slice mounted to a scrap wood fence on your table saws
a line so straight youll think you cut it with a laser. miter gauge to create perfectly spaced pins and slots
Along the same lines, jigs make tasks repeatable. for finger joints. Attach a fence to a piece of plywood
Henry Ford taught us that repeatability is the key to with a slot cut in the middle and suddenly you have a
improving productivity. If youve got a kitchens worth simple way to make router-cut mortises for mortise
of cabinet doors to hang, a hinge-mortising jig and a and tenon joints. In both cases, jigs limit the cutting
router are hours faster than the sharpest chisel in even path, which improves control and makes precise
the most skilled hand, and each mor tise will be repetition possible.
identical, thanks to the jig. Same goes for drilling shelf
pin holes. Rather than measure, mark and drill each Making Tools Work Even Harder
hole separately, use a scrap of pegboard clamped to the Aside from improving accuracy or building
cabinet wall for a drilling jig. No guesswork or repeatability into the machining process, the right jig
can squeeze every ounce of versatility from your tools.
Theres no denying that straight rip cuts are a table
saws bread and butter, but a shop-made tapering or
panel-raising jig takes rip-cutting to a whole new level.
Suddenly straight cuts arent limited to workpieces
laying flat or following the fence. You can even clamp a
pair of fences at an angle to the blade to create a safe
tunnel for milling cove moldings on a table saw. A little
scrap turns a straight-cutting saw into a shaper.
In a sense, even router tables are really just oversized
jigs that turn a handheld tool into a stationary machine.
Here, a jig conver ts your router into a makeshift
molding cutter, jointer and first-rate jointmaking tool. A
similar bit of magic happens when you add a drum
sanding station to your drill press: suddenly a hole-
drilling machine morphs into a smoothing center,
without taking an inch more floor space. Its sweet
indeed when a few picks from the scrap bin or piece of
old countertop can make a good machine even better.
A jig doesnt have to be complex to be effective. Two scraps held
together with hot-melt glue and stuck to a workpiece form an effective continues on page 12 ...
and safe way to secure odd-shaped stock for deep bandsaw cuts.
10 Workshop Projects
SIP_WP2.11 10/28/05 1:57 PM Page 11
SIP_WP2.14 10/21/05 6:46 AM Page 14
Celebrating
Our 50th Year!
C4 carbide teeth are Ultra-sharp cutting edges Heavy-gauge plates are Available in several sizes
precision ground for an dramatically reduce splintering laser cut and precision for any woodworking
exceptionally smooth finish and tear-out balanced for accurate cuts application
and tight joints
2005 DEWALT. The following are trademarks for one or more DEWALT Power Tools and Accessories: The yellow and
black color scheme; the D-shaped air intake grill; the array of pyramids on the handgrip; the kit box configuration; and
the array of lozenge-shaped humps on the surface of the tool.
14 Workshop Projects
SIP_WP2.15 10/21/05 10:06 AM Page 15
Winter 2006 15
SIP_WP2.16 10/28/05 2:16 PM Page 16
16 Workshop Projects
SIP_WP2.17 10/21/05 5:07 PM Page 17
Workshop Classic:
A Bench You Can Rely On
A family tradition continues with this
no-nonsense maple workbench. Granddad he worktop on regular contrib-
Winter 2006 17
SIP_WP2.18 10/26/05 11:01 AM Page 18
20
4
7
18
1
3 2
9
1
16
2
7
6
9 19
11 17
10 13
1" Endcap
(Front View) Slotted holes
5 4 3 4"
3
2 /4"
1
8
Trim to fit 6 /4" 6" 3
/4"
43/4" 8" 61/4" 17/8"
1
/2"
3" 1
10 /8" 8 (Top View)
1
/2"
Worktop 1"
51/4" (Front View) 13/4"
12 15 16 14
17 See full-size
5"
pattern on the Pinup
Shop Drawings for 17
17 jaw profile.
Round
Vise bench dog
Leg Jaw Laminated Jaw
Subassembly location.
(Section View) Lamination
(Section View)
18 Workshop Projects
SIP_WP2.19 10/26/05 10:24 AM Page 19
Options for a Butcherblock Top clamp these subassemblies together in Figure 1, above.
While designing this bench, John to for m the completed piece. Rip a 3"-wide strip of f one side
recalled something from his Biscuits help to line up all these of the top and set it aside, then
days in the kitchen cabinet edges as you clamp. After the glue biscuit, glue and clamp the inside
business: one of the most common dries, take the entire piece to a liners (pieces 2) in place. Place
kitchen renovations is countertop cabinet shop and ask them to run it the worktop on a couple saw
replacement, and more and more through their wide drum sander, to horses while attaching these liners,
homeowners are discarding their reduce it to final thickness. Another so your clamps have plenty of
gorgeous old solid-maple butcher- option is to order your top glued-up room to operate.
block tops. He got lucky on his third and made to order at a local home The liners need to be flush with
phone call: a shop in the citys center. This is a little more the top of the butcherblock when
historical district sold him an eight- expensive but often results in a its finished, so its a good idea to set
"
foot-long section of 1 12 "-thick more secure and stable top. them in place a hair proud of the top
butcherblock for just $10. It took rather than shy of it.
only a few minutes of trimming to Adding the Bench Dog Holes The bench dog holes are formed
make the worktop (piece 1). He After trimming the top to size, when a series of spacers (pieces 3, 4
rough-cut the blank a bit oversized chuck a 12" rabbeting bit in your and 5) are attached to the liners.
with a circular saw, after first por table router to cut the The business edges of these
scoring with a utility knife to help spline groove in each end of the spacers are cut at a 2 angle (verify
avoid tear-out. worktop (see the Exploded Drawings this angle by reading the bench dog
Then John clamped on a on the previous page and as shown manufacturers instructions), and
straightedge and trimmed the top to theyre notched to allow the bench
final dimensions with a straight bit dogs to be stored below the work-
chucked in his router. During top surface. All of these dimensions
this process he cut across the grain are shown on the Elevation
first, then with the grain: this Drawings, and the cuts can be made
approach vir tually eliminates on a bandsaw. Dry-fit and mark the
blowout on the corners. spacer locations on the inside liners,
If you prefer to build a top from verifying each placement with a
scratch, make sure the quartersawn bench dog (see Figure 2). Score a
(tight) grain is visible, and the more shallow line about a 14" in from the
open, wavy plainsawn becomes the edge on both sides of each spacer
gluing sur face. Glue and clamp using a sharp knife or a rotary tool.
three or four overly long pieces of Figure 2: Dry-fit the bench dogs and spacers, This will create a glue well to limit
ripped and jointed stock together at leaving gaps that are the size recommended excessive squeeze-out.
a time. When theyre dry, glue and by the dogs manufacturer. When everything
fits, trim the final spacer to length.
Winter 2006 19
SIP_WP2.20 10/21/05 5:08 PM Page 20
Getting Started:
You should have the vise and bench
dogs on hand before construction
begins, in case you have to adjust the
plan to fit the hardware. Beech and hard
maple are the traditional species of
choice for the frame and top, and walnut
makes an excellent accent. During the
course of construction youll use a table
saw, biscuit joiner, band saw, drill press,
portable and table-mounted routers and
a belt sander.
Attach the spacers to the inside assembly such as the worktop, the
liners with glue and clamps. When endcaps (pieces 8) are splined and
theyre dry, you can glue and clamp attached with lag screws driven
the outside liners (pieces 6) in through oversized, slotted holes
place. Use biscuits and glue to (see the Elevations on page 18 for
attach the remaining 3"-wide marking the slotted hole locations).
butcherblock strip to one of the Chuck the rabbeting bit (the one
outside liners (see the Exploded you used earlier to create grooves in
View on page 18 for its location), the worktop ends) in your portable
then glue and clamp the worktop router and, with the workpieces
sides (pieces 7) in place. held securely, create a stopped
groove in each end cap. Then mark
Adding Splined Endcaps the locations of the lag screw holes
As woodworkers well know, wood in each groove.
has an annoying habit of shrinking T rim splines (pieces 9) to fit Figure 3: Use your drill press to bore two-step
slotted holes in the endcaps: these will allow
and swelling across the grain. To around the lag screws, then move to the benchtop to adjust to various levels of
cope with this tendency in a large the drill press to bore the two-step moisture in the workshop.
Side
(Inside View)
21/8" 15/8"
3
/4" 33/4"
3
/4"
22 24 115/8" 23
43/4"
3
/4"
Back
3
/4" 23/8" (Inside View)
Toolbox Elevations
Set up your router table
with a 34" straight bit and 113/8" Drawer Slide
make multiple passes for (Top View)
these rabbets, grooves 21 34"-wide by
and dadoes, removing a 14"-deep 3
/8"
small amount of stock Top and Bottom dado.
with each pass. (Inside View) Chamfer one 3
/8"
end of each
drawer slide. 39
20 Workshop Projects
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29
28
21 22
26
39
24
23
30
22
21 25 27
Winter 2006 21
SIP_WP2.22 10/28/05 2:17 PM Page 22
12
38
34 36
12
Building the Toolbox
Stability is perhaps the number
38 one requirement in a workbench, so
34
the storage area on this bench is
(End View) (Side View) designed to add weight and lateral
stability to the legs, while also
32 23/8" providing three drawers, a cupboard
34 and a large shelf for tool storage.
21/4"
The toolbox top, bottom, sides,
33
divider and back (pieces 21, 22, 23
33 Customize 11/4"
the height of
and 24) are cut from one sheet of
your bench 34" hardwood veneered plywood.
by adjusting 33 John used birch ply, a good color
the length of
your stile
and grain match for the maple in the
laminations. rest of the bench, and far easier to
341/2" find as a stock lumber yard item
than maple ply. Use the Elevation
Drawings to lay out rabbets on the
appropriate edges of these pieces,
then mill them with a 34" straight
Mount the bit chucked in your router table. For
3" tool box so
its flush with
clean and safe cuts, make several
the top of the passes to mill each rabbet.
bottom rail.
27/8" Use the same bit to plow dadoes
for the drawer slides and divider,
then glue and clamp the top and
35 35/8" bottom to the sides. Dry-fit the back
and glue it in place.
1"
The front edges of the case are
31 trimmed with walnut (piece 25).
Leg Apply this with glue and 3d finish
Sub-assembly nails. Set the heads and fill them
after the glue dries, then scrape or
plane the trim flush with the
plywood. Now you need to build and
install the legs before coming back
36 37 to finish up the rest of the toolbox,
namely the door, top trimmers and
knobs (pieces 26 through 30).
22 Workshop Projects
SIP_WP2.23 10/21/05 5:09 PM Page 23
43 45
42
44
43 30
47
1
1
/4" /4" 21/4"
Making Stile and Rail Legsets (pieces 33): their dimensions are laminations (pieces 34 and 35), then
The benchs legs are standard shown on the Leg Elevations on cut these to shape on your band
stile and rail construction, with a page 22. Face-glue and clamp each saw. Dry-fit these and the rail center
twist: both stiles and rails are built- set of three laminations together to laminations (pieces 36) to the legs,
up laminations. This allows you to create four individual legs, then set then temporarily clamp them in
assemble the legsets with mortise them aside. place. Use this setup as a template
and tenon joiner y without ever Dont be overly anxious about to lay out and mark the foot and top
having to chop a single mortise. per fect matches or glue squeeze- inserts (pieces 37 and 38), as shown
After cutting all the leg par ts out; after the glue dries, you can in Figure 4. Trim the inserts to size
(including the feet, pieces 31) to the scrape off any excess and then joint on your band saw, glue and clamp
sizes on the Material List, dr y-fit the uneven edges. each legset together and set them
the stile center laminations (pieces Use the Elevation Drawings to lay aside to dry.
32) to the outside laminations out the top and bottom rails outside
Winter 2006 23
SIP_WP2.24 10/21/05 5:10 PM Page 24
24 Workshop Projects
SIP_WP2.25 10/21/05 5:11 PM Page 25
Step-by-step
drawer joinery
Glue and clamp the drawers toolbox top, to stop tools from falling
together, checking that theyre off the shelf. Finally, chamfer the top
square and flat before setting them and bottom edges of the feet and
aside. When the glue is dry, trim the screw them to the legs.
top edges of the plywood drawers
with solid hardwood (piece 45), Finishing Up
gluing and nailing at 6" intervals. Fill Disassemble the entire bench,
the nail holes and sand the filler then sand all surfaces with 120-grit,
flush, then install a dado head in 180-grit and finally 220-grit
your table saw to mill grooves in the sandpaper. Wipe it down with a tack
drawer sides for the slides. Test cloth and apply four coats of natural
your setup with scrap, using three Danish Oil to the legset and toolbox,
pieces to represent the three drawer and an additional couple of coats to
sizes, and make any minor the worktop. Sand each coat except Step 1: Install a 38" dado head and a
zero-clearance insert in the saw and cut
adjustments needed to ensure that the last, using 400-grit paper, wiping a rabbet at the end of each drawer front
the drawers will slide properly. it clean before and after sanding. and back.
After milling, test-fit the sides in When the finish is dry, reassemble
the case to be sure they slide easily. the bench and mount the knobs on
the drawers and door.
Building the Drawer Fronts and Door Install a pair of bench dogs (pieces
John cut the drawer fronts and the 18) by using the Elevation Drawings
door for his bench from a single to locate their holes in the top of the
wide board, to take advantage of a vise jaw. Drill the right-hand hole
ver y attractive grain pattern. You vertically all the way through the jaw
may have to glue up stock for this (back up the exit area with some
process. Cut the faces (pieces 46 scrap, to avoid tear-out). Drill the left
and 47) to size, then shape their hole to a depth of 412", then use a bit
front edges on the router table with extender or a long twist bit to drill a
a chamfering bit (see the Elevation second hole in the bottom of this
Drawings for dimensions). boring (see the Elevation Drawings Step 2: Without moving the rip fence,
You can now return to the door for dimensions). This hole is for a switch to the miter fence to form
matching dadoes in the drawer sides.
and finish machining it. The grain brass pin thats actually a door hinge
pattern on Johns door (piece 26) pin, available at most hardware
ran horizontally. To prevent cupping, stores. This pin is used as a button
he plowed three dadoes from top to to push the top of the bench dog up
bottom in its back and glued in three above the surface of the jaw when
stiffeners (pieces 27). After sanding, you need to use it.
he chamfered the doors front Pop the square dogs into their
edges to match the look of the holes at this time, then fill the top
drawer faces. drawer in the toolbox with all those
European style hinges with a 14" project plans youll need over the
overlay (pieces 28) are completely next few decades. After all, once
hidden when the door is closed. people see the great job you did on
Follow the included instructions for building your workbench, theyre
mounting these hinges. bound to have all sorts of great ideas
Step 3: Dry-fit the joints and then switch
On your bandsaw, shape the that will help you use it!
to a 14" dado head to cut the grooves for
walnut toolbox trimmers (pieces the bottoms.
29), then sand them smooth. Screw
one to the legs at each end of the
Winter 2006 25
SIP_WP2.26 10/20/05 3:07 PM Page 26
SIP_WP2.27 10/21/05 7:41 AM Page 27
SIP_WP2.28 10/26/05 1:56 PM Page 28
Multi-functional
Routing System
Heres a router table complete
with its own dust collection
system that can be used
with or without its base.
28 Workshop Projects
SIP_WP2.29 10/25/05 10:44 AM Page 29
14
13
16
11
10 18
12
15
17
7 8
9
10
6
4
2
3
11
I
2 Wings (2) 112" x 26" x 12"
floor space nor a central dust col- 3 Piano Hinges (2) 112" x 26"
lection system, this multi-func- 4 Edging (2) 112" x 8' Plyedge
tional router table is for you. 5 Tabletop Laminate (2) 1/40" x 2614" x 2612"
With its wings up, it provides plenty 6 Wing Laminate (4) 1/40" x 2614" x 1214"
of support for long stock. Flip the
7 Miter Gauge Track (1) 1/2" x 1" x 2614"
wings down, and it rolls up against a
8 Fence T-track (2) 1/2" x 13/16" x 1512"
wall for ordinary-sized routing tasks
or doubles as an extra table for stor- 9 Router Base Insert (1) 1/4" x 9" x 12"
age. In this mode, it only occupies a 10 Gussets (2) 3/4" x 8" x 8"
little over 4 square feet of floor 11 Threaded Inserts (8) 1/4"-20
space. Weve designed the fence 12 Brass Knurled Knobs (4) 1/4"-20
with a port to hook up to your shop 13 Screws (36) #8 x 112"
vac, which should help keep your 14 Plugs (36) 3 8" Dia.
lungs cleaner. Best of all, the top 15 Fence Face and Brace (2) 3/4" x 3" x 2614"
comes off and becomes a stand- 16 Dust Collection Port (1) 2" x 2" x 9"
alone benchtop unit that you can 17 T-slot Bolts (2) 5/16"-18 x 112"
take with you for those routing jobs 18 Star Knobs (2) 5/16"-18
outside the shop.
Winter 2006 29
SIP_WP2.30 10/21/05 5:13 PM Page 30
30 Workshop Projects
SIP_WP2.31 10/21/05 5:13 PM Page 31
Adding Portability
To use the tabletop as a stand-
alone unit, the wings serve as legs.
They are secured in position with a
pair of gussets (pieces 10) that are
mor tised into the back of the
tabletop like hinges are mor tised
into doors. These mortises (see the
drawings) are cut with a router
equipped with a straight bit (after
removing the piano hinges), then
cleaned up with a chisel. A The fence is secured to the hole in the top (see drawings) for
matching mortise is then cut in the tabletop with two T-slot bolts your router. You also need to drill a
back of each wing. (pieces 17) and a couple of star hole in the back of the shelf for your
Bore holes in each wing for the knobs (pieces 18). This hardware routers power cord. Note: If you
threaded inserts (pieces 11), and in also allows you to easily move and decide not to install wheels on your
each gusset (see Figure 2, above) set the fence. cabinet, the bottom should be the
for the knurled knobs (pieces 12). same size as the top.
The drawings locate the holes for Building the Base Cabinet You can now assemble the top,
the inser ts plus the screws and Even though it becomes a bottom and shelf to the sides and
plugs (pieces 13 and 14) that anchor por table, self-contained unit, the back, using glue and 1 1 2" screws.
the gussets to the tabletop. To tabletop subassembly is designed so The screw heads should be sunk
secure the wings in the down it can rest on a mobile base cabinet. 14" below the sur face in 38"-
position, pass the brass knobs This bases two sides (pieces 19) diameter counterbores that are
through the holes in the gussets are rabbeted on their top, bottom drilled with a Forstner bit (for clean
and screw them into the inserts. and back (see the drawings for edges and a flat bottom).
locations and dimensions), and
Making the Fence these are easy cuts to make on Adding Some Trim
Use straight hardwood stock to your table saw. Theres something about a well-
make the fence face and brace The cabinet back (piece 20) is built shop fixture (a fine European
(pieces 15), then cut a hole in the milled next. The only machining workbench, for example) that brings
middle of the face (see drawings) for here is a rabbet along the top edge pleasure to the most mundane
router bits before screwing and and a large hole (see the drawings) woodworking tasks even sanding!
gluing the two pieces together. that will allow air to reach your shop Thats why we suggest you trim out
Counterbore the screw heads (theyll vac if you stow it in the cabinet and the router tables base cabinet, giving
be plugged later), then make the the router cord to exit the cabinet. If it a frame-and-panel look. The trim
dust collection por t (piece 16), a you already have a dust collection pieces are simply cut and jointed
block of wood (see Pinup Shop system, all youll need is a hole to size, then applied to the cabinet
Drawings for profile) with a hole large enough to accept your cords with glue and clamps.
drilled in it at an angle: Use a hole plug. If not, the hole can be cut with The trim pieces must be applied in
saw or Forstner bit that matches the a jigsaw after first drilling out the a specific order so that everything
diameter of your shop vac hose four corners. Finish up by sanding fits perfectly. Begin by attaching the
fitting. Screw, but dont glue, the port any jagged edges left by the saw. side stiles (pieces 24), followed by
to the back of the fence behind the After you have cut the top, shelf the front and back stiles (pieces 25),
hole: You may need to replace the and bottom (pieces 21, 22 and 23) to the side rails (pieces 26) and the
fence face sometime in the future. size, return to your jigsaw to cut the edging (pieces 27).
Winter 2006 31
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32 Workshop Projects
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Winter 2006 33
SIP_WP2.34 10/26/05 2:00 PM Page 34
39
42
40
45
46
44
38
43
MATERIAL LIST (Wheel Assembly)
Wrapping Up T xW x L
38 Wheels (2) 8" Dia.
After all the assembly is
accomplished, youre ready to finish 39 Lower Shelf (1) 3/4" x 2214" x 1014"
the cabinet. We sprayed the base 40 Lower Shelf Support (1) 3/4" x 2214" x 9
and tabletop edging with four coats 41 Lower Shelf Edging (1) 1/4" x 3/4" x 2214"
of lacquer, sanding between coats. 42 Axle (1) 1/2" x 22" Steel Rod
Mount your router to the insert 43 Axle Clips (4) 1/2" I.D. Spring Clips
plate youve selected for your 44 Axle Washers (4) 1/2" I.D. x 2" O.D. Fender
project. It probably comes either 45 Axle Frames (2) 1/2" x 934" x 9"
drilled to fit your router or with 46 Wheel Retainer Panel (1) 3/4" x 23" x 1012"
instructions for drilling the holes
yourself. If not, remove the
baseplate from your router and use
it as a template for locating the
countersunk screw holes in the RESOURCE GUIDE
insert plate. Attach the router to the
insert plate with screws and drop Find the piano hinges, plywood edging and other hardware
it into place. along with all your woodworking necessities at Rockler
Woodworking and Hardware. Call 800-610-0883 or visit the
web site www.rockler.com to order.
34 Workshop Projects
SIP_WP2.35 10/21/05 11:41 AM Page 35
HARDWOOD QUARTERSAWN
FIGURED
walnutwoods.net
Featuring Superior
YOULL APPRECIATE
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All lumber is Select and better grade, 4" and wider,
averaging 6"-7" in width, lengths are 6'-8'. All stock meets
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exhibiting characteristics of fine grain, texture and
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NIAGARA LUMBER &
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East Aurora, NY 14052
Call Toll-Free 1-800-274-0397
www.niagaralumber.com
Winter 2006 35
SIP_WP2.36 10/21/05 5:16 PM Page 36
Sandpaper Caddy
If finding a specific grit sandpaper in
your sandpaper drawer is a frustrating
chore, heres an easy way to bring some
order to the chaos. The alignment blocks dont just store the
disks, they make it easy to center them on
your orbital sander: just press down. The dust
extraction holes line up every time.
reader once submitted this 60, 80, 100, 150 and 220 grits. 6 and 7) to size, and glue them to
36 Workshop Projects
SIP_WP2.37 10/21/05 5:17 PM Page 37
MATERIAL LIST
Alignment Block TxWxL
(Top View)
1 Alignment Blocks (5) 3/4" x 57/8" x 57/8"
Note: The easiest way to
locate the pin holes is to 2 Guide Pins (20) 5/16" Dia. x 114"
draw the layout lines 3 Sides (2) 1/4" x 57/8" x 107/8"
shown at left, then lay a
"
21/2"
3
7
6
41/4"
3 6"
4
4
73/4"
3 5
4
Winter 2006 37
SIP_WP2.38 10/27/05 5:20 PM Page 38
ADVERTISING INFORMATION
Amana Tool Corporation pg. 15 MacBeath Hardwood Company pg. 35
800-445-0077 www.amanatool.com 800-479-5008 www.macbeath.com
American Clamping Company pg. 71 Micro Fence pg. 55
800-828-1004 www.jamesmorton.com 800-480-6427 www.microfence.com
Arrow Fastener pgs. 9,70 Mule Cabinetmaker Machine pg. 71
201-843-6900 www.arrowfastener.com 877-684-7366 www.mulecab.com
Colonial Saw pg. 71 Newton Woods pg. 35
781-585-4364 www.csaw.com 559-277-8456 www.walnutwoods.net
Cookss Saw Manufacturing, LLC pg. 75 Niagara Lumber pg. 35
800-473-4804 www.cookssaw.com 800-274-0397 www.niagaralumber.com
Country Accents pg. 82 Osborne Wood Products pg. 69
570-478-4127 www.piercedtin.com 800-849-8876 www.osbornewood.com
Creative Woodcraft Plans pg. 82 Porter-Cable Corporation pg. 84
800-296-6256 www.woodcraftplans.com 800-487-8665 www.porter-cable.com
DeWALT Industrial Tool pg. 14 Premier Wood Products, Inc. pg. 15
800-433-9258 www.dewalt.com 800-277-7971 www.premierwood.com
Delta Machinery Corp. pgs. 2-3 Protective Coating Company pg. 63
800-223-7278 www.deltawoodworking.com 610-432-3543 www.pcepoxy.com
Direct Sales Ltd. pg. 14 Quality Web Alliance pg. 62
604-876-9909 www.omertools.com 859-494-0790 www.laserkerf.com
Drill Doctor pg. 11 R & R Clamp pg. 75
800-597-6170 www.drilldr.com 920-863-2987 www.rrclamp.com
Elmers Products, Inc. pg. 83 Red Hill Corporation pg. 70
800-848-9400 www.elmers.com 717-337-3038 www.supergrit.com
EpoxyHeads, Inc. pg. 82 Rikon Power Tools pgs. 13,35
866-EPOXY IT www.epoxyheads.com 877-884-5167 www.rikontools.com
Eureka Woodworks pg. 62 Rockler Woodworking & Hardware pgs. 61,63
877-225-0521 www.eurekabusiness.com 800-279-4441 www.rockler.com
Fein Power Tools pg. 62 Rousseau Company pg. 82
800-441-9878 www.feinus.com 800-635-3416 www.rousseauco.com
Franklin International pgs. 26-27,75 Safety Speed Cut Manufacturing Co., Inc. pg. 75
800-347-4583 www.titebond.com 800-772-2327 www.safetyspeedcut.com
Freud, Inc. pg. 5 The Silky Store, LLC pg. 70
800-334-4107 www.freudtools.com 888-605-0001 www.silkystore.com
Fuji Industrial Spray Equipment, Ltd. pg. 70 Simpl Products pg. 74
800-650-0930 www.fujispray.com 914-662-2820 www.woodjigs.com
General International pg. 15 Specialty Furniture Design pg. 62
514-326-1161 www.general.ca 800-892-4026 www.sfdplans.com
Granberg International pg. 82 Tech Mark, Inc. pg. 61
800-233-6499 www.granberg.com 800-787-6747 www.rojekusa.com
Harbor Freight Tools pg. 47 Toolmart Inc. pg. 70
800-423-2567 www.harborfreight.com 800-869-3395 www.toolmartinc.com
Hut Products for Wood pg. 14 Tormek USA pg. 62
800-547-5461 www.hutproducts.com 800-586-7635 www.tormek.com
JessEm Tool Company pg. 74 West Penn Hardwoods pg. 35
866-272-7492 www.jessem.com 888-636-9663 www.westpennhardwoods.com
Jobmaster Magnets Canada, Inc. pg. 62 West System Inc. pg. 61
877-922-0226 www.jobmastermagnets.com 866-937-8797 www.westsystem.com
JWW Services, Inc. pg. 62 Williams & Hussey Machine Co. pg. 14
888-598-3633 www.veneersupplies.com 800-258-1380 www.williamsnhussey.com
Klockit pg. 74 Wood-Mizer pg. 63
800-556-2548 www.klockit.com 800-553-0182 www.woodmizer.com
Kreg Tool Company pg. 69 Wood-Ply Lumber Corp. pg. 35
800-447-8638 www.kregtool.com 800-354-9002 www.woodply.com
Laguna Tools pg. 7 WoodRat Precision Joinery Machines pg. 69
800-234-1976 www.lagunatools.com 011-44-1458-832744 www.woodrat.com
Leigh Industries pg. 13 Woodturners pg. 82
800-663-8932 www.leighjigs.com 877-603-9663 www.woodturners.on.ca
LRH Enterprises pg. 74 Woodworkers Source pg. 35
800-423-2544 www.lrhent.com 800-423-2450 www.woodworkerssource.net
Full-size Drawings Workbench
Workbench
Laminated Jaw
17
Top Trimmer
(Front View) Round Dog
Use a simple
Button
29 19 brass hinge
pin to make
this piece.
Screw
Location
Technical Drawings Multi-functional Routing System
1
Supplies
Tabletop Multifunction Router Table
(Top View) 112"x 36" Piano Hinges (2 required) ...#19283
Birch Plyedge Roll (2 required) .........#10991
1 5/16" 5-Star Knobs (2 required) ..........#23812
Cut the router plate 1/4"-20 Threaded Insert 21 ....................#28803
insert hole according to Aluminum T-Track (2 required) ...........#20054
the instructions that Router Bit Guard ................................#67157
1/4" Knurled Knob ............................#99615
come with the plate.
Please call for current pricing 800-610-0883
20
28
Door
knob
hole
20
28
Door
catch
holes
1 4" Radius
Axle frame
screw locations
45
Door
(Back View)
Base Back
Axle Frame (Front View) Use a hacksaw to cut
45
(Side View) shallow grooves for
spring clips .
42
Axle
(Front View)
42
Technical Drawings Multi-functional Routing System
Base Top
(Top View)
Wheel Retainer Panel
21 (Top View)
When you
When you position
position 46
the insert in the table-
the insert in the table-
top, make
top, make suresure this
this
hole lines
hole lines up
up so
so the
the
router can pass
router can pass
through it.
through it.
46
1
516" holes for Knurled Knob
Tabletop Joint
(End View) Mortise for
1 gusset is 34"
1 8" 19 for hinge
x 1" rabbet deep by 10
7 8"
wide.
2
19 10
2 Gusset
(Front View)
15 16
6" Radius
33
6" Radius
11/4"
Spring catch
9"
Bar
Bar clamp bracket clamp
41" bracket
7
/8 " 691/2"
11/4"
Handscrew
clamp bracket
15"
47"
de x 3/8"
rabbet Mount magnetic catches
8"
1
behind upper inside corners /4" Oak banding
of cupboard doors. 11/4"
2 /4"
1
1" 2"
27 /4"
1
255/8"
183/4"
Piano hinge 1
/4" Walnut banding
11/4"
wide x 3/8"
ep rabbet
3
/4"
Elevation Carcass Elevation Div
21 Drill pilot holes and screw
bracket to left side of cabinet.
3 6 Retainers
461/2" 14
4
8
Technical Drawings 9 9
Clamping Station
Frame Side Elevations
13 Pipe clamps I-bar clamps
8
62 1
/ 2" Upper the remaining waste bracket to left side of cabinet.
3
/4" Bracket with your table saw.
Frame Side1 Elevations /2"
1
461/2" 18 3
/4 " 25 25
3
/ 4"
3
/4" 3
strikeplate and block 3
/4" wide x 3/8" deep rabbet 2" /4" wide x 3/8" deep
Magnetic catchrabbet 2" Magnetic ca
583/4"
541/2"
3
/ 4" 3
/4"
Drill pilot holes and
bracket to left side
1
k banding /4" Oak banding
461/2" 46
Frame
Pipe clamps
11/2" 3 1/ 4
7" 381/2" 381/2"
11/2" 11/2" Pivot hinge location
1 1/ 2" 11/2"
301/2" 301/2"
11/4"
21/4" 21/4" 21/4"
1 1
/4" Oak banding /4" Oak banding
1"
1" 1"
25 /8"
5
181/2" 181/2"
25
103/8"
1 /4"
1
3
/4" wide x 3/8" / 4"
3
2"
3
/4" wide x 3/8"1" 3/4" 2" 1 1/ 2" 1"
deep rabbet deep rabbet 11/2
3
/4" wide x 3/8"
levation Right Side
Divider Elevation
Elevation Side Door
Right Side Elevation
Elevation deep rabbet Side Door Elev
3 6 cutting plywood
12 to shape.14
4 9 9
5 6
Technical Drawings
3
/4" wide x 3/8"
Clamping
8
Station 3
/4" wide x 1/4" 13 deep rabbet
8
deep rabbet
/4"
3
3
3
/4" wide x 3/8" deep rabbet /4" wide x 3/8" deep rabbet 2" Magnetic catch strikeplat
Magnetic catch
3
/4" 11/4" Cut ou
Spring catch corne
4
3 2 9" Rabbe
wedg
Bar
Bar clamp bracket clamp
41" bracket
" Oak banding /8"
7 13/4"
3
/4" wide x /4" 1
13/4"
deep rabbet 11/4" L
3
/4" wide x /4" 1
9" 9" 1 /8"
1 B
deep rabbet 621/2"
43/4" 3
/4"
1
/4" /4"
3 17/8"
381/2" 47"
1 /2"
1 1 /2"1
Pivot hi
11/2" 11/2"
3
/4" wide x 3/8" 301/2"
deep rabbet Mount magnetic catches
8"
1
behind upper inside corners /4" Oak banding
of cupboard doors. 11/4"
2 /4" 21/4" 2 /4" 21/4"
1 1
1
/4" Oak banding
183/4"
Piano hinge 1
/4" Walnut banding
103/8" 10"
1" 11/4"
/4"
3
3
/4" wide x 3/8" /4" wide x 3/8" 3
2"
deep rabbet deep rabbet
3
/4" wide x 3/8"
3
/4"
Divider
LeftElevation
Side Elevation Right Side Elevation
Carcass Elevation Side Door Elevation deep rabbet
Technical Drawings Router Dadoing Jig
Front Rail Return
(Top Views) (Right Side) 2" 61/2"
(Left Side)
Depth setters
3
3
24"
Rail
(Front View)
* 24"
2 1"
72"
Hold Down Clamp
Subassembly * This measurement is determined by the size of your router.
(Side View)
/4"
3
Centering Stop 2
2
(Front View) (Side View)
18 /4"
3
1
1
/4" /8"
5
14 14
6 11/4"
15 15 11/4"
7 11
Router Rest
/4"
(Top View)
13
3
/8"
* *
7
FREE
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Anti-jam magazine
$19
18 NPT; Wt.: 8-8/10 lbs. Uses most oil based paints
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control ITEM Arbor tilt: 0 - 45, Table size: 25-3/4'' L x
ITEM
$
18999 Required air supply: 1-3 HP compressor; Re-
quired air pressure: 50-60 PSI; Air consump-
44914-2KTA 16-1/4''W, Extension wing: 9-3/4'' L x 16-1/4''
W, Miter gauge scale: 30 to 60 left & right,
94000-0KTA tion: 14 CFM; Output: 200-300 CCs per minute; 3 PC. STRAIGHT Miter gauge groove: 5/8'' slot, Dust collection
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34 DEGREE NAILER
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inlet: 1/4''-18 NPS
189 $79
Includes 1/4'', 3/8'' and 1/2'', straight bits L x 35-5/8'' W x 29-1/4'' H, Weight: 75 lbs.
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carbide tips. 1/4'' shanks.
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ITEM
91484-1KTA
$
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soft or slow start motors. SWIVEL FLASHLIGHT RPM; 1/2'' shanks
2499
$
24999 90 swivel head
5999
11999
$ $
ITEM ITEM ITEM $
43060-7KTA 45378-5KTA 45803-2KTA ITEM 90011-4KTA
7''
INDUSTRIAL 350 LB.
SAVE RABBETING CAPACITY
20'' RUGGED
$70 SAVE JOINTER SAW
DISC $100 WITH STAND
2 HP, SANDER/ Heavy-duty cast HORSES, SAVE
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SAVE These supports are no lightweights, even
Precision table adjustment makes it easy to Rabbet cut: 1/2'' $80 though they weigh less than 4 lbs. each. Each
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Cutting width: 7''
sawhorse has a capacity up to 350 lbs. 700
lbs. for the pair! Fold easily for storage. Injec-
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$
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$219
Capacitor start, fan cooled motor for long Overall dimensions: 22-1/2''L x 20-7/8''W x
switch on @ 80 PSI and pressure switch life 32-1/2''H Weight of each: 3.95 lbs.
$9
unloader @ 115 PSI; and recommended maxi- Table tilts 30 up, 45 down ITEM
mum pressure: 125 PSI
115V, 60 Hz 3450 RPM 5.2 SCFM
2-1/2'' vacuum chute with 2-3/16''
adapter
31849-5KTA
$
1699
@ 40 PSI Motor: 2 HP, 220V, 60 Hz, single phase; Table 3 PC. REPLACEMENT PLANER ITEM 47782-1KTA
4.2 SCFM @ 90 PSI Oil lubrication size: 27-1/8'' x 10-3/8''; Base: 22'' x 22''; Miter
BLADES
$79
Tool wt.: 51 lbs. slot: 3/4''; Disc speed: 1740 RPM; Shipping
7'' long x 5/8'' wide SAWHORSE TOOL TRAY
149 99
$ weight: 446 lbs.
$
499 99
9
$ 99 $
499
x 1/8'' thick
ITEM ITEM
38898-2KTA 45725-2KTA ITEM 90179-1KTA ITEM 03207-0KTA
Catalog and Internet Only
1-800-423-2567
Call To Order or Ask for Free Catalog:
Order 24 Hours a Day/7 Days a Week Or Send Check or Money Order to: Harbor Freight Tools,
Most Phone Orders Shipped in 48 Hours 3491 Mission Oaks Blvd. Box 6010, Camarillo, CA 93011
Winter 2006 47
SIP_WP2.48 10/26/05 10:26 AM Page 48
The Ultimate
Clamping Station
Organize all your clamps and glue-up supplies within
arms reach, and enjoy the advantages of the space-saving
fold-down clamping tableyoull never have to scrape
glue off your workbench again.
Glue supply
C-clamps
Pipe and
I-bar clamps C-clamps
Joinery biscuits
Joinery dowels
Light-duty
bar clamps
Spring clamps
Straight edge
Handscrew clamps
clamps
Miscellaneous
supplies
Power tools
48 Workshop Projects
SIP_WP2.49 10/21/05 5:22 PM Page 49
After youre
finished with a
glue-up, the
clamping station
closes flat and
takes on a clean,
modular
appearance.
Youll appreciate
this if floor space
is in short supply
in your shop.
Winter 2006 49
SIP_WP2.50 10/28/05 2:54 PM Page 50
1 5 18
29
30
1 2
3
12
4
27
Planning Ahead: 17
Clamping 11
7
Station Project
20
Constructing the clamping 10
station will require about 30 11
hours of shop time. Youll need 19
a circular saw, table saw, jigsaw
and drill. A dado blade is also 1
called for extensively. Finish the
project in varnish or lacquer. 16
3 sheets of 3/4" 15
white oak plywood
15 board feet of 3/4" white oak 14
4 board feet of 3/4" walnut
3 board feet of 134" walnut
One 24" x 24" piece of 6
1/8" acrylic 22
1
50 Workshop Projects
SIP_WP2.51 10/28/05 2:54 PM Page 51
Clamping
Table
Elevation 23
31/4"
11/2"
28 10
1" 23
24
11/2"
11 /2" Rip at 7 angle
27
26
Lay out the
appropriate
notches for
your style of 11
clamps.
10 25
MATERIAL LIST (Table)
T xW x L
23 Sides (2) 3/4" x 3" x 36"
Angling the legs 24 Front (1) 3/4" x 3" x 3412"
increases the 25 Legs (2) 3/4" x 234" x 32"
stability of the 25
clamping table. 26 Stop (1) 3/4" x 3" x 3312"
27 Pivot Hinges (4) Heavy-duty
28 Oak Plugs (50) 3/8" Dia.
Cut at 7 angle
29 Spring (1) 1/2" x 112" x 514"
30 Catch Base (1) 134" x 212" x 112"
Winter 2006 51
SIP_WP2.52 10/28/05 2:54 PM Page 52
1
Storage 17
9
1
Storage
Strategy
In addition to storing 13
glue, dowels, biscuits
and light-duty clamps,
keep some 3/4"
dowels on hand for
use as clamping
pads. When gluing-up
a panel the dowels
direct the clamping
pressure right where
its needed.
16
19
1
Storage Bins
with acrylic fronts and
dividers keep small joinery
supplies organized and in
full view.
1/8"-thick
acrylic
8
1/4" walnut
banding 16
Storage Shelves
with a tall front lip are
ideal for holding extra 10 11
glue bottles, solvents
and band clamps.
8
3/4" oak
plywood
52 Workshop Projects
SIP_WP2.53 10/28/05 4:03 PM Page 53
Table
Catch Outfitting Your
The wood
spring lock
allows quick
Clamping Station
release of the
fold-down Simplicity is the key to designing
clamping clamp supports and other clamping
table. station fixtures. If they work in different
situations and are easy to make and
install, youll get the most mileage out
Glue into base, then of the design. Once youve made the
screw the catch fixtures, move them around to find the
to the cabinet best arrangement in your cabinet.
Keep your heavy-duty clamps close to
the clamping table, where theyre used
most often, and put the light-duty
To build the clamping table, cut clamps and other supplies in the side
oak for the sides, front and legs, and compartment and door.
cut walnut for the stop (pieces 23
through 26). Shape the ends of the Spring Clamps and
legs with a jigsaw, as shown in the
C-clamps
Simple wood bars are sufficient
Elevation Drawings on page 51. Cut for hanging these light-duty
the bottom end of each leg at a 7 clamps. Be sure to size the
back-up blocks to accommodate
angle so that its more difficult to the clamp sizes in your shop.
accidently kick the legs out from
under the table. Use the jigsaw to
notch the frame sides (see the
drawings) to form holders for your
bar or pipe clamps, then cut Drive screws through
the dado near the end of each block into back of cabinet
piece with your table saw and a
3/4" dado blade.
Now drill holes for the pivot
hinges (pieces 27) in the frame
sides, legs and carcass, as shown in
the Clamping Table Elevation (page
51) and on the other carcass
elevation drawings. Install the frame
sides in the carcass with the hinges,
then glue the front rail into the side Bar Clamps and Handscrew Clamps
rail dadoes. Drill counterbored pilot For balance, install two brackets at different Offset brackets
holes into these joints and drive the heights to support each set of bar clamps. keep clamps
Handscrew clamps, on the other hand, balance
screws, then cover the screws with on a single bracket once the jaws are tightened.
level
oak plugs (pieces 28). Next, join the
legs to the frame sides with the
pivot hinges and mount the walnut
stop to the front legs with screws Pipe and I-bar Clamps
Because theyre heavy and
and plugs. unsteady, these clamps should
The catch (pieces 29 and 30) for be stored in individual slots.
The lower bracket carries the
holding the clamping table closed is weight while the upper bracket
shown on page 50. Lay out the assembly pins the clamps in
spring shape on the edge of some for safe keeping.
oak stock and band-saw it to shape.
Sand the piece smooth and cut the
base to size. Kerf the base with a
table saw blade to fit the spring and
glue the pieces together. Glue and
screw the catch to the roof of the Make lower
Screws hinge retainers bracket from one
main cabinet compartment. to upper bracket piece of wood
Winter 2006 53
SIP_WP2.54 10/21/05 5:24 PM Page 54
Adding Clamp Supports and Bins assembly into the compartment so The best place for storing pipe
All the fixtures you can the strikeplate is just a hair past and I-bar clamps is on the outside of
make for the side door and side the front edge of the cabinet. the cabinet. For the upper clamp
compartment are versatile enough This will allow the magnetic bracket glue two pieces of walnut
to hold a variety of clamps and shop catch to fully contact the strikeplate. face to face, then lay out notches.
supplies. You may need to Finally drill a pilot hole for the door Use a Forstner or spade bit to drill
redesign some of them or come up knob (piece 19). the ends of each notch, then remove
with designs of your own to suit Now make the fixtures for the the rest of the waste with your table
your tools. In addition, we side compartment, as shown page saw. Next, rip a 1/2" x 1/2" strip of
recommend that you use our fixture 52. Cut walnut bars and blocks for walnut for the retainers and cut
sizes and layouts as a guide (theyre the C-clamp and spring clamp them to length for spanning each
not in the Material List) and hangers, and glue them together. notch. Screw the retainers into
spend time figuring out the best Drill counterbored pilot holes place. Cut the lower bracket out of
position for each bracket according and screw the hangers to the back one thick piece of walnut. Screw the
to your needs. of the compartment. brackets to the side of the cabinet
Begin by making the fixtures for Cut two more walnut bars for the and plug the holes.
the side door. Install shelves and dowel bin and install them by
bins in the door for holding all sorts driving screws through the divider Finishing Up
of glue-up odds and ends, including and right side wall into the ends Stain the door knobs dark brown
glue bottles and a scraper, fluted of the bars. and give the clamping station two
and spiral dowels, biscuits, band To make the fixtures for the main coats of var nish or lacquer to
clamps, clean-up rags and a can or compartment, lay out and cut the protect it from glue drips. Slide the
two of solvent. Build the shelves and clamp brackets to shape (see page cabinet into position and screw it
bins, as shown on the previous 53) and band-saw as many as you to the wall to prevent it from
pages, to span the width of your think youll need. Screw the tipping forward once the clamps are
door. The walnut strip on the front brackets to baseplates, then screw loaded up.
of each shelf rises 1" above the the baseplates to the back panel. Fill
plywood to prevent your supplies the counterbores with oak plugs.
from falling of f. The see-through
acrylic bin fronts and dividers slip
nicely into 1/8" grooves cut with a
standard table saw blade. Be sure to
cut the grooves in the plywood
before adding the walnut strip to the
front edge (other wise youll cut
through the walnut).
Mount the shelves and bins by
driving screws through the door
sides into the plywood base of each
fixture. Remember to counterbore
all the pilot holes and fill them with
walnut plugs.
Our piano hinge lengths were 36", If you like the design
of this clamping
so we butted two hinges end-to-end station, why not
to mount the side door to the start a system of
cabinet. Once the door is in place other wall cabinets
screw the magnetic catch to the top and tool organizers
panel and cut a block (piece 18) for based on the same
style? Youll end up
holding the strike plate in the side with a shop that looks
compartment. Screw the strikeplate as good as it stays
to the block, then glue this neatly organized.
54 Workshop Projects
SIP_WP2.55 10/25/05 12:25 PM Page 55
MICROFENCE
Fine precision
measurement system
for the hand-held router
Mill
ree-Axis
h
ble T
Porta
Inlays-Hinges-Locks-Mortises
Dadoes-Rabbets-Flutes
Straight-Line Work
MICRO FENCE
800-480-6427 WWW.MICROFENCE.COM
SIP_WP2.56 10/26/05 2:58 PM Page 56
alf the challenge of cutting one board foot of 3/4" stock. Buy a This may seem odd, but through
56 Workshop Projects
SIP_WP2.56-59 Trapped Wedge.CM 10/28/05 3:11 PM Page 57
4 5
/8"
9
/16" 1
7 6 5
/4"
13
/16" 23/4"
43/8" 1
11
/16" /2"
Start machining
by dadoing out
shaded area. 1
/4"
6
Small Wedge Assembled Top View
(Side View) 3 3 3
5 /4" /4" /4"
/16" 5
5
/16"
1
/4"
4 11/4"
3
/4" 1 6 8 2 1
/4"
17/8"
3
Hole length tapers
7 from 11/32" at top to
5/16" at bottom
3
/16"
3
Assembled Side View 9
11
/16" 8 1
/2" 4
5
11/4"
9 1
7
6
1
3
4
Winter 2006 57
SIP_WP2.58 10/28/05 4:23 PM Page 58
Flush
with edge
Figure 1: softwood scraps. First, draw the
For a safe Figure 4:
pitch for the wedge taper, then mark Cut the
ripping operation 11/4"
on such thin
this measured wedge with an X tapered
stock, use a 1/16" Overhang (see Figure 2). Next, cut a 1/4" x dado in
hold-down block 112" x 12" piece of plywood and nail several
passes,
to keep the material pressed tightly it to the wedge stock so its aligned
to the saw table throughout the cut. moving the fence a little for each pass.
with the pitch line and covering the
side marked with the X. With your
assembly so you can reorder it fence set at 112", rip the wedge stock Assembling the Head Pieces
again later. Next, separate the while the plywood rides against the After a careful sanding, dr y-
pieces and rip a 3/16"-deep groove fence, as shown in Figure 3. assemble the head pieces and
in the center of each adjoining edge Trim the wedge ends so theyre splines around it, sanding the 3/4"
for inserting the splines. For perfect identical. Complete the jig by dimension of the beam, if necessary,
alignment, be sure to always run nailing the wedges to a 3/4" x 312" x so it slides through the opening.
the front face of each piece against 14" board (see Figure 4), and nail a To prevent the beam from
the saw fence during these cuts. fence block on top bonding to the head, coat its first
Ripping the splines to their final of the wedges. 2" with paraffin wax. Now glue the
size requires a special hold-down To use your head and spline pieces together
block. Cut a block measuring 3/4" x tapered dado jig, and, while pinching the assembly
4" x 9", and screw a thin, narrow just raise your with your fingers, quickly clean out
piece to its back end as shown in table saw blade 1" the excess glue in the opening. Slip
Figure 1, left. Set the blade height at and set the fence the waxed end of the beam into the
3/8" and rip your spline, using the 114" away. Push the head assembly and clamp
block to hold it tightly to the table. jig into the blade everything tight in both directions
Next, crosscut the strip into four until the center of (top to bottom and side to side).
Figure 3:
segments (pieces 1) and check their the blade just Jig for making the Later, when the glue has dried, you
fit in the head piece grooves you passes under the tapered dado. can sand the beams 1116" dimension
just made. front of the fence so it slides in the opening easily,
block. At this point, clamp a stop to trim the head to final size and
Cutting the Head Dado the saw fence in front of the jig, as chamfer all its edges and corners.
The bottom of the dado in the side shown in Figure 4. Draw a line on
head (piece 5) is tapered to fit the the front edge of the fence block Making the Trapped Wedge
large wedge. The tapered dado jig 1/4" from its bottom and raise the Begin making a the trapped
for making the cuts is built from saw blade to hit the line. wedge (piece 4) by ripping the
Make your cut by placing the side stock you cut earlier to 5/8" wide
2 1/8" head (piece 5) on the jig with its and cutting a dado as shown in the
11/4"
marked front facing the fence block Large Wedge Side View on page 57.
and one end bearing against the saw Once the dado is cut, remove one of
fence. Make your first pass, then the wedges from the tapered dado
Figure 2: Begin making continue moving the saw fence to jig and nail a stop to its wide end to
the jig for cutting a make several more passes until the make a tapering jig for the large
10"
tapered dado by laying dado is 1/2" wide. Be sure to fine- wedge (see Figure 5). Set the
out a 1:20 slope on a tune the last pass so the dado fits wedge against the taper jig and rip
3/4" x 214" x 10" piece of
the large wedge precisely, then the piece, splitting the lead corner
scrap wood, then label
the measured wedge smooth the dados angled bottom with the blade. For safety, use
with an X. with a file. scrap wood to press down on the
3/4"
58 Workshop Projects
SIP_WP2.59 10/28/05 4:29 PM Page 59
Taper
jig
Step 1:
Get started by
Figure 5: To use your
Fence beam insert. To cut the strip in half, grinding the tip of
tapering jig, adjust the
saw fence so the cut set your tapering jig against the your 1/4" spade bit to a
table saws miter gauge, then place 90 point, making sure you
splits the leading
remove the original cutting
corner of the stock. the strip against the jig. The edges.
During the cut, be sure resulting angled cut is just what you
to control the trapped wedge stock with a
need for the end of the beam insert.
narrow hold-down block.
Sand one of the pieces to fit into the
slot in the beam, then glue it into
wedge as you cut. Now center the place with the angled end pointing
wedge in the dado to see if its back into the beam and leaving a 5/16"-
edge is flush with the shoulder of long hole on the bottom side for the
the larger hole. If the fit isnt right, cutter and the small wedge. Trim
continue trimming the wedge in of f the excess when its dr y, and Step 2:
very small increments, then shape chamfer the ends of the beam. Grind the shaft
above the blade to
the ends of the wedge with a A a stout knife blade (piece 9) is
lengthen the flat area to
coping saw and a file. easy to resharpen, and weve found 2", then file the edges
that regrinding a 1/4" spade drill bit square so the bit is just under
Cutting the Beam Slot is ideal (see sidebar at right). In use, 1/4" wide.
The hole in the beam that holds the knifes bevel should always face
the knife and small wedge is the waste side of the work, leaving a
tapered on its for ward edge. square shoulder on the proper side
It sounds unor thodox, but this is of the cut.
easily done on the table saw. Make Use the remaining 1/4"-thick
the jig shown in Figure 6, then use piece for the small wedge (piece 3).
it to cut a 1/4"-wide by 114"-deep slot First taper one edge on the table
in the end of the beam (remember, saw with the tapering jig, then plane
the beam isnt square, so be sure to the piece to width and cut it to
cut into its wider edge). length (see Small Wedge Detail on
Earlier you cut a 1/4"-thick strip page 57). Shape the top of the
for making the small wedge and the wedge with a file and smooth any Step 3:
saw marks. Hone the back
of the blade on your
Final Assembly and Finishing sharpening stones, then,
3/4" Slip the cutter into the beam hole while rounding the end into a
fingernail shape, grind a 25 bevel.
and install the small wedge. Trim
the end of the wedge so its flush
11
/16" with the bottom of the beam, then
91/2" pull it back out to chamfer the end
with a file. Coat the gauge with a
penetrating oil-type finish and put
more wax on the beam so it slides
easily. Youll quickly find that the
trapped wedge locks with slight
hand pressure to maintain the exact
position you set it at. Step 4:
Figure 6: Cutting a 114"-deep slot for the beam Hone the bevel with
insert is safe and easy using this jig. a slipstone and finish up by hacksawing
the cutter off the shaft 2" from the tip.
Winter 2006 59
SIP_WP2.60 10/26/05 2:25 PM Page 60
5"
121/2"
5"
60 Workshop Projects
SIP_WP2.61 10/21/05 10:17 AM Page 61
A gripping tale.
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Winter 2006 61
SIP_WP2.62 10/28/05 3:17 PM Page 62
workshop-friendly compartmental
box. Now, Jobmaster Magnets is
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For ordering info,
call 1-877-922-0226
detail sand profile sand rasp flush-cut regrout scrape notch drill/screw power recharge
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set.Theres no end of things you can do, when you purchase this FEIN
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62 Workshop Projects
SIP_WP2.63 10/25/05 12:24 PM Page 63
Precisely.
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Winter 2006 63
SIP_WP2.64 10/26/05 2:40 PM Page 64
Dovetail
Puzzle
Mallet
Even though this intriguing mallet design has been around for
centuries, the method for building it had nearly been lost. Thanks
to the counsel of experienced hand tool woodworker, Stephen
Sheperd, weve revived the methodology here. And, making this
mallet provides a double bonusyoull have a beautiful tool to
display and a powerful workhorse around the shop.
64 Workshop Projects
SIP_WP2.65 10/24/05 4:50 PM Page 65
here will always be a place in tails of a conventional dovetail joint consider switching to a round tenon
Winter 2006 65
SIP_WP2.66 10/26/05 2:14 PM Page 66
The
Secret
Taper
The
slots are
twice as Bottom
deep at the
bottom
as they
are at
the Top
top.
(Top View)
1
/2" Ramped
dovetail
(End View) 5
/16"
1 slots are the
/2" 6"
secret to
this mallets This is a very
1
/2" 3
/4" seemingly tricky piece of
impossible joinery because
joints. you cant test-fit
the handle to
the mallet head
prior to the final
assembly.
5
/8"
23/4"
Mallet Head
(Side View) 1
/2"
For better
Shape the Handle
Make the mallet head
control, the
with its mortise and
mallets 3" dovetail slots first. Then
faces are
form the handle to fit the
beveled 3
/4" machining youve done in
at 5.
the head. Shape the
15"-long handle to please
5
5
/16" your sense of proportions.
66 Workshop Projects
SIP_WP2.67 10/21/05 5:37 PM Page 67
Step 2: The dovetails are half as deep at the top of the mallet head Step 3: Connect the scribe marks with a reliable straightedge and a
as they are at the bottom (where the handle enters). Scribe the depths sharp marking knife to ensure precise layout lines.
with a marking gauge.
The best and safest way to create bottom shoulders and sloped sides Check the softening process
the dovetail slots in the head is with of the pins with a handsaw. periodically by squeezing the pins
a dovetail saw, followed by a sharp A backsaw works well for this together. As soon as they bend
chisel to remove the waste material. purpose. If the wood is straight- easily, youre ready to assemble the
Saw the angled sides of the dovetail grained enough, you can carefully mallet. Star t by tightening one
slots first, then cut a couple more split it away with a chisel. Pare the clamp across the flat of the handle
ker fs between them, stopping at pins until they align with your layout (below the pins) to prevent the
your layout lines on the top and lines using a sharp chisel. wood from splitting as the pins are
bottom ends of the head, as shown This is a dif ficult joint because bent inward. Then, place another
in the five-step photo sequence you cant dr y-fit the handle to clamp near the ends of the pins
star ting on page 65. These ker fs the head to check the fit. You have and tighten it until the pins
provide a depth reference when to carefully check all of the are close enough together to fit
youre removing the waste wood measurements and angles on your into the dovetail ramps in the
with a chisel. Once the slots are cut, pins and tails to make sure they head, as shown in the lower right
drill or chisel out the mortise for the match their corresponding surfaces photo on the next page.
center tenon. perfectly. Its exacting work, but the Line up the center tenon with its
end result is quite satisfying if you mor tise and tap the end of the
Making the Handle work carefully and keep your handle with another mallet to force
The wood you pick for the handle patience in check. the joint together. Since the center
must be strong enough to stand up Once youve cut the pins and tenon is longer than the pins, it
to the abuse a handle on a mallet tenon, band-saw the rest of the goes into the mortise first and helps
gets, yet it should be flexible enough handle to its approximate shape, but align the pins when you engage
that the pins may be bent. Weve leave the final smoothing until later. them in the head.
found that ash and hickor y both Once the pins are par tway into
work well and that quar tersawn Assembling the Mallet the slots, you can remove the end
stock in either species is best for In order to assemble the mallet, clamp; the sides of the slots will
both strength and bending qualities. you will need to bend the pins guide the pins the rest of the way.
Lay out the tapered dovetail pins inward to meet the grooves in the To protect all the work youve done
and the center tenon to match the head. The pins are likely to be too on the handle, leave the other
slots in the head. Make the handle stiff to bend easily, so soak the pin clamp in place until it is completely
slightly wider than the head so the end of the handle for a few minutes seated in the head.
pins will stand proud when in boiling water to make it more Even with a tight friction fit, its
assembled. Also, allow about 1/8" of pliable. Use filtered or distilled water still a good idea to secure the joints
extra length on the pins and 1/2" on to reduce mineral staining. Cold with glue. We use hot hide glue. It
the tenon for ease of assembly, as water will also work, but it will take has a suitable working time and is
well explain later. longer to soften the wood, and you compatible with the moisture
Band-saw the waste between the risk staining the wood if you soak it saturating the boiled tenon and
pins and the tenon, then cut the for a long time. pins. With the tenon engaged and
Winter 2006 67
SIP_WP2.68 10/21/05 5:38 PM Page 68
Step 4: Saw the sides of the dovetail slots with a backsaw. Slice kerfs in Step 5: Chop out the waste with a chisel, working your way up from the
the slots middle to help you gauge the depth when paring. bottom end.
the hide glue br ushed into the takes a few days to dr y, so you
openings, firmly drive the handle might prefer a faster dr ying mix
home with a mallet. Wipe off any such as wood flour (fine sawdust)
excess glue that has been squeezed and hide glue.
out, then clamp the handle tightly When the filler is dr y, sand or
into the head until the glue and scrape the joints flush. The scraper
wood dries thoroughly. impar ts a smooth hand finish on
the tool that feels wonderful to the
Finishing Up touch. As a final finish, soak the
When the wood and the glue mallet in a 50/50 mixtur e of
have dried, trim the ends of the turpentine and linseed oil. Its an
pins and tenons flush with the appropriate finish for wooden tools
head and scrape or sand them and easy to reapply as necessary.
smooth. Then you can softly bevel Once the finish dries, its time to
the edges of the head and chamfer put your new handmade mallet to
or round the handle to final shape. work. Reach for it the next time
To fill any slight gaps in the you have some serious mortises to
joints, after they shrink, use an square up. Theres nothing quite
authentic 19th-centur y mixture of like swinging a mallet youve
linseed oil, whiting and a little dry made yourself.
powdered pigment. This mixture
68 Workshop Projects
SIP_WP2.69 10/21/05 11:09 AM Page 69
Introducing the
W
2 Ways to Buy!
NE
K3 Master System
(1) Interchangeable Drill Guide
Benchtop Base
Portable Base
Dust Collection Shroud
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Quickly switch Drill Bit
6- #2 Driver Bit
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between Material Support Stop US MSRP: $79 99
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this pace-setting tool is poised to take Pocket Hole Joinery to a whole new level!
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Winter 2006 69
SIP_WP2.70 Ad Page 10/21/05 10:30 AM Page 70
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70 Workshop Projects
SIP_WP2.71 10/28/05 3:59 PM Page 71
The Last
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.OT ALL CLAMPS ARE CREATED EQUAL Consistently rated the ultimate biscuit
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Winter 2006 71
SIP_WP2.72 10/26/05 2:27 PM Page 72
11/2" 8
1
/4"
Sliding Block
(Top, Front and End Views)
11/4" 1
3
/8" Dia. 1" R.
2" 2"
11/4" 3
3
/8" Dia.
1
/2" Handle Fence Detail
3
11/4" 11/4" /8" Dia.
NOTE: The holes
for the threaded
Sliding Block bolts must reach
(Top, Front and End Views) the holes for the
guide bars.
11/4" 1
3
MATERIAL LIST
/8" Dia.
2" 2" 2" 11/4" T xW x L
3
/8" Dia.
1 Sliding Blocks (2) 1" x 212" x 8"
1
/2" 2 Handle (1) 1" x 212" x 8"
3
11/4" 11/4" /8" Dia. 3 Handle Fence (1) 1" x 2" x 8"
Handle 4 Steel Bushings (5) 3/8" O.D. x 3/4"
(Top, Front and End Views) 5 Threaded Inserts (4) 1/4-20 x 3/4"
72 Workshop Projects
SIP_WP2.73 10/21/05 5:40 PM Page 73
Winter 2006 73
SIP_WP2.74 10/28/05 3:28 PM Page 74
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74 Workshop Projects
SIP_WP2.75 10/27/05 4:04 PM Page 75
4HE IDEAL SPACE
SAVING SOLUTION FOR g AND g 3TARTER +ITS AVAILABLE
CLAMPING CABINET DOORS AND PANELS
#OMES WITH SIX CLAMPS
ENOUGH TO +IT )NCLUDES
CLAMP THREE DOORS OR PANELS AT ONE CLAMPS
ALIGNMENT BARS
TIME
OR USE AS A SINGLE BAR CLAMP STABILIZER BARS
3OLID STEEL CONSTRUCTION PACKS OF RUBBER GUARDS
3TACKING CLAMP SYSTEM IS AS EASY AS DRILL ADAPTER
*UST CLAMP PANELS STACK gEM
HIGH AND LET gEM DRY
Winter 2006 75
SIP_WP2.76 10/21/05 5:51 PM Page 76
Accurate Dadoes...
In a Hurry
76 Workshop Projects
SIP_WP2.77 10/21/05 5:44 PM Page 77
Quick and
Easy Grooves
Quick, easy and accurate ...
thats what youll get with this jig.
Its quick to set up (both depth
settings and dado placements),
and its quick when it comes to
making repeatable cuts: the sliding
hinged stops help you plow
successive indexed dadoes
(like those on matching bookcase
sides) in a hurry.
Because you move the router
across the stock not the stock
across a table saw its also a lot
easier (especially on your back).
And if you do any type of cabinetry,
from bookcases to entertainment
centers, youll find this jig
indispensible for plowing three
This jig provides quick and accurate setups styles of common dadoes:
stopped, through and sliding
when cutting through or stopped dadoes dovetail.
Winter 2006 77
SIP_WP2.78 11/3/05 4:52 PM Page 78
18
he inspiration for this jig came 3
19
25
2
16
18 17
20
17
lumber, it was constantly in demand.
Ours is made of oak and walnut, but
feel free to use whatever hardwood Stop Block Detail
scrap you have on hand to create
your own version.
Start by cutting the deck (piece 1)
from a sheet of melamine and the
rails (pieces 2) from hardwood
stock. Go ahead and cut the front
and rear rail returns (pieces 3 and
4) at the same time. Move to your
table saw, and with a dado head in
place, plow the long grooves in the
rails and the shallow rabbets on the
front and rear rail returns. Look to
the Exploded Drawings on the next
page and the Pinup Shop Drawings
for the machining details.
Remember most sheet stock these
days is just a bit under a tr ue Figure 1: Determining the space required for your router is critical to the
success of this jig. Measure your router and the two pieces of laminate
3/4" thickness. Check your grooves to get the exact dimension.
in scrap lumber to be sure they fit
properly. Now take a few moments
to find out how large an opening means theyll wear better for you. these notches with the help of a
you will need to create for your If the liners do begin to show wear, miter gauge.
router base. you can just peel them of f and Measure from the end of the rails
For this jig to be accurate, your replace them with fresh laminate. to the edges of your notch and cut
router must fit snugly between the (Voila!, good as new!) your front and rear rail returns into
guide rails. And to ensure smooth Measure the width of your router properly sized segments. Then look
sliding action, these rails are lined base plus the two pieces of the to the drawings for the location of
with plastic laminate. This also plastic laminate you will be using. the track groove in the face of the
This is the only way to arrive at the left front rail return segment. While
opening youll need for your router, youre at it, find the locations of the
as shown in Figure 1, above. quick depth-setting aids in the face
of the right front rail return. Use a
Taking Custom Measurements Forstner bit to bore these four 1"-
Take the measurement you found diameter stopped holes at exactly
for the router opening and transfer 1/8", 1/4", 3/8" and 1/2" depths.
it to the top edges of the rails, 24" These holes ser ve as instant bit
from one end (see the Pinup Shop depth setters when setting up a cut.
Drawings). Form a notch on each Now youre ready to star t the
rail to accommodate the router first assembly phase. Drill and
rest and receiver. We left the dado counterbore pilot holes, then attach
head in the saw to nibble out the rails to the deck with #8 x 114"
Melamine, an easy-to-find sheet stock, is a good choice for this shop jig, due to its hard plastic
surface and dimensional stability. It is sized in sheets measuring 49" x 97" to allow for trimming.
The factory edge is often damaged during shipping.
78 Workshop Projects
SIP_WP2.79 10/28/05 4:48 PM Page 79
4
Front Rail
Assembly
(Section View)
1
/8"
3 2
8
5
/8"
1
/4" 1
6 10
14
13
15
7
11
6
23
21
4
24 5
9 22
2
3 1
12
MATERIAL LIST
TxWxL TxWxL
1 Deck (1) 3/4" x 2612" x 72" 14 Centering Stop (1) 3/4" x 212" x (*)
2 Rails (2) 3/4" x 238" x 72" 15 Center Stop Return (1) 3/4" x 112" x (*)
3 Front Rail Return (1) 3/4" x 4" x 72" 16 Side Stop Tops (3) 3/4"" x 234" x 278"
4 Rear Rail Return (1) 3/4" x 212" x 72" 17 Side Stops (3) 3/4" x 238" x 278"
5 Walnut Plugs (bag) 3/8" Dia. flat 18 Stop Knobs (5) Plastic, 5/16" thread
6 Guide Rails (2) 3/4" x 212" x 39" 19 T-Bolts (5) Steel
7 Under Rails (2) 3/4" x 214" x 2578" 20 Stop Hinge (1) 112" x 36" (Piano)
8 End Spacer (1) 3/4" x 212" x (*) 21 Hold Down Clamp (1) Steel
9 Router Rest (1) 3/4" x 834" x 12" 22 Clamp Spacer (1) 3/4" x 212" x 4"
10 Router Receiver (1) 3/4" x 614" x 12" 23 Hex Bolt (1) 5/16" x 1" Steel
11 Laminate Liners (2) 1/16" x 114" x 2578" 24 Connector Nut (1) 5/16 I.D.
12 Deck Trim (2) 1/8" x 3/4" x 2612" 25 Hanger Cleats (2) 3/4" x 134" x 24"
13 Aluminum T-Tracks (3) 48" (*) Adjust these pieces lengths to accommodate your router.
Winter 2006 79
SIP_WP2.80 10/21/05 5:48 PM Page 80
Four holes
drilled to
specific depths
become a
feature that lets
you quickly set
your router to
predetermined
settings. Use a screws and glue (see Figure 2). Cap
Forstner bit to the screw holes with walnut plugs
bore these holes
to 18", 14", 38"
(pieces 5). Next, join the front and
and 12". Its rear rail retur n segments to the
quicker and deck/rail subassembly, again using
safer than glue and screws capped with
flipping the the walnut plugs. Check to be
router over to
measure from
sure the rail segments are square.
the base plate. Cut the guide rails and under rails
(pieces 6 and 7) to size. Move back
to the table saw and plow grooves
for more aluminum track down the
80 Workshop Projects
SIP_WP2.81 10/26/05 2:43 PM Page 81
Adding More Bells and Whistles tops and sides, forming two flip-up
Now youve come to the features sliding stops. Glue up the third side
that really add to this jigs versatility. and top for the end stop, which does
Star t by mounting the aluminum not flip up.
tracks (pieces 13). Cut the pieces to To hold your work in place as you
length with a hacksaw, and be sure are routing, mount a hold-down
to file or sand the ends smooth to clamp (piece 21) just to the right of
remove any sharp edges. Next cut the guide rail. We found that to get
the centering stop (piece 14) to the the proper reach and clearance
same length as the end spacer and when operating the clamp, we
the center stop return (piece 15) so needed to glue a clamp spacer
its 1/16" less than the distance (piece 22) to the front rail and add a
between the laminate liners. Glue hex head bolt and connector nut
these pieces together (as shown in (pieces 23 and 24) to the clamp, as
the Pinup Shop Drawings). After the shown in Figure 3.
glue has cured, place the stop on One quick note: This jig is
the guide rails and drill 5/16" designed to plow dadoes into 3/4"
diameter holes to align with the stock. If you need to work in 1/2" or
Keep your jig out of harms way by machining aluminum track. Next, cut the side 3/8" material, all you need to do is
matching beveled hanger cleats. One goes on stop tops and side stops (pieces 16 slide the appropriate thickness
the back of the jig, the other on the wall.
and 17) to size. Reveal the tops spacer on top of the deck. (Double-
raised tenon, which slides in the stick tape will help keep the spacer
aluminum track, in two passes on from sliding.)
into the notched openings that you your table saw. Drill the 5/16" holes
created earlier in the rails. Both of to mount the knobs and T-bolts Final Details
these pieces must be sur face- (pieces 18 and 19) and cut sections When properly marked, the
sanded or planed down to the of piano hinge (piece 20) to join the center stop can help you line up
nominal thickness of manufactured one-of f dadoes. To find your
sheet stock (about 1116"). This will registration lines, use your router to
keep your router from stepping plow a 3/4" dado in a scrap of
down as it enters sheet stock that plywood that is clamped in place.
will be clamped to the deck. Slide the center stop over the dado
On the bandsaw, shape both and use a combination square to
pieces to fit into the notched transfer the edges of the dado onto
opening and for m the rounded the stop. Find the halfway point and
rests back edge. Drill for mark it. Take the center stop to the
countersunk screws as shown on table saw and, with the blade just
the Exploded View, page 79, and barely above the tabletop, scribe the
mount them to the jig with screws three lines into the face of the
only. On your table saw, slice the center stop. Once you clean up the
laminate liners (pieces 11) from ker fs, you can paint them
high-pressure plastic laminate. contrasting colors.
Then, using contact cement, glue Now would be a good time to
the liners to the inside faces of mount the hanger cleats (pieces 25)
the guide rail subassembly. Use a to the back of the jig and on a
file to smooth the edges of the convenient spot on your shops
plastic laminate. wall. Apply a couple of coats of
Slice the deck trim (pieces 12) an oil finish to it to keep the dust
from a piece of hardwood, cut two Figure 3: The hold-down clamp is mounted on a
from sticking.
pieces to length and glue them to spacer block and modified with a 1"-long hex
both ends of the deck. head bolt and a connector nut.
Winter 2006 81
SIP_WP2.82 10/21/05 11:56 AM Page 82
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82 Workshop Projects
SIP_WP2.83 10/28/05 3:36 PM Page 83
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