Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
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THEARTOFWOODWORKING
HOMEWORI$HOP
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WORKSHOPGUIDE I
BASICW()ODWORKING
TO()TS
AI{DACCESSORIES
t
MEASURING ANDMARKING
TOOTS BORING TOOLS TOOLS
STRIKING t
. Tapemeasure . P u s hd r i l l F'4"4 . Woodenmallets(square
. Steelruler . H a n dd r i l l
'sF androundheads) I
. Trysquare . Brace . Rubber mallet
. C o m b i n a t i osnq u a r e . Gimletor screwstarter . Clawhammer I
. Carpenter's square . Electric
drill(cordless r Nailsets
. Straightedge andcorded) . Utilitybar t
. Level r T a c kh a m m e r
. C h a l kl i n e I
. Slidins
bevel SUPPTIES
I
:::'ff:::'a
. Trammel
ry
points
r N a i l s( fi n i s h i n g ,
common,
ring-shank)
box,
v\\-Y\1+ I
o Markinggauge . Brads
FlNlSHlNc
t00LS I
. Cutting
gauge . Screws(flat,
. Mortise
gauge r o u n da , n do v a lh e a d ) . Foambrushes I
. Awl r Sandpaper . Lint-free
cloths
. Dovetail
square . P u m i c es t o n e . HVLPsprayer I
. Steelwool . Paintscraper
. Glues(woodworker's, .
white,contactcement, .
Moldingscraper
Puttyknife
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epoxy,instant)
. Woodputty I
. M a s k i n tga p e
SAWS . P e n c i l sa n d m a r k e r s
FASTEI{ING TOOLS
I
. Handsaws
(rip,crosscut, . W o o df i n i s h e sa n d . Screwdrivers(offset,
backsaw,
coping, compass, _- appropriate solvents stubby, cabinetmaker's
in
t
flush-cutter)
ref- . H o u s e h o lodi l
. Miter box ['i'.' ''r]'ttP flat-,Phillips-
andsquare- I
o Penetrating oil
with integralsaw
tip varieties)
. Sponges o Nutdrivers
. Hacksaw o Reoq
r Pliers(standardslip-
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. C i r c u l asr a w
jointtype)
t3r
I
. Sabersaw
r I nno-nnqp nliorc
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I
. Locking
pliers
. Channel-joint
pliers
t
. Wrenches
(adjustable,
open-end)
I
CUTTING TOOLS
. Chisels (paring, firmer, SMOOTHING TOOTS I
mortise) . Handplanes (block,
:TT,fu
butt,
. Sharpening stone jack,jointer) I
o H o n i nggu i d e . Scrapers
. Gouges (woodcarving set) . Files(flat,half-round, -w
I
. Router andbits round, . Triggerclamps v
triangular)
.Utirityknife . Rasps (patternmaker's) . Q u i c k - a c t i obna rc l a m o s I
@ . Sanding (flat . Barclamps
. H O D D YK N I I C blocks
. Single-edge
razorblade andcontoured) . Pipeclamps t
.
.
.
Scissors
Wirecutters
Tinsnips
:3:ll'::ff:,#
. Orbital
sander
. Springclamps
o Webclamps
. Handscrews
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THEARTOFWOODWORKING
HOMEWORI$HOP
THEART OFWOODVV'ORKING
HOMEWORI$HOP
BOOKS
TIME-LIFE
ALEXANDRIA,VIRGINIA
ST.REMYPRESS
NEWYORK
MONTREAL.
THE ART OF WOODWORKING was produced by THECONSULTANTS
ST. REMY PRESS
Jon Arno is a consultant,cabinetmakerand
freelancewriter who livesin Tioy, Michigan.
PUBLISHER KennethWinchester
He alsoconductsseminarson wood identifica-
PRESIDENT PierreLdveill6
tion and earlyAmericanfurniture design.
SeriesEditor PierreHome-Douglas
SeriesArt Director GilesMiller-Mead taught advancedcabinet-
FrancineLemieux
rnakingat Montreal technicalschoolsfor more
SeniorEditors Marc Cassini(Text)
than ten years.A nativeofNew Zealand,he has
HeatherMills (Research)
worked asa restorerof antiquefurniture.
Art Directors Normand Boudreault,Luc Germain,
SolangeLaberge
Designers Jean-GuyDoiron, Michel Gigudre fosephTruini is SeniorEditor of Hone
Mechanixmagazine. A former Shopand Tools
Research Editor Iim McRae
Editor of PopularMechanics,he hasworked as
PictureEditor ChristopherJackson
a cabinetmaker,home improvementcontractor
Writers Andrew Jones,Rob Lutes
and carpenter.
Cont r ibuti ng IIlustrhtors GillesBeauchemin,RollandBergera,
Jean-PierreBourgeois,Michel Blais,
Nicole Chartier,RonaldDurepos,
Philippe Gauvreau,G€rardMariscalchi,
Home Workshop
JacquesPerrault,RobertPaquet, p. cm.-(The Art of Woodworking)
IamesThdrien
Includesindex.
Administrator NatalieWatanabe
Production Manager MichelleTurbide
ISBN0-8094-9920-7 . (trade\
ISBN0-8094-992 1-s oib)
System Coordinator Iean-LucRov
1.Woodshops.
Photographer RobertChariier
2. Woodwork--Equipmentand supplies.
I. Time-Life Books. II. Series
TTI52.H6 1993
Time-Life Booksis a division of Time-Life Inc.,
a wholly ownedsubsidiaryof
684'.08-dc20 92-682r
CIP
THE TIME INC. BOOK COMPANY
6 INTRODUCTION 68 SHOPACCESSORIES
70 A storeof shopaccessories
12 SAFETY 72 Air compressors
L4 Accidentprevention 74 Portablegenerators
15 Working with safefinishes 76 Benchgrinders
16 Fire safety 78 Dust collection
17 Electricalsafety 85 Portabledust collection
18 Personalsafetygear
23 First aid 88 STORAGE
90 Storingwood
28 SHOPTAYOUT 94 Storingtools and supplies
30 Workshopplanning
32 Planningfor stationarytools IIO WORKSURFACES
36 Shoporganization LL2 Work tables
4L Electricalpower 118 Sawhorses
43 Lishtins I25 Work supports
44 FlSors,i"a[s, and ceilings I29 Extensiontables
45 Heatingand ventilation I34 Tool standsand tables
I4O GLOSSARY
46 WORKBENCH
48 Anatomv of a workbench I42 INDEX
50 Buildingthe base
53 Buildingthe top I44 ACKNOWTEDGMENTS
56 Visesand accessories
62 Benchdogsand hold downs
INTRODUCTION
PeterAxtell talksaboutplanninghis
DREAIVI
WORKSHOP
f startedwoodworkingaround1974nEngland,whereI wasplayingrockmusic
I andneededa hobbyto helpmeunwindfromtherigorsof theroad.My shopat
thetimewasjustbigenoughfor aworkbench, a radialarmsawandnot muchelse.
I rememberconstantlybumping thingsinto thelow ceiling.
WhenmywifeandI movedbackto AmericaI wasofferedajob in alocalwood-
shoprun by a friendof mine.It wastherethat I beganto acquirea feelfor how
a shopshouldbelaid out.Aftera fewyearswith my friendI left andsetup my
ownshopin our three-cargaruge.Isoonlearnedwhatworkedandwhatdidn'g
Whenit cametimeto plana shopfromscratch,Isoughtoutmylocalwoodwqrft-
ing organization, whichturnedout to bea fountainof information.I studi/dlots
of shopsin my areaandaskedhundredsof questions aboutwhatpeoplelikedand
whattheywantedto changein their ownshops.
I sawoneplacein particularthatseemed thebestforjry needsandsettledonthat
asmy model.My budgetallowedme 1,500sqlrgtt.feet, sothat wasonelimit set.
Light-both naturalandartificial-wasamaiorconsideration. I placedmybuilding
andplannedthewindowsto takemaximumadvantage ofthe abundantsunlightin
northernCalifornia.I wasalsodetermined to haveawoodfloor.I quicklyfoundout
thatahardwoodfloorwouldbetooexpensive soI usedl%-inchtongue-and-groove
plywoodandeporypaint,whichhaveheldup verywelloverthelastnineyears.
I figuredout thefloor planon graphpaperandcutout scaledrawingsof all my
machinesaswell asareasfor plywoodstorage,officespace,anda spraybooth.It
is importantto allowenoughspacearoundyourmachines, soI spentconsiderable
time movingsthingsaroundandtestingdifferentscenarios.
Thecrawlspace undermyshophasextraclearance because I choseto run my
dustcollectionpipeunderthefloor,whichhasallowedmeto keepthewholeceiling
spaceclearandairy.Oneof thebestinvestments I madewasin super-insulating
thewholeshop-floors,walls,andceiling,whichhasmadeit easierto keepthe
placewarmin winterandcoolin summer.
I put a lot of thoughtandresearch into my shopandthereisrt'tmuchI would
change exceptfor onething:I wishI hadbuilt it bigger.Butthatis a commoncom-
plaint.It seems thatyoucanneverhavetoo muchspace.
PeterAxtellbuilikfinefurnitureat his
shopin SonomaCounty, Californin.
bUa -- - ---'-
lFr o cnotrsrrxT'cAf€ cttEz'tAllpsE
- - { - F
INTRODUCTION
Martha Collinsdiscusses
SHOPSTORAGE
I makejewelryfrom exoticwoodanddy.d ulne.r. Somepieceshaveasmany
I as800bits of woodin them,combiningthe colorsandtexturesof various
rarewoodswith brightlyhuedveneers. Beingableto find someoffbeatscrew
or fastenerwhenI needit, or knowing where to retrievethat wonderfulsmall
chunkof rosewood that I'vebeensaving for 10 years isrlt a luxury;it's a necessity.
Throughtheyears,I havelearnedthat the strenghof a workshopdependson
proPerorganization andstorage.
"storageareas"in my shop.Theinfeedandoutfeedtablesof
I havefour distinct
myradialarmsawholdscrapwoodandlessfrequently usedtoolsMyjewelrystorage
benchholdsall themachinedandmilledexoticwoodsanddyedveneers. The4-by-
8 outfeedtableon thetablesawhousesavarietyof items:work in progress, exotic
lumber,furniturepads,andleftoversfromthe jewelry-making process.
Themostimportantstorageareais in themainworkbenchandtool chestarea.
Thisistheheartof myshop.I keepwerythingfromscrews andscrewdrivers to planes
andhingesin cabinets closeto thebench.All of thehandand power toolsthatI use
regularlyarekeptin mymainchest,whichis featuredin thephotograph.
Thechestis6 feethighand4 feetwide.In theuppersection, I storewerythingfrom
hammers andonesetof chisels in theleft-handdoorto files,screwdrivers, andplanes
in theright-handsection. Thefivedrawers in thecenterarefilledwith wrenches and
bitsof allkindrspurs, twists,andForstners. I assembled thedrawers with dovetail
joints,a satisfringeffortthatonlyaddsto thepleasure of puttingthingsaway.
Theleft-handdoorin thebottomsectionof thechestholdsall my measuring
andmarkingtools;theright-handdoorhousesa setof pliersalongwith my hand-
saws.Thecubbyholes arehometo my portablepowertools-circular saws,saber
saws, router,sander, cordless drills,pneumatic tools,andsoon.
Thetoolsin my chesthavechanged overtheyears.FifteenyearsagoI hadonly
onecordlesd,rill;nowI havethree.Butmychesthasbeenableto adaptandaccom-
modateall thenewtools-eachwith its ownspecificplace.
LeonardLeeon
THE\ALUEOF
AWORKBENCH
worlshopcanbeanywhere A retiredcarverfriend
youcanfit a solidsurface.
builtasuperb worlshopin thelinendosetofhisaparhnent. Heonlyhadto gpel
the closetdoo5pull out a stool,andgoto work.Everythingheneededwasfitted
into a spaceoflessthan l0 squarefeet.
I built thesmallcherrybenchin thephotographto fit an awkwardalcovein
my officethat measures only 23 by 37 inches.For yearsI hadbeenusingmy
deskasa makeshiftworkbenchand I wasfrustratedby both the lack of any
decentclampingsystemandenoughclearwork surface.The deskis oftenas
clutteredasthebookcase in thebackground.
With theworkbenchin place,I cannow clampwoodfor testingsaws,chisels,
bits,andsoon,withoutknockinga coffeecupto thefloor or spillingpapersevery-
where.Thebenchis alsojust theright h.tght for usinganinspectionmicroscope,
aninvaluable andsuccesses
tool for analyzngfailures in theworld of sharpedges.
Thebenchoccupiesan otherwiseunusablespacenextto a doorway.Sincethe
floor spacenextto it canbe usedonly for foot traffic,thebenchonly addst9
theusibility of my office;it doesnot detractanything.Incidentallythebench
waspulledout of thealcovefor thisphoto.
Moreimportantthanits utility, my benchaddsa wonderfullyrelaxingand
humanizingelement.Likemanypeople,I tire quicklyof administrative detail.
With a workbenchhandy,I cangetup from my desk,wanderoverto thebench
andtinkerwith toolsfor awhile.It islikea mini-vacationin themiddleof theday.
Thehumanizing part comesfrom surrounding yourselfwith thingsyoulike.
I like everythingaboutwoodworking.My officeis filled with old toolsaswell as
booksaboutthiir historyanduse.To adda workbench to thegeneralclutteris
just anotherlayerto thecocoon.Theworldlools muchbetterwhenviewedfrom
anofficewith aworkbenchin it.
t3
ACCIDENTPREVENTION
SAFETY
TIPS
GENERAL POWER
TOOTS FINISHING
r Makesureworkshop lighting
andventi- o Wearappropriate safetygear:safety . Donoteai,drink,or smoke
whenusing
lationareadequate. glasses or faceshieldandhearing protec- products.
finishing
tion.lf thereis nodustcollectionsystem,
r Keepchildren, andpetsaway
onlookers, weara dustmask.Forallergenic woods, r Avoidexposure
to organic
solvents
if
fromtheworkarea. suchasebony,usea respirator. youarepregnant
or breast-feeding.
. Concentrate on thejob;do notrushor . Readyourowner'smanualcarefully . Installat leastonesmokedetectoron
takeshortcuts. Neverworkwhenyouare beforeoperating
anytool. theceilingof yourshopabovepotential
tired,stressed,or havebeendrinking firehazards; keepa fullycharged
ABC
alcohol or usingmedicationsthatinduce . Tiebacklonghairandavoidloose-fit- fireextinguisher nearby.
qrowstness. tingclothing.Removeringsandother
jewelrythatcancatchin movingparts. r Neverstoresolvents
or chemicalsin
. Finda comfortable
stance:avoidover- unmarked containers.
Chemical solutions
reaching. . Unpluga toolbeforeperforming
setup shouldalways bestoredin darkglassjars
or installationoperations. to shieldthemfromlight,whichmay
r Keepyourworkareacleanandtidy; change theircomposition.
cluttercanleadto accidents. r Whenever
possible,
clampdownthe
workpiece,
leaving
bothhandsfreeto o Storefinishing
products
in a locked
perform
an operation. cabinet.
HAND
TOOTS
. Keepyourhandswellawayfroma turn- oTopreventeyeinjury,wearsafetygog-
o Usetheappropriate toolforthejob; ingbladeor bit. gles,anddonrubber gloves
whenworking
do nottry to makea tooldo something withcaustic products.
ortoxicfinishing
for whichit wasnotdesigned. . Turnoff a toolif it oroduces
an unfa-
miliarvibrationor noise: havethetool . Donotflushusedsolventsdownthe
r Whenpossible, cut awayfromyour- servicedbeforeresuming operations. theYellow
drain.Consult Pagesto find
selfratherthantowardyourbody. outwhohandles chemicaldisoosalin
o Donotusea toolif anypartof it is yourarea,orcheckwithyourlocalfire
. Keeptoolscleanandsharp. wornor damaged. deoartment.
"fl|"ff'lll""1{l"lll"'llll'1lll'lII
illllll'llll'll|l
lllllltilllllllltrlll
IlIl
1HO?TI?
Disablinga powertool
To preventunaulhorizeduse of a ?ow-
er lool, oliplhe boll of a mini-Vadlock
throuqhoneof the tinee in lhe power
cord pluq.Thelockwillmakeit im?o6-
sibleto plu6in trhetrool.lfyou are
ueinqakeyedlock,slorelhe t
keyeout of vhe way in
a cupboardor draw-
er thal can be
locked.
t4
WORKINGWITH SAFEFINISHES
Toxrc
soLvENTs
PRODUCT
FINISHING SOLVENT
filler(paste
Wood andliquid) Petroleum
naphtha,*
mineral spirits,*
acetone,**
methyl
ethylketone,**
methyl
** isobutyl
isopropanol, ketone***
Stains(aniline,
wiping,NGR,gelandglaz- Ethanol,*
mineralspirits,*
toluene,***xylene,*** glycol
methanol,*** ethers***
colorpigments)
ingstains;
Shellacs(whiteandorange) Ethanol,*
methanol***
(spray
Lacquers andbrush,sanding
sealers) Acetone,**
methyl
ethylketone,**
isopropanol,**
methanol,*** glycolethers***
xylene,***
Lacquer
thinner Acetone,**
methyl
ethylketone,** glycol
isopropanol,** ethers,***
toluene***
oils(Danish
Rubbing oil,antique
oil) naphtha,*
VM&P turpentine,**
toluene***
oils(boiled
Drying linseedoil,polymerized
tungoil) Mineral
spirits,*
turpentine**
(tung
Varnishes oilvarnish, sparvarnish,
varnish
stain) Mineral VM&P
spirits,* naphtha*
(polyvarnish,
Polyurethanes urethane
stains) Mineral
spirits,*
toluene***
ishremovers
Lacouer/varn Acetone,**
xylene,*** methyl
methanol,*** isobutyl
ketone,***
toluene***
Waxes(pastewax,furniture
wax) Petroleum naphtha,*turpentine**
* Safestproduct** Mildlyhazardous
product*** Product if possible
to beavoided
w00Ds
Toxtc
Asanyone whohassuffered through Somespecies, likeebony,South cleanandwellventilated. Weara
an allergicor irritatingreaction
to American mahogany,andWestern dustmaskfor cuttingoperations.
wooddustwilltestify,working with redcedar, containtoxicchemicals Whenhandling a specieswhichyou
certainwoodscan ooseserious thatcanbe inhaled, ingested,or knowor suspect maytrigger an aller-
healthrisks,Thedustfrommany absorbed throughcutsandscratch- gicreaction, spread a barriercream
species,likeblackcherry, Douglas- es.Although thechemicalsarepre- onyourskinor wearprotective gear,
fir,andpine,is known to causerespi- sentin minutequantities,
theymay including gloves,safetyglasses, and
ratoryailments suchasrhinitis(or causeproblems ranging
fromhead- longsleeves andpants.Referto the
nasalinflammation) andasthma. achesto inegularheartbeat. backendpaper for a chartlistinga
Other woods,including oak,ash,and Protectyourself
fromdirectexposure varietyof toxicwoodsandtheirpos-
birch,canirritatetheskinandeyes. to wooddustby keeping yourshop siblehealtheffects.
15
FIRESAFETY
/a onsiderins thenumberof flamma- The first stepin fire safetyis preven- shopceilingor a wall,andkeepanABC
\-, Ut.rut.ri"ul,andpotentialignition tion.All finishingproductsandsolvents, fire extinguishernearby.Designa fire
sourcesin a woodworkingshop,firepre- for example, shouldbestoredawayfrom evacuation planthat mapsout two pos-
ventionshouldbeoneofyour foremost heatsourcesin airtight glassor metal sibleescape routesfrom eachroom of
safetyconcerns. Sawdust,wood,paint, containers, preferably in a fireproofcab- thebuildingin whichtheshopis locat-
andthinnerstendto accumulatel often inet (pageB9).Hangragssoakedwith ed.Ifthe fireinvolvesan electrictool,a
theyareneartoolsthat producesparks flammablechemicals to dry outdoors, powercord,or an electrical outlet,shut
andheat.Thecombination canorove or soakthemin waterandstorethemin offthe power.Callthe fire department
volatile:When vaporizedin a imall sealedmetalcontainers. Whenworkine immediately, inform themof thenature
enoughconcentraiionof air, a small with finishingproducts, keepwindowi of thefire,andtry to extinguish
theblaze
quantityof lacquerthinner,for exam- openandthe shopwellventilated. yourself.But if theflamescannotbecon-
ple,canbeignitedby a sparkfrom a tool Bepreparedto dealwitha fireeffec- tained,or thefireis comingfrom inside
andcausea life-threateningexplosion. tively.Installa smokedetectoron the a wall or ceiling,evacuatethebuilding.
PREPARING
AGAINST
FIRE
Installinga smokedetector
Openthecoverof thedetector, holdthebaseonthe
ceilingorwall,andmarkthescrew holes.Borea hole
fora screwanchor at eachmark.Taotheanchors into
theholes and,holding in position,
thedetector drive
a screwintoeachanchorto secure the base(right).
Installa battery
andclosethedetector cover. Testthe
device onceeverymonth.First,press thetestbutton.
Then,blowouta lit matchor candlebelowa vent,
letting
smoke enterit. Replace
thebatteryif thealarm
doesnotsoundforbothtests-orif it emitsa chirping
sound, indicating
thebatteryisweak.
Controllinga fire
Toextinguish a small,contained f ire,useanABC-rat-
eddry-chemical f ireextinguisher, whichis effective
against allthreemajorclasses of fires:burning woodor
othercombustibles (Class
A),oil-orgrease-fed flames
(ClassB),andelectrical blazes (Class C).Position your-
selfa safedistance fromthefirewithyourbackto the
nearest exit.Holding theextinguisher upright,pullthe
lockpinoutof thehandle (insef)and aimthenozzle at
thebaseof theflames. Squeeze thehandle andspray
rna quick,side{o-side motion(/eff)untilthef ireisout.
Watch for"flashback," orrekindling, andbeprepared
to spray again.lf thefirespreads, leavethebuilding.
Dispose of burned wastefollowing theadvice of thef ire
department. Afteruse,havetheextinguisher profes-
sionallyrecharged; replace
it if it is non-rechargeable.
T6
ELECTRICALSAFETY
lectricityplaysa majorrolein the INSAFELY
PLUGGING
modernwoodworking shop,pow-
eringmachines andtools,lightingfix-
turesandlamps,andheatingsystems.
Electricityis
socommonplace thatit isall
tooeasyto forgetis potentialfor danger.
An electrical shock,evenonethatcan
hardlybefelt,canbedeadly. Forthisrea-
son,theelectricalsystem is strictlyreg-
ulatedbycodes andstandards designed
to protectyoufromfireandshock.
Livingsafelywith electricityalso
requiresfollowingbasicprecautions
designed to preventmishaps. Inspect
plugsfor cracksandpowercordsfor
frayrng,andreplace anywornor dam-
agedpart beforeusinga tool.Never
replaceablownfusewithoneof ahigh-
eramperage. Donotplugathree-prong
pluginto a two-slotoutletby remov-
ingthegroundingprongfroma three-
prongplug.Instead, replace theoutlet
withaGFCI|WA.
Beforeundertaking a repair,shutoff
theoowerattheservice oanel.Towork UsingGFGI outlets
on thesystem, wearrubbergloves and, TheU.S.National Electrical
Coderequires thatanynewoutletin a garage
wherepossible, useonlyonehand,keep- or unfinishedbasement mustbe protected bya ground-fault circuitinter-
ingyourfreehandbehindyourback. rupter(GFCI).A GFCIprotectsa circuit-andyou-by monitoring theflowof
passing
electricity throughit andtrippinginstantly
whenit detects a leakto
ground.lf youneedto replaceanoutletin yourshop,installa GFCI, suchas
theoneshown above,followingthe manufacturer's
directions,or havea quali-
fiedelectrician
dothework.Testtheoutletonceevery monthbypushing the
TESTbutton; theRESET buttonshouldpopout.lf it doesnot,havetheoutlet
Toreactivate
serviced. theoutlet,presstheRESET button.
MINIMUM F(|REXTENSION
WIREGAUGE CORDS
Choosing a wirewiththepropergauge
AMPERAGI MINIMUM F(lR
GAUGE Usinganextension cordwiththewronggauge can
RATII{G
OFTOOL TENGTH
DIFFERE}IT CORDS causea dropin linevoltage, in lossof pow-
resulting
25' 50' 75' er.excessive heat.andtoolburnout. Referto the
chartat leftto determine
theminimum wiregauge
o-2.0 18 18 18 forthetoolandtaskat hand.lf, for instance,your
2,1-3.4 18 18 18 toolhasa 7 -ampmotorandyoulre usinga 75{oot
3.5-5.0 18 18 16 extension cord,theminimum gauge should be 14.
5.1-7.0 18 16 t4 Choose onlyround-jacketed extensioncordslisted
byUnderwriters (UL).
Laboratory
7.I-12,0 18 T4 T2
12.1-16.0 16 I2 10
t7
PERSONALSAFETYGEAR
-f h. personal safetyequipment
shown areveryreal.Fewwoodworkers needto Iongestrecommendedtime that an
I belowcango a longwaytoward beremindedof thecuttingpowerof a unprotectedpersoncanbe exposedto
shieldingyoufrommostdangers in the spinningsawbladeorjointercutterhead. variouslevelsbeforeriskingpermanent
workshop. Butcarryingan inventory Lesswellknownarethelong-termeffects hearingloss.
of safetygearis not enough;theitems ofbeingexposed to thesoundgenerated Remember, too,that evenshort-term
mustbeproperlyusedto protectyou by powertools.Thecharton thenext exposureto somenoise,while it may
frominjury. pagelistsa varietyof powertoolsalong not leadto hearingloss,can dull the
Theneedfor someitemsmaynotbe with theirapproximate noiselevelsin sensesand causea woodworker'salert-
readilyapparent, althoughthedangers decibels.Thechartalsoindicates the nessto flag-a setupfor an accident.
A PAI{OPIY
OFSAFETY
EOUIPMENT
5afety gogglee
Flexible,moldedplaati" f,:
6o6qleoprotect eyee. lli
Typewith perforated vani \
holeaehieldaaqainat impact
injury and sawduat; type with
baffled vents protecto a7ainot
ahemical apla ehea: nonvented
qoq7leaalbo available.
Faae shield
Clear plaatic ahieldpro- for one-time-uoe protec-
tecta a4ainat. flyinq debria tion aqainet inhaiationof
and eplaahea;featurea duat or miaX featurea a
adjuetable head 4ear cotton or fiber shield with
an adjuotable head atrap
and a metal noee olip
Rubber glovea
Houaeholdrubber
gloveoor dieposable
vinylqloveoprotect
aqainot mild chemicals
Dua l-aaftri dg e res pi rato r
or finishea;neoprenerub-
Frotecta aqainet fumeawhenworkin4
ber aloveashield akin
with chemicalaor aprayinqa finiah.
from cauetic finiahinq Reuaableduat mask
lnterchanqeablefiltera and chemical
Producto cartridqee ehield aqainat opecific haz- Features a neoprenerubber
ards; filter prevents inhalationof dust. or aoft plaatii frame with
Cartridqea purify air and expeltoxina an adjubtable head etrap
th rough exhalation valve and a replaceablecotton
fiber or 7auzefiltec protecte
againet duet and misL
Ear plugs with neakband
Detachablefoam-rubberpluqa compreooed
and inaerted into ear canals providehearinq
protection from high-inteneity power tool
noiae;plaatic neckbandfits around neck
Work gloves
Ear muffs For handlinqrouqh 2afetyglaeeee j I
Cuahionedmuffa with
adiuetable plaatic head
lumbentypically fea-
turee leather or thick \
?;f:lT,if'tr:;i::fT:f
eirap protbct hearinq fabrio palmo and finqer- leneeeproteot eyeb from flyinq
againot hi1h-intenaity tipe with elaaticized or woodchipo and other debris:
noiae from power toola knitted wrists t.ypicallyfeature aide ahielda
t8
SAFETY
NOISE PR(IDUCED
LEVELS T(|(ILS
BYPOWER
MACHII{E
SOUND *
IEVELS 115
112
1%-Hfrouter I09
drillpressis unlikely
Whilea %-horsepower to damage yourhearing-unlessyourunthemachine all day
long-unprotectedexposure produced
to the noise by a 1 %-horsepower
routercanbe dangerous
after only
30 minutes.
Theabove chartshows approximatenoise produced
levels bya variety
of power Keep
tools. in
mindthattoolswithdullcutters generate
or blades morenoise with
thanthose well-sharpened
cutting
edges.
A RESPIRATOR
TESTING
Checkingforairleaks
is onlyasgoodasitssealagainst
A respirator yourface.No
seal,no protection.
Totestyourrespirator,placeit overyour
,.+s\N\\
face,settingthetopstrapoverthecrownof yourhead.Adjust
thesidestrapsfora snugfit. Totesttherespirator,coverthe
,$;
outletvalvewithyourhandandbreathe outgently(right).There
shouldbe noair leakagearound lf air leaksout
thefacepiece.
thestrapsfora tighterfit. Replace
readjust
of therespirator,
thefacepiece whennecessary following
themanufacturer's
instructions, therespirator.
or replace Usetheappropriate fil-
tersforthejobat hand.(lf youhavea beard,usea full-face
maskwithforced-air ventilation.)
{ / fl \ /
I9
SAFETY
()FPUSHSTICKDESIGNS
A VARIETY
-
12"
'
12"
20
SAFETY
PUSHBTOCK
A PUSHBLOCK FORFACE JOINTING yourown.Referto the illustration for top,positioning it sothebackis even
Thelong,widebaseof thepushblock suggested dimensions, buttailorthe withthe endof the base.Drivethe
shownaboveis idealforsurfacing the design to suityourownneeds. screws fromtheunderside of the base;
faceof a boardona jointer.Although Cutthepieces to size,thengluethe besureto countersink thefasteners to
pushblocks forsuchjobsareavailable lip to theunderside of thebase,flush avoidmarring theworkpiece whenyou
commercially,youcaneasily fashion withoneend.Screw thehandle to the feedit across thejointerknives.Borea
holenearthefrontendof the baseso
youcanhangthe pushblockon the
wallwhenit is notin use.
Tousethepushblock,setthework-
pieceon thejointer's infeedtablea
fewinches fromtheknives, butting
its edgeagainst thefence.Thenlay
thepushblocksquarely ontopof the
stock,centered between itssides,with
thelip overthetrailing endof the
workpiece. Withyourleading hand
on thefrontendof thestockandyour
thumbbraced againstthepushblock,
slowlyfeedtheworkpiece across the
knives(/efil.(Forstockthinnerthan
3/a
inch,useonlythepushblock.) Apply
downward pressure to keepthestock
flatonthetablesandlateral Dressure
to keepit buttedagainst thefence.
2I
SAFETY
FEATHERBOARDS
Featherboards, alsoknown asfin- FEATHERB()ARDS
gerboards, areusedto keepstock
pressed snuglyagainst thefenceor
tableof a stationary tool.Theyalso 9tandard
serve asanti-kickback devices,since featherboard
thefingers allowa workpiece to
movein onlyonedirection-toward
thebladeor bit.Twobasicdesigns
areshown at right.Themiter-slot
featherboard is attached to a bar
thatisclamped in themiterslotof
a woodworking machine table.The
standard featherboard isclamped
directlyto thetableorfence.
Tomakeeithertype,cuta %-inch-
thickboard 3 to 4 inches wideand
longenough to suitthejobat hand. themiter-slot
type,routa slotdown the underside of thebar.(Acarriage
Cuta 30"-to 45o-miterat theend themiddleof the boardwideenough boltorflat-head machine screwwill
of theboard, thenmarka parallel line for a machinescrew;
alsocuta wood workwell.)Tosetupthefeatherboard,
about5 inches fromthemitered end. barthelength
andwidthof thetable's slipthescrewthrough thebar,fit the
Cuta series of X-inch-wide slotsto miterslot,Borea holeforthescrew barin thetablemiterslot,andusea
themarked lineabout1linchaoart, throughthebar,countersinking
it so washer andwingnutto fastenthe
creating a rowof pliable fingers. For thescrewheadcanbe recessed in featherboard tightlyto thebarso its
f ingersholdtheworkpiece against
thefence.Clamp themiterbarin
placeat thefrontor backof thetable.
Forthestandard featherboard,cut
a notchoutof oneedgeto accom-
modate a supportboard.Tousethe
deviceonthetablesaw(/eftl,clamp
onefeatherboard to thefenceabove
the blade, andplacea second one
halfway between thebladeandthe
frontof thetable.Clampa support
boardperpendicular to thefeather-
boardfor extrapressure to prevent
it fromcreeping outof place.For
thecutshown, feedtheworkpiece
intothebladeuntilyourtrailing fin-
gersreachthefeatherboards. Then,
withthesawstillrunning, moveto
thebackof thetableandpullthe
workpiece pasttheblade.0r, use
a pushstickto complete thecut.
22
FIRSTAID
FIRST.AID
SUPPTIES Oauze roller bandage
Otedle roll oecureaqauzedreoa-
Adheaive bandagea
inga; faotened with medical tape
)terile 4auze dreeeinqo
or aafety pin, or by knottinq. Avail-
with adheaiveatripa for
protecting acratchea or able in lenqtha of 5 to 10 yardo
minor cuta. Availablein a and widtha of 1 to 4 inchea
widevariety of sizes and
ahapes:gquare,rectan'
qutAr,rouid, butterfty, Medical tape
and finaerbip )ecurea qauzedreeein7a,1auze
roller bandaqesor eyepada: hypo-
aller4enicfor aenaitiveakin.Avail'
able in lenqthaof 2 %to 10yarda
and in widths of %to 5 inches
Tweezera
Extract eplintera or other emall
objecto lod7ed in akin. Made of
etainlese steel in a variety of
ohapeeand aizea;flat-tipped Ipeaaa eyrup
type 41/z inchealon7 ie common For inducin7vomitinq
in a poiaoningvictim.
Caution:Administer
only if advieed by a Triangular bandage
phyeicianor poiaon Multipurpoee cotton banda7ecan be
control center folded to make alin4,pad, or bandaqe;
meaeurea55 incheaacroeo baoeand
36 to 40 incheaalona each aide
Eye irrigator
Filled with water and
ueed to fluah foreiqn
particleo from eye
Hydrogen peroxide
r\r\
Rubbingalaohol For cleaninqwounds Gauze dreeaing \\\)
Alao knownaa beforeapplyinqadheoive )terile pad for coverin7 a Eye pada \-'l
iaopropylalcohol: banda7ee,1auzedreaa' wound;becuredwith medical )terile pado taped over eyee
aterilizea tweezero inga,or qauze roiler tape or qauzeroller bandaqe. to protect them and pre-
and other firat' bandaqea;aommonly Availablein aizes of 2-by-2, vent movement:aelf-aane-
aid equipment availablein 3% aolution 3-W-3 and 4-by-4 inchea oivepatchea alao available
23
SAFETY
PROVIDING
MINOR
FIRST
AID
//
J
Clearinga pailiclefromtheeye
Holdyouraffected eyeopenwiththeforefinger
andthumbof irrigator
againsttheaffected eye,andtilt backyourhead.Open
onehand.Slowlyrotateyoureye,if necessary,to helpexpose youreyes(above, right)andblinkseveral timesto flushoutthe
the particle.
Gentlywipeawaythe particle usingthetwisted particle.
lf youcannotremove theparticle, seekmedical help
endof a tissuemoistened withwater(above,
left).Or,till an immediately. Caution: Donotremove a particlethat is onthe
withcoolwateranduseit to flushoutthe particle.
eyeirrigator cornea,is embedded, or hasadheredto theeye.
Leanforwardwith botheyesclosedandpressthe rim of the
Flushinga chemicalfiomtheeye
Holding the eyelids
of theaffected eye
apart,flushtheeyethoroughly forat least
15 minutesundera gentleflowof cool
waterfroma faucet(right)or pitcher;tilt
yourheadto onesideto prevent thechem-
icalfrombeingwashed intotheuninjured
eye.lf youareoutdoors, flushthe eye
usinga gardenhose.Gentlycoverboth
eyeswitheyepadsor sterilegauzedress-
ingsandseekmedical helpimmediately.
24
SAFETY
Pullingouta splinter
Washtheskinaround thesolinter with
soapandwater.(A metalsplinter, even
if youareableto remove it, mayrequire
treatmentfortetanus; seekmedical help,)
To remove thesplinter, a needle
sterilize
andtweezers withrubbing alcohol.Ease
theendof thesplinter outfromunderthe
skinusingtheneedle, thenpullit outwith
the tweezers(right).Cleanthe skinagain
withsoapandwater.lf thesplinter cannot
beremoved. seekmedical attention.
Treating a cut
Wrapthewoundin a cleanclothand
applydirectpressure withyourhandto
stopanybleeding; keepthewoundelevat-
ed. lf theclothbecomes blood-soaked,
wrapanother clothoverit. lf bleeding per-
sistsorthewoundis deeporgaping, seek
medical help.Otherwise,washthewound
withsoapandwater,thenbandage it; for
a narrow, shallowwound, draw itsedges
closedwith a butterflybandage (left).
25
SAFETY
CONTROTLING
BLEEDING
4@= \,
Applyingdirectpressureto stopbleeding
To helpstopprofuse or rapidbleeding, applydirectpressureto dressingto inspect thewound.lt willbeeasierto maintain
thewoundwitha gauzedressing or a cleanclothand,if possi- steady
pressure if youwrapthewoundwitha rollerbandage
ble,elevatethe injury(above,left).DiecIpressureshouldstop (above, right)toraddeddirectpressure. lf youcannotstop
theflowof bloodandallowit to clot.lf thedressing becomes thebleeding, callformedicalhelp.
blood-soaked,addanother overthefirstone;avoidliftingthe
HANDTING
A SH(ICK
VICTIM
Treating
a shockvictim
Somedegree of shock-either immediate or
delayed-accompanies anyinjury.
Shockcanbe
provoked by lossof blood,pain,or an allergic
reaction.
Signsof shockinclude anxiety orconfu-
sion;coldorclammy skin;weak,iregular breath.
ingor pulse;andlossof consciousness. lf you
suspectan injuryvictimis suffering
fromshock,
immediatelycallforemergency help.lf thevictim
is conscious,placehimon hisbackwithhisfeet
propped up8 to 12 inches abovethelevelof his
head(right).Loosen thevictim'sclothing around
theneck,chest,andwaist.Keepthevictimwarm
witha blanket,butavoidoverheating. Donotgive
thevictimanything to eatordrink.
26
SAFETY
A VICTIMOFELECTRICAL
TREATING SHOCK
Freeing a victimfroma livecurrent
A person whocontacts a livecurrentmay
experience onlya mildtingling sensation.
Sometimes, however, thevictim'smus-
clescontract involuntarily around the
source. Donottouchthevictimorthe
electrical source. lnstead, immediately
stopthef lowof electricity in thecircuit
at a wallswitchor theservice panel.lf
theelectricity cannot beshutoffimmedi-
ately,usea drywoodimplement, suchas
a broom handle, to knock thevictimfree
of the electrical source(right).CallIor
m e d i c ahle l pi m m e d i a t et lhye, nc h e c k
thevictim's breathing andpulse. lf there
is nobreathing, givemouth-to-mouth resus-
citation; if thereis nopulse, givecardiopul-
monary resuscitatton (CPR) onlyif youare
q u a li e
f d .l f t h ev i c t i mi s b r e a t h i n
agnd
hasnoneckor backinjury, placehimin
the recovery position (below). Ttltthe
victim's headbackfaceto drawhistongue
awayfromhisthroatandkeepthe air-
w a yo p e n K . e e pt h ev i c t i mc a l mu n t i l
heloarrives.
27
t"tr,,,
{r. -
. ." \\
; r f ,
''a*6*"'n'
\
,9
. G
*-
i
SHOPIAOI-]T
Everyhour spentplanningshoplayoutpaysdividendslater
on. Tbdeterminethebestwayto arrangethetoolsplannedfor
theshop,e woodworker placesoverhead-view
silhouettes
of the toolson a scaledrawingof thespace.
29
WORKSHOPPLANNING
I t is fareasier
to shufflepapercutouts anyshop,illustrated
below,thatthelum- Referto the illustratedinventoryof
I of vourtoolson a templatethanit isto bershouldtakea relativelystraightpath stationarymachines andtablesstarting
draga tablesawhalfwayicrosstheshop. asit is processed-almostasthoughthe on page32asa guideto spaceandlight-
Time spentplanningthe layoutof your shoowerean assemblv line. ing requirements. Thebestwayto design
shopwill be morethan amplyrewarded
in reducedfrustrationandincreased effi- A multipurpose stationary
ciencywhenyou go to work. power tool can helpyou make
Designinga shopinvolvesjuggling the most of a crampedwork-
many interdependent variables,from space.The machineat right is
localhumidityandtheqpe of work you an all-in-one tablesew,drill
do to the heightof the ceilingand the press,disk sander,and lathe.
costof wiring. To help sort them out, Accessory attachmentsalso
askyourselfasetofquestions, likethose allow it to serveas a band
in the checkliston page31, to help saw,jigsaw, and jointer.
determinethe kind of shoomostsuit-
ablefor yourneedsandremindyou of
factors that may affect its design.
Remember, too, a basicprinciplefor
T()OIPLACEMENT
ANDWORKFLOW
Designing a shoparound
thewoodworking process
F o rm a x i m u e mf fi c i e n c yl a, yO u t h e
t o o l si n y o u rs h o ps ot h a tt h el u m b e r
followsa f aily directroutefromrough
stockto f inished pieces. Thediagram at
leftillustrates a logical workf lowfora
medium-size workshop. At theupper
left-hand corner istheentrance where
lumber isstored onracks. Totherightis
Lumbergtoraqe thestockpreparation area,devoted to the
Dand saw
tablesaw(orradral armsaw), jointer, and
lxH
'€_-J
p l a n ear ;t t h i ss t a t i o nl u, m b ei rs c u tt o
roughlengthandsurfaced.
thenextworkarea,nearthebottom
Theheartof
right-
handcorner of thedrawing, is thework-
Wi,ft bench.
thiscase,
(orshaper),
Radiating outward
aretheshop'sotherstationary
a drillpress, lathe,
fromthebench
andbandsaw.A toolcabinet
tools-in
routertable
Izil,",t areaissetasideforassembly
ing.Thisstation
up pieces
features
andshelves fordrying
andf inish-
a tableforgluing
andstor-
ing.Thesprayboothis closeby,butisolat-
edfromtheshopbywallsonthreesides.
30
SHOP LAYOUT
A SHOPTAYOUT
CHECKLIST
TOGATION TYPE
OFWORK WORK
HABITS
o Whichavailable
areas
in andaround . Whattypeof woodworking
projects
will r Whatroomtemperature
will youneed
yourhomeareappropriate
fora shop? youbedoing? to workcomfortably?
o Howeasyis theaccess
to theseareas? o Whatsizearethe materialsyouwill . Whattypeof lightdo youprefer
needto movein andoutof theshop? forworking?
. ls theelectric for pow-
wiringadequate
eringyourtoolsandlighting? ' Howmuchspacewill bedevoted
to r W i l ly o ub ew o r k i ndgu r i n gd a y l i g h t
lumber
storing andwork-in-progress? h o u r so, r w i l ly o ub e u s i n gt h es h o p
. Howwellaretheareas
heated,
insulat- at night?
ed,andventilated? r Whatstationary
machines, podable
pow-
ertools,andhandtoolswillyouneed? o Whichtoolsdo youexpectto use
r Willshopnoisedisturb
otherareas? mostoften?
. Arethereenoughelectrical
circuits
to
. lf thelocation
is a basement,willthe supplyyourpowerneeds? . Willyoubeworking alonein theshop,or
shopbesharing space witha furnace will it be usedbyanotherworker?Would
roomor laundry room? o Howmanylighting doesyour
fixtures thatperson haveeasyaccess
to theshop?
workreouire?
. l f t h e l o c a t i oins a n o u t b u i l d i nogr o Willyouneedto locktheshopor keep
garage, howmuchspaceistakenup by . Howmanyworkbenches, assembly it off-limits or pets?
to children
cars,bicycles, lawnmowers, andsoon? liketoolcabinets,
tables,andaccessories
willyouneed?
scrapbins,andsawhorses o Howmanyhoursperdaydo youexpect
. Does
thebuilding orgaragehaveany to spendin theshop?
heating, or plumbing?
electricity, . Willlocalseasonal
temperatures
and
humidityaffectyourwork? r ls theflooring
madeof a materialthat
o Howsecureis the buildingor garage is comfortableto standon for longperi-
fromtheft? . Willyoubedoinga lotof f inishing
work? odsof time?
31
PLANNINGFORSTIIfIONARYTOOLS
TABTE
sAw
LIOHTING
Naeda liqht from
above, to the laft of
and behindblade
LIGHNNA
Needeliqht.from
aboveand to
CLEARANCE the riqht of
Needa enouqh clear- blade;porLable
ance around table for clamp-onli7ht
lon6 boarde;keeplineof can be uaed
work clear. Best loca-
tion ia center of ahop
CLEARANCE
No clearanceneededon throat-
column aide; requirea4 feet of
clearanceon other aideefor lonq
boarda. Keepline of work alear.
RADIAT Can be poeitionedaqainat a
ARMSAW wallor in a corner
LIOHTINO
Needali7ht
ROUTER
TABTE
from aides,
front and
above LIOHTING
Needaliqht
from front
and both
aides
CLEARANCE
Relativelyportable.Allow
CLEARANCE at leaat 6 fert of clearance
Na clearanae need- in front and to the aides
ed behindtool; qood whenin operation;needo
location ia againat no clearancebehindtable.
wall.Allowabout 12 Good location ie aqainet
feet of clearance wall: keepline of work
on either eidefor clear so that a kiaked
long boarde back workpiecewould
not.atrike another worker
32
SHOP LAYOUT
SHAPER
DRITL
PRESS
LIGHTING
Needalight from
fronL and aidea
LIOHTING
Liqht muat focua
directly on bit
CLEARANCE
from overhead;
Allowat leaat 6 feet of alear-
portable clamp-on
ance in front and to the sides:
Iiqht can be uaed
no clearanceneededbehindtool.
Good location is aqainat wall;
keeplineof workclear ao that a
CLEARANCE workpiecethat ie kickedback will
No clearanceneeded not atrike another worker
behindtoob qood loca'
tion ia aqainet wall,
AIIow3 feet of clear-
ance on either aide,
and enou4hclearance JOINTEUPTANER
in front for widework
LIOHTINO
Needalightfrom
aboveand front
of tablea
JOINTER
CLEARANCE
Allow3 to 4 feet of clearance
on aidea,more for lonqboarde;
LIGHTINO keeplineof workclear. Good
Needaliqht location ta near lumberatoraqe
from lefL rack for eaey aurfacin4of atock
and rear
of tool
TATHE
LIOHTING
)verhead li4ht
muat focua
directly on work
CLEARANCE
Allow3 feet of clearancein front of
tablea and enouqhclearanceon
CLEARANCE
both aideafor long boarde;keep
Leave3 feet of clearancein front:
lineof workclear. Dest location ie
can be poaitioneda7ainet a wall
behindor to [ef, of table eaw
ainceworkis containedbv tool
33
SHOP LAYOUT
ASSEMBLYAND LIGHTING
FINISHING
TABTE Needeliqht from
BENCH
GRINDER
aboveand aidea:nat-
Deet.location ia near ural li4ht preferable
lathe aincethe cutting
toola ueed with it require
frequenL4 rindinq. Needa
clearanceand
li4ht on front
only;porEable
clamp-onlight
can be aimed
directly
at whee[ CLEARANCE
Minimalclearance
needed;qood loaa-
tion ie near window
STATIONARY
BEtTSANDER
LIOHTINO
scR0ltsAw Needeliqht from
front and left of tool
CLEARANCE
Allow 5 to 6 feet of clearance to
bhe aidea for lon4 work;leave3 to 4
feet in front of and to either side of
diak aander. Keepline of work clear
LIOHTINO
Li4ht needed
to the riqht. of
blade;portable WORKBENCH
clamp-onlight
can be uoed to
ehinedirectly
on work
LIGHTING
Needali4ht
from above,
CLEARANCE parLicularly
Needa 5 feet of over viaeo
clearanceat front
and eidea;no alear-
ance neededbehind
tool. Oood location
ie a4ainot wall CLEARANCE
Allow 3 feet of clearance
around viaea;can be placed
a4ainet wall if neceoear,
34
SHOPLAYOUT
DRAWINGS
SCATE TOOTS
OFSTATIOI{ARY
35
SHOPORGANIZATION
LAYOUT
OFA SMALL
SH()P
Layingouttheshop
Theillustration
belowshowsonewayof making efficient
useof f r a m i nign t h ec e i l i n cgo u l da l s ob eu s e dt o h o l ds t o c kR. e f e r
thespacein a smallshop-inthiscase,one-halfof a two-car to thekeyin the bottomright-hand corner of the illustration
garage.Thethreestationary
machines chosenareessential
for forthetypeandlocation of electrical outlets andlightfixtures.
mostprojects:thetablesaw,thejointer,
andthebandsaw.The Notethatthereisanoverhead master swrtch (near thebench's
sawandjointeraremounted oncasters sotheycanbemoved if t a i lv i s et)h a tc o n t r o a
l sl lt h r e em a c h i n eAs t. t e n t i oi ns a l s o
necessary.Withthebenchandtablethereis amplespace for paidto feeddirection of eachmachine (represented bythe
handtoolandportable power toolwork.Thestorage space- arrowhead in the key);theaccess doorto theshopis always
perforatedhardboard
andshelving-islocatedalongthewalls; in theuser's fieldof vision. Caution: lf yourshopshares space
a lumberrackis positioned
nearthegarage door.Anyexposed withmotorized equipment youwillnotbeableto spray finishes.
11'
r-)t
\ _ / 1.. .y':,"-n":
. -?r:
^ r c
scrap I
bin I
\ strort
atock atoraqe
thelvinq
e
Worktable
Ferforated hard-
board wall etoraqe
Dand aaw
db db (a)
l l l l v
ll ll )awhoreee e KEY
q_Fq_F
Jointer o 24O V outlet
T
t t
0
o
12OV outlet
Incandescent liqht fixtu re
| | t,mu", o FIuoreecent liqht firtu re
| |
racr o Overheadewitch for power toole
o Direction of feed
tJ
36
SHOP LAYOUT
tlltllllfillllllffilllllllllllllllllllllllllllllllillltllllllllllllllll
1HO?TI?
A s af e att'enti o n-get t er
lf the door to t'heehopis outside
yourfieldofvieionwhenyou are aI
a machine,lhereie the riekIhat'
oomeonemiqhl enLerthe ehoV,t'ap
youon the ehoulder, and etarLleYou,
Io avoidaccident'caueinq ourprioee,
mounf,a liqht bulbaI eyelevelnear
the t ool and wireNheswiLchNothe
doorframeeo thaLthe bulbliqhto
whenlhedooris oVened,Wirinq
ano|herbulbto the bellcircuiLof Nhe
relephone can solvethe problemof
misbina ohone calle:Eaih t'ime th e I
\._.2
bellrinio,rhe bulbwillliqht.
a casterontoeachblock(abovd.
To buildtheshelved section, cut
theskirtsandthe eightpieces for
the legsfrom1-by-3stock;the shelf
from%-inchplywood; andthe toP
from%-inchplywood. Thelegsshould
be longenough for the topto sit at
a comfortable height.Screwthe leg
pieces together, thenattachthe
skirtsto the legs'insidefaces.Fasten
theshelfandthetopto theskirts.
Secure the legsto the basewith
angle brackets.
37
SHOPLAYOUT
SAVING
SPACE
Setting upa shopin theattic
Atticshopshaveseveral strikesagainst
them:Theyareoftenuninsulated and
theirf loorsarenotdesigned to support
heavy weight. In addition, headroom is
limitedandaccess canpresent problems,
e s p e c i a li lf yy o ua r ew o r k i nwg i t hl o n g
planks orfull sheets of plywood. Butfor
a luthier, carver, orwoodworker whospe-
cializes in smallprojects, an atticcan
bean idealspotfora shop.Asshownin
theillustration at left,nailing sheets of
sheathing-grade plywood to thejoistswill
produce a floorthatis sufficiently sturdy
to holdup a workbench andoneof the
lighter stationary machines, liketheband
saw,Thespaces between thestudsand
rafters anddownneartheeaves-where
theroofandatticf loormeet-areideal
forstoring lumber, tools,andsupplies.
38
SHOPLAYOUT
SH()P
OFA MEDIUM-SIZE
LAYOUT
20'
thelvee
- :o:*".n*- - -? ofr.Er
e Drill prena
e
ilt Sawhoreea
e ?erforated
hardboard
Duai;collector
o
Jointer/
grrrl[)
Lathe
thelvea o
e Eand saw
Windowfan
Lumberrack
39
SHOP LAYOUT
LAYOUT
OFA LARGE
SH()P
Converting
a two-car garage
Settingupa shopwithallthefeatures shown belowcallsfora shopboasts threeseparate worksurfaces:onein thefinishing
largespace,likea two-car garage.Thisshophasmanyof the room,oneforglue-up nearthedrillpress, anda workbench
characteristics
of thesmaller
shops examined earlier,
withaddi- besidethe tablesaw. A shopof this would
size needan inde-
tionaltoolsandconveniences thatallowit to handlea wider pendentelectricalservice panelto powerallthetools.Tokeep
rangeof projects. At onecorneris a spaciousfinishingroom, thewiringoutof theway,halftheflooris covered witha raised
partitionedfromthe restof theshopandequipped withan 3/rinchplywood floor;asshownon page44,an understructure
fanto exhaust
explosion-proof fumes. Theshopincludes a bath- is laidontheconcrete
of 1-by-2s flooron 12-inchcentersand
roomwitha sinkanda toilet.In addition to themachines fea- the plywoodis nailed Wires
to theboards. are run in conduits
thishasa radialarmsaw,shaper,
turedearlier, andplaner. The undertheplywood between the 1-by-2s.
w -
T- F-t
Mobite
Explooion' l-l -l
proof fan ctampI rl Fr I
rACK
Work (-
$-;
v
Taorc
u: ul
flt--------t
FINI'HINOROOM
6'x|O' Work'l" I ll
u^"n
li I ll
trb*l
IUF
-f--l
\ I
\ Lu"h" O
RAI9EDFLOOR
o l''lll
\J-gtuor
KEY
CONCRETE
FLOOR lllll,*,"*- lIHHltr|l l I ^
(]
0 24O V outlet
0 12OV outlet Ferforated'
o Incand eacent Iiqht fixtu re hardboard
o Fluoreacent liqht fixbure
o Eleatriaal aervice oub-panel Drill
e, Direction of feed Pree6
?lywood
stora4e
ilil Sawhorees
Radial
Disk/belt
aander
o
6v ) -zcraP ptn
o Aeeembly
table
/-\ .----.....--..-.
snetves
fr
O \_/ | lpfl
40
POWER
ELE,CTRICAL
shouldbe paneldedicatedto the shop.Another
f, lectricpowerrequirement
I ; considered earlyin the process of point to remember:Any woodworking
planning a shop'slayout. Allow for machinethat drawsmorethansixamps
growth.Then,asyou addnewtoolsand shouldbe on a separate (dedicated)cir-
light fixtures,youwill avoidtheheadaches cuit,unlessthetool'smotor is shielded.
of an inadequate system:repeatedtrip- Referto theillustrationon page42 as
ping of circuitbreakersor blowingof fus- a guideto planningthe electricallayout
es,andoctopusadapters funnelingseveral of your shop.As you plan,remember
oowercordsinto oneoutlet. that evensimple electricaljobs, like
If you planto wire your shopto your extendinga circuit or replacingan out-
home'smainservice panel,be surethat let, canbe dangerous. They can also
your electrical supplyhasenoughaddi- causea fairamountof damage-ranging
tional power.You can geta rough idea from burned-outtool motorsto a house
of how manyamperesyour shopwill fire-if theyarecarriedout improperly.
draw from the systemby totalingthe Unlessvou arecualifiedand comfort-
amperage of all thetoolsyou planto use ablewiih the ideaof wiring your shop
and dividing the resultin half.If your to theelectricalsystem,havea qualified
svstem is barely able to handle the electriciando thejob.
demands being'placed on it by your
household, you probably will needto
upgrade your service entrance-in oth- Theworkbenchis a naturalwork
er words, increase the number of amps surfacefor usingportablepower
theservicepanelcandrawfrom theutil- tools.Mountinga powerstripon
ity company.If the shopwill be some oneofthe legsandpluggingit into
distancefrom the main servicepanel,it an outleteliminatestheneedfor a
is a goodideato installa 50-ampsub- separate extensioncordfor everytool.
TIPS
TAYOUT
ETECTRICAT
r Whenplanningtheelectricallayoutfor thatthewiringof yourshopis inade- . Donottoucha metalfaucet,pipe,
yourshop,makesurethatoutletsfor quate.Upgrade thesystemby installing or otherobjectwhenworking
appliance,
powertoolsandlightingfixturesareon newoutlets andwiringthemto a sepa- onyourwiring.
circuits.
seDarate panel.
ratecircuitontheservice
. Neversplicea powercordor an exten-
o Unless yourshophasbrightwindows o Protectanynewoutletin a garage
or sioncord,or removethegrounding prong
or yourlightsareequipped withbattery basement a ground-fault
by installing froma three-prongplug.
backups, includeat leasttwoseparate circuitintenupter(GFCI).
lightingcircuitsin yourelectrical
layout. . Usean extension cordto supplyelec-
In theeventonecircuitis disabled, the . Neverworkon thewiringof theservice tricityto an areaonlytemporarily-not
lightsplugged intotheothercircuitwill panel;
entrancewiresmayremain live aspermanenl wrnng.
stillwork. evenwhenpoweris shutoff at the main
orfuseblock.
circuitbreaker . Neverruna oowercordor an exten-
r Placeoutletscloseto theeventualloca- sioncordundera rug,mat,orcarpet;
tionof thetoolstheywillpower;
distrib- . Makecertainthatanynewcircuits or do notfastenthecordusingtacks,pins,
uteoutletsall aroundtheshooto allow service
sub-panels in yourhome
installed orstaples.
forfuturetoolacquisitions. aregrounded
or outbuilding to themain
panel.Individual
service outletsmust . Neverreplace a blownfusewithoneof
. Avoidlocating onthefloor;they
outlets alsobegrounded. higheramperage; do notusea penny,a
become
willeventually filledwithsaw- washer, fora fuse.
or foilasa substitute
dustandbea firehazard. . Donottakeoff thecoverof theservice
o a nle. o lf a circuitbreaker
tripsor a fuseblows
. Avoidplugging
toolsintooneoutlet repeatedly, checkfora shortcircuit,and
usinganoctopus thiscanover-
adapter; o Never
workonyourwiringin dampor determine whetherthecircuitis over-
loadyourelectrical
system, andis a sign wetconditions. loaded.
4I
SHOPLAYOUT
ETECTRICAT
TAYOUT
FORA MEDIUM.SIZE
SH(IP
Wiringtheshop
Theillustration at leftshowsoneelectri-
cal layoutfor a medium-size shop.The
shophassixseparate electrical circuits:
fourfortoolsandtwofor lighting. The
basicprincipleto keepin mindis thatno
circuitusing!2-gauge wireshouldcarry
morethan80 percentof its capacity; for
20-ampcircuits, thismeans thecom-
binedamperage of the toolsonthesame
circuitplus25 percent of theratingof the
largestmotormustnotexceed16 amps.In
thisshop,thetablesawandjointerare
orfseparate 240 V circuits; theirpower
cordsaresuspended fromtheceilingwith
twist-typeoutlets,whichkeepthe plugs
in place,Witha combined loadof 15 amps,
the bandsawandthedrillpressareon
thesame120V circuit;the latheis on
another. Additional outletson the 120V
circuitscanbeusedforportable tools.The
incandescent andfluorescent lighting
circuitsareseparate sothatif onefails
theotherwillstillwork.
KEY
rh
\v 24O V outlet
0 12OVoutlet
o Incandeecentliqhtinq firtu re
t FIuoreacentIiqhtinq fixture
o Directionof feed
42
LIGHTING
llllllllllllllllllllllll
IllIilltllllfillIIIfillfillilllllllllllllllI]I1 A clamp-onlampcanshedall thelight
you needto worksafelyat a tool.
Mountedon a drill press,thislamp's
1HO?Tt? flexibleneckaimsa 4)-watt bulb
worktable.
directlyat themachine's
A benah'dog 1,,,,,\,
lamo oupport l'lllt'+qil'\'-.
" - A " . a-'\ r:--:\
l ----t\
Fora movablesourceof ,/ ."r:r'i
liqhl aI your workbench, / \
aitach A desklampNo {-'- *--"'"'
oneof the benchdoqe.Dore
a holeNheeamediameNer
as the ehafLof Lhe lamp
into the headof
a wooden.do,q +:==::::=--::R-::::-..--=.:
(pa4e62).The -- -------=:*:
li,ahr,
canLhen -:]
b:epoeitioned *.
al any of the - *-<<*.*t3-
ja-. _;
doqholeo alonq -__--
the bench.
43
FLOORS,
WALLS,AND CEILINGS
most workshopsare set up Iated.If you livein a northernclimate,
Q i":.
\,, In basements or garages, concrete you canincreasethe thermalefficiency
floors are a common feature.Yet for of your shopby coveringits wallswith
anyonewho hasto spendmuch time wood panelingor sheetmaterial,and
standingon concreteor sweepingit filling the gap in betweenstudswith
clean,the materialcan prove both insulation. Woodpanelingin particular
uncomfortable and inconvenient. The creates a warm,comfortable atmosphere.
hard surfaceis particularlytough on Interior wall coveringwill makeyour
toolsthat aredroppedaccidentally. shop quietertoo, sincethe wallswill
Simplypaintinga concretefloor with absorbsomeof the din of vour Dower
a paintmadespecifically for thepulpose tools.fu a bonus,youcanconceal wiring
will keepdown the dust and makethe behindthe walls.Makesurethe base-
surfaceeasierto clean.Adhesivevinyl mentwallsdo not leakbeforecovering
floor tile canbe laid down aswell.Yet themwith insulationandpaneling.
manywoodworkerspreferthe comfort To hide the exposedjoists,ducts,
of a raisedwoodenfloor.A simolefloor and wiring aboveyour head,consider
canbe constructed from sheeisof %- installinga ceiling.A suspended tile ceil-
inch plyruoodlaid atopa grid of 1-by- ing,in whichthetilessit in a framework
2son 12-inchcenters. Not only is this of supportshangingfrom thejoists,is
qpe of flooreasieron thefeet,but wiring onepopularoption.In a largeshop,a
for stationarypowertoolscanbe rout- droppedceilingsuchasthiswill alsohelp
ed underneath the raisedsurfacein %- retainheat.Acousticalceilingtilesare
incholasticor steelconduit. an inexpensive alternative;the tiles are
Unlikethewallsof mosthomes,those attachedto furring stripsthat arenailed
Standingin oneplacefor hourson ofseparate workshops seldomareinsu- to thejoists.
a concretefloor can strain your feet
and legs.An old pieceof carpetor a
commercialanti-fatigue mat pro-
videsa cushionthat can be easily
movedabout the shop.
lll1
ljlliltfilllll1
lllillllfirlilutllllllltlllilIIlllllllllll1
fiulllt
9HO7Tt?
Making the transition to a raieedfloor
lf parl of yourehophaoa raisedfloor,youcan makea smoolh
lransilion from Nhelowerconcretefloor with eeveralbeveled
2-by-6o laidend-No-end. Cut a rabbeNin oneedqeof each
2-W-6lo accommodate the plywoodfloor and the 1-by-2
qrid undernealh, Thenbevellhe oppoeiteedqe,forminqa ram?
lo f acilitatemovinqit emsfrom onefloort o the oLher.Nailor
screwIhe plywoodtothe 2-by-Oe.
\
*ri.
44
HEATINGAND VENTILATION
A SHOP
VENTILATING
Installing a general exhaust setup
lf yourshopdoesnothavewindows or
doors to provide proper cross-ventilation,
install anexhaust setup to cleantheair.
Thesystem shown at leftis a simpleone,
consisting of anairintake at oneendof
theshopconnected to theoutdoors or
yourhome's airducts, andanexplosion-
prooffanmounted in thewallat the
oooosite end.Theintakeis covered with
a f u r n a coer a i r - c o n d i t i o nf i lnt g
e rt o
cleantheincoming air.Theexhaust fan
is placed higher thantheintake, causing
theairthatrisesto bedrawnoutof the
shop.Forbestresults, orienttheexhaust
setupalongthelongest axisof yourshop.
45
WORKBENCH
47
l
r-r
ANTATOMY
OFAWORKBENCH f
5tretcher
Frovidealaf,eralatability to
bench;attached to the leg6
in oneof aeveralwayo(paqea
50 and 51)
_l
Attachingtheendcapsof a worl&enchto the l
apronscallsfor a strongand attradivejoinery - t
methodThefingu joint (alsoknownasthebox
joint) and thedovetailjoint shownatw are
traditionalfavorita.
48
-_l
WORKBENCH
ToP
OfLenlaminal;edfrom a hard
and densewoodauchae mapleor
beech:boardathat makeup top
ehouldbe aelected,prepared,and
7luedup carefullyto provtdea
per-fectly fl at Eurf a ce
Theworkbench at left
improvedthestandard
designby incorporat-
ing a tilting toolchest
underthetop.
Tooltray
Aenahdog
Uaedwith tarl or face viseto
) clamp eLock;made of metal or
wood.Teneionoprinq keepadoq
aL deeiredheiqht;afLer uae,
dog io pueheddownbelowaur-
/ , , face of benchtop
End cap
Llenarate niere rntt-
Moveeelidin7do1 blockLo
adjueLclamptn4capaciLx
to len7th of work
49
BUILDINGTHE BASE
"f h. baseof a workbenchtypically belowshowsa knockdown alternative wantto movethebench.Consequently,
J- consists of two rectangular frames to assembling thebasewith mortise- knockdownhardwaredesignedfor the
connectedby a pair ofstretchers.The and-tenons. purposeis oftenusedto join thestretch-
framesareessentially identical,eachwith Thejointsbetrveenthestretchers
and ersto the legs.The pagesthat follow
a foot,an arm,andtwo legs.Thearm of thelegsneedto besolid,yetsufficient- detailsomeothermethodsof reinforc-
the left-handframeis sometimesabout ly flexibleto betakenapartshouldyou ine knockdownconnections.
3 incheslongerthantheotherarmto pro-
videadditionalsupportfor thefacevise. Bunjoints connecting thelegs
For a benchlike the one shownon of a workbenchto thestretch-
pages 48 and,49,use % maple(l% inch- erscan be reinforcedwith
esthick aftersurfacing).The feet,arms hardwoodknockdow n finings.
and legs are made from two boards Thefittings are insertedinto
apieceface-gluedtogether,and then mortises cut into theends
reducedto the properthicknesson the of thestretchers;matching
jointer and planer.If you wish to build machineboltsand nutsare
the basewith mortise-and-tenons, cut thenusedto securetheioint.
four-shouldered tenonsat theendofthe
legsand rout matchingmortisesin the
feet and arms.Tenonsare alsocut at
the endsof the stretcherswith mortises
requiredin the legs.The illustration
REINF(|RCING
KN(ICKD(IWN
J(|INERY
Using trussrods
Instead of usingmortise-and-tenon
jointsto buildthebase,usebuttjoints
reinforced bytrussrods,asshownat
right.Available in kits,therodscanbe
loosened or tightened afterassembly
to compensate for woodmovement as
a r e s u lot f c h a n g ei sn h u m i d i t yR. o u t
grooves for the rodsintotheedgesof
thestretchers andthe insideedgesof
the legs;the depthandwidthof the
c h a n n esl sh o u l ed o u atlh er o d ' sd i a m e -
ter.Test-assemble the baseandmark
thegroove locations on the legsand
arms.Thenborea holeat eachmark,
m a k i n tgh ed i a m e t eerq u atlo t h a to f
the rods;countersink the holessoyou
candrivethe nutsf lushwiththewood
surface. Assemble the base, f ittingthe
rodsintothegrooves andholes,and
tightening theconnections withwashers
andnuts.Cover thegrooves withsolid @8
woodinlayif youwishto conceal therods.
50
WORKBENCH
Usingmachine boltsandwoodblocks
To reinforcetheconnection between the
legsandstretchers, gluea woodblock
of the samethickness asthe stockto
eachedgeof the stretchers. Theblocks
will increasethe contactareabetween
the stretchers andthe legs.Oncethe
glueis dry,cut a tenonat theendof each
stretcher anda matching mortisein the
leg.Fit the piecestogetherandboretwo
holesfor machine boltsthroughthe leg
andthetenonin the blocks; countersink
the holes.Makethe connection fast by
fittingthe boltsintothe holes,slipping
onwashers andtighteningthe nuts(right).
Usinglagscrewsanddowels
Another wayto stren$hena mortise-and-
tenonjoint between thestretchersand
legsis shownat left.Cuta 1-inch-diame-
ter hardwood dowelto a lengthequal
Then
to the thicknessof the stretcher.
borea 1-inch-diameter holethroughthe
stretcher aboullVzinchesfromits end.
Alsoborea holefor a lagscrewthrough
the leg,stopping the drillwhenthe bit
reaches the holein thestretcher:coun-
tersinkthe holesothe screwheadwill
sit flushwiththesurface.Fitthestretcher
tenonintothe legmortise, tapthe dowel
intoplacein thestretcher,anddrivethe
screw.Choose a screwthatis longenough
to bitethroughthe dowe,.
51
WORKBENCH
PREPARING
THEFEET
Relievingthefeet
Onceyouaresatisf iedwiththef it of the
partsof the base,disassemble thestretch-
ersandlegsandrelieve thefeetonthejoin-
ter.Installa clamponthejointer's infeed
tableto holdtheguardoutof thewaydur-
ingtheoperation. Setboththeinfeedand
outfeed tablesfora %o-inch depthof cut,
andclampstopblocks to bothtablesto
guidethebeginning andendof thecut.To
makethefirstpass,lowerthefootontothe
knives, keeping it flushagainst thefence
andthestopblockontheinfeedtable.Feed
thefootacross the knives(/efiluntilit con-
tactsthestopblockon theoutfeed table.
Keepbothhandswellabovethecutterhead.
Makeasmanypasses asnecessaryto com-
pletetherecess, lowering thetables%oinch
at a time,andreadjusting thestopblocks
asnecessary.
Installingadjustablelevelers
To levela workbench onan uneven shop
f loor,installadjustable levelersin the
feet.Eachleveler consists of a T-nut
anda threaded portion witha plastic tip
0nsel.Boretwoholesintothe bottomof
thefootneareachend.Makethehole's
diameter eoualto thatof theT-nutand
its len$hslightlylonger thanthethreaded
section. TaotheT-nutsintotheholes and
screwin the levelers(right).Oncethe
benchis assembled, adjustthelevelers
untilthebenchtoo is level.
52
BUILDINGTHETOP
neof themostimportantfeatures of all theboardsrunsin the samedirec- are bolted to the slab and joined to
of a workbench is a perfectlyflat tion. Thiswill makeit easierto planethe the aprons by means of dovetail or
top.At onetime,a benchtopcouldbe top surfaceof theslabsmooth. fingerjoints.
built of solidmapleor beechboards Aftergluingup theslab,prepare the
12incheswideand2 inchesthick.But dog blocks. They are gluedup from
todaysuchplanksaredifficultto come a lengthof% stockandoneof% stock
by,andbenchtop slabsarebuilt up from with thebenchholesdadoed outof the
narrowboards, layersof ply,voodsand- thicker board. The slidingdog block
wichedbetweenstripsof hardwood, for thetail viseis sawnoff beforethe
or laminatedplywoodstripssheathed front rail and fixedblockareglued
in hardboard. However, edgegluing together(page 5a).Next,theslab,fixed
solidwoodboardstogetherbutcher- dogblock,andrearrail aregluedup
blockstyle, asshownbelow isthetime- (page55);hardwoodkeysand ply-
honoredmethod. woodsplinesareusedto strengthen
Cut from % stock,theboardsare theconnections.
gluedtogetherfirst,thenthe slabis Aftertheslidingdogblock,tooltray, Oncethetop of a benchis installed
cut to length.To minimizewarping, andapronsareinstalled, thefinalstep on thebase,a straightedgeheldon
arrange thepiecessothattheendgrain involvesattaching the end capsto the edgeacrossthesurfacecanbeused
isreversed.Alsomakesurethefacegran top.Twoconnections areused:Thecaps to checkit for Jlatness.
(lFA BENCHT(|P
ANATOMY
9lidin4
do7 block
Front rail
End cap
53
WORKBENCH
PREPARING
THEFIXED
D(|GBTOCK
Guttingthebenchdogholes
Benchdogsarefabricated fromtwoboards,
soit issimple
to cutthedogholesin the
tsenchdoq hole thickerpiecebeforeglue-up.Twosteps
areinvolved.First,cut a rowof evenly
spaced dadoeswideenough to accept
thedogs;anglethefixed-block dadoes
slightly
towardthetailvise,andtheslid-
ing-blockdadoesawayfromthetailvise
sothatthedogswillgriptheworkfirmly
whenclamping pressureisapplied.Next,
clamptheboardto a worksurface and
usea chiselto notchthetopof each
dadoto acceptthedogheads(lefl.fhat
way,thedogscanbepushed downflush
withthebenchsurface whentheyarenot
in use.Nowthetwopartscanbeglued
upto formthefinishedblocks.
@tsenchdo4
54
WORKBENCH
THEBENCHTOP
ASSEMBLING
'l Gluing upthetop
I First, glueupthetopslab.Before glu-
ingupthebenchtop, routgrooves on both
sides of thedogblocks andfrontrail,on
one face of the front apron andbackrail,
and along the edges and ends ofthetop
slab.Cut matching keys and splines. Refer
to the drawing on page 53 forthe size
andplacement of thegrooves, keys, and
splrnes. lf you want to incorporate a tool
trayin yourbench,cut r/z-inch rabbets
intothebottom edges of the backrailand
apron; later in the assembly process you
it
willf a piece of r/z-inch plywood to form
thetray. Set aside the sliding dog block
(withthehardwood keysgluedin place)
andfrontand back aprons, spread glue
on all mating surfaces, and clamp (right),
alternating thebaror pipeclamps onthe
tooandbottom of the work.
r) Attaching theendcaps
L m " e n dc a p sc a nb ea p p l r ewdh i l e
thetailviseis beinginstalled (page 57).
Whenthatisdone,invert thebenchtop
androuta T-shaped recess at eachend,
centered between theedges. Cuttworec-
tangular f ittingsfromscraphardwood so
thattheyfit in thebaseof eachrecess.
Notchonesideof eachfittingto accept
a 7e-inch nut,andplacea fittingandnut
in eachrecess. Settheendcapsin oosi-
tionandmarkwhere theycontact the
recesses. At eachmarkborea holefora
%-inch otgh eb o l t
b o l t c, o u n t e r b o rsi n
heads areflush.Routa groove in each
e n dc a pt o a c c e ptth e p l y w o osdp l i n e ,
androuta r/z-inch rabbetonthe bottom
inside edgeof thebackrailto acceptthe
tooltray.Install thetailviseontheright-
handendcap(page5/). Spread glueon
thecontacting surfaces, fit theendcaps
(\efl, andboltthemin place(inseil.Finally,
fit thefrontandrearaprons andtooltray
a n 0c r a m p .
55
VISESAND ACCESSORIES
\ / isesarethe toolsthat transform a faceviseby boringholesin thebench- Thil visesareavailablein two types:
V the workbenchfrom a simple,flat top andsecuringwork betweena bench an enclosed modelthat incorporates a
surfaceinto a versatile
work station.The dog in the vise'sjawsand one inserted slidingdog block (belowandpage57)
modernwoodworkingbenchincorpo- in oneof theholes. and one that featuresan L-shaped
rateshvo tlpes of vise:the facevisethat block,asin the photo at left. Sometail
secures work to the front edgeofthe visesextendacrossthe entireend ofa
bench,andthetail visethatuseswoodor workbenchand havetwo screws;these
metalbenchdogsto securework on the areknown asendvises,andtheyextend
top of the bench.The pagesthat follow the utility ofan alreadyversatiletool.
examinewaysof installingboth the tail
vise (page57) and facevise (page58).
Facevisesmadeentirelyof wood are
rare.However,a woodenviseis prefer-
ableto a metaltypebecause wooden
jawscangrip work withoutmarringits Sometail vises,like theoneshown
surface.A good compromisecan be at left,incorporate
an L-shapedshoul-
reachedby buyingthe hardwarefor a derblock.Theblockallowswork to be
metalviseand mountingwoodenface clampedbetweentherearjaw of the
blocks.Youcanextendthe capacitvof viseand theendof thebench.
ANATOMY
OFA TAIIVISE
Fixed doq
block
Apron
Vieeflanqe
Viaecollar
-
56
WORKBENCH
A TAILVISE
INSTALLING
1 Installing thevisehardware
I T o i n s t a al l t a i lv i s eo na b e n c wh ith
a sliding dogblock,position thevisecol-
laragainst theright-hand sideendcap
andoutline theholeforthevtsescrew.
Thenseta support board onthedrillpress
tableandclamptheendcapontopof it.
Fitthedrillpress witha spade bitslightly
larger thanthevisescrewandborea hole
throughthe end cap(nearright),Screw
thevisecollarto theendcapsothetwo
holes lineup.Next, secure thesliding dog
block end-up in handscrews andclamp the
handscrews to a worksurface. Position
thevisef langeontheblockandmark
i t ss c r e wh o l e sB. o r ea p i l o th o l ea t
eachmark,thenscrew theflange to the
block(farright).
r) Assembling thevise
L f ttthesliding dogblockin thebench
sothe hardwood keysin the blockrun
i n t h eg r o o v ei sn t h es i d e so f t h e r a i l .
Thread thevisescrewthrough thevise
collar, test-fit theendcaponthebench-
topandlocktheballjointontheendof
thescrewintotheviseflange.Setthe
frontapronin position against thedog
blocks(/eff)andtestthe movement of
thevisebyturning thescrew. lf theslid-
i n gb l o c kb i n d sr,e m o vteh ee n dc a p ,
d o gb l o c ka, n de a s e
a p r o na, n ds l i d i n g
thef it byparing thekeyswitha chisel.
O n c ey o ua r es a t i si ef dw i t ht h e v i s e ' s
movement, attachtheaprons, endcaps,
and trays following the procedures out-
linod nn neop 55
57
WORKBENCH
ANATOMY
OFA FACE
VISE
fixea ,,',------l
doq block
Apron
Face block
Faceplate
INSTALTING
A FACE
VISE
1 Preparing thefaceblock
3/a-by-31/z
I Cutan 18-inch-long inch
hardwood support blockandscrewit in
placeunderthe frontleftcornerof the
bench,afterboringa rowof clearance
h o l e sf o rt h e b e n c hd o g sN. e x t b, u i l d
up thefaceblockbygluing twopieces of
7ahardwood together; cut it to a finalsize
of 5-by-18inches. To markandborethe
holesforthevisescrewandguiderods,
marka lineacross thefaceof theface
block;offsetthelinefromthetopedgeby
thethickness ofthebenchtop slab(notthe
frontaprondepth).Nowusethecarriage
as a template: Centeritstop edgeon
thelineandusea brad-point bitto accu-
ratelymarkthe position of thethree
holes(right)andborethem.
58
WORKBENCH
r) Preparing thebench
L Oncethe holeshavebeendrilled
through thefaceblock,transfer thetr
location to theworkbench apron. Setthe
faceblockandbenchtop on sawhorses
andusebarclamps to holdtheblockin
position against theapron;protect the
stockwithwoodpads.Makesurethetop
edgeof theblockisf lushwiththebench-
topanditsendisf lushwiththeendcap.
Marktheholelocations ontheapronusing
the brad-poinI biI (right).Remove the
f a c eb l o c ka n db o r et h eh o l e st h r o u g h
theapronandbenchdogblock,
Mounting thevise
Attach theviseassembly- theface-
plate,screw, andguiderods-totheface
b l o c kT. u r nt h eb e n c h t oupp s i d de o w n ,
p l a c et h ev i s ec a r r i a goent h eb e n c h ' s
underside, andfeedthevisescrewand
guiderodsthrough theholesin theapron
andintothecarriage. Makepilotholes
ontheunderside of thebench andfasten
thecarriage in place.Next,fastenthe
guiderodbushings to theapron: Remove
t h ev i s ea s s e m b lfyi t, t h eb u s h i n gosn
t h er o d sr, e m o u nt h t ea s s e m b layn, d
outline thebushings' location ontheapron.
Thenremove theviseassembly againand
secure thebenchtop sotheapronis fac-
ingup.Witha router andstraight bit,cut
recesses forthebushings withintheout-
lines(left).Screwthe bushings to the
recesses in theaoronandattachthevise
to thebench. Nowtheworkbench topis
readyto beattached to the base.Laythe
topupside downonthef loor,placethe
basein position, anddrivelagscrews
through thearmsintothetop.
59
WORKBENCH
JIGSFORIRON.JAWED
BENCH
VISES
Eaeia auxiliaryjaw
Tapered vieejaw
V-grooveviaejaw
60
WORKBENCH
VISERACKING
PREVENTING
Using a stepped block
Whensecuring a workpiece at oneend
of a facevise,theotherendof thevise
the
i s l i k e l yt o r a c k - o rt i l t t o w a r d
bench-and cause theworkto slip.To
prevent racking, usea stepped hardwood
b l o c kt o k e e pt h ej a w ss q u a r eC. u ta
series of stepsin onefaceof theblock,
spacing themat equalintervals, suchas
r/zinch.Placethe blockin theopen
endof theviseat thesametimeyouare
securing theworkpiece sothatthevise
is parallel to theedgeof thebench(/eft).
6l
BENCHDOGSANDHOLD DOVNS
p enchdogsareasimportantasvises
Ll in maximizingthe flexibilityand
utility of a well-designedworkbench.A
setof benchdogsworkslike a second
pair of handsto secureworkpieces for
planing,chiseling,mortising,carving,
or otherwoodworkingtasks.
Althoughthe benchdog lookslike a
deceptivelysimplepeg,it incorporates
designfeaturesthat enableit to hold a
workpiecefirmly without slippingin
its hole. One featureusuallyis a thin
metalspringattachedto one sidethat
presses againsttheinsidewallof thedog
holein theworkbench. Tohelpstrength-
en the grip of benchdogs,the holes
arealsoangledtowardthe viseat 4o.
Benchdogs can be either round
or square.Round dogsare easierto This benchdogfeaturesa threadedscrewthat converts
incorooratein a benchthat doesnot it into a miniature tail vise. Usedin conjunction with
yethJvedogholes;it is simplerto bore other benchdogs,it excekat clamping small or irregu-
holesthan to makesquaredog holes. lar work, like thepanel shown above.
Sinceround dogs can swivel,their
notched,flat headsenablethem to
clamp stockin practicallyany direc- BENCH
DOGS
tion. Thiscanbe a disadvantage: Some
Making a wooden bench dog
woodworkersclaim that round dogs
Benchdogscanbecrafted fromhardwood
tend to slio in their holesmorethan
stock; theoneshown at leftusesanangled
squaredogi, which cannotrotate.
wooden tongue asa spring. Cutthedogto
Benchdogscanbe madeof either
fit theholesin yourworkbench, thenchis-
metalor wood.Metaldogshaveaweight,
el outa dadofromthemiddleof thedog.
strength,andstiffiress thatwoodenones
Sawa shortkerfintothe lowercornerof
cannotmatch.Yetwoodendogshave
thedado,angling thecutsothetongue
their advantages-asanywoodworker
willextend beyond theedgeof thedado,
who hasnickeda planebladeon a met-
Cutthetongue fromhardwood, making it
al dogwill attest.
aboutaslongasthedado,aswideasthe
Benchdogsarenot the only method
doga , n da st h i c ka st h ek e r f G
. l u et h e
ofsecuringstock;benchhooks,carving
tonguein thekerf.
hooks,wedges, andhold downsarealso
usefulfor keepingstockin place.The
followingpagesillustratea numberof
commercial andshop-made optionsto
keepworkpiecesput while you work.
62
WORKBENCH
Makinga spring-loadedbenchdog
A wooden benchdogcan be madeto fit snugly
byequipping it witha metalspringcutfrom
an oldbandsawor hacksaw blade.Cut your
dogto size,thenchiselouta small recess for
thespring.Thewidthanddepthof the recess
shouldeoualthewidthandthickness of the
butits lengthshouldbeslightly
spring, shorter
thanthatof thespring. Pressthespringinto
therecess;the metalwill bowoutward, hold-
ingthedogfirmlyin itshole.
63
WORKBENCH
Makingandsettingupcarvingdogs
Usinga standard benchdogasa model,
youcanfashiona pairof customized dogs
thatwill gripa carvedor turnedwork-
piece,orsecureirregular-sizedwork,such
as miteredmolding. To makethese
accessories,cut bevelson eithersideof
the headof a standardbenchdogand
drivea smallscrewor nailintothecen-
ter of the head;snipoff the fastener's
headto forma sharppoint.To usethe
devices, placeonedogin a dogholeof
thebench's fixeddogblockandtheother
in thetailviseor a slidingdogblockhole
(above). Tightenthe visescrewuntil
the pointscontactthe endsof thework-
pieceandholdit securely.
64
WORKBENCH
ANDBENCH
HOLD-DOWNS STOPS
65
WORKBENCH
Installing
a wedgestop
A wedgestopcanalsobe usedto secure
stockon a benchtop (left).Thestopcon-
sistsof a fixedrailanda movable rail
thataresecured bydowelsrestingin a
doublerowof holesboredintothework-
bench.Together witha triangular wedge,
therailskeepa workpiece frommoving.
Cuttherailsandthewedgefrom%-inch
plywood. (Youcanchoose thickerstock
fortherails,depending onthethickness
of yourworkpiece.) Boretwo L/z-inch-
diameter holesin eachrail,thengluea
2-inch-long dowelin eachhole.Bore
tworowsof %-inch-diameter holesin the
workbench for the dowels.To usethe
stop,placethefixedrailat oneendof
the rowof holesandthe movable railthe
appropriate distance awaysothewedge,
whenpositioned between the rails,will
keeptheworkpiece steady.
Making a benchhook
Theshop-built jig shownat rightwillensure
thatthe crosscuts youmakeon thework-
benchwill besquare.Use3/a-inch plywood
for the baseandstripsof 2-by-2stockfor
the lips.Makethe baseat leastas long
asthewidthof yourworkpiece andwide
enough to supportit. Screwthe lipsto
theguide,attaching oneto eachface.
To usethe jig, buttonelip against the
edgeof the benchand pressthe work-
piecefirmlyagainst the other.Alignthe
cuttinglinewiththeedgeof the baseand
makethe cut (inset).
66
WORKBENCH
67
*\.
{: r
t
SHOPACCE,SSOruES
,-n3 :,jrl?tt 'ill L!!uur-'r''Lrrlq rrLdur rr@ rLu Lv urL
ii-r- r:ne3'jr I'l - I
makethework saferan
importantfor safetyand
,.:,j:,-!1':]:.-,-:.-.:::r.::=::::-Gf---=--_o*=.*.'.-,'j--.-:,.:,-
ishingwork-to
;:i lWw'jffi
,,,#f,i1,ffiil:,H1,,yffi
applylacquer and
-72:i*.ii;*''{ r"-rqrffi
;ilH:.t.:i:,::ii::?,#,:,
of ailments, inclt'ding dermatitis,
varniih *ore smoothlythin with Mostof thewoodchipsandsawdust generated shortness of breath,anddizziness.
abrush.Butwiththeadventofsuch bythisl0-inchtablesawarecapturedbya Recent studies haveshownthat
toolsas pneumatic nailers,com- portable dust system.
collection Ofien neglected long-term inhalationofwooddust
pr.rrotrir. foundmorefrequent- in thepast,dustcollection hasbecome a central is at leasta contributingfactorin
iy, .u.n in smallhomeworkshops. tort"i, of manysafety-conscious woodworkers cancers of thetongue,tonsils'lung,
Air-poweredtools are discussid in planningthelayout of their
shops. *9 b.fnt'
startingonpage72. Whenyouad{ 1otheequation
Geniratorsltoo,arefindingaplace,especiallyamongthose thefireriskandthehazardof a dust-covered.lhop floor,there
woodworkers whotake theirirait awayfrom home and pow-
- are compelling reasons for installing some kind of dustcol-
erlines.Theyareexplored onpageTl'. lection system in yo_urshop. Pages 78 to 87.provide you with
Grinders, canspeed
of course, toolsharpening.More impor- information you will needto setup_ and-maintain both central
tantly,asyouwill seeonpage76,theycanpermityouto mod- andportablesystems. Remember.that designing a centralsys-
ifi'tools
' andreclaimdariraged cuttingedges. temrequires carefrrlattentionlo {etail an{Precise calculation
Airbornedustoncewasionsidered an unavoidable conse- ofyour specific requirements. To be safe,checkyour plansand
quenceofworkingwith wood.Butthe increased emphasison figureswith an engineer before installing thesystem.
69
A STOREOF SHOPACCESSORIES
Multitester
Aleo knownaa volt-ohmmeter,
or VOM.tsatte ry- powered to ol
uaed in troubleahootinaand
repairing electric deviceZ:mea-
eures reeiatanceand AC or DC
voltaqe in a circuit
Air compreaoor
Supplieaatream of highpreeeureair
throuqh hoaeto powera variety of
air-operated toola, auch aa aandere,
epray qune,and drilla; coneumer-
4rade modeleranqe froml/a to 5
nor9ePowerand can qenerate uP to
2OO pounda p€r oquare inch (pei) of
air preeaureand O.3 to 15 cubic feet
of air per minute (cfm).
SHOPACCESSORIES
Generator
Typically ga aoline' powered,featu ri nq
uo to four 12O-and 24O-volt out-
leta. Motors on congumer'qrade
qeneratoro ranqe batween 3 and B
horaapowerand produce 5OO to 4OOO
watto of output; moet modela weiqh
leaathanlSOpoundoand can befit-
ted with wheelafor eaay portabili$
thop vacuum
Cleanaup duat and liq-
uid apills; hoae can be
attached to individual
tools to collect duat as
it ia produced. Typically
featurea 1%-to 2%-inch'
diameter collection hoae
and 5- to 1O'qallontank;
some modelecan double
aa portable blower
Bench grlnder
Coarse wheel(left) 6quarea, aharpena,and
amootha bladeaand bits; cloth wheel(ri4ht)
poliaheaand cleana.Features a 1/+-tol/z'
'horoepower
electric moton eye ahielda,
adjueiable tool resta, and wheel1uarda
atandard on most modela,Benchtop
grindero ueually bolted to work aurface
Wheeldreeeer
Used to true or reehapabench4rinderwheel.
gtar-wheel dresaer (above) ueea uP to four
ota r- ohapedwheela;diamond-pointdreaser
(below)fiatureal/+'carat diamondaet in
bronze tip and metal shaft
7T
AIR COMPRESSORS
AIR-POWERED
TOOTS
ANDACCESSORIES
Jitterbug sander
)rbital eander capableof pro- Drill
ducina 25OO atrokes oer 3/a-inch
drill that turna bita
minute: weigholeas than 5 at 25OO rpm; wei4heonly
pounda.Keauirea6.5 cfm at
'9O 2 %pounde.Kequirea5
pai; muat be uaed with cfm at 90 pei; muet be
tank-mountedcompreeaor ueedwith tank-mounted
with at leaat 3 horaepower compresoor with at leaat
'l horeepower
Air-poweredtoolswork bestat a
pressure
specific indicatedin the
owner'smanualfor theparticular
tool.Beforestartinga job, thecom-
pressor'sair regulatorshouldbe
adjustedto thepropersettingfor
thetaskat hand.
9pray gun
Heavy-duty aprayer with
adjuatablefluid and air
controle. Kequiree5.5 cfm
at 40 pai; can be uaed with
any compreoaorwith more
than t horeepower
72
SHOPACCESSORIES
TIPS
SAFETY
C(|MPRESSOR
o Readyourowner's carefully
manual . Alwayspluga compressor intoa . Allowthecompressorto coolbefore
a compressor
beforeoperating or any groundedoutletof the appropriate performing anymaintenance;
wear
tool.
air-powered amperage. gloves anypartsthatare
to disconnect
stillhot.
r Donotresetanyswitches on
or valves r Relieve
pressureslowlywhendepres-
the compressor; theyhavebeenpreset thetank.
surizing r Turnthecompressor
off beforemovingit.
at safelevelsat thefactory.
o Donotpressthetriggerof an airtool o Donottouchthecompressor while
. Check thehoses,plugs, wires,pipes, whenconnectingit to anairhose. usingit or immediatelyafter;themachine
andtubesof thecompressor, andthe canbecome veryhot.
toolair inletsbeforeeachuse.Donot r Donotremove the beltguardof a belt-
usethecompressor or toolif anypart drivencomoressorwhenthe machine r Drainanymoisture
lromthetankafter
is wornor damaged. is operating. rust;tankpressure
eachuseto prevent
than10 psiwhen
shouldbe nohigher
o Wearsafetyglasses pro-
andhearing . Turnthecompressor off if it produces drainingit.
tectionwhenusingair-powered
tools. noiseorvibration,
an unfamiliar pro-
air pressure,
ducesinsufficient or con- . Replacethetankif it hasanypin
. Donotexceed the pressure
rating sumes excessiveoil;havethemachine holes,rustspots,or weakspots
of an airtoolor accessory. servicedbeforeresuming operations. at welds.
j:i,2";:#:fi;"",.
Presgor Or Connect?
ww
two len4thaof com'
preeeor hooe toqether
Quiak coupler
Uaed with hoae connectora to
attach air tools to compreeeor
hoseor to join lenqthaof com-
preooorhoeetoqether; auto'
Router matically ahuta off air when
%-inchdirect-drive router that turns uncoupledfrom compreeeor
bits at 2O,OOOrpm; wei1hajuat over
1pound. Featuree neoprenerubber qrip
to reduce vibration, Requiree90 poi;
will function with most compreoaore
73
PORTABLE
GENERATORS
,| heaverage homeandshopissowell Thereareseveral factorsto consider Althoughall modelsfeaturea surgeor
I equippedwith electricfixtures,
out- whenselecting agenerator,
andthechart maximumratingasmuchas25percent
lets,andextension cordsthatit is easy onpage75canhelpgurdeyou.Thegen- higherthan the running value,you
to takefor grantedtheessential rolethat eratormustproduceenoughpowerto shouldrelyon therunningwattage rat-
electricityplaysin our lives.Yeta pow- startandrun thetoolsandanyother ingwhenchoosing a generator. A gen-
er outagecanquicklyremindyou of electrical devicesyoupluginto it. The eratorwith morepowerthanyouneed
thatrole.At sucha time,a portableAC wattageratingslistedon thechartare will run more smoothlyfor longer
generator becomes an indispensable typical.Youshouldreferto theactual stretches
andrequirelessmaintenance.
accessory for yourhome,yourshop,or ratingof your tool,whichis usually Mostgenerators areequipped with
in a remotecabinwherepowerlinesdo printedon thetool body.Ifnot, you oneto four 120-volt
outlets.Manymod-
not reach. cancalculate theratingby multiplying elsalsohavea 240-voltoutletanda12-
AC,or alternating current)genera- thetool'samperage ratingby thevolt- voltDC outputfor charging batteries.
torstypicallyfeaturea gasoline motor age.(Forexample, a 3-amptool oper- Makesurethatanygeneratoryoubuy
that drivesan alternator.Modelsare atingon 120voltswouldhaveawattage is equippedwith an effectivemuffler.
availablewith motorsrangingfrom3 to ratingof 360.) Alsocheckthesizeof thefueltank.The
8 horsepower, producing500to 4000 Thewattageratingof a generator generatorshouldbeableto run for at
wattsof power. refersto itscontinuousrunningwattage. least90minuteson a frrll tank.
Portablegeneratorsare
a handysourceof elec-
tricity duringpower out-
agesor in locationswhere
a conventional electrical
supplyis unavailable.
Ratedat 3500watts,this
modelis ableto drivevir-
tually any electricwork-
shoptoolor appliance.
74
SHOPACCESSORIES
Choosing a generator
with
POWER
TYPICAT WATTAGE
TOOL RATINGS a suitable
waftage rating
All electric
toolsrequiremorepower to
Tool Watts(Start-up) Watts(Running) startupthanforcontinuous running. The
(%-hp)
Aircompressor 4000 2000 chartat leftgivestypicalpowerrequire-
Tablesaw(10") 4000 1500 mentsfora number of tools.When select-
2500 1200 inga generator,makesureits wattage rat-
Sabersaw
ingis higherthanthestart-up wattage
saw(7%")
Circular 2500 1200 of yourmostpowerful tool.Adda safety
saw(6%")
Circular 2200 1000 margin of about 20 percent to the com-
Beltsander 1500 600 binedrunning wattage of all toolsyou
r200 will plug intothedevice and operate at
('t-hp)
Benchgrinder 1500
thesametime.
Orbitalsander 900 360
Router 900 700
drill(%")
Electric 800 600
drill(%")
Electric 600 350
Powerplane 600 450
drill(%")
Electric 500 250
Random-orbit
sander 500 360
HVLPspraysystem 400 240
TIPS
SAFETY
GENERATOR
. Readyourowner'smanualcarefully e Keepgasandoilonlyin containers . Never wirethegeneratorto theelectri-
a generatot.
beforeoperating designed forfuelstorage
specifically calsystem of yourhomeor shopin an
andclearly
markedFUEL.Keepthe attemptto provide powerduringan out-
o Neverruna generator
indoors;likeany awayfromsources
containers of heat age.Thispractice, knownas"backfeed-
internal engine,it produces
combustion andflames. ing,"is unlav'rful
in someareas, asit
carbonmonoxidefumesthataredeadly poses a riskto anyoneworking onthe
space.
in a confined r Checktheengineoil leveleachtime electricalsystem.
yourefuelthegenerator.
. Donotfill thegenerator's
fueltank . Keepyourhandsandfaceawayfrom
whilethemotoris runningor hot. . Checkthegenerator'sfuelIinesand whenever
carburetor theaircleanerhas
connections if younoticeany
regularly; beenremoved; a suddenbackfire--or
r Addfuelto thefueltankat least10 feet leakage,turnthemachine off andhave of fuelin anengine
explosion cylinder-
fromyourworkareaandanysources of beforeresuming
it serviced operations. cancauseserious burns.
heator flames.Donotfill thetankrightto
thebrim;thefuelcanexpand ahdoverflow. o Neverusea generator witha faulty . Donottouchthegenerator engineor
or damaged exhaust system exhaust pipingwhilethemachine is run-
. Donotsmoke whilefillingthefueltank. ningor immediatelyafterturningit off;
. Groundthegenerator followingthe thesepartscanbecome veryhot.Allow
o Cleanupanygasoroilspillsimmedi- manufacturer's thiswill
instructions; thegeneratorto coolbeforeperforming
ately,wipinguptheareawitha clean divertanystraycurrentfroma shottcir- anymatnlenance.
cloth,or soakingit up withan absorbent cuitto ground, reducing theriskof elec-
material suchascatlitterorvermiculite; tricalshock. r Turnthegenerator
off beforeperforming
avoidusingsawdust, whichiscom- anymaintenanceon it; alsodisconnect
bustible.Placefuel-soaked ragsin sealed . Donotconnect a 240-volttoolor appli- thesparkplugwireandthebattery to pre-
metalcontainers anddispose of themfol- anceto a 120-voltreceptacle. startupof themotor.
ventaccidental
lowinglocalenvironmental regulations.
. Donotoverload thegenerator by plug- r Generatoruseis regulated
byfederal
r Donotremoveanysafetyguards,cov- gingin powertoolsor applianceswith andstatelegislationin someareas;con-
ers,or screensfromthegenerator while higherwattageratingsthanthatof the tacttheappropriate in your
authorities
themachine isoperating. generar0r. community foranyapplicable laws.
7\
BENCHGRINDERS
DRESSING
A GRINDER
WHEEL
Truing thewheel
Totruea grinder wheelandsquareits
edges,usea star-wheel dresser or a dia-
mond-point dresser.Forthestar-wheel
dresser, movethegrinder's toolrestaway
fromthewheel.Withtheguardin posi-
tion,switchonthegrinder andbuttthe
tip of thedresser againstthewheel. Then,
withyourindexfingerresting against the
toolrest,movethe dresser side-to-side
across the wheel(right).Forthediamond-
pointdresser, holdthe devicebetween
theindex fingerandthumbof onehand,
set it on thetoolrest,andadvance it
toward thewheeluntilyourindexfinger
contacts thetoolrest(inset).Slidethetip
of thedresser acrossthewheel,pressing
lightlywhilekeeping yourf ingeronthe
toolrest.Foreitherdresser, continue until
theedgesof thewheelaresquare andyou
haveexoosed freshabrasive.
76
SHOPACCESSORIES
U^
GOUGE.SHARPENING JIG
Thejig shownat rightguarantees
Tool9upport
thatthetip of a gouge willcontact (back)'1"x2"x2'1"
thewheelof yourgrinder at thecor- (bottom)%"x1%"x2'/o"
rectangleto restore the bevelonthe Ouide
c u t t i n ge d g eT. h ed i m e n s i o ni ns (rop)%"x1%"x9"
the illustration will accommodate (atdee)'h"x1u/a"x9"
mosrgouges.
Cutthe baseandthe guidefrom
%-inch plywood. Screwtheguide
together andfastenit to the base
withscrews countersunk fromunder-
neath.Makesuretheopening cre-
atedbytheguideis largeenough to
allowthearmto slidethrough freely.
Cutthe armfrom1-by-2stock
andthetoolsupport from%-inch
plywood. Screwthetwopartsof the
toolsupporttogether, thenfasten
77
DUSTCOLLECTION
DESIGNING
A SHOPF()REFFICIENT
DUSTC()LTECTION
Layingouta shop
Thediagram at rightillustraies a typicalhomeshop
layout. Thepower toolsanddustcollection system
havebeenarranged formaximum dustcollection effi-
ciency. Withtheexception of thetablesaw,allthe
machines aresituated ontheperimeter oftheworkarea.
Theducting forthecentral dustcollection system runs
close to thewalls.Despite requiring a relatively long
m a i nl i n et,h i sd e s i ganl l o wfso rs h o rbt r a n c lhi n e s
andminimal directional changes-both efficient
arrangements. Thespace takenup bythedustcollec-
tionsystem is minimized byplacing thecollector out
ofthewayin a corner of theshop.Theplaner, proba-
blythe heaviest dustproducer, is positioned closest
to thecollector to reduce strainonthesvstem.
78
SHOPACCESSORIES
Tsfor branchconnections, wherever canalsoeffectively join plasticpipe,but requirementsof the heaviestdust col-
possible.A blastgateshouldbelocated it is unsightlyandwill decayovertime. lection taskvour svstemmust handle.
ateachbranchoutletto sealductswhen A high-quality silicone sealantisproba- This usually'willbi the sum of system
theyarenotbeingused,therebyincreas- blyabetterchoice for a permanent sys- lossesandthe air volumedemandedby
ing air flow to the machinein use. tem.Toensuresmoothair flow metal the machine most distant from the
Hoods,whethercommercially madeor ductsshouldbejoinedwithrivets,rather collector.Purchasea collector with
shop-built,shouldbepositioned asclose thanscrews or bolts. slightlymore capacity.Systemlosses
aspossible to thesourceof thedust. Onceyouhavecompleted thelayout are causedby such inefficienciesas
Youhavea choiceof methodsfor ofyoursystem andselected thetypeof bendsin the line, corrugatedducting,
connecting ductwork.Manyductsand ductyouwill use,it is timeto calculate leaks, and hoods without flanges.
fittingscanbefrictionfit andsecured yourdustcollection needsandselecta Usethechartsandinformationon page
with adjustable hoseclamps. Ducttape collector.Thisinvolves determining the 80 to sizeand selecta collector.
(lFA DUST
ETEMENTS COTTECTION
SYSTEM
Reduaer
Connecta duct of different
Metal duct diametere; alao used to
)tanda rd duat aollection increaeeauction in oyatem or
ioin a branah line to hood Corrugated fl exible hoae
pipe;availablein wideranqe
'of Kibbedplaatic hose uaed for ahort
diametera runs or to connect machineaf,o
main duct: smooth-aided rubber
or plaatic varietiea aloo available
Elaet' gate
?ipe fittin7 with
alidin7qate which Splice
ia openedor cloaed Forjoinin6 two ffi
to direat.duat col-
lection air flow to a
len4tha of duct \--J _ I'
partiaular machine Hoee alamp
9lotted metal band T aonneator
and acrew ueed to Connectetwo ducte
join two len4the of at 90" anqle
duct or hoae
PVCpipe
Plastic pipe for emall ehop
duat, collection system6;
availablein different diame-
tere and wall thiakneasea
Hood
Duat- capt uri n4 d evicepoai'
tioned cloee to aource and
connected to branch line
Elbow
Att,acheeto duc-t'
to chan1edirec-
!
Y conneator
Joina two ducte at
3Ooor 45" an6le
tion of line
Adaptere
Joina non-atandard hose
and duat to atandard dust
colleotion hoae:also uaed
to abtach collection hoae Floor aweep
to facto ry- ineta lled porte Attached to branch duct of central
on etationarv maohines eyetem to vacuumduat off ahop floor
79
SHOPACCESSORIES
CATCUTATING
DUST NEEDS
C(|LTECTI(|N
Determining staticpressure loss
Dustcollectors areratedbytheirabilityto (1)EOU|VAIEI{T
TENGTH
0FSYSTEM
EIEMENTS
movea certainnumberof cubicfeetof air per Ductor Fifting Equivalent
Lengh,in Feet
minute(cfm)against a specific staticpres-
Smooth-wall pipe Actuallength
sure.Themostimportant variable to keepin
mindwhenchoosing a dustcollector foryour pipeor hose
Corrugated 1.5x actuallen$h
shopis staticpressure loss,whichis a mea- Unflanged
duct,hose,or hoodconnections 10
sureof thefrictionairencounters asit passes 90" sharpelbow 20
through a duct.Thelonger theducting andthe
90ocurvedelbow 10
morenumerous thesystemrosses, thegreater
the staticDressure loss.To determine the 90" hosebend 10
sizeof collector youneed,calculate thestatic 45' curved
elbow 5
pressure lossforthe heaviest collection task 45" hosebend 5
in theshop.In thediagram on page78, it is
Sidelegof 90" T 20
thejointer.Thefollowing calculations are
based on it. Foryourownshop,youmayneed Sidelegof 45" Y 5
to dothecalculations for a fewmachines-
thosefarthest fromthecollector andat the
endof branchlines-andchoose a collector
based onthehighest resultyouobtain. (2)AIREXHAUST
V0LUME
RE0UIREMENTS
FOR
MACHINES
Startwithchart1 (right,top)to calculate Machine CubicFeetperMinute(CFM)
theequivalent lengthof theductingrunning
Jointer
@-r2') 300
to the machine. In ourexample, thereare
45 straightfeetof smooth4-inch-diameter (upto 12")
Discsander 300
ductandtwo90'curvedelbows. Theequiv- Vertical (upto 6")
beltsander 350
alentlengththerefore is:45 feet+ 20 feet= (up
Bandsaw to 2" blade) 400
65 feet.Thenusechart2(middle) to deter-
Tablesaw(upto 16") 300
mrnerneexnausr reourremenrs rncTmoTrne
machine; forthejointer,it is 300 cfm. Radialarmsaw 350
Finally,usechart3 (bottom)to determine Planer(upto 20") 400
staticpressure lossfordustcollection at the Shaper (%"spindle) 300
machine. choose fromeither thethirdorfourth
Shaper(1"spindle) 500
columnof thechartdepending on whether
the machine is joinedto a main-line duct Lathe 500
(3500feetperminuteof airvelocity, orfpm) Floorsweep 350
ora branch line(4000fpm).Inthisexample, Drillpress 3OO
a 300-cfmmachine connected to a 4-inch-
Jigsaw 300
diameter mainlinehasa staticoressure loss
of .05 inchesperfoot.Thusthestaticpres-
surelossfor thisjointeris: 65 feetx .05
inches/foot = 3.25 inches. Addtwoinches
for unmeasured losseslikeair leaksandthe (3)STATIC
PRESSURE
L(ISS AT3500Al{D21000
PERF00T0FDUCT FPM
valuerisesto 5.25 inches. Theshopon page CFM Ductdiameter 3500 fpm 4000 fpm
78 wouldneeda collector witha 300 cfm
300 4' '05 in/ft '07 in/ft
ratingat 5.25 inchesof staticpressure. A
system20 percentlargerwouldallowfor 350 4u '05 in/ft .07 in/ft
futureexpansion. 400 4' ,05 in/ft .06 in/ft
500 5u .04 in/ft .06 in/ft
80
SHOPACCESSORIES
DUSTCOLTECTORS
81
SHOPACCESSORIES
DUSTHOODS
Adapter
CollecLion
hoae
82
SHOPACCESSORIES
Connecting a collection
hoodto a router table
fitlrlllllllllttlllllllllllllllllllllllllllfiIllllllllllllllllll]I1
llll A hoodattached
tablewillcollect
to thefenceof a router
mostof thedustpro-
ducedbythetool.Cutthehoodfrom
1HO?TI? l/z-inch plywood, sizingit sothesides
hugtheoutside edges of thefence's
Adapt inq st andard sheet' supportbrackets. Thebottomedgeof
metal ducts as dust,hoode restonthetable;
thebackflange should
Commercial eheet-metal duc|'scan bemodified
s i t o n t h et o p
t h et o pf l a n g es h o u l d
Lo eerveae efficienthoodetor your ohop'e
duet,collecLionoyofem.Someexampleaare edgeof thefence.Before assembling the
shownhere.UeeLin sniosI'o cuNNheducLt'o pieces of thehood,cuta holethrough
a ehapethaNouit6 the tool aI hand.TheducN the backforthecollection hose.Also
shoulAfi1;enuqlyaroundthe chipdiocharqe Vort boreholes forscrews through thesides
or dusNopoutof the machine. )crew iL in Vlace andscrewangleironsto the backso
wibheheet melal screwe. thattheirinside edges areflushwiththe
opening forthehose.Screw the hood
together, thenfit thecollection hose
in theback.Usea hoseclampto secure
thehoseto theangleironsandposition
thehoodonthefencebbove).Screwthe
sidesof thehoodto thefencebrackets.
B3
SHOPACCESSORIES
84
DUSTCOLLECTION
PORTABLE
system may drawbacls. Shopvacuums aredesigned
I centraldustcollection
A soundlikeoverkillto thecraftsman to movea smallvolumeof air at high
with asmallhomeshop.Althoughsuch velocitythrougha small-diameter hose.
systems aregenerallymore efficientthan Dust collectors, on the otherhand,
independent collectors, theycanbecost- movea largeamountof air at a lower
ly andconsume considerable space. If speed. A shopvacuum dusthood,there-
yourshop area is restricted, and only fore,shouldbepositioned verycloseto
onemachine will beoperated atatime, thetool.Largerchipswill tendto clog
consider a portable dust collector. vacuumhoses, requiringfrequentclean-
Manytypesof portabledustcollec- ing.And,vacuums powered by univer-
tors are available. Most are strong salmotorstendto wearout quickly.
enoughto power a central system, yet Modelswith induction-type electric
light enoughto be toted around the motorswill lastlonger,but costmore
shop.Ifyou areplanningto setup a thana portabledustcollectorof the
portablecollectionsystem, shoparound sameDower.
for themosttransportable collector that If thereisnodustcollectionsystem-
canhandleyourneeds. Keep in mind Althoughyou canhookup a bandsmu portableor central-in yourshop,try
thatyoumaywantto expandto a cen- system,
to a centraldustcollection themethods describedstartingonpage
tral system later. anothersolutionis to attachit to a 86to controlairbornedust.These meth-
Manyhomewoodworkers will find portableshopvacuum.Thevacuum's odsarealsoeffective supplements to
thatashopvacuum,although ideal, not hosecanoftenbeslippedaroundan collectors that suckup a majorityof
candoasatisfactory jobmostof thetime existingporton themachineusing shopdust,but stillleavesomeparticles
if you arewillingto work aroundthe a simplecommercial reducer. floatingin theair.
DUST
PORTABLE
ANAUXILIARY SYSTEM
C(ILLECTION
Expandinga dustcollecto/scapacity
Youcanmorethandoublethecapacity
of yourportable dustcollector or shop
vacuum byattaching a 55-gallon drumor
a largeplasticbarrelasa mid-stage col-
lector.Installplasticintakeandexhaust
oortsonthedrumasshownat leftand
mounta hoseto the intakeporton the
drumto collect wooddustandchips.The
90" elbowonthe intakeportwillcreatea
cyclone effectinsidethe barrel, forcing
chipsandheavier sawdust against the
wallsof the barrel.Lighter dustwill be
drawnthrough theexhaust portintothe
shopvacuum or dustcollector. Foreasy
assembly anddisassembly, usepipefit-
tingsthatforma frictionfit withthe hose
fromyourvacuum or collector.
85
SHOPACCESSORIES
CONTROLLING
AIRBORNE
DUST
settinguppositive-pressure ventilation
Tomaintain clearairin a shopwhenyou
aregenerating a greatdealof airborne dust
or chemical fumes,setupa positive-pres-
sureventilation (PPV) system. Openall the
windows in theshopandposition a fanout-
sidethedoorasshownat rightsothatthe
airflowit produces will envelop thedoor-
way.Thestream of airwillfollowthepath
of leastresistance-through thedoorand
shop,andoutthewindows, clearing air-
bornedustandfumesquickly. PPVhas
somelimitations, however. Thesystem will
onlyfunction properly if thewindow open-
ingsarelargeenough to handle a sufficient
volume of air.Also,therestof yourhome
mustbewellsealed off fromtheshoo.A
morepermanent alternative to PPVcanbe
fashioned bymounting anexplosion-proof
exhaust fanin a shopwindow. Setupto
pullairoutof theroom,thefanwillcre-
ate negative pressure, expelling f umes
anddustin larger volumes thanis possi-
blewithPPV.
filllllltlt'lltllt'lll-llll
tIIiltt'Ixl
IItlltll|l'lllt
lllfil'fiI'l||l
1HO?TI?
Vaauumeareeningramp
Forcleaninqdust off Xheohopfloor,builda wedqe-
ehapedecreenin7
aL^a^-) zrqa^qia^
ramVfroml/z-inchplywood.
-^*^ t-^^ 1/^ i--r ^1.,,,,^^-J
86
SHOPACCESSORIES
shopair
Filtering
Another quickandeasymethod of rtd-
l|Ilillllllllllllll lllilllllllllllllllllllllllllllllllllllllltllllll]l} dingtheshopof airborne dustusesa fur-
nacefilteronthebackof a podable room
fan(above). Whenthefanisturnedon,
1HO?Tt? suction willholdthefilterin placeand
draw dust outof theair.Thedustwill
?anty hoee ahop vacuum ftlt'er remain on thefilter,whichcanthenbe
Uoedpanty hoeecan oerveao an brushed off outsideorvacuumed.
inexpeneive lo replace-
alt'ernaLive
ableshopvacuumdust'filNero.Fit
the waieLbandaroundIhe loam
filf,ersleeveon Lhe undereideof
lhe molor houein4of the vacuum
and knotIhe lege.)lide the ret'ain-
inq rinqaroundIhe panty hoset'o
aecureiNin place.
87
STORAGE,
n'd'ub'laccumula'fesliffi#
rate:Lumber
astonishing
saws,saw
planes,
blades,
clamps,
drills
filt
chisels, frfi*[T"i!,{if.#i-.
h * d * d p o * . ' t o o l s t h a t m u s t b e c o m m e r c i a l s t o r a g e d e v i c e s ' o n t h e . l
89
STORINGWOOD
p roperlystoredlumberandplyr,vood therackon page92,whichallowsyou to
I. arenotonlykeptoutofthewaybut storeboardsboth horizontallyandver-
straightand dry, too. For most shops, tically.AvoidusingZ-shapedbrackets;
this involvesstoringlumber in racls that theywastetoo muchspace.
hold the wood off the floor. Wood Thetypicalshopcanstockhundreds
shrinksand expandsaccordingto the of poundsof lumbet so it is crucialto
amount of humidity to which it is anchoryour rack firmly-to at least
exposed.A wet floor canwarp lumber everysecondwall studor floor joist.
and delaminatesomeplywoods.The Make the most of spacesthat you
lumberracksfeaturedin thissectionare would not ordinarilyconsiderasprime
easyand inexpensiveto build; you storage areas.Ifyour ceilingis unfin-
shouldbe ableto find a suitabledesign ished,nail furring stripsacrossthejoists
and adaptit to your needs. for handyshelvingto storeshort stock
Ifyou havethe space,you cansetup and dowels.
an end-loadinglumber rackliketheone
shownon page91.Sucha systemis rel- Everyitem in a workshopdemands
ativelyeasyto constructbut youwill need its own storagemethod.Thedowel
a walltwicethelengh of yourlumberto rackat left,builtfrom 3/t-inchply-
allowfor loadingandunloading.If space wood,1-by-4stockand6-inch-diam-
in your shopis at a premium,considera etercardboardtubes,sortsdffirent
front-loadingracklike the one shown sizesof dowelswhiletakingup a min-
below.If versatilityis needed,examine imum offloor space.
A LUMBER
RACK
Storing planks andboards
Thestorage rackat rightfeatures vertical
supports screwed to wallstuds.Cutfrom
2-by-4stock,thesupports buttress shop- o
madewoodbrackets, whichholdupthe
lumber. Youwillneedonesupport at each o
e n do f t h er a c kw
, i t ha n a d d i t i o noanl e
every 32 inches alongthewall.Afterbolt- o
ingthesupports to thestuds,prepare the
brackets bycuttingthesidesfrom%-inch
plywood andthemiddleshelfpiecefrom
2-by-4stock1% inches shorter thanthe
brackets. Anglethetopedgeof thesides
byabout5'so the o
brackets willtilt up
slightly(inset)and o
prevent thelumber
fromfalling offthe o
rack.Screw themid-
dleshelfpiece to
thesides, thenscrew
thebracket io the
vertical supports.
90
STORAGE
CUTflNO LI5T
Rails (9): 11/2"x 31/2"x 36"
'l
?tilea (6): 1/2"x 31/2"x 96"
Croeebars (2)t 3,/+"x 3t/2" x 1OB"
Trough
- back 1"x B" x 1OB"
- bottomt 1"x 10" x 1OB"
- lip: 1"x 3" x 1OB"
Hinged bar: 3/c"x 3 1/2"x 65"
9l
STORAGE
ADJUSTABTE
LUMBER
RACKS
Building
anadjustable piperack
Therackshown above, madeof 4-by-4stockandsteelpipe,is thecrosspieces (inset), making sureall thecrosspieces in
attachedto wallstuds.Thesteel pipesshouldbe roughly 24 thesamehorizontal rowwillbeat thesamelevel.Boreholes
incheslongand% inchin diameter. Theycanbe inserted into i n t ot h eu p r i g h tasn dc r o s s p i e cf eo srt h ep i p e sd; r i l lt h e
anyof the holesdrilledintothe verticalsupports or cross- holes3 inchesdeepand6 inches apart,angling themby
pieces,allowing
lumber to bepiledonthepipesorstacked on about5' sothepipes willtilt up slightly. Boltthe uprights
endbetween them.Beginbycuttingtheuprights to lengthand to thestuds,thencut the crosspieces to lengthandtap
markeachpointon themwhereyouwantto locatea cross- t h e mi n b e t w e etnh e u p r i g h twsi t ha m a l l e tF. i xt h e mi n
piece.Cutdadoes in thesidesof theuprights
to accommodate placewithglueor bydrivingin screws at anangle.
92
STORAGE
93
STORINGTOOLSAND SUPPLIES
((
[ placefor everythingand every-
A thing in its place."That time-
worn adageis especially appropriatefor
the homeworkshop.From shelvesand
racksto tool chestsand partitioned
drawers,many deviceswill eliminate
clutterwhilekeepingtoolsand supplies
easilyaccessible. A few methodsare
shownin the followingpages.
For certaintools,particularlyitems
that arevaluableor dangerousenoughto
be out of the reachof children,wall-
mountedboxeslike thoseshownbelow
areideal.For a moretraditionalsystem
ofenclosedstorage, you canbuild a tool
cabinetor cupboardin the shop (page
96).Butnot everystoragedeviceneeds
Shelvesarean idealtoolstorageoption.Thisshop-built to be elaborate. As shownon pagel0l,
unit featuresgroovesand cleatscustom-cutto hanga suspendinga tool from a fastenerdri-
panoplyof took in full viewoyera workbench. veninto a wall canwork just fine.
WALL
STORAGE
Installing portable cabinets
Theboxat rightcanbehungsecure-
ly on a shopwallandeasilymovedif
necessary. Buildit from3Z-inch ply-
woodwitha hinged top.To hangthe
cabinet onthewall,cuta 45' angle
beveldownthemiddleof a 1-by-6,
thencrosscut thetwopieces slightly
lessthanthewidthof thebox.Screw
oneof theoieces to thewallasa bat-
ten,withthebevelpointing upand
f a c i n gt h ew a l l ;a n c h oar s m a n y
of thefasteners as oossible in wall
studs.Screwthe otheroieceto the
backof the boxwith its f lat edge
buttingagainst the lip andthebevel
pointing downandfacingthe back. SIDEVIEW
Thetwopiecesinterlock whenthe
boxis hungon thewall(inset).
Wall
tsalten
94
STORAGE
Adaptingdrawers to holdsmallitems
Theaddition of somesimpletrayscanmakedrawers much
moreefficient storage forsmallitemslike
units,especially
andwashers,
screws whichcanbeeasilylost.Thejarorganizer
shownabovekeepsdifferent-sized jarsin order.Theshelfrais-
esthesmaller jarsto makethemmoreaccessible. Beginby jarsslightlylargerthantheiractual diameters.Holdthedivider
collecting thejars:Findsomelarger onesnearly thesame andtheshelfin placewitha pairof plywood supports(above).
heightasthedrawer andsomesmaller onesabouthalfthat Another usefuldrawerorganizer is theslidingtray(inseil.
fhe
Makethedivider
height. bytrimming ply-
a pieceof 7z-inch trayis a basicboxthatfits insidethedrawer. Thedividersare
woodto f it insidethedrawer. Layoutthejarsontheplywood notched togetherandthensecured nails.Attach
withfinishing
andmarktheiroositions. Usea holesawto cut holesforthe a pairof slidesto thedrawer sidesto support thetray.
95
STORAGE
Leathereaw etrap
96
STORAGE
97
STORAGE
o o o o o o o o o o
o o o o o o o o o
o o o o o o o o o o
o o o o o o o o o a
Frame o o o o o o o o o o
o o o o o o o o o o
o o o
11 o o o o
hinge
CUTTINGLI9T
Frame
- Raile(2):3,/+"x21/2"x 48"
- Stilee (2):3/+"x21/2"x 24"
Cabinet
- Back:1/a" x 24" x 48"
- Top:3,/+"x 10"x 48"
- Eottom:3,/+"x 10"x 48"
- 1ides (2):3,/+"x 10"x 221,/2"
- Divider:3,/q"
x 10"x 221,/2"
- thelf 3/+"x 10"x 3O1/2"
Workbenah
- Top:3,/+"x 23 1,/+"
x 48"
- Eenchtoprail:3/+"x 4" x 48"
- Bencht'opatileo: (2):3/+"x 4" x 221/2"
- Hingebrace rails (2):3/+"x 31/2"x 461/2"
- Hingebrace stilea (2):3,/+"x 31/2"x 16"
- Lege(2): 11/2"x 31/2"x 34"
- Legrail: 11/2"
x 3 1/2"x 461/2"
9B
STORAGE
99
STORAGE
SAWSANDBLADES
STORING
Buildinga handsaw storagerack
Thehandsaw storage rackshownat left
saves spacebystoring sawsupright.The
handles fit on oieces of woodthesame
shape astheholeinthehandle. Theblocks
aremounted to a holderthatslidesin
grooves cut in thetopandbottomof the
box.Cutthepartsof theboxto size,then
equipyourtablesawwitha %-inchdado
blade.Toaccommodate theoutsidesaw
holders, cut %-inch-deep grooves 2%
inches fromeachendof thetopandbot-
tom.Sawanother groove oneachpiece
centered between thefirsttwoforthethird
sawholder. Screw thetopandbottomto
thesides, thentackthebackin place.
Baak
1/+"x 9" x 29 3/+u Trace theoutline of theholein eachsaw
handle ona blockof woodandcut outthe
piece. Glueandscrewit to thesawhold-
er,thenscrewa pivoting pieceof woodto
thetooof the blockto serve asa turnbuck-
lethatwillkeepthesawin placewhenit
is beingstored. Usea sabersawor a band
5aw holder sawto cut handles in theholdersto make
1/+"x10"x291/2" it easier
to slidethesawsin andoutof the
box.Place themat staggered heightsso
theydo notinterfere witheachother.The
dimensions shown will makea boxthat
canholdsawthreesaws.lf youwantto
storemoresaws,simplymakethetopand
bottomwiderandspaceadditional
grooves 1% inches apart.
3/+"x8"x29"
Turnbuakle
re
.J- /
I00
STORAGE
A HANDSAW HOTDER
Builda wall-mounted rackfor hand-
sawswith a fewwoodscraps, dow-
eling,andsomerubberhose.Cut
the basetromr/z-inchplywood
andthedividers from4-by-4stock;
thedividers should be 10 inches
long.Cuta taperat theendof each
4-by-4,asshownat right.Screwa
2-by4alongone edgeof the base,
thenscrewthedividers in place,
leavingaVz-inchgapbetween
them.Thestoppers arecutfrom4-
inchlengthsof l/z-inchdoweland
slightlylargerrubberhose;use
hosewithridgesratherthansmooth
gardenhose.Slipa sawintothe
rackfrombelow, thentugdownon
thehandle. Thestopper willpinch
the bladein place.Markthedow-
el'sposition
andscrewit to the base.
101
STORAGE
r02
STORAGE
TOOLS
KEEPING ORGANIZED
Storinghandtools
Thetooltrayshownabovekeepsdifferent toolsapartandsim-
ilaronestogether,helping to protectthem while making a need-
ed itemeasyto locate. Thetray has the additional advantage of
being suspended fromoverhead joistsso thatit takesup no valu-
ableworkspace. Startbybolting two2-by-4s to joists,spacing
themto accommodate thetray.Cutoffthe bottom endsof the
Z-by-4s at a convenient height.Next,build the tray,cutting
thesidesfrom%-inchstock,andthebottom and dividers
the
from7+-inch plywood.Cutdadoes forthedividers according to
you
how wishto group your tools,thenscrewthesides together
andto thebottom. Gluethedividers tnthedadoes andscrew
thesidesto the 2-by-4s. Screwthe backto wallstuds,or,
usingleadanchors, to a concrete wall.lf youplanto install
thetrayat anangle, asshown, drivethescrews through wood
Addingtool-tray
dividers wedges placed between thetrayandthewall.
To protecttooledgesin storage
drawers,sawa 2-by-4to a
lengthequalto thespacebetween thedrawer sides.Thencut
dadoes acrossonesideof theboardto holdthetools-inthis
case,narrow dadoesto accommodate file blades(above).
103
STORAGE
t04
STORAGE
105
STORAGE
llllIIlllt'filt
IIltll'ffiIIllllllllilltfit'IllilIt
filtlllllltttlll
)HO? TI?
?toring alampein a oan
Atraeh canfilhedwitha ehoo-
madelid eeryel as a conveniertl
wayto sLoresmallbar or pipe
clampe.Cul a oieceof 1/z-inchplv-
wooAinto a ciicle oliqhtlyemaiti,
lhan the diameLer of lhe can'orim.
Thenscribea seriesof concenlric
circleson trheplywoodto helpyou
localethe holesfor the clampbare,
1Vacetrhe circlesaboutb inchee
apart and markpoinLeevery3 inch-
ee alonqlhem, Borea f-inch-diame-
ter holethrouqheachpoint, fit, the
pieceof plywoodin the can and drop
the clamoslhrouahlhe holes.
106
STORAGE
TWOWALIRACKS
FOR
CLAMPS
t07
STORAGE
ITEMS
SMALL
STORING
108
STORAGE
A SCRAPBOX
Usea scrapbox to keepfromclut-
teringthe shopfloorwithcut-offs,
shavings, andotherrefuse. The
designshownat leftcanbe built
quicklyfrom%-inchplywood; cast-
ersallowtheunit to berolledwhere
it is needed andmovedoutof the
waywhenit is not.Sawthesides
andbottomto a sizeappropriate to
yourneeds, thencut fourcorner
blocksfrom2-by-2stock.Screw
thefoursidestogether, drivingthe
screws intothecornerblocks. Turn
theboxoverandnailthebottomto
thecornerblocksandsides.Adda
liparound thetopto hidetheply-
woodedges. Finally,
screwcasters
to eachbottomcornerqnda pull
handleat oneend. f'{'
Somestoragedevices, particularly
thosedesigned for smallitems,are
lesstroubleto buy than to build.
Thesystemshownat leftfeatures
openplasticbinsthat canbelined
up or stacked. Thebinsaresus-
pendedfrom plasticstripsthat are
screwed to thewall.
109
::}tu
f" -itffi a
r <at
"-r
r l
. l
. :
+.""{hi*.
v'
n{;i4
w
.:.|
.::
' 1
l
H
b+
'--*}*
lre,.*
i3
q s
.,
"''airi+:r:,'Y,e-:
_' ffiSdg**ffft
.f,
WORKSreS
l1l
WORKTABLES
rt2
WORK SURFACES
Tabletop
%"x36"x60"
Brace
'l%"x 5%"x 12"
Front rail
'l
%"x 3%" x 60"
9ide rail
11/2"x3%"x36"
Leo
3%"x5%"x36"
113
WORKSURFACES
. , / % \- -
Erales %
'16"
1 1/2"x 31/2" x
31/2"x31/2"x25"
II4
WORKSURFACES
WORK
STOW.AWAY TABLES
Making andinstalling
a fold-down worktable
Thetableshownaboveincorporates a largeandsturdyworksur- attachthefrontrailsto thesiderails.Adda 45-inch-long top
face,butstill conservesspacebyfoldingup against a wallwhen rearrailandfastentwo l7-inch-longstretchers
between the rear
it is notin use.Thedimensions yielda work
in theillustration railandthetopfrontrailto provideaddedsupportfor thetop.
surface measuring 20 by48 inches. Cutthebracing, legs,rails, Next,screwthetopto the rails,countersinking the fasteners.
andstretchers from2-by-4stockandscrewthe bracingbetween Toallowthetableto folddownwithoutbinding, screwshimsto
thewallstuds(insef); thereshouldbeonebracefor everypairof theendsof the bottomsiderails,thenattachthetableto the
studsalongthetable'slength.Fasten thefrontlegsto theside bracing withbutthinges; usetwohinges foreachoutsidebrace,
railsusingcarriage boltsandlocknuts;placewashers on both Finally,driveaneyeboltintothebottom frontrailanda catch
sidesof the legs.Leave the boltsjustlooseenoughto allowthe intothewallto secure thetablewhenit is foldedup.
legsto pivotwhenthetableis foldedup.Tocomplete theframe,
115
WORKSURFACES
Suppoilinga fold-down
worksurfaceonsawhorses
Rather thanbuildinga framework for a fold-down
worksur-
face,youcanusea panelof %-inchplywood hingedto the
wallandsupported bysawhorses. Thesurfacecanbeof any
size.Beginbysettingthe panelontwosawhorses; oneedge
of thepanelshouldbeflushagainst thewall.Marka point
onthepanelat every wallstud,theninstallbutthinges,
screwing oneleafof eachhingeto a studandtheotherleaf
to thepanelat a pencilmark.Tosecure thepanelwhenit is
foldedup,screwa notched pieceof 2-by-4tothestudclos-
estto themiddleof thepanelat a heightthatwillallowthe
notched endto slipovertheedgeof the panel(inset).
116
WORKSURFACES
rt7
SAWHORSES
MAKING
SAWHORSES
Using commercial sawhorse brackets
A pairof metalsawhorse brackets can
helpyoutransform a coupleof 2-by-4s
and1-by-3s intoa sturdysawhorse, like
theoneshown at right.Sawthelegsand
crosspiece from2-by-4s, thencuta bevel
at the bottomof the legssotheywillsit
flatonthefloor.Fitthelegsintothebot-
tomof thebrackets, insert thecrosspiece
andspread thelegs;thebrackets willgrip
t h ec r o s s p i eacneds t a b i l i zt e
h eh o r s e .
Screw thebrackets to thelegsandcross-
piece.Foraddedstability, addbraces
anda stretcher. Thebraces arecutfrom
1-by-3s andscrewed to the legs,making
surethattheendsareflushwiththeout-
sidefacesof the legs.Forthestretcher,
cuta 1-by-3 to sizeandscrewit between
thebraces.
118
WORKSURFACES
119
WORK SURFACES
Assembling a frame-and-footsawhorse
Lightweight, compactf rame-and-foot
sawhorses liketheoneshownat leftcan
bebuiltfrom2-by-4stock.Startbycut-
tingthelegsto a suitable height, then
prepare themto jointo theotherpartsof
theunit:Cuttenons at thebottomends,
routthrough mortises halfway up the
faces, andsawl-inch-deep notches in
themiddle of thetopends.Cutthefeet
to lengthand,for addedstability, cut
recesses alongtheirbottomedges, Ieav-
inga 2-inchpadat eachend.Routmor-
tisesthrough themiddleof thefeetfor
thelegtenons.Next,sawthestretcher to
fit between the legsandcuttenons at
bothends.Cutthecrosspiece andsawa
notch4 inches fromeitherendthatwill
fit intothe notchat thetopof the legs.
Toreinforce themortise-and-tenon joints,
sawa pairof kerfsin theendof each
tenonandmakewedges to f it intothe
WEDGED kerts(inset). Tapthewedges in to expand
MORTISE- thetenonwhenthejointis assembled.
A1{D-TENON
JOINT
?addingsawhorses
To prevenla sawhorsefrom
marrinqyour work,coverils
croeeViecewilh a ebripof old
carpeN.Foldthe caroet over
theNopedqeoflhe cross-
pieceand ocrewit,to the
eidee.Fora smoolherour-
face,usean oldNowel or
blanket,ralherthan a i
.^r^^^ -c i
pieceof car?et.
r20
WORKSURFACES
r2r
WORK SURFACES
Top railo
3/o"x5%"x36"
(fl
W
half-lap joint.
Hingedcro66brace
3/^"x5%"x16"
a
IW
a\)
3A"x5%"x54"
I^
is longenough sowhenthehorselegs
sawhorses and
spread, thepianohingeis recessed handscrews as
between thetop rails.Sawthecross- neededNo ade-
bracein halfandconnect thepieces 6u??ort I
quabe,ly
witha piano hinge, making surethatthe Tne ?ECe, I
hingeis installed sothebrace willpivot
upwards. Then,fasten thecrossbrace to
bothsiderails, again usingpiano hinges.
r22
WORK SURFACES
Sawhorse panelsupportframe
Whensawing largepanels,proper
supportis needed to keep theendsof theS{ootlengths forthecrosshalf-lapjointsthat
theworkfrombuckling andbindingonthebladeasthecut is holdtheframetogether asshown. Thencuttwo4-inch-long
made,andto stopthecutofffromfallingawayasthecut is fin- blocksfrom2-by-4andsawa two-inch-deep notch,wide
ished.Toaccommodate thesecumbersome jobs,constructthis enough to fit over 7%-by-I%-inch deep notchesin themiddle
4-by-8-footsupport frame,whichis easilyheldin placewith of thecrosspieces of the sawhorses youplanto use. Screw
notched woodblocks.Cuttwo4-footandtwo8-footlengths theblocks to the bottom of the end pieces
and assemble and
of 2-by-4fortheendsandsidesof theframe.Cutdadoes six glueuptheframe.Secure theframeto thesawhorses bymat-
inchesfromtheendsof the4joot lensthsand18 inches from ingthenotches in theblocks withthosein thecrosspieces.
r23
WORKSURFACES
A VARIABLE.HEIGHT
WORK SURFACE
24"
Buildingthebox
Constructing a boxwithdifferent width,
II
lengh,andheight dimensions willpro- t
videyouwitha worksurface thatcanbe
usedatthreelevels. Thetoosurface of
theboxshownat right,forexample, can
beeither 24,30,or36 inches high.Saw
allthepieces from1-by-4stock,making
eightboards 36 incheslong,eightboards
23tlaincheslong,fourthatare30 inches
long,andfourmore29tl+incheslong.
Usinghalf-lap joints(lnset)assemble
theboards intosixframes: twomeasuring
30 by36 inches, twomeasuring 23Ll+ by
29tlqinches, andtwomore23% by36
inches.Oncetheframes areassembled, ?HO?TI?
cuta s/e-by-3/e-inchrabbet alongallfour A ehop-madeglue raak
edges of eachofthesixframes. Usea A rack madefrom two mef,-
lightweightwoodlikepineto makethe al-brackettyp e eawhoreee
boxeasilyportable. lf youchoose to Vrovideoa coinvenienNway
reinforcethejoinery at thecorners with to holdbar clampofor qlu-
screws,besureto countersink the inqup panele.To buildlhe
screwheads. ji6, replaceihe crooepiece
of your sawhorseswilh
oubstitutea thal are at
leaet ao lonqao lhe boards
t'o be6luedt o6ether.Notch
oneed6eof eachcrooopiece
at, 6-inch inlervalo,mAkinq
bhecuts wideenouqhto
holda bar clampenu6ly
and deepenou7hlohold
the barlevelwith the top
of t'he croeepiece.
r24
WORKSUPPORTS
Q upporlinglongplank andlargepan-
J elsasthevarefedacrossa sawtable
ranksasone of the mostcumbersome
taslsin thewoodworkingshop,Outfeed
tablescanbeattached to mostsaws, but
theytendto takeup a lot offloor space.
Oncesidesupportsareaddedto your
machine,your shopmay becomean
obstacle course.
Commercial rollerstands,liketheone
shownin the photoat right,makebet-
ter useof shopspace;they canalsobe
movedeasilyto wheretheyareneeded
andadjusted to whateverheightis suit-
able. The shop-made standsdescribed
below and orthe following pageshare
theadvantages ofthe store-bought vari- Thereareotherwork-support jigs A commercial rollerstandsupportsa
ety,with the additional benefitof being that
make life in
easier theshop.The vise boardbeingrippedon a radialarm
easyand inexpensive to build. They extension standshownonpage127,for saw.Thestandshouldtypicallybeset
canalsobe dismantled and stored when example,solvestheproblem of keeping l,/t-inchbelowthelevelof thesawtable
not needed. long boardsedge-up in a bench vise. andpositionedtwofeetfrom itsedge.
ROLLER
TW()SHOP.MADE STANDS
Setting upa temporary stand
Withonlya sawhorse, twoC clamps, and
a commercial roller,youcanmakea sim-
plerollerstandliketheoneshown at left.
Makea T-shaped mastfortherollerthat
i s l o n ge n o u gtho h o l di t a t a s u i t a b l e
height. Screw theroller to thehorizontal
partof themast.Adda brace to theside
of thehorse forclamping themastin
place:Cuta I-by-4to spanthelegs
between thesawhorse bracket andthe
original braceandscrewit to thelegs.
Cuta 1-by-2 to spanthetwobraces and
screwit in placeasa vertical guidefor
themast.Tosecure therollerstandto
thesawhorse, clampthemastto the
braces, making sureit isf lushagainst
theguide.
r25
WORKSURFACES
Buildinganadjustable rollerstand
To buildtherollerstandshown at right,
startbyconstructing theframeforthe
roller,
cutting thefourpieces from1-by-4
stock.Gluetheframetogether withbutt
joints,adding screws to reinforce thecon-
nections.Thenborea holeinthemiddle
of eachsideof theframefor a t/t-inch-
diameter carriage bolt.Locate thehole
3 inches fromthebottomof theframe.
Inserttheboltsfromtheinside of the
frameandscrew therollerto thetoo.As
/^ rnaaniera
wellasthecommercial rollershown, two 3/+"x51/z"x19"
variations thatpermityouto feedthe
workpiece fromanydirection areshown
below. Cuttheremaining pieces of the
standfrom1-by-6stock,referring to the
dimensions provided,thenroutar/q-inch-
wideslotdownthe middleof thetwo
uprights; theslotshouldbeabout14
incheslong.Screw thecrosspiece to the
uprights,aligning thetopof thepiece
withthe bottomof theslot.Fasten the
uprightsandrailsto thefeet.Toguide
therollerframe, nail1-by-1 cleats to the
uprightsaboull/qinchin fromtheedges.
Tosetupthestand,position theroller
framebetween theuprights, fittingthe
carriageboltsintotheslots.Slipwashers
ontheboltsandtightenthewingnutsto
settheheishtof theroller.
Plate-mounted aaatere
t26
WORKSURFACES
STAND
A VISEEXTENSIOI{
Making andusingthestand
Alsoknownasa benchslave,a viseextension standis usedto otherfoot.Gluethetwofeettogether. Oncetheadhesive is dry,
support the freeend of a long board clamped in the shoulder screw the upright to the feet.Cut the support pieceand swivel
viseof a workbench, Referto thedimensions in the illustration bars,anglingthetopof thesupportpieceabout10" (inset).To
for a stand that workswell with most workbenches. jointhesupport pieceto theswivelbars,boreholesfor %-inch-
To build the stand,cut the uprightto length and, starting5 diameter dowels throughthe pieceandnearthe endsof the
inches from the bottom, saw angled notches at2L/z-inch inler- bars, and slipthe dowels intotheholes; gluethemin place.To
valsalong its Cut
length. the notches about 1 inch long and r/z use the stand, insert the dowel at the top endof the swivelbars
inchwide. Then saw the feet to length and cut recesses along in the appropriate slot in the uprightfor the heightyouneed
theirbottom edges.Join the feet with a cross lap joint:Cut a and propyour workpiece on thesupport piece.
lap in thetop edgeof onefootandin the bottomedgeof the
t27
WORKSURFACES
LARGE
CUTTING (lNTHEBAND
PANELS SAW
Making andusingthejig
Formaking circularcutsoutof largepanels onthebandsaw,use sinkthefasteners. settingupthejig, markthecenterand
Before
a jig liketheoneshown above. Buildthejigfrom3/q-inch
plywood, circumference of thecircleontheworkpiece. Thencut fromthe
cuttingthepieces sothetopof thejig is levelwiththesawtable edgeof thepieceto themarked circumferenceandbackto the
whenthefeetarescrewed or clamped to a worktable.Before edge,creating a startingpointforthecircularcut,Nowsetupthe
assembling thejig, drivea IV+-inch-longscrewasa pivotpoint jig:Attachit to a tableandplacetheworkpiece onthejig sothe
through thecenterof thetoppiecesothetip of thescrewpro- marked centerof thecirclecontacts thepivotpoint.Position
the
jectsfromthesurfacebyaboutVzinch(inset).Thenscrewthe tablesothebladebuttsagainst themarked circleandthe pivot
topandfeetto thesidesof thejig, andattachthetriangular- pointisaligned withthecenter of thebladeandthemachine's
shaped supportbrackets to thetopandsides;besureto counter- centerline.Cutthecirclebyrotating theworkpiece intotheblade.
t28
EXTENSIONTABLES
Q tationarymachines liketablesaws,
J bandsaws,anddrill presses come
fromthemanufacturer equipped with
tablesthatareadequate for mostrou-
tine ooerations. But therearesome
tasls-crosscutting longplanlsor pan-
elson thetablesaw,performing long
cutson thebandsaw,andsmoothing
largepieces witha sanding drumonthe
drill press-thatcanbe awkwardor
evendangerous to attemptwithout
extending thesizeof themachine's table.
Often,thesolutioncreates a newprob-
lem,however, because increasing the
sizeof a stationarymachine with aper-
manentadditioncancrowdeventhe
roomiestworkshop.
Thefollowingpages illustrateavari-
ety of devicesfor extendingthework
areaof woodworking machines. Al-
thougheasyto build anduse,eachjig
isdesigned to beremoved or foldedout
of theway.
An extensiontablegreatlysimpli-
fiesthetaskof crosscuttingwide
panelson thetablesaw.Thiscom-
mercialmodelmorethan doubles
1HO?TI? thesawtable'ssurfacearea.It also
featuresa speciallydesignedrip
Double-dutyworkNable fencethat canbemovedto any
To qet maximumueefrom positionacrossthetable.
lhe worktablein your ohop,
buildit oo the too ie althe
oame heiqht,or eli7hr,lylower
than lhe levelof your table
oaw.lnadditrion bo beinq
a handyworkeufiace
tor light jobo,the
lable can butt
againotthe
saw lable to
eervea5 an
outfeedoup'
port.lf neaee'
oary,modify
the iableto
male liqhtly with you?eaw
by cutlinq a nolch in the
top to clearthe blade7uard
or' oth er obsl,r ucIi ons.
r29
WORKSURFACES
EXTENSION
TABTES
Buildinganextensiontablefora radialarmsaw
Madeentirelyfrom2-by-4and 1-by-3stock,the extension the legs,Miterthe endsof the bracesandscrewthemin
tableshownabovecanbe attached to theoutfeed or infeed place.Tofastentheextension tableto thesawtableshown,
endsof a radialarmsawtable.Using2-by-4s, cut the legs, cut twowoodstripsandscrewoneendof eachpieceto the
rails,andstretchersto suitthedimensions of yoursaw,mak- underside of the insiderailstretcher,Settheextension table
ingthe lengthof the legsequalto the distancebetween the flushagainst thesawtableandfastentheotherendof the
topof thesawtableandtheshopfloor,lessthethickness of stripsto the underside of thetable,usingshimsor spacers
the stretchers.
Attachthe railstretcherssothattheirtopsare asneeded. lf youpreferto spanthetable'srailswithrollers
flushwiththe rail'stopedges. Attachthe legstretchers to (inset),ratherthanwoodstretchers, cut the rail stretchers
the legs,thenscrewthe legsto the insideedgesof therails. longenoughto fastenthemto the bottomedgeof the rails.
Makecertaintheoutsiderailstretcher is buttedagainst the Thenscrewcommercial rollersto the topsof the stretchers,
topsof the legs.Cutthe bracesfrom 1-by-3sto reachfrom placingshimsunderthe rollers,if necessary, to setthemlev-
the bottomof thesecondrailstretcher to the insideedgesof el withthetooof thesawtable.
130
WORK SURFACES
131
WORK SURFACES
t32
WORK SURFACES
t33
TOOL STANDSANDTABLES
stand or table can transforma comfortable height.Theextension router
portablepowertool into a reason- tableshownoppositenot only converts
ablefacsimileof a full-sizestationary a routerinto a mini-shaper, but canbe
machine.Whattheyconcede in power easilyremoved whenit ii not needed, A
to theirlargercousins,
bench-mounted moreelaborate, but versatileoption is
toolscompensate with portability,ease illustratedon page136.Thethree-in-one
of storage,andlowerprice. portable power tool table features
There are commercialstandsfor replaceable insertsfor a router,anelectric
benchtoptools,but you caneasilybuild drill, and a sabersaw.
a standliketheoneshownbelow.Storase Because of its centralrole in wood-
shelvesanddrawerscanbeaddedto cui- working,the routermeritsa dedicated
tomizethe basicdesign.Thereis one tablein most shops.The shop-built
requirement, however:
Ensurethestand's benchtopversionillustratedon page139
surfaceareais largeenoughfor your allowsyou to takeadvantage of this tool's
needsand that it supportsthe tool at a greatversatility.
SUPPORTS
F()RPORTABTE
POWER
TOOLS
Building a benchtop toolstand
Thestandshownat rightis constructed
from4-by-4and2-by-4lumberandply-
wood.Sawthe legsfrom4-by-4s andthe
railsfrom2-by-4s, sizingthepiecesto
suityourneeds. Notchthelegsat thetop
and6 inchesdownfromthetopto fit Toprail
therails,thencutmatching rabbets
at the
endsof all therails(inset). Glueupthe
legsandrails,adding countersunk
screws
to reinforce thejoints.Cutthetopfrom
3/o-inch plywood. lf youplanto placea
tablesawon thestand,sawa square
holeoutof thecenter of
thetopasshown to allow
sawdust to fallthrough;
place a boxunderneath to
catchthewaste. Finally,
screw thetopto thelegs
a n dr a i l sa, g a i nc o u n -
tersinking thefasteners.
Whenusinga toolon
thestand, secure rttothe
topwithscrews orclamps.
134
WORK SURFACES
135
WORK SURFACES
Eottom rail
CUTflNG LIST
- Tabletop:'1"x 25" x 40"
- Lega(4): 1%"x 31/z " x 30"
Le4 - Suppott bracketa (6):1/+ " x 9" x 9"
- Front and back rails (4):5/o"x 2'/2"x 40"
- 1lde raila (4): 5A"x 2 %"x 25"
- thelfr "/o"x 25" x 33"
- Cleats (2): %" x 3" x I %"
- Cleate (2): %" x 5" x 16"
- Inserte (3): 3A"x 121/2"x 14%"
r36
WORK SURFACES
andthe fence;14-inch plywood for screwthecleatsto the underside of topof the legs.Screwthebottomrails
thesupport brackets; and solidlum- thetop,forming a ledgeto whichthe (placed on edge)to the legs,then
berfor the otherparts(2-by-4sfor insertscanbefastened(below). attachtheshelf.Youcaneithercoun-
the legsand 1-by-3s fortherails). Before assemblingthetable,routa %- tersinkthefasteners or counterbore
Referto the cuttinglist for suggested inch-deep dadoacrossthetableabout theholes, andthenconceal thescrew
dimensions. 12 inches fromthe left-hand endto heads withwoodplugs.
Startbuilding thetableby prepar- accommodate a mitergauge. Then Next,sawthethreetoolinserts, siz-
ingthetabletop thetoolinserts.
for screwthe partsof thetabletogether. ingthemto f it precisely
in theholein
Cuta rectangular holeoutof itscenter Uselapjointsforthetoprails(placed thetabletop, Preparetherouterinsert
the samesizeasthe inserts. Then flat),thenscrewthisframeontothe asyouwouldthetopof theremovable
t37
WORKSURFACES
routertableshownon page135.To
mountthe insertin the table,set
it in placeon the cleatsandbore
a holethroughthe insertandthe
cleatsat eachcorner;the holes
shouldbecountersunk. Screwthe
insertto the cleats.
Fortheelectric drillinsert,bore
a holethroughthe centerof the
insertthat isslightlywiderthanthe
largestaccessory youplanto use.
Thenscrewa commercial drillguide
to the underside of the insertsothe
drillchuckwill becentered in the
hole.(Youmayneedto drillholes
through thebaseof thedrillguide
to fastenit in place.)Thebit or
accessory in thedrillchuckshould
protrude fromthetop of the insert
withoutthe chuckbeingvisible.
Placewooden washers underthe
guiderodsof the drillguideto
138
WORK SURFACES
r39
GLOSSARY
A.B-C Countersink: To drill a hole so that Facejointing: Using a jointer to
Bench dog: A round or squarepeg the headof a screwor bolt will lie cut shavingsfrom the faceofa
of metal or wood that fits into a hole flush with or slightly below the sur- workpieceuntil it is flat and square
in a workbench to grip and hold a faceof a workpiece. with the edge.
workpiecein place.
Crosscut A sawcut acrossthe wood Faceviss A vise that holds work
Bevel cut: A cut at an anglefrom grain of a workpiece. againstthe front apron of a work-
faceto facealong the length or width bench.
of a workpiece. D-E-F
Dado: A rectangularchannelcut Featherboard:A pieceofwood cut
Box joint: Identical interlocking into a workpiece. with thin fingersor "feathers"at one
fingersthat meshto form end;usedin conjunctionwith clamps
a cornerjoint. DecibehThe standardmeasuring to hold a workpiecesecureagainst
unit of sound intensity; the decibel the fenceor table of a power tool.
Butt joinery: A method of joining (db) scaleextendsfrom 0 to about
wood in which the end or edgeof 130,with 0 representingbarely Fence:An adjustableguide designed
one board is setsquarelyagainst perceptiblesoundsand 130delin- to keep the edgeor faceof a work-
the faceor edgeofanother. eating the averagepain level. piece a fixed distancefrom the cut-
ting edgeof a tool.
Carcase:A box-like construction Dedicated circuifi An electricalcir-
that constitutesthe body of a piece cuit to which only one tool or fixture Furring strip: A thin board that is
of furniture. is connected. nailed to a wall or ceiling to provide
a flat or levelsurfacefor securing
Cheek The faceof the projecting Dovetail joinery: A method of drywall or paneling.
tenon in a mortise-and-tenonjoint. joining wood at cornersby means
of interlocking pins and tails; the G-H-r-J
Circuit: Continuous path for electri- name is derived from the distinc- Ground-fault circuit interrupter
cal current; from the main service tive shapecut into the endsof (GFCI): A tFpeof electricaloutlet
panel in a houseor garage,a branch the joining boards. that trips instantly when it detects
circuit runs to a seriesof outlets, a short-circuit leak in current.
wall switches,and light fixtures, and Dowek A wood pin usedto rein-
returns to the panel. force certaintypes of wood joints. Hanger bolt A bolt with no head;
one end of the bolt has screw
Counterbore: To drill a hole that End cap:A pieceofwood that covers threadswhile the other end fea-
permits the head of a screwor bolt eachend of the top slab of a work- tures machinethreads.
to sit below a wood surfaceso it can bench; bolted to the slab and glued
be concealedby a wood plug. to the aprons by meansof dovetail Inlay: A decorativestrip of metal,
or finger joints. hardwood, or marquetry that is glued
in a groovecut into a workpiece.
Facegluing: Bonding several
boardstogetherface-to-faceto Joist:A horizontal support for
form a thicker workpiece. a floor.
140
GLOSSARY
Kerf splitter: A metal device that Push block or stick A device used Stud: A vertical member forming
holds a kerf slightly open during a to feed a workpiece into the blade, walls and supporting the framework
sawcut to preventthe blade from cutterhead,or bit ofa tool to protect of a building.
binding. the operator'sfingers.
T.U-V-W-X-Y-Z
Kickback The tendency of a work- Rabbet A step-likecut in the edge Tirilvise: A screw-typevise on the
pieceto be thrown back in the direc- or end of a workpiece;usuallyforms right-hand end of a workbench
tion of the operator of a power tool. part of a joint. incorporatinga sliding dog block
to securestock on the top surface
Knockdown fitting: A piece of RaiL A board running along the ofthe bench.
hardware that acceptsa screw or bottom edgeof a tabletopto which
bolt, allowing the quick assembly the legsofa table can be attached. Tenon:A protrusion from the end
and disassemblyof a workbench of a board that fits into a mortise.
or other furniture. Service entrance: A box contain-
ing circuit breakersor fuses,from Truing: Squaringthe end of a blade
Lap joint A typ" ofjoint in which which power is distributed to house or the working surfaceof a grinder
matching dadoesor rabbetsoverlap branch circuits. wheel so that it conforms to its orig-
to connecttwo boards. inal shape.
Shoulder: In a mortise-and-tenon
Lead anchor: A type of fitting that joint, the part of the tenon that is Trussrod: A type of threadedmetal
is insertedinto a hole in concrete perpendicularto the cheek. rod usedto reinforce the legsand
or masonry; expandsto hold a screw stretchersof a workbench.
or bolt securely. Shouldervisq A fixed type offace
vise with a jaw that moYesto clamp Wheel dresser:A star-wheelor dia-
Legvise: A visethat securesstock a workpiece againstthe front apron mond-point deviceusedto true the
to the front left-hand leg of a work- ofa workbench. working surfaceof a grinding wheel
bench. and exposefresh abrasiveparticles.
Sliding dogbloclc A wood block,
M-N-O-P-Q-R-S part of the tail vise of a workbench,
Miter cut A cut that anglesacross that appliesthe clamping faceto hold
the faceof a workpiece. a workpiecebetweenthe bench dogs.
t4r
INDEX
Pagereferencesin ltalicsindicate Circular saws: Garages:
an illustration of subjectmatter. BIades Workshop layo:ut,36,40
Pagereferencesin bold indicate circular sawbladecarriers(Shop Generators, 71,74-75
a Build It Yourselfproject. Tip), 102 GIueracks:
storage,102 Shop-made glueracks(ShopTip), 124
ABC Clamps: Ground-fault circuit interrupters
Air compressors,69, 70, 72, 73 Storage,LO5,106,107 (GFCIs),17
Air-powered tooIs, 68,72-73 Storinghandscrews(ShopTip), 107 Handsaws:
Attics: Collins,Martha, 8-9 Storage,100,101
Workshop layout, 38 Compressed-airtools. SeeAir-powered Hand tools,/ront endpaper
Axtell, Peter,6-7 tools Safetyprecautions,14
Band saws: Hearingprotection, .18,19
Curved cuts DE Heatingsystems,45
circle-cuttingsupportjigs, 128 Doors: Hickman,Ron,47,112
Dust collectionsystems,82, 85 Opened-doorsignals High-volume,low-pressure (HVLP)
Extensiontables,111,132 safeattention getters(ShopTip), 37 spraysystems,70
,.
Workshop IayouI-,j2, 38 Dowel racks,90 Jlgs:
Bar clamps: Drill presses: Band saws
Shop-madeglueracks(ShopTip), 12a Extensiontables,.133 circular cuts, 128
Storage,106, 107 Workshop layout, 33 Benchdog holes,54
storing clampsin a garbagecan Drills: Benchgrinders
(ShopTip), 106 Nr-powered,,72 gouge-sharpening jigs,77
Basements: SeealsoElectricdrills Vises
Workshoplayout,39 Dust collectionsystems,69, 70, 78-81 steppedblocksto preventracking, 6.1
Bench dogs,62-63 Dust hoods,82-84 Workbenches
Carving dogs,64 adaptingstandardsheetmetal ducts benchstops,61,65-67
Edgedogs,63 asdusthoods(ShopTip), 83 carving dogs,64
Holes,54,54 Electricalsweepsfor right-anglejoints edgedogs,63
Benchgrinders,71,76 (ShopTip), 81 woodeninsertsfor metal-jawed
Gouge-sharpe ning jrgs,77 Portable,85,87 vises,60
Workshop layout, 34 shopvacuums,71,85,87 Iointer/planers:
Benchslaves.122 Shop-madeblastgates(ShopTip), 84 Workshop layout, 33
Black& DeckerWorkmater",47,112 Vacuumscreeningramps(ShopTip),86 Iointers:
Build It Yourself: Electricalsystems: Pushblocks.2l
Benchgrinders Electricalshock,27 Workshop layout, 33, 38
gouge-sharpening jigs,77 Portablegenerators,71, 74-75
Safetyequipment Powercord covers(ShopTip),42 KLMNO
featherboards, 22 Powertool ratings,75 Lathes:
pushsticks,20-21 Safetyprecautions, IZ Workshop layout, 33
Shoplayout Shoplayout,41-42,44 Lee,Leonard,l0-ll
shop dollies,37 Electricdrills: Lighting:
Storage Tables,136-138 Bench-doglamp support(Shop
fold-down workbenchand tool Emergencyprocedures: Tip), a3
cabinet,98-99,I10 Fire,16 ShopLayout,43
handsawholders,101 SeealsoFirst aid; Safetyprecautions Lumber:
lumber-and-plywoodracks,91 Extensioncords,l7 Sizes,backendpaper
mobile clamp racks,105 Lumber racks,94 9l
scrapboxes,109 FGHII Adjustable,92-9j
shelvesfor clamps,106 Fasteners: Anchoring lumber racksin concrete
tool cabinets,95 Anchoring lumber racksin concrete (ShopTip), 93
tool cupboards,96 (ShopTip), 93 Multitesters,T0
Workbenches Storage,108,109 Nail guns:
benchdog holes,54 Featherboards, 22 Air-powered,73
edgedogs,63 Finishes: Outfeedtables,125,I 29-I 33
slidingbenchstops,6l Safetyprecautions,14,15
Work surfaces Fire,13,16 PQR
Iibrary-typework tables,113 Fire extinguishers,16 Pipeclamps:
portablepowertool tables,136-138 Fftstaid.23-27 Storage,106, 107
Carving dogs,64 Eyes,24 storing clampsin a garbagecan
Shock,26 (ShopTip), 106
electrical,27 Planers:
Wounds,25-26 Dust hoods.82
t42
Plywood: Stackingsawhorses (ShopTip), lI9 Positive-pressureventilation, 86
Storageracks,91 Scrapboxes, 109 SeealsoDust collectionsystems
Powertools: Scrollsaws: Vises:
Hanging portablepower tools from Workshop layott,34 Extensionslands,127
the wall (ShopTip), l0.l Shapers: Workbenches,56
Multipurpose, 30 Workshop layout, 33 facevises,56, 58-59,60, 61
Safetyprecautions,14 Shopdollies,37 quick-switchvises(ShopTip), 60
disablinga power tool (Shop ShopTips: tail vises,56-57,60, 62
Tip), 14 Dust collectionsystems,81,83,84, woodeninsertsfor metal iaws,60
featherboards,22 86,87
noiselevels,-19 Safetyprecautions,14 WXYZ
pushsticks,20-21 Storagesystems,93, 101,102,104,106, Wheeldressers,71,76
Wattageratings,75 107,108 Wide panels:
Workshop placement,30 Workbenches,60, 64 Circle-cuttingsupportjigs, 128
spaceand light requirements,32-34 Workshop layout, 37, 42, 43,44 Support frames,123
SeealsoLir-poweredtools Work surfaces, 117,119,120,722,124, Tablesaws,129
Protectiveclothing, 13, 18-19 129 Wood:
Pushsticks,20-21 Shopvacuums,71,85 Toxic effects,backendpaper,13, 15
Radialarm saws: Panty-hoseshopvacuumfilters (Shop SeealsoLumber
Dust hoods,82 Tip),87 Workbenches,10-ll, 46-49
Extensiontables,130 Smokedetectors,l6 Bases,50-52
Workshop Iayout,j2 Solvents,15 Benchhooks,66, 67
Respirators, 18,19 Sprayguns: Benchstops,65-67
Roller stands,125-126 Ait-powered,72 sliding benchstops,61
Routers: Storagesystems,8-9, 89 Black& DeckerWorkmater',4T,112
Air-powered,73 Flammableproducts,89 Carvingscrews(ShopTip),64
Tables,134,136-137,139 Tool chests,88 Fold-downworkbenchand tool
dust hoods,83 TooIs,94-95,96, 97, 103-104 cabinet,98-99, 110
removablerouter tables,135 clampracks,105,106 Hold-downs,65
workshop layout, 32 fold-down workbenchand tool Tops,43-55
cabinet,98-99, 110 Vises,56
STUV handsawracks,104 101 facevises,56, 58-59,60,61
Sabersaws: hangingportablepower tools from tail vises,56-57,60, 62
Tables,f36-f38 the wall (ShopTip), JOI woodeninsertsfor metal jaws,60
Safetyprecautions,13 magnetictool racks(ShopTip), 104 Workshop layo:ut,j4
Anti-fatigue mats,44 SeealsoLtmber racks SeealsoBenchdogs
Compressed air, 73 Tables,lll,112 Workshop layout,29-31
Door-openedsignals Assemblyand finishing tables,34 Dust collectionsystems,78
safeattention-getters(ShopTip), 37 Extension tables,129-133 Electricalsystems,41-42,44
Electricalsystems,12 double-dutywork tables(Shop Floorc,44
Finishes,14,l5 Tip),129 Largespaces,40
Flammableproducts,89 Library-typework tables,113 Lighting, 43
Generators,75 Low assemblytables,114 Medium-sizedspaces, 39, 42
Hand tools.14 Stow-awaytables,115- 116 Scaledrawings,28, 30, 36,39, 40, 42
Powertools, 14 Temporary,117 tools,35
disablinga power tool (Shop stabilizinga temporarywork Smallspaces,36-39
Tip), 14 surface(ShopTip), 117 Workshops:
Protectiveclothing, 13, 18-19 SeealsoWorkbenches Ceilings,44
Tool storage,94 Tablesaws: Floors,44
SeealsoToxic substances Extensiontables,129 making the transition to a raised
Sanders: double-dutywork tables(Shop floor (ShopTip),44
Air-powered,68, 72 Tip), 129 power cord covers(ShopTip),42
Sandingstations,84 fold-down outfeedtables,I3-l Heatingsystems,45
Storingsandingdisks(ShopTip), 108 Safetydevices,12 Planning,6
Workshop layout, 34 Wheelbases,29 Ventilation systems,45, 86
Sawhorses, 118-120 tablesawon wheels(ShopTip), 3i Walls,44
FoIding, 122 Workshop layout,29, 31, 32 SeealsoDust collectionsystems;
Heavy-dfiy, 121 Telephones: Workshop layout
Paddingsawhorses (ShopTip), 120 Visual ringing signals,37 Work surfaces:
Panelsupport frames,123 Toxic substances: Tool stands,134,135,136-138,139
Securingworkpiecesedge-upon rlnrsnes.15 Variable-heightwork strfaces,124
sawhorses (ShopTip), 122 Woods, backendpaper,13, 15 SeealsoT ables;Workbenches
Shop-madeglueracks(ShopTip), 124 Ventilation systems,45
r43
ACKNOWLEDGMENTS
Theeditorswishto thank thefollowing
SAFETY
AdjustableClampCo.,Chicago,IL; Black& Decker/EluPowerTools,Towson,MD; DeltaInternational
Machinery/Porter
Cable,Guelph,Ont.; FisherHill Products,Inc.,Fitzwilliam,NH; FreudWestmoreTools,Ltd.,
Mississauga,
Ont.; LeeValleyToolsLtd.,Ottawa,Ont.; Sears,Roebuckand Co.,Chicago,IL;
VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
SHOPLAYOUT
Black& DeckerPowerTools,Towson,MD; DeltaInternationalMachinery/Porter Cable,Guelph,Ont.;
Hitachi PowerToolsU.S.A.Ltd.,Norcross,GA; LeeValleyToolsLtd.,Ottawa,Ont.; Sears,Roebuckand Co.,
Chicago,IL; ThoroughbredSawhorsesand Equipment,Divisionof the Ivy Group,Inc.,Valparaiso,
IN
WORKBENCH
AdjustableClampCo.,Chicago,IL; Black& Decker/EluPowerTools,Towson,MD; DeltaInternationalMachinery/Porter
Cable,Guelph,Ont.; FreudWestmoreTools,Ltd.,Mississauga, Ont.; GreatNeckSawMfrs. Inc. (BuckBros.Division),
Millbury, MA; Hitachi PowerToolsU.S.A.Ltd.,Norcross,GA; The WorkbenchBook (TauntonPress,1987)by ScottLandis;
LeeValleyTools Ltd., Ottawa,Ont.; RecordTools Inc., Pickering,Ont.; RobertLarsonCompannInc.,SanFrancisco,CA;
SandvikSawsand ToolsCo.,Scranton,PA;Sears, Roebuckand Co.,Chicago,IL; ThoroughbredSawhorses
and Equipment,Divisionof the Iry Group,Inc.,Valparaiso, IN; VermontAmericanCorp.,Lincolnton,
NC and Louisville,KY; Woodsmirh,2200GrandAve.,DesMoines,1A50312
SHOPACCESSORIES
CampbellHausfeld,Harrison,OH; DeltaInternationalMachinery/Porter
Cable,Guelph,Ont.; DewaltIndustrial
Tool Co.,Hampstead,MD; GreatNeckSawMfrs. Inc. (BuckBros.Division),Millbury, MA; Ingersoll-Rand
CanadaInc.,Rexdale,
Ont.; Sears,
Roebuckand Co.,Chicago,IL; WagnerSprayTechCorp.,Minneapolis,MN
STORAGE
AdjustableClampCo.,Chicago,IL; AmericanTool Cos.,Lincoln,NE; FreudWestmoreTools,Ltd.,Mississauga, Ont.;
Hitachi PowerToolsU.S.A.Ltd.,Norcross,GA; The WorkshopBook (TauntonPress,1991)by ScottLandis;
LeeValleyToolsLtd.,Ottawa,Ont.; RobertSorbyLtd., Sheffield, U.K./BusyBeeMachineTools,Concord,Ont.;
SandvikSawsand Tools Co., Scranton,PA; StanleyTools, Division of the StanleyWorks, New Britain, CT;
VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
WORKSURFACES
AdjustableClampCo.,Chicago,IL; Black& DeckerPowerTools,Towson,MD; DeltaInternationalMachinery/Porter Cable,
Guelph,Ont.; FreudWestmoreTools,Ltd.,Mississauga, Ont.; HitachiPowerToolsU.S.A.Ltd.,Norcross,GA; The WorkshopBook
(TauntonPress,1991)by ScottLandis;LeeValleyToolsLtd.,Ottawa,Ont.; RecordToolsInc.,Pickering,Ont.;
SandvikSawsand ToolsCo.,Scranton,PA; Sears,Roebuckand Co.,Chicago,IL; Shopsmith,Inc.,Montreal,Que.;StanleyTools,
Divisionof the StanleyWorks,New Britain,CT; ThoroughbredSawhorses and Equipment,Divisionof the Ivy Group,Inc.,
Valparaiso,IN; Tru-Align ManufacturingInc.,Tempe,AZ; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
Thefollowingpersonsalsoassisted
in thepreparationof this book:
Ren6Bertrand,ElizabethCameron,DonnaCurtis,LorraineDor€,RdjeanGarand,GraphorConsultation,
Irene Huang,CarolynJackson,LeonardLee,GeneviEve
Monette
PICTURE CREDITS
Cover RobertChartier
6,7 RobertHolmes
8,9 RaymondGendreau
10,ll Ron Levine
30 CourtesyShopsmith,Inc.
47 CourtesySjcibergsof Sweden
49 CourtesyWoodcraftSupplyCorp.
70 CourtesyMakitaCanadaLtd.
89 CourtesyIustrite ManufacturingCo.
l12 (upper)CourtesyShureManufacturingCorp.
t44
I
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t
GPU I D E
WORKSHO
t
Toxtc
w00Ds Al{DACTUAT
1{0M[{At
t yourself
Protecting fromtoxicspecies
SOFTWOODTUMBERSIZES
Thedustfrommanywoodspecies canposehealth ilominal Actual
I risksranging fromrespiratoryailmentsto skinanc (lnches) (lnches)
eyeirritations.Somewoods chemicals
contain that
t cancausetoxiceffects(page10. Thechartbelow
dry
Surfaced
3h-by-It/z
green
Surfaced
25h2-by-IeA6
listsa number of speciesandtheirpossiblehealth l-by-2
t effects.To reduce to dustfroma
directexposure
reaction,keepyour
1-by-3 3/+-by-21/z 25/zz-by-2eA.o
woodthatmaytriggeranallergic 3/q-by-3r/z 25/zz-by-3e/rc
1-by-4
I shopcleanandwellventilated,
forcutting,operations.Before
andweara dustmask
handlingthespecies, 1-by-6 3h-by-5t/z 25/zz-by-55/a
spread a barrier creamonyourskinor wearprotective
I gear,including longpantsandsleeves, gloves,
and
1-by-8 3h-by-7th 25Az-by-7Vz
^^J^+., ^l^^^^^ 1-by-10 3h-by-9|h
I 5drur.y Brd55cs.
t Ebony
Europeanlarch
RST
RS
4-by-6 3Vz-by-51/z 3eAe-by-55/a
EUrOpeanspruce RS
I lmbuia RS
lroko RS
I Lacewood RS THICKI{ESSES
STAI{DARD
Mahogany, African RS FOR HARDWOOD
SURFACED
I Mahogany, SouthAmerican RST
l{ominal Actual
0ak RS
I Pine RS
(rough) (surfaced
twosides)
3An 3/:.a"
Redcedar RS
I Rosewood. Brazilian v'
Rosewood, EastIndian
I Satinwood,Ceylon
%'
,1.
%ott
slu"
Silkyoak RS
I Teak 1u % "o r ' % e "
Walnut RS 7Yo' IrAe"
I Wenge RS T''' I5lu"
Westernredcedar RSI
I Whitecedar RST
2', l % "o r I % "
3' 23/o'
I R = Respiratory
ailments
S = Skinandeyeirritations 4" 3%',
T = Toxiceffects
I
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