Bill of Materials
M a t l . Q t y .
A horizontaltableB tabletopsidesFENCE AND HOLD-DOWNC tabletopcenterD horizontalfence baseE horizontaltable fence‡"‡"
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Start with the horizontaltable pieces1
Cut the horizontal table (A) to the sizelisted in the Bill of Materials. (Due toits stability and strength, we used ‡"Baltic birch plywood as sourced in theBuying Guide.)
Cut the horizontal tabletops (B, C) tosize. (After using the drill-press tableawhile, the center piece will get severalholes drilled into it. For ease in replacingthe tabletop center C, we constructedthe tabletop out of three pieces ratherthan one.)
Using a hacksaw, crosscut three piecesof metal mini channel to the lengths listedon the Exploded View drawing. (We usedB-Line Systems B72 mini channel. Seethe Buying Guide for our source.) Drillcountersunk mounting holes at 4"intervals through the mini channel forscrewing to the plywood tables later.
Mark the location of the groove on thebottom surface of the horizontal table(A). Position the table on the top of yourmetal drill-press table. Looking throughthe slots on your drill-press table, verifythat the marked groove crosses at leasttwo of the grooves in your metal table.If not, adjust the position of the groove.
Using a dado blade in your tablesaw,cut a Å" dado and rabbets (wideenough to house the mini channel justcut) in parts A and B, wheredimensioned on the Exploded View andFront View drawings.
Position and clamp the tabletops (B, C)onto the horizontal table (A) where shownon the Exploded View drawing. Drillcountersunk holes through the bottomside of A to secure B and C in place.Remove the clamps, and glue and screwboth Bs in place. Then, just screw (noglue) part C in place.
Cut a 2ﬁ" radius centered on the back edge of A/C.
Screw the three pieces of mini channelin place.
Build the fence forprecision alignment1
Cut the horizontal fence pieces (D, E)to size. Mark a 2ﬁ" radius on each whereshown on the Horizontal Fence drawing,and bandsaw and drumsand the radii toshape. The radius centered on E allows thedrill-press chuck to come closer to theworkpiece, which is especially helpfulwhen using a small bit in the chuck. Theradius in the fence base (D) allows thefence to be moved closer to the drill-presscolumn when drilling into wide stock.
Mark a pair of hole centerpoints on thefence base (D). Before drilling the holes,verify that the marked points are centeredover the dadoes opening in the tabletop.Improperly located, the carriage bolts willbind in the mini channel. Adjust if necessary, and drill the ›" holes.
Drill the countersunk mounting holes,and screw part E to D, checking for square.
To mount the fence to the table, startby grinding two opposing edges of four›" carriage bolts until the bolt heads slideeasily in the metal mini channel. See theCarriage Bolt details accompanying theFront View drawing for reference. Then,insert the bolts through the fence pieceD through flat washers and into the plasticwing nuts (knobs). The fence should slideback and forth in the table easily, butwithout slop.
The hold-downs come next1
Cut the clamp hold-down base (F) tosize from ﬂ" stock. (We resawed some of the ‡" plywood we used for the otherpieces.) For holding ‡"-thick stock later,the base must be less than ‡" thick. Cutor sand a ‹" radius on each corner of F.
Drill a ﬁ" hole ˇ" deep in the topof the hold-down base. Now, drill aˇ" hole, centered through the middleof the counterbore.
Insert a ˇ" carriage bolt into the bottomsurface of the hold-down base. (For easein using the hold-down clamp, we foundthat the hold-down base must swivel onthe tops of the tables. To do this, we hadto use a ˇ" carriage bolt instead of the›" bolts used on the fences.)
Grind the threaded end of the four#12
ﬂ" panhead sheet-metal screws untilthe threaded end is ﬁ" long. Then, drillpilot holes, and secure the hold-down clampto F with the four screws.
BP—Baltic birch plywood
1ﬁ" flathead wood screws; 4–›
1ﬁ" and 1–ˇ
1" carriagebolts; 1-ˇ" locknut; 4–ˇ" flat washers; 2–ˇ" plastic wing nut; 2–3Œ" oval-tapered knob; 2–2"-reach hold-down clamp; 1–›
24‡" mini channel (available at most electrical supply outlets);2–›
15" mini channel; 4–#12
ﬂ" panhead sheet-metal screws; clear finish.
Buying GuideHardware kit.
Three pieces of ›
Å" mini channel cut to length; one 2"-reach hold-down (toggle)clamp; two plastic wing nuts (knobs), two 3Œ"-long oval-tapered knobs, four ›" carriage bolts1ﬁ" long, and one ˇ" carriage bolt 1" long, plus the screws, washers, and locknuts listed above.WOOD KIT SDPT1, $42.95 plus $3.75 shipping. Schlabaugh and Sons Woodworking, 720 14thStreet, Kalona, IA 52247 or call 800/346-9663 to order. (Contact via e-mail: firstname.lastname@example.org)
All the pieces listed in the hardware kit above, plus all the Baltic birchplywood pieces listed in the Bill of Materials cut to size and shape with predrilled holes. WOODKIT SDPT2, $99.95 plus shipping (call for shipping charges). Schlabaugh and Sons Wood-working, address and phone number above.