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Fine Woodworking 216 (Winter 2010-2011)

Fine Woodworking 216 (Winter 2010-2011)

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Step Up to a Serious Bandsaw

A powerful, solid saw with big cutting capacity is more affordable than ever

up front
6 On the Web


The North Bennet Street Tool Chest
Learn what the students learn as you build a handsome horne for your hand-tool collection
BY 5T!;"'E 6ROWN

8 Contributors 10 Letters

12 Methods of Work
• Overhead rack for project lumber Easy way to support long boards • Knee paddle cuts power safely


It's the olel tablesaw

~outelr Table
extension trick. but done right this time


Cuttmg-Edge iFirst Arid
ER doctor: Throw you've been told

18 Tools & Materials
• Everything you want in a drill press • Better mounting plate for router tables

away your old kit and forget what


22 Fundamentals
A drill press will make you a better woodworker


How Many Routers Does Your Shop Need?
For most people, the answer BY JIE F[F M! L LE R is three


Make a Bargain-Basement Like Royalty
Even a pauper

Plane Petiorm

can own a prince of a plane


Treat Your Feet

mats are an affordable

cure for concrete floors




in the back
78 Shop Design
Think your shop Is small?

82Q &A
The right bit for template How to clean an oilstone routing Best plane for gnarly grain

88 Handwork
The Woodwright's favorite tools

98 How They Did It ~
The back cover explained

Back Cover
A Case for Apprenticeship


S and Canada. Newtown. please). Inc .S and Canada. $8. $83.': Return undeliverable Canadian addresses to Fine WDodworklng. 63 S. 50). Outside U. Consulting Editor Jonathan MethOdS of Work Jim Richey Shop Questions: Our shop about table guru tools. dollars.S.rking GST paid registrauon and at addluonat 11123210981. Periodicals postage Newtown. Single copies outside the U. Newtown.95 (or one year. and possessions. Including FineWoodworking. $41. Postmaster: Send address changes to Fme Woodworking. .. .aunton. or emau to mn(a@l. The Taunton Press. and must-read free Web tie-Ins. to serve can also a laptop modern Includes: ThrougMovetails • Breadboard ends plan • Dcwnloadable 6 FINE \VOOD\VORKINC.95 (or three years (in U. articles and project Build a Shaker Lap Desk The perfect Becksvoort for a touch store purpose. Inc.. Ask John White your questions and even his new router FlneWoodworking. maintenance. 2835 Kew Dnve..THIS MONTH ON Visit our Web site to access collection of free content.com.. more than plans -.com/ available October extras there. WqqQWorking Editor Art DIre ctor Managing Editor Asa Christiana M lc h a et Pekovlc h Mark Schofield Thomas McKenna steve Scott An isse Ka psal es Mallhew Kenney Patrick McCombe Senior Copy/ Production Editor ASSOCiate An Directors Elizabeth Healy Fine Senior Editor Associate Editors Kelly J. Canadian GST included. ON N8T 367.comj newsletter.S. 1400-plus . holiday project Subscription Rat$s: U. iii shops VIDEO. While project you're tool reviews. an extensive gallery.99. paid 81 500 exclusive than project 30 years and technique of archives videos by subscribing including You'll also get more at your fingertips. Windsor.s. Main St.. Canada P". Dunton John Tetreauli Administrative Assistant Betsy Engel William Christian Garrell Peck Becksvoort Hack Shop Manager Get free plans and more b~ 5i gn ing up for ou reletter ar FlneWoodworking. Shop Makeover Pekovlch's around revamped garage out other great Tour shop (p. $59.. $7. PO Box 5506. Inc . don't miss our blogs. Telephone 203-426-8171. 28. $104.95 for one year.com. VIDEO· Frame Pictures November from 22: Whip out custom series-Justin picture time our free video Like a Pro frames with tips for the holidays. please) Single copy. mailing offices. wilh a special seventh Issue In the winter. The Taunton Press. 28) of Contributing Editors Tour Michael and scope from Roland Johnson Steve Latta Michael Fortune Binzan workspaces In our gallery the world. c/o WorldWide Mailers. CT 06470 to FineWoodwo. dollars. Printed In the USA gift: Th Is Christian features an inkwell drawer but the desk a thoroughly of nostalgia.95 for three years (in u. b) Become an online member Access . CT 06470-5506.95 fo' two years.99. CT 06470-5506. $73 95 for two years. $34. (p.com Senior Web Producer Web Producer Gina Elde Ed Plrnlk Is on tap to answer Fine Woodworking: (ISSN: 0361-3453) Is published bimonthly.

()r~ fOJ he nds-on lmnglIO Independent pGI>I. he's been known to cling to old hand tools as well ("Make a Bargain-Basement Plane Perform Like Royalty"). Now that's a big Idea. Stavrinides.cine.com Kimberly Parrilia 203-304-3590 kparrilla@t.Taunton Interactive Suzanne Romen Ti m othy Rahr Paul Spring Susan Edelman Stephen Giannetti Jay Hartley Thomas Luxe<ler Jason Rel/zon Anatole Burkin Marla Taylor Jay Annis Wayne Reynolds Kathy Worth Carol Marotti Patricia Wllllam$On Nick ROldlisky books. but still has not found a permanent home for all his tools. Videos" and online fine Homebuilding Patrick Sullivan ("CUtting. Stavrinldes (Shop Design: "Think your shop Is smail?"). Before retiring last year. .Edge first Aid") started his career in Vp. But that magnetism isn't just for power tools.Operations SVP.eom 8 FINE WOODWOHKING .com/authors. For more Information all our contributors. go to Fi neWoodworking. Fine Garoenlng : FineCooking www. ProClrc Melissa Robinson Robert Harlow Michael Stoltz The Taunton Press !n. Jan Roman Steve Brown President EVP & CFO SVP & Chief Content Officer SV~ Creative SV P.Digital Marketing emergency medicine and migrated to internal medi. he served as chief of medicine and chief of staff at two hospitals .. on the Mediterranean Island of Cyprus-one of the world's smallest nations. I We are a reader-written magazine..com Fine Senior Natrona I Account Manager Associate Account Manager Advertising Sales ASSistant Adverusmg DIrector of Marketing Heather Sims Kristen lacey Ka ren LutJen Megan Kolakowski Senior Marketing Manager. self-confessed gearhead who's drawn to iron..Finance VI?Human Resources V~ Fulfillment Vp. learn how to propose an article. ("North Bennet Street Tool Chest~)is a 1990 graduate of the Cabinet and Furniture-Making program at the venerable Boston school.com/ su bmissions. with his wife and sons. Roland Johnson Marketing ASSOCiate Member Audit Bureau of Circulation Senior Consumer Marketing Director Senior Consumer Marketing Manager Senior Manager Web Marketing Senior Online Product Manager Beth Reynolds.she(s Since 1975 Founders.kend woodworker.. Fine Woodworking' fhleads . He Is an adviser and will be an occasional guest on the new PBS woodworking show Rough Cut-Woodworking with Tommy Mac.contributors 6. Johnson's been a contributing editor to the magazine for six years.A. . says he hopes to one day build a300-sq. who "dream shop" that he envisions describes himself as a self-taught. A professional woodworker for more than 30 years.Technology SVp. Mass. ·Wd kl go to F me 00 war lng.!>pLr::ir. To Publishers of magazines. Brown lives in Manchester.launtol1. Adverusmg ("Step Up to a Serious Bandsaw") Is a passionate. he does indeed patch up his own Injuries at home. The Web graphic designer lives in Nicosia. wee. Paul &.aunton.auFlIOf\. He spent nine years as head of the department and is starting his 12th year as an instructor. 1 III Wqqc!Working AdvertiSing Senior Vice President AdvertiSing Director Stephen Giannelli 203·304-3569 sgla n nettl@tAunton.Advertl sing SVP. he is building an entertainment center and a fireplace surround for his new house in california. And in case you're wondering. Working in small spaces comes naturally to SteUos L.oom Peter Badeau 203-304-3572 pbadea u@l.com Linda Abbett :2 03-304-3538 la bbett@taunton. as both workspace and teacnlng faCility.A lifelong woodworker.Digilal Content VI?Editorial Development VI?Single Copy Sales VP & Controller VP..-ft. and specializes in tool tests and evaluations.

but if the gift took [he form of the $1. is it really (he best saw' Why not compare a company's daily hours of technical support versus their customer service. but you'll travel monthly to visit talented furniture makers around the country. We 'If consider all of them for future tool tests. Go to http://careers. Tecbnical support is ['(!'I:Y important. and some companies do it better than others. We use more than 100 different authors each year. and thus the overall performance of the unfts. You'll be based in our Connecticut headquarters. I have a fine-art tiackground. They might make a great tablesaw. rhe excellent Bosch edge guide. N. but it would be a good idea for the costlier items. fits the DeWalr just fine. there is no right way--only a critic's opinion. Calil. letters III 1 Issue No. but if you can't get technical support from them several years down the road. provoking rather than rigid and dogmatic.. and sander with no dust collection in place.1 ro 10 microns in size.3S NO RIGHT OR WRONG WAY TO USE CONTRASTING WOODS I am a longtime reader of the magazine and Web site. Editor replies: Please accept our apologies more critical than constructive. We Write all get carried away trying to grab was to be hetpful and thought- for example. is it a toll-free number? How about trying to contact various well-known companies and see how successful you are at obtaining technical support.100 it would take to buy the Festool. how many woodworkers old enough to drive really want a [001 [hat looks like a preview for the next Transformers movie? -HOWAR D SKILl! NGTON. the headlines. or how eJ. perhaps. in order to give a more complete assessment of these units. In fact. Correction In a chart in "Tool Test: Air Filters" (F\. we should have tested for the total amount of dust. is one of FWW's strengths.C. I felt a wet blanket being spread over a large group of up-andcoming woodworkers. resume. Wlnston·Salem. Festoolls good and expensive If someone were to give me the Festool OF2200 router and accessory kit (the Best 10 FINE WOODWORKtNG . and in art. Photography and video skills are a plus. As for your Best Value recommendation of the Hitachi.~y it is to find out how [0 get a tool serviced in your area? This doesn't need to be done for every tool you (est. In general. but many 0/ your otber suggestions are very feasible. I read the article. opinions" And I'll bet we cut a few "ln mY and such out of the text in our usual effort to tighten things up." BOND. three fine handplanes. it stands to reason that there was much more dust in the air than the 3 to S mglm3 shown in the chart In retrospect. Attach a cover letter. 2U! Spotlight March/April 2010 p. Our meter measured only the dust from 0. but one thing you never cover is a company's technicalsupport service. Proper dust collection at the source is the only way to reduce airborne dust to a safe level. Burbank. I don 't kJWW if toe could follow the tecbnical support for seoeral years after a tool is introduced. they did not bring it down to safe levels. if Hack's advice came across as You can blame us editors for that.VlV #213) we gave misleading information about the total amount of dust in die air. nothing larger. So after using the tablesaw. So labels and headlines in the article rhat read "Clear the air ~d protect your lungs" and "Air filters get the job done" were misleading. and we regret giving any other impression. By the W2Y. But I was disappointed with you for the first time when I read Garrett Hack's article on how to use contrasting woods. and pictures of your woodworking projects and shop space. Madison. readers should take each article as one person's opinion. Editor replies: You are righi.com to apply. I have alWays valued FWW asa skill-builder and a technical resource. Assistant/ Associate Editor wanted Fine Woodworking magazine seeks a journalist with a passion for woodworking. Never once did I read "in my judgment" or "it is my opinion. When Overall winner in "Heavy-Duty Plunge Routers. that variety of perspectives Please investigate manufacturers' technical support I enjoy your tool reviews. and they don't always agree. -KENNY Wis. Bottom line: While these units reduced the levels of airborne dust in our tests. I'd sooner buy the DeWalt DW625 and. or find out if the support is easy to access? for example. and we sometimes I know that Hack's intention people's attentlon. r would graciously accept it.taunton. router. which you recommend as a $40 option. We have reworked the online version of the article to correct these mistakes. -ANGELA WEEKS. FWU"/ #214).

finewoodWorking.." Fine Woodworking Tools and Shops Winter 2(J08-f){} PalMI cllip-ciearing Copyright 2010 by The Taunton Press.com/products To gel help wllh online member services: Visit WW'h'. very smooth cut all the way 1'0 the lip and edges Visit www.com/FAQs To contact Fine Woodworking customer service: Email usatsupporl@CUSlOll. oTherpalem I>"nclIlg.lerservice. • ..Junlon.'k"lpl. of the entire subscription refund Questions a full and Immediate subscription steel for long life.tom/m.Wqqc!WorkinK To contact The Taunton us: Press Fine Woodworking Fine Now Sharpens K· ruves:. No without permission of The Taunton . -Individual or 4 piece set. _"..teunton. Woodworker's Supply.27 9am-5pm For employment Informillion: Visit www.. PO Box 5506. inc. excellent If at any time you're not completely Fine Woodworking.woodworker.71.Inl :. reproduction Press.com I ilo0-719-6906 x71133 To sell Fine Woodworking email in your store: or Cali us tOil-free at 866-505-4074. Newtown.corradishop.finewoodworking.~ .._' __. capability'· "Every hole was drilled cleanly in one snot.com Mailing lisl: of our' mailing If you would please list available prefer thai firms.com/privacy or call: 800-477-87.com/i'worder or call: 80Q. Inc.'I<e1DI..t..41 I fi"""'OOClwor<Jog.:.com/cuSlomerservice To find answers 10 frequently asked questions: Visit www.com To advertise In Fine Woodworking: Call 800-309-8954.5pm ET Sat To find out about Fine Woodworking products: Visil www.careers.corn an article proposel: at the address To submit Write \0 FIne Woodwor!<fng above or Cali: 800·309·8955 Fax: 203-270-6753 Email: i.tit)ewoodworklng. finewocdworklng..8-6906. 2()3-4'26-8'11 :i_ Send an email: fw@Launton.finewoodworlling.com or 'place' an order: To subscribe Visit wNw. and receive asked. • Clutch action patymer cap. 1·800-321·9841 (Mention Code fwwts(0) Or online: pro. CT 06470-5506 "tel'.corn The Taunlon with guarantee: satisfied your No you can cancel price. We make a portion to reputable we not Inclutle card #33 I fl".5. usalmagazinesales@tauntoll.w@taunton.oomlm.cc your name.com To speak dlrecUy to a customer Call 800·477-8727 9am-5pm servlceprofesslonal. ET MowPri PRECISION RASPS made in Italy TRULY • leave NO scratches! very aggressive.7041 TOOLS & s IIOPS 10 II 11 . 9am . I 800. visit: ET Mon·Fri www..110.795.finewoodworklng. or eman us at furads®tauntol1.cOm/nvwtsl0 (.w"o<Iw"'kl"~.&!8-8286 9am-9pm ET Mon-Fri.com Visit: WNW.. 63 South Main Street.

The removable member is laminated from IwO pieces where piece. We pay for every tip we publish. The fixed member is screwed (0 the ceiling joists and the removable member firs inro the dovetailed housing and is screwed in place. I designed and built a temporary rack for the project wood. -JI M WHETSTONE. and I used a half-lap the horizontal piece meets the vertical gluing and screwing them together. rack holds a lot of weight but can be removed and stored when not in use. the best tip also wins a Forrest Woodworker II combination blade. Pa.58-59).all rack is laminated from -%-in. Ceiling cleat Is screwed to joists. pp. To get around the problem. _Best Tip Overhead rack for project lumber I needed additional lumber storage for a large project. Half-lap connects vertical to horizontal piece. The fixed member is a three-piece lamination. Dovetailed housing is glued and screwed to ceiling cleat. and a removable member that holds (he wood. or email fwmow@ taunton. Newtown. The 22-in. The rack has two main parts: a fixed member (hat consists of a dovetailed housing and a mounting cleat.com. but he manages to get the most out of the space (see FWW#91. PO Box 5506. but the existing storage in my small shop was full. In his 44 years woodworking. 12-in. jim Whetstone has made 1. WOODWORKING . 12 FINE A Reward for the Best Tip Send your original tips to Methods of Work. This part can be removed and stored. New Cumberland. Racks are made from %-in. plywood.ill methods of work 1~ EDITED AND DRAWN BY JIM RICHEY Removable member is screwed into dovetailed housing.-r. CT 06470. plywood.127 pieces using wood from all over the world. Fine Woodworking.-wide. His basement workshop Is small. It allows easy access (0 the lumber without being in the way. and it can be removed and pur away until needed again. The easily of plywood.

Bench jack can handle wide work. long work clamped in front vi se. I looked into installing a paddle-style shut-off switch. sometimes called a panic switch. I installed similar switches on my jointer. The bench jack provides a way of supporting wider items. A( (he end of a cut. Rubber bumper engages 'OFF switch with a flick of the knee. and you're ready to go. France continued ( Dogs In apron support narrow. Paddle-style shutoff switch al knee height ON button is easily accessible.methods of work Use dogs and a bench Jack to support long boards A row of dog holes drilled in the side of a workbench provides a quick and solid way of supporting long boards for edge-planing. -ANDR EW JOH NSON. damp the workpiece in the front vise. Simply install a benchdog or two in the holes.TIM NQTT. You can also use the dog holes to install a plug-in bench jack. router table. 14 FtNE WOODWORI(ING . Idaho Piano hinge screws attach piano hinge to fence raj I. . Planioles. It's very easy to operate. which is simply a vertical support piece with a series of dog holes on its face. This concept should work with almost any pushbutton switch as long as you can find a convenient place [0 attach the paddle. So I built this oversize maple paddle and attached it to (he saw above the existing switch housing. A rubber bumper (available at most hardware stores) installed over the OFF switch ensures that the paddle hits the switch. Boise. and handsaw. Row of benchdog holes along front apron of bench ~ Knee paddle cuts power safely One (by after having a board bind up in my tablesaw and almost kick back. such as doors for edge-planing or hinging. a mere flick of my knee cuts off power with both hands still safely above the table and on the workpiece. A commercial version I found would have required major alterations and rewiring.

and the 1/2-in. with the front edge shaped 10 form a pull. Dowels fit through holes in bar clamps. grab the bar.-in. -KONRAD PLACHTA.-thick pine 16 FINE WOODWORKING .. it occurred to me [hat a swinging ann would be an efficient means to hold them.. and it also marks the new insert for its own leveling holes. You can easily withdraw a tray for individual bit selection or pick up the entire cabinet when working at another location. lift the swing ann away from the others. Removable tray made of 1-in. The trays are made of 'l-in-thick pine. rod continued Swing arms CB spacers 1<0'" ) Bracket mounts to wall. To remove a clamp.methods of work V. The entire assembly is supported by wooden brackets. Tasmania. The rack consists of several arms that are strung together like beads on a metal rod. dowels in each arm fit the holes in the clamp bars. dowels. -RICHARD BOWEN. Conn. I built a rack. -DAVID UNDERWOOD. Seymour. The arms are spaced apart on the rod with center-drilled l-in.-dia.-dia. I had to find a way to store some Bessey clamps without taking up 100 much space.-dia.I find it a lot easier to attach the two pieces with four screws through ~he leveling holes. The cabinet is made from Baltic-birch plywood. This approach is quicker and cheaper. convenient storage for router bits. Wellesley. Australia Cabinet made of Baltic-birch plywood Storage trays and cabinet for router bits This quick project provides compact. Ont. and it works quite well. Rack for storing paral.lel·jaw clamps In my small basement shop. Canada ) Parallel-jaw clamps It is common practice to make a new zeroclearance tablesawinse:rt from a factory Insert with a pattern-following bit in a router. Most articles recommend joining the old insert to the new blank with double-slded tape . Because Bessey-brand clamps (and some similar parallel-jaw damps) have a large hole through the end of the bar. and slide the damp off the dowel.

-''q.jn. of power: I was able to drill a 2·in. But this one also lilts forward to 48°.~es have a stroke that's less than Li 1/2 m . offering [he added convenience of being able to drill at compound angles-a plus for chairmakers.000 rpm Delta you just slide a Runout: 0.-thick stock. it tilL~ 90° to the left and nght for angled drilling. like most drill-press tables. of len round tables lavored mostly by metalworkers. a retired associate editor afFine Woodworking. For more information..tools & materials . Street price: $830 the machine makes it Motor: % hp easy and fast to change between the 16 speed Chuck: % in. U1LL STROKE LARGE TILTING TABLE The table IS big (14 in. and accurate. easy. Most drill pre~. The quill stroke on rhis machine is a very ..70-3. go to delta porte rca ble. . UlCY improved the table's capacity and holding power. To change speed.cnerous 6 in. 6·IN. wide) and tilts forward as well as side 10 side.corn. deep by 20 in.. meru over the pulley Quill stroke: 6 In. T HE DRILL PRESS HASN'T CHANGED MUCH since the first The extralarge rectangular table b better than the typical small. Alrhough it doesn't DELTA loS·900l offer variable speed.001 in. by 3. which automatically re-rensions the belts Model 18·900l has plenty hard maple in just 8 seconds. So I was happily surprised to see severa I key innovations on Delta's new 18·in.-deep hole in 18 FiNE WOODWORKING . A spring· loaded depth stop is another clever touch. on rhe J.Tom Begnal I:. electric-powered one was built in the early 20th century. The same type of Slap locks the quill in place The machine also has a very accurate laser system.·di<l. drill press. forcing you ro position the table twice for deep holes. 1 1 1 :1 QU ICK-R ELEASE TENSION LEVER • MACHIHE. Speed changes a re a breeze. systems typically found Speed range: on drill presses. A fairly gener· ous flat area underneath the perimeter better accepts the jaws of woodworking clamps The table has another strong feature. which helps you align the bit with a layout mark on the workpiece.. slip a pair of bells onto the appropriate pulleys. model 18·900L. Allows drilling through about 5'h-in. Setting the stop is quick. Everything you want in a drill press QUICK·RELEASE DEPTH STOP No need to waste time spinning the depth stop up and down the post. options. lever to the right (0 Speed change: Very easy release the belt tenDepth set: Very easy sion. Simply depress a quick-release button and slide it Into position. In a nod co woodworkers. then release the tension lever. Tvslots in the table accept hold-downs (not included) that make it easier ro damp workpicces. In an improveChuck to post: 8 in.

). Some models use a plastic wrench to lock and unlock the ring with a twist. delicate pins-there b usually less than 1/8 in. it's critical that you use solid sawing techruque with it. That's nor much thinner than lie-Nielsen's standard dovetail saw (0. lncra's MagnaLock mounting plate makes things much easier. -lHall Kenney is an associate editor: 20 I' I N E \V 0 0 [) W 0 l{ KIN G . Less effort is needed to lise the thinner $ilW and i( cuts quicker. You also could buy a blank plate and drill your own mounting holes.com. That makes for more accurate and less finicky dovetailing. If you use a gorilla (Ouch.just lever up the ring with an Allen key. thick). between the tails.tools & materials • OR • continued A better mounting plate for router tables IF YOU'RE BUILDING A ROUTER TABLE.015 in. =Iom McKenna Is senior edilor. ea·sy out. You can also level the Insert rings easily.com (1\ 125). visit incra. r hand-cut dovetail-. I can easily fit two kerfs into the end grain between the (ails. Both options sell for $77 each (woodcraft. which you have to change when you use different"'Size bits. with lilly. but that the saw's blade is Just 0. The aluminum plate itself is thick (a full % in. The problem with most of these plates Is the insert rings. J'm left with no end grain to cut into. You just pop in the ring and remove it by levering up an edge with-an Allen key. Note that because (he saw's blade is so thin. However. table height adjustments. For more information. but the difference is noticeable. com). After cutting one side of the pin socket with a normal dovetail saw. which is designed to hold the router and provide a smooth. If needed. you have to screw the ring Into place. The plate is made to lit anumber of routers. vou could kink the blade and ruin it. To remove it. On others. Not very convenient. which makes it tricky to start the cut. screws that allow you to coned for any minor mistakes made while routing the rabbet for the plate. The MagnaLock harnesses the power of rare-earth magnets to hold the insert ring in place. You C:Jn buy (he Thin-Plate Dovetail Saw at Lie-Nielsen. one of the most important pieces of hardware is the table Insert'. level surface to guide the workpiece Into the bit safely. but you'll have to drill the access hole for above-the. Easy in.and perfectly flat It comes with nine leveling. Rareearth magnets Jock the insert ring in place. thick. strong •. • HAND TOOL Nimble dovetail saw makes extrafine cuts THE BIG NEWS HERE is not that Lie-Nielsen is selling a new dovetail xaw. with Lie-Nielsen's thinner saw.020 in.

com TOOLS SHOPS 2011 21 . on up to four stiles in one quick and accurate set-up. even with shallow dadoes. email: iofQ@scherrs. The tool cuts an S5-rnrn-dia.oom/n)Orke'placo I BO()-719-6906 . the WoodRlt is not just there for the dovetailing The MR4 Mortise rail clocks in the size and position of any number of mortises. What I love about this tool is the fact that [here's no stop T collar to fuss with to adjust the depth. if that's what you're after. it has an intcgrated stop collar thai stops spinning when you've reached full depth.-elia. which is perfect for most wood and drywall screws. and it leaves a very dean rim. The Smart Bit is designed to make screw-and-plug joinery even fas(er. The Smart Bit Tool sells [or $20 (Amazon. it's much cheaper to make your own plugs. CUlling your own plugs also makes it a breeze to get seamless grain matches.corn).finewoodworking.woodrat. The stop collar can't be adiusred. For more information about the complete Pro Plug System.com go see the movie . And it succeeds. It makes a perfect fit for the round ended tenons.klng.com/marketplaee I 80()-719·5906 & xJ005 www. easier HE SMARTBIT TOOLfrom Starborn Industries can help you bang our counierbored holes in a jiffy.• 811S •• LADE. stock.www.scherrs. Although the Smart Bit is designed (0 work with the Pro Plug System (a separatE' kit that includes fasteners and plugs. bur It's just right for 3A-in. $41).com card #65 www."".7065 ~o51 finewcQOworklng. I( comes with three VB-in. a stub bit. and the counterboring 1001 with hex shank.bits.) hole. Instead.corn/ sma rt-bit. visit starborn industries . -TlYf. Smart Bit makes screw-and-plug [olnery faster. (about YI6-in.com tard I finellOOd.

and it lees you raise and lower the bit repeatedly without altering the shape of the hole. It lets you precisely determine the placement and angle of the hole as well as its depth. Store-bought versions include a fence. so it is easy to find :I good usee! one. plus counrerbores and countersinks that arc precise and chatter-free. you need a drill press. A handheld drill is prone to tearout and lacks the power to drive larger hits. fundamentals . It abo provides power and leverage to drive the bit easily. which prevents ugly blowout on the bottom side. Yatdl end up with perfect holes. The drill press is all about control. even in hard stock. . The drill press is a useful machine. but not an especially expensive one. here's no disputing the usefulness of a handheld drill. I bought a big.. II'S designed for metalworking. But that flexibility comes at a cost. To do your best work. and makes it easy to place a backer board below the hole. And they are hard 10 damage.. A larger table will give you plenty of room for bigger workpieces. so even the less-expensive models have plenty of power and stahiliry for woodwork. And even with careful layout. drilling in exactly the right place at the right angle can be hit-or-miss. It can drill pilot holes and drive screws at the bench or inside cabinets. ~ ~ ~ A drill press will make you a better woodworker A HANDHELD BY ASA DRILL CAN'T MATCH ITS POWER AND ACCURACY CHRISTIANA Start by expanding the work surface. The table supports the workpiece nicely. II's perfect in situauons when you need 10 bring the [001 to the work.

rw contributing edrror Roland Johnson. bit Once you've established the dis- tance between the bit and the edge of the workpiece.-dia. "Basically. Set the height The fir t r\)jng t do with it new drill press is to flt it with an auxiliary table. You can buy a variable-speed model for on-the-fly speed changes-s-and spend a lor more money-but 1 think the old-fashioned pulley-style machines offer plenty of speed set! ings for woodworking tasks. and you should 510\1\1 the speed considerably for bigger bits. Each of these takes less than a minute.:. It can be as simple as a piece of MDf. TOO L S "" sir 0 P S :2 0 I I 23 . That's because tile typical drill-press table is 100 small to support big workpieces The stock table also has a big hole in the center for bit clearance. with the occa ional fence clamped on for repetitive work. f th machin . plunge the bit to that point. hut once you have" dnll press in your shop. then adjust and lock the depth stop. Two other accessories you'll to ear a clip-on light (the lop of a drill press Lends (0 cast a shadow on the work area) . These typically feature accessories like zero-clearance plates in the middle. Plunge the bit once more to be sure it stops at the right spot. table height. and to give vours If plenty of room ro work. On pulley-driven drill presses. First things flrst Setting up TABLE HEIGHT You can raise or lower the table to accommodate any drilling task. have enough room for the bit to clear the work. and a foot-activated switd1. and control of a real drilling machine. To qUOIE' m.strong benchtop model out of the local classified. You won't want to throw OUt your cordless drill. you can install one of the snazzy auxiliary tables available in woodworking catalogs. The recommended speed varies with the size of [he bit. Know the controls The three adjustments you'll make most often are speed. you'll appreciate the power. for sroo. Of just make your own table. you can lock down the fence and drill dozens of holes in a row.000 rpm. That big opening allows far too much tearout on the bottom of the workpiece.ofr n inside the pulley cover. so much travel that It makes drilling Inconve- A stop on the drill-press column (far left) lets you make repeated cuts at the same depth. you'll find a speed guide somewhere near the top so you'll but not nient. you should not run any bit faster than 3. To eliminate that problem. a I-in. Mark the deSired depth on the side of the stocx. and hand)' fences that lock down quickly and accurately. accuracy. and plunge depth. for example.

you'll know where to set the table's height. or hung up between rwo of the three jaws. This means it is not necessary to tighten each jaw individuallv. This IS easy. Now. gelling the best results calls for some attention to the details. if you are not drilling all the way through the workpiece. This means that once you've dialed in rhe distance between the bit and the edge of the workpiece. Finally. Plunge the bit once to be sure it stops at precisely the right spot. the lower the fence the better. should run at 300 rpm to 500 rpm in hardwood. and sighting carefully along both axes as you bring the tip of th~ bit clown. location where the bit exits the work. Fine-tune the fence or the stop if necessary. Most bits tend is painless. By the way. with the bit in place and the workpiece on the table." After setting the speed. and you've locked in the hole location in both directions. and you are set. tall fences sometimes get in the way of the crank handles. Also. ere. I still use the fence in most cases. If nothing else. But don't bring the bit all the way out of the work or you risk tearing the rim. PlaGlng a backfJr the wQrkplece supports. don't set the bit speed toO 24 FtN r. meaning that all three jaws move in unison when the key is turned. and lock it there. plunge the bit down to that point. pull the bit partially out of the work to clear the chips. tum on the machine. spin the depth stop down until it is i>nug. find a way to keep track of the chuck key. using magnets. Even if I have only one hole to drill. put the bil in the chuck and tighten it. he sure to use a sharp. If the surface are unsupported you'll get tearout (Board is inverted A tip for efficient drilling. it keeps the stock from spinning when the going gets tough. \\1 00 0 \Xi 0 R KIN G . you'll need 10 set the depth stop. fibers Prevention How tearout happens. pen caps. resulting at the exit. you want the lip of the bit just above the workpiece so you can take advantage of the drill press's full plunge depth. Also. To prevent tMs. but I've also seen lots of ideas for Another great thing about a drill press is that you can puc a fence 00 it. For deep holes. board underneath on the bottom of the piece. Always remove the chuck key right away! You don't want any surprises when you hit the "on" switch. The chuck is self-cenrering. To avoid burning the stock. high-quality bit. I still recommend laying out the holes carefully (or at least the first one in a series) using a crisscross mark. most drill presses still use a keyed chuck that must be tightened manually to hold the bit in place. to show tearout. and touch the tip down lightly to doublecheck the position. you can lock down the fence and drill dozens of holes in a row. to clog with chips. Add a stop block to the fence. when it looks perfect.) the surface fibers.fundamentals Drilling tips continued chuck-key holders. How to drill clean holes Even with all this heavy-duty drilling hardware at your fingertips. Mine hangs on a chain. 100: Mark the desired depth on the side of the stock. Be sure the bit isn't bottomed out in the chuck. in a cleaner rim Location. Unlike modern handheld drills with keyless chucks.

A piece of tape keeps the plugs on the table. (right). but again prevention is painless: Make sure there is a fresh wood surface under rile workpiece at the exit point. The solution IS simple: As you feel {he bit start ro hesitate in the hole. If you do. tend not to wander. you can JUSl replace it. which can drill partial over location and depth. Use a thick board so the cutter doesn·t bandsaw go through (left). withdraw it momentarily to allow the flutes ro clear themselves. bur I'll leave it to yOH to discover (hose. 0 How to use a plug cutter. But here's the trick: Don't bring the bit all the way out of the hole. Clogged chips are the only other thing that will cause burning. With the drill press's control mortising diameter.fundamentals Bits matter. The slng/e-edge The drill press makes of precise cuts. with a Forstner bit. type with a diagonal Fun with FOTstnets. Then use the (right) to free the plugs. like this hardware mortise it easy to bore even countersinks The drill press also handles large Forstner bits. Or you ca n loose" (he drill-press table and shift it sideways. A simpler approach is just to keep a big piece of MDF or plywood on the table. Some auxiliary tables have removable panels Cleaner counterslnks. Brad-points center easily on a mark. like lilting the table or making ramp-like jigs to drill angled holes. Just bring it up high enough to let the packed chips fly free. Asa Christiana is editor of Fine Woodworking. Tearout is more of a problem on the bottom of the workpiece. And a set of twist bits. shifting it around to find a fresh surface. making hole through the tip makes chatter-free The hole's flat bottom makes it ideal for applications in the middle. You '/I need them to drill metal and plastic. They also stay centered wet! when drilling a small hole below a larger one. 26 FJNE WOODWORKING . it easy to drill holes as large as 2118in. When it becomes riddled with holes. and will handle most of your drilling tasks in wood. too continued Get a set of brad-point bits. it's an ideal setup for or overlapping holes (left) without wandering. fast or lower [he bit into the work too slowly. it will sometimes tear the rim. There are 100s more things you can do with your drill press. depth. and these can be flipped around to find a fresh surface.



and letting in sunshine on nice days. 1 still wanted to leave a door wide enough to drive through in case we ever decide (0 sell the house. walkout door way to accomplish any of those tasks. well insulated. and really rigid to resist sagging over time. After getting a quote of $4. lnstead of a roll-up door. go to FlneWoodworking. in fact. including a video tour. biscuits would work fine.000 for professionally made doors. I started with a 11/2-in. I opted for a pair of swing-out carriage doors. 3·ft. This would create a very rigid structure with plenty of room for insulation.com/ extras. lights Drywall ceiling Drafty doors provide easy entry and create a few extra feet of much-needed wall space. I filled tbe caviry with rigid insulation and glued and nailed plywood to each face. Instead. prehung steel entry door. doors. By adding insulation. True frame-and-panel construction didn't seem to be a good ~ Online Extra For mote details. sirnilar to the way a hollow-core door is made. transformed Improving floor. [ did this by framing in a pair of narrow panels that would flank an inexpensive. because all the strength comes from (he plywood skins. Long tenons aren't necessary. workspace. and replacing year-round made the space feel cramped carriage the garage doors with shopmade the space Into a comfortable. I also used the dado blade to cut stub tenons on the ends of the parts to fit the groove. dark walls. The frame was glued and screwed through the tenons. [ also like the idea of having a large opening for machinery and lumber. This created a very rigid torsion box that should Drawing. en this shop.-(hick poplar frame joined with stub tenons. [ used a dado blade to cut a 1/2-tn.-wide by l-In-deep groove in the frame pans. lohn Hartman 30 FtNE WOODWORKING . Even though J never intend to park a car in the space. Each panel consists of a 2x4 frame faced with CDX plywood (raced for exterior lise). Carriage doors anyone can build=-l wanted the doors to be lightweight. [ glued and nailed pine boards to the plywood for a frame-and-panel look. he the low ceiling. Eliminating the garage door's overhead tracks would also give me additional headroom and provide greater flexibility with the lighting layout. [ thought the carriage doors would be easier to weatherseal and would offer more insulation. and minimal the lighting. and dreary. I decided I could make my own. The frame is filled with rigid insulation and covered with drywall on tbe interior face. Pekovlch's uninsulated shop was limited lighting to warm-weather woodworking. Windows with square corbels below [he sill added an Arts and Crafts element [hat would complement my home's bungalow style. [ chose a torsion-box design consisting of a solid-wood fr-amewith plywood on each face. T needed a different approach. Nine 4-bulb fixtures Three 8·ft. To dress up the exterior. For the second bay.THE BIG PICTURE With Its drafty doors and concrete Even In the summer.

For the floor.~"vicle door that weighs les. ) bolted the hinges to the door framc. I glued and nailed pressure-treated 2~"I:. ass attic floor with folding ladder for access Insulation and drywall on walls I sua bed the hinges to tilt: doors with lag screws Then T."&SHOPS20tl 31 . on center." F'i\"\r"" 160).. would be necessary La prevent r.Y.~cl the doors in place using shims to locate them properly. The insulation I used ~\<S the same thickness 3S the 2x'iS. [han a ryplcal solid-oak entry door.he floor from sagging under the weight of heavy machines. I mounted the doors with long strop hinges that are plenty strong and look grear.thick lumber for a frame-and-panel look similar to the other bay. 211 in. 1 stapled TOOI. plywood while [he inside face is I/I-in. The guys at Fine Hontebtttldtng were impressed. I added windows and framed the outside f:ICl· with 3..2-iJl.. placing rigid insulation in betv 1::1.8-irJ. [0 the concrete floor. Before screwing the ~I-in T&G (tongue-and-groove) plywood in place. is fmc.:11. hut since the rigid insulation has good compressive strength. Normally a ~pa ing of 16 in. They were also very easy to install. is far cheaper than a custom-built door. The final result is .l Shop Floor.h consi tent gaps all around. plywood to help keep the weight down.-In. 1 took a cue frnm :11.1 article on shop flooring by SCOtl Gibson ("LO\. so I spaced the sleepers 24 in. and at 00. A wood floor Is warm and easy on the feet resist sagging for many rs. TIlL· Outer face is J. First."j-in.~CO. Wir.

·th. COX plywood r J I I -I I I I 1 II I I Glass stop 'A-in. the interior compartments most of the strength rigid insulation.ck poplar frame Ph-in.Hn. thick poplar stock receives stub tenons formed on the ends of the rails with a dado set (left). are filled with I1f. Torsion-box yet very strong-and 1 'I. pine %·in.TWO OPTIONS MAKE LIGHTWEIGHT Filled with rigid Insulation shopmade conventional carriage overhead FOR DRAFTY CARRIAGE DOORS GARAGE DOORS treatment._ "'- I .c - 1 Water-shedding pressure-treatec threshold 2x6 pressuretreated bottom plate Shims Poplar frame. upgrade over makes them lightweight Groove..-thick 32 F1NE WOODWORKING . deep garage doors. Pine dresses up the plywood_ Pekovich applied flat pine pieces to create a frame-andpanel effect and an Arts and Crafts look. Although from the plywood skins. rigid insulation ·%-in. stub tenons help keep everything Once the glue dries. comes square during the large glue-up (right). wide by 1 in. plywood skin. plywood 1 I I 1 stub tenons . 'h in. A groove in the center of the 1 ¥2-ln._I ~ I I r 1 I 1 1 3 strap hinges lag-boltec to door and post 3x3 post lag-bolted to framing " .·in.. Pekovlch's and covered with a frame-and-panel and energy-efficient construction doors are an attractive simple to build.

COX plywood 6-mil plastic over the insulation to act as a vapor barrier.corn) that was dropped off in my driveway before construction started. I'm a woodworker. pine 3/4 . Compared to II garage door. so the idea of raising ceiling joists was a little scary. My first thought was to spray insulation on the underside of the roof and leave the ceiling joists open. and much kinder to my feet and joints. I had always thought of building inspectors as something best avoided on small borne-improvement jobs. Again. a 3-ft. (prehung) opening reduces heat loss. Side panels flanking garage's original 8-ft. but 1 was able to get the entire floor done in a day.FRAME smaller IN A WALKOUT DOOR steel entry door makes it easy to come and go and Its the walkout door were used to shrink the light and boost curb appeal. some machinery didn't fit. off my new plywood 1100r. easier to sweep. the actual process wasn't that bad. by 12-ft. just as Gibson recommended. not a carpenter. Enclose the ceiling for a brighter. but the bottom of my ceiling joists were now only 7Y2 ft. rigid insulation 'h·in. Fortunately. so I decided to look into raising the joists and enclosing the ceiling. Installation would have been easier in an empty shop. They also provide additional ·in. was able to reuse the existing joists by Culling them one at a time and nailing them in their new location (some TOOtS & SHOPS 201 t 33 . so Thad (0 install the floor in two parts. The new floor is warmer. The insulation contractor said I'd still need to cover the insulation with plywood or drywall if the joists were left open. drywall 'h·in. Unfortunately. The space felt more cramped and claustrophobic. the looks and reflected light provided by an enclosed ceiling. J moved as much as possible out of the shop by filling an 8-ft. opening. but on this project. Side panels nailed to header and concrete slab Glass stops 1¥~in. . without creating structural problems. moving the equipment fronr one side to the other. I like. they were a big help. portable storage container (pods. ) spoke (0 the local building department about my suuanon and an engineer in the department concluded T could raise the ceiling joists 2 fl.". warmer shop The ceiling posed a challenge.

Simple process. deep. Pekovlch uses fasteners while the glue sets (right). But the walls of my shop are concrete block. tongueand-groove plywood floor installed over rigid insulation Is easier on the knees and helps dampen Three coats of polyurethane from splns and wet shoes and make sweeping . by 8-ft. so I used an insulation method more suited to a basement shop. I decided to spray the underside of the roof with open-cell foam insulation. on center local codes don't 311mv the reuse of materials. foam panels and 2x4 pressuretreated sleepers fit tightly together. AND COMFORT protect the plywood 'I. it should perform very well. I took a different approach. which experts say is the real nemesis in heat loss. 1 'I>-In. Rather (han frame OUI the concrete wall in the typical fashion with studs on edge and (he insulation in between.-Jn. Then the whole floor is covered with a layer of 6-mll polyethylene 3f. But since foam practically eliminates air movement.q-ft. I replaced my three old 8-fl. so check first). With the addition of the white ceiling and walls. tongue-and-groove Basement approach to wall insulation 11K walls of a typical frame-construction garage are easy to insulate.. I installed a fold-down attic ladder and wired a light in the attic. an expen on green construction at Fine Homebuilding. plywood (bottom). J only was able to achieve an R20. I started by covering the masonry wall 34 FIN r WOO~ W 0 R KIN G . my shop now glows like a beacon. One smarr thing I did was to rent a cordless Paslode framing nailer from my local home center. Working from one wall toward the opposite wall Is an easy way to ensure the 2-ft. For insulation. On the advice of Rob Wmzak. WARMTH easier. I have some much-needed storage above the ceiling.·In. After applyIng construction actuated tool to keep the sleeper In position underlayment. two-bulb fixtures with nine . four-bulb fixtures. rigid insulation 2x4 pressure-treated sleeper glued and nailed to concrete 24 in..> 6·mil polyethylene sheeting (moisture barrier) Blocking was installed at the workbench location to ensure a solid footing. To access that .grade a generous bead of from a powderand adhesive (Jeff). but with a modem twist. the shop now has J more spacious feel and by adding some 1/2-in OSB (oriented strand board) on top of the ceiling joists.PLYWOOD A plywood noise and vibration FLOOR ADDS from shop machines. Since my rafters are only 6 in. The final ceiling is a lofty 9 ft. W'ben it came time to reinstall the lights. effectively tripling the amount of light in [he shop.~pace. I decided on an upgrade. While the floor plan didn't grow.

A second layer of Insulation the studs. but the result is a quaint backyard shop that's bright and inviting. wedging it between a (OP and bottom plate (hat I nailed to the block wall. With 2x4 nailers already installed top is put up horizontally and then the first layer of Insulation studs are turned sideways and placed on lOp. [ installed a second layer of insulation between the studs and finished with drywall. reducing the insulating properties of the wall. thick hut boasts an R-value over 20. drywall is the last step before trim. It's not just the shop that has had a makeover. From there. Is fit between framing in two layers.com Wall Insulation and bottom. Over that. nailing them to the plates. Use spray foam to seal any gaps between the and insulation.-in. A true transformation What started as a long-overdue insulation job ended up as completely transformed workspace.on center Second layer of 1'/. Installing the studs 011 edge would have created a thermal bridge from the block wall to the drywall. 2x4s nailed flat to 2x3s. 24in. But. I've acquired new drywall skills and an appreciation for those people who do it well. I've also picked up a few new skills. creating 2x3s nailed to cinder block wall Outlet box extension 1x3 pine trim First layer of 1'12-11"1. as much as I've enjoyed (he new challenges. I'm happy to put my (001 belt aside and get back (0 woodworking. the first layer of Interruption WALLS and a second a layer of 'h-in. drywall white was placed on top. Basic wiring is no longer a mystery to me. I wasn't looking to beauufy my home. The finished wall is only 3)/2 in. [ attached [he studs flat against the insulation. rigid insulation with a continuous layer of rigid insulation. Finally workspace. www. ln replacing the doors. D Michael Pekovich is Fine Woodworking's art director. TOOL) Sc SHOP5 2011 35 . I've done some serious framing and remodeling.finewoodworking. The continuous layer of insulation between the block wall and studs acts as a thermal break and should result in lower heating bills.HOW TO INSULATE To get the maximum Insulation painted layer is fit between a bright and inviting insulation studs. rigid insulation Insulation notched tor conduit 'hAn. spans the wall without CONCRETE value.


evaluating a bandsaw.Benefits of a bigger saw Even though you can boost a 14-ln. saws. All the machines tested weigh close to 400 lb. l discovered several steel-frame handsaws priced under $1. so we chose eigl\l models with at least 13/4 hp. a bigger saw will still outperform it in a number of key areas. machine. of resaw capacity while researching my new hook 011 I 'm sure you had great expectations when you added a riser block to you r ) 4 -i n. bandsaw. but they also have more inertia (or smoother operation and less bogging down. bandsaw techniques aile! maintenance (Taunton 's Complete tllustrated Guide In Band- saws. you'll wonder how you ever got by without it. bandsaw's resaw capaclty to 12 in. Resawing 12 in. but a riser block doesn't provide additional power for big resaw curs. on sale in November 2010). one. STRONGER FRAME ---A sturdier (rame is especially valuable for ripping large stock and resewing. particularly guide is the rigidity of the upper TOOLS & SHOPS 2011 37 . requires plenty of power. MORE POWER----- All the saws rn the test have large motors rated between 1% and 3 hp. you can realize your dreams of making big book-matches and large veneers.600 with 12 in. Fortunately. Wuh these HC"'". And once you have Sturdy guide post equals a straight cut The first lhing r check when one with big resaw capacity. In [act. which is twice as much as an ordinary 14--in. or stiffen the saw's frame. BIGGER WHEELS The bigger wheels not only provide greater throat capacity. bigger machines. Thrs means better support for all kinds of cutting tasks. one of these extra-capacity machines will likely be the last bandsaw you'll ever need. with a riser block. and build quality. machme. or help with an undersize table. or more. thicker blades. generally about twice as big as the table round on a 14-in. J put them through a series of rests to judge their power. The larger diameters also mean you can use bigger. compared to the % hp or 1 hp motors round on most 14·in. Larger roller guides and Laguna's ceramic guroes provide more surface area and berter control for larger blades. LARGER TABLE Tables are larger. cuuing ability.

the 19-in. About 20 percent larger than its closest competitor. 1 placed table to simulate an average resaw height. post: If the guide post flexes.ero de- the deflection. setup easy and quick. makIng It more to set the right gap. So. resulting in a w. by 27-in. I've found that a sharp blade and a rnoderare feed fate can compensate for about 0.inderfng cut. rack-and-pinion mechanism. of th -'iI It should be easy to adjust blade guides and fences \X!jtb the exception of the Laguna's in the group ceramic have heavy-duty can be in direct guide" ceramic guides.Jet's easily adjustable roller guides move without tools and stay put when locked down. the blade wUJ twist acd bind. Laguna:S ceramic side guides are easy to set and give excellent blade support.he blade. making roller guides. of flex.Some guards get In the way. Roller guides need to be a couple thousandrhs of an inch away from the blade to keep the rollers from constanrlv spinning 00. force to the blade and measured me guides 9 in. the downside. . But if the IIIljllT guide post isn't parallel to the bLacfe. Crank it up. contact [ like that Laguna's with the blade. because they can be adjusted without fools and they stay m position as YOl1 tighten their mounts. after checking the guide posts for flex. The Jet's guides are a favorite lOO. TooI·free is faster . both front lO back and side to side. rhe upper Laguna thrust guide requires a wrench for adjustment and you need rwo different wrenches to adjust the lower guides. table on the larger Grizzly saw Is easy to tilt thanks to a Grizzly's guides adjust with a Single wrench and stay PUI during nghtcning. To measure guide post flex. Unfortunately. 38 r IN~ woo 0 \Xi 0 R K TN G . pressure on t. of Whilel. all the saw. above the Then 1 applied 6 lb. obscure Blade guards on the Grizzly and Shop Fox saws partially difficult the thrust bearing. I used a dial indicator to measure [he position of the guides a! the top and bottom adjustrneru. flection is [he goal.005 in. this is the number one cause of bad bandsaw cuts. too-For good blade support. Straight post is important. the upper guides should always be kept dose to the workpiece. Other than a dull blade. borh the Gnzzly and SllOP Pox saws partially obscure the upper thrust guide behind the blade guard. the guides will have to be readjusted every time the guide post moves up or clown.

All fhe saws had 110 lem splifting prob8-in. Rikon has a rwo-positlon fence too. blocks of 8/4 soft maple info per· fect %·in. The Jet and Rikon saws had similar problems. dle Rikon. [ also liked Laguna's fence. sweeping curs and fight S-curves. Wit.lrd makes il Lough 10 see the thrust and the ing field.-wide.-thick.) for resawing. despite my overly aggressive feed rate. Grizzly's two models two-position in the tall easily have the best fence setup. bur fhe blade guard" All offer plenty of power and control To gJl1ge the power 2-fr -long marie of these machines. on the jet saws. Where's the line? Compared to the wide-ope« view on the Laguna saw (top). Before cutting. www.032-in. Steel City's blade side guides. but even position ir\ too short (2Y2 in. 3-lpi hook-tooth blades (supercutbandsaw. we switched to SupcrCut I.com TOOl s 8. Shop fox. To level the play- Great resaw cuts all around. 6-rpi hooktooth blades and made a series of long. Steel City and Rikon tned to improve cut-line visihility through their guard with little plastic windows. we resawed 8-in. I found the Rikon. To rest the saws' abili!y to cut curves and rhe performance of their side blade guides. and Steel City guides tedious 10 set because they move as they're tightened. despite the acrylic window that to is meant to help. and trued the fences by setting them parallel the blade. slices of veneer. but disrortion and fence mounted 10 a cast-iron primary fence. both Grizzly machines make it easy 10 angle the fence to correct for drift.! gnides handled the task with ease.com) All the saws handled this task with ease: Even the 1~-hr Jet did a good job.finewoo<lworklng. Johnson aligned the blade and guides properly. and the Sreel City slightly obscure rile cut line with the guides set close to the workpiece. gU.-thick veneers.-wide by blanks into IIS-in. we equipped all of the saws with SupeCut 3A-in. visibility of Ihe cut line is hampered on the Steel City saw (bot· tom). All of the saws aLK. last.h an easy adjusuneni for elrift and a rwo-posiuon auxiliary O.Get my drift? With star knobs holding a tlllc" bar that turns on a pivot. SHOP:' 201 j 39 .Hn .

lOO. lall Wheel size: 19 in.I GIJ5rJX2U The 17 -. table. wheels. flex. It has a smaHer motor. Rikon.in.com 40 F J NEW 0 0 D \V 0 R KIN G . the Laguna.004 Source: grinly. The Laguna and Steel City saws have mechanical brakes actuated b)' a foot pedal. by 24 in. tall Wheel size: 17 in. a great fence. in.G0514X28 the big Grizzly has a powerful motor position motor.49. and Steel City saws have blade-tension gauges that show the right setting for specific blade sizes. and the Shop Fox have a graph that doesn't directly relate to blade size. Johnson used a push-pul/gauge of force to the upper gu. 240v Fence. '111e Jet. easily adjustable blade guides. Both Grizzly saws have electronic motor brakes that Stop the blade within 2 seconds. Laguna's foot brake also has a switch that kills the motor. / '!2 in. Theguldes also very good and its twofence is the best of the bunch. Laguna. D Roland Johnson is a contributing editor. . Street price. 6 in. The best va IDe was an easier choice. It would be nice if the tires were white or yellow taaid without blade' tracking the door.: 0. Grizzly is a very good value. The Laguna is also a capable saw with great guides. Grizzly. ~!llde-post fleX: 0. but the saw works well and has the same great fence as the larger Grizzly.ide post and measured why they handle big resaw cuts so well. the 13A-hpJel is an excellent choice. Source: grlzzly.: Iwo-positlon.y to record the settings after you've worked them out. which is probably dust make them tough to see through. opening but that's nitpicking. Table si%e:17% Guide-post in. It has good power. a huge are table. $1. but it does provide a W3. 240v Fence:' Iwo-posltlon. r pick [he Grizzly GOS14X2B as best overall. Rikon. Table size. and Shop Fox provide a wide open view of the cut line. and rigid frames. For ~l. 19 in. a huge table with sturdy trunnions. / y. and an electronic brake. and wheel size than Its bigger brother. Brakes and tension scales are nice perks Bandsaw brakes are a good idea. Street pricel $1. because big bandsaws can take the better pan of a minute to come to stop. by 27 in. I also really like the Jet saws wah their smooth power.100 Motor: 2 hp. except a smaller table and throat width and a motor that's 2 hp instead of 3 hp: I think the motor size is a non-issue. The Grizzly saws. with the deflection 3 hp. but given its 14-in. and an electronic brake. and Shop Fox saws don't have brakes. The saws I like best While all of the saws are capable machines.5 Motor: Push on the post. If you don't have 240-volt power. The Grizzly G0513X2 B has the same features as its big brother. to apply 6 lb. in. it's a whole lor of saw.004 in.ccm a dial indicator. All the saws passed t. 6 in. it doesn't have the throat capacity of (he other larger saws. and they proved accurate. The jet.he test.

002 Source: lagunatools. Fence: Iwo-pcsttion. and its in have excellent tool-tree roller guides and sturdy frames.008 in. Table size: 17% in. and has the only motorconnected foot brake in the group. Table size: 19 in.003 Source: jettools. 3'h in. Motor: 3 11P. It also includes a mobility kit.$1. 120v Wheet stze: 18 in. in the guides that are a little finicky to adjust.JET JWBS Jet's saws lBQT Jet's 18QT3 Is nearly identical to the 18QT. Street price: . 240v 2'10 in. stee lcitytoolworks. Guide-post flex: 0. lall Johnson's favorite.005 in.y. whleh will slow you down between cuts and setups. Guide-post flex: 0.corn RIKON 10-345 This machine SHOP FOX W1107 This saw shares a strong resemblance many features and parts with the smaller Grizzl. Guide-post flex: 0. by 20 in. by 24 in. It Drawback.400 Motor: 2'12 hp. Unfortunately.com machine Just in the test and it fine. Guide-post flex: 0. But it doesn't excellent have rip and STEEL CITY 50250 The Steel City has yellow tires for easter blade tracking. machine the test.int would bean advantage in smaller shops.003 in. /'12 in. The guides are All the other features and specs are the same. Wheel size: 17 in. even when small footpr'. Source: jeuools. has it a short rip fence and the table tilts when a It's banged with brake or Grizzly's fence.com TOOlS & ~HOPS 2011 41 . Table stae: 19 in. 240v 4 in. in. $1. 2'12 ln.065 Motor: 2 hp. Fence: Single-positlon. / '12 in. But there's brake. The saw cuts well.600 Motor: 3hp. Source: rlkontools. a large board. 240v Wheel size. 3'1.s Include a short fence and blade is one of the two most expensive machines test.495 Street price: $1. Whee! size: 18 In. by 19 in. tall Wheel size: 18 in. tall Fence: Slngle-posltlon. Table size: 19 in. 18 in. Source: woodstockint. by 21 in. Is a capable basic machine. Guide-post flell: 0. 14 in. and the table wouldn't hold 'its position when bumped with a big board.600 Motor: 2 hp. Fence: Single-position. but it has a 3-hp motor and an illuminated power switch.com in. Street prlce: $1.500 Motor:1% hp.corn Street price: $1. Source. This is the only 120-voll performed resawlng. tall Fence: Single-position. by 20 in.007 in. no LAGUNA LT14 SUV This is the only 14-ln. Street price. com www. and good-looking metal handwheels for guide-post and tension adjustments. tall in. Guide-post flex: 0. Table size: 20 in. 240v Wheel stze.com Street price: $1. by 19 ln. tall Table size: '16 in. This is one of the two most expensive machines test in the' ~-"""'' '"IIIl~'' ' i!iiii~'' !F 3i/2 in. . 240v Fence: Two-position.finewoodworking.

it challenges our studenrsin genuine and surprising ways. I can't go into all or it in (me article Here.WAY _A secure lid. Although every .g curriculum at the North Bennet Street School. the top drawer and the top of the chest 42 F J i'f. and pLne: (for drawer parts only). Above the top divider is a spate to pur.(16 in. A lock mortised into the top hold the lid ~d. (For a complete article on our method for dovetailing and also making drawers. ta 11)is at the small end of ou I: size range. cherry. scaled or full-size. Drawer size and configuration is another place when': individual desrgns vary. tall. between When not locked in place. The lid provides a means of locking the box as well as an introduction to setting a full-mortise lock. the frame-and-panel 1lei. so we've narrowed the parameters to make sure that rhe focus stays 011 the craftsmanship and 11m the overall design and dimensions.£'. nOT just working from tile drawing: and choosing between various methods and techniques. Though simple in design and appearance. \'(!e allow students [0 use highly figured woods only' for the panels.cated storage space. the lid tucks neatly away in the spece edge and two pins on the bottom in place.! N G . fitting the actual pieces. and so is. the fool chest project has become a familiar step in the two-year Cabinet and Furniture Makln. deep hy 24 in. deep by 30 in. I'm going to focus on machining the dad(ic§.\I 0 o D W' 0 R Ie. bur students can build U1C'JTl up to Ul in. This fool chest. Primary woods can be maple. the lid when the box is unlocked. This tool chest is the students' first major project. wide by 17 in.aspect of bullding this tool chest-from the dovetails to [he shiplapped back-cremes a valuable learning experience. .E.The North Bennet Street Tool Chest BY 5liIEV. wide by14 in. and rabbets: fitting and LID STOWS A. Choices for secondary woods are soft maple" poplar. or mahoga- ny. see former instructor janet Collins's article in FW'\I1 #157). Learn what the students learn as you build a handsome home for your hand-tool collection BROWN dginally conceived simply as a place to put your tools. and consists of a through-dovetailed carcasewith dovetailed drawers running on mortise-and-tenoned divider frames. The typical chest starts w_iU)a drawing. vVidnut. They learn the value of planning the order of tasks.


'/0 in. thick by 2'/0 in. by % in. in. groove 'Its in.. deep by 'I.. Brass knob. blocks.... thick by 1".. _.1 Point" 44 FINE WOODWORKING . in. ~-- before _... 'Ae in. '10 in.... long Door stop..... wide by 24 in.. % in.-in... .. G!ue brackets to front of top frame rail. but the lesson partition. long Drawer runner . 0/'._- Drawer bottom. 'Is In..-----.. wide I -----~ ------L_ __ ~_. 3j.. Wide by 7AG In. 'h in. ~ Top and bottom.~_:=:~= ~ I -- ~------~.. diameter Drawer fronts.. wide by 22'h In. 'Ia in. wide by 22'h in.. long dividers... wide by 22% in. and a frame-and-panel the chest. th ick by 1"4 in. in.. a dovetailed doesn't end there. in. beveled to fit 'I. long HALF-BLIND DOVETAILED DRAWERS Wait until the case is completed building and fitting the drawers..___ --__________ Rabbet. thick by 16 in.. Tenons. '/16 in.. 'h in.-:. thick by 1% in.. wide ..'. thick DOOR-STOP DETAIL Drawings ilob 1..DOVETAILED Through-dovetails TOOL CHEST are an attractive. Mortise-and-tenoned lid round out the list of furniture funda. traditional joinery option for this tool chest. - Rear rails. ~ Dadoes. thick.. long Front rails. thick by 2'12 in.2.

(ions (0 the inside faces of (he case ends. in. ~I 4 in. long Secure back boards with round-head screws. The process requires careful layout. and installing the lid and its hardware.====::. or starting through the back and stopping at the tronr. The dado will run out [he back edge..==. A( NBSS. and fitted all by hand. cutting and fitting the vertical dovetailed partition. Use a marking gauge off the front edges of [he case to layout the front end of the =~~~~ -~~ ) stopped dado. or firs neatly under a typical workbench.BRACKET DETAIL installing the horizontal dividers. labels to help with orientation. use a marked story stick to transfer the dado 10c. Plenty of learning opportunities There is nothing stronger than a dovetailed carcase... the dovetaus can be laid out. in front of the stopped dadoes.. So the choice for the carcase joinery is a natural. Rabbets are the next step-After the dadoes. as well as safe and effective ways to make plunge and stopped cuts. I -_--'"----- Q T 3%in. and square IIp the ends to the layout lines with a chisel.ln.~.=::. clearance be/ween divider frame and back. We finish the dadoes with a router plane for consistent depth._~ Sides.. Mark the fence to show the extent of where the blade will CU( [0 know where to stop and start. Because the front is already Hush.1. so ic will show in the rabbet until it is covered by [he shiplapped back. tali l J_. and that allows me to run the rabbet through them. One of the most important safety rules in the NBSS shop is that we never do stop-cuts on the tablesaw without a clamped block backing up the workpiece. I I. T _jI_ 3'1. cut. in. cui the rabbets for the case back.." FWU7 #171.) How to cut stopped dadoes safely on the tablesaw. Not designed (0 be portable. wide by 14 in. and dovetails are one of (he fundamentals of woodworking. j_ lc::. FRONT VIEW SIDE VIEW TOOLS & SHOPS 20 t 1 45 .-wide dado sec because it's faster and easier than cutting them with a router. I cut them on the tablesaw with a 1/2-in. we check the case for square before laying out the dadoes and rabbets. 1 yin.::==~ I I I - I 24 in.::. the chest looks great on a countertop. each pair of dadoes involves one plunge and one stopped cut.The dadoes hold the divider frames securely. % in. with joints dosed and (he case square. With the panels cut to length and width. 3/8 Shiplapped back boards. we start with pins and then scribe and fit the dovetails. Prom the inside face of the case bottom. a _ .. Q pi. (for more all throughdovetails... thick by 23'14 in. So for every dado you are either plunging in at the from and running out the back. Because you are working on the two opposite sides and it's safest 10 keep the end of the panel closest (0 the dado against the rip fence. A very important component of the layout is that the franc and back edges of the case must be flush to serve as consistent reference surfaces. and mental focus. thick by 16 in. I'~/ 14 in. in. '1I .. ~ . I lay out my pins so they are at least as wide as (he rabbet. Once the dadoes are laid out. The sides get SLOpped rabbets on each side. The rabbets in the (OP and bottom run all [he way rhrough.. But they also provide (he opporruniry to learn layout principles and techniques. J cut them on the tablesaw as Leave v. TI1e key is to reference from the inside surfaces of the case while it is dry-fitted. see Christian Becksvoort's "My Favorite Dovetail Tricks. the front edges of the divider and (he drawer fronts will lie in the same plane. Once all four corners are dry-fit.. I i I C::'=='::'::====::''::::':::::::'=I.

Re'ference from the inside faces of the stdes and the bottom. The story stick has one clean end and knife nicks along the edge to indicate the dadoes.ES: CUT THEN LIFT RIG. LEFT-SIDE DA. and the top one creates aspol for the lid when it's lucked away. leave them . Then carry the marks to the back of each side. keeping the pressure under the workpiece against the fence. plane only the bonom of [he frame (0 Ill. To keep the end against make these stopped cuts in both directions. We use . I would stopped [he dadoes. use the miter slot to reach and 11ftIt off the blade. router. pivot down into the moving blade and then cut through the back of the side. Once each 46 FINE WOODWORKING . Simple mort be-and-tenon joints keep them 10gether. When the end mark on the workpiece meets a mark on the fence. Drawers run on mortise-and-tenoned The drawer dividers frames live in the dadoes in [he sides and provide a place for the draw- ers to ride. Stop then go_ The opposite dado cuts begin with a plunge cut.North Bennet method STOPPED DADOES ON THE TABLESAW Most woodworkers same reference do these with a plunge the rip fence. marks with a handplane. After gluing glue. bir for the mortises and cut the tenons on the rablesaw. but a dado set Is taster. and clean up [he skim any mill the [oints. flush lip [he frames. With an L-shaped stop block backing up the workpiece. Check [he length of the frame lO the space from dado ro dado.DO.I router table with a 3/16-in. Test-fit the thickness of each frame to us dado. Trim the frame if needed. cut instead The only difference cut and a is that each piece has a plunge of one or rhe orher. When milling the parts. If the frame has been skimmed.~lighily rhick So their fit in the dadoes can be fine-tuned with a handplanc.HT-SIDE DADOES: DROP THEN CUT Go then stop_ Start cutting into the side. Dry·fit and use a story stick for layout.

It won't be notice- able. It also has brackets attached to [he front. fective way to glJarantee this is to make the distance between rhe step" J hair larger than needed. according (0 (he back step. With the dividers pushed up against the end of the dado (far le(t). If the fit needs adjustment. That way. An efoversize blocks to the frame and the. which act. The dimensi and the top n befillet the from edge or step has to be accurate. The bot[om drax. If both the stopped dadoes and the frame notches were laid OUI and executed carefully. as a stop for tile lid. Dry-clamp the Stop in place. which r make by gluing a slightly oversize block to each side of [he front of the divider. Check the front edges for alignment relative to the case front. shaping it at the bandsaw.11 to fit. trame filS in its dado. Bottom drawer runs on a different system-You've created the space. plane the bottom face of the frame lay alit the notch and trim with a handsaw. but the botstop (which tom drawer space isn't complete. layout the notch and use a handsaw and and cleaning it up the bench. as does the position of the piece in the case. TOOLS IX ~rIOP~ lOl I 47 . adjust them. the frames' front edge should lie in a plane I( nor. They lie in the same plane as the stepped stop a: the bottom of the case. and then Test-fit the dividers. rides on a stepped er is also a transirion from the plane of the drawer fronts and door stop) and blocks glued in behind tween it.for the [Host ADD BRACKETS TO THE TOP DRAWER DIVIDER lid and of tile drawers. . and clean out the a router plane.Hand tools complete end of the dado with bottom with the dadoes. Square the a chisel. skim the front edge of each frame with a handplane..n shape them than It is to shape tiny pieces on the bandsaw and then try to clamp these Irregular parts to the divider. if there Is tearout or any other Is-sue. The top drawer divider is laid OUl so there is enough space above it 10 store the lid.. Theil glue in the first block behind (he stop..

Base it on the space at the ends of the drawer pocket.0 with the other and mark the top is and bottom of the partition. Locate the first side of the dado The shoulders me dovetail dividers. for the case to expand should be ready The clamps and to tighl to the front given the of the joint grabbing before A handsome lid and well-fitted Size t he lid fra me to fit the in the front created If. in. Make (he dovetail pencil. of 10 the socket. the front lfz in. and what clamps applied to is onJy the front 3 Ln. 1 N G . The results are more consistent partition. filled. requirement you can check needed gIving it Dovetailed partition-A the project is that One level of drawers be divided by a vertical dovetailed partition Before gluing the divider and frames in. clamp In a spacer block (right). for the are This sunk into a lis-in. Our method use a story stick and reference this way. The rest of the frame needs be free enough contract: pull rhe frame real possibility it closes fully. These lines are transferred layout. Raise the panel anel then fit it by hand finish the frames with a rabbet plane: them Preinto the panels A well-fitted drawer is a hallmark of our program. Chop the the location to the divider. transfer in and our easily and quietly. Now and adjust the front step position it when of and accurately in. 48 FIN E \V a0 D W 0 R I. This provides on the tablesaw before gluing the exact size for the panels. the dovetail If adjustments and partition is rest-fitted are needed. of [he partition becomes the doveand. guide block makes the dovetail easy. dryGlue in. drawers Iid space After of the case. \Villl do them to the socket. dividers clamp everything cedure so you'll know your proare needed.o glue [he stop yet. rigidity doesn't.to 4 the dado.'IS sure not t. the lines. with only enough clearances for its function and wood movement. of all one of the inside faces of the case. so [hat the that the dovetail alone After notchlng shoulders Dry-fit and use a story stick. the far Side. making the frame.\\7e want a drawer that slides Angled DOVETAILED PARTITION socket. and cut the dovetail.he partition and gives il. dovetails by hand.making When there are only one or two vertical partitions. using a sharp 1ines onto die dito comsawn and Once scribe the socket the socket La bouom [ail. use fit the dovetailed partition. Often a student's first. inclination is to align one divider 1. dry-fit it and mark the groot!e depths on ("he (ace of [he frame to outline the panel sizes. Use the story stick to mark the near side of the partll/on (above) and to mark then the actual partition the partition out in the dado. dado in the registers t. a story stick to establish its location. . Before fitting the partition into Its dadoes. Brown cuts their small . Jay out Again. plete pared lO viders. Now remove the two dividers and cut the shallow dadoes in them.

wide by 1 in. thick by 1'h in. Haunched tenon. ~h~~~)". Steve Brown is department at the head of the woodworking NBSS.'~W panels are an Ideal place 10 showcase Upright piano lock kit .iel is held in place by pins and sockets on the bottom edge and the full-mortise lock Before a pplyi ng fintsh I handplane. in. the location of the pins and sockets and drill the small holes. '/. com. After the first coat. Inner stile. thick by 1'14 in. correct it with a smoothing plane before filling. Wide by 22'h in. Ill. beautiful grain. After [he second coat. % in. check it for wind by setting it on . long Groove. long First. deep I L wood.finewoodworking. in. :y. wide by 11'1. V. wide by 'I. th ick by l/. in.1 shallow strike plate mortised in the top to catch [he bolt. in. 1 make the shiplapped parts on (he tablesaw with a dado set and install them by counterborlng and using round-head screws. wide by 22 'I. Brown applies the finish to the panels before gluing them Into the frames so seasonal movement doesn't expose unfinished Bottom rail. No. th lck by 1in. thick by 1~ in. J use shellac and wax on (he interior and areas of sliding in the top edge. shorter than the front to aid in the fitting scrape. :y. thick by 1 % in. long Stile. As for the back of the chest. surface with steel wool and ton Polish butcher's wax. 1 put the lid in place contact On the exterior. fit the drawer parts to their cor- Add the hardware and finish The I. I smooth W. responding spaces. process Once the drawer is dovetailed and glued up. wide by 11'14 in. and then the hardware simply presses hand-cut into place: morso mortise The lock set is a matter of a deeper tise with a shallow to by out I wipe on Minwax Fast-Drying Polyurethane. '14 in. long polyurethane Pre finIsh the panels.lX with the Bos- D the whole piece sits flush in the lid. If needed. Ba· sic brass hardware (rockier. You want no g a ps M this point I cut the drawer back 1/32 in. '/. in. & www. 1 sand with p400 grit. long PIns and sockets keep the lid In piau. 32334) Is pressed Into holes drilled Into the case and lid bottom.l Oat surface. wide by 1 in. in. in. and . long I Tenon. I -!LJ: I Top rail.com TOOLS 5HOl'S 20 t t 49 . in. and sand (he chest up to P220 grit.The panels are Ihe only place where students and Ihese molded are allowed 10 use highly figured wood.


. he buned but the bit must in the fence for most tasks.. Pir«t .1I1cl rake off.I\\! extension s Into router tables. which will save you hours of hassle. too. Plus. Hut 1t'5 not enuugh In sim- ply drop a router plate into Ihl:' melamine extension wing For one rhing.J('hing (he router directly to the table.-'s J -nap to put on .ue fence already in place on the .<. you can rake advantage of the solid. MO)."ag. so adjusrmcnrs arc easy. Til is router solves all of those problems and a FeIN more.. and screwing a couple of scraps to the back of (he rip fence JUSt doesn't cut it Dust collection also \)eCHlS(:'tlil'rc\ IS a problem. d Balric-huch e plywood for the lable\ support frame and fence because roo L -" IX S II () I' S 20 I J 51 . because il specializes in t:) blc-routing and has un- pressed edhors in past (001 reviews. accur.50has great dust collection of us own. rhe rip fence is nor rcadv for routing.and ir\ not . .Jhle~. [t :11. Above-the-table dust collection l:'i integrated into the [ence-~lJld il really WOI'k. Tv "void the hassle of .(-fr<. Not only is it roo shm'( for vertical job~ like slkling dovetails. Finally.~ above-the-table bit changes and beight adjustments. i. It alJ()W. And single-layer !able~ everuually begin (0 ~<lg under 1<1 hie the weight of the router.>e..so you can carch dust from beneath the table. And. The fl'l1ce clamps to the tahlesaws rip fence. I( has a ximple hut effective fence rhat is tall enough for venio! routing.It{. There h a replaceable insert. too \ chose the Triton TReOOl router. The router matters. WH)gs turned ing machine without consuming an extra inch of shop space."()you think)..:1W (or .'. no effiei eur way to collect from ahove the table. so you Gill bury bits in the fence and gel zero-clearance routing when you need it .1 had i(\c" on paper YOIl gC( :111 indispensable woodwork- I 'veeen many t. I u:. a rigid plvwood frame under the table eliminates . making most jobs pracucally dll. r used :t preclrilled router plate from Rockier (rockier COIll.

---------~~ 52 F1N.. 5% in. dla. square. flanges. smooth MDF for top and the plywood for everything else. -. 6'1. :-1 t:=':O ~n:. I 9 in. -?I ~ "__ . Note: Frame . -7 <E- I=:=:::. made from lkin. FIe In. :I I I :I I I-f:L~-I--o---"-I. ----j ~_-_-_-_-_-_J_+Ul I Screws driven through frame flanges attach the top. so you can attach a shop vacuum 100. .. j. drywall screws. sized to fit between fence ralls '-Yl&-in.• in. I ~ . long ~~ Fence face. 5/. tall by 10 in. 5'h In. Top. In. 3Y2 in. : I I' . A dust box beneath connects the table to one In Ihe below but inserts ~ ~ c3 Slot for clamp bar.... . wide by 7'1~In.~ li)OP _ ~ -: : :. narrower and % in..E WOODWORKING Drawmgs JJm Richey . memrersare fastened with 2-m.::==_::::j~ . deep Rib.0 ir). 2'l:rin. ~ __li:j:" 0 I ==~I' : 0 : 13% . tall Frame. long Frame part.../' and collet wrenches Dust-box cover. shorter than top TOP VIEW Dust-box bottom.! in.• JUST SCREWS AND PLYWOOD Use lightweight a flat.. and faces Replaceable insert. 5V~ in. top. wide by 10% in.! in. %6 in. .I I 1< 2?~8i~. 41in. I 28 in. .-thick lightweight M OF. long c-:rJ' t-------------ljf-----J ! . drywall screws. . Plywood shelves bolted to ralls . with dadoes for the height-adjustment . I: 1 i "f--~_. 2'1. 2¥. wide by 11% in. offset --_ Opening for router plate. 8% in. wide by 10 in. wide by 9/. in. long Opening for shopvacuum hose.-- Flange for router plate. Replaceable collect dust from above. 5'12 in..= ~ 6'14 lh. in. assembling pieces with drywall screws._Ya_i_n_. tall by ~ Tool storage. long fence. tall by 10¥. long will add years to the fence's service.t______.' . and dust-box bottom are attached with 1'/4-ln.

nally. Begin by laying out their locations on the underside. but I have iI great trick for MAKE AN ACCURATE OPENING FOR THE ROUTER PLATE %-in . You'll need to rout two openings in the table. Add lag bolls on Ihe oouorn of the legs 10 adjust the height ~ d I II _. The box's bottom gets two holes: one for (he hose that runs to your shop vacuum and one for the bose that runs from the router to the box. One sheet of each is more (han enough to make the entire table. Press the plate firmly against two sides.. you might need to add HAVE A SMALLER If your saw has 30-in. bit. and rout it flush to the strips. The extra space makes It easier to the plate and the oththe plate In and out. to be removed by a nottombearing. .r used it is stable and holds screws very well..ln. . ~~~~==. The table's table doesn't canWevered have weIght legs al. bit so that the corner the radius on the Template strips attached to underside Bearing rides on template strios. TABLESAW EXTENSION? Keep dimensions from the router plale fbrward the same as for the . . Running both hoses into 'his box means (hat a single shop vacuum can collect dust from above the table (through a port routed in the top) anel below it without joining three differenr hoses to one another. leaving about ¥. of table get ADD LEGS FOR SUPPORT If your extension some. . _. The opening for the router plate must be more precise.. flushtrimming bit Router table Rout the opening Rush to the template.-dia. Drill a hole in the dust-collection box cover for the shopvacuum hose.. driven in from the outside of the frame. For the dust port. and pre-drill clearance holes and countersinks.-. drywall screws. --- 1 SMALLER TABLE MODifiED FENCE TOOLS & SHOPS 20 t I 53 . and lightweight !'vi [)F for the tor because it routs well and makes a smooth.~~====~==~==~~ . Use a 3J. radius matches plate's corners.. one for the router plate and one for the dust pan) but neither is difficult.. to fit a dust- the . The joint is st. After assembling the basic frame.l.ready. Sbrink the area behind the plate so thaI the table fits Ihe shorter ralls. don't rOUI the small dust-collection ocr: in Ihelable.Jarger lable. but use business cards between er two sides... dust from tnc top of thefcnce. ~ -----__l 1-------1 1< \ __ _-_-"'-)-----':l>1>I ~~I~ c-" router plate. rails.long drywall screws. durable work surface.rong and no glue is needed. Cut away most of the waste with a jigsaw. Pi. Make the table first The table has two pans: a large tOP and its underlying frame with integrated dust collection and support for the router plate... The frame is a simple affair.-dia. Make the frame and then the lap. assemble [he frame for the dust-collection box. enough coltectlon behind opening Instead. simply attach template strips on your layout lines) rough-CUI [he opening. flush-trimming Bujld a routIng template around the plate. attach (he flanges.I In. *For l/)is version. there won't be room box for the cotlect could be enough to make your saw prone to Upping over. Use 11/4-iI._ ~--. Strips of plywood-ali ripped to the same width-are butt-joined and held together with 2-in.

I then laid :1 6-fl. 0 John While is a former shop manager al FIIfIN.1-io. I bolted plywood shelves to the underside of the fence rails. anach the frame to the top. with bun joints and screws. The drywall screw It right White filed a notch In the tip of an extra screw to cut threads in the plywood. cut a bir opening in [he front sub-fence and slots for the damp bars in the rear one. port. 54 r I N I: W0 o f) \X'O R KIN G . A strew In eath corner fine-tunes the heIght. are Make the fence and install the table The fen . Finally. Next. To ease installation. 'which sirs over the dust. J leveled the router plate in a similar way.l cover over the center bay created by the ribs. six per face. attach . After attaching the plate to your router and dropping it in place. will thread its OWl) hole. To level the router plate. The fence faces are screwed to the sub-fence wlth 1 \l. level across the saw's table andthe router table and adjusted the screws unt il they were level. and you're ready to do great work and do it Llsler. To create suction at the bit opening. After both openings routed. A long level lets you know when you've got Same trick for the router plate.e is assembled just like the frame. White uses a drywall screw in each corner. attach the dust-collection hoses. Before you screw it together. [ drove four Allen-head screws up through the shelves-one for each COrner of the table-s-and set the table in place.[hat (see p. resting its corners on the heads of drywall screws driven into plywood flanges at either end of rile opening in the table. 53). clamp the fence to the saw's rip fence. The replaceable insect fits between the two faces and is screwed in place. drywall screws. ClI! two dadoes in a square of pIY""oodfor storing the wrenches-s-and screw it to the cover.

A shop vacuum is strong enough to couect dust from above the table and from the router at the same time. leaving very little behind... DUST COU.com/ extras. Ask shop guru John White at FineWoodworklng. • k Expert answers to all your WOL SllOP questions are on Iy a eli el( away. Illsert . Make bits 10 eliminate learout. Hook up the dust collec{ioll. Ribs make the fence rigid.com s: SHOPS 2011 55 .. c router TOOLS www.s replaceable. g.ECTION ~ Online Extra r .Is newo odwor k i . 100. The tall one for each of your most common fences on both sides can be replaced. Clamp a plywood spacer next to the rib so that it remains vertical as you screw it in place. Four screws hold it in place from behind.

For more serious cuts and eye injuries. and occasionally the palms of their hands Although the hand often will recover from minor injuries even jf it receives no care at all.IVAN W OOcl".LL. As it woodworker and physician. however.. what you clo first can have an impact on the rest of your life.orkers spend a lifetime handling razor-sharp fools. In this environment. there's always the risk of an injury. Forget the first-aiel kits of" fered in drug stores 'Forget much of the 56 r rNB \V () 0 D W 0 It KIN (~ . [ understand the types of injuries 111<1[are common in the shop. power equipment with exposed blades.liJ.Edge First Aid ER doctor: Throwaway your old kit and forget what you've been told BY PA'iI'RICK S.Cutting.I. and boards that harbor splinters and fasteners. . recovery' is faster with less scarring and less risk 01' infection if it's [reared properly. Usually woodworkers cut their fingers. and I know how they should be treated.

S &: SHOPS '2011 57 .1. looks very different from the kits and eye wash. The woodworking environment is unique. Now retired from his medical practice. In the end. 1111O[u::::: J61'1r\ Teueaoh TOOl. flexible Many of these products are av. conan tape 7. he has more time for woodworking. 2. --~---.6. Examination gloves coverings for wounds. Patrick SuJlivan is an internal medicine specialist with extensive emergency room experience.aUable from multiple manufacturers. 1. Eye wash 4. Glue syrInge 3.. Magnifying 8. Tape 13. Tegaderm bandages 5. Kl'azyGllJe 1.. . Scissors 12.. Sterl-5trlps lens It contains materials for closing cuts. X-Acto knife 10. tools for removing splinters. Band·Aids . Tweezers misguided advice found in popular manuals.. 9. and I'll tell you about some specialized equipment and supplies that work well there I'll also show you a few tricks on trearrng wounds=from stopping bleeding to cleaning to bandaging=-based on proven medical principles.I way that gets you back to work as soon as possible.Build a custom kit A first-aid kit: for woodworkers sold In drugstores.-------------~ -. you'll learn how to treat injuries in .

and debris in WhIch bacteria can hide and multiply. debriS. GET IT STITCHED Wate. Wash every wound.Christopher Mill.Do you need a doctor? VULNERABLE AREAS OF THE HAND Areas highlighted in green contain very few vulnerable structures. cuts here typically can be treatedeastly at home. ~ . contain tendons. the decision to gel stitched depends on the location of the wound (see below). If soap Is not available. It is short. but they are not a proven substitute not need these products. or dead tissue In the wound . which Is:the most effective wound closure available . because they will clean it there). such 8. Moreover.. If you can wash effectively. A deep cut Iike this that's under 1 in. The prob-for all wounds is immediate washing with soap reduces tile number of germs. How to handle most cuts SOAP AND WATER The enemy of healing Is Inf~Uon. Dry both hands on a clean paper towel. LATHER UP Wash both hands vigorously enough to generate lots o( lather under a strong stream of warm running water (or several minutes. cause disease. the oint· need no antibiotic for washing. (You can skip this If you need to go to the emergency room. sawdust. you do Cuts that do not slice all the way through don't require stitches because the lower layer of skin keeps the wound reasonably closed. Normal hand movements will not apply stress to the wound. Unless the wound obviously penetrates into a bone or joint.. essentlany. cut on the palm and index finger begs for stitches. In between 1 in. several minutes and lather thoroughly. hold the cut open and flush the wound for at least a minute. the wound needs to be stitched. however. all the risk is from bacteria you already carry on your skin.. IF THE CUT WON'T ClO~E.nerally do not. While washing. The cut on the right penetratesall tho way through the skin. can be treated at home. Deep cuts in these areas are likely to have damaged the tendons or tendon sheaths and should be examined by a doctor. The surest way to clean a wound Is to hold the cut under running ~er do a credible job. Washing drastIcally and takes away dirt.rless hand cleaners and antiseptiC solutions may be better than nothing. I have seen several Internet pictures and videos that show first-aid techniques In which they advocate wiping the wound clean with a damp paper towel or gauze pad. This Is the most Ineffective way to wash a wound. revealing the fat beneath. . The germs that live on lumber and tools ge. effective treatment and clean water. whether you can see contamInation for or not •. The most. It is long ahd deep and in a location where every hand activity will stretch the wound apart. 58 FINE WOODWORKING Drawings. tends to close itself. A wound allows those skin germs to reach the more vulnerable tissue beneath the skin.S tendons. Ignore any bleeding this may cause. if it's longer than 2 in. and although deep. ment preparation discourages the formation of a scab.notbe washed out. and 2 in. Doctors and first-aid manuals In the past have routinely recommended the use of an antibiotic ointment. but recent surgical research proves that clean wounds If they are washed well and closed promptly.em gets worse If there Is dirt.•Skip any antiblot1c ointment unless dirt and debris were driven rnto the wound and can. long usually can be treated at home. plain water will Areas in red.

r. Remove the paper backing.ruptlon to help form a clot. 'keeping the two edges of the wound firmly closed will help It heal rapidly. better If you have a helper to either hold the wound closed or to apply the Sterl-Strlps or glue. Cuts from sharp tools penetrate cleanly. Hospitals often use a specialized t.st. In either case.(. Don't use the activator spray that comes with some glues. then cut the strips to length. Adhere the strip to one side of the cut. and apply. skin movement wIn reopen t. Instead. you don't have to stop working. Do not apply glue inside the wound. e . It . USE A GLOVE BE !DIRECT Don't be afraid to touch the cut. interrupting the glue at short intervals to preserveflexibiltty. Wounds with frayed or crushed edges (such as those made by a spinning tool) take a bit longer to heal'. The glove keeps blood off the woodwork.Is also possible to glue wounds closed with ordinary cyanoacrylate Both methods work.I@" A DIFF"ERENT KIND OF GLUE-UP Cyanoacrylate glue works for closing a wound.he cut.Jn. . say.dges together and spread a thln layer of glue across the top of the skin. glue. you need to stop the bleedIng. and wrap masking tape snugly around the finger directly over the cut. and pressure from the tape will usually stop the bleeding in 5 to 10 minutes.rlps. while you're in the middle 01 a glueup. push the skin e. Appl. iTjJ.FIVE MINUTES OF PRESSURE After washIng the wound.. you want to wash and close the wound to pull the sliced skin back together. not below it (left). push the wound edges together so they just meet. wash your hands thoroughly. cut. and stick the strip down on the other side. Apply pressure directly over the wound (right). the clock starts all over again. BEFORE BANDAGING When you get cut. which you can buy without a prescription In most drugstores or online.y pressure directly over the wound for five minutes without Inte. . After removing the tape and glove. As SOonas you start using your hands. Put on an examination glove. I~ ADHESIVE-BACKEr!) STERHHRIPS KEEP CUTS CLOSED Dry the skin around the wound. But the job is not like butting two boards together. If you peek. which makes them easier to close and faster to heal. Standard adhesive bandages cover the wound but don't securely close It. and close and dress the wound. I. CLOSE THE WOUND .ape product called Sterl. If you get a rrunor WHEN YOU CAN'T STOP WORI<ING.

lent for . Here are two bandages that you can use afte. fluffy bandage that will attract a lot of sympathy but render you unable to work. they may be unnecessary. tough. sawdust. absorbent pad In the ce. USE COBAN TAPE Irs hard to keep a bandage in place on the palm of your hand. it stretches great· the palm or 60 r I NEW 0 0 0 W 0 RKIN G . Injuries that Involve the palm or the webs between the fingers are very hanl to bandage •. and stretchy. wide usually is sufficient). and yet breathe so the sldn stays dry. apply a Tegaderm bandage. First take a couple of wraps around the wrist. Put on the bandage and then peel off the paper frame.is so smooth that it won't catch on any sharp edges. Then continue with several wraps around the palm.Cuts contlnued SMARTER BANDAGES If you go to an emergency room with a hand 'Injury. is a transparent medical' dressing (made by 3M) that's flexibl. consider wearing leather or fabric gloves to protect the dressing. Tegaderm. and breathes like it wasn't there at all.lf. where it will receive the least rubbing. Gauze is light as air. Emergency rooms use gauze as the main e'lement of bandaging. or do work that applies a lot of friction or abrasion to your hands. but always remains snug •. This serves to anchor the whole bandage. but not to anything else •. then wrap Co-ban around the hand as necessary. End the Coban on the back of the hand or wrist. Coban is a very stretchy bandage that sticks to Itse. so wrap the dressing with Coban tape (lin. and the absorbent pads are useful then •. This product is available with and without a non-stick. extremely flexible. It Is great for ha. and glue. and tough. you cannot work wood while wearing gauze. If you have to handl. WoOdworkers need bandages that are flexible. However. you'll come home with a huge. This might be all you need..because Iy. Many wounds will seep a small amount of serum In the nrst few hours after bandag. like an adhesive bandage can. do It while all the backing paper is still in place.Later. The BETTER THAN A BAND-AID After closing the wound with a sterl-strlp. and. It you need to cut the bandage to a smaller size.It is excea.nter.For these areas. with a Tegaderm dressing. cover the closed wound with Tegadenn. The bandage is thin and flexible.r you've closed the wound or after you've come home from the ER. It Is also convenient to have bandages that shed water.e.e rough lumber. ing. allowing nearly full knuckle movement. thin. first: option is to cover the area WHEN YOU NEED MORE HOLDING POWER.nd wounds because it can be conformed to a number of shapes and .bandageslnvolvlng wrlst.

Important.be around in the skin. 11 blade in either a disposable scalpel or an X·Acto knife. use an x-Acto knife with a No. Sterility Is not necessary. If you have a puncture wound caused by a dull tool. These magnifiers maycGme in handy for other shop uses. These wounds really need to be flushed out. sharp tools like nanow chisels. long distance under your skin.pull out the spUnter with tweezers. you had to dig so deeply that the wo. FIrst wash the area thoroughly.end to close themselves. tendons). dirt. but your immunity needs a booster every 10 years.1th small parts or chiseling to a line in tight spaces between dovetails. However.roughly and apply a small bandage until bleeding stops.ughly before youpro. If the wound becomes more puffy and painful over a period of several days. use magnifying glasses.finewoodworking. then pull it out with tweezers. DULL TOOLS CAUSE MORE HARM Punctures from dull tools like screwdrivers leave more crushed and damaged cells. First wash your hand and the blade. splinter has tunneled a.com TOOLS & SHOPS 2011 61 . and squirt water In with a squeeze bottle or a glue syringe. if a.type m.rking w. scratch awls. cut. Apply Tegaderm with an absorbent pad. marking knives should pose very little hazard and DEEP CLEANING As you wash. and debris back Into the wound. open the wound as much as possible. Puncture wounds can}' a very small risk of tetanus. As you wash. If you have trouble seeing the splinter. but If then dress this as you would a. and the dull edge often pushes the skin.Punctures WASH AWAY DEBRIS Punctures from clean.ng Is needed.!.rs that you can wear over eyeglasses. have It seen by a doctor. The wounds t. Keep this up to date..agnlfie. nush out the wound with water using a squeeze bottle or glue syringe. too. 11 blade. Usually you can pull Gut the splinter with a pair of tweezers. You were Immunized against.Ike wo. Don't be bashful about the amount of water. right). You want to flush the wound vigorously enough to get rid of any debris at the bottom of the puncture. Insert the back of the blade along the top of the splinter.und bleeds www.d has had splinters in their skin. you have an Increased chance of . and virtually everyone has struggled to remove them. signlfl'cantly. Slice along the splinter's length to expose it as much as possible.and require very little treatment (unless they penetrate into Joints or cut. you'll have to gently slice the skin to' !reach it using a No. whether It's a pair of Inexpensive reading glasses or vlsor. Usually no dressl. Be sure to wash your hands and the blade thOro. Wash tho.Infection (see drawing. creatlng more chance for surface skin bacteria to be lodged in underlying tissue. S linters PULL OR SLICE THEM OUT Everyone who. but cleanliness Is very STUBBORN SPLINTERS NEED TO BE SLICED OUT To reach long slivers that tunnel through the skin. and gently slice open the skin with the tip of (he blade. works with woo. tetanus In childhood. After sllclng.

Lift the eyelid and spray vigorously. RINSE: AND REPEAT The safest and easiest way 10 remove foreign particles In the eye Is to rinse them away with a spray of eye wasn. and use plenty of liquid. Even tiny scratches in the cornea can lead to vision Impairment. your natural tears will usually wash It away. Use towels or tissues to sop up the excess. Any Injury that penetrates tt)emselves the eyeball or cuts through the eyelid must be If tiny flecks of wood or metal embed in the Cornea (the clear layer overlaying the seen by a specialist. Amputated for more than six hoors. Regardless of whether they see the offending particle or not. wh!c.AD TO THE HOSPITAl!.rgenc. iris and pupil) have them removed in the ER. have them squirt the solution under both lids. If some of that small debris ends up In your eye.If repeated Irrigation of the eye does not dislodge the particle. Don·'t try to drive yourself. the best answer Is to retract the eyelid away from tihe eyeball. Cuts seal the amputated part In a zl.l tangle with a power saw. They a. carry the plastic bag In some lee or cold products f. For these wounds. that Is going to mean a trip to the hospital. When In doubt atrout any eye injUry. and preventive antibiotic the hospital fast.ld be treated by a docfor within a couple of hours. seek profeSSional help. If particles embed themselves in this area. If there Is so much spasm of the eyelids that you cannot open the eye enough to see ~----- what Is going on. ot that appear t. ~ embed themselves III the clear layer over the iris and pupil (the cornea). and may require special suturing.h usua. Is sometimes needed. Never use tweezers or hard Instruments In the area ~_/ If particles embed themselves in this area.y on the wound to stop tl)e Ibleedlng. other than applying pressure to the wound and arranging for r~pld transportation to the hospital. shou.lly reduces any 62 FINE WOODWORKING . Tape a gauze pad or a tissue over the closed eye while you are ~I!tcomfort.E.180carry treatment grea1er risks of Infection. that suggests a more sertous eye Injury. If that trip is going to take more than an hour. Some woodworking Injuries demand professional care.rom your freezer. 00 your way to the hospital. have the eye examined by a doctor. Any kind of Injury to the eyes Is scary. and gat to that are deep enough to obviously penetrate Into Joints or bone. Have your helper 'put on your magnifiers debris. of the eye. it is sale to try to wash them out at home. rills discourages the eyelids from moving. If yol. repeal several times.ppered plastiC bag. stop the bleeding by applying pressure with a gauze pad or a clean paper towel an. These Injuries require the removal of foreign material embedded at the bottom of the wound.E es RINSE CAREFULLY OR SEE A DOCTOR When you cut wood. If particles Serious injury? WI:U('ii:"TO DO AS YOU H. to help you.d have someone drive you to the eme. and you should get Immediate professional help. sawdust (and sometimes other material) will fly. you should have the eye examined by a pro. especially with a router or tablesaw. it is safe to try to wash them oul at home. If that does not work. prS$9 d":ectl. do It again •.and resists being washed away by tears. If the debris digs In. fingers can survlv~.o cut tendons. There Is little that can or should be done In the shop. lie on your Is hard to flood the eye with solution and look In your eye for the while you are uprIght. and flush the eye with aneye-wash Get someone back-It solution.y room. If necessary. If you cut off some part of your hand.

.1I0<. when the router is mounted in the table. whether you're cutting edge profiles with large. I discovered For good value.1 ndheld work Second. Nine! How did that happen? Does the average woodworker really need that many routers') The short answer. You COl 11 leave one' in you r [Outer table and have another for h.How Many Routers Does Your Shop Need? For most people. happily. but which ones do you really need? HI suggest two approaches Ehher one will tackle a wide range of work. one plunge. This lets you mount the fixed base in a table and keep the other for topside use. start with a combo kit A combination router kit (we reviewed them in "Router Combo Kit's. Sull. I recommend purting [he fixed base in the table. D oing a quick inventory of my rhar shop recently. 173)." FWW.. the argument for having more than one router is powerfu I. adding a router with particular strengths can make certain tasks much more convenient. The kit comes with one router motor and two bases. is [10. but the first is kinder to your wallet. it's often easier to adjust bit height with the fixed base than it is wirh 63 . mainly because the plunge base is so much more versatile for topside use. heavy bits or routing 5h." hinge mortises on narrow stock: There are many router types available. the answer is three BY JEFF MILLER over the years I have accumulated nine routers. Second. is a very cost-effective wav of setting up your shop (or both table and handheld routing.---Qne fixed.

At1ach the base to the router-table combination kit that offers through-the-table height adjustment and square fence simplify insert (left). 64 FINE WOODWORKING . Look for a surface (center).Kill two birds with one combo kit A combination kit will handle both table and topside routing and costs trim router. these much less than two separate routers. So you'll have plenty of money left over for a good-quality small. like routing precisely along a narrow edge (right). The table'sf/at dozens of tasks. simple. Combination kit handles table and Trim router for detail work is great ~ Plunge base The filled base lives in the table. one-handed routers are easy to set up and even easier to use. Also called laminate trimmers.

but its lower torque and one-handed size are perfect for hinge mortising. Second. and much more. It is also limited ro working with 'A-in. A heavyroo LS & or round over all the edges on a project. It's great for any task that doesn't call for large bits. With this package of routers. inlay. and when you need to chamfer Stepping up The combination kit is a great value. you should consider investing in more horsepower. deep cuts. The easily balanced trim router Is perfect for this application.ich requires delicate control and good visibility. saving $50 to S100 or more compared with the purchase of two individual routers of a similar size and power: To the combo kit. For one. The motor switches quickly between the two bases for topside use (above). The plunge lets you lower the bit safely into the work while the tool is running. Inlay work. You'll also love it for flush-trimming face frames.t [0 lighter-duty tasks. This allows you to make stopped cuts /ike the dadoes at right. Although its limited horsepower confines i.The plunge base . and small edge profiles like chamfers and roundovers. you «In tackle almost everything. S 1-1 0 P ~ 20 I j 65 .-shanl< bits. it is much easier 10 COI1trol than a larger router. switching one motor between table and topside is much Jess convenient than having two individual routers.s best for handheld function routing. in most combination kits. bur it does force a few compromises. wh. This makes for an economical choice-you can find a good combination kilo for around $200. the plunge. the motor is limited to 2 hp or 21/l hr. and do them in several passes. Of lots of horsepower. add a trim router. If you cut deep mortises with your router or work with large shaping or panel-raising bits.

offer bigger motors for smoother cuts. One Job to do.l.KIi\G . ready for action at a moment s 66 FINF \'i/OODWOJ. Large router designed for router tables Large plunge router for handheld routing Trim router for detail work This Triton router (TRC001) was a reviews of tablemounted automatic routers. A dedicated notice. as with this panel-raising bit. In addition features. table router stays put. but not as well as two separate and height adjustments routers And both bit changes easier.and held held routing will. spindle bit lock that makes above-the-table changes a breeze. Bigger bits.Stand-alone routers are a heavy-duty upgrade A router combo kit will cover your table. A router designed also collects for table use makes above-the-table A dedicated dust efficiently. and plunge router offers better height <lendplunge adjustments. needs. to heavymore convenient a duty table router easily removes a lot of stock safely in one pass.

with the router base riding a a ience. instead of something you have to fuss with for 1S minutes just so you (In spend 30 seconds cutting an edge. and a handle-mounted power switch. especially pros. the y~ hp motor will provide smooth. An extra router can to a single task. duty plunge router Like those reviewed in r""1f!W :. The assembly typicaily hasa l:ow center of gravity and handJes easily.214 C'Heavy-Dury Plunge Rout I"S") will rvpically come ".tne Identical.Still not satisfied? There's always room for more ). route [ion and you're set of routing tasks. You might want to have a router set up with a straight bit to clear the waste and another one set up with the dovetail bit to cut the socket . :x www. Many woodworkers. an~j do certain jobs over . with an edge guide. Also. and extra heft helps too.ven' wJth' theee versetile routers In yO!Jf'shop.. l'l1y case. This lets your router table become it dedicated shop tool with excellent controls. effortless action on the heaviest cuts A~ another st€r up from the combinationkir approach. So I keep a fixed-base router set up with an extrawlde bas-e that has a handle to help prevent tipping. there are sonre situations when It can Iile nice to have another router or two dedicated to specific tasks. less expensive and very simple operate. These maple bed posts require a mortise % In.finewoodworking. I often cut edge profiles with larger bits. I'd recommend getting a router built to be installed In a (able. by using pair of routers.to Add a fixed-base be dedicated router. In. Miller keeps an offset base on one of his routers for better balance when molding edges. add a (rim router to this combina- If one Is #ood. I don:'t use it for anything else.com) builds furniture and teaches woodwOrking in Chicago. two ate You wjJJ better. In this setup.and over. like a iablesaw. 10 tackle the full range 0 ers should be Jeff Miller (furnituremaking. fixed-base router makes a great fourth router because it's. deep. A router for every router bit? Now that's excessive. . wide and 1 Y4 in. Routers of this rype-all of which come with a through-tbe-table lift-were reviewed in F\~'U7 #189 ('"Routers for Router Tables").com TOOl S SHOPS 20J \ 67 . Again. settle lnto patterns of work. The motor also slides In'to the !base in a way that makes depth adjustment simple. a smoother plunge mechanism. like sliding dovetetts. Tasks like this call for serious rouling power.r ith better features than the plunge base in a combo kit. You'll get heigh! adjustment that is easier and more accurate. simplify tasks that require two bits. Or suppose that you regularly cut dovetails with a Jig or cut sliding dovetails Serious power. A.

so it W:1S produced in significant numbers and had :1 lower price point.Tl:ln the Railey. S Why Baileys are a bargain Stanley was making tWO styles of bench plane in the late 19th and early 20111 centuries: the Bailey and the Bedrock. But you don't need to spend a fortune to catch the hanel-tool wave.Make a Bargain-Basement moorhing :l board with a handplane is one of the most pleasurable processes in a woodworking shop. I love the feel of a well-tuned plane gliding across the surface. 1 have rebuilt dozens of R:1iley planes for friends and for myself. you'll (urn a clunker into a classic. the tool W~L~ more expensive r. Tile Bailey came frrst It W:1S considered a working-man's plane. you don't need special tools to get the job done. Tearing a plane clown to its bare chassis and building i( bach: to blueprint spec~ not only creates a great performing plane. With my step-by-step approach. Even a pauper can own a pri nee of a plane BY ROLAND JOHNSON 68 flNE \Ii'OOJ)W'ORKINC . Rejuvenating an old Stanley Bailey plane. but also gives you an msight intohow these wonderful bench mares work. is a great way to get started handplaning without breaking a slim woodworking budget. Best of all. dead-Hat surface for finishing. A common misconception among many new woodworkers is that you need an expensive plane to get the job done. whether it's a garagesale find or an eRay purchase. And there is no Lister way 10 create a glass-smooth. The more refined Redrock followed and because there were fewer made. with whisperthin shavings rising from the tool's throat. and I've given more than 100 seminars on the subject. Today.

you can purchase a restorable Bailey plane for under $40.. then rinse off the parts In waler. chtporeakers. can be replaced easily (see "Where 10 buy. alcohol. \\/hile you'd be hard-pressed to get a Bedrock for under $100. Buying from an online SOUrcesuch as eBay is tricky because you have to rely on photos and the honesty of the seller. If you seC' cracks in the plane body.. because the plane ANTfQU&USED·TOOLS.COMI STANlEY . especially on the sole in the area around the throat. that has nicks larger than. When a bargain becomes a. which often is easy to remove and repair. Bur avoid :1 1001 Blades.s STJAMfSBAYTOOLCO. chipbreakers. A lot of the tools will have some rust. You abo should be real cautious about buying a plane in which the body has obvious WHERE TO BUY welds or repairs.Plane Perform Like Royalty that price differential remains. Some damaged or missing parts. and totes say. areas. COM body is probably toast. But if it's so bad that parts have Seized up or are seriously pockmarked. you end up with a great 100[ at a gee. REPLACEMENT Small nicks around the PARTS throat are signs of normal aging and wear and Me easy HIGHLANOWOODWORKING . Be sure to get /I Inlo crevices and even threaded Follow with an alCOhol bath. bummer-A used handplane is a bargain only if it's serviceable. ANATOMY Cnipbreaker Blade OF A BASIC BAILEY Tote Take a close look at rhe castings. I/S in . TML H Reproduction Stanley plane parts Throat-adiustment screw TAKE IT APART AN D CLEAN IT UP Naval Jelly sinks rust. you may want 10 P<lSS on Ihelon!. SIan original and replacement Stanley part.COM to flle away. A wide assortment of Knob Start with a cleaning You can get thar used Bailey performing like a star with just a few hours of work. including shipping. Dry and then lubricale threaded parts with camellia TOOLS . LeI it sit for 10 10 15 minutes. it will be more useful as a paperweight..< SHO PS 2011 69 . walk away from the tool. such as knobs. Inspect the plane for obvious flaws. So with a small investrnent in labor. totes.!t price. and lever caps. knobs." below). Soak and scrub a/I the parts in denatured all.

will not be fully supported and could move slighLly under cuning pressure. a rustremoval product. You can refinish the knob and tote. the frog. TUNE UP THE FROG Solid frog makes a solid plane The frog of a bench plane SUppOrTS rhe blade assembly in the plane body.the area' from the levercap screw to the bottom. He works through to 220 grit until all f'he hlg. Check your progress as you go. 1 lise shellac.h spray adhesive.com). Then give all the parts a thorough washing <Inc!scrubbing in denatured alcohol. You·re finished shows on all 'the contact points. Let them dry. and then coat themwith a light oil such as camellia oil. Tf there is <111y inaccuracy in the machining of the frog or the plane body. The frog in a Bailey-style plane rests 011 four points.ing the plane If the plane is nlsry slather 011 some naval jelly (Amazon. Johnson glued to a granite plate w/l. first coat the mating surfaces of the frog Flatten . lapping when an even rub pattern 70 FJ N E \XI 0 0 j) \V 0 R K 1 N G . assembly. simply because it is easy to repair or refresh and wears well.by dismantl. and in turn the blade. which wil] cause blade chatter.h spots are removed. To sear [he frog precisely and firmly to the bed of the plane. if they are in a bad wav. Grind until It shines.

The goal is a knife edge so that the chipbreaker body exerts maximum spring pressure along the entire width secured 220-grit of the blade when the chipbreaker and blade are Smooth the curve. and a piece of plate glass.finewoodworking. II the bottom is in had Stan tuning by "anding www. Holding the chlpbreaker so that its end is below the tip. Polishing the top front of the chipbreaker chips slide by smoothly. the top. Then rub the frog fore and aft in the plane body.IW.grjf sandpaper adhered to a flat surface knife edge that meets the (above).and the plane body 80037. tearout must be tuned to meet For it to work properly. keeping even. The best approach adhered to ~ /" ~. their for ups on filling Flallen both sides of the blade and then sharpen it. If needed. The goal is a forget the salvage job Note in .com rOOLS . and buy a replacement. Fine-tune the chipbreaker The chipbrcaker does just what its name unplles=-h breaks chips. Now you can reinstall the frog on the plane body. or heel side of the blade. ity steel. When flat- tening the back. ~ WHERE CHIPBREAXER MEETS BLADE ChipbreaKer. to a dead-flat surto 220 grit. of the blade should be polished to as Iine a surface as the bevel. stiff brush. But if the blade is really beat up. The constant prevent. work block. in." SHOPS 20 I I 71 . Ratten and sharpen the blade In my experience. [hat J. Any gaps between the chipbreaker and blade (left) will catch and jam chips. sandpaper the bottom or the front edge flat. The front. available with valve-grinding compound (Permatex simply at most automotive-supply stores). Concentrate on the area from the keyhole to the bevel. set back lhl compound using denatured alcohol flattening it is to rub it on sandpaper Begin with 120-grit paper the grits.. helps together.I back of the blade all the way across (right). preventing curling action also works to break or curl up and 10 . (he chipbreaker the back of the blade perfectly. such as a granite tabletop. rub the bottom of the front edge on these planes are good qualMost often you just need to clean them lip and sharpen them. r usually start with nO-grit paper and work up to 320 grit. particularly if it has lots of deep rust pockmarks. until <1[[ four poirus mate evenly and firmly.lY frOI11the breaking! them from clogging it. the front of the chipbreaker forces the shavings throat. Positioned directly behind the cutting edge. or loe side. replacement so check with the blade blade to your plane blade may not fit correctly manufacturer Bailey plane. Coat the fresh surfaces and threadeel parts with camellia oil and wipe off the excess. J use on a granite stone. moderate pressure on the frog. or grit from any thread- ed holes (do this after you flatten Of beel any parts to prevent debris from ruining threads as you reinstall the screws).. Clean off the grinding and a small. the blades Milld the gap. you don't need a polished finish. trom tip of blade lip through Use compressed air to blowout any filing). on 220. The (rag also must be flat across face. POLISH THE CH I PB R EAKER Critical ~ contact pOint~8lade . you can start with a more 'lggressive ( to 'A. or a Gist-iron and work through sandpaper /' in.

then move up through the grits to 400. Use a mill bastard file 10 dress the edge flat. ease all of the edges wirh a mill bastard file. be sure the blade is backed off inside the body. Assemble plane before you flatten the so/e. GCI the sole llat by running the plane over sandpaper glued to :1 flat substrate. Cast iron is slightly flexible ancl can move a bit hom pressure exerted on it. Look for any gaps between the blade and chiphreaker: keep working until they arc gone. so having the plane assembled and "tensioned" will ensure accuracy during (his <rep. to Harten and fix up the sale of the plane. add . the lever cap won't slide easily past the screw nor will the head hold the lever cap accurately.FLATTEN THE SOLE Reassemble and the lube.ld down the gr:lin of (he board in front of the blade while making a pa"s. you go.:I{(e sure the bottom surface of the head on the lever-cap screw b smooth Often a pair of pliers has been used on the screw -ometimc du ring irs life. start with 80 grit. Tweak the lever-cap screw M. polish (he top front of the chipbreaker. Otherwise. creating a rough edge. He-move unv small burrs: otherwise. which will keep the new Sllrface slick and free of rust. To check your progress. the blade could lever up the grain. TensIon the plane before truing the sole The final steps are. hone the blade . begin with 120 grit. Once you have the sole flat. causing rearout. you nuy have to start with coarser paper. carefully holding the file perpendicular to the bottom of the plane body (sole) Once that's done. After smoothing our the burrs.i light coat of camellia oil on the sole. which will help the curls of wood glide over the curved surface. Some tips on setup After you've finished rehabbi0g the plane. If the bouom is scarred and badly out of flat. If the plane bas small nicks or a wear curve at the front edge of the throat. lubricate the pans with camellia oil. straight edge [0 help h-. Rough throat? Smooth it with a file The throat area must be flat with a crisp. parts and Be sure to lubricate threaded the lever cap as shape. Once you're finished working the bottom. rut the blade and chipbreaker together and hold the assembly In front or a white sheet of paper or IJgllr background. Ar this point the plane should be completely assembled.

Now adjust (he throat' opening. Soften the edges. When the desired opening is reached. which is located behind [he [rog. dress the edges carefully with a mill bastard file.com . 10 move it forward or backward. After flattening the sole. Now turn the frog-adjustment screw. Tighten rhe lever-cap screw until it Just touches the lever cap. adjust the frog to create a tight opening between Ille blade and the fronl of the tllroat.REFINE THE ROUGH SPOTS Remedy for a rough throat. to perfection. www. "Handplaning 101. breakrhe screws loose so that the frog can move. When reassembling the plane. Be sure to hold tile file perpendicular to the sole.2 in. you're ready ro tackle any wood like a pm. (For more tips on setting up and using a smoothing plane. When reassembling the blade and the chipbreaker. And you'll have a reliable tool for life. JUSt. with (l carefully restored plane and a razor-sharp blade. J/1. First. For most work. A narrower opening will help you tackle more difficult woods. a thrQat opening of about 3. Place the blade assembly on [he frog.Fmewoo dwor k l ng. For most work.}2 in.) Roland 0 Johnson is a contn'buting editor. set the chipbreaker about I/l6 in or less from the tip of the blade. Now. is plenty. If the throat has small nicks." FI1YlV #204. between the tip of (he blade and the front of the throat will be sufficient. and then give it about a quarter turn more. The lever should he easy to open and close but will still offer sufficient pressure to keep the blade assembly in place. ease the comers with a mill bastard file. remove [he lever cap and blade assembly and tighten the frogholding screws just enough to hold the frog securely in place. and acid the lever cap with the lever in the down position. see Fundamernals. READY FOR TAKEOFF Dial in the throat opening.


finewoodworking. said Torn Waters. anti-fatigue mats have be- come a staple of workplace design. In general. "my reel and Jegs would be a mess. too. Woodwmkers swear by rhein. Before he beg~ln using the mats. \v'ltb a little digging. and back. helps prevent serious damage to chisel Cold floor. Exactly how they ruysrerv. those rubbery slabs that go underfoot where you spend the most time standing. I did a bit of research [0 sec what [he expert's say. govern- ment. 1:0 1 in.l from providing whole new shop floor' The cornmon an- swer for most people is anti-fatigue mats. The demos typically take place in convention spaces wuh concrete floors.1l1c1 Health. A mat is a barrier between your feet and a chilly concrete slab. I-Ie credits the mms. squares. however.colJl TOOL. or otherwise-for what constitutes an "ami-fatigue' floor mal. .lick. of his school's benches.ny woodworker who spends long afternoons on a concrete floor in [he basement or garage the Taunton Press credit card.I uncovered .l senior safety engtneer at [he knows there is a physical price to pay for enjoying one's hobby. Marc Adams spent nearly $4. Concrete is a punishing surface. One recent study concluded at the University that anti-fatigue of Pittsburgh mats.-tJ. And in this issue. Bur studies show that these mats do prevent pain in the feet and legs. we looked ar a variety of shop flooring options including interlocking tiles of pvC or wooel composite. In any case. recommended for grocery checkers. But what if you don't wanr or can't afford it They really do work There are no standards-e-lndusrry.foam--~vill. one theory holds that the mat's resilience encourages and subtle movements hel p prorrlOlt' of the feet circulation. thick. making a full day at the bench much less [axing.000 to put mars on the concrete floor at each. they are made of rubber or closed-eel! foam and they range from . . Apart work is a bit of . The solution is to put something more forgiving between your feet and the concrete. he says.- 65 student significant difference. assembly-line workers. &: SHOPS 201 t 75 . and other tools. Bur before whipplng This keeps the blood from settling uncomt()J"wbly in your lower Ii/nbs.1 a simple cushion between foof and floor. TIle mats are. art director Michael Pekovich shows how to insrall . Deneb Puchalski considers a mat essential for (he hand-tool demonsrrations he does for Lie-Nielsen Ioolworks. III Fll?IVi1174. and especially so when (he test subjects stood for more than rwo hours.l legs that wide our range of choices. plywood over 2x4 sleepers. made a National Institute of Occupauonal Safety .1 shop Iloor of 3/j-in. kitchen staff. legs." made of 1/2-in.'Is in. Research confirms that standing OJ) a hard HOOf for hours <I[ a time will leave you with achy feet. warm feet. operating-room nUfsesjust about anyone who spends most of the workday standing in one place. www. A mats cushioning edges. SIeve Scott is an associate eoito: Soft landing.

A mat that's too thick and soft. Photos. sharp chips. can make for unsteady footing. dust. compressing so much that your foot Is basically resting on concrete again. thick gives the foam better protection against sharp edges Not enough cushion. foam is best. some manufacturers oHer mats with an armor-like layer of rubber or semi-rigid plastic. So Ii d rubber offers terrific durability. At ¥. These attributes are great for constant use in an industrial setting. Marc Adams reports that the vinyl-covered mats in his school have stood up to more than four years o-fheavy use with no serious damage. mat. These are pricier but easier to sweep off. which are less likely to catch a toe and send you sprawling. But it will make your footing less stable. A mat that's too thin or soft will bottom out. experts agree it's worth looking for a mat with gently beveled edges. Mats are most often made either from solid rubber or from closed-cell foam. SOFT SHELL A soft vinyl cover keeps the foam free of dust and safe from abrasion by shoe treads. suggests looking for a foam mat that's 1h in.-thlck model isn't dramatically more comfortable than a ¥2-in. Still. the sponge is typically bonded to an outer skin of textured vinyl. An extra-beefy mat like this 1-in. RUBBER Solid rubber mats are extremely durable. Overkill. A foam mat provides a better balance of support and cushioning for less-intensive use. FOAM A good foam mat has a little mare 'give" than solid rubber. Dunton . the next step was to find out whether some work better than others. but Is quite firm underfoot and heavier than foam. researcher who authored the Pittsburgh study. The good news Is that a 1h-In. for greater protection. but less crucial in a garage or basement. They do. The sponge at the heart of most foam mats wouldn't stand up long to abrasion caused by shoes. Regardless of thickness.I In.or %-in. thick. he suggests. thick or so and relatively firm. but most don't provide as soft a cushion as foam.wnat to lOOK for Once I found out that mats really work. For this reason. and tool edges. this yoga mat doesn't put enough foam between you and the concrete. Kelly J. For the home shop. but enough resilience to prevent pain and fatigue. Here's what to look for. foam mat wlll probably work Just fine for you. It should be fine for HARD SHELL A layer of rubber or flexible plastic about Va in.

Consider the type of work you do and where you spend the most time In the shop. A long mat like this one {rom for tasks /Ike planing long stocx And one f'or the fableS8w. Any work in One tor the bench.ATS AROUND THE SHOP A mat comes In handy anyplace in the shop where you stand stili tor extended periods of time while working. The top priorities are the bench and tablesaw. but It's travel not the most adequate runway for the back-and-forth you'll do at your bench. They are less crucial at the jointer or planer. Joinery means it's In use nearly every time I visit the shop. The tablesawversatility The saw's for both milling and m Bandsaw ( Router table Drill press Jointer Planer Note: Lathe Thejointer and planer need no mat because users are in motion while operating them. t/on) offers support that require the full length of the bench. A 2x3 mat might be perfect at the drill press. This 2x3 mat offers plenty tasks like cutt/ngloln- Woodworker's Supply (see p. Other tools-Share a smaller mat. But a larger mat offers much more maneuvering room. router table. a 2x5 or larger mat is a good size. you'll do at the bench is typically slow-paced (titting joinery. and this Is fine.) and requires a lot of time and attention. If you had enough money. But let's assume you're working on a budget and will be doing this one piece at a time. A well-made 2x3 mat-the smallest comcushion as monly available-will your feet just as effectively a larger one.What size and where to put them The cost-consclous among us may be drawn to a small mat. chopsaw. In order of priority: The bench-This ral starting is a natuplace. and drill press. But It's the Joinery cuts-small scale and repetitive-that will I ~ have you standing at the saw for a long time. For those. you could put one of these mats at every workstation the shop. surfaclng by hand. but you should also consider putting mats at the bandsaw. TOO IS&' S HOP ~ 20 j I 77 . PLACING M. or place individual mats at the bandsaw. drill press. where you walk back and forth during use. 75 for source informa- of standing surface for stationary ery or trimming parts to final size. etc. Here are our suggestions. a 2x3 mat fits the bill. Because you'll move back and forth from front vise to end vise. and certainly the lathe.

on the Mediterranean island of Cyprus. using Skerchl. 80).A. mounting them on a compact. -\X/here I live.. To make it work I converted (be portable power tools I already had into stationary machines. After connecting outlet.lp.~l]qpdesign Think your shop ls sm1all? Th1ink agalin BY SIEillOS L. But 1 love woodworking. to a nearby power is ready to begin work on any of five power tools . I designed a fully functioning shop that would fir into a 5-fL by 5-1'(storage room when not in use. So. STAVRINIDE5 t the very least. so it rolls easily out of its storage area . Rolling workstation is the key The power-tool station rides on casters. and [ didn't want TO let these problems stand in my way. starting a woodworking shop requires two things: good woodworking tools and adequate space. Stavrinides (see p. both ~lre in short supply.

deep. jigsaw. In a II. and other tools including power drills. A CABINET IN A CABINET Interior doors provide space to hang more tools inside this roiling storage piece. Also. Sketchtlp rlr:lwmg_. THREE-DRAWER CHEST The top drawer is for sketches. and . The middle drawer holds 1001manuals and small accessories that come with the tools. Stelios L. drill press.A Stavrinides is a graphic Web designer and woodworker in Nicosia. It's not good for cold weather. CABINETS An old. alld woodworking plans.satety gear. LUMBER STORAGE rolling bench. square and 8 ft. Cyprus. finishing supplies. One end of the cart is angled to allow access into tile space. and disk sander. the space holds about 65 clamps of varying types. This bench houses five major tools tablesaw. I don't have a jointer or a planer. kit. open top holds cutoffs of varying lengths and tucks under the lower shelf. and miscellaneous gear. featherboards. so I have (0 start with stock that is already jointed flat and milled to thickness. measures high-a The room approximately little more than inside modern 5 ft. we have very lude or rhat here. the tools mUSI be rolled OUI into the covered parking area of my apartment complex for use. Here's a look at how i·t works. router table. The larger. a biscuit Joiner. Three levels wrap around three walls to provide storage space for lumber. Apart from tbose drawbacks. Stavrinides planned the 1001 layout on paper first. a flrstaid.HOW TO FIT A WHOLE HOBBY INTO A 5X5 CLOSET Stavrlnldes supplies packs all 01 tools and CLAMP STORAGE A section of upper shelf serves as a rack for C-ctemos and small pistolgrip clamps. my little shop Gin do a 101 of WOOdworking. supplies. The bottom drawer provides storage (or sandpaper of all types-sheets. holddown clamps. narrow bookcase mounted horizontally and fitted with doors holds fasteners. and a mortising attachment for the drill press. glue. his woodworking Into this storage room In the parking area of his apartment building. circular pads. And ic leaves plency of space in m~J score room for lumber and other tools. which measures 32in.. and rolls. . Larger pipe clamps and parallel clamps are stored flat on the she I f itself. wal-rnconte« cabinet is stocked with router bits.. square by 13 in. but fortunatelv. Of course. twice the volume Volkswagen's Beetle.lw . the shop hJS limits. computer printouts. hardware.uuhor: fjo:~l~ndt:rlogs by Dnve Rir-bard- TOOLS & SHOPS 2011 79 . To get the most out of the space. A narrow bOX Witt1 an angled.

forward/reverse.com) and removed for tablesaw use. to keep the blade from wandering in the cut. ROUTER TABLE LIFT The scissor jack from the author's Alfa Romeo serves as a router-lift mechanism that is precise to a millimeter. variable speed) rewired to a bench-mounted control panel. Shown here are the jigsaw. with a plywood skin and a %-In. The built-in bins underneath provide space for tool accessories. In addition lumber. the bench also features a vise. The wooden pad on which tile route r rests is re lieved slightly to let air circulate over lhe motor vents. circular saw" and router. TABLESAW A 7lkin. UNDE. but can be removed to handle large sheet goods. and eight electrical A table-rnounted array of portable power tools serve as standard 5110P machines. extension cords. long. live small drawers sockets. WHAT'S ROLLING WORKSTATION: THE BIG IDEA INSIDE THE SMALL SHOP Stavrlnldes multiple designed this power-tool bench on wheels to serve of 2x4 and 2x2 to the power for functions and fit Inside his storage space.shop design continued FOR CUHiNG CURVES RIP FENCE The rip fence is shonrnade of MDF and serves both the tablesaw and tile router table. wide by 59 In. 0151< SANDING The disk-sanding attachment is powered by an e lectr!c dri II with its controls (on/ off. laminate for durability. and small pieces of lumber. The bench. 80 fiNE WOODWORKING . clrcular saw Is bolted under the bench. MDF top surfaced tools. An armmounted guide uses a pair of roller bearings. Separate fence faces for the router are secured witll fence clamps (rockler. Stavrlnides uses a bench-mounted jigsaw instead of a bandsaw or scrollsaw. Is built on a frame with plastic accessories.R THE HOOD? 20 In.

The power-tool bench at work
For this article, template Stavrinides used the tablesaw, jigsaw, and sanding drawer front. He then used the template station in his (oiling bench to create a, router on the router table.

for a decorative

to shape the workpiece


The circular

saw yields straight, clean cuts. Note that" the rip fence fence and Includes dust collection.

For curves, the inverted in high-quality straight

jigsaw_ Stavrinides



doubles as a router-table

blades. His s-hopmade guide assembly

keeps the blade

and vertical during the cut.

Fair the curve at the sanding work. The sanding attachment ered by a variable-speed

station. A flip-up table supports uses hoek-and-Ioop


Shape the workpiece af the router table_ The author's version
doesn't have through-theC!ab/e tive technology helgfft adjustment, relying on automoinstead (see- drawing, facing page).

pads and is pow-

electric drill.



8:. SHOl'~



Use a bottombearing bit for template routing
Q:.I use a tap-bearing, flush.;trimming bit for template routing, but it keeps digging into the workpiece. What can I do to prevent this?


MonIca, Calif.

A: HERE'S THE SHORT ANSW.ER: Use bottom-bearing bits. They have a distinct advantage over their topbearing cousins. As the router moves around the template and workpiece, there is a chance that the router will tip outward as you shift your grip, because the power cord snags. or because it's just not your clay in the shop, If that happens when you're using a topbearing bit, the cutting edge is forced into your workpiece, taking a divot from its edge and ruining it. If [he same thing happens with a bottombearing bit, there is no harm because the cutting edge moves away from the

Router.s can' be ,Iufstable when template routing. Because its cutters are pulled away from the workpiece if the router tilts downward, a bottom·bearing bit lessens the chance of damage
(see below). Template TOp·BEARING BITS CAN DAMAGE WORKPIECE. When the router lips over the edge of the template, the bit is driven into the workpiece, ruining it.

Another good tip for template work or edge-profiling is (0 use 3 D-handle router base or a wider baseplate that Jets you concentrate more pressure on the side of (he router that is supported.




White 1~)a former sbop 'manager
lit Fine


BOHOM-BEA~R'I N G BHS TIP AWAY FROM TROUBLE Because the cutters are above the bearing, they move away from the workpiece when the router ti ps over the edge. The workpiece Isn't damaged.

Ask a question
Do you ha've a question you'd like us to consider for the column? Send it to Q&A, Fine Woodworking, 63 Main St., Newtown,CT 06470,. or


em'!!ii fwqa@taUnl.on.co"m. Template






Smoothing plane is first choice for gnarly grain
Q: I have some
figured hardwood that I'm having trouble planing with my No.4 smoother. Would I be bette.r off using a scraper plane?
-ALLEN WINSTON, Wash. Kennewick, A SMOOTHING PLANE is the better choice, MJ give vours another chance first. Sharpen the cutting edge, then hone it on an B,OOO-grit tone. Close s the plane's throat tightly, leaving just enough room for very thin shavings. This should work with most figured woods. When it doesn't, increase the blade's cutting angle. For most planes, that mean" honing a 5° to 10° back bevel on the iron. With a Lie-Nielsen smoother, you could change (0 a higherangle frog instead. If you are still getting tea rout, then resort to a scraper plane or card scraper, which because of their very high angle of attack do not cause tearour. =Deneb Pucbalski leaches plane use and sharpening for Lie-Nielsen Tooltoorles.



smoothers with


No.4 smoother

are up to the job. Even on grain a sharp blade leaves a finish-ready





Moisture meter tells when lumber can be used
Q: How do I know
If the kiln-dried lumber I order from out of state needs to acclimate to my shop before use?




buy one if you don't

have one already. Then, find



a piece of lumber that has been in your shop for at least ,[ year and lise the meter to determine its moisture content, Next, determine the moisture content of the delivered wood. lf the difference between them is more than 2% to 3%, the delivered wood needs to be acclimated 10 your shop. How long depends on how great the difference b. A difference around 5% should disappear in just :I few weeks. Check the wood weekly, and use it when the difference is around 2% to 3%.


meter removes doubt. Ideally, the moisture

content of new

lumber should match the moisture

content of wood already acclimated

to your shop.

However, if you work in less-than-ideal conditions, like a clamp basement or unhealed garage, you should use the new wood immediately and get the finished piece into a kinder environment (like

an air-conditioned house). Letting wood acclimate to a damp space with 12% to 14% )"[C will only make things worse in the long om. -Chrislhm Bechsuoort isa
coni ributing editor






Hatten an oilstone to clean it
Q: My oilstones no
longer sharpen as ,effectively as they once did, and seem to be clogged. How can I rejuvenate them?
- BILL PLANTZ, Westlake, Ohio



CLOG with bits of worn grit

and steel, and that keeps them from sharpening. To sur-

undo the clogging,

lap your

on a flat, abrasive

face, like J coarse diamond plate or some P-180 grit wet-

or-dry sandpaper
lubricant. I prefer

on a piece

of thick glass. Use a lot of because it does a good job flushing away swarf and worn grit. ! watch for the color to brighten over the enure stone to know when l'm done, but you also could hatch When draw ;1 crosssurface. over (he stone's

all of the pencil lines well with
A little elbow

are gone, you're done. Finally, flush the stone Don't toss your old stones. Instead, take a few minutes to
flatten and clean them.

kerosene, -Can-ell Hack is a


Use kerosene as a lubricant

and flatten the stone



coarse diamond plate. The stone will work much faster and produce straight





For veneering, MDF is better than plywood
Q: following Thomas Schrunk's advice on shop made veneers (Q&A, FWW #210), I am making a table with a veneer top. What's the best material for the substrate?
-NIC BEAUMONT, cieveta nd, Ohio




BOARD (MDF) is the best mate-

rial for veneering, is uniform

because and


in thickness

density, and does not contain any internal voids. Wilh
MDF, what you see is what you gel. That's not the else with

plywood The plies used to
make the core are rotaryknife cuts a thin, sheet of wood of sliced-a continuous



more stable and doesn't have any voids or defects.

from the circumference

the log as it is turned on a
giant lathe. Rotary-cur plies create because two problems. First, or


ply is largely




the density of a

plainsawn, is more


means ir
move with

graph through

rhe outer ply

tree's grain can vary from one side of the tree to the other, the strength and den-



show up in the veneer.

changes in humidity and is less stable as a result.

siry of the resulting
consistent. Second,

ply is inthe grain

The internal plies abo might
contain voids and defects that

+Tbomas Scbrunle u.orles ioitb exotic veneers in Min neapolis. Min n ,







I'ellr'll .. .v

One or two hold fasts can then position a plank perfectly for edge-Jointing. Some of these classic hand tools are unique and some are cookie-curter castings. like the shaVing horse and spring-pole lathe.. Some YOt! can buy with a card and a click. Tennant. Roy Underhill. I handwork I 1. and SOllie. quirky orchestra of tools-all beechwood and brass. the holdfast springs It free. it does just fine. or the Doctrine of HandyWork3: "Its office is to keep the Work fast upon the Bench. you'll have to make for yourself. For chamfering or rabbeting the edge of a piece held on the benchtop. Nothing holds like a holdfast The holdfast Is a versatile bench helper. All of my favorites are brilliant work partners. The delightful. did when the venerable Joseph Moxon described it in 1678 in his book Mechanlck Exercises.C. THESE ARE THE TOOLS I'D BE BURIED WITH' BY ROY UNDERHILL vel' three decades of reaching traditional woodworking. star of PBS's The Woodwright's Shop. though. I can't help but smile when I pick lip an 1875 D-9 ripsaw and hear irs crisp basso continuo as it carries its kerf down rhe length of a plank. give It a whack with a mallet. slide the work When your work is done. whilst you either Saw. Each one is a noble instrument of long service that would certainly serve you equally as well. but if I were a Viking. but each does a lirtle bit more for me than just get the job done. these are the ones I'd be buried with. a/so runs a woodworking school in Pittsboro. and all the force of the blow Is captured. holdfast works as well today as It. N. Other tools speak to me of days of hard labor-c-rhe r3W handprint worn into the beech of an old plane that is otherwise black with tallow and linseed oil. Set it In a benchtop hole. The Woodwright's favorite tools 'IF I WERE A VIKING. Vou also can bote holdfast holes through the front legs and skirt of your bench. 88 fiNE woonW01<KING . I have great regard for them all. MaTtess. I have adopted a big. or sometimes The "sometimes plain" qualification Plain upon it.com)." comes from the fact that the holdfast bears down on the very surface that you probably want to plane. (woodwrightschool. a tap on the back of under It. but I'd be lying if ( didn't confess to having favorites. rosewood and steel. locking the wood to the benchtop..

and the shoulder of the plane Is made of hard boxwood inserted depth stop. It's a strange visitor amid the Vlctoriana tage hand tools il own-and out piece of beech.the Eastman lenlte. splintery bing a floor-and shavings spewing up over your hands as the plane hogs away wood. I'm different. The rounded han shaves a trench across the grain and cuts very. The body is cast iron. very fast. end grain Ilks a shoulder plane. coffin-shaped plane-a legendary smoothing "Buck Rog- r smooth with an outrageous tuned-up 1955 Millers Falls. The moving ftlllster won't cut. I have never used anything that ::I. long before It lawn several scrubs. no hand tool tops a scrub plane. beech. too. but choosing this crotch with the grain flowing around it like a ship's knee has to be the work of a fellowcounlryman. but It is far too battered to tell. Rogers looks like It's going 300 miles an It works like a jet-age charm! hour . When with a sawnPerhaps the beech body Is Eng1ish too. it has a huge depth·adJustment.handwork continued The Buck Rogers smoother is an outrageous plane When I'm not using respectable planes. the moving fillister plane is a champ Despite the temptations ·of metal planes. Rldi ng Just ahead (Jf the Iron. an English maker. But for rabbeting. a little vertical nicker severs the cross-grafn to keep a clean shoulder. The bright red fore and aft. The skewed iron shaves the cross-grain with a shearing cut and draws the fence tight to the edge of the wood.n. A brass this marvelous instrument. I savor the task •. For leveling a board.• the Buc. on my bench. No. The fence exposes only the width of the blade that you need... It's thoroughly the original tote broke. along or across the gra'l. red-knobbed.9thcuts a cross-grain shoulder as well as a wooden moving flillster-a century gem made by H. Just Sitting of the other vinBuck. For rabbeting. American now. Working back and forth In short strokes wIth the cool. and the onepiece frog and handle assembly are of tough aluminum alloy. and the fence makes it di'fficult to use on the cheeks of tenons." Designed in 1948 by the Huxtable brothers and sold by smoother was Intended Gis makers but for returning In the post-war boom years. It probably dates from the 1830s because it has Iron made by WlIIlam Ash. In any case.For leveling a board. you look as if you were scrubsoon feel like it.kRogers not for the hands of fine furniture ers. Chapin and Sons. the movIng fmister is a champ. grips are "unbreakable" dead solld. the user replaced It-not As weH as the frog and handle assembly that renders the iron wheel. American dogwood is tough enough anywsy. I like the hungry scrub plane Some say flattening a board by hand Is drudgery . controlled by a screw completes Into the beech body. but I favor an ancient wooden [aek plane that was forced into a Ufetlma of scrubbing a single laminated came to me. but with a piece made from the crotch of a dogwood branch. 709-the the Millers Falls Co . 90 FIN E \V 0 0 D \'{' 0 1\KIN G .

screw-baereted chucks. have 3 cool tool working along w. I N G . transverse thumbscrew. The spur strikes next.When you have a boring job to do.e. look down.. and even if there's nothing mystical about it.Whlle other bit braces on their rattle. and then back into the blade.'and the gate-headed "bodger's horse" (shown here) used by chair makers.severing the cross-grain of fibers so the blade can shave its way down into the wood. The horse Is essentially a Spofford brace and center bit bore holes with style A Spofford·chucked bit brace Is cool . Sitting Is a free blade. it sure helps If you center bit In a Spofford brace. but Spoffords are rosewood pad and the pewter rings understated on the crank handle give these braces an effortless. up through the lever of the shaving horse.ray by a single Conn. and the main blade. 92 r INE \V 0 0 D \\I 0 R K.. Chuck Up. I work with a variety of drawknlves and use both the solidheaded shaving horse favored by cocpers. the flrmerthe grlp. the Spofford foot-operated vise that allows you to reposition the wood as you only work. In the late 18008. The power flows from the drawknife Into your hands. a cross-grain scoring spur. company of Bridgeport.fe In with someone.Drawknife and shaving horse. through your body and down to your feet. and your hands. The pike spears the wood and drills in as you crank the brace. ratchet. the drawknife by constant every stroke. split jaw tightened not Just Iron and irony-the It's a clean forging. controlled feedback and minute muscular adjustment through on a shaving horse with a drawkni. circle of strength. And where a handplane takes the same metered shaving with every stroke. They'tea fast pair. the harder you pull.. It's a filII.3 panache .ith you. ideal for boring shallow holes. too. and you're werkefficiency. and reverse with nlckel-platedknurtlng clamshell jaws with detached self-cenlldence. you can get talking discover that you've made a chair by mistake. an inseparable pair There are few more personal tools than your shaving horse and drawknife. In both forms. the a central ing with elemental business end of the bit has Just three simple elements: pike. brace Is defined by the forged. the Spofford brace just clamps your bit In Made by the F. no one can deny that it's wonderful. scaring the clreumrerence the 1101.

the centers foot on the beadle stroke. large opening you might not use-something handle Is special-the easier start and accounting Even the applewood gtves you a grip for two-handed It sings. But you can't just cobble one together. it talks. I've got no complaints. German technical and infinitely encyclopedia.a stroke and handsaw. tension the spring pole lively. it may seem that your tool of destiny Is a big handa sorry fate to discover saw. rising burr. giving It an for the rising note of each stroke. yet spins the back. The speed and ease of the saw me first. quickly adjustable. It spoke out wIth a crisp. But then I listened. giving It the forward spin for the cutting Raising your foot then lets the spring pole rewind the cord. . precise turning tool Properly butlt.nts create a sUghtly finer cut at the toe.handwork ripping pieces of oak flooring flea market impressed continued Disston ripsaw sings as it cuts In every young person's life. appreciate for the first 5 ft. found at a On every downstroke. SI. compact. based on a design I found in a Is solid.ke-:Justlik.lding the collar joining the two ash poles back and forth changes the tension from wimpy to wow! workhorse with true This little lathe Is a rock-steady the added benefit of the deHghted look on people's faces when they try it for themselves-another believer born every time. but 35 years later. ready for the adjusted excessively work quickly 17th-century next cut. on every upstroke. The lathe I built. it even cuts wood. My epiphany came whUe I was a Disston saw. frame must be solid. To many. and push of your sprIng pole lathe is a powerful and reciprocal tool with a cutting a plane or precise machine-a a return stro.It was speaking singing to me. a little lltt. If they're lucky. the spring pole does not resist your down stroke. they'll with light on a tool that just clicks with them. The downward The polished. for a. even giving your foot. Pole lathe is a powerful. With the properly.It rang with a faint echo of the moan the saw makes when bent Into an Sand plunked with my thumb •. to me-aliI had to do was work and listen. of ripping.e a putls the cord wrapped around the work.few dollars. The pol.

Hadden used traditional doors in the middle hut sliding doors below and above to avoid the opening and closing arc. Drawings: JoJ)J1 Tcrreauh 98 t\NE WOODWORK1NG . adding more of a particular depth and fewer of another. but Hadden [adored the anatomy to his own tools. An A+ tooll chest BY AN!ISSA CASE JOINERY Hand-cut coveralls are left proud.SECRET DRAWER False rail is friction fii and held in place by iwo bullet catches. enlarging some drawers. wedged tenons. he didn'T veer from tradition in the construction. and tapered sliding dovetails to keep the case solid and functioning smoothly for years to come. SLiOING DOORS Doors ride on their ra bbeted lower edges. PARTITIONS Tapered sliding dovetails rever Hadden's [raining with Michael Cullen nor only yielded the woodworking knowledge and skills he needed [0 go it on his own. using hand-cut dovetails. mortiseand-tenon Joinery (through and hidden). but also culminated in the Arts and Crafts tool chest seen on the back cover. Open lower drawer to remove rail and access hidden drawer. The design is loosely based on Cullen's. However.

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