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Projects, Techniques, and Products

Create a Great Home Shop With Just Two Walls!

4 All-Star Shop Projects
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Compact Workbench Precision Mitersaw Cabinet Mobile Planer Cart Power Tool Tower
Vol. 9/No. 54 Aug/Sept 13

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Apply a Tough Epoxy Shop Floor Build Time-Saving RTA Cabinets 12 Shop Setup Products

Display until October 1, 2013 What’s The Secret To Flawless Edge Profiles With NO REWORK?

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Aug/Sept 2013

Contents: Projects


Mobile Mitersaw Stand

Designed for a 10" or 12" compound mitersaw, the cabinet includes built-in dust collection, drop-down wings for easy storing, and adjustments for customizing the fence, shelf, and wings to your tool model.

48 55 64

Construct the sturdy bench base in just few weekends. Then save time by buying and bolting on the 24 × 60" laminated top. Add a pair of vises to make your bench work harder.

Compact All-Purpose Workbench

Workbench Tool Cabinet

Make the compact workbench work even harder with this four-drawer cabinet. The simple-to-make case can be resized to fit the bench you already own.


Give your benchtop planer a permanent home with this two-drawer mobile unit, complete with locking casters. (Your back will thank you.)

Planer Cart

Store benchtop machines and other portable power tools in this 32" wide × 24" deep × 76" high cabinet. Adjustable shelves let you customize the interior space to suit.

Power Tower

2 Aug/Sept

Cover photo: Larry Hamel-Lambert


epoxy paint and sealer. and products featured here to create a great home shop or to improve the one you already own. versatility. lights. Departments 06 Cutting In 08 Mailbox 10 Hot New Tools Ready-ToAssemble Cabinets • Micro Jig Pushblocks • Whiteside Pro Pen Mandrels 28 Get your workshop up and running in a weekend with these made-to-order cabinets from Cabinotch. .com Aug/Sept 2013WorldMags.Contents: Tools & Techniques WorldMags. nonslip. or comfort. We team up with the experts at Rust-Oleum to show how to prep a concrete floor. 14 Tips & Tricks 70 WoodSense: Boxelder 74 Well-Stocked Shop: Detail Saws 4 20 24 The Two-Wall Workshop Epoxy Paint Shop Floor Gather in the ideas. and cabinets. consider the 12 products in this roundup to add specialized storage. 34 Shop Setup Products After equipping your shop with power. Complete the cabinets with drawers and doors as explained here. and then coat it with an attractive.

Ohio 44087 • tel 800-843-3904 • fax 800-626-6970 . Twinsburg. variable power vacuum that is strong enough for use by multiple users with the optional dual operator fitting. Mirka’s net abrasives offer unparalleled dust extraction across the entire abrasive surface and virtually dust-free sanding! Mirka’s CEROS electric finishing sanders are effective and durable tools for professional sanding. Mirka Abrasives. The MV-912 portable dust extractor is a premium.Innovative Solutions for Wood Finishing WorldMags.mirkawoodworking. • 7950 Bavaria Road. White Wood Finishing High Gloss Finishing Solid Surface Finishing Mirka offers the perfect combination of net abrasives. These machines are built for maximum dust extraction even at low suction power. tools and dust extractors for a virtually dust-free sanding solution.

com Woodcraft Magazine (ISSN:1553. Suite A P. Techn Aug/Setp 2013 Volume 9. a lumber storage/mitersaw station Extreme Gar ver eo ak M Shop combo. LLC. nonslip surface on which to work. including a workbench with cabinet storage. Rather than build an assortment of cabinets from a stack of plywood. ucts iques.99 customer_service@woodcraftmagazine. it’s worth it. clamp racks. In Our history of idea-filled workshops hile the effort can prove exhausting. All you do is build the doors and drawers and apply an exterior finish. 4420 Emerson Ave. In the October/November 2011 issue. $5. using appropriate guards and safety devices. the editorial staff teams up to create an ideafilled home workshop using real-world LLC.S. P. SHOP beginning with a basic workbench/assembly PROJECTS table that provided a staging ground to PLUS… Workstations & Start-to-Finish Storage Solutions Game Plan complete the remainder of the projects. May. July. Periodical Postage paid at Parkersburg. Parkersburg. Alan Turner Shop Manager Shawn Staats Jim Harrold Paul Anthony Joe Hurst-Wajszczuk Chad McClung Shayne Hiles W Publisher Advertising Sales Manager Advertising/ Circulation Support Circulation Circulation Specialists.2461. WV 26102-7020. Parkersburg. Canada Post: Publications Mail Agreement #40612608 Canada Returns to be sent to Pitney Bowes. Please note that for purposes of illustrative clarity. then. For those starting from scratch. a mobile mitersaw stand. the g osin Cho Mobility for ace Perfect Workbench Multiuse Spa Fast forward to this August/September 2013 issue and its two-wall workshop (page 20). Inc. hey. and at additional mailing offices. guards and other safety devices may be removed from tools shown in photographs and illustrations in this publication and others. Suite A. we went with simple. Always make shop safety your first priority by reading and following the recommendations of your owner’s manuals. We also worked through the steps for nailing down a workshop wood floor and installing a small-shop dust-collection Online: (800) 542-9125 Contact Us Woodcraft Magazine 4420 Emerson Avenue. WV 26102-7020 1-800-542-9125 Fax: (304) 420-9840 Email: editor@woodcraftmagazine. a workbench/assembly e ag table. and tools. every two years at Woodcraft Magazine. Box . and that go together in just minutes. we featured the magazine’s new workshop in a 30 × 50' enclosed space. If the effort we pour into these special editions helps you improve your shop or create an awesome new shop that fills your woodworking needs. ON N6C 6B2 Printed in the USA Safety First! Working wood can be dangerous. In the June/July 2009 issue. USPS 024-953) is published in January. March.97 for one year Single copy. ready-to-assemble base and wall cabinets that you can order in any size and configuration. Four featured projects round out the Aug/Sept 2013WorldMags. Box 25542.O. Larry Osborn.. we show how to lay down a twopart epoxy floor paint to give you an attractive. and maintaining all your tools properly.Cutting WorldMags. There. Tel: (304) 485-2647. find the digital versions at woodcraftmagazine. WV 26104. Use adequate sight and hearing protection. P. To see the previous shop issues. complete with modular flooring tiles. we showed how to make MDF (mediumdensity fiberboard). Pete Stephano.O. we took a cluttered 24 × 24' two-car garage and transformed it into a hardworking HOP ISSUE! SPECIAL WORKS workshop. All rights reserved. Box 7020 Parkersburg. designed to help you outfit adjacent walls in a garage or basement with storage. $19. lumber. and Canada. Arnold Johnston. Issue 54 Editor-In-Chief Senior Editors Art Director Graphic Designer Copy Editor. London. Bill Sands. a planer cart. and birch plywood shop cabinets. Proofreader Sharon Hambrick Contributing Consultants/ Craftsmen/Project Designers Chuck Hedlund. we even suggested a logical order of construction. September and November and printed in the United States by Woodcraft Supply. and other projects BEFORE destined to instantly earn their place in any shop. and a power tower storage unit for your benchtop and portable power tools. hardwearing. 8 I I MUST-HAVE I I 6 woodcraftmagazine. and Prod Projects. Copyright 2013 by Woodcraft Supply. melamine. POSTMASTER: Send address changes to Woodcraft Magazine. Jody Garrett Vic Lombard Miranda Springer Subscriptions U. In addition.

net .WorldMags.

Piedmont. editor-in-chief . there’s enough mica in the 18 × 36" sheet for a second lamp. My wife and I lived in Parkersburg. The plans were great. Woodcraft product 8 woodcraftmagazine. three generations of WVU fans. Three second place prizes include $250 Woodcraft gift cards plus two-year Woodcraft Magazine subscriptions. where we raised our family and worked in the education system for 35 years. The plan came from Woodcraft Magazine. Ridgecrest. As a bonus.000 in Powermatic tools. who now resides in Texas. complete. — Woodcraft Magazine staff I just completed the Arts and Crafts table lamp from your Apr/May 2013 issue. offering you a chance to win the grand prize of over $15. and Jeff loves his new shop addition. editor-in-chief Salvaged treasure Gold rush Woodcraft and Woodcraft Magazine are sponsoring a mega sweepstakes. your choice of salvaged Siberian elm shows that the style can look great in other woods as well. Thanks for the quick. and more. Beside me in the photo are my son and grandson Austen. —Jim Harrold. —Charles . I painted the table with the school’s colors. his lamps also look impressive. To enter. Nice touch. Oklahoma Wayne. Like your piece. floor-model drill press. As you can True colors shine in the shop I built this router table for my son Jeff. I used some quartersawn and riftsawn Siberian elm that a friend and I milled from a tree that was destined for the landfill. 10" cabinetstyle tablesaw. 15" planer. a huge WVU (West Virginia University) fan. adding school colors to your son’s router table is a great way to remember your roots and all the good family times cheering on the Mountaineers. The table is one of our finest shop projects and is still available through woodcraftmagazine. Fifty third prize winners will receive a one-year subscription to Woodcraft Magazine. California Charles. see the ad on page 7. full-sized lathe. Recently. —Wayne development manager Ben Bice is making a pair of the lamps out of cherry. That’s a shop full of hardworking. However. —Jim Aug/Sept 2013WorldMags. we moved to Oklahoma to be near the grandchildren.Mailbox WorldMags. turbo-cone dust collector. 14" bandsaw. purist builders of Arts and Crafts pieces typically employ quartersawn white oak. and straightforward project. West Virginia. high-quality machines! The tools include an 8" jointer.

Standard Shown With Brass Tubes Inserted “Get The Right Fit” MADE IN USA TAKE OUR CHALLENGE.250 RPM Continuous Feed For Optimum Performance • Provides Better Fit/Adhesion Between Brass And Blank • Made In The USA From Premium M2 High-Speed Steel 154023 154024 154025 154026 154027 7mm (.412") 12.516") 154031 letter “O” (.272") 10mm & 25/64" (.488") 3/ " (.154023 .389") 10.476") 154030 33/64" (..154031 • Designed Specifically For Woodcraft Kits • Tip Designed To Allow For Better Alignment And Clean Exit Hole • 1.000-1. right into your Or Call 800-225-1153.457") 154029 31/64" (.314") Whiteside Pro Pen Mandrel #2MT .372") 8 154028 15/32" (.net 154275 (A) Flush Trim 154276 (B) Pattern/Plunge 154274 (C) Combination .. previously manufactured for CNC machines. Collet Nut. Whiteside Pen Maker’s Bits . (A) (B) (C) WorldMags. ULTIMATE Trim Bits The “ULTIMATE” Trim series brings industrial engineered bits.157776 • New Design Allows for Fast & Easy Mandrel Adjustment • Fits #2 Morse Taper And Promotes A Better Lock To Lathe • 4-Piece Design Includes PEN MAKING Accessories TruFit vs. Mandrel And Brass Nut Available At Woodcraft! For A Free Catalog Or To Find Your Local Woodcraft Store. STEP 2: Measure the outside diameter of your current drill bit.5mm & 27/64" (. STEP 3: Compare to a Whiteside “TruFit” Drill Bit. STEP 1: Use a caliper to measure the outside diameter of your brass tube.WorldMags. Visit woodcraft.5mm (. Aug/Sept 2013WorldMags. and sometimes makes for a less-than-perfect cut. the rubberized pad holds your stock firmly against the table while providing enough friction to push it forward. #856321 $29. all the while keeping your digits at a safe distance from the Photo: Brian Francis . The block costs more than a typical commercial pushblock. At the end of the cut. it’s easy to see how quickly it can earn its keep. positive purchase during the last bit of crucial travel past the blade. but if it helps keep fingers safely away from blades and bits at all stages of the cut. By adding flip-up feet to their latest pushblock. Micro-Jig has combined the best of both worlds. So I typically use both. Like a standard pushblock. 10 woodcraftmagazine. stopping near the end of the cut to switch pushers can be dicey.99 Tester: Joe Hurst-Wajszczuk Featured products available from Woodcraft Supply unless otherwise noted.Hot New Tools WorldMags. the feet drop down to hook the end of the board for secure. I find that rubber-soled pushblocks have the advantage mid-board while notched pushsticks have the edge when feeding the last MICRO JIG GRR-RIP Block Model GR-1 few inches of stock past the blade or A block with legs When feeding stock on the tablesaw or router table.

net . when are you going to start living yours? FOR FRANCHISE INFORMATION. we wanted to challenge ourselves. From site location and demographic research.WorldMags. CALL 1.woodcraftfranchise. Woodcraft provides in-depth franchise models to assist the franchise owners in meeting their goals. one of the most trusted names in woodworking. Which makes you stop and think. Bill would tell you that thanks to Woodcraft and a lot of hard work. For Bill. If you sat down and talked with P.7326 www. and this was a great fit. No wonder.923. All the while being backed by the power of the most recognized brand in the industry. Box 245.O.855. the dream of owning a Woodcraft store started with his desire to challenge himself and break out of the routine world he knew as a paper company executive for 18 It was difficult to walk away from the security of long-term jobs. That’s why when he saw a franchise opportunity ad for Woodcraft. he and his wife Heather both knew it would be the perfect fit. to a detailed training program and ongoing technical support. Say hello to Bill – experienced woodworker. Parkersburg. WV 26102 Bill Caillet Woodcraft Store Owner Norfolk. savvy entrepreneur and all around good guy. VA WorldMags. he’s well on his way to living his dream. But.

99 Tester: Ben Bice Featured products available from Woodcraft Supply unless otherwise noted. 157776.Hot New Tools WorldMags. simply loosen the collet nut. mandrel shaft. and Aug/Sept Penned to perfection Although it costs a few dollars more than the competition. 157777.99 #2 MT. To make the Photo: Bob Etter . guarantees vibration-free operation. $39. #1 MT. slide the shaft to the desired length. $39. In addition. Whiteside’s Pro Pen Mandrel makes all the difference when turning pens. collet nut. the redesigned mandrel makes it easier to Whiteside Pro Pen Mandrels adjust the shaft length for turning everything from key chains to pens without the need for spacers. the precision machined taper on the mandrel ensures a better fit in the lathe headstock. 12 woodcraftmagazine. along with the mandrel’s overall quality of manufacture. The set includes a 1⁄ 4" collet. This. and brass knurled nut. By incorporating the same technology used to hold cutterheads in CNC machines.

Both parts will be square and secure from unwanted movement. This simple tool eliminates the hassle of cumbersome bar clamps and eliminates the need to continuously make adjustments to square the corners. Woodpeckers Box Clamps are designed for most 90 degree joints including pocket hole joints. Once your project is glued and clamped. half-blind and through dovetail joints. Ohio 44133 • (800) 752-0725 WorldMags. lap joints. The new Box Clamp™ is also perfect for box joints. Virtually any joint found in common cabinetry. dado as well as T-joints.WorldMags. • North Square Up Your Projects F a s t e r T h a n E v e r New From The New Woodpeckers Box Clamp™ is just the ticket for your cabinet and box making projects. You’ll know right from the start if your project is square and be able to confirm part placement and dimensions. you can easily install pocket screws from the inside or any other fasteners from the outside. When you need square corners. Imagine being able to dry-fit all parts at the same time without any clamps to interfere with the assembly process.A. Made in U.S. Whether the corner is flush or has material extending from the surface. the clearance is there to ensure a square corner. you can’t beat the Woodpeckers Box Clamp™.net . 11050 Industrial First Ave. See our full line of American made woodworking tools at your local Woodcraft store. you can to do all that without a second set of hands. Even better.

Counterbore for machine screw head and washer Hex-head cap screw 1⁄4-20 × 1" Tap for 1⁄4-20 threads. Next issue’s Top Tip will receive a Woodcraft Gift Card worth $250.O. stacking pieces at the center to serve as a blade cover. Drill 5⁄16"-diameter holes at those Glue and clamp fence to base. and 3⁄ 4"-thick hardwood plywood for the base. Drill the attachment holes through the steel bar stock (available at www. Asheville.BigGatorTools. The tapered ends of the fence allow better hand access for holding down narrow work. and readjust if necessary. and transfer those locations onto the base. and then tighten the screws. round parts and corners. Woodcraft Magazine. Win Cash or a Prize! Here’s your chance to help someone become a better woodworker and get rewarded for the effort. Send your original ideas to: Tips & Make a test cut. With the runners in their Aug/Sept 2013WorldMags. also counterboring to recess for 1⁄ 4 -20 × 1" hex-head cap screws and washers. as there’s no bottom sled panel raising the workpiece. Use quartersawn hard maple or other straight-grained hardwood for the fence. Runners-up will receive $125 for an illustrated tip. Hanger hole Fence 2 × 33⁄4 × 31" Steel runner ⁄8 × 3⁄4 × 24" 3 This handy jig–which is basically an oversized miter gauge with a large fence and double runners for better workpiece bearing and stability–lets you crosscut large workpieces with accuracy and ease. www. and then glue the fence to it. mcmaster. When correct. as an editor will need to call you if your trick is considered for publication. WV 26102-7020 or email 913-377-2444 . Loosely attach the runners with the cap screws and washers. cutting the threads with a 1⁄ 4 -20 tap. —Andy V-DrillGuides Drill Straight – Every Time! Can be used on flat surfaces. measure the precise distances between the hole center points. Winning entries become the property of Woodcraft and other metal suppliers) with a #7 bit before Plywood base 3 ⁄4 × 5 × 24" Stacked plywood serves as blade cover. Parkersburg. square the fence to the fully raised blade. Box 7020. Important: Please include your phone number. 14 woodcraftmagazine. $75 for a non-illustrated one. The plywood base keeps the fence dead-straight and serves as a solid connection for the runners while allowing adjustment if necessary to square up the fence.TOP TIP Bottomless tablesaw crosscut jig Tips & Tricks WorldMags. Its advantage over a traditional crosscut sled is the ability to make a full-depth cut. P. you’ll get perfectly square crosscuts every time. Trim the leading edge of the base flush and square. North Carolina Workpiece R BIG GATOR TOOLS Share a Slick Tip.

Inc. Zero-clearance base prevents wedges from falling into throat opening. readjusting the fence if necessary to adjust the thickness of the wedge to create a sharper or blunter Attach handle for safe feeding. (My jig includes 3°. wbgu. To quickly and accurately bandsaw multiple wedges.WBGU Public Television WBGU Public Television presents 13 PBS TV shows of The American Woodshop “Home Restorations. Delta Power Equipment. All Rights Reserved The American Woodshop Is Underwritten By: WorldMags. offset the bandsaw fence from the blade a distance equal to the width of the Aug/Sept 2013 woodcraftmagazine. begin with a squared chunk of 8/4 or 12/4 scrap about 7" wide by 9" long. —Alan Turner. adding a handle for safety. When your fence is set properly. cut a few inches into a piece of plywood.WorldMags. Then rotate the stock 180° and reinsert the same end in the notch to make the next cut. Test-fit it in your joint. glues & finishes in action. Next. Nestle the end of the wedge blank in the notch. and I often require lots of them. Kreg Tool Company. and then slice off a wedge. Recycle and Renew beautiful spaces!!!! Get your Tools Out!!! Join Scott & Suzy to get the most out of your woodshop tools! See new tools. Visit www. Gorilla Glue & Easy Wood Tools © 2013 Sylvan Tool Works. The American Woodshop with Scott & Suzy Phillips Season 20 Home Restorations Home and Away Green Energy Solutions Presented by . Notch the edge to match the angle of your desired wedge. Repeat to make all subsequent wedges.) To make your wedges. Grain direction Automaxx™ Clamps adjust automatically to match any thickness Just set the clamping pressure once.kregtool. 4°. Pennsylvania Illustrations: Chris Glowacki Available in Face Clamp and Bench Klamp styles.” Season 20 Re-creates restored furniture accents for every to see them in action. I use a thick block of wood with wedge-shaped notches cut into its side. I need the wedges to be spot-on. To make a jig like this. Seat wedge stock in notch to make cut. first prepare your wedge blank by thicknessing a board to the desired width of your Woodcraft Supply. and Automaxx™does the rest! You set the clamping pressure The clamp adjusts to any thickness Wedge cutting jig When making wedged through mortise-andtenon joints. Now cut a wedge as before. 15 . Then crosscut away a piece that equals the desired length of the wedges. and clamp or tape it to the table surrounding the blade as a zero-clearance base. and 5° notches. See the innovations that Rebuild.

I often wear disposable gloves. —Alan Wahlburg. C O M 16 woodcraftmagazine. Tennessee COMPLETE THE JOB WITH THE POWER OF FORCE™ 1. Available at Woodcraft! For A Free Catalog Or To Find Your 3939 Royal Dr. Improvised edge clamp I needed to glue a piece of edging to a panel where it would have been awkward to span the panel’s surface with long bar or pipe clamps. One day it dawned on me that compressed air might help me get more life from lightly-used pairs. F O R C E T O O L S U S A . Then I remembered a trick a friend showed me a long time . I was then able to easily slip my hand out of the inflated glove without damaging it or turning it inside out. Tennessee Squeeze opposing wedges together under clamp bar to apply clamping pressure to workpiece Inflate glove with compressed air to remove it without tearing or inverting Aug/Sept 2013WorldMags. Visit www.2 AMP MULTI-PURPOSE TOOL Variable Speed Optimized For Different Materials Over Mould Comfort Grip Increased Control And Handling Dust Tube Cleaner Work Area MULTI-PURPOSE TOOL .5 AMP ANGLE GRINDER Spindle Lock Quick & Easy Disc Changes Side Handle More Control. Mount Juliet. I slipped the air nozzle in at the wrist and pulled the trigger. I secured a couple F-style clamps to the panel as shown. Knoxville. Better Handling Soft Grip For Better Comfort ANGLE GRINDER 158540 Local Woodcraft Store.1 AMP ROTARY TOOL KIT Spindle Lock Quick-Change For Different Accessories Outer Carbon Brush Extended Lifetime Variable Speed Professional-Looking Cuts & Finish ROTARY TOOL KIT 158538 2. Edging Taking off the gloves without a fight When hand-applying finishes. making their reuse impractical.Tips & Tricks WorldMags. Sure enough. Unfortunately. GA 30144 T 1-866-902-9690 W W W. Kennesaw. and slipped opposing wedges between the clamp bar and the edging to apply clamping Or Call 800-225-1153..158539 7. removing them usually resulted in tearing or inverting them. —Dennis Beadles.

com | 1-866-963-0294 New product ™ Solid Body Fit Thread Sizes: 1”. 1 1/4” .5 Other Easy Chuck exclusives: S LT Snap-Lock™ Hardened jaws and jaw slides will last for generations Rounded jaw corners for safety that will not cut your knuckles Jaws are not numbered They can go in any slot Strong jaw design uses no screws for Change out jaw sets in under 30 seconds and get right to your next project Quickly adjust the gripping diameter with just your fingertips! Then final tighten with included chuck key mounting See videos at 17 .WorldMags. and M33 Aug/Sept 2013 woodcraftmagazine.8.

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chisels and more – all made of the highest quality steels and other materials to complement the woodworking artisan’s skills. planes. 13WD09P4 to see our selection or call 1-800-537-7820 to receive a catalog. Visit . For more great tools visit www.japanwoodworker. measuring and marking The Fine Art Of Japanese Joinery Begins With Excellent Tools Japan Woodworker offers the carefully designed and crafted tools required for the functional yet very beautiful art of Japanese joinery – or call 1-800-537-7820.

attractive shop floor. By Jim Harrold . and seal the surface in three days for a hardwearing. Prep the concrete. Just add doors and drawers. WorldMags. mix and roll out the epoxy paint.The Two-Wall Workshop Transform a garage or basement with this smorgasbord of ideas and 28 20 Ready-to-Assemble Cabinets Save Time and Money 24 Nonslip Epoxy Paint Surface for $600 These made-to-order cabinets by Cabinotch let you build a wall of storage in a weekend or less.

58 Back-Saving Planer Cart with Storage Give your benchtop planer a permanent home. dog holes. and multiple adjustments for super accurate cutting.WorldMags. fences with stops. Compact Workbench 65 Versatile Power Tool Tower Two vises. Customize this wheeled cabinet to your arsenal of portable tools by adjusting the shelves up or down as needed. 38 Mobile Mitersaw Stand with Built-in Dust Collection This shop-smart cabinet features work support 48 Sturdy. a solid base. and avoid the heavy lifting and carrying of the machine with this two-drawer mobile 21 . and cabinet storage make this a workshop workhorse. Save time by going with a store-bought laminated top. Photo: Larry Hamel-Lambert WorldMags.

compact workbench. They include a mobile mitersaw stand. and power tool tower. our senior editors and two talented freelancers designed and constructed four all-star shop projects to fill a variety of common needs. and bandsaw. five 110V duplex receptacles.Figure 1: Wiring and Lighting Plan WorldMags. As shown on pages 20 and 21. Prominent here are the ready-toassemble Cabinotch cabinets that you literally build in minutes. Assuming that most of the woodworking will take place in the back half of the garage. we ramped up both the electrical and lighting output in that area. and the heavy-duty Duraboard polypropylene pegboard system. we packed our featured “Two-Wall Workshop” issue with a multitude of adaptable ideas. for further assistance. projects. They’ll also help you get organized and get your shop up and running in short order. basement. complete with hooks. three 220V single receptacles. The concept behind the twowall workshop is that every woodworker has–if not a whole room–at least two walls in a garage. 220V single receptacle Existing 110V duplex receptacles. n Illustration: Charles Lockhart . and five 2-bulb fluorescent ceiling fixtures that mimic natural daylight. To do this. Like the previous Radiant space heater (30" long) 6' 26" 4' 1' 100 amp sub panel 200 amp house service panel House storage shelves Attached house 2-bulb (60w) T-8 fixtures  Smoke and fire alarm Existing light switch 16'-wide garage door 8'-wide garage door New 110V duplex receptacles. where you can store your tablesaw. or other area that he or she can claim as shop space. black. even when coated with fine sawdust. money. space. is the nonslip epoxy floor paint (on concrete) by Rust-Oleum. while a special sealer offers long-term protection. as shown in Figure 1. specialized elcome to Woodcraft Magazine’s third workshopthemed issue. we had a certified electrician install a 100-amp subpanel. for instance. You’ll find that many of the ideas will save you time. and lights 22 woodcraftmagazine. To further improve the space. planer cart. Providing a sure grip underfoot. and white add interest and texture to the surface. check out the “Dream Shop Planner ” (pullout insert) and “Shop Setup Products” (page 34). in some cases. and products to help you improve the shop space you already have or create a whole new shop from scratch. or. we’ve dedicated a 25'-long wall at the back of a garage for shop storage and to provide valuable counter space. The adjoining second wall serves as the place to store lumber and park mobilized machines when not in use. These improvements are on top of the existing 110V wall outlets and two fluorescent ceiling fixtures. It's here. switches. and lights W Note: All wall receptacles are 48" above floor. switches. mobile dust-collector. Finally. Decorative color chips in Aug/Sept 2013WorldMags. and bins.

125x4.indd 1 6/13/13 3:46 PM WorldMags. style and performance! Visit www. with nine hardwood species options. flush joint that slides together fast! The custom cabinet box system that’s engineered for speed. customsized. Exclusive patent-pending assembly notch creates a strong.You’ve read the today and claim your special limited time discount code! CFP018_Woodcraft_Ad(3. formaldehyde-free.625). Aug/Sept 2013 woodcraftmagazine. Now try it for yourself! The Cabinotch® custom cabinet box 23 .

woodworking stains. Beyond that. consider laying down an attractive twopart epoxy paint and sealer on your concrete that lets you easily wipe up spills. floor squeegee. when you do the installation Epoxy Paint Shop Floor Achieve a showroom-quality surface in just three days. two-thirds of a day for painting and adding the decorative color chips (for a terrazzo-like appearance). And while concrete provides a flat surface on which to roll mobilized tools. I and Jim Harrold teamed up with the experts at Rust-Oleum to lay down a tough two-part epoxy paint (EPOXYSHIELD Professional Floor Coating Kit) and sealer (EPOXYSHIELD Premium Clear Floor Coating Kit). chemical/liquid-resistant latex or rubber gloves. Full cure takes at least three more days. These include a good scrub brush. and provide a sure grip underfoot. and two hours on the third day for rolling out a sealer containing a nonslip additive. and a 3" utility nylon paintbrush. capturing the steps from beginning to end. plastic watering can. By Gary Lombard with Jim Harrold Consultants: Rust-Oleum W 24 hether in a garage (shown here). To properly follow through on the prep and installation for the featured workshop in this issue. far exceeding the number of wood floors. its look is not all that great. the work took one full day for prepping. an epoxy-safe 1⁄2"-nap paint roller. Another problem: Smoothly troweled or sealed concrete can prove slippery when coated with fine sawdust. laying down a two-part epoxy paint and sealer on a concrete shop floor requires a few common tools. Plus. it can absorb drips and spills from motor oil. To remedy these issues. roller Aug/Sept 2013WorldMags. . five-gallon bucket. basement. paint-mixer attachment for a cordless drill. concrete floors for home shops are the norm. In all.WorldMags. roller extension handle. pan liners. eye protection. sweep up dust. or dedicated outbuilding. Tools for the Job The resulting showroom-quality surface promises a lifetime of wear-resistant good looks. big savings are in store. From prepping to painting to final sealing. and other liquids.

a poorly bonded painted surface. dust. After. a previously applied sealer. If so. woodcraftmagazine. or other sources create areas on a concrete floor that resist adhesion. lawn mowers. Oil stains If the concrete proves unsealed. some can’t. repair the surface with a concrete patch product. chemically etch the surface to clean it. (With newly poured dry concrete. provided Poorly cured or damaged concrete Day 1: Prep the surface For poorly cured or loose concrete. the bond is 25 Opener: Larry Hamel-Lambert. or chipped areas with a nonflexible concrete patching product (found at home centers). use the same scrubbing approach to etch an unsealed floor. the concrete is sealed. conduct the test in Photo B. If the water sits. B Pour water onto the concrete to see if it is absorbed or if it sits or beads on the surface. skip the grinding and etching concrete Before buying a two-part epoxy floor paint kit. scrub stained areas with a stiff bristled brush. as shown in Photo C . (One patch product is RustOleum’s EPOXYSHIELD Concrete Patch and Repair Kit. poorly cured spalling concrete. If the test proves positive. Rinse clean. tape a 3 × 3' piece of 1 mil plastic sheeting to the floor and let it sit for 24 hours. For oil Aug/Sept 2013 . resulting in an extremely hard surface.Test the WorldMags. incise a small X on the surface. Then peel it up. keeping in mind that preparation is critical to a well-bonded epoxy paint job. C Using EPOXYSHIELD Heavy-Duty Degreaser. scrub the surface. To etch an unsealed floor. If surface erosion resulting in excess concrete dust and spalling persists–even after cleaning–do not paint the floor. you shouldn’t paint it. follow through with the appropriate strategy. or if a dark shadow appears in the concrete–both telltale signs. as shown in Photo A . grind the surface to remove the sealer. With an existing (versus new) concrete floor. Dispense with the problem as explained under “Day 1: Prep the Surface. If the paint does not come off–meaning it is well bonded–scuff-sand and clean the surface to prep it. the slab has been allowed to cure for a minimum of 28 days before coating. if the concrete contains moisture. and the floor will need surface-grinding to remove the paint. Moisture in the slab. Moisture Certainly. Let’s deal with these one at a time. Some can be fixed.) Painted slab Sealed surface To see if the concrete is sealed. and clean it thoroughly to remove the cracks. To test for moisture.) This twopart epoxy-based patch dries fast.” Once you have established that the floor is a candidate. and stick a piece of duct tape over it. Project photos: Staff WorldMags. A Remove the plastic sheeting to see if water beads cling to the bottom face. Unsealed surface To test the adhesion of an existing paint slab. Pull off the tape to see if some paint came with it. patch any holes. analyze the condition of your concrete to see if it meets the requirements and to determine the prep work approach. mix up a solution of one part phosphoric acid to four parts water in a plastic watering can. and oil stains all pose adhesion problems for epoxy paint. Motor oil drips and stains from autos.

Pour part B into a five-gallon bucket. Open all doors and Aug/Sept 2013WorldMags. Let it thoroughly dry for 24 hours. furnace. one that is free of all E Abrade the open floor with the floor grinder. It should fizz slightly from the chemical reaction. use a foam or rubber floor squeegee to remove the rinse water from the surface. depending on the air temperature (see instruction sheet for more information). mix larger quantities of the A parts and B parts separately. working toward a door opening as an exit strategy. and use fans to exhaust dust-filled air to the outside. Rent these for about $100. or other source of ignition. and then.WorldMags. Be sure to wear eye protection and gloves when prepping and cleaning the floor with chemicals. Turn off pilot lights to any nearby hot water heater. and wash it. working from back to front. and then pour in part A. F Mix the two parts of the epoxy paint for 3 to 5 minutes using a paint-mixer accessory (found at home centers) and a cordless drill. you have just 90 minutes to apply the mix. and use a shop vacuum to gather floor dust. Ideally. Note that if you leave the garage door open and regularly expose the floor to sunlight. and use them as shown in Photos D and E . 26 woodcraftmagazine. as shown in Photo 60-minute induction process. Begin painting by cutting in 4' along the corner allow the ingredients to sit for 30 minutes in order for them to chemically combine. scrub the entire surface in manageable 10 × 10' D Grind the sealed floor along the walls with an industrial-grade orbital sander and 60-grit discs. Next. blending the parts as shown in Photo F. Following the 30. roll out a 4 × 4' section in the same area. Pre-wet the floor. On larger floors. then cross-grind at 90°. A two-gallon mix lets you do a 300-square-foot space or about a one-car garage. coating the floor with epoxy paint and chips is a twoperson job–one to cut in along the walls and broadcast the chips and one to roll out the floor. the epoxy coating will become damaged over time. . working in one direction. mark and lay down strips of duct tape along the line to establish the border between the driveway and garage/shop floor. Rinse and scrub the floor three times to achieve the cleanest possible surface. This guarantees that the color remains consistent across the floor. dirt and contaminants. Vacuum the floor several times for the cleanest possible surface. To do this. plan the floor coating to align with the inside edge of the garage door. For best results. sand the surface with an industrial orbital disc sander and a floor grinder having 60-grit abrasive stones. To prep a sealed floor. Don’t expect to take a break. When the fizzing stops. Because constant daily sunlight will cause a two-part epoxy coating to yellow and degrade. Wear a dust mask and hearing protection. rinse the surface clean. and then mix equal amounts of the parts together when you are ready to continue covering the floor. After mixing. Day 2: Mix and apply the epoxy paint Ensure that the workspace is properly ventilated and that the room temperature is between 55 and 90 F°. as shown in Photo H.

as shown in Photo or call (888) 683-5667. and Brendan Steidle at Rust-Oleum for serving as technical consultants during the floor installation. For more on the products featured here. and miscellaneous materials for a do-it-yourself cost under $600. toss the decorative color chips up and away from you so they land flat on the wet paint film. as shown in Photo I. letting them float down and blend in evenly. visit rustoleum. Let the sealer cure for at least 24 hours before walking on it.000. slip-resistant sealer using a clean roller and working in manageable sections. a rented grinder and orbital 27 WorldMags. Be careful to contain chips in each painted section as you work so you don’t get any on the roller or unpainted surface. Let the floor cure for 24 hours. we used two EPOXYSHIELD Professional Floor Coating kits (four gallons total). cut in with a brush and roll out the floor with the sealer. mix in the slip-resistant ingredient (EPOXYSHIELD AntiSkid Additive) into the sealer (EPOXYSHIELD Premium Clear I Broadcast chips by the handful over the painted area with an underhand motion. Repeat until you’ve painted the entire floor and dispersed the chips. n Day 3: Roll on a slip-resistant sealer Costs and Savings J Coat the two-part epoxy painted floor with a Aug/Sept 2013 . Determine the level of chip coverage for the look you want ( Photo I Inset). the painted surface. as before. Do not drive on the surface for another three days to allow for a complete. a 600-square-foot G Use a brush to cut in 4"-5" from the wall in 4'-long bands while working out of a small paint pot. Floor Coating). To have the floor professionally done would cost about $2. woodcraftmagazine. You want the chips to be distributed evenly onto H Roll out the floor in a manageable 4 × 4' patch with a solventresistant paint roller having a 1⁄2" nap and plastic core. three EPOXYSHIELD Premium Floor Coating Kits (as the sealer). Robert Shoenberger. undisturbed cure. To paint and seal this garage floor. rollers. Before moving to the next section. Special thanks to Don Evans. following the precautions mentioned earlier.WorldMags. Before sealing the painted floor. Now. Mike Ortiz. brushes.

a cabinet box system consisting of made-to-order base and wall cabinet parts that you assemble in minutes with glue and a nail gun. Over the next few pages. and from several wood choices. I learned firsthand just how easy it is to build and hang attractive. W . you can order just the cabinets you need in any Aug/Sept 2013WorldMags. What if you could address your shop’s storage needs in a few short days? Enter Cabinotch. By Gary Lombard with Jim Harrold WorldMags. The end result: big-time savings in both time and money. hile creating a two-wall or larger shop (or a kitchen. drilled holes for supporting shelves. while allowing you to assemble and hang a shop full of quality cabinets in a weekend or less. While the cabinets–once constructed–include a UV finished interior.Ready-To-Assemble Cabinets Outfit your shop in a weekend or less. for that matter) with a variety of storage cabinets that you design and make seems daunting and time-consuming. Better still. configuration (door and drawer openings). it’s up to you to construct and add the doors and drawers and finish the exterior. maple plywood box parts and maple hardwood face frames were used. I’ll share with you how I did it. For this issue’s featured workshop. and perfectly square shop cabinets in my shop when I used the Cabinotch system and its builder-friendly joinery. it doesn’t have to be. and edged and finished 28 woodcraftmagazine.

net Note: Here is what you’ll need for a guaranteed hitch-free assembly and installation: a flat assembly surface such as a floor or assembly table. rubber mallet. 18-gauge brad nail gun with 11⁄4"-long brads. Apply glue in the mating 29 . Lay out the cabinet parts on a flat assembly surface with the sides alongside the face frame. cordless drill and square drive bit. WorldMags. Stop short about 6" from the end of the groove. compressor. holding the gun perpendicular to the mating plywood edges. four bar clamps. (I measured in to locate the centers of the back edges of the cabinet’s top and bottom and struck a guideline to ensure that the nails hit pay dirt. as shown in Photo A and Photo A Inset . Apply glue and fit the back in the side rabbets. The excess glue on the leading edge of the sliding side should spread to this area.) With base cabinets. #8 × 3" screws. as shown in Photo B. glue and nail the cabinet screw cleats in the side top rabbets for attaching a countertop. shoot the back in place with 11⁄4" brads. using a mallet to gently tap and seat the parts as needed.Note: To view your cabinet options or to order cabinets like the ones shown here. and slide in the bottom and top. Project photos: Morehead Photography WorldMags. Then. nail the back in place. go to cabinotch. Now. Super-fast assembly A With the face frame clamped to prevent movement. Then. Opening photo: Larry Hamel-Lambert. 2 3 4 B Use clamps to snug the sides to the back and check for or call (877) 413-4299. slide in the sides. and level. 1 B Align and slide the cabinet top and bottom in the mating Aug/Sept 2013 woodcraftmagazine. as shown in Photo C . stud finder. measuring tape. Next. At the website check out the videos about the Cabinotch system construction. using an 18-gauge nail gun. square. moistened rag and clean water to deal with squeeze-out. apply a moderate bead of glue in the face-frame grooves. Wipe up any squeeze-out with a rag moistened in clean water. woodworker’s glue. ensuring that the ends are flush top and bottom. slide in the interlocking sides.

for . crosscut the needed number of stiles to length. keeping it in contact with the router fence and/or the bit bearing. Mill extra stock for test pieces to set up the rail and stile router bits. Crosscut a few router setup test pieces. Stile 2 Rail Make shoulder and groove offset the same height. plus 1". Next. That dimension will give you the rail length. E With a featherboard hold-down in place. cut or cope the end of the test rail. including the interlocking coped ends. plan all of your door sizes and the number needed. Locate hinges 3" in from top and bottom edges of door D Using a coping sled to hold the workpiece firmly in place. Figure 1: Frame & Panel Overlay Door Exploded View Adding doors and drawers to 3⁄4" thick for the door frames and the drawer fronts for the assembled cabinets. At this point. rip the rail and stile door stock to 11⁄2" wide. take the inside opening measurement from stile to stile of the planned door and add the depths of both opposing grooves. Install the coping bit of a rail-and-stile bit set in a tablemounted router. The goal is to create door frames that overlay the cabinet face-frame openings by 1⁄2" all around. using a shoe-style pushstick to safely make the Aug/Sept 2013WorldMags. profile the inside edges of the rails and stiles. 3 30 woodcraftmagazine. you’ll want a 14 × 30" door frame. Crosscut the rails to length. Next. and adjust its 1 Mill enough hardwood stock 3" 11⁄2" Note: Size door to overlay face-frame opening by 1⁄2" all around.WorldMags. On a 13 × 29" face-frame opening. If using a rail-and-stile bit set as suggested here.

rout the inside edges of both the rails and stiles. using a coping sled. Base 1 ⁄2 × 14 × 21" (Final length determined after trimming end of base.) 90° #8 × 1" flathead screw #6 × 1⁄2" flathead screw Final distance between runner and end of base determined when base is trimmed to length. see page 61.) 1 4 5 F Align the outside edge of a door with the cut edge of the sled. and doors to 220 grit. use the edge of a rule to adjust the infeed and outfeed fences to be perfectly in line with the bit’s Aug/Sept 2013 boxes 1" smaller than the width of the opening. Once the glue Step 1: Cut plywood base to size. as shown in Photo E .com 31 . (Because I used a coping sled for safety and workpiece control. Dry-fit the rails and stiles of a door frame. Glue and clamp the rails to the stiles with the panels in place. From 1⁄ 4" plywood. Cut any remaining door panels to size. Runner ⁄4 × 3⁄4 × 30" (Adjust to the dimensions of your miter slot. run it through the blade to establish a true edge.) Next. ensuring the piece is square. (I sprayed on two coats of General Finishes Polyacrylic Water-Based Top Coat. face frames. aligning the outside edges of the rails with the marks. cut a door panel to size and test-fit the door assembly. Locate so end of base extends beyond blade by 1". To make the overlay drawers. 3 Fence ⁄4" × 7⁄8" × length of base Step 2: Cut runner to size. (Later. using a shoestyle pushstick for safety and control. running it past the cutter outside face down. as shown in Photo F. (I made the drawer WorldMags. placing a test stile piece outside face down against the fence. Once satisfied. For the drawer depths. measure the distance from the rail and stile groove bottom to opposing groove bottom. I needed to raise the bit to account for the thickness of the coping sled base. make a cut in one pass on the end of a test rail piece. Now. Finally. Subtract 1⁄8" in each direction from these length and width dimensions to determine the size of the door panels.) Now. Now. apply your choice of finish. rout the ends of the door rails with the outside or best faces down. To customize the sled to your saw. I used the lengths of the slide hardware. Note the rail-and-stile end views and bits in Figure 1 for reference. Adjust the bit up or down as needed to match the profile. in Step 8. 7 Make the panel sled in 8 6 9 Illustrations: Christopher Mills Figure 2.) Finish-sand the outside of the cabinets. Check for square. cut the inside edge in one pass. I made the height of the drawer boxes 1 ⁄ 2" shorter than the height of the drawer openings. as shown in Photo D. Step 3: Angle fence with front edge of base and attach.) 10 woodcraftmagazine. trim the door ends using the panel sled. Test-fit the piece against a rail. I’ll trim off the excess to achieve a perfectly square door with flush joints. Make marks 1⁄2" in from the ends of the stiles indicating the total door length. Figure 2: Crosscut Sled WorldMags. Switch to the stick bit in your router table and.height to cut the coped ends of the door rails. aligning the outside edges of the rails with the marks made earlier on the stiles. Adjust the bit height if needed. and trim off the proud ends of the stiles one door corner at a time. Step 4: Run sled through saw to establish a true cut-off edge. attach at 90° to front edge of base.

Using a helper to hold the cabinet in place. 32 woodcraftmagazine.) Strike a level horizontal line on the wall at this location. Doublecheck the cabinet’s position after driving the first screw. Installing the cabinets 1 2 Establish the height on the wall above the floor where you want to hang your wall cabinets.WorldMags. indicating where you want the outside edge of the cabinet. snapping off any excess. You may need to shim the cabinets along the back to flush them along the front. Check for plumb and the overall fit before securing it to the wall. drive #8 × 3" screws to secure it to the wall. clamp the next cabinet to the secured cabinet using cabinet clamps. drill pilot holes. first hang one cabinet with Aug/Sept 2013WorldMags. (I hung my cabinets 18" above the base cabinets. and use this distance to mark the stud locations on the inside face of the cabinet back. H With the cabinet face frames aligned top and bottom and . Measure from the plumb line to the stud G With the cabinet held to the wall. and then drive 21⁄2" screws through one face frame and into the other. Strike a plumb line that intersects with the horizontal line. J Level the base cabinets with shims wedged between the floor and the cabinet’s bottom edges. a helper? Consider temporarily screwing a leveled ledger to the wall to support a cabinet while you screw it to the wall. drive the screws through the clearance holes and into the wall studs using a drill. Adjust as needed. Don’t have 4 I With a helper holding a cabinet door and hinges in place while resting it on the spacer. Then. as shown in Photo G. as shown in Photo H. To hang wall cabinets side by side. using a stud 3 finder. drive the screws to secure the door. and then drive the remaining screws. Locate the wall studs in the area where you intend to hang the wall cabinet. Drill clearance holes at these locations.

For my countertop. 9. 33 . 1 #820246 #151148 #85T56 #611211 #611210 #128247 #130132 #130144 #27I11 $114.99 $20. WorldMags. centering them in the hinge slots. 3. 6. 2/pkg.) Finally. 100/pkg. I sized the countertop and edging to allow for a 2" overhang along the front and ends for clamping. I applied Aug/Sept 2013 woodcraftmagazine. 4. Convenience-PLUS Buying Guide 1. Above items are available at Woodcraft stores. ⁄2" Brass. (You may need to scribe and trim the back edge for an uneven wall. 5. drill the pilot holes in the face frame edge.) Note that the slots allow you to adjust the doors up and down as needed. 1qt. To install a base cabinet. and secure the door to the cabinet. seal the top with multiple coats of wax.99 $139. to make any or by calling (800) 225-1153. 8. Make or buy a countertop for the base cabinets. 2/pkg. 100/pkg. n Thank You! A special thanks to our friends at Cabinotch Cabinet Box System for supplying the cabinets for this issue’s featured workshop. and drive screws to the Figure 3: Countertop Cutaway WorldMags. I trimmed the countertop 5 to size and attached 3⁄ 4 × 1⁄ 8" edging strips of maple. (See Figure 3 for reference.09 $87. 15⁄8" OD × 7⁄8" CL. Prices subject to change without notice. woodcraft. Then screw the cabinet to the wall studs. and drove screws through the bottom panel and into the top panel for a full bond. Cut a toekick plate from 1⁄2" plywood. Highpoint #8 × 3" Square-Drive Screws. 2. Brass Shelf Pins. When driving brass screws into a hardwood .99 $7. Clamp a spacer to the lower rail 1⁄2" down from the face frame opening to support the door during installation. clamped the panels together. I started with two oversized panels of 3 ⁄ 4" MDF. and install the 3 ⁄ 4"-thick edged shelves.doors 3" in from the top and bottom edges.99 $4. as shown in Photo I. Highpoint #8 × 21⁄2" Square-Drive Screws. (Also see the Tip Alert below. as shown in Photo J. Rest the door on the spacer.99 $3. With a 5⁄32" Vix bit. level it from side to side and from front to back. 7.89 $9. Amerock Pull. Use shims. and nail it to the cabinet to cover any unsightly gaps between the cabinet and floor. 1⁄4" Brass Plt.) Put the top in place. Apply wax or bar soap to the screw threads to ease driving the screws. and fit the hinges in place. 1⁄2" SH (Optional) Woodpecker’s Coping Sled General Finishes Polyacrylic Water-Based Top Coat.25 Tip Alert Amerock Self-Closing Overlay Hinges. 25/pkg.99 $11. 8 Insert the shelf pins in the cabinets where desired. consider prethreading a pilot hole for the brass screws using a steel 5 Add a pair of hinges 3 ⁄4" layers of MDF 3 ⁄4" maple edging 6 7 through the cabinet’s stretchers to secure it. Pony Cabinet Claws. Whiteside Straight Stile and Rail Bit Set.

net . and items aimed at improving the comfort level of your favorite getaway. Durable Wall Storage Triton Products’ Duraboard wall storage solution does flimsy hardboard pegboard one better with its strong 1⁄4"-thick polypropylene panels that can hold three times more weight. woodcraft. See the Online Extra below for a free 23 × 29" tabletop plan. Included in this variety pack of problem solvers are wall boards. a 48-piece assortment of hangers. Note that items with a SKU number can be purchased at Woodcraft stores. To make outlet openings. keep in mind that there’s plenty you can buy to further the effort. and plastic bins. the kit includes panel-hanging hardware. Along with two Make your space work smarter. Folding-Table Frame This wall-mounted metal stand by WoodRiver comes in at workbench height (around 34") and includes adjustable feet for an uneven shop floor. Waterproof and impact-resistant.Shop Setup Products WorldMags. or by calling (800) 225-1153. After the work’s complete. use a drill to bore blade-start holes and a jigsaw to cut out the waste.99 Online Extra To make the table designed specifically for the folding table seen Aug/Sept 2013WorldMags. with these 12 items.99 tools or assembling small projects. go to woodcraftmagazine. the 2 × 4' panels can be sized at the tablesaw. 34 By Jim Harrold hile this issue offers lots to build in order to create a great home workshop. simply fold the table against the wall and lock it in place. and racks W for specialized storage. containers. tables and stands. It’s ideal for providing instant counter space when using benchtop power #412029 $149. better. #158253 $ and click on the Online Extras button to download the free plan.

such as a workbench for maximum effectiveness. Or.99 woodcraftmagazine. the ceramic infrared element can be hardwired to either a 120V or 240V circuit. add concentrated light where you need it with this 16"-long LED dual-power shop light. Locate it above an oftenused area. the heater Photos: Larry Hamel-Lambert LED Task Light Whether reading fine measurements or performing a detailed task. (3) 10" Aug/Sept 2013 . Sporting an almond steel housing.or ceiling-mounted Comfort IR space heater. according to the maker. When in use. Wall-Mounted Lumber Rack This rugged coated-steel system of standards and brackets attaches to the wall at stud locations using 3" bolts and washers (not included). quiet. Add to this the adjustment holes on 11⁄2" centers along the standards lengths. #417562 $249. (3) 55" standards. Its focusing head provides 250 lumens while running off AAA batteries or a 110V outlet. you can attach an appropriate plug (not included) to the cord. (3) 14" brackets.WorldMags. if you choose. #131189 $249.99 Ceramic Infrared Space Heater Take the chill out of frosty winter days in the shop with this 1950W wall. the space heater mounts easily with screws to either wall anchors or studs. #154491 $ 35 can warm up a 12 × 12' area and costs approximately 19 to 20 cents per hour to run. and odorless. and you have a versatile lumber rack capable of supporting hundreds of pounds. Hold it in place with either its strong rare-earth magnet or a clamp.99 WorldMags. and (6) 18" brackets. The set comes with (3) 24" standards.

and pipe clamps can all find a home here. the need for protecting them in a suitable storage unit becomes more pressing with each new purchase. you can build a handsome chest like the one featured in the Feb/March 2013 issue of Woodcraft Magazine. Its total weight capacity tops off at 500 A-Frame Clamp Rack Tired of rummaging through the shop looking for the right set of clamps for an assembly job? That won’t happen again with this place-for-everything mobile rack by HTC. To order the rack. #154637 (large box) $32. Spring clamps. Measuring 24"w × 10"d × 16 1⁄4"h. Of course. Because of its four swiveling casters. F-style bar clamps. and return them to the rack. #147378 $329. 16 (2" wide) drawers. nail. Green felt lines the upper case interior and drawer bottoms.WorldMags. K-body parallel jaw clamps. offering a safe haven for prized items. Why not let these handy plastic organizers by Akro-Mils come to your rescue? The larger box features 44 drawers in two sizes (2" and 4" wide). This 10-drawer model by Gerstner comes in red oak and employs tongue-andgroove joinery throughout for strength and durability. go to htc. remove the Aug/Sept 2013WorldMags. Inc. making the rack a good fit for even a small shop.productsinc. but that takes time. 10-Drawer Tool Chest As you expand your arsenal of fine hand tools. at (800) 624-2027.50 #154638 (small box) $ . After the glue-up dries. or call HTC Products. the smaller box. clean off the glue.99 Hardware Organizers Few things are more frustrating (and timeconsuming) for woodworkers than looking for the right screw. The alternative: Buy a chest that serves the need. the chest features a front lid at the bottom that pulls out and covers the drawers when in its locked position. it's easy to roll the rack away from the wall and park it alongside your assembly table or workbench for a glue-up. The overall size measures 30"w × 24"d × 53"h. or nut while sorting through old coffee cans and jars.99 36 woodcraftmagazine. The steel crossbars located at intervals along the A-frame angle-iron rack allow you to organize the clamps in your collection based on their lengths.

The TrueFlex featherboard is an extra purchase. Use the three-outlet power strip to plug in portable power Retro Shop Stool The next time you need to rest your dogs. providing a rigid structure and a place to park your feet. Rubber feet grip the surface underneath to prevent slippage when in use. buy three or four and hook them together to create a large countertop for finishing or project assembly. Give them relief with one or more of these 2 × 5' anti-fatigue PVC mats. They include tool and hardware wells. this Kreg benchtop workhorse can be pressed into service in the few minutes it takes to install a bit and adjust the fence.99 (featherboard) Instant Workbench This portable QuikBENCH folds up when you want to store it. #158284 $229. a 21⁄2" dust Aug/Sept 2013 37 . and a bit guard. Anti-Fatigue Floor mat #154269 $69. #154760 $129. adjustable sub-fences. the table’s splayed 28"w × 20"d steel base offers plenty of stability. and sets up in a jiffy when you need to work. While it is not designed to stand on. Or. It supports up to 350 pounds. Standing 19" At-the-Ready Router Table When equipped with a router that you supply.99 (table) #148436 $19.50 WorldMags. a pair of bench dogs. and dog holes letting you clamp workpieces in place for sanding or other tasks. Buy two and use them as sawhorses. Standing 32" high. consider taking five on this cushioned shop stool. the benchtop surface measures 24 × 30" and comes with some pretty neat features. Other features include a flat 1 × 16 × 24" laminated MDF top with a standard miter gauge slot.99 Hard shop floors make tired feet cry for mercy. a two-crank vise.99 woodcraftmagazine. The stool measures 16"w × 29"h and easily stores under a countertop. Resting on it is an adjustable extruded aluminum fence with locking cam clamps. the QuikBENCH can hold up to 300 pounds. and a three-ring phenolic insert plate. #146033 $36.WorldMags. better still. A throwback chrome base sets the style with rings that screw to the flared legs.

that at least one wing must be raised and locked in place for all but the shortest of cuts. allowing for a cleaner work area. Designed for popular 10" and 12" compound mitersaws.WorldMags. Aug/Sept 2013WorldMags. See the inset photo. the sturdy open plywood cabinet offers enough interior space for a shop vacuum and cutoff tub. Its fixed shelf provides storage for a wrench. Finally. and extra blade. (Note. simply lower the drop-down wings and roll the stand against the wall. however.) For adjustability and precision cutting. . By Chuck Hedlund B 38 woodcraftmagazine. There’s even a hardware adjustment for an uneven shop enefits abound with this shop-friendly workhorse. measuring tape. Its 48"-high back and sides contain spraying sawdust. To reduce the cabinet’s footprint when not in use. use the hardware components to easily level and fine-tune the saw shelf and wings and to align the fence with your saw’s Mobile Mitersaw Stand Multiple features make this project a welcome shop addition. a pair of quick-lock fence stops lets you make repeatable cuts.

⁄8" deep ⁄16 × 1 ⁄4" lag screws 1 3" double-locking. 1 1 ⁄2" × 6" carriage bolt ⁄4" Side inside face 1 ⁄2" flat washer Plywood Cutting Diagram Photos: Larry Hamel-Lambert. ⁄16"-18 brass threaded insert 3 5 ⁄16" washer 3 ⁄4 × 151⁄2" dado. swiveling casters 1 Shelf-Adjustment Hardware Detail ⁄2" nut Side Trim Detail Center biscuit in plywood.Figure 1: Mitersaw Stand Exploded View 3 3 WorldMags. ⁄8" deep #10 biscuit Note: Back top trim is flush with back edge. nonswiveling casters 5 ⁄4" Aug/Sept 2013 woodcraftmagazine. 1 ⁄4" deep on underside #8 × 11⁄2" flathead wood screw 11⁄2 × 10" piano hinge 11⁄2 × 32" piano hinge Notch 3 3 ⁄4" rabbet. ⁄8" deep Heavy-duty lifting leveler 3 × 3" corner brackets 3 3 3" ⁄4" rabbet. Illustrations: Christopher Mills WorldMags. #8 × 3" flathead screw Four-arm knob with 11⁄2" stud 5 See detail on page 39 . ⁄8" deep 11⁄4 × 11⁄4" aluminum angle 13⁄4" recess.

adjust the fence 163⁄ 4" from the blade. adjustable shelf (E). stopping at the stop. fixed shelf (D). and make the stopped dado on the inside face of the left side (A). and glue and clamp it to the front edge of adjustable shelf (E). Cut the notch at the other back corner the same way. Clamp an auxiliary fence to your saw fence. When the glue has dried. fixed shelf. Now. where shown in Figure 1. allows for more control during the cut and keeps the shelf from tipping into the dado blade. and wings (H) slightly oversized. With the inside face of the right side (A) down. and slide it over to the blade. cut the notch up to the stop. cut the dado in both sides (A) on their opposing inside faces. using a straightedge and circular saw with a plywood blade. Now. Adjust the saw fence to 301⁄4". Remove the stop. cut the parts to finished overall size. cut the rabbets. Turn off the saw. This. Now make the notch cut. you’ll use it in the following steps. Make a test dado in scrap plywood. To do this. I’ll call this “point X. you’ll trim the sides. where shown in Figure 1.) Leave the blade height and fence setting for the next step. Using a 1⁄8" round-over bit in a table-mounted router.WorldMags. sand it flush with the shelf and break the edges. To make the shoulder cuts on the fixed shelf (D). with the back corner of the shelf toward the blade and the shelf’s face against the fence. mark its location on the fence. Raise the blade to 3 ⁄8". Use the mark to locate the stop. but do not change blade height. refer to the Plywood Cutting Diagram on page 39. Set the piece aside.) Rip a 1⁄ 4" strip of maple from 3 ⁄ 4" stock for the adjustable shelf edge (F).net A With a block against the dado set. and with its top edge against the fence. bottom (C). wing supports (G). place a “point X” mark on your auxiliary fence as in Step 2 and Photo A . (Make a test cut on scrap to check the cut. placing the bottom end against the rip fence. in the sides (A) and back (B). back (B). Clamp a stop 21⁄ 4" back from that mark.” B With a featherboard and guide rail to keep the shelf upright and snug to the fence. Remove the auxiliary fence. Turn off the saw and remove the part. adjust the dado set width if needed. at the tablesaw. and place a stop on your saw fence at this location. To make the stopped dado in the sides (A). round over the back edges of the shelves (D) and (E). and wings to final shape. To reduce waste and for grain orientation. Using the same dado set . Lay out the inside corners on the cabinet’s right and left sides Cut the plywood parts 1 6 Stand the fixed shelf on one end 3 7 2 4 8 5 9 40 woodcraftmagazine. and replace the dado set with a standard blade. Cut it just over in length.) Install a dado set that is the same width as the plywood’s thickness. (In later steps. cut the right and left sides (A). From that mark measure back 151⁄2". For ease of handling. and check its width using a mating plywood part. Clamp a guide rail to the shelf so it rides on the fence top edge. along with the featherboard. move the part forward to make the dado cut. wing supports. as shown in Photo Aug/Sept 2013WorldMags. (Doing this keeps the vacuum hose from getting hung up when adjusting the mitersaw cutting angle back and forth. make a reference mark on the saw fence where the blade starts to make contact with the piece to be cut.

Next. as shown in Photo D. Then add the right side (A). glue. After reaching the stop. and relocate the stop to 103⁄8" from “point X. Start by attaching the back (B) to the bottom (C).net Aug/Sept 2013 41 .) ⁄ Now. and then cut the slots. keeping them at least 2" from the ends. with the inside face WorldMags. (See the Side Trim Detail in Figure 1. Plan to use both sides of the tablesaw fence and table to cut out the corners.) Start by adjusting the biscuit cutter fence for slots centered 5⁄8" in C With the back edge of the side panel against the saw fence. woodcraftmagazine. crosscut into the right side panel. cut enough linear feet of 11⁄2"- 11 Using a handsaw. D With a side clamped to the bench and the waste piece clamped to the side. the cuts in the corner. Clamp and secure the shelf with screws. as shown in Photo E . Mark the biscuit locations for #10 biscuits for all plywood cabinet parts receiving trim. Turn off the saw.) On all plywood cuts use the attached spacer. complete Assemble the case and add the trim 1 On a flat surface. from 3⁄4"-thick maple. 4"-thick spacer and adhere a 1⁄ (I used 1⁄ 4" MDF) on the biscuit cutter’s fence with double-faced tape. Next. move the side panel forward until you reach the stop.” Now. (A). as shown in Photo C with the inside face down. Now. apply glue and slide the notched fixed shelf (D) into the dadoes. ripcut the right side panel. and drive screws to assemble the cabinet plywood parts. cut 3 2 E With the cabinet on its side. handsaw out the waste. and stop and ripcut the left side panel (A). drill. and slide the fence to the left side of it. make blade entry reference “point X” marks–this time on both sides of the saw fence. cut the biscuit slots in the plywood using the 1⁄4" spacer. working from the other side of the blade. 10 clamp. as well as a handsaw. Next.WorldMags. Sand the joints smooth. keeping its front edge flush with the sides (A). Note that I offset the side trim pieces by 1 ⁄ 4" from the outside plywood faces. Repeat the blade height and measurements for setting the fence. (I raised the blade to this height to reduce the arc at the cut’s end. Drill the holes 11" apart. (Doing this simplifies cutting the biscuit slots by having just one fence depth adjustment for two different cuts in the trim and plywood–flush and 1⁄ 4" offset. Move the fence 103⁄8" to the right of the blade for the cabinet’s right side. Repeat for the left panel. turn off the saw and remove the part. With the blade raised 21⁄2". Use Figure 1 as a general guide for the number of biscuits per edge. place a stop 107 8" back from the mark on one fence side. Set the right panel aside. ⁄8" to the Adjust the fence 157 right of the blade. Note the waste piece will still be attached to the panel at the inside corner. outside face up. followed by the left side (A). I used a 9⁄64" countersinking bit for #8 × 11⁄2" flathead wood screws. Lower the blade.

Allow a little for waste.) Cut the wheel supports to size.) Tighten each nut with a wrench. attach the adjustable shelf (F). The filler and backer prevent tear-out. L).) Filler strip 7 Backer F Use a guide on your drill to bore the shelf-adjustment holes. To mount the hinges for the wings. Do this to all four levelers for the cabinet and wing supports [G]). and then apply two coats of finish. On the inside measure up again 31⁄4".out. Start by measuring and marking 2" from each corner.) Now. (I used the General AccuDrill. Glue and clamp the strips in place. at these locations. Glue and clamp the trim in place. 2 8 4 Add the wheel supports and adjustable shelf 5 1 Provide added strength 6 42 woodcraftmagazine. followed by a washer and a nut. and the 21⁄2"-wide center and bottom rails (K). apply the heavy-duty lifting levelers 3" from each front corner with the screws provided. Cut off the front inside corners of the wings (H). Place another nut on each bolt.5] purchased at a local hardware store for ease of locking. Sand the trim flush as needed. Next drill holes 21⁄ 4" in from each end with the countersink bit. Sand the mating surfaces smooth. K. Measure up from the bottom edge of the sides (A) 31⁄4". swiveling casters at the front. To level the cabinet on an uneven floor.and 21⁄2"-wide trim material for the cabinet and wings (I. (I used a waterbased satin polyurethane. as shown in Photo F. cutting miters on the trim pieces as you go. mark the holes for the 5⁄16 × 11⁄ 4" lag screws. (I used 8/4 [2"-thick] maple but you could laminate two pieces of 4/4 [1"thick] maple. Mark the location for the biscuits from the plywood reference marks. and the top back (J) and bottom rail (K) will be flush with the cabinet back (B) and bottom (C). Starting with the long front edges of the sides (A). To keep the cabinet close to the floor and the mitersaw at a WorldMags. Now spread glue and clamp a wheel support in place. and then cut the slots without the spacer. non-swiveling casters at the back and two double-locking. referencing the Cut List. add the 11⁄2"-wide back top trim (J). The center rail will extend 1⁄4" above the top edge of the fixed shelf (D) and be slotted without the 1⁄4" spacer. work your way up to the back. you’ll need a 1⁄ 4" filler strip placed between the fixed shelf (D) and the adjustable shelf. and drive #8 × 11⁄2" flathead wood screws to secure the strips. respectively. Next. cutting the parts to exact lengths. and mark the locations for the #8 × 2" flathead wood workable height. J. making sure you maintain a 1⁄4" overhang on the sides. Then. where shown in Figure 1. cut the hinge mounting strips (M) for the cabinet sides (A) (see Figure 1). vertical 1⁄2" holes for the 1⁄2 × 6" carriage bolts. Finish-sand the cabinet and wing parts. Remove the clamps and repeat for the other wheel support. using the caster plates as a template on the outside corners of the bottom faces of the supports. drill perfectly vertical and aligned 1⁄2" holes. nuts [metric M10-1. flush with top face of the horizontal side trim (I) and 1⁄2" from the front face of the trimmed cabinet front. Drill 1⁄ 4" pilot holes. Use the countersinking drill bit to drill the pilot holes and drive the screws. where shown in Figure 1. screw on two non-locking. Then. drill countersunk shank holes and pilot holes for #8 × 3" flathead wood screws. using the screws provided. 11⁄ 4" deep. add a pair of outrigger-like wheel supports (N) to the cabinet sides (A) (see Figure 1). as well as a 3⁄ 4"-thick backer strip clamped to the bottom of the fixed shelf. add the wing trim (L) to the wings using the spacer.) Now. (I removed the threaded leveler studs and added locking wing 3 . To secure the rail joints.) Place a carriage bolt in each of the fixed shelf (D) holes. but you could use a 11⁄2"-thick wood block with a 1⁄2" hole that you pre-bore at the drill press. Sand the trim flush to the wings. and strike an alignment line for the bottom face of the wheel supports (N). (I bought the braces at local home Aug/Sept 2013WorldMags. Both are slotted with the 1⁄4" to the wheel supports (N) by attaching 3" corner braces. To make clean. (I used these to reduce tear. When both sides are done. (See the Shelf-Adjustment Hardware Detail in Figure 1.

Clamp the saw in position. Your saw may require a different height. To do this. You’ll adjust them to the exact height later when finetuning your saw to the stand.followed by a washer. double-checking its location. Return the saw and fasten it in place. Now.) Cut a scrap block equal in width to the nut height to use as a spacer. Using the Vix bit. and mount the lifting levelers with the screws provided.) Remove the saw to drill the four pilot holes for #14 × 2" sheet metal 43 WorldMags. (Remember that you will have a left hinge and a right hinge. cut two piano hinges to 32" long with a hacksaw. place the adjustable shelf (E) over the bolts. drill the screw pilot holes using a Vix bit. as shown in Photo G. followed by a washer and nut. guiding off the hinge holes. Mount the 10" piano hinges on the side faces of the hinge mounting strips (M). drill the pilot holes and drive just two of the end screws into each Aug/Sept 2013 . Mark the center location of the leveler foot on the bottom face of the wing. them on the wing supports (G). Adjust the shelf so it rests flat on the spacer. Set it back so the saw’s front feet measure 3 ⁄ 4" from the shelf’s front edge. a height that worked for my saw. (I placed the second nut and washer 31⁄2" up from the fixed shelf. Remove the piano hinges from the cabinet. Now. measure 17" over from the inside corner. and place the wing (H) bottom Attach the wing supports and wings 4 7 (G). cut two 10"-long piano hinges for the wings (H). With the wing supports (G) folded against the cabinet. attach the wings (H) to the mating piano hinges. remove the clamps. WorldMags. as shown in Photo H. locating them 203⁄8" from the back edge to the edge of the hinge. and center it side to side. then mark the hinge hole locations. Also. Tape the hinges (cut edge down) in place and 3⁄16" below the hinge mounting strips (M). Now. (My mitersaw has 1⁄4" holes in the feet for fastening the saw to the shelf. and mount 1 To attach the wing supports 2 5 1 ⁄8" spacer 6 H 1 3 Clamp the wing in place inserting ⁄8" spacers where shown. Place your mitersaw on the adjustable shelf (E). position a wing support (G) so the wing rests on it.) The hinge barrel should be flush with the back edge of the wing support. Then drill pilot holes for the hinge screws. Using clamps and a pair of 1⁄8" spacers placed between the saw’s table and the vertical trim (I) and wing. Lay out each side of the cabinet for the hinges. with the barrel of the hinges facing 4 G With the wing support piano hinge taped in place. flushing them at the top corner.) Next. Now. transfer the hole locations in your saw’s feet onto the shelf with a pencil or awl. File the burrs from the cut ends. (You’ll take them off after locating the wings [H] in the next step. mount the wing supports to the sides (A) with screws in the pilot holes drilled earlier. ⁄ I used a 7 64" self-centering Vix bit. woodcraftmagazine. Finger-tighten the nuts for now. clamp the wing in position and mark the underside where the screws will go.

Next. drill a hole at the end of the slots. side up. (See Figure 1. Using a pencil. ⁄ and then install a 7 16" bit in the drill guide and cordless 1 11⁄ 4 × 1⁄ 4 aluminum angle to the length of the wings (H). Fit the guide against the vertical trim and centered on the marked line. reattach the wing assemblies (H/L). and position it against the hinge mounting strip (M). (It must be square for the table to fold down properly. and screw the four-arm knobs with 11⁄2" studs through 5⁄16" washers and into the holes. add a four-arm knob with a 11⁄2" stud that goes through each wing and into the horizontal trim (I) on sides (A). a pair of jam nuts. Use a square to see if the hinge is square with the edge of the wing. Now. as shown in Photo J. as shown in the Photo J Inset . where shown in Figure 1. and drill the hole. Next. To drive the 5⁄16" threaded inserts in the holes in the horizontal trim parts (I). and drive the screws. Drive all of the screws in place. rigid and Aug/Sept 2013WorldMags. Repeat for the other side. for the leveler feet. and drive the inserts. J Drive the threaded inserts using a drill and socket as seen in the Inset.) Now. File off any burrs on the cut ends. support them with the wing supports (G). and align the hinge holes with the screw holes drilled earlier. outfit the drill guide or shop-made guide block and drill with a 5⁄16" brad-point bit. use a 5⁄16" bolt. Attach the socket to an impact driver using a socket adaptor. Repeat for the other wing. rest the wing on the wing support (G). and set the guide’s stop to bore 3 ⁄ 4" deep. Open the hinge of a wing (H).) Drill the holes with the Vix bit. Tighten the knobs to make the wings rigid. 12 Add the fence and stop 9 1 Hacksaw two pieces of 11 44 woodcraftmagazine. That way. you will be able to reattach the hinge at that exact location later. recess the inserts 1⁄16" below the surface. and then cut between the holes with a coping saw. ⁄ 4" deep. Remove the orientation tape. make a mark 21⁄8" in on the top face of the wing. They should be directly above the leveler feet when the wing supports are at a right angle to the cabinet sides. drill 13⁄ 4" recesses.) To do this. 5 ⁄ lay out the 7 32 × ⁄ 8" slots. Drill the hole. measuring from the center of the vertical trim (I) at the side’s inside corner.WorldMags. (The mark must also be centered on the horizontal side trim beneath the wing. The bit should make a center point on the horizontal trim beneath the wing. where shown in the Fence and Stop ⁄ Details. With a small . again setting the stop for a 3⁄ 4"-deep hole. as shown in Photo I. remove the hinge and place it on the wing aligned with the marked I Use the drill guide and cordless drill to bore the vertical hole for the threaded brass insert. Remove the wing (H). mark the orientation of the attached hinge on a scrap of masking tape and stick it to the hinge. and a mating socket. Then. With a 7 32" bit. On the bottom face of the 1 wings (H). Position the bit so it is centered on 10 To make the wings (H) more 8 the center point.

Figure 2: Fence and Stop Details
5 7 9

⁄16" hole, ⁄16" deep


⁄16"-18 brass threaded insert 3 ⁄4" recess, 1⁄4" deep with 5⁄16" through-hole

Align front face of angle with saw fence.

⁄4" washer
Adjustable handle

#12 × 3⁄4" panhead screw

11⁄8" rabbet, 1 ⁄8" deep
1 4 13

⁄ " rabbet, ⁄32" deep

Center hole for four-arm knob over side trim. 11"

⁄32" slot, 5⁄8" long, centered

11⁄4" aluminum angle, 391⁄2" long

Fine-Tune The Stand To Your Saw
Several fine-tuning adjustments exist in the mobile miter stand, allowing you to make precision cuts. • Adjusting the adjustable shelf: With the wings (H) held in place by the wing supports (G), place a long level on the mitersaw table and fences. Now, use a wrench to turn the nuts on the 6" bolts to raise or lower the adjustable shelf (E) front and back to make the saw table even with the wings. • Leveling the wings: With the long level still spanning the saw table and wings (H), adjust the lifting levelers on the wing supports (G) to bring the wings flush with the bottom edge of the level. • Aligning the fences: With the wings (H) and saw table even, place the straight edge of a long level against the saw’s fence and clamp it in position. Place the aluminum fences against the level and even with the outside ends of the wings. Make a center mark in each slot. Drill pilot holes in the slots, and install #12 × 3⁄4" panhead screws to secure the fences in perfect alignment with the saw fence. Aug/Sept 2013 45

file, remove the burrs. Hold off attaching the fences for now. To make the two stops, cut two blanks, one at 3⁄ 4× 2 3 ⁄8 × 8" for the backs (O), and 1 one at 3⁄ 4 × 2⁄ 2 × 8" for the fronts (P). (I made them this length for safe machining.) Using a dado set, cut the 1 ⁄ 1 8" rabbet, 3⁄32" deep on one face of the back blank, where shown in the Fence and Stop Details. Then, adjust the fence and dado set height, and cut the 1 3 ⁄ 4" wide rabbet, 1 ⁄ 32" deep. Switch to a standard blade and, using an auxiliary fence on your miter gauge, cut two stop backs (O) and two stop fronts (P) to 21⁄2" long from their respective blanks. Install a 3⁄4" brad-point bit in your drill press, and set up your fence at 5⁄8" from the center of the bit. Set a stop to be at exactly 11⁄4" from the bit’s center. This is important for the alignment of the two parts making up the saw stop. As shown in the Fence and Stop Details, drill a 3⁄4" hole 1⁄4" deep in the two stop backs (O). Chuck in a 5⁄16" bit, and drill the through-holes in the backs using a backer to prevent tear-out. Now, switch bits and drill the 7⁄16" holes, 9⁄16" deep, in the stop fronts (P).

2 6
Insert the threaded inserts in the stop fronts (P), sinking them just below the surface by 1⁄32". Finally, place a 1⁄ 4" flat washer onto the stud of a ratchet-

Mitersaw Stand Cut List
A B C D E F G H I* J* K* L* M N O P Part Left and right sides Back Bottom Fixed shelf Adjustable shelf Adjustable shelf edge Wing supports Wings Right and left side trim Back top trim Center and bottom trim Wing trim Hinge mounting strips Wheel supports Stop back Stop front

style adjustable handle, and connect the backs (O) to the fronts (P) to form two saw stops. Attach the stops to the aluminum angle fences. n
Width 267⁄8" 351⁄4" 351⁄4" 351⁄4" 16" 3 ⁄4" 201⁄4" 11" 11⁄2" 11⁄2" 21⁄2" 11⁄2" 3 ⁄4" 53⁄4" 23⁄8" 21⁄2" Length 473⁄4" 473⁄4" 261⁄2" 16" 343⁄8" 343⁄8" 32" 391⁄2" 42" 36" 351⁄2" 42" 10" 267⁄8" 21⁄2" 21⁄2" Qty. 2 1 1 1 1 1 2 2 4 1 2 2 2 2 2 2 Mat’l BP BP BP BP BP M BP BP M M M M M M M M



Thickness 3 ⁄4" 3 ⁄4" 3 ⁄4" 3 ⁄4" 3 ⁄4" 1 ⁄4" 3 ⁄4"


⁄4" ⁄4" 3 ⁄4" 3 ⁄4" 3 ⁄4" 1 ⁄2" 13⁄4" 3 ⁄4" 3 ⁄4"
3 3

*Indicates parts are initially cut oversized. See instructions. Materials: BP=Birch plywood, M=Maple Hardware/Supplies: (10) #8 × 3" flathead wood screws; (14) #8 × 2" flathead wood screws; (28) #8 × 11⁄2" flathead wood screws; (4) #14 × 2" sheet metal screws; (4) #12 × 3⁄4" panhead wood screws; (16) 5⁄16 × 11⁄4" lag screws; (2) 1⁄4" flat washers; (2) 5⁄16" flat washers; (12) 1⁄2" flat washers; (4) 1⁄2 × 6" carriage bolts; (4) 1⁄2" nuts; (4) M10-1.5 metric wing nuts; (4) 5⁄16"-18 brass threaded inserts (Hillman #H880550 at Lowes); (1) 11⁄4" aluminum angle 1⁄8" thick × 96" long; (4) heavy-duty 3" corner brackets (Everbilt #824550 at The Home Depot).

Convenience-PLUS Buying Guide
1. 2. 3. 4. 5. 6. 7. 8. 9. Milescraft #10 Biscuits, 100/pkg. General Tools AccuDrill #36⁄37 Adjustable Handle with ⁄16" - 18 × 1" Stud (2 needed)

#153580 #17W33 #129132 #142906 #141052 #141051 #145840 #152161 #16I41

$7.75 $49.99 $5.29 $3.25 $11.99 $18.99 $20.99 $17.99 $12.50

About Our Designer/Builder Westerville, Ohio, resident Chuck Hedlund began his woodworking life as a cabinetmaker. Beginning in 1993, he began serving the needs of several woodworking publications as a builder and designer. He is a regular contributor to Woodcraft Magazine.

Four-Arm Knob with 5⁄16"- 18 × 11⁄2" Stud (4 needed) 3" Casters, Non-locking, Non-swiveling (2 needed) 3" Casters, Double-Locking, Swiveling (2 needed) Heavy-Duty Leg Levelers, 4/pkg. Piano Hinge, Nickel Plated, 11⁄2 × 48" (2 needed)

⁄64" Vix Bit

Above items are available at Woodcraft stores, or by calling (800) 225-1153. Prices subject to change without notice.

46 Aug/Sept


Build Your Dust-Collection System with Woodcraft Fittings
Our extensive line of Dust-Collection Fittings will help you build a high performance Chip Extraction System for your shop – one designed to stand up against the abrasive nature of sawdust and wood fiber. Whether you need a Flanged Dust Port for an older table saw, distribution fittings like elbows, Y’s and gates, or a Universal Tool Adaptor to connect your shop vacuum hose to various stationary or portable power tools – we have what you need and more!

Table Saw Fittings

8" x 8" Jointer Fitting

4" Y Fitting

4" x 4" x 21/2" Y Fitting

Tabletop Dust Collectors

4" T Fitting

4" Elbow

4" Splice

4" Hose To 4" OD Quick-Disconnect

4" Aluminum Blast Gate

Floor Sweep Collector

Router Fence Dust Fittings

4" ABS Blast Gate

6" To 1" Universal Adaptor

4" To 1" Multi-Step Reducer

Universal Tool Adaptor

21/2" Aluminum Blast Gate

4" 45° Elbow

4" Swivel Fitting

ABS Quick-Conn. Thread Gate

Reducer Fittings

ABS Blastgate 4" Hose To 4" OD

Self Clearing 4" Blast Gate

4" Universal Fitting

11/2" To 21/4" Adaptor

21/2" Flanged Hose End Fitting

4" Flanged Hose End

Quick Disconnect Fittings

4" x 21/ 4" Funnel Reducer

Dust Control Dual Port Kit

Dust-Collection Fitting 4" 3-Way Junction

4" Flex Cuff W/Clamps

21/2" Flex Cuff W/Clamps

EZ Squeeze Dust-Collection Hose Clamps

21/2" Hose Hangers

4" Hose And Pipe Hangers

4" Flanged Inlet Fitting PVC Pipe To DC Fitting Adaptor 4" Hose To PVC Pipe Adaptor Quick-Release Band Clamps 21/2" Wire Hose Clamps Keyed Hose Clamps 4" Wire Hose Clamps

For A Free Catalog Or To Find Your Local Woodcraft Store, Visit Or Call 800-225-1153. 13WD09P2
For Information On Woodcraft Retail Franchise Opportunities, Visit

Compact, All-Purpose Workbench
A simple, solid, small-shop solution
By Alan Turner

Overall dimensions: 24"w × 60"l × 341⁄2"h
48 Aug/Sept

centered. Remove a pair of lag screws in the top and four bolts in the legs. 3 ⁄8" deep 21⁄4" 9 ⁄16" hole 1 ⁄2" 1 1 ⁄2 × 4" lag screw and washer 1" washer 1 × 41⁄2" tenon. ⁄2" deep 2" long kerfs. it does not 21" ⁄4" 21⁄4" Aug/Sept 2013 don’t let the knock-down hardware fool you.Figure 1: Leg Assembly Exploded View Leg Front View 3 WorldMags. My students finish their benches in six evening classes. woodcraftmagazine. Even under heavy hand-planing. working at home. but who don’t have enough space for a full-sized workbench. I designed a bench to accommodate those who want to do serious woodworking. 5 ⁄8" deep 63⁄4" 21⁄2" S 11⁄4" Photos: Paul Anthony. 3⁄8" deep. make the complementary cabinet shown on page 49 . This compact copy of our school’s traditional bench is perfectly suited for cramped garages and basements. ⁄8" long 3 9 ⁄16" shaft hole 1 ⁄2 × 6" machine bolt 3" 1 Drill 11⁄2" hole after shaft hole. cannot afford. and this bench is ready for transport. For example. #8 × 15⁄8" flathead screw ⁄2" nut 11⁄4" dado. especially those living in the city. Pre-built components and modern vise hardware make for a fast and easy build. this bench is meant for serious work. the laminated butcher-block top saves days of milling and assembly. To fully accessories your bench. 1 ⁄4" from outside edge 31⁄8" 15° 213⁄4" 7" Flare dado 5° flare for wedge. At the Philadelphia Furniture Workshop. Illustrations: John Hartman pace is a luxury that many woodworkers.with a 9⁄16" through hole. you can complete this bench in a couple of weekends. This bench solves another problem faced by woodworkers: mobility. But WorldMags. And the metal front and end vises can both be attached in a few hours. 13⁄8" counterbore. centered 1 1 × 41⁄2" mortise.

” on page 51. 4 Cut a pair of 1 ⁄ "-thick 3 16 5 C Guide the blade just below the top edge of the 1 ⁄2" spacer 3 ⁄4" dado A Set the sled foot half against a stopblock and cut the inside shoulder of the dado. and then angle the ends at 15°. and make the first cut. (Feel free to adjust the length to suit. or laminate thinner boards as needed. Using these blocks for alignment. 2 3 . Next. set a stopblock to cut the shoulder that’s farthest away from the end ( Photo A). Lay out the dadoes where shown in Figure 1. Mill the uprights (C) from 10/4 (21⁄2"-thick) stock. remove the clamps. leaving the ends square. clean up the assembly at the jointer and planer. Remove the remaining waste with a chisel. Using a spacer – instead of moving the stopblock – ensures perfectly consistent dadoes. install a 3⁄ 4" dado blade in your tablesaw. as shown in Photo C .com Aug/Sept 2013WorldMags. and wrap them with packing tape. and flare the bottom edge for the wedge. Cut the sled feet (A) to the size listed in the Cut List . Cut the uprights (C) to length. Using a dado sled. D Use tape-wrapped spacers to keep the sled feet halves in perfect alignment.) Start with the leg assemblies mill material for the sled foot halves (A) and top rails (B). 50 woodcraftmagazine. Gluing the dadoed halves together creates clean through . Refer to “Build Your Bench To Fit.WorldMags. Tilt the table in the opposite direction to cut the opposite edge. glue and clamp the sled feet halves together as shown in Photo D. Tilt your bandsaw table 5° and flare the bottom edges of the dadoes on the sled feet halves (A).with an auxiliary fence. Allow the glue time to dry. scrap blocks to fit the width of the dadoes exactly. or a miter gauge 1 From 8/4 (2"-thick) stock. insert a 1⁄2"-wide spacer block (the spacer size is determined by subtracting the width of the dado head from the desired dado width) and make the second cut ( Photo B). Next. B Insert a spacer and cut the outside shoulder.

and bore a row of overlapping blind holes to create a 1⁄2"-deep × 41⁄2"-long mortises in each of the uprights. Now nibble out the middle waste. To ensure a centered slot mortise. where shown in Figure 1. Set up your tablesaw with a 3⁄ 4" dado head. while keeping the stopblock in place for the first cut on the next piece. but to find a ballpark number. Replace your dado cutter with a standard saw blade. and uprights (C). drop your arms against your sides and measure the distance from floor to your wrist. Flip the workpiece over. and the slot mortises and dadoes for the T-bridle joints. With the stopblock/ spacer technique used for the sled feet halves. drill a 13⁄8" × 3⁄8" deep counterbore and 9⁄16" through hole on 8 the opposite face of each upright. Set the bottom end of an upright (C) against the rip fence so that the first cut establishes the tenon’s Aug/Sept 2013 woodcraftmagazine. cut the uprights shorter and use thicker footpads to fine-tune the height.WorldMags. Next. shifting the upright away from the fence until you complete the tenon’s face. and make a series of Build Your Bench To Fit These plans are for a 341⁄2"-high bench top. where shown in Figure 1. mortises. F Inserting a spacer repositions the rail for cutting the opposite shoulder of the dado. do not reset the fence. Repeat the process for the remaining three ends. then insert a 11⁄2"wide spacer block and make the second cut ( Photo F ). and do the same on the other face. At the drill press. E Use a tenoning jig to cut the slot mortises and a bandsaw to remove the waste. Next. where shown on Figure 1. as shown in Photo E . Clean up the edges of the mortises with a sharp chisel. kerf the tenons for the wedges. and adjust the cutter height to 1⁄2". cut the shoulder that’s farthest away from the stopblock. cut the T-bridle slot mortise on the top end of each upright (C). where shown. drill the 9⁄16" hole for the top lag screw. where shown in Figure 1. top rails (B). Using the wedge- 9 10 11⁄2" spacer Tip Alert 3 ⁄4" dado If you over-cut the slot. 6 7 Instead. WorldMags. While you’re at the bandsaw. Finish-sand the assembled sled feet (A). Using a shop-made or commercial tenoning jig. Lay out the tenons.) Chuck a 1" Forstner bit into your drill press. add a screw to the bottom of the slot and use it to micro-adjust the height of the top rail. Cut each face in the same manner. install a 3⁄ 4" dado blade in your tablesaw. (Be sure to orient the kerfs so that the wedges push against the end grain of the 51 . and then clean up the slot bottom with a sharp chisel. Cut the top rails (B) to the size listed in the Cut List . When in doubt. stand up straight. and make the second cut. rotate the upright so that the opposite face is against the jig. then repeat the sequence with the remaining three uprights. Remove the remaining waste at the bandsaw. There are different ways to determine the “best” height (the ideal bench height also depends on the kind of work you do). a nice height for the average-sized woodworker (5' 8" to 6').

From 6/4 stock. and then drive the wedges. drill the 11⁄2" nut holes. (If you prefer round dog holes. cut a centered 3⁄8 × 41⁄2" tenon at each end.WorldMags. glue and clamp the sled feet onto the uprights. Clamp the tapered strip to the dado sled. trim the wedges flush. H Clamp the stretchers between the leg assemblies. After the glue dries. where shown in Figure 1. and finish the shaft holes. From 10/4 stock. miter gauge. and cut the dadoes as shown in Photo I. Using a 1⁄2" corded drill and 9 ⁄ 16" bit (don’t use a Forsnter. and clamp the base together. Mill stock for the foot pads. insert a dowel or metal rod into the shaft hole. lay out the mortise for the front vise on the inside face of the front-edge strip (I). Using a 14 4 Build the top 11 1 Unpack the laminated maple 2 top (G). cutting tip on page 15. Remove the stretchers from the upright. Now equip your saw with a 3⁄ 4" dado head. and auxiliary fence. skip steps 3 and 4 and refer to the Online Extra on page 53. where shown in Figure 1. Using a tablesaw outfitted with a dado .com Aug/Sept 2013WorldMags. adjust the location of the nut hole to suit. (F) but put them aside until after you’ve assembled the base. Remove the uprights. and finish drilling the shaft hole. joint an edge. Referring to Figure 2. it will wander). Make the vise spacer (J) from any available piece of scrap. mill two stretchers (E) to the size listed in the Cut List . Lay out ten 3⁄ 4"-wide dadoes 5 12 3 13 I Rest the dog-hole strip against the tapered stock. make a 2° tapered strip. mill the dog-hole and front-edge strips (H.) From 11⁄2 -thick scrap.) At the drill press. 52 woodcraftmagazine. glue and clamp the top rails into the uprights. Lay out the nut holes in the stretchers (E). (Before G Clamp the sled feet to the uprights. Fit the stretchers (E) into the leg assemblies (A. C). washers. then tap in the wedges to lock the leg assembly together. and cut the slanted dado. If the rod tilts up or down. and raise the stack to make 3 ⁄ 4"-deep cut. and then put it aside for now. Working one leg assembly at a time. position the dog-hole strip against the tapered piece. Orient the strip so that the dog holes tilt toward the inset vise. Next. drill through the holes in the leg assemblies and into the ends of the stretchers (Photo H ). B. I) and cut them to the sizes listed in the Cut List . and nuts. on the dog-hole strip (H). and then rip the top to 21" wide. as shown in Photo G. cut eight 5° wedges (D). Assemble the base with 6" machine bolts. and use the predrilled uprights to guide your bit. where shown in Figure 3.

pdf 11⁄2" chip clearance hole 103⁄4" 3" 15 ⁄32" 1 ⁄8"-deep lip 15 21⁄16" Aug/Sept 2013 onlineextras/41-Vises. ⁄16" deep 171⁄4" 88° 3 Veritas Inset Vise (see Figure 3) 35⁄8" #8 × 2" flathead wood screw 3 3 ⁄4" 53 . check out: http://www. woodcraftmagazine. plus additional instruction about installing a metal vise. 3⁄8" long 1 ⁄2 × 6" machine bolt #8 × 1 ⁄8" flathead wood screw 5 Figure 3: Inset Vise Detail #8 × 1" flathead wood screw Online Extra To learn how to drill perfectly perpendicular round dog holes. 3⁄4" in from end of (I) Jorgensen 4 × 7" Vise 1 ⁄2 × 4" lag screw 1 1 ⁄2" nut 1 × 4 ⁄2" tenon.Figure 2: Workbench Exploded View 60" 24" WorldMags. ⁄4" deep ⁄8 × 21⁄2" lag screw 17⁄8 × 71⁄4 × 5⁄8"deep mortise.

then clean up the mortise with a Aug/Sept 2013WorldMags. Position the vise on top of the spacer. Then rout the shallower 1⁄8"deep recesses on either side. Prices subject to change without notice. make yourself a few simple bench dogs. He teaches at the Philadelphia Furniture Workshop which he founded in 2006 to provide woodworking instruction to woodworkers of all skill levels. visit philadelphiafurnitureworkshop. (4) 3⁄8 × 21⁄2" lag screws. Allow time for the glue to dry. gradually rout out the main cavity to 15⁄16"-deep. and then use a plane and scraper to correct any misalignment on the top face. WorldMags.01 $89. 54 woodcraftmagazine. Finally. and then install the front vise with 3⁄8 × 21⁄2" lag screws. and transfer the mounting-hole locations using a pencil or punch. Test-fit the vise and transfer the mounting screw locations.99 2 Above items are available at Woodcraft stores. (800) Hardware/Supplies: (16) #8 × 15⁄8" flathead wood screws. 3. I applied two coats to the top. See instructions. then install the vise with the screws Now using your drill press equipped with a 1" Forstner bit. I) to the laminated top (G) with glue and clamps. 1 Lay the assembled top Materials: HM=Hard Maple *Indicates that parts are initially cut oversize. To bring out the color of the wood. face down. and position the assembled base on its bottom face. leevalley. (4) 1⁄2 × 6" machine bolts. Mat’l 4 2 4 4 2 4 1 1 1 1 HM HM HM HM HM HM Butcher block HM HM HM ⁄4" 13⁄4" 113⁄16" 13⁄16” 1" Final assembly (G/H/I) on a pair of sawhorses. #145685 #16T51 #157863 $219. Convenience-PLUS Buying Guide 1. Drill 1⁄4" pilot holes. Apply the front-edge and dog-hole strips (H. Veritas Inset Vise 05G31. Referring to Figure 3. (6) 1" SAE washers. Using a router equipped with a 1⁄2" straight bit and edge guide.) Apply a protective finish. (Consider the 3⁄4"-thick pads as a starting point. Drill pilot holes. Attach the vise spacer (J) with screws. You can adjust the thickness of the footpads for comfort. Workbench Cut List Part A B C* D E F G H I J Sled feet halves Top rails Uprights Wedges Stretchers Foot pads Benchtop Dog-hole strip Front-edge strip Vise spacer 11⁄4" 3 Thickness 11⁄2" 11⁄2" 21⁄4" Width Length 21⁄2" 23⁄4" 21⁄4" 21⁄4" 5" 3" 21" 21⁄4" 21⁄4" 41⁄2" 213⁄4" 21" 311⁄2" 21⁄2" 41" 3" 60" 60" 60" 71⁄2" Qty. I rubbed on a coat 6 7 4 of Odie’s Oil to all surfaces.. n 5 8 About Our Designer/Builder Alan Turner has been a woodworker for 50 3 Attach the four pad feet (F) to the leg assemblies ( or by calling (800) 225-1153. Using 3⁄ 4"-thick scrap hardwood. B. C).net .00 Above items available at Lee Valley Tools. Laminated Maple Benchtop. (4) #8 × 2" flathead wood screws. Ltd. To resist stains and glue. and then put your bench to work. Attach the base to the top using 1⁄ 2 × 4" lag screws and washers.99 $159. (2) 1⁄2 × 4" lag screws. 9 oz. 2. woodcraft. Make certain to clean out any squeeze-out that oozes into the dog holes and vise mortise. 24" × 60" Jorgensen Rapid Acting Bench Vise 4" × 7" Odie’s Oil. drill a 11⁄2"-diameter hole through the workbench so that chips can fall through before interfering with the vise. For information on classes. remove the bulk of the waste. (4) 3⁄4" SAE washers. make angled cuts at the ends of the mortise to establish the length. lay out the main mortise cavity for the inset vise. 4.handsaw. Glue and clamp the dog-hole strip (H) to the front-edge strip (I).99 $27.

⁄8 (9 mm) deep 11⁄2" hole 21⁄2" 161⁄4" 17" 3" 193⁄4" 153⁄4" #8 × 11⁄2" flathead wood screws Overall Dimensions: 161⁄2"w × 393⁄4"l × 17"h T Photos: Paul Anthony. By Alan Turner 55 WorldMags. the case and tools within will provide extra mass to your bench to help keep it firmly planted when working with hand tools. Designed to be built and put into service Figure 1: Tool Cabinet Exploded View 393⁄4" #8 × 11⁄2" flathead wood screws 197⁄8" ⁄2" (12mm) rabbet.Workbench Tool Cabinet Get more bang from your bench with this easy-to-build box. for example. All-Purpose Workbench (page 48). Note: Baltic birch (used to build this cabinet and drawers) is manufactured to metric specifications. 3⁄8" (9mm) deep 1 #6 × ⁄4 flathead wood screws 3 ⁄4 (18mm) dado. refer to the metric measurements listed in parentheses beside their imperial equivalents. woodcraftmagazine. 3 ⁄8 (9 mm) deep 3 3 3 ⁄4 (18mm) rabbet. 3⁄8" (9mm).net Aug/Sept 2013 . ⁄8 (9 mm) deep 1 3 ⁄4 (6mm) dadoes. For best results when using this material. Illustrations: John Hartman his under-bench cabinet offers superconvenient storage without sacrificing additional floor or wall space. the cabinet employs simple joinery and requires only a small handful of hardware. Once installed and stocked. This cabinet is intended to complement the Compact. but if the cabinet fits (or you alter the dimensions to suit) it can serve as a fitting upgrade to almost any workbench.

L). bury the dado head slightly. G. . Using the back to square the case. Install a 3⁄ 4" (18mm) dado set in your tablesaw. and adjust the fence as needed to rabbet the bottom edges of the drawer fronts. G. adjust the dado height to 3⁄8". sides (J. where shown in Figure 3. where shown in Figure 1. I). where shown in Figure 3. hole 3 ⁄4" 1 3 ⁄2 (9mm) dado. cut each matching pair of dados before adjusting the fence. Attach the back to the case with 3⁄4"screws. drill the finger holes in the drawer fronts. as shown in Photo A . Attach a sacrificial fence to your rip fence. ⁄8 (12mm) deep 11⁄4" nails 20" A Make sure that the bottom lip projects evenly on both sides. N. 1 Cut the drawer bottoms (E) (C). At the drill press. reassemble the case with glue. 2 3 11⁄2"-dia. O) to the sizes listed in the Cut List . attach a sacrificial fence to your saw’s rip fence. and then rabbet and dado the top and bottom (A) for the Start with the case 1 2 sides (B) and center partition (C). 1⁄2 (9mm) deep on bottom drawer Cut the top and bottom (A). H.) Dry-assemble the case and cut the back (D) to fit. 56 woodcraftmagazine. Adjust your dado set width to 1 ⁄ 4" (6mm) and cut the dadoes for the drawer bottoms (E) in the sides (B) and center partition 3 Figure 3: Exploded Drawer 11⁄4" nails to fit your cabinet. where shown with a 11⁄2" Forstner bit. (To ensure that the dadoes line up. K. adjust the dado height to 3⁄8" (12mm). Next. I). sides (B). and backs (M. where shown in Figures 1 and 2. Now cut the drawer fronts ( Aug/Sept 2013WorldMags. Assemble the drawers with glue and pin nails. and center partition (C) to the sizes listed in the Cut List . Install a 1⁄2" (9 mm) dado set in your tablesaw. L). then shoot a few nails to hold the parts together. K. and then cut the 1⁄2" (12 mm) rabbet in the rear edges of the top/ bottom and sides for the back (D).Figure 2: Drawer Detail Note: Refer to Figure 2 for part letters. and then dado each drawer front (F. 1⁄2 (9mm) deep on top three top drawers 1 Drawer 1 Drawer 2 13⁄8" 13⁄8" 21⁄2" 13⁄4" 4 Drawer 3 35⁄8" 4" Make the drawers 14 ⁄4" 1 121⁄2" 81⁄2" 1 Drawer 4 71⁄2" 85⁄8" ⁄2" 1" rabbet. to fit the drawer sides (J. ⁄4 (6mm) rabbet.

n 1 Remove the doors. where shown in Figure 4. Apply a clear 37mm 22. round up your favorite tools and stock your cabinet. Mat’l 2 BB 2 BB 1 BB 1 BB 4 BB 1 BB 1 BB 1 BB 1 BB 4 BB 2 BB 2 BB 2 BB 1 BB 1 BB 1 BB 2 HM Materials: BB=Baltic Birch Plywood. Semi-Gloss.99 Above items are available at Woodcraft stores. Full Overlay. and ⁄ then drill 7 16"-deep hinge cup holes on the door using the reference lines as guides. 110° fulloverlay hinge Make and hang the door 1 Cut the door (P) to the size 2 3 3 Finishing up and hardware. 57 . and finish-sand as needed. Prices subject to change without notice. where shown in Figure 1. where shown.50 $17. Draw a pair of lines.99 $29. set the fence as shown in Photo B. Chuck a 35mm bit into your drill press. At the drill press. on the hinge side of the case and door. Attach the hinge mounting plates to the inside of the case. drill the finger hole. Workbench Cabinet Cut List A B C D E F G H I J K L M N O P Q Part Top/bottom Sides Center partition Back Drawer bottoms Drawer 1 front Drawer 2 front Drawer 3 front Drawer 4 front Drawer 1 and 2 sides Drawer 3 sides Drawer 4 sides Drawer backs for 1 and 2 Drawer back for drawer 3 Drawer back for drawer 4 Door Cleats Thickness 3 ⁄4" 3 ⁄4" 3 ⁄4" 1 ⁄2" 1 ⁄2" 3 ⁄4" 3 ⁄4" 3 ⁄4" 3 ⁄4" 1 ⁄2" 1 ⁄2" 1 ⁄2" 1 ⁄2" 1 ⁄2" 1 ⁄2" 3 ⁄4" 3 ⁄4" Width Length 153⁄4" 393⁄4" 153⁄4" 161⁄4" 151⁄2" 161⁄4" 161⁄4" 391⁄16" 193⁄8" 153⁄4" 21⁄2" 20" 13⁄4" 20" 4" 20" 81⁄16" 20" 13⁄8" 153⁄8" 35⁄8" 153⁄8" 1 7 ⁄2" 153⁄8" 1 2 ⁄2" 171⁄2" 5 3 ⁄8" 171⁄2" 71⁄2" 171⁄2" 17" 193⁄4" 1" 121⁄4" Qty. HM=Hard Maple Convenience-PLUS Buying Guide or by calling (800) 225-1153. (9) #6 × 3⁄4" flathead wood screws. WoodRiver 6" (150mm) Stainless Steel Cabinetmaker’s Rule DrillRite 35mm Hinge Jig and Bit Blum 110° CLIP Top Hinge with Blumotion.19 $11. Cut and attach the cleats (Q) to the case bottom to prevent the cabinet from sliding out when moving your workbench. drawers. Quart #140655 #143958 #152740 #151028 $4. 11⁄4" pin Aug/Sept 2013 woodcraftmagazine. inspect the parts. Finally. 4. Press the hinges into place. 2. Hardware/Supplies: (26) #8 × 11⁄2" flathead wood screws. to locate the centers of the hinges. and then drive the supplied screws. pair General Finishes Enduro-Var Top Coat. WorldMags.5mm Hinge-clip mounting plate 3" 3" B Measure the hinge-to-edge distance on a piece of scrap to set the drill press fence. Now attach the door to the case by clipping the hinges to the mounting plates. Reinstall the drawers and the mounting plates and door.Figure 4: Cabinet Hinge Detail WorldMags. 2 3 listed in the Cut List . 3.

The lower drawer is deep enough to house general tools and supplies. W .net hen it comes to portable planers. And yet a portable planer needs to be moveable so it can be stored when not in use in a space-starved shop. A shallow top drawer accommodates machine wrenches. the answer is to mount a portable planer on a space-saving mobile cart that includes drawers so that the space below the machine isn’t wasted. but low enough to ensure stable Aug/Sept 2013WorldMags. extra knives. Any of these machines is heavy enough to cause your back to protest when stashing the tool away on a shelf or under a bench. The heavy-duty casters ensure smooth. reliable mobility when needed and rock solid footing when locked for planing operations. the term “portable” is a bit of a stretch. and the self-closing slides keep the drawers from opening when pushing the unit around. and other small accoutrements. For me. This cart is tall enough to allow comfortable stock feeding. with its solid wood face Planer Cart Portability without the back strain By Paul Anthony Overall dimensions: 24"w × 201⁄2"d × 25"h 58 woodcraftmagazine. is stout enough to carry a heavy machine and large enough to accommodate most portable planers models currently on the market. This is one shop accessory that really earns its keep. The 3 ⁄ 4"-thick plywood case.

Using a dado head on the tablesaw. adjust the rip fence for a 1⁄2"-wide cut. where shown in Figure 1. ⁄4" deep Non-swiveling caster 5 ⁄16 × 1" Lag screw (with washer) Swiveling caster 17⁄16" #6 × 1" flathead screw Build the case 1 Lay out and cut the case sides (A) and top and bottom (B) to the sizes shown in the Cut List .Figure 1: Planer Cart Exploded View WorldMags. and saw the rabbets in the rear edges of the sides. Alternatively. you could use a router and straightedge for the job. setting up the cut with Aug/Sept 2013 woodcraftmagazine. 59 . Project photos: Paul #6 × 11⁄4” flathead screw #6 × 11⁄4" flathead screw 21⁄2" 8-32 × 11⁄2" panhead screw 1 1 ⁄2" rabbet. cut the 3⁄ 4"-wide by 1 ⁄ 4"-deep rabbets in the sides (Photo A). With the dado head at the same height. Illustration: Frank Rohrbach III WorldMags. ⁄4" deep 12" 2" 3 1 ⁄4" rabbet. 2 3 A Saw the rabbets in the case sides using a dado head and a sacrificial fence clamped to your rip fence. Opening photo: Larry Hamel-Lambert. and bottom.

D Clamp a rail and stile into alignment using locking pliers designed for the where shown in Figure 1. puttying the nail holes later. (You’ll trim their edges flush to the case after attaching the face frame.WorldMags. Using a pocket-hole jig. Temporarily clamp the face frame (D. and pull the parts together with screws. Use clamping cauls to distribute the clamping pressure across the Aug/Sept 2013WorldMags. Working on a flat surface. drill the screw pockets in the ends of the rails ( Photo C ). carefully centering it side to side. A tab of duct tape allows easy removal of the back for internal inspection. 6 Mill the stiles (D) and rails 7 8 10 C Drill screw pockets into the rear faces of the rails to allow their attachment to the stiles. Then screw the face frame together using 11⁄ 4"-long washer head screws designed for pockethole joinery ( Photo D). Saw the panel to size. Mark the intended location of the center rail 12" from the bottom end of each stile. If necessary. Slip the back (C) into place unglued. glue up the case with the unglued back dry-fit in its rabbets to keep things square ( Photo B). Now make and fit your drawer slide shims (F) to the sizes shown in the Cut List . (Instead of clamping. 60 woodcraftmagazine. sand or plane the rear face of the assembled face frame flat and smooth at its perimeter for good contact with the edges of the case. and measure for an exact fit of the back panel (C). and lay the case on its back on a dead flat surface. making sure it’s absolutely square. gluing paper or cardboard to them if necessary to perfectly align the faces of the shims with the interior edges of the stiles (D). with one exception: make each stile about 1⁄16" oversized in width for now.) 9 4 5 (E) to the sizes shown in the Cut List . Mark out the screw-hole locations on each drawer slide shim (F). and then B Glue up the case with the unglued back inserted to keep things . E) to the front of the case. you can glue and nail.) Use a stopblock when cutting the rails to length to ensure they are all cut to precisely 191⁄2" long for proper drawer fit and operation. positioning them to avoid interference with the future locations of the drawerslide mounting holes. Note the particular location of each shim with a number. Dry-clamp the case sides (A) to the top and bottom (B).

drill and countersink clearance holes for #6 screws. H Check the square of the glued-up drawer boxes by comparing diagonals to ensure they’re equal. top. Glue up the drawer boxes. you can use pocket screws. I. 2 Carefully sand away any 12 3 4 Make the drawers 1 Cut the drawer box parts ( Aug/Sept 2013 woodcraftmagazine. and rehearse your face frame clamp-up. and then attach the shims to the case sides (A) using #6 × 11⁄ 4"-long screws ( Photo E ).com 61 . 11 glue and clamp the face frame to the case. G Use a flush-trim bit to rout the perimeter of the face frame flush to the case sides.WorldMags. Make any necessary adjustments. Dry-assemble the drawers to rehearse your clamp-up procedures and check the joint fits. (Alternatively. as shown in the photos on page 67. pre-adjusting your clamps in the process ( Photo F ).net E Use spacers to ensure accurate placement and quick attachment of the drawer slide shims. plane the front edges of the case if necessary to flush them up. making sure the assemblies are square under clamping pressure ( Photo H ). fuzz on the joint edges with 220-grit paper. Referring to Figure 1. page 62. and F Raising the case on wooden I-beams allows full clamping access around the case perimeter for attaching the face frame.) After the glue dries. carefully aligning the interior edges of the face frame with the faces of the drawer shims (F). carefully squaring every end. Also. In preparation for attaching the face frame. Then reinsert the case back (C) unglued into its rabbets. J. and bottom. use a flush-trim router bit to shave the edges of the face frame flush with the case sides ( Photo G). H. set the bottom shims 2" up from the inside bottom of the case and the top shim 21⁄2" down inside from the inside top of the case. K) to the sizes shown in the Cut List . Then saw the joints as described in the sidebar. spot-gluing the bottoms here and there in their grooves. ease the sharp corners of the tongues on the drawer bottoms (K) for easy insertion into their grooves during glue-up. WorldMags. Work on a flat surface.

All you need are your precut drawer parts. Rout or hand-plane a 1⁄8" chamfer around the edges of the false drawer fronts ( Aug/Sept 2013WorldMags. (This will allow the drawer bottoms to slide easily in their grooves for trouble-free assembly. Then. setting the forward end of the slide flush with the front edge of the drawer. To set up for the process. I use a plywood spacer for the job. and some scrap to test your setup. and offsetting the bottom edge of each slide 17⁄16" up from the bottom edge of the drawer sides (G. 2 Readjust the fence until test cuts yield a rabbet with a tongue that fits snugly without force into the dadoes you cut in Step Perfect. edgegluing boards to make the large drawer front (M) if you don’t have wide enough stock.) Cut the rabbets on all four edges of each drawer bottom. Then adjust the blade height for a 1⁄4"deep cut using scrap to confirm the setting. Screw the drawer-half of each slide to its respective drawer side. and backs. and then saw it to the dimensions shown in the Cut List . 3 Reposition the fence about 1⁄64" closer to the blade. using 1 2 3 Side Front and back Bottom I A 17⁄16"-wide spacer makes quick. aligning the bottom edges of each. Then saw the rabbets on the drawer fronts and backs by standing the parts on end. accurate work of aligning the drawer slides for attachment. and recessing the forward end 1⁄16" back from the front edge of the face frame. The drawers are now ready to assemble. Lock the blade at that height for the entire following process. 1 Saw the dadoes in the drawer sides. Now you’re ready to make your cuts: the same Screw the case-half of each drawer slide to its shim (F).WorldMags. Simple Drawer Joinery Building drawer boxes from 1⁄2"-thick plywood doesn’t get much easier than this. M) and top (N). Stand a piece of plywood drawer stock on edge against the fence. supported by a raised featherboard. M) to the sizes shown. adjust your dado head for a 1⁄4"-wide cut. Attach the false drawer fronts with countersunk #6 × 1" flathead screws through clearance holes drilled in the 1 Make the false drawer fronts 2 3 . a good quality dado head. and position the fence so that the outer face of the plywood is flush with the outer edge of the saw teeth. Install the drawer slides 1 Make the top and drawer fronts 2 (L. fronts. cut the drawer bottom grooves on the inside faces of the sides. I) ( Photo I ). Also joint and edge-glue enough boards to make the top (N). 62 woodcraftmagazine.

Mat’l 2 2 1 2 3 4 2 2 2 2 2 1 1 1 HP HP HP M M HP HP HP HP HP HP M M M ⁄4" 20" 211⁄2" 19" 20" 19 ⁄2" 1 3 ⁄4" ⁄4" ⁄4" ⁄4" 181⁄4" 21 ⁄2" 1 Finish up ⁄2" 1 Ease all sharp edges with 3 3 3 1 1 1 1 1 11⁄2" 1 ⁄2" 1 2 3 4 5 6 150-grit paper. right? Well. Planer Cart Cut List Part A B C D E F G H I J K L M N Sides Top and bottom Back Stiles Rails Drawer slide shims Small drawer sides Small drawer front and back Large drawer sides Large drawer front and back Drawer bottoms Small drawer false front Large drawer false front Top Thickness 3 3 1 Width Length 18 ⁄4" 1 Qty. Thoroughly blast away any dust on the case interior and exterior using compressed air. as shown in Photo J. Prices subject to change without notice. Inset each fixed caster 1⁄2" from the rear edge of the cabinet. maybe. 3. and then attach the back (C) with glue and 11⁄2"-long finish nails. Amerock So why bother sanding and finishing this cart? It’s just a shop accessory. Semi-Gloss. Offset the bottom edge of each drawer front 3⁄ 4" away from the bottom edge of its drawer box. Alternatively. Truth is.99 each Above items are available at Woodcraft stores. Clear Zinc (2 sets needed) 3" Caster.99 $29. Brass (2 needed) #142861 #141052 #141051 #151028 #130144 $21. Attach the top with countersunk #6 × 1" flathead screws from inside the case. Then lay out and drill the 3⁄16"-diameter through holes for the drawer pulls. Non-locking. 2. Attach the pulls with 8-32 × 11⁄2" panhead machine screws. Swiveling with 4-Hole Mounting Plate. Aug/Sept 2013 woodcraftmagazine. 4. WorldMags. It would be a shame if it was too shoddily dressed for the occasion.Refined or Rough-andReady: Your Choice WorldMags. which are centered on the drawer fronts.* Accuride 3832SC 18" Self-closing Drawer Slides. qt. 5. *Available only by calling (800) 225-1153.50 $11. Attach the casters with 5⁄16" × 1" lag screws. screw your planer to the cart. n 2" 4" 4" 91⁄2" 9 ⁄2" 1 17 ⁄4" 18" 18" 18" 18" 17 ⁄16" 15 ⁄2" ⁄2" ⁄2" ⁄2" ⁄2" ⁄4" ⁄4" ⁄4" 17 ⁄16" 7 3 3 3 6" 11 ⁄2" 1 201⁄2" 20 ⁄2" 1 201⁄2" 24" Materials: HP=Hardwood Plywood. 41⁄4" Tall (2 needed) 3" Caster. Align the long edge of each swiveling caster flush with the front of the cabinet. you can attach cleats to the top at the perimeter of the machine base.99 $18. M=Maple Convenience-PLUS Buying Guide 1. 41⁄4" Tall (2 needed) General Finishes Enduro-Var Top Coat. this handy little unit would be just as much at home in an office or other workroom after it has served its shop time. I used three coats of Enduro-Var.99 $4. Apply the finish of your choice. Install the swiveling casters at the front of the cabinet and the fixed casters at the rear. Non-swiveling with 4-Hole Mounting Plate. J drawer box. You just want to keep it from sliding off the top should the casters suddenly encounter an obstruction during travel. 63 . or by calling (800) 225-1153. and sand all exposed surfaces through 220 grit.

net Power Tower By Joe Hurst-Wajszczuk Custom-made parking for portable power tools Overall dimensions: 32"w × 24"l × 761⁄4"h And when you need even more space. the worst space-eaters aren’t the tools you’re using. (You’ll need only two sheets of 3 ⁄ 4"-plywood and about 20 board feet of hardwood). I designed the cabinet to accommodate a wide assortment of benchtop tools and to minimize material costs. and adjustable sawtooth shelf hangers to make the most of available space.WorldMags. This “closet on wheels” features hardwood face frames. and you’ll learn that the most valuable commodity isn’t tools or materials–it’s space.) . Often. By offering convenient parking spots for all sorts of portable and benchtop tools. they’re the ones you aren’t. this storage tower can help fix your power tool Aug/Sept 2013WorldMags. (The plywood sides can provide extra wall space for items such as clamp racks or tool boards. And for those A 64 woodcraftmagazine. a center divider to reinforce the open case. the heavy-duty casters enable you to quickly roll a shop’s worth of tools out of the sk any woodworker struggling to carve a workshop from a basement or garage.

From a second sheet. once it’s fully loaded. Build the case 1 From one sheet of ⁄ " 3 4 Tip Alert For convenience. plywood. you’ll make the center divider (F) from the material left over from cutting the sides.) Opening photo: Larry 11⁄4" pocket screw 1" pocket screw 11⁄4" pocket screw Notch Detail 1 ⁄4" 1 1" 3 7 ⁄2" ⁄4" dado. have the plywood ripped to 24"-wide at the lumberyard. This cabinet takes up six square feet of floor space. (Note: Later. but surprisingly. cut the sides (A). and the adjustable shelves (I) from the shelf sheet. Illustrations: Frank Rohrbach III WorldMags. ⁄32" deep* 3 ⁄4" brads 6" 3" sawtooth shelf support system 103⁄8" 183⁄4" 151⁄2" 1 ⁄2" 4" locking caster 5 15⁄8" flathead screw *Adjust dado depth so that remaining plywood is 1⁄2". cut the top. your shop may feel a little bigger. there should still be enough material for you to recut both edges. ⁄16 × 1" lag screw 5 ⁄16" SAE Washer working without the benefit of a full-fledged workshop. I employed a few tricks so that they can build this tower with a few portable power tools and a small collection of clamps.Figure 1: Power Tower Exploded Drawing WorldMags. Even if the store’s cut is a little Aug/Sept 2013 woodcraftmagazine. bottom. and fixed shelves (B) to the sizes listed in the Cut List .com 65 .

Using a framing square. and then cut the opposite edge. To cancel out sheet good shortcomings. use a pocket-hole jig to drill holes along the ends of the top. (C). (Alternatively. the depth difference–barely a 1 ⁄32"–makes fitting the face frames easier and ensures that the finished case is 24" wide. and use a straightedge guide to rout the dadoes across both sides.) Test-assemble the case without glue. the bottom-face edges of the bottom and fixed shelf. where shown in Figure 1.” bottom left. position the face frame on top. With help. to ensure that the parts fit and to obtain the exact dimension of the center divider (F). lay the guide rail in place. apply glue to the outside edges. use a scrap piece of plywood to determine the actual cut width. lay out the dadoes on one side (A). and then attach the frame with 11⁄ 4" pocket screws ( Photo D).net A Set the cut depth so that the saw teeth graze the underlying foam. Stacking and sawing saves time and ensures symmetrical parts. Again using a pocket-hole jig.WorldMags. and fixed shelf (B). rails (D). bottom. measure the cut on both ends. I set my “1⁄4"-deep” dadoes so that the remaining material is 1⁄2" thick. While the glued-together case dries. Square the assembled plywood case. In this case. Repeat with the opposite face frame. I use a V-groove flush-trim bit for concealing less-than-perfect joints. clamp the sides (A) together. leave the shelf edging long for into a handheld router.) 3 Chuck a ⁄ " straight bit 4 5 2 Three-quarter inch plywood is rarely 3⁄4" thick. and the top-face edges of the top (C). and then rout both sides at once to ensure that the dadoes line up. With the cabinet lying face frame up. (Note: For tight-fitting dadoes.) Cut one long edge. Unless you have a tablesaw with a large infeed and outfeed table. Attach the opposite side in the same manner. mill the stock for the stiles 8 9 10 11 . you can use a standard circular saw with a shop-made or store-bought straightedge guide. To limit the number of clamps needed to assemble the case. (Note: You may also use a standard flush bit. Also. drill holes at the ends of the rails (D). apply glue to the dadoes. Now. (Note: Drill the pocket holes on the faces that won’t be visible after assembly. cut the parts to length. Finally.) 1 2 B Use an offset guide to position the straightedge. and set the bit depth according to “Dado Depth Makes All The Difference. as shown in Photo B. Dado Depth Makes All The Difference 6 7 66 woodcraftmagazine. and then assemble the face frames using 11⁄ 4" pocket screws and glue. and shelf edging (E) to the sizes in the Cut List . as shown in Photo C . where shown in Figure 1. but make the stiles about 1⁄16" oversized in width. Position the stiles (C) on top of the assembled case to double-check the position of the rails. drill holes along the inside edges of the sides (A). Lay out and then rout the stopped grooves in the sides and the corresponding dadoes in the fixed shelf and bottom for the center divider (F). use a handheld router and flush-trim V-groove bit to trim the outside edges of the Aug/Sept 2013WorldMags. and fixed shelf into one side (A) and clamp the parts together with 1"-long pocket-hole screws. Using a pocket-hole jig. and then fit the top. bottom. the easiest way to break down sheet goods is by laying the plywood on a piece of rigid foam and using a rail-guided saw (Photo A). Cut the divider to fit.

Swiveling with 4-Hole Mounting Plate. From 3⁄ 4" hardwood. cut the support strips (included with the brackets) to fit. Project photos: Brian Francis WorldMags. (16) 5⁄16" SAE washers. Attach the spacers and mounting boards to the case bottom with glue and 15⁄8" screws. n Width 221⁄2" 221⁄2" 2" 2" 2" 171⁄4" 43⁄4" 51⁄2 21" Length 72" 31" 731⁄2" 28" 18" 31" 24" 24" 303⁄4" Qty. drill clearance holes in the caster mounting board (H) for the attachment screws and pilot holes for the lag screws. saw spacers (G) and caster mounting boards (H) to the sizes listed in the Cut List . Double Locking. (16) 5⁄16 × 1" lag Aug/Sept 2013 woodcraftmagazine. Prices subject to change without C Using pocket-screw holes along the outside edges reduces the need for clamps.99 $29.97 $18. 2 3 4 6 4 1 2 2 2 Mat’l HP HP M M HP HP HP HP HP 2 3 Part Sides Top. Sand the case interior to 220 grit. At the drill press. and then apply your desired finish. Convenience-PLUS Buying Guide or by calling (800) 225-1153. lay out mounting holes. where shown on Figure 1. 1" CL (1⁄4" SH) 3" Caster. Make the adjustable shelves (I) about 3⁄16" shorter than the interior dimension so that they can be installed and readjusted. Semi-Gloss. and fixed shelf Stiles Rails Shelf edging Center divider Spacer Mounting boards Adjustable shelves Thickness 3 ⁄4" 3 ⁄4" 3 ⁄4" 3 ⁄4" 3 ⁄4" 3 ⁄4" 3 ⁄4" 3 ⁄4" 3 ⁄4" Materials: HP=Hardwood Plywood. Lay out 1⁄2 × 1⁄ 4" notches on the plywood corners. (I used two coats of General Finishes Enduro-Var. 3⁄4" brads. 41⁄4" Tall (4 needed) General Finishes Enduro-Var Topcoat. Glue the edging to the plywood shelf. Insert the adjustable shelves into the case. 4. Hardware/Supplies: (16) 1" pocket screws.) Finish up 1 Sand exposed surfaces 2 Power Tower Cut List A B C D E* F G H I* through 220 grit.99 4 5 Above items are available at Woodcraft stores. Poplar #838923 #141051 #151028 #153504 $27. bottom. load up your tower. See instructions. and apply your desired finish. 3. Attach the casters and shelves 1 6 Trim the shelf edging (E) to match the notch-to-notch distance on the plywood. Fit them in at the top and slide them between the sawtooth brackets. and you’re ready to roll. woodcraft.WorldMags. (16) 11⁄4" pocket screws. Then. 15⁄8" production screws. attach the casters with washers and 5⁄16 × 1" lag screws. (The shelves should fit snugly. Reposition the clamps as you work your way across the case. 5 ⁄8" D.) Now attach the sawtooth brackets to the inside of the case with 3⁄ 4" brads.99 $29. qt. M=Maple *Indicates that parts are initially cut oversized. Using the caster bracket as a 67 . (2 needed) Sawtooth Shelf Supports. Cut the notches with a fine-tooth handsaw. D Clamp the face frame tightly to the case. and drive in the pocket screws. 2. Freud Flush Trim V-Groove Bit. Finally.

com 68 Made With American Grown Soybeans 100% Biodegradable • Virtually No Odor Non-Caustic & Non-Hazardous Professional Paint & Urethane Remover Lead-based Paint. Varnishes & Urethanes Cabinets • Furniture • Trim • Molding • Brick • Metal Now Available at .com Aug/Sept 2013WorldMags. INFRARED HEAT /Z Ϯ ¾ϭ͘ϯŬt ϭϭϱǀ ;ϭϮ ĂŵƉƐͿ ¾WŽůŝƐŚĞĚ ƐƚĂŝŶůĞƐƐ ƐƚĞĞů ĨŝŶŝƐŚ ¾ ǀĂŝůĂďůĞ ǁŝƚŚ ŚŝŐŚ ĞĨĨŝĐŝĞŶĐLJ ďůĂĐŬ ŐůĂnjĞĚ Žƌ ǁŚŝƚĞ ŐůĂnjĞĚ ĐĞƌĂŵŝĐ ŝŶĨƌĂƌĞĚ ĞůĞŵĞŶƚƐ ¾^ƵƉƉůŝĞĚ ǁŝƚŚ ϰ͘ϱ͛ ƉŽǁĞƌ ĐŽƌĚ ¾DŽƵŶƚƐ ĞĂƐŝůLJ ƚŽ ĂŶLJ ĨŝŶŝƐŚĞĚ Žƌ ƵŶĨŝŶŝƐŚĞĚ ǁĂůů ¾ŽǀĞƌƐ ϭϬ͛džϭϬ͛ ĞŶĐůŽƐĞĚ ĂƌĞĂ ĐŽŵĨŽƌƚĂďůLJ /Z ϯ ¾ϭ͘ϱŬt ϭϭϱǀ ;ϭϰ ĂŵƉƐͿ ¾WŽůŝƐŚĞĚ ƐƚĂŝŶůĞƐƐ ƐƚĞĞů ĨŝŶŝƐŚ ¾ ǀĂŝůĂďůĞ ǁŝƚŚ ŚŝŐŚ ĞĨĨŝĐŝĞŶĐLJ ďůĂĐŬ ŐůĂnjĞĚ Žƌ ǁŚŝƚĞ ŐůĂnjĞĚ ĐĞƌĂŵŝĐ ŝŶĨƌĂƌĞĚ ĞůĞŵĞŶƚƐ ¾^ƵƉƉůŝĞĚ ǁŝƚŚ ϰ͘ϱ͛ ƉŽǁĞƌ ĐŽƌĚ ¾DŽƵŶƚƐ ĞĂƐŝůLJ ƚŽ ĂŶLJ ĨŝŶŝƐŚĞĚ Žƌ ƵŶĨŝŶŝƐŚĞĚ ǁĂůů ¾ŽǀĞƌƐ ϭϭ͛džϭϭ͛ ĞŶĐůŽƐĞĚ ĂƌĞĂ ĐŽŵĨŽƌƚĂďůLJ ŽŵĨŽƌƚ /Z ϯϲϬ ¾ϭ͘ϵϱŬt ϮϯϬͬϮϰϬǀ ;ϵ ĂŵƉƐͿ ¾WŽůŝƐŚĞĚ ƐƚĂŝŶůĞƐƐ ƐƚĞĞů ĨŝŶŝƐŚ ¾YƵĂƌƚnj ŵĞĚŝƵŵ ǁĂǀĞ ŝŶĨƌĂƌĞĚ ĞůĞŵĞŶƚƐ ¾^ƵƉƉůŝĞĚ ǁŝƚŚ ϰ͘ϱ͛ ƉŽǁĞƌ ĐŽƌĚ ¾ ĚũƵƐƚĂďůĞ ƐƵƐƉĞŶƐŝŽŶ ĨƌŽŵ ĐĞŶƚĞƌ ŽĨ ƵŶŝƚ ¾ŽǀĞƌƐ ƵƉ ƚŽ ϭϮ͛džϭϮ͛ ĞŶĐůŽƐĞĚ ĂƌĞ ĐŽŵĨŽƌƚĂďůLJ www.7564 Phone: 810.7221 Fax: 810.686.

boxelder lumber grades range from FAS (first and seconds. Boxelder stock is light-colored. How to select the best stock While boxelder lumber is normally mixed with the other soft maples. and because it can thrive in cold. the highest) to No. Crafters have cut wooden utensils (treenware) from the wood. even into Saskatchewan and Manitoba. 4/4 (1"-thick) boxelder board foot should run about $3. boxelder pulp has gone into the making of fiberboard. as well as carvings. It's not always an easy find. Aug/Sept 2013WorldMags. boxelder offers up a nasty aroma that fades once the wood dries. However. The largest trees of this species–70' tall and up to 4' in diameter–are found there. the greatest quantity of boxelder grows from the Great Lakes states to the central Atlantic states and from southern New England to northern Florida. making it suitable for woodworking novices to practice on and use for a variety of projects. but specialty dealers will have carving and turning blanks. By Pete Stephano Technical Consultant: Larry Osborn he forest products industry classifies boxelder (Acer negundo) as a “soft maple. Although a bit brittle. some specialty sawmills within the tree’s range . What you’ll pay Where the wood comes from 70 woodcraftmagazine. and cabinets. because the tree grows rapidly. Expect to triple that cost for red-streaked stock. fine-textured. punishing climates. An FAS. 3B Common (the lowest). about the same as white pine. and close- T Spotlight on Boxelder The softest of the maples has lots to offer woodworkers of all ages. especially along streams and in lowlands. it works easily with hand and machine tools. Like sugar maple.” along with silver maple and red maple.WoodSense WorldMags. Normally lackluster. Add to this list toys. You won’t find any boxelder veneer. At 27 pounds per cubic foot In North America. When wet or unseasoned. for erosion control and windbreaks. basic furniture. the wood sometimes displays raspberry-colored streaks caused by fungal infection. Commercially. and possibly live-edge slabs. boxelder rates as the lightest and weakest of the maples. The three are normally mixed and sold together under the soft maple label. Beyond that. you’ll have to shop local sawmills or small outlets for boxelder within the species’ growth range. both woodturners and box makers prize the red-streaked stock for making eye-catching turnings and decorative boxes. History in woodworking Turning of stained boxelder Boxelder has been used for food containers such as crates and barrels. it was planted extensively in the West and Northwest.

When ripping boxelder. there’s little noticeable difference between boxelder sapwood and heartwood. turnings. neither of which affects value and are allowed in grading. bowls. To fasten boxelder project parts together with screws. it. slow down the process with a clear finish having UV protection. fungistained boxelder Durability Low (due to rot and insect attack) Strength Toxicity Tool Type Moderate Skin irritation possible Hand and power tools with sharp blades and cutters Decorative and ornamental pieces.WorldMags. and toys may separate boxelder and sell it for a very reasonable price. only here trim excess wood in several light passes. use a sanding sealer. They also boiled down the sap for syrup and treats. Spread the glue evenly on the mating surfaces. rubbing them together if possible before clamping for a complete bond. Because the wonderful red streaking on fungal-infected wood turns brown after prolonged exposure to sunlight. tight pin knots and Boxelder Quick Take Cost Weight Hardness Stability Moderate About 25% lighter than sugar maple Roughly half as hard as sugar maple Moderate Flatsawn. too. n woodcraftmagazine. Boxelder sands wonderfully. Vase Photo: Bob Hawks When drilling. Common Uses It’s a fact that… Native Americans sought out the burls and knots on the lower trunks of boxelder trees for WorldMags. For best results. will burn if precautions are not taken. Because of the wood’s poor resistance to Aug/Sept 2013 71 . avoid it for all outdoor projects. They boiled the inner bark to make a tea that served as an emetic. carvings. Some woodturners and others who regularly work red-stained boxelder fortify the streaking with aniline dye of the same color to prolong its vividness. crates. some furniture. but its tight grain won’t absorb glue easily. Boxelder may also display small. Sample Photo: Larry Hamel-Lambert. The same is true when routing. eliminate burning by using high-quality sharp bits at a moderate to slow speed and by occasionally raising the bit and clearing the hole of chips. just like sugar maple. dewaxed shellac. but blotches when stained. feed the workpiece at a constant moderate rate to reduce or eliminate burning. you’ll find the much softer boxelder a lot easier to work. and drums. All adhesives work well on boxelder. or a thin coat of a wipe-on finish to partially seal the wood before staining. Working boxelder in the shop If you’re familiar with machining the “hard” maple known as sugar maple. Make sure the sealer and stain are compatible by testing them on a piece of boxelder scrap. That said. Another trick is to go with a gel or heavy-bodied stain that you wipe off and reapply to achieve the desired color. Illustration: Steve Sanford. boxes. drill pilot holes first to avoid splitting. Except for those trees that display wood with the unmistakable fungiproduced red streaks. dishes. like sugar maple. so selecting boards for a project isn’t a difficult chore.

To Find Your Local Woodcraft Store Or For A Free Catalog. These clamps have large pivoting jaws with added pads for aligning face joints and comfortable handle grips for reduced hand fatigue. The Lynx saw range – Available at Woodcraft www. thanks to new technology that allows you to clamp materials of varying thicknesses without ever adjusting the clamp. Kreg joinery just got a little Aug/Sept 2013WorldMags. thanks to the versatility and simplicity of Automaxx™ Or Call . 13WD09H2 72 using an easy-to-regulate thumbscrew. and Automaxx™ clamps do the rest – locking closed easily and consistently every time and with every thickness. Just set the clamping pressure once. Visit Tel: +44 114 2725387 QUALITY WOODWORKING TOOLS • SUPPLIES • ADVICE ® KREG® Automaxx™ Clamps 158503 3" Face Clamp 158504 6" Face Clamp 158505 3" Bench Klamp 158506 6" Bench Klamp 158507 3" Bench Klamp System Set The Pressure Once – KREG® Automaxx™ Clamps Do The Rest Automaxx™ Face Clamps and Bench Klamps make clamping fast and foolproof every The perfect way to cut logs the traditional

Duraline Hi-AT Woodshop News Dado King Wood Magazine 73 . online. call 973-473-5236) © 2013 Forrest Manufacturing Code WC WorldMags. In fact. and flooring. quiet cuts without splintering. and I have tried them all. all-purpose blade for rips and crosscuts. Our proprietary manufacturing process. Woodworker II—Best rated. independent tests rate us #1 for rip cuts and crosscuts. Order from any Forrest dealer or retailer. and backed by our 30-day. or tearouts. countertops. and unique grade of C-4 micrograin carbide are perfect for cabinets.” Bob Aug/Sept 2013 woodcraftmagazine.A. money-back guarantee.ForrestBlades. or by calling Experienced woodworkers know that Forrest blades are ideal for remodeling high-end kitchens and baths. hand straightening. Our blades are manufactured in the U. MN Woodworker II Fine Woodworking Chop Master Woodshop News Our Most Popular Saw Blades: Duraline Hi-AT—Great for cutting two-sided veneers and low pressure 1-800-733-7111 (In NJ.S. Fridley. Forrest blades deliver smooth. scratching. “Your blades are without question the best by miles.

Sadder Detail Saws Terrific cuts from tiny teeth O ddly enough. many woodworkers spend top dollar on premium tablesaw and chopsaw .99 (above) Hishika Miki (43⁄4" Detail Saw) #157068 (JW).Well-Stocked Shop WorldMags.99 74 WorldMags. because these smallcut specialists really earn their keep. cutting veneer. as shown in the offerings here. trimming plugs. senior editor Typically. thinwalled brass and wood. For an exceptionally smooth cut in stock less than 1⁄2" thick. If forced to select only one saw. For the right balance between cut quality and speed (to be consistent) for general detail work. Choosing a saw with the proper tpi for the job at hand requires some experimentation. although it stalls in thicker materials. consider the Zona. —Joe Hurst. That way. I prefer a 19 tpi Hishiki Folding Saw #845243 (JW). it handles thinner stock well. I’ll reach for a saw with a 36-tpi blade. the next time you’re finessing fine work or sawing 19-tpi dozuki. and other cleanup and Tooth Talk detail work. The 60-tpi “model makers” razor saw is capable of super-smooth cuts in plastic. Too bad. but are satisfied to work with junk handsaws. the more teeth per inch (tpi) that a saw blade has. The blade can also be reversed to cut on either the push or pull stroke. but they are good for more than pine board sailboats and rubber-band guns. and reach for the right tool for the job. This is particularly true in the case of small handsaws used for scroll work. making small joints. $22. Although its 24-tpi blade tends to stall a bit on 3⁄4"-thick stock. many woodworkers don’t even own cheap versions of these saws and don’t know what they’re missing. $28. Frame saws Coping saws have introduced many youngsters to the world of woodworking. $52. the smoother and slower the cut. and comes with a miter box.00 24 tpi Zona Saw and Mini-Miter Box #140347. $21. So check ’em out. ignore the power saws. thin or delicate stock.35 36 tpi 60 tpi Gyros Razor Saw #126820.

which are deep enough to enable the blade to reach the middle of wide panels. pegs. tapered blade saw is equally suited for straight cuts and tight curves. step up to a fretsaw.99 A go-to jobsite tool for fitting moldings. dowels. enabling an aggressive cut without scratching the surface below. $23.99 Olsen Adjustable Frame Saw. a fretsaw can make smooth cuts and super- tight turns in a wide variety of materials. which is the thinnest (and often most expensive) stock in your shop. you need a Veritas DoubleEdged Flush-Cut Saw. Flush-cut saws slice plugs. these solid C-frame saws are also useful in the shop for tackling curves or pierced work that might be too dicey or awkward to cut on a scrollsaw. #154762. smaller saws (which use adjustable C-frames) are easier to handle.Eclipse Coping Saw. Veneer saws Featured products available from Woodcraft Supply or Japan Woodworker (JW). #141410. The double-edge blade allows you to approach the cut from either the left or the right. 25 tpi #154480. as long as you don’t need the deeper throat capacity. Saw on the pull stroke. Only 1⁄2" wide at the handle. The 13⁄8"-wide paddle-shaped blade on Veritas’ flush-cut saw is flexible enough to be bent perpendicular to the handle.99 WorldMags. 22 tpi Aug/Sept 2013 . which is basically a hand-powered scrollsaw. and solid wood. For veneer. including metal. $49. Considering the prices. The teeth are set to one side only. $17. rocking it backwards as the cut progresses. For really fine work. The teeth on veneer saws have no set and are designed to cut cleanly both with the grain and across it. $23. and other protrusions flush to the surrounding surface without scratching it. The saw is generally guided against a straight edge of some sort. Fretsaws are available with both fixed and adjustable frames. you can’t afford not to have both of these problem solvers in your toolbox. n Detail Saw 25 tpi #156791 (JW). $24. Although listed as a trimmer for bamboo and bonsai. However.99 saw that won’t split or tear the fragile material. beginning the cut with a few light scoring strokes to prevent splitting the veneer. The adjustable frame will also help you squeeze a few more cuts from shorter broken blades. and ending with the trailing teeth contacting the work. The convex blade allows you to make long cuts while keeping some teeth fully engaged in the stock– something that would be difficult to do with a straight-edged Lynx Offset Handle Veneer Saw. this economical saw can start a cut from a 5⁄32"-diameter hole in the middle of a panel. but they’re inexpensive and easy to replace when bent or broken. veneer.85 Special Problem Solvers These oddly shaped saws fill a niche not met by other detail 75 WorldMags. $17. Outfitted with the proper blade to match the job. Photos: Gary Tramontina Keyhole saws are designed to make pierced cuts. 15 tpi #147415.99 Crown Straight-handed Veneer Saw. Larger saws typically have fixed U-shaped frames. Coping saw blades are somewhat delicate. Japan Woodworker’s stiff. woodcraftmagazine. starting at the far end and pulling the saw toward you.

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org/americanwoodshop Woodcraft is pleased to continue sponsorship of The American Woodshop with Scott and Suzy Or Call 800-225-1153. including an episode on how wine barrels are made in Napa Valley.thomasjmacdonald. From providing in-store classes and demonstrations to funding educational woodworking programming.“Your Hand Tool Coach. See the innovations that Rebuild. now in its 20th season on PBS. 13WD09P QUALITY WOODWORKING TOOLS • SUPPLIES • ADVICE® . Rob Cosman’s daily online episodes teach the proper use of hand tools and power tools in a motivational and educational way. Woodcraft Stores In Your Area: Alabama Birmingham/Pelham: 205-988-3600 Arizona Phoenix/Chandler: 480-539-9663 Tucson: 520-742-9663 California Orange County/ Stanton: 714-899-1422 Sacramento: 916-362-9664 San Francisco Bay Area: Dublin: 925-875-9988 San Carlos: 650-631-9663 Ventura: 805-658-9663 Colorado Colorado Springs: 719-266-9889 Denver: 303-290-0007 Loveland: 970-292-5940 Connecticut Hartford/Manchester: 860-647-0303 Norwalk: Woodworker's Club 203-847-9663 Delaware Wilmington/New Castle: 302-323-0400 Florida Jacksonville: 904-721-9796 Orlando: 407-260-5002 Tampa/Clearwater: 727-532-6888 Georgia Atlanta: 770-587-3372 Hawaii Honolulu: 808-841-9876 Idaho Boise: 208-338-1190 Illinois Chicago Area: Libertyville: 847-680-9663 Woodridge: 630-435-9663 Indiana Indianapolis: 317-578-3400 Kansas Kansas City/Lenexa: 913-599-2800 Kentucky Lexington: 859-231-9663 Louisville: 502-671-0900 Maryland Rockville: Woodworker's Club 301-984-9033 Massachusetts Boston/Woburn: 781-935-6414 Boston – Walpole: 508-668-2413 West Springfield: 413-827-0244 Michigan Detroit Area: Canton: 734-981-6808 Sterling Heights: 586-268-1919 Grand Rapids: 616-957-9663 Saginaw: 989-249-6662 Minnesota Minneapolis/ Bloomington: 952-884-3634 Missouri St. which promises interesting side For A Free Catalog Or To Find Your Local Woodcraft Store.” featured on the educational The American Woodshop www. Visit R OB COSMAN www. Woodcraft has remained steadfast in our commitment to the beginner. California. Purchase any WoodRiver® Hand Plane. Join Tommy and Eli Cleveland for Season 3. Rough Cut – Woodworking with Tommy Mac. Wednesdays and We are also proud to provide major funding for the two-time Daytime Emmy® Award-nominated public television series.wbgu. Louis/ Maryland Heights: 314-993-0413 New Hampshire Portsmouth/Newington: 603-433-6116 New York Rochester: 585-292-9690 North Carolina Charlotte/Matthews: 704-847-8300 Greensboro: 336-235-0900 Raleigh: 919-781-1911 Ohio Cincinnati: 513-407-8371 Cleveland/Oakwood: 440-232-7979 Columbus: 614-273-0488 Dayton: 937-438-1282 Toledo: 419-389-0560 Oklahoma Oklahoma City: 405-748-8844 Tulsa: 918-384-0100 Oregon Eugene: 541-685-0677 Portland/Tigard: 503-684-1428 Pennsylvania Allentown: 610-351-2966 Harrisburg: 717-939-6770 Philadelphia/ Downingtown: 610-873-5660 South Carolina Greenville: 864-627-8760 Tennessee Johnson City: 423-282-9973 Knoxville: 865-539-9330 Nashville: 615-599-9638 Texas Austin: 512-407-8787 Dallas/Addison: 972-241-0701 Fort Worth: 817-569-0777 Houston: 281-880-0045 South West Houston: 281-988-9449 San Antonio: 210-545-5885 Utah Salt Lake City/ South Jordan: 801-566-5652 Virginia Leesburg: 703-737-7880 Norfolk: 757-466-1166 Richmond: 804-355-3945 Roanoke: 540-366-7144 Springfield: 703-912-6727 Washington Seattle: 206-767-6394 Spokane: 509-892-9663 West Virginia Parkersburg: 304-485-4050 Wisconsin Appleton/Fox Cities: 920-730-9663 Madison: 608-273-8868 Milwaukee/New Berlin: 262-785-6770 20 Woodcraft is privileged to partner with Rob Cosman. and receive a one-month FREE subscription to Rob’s online workshop. supplies and advice to our customers.WorldMags. Look for Tommy’s blog featuring a post called “Over a Aug/Sept 2009WorldMags.” Image of Tommy MacDonald Photo © Anthony Tieuli for WGBH Educational Foundation “YOUR HAND TOOL COACH” www. Woodcraft has been committed to providing quality tools. Since 1928. Recycle and Renew beautiful spaces!!!! Get your Tools Out!!! Join Scott and Suzy to get the most out of your woodshop tools! See new tools. Hand-tool demonstrations are Tuesdays and Thursdays. intermediate and experienced woodworker for over 80 years running. glues and finishes in action. Season 20 re-creates restored furniture accents for every home. and power tools are demonstrated Mondays.

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