thrifty hold- down knobs Turn to the lathe for savings. ‘You can sink alot of money into knobs with threaded studs, such as those used fn the routertable fence shown above. “Why not make them?” we asked our selves the other day when we needed four knobs for project To make your own knobs, stat by mounting @ piece of oak to an auxiliary faceplate, as shown below. Then, using a skew or small gouge, tur the knob to shape and sand smooth, Next, drill ae" hole with a Forster bit, and epoxy.a 17 hexhead bottinco the hole. Before epoxying. check thatthe bolt isthe ‘mating T-nut and thatthe exposed thread will be long enough to zo throvgh the stock and into the T-nut, Our knobs mecsured 2” in diameter.® sgn expLooED VIEW Pi ese bot fee ‘He hole 94" doop, ‘contere in kn Stock Wsiter—”/ Vi rondovers Hormet adhesive Project Desi: Merten Kort Protapaph. Bob Gamer fusuator: Jamie Downing Setter Homes and Gardens® 101Best-Ever Workshop Projects: Song eM KET Peter AF ABEL ten DE SNE Pas er BE PL ove a Pet ae owen ‘eet on OUR Se ei xO ‘ip Je ‘etn CRS MLN Pest ng MAREE USER Cea Cae m4 HEY Poe sm SoS Petter Rt EA ‘esses Ne RS ‘Deas Pre 2207 FOO Soca rent URAL ethyl ann ‘sine pen dey Me 25th at AS Fone USS act Sue as ny nec ST Sanat erg ARE. ISON Pere 2255 OO ae PRST IN Soe Paw fe SR UA Enna ans: Dean, er me oem east c.0 Sete a ‘St qatar Se ep ‘gape vnen eae Sofa enor fee ene are re ms ‘Sentra ots no tine team wa cer 2 A 101 Workshep Projects 2002saw-blade selector Slotted holder keeps your blades in sight and ready. ‘Walk meunt this handy holder near the stationary saws in your shop. or, if you like, place it on a convenient beachiog. You'll find i the ideal storage proj ‘organizing an assortment of sa blades and a dado-blade se, TTormake the notches, eu the side pieces {o shape, and mark the noich locations ‘Then, mount a ¥4" dado blade to your tablesaw tilt the blade 45° from center, ‘nd using your miter gauge with an attached auxiliary wood fence for suppor make the cuts. Prject Desig: James 8, Downing 4 Pretogagny. we. Hopkins usratns: Kin Downs 2 FH. wocd screw for mounting fo wall s _ Vxerbed ae Y plywood sdes EXPLODED VIEW 4 notches —7 su deep PART VIEW “48 AH, wood seis for mounting 4 101 Workshop Projects 2002stay-put Forget scrapwood. Once you try these these easy-to- make pads, you'll want to crank out a pair for every pipe clamp you own. ‘Trying to hold a scrapwood pad in place ‘hile snugging up a pipe clamp can prove nextto impossible, And, the small base on most pipe clamps also makes tem prone to tipping over. Oureasy-i0- make pipe-lamp pads solve both of these annyoing problems. The pads shown here fit a Pony-brand ‘4 pipe clamp, bur you cen adapt the design to fit otter brands and sizes. For a Y& pipe clamp, bore a %" hole, The size, shape, and lecation ofthe retainer notch also may Vay. ‘To start, cut a ¥ed~24" piece of ply- ‘wood, then lay out the shape and hole locations for four pads. where dimen sioned on the pattern below right. Cut the pads to shape, and then drill the holes ‘here marked, Sand or rout a slight round-over on all the edges. Cut the hardboard spacers and retainers to size, attach them with serews as shown, and. you're all set to clamp down on your next project PAD PATTERN Note: Enlarge | 200% to maxe fusing pattem. pipe clamp pads vans te a" shank hole, countereunk hardboard epacor = wen (\ Pre Lezak gen “US Peer Bey 36" roundovers routed botore ettng noiehos 4Yf forstding-read damos Tut for Quehare camps. BAR-CLAMP RACK 12 101 Werkohop Projecto 2002eee “A. EXPLODED VIEW Washer 0x2) Ey Ws reund-over~ amping pressure applic sever utsde edges fora good bond. seeas, ve turn to our locking C-clamps, asa throat depth of over 15". To. on of locking C-clumps, we found this jpport an organizer's dream, } 117 x4 brads LOCKING C-CLAMP SUPPORT 7 All-in-a-row C-clamp rack EXPLODED VIEW Stet shark noe, ‘cunversune on beck sd 1 cowal ‘slong 7s hola 1" dep Qe A #101270 FH Wood we 0s Y ve shankoles (obama) 76° (< ‘Yat hole 1" deop onbboth endo ‘When the job calls for plenty of clamping pressure, no- nonsense C-clamps provide the answer. Te hang and organize this type of clamp, build our four-piese wall- ‘mounted hanger with its notched front support. The notches allow you to hang the clamps on the ruck /— #10 x2" FH. wood screw ‘without having to tighten them ‘outed before eating "shark hele, countersunk C-CLAMP RACK vesracoodonlin.corm 13Ifthere was ever a simpler organizer for hand- screw clamps, we haven't seen it, Just cut the sup- pport extension (A) to fit between the threaded rods of the clamp, chamfer the outside end of the sup- port, and securely mount it to the backboard (B). ‘We've found that about four clamps per supportis | afull load, # | cut Maran Kot Project Desgns: Richard Tollastson; \ SelSontng Janet dowbe \ Pieces ie tone | crane mee Ue | oiaeares ccuntoreuni on back side EXPLODED VIEW { : ve chamfer ee 4 #10 finish (courtarsure) washer 0x20" FH, wood serow — HANDOSCREW-CLAMP ORGANIZER 4 404 Workthop Projects 2002 oe doeeoe 9double-duty clamp/lumber rack Great storage for both! Ve washer {Lamber inventories inthe typical home ssvodworking shop always vary. If you stock up on material to make a big project or a lot of holiday gifts, the stacks of lum- ber on the floor can become a trafic huz- xd. Buti you build « permanent home ve wing nut trea eneaier necpend fr these plans, the space stile when wat cur wood supply is Here's one sohition foldable racks ) shat can keep pipe clamps tucked against ecb ae the wall bt dp fer isan amber ste~ eB ODED YEW Naser sexier 298 when you nved it "With sides of 4" plywood and center blocks of 2x material, these brackets are trong and eay to make, The rea pivot point ots acund a" bot that's placed in the wall stad on if te wal studs ae covered, ina 2 upright LUMBER /CLAMP RACK secured to the top and botem of the wll The serzs of hoes (on 6” centr) in the stud or upright ets you position the brackets ight where you need them, and also provides a ocking bolt location when they're olde The clamp-holding feature requires jut thee Yo" screw oks threaded ito cach corter block, Tey'l hold 4" and ‘pipe clamps, as well as clamp styles wih square or rectangular bars. Find all the needed hardvare at your loal kad ware Tetailer or home center. ve hole ts" washer ea) W hexhead bolt ve wing nt usuators: Roxanne Lomein Photographs: HetRenngton Pnotograpty PART VIEW i ce ai wee law LE Leg Lg Lar — for serew hock wr mocaoniine com 18scrolisaw-b organizer With just a little effort and scrapwood you'll finally have the perfect place for those easly misplaced blades. Scrollsawers know that laying their hands on the right biade can be tricky and time- consuming, especially if these tiny cuting tools get mixed together. This handy litle organizer, designed to separate and store your blades comes from WOOD» maga- vine reader John M. Turok of Coon Rapids, Minnesou. To build it, all you need is smal bit of serop stock and some ¥3'-diameter (54" OLD.) CPVC pipe and caps. For still more convenience, dill few extra holes in a rack top to hold serollsaw tools, such as Allen wrenches, Consider EXPLODED VIEW Paper label labeling the tubes for easy reference. You tgpod'te tte. t can hang the unit on a wall or set iton a fat surface near your serolisaw pei inte % boron! CVE hob Iuswaton: Jame Downing Photegraan. Wns Hepline [Hote sized to op ecrotcaw too! uc SO tu Su toes sens esac cane ac sae totam eavoaree “test ae #8x2" FH. 19.1 FH wood ocow — ead sre ‘listo ek, os ve deep yy 7 bentone te eye he same es cane | Sue Bis" shank hole, Bete pret ip ae ieee SUA 16 40% Workshop Projects 2002‘Meke this fabulous little storage unit with common cove moldings available at any home center. Tired of constantly fussing around with your scsollsaw blades? With this clever helper made ‘Som commen cove moldings, you can easily remieve blades by reaching in with a finger and jwceping the blades up along the eurved edge of exh hollow. To baiid the drawer, glue and clamp the cove ‘ogether. Then, serew the guides under- seath your bench or srollsaw stand. A sting seeps the drawer from sliding out too far, and a ‘rad nailed to one guide stops the drawer flu ‘vi the front of the bench. ® eet Design: James R. owning = togrpn, Hopeis Associates “svaon Roxanne LeMiine Fagtan to undersda of mounting surace fo provent drawar rom pulling outcompetely. EXPLODED VIEW PS eee | sworn mocdenine.com 7workbench tool crib Keep. power tools out of sight and out of the i way, yet rignt at hand when you want them, with this easy-to-make workstation helper. END DETAIL ‘To stores tols cose at Hand, reader Donovan Nagel of “Madison, Wisconsin, designed and built this flip-down tool crib that neatly secures in place beneath the benchiop. He sores power ts in it but you can use ito suit your needs. ‘Simply build the exib as shown to fit between the logs of your ‘workbench. Fasten it in place with twos” cariage bolts, To put your crib into action, simply pull on the handle cutout and swing it out A pair of stops srowed to the bottom of your workbench help prevent the eri from ever falling {0 far forward or backward, ‘Asan added feature, cuta hole in the back piece and install a ‘multiple out in the ‘00h crib EXPLODED VIEW Note: A stocks 3" plywood ‘excep! stonblotks. mmulteoutet Powertip “1 hale fer cor Wate FH, ‘wood cereus 4 groves it Siiomtovom eae Ser reppel i deep Pre! Design: Donovan Nagel Tuan: Kim Deora 18 ‘101 Workshop Projets. 2002simple saw rack Heng up your: up your saws safely aaa reacily at hand. Test eee poor ancaws en pep- east feos cx worse, mails? Iso, dress Soe Sep with this sturdy maple Sssssse= Asdimensioned on the draw eee Se 19 thick spacers between {Se epee fee rezulerhandsaws and 36 Sees forhicksaws. Thea, we s@es Se mp between the ends and on top Se sport stp. For safety, hang all of soe ses wth the tee Facing the wall ® SSS ate Downing: Mike Henny ‘he! shank hole, ‘countersunk tex2 Fi, EXPLODED VIEW ie pilot holes 114" der ue e 0 ‘ee shark noe, ey ( #83" FH. wed stow ‘et shank hole, ‘or drywall sevew “courtorourk| 19ready wrench rack Hang ’em up and keep ’em handy! We built cur racks to handsomely hold 16-pcce ("to 1%") Stanley combination wrench set As desenbed betow and onthe Notch det you may need wo change afew dimensions for your puter set. A, depending upon how mach space you have fr banging your wrenches ‘you may vant to place the racks end to-end, as shown at righ. or ang ne rack under the ote: ‘Note In or research, we discovered hat several marafecters offer lghl deren wrench designs and ell ses containing varingrum- bers wrenches. For this reason, she size and numberof epenings in the racks you me may reed to difer fram the ones shown here “ottild the racks, cu the ont and hack pieces to size. Measure the di shane ne, ‘width (A) of each wrench, and lay out the comesponding dadoes to ths: ee Holitha stan os bol one arene Tee agact be eZ dade inthe bck piece wl eth width ofthe wrench (A) plus. ‘Now, measure the thickess(B) of each wrench, and et the dadoes Wo this dept plus" on he fon face ofthe back pies. Gi the pieces toetr, and then cutaway the waste (Shaded acs) fom the from pees, wheteshown 14 4" onthe dravings ® Weste s1ox20' FH, wood sera ay shank hoe, ‘countersunk NOTCH DETAIL, het shank hol, ‘saunter EXPLODED VIEW shes tta tu ee ‘4c! shank hoe, ve ‘countersunk HOx2u EM, ‘wood eoron Projet Desir: cae atson Ioseators: Jamie Downing Photeoreph Hopkins Assocites 20top-notch chisel rack ‘You won't need much time or materials to make our practical wall-mounted holder. Smctimes, the best ideas are also the simplest. For this handy lit Se shop project, we went to our scrap pile for the material and covesied about a half hour of shop time, Now, we have a top-notch sack for our chisel set Note: All siook is 4" thick, Hole sizes may vary with diferent brands of cists. ® #8 iish (countersunk) washer 483.108" FH. wood seraw TE at res web gem Been Ce 14" round-overs on _7 es he only 7 i 6 Bis ee Fe ey iris: a All holes (except for the far let one) 4 fe dismetee Hol Sige maya) Ne Sit dterentbrand of cess EXPLODED VIEW Project Desir: Raymond Pusell Photograph Hopkins Assosites puswaters: Ki Downing acustomized chisel rack Keep sharpened chisels safe and sound and easy to find when you need one. ‘Note: We built our rack fora set of Stanley no, 60 chisels. The dimensions tight vary slightly jor your chisel set. a ‘You can use this pracicl ack as a ioe- standing unit, or remove the feet an fas- ten it your workshop wall. Eber way, this project displays your ehisels proudly : and protects ther finely honed edes ® neal eiae ‘62 share hele, ‘councereure ‘ WALL-MOUNTED CHISEL RACK et ch CHAMFER DETAIL EXPLODED VIEWS Parts © through @) Project Desig: Richaré Bakar, top kes, Texas . Masato’ mle Downing: Roxanne Latiine was Photograph John Hetherngton 9 chamfer 54" shank hole, ‘Seuntarounk en Gorter hoe Inslce 0309. Dri Be LS wexren woodesen 22 101 Workshep Projects 2002stay-put tool holde: Our Peg Board rack keeps tools ready for work. WWall-mounted perforated hardboard pro ses heal wel storage—a long as you cas gt the hanger “pegs” to stay put Faced with that challenge, we designed ool oer that itech firmly, but takes cely a minute oF two to move to a new, ‘sere convenient location on the perforat- oo hardboard. ‘To make the pliers holder, mark slots ‘shere shown on the drawing at right, and snl 4" holes at each end of the marked Joes, Dall slightly over-lapping holes to remove the stock between the end boles, snd smooth up the sides of the slots with MULT: PURPOSE HANGER Yio x2" aluminum bar eck ‘chin Then ata the wogghtstesl—afneadied— Sy eased | deskop fastener (Par ro. 866226, aval- 2 he ones us txoe re een ee : ene SONGIS29) wth deg shown, ve ms ‘The 50 handserew-clamp holder, - - A “own right tp, mounts the prt i hoead haat amen ‘led hardboard with «shor lengh of - woodasren Zc alum ba tock and 0 hex- tal hea stil eve lag courant luandscrew clamps, make ihe wooden block longer, and wider By using varying lengths of allhread rod, you can create mul-purpose hangers ot hole ‘weep. EXPLODED VIEWS, for bar clamps ce individual tls, such as te adjustable wrenches in the photo- SEE PUERS H graph. We dipped the all-thvead rd in Pos a VOTES plastic coating for protection from sharp ee 16 edges and to provide a no-slip surface 10 keep tools in place. Pee wood screw a Note: When you install the mounting & screws tn the perforated hardboard, just snug them up: over tightening will easily =, ‘ Wireugh coo! stip out the holes in the hardboard. Seki amore ee eae witha oe pot no we +"'ceep centered insice Project Design: James Downing Iuaranons Roxane LeMoine Prosrrank Bi Hopka mm moederiing con 29cutoff catchall This upright organizer gives you a place to put the stock that might otherwise be fost or tossed. Designed to hold entoffs and other short pieces upright, this handy organizer Allows you to seo ata glance what stock ‘you have available, And its wall-mngging profile takes good advantage of limited shop space. oc A fier SPS 3 botom ¥ or Oe PT bak i a D kot or ew Eon wa ee F ie OW 8 Cin ow laterals Ker P-sjpo0d E-Bec Project Desir: ele Alison EXPLODED VIEW 28 ‘Yt ahankholeg countersunk fom bask le 401 Workshop Projects 20023-ring binder drilling jig Seady to store your WOOD magazines n an easy-to-find location? Prepare them for a three-ring binder with this handy drilling jig. Rip, then erosscu the drill guide (A), ‘nase (B), and cleats (C) to size. (Clamp one cleat each end ofthe base. Then, glue and screw the cleats sothe base. (We used a dril/countersink 0 pre-bore the screw holes.) Mark the location ofthe dil guide Fnoles and those forthe dowel pins 1D) on part A. (See the drawing at right oc cone positioning.) Now, clamp parts Ato the B/C assembly and dail the oles through both part and the base, Place a piece of serapweod bencath the bese when drilling t0 prevent chipping.) Cut the walnut pins (D) to length and chamfer one end of each. Glue the pis into the Vs" holes ia the base. Using 2%" i enlarge the 14° holes in A for an easier fit of te pins through the guide. (Test the ft by sliding the guide ento the dowels; sand if necessary. Finish-sand all the parts and apply a polyurethane or lacquer finish. (When spplying the finish, try {0 keep it out of the drilled holes.) Apply wax tothe pins | oe smoother fit ino the guide ® Socata ~“ CUTTING DIAGRAM Ast guide: ow soe ‘Mx Bex 36" Maple: Boa ar eM = SSeS a ew Sate — oer (eae aaa oo Dug: Raymond A Btebstein suppl: 10 ae word som) ‘sralons Roxane Looe pohwebane race sh, wax, wrmwoodontine.com EXPLODED VIEWrouter-bit orage it's as easy as 1-2- Most router bit storage systems force you to guess how many bts you'll ado your arsenal inthe coming year, WOODe ‘magazine's Dave Campbell neatly side stepped that dilemma by designing this modular sorage system that fits in any drawer and ecsily grows io mest your expanding bit collection. A. 1-2-3 progres- sion of block sizes maximizes the number of possible arrangements. Dave set aside one large square, an dil ito hold rexary-toc bit ‘To build your moder storage, rip 32" MDF (medium density fiverboard into 14,24", and 39-wide strips then rosscut them into squares. Drill centered, slightly oversized holes for easy bit removal Zand [3mm holes for "= anid 4"-shank router bts, and 76" and Ya" oles for ¥"- and 14"shank high- speed rotary tol bis. EXPLODED VIEW Sex2AxZH MOF Ye chamfer along op edges \ S&S 9x9 MOF Dri blocke with ether ea Samm noes = (ore shanks) or Secnoles (ior "shan block aes 10 ra nigh-speed ard spacers customize tf, and io trays for urenches, boarines, ander accessories. ‘To add voreatilty to thie eyster, simply bore hholes into the mocuie(s) of your choice and glue In craft magnets. They hold small steel parts just ‘reat Our thanks f0 Jeff Hilton of Mission Viejo, California, for sonding inthis tip. Note: Finding a *%¢" bit ro dril the ‘oversized holes for V2" shanks is nearly impossible. Commonly used to install metric hardware, a 13am bit is « readily ‘aveilable substitute, Slightly countersink the holes’ edges. CChamfer the blocks’ top edges on your table-mounted router. Hold the pats with a padded jointer pushblock to keep your fingers safely away from the router bit, Pour some Danish ol-type finish inio-a small container and dip the blocks. After ‘wiping off the excess finish with a rag, dry the blocks on a window sereen propped on sawhorses. ‘With the finish dry, arrange the blocks in your drawer. Fill inthe ext space in the drawer with smug-fitting pieces of 1" hardboard. You can use these tray-like spoces for storing accessories. eit by Robot Sten Prose! Design Dave Campbell stration Rexaane LaMoine Loma Johneoa Photograph: Douglas . Sith ‘101 Viorkshop Projects 2002center Two simple projects, one great idea: Give the notes or papers you need 2 place to be stored, then studied. sference material close at hand with this 1wo-project Simply swing the table up when you need to take afew or consult reference material. When you're not using it, slaps the brackets and the table folds back agains the wall cnet, with ts drop-down door, provides necessary sior- ‘or books, magazines, (001 catalogs, and other shop-related +s, Fitthe table with an inexpensive stool, and you've ere- ec comfortable workstation. EXPLODED VIEW jj abbot doep around allodgoe a jrorewve Bask s4rdado _Sellcbosing hinge SN SEES ctor Moodtoning catalog #1115516" tppar Spe? door ofdo and #40361 hingo \ ax 194x314 plywood pve trax 137" mape ae 2 plywood: SE Geer wxsix tye maple “Ye 4x 36° maple — 4 34124" maple © deep on bntom sie for ‘mounting bracest pow ‘positon muttuse oracket (Beckter Woedwerkang cataon #24893) 49 1¥6%98" maple #82 FH. wood Soren, 10 secure. Drackét fo stun wall fi usratjon: Roxanne Lattone Photo: Bill Hopkins neem oroedoniine.2om 275 super shop organizers if you're like us, you don’t like hunting around for your tools when you could be working on a project. With our five convenient shop organizers, you'll spend less time cursing and more time working! 4. Super-smooth sander/sand- paper cabinet, pave 28. 2. Wall-hung board for router ‘and accessories, page 0. A 3. Under-and-over table clamp storage combo, 2 4. Lathe tool and accessory board, p: 5. Three-compartment cabinet for drill bits, page 33,roma sheet of 2" particleboard, lay ‘out and cut parts A through 10 fin- ished size. (We cut E and F to size plus 2 in length to allow for ease in bevel cating these pieees later.) Bevel-cut the front end of the shelves, E,F) forthe two sanders o 2 60° angle; the back end to a 30° angle, Cut dadoes in the shelf dividers (D) and ‘inside the righ-Hand side (C), where shown on the drawing. Glue and screw the back (A), botiom (B). and sides (C) together. Then, lve and serew the cleats U, K) and the slanted shelves (E,F) in position. Drill ‘two holes in the back for screws or wall anchors, according to wall-stud spacing, LLoote-fit the shelf dividers (D) and shelves (G, H), starting with the le- EXPLODED VIEW pth << Sh sv roedenine.2om “rex tt FH. wood screw All-in-One Sander Cabinet You'll spend less time gritting your teeth and more time sanding when you store ‘everything you need-sanders, sandpaper, ‘and sanding belts-in one convenient wall-hung cabinet, The cabinet accom -modates a portable belt sander and 2 palm-grip sander. hand divider and working toward the right-hand one. As you slide in the center and right-hand shelves (H),glve in the false back () foreach shelf, where shown ‘on the drawing. ‘Glue and screw the top (B) on the cabinet Sand all edges flush. Mask ‘ff the pine cleats, them paint all exposed surfaces to the desired color. Cu te pine tuim strips (L. M. N. Q) 10 finished size. Finish all the pine pisces with polyurethane or other clear finish. Attach the trim strips tothe cabinet face. Attach ‘cup hooks for elecrical cords. Finally, hang the cabinet. 8x 11 FH, woed serew 1 Mounting“ (owe \| SStexiwrnt ‘wood serews Mall Oty. canny wi “ ¥ Mam ca Nem we Om me “Gat hese paces rez, Fen bevel e fl brats, Meters x Seppe: 861 cap ros eur, PS-pstcetoud, F-pne, boas word ses, tas 1" pan wal anchors Sr fal 2 hole, countersunk (eae Weer od sero st hoe, | countersunk 28Time-Trimming Router Organizer ‘When you want to use your router, you don’t want fo vaste time routing through Paint the mounting board the desired drawers and toolboxes for ronter bits, color. Afier the paint dries, ail the ‘wrenches, and other accessories, This com trim strips to the edge ofthe board. ppact, wall-mounted organizer keeps every= Apply clear polyurethane or varnish to ‘thing you need, including your router, in the pine trim pices, dowels, and bit orga plain ight. nizer. Glue the dowe's into the boar, and attach the cup hooks and bit organizer to the board [Seeman oem. orn. 260 mm aps BO. ‘Moat the board to the wall with ished size shown inthe Materials finished lengths. To make the bit __serews, making sure to align the boards Lay the board on fiat surface, and posi- shelf (D), cut two pieces of 14" stock ‘mounting holes with the wall sus. tom the accessories you want fo hang on slightly oversize an laminate them. the board. The drawing below shows the together, Face to faze, with woodworkers dowel sizes and locations fer typical ‘glue. When the glue has dried, cut the accessories-wrenches, router edge guide, piece to finished length and width, bevel- ‘and one or more trammel bases for cut- ing the back edge to a 30° angle, where ting circles. Once you've established shown on the drawing below. Radius the locations for your accessories, drill %8°- front corners and rout a ¥" round-over on deep holes in the board for the dowels all edges except the back. and cut the dowels to length. To make thes) Lay out and drill shank holes inthe 15° hole for the router dowel, use an bitorganizer for your router bits. YOU aninaled om Apes fH phe adjustable dill guide, or make a ray want to leave extm space onthe bit aes Ke PE-saricetnad, Pe, 15-angle drilling gue similarto the 30° organizer fr future acquisitions. Our supa: cup ha ihm #1024 fa ‘Quide shown on page 31 ‘organizer holds 24 bts of various sizes. pe woot sree," cowel i owe dove. Se" shank hoa, countersunk en beck Ye" hole, countersunk. fexie RH, HOx2% FH. <__ wood screw Tee _—— Dowel for wrenches ‘Space holes according to -“® dowels ‘bs you rave. ee at 15° ange (for ruten) swt tep and botiom — 118" cup nook ‘ie! bole, countersunk EXPLODED VIEWClamp-Rack Combo Where's the best place to hang your clamps? Right where you use them—at the clamping ‘bench. The overhead rack easily holds several zen small clamps of any type. You ean hang your longer bar clamps and pipe clamps directly on the bench itself for conve nent, easy access. ‘Cut the Det forthe overhead rack to the desired engin (We cut ous sight ly shorter than the length of the work- Seach) Then dil oles forthe two 1" soreaded hanger rds, where shown on she dawing Ifyou want to hang the ack xossvie (0 the joists just the length ofthe 2x¢ and/or rod-hoke lations 10 comrespondl with jist spacing. Os, you nail suppor block between the joists snd suspend rods from them. Use the acksaw to cut the threaded ods to length thet wil position the rack about 6” lower than te fina antici- pated height Attach the thresded ro to the Dut rack, then ceiling joists, using the fasteners specified on the dawn. : Hang a few clamps on the rack, and ve at washer then adjust the rack 1 a convenient ve nut height. (We posttioned oar rack about 35° hove the table surface so taller projec, such asa stool in the photo en pe 28, ‘would fitundemeath it) Cut off the rod cds extending beneath the 2x4, el 11930" ANGLE DRILL GUIDE hanger bot Bench pegs and rack Dill the 30°-angled heles forthe pegs, using an adjustable drill guide or the homemade drill guide, shown on Drawing 1B, Space the holes 4" apart. Cut Det rack to the desired length ‘Tomake the notches, use 114" hole sow or drill bit, and cut the oles 1/2" ccener to center: then complete eutout ‘with a handsaw. Attach the rack to the bench, where shown on Drawing 1. Supplies: 2h "lag serews 4" tong (2), 14 threaded rod, "nuts and washers, 14" 2% gow orleng ize ‘hanger bolts, "couplers, ¥" dowel stock. eer Sor “wenrw.woodonline.com ‘%4" hole 1* deep, diilled at 0° angle 7Lathe Tool Board Your lathework will fake a turn for the better when, you can quickly grab needed tools and accessories from {his convenient lathe-tool board. Paint te board the desived cofor and let dry. Then lay the board flat and position the too! holder, magnet support, and accessory holders, Position your tum- Cut the mounting board (A), tool ing accessories on the open area. Mark holder (B), magnet support (C).and and dri dowel holes 36" deep to hang Slanged accessory holders (D) to size, these items, and cut dowels to length bevel-ipping the font edge of Cat 10° Nail the trim pieces (E,F) tthe sciustereipeareon Dats Ca hoard. Apay payuciane w rin trim pieces (E, F)10 size. except the front edge of he magnet sup- a . clk a TET, erat nd (B) "lrg in diameter than the Sip. available at erafts supply stores. to. Fialemagrte st. butt of your late-too! handles. Next, dill the foot ofthe magaete support -deep hoes in the accessory holders (D) for your ciculer sanding attachments and ive 2nters. Drill boles the same diameter asthe shanks of your acces- } sores. Radius the front comers ofthe {ool holder and accessory holders, and | rout a4" ound-over along al egos | except the back } (Crslarsander holder Live-conterhelder encen ees Sid alae au Lome See atc aa ‘Ue holes sized and spaced according toxin toeze of tuning tool handles "wood screw we Ac44 sh nal ‘i reund-over‘This swing-out wall cabinet holds a surprising ‘number of assorted drill bits and accessories. To ‘make i, you frst assemble the box, then rip-cut it into three separate sections, Rip and crossout apiece of 3" pine 6 ¥eS2’. From it cut two pieces 716° song (A) and two pieces 174" long (B). Rabbet the ends ofthe wo longer picees, ‘where indicated onthe Basic-Box draw- ing below. Glue and clamp the ‘op and betom ees (A) to the two sie pieces (8) to fom the fame. Now, ut the plywood sides (C), then atach them tothe frame ‘After the glue dries, use your table- saw and ip fence trip the frame into three sections to the widths shown in the Exploded View drawing. Cut shelves (D, E,F) 0 finished size Drill hoes in the shelves and sections 1 ang 3 for ceil its. ’, fl me Section 1 1 g. hinge ook _-BASIC BOX Glue and nail the shelves to the fame sections where shown cn the draw ing. Aitach the cleats (6) to the bottom of section 2. Connect the frame with hinges. Cattwo pieces of %" pine 1/34" then laminate to form a piece 12" ‘hick. From this, cut the mounting bracket pieces (HI) to finished size, Rabbet both ends of [and one end of H. ‘Assemble the backet pieces with lie and reinforcing dowels, then radius the ends and corners Drill holes in the bracket upright for wood serews oF wall anchors. Dail piv holes inthe mounting ‘racket and in Setion 2 forthe dowel pivot pins. Ct the botom pivot pin to length and glue it into the bracket, CCutthe removable tp pinto length and EXPLODED VIEW pa he Ye hole ¥ deo Section? vy Ree Whele 1 doop a“ ‘ale the wooden bal to it. Mount the bracket tothe wall and the cabinet to the Drackeu® Nateras Koy PW-ppoos Pr. ‘Sap: rads ns nas done ‘oder tll pars ofl sures ces. stows fermearing teva hokandaye cy, pojroane e aia deep imo a 38 dowel 214" tg +1 ratbat ve dep Rew Whole ‘aplain-handy plane holder With just a little time and some scrapwood, take storage for an essential tool to a higher plane. Like all precision tools in te shop, your planes need and deserve safe, sturdy storage. Consider this adap abl wall-hung organizer the answer, regardless of ‘hich size planes you may own. Using the sign shown andthe construction notes Blow, you can build these hokers fromm serapwoodl. Then secure them to your shop wal. o oa piece of plywood tached to the wall. We incladed a dado inthe base (Ato prowet the plane Blase fem damage. Polect Dosen: Kevin Haliman Photooraok: Win. Hopkins isvaion Jame Downing aaa Zs ye" expLoveD view | 16" dado peetacdusase wox26" FH wood screw —_ i plothole vi coop ex ive ee wood Seren Construction Notos Sunesure Length of (A) equals langth of plane plus v4 1 platle Length of (B) equals length of (A) plus 172" foresee, Width of (A) and (C) equals width of plane plus 1". Locate the dado in (A) undar the plane blade. 34 104 Workshop Projecte 2002level lathe tool rack with the look of a fine gun rack, this storage unit keeps long-handled turning tools in a secure horizontal display. tuandied tools can be cumbersome, especialy your try ta store them in vertical rcks. Asan anve to vertical storage, this wal-hung orga- sizer maces infinite sense, [¢ even features tray at bottom to hold your suming accessories. Get crssnized, while prowecting, your too investment, this casy-to-make unit&® EXPLODED VIEW ewe mvodontine.com NaN het tial} the width ofthe entire rack.poe glue caddy ieiorhp iota Here's a great way to start—make a holder for your supplies. qcnvenes pine 1%12) 10 1 have stock this wide, laminate narrower pieces together. Find the center of one ofthe squares by marking diagonals. Mark a iameter crcl atthe center, Stick the two squaves together, ‘marked circle up, with double-facea tape, Cat the diss to shape. Arrange your glue botles and acees- sories on top of the discs. Trace around each container. (We added 35-1nm film canisters for holding coiton swabs, brushes, and other items used to apply glue into those hard-o-get-at places. We also included a foam cup for soaking the glue brushes after each use.) ‘To prevent eriling into your érill- ‘ress table, mount a pice of serap ‘material to it. Drill a4" hole through the center of both discs. Then, if you plan on using the film eanisters, as shown in 10 38. Holes sized ait your ole container hole Ve deep We used a circle cutter for cutting the larger-dlemeter hoves, Photo A, switch bits, and drill 1¥4" holes {through the frst disc and 2" deep into the second (We used a Forstner bit) Separate the dises, and remove the tape ‘With the 1/« bt stil chucked to ‘your dail press dil holes through the top dise for additional film canisters Now, using a circle cutter or holesaw bore the ler oles, as shown in Photo B. Bore through the top dise and just a fraction into the scrap top mounted to ‘your dill-press tabi, Sand both dises and the openings smooth ishing up Cuta pice of 3" dowel stoke LIV" long forthe handle Slide the top disk ono the 4" dowel, and poston is top face 710" sehen | 24" dowel 11% lona Ye x 10"-dameter discs _2—Slightround-over voc isam, ‘wood knoe EXPLODED ‘VIEW 1 hole 6 doe Toefl eanistor dwn from the top end of the dowel Marthe position of the dis Lop and Dottom) on the dowel. Side the dsc away from the marked area, and apply glue between the marked lines onthe dowel. Now, side the disc bac onto the slved aca tm it upside down, and un a smal i bead of glue cround the dowel below the top disc. Later, ater the tp isis firmly alued in place, lue the dovel ino the hole i the base dsc, aligning the holes in the disc. Mask a 1/2" cite on a piece of "sto fer the knob Bore a" hole 18" deep at the centerpoint. Cut the knob to shape on a bandsaw, sand smoot, and glue it10 the top end of the dowel. Finally, apply clear finish to all the puts Project Desa: sim Boating Protogaohs: Bob Calmer Iusvator Roxanne LeNoine 101 Workshop Projects 2002around your shop? Solve the problem with our wall-mounted holder. Drumshatts fit in holes in the top, while sleeves fit below. [4a ris nit "shank noe, court sex2 FH wood screw pattioned on Lay out roles tot Ho htsues your drum senders, | ote 4" rabbet i" deen - . em #8116 FH. wood sore Use a %2" stenk toe a ‘it gioove Vigogen end a %x pilothoe in @)- Ny EXPLODED VIEW meses ery Cathe back (A), storage box tops Giuo and clamp the drawer together, and bottom (B), and dividers (C)t0 checking for square. Drill hole size. Laminate the wo top pieces. Lay through the rawer fron: attach a knob. cut and dil 1"-doop holes in the top Cut tim pices (H, 1 size; elue and house the shanks of your drum sanders rail ther to the back (A), Glue and clamp he storage box Glue and clamp the storage box to the together. Dri shank end pilot holes, "OP back pie, Dil shank and pilot holes and drive the screws from the ck side ofthe ack piece into Cut the drawer front (D), sides (E), the back ofthe box, and serew the bck 10 back (F), and bottom (G)tosize. the box Cut or ruta i" groove 1" deep 3" Mesh off the trim pices and paint the 3 fiom the botom inte drawer from and storage box and back. Remove the Seppe: aad wed sens, 12 ft sides, Cut a)" dado 14" deep 114" from masking ape and apply a clea finish 10 patomnetm™ worsen ac. 4 inshrals, mask ita at. the hack edge of each side. Finally, cuta the trim and drawer. rate eno ck Pele Ds: a Lava 13 abet 4" deep along both ends of Drill mounting nls though the back Pee aio: Ba ova the fiont piece pico, and fasten the wit toa wal facie none Lateoe ‘wwe woedontine.com 37grab-it-and-go glue tote Don't let your glue bottles get scattered i around your shop. Store them in this easy- to-make mobile home for easy transport. your shop gets too cold to store ghie safely during the winter, this handy glue {ote allows you to haa ahaldozen bot- tles between the shop and the honse wit ‘one hand, You can build this project with the box joints shown in the photograph or rabbet the comers. Ifyou choose the box= joint option, you'l need to change the length ofthe bottom (D) to 12" andthe length of the handle (F) to 1334" For the two sides and two handles of the box, photocopy the pattems, skowa ‘on page 30% BOX JOINT oN EXPLODED VIEW 4 dowel Aas" long an Bu ve dowel I) long 3a" grooves, 340 doen ye Kombonon See 38ie hole ‘4 hole 36" daep on ince taco HANDLE SUPPORT. (2needed) GLUE TOTE FULL-SIZE PATTERNShose/cord holder Build our simple solution to everyday entanglements. ‘Shop-vocuum hoses have a way of unwinding on their own, creating a haz- ard underfoot. To keep yours in cheek, build our hose holder. When you install ‘the mounting screws in the perforated hardboard, just stu them up because overtightening will easily sip out the | holes. You can use it to wind up messy cords as well Project sige: Sry Roberts Protoyaph. Bil Hopkins Iicatons: Roxanne LeMoine | 7 (geanc END VIEW “+; pestoard hoes) =— DETAIL Yperion nat ntl enw —. HBA wot oom eee 5 Hone 4 y atitop wer fetorar 4 cosnbtbere deep wth Mia onrednee y ) ann / 48x11 FH, wood serous — Tabletop fstonar oe ~ 3.0) VC pipe vertickgoce OF ena sank tes conte r 2, $8116 FH, wood screw 7/3" pilot hole 116" deep EXPLODED VIEW Rete ~— Retainer board 4101 Vlorkshop Projects, 2002organizer 2ep your drill and accessories thin arm's reach in one handy wall-mounted unit. our cordless drill, charger, and bits close bandwithout sacrificing valuable work space this wall-hung rack. ull es shown helow. To fasten the charger she top shelf, remove the screws securing the eto the charger ease and replace them with ones of the same diameter Prctaraph: Hopkins Assactates “Sirtors: La Joann EXPLODED VIEW wines Soa es <7 , x iN oe we Holes to screwarver its, ete aBirds of feather work wonders together. In this case, we're talking about a feather board system, including a fence anti-lift mechanism that gives you additional stock control and safety. When working with your tablesaw, you'll appreciate the additional stock control and safety provided by this simple feather board system, Build a pair of feather board assemblies using the drawing on the opposite page as ‘and attach the mini-channel to ounting rail (which you may need to ‘modify slightly to suit your fence). ‘Align the mounting rail lush with your fence's face. Then, dill pilot holes inthe ral where shown, and mark their loca tions on the top of the fence. Drill and top anole to accept a #10-32 machine screw teach mask, then attach the rail assem- bly to the fence 1¢ locks down atthe back of lift assembly shown in the drawings However, a fence that locks orly atthe front will aise at the rear without this Fully adjustable feather boards ee een Ly 4101 Workshop Projects 20022 ole Sp" canteredon block abot 2e x2¥" cago cut at FEATHER BOARD HOLDER DETAIL| fie oid a ai Yox23Shardwo3e RABBET DETAIL ti hole | MO-Se xe DOWEL END VIEW ¥ dowel st (i chamieron enc) EXPLODED VIEW VF rabbet 2" a2ep. mechanism. To cut the 20° rabbet, rip the dowel 2" down its cemer. Lay the dewvel on your deill-press table, oriented as shown in the Rabbet detail drawing, sand bore the 6" hale to accept the tivesded rod. Buying Guide Hardware, Knobs, squate-head channel- bolts, and mini-channel fr a par of feath- xboard, Kit no, TS-FB, $1695 ppd. in veomvmsedontine.com on itee | FA-machine sew ——- ee 2fon yy 2 MOUNTING RAL 4" el to forwloae stron __-39° nate 7a rom end ~~ (anil ata 20rangle to rabbet) 4¥" dowel 3" long (ie chamfer on anes) ANTI-LIFT MQUNTING DETAIL 24e stp. US. Schlabaugh and Sons me: Woodworking, 720 Idih St, Iw" Ret weshers| Kalona, IA $2247. Call $00/346- 9603 10 order. Propet Design James R. Downing: — fy top roc Dei Sam Ha; stop nets svar Ravanne LeMone Patograph: Steve Ural 43master of angles Put the squeeze on odd shapes ave you ever stuggled to clamp a tapered projet part, sch a a tiagular pediment on top of frame or plage? Our wedge-shaped jig and auxiliary vise jaws can help because the vertical dowel in the comer of the wedge pivots inthe groves, With hs clamp you can pt the eqeze on avanety of angles. Tomah the auiary jaw liners, cut wo pieces of thie hardwood equ in ent and width to your vse js. Then, puts 4"-radus roundno it ino Your tble- rmousted router Rou thee equally spaced proves across the with of th jaw liners and two grooves lor the length (Of the jaws. Ceater the lengthwise grooves 1” from the top and botom ofthe jaw liners Now, sue the liner tthe jaws. Consruc the wedge hy cuting several pieces of sock using the guidelines in the Wedge dtl, below, for sie. Clue up suficont tock to make the depth of he wedge ext the wit ofthe jew Tiers. Rott the grove inthe 0° comer ofthe wedge as Shown, and fase the dowel Wiaintott ‘with glue and brads. Finally, give the wedge some grigping ‘ ower by alin a piece of ahexive-backed 100-g sand- per tos longest face ® WEDGE DETAIL (C8 dowel 4 ora + Length tft ‘Ausilary Jawiiner EXPLODED ‘VIEW \ Api achesive- SEB Seno tots face, ee vise lew ~ grooves Ye doenlong-reach clamp extensions Nieed added pressure? These provide it Stationary neae oa EXPLODED VIEW = slike that shown below ze clamping pressure father in from se edge than sliding-hend clamps provide ese hardworking extensions solve the sublem. (We've used them on Jorgensen ing-beadLtype steel bar clamps and ie eanesra be CAE Simply cut 2 pair ofthe extensions 10 ape from |"ssquae stock (we laminate 4 two pieces of 34" maple), using ou fll- Sze pattern, Pop the bar pin out of the end # your clamps bar. Then, drill and cut a sl in each extension soi slides smoothly, but fits snugly onthe br Pur the extensions on the bar in the con- figuration shown on the drawing at right Mark the location of the swivel on its mat~ ing extension. Remove that extension from Sf tne bar, and drill a%4'-deep hole ¥ ¢ Sate 7 Janger than the diameter ofthe swivel- head clamp end where marked. ” As shown in the photo at right, position tne Siding head next the extension when roving the 10 back and forth on the bar If you leave a gap between them, they tend wo bind and are harder to move in unison, Drilling the hole forthe swivel inthe extension allows you t sii the extension ‘lush agains the metal head. ceep hole ‘Yee larger nan the lametar of the svivel Project Desion: Mike Sarmes, alvin, Michigan: Chaves L Hediund Isto: Roxana Cetaing Protacrote: Dean Tannor FULL-SIZE CLAMP EXTENDER, PATTERN (@ needed) 45You're not likely to misplace this shop heirloom. Use if for measuring dadoes, mortises, and other recesses where precision is critical, inut body Cata piece of %'-thick walnut stock {0 134.6" for the body. Make a photocopy of the Full-Size Body Pattern. Using spray adhesive, adhere the paper patiem to the walnut (You could transfer the pattern directly to ‘the walnut with carbon paper.) Mark a centerpoint on the top edge of the walnut directly above and aligned with the 3 hole centerpoint. (See Photo A for reference.) Drill a3” hole 4° deep imto the face ofthe body at the center point ‘Thread the %" cap onto the 34" nipple as far as it will tread. (See the Buying Guide for our hardware sours) ‘As shown in the Photo B, clamp the cap into a handserew clamp, and file the exposed nipple threads. (We used a dowet to hold the nipple stationary when fling.) File the threads until the nipple slides eas ily into the hole in the walnut. Hold the nipple (cap still threaded on) witha pair of pliers, and rotate the 6 cap 2 tums counterclockwise. Push the nipple snd cap ino the 4" hole in the ‘walnut, Drill a %2" hole through the assembly, as shown in Photo B. Remove the nipple and cap from the ‘walaut body. Retain the paper pattern. ‘Secure the cap, and file nipple threads ‘or easy Insertion nto the walnut body. Add the brass base Crosseut a piece of Vio" brass 106” long. Use double-faced tape to adhere brass to the bottom of the body. Using the screw-hole location lines on the pattern, 401 Workshop Projecte 20026 hole +4 coop / 2: and countersink Yi’ holes 7 TL de routioese 3 Hethorington Photography ‘ihstaions: Roxanne teMoine %e hates 1 doap cov orm 10.28 nexead mactne screw ama eune a W covet Fol penal 46 thigh nal cippas to retusa —] ve seuntertore Mz tha bettors ea cw | meine {Sharpenegte spor “ ver ving ot i $e" Cortred insice elec i af , EXPLODED VIEW END SECTION VIEW DETAIL 48 101 Workshop Prajects 2002economi dial-indicator Al ion jointer knives accurately with a simple magnetic jig. ‘You don’t need a fancy dial-indicator gauge to set the .ves on your jointer; you simply wan them set to ‘Se same height as the outfeed table. So, rather than ying an expensive gauge to do the job, WOOD sgazine reader Jim Murphy of Morgantown, West ‘Virginia. designed the magnetic ji, shown at night. which helps align jointer knives precisely. ‘To make your own, stat by shaping and machining the body of the Jig from 11 solid sock, as shown in the Parts View drawing. ‘Counterbore two 14"-deep holes in the bostom, and epoxy a stall sound magnet in each hole. (Wo used a pair of Vox rare-earth mag- nets from Lee Valley, 800/871-8158.) Drill holes in ¢ 1" dowel as shown in the Hub detail and assemble the jig, leaving the hub loose The doviel-nole depth gauge gives n> ( ( D you two bokes that measure oneal \ ‘= os length of two standard dowel pin lengths—1 380" ve Sea" tod ps Yi Use se holes mak te - Separate the two pieces, and, using a from the edge of a "jock the walnut top and bettom pieces to ¢ fin flat-bottomed bit, dil « 14" hoe 18° Crosscut each to 10" fo the sides (B) ‘shed thickness of 1" each. Now, joint or deep into the tp ofthe palm grip, cen st 101 Workshop Projects 2002VE wing rut TS, ("fender washer red over the guide hole. (See drawings ahove for hole size details Then, dill and counterbore a 34” bole 1" deep cen tered over the guide hole on the bottom ie of the base, © Drila 4 hote through the base and Yo" hoke through the palm grip, ccentetng both holes on the guide hole ‘nw sroosontine.com CCountersink the i" hole on the bottom, side ofthe base. Plane or sand is" off each sie (not the ends) ofthe palm grip fora 216" finished wicth. Clamp the base, bottom up. ina woodivorker’s vise, Thread a Yon 3" machine serew through the hole, and tighten the palm grip to the base with a wing mut. Epoxy the screw in the hole in the base. Cut a 14" maple plug, and epoxy it over the head of the screw. Detach the base from the palm grip, ‘and sand the plug flush with the base, Sond the base smocth. 7 Fit your table-mounted router with a £ 2" round-over bit, and rout the top edges of the palm grip. Finally, sard the palm grip to fit comfortably in your hand. Gprsrnamwaremd aveapice lof felt tothe bottom of one or all of the sanding blocks for sanding pieces with slight contours, Trim the edges of the felt lush with the base END SECTION ve gop {% hole %6 doop filed with dameter magle pug Final assembly Fita fender wesher in the hole inthe palm grip. Then, aply the finsh of Your choice to the base and palm sip. To use sip the palm grip over the Delton the hase, and just star the wing nu, Quarter standard sheet of sandpaper, and tuk the sides under the palm grip. Now, tighten the wing nut to hold the sandpaper Srmly in position ® Photographs: Bob Cale hhustators: Roxanne Leeine 3 sies ww Haterais Fey: Voip, Wren. *Patsmarhd wth rect perniay, than tine toned sae ease a nsrusnsblrcutirg Supple: Sot" fahend mac sow wih feeder athe en wing na opr, epi, 5beautiful - | angle bevel Note: You'll need Yn" wane for this project, You can either resaw or plane thicker stock to se Cat a piece of walnut to Yisx1x18" (We planed 3" stock to %e" thick.) Cur @ 19" rabbit ie" deep across both ends ofthe stock where, shown ‘on Drawing 2. Fit your table-mounted router with a "core box bit and raise it" above the surface of the table, Clamp a fence to {your router table, and clamp a stat-and siopbleck tothe fence, where shown on Drawing 4.0n page 58. | With the rabeted ends facing down, position ore end of the handle blank 68 against the star-bleck, and lower the blank onto the spinning cove bit. Ffld the blank firmly against the fence, and push the stock util the opposite ead ofthe boank reaches the stopblock. Keep the same surface down, and tum the blank end for end; repeat the process to form the second cove on the other end where shown on Dravring 2. Crosscut two 714"-Jong picees from the 18" blank, where shown on Drawing 2, To form the brass side caps, stat by scribing a 4" radius on both ends of. one of the 12" lengths of Y"thick brass ‘See the Buying Guide at the end of the anicle for our source of Ys"-thick brass.) Cut the radii to shape, (We used a band sauv ited with a 4" blade) File the cu edges smoot. ‘Using a hacksaw or bandsaw, cross ‘cut each end of the brass strips to obtain the two '4"-Jong brass side Neat, cut a third piece to "Ae!" forthe end cap. For beter ahesion tothe epoxy in the next sep, use 60-grit sendpaper to rough up one surface of each brass piece. Spread an even coat of epoxy on the sanded surfaces, apd lightly clamp continued on page 58HEEXPLODED VIEW ‘Sad or grr comers sowsanutwl sibowat WING NUT DETAIL Mex 1x7 brace blade Brass side caps. | TOP VIEW DETAIL srthe brass side caps into the rabbets in the handle pieces where shown on Drawing 2 ‘onthe previous page. (Note: Excessive clamping pressure will cause all or most of the eposy to squeeze out, resulting in a weak bond berween the walnut and ‘brass.) Ale the epoxy has cured, cut and ‘sand the wainut flash with the brass. Cut a Ys"thick piece of walnut tha's just a hair thicker than your brass and cut it to the shape shown on Drawing 3 forthe specer piece. ‘With the ends and edges lush, ue and clamp the spacer between the handle pieces: see Drawing 1 for refer- ence. Later, trim the tandie end square. Epoxy the last picoe of brass o the ‘rimmed end of the laminated handle. Mak the flager recess on the huni, Whore shown on Drawing 3. Using & drum sander, sand the recess to Shape, ‘Marthe slight radius on the walnut ‘next tothe ends of the brass side caps, where shown on the Top View detail accompanying the Drawing 1. Drum sand 10 te line and even with the brass, being careful not to sand the brass, as shown in the photo aright Next, add the brass blade “To form the blae (alo called a tongue), mite-cut one end and ragius the other end of a piece of Ye!" brass to the shape shown on the Fall-Sze pate Slide the bras blade iso the handle assembly withthe rounded ends of ths blade and handle ust, Tape the blade finnly in place. Punch acenterpoin on one ofthe bras side caps. Using a twist bit dil a" hole though the hnndle/tade assembly, Remove the tp, and remove the bade from the ndle. Assemble, add the finish Sie wes of "tas ‘wing mut tothe shape shown on the ‘Wing Nut detail sccompanying Drawing 1. For accurate measuring later, the wings ‘on the nat must not protrude beyond the ‘edges ofthe handle assembly, where shown on te detail 58 ‘Mark the raion the walnut portion ot the handle, and then sand tothe line boing caretul not to eand tho brass. Fora beter finished appearance, sand or file the slotted head of a x roundhead beass machine screw to remove the slot. Insert the /4° brass machine serew though an internal tooth washer and the handle assembly, Adi the wing nut Polish the brass with 400-gnitsandpa- 210 remove any filing or sanding marks. Remove the blade ftom the wal- nu handle. Mask the brass and add the finish to the handle. (We applied Waco Danish il.) When the finish dies, remove the tape and add the blade Buying Guide Bevel hit. Two pieses of Ysx12” brass, Vox brass machine serew, Ya" intemal tooth washer, "brass wing nut. Kit no. ‘AB, S11.95 pps. Schlabaugh and Sons, 720 Ih Suret, Kalona, [A 52247, Call $00346.9663, rodused by Maron Kemet Project Desi, Jim Boeing Photographs: Hetherington Photography Inteaiens: Kim Dewneg” Mike Mery 101 Workshop Projects 2002*eep edges sharp with is shop-made aid. Sanding by hand often eras what should “one een erp eg into one tits nde and uneven, Reader hil Oar Breese Coat eg oc ri wers are especially noticeable on the i projects he ies ors. tea of spending money on a pover edge ender, se designed a manual edge sander that uae Wie nace Toe Beit jitlen mipcteiapaosetde ex eeeieeemne. HCUTING THE PENCE SLUTS sandpaper attached to a fence, Three slots in the fence let you slide it, op acl i Gace lene tees a rote on one side of th fence; ibe ober se hs fer pope sep aps srovirg Sav ails nto te space between te fence and patio Nabe i fre foun eB scr Westone de daring gt: Rost cock dein theo pasos —e ft about Yi" dep, and each ofthe ates abot deeper than the ane Before. The fee shld be sytactica) so roie ta ea doth te feoe ui bist ee eateg. When you's ais i de rneasur cally and reset the fence orate cnr sit Once 300 ve bed outing, ay out criage-bok hes inthe paform ting the sts as a guide, ply a cot of el vanish opt he ‘ood and reduce Fiction. ‘We bought 2/2180" ils of pressure sensveahesive sandpaper cut 18" eng and stock them o bot faces of the eno. Thee lls ane available in 8-320 grit from Supergt, Cll$0V82-43 fora ‘copy of their catalog, # ‘4 straight bit ton by Jett Oey asters: Roxanne LeMoing; Lorna Johnsen Proogrh: Mary Baan Hee Zoeners APO 10 cauriage bott Pere er 2 long aay le FH 1 ase sanded. ames Woedseron sardbeper pwned Wanita ie: (Hest Wing nut Yet Washar 7" 59 em waodentina.comThis heirloom quality walnut and maple strip sander is the perfect tool for detail work, like cleaning cabinet joinery. It lets you sand right up to an edge or corner, and leaves the smoothest surfaces you can imagine. Let's start with the maple body Rip and erosscut a piece of ¥"thick ‘maple to 114" wide by 1314" long for the strip-sander body (A), Using the two dimensions listed in Step | on the Full-Size Patern draw ing opposite, mark an angled culine on ‘one edge of the maple body. Cut along. the marked line, (We used our bandsaw ‘ited with a 3" blade.) Time for the hold-down Bandsaw the abrasive stp hold-down (C)to 4" thick by 114" wide by 1140" Jong. (We cut a %"-thick piece of maple vo 14 wide by 12" long—you need the extra length for safety, Thea, we planed the stock to" thick and erosscut the Following Step 2 on Drawing 2, cut hhold-down wo length from the stip.) whe wedge (B) from your waste piece ‘Measure %" from the front end of of maple. the hold-down, and mark the hole Mark a reference Line along eliher side ofthe maple body ¥ic" from the centerpoint forthe brass machine serew, where dimensioned on Drawing 1. Secure Mark the reference tine, position the tep edge, where shown cn Step 2 olaaten Be: ed the hod-down na smal unscrew Postion the mple wedge along thi line, rege ouine oto te sie the ody, clamp, and dll a" hoe trough fs shown in the Photo A and trace its whore marked. ‘outline onto the side of the maple body. ‘Sand a reund-over on the fremt edge Position the bold-down on the body. (Cat the notch to shape andl check te ft ‘ofthe maple body apd wedge. (See with the back and side edges Mush fof the wedge in the sit; you wantitto ‘Step 2 on the drawing for reference.) Trace the hole location onto the bod slide in easily. Sand the body smooth, remove the hold-down, and drill a Ys 60 40% Workshop Projects 2002*8i"Tong in he row) He mi Soe es Es EXPLODED VIEW V2 round-overs net round overtop and bottom, anne vax 9" brass Fa, {ityoushape the “machine sere snob Sate el press, © oma hoet ae Koc SE ae tase ‘ob, ani ue a con i washer 4" walnut dowel Pg eee eT See a Hague 20 tended aardas .. neaye @ Sie! "4" holo, ee j ee x save ao ere elaine boge of sex2 Fi. ‘wood scien THREADED INSERT DETAIL Section View 8 done! 194" ong ‘glued into he dowel ve" hole 1" deep hole 56” deep, centered over the drawn Mark the centerpoint forthe V4 cite dowel on the joint line between the Rub the threads of a «20 threaded body and the hold down, (See the insert against a piece of paraifin wax, Threaded Insert detail above for exact ‘Mark the centerpoint on the joint tine, ‘and dri a" hele whore mared. (This makes driving the inser into the _Jocation.) As shown in Photo B, drill a maple casir.) Using a large screwdriver, Va hole on the joint line where marked. Remove the held-dowa from the body. rive the insert iso the 7a" hole in the Marc the angled cutline along the From 14" walnat dowel stack, cut a body. With a Yoc/a" machine serew and ‘ack side edge of the body and hold piece 1/6" long. Giue and clamp the ‘#14 finish washer, serew the hold-dawn down (again, se the detail). Miter-cut the dowel into the groove drilled into the tothe body, boaly and holddown where marked. hokddown nmwoodontine.com 6Now, get a handle on this project Using carbon paper, taser the han- dle patiem to 1c" walnut, noting the direction ofthe grain on he full-size Mane Patera draving below rigs If you don't have ie" walnut, laminate thinner stock to size. Bandsaw the han to shape. With ‘your table-mounted router. rout 12" rour-overs along the elges. DO NOT roatthe tp and botom ofthe bande (Stop routing just short of the top and bot- tom, then sand the top and botom éeges to complete the ound-overs) 23 ommuntte nde, tet fing 1 for the position of the 2" mooning hole, and markitscenterpcnt Nex il and countersink the le. Carefily postion te handle onthe body (see Drawing 4). Stick a nil up through the hole in the body ‘© mark the centerpoint on te botem of the handle, Dail a 7 pile hole 1" deep in the bettom of he handle. Sard ua smoot ane set side Turn the knob to shape “To make the knob (E), begin with a2" square piece of walnut 3 lng. Ifyou n't have stock tis thick, laminate thin- ner stock. Using carbon paper, wansferthe Knob Template Pattern (see Drawing '8)10 poster board. Cut template to shape ‘Mount the wal square between enters onthe lathe. Tum the knob to shape, using the tema. Finish-sand dhe Kod hefere removing trom the lathe NOTE: Ifyou don't have a lathe, ou can dil a!" hole I" dep, centered on the bottom ofthe knob blank. Glue a" dowel 174" ong ina hole Using a rasp and the tpt, shape the nob on your Ail press, as shown on Drawi ‘mount the handle, dria" hole through the bod at the same location where you'd drill he hole forthe 82" wood serew. Refertng o the Drawing 1 for positioning particulars, locate and then drill 20" shank hole tough the body (A); countersink the hole on the bottom side 82 Hold the knob in a handscrew clamp, and dill aa" pilohole 14" deep into the comer of. Add the finish and the sanding strip ‘Glue ard serew the bandle ané knob to the body. Serew the hokdsiown in race. Adé the finish Cut a 17%4"4ong piece from a 13" ie abrasive rol (See the Buying Guide fo our source; you also could cut sanding belts 1 make the stip.) Follow te two-step Drawing 5 Delon right © _ttach the abrasive strip to the body ® ‘roet Design James 8. Downing Protegranne: Hopkins Associates Inustatons: Roxane Lemoine FULL-SIZE HANDLE PATTERN *hiay ot “pars crest. The em wnbted se scoring he tows iretucins, Supp: 20 treads atin nx, one bas aed nasties, #8 bass waste, #82 tataed wood ecowe i waht dol fic. Buying Guide (tracked abrasive shop wi ty 25 yas long, Alain 6 3, 100; 120, 10, 180, 40, 820, and 40 4 os, $8.0 poral ss SS shiping ecandirg x res ander 0; eos $8010, 57 fer acre oa S10, ai bases, 649. BS. Rend, PA 112. Prone BONLZE- 2222 (eoneze2z.2in PA) 0 ae. ATTACHING THE ABRASIVE STRIP ip he sn sees, eres Rin lv eae strip around thetbody,fine-fini scrape! comfortable, good- ng tool is easy to build d its adjustable blade akes getting into tight omers a snap. How to begin this project 4 Cut a 32"-thik piece of walnut to 2!" nide by 17" long for the handle pars B) (We resawed apiece of 10/4 tek; you also could plane or ata thicker piece to's") Cresseut the walnut strip in half ) Cut or rout a1 groove 4" deep al dog toes eA TES mLaoED Ve lade om the tablesaw to cut the groove) bs Suse. i rounc-evers A Tilt your saw blade 40° from verti + and bevekeut the front end ofeach Yi altvead ed \ wit handle past \\ Fhe and clamp the Rance ices D iogetner withthe edges sh, Align as door sti plate \ a wien as ess (one Side Section View detail > Using carbon paper or a photocopy, D transfer the handle pattern shown on page 64.0n heavy paper ce poster board ‘Cut the paper template 1 shape, and wrace is outline onto the bottom face of the seraper by Jnut handle lamination, Bandsaw the (P#0%8aw blade) adte (shape, Drunnsand the concours ove the say marks. smooth tore =» Chuck a 3" round-over Fit into your T sie sscaes cn Fes tr worm Ale, where shown on the Drawing 1. Sand ve “® | | sd eda tlt boa aor (Fe mn “Soesecnion” / = handle, ™ eon on oa \ eee Ve ws 4 apply the finish ee | mei 8fine-finish scraper Cut, shape, add hardware “Apply masking tape tothe polished side {the top fae) ofa sobid-brass door stk. (We used a Scege ANSI 10-025605 pal- ished brass srk see the Buying Guide for ‘our hardware kit) The tape is ‘easy to mark cutlines on, ané helps to prevent the polished brass fiom being marred when you are cutting Mark centerline across the site, where shown on Drawing 2. Using the dimen- sions on the raving. trim the strike ends and front lip. Fle the eut edges to remove burrs. ‘Clamp 76” of the sire in a ‘ise and bend the exposed portion as shown on Drawing 3 above. Pace the strike in the handle to check the angle con tinue bending uni the angle is the same as the fot of the Nan ‘de, ee the Sie Section View detail accompanying Drawing 4 for reference.) Cut a 72" length of 4" all- threat rod. As shown in Photo A, use a #8 mill bastard filet cut a notch in the thvead- ‘ed rod, See the Noich detail for dimensions. (We wrapped ‘masking tape around the rod to DOOR STRIKE PLATE ‘curs ana? ‘rll Soh as PATTERN Mark the reterance tne, position he ‘wedge aions the line, and trace the out- Tine onto the sido of the body, ‘Sribe marks every 213" on the hacksaw ‘blede, Then, cheat r Ale theseraper sgh stan 45 Using straight strokes, ile the blace with a mill bastard fie. e7- w Beno vee Mal ae 4101 Workshop Projects 2002location on the rod andfo the scraper blade firmly in positon. (We Buying Guide vssibe marin ofthe red cep about 4" of the bads exposed). __Seraper hardware kit. Brass strike ate vse) pla, Y" bass wing mt, J" allthread sake the soaper blades, mark Time to sharpen 10d 7" long. Kit mo. SCR, $8.95 pod. ments every 2" ena used or ‘To sharpen te scraper Dade, angle the _-Schlabaugh and Sons, 720 th Sireet, 58 backsawy blade. Clamp the blade ina seraper as shown in Photo. and sharp- Kalons, [A $2247. Call 300/346-0663, Using «cold chisel, shear off heen with a mill esta file. ASYOU MOVE prcgaph: Bob emer ssczments where marked, asshown the fileback and fonh, keep the filein__usttar: Renee Lslaine Photo B. Hammerthe comers ofeach contiet with the total length ofthe se fat—they tend to bend slignly blade to avoid curving the Dade. (We chiseling to length held our seraper stihl less than 48° > Ascembie the seraperandslipthe when sharpening) ® ‘© scraper blade imo position, ‘Tighten wing nut on che all-thread rod to hold precision miter stop Make it in minutes, use it asa lifetime addition to your shop. Use this handy stop on your own 2%"-wide miter uige extension, or adit to your raial-arm saw fence, IUfis on the fence, and allows you to eu piece after piese tothe same length caunerbore Ys doap with 2 Seow cenered nse 2 pounterore "deep in a ‘ohole centered nae ve WT at ibeervat EXPLODED VIEW u Piet ati ames Doaing Se Note: 1! you use ts on 2 Prater Haerngton Porahy i 2yCrabbe! mer gadge acension, rd Iusvten:Rasanne Leleine i se Seep wontenonto ee nae sronoedeniine com Costand-tall Hore’s @ simple | fixture that makes work- pieces stand upright and ready for cutting. Now you can stand workpicces, such as webbed exten raised panels, upright and cut their edges wings, measure 1m your tablesan. Just use this auxiliary between the centers, tablesaw fence designed by WOODs ‘of the webs atthe magazine reader Joe Xaver of Aubam, front and rear of the Mlinois. The jig bols temporarily to your extensions. Make the removable spreader location of the tuts, and bolt the tall saw’s existing fence to let you make these this length, and add 114" to find the fence to your saw’s fence as shown in cuts safely and accurately, and folding length ofthe crossmember. (The dimen- the photo above. supports make for flat storage sions shown are fora table thats 261%" Before using the jig for the first time, Before you begin, take afew measure- between the centers ofthe front and reer adjust the nylon glides so the tall fence ‘mens from your saw to ensure proper fit, webs.) For saws with soli extension. is perpendicular to your saw’s table Firs, examine your saw’s existing fence wings, shorten the dimensions shown for top. When you're done, unbolt the unit ‘to see if drilling it for the machine screws, those pieces by 4° from your fence, pop out the removable ‘where shown in the drawing befow, will Armed with that information, build the spreader (atach it tothe 1op edge of the incerfere wit the fence's operation, and auxiliary fence as shown in the drawing. _crossmember for storage), fold up the adjust the locations if necessary. For Drill Sie" holes in your fence to match the legs, and hang the unit on a wall. [GLIDE MOUNTING DETAIL] EXPLODED VIEW Hex 16¥ax 31" os See 7 Ww Gross menber, hares [rE sock Leveing gid0 Front or rearveb usraion Roxamne LoMcins Proto: Hetherngton Photography 66 why Hootansioop 11 bole deep {tener dos sido ‘ia Se hole went ‘¥ doop centored ince ‘leveling ge ee 401 Workahop Projects 2002rotating finishing table Avoid smudges and sticky gers with a mini-lazy Susan that tums while you stay put and spray. Unless you can walk completely around your workbench, you're limited to finish sg only two, maybe three, sides of your projects without lifing them, With his versatile finishing tumtable designed by WOODs magavine reader Mike Sarnes, of Fairview, Michigan, you can apply fin ish to every surface without taking a step or lifting the project. ‘Tose the table, space three or four sharpened dowels where they'll best sup- ort your workpiece. (You may need to sand the base of the dowels slightly to fit the holes.) Finish the back or bottom, then place the piece finished side down fon the dowels—the points make minimal 9%" holes 4" deop contact withthe fresh finish, Finish the remaining surfaces by roxating the turntable while you spray. Hold ‘smaller pats with lothespins _glued to dowels as showa in the ‘small photo, above rig Buying Guide 6" lary Susan. Available from woodworking harivare cations, including Woodworker's Supply, 800/645-0202, and Wooderalt, 800/225-1153 aration: Kim Downing Protogrsnhe Baldwin Photography wow. weodontine.com choponiog EXPLODED VIEW orate an inper Sparen. Catosrin : ) =x on ) fn 9) isto ex 12am, ia a % ten sn 4 a8 x50" Bi nin ifm, \ | ea ie ( Wax3iax 12" toot o/ Rubbe: fet| 67pattern sander Let a template ensure safe, repeatable results. ‘When it came to shaping the flared-out bottoms ofthe legs fora nightstand, WOODe magazine stafers had 10 do ‘some brainstorming. For uniformity, the staff needed 10 guide a shaping tol along, template. Buta fush-timming bit chucked in the table-mounted router ceaused chipping where the leg curves and the wood grain intersected the routed face. There was aso the problem of safe- ly holding on tothe narrow workpiece, ‘The solution? A dail-press mounted jiz that combines a *pilot-bearing” rub block witha sanding drum. Here's how yeu can ‘make one yourself. Cut the base from plywood or particle- ‘board, and place it on your drill-ress table, centered under the chuck. Mark the locations of your éll-press table sles, ‘and drill ccunterbored holes for the ‘block foreach size of sanding drum you and éeill he centered hole to clear the end ‘mounting bolts, Drill holes forthe dowel have, sizing them about Vis" larger than ofthe sanding drum’s shaft. ‘and the rub-bleck locking bolt. Glue the the drums) Cuta piece of '4" hardboard “To use your pattern sander, fasten the dowel in place. Measure the diameter of to this width, and bandsaw and sand the base to your drill-press table with the ear= your sanding drum, (You can make a ub radius on one end. Rout or saw the slot. riage bolts. Install the ub block, and ‘chuck up your sanding drum. Swivel the gs se WAOOREETEERE raERORGELRES EXPLODED VIEW Few sencing crm deil-press table to align the rub block eee | Pee ee | setae suienices ea esaeomeammed cla) @ SINAC! nk ep. Sle i blk veimageatanavanee t the dowel and locking betto align ie ‘Rub block > (Seeds ailace er eaneh ‘front-to-back. Tighten the locking bolt, x 2¥iex ates amiacs 2% your templaic em from ee unto setgectunieg Mae epee ae ines eee is re Kaen uatan face \ = loca mnie ee ' Sad es papier oes wna tdecerar nice wore: aati ia SS elpmoereaeaiegans ‘contac the rub block. lution: Roxanne LeMsie: Lona Johnson Protegrap: Mary Baldwin Base 1x 10 x18" plywood i wing nut and washerTable inserts are a snap to ake with a trimming bit. matter how finely sharpened a saw o set, or molding knives may rain tearout can oocur when the ukpiece is aot completely supported by st. To alleviate that problem, 2 followed the advice of WOOD» mas ine reader Michael Coygrove, of Goo 2k, South Carolina, and created 2210. earance inserts for all oar diferent Jades using a router and plywoed scraps. To make insets, use double-faced tape adhere your metal tablesav insert to a plywood blank the 2 s the metal insert Then, cut the plywood blank slightly over-sized with a bandsaw, being extremely careful not 10 cut ino the metal inser. Next, fit your router with a laminate flush-rimm setting so the bit’s beat ame exact thickn edge ofthe metal inser contacts only the wood. Reut the ply- wood to the exact shape as the metal insert. Keep several blanks on hand for 2 variety of tasks and blades, Nowe: you cant make @ blank thar is the same thickness at the inal insert, make one that is slightly '00 iin. Then apply dabs of hornet glue co the tablesaw's inzert-support surfaces before puting the blank in place and set ting i flash wih the tabletop. ® Wt Photo shows the ineort blank after being bandsawn to rough shape, bul prior to being routed to exact shape, wranwaveodonine.com PsThis pair of hancheld blocks will provide an added measure of safety and even increase your productivity, CCatiing wedges and ripping thin strips renk among the more dangerous tasks you can perform on a tablesaw. Our two ripping blocks x « measure cof safety to these operations. pus you only posi tion the fence once to make multiple pie ‘You can build these from any Mat pieces of ‘serapwiood. Just follow the guidelines given in the drawing below right. To make the handle, cut out ‘and ealarge the patiem provided belo. And don’t neglect to ad the keepers onthe bade side ofthe handle ofeach block. These prevent the cut pieces from kicking back. ‘To use either block, set the distance from the fence to the inside edge ofthe blade equal tothe ‘width of the rear of the block. Place the workpiece in the notch inthe block, and push it and the block together past the blade. Wit the fence in the same positon, repeat the eating operation for any numberof identical wedges or thin strips ® Photograpt: Hatherington Photography Ihersione: Roxanne CeMoine HANDLE PATTERN Note: Enlar 200% tomane fulkstze pattom 70 Seer oe ee Piaesuiemala=i EXPLODED VIEW omamff cS RIPPER 14x46 4 ood ten ie — ‘1 pled tax BH oa wood screw Poe Notch equals widest X_cutneteh te ‘once oe 401 Workshop Projects 2002sure-grip jointer pushstick your hands safely above the fence with our simple, ‘a-tall shop aid. time you'e jointing Wood, keep hand safely above the fence and out of s way while applying even “down” with his xtra-tall pusbstick. A ~etchod bottom edge provides a necded grip « pushing the wood smoothly and effec- vely over your too's knives. copy the pa- im forthe handle, below; ané follow the smensions onthe drawing, below veh, to construct the one-piece pushstck. oj: Design James R Downing ‘ation: Rm Downing Photog: Wi. HOpKN We uso6 cur smoctring PULLS: plana Randle as a pattern. — HANDLE PATTERN EXPLODED VIEW swans weodentine.comcam-action fence stop Make sure your multiple cuts are precise with this easy-to-make device. This handy helper takes the guesswork ut of setin ip for precise multiple cuts aw. Frazier Mocre of Proton: od Gamer hetratons: Kim Downing #8 11 FH, wood seren ‘¥=" shank hove, countersunk (. pilothole &" daep ‘ee shark hole, countersunk flat washer Locking lver FULL-SIZE PATTERNS: ] exons bot ‘ong Sé hole i deep with a vi" hole centered inside Ege. Re re alas angle eprovent ‘salust S buku 72 101 Workshop Projects 2002thin-strif rippin’ p Our handy support helps a cut down ripping risks. Ssiely rip thin strips between your table- sv blade and rip fence with this fence- spored pushblock. The replaceable end stock allows you t push the thin pice being cu! completely trough the cutting ‘liminatng the chance of kickbock. Copy the Full-Size Handle pattern, below right, .o mark the outline forthe block henall, We've located the han Je up and out af the way so your fingers main safely away from the blade during fae eating operation. EXPLODED VIEW NS AxTAx 12" Hande side ee N 4 x12" pyweod cult width of ono at Allscraws are #8 x 1 ~ brags FH. wood serews. cur to tt with oftablasaw rp fence. vex rapaneable Er tee FULL-SIZE HANDLE PATTERN eject Desig: Richard W. Braniow Petco: Balen Protography Nutri: Roxanne LoMoine vwoveroedentine com 73back-to-basics sawhorses These great shop assistants come in the a four-legged variety, and there's never a problem with upkeep. Oursimple, sturdy sawhorses are only 2 tal but you can build a pair any size you want and get the help you need. Here's how: To build a 30"-tong 24" high sawhorse, begin by crosscutting 1 30 top beam and four 30" legs. (We used a serap construction-grade 2x6 forthe top and 136 for the legs. ‘Tilt the tablesaw blade to 15° and bevel cone edge of a 12"-long scrap 2 the miter gage a shown inthe Side View. ‘Remove the saw blade and insert a dado blade. Set the blade at 0° (parallel with the miter gauge grooves), and rae it" above the surface ofthe table ‘To cut the dadoes inthe top beam, position the miter gauge in the slot othe right ofthe blade anset the miter gauge 10" ightot Ss \ centr asshown inthe Compound Angle 425 go ® or HD oxo Dat Cuag deeig: Betis eating ck e 2 | Nee reference lines for the location of the four J aco cuting Gatos on the Brn ste ofthe 26 then Me ere as ie a ee BE Ks on ae Genk eh apoE \ pe make sure you cut on the comect side ofthe lines. With the 2x6 positioned. ist the “a, “Gusset beveled fence, cu dado no. I then Hip the | _ 2x6 end forend and cut dado 0.2. Nov. = move the miter gauge tthe Ket side ofthe EXPLODED VIEW blade and set the miter gauge to 10 et of 4 10 Werahop Proves £082COMPOUND ANGLE DADO CUTTING 18, a Pi tom sive always faces ‘onward SIDE VIEW ~ Poston a0.2 Sadooe 3 84 ‘emer, and cut dadoes nos. 3 apd 4s you id | end 2. Remove the serap 253 from the miter gauge, and replace the dado blade with a regular ¥ blade, Set the blade at 15° Ieft ‘of center, and with the miter gauge 10° right of center and on the left-hand side of the blade, cut one end of each leg. If your saw blade tits right from center, you will ‘need to change the miter gauge setting to 10° left of center and make the first cat With the miter gauge on the right-hand ramondorsine com TOP VIEW! side ofthe biad.) Keep the settings the sane, and move the miter gauge tothe ‘eppesit sie ofthe blace: cat the remain- ing ends toa finished lenath of 25 ‘Attach the legs tothe op, using 196" ‘rywall screws. (We used tree serews for each lez) Do rot use glue on the assembly, because You may need to replace a pa if it gets cut accidently. “To make the four gues, return the ‘lade to 0° and set the miter gauge at 15°, Ceoscut the gusststo the dimensions iter gauge / BoveLout wood tence rewed to mter gauve. Sano fo mte Provont buck shown in the EXpioded View drawing, and attach them with 15" deywall serows, IF you want a smoother finish lightly ‘bel-sand all the joinery Must. ® Frotcgrapt Bab Cater Nusratns: Rexam Lantne; Si Zaun Bknockdown sawhorses After a hard day's work, these sturdy horses stow away in minimal space while waiting for their next task. A pair of snhorses come in mighty andy when you cut sheet goods or need to setup a temporary work area. But whore do you coral them when you're not using them? Build these turd horses, designed by WOODo magazine reaer Wade Olson, of Clfax, Wash, and when you ate ini f \~ | eters werd ‘Taper jigs don’t get much mare basic than this ‘nold-down taper jig Build the plywood base and hardwood hold-downs, as shown on the drawing lei, Then, mark the angled eutline(s) on your workpiece. Position the rip fence so the inside ‘edge ofthe jig base is against the fence and the ‘outside edge ofthe base is fluch with the table- saw blade. Align the marked cutine on the workpicce with the outside edge ofthe jig nent to the blade, Tighten the workpiece in place, and ‘make the cu, &8 shown in the photo above. “To simplify matters, we've added a Bus Guide for the hardware used on the jig: Buying Guide Hardware kit. 2" T-kacbs 2), 4" cage bolis 5" long with mating muts and washers (2), and a 23x22" strip of sandpaper. Kit no. TAP-J, $10.95 ppd. Schlabaugh and Sons, 720 14 Street, Kalona, 1A 52247, oF call $0/345-9668, to order. Projet Desi: Jan Sree Pragya Hetherington Photepraphy hnusreten: Roxanne Leone aThis resawing guide lets you correct for blade drift, and you can build it from parts you probably have lying around your shop. After suugeling with his bandsaw fence, blocks, clamps, and 2 resaw guide, WOODe magazine reader John Hodges ‘of Kaulinan, Texas, decided to design his ‘own bandsaw resawing guide. You ean build one just ike i by gathering up some serap stock and following the illuy- trations al right. ‘To use this guide, first mark tine along the top edge of the pieve to be gait ji) unt he anes Bade ies yy): heme ie on he wood i “Tieton te wing mis fat hold see — . 1s 1B Tighien he wing nn prt to ——-4 secre tink miter snes . Because few bandsaw blades track per- | * Dob cater =i fey et rikng eve anos Se hen oe sees for rexiving) he crved en of | ; part A allows you to steer the board into: 1 the baa blade and make aime Sep ve hale to follow your marked ine. We resom- mend using 016". 10 V"-wide skip-tooth ‘0r hook-tooth blade for cleaner cuts. And, always use a pushstick for safety when resawing on a bandsast reine Kin evening Phesgreph: Hetherington Photograshy 93. Co jute, gm | We dado bn ee venole, countersink ‘on pater 46x00 FH \ ‘wood corew erg aoe H, machine row +4 tong | [GB aio sre .983%8 is countersunk ~ countersunk | _-enbottor Ye kort EXPLODED VIEW gal Bottom View a ia 1210 stock (0 ftmtergeuge sin, ne 40% Werkhop Projects 2002angled tablesaw miter jigs se either of these simple jigs, and make cutting accurate 45° miters easier than ever before. ang Square and aocurate 45° mites just gota whole Sot hese angled cablesew miter jigs. The jig ccked R on the deawing below fits on the rit hand side 2 Dale, 28 stown in Photo A. The jg mavked L, wn in Photo B, rhe bodom, is ino the miter-gause ¢on the left-hand side ofthe blade se either jg for mite-cutding 45° angles, Or tur the jig srked Lend for end and use the Fence to support pieces J crossuiting them at 90°, as shown in Photo B. sefully poston and glue the Yo" guides in plac imately, the angles cut are only as accurate as the pos sing of the gies. EXPLODED 5. tore Ber 45° tere ‘i te saat kee cut aiong front ge Kop xx tnt "ia shark roles Re sees Sy ms Wa Vex oie stock cut to rite guage sto lywcod Fhe pilot holes esp ova QQ < ~& oe ‘evestoadorine.cort Note: Our jigs were designed to {Ata 19” contractors saw. Adjust ‘as necessary to fit your tablesav, Far ease in construction, attach the three fences 10 one piece of 1/4" siock, dnd then cut the 1A" siack i hl, where shown on the drawing 98versatile panel-cutting sled our wide-body tablesaw accessory. When you use our parel-cutting led, ‘you'll never wonder if the comer you just ‘ut is square, For hairsplittng accuracy the beefy fence is fixed at 90° to the blade ‘and shows exoelly where your saw blade will cut. Additionally, the fence-leading design holds wider workpieces more solidly and koops your work closer than fence-trailing jigs. Build the jig according wo the drawing stright, We made oars from birch-veneer plywood with a solid poplar fence, but ‘you could use any 12” plywoedl or medi= ‘um-density fiberboard and a straight serap ‘of 2x4. Cut beth pieces 4" longer than shown: you'll rim them to their exact length after you build the jg. Note: A well-timed wablesaw is essential to complete the job. The saw blade must be perfectly paruliel tothe miter sl, Before attaching the miter-lot har, censure the corner formed by the fence and the right edge ofthe sled is square. Make ‘a mark 3" from the comer along one ‘edge, and 4” along the perpendicular edge. Measure diagonally between the ‘wo marks, Ifthe diagonal measures exactly 5°, your corer is square, IF it's sore than 5", the angle is greater than 90"; ess thaa 5", and it's less than 90° Next, measure the distance between your tablesaw’s blade and miter slot and ‘add V4 Using that measurement and a combination square, seribe a line on the boitom of the sled, measuring from the saw blade edge. Attach the miterslot bar along the scribed line, With the sled’s guide bar in your table- saw’s miter-gauge sot, crank the saw blade upto full height, Run the sled 100 4x 2/6' RH. machine erow wth head out of ss tmcsom y weerl i weet V6 thveaced ise rod 24° ong 4 0 24 ong a SAE fia washer 122 Ya Ve X18" Sock * Or, the width ofthe miter — (gauge slot nets eke x Distance trom blade tomer gauge slet through the blade, sing off the exis 4" from both the base and the fence ‘You can now cut with confidence by ligning the cut Tne on your werkpicce ‘ith the edge of the fence, For epeiive cats les than 27°, clamp a stopbock 10 the fence. When cuting pieces upto 48°, Tock in the sleds built-in stopblock roger sosin: hares | Hedune Phetograp: Balewin Photography liustatons: Roxanne Lakloine Epoxy wing nut lo machine screw. EXPLODED VIEW = er ‘| Pe Ye koop® e STOP DETAIL Yax2! EH. —— machine sorow 2¢ ale (Oe belo cuitng tt) i Ye" sot 17 Fong), hale 1 SAE fat washer“ a toe rut 104 Workshop Projects 2002poove Been Keep your fingers safe and your workpiece steady with a few pieces of wood and the turn of a T-nut. For drilling jobs it's essential that you hold the workpiece securely tothe table and sgainst a fence before engaging the bit. ‘With smaller workpieces you may not have lamps with the necessary jaw depth, and, 1s shown in the example above, you don’t \wantto get your fingers close to knuckle- busting cicle caters. Hold-downs are the answer, and here's aversion that will only 6-20 b-star knob set you back the cost ofthe knobs and all- tread red. (Many woodworking catalogs carry such knobs.) Use the full-size pattem ‘elow and the drawing at right to make a ‘ holdsdown. 4° dowel "tong We drilled three holes into each side of cour drill press table for accommodating ‘workpieces of various sizes. Each hole is ‘outed with a T-nut for accepting the ¥° ‘ye alttheead 108 all-thread 10d. EXPLODED VIEW FULL-SIZE HOLD-DOWN PATTERN sronaoedeniine.2om 101ball-drillinc Our simple cal goes to the very center of a common drilling problem. Drilling perfectly centered holes in hardwood balls can be tough. While you can hold 2 ball securely in 2 weod handserew, centering it under the bit on your dill press isdiffieal. Solve this problem with this quick-to-buil ji make it easy to clamp the jig t0 your dill press, make the length ofthe base the same asthe width of your dntlpress table Drill the counterbored holes for the carriage bolts and the lage holes in the base and eap. (See the Jig Hole Guide below.) Insert the bolts and center the base by lowering the bit back into the hole, and holding it there ‘while you clamp the base to your érill-press table. Place ihe bell over the hole, slide the cap down on the protruding carriage bots, and tighten it onto the ball with washers and wing nuts. Chuck in the proper bit and drill away. ‘station: Kin Downlhc: Loma Johnsen Pratagraai Balin Photography, JIG HOLE GUIDE (Bat gam, [row sam | 4s - re zi With of eitprose tabi“ Bie Bar| ae Taek ace = EXPLODED VIEW ~~ _ 2 ee ae ~ 102 ion patton 2) with Z hole centered insile ‘W cariege bot $*Iong 101 Workshop Projests 2002 x a ees oe 4 ow DDSpacers help you locate hole positions for fast, accurate ee production drilling. sex te F 7 wood serews Having worked for more than forty years as 2 printer, WOOD» magazine reader Bill Lacey is familiar with the process called “step and repeat.” In printing, small images, such as business cards, ae repro- duced in rows and colunnns fo fil fall sheot of paper. Because he builds toys in small batches and need: to quickly and accurately 5 ee repeat dling operations, Bll adapted "meeps this idea to his woodworking, the carriage n ‘The jig has two components the ear saa sage, equipped with rear and end fences, ‘andthe spacers, which allow you © posi- tion your workpisce. The sequence of ‘Photos shows how to use the jig ‘Build the carriage as shown in the sdeawing. The siz of the eartiege can vary according tothe size of pieces you are ddiling and the maximum reach of your dil press. You can cut spacers to stan dard widths ahecd of time, cr custom- make spacers for each different job. Bill took the first approach, cuting spacers in widths from 4" to 1" in Ye increments, and from 1° 0.6" in 1" increments. Cat all the spacers ofthe same width at the same time to ensure uniformity. ‘The photographs demonsrate using the jig to dell holes in a eribbage board. We positioned the workpiece by insering spacers between the fences and ihe piece to progressively move it away from the fend fence and out from the ear fence ‘The green spacers move the piece in 6" increments; the yellow spacers in VA" increments Photographs: Bakiwin Photography IWosvation Rosanne LeMelne, euncwdentine.com 103pocket-hole drilling guide Take ihe hassle out of angled mounting holes with our simple drilling accessory. Equipped with this handy shop si, you can dil uik secure pocket oles for fastening face flames to cabires, aprons to tbleops, and ier similar tasks requiring angled . mounting holes To build the dil guide show at igh, just follow the instrustons onthe dravings below Cut a block and apply the patterns oj From 1Yi" sock, cut block to 24x34". Adnere the * Full-Size Patiems to it, Locate and bore as" hole, using ‘a spade bitin the drill press. Bandsaw the guide to shape. ©} Clamp 03" length of 1 iro pipe €%«' 0.D) into © machinis’s vice. Using 2 %" ovis drill, slowly ream out the inside ofthe pipe t ¥". Epoxy the pipe into thee" hole fash withthe top ofthe block. After epoxy’sets up, hacksaw the pipe of at an ange to match the block. Use a sxationary sander to sand te pipe flush, Break sharp edges ‘of steel with file and emery cloth Froject Design: James R. Downing Musratons: Kin Downing Fhetearap: Wi, Hopkins FULL-SIZE PATTERNS: baie ow ENDVIEW FINISHED GUIDE SIDE VIEW pe (%6" OD) ERAN Se hoe 104 101 Workshep Projects 2002drill-press jig for dowels 5 When boring holes in dowels, the cowels can roll around freely. Here are two ways to hold them still. Drilling Holes into the sides and ends of dowels can cllenge even the best woodworkers. The problem: tying hold round stock in postion. Try thse simple jgs to hold the dowels roccstealy Bath jigs rely on & V-groove that you cat inte piece of 0820" serapwood. To cut the V, tlt the blade of your tublesaw to 30° from vertical nd set the cutting depth 1 9°, ence to place the top ofthe cut onthe centerline ofthe board, Make one pass over the saw blade, turn the board ‘around, and run it through again, creaing 60° V-groove, ‘Crosscut a4" pisce off one end. The longer piece holds your dowels flaton the table, as shown in the photo at right lop. The shorter piece forms the bass for the second jig, ‘whieh holds dowels vertically for drilling ino their ends. ‘To complete the vertical jg, cut @ 173x3" block, clamp it to the back of the 414" pieve and check to make sure thatthe V-groove is perpendicular to the base, Then glue andl screw the two pieces together, as shown in the Exploded View drawing. Use the vertical jig, a8 shown in the photo righ ® Pretegrapns: Hetherington Photography ‘stration: Roxanne Leno Clamped to as shown in Cuting the V-Groove detail drawing, Adjust the e0@ holes drilkpress table, this grooved plece of scrap- als steady for Norizental criling, ‘Screw the shorter V.groove block to an upright to dil straight down into the end of the dowel. EXPLODED VIEW oe == veRTicAL to Lert faci wood serow Hoel ees a ‘shank hole, countersunk \woawoedentine.com CUTTING THE V-GROOVE DETAIL 105,drawer-p mounting j Mounting drawer pulls has never been easier than with this handy shop helper. Mount drawer plls in jiffy by taking a few minutes to build this jig. With it, you ‘an shave os of time off the tsk of ring drawer pull mounting hoes. “Touseit frst cut a 4" scrap piece 1 ‘5vex12". Then, natk a vical centering ‘nthe jig. Mark and drill centered hols for the pulls on both sides of the vertical line, For mos drawers you will want 10 locate th les in the jig so the pulls are centered on the height ofthe drawer ‘fonts. Ten, mack the center of each drawer front on its top edge, align the Jigs vertical centertine wit it, snd dil the holes, as showin the phoxo® EXPLODED VIEW 108 4101 Workshop Projects 2002Line up and drill your door handle locations with this simple, can't-fail jig. Here's an efficient way to install door hanates, This jig works much ike the drawer pul jig on the previous page. But, ss you can see in the drawing. it has solid-wood cleats on both sides so that you can locate hardles on either the left orright side of adjoining doors. After 3" plywood indox ar blocks for each hinge. Glue and clamp the stopblocks tothe rail at one end, as shown in Drawing 1. Now, temporarily remove the ral, Stick small pieces of double-ficed tape tothe doornext tothe hinges. Adhes blocks to the door, snug against the hinges, as showa on Drawing 2 Stick a large piece of double-faced tape to each installed index block. Now. hook one of the rails stopblocks on the door’s top edge, and press the rail orto the index blocks. as shown on Drawing 3. Keep the rail's buck ed ‘and the index blocks’ back edges flush Stopbiocs Hinges prevou stalled n des Tosalione, dex 114So ett Jal oS ~ = a sostiocs io gral win v brads ‘te removing fa ‘Doublefaced ‘tape jig rallatthe bottom “Trim the fi al ‘yt longer than the door. Pai i Hooking one stopblock on each door’s Mathes top end. Remove the stop- blocks bracket the hinges, jt as they did ‘lop edge, use the jig to locate the hinges blocks by cutting the rail just above the on the doors. Finally, position the hinges: on the rest of the doors, Dil ti hinge_tapindexbicks, as shown, Tetween the inden blocks, and dil the s holes, Now the jig is ready to position the screw pilot holes. Once again, hook the jig’s stopblock on hinges in the carcase, Simply place the jig doors top edge. Mar and tim the il against the inside ofthe cabinct wit the to extend Vic beyond the doors botom, —rai’s marked end wp, as shown cn Seaton tie age Ler stan 2 shown on Drawn 6. This extras Drang 6, Clap or use double face the gap between the door andthe cacase. tape to hold the jig in place. The index wow weodonine.com 15Clear the air in your workshop with these hardworking add-ons for existing dust-contral systems. 1186 plywood — Se" shank hola tex 1utFH wood sore Alam, rele {Gired tlt a & dust eolecton — ‘connector or 4" VC pipe) Ste" shark nee, courrersure erbottor ice ¥6¢ holes (sized to elie over condat pipe) #0. 2°FH. wood screws conduit pine Tong ES MITERSAW BOX EXPLODED VIEW © 4s" shank hole, —— countersunk fox se Fi, ‘weed screws ‘The mitersaw fixture accepts a4’ hose from a standard dust collector while the iblesaw addition directs saw-

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