® Cutting Diagram
roll-around Work Cart (baltic birch)
Materials
CASE
A Case Top/Bottom (4) 191/2 x 431/2 - 3/4 Ply.
B Case Sides/Divider (3) 191/2 x 243/4 - 3/4 Ply.
C Wide Back (1) 24 x 24 - 3/4 Ply.
D Narrow Back (1) 24 x 133/4 - 3/4 Ply.
E End Edging (4) 11/2 x 11/4 - 191⁄2
F Corner Posts (4) 11/2 x 41/2 - 27
G Side Edging (4) 11/2 x 11/4 - 37
H Vertical Edging (4) 11/2 x 11/4 - 24
SHELVES
I End Shelves (2) 1/ x 31/ - 19
2 4
J End Shelf Sides (4) 1/ x 21⁄ - 31/
2 2
K Upper End Shelf Faces (2) 1/ x 3 - 19
2
L Lower End Shelf Sides (4) 1/ x 3 - 31/
2 4
M Lower End Shelf Faces (2) 1/ x 3 - 19
2
N Back Shelf (1) 1/ x 51/ - 13
2 4
O Upper Back Shelf Sides (2) 1/ x 51/ - 21⁄
2 4
P Upper Back Shelf Face (1) 1/ x 3 - 13
2
Q Lower Back Shelf Sides (2) 1/ x 51/ - 3
2 4
R Lower Back Shelf Face (1) 1/ x 3 - 13
2
S Cord Cleats (4) 1x2-6
TOP
T Top Support (2) 221/2 x 481/2 - 3/4 MDF
U Top (1) 221/2 x 481/2 - 1/4 Hdbd.
V Top Side Edging (2) 3/ x 13/ - 50
4 4
W Top End Edging (2) 3/ x 13/ - 24
4 4
Page 1 of 4 ShopNotes 90

DRAWERS
X Drawer 1 Front/Back (2) 33/4 x 211/2 - 1/2 Ply.
Y Drawer 1 Sides (2) 33/4 x 18 - 1/2 Ply.
Z Drawer 2 Front/Back (2) 33/4 x 111/4 - 1/2 Ply.
AA Drawer 2 Sides (2) 33/4 x 14 - 1/2 Ply.
BB Drawer 3 Front/Back (2) 5 x 211/2 - 1/2 Ply.
CC Drawer 3 Sides (2) 5 x 18 - 1/2 Ply.
DD Drawer 4 Front/Back (2) 5 x 111/4 - 1/2 Ply.
EE Drawer 4 Sides (2) 5 x 14 - 1/2 Ply.
FF Drawer 5 Front/Back (2) 61/4 x 211/2 - 1/2 Ply.
GG Drawer 5 Sides (2) 61/4 x 18 - 1/2 Ply.
HH Drawer 6 Front/Back (2) 61/4 x 111/4 - 1/2 Ply.
4
II Drawer 6 Sides (2) 61/4 x 14 - 1/2 Ply.
JJ Drawer 7 Front/Back (2) 73⁄8 x 111/4 - 1/2 Ply.
KK Drawer 7 Sides (2) 73⁄8 x 18 - 1/2 Ply.
LL Drawer 8 Front/Back (2) 73⁄8 x 111/4 - 1/2 Ply.
MM Drawer 8 Sides (2) 73⁄8 x 14 - 1/2 Ply.
2
NN Lrg. Drawer Bottoms (4) 171/2 x 213/4 - 1/4 Ply.
OO Sm. Drawer Bottoms (4) 131/2 x 111⁄2 - 1/4 Ply.
PP Drawer 1 False Front (1) 23/4 x 237⁄16 - 3/4 Ply.
QQ Drawer 2 False Front (1) 23/4 x 133⁄16 - 3/4 Ply.
RR Drawer 3 False Front (1) 4 x 237⁄16 - 3/4 Ply.
SS Drawer 4 False Front (1) 4 x 133⁄16 - 3/4 Ply.
TT Drawer 5 False Front (1) 51/4 x 237⁄16 - 3/4 Ply.
UU Drawer 6 False Front (1) 51/4 x 133⁄16 - 3/4 Ply.
VV Drawer 7 False Front (1) 63⁄8 x 237⁄16 - 3/4 Ply.
WW Drawer 8 False Front (1) 63⁄8 x 133⁄16 - 3/4 Ply.
©2006 August Home Publishing. All rights reserved.
Page 2 of 4 ShopNotes 90 ©2006 August Home Publishing. All rights reserved.
Page 3 of 4 ShopNotes 90 ©2006 August Home Publishing. All rights reserved.

Page 4 of 4 ShopNotes 90 ©2006 August Home Publishing. All rights reserved.
 ® Cutting Diagram
roll-around Work Cart
Materials
CASE
A Case Top/Bottom (4) 191/2 x 431/2 - 3/4 Ply.
B Case Sides/Divider (3) 191/2 x 243/4 - 3/4 Ply.
C Wide Back (1) 24 x 24 - 3/4 Ply.
D Narrow Back (1) 24 x 133/4 - 3/4 Ply.
E End Edging (4) 11/2 x 11/4 - 191⁄2
F Corner Posts (4) 11/2 x 41/2 - 27
G Side Edging (4) 11/2 x 11/4 - 37
H Vertical Edging (1) 11/2 x 11/4 - 24
SHELVES
I End Shelf (2) 1/ x 31/ - 19
2 4
J End Shelf Sides (4) 1/ x 21⁄ - 31/
2 2
K Upper End Shelf Face (2) 1/ x 3 - 19
2
L Lower End Shelf Sides (4) 1/ x 3 - 31/
2 4
M Lower End Shelf Face (2) 1/ x 3 - 19
2
N Back Shelf (1) 1/ x 51/ - 13
2 4
O Upper Back Shelf Sides (2) 1/ x 51/ - 21⁄
2 4
P Upper Back Shelf Face (1) 1/ x 3 - 13
2
Q Lower Back Shelf Sides (2) 1/ x 51/ - 3
2 4
R Lower Back Shelf Face (1) 1/ x 3 - 13
2
S Cord Cleats (4) 1x2-6
TOP
T Top Support (2) 221/2 x 481/2 - 3/4 MDF
U Top (1) 221/2 x 481/2 - 1/4 Hdbd.
V Top Side Edging (2) 3/ x 13/ - 50
4 4
W Top End Edging (2) 3/ x 13/ - 24
4 4
Page 1 of 3 ShopNotes 90

DRAWERS
X Drawer 1 Front/Back (2) 33/4 x 211/2 - 1/2 Ply.
Y Drawer 1 Sides (2) 33/4 x 18 - 1/2 Ply.
Z Drawer 2 Front/Back (2) 33/4 x 111/4 - 1/2 Ply.
AA Drawer 2 Sides (2) 33/4 x 14 - 1/2 Ply.
BB Drawer 3 Front/Back (2) 5 x 211/2 - 1/2 Ply.
CC Drawer 3 Sides (2) 5 x 18 - 1/2 Ply.
DD Drawer 4 Front/Back (2) 5 x 111/4 - 1/2 Ply.
EE Drawer 4 Sides (2) 5 x 14 - 1/2 Ply.
FF Drawer 5 Front/Back (2) 61/4 x 211/2 - 1/2 Ply.
GG Drawer 5 Sides (2) 61/4 x 18 - 1/2 Ply.
HH Drawer 6 Front/Back (2) 61/4 x 111/4 - 1/2 Ply.
4
II Drawer 6 Sides (2) 61/4 x 14 - 1/2 Ply.
JJ Drawer 7 Front/Back (2) 73⁄8 x 111/4 - 1/2 Ply.
KK Drawer 7 Sides (2) 73⁄8 x 18 - 1/2 Ply.
LL Drawer 8 Front/Back (2) 73⁄8 x 111/4 - 1/2 Ply.
MM Drawer 8 Sides (2) 73⁄8 x 14 - 1/2 Ply.
2
NN Lrg. Drawer Bottoms (4) 171/2 x 213/4 - 1/4 Ply.
OO Sm. Drawer Bottoms (4) 131/2 x 111⁄2 - 1/4 Ply.
PP Drawer 1 False Front (1) 23/4 x 237⁄16 - 3/4 Ply.
QQ Drawer 2 False Front (1) 23/4 x 133⁄16 - 3/4 Ply.
RR Drawer 3 False Front (1) 4 x 237⁄16 - 3/4 Ply.
SS Drawer 4 False Front (1) 4 x 133⁄16 - 3/4 Ply.
TT Drawer 5 False Front (1) 51/4 x 237⁄16 - 3/4 Ply.
UU Drawer 6 False Front (1) 51/4 x 133⁄16 - 3/4 Ply.
VV Drawer 7 False Front (1) 63⁄8 x 237⁄16 - 3/4 Ply.
WW Drawer 8 False Front (1) 63⁄8 x 133⁄16 - 3/4 Ply.
©2006 August Home Publishing. All rights reserved.
Page 2 of 3 ShopNotes 90 ©2006 August Home Publishing. All rights reserved.
 48" x 96" - !/4" PLYWOOD

Page 3 of 3 Shopnotes 90 ©2006 August Home Publishing. All rights reserved.

Building a Simple:
Plunge Router
Mortising Jig
One of the best ways
to get the biggest
bang from a plunge
router is to put it to
work routing mor-
tises. The technique,
explained in Shop-
notes No. 90, is easy
to master and the
results are topnotch.
And the clincher is
that, from setup to
completion, the whole process takes only
a few minutes. The key is the simple-to-
build and easy-to-use mortising jig you
see in the photos. heart of the jig and serve two purposes. baseplate is cut to size from 1⁄4" hardboard.
Overview — A Simple Jig. So before First, they’re used to easily and accu- (You could substitute 1⁄4" plywood or phe-
you can start routing mortises, you’ll need rately position the mortise in the workpiece nolic.) The long rectangular shape gives
to build the jig. My emphasis here was on by allowing you to reference the cut off one you more stability and allows for longer
keeping things very simple, so this won’t edge. Second, the two guides sandwich guides. I used the standard baseplate to
keep you away from the work for long. the workpiece snugly to give you steady locate the countersunk holes for the attach-
Take a look at the drawing below and control of the router as the mortise is being ment screws and a centered hole for the
you’ll see that the working parts of the jig cut. This makes it possible to cut accurate bit. You’ll want to use the largest Forstner
consist of an auxiliary baseplate and two mortises in even very narrow stock. bit in the shop to drill the center hole. This
adjustable guides. The baseplate is simply First, the Baseplate. Now let me give will give you a better field of view around
a “slotted” piece of hardboard that rides you the “short course” on how to build the the bit while routing.
along the workpiece. The guides are the jig. As shown in the drawing, the auxiliary Two slots in the baseplate, along with
carriage bolts and wing nuts, allow you to
adjust and tighten down the guides. The 5"-
long slots let the jig accommodate a wide
range of workpieces. After routing the
slots with a straight bit in the router table, I
screwed the baseplate to the router.
The Guides. Next, I cut the two guides
from ¾"-thick hardwood. You’ll notice that
they’re a little longer than the baseplate.
This simply makes them easier to grasp
and adjust when the router and jig are
resting on the workpiece.
Once the guides are cut to size, you’ll
need to drill a pair of counterbored bolt
holes through each one. The spacing of the
holes in the guides should precisely match
that of the slots in the baseplate. When
installed, you want be able to adjust them
easily on the baseplate.
And that brings us to the final step. Sink
a carriage bolt firmly into each hole, pass
the ends through the slots in the baseplate
and add washers and wingnuts. All you
need is a bit in the router and you’re ready
to go to work.

Page 1 of 1 ShopNotes No. 90 ©2006 August Home Publishing. All rights reserved.
 Cutting Diagram
®
3-in-1, shop built
Multi-Tool
Materials
CASE
A Base (1) 14 x 12 - 1/2 Ply.
B Sides (2) 10 x 12 - 1/2 Ply.
C Case Back (1) 10 x 13 - 1/2 Ply.
D Top (1) 14 x 12 - 1/2 Ply.
E Back (1) 14 x 14 - 1/2 Ply.
F Router Plate (1) 5 x 12 - 1/4 Phenolic
G Filler Plate (1) 5 x 12 - 1/4 Phenolic
WORKPIECE SUPPORTS
H Cleats (2) 21/2 x 121/2 - 1/2 Ply.
I Tops (2) 5 x 11 - 1/2 Ply.
J Sides (2) 5 x 8 - 1/2 Ply.
Page 1 of 1 ShopNotes 90

K Supports (2) 7 x 7 - 1/2 Ply.
L Pinch Blocks (2) 7/ x 2 - 1/2 Ply.
8
FENCE
M Face (1) 3 x 14 - 1/2 Ply.
N Base (1) 21/2 x 14 - 1/2 Ply.
O Braces (4) 2 x 2 - 1/2 Ply.
P Dust Port (1) 33⁄8 x 3 - 1/2 Ply.
JOINTER FENCE
Q Fence (1) 3 x 25 - 1/2 Ply.
MORTISING GUARD
R Hold-Down Face (1) 2 x 12 - 1/2 Ply.
S Plate (1) 1 x 12 - 1/4 Phenolic
©2006 August Home Publishing. All rights reserved.