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THEARTOFWOODWORKING

HOMEWORI$HOP
 WORKSHO
GPU I D E
INVENTORY
OFJIGHARDWARE

Wood acrewa
Oval(below,lefL)and flat head (below,
cenLer)are ueedfor counLereinktnq;
@@(a
Waehera
I
roundhead(below,
Uaedt.o helpdiaLributeload
whenueinqnuta and bolte;lock
Toggle I
ffi;rfr
rtqht) can be clampe
removedeaerly.
(cenLer)and epltL(rt4hL)Lypee
deai7nedto keepnu1,from looaen-
Qutck-acLin4
clampe that are faaLened to
t
Typtcallyavail- tnq;avatlabletn a vanety of aizeo jiqa Lo hold etock in place
ablefrom'l Lo 6 I

AHH
incheelonq;com-
mon head typee Threadedinaert
I
includeelotted,
Fhilipe,and equare
iifir:'@W& 1eneralfaetentn4of wood;etandard hexnut
Knockdown faatener
usedwith acrewgor
bolt;oLojoin compa- I

l#t#,'w
(above,left) provideaeaeyacceeafor t urnrn4;
wtngnuL (above,cent,er)ta uaed wheredio- t
aeeemblyand reaeeemblyie expecLed;T-nut
(above,riqhL) te ueed ae a knockdown faeLen-
er or rn ertuaLionswherebolLie no| acceeetble
applicattone I
after aeeembly;avatlabletn a varieLyof aizee
C,f
v v '
r nv n| v n) , at ahle TT T7 TT I
and eaeilymachrned,plaeLice auchaa_ Common naile Fl Fl FI
acryltc,polycarbonaLe,phenoliceheel,, Featureqroovedll Fl trI T
and polyeLhylene(HDFE) are often ueed
ae eee-throu7h 4uarde, Lemplateo,and
tneertplaLeefor rouLerLablee Knockdown hardware iLem allowtnqjt7
Lo be taken aparL and reaesembled
wiLhouLeLripptng ecrew Lhreade;
ahankafor
otrenqthand ll

lenathtvpicallv ll
J r t
ll
h o l d i n 7 p o w e rl :l

b e L w e e n l a n dl l
6 inchee
v | |
ll
Il
ll
II
|

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U
threaded dowel te ineert ed in one
part of ji4 perpendtcular to bolL; bolLs [J
" llV I
ranqe between 1and 3 inchee

6olta
I
Ueed wiLh nuLe for faeLenin7 E
wood; carria7e bolt (near rtght)
E
E
E
I
Plaetic knobsand handlee feaLurce oquare necl Lo keep bolr E
jiqe durin4opera-
For conLrolltnq
ttona;offer comfortablegrtppin4eur-
from roLaLtng, hanger bolt (far E
R
I
ri7ht) featuree machine fhreade
face;nylonwaaherareducevibration on one end and wood 1crew thread'
on Lhe o1;her;eizeo typtcally ranqe
I
'/,
from 1 Lo 6 tnchea rn lenqLh
Cam clamp and I to /, inch in diameLer F+
t*
>
Pneumatic
clamp
I
Ueedto aecure Ueeeair
workpiece
injiq; Lurn Miter bar
nrpaat trp f ^ I
'/," oecure workpteceer;ojiqe:
handleLo Ftl,eetandard x'1" miter 4auqeelol,;
increage aerveoa6 foundaLtonfor a number clampinqpreaeure adju.,t -
able from 20 to 160
I
clampinq of ueefuljtge tncludtnq
a Lable
Preaaure
eaw croaacul;jig, a miter
jtg, and a feaLher-
pounde: varieLy of clamp-
inq arme available for a
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POara ran7e of applrcatlonz
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S O U R C EFSO RJ I GH A R D W A R E
I
,j M a n yh a r d w a rset o r e a s n dw o o d w o rnkgi w a r ei n a v a r i e toyf s i z e o
s n h a n di n listof essential jig hardware: formorespe-
",ad
supplh y o u s eosf f e rs p e c i a l i z he ad r d w a r e
f o rs h o p - m a d e sa n df i x t u r e sl t. i s a
y o u rs h o p ,s i n c es p e n d i nt o
t i m em a k i n a
g om u c h
g j i g d e f e a tpsa r ot f i t sp u r -
c i f i ca p p l i c a t i ocnhse, c o
tradedirectories
k u tb u s i n e a
aswellasmanufacturers
s sn d I
lig
g o o di d e at o h a v ea s u p p loy f 1 i gh a r d - p o s eT. h ei t e m sa b o v e p r o v i dae b a s i c a n ds u p p l i eor fsi n d u s t r i p a rl o d u c t s .
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THEARI OFWOODWORKING
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I SHOP-MADE
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IIGSANDFDilURES
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 THEART OF WOODWORKING

SHOPME
FDffT'RES
IIGSAI.{D

TIME-LIFE
BOOKS
ALEXANDRIA,VIRGINIA
ST.REMYPRESS
MONTREAL.
NEWYORK
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THE ART OF WOODWORKING was produced by
ST. REMYPRESS
THECONSUITANTS
r
JonArno is a consultant,cabinetmaker, and
PUBLISHER KennethWinchester
freelancewriter who livesin Troy,Michigan. He
alsoconductsseminarson wood identification
I
PRES/DENT PierreL6veill6 and earlyAmericanfurniture design.
SeriesEditor PierreHome-Douglas
I
I(am Ghaffari is a freelancewriter and editor.
SeriesArt Director FrancineLemieux
SeniorEditors Marc Cassini(Text)
He hashis own businessin RhodeIsland
designingand building one-of-a-kindand lim-
I
HeatherMills (Research)
ited production furniture. Kam'sbackground
Art Directors Normand Boudreault,Luc Germain,
SolangeLaberge
alsoincludesworking professionallyin furni-
ture reproductionand fine carpentryand
I
Designers Lina Desrochers,H6ldneDion, studyingwith furniture patriarchsWendell
Research
Jean-GuyDoiron, Michel Gigudre
Editor Jim McRae
Castleof the U.S.and England'sFredBaier. I
PictureEditor ChristopherJackson
Writers Andrew Jones,Rob Lutes
GilesMiller-Mead taught advancedcabinet-
making at Montreal technicalschoolsfor more
I
ResearchAssistant BryanQuinn than ten years.A nativeofNew Zealand,he has
Contr ibuting lllu strators GillesBeauchemin,RolandBergerat,
MichelBlais,Jean-Pierre
Bourgeois,
worked asa restorerof antiquefurniture. I
RonaldDurepos,RobertPaquet,
fosephTruini is SeniorEditor of Hoze
IamesTh6rien
Administrator NatalieWatanabe
Mechanixmagazine. A former Shopand Tools I
Editor of PopularMechanics,he hasworked as
ProductionManager MichelleTurbide
SystemCoordinator ]ean-LucRoy
a cabinetmaker,home improvementcontrac-
tor, and carpenter. / I
Photographers RobertChartiet ChristianLevesque
Administ rativeAssistant Dominique Gagn6
Proofreader Iudith Yelon
t
Indexer ChristineM. Jacobs Shop-madejigs and fixtures
p. cm.-(The Art of Woodworking) I
Includesindex.
Time-Life Booksis a division of Time Life Inc.,
a wholly ownedsubsidiaryof
ISBN0-8094-9508-2
l. Jigsand fixtures.
(trade)
I
THE TIME INC. BOOK COMPANY I. Title: Shop-madejigs and fixtures.
IL Series
Tll l87.ss41993
t
TIMELIFEINC. 684'.083-dc20
Presidentand CEO JohnM. Fahey
93-34t03
CIP I
Editor-in-chief JohnL. Papanek
For information about any Time-Life book,
t
pleasecall l-800-621-7026,or write:
TIMB-LIFEBOOKS ReaderInformation
Time-Life CustomerService
I
President JohnD. HaIl P.O.BoxC-32068
Directorof Marketing NancyK. fones
Vice-President,
ExecutiveEditor RobertaConlan
Richmond,Virginia I
23261-2068
ExecutiveArt Director EllenRobling
@ 1994Time-LifeBooksInc.
I
ConsultingEditor lohn R. Sullivan All rights reserved.
ProductionManager MarleneZack No part of this book may be reproducedin
any form or by any electronicor mechanical
I
means,including information storageand
retrievaldevicesor systems,without prior I
written permissionfrom the publisher,except
that briefpassages may be quoted for reviews.
First printing. Printed in U.S.A.
I
Publishedsimultaneouslyin Canada.

TIME-LIFE is a trademarkof Time Warner

I
Inc. U.S.A.
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I CONTENTS
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I 6 INTRODUCTION 68 TURNING IIGS
I 7l TWocenteringjigs
t 2 ROUTING AND 72 Gouge-sharpening jig
I SHAPING JIGS 73 Spindle-turningjigs
t t6 Dadoingjigs 75 |ig for fluting columns
20 Circle-cuttingjigs 77 figs for sandingand checkirg depth
I 2T Routerjointing jig
22 Hinge mortising jig 78 GLUING AND CLAMPING JIGS
t 23 Corner-roundingjig 81 Edge-gluingjigs
I 24 Panel-raisingjig 86 Frame-clamping jigs
25 Adjustablerouting guide 89 Carcase-clamping jigs
t 26 Joint-makingjigs 90 Workbenchclampingjigs
r 31
34
Shaperjigs
Vacuumjigs 94 SANDING IIGS
I 96 |igs for face-and edge-sanding
I 36 CUTTTNG
IrcS 98 Auxiliary sandingtables
40 Sizingboard for crosscuts 100 Hand-sandingjigs
I 4l Miter and crosscutguide
42 Ripping jigs IO2 TOOL EXTENSIONSAND TABTES
I 43 TWocircle-cuttingjigs 105 Plateioiner stand
I 46 Wedge-makingjig 106 Tablesfor power tools
47 Two jigs for anglecuts II2 Viseextensionstand
I on the band saw 113 Adjustableroller stand
48 Thperjigs
I 49 A bladeheight gauge II4 STORAGEDEVICES
I 50 Crosscutand miter jigs II7 Storingsawsand blades
52 Raisedpaneljig 118 Mobile clamprack
I 53 Board-straighteningjig 120 Lumber storageracks
I 54 Auxiliary fencesand tables
56 Cove-cuttingjig T22 SHOPAIDS
I 57 TWotenoningjigs 125 Safetvdevices
I28 Sawhorses
I 60 DRIIIING JIGS 130 Workshophelpers
I 62 Center-drillingjig
63 Tilting tablejig I4O GLOSSARY
t 64 fig for drilling equally
I spacedholes I42 INDEX
65 V-block jig
I 66 Pockethole jig I44 ACKNOWLEDGMENTS
67 Boring deepholes
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 INTRODUCTION

R. J.De Cristoforoon

DESIGNINGIIGS
J lookat anewtoolasabeginning.Onceit istakenfromitsboxor crateI readthe
I owner'smanualto learnwhatthemanufacturel strggests
thetool cando.ThenI
standbackandthink, "Theremustbemoreto it thanthis."
Inevitably,
bysomestrange thoughtprocess I cantexplain,thereappears amental
picttueof ajig, sometimes simpleenoughto testimmediatehothertimeselaborate
enoughto requirea session atwhatat onetimewasa drawingboard;now,I design
onmycomputer. Thenewjigmight enablethetoolto dosomethingits desigrernever
envisioned or it mightincrease accuracywith minimumfuss,or it couldadda safety
factorto a routineoperation.ln anycase, it hasto becustom-made sinceit is rarely
available commerciallv.
I'vedesigred dozeniofjigsfor powerandhandtools.Still,for meit'snotanobses-
sion:Practicality andshoptestingmustprovethejig'sworth.Somefolla
is essential
jigs
think that areonlyfor amateurs. If so,therearemanyprofessionals workingin
amateurish ways!
|igsaremeantto beused.ThosethatI designarenot madefor thesakeof a mag-
azinestoryor abookandthenstoredor discarded. ln a sense,I conceiveaprojectthat
helpsmeexploitamachine, or assists
mein workingmoreaccurately andsafely, and
thenI shareit with otherwoodworkers. If I'veproventhatajig will beusefulto just
onereaderthenit hasvaluefor me.
I m fondof themasterjigsthatI havemadefor thedrill pressandbandsaw,and
especially theunit for thetablesawshownin thephotoat left.Itsbasiccomponent
is a generous slidingtablewith removable insertssoit canfunctionwith a dadoing
toolaswellasasawblade. Itsattachments includeadjusable guides for accurate cross-
cuttingandmiteringandamountable unit-a jig in itself-thatallovrscutsliketenons
andslotsin theendof narrowstock.Thedeviceincludesa numberof essential but
usuallyseparate jigsandaddstheadvantages of a slidingtableto eachof them.
There's no doubtthatjigscanhelpanywoodworker, but theymustbemadecare-
frrlly.Thesearesituationswhereit pap to take10minutesto do a five-minutejob.
Consider thatthejigwillbe alifetimetoolandyodllagreethatmakingit rightisthe
onlywaytogo.

R. J. De Cristoforo,author of numerous
boolcson woodworkingand othersub-
jeds,liva in LosAltos Hills, Californin
 INTRODUCTION

Ted Fullerandhis

ROUTERIIG
\r/ earsago,I workedin an autobody shop,wherewe hand-formedbodypanels.
I Oftenweneededtwo matchingpanels-one for eachside-but weneverpro-
"You
ducedexactmirror images.Subtledifferences wereeasilyexcused: can'tseeboth
sidesat thesametime."it wassaid.
In cabinetmaking, hor.vever, matchingpiecesmustbeexactduplicates. Youusually
canseethemat thesametime. Although some masterscanaccomplish thisfreehand,
most of us must rely on carefullyconstructedjigs.
I wasluredto woodworkingin gradeschoolwhentheshopteacher put meto work
on the props for a Christmas play.I learnedearlythatthetimespenton thejig or tem-
platemeanttime savedand consistency gained.
Thereareplentyof jigs and fixtures'onthe marketbut, like baseballgloves,only
your own hasjust the right fit. Whenyou makeajig yourself,it is designedfor a specific
applicationandsizedto matchyour project.Bestof all,you don'thaveto changethe
projectto fit the store-boughtfixture.It's alsolessexpensive.
Making arched-topraisedpaneldoorsis one example.A manufacturedjig, and
pre-cuttemplatesthat enableyou to do thejob costseveralhundreddollars.Forthe
custompieceI amworkingon in thephotographI built a simpletemplateout of ply-
woodto createthe contourfor thearchedtop rail.Thisparticularjig is adjustable for
two widthsof doors.Wideror narrowerdoorswill requireanotherjig anda re-draft
ofthe curve.
With the multitudeof top-bearingrouterbits on the market,exactcontoursare
quickandeasyto duplicate.Simplyroughout thepieceto shape,clampon thetem-
plate,androut to thefinishedshape. Anotherbenefitof thisform of duplicationis
thatit doesnot leavethetool mark thatabandsaw wouldandtherefore reduces sand-
ing considerably. Thenextstepis to run thepiecesthrougha matchedsetof rail and
stilecuttersto rout the profile on the sticksand makethe copecuts.It's a goodidea
to markthedimensions, bit selection,andset-upinformationon thejig sorecalcu-
lationis not recuired.
I think oneolthe mostintriguingthingsaboutwoodworkingisthatthereis always
someriggingthatwill makethework easier, faster,andbetter.Theonlyreallimitation
is your own imagination.

TedFuller is theproductmanagerat Delta

Cable(Canada)
InternationalMachinery/Porter-
in Guelph,Ontario.He is currentlyworkingin
newproductdevelopment and marketingfor
woodworking tootsqnd' r"n2::
: #;":fri.
 INTRODUCTION

BruceBeekenand Ieff Parsonsdiscuss

PLANNINGIIGS
p u.ry*oodworkeruses jigsregularly.Markinggauges, combination squares, the
I-l rip fenceon a tablesaw,androuterbitswithball-bearing pilotsarealljigsthat
aretakenfor granted. Andwhohasn't, atonetimeor another, madeasimplethinga-
majigon thespurof themomentto helpgeta certainjob done?
In ourshop,wedesign mostof thefurniturewemake.In developing a newpiece,
weconsider theesthetic andthebuildingprocess atthesametime.Our chairs,for
example, havepartsthatdorit comestraightfrommachine tables becausewelikethem
to havea certainstance to supportthepersonsittingon themjustso.
Someof our morecomplex jigsareusedin chairmaking.Thesesortsof jigsare
plannedfromtheoutset,tailoringtheprocess to thedesign. Wedevelop themon a
full-scaledrawingasweworkoutourconcept of thefurniturepiece. A clearunder-
standing of thestepsandtheirsequence notonlymakes thewholejoblessintimidating
but oftensuggests waysto simplifytheprocedure andrefinethepieceitself.
Sometimes ajig isassimpleasa wedge to jackup a partattheproperangle.We
havealsofoundthatjigscanservemorethanonepurpose, travelingwith apartfrom
machine to machine. Thehome-made deviceshownin thephoto,for example, isused
forbothformingchairlegsontheshaper andcuttingmortises in themonthemortiser.
Westartby bandsawingblanksto approximate size.Theyarethenfastened to the
jig-in pairs,sincethejig hastwoedges. Weshape theinsidefaces of thelegs.Then,
by changing shaper knives,shiftingthedowelpegsin thejig, andrepositioning the
legs,wecanusethesamejig to shape thefeet.Onceallthepartshavebeenformed,
wereturnthepegsto theface-shaping positionandboltthejig to ourmortiser's table.
Thejig thenholdsthelegsin theproperpositionasthemortises arecut.
Therearetimesthat,with a littleextraeffort,ajig canbemadeto serve a general
purpose: for instance, ahingedtaperjig forthetablesawor thickness planer,or arouter
boomfor cuttingarcs.
Theuseofjigsisinseparable fromourunderstanding of howto makethefurniture
wedesign. Evenif apieceisto bemadejustonce,it islikelythatwewill develop and
useajig somewhere alongtheline.Whenweareproducing abatchof several hundred
chairs,jigsarecriticalin almosteverymovewemake.Whethersimpleor complex,
theyserve asthelinkbetween drawingandtool,ensuring consistent,preciseresults.

BruceBeekenandJeffParsons aregraduatesof Boston

University's
Programin Artisanry.Theybuildfinefurniture
at theirshopat Shelburne
Farms,Shelburne, Vermont.
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I ROUTING
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I Q in.. itsinvention earlyin the20th (lF ROUTING
A SEIECTIOI{ ANDSHAPING
JIGS
tJ Centurv. therouterhasbecome one
I of themostpopularportablepower
tools-andwithgoodreason. Fewtools Dado-routin7 jig
canmatchitsspeed,accura6/> andver- (pa6e 17)
I satilityfor shapingwoodor cutting
Faatenedto router
baae plate to cut
t joints.Butjigsarealmosta necessity; equallyopaced
althoughtheroutercanbeusedfree- dadoea
I hand,mostcutsrequirea guide-par-
ticularlyrepeatcuts.
I Thejigsfeatured in thischapter pro-
videvariouswaysof obtainingquickand
I precise resultsfromyourrouter.Some,
likethedadoing jigsshownbeginning
I on page16,reducethesetuptimefor
simpleprocedures. Others, likethelap Auxiliary rout'er
aub-baae (page 21)
joint jig on page27,allowthetoolto
I produce multiplecopies of thesame
)ff-oquare base eecured
to router baoe plate to
joint in a fewminutes. A relativelynew
I woodworking development, vacuum-
enabletool to makecuta
wider than bit diameter
poweredaccessories (page34)elimi-
I natethe need for conventional clamps Freeatanding ahaper
whenrouting patterns usingatemplate. suard (pa6e 33)
I Thevacuumpumpis alsousefulfor Trian4ularcutter \
K
auard with viewhole
I securing featherboards to a routertable. for freehand ehaping
All of these jigsareeasyandinexpensive
I to build.
Theroutertlargercousin, theshaper,
T canperformmanyoperations better
thanthesmallertool,but it isgenerally
I regarded asoneof themostdangerous
toolsin thetypicalwoodshop. A shop-
madefeatherboard (page 32)andguards
I (page jj) will makeit a safertool.
I
_---:
shaperguard (page55)
I quardprotectaueerdurin4fence'
L-ehaped
quidedehapinqoperationo;featureaviewhole
I Aidedbya simplejig, a table-mounted
routercutsa perfectboxjoint.

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ROUTING AND SHAPING IIGS
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5liding dovetail jig
Corner halFlap
joint jiq (page 27)
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(paqe 26)
Uaedwith router to cut
Uaedfor routin7 cor-
ner half-lapjointa
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both parta of alidin7 dove-
tail joint; holda router hor-
izontallyand eliminatea
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need for router table
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Hinge-mottiaing jig
(pase 22) t
Clampedto edqe
of workpieceto rout
hinqemorLiaea
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Movable-jaw I
moftiain7 ji6 Qa6e 29)
Adjuatablejawo enaure
that cut ia centered on
t
the edqe of atock
I
?anel-raising jig
(pase 24) I
Uaed with router to
bevelpanel edqea;holda
router in horizontal
I
poaition, eupportinq
panel on a broad table I
Adjuetable mofiiaing jig
(pase 28)
Holda workpieceed4e-up
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for cuttina morLiaee
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I ROUTING AND SHAPING IIGS
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Extended ehaper Adjuatable airale-
I featherboard (paqe 32) autting jig (page 2O)
Clampedto ohaper fence Lo Ueedwith router to cut
I aupporb workpieceedurin4
fence-7uidedcuta and pro-
circlea. )crew ia fixed to center
of circle; radiua determined by
diatance betweenscrewand bit
I tect uoer from cutter

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to router baeeplate to 4uide
tool around circular cuLs

Adjuetable routin4
guide (page 25)
Adjuatable edqe quidee
ueed with router to cut
I recta nquIar qroovea;tem -
platea can be added to
I rout patterne

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Quiak-aetup
t Shaper airale-autting jig
(pase 31)
dadoing jig (page 18)
Conaiataof two L-ehapededge4uideefor
V-ehapedjiq quideacircular
I atock duringahapin4operationa
routin7 dadoea:quideereatfluah aqainet
oppoaite ardeaof router baee plate
I
I T-equarejig (paqe 16)
Clampedto workpiece,
I Adjuatable dadoing jig
(pase 19) jiq qurdearouter
Securesworkpieceo through dado cute
I of varyinqwidtha ,
for dado cuta
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DADOINGJIGS
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A T-SOUARE
JIG
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Edqe qutde
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1 Building theiig
I Toroutdadoes thatarestraight and I
square to theedges of yourstock,usea
r) Routing
T . s n r r airi epl i k et h eo n es h o w a
" I'b "''" nb o v e .
M a k et h e j i g f r o m3 / q - i n cphl y w o o ds,i z - L Clamp
a dado
thejigto theworkpiece, aligning thedadoin thefence
I
i n gt h e p i e c e tso s u i tt h e s t o c ky o uw i l l . h e nm a k i ntgh ec u t ,p r e stsh e
w i t ht h eo u t l i n oe nt h es t o c kW I
b e u s i n ga n d t h e d i a m e t eor f y o u rr o u t - routerbaseplatef irmlyagainst theedgeguide(above). Continue
fence stopping the router.
or haco nl:tp

b ea b o u 4 t inchew
Thp cd'sc srridp shnrrld

s i d ea n d l o n g etrh a n
thecuta short distance into the before I
t h ew o r k p i e c ew' si d t h :t h e f e n c e .a l s o I
a b o u t4 i n c h e sw i d e ,s h o u l de x t e n do n il lll ilil,l|lllllill '[l il dliltt
NiifilxllXl,lli,lii]}1iittr
orthor side nf thp orrido hv ehnrri thp

w r d t ho f t h e r o u t e rb a s ep l a t e A
. ssemble
I
t h e 1 i gb y a t t a c h i ntgh ef e n c et o t h e e d g e 1HO?Tt? ) a '

t;t-
.r f t
g u i d ew i t h c o u n t e r s u ns kc r e w sU. s ea ( - @
T-equareroulinq guide
try squareto makecertainthe two pieces A draflingToquarecan I
a r ep e r p e n d r c u tl a o re a c ho t h e r T. hen b e u e e dt o g u i d ey o u r
c l a m pt h e l i g t o a w o r ks u r f a c e a n d ,w i t h rouf,erthroughdado I
t h e b a s ep l a t ea g a i n stth e e d g eg u i d e , culs. To cuslomize
r o u ta s h o r td a d oo n e a c hs i d eo f t h e t h e j t q f o r y o u rt o o l , I
fencewith yourtwo mostcommonly used clam?Lhe7quareto
bits-often r/zand3/qinch Thesedadoes a ocra?board,buLLinq
iLecroooViece aqainel I
i n t h e f e n c ew i l l m i n i m i z tee a r o uwt h e n
the boardedqe.KideIhe
t h e l r g r s u s e da n d h e l pa l i g nt h e l t g
rouLerbaoeplabealonq I
w i t ht h e c u t y o uw i s ht o m a k e .
the arm of the oquare,
cuLLing into the boardand I
Lrimminq LhecroseViece. Touse
lhe jiq, clamViI Lo Nheworkpiece I
wilh the cuf,edgeof NhecroooViece
aliqnedwilh Xhecu|Ninqmarkon Lhestrock.KouNthe
dado,keepinq NhebaeeplatrebutrtedagaineN
Ihe arm.
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I ROUTING AND SHAPINGIIGS
I
I A JIGFOR
EVENLY
SPACED
DADOES
I 1 Assembling thejig
I Thejig shown at rightis idealforcuttingequally
I spaced dadoes witha router. Dimensions depend on
thesizeof theworkpiece andthespacing between the
I dadoes. Beginbycuttinga pieceof lo-inchplywood
forthe base,makingit a fewinches widerthanthe
I diameter of yourrouter's baseplateanda fewinches
longer thanthespacing between thedadoes. Setthe
I baseona worksurface andplaceyourrouternearone
end.Markthescrewholesin therouterbaseolaieon
I thebase; alsomarka spotdirectly below thetool'scol-
let.Boreholesfor the screws andcut a holeat the
I colletmarklargeenough fortherouterbit.Remove the
r o mt h et o o l ,s c r e wt h ej i g b a s et o t h e
s u b - b a sf e
t routerbaseplate,andinstalla straight bitthesame
widthasthedadoes youwishto rout.Next,cuta spac-
I erto fit snuglyin thedadoes, making it slightly longer
thanthewidthof theworkpiece. Screw thespacer to
I the bottomof thejig, making thedistance between
it andthe bii equalto thespace youwantbetween
I vour dadoes.

I
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t
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r) Cutting thedadoes
I L Clamovour stockto a worksurface and
setthejig ontheworkpiece withthespac-
I erflushagarnst oneendandtherouter bit
a t o n ee d g eH. o l dt h er o u t efri r m l ya n d
I feedit across thesurface to routthefirst
dado,keeping thespacer flushagainst the
I workpiece. Turnoff therouterandinsert
thespacer in thedado,repositioning the
I clamps asnecessary. Routthenextdado,
sliding thespacer in thefirstdado. Contin-
t ue(lefluntilallthe dadoes havebeencut.
(Tovarythe location of yourfirstdado,
I routit witha T-square guideliketheone
shown on page16,rather thanwiththe
I spacer jig.)

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ROUTINGAND SHAPINGiIGS t
t
DAD()
A OUICK.SETUP JIG I
1 Assembling thejig I
I Thejig shownat leftmakesit easy
to routdadoes withminimal tearout. The I
device consists of fourstriosof %-inch
plywood attached to formtwoLs.Ripall I
thepieces of thejig about4 inches wide.
Cuttheedgeguides a fewinches longer I
t h a nt h ec u t y o ui n t e n dt o m a k eT. h e
cleats shouldbe longenough to overlap I
theadjacent edgeguidebyseveral inches
whenthejig is setup.Fasten theedge I
guides to thecleats, making certain the
pieces aresquare; usefourcountersunk I
screws foreachconnection.
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t
t
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r) Routing a dado
L Setupthejig byclamping thestockio a worksurface and theedgeguides, plunge
thebit intothecleatat thestartof the
I
butting thecleats against theworkpiece at thebeginning and cutto formanentrydado.Guidetherouteracross theworkpiece
endof thecut.Thensetyourrouterbetween theedgeguides, (above),extending thecut completelythrough thestockand
t
aligning thebitoverthedadooutline. Slidetheguides together intothesecond cleat.Thiswillminimizetearoutasthebitexits
u n t i lt h e yb u t ta g a i n seta c hs i d eo f t h er o u t ebr a s ep l a t e . theworkpiece, lf youneedto routseveraldadoes of thesame
I
S e c u rteh ej i g b yc l a m p i ntgh e L st o e a c ho t h e a r n dt o t h e size,leavethejig clamped togetherandaligntheentrydado
w o r k p i e cTeu. r no n t h e r o u t ear n d ,w i t ht h et o o lb e t w e e n withthedadooutline marked onthestock.
I
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18 I
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I ROUTING AND SHAPINGIIGS
I
I DAD()
ANADJUSTABLEJIG
I 1 Building thejig
j i g
I T h e s h o w na t r i g h ti s i d e afl o r
I routing dadoes in widepanels. Sizethe
pieces sothedistance between theedge
I guides equals thediameter of yourrouter's
b a s ep l a t eT. h eg u i d e s h o u l db e l o n g
r enough to accommodate thewidestpanel
youplanto rout.Cutthefouredgeguides,
I t h et w oe n d sa, n ds p a c e rf sr o m% - i n c h
plywood m; a k ea l l t h ep i e c e4s i n c h e s
I wide.Sandwich theendpieces between
the guides andscrewthemtogether. At
I oneendof theframe,attachspacers to
t h et o pa n db o t t o mo f t h ee n dp i e c e .
I Countersink allfasteners. Cuttheclamp-
ingblockfrom%-inch-thick stock;make
I i t a b o u3t i n c h ew s i d ea n dl o n g et rh a n
theendpieces. To installthepressscrew,
I b o r ea h o l ef o rt h et h r e a dtsh r o u gthh e
endpiecewiththespacers (right,below).
I Remove theswivelheadfromthepress
screwandfastenit to themiddleof the
t clamping block.Attachthethreaded sec-
tionto theswivelheadandscrewthecol-
I larto theendoiece.Usetherouter to cut
shortreference dadoes in theotherend
I pieceandtheclamping block.

I
I
I
t r-) Cutting a dado
Z- StlOe theworkpiece between theedge
I guides, aligning themarked outline with
thereference dadoes. Secure theoanelin
I p o s i t i owni t ht h ec l a m p i nbgl o c kC. l a m p
t h ej i g t o a w o r ks u r f a c eW. i t ht h e b i t
I clearof thestock, turnontherouter and
startthecut at thereference dadoin the
I e n dp i e c em , a k i ncge r t a itnh er o u t eirs
beiween theedgeguides. Feedthe bit
I intotheworkpiece, keeping thebaseplate
flatontheslock(left).Tominimize tearout,
t waituntilthebitenters thereference dado
i n t h ec l a m p i nbgl o c kb e f o rrea i s i ntgh e
I routerclearof thestock.
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I I9
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 I
I
CIRCLE-CUTTING
JIGS
I
Comprisingtwo hardwooddowelsand
I
a centerblock,thisadjustable jig allows
your routerto cut circlesof virtually
I
any diameter.The jig is assembled by
slippingthedowelsinto theaccessory
I
holesin the routerbaseplate,fixing the
dowelsto theblock,and attachingthe
I
blockto thecenterof thecirclemarkedon
theworkpiece. With woodcleatsholding
I
thestockto a worksurface,therouter
bit is alignedwith the end of the cir-
I
cle'smarkedradiusand thescrewsthat
clampthedowelsto the baseplate are
I
tightened.Thecirclecan thenberouted.
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I
I
JIG
C()MPASS I
Making thejig androuting a circle
Tocut larger circles
thanmostcommercial I
guides allow,usethecompass jig shown
at right.Makethe devicefromr/rinch I
hardboard, sizingit to suityourrouter.
Therouter endof thejig should becircu- I
larandaboutthesizeof yourtool'sbase
plate.Makethearmat least2 inches wide I
andlonger thantheradius of thecircle
youwillbecutting. Borea holein thecen- I
terof the rounded endforthe routerbit.
To mountthejig onyourrouter, remove I
thesub-base andcenter the bit overthe
clearance hole.Markthescrewholeson t
thejig,boreandcountersink them,then
screwthejig to the router.Drawa line I
downthe centerof thejig armandmark
theradius of thecircleon it, measuring t
fromtheedgeof thebit.Drilla holeat
thecentermarkandscrewthejig to the I
workoiece. Secure thestockto thework
surface withcleats. Plunge thebit into I
thestockandroutthecirclein a clock-
wisedirection. I
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20 I
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ROUTERIOINTINGIIG
I
ROUTER
JOINTING
I
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I
I Jointing widestock

llllillltlllllltjjitllllilrilllrlll}llltilllrufilllll1
Tosurface boards thataretoocumber-
I llljlll llllllll someto moveacross
routeralongwitha perfectly
thejointer,
square
usea
edge
I 5HO7Tt?
guide. Thistechnique worksbestusing
a top-piloted straightbit withal/z-inch
I An auxiliary oub-
shank. Position theedgeguideatopthe
baoelor widecuts board to bejointedwiththeedgeof the
I To makea cut,Nhat is wider board protruding fromtheguide's edge
than a particularrouler bif, b y a b o u% t oi n c h C . l a m pb o t ht o t h e
I youwouldnormallymakeone w o r ks u r f a c eM. a k et h e e d g eg u i d e
Vaee,ohiftyoured6equideand longerthantheworkpiece to prevent the
I clamps frominterfering withtherouter;
place a s h i mu n d etrh ec l a m pj a wt o
I B-inchequare.Kemovelhe router's
keeptheguidefromwobbling. Withthe
routerflatontheguide,adjustthebit
Andborelhe screwholeeand
t eub-base
clearanceholefor the bit trhrouah Lhe
height soit willcuttheentireedgeof
the board(inset). Feedtherouterfrom
auxiliaryeub-base so Ihe Loolwillbe cen'
I Leredon the jiq. Next,cut 1/rcinchof woodfrom oneedqeof the oneendof theboard to theother;the
eub-baee,1/sinchfrom an adlacenN edqe,andl/+inchfrom a lhird p i l ow
t i l lr i d ea l o n tgh eg u i d ea st h e
I edqe.Markthe amounloyou removed on eachside.ecrewthe 1iq cuttertrimstheworkpiece flush(above).
to trherouNerand makea ?ae6withNheuncul endfluehaqaineLthe
I 4uide.KotaLeNheeub-baee and makea secondpaoo,wideninqNhe
qrooveby 1/o,1/a.
or 1/+inch,dependinq on whichoideyou uee.
I
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 I
I
HINGEMORTISINGIIG I
I
1 Building theiig
I A j i g l i k et h eo n es h o w n
a t l e f tw i l l I
allowyourrouterto cut hingemortises
quicklyandaccurately. Tomakethecuts, I
youwillneedto equipyourrouter witha
straight bit anda template guide.Build I
thetemplate froma pieceof %-inchply-
wood.Sizeit wideenough to support the I
router.Outline thehingeleafonthetem-
plate;remember to compensate forthe I
template guideandthethickness of the
fence,whichis alsomadefrom7+-inch I
plywood. Cutoutthetemplate, thenattach
thefencewithcountersunk screws. t
I
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t
I
r') Routing hinges I
4 Secure theworkpiece edge-up in a
vise.Markthehingeoutlineonthestock I
andclampthetemplate in position, align-
i n gt h ec u t o uw
t i t ht h eo u t l i n eo n t h e I
edgeandbuttingthefenceagainst the
innerfaceof theworkpiece. Makethe I
cuI (right)by movingthe routerin small
clockwise
andsouare
circles, thenremove
thecorners
thejig
witha chisel.
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22
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CORNE,R-ROUNDING
IIG
t
t 'l
Constructing thejig
r I Forcurvingthe cornersof a workpiece,
y o uc a n u s et h e s i m p l ec o r n e r - r o u n d i n g
VIEWOF UNDERSIDE

I 1 i gs h o w na t r i g h t .T h ej i g c o n s i s tosf a
p l y w o o db a s ea n d t w o l i p st h a t a l i g nt h e
t e d g e so f t h e j i g a n d t h e w o r k p i e c eC. u t
the basefrom7a-inchplywood. Formost
I j o b s ,a b a s ea b o u t1 0 i n c h e sw i d ea n d 1 6
i n c h e sl o n gw i l l b e a d e q u a t eD. r a wt h e
t c u r v ey o u w i s ht o r o u t o n o n e c o r n e ro f
t h e b a s ea n dc u t i t w i t ha b a n ds a wo r a
I sabersaw;sandthe edgesmooth.Cutthe
lipsfromsolidstockr/zinchthickand 1%
I i n c h e sw i d e ,t h e n n a i lo r s c r e wt h e p i e c e s
t o t h e b a s e l, e a v i n g
a b o u t3 t o 4 i n c h e s
I betweeneachlip and the roundedcorner.
T h et o p e d g eo f t h e l i p ss h o u l db e f l u s h
I with the top surfaceof the base.

I
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I
t
I
I
I r) Rounding a cornel
I I Setvourstockon a worksurface with
t h ec o r n etro b er o u n d eedx t e n d i nogf f
I thetablebyseveral inches. Place thejig
o n t o po f t h ew o r k p i e cs eot h el i p sa r e
I buttedagainst the edgesof thestock.
Useclamps to secure thetwopieces to
I theworksurface. Tomaketherouter cut
easier, usea handsaw to cutawaythebulk
I of thewaste. Then,usinga top-piloted
flush-cutting bit in yourrouter, startclear
I o f t h ec o r n ear n de a s et h eb i t i n t ot h e
s t o c ku n t i lt h ep i l o tc o n t a c t sh ee d g e .
I Pulltherouter around thecorner, moving
against bit rotation andpressing thepilot
I flushagainst theedgeof the1igthrough-
(/eff).
outtheoperation
I
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 I
I
PANE,L-RAISING
IIG t
I
1 Building thejig
I Featuring a fence andtilting table, the I
jigshown at leftenables youto raisepan-
elsusing a router without mounting thetool I
i n a t a b l eT. h ej i g i sc l a m p ei d
na b e n c h
v i s eC. u ta l lt h ep i e c eosf t h ej i gf r o m I
l-inchplywood; thedimensions suggest-
ed in theillustration willworkwellwitha t
typical workbench. Startassembling thejig
byscrewing thebrackets to theunderside I
of thetableat oneend,thencutadjust-
NoLch mentslotsthrough thearms.Secure the I
for vrse topendsof thearmsto thebrackets and
9CTEW
thebottom endsto thefenceusinghanger I
bolts,washers, andwingnuts.Attachthe
tabletothefence witha piano hinge posi- I
tioned about 6 inches below thetopof the
fence. Toprepare thefenceforyourrouter, I
borea holejustabove thetablelevelto
accommodate thelargest %-inch vertical I
panel-raising bitorstraight bityouwillbe
using. Screw theguardto thefenceabove t
thehole.Finally, cuta notchin thebottom
endof thefence to cleartheworkbench's I
Adjuotment alot visescrew. lnstallthebit in therouter and
screw thetoolto thejigfencesothebit t
orotrudes fromthehole.
I
I
I
I
r) Raising
t
a panel
L Secure the1igfencein thevisewith I
thetableat a comfortable height. Adjust
thebitfora shallow cut,turnontherouter, I
andmakea testcut in a scraooiece, To
adjustthebevelangle, turnoffthetool, I
loosen thewingnutssecuring thearmsto
t h ef e n c ea, n dt i l tt h et a b l eu po r d o w n .
Raise theendsof thepanelbefore routing
t
thesides; thiswillreduce tearout. Feed the I
panelacross thetableface-up, keeping
yourf ingers wellclearof thebit.Test-f it I
thepanelandincrease thecuttingdepth
slightlyto makea secondpass(right).Con- I
tinueuntilthepanel fitsin thegrooves.
I
24
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I
ROUTINGGUIDE
ADIUSTABLE
I
t
1 Building theiig
t I Thelig shown
inggrooves
at leftis idealforrout-
in a rectangular pattern; it can
I Edqe7uide alsobef ittedwithtemplates for curved
cuts.Sawtheguides from1-by-2stock
I androuta groove %inchdeepandwide
along theinside edgeof eachone.Cuta
t two-shouldered tenonat oneendof each
guideto fit in thegrooves andborea pilot
t holeintothemiddleof eachtenonfora
hanger bolt.Screw the
%-inch-diameter
I boltsin place,leaving enough threadpro-
truding to feedit through theadjacent
I edgeguidewitha washer andwingnut.
Finally, rout%-inch-wide mortises through
I theguides; startabout3%inches from
t h ee n dw i t ht h et e n o na n dm a k et h e
I mortises 4 inches long,separating them
withabout%inchof wood. Assemble the
I jig byslipping thetenons andboltsthrough
thegrooves andmortises of theadjacent
I guide andinstalling thewashers andnuts.
Forcurves. maketemolates likethose
I shown in theillustration.

I
I
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I
I
I
I
I
I
I r) Routing
thegroove
I thepattern
Z- Outline onyourstockandlayit ona worksurface. (Usedouble-sidedtapeto secure thetemplatesto theworkpiece.)
Loosenthewingnutsofthejigandpositionit onthestocksothe Tighten thewingnutsandclampthejig andworkpiece to the
I edgeguidesframetheoutline.Placetherouterflatonthework- table.Afterplunging thebit intothestock,makethecut in a
pieceandalignthebitwithoneedgeoftheoutline.Buttoneof clockwise direction, keeping thebaseplateflushagainstthe
I theedgeguidesflushagainst therouterbaseplate.Repeat on edgeguideortemplate at all times.Forrepeatcuts,simply
(abovd.
theotheredgesuntilallguides
andtemplates arein position. clampthejig to the newworkpiece androutthepattern
I
I 25
I
 I
I
JOINT-MAKING
IIGS I
.l
A SLIDING
DOVETAIL
JIG
Building thejig I
1
I Thejig shown at leftallows youto routslid-
Eit clearancehole ingdovetails (rnset) without a router table.Cutthe I
fence, table,andsupport piecef rom%-inchply-
wood.Makeall the boards 16 inches long;the I
fenceandtableshould beabout10 inches wide
andthesupport pieceabout3 inches wide.Screw I
thetableto thetablesupport sotheyforman L.
Position thetable4 inches fromthe bottomof t
thefenceandboretwoholesthrough opposite
endsof thefenceintothetablesupport. Usea I
routerwitha straight bit to lengthen the holeon
theoutfeed sideof thefenceintoa curved slot. I
Attach thetablesupport to thefencewithcarriage
Curved
-----=-\\\\\\\ bolts,washers, andwingnuts.Leave theboltat I
etot theinfeedendloose enough forthetableto pivot
I
\ W whentheslotted
thesub-base
endis raised or lowered.
fromyourrouteranduseit asa tem-
plateto markthescrewholesandbit clearance
holeonthefence.Thebottom
Remove

edgeof theclear-
I
a n c eh o l es h o u l ldi n eu pw i t ht h et o po f t h ej i g t
tablewhenthetableis level.
I
Routing thejoint
I
S e c u rteh ef e n c ei n a v i s ea n dr o u t
groove
I
thedovetail first,thenthematching
slide.Forthegroove,
straight
startby installing
bit in therouter, attaching
a
thetool
I
to thejigfence, andadjusting thecutting I
depth.Setthegroove workpiece face-down
onthetable,buttingitsedgeagainst
bit.Loosen thewingnutat theslotted
the
end
I
andadjustthetableto centerthebit on
theedgeof thestock, thentighten thenut.
I
Secure
boards,
theworkpiece
clamping
withthreefeather-
oneto thetableandthe
t
othertwoto thefenceon bothsidesof the I
cutter.Make thestraight cut,thencomplete
thegroove witha dovetail
setyourworkpiece
bit.Fortheslide, I
onthetableandlower
thetableto produce a 7e-inch-wide cut. I
Makea passon bothsides, finishing each
cutwitha pushstick(right).
tration,thefeatherboard
(lntheillus- I
on theoutfeed
sideof thefencehasbeenremoved
clarity.)
Test-f it thejoint.lf necessary,
for
raise
I
thetableslightly andmakeanother pass I
oneachsideof thestock
I
26 r
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I ROUTING AND SHAPING IIGS
I
I
A CORNER
HAIF.LAP
JIG
I thejig
1 Building
I Cutthetwobasepieces andthestop
I blockfromplywood thesamethickness as
yourstock. Thebasepieces shouldbewide
I enough to accommodate theedgeandend
guides andsupport yourrouter's baseplate.
I Usesolidwoodstripsforthefourguides.
Next,marktheshoulder of thehalf-lap
I (inset) on one workpiece and buttthebase
pieces against edges theshoul-
its with
I dermarkpositioned nearthe middleof
the boards. Installa straight bit in the
I router andalignit withtheshoulder mark,
thenmountanend guide across thebase
I pieces andagainst thetool'sbaseplate.
Repeat theprocedure to position a guide
I a t t h eo p p o s i teen d .N o wa l i g nt h e b i t
withtheedges of theworkpiece andattach
I t h ee d g eg u i d e sl ,e a v i nag s l i g h gt a p
between therouterbaseolateandeach
I guide.(Thef irsthalf-lap youmakewill
Corner half-lap
routreference notches in thebasepieces.)
I End quide F i n a l l yi n, s t a tl lh es t o pb l o c ku n d eor n e
endguide,against theendof thework-
I oiece. Countersink all fasteners.
I
I
I Routing thehalf-laps
Clampthejig to a worksurface and
I s l i d et h ew o r k p i e cbee t w e etnh eb a s e
pieces untilit buttsagainst thestopblock.
I Protecting the stockwitha woodpad,
clamptheworkpiece in place. Adjust the
I router's cuttingdepthto one-half thestock
thickness. Then,withtherouter positioned
I inside theguides, turnonthetoolandlow-
erthebit intotheworkpiece. Guidethe
I routerin a clockwise direction to cutthe
outside edges of thehalf-lap, keeping the
I b a s ep l a t ef l u s ha g a i n sat g u i d ea t a l l
times.Thenroutouttheremaining waste,
I feeding thetoolagainst thedirection of
(right).To
bit rotation asmuchaspossible
I routa T orcrosshalf-lap, simplyremove
thestopblocksothecutcanbemadeat
I anypointalongthefaceof thestockand
clamotheworkoiece on bothends.
I
I 27
I
 I
I
ROUTINGAND SHAPINGIIGS
I
I
ANADJUSTABLE
MORTISING
JIG
thejig
I
1 Making
jig
I The shown at leftwillguideyour
)top block
t/o"x1%"x5" routerandsecure theworkpiece asyoucut
I
a mortise. Thedimensions suggested inthe
illustrationwillsuitmostrouters. Cutthe
I
jig sidesfrom%-inch plywood. Makethe
baseof laminated solidwood.Attach the
I
sidesto thebasewithcountersunk screws,
making surethepieces areperfectlysquare
I
to eachother. Fashion eachstooblockfrom
solidstockbycutting a rabbet %inchdeep
I
and1 inchwide, thenrouting a 4-inch-long
slotto accepta %-inch hanger bolt.Mount
I
thebolts3 inches fromeachendof one
Jiq aide
t/o"x6"x16"
side,slipthestopblocks in place,andf ix
I
Jig baee themwithwashers andwinsnuts.
3"x3"x16" I
I
I
r) Routing a mortise
L Settheworkpiece onthejig'sbasewith I
themortise outlinebetween thestopblocks
andonesurface f lushagainst thesidewith I
theblocks. Place a shimunderthestockso
itstopsurface buttsagainst thestopblocks, I
t h e nc l a m pt h ew o r k p i e tcoet h ej i ga n d
secure thejig in a workbench vise.Next, I
install a straight router bitthesamediam-
eterasthewidthof themortise, setthe I
depthof cut,andattach a commercial edge
guideto therouterbaseplate.Center the t
bit overthemortise outlineandposition
theedgeguidesoit restsflushagainst the I
opposite sideof thejig.Adjusteachstop
blockbyaligning thebitwiththeendofthe I

N\:
mortise outline, butting theblockagainst
therouter's baseplate, andtightening the I
w i n gn u t .O n c et h eb l o c kas r el o c k e idn
position, turnonthetoolwiththebitclear I
of theworkpiece. Gripping therouter firmly,
butttheedgeguideagainst thejig,press I
the baseplateagainst onestopblockand
plunge thebit intotheworkpiece. Holdthe t
edgeguideagainst thejig asyoudrawthe
routerthrough thecut untilit contacts the I
otherstopblock(right).Cuta deepmortise
in several passes, increasing thebitdepth t
e a c ht i m e .
I
28
t
t
I
I ROUTING AND SHAPINGIIGS
I
I A MOVABLE.JAW
MORTISING
JIG
r 'l Making theiig
I Thejig at rightallows youto routperfectly centered
I mortisesin stockof anythicknessusinga straightbitand Viewin4hole
a template guide.Cutthejig topfrom%-inch plywood;
I makethepieceabout15 inches longandwideenough to
acceptthethickestboardyouexpect to mortise.Cutthe
I twojawsfrom2-by-4-inch stockthesamelengthasthe
top.Toprepare thetop,marka linedownitscenter and
I routa notchcentered overthelineat oneend.Thenotch
should bethesamewidthasthetemplate guideyouwill
I usewithyourrouterbit,andlongenough to accommo-
datethe longest mortiseyouexpect to cut.Next,routtwo
I adjustment slotsperpendicularto thecenterline.Finally,
borea viewing holebetween thetwoslots.Toassemble
I thejig,screwhanger boltsintothejawsandfasten the
topto thejawswithwashers andwingnuts.
I
I
I
t
I
I
I
r) Cuttinga mortise
I L trttarka linedownthe centerof the
mortiseoutline ontheworkpiece. Loosen
I thewingnutsandsecure thestockbetween
thejawssothemortise centerlineisaligned
I withthatof thejigtop;makesurethetop
edgeof theworkpiece is buttedagainst
I theunderside of thetop.Alsoalignone
endof themortise outlineundertheend
I of thenotch-offset bythedistance from
theedgeof thebitto thetemplate guide's
t edge-thentighten thehanger bolts.Align
theedgeof thebitwiththeotherendof
I theoutlineandclampa stopblockto the
topflushagainst therouterbaseplate.
I Routthe mortise(left),slarlingthecut
withthetemplate guidebuttedagainst
I theendof thenotchandstopping it when
thebaseplatecontacts thestopblock
I at theotherend.
I
I 29
t
 I
ROUTING AND SHAPING IIGS I
I
A B(lXJOINT
JIG I
1 Setting upthejig I
I Thejig shown onthispageallows
youto cutthe notches fora boxjointon I
a routertablewithlittlesetuptime.lt
consists simplyof an extension board I
screwed to the miter gauge and f itted
witha keythatdetermines thespacing I
of thenotches. Installa straight bitsized
to thedesired width of the notches and I
mounttherouterin a table.Setthedepth
of cutequalto thethickness of yourstock t
andfeedtheextension intothebitto rout
a notchthrough its bottomedge.Reposi- I
tiontheextension sothatthegapbetween
thenotchandthebitequals thediameter I
of thebit,thenscrewit in place.Feedthe
extension intothebitagain, cuttinga sec- I
ondnotch(/eff).Fashion a woodkeyto
f it in thefirstnotchandglueit in place I
soit projects about1 inchfromtheexten-
sionboard. I
I
I
I
I
r) Gutting theboxjointnotches
L nod oneedgeof theworkpiece against
I
the key,buttingitsfaceagainst themiter
gaugeextension. Turnon the routerand,
I
hooking yourthumbsaround thegauge,
slidethe boardintothe bit,cuttingthe
I
first notch(right).Fit the notchoverthe
keyandmakea second cut.Continue cut-
I
tingnotches thiswayuntilyoureachthe
opposite edgeof the workpiece. To cut
I
thenotches in thematingendof thenext
board, fit thelastnotchof thefirstboard
I
overthe keyandbuttoneedgeof the
matingboardagainst thefirstboard.Move
I
theentireassembly
notchin themating
fonruard
board,
to cutthefirst
holding both
t
pieces flushagainst themitergaugeexten-
sion(page12).RouItheremaining notch-
t
es in thematingboardthesamewayyou
madethecutsin thef irstboard.
I
I
30 I
I
t
t SHAPERIIGS
I
I A CIRCTE.CUTTING
JIG
I 1 Making theiig
I Shaping circular workfreehand onthe
t Adjuetment alot
shaper isa riskyjob.Onewayto makethe
tasksaferandmoreprecise isto usea V-
I blockjig liketheoneshown at left.Build
it froma pieceof %-inchplywood about
I 14 inches wideand24 inches long.To
customize thejig foryourshaper, holdit
I above thetableflushwiththebackedge
andmarkthelocation of thespindle on
I thesurface. Cuta right-angle wedgeout
of thejig,locating theapexof theangle
I at yourmarked point.Thencuta circle
outof thejig centered ontheapex;the
t holeshouldbelargeenough to accommo-
datethelargest cutteryouplanto usewith
I thejig.Routtwoadjustment slotsrntothe
backedgeof thejig oneithersideof the
I h o l e - a b o u%t i n c hw i d ea n d5 i n c h e s
long.Theymustlineupwiththeshaper's
I fencelocking handles, ason themodel
shown. Thejig canalsobesecured to the
t shaper bymaking it asIongasthetable
andclamping it in place at eitherend.
I
I
I
r) Shaping circular work
I Z. Position thejig onthetable,centering
thebit in thehole.Seattheworkpiece in
I thejig,buttingit against bothsidesof the
V,andadjust thejig andworkpiece until
I thewidthof cut is setcorrectly. Secure the
jig in place.Youmaywantto makea test
I cuton a scraooiecethesamethickness
anddiameter asyourworkpiece
t tainthatthedepthandwidthof cut are
to becer-

c o r r e c tT. u r no n t h es h a p ear n db u t t
I t h ew o r k p i e caeg a i n st h
t eo u t f e e sdi d e
of theV. Slowly pivotthestockintothe
I cutteruntilit restsf irmlyin thejig'sV,
moving it against thedirection of cutter
I rotation to prevent kickback (ieff).Continue
rotating theworkpiece untiltheentirecir-
I cumference hasbeenshaped, keeping
theedgein contact withbothsidesof
I thejig throughout thecut.
I
t 31
I
 I
ROUTING AND SHAPINGIIGS I
I
ANEXTENDED FEATHERBOARD
SHAPER I
1 Making thefeatherboard t
I F o rw i d ec u t s s, u c ha ss h a p i ntgh e
edges of a panel,useanextra-wide feath- I
erboard liketheoneshown onthispage.
It will bothpress thepanelagainst the I
tableandshieldyourfingers fromthecut-
ter.Cuta 2-by-4at leastaslongasyour I
shaper's fence,settheboardagainst the
fence, andoutline thelocation of thecut- I
ter on it. Curvethe bottomedgeof the
featherboard slightly sothatonlythefin- I
gerswillcontact thepanel during theshap-
ingoperation. Bandsaw a series of %-inch- I
wideslotsat a shallow anglewithinthe
outline, creating a rowof sturdybutplt- I
ablefingers. Screwtwospacers to the
backfaceof thefeatherboard sothejig I
willclearthecutter;countersink allfas-
teners(/eff). I
I
I
I
I
I
t
I
I
I
t
I
r) Raising thepanel
I
I Clampthe to thefence,
featherboard
centeringthefingersoverthebit,andturn
I
ontheshaper. Foreachpass,useyourright
handto slowlyfeedtheworkpiece intothe
I
cutter;useyourlefthandto keepthe pan-
el againstthefence(right).
t
I
JZ t
I
t
I ROUTING AND SHAPINGTIGS
I
I TWOSHAPER
GUARDS
I Building a fence-mounted guard
Theshaper guardshown at rightis ideal
I forfence-guided operations. Cutthepieces
from%-inch plywood, making theguard
I i n t h es h a p eo f a n a r cl a r g ee n o u gtho
extend f r o mt h ef e n c ea n ds h i e l dt h e
I c u t t e cr o m p l e t e lTyh. es u p p o rbt o a r d
shouldbewideenough to beclamped to
I thefencewhentheguardisalmost touch-
i n gt h es p i n d l eS. c r e w t h eg u a r df l u s h
I withthebottom edgeof thesupport board;
c o u n t e r s itnhkef a s t e n e rN s .e x ct l a m p
I t h ej i g i n p o s i t i oann dm a r ka p o i n o tn
theguardabove thecutter.Remove the
I j i g a n db o r ea 1 % - i n c h - d i a m e h toel e
r
t h r o u gthh eg u a r da t t h em a r kt;h eh o l e
I w i l la l l o wy o ut o v i e wt h ec u t t edr u r i n g
shaping operations.
I
I
I
t Making a freestanding guard
Forfreehand shaping, makea guardlike
I theoneshown at left.Sawnfrom%-inch
plywood, it covers
I thecutterfromthe
s h a p e rt 'osp ,b a c ka, n ds i d e sC. u tt h e
topabout16 inches
I to extend
longandwideenough
fromthebackof thetableto
I aboulIYzinchesin frontof the cutter.
Bevelthefrontendsof thesidessothey
t canbe positioned
thecutter.
ascloseaspossible
Ripthesidessothetopwillsit
to

above thebit withjustenough

I for you to seethecutter.Holdthetopon
clearance

t thetableandmarka pointon it directly

overthespindle. Cutanoval-shaped hole
t through thetopat themark,largeenough
t o c l e a trh es p i n d laen da l l o wy o ut o
movetheguardacross
I accommodate different
thetableslightly
cutters.Fasten
to

t h et o pt o t h es i d e sw i t hc o u n t e r s u n k
I screws. To usetheguard,position it on
I t h et a b l ew i t ht h es p i n d l pe r o j e c t i n g
t h r o u gthh et o p ,a n dw i t ht h es i d e sa s
I c l o s ea s p o s s i b lt eo t h ec u t t i n ge d g e s .
Clamp t h eg u a r di n p l a c e ,
I
I 33
I
 I
I
VACUUMIIGS
t
n-[' h. vacuulnsystem shownhereisan
t
Vacuum
l- excellentwav to anchorfeather-
boardsto work tablesand fastentem-
t
platesto workpieces. Thesystemis more
convenient thanconventional clamping
I
andoffersasmuchholdingpowerwith- I
out riskingdamageto stock.The only
limitationis that matingsurfaces must
I
be flat andsmooth.
To setup a vacuumsystem,you need I
thepartsshownin thephotoat left.The
taueis fastened to the undersideof the
I
feitherboard or template,creatinga cav-
ity.Thehosefrom thepump is inserted
in a holein thefeatherboard or template.
t
\{hen thejig is placedon thesuifac.,
thepump suckstheair from thecavity,
I
The heart of the vacuurrlsysten is thepump, herea1/: horsepoweroil-Iess
ntodel,which drawsair at a maximtrm of 4.5 cubicfeetper minute. The
producinga vacuum.Anypump ratedat
3 cubicfeetperminuteor higheris ade-
t
hosefeaturesa quick couplerthat attachesto a connectorthat is screwed
into a lrcIethrough the templateor featherboard.Youwill qlsoneedto use
quatefor the homeworkshop.If you
own a compressor, you can convertlt
t
vaatum tapeor closed-cell foam weotherstripping as a gasketto sealthe into a vacuumpump with a transduc-
ing pump.
I
cavity betweentemplate and workpiece or featherboardand work table.
I
FEATHERBOARD
A VACUUM I
Anchoring a leatherboard to a sawtable
B o r ea n o u t l eht o l et h r o u gthh ec e n t e r I
of thefeatherboard. Thehole's diameter
should b es l i g h t llye s st h a nt h a to f t h e I
threaded endof thehoseconnector you
willuse.Next,applyfourstrips of closed- I
cellvacuum tapeto theunderside of the
featherboard, forming a quadrilateral with I
nogaps(insef). Screwthe hoseconnector
intotheoutletholeonthetoofaceof the I
featherboard; usea wrench asshown oppo-
site.Tosetupthevacuum jig,placethe I
featherboard onthesawtable-forthe
m o l d i ncgu ts h o w ni t, r sp o s i t i o n e t od I
press theworkpiece against thefence.
Makecertain thetapestripsaref laton I
the t a b l eS. n a pt h eq u i c kc o u p l eart t h e
endof the vacuum oumohoseontothe I
h o s ec o n n e c t o r dt u r no nt h ep u m p .
a n
Airoressure willanchor thefeatherboard I
t o t h et a b l ea s y o u f e e dt h ew o r k p i e c e
throughlhe cut (right). I
t
I
34 I
t
t
I ROUTINGAND SHAPINGIIGS
I
I VACUUM
TEMPLATE
ROUTING
t 1 Installing thetapeandconnector
I A vacuum provides an effective alter-
t nativeto double-sided tapeforfastening
a plywood template atopa workpiece. Once
I yourtemplate is theproper size,traceits
patternon yourstockandcut out most
I of the wastefromyourworkpiece, leav-
i n ga b o u %
t i n c ho v e r h a n g itnhget e m -
t plate.Boretheoutletholethrough the
middleof thetemplate andapplyvacuum
I tapealong theperimeter of itsunderside;
makesuretherearenogapsbetween adja-
I centpieces of tape.Withthinstock, add
twothinstripsof tapeoneithersideof the
I outletholeto prevent thevacuum pres-
surefrompulling themiddle of thework-
I pieceagainst thetemplate (insef). Attach
thehoseconnector to thetooof thetem-
I platein theoutlethole(right).

I
I
I
I
I
t
I
t r') Routing thepaftern
Z- Install a piloted flush-trimming bit
I in a router, mountthetoolin a table,and
adjust thecuttingheight sothebitwitl
I shape theentireedgeof theworkpiece.
Placethetemplate tape-side-down cen-
I teredontopof theworkpiece. Attachthe
vacuum hoseto theconnector andswitch
I o n t h ep u m pt o c l a m pt h et w ob o a r d s
together. Turnontherouterandeasethe
I stockintothebit untilthetemplate con-
tactsthe bit pilot(/eff).Complete the
t c u t ,k e e p i ntgh ew o r k p i e cf lea to n t h e
r o u t etra b l ea n dt h ee d g eo f t h et e m -
I platepressed flushagainst thepilot;move
against thedirection of bit rotation.
I
I 35
t
 't

,{
,,{
..u

,f

f
I
I
I
t
I
I CUTTINGIIGS
I
I
I
t I rom thetimeyoucut roughlumber
I to Iengthat thestartofa projector OFCUTTING
A COTTECTION JIGS
I miter trim to finish it, your powersaws
andhandsaws arelikelyto beyour most- Miter and croeeaut guide (page 41)
Makeamiter cuta and croaacuta
t usedtools.Althoughmanycuttingtasks
canbe accomplished without them,the
with a saber gaw or circular saw
jigs shownin this chapterwill make
I theseoperationseasier-particularly
I whenthe samecut mustbe repeatedon
several workpieces.
I With its iniersecting arms,a tablesaw
miter jig (page50)guaranteesmiter
jointsthat form perfect90"angles.
I tenoningjigsshownon pages57and58
The

I allowyouto cutbothpartsof openmor-

Saber aaw airale-
tise-and-tenon jointson thetablesaw. cutting ji6 @age a3)
jigs
I Some facilitatecuttingtasksthat
aretoughto performfreehand.Thecir-
Attachea to eaberaaw
and pivote around center
cle-cuttingjigsfor the sabersaw(page of workpieceto cuL cir-
I 43) andband saw(pageaa) help make clee:pivot point can be
located at any point
I quickwork of circulartabletops.In tan- )izing board alonqjig arm
demwith your tablesaw,theraisedpan- for aroeaauta
eljig (page52) canproducebeveled @a6e aO)
I oanelsfor frames.
Ueedwith a back-
aaw for croggcut-
t Thesejigs will saveyou time in the
shoo.An addedbenefitis that mostcan
ting; eLop block
ie adjuetable
I bebuilt from scrapwood,makingthem
considerablyless costly than store-
I boughtcounterparts.
Eand eaw airale-
autting jig
I (pase 44)
Adjuetablejiq for
I cutttnq circleaon
the band eaw;jiq
I The crosscutjig shown at left provides a
safeand accurateway to cut long, wide,
ia clampedto oaw
table and work-
piece ie ecrewed
I or heavystockon the table saw.Because
it slidesin the saw table'smiter slots,
to alidinqbar and
rotated into blade
I this sturdy, adjustablejig makesit easy
to hold workpiecessquareto the blade.

I 37
I
 I
CUTTING IIGS I
I

A COLTECTION
(continued)
OFCUTTING
JIGS
Table aaw taper jig (page 4A)
t
For cutLin7[apero on the table aaw;quide
bar with to4qle clampa is acrewedin place to I
hold workpieceat proper taper anqle.A aimi-
lar ji4 with a handleand LheL-ehaped ,{
fence poeitioned differently can

Olade height gauge

be ueedon the radial arm
aaw (page 48)
t
Qasea9) I
Meaouringgauqe
for eettinq the
heiqht of a table I
aaw blade
I
Ker-faplitter
(paqe 42)
t
Used with a ctrcularaaw
Mitering ji6 to prevent the blade from I
Qase a7) btndinqin the kerf; placed
Uaedto mtter
trim on band
in kerf of lonq rip cuta part-
way Lhrou7hoperation
I
eaw: ecrewe to
mttrerlauqe I
I
I
Table saw croaacutjig (page 5O) t
Adjuatablejig uaedto makecroea-
cutg on the table eaw tn wrde,lon4, I
or heavyotock
I
Wedge-makingjiq (paqe aO) I
For cuttinq ehimaand wed4eo
on the band eaw Band aaw taper jig I
(paqe 47)
Fixed-anqleji4 for
makin7taper cute
r
on the band aaw
I
t
?traightedge guide
I
(page 42)
For ripping wif,ha t
circular aaw
I
I

I
I
I
I CUTTING IIGS
I

I
I
I
I
I
I
I
Radial arm saw auxiliary
I fence and table (page 54)
Termtta the radial arm
Tenoningjig
(pase 57)
qaw f,o cuT.qrooveqor For cuttin4 both Raioed paneljig
I moldin4owith ito bladein parte of open mor- (pase 52)
tiae-and-tenon Attachea to the table
the hortzontalpoeition
I jointe on the Lable
aaw;rune alonq
eaw rip fence to bevel
the edqeeof raised
rip fence panelefor frame-and'
I nanel aaaemhlica

T
Cove-cutting jig (page 56)
t Uaedto eet up 4uideboardeon eaw
table for cuttin4 cove moldin4
I
I
I Adjustable tenonin7 jig
(pa6e 58)
I Uaedto cut openmorLiae-and'
tenone on the table aaw;adjuata
t to etock of varyinq thickneaa Eoard -strai g hte ning ji g
(pase 53)
I Uaedon the table eaw to
true the ed4eeof uneven
atock; featurea a bar that
I Table oaw miter jig (paqe 5O)
)imilar to the croaacutjiq, except
runa in mtter alot
with analedarma uaedto make
I matinq 45' miter cuta

I
t
I
I

I
t
 I
t
SIZINGBOARDFORCROSSCUTS
I
thejig
I
1 Building
I Thejig shown at rightmakes it easy
to crosscut several workpieces to thesame
I
length byhand.ltsadjustable stopblock
canbe positioned at varying distances
I
fromthe kerfin thefence.Cutthebase
a n df e n c ef r o m% - i n c h p l y w o otdo t h e
I
dimensions suggested in theillustration.
Usesolidwoodforthestooblockandlio.
I
Screw thelipto theunderside of thebase,
takingcareto aligntheedges of thetwo
I
pieces. Sawthefenceintotwosegments
about7 inches fromoneendandusea
I
router fittedwitha %-inch bitto cutgrooves
t h r o u gbho t hp i e c easb o u It i n c hf r o m
t
theirtopedges; stopthegrooves about2
inches fromtheendsof eachpiece. Screw
I
thetwofencesections to thebase, ensur-
ingthatthegapbetween thetwopieces
I
i s w i d ee n o u gtho a c c o m m o d aatsea w
blade. Sawa 9O' kerfacross thesurface
I
o f t h e b a s ei n l i n ew i t ht h e k e r fi n t h e
fence. Toprepare thestopblock, cuta 3-
I
inch-long rabbetononefaceandborea
clearance holethrough itscenterfora I%-
I
inch-long, %-inch-diameter carriage bolt.
F a s t etnh e b l o c kt o t h ef e n c ew i t ht h e
I
bolt,washer, andwingnut.
I
I
I
T
I
I
t
r) Making a crosscut
I
L eufithelip againsttheedgeof your
workbench,
loosen
thewingnut,andslidethe
I
stopblockalongthefenceto theproper
distance
fromthekerfbetween thetwo
I
fencesections.
Tightenthewingnutand
butttheendof theworkpiece againstthe
I
stopblock,Holdthestockf irmlyagainst
thefenceasyousaw(right).
I
I
40 I
I
I
I
I
MITERAND CROSSCUT
GUIDE
t
1 Assembling theiig
t I Themultipurpose edgeguideshown
t i l la l l o wy o ut o c u te i t h e4r 5 "
a trri g h w
t m i t , cutsor 90" crosscuts
miter
S A Wo r a
witha saber
c i r c u l asr a w .M a k et h e j i g f r o m
I ao p iie c eo f l - i n c h p l y w o o dr .e f e r r i ntgo
t h e i l l u s t r a t i of n
o r s u g g e s t eddi m e n s i o n s .
I C u tt h e b a s ei n t h es h a p eo f a t r i a n g lw
o n e9 0 " a n g l ea n dt w o 4 5 " a n g l e s(.T o
e ith

I m a k ea ; r gf o r 3 0 " o r 6 0 " m i t e rc u t s .t h e
s i d e s h o r r lhde 1 2 1 6 a n d2 0 i n c h eos r
I a v a r i a t i o on f t h e 3 - 4 - 5 r a t i o . S
) c r e wt h e
f e n c e st o t h e b a s e- o n e o n e a c hs i d e
I o p p o s i toen eo f t h e 4 5 " a n g l e sT. h ef e n c e s
m u s tb e f l u s hw i t ht h ee d g eo f t h ej i g b a s e .
I
I
I
I
I
I
I
I
I
I
t
I r) Makinga mitercut
L t o c u ta m i t e ru s i n gt h e j i g ,s e tt h e
I s t o c ko n a w o r ks u r f a c w e i t ht h e c u t t i n g

t l i n eo n t h e b o a r de x t e n d i nogf f t h e t a b l e .

t
t
N A l i g nt h e c u t t i n ge d g ew i t ht h e l i n ea n d
b u t tt h e a n g l e ds i d eo f t h e j i g a g a i n stth e
s a w ' sb a s ep l a t e ,w i t h t h e f e n c eo n t h e
bottomof the guideflushagainst
o f t h ew o r k p i e cC
the edge
e l. a m pt h ej i g i n p l a c e

t a n dm a k et h e c u t , k e e p i n tgh e s a wf l u s h
a g a i n stth e . 1 i tgh r o u g h o ut ht e o p e r a t i o n
(left).To makea 90" crosscut,usethe
I s q u a r es i d eo f t h e j i g a sy o u rg u r d e .
t
I
I
 I
RIPPINGIIGS t
t
TW()CIRCULAR
SAWIIGS I
Using a kerfsplitter I
A kerfsplitterliketheoneshownat left
w i l lh e l pp r e v e natc i r c u l asra wb l a d e t
frombinding rnitskerfandkicking back.
Choose %-inch hardboard forthesolitter t
pieceand%-inch plywood fortheshoul-
ders;referto theillustration forsuggest- I
ed dimensions. Fasten thethreeoieces
together withscrews. To usethejig,start I
thecut,turnoffthesaw,andinsertthe
splitterin thekerfa fewinches behind I
t h es a w B . a c ku pt h es a ws l i g h t l yt h, e n
continuethe operation (left).Forparlic- I
ularlylongcuts,advance thekerfsplitter
periodically to keepit nearthesaw. I
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Edge atrip
tl"x4"xB' I
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Ripping guide
witha straightedge
t
Thejig shown above enablesyouto makeaccurate ripcutsin stripandcuttingalongthe lengthof the base.To usethejig,
longmanufactured panelslikeplywood.Makethebasefrom%- marka cuttinglineonthepanelandclampthestockto a plat-
I
inchplywood; use%-inchplywood fortheedgestrip.Gluethe formof 2-by-4sresting
atopsawhorses.Clamptheguideto the
stripparallelto the base,offsetting
its edgeabout4 inches panel,aligningthetrimmed edgeof thebasewiththecutting
I
fromoneedgeof the base.Trimthebaseto its proper widthfor lineontheworkpiece. Makethe cul (above),
keepingthesaw's
yoursawbybuttingthetool'sbaseplateagainst thejig'sedge baseplateflushagainst
theedgestripthroughouttheoperation.
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42 I
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t TWOCIRCLE-CUTTING
IIGS
I CUTTING
CIRCLES
WITHTHESABER
SAW
I 1 Building thejig
I Tocutcircles bigger thanthecapac-
I ity of commercial sabersawjigs,usea
shop-made guidecustomized foryoursaw.
t Theexactsizeof thejig canvary,butthe
dimensions suggested in the illustration
t ai leftwillyielda jig largeenough to cut
a circleto theedges of a 4-by-8panel.
I Beginby removing the bladefromyour
sawandoutlining itsbaseplateona piece
I of %-inch plywood. Reinstall thebladeand
c u ta l o n g t h em a r k sm, a k i ntgh es e c t i o n
I thatwillbebeneath thebaseplateslightly
larger thantheplate.Lighten thejig by
I trimming it to theshape of an L, thencut
outthenotch forthe blade.Screw thejig
I thejig to the baseplate, ensuring thattheback
J Using o f t h eb l a d ei s f l u s ha g a i n st ht eb o t t o m
I f- Clampdownthestockwithasmuchof theworkpiece
possible extending off thetable,usingwoodpadsto protect
as
of thenotch.Usea pencil to marka pivot
l i n eo n t h ej i g t h a ti s a l i g n ewd i t ht h e
I thestock.Cutintothestockto bringthebladeupto theout-
l i n eo f t h ec i r c l ey o uw i l lb ec u t t i n gT. h e nd r i v ea s c r e wi n t o teethof theblade.

I thejig onthepivotlineat thecenter of thecircle.Holding the

sawandthestockfirmly,cut outthe cicle (below), shifting the
I clamps andworkpiece asnecessary.

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CUTTINGJIGS
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CUTTING ONTHEBANDSAW
CIRCTES
I
1 Building thejig I
I Forcuttingperfect circles ontheband
saw,usea circle-cutting jigcustom-built for I
yourioolliketheoneshown
the illustration forsuggested
at left.Refer
dimensions.
to
r
Usea routerfittedwitha dovetail
a %-inch-deep groove inthemiddle
bitto cut
ofthejig r
base.Thenusea tablesawto rip a thin,
beveled board thatwillslidesmoothly in I
thechannel. (Setthesawbladebevel angle
b y m e a s u r i nt hgea n g l eo f t h ec h a n n e l I
edges.) Cutoutthenotchonthebandsaw.
Thenposition thejig baseonthesawtable I
sothatthebladeliesin thenotchandthe
d o v e t agi lr o o vies p e r p e n d i c utloatrh e I
direction of cut. Nowscrewthe suooort
armsto theunderside of thejig base; the I
a r m ss h o u l dh u gt h es i d e so f t h e b a n d
sawtable.Boretwoscrewholesthrough I
thebottom of thedovetail channel in the
jig baseroughly 1 inchand3 inches from I
theunnotched end;alsoborethreeholes
throueh thebar. I
I
Contact point
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Keleaaecut
I
Circleoutltne
I
I
r) Preparing theworkpiece
I ftlarX thecircumference andcenter of thecircreyouptan cumference andveeroff to the edge(above, /eff).Screwthe
I
pivotbarto thecenterof theworkpiece
to cuton its underside.
fourcorners
Then,usethebandsawto cutoffthe
of theworkpiece to keepit fromhittingtheclamps holes(above, right),leavingthe
throughoneof thebar's
screwlooseenough to pivotthe
I
thatwillsecure thejig to thetableastheworkpiece turns.Make workpiece.Turntheworkpiece overandmarkthecontact point
I
a releasecutfromtheedgeof theworkpiece to themarked cir- wheretheblade touched thecircumference
durinstherelease cut.
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44 I
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I CUTTINGJIGS
I
I
Q Securing theworkpiece tothejig
I r-,f Clampthejig baseto the bandsaw
table,making surethesupport armsare
T butted against
thetable's
pivotbarintothechannel
edges.Slidethe
in thebaseand
I oivottheworkorece untilthemarked con-
tactpointtouchestheblade. Screw through
t oneof theholesin thejig baseto lockthe
pivotbarin place(left),
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t Completing
thecircle
T Turnonthesawandoivotthework-
pieceintothebladein a clockwise
direc-
I tion(below),
feedingthepiecewithyour
righthanduntrlthecutis completed.
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I 45
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WEDGE-MAKINGIIG
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Building thejig
I Smallwedges areusedforwedged tenons, I
orto shimcabinets on uneven f loors. Thejig
9top block youto makethemquick-
'/""x1%"x4"
% "x 1 "x 1 5 % "
shown at leftallows
l y o nt h eb a n ds a w (. Y o uc a na l s ou s et h e
I
s a m ed e v i c o
illustration
e n a t a b l es a w . R) e f etro t h e I
forsuggested dimensions, making
surethehardwood runner fitssnuglyin the I
sawtablemiterslot.Screw therunner to the
underside of thebasesothattherunner ex- T
tendsbeyond thetabletop andthebasesits
s q u a r eol ynt h et a b l ew h e nt h er u n n ei rs i n I
theslot;countersink thefasteners. Next,screw
t h ef e n c et o t h et o po f t h eb a s ea; n g l et h e I
fenceat about4oto thefrontandbackedges
of thebase. Setthejig onthetablewiththe
r u n n ei rn t h es l o tt,u r no nt h es a wa, n dc u t
t
through thebaseuntiltheblade contacts the T
fence. Turnoffthesaw,remove thejig,and
cuta slotthrough thestopblockfora machine I
bolt.Attachtheblockto thebase,addinga
Kunner
'/""x%"x19"
w a s h earn dw i n gn u t .T h eb l o c ks h o u l b de t
f lushagainst thefencewiththetip of itsan-
gledendaligned withthekerf. T
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r) Cutting wedges
I
L for yourwedge stock,cut a stripof
cross-grain woodfromtheendof a board;
I
makeit aswideasthedesired lengthof
t h ew e d g e sP.o s i t i ot nh ej i g o n t h es a w
t
tableH . o l d i nygo u rs t o c kw i t hi t s e d g e
flushagainst thefence andoneendbutted
I
against thestopblock, feedthelig across I
thetable.Makesureyourhands areclear
of thebladeasyoucut eachwedge(right). I
Tocreate 4" anglewedges, square theend
of yourstockonthetablesawbefore each
c u t .l f y o us i m p l fyl i pt h ew o r k p i e bce -
t
tweencutsonthebandsaw,allthewedges I
afterthef irstwillhave8' angles. Topro-
ducethicker wedges, loosen thewingnut I
andslidethestopblockslightly away from
thekerf. Tighten thewingnutandcutthe I
wedges (inset).
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TWO IIGSFORANGLECUTSON THE BAND SAW
I TAPER
JIG
I Making tapercuts
Thesimple L-shapedjigshown at rightwill
T enable youto cuttapersonthebandsaw.
Markthedesired taperon theworkpiece
I andplaceit on a boardwitha perfectly
square edge, aligningthemarked linewith
I theboard's edge.Usethelongedgeand
theendof theworkpiece asa straightedge
I to markanangled cuttinglineandthelip
ontheboard. Sawalongthecuttingline,
I stopping 2 inchesfromtheendof thecut Jis <-
3/n"x B" x'14"
at the bottomendof the board. Turnthe
I board90" to cut outthe lip.To usethe
boardasa jig,setup the bandsaw'srip
I fenceto therightof thebladeandholdthe
jig flushagainstthefence. Aligntheedge
t of thejig'slipwiththesawblade andlock
thefencein position. Seattheworkpiece
I against thejig.Turnonthesawandslide
theworkpiece andthejig together across
I the tableintothe blade(right),keeping
bothhandsclearof thecuttingedge.
I
I MITER
JIG
I Miteringtrim
Usethejig shownat leftto mitertrimon
I Fence thebandsawwithout angling the miter
%"x13A"x13"
gauge. Formthejig bodybyface-gluing
t twosquarepiecesof %-inchplywood to-
gether.Oncetheadhesive hasdried,cuta
I 45' miterfromcorner to corneracross the
body,forming a ledgeonwhichthework-
I piecewillsit.Cuttwoslotsintotheface
of thebody% inchbelow theangled ledge
I to accommodate springclampjaws.Next,
cutthefencefromsolidstock,notchit for
I Guide Jiq body \ theclamps, andattachit to thejig body
a69embly 1%"x11"x11" sothatitstopedgeextends %inchabove
I theledge, Screwthejigto themitergauge
andfeedthejig intotheblade to trimthe
t lower end.Tocuta miter,clampthework-
pieceface-down ontheledgeandf lush
I againstthefence,andfeedthejig foward
withthemitergauge(left).Besureto raise
I thesaw'sguideassembly highenough to
avoidhittingthejigorworkpiece.
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I 47
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I
TAPERJIGS
T
I
A taperjig for theradialarm sawcanbe
built exactlylike thetablesawjig shown I
below.with oneaddition:Because thesaw
motoris suspended abovethetable,the
radialarm sawjig canonly befed with
t
onehand,makinga handlenecessary. I
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A TAPER
JIGFOR
THETABTE
SAW
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1 Making a tapercut I
I Foraccuratetapercutsonthetablesaw,buildthisjig (tnsef) of thejig basenearest
theblade.Holding theworkpiece securely,
from%-inchplywood. for suggested position
Referto the illustration theguidebaragainstit,withthelipsnugly against theend I
Toassemble
dimensions. thejig,setthesawbladeto its maxi- of theworkpiece. Screw theguidebarto thebaseandpress the
mumcuttingheight, buttonesideof thejig baseagainst the toggle clamps downto securetheworkpiece to thejig.Tomake t
andposition
blade theripfenceflushagainst theothersideof the thecut,setthe bladeheightandslidethejig andworkpiece
base.
Lowerthebladeandmarka cuttinglineforthetaperonthe across
workpiece,
thensetit onthebase, aligning
thetable,making
thelinewiththeedge blade(above).
surethatneither
(Caution:
handis in linewiththe
Bladeguardremoved for clarig.)
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48 I
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ABLADEHEIGHTGAUGE
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I THEBLADE
SETTING (lNA TABTE
HEIGHT SAW
I Using a bladeheight gauge
Yourtablesaw'sbladecanbe setat a
I specific height quickly witha bladeheight
gauge.Makethejig fromstripsof %-or
I % o - i n c h - t hhi cakr d b o aor dr s o l i dw o o d
laminated together. First,rip a lengthof
I the stockto a widthof 3 inches. Crosscut
thepieceintostrips,starting withan 8-
I inchlength. Makeeachsuccessive strip%
inchshorter thantheorevious one.Once
I allthestripsarecut,gluethemtogether
face-to-face withoneendaligned. Touse
I thejig,setit on thesawtablebeside
the bladeandrotatethe bladeheight
I adjustment crankuntiltheblade contacts
thegaugeat thedesiredheighl(right).
I
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I
I Illlllllllllllltllllllllillllltfilllllfit-l1ll"tlll-1[t'llt"lltl
llt'tlll
I 1HO?TI?
I Shop-made
table ineerte
I lf ihe table
inserLseupplied
t wiih vour Nablesaw are
aL leaeN%inchthick, youcan
makeyour ownfrom woodecrape.
I The inserle willminimizeNheqap
belweenlheeawbladeandNheLable
I ineerLo?eninqand ?reventecrapwoodfrom \
jamminqaqaineN the blade.UeeLhefactory-eup-
I pliedineerl ae a lemplale t o cul a blankfrom a /.7
pieceof woodof lhe eamethickneee.Tap a finisfur(gnailinVoIhe blank'e
I front enAunlil'/oinchprotrudeefrom if. (Thenailwilloerveae an anchor
pint o keeplhe ineerLin Vlacewhilethe eawie runninq.) CrankNheblade
I to ite loweet,eetlinq and eellhe newineert in place.TosilionLhe rip
fenceto etraddleNheinserl,makinqeureIhat iI is noI directlyin line
I withlhe cuttinqedqe.Iurnonbheeawand crankNheblade
to itrohiqheotoetlinq, cutlinq a eloLNhrouqhNhewoodineerl.
olowlyup

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MITERIIGS
CROSSCUTAND I
I
The tablesaw miterjig shownat right k
similar to the crosscutjig describedbelow, I
exceptthat insteadof an extensionand
safetyblockit featurestwo l2-inch-long I
1-by-4 miter arms.Placedat 90" to each
other in the middle of thejig, the arms I
ensurethat a workpiecemiteredalong
oneguide will form a perfect90" corner I
with a boardcut along the other arm.
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JIGFORTHETABLE
A CROSSCUT SAW
I
Clearplaetic
quard
I
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I
)top block
2"x4"x4" I
t
I
Kernforcinqblock
2"x2"x8"
t
9upporEframe
2"x3"x36" I
I
1 Aftaching therunners tothebase
jig custom-made
I
I A crosscut foryourtablesawliketheoneshown above is
especially valuable
tionforsuggested
if youareworking
dimensions.
withunwieldy
Startbycutting
stock.Refer
two25-inch-long
to the illustra-
hardwood runners
t
to fit yourmiterslots.Boreandcountersink
undersides of therunners, 3 inches
clearance
fromeachend.Place
holesforscrews
therunners
intothe
in theslots
t
a n ds l i d et h e mo u tt o o v e r h a nt hgeb a c ke n do f t h et a b l eb ya b o u8t i n c h e s .
Position thejig basesquarely onthewoodstrips, itsedgeflushwiththeirover-
I
hanging ends,andscrew therunners to thebase(/eff).Slidetherunners andthe I
baseoffthefrontendof thetableanddrivein theothertwoscrews.
I
50
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I CUTTING IIGS
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I p
6@^

t @
,@O

I E=-Itr*-
\:/-t'r

I
I r) Installingthesupport
frame andguide
I W,tntherunners still themiterslots,
in attach thesupport thebasefromunderneath thejig,making sureyoucountersink
I framealong jig
thebackedgeof the and glueonthereinforcingthefasteners. Gluethesafety blockto theoutside faceof the
block,centered betweentherunners. Thenmakea cutthrough guide, again
centered onthekerf.Raise thesawblade andfin-
I thesupport frameandthree-quarters of thewayacross thebase. ishthecut,sawing completely
through theguidebutonlyslight-
Turnoffthesawandlowertheblade.Screw a reinforcingblock ly intothesafetyblock.Mounta clearplastic sheetoverthesaw
I to theguide andpositiontheguide alongthefrontedgeof the kerfasa bladeguard, fasteningit to thereinforcing
blockswith
jig,usinga carpenter's
square to ensure thatit is square
with wingnutsorscrews.
t thesawkerf.Clamp theguidein place(above)and screwit to

I
I
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I Q Crosscutting
r-,1Formaking repeat cutsto thesame
I length, screwan extension to the right
sideof theguideandclampa stopblock
r to it. Cuta notchin theblockto holdthe
clampin placewhenit is loosened. Touse
I thejig,fit therunners intothemrterslots
andslidethejig toward the backof the
I tableuntiltheblade enters thekerf.Hold
theworkpiece against theguide, slidethe
I s t o pb l o c kt o t h ed e s i r epdo s i t i o na,n d
c l a m pi t i n p l a c eW . i t ht h ew o r k p i e c e
t t eg u i d ea n dt h e
h e l df i r m l ya g a i n st h
s t o pb l o c ks, l i d et h ej i g s t e a d r a
l yc r o s s
t thetable(left),feeding
intotheblade.
theworkpiece

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RAISEDPANELIIG
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1 Making thejig I
I Toraise a panel onthetablesawwithout adlusting theblade
jigshown
angle, usetheshop-built
forsuggested dimensions. Screw
at left.Refer
thelipalong
totheillustration
thebottom edge
I
of theangled fence,making sureto position thescrews where t
t h e yw i l ln o ti n t e r f e rwei t ht h e b l a d eP. r o pt h ea n g l e fde n c e
against theauxiliary fenceat thesameangle asthecuttingline I
marked outonthepanelto beraised. Usea slidingbevelto trans-
ferthisangle to triangular-shaped supports thatwillf it between I
thetwofencesandcut thesupports to fit. Fixthesupports in
placewithscrews(above).
I
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I
r) Raising a panel
L Snttttheripfenceto position thejig
I
w i t h j o i n t
o f t h el i p
o nt h es a wt a b l e
a n da n g l e df e n c e
the
o v e trh eb l a d ee; n s u r e
I
thatthescrews arewellclearof thetable I
o p e n i n gT.u r no nt h es a wa n dc r a n kt h e
bladeup slowly to cut a kerfthrough the I
l i p .N e x ts, e a t h ep a n eiln t h ej i g a n d
a d j u stth eh e i g hot f t h eb l a d eu n t i al sin- I
gletoothis protruding beyond thefrontof
thepanel.Makea testcut in a scrapboard I
thesamethickness astheoanelandihen
testitsf it in theframegroove. Adjust the I
position of thefenceorblade, if necessary,
a n dc u tt h ea c t u apl a n e bl ,e v e l i nt hgee n d I
grainfust (right).
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52 I
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BOARD-STRAIGHTENINGIIG
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I Truing a board
Totrueuneven boards on a tablesaw,
1iililil ilil tiiilililil|il ilil|ill tiiillil illl llll llil illl llll liil llll buildtheboard straightening jig shown
I ili iii ill {il lti {$ {il i.Uui ul l$ ili i.ti iii iil iil ul ill
a b o v eB. u i l tf r o m% - i n cphl y w o o tdh, e
jig slidesin thetablesaw'smitergauge
I 5HO7Tt? slot,whrletheboard to bestraightened
i s h e l di n p l a c eb ys u p p o rbtl o c kas n d
t Crosscult'ingwide panele toggleclamps. Firstcut the basefrom
lf yourIable oawdoeenot havean exLension, or you are workinq %-inch plywood; makeit about9 inches
I wiNhVanelolhal are t'oo larget'o cuNwiLha mit'erqauqe,you can
wideandlonger thanthewidthof your
crosscutlheee paneloby clampinqa equare1-by'3fencelo the
I undereide of the panel.Uoea 1-by-3Nhatis lonqert'hanthe Vanelio s a wt a b l eC . u ta r u n n etro f i t t h e l e f t -
wideand carefullypoeition handmitergauge slot;makeit longer
I it, undernealhperVendicular thanthejig baseandposition it onthe

r "n22"
i:o;:," :?"|flV
F
H
" underside of thebasesothattheinside
edgeof thebaseoverlaps thebladeby
Nhefenceto the %inch.Screw therunner to thebottom
'

I VanelwiLhC '.t:t--/ '

of thejig,countersinking allthescrews.
clampo.Guide Next,screwtwosupportblocksto the
Nhefence along baseandinstall toggle clamps onthem;
I the ouler edge position thesupport blocks sothework-
of your eaw'e p i e c ei s c e n t e r eodnt h eb a s eF. i n a l l y ,
I table ao you
fashion a handle andattach it totheend
makethe cuN.
I o f t h ej i g .T o u s et h ej i g ,f i r s t r i mt h e
inside edgesquare byrunning it across
to be
I t h eb l a d et .h e nc l a m pt h eb o a r d
straightened to thejig andrepeat to true
I itc odopc (zhnvp)

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AUXILIARYFENCESAND TABLES
I
A RADIAL
ARMSAWM()TDING
FIXTURE
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Cutout
2 % "x 9 % "
T
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LiP
'/+"abovetable I
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Buildingandsettingupthejig
I
1
I lf youwantto cutgrooves or molding
withthebladein thehorizontalposition,
ontheradialarmsaw
tryanauxiliary
fence
to createa gapalongthefencethatwill prevent
fromaccumulating between the baseandthefence.When
sawdust t
andtableliketheoneshown above. Thebaseraises thework- sawingthe fencecutout,leave a lipthatwillprotrude at least
pieceto thecutter,andthefencesupports theworkwhilepro- %i n c ha b o v teh eb a s ew h e nt h ej i g i s i n s t a l l eTd h. el i pw i l l
I
vidinga clearance
cutoutforthedadoor molding headguard. support theworkpiece asit ridesalong thefenceduring a cut.
Cutthefenceandthetwopieces forthebasefrom%-inch ply- Screw thefenceto thebase. Tosetupthejig,slipthefence
I
wood;makethe basepieces thesamesizeasthe frontsaw between thefrontsawtableandthetablespacer, thentight-
table.Screwthe basepieces together,offsetting
thetopslightly enthetableclamos to secure it.
I
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r') Cutting a molding
I
L lnstalla molding headonyoursaw,
thensecure theworkpiece byclamping
I
onefeatherboard to theoutfeed
thefenceandanother
sideof
to thetable,braced
t
witha support board, Adjustthemolding
headfor a %-inch-deep cut,making cer-
I
t a i nt h e b l a d eg u a r di s p o s i t i o n e j uds t
abovetheworkpiece. Feedthestockinto
I
the cutterswithyourrighthand(right);
useyourleft handto presstheworkpiece
I
against thefence.Finish thepasswitha
pushstick.Makeasmanypasses asnec-
I
essary, advancing themolding headno
morethan%inchintotheworkpiece at
I
a t i m e .O n c ey o uh a v ec u tt h ed e s i r e d
p r o f i l em, a k ea f i n a l ,v e r ys h a l l o w
pass,
I
f e e d i nsgl o w l ay n de v e n ltyo p r o d u cae
smooth finish.
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I CUTTINGIIGS
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I F()RTHETABLE
FENCE
ANAUXITIARY SAW
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Using anauxiliary fence
I Anytime youusea dadoormolding head
I illtilllllillllllll llltlllllllllllllllllltillll
fillrlllllltijllfiitlll1 onyourtablesawin conjunction
rip fence,youneedto attacha wood
withthe

fenceto orevent the blades fromcon-

I 9HO7Tt? tacting themetalone.Cutthefencefrom
%-inch plywood thesamelengthasthe
I A miter Oauge
ripfenceandslightly higher. Lower the
extension
blades below thesawtableandscrew the
I Io increasef,hebear-
woodfenceto theripfence.Markthe
inq eurfaceof your
depthof cut onthefenceandposition
I tableeaws miler gauqe
or Nomakere?eatcrogo' theauxiliary fencedirectly overthedado
cu|s wiNhthe aid head, ensuring thatthemetalfenceis
I of a eNopblock, clearof theblade. Turnonthesawand
athach a wood s l o w lcyr a n ku pt h ed a d oh e a dt o t h e
I exDeneionlo the marked line,producing a reliefcutin the
qau7e.The excension auxiliary fence.Buttthecuttinglineon
I muel be lonqenouqhlo theworkpiece against theouterblade
extendbeyondthe eaw blade.)crew iNNolhe qauqeand Vuoh
a n dl o c kt h ef e n c ef l u s ha g a i n st ht e
I NhegauqeLo cut,off the endof t'heexEension.Turn off Nhesaw
stock.Formostcutting operations, like
and slideLhemiLer6auqeto Ihe fronLof Nhelable.Toeet up a
therabbet cutshown in theillustration,
I ehopblock,clampa woodblockloNheexEension
lance from Nheb1ade,
Nhedesireddis'
Foreachcut, butt' trheedqeof the work' theworkpiece should besupported with
andlhe enda7aineNthe olop block. featherboards. Feedtheworkpiece at a
I pieceaqaineNNheexLeneion
steadyrate,usingbothhands(above).
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I 55
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COVE,.CUTTING
IIG I
thejig
I
1 Building andusing
I Fashion moldins
thehelpof thecove--cutting
onthetablesawwith
guideshown at
I
left.Toconstruct thejig,fastentwo 18- I
inch-long l-by-2s to two9-inch-long 1-by-
2 s w i t hc a r r i a gbeo l t sa n dw i n gn u t s ,
forming twosetsof parallel arms. Adjust the
I
jigsothedistance between theinside edges
o f t h et w ol o n ga r m se q u a ltsh ew i d t ho f
I
thecove.Crank thebladeto thedesired
depthof cut.Laytheguideacross theblade
I
a n dr o t a t er t u n t i lt h e b l a d et,u r n e db y
hand,justtouches theinside edges of the
I
a r m sT. h e nr u na p e n c ial l o n g
edges of thelongarmsto traceguidelines
t h ei n s i d e I
across thetableinsert(/eft). I
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r) Cutting a cove
1 Remorethe euideandlower thebladebeneath thetable.Outline thedesired cove
I
profile ontheleaJing endof theworkpiece, thensetthestockonthesawtable,aligning the
marked outline withtheguidelines onthetableinsert. Buttguideboards against theedges
I
o f t h ew o r k p i e caen dc l a m pt h e mp a r a l l e
t ol t h eg u i d e l i n euss; eb o a r dlso n ge n o u g h
t o s p a nt h es a wt a b l eC. r a n tkh eb l a d e%i n c ha b o v teh et a b l eT. om a k e t h ef i r s tp a s s ,
I
feedtheworkpiece steadily (above), usingpushblocks whenyourhandsapproach the
blade area.Makeasmanypasses asnecessary, raisingthe blade%inchat a time,
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56 I
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I
r TWOTENONINGJIGS
t A SIM PLTEEN O N IN
JIG
G
I 1 Building thejig
I Easy to assemble, thefence-straddling
I j i gs h o w n at righw t o r k sw e l lf o rc u t t i n g
two-shouldered openmortise-and-tenon
I joints.Refer to thedimensions suggested
in theillustration, making surethethick-
I nessof thespacer andwidthof thebrace
a l l o wt h ej i gt o s l i d es m o o t hal yl o n g
your
I r i pf e n c ew i t h o uwt o b b l i nC g .u tt h eb o d y
andbracefrom34-inch plywood andthe
I guideandspacer fromsolidwood. Sawan
ovalholefora handle in onecorner of the
I jig bodyandattach theguideto thebody
directly in frontofthehandle hole,making
I s u r et h a tt h eg u i d ei s p e ref c t l yv e r t i c a l .
(Theblademaynotchthe bottomof the
I guidethefirsttimeyouusethejig.)Screw
a s m a lw l o o db l o c kt o t h e b o d yb e l o w
I t h eh a n d l ae n da t t a c a h t o g g l cel a m p
t o t h e b l o c kF . i n a l l yf a
, s t e nt h es p a c e r
I andbracein olace.

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I r) Cutting a mortise
I Placetheiig astride thefence.Butt
I t ej i g g u i d ea n d
t h ew o r k p i e caeg a i n st h
c l a m pi t i n p l a c eP. o s i t i ot nh ef e n c et o
I alignthecuttingmarks ontheboard with
theblade andslidethejigalong thefence
I to makeIhe cuI (lefil.
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CUTTING IIGS I
I
ANADJUSTABLE
TENONING
JIG I
I
Blade4uard I
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Erace I
3/+"x13/+"x351/q"
I
Fence 11,/2"x51/2"x24"
v Kunner
I
3/+"x5%"x351/+"
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1 Assembling
thelig
I Thejig shown above canbeusedon
the tablesawto cut bothpartsof an
I
openmortise-and-tenon joint.Refer to
theillustration forsuggested dimensions.
I
Cutthejig fenceandbackfromthree
piecesof %-inchplywood andsawa
I
45' bevelat oneendof eachboard; the
pieces should bewiderthantheheight
I
ofyoursaw'sripfence.Fasten twopieces
together face-to-face to fashionthe
I
back,thenusecountersunk screws to
attachthefenceandbacktogether in
I
an L shape; makesurethefasteners will
notbein theblade's pathwhenyouuse
I
the jig (inset).Next,cut the bracefrom
solidstock,bevelits endsandattach
I
i t a l o n gt h et o p e d g e so f t h e f e n c e
andback,forming a triangle. Cuttherun-
I
nerfromsolidwoodandattachit to the
fencesothatthejig runssmoothly across r') Mounting
theeccentric
clamp
I
thetablewithout wobbling. (Therunner 1 tttat,,e
theclampbyface-gluing threepieces of %-inchplywood andcuttingthe
in thisillustration hasbeennotched to assemblyintotheshapeshown. Borea prlotholethrough thejig backandtheclamp,
t
fit theparticular desrgn of thesaw'srip thenfastentheclampin place;wedgeoneof yourworkpieces between theedgeof
fence.) Finally, cuta pieceof clearplas- theclampandthefenceasyoudrivethescrew. Offsetthefastener sotheclampcan
I
tic asa bladeguardandscrewit to the (above),
pivoteccentrically (Drilladditional
holesin thejig backto enableyouto move
jig backflushwithitsfrontface. theclampto accommodate stockof varying
thicknesses.)
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I CUTTINGIIGS
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I Cuttinga tenon
S e tt h e l i g o n t h e s a wt a b l ei n f r o n t
I lllllllllllll]lllll illlillllllllllltlll
,lllllllljlllllllll]lllilll,ll1 of theblade
straddling
withtherunner
theripfence. Secure
andfence
thework-
piecein thejig byturning theeccentric
I 1HO?TI? clamp, andposition theripfencesothat
t h eb l a d ei s i n l i n ew i t ha t e n o nc h e e k
I A miter 4augeangle-eetlingjig
cuttingmarkontheworkpiece. Feedthe
Tokeeplrack of non-eLandard angleolhalyou commonly useon
jig intotheblade. (Your f irstuseof the
I yourtable oaw'6miter qauqe,makea sel of anqle-eeNIinq 1iqo.
)implycut Lwo1-by-2eand clamVIhemto the miler 1 i gw i l lp r o d u caek e r fi n t h eb a c k .F) l i p
theworkpiece in the1igandrepeat to cut
I q a u q eo, n ea q a i n e l t h eb a ra n d o n ea q a i n o t r L h e
f a c e . 7 c r e wt h e m N o q e L h ei nr N oa n a n g l e dL i theothercheek(above). Remove thejig
ohapeand markdownf,heanqlethey form fromthetable,lower thecuttingheight
I o n t h e j i g , U e et h e d e v i c el i k ea o l i d i n g
,,
t o t h el e v eol f t h es h o u l d e rasn, ds h i f t
bevel t o ee| the miter
I qaugequicklyLo a
theriofence to cutthetenon shoulders.
opecific angle.
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'!
',r;&c !-.
&w
'C.''.-''..'l
weba
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I DruLLINGIIGS
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t
I rillinga holeis simple,but there
A SETECTI(IN
OFDRILTING
JIGS
aretimeswhenajig cansave you
I time and frustration,especially
the hole mustbe locatedprecisely,
when
or at
jig,
I an exactangle.The center-drilling
for example,ensuresthat doweljoint
Cenier-drilling ji6 Qaqe 62)
Uaed with an electric drill to locate
t holeswill be centeredin the edgesof
matingworkpieces.Thejig for drilling
the center of a board ed1e; dowelo
at the enda of the arm are butted
Jig for boring
aqainet oppoeite board facea
I equallyspacedholeson the drill press
virtually eliminatesthe needfor meas-
equally spaced
holes (pa6e 64)
Uaedon drill preaa
I uring andmarkingandguarantees
sistentlyaccurate results.
con-

t The tilting tableandpocketholejigs

areboth invaluablefor boringthe angled
holesthat arecommonlyusedto attach
I tabletops andchairseatsto legsandrails.
The techniquefor drilling deepholes
I shownon page67 willdoubleyour drill Pocket holejig (page 66)
press'squill stroke,allowingyou to bore Clampedto drill preaa
I straightthroughthick stockwithout table to bore pocket
holee;workpiece
I resortingto an extension bit.
V-bloakjig (page 65)
reste edqe-down
in an4ledcradle
Holde cvlindrical
I stock on drill
preee table
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t Tilting table jig
(pase65)
t Equippedwith thejig shownat left,
Adjuetableji4
attached to drill
I a drill presscanborea rowof equally preae table for borin7
spacedholesquicklyand accurately. anqled holea;workpiece
lies face-downon top
I Thejig is simpleto buildfrom scrap
woodanda shortdowel.
 I
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CENTER-DRILLING
IIG I
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Drilling dowel holes
I
j i g
lllillllllllilllllillIJllrlitllilltilllillll]lllljrJl I
T h es i m p l e s h o wanb o vw e i l le n a b l e
youto boreholesthatarecentered on ltllLiilllllll
theedgeof a board.
suggested dimensions.
Theinsetprovides
Markthecenter
I
of thetopfaceof thearm,andborea 1HO?TI? I
holefora guidebushing. Theholein the
lnoertin7dowels
bushing
holes
should bethesamesizeasthe
youplanto drill.Turnthearmover
wilh a deprh gauqe I
ToavoidNheriekof drivinq
anddrawa linedownitsmiddle,
points ontheline1 inchfromeachend.
Mark doweletoo deeVlyand epliN- I
Iinq the board,try thie
(Check yourmeasurements: Thepoints
m u s tb ee q u i d i s t afnr ot mt h ec e n t e r . )
eimpledeplhqauqe. I
U e ea 6 - i n c h - l o n q
Thenborea %-inch-diameter
through thearmat eachmark.Dabsome
holehalfway Vieceof ebock
one-hala fe 7 I
N h i c ka e t h e
g l u ei n t ot h eh o l e sa n di n s e rdt o w e l s .
Theyshould protrude byabout%inch.To lenqlhof the
I
dowele.9ore a hole
usethe1ig,position
sothatthedowels
it ontheworkpiece
buttagainst opposite n e a ro n ee n d L h a N I
i e e l i q h b l yl a r q e rL h a n l h e
facesof thestock.Holding thejig wrth
o n eh a n df,i t t h ed r i l lb i t i n t ot h eb u s h -
doweldiameler.Then elipthe 1igaroundeach t
dowelwhenyou laV it, in Vlace.Thedowelwill
ingandborethe hole(above). be aI Nhecorrecldepthwhenit ie fluehwith t
t.heNoVof the deplh qauqe.
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TITTINGTABLEIIG
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1 Making thetable
I I T o b o r ea n g l e d h o l e sw i t h o utti l t i n g
t h ed r i l lp r e s tsa b l e u, s et h et i l t i n gj i g
I shown
%-inch
at right,builtfromsolidstockand
plywood. Refer to theillustration
I for suggested dimensions. Connect the
j i g t o pt o t h eb a s eu s i n ga s t u r d yp i a n o
I hinge. Cuta %-inch-wide
portbrackets
slotin thesup-
andscreweachoneto the
t top;secure
wingnuts,washers,
thebrackets to thebasewith
andhanger bolts.
I
I
t r) Drilling
(-, a ^Center
angled holes
thejig underthedrillpress
t s p i n d l ec,l a m pt h eb a s et o t h et a b l e ,
andloosen thewingnuts.Usea pro-
I tractoranda slidingbevelto setthe
angle of thetop,thentighten thewing
9upport bracket
t/o"xl %"x'lO"

I nuts.Clamp theworkpiece to thejig

andborethehole(below).
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IIG FORDRILLINGEQUALLYSPACEDHOLES I
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1 Making thejig I
I Makethisjigto simplify thetaskof boring a rowof equally spaced holes
o n t h ed r i l lp r e s s .
Screw t h ef e n c ef l u s hw i t ho n e e d g e
o f t h
holder.
e b a s
(The
et,h e n
hole r) Boring theholes
I
attacha woodblockto thecenter of thefenceasa dowel
forthedowelis madethefirsttime
i n t h ei l l u s t r a t iw
on
you usethe jig.)Tne
i l ls u i tm o s dt r i l lp r e stsa b l e s .
dimensions given L S e t h e1 i go nt h ed r i l lp r e stsa b l e .
Markthe location of thef irsttwoholes
t
thefence
andseattheworkpiece
of thejig,aligning
against
thefirstdrilling mark
I
under thebit.Butta guideblockagainst I
l]Illlllllllilll
llllullltiilltllrljlllllllirufiililllillll]lllllll]I1 t h eb a c ko f t h ej i g a n dc l a m pi t t o t h e
t a b l eB. o r et h ef i r s th o l e s, l i d et h ej i g I
along t h eg u i d eb l o c ka, n db o r ea h o l e
5HO7Tt? t h r o u g thh ed o w ehl o l d e rF. i ta d o w e l I
through theholeintheholder andintothe
Making
wood plugo
holein theworkpiece.
thesecond drilling
Slidethejig until
markisaligned under
t
eavelime
makinqwood
the b i t
b o r et h e
.C
s
l a
e
m
c o
t
p h
n h
d
ej
o
i g
l
t
e
o
T
.
t
o
h
d
e
r
t
t
a
l
b
le
l
a
ea n d
ch
t
pluqeby uoin4a
al n d
pieceof IaVe Noremove remaining
slidethe
h o l
workpiece
e r
, e t r
along
a c t t
h e
the
d o
jig
w e
fence.
I
themfromtheirholee, Use
a oluacull,eron the drill Pushthedoweldownintothelasthole I
Vr:"eir,o borea rowof plugeNo youmaoe.
Lhedepthyou require.CoverNhe I
row wilh a eNripof maekinq t aVe,
then rip Ihe pluqelo lenqthon Nhe
bandsaw and eimplypeeloff the I
ta?e to removethe rowof Vluqe.
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t V-BLOCKIIG
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I Boring holesin cylindrical stock
T o m a k et h es i m p l eV - b l o cjki g s h o w n
t llllilI1
lllltlllll1
llltilij]ltiluili ll11
illlllitfillilltllr1
lllll]t1 above, marka right-angle V on theend
o f a p i e c eo f s o l i ds t o c kt h a ti s l o n g
I e n o u gtho h o l dy o u rw o r k p i e cTeh. e n ,
I 1HO?TI? adjust theblade angle onyourtablesaw
to 45"andalignonecutting linewiththe
Depth guideo for drilling I i'l I b l a d eB. u t t h er i pf e n c ea g a i n st ht e
I To borea holelo an exacL I | il
q-hr".t:','*
: I
stockandfeedtheboard to cutthefirst
d,epNh, uee a maekin4t ape I
s i d eo f t h eV . R e v e r st he ep i e c ea n d
I flag or a deplh orop block, I : ll|;t
m a k et h es e c o n cdu t .T o u s et h ej i g ,
lf you are ueinqNheNape, F:;=
y secure it to thedrilltablesothedrillbit
I meaeure the drillinqdepth t -
from the Lip of the"biv,'then ffufl-{- t o u c h etsh ec e n t eor f t h eV w h e nt h e
-ffi;{.
wra?a eNriVof NaVearound quillisextended. Holdtheworkpiece in
t ive'ehank. Wnnarhwlhe bit W t h eV , a l i g n i ntgh eb i t o v e tr h ec u t t i n g
whenlhe NaVetouch,eethe sy1#' m a r ks, e tt h ed r i l l i n d
g e p t ha, n db o r e
I s t o c k . T ou e ea b l o c k e, u b - W the hole(above).
tractNhedrillinadeplh from f il
I Nhelenqth ofrhibit'Vrotrud- tT--*l
i n qf r o m l h e c h u c k C
. U La Y --
tD'
t piiceof 1-by-1 eNockNo lhie
length,Nhenborea holeNhrouqhite middle.
I )lip the bit throuqhthe blockandboreyour
holeunlilthe block t ouchee Lhe workpiece.
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I 65
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POCKETHOLEIIG
I
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1 Making theiig
I T o b o r eo o c k eht o l e so n t h ed r i l l
press,usethisjig madefrom%-inch
I
plywood andtwosmallpieces of solid
stock.Referto the illustration at left
I
for suggested dimensions. Screwthe
twosidesof thecradletogether to form
I
an L. Thencuta 90" anglewedge from
eachsuooort bracket sothatthewide
I
sideof thecradle willsit at anangleof
about20" fromthevertical. Screw the
I
to thejig baseandattachthe
brackets
cradle to thebrackets.
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Da'ee I
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t
r) Drilling pocket holes
I
I Seatthe workoiece in thecradle
t h es i d et o b ed r i l l e fda c i n g
with
o u ta n dt h e
t
t o ne d p es i t t i n si n t h eV o f t h ec r a d l e .
Boretheholesin twostepswithtwodif-
I
ferentbits:a Forstner
thanthediameter
bit slightly
of thescrewheads,
larger
so
t
theycanberecessed, anda brad-point
b i ta l i t t l el a r g et rh a nt h es c r e w shanks
I
t o a l l o wf o rw o o dm o v e m e nI n t .s t a tl lh e
b r a d - p o ibni t i n t h ec h u c ka n dp o s i t i o n
I
t h ej i g o nt h ed r i l lp r e stsa b l es ot h eb i t
alrgns withthecenter of thebottom edge
I
o f t h ew o r k p i e c( ien s e t C ) .l a m p t h ej i g
to thetableandreplace thebrad-point bit
t
withtheForstner. Holding theworkpiece
firmlyin thejig,feedthebitslowly to bore
I
eachholejustdeepenough
screwheads(ilgh|.fo complete
to recess
thepock-
the
t
e t h o l e sr ,e i n s t a l l t b
borethrough theworkpiece.
h rea d - p o bi ni ta n d
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BORINGDEEPHOLES
I
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t Exceeding a drillpress's quillstroke
Themaximum distance thattheouillof
I
lllllnillltilljl]lJ
l]llillJlfllll1
ullllullllillll]illlllilllllllllll a d r i l lp r e scsa nb ee x t e n d ei sdc a l l e d
itsstroke. 0n mosttools,thisis nomore
I than4 inches. Todrilla deeper hole,you
I 1HO?Tt? mayuseanextension bitor,if thehole
andtheworkoiece measure lessthan
Cuttinq roaettes
t on the drill preao
twicethequillstroke,
ationin twostages
perform
witha standard
theoper-
bit.
Youcan cuI decoralive
A s i m p l jei g s o l v easn ya l i g n m e pn rt o b -
t rosetNeeby modifyinga
lems.First,clampa scrapboard to the
drill oreeeflv culter wilh
d r i l lp r e stsa b l ea n db o r ea g u i d eh o l e .
I a be'adinq biadefrom a
Nablesawmoldinqhead. Then,clamptheworkpiece to theboard
NotchNhefly cuNLerarm a n db o r ei n t oi t a sd e e p layst h eq u i l l
I to accommodat e Nhebead' stroke willallow.Remove theworkpiece,
inqblade,locaLinq LhecuL-
t Neraboull inchfromlhe
f i t a d o w ei ln t ot h eg u i d eh o l es, l i pt h e
workpiece overthedowel, andfinishbor-
endof the arm. Makeeureit ingtheholefromtheotherside(above).
t fite eecurely in the notcheo il cannolehifLduringuee.borea Thedowel willensure thatthetwoholes
holethroughthe armand ueeabolN,waeher, and nuNLofashenNhe
areperfectly aligned.
I bladein I,henobchwith i|s flat,lace t owardthe direcNion
of cuNter
rot ation,1eI your workpieceon a woodbaeewibhetoV blockeNo
I holdit oecurely. ClamVthe oebupto LhedrillVreeeNable, aliqning
lhe centerof the fly culter overlhe cenherof lhe slock.Turnon
I the drilland lowerthe quilluntil lhe bladeliqhtlyconlacts the
wood.Continue cuNlinqunlilLherose|te hasLheprofileyou want.
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TTIRNINGIIGS
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I athesenablea woodworkerto turn ()FTURNING
A COLTECTION IIGS
blocksof woodof almostanyirreg-
I ular shapeinto beautiful,roundedcre-
Center-finding jig (pa6e 71)
ations,Woodturnersoftenspeakof how Locateathe center of irre7ularly
I visualtheirart is; theyseea chairleg, ohapedworkfor faceplate turninq
bowl,or peppermill seemto growfrom
t a spinningblank.Yetdespiteits visual
"feel" Diamet'er
elementandtheemuhasis on for gauge (paqe 73)
t judgingthe progresiof a turnedwork- Uaedto checkthe diameter
of a turned workpiece;ocrewo
piece,turning alsodependson accuracy
t andcarefulmeasurement. orovidefine adiubtm ent
Thejigsin thischapterwill helpyou
I turn a workpiece with precision.Useone
of thesetupjigsshownon pages70 and
I 71 to mount a blankproperlyon the
lathe,evenif theworkpieceis irregular-
I ly shaped.A layoutjig (page73)isideal Faaeplate-aenteringjig (page 71)
for quicklyandaccurately outliningthe For mountinqthe lathe faceplate
I locationof the contourson a blank, Lo the center of circular workpiecee
while measuringjigs like the diameter
I gauge(page73)orbowl depth gauge
Gouge-sharpeningjig (page 72)
(page77)comein handyfor checkinga Uaedin conjunctionwith a benchqrinder
I workoiece's dimensions. to eharpenLurnin7toola; holdatool,
Tlie lathecanalsobe usedfor pur- bladeat the properanqlefor
T posesotherthanturning;seethesand- qrindinqthe bevelon
the cuttin4 edqe
ing drum (page77) and the jig for
I routing flutesin columns(page75).

I
I
I Mo unting h ollowed- out workpieces
on a lathe can be challenging.For
I the cocobolobud vasebeingsanded
at left, a conicalbull-nosetailstock Layout jig (page 75)
I waspositionedbetweenthe lathe's Uaedto tranafer lay-
out lineafrom a pat-
metal tailstockand the workpiece,
tern to a f,urnrnqblank
t allowing the vaseto be supported
snuglywithout dantage.
I
I 69
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 I
TURNING JIGS
I
I
I
A COTTECTION
(continued)
OFTURNING
JIGS I
I
Tailetock for hollowed-
out work (paqe 74) I
Conicalwoodentailatock
placed betweenmetal tailetock I
of lathe and workpieceto 6uppor, open-
mouth workfor final turnina and finiahina
I
1anding drum (page 77) I
For amoothingcontoured work;aand- Column fluter
paper ie held in place by a hard-
wood etrip acrewedinto -a
(pa6e 75) t
Uaedto rout flutea in turned
a 1roove rou'ea
in the drum
columna;columnblankia mountedon lathe while
jig elideealonq the lathe bed and 4uidee router
t
blank
I
Bowl depth gauge (page 77) I
Uaedto determine the depth
of a bowldurinqturnin7
I
I
I
I
tllltll]lllllllrtlllllltlllfitttlllll11
lllllllltllllllllllilllltlltllj I
1HO?TI? I
Centering a epindle blank
F i n d i n q L hcee n N eorf a b l a n k T
for epindle turninqie tradi-
Nionally doneby markinqNwo I
diagonallinesfrom cornerlo
corneron eitherend of Nhe
workpiece. )till, for bolh
t
eafetyand accuracy,iNie a I
aoodideat o double-check
lhe localion of the center.
With lhe lathe swilchedof*, pooilionLhetool resLclooeto the I
blankparallelto oneol ite corners.KoIaIe the blankby hand,The
qap belweenLheNoolreet and the blankshouldbe the eameat I
eachcorner;adjuol lhe poeibionof the LoolreeI, if neceoeary. Ae
an addiLional check,ewiLchon the laLhe,placea pencilon NheIoot I
resL,and ecribea circleon the endof the opinninqblank,as ehown.
Turn oft the Nool.Thecircleshouldbe centeredon Ihe endof the I
blank;if not, adjuetthe tailslock and repeat,
I
I
70 I
I
I
t
I
TWO CENTERING
IIGS
I
JIG
A FACEPLATE.CENTERING
t Centering thefaceplate ona workpiece
Tocenter yourlathe's faceplate ona cir-
I cularworkpiece, usethehandy jig shown
at right.Turna cylindrical pieceof woodto
I thediameter of thefaceplate's threaded
hole,tapering theendslightly. (Youmay
I wishto forma handle at thetopendof the
j i g . )D r i v ea n a i li n t ot h ec e n t eor f t h e
T t a p e r eedn d ,c u t o f f t h e n a i l h e a d a ,n d
grinda sharppoint.Tousethejig,mark
I thecenterof theworkpiece withan awl
(page132).Next,setthefaceplate onthe
I workoiece withtheawlmarkin themid-
C
dleof thethreaded hole,insert thejig in
I theholeasshown, and"feel"forthemark
w i t ht h en a itl i p . H o l d i ntgh ej i g i n p l a c e ,
I screw thefaceplate to theworkpiece.
I
I
I
A CENTER.FINDING
JIG
I
I
I
I
I
I
I
t
I
I
Attaching to anirregularly
thefaceplate shapedworkpiece
I Thejig shownabovewrllenableyouto centerthefaceplate
on centricringsintothedisk(above, lefl. Removetheplastic
disk
an irregularly
shapedworkpiece.Cut pieces of Ya-inch
clear andspray it withblackpaint.Oncethepainthasdried,peelthe
I and%-inchplywood
plastic
acrylic into12-inch-diameter
disks. backing paper offbothsrdes oftheplastic.Tousethejig,set
Attachthetwotogether withdouble-sidedtapeanda screw. it ontheworkpiece soasmuchof it aspossible iswithinoneof
I Mounttheassemblyto yourfaceplate
sotheplasticisfacingout, the ringsandmarkthecenterwithan awl(above, righil.Use
thenusea skewchiselto cuta series
of eouallv
spaced,con- themarkasa centerpoint for mounting thefaceplate.
I
I 71
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GOUGE-SHARPENING
IIG I
I
1 Making thejig

Tool aupport
I Thejig shown at leftguarantees that I
thetip of a turning gouge willcontact the
(back)t/z'x 2" x 2 3/+"
(bottom) 1/2"x 1 1/2"x 2 3/+"
wheelof yourbench grinder at thecorrect T
angle to restore thebevelonthecutting
e d g eT, h ed i m e n s i o n
i nst h ei l l u s t r a t i o n I
willaccommodate mostgouges. Cutthe
Guide baseandtheguidefrom%-inchplywood; I
(top)1/2"x13/+"x9" screw theguidetogether andfastenit to
(eidee)1/2"x15/a"x9" the basewithscrews countersunk f rom T
underneath. Makesuretheopening cre-
atedbytheguideis large enough to allow I
thearmto slidethrough freely. Cutthearm
from1-by-2stockandthetoolsupport I
from7z-inch plywood. Screw thetwoparts
of thetoolsupport together, thenfasten I
thebottom to thearm,flushwithoneend.
FortheV block,cut a smallwoodblock I
to sizeandsawa 90'wedgeoutof one
side.Gluetheblockto thetoolsupport. I
I
I
t
t
I
I
I
I
t
t
I
I
r) Sharpening
I
a gouge
L Setthejig on a worksurface sothearmlinesup directly gouge switchonthegrinder
clearof thewheel, andreposition the I
under thegrinding wheel. Seatthegouge handle in theV block toolin thejig.Holding
thegouge withbothhands,rotate it from
andslidethearmsothebeveled edgeof thegouge restsflaton sideto sidesothebeveled edgerunsacrossthewheel(above). T
t h eg r i n d i nwgh e e C
l . l a m tph ea r mi n p l a c eT. h e nw, i t ht h e Check thecutting periodically
edge untilthe
bevelisfullyformed.
I
72
t
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I
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SPINDLE-TURNING
IIGS
t
A DIAMETER ANDA LAYOUT
GAUGE JIG
I
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I
T
t
I
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I
I
I Resemblinga tuning fork, the dismetergauge
shownabovecan be usedlike calipersto checkthe
I diameter of turned workpieces.The jig is cut from
solidwood;thedistancebetweenthe armsshouldbe
I slightly wider than the largestfinished diameter to
be turned. Two screwsdriven into the insideof the
t anns can be adjustedto setprecisemeasuremenls.

I Making andusinga layout jig

forspindle turning
I lll llllfirlillrllllilltlllllll ilillllllllJlll llllllllllltlll llllltll T h el a y o uj ti g s h o w na b o v em a k e si t
easier to turnmultiple copies of spindle
I jHO? TI? worksuchastablelegsbyallowing you
to scribe layout linesin exactly thesame
I location onevery blank. Trace yourdesign
ona pieceof scrapaboutthesamelengh
t asyourblanks andwider thantheirdiam-
eter.Drive a nailintotheedgeof thejig
I 'v:
at eachoointwhere a transitional element
identicalworkViecee, of thedesign-such asa beadorf illet-
I adjuel,a eeNof caliperolo
e a c hf i n i s h e dd i a m e N eyro u n e e d .
begins andends.Snipoffthenailheads
andgrindthenailsto sharp points. Once
L h e n e e dt o r e a d -
t h i e w i l le l i m i n a t e
I jueLoneeeNrepeaNedly. Uoeyour deoign
youhaveroughed outa cylinder, simply
press thejig intothespinnrng blank; the
of the pieceae a quidelo sel the calipero
I and a eNripof t ape lo identifythe adjuot,-
nailswillscore thelayoutlines(above),
ment on eachone.A cheaperaltrernaLive ie
I t o m a k es e v e r adl i a m e l e rq a u q e al i k et h a T ,
ehownin the pholo above,
I
I
I
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 I
TURNING IIGS
I
T
I
A TAITSTOCK
F(lRHOII()WED.OUT
W()RK
I
t
T
I
I
I
I
T
r) Turning
I
hollowed-outwork
L Mounttheworkpiece to a multi-purpose
chuckandsecure T
thechuckto thelathe. Turntheinsideof thework.Onceyou
arereadyto turntheoutside,insert
thetapered endof thejig I
intotheopening in theworkand,holdingtheauxiliarytailstock
in place,
advance themachine'stailstockuntilit contacts
the I
jigandholds thejig andworksecurely.
Tighten thetailstock
andfinishtheworkpiece (above). I
Making thetailstock
1
I Tosupport hollowed-out workpieces t
o nt h el a t h eu, s ea n a u x i l i a tray i l s t o c k
liketheoneshown above, Turned from lllllltlltllutlllilltfiltlllt I
h a r d w o otdh,i ss i m p l jei g s u p p o r t hs e
workpiece at therimonly,androtates 5HO?TI? I
alongwiththelathe's tailstock, prevent-
i n gv i b r a t i oann db u r n i nogf t h ew o r k - ?reoervin6 I
p i e c eT. o m a k et h ed e v i c ef ,i r s tt u r n oquare oornere
a c y l i n d ef r o ma b l a n ka b o u4t i n c h e s Wheneoindle lurnina I
workpieceo th at, require
i n l e n g t ht ,h e ns h a p teh ec o n ew i t ha
roughing gouge andusea skewchisel to
a eharpdivisionbeNween
lurnedand oquareoec-
I
smooth theconeandseoarate it from Nione,euchas the
thewaste(above). Thesizeandtaperof oquareVommel at the
I
thetailstock willvaryaccording to the Lop of a chair leq,
sizeanddiameter of theworkpiece; a wra?a lenqNh of duct I
cone3%inches wideat thebasewitha or maekinq lape around
60"tapersuitsmostsmallwork. the blankatthe lraneiNion I
linebeforeturnin4trhecylin-
der.TheNaVewillhelpreduce t
learoul and Vrovide a visual
quideto whereyou shouldoNoVturn-
inqlo preoeweyour oquarecornerg.
t
t
I
74
I
I
I
I
I
IIG FORFLUTING
COLUMNS
I
1 Building theiig
I I Withthebox-like jigshown at rightyou
Dit clearancehole
c a nr o u tf l u t e si n a c o l u m w n h i l ei t i s
I mounted in thelathe, Cuttheoartsof the
jig from%-inch plywood, except forthetop,
I w h i c hi s m a d ef r o m% - i n cchl e a ar c r y l i c .
R e f etro t h e i l l u s t r a t i of onrs u g g e s t e d
T d i m e n s i o nt h s ;ej i g s h o u l db e l o n ga n d
w i d ee n o u gtho s u p p o rt h t er o u t ear n d
I highenough sothetopjustclears thecol-
umnwhenthejig restsonthelathebed.
I Oncethetop,bottom, andsides areassem-
bled,addtwobraces to makethelig more
t r i g i d .I n s t a lal d o u b l e - b e a rpi ni lgo t e d
f l u t i n gb i t i n y o u r o u t e d
r ,r i l la b i tc l e a r -
I anceholethrough thejig top,andscrew
thetool'sbaseplateto thejig.Therouter
I shoulb d e p o s i t i o n seodt h eb i tw i l ll i e
alongsid t heec o l u m w n h e nt h ej i g i s
t u s e dB . es u r ea l l t o o l sa r eu n p l u g g e d
d u r i n sge t u p .
I
I
I
I
I
I r) Preparing thecolumn andthelathe
I Z- Toensure thatthef lutesaresoaced
equally around thecolumn, markcutting
T linesforthef lutesontheblank-inthis
example, 12 in all.Makecorresponding
I reference marks onthelathefaceolate
b yd i v i d i nigt sc i r c u m f e r e nocre3,6 0 ' ,
I i n t ol 2 e q u asl e g m e nst sp a c e3d0 '
apart. Markthelines witha pencil anda
I protractor (/eff).Setthejig onthe lathe
bed.mountthefaceolate onthe lathe
I sothatoneof the reference marksis
in the12 o'clock position, andmount
I thecolumn soa cuttingmarkis at the
3 o'clock position, Tighten a handscrew
I around the lathedriveshaftto prevent
it fromrotating andclampstopblocks
t to thelathebedto makesurethatall
fluteswillbethesamelensth.
I
I 75
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 I
I
TURNING ITGS
I
t
t
T
I
I
T
I
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I
I
I
I
I
I
t
I
I
I
-) Flutine
thecolumn I
<'
r - J A d j u s t h e r o u t e ' sc u t t i n gd e p t hs o t h e b r t i s
: l r o n p d r a r r l hl h o ? n ' e n r k n r r l l n o m , ,: r- k, , .R-,-r r. t.l l.h, o, ,J r g I
a p an q to n F c l o nh l n c ki r t r no n l h e r o r r ' l e a "n dn u s h
o n t h e s i d eo f t h e i i s t o f e e dt h e b i t i n t ot h e b l a n k , I
O n c et r r en i l n t sa r cf l r r q ia p a i n s- th es t o c ks. l i d et h e
j i g a l o n gt h e l a t h eb e du n t I i t c o n t a c ttsh e o t h e rs t o p
L ^- + ^ ^ r-..
I
h l o c kK . e e nt h etns i. .l,o. - t srn. -r) cJ g-u- ^ ,o^6^o ^i l ;r^> l- +
l|c >luun d) it

routseachflute (inset). Turnoff the router,remove I

thehandscrew a n, d r o t a t et h e b l a n kb y h a n du n t r l
t h e n e x tr e f e r e n cmea ' ki s i n t i e l 2 o ' c l o c kp o s i t i o n I
a n dt h e r e x tr ^ . r t' l rDn l rpr" e'i s i n l h e3 o c l o c kn o s i ' i o n .
R e i n s t at lhl e h a n d s c r eawn dr e p e atth eo p e r a t i ot n o t
c u t t h e ' e n a l n r fg ' u l . e s( a b o v e ) .
I
t
76
I
I
I
I
t
IIGSFORSANDINGAND CHECKINGDEPTH
I Accuratelydeterminingdepth is
I essentialtofnceplateturning:too
deepa cut can ruin a bowl.Made
t from solid wood stock,the bowl-
depthgaugeshown at right fea-
I turesa pair of perpendicular
',4-inchdowels;the holes
for the
I dowelsoverlapso that the longer
dowel can be adjustedand wedged
I in place by the shorter, tapered
one.Marking depthincrementson
t the long dowel will speedsetup.

I
I
I
I
I
I A SANDING
DRUM
F()RTHELATHE

I
I
I
I
I
I
I
I
I
t Making andusing a sanding drum
I T h ej i g s h o w a n b o vw e i l lt u r ny o u rl a t h ei n t oa p o w e r f d
u rl u m of thegroove.
Toholdthesandpaper in place,
makea hard-
g % - i n c h - w i d%e-,i n c h - d egerpo o v e woodstripto fit in thegroove
s a n d e rS. t a r tb y r o u t i n a andscrewit in place(above,
I alongthecenter of onesideof a square blankabout14 inches left).To usethesanding
i n l e n g t hM. o u ntth eb l a n ko nt h el a t h ea n dt u r ni t i n t oa c y l i n - stockandtailstock
drum,mountit between the head-
of thelathe.Youcanthenusethedrum
I der3%inchesin diameter. Next,cuta sheetof sandpaper to to sandworkpieces
withcurved contours,suchasa cabriole
wraparound thecylinder; itsendsshould overlap at thebottom leg (above,right).
I
I 77
I
I
i
i '
I fl
! l! i
:*
irtk llui-t.
I ,lbi (4
'lu ,li;i .<
$
r{
t
!l_{i;
I t {
|.
Ttqi A

f,tll x-
H :
{';

'\
?-8,

I
::,li I
I
I

: , ,l l
' . :
. l
l-
t
.;'

i
I
I
I
I
t
t
t GLI.INGA]\ID
I
I CIA4PINGIIGS
I
I lampsand benchvisesareindis-
peniableto thewoodworker.Their A C(|TTECTION
OFGTUING
AND CTAMPING
JIGS
verysimplicitymakesthemversatile,but
I the basicclampor visecanbe madeto
work betteror moreeasilvwith thehelo Caroaae-aqua ri ng block
I of ajig. Theitemsshown'inthischaptei (pase 89)
Flaced on corner of car-
will enableyou to getthe mostfrom the
I clampsandvisesyoualreadyhave.Other
case to keep it sauare
duringqlue-up
jigs providealternatives Miter clamping blocka (paqe 88)
I to commercial
devicesthat maynot bethebesttool for
Ueed with handacrewato clamp
mitered cornerg toqether; two
I a specifictask.
Gluingboardsedgeto-edge to assem-
blockaat each corner are aecured
to atock with cord
I blepanelsis a commonstepin furniture-
making.Thejigsshownstartingon page
8l providewaysof keepingyour clamp-
I ing setupsflat, square,and stableasthe
Bench dog (page 92)
Hardwooddog alipo
adhesive dries.Thewall-mountedglue into benchdoq holee;
I rack (page85) can saveconsiderable anqledton7ueacte
aa a opringto hold
shopspace, whilethewedgedclamping
I bar (page83)andthejig for edgegluing
dog in place

thin stock (pageBa)will takethe place

I of bar clamps.
For securingstockto your work- Eench etop (page 9O)
I benchfor sandingor planing,makea For eecurinaatock
to a work aurtace
temporarybench stop (page90).To
t fashiona handywood-carver's vise,try
without.benchdo4
holea.Workpieceie
thejig on page93thatcombines
I dardpipeclampwith two woodblocks.
a stan- wed4ed betweentrianqular
piece and baae, whichia
All thedevicesin thischapteraresimple clamped to table
I to build with only a fewmaterials. The
dividendstheywill payarewell worth
I the effort and expense.
I
I Madefromjust afewpiecesof wood
Benah dog (page 91)
Cuatomizeddoqa with naile
in center of bevelledhead
I andsomehardware,theframing
clampat left allowsyou to keepthe for grippinqa curvedor
turned workpiece
cornersof a pictureframesquareand
I tightlyclosedduringglue-up.

I 79
I
 I
GLUING AND CLAMPING IIGS
I
I
I
Pipe clamp extender (pa6e 86) I
ExLendethe clampinqcapaciLyof
ptpeclampe;jtq cleat huqa work-
piece whileaemicircularnotch
I
accommodatesclamp iaw
I
I
I
Wall-mounted I
glue raak (page O5)
For ed4eqluinqeLock.
Dar clampoait in notched Crosebar for edge I
gluing (page 82)
c rooepiecee:ba ck c roeepiece
ia anchoredto walletuda Ueedwith bar or pipe
dampa f,o keepatock flat
I
durinqed6egluinq;panel
fita betweencrooabara,whrch I
are securedwith wingnuLe
I
Glue rack (page 81)
9awhoraeawith notchedcroeaptecee
I
deeignedto hold bar clampaeteady
Wood-aaruer'svise
(pase 93) for edqeqluin7 I
Two-parDvteefor hold-
tng carvrnqblanks;made I
from wood blocksand
pipe clampe.Dof,tompipe
clampie mounted to
I
benchand Loppart ia
elippedtn place I
I
I
Wedqedclamping
bar (page 83)
I
9imtlar to edqe 7luin7
croaabar, excepLwed4eepreeaedqee I
of boarde togeLher,taktnq the placeof clampe
I
Framing clamp (page O7)
Ueedwtth a handacrewLo
Ji6 for clampingthin atoak
(paseO4)
I
alue uo frames wiLhmitered
-cornere: Foredqegluingthin boarda;
modelahowncan
wedqeeapply the clamp' I
clamp framee up Lo 24 in6 0reogure
rncneoaquare
t
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I
T
EDGE-GLUING
IIGS
I
I RACK
GLUE
I 1 Building theiig
I A pairof racksmadefromtwosaw-
I horses liketheoneshown at rightprovides
a convenient wayto holdbarclamps for
I gluingupa panel.Remove thecrosspiece
fromyoursawhorses andcutreplacements
I thesamewidthandthickness astheorig-
i n a l sm, a k i ntgh e ma t l e a sat sl o n ga s
I t h eb o a r dyso uw i l lb ea s s e m b l i nCgu.t
notches alongoneedgeof eachcross-
I p i e c ea t 6 - i n c hi n t e r v a lms ,a k i ntgh e m
wideenough to holda barclampsnugly
I anddeepenough to holdthe barlevel
withthetopof thecrosspiece. Youcan
t alsocut notches to accommodate oioe
clamps, butit is better to usebarclamps
I withthisjig sincetheywillnotrotate.

I
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I
r) Gluingupa panel
I L Seatatleasttwobarclamps in thenotches sothattheboardstheclamps justenoughto butttheboards together(above),
to begluedaresupported Toavoidmar- thenplacea thirdclampacross
I ringtheedges
every
24 to 36 inches.
of thepanelwhenyoutighten theclamps,use ingit between theothers.
thetopof theboards,
Finishtightening
center-
alltheclampsuntil
twowoodpadsthatextend
I boardsface-down
thefull lengthof theboards.
ontheclamps
Setthe therearenogapsbetween
andaligntheirends.Tighten sivesqueezes
theboards
fromthejoints.
anda thinbeadof adhe-

I
I 81
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 I
GLUING AND CLAMPING IIGS
I
I
I
F(lREDGE
CR()SSBARS GTUING
1 Building thecrossbars I
I To keeppanels frombowing during
9pacer glue-up whenclamping pressure isapplied, I
bolta oairof crossbarsliketheoneshown
at leftbetween eachpairof clamps. Make I
each crossbar from two short wood spac-
ersandtwostripsof 1-by-1hardwood I
stocka fewincheslonger thanthe pan-
el'swidth.The spacers should beslight- I
lythickerthanthe diameterof the bolts
usedto holdthe crossbarsin place. Glue t
thespacers between the ends of thestrips,
andspread waxon thecrossbars to pre- I
ventexcess glue from adhering to them.
I
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I
O Installing
thecrossbars
L Glueup the boardsasyouwouldon a rack(page81).fo ingthembetween theclamps
already in place.Insert
carriage I
the barclampsfromtippingover,placetheendof
prevent boltsthrough thecrossbarslots,usingwashers andwingnuts
eachonein a notched the barclamps
blockof wood.Before the panel(above).
to tightenthejig snugagainst Then,tighten I
havebeenfullytightened, in pairs,
thecrossbars
install center- thebarclamps completely.
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I GLUING AND CLAMPING TIGS
I
I WEDGED
CTAMPING
BAR
I 1
B u i l d i ntgh el i g b o d y
I T h ew e d g e dc l a m p i n gb a rs h o w na t
I l e f t i s a n e x c e l l e nat l t e r n a t i vt eo a b a r
c l a m pf o r e d g eg l u i n gb o a r d sb, e c a u s e
I i t p r e v e n ttsh e s t o c kf r o m b o w i n gw h e n
p r e s s u r ies a p p l i e dC . u tt h e t o p a n d b o t -
I t o m f r o m% - i n c h - t h i cskt o c k ,m a k i n g
t h e m l o n g e trh a nt h e w i d e s tp a n e yl o u
I w i l l g l u eu p . C u tt h e s p a c e rt .a i l b l o c k .
a n d w e d g e sf r o m s t o c kt h e s a m et h i c k -
I n e s sa s t h e b o a r d tso b e g l u e d (. K e e p
setsof spacers, tail blocks,andwedges
I on handto accommodate boardsof vary-
i n gt h i c k n e s sU . )s ea m a c h i n e b o l t ,w a s h -
I e r ,a n dw i n gn u t a t e a c he n do f t h e j i g
t o s e c u r et h e t o p , b o t t o m a, n d s p a c e r s
I together.Waxthe barsto preventadhe-
s i v ef r o mb o n d i n tgo t h e m .
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I r ) P r e p a r i nt g h ej i g f o r g l u e u p
y o u n e e dt o b o r eh o l e st h r o u g ht h e j i g t o a d j u s ti t f o r
gluingboards
Edge
l S p r e a da d h e s i v oe n t h e e d g e so f y o u rs t o c ka n d s e tt h e
I t h ew i d t ho f t h e p a n etlo b e g l u e d S . i n c ey o uw i l l b e d r i l l i n g
s t r a i g htth r o u g ht h e j i g , c l a m pa b a c k u pb o a r dt o y o u rd r i l l
b o a r d sf a c e - d o wonn a w o r ks u r f a c eS. l i pa c l a m p i n gb a ro v e r
t h e b o a r d sa n d p o s i t i o ni t 6 t o 1 2 i n c h e sf r o mo n ee n do f t h e
I p r e s st a b l ew i t h a f e n c ea l o n gt h e b a c ke d g et o e n s u r et h e
h o l e sa r ea l i g n e dI.n s t a l al b i t t h e s a m ed i a m e t ear s t h e
assembly. Butt the tail blockagainstthe far edgeof the boards,
u s i n g t h em a c h i n be o l t ,w a s h e ra,n dw i n gn u tt o f i x i t i n p l a c e .
I m a c h i n eb o l ta n d p l a c et h e t a i l b l o c ki n p l a c e B
a g a i n st th ef e n c ea n dd r i l la h o l et h r o u g h
. u t tt h e j i g
t h et o p ,t h e b o t t o m ,
To applyclampingpressure, tap oneof the wedges
edgeof the panel(above)until thereare no gapsbetweenthe
at the front

I a n dt h e t a i l b l o c k .B o r et h e r e m a i n i n hg o l e st h r o u g ht h e j i g
bodyat 7r/z-inchintervals(above),
b o a r d sa n da t h i n g l u eb e a ds q u e e z eosu t o f t h e j o i n t s .I n s t a l l
t h e b a r sa t 1 8 - t o 2 4 - i n c hi n t e r v a l s .
t
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GLUING AND CLAMPING JIGS
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THINST()CK
A JIGFORCLAMPING
Edge gluing thinstock
I
Thebenchtop jig shown at rightallows you
to applythecorrect clamping pressure for I
edgegluingthinstock.Cutthebasefrom
1-inchplywood andtheremaining pieces I
fromsolidstock.Refer to theillustration
forsuggested dimensions, butbesurethe I
baseis longer thantheboards to beglued
a n dt h es p a c eirs l o n ge n o u gtho b u t t
I
against theentirefrontedgeof thepanel.
Theedging stripsshould bethicker than I
yourpanelstock.Screw themalongthe
edges of the baseandfastentwowedges
I
f lushagainst onestripwiththeirangled
edges facingasshown at right.Waxthetop t
faceof the baseto keepthe panelfrom
o i t . A p p l yg l u et o y o u rs t o c k
a d h e r i nt g
I
Edainaatrip
a n ds e tt h ep i e c eos n t h eb a s eb, u t t i n g
t h ef i r s tb o a r da g a i n st ht ee d g i n sgt r i p
* i '7r",'19 ttr"
s7o';
t
opposite the wedges. Buttthe spacer
against the lastboardandslidethetwo
I
loosewedges between thespacer andthe
fixedwedges. Tapthe wedges tightto I
applyclamping pressure (below).
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GLUING AND CLAMPING IIGS
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t
GLUERACK
A WALL.MOUNTED
t
I
FronLpoeL
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I Notched
ctamP racK
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I --t ":'

.-.-/t-
I -_-----=

t ---'--
I \

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B u i l d i ntgh er a c ka n dg l u i n gu p a p a n e l
I T h el r g s h o w na b o v ea l l o w sy o ut o g l u eu p p a n e l su s i n gb a r 8 to 10 inchesfromthe wall.Screwthe frontrackto theseposts,
c l a m p sb, u t s a v e s h o ps p a c eb y b e i n gm o u n t e tdo a w a l l .F o r p o s i t i o n i nt hge n o t c h efsa c e - u p s o t h e yw i l l h o l dt h e c l a m p s
I c l a r i t yt,h e i l l u s t r a t i osnh o w so n l yo n ep a i ro f c l a m pr a c k sb, u t l e v e lN
j i g
. ext,
.
m o u n t wo % - i n c p
h l y w o o ed n d p a n e l st o f i t a r o u n d
y o uc a ni n s t a lal s m a n ya sy o ul i k ef r o mf l o o rt o c e i l i n ga t 1 2 - i n c h the N o t c h
the b o t t o m e n d o f t h e p a n e l st o f i t o v e rt h e s o l e
I i n t e r v a l sC.u tt h e c l a m pr a c k sf r o mB - f o o t - l o n1g- b y - 4 a s n ds a w p l a t ea n df a s t e nt h e t o p t o t h e c e i l i n gD . r i v es c r e wtsh r o u g ht h e
notches alongoneedgeof eachpieceasyouwouldfor a sawhorse s i d e so f t h e e n d p a n e l s
i n t ot h e e n d s o f t h e r a c k sT . o u s et h e
I r a c k( p a g eB l ) . A t t a c ho n er a c ko f e a c hp a i r t ot h e w a l l ,d r i v i n g j i g t o g l u eu p a p a n e ls, l i d eb a rc l a m p st h r o u g h t h e n o t c h e isn
two screwsintoeverywallstud;makesurethe notchesarepoint- t h e f r o n ta n d b a c kr a c k sm , a k i n gs u r et h e e n d so f t h e c l a m p s
I i n gd o w n T . o s u p p o rtth e f r o n tc l a m pr a c k ,c u t f l o o r - t o - c e i l i2n g extendbeyondthe stud-mounted rack(rnset). Therestof the
b y - 4 sa s p o s t sa n d p o s i t i o o n n ed i r e c t l fya c i n ge a c hs t u da b o u t o p e r a t i oins i d e n t i c at o
l edge g l u i n g
w i t h a n y o t h e rc l a m pr a c k .
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FRAME-CLAMPING
JIGS I
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A PIPECLAMPEXTENDER
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Gluing upa largeframe I
T h ej i g s h o w na b o v e w i l le x t e n tdh e
c a p a c i toyf y o u rp i p ec l a m p sC. u tt h e
mainbodyof theextender from1-by-6
ti,.ultlilliltiilltllllrfilr]lltlllllljtlllriljlillrllilIfllll] iili I
stockandthecleatfroma 2-by-2. Saw I
a D-shaped cutoutnearoneendof the 1HO?TI?
bodyto accommodate thepipeclamptail
Ooubling up I
stop,thenscrew thecleatto theopposite
pipeclampo
end(inset). Toapplyclamping pressure
Anotherway I
o n t h et o pa n db o t t o mr a i l so f a l o n g lo exlendlhe \.'.,r"
frameliketheonein theillustration, set capaci|yof . -,4;r= I
thecleatagainst oneendof thework- 1norter ?t?e
p i e c ea n df i t t h ep i p ec l a m pt a i ls t o p I
intothecutout. Thentighten theclamp u s e l h e mi n
s ot h a tt h e h a n d l e - e n j adwi s p r e s s i n g naira l n lt tnr -

lion as a oinqle
I
against theopposite endof thework-
lonqone,)et,upLhe
piece(above). Usewoodpadsto protect
workViece(herefour
I
theworkpieces.
boardsto be edqeqlued)ae
you wouldon a 4luerack (pa4e t
B1).Tofashiona lonqclamV,?oeition
lwo ehofLerclampeacroasNhework- r
pieceeo NhaNthe handle-end jawe reet,aqainet.oVVoeile
edgeeandNhetaileNoVe ofNheclamVooverlap. Aeyou I
Liqhhenoneof the clampe,iNwillpullthe joinXeNoqebher.
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I GLUING AND CLAMPING TIGS
I
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A FRAMING
CLAMP
I Clamping a mitered picture frame

r Corner block
3./+"x21/2"x21/2"
In conjunction witha handscrew, theself-
a l i g n i njgi g a t l e f ti s i d e aflo rg l u i n gu p
frames withmitered corners. Thedimen-
I sions uggeste i ndt h ei l l u s t r a t i w
o ni l l
accommodate frames measuring upIo 24
I Center block
inches ona side.Cutthearmsandcenter
3,/+"x21/2"x6" blocks from1-by-3 stockandthecorner
t blocks from3/q-inch plywood. Drilla series
of holesdownthemiddleof thearmsfor
I %-inch-diameter machine bolts;begin
1 inchfromoneendandsoace theholes
I a t 1 - i n c hi n t e r v a lcso, u n t e r b o r it nh ge
underside to house the boltheads. Also
I Corner block drillholes through thecenter blocks 1 inch
fromeachend.To DreDare thecorner
I blocks, drilltwoholesthrough eachone:
thefirstfora machine boltabout1 inch
I Arm fromoneend,anda smaller holeabout
3/+"x21/z"x19"
1% inches in fromthesameend.Finish
I bycuttinga 90'wedgeoutof theopposite
end,locating theapexof theangleat the
I center of thesecond holedrilled(inset).
Assemble jig
the bysecuring onecenter
I blockto eachpairof armswithbolts, wash-
ers,andwingnuts;leave thenutsloose
I e n o u gtho a l l o wt h ea r m st o p i v o tT. o
clampa frame, setthejig on a worksur-
I face.Fasten thecornerblocks to thearms
sothatthecenterblocks areabout%inch
I apartwhentheframeliessnugly withinthe
j i g . U s ea h a n d s c r et owp u l lt h ec e n t e r
I blocks together, tightening theclampuntil
allthecorner jointsareclosed(/eft,below),
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GLUING AND CLAMPING IIGS
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MITER
I
CLAMPING
BL()CKS
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Gluing upa mitered frame
I
Clampmitered corners usinghandscrews I
a n dt h es p e c i abl l o c k s h o w na b o v e .
Youwillneedoneclampandtwoblocks
lli llrllntultllllllltfiljlltJ
ljllllljlltuittllllll]ljllillJllllllt I
f o r e a c hc o r n e rC. u tt h e b l o c k fsr o m
stockthesamethickness asyourwork- 1HO? Tl7 I
piece. Referring to theillustration above, ii.
-i
A rope clamp for aarving
shape
surface
oneedgesothereis a 45" bearing
forthehandscrew nearoneend,
I
Carvinqoften requireefre- I I ] ..... I
quentrepooitioninqofthe I j I
anda smallV-shaped notchneartheoth-
e r .T os l r e u n A c o r n e tr i et h eb l o c k s
workpiece,whichcan be l,l l I
Lime-consumin7when . jl,
s n r r p lt vo t h e e d p c sn f i h e f r a m ew i t h ueinqholddowns,clampe, \*r I
c o r d ,s e c u r i ntgh e l o o s e n di n t h e n o t c h . and benchdoqe.VakeLhe
S e t t h e j a w so f t h e h a n d s c r e w
the 45" anglesandtightenthem (above)
against taek of eecurinq
moreconvenient
carvinqeLock
by ueinqa eimple
I
ropeclamplikeLheoneehownhere.1orelour holesthrouqh
u n t i lt h e r ea r en o g a p si n t h e j o i n ta n d
a t h i n b e a do f g l u es q u e e z eosu t o f i t . Ihe middleof a lowcarvinqbench,Thencut a lenqthof rope
I
or lealher,looVit throuqhNheholeeand tie Nheendst ogether,
T o k e e pt h e j o i n ts q u a r et.i g h t e ne a c h
h a n d s c r eawl i t t l ea t a t i m e ,c h e c k i n g Theropeehouldbe lonqenouqheo Lhat the boLLom endof I
Ihe loopie no moreIhan 12 incheefrom lhe floor.Slipyour
t h e c o r n ew r i t ha s q u a r e .
workpiece underlhe loopoon the tabletopand eNeV on the I
botrtomlooVNoholdIhe oLockfirmly in place.
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CARCASE-CLAMPING
JIGS
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I
BLOCK
A CARCASE.SSUARING
t
Carcaae-squaring block
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Keeping a carcase square
t It canbedifficult to keepthefoursidesof a carcase
d u r i n g l u e - uoprw h i l ei n s t a l l i nagb a c kp a n e A
square
l. carcase-
headonyourtablesaw,adjustit to thesamewidthasthe
thicknessof thecarcase stock,andcut twogrooves at right
I squaring blockplaced oneachcorner willsolve theproblem. anglesto oneanother,
(above,
intersecting
at thecenterof the block
Eachblockconsists of an 8-inchsquare of %-inchplywood. lefil.f o usethejig,applyglueandassemble thecar-
I To prevent gluesqueeze-out frombonding theblockto the case,thenfit a blockovereachcorner(above, right),center-
carcase, borea 2-inch-diameter holein thecenterof each ingtheholeat thepointwhere thetwopanels join.Installand
I blockwitha holesawor circlecutter.Next,installa dado tightentheclamps.

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TW()WEBCLAMPS
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Cardboard
I

re
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K Wood
block

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Gluingupsmallcarcases
t Youcanmakewebclamos
clamps.
outof rooeanda handscrew
0nedeviceusestwowoodblocks andtwo
or C t h ec o r n e rwsi t hc a r d b o a pr da d sU
lengthsof blockstoward each other and clamp
. s eC c l a m ptso p u l l t h e
thejoints(above, lefil.A
I ropethat,whenknotted,areslightly
shorter
thanthe perimeter second clamping method employs a singlehandscrew. Wrapa
of yourcarcase.Boretwoholesthrough eachblock nearthe lengthof rope around the carcase and feedthe ends through the
I ends,threadoneropethrough a holerneachblockand knot clamp. With the tip of the handscrew pressing the rope against
itsendsagainsttheblock.Repeatwiththeotherrope,adjusting thecarcase, tightenthebackscrewto pinchtheropebetween
I thelengthsothattheblocksare parallel
whensetonthecar- the back end of thejaws,thenclosethefrontendof thejaws
pressure (above,
case.Wraptheropesandblocksaround thecarcase,protecting to apply clamping right).
I
I 89
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WORKBENCH
CLAMPINGIIGS r
I
Youcan increasethe reachof a
I
C clampwhenyou needto apply I
clampingpressure awayfrom the
edges of a worksurfaceby usinga I
strip of woodasa clampextension.
Tosecuretheframeshownat right, I
thestrip extendsacrosstheframe
and clampingpressure is applied I
overtheinteriorof theframe,
securingbothsidesat once. t
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A BENCH
STOP I
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Securing
a workpieceto a worksurface
t
Youcanusea clamped-on
bench
benchstopcutfrom%-inch
stopto size,thenmarkouta triangularwedge,
plywood
typically
to secure
3 inches
stockto a worksurface.
shorter
Cutthe
thanthestop.Sawoutthe
I
wedgeandsetit aside.
notch,butting
Tousethebench
onesideagainst
stop,clampit to theworksurface
thestraight
edgeof thenotch.
andslidetheworkpiece
Thentapthewedge
intothe
tightlyin place(above).
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I GLUING AND CLAMPING IIGS
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BENCH
DOGS
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Makingandsettingup carvingdogs
I U s i n ga s t a n d a r b d e n c hd o ga s a m o d e l ,

I
youcanfashiona pairof customized dogs
t h a t w i l l g r i pa c a r v e do r t u r n e dw o r k -
lllJllttlltfil1
lllllllllllll|llllflilllllltr]lrfiIlllllilltliltIIIilil
piece,or secureirregular-sized work,such
I a s m i t e r e dm o l d i n gT. o m a k et h e s e ?HO?Tt?
accessories, cut bevelson eithersideof Carvinqgcrewo
I t h e h e a do f a s t a n d a r d b e n c hd o ga n d A Vairof han4er
d r i v ea s m a l ls c r e wo r n a i l i n t ot h e c e n - boltecanenableyou
I t e r o f t h e h e a d ;s n i po f f t h e f a s t e n e r ' s Nogecurean ircequ'
h e a dt o f o r ma s h a r oo o i n t .T o u s et h e lar-ehaVed workViece,
I d e v i c e sp, l a c eo n ed o gi n a d o gh o l eo f suchas a carvinq
block,toyourbench.
the bench'sfixeddogblockandthe other
ThebolNsfeature
I i n t h et a i lv i s eo r a s l i d i n gd o gb l o c kh o l e
( a b o v e )T. i g h t e nt h e v i s es c r e wu n t i l woodecrewNhreade
on oneenaana
t t h e p o i n t sc o n t a ct h e e n d so f t h e w o r k -
p i e c ea n d h o l di t s e c u r e l y .
machine screw
lhreadeon
T the oLher.
fo securea
I workpiece,boreNwoholee
Nhrough lhe bench-lopfor Nhebolte.ScrewNhebolls inLoIhe
I carvinqblockfrom underneaNh
the undereide
Nhetop and holdLheboltsto
of the loV wilh washereand winqnuLe.
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GLUINGAND CLAMPINGTIGS
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A SUBSTITUTE
BENCH
VISE
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r
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If yow' workbenchtloestrct lnve a bettchvise,yott cnrt itrtpro-
Makinga benchdogwitha wooden tongue vises substituteusirtgreodilyovnilableshoprrcccs-soric-s. I
B e n c hd o g sc a n b e c r a f t e df r o m h a r d - Two largehartrlscrews nrrartgedns showrrnbovewill holtl
w o o ds t o c k ;t h e o n es h o w na b o v eu s e s n board upright at tlte corrrer-
of the work sttr.face. I
a n a n g l e dw o o d e n t o n g u ea s a s p r i n g
t h a t p r e s s easg a i n stth e w a l lo f t h e d o g I
h o l et o k e e nt h e d o s i n o o s i t i o nC. u tt h e ffi.jjil,llillldl,l]ljlllillllild,li iilii i l $ r " * r u * r i i
d o gt o f i t t h e h o l e si n y o u rw o r k b e n c h , t
t h e nc h i s eol u t a n o t c hf r o mt h e m i d d l e
o f t h e d o g .S a wa s h o r tk e r fi n t h e l o w e r 1HO?Tt? I
c o r n e or f t h e n o t c h a , ngling t h ec u t s o
t h e t o n g u ew i l l e x t e n db e y o n d
t h ee d g e Grippingthinstoak
Securinga Ihin workpiece on
i;-'''
II
t
o f t h e n o t c hC . u tt h e t o n g u ef r o mh a r d -
ed,qercuallyrequires
w o o d .m a k i n gi t a b o u ta s l o n ga s t h e
v i s eo r b e n c hd o q s .
I
]r
I
notcha , s w i d ea s t h e d o g ,a n da st h i c k lowever.you can < i I
a s t h e k e r f .G l u et h e t o n g u ei n t h e k e r f . faelton abench i\--
-a
{-t
' "l
[: I
a L o Vl i k eL h e o n e \ - - - - ij
--ii:
shown on ?aqe 90 No
rl I
a c c o n V l i e iihh e t a s k . l n ",,ti.- ir)
Lhis case, make Nheetop fr,om
,
L h i c k e re t o c k - a b o u N 2 i n c h e sN h i c k
-
_- ' -ft'ji"
r' i"l
il
I
-Lo qet a bef,Leq r r i Vo n r h e w o r V p i e c e J I
a n d l o c a t r et h e w e d q ec l o s e rt o L h e m i d d l e
o f N h ee l o p . C l a m pI h e 1 i qr , o I h e b e n c h t o p ,
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I GLUING AND CLAMPING TIGS
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I A WO()D-CARVER'S
VISE
I 1
M a k i n gt h ej i g
I T o h o l dc a r v i n sb l a n k sa n dc u r v e d
t w o r k p i e c east v i r t u a t tayn ya n g l e u , s ea n
Upperblock
3"x3"x3%"
adjustable viselikethe oneshownat right.
I A t t a c h e dt o t h e e n d o f y o u rw o r k b e n c h ,
t h e j i g c o n s i s tos f t w o p i p e - c l a mhpe a d s ,
I t w o l e n g t h so f p i p e ,a n d t w o p i v o t i n g
b l o c k sT . h e u p p e rb l o c kg r i p st h e w o r k
I a n ds w i v e l sh o r i z o n t a l lwy h , i l et h e l o w e r
b l o c kh o l d st h e u p p e rb l o c ki n p l a c ea n d
I r o t a t e vs e r t i c a l layr o u n dt h e p i p e .F a s h i o n
t h e t w o b l o c k sf r o m l a m i n a t e hd a r d w o o d
I s t o c k ,r e f e r r i ntgo t h e i l l u s t r a t i ofno r s u g -
g e s t e dd i m e n s i o n sB.o r ea 1 - i n c h - d i a m e -
I t e r h o l ei n t h e u p p e rb l o c k ' su n d e r s i d e
a n dg l u ei n a 2 - i n c h - l o ndgo w e lr,e i n f o r c e d Lowerblock
I w i t h a w o o ds c r e w B . o r ea m a t c h i n gh o l e 3"x3"x4"
t h r o u g ht h e l o w e rb l o c ka n d c u t a k e r f
I t h r o u g ht h e b l o c k ' sr o u n d e de d g et o t h e
hole.Next,borea holeintothe end of your
I w o r k b e n cnhe a ro n ec o r n e rl,a r g ee n o u g h r) Securinga workpiece
t o a c c o m m o d aal e1 2 - t o 1 4 - i n c hl e n g t h pipewitha pipe-clamp
L lnsert-the12-to l4-inch-long headat oneendthrough
I o f p i p e .D r i l la m a t c h i n g h o l et h r o u g hthe
thebottom blockandintothebench. Fixthepipein placewitha lockingpin-
l o w e rb l o c k , p o s i t i o n i ni g
t n e a rthe r o u nd-
a smallmachine boltor largewoodscrew. Fittheupperblockrntothelower one
t e d e d g eo f t h e b l o c k . F i n a l l y ,
bore a h o le
andtightenthelower pipe-clamp headto secure theupperblock.Next,inserta
forthe p i p e t h r o u g ht h e u p p e rb l o c k .
longer of pipe-also
length witha pipe-clamp headat oneendandholesdrilled
I every4 inchesfora lockingpin-through theholein theupperblock.Place the
workpieceagainsttheupperblockandthepipe-clamp's headasshown below,
I fixthepipewiththelocking pin,andtightenthehead. Toreposition
thework-
piece,loosen
thelower clamphead,pivotthetwoblocks, andtrghtenthehead.
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I SATDINGIIGS
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I
anding is one of woodworking's
I most tedioustasks.but thereare Auxiliary aanding table
tools and techniquesto makethe job
I easierandimproveyour results.Theuse
(pase 9B)
Secured to drill preaa table for
of a simplejig will help improvethe aandinq oper atib ne; feat uree
I speedandefficiencyof mostoperations,
clearanceholefor aandinadrum
and maketricky taskseasierto accom-
I plish.Several areshownhereandon the
loilowingpages. A custom-made sand-
I ing block (page100),for example,allows
Contoured aandin7 bloak
(pasetoo)
you to smoothcontoursthatwouldoth- Cuetom-profiledaand-
I erwisebe difficult to reach.For sanding in4 ourface for smooth-
inq moldin4a
the edgeof circularworkpieces, a circle-
I sandingjig (page96)is designed to hold
a belt sanderon its sidewhile you feed
I the stockacrossthe belt.Also usefulis
a jig for surfacingthin stock (page99)
I on the radialarm saw.
For everyday sandingtasks,usethe
I auxiliarysandingtableshownon page
Radial-arm-saw sanding
jiq (pase 99)
t 98 or the sandingblockon page100.
Thelatterdevice,alsoshownin thepho-
For eandtnqthin atock on
the radial arm saw;clear-
ance holeaizedto accom-
t to at left, offersa simplewayof holding
a pieceof sandpaper in placeagainst
modate aandinadrum
a flat surface. To savetime andsandoa-
I per,considerthe tipson gangsanding
andfoldingsandpaper shownon pages
I 96and101.
Circle-eandingjig (page 96)
I Holda belt eander etationary
on ite aide for aandina the
I edqe of circular atock

t
Fittedwith 220-gritsandpaper, a
I shop-made sandingblockis usedto
t smooththesurfaceof therail joining
two tablelegs.A felt or corkpad can
begluedto thebottomfaceof theblock
I toprovideevensandingpressure.
 I
I
AND EDGE-SANDING
IIGSFORFACE,-
I
Youcan savetime nnd lchieve
I
uniform resultsby sntoothing
severalworkpiecestogether,a
I
"gang
techniqueknown as
sanding."If theyare thesame
t
width, the boardscan lte se-
cured to a work surfaceface-
I
to-faceand edge-up,and
sandedas though they were
I
a singleworkpiece.
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A CIRCLE-SANDING
JIG
I
1 Building thejig
I Thejig shownat rightallows youto I
smooth the edges of a circularworkpiece
witha beltsander. Thedimensions of the I
jigwilldepend onthe size of yoursander.
Makethebaseandtablewith%-inchply- I
woodandaddsolidwoodsupport poststo
fit in thehandles of thesander. Setthetool t
on itssideonthetableandsliptheposts
in place, thenscrew themto thetableand I
screw thetableto thebase. Cutthepivot
barandsupport boards from1-by-2stock, t
making theboards longer thanthediameter
of yourworkpiece andthebarlonger than I
theboards. Screw thesupport boardsto the
basesotheywillsupport theworkpiece near I
itsedge.Next,drivea screw through the
middleof theoivotbarandfasten it to the t
underside of theworkpiece. Fliptheassem-
blyoverandscrewoneendof thepivotbar I
to thebasemidway between thesupport
boards, leavingthescrewlooseenough to t
allowyouto pivotthebar'sotherend.
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96 I
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I SANDING IIGS
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t Sanding a circular workpiece
Clampthejig baseto a worksurface
I andsetthesander
fittingthetool'shandles
in placeonthetable,
overthesupport
illlfilllltl{tIlll'IIl
tllllIlfllltlllltlllilllillltllltlllilltllll
posts. Turnonthesander
I essary, adjustthetool'stracking
and,if nec-
mech- 9HO7Tt?
I anismto movethebeltdownto thejig Drillpreseaanaingdruma
table.Lockthe On/offtriggerin theon lf you needa epecialoff-sizeoandinq
I oosition andmovethefreeendof the
pivotbartoward thesander untilthe
drum for your drill ?rees,you can
makeyour ownfrom a dowel.Find
t workpiece edgetouches
thefreeendof thebarto thebase,
thebelt.Clamp
then
Ihe riqhl sizedowel,lhencut a
elrip of oandpaperae lonqae iNe
rotatethepieceagainst circumference. Applya Nhincoa|
I beltrotation (above)
thedirection
untiltheedgeis
of
of qlueto the woodand faelen lhe
?a?erIo ft (ri7ht, top). For a flexible
t smooth. Keeptheworkpiece in motion
a n dp e r i o d i c a sl lhy i f tt h e p i v o a
t rm eanderIhal can smooth irce4ularly
ehapedworkViecee or enlarqeholee,
I toward
against
thesander
thesanding
to maintain
belt.
Dressure
cut a elot in a doweland eliVa etrip
of abraeiveVaperinlo it (ri6hifr,bottom).
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I 97
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AUXILIARYSANDINGTABLES
I
TABLEFORTHEDRILLPRESS
A SANDING
I
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Holefor aandinqdrum
3'/a"dtameter
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Jiq baoe
1%"x1%"x11"
I
' / o x" 2 % " x 1 1 "
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I
1 Making thejig
I Sanding drumslargerthan%inchin diameteraretoolarge drillfittedwitha holesawto cuta holein theplywoodtop,cen- I
to fit throughtheholein mostdrillpress Tomakefull
tables. tering theopening 3 inchesfromthebackof thetable.Screw
useof thesanding of larger
surface drums,builda tablelikethe the L-shaped basepieces from1-by-3and2-by-2stock
together I
oneshownabove. Usea copingsaw,a sabersaw,or anelectric (above, right),thengluethemto thetable.
T
I
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t
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r) Sanding curved stock
t
Z Clu^pthejig baseto thedrillpress
tablewiththeholedirectly underneath the
t
drumA . d j u stth et a b l eh e i g htto b r i n g
the bottomof thesanding sleeve level
I
withthejig.Holding
feedit at a uniform
theworkpiece
speedin a direction
f irmly, t
opposite
(right).
therotation
Toavoidburning
of thesanding
or gouging
drum
the
I
workpiece,
uousmotion.
feedit witha smooth,
Assegments
contin-
of thesanding
I
sleevewearout, rarse
to brinsa freshsurface
thedrillpress
to bear.
table I
I
98 I
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I SANDING IIGS
t
t A RADIAL-ARM-SAW TABLE
SANDING
I 1l Buildins -
thetable
I Thesimple jig shown at rightwillen-
I ableyouto sandthinstockonyourradial
armsaw.Cutthetableandfencefrom
I l - i n c hp l y w o o d s i,z i n g
t h e p i e c etso f i t
yoursaw.Cuta slotoutof oneedgeofthe
I tablelargeenough to accommodate the
sanding drumyouwilluseandallowyou
t to shiftthedrumforward andbackfordif-
ferentsizedstock.Routa %-inch-wide
I groove alongthelength of thefence,leav-
ing% inchof stockbelowthechannel to
t slipintothesawtable's fenceslot.Insert
t h e s l o t t e de d g eo f t h et a b l ei n t ot h e
I groove in thefenceandscrewthetwo
nipcps ioopihpr
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r') Smoothing
I thinstock
I lnstalla sanding drumin yoursawfollowing themanufac- sanding.
Turnonthesawandfeedthestockslowly andcon-
I turer's Slipthejig fencebetween
instructions. thefrontand tinuously
fromleftto right-against
therotation
of thedrum
reartablesof thesaw,positioning theopeningin thebasedirect- -betweenthefenceandsanding drum(above).(Clamping
jig
I ly below thedrum,thentighten
jig in place.
Lower
thetableclamps
thedrumsoit isjustbelow
to secure
the
thetopof thejig
a featherboard
to the tableto
fencecanalsohelpprevent
press
gouging.)
thestockagainstthe
Foreachsuccessive
I table;positionthedrumsothedistance between it andthejig pass,reducethegapbetween thefenceandsanding drum
fenceis slightlylessthanthethickness of thestockyouwillbe bynomorethanXeinch.
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I 99
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HAND-SANDING
IIGS I
BLOCK
I
A C()NTOURED
SANDING
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Making theblock
I Forsmoothing thecontoursof a pieceof molding, youcan Laya single thickness of plastic wrapovertheboxand,whilethe
inloiI (above,
I
usea shortsample of themolding to shapea sanding blockthat filleris stillsoft,press themolding sample left)
matesperfectlywiththesurface
theblockrequires
of theworkpiece.
autobodyfillerormodeling rubber
Fashioningandclampit firmlyin place.
to makea
Letthefillerharden, thenremove
t h em o l d i nsga m p lfer o mt h eb o xa n dt h en a i l sf r o mt h ee n d s .
I
moldof theprofile.
larger
Startbynailing
thanthesample molding
a smallboxslightly Nowsawoff bothendsof thebox.Stretch
together
andat least%inchdeeper than abrasive-side upacross themolded
a pieceof sandpaper
sideof thebox.Usethemold-
I
thethickestpartof themolding.
manufacturer's
instructions
Prepare thefillerfollowingthe ingsample
andf ill abouthalftheboxwithit. staple
to press thepaperagainst
theendsto thesidesof thebox(above,
thehardened
right).
filler,then I
I
I
llllilllilllllltilllill]firlillrllllllrllll1
tlllllflllltfilItllJ ljllilIl
t
1HO?TI? I
5andingbloak
CUNa woodblockLhatyou t
can qrip comforLably.0n ile
Nooface. saw Nwonarrow
grborruand cultwo wedge-
t
ehaVedwoodeNriVeto fit in the qapo
enuqly.ToVrovideevenoanding?reosure,
I
you can qluea felLor cork ?ad to Ihe bo|tom,
WraVa Vieceof oandpaper aroundtheblock, I
ineerllhe endsinto the qroovee, then t ap in
Nhewed7eoto holdlhe VaVerin place. I
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I SANDING TIGS
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I r) Smoothingthemolding
I Clamp theworkpieceto a table,
I
rlllilltill fitllll]Illllilllllllllilllllllilllllllllllilllllllllllllll usinga woodpadto protectthestock.
Slidetheblockbackandforthalons
I themolding(above).
I 1HO?Tt?
Foldinqaandpaper
I Toqetthe moetlrom a sheet,of oandpaper,
ueeonlyone-quarNer of rhe abrasiveeurtace
I al a lime. FoldNheVieceinto quariere,lear
the sheethalfwayalonqonefold line,and then
fold it inboa four-Vlyoandinqpad eo LhaN
I no lwo of the abrasivesurfacesare in con'
tacL.Whenthe first surlaceweareouN,
I refoldNheeheet,Noex?o6e
anunueed
Vly. :T
I ,/ S $
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I 101
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I TOOLEXTENSIONS
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t ATDTABLES
I
I hejigsin thischapterwill allow
youto transformportablepower
I toolsinto smallstationarymachines
and handlelargeworkpieces on your
I stationarypowertoolsmoreeasily.The
standshownon page105,for example,
I convertsa platejoinerinto a stationary
biscuit-slot cutter,a moreconvenient
t setupfor someoperations. The router
tableon page106is essential for some
I cuts.Featuringan adjustable fenceand
a storagecompartment,it allowsyou
I to setup your routerasa mini-shaper.
In a smallshop,a removablerouter
tablecan be attachedto a tablesaw
I (page107).Thethree-in-one tool table
I shownon page108can convertyour
router.sabersawandelectricdrill into
stationarytools.
I Extensiontablesand roller stands
greatlyexpandtheversatilityof toolslike
I band sawsand drill presses. Seepages
I 10 and I I I for jigs that enhancethe
I capacityofthesetoolsto handlelarge
workpieces safely.All theaccessoriesfea-
I tured in this chaptercanbe custom-
I madeto suityour needs,at a fractionof
thecostof commercial versions.
I
I
I
I Secured to a bandsawtable,theply-
I woodextension tableat left morethan
doublestheoriginal table'ssurface
I area,allowingbetter controlovera
cut-especiallywith longstock.

103
 I
TOOL EXTENSIONSAND TABLES
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Drill presa extension
table (paqe 111) I
Attached to drill preea
to extend oriqinaltable t
Removablepower I
tool table (paqe lOB)
Holds router, aaber saw, I
or electric drill upaide-down
Vise extension for atatonary work;attached
atand (page 112) Lo workbenchwtth winqnuta for I
suPPorcaffee eaayinetallationand removal
end of lon4
board clamped
I
in workbench
ahouldervise Adjuatable roller etand I
(pase 113)
1et juat belowaaw table levelon
the outfeed aide to aupporL lonq
I
or wideworkpieceo
aa they are cut I
T
I
q*..,;

I
Eand aaw exteneion
table (page 11O)
I
Fastened to band
aawtable Lo increaae I
aurfacearea
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104 I
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PLATEIOINERSTAND
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Barreleupport(top)
I 1%"x3'tr"x6"

I
Auxiliarytable
t 7" x 12"

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Darrel oupport
I (bof,tom)
1%"x5%"x6"
Handleeuppor,
I 3'/r" x 12"

I thejig
1 Building
I I Paired witha platejoiner,theligshownabove willreducethe shape onthestock.Borea holeforthebarrelandcutthesup-
setuptimeneeded in a series
to cutslotsforbiscuits of work- portin twoacrossitswidth,through of thehole.Screw
thecenter
pieces.Buildthejigfrom%-inch plywood,
except forthebarrel thebottompartto thebaseandfit theotherhalfontop.Boreholes
I whichshould
support, besolidwood. to theillustration
Refer for forhangerboltsthroughthetoponeachsideof theopening, then
suggesteddimensions. Screwthehandlesupport to thebaseand drivetheboltsintothebottom of thesupport.Usewingnutsto
T attachthehandle brackets,spacing themto fit yourtool.With holdthetwohalves together. screwtheauxiliary
Finally, tableto
theplatejoinerresting upside-downonthehandle support,butt thejoiner's fence.(lt maybenecessary
f ixed-angle to drillholes
I thebarrelsupport againstthemotorhousing andoutlineits in thefenceforthescrews.)
I
I
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I
I
I r) cuttingtheslots
4 Secure theplateloinerin thestand
I andclampthejig baseto a worksurface.
t Setthefenceat thecorrect
forrepeat
height
cuts,clampstopblocks
and,
to the
auxiliarytableto centertheworkpiece in
I frontof thecutter.Foreachcut,putthe
workpiece f latonthetableandbutted
I againstthejoiner's faceplate,thenturn
onthetoolandpushthestockandthe
I tableintotheblade//eft)
I
I 105
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TABLES
FORPOWERTOOLS
I
A ROUTER
TABLVCABINET
I
1 Assembling thetable I
I B u i l te n t i r e fl yr o m% - i n c hp l y w o o d ,
thetableshown at leftallows youto use I
yourrouter asa stationary tool-a require-
mentof manyoperations. lt features a I
largetopwitha slotfor a mitergauge,
anadjustable fence, a storage shelf,and I
cuoboards. Startwiththe basicstruc-
tureof thetable,sizing thebottom, sides, t
back,shelf, dividers, anddoors to suityour
needs. Fixthesepartstogether, usingthe I
joinerymethod of yourchoice. Thetable
shownisassembled withbiscuit jointsand I
screws. Borea holethrough thebackpanel
to accommodate theswitch's power cord. I
Forthetop,cuttwo pieces of plywood and
useglueandscrews to fastenthemtogeth- I
er;thepieces
overhang
shouldbe largeenough
thesidesof thecabinet
to
by2 or r
3 inches. Fixthetooto thecabinet. Final-
ly,fastena combination switch-recepta- I
cleto oneof thedividers, witha power
cordlongenough to reacha nearby out- T
let.Whenyouusethetable,plugin the
routerandleaveits motoron.Usethe t
table'sswitchto turnthetoolonandoff.
t
r) Preparing thetabletop
I
I me routeris attached to thetoowith
a square sub-base of %-inchthick clear
I
acrylic. Several stepsarenecessary to fit
thesub-base to thetopandthento the
I
router. First,position thesub-base at the
center of thetopandoutlineitsedges with
I
a pencil. Markthecenter of thesub-base
anddrilla pilotholethrough theacrylic
and
I
thetop.Remove thesub-base androutout
a %-inch-deep recess withintheoutline
I
(right).Usea chiselto pareto thelineand
square thecorners. Then,usingthepilot
I
holeasa center, cut a holethrough the
topto accommodate yourrouter'sbase
I
plate.Next,usea straightedge guideto
helpyouroutthemiterslotacross thetop:
I
Clamp theguidesquare to thefrontedge
of thetopandbutttherouteragainst it
I
asyouplowa slotthatisjustwideenough
to fit yourmitergauge barsnugly.
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I TOOL EXTENSIONSAND TABLES
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I Preparingthesub-base
Drilla holethrough
thecenter of thesub-base
slightlylarger
I thanyourlargest bit,andfasten
router to therouter
thesub-base
usingflat-head machinescrews (above).Setthesub-base in
I thetablerecess andattachit withwoodscrews, drillingpilot
holes allfasteners.
firstandcountersinkine
I thefence
Making
Cut two piecesof 3/q-inchplywood
I
llllilI1
illtillltllJ lllrilljll11 lljllllllll
l]llulllltllljlllllll]l]11 andscrew themtogether
Sawa notchoutof thefence's
in an L shape.
bottom
I edgeto accommodate yourlargest bit,

I 1HO?Tt? andscrewfourtriangular
the backfor addedstability(above).
supports to

A router table on the table eaw Attacha clearsemicircular plastic guard,

I To makethe moet,of Nheepace witha hingeso it canbeswungoutof
in your ehoV,builda router theway.To usetheroutertablefor a
I table intoyourNableoawo . - s t r a i g hctu t ,c l a m pt h ef e n c ei n p o s i -
ex\eneiontable,RouN
tionandfeedtheworkpiece intothebit,
t a'/+-inch-deep
receeeinto a 6t j:
holding it flushagainst thefence.
non-meNallicsei-
t
I
eaw,cu| a holein the receee
I Noaccommodalevour rouler'o
baeeplate.Thenremovelhe eub-baee from Nhet.ool,ecrew'
I ingthe rouf,ert o the plaeticVieceinetead.NexNecrewlhe
plaoticinto the receeoicountersinkall Nhefasteners.Keat-
I LachIhe rouNerNoNhebaeeplaIe.A fencecan becul from
plywoodand atNachedto tie sawfencewhennecessar'l,
I
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I r07
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 I
TOOLEXTENSIONS
AND TABLES
I
I
A REMOVABTE
POWER
T()()LTABLE
I
1 Building thetable I
I A t t a c h etdo a w o r k b e n cohr t a b l e ,
theremovable extension tableshown at I
leftallows youto convert threedifferent
portable power toolsintostationary devices: I
therouter, theelectric drill,andthesaber
saw.Sizethepartsaccording to yourneeds. I
Startbycutting thetopfrom%-inchply-
wood,andtherailsandbraces from2-by- I
4 stock. Sawtherailsa fewinches longer
thanthewidthof thetopsotheycanbe I
fastened to the underside of the bench
using w i n gn u t sa n dh a n g ebro l t sT. h e I
hinged braces should belongenough to
reach fromtheunderside of therailsto a I
l e gs t r e t c h e
o rnt h e b e n c hC. u ta b e v e l
at thetopendof thebraces anda right- I
angled n o t c ha t t h e b o t t o mM. o u nat n
On/off switch forthetoolontheunderside I
o f o n eo f t h er a i l sa sy o uw o u l df o ra
table/cabinet (page106). I
T
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I
r) Preparingthetabletop
I
L Cutarectansular holeoutof thetable- I
top'scentertheiamesizeastheinserts
youwillusefortheIools(page109.fhen
screwcleatsto theunderside of thetop,
I
forminga ledgeto whichthe inserts can I
befastened (rrghf).
I
108 I
I
I
t TOOL EXTENSIONSAND TABLES
I
I
Q Preparing therouter insert
I :.f Sawthethreetoolinserts, sizingthemprecisely to fit rn
t h et a b l e t ohpo l eA. na c r y l irco u t esru b - b a si sef i t t e di n t ot h e
I insert following thedirections fortherouter tableonpages 106
a n d1 0 7 .T oi n s t a l l t hien s e ri tn t h et a b l es, e ti t o nt h ec l e a t s
I andscrewthe insertto thecleatsat eachcorner(right).Drill
pilotholesforthescrews. Makea fenceasyouwouldforthe
I router tableon page107.Secure thefencei1 l[s clesirocl nnsi-
t i o nw i t hc l a m o s .
r
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I Electric drill inaert

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I
I
I Preparing theelectric drillinsert
B o r ea h o l et h r o u gthh ec e n t eor f t h ed r i l li n s e rstl i g h t l y
I widerthanthe largest sanding drumor otheraccessory you
planto use.(Thestationary drillis particularly useful forsand-
I i n g .S ) crew a c o m m e r cdi ar li l lg u i d e t o t h eu n d e r s i o d fet h e
insertwiththedrillchuckcentered overthehole(above). (You
I mayneedto drillholesin thebaseof thedrillguideto fasten
f,
Preparing
thesaber sawinsert
i t i n p l a c e . ) T hb ei to ra c c e s s oi nr yt h ed r i l cl h u c ks h o u lpdr o - thesaw'sbaseplatesothebladewillbeinthecen-
r,l Position
I trudefromthetopof theinsert without thechuckbeing visible. terof theinsertandmarkitslocation.Borea holeat themark
P l a cw e o o d ewna s h e rusn d etrh eg u i d er o d so f t h ed r i l lg u i d e large
enough to cleartheblade.
Screwthesaw'sbaseplateto the
t to adjust
to thecleats
theheight of thedrill,if necessary.
asyoudidtherouter insert.
Fasten the insert inserlhbovd lf therearefewerthanfourscrewholesin the
baseolate.drilladditional
holes.
Mount theinsert
to thecleats.
I
I 109
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 I
TOOL EXTENSIONSAND TABLES
I
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I
TABLE
A BANDSAWEXTENSI()N
I
UNDERSIDE VIEW
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Cleat groove
(rf needed)
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Building andinstalling a tableforthebandsaw
A n e x t e n s i otna b l eo n y o u rb a n ds a ww i l l e n a b l ey o ut o c u t l o n g I
o r w i d ep i e c e sw i t hg r e a t eer a s ea n dc o n t r o lU . s i n g% - i n c hp l y -
w o o d ,c u t t h e j i g t o p t o a s u i t a b l e d i a m e t e tr h, e ns a wo u tt h e I
c e n t e tro f i t a r o u n dt h e s a wt a b l ea n dt r i m a o o r t i o no f t h e b a c k
e d g et o c l e a rt h e t h r o a tc o l u m n C . u t a i % - i n c h - w i dc e hannel I
f r o mt h e b a c ko f t h e t a b l et o t h e c u t o u ts o t h e t a b l ec a n b e
installew d i t h o u rt e m o v i ntgh e b l a d e N . e x t ,p r e p a rtew o c l e a t s I
that will be usedto attachthe jig to the sawtable.Forthese,two
1 - b y - 3ssh o u l db e c u t a f e wi n c h e sl o n g e trh a nt h e s a wt a b l e . I
P o s i t i o tnh e ma g a i n stth e s i d e so f t h e s a wt a b l es o t h a t t h e y
a r e % i n c h b e l o wt h e t a b l es u r f a c ew , i t h a t l e a s t% i n c ho f I
s t o c ka b o v et h e t h r e a d e dh o l e s (. M a k es u r ey o u rm a c h i n h eas
theseholes;mostbandsawshavethemfor mounting an accessory I
r i pf e n c e .D ) e p e n d i nogn t h e p o s i t i o no f t h e h o l e so n y o u rs a w
t a b l e ,y o um a yh a v et o p o s i t i o tnh e t o p o f t h e c l e a t sc l o s etrh a n I
% i n c ht o t h e t o p o f t h e s a wt a b l e .I n t h a t c a s ey o uw i l l h a v et o
r o u tg r o o v efso r t h e c l e a t so n t h e u n d e r s i doef t h e t o p t o a l l o w I
the tabletopto sit f lushwith the machine'stable (above). Mark
t h e h o l el o c a t i o nosn t h e c l e a t sb, o r ea h o l ea t e a c hs p o t ,a n d I
f a s t e nt h e c l e a t st o t h e t a b l ew i t ht h e m a c h i n e s c r e w sp r o v i d e d
f o r t h e r i p f e n c e( r i g h t .t o p ) .T h e np l a c et h e t a b l e t o po n t h e I
cleatsand screwit in place(right,bottom);be sureto counter-
s i n kt h e s c r e w sT. h et o p s h o u l ds i t l e v e w l i t h t h e s a wt a b l e . I
Toremove t h ej i g ,r e m o v e o n l yt h e m a c h i n es c r e w sl,e a v i n tgh e
c l e a t sa t t a c h e dp e r m a n e n ttl o y t h e t o p . Y o um a yn e e dt o c u t I
clearance n o t c h e si n the u n d ersido e f t h e t o p s o t h a ty o uc a n
r e a c ht h e m a c h i n e screws. I
I
110
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I TOOL EXTENSIONSAND TABLES
t
I A DRILL
PRESS
EXTENSION
TABLE
I Fitting a drillpress withanextension table
Thesmalltabletypical of mostdrillpress-
I eswillnotadequately support largework-
pieces, especially whenthetoolis setup
I forsanding operations. Tobuildanexten-
s i o nt a b l e s, t a r tb yc u t t i n ga p i e c eo f
I %-inch plywood intoa square withdimen-
sions thatsuityourneeds. Thenmarka
I linedownthemiddle of theoiece anddraw
t w oc i r c l e cs e n t e r eodnt h e l i n e .L o c a t e
I t h ef i r s ta b o u 4t i n c h e fsr o mt h e b a c k
edge, sizing it to fit snugly around thedrill
I o r e s cs o l u m nL. o c a t teh es e c o n h do l e
under thechuck;makeitsdiameter about
I %inchgreater thanthelargest accessory
youplanto use.Tohelppinpoint thecenter
I o f t h eh o l ei,n s t a al l b i t i n t h ec h u c ka n d
measure thedistance fromthecolumn to
I thebit.Prepare to install thejigonthedrill
press tablebycutting itsbackedge, leaving
I a rectangular "ear"thatprotrudes
behind
thebackhole.Borea holethrough theear
I fora %-inch-diameter carriage bolt.Next,
sawthejig in halfalong thecenterline and
I cutoutthetwocircles. Youmayneedto
make o t h e cr u t st o c l e a rp r o t r u s i oonns
I y o u rm a c h i n eO. nt h em o d esl h o w na,
n o t c hw a sn e e d efdo rt h et a b l eh e i g h t
I a d l u s t m etnr ta c ko n t h et h r o act o l u m n .
F i n a l l ys,c r e wa b u t th i n g et o t h ef r o n t
I e d g eo f t h ej i g t o j o i nt h et w oh a l v eass
shown. Thecarriage boltandwingnutwill
t clamp thetablein placeon topof the
drill nrpss t:hlo
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VISEEXTENSIONSTAND I
I
M a k i n ga n du s i n gt h es t a n d
T h ev i s ee x t e n s i osnt a n ds h o w na t r i g h ti s u s e dt o s u p p o r t I
t h e f r e ee n do f a l o n gb o a r dc l a m p e di n t h e s h o u l d evri s e
of a workbench T .h ed i m e n s i o ngsi v e ni n t h e i l l u s t r a t i o n I
w i l l w o r kw e l lw i t h m o s tb e n c h e sC. u tt h e u p r i g htto l e n g t h ,
t h e n s a w a n g l e dn o t c h e sa l 2 t / z - i n c hi n t e r v a l sa l o n gi t s
Uprighl;
I
l e n g t hs, t a r t i n g5 i n c h e sf r o mt h e b o t t o mM . a k et h e n o t c h - 3/,"x2i/+x30'
e s a b o u t1 i n c h l o n ga n d 1 , /i:n c hw i d e .T h e ns a wt h e f e e t I
t o l e n g t ha n d c u t r e c e s s easl o n gt h e i rb o t t o me d g e sJ. o i n
t h e f e e tw i t h a n e d g eh a l f - l a pl o i n t :C u t h a l f - l a pisn t h e t o p I
e d g eo f o n ef o o t a n d t h e b o t t o me d g eo f t h e o t h e r ,t h e n
g l u et h e t w o t o g e t h e rO. n c et h e a d h e s i v ies d r y ,u s ea l a g I
s c r e wt o a t t a c ht h e u p r i g ht o t h e f e e t ;d r i v et h e s c r e wi n t o
t h e u p r i g h ft r o mu n d e r n e a t h e f e e t .C u tt h e s u p p o rpt i e c e I
a n ds w i v ebl a r s ,a n g l i n gt h e t o p o f t h e s u p p o rpt i e c ea b o u t
1 0 " t o w a r dt h e u p r i g h tT. o l o i nt h e s u p p o rpt i e c et o t h e I
s w i v e bl a r s ,b o r eh o l e sf o r % - i n c h - d i a m e tdeor w e l st h r o u g h
t h e s q u a r ee n d o f t h e s u p p o r p t i e c ea n d n e a rt h e e n d so f t
thebars, a n d s l i p t h e d o w e l i
s n t ot h e h o l e sg; l u et h e d o w -
e l st o t h e b a r s , b u t l e a v et h e s u p p o rpt i e c ef r e et o p i v o t T . o I
u s et h e s t a n d , i n s e r t h e d o w e a
l t t h e t o p e n d o f t h e s w i v el
b a r si n t h e a p p r o p r i a t e s l o t i n t h e u p r i g hfto r t h e h e i g h y
t o u I
n e e da n d p r o py o u rw o r k p i e c o
e n t h e s u p p o r p
t i e c e .
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APIUSTABLE
ROLLE,R
STAND
t
I
Building thestand
t Frame
Setupontheoutfeed
a n a d j u s t a brl o
sideof a sawtable,
e l l e sr t a n dl i k et h eo n e
I 10"x 18" shownat leftwillhelpyousupport
workpieces. Startbyconstructing
large
theframe
t fortheroller,cuttingthefourpieces
1-by-4
from
stock.Gluetheframetogether with
I buttjoints,adding screws to reinforce the
Carria4e bolt connections. Thenborea holein eachside
I fora %-inch-diameter carriage bolt.Center
thehole3 inches fromthebottomof the
I frame.Screw therollerto thetoo.Cutthe
pieces
remaining of thestandfrom1-by-6
I stock, referring to thedimensions provided,
a n dr o u ta 1 4 - i n c h - l o n%g-, i n c h - w i d e
I slotdownthemiddle of thetwouprights.
S c r e wt h ec r o s s p i e tcoet h e u p r i g h t s ,
I aligning thetopof thepiece withthebot-
tomof theslot.Fasten theupright andrails
I to thefeet.Toguidetheroller frame, nail
1-by-1 cleats to theuprights aboutr/t inch
I in fromtheedges.
position
To setup thestand,
Foot theframebetween theuprights,
3/+" x 5 1/2"
t f ittingthecarriage
frominside theframe.
boltsintotheslots
Slipwashers over
I theboltsandtighten thewingnutsto set
theheight of theroller slightly below the
I levelof yoursawtable.

I rllillltfiilllltl]lJ
lll1
illtllllllltlllllltlllltlllltll]fiIjlllJlltillll
I 5HO7Tt?
I Atemporary rollerstand
Ueinqonlya eawhoree, LwoC clampe,
t s o m ew o o d a , n d a c o m m e r c i ar o
you can makea eimplebuI effect,ive
l ller,

I eland Lo supporNt.heoutfeedfrom
anyof yourmachinee. Makea T-ohaped
maeNfor the roller,eneurinqit io long
I e n o u q hN oh o l dl h e r o l l e ra L a s u i i a b l e
heiqht.)crew Lherollerto Lhehorizontal
I memberof Nhemast. Add a bracelo
oneendof Ihe horeefor clamoinalhe
I maet,in place:Cul 21-by-4oto opanthe
l e g ea n d 6 c r e wl h e m l o N h e l e q eao
I e h o w n . Tsoe c u r e t h er o l l e re N a n dl o
lhe sawhorse,clampthe maeNNotrhe
I bracee,makinqsurelhe rollerie horizontal.

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I 113
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I

$
-$
ffi
ffi&
sYs=i
J- I

elb
lf$
fff , r :
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ifl.
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l:- , - - -: ' *
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ir ii' r: ii I
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s
fit

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$t i; I' i
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it i; ir i I
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\
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uaemfia1" I
F."t i 1 I
$ i, I g*+a
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I STORAGEDEVICES
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I
t
t hethervour workshoois tucked
A SETECTI()N
OF
awavin a cornerof vour base-
ST(lRAGE
DEVICES
I ment or sDreadout over a two-car
garage, stoiingthe toolsand materials 2aw blade otorage
I thataccumulate is a persistent
Thischapterofifers several
challenge.
simplestorage
box (page 117)
Keepectrcularaaw
I devicesthat canhelpyou win the on-
goingbattleagainstclutter.Theywill
bladeavieibleand pro-
tecLed; dividere keep
bladeafrom touchina
I keepyourtoolsandmaterials within easy
reachwhentheyareneeded, andout of
I thewaywhentheyarenot.
For storinghandtools,considerthe
I handsaw holder (page117)andthetool Chiselrack
)ecured Lo wall to keep
tray,the chisel,and routerbit racks
chiaeleor4anized.Made
I shownopposite.As well ashelpingto
organizeyour tools,thesedeviceswill
from Lhreewood atrtpa;
elota for chiaelaare
I preventdamageto cuttingedges.
An effectivesystemfor storingclamps
dadoedalongedqeoof
middlepiece,then etdpe
are qluedtogether.
I is a must.Therackshownon page118
will accommodate a largeselection
and,
I because it is mountedon casters,
rack can be movedto whereverit is
the

t needed.Lumberand ply,voodstorage
racksareshownon pages120and12l.
I Eachof the examplesshowncanhold
enoughstockfor several projectswhile Router bit atorage rack
I conserving preciousfloor space. Holderouter btta
upright; holee
are epaced to
I preventcuttin7
edgeefrom com'
I tnq into contact.

I Clampscan be a nuisanceto store Tool tray

I because of their sheernumber in the
shop.The simplerackshownat left
Drawer wiLha
notched2-by-4
dividerfor houetn4
I is madeof stripsof wood nrounted
and protecLinq
on wall studs. Tlrc lowerstrip is filee and raope
I thicker, to keepthe clampsleaning
toward the wall.
 I
STORAGEDEVICES
I
I
t
I
Handsaw
holder
I
(pase 117)
Wall-mounLed I
rack for holdinq
handeawe;made
from 2-by-4
I
atock, plywood,
dowela,and rub- I
per noqe
I
I
Lumberatorage
rack (page 121) I
FronL-loadin4rack
for lumber,with Eide-
loadinqarea under'
I
neath for etonnq
/ywood and oLher
I
manufacturedpanele
I
I
Vefticalplywood
I
rack (page 12O)
For etackin7ply- t
wooaon ena;Pan'
elE held by furrtn7 I
eLrip, Lhreaded
rods,and winqnuto
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Mobile alamp
rack (page 118)
Uprtqhtframe
t
holds wrderan4e
of clampa;caetere I
mounLedunderbaee
allowrack to be I
movedeaeily
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I
I
STORINGSAWSAND BLADE,S
I
t A SAWBLADE BOX
STORAGE
I Stolingcircularsawblades
O r g a n i zyeo u rc i r c u l asr a wb l a d e si n a c u s -
t tom-made storagb e o xl i k et h e o n es h o w n
a t r i g h t .B u i l dt h e b o xf r o m% - i n c hp l y w o o d ,
I c u t t i n gi t a f e w i n c h e sl a r g e trh a ny o u r
l a r g e sbt l a d ea n d w i d ee n o u g ht o h o l da l l
I y o u rb l a d e sM . a k et h e b o t t o ma n d b a c k
f r o mt h e s a m ep i e c e ,r o u t i n gt h e d a d o e s
I f o r t h e d i v i d e r fsi r s ta n d t h e nc u t t i n gt h e
p i e c ei n t w o . T h i sw i l l e n s u r ep e r f e c t
I a l i g n m e not f t h e d a d o e sC. u tt h e d a d o e s
I i n c hd e e pa n dw i d e ,s p a c e da t l / - i n c h
I i n t e r v a l sM, a k et h e d i v i d e ros u t o f % - i n c h
p l y w o o do r h a r d b o a r dF. i t t h e d i v i d e r si n
I t h e i rd a d o e sg, l u et h e mt o t h e b o t t o ma n d
back,then screwthe boxtogether. To keep
I t h e b l a d e sf r o mr o l l i n go u t o f t h e b o x ,c u t
a battenfromscrapstockand nail it to the
t d i v i d e r sn e a rt h e b o t t o mo f t h e b o x .

I
I
I HOLDER
A HANDSAW
I B u i l d i nagn dm o u n t i nt g h eh o l d e r
Thewall-mounted rackshownat left,made
I w i t h a f e w w o o ds c r a p sd, o w e l i n ga,n d
s o m er u b b e rh o s e ,u s e sf r i c t i o nt o h o l d
I y o u rh a n d s a wi sn p l a c eC . u tt h e b a s ef r o m
%-inch p l y w o o d .
E a c hd i v i d eirs m a d ef r o m
I a 1 0 - i n c h - l o n g 2 - b y f-a4c e - g l u etdo a
s h o r t t, a p e r e d2 - b y - 4 .B e g i nb y s c r e w i n g
I a 2 - b y - 4a t t h e l e f te n do f t h e b a s et,h e n
s e c u r et h e d i v i d e r si n p l a c e ,l e a v i n ga
I ' / - i n c hg a p b e t w e e nt h e m .T h e s t o p p e r s
are4-inchlenghsof l-inch dowelpressed
I i n t os l i g h t l ys h o r t epr i e c e so f r u b b e g
r ar-
den hose;usehosewith ridgesratherthan
I s m o o t hh o s e .S l i p a s a wi n t ot h e r a c k
f r o mb e l o wt,h e nt u g d o w no n t h e h a n d l e .
I T h es t o p p ewr i l l p i n c ht h e b l a d ei n p l a c e .
M a r kt h e d o w e l ' sp o s i t i o nb, o r ea % - i n c h -
t d i a m e t esrt o o o e d h o l ei n t ot h e b a s ea t t h e
m a r k t, h e ns c r e wt h e d o w eiln p l a c eO , nce
I a l l t h e s t o p p e ras r e i n p o s i t i o nm , ount
t h e h o l d e tro t h e w a l l .
I
I
I t17
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MOBILECLAMPRACK
I
thestockforthejig
r
1 Gutting
I T h el a r g ec o l l e c t i oonf c l a m p si n
mostshoos-andtheirawkward sizeand
t
shape-canstretch
izedspace
eventhemostorgan-
to thelimit.Themobile clamp
I
rackshownat leftcanbestoredagainst
thewall,thenrolled to anypartof theshop
I
Top rail
1 1/2"x 31/2"x 22" where clamps
tingthe pieces
areneeded. Startbycut-
to size,referring to the
t
i l l u s t r a t i of onrs u g g e s t e
Thesixrails(top,median,
ddimensions.
andbottom)
t
Median rail
x 31/2"x 23 1,/2"
11/2" thetwostiles, andthreecrosspieces
all sawnfrom2-by-4stock.Cutthefour
are t
?tile skirtpiecesfroma 2-by-4andthe base
fromr/z-inchplywood (inset).
I
1 1/2"x 31/2" x /yl1/2tl

I
I
Eottom rail
1 1/2"x 3 1/2"x 23 1/2"
I
I
I
t/2"x 23 1/2"x 231/2"
I
I
I
1 1/2"x 3 1/2"x 23 1/2"
I
I
I
I
r) Attaching therailsto thestiles
L Prepare the railsforthejoinerybycuttingendrabbets
I
thatwillfit intonotches
betsshouldbe 71/zinches
anddadoes in thestiles.Therab-
wideand3/qinchdeep,except
t
f o rt h et o pr a i l sw
, h i c hr e q u i rae r a b b eot n l y1 i n c hw i d e .
N o t c ht h et o pe n do f e a c hs t i l eo nt h r e es i d e st,h e nr o u t
I
back-to-back dadoes nearthe bottomendandmiddleof
thestiles;makethedadoes 3% inches wideand3hinch
I
deep. Alsocuta notch3% inches wideand32inchdeep
fromthebottom of eachstile.Whenyouassemble therails
I
andstiles, alignthetwohalves of eachrailface-to-face
(right)and attachit to thestileswithscrews.
I
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118 I
I
I
I STORAGEDEVICES
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I
r Mounting tothestiles
thecrosspieces
I T o l o i n t h e c r o s s p i e c et os t h e r a c k ,c u t a 3 t l z - i n c h - w i d e
d a d oi n t h e m i d d l eo f e a c hp i e c ea n d s c r e wt h e m i n p l a c e
( a b o v eT) .h e m i d d l ec r o s s p i e cwei l l r e s to n t h e m e d i a nr a i l .
I T h et o p p i e c e sw i l l r e s to n t h e o u t s i d e
s h o u l d e rosf t h e n o t c h e d
t tnn nf p:r^h s,tilo

Attaching thestilesto the base

,{
I -t Finishthe rackby sawingtwo notch-

I llllilliilllljl1tlllillJlllillrlilllrlllrlllilltilllllilllliilillllllllj es in the baseandskirtto accommodate

t h e s t i l e s ,r a b b e t i n og n e e n d o f e a c h
skirt piece,andscrewing themtogether to
I 1HO?TI? form a box (page118, insef).Usescrews
t o a t t a c ht h e b a s et o t h e s k i r t .F i n a l -
I 1toring clampoin a can l y , a t t a c hc a s t e r st o t h e u n d e r s i d e of
A Lraehcan fiNNeA wibha ehop- t h e s k i r ta t e a c hc o r n eor f t h e r a c k t, h e n
I madelid oervegas a convenienl s l i pt h es t i l e si n t ot h e n o t c h e si n t h e
waylo eNoreemallbar or pipe basehbove)and secure thestilesto the
I clamVe. CuNa Vieceof '/z-inchVly- b a s ea n ds k i r tw i t h e l u ea n ds c r e w s .
woodinLo emaller ',.",
a circleeliqhLly
NhanNhe diamelerof Lhecan'srim. r-:
I Thenscribea eeriesof concenf,riccir-
cleson LheVlywood to helVyou locate
I Lheholesfor the clamVbaro.Space
LhecircleeaboutZinchesaVarLand
I markpointoevery3 inchesalon4them.
Sorea |-inch-diameter holethrouqh
I eachpoint,fit Lhepieceof plywoodin
Lhecan,anddropNheclampethrough
I Nheholee.To
corrodinq,
prevenNNhe clampefrom
keepthe can dry aL all Nimes.
I
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I 119
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 I
I
RACKS
LUMBERSTORAGE
t
I
Commerciallumber racl<s,suchas these
cantileveredlumber shelves,are both I
adaptableand strong, making them
idealfor the home workshop.Screwed I
to a concretewall or to wall studs,they
can be adjusted to various heightsto I
suit your particular storageneeds.
I
I
t
r
PLYWOOD
A VERTICAL RACK I
I
I
I
I
Threadedrod
I
Furrin7 atrip
I
Constructing therack
I
Forlong-term
ableshopfloorspace.
storage, stacking plywood onendsaves
Therackshownat leftis builtfrom
valu- t
furring
two1-by-3
strips, threaded
furring
rods,andwingnuts.Startbyscrewing
stripsto thestudsof onewall,2 and5 feet
I
rods4Y,feetapart
fromthefloor;first bolttwothreaded
intothetopstrip.Cuta thirdfurringstripandborea hole
I
through it at oneendandsawa notchat theotherendto
l i n eu p w i t ht h er o d sB
. o t ho p e n i n gssh o u l d
b es l i g h t l y
I
larger thanthediameter of therods.Place twowoodpads I
onthefloorbetween therodsandstacktheplywood sheets
upright onthem.Holding
faceof thelastpanel,
thethirdfuningstripacross
sliponerodthrough theholeandthe
the I
otherintotheslot.Putwashers andwingnutsontherods I
andtighten them,pulling thefuningstriptightlyagainst the
plywood (above). Toremove a sheetfromthestack,loosen
wingnutsandswingthefurringstripupandoutof theway.
the I
Woodpad
3/r"x3%"x12"
t
t
t
r20 I
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T
I DEVICEs
STORAGE
t
I RACK
A LUMBER.AND.PTYW()()D
I Fastening therackto anunfinished
wall
Therackshownbelow, madeentirely oI2-by-4stock,is attached to wall
I studsandceiling joists.
Lumber canbepiledonthearms, whileplywood is
stacked on edgeagainstthesupport Youwillneedat least8%
brackets.
I feetof freespaceat oneendof therackto beableto slidein plywood panels.
Beginbycutting thetriangular-shapedbracketsandscrewing themto the
t sluds(right). slipthemunderthebrackets
Cutthefootings, andnailthemto
theshopfloor.Next, sawtheuprightsto length
andtoe-nail theirendsto the
I footings andthejoists.Cutasmanyarmsasyouneed, aligningthefirstrow
withthetapered endof thesupport brackets.
Usecarriage boltsto fasten
the
I armsto thestudsanduprights, making surethearmsin thesameroware 9upport bracket
11/2"x31/2"x41/z'
Therackin theillustration
level. featuresarmsspaced at 18-inch intervals.
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Wallatud
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t
t )ole plate

t
t 11/2"x31/z"x20"

I 11/2"x31/z"xB"

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t
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t
I
I
t SHOPAIDS
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t
I
I ostjigsthathangfromthewalls (lFSH(IPAIDS
ANASSORTMENT
of woodworkers'shopstypical-
t ly providea shortcutto a commontask,
from boring mortisesto edge-gluing
Eeveledfeatherboard 9tandard featherboard
(pase127) (pase 125)
I panels.As the previouschaptershave ldentical to atandard Aleo knownae fin4er'
shown,the mostpopularjigsarethose featherboard, except the board: preaeea atock
I that makea job easierand more accu- fin4eroare beveledeo they enu7lyaqainat the
rate,or improvea tool'sperformance. preoo workpieceaqaineL table or fence of a
both the fenceand table etationary tool
t But eventhe mostmundaneof work-
shopchorescanbenefitfrom a helping
of a stationary tool

I hand, whetheryou are moving large

sheetmaterialsarounda shopor throw-
I ing somelight on your work.
Thischaptercoversa collectionofsuch
shopaids.Somedevices,suchasfeath- thimmed featherboard
I erboardsandpush sticks(page125),are (pase12Q
A atandard featherboard
t indispensable for everywoodworking
shop.Othersaredesigned for morespe-
aupported b5ta ahim ao
that finqere apply preaaure
cializedtasks,suchasmeasuringand
I markinglargearcl"'s(page133)or prepar-
hiqher on workpiece
Push atiak (page 125)
ing thin or smallstock(page130).lf iou
I frequentlywork alonewith largesheet
Uaedto feed atock
acroao atation-
ary tool table
t materialssuchasplywoodandparticle-
board,collapsiblesawhorses (page128)
I areashandy asan extrapair ofhands, Plywood carrier (page 13O)
while an auxiliaryoverheadswitchfor Features a handleand a lip for
thetablesaw(page131)wrJJmake your carryin7 large eheet materiale
I shop a saferplace.Evenmany of the Iikeplywoodand particleboard

I stickyproblemsof finishingcanbesolved
with a fewsimpledevices(page1j5). Bench dog lamp
euppora (page 157)
t Fite into benchdo7
hole;featurea a hole
t A sprayingturntableallowsyou to
to accommodate
deak lamp

I applyafinish evenlywithouttouching
theworkpiece or movingaroundit; Auxiliary table aaw switch (page 131)
I theend tqbleshownat left restson
As shownon
For turnin7 table aaw on and off when
main awitch is out of reach; inetalled
four dryingsupports. near ceilingand wired to eaw
I page136,the jigis easilybuiltfrom
p\nvoodanda "lazySusan"bearing.

I t23
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 SHOPAIDS
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I
I

I
V-bloakjig Planingjig for thin
(pase 132) atoak (page 131) I
Clampedto For thrckneaeplanin4
Compaoe (paqe 133)
For drawin4 circlee;
jointer table
for cham-
of aLockthinner than I
%inch;beveledcleate
awl ie fixed to ctrcle's ferinq a hold workpiece
center and pencit workpiece in place
drawa circumference
I
I
I
I
Trammel
t
I
gtaaking handlee (paAe 135)
9praying Tack-nailedLo the endaof a clamped to a board for I
turntable (paqe 136) board to enableboth facee acribinglarqe circlea
Kotatin4 platform ueinqa
"lazv to be ftniahed before piece I
)uean" bearina ie left to dry; can be
etacked for multi'
ple workpiecea
I
Vacuumacreeningramp (page l3O)
Dust is ewept onf,oramp and falle
throu7h holes;holetn backaccepLo
duet collectionhoaeao that duaL
ia auckedinf,ocollectionavatem
t
S S S 6 S
Center finder
(pase 152)
I
Ueed to def,ermine
.-a"-*"'\
s s s s s \ the cenLer of a ctr- I
cular workptece
s '-
t-s
I
Shooting boards (page 134)
Ueedwtth a planeto emoothend7rain. I
Kiqht-an1leboard (top) ro for planinq
atraight end grain;anqledveraion
(bottom) ie ueed for milered ende
t
Folding sawhorae (page 129)
A hinqedaawhoraethaL I
can be folded flat
I
I
I
Knoak-down
aawhoree (page 128) I
Three-pieceaawhorae
whichcan be dieassem-
bledquicklyand atored
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I
SAFETYDE,VICES
I
I PUSH ANDPUSH
STICKS BL(ICKS
I Making pushsticksandpushblocks
Pushsticksandpushblocks forfeeding
I stockacross thetableof a stationary power
Pueh etiak
toolcanbemadeusing%-inch plywood or %"x5%"x12"
I solidstock. Nooneshape is ideal; a well-
designed pushstickshouldbecomfortable
I t o u s ea n ds u i t a b lfeo rt h em a c h i naen d
t a s ka t h a n d F . o rm o s tc u t so n a t a b l e
I saw,design a pushstickwitha 45' angle
between the handleandthe base(right,
I f o p ) .R e d u cteh e h a n d l e a n g l ef o r u s e
withtheradial armsaw.Thenotchonthe
t bottom edgemustbedeepenough to sup-
porttheworkpiece, butshallow enough not
I to contact thesawtable.Thelongbaseof
a rectangular pushstick(right,middle)
I enables youto applydownward pressure
ona workpiece. Forsurfacing thefaceof
I a boardon a jointer, the long,widebase
of a pushblock(right,bottom)isideal.
I I t f e a t u r easl i p g l u e dt o t h eu n d e r s i d e
o f t h eb a s ef,l u s hw i t ho n ee n d .S c r e w
I thehandle tothetop,positioning it sothe
backis evenwiththeendof thebase.
I
t A STANDARD
FEATHERBOARD
T
t
I 1t Makins a standard featherboard
-
I Featherboards serve asanti-kickback
I devices, sincethef ingers allowthework-
p i e c et o m o v ei n o n l yo n ed r r e c t i o n -
I toward a stationary tool'sbit or blade.To
I makea featherboard liketheoneshownat
left,cuta 30"to 45" miterat oneendof
I a % - i n c h - t h i3c -kt,o 4 - i n c h - w i b
doeard;
thelengthof thejig canbevaried to suit
I t h ew o r ky o up l a nt o d o .M a r ka p a r a l l e l
lineabout5 inches fromthemitered end
I andcut a seriesof slotsto the marked
l i n eo nt h e b a n ds a w s, p a c i ntgh ek e r f s
I about%inchaoartto create a rowof stur-
dybutpliable f ingers. Finally, cuta notch
I outof oneedgeof the featherboard to
accommodate a supDort board.
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I r25
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SHOPAIDS
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T
I
Usingstandard featherboards
onthetablesaw I
Clamponefeatherboard to thefenceabove
theblade,andplacea longer onehalfway I
between the bladeandthefrontof the
table.Clampa support
perpendicular
boardin thenotch
to thehorizontal feather-
t
boardto prevent it fromcreeping
placeduringthecut.Fortheoperation
oui of I
shownat left,feedtheworkpiece
bladeuntilyourtrailing fingers
intothe
reachthe
t
featherboards.Thenusea pushstickto t
finishthecut,or moveto thebackof the
tablewiththesawstillrunning andpull I
theworkpiece pasttheblade.
I
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t
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I
Pushsticl<sandfeatherboards makean
t
operationlike rippingon thetablesaw I
muchsaferby keepingyourhandswell
awayfrom theblade.Thepush stickis I
usedtofeedthestockand keepit flat on
thetable,whilethefeatherboard presses I
theworkpiece againstthefence.The
featherboard
secured
shownin thephotois
to thetablewith specialhard-
t
wareratherthanwith clamps.A clamp- I
ing bar in themiterslotfeaturestwo
scrsusthat canbetightened, causingthe I
barto expandand locktightlyin theslot.
I
r26 T
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I SHOPAIDS
I
I A BEVELED
FEATHERBOARD
I Rippingstockwitha beveled featherboard
A featherboard clamoed to thefenceof a
I tablesaw,asshown ontheprevious page,
cangetin thewayof a pushstickduring a
I ripcut.A featherboardwitha beveled end
will pressa workpieceagainst boththe
t fenceandsawtable,eliminating theneed
to thefence(rrghf).
to clampa featherboard
I Makethedevice asyouwoulda standard
featherboard (page125),but cut a 45"
I bevelon its leadingendbefore cuttingthe
f ingers
andslots.Alsomakesurethatthe
I featherboard isthicker
thanthestockvou
ara rinnina (incef)

t
" ' ' l i t s H " ' b

I
I
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T
I
I A SHIMMED
FEATHERBOARD
Shimming a featherboard
I Whenworking withthickstockor run-
ninga boardon edgeacross a saw
t table,a featherboard clamped directly
to thetablemayapplypressure too
I lowontheworkpiece, causing it to tilt
awayfromthefence.To applypres-
T surecloser to themiddleof thestock,
screw thefeatherboard to a shimand
I thenclamptheshimto thetable(/eff).

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SAWHORSES I
I
SAWH()RSE
A KN()CKD()WN
B u i l d i ntgh es a w h o r s e T
A s t u r d ys a w h o r slei k et h e o n es h o w na t
l e f tc a nb e m a d ew i t ho n l ya s m a l a l mount I
o f l u m b e ar n d p l y w o o da,n dt a k e na p a r t
a n d r e a s s e m b l qe ud i c k l yC. u tt h e l e g s T
f r o ml - i n c h p l y w o o dt h, e ns a wa 3 - i n c h -
d e e pn o t c hi n t h en i d d l eo f t n et o oo f b o t h I
p i e c e sN. e x t c. u t t n e c r o s s p r e cf reo m
1 - b y - 6s t o c ka n d s a wa 1 / - i n c h - d e e p I
s l o t8 i n c h e si n f r o me i t h e re n dt o f i t i n t o
t h e l e g sA . n g l et h es l o t s ' o u g h5l y' f r o m I
iho vorlinal tn cnrped lho looc cliohtlv nrrl
I
! i i ! i ! b J

w a r dF. o ra d d e ds t a b i l i t ys,c r e w4 - i n c h
l o n g1 b y - 2c e a t st o t h e c r o s s p i e coe' r
e a c hs i d eo f t h e s l o t s . I
I
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I
-lb I
phrtc lottgworkpict'c:tt,itltottt
t l t cl t c l p o . l ' rbr t ' t r c l rv i s c ,c l t r t r t p I
t l t t ' r tcr d g c - r rrpt , i t l h
r atttlscrcn o ,rsr
l fi t() ()t' il t o t'c -srlrr,/irl r--sc-s,
ri.s-s/io ttri i I
o t r i g l t t .S c c t t rtcl r cl r a r t t l s c r c tno' s
l/rcci.rr-s-slls1-r'-s rlitlr (.' clorrrps Io t
prcIcItt thcttr .li'ort t slipp i trg.
I
128
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I
t SHOPAIDS
I
I A F()LDING
SAWHORSE
I
t Top rarl
3/o"x5%"x36"

I
I
I Corner half-
Iapjoint
I
I
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t
I
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I
I Making thesawhorse
t lll1
lllllll1
illllltlll rlitljljllltllltilltlll1
llitillll]|tlltlilllljll
M a d ee n t i r e lfyr o m1 - b y - 6
lightweight sawhorse shown
s t o c kt,h e
above, fea-
turinga hinged topandcrossbrace, folds
I flatforeasystorage. Cutthe legsand
1HO?Tt? r a i l st o l e n g t a
h n dl o i nt h e mt o g e t h e r ;
I usecornerhalf-laps (inset,top)Io loin
Taddingeawhoroes
t To VrevenL a sawhorse
from marrinqyourworK,
thetoprailsto thelegsandT half-laps
(inset, bottom) to attachthelegsto the
I coverits croeepiece bottomrails.Reinforce thejointswith
with a elriV of carpeL, glueandscrews, thenjointhetwosec-
an oldlowel,or a blan- tionsat thetoprailswitha pianohinge.
I ket,Foldthe maLerial Finally, cutthecrossbrace; besureit is
overf,heNoVedqe longenough
I nl lhe rraaaniere
sothatwhenthe legsare
spread, thepianohingeis recessed below
andscrewor nail
t it,to the eidee, t h et o pe d g eo f t h et o pr a i l s S
crossbrace in halfandconnect
. a wt h e
thetwo
I pieces
crossbrace
withthehinge. Thenfasten
to bothsiderails,againusing
the

pianohinges.
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T r29
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WORKSHOPHELPERS
t
I
CARRIER
A PLYW()()D
Moving l a r g ep a n e l s t
Sheetsof plywood, particleboard, and hard-
boardareoften heavy and awkward to car- I
ry. T h ec a r r i esr h o w n
a t l e f tw i l l m a k et h e
l o a de a s i e tro b e a r .R o u ta 1 - i n c h - w i d e I
r a b b eat l o n go n ee d g eo f a l 2 - i n c h - l o n g
b o a r dC . u t a n o t c ho u t o f o n ee n d o f a T
pieceof plywood, thenscrewa woodblock
acrossthe end of the notchto serveas a I
h a n d l eA. t t a c ht h e o t h e re n d o f t h e p l y -
w o o dp i e c et o t h e r a b b e t e df a c eo f t h e I
b o a r d( i n s e t )T. o u s et h e c a r r i e rs, i m p l y
h o o ki t u n d e rt h e s h e e ta n d p u l l i t u p I
underyour arm (left).Somewoodworkers
f i n d i t m o r ec o m f o r t a b lteo s t a n do n t h e I
c a r r i esr i d eo f t h e p a n eal n du s et h e i ro t h e r
h a n dt o s t e a d yi t . I
I
t
I
I
T
t
PLANING ANDTHINSTOCK
SH()RT t
U s i n gr u n n egr u i d e tso p l a n es h o rst t o c k
F e e d i n sgh o r tb o a r d st h r o u g ha t h i c k n e s s I
p l a n ecr a nc a u s es n i p r n ag n dk i c k b a c k .
T o h o l ds h o r ts t o c ks t e a d ya s i t e n t e r s I
a n de x r t st h e n l a ,n" . e, rbs., l" u et w os o l i dw o o d
s c r a pr u n n e r st o t h e e d g e so f y o u rw o r k - I
n i p c p [ \ , 4 : kspr r r pt h p n l n n e f sa f e t h e
s a m et h i c k n e s a s s t h e w o r k p i e caen d I
e x t e n ds e v e r ai ln c h e sb e y o n db o t he n d s .
Feedthe workpiece intothe planer(rrght), I
makrng a s e r i e so f l r g h tc u t su n t i l y o u
h a v er e a c h e tdh e d e s i r e tdh i c k n e s sT.h e n I
cutofftherunners.
I
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130 I
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I SHOPAIDS
I
I U s i n ga p l a n i n jgi g f o rt h i ns t o c k
I T h i c k n e spsl a n i n g s t o c kt h i n n e tr h a n
r/ainchoftencauseschatterand splinter-

I ing of the workpiece.

l e m sm a k et h i ns t o c k
To avoidtheseprob-
"thicker"
w i t ht h i sj i g .
I To makert,srmplygluetwo beveled cleats
t o e i t h e re n d o f a b o a r dt h a t i s s l i g h t l y
I l o n g e rt h a n y o u rw o r k p i e c e( i n s e t ) T . o
makethe cleats,cut a 45' bevelacrossthe
t m i d d l eo f a b o a r da p p r o x i m a t et h
t h i c k n e sa
l ye s a m e
s s t h e w o r k p i e c eN. e x t ,b e v e l
I t h e e n d so f t h e w o r k o i e c eS. e tt h e s t o c k
o n a b a c k u pb o a r d p , o s i t i o nt h e c l e a t s
I f l u s ha g a i n st h e w o r k p i e c seo t h e b e v e l
c u t sa r ei n c o n t a c ta, n dg l u et h e c l e a t si n
p l a c et o t h e b a c k u pb o a r dR
I . u nt h e1 r ga n d
w o r k p i e cteh r o u g ht h e p l a n e r m , aking
I s e v e r alli g h t p a s s e sd o w nt o t h e d e s i r e d
t h i c k n e s s( r i g h t )t,h e n c r o s s c utth e e n d s
I o f t h e w o r k o i e cseo u a r e .

I
I ANAUXILIARY F()RTHETABLE
SWITCH SAW
T
I
I
t Installing an overhead switch
I S w i t c h i nogn a t a b l es a ww h i l eb a l a n c i n g
a l a r g ep a n eol n t h e t a b l ec a np r o v ed i f fi -
c u l t .T h ea d d i t i o no f a n o v e r h e asdw i t c h
I w i l l e n a b l ey o ut o s t a r t h e s a ww h e nt h e
t mainswitchis out of reach//eft).Locate
t h e n e ws w i t c hs o y o u c a n r e a c hi t c o m -
f o r t a b l yw i t h a 4 - b y - Bp a n e lo n t h e s a w
I tablejust in frontof the blade;screwa tri-
I a n g u l abr r a c k etto t h e c e i l i n ga n da t t a c h
t h e s w i t c ht o t h e b r a c k eat t a s u i t a b l e
I h e i g h tR . u na l e n g t ho f n o n - m e t a l l i c
s h e a t h e ld2 - g a u g ec a b l ef r o mt h e s w i t c h
I a l o n gt h ec e i l i n gd, o w nt h ew a l l ,a n da c r o s s
the floorto yoursaw.Havea licensed elec-
I t r i c i a nw i r et h e s w i t c ht o t h e s a ws o t h a t
b o t hi t a n dt h e o r i g i n asl w i t c ha r ea b l et o
I startor stopthe machine;neverdisconnect
theswitchonthesawitself.
I
I 131
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SHOPAIDS T
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V.BL()CK
IIG I
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T
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I
Cutting
a chamfer
Tocutchamfers onyourjointer,
usethesimplejig shown above. ingthejointertable.Tousethejig,clampit in placewithone
I
Referto the illustration
bevelcutting2-by-2s
forsuggesteddimensions. Beginby
of thejig. Position
fortheV section the
endof thebasealigned
table.Lower theinfeed
withthecutterhead-end
tableuntiltheV section
of the infeed
of thejig lies
t
twocut piecesonthe basesotheyextendbeyond oneendby flushonthejointer'soutfeedtable.Seattheworkpiece in the
about12 inches, gapbetween
witha %-inch them.Attachthe gapof thejig,thenfeedit acrosstheknives whileholding it
I
twopieces to the basewithcountersunk
screws to avoidscratch- firmlyin IheY (above).
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t
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Finding the centerof a circular workpiece
I
is easyif you use the jig shown at right.
The simple deyice consis* of a piece of
t
plywood with a 90" wedgecut out of it
and a l2-inchJong 1-by-2 mountedso
I
that one edgebisec* the wedge.To usethe
jig, seat the workpiece in the wedgeand
I
draw a line acrossits diameter using the
1-by-2 as a guide. Rotate the workpiece
I
about 90oand draw anotherline. The nvo
will intersectat the centerof the circle.
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t SHOPAIDS
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FORSCRIBING
TW()DEVICES CIRCLES
I M a k i n ga n du s i n gt r a m m ebl l o c k s
Y o uc a ns c r i b ea l a r g ec i r c l eu s i n ga s e to f
I t r a m m ebl l o c k sl i k et h eo n es h o w na t r i g h t .
C u tt h e p i e c e so f t h e j i g f r o ms o l i dw o o d ,
I referring to the insetfor dimensions; make
s u r et h e b e a mi s l o n g e tr h a nt h e r a d i u s
I o f y o u rc i r c l eC . u ta n a n g l e dn o t c h% i n c h
f r o mt h e t o p o f e a c hb l o c kt o a c c o m m o -
I d a t et h e b e a ma n da w e d g eF. o rt h e p i v o t ,
d r i v ea n a i l i n t ot h e b o t t o mo f o n eb l o c k ,
I s n i p o f f t h e h e a d ,a n d f i l e i t t o a p o r n t .
Mouna t s h a r oo e n c iiln a h o l eb o r e di n t h e
I b o t t o mo f t h e o t h e rb l o c k .M a k es u r ei t s
p o i n ti s l e v e wl i t ht h e n a i l .T o u s et h e j i g ,
I l o o s e nt h e w e d g e sa n d s l i d et h e b l o c k s
a l o n gt h e b e a mu n t i lt h e g a p b e t w e etnh e
I n a i l t i pa n dp e n c ipl o i n te q u a l tsh ed e s i r e d
r a d r u so f y o u rc i r c l e T. rghten t h ew e d g e s ,
I h o l dt h e p i v o tp o i n t
steady t thecenter
a
o f t h ec i r c l ea , nd r o t a t et h e p e n c i p
l oint
I aroundit (right).

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Making a n du s i n ga f i x e dc o m p a s s
I C o n s i s t i nogf a n a r m ,a n a w l ,a n da p e n c i l ,
the compass shownat leftwill allowyouto
I s c r i b ea c i r c l eo f v i r t u a l layn yr a d i u sF. o r
t h e a r m ,c u t a l - b y - 2a f e w i n c h e sl o n g e r
I t h a nt h e r a d i u so f y o u rc i r c l e B
. o r ea h o l e
a b o u t1 i n c hf r o mo n ee n d o f t h e a r m ,
I l a r g ee n o u g h t o h o l dt h es h a f to f t h e a w l .
M a k ea n o t h ehr o l eb i ge n o u g ht o a c c o m -
I m o d a t et h e p e n c i lt;h e d i s t a n c b eetween
t h e h o l e ss h o u l de o u atl h e r a d i u so f t h e
I c i r c l e .F i t t h e a w l a n d s h a r o e n eode n c i l
i n t ot h e i rr e s p e c t i vheo l e sm , a k i n gs u r e
I the twoextendfromthe bottomof the arm
b y t h e s a m ea m o u n tU . s et h e c o m p a s s
I a sy o uw o u l dt r a m m ebl l o c k sh, o l d i n gt h e
t i p o f t h e a w la t t h e c e n t e ro f t h e c i r c l e
I a n d r o t a t i n gt h e p e n c i la r o u n di t t o
s c r i b et h e c u c l e( l e f t ) .
I
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SHOPAIDS
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TWOSHOOTING
BOARDS
I
1 Making shooting boards I
RIGHT-ANGLE
SHOOTING
BOARD I T os m o o t eh n dg r a i nw i t ha p l a n e ,
usea shooting boardlikethoseshown at I
)quare etop block
left.Theright-angle shooting board(left,
1"x4"x5"
above) is for planing straight endgrain; I
Top a mitered version canalsobe built(/eft,
t/r"x5"x19"
below). Cutthepieces according to the I
dimensions suggested in theillustrations.
Buildthebase, top,andmitered stopblock I
t/o"xB"x1B"
from%-inch plywood; usesolidwoodfor
thelipandthesquare stopblock. Screw I
thetopto thebasewiththeendsandone
edgealigned. Thenattachthe lip to the I
b a s em
, a k i nsgu r et h a tt h el i p l i n e su p
withthe endof the base.Forthe right- I
angleshooting board, fasten thestopblock
to thetopflushwiththeotherendof the I
jig.Forthemitered shooting board, cen-
terthestopblockonthetop. I
MiLered I
atop block
'1"x5%"x12" r
I
I
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I
r) Smoothing endgrain
L to useeitherjig,hooktheliponthe
I
edgeof a worksurface. Setyourwork- I
pieceonthetop,buttingtheedgeagainst
thestopblocksothatit extends overthe I
edgeof thetop byabout%oinch.With
themitered shooting board, position the
workpiece against theappropriate sideof
I
thestopblock.(Fora longworkpiece, it I
maybenecessary to placea support board
undertheopposite endto keepthework- I
piecelevel.) Seta plane on itssideat one
e n do f t h ej i g a n db u t tt h es o l ea g a i n s t I
theedgeof thetop.Holding theworkpiece
firmly, guidetheplanealong thejigfrom I
oneendto theother(rghf).
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t34 I
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I SHOPAIDS
I
t A cleanmetalcanwith wire strung
I acrossthemouthoffersa neatand sim-
ple way to controltheJlowof stainor
I varnishfrom a brush.Punchholesin
oppositesidesof thecan neartherim,
I stringa wire betweentheholesandpour
theliquid into thecontainer.After dip-
I ping thebrush,draw the bristlesacross
thewire to wipeoff any excessliquid.
I
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t
I
HANDLES
STACKING ANDDRYING
SUPPORTS
I
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I Stacking
Finishing
shelves to dry
a shelfonesideat a timedou-
I blesthetimeneeded forthistask.Using
t h es i m p l es t a c k i nhga n d l essh o w na t
t l e f t ,y o uc a nf i n i s hb o t hs i d e sa t o n c e .
Cutthehandles fromsolidwoodstockand
I m i l la t o n g u ei n o n ef a c eo f e a c ho n e .
M a k et h eh a n d l east l e a s% t i n c hw i d e r
I thanthethickness
finishing
of thestockyouare
D.r i v se m a lnl a i l sl o n g et h
r an
I thehandles'
gentlypress
thickness
the protruding
through themand
pointsinto
I theendsof theworkpiece before finish-

r^gwn
re
ingit. Usethehandles to turntheboard
I asyouapplyf inish;whenyouaredone,
theboards canbestacked, allowing airto
I circulate
finishing
freely
a larger
asthef inishdries.
pieceof furniture,
When
setthe
\L---l (inset).
I \Y;--r pieceon a setof dryingsupporls
These2-inch-souare woodblocks have
I s m a lnl a i l sd r i v e tnh r o u gthh e i rc e n t e r s
to support a workpiece at itscorners.
I
I 135
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SHOPAIDS
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t
I
A SPRAYING
TURNTABLE
I
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I
1 Building theturntable I
I Consisting of a baseandtopcutfrom
%-inch
ingfastened
plywood witha "lazySusan"
in between, theturntable
bear- lllllllllllfillllllllllultllllllltlll llllilltllilllllilIllltlillll][t I
shownabove allows a pieceof furniture
5HO?Tt? t
to berotated asit is beingsprayed with
a f i n i s hC. u tt h eb a s ea n dt o ps l i g h t l y Lubricatingtoole I
larger thanthebaseof thepieceof fur- LighNly oilinqa handsaw
n i t u r teo b ef i n i s h e d
C.u ta h o l ei n t h e bladeor a planeeole I
centerof thebaseto allowaccess to the beforeeNorinqiNkeepe
screwholesforattaching theupperbear- the Loolcleanand pre-
venberueN.Tooilyour
I
ingto thetoponcethelowerbearing is
secured
er bearing
to thebase.Firstattachthelow-
to thebasewithscrews. To
toolo neatly,ueea lubri-
calinq pad madefrom a
r
lonqoLripof burlaV,Liqht-
fastenthejig top,setthebaseontopof
lv rolledand oackedin a i I
it withthebearing sandwiched between v l

smallcan as shownhere.
t h et w op i e c e as n df l i p t h e mu p s i d e MakeeureNheeLriVie '.- I
d o w nW . i t ht h ee d g e os f t h ep i e c e s wide enoughto exbendpael
flush,rotate thebearing sotheremaining the loo of the can.)oaklhe maNerial
in Ihin I
screw holes areexoosed. thenscrew the machine oil,andwipeyourplaneooleeand
upperbearing to thetop (above, right). handsawbladesoverit beloreeNorinqthe
toolo.Tiqhtly
I
coverlhecanwhennoNinuee.
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r36 I
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I SHOPAIDS
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t
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r) usingtheturntable
I C- ltlahe foursmalldryingsupports
I BENCH
DOGLAMPSUPPORT (page135).Setthe workpiece on the
tipsof thenails, rotate
thenslowly the
I turntablewithonehandwhileoperating
a spraygunwiththeother(above).
I
I
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I
I
I A movable lightfora workbench
A desklampattached to a benchdogas
I shown at leftwillenable youto position
thelightat anyof thedogholesalongthe
I b e n c hT. o m a k et h ej i g , b o r ea h o l e
t h es a m ed i a m e t earst h es h a f o t fthe
I l a m oi n t ot h eh e a do f a w o o d ebne n c h
dog(page92).
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I t37
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SHOPAIDS
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A VACUUM RAMP
SCREENING
I
I
t
S S S 6 S I
S S S Top
S S I
^ A.
S S
S S,OOS I
S S \ t
S S
S t
\ S S S = I
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I
Collecting
Forcleaning
shopdust
dustofftheshopfloor,build
I
a wedge-shaped
plywood andhardboard
screening rampfrom
(above). Before
ljltllltlllllIllllllltlllllltllltllllllltl]llllljllllultlluilllllll I
assembling thepieces,
backto fit a dustcollection
cuta holein the
hose,and 9HO7Tt? I
borefiverowsof 1%-inch-diameter
through thetop.Whendustandwood
holes A drawer-elidepoeitioningjig I
Tohelpyou correcLly pooilioncommercialelideeon drawereidee,
chipsaresweptupontotheramp,small-
e rp a r t i c l ewsi l lf a l lt h r o u gthh eh o l e s
uoelhe jiq shownhere.CuLa rabbet,in a ecrapboard;make t
Lhedepthofthe rabbelequaltolhe deeireddielance
a n dc o n t i n uoen t o t h ed u s tc o l l e c t o r . beLween the slide and the botlom of Nhedrawer
'I:!:,1::"n"^--' ,-----.-. I
L a r g edre b r i w
foreasydisposal.
s i l lr e m a i o n nt h er a m p
3:i;^':^izl"J"jil;Pii"If
lf - - --
j,.s:fu I
onthedrawer
sia",iili tii '{
--' o41l*
bottomedqeof thehara- --' -# . -,i'5 ,. )
warebuIIed a4ainot I
I h e j i q .H o l d i n q N h e
s l i d ea n d L h ej i q I
in place,markthe
ecrewholee,bore I
pilot holee,and
ecrewthe elide I
to lhe drawer.
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I SHOPAIDS
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A STEAM-BENDING
JIG
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I Steam-bendinga workpiece
I Tosteam-bend smallworkpieces, such

I
filtrlllllltllltfinfiltllllfiltfillfilllllllllllll llllllllllllllll
lll1 asstripsof molding,
steamer shown
buildtheportable
above. Cuta lengthof
ABSpipelonger thanthewoodyouwish
t 1HO?Tt? to bendandaboutthesamediameter
Ahoning jig asthespoutof anelectric kitchenkettle;
I TheoimVle 1igehownherewillenableyou Nooharpenplane
usea kettlewitha roundspout.Connect
oneendof thepipeto thespout,mak-
bladeewiNhoulthe aid of a commercial honing6uide.)lip a
I 4 - inch1 onq, 3/ s- inch-diameter car ria4e bolt throuqh th e inga tightsealwithducttape.Support
blade'eeloN.Faetenwaehersand wingnulo on both sidesot theotherendof thepipeat a slightangle
I Nheblade.Wil'h lhe cuLtinqedqeon lhe oharpeninq
and Nheheadof lhe bolt on your worksurface,ueea
etone ona notched pieceof plywood clamped
-..-/'\, in a benchvise.Tousethejig,bringthe
I ?rotractor and a olidingbevelIo adjuoLthe winq waterto a boil,inserttheworkpiece to
nuNeeo Nhatthe bladecan be slidalonalhe besteamed (above),andstuffa raginto
oione allhe properan4le,typically 3O". ,,t-.Yat
I theopenendof thepipeto contain
steam. Lettheworkoiece
the
"cook"until

I thewoodsoftens;
per
asa roughguide,allow
t hour inchof thickness. Refillthe
I kettleasnecessary,
thetubetemporarily
pluggingtheendof
to containthesteam.
I
I
I
I 139
I

A-B-C
Auxiliaryfencs A wooden attach-
ment to the rip fenceof a table saw
or other machine,for the purpose
of avoiding accidentaldamageto
the metal fence.
Bench dog: A round or squarepeg
made of metal or wood that fits
into a hole in a workbench to hold
a workpiece in place.
Bench stop: A jig fastenedto a work
surfaceto steadya workpiece.
Bevel cut A cut made at an angle
from faceto facethrough the thick-
nessof a workpiece.
Biscuit joiner: A portable power
tool usedfor cutting slotsfor wood-
en wafersin biscuit joinery. Also
known asa platejoiner.
Biscuit jointz Seeplatejoint.
Box joint A corner joint featuring
straight, interlocking fingers.
Carcasq The box-like body of a
pieceof furniture.
Chamfer: A bevelcut along the
edgeof a workpiece.
Chuck Adjustable jaws of a drill that
hold bits and other accessories.
Clampingcapacity: The widest span
of a clamp'sjaws.
Clearancehole: A hole bored in
a workpieceto accommodatethe
shank of a screw.
Collet The sleeveof a router that
holds the bit shank.
I
I
GLOSSARY I
I
Countersink: To drill a hole that Frame-and-panel joinery: A method
allowsa screwheadto lie flush with of assemblingboardsinto rectangu- I
or slightly below the surface. lar frames;groovesalongthe inside
Cove:A concavedecorativeprofile
edgesof the frame enclosea panel. I
cut in wood, usuallyalong an edge. Furring strip: A thin board that is
nailed to a wall or ceiling to provide
I
Crosscut A cut made acrossthe a flat or level surface;normally used
grain of a workpiece. for securingdrywall or paneling.
I
D.E-F-G.H-I Groove A cut along the grain of a I
Dado: A rectangularchannelcut workpiece,forming a channel;fre-
acrossthe grain of a workpiece. quently decorative,but sometimes I
part of a joint.
Doweft Wood pin usedto reinforce I
certaintypesof joints. HeadstoclcThe spindle attachedto
the motor of a lathe;holds work for I
Edge-gluing:Bonding boardstogeth- spindle-turning in conjunction with
er edge-to-edgeto form a panel. the tail stock,or usedalonefor turn- I
ing with a faceplate.Seetailstock.
Extensiontable: An accessorywork
surfaceusedto expandthe working
I
l-K-L-M-N-O-P-Q
areaof a stationarymachine. fig: Devicefor guiding a tool or
holding a workpiecein position.
I
Face-gluing:Similar to edge-gluing,
exceptthat boardsarebonded fointing: Cutting thin shavings
I
face-to-face. from the surfaceof a workpiece
until it is flat and perpendicularto I
Faceplateturning: Turning circular the adjoining surface.
or cylindrical workpiecessuchas I
bowls on the faceplateof a lathe. Joist A horizontal support for a floor;
analogousto the raftersof a roof. I
Featherboard:A board with thin
"feathers"
fingersor along one Kerf: The cut madeby a sawblade. I
end, clampedto the fenceor table
of a stationarytool to hold a work-
piecesecurely.
Kickback The tendenry of a work-
pieceto be thrown back toward the
I
Fence:An adjustableguide to keep
operatorof a machineor tool. I
the edgeof a workpiecea setdistance Lap joint A joint in which match-
from the cutting edgeof a tool. ing dadoesor rabbetsoverlapto
I
connecttwo boards.
Fixture Shop-madedeviceattached I
to a stationary or portable power tool Miter cufi A cut that anglesacross
to increaseits capacityor efficiency. the faceof a workpiece. t
I
T
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I
140
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t
t
I Miter gauge A devicethat slidesin
a slot on the sawtable,providing
I support for the stockasit moves
pastthe blade for crosscuts;its angle
I can be adjustedfor miter cuts.
I Mortise: A rectangular,round,
or oval hole cut to accommodate
I a tenon.
I Mortise-and-tenon joint A joinery
techniquein which a projecting
I tenon on one board fits into a cavi-
ty-the mortise-in another.
I Pilot bearing: A cylindrical metal
I collar aboveor below the cutting
edgethat guidesa router bit along
the workpieceor a template.
I the centralportion is raised.
Pilot hole: A hole bored into a work-
t pieceto accommodatea nail shaft
or the threadedpart of a screw;usu-
I ally slightly smallerthan the shaft
or threadedsectionof the screw.
I The hole guidesthe fastenerand
preventssplitting.
I ducedwhen a bladeor cutter tears
Platejoint A method ofjoining
I wood in which oval wafersof com-
pressedwood fit into slotscut in
I mating boards.
t Pockethole: An angledclearance
hole that allowsa screwheadto be
recessedbelow the surface;often
I usedwhen joining rails to a tabletop.
I Push block or stick: A deviceused
to feeda workpieceinto the blade,
I cutter, or bit of a tool to protect the
operator'sfingers.
I workpiece,the result of improper
I
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I
I L4T
I
Quill stroke The length of travel of
the quiil of a drill press.
R-S
Rabbet A step-likecut in the edge
or end of a board; usuallyforms part
of a joint.
Radius:The distancefrom the center
of a circleto its outsideedge;one-
half the diameter.
Rait The horizontal member of a
frame-and-panelassembly.Seestile.
Raisedpanet A pieceof wood that
forms the centerof a frame-and-
panel assembly.Bevelingthe edges
of the panel createsthe illusion that
Releasecut A preliminary incision
from the edgeof a workpiece to
a line about to be cut; enablesa
band sawor sabersawto cut tighter
curvesby facilitating the removal
of wastewood.
Rip cufi A cut that follows the grain
of a workpiece-usually made along
its length.
Shooting board: A jig for holding
the end grain of a workpiecesquare
to the soleof a plane.
Sizing board: A jig usedto cut work-
piecesto length, typically with a
handsaw.
Snipe A concavecut createdby a
jointer or planer at the end of a
pressureor table height.
Spindle: The threadedarbor on a
lathe that holds the headstockor
faceplate;alsothe threadedarbor
on a drill pressor shaperthat holds
cutters,bits, and other accessories.
Spindle turning: Turning cylindri-
cal workpiecesheld betweenthe
headstockand tailstockof a lathe.
Square:Adjoining surfacesthat
meet at an angleof 90o.
Stilq The vertical member of a
fr ame-and-panelassembly.Seerail.
T-U-V-W-X-Y-Z
Tirilstock The adjustablespindle on
a lathe; usedin conjunction with the
headstockto hold work for spindle
turning. Seeheadstock.
Thpercut An angledcut along the
length of a workpiecethat reduces
its width or thicknessat one end.
Tearout The raggededgespro-
the wood fibers rather than cutting
them cleanly.
Template A pattern, typically made
of plywood or hardboard,usedwith
a power tool to produce multiple
copiesof an original.
Tenon:A protrusion
from the end ofa board: cut to fit
into a mortise.
Wall stud: A vertical framing mem-
ber forming wallsand supporting
the framework of a building.
 I
I
INDEX
I
I
Pagereferencesin irallcsindicate D-E.F G-H-r-J-K
an illustration of subject matter. Dadoes:
Routers
Glue racks, 80, 8l
Wall-mounted, 80,85 I
A-B-C adjustabledadoingjigs, 15, I9 Har dw are, fr ont endpaper
Band saws:
Circle-cutting jigs, j7, 44-45
jigs for evenly spaceddadoes,J3, I7
quick-setup dadoing jigs, .15,l8
Hinge mortises:
Router jrgs, 14,22
I
Extension tables,102, 104, 110
Miter jigs, j8,47
T-squarejigs,15, 16
T-squarerouting guides(ShopTip), 16
Jigs:
Planning,l0 I
Taper jigs, j8,47 De Cristoforo,R.J.,6-7 Seealso namesof specifictools
Wedge-making jigs, 38, 46
Bar clamos:
Dovetail joints:
Sliding dovetail router jigs, 14,26
Joinery:
Routers
I
Crossbirs for edge gldng, 80,82 Dowels: box joints, 12
Glue racks, 8O 8l Inserting dowels with a depth gauge corner half-lap jointjigs, 14,27 I
wall-mounted, 80,85 (ShopTip), 62 sliding dovetail roter jigs, 14, 26
Storage
mobile storageracks,ll6, 118-119
Drawers:
Drawer-slidepositioningjigs
Table saws
tenoningjigs, 39, 57-59
I
storing clamps in a can (Shop (ShopTip), 138 SeealsoDadoes;Mortises; Plate joiners
Tip),119 Drill oresses: Jointers: t
Beeken,Bruce, 10-11 Cuiting rosetteson the drill press V-block jigs for chamfers, 124, 132
Belt sanders.SeeSanders
Benchdogs,79,91-92
(ShopTip), 67
Deep hole-drilling jigs, 67
Jointing:
Routers, 2l
I
Lamp supports,123,137 Depth guides (Shop Tip), 65
Bench grinders: Extensiontables,104, 111 L-M-N-O I
Gouge-sharpeningjigs, 69, 72 |ig for drilling equally spacedholes, Lathes:
Benchslaves,104,112
Biscuit joints. SeePlate joiners
60,61,64
Making wooden plugs (Shop Tip), 64
Center-finding jigs, 69, 71
Column fluters, 70, 75- 76
I
Boxjoints, 12 Pocket hole jigs, 61, 66 Faceplate-centering jrgs,69, 71
Carcases: Sandingdrums (ShopTip),97 Gauges I
Carcase-squaringblocks, 79, 89 Tables bowl depth gatges,70, 77
Chiselracks,ll5
Circles:
auxiliary sanding tables,95, 98
tilting tablejigs, 61,63
diameter gauges,69,73
Gouge-sharpening jrgs,69, 72
I
Centerfinders, 124,132 V-block jigs, 61,6s Sandingdrums,70,77
Circle-cuttingjigs
band saws,37,44-45
Drills. SeeDrill presses;Electric drills Spindleturning I
Drum sanders: centering a spindle blank
rotters, 15,20
sabersaws,37,43
Drill presses(ShopTip), 97
Lathes,70,77
(ShopTip), 70
faster turning with preset calipers
I
shapers,15,31 Electric drills: (ShopTip), 73
Circle-sanding jigs, 95, 96-97
Faceplate-centeringjigs for lathes,69, 71
Center-drilling jigs, 61, 62 layott jigs, 69, 73 I
Depth guides(ShopTip), 65 Preservlngsquarecorners
Scribing jigs
compassjigs, 124,133
Removablepower tool tables,104,
108-109
(ShopTip), 74
Tailstocks for hollowed-out work,
I
router compassjigs, 15,20 Extension stands: 68,70,74
trammel points, 124, 133
Circular saws:
Yises,104,112 Lumber: I
Extension tables, 103 Sizes,backendpaper
Bladestoragebox, 115,117
Kerfsplitters,38, 42
Band saws,102,104, 110
Drill presses,104, 111
Storageracks,ll6, 120,121
Truing uneven boards, 39, 53
I
Miter and crosscutguide,37,41 Routers attachedto saw tables Mortises:
Straightedgegtides, 38,42
Clamps,79
(ShopTip), 107 Routers I
SeealsoTables adjustablemortising jigs, i4, 28
Framing clamps,78, 80,87
figs for clamping thin stock, 8O 84
Fasteners,/ron t endpaper
Featherboards, I 5, 32, 12i, 125-126
hinge-mortisin g jrgs, 14, 22
movable-jaw mortising jigs, .14,29 t
Miter clamping blocks, 79, 88 Beveled,123,127
Rope clamps for carving (Shop Tip), 88
Storageracks,114,116,118-119
Extended shaperfeatherboards, 15,32
Shimmed,123,127
P-Q-R
Panels,raised:
I
Wedged clamping bars, 8Q 83
SeealsoBarclamps; Pipe clamps; Vises
Vacuum jigs, 34
Finishes:
Routerjigs,8-9,14,24
Table sawjigs, 3t 52 t
Curved cuts: Controlling finish on brushes, J35 Parsons,Jeff,l0- I 1
Routers
corner-rounding jigs, 14, 2j
Drying supports,124, 135
Sprayingturntables, 122, 124, 136-137
Pipe clamps:
Crossbarsfor edge gluing,80,82
I
Sanding,98 Stackinghandles, 124, 135 Extenders,80, 86
Seealso Circles Fuller,Ted,8-9 doubling up pipe clamps I
(ShopTip), 86
I
I
r42 I
T
I
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I
I Storage S-T-U Routers
mobile storageracks,118-119 Sabersaws: attachedto saw tables
I storing clamps in a can Circle-cutting jigs, 37, 43 (ShopTip), 107
(ShopTip), lJ9 Edge guides removable power tool tables, I04,
I wall racks, 1.16
Planes:
miter and crosscut gtide, 37,41
Removablepower tool tables,
108-109
table/cabinets,103, 106-107
Clamping long workpieces, 128 104. 108-109 Sabersaws
I Honing jigs (ShopTip), 139 Safetydevices, 13,32, 33, 123, 125-127 removable tables,104, 108-109
Planing jigs for thin stock, 124, lj1 Sanders: Table saws
I Running guides for short stock, J30
Shootingboards,124,134
Circle-sanding jigs, 95,9G97
Gang sanding, 96
routers attached, (Shop Tip), 107
shop-made inserts (Shop Tip), a9
Plate joiners: Sanding: Seea/soWorkbenches
I Stands,103,105 Blocks. 94 Table saws:
Plywood: contoured, 95,100-101 Blade height gauges,8, 49
I Carriers,123,130
Storageracks, 116,120
wood sanding blocks (Shop Tip), 100
Drill oresses
Bladestoragebox, 115,117
Board-straighteningjigs, 39, 53
Push blocks, 123, 125 auxiliary sanding tables,95 98 Cove-cutting jigs, j9, 56
I Push sticks,123, 125,126 sanding drums (Shop Tip), 97 Crosscutjigs, 36, 38, 50-51
Radial arm saws: Folding sandpaper(Shop Tip), l0l Crosscuttingwide panels (Shop Tip), 53
t Auxiliary fence and table molding
fixtve,39,54
Lathe sanding drums, 70, 77
Radial arm saws
Miter gauges
angle-settingjigs (Shop Tip), 59
Sanding jigs, 95, 99 sandingjigs, 95, 99 extensions(Shop Tip), 55
I Taper jigs,48 Thin stock, 99 Miter jigs, 39, 50
Roller stands, 103 SeealsoSanders Raisedpanel jigs, 39, 52
t Adiustable,104,113
Temporary (Shop Tip), 113
Sandpaper:
Folding sandpaper(ShopTip), I0I
Routers attachedto saw tables
(ShopTip), 107
Rosettes: Sawhorses,124, 128-129 Shop-madetableinserts(Shop Tip), 49
I Cutting rosetteson the drill press
(Shop Tip), 67
Padding sawhorses(Shop Tip), 129 Switches
auxiliary switches,123, 131
Saws:
t Routers:
Adjustableedgeguides,15,25
Back saws
sizing boards for crosscuts,3Z 40
Tables
routers attachedto saw tables
Auxiliary sub-bases(Shop Tip), 13,21 Handsawholders, 116,117 (ShopTip), ]07
I Bit storagerack, I 15
Circles
SeealsoBand saws;Circular saws; shop-made inserts (Shop Tifl, a9
Taper jigs,48
Radial arm saws;Saber
adjustable circle-cutting jigs, 15,20 Tenoning jigs, 39,57, 58-59
I compassjigs, 15,20
saws:Table saws
Shapers: SeealsoFeatherboards:Push sticks
Column flrters, 70, 75-76 Circle-cutting jigs, 15,31 Templates:
t Corner-rounding jigs, 14, 23
Dadoes
Featherboards,15,32
Guards,13,33
Vacuum templates,35
Tools, backendpaper
Lubricatingtools (ShopTip), 136
t adjustabledadoingjigs, 15, l9
jigs for evenly spaceddadoes, 13,17
Shop Tips:
Clamps, 86, 88,92, 119 Storage,I 15
quick-setupdadoingjigs, 15, l8 Drilling, 62,64,65,67 chiselracks,ll5
I _
T-squarejigs,15,16
Jolnery
Lathes,70,73,74 handsawholders, 716,117
tool trays, l.l5
Planes,139
box joints, 12 Seealso Clamps;Drill presses;Electric
I corner halfJap jointjigs, 14,27
Routers,16,2l
Sanding,97,100,101 drills; Jointers; Lathes;Planes;Plate
sliding dovetail jigs, 14,26 Sawhorses,129 joiners; Routers; Sanders;Saws;
I Mortises
adjustablemortising jigs, 14,28
Tablesand stands,107, 113
Table saws,49, 53, 55,59
Shapers
Turning tools:
hinge-mortising jigs, U, 22 Gouge-sharpening jigs, 69, 72
t movable-jawmortising jigs, 14,29
Tools. i36
Square:
Panel-raisingjigs,8-9, 14,24 Checking,backendpaper V-W-X-Y-Z
I Tables
removable power tool tables, 104
Tables,103
Band saws
Vacuum jigs, 34-35
Vacuum screeningramps, 124, 137
108-109 Vises:
t table/cabinets,10i, 106-107
extension tables,102, 104, 110
Drill presses Extension stands,104, 112
tablesattached to the table saw auxiliary sanding tables,95, 98 Wood-carver's vises,8O 9J
I (ShopTip), r07
Vacuum templates,35
extension tables,104, 111
ti-lting table jigs, 67, 63
Wood. SeeLumber; Plywood
Workbenches:
Bench stops, 29, 90
t V-block jigs, 61,65
Electric drills Gripping thin stock (Shop Tip),92
Lamp supports, 123, 137
removable tables, 104, 108-109
I Plateioiner stands,103,105 SeealsoBenchdogs;Tables

t
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I
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ACKNOWLEDGMENTS
I
Theeditorswishto thank thefollowing I
ROUTING AND SHAPING IIGS
AdjustableClampCo.,Chicago,IL; AmericanTool Cos.,Lincoln,NE; Black& Decker/EluPowerTools,Towson,MD;
I
DeltaInternationalMachinery/Porter-Cable,
Guelph,Ont.; De-Sta-Co, Troy, Ml/WainbeeLtd.,Montreal,Que.;
FreudWestmoreTools,Ltd.,Mississauga, Ont.; LeeValleyToolsLtd.,Ottawa,Ont.; I
Sears,Roebuckand Co.,Chicago,IL; Shopsmith,Inc.,Montreal,Que.;PatrickSpielman(jig on pp. 34-35),
FishCreek,WI; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY I
CUTTINGJIGS
AdjustableClampCo.,Chicago,IL; DeltaInternationalMachinery/Porter-Cable, Guelph,Ont.; De-Sta-Co, I
Troy, Ml/WainbeeLtd.,Montreal,Que.;FisherHill Products,Inc.,Fitzwilliam,NH; FreudWestmoreTools,Ltd.,
Ont.; HitachiPowerToolsU.S.A.Ltd.,Norcross,GA; FrankKlausz(jig on pp. 58-59),
Mississauga,
Frank'sCabinetShop,Inc.,Pluckemin,NJ; SandvikSawsand ToolsCo.,Scranton,PA;
I
DaveSawyerand JoanSawyer(jig on p. 46), SouthWoodbury,VT and RanchoSantaFe,CA;
Sears,Roebuckand Co.,Chicago,IL; Shopsmith,Inc.,Montreal,Que.;Skil PowerToolsCanada,
Markham,Ont.;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
I
DRILLINGIIGS I
AdjustableClampCo.,Chicago,IL; DeltaInternationalMachinery/Porter-Cable,
Guelph,Ont.; Sears,
Roebuckand Co.,Chicago,IL; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY I
TURNINGIIGS
AdjustableClampCo.,Chicago,IL; DeltaInternationalMachinery/Porter-Cable,
Guelph,Ont.; I
LeeValleyToolsLtd.,Ottawa,Ont.;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
t
(jigonp.8s),H".:1,,X:)glil?,rc"t#t:tJS,Iirc,sr,,r.*t'u
BiltBivona collins(jigonp.84),
LostMountainEditions,Ltd.,Sequim,WA; LeeValleyToolsLtd.,Ottawa,Ont. t
SANDINGIIGS
AmericanTool Cos.,Lincoln,NE; Black& Decker/EluPowerTools,Towson,MD; DeltaInternational I
Machinery/Porter-Cable,
Guelph,Ont.;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY

TOOL EXTENSIONSAND TABLES

I
AdjustableClampCo.,Chicago,IL; AmericanTool Cos.,Lincoln,NE; DeltaInternationalMachinery/Porter-Cable,
Guelph,Ont.; Hitachi PowerToolsU.S.A.Ltd.,Norcross,GA; LeeValleyToolsLtd.,Ottawa,Ont.; Steiner-Lamello
A.G. I
Switzerland/ColonialSawCo.,Kingston,MA; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY

STORAGEDEVICES
I
AdjustableClampCo.,Chicago,IL; AmericanTool Cos.,Lincoln,NE; GreatNeckSawMfrs. Inc.
(BuckBros.Division),Millbury, MA; LeonardLee(rackon p. l2l), LeeValleyToolsLtd., Ottawa,Ont.; SandvikSaws I
and ToolsCo.,Scranton,PA;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY

SHOPAIDS
I
AdjustableClampCo.,Chicago,IL; CampbellHausfeld,Harrison,OH; DeltaInternationalMachinery/Porter-Cable,
Guelph,Ont.; Hitachi PowerToolsU.S.A.Ltd.,Norcross,GA; TaylorDesignGroup,Inc.,Dallas,TX;
VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
I
Thefollowingpersonsalsoassisted
in thepreparationof this book:
I
LorraineDor6,R€jeanGarand(Atelierd'Eb6nisterie
R6jeanGarandEnr.,St-Rdmi,Que.),GraphorConsultation, I
ClaudeMartel,GeneviiveMonette,Alain Morcel (LesR6alisations
Loeven-Morcel,
Montreal,Que.)
I
PICTURECREDITS I
Cover RobertChartier
6,7 RobertHolmes I
8,9 MichaelMorissette
10,ll Ron Levine I
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WORKSHO
GPU I D E
INVENTORY
OFMEASURING
TOOLS
ANDDEVICES
Utility knife Combination 6quare
tharpenedLipacoree For checkin4or markinq 45' or For checktn7or
lineaon woodmore 90" an4lea;detachable blade meaeunn690'
preciseiy _-<--b doublee ae ruler or an4lee on a flat

izi:f67 surface; can aleo be

ueed ae a ol,ratqhLedqe

Uaeful for eetLtnq etraiqhtedqe, one pointt eervea aa

an4leeof machtne the pivot and the other acilbee a
circle or an.arc around it.

9traightedge
For precieion markin1 of etrai4hL ltneeand checkinqflat 9liding bevel
Adjuet e to copy any an7le, French curue
eurfacea. Thick metal ed4ee are machtnedetrai4ht;
then 1;otranefer or mea7ure For drawing curved
i[. 7lade al;oree tn handle linea on a workptece

I TIPS()NWORKING
WITH C H E C K I NAGS O U A R E
PTYWOODANDSHEET
MATERIATS
t . Whenusingplylvood, layouttheelements
Deforeuornqa cquare,makeeure iL ia accurate. Workinqon a large
sheet of paper,draw a baaelineueinqa eLraiqhLedqe. (For a combi-
of yourprojectonthe sheetfor economy
and natton or t ry zquare,uee the perfecLlyetratqht edqeof a board ae
I bestappearance of grainpattern. the baeelrne.)Flace Lhe equare wtth one arm flueh wit;hLhe ltne,and
o Tocutsheetmaterials,usecarbide{ipped draw anoLherlinealonqthe outetdeof Lheother arm. Fltpl;heaquare
t bladeswithat least10 teethperinch. over,keepinqLhe eame arm flueh on the baeeltneand repeal;,Thbtwo
lineeyoujuet. drew ehouldbe per-fecLlyparallel.To true a carpenlter'e
oAlways cut plywood
withthegoodface equareugea cenlierpunchta tap Lhe
I up to avoidtearout. gquare on iLa outeide corner Lo
r Whenfastening move the arme cloeer toqether,
I usescrews
edgesof sheetmaterials,
that areno largerin diameter or on iLe inoide corner to move
thanone-quarter of the sheet'sth ickness, the arme aparL.TeaLa4ain,
I Drillpilotholesto preventsplitting. and repeat until the arme
are perfecLlyequare.
. Storesheetmaterials
flat or wellsuooorted
t vertically:
do notstorethemat an angle.

t
NOMINAL
ANDACTUAL
SIZES
OFSOLID
WOOD
t STANDARD
THICKNESS N()MINAL
ANDACTUAL
SIZES
FORSURFACED
HARDWOOD FORSOFTW()OD
LUMBER
I
NOMINAL ACTUAL N()MINAL ACTUAL NOMINAL
I (rough) (surfaced
twosides) (INCHES) (rNcHES) 0NcHES)
ACTUAL
flNCHES)
3/rc"
I %'
t/z'
Surfaced
dry Surfaced
dry
5/rc" I-by-2 3h-by-7t/z Z-by-2 It/z-by-Ir/z
I u/"' 7Aa" 1-by-3 3h-by-2r/z 2-by-4 It/z-by-3r/z
'/o' a' / / t
3h-by-3r/z
1-by-4
t I
16

3/4t or l3/rctl
1-by-6 3h-by-5r/z
2-by-6
Z-by-8
Ir/z-by-5r/z
It/z-by-7rh
I LYqu Ir/rc" 1-by-8 3h-by-7rh 2-by-I O It/z-by-9rh
IYr" 1 q /
r"/ t6
n
1-by-10 3/q-by-9r/a 2-by-12 I\/z-bY-IIrh
I 2u IVz"or I3/+" I-by-12 3h-by-l|rh 4-by-4 3r/z-by-3t/z
I
I