5Oiiase a rh =="5 Ose moe JIGS & FIXTURESread this important safety notice ‘To present accidents, keep safety in mind while you ‘work: Use the safety guards installed on power equip. ‘ment they are for your protection, When working on power equipment, keep Fingers away from sa blades, wear saety goggles to prevent injuries from flying wood chips and sawdust, wear headphones t protect your ‘hearing and consider installing a dust vacuum to reduce ‘the amount of airborne saydust in your Woodshop. Don't ‘wear loose clothing, such as neckties or shirts with loose sleeves, orjewelry, such as rings, necklaces or bracelet, ‘when working on power equipment, Tic back long hair to prevent it from getting caught in your equipment. People who are sensitive to certain chemicals should chock the chemical content oFany product before using it The authors and editors who compiled this hook have tuied to make the contents as accurate and correct ae possible. Plans, illustrations, photographs and text have been careflly checked. All instructions, plans and proj ‘cis should be carefully rea, studied and understood before begining construction, Duet the variability of local conditions, construction materials, skill level, etc. neither the author nor Popular Woodworking Books assumes any responsbily for any accidents, injuries, damages or oler loses incurred resulting ftom the material presented inthis book, Prices listed for supplies and equipment were current atthe time of publication and are subject to change. Glass shelving should ave all ‘edges polished and must be tempered, Untempeted lass shelses may shatter and can case serious bodily ijuy ‘Tempered shelves are very strong and ifthey break will just crumble, minimizing personal injury ‘metric conversion chart fo convert to multiply by Andie ssoesseeseees Cerner as emimeersseeseee ses Inches a Feat Centimeter. wns, Genie -ssesssres sees Fettesscee 005 Yard sevsoreeeereee ees MAREE 09 Mert Yan. u Danny Prous So Shop-Mage ig & Fotues Cony © 208 by Danny Pros ante and bound in Singapore. Ah aed No pr ofthis aye reproducdin any form ory ry electrons or mechani moans nln noma {Sr aerage debit ptm witht persion in wrt om the phen ‘esp by seo, who may te be umes vie Pushed Popa “Wootnaring Books an impr of 4 Puen Ine, 470 at Galva Rod ‘Gc, Obi, 4536 Ft etn stb Cara by Frater Dist 10 Armszeng vam CGergetmn Orta L7G 5S! Coma siti the UK apd Eup by Dal & Charles rane Home ‘Newton Al Deven TQ12 PU Enghnd "ol (4) 626325200 a (14) 105 325819 Emel devidanehrls cok ‘iit Ausealaby Cpscre nk PO tow 708 Wine, NSW 2756 Avan “aout Wh te mwpeplarwoodwekng com Sr nianaton on ee ea = forwooduoers Fs foe ogee Wonicetang Boats rete ee ome al ecboem a fete pte wo mm w% saad [abeay of Cngress Catalin Pubcon Data Pron Danny, 1987 ‘Dany Pou 0 shop me ig fists Danny Pro. st 7 a echoes ISBNIE 9781559707528 fp: alk. pope) ISDN3. 741554709362 (PUD) ISBN10- 1559707522 (hk alk pups) 1SBN18-973.155870 7556 pardons lk pe ISBNI0: 1559707859 hardcor:a pper) 1. Woodworking wols-Desn and corstrucion. 2 Woodork-Fqupren and supple Dos and constuction, 3. sand atres- Desh and concescton [CTs shop mde fie 8 ten IL Tiel chp made ie and res. Tite ‘Tras 206 No na ios AcqUisttoxs xbox: Jin Suck tron Amy Hasery besten ran Roth INHRIOR LAYOUT: on: Debs PropurtoN cooRDINsTOR: rife L Wager ‘moroctar ik bury Paul otocRAFic CONSULTANT: Mehul Bowie, an Photograph Sees ‘CoM en ilsTaATOR: Ln Charl ona Communes Li {oHKSHOP ITF PRONIDND EY: Relbw Cabinetsabout the authors ‘On November 26, 2004, Danny Proulx passed way suddenly while setting up forthe Ottawa, ‘Wood Show. His death wil leave avery large -boe in the woodworking commu: nity, For over 18 years, Danny ‘shared ith us his passion for woodworking through hi Books, magazine ailes and Web site advice, as well as through teaching and ‘mentoring his students and clients. He founded Rideau Cabinets in 1989 and stared building kitchens and specialty cabinets, Overtime, Danny married his lore of woodworking and writing with his photo. graphic skis and wrote 15 books over the lst 9 years. He seo wrote for several magazines including Canadian Woodworking and Cabinet Maker Magazine. He stated giving seminars in bis home to new woodworkers and eventually started teaching courses at Algonquin College in Onawa, Luc Rousseau, who was Danny's student and later assistant, courageously took up the challenge and agreed to complete Danny's book: Luc talented woodworker in his own right, s ow the owner of Rideau Cabinets re teaches woodworking and eabinetnaking. ‘courses at Algonquin College. The college was fortunate when Luc took on Danny's courses ‘while continuing to teach his own students. Contact Luc at Iue@eabinetmaking com or through his Web site: ww-eabinetmakingcom Jim Stack has worked in commercial ‘abit and farniture-making shops for 16 years and ran his own furiture-making shop for 5¥a oars (bat halla year is very memo rable, 80's Important wo include it). For the past six years he's been the Acquisitions Editor for Popular Woodworking books, Jim isthe author of Northwoods Furniture, The Biscuit Joiner Project Bok, Design Your Qun Furniture, Building the Perfect Tool Chest and Cutting Edge ower Tips «Tricks Over the lst and email and al sce nny ee Banya ed hance his valuable advice to his numer oe ea to thank tose who woe ome shanay chan ‘Ties and sending me pictures of their Projects, " "dot now what wen ne dane ag Lc ep diving ths it ie He te i Soak ht mason ond writen cher Danny. Stings projec par ay hough aro cay but Luc wae inch han st? Da 9k Caters we may yas wa am skint, moned end heen book king al te pte Howe voned ne one last book was finished. Luc found Dad's i. htt woke rou epic ay att ten Chr ect a tht Len wre nis bo crn ok Len These met but though the emails and nee exchanged kno hat he and Dany had a respect and that he was please, 5 pean the war lowed te apatortig Tim Stack te eto 50k : 5 Shap ae or fete has be early hela ng Practical adic and ml spot tine Dor yl which weal envy chapped Weave hada huge cheng ation toh i Drojct nd Lc and wat hank or ae Sens who emg nhs bk ey Gale Prouty technical support ‘There are a number of companies that we often turn to for advice and supplies. They ae always helpful and are ‘a source of valuable information. They have been major players in the creation ofall of Danny's books, includ ‘ng this one, and we listed them in the back ofthis. book under the heading f'supplie sources, We would prelate your support ofthese fine compan ‘We would like to offer special thanks to General & General Intemational for their great woodworking ma chines that you see featured in many of the pictures.@ safety jigs and fixtures... 6 table-saw jigs and fixtures... 18 © router-table jigs and fixtures... 52 OQ router jigs and fixtures... 64 6 drill-press jigs and fixtures... 84 Go band-saw jigs and fixtures... 92 @ hand-tool jigs and fixtures... 98 oO miter-saw jigs and fixtures... 120 ‘SUPPUERS...126 INDEX...127This book is about jigs and fixtures for power woodworking tools. above ai cise, however, i's about safety! Woodworking power tools are designed to cut, mil, ore and ‘shape wood. To accomplish those tasks, they are equipped with sharp blades, ‘esves or dil bits, which can just as easily cut and damage our hands and fin- ‘gers. Those accidents must be avoided, and the risks minimized, at all costs. ‘The frst chaptor Is about jigs and fixtures for power tool operations. that are high risk. Pushing strips of wood through a table saw blade, cutting thin laminates or forming wooden parts on a router table brings our hands ‘and fingers close tothe cutting tools. Those potentially dangerous situations ‘can be eliminated by using igs and fixtures. ‘Many of the photographs inthis book, such as those taken atthe table ‘au; illustrate a technique or ig in action without a guard in place. The cutting ‘tools are not under power for these photos; they are staged for clarity only. ‘The guards are always in place when the tools are under power in my shop! Chapter 2 details many igs and fixtures that can be made to enhance ‘and increase the abilities of my favorite tool ~ the table saw. | wouldn't want to-be without a high-quality table saw in my shop. And 2s I discovered many years ago, the usefuiness ofthis power tool can be increased by using a few: simple jigs and fixtures In adltion, because the highest percentage of ac cidents happen atthe table sav, | tend to build jigs for this tool that minimize the tsk of injury.‘The table saw is number one on the injury ist, but all the other power ‘tools we use demand an equal amount of respect. Chapter 3 deals with router {ables while chapter 4 itustrates jigs and fixtures tor handheld routers. Rout- rs need jigs and fixtures because they can't be used for much without being guided In some way. & router simply spins a high-speed cutting bit and must be guided by a bearing or jig to be of any use in a woodworking shop. In the following chapters, detail - and Ficture-buleing forthe dil press and band saw. Chapter 7 deals with hand and portable power toot gs. ‘The final chapter has a couple of ideas for your miter saw. Fifty jigs and fixtures seems to be a large number. However, you'll be surprised how many you'll have and use as your woodworking hobby grows. ve seen some shops with many more than 50 ig, and they ae al used on «regular basis, Have fun making, and using, these igs and fixtures. Please, ‘work safe ~ifit doesn't fel right, don't do it until you find anothe safer way ‘to work that wood.ONE safety jigsand fixtures Power woodworking tools utilize sharp blades that are designed to cut wood, but they are aso very good at cuting flesh Blade guards can reduce the risk of accidents, but you can't completely cover the edge wihout compromising the efficiency ofthe cutting took Jig and faturs are addtional devices that can increase your safety winon working with power tools. Many ofthe jigs and fistures deserbed in this chapter are designed {or the table saw, the power tool that accounts for most woodworking ‘accidents. You can reduce your risk of injury by constantly paying attention to your hand postions and making sure that the workpiece is held tight against the fence. I's human nature to want to watch a spinning blado, but in order to avoid trouble you must concentrate on holding the wood tight against the fence during cutting. Use the saw’s blade guard, and re- ‘member that @ dull cutting tool is more dangerous than one that is properly ‘sharpened, ‘The jigs inthis chapter are designed to improve workpiece travel and ‘to keep your fingers away from the blade. I the wood is less than 4" (102mm) wide or less than 4” (102mm) fong, use a push stick when cut- {ing on the table saw. When cutting long, narow board, uso a panel-cut- {ing fre.____ Improved Push Sticks ‘THIS VERSION OF A PUSH stick places downward pressure ‘om top ofa board also has ‘lip on the back for positive contact. The operator's hand is high above the saw table and well placed for good control ‘over the wood. This push stick is thin enough to pass easily between a blade guard and rip fence. ‘The long “nose” on this ard prevents workpiece chat ter (boards bouncing up and don) through the operator's dlvinvard and forward pres: ‘sue, Is, by fr, the best ype ‘of push stick that I've used, $0 1 iypically make four or five ata time so I can easily replace any ‘that get damaged. STEP OME Create a patter on a Ys"thick (13mm) Balic bitch __STEP-TWO Use a scroll saw or jg saw to cut out the pat> plywood panel, Use a combination equare and any ound shop tem, Sand the edges smooth and apply nich you wish ‘objects (plastic jar lids work wall to form a patter. Take your time te draw a pattem that wil fit your han, then label tas your master template. Once you've made a push stick tha’s comfortable to use, keep it to trace more pustrstick pattems,____ Thin Strip Pusher (CUTTING THIN STRIPS OF WOOD ON ‘table saw can be dangerous. Controlled force mast be applied tothe par ofthe ‘wood that pases between the blade and the ip fence, while the ouside portion of ‘the wood should be lft without pressure so that ican fll aay. You want to avoid pushing onthe outer portion, which may ‘wedge tne bade and cause a kickback, So how do you cu thin strips ona table saw? There area number of safe methods, incuding having the thin strip onthe out side face of the blade. But you ean also ext between the fence and the blade, using this “Thin Strip Pusher, shown at righ. Is de- signed for use om a aqsate or rail fence ike the one on my General Tool saw. However, i: can also be adapted to work with a Dea style fence by adding a cleat that rides on the backside groove With slight modifica tions, this safety pusher ean be adapted to just about any fence on the market, A 1 orion panel MOF % x wh of sm fence x 10 19 with of saw fence x 254 B 1 rightgude MOF Max ight of saw fnce x 10 19 height of sve fence x 254 C1 pusher ywwod Ye height of saw fence mins Mie x 10 6x eight of saw fence minus? x 258 Dt handle ywwod Hx 17 x width of saw fence 19.38 x width of sa fence SAFETY 1108 AND FIXTURES 1"‘STEP OnE Cutout all the parts shown above to ft your fence. used %thick (18mm) medium-denst fiberboard (MDF) forthe ‘ido and top guides, "stick (6mm) venoer phywoad fr the pusher, ‘and hardwood book forthe handle. The quides and pusher are 10" (254mm long to ft snug on my fence. The 1'thick (6mm) pusher plywood pane is cut soit rides Ya" (2mm) above my saw table. ‘Sve Two _Altach the back guide pane othe top guide using ‘glue and 1%4"Yong (88m) sorews. The top guide should be Yu" (0.5mm) wider than your fence rail soit wil side easily along the {ence alter the pusher panel has been attached. Sve THEE Before attaching the pusher pana, out a notch slong the botiom edge. Leave approximately 2° (51mm) uncut atthe end of thie panol. The notch depth is variable and dopends onthe thickness of material you wish to eu Ihave three of thoge Thin-Stip Pushore with notches cut to securely hold A (Bra), 7" (18mm) and %hick (198mm) wood, For example, my "thick (6mm) pusher has a notch ‘hati slightly loss than Y"-high (6mm) withthe back 2" (Se) uncut as shown. When I need thin strips of 4" (Gm) mater |use the !" (mm) pusher because it hols the maria tight o the save table as cut the ets. ‘The Vthick (Grn) pusher pane is attached to the MDF top guide using glue and sorews. sree roun The thin sip pusher handle isa small lack of wood that’s attached with screws. It il provide a positive grip when cutting materia_____ Laminate-Cutting Guide ” = ys CUTTING THIN HIGH-PRESSURE “laminates (HPL) on a table saw is dan- ‘gerous, In fact, cutting any type of thin ‘material ona table saw demands alot of. attention to safety procedures. These thin ‘pieces tend to ind easly because they can slip and become trapped between the saw fence and the ‘able. ‘Thie Laminate Cutting Guide traps the ‘material between a stip of sheet hardboard ‘and a wood guide block. The hardboard strip is secured to the particleboard fence ‘with serews to eliminate the gap where Jaminates can get trapped. The hardwood. block holds the laminate against the lower guide, whieh eliminates “chatlering® as the ‘material is pushed through the saw. STEP THREE Allach the hardboard guide strip to the particleboard fonce with glue and sorews every 6" (152mm rer Foun The hardwood guide block should now be secured to the fence in the contr, with two 2"-ong (51mm) screws. Use fa piece of HPL and a couple of sandpaper shim to epace the block above the hard- board stip. The gap should be about 1.5 times grente than standard general-purpose (GP) laminate, cr about ¥" (Bm. STEP OME Cut pisce of" (19mm) ‘or "thick (25mm) particleboard that's 4° (102m) high by 36° (@14rer) long, You'l ‘also nocd a Ysthick (me) strip of harde board sheet material 2" (1mm) wide by 36" (814mm) long and a hardwood block 9x 16"x 10" 19mm x 38mm x 254mm). sree nwo Round over the ends an one ‘edge of the hardwood guide biock 1 rail pattdkboard 4x43 19x 102x514 1 ship acboad = Yaex2x36 3x51xS18 1 bock — hardwood x Mex 10 19x38 x 256 SAFETY 1108 AND FIXTURES 13Featherboards EVERY WOODWORKING SHOP should have a least sv or eight feather: boards. They can be used on table saws, router lables, and band saws. They hold the ‘material being cu ightly against fence cordown onthe saw surface to eliminate vibration. Moreover, they keep our hands array from cutter, wiere accidents oflen happen. ‘In the photo at left 'm using two fet crboards 10 contol the material as 1 push it through the saw. 'm using 2 raised panel cutting fence because the sot et me clamp the featherboards wire they are ‘most effective. The raised-panel fence wil the described later inthis chapter. svmP OWE Tam making two featherboards so each piace of hardwood will bo *"x 274" x 24" (19mm x ‘4mm x 61Omm). Marka Ene on each board at a 45° {angle to one end 30 the ong point of the angled in is bout 5" (127mm) from the beaud's end. srep Two Gut each board end ata 45° angle, paral lol 0 the guideline. Draw ine, 4" (3mm) wide and spaced (3mm) apart, to help when cuting the feath- ‘ers on your table saw. The ker (saw blade thickness) nes are drawn parallel to the board's edge. ‘STEP THRES Push the featherboard into the saw blade and stop atthe angled guidaine wth each cut Move the fence %" (ame) and make the net cut Repeal the process until al the “ingers have been ‘HOMES X wiETH x LENGTH forme. no. peat ‘stock nemes ances + feateivoard blank —hardvocd Ya x2ax2 19 64x 610 ach bank yes 2 feathaboards 4 HAPTER ONE(CUTTING AN EDGE PATTERN, SUCH ‘asa roundover or cove edge, on a circle ‘or arc with a router table has to be done with the bit unguarded. A safety can be installed, but working with an exposed bit sil makes me a litle uncomfortable. Irs all 00 easy forthe work to slip past the bit and contac the operators fingers or hand. ‘This Circle Edging Safety Board acts a5 1 positive backstop should the workpiece slip past the bit. The formation of the edge js still controlled by the bi's bearing, and if you do slip, the workpiece will be stopped by the angled opening of the safety board Iteliminates a Jot of potential hazards srhen routing this type of edge patern, sve One The board isan B"-wide (208mm) piece of "thick (18mm) plywood with a 45° V cut inta ene edge. Dri a 3"-diameter (76mm) hale atthe intersection ‘ofthe angled nes. Tat size hole should be lage enough for any router bit, but you might want to chango the diameter, making it ether amallor or larger, to accame date diferent bits for other applications. 1 igblank —piywood sxx 08 19.208 1219 15____ Raised-Panel-Cutting Fixture ‘THE FIRST STEP IN MAKING RAISED PANELS ON ‘table sav is the building ofa fixture that will allow ‘you to safely and accurately cut the panels. Tis fixture ‘an be built using any sheet material but | prefer low-cost?/4"thick (19mm) medium-density fiberboard (MDF), It’s a simple ool that’s safe to use and one that Inproves the accuracy of your cus. ‘A glued-xp pane canbe safely raised on the table saw with the Fixture, The slois make it possible to clamp the panel tight, Set the tablesaw blade ata 10° “angle and push each edge on the panel through the lade. ‘Adjust the bade to cut an angled slice ofeach cege, leaving the outside edges Smm) thick oft in the “A"-ide (6mm) stile and rail grooves. Once all ‘the edges are cut, sand the raised panel smooth. STEPONE Guta ‘square. Dil threo ‘diameter (131) holes inthe middle of tis pana, spaced ‘evenly across the panes width step-1wo Daw lines extending from each hole's outside ‘ameter to one ond of the panel, Cut the slots on a band savy ‘or with ahandheld saw. A 1 vertcal pane 34x 20x20 19508 x 508 1 81 fence corr Ux width of saw fence «16 19 x wth of sa ence x 406 ‘ C4 eee eta ix helght of sa fence x 2019. height of aw fence x 58 Dt bande ax width of sa fence x2 19x with oF sa ence x 102SvaP THmEe Cut second piece of MDF 20° (508m) long and ‘equal ta the width of your fence (see Shop Tip). Attach it to the main ;panel using glue and 1!" (28mm) screws. It should be located so it teats on top of the fence when the lower edge ofthe main panel ie lightly touching the table on your sav. sveP FOUR Attach a skirt board, using glue and 17" (88m) ‘screws, 90 the fiture wil track along the fence. The fsture should slide Ireely without any side movement. SHOP tip MY GENERAL TABLE SAW is eaupped win 9 ‘sare ube-svle fence. Many table saws hove a fence simi to is but he dt is ight citar ‘2 De able-sew fences ae dierent because they have a groove. which Wack ona squste piece ‘f metal 80 the fence canbe adjusted tothe ont 2a fe table. The Wl ride on such square "ube fences with he help ofthe simple box form ‘shown in he stepson these pages. eta fences require an extra cleat, cut to alow {or te 0016 at the top baci ofthe fone, so wi track long the fence witout sipping. With a tle ral and eo bul custom i forthe ste offence on your sam Sra Five Abardwood handle should be attached to the back end ofthe fisture. This handle allows the operator to grip the fature securely and control the feed rate safely. Use glue and scrows to secure the handle, SAFETY 1108 AND FIXTURES 7table-saw jigsand fixtures A good, well-equipped table saw can perform a ‘mutitude of woodworking tasks, butt aloo may presenta multitude of, ‘safety hazard, Many ofthe jigs and! fitures in this chaptac are designed primarily to help you avo accidents. For example, an appropriate panel ‘cutting sled can minimize the risks of erosscutting on @ table saw. ‘Apanoaisng fonce can decrease your chances of gottng hut while cuting panels at an angle for raised-panel doors. The ripfence saddle can help you positon material to avoid potential problems. ‘Other devices described in this chapter, such as the FingerJoint and: ‘Tapering Fotures are designed to improve the accuracy and consistency ‘f your cultng. Additonal devices, such as the Mull-Angle Miter Gaugo ‘and the Adjustable Mitor Gauge Fence, seek to enhance the accuracy and ‘ease of use of various table saw accessories. Often, woodworkers are re luctant to use accessories such as the miter-gauge slide because they are difficult to align and may not seem very accurate. hope thatthe figs and {iacures in this chapter encourage you to make full use of your table saw ‘and ts accessories by meroasing thet safely and improving ther efficiency.THREE VERSIONS OF PANEL CUTTERS IN MY OPINION, THIS paneling fxtire is one ‘of the most valuable tools for the table saw. I's easy to han- dle and improves the safety ‘of crosscutting long sheets of ‘wood, Crosscutting long pan- els om a table saw without a sliding lable or pancl-eutiing fire accounts for numer- ‘us accidents each year. This is one fue that youl use on a regular basis, and I'm sure its accuracy and ease of use will impress you. Follow these steps to make your own panel cutter. Inthe first part ofthis chapter I show three variations of panel cutters. he same fence ean be used for each one. I's only the bases that are diferent. Each panel cuter has a specific use, so | recommend thet you make the straight panel cutter first because i's the fone youl be using the most. rer one Using "Ahk (19mm) partcloboard, cut a panel thas 24" (610mm) wide ‘and 32” (813) long cree 1wo The mi ot guide rail can be made of wood, otal ‘or polyethylene ultra-high molecu lar weight (UHMW) rigid plastic that's available at many wood- ‘working stores. i often sold to ft nthe mitr-fenoe slot on your table saw maasuring (1m) thick by % (18mm) wide Muse ‘wed guide mils on the next two pane cutter versions. ‘The 80° (762mm) UHM strip ig soured to the underside ofthe cut pane! using 1" (25m) screwe at 6" (152mm) on canter in countareunk holae. Leave 2° (76m) in ront and behind the panel. W's attached paral to fone short edge ofthe panel and positioned so there i Y" (13mm) of panel material on the other side ofthe blade when the guide rls placed inthe itor sot.CUTTING LIST | hardware J Ree No. pane ‘srock ces umereRs 1 tence hardwood 9x17 x30 19 45x 762 Toe or Me 1 30" (0mm x 9mm x 762) B 1 tepstopblock ——harwond Fax Pax? — 19x45 x51 1 tveaded tno %-20 x 1¥4"(22mm) C1 frotstop bide —adwood ax The? 19.35 x51 ‘ight M20 SHOP tip ‘ULTRAHIGH MOLECULAR WEIGHT (UitaN) laste can bend casi ro securely lam ‘tlghtedse to your work surface and hold the lst sap ahty agua ne edge to Keep it rope lane, SvEP Thine Place the panol an the saw with the guide rain the miter track “Tim the /" (13mm) overhang off he pane! by pushing the assembly through the saw blade, The cu side of your panel is now perfect aligned tothe mitersaw slot TABLE-SAW JIGS AND FIXTURES aay vem roUR The front fence requires a rabbet on one face th 8" (10mm) deep by 72 (19m) wide. The rabbet can be cut on 2 router table or table saw and will be used to secure aTlot rack, ‘hich wil hold the adjustable stop assembly. rep rive The fence must now be secured to the panel assembly Use a large framing square, with one leg held tight tothe previously cut pane! side edge, and draw a reference ine 124" (am) from the panel's ont edge. ssvep sic Temporarily secure the fenoe from the underside ofthe ‘panel using one 14° (82mm) screw in each end ofthe fence. Cut a test panel and check it wth a square. Ht the cutis accurate, secure the rail using 14" (32mm) screws at 4° (102mm) centers suor tip outs and other rete’ wipe SELECTION OF Tack Knob and tome wore avaeble at mont womawnorti STE ardware can be seo make nds of MOP contrs Tis hardware js, fiatrae ond workstont 2 chapter TWOSTEP SEVEN Install he Track inthe rabbet with %" (16mm) screws every 6" (152mm) along the fence length. STEP EIGHT The adjustable stop block is made using two pieces of wood that are joined as shown using 114" (38mm) ‘revs and gle, ‘STEP Winter hole through the 12" (48mm) block that’s con- tered om the track when the stop block sin its normal position. lta a ‘threaded knob and ight nut in the hale, which wil be used ta postion land secure the stop block rer veh Im inetaling ase adhasive menauring tape to my ‘aight panel cuter so | can quiclly position the stop block or specific cut lengths, With the panel cuter in place, measure the reference kine 12" (305mm) free the blade. TABLE-SAW J1G8 AND FIXTURES 23____ Fixed Miter Panel Cutter YOU MIGHT THINK THAT A dedicated 45® panel cutter is waste of ‘material, However, for those wookworkers ‘Who cut 4° miters on an ongoing basis, accuracy is critical. This dedicated angle cater can be used for picture framing or for those woodworking projec that re- quire alt of mitered trim work. ‘The standard table-saw miter side, or an adjustable miter slide, can be used for ‘mitered pane! and trim exting. However, ‘because they are adjustable, sometimes they become difficult to align to an exact 45° angle afer they've been used in other positions. Seting adjustable mitercut- ng tools, testing and tweaking until your | angles are perfect. is time consuming and never absoluely accurate. © On the other and, a fied miter eut- ‘er never changes, s0 you're guaranteed perfect 45* cuts every time, without having to spend an hour aligning te fixture. 1s, this Fixed Miter Panel Cuttera waste of ‘money? I don't believe so — not when you ‘need consistently accurate 45° mites for every cut, ster one Cute’ (19mm) partcieboard pane! that's 24" (610mm) wide and £32" (813mm) long, as well as a hardwood fence 94" 122" 96" (19mm x 45mm x 914MM). This tie, in place of the UHMW plas tic for the miter sot guide rail, will use a stip of hardwood that's 2 23230" (1mm x 18cm x 762mm), 24STEP TWO Attach the wood guide stip to the underside ofthe STEP. FOUR Postion he 36" (014mer) fence at 48° to the panel's ppanel as described in step two ofthe Straight Panel Cutter project. straight edge and draw a reference line so the fence can be reposi- “Tim as prviously described to align one edge of the pane! with toned alter its trimmed, Relerence the fence postion to the panels the saw blade and miter at. ledge closest tothe table-saw blade (rimmed ond). Mark the overhang fon the underside ofthe fence and im to ft SveP THREE Cute stopped rabbet in the hardwood fence, leaving 6" (182mm) at one end uncut. Square the rabbet cut with achisel TABLE-SAW J1G8 AND FIXTURES 25ive_Alterithas been trimmed, place the fence along the 45° ine previously marked. Use a 1% (82mm) screw on each end, through the fence's top surtace, to sooure it o the pane rep soe Cuta panel eating against the fence to vari ‘ut isa 45°. In addition, cut two Boards to verily thatthe 48° mitora form a 80° joint. the angle cuts are not at 48% adjust the fence position and try the test proceduas again. Once you have vaiied the cuts aocuraoy, secure the fance to the panel with 112" (82mm) screws at 5" (127mm) canter, VEN Install a Track and etop block assembly folowing the same stops as previously described in the Straight Panel Cutter pro ‘ect, Matra tends to side when it is pushed through a table saw at an angle. To prevent this, use the stop block in combination witha toggle clamp. This can be installed inthe area that dosent havea rabbet cut Hinetalled a sett adhesive measuring tape. The tape was set ta mansure angle cuts from the long and of the miter to the b nd of the board being cut. The positon can be determined by out- ting any length of wood and measuring it length ater the cut. can then be used to mark a position refecence forthe selfadhesive eer Reinstall the toggle clamp once the uler tape is secured inthe comect positionAdjustable Panel Cutter 1 SUPPOSE YOU COULD CALL THIS ‘the ultimate panel cutter. It incorporates all the features found on the Straight Pane! ‘Cutter and Fixed Miter Panel Cutter previ- ‘ousiy described. Tis adjustable version is ‘the most versatile, but don’ discount the ‘usefulness of the first wo. 1 have and use al three. When I want simple straight eu, | grab the straight version or the fixedangle model. | know ‘they wil deliver the cut I want because ‘they haven't — and can't — be adjusted. ‘The adjustable cutter is available to me for ‘ox-angle cutting needs that always seem ‘arise in the shop. Which panel eutter should you build? ‘Why not build all three? They're handy and inexpensive to make. The mast expensive par ofall tree panel cuter is the toggle ‘lamp, so next ime you see these on sal, pick up a few for these projects. STEP ONE Cut a paricleboard panel 2" x 24" x 28" (1mm x {810mm «71 tm). Youll also ned a miter slot rall’4" x4" x 30° (10mm x 18me) x 762mm), aswell as a board that's "x 192" 26" (19mm x 45mm x {860mn) forthe fonce. Altach the iter slot ell to the | panel and cut the edge vale! to the ral, following the same procedures that were described in the previous twa pano-cuttr projects, Use a %" (1Smm) router bitin a router (or table-mounted router) to form a stop rabbet on the fence, as previously shown. It should stop 6" (183mm) rom the fend forthe Track TABLE SAW J1G8 AND FIXTURES aADJUSTABLE PANEL CUTTER continued svar ro. Dilla ameter (18m he (Ome dep on the under cho pan eut or a Fut ahold conte" . {rem tom the pane cuter tnt edge and (02m) fo he penal se edge copie ta aes bad dda Now Sa es SH oP til p fete (an) le completely trough the pnd inthe enter ofthe Siciameter (1mm) hole ne tnuris ven into thames tom he Se rep THREE Drlla "diameter (6mm) hole contered on the fence “te ancost yt proper reared S02 that is 24" (610mm) trom the saw blade end. Screw a knob with a % sie ofthe pore The oe by 20 threaded shalt into the Tout to secure the ence to the panel recessed Tmt isto use a snort pice of 7 esa seaina inch. 28 chapter TWOsveP FOUR Dra Yé'sdiametor (6mm) hele centered an the fence that’s 3" (8mm) in from the saw blade end, Use a pencil ro mark the travel are ofthe fence. The are should begin at the O" position ‘and end atthe 50° position ofthe fence. svi rive Now, tage the same arc onto a sheet of "thick (6mm) hardboard to mark the ar for@ router tomplate. Cut the are ‘along the fine with a jigsaw or band saw. The arc travel passes over the guide bar soit can be removed forthe next few stops. ssvep sic Install ae" (8mm) template guide and a %"ciametor (Gam) straight bit in your router. lamp the template in pace so it will guide the router along the are and cut thraugh the panal ts best touse a plunge router and make four orf cutting passes unt you ‘ut completely through the panel. TABLE-SAW J1G8 AND FIXTURES 29ver Seven Flip the panel and clamp the hardboard template in place so this cut can be made on the tom face of the pane cu tex Install a template guide that wil accept a%s"-iameter (18mm) ‘aight outing bit. Set the depth of cut so the head of a % by 20 carriage bolt wil ride slighty Below the lower pane's surtace. Center the %4"-dameter (1mm) cut onthe 4" (6mm) arc slot and cut along the ene length of the are ‘STEP EicH Reinstall the miter slot gue bar and fence. Screw a 2! ang (1mm) V4 by 20 carriage bolt into a % by 20 knob to lock the fence at any poston (0° to 80°) along the arc radius. STEP nines Installalongth of Track inthe fonce rabbet, a stop block assembly as previously described and a toggle clamp like that shown in the previous project. The panel can be marked at various Pesitons ance the cuts havo been verified. | use the backside ofthe fence for straight cus (similar to the Staight Panel Cutter) and the front edge to secure material when making angle cus. 30 cnapter TWO____Fence-AlignmentJig ees ‘THIS JIG IS BUILT USING THE KISS THEORY (keep it simple, silly) and irs one that makes many ‘woodworkers say, "Why didn't I think ofthat? Ie so simple!” Like a lot ofthe jigs and fixtures in our shops, its the simple ones that always seem to be the ‘most valuable. Proper tabe-caw fence alignment i ereal for ac- ‘curate cutting, But more imporant, preise alignment ‘ofthe fence will prevent serious kickback accidens, In _my opinion, the fence must be parallel to the blade. I Ikmow some woodworkers mainain that a slight “kick- ‘ut ofthe fence away from the blade is safer, but 1 don't hold to that belief: No mater which method you prefer proper alignment isa critical issue, is simple jg is made with thre pieces of wood and a few serews. To align your saw fence, place the jig in the table groove and bring the fence to the dowel ‘od s0 it just touches the end. Lock the fence and slide the ig forward to the end ofthe fence and check ‘the alignment, Ifthe jg binds on the way othe end, youl know the fence is improperly aligned toward the blade. there's a gap, it's out of parallel away from ‘the blade. Adjust the fence alignment screws tnt the front and rear ofthe fence touch the jg equaly. Fence alignment is quick and accurate with this jig so Keep it Ihandy and check your settings on a regular basis. STEPONE Cuta piece of wood" (19mm) thick by 6" (182m) square. Then ‘cut a ship of wood %"x%!x 12" (10mm 419mm x 308m) that fis in the miter sot groove an your table say, Attach the stip in the center ofthe square board with glue ‘and 1" (25mm) screws. Remembor to coun tersink the screw heads and align the strip parallel to the board TABLE-SAW J1G8 AND FIXTURES a32 cnapter TWO srep-Two Cuta 14" {856mm} length of "ameter (25mm) harcwwood dowel rod. CCountersnk through-holes 1" (250m) and £8 (127mm) from ane end of the dowel. Dil the holes large enaugh so the screws vil tuen with theeacing in the rod, This technique: holpe provent “screw bridging” that ocours “when the screws lock down (or “bottom aut) as some peopl say) tothe material being attached before both pieces are drawn to gether. SveP THREE Use two 1%" (88mm) serewe to socure tho dowel rod to tho flat board. Align tho rod so it's at 90° to the iter groove stip and ash with one edge of the square board,FINDING DEALS ON ROUGH LUMBER isa passion with many woodworkers. The savings over dressed lumber can be signif Jeant. However, processing rough lumber isa lot of work and requires a jointer and «planer. Often alt of time is spent joint- ing the first edge after one face has been. jointed flat. Many boards have a large edge ‘curve that will equire quite afew passes to true it up. Ths sawing fire can shorten the time considerably because the saws able totake alot more material off per pass than ajointer. ‘This fixture is also useful for those who don't have ajointeror planer. One edge «an be ext straight in the fixture, and that ‘cut edge can then be pushed against the table-saw fence to cut the opposite edge parallel. You'll soon see the value this srcr- owe Cut length of sold wood 2" 35x 48" (18mm x 8mm x fixture no matier how you use it 12191). This guide board must have parle! edges, soi you don't have ajenter ask your lumberyard to joint the edges for you, CUTTING LIST hardware A 1 guide board hardwood 3 x3Yexe® 19x89 1219 2 togple domes B 1 camer panel masonite Yax7 x48 6x 1781219, 1 teats kno 4-20, 2 ants hardwood tla 3h 25x88 ‘hange bolt %620.x 1% x @2mm D2 stop blocks hardwood Fx ext — 1945 x45 TABLE-SAW J1G8 AND FIXTURES 33ROUGH-LUMBER SAWING FIXTURE continued "ee "wo Alach he carer panel tothe underside othe guide EY ‘board using 1" (25mm) sorews every 4" (102mm) along the length ‘Auach the handles to the top af the guide board with 2" (51mm) ‘screws from the underside, Locate ane hancle 3" (76mm) from the ‘operator's end ofthe fixture and the other atthe 24” (610mm) posi tion, These handles can be used i needed for exta control when you ae feeding the loaded fists into the saw blade, REE Install wo toggle clamps at tho 18" (406m) and 32" (787mm) positan, measured irom the operator's end ofthe fe ture, Use 4" (1mm) screws to secure the clans clase to the inside ‘edge ofthe carior boar, rep FOUR To make the stop black, glue the two stop-block parts together to create an L shape. I's secured tothe fixture using a hanger bol that accopts a threaded knob. The stop block prevents ‘board slippage during the ripping process, particularly when cutting thick hareveod. suo tip a eaightan bor 29108 sane 48" (:219m) gue bowed wil talon in ature frlonger mbt, {sen er ou me senna ene save wo nesase lena ofthe gue bout and ree it dieu to nolan & (24am SAM ig te loth of 80 boar However tna fue, 201 would S498 jumper to (1s2Aem i possible.Finger-Joint Fixture CUTTING FINGER OR BOX JOINTS IS AN EASY PROCEDURE ‘using your table saw, dado blade and this shop-made fixure. You'll ‘get perfect results everytime and you won't hesitate to show these joints on your projects. Finger joints aren't restricted to drawer-box construction. They ‘can be used in dozens of woodworking applications such as jewel ‘or display boxes, picture frames and chests. Take your time mak ing this fice because you'll be using it often. ‘sree ons Attach along 4x2 beard extension to your table-saw miter ‘ence. I willbe used to support the fingerjoit indexing panel ‘sraP 1wo Clamp an indexing panel, about 8" (203mm) high and 28" (610mm) long, tothe extension bonrd on your miter fence, This tallindesing panel vill help suppor large boards as they are pushed thraugh the dado blade, Once this ie secured, cut through the indexing panel. Lam setting up and testing ths ature with a Ys!-wide (13me) dado blade. TABLE-SAW J1G8 AND FIXTURES 35FINGER-JOINT FIXTURE continued SvEp THREE Cul a wood indexing pin equal to the cut width, ‘and glue it in the notch onthe parol SrEP FOUR Use a lose indexing pin, ‘the notch, to set the fed indexing pin 4" (13mm) away from the dado blade. Clamp the indexing board securely tothe miterfence extension. 36 cnapter TWO Svup rive Cul the two boards to be joined together. Hold the rear ‘board tight tothe fired indexing pin and set the front board away from ‘the fixed pin using the loose spacer block as @ guide. Remove the ose index pin and make the frst cu. sve She Make the second cut wth the rear board notch over the index pin and the front board tight to the pin. Make the remaining cuts ‘by moving the notches over the pin unt al ingers and slots have been formed Ifthe test joints loose, move the indexing panel so the fied pi is ‘ght farther assay from the blade the Fingers are too wide for he notches, move the fied indesing pin towards the blad. Ba careful ‘while moving the index board because it doesn't take very much pin ‘movement toward or aviay from the blado to dramatically change the finger and sot width.(CUTTING LIST 1 vertical pane! djs fence hovizontal plate base plete sss rac rade ‘rwewness x wom x veer oe Hx 12 x20 hardwood ax 1a x16 Mo ax 12x20 oe 54110120 Moe Bex TXT Mor Sax Yex22 Mor Fart ta 19 4305 x 508 19138 x 405 19 1 305 x 508 19 x 254 x 508 soxt7ex 178 10 x19x559 10x19 356 ‘toggle dae 1 tread knob 2 treaded knots 2s ‘ eaniage bolt 2a washers ‘20 20 x 1% 2mm) Ye20 420 x2" imm) WeSTEP ONE I marked my pivot point at 1%" (32mm) from the bo tom of the vertical panel on center. Mensiring 10" (254mm) from that pivot point, draw an arc tothe 45° dagree angle front and back. sree Two Using the band saw, cut a template out of "thick (6mm) material ortho same arc then using a 1 (6m) straight it ‘with a.collar on a plunge router, rout a groove through the MDF; fol lowing the arc. Make a few passes a clferent depths to gota clean through cut. 38 cnapter TWO SreP-THREE Round over the adjustable arm at both ands. Fix it on the board at the pivot poi with a 194" @Bmn) particleboard screw. STEP FOUR The locking knob is put on by simply ailing trough the ‘arm where it meets the groove. Inset the cariage bolt fram the back, using @ serew-on knob fo lock the arm in place. Attach a toggle clamp onthe adjustable arm roughly 3° (76mm) above the pivet point.STEP rive Cut %".wide (19mm) by %4"doop (10mm) dado in the center a he bottom pate. This isthe groove forthe track that wil be attached tothe horizontal pte STEP S0C Install the 22" (558mm) track on the bottom ofthe bot tom plate 80 the panel can move font to back onthe table sav ven On the router table, cut two slots mensuring "2" wide {6rnm) by 8" long (203erm) and 12° (805mm) apt along the width of the horizontal plato cp icity Install the 14" (256mm) track in the bottom center of the horizontal plate, soit can move sideways inthe groove on the bot tom plate. TABLE-SAW J1G8 AND FIXTURES 39In the underside of the bottom plat, dil holes and a ‘tach the vercal pane to the horizontal plate using ‘counterbore for Tuas 12" (205mm) on center and ini with the 2" (Stenm) particleboard screws. Then ailach the gussets tothe vet: slate of the horizontal panel cal and horizontal patos. Install the threaded knobs through the slots in the hor= Put the ene assembly onthe table to make sure i's zontal plate and into the nuts inthe base plate at 90" tothe saw table. Mako adjustments if needed. 40 cnapter TWOSacrificial Fence "THERE ARE MANY FENCES ON THE ‘market, but the problem is that you can't drill through them or puta screw into ‘them. One way tallow you that flexibility is to build a saddle over our fence and securea Sacrificial Fence toi. There are ‘many different styles of fences, so adapt these measurements o your particular fence. The one I'm using is made by Gen- eral. It's-4* x 4214" (102mm x 1073mm). ‘With the Blade lowered, slide the Sac- rifcial Fence over the dado blade tothe ‘width needed oF zero clesrance."Then start ‘the saw and slowly raise the blade to the depth of cut needed, SveP OME Cutout the parts forthe box. This bos ts over your ex isting table saw rp fence. sve Two To make the assembly easier, I clamped the pieces ia place over the fence and fastened them using 2” (61mm) particle board serows with a plot hole. The box should ft snugly over the {ence to prevont forward or backward movement ofthe bos. TEP THREE Attach the Sacrificial Fonce to the box with screws. “The Sacrificial Fence can be a scrap of hardwood, particleboard or MOE When tis fence is no longer usable, it can easily be replaced, 2 sides patleoard 4x4 x length of sa fence pls 12" 19% 102 length fsa fence pls 1A" 1 cp Paticleboard x witthofsaw fence xlength of saw fence 19x width of sa fence x length of sa ence 2 endeaps—pateeboard x width ofsaw fence x 4 19x wih of sa fence x 102 TABLE-SAW J1G8 AND FIXTURES a