Issue 75

Plank-Top Workbsn~h
m-~.&-#>m:lfi-e

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Dual Tool S W o n
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Departments

Shop-Made Studded Knobs

A E A q k e k W f o r kn&clrpbe&qml,TodoMs,f ttmetpp~nofl%ekmbaPrthawwd&,mhThed&ph&o. c~&/n(~tsandjigs ~ w t E m e l m o b ~ t h e 8 t f laIcro n . ~ &me, a~ shown In the Ieit p b b ~(Youmuldhwea I frcxmscrapby u&gafmdmpIeWs. &~wv&,W InaWng c d t r n ' w e bolts, then hrmlngF -

-I

--

MI press u e ~ n ~ rasps and fum#

I
PVC Clamp Holders

1
'

TIPS

&

TEGHNIPUES

Quick Tips1

Sharpening
< >-

Corral a

. . ,. .

. ,

out of l/,r' l w c b h h ply-

H100d,sOBnIhadbdo~ cut the p k to~ b . But beareaqpuplethhgsb keePb~wyoud0W

3 w r m . t h c b ~ ~ ~ ~ crass/: tmk and ~ mrade m y b h h about 8" wide.) The

rn

~youllwantto~e

&xCepfima/ 5mwth ~ w i d t h ~ a n ~ m t p u r m u * d a box joinf, make$ pe-habmforanydahh / I the perf@ct Mce h e o r c t t t a l ~ o f ~ ~ ~ ~ a s for ~tswmbling t ~ m t ~ a n . ~ ~ a m l s smll bma. kltsetof*and&t8arteaeh

d e . ~ b

coraeroftbebwcwha~roucutthe amgartmenb to id s b . @or an altemk joinery method, t o the Iwx on the oppite page.) Tlleotherthingtakpbmiadh tamakea~~~pIedmbEankatom

' ~ ~ B Q x A p m t - A t ~ s yw're m d y to cut th* box

I W ihe blade to about 1/d1 less

$ .& I

the h i c l a w of the p?qwood :andmake a scoring cut through the :dwtsidest, lining the blade up with

: t f i e w O u cuts $

,m 331.

I Optional Fnlinmdl

Line It & Divide I t

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TALL PWW

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SHOP

S T O R A G E

;&he m w ' s l o a s i u the lower corn

;~f&mgbandawtocut

~ ~ c u r v e s ~ 5 d W .
~ ~ ~ e t a s t ~ f
~ d j d t o ~ t h @ ~ b o x
: ~ m t o ~ s ~ m e ~ d ~ t o t h e

:ht&kdoutsideofthelid Why both siddkldhgitto the ;-allowsywbotlsefhelidasa #,,&-When you're shmdw, :!&e &me wont be d G g wound ~adanymess~in&elid,nOaon
: g w r ~ ' r h e ~ a n ~ o u t -

:ddekeqsthelidinphmmyour

adh&e,aa~~and*

pb0bDatlowerW.w~~

tap,lhere'saninsa-t ~ ~ ~ a l a m l b o m e m t e Pl rb w a l l y o u h m t o d o i s ~ q thelid Ir;*qpre8).A wherewditbttseM.) dy.o~rsharpeains~~H

.*to W W e of the lid hadtobuttahvstripa-b wtheexamthatywcaaYMd ~ y o u ~ t h e i n ~ s i z e~ d . e a c h ~ ~ yo ~r r r d t t o kh ~you ehmputtinga arrtmrne memid piwwof 8eU- tape flu& with autilityhife (* aharpedgeonaflyowtoo~s.~

Ends

END W L
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F E A T U R E

P A O J E C I

Plank Top & Shelf

No.75

llne Extra

t's Vises

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rn ,,JW mw% -w,wj,

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p!,M$@; p m

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A ww.

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V b . A plecB ofplywadandacfsai allow you to mount tr

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Metal Bending. Tllrs set ol malleable Iron auxiliary j a ws can be used lo bend sotf meta/s and

m&InI#t%
vise to your

7 % t w p p 1 m Jaw set w i s h of a ,die that .fm$ the mtal &galnst a Fbfock, creating a Meet 90p bend. Sse page
35 for wm,

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Dual Tool

SHOP

PRO

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The heart of the W n &met you = i n the
b o x w i ~ d o o r s o n ~ ~ ~ a d bemhdeofthec~bimtarethe h~forthehldmtwiogmp ports F d , a pair of mmmlmnts 0 4the M e p m v & s t o w for the f m cthat ~~ &readded later. WngtltaeCsdtfnet-Sin,cedliter ~ a n b ~ m n v a r y ~ a b i in size, the most i m p o m tbhg to d ~ e i s h o w ~ t h e ~ ~ to be. Depeading on whicb tml you're udng,the other win n d DO jit W e the cabinet And h e height of thetabl#on~tool~affgct howtanthe h o W i Q g s f Q r t h e ~ n -

&n*needbbe, The dhmdona for the cabinet

s h o w n p k e t k t a b l e s o f t h e ~ sheet ofplywood, thewidthofthe d . ~ d o ~ t h k I ~ t h e & m v and p h e r at a height of 3@/4" wo&kes is just under 24". 7hh bet for arr inhior width ofBi/zn. o m the we addud - a good allows b r an iutaior depth of S/J". Fh@, doat forget about fie foW The &id hr ihe owdl up extension tablea an yaw planer. work@ h & t And it alms for miter s a w and planer tables that w i a t h d t h e ~ w a a t h e Theycanaffecttheoverallwidthof ~ messure41/4t1hi&.Thisshould pro "footpbt" 1 a d d weate with my the cabinet as well. Y d wmt o t p vfde wwgh hHor height t o silidingmltsraaw,Todetrenninethis,I make sure they'll 0t between h e ~ ~ ~ ~ & ~~ i t ~ ~ t t i m t~ t h a e m d i b sugport ~e r ~ . when in the skired pmidon. -~-~aawf~thelaftand$lentherigfit, foldeddowndwbguse~waa Bethe height of the &net, n m w @ ttae w e d width (and W' for my cabbet,.) y o u l l a h n e e d t r r condderthe checldrmgthed@&atthemtime). BuUdaBOK-Whenyoucutthe depth aad width. T o get the max- For nry am,I &me n poWn m & tm (4, RW (Bl, and back immdeptPI,retotilIbeabIetogeo w h e f e r n y ~ ~ s a w w a s s e (CJtudzeTigum3, t beamto 'thebtuseoutofa@fandard4'~8~ t o ~ ~ t a n d p u l i e d & h t I y f m accountbrthebngueandpm ~tneryudtambkbcabInetYoumseethhjoheryin
JWm2a,&,andk Onoe&*mcutto*,

you can cutthem-in the side pieces d hwk Then cut the tongum on the end8 and back e d g ~ ofthetop&bo#omta&tthe ~ ~ r l $ w i a t ohm e along
the back edge ofthe side pi-.

mnw-*thea
isghled~roatcantzsrnpuf~ timto~smallcubbyho~on~

indeoftbeabbtdtKshittgthe forbmitersaw.

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C ~ t b e ~ ~ i s j u s r of c u m a #id%(Dl an

~ ~ ( ~ f o r ~ a n d -t b $cz~thesninplace,as~ i a F i g u m3m d 3b,

Extension Wings & Gupports

thenotdm~c~rn~,waji etoshaped~~pj~ftand sand ~e * 8 1 3 1 w t h . A d d t h e ~ - ~ t ~ ~ t h e the-~ o

~ ~ b o ~ i t e a 3 y t o ~ d
~ X ~ ~ ~ E

~ ~ ~ a r e ~ I e v
~ ~ b d m -b (Elmm74, T h i s i s j u s t a ~ o f ~ * a f

I>aiaofh&shthe~edgr!forsome ~ . ~ ~ ~
w h a you swing them in, o f h t h m &other when ~ d 7 ~ t m d t h e n l ~ t yw hW e t~h e m , Y b u a m m h o w tobrna~mtbn. ~ w Q ~ I ~ ~ Wiwg&pgwb-Ifsagoodkh ~ ~ ~ e ~ o n t o W d t h @ W i a g ~ ~ f f r a r t . T h Si a a ~ e ~ ~ ~ i a ~ ~ the f m m t h e b a c k o f t h ~e b o u d n g ~ ~ ~ e l o t ~ . ' 9 l f 3 t h t7c).ToWtheotherwppott, h e use

~ j r o u m ~ t h e ~ T o ~ ~ b r ~ t P

Cr,

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~

WhatIrdylke s u ~ i n ~ o n , y a u c a n s e t t h s ~ t o p d l h n f h hinge e 1" ~ ~ ~dghtan@pw31enyouIleedto l ~ o n 6nrmtbe~dekeofthebW1'~ h t h e ~ ~ ~ f~ o t h e ~ & miambatedin FWre 7b. The & t ILI are Make&--Thewinp 'IheyprovEdttmhmpmrt H fM,lWx~tontnpdthe~~ forcutlhgalmgmdphe n&hg more than Vdl! p o n t . h e ~ ~ s m p v e n ~ e ~ ~~ ~ ~ B u t t o ~ ~ a j ~ u~ 1 s t a ~ o f f ~ l u r n b e r ~ t h e ~ + ~ w i i h a p a k o bardmodd&~fNjalorigthe fronta11dbtmk~8md8h), & I t w h a f ~ e v m b e t t e r i ~ h o wblanksdmteachpdrafidenthl ~ pp Topmidethesmedurabksw i t i e ~ s t M ' e t h e ~ ~s u m t rbhnlh-71. A notch h the uppm inside fmasthetopdgeoftRehdng,I dthe~vrehenyobtBon"teed r of each m r t pmidea ~ ~ ~,Tt'9juatafinatterufm ~ e the~gpwtshaiedghtrnbogd d e m c e for the hinges w t t h m d i t Bush, -the iag @pasbebm.ThenPo~tany t h e ~ , ~ ~ r o u ~ i s nw ~ 7t h t e,~ ~ i n a n d s u t O a c e

You're on the home stretch at *thi~ slid&mt allelf- ,!wmu& you makes a conwent handbold far m set the: tool ~rou're not pullInsthe &eIf out a & couple stepe are to d d j slides pro~dm easy poiat. l h e l -1 b e -Toprevent thedm using in& the mbhet t o store It, I amiss b rn dctadmmforsbrisgiz#mlfs of m dong wilh a & h u t shelf for 4 t o m a k e i t a U t t l e d e r t o g e t m w ~ f r o m ~ each tml on a itinatidout S o I a d d d a d h t s m g e dfaw~: st&ng the tool you're IM wing, use,I ol~ i?R~ mfnFfgve tl 1 0 . ~and~uwdagroovemd B g W a %~ - ' l h e s ~ d rt O a ~E l~ Wension slide between the fmw h a ~ ~ d e t h eThesh@ffRIbaphed3/at1& cieattolocsklbebawinpb. o mount the B/sartenfrlon EachtodbagsIT1isjwtapi=of makes it easy to m b t n l a t . A e y o u a u s e e i n ~ 9 , d T ~ w ihagroowelctttdmtiw ntn'ew a stored !ad thedmmrWisrathershpkta d r a m &dm, there: are a pair of W u t mMng ,Me cmwtmk The f m t h e k 1 0 1 and a i h {SJ d e h m 3 / 4 t W M- ~ , ~ f a ~ l l . ' f w *t h a ~ c W f U ' 1 cabinet unstable, & m (P)m d e h m $/dl1 pbr- w w d , ~ ~ c a n ~ h ~ r @ ~l O T o ac~ept the he& the tap inside ~ m t h e ~ ~ m t wood And thedram k t o P w {QJ i s &$t0 p b of '/h" m . edges are r 0 1 b M as IfIu~hterl in t o p e d g a o f ~ $ e p b ~ B ~ a h i y t o r4e ml b e o w the &at Asyou&theparts,tll,emarea F'Qgm1WAndadotatht)reM

caupkthInggtaIreeph~d.For dartem, the drawer rides on fullextension, metal did= The o m I u~meatltthe~h&dtoI I" se nwmww than the space betweea the fenceholdem. TheotherthIngto~tuithr when &?& the d m w k the ~ ~ j p i a t ~ t o b o f d t h e ~fotfie~mdb&Yaumn raeetfiis~mtio~~.

Wfilhe~&dsndlhe
~ou~ctrfthegroow

fmthedmwrboteomaacl:then ~ e t h e ~
themefial~~md&pthe

drawerinpke,min~Cfa

SHOP PRDJECT

h Y *W.*&bb

saamightib WALL PARTS& IIVIC. it = w 9

No* n

mow

Freud

Dado Blade
*old,
m h w w.

c a n m r e r r a e m h e r t h e m t i m e I u s d B ~ d a d o b W I ~ ' t ~ h o w m u & ~ i t
cut h u

Iefftjrt4abh u t m -fmtr ~ ~ t o r ~ t i c ~ r r h i m s~ ~ bt h ~ em d ~ ~ n e x t t O % t , aaw9,B

~ ~ m b ~ ~ o r tm t ow l

p l a e c a n ~ a ~ ~ i m

ee i rr t o r o t r L ~ t h ew ~ WmmessmWnbetbe plate aia hebl h e ~ , ~ ~ ~ In place with three smma and lock nuts. The W h a t d ~ ~ i s t k a t g o maeMne u~ Io&nutsdickoutmfw thatthey hit ButWsaotthemewithebe ~ t h e w i d t h o f ~ ~ o w l ~ t t uh e ~ ~ t h e * o D i & - ~ ~ b p ~ T h ~It h se ~ o t f t h e m v ~ A U s n p atla W & b a e t d & d t r e W e a ~ hbdoLb&coftbearbrnvt some aqhm.le, wfw-CdpUwbe&e ~ l dightlyand~lprnthehub. u ~ hub* B r o t w h f ~ r & & e d m t t h i ~ o o g e t ~ l l n a ~ ~ l e m b y
~frolntheeraftt,*~b
d t

m ~ ~ b I & *

~wnytmrk~iaatdypmtty taken out of mrrking the a m - the of^^.^ Qneothm4Mngtolaemared ~ ~ ~ e d h t o t h e h u bmen& h u Alsround t h e h u b m a the hub hmmm the M d t s t : ~ ~ t n s e t p h o t o a tw ~ .m k O f ~ A B ~ t m t b e ~ o f t h e T h l r a ~ hub, ~ gou ~-feel a it*dickum ~ ~ it d
a m -

b l a d e i i W ~ ~ a q~ xm *r - t ~h e ~W W a a d

y n & ? 1 / 4 " , y c n t w m m * p w w a c h * . ~ ~ o f t $ e b h u b ~ t h e ~ o f t b a d a d*0f~tBblewi8m~ttO o by fmr t b i t ~ d t h ad m inch ticmmdak tttie

Cb

m&*dalI&rchIn. GW'3.M,wm-the width d the M a d e by up to lhon I f ~ L ~ ~ , ~ h g v e t o m a k

m-a-wm

-b-whb*

-albfMwiderdpldm.

--Thehubmbe

~ - o f ~ , t h e r e a i

~ ~ e t t h e r c b t h e r n w t emy r dado blade is in how well it cubb T o do d & you need b Artd here, the lbd &k-W ar stQh'tdi~~Ftpr0d~ ~ a ~ ~ f r o m t h e c e n ta&

h , ~ c uw t s l i n ~ o ~ p d 8 6 1

ws e iel a s ~ d w o o d . B ~ a s ~ r o 1 2 ~ mthe~k~~youtoa i t ~ a &eda&s#m&herii&4lor ~ lk a"& DbbTwh I M O set &fw&ut:$2aO, &Emarg.inon

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m $ p ~ ~ b p l t

~
W s

lictlermffettm~herdadosets* c m p a d k ~ . h d t o m etwt , ~ b t W ~ ~ ~ m m l y d t h e db ~ ~

Sources
t

WTZle o *

fl 4to W d the

hdwm

~ s u ~ k honpgeBlsa&of I four d d m ~ W e pm &ad&eseloEa$.h

I

ahmhmdm.

are corn~w ~ xt a h a r &lion r E (page a) ~~-~ watestom3utifyouhave Irk& adable. This 3/4-ex&ioa ctrawer did= trouble finding it i n d u ~ t h e w o a dw ~ e ~ o n t h shelf are milable from y o u ~ o r d a i t h r n~h i n g e s , T b l , itemJT35m. ~ d o o r -w ~ m~ , a ad re thrededinerh. h i h k m d o n ddes h d i h , you'll a h wed on the drmw need muding h d w e (#32516). @th are 22! Hil.Lma~a m w ~ a d h~ farhbwhthatyouplanto long.) You can tirtd s h h r k n m w e ~ b y ~w ~f t h t h e d a b n . drawer&deBfram~Of eral aqlw home centem, ~ i t ~ the t w u com W i~ ntk 7'lw m E m 8 item Earn oflheotherhardwarr: mar&. Julfftmakewtfiat number is 47877. i t e m s ~ ~ t o --you o l ~ If yw M trouble youmayhmtoMrUttle c h m is rmd to b d k t t u t h e r ~ y w r r I o c a l theWeightofrhe~yau11 findiRstb=-k! we t u & beplradngonthe~ = = m mdtaary k bolt8 hwdwm @tmv. and w m h m win w* t o R a c k b r h r h ~ b The hard.

T t z e a n W i d ~ u s d MmvPfdzehardtRare kh.Youllneedtosrdtr 0ntheIidofthehxwa itemsudandledualw 6rrur ofitem#lWMV.

w,

wareudbo1dwtEhe equstbr w d -just with a s k d r h . won't look asowl.) Wl9, T . t r a c k(&lS3), F s h $ i o n * i e 3" lodptudt s w h l saws nohhgmEbanamtof d f u w l e furw31810),atPd iludl hhgm four 7/ut'& a (HBlO).H ~ , y w a m n b e g l i d a T h e oneswe M d i d ~ t ' s v i m Ifke &ormatthetlopofpageB h l d ~ h a t d w a r e uaed ~ eame with the tIteon~~orwaon~2 are 2 both adable h m h m m a a y d t h e m u m s nylon and s e WaihbIe h I n many "Ibol~i$tiasNorth,B ~ I n ~ ~ ~ r were d 4 purchasRd i l t at a l b o J 5tm% Mwm w e B a s * ~ T h e T h e ~ ~ k u a eh d ardwwe~Butifyou ~ d d ~ h~~ t o ra n ~ t $ c h ~ ~ b o ~ . m'tftndkyouw dmgdEisryJaw&wsa t b l m b t a m o f t h e ~ ~ W i f l g 8 a m dh m w e t D * f a m t & g ~ The pplylmth~ne and m sold timu& h able hm ShyNOtM ibr and IM! hem with p p r d ~ ~ f ~ ~ l h m i n ~ rubber-Hned ~ j 4 t w Wq, ~ item mmot.

knob

(rn12), f h e bolt

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' Wewwfdmhardwsrehm ROCKLBR in mangdo~new~~kikToot$er,~ulase:

omM-he&line, seet3el6w. h o p e n Monday through Friday, h m 8 AM to 5 PPA CentdTm.
I

B d m ~ ; p k h a v e y ! o t a ~ ~ ~ ~ ~ , @ m r , or h e r i ' c a n card ready. Tfyou W d prefer t o mail i n an order, please caIl the WII-he phone number below for more & W o n concerning shipping charges a s

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scenes from

' Nb M m S h i m An a~$imW& hub ~ c h ~ mm ~,@B r n tack aado blade allows y ~ t@~ he-tune l h e Widfh M Me lade without shims. Learn m Gbout it #,#age 34,

O N L I N E

E X T R A

Making a Longer Plank-top

Workbench
T
he Plank-Top Workbench in issue No. 75 will work fine in most workshops. If you need something smaller, all you have to do is shorten up the stretchers and cleats. A Longer Workbench But if youd like a longer workbench, youll want to consider adding some additional support for the top, like you see in the drawing below for a 12'long plank-top workbench. The additional support is provided by adding a center assembly. The nice thing is this center assembly is identical to the end assemblies. So you dont have to worry about any different parts or measurements. Work on the Stretchers Once you have the end and center assemblies complete, you can work on the longer stretchers. Whats different here is that to fit the center assembly in place, youll need to cut a centered half lap on the inside face of each of the stretchers (see drawing below). After completing the half laps, you can assemble the workbench. Add the Cross Rails The next step is to add the cross rails that support the top. How many you need to add depends on the overall length of the workbench. But its best to add enough cross rails between the end and center assemblies so the rails

a.

are spaced evenly and theyre no more than 22" apart. Cleats and Slats All thats left to do is add the cleats and slats. After sizing the cleats to fit between the end and center assemblies, you can add the slats. For the even number of slats shown between the end and center assemblies, its best to work out from the center of the opening and cut the end slats to fit.

a.

Page 1 of 1

ShopNotes No. 75

2004 August Home Publishing. All Rights Reserved.