GREAT-LOOKING FURNITURE! 373723135)" ‘Shopllotes.com at Transform Your Shop rt TWAS ] J Sturdy Assemblies with No®Fuss, Time-TestedYoinery — EJ Top Rust Fighters Protect Your Tools‘Smal Parts Carousel page 14 2 | Features Contents Smal Parts Carousel (OS 14 16 Make beter use a space wih tis tables ‘ade-on that doubles asa sancing stator fine tele Custom Chisel Set. 20 Ths his! at aves you te satan of ing tots youve made youre hereon wen Strong, No-Fuss Assemblies __ [SEES 25 ‘Dow joinery is e887 to oo, doesnt veque much time or tois andi rock sol ‘dream shop project Fold-Away Workcenter (EE 30 Compact when atrad ti projet tanstoms Intoa one of king workoonter in minut, Departments Readers’ Tips 4 Gd S Easy Drawers 3 Wi just single setup, you can bul raat ‘aware in ro time a at Jost aceseres Unleash Your Rotary Tool 10 These ol accossoes aaa way Betrmre on youreany ot nates &hardvere i: : Simple Solutions for Hanging Cabinets __ 12 han teamas ih hanging cabinets saa thoae topnochcousone doth job rg Shop Short Cuts. 28 Check out curatop tested ips and wamigu0s Jor solving your woodworking problems. hande-on tec Great-Looking Furniture 40 Lean how to make beter loking lege with ‘one rever sand a simple technique ‘ShopNotes No, 123nietop 8 Must-Have Chisel Helpers. 42 Cts nani ery nacho fon ng hl ccersoree sxng woo Super Options for Tool Storage. “4 Wat Dest ken entg ae ‘ake ook a tve te ested metnocs ‘mastering the table sem Easy, Accurate Joinery. 46 ‘A standard saw ado al ya peed oot Scout rar lor your ht project. — Protect Your Tools — Top Rust Fighters_48 Keeping yout foe nda re oton oan ote newonae recs. QsA 50 Sources. 5 ‘ShopNotescom shops We work with the space we have, ‘earforming it cver te (and sometimes aly) to sito needs andthe projects wer bulling Top xt with ht his tssue features a numberof dea for making etter usaf the pce you ave ‘Our feetre project takes thi ie to & whole new level — lealy. If 8 shop workcete that we've afectionately nick named “Shoptimus Prime” afer the Tra formers her frm Hest, When it’ olde ‘up, the workcenie loks like a tal storage locker. But when everything is opened up nd lacked in place, youl have all your tools at the rey lange, rocks work: surface, and the eilty to hale a wide rang fas, as shown inthe photo at eft Along the Same lines, but on a smaller seal, isthe router table extension wing you! nd on page 16 Instead of buling 8 dedicated rote table hat takes up lot of space, you sinly replace the wlag on your table saw with a custom, shop-made ‘version. For even sore versal, you can slip in an optional inser for taking are of small-scale, dust ine sanding. Finally if you're looking fora quick and easy projec that wil help you clear up the later in your shop, check out the small arts carousel (page 4). After ulding itn ‘he morning all he hardware that's chalk lenge tofnd can be organized and ready for ‘easy acre by the aerne0n.Multipurpose Benchtop Table? Tusemyignenteueniyinny ina wep. Are ss my che sa ater braking Sound e preter ae pre downs ge wai Sader gee sal Tee ar a Ms esses dale eo he ae Tier mare efter sty ssi nme st yume ser eagle Fu awisoT odd sone she emrorteneeeen cs gvienrcuel Tewie “opeveasoul pee ‘Sitar ecmeret te ule fr tage orice Tse Spe wher making shor, spa ene fat isa SelStassintelgiert tenets Te Stem cuvet es pret spt plas drwingbow ho Se “Se Das iat Once a Nr aes 4 ‘ShopNotes No. 123Like many woodworkers, use my table saw forthe majrty of asks tn my shop. For most ca, the ip fence works just fine ab Is. Some tanks, though ike cating 2 abet on he edge ofa workpiece requze sn auxiliary fence tobe tached 0 the face ofthe rp fence ‘ve used several methods for aching airy fences inthe pst If you have an viginal shop tp, we would ‘ShopNotes.com ‘rd ehskon ink ‘SUBMIT A TIP “There yout be sie to dexrbe eur pin deta end tose Dots or rewngs OF ou con tal your tp tothe esto ‘sree ehown inthe ight margin. ‘We will pay up 10 $2001 wo publish your tip. And if your tip is ‘elec asthe top ti, you also ‘eotive the PorterCabie cornet rovterkt shown onthe ight ‘ShopNotes.com inserts With coupe of insets added tothelaceofmynp fee, ean guy fed and remove an audiary fee, ‘The drawing above shows that I dalled two countersunk ols ny avila fence. [used those holes © ‘hark the lection for the ise ee each en ofthe rp fence. A couple of machine sews areal ned hol treything securely in place ‘Thoms Holly Bawardsvle, iis Issue 123 Mayidune 2012 sonon eas es a ay "ut yes Ses Pete sewonttmaon be ef aon Vu Ce ooo sincere casi ——= See ee ee sen Saat 5Case Assembly Stands ‘They toa sald ose geting all ofthe pecs square But ry- {ng to balance wide worepeces fon edge during assembly can really bea challenge “The stands you see ine photo stright an in the drswing above Se the solution Teame op whe ‘he simple design make it easy ‘sand your workpieces cade "Thee snl pets of NDF are all you need te make the stands ‘Thebes two dadoes it pa alle teach other and spsed for {he thickness ofthe case material. ‘The two vert supports cre- ste a rade to hold the works sces upright You may want to ‘modify thehoght ofthe supports ‘B work bet for you pees Tvemadeseveralfthee sands sn varios soe for supporting rater of diferent theses Chisel Edge Pro chisel must ave a sharp edge fre of riks ifs going fo per form well But ths edge can bbe easly damaged, especially when os ina toolbox forbs teay fom the shop. Tastendof sig large ool al, ‘The only change is the space betwen ese "Acouple of these bendy help ers for each workpiece ial you feed for that Bid nd ding yournent case assemby. ‘ef Haroey Delon, Fre tector photo that dye jut a place of wood ith 2 stillow groove ut he width ofeach el A lew of hardboard glued to one 2 ‘SIDE VIEW ‘ShopNotes No. 123{Gluing up wide panes can be a chore Thasisexpecaly rei the anal swidr than your woek- bench because is almost impos sbletovand thedampa up wile Postioning your workpieces. To avold tis hasle Lene up with the solution you see here made two clamp supports by mounting & place of xt uber tos hardboard bate, Notches cit tong the top edge of the sup ots fit the damp bars perfec Now ging up ange panel assimpleas dropping the dames into te notches td placing the panel woepiee in place Toh Blakeney Vig Beach, Virgina aa bes 7 aut Sait crear ‘ ie oe | He) Aj Buble A Cain Noman o Carson neshroer aves ea (Gusbec keeps his av/n shape time and space ints shop when fishing selves. ew wi adhesivebacked sandpaper He femporaly tacks wide stips of plywood othe Sanda centered dowel ends of ah sha then stacks them toy ‘ShopNotescom 1elie ~ Workshop Create perfect drawer joinery in almost no time with this simple but proven method. One mat qusy dover tein und fo connect he danerfonttote side hen You pea ea ne are Jor nd. wo tase drawer Dmry ed oval and takings Wh king drawers that dont ives ae fen pe JOINERY | tye thing tht Jon ANATOMY | Gousy ten lujstsgh can Senchllenge hohe ont he | ee and the setup cane tech, There an easer method, however, that rues jst oe simplesetup. And fs doe witha Nove camer roe sotcting bit tthe rote ble ‘The end sul the samme —a caer rot that lock n place ‘whe concaing the end grain of the sides Gnset photo tight). Workpiccen’ Prepare your woripieos by planing them to Pheer ticles. Fortis ch nique theses must be Uk. ‘The material for the fo can be ay his ogee ‘itd Spacers. T gt stated, you need a i aloe Bt You leo need two pecs of rater to ua sper. You' tie a thick spacer along the face ofthe fence ae a thick spacer on the able surface a.) By adding o© remov- ing thew spaces for dit ferent cuts, you can make the oint without changing your bi heght or fenoe fetup. Since the presse hides "of the. spec fs i important T Used High Density Plpeth ylene (HDPD, For more in casi jan snfrmatinon this materi so {he tonen te opposte page. Proper stip he yf ths tee andere wth he ‘Say tang te at tern your oe an tig ebthapaodurttopere cotingedge is above the tble {ope ence can the be ot 99 Ge wll mate a dep cat ‘Youmay vant male se et queens soap pa tocouete fonmetheght and ph "2s I mene! exe yout ets 9 and aH pace fecthistebique Now it aged Aine eat our pace ater to see The mtr sould overt fallen fhe ce. Curiting enough so when you damp tte nel te ce the danps wont intr with ‘ShopNotes No.128the routing. The 34” spacer is ‘ued elevate your workpieces ‘on the table sutfce Take lok 1 the photo inthe box below to Seewnati mean. ‘When you camp the spacer to the fae ofthe fence secre so the bttam edge of the spacer is above the table top by about 3g" more than the tuckness of ‘he drawer front. This loves ‘enough oom forbot the dane ‘ont andthe 4" spacer to easly ‘itunder The table pacer wll ‘be used ltr though so you can setitaid for nove ‘Drawer Front. When sake ing drawers ike to start with the drawer feats The cas on the ends ofthe drawer fot are smade in three passes with the Inside face of the front always agains the table or fnce "The fist cut made on each ‘nd of the workpiece with i lat fn the table (Figure 1). Be sure to use a backer board to prevent ny ehiput tht may occur For the ned ext side your 1" spacer onto the table surtace, under the Bit and against the fence: Clamp it ito place. Now snake a second past on each end ofthe drawer font (Figure2)__ ct then fp the workpiewe end shown in Figure 4 Repest thie You should now have a 3" forend and make the same cut cutfor the oder side. wide slot" deep. With the table onthe opposite end ‘Thats all you need to make spacer sll in place, make the Sides. The drawer font i beau drawerjinery that will, ‘hind cuby standing the drawer now complete. You can remove lat Ym sure you find ths tech fronton end against the fence the abe spacer and werk on the rique useful when making rw spores, a6 shown in Figure 3. sides. Sand the drawer side on efor your ext prot the right choice for Accurate Cuts This techriqu requis 24st sheet tothe next HDPE sa grst cutingbitand wopieesof mate option to use because i strkes alto use as spaces I's crcl balance between cost and can thatthespocesareeacly "and sistent thickness. ‘itick Thats why used High- HDPE is alo ighweght and Denaty Polyethylene (HDPE See lebl so itwor't break or cack thematrl nuseinthephotost easly. And’ workpieces de righ Sources on page Sas the smoothly acess it sulace. 5 etalon wheretobuy this exsytcutattheable saw, 0 2- 4 tigh-Density Polyethylene. “The thickness of many plas- ng i to your rut able and Tho consort tcinots of HOPE ‘sc can vary greatiy fom’ ne feels poem males great choc fo space. ‘ShopNotescom 9Accessories getting more from your Rotary Tool Your rotary tool will see a lot more shop time with these inexpensive accessories. I | es probaly safe to say that many woodworkers ownarotany tool ikea Dee) ether i's tv hey pose re hey tecrved ara git And Talo be ‘ring to bet that many end sp ‘icked away ne deawer. EZ Lock f Accessories ae With Drones £2 Lack mandrel, etaling EZ ck accessories sa sap, You can quick spot an EZ Lock accessory by its bat shaped center Dole T install slmply react the spy loaded collar on the marca sip on the aces sory rotate it 90% then else he al. 0 ‘But while browning the hard ‘ware sil at he local heme en ter | noted the wide range af [wae fair with te old tan ysl cating wheel an san ing drums. But there are hoe of other acess that made me ‘want to petthat id Droel ot a the drawer and put ito work "Yn can find fer cess at most Rome centers ane ard ware sores You can also find tet online at Amazon com. 1 Cutting ‘common tik fr artery teat fe cuting. Equipped with a cat ting disk specly designed for ‘he mater ovary toot mals Ita quick tsk few examples sreshown below. ‘The diamond whee great for euting hand materials tke ‘ceramic oor tle The carbide wheel cus and shapes wood, For most materials youl get beter reals wth + vanable- speed rotary toa. Tas wa, you fan slow down the speed 0 tinimize boring te material fr damaging the whe Taking it Slow isthe way to go. a s A. Pn you can se. how Tm cuting the he (of ofa bol using a ‘berglase reinforced cutetf wheel ike ‘he Thin Ca at ight ShopNots No, 122 Grinding eG Wen it comes wo grinding and Sep me we } Fran acer to lp on the job done, Grinding tots ‘Aum fe arable in lon exbide tnd aluminum oxide, Both ypes nist, sharpening, and grinding fe avaable na wide varity of ll ypesof ste Ser nd shapes Grding wheels work espe: "ou can tie sion cubide cially well for smoothing su sonesfordeburngandahaping faces and resovng mist. The EZ rater ike stone, gli, and Lack grinding whee shown in : coe Torderousmeilbliebnavand the poo atrgitatows yout Cleaning & Polishing lamin: The aiminum one se aco he whee to pind Sones work grat for memoving. suricesandedgmamonth, Threhave ren anamberof tins when yg tocdeana ight res and cotton swab ut doe? do thetic But with te wide section of brash, braves and fl posting acess th ol ishing compoune) caning sd psahing male tsk lmost no ine or float When desing metal rd too, ee the wre ‘ruses to remove stand bultp gine, Then, fellow ap ethan abrasive whol Fors fia posh ‘sea ell whee or cone with plein compound 3 Sanding Sancing ‘dum, nara A rotary tool excels at help ing. you sand Jstheabrasve brush You cance sera deta ard the fine brash (20 grt) on the Woven Fardtoreach areas. You ind a left and the medium Brosh (120- ‘arty ofsine, git and shaper gH i the photo above, Thar Sch as drums, Map wheels, and also a bg coare rath, The disks Justafewareshownabove. abrasives incorporated into the \e et | ‘One ofthe more ungue tnd uber bristly gre for ) ingeottvepowatoappecate ncaa sin ents, e Wire 5 carving & Engraving "YC yousop around, youTNhe sur cutee ave designed for carving, ‘Guneet red a he mamberofaceso- etching engraving, or shaping ll es you can bey forcarving and sorts of materials engraving. These sto carbide, Tve used the dlamoed burs for damondated burs and to etch designs on glass for ab Diamong 4 doors The highspeed esl mame cers work great for caving pattems on weed (ft phot) ‘The dazers of types shapes and sine of cutters make ety tobe Highspeed podoined erative with yourrtay tool & ‘ShopNotescxm nLHardware shop-duty Cabinet Hangers With the right hardware, installing and supporting shop cabinets is easy. 1 | The last thing you want to hap- pen to a wall cabinet full of tools or shop supplies isto ave itcome lowe and ers 19 the ‘oor Fortuny ths sina s svoidable with aise common ‘Se and the ight hardware Y Fastoners. |” T four a few cabinet hangers Selec fataners | that ar worth look They ange ‘appropriate for | from clase standbys to newer, tmewal ype and | adjustable hangers that make weight of your | cabinet istllaton a breeze. abina. fastonors eae “The Right Fasteners. Before alk about the hangers, I wart to review your options for secur Sng them tthe wall You canoe several examples In the lower let photo. Your choice depends cn the wal contin andthe sweight of the cabinet when ifs loaded up with supplies. T ty to secune the cabin: hanger into wal stad hen ever poole ing at eat a #10 woodserew or Wg ser Use 2 crew length that wll go to (he stud atleast P02 1F you ex’ secure a fastener {nto 4 stad, use a allow wal anchor lke a togle lock or strap fees Foo mate ve they Inte forthe toa weight of the Cabinet nd its content For concrete or block walls Tico sre are easy to install, Jus dail ole with the carbide ‘masomey bi included with mest ‘seve. Then drive the fstne: into the bole find an impact drivers great fr this ack. ‘After you've selected the appro priate een, youre Kl with A Uitte Acjustabity. Loe \alay’s eatinet hanger offers three-way ajusiment vacety of colon in hanger 1 ‘rant to mention afew that ike tomer my shop ‘Way Adjustment. The shaped hanger shown above isa gaat choke for shop cab not A pir cot es than $20. ‘The hanger mounts to te top cof the cabinet with te ince ‘arrage bot. The slotted hanger Soe Mow ip rr ‘djustment in ode to compen: fate fren uneven wall "The lange opening i the ver- ‘ia leg of the hanger slips nto {grooved plist cam that you ‘secure to the wal witha ia fartener By rotting deca, you. ‘an adjust the veral poston as much as to level the ab net You have approximately 4° sldeto-side adjustment by si ly hiding the hanger along the {ove in te edge of the cm, ‘ShopNotes No. 128Te 7 Positive Engagement. The ext tne types of hangers want ‘orale sbout ar allavariaon of the traditional French lest One ice of the hanger i attached to {he back ofthe cabinet. Is mat Ing piece is fastened to he wall They're ary 10 inal, respon: sive and inetlck to suppoet @ lot of weight. Tat’ a combine ‘on that's hard beat. ‘Adjustable Flush Mount The ‘ype af hanger shown in the let drawing above has been around fora lt of years. The diference wih this model is hat the slo in (he feral portion ewer tha ‘he mating tab This alo for 2 lite sdeto-ide “gg oor” for aligning the pare when mounting the hangers and ater ‘when hanging the cabinets. Zclips. Another simoteted hangers the ip shove in the center drawing above. The mat ing parte provide a strong co rection. These alin ext slons ar olin precutsesons or longer strips (up t 367) you ane tolengh ‘ShopNotes.com Strong. & Level. A sinar danger made from to akan ‘um extrusions ls the Hangman Shown inthe photo ard dra Ings below. The wall-mounted portion inches 4 level for 2 foolproof instalation. The pnce ‘mounted fo the cabinet wages hind the mating pice om fe wall for astro conection High-Tech Hangers. The lst type of hanger I want fo ere ‘So ie shown inthe drawing on ‘bint You gt upto ast ‘ben in tt ard veal poston by fuming he op two sews ‘Tet sw oc ab et ono the wall-A ple cap Covert date youve made ‘Motte adam egal f your dace all these hangers prove pce gf rind when hanging oes 4A Moder Clest. A buitin ive! ‘makes instating cabinets with ie Hangman hanger abreczestorage solutions HE One thing tha frstates me ‘when ulin aprojeti aving, {o round up all the sews and ‘ther ardwae need. The har ‘ware carte show above to onganie al be parts and tener and end that ita, ‘You can buildin short oer swith ust a fee pple. Al you ‘ead are some paste bis eazy Sasartbearing afew psf air rina bar sok, ad 8 quarter sheet of plywood “ ‘Thebestpartisthecarousel sits right onthe bench. Pls, de bins ae easly removed fo tae ‘hem ight hee Teed ther, "A Round Bae. To pt sarted take look atthe desing on the next page. Thay show you how everything goes together [worked from the bottom up, begining wath the ound bse “Footsie acinte [used see pst to lay out te ce then Faded over to the band sa ‘Alter cuting close 10 the line, you can sand the edge smooth, ‘The now step is to Tout 2 roxindoveronthe tp ge beore ‘moving on othe platform, ‘Square Platform. The pt form holds he four versal pa cdathat suppor the bine Its si square with rounded cores ‘Once thats complete, you can ‘rake the four panel Panels, As showin the draw ing allofthe panels areidentcal ShopNotes No. 123Panel Assembly. Detall ‘a! shows how the four pans are ‘ssembled with screws The only trick sto stagger the srw loc tne vert 0 avoid interfer ing with one anther. Once the panels are assemble, attach this Unio the plato “Alsmingm Brackets To make le easy to stow the paste bins, [made some hanging brackets from aluminum sips: Deal‘ shows how the tworplae brick (es work. They're all ential, ‘itsenry oot up an assembly Tne process to cut and del then. Before dling the screw holes, stoned theo paces ogee swith cyanoncyate (CA) hoe ‘To poition the brackets on each ‘ShopNotes.com ‘ofthe four pants, [are yout lines to locate the btm edge Fastening the Bearing, Now you're ready to mate the panel ‘and platfom ascembly 10 the bse Simply center the lazy ‘Susan beating on the base and ‘mark the lotion forthe Ig ‘tawss hole snd sew holes Aer dling the acu, ate he bearing tothe base, Now youcan ine up the aces hole with each scm hole and attach the pat {orm ately to the bearing ‘Althatsleftto dona ieslipa ‘dozen bing onto the brackets a ‘them full of your mostaten ‘ued crews and fasteners. A sano dary, 2 Recemo 1n10-3Fy © fare) Saiz 3. D BradetRewstt) esha E medet roms) 1184-14" Am, tga ny ian eng ‘yi so" Alarm ar) 1} 6" Arr Pts "Weodeoene Sa) ew aM be 15extension wing n A Saraing Staton. Hopi ‘route plte wih dow insert to DJ Maximize the benefits of this essential tool without sacrificing valuable floor space in your shop. Foor space at promi in ‘ost shops S0 when Tadd ew too to my shop, The 19 find ways to make the Best use Sf thespac tat sabe: One sae shop tol that doest’t Strowterabe 6 “The skin is the table in the snain poo above replace the tenon wing of your ble se, Phas itdoes doubled sea san ing siaion, You simply wich (ut the outer inset ae for an tachment with inteprat dst ‘alacon eset pots above) The wing comes together with basi contrition and easy-to check the dimersons of yours bore you get stated and ue he ssjstment ‘ShopNotes No. 128fend ofthe ibe it dado ut in the back ell igure 8) And lange notches on the other end Delp socure the bet the font fille igure 23. Bele fiting the font fle, 1 lu 2 eat each nd a that Ieips suppor the op (igure 29) ‘With the fon ler ple yes can cata back fle and se i as sper when aang the ibs ‘othe rot fil, Afr png the ‘Soul togeter youcan und the vo cutie comers of the ‘eae atthe band a (gee). “Top. ct a hardboard tp to St inside the frame. And then tdided 2 laine skint cover ‘he whole assembly. Cut thelam- inate oversize ana gi othe top and frame A dush tin tia at handheld router makes quick “work timing the exas mate al igure) "Track & Insert. Use 2 dado bade to ut the powve fr the combination track Te opening or the invut plate canbe ade swith a jigsaw and» handheld outer Youcan nal the dens in hop Short Cus on page. ‘ShopNotes.comadding a Fence “The router table wing is opert- To provideclearancefora wide inal a ths pint But for mare range of router bis, cut a seme verality Tadded a fence. The cicular notch centered along fencrisn'tcompliated ifs jut the front edge ofthe Base Let face, abese anda few suppor the notch at the bandsaw thn Base. started by cutting the sanded t smooth witha sand use to size and then dilled ng drum A chamler around holst esabish the ends ofthe the top ege ofthe notch helps slo ed to secure the fence 19 dict debris into the dust ck the uble The est ofthe waste lector This ie enly done with a removed with jigsaw. hmverbitins hand-held router A Featherboard. Use ma_comanstian trackto adda featerboar oho abl. OF ‘anaon ¢10 he fence wih headed insert. TOR VEN da. ‘You can then cut the mapports © sia ed attach ther to the base ‘with screws asin Figure 5 Face The ace of the fences just shag pace withanotchcut out St he band saw Cat to shape ‘stand then make the noch or sey I wanted tobe able to atach a bit guard or feats ‘boar 1 the fence. So Faded tive headed inserts to he fce ofthe fence, which let me tach ther aceuory as neces igure Sb shoves the lctlons to dil the holes for the ince. We important to note tat the spacing ofthe holes Is speci to the secesories 1 used. You ‘see them in ue in the mala ‘hoo on page 16 and inthe box fo the left Bor information on ‘hare 10 uy these items, se Sources, page 5 ShopNotes No. 123ample he fe by ging ss tt a Se Ito spre Then Jou Chad niet mere SS sn te ee wth ‘dad ube town Stent ryote page joven wang savows sraTOn Sending ne fy fro actin wen erg on het Teh dn salSre nto ee ac yur hah ole Gera yo sin iovingat ges peta Cnet te Tha pened aod diet pine barat mine an Setar we pie pes in opening on ‘Sle The yn Ce sited come get Secettoreting er r tes ine’ ith hed Sot eft ack Pins the ame a aed Eieerwitecene Ale, ‘adn tee leutintecentd theta ple for dt port Tne pce oth er siete way at Argon dst porasbwe ‘eK Tas hae pve easton Theses pce oe MDE pad ger Materials & Hardware ‘ShopNotescom Arn ai Yrh-25 —-()RoerraePine seer) Yathas — one more hing ‘Te finished bes ae only 9° wie so youl ee o gen and fle of eachsde. The margin drawing sows you where the blade narrows just below the Iseation of the bolster A pal of Serbo lines Serve s your guide ‘en rindng a fling ‘Aga 2 sanding drum helps senooth the ar that transitions from the to 4° width Fal, smooth the stright edges with a Sle before ling the bevels Bevel Edges The decorative bevel along the top edges ofthe Bade also sewer @ couple of practical purpeses It softer the top edge ae alws the chisel to ‘tino ght camer. ‘o crate thobovl, I attache the bade toa wide Iardwood blank with doublesded tape, The thickness of the lank matched the wid ofthe Blade (Gar left photo). The wide blank slevates the bade shove your benchtop to prevde clearance for fling the bevels. ‘Aller dampig he blank in Vise, sea conse fe fo remove most of the waste To create 2 casi eve, ve found hatit Fret to make ig ok logs thee engthof the bevel Fn |sh up wih a sooth fle and 2 1d gitanding Bock Rough Bevel. At this point I ook the oprorsity 1 form the rough bevels on the ends of the bade. For the shew chisel, youl ned opin the 20 skew ‘StopNotes No. 1284 rit for Rivets. Use CA ge to fasten the boisters 10 the lage betee ailing net Poles angle before crating the rough 25"bevel angle Take lok the ‘margin drawing on the opposite age forthe detail “The steel i soft enough to make forming the bevel an easy task using a honing guide and 2 coarse diamond stone, Coase Sanupaper works ast a wel You don't need to form sharp eget this point Youll do that ‘tert handle attached. ‘Adding the Bolster. You can set the Made de for now and fat fo work on the brass and feel pins Bat make up the A Hardening. Use ples 10 ald the binde blank whe you beat o an orange-red gow ‘ShopNotes.com 4 Peon the Rivets. ith the vets eighty prous, peen them onbotnaises decorative bolster Youll find fullsize pates in the right nar Te yout proces i the sme coat the blank wih dye nd then seb the ptt, "The pats that wil aie the most atention are the visbl, ‘apered portions Both pecs are lghely chamfered along these tgs Note thatthe ste! pce is tls sigh tapered in thickness (sce the sie won the ih), Rivets With thewe pices in hand, you'll work on attaching sham thebade bank Itared tbymarhing the hol oeatios for the rivets with 9 center punch Using a gel cyanoacrylate (CA) le, align the bolster pieces on the blade and clamp them in place for fey minutes. Then You can dil he four vet oles Uhrough he tack, as you can se inthe left photo above. 4 Quenching. aucdy immerse the or banking ol and move t around to coo the ead, 4 Smooth the Are. A sanding (hum is periect fr making the fare ush on al twee pieces Shor lengths of brass rod form ‘he rvs, Use ballpeen ham rer to “mushroom” the vets, locking the Bolster tothe Bade ‘Aliiefling and sanding wl snake evrything smecth 25 You Canseein the photon above. Hardening. & "Tempering Since the sl is prety sft won't hold a sharp edge fr very Jong, As shown onthe et youl eed to harden i by heating the fiting, end tan orange-red sow then quickly quenching it {acanof vegebl ol (89 Best todo this outdoors) used MAPP {5 since i bur ite hoter {han propane You can sil use a propane tor butt might ake a [ite ange to eat up the bade. ‘The ste i hardened at this point, bat brite To temper the lel sot wil maintain scp ‘ge youl noe to heat tin the (ven following the irtractions Inciaded with the ste. Mine speed 450° for one wr The blade and bolster ean up nicely vith bufing wheel and 2 ie poling compound,la [Now that the metal work is done, you can tom your atenon 4 ‘aking the handle [chose coco. bolo for an atiactive compe ‘ent to the bras and see. A brass gas fing serves as the feral nice tanaton fom the blade tothe hardwood han- dl, (When working with exotic woods, be sure © Wear @ dust ‘mask. Some woods can che ‘lege reactors) ‘A. Brass Ferule. The frst order of busine i to obtain the ‘ras iting that makes up the feral (phot atl) Youle ittosize the tenon on the handle The fist steps to dla cx ter hole nthe fiting, a8 shown blow: This ole provides a cen ‘epoint for mouring the handle aXe’ 1 Shaping a Handle. The lathe i he perlect fool fo shape the oxoic havood handle and brass feu. Take it sow and steady {o.gata smoot, palshed hance. sembly onthe tlstck of your Inthe after you tam the enon on the handle Bank Yul stator that task next ’As you can sce in the lower Jee photo below, the next step in making the handle i 9 fm ‘tenon on the ed ofthe handle ‘lank You're aiming fora fi that ‘engages the threads on the Bass 1 Center Hole. 4 smal center hole serves asa conterpoit for lane ofthe ere Siting ower right photo). You rant main a square hole (der on the ani for aight ft wvith fe brane iting, One you fan ead the iting onto the tenon soit mst tight agai the shoulder app ate epoxy fastenthe iting permanent “Tur the Handle. Now you ‘anttount he handle and ferrule ‘sent on your athe to begin shaping ft Bt youl do some ough shaping tum the handle Toure. Twsed a oughing gouge toremove the bulk the waste ‘Net, youl need to tum the ‘ras fig round. Tis ls easy ‘enough to do with a couse fle ‘wie raring the lhe st ow ‘ped (upper et phot, opposite page) Then swith to a smooth le tohome non the nal ehape of the handle and fer, a8 howain the drawing ate 4 Checking the Fit Tarn the tenon close tat nl size, thn ‘heck the fin the theaads. Sopot No. 1232 Turning wit ls. turning the fre and 1 A Smooth nish. Use progressively finer gts hancie ound, uso a series o es 10 bring them of sandpaper fo smooth the handle and forule tas tare spinning on th athe ‘0 nal shape bore sarang To cele atin sheen on the handle asembly, sand it wule thelatheis manning with progres ‘vey finer gis of sandpaper 1 ‘sare with 120 grt and worked ny way up through gat (upper right photo), Fora higher ‘los, you can sand toa higher ‘Bat and apply a wax withthe Farle sil pinning onthe athe T'aimply sprayed my handles sith coat of oer x 4 Hote fr Hand. Dri th Ye" hale 59 you can begin to mato the bac with te hand Filing the Tang. The final step inthe pres iting the blade asembly ino the handle Toatvold gaps between the Bade and fete, you'll want to exe fe a ile pasence. The gl forthe shoulders of thetang oft tight apne the fae ofthe fe- ‘le wit no notable gape. Stat with a Round Hole. Before you can sat iting the tang tothe handle, you need to ‘cane he hole in he fel. ‘sed the camer olin he f= rule as guide (upper et photo below) A wood handscew with Y of Whe es A Shape the Hole. Uso smal es 10 square to foe who testing te tang 1 Shaping the Tang Round aver tha sha comers of na tang fo ‘make easier of no the hanate, Continue shaping he fang nd tale inte nance unl he fis seamieas ‘ShopNotes.com | Vnotch cin each a mks it eagy to damp the handle for dri. Then use a ie bi to dal te hole forthe tang. ile & Fit Here is where patience comes into ply You're bg to fle the sharp comers a the tng round and shape the hole in the ferue toa squae shape (photos blow) "The target here 2 snug ft. Alm to get the tang of he Bade into the handle t0 the point were the shoulders ane within eto ofthe feral ou should beable to dive the handle onto the blade with fer light tp Bat you need fo apy some epony into the hole fs. Then igh top the handle wil the shoulders onthe blade are bate tight agains the end of ‘hebrasferale Polish & Hone. Now is the time to wipe the Bide dean with laser thinner and pol ie ith a ite pate wax {S balp prevent rus The last thing to do is one the edge Sart by fatening the book, ‘working your way fram ‘corse through ie grits T Hi tousewatestnes for this task Finally, hone the bevel 8 rar sharp alge using the same process. Now you an pal te {ge to wood fora alien %Technique tips for strong Dowel Joinery Learn how to get better results with this time- tested joinery method. are square, Making acorate cus {tthe ables imporant ‘Aer the paces arcu ie, youll need to make a decision Shout the dowel you ue ‘Dowel Selection. The best doves are ited grooved fitin the dowel hae. When glue ‘sapplid they Lewelfora tight fit You can se a variety of dow deat the bottom ofthe net page Dowel Diameter The next ‘consideration isthe diameter of the dowelA good ue of thumb ‘stousea dowel equal half the ‘thickness ofthe thinnest ork: lee youl being $0 for 3° ‘tock Tus 3 dowels. Dowel Length, In. genes! terms the longer the dowel, the stronger the jt Bat here api, youre nea by te tannest ot rarowest workpiece T exp 2 supply of 1° dowels on hand for meet tasks, Teer longer 2 dowels for larger projets ke tables et photo above Dowel Spacing. When lay- sng out the dovel leans ts good idea to stay at lest 3 ‘ro from the edge ofthe work pice. This hips avoid any tn ‘Seney for he pice ost when the jolt ie asembld. or the remainder of the dowels an for ros joints, I space te dowels Bt camer Oconee ‘Number of Dowels. The spac. ing wil determine the umber of dowel ose. You want fo ‘ShopNotes No, 128y A Layout. Mark the locations ‘or the dowele wih centrines ‘erawn aeross the on. 4A Drill with Accuracy. A brad pont bt and accurate setup ‘ure clean, square Noles we atest tot agp the work pie surface lied ‘Accurate Layout. The 1p thee photos above fake you Uivough te stp ute to late the dowel les, It begins by liging the mating workpieces fand marking a Une across the joint at each dowel ation T then use © marking. gaoge to lay out the centerline of the ported ene wing ata tine on a= ome. Then Thine evel and fh withthe cater aston. ‘The holes in the center socton serve a a gulde for dling the ‘vot holes inthe wing, Then 1 Inaalled artwood dowels to serveaspivt pins asin Figure 6 4 Easy Pvotng. The fog wings of tne berettop pivot an harawood ‘owes,making the Support Assembly ‘The canter ate of the workcen ter camies the lions share of the weight — expecially when 1s al folded up, What the case ‘won't doi provide suppor for the wings ofthe benchtp wher ‘hey lowered for use. THs gets trey since everthing needs to fold up compact 8 wel ‘The tak of supporing the wings when in use falls tate past Neged ase made up ofthe legs a brace, and a hinge lod a haste in Figure 6 ‘The legs angle outward 10 cate 4 mom sabe ance. Lg eve (2s allow you fo compensate or tieven fon and evel he Wing "The thee prt ave fled By “This allows the asem- yf fod fal agit the seo ‘he woken Infact the thee pets wil “snap” into positon pune the cat to prevent the ‘ings from dropping ‘Side Blocks, Boone making and instaling the support assem bly, you new to add a pair of blade to each side of the case ‘These Leshaped_piees reste ‘recess to owe the support fssombly when retracted 5 you ‘ance in Figure ‘The side blacks are cat fom ‘neo gd-up layer of plyeood. “They should ft smugly between the easter plates and the feed Dbenchtop a shown in Figs 7a and 7. Aer cuting th ples to shape, [outed a W”roundover ‘on al the eutsde edges before sing them tothe ase sides "The Leg. With the side locks inplace, you now havea defined space in which ot the supprt ‘Ssombiy. stared onthistask by snaking the lage Lk the side blocks, the lg, se well atthe braces and hinge Boks, ae made from two 1 ce of plywood, as shown in Figure 8. When making the up ort parts, my main goal was © {tthe dimensions acura Ts ‘way the asembly is guaranteed to fod and unfold ently and ft intl paket sooth ‘Once the legs ae shaped, you ‘anon overall thecal. the exception of the top edge Then cla deep hoe in each fot to hod aleve as In tal 8, ‘The ge ill eed hinge mors, but el of here ul he bce sd ings block were made ‘Brace & Hinge Block Making ‘he eaning pts goes qucky oth the brace and hinge bok can be cut sie fom lued-up ‘lans. However Tf the hinge ‘ShopNotes No, 128rounding over 4 few selected fees, you can Bt the hinges fat connect all the parts As explained on page 252 router anda simple template make cre- thing the hinge morte anesy Job. Just take care to rout each pir of mortises the comrect face as shown Figure 8 the leg and brace connected, attached the let the wing at ‘damped the wing in stowed poston. Figure 9 shows how to St the hinge block positon Aang to the brace and marked where it met the caster pate ‘Afr citing i fo lng, soured ‘over the bottom outside age, luittothecase side, anc srew the hinges into the mortises. “The Vise, lace the wings ae row funciona, you ean add the ioe The dts ae shown below, The vise fe mounted to 8 Plate tha can be verted ino the ‘A Quick Dhenge. An acted lt ets you qu slo in lard secure he we0 on eer ert wing. 37ae add more Storage Construction of the workeenter Ibin the home stot Hare, the tasks toad someactiona, BD cere regponeo eis | ec ‘bench. And I also wanted to Sniieans ‘rea way to enclose the work ‘SS ate enter atthe en ofthe dy Sees "fo handle stage, thre ae theo age peghoud panel. This rovidesaltof option for ong Wsallcloned vp. Now all that sneeded away to closeup the font an ep. A al of doce and a two-patp fomplete the tarsformation : from workbench back #9 3m a unassuming storage cabinet. ‘Cabinet Back The ist stein ‘Thee isnt sccomplihing al this to add much avoved {lage eabinet back (Figure 10). here, ether. The ‘This plywood panelservesacou back is simply cut pleot purposes. to size and. glued and Tint st acs as the mounting screwed to the lowercase an surface forthe pegboard storage the fixed workbench ston. ‘panels. The other thing the back Pegboard Panes. Asche 9 back and 2 pepboard one flows create an anchor pot tothe font face ofthe cabinet ack Between these isa framework lock the workbench wings and i one ofthe pegboard panck. of sles and rat that create the legeintheuprght postion, You can se in Figure 10 at ir Fesine sor, mn fe ‘And tet me point out tt the nel scented on the back and potted witha aight gep shove the worksrfge to ro ‘ide dearnce forthe dooms, ms lysuated in gure 103 Side Panels. Hanging on citer ide ofthe center pane are pair of swinging pegboard pan- {3h These panes share the sme onstruction asthe centr one as youean sce in Figut Tnweded a way 10 hold the panels in the open postion So Pintle & pair of rare-earth magnet sts (washes and cups) fneach dors i gus Ha tnd 11, The wide "tbe" ofthe Cabinet back provide bracing for the panel swell ‘Wrap-Around Doors. The nal ditions to the pegboud panes ‘ae a pal of doors, a shown in Figure 2. Theyre simply ples ‘of pljwood cto aie The dors far tached tothe singing eg. ‘boar panels with 277 ngs (Figure 12). Tis lows them > fold fat behind the panels and ut ofthe wa A ct on the Cap WO. The fal pies © snd tothe project are the cabinet {ope My goal wae fo inclade » sway to endow the top without Timing headroom oF biocking light. The solution ira borpat ‘opassembly Theback secon of the opis screwed fo the cabinet back (gure 123). Apairabrake ‘te provdeaditiona suppor. “The rant Seton i hinged the back scion. A set of mag. etic etches inte om fan on the doors keeps the doors dosed asin gure e. “Thee are a few more items ‘etal Bint tide bolt under ‘och wing fils into a hole dled inthe cabinet back (upper mar fie photo). Then I mounted Power and light strip under the top, a shown the Bo below “At at the workentr is done Once you've gathered up all your tes, your have an ideal place to ‘ull journo projet 2Technique craftsman-style Asingle bit and this simple technique guarantees great-looking furniture legs. ‘One anda sie sou tows you cut bth haes one terockng ant The sight grin and ray Bc fount in quarenavn white conk aw one of the hala of Cestaratyle Fumie Bat wisn furureegs are made fom, 2 sgl sob! Mlk you are Wp aly et with quatasavn figure oncnly wo fae le ‘One soution isto ete lags from four separate pious ld togeher with lok miter jae ‘Youcan ein he photo a ght thoteach eg secon has a protie ‘het inti ih the ajcint secon. oth profes oe cut using, 2 lk miter bit (margin photo). ‘This wctnique at dit but rer setup sky. An theres reel worth the ert 0 Prepare Workpieers. Fr each leg ifs bet fo tart by planing ‘ne wie blank ofa hcknese ‘Al our faces of the el Be ‘ut fon this blank, ensuring that {Bey ae the same thickness and Inve matching eloe and gue Lave the blank eta long for now Ife alsos good idea to plane 2 few scrap ples to te sae thks 0 uoe when sting up therouter table ‘Sart by sting the rp fone on of your kg and ip he Bao four sete, At Ts oi 1 Bk to ly out the workin in thee cig order and ask a V ‘se the outside faces gre, Four Quartrsawn Sides. Get poroct quartersawn logs froma single, wide workpiece ‘ShopNotes No. 128ENDIEW Names 1g Ts ecave ae ya Nee “This ns that Lou the comet the Bit height. The hey i for he profle cn ach edge and hep 9 inteocking section of the bit © famange hele during sem be eral centered onthe work Ws abo a good idea to ough piace. Adjust the eight ofthe Bit cut the miters on your Woske un the face of two fest pes Pies at thir time. The lock with matching profes etapa Init biti age and can create seumlealy an igre 3. 4 stain on your Toute So ifs” You can then adjust the fence beat to make smal, 4° bevel so the Bt jut barely cuts all he cut along the edges of cach way to thetop fac ofa tx pie ‘workpiece asin Figure2above Figure 4). The gol is @ sharp Router Setup. Baas of the edge where the profil meets the Jage bt sz, you also Wan! to ouideface of the workpiece set the speed of your router t.—Shaping the Leg, Once the it ‘ound 18000 9a Proper setup and ene ave been st the sti oftherouer bless by sting fay straightforward, The setup custom-profile Push Block Thepushblockyousec areal alps when cutting the seco proc each eg sacs, ‘Ahandle and det help push the workpiece through the Bit. And the boom slg is securely in the workpiece (Cat the profile with te block laying at again te table ‘ShopNotes.com puree Tobelp wit fh, Tmade «custom push Bock Have lok at he box at Iefttose what mean Complete egy sbi theses wh ond camps ral ate gt Te cod ula leg wih bens ‘tulgainonerery ae & a AAitemato (lamps. Hit ‘each sector inplace ang ghew by using Clamps abrg tne legs long2 Wn wos on SN ee pee peers Samatepeee ae soescermeart Sucyecs: wir Dagon romaine Nonedoteafns Stig [OMENS wk coin Se mace at erage choitinetitng | Reker « eee Scat swieated aot Papeete | | Suis aaTaas Ee =6 & Marking Gauge. Tho force ‘on a marking gauge flows an ledge to seribe a ayout ine. These accessories give you a head start on making smooth, accurate cuts with a chisel. rake accurate cut. Over tine, thiscan ed a cronicjent pain ‘caring friend showed me nother way, Carvers use 2 mal Jet for bth hoavy stock removal snd pecs cus. Theses ie ‘ype of mallet and how i's used, “Ahesvy malt wed with em blows sulky chops out waste ‘smaller mallet ed with ght psig cuts, Th strategy lets me ve the pushing for one oto ery ligh final panes ‘Matking Gauge & Knife Another key in making scurate ‘as is postoning th chisel in tBerightplice, Toprovideastart ingpoint ike to srbeacut ine rather than use a peel You cin do this with wither a marking tage or 2 masking he. The ested line caches the sharp SopNotes No. 123ade ofthe chisel and postions it while you tapi apply force tomake the cil A masking gauge works by scribing Hes parallel toa refer fence age (ower left photo on the facing page). Froter layout ‘chores a marking knife does the job, down inthe ower ght Photo onthe apposite page, Fence. A big part ofthe ver. sat of ciel stat you cn Appreach the workpiece from 4 ‘ant of ange. There are tins, however, when you nec to koep the chisel “och in” to a fed newton. One good example ‘Shen tezeing the baie of dovetals as you can see inthe ‘per right photo. in order t gat 2 snug the tacline should be perfectly staight and aqua to the face To achive this Tus a stalght plese of hardwood a fence By ‘damping tnplace on the ayout line, can make the fine pacing ces necessary to tot the at vith perfoet acca. Martie Block. Archer sit ation where guiding 2 chisel ‘mpoant is aguanng up. the fds of «mort, You alm ere 'S making sure each end is per fetly square to the surface fora {good slid connection. Todos, Tada hardwood block with 2 ‘ence tongs and amp hog fae. As you can sein the lower Jet phot above, the Bak ofthe ‘tise rides aginst the block Miter Block The block nthe lower ight photo above works 1 Simple Accessory. Ack hardwood fen clarped along he baseline Kops your ches on tack whan tinming tha socket of @ doveta 1 Square Up. Camp a boek to a weripiece fo ensure the (end8 ofa morte aro square along the same lin as the mor. tse block. However, instead of holding the chisel vet, here the fence cut at 4 es and to mer the inside comers of & role mots nd enon rae, ‘This allows the molded edges 0 Atiogetier sere ‘Chisel Roll | mentioned er- er that yess are neve fa 2 erect Mites. This Bock guides achise! to mter mocied ledges fra fight in a rae. from ie when fm working. To keep than organized and the ‘eges sale, I stow my chisel in 1 Tether oll, a you se in the lower let photo. The rll makes iene to take ny st of cise anyorhee safely ‘trop. Finally, sharp chis- ‘es area mist for dan and ‘accurate st So between some orkng compound touch up the ges while I work. You tanacethis inthe right margin, doen't take much to Improve the rest you get wen ug a chisel. Even f you Prt jast ene or woof these Sm Ble dens 0 workin your shop, Yyoullsee what Tmean. & Safe. A eater ro protects the edges of your chisels and ‘makes hem easy to carywet a TT. Shop potions for Looking for a way to store hand tools? Here are a few tried and true methods. Ak fie woodworkers how they store thee shop tools and youre lly ogetive diferent ancwers ‘You aso may ge five passionate defers of ach syst ‘Butthe realty about shop sor geisha there’ snota "one sae- fea” answer What works for ‘ane stop might notin anothe, Wit that sentiment i mind, etna oot the pros nd eons ‘ofthemcet common shop storage ‘option. Based on these evalua ‘ons he hopesthat youcan inet theright san or combination of sclations for your shop. Tliteescie iioendtues Pree See aieatcoee tmemsoe Senators ome ee er Sanne fears ci Nonfat pad tool dean and dust. Soca ls makeitany size you wantand add waysor drawersto izes ite verti ‘Cons. A tol chest lakes 9p valuable Noor space, wich can bea drawback in «small shop “They can abo get heavy and ‘kckly. And when you need a foo, you hay have stoop down and do some digging, iptto it depending on whe its Teste inthe ces. Mobile Tool Cabinet ‘You ca ook atthe mobile tol cabinet asthe logis! evolution Of the tol chest I's generally large, as some. convenient combination of doors and dra fs, and features heavy-duty ‘ters to make teaser to move round the shop. Pros, The overall design of 3 twolcabinetismore exible than a tool chest. As ¢ result can ‘eas lps atl ex you re ito And ican feature Both ‘compartments with doors (CF larger tools and. focus) and drawers (for smaller tools and Irdwars) to meh the way Yyouwork Plus thetop ean dow Uicasa handy place stl, pln, or hardware wile you Weak ate neat workbench ‘Cone. Even wih ily 2 cabinet ent up aot of ale fbi Boor ape And most of them get quiche onceloaded treo The econ sore $B ie for protecting tol rom Tccomparne enn wih orca etched in our if you dent tay vga about your orgiaton hai ‘ShopNotes No. 123> Wall-Mounted Tool Cabinet 1 oor space ata premium in your shop then why not ep that space by mounting your ‘ool rage cabinet on the wal? ‘has the handy slution tat many woodworkers ave chosen. Pron The main advantage of the wall mounted cabinet Is the peeration of shop space You ean store all your tals up high and even park power tol bow It Plus a wallanoured bine meane no sping ore to gett the tals and hardware > Open Shelving Sometimes, simpler is better That's why many woodwork: rs choose a sete of open shelves, or “cubis” to get at ‘Ml her tool enaily Pros. Open shelving units ae probly the least expensive Shop storage option and hey ze also the easiest to put togetier Ps, they kep all yours i bl and wit easy rach wile you're working Ifyou ever ned toreconfgure your storage ws ite ot easier to move shelves younced.Youcan even add {es 0 the doors to make ‘Deconentseny toate ‘Cons. With 3 wall mound cae, “eae ‘st btn fo mown it ‘seurely. Considering thi, its alo important not to overload a cabinet with oo ‘many tools and create an ‘unsale sinter Final, ‘wallountad cabinet are arder to move if you want torecaniigure you hop, Cons, Shelves might be cane venient for geting acess to ‘ool but they just don’t look as ood a some of the other tor ge options dicutsed hee. This 1s expecially true if you let the shelves get disorganized and ‘lateeds whichis easy todo, ‘The fina drawback to str ing tools on open shelving is the protection factor: Tools on open shelves are completly exposed fo dust and moisture In the air, which makes rust and other types, of damage # real possibilty. «Workbench Storage Just ike storage cabinets, a workbench i an indispensable pat of any shop setup. ‘And since you spend so much me work ingatthebench i'shardtoimagines more ‘wenden oeaion fra bank of drawers tnd a coupieof torage compartment Pros. Istough to beat proximity. And if you prioritize the deawer apace according To how much you se each tol for bench ‘work, yout! find you can accommodate ‘most of then in the space below the bench top, (Hin Full xtersion drawer sides are 1 big advange hee) The apces on the nde are gat foc lnger ies Uke power tools orf edi ‘Cons. Sce the sorage is under the bench, youre going tohavetostoop down, to get at what you eedae ] ING THE Table Saw ass Rabbets A couple of simple setups and two cuts are all it takes to make clean, accurate rabbet joints. The rabbetjont may not bea ashy asa dover but Tuseiton int about every projet I bald he advantage a fabbet has ver simple but joint i erased ‘ue suace and 2 square shoul ‘er that makes it easy to atign the pars sing sembly. heck ‘iting abet with oath faces and a esp shoulder. Ths allows ‘he pars fo pl together thy, asshowintheinet phot. ‘Uke many woodworking tasks, ‘here are several approais You fan fake wo make rbbet ft ‘The approach Fike to share ‘with you here quck and easy method that works remarkably ‘wel dove’ mai ry spel cquipment or fussy setups All Irtaks sto quick cuts with 2 sfendard table sa bade "At is most asc, you use one saw cto define each ae of he A Tight Ft A gap-teo joe fe the rut of flowing these simple steps rabbet joint OF course, geting ther takes aie Know how and afew handy tps “The Right Sequence. There's dette onder when making each of tiects oth to ensure the best rst and to make thecutssaely (ore on ths ate). The fst ext ‘made on the face of the week piece. And fr the second the ‘workpiece ished on edge Tita Setup, In the far lft rang, you can soe the setup forthe int cut There are 2 fe eta want to point out int, Taach 8 fall salary fence to the rip fence This wed ‘osupportthe workpiece om edge snd beep your hans well eae ‘ofthe lad or the econ cat ShopNotes No. 128have a couple tips for kaep- ing the inde comme square aed clean. I use 9 combination blade to make te cul in plywood Forculting abtetsin hardwood, 2 flstopped ip blade can make Ressler tgetaeip corner, ‘The nest step is to poston the ip fence The distance fom the np fence tothe ouside edge ofthe blade etablishes the Bal ‘width othe abe. Mot of te He, she width reeds tomate the thickness of mating pce: Rather than es fe (ike to use that pace a8 4 ge to set the rp ence "The height ofthe bade plays role ere fo. ifs stomach the depth of the abet Guiding the Cut. n ation to sting the blade bright and the ip fr, Ike include one more tem a featheroand ts role Is consistency. BY pressing the workpiece down onthe sw table lt guarantee tht you get A comisent depth of cut even if the workpiece flighty bowed Its dampes to the mp fence jut shead ofthe Bade ‘with these tps taken care of making the cts atally prety Straightforward. Just lide the ‘workpce tan even pace wile preasng i agaiat the ip fnce. Final Cat. The scond cat’ ny more complain! han the cutting End Rabbets Cutting arabbet on the end of narrow ‘workpiece addr a wrinkle tothe woes (echnigue deserbed above, The hal lenge keeping the workpiece square to ‘heblade for both ofthe cat. Thankly the solutions are prety staightferwand For the Sst cut I guide the workpiece with the miter gauge let dawn at righ). An airy fence backs up the itt prevent teaout and ad con For the seond cat damp a ume © he workpiove Theranoer see along the topo the fence to increase the being ut face and give youasmeooth mbbet. ‘ShopNotes.com fit one. And it nwo al the ste coalderations for sting i ‘up. Yuan se these in he da Inguabove However Idowantso ‘mention something shout ae Unless youre making 8 very shallow sabbet a thun waste ice wil be eat fve during thie ftp, You don't wast i tapped ‘benwoen the bade ane ip fence ‘Otherwise the pec could bind and cbc Eten the pce Should fll to dhe outside of the lade (upper night drawing. ‘This means the position of the np fence lest to match the depth ofthe abet as shown in the drawing. Acouple of textcuts ‘will help you zre non the ght Fence potion for this cut "To atthe Blade height, [use theft cutasa guide The blade {seta tnd lower thn the inside cee ofthe het (eft devin. ‘Ths gives you acrsp shoulder ‘A Helping Hand. The main ference in the second cit that the pie is cut on edge The lay here i supporting the pce soit wort tp and spa the et (Once again, the solution to ‘use featherboord or two, You tease the one sen the main photo on the previous page, This Stacked design keeps the work le my egal te fence ‘When you've made the second cut the mbbet is compete and ‘eody fr the mating pce. you find ite fazror evenness therabbet youcan wea sanding Dlockveth some adhesive backed sandpaper touch up the jo, ssinthoright margin & ” 4 Sanding Block. ‘Aopy sandpaper (ustto te ego of {a sanding block to Tine-tune araboet jain accuratyno-fuss Rust Inhibitors Stop rust in its tracks with a little preventive medicine. It's easy with these simple products. 1 wan ong afer I Rough a new hand pine tt ok down tm el nd red Some ight te then tat someting ved tobe doe imp rut omy fn my oe. Bate in spying oi ingens natprrenate ey fine T wed te al seed ke fomedfshante ora tee at coupe copes of wie at Y Variety. No | don't require a lot of tine or ‘mater wnat | effort apply or mains: Vapor 820 ioage | phase crest lahbtors (VCs area yourtoot | or vcs) ands go (Find out ‘ocuy, thre | more abou sie gel products in ‘sproduet that | the box on tx oppo page) ‘ile Koop | What are VCis? VCI products thom rset. | contain chemical rst nubor -S Foam tnor that evaporates into the alr and bonds toate surfaces, The ‘hemi forme thin, protective layer only a few moles thik. “This layer of molecules prevents the intacion of most with the sel wich i the cause of stand corrosion "Yu can se just a small sampling of the pe ot Vel padeaging In the photo at let J Veber you watt 10 protect a cabinet fll of pats tol box or 2 small, drawer of fasteners, you're suze tofind a VC thats up tothe tsk Not Really New. VCs have been around for several year ‘And they've one roel fin ing ther way nto home wood woeking shops “The roots of Ys go way back tothe 1880. Test commercial product was develope by Shell OitCompary ope ems dur tng shipping Unirtunately, the chemical they sed proved tobe taal over ine ‘Since hat tne, a number of manufacturers have developed fSfer chemicas and packaged them for home use. AS mat ter af ac most VCs have been, shown to be ae and approved foruae in oodstrage aes, Protecting, Your, Tool. The btn le for me wa to find ShopNotes No, 1284A Too! Liner. Line too! crawers, boxes, and ‘shelves wih this materi! eated wih a vapor ‘phase carasin inh costeffestive way 40 prt the tools in my shop. T found that most ofthe procs mentioned bet only costa few dallas, As far a pitng them to use ‘hey work bein sal enclosed ‘he consionsnhibiting. chemi cal permeates the ale So the more Alctght the space is the more ‘fictive VI wil be ‘The dovnside to this tecnal- ogy is that evenly all ofthe theme dsipte ito the siz “he good nev mest VCIs ast fora year or ore depending on how alight the space i. Ad thei low cost makes replacing ther aay on the walle, Product” Selection. Stor. tng your too in drawers and [Smelt Parts. Protecting festenersis no problem Unt) theso ani-corosion cardboard stipe and paste tbs avaiable ia wide range of ses. cabinets th. VOL product works the est Sot the "eh VC bate down Bing Cut te eb fet of ogee you wan protic. Each prod Temaremkenein tesa, ‘Ad tha’ sly ste nthe prodbet' alo descrip, Th the main photo on be prot page, "ope" for tend othe nde ecb prot content In het Po shove, you cen how a Yrimpregroted ner protec the tos mone of my tolbowes Stalbonmat prota won in sal denver a show in the Specht pot. Loren ford tock at ues a Vo chem Salto prot tht hind plane soak up humidity with Silica Gel You're probaly familar with lca gel You Bnd the ite “pi lows" containing ica gel in ‘many products you purchase. ‘Sila gels realy a gel but the beads act asa desieant, ce {yngagent to semave este from the ae But the best pats, when the beads have Become Saturated with moisture, you can reactivate them by deying ther In your oven flowing the mane fate sinsiuctons ‘ShopNotes.com Like the VCs mentioned shove, you can purchase ar ‘ous alae packages of een gel to exp an enclosed storage area Jaw in uty to prevent rust ‘You can see some samples in the photo at right You can even buy {hebeadsinbulk Some products hve indicators to lt you know ‘when they ned tobe activated. ‘Combined with Vis sca get prodctncan tetas pat of to ronged strategy to prevent rust. {mentioned ete The photo {Bove shove one Camp of Product hs pe The produce own hee can te onered fom the sources Watton page Te ow cnt tae cormennee a Up ‘ecyourtoolinvesment isk wen satrated ‘Sea gol beads | Varios, Sica got products come ina varity of sizes. Yeu can make your own wth beads Bought in bulk ten placed into vertiatad container 0questions from Our Readers choosing the right size Dado Blade 1m looking fora new dado Bade for my | A good, stack dado blade ailows withan dado ade. Especially table ase The blades come i either 6" oF {youtequkly and accurataycut when you're making deep, wide {F dlamaters, Which one should ge? {AD Kinds of joinery at your table cats in dense ood. The heavy evn teil ‘ave Choosing which sie tobuy duty motor on a cabinetsiyle —) sk Wiscosie ‘comes down to balancing how tablosaw can enly handle this. Soul we ithe eapablies cf Onde oer hand the ama, Yourssw and yourbodget lowerpowered motors typically ‘Capacity. Thefintismetocon- found in conzacter's and bench sidertathetypescf cts you plan top table save can tog down to make, For instance, in most with an 8a. dado blade. Sof eu fume projec, you carly You have coe of those types of Soe reed 10 set Your dado blade Saws. 6a, dado blade ssi wees for more than 3 exp cut A. aly abater otc edi blade has @ maximum Theamalle bide ameter ig cating height of as shove in _nifcaly meus the load en the the lef drawing Sot can easly toe This allows you to make taeke these asks smoother cut with le bung However, if you plant build in fac this size dado Blade I lt of lrgeseae projets, you say find that you need the | grater cating depth 27) hat an ‘Fda dado blade offers ‘Then’s one more thing tocon- dado sets ks expensive than an sider when tcomestosize Some 8st While the difference may table saw fige ad sls have aot seem ike much ifs enough ‘aay base tat rales the to allow the purchase of router workpiece ff the saw table This bitor other seamsery. ‘ectvely reduces the depth of” Youmay have voublefindinga {hecitadadoblade wilmake. 6° bladeat heme center or had Power In adaon to the cat- ware store But most lade man- A Pick a Siz. 6 cisco S ting capa, your table saw's lecturers make them and ou lade can do almost everthing motor i another key factor team ealy find sources online 35 ‘an blade can do. {ales aloof power tomake cus shownonthenext page. & eT ‘ShopNotes No. 123, Sources Most of the materials and sup- plies youll need to build the projets are avalable at had trate stores or home centers For pele produce or hard God ams take a ook at the sours sted here. You'd each part number Usted by the company ame. See the ight margin for contac informatcn. The Wain Sow in Des Moines, Iowa i an authorized Rockler dele. They cry mary ofthe hardware used incu Projets And they ship ration ‘ride. Their customer evi rp receives ane avalible for your falls fom 8am —Sprm_ Centra Tine, Monday tough Fda. LOOKING RABBET JOINTS (7.2) + Rocker 1 So Cuter om asks, CABINET HANGERS ¢p.12) + Lee Valley A Cabinet Hangers. .15945 18" Horgan Henge 081726 Cabin Hangers... 010080, PZcipe, ‘wei8a0 + Racker 18° Hargon Honger.. 049 ‘Adj la Mout 53 PZ, sr SMALL PARTS CAROUSEL (p14) + Rocker 9" Lay Scan Bing. 18501 + Reid Supply el Past Bin... ARRAR ‘ROUTER WING (p16) + Woodsaith Store ower i Gud... 870 Insert Pe fan SY Combination ack 5807 ater. miss Rooker Dist Pot sas $0225 Racor 85 Sie Kobe a Round abe oe \GHISEL SET (p.20) + MeMasterCare. Y24"O1 Sal... 918K Ye x 0068" Base SKE Ya" Bess Rad RS Ye" Bs Rad aS Fired Tbe Fit SOSA Buping Wee. 818412 Tap Compound. 7863 Woodsmith. Back Issue Library \WORKCENTER (p20) + Lee Valley 4 Lec Cater... cx2001 Reversing Hinges... aH750 35° Cont Hinge €ON0231 all st Sos caxa022 + Rockler 7° Quick Rese Vie. 3375 1+ MeMasterCare Sure Mun Hinges. 79805 Sip Ligh aI Sip Out, ralkes ‘Adib Handle 058 + Woodworker's Hardware Sure Maun Hinges. LAX, Magnetic Cees. AOS + Reid Supply eding Fe, san Pal nd, i010 TABLELESS (p.40) + Wooden ak Miter Ba ‘20% UST INHIBITORS: (40) You ind a variety of VCH and silica gel products at Roster, Brownaly, Woda, The Rast Slr, erst and Zo on DVD CColebate all 200 isues of Weedemithl The OW incdes ‘every ave of Woodeith magazine from jue 1 fecugh 200, ‘Order fhe DVD end you con quicy and esiy have oll he grect ‘ips, techniques, ond proj rom themes! Rd magazine in sng vole ight ot your Fgarips. 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