A Publicatlon of August 1-:Jome Publlshlng
EDilOR ' S NOTE
PUBLISH'ER EDITOR ASSOCIATE EDITORS
CONTRIBUTING EDITOR ART DIR~CTOR SENIOR ILLUSTRATOR ILLUSTRATORS
D nalcl . Peschke Terry J. t rohman Bryan Ne l 0 11 incent An ona m] HUber ary hr i t OSen Hog l ' Reiland David Kaliemyn
Pet r J. Larson SR. GRAPHIC DESIGNE A
J ami. Downing
CIIUTIV. lll.aotJRCEa c,..alh·•J)¡r~·'u'r:'l't'li Knilirck • r Pmju-J O.s !)llf'TT. K"l!Munkd. Kent WeJ>h,ltyat~Mimlck. 'hrlFF'itch • .'íhpprn¡/7••w•mS< ve urtk Sh'• ,Ioim n1 • .~,, l'll"l'l(fl''f"'"" C'rnynl" ~:n¡chwd • l'lt~ttlfll'r'J'/"r: i llnH,~m\t't.l
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Be i clud d, as a part o th
Woodwork1ng Shop Tours
maíl: n 1pn tes@!ihopnote. .e m Write t SlwpNott ·, P. . Bo 842. Des Moin , '1 . - 0304 or calll-800-333-5075, :00 a.m to 5;00 pm, entra! T11ne, weekda} . Or send an email to: orders@sh ;pnotes.com
2
hopNote
N . 75
Features Sharpening Suppliet5 Box
6
The inside of thís stacking storage box features multíple comparlments on two different Jayers - plenty of space for al/ your sharpening supplies.
Making Box Jointt5 _ _ _ _ _ _ _ 12 Here :S a simple table saw teclmique lhar allows you to cut the time spent making box jomts in half But don 't worry. you won 't have to sacrific accuracy to do it.
Plan k-Top Workbench
'harpen:i11g nppUe ua:
pag 6
16
This heavy-duty workbenoh is equally al home m /he shop or the garage And while it on/y lakes a weekend to build. it's guarantoed to g1ve you a lifetlme or use.
Machini5ts Vieee ________ 22 Discover what machinist's vise can do for you and what to look for when selecting one for your shop. Plus, learn about sorne handy vise accessorfes
Dual Too/ Station _ _ _ _ _ _ _ 24 Tl?ls too/ sta/Ion pulls double duty by serving as a planer stand as wett as a miter saw stallon - complete with extenslon wings and fences
Departments Readere' Tipt5
4
Shop-tested tips toso/ve common woodworklng problems.
Shop Talk
32
Looking for jusi the right part or hardware ítem for your next project? Heres a peek at sorne of our "secret" supply sources.
Too/Cheet ___________________ 34 Take the hassle out of fine-tuning the widlh ot your dadoes wilh lhis innovatíve stack dado blade.
Sourcee ____ _ _ _ _ _ ___ 35 Mai/-order sources and supp/ies to help you complete the pro¡ects feaiUred m lhrs 1ssue.
No. 75
Shop ot
3
1
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 cdtrn'we bolts, then hrmlngF -
-I
MI press u e ~ n ~ rasps and fum#
I PVC Clamp Holders
1 '
TIPS
&
TEGHNIPUES
Quick Tips1
Sharpening < >-
Corral a
.,
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out of l/,r' l w c b h h ply-
H100d,sOBnIhadbdo~ cut the p k to~b.But beareaqpuplethhgsb keePb~wyoud0W
rn
~youllwantto~e
3 w r m . b ~ ~ ~ ~ crass/: tmk and ~mradet myhb hc h about 8" wide.) The
w
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&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@ctM c e for ~tswmbling t~ h me ot r ~c tat tn a .l ~~ o ~f ~a ~ m~ ~l a ss smll bma. kltsetof*and&t8arteaeh
coraeroftbebwcwha~roucutthe amgartmenb to £id sb.@or an altemk joinery method, to the Iwx on the oppite page.) Tlleotherthingtakpbmiadh tamakea~~~pIedmbEankatom
-
4
' ~ ~ B Q x A p m t - A t ~ s yw're m d y to cut th* box
IW ihe blade to about 1/d1 less the hiclaw of the p?qwood :andmake a scoring cut through the :dwtsidest, lining the blade up with
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: t f i e w O u cuts $
,m331.
I Optional Fnlinmdl
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Line It & Divide It
TALL PWW
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S T O R A G E
;&he m w ' s l o a s iu the lower corn
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: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
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tap,lhere'saninsa-t ~ ~ ~ a l a m l b o m e m t eP lrb 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 ~ ~ y o~r r r dt t o kh~ y o ue h m p u t t i n g a arrtmrne memid piwwof 8eU- tape flu& with autilityhife (* aharpedgeonaflyowtoo~s.~
Ends
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END W L x .CL -.-
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F E A T U R E
Plank Top & Shelf
P A O J E C I
d
No.75
llne Extra
t's Vises
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V b . A plecB ofplywadandacfsai allow you to mount tr
m&InI#t% vise to your
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Metal Bending. Tllrs set ol malleable Iron auxiliary ja ws can be used lo bend sotf meta/s and
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,
Dual Tool
Station
SHOP
PRO
C The heart of the W n &met you = in the
a
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 04the M e pmv& 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 br 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 saw 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 tp vfde wwgh hHor height to silidingmltsraaw,Todetrenninethis,I make sure they'll 0t between h e ~ ~ ~ ~ & ~ ~ i t~ ~ t t i m t~ t ha e md i bsugport ~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. To get the maxFor 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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Extension Wings & Gupports
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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 ~ ty w 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 S ia 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
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WhatIrdylke s u ~ i n ~ o n , y a u c a n s e t t hs ~ 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 mp ve n~ e~ ~~ ~ ~ B u t t o ~~ a j ~ u~ 1s 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 ~ Topmidethesmedurabksw i t i e ~ s t M ' e t h e ~ ~s u mp p 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 t h e ~ , ~ ~ r o u ~ i snw ~i a g7 t ht e,~ ~ i n a n d s u t O a c e@ p a s b e b m . T h e n P o ~ t a n y
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You're on the home stretch at *thi~ slid&mt allelf- ,!wmu& you makes a conwent handbold far slides pro~dmeasy poiat. l h e la& couple stepe are to d d jm set the: tool ~rou're not pullInsthe &eIf out -1 b e -Toprevent thedm using in& the mbhet to 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 tl 10. ~ a n d ~ u w d a g r o o v e m d B g W a %~ - ' l h e s ~ d rt O ao l ~~E l~i ? R ~mfnFfgve Wension slide between the fmw h a ~ ~ d e t h eThesh@ffRIbaphed3/at1& cieattolocsklbebawinpb. 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 To mount the B/sartenfrlon ~ w ihagroowelctttdmtiw ntn'ew a stored !ad thedmmrWisrathershpkta d r a m &dm, there: are a pair of Wut mMng ,Me cmwtmk The f m t h e k 101 and a i h {SJ d e h m 3 / 4 t W M- ~ , ~ f a ~ l l . ' f cabinet unstable, &m (P)m d e h m $/dl1 pbr- w w d , ~ ~ c a n ~ h ~ r @ ~l Ow * t h a ~ c W f U ' 1 To ac~eptthe he& the tap inside ~ m t h e ~ ~ m t wood And thedram ktoPw {QJ is &$t0 p b of '/h" m. edges are r 0 1 b M as IfIu~hterlin 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
9
caupkthInggtaIreeph~d.For dartem, the drawer rides on fullextension, metal did= The o m I u ~ m e a t l t t h e ~ h & d t o II"s e 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~~.
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eei r rt o r o t r L ~ t h e w ~ WmmessmWnbetbe h e ~ , ~ ~plate aia hebl ~ In place with three smma and lock nuts. The W h a t d ~ ~ i s t k a t g o maeMne u~ thatthey hit ButWsaotthemewithebe ~ t h e w i d t h o f ~ ~ o wIo&nutsdickoutmfw l ~ t D i & - ~ ~ b p ~ T h ~It hs e ~ o t f t h e m v ~ A U s n pt u h e ~ ~ t h e * o atla W & b a e t d & d t r e W e a ~ hbdoLb&co£ftbearbrnvt 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 ~
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~w ~ xt a h a r &lion r E (page a)are corn~~-~ watestom3utifyouhave Irk& adable. This 3/4-ex&ioa ctrawer did= trouble finding it i n d u ~ t h e w o a d w~ 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 a dr e 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 ~ t h et w u com W i~n t k 7'lw mEm-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! beplradngonthe~ ==m mdtaary k bolt8 hwdwm @tmv.we tu& and wmhm win w* t o R a c k b r h r h ~ b The hard.
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-
wareudbo1dwtEhe equstbr w d -just with a s k d r h . won't look asowl.) Wl9, T.track(&lS3), F s h $ i o n * i e 3" lodptudt s w h l saws nohhgmEbanamtof w31810),atPd iludl hhgm four 7/ut'& adfuwlefur(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 t I t e o n ~ ~ o r w a o n ~ 2are 2 both adable h m h m m a a y d t h e m u m s nylon and se WaihbIe h I n many "Ibol~i$tiasNorth,€B ~ I n ~ ~ ~ r were d 4 purchasRd i l t at a l boJ 5tm% Mwm w e B a s * ~ T h e T h e ~ ~ k u a eh d ardwwe~Butifyou ~ d d ~ h~~ t or a n t $ c~h ~ ~ bm'tftndkyouw o ~ . 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 hm i n ~ rubber-Hned ~ j 4 t wWq, ~ item mmot.
knob
' Wewwfdmhardwsrehm ROCKLBRin mangdo~new~~kikToot$er,~ulase: omM-he&line, seet3el6w. h o p e n Monday through Friday, h m 8 AM to 5 PPA CentdTm. I
B d m ~ ; p k h a v e y ! o t a ~ ~ ~ ~ ~ , @ m r , or h e r i ' c a n card ready. Tfyou W d prefer to mail in an order, please caIl the WII-he phone number below for more & W o n concerning shipping charges as
~~
~
&
scenes from
I
' Nb M m Shim An a~$imW& hub ~ c h ~ mm ~,@B r n tack aado blade allows y ~ t@~ he-tune l he 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 you’d like a longer workbench, you’ll 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 don’t 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. What’s different here is that to fit the center assembly in place, you’ll 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 it’s best to add enough cross rails between the end and center assemblies so the rails
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are spaced evenly and they’re no more than 22" apart. Cleats and Slats – All that’s 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, it’s best to work out from the center of the opening and cut the end slats to fit.
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ShopNotes No. 75
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