ShopNotes_014.pdf
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Router
Bits
Preparation
~~1101
Donald
B.
Pesehke
The end result will be worth it. I'll keep
0
you posted on the progress.
While the new construction has been
a bit inconvenient, it hasn't stopped us
from putting together a couple of new
projects for this issue.
WORKCENTER
Like many of the
projects we design, the work center
started out as a solution to an everyday
problem. In this case, we were looking
for a way to provide work space and
storage space without taking up room.
ily that needs a larger house, our"fam-
Our first version wasn't much more
ily" has grown toapoint where weneed
than a hinged slab attached toa wall.
A
more room. So a few mouths back we
good work area, hut there wasn't any
started a remodel-
mm
Douglas
L.
Hicks
uuralwa
6~lr.m
Terry
J. Strohman
uroeurr
ED~TOR
Rlehard
S.
Peters
rrnrrmr
Eonm
Tim
Robertson
couramunw
SDIT~
Philip
A.
Tdtten
w~lnvr
maEnoe
Ted
Kralicek
ur
MRrrmm
Cary Christensen
sewtom
,numu
Kurt
Sdrultz
~r~usnummr
WlV Niskanen
Roger Redand
Mark Higdon
ing hearing protectors around here.
We all wear them when working in
the shop. But lately many of us have
taken to wearing them in the office as
well. (As
I
write this, I'm wearing ear
plugs
and
"ear muff" protectors.)
If you think this sounds funny, he-
lieve me, it looks even funnier. But
we're not doingthis for fun. We're doing
it out of necessity. Let me explain.
REMODELING.
Like a growing fam-
MTOCRIRISR
Crayola England
nutaw
mn~emn
Ken Munkel
s~tdlon
DES1BMLI.
Jan Hale Svee
Kent Welsh
MIOP
W~~ER
Steve Curtis
SMOC-JFLCIUTISS
Steve Johnson
storage. The sec-
ond was similar to
ing project.
New construction.
.
-
a locker
-
lots of
addinganother floor
New projects.
storage, but it took
to
the back part of
And
a
newfeature.
up too much space.
our building, con-
It
wasn't until
structingnew stair- we decided to
ways, and installing an elevator. mount itup out of theway on awallthat
Except for a few minor problems things started to click. Then we com-
(like the backhoe that tried to take a bined both ideas and added a couple of
short cut through one of the windows), other unique features. The final result
work seemed to progress quickly. The
is shown on page 16.
weather was good. The walls went up,
CHISEL
PLANE.
The chisel plane that
and the new roof went on. is shown on page 8 is also a solution to
Then winter set in. And when the
a common problem. But this time it's
weather turned cold, work began on the
inside
of the building.
So what does this have to do with
wearing hearing protectors? Well, re-
modeling the inside of the building
means lots of drilling, hammedng, and
eutting-most ofit in concrete. Andfor
the last few days the drilling and
pounding has been going non-stop. So
hearing protectors have become the
The plan included
Designer:
Robert
H.
Whitmer
.
hphic
Adst
Cheryl
L.
Cynor
-WIUIEsERVICE.
Con~1~:KobinH~te~n~Acc~nting:Laufa
Thomas.
Bwkkqing.JulieGdeeeFbdx&bn
Ma~:Carol
&uijano.
Znfi.
Sfo.sMawqsr:
JoyceMoore.Eleet Pub.
Coardimfm:DouglasM.
Lidster.
App.
Spcinlist:
Linda Momw
-Admi%
Assistants: Chql
S~tt,
Julia Fkh
-
Recept,:
JeanneJohnson.
Buildkg
Maint:
Ken
Gath
Mamgw:
Valerie WlesemCataTq
Prodwts
Manager: Bob
Baker-Pmjeet
SuppliestLindaJones.Technica1
Supph:
Jeff
Janes.
Recept:
Cynthia
Kerman
EUImWER SERVICE
finding a simple way to clean up hard to
reach places like the corners of a
drawer, door, or panel.
NEW
FEATURE.
Projects aren't the
only thing new in this issue. We've also
added a new feature
-
the Finish
Room. Here we'll take an in-depth look
at finishing problems and their solu-
tions. We'll also talk about new prod-
ucts and show tips and techniques for
using them. This time we give gel stains
a try (see page
30).
NEW
FACE.
AS
I
mentioned earlier,
we're growingrapidly. Carol Quijano is
our new production manager. She's
here to make sure we're on schedule
and the issue is printed on time.
Supvi.sm:JeMie
Enos
-
Cwtome~S&e
Rep-
msentatiw
Jedr
Murphy, Joy JohqSara
Knno,
h
Cox,
Tammi
Aldini,
Kristi
Andrea,
Stephanie
Hagen
SWIPP1YO
DEPARTYEW
Sup&ol-
Jerry Carson
.Fdfillmt:
Gloria
SheehqDonMcVey, ChuekCarhn,SyIuiaCmy
m
thing to wear around here.
The surprising thing is, I've heard
very few complaints (even without my
hearing protectors). Everyone is deal-
ing with the noise and confusion the
best way possible. If that means look-
ing a little silly for a while, that's okay.
rights-m&ed.
"
subsoliptiorn:si"g1e
C~W,%.SS.
one
year
suhaenp
tian
(6iasuea).
$19.95.
Woyeara
(12issues),835.95.
Cai-
addForeig",
add
$5WperyYYY
Second Clasp Postage Peidat
Den
Moines, IAsnd
ataddxiad
offim.
Poetmaster;
Send change
ofaddress
to
ShnpNates.
Box 11204.
Des Makes,
IA
50540-1204
SubserlpdonQvestionsT
Cali
1-8W333-5854.8am
PRINTED IN U.S.A.
I
t's
not unusual to see people wear-
~anmv~
PVBLISWMCSERYIEES
Associate
Editm.
Gordan
C.
Gaippe.
Sr
Gm.phic
PROJSET
SUPPLIES
Mavkehw
Lbiredm:
RobertMw=Ca6dq
Art
Dimctor.
Cindy
?&on
~Fu1fill~t
''.
I,
Contents
Miter Gauge Fence
4
Make quick and accurate cuts on the table saw with this
shop-built fence for your mlter gauge
'I
Anti-Kickback Bits
6
1
An in-depth look at how anti-kickback router bits work
Also, a companson of the different bits available
Chisel P/ane
8
Cleaning up hard to reach places (like the corners of a
drawer or panel) is easy w~th
a
chisel plane All
I?
takes to
make your own is some slmple hardware, a blade, and a
scrap of
wood
Chisel Plane
Stock hparation
12
The foundation of a quality project can be traced back
to how carefully the stock 1s prepared before the actual
building beg~ns
Fold-Down Work Center
16
This wall-mounted work center offers plenty of built-m
storage to keep your tools r~ghtat hand It also features
a bench that folds down to provide a solid worksurface
And a fl~pupdwr holds an optional shop 11ght
Drill Press Tips
24
Solutions io some of the most common driIIingproblems
in the shop. Also, simplejigs you can make to increase
your accuracy when working with a drill press.
2
Shop 5o/utions
28
Five Shop-Tested
TIPS
Plpe Clamp Caddy, Bench-
Mounted Belt Sander, Shop-Made Chisel Holder, Foot
Pedal Modlhcation,and a
TIP
for Mixing Powdered Glue
Work Center
page
16
Gel Stains
30
The thicker consistency of gel stains offers a number of
advantages over 11qu1dstalns
50ume6
31
Hardware, project supphes, and mail order sources for
the projects in this issue
Drill
Press
Tips
page
24.
No.
14
ShopNotes
JIGS
&
ACCESSORIES
I
iter
Gauge,
Fence
*
mL
A
built-in stop block
and
measuring
tape provide quick
a&
accurate
set-ups when crosscuttifig.
ike many woodworkers, I at- and accurately,
I
made a miter
tach an auxiliary fence to the gauge fence with a built-in stop
miter gauge when crosscuttinga block,seephoto.Ameasuringtape
hoard on the table saw.
This
pro- attached to the back of the fence
vides more support for the board makes it easy to accurately posi-
than the miter gauge by itself. tion the stopblock,seeinset photo.
But what I like best about an FENCE.The fence consists of
auxiliary fence is you can clamp a two pieces of @-thick hardwood,
T-slot in the top of the fence. The
bottom part of this slot is cut
be-
fore gluing the fence pieces to-
gether, seeFig. la.
To
keep these
kerfs aligned when gluing up the
fence, see tip in margin at left.
When the glue dries, the T-slot
can he completed by cutting a
centered slot in the edge of the
fence, see
Figs. 2
and Za. Next,
I
cut a shallowrabbet for themeas-
uring tape
(Fig.
2b), and cham-
fered the bottom edges of the
fence for sawdust relief.
BOTH HALVES
4
ShopNotes
No.
14
stop block to it and cut several see Fig. 1. Although the fence can
A
waxed 'key"
pieces to the same length. The be as long
as
you want, make sure
aligns the
kerfs
only problem is it can be a bit it's not so long that it's awkward
when glutng
frustrating to clamp the block em- to use.
(I
cut each piece 26" long.)
up
the fence.
actlg
where you want it.
T-BLOT.
To
allow the stop block
To
set up repeat cuts quickly to slide hack and forth, there's a
@
attached to the miter gauge.
Start by placing the miter
gaugein the slot in the saw table.
Then, with the fence clamped to
the miter gauge so the end butts
against the side of the blade (not
the teeth), mark the location of
the holes, see Fig.
3.
Now it's just a matter of drill-
ing the holes and installing the
inserts. After attaching the fence,
trim off the end, see Fig. 3b. (To
it's
This is nothingmore than a toi-
let bolt that passesthrough a cen-
tered hole drilled in the short
piece. When you-tighten a knob
on the end of the bolt, the head
pinches against the T-slot and
locks the stop block in place.
INDICATOR.
To position the
stop block accurately, I added an
indicator. This is just a piece of
!@-thick Plexiglas with a "hair-
linee'etched in the back side with
a utility knife, see Fig. 4a. To
make the line easierto see,seetip
in margin at right.
To attach the indicator and al-
low
it
to be adjusted later, there
are two slots near the top. (I made
these slots by drilling a series of
overlapping holes.) Then, after
screwing it in place, I
sanded a
chamfer on the top edges of the
indicator and stop block.
INSTALL
TAPE. The next stew
is to install the measuring tape.
Note: Because I place the miter
gauge on the
left
side ofthe blade,
I used a self-adhesivemeasuring
tape that reads from
right
to
left,
see Sources on page 31.
To
install the tape, lock the
stop block flush with the end of
the fence, see Fig. 5. Then slide
the tape under the indicator so
the "0"mark aligns with the hair-
After filling in the
line and press it in place.
line with ink from
a
PINE
TUNING.
After trimming
permanent
off the excess tape, the last step
marker, wipe off
is to 'Tine tune1'theindicator. This
the excess.
requires making a test
at
and
comparing the length of the piece
with the position of the hairline.
If necessary, loosen the screws
and adjust the indicator.
reposition the fence fg45" cuts,
see the box at right.)
STOP BLOCK.
With the fence in
place, the next step is to add the
stop block. It's made from two
&-thick pieces of hardwood that
are glued together in an L-shape.
Both pieces are
2"
wide, but their
lengths are different, see Fig.
4.
The long (314") piece hangs in
front of the fence and acts as the
"stop." Note: The bottom corners
are chamfered for sawdust relief.
0
And the short
(ll/4")
piece holds the
1
45' Miter
Cuts
I
To keep the blade
from
cutting
through the
fence
when making a
45"cut, yow'll need to reposition
the
fence on the
miter
gauge.
This requires adding another
pair of threadedinserts. The holes
for these inserts are located by
tiltingthe mj'cer gauge to
45",
then
positioning the fence so the back
corner$
Ms"
away
from
the
blade.
Note:
Since
tlte
taw
is
set
upfor
$0"
cuts,
it won%pr&&?
TILT MITER
GAUGE
TO 46.
aecumte
readings wknmaking
45"
cuts.
stop block's locldng mechanism.
No.
14
ShopNotes
5
mACHFENCE.The fence
is
held in place with machine
mews
that pass through the head of the
miter gauge. and into threaded in-
serts in the back of the fence, see
Fig. 3a.
The location ,of the holes for
these inserts determines the po-
sition of the fence on the miter
gauge. I wanted the end of the
fence to be right up against the
blade. This requires shaving off
just a bit of the fence a*
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