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THEARTOFWOODWORKING
HOMEWORI$HOP
WORKSHO GPU I D E INVENTORY OFJIGHARDWARE Wood acrewa Oval(below,lefL)and flat head (below, cenLer)are ueedfor counLereinktnq; roundhead(below, rtqht) can be removedeaerly. Typtcallyavailablefrom'l Lo 6 incheelonq;common head typee includeelotted, Fhilipe,and equare
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6olta Plaetic knobsand handlee jiqe durin4operaFor conLrolltnq ttona;offer comfortablegrtppin4eurface;nylonwaaherareducevibration
Cam clamp Ueedto aecure workpiece injiq; Lurn handleLo increage clampinq Preaaure
Common naile Fl Featureqroovedll ahankafor ll otrenqthand ll h o l d i n 7 p o w e rl :l
Knockdown hardware iLem allowtnqjt7 Lo be taken aparL and reaesembled wiLhouLeLripptng ecrew Lhreade; threaded dowel te ineert ed in one part of ji4 perpendtcular to bolL; bolLs ranqe between 1and 3 inchee
Ueed wiLh nuLe for faeLenin7 wood; carria7e bolt (near rtght) feaLurce oquare necl Lo keep bolr from roLaLtng, hanger bolt (far ri7ht) featuree machine fhreade on one end and wood 1crew thread' on Lhe o1;her;eizeo typtcally ranqe '/, from 1 Lo 6 tnchea rn lenqLh and I to /, inch in diameLer
Miter bar '/," Ftl,eetandard x'1" miter 4auqeelol,; aerveoa6 foundaLtonfor a number of ueefuljtge tncludtnq a Lable eaw croaacul;jig, a miter jtg, and a feaLherPOara
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Threadedinaert Knockdown faatener usedwith acrewgor bolt;oLojoin compa-
1eneralfaetentn4of wood;etandard hexnut (above,left) provideaeaeyacceeafor t urnrn4; wtngnuL (above,cent,er)ta uaed wheredioaeeemblyand reaeeemblyie expecLed;T-nut (above,riqhL) te ueed ae a knockdown faeLener or rn ertuaLionswherebolLie no| acceeetble after aeeembly;avatlabletn a varieLyof aizee
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w a r ei n a v a r i e toyf s i z e o s n h a n di n y o u rs h o p ,s i n c es p e n d i nt o g om u c h t f i t sp u r t i m em a k i n a g j i g d e f e a tpsa r o p o s eT. h ei t e m sa b o v e p r o v i dae b a s i c
jig hardware: listof essential formorespec i f i ca p p l i c a t i ocnhse, c o k u tb u s i n e a s sn d tradedirectories aswellasmanufacturers a n ds u p p l i eor fsi n d u s t r i p a rl o d u c t s .
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THEARI OFWOODWORKING
SHOP-MADE IIGSANDFDilURES
THEART OF WOODWORKING
SHOPME FDffT'RES IIGSAI.{D
TIME-LIFE BOOKS ALEXANDRIA, VIRGINIA ST.REMYPRESS MONTREAL. NEWYORK
I I I I I THE ART OF WOODWORKING was produced by ST. REMYPRESS PUBLISHER KennethWinchester PRES/DENT PierreL6veill6 PierreHome-Douglas FrancineLemieux Marc Cassini(Text) HeatherMills (Research) Art Directors Normand Boudreault,Luc Germain, SolangeLaberge Designers Lina Desrochers,H6ldneDion, Jean-GuyDoiron, Michel Gigudre Research Editor Jim McRae PictureEditor ChristopherJackson Writers Andrew Jones,Rob Lutes ResearchAssistant BryanQuinn Contr ibuting lllu strators GillesBeauchemin,RolandBergerat, Bourgeois, MichelBlais,Jean-Pierre RonaldDurepos,RobertPaquet, IamesTh6rien Administrator NatalieWatanabe ProductionManager MichelleTurbide SystemCoordinator ]ean-LucRoy Photographers RobertChartiet ChristianLevesque Administ rativeAssistant Dominique Gagn6 Proofreader Iudith Yelon Indexer ChristineM. Jacobs SeriesEditor SeriesArt Director SeniorEditors
Time-Life Booksis a division of Time Life Inc., a wholly ownedsubsidiaryof THE TIME INC. BOOK COMPANY TIMELIFEINC. Presidentand CEO Editor-in-chief
JohnM. Fahey JohnL. Papanek
TIMB-LIFEBOOKS President JohnD. HaIl Directorof Marketing NancyK. fones Vice-President, RobertaConlan ExecutiveEditor ExecutiveArt Director EllenRobling ConsultingEditor ProductionManager
lohn R. Sullivan MarleneZack
THECONSUITANTS
r
and JonArno is a consultant,cabinetmaker, freelancewriter who livesin Troy,Michigan. He alsoconductsseminarson wood identification and earlyAmericanfurniture design.
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I(am Ghaffari is a freelancewriter and editor. He hashis own businessin RhodeIsland designingand building one-of-a-kindand limited production furniture. Kam'sbackground alsoincludesworking professionallyin furniture reproductionand fine carpentryand studyingwith furniture patriarchsWendell Castleof the U.S.and England'sFredBaier. GilesMiller-Mead taught advancedcabinetmaking at Montreal technicalschoolsfor more than ten years.A nativeofNew Zealand,he has worked asa restorerof antiquefurniture. fosephTruini is SeniorEditor of Hoze Mechanixmagazine. A former Shopand Tools he hasworked as Editor of PopularMechanics, a cabinetmaker,home improvementcontrac/ tor, and carpenter.
Shop-madejigs and fixtures p. cm.-(The Art of Woodworking) Includesindex. (trade) ISBN0-8094-9508-2 l. Jigsand fixtures. I. Title: Shop-madejigs and fixtures.
IL Series Tll l87.ss41993 684'.083-dc20
93-34t03 CIP
For information about any Time-Life book, pleasecall l-800-621-7026,or write: ReaderInformation Time-Life CustomerService P.O.BoxC-32068 Richmond,Virginia 23261-2068 @ 1994Time-LifeBooksInc. All rights reserved. No part of this book may be reproducedin any form or by any electronicor mechanical means,including information storageand retrievaldevicesor systems,without prior written permissionfrom the publisher,except may be quoted for reviews. that briefpassages First printing. Printed in U.S.A. Publishedsimultaneouslyin Canada. TIME-LIFE is a trademarkof Time Warner Inc. U.S.A. R 1 0 9 8 7 6 5 4 3 2 1
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CONTENTS 6 INTRODUCTION
t 2 ROUTING AND t6 20 2T 22 23 24 25 26 31 34
SHAPING JIGS Dadoingjigs Circle-cuttingjigs Routerjointing jig Hinge mortising jig Corner-roundingjig jig Panel-raising Adjustablerouting guide Joint-makingjigs Shaperjigs Vacuumjigs
36 CUTTTNG IrcS
40 4l 42 43 46 47
48 49 50 52 53 54 56 57 60 62 63 64
Sizingboard for crosscuts Miter and crosscutguide Ripping jigs TWocircle-cuttingjigs Wedge-makingjig Two jigs for anglecuts on the band saw Thperjigs A bladeheight gauge Crosscutand miter jigs Raisedpaneljig Board-straighteningjig Auxiliary fencesand tables Cove-cuttingjig TWotenoningjigs
DRIIIING JIGS Center-drillingjig Tilting tablejig fig for drilling equally spacedholes 65 V-block jig 66 Pockethole jig 67 Boring deepholes
68 7l 72 73 75 77
TURNING IIGS TWocenteringjigs jig Gouge-sharpening Spindle-turningjigs |ig for fluting columns figs for sandingand checkirg depth
78 81 86 89 90
GLUING AND CLAMPING JIGS Edge-gluingjigs jigs Frame-clamping jigs Carcase-clamping Workbenchclampingjigs
94 96 98 100
SANDING IIGS |igs for face-and edge-sanding Auxiliary sandingtables Hand-sandingjigs
IO2 105 106 II2 113
TOOL EXTENSIONSAND TABTES Plateioiner stand Tablesfor power tools Viseextensionstand Adjustableroller stand
II4 II7 118 120
STORAGEDEVICES Storingsawsand blades Mobile clamprack Lumber storageracks
T22 125 I28 130
SHOPAIDS Safetvdevices Sawhorses Workshophelpers
I4O GLOSSARY I42 INDEX I44 ACKNOWLEDGMENTS
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INTRODUCTION
R. J.De Cristoforoon
DESIGNINGIIGS J lookat anewtoolasabeginning.Onceit istakenfromitsboxor crateI readthe I owner'smanualto learnwhatthemanufacturel strggests thetool cando.ThenI standbackandthink, "Theremustbemoreto it thanthis." Inevitably, bysomestrange thoughtprocess I cantexplain,thereappears amental picttueof ajig, sometimes simpleenoughto testimmediatehothertimeselaborate enoughto requirea session atwhatat onetimewasa drawingboard;now,I design onmycomputer. Thenewjigmight enablethetoolto dosomethingits desigrernever envisioned or it mightincrease accuracywith minimumfuss,or it couldadda safety factorto a routineoperation.ln anycase, it hasto becustom-made sinceit is rarely available commerciallv. I'vedesigred dozeniofjigsfor powerandhandtools.Still,for meit'snotanobsession:Practicality is essential andshoptestingmustprovethejig'sworth.Somefolla jigs think that areonlyfor amateurs. If so,therearemanyprofessionals workingin amateurish ways! |igsaremeantto beused.ThosethatI designarenot madefor thesakeof a magazinestoryor abookandthenstoredor discarded. ln a sense, I conceive aprojectthat helpsmeexploitamachine, or assists mein workingmoreaccurately andsafely, and thenI shareit with otherwoodworkers. If I'veproventhatajig will beusefulto just onereaderthenit hasvaluefor me. I m fondof themasterjigsthatI havemadefor thedrill pressandbandsaw,and especially theunit for thetablesawshownin thephotoat left.Itsbasiccomponent is a generous slidingtablewith removable insertssoit canfunctionwith a dadoing toolaswellasasawblade. Itsattachments includeadjusable guides for accurate crosscuttingandmiteringandamountable unit-a jig in itself-thatallovrs cutsliketenons andslotsin theendof narrowstock.Thedeviceincludesa numberof essential but jigsandaddstheadvantages usuallyseparate of a slidingtableto eachof them. There's no doubtthatjigscanhelpanywoodworker, but theymustbemadecarefrrlly.Thesearesituationswhereit pap to take10minutesto do a five-minutejob. Consider thatthejigwillbe alifetimetoolandyodllagreethatmakingit rightisthe onlywaytogo.
R. J. De Cristoforo,author of numerous boolcson woodworkingand othersubjeds,liva in LosAltos Hills, Californin
INTRODUCTION
Ted Fullerandhis
ROUTERIIG \r/ earsago,I workedin an autobody shop,wherewe hand-formedbodypanels. I Oftenweneededtwo matchingpanels-one for eachside-but weneverpro"You ducedexactmirror images.Subtledifferences wereeasilyexcused: can'tseeboth sidesat thesametime."it wassaid. In cabinetmaking, hor.vever, matchingpiecesmustbeexactduplicates. Youusually Although masters canseethemat thesametime. some canaccomplish thisfreehand, most of us must rely on carefullyconstructedjigs. I wasluredto woodworkingin gradeschoolwhentheshopteacher put meto work props play. I learned on the for a Christmas earlythatthetimespenton thejig or templatemeanttime savedand consistency gained. Thereareplentyof jigs and fixtures'onthe marketbut, like baseballgloves,only your own hasjust the right fit. Whenyou makeajig yourself,it is designed for a specific applicationandsizedto matchyour project.Bestof all,you don'thaveto changethe projectto fit the store-boughtfixture.It's alsolessexpensive. Making arched-topraisedpaneldoorsis one example.A manufacturedjig, and pre-cuttemplatesthat enableyou to do thejob costseveralhundreddollars.Forthe custompieceI amworkingon in thephotographI built a simpletemplateout of plywoodto createthe contourfor thearchedtop rail.Thisparticularjig is adjustable for two widthsof doors.Wideror narrowerdoorswill requireanotherjig anda re-draft ofthe curve. With the multitudeof top-bearingrouterbits on the market,exactcontoursare quickandeasyto duplicate.Simplyroughout thepieceto shape,clampon thetemplate,androut to thefinishedshape. Anotherbenefitof thisform of duplicationis thatit doesnot leavethetool mark thatabandsaw wouldandtherefore reduces sanding considerably. Thenextstepis to run thepiecesthrougha matchedsetof rail and stilecuttersto rout the profile on the sticksand makethe copecuts.It's a goodidea to markthedimensions, bit selection, andset-upinformationon thejig sorecalculationis not recuired. I think oneolthe mostintriguingthingsaboutwoodworkingisthatthereis always someriggingthatwill makethework easier, faster,andbetter.Theonlyreallimitation is your own imagination.
TedFuller is theproductmanagerat Delta InternationalMachinery/PorterCable(Canada) in Guelph,Ontario.He is currentlyworkingin newproductdevelopment and marketingfor
woodworking tootsqnd' r"n2::
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INTRODUCTION
BruceBeekenand Ieff Parsonsdiscuss
PLANNINGIIGS p u.ry*oodworkeruses jigsregularly. Markinggauges, combination squares, the I-l rip fenceon a tablesaw,androuterbitswithball-bearing pilotsarealljigsthat aretakenfor granted. Andwhohasn't, atonetimeor another, madeasimplethingamajigon thespurof themomentto helpgeta certainjob done? In ourshop,wedesign mostof thefurniturewemake.In developing a newpiece, weconsider theesthetic andthebuildingprocess atthesametime.Our chairs,for example, havepartsthatdorit comestraightfrommachine tables because welikethem to havea certainstance to supportthepersonsittingon themjustso. jigsareusedin chairmaking.Thesesortsof jigsare Someof our morecomplex plannedfromtheoutset,tailoringtheprocess to thedesign. Wedevelop themon a full-scale drawingasweworkoutourconcept of thefurniturepiece. A clearunderstanding of thestepsandtheirsequence notonlymakes thewholejoblessintimidating but oftensuggests waysto simplifytheprocedure andrefinethepieceitself. Sometimes ajig isassimpleasa wedge to jackup a partattheproperangle.We havealsofoundthatjigscanservemorethanonepurpose, travelingwith apartfrom machine to machine. Thehome-made device shownin thephoto,for example, isused forbothformingchairlegsontheshaper andcuttingmortises in themonthemortiser. Westartby bandsawingblanksto approximate size.Theyarethenfastened to the jig-in pairs,sincethejig hastwoedges. Weshape theinsidefaces of thelegs.Then, by changing shaper knives,shiftingthedowelpegsin thejig, andrepositioning the legs,wecanusethesamejig to shape thefeet.Onceallthepartshavebeenformed, wereturnthepegsto theface-shaping positionandboltthejig to ourmortiser's table. Thejig thenholdsthelegsin theproperpositionasthemortises arecut. Therearetimesthat,with a littleextraeffort,ajig canbemadeto serve a general purpose: for instance, ahingedtaperjig forthetablesawor thickness planer, or arouter boomfor cuttingarcs. Theuseofjigsisinseparable fromourunderstanding of howto makethefurniture wedesign. Evenif apieceisto bemadejustonce,it islikelythatwewill develop and useajig somewhere alongtheline.Whenweareproducing abatchof several hundred jigsarecriticalin almosteverymovewemake.Whethersimpleor complex, chairs, theyserve asthelinkbetween drawingandtool,ensuring precise consistent, results.
BruceBeekenandJeffParsons aregraduates of Boston University's Programin Artisanry.Theybuildfinefurniture at theirshopat Shelburne Farms,Shelburne, Vermont.
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ROUTING A].{DSHAPNGIIGS earlyin the20th Q in.. itsinvention therouterhasbecome one tJ Centurv. of themostpopularportablepower Fewtools tools-andwithgoodreason. andvercanmatchitsspeed,accura6/> satilityfor shapingwoodor cutting joints.Butjigsarealmosta necessity; althoughtheroutercanbeusedfreehand,mostcutsrequirea guide-particularlyrepeatcuts. proin thischapter Thejigsfeatured videvariouswaysof obtainingquickand precise resultsfromyourrouter.Some, jigsshownbeginning likethedadoing on page16,reducethesetuptimefor likethelap simpleprocedures. Others, joint jig on page27,allowthetoolto produce multiplecopies of thesame joint in a fewminutes. new A relatively vacuumwoodworking development, (page34)elimipoweredaccessories need for clamps natethe conventional patterns whenrouting usingatemplate. Thevacuumpumpis alsousefulfor featherboards to a routertable. securing jigsareeasyandinexpensive All of these to build. Theroutertlargercousin, theshaper, better canperformmanyoperations thanthesmallertool,but it isgenerally regarded asoneof themostdangerous A shoptoolsin thetypicalwoodshop. (page madefeatherboard 32)andguards jj) will makeit a safertool. (page
(lF ROUTING A SEIECTIOI{ ANDSHAPING JIGS Dado-routin7 jig (pa6e 17) Faatenedto router baae plate to cut equallyopaced dadoea
Auxiliary rout'er aub-baae (page 21) )ff-oquare base eecured to router baoe plate to enabletool to makecuta wider than bit diameter Freeatanding ahaper suard (pa6e 33) K Trian4ularcutter \ auard with viewhole for freehand ehaping
_---: shaperguard (page55) quardprotectaueerdurin4fence' L-ehaped Aidedbya simplejig, a table-mounted routercutsa perfectboxjoint.
quidedehapinqoperationo;featureaviewhole
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T I I I I Corner halFlap joint jiq (page 27) Uaedfor routin7 corner half-lapjointa
5liding dovetail jig (paqe 26) Uaedwith router to cut both parta of alidin7 dovetail joint; holda router horizontallyand eliminatea need for router table
Hinge-mottiaing jig (pase 22) Clampedto edqe of workpieceto rout hinqemorLiaea Movable-jaw moftiain7 ji6 Qa6e 29) Adjuatablejawo enaure that cut ia centered on the edqe of atock
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t ?anel-raising jig (pase 24) Uaed with router to bevelpanel edqea;holda router in horizontal poaition, eupportinq panel on a broad table
Adjuetable mofiiaing jig (pase 28) Holda workpieceed4e-up for cuttina morLiaee
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-\\ Extended ehaper featherboard (paqe 32) Clampedto ohaper fence Lo aupporb workpieceedurin4 fence-7uidedcuta and protect uoer from cutter
Adjuatable airaleautting jig (page 2O) Ueedwith router to cut circlea. )crew ia fixed to center of circle; radiua determined by diatance betweenscrewand bit
to router baeeplate to 4uide tool around circular cuLs
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Adjuetable routin4 guide (page 25) Adjuatable edqe quidee ueed with router to cut recta nquIar qroovea;tem platea can be added to rout patterne
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Quiak-aetup dadoing jig (page 18) Conaiataof two L-ehapededge4uideefor routin7 dadoea:quideereatfluah aqainet oppoaite ardeaof router baee plate
Shaper airale-autting jig (pase 31) V-ehapedjiq quideacircular atock duringahapin4operationa
T-equarejig (paqe 16) Clampedto workpiece, jiq qurdearouter through dado cute
Adjuatable dadoing jig
(pase 19) Securesworkpieceo of varyinqwidtha ,
for dado cuta
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r theiig 1 Building and I Toroutdadoes thatarestraight to theedges of yourstock,usea square T . s n r r airi epl i k et h eo n es h o w a nb o v e . "
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M a k et h e j i g f r o m3 / q - i n cphl y w o o ds,i z i n gt h e p i e c e tso s u i tt h e s t o c ky o uw i l l b e u s i n ga n d t h e d i a m e t eor f y o u rr o u t or haco nl:tp
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t inchew s i d ea n d l o n g etrh a n b ea b o u 4 t h ew o r k p i e c ew' si d t h :t h e f e n c e .a l s o a b o u t4 i n c h e sw i d e ,s h o u l de x t e n do n orthor side nf thp orrido hv ehnrri thp
. ssemble w r d t ho f t h e r o u t e rb a s ep l a t e A t h e 1 i gb y a t t a c h i ntgh ef e n c et o t h e e d g e g u i d ew i t h c o u n t e r s u ns kc r e w sU. s ea try squareto makecertainthe two pieces o re a c ho t h e r T . hen a r ep e r p e n d r c u tl a a n d ,w i t h c l a m pt h e l i g t o a w o r ks u r f a c e t h e b a s ep l a t ea g a i n stth e e d g eg u i d e , r o u ta s h o r td a d oo n e a c hs i d eo f t h e used fencewith yourtwo mostcommonly bits-often r/zand3/qinch Thesedadoes i n t h e f e n c ew i l l m i n i m i z tee a r o uwt h e n t h e l r g r s u s e da n d h e l pa l i g nt h e l t g w i t ht h e c u t y o uw i s ht o m a k e .
r) Routing a dado aligning thedadoin thefence L Clamp thejigto theworkpiece, w i t ht h eo u t l i n oe nt h es t o c kW . h e nm a k i ntgh ec u t ,p r e stsh e Continue theedgeguide(above). routerbaseplatef irmlyagainst router. fence stopping the distance into the before thecuta short
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( T-equareroulinq guide A draflingToquarecan b e u e e dt o g u i d ey o u r rouf,erthroughdado culs. To cuslomize t h e j t q f o r y o u rt o o l , clam?Lhe7quareto a ocra?board,buLLinq iLecroooViece aqainel the boardedqe.KideIhe rouLerbaoeplabealonq the arm of the oquare, into the boardand cuLLing Touse LhecroseViece. Lrimminq lhe jiq, clamViI Lo Nheworkpiece wilh the cuf,edgeof NhecroooViece aliqnedwilh Xhecu|Ninqmarkon Lhestrock.KouNthe Ihe arm. NhebaeeplatrebutrtedagaineN dado,keepinq
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A JIGFOR EVENLY SPACED DADOES thejig 1 Assembling I Thejig shown at rightis idealforcuttingequally spaced dadoes witha router. Dimensions depend on thesizeof theworkpiece andthespacing between the dadoes. Beginbycuttinga pieceof lo-inchplywood forthe base,makingit a fewinches widerthanthe diameter of yourrouter's baseplateanda fewinches longer thanthespacing between thedadoes. Setthe baseona worksurface andplaceyourrouternearone end.Markthescrewholesin therouterbaseolaieon thebase; alsomarka spotdirectly below thetool'scollet.Boreholesfor the screws andcut a holeat the colletmarklargeenough fortherouterbit.Remove the s u b - b a sf e r o mt h et o o l ,s c r e wt h ej i g b a s et o t h e routerbaseplate,andinstalla straight bitthesame youwishto rout.Next,cuta spacwidthasthedadoes erto fit snuglyin thedadoes, making it slightly longer thanthewidthof theworkpiece. Screw thespacer to the bottomof thejig, making thedistance between youwantbetween it andthe bii equalto thespace dadoes. vour
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r) Cutting thedadoes L Clamovour stockto a worksurface and setthejig ontheworkpiece withthespacerflushagarnst oneendandtherouter bit a t o n ee d g eH . o l dt h er o u t efri r m l ya n d feedit across thesurface to routthefirst dado,keeping thespacer flushagainst the workpiece. Turnoff therouterandinsert thespacer in thedado,repositioning the clamps asnecessary. Routthenextdado, sliding thespacer in thefirstdado. Continue(lefluntilallthe dadoes havebeencut. (Tovarythe location of yourfirstdado, guideliketheone routit witha T-square shown on page16,rather thanwiththe jig.) spacer
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DAD() A OUICK.SETUP JIG thejig 1 Assembling I Thejig shownat leftmakesit easy to routdadoes withminimal tearout. The device consists of fourstriosof %-inch plywood attached to formtwoLs.Ripall thepieces of thejig about4 inches wide. Cuttheedgeguides a fewinches longer t h a nt h ec u t y o ui n t e n dt o m a k eT. h e to overlap cleats shouldbe longenough theadjacent edgeguidebyseveral inches whenthejig is setup.Fasten theedge guides to thecleats, making certain the pieces usefourcountersunk aresquare; screws foreachconnection.
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t r) Routing a dado L Setupthejig byclamping thestockio a worksurface and against theworkpiece at thebeginning and butting thecleats theedgeguides, endof thecut.Thensetyourrouterbetween Slidetheguides together aligning thebitoverthedadooutline. u n t i lt h e yb u t ta g a i n seta c hs i d eo f t h er o u t ebr a s ep l a t e . S e c u rteh ej i g b yc l a m p i ntgh e L st o e a c ho t h e a r n dt o t h e w o r k p i e cTeu. r no n t h e r o u t ear n d ,w i t ht h et o o lb e t w e e n
plunge theedgeguides, thebit intothecleatat thestartof the theworkpiece cutto formanentrydado.Guidetherouteracross (above), extending thecut completely through thestockand intothesecond cleat. Thiswillminimize tearout asthebitexits theworkpiece, lf youneedto routseveral dadoes of thesame size,leave thejig clamped together andaligntheentrydado withthedadooutline marked onthestock.
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DAD() JIG ANADJUSTABLE thejig 1 Building j i g I T h e s h o w na t r i g h ti s i d e afl o r in widepanels. Sizethe routing dadoes pieces theedge sothedistance between guides equals thediameter of yourrouter's b a s ep l a t eT. h eg u i d e s h o u l db e l o n g enough to accommodate thewidestpanel youplanto rout.Cutthefouredgeguides, t h et w oe n d sa, n ds p a c e rf sr o m% - i n c h plywood m; a k ea l l t h ep i e c e4s i n c h e s wide.Sandwich theendpieces between guides At andscrewthemtogether. the to oneendof theframe,attachspacers t h et o pa n db o t t o mo f t h ee n dp i e c e . allfasteners. CuttheclampCountersink stock;make ingblockfrom%-inch-thick i t a b o u3t i n c h ew s i d ea n dl o n g et rh a n theendpieces. To installthepressscrew, b o r ea h o l ef o rt h et h r e a dtsh r o u gthh e (right,below). endpiecewiththespacers Remove theswivelheadfromthepress screwandfastenit to themiddleof the clamping block.Attachthethreaded sectionto theswivelheadandscrewthecollarto theendoiece.Usetherouter to cut shortreference dadoes in theotherend pieceandtheclamping block.
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r-) Cutting a dado Z- StlOe theworkpiece between theedge guides, with aligning themarked outline thereference dadoes. Secure theoanelin p o s i t i owni t ht h ec l a m p i nbgl o c kC. l a m p t h ej i g t o a w o r ks u r f a c eW. i t ht h e b i t clearof thestock, turnontherouter and startthecut at thereference dadoin the , a k i ncge r t a itnh er o u t eirs e n dp i e c em beiween theedgeguides. Feedthe bit intotheworkpiece, keeping thebaseplate flatontheslock(left).Tominimize tearout, waituntilthebitenters thereference dado i n t h ec l a m p i nbgl o c kb e f o rrea i s i ntgh e routerclearof thestock.
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CIRCLE-CUTTING JIGS Comprisingtwo hardwooddowelsand jig allows a centerblock,thisadjustable your routerto cut circlesof virtually any diameter.The jig is assembled by slippingthedowelsinto theaccessory holesin the routerbaseplate,fixing the dowelsto theblock,and attachingthe blockto thecenterof thecirclemarkedon theworkpiece. With woodcleatsholding thestockto a worksurface,therouter bit is alignedwith the end of the circle'smarkedradiusand thescrewsthat clampthedowelsto the baseplate are tightened.Thecirclecan thenberouted.
JIG C()MPASS Making thejig androuting a circle Tocut larger circles thanmostcommercial jig shown guides allow,usethecompass at right.Makethe devicefromr/rinch hardboard, sizingit to suityourrouter. becircuTherouter endof thejig should larandaboutthesizeof yourtool'sbase plate.Makethearmat least2 inches wide thantheradius of thecircle andlonger youwillbecutting. Borea holein thecenendforthe routerbit. terof the rounded remove To mountthejig onyourrouter, thesub-base andcenter the bit overthe clearance hole.Markthescrewholeson thejig,boreandcountersink them,then screwthejig to the router.Drawa line downthe centerof thejig armandmark theradius of thecircleon it, measuring fromtheedgeof thebit.Drilla holeat thecentermarkandscrewthejig to the workoiece. Secure thestockto thework surface withcleats. Plunge thebit into thestockandroutthecirclein a clockwisedirection.
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ROUTERIOINTINGIIG ROUTER JOINTING
llljlll llllllll llllillltlllllltjjitllllilrilllrlll}llltilllrufilllll1 5HO7Tt? An auxiliary oubbaoelor widecuts To makea cut,Nhat is wider than a particularrouler bif, youwouldnormallymakeone Vaee,ohiftyoured6equideand
B-inchequare.Kemovelhe router's eub-base Andborelhe screwholeeand Lhe clearanceholefor the bit trhrouah so Ihe Loolwillbe cen' auxiliary eub-base Leredon the jiq. Next,cut 1/rcinchof woodfrom oneedqeof the inchfrom an adlacenN edqe,andl/+inchfrom a lhird eub-baee,1/s on eachside.ecrewthe 1iq edqe.Markthe amounloyou removed to trherouNerand makea ?ae6withNheuncul endfluehaqaineLthe and makea secondpaoo,wideninqNhe 4uide.KotaLeNheeub-baee qrooveby 1/o,1/a. or 1/+inch,dependinq on whichoideyou uee.
Jointing widestock Tosurface boards thataretoocumberthejointer, usea someto moveacross routeralongwitha perfectly square edge guide. Thistechnique worksbestusing a top-piloted straightbit withal/z-inch shank. Position theedgeguideatopthe board to bejointedwiththeedgeof the protruding board fromtheguide's edge b y a b o u% t oi n c h C . l a m pb o t ht o t h e w o r ks u r f a c eM. a k et h e e d g eg u i d e longerthantheworkpiece to prevent the withtherouter; clamps frominterfering place a s h i mu n d etrh ec l a m pj a wt o keeptheguidefromwobbling. Withthe routerflatontheguide,adjustthebit height soit willcuttheentireedgeof Feedtherouterfrom the board(inset). oneendof theboard to theother;the p i l ow t i l lr i d ea l o n tgh eg u i d ea st h e flush(above). cuttertrimstheworkpiece
HINGEMORTISINGIIG theiig 1 Building I A j i g l i k et h eo n es h o w n a t l e f tw i l l allowyourrouterto cut hingemortises quicklyandaccurately. Tomakethecuts, youwillneedto equipyourrouter witha guide.Build straight bit anda template froma pieceof %-inchplythetemplate wood.Sizeit wideenough to support the router. Outline thehingeleafonthetemplate;remember to compensate forthe guideandthethickness template of the fence,whichis alsomadefrom7+-inch plywood. Cutoutthetemplate, thenattach thefencewithcountersunk screws.
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r') Routing hinges 4 Secure theworkpiece edge-up in a vise.Markthehingeoutlineonthestock andclampthetemplate in position, aligni n gt h ec u t o uw t i t ht h eo u t l i n eo n t h e edgeandbuttingthefenceagainst the innerfaceof theworkpiece. Makethe cuI (right)by movingthe routerin small clockwise circles, thenremove thejig andsouare thecorners witha chisel.
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CORNE,R-ROUNDING IIG 'l
Constructing thejig I Forcurvingthe cornersof a workpiece, y o uc a n u s et h e s i m p l ec o r n e r - r o u n d i n g 1 i gs h o w na t r i g h t .T h ej i g c o n s i s tosf a p l y w o o db a s ea n d t w o l i p st h a t a l i g nt h e e d g e so f t h e j i g a n d t h e w o r k p i e c eC. u t Formost the basefrom7a-inchplywood. j o b s ,a b a s ea b o u t1 0 i n c h e sw i d ea n d 1 6 i n c h e sl o n gw i l l b e a d e q u a t eD. r a wt h e c u r v ey o u w i s ht o r o u t o n o n e c o r n e ro f t h e b a s ea n dc u t i t w i t ha b a n ds a wo r a sabersaw;sandthe edgesmooth.Cutthe lipsfromsolidstockr/zinchthickand 1% i n c h e sw i d e ,t h e n n a i lo r s c r e wt h e p i e c e s t o t h e b a s e l, e a v i n g a b o u t3 t o 4 i n c h e s betweeneachlip and the roundedcorner. T h et o p e d g eo f t h e l i p ss h o u l db e f l u s h with the top surfaceof the base.
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r) Rounding a cornel with I Setvourstockon a worksurface t h ec o r n etro b er o u n d eedx t e n d i nogf f thetablebyseveral inches. Place thejig o n t o po f t h ew o r k p i e cs eot h el i p sa r e buttedagainst the edgesof thestock. to Useclamps to secure thetwopieces theworksurface. Tomaketherouter cut easier, usea handsaw to cutawaythebulk of thewaste. Then,usinga top-piloted flush-cutting bit in yourrouter, startclear o f t h ec o r n ear n de a s et h eb i t i n t ot h e s t o c ku n t i lt h ep i l o tc o n t a c t sh ee d g e . Pulltherouter around thecorner, moving against bit rotation andpressing thepilot flushagainst theedgeof the1igthrough(/eff). outtheoperation
PANE,L-RAISING IIG thejig 1 Building I Featuring a fence andtilting table, the jigshown youto raisepanat leftenables elsusing without a router mounting thetool i n a t a b l eT. h ej i g i sc l a m p ei d na b e n c h v i s eC . u ta l lt h ep i e c eosf t h ej i gf r o m l-inchplywood; thedimensions suggested in theillustration willworkwellwitha typical workbench. Startassembling thejig byscrewing thebrackets to theunderside of thetableat oneend,thencutadjustmentslotsthrough thearms.Secure the topendsof thearmsto thebrackets and thebottom endsto thefenceusinghanger bolts,washers, andwingnuts.Attachthe positabletothefence witha piano hinge tioned about 6 inches below thetopof the fence. Toprepare thefenceforyourrouter, borea holejustabove thetablelevelto accommodate thelargest %-inch vertical panel-raising bitorstraight bityouwillbe using. Screw theguardto thefenceabove thehole.Finally, cuta notchin thebottom endof thefence to cleartheworkbench's visescrew. lnstallthebit in therouter and screw thetoolto thejigfencesothebit fromthehole. orotrudes
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r) Raising a panel L Secure the1igfencein thevisewith thetableat a comfortable height. Adjust thebitfora shallow cut,turnontherouter, andmakea testcut in a scraooiece, To adjustthebevelangle, turnoffthetool, loosen thewingnutssecuring thearmsto t h ef e n c ea, n dt i l tt h et a b l eu po r d o w n . Raise theendsof thepanelbefore routing thesides; thiswillreduce tearout. Feed the panelacross thetableface-up, keeping yourf ingers wellclearof thebit.Test-f it thepanelandincrease thecuttingdepth slightlyto makea secondpass(right).Continueuntilthepanel fitsin thegrooves.
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theiig 1 Building at leftis idealforroutI Thelig shown pattern; it can in a rectangular inggrooves for curved alsobef ittedwithtemplates from1-by-2stock cuts.Sawtheguides %inchdeepandwide androuta groove edgeof eachone.Cuta along theinside tenonat oneendof each two-shouldered guideto fit in thegrooves andborea pilot holeintothemiddleof eachtenonfora bolt.Screw the hanger %-inch-diameter threadproenough boltsin place,leaving theadjacent truding to feedit through andwingnut. edgeguidewitha washer through rout%-inch-wide mortises Finally, from theguides; startabout3%inches t h ee n dw i t ht h et e n o na n dm a k et h e them 4 inches long,separating mortises Assemble the withabout%inchof wood. jig byslipping thetenons andboltsthrough andmortises of theadjacent thegrooves guide andnuts. thewashers andinstalling maketemolates likethose Forcurves. shown in theillustration.
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r) Routing thegroove to theworkpiece.) thetemplates tapeto secure Z- Outline thepattern onyourstockandlayit ona worksurface. (Usedouble-sided to the thewingnutsandclampthejig andworkpiece it onthestocksothe Tighten Loosen thewingnutsofthejigandposition thebit intothestock,makethecut in a flatonthework- table.Afterplunging Place therouter frametheoutline. edgeguides the keeping thebaseplateflushagainst direction, pieceandalignthebitwithoneedgeoftheoutline.Buttoneof clockwise at all times.Forrepeatcuts,simply on edgeguideortemplate therouterbaseplate.Repeat theedgeguidesflushagainst (abovd. androutthepattern clampthejig to the newworkpiece arein position. andtemplates theotheredges untilallguides
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JOINT-MAKING IIGS
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A SLIDING DOVETAIL JIG Building thejig 1 youto routslidI Thejig shown at leftallows (rnset) ingdovetails without a router table.Cutthe piecef rom%-inchplyfence, table,andsupport wood.Makeall the boards 16 inches long;the fenceandtableshould beabout10 inches wide pieceabout3 inches andthesupport wide.Screw thetableto thetablesupport sotheyforman L. Position thetable4 inches fromthe bottomof thefenceandboretwoholesthrough opposite endsof thefenceintothetablesupport. Usea routerwitha straight bit to lengthen the holeon theoutfeed sideof thefenceintoa curved slot. Attach thetablesupport to thefencewithcarriage bolts,washers, andwingnuts.Leave theboltat theinfeedendloose enough forthetableto pivot whentheslotted endis raised or lowered. Remove thesub-base fromyourrouteranduseit asa templateto markthescrewholesandbit clearance holeonthefence.Thebottom edgeof thecleara n c eh o l es h o u l ldi n eu pw i t ht h et o po f t h ej i g tablewhenthetableis level.
Eit clearancehole
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\ W Routing thejoint S e c u rteh ef e n c ei n a v i s ea n dr o u t groove thedovetail first,thenthematching slide.Forthegroove, startby installing a straight bit in therouter, attaching thetool to thejigfence, andadjusting thecutting depth.Setthegroove workpiece face-down onthetable,buttingitsedgeagainst the bit.Loosen thewingnutat theslotted end andadjustthetableto centerthebit on theedgeof thestock, thentighten thenut. Secure theworkpiece withthreefeatherboards, clamping oneto thetableandthe othertwoto thefenceon bothsidesof the cutter. Make thestraight cut,thencomplete thegroove witha dovetail bit.Fortheslide, setyourworkpiece onthetableandlower thetableto produce a 7e-inch-wide cut. Makea passon bothsides, finishing each (lntheilluscutwitha pushstick(right). tration,thefeatherboard on theoutfeed sideof thefencehasbeenremoved for clarity.) Test-f it thejoint.lf necessary, raise pass thetableslightly andmakeanother oneachsideof thestock
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A CORNER HAIF.LAP JIG
Corner half-lap End quide
Routing thehalf-laps and Clampthejig to a worksurface s l i d et h ew o r k p i e cbee t w e etnh eb a s e pieces untilit buttsagainst thestopblock. Protecting the stockwitha woodpad, in place. Adjust the clamptheworkpiece thestock router's cuttingdepthto one-half positioned thickness. Then,withtherouter inside theguides, turnonthetoolandlowerthebit intotheworkpiece. Guidethe routerin a clockwise direction to cutthe edges of thehalf-lap, keeping the outside b a s ep l a t ef l u s ha g a i n sat g u i d ea t a l l waste, times.Thenroutouttheremaining thedirection of feeding thetoolagainst (right).To bit rotation asmuchaspossible simplyremove routa T orcrosshalf-lap, thestopblocksothecutcanbemadeat anypointalongthefaceof thestockand clamotheworkoiece on bothends.
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thejig 1 Building I Cutthetwobasepieces andthestop as blockfromplywood thesamethickness yourstock. Thebasepieces shouldbewide theedgeandend enough to accommodate guides yourrouter's andsupport baseplate. Usesolidwoodstripsforthefourguides. Next,marktheshoulder of thehalf-lap (inset) one workpiece and buttthebase on pieces its with against edges theshoulnearthe middleof dermarkpositioned the boards. Installa straight bit in the mark, router andalignit withtheshoulder guide thenmountanend across thebase pieces thetool'sbaseplate. andagainst to position a guide Repeat theprocedure a t t h eo p p o s i teen d .N o wa l i g nt h e b i t withtheedges of theworkpiece andattach t h ee d g eg u i d e sl ,e a v i nag s l i g h gt a p between therouterbaseolateandeach youmakewill guide.(Thef irsthalf-lap routreference notches in thebasepieces.) F i n a l l yi n, s t a tl lh es t o pb l o c ku n d eor n e endguide,against theendof theworkoiece. Countersink all fasteners.
ROUTINGAND SHAPINGIIGS
ANADJUSTABLE MORTISING JIG )top block t/o"x1%"x5"
Jiq aide t/o"x6"x16"
Jig baee 3"x3"x16"
r) Routing a mortise L Settheworkpiece onthejig'sbasewith themortise outlinebetween thestopblocks f lushagainst thesidewith andonesurface Place theblocks. a shimunderthestockso itstopsurface buttsagainst thestopblocks, t h e nc l a m pt h ew o r k p i e tcoet h ej i ga n d secure thejig in a workbench vise.Next, install a straight router bitthesamediameterasthewidthof themortise, setthe depthof cut,andattach a commercial edge guideto therouterbaseplate.Center the bit overthemortise outlineandposition theedgeguidesoit restsflushagainst the opposite sideof thejig.Adjusteachstop blockbyaligning thebitwiththeendofthe mortise outline, butting theblockagainst therouter's baseplate, andtightening the w i n gn u t .O n c et h eb l o c kas r el o c k e idn position, turnonthetoolwiththebitclear of theworkpiece. Gripping therouter firmly, butttheedgeguideagainst thejig,press the baseplateagainst onestopblockand plunge thebit intotheworkpiece. Holdthe edgeguideagainst thejig asyoudrawthe routerthrough thecut untilit contacts the otherstopblock(right).Cuta deepmortise passes, in several increasing thebitdepth e a c ht i m e .
thejig 1 Making jig I The shown at leftwillguideyour router andsecure theworkpiece asyoucut a mortise. Thedimensions suggested inthe illustration willsuitmostrouters. Cutthe jig sidesfrom%-inch plywood. Makethe baseof laminated solidwood.Attach the sidesto thebasewithcountersunk screws, making surethepieces areperfectly square to eachother. Fashion eachstooblockfrom solidstockbycutting a rabbet %inchdeep and1 inchwide, thenrouting a 4-inch-long slotto accepta %-inch hanger bolt.Mount thebolts3 inches fromeachendof one in place, side,slipthestopblocks andf ix themwithwashers andwinsnuts.
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A MOVABLE.JAW MORTISING JIG 'l
Making theiig youto routperfectly I Thejig at rightallows centered mortises in stockof anythickness usinga straight bitand guide.Cutthejig topfrom%-inch plywood; a template makethepieceabout15 inches longandwideenough to acceptthethickestboardyouexpect to mortise. Cutthe twojawsfrom2-by-4-inch stockthesamelengthasthe top.Toprepare thetop,marka linedownitscenter and routa notchcentered overthelineat oneend.Thenotch guide youwill should bethesamewidthasthetemplate usewithyourrouterbit,andlongenough to accommoyouexpect datethe longest mortise to cut.Next,routtwo adjustment slotsperpendicular to thecenterline. Finally, borea viewing holebetween thetwoslots.Toassemble thejig,screwhanger boltsintothejawsandfasten the topto thejawswithwashers andwingnuts.
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r) Cutting a mortise L trttark a linedownthe centerof the mortise outline ontheworkpiece. Loosen thewingnutsandsecure thestockbetween thejawssothemortise centerline isaligned withthatof thejigtop;makesurethetop edgeof theworkpiece is buttedagainst theunderside of thetop.Alsoalignone endof themortise outline under theend of thenotch-offset bythedistance from guide's theedgeof thebitto thetemplate edge-thentighten thehanger bolts.Align theedgeof thebitwiththeotherendof theoutline andclampa stopblockto the topflushagainst therouterbaseplate. Routthe mortise(left),slarlingthecut guidebuttedagainst withthetemplate theendof thenotchandstopping it when thebaseplatecontacts thestopblock at theotherend.
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JIG A B(lXJOINT upthejig 1 Setting onthispageallows I Thejig shown youto cutthe notches fora boxjointon a routertablewithlittlesetuptime.lt consists simplyof an extension board gauge f itted to the miter and screwed witha keythatdetermines thespacing Install a straight bitsized of thenotches. width notches and to thedesired of the mounttherouterin a table.Setthedepth of yourstock of cutequalto thethickness intothebitto rout andfeedtheextension its bottomedge.Reposia notchthrough sothatthegapbetween tiontheextension thediameter thenotchandthebitequals of thebit,thenscrewit in place.Feedthe intothebitagain, cuttinga secextension a woodkeyto ondnotch(/eff).Fashion f it in thefirstnotchandglueit in place soit projects about1 inchfromtheextensionboard.
r) Gutting theboxjointnotches against L nod oneedgeof theworkpiece themiter the key,buttingitsfaceagainst gaugeextension. Turnon the routerand, yourthumbsaround thegauge, hooking slidethe boardintothe bit,cuttingthe first notch(right).Fit the notchoverthe cutkeyandmakea second cut.Continue thiswayuntilyoureachthe tingnotches To cut edgeof the workpiece. opposite in themating endof thenext thenotches fit thelastnotchof thefirstboard board, overthe keyandbuttoneedgeof the matingboardagainst thefirstboard.Move fonruard theentireassembly to cutthefirst holding both notchin themating board, pieces flushagainst themitergaugeextennotchsion(page12).RouItheremaining es in thematingboardthesamewayyou madethecutsin thef irstboard.
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SHAPERIIGS A CIRCTE.CUTTING JIG theiig 1 Making I Shaping circular workfreehand onthe isa riskyjob.Onewayto makethe shaper tasksaferandmoreprecise isto usea Vblockjig liketheoneshown at left.Build it froma pieceof %-inchplywood about 14 inches wideand24 inches long.To customize thejig foryourshaper, holdit above thetableflushwiththebackedge andmarkthelocation of thespindle on thesurface. Cuta right-angle wedgeout of thejig,locating theapexof theangle point.Thencuta circle at yourmarked outof thejig centered ontheapex;the holeshouldbelargeenough to accommodatethelargest cutteryouplanto usewith thejig.Routtwoadjustment slotsrntothe backedgeof thejig oneithersideof the h o l e - a b o u% t i n c hw i d ea n d5 i n c h e s long.Theymustlineupwiththeshaper's fencelocking handles, ason themodel shown. Thejig canalsobesecured to the shaper bymaking it asIongasthetable andclamping it in place at either end.
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r) Shaping circular work Z. Position thejig onthetable,centering thebit in thehole.Seattheworkpiece in thejig,buttingit against bothsidesof the V,andadjust thejig andworkpiece until thewidthof cut is setcorrectly. Secure the jig in place.Youmaywantto makea test cuton a scraooiecethesamethickness anddiameter asyourworkpiece to becertainthatthedepthandwidthof cut are c o r r e c tT. u r no n t h es h a p ear n db u t t t h ew o r k p i e caeg a i n st h t eo u t f e e sdi d e pivotthestockintothe of theV. Slowly cutteruntilit restsf irmlyin thejig'sV, moving it against thedirection of cutter (ieff).Continue rotation to prevent kickback rotating theworkpiece untiltheentirecircumference hasbeenshaped, keeping theedgein contact withbothsidesof thejig throughout thecut.
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FEATHERBOARD SHAPER ANEXTENDED thefeatherboard 1 Making I F o rw i d ec u t s s, u c ha ss h a p i ntgh e feathedges of a panel,useanextra-wide onthispage. erboard liketheoneshown the It will bothpress thepanelagainst fromthecuttableandshieldyourfingers ter.Cuta 2-by-4at leastaslongasyour the fence,settheboardagainst shaper's thelocation of thecutfence, andoutline ter on it. Curvethe bottomedgeof the featherboard slightly sothatonlythefingerswillcontact theshapthepanel during of %-inchingoperation. Bandsaw a series wideslotsat a shallow anglewithinthe a rowof sturdybutpltoutline, creating to the ablefingers. Screwtwospacers sothejig backfaceof thefeatherboard allfaswillclearthecutter;countersink teners(/eff).
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r) Raising thepanel featherboard to thefence, I Clampthe overthebit,andturn centering thefingers Foreachpass,useyourright ontheshaper. intothe handto slowly feedtheworkpiece cutter;useyourlefthandto keepthe panthefence(right). el against
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TWOSHAPER GUARDS guard Building a fence-mounted guardshown Theshaper at rightis ideal forfence-guided operations. Cutthepieces plywood, from%-inch making theguard i n t h es h a p eo f a n a r cl a r g ee n o u gtho f r o mt h ef e n c ea n ds h i e l dt h e extend c u t t e cr o m p l e t e lTyh. es u p p o rbt o a r d shouldbewideenough to beclamped to thefencewhentheguardisalmost touchi n gt h es p i n d l eS. c r e w t h eg u a r df l u s h withthebottom edgeof thesupport board; c o u n t e r s itnhkef a s t e n e rN s .e x ct l a m p tn t h ej i g i n p o s i t i oann dm a r ka p o i n o theguardabove thecutter.Remove the j i g a n db o r ea 1 % - i n c h - d i a m e r h toel e t h r o u gthh eg u a r da t t h em a r kt;h eh o l e w i l la l l o wy o ut o v i e wt h ec u t t edr u r i n g shaping operations.
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guard Making a freestanding Forfreehand shaping, makea guardlike theoneshown at left.Sawnfrom%-inch plywood, it covers thecutterfromthe s h a p e rt 'osp ,b a c ka, n ds i d e sC. u tt h e topabout16 inches longandwideenough to extend fromthebackof thetableto aboulIYzinchesin frontof the cutter. Bevelthefrontendsof thesidessothey canbe positioned ascloseaspossible to thecutter. Ripthesidessothetopwillsit above thebit withjustenough clearance you for to seethecutter.Holdthetopon thetableandmarka pointon it directly overthespindle. Cutanoval-shaped hole through thetopat themark,largeenough t o c l e a trh es p i n d laen da l l o wy o ut o movetheguardacross thetableslightly to accommodate different cutters.Fasten t h et o pt o t h es i d e sw i t hc o u n t e r s u n k screws. To usetheguard,position it on t h et a b l ew i t ht h es p i n d l pe r o j e c t i n g t h r o u gthh et o p ,a n dw i t ht h es i d e sa s c l o s ea s p o s s i b lt eo t h ec u t t i n ge d g e s . Clamp t h eg u a r di n p l a c e ,
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VACUUMIIGS Vacuum
The heart of the vacuurrlsysten is thepump, herea1/: horsepoweroil-Iess ntodel,which drawsair at a maximtrm of 4.5 cubicfeetper minute. The hosefeaturesa quick couplerthat attachesto a connectorthat is screwed into a lrcIethrough the templateor featherboard.Youwill qlsoneedto use as a gasketto sealthe vaatum tapeor closed-cell foam weotherstripping and workpiece or cavity betweentemplate featherboardand work table.
FEATHERBOARD A VACUUM Anchoring a leatherboard to a sawtable B o r ea n o u t l eht o l et h r o u gthh ec e n t e r Thehole's diameter of thefeatherboard. should b es l i g h t llye s st h a nt h a to f t h e you endof thehoseconnector threaded willuse.Next,applyfourstrips of closedof the tapeto theunderside cellvacuum with forming a quadrilateral featherboard, nogaps(insef). Screwthe hoseconnector intotheoutletholeonthetoofaceof the oppofeatherboard; usea wrench asshown jig,placethe site.Tosetupthevacuum onthesawtable-forthe featherboard t od m o l d i ncgu ts h o w ni t, r sp o s i t i o n e press against thefence. theworkpiece Makecertain thetapestripsaref laton t a b l e S . n a pt h eq u i c kc o u p l eart t h e the vacuum endof the oumohoseontothe a n h o s ec o n n e c t o r dt u r no nt h ep u m p . willanchor thefeatherboard Airoressure y o u f e e dt h ew o r k p i e c e t o t h et a b l ea s (right). throughlhe cut
n-[' h. vacuulnsystem shownhereisan l- excellentwav to anchorfeatherboardsto work tablesand fastentemplatesto workpieces. Thesystemis more thanconventional clamping convenient andoffersasmuchholdingpowerwithout riskingdamageto stock.The only must limitationis that matingsurfaces be flat andsmooth. To setup a vacuumsystem,you need thepartsshownin thephotoat left.The to the underside of the taueis fastened a cavfeitherboard or template, creating ity.Thehosefrom thepump is inserted in a holein thefeatherboard or template. \{hen thejig is placedon thesuifac., thepump suckstheair from thecavity, producinga vacuum.Anypump ratedat 3 cubicfeetperminuteor higheris adequatefor the homeworkshop.If you you can convertlt own a compressor, into a vacuumpump with a transducing pump.
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ROUTINGAND SHAPINGIIGS
VACUUM TEMPLATE ROUTING thetapeandconnector 1 Installing provides I A vacuum an effective alternativeto double-sided tapeforfastening a plywood template atopa workpiece. Once yourtemplate is theproper size,traceits patternon yourstockandcut out most of the wastefromyourworkpiece, leavi n ga b o u % t i n c ho v e r h a n g itnhget e m plate.Boretheoutletholethrough the middleof thetemplate andapplyvacuum tapealong theperimeter of itsunderside; makesuretherearenogapsbetween adjacentpieces of tape.Withthinstock, add twothinstripsof tapeoneithersideof the outletholeto prevent presthevacuum surefrompulling themiddle of theworkpieceagainst (insef). thetemplate Attach thehoseconnector to thetooof thetemplatein theoutlethole(right).
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r') Routing thepaftern Z- Install a piloted flush-trimming bit in a router, mountthetoolin a table,and adjust thecuttingheight sothebitwitl shape theentireedgeof theworkpiece. Placethetemplate tape-side-down centeredontopof theworkpiece. Attachthe vacuum hoseto theconnector andswitch o n t h ep u m pt o c l a m pt h et w ob o a r d s together. Turnontherouterandeasethe stockintothebit untilthetemplate contactsthe bit pilot(/eff).Complete the c u t ,k e e p i ntgh ew o r k p i e cf lea to n t h e r o u t etra b l ea n dt h ee d g eo f t h et e m platepressed flushagainst thepilot;move against thedirection of bit rotation.
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CUTTINGIIGS I rom thetimeyoucut roughlumber I to Iengthat thestartofa projector miter trim to finish it, your powersaws arelikelyto beyour mostandhandsaws usedtools.Althoughmanycuttingtasks without them,the canbe accomplished jigs shownin this chapterwill make theseoperationseasier-particularly whenthe samecut mustbe repeatedon workpieces. several arms,a tablesaw With its iniersecting miter jig (page50)guaranteesmiter jointsthat form perfect90"angles. The tenoningjigsshownon pages57and58 allowyouto cutbothpartsof openmorjointson thetablesaw. tise-and-tenon jigs Some facilitatecuttingtasksthat aretoughto performfreehand.Thecircle-cuttingjigsfor the sabersaw(page 43) andband saw(pageaa) help make quickwork of circulartabletops.In tandemwith your tablesaw,theraisedpaneljig (page52) canproducebeveled oanelsfor frames. Thesejigs will saveyou time in the shoo.An addedbenefitis that mostcan bebuilt from scrapwood,makingthem considerablyless costly than storeboughtcounterparts.
OFCUTTING JIGS A COTTECTION Miter and croeeaut guide (page 41) Makeamiter cuta and croaacuta with a saber gaw or circular saw
)izing board for aroeaauta @a6e aO) Ueedwith a backaaw for croggcutting; eLop block ie adjuetable
Saber aaw airalecutting ji6 @age a3) Attachea to eaberaaw and pivote around center of workpieceto cuL circlee:pivot point can be located at any point alonqjig arm
Eand eaw airaleautting jig (pase 44) Adjuetablejiq for cutttnq circleaon the band eaw;jiq ia clampedto oaw table and workpiece ie ecrewed to alidinqbar and rotated into blade
The crosscutjig shown at left provides a safeand accurateway to cut long, wide, or heavystockon the table saw.Because it slidesin the saw table'smiter slots, this sturdy, adjustablejig makesit easy to hold workpiecessquareto the blade.
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CUTTING IIGS
A COLTECTION OFCUTTING JIGS (continued)
Olade height gauge
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Table aaw taper jig (page 4A) For cutLin7[apero on the table aaw;quide bar with to4qle clampa is acrewedin place to hold workpieceat proper taper anqle.A aimilar ji4 with a handleand LheL-ehaped ,{ fence poeitioned differently can be ueedon the radial arm aaw (page 48)
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Meaouringgauqe for eettinq the heiqht of a table aaw blade
Ker-faplitter (paqe 42) Used with a ctrcularaaw to prevent the blade from btndinqin the kerf; placed in kerf of lonq rip cuta partway Lhrou7hoperation
Mitering ji6 Qase a7) Uaedto mtter trim on band eaw: ecrewe to mttrerlauqe
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Table saw croaacutjig (page 5O) Adjuatablejig uaedto makecroeacutg on the table eaw tn wrde,lon4, or heavyotock
Wedge-makingjiq (paqe aO) For cuttinq ehimaand wed4eo on the band eaw
Band aaw taper jig (paqe 47) Fixed-anqleji4 for makin7taper cute on the band aaw
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t ?traightedge guide (page 42) For ripping wif,ha circular aaw
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CUTTING IIGS
Radial arm saw auxiliary fence and table (page 54) Termtta the radial arm qaw f,o cuT.qrooveqor moldin4owith ito bladein the hortzontalpoeition
Tenoningjig (pase 57) For cuttin4 both parte of open mortiae-and-tenon jointe on the Lable aaw;rune alonq rip fence
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Cove-cutting jig (page 56) Uaedto eet up 4uideboardeon eaw table for cuttin4 cove moldin4
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Raioed paneljig (pase 52) Attachea to the table eaw rip fence to bevel the edqeeof raised panelefor frame-and'
Adjustable tenonin7 jig (pa6e 58) Uaedto cut openmorLiae-and' tenone on the table aaw;adjuata to etock of varyinq thickneaa
Table oaw miter jig (paqe 5O) )imilar to the croaacutjiq, except with analedarma uaedto make matinq 45' miter cuta
Eoard -strai g hte ning ji g (pase 53) Uaedon the table eaw to true the ed4eeof uneven atock; featurea a bar that runa in mtter alot
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SIZINGBOARDFORCROSSCUTS thejig 1 Building I Thejig shown it easy at rightmakes workpieces to crosscut several to thesame length byhand.ltsadjustable stopblock canbe positioned at varying distances fromthe kerfin thefence.Cutthebase p l y w o otdo t h e a n df e n c ef r o m% - i n c h dimensions suggested in theillustration. Usesolidwoodforthestooblockandlio. Screw thelipto theunderside of thebase, takingcareto aligntheedges of thetwo pieces. Sawthefenceintotwosegments about7 inches fromoneendandusea router fittedwitha %-inch bitto cutgrooves t h r o u gbho t hp i e c easb o u It i n c hf r o m theirtopedges; stopthegrooves about2 inches fromtheendsof eachpiece. Screw thetwofencesections to thebase, ensuringthatthegapbetween thetwopieces i s w i d ee n o u gtho a c c o m m o d aatsea w blade. Sawa 9O' kerfacross thesurface o f t h e b a s ei n l i n ew i t ht h e k e r fi n t h e fence. Toprepare thestopblock, cuta 3inch-long rabbetononefaceandborea clearance holethrough itscenterfora I%inch-long, %-inch-diameter carriage bolt. F a s t etnh e b l o c kt o t h ef e n c ew i t ht h e bolt,washer, andwingnut.
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t r) Making a crosscut L eufithelip against theedgeof your workbench, loosen thewingnut,andslidethe stopblockalongthefenceto theproper distance fromthekerfbetween thetwo fencesections. Tighten thewingnutand butttheendof theworkpiece against the stopblock,Holdthestockf irmlyagainst thefenceasyousaw(right).
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GUIDE MITERAND CROSSCUT theiig 1 Assembling I Themultipurpose edgeguideshown a trri g h w t i l la l l o wy o ut o c u te i t h e4r 5 " witha saber m i t , cutsor 90" crosscuts miter c i r c u l asr a w .M a k et h e j i g f r o m p iie c eo f l - i n c h p l y w o o dr .e f e r r i ntgo ao o r s u g g e s t eddi m e n s i o n s . t h e i l l u s t r a t i of n e ith C u tt h e b a s ei n t h es h a p eo f a t r i a n g lw o n e9 0 " a n g l ea n dt w o 4 5 " a n g l e s(.T o m a k ea ; r gf o r 3 0 " o r 6 0 " m i t e rc u t s .t h e s i d e s h o r r lhde 1 2 1 6 a n d2 0 i n c h eos r ) c r e wt h e a v a r i a t i o on f t h e 3 - 4 - 5 r a t i o . S f e n c e st o t h e b a s e- o n e o n e a c hs i d e o p p o s i toen eo f t h e 4 5 " a n g l e sT. h ef e n c e s m u s tb e f l u s hw i t ht h ee d g eo f t h ej i g b a s e . S A Wo r a
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r) Makinga mitercut L t o c u ta m i t e ru s i n gt h e j i g ,s e tt h e e i t ht h e c u t t i n g s t o c ko n a w o r ks u r f a c w l i n eo n t h e b o a r de x t e n d i nogf f t h e t a b l e . A l i g nt h e c u t t i n ge d g ew i t ht h e l i n ea n d b u t tt h e a n g l e ds i d eo f t h e j i g a g a i n stth e s a w ' sb a s ep l a t e ,w i t h t h e f e n c eo n t h e the edge bottomof the guideflushagainst o f t h ew o r k p i e cC e l. a m pt h ej i g i n p l a c e a n dm a k et h e c u t , k e e p i n tgh e s a wf l u s h a g a i n stth e . 1 i tgh r o u g h o ut ht e o p e r a t i o n (left).To makea 90" crosscut,usethe s q u a r es i d eo f t h e j i g a sy o u rg u r d e .
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RIPPINGIIGS TW()CIRCULAR SAWIIGS Using a kerfsplitter A kerfsplitterliketheoneshownat left w i l lh e l pp r e v e natc i r c u l asra wb l a d e frombinding rnitskerfandkicking back. Choose %-inch hardboard forthesolitter pieceand%-inch plywood fortheshoulders;referto theillustration forsuggested dimensions. Fasten thethreeoieces together withscrews. To usethejig,start thecut,turnoffthesaw,andinsertthe splitterin thekerfa fewinches behind t h es a w B . a c ku pt h es a ws l i g h t l yt h, e n (left).Forparliccontinuethe operation ularlylongcuts,advance thekerfsplitter periodically to keepit nearthesaw.
Edge atrip tl"x4"xB'
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t I guide Ripping witha straightedge youto makeaccurate Thejig shown above enables ripcutsin panelslikeplywood. longmanufactured Makethebasefrom%plywood inchplywood; use%-inch fortheedgestrip.Gluethe stripparallel to the base,offsetting its edgeabout4 inches fromoneedgeof the base.Trimthebaseto its proper widthfor yoursawbybuttingthetool'sbaseplateagainst thejig'sedge
t t stripandcuttingalongthe lengthof the base.To usethejig, marka cuttinglineonthepanelandclampthestockto a platformof 2-by-4s resting atopsawhorses. Clamptheguideto the panel, aligning thetrimmed edgeof thebasewiththecutting lineontheworkpiece. Makethe cul (above), keeping thesaw's baseplateflushagainst theedgestripthroughout theoperation.
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TWOCIRCLE-CUTTING IIGS CUTTING CIRCLES WITHTHESABER SAW
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thejig J Using f- Clampdownthestockwithasmuchof theworkpiece as possible extending off thetable,usingwoodpadsto protect thestock.Cutintothestockto bringthebladeupto theoutl i n eo f t h ec i r c l ey o uw i l lb ec u t t i n gT. h e nd r i v ea s c r e wi n t o thejig onthepivotlineat thecenter of thecircle.Holding the sawandthestockfirmly,cut outthe cicle (below), shifting the clamps andworkpiece asnecessary.
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thejig 1 Building I Tocutcircles bigger thanthecapacity of commercial sabersawjigs,usea guidecustomized shop-made foryoursaw. Theexactsizeof thejig canvary,butthe dimensions suggested in the illustration ai leftwillyielda jig largeenough to cut a circleto theedges of a 4-by-8panel. Beginby removing the bladefromyour sawandoutlining itsbaseplateona piece plywood. of %-inch Reinstall thebladeand c u ta l o n g t h em a r k sm, a k i ntgh es e c t i o n thatwillbebeneath thebaseplateslightly larger thantheplate.Lighten thejig by trimming it to theshape of an L, thencut outthenotch forthe blade.Screw thejig to the baseplate, ensuring thattheback o f t h eb l a d ei s f l u s ha g a i n st ht eb o t t o m of thenotch.Usea pencil to marka pivot l i n eo n t h ej i g t h a ti s a l i g n ew d i t ht h e teethof theblade.
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t CUTTING CIRCTES ONTHEBANDSAW thejig 1 Building I Forcuttingperfect circles ontheband jigcustom-built saw,usea circle-cutting for yourioolliketheoneshown at left.Refer to the illustration forsuggested dimensions. Usea routerfittedwitha dovetail bitto cut groove a %-inch-deep inthemiddle ofthejig base.Thenusea tablesawto rip a thin, beveled board thatwillslidesmoothly in (Setthesawbladebevel thechannel. angle b y m e a s u r i nt hgea n g l eo f t h ec h a n n e l edges.) Cutoutthenotchonthebandsaw. Thenposition thejig baseonthesawtable sothatthebladeliesin thenotchandthe d o v e t agi lr o o vies p e r p e n d i c utloatrh e direction of cut. Nowscrewthe suooort armsto theunderside of thejig base; the a r m ss h o u l dh u gt h es i d e so f t h e b a n d sawtable.Boretwoscrewholesthrough thebottom of thedovetail in the channel jig baseroughly 1 inchand3 inches from theunnotched end;alsoborethreeholes throueh thebar.
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r) Preparing theworkpiece youptan I ftlarX thecircumference andcenter of thecircre to cuton its underside. Then,usethebandsawto cutoffthe fourcorners of theworkpiece to keepit fromhittingtheclamps thatwillsecure thejig to thetableastheworkpiece turns.Make a release cutfromtheedgeof theworkpiece to themarked cir-
cumference andveeroff to the edge(above, /eff).Screwthe pivotbarto thecenterof theworkpiece through oneof thebar's holes(above, right),leavingthe screwlooseenough to pivotthe point workpiece. Turntheworkpiece overandmarkthecontact where theblade touched thecircumference durinstherelease cut.
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theworkpiece tothejig Q Securing r-,f Clampthejig baseto the bandsaw table,making surethesupport armsare butted against thetable's edges. Slidethe pivotbarintothechannel in thebaseand oivottheworkorece untilthemarked contactpointtouches theblade. Screw through oneof theholesin thejig baseto lockthe pivotbarin place(left),
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Completing thecircle Turnonthesawandoivottheworkpieceintothebladein a clockwise direction(below), feeding thepiecewithyour righthanduntrlthecutis completed.
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WEDGE-MAKINGIIG 'l
9top block '/""x1%"x4"
% "x 1 "x 1 5 % "
Kunner '/""x%"x19"
Building thejig I Smallwedges areusedforwedged tenons, orto shimcabinets on uneven f loors. Thejig youto makethemquickshown at leftallows l y o nt h eb a n ds a w (. Y o uc a na l s ou s et h e s a m ed e v i c o e n a t a b l es a w . R ) e f etro t h e illustration forsuggested dimensions, making surethehardwood runner fitssnuglyin the sawtablemiterslot.Screw therunner to the underside of thebasesothattherunner extendsbeyond thetabletop andthebasesits s q u a r eol ynt h et a b l ew h e nt h er u n n ei rs i n theslot;countersink thefasteners. Next,screw t h ef e n c et o t h et o po f t h eb a s ea; n g l et h e fenceat about4oto thefrontandbackedges of thebase. Setthejig onthetablewiththe r u n n ei rn t h es l o tt,u r no nt h es a wa, n dc u t through thebaseuntiltheblade contacts the fence. Turnoffthesaw,remove thejig,and cuta slotthrough thestopblockfora machine bolt.Attachtheblockto thebase,addinga w a s h earn dw i n gn u t .T h eb l o c ks h o u l b de f lushagainst thefencewiththetip of itsangledendaligned withthekerf.
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r) Cutting wedges L for yourwedge stock,cut a stripof woodfromtheendof a board; cross-grain makeit aswideasthedesired lengthof t h ew e d g e sP.o s i t i ot nh ej i g o n t h es a w tableH . o l d i nygo u rs t o c kw i t hi t s e d g e flushagainst thefence andoneendbutted against feedthelig across thestopblock, thetable.Makesureyourhands areclear of thebladeasyoucut eachwedge(right). Tocreate 4" anglewedges, square theend of yourstockonthetablesawbefore each c u t .l f y o us i m p l fyl i pt h ew o r k p i e b ce tweencutsonthebandsaw,allthewedges afterthef irstwillhave8' angles. Toprowedges, ducethicker loosen thewingnut andslidethestopblockslightly away from thekerf. Tighten thewingnutandcutthe (inset). wedges
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TWO IIGSFORANGLECUTSON THE BAND SAW TAPER JIG Making tapercuts jigshown Thesimple L-shaped at rightwill youto cuttapersonthebandsaw. enable Markthedesired taperon theworkpiece andplaceit on a boardwitha perfectly square edge, aligning themarked linewith theboard's edge.Usethelongedgeand theendof theworkpiece asa straightedge to markanangled cutting lineandthelip ontheboard. Sawalongthecuttingline, stopping 2 inches fromtheendof thecut Turnthe at the bottomendof the board. board90" to cut outthe lip.To usethe boardasa jig,setup the bandsaw'srip fenceto therightof thebladeandholdthe jig flushagainst thefence. Aligntheedge of thejig'slipwiththesawblade andlock thefencein position. Seattheworkpiece against thejig.Turnonthesawandslide theworkpiece andthejig together across the tableintothe blade(right),keeping bothhandsclearof thecuttingedge.
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MITER JIG
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Fence %"x13A"x13"
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Jiq body \ 1%"x11"x11"
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Mitering trim Usethejig shownat leftto mitertrimon thebandsawwithout angling the miter gauge. Formthejig bodybyface-gluing twosquarepiecesof %-inchplywood together. Oncetheadhesive hasdried,cuta 45' miterfromcorner to corner across the body,forming a ledgeonwhichtheworkpiecewillsit.Cuttwoslotsintotheface of thebody% inchbelow theangled ledge to accommodate springclampjaws.Next, cutthefencefromsolidstock,notchit for theclamps, andattachit to thejig body sothatitstopedgeextends %inchabove theledge, Screw thejigto themitergauge andfeedthejig intotheblade to trimthe lower end.Tocuta miter,clamptheworkpieceface-down ontheledgeandf lush against thefence,andfeedthejig foward withthemitergauge(left).Besureto raise thesaw'sguideassembly highenough to avoidhitting thejigorworkpiece.
TAPERJIGS A taperjig for theradialarm sawcanbe built exactlylike thetablesawjig shown thesaw below.with oneaddition:Because abovethetable,the motoris suspended radialarm sawjig canonly befed with onehand,makinga handlenecessary.
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A TAPER JIGFOR THETABTE SAW
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t a tapercut 1 Making I Foraccurate tapercutsonthetablesaw,buildthisjig (tnsef) of thejig basenearest theblade.Holding theworkpiece securely, from%-inchplywood. Referto the illustration for suggested position theguidebaragainst it,withthelipsnugly against theend Toassemble thejig,setthesawbladeto its maxi- of theworkpiece. Screw theguidebarto thebaseandpress the dimensions. mumcuttingheight, buttonesideof thejig baseagainst the toggle clamps downto secure theworkpiece to thejig.Tomake theothersideof the thecut,setthe bladeheightandslidethejig andworkpiece blade andposition theripfenceflushagainst handis in linewiththe base. Lower thebladeandmarka cuttinglineforthetaperonthe across thetable,making surethatneither (Caution: Bladeguardremoved for clarig.) workpiece, thensetit onthebase, aligning thelinewiththeedge blade(above).
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ABLADEHEIGHTGAUGE (lNA TABTE HEIGHT SETTING THEBLADE SAW gauge a bladeheight Using Yourtablesaw'sbladecanbe setat a quickly specific height witha bladeheight gauge.Makethejig fromstripsof %-or % o - i n c h - t hhi cakr d b o aor dr s o l i dw o o d laminated together. First,rip a lengthof the stockto a widthof 3 inches. Crosscut withan 8thepieceintostrips,starting inchlength. Makeeachsuccessive strip% inchshorter thantheorevious one.Once allthestripsarecut,gluethemtogether face-to-face withoneendaligned. Touse thejig,setit on thesawtablebeside the bladeandrotatethe bladeheight adjustment crankuntiltheblade contacts thegaugeat thedesiredheighl(right).
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Illlllllllllllltllllllllillllltfilllllfit-l1ll"tlll-1[t'llt"lltl llt'tlll 1HO?TI? Shop-made table ineerte lf ihe table inserLseupplied wiih vour Nablesaw are aL leaeN%inchthick, youcan makeyour ownfrom woodecrape. The inserle willminimizeNheqap belweenlheeawbladeandNheLable ineerLo?eninqand ?reventecrapwoodfrom \ jamminqaqaineN the blade.UeeLhefactory-euppliedineerl ae a lemplale t o cul a blankfrom a /.7 pieceof woodof lhe eamethickneee.Tap a finisfur(gnailinVoIhe blank'e front enAunlil'/oinchprotrudeefrom if. (Thenailwilloerveae an anchor CrankNheblade pint o keeplhe ineerLin Vlacewhilethe eawie runninq.) to ite loweet,eetlinq and eellhe newineert in place.TosilionLhe rip fenceto etraddleNheinserl,makinqeureIhat iI is noI directlyin line withlhe cuttinqedqe.Iurnonbheeawand crankNheblade olowlyup to itrohiqheotoetlinq, cutlinq a eloLNhrouqhNhewoodineerl.
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MITERIIGS CROSSCUTAND The tablesaw miterjig shownat right k similar to the crosscutjig describedbelow, exceptthat insteadof an extensionand safetyblockit featurestwo l2-inch-long 1-by-4 miter arms.Placedat 90" to each other in the middle of thejig, the arms ensurethat a workpiecemiteredalong oneguide will form a perfect90" corner with a boardcut along the other arm.
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SAW A CROSSCUT JIGFORTHETABLE Clearplaetic quard
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)top block 2"x4"x4"
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t I Kernforcinqblock 2"x2"x8" 9upporEframe 2"x3"x36"
tothebase therunners 1 Aftaching jig custom-made above is foryourtablesawliketheoneshown I A crosscut to the illustrawithunwieldy stock.Refer valuable if youareworking especially hardwood runners Startbycutting two25-inch-long dimensions. tionforsuggested intothe clearance holesforscrews to fit yourmiterslots.Boreandcountersink in theslots fromeachend.Place therunners of therunners, 3 inches undersides a n ds l i d et h e mo u tt o o v e r h a nt hgeb a c ke n do f t h et a b l eb ya b o u8t i n c h e s . itsedgeflushwiththeiroveronthewoodstrips, Position thejig basesquarely andthe to thebase(/eff).Slidetherunners hanging ends,andscrew therunners baseoffthefrontendof thetableanddrivein theothertwoscrews.
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r) Installing thesupport frame andguide I W,tntherunners in still themiterslots, attach thesupport thebasefromunderneath thejig,making sureyoucountersink jig glue framealong thebackedgeof the and onthereinforcingthefasteners. Gluethesafety blockto theoutside faceof the block,centered between therunners. Thenmakea cutthrough guide, again centered onthekerf.Raise thesawblade andfinthesupport frameandthree-quarters of thewayacross thebase. ishthecut,sawing completely through theguidebutonlyslightTurnoffthesawandlowertheblade.Screw a reinforcing block ly intothesafetyblock.Mounta clearplastic sheetoverthesaw guide position guide to the and the alongthefrontedgeof the kerfasa bladeguard, fastening it to thereinforcing blocks with jig,usinga carpenter's square to ensure thatit is square with wingnutsorscrews. thesawkerf.Clamp theguidein place(above)and screwit to
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Q Crosscutting r-,1Formaking repeat cutsto thesame length, screwan extension to the right sideof theguideandclampa stopblock to it. Cuta notchin theblockto holdthe clampin placewhenit is loosened. Touse thejig,fit therunners intothemrterslots andslidethejig toward the backof the tableuntiltheblade enters thekerf.Hold theworkpiece against theguide, slidethe s t o pb l o c kt o t h ed e s i r epdo s i t i o na,n d . i t ht h ew o r k p i e c e c l a m pi t i n p l a c eW h e l df i r m l ya g a i n st h t eg u i d ea n dt h e s t o pb l o c ks, l i d et h ej i g s t e a d r a l yc r o s s thetable(left),feeding theworkpiece intotheblade.
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RAISEDPANELIIG
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t thejig 1 Making I Toraise a panel onthetablesawwithout adlusting theblade jigshown at left.Refer totheillustration angle, usetheshop-built forsuggested dimensions. Screw thelipalong thebottom edge fence,making thescrews where of theangled sureto position t h e yw i l ln o ti n t e r f e rwei t ht h e b l a d eP. r o pt h ea n g l e fde n c e against theauxiliary fenceat thesameangle asthecuttingline marked outonthepanelto beraised. Usea slidingbevelto transferthisangle to triangular-shaped supports thatwillf it between in thetwofencesandcut thesupports to fit. Fixthesupports placewithscrews(above).
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r) Raising a panel thejig L Snttttheripfenceto position j o i n t w i t h o nt h es a wt a b l e the o f t h el i p f e n c e a n da n g l e d o v e trh eb l a d ee; n s u r e thatthescrews arewellclearof thetable o p e n i n gT.u r no nt h es a wa n dc r a n kt h e to cut a kerfthrough the bladeup slowly l i p .N e x ts, e a t h ep a n eiln t h ej i g a n d l sina d j u stth eh e i g hot f t h eb l a d eu n t i a gletoothis protruding beyond thefrontof thepanel.Makea testcut in a scrapboard thesamethickness astheoanelandihen Adjust the testitsf it in theframegroove. position of thefenceorblade, if necessary, l ,e v e l i nt hgee n d a n dc u tt h ea c t u apl a n e b grainfust (right).
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BOARD-STRAIGHTENINGIIG
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1iililil ilil tiiilililil|il ilil|ill tiiillil illl llll llil illl llll liil llll ili iii ill {il lti {$ {il i.Uui ul l$ ili i.ti iii iil iil ul ill
5HO7Tt? Crosscult'ingwide panele or you are workinq lf yourIable oawdoeenot havean exLension, wiNhVanelolhal are t'oo larget'o cuNwiLha mit'erqauqe,you can crosscutlheee paneloby clampinqa equare1-by'3fencelo the undereide of the panel.Uoea 1-by-3Nhatis lonqert'hanthe Vanelio wideand carefullypoeition it, undernealhperVendicular H
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"n22" :? "|flV i:o;:," F Nhefenceto the
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VanelwiLhC clampo.Guide along Nhefence the ouler edge of your eaw'e table ao you makethe cuN.
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Truing a board on a tablesaw, Totrueuneven boards jig shown buildtheboard straightening a b o v eB. u i l tf r o m% - i n cphl y w o o tdh, e jig slidesin thetablesaw'smitergauge to bestraightened slot,whrletheboard i s h e l di n p l a c eb ys u p p o rbtl o c kas n d Firstcut the basefrom toggleclamps. plywood; %-inch makeit about9 inches wideandlonger thanthewidthof your s a wt a b l eC . u ta r u n n etro f i t t h e l e f t handmitergauge slot;makeit longer it onthe thanthejig baseandposition underside of thebasesothattheinside thebladeby edgeof thebaseoverlaps %inch.Screw therunner to thebottom allthescrews. of thejig,countersinking Next,screwtwosupportblocksto the toggle clamps onthem; baseandinstall position sotheworkthesupport blocks p i e c ei s c e n t e r eodnt h eb a s eF. i n a l l y , it totheend fashion a handle andattach o f t h ej i g .T o u s et h ej i g ,f i r s t r i mt h e it across inside edgesquare byrunning to be t h eb l a d et .h e nc l a m pt h eb o a r d to thejig andrepeat to true straightened itc odopc
(zhnvp)
AUXILIARYFENCESAND TABLES A RADIAL ARMSAWM()TDING FIXTURE Cutout 2 % "x 9 % "
LiP '/+"abovetable
Building andsetting upthejig 1 I lf youwantto cutgrooves or molding ontheradialarmsaw position, withthebladein thehorizontal tryanauxiliary fence andtableliketheoneshown above. Thebaseraises theworkpieceto thecutter,andthefencesupports theworkwhileprovidinga clearance cutoutforthedadoor molding headguard. plyCutthefenceandthetwopieces forthebasefrom%-inch wood;makethe basepieces thesamesizeasthe frontsaw table.Screwthe basepieces together, offsetting thetopslightly
to createa gapalongthefencethatwill prevent sawdust fromaccumulating between the baseandthefence.When sawingthe fencecutout,leave a lipthatwillprotrude at least %i n c ha b o v teh eb a s ew h e nt h ej i g i s i n s t a l l eTd h. el i pw i l l support theworkpiece asit ridesalong thefenceduring a cut. Screw thefenceto thebase. Tosetupthejig,slipthefence between thefrontsawtableandthetablespacer, thentightenthetableclamos to secure it.
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r') Cutting a molding L lnstalla molding headonyoursaw, thensecure theworkpiece byclamping onefeatherboard to theoutfeed sideof thefenceandanother to thetable,braced witha support board, Adjustthemolding headfor a %-inch-deep cut,making cerj uds t t a i nt h e b l a d eg u a r di s p o s i t i o n e abovetheworkpiece. Feedthestockinto the cutterswithyourrighthand(right); useyourleft handto presstheworkpiece against thefence.Finish thepasswitha pushstick.Makeasmanypasses asnecessary, advancing themolding headno morethan%inchintotheworkpiece at a t i m e .O n c ey o uh a v ec u tt h ed e s i r e d p r o f i l em, a k ea f i n a l ,v e r ys h a l l o w pass, f e e d i nsgl o w l ay n de v e n ltyo p r o d u cae finish. smooth
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F()RTHETABLE SAW FENCE ANAUXITIARY
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illtilllllillllllll llltlllllllllllllllllltillll fillrlllllltijllfiitlll1 9HO7Tt? A miter Oauge extension Io increasef,hebearinq eurfaceof your tableeaws miler gauqe or Nomakere?eatcrogo' cu|s wiNhthe aid of a eNopblock, athach a wood exDeneion lo the qau7e.The excension muel be lonqenouqhlo extendbeyondthe eaw blade.)crew iNNolhe qauqeand Vuoh off Nhesaw NhegauqeLo cut,off the endof t'heexEension.Turn and slideLhemiLer6auqeto Ihe fronLof Nhelable.Toeet up a Nhedesireddis' ehopblock,clampa woodblockloNheexEension Foreachcut, butt' trheedqeof the work' lance from Nheb1ade, olop block. andlhe enda7aineNthe pieceaqaineNNhe exLeneion
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anauxiliary fence Using youusea dadoormolding head Anytime withthe onyourtablesawin conjunction rip fence,youneedto attacha wood the blades fromconfenceto orevent themetalone.Cutthefencefrom tacting plywood thesamelengthasthe %-inch higher. Lower the ripfenceandslightly the thesawtableandscrew blades below woodfenceto theripfence.Markthe depthof cut onthefenceandposition fencedirectly overthedado theauxiliary head, ensuring thatthemetalfenceis Turnonthesawand clearof theblade. s l o w lcyr a n ku pt h ed a d oh e a dt o t h e line,producing a relief cutin the marked fence.Buttthecuttinglineon auxiliary theouterblade theworkpiece against a n dl o c kt h ef e n c ef l u s ha g a i n st ht e like stock.Formostcutting operations, in theillustration, cutshown therabbet with should besupported theworkpiece at a featherboards. Feedtheworkpiece steadyrate,usingbothhands(above).
COVE,.CUTTING IIG andusing thejig 1 Building I Fashion moldins onthetablesawwith guideshown thehelpof thecove--cutting at left.Toconstruct thejig,fastentwo 18inch-long l-by-2s to two9-inch-long 1-by2 s w i t hc a r r i a gbeo l t sa n dw i n gn u t s , forming twosetsof parallel arms. Adjust the jigsothedistance between theinside edges o f t h et w ol o n ga r m se q u a ltsh ew i d t ho f thecove.Crank thebladeto thedesired depthof cut.Laytheguideacross theblade a n dr o t a t er t u n t i lt h e b l a d et,u r n e db y hand,justtouches theinside edges of the a r m sT. h e nr u na p e n c ial l o n g t h ei n s i d e edges of thelongarmsto traceguidelines across thetableinsert(/eft).
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t r) Cutting a cove 1 Remorethe thebladebeneath thetable.Outline euideandlower thedesired cove profile ontheleaJing endof theworkpiece, thensetthestockonthesawtable,aligning the marked outline withtheguidelines onthetableinsert. Buttguideboards against theedges o f t h ew o r k p i e caen dc l a m pt h e mp a r a l l e t ol t h eg u i d e l i n euss; eb o a r dlso n ge n o u g h t o s p a nt h es a wt a b l eC . r a n tkh eb l a d e%i n c ha b o v teh et a b l eT. om a k e t h ef i r s tp a s s , (above), feedtheworkpiece steadily usingpushblocks whenyourhandsapproach the blade area.Makeasmanypasses asnecessary, raisingthe blade%inchat a time,
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TWOTENONINGJIGS
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JIG G A SIM PLTEEN O N IN thejig 1 Building thefence-straddling I Easy to assemble, j i gs h o w n at righw t o r k sw e l lf o rc u t t i n g openmortise-and-tenon two-shouldered joints.Refer suggested to thedimensions making surethethickin theillustration, andwidthof thebrace nessof thespacer your a l l o wt h ej i gt o s l i d es m o o t hal yl o n g r i pf e n c ew i t h o uwt o b b l i nC g .u tt h eb o d y plywood andthe andbracefrom34-inch guideandspacer Sawan fromsolidwood. of the in onecorner ovalholefora handle jig bodyandattach theguideto thebody hole,making in frontofthehandle directly s u r et h a tt h eg u i d ei s p e ref c t l yv e r t i c a l . (Theblademaynotchthe bottomof the guidethefirsttimeyouusethejig.)Screw a s m a lw l o o db l o c kt o t h e b o d yb e l o w h t o g g l cel a m p t h eh a n d l ae n da t t a c a , s t e nt h es p a c e r t o t h e b l o c kF . i n a l l yf a andbracein olace.
r) Cutting a mortise I Placetheiig astride thefence.Butt t h ew o r k p i e caeg a i n st h t ej i g g u i d ea n d c l a m pi t i n p l a c eP. o s i t i ot nh ef e n c et o with ontheboard alignthecuttingmarks thefence theblade andslidethejigalong to makeIhe cuI (lefil.
CUTTING IIGS
ANADJUSTABLE TENONING JIG Blade4uard
Erace 3/+"x13/+"x351/q"
Fence 3/+"x5%"x351/+"
11,/2"x51/2"x24"
v
Kunner
thelig 1 Assembling
I Thejig shown above canbeusedon the tablesawto cut bothpartsof an joint.Refer openmortise-and-tenon to theillustration forsuggested dimensions. Cutthejig fenceandbackfromthree piecesof %-inchplywood andsawa 45' bevelat oneendof eachboard; the pieces should bewiderthantheheight ofyoursaw'sripfence.Fasten twopieces together face-to-face to fashionthe back,thenusecountersunk screws to attachthefenceandbacktogether in an L shape; makesurethefasteners will pathwhenyouuse notbein theblade's the jig (inset).Next,cut the bracefrom solidstock,bevelits endsandattach i t a l o n gt h et o p e d g e so f t h e f e n c e andback,forming a triangle. Cuttherunnerfromsolidwoodandattachit to the fencesothatthejig runssmoothly across (Therunner thetablewithout wobbling. in thisillustration hasbeennotched to fit theparticular desrgn of thesaw'srip fence.) Finally, cuta pieceof clearplastic asa bladeguardandscrewit to the jig backflushwithitsfrontface.
r') Mounting theeccentric clamp 1 tttat,,e plywood theclampbyface-gluing threepieces of %-inch andcuttingthe assembly intotheshape shown. Borea prlotholethrough thejig backandtheclamp, thenfastentheclampin place;wedgeoneof yourworkpieces between theedgeof theclampandthefenceasyoudrivethescrew. Offsetthefastener sotheclampcan (above), (Drilladditional pivoteccentrically youto move holesin thejig backto enable theclampto accommodate stockof varying thicknesses.)
5B
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Cuttinga tenon
lllllllllllll]lllll illlillllllllllltlll ,lllllllljlllllllll]lllilll,ll1 1HO?TI? A miter 4augeangle-eetlingjig useon Tokeeplrack of non-eLandard angleolhalyou commonly yourtable oaw'6miter qauqe,makea sel of anqle-eeNIinq 1iqo. )implycut Lwo1-by-2eand clamVIhemto the miler q a u q eo, n ea q a i n e l t h eb a ra n d o n ea q a i n o t r L h e f a c e . 7 c r e wt h e m N o q e L h ei nr N oa n a n g l e dL i ohapeand markdownf,heanqlethey form ,, o n t h e j i g , U e et h e d e v i c el i k ea o l i d i n g t o ee| the miter bevel qaugequicklyLo a opecific angle.
S e tt h e l i g o n t h e s a wt a b l ei n f r o n t
of theblade withtherunner andfence straddling theripfence. Secure theworkpiecein thejig byturning theeccentric clamp, andposition theripfencesothat t h eb l a d ei s i n l i n ew i t ha t e n o nc h e e k Feedthe cuttingmarkontheworkpiece. jig intotheblade. (Your f irstuseof the 1 i gw i l lp r o d u caek e r fi n t h eb a c k .F) l i p theworkpiece in the1igandrepeat to cut Remove thejig theothercheek(above). fromthetable,lower thecuttingheight t o t h el e v eol f t h es h o u l d e rasn, ds h i f t theriofence to cutthetenon shoulders.
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rillinga holeis simple,but there you aretimeswhenajig cansave when time and frustration,especially the hole mustbe locatedprecisely, or at jig, an exactangle.The center-drilling for example,ensuresthat doweljoint holeswill be centeredin the edgesof matingworkpieces.Thejig for drilling equallyspacedholeson the drill press virtually eliminatesthe needfor measuring andmarkingandguarantees consistentlyaccurate results. The tilting tableandpocketholejigs areboth invaluablefor boringthe angled holesthat arecommonlyusedto attach tabletops andchairseatsto legsandrails. The techniquefor drilling deepholes shownon page67 willdoubleyour drill press's quill stroke,allowingyou to bore straightthroughthick stockwithout resortingto an extension bit.
A SETECTI(IN OFDRILTING JIGS
Jig for boring equally spaced holes (pa6e 64) Uaedon drill preaa
V-bloakjig (page 65) Holde cvlindrical stock on drill preee table
Tilting table jig
(pase65) Equippedwith thejig shownat left, a drill presscanborea rowof equally spacedholesquicklyand accurately. Thejig is simpleto buildfrom scrap woodanda shortdowel.
Adjuetableji4 attached to drill preae table for borin7 anqled holea;workpiece lies face-downon top
Cenier-drilling ji6 Qaqe 62) Uaed with an electric drill to locate the center of a board ed1e; dowelo at the enda of the arm are butted aqainet oppoeite board facea
Pocket holejig (page 66) Clampedto drill preaa table to bore pocket holee;workpiece reste edqe-down in an4ledcradle
CENTER-DRILLING IIG
Drilling holes dowel j i g T h es i m p l e s h o wanb o vw e i l le n a b l e youto boreholesthatarecentered on theedgeof a board. Theinsetprovides dimensions. Markthecenter suggested of thetopfaceof thearm,andborea Theholein the holefora guidebushing. bushing should bethesamesizeasthe youplanto drill.Turnthearmover holes anddrawa linedownitsmiddle, Mark points ontheline1 inchfromeachend. (Check yourmeasurements: Thepoints m u s tb ee q u i d i s t afnr ot mt h ec e n t e r . ) holehalfway Thenborea %-inch-diameter through thearmat eachmark.Dabsome g l u ei n t ot h eh o l e sa n di n s e rdt o w e l s . protrude Theyshould byabout%inch.To it ontheworkpiece usethe1ig,position opposite sothatthedowels buttagainst facesof thestock.Holding thejig wrth o n eh a n df,i t t h ed r i l lb i t i n t ot h eb u s h ingandborethe hole(above).
ltllLiilllllll lllillllllllilllllillIJllrlitllilltilllillll]lllljrJl 1HO?TI? lnoertin7dowels wilh a deprh gauqe ToavoidNheriekof drivinq doweletoo deeVlyand epliNIinq the board,try thie eimpledeplhqauqe. U e ea 6 - i n c h - l o n q Vieceof ebock one-hala fe N h i c ka e t h e lenqlhof the
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dowele.9ore a hole n e a ro n ee n d L h a N i e e l i q h b l yl a r q e rL h a n l h e
doweldiameler.Then elipthe 1igaroundeach dowelwhenyou laV it, in Vlace.Thedowelwill be aI Nhecorrecldepthwhenit ie fluehwith t.heNoVof the deplh qauqe.
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TITTINGTABLEIIG thetable 1 Making I T o b o r ea n g l e d h o l e sw i t h o utti l t i n g t h ed r i l lp r e s tsa b l e u, s et h et i l t i n gj i g shown at right,builtfromsolidstockand plywood. %-inch Refer to theillustration for suggested dimensions. Connect the j i g t o pt o t h eb a s eu s i n ga s t u r d yp i a n o hinge. Cuta %-inch-wide slotin thesupportbrackets andscreweachoneto the top;secure thebrackets to thebasewith wingnuts,washers, andhanger bolts.
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r) Drilling angled holes (-, a ^Center thejig underthedrillpress s p i n d l ec,l a m pt h eb a s et o t h et a b l e , andloosen thewingnuts.Usea protractoranda slidingbevelto setthe angle of thetop,thentighten thewing nuts.Clamp theworkpiece to thejig andborethehole(below).
9upport bracket t/o"xl %"x'lO"
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t thejig 1 Making holes spaced a rowof equally thetaskof boring I Makethisjigto simplify p r e s s . b a s et,h e n e d g e o f t h e Screw t h ef e n c ef l u s hw i t ho n e o n t h ed r i l l (The hole holder. of thefenceasa dowel attacha woodblockto thecenter jig.)Tne given you dimensions usethe forthedowelis madethefirsttime i l ls u i tm o s dt r i l lp r e stsa b l e s . i n t h ei l l u s t r a t iw on
l]Illlllllllilll llllullltiilltllrljlllllllirufiililllillll]lllllll]I1 5HO7Tt? Making wood plugo eavelime makinqwood pluqeby uoin4a pieceof IaVe Noremove themfromtheirholee, Use a oluacull,eron the drill Vr:"eir,o borea rowof plugeNo Lhedepthyou require.CoverNhe t aVe, row wilh a eNripof maekinq then rip Ihe pluqelo lenqthon Nhe bandsaw and eimplypeeloff the ta?e to removethe rowof Vluqe.
r) Boring theholes L S e t h e1 i go nt h ed r i l lp r e stsa b l e . Markthe location of thef irsttwoholes thefence against andseattheworkpiece mark thefirstdrilling of thejig,aligning under thebit.Butta guideblockagainst t h eb a c ko f t h ej i g a n dc l a m pi t t o t h e t a b l eB . o r et h ef i r s th o l e s, l i d et h ej i g along t h eg u i d eb l o c ka, n db o r ea h o l e t h r o u g thh ed o w ehl o l d e rF. i ta d o w e l andintothe through theholeintheholder Slidethejig until holein theworkpiece. markisaligned under thesecond drilling j i g t o t h e t a b l ea n d b i t . C l a m t p h e the T o d r t l l e a ch s e c o n h d o l e . b o r et h e al n d h o l e r , e t r a c t t h e d o w e remaining jig fence. workpiece along the slidethe Pushthedoweldownintothelasthole youmaoe.
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Boring holesin cylindrical stock T o m a k et h es i m p l eV - b l o cjki g s h o w n above, marka right-angle V on theend o f a p i e c eo f s o l i ds t o c kt h a ti s l o n g e n o u gtho h o l dy o u rw o r k p i e cTeh. e n , adjust theblade angle onyourtablesaw to 45"andalignonecutting linewiththe b l a d eB. u t t h er i pf e n c ea g a i n st ht e stockandfeedtheboard to cutthefirst s i d eo f t h eV . R e v e r st he ep i e c ea n d m a k et h es e c o n cdu t .T o u s et h ej i g , secure it to thedrilltablesothedrillbit t o u c h etsh ec e n t eor f t h eV w h e nt h e quillisextended. Holdtheworkpiece in t h eV , a l i g n i ntgh eb i t o v e tr h ec u t t i n g m a r ks, e tt h ed r i l l i n d g e p t ha, n db o r e the hole(above).
llllilI1 lllltlllll1 llltilij]ltiluili ll11 illlllitfillilltllr1 lllll]t1 1HO?TI? Depth guideo for drilling I i'l I To borea holelo an exacL I | il : I q-hr".t:','* d,epNh, uee a maekin4t ape I flag or a deplh orop block, I : ll|;t lf you are ueinqNheNape, F:;= y meaeure the drillinqdepth t from the Lip of the"biv,'then ffufl-{-ffi;{. wra?a eNriVof NaVearound ive'ehank. Wnnarhwlhe bit W whenlhe NaVetouch,eethe sy1#' s t o c k . T ou e ea b l o c k e, u b - W tractNhedrillinadeplh from f il Nhelenqth ofrhibit'Vrotrud- tT--*l i n qf r o m l h e c h u c k C . U La Y -tD' piiceof 1-by-1 eNockNo lhie length,Nhenborea holeNhrouqhite middle. )lip the bit throuqhthe blockandboreyour holeunlilthe block t ouchee Lhe workpiece.
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POCKETHOLEIIG theiig 1 Making I T o b o r eo o c k eht o l e so n t h ed r i l l press,usethisjig madefrom%-inch plywood andtwosmallpieces of solid stock.Referto the illustration at left for suggested dimensions. Screwthe twosidesof thecradletogether to form an L. Thencuta 90" anglewedge from eachsuooort bracket sothatthewide willsit at anangleof sideof thecradle about20" fromthevertical. Screw the brackets to thejig baseandattachthe cradle to thebrackets.
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r) Drilling pocket holes in thecradle with I Seatthe workoiece t h es i d et o b ed r i l l e fda c i n g o u ta n dt h e t o ne d p es i t t i n si n t h eV o f t h ec r a d l e . Boretheholesin twostepswithtwodifferentbits:a Forstner bit slightly larger of thescrewheads, so thanthediameter theycanberecessed, anda brad-point b i ta l i t t l el a r g et rh a nt h es c r e w shanks t o a l l o wf o rw o o dm o v e m e nI n t .s t a tl lh e b r a d - p o ibni t i n t h ec h u c ka n dp o s i t i o n t h ej i g o nt h ed r i l lp r e stsa b l es ot h eb i t withthecenter edge alrgns of thebottom ) .l a m p o f t h ew o r k p i e c( ien s e t C t h ej i g bit to thetableandreplace thebrad-point withtheForstner. Holding theworkpiece firmlyin thejig,feedthebitslowly to bore eachholejustdeepenough to recess the screwheads(ilgh|.fo complete thepockh rea d - p o b i ni ta n d e t h o l e sr ,e i n s t a l l t b borethrough theworkpiece.
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lllllnillltilljl]lJ l]llillJlfllll1 ullllullllillll]illlllilllllllllll 1HO?Tt? Cuttinq roaettes on the drill preao Youcan cuI decoralive rosetNeeby modifyinga drill oreeeflv culter wilh a be'adinq biadefrom a Nablesawmoldinqhead. NotchNhefly cuNLerarm to accommodat e Nhebead' inqblade,locaLinq LhecuLNeraboull inchfromlhe endof the arm. Makeeureit fite eecurely in the notcheo il cannolehifLduringuee.borea holethroughthe armand ueeabolN,waeher, and nuNLofashenNhe bladein I,henobchwith i|s flat,lace t owardthe direcNion of cuNter rot ation,1eI your workpieceon a woodbaeewibhetoV blockeNo holdit oecurely. ClamVthe oebupto LhedrillVreeeNable, aliqning lhe centerof the fly culter overlhe cenherof lhe slock.Turnon the drilland lowerthe quilluntil lhe bladeliqhtlyconlacts the wood.Continue cuNlinqunlilLherose|te hasLheprofileyou want.
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quillstroke Exceeding a drillpress's Themaximum distance thattheouillof a d r i l lp r e scsa nb ee x t e n d ei sdc a l l e d itsstroke. 0n mosttools,thisis nomore than4 inches. Todrilla deeper hole,you mayuseanextension bitor,if thehole measure andtheworkoiece lessthan perform twicethequillstroke, theoperationin twostages witha standard bit. A s i m p l jei g s o l v easn ya l i g n m e pn rt o b lems.First,clampa scrapboard to the d r i l lp r e stsa b l ea n db o r ea g u i d eh o l e . Then,clamptheworkpiece to theboard a n db o r ei n t oi t a sd e e p layst h eq u i l l stroke willallow.Remove theworkpiece, f i t a d o w ei ln t ot h eg u i d eh o l es, l i pt h e workpiece overthedowel, andfinishboringtheholefromtheotherside(above). Thedowel willensure thatthetwoholes areperfectly aligned.
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TTIRNINGIIGS athesenablea woodworkerto turn blocksof woodof almostanyirregular shapeinto beautiful,roundedcreations,Woodturnersoftenspeakof how visualtheirart is; theyseea chairleg, bowl,or peppermill seemto growfrom a spinningblank.Yetdespiteits visual "feel" for on elementandtheemuhasis judgingthe progresiof a turnedworkpiece,turning alsodependson accuracy andcarefulmeasurement. Thejigsin thischapterwill helpyou with precision. Useone turn a workpiece of thesetupjigsshownon pages70 and 71 to mount a blankproperlyon the lathe,evenif theworkpieceis irregularly shaped.A layoutjig (page73)isideal outliningthe for quicklyandaccurately locationof the contourson a blank, while measuringjigs like the diameter gauge(page73)orbowl depth gauge (page77)comein handyfor checkinga workoiece's dimensions. Tlie lathecanalsobe usedfor purposesotherthanturning;seethesanding drum (page77) and the jig for routing flutesin columns(page75).
()FTURNING IIGS A COLTECTION Center-finding jig (pa6e 71) Locateathe center of irre7ularly ohapedworkfor faceplate turninq Diamet'er gauge (paqe 73) Uaedto checkthe diameter of a turned workpiece;ocrewo orovidefine adiubtm ent
Faaeplate-aenteringjig (page 71) For mountinqthe lathe faceplate Lo the center of circular workpiecee
Gouge-sharpeningjig (page 72) Uaedin conjunctionwith a benchqrinder to eharpenLurnin7toola; holdatool, bladeat the properanqlefor qrindinqthe bevelon the cuttin4 edqe
Mo unting h ollowed- out workpieces on a lathe can be challenging.For the cocobolobud vasebeingsanded at left, a conicalbull-nosetailstock waspositionedbetweenthe lathe's metal tailstockand the workpiece, allowing the vaseto be supported snuglywithout dantage.
Layout jig (page 75) Uaedto tranafer layout lineafrom a pattern to a f,urnrnqblank
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TURNING JIGS
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A COTTECTION OFTURNING JIGS (continued) Tailetock for hollowedout work (paqe 74) Conicalwoodentailatock placed betweenmetal tailetock of lathe and workpieceto 6uppor, openmouth workfor final turnina and finiahina
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1anding drum (page 77) For amoothingcontoured work;aandpaper ie held in place by a hardwood etrip acrewedinto -a a 1roove rou'ea in the drum blank
Column fluter (pa6e 75) Uaedto rout flutea in turned columna;columnblankia mountedon lathe while jig elideealonq the lathe bed and 4uidee router
Bowl depth gauge (page 77) Uaedto determine the depth of a bowldurinqturnin7
tllltll]lllllllrtlllllltlllfitttlllll11 lllllllltllllllllllilllltlltllj 1HO?TI? Centering a epindle blank F i n d i n q L hcee n N eorf a b l a n k for epindle turninqie tradiNionally doneby markinqNwo diagonallinesfrom cornerlo corneron eitherend of Nhe workpiece. )till, for bolh eafetyand accuracy,iNie a aoodideat o double-check lhe localion of the center. With lhe lathe swilchedof*, pooilionLhetool resLclooeto the blankparallelto oneol ite corners.KoIaIe the blankby hand,The qap belweenLheNoolreet and the blankshouldbe the eameat eachcorner;adjuol lhe poeibionof the LoolreeI, if neceoeary. Ae an addiLional check,ewiLchon the laLhe,placea pencilon NheIoot resL,and ecribea circleon the endof the opinninqblank,as ehown. Turn oft the Nool.Thecircleshouldbe centeredon Ihe endof the blank;if not, adjuetthe tailslock and repeat,
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TWO CENTERING IIGS JIG A FACEPLATE.CENTERING ona workpiece Centering thefaceplate yourlathe's faceplate ona cirTocenter jig shown usethehandy cularworkpiece, pieceof woodto at right.Turna cylindrical threaded of thefaceplate's thediameter (Youmay hole,tapering theendslightly. wishto forma handle at thetopendof the j i g . )D r i v ea n a i li n t ot h ec e n t eor f t h e a ,n d t a p e r eedn d ,c u t o f f t h e n a i l h e a d grinda sharppoint.Tousethejig,mark withan awl thecenterof theworkpiece (page132).Next,setthefaceplate onthe workoiece withtheawlmarkin themidhole,insert thejig in dleof thethreaded and"feel"forthemark theholeasshown, w i t ht h en a itl i p . H o l d i ntgh ej i g i n p l a c e , to theworkpiece. screw thefaceplate
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shaped workpiece Attaching thefaceplate to anirregularly youto centerthefaceplate on Thejig shown above wrllenable pieces Cut of Ya-inch clear irregularly shaped workpiece. an plastic into12-inch-diameter disks. and%-inchplywood acrylic tapeanda screw. Attachthetwotogether withdouble-sided to yourfaceplate sotheplasticisfacingout, Mounttheassembly conto cut a series of eouallv spaced, thenusea skewchisel
lefl. Remove theplastic disk centricringsintothedisk(above, andspray it withblackpaint.Oncethepainthasdried,peelthe paper Tousethejig,set offbothsrdes oftheplastic. backing iswithinoneof it ontheworkpiece soasmuchof it aspossible righil.Use the ringsandmarkthecenterwithan awl(above, for mounting thefaceplate. themarkasa centerpoint
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GOUGE-SHARPENING IIG thejig 1 Making I Thejig shown at leftguarantees that gouge thetip of a turning willcontact the grinder wheelof yourbench at thecorrect angle to restore thebevelonthecutting e d g eT, h ed i m e n s i o n i nst h ei l l u s t r a t i o n willaccommodate mostgouges. Cutthe baseandtheguidefrom%-inchplywood; screw theguidetogether andfastenit to the basewithscrews countersunk f rom underneath. Makesuretheopening createdbytheguideis large enough to allow thearmto slidethrough freely. Cutthearm from1-by-2stockandthetoolsupport plywood. from7z-inch Screw thetwoparts of thetoolsupport together, thenfasten thebottom to thearm,flushwithoneend. FortheV block,cut a smallwoodblock to sizeandsawa 90'wedgeoutof one side.Gluetheblockto thetoolsupport.
Tool aupport (back)t/z'x 2" x 2 3/+" (bottom) 1/2"x 1 1/2"x 2 3/+"
Guide (top)1/2"x13/+"x9" (eidee)1/2"x15/a"x9"
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r) Sharpening a gouge L Setthejig on a worksurface sothearmlinesup directly wheel. under thegrinding Seatthegouge handle in theV block andslidethearmsothebeveled edgeof thegouge restsflaton t h eg r i n d i nwgh e e C l . l a m tph ea r mi n p l a c eT. h e nw, i t ht h e
gouge clearof thewheel, switchonthegrinder andreposition the toolin thejig.Holding thegouge withbothhands, rotate it from sideto sidesothebeveled edgerunsacross thewheel(above). periodically Check thecutting edge untilthe isfullyformed. bevel
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Resemblinga tuning fork, the dismetergauge shownabovecan be usedlike calipersto checkthe diameter of turned workpieces.The jig is cut from solidwood;thedistancebetweenthe armsshouldbe slightly wider than the largestfinished diameter to be turned. Two screwsdriven into the insideof the anns can be adjustedto setprecisemeasuremenls.
lll llllfirlillrllllilltlllllll ilillllllllJlll llllllllllltlll llllltll jHO? TI?
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'v: identicalworkViecee, adjuel,a eeNof caliperolo e a c hf i n i s h e dd i a m e N eyro u n e e d . t h i e w i l le l i m i n a t e L h e n e e dt o r e a d jueLoneeeNrepeaNedly. Uoeyour deoign of the pieceae a quidelo sel the calipero and a eNripof t ape lo identifythe adjuot,ment on eachone.A cheaperaltrernaLive ie t o m a k es e v e r adl i a m e l e rq a u q e al i k et h a T , ehownin the pholo above,
jig Making andusinga layout forspindle turning T h el a y o uj ti g s h o w na b o v em a k e si t easier to turnmultiple copies of spindle you worksuchastablelegsbyallowing to scribe layout linesin exactly thesame yourdesign Trace location onevery blank. ona pieceof scrapaboutthesamelengh asyourblanks andwider thantheirdiameter.Drive a nailintotheedgeof thejig a transitional element at eachoointwhere of thedesign-such asa beadorf illetbegins andends.Snipoffthenailheads points. andgrindthenailsto sharp Once youhaveroughed outa cylinder, simply press thejig intothespinnrng blank; the nailswillscore thelayoutlines(above),
TURNING IIGS
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r) Turning hollowed-out work L Mounttheworkpiece to a multi-purpose chuckandsecure thechuckto thelathe. Turntheinside of thework.Onceyou areready to turntheoutside, insert thetapered endof thejig intotheopening in theworkand,holding theauxiliary tailstock in place, advance themachine's tailstock untilit contacts the jigandholds thejig andworksecurely. Tighten thetailstock (above). andfinishtheworkpiece Making thetailstock 1 I Tosupport hollowed-out workpieces o nt h el a t h eu, s ea n a u x i l i a tray i l s t o c k liketheoneshown above, Turned from h a r d w o otdh,i ss i m p l jei g s u p p o r t hs e workpiece at therimonly,androtates preventalongwiththelathe's tailstock, i n gv i b r a t i oann db u r n i nogf t h ew o r k p i e c eT. o m a k et h ed e v i c ef ,i r s tt u r n a c y l i n d ef r o ma b l a n ka b o u4t i n c h e s i n l e n g t ht ,h e ns h a p teh ec o n ew i t ha gouge roughing andusea skewchisel to smooth theconeandseoarate it from thewaste(above). Thesizeandtaperof thetailstock willvaryaccording to the sizeanddiameter of theworkpiece; a cone3%inches wideat thebasewitha 60"tapersuitsmostsmallwork.
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lllllltlltllutlllilltfiltlllt 5HO?TI? ?reoervin6 oquare oornere Wheneoindle lurnina workpieceo th at, require a eharpdivisionbeNween lurnedand oquareoecNione, euchas the oquareVommel at the Lop of a chair leq, wra?a lenqNh of duct or maekinq lape around the blankatthe lraneiNion linebeforeturnin4trhecylinder.TheNaVewillhelpreduce learoul and Vrovide a visual quideto whereyou shouldoNoVturninqlo preoeweyour oquarecornerg.
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COLUMNS IIG FORFLUTING theiig 1 Building jigshown at rightyou I Withthebox-like c a nr o u tf l u t e si n a c o l u m w n h i l ei t i s mounted in thelathe, Cuttheoartsof the jig from%-inch plywood, forthetop, except w h i c hi s m a d ef r o m% - i n cchl e a ar c r y l i c . R e f etro t h e i l l u s t r a t i of onrs u g g e s t e d d i m e n s i o nt h s ;ej i g s h o u l db e l o n ga n d w i d ee n o u gtho s u p p o rt h t er o u t ear n d highenough sothetopjustclears thecolumnwhenthejig restsonthelathebed. areassemOncethetop,bottom, andsides bled,addtwobraces to makethelig more r i g i d .I n s t a lal d o u b l e - b e a rpi ni lgo t e d f l u t i n gb i t i n y o u r o u t e d r ,r i l la b i tc l e a r anceholethrough thejig top,andscrew thetool'sbaseplateto thejig.Therouter shoulb d e p o s i t i o n seodt h eb i tw i l ll i e n h e nt h ej i g i s alongsid t heec o l u m w u s e dB . es u r ea l l t o o l sa r eu n p l u g g e d d u r i n sge t u p .
Dit clearancehole
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r) Preparing thecolumn andthelathe Z- Toensure thatthef lutesaresoaced equally around thecolumn, markcutting linesforthef lutesontheblank-inthis 12 in all.Makecorresponding example, marks reference onthelathefaceolate b yd i v i d i nigt sc i r c u m f e r e nocre3,6 0 ' , i n t ol 2 e q u asl e g m e nst sp a c e3d0 ' apart. Markthelines witha pencil anda (/eff).Setthejig onthe lathe protractor bed.mountthefaceolate onthe lathe sothatoneof the reference marksis position, in the12 o'clock andmount thecolumn soa cuttingmarkis at the position, 3 o'clock Tighten a handscrew around the lathedriveshaftto prevent it fromrotating andclampstopblocks to thelathebedto makesurethatall fluteswillbethesamelensth.
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-) Flutine thecolumn <'
r - J A d j u s t h e r o u t e ' sc u t t i n gd e p t hs o t h e b r t i s : l r o n p d r a r r l hl h o ? n ' e n r k n r r l l n o m , ,: r- k, , .R-,-r r. t.l l.h, o, ,J r g c l o n a p an q to n F h l n c ki r t r no n l h e r o r r ' l e a "n dn u s h o n t h e s i d eo f t h e i i s t o f e e dt h e b i t i n t ot h e b l a n k , O n c et r r en i l n t sa r cf l r r q ia p a i n s- th es t o c ks. l i d et h e j i g a l o n gt h e l a t h eb e du n t I i t c o n t a c ttsh e o t h e rs t o p L ^- + ^ ^ r-.. h l o c kK . e e nt h etns i. .l,o. - t srn. -r) cJ g-u- ^ ,o^6^o ^i l ;r^> l- + l|c >luun d) it (inset). routseachflute Turnoff the router,remove thehandscrew a n, d r o t a t et h e b l a n kb y h a n du n t r l t h e n e x tr e f e r e n cmea ' ki s i n t i e l 2 o ' c l o c kp o s i t i o n a n dt h e r e x tr ^ . r t' l rDn l rpr" e'i s i n l h e3 o c l o c kn o s i ' i o n . R e i n s t at lhl e h a n d s c r eawn dr e p e atth eo p e r a t i ot n o c u t t h e ' e n a l n r fg ' u l . e s( a b o v e ) .
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IIGSFORSANDINGAND CHECKINGDEPTH Accuratelydeterminingdepth is essentialtofnceplateturning:too deepa cut can ruin a bowl.Made from solid wood stock,the bowldepthgaugeshown at right featuresa pair of perpendicular ',4-inchdowels;the holes for the dowelsoverlapso that the longer dowel can be adjustedand wedged in place by the shorter, tapered one.Marking depthincrementson the long dowel will speedsetup.
A SANDING DRUM F()RTHELATHE
Making andusing a sanding drum u rl u m of thegroove. T h ej i g s h o w a n b o vw e i l lt u r ny o u rl a t h ei n t oa p o w e r f d Toholdthesandpaper in place, makea hards a n d e rS. t a r tb y r o u t i n a g % - i n c h - w i d%e-,i n c h - d egerpo o v e woodstripto fit in thegroove andscrewit in place(above, alongthecenter of onesideof a square blankabout14 inches left).To usethesanding drum,mountit between the headi n l e n g t hM. o u ntth eb l a n ko nt h el a t h ea n dt u r ni t i n t oa c y l i n - stockandtailstock of thelathe.Youcanthenusethedrum der3%inchesin diameter. Next,cuta sheetof sandpaper to to sandworkpieces withcurved contours, suchasa cabriole wraparound thecylinder; itsendsshould overlap at thebottom leg (above,right).
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GLI.INGA]\ID CIA4PINGIIGS lampsand benchvisesareindispeniableto thewoodworker.Their verysimplicitymakesthemversatile,but the basicclampor visecanbe madeto work betteror moreeasilvwith thehelo of ajig. Theitemsshown'inthischaptei will enableyou to getthe mostfrom the clampsandvisesyoualreadyhave.Other jigs providealternatives to commercial devicesthat maynot bethebesttool for a specifictask. Gluingboardsedgeto-edge to assemblepanelsis a commonstepin furnituremaking.Thejigsshownstartingon page 8l providewaysof keepingyour clamping setupsflat, square,and stableasthe adhesive dries.Thewall-mountedglue rack (page85) can saveconsiderable shopspace, whilethewedgedclamping bar (page83)andthejig for edgegluing thin stock (pageBa)will takethe place of bar clamps. For securingstockto your workbenchfor sandingor planing,makea temporarybench stop (page90).To fashiona handywood-carver's vise,try thejig on page93thatcombines a standardpipeclampwith two woodblocks. All thedevicesin thischapteraresimple to build with only a fewmaterials. The dividendstheywill payarewell worth the effort and expense.
A C(|TTECTION OFGTUING AND CTAMPING JIGS Caroaae-aqua ri ng block (pase 89) Flaced on corner of carcase to keep it sauare duringqlue-up
Miter clamping blocka (paqe 88) Ueed with handacrewato clamp mitered cornerg toqether; two blockaat each corner are aecured to atock with cord
Bench dog (page 92) Hardwooddog alipo into benchdoq holee; anqledton7ueacte aa a opringto hold dog in place
Eench etop (page 9O) For eecurinaatock to a work aurtace without.benchdo4 holea.Workpieceie wed4ed betweentrianqular piece and baae, whichia clamped to table
Benah dog (page 91) Cuatomizeddoqa with naile in center of bevelledhead for grippinqa curvedor turned workpiece
Madefromjust afewpiecesof wood andsomehardware,theframing clampat left allowsyou to keepthe cornersof a pictureframesquareand tightlyclosedduringglue-up.
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GLUING AND CLAMPING IIGS
Pipe clamp extender (pa6e 86) ExLendethe clampinqcapaciLyof ptpeclampe;jtq cleat huqa workpiece whileaemicircularnotch accommodatesclamp iaw
Wall-mounted glue raak (page O5) For ed4eqluinqeLock. Dar clampoait in notched c rooepiecee:ba ck c roeepiece ia anchoredto walletuda
Wood-aaruer'svise (pase 93) Two-parDvteefor holdtng carvrnqblanks;made from wood blocksand pipe clampe.Dof,tompipe clampie mounted to benchand Loppart ia elippedtn place
Crosebar for edge gluing (page 82) Ueedwith bar or pipe dampa f,o keepatock flat durinqed6egluinq;panel fita betweencrooabara,whrch are securedwith wingnuLe Glue rack (page 81) 9awhoraeawith notchedcroeaptecee deeignedto hold bar clampaeteady for edqeqluin7
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Wedqedclamping bar (page 83) 9imtlar to edqe 7luin7 croaabar, excepLwed4eepreeaedqee of boarde togeLher,taktnq the placeof clampe Framing clamp (page O7) Ueedwtth a handacrewLo alue uo frames wiLhmitered -cornere: modelahowncan clamp framee up Lo 24 rncneoaquare
I I I Ji6 for clampingthin atoak (paseO4) Foredqegluingthin boarda; wedqeeapply the clamp' in6 0reogure
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EDGE-GLUING IIGS RACK GLUE theiig 1 Building I A pairof racksmadefromtwosawhorses liketheoneshown at rightprovides a convenient wayto holdbarclamps for gluingupa panel.Remove thecrosspiece fromyoursawhorses andcutreplacements thesamewidthandthickness astheorigi n a l sm , a k i ntgh e ma t l e a sat sl o n ga s t h eb o a r dyso uw i l lb ea s s e m b l i nCgu.t notches alongoneedgeof eachcrossp i e c ea t 6 - i n c hi n t e r v a lm s ,a k i ntgh e m wideenough to holda barclampsnugly anddeepenough to holdthe barlevel withthetopof thecrosspiece. Youcan alsocut notches to accommodate oioe clamps, butit is better to usebarclamps withthisjig sincetheywillnotrotate.
r) Gluing upa panel justenough (above), L Seatatleasttwobarclamps in thenotches sothattheboardstheclamps to butttheboards together to begluedaresupported every 24 to 36 inches. Toavoidmar- thenplacea thirdclampacross thetopof theboards, centerringtheedges of thepanelwhenyoutighten theclamps, use ingit between theothers. Finish tightening alltheclamps until twowoodpadsthatextend thefull lengthof theboards. Setthe therearenogapsbetween theboards anda thinbeadof adheboards face-down ontheclamps andaligntheirends.Tighten sivesqueezes fromthejoints.
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GLUING AND CLAMPING IIGS
F(lREDGE GTUING CR()SSBARS thecrossbars 1 Building frombowing during I To keeppanels pressure glue-up isapplied, whenclamping liketheoneshown bolta oairof crossbars Make at leftbetween eachpairof clamps. wood from two short spaccrossbar each ersandtwostripsof 1-by-1hardwood thanthe panstocka fewincheslonger beslightwidth. The spacers should el's bolts diameter of the lythicker thanthe place. Glue crossbars in usedto holdthe the ends of the strips, thespacers between to prewaxon thecrossbars andspread glue from adhering to them. ventexcess
9pacer
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thecrossbars O Installing L Glueup the boards asyouwouldon a rack(page81).fo prevent the barclampsfromtippingover,placetheendof the barclamps blockof wood.Before eachonein a notched centerin pairs, install thecrossbars havebeenfullytightened,
in place.Insert carriage theclamps already ingthembetween andwingnuts slots,usingwashers boltsthrough thecrossbar Then,tighten the panel(above). to tightenthejig snugagainst completely. thebarclamps
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GLUING AND CLAMPING TIGS
WEDGED CTAMPING BAR B u i l d i ntgh el i g b o d y 1 I T h ew e d g e dc l a m p i n gb a rs h o w na t l e f t i s a n e x c e l l e nat l t e r n a t i vt eo a b a r c l a m pf o r e d g eg l u i n gb o a r d sb, e c a u s e i t p r e v e n ttsh e s t o c kf r o m b o w i n gw h e n p r e s s u r ies a p p l i e dC . u tt h e t o p a n d b o t t o m f r o m% - i n c h - t h i cskt o c k ,m a k i n g t h e m l o n g e trh a nt h e w i d e s tp a n e yl o u w i l l g l u eu p . C u tt h e s p a c e rt .a i l b l o c k . a n d w e d g e sf r o m s t o c kt h e s a m et h i c k n e s sa s t h e b o a r d tso b e g l u e d (. K e e p setsof spacers, tail blocks,andwedges on handto accommodate boardsof varyi n gt h i c k n e s sU . )s ea m a c h i n e b o l t ,w a s h e r ,a n dw i n gn u t a t e a c he n do f t h e j i g t o s e c u r et h e t o p , b o t t o m a, n d s p a c e r s together.Waxthe barsto preventadhes i v ef r o mb o n d i n tgo t h e m .
r ) P r e p a r i nt g h ej i g f o r g l u e u p y o u n e e dt o b o r eh o l e st h r o u g ht h e j i g t o a d j u s ti t f o r l . i n c ey o uw i l l b e d r i l l i n g t h ew i d t ho f t h e p a n etlo b e g l u e d S s t r a i g htth r o u g ht h e j i g , c l a m pa b a c k u pb o a r dt o y o u rd r i l l p r e s st a b l ew i t h a f e n c ea l o n gt h e b a c ke d g et o e n s u r et h e h o l e sa r ea l i g n e dI.n s t a l al b i t t h e s a m ed i a m e t ear s t h e . u t tt h e j i g m a c h i n eb o l ta n d p l a c et h e t a i l b l o c ki n p l a c e B a g a i n st th ef e n c ea n dd r i l la h o l et h r o u g h t h et o p ,t h e b o t t o m , a n dt h e t a i l b l o c k .B o r et h e r e m a i n i n hg o l e st h r o u g ht h e j i g bodyat 7r/z-inchintervals(above),
gluingboards Edge S p r e a da d h e s i v oe n t h e e d g e so f y o u rs t o c ka n d s e tt h e b o a r d sf a c e - d o wonn a w o r ks u r f a c eS. l i pa c l a m p i n gb a ro v e r t h e b o a r d sa n d p o s i t i o ni t 6 t o 1 2 i n c h e sf r o mo n ee n do f t h e assembly. Butt the tail blockagainstthe far edgeof the boards, u s i n g t h em a c h i n b e o l t ,w a s h e ra,n dw i n gn u tt o f i x i t i n p l a c e . To applyclampingpressure, tap oneof the wedges at the front edgeof the panel(above)until thereare no gapsbetweenthe b o a r d sa n da t h i n g l u eb e a ds q u e e z eosu t o f t h e j o i n t s .I n s t a l l t h e b a r sa t 1 8 - t o 2 4 - i n c hi n t e r v a l s .
GLUING AND CLAMPING JIGS
THINST()CK A JIGFORCLAMPING gluing thinstock Edge jig shown you at rightallows Thebenchtop pressure for clamping to applythecorrect edgegluingthinstock.Cutthebasefrom pieces andtheremaining 1-inchplywood to theillustration fromsolidstock.Refer butbesurethe dimensions, forsuggested to beglued thantheboards baseis longer a n dt h es p a c eirs l o n ge n o u gtho b u t t theentirefrontedgeof thepanel. against than bethicker stripsshould Theedging yourpanelstock.Screw themalongthe of the baseandfastentwowedges edges onestripwiththeirangled f lushagainst at right.Waxthetop facingasshown edges faceof the baseto keepthe panelfrom o i t . A p p l yg l u et o y o u rs t o c k a d h e r i nt g a n ds e tt h ep i e c eos n t h eb a s eb, u t t i n g t h ef i r s tb o a r da g a i n st ht ee d g i n sgt r i p Buttthe spacer the wedges. opposite the lastboardandslidethetwo against andthe thespacer between loosewedges tightto Tapthe wedges fixedwedges. (below). pressure applyclamping
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B u i l d i ntgh er a c ka n dg l u i n gu p a p a n e l T h el r g s h o w na b o v ea l l o w sy o ut o g l u eu p p a n e l su s i n gb a r c l a m p sb, u t s a v e s h o ps p a c eb y b e i n gm o u n t e tdo a w a l l .F o r c l a r i t yt,h e i l l u s t r a t i osnh o w so n l yo n ep a i ro f c l a m pr a c k sb, u t y o uc a ni n s t a lal s m a n ya sy o ul i k ef r o mf l o o rt o c e i l i n ga t 1 2 - i n c h s n ds a w i n t e r v a l sC.u tt h e c l a m pr a c k sf r o mB - f o o t - l o n1g- b y - 4 a notches alongoneedgeof eachpieceasyouwouldfor a sawhorse r a c k( p a g eB l ) . A t t a c ho n er a c ko f e a c hp a i r t ot h e w a l l ,d r i v i n g two screwsintoeverywallstud;makesurethe notchesarepointi n gd o w n T . o s u p p o rtth e f r o n tc l a m pr a c k ,c u t f l o o r - t o - c e i l i2n g n n ed i r e c t l fya c i n ge a c hs t u da b o u t b y - 4 sa s p o s t sa n d p o s i t i o o
8 to 10 inchesfromthe wall.Screwthe frontrackto theseposts, p o s i t i o n i nt hge n o t c h efsa c e - u p s o t h e yw i l l h o l dt h e c l a m p s p l y w o o ed n d p a n e l st o f i t a r o u n d m o u n t % i n c h l e v e lN . ext, wo j i g . N o t c h b o t t o m e n d o f t h e p a n e l st o f i t o v e rt h e s o l e the the p l a t ea n df a s t e nt h e t o p t o t h e c e i l i n gD . r i v es c r e wtsh r o u g ht h e p a n e l s . o u s et h e i n t o t h e e n d s o f t h e r a c k sT s i d e so f t h e e n d j i g t o g l u eu p a p a n e ls, l i d eb a rc l a m p st h r o u g h t h e n o t c h e isn , a k i n gs u r et h e e n d so f t h e c l a m p s t h e f r o n ta n d b a c kr a c k sm rack(rnset). Therestof the extendbeyondthe stud-mounted g l u i n g w i t h a n y o t h e rc l a m pr a c k . l edge o p e r a t i oins i d e n t i c at o
I
FRAME-CLAMPING JIGS A PIPECLAMPEXTENDER
Gluing upa largeframe T h ej i g s h o w na b o v e w i l le x t e n tdh e c a p a c i toyf y o u rp i p ec l a m p sC. u tt h e mainbodyof theextender from1-by-6 Saw stockandthecleatfroma 2-by-2. a D-shaped cutoutnearoneendof the bodyto accommodate thepipeclamptail stop,thenscrew thecleatto theopposite pressure Toapplyclamping end(inset). o n t h et o pa n db o t t o mr a i l so f a l o n g frameliketheonein theillustration, set thecleatagainst oneendof theworkp i e c ea n df i t t h ep i p ec l a m pt a i ls t o p intothecutout. Thentighten theclamp j adwi s p r e s s i n g s ot h a tt h e h a n d l e - e n against theopposite endof theworkpiece(above). Usewoodpadsto protect theworkpieces.
ti,.ultlilliltiilltllllrfilr]lltlllllljtlllriljlillrllilIfllll] iili 1HO?TI? Ooubling up pipeclampo Anotherway lo exlendlhe capaci|yof 1norter ?t?e
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lonqone,)et,upLhe (herefour workViece boardsto be edqeqlued)ae you wouldon a 4luerack (pa4e B1).Tofashiona lonqclamV,?oeition lwo ehofLerclampeacroasNheworkjawe reet,aqainet.oVVoeile pieceeo NhaNthe handle-end Aeyou edgeeandNhetaileNoVe ofNheclamVooverlap. Liqhhen oneof the clampe,iNwillpullthe joinXeNoqebher.
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CLAMP A FRAMING
Corner block 3./+"x21/2"x21/2"
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Center block 3,/+"x21/2"x6"
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Corner block
Arm
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picture frame Clamping a mitered witha handscrew, theselfIn conjunction a l i g n i njgi g a t l e f ti s i d e aflo rg l u i n gu p Thedimenframes withmitered corners. sions uggeste i ndt h ei l l u s t r a t i w o ni l l frames measuring upIo 24 accommodate inches ona side.Cutthearmsandcenter from1-by-3 stockandthecorner blocks plywood. Drilla series blocks from3/q-inch of holesdownthemiddleof thearmsfor machine bolts;begin %-inch-diameter 1 inchfromoneendandsoace theholes a t 1 - i n c hi n t e r v a lcso, u n t e r b o r it nh ge Also to house the boltheads. underside blocks 1 inch drillholes through thecenter thecorner fromeachend.To DreDare blocks, drilltwoholesthrough eachone: thefirstfora machine boltabout1 inch holeabout fromoneend,anda smaller 1% inches in fromthesameend.Finish bycuttinga 90'wedgeoutof theopposite theapexof theangleat the end,locating holedrilled(inset). center of thesecond jig onecenter Assemble the bysecuring washblockto eachpairof armswithbolts, thenutsloose ers,andwingnuts;leave e n o u gtho a l l o wt h ea r m st o p i v o tT. o clampa frame, setthejig on a worksurface.Fasten thecornerblocks to thearms areabout%inch sothatthecenterblocks withinthe apartwhentheframeliessnugly j i g . U s ea h a n d s c r et owp u l lt h ec e n t e r theclampuntil blocks together, tightening jointsareclosed(/eft,below), allthecorner
GLUING AND CLAMPING IIGS
MITER CLAMPING BL()CKS
Gluing upa mitered frame Clampmitered corners usinghandscrews a n dt h es p e c i abl l o c k s h o w na b o v e . Youwillneedoneclampandtwoblocks f o r e a c hc o r n e rC. u tt h e b l o c k fsr o m stockthesamethickness asyourworkpiece. Referring to theillustration above, shape oneedgesothereis a 45" bearing surface forthehandscrew nearoneend, anda smallV-shaped notchneartheothe r .T os l r e u n A c o r n e tr i et h eb l o c k s s n r r p lt vo t h e e d p c sn f i h e f r a m ew i t h c o r d ,s e c u r i ntgh e l o o s e n di n t h e n o t c h . S e t t h e j a w so f t h e h a n d s c r e w against the 45" anglesandtightenthem (above) u n t i lt h e r ea r en o g a p si n t h e j o i n ta n d a t h i n b e a do f g l u es q u e e z eosu t o f i t . T o k e e pt h e j o i n ts q u a r et.i g h t e ne a c h h a n d s c r eawl i t t l ea t a t i m e ,c h e c k i n g t h e c o r n ew r i t ha s q u a r e .
lli llrllntultllllllltfiljlltJ ljllllljlltuittllllll]ljllillJllllllt 1HO? Tl7
ii. -i A rope clamp for aarving I Carvinqoften requireefre- I I ] ..... quentrepooitioninqofthe I j I workpiece, whichcan be l,l l Lime-consumin7when . jl, ueinqholddowns,clampe, \*r and benchdoqe.VakeLhe taek of eecurinq carvinqeLock moreconvenient by ueinqa eimple ropeclamplikeLheoneehownhere.1orelour holesthrouqh Ihe middleof a lowcarvinqbench,Thencut a lenqthof rope or lealher,looVit throuqhNheholeeand tie Nheendst ogether, Theropeehouldbe lonqenouqheo Lhat the boLLom endof Ihe loopie no moreIhan 12 incheefrom lhe floor.Slipyour workpiece underlhe loopoon the tabletopand eNeV on the botrtomlooVNoholdIhe oLockfirmly in place.
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CARCASE-CLAMPING JIGS BLOCK A CARCASE.SSUARING Carcaae-squaring block
square Keeping a carcase square It canbedifficult to keepthefoursidesof a carcase l. carcased u r i n g l u e - uoprw h i l ei n s t a l l i nagb a c kp a n e A willsolve theproblem. blockplaced oneachcorner squaring of %-inchplywood. Eachblockconsists of an 8-inchsquare gluesqueeze-out frombonding theblockto the To prevent holein thecenterof each borea 2-inch-diameter carcase, blockwitha holesawor circlecutter.Next,installa dado
headonyourtablesaw,adjustit to thesamewidthasthe at right stock,andcut twogrooves thickness of thecarcase intersecting at thecenterof the block angles to oneanother, (above, thecarlefil.f o usethejig,applyglueandassemble right),centercase,thenfit a blockovereachcorner(above, join.Install and ingtheholeat thepointwhere thetwopanels theclamps. tighten
TW()WEBCLAMPS
Cardboard
re K Wood block
upsmallcarcases Gluing . s eC c l a m ptso p u l l t h e or C t h ec o r n e rwsi t hc a r d b o a pr da d sU outof rooeanda handscrew Youcanmakewebclamos lefil.A each other and clamp thejoints(above, two lengths of blocks toward and clamps. 0nedeviceusestwowoodblocks perimeter Wrapa method employs a single handscrew. second clamping areslightly shorter thanthe ropethat,whenknotted, your rope the carcase and feed the ends through the near the length of around Boretwoholesthrough eachblock of carcase. pressing handscrew the rope against knot clamp. With the tip of the a holerneachblockand ends,threadoneropethrough tightenthebackscrewto pinchtheropebetween withtheotherrope,adjusting thecarcase, itsendsagainst theblock.Repeat parallel the back end of thejaws,thenclosethefrontendof thejaws whensetonthecarthelengthsothattheblocksare (above, pressure protecting right). clamping thecarcase, to apply case.Wraptheropesandblocksaround
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WORKBENCH CLAMPINGIIGS Youcan increasethe reachof a C clampwhenyou needto apply clampingpressure awayfrom the edges of a worksurfaceby usinga strip of woodasa clampextension. Tosecuretheframeshownat right, thestrip extendsacrosstheframe and clampingpressure is applied overtheinteriorof theframe, securingbothsidesat once.
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Securing a workpiece to a worksurface Youcanusea clamped-on plywood benchstopcutfrom%-inch to secure stockto a worksurface. Cutthe bench stopto size,thenmarkouta triangular wedge, typically 3 inches shorter thanthestop.Sawoutthe wedge andsetit aside. Tousethebench stop,clampit to theworksurface andslidetheworkpiece intothe notch,butting onesideagainst thestraight edgeof thenotch. Thentapthewedge tightlyin place(above).
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BENCH DOGS
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Makingandsettingup carvingdogs U s i n ga s t a n d a r b d e n c hd o ga s a m o d e l , youcanfashiona pairof customized dogs t h a t w i l l g r i pa c a r v e do r t u r n e dw o r k piece,or secureirregular-sized work,such a s m i t e r e dm o l d i n gT. o m a k et h e s e accessories, cut bevelson eithersideof t h e h e a do f a s t a n d a r d b e n c hd o ga n d d r i v ea s m a l ls c r e wo r n a i l i n t ot h e c e n t e r o f t h e h e a d ;s n i po f f t h e f a s t e n e r ' s h e a dt o f o r ma s h a r oo o i n t .T o u s et h e d e v i c e sp, l a c eo n ed o gi n a d o gh o l eo f the bench'sfixeddogblockandthe other i n t h et a i lv i s eo r a s l i d i n gd o gb l o c kh o l e ( a b o v e )T. i g h t e nt h e v i s es c r e wu n t i l t h e p o i n t sc o n t a ct h e e n d so f t h e w o r k p i e c ea n d h o l di t s e c u r e l y .
lllJllttlltfil1 lllllllllllll|llllflilllllltr]lrfiIlllllilltliltIIIilil ?HO?Tt? Carvinqgcrewo A Vairof han4er boltecanenableyou Nogecurean ircequ' lar-ehaVed workViece, suchas a carvinq block,toyourbench. ThebolNsfeature woodecrewNhreade on oneenaana machine screw lhreadeon the oLher. fo securea workpiece, boreNwoholee Nhrough lhe bench-lopfor Nhebolte.ScrewNhebolls inLoIhe carvinqblockfrom underneaNh Nhetop and holdLheboltsto the undereide of the loV wilh washereand winqnuLe.
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Makinga benchdogwitha wooden tongue B e n c hd o g sc a n b e c r a f t e df r o m h a r d w o o ds t o c k ;t h e o n es h o w na b o v eu s e s t o n g u ea s a s p r i n g a n a n g l e dw o o d e n t h a t p r e s s easg a i n stth e w a l lo f t h e d o g h o l et o k e e nt h e d o s i n o o s i t i o nC. u tt h e d o gt o f i t t h e h o l e si n y o u rw o r k b e n c h , t h e nc h i s eol u t a n o t c hf r o mt h e m i d d l e o f t h e d o g .S a wa s h o r tk e r fi n t h e l o w e r c o r n e or f t h e n o t c h a , ngling t h ec u t s o t h ee d g e t h e t o n g u ew i l l e x t e n db e y o n d . u tt h e t o n g u ef r o mh a r d o f t h e n o t c hC w o o d .m a k i n gi t a b o u ta s l o n ga s t h e notcha , s w i d ea s t h e d o g ,a n da st h i c k a s t h e k e r f .G l u et h e t o n g u ei n t h e k e r f .
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If yow' workbenchtloestrct lnve a bettchvise,yott cnrt itrtprovises substituteusirtgreodilyovnilableshoprrcccs-soric-s. nrrartgedns showrrnbovewill holtl Two largehartrlscrews of the work sttr.face. n board upright at tlte corrrer-
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Grippingthinstoak on Securinga Ihin workpiece ed,qercuallyrequires v i s eo r b e n c hd o q s . lowever.you can < \--
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-a ' "l a L o Vl i k eL h e o n e \ - - --ii: shown on ?aqe 90 No a c c o n V l i e iihh e t a s k . l n ",,ti.Lhis case, make Nheetop fr,om r' , _- ' -ft'ji" L h i c k e re t o c k - a b o u N 2 i n c h e sN h i c k -Lo qet a bef,Leq r r i Vo n r h e w o r V p i e c e a n d l o c a t r et h e w e d q ec l o s e rt o L h e m i d d l e o f N h ee l o p . C l a m pI h e 1 i qr , o I h e b e n c h t o p ,
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GLUING AND CLAMPING TIGS
VISE A WO()D-CARVER'S M a k i n gt h ej i g 1 I T o h o l dc a r v i n sb l a n k sa n dc u r v e d , s ea n w o r k p i e c east v i r t u a t tayn ya n g l e u viselikethe oneshownat right. adjustable A t t a c h e dt o t h e e n d o f y o u rw o r k b e n c h , t h e j i g c o n s i s tos f t w o p i p e - c l a mhpe a d s , t w o l e n g t h so f p i p e ,a n d t w o p i v o t i n g b l o c k sT . h e u p p e rb l o c kg r i p st h e w o r k , i l et h e l o w e r a n ds w i v e l sh o r i z o n t a l lwy h b l o c kh o l d st h e u p p e rb l o c ki n p l a c ea n d r o t a t e vs e r t i c a l layr o u n dt h e p i p e .F a s h i o n t h e t w o b l o c k sf r o m l a m i n a t e hd a r d w o o d s t o c k ,r e f e r r i ntgo t h e i l l u s t r a t i ofno r s u g g e s t e dd i m e n s i o n sB.o r ea 1 - i n c h - d i a m e t e r h o l ei n t h e u p p e rb l o c k ' su n d e r s i d e a n dg l u ei n a 2 - i n c h - l o ndgo w e lr,e i n f o r c e d w i t h a w o o ds c r e w B . o r ea m a t c h i n gh o l e t h r o u g ht h e l o w e rb l o c ka n d c u t a k e r f t h r o u g ht h e b l o c k ' sr o u n d e de d g et o t h e hole.Next,borea holeintothe end of your w o r k b e n cnhe a ro n ec o r n e rl,a r g ee n o u g h t o a c c o m m o d aal e1 2 - t o 1 4 - i n c hl e n g t h h o l et h r o u g h the o f p i p e .D r i l la m a t c h i n g p o s i t i o n i n g i t n e a r r o u ndl o w e rb l o c k , the F i n a l l y , a h o le e d e d g eo f t h e b l o c k . bore p i p e forthe t h r o u g ht h e u p p e rb l o c k .
Upperblock 3"x3"x3%"
Lowerblock 3"x3"x4"
r) Securing a workpiece pipewitha pipe-clamp headat oneendthrough L lnsert-the 12-to l4-inch-long pinblockandintothebench. Fixthepipein placewitha locking thebottom a smallmachine boltor large woodscrew. Fittheupperblockrntothelower one pipe-clamp headto secure theupperblock.Next,insert a andtighten thelower longer length witha pipe-clamp headat oneendandholesdrilled of pipe-also pin-through 4 inches fora locking theholein theupperblock.Place the every headasshown below, workpiece against theupperblockandthepipe-clamp's pin,andtighten fixthepipewiththelocking thehead. Toreposition theworkpiece, loosen clamphead,pivotthetwoblocks, andtrghten thehead. thelower
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SATDINGIIGS anding is one of woodworking's most tedioustasks.but thereare tools and techniquesto makethe job easierandimproveyour results.Theuse of a simplejig will help improvethe speedandefficiencyof mostoperations, and maketricky taskseasierto accomplish.Several areshownhereandon the loilowingpages. A custom-made sanding block (page100),for example,allows you to smoothcontoursthatwouldotherwisebe difficult to reach.For sanding the edgeof circularworkpieces, a circlesandingjig (page96)is designed to hold a belt sanderon its sidewhile you feed the stockacrossthe belt.Also usefulis a jig for surfacingthin stock (page99) on the radialarm saw. For everyday sandingtasks,usethe auxiliarysandingtableshownon page 98 or the sandingblockon page100. Thelatterdevice,alsoshownin thephoto at left, offersa simplewayof holding a pieceof sandpaper in placeagainst a flat surface. To savetime andsandoaper,considerthe tipson gangsanding andfoldingsandpaper shownon pages 96and101.
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Fittedwith 220-gritsandpaper, a shop-made sandingblockis usedto smooththesurfaceof therail joining two tablelegs.A felt or corkpad can begluedto thebottomfaceof theblock toprovideevensandingpressure.
Auxiliary aanding table (pase 9B) Secured to drill preaa table for aandinq oper atib ne; feat uree clearanceholefor aandinadrum
Contoured aandin7 bloak
(pasetoo) Cuetom-profiledaandin4 ourface for smoothinq moldin4a
Radial-arm-saw sanding jiq (pase 99) For eandtnqthin atock on the radial arm saw;clearance holeaizedto accommodate aandinadrum
Circle-eandingjig (page 96) Holda belt eander etationary on ite aide for aandina the edqe of circular atock
AND EDGE-SANDING IIGSFORFACE,Youcan savetime nnd lchieve uniform resultsby sntoothing severalworkpiecestogether,a "gang techniqueknown as sanding."If theyare thesame width, the boardscan lte secured to a work surfacefaceto-faceand edge-up,and sandedas though they were a singleworkpiece.
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t A CIRCLE-SANDING JIG
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thejig 1 Building youto I Thejig shownat rightallows workpiece the edges of a circular smooth Thedimensions of the witha beltsander. jigwilldepend your size of sander. onthe Makethebaseandtablewith%-inchplypoststo woodandaddsolidwoodsupport fit in thehandles of thesander. Setthetool on itssideonthetableandsliptheposts in place, thenscrew themto thetableand Cutthepivot screw thetableto thebase. from1-by-2stock, barandsupport boards longer making theboards thanthediameter of yourworkpiece andthebarlonger than theboards. Screw thesupport boards to the near basesotheywillsupport theworkpiece itsedge.Next,drivea screw through the it to the middleof theoivotbarandfasten Fliptheassemunderside of theworkpiece. blyoverandscrewoneendof thepivotbar to thebasemidway between thesupport boards, leaving thescrewlooseenough to allowyouto pivotthebar'sotherend.
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Sanding a circular workpiece Clampthejig baseto a worksurface andsetthesander in placeonthetable, fittingthetool'shandles overthesupport posts. Turnonthesander and,if necessary, adjustthetool'stracking mechanismto movethebeltdownto thejig table.Lockthe On/offtriggerin theon andmovethefreeendof the oosition pivotbartoward thesander untilthe workpiece edgetouches thebelt.Clamp thefreeendof thebarto thebase, then rotatethepieceagainst thedirection of (above) beltrotation untiltheedgeis smooth. Keeptheworkpiece in motion t rm a n dp e r i o d i c a sl lhy i f tt h e p i v o a toward thesander to maintain Dressure against thesanding belt.
illlfilllltl{tIlll'IIl tllllIlfllltlllltlllilllillltllltlllilltllll 9HO7Tt? Drillpreseaanaingdruma lf you needa epecialoff-sizeoandinq drum for your drill ?rees,you can makeyour ownfrom a dowel.Find Ihe riqhl sizedowel,lhencut a elrip of oandpaperae lonqae iNe circumference. Applya Nhincoa| of qlueto the woodand faelen lhe ?a?erIo ft (ri7ht, top). For a flexible eanderIhal can smooth irce4ularly ehapedworkViecee or enlarqeholee, cut a elot in a doweland eliVa etrip of abraeiveVaperinlo it (ri6hifr,bottom).
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AUXILIARYSANDINGTABLES TABLEFORTHEDRILLPRESS A SANDING Holefor aandinqdrum 3'/a"dtameter
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Jiq baoe 1%"x1%"x11" ' / o x" 2 % " x 1 1 "
thejig 1 Making aretoolarge I Sanding drumslarger than%inchin diameter Tomakefull tables. to fit through theholein mostdrillpress builda tablelikethe surface of larger drums, useof thesanding Usea copingsaw,a sabersaw,or anelectric oneshownabove.
top,cendrillfittedwitha holesawto cuta holein theplywood 3 inches fromthebackof thetable.Screw tering theopening together from1-by-3and2-by-2stock the L-shaped basepieces (above, right),thengluethemto thetable.
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r) Sanding curved stock Z Clu^pthejig baseto thedrillpress underneath the tablewiththeholedirectly drumA . d j u stth et a b l eh e i g htto b r i n g level the bottomof thesanding sleeve f irmly, withthejig.Holding theworkpiece feedit at a uniform speedin a direction therotation of thesanding drum opposite (right). Toavoidburning or gouging the workpiece, feedit witha smooth, continAssegments of thesanding uousmotion. rarse table sleeve wearout, thedrillpress to brinsa freshsurface to bear.
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SANDING IIGS
A RADIAL-ARM-SAW TABLE SANDING thetable 1l Buildins jig shown I Thesimple at rightwillenableyouto sandthinstockonyourradial armsaw.Cutthetableandfencefrom l - i n c hp l y w o o d s i,z i n g t h e p i e c etso f i t yoursaw.Cuta slotoutof oneedgeofthe tablelargeenough to accommodate the sanding drumyouwilluseandallowyou to shiftthedrumforward andbackfordifferentsizedstock.Routa %-inch-wide groove alongthelength of thefence,leaving% inchof stockbelowthechannel to fenceslot.Insert slipintothesawtable's t h e s l o t t e de d g eo f t h et a b l ei n t ot h e groove in thefenceandscrewthetwo nipcps
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r') Smoothing thinstock I lnstalla sanding drumin yoursawfollowing themanufacinstructions. turer's Slipthejig fencebetween thefrontand reartablesof thesaw,positioning theopening in thebasedirectly below thedrum,thentighten thetableclamps to secure the jig in place. Lower thedrumsoit isjustbelow thetopof thejig table;position thedrumsothedistance between it andthejig fenceis slightly lessthanthethickness of thestockyouwillbe
sanding. Turnonthesawandfeedthestockslowly andcontinuously fromleftto right-against therotation of thedrum -betweenthefenceandsanding (Clamping drum(above). jig press a featherboard to the tableto thestockagainst the gouging.) fencecanalsohelpprevent Foreachsuccessive pass,reduce thegapbetween thefenceandsanding drum bynomorethanXeinch.
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HAND-SANDING IIGS BLOCK A C()NTOURED SANDING
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Making theblock youcan Laya single of plastic wrapovertheboxand,whilethe thickness I Forsmoothing thecontours of a pieceof molding, sample inloiI (above, left) themolding of themolding to shape a sanding blockthat filleris stillsoft,press usea shortsample Letthefillerharden, thenremove Fashioningandclampit firmlyin place. withthesurface of theworkpiece. matesperfectly rubber to makea t h em o l d i nsga m p lfer o mt h eb o xa n dt h en a i l sf r o mt h ee n d s . autobodyfillerormodeling theblockrequires a pieceof sandpaper Startbynailing together a smallboxslightly Nowsawoff bothendsof thebox.Stretch moldof theprofile. upacross themolded sideof thebox.Usethemoldmolding andat least%inchdeeper than abrasive-side larger thanthesample partof themolding. filler,then to press thepaperagainst thehardened Prepare thefillerfollowing the ingsample thethickest right). theendsto thesidesof thebox(above, manufacturer's instructions andf ill abouthalftheboxwithit. staple
ljllilIl tlllllflllltfilItllJ llllilllilllllltilllill]firlillrllllllrllll1 1HO?TI? 5andingbloak CUNa woodblockLhatyou can qrip comforLably. 0n ile Nooface. saw Nwonarrow grborruand cultwo wedgeehaVedwoodeNriVeto fit in the qapo enuqly.ToVrovideevenoanding?reosure, you can qluea felLor cork ?ad to Ihe bo|tom, aroundtheblock, WraVa Vieceof oandpaper then t ap in ineerllhe endsinto the qroovee, Nhewed7eoto holdlhe VaVerin place.
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rlllilltill fitllll]Illllilllllllllilllllllilllllllllllilllllllllllllll 1HO?Tt? Foldinqaandpaper Toqetthe moetlrom a sheet,of oandpaper, of rhe abrasiveeurtace ueeonlyone-quarNer al a lime. FoldNheVieceinto quariere,lear the sheethalfwayalonqonefold line,and then fold it inboa four-Vlyoandinqpad eo LhaN no lwo of the abrasivesurfacesare in con' tacL.Whenthe first surlaceweareouN, refoldNheeheet,Noex?o6e
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r) Smoothing themolding I Clamp theworkpiece to a table, thestock. usinga woodpadto protect Slidetheblockbackandforthalons (above). themolding
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TOOLEXTENSIONS ATDTABLES hejigsin thischapterwill allow power portable youto transform toolsinto smallstationarymachines on your and handlelargeworkpieces stationarypowertoolsmoreeasily.The standshownon page105,for example, convertsa platejoinerinto a stationary cutter,a moreconvenient biscuit-slot The router setupfor someoperations. for some tableon page106is essential fenceand cuts.Featuringan adjustable a storagecompartment,it allowsyou to setup your routerasa mini-shaper. In a smallshop,a removablerouter tablecan be attachedto a tablesaw (page107).Thethree-in-one tool table shownon page108can convertyour router.sabersawandelectricdrill into stationarytools. Extensiontablesand roller stands greatlyexpandtheversatilityof toolslike Seepages band sawsand drill presses. I 10 and I I I for jigs that enhancethe capacityofthesetoolsto handlelarge feaAll theaccessories workpieces safely. tured in this chaptercanbe custommadeto suityour needs,at a fractionof versions. thecostof commercial
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Secured to a bandsawtable,theplytableat left morethan woodextension doublestheoriginal table'ssurface area,allowingbetter controlovera cut-especiallywith longstock.
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TOOL EXTENSIONSAND TABLES
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t I I I Drill presa extension table (paqe 111) Attached to drill preea to extend oriqinaltable
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t Removablepower tool table (paqe lOB) Holds router, aaber saw, or electric drill upaide-down for atatonary work;attached Lo workbenchwtth winqnuta for eaayinetallationand removal
Vise extension atand (page 112) suPPorcaffee end of lon4 board clamped in workbench ahouldervise
Adjuatable roller etand (pase 113) 1et juat belowaaw table levelon the outfeed aide to aupporL lonq or wideworkpieceo aa they are cut
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Eand aaw exteneion table (page 11O) Fastened to band aawtable Lo increaae aurfacearea
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PLATEIOINERSTAND
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Barreleupport(top) 1%"x3'tr"x6"
Auxiliarytable 7" x 12"
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Darrel oupport (bof,tom) 1%"x5%"x6"
Handleeuppor, 3'/r" x 12"
thejig 1 Building above willreduce the theligshown I Paired witha platejoiner, in a series of workto cutslotsforbiscuits setuptimeneeded plywood, pieces. forthebarrel except Buildthejigfrom%-inch for Refer to theillustration whichshould besolidwood. support, support to thebaseand dimensions. Screw thehandle suggested themto fit yourtool.With brackets, spacing attachthehandle butt onthehandle support, upside-down theplatejoinerresting andoutlineits against themotorhousing thebarrelsupport
shape onthestock.Borea holeforthebarrelandcutthesupportin twoacross of thehole.Screw itswidth,through thecenter thebottompartto thebaseandfit theotherhalfontop.Boreholes then boltsthrough thetoponeachsideof theopening, forhanger Usewingnutsto of thesupport. drivetheboltsintothebottom screwtheauxiliary tableto together. Finally, holdthetwohalves to drillholes f ixed-angle fence.(lt maybenecessary thejoiner's in thefenceforthescrews.)
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r) cuttingtheslots 4 Secure theplateloinerin thestand andclampthejig baseto a worksurface. height and, Setthefenceat thecorrect forrepeat cuts,clampstopblocks to the in tableto center theworkpiece auxiliary frontof thecutter.Foreachcut,putthe f latonthetableandbutted workpiece faceplate, thenturn against thejoiner's onthetoolandpushthestockandthe tableintotheblade//eft)
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105
TABLES FORPOWERTOOLS A ROUTER TABLVCABINET thetable 1 Assembling I B u i l te n t i r e fl yr o m% - i n c hp l y w o o d , youto use thetableshown at leftallows yourrouter asa stationary tool-a requirementof manyoperations. lt features a largetopwitha slotfor a mitergauge, anadjustable fence, a storage shelf,and cuoboards. Startwiththe basicstructureof thetable,sizing thebottom, sides, back, shelf, dividers, anddoors to suityour needs. Fixthesepartstogether, usingthe joinery method of yourchoice. Thetable jointsand shownisassembled withbiscuit screws. Borea holethrough thebackpanel power to accommodate theswitch's cord. pieces plywood Forthetop,cuttwo of and useglueandscrews to fastenthemtogether;thepieces shouldbe largeenough to overhang thesidesof thecabinet by2 or 3 inches. Fixthetooto thecabinet. Finally,fastena combination switch-receptacleto oneof thedividers, witha power cordlongenough to reacha nearby outlet.Whenyouusethetable,plugin the routerandleaveits motoron.Usethe table'sswitchto turnthetoolonandoff.
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r) Preparing thetabletop I me routeris attached to thetoowith a square sub-base of %-inchthick clear acrylic. Several stepsarenecessary to fit thesub-base to thetopandthento the router. First,position thesub-base at the center of thetopandoutlineitsedges with a pencil. Markthecenter of thesub-base anddrilla pilotholethrough theacrylic and thetop.Remove thesub-base androutout recess withintheoutline a %-inch-deep (right). Usea chiselto pareto thelineand Then,usingthepilot square thecorners. holeasa center, cut a holethrough the yourrouter's topto accommodate base plate.Next,usea straightedge guideto helpyouroutthemiterslotacross thetop: Clamp theguidesquare to thefrontedge of thetopandbutttherouteragainst it asyouplowa slotthatisjustwideenough to fit yourmitergauge barsnugly.
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Preparing thesub-base larger Drilla holethrough thecenter of thesub-base slightly to therouter router bit,andfasten thesub-base thanyourlargest (above). in machine screws Setthesub-base usingflat-head drillingpilot thetablerecess andattachit withwoodscrews, allfasteners. holes firstandcountersinkine Making thefence Cut two piecesof 3/q-inchplywood
lljllllllll llllilI1 lllrilljll11 l]llulllltllljlllllll]l]11 illtillltllJ 1HO?Tt? A router table on the table eaw To makethe moet,of Nheepace in your ehoV,builda router table intoyourNableoawo . ex\eneiontable, RouN a'/+-inch-deep receeeinto a 6t j: non-meNallic sei-
eaw,cu| a holein the receee Noaccommodalevour rouler'o from Nhet.ool,ecrew' baeeplate.Thenremovelhe eub-baee ingthe rouf,ert o the plaeticVieceinetead.NexNecrewlhe plaoticinto the receeoicountersinkall Nhefasteners.KeatLachIhe rouNerNoNhebaeeplaIe.A fencecan becul from plywoodand atNachedto tie sawfencewhennecessar'l,
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andscrew themtogether in an L shape. Sawa notchoutof thefence's bottom yourlargest bit, edgeto accommodate andscrewfourtriangular supports to the backfor addedstability(above). plastic guard, Attacha clearsemicircular witha hingeso it canbeswungoutof theway.To usetheroutertablefor a s t r a i g hctu t ,c l a m pt h ef e n c ei n p o s i intothebit, tionandfeedtheworkpiece holding it flushagainst thefence.
TOOLEXTENSIONS AND TABLES
A REMOVABTE POWER T()()LTABLE thetable 1 Building I A t t a c h etdo a w o r k b e n cohr t a b l e , theremovable extension tableshown at youto convert leftallows threedifferent portable power toolsintostationary devices: therouter, theelectric drill,andthesaber saw.Sizethepartsaccording to yourneeds. Startbycutting thetopfrom%-inchplywood,andtherailsandbraces from2-by4 stock. Sawtherailsa fewinches longer thanthewidthof thetopsotheycanbe fastened to the underside of the bench w i n gn u t sa n dh a n g ebro l t sT. h e using hinged braces should belongenough to reach fromtheunderside of therailsto a l e gs t r e t c h e o rnt h e b e n c hC. u ta b e v e l at thetopendof thebraces anda rightangled n o t c ha t t h e b o t t o mM . o u nat n forthetoolontheunderside On/off switch o f o n eo f t h er a i l sa sy o uw o u l df o ra (page106). table/cabinet
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r) Preparing thetabletop L Cutarectansular holeoutof thetabletop'scenter theiamesizeastheinserts youwillusefortheIools(page109.fhen screwcleatsto theunderside of thetop, forming a ledgeto whichthe inserts can (rrghf). befastened
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TOOL EXTENSIONSAND TABLES
therouter insert Q Preparing sizingthemprecisely to fit rn :.f Sawthethreetoolinserts, t h et a b l e t ohpo l eA. na c r y l irco u t esru b - b a si sef i t t e di n t ot h e insert following thedirections fortherouter tableonpages 106 a n d1 0 7 .T oi n s t a l l t hien s e ri tn t h et a b l es, e ti t o nt h ec l e a t s andscrewthe insertto thecleatsat eachcorner(right).Drill pilotholesforthescrews. Makea fenceasyouwouldforthe nnsirouter tableon page107.Secure thefencei1 l[s clesirocl t i o nw i t hc l a m o s .
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Preparing drillinsert theelectric B o r ea h o l et h r o u gthh ec e n t eor f t h ed r i l li n s e rstl i g h t l y you widerthanthe largest sanding drumor otheraccessory planto use.(Thestationary drillis particularly useful forsandi n g .S ) crew a c o m m e r cdi ar li l lg u i d e t o t h eu n d e r s i o d fet h e (You insertwiththedrillchuckcentered overthehole(above). mayneedto drillholesin thebaseof thedrillguideto fasten i t i n p l a c e . ) T hb ei to ra c c e s s oi nr yt h ed r i l cl h u c ks h o u lpdr o without visible. trudefromthetopof theinsert thechuckbeing P l a cw e o o d ewna s h e rusn d etrh eg u i d er o d so f t h ed r i l lg u i d e Fasten to adjust theheight of thedrill,if necessary. the insert to thecleats asyoudidtherouter insert.
Preparing thesaber sawinsert f, r,l Position thesaw'sbaseplatesothebladewillbeinthecenterof theinsert andmarkitslocation. Borea holeat themark large enough to cleartheblade. Screw thesaw's baseplateto the inserlhbovd lf therearefewerthanfourscrewholesin the baseolate. drilladditional holes. Mount theinsert to thecleats.
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I TOOL EXTENSIONSAND TABLES
TABLE A BANDSAWEXTENSI()N UNDERSIDE VIEW
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Cleat groove (rf needed)
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Building andinstalling a tableforthebandsaw A n e x t e n s i otna b l eo n y o u rb a n ds a ww i l l e n a b l ey o ut o c u t l o n g . s i n g% - i n c hp l y o r w i d ep i e c e sw i t hg r e a t eer a s ea n dc o n t r o lU w o o d ,c u t t h e j i g t o p t o a s u i t a b l e d i a m e t e tr h, e ns a wo u tt h e c e n t e tro f i t a r o u n dt h e s a wt a b l ea n dt r i m a o o r t i o no f t h e b a c k hannel e d g et o c l e a rt h e t h r o a tc o l u m n C . u t a i % - i n c h - w i dc e f r o mt h e b a c ko f t h e t a b l et o t h e c u t o u ts o t h e t a b l ec a n b e installew d i t h o u rt e m o v i ntgh e b l a d e N . e x t ,p r e p a rtew o c l e a t s that will be usedto attachthe jig to the sawtable.Forthese,two 1 - b y - 3ssh o u l db e c u t a f e wi n c h e sl o n g e trh a nt h e s a wt a b l e . P o s i t i o tnh e ma g a i n stth e s i d e so f t h e s a wt a b l es o t h a t t h e y , i t h a t l e a s t% i n c ho f a r e % i n c h b e l o wt h e t a b l es u r f a c ew eas s t o c ka b o v et h e t h r e a d e dh o l e s (. M a k es u r ey o u rm a c h i n h an accessory theseholes;mostbandsawshavethemfor mounting r i pf e n c e .D ) e p e n d i nogn t h e p o s i t i o no f t h e h o l e so n y o u rs a w t a b l e ,y o um a yh a v et o p o s i t i o tnh e t o p o f t h e c l e a t sc l o s etrh a n % i n c ht o t h e t o p o f t h e s a wt a b l e .I n t h a t c a s ey o uw i l l h a v et o r o u tg r o o v efso r t h e c l e a t so n t h e u n d e r s i doef t h e t o p t o a l l o w Mark the tabletopto sit f lushwith the machine'stable (above). t h e h o l el o c a t i o nosn t h e c l e a t sb, o r ea h o l ea t e a c hs p o t ,a n d f a s t e nt h e c l e a t st o t h e t a b l ew i t ht h e m a c h i n e s c r e w sp r o v i d e d f o r t h e r i p f e n c e( r i g h t .t o p ) .T h e np l a c et h e t a b l e t o po n t h e cleatsand screwit in place(right,bottom);be sureto counterl i t h t h e s a wt a b l e . s i n kt h e s c r e w sT. h et o p s h o u l ds i t l e v e w Toremove t h ej i g ,r e m o v e o n l yt h e m a c h i n es c r e w sl,e a v i n tgh e y t h e t o p . Y o um a yn e e dt o c u t c l e a t sa t t a c h e dp e r m a n e n ttl o n o t c h e s i n u n d ersido e f t h e t o p s o t h a ty o uc a n clearance the r e a c ht h e m a c h i n e screws.
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TOOL EXTENSIONSAND TABLES
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A DRILL PRESS EXTENSION TABLE Fitting a drillpress withanextension table Thesmalltabletypical of mostdrillpresseswillnotadequately largeworksupport pieces, especially whenthetoolis setup forsanding operations. Tobuildanextens i o nt a b l e s, t a r tb yc u t t i n ga p i e c eo f plywood %-inch intoa square withdimensions thatsuityourneeds. Thenmarka linedownthemiddle of theoiece anddraw t w oc i r c l e cs e n t e r eodnt h e l i n e .L o c a t e t h ef i r s ta b o u 4t i n c h e fsr o mt h e b a c k edge, sizing it to fit snugly around thedrill o r e s cs o l u m nL. o c a t teh es e c o n h do l e under thechuck;makeitsdiameter about %inchgreater thanthelargest accessory youplanto use.Tohelppinpoint thecenter o f t h eh o l ei,n s t a al l b i t i n t h ec h u c ka n d measure thedistance fromthecolumn to thebit.Prepare to install thejigonthedrill press tablebycutting itsbackedge, leaving "ear"thatprotrudes a rectangular behind thebackhole.Borea holethrough theear fora %-inch-diameter carriage bolt.Next, sawthejig in halfalong thecenterline and cutoutthetwocircles. Youmayneedto make o t h e cr u t st o c l e a rp r o t r u s i oonns y o u rm a c h i n eO. nt h em o d esl h o w na, n o t c hw a sn e e d efdo rt h et a b l eh e i g h t a d l u s t m etnr ta c ko n t h et h r o act o l u m n . F i n a l l ys,c r e wa b u t th i n g et o t h ef r o n t e d g eo f t h ej i g t o j o i nt h et w oh a l v eass shown. Thecarriage boltandwingnutwill clamp thetablein placeon topof the
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VISEEXTENSIONSTAND M a k i n ga n du s i n gt h es t a n d T h ev i s ee x t e n s i osnt a n ds h o w na t r i g h ti s u s e dt o s u p p o r t t h e f r e ee n do f a l o n gb o a r dc l a m p e di n t h e s h o u l d evri s e T .h ed i m e n s i o ngsi v e ni n t h e i l l u s t r a t i o n of a workbench w i l l w o r kw e l lw i t h m o s tb e n c h e sC. u tt h e u p r i g htto l e n g t h , t h e n s a w a n g l e dn o t c h e sa l 2 t / z - i n c hi n t e r v a l sa l o n gi t s . a k et h e n o t c h l e n g t hs, t a r t i n g5 i n c h e sf r o mt h e b o t t o mM e s a b o u t1 i n c h l o n ga n d 1 , /i:n c hw i d e .T h e ns a wt h e f e e t t o l e n g t ha n d c u t r e c e s s easl o n gt h e i rb o t t o me d g e sJ. o i n t h e f e e tw i t h a n e d g eh a l f - l a pl o i n t :C u t h a l f - l a pisn t h e t o p e d g eo f o n ef o o t a n d t h e b o t t o me d g eo f t h e o t h e r ,t h e n g l u et h e t w o t o g e t h e rO. n c et h e a d h e s i v ies d r y ,u s ea l a g s c r e wt o a t t a c ht h e u p r i g ht o t h e f e e t ;d r i v et h e s c r e wi n t o t h e u p r i g h ft r o mu n d e r n e a t h e f e e t .C u tt h e s u p p o rpt i e c e a n ds w i v ebl a r s ,a n g l i n gt h e t o p o f t h e s u p p o rpt i e c ea b o u t 1 0 " t o w a r dt h e u p r i g h tT. o l o i nt h e s u p p o rpt i e c et o t h e s w i v e bl a r s ,b o r eh o l e sf o r % - i n c h - d i a m e tdeor w e l st h r o u g h t i e c ea n d n e a rt h e e n d so f t h e s q u a r ee n d o f t h e s u p p o r p i n t ot h e h o l e sg; l u et h e d o w t h e d o w e l s a n d s l i p thebars, . o l e a v e t h e s u p p o rpt i e c ef r e et o p i v o t T b u t e l st o t h e b a r s , e n d o f t h e s w i v el a t t h e t o p d o w e l i n s e r t h e u s et h e s t a n d , y o u f o r t h e h e i g h t i n u p r i g h t s l o t t h e b a r si n t h e a p p r o p r i a t e p i e c e . p r o p y o u r s u p p o r t o n t h e w o r k p i e c e n e e da n d
Uprighl; 3/,"x2i/+x30'
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Building thestand Setupontheoutfeed sideof a sawtable, a n a d j u s t a brl o e l l e sr t a n dl i k et h eo n e shownat leftwillhelpyousupport large workpieces. Startbyconstructing theframe fortheroller,cuttingthefourpieces from 1-by-4 stock.Gluetheframetogether with buttjoints,adding screws to reinforce the connections. Thenborea holein eachside fora %-inch-diameter carriage bolt.Center thehole3 inches fromthebottomof the frame.Screw therollerto thetoo.Cutthe pieces remaining of thestandfrom1-by-6 provided, stock, referring to thedimensions a n dr o u ta 1 4 - i n c h - l o n%g-, i n c h - w i d e slotdownthemiddle of thetwouprights. S c r e wt h ec r o s s p i e tcoet h e u p r i g h t s , aligning thetopof thepiece withthebottomof theslot.Fasten theupright andrails to thefeet.Toguidetheroller frame, nail 1-by-1 cleats to theuprights aboutr/t inch in fromtheedges. To setup thestand, position theframebetween theuprights, f ittingthecarriage boltsintotheslots frominside theframe. Slipwashers over theboltsandtighten thewingnutsto set theheight of theroller slightly below the levelof yoursawtable.
Frame 10"x 18"
Carria4e bolt
Foot 3/+" x 5 1/2"
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rllillltfiilllltl]lJ lll1 illtllllllltlllllltlllltlllltll]fiIjlllJlltillll 5HO7Tt? Atemporary rollerstand Ueinqonlya eawhoree, LwoC clampe, s o m ew o o d a , n d a c o m m e r c i ar o l ller, you can makea eimplebuI effect,ive eland Lo supporNt.heoutfeedfrom anyof yourmachinee. Makea T-ohaped maeNfor the roller,eneurinqit io long e n o u q hN oh o l dl h e r o l l e ra L a s u i i a b l e heiqht.)crew Lherollerto Lhehorizontal memberof Nhemast. Add a bracelo oneendof Ihe horeefor clamoinalhe maet,in place:Cul 21-by-4oto opanthe l e g ea n d 6 c r e wl h e m l o N h e l e q e ao e h o w n . Tsoe c u r e t h er o l l e re N a n dl o lhe sawhorse,clampthe maeNNotrhe bracee,makinqsurelhe rollerie horizontal.
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STORAGEDEVICES hethervour workshoois tucked awavin a cornerof vour basement or sDreadout over a two-car garage, stoiingthe toolsand materials is a persistent thataccumulate challenge. Thischapterofifers several simplestorage devicesthat canhelpyou win the ongoingbattleagainstclutter.Theywill keepyourtoolsandmaterials within easy reachwhentheyareneeded, andout of thewaywhentheyarenot. For storinghandtools,considerthe handsaw holder (page117)andthetool tray,the chisel,and routerbit racks shownopposite.As well ashelpingto organizeyour tools,thesedeviceswill preventdamageto cuttingedges. An effective systemfor storingclamps is a must.Therackshownon page118 will accommodate a largeselection and, it is mountedon casters, the because rack can be movedto whereverit is needed.Lumberand ply,voodstorage racksareshownon pages120and12l. Eachof the examplesshowncanhold projectswhile enoughstockfor several preciousfloor space. conserving
Clampscan be a nuisanceto store because of their sheernumber in the shop.The simplerackshownat left is madeof stripsof wood nrounted on wall studs. Tlrc lowerstrip is thicker, to keepthe clampsleaning toward the wall.
A SETECTI()N OF ST(lRAGE DEVICES 2aw blade otorage box (page 117) Keepectrcularaaw bladeavieibleand protecLed; dividere keep bladeafrom touchina
Chiselrack )ecured Lo wall to keep chiaeleor4anized.Made from Lhreewood atrtpa; elota for chiaelaare dadoedalongedqeoof middlepiece,then etdpe are qluedtogether.
Router bit atorage rack Holderouter btta upright; holee are epaced to preventcuttin7 edgeefrom com' tnq into contact.
Tool tray Drawer wiLha notched2-by-4 dividerfor houetn4 and protecLinq filee and raope
STORAGEDEVICES
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t Handsaw holder (pase 117) Wall-mounLed rack for holdinq handeawe;made from 2-by-4 atock, plywood, dowela,and rubper noqe
Lumberatorage rack (page 121) FronL-loadin4rack for lumber,with Eideloadinqarea under' neath for etonnq /ywood and oLher manufacturedpanele
Vefticalplywood rack (page 12O) For etackin7plywooaon ena;Pan' elE held by furrtn7 eLrip, Lhreaded rods,and winqnuto
Mobile alamp rack (page 118) Uprtqhtframe holds wrderan4e of clampa;caetere mounLedunderbaee allowrack to be movedeaeily
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STORINGSAWSAND BLADE,S BOX A SAWBLADE STORAGE Stolingcircularsawblades O r g a n i zyeo u rc i r c u l asr a wb l a d e si n a c u s storagb e o xl i k et h e o n es h o w n tom-made a t r i g h t .B u i l dt h e b o xf r o m% - i n c hp l y w o o d , c u t t i n gi t a f e w i n c h e sl a r g e trh a ny o u r l a r g e sbt l a d ea n d w i d ee n o u g ht o h o l da l l y o u rb l a d e sM . a k et h e b o t t o ma n d b a c k f r o mt h e s a m ep i e c e ,r o u t i n gt h e d a d o e s f o r t h e d i v i d e r fsi r s ta n d t h e nc u t t i n gt h e p i e c ei n t w o . T h i sw i l l e n s u r ep e r f e c t a l i g n m e not f t h e d a d o e sC. u tt h e d a d o e s I i n c hd e e pa n dw i d e ,s p a c e da t l / - i n c h i n t e r v a l sM, a k et h e d i v i d e ros u t o f % - i n c h p l y w o o do r h a r d b o a r dF. i t t h e d i v i d e r si n t h e i rd a d o e sg, l u et h e mt o t h e b o t t o ma n d To keep back,then screwthe boxtogether. t h e b l a d e sf r o mr o l l i n go u t o f t h e b o x ,c u t a battenfromscrapstockand nail it to the d i v i d e r sn e a rt h e b o t t o mo f t h e b o x .
HOLDER A HANDSAW h eh o l d e r B u i l d i nagn dm o u n t i nt g rackshownat left,made Thewall-mounted w i t h a f e w w o o ds c r a p sd, o w e l i n ga,n d s o m er u b b e rh o s e ,u s e sf r i c t i o nt o h o l d . u tt h e b a s ef r o m y o u rh a n d s a wi sn p l a c eC p l y w o o d . E a c hd i v i d eirs m a d ef r o m %-inch a 1 0 - i n c h - l o n g 2 - b y f-a4c e - g l u etdo a s h o r t t, a p e r e d2 - b y - 4 .B e g i nb y s c r e w i n g a 2 - b y - 4a t t h e l e f te n do f t h e b a s et,h e n s e c u r et h e d i v i d e r si n p l a c e ,l e a v i n ga ' / - i n c hg a p b e t w e e nt h e m .T h e s t o p p e r s are4-inchlenghsof l-inch dowelpressed r ari n t os l i g h t l ys h o r t epr i e c e so f r u b b e g den hose;usehosewith ridgesratherthan s m o o t hh o s e .S l i p a s a wi n t ot h e r a c k f r o mb e l o wt,h e nt u g d o w no n t h e h a n d l e . T h es t o p p ewr i l l p i n c ht h e b l a d ei n p l a c e . M a r kt h e d o w e l ' sp o s i t i o nb, o r ea % - i n c h h o l ei n t ot h e b a s ea t t h e d i a m e t esrt o o o e d , nce m a r k t, h e ns c r e wt h e d o w eiln p l a c eO , ount a l l t h e s t o p p e ras r e i n p o s i t i o nm t h e h o l d e tro t h e w a l l .
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MOBILECLAMPRACK
Top rail 1 1/2"x 31/2"x 22"
Median rail 11/2" x 31/2"x 23 1,/2" ?tile
1 1/2"x 31/2" x /yl1/2tl
Eottom rail 1 1/2"x 3 1/2"x 23 1/2"
t/2"x 23 1/2"x 231/2"
1 1/2"x 3 1/2"x 23 1/2"
r) Attaching therailsto thestiles L Prepare the railsforthejoinerybycuttingendrabbets thatwillfit intonotches anddadoes in thestiles.Therabbetsshouldbe 71/zinches wideand3/qinchdeep,except f o rt h et o pr a i l sw , h i c hr e q u i rae r a b b eot n l y1 i n c hw i d e . N o t c ht h et o pe n do f e a c hs t i l eo nt h r e es i d e st,h e nr o u t back-to-back dadoes nearthe bottomendandmiddleof thestiles;makethedadoes 3% inches wideand3hinch deep. Alsocuta notch3% inches wideand32inchdeep fromthebottom of eachstile.Whenyouassemble therails andstiles, alignthetwohalves of eachrailface-to-face (right)and attachit to thestileswithscrews.
thestockforthejig 1 Gutting I T h el a r g ec o l l e c t i oonf c l a m p si n mostshoos-andtheirawkward sizeand shape-canstretch eventhemostorganizedspace to thelimit.Themobile clamp rackshownat leftcanbestoredagainst thewall,thenrolled to anypartof theshop where clamps areneeded. Startbycuttingthe pieces to size,referring to the i l l u s t r a t i of onrs u g g e s t e dd imensions. Thesixrails(top,median, andbottom) thetwostiles, andthreecrosspieces are all sawnfrom2-by-4stock.Cutthefour skirtpiecesfroma 2-by-4andthe base (inset). fromr/z-inchplywood
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Mounting tothestiles thecrosspieces
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T o l o i n t h e c r o s s p i e c et os t h e r a c k ,c u t a 3 t l z - i n c h - w i d e d a d oi n t h e m i d d l eo f e a c hp i e c ea n d s c r e wt h e m i n p l a c e ( a b o v eT ) .h e m i d d l ec r o s s p i e cwei l l r e s to n t h e m e d i a nr a i l . T h et o p p i e c e sw i l l r e s to n t h e o u t s i d e s h o u l d e rosf t h e n o t c h e d
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Attaching thestilesto the base Finishthe rackby sawingtwo notches in the baseandskirtto accommodate t h e s t i l e s ,r a b b e t i n og n e e n d o f e a c h skirt piece,andscrewing themtogether to form a box (page118, insef).Usescrews t o a t t a c ht h e b a s et o t h e s k i r t .F i n a l l y , a t t a c hc a s t e r st o t h e u n d e r s i d e of t h e s k i r ta t e a c hc o r n eor f t h e r a c k t, h e n s l i pt h es t i l e si n t ot h e n o t c h e si n t h e basehbove)and secure thestilesto the b a s ea n ds k i r tw i t h e l u ea n ds c r e w s .
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llllilliilllljl1tlllillJlllillrlilllrlllrlllilltilllllilllliilillllllllj 1HO?TI? 1toring clampoin a can A Lraehcan fiNNeA wibha ehopmadelid oervegas a convenienl waylo eNoreemallbar or pipe clamVe. CuNa Vieceof '/z-inchVlywoodinLo a circleeliqhLly emaller ',.", NhanNhe diamelerof Lhecan'srim. r-: Thenscribea eeriesof concenf,ric cirto helVyou locate cleson LheVlywood Lheholesfor the clamVbaro.Space LhecircleeaboutZinchesaVarLand markpointoevery3 inchesalon4them. Sorea |-inch-diameter holethrouqh eachpoint,fit Lhepieceof plywoodin Lhecan,anddropNheclampethrough Nheholee.To clampefrom prevenNNhe keepthe can dry aL all Nimes. corrodinq,
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RACKS LUMBERSTORAGE Commerciallumber racl
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r PLYWOOD RACK A VERTICAL
Threadedrod Furrin7 atrip
Constructing therack plywood onendsaves valuForlong-term storage, stacking Therackshownat leftis builtfrom ableshopfloorspace. rods,andwingnuts.Startbyscrewing furring strips, threaded two1-by-3 furring stripsto thestudsof onewall,2 and5 feet rods4Y,feetapart fromthefloor;first bolttwothreaded intothetopstrip.Cuta thirdfurringstripandborea hole it at oneendandsawa notchat theotherendto through . o t ho p e n i n gssh o u l d b es l i g h t l y l i n eu p w i t ht h er o d sB twowoodpads larger thanthediameter of therods.Place sheets onthefloorbetween therodsandstacktheplywood the upright onthem.Holding thethirdfuningstripacross faceof thelastpanel, sliponerodthrough theholeandthe andwingnutsontherods otherintotheslot.Putwashers them,pulling thefuningstriptightlyagainst the andtighten (above). plywood Toremove a sheetfromthestack,loosen the wingnutsandswingthefurringstripupandoutof theway.
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RACK A LUMBER.AND.PTYW()()D Fastening therackto anunfinished wall to wall madeentirely oI2-by-4stock,is attached Therackshownbelow, joists. is Lumber whileplywood studsandceiling canbepiledonthearms, brackets. Youwillneedat least8% stacked on edgeagainst thesupport panels. feetof freespace at oneendof therackto beableto slidein plywood themto the Beginbycutting thetriangular-shaped brackets andscrewing andnailthemto Cutthefootings, slipthemunderthebrackets sluds(right). andtoe-nail theirendsto the sawtheuprights to length theshopfloor.Next, footings Cutasmanyarmsasyouneed, aligning thefirstrow andthejoists. brackets. Usecarriage boltsto fasten the withthetapered endof thesupport making surethearmsin thesameroware armsto thestudsanduprights, features armsspaced at 18-inch intervals. level. Therackin theillustration
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9upport bracket 11/2"x31/2"x41/z'
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ostjigsthathangfromthewalls of woodworkers' shopstypically providea shortcutto a commontask, from boring mortisesto edge-gluing panels.As the previouschaptershave shown,the mostpopularjigsarethose that makea job easierand more accurate,or improvea tool'sperformance. But eventhe mostmundaneof workshopchorescanbenefitfrom a helping hand, whetheryou are moving large sheetmaterialsarounda shopor throwing somelight on your work. Thischaptercoversa collectionofsuch shopaids.Somedevices,suchasfeatherboardsandpush sticks(page125),are for everywoodworking indispensable for morespeshop.Othersaredesigned cializedtasks,suchasmeasuringand markinglargearcl"'s(page133)or preparing thin or smallstock(page130).lf iou frequentlywork alonewith largesheet materialssuchasplywoodandparticle(page128) board,collapsiblesawhorses areashandy asan extrapair ofhands, while an auxiliaryoverheadswitchfor your thetablesaw(page131)wrJJmake shop a saferplace.Evenmany of the stickyproblemsof finishingcanbesolved with a fewsimpledevices(page1j5).
(lFSH(IPAIDS ANASSORTMENT Eeveledfeatherboard (pase127)
9tandard featherboard (pase 125) Aleo knownae fin4er' board: preaeea atock enu7lyaqainat the table or fence of a etationary tool
ldentical to atandard featherboard, except the fin4eroare beveledeo they preoo workpieceaqaineL both the fenceand table of a stationary tool
thimmed featherboard
(pase12Q A atandard featherboard aupported b5ta ahim ao that finqere apply preaaure hiqher on workpiece Push atiak (page 125) Uaedto feed atock acroao atationary tool table Plywood carrier (page 13O) Features a handleand a lip for carryin7 large eheet materiale Iikeplywoodand particleboard Bench dog lamp euppora (page 157) Fite into benchdo7 hole;featurea a hole to accommodate deak lamp
A sprayingturntableallowsyou to applyafinish evenlywithouttouching theworkpiece or movingaroundit; theend tqbleshownat left restson As shownon four dryingsupports. page136,the jigis easilybuiltfrom p\nvoodanda "lazySusan"bearing.
Auxiliary table aaw switch (page 131) For turnin7 table aaw on and off when main awitch is out of reach; inetalled near ceilingand wired to eaw
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Compaoe (paqe 133) For drawin4 circlee; awl ie fixed to ctrcle's center and pencit drawa circumference
V-bloakjig (pase 132) Clampedto jointer table for chamferinq a workpiece
Planingjig for thin atoak (page 131) For thrckneaeplanin4 of aLockthinner than %inch;beveledcleate hold workpiece in place
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9praying turntable (paqe 136) Kotatin4 platform ueinqa "lazv )uean" bearina Vacuumacreeningramp (page l3O) Dust is ewept onf,oramp and falle throu7h holes;holetn backaccepLo duet collectionhoaeao that duaL ia auckedinf,ocollectionavatem
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gtaaking handlee (paAe 135) Tack-nailedLo the endaof a board to enableboth facee
clamped to a board for acribinglarqe circlea
to be ftniahed before piece
ie left to dry; can be etacked for multi' ple workpiecea
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S S S 6 S
Ueed to def,ermine the cenLer of a ctrcular workptece
.-a"-*"'\ s s s s s \ s '-
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Shooting boards (page 134) Ueedwtth a planeto emoothend7rain. Kiqht-an1leboard (top) ro for planinq atraight end grain;anqledveraion (bottom) ie ueed for milered ende
Folding sawhorae (page 129) A hinqedaawhoraethaL can be folded flat
Knoak-down aawhoree (page 128) Three-pieceaawhorae whichcan be dieassembledquicklyand atored
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SAFETYDE,VICES BL(ICKS PUSH STICKS ANDPUSH pushsticksandpushblocks Making forfeeding Pushsticksandpushblocks power stockacross thetableof a stationary plywood or toolcanbemadeusing%-inch is ideal; a wellsolidstock. Nooneshape pushstickshouldbecomfortable designed t o u s ea n ds u i t a b lfeo rt h em a c h i naen d t a s ka t h a n d F . o rm o s tc u t so n a t a b l e a pushstickwitha 45' angle saw,design between the handleandthe base(right, a n g l ef o r u s e f o p ) .R e d u cteh e h a n d l e withtheradial armsaw.Thenotchonthe bottom edgemustbedeepenough to supporttheworkpiece, not butshallow enough thesawtable.Thelongbaseof to contact pushstick(right,middle) a rectangular youto applydownward pressure enables Forsurfacing ona workpiece. thefaceof a boardon a jointer, the long,widebase of a pushblock(right,bottom)isideal. I t f e a t u r easl i p g l u e dt o t h eu n d e r s i d e o f t h eb a s ef,l u s hw i t ho n ee n d .S c r e w tothetop,positioning it sothe thehandle backis evenwiththeendof thebase.
Pueh etiak %"x5%"x12"
A STANDARD FEATHERBOARD
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a standard featherboard 1t Makins I Featherboards serve asanti-kickback allowtheworkdevices, sincethef ingers p i e c et o m o v ei n o n l yo n ed r r e c t i o n toward a stationary tool'sbit or blade.To liketheoneshownat makea featherboard left,cuta 30"to 45" miterat oneendof a % - i n c h - t h i3c -kt,o 4 - i n c h - w i b do eard; to suit thelengthof thejig canbevaried t h ew o r ky o up l a nt o d o .M a r ka p a r a l l e l fromthemitered lineabout5 inches end andcut a seriesof slotsto the marked l i n eo nt h e b a n ds a w s, p a c i ntgh ek e r f s about%inchaoartto create a rowof sturdybutpliable f ingers. Finally, cuta notch outof oneedgeof the featherboard to accommodate a supDort board.
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Usingstandard featherboards onthetablesaw Clamponefeatherboard to thefenceabove theblade,andplacea longer onehalfway between the bladeandthefrontof the table.Clampa support boardin thenotch perpendicular to thehorizontal featherboardto prevent it fromcreeping oui of placeduringthecut.Fortheoperation shownat left,feedtheworkpiece intothe fingers bladeuntilyourtrailing reach the featherboards. Thenusea pushstickto finishthecut,or moveto thebackof the tablewiththesawstillrunning andpull pasttheblade. theworkpiece
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A BEVELED FEATHERBOARD Ripping stockwitha beveled featherboard A featherboard clamoed to thefenceof a page, tablesaw,asshown ontheprevious cangetin thewayof a pushstickduring a ripcut.A featherboard witha beveled end will pressa workpiece against boththe fenceandsawtable,eliminating theneed to clampa featherboard to thefence(rrghf). Makethedevice asyouwoulda standard (page125),but cut a 45" featherboard bevelon its leading endbefore cuttingthe f ingers andslots.Alsomakesurethatthe featherboard isthicker thanthestockvou ara rinnina
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(incef)
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A SHIMMED FEATHERBOARD Shimming a featherboard Whenworking withthickstockor runninga boardon edgeacross a saw table,a featherboard clamped directly to thetablemayapplypressure too lowontheworkpiece, causing it to tilt awayfromthefence.To applypressurecloser to themiddleof thestock, screw thefeatherboard to a shimand thenclamptheshimto thetable(/eff).
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SAWHORSES SAWH()RSE A KN()CKD()WN B u i l d i ntgh es a w h o r s e A s t u r d ys a w h o r slei k et h e o n es h o w na t l mount l e f tc a nb e m a d ew i t ho n l ya s m a l a o f l u m b e ar n d p l y w o o da,n dt a k e na p a r t a n d r e a s s e m b l qe ud i c k l yC. u tt h e l e g s f r o ml - i n c h p l y w o o dt h, e ns a wa 3 - i n c h d e e pn o t c hi n t h en i d d l eo f t n et o oo f b o t h p i e c e sN. e x t c. u t t n e c r o s s p r e cf reo m 1 - b y - 6s t o c ka n d s a wa 1 / - i n c h - d e e p s l o t8 i n c h e si n f r o me i t h e re n dt o f i t i n t o . n g l et h es l o t s ' o u g h5l y' f r o m t h e l e g sA iho vorlinal tn cnrped lho looc cliohtlv nrrl ! i
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w a r dF . o ra d d e ds t a b i l i t ys,c r e w4 - i n c h l o n g1 b y - 2c e a t st o t h e c r o s s p i e coe' r e a c hs i d eo f t h e s l o t s .
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-lb phrtc lottgworkpict'c:tt,itltottt t l t cl t c l p o . l ' rbr t ' t r c l rv i s c ,c l t r t r t p o ,rsr r atttlscrcn t l t t ' r tcr d g c - r rrpt , i t l h ri.s-s/io ttri i l fi t() ()t' il t o t'c -srlrr,/irl r--sc-s,
o t r i g l t t .S c c t t rtcl r cl r a r t t l s c r c tno' s rlitlr (.' clorrrps Io l/rcci.rr-s-slls1-r'-s prcIcItt thcttr .li'ort t slipp i trg.
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A F()LDING SAWHORSE
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Top rarl 3/o"x5%"x36"
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lll1 lllllll1 illllltlll rlitljljllltllltilltlll1 llitillll]|tlltlilllljll 1HO?Tt? Taddingeawhoroes To VrevenL a sawhorse from marrinqyourworK, coverits croeepiece with a elriV of carpeL, an oldlowel,or a blanket,Foldthe maLerial overf,heNoVedqe nl
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Making thesawhorse M a d ee n t i r e lfyr o m1 - b y - 6 s t o c kt,h e lightweight sawhorse shown above, featuringa hinged topandcrossbrace, folds flatforeasystorage. Cutthe legsand r a i l st o l e n g t a h n dl o i nt h e mt o g e t h e r ; (inset,top)Io loin usecornerhalf-laps thetoprailsto thelegsandT half-laps (inset, bottom) to attachthelegsto the bottomrails.Reinforce thejointswith glueandscrews, thenjointhetwosectionsat thetoprailswitha pianohinge. Finally, cutthecrossbrace; besureit is longenough sothatwhenthe legsare spread, thepianohingeis recessed below t h et o pe d g eo f t h et o pr a i l s S . a wt h e crossbrace in halfandconnect thetwo pieces withthehinge. Thenfasten the crossbrace to bothsiderails,againusing pianohinges.
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CARRIER A PLYW()()D Moving l a r g ep a n e l s particleboard, and hardSheetsof plywood, to carheavy and awkward boardareoften l e f t w i l l m a k et h e T h e c a r r i e s r h o w n a t ry. l o a de a s i e tro b e a r .R o u ta 1 - i n c h - w i d e r a b b eat l o n go n ee d g eo f a l 2 - i n c h - l o n g b o a r dC . u t a n o t c ho u t o f o n ee n d o f a pieceof plywood, thenscrewa woodblock acrossthe end of the notchto serveas a h a n d l eA. t t a c ht h e o t h e re n d o f t h e p l y w o o dp i e c et o t h e r a b b e t e df a c eo f t h e b o a r d( i n s e t )T. o u s et h e c a r r i e rs, i m p l y h o o ki t u n d e rt h e s h e e ta n d p u l l i t u p underyour arm (left).Somewoodworkers f i n d i t m o r ec o m f o r t a b lteo s t a n do n t h e c a r r i esr i d eo f t h e p a n eal n du s et h e i ro t h e r h a n dt o s t e a d yi t .
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PLANING SH()RT ANDTHINSTOCK U s i n gr u n n egr u i d e tso p l a n es h o rst t o c k F e e d i n sgh o r tb o a r d st h r o u g ha t h i c k n e s s p l a n ecr a nc a u s es n i p r n ag n dk i c k b a c k . T o h o l ds h o r ts t o c ks t e a d ya s i t e n t e r s a n de x r t st h e n l a ,n" . e, rbs., l" u et w os o l i dw o o d s c r a pr u n n e r st o t h e e d g e so f y o u rw o r k n i p c p [ \ , 4 : kspr r r pt h p n l n n e f sa f e t h e s a m et h i c k n e s a s s t h e w o r k p i e caen d e x t e n ds e v e r ai ln c h e sb e y o n db o t he n d s . Feedthe workpiece intothe planer(rrght), makrng a s e r i e so f l r g h tc u t su n t i l y o u h a v er e a c h e tdh e d e s i r e tdh i c k n e s sT.h e n cutofftherunners.
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U s i n ga p l a n i n jgi g f o rt h i ns t o c k T h i c k n e spsl a n i n g s t o c kt h i n n e tr h a n r/ainchoftencauseschatterand splintering of the workpiece. To avoidtheseprob"thicker" l e m sm a k et h i ns t o c k w i t ht h i sj i g . To makert,srmplygluetwo beveled cleats t o e i t h e re n d o f a b o a r dt h a t i s s l i g h t l y . o l o n g e rt h a n y o u rw o r k p i e c e( i n s e t ) T makethe cleats,cut a 45' bevelacrossthe m i d d l eo f a b o a r da p p r o x i m a t et h l ye s a m e t h i c k n e sa s s t h e w o r k p i e c eN. e x t ,b e v e l t h e e n d so f t h e w o r k o i e c eS. e tt h e s t o c k o n a b a c k u pb o a r d p , o s i t i o nt h e c l e a t s f l u s ha g a i n st h e w o r k p i e c seo t h e b e v e l c u t sa r ei n c o n t a c ta, n dg l u et h e c l e a t si n p l a c et o t h e b a c k u pb o a r dR . u nt h e1 r ga n d , aking w o r k p i e cteh r o u g ht h e p l a n e r m s e v e r alli g h t p a s s e sd o w nt o t h e d e s i r e d t h i c k n e s s( r i g h t )t,h e n c r o s s c utth e e n d s o f t h e w o r k o i e cseo u a r e .
ANAUXILIARY F()RTHETABLE SWITCH SAW
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Installing an overhead switch S w i t c h i nogn a t a b l es a ww h i l eb a l a n c i n g a l a r g ep a n eol n t h e t a b l ec a np r o v ed i f fi c u l t .T h ea d d i t i o no f a n o v e r h e asdw i t c h w i l l e n a b l ey o ut o s t a r t h e s a ww h e nt h e mainswitchis out of reach//eft).Locate t h e n e ws w i t c hs o y o u c a n r e a c hi t c o m f o r t a b l yw i t h a 4 - b y - Bp a n e lo n t h e s a w tablejust in frontof the blade;screwa tria n g u l abr r a c k etto t h e c e i l i n ga n da t t a c h t h e s w i t c ht o t h e b r a c k eat t a s u i t a b l e h e i g h tR . u na l e n g t ho f n o n - m e t a l l i c s h e a t h e ld2 - g a u g ec a b l ef r o mt h e s w i t c h a l o n gt h ec e i l i n gd, o w nt h ew a l l ,a n da c r o s s the floorto yoursaw.Havea licensed elect r i c i a nw i r et h e s w i t c ht o t h e s a ws o t h a t b o t hi t a n dt h e o r i g i n asl w i t c ha r ea b l et o startor stopthe machine;neverdisconnect theswitchonthesawitself.
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V.BL()CK IIG
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Cutting a chamfer Tocutchamfers onyourjointer, usethesimplejig shown above. Referto the illustration forsuggested dimensions. Beginby bevelcutting2-by-2s fortheV section of thejig. Position the twocut piecesonthe basesotheyextendbeyond oneendby gapbetween witha %-inch about12 inches, them.Attachthe twopieces to the basewithcountersunk screws to avoidscratch-
ingthejointer table.Tousethejig,clampit in placewithone withthecutterhead-end endof thebasealigned of the infeed table.Lower theinfeed tableuntiltheV section of thejig lies flushonthejointer's outfeed table.Seattheworkpiece in the gapof thejig,thenfeedit across theknives whileholding it firmlyin IheY (above).
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Finding the centerof a circular workpiece is easyif you use the jig shown at right. The simple deyice consis* of a piece of plywood with a 90" wedgecut out of it and a l2-inchJong 1-by-2 mountedso that one edgebisec* the wedge.To usethe jig, seat the workpiece in the wedgeand draw a line acrossits diameter using the 1-by-2 as a guide. Rotate the workpiece about 90oand draw anotherline. The nvo will intersectat the centerof the circle.
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FORSCRIBING CIRCLES TW()DEVICES M a k i n ga n du s i n gt r a m m ebl l o c k s Y o uc a ns c r i b ea l a r g ec i r c l eu s i n ga s e to f t r a m m ebl l o c k sl i k et h eo n es h o w na t r i g h t . C u tt h e p i e c e so f t h e j i g f r o ms o l i dw o o d , make referring to the insetfor dimensions; s u r et h e b e a mi s l o n g e tr h a nt h e r a d i u s . u ta n a n g l e dn o t c h% i n c h o f y o u rc i r c l eC f r o mt h e t o p o f e a c hb l o c kt o a c c o m m o d a t et h e b e a ma n da w e d g eF. o rt h e p i v o t , d r i v ea n a i l i n t ot h e b o t t o mo f o n eb l o c k , s n i p o f f t h e h e a d ,a n d f i l e i t t o a p o r n t . Mouna t s h a r oo e n c iiln a h o l eb o r e di n t h e b o t t o mo f t h e o t h e rb l o c k .M a k es u r ei t s p o i n ti s l e v e w l i t ht h e n a i l .T o u s et h e j i g , l o o s e nt h e w e d g e sa n d s l i d et h e b l o c k s a l o n gt h e b e a mu n t i lt h e g a p b e t w e etnh e n a i l t i pa n dp e n c ipl o i n te q u a l tsh ed e s i r e d r a d r u so f y o u rc i r c l e T t h ew e d g e s , . rghten p i v o t p o i n t a h o l dt h e steady t thecenter l oint r o t a t et h e p e n c i p o f t h ec i r c l ea , nd (right). aroundit
Making a n du s i n ga f i x e dc o m p a s s C o n s i s t i nogf a n a r m ,a n a w l ,a n da p e n c i l , the compass shownat leftwill allowyouto s c r i b ea c i r c l eo f v i r t u a l layn yr a d i u sF. o r t h e a r m ,c u t a l - b y - 2a f e w i n c h e sl o n g e r t h a nt h e r a d i u so f y o u rc i r c l e B . o r ea h o l e a b o u t1 i n c hf r o mo n ee n d o f t h e a r m , l a r g ee n o u g h t o h o l dt h es h a f to f t h e a w l . M a k ea n o t h ehr o l eb i ge n o u g ht o a c c o m m o d a t et h e p e n c i lt;h e d i s t a n c b eetween t h e h o l e ss h o u l de o u atl h e r a d i u so f t h e c i r c l e .F i t t h e a w l a n d s h a r o e n eode n c i l i n t ot h e i rr e s p e c t i vheo l e sm , a k i n gs u r e the twoextendfromthe bottomof the arm b y t h e s a m ea m o u n tU . s et h e c o m p a s s a sy o uw o u l dt r a m m ebl l o c k sh, o l d i n gt h e t i p o f t h e a w la t t h e c e n t e ro f t h e c i r c l e a n d r o t a t i n gt h e p e n c i la r o u n di t t o s c r i b et h e c u c l e( l e f t ) .
SHOPAIDS
TWOSHOOTING BOARDS RIGHT-ANGLE SHOOTING BOARD )quare etop block 1"x4"x5"
Top
t/r"x5"x19"
t/o"xB"x1B"
MiLered atop block '1"x5%"x12"
shooting boards 1 Making I T os m o o t eh n dg r a i nw i t ha p l a n e , usea shooting boardlikethoseshown at left.Theright-angle shooting board(left, above) is for planing straight endgrain; a mitered version canalsobe built(/eft, below). Cutthepieces according to the dimensions suggested in theillustrations. Buildthebase, top,andmitered stopblock plywood; from%-inch usesolidwoodfor thelipandthesquare stopblock. Screw thetopto thebasewiththeendsandone edgealigned. Thenattachthe lip to the b a s em , a k i nsgu r et h a tt h el i p l i n e su p withthe endof the base.Forthe rightangleshooting board, fasten thestopblock to thetopflushwiththeotherendof the jig.Forthemitered shooting board, centerthestopblockonthetop.
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r) Smoothing endgrain L to useeitherjig,hooktheliponthe edgeof a worksurface. Setyourworkpieceonthetop,buttingtheedgeagainst thestopblocksothatit extends overthe edgeof thetop byabout%oinch.With position themitered shooting board, the workpiece against theappropriate sideof thestopblock.(Fora longworkpiece, it maybenecessary to placea support board undertheopposite endto keeptheworkpiecelevel.) Seta plane on itssideat one e n do f t h ej i g a n db u t tt h es o l ea g a i n s t theedgeof thetop.Holding theworkpiece guidetheplanealong firmly, thejigfrom oneendto theother(rghf).
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A cleanmetalcanwith wire strung acrossthemouthoffersa neatand simple way to controltheJlowof stainor varnishfrom a brush.Punchholesin sidesof thecan neartherim, opposite stringa wire betweentheholesandpour theliquid into thecontainer.After dipping thebrush,draw the bristlesacross liquid. thewire to wipeoff any excess
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Stacking shelves to dry Finishing a shelfonesideat a timedouforthistask.Using blesthetimeneeded t h es i m p l es t a c k i nhga n d l essh o w na t l e f t ,y o uc a nf i n i s hb o t hs i d e sa t o n c e . fromsolidwoodstockand Cutthehandles m i l la t o n g u ei n o n ef a c eo f e a c ho n e . t i n c hw i d e r M a k et h eh a n d l east l e a s% thanthethickness of thestockyouare finishing D.r i v se m a lnl a i l sl o n g et h r an thickness through themand thehandles' gentlypress pointsinto the protruding before finishtheendsof theworkpiece ingit. Usethehandles to turntheboard asyouapplyf inish;whenyouaredone, theboards canbestacked, allowing airto circulate freely asthef inishdries. When pieceof furniture, finishing a larger setthe (inset). pieceon a setof dryingsupporls These2-inch-souare woodblocks have s m a lnl a i l sd r i v e tnh r o u gthh e i rc e n t e r s to support a workpiece at itscorners.
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A SPRAYING TURNTABLE
theturntable 1 Building I Consisting of a baseandtopcutfrom plywood %-inch witha "lazySusan" bearingfastened in between, theturntable shownabove allows a pieceof furniture with to berotated asit is beingsprayed . u tt h eb a s ea n dt o ps l i g h t l y a f i n i s hC larger thanthebaseof thepieceof furn i t u r teo b ef i n i s h e d C.u ta h o l ei n t h e centerof thebaseto allowaccess to the screwholesforattaching theupperbearingto thetoponcethelowerbearing is secured to thebase.Firstattachthelower bearing to thebasewithscrews. To fastenthejig top,setthebaseontopof it withthebearing sandwiched between t h et w op i e c e as n df l i p t h e mu p s i d e d o w nW . i t ht h ee d g e o s f t h ep i e c e s flush,rotate thebearing sotheremaining screw holes areexoosed. thenscrew the upperbearing to thetop (above, right).
lllllllllllfillllllllllultllllllltlll llllilltllilllllilIllltlillll][t 5HO?Tt? Lubricatingtoole LighNly oilinqa handsaw bladeor a planeeole beforeeNorinqiNkeepe the Loolcleanand prevenberueN.Tooilyour toolo neatly,ueea lubricalinq pad madefrom a lonqoLripof burlaV,Liqhtlv rolledand oackedin a i smallcan as shownhere. '.MakeeureNheeLriVie wide enoughto exbendpael the loo of the can.)oaklhe maNerial in Ihin machine oil,andwipeyourplaneooleeand handsawbladesoverit beloreeNorinqthe toolo.Tiqhtly coverlhecanwhennoNinuee. v
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r) usingtheturntable C- ltlahe foursmalldryingsupports (page135).Setthe workpiece on the rotate tipsof thenails, thenslowly the turntable withonehandwhileoperating a spraygunwiththeother(above).
BENCH DOGLAMPSUPPORT
A movable lightfora workbench A desklampattached to a benchdogas youto position shown at leftwillenable thelightat anyof thedogholesalongthe b e n c hT. o m a k et h ej i g , b o r ea h o l e t h es a m ed i a m e t earst h es h a f o t fthe l a m oi n t ot h eh e a do f a w o o d ebne n c h dog(page92).
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SHOPAIDS
A VACUUM RAMP SCREENING
t S S S 6 S S S S Top S S ^
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Collecting shopdust Forcleaning dustofftheshopfloor,build a wedge-shaped rampfrom screening (above). plywood Before andhardboard assembling thepieces, cuta holein the backto fit a dustcollection hose,and borefiverowsof 1%-inch-diameter holes through thetop.Whendustandwood chipsaresweptupontotheramp,smalle rp a r t i c l ewsi l lf a l lt h r o u gthh eh o l e s a n dc o n t i n uoen t o t h ed u s tc o l l e c t o r . L a r g edre b r i w n nt h er a m p s i l lr e m a i o foreasydisposal.
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ljltllltlllllIllllllltlllllltllltllllllltl]llllljllllultlluilllllll 9HO7Tt? A drawer-elidepoeitioningjig pooilioncommercial Tohelpyou correcLly elideeon drawereidee, uoelhe jiq shownhere.CuLa rabbet,in a ecrapboard;make Lhedepthofthe rabbelequaltolhe deeireddielance beLween the slide and the botlom of Nhedrawer ,-----.-.
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bottomedqeof thehara-
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warebuIIed a4ainot I h e j i q .H o l d i n q N h e s l i d ea n d L h ej i q in place,markthe ecrewholee,bore pilot holee,and ecrewthe elide to lhe drawer.
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SHOPAIDS
A STEAM-BENDING JIG
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lll1 filtrlllllltllltfinfiltllllfiltfillfilllllllllllll llllllllllllllll 1HO?Tt? Ahoning jig TheoimVle 1igehownherewillenableyou Nooharpenplane honing6uide.)lip a bladeewiNhoulthe aid of a commercial 4 - inch1 onq, 3/ s- inch-diameter car ria4e bolt throuqh th e blade'eeloN.Faetenwaehersand wingnulo on both sidesot etone Nheblade.Wil'h lhe cuLtinqedqeon lhe oharpeninq and Nheheadof lhe bolt on your worksurface,ueea -..-/'\, ?rotractor and a olidingbevelIo adjuoLthe winq nuNeeo Nhatthe bladecan be slidalonalhe oione allhe properan4le,typically 3O". ,,t-.Yat
139
Steam-bending a workpiece Tosteam-bend smallworkpieces, such asstripsof molding, buildtheportable Cuta lengthof steamer shown above. ABSpipelonger thanthewoodyouwish to bendandaboutthesamediameter kitchen kettle; asthespoutof anelectric usea kettlewitha roundspout.Connect oneendof thepipeto thespout,makinga tightsealwithducttape.Support theotherendof thepipeat a slightangle pieceof plywood ona notched clamped in a bench vise.Tousethejig,bringthe waterto a boil,insert theworkpiece to (above), besteamed andstuffa raginto theopenendof thepipeto contain the "cook"until steam. Lettheworkoiece thewoodsoftens; asa roughguide,allow per t hour inchof thickness. Refillthe plugging kettleasnecessary, theendof thetubetemporarily to contain thesteam.
GLOSSARY A-B-C Auxiliaryfencs A wooden attachment to the rip fenceof a table saw or other machine,for the purpose of avoiding accidentaldamageto the metal fence.
Countersink: To drill a hole that allowsa screwheadto lie flush with or slightly below the surface.
Bench dog: A round or squarepeg made of metal or wood that fits into a hole in a workbench to hold a workpiece in place.
Crosscut A cut made acrossthe grain of a workpiece.
Bench stop: A jig fastenedto a work surfaceto steadya workpiece. Bevel cut A cut made at an angle from faceto facethrough the thicknessof a workpiece. Biscuit joiner: A portable power tool usedfor cutting slotsfor wooden wafersin biscuit joinery. Also known asa platejoiner. Biscuit jointz Seeplatejoint. Box joint A corner joint featuring straight, interlocking fingers. Carcasq The box-like body of a pieceof furniture. Chamfer: A bevelcut along the edgeof a workpiece. Chuck Adjustable jaws of a drill that hold bits and other accessories. Clampingcapacity: The widest span of a clamp'sjaws. Clearancehole: A hole bored in a workpieceto accommodatethe shank of a screw.
Cove:A concavedecorativeprofile cut in wood, usuallyalong an edge.
D.E-F-G.H-I Dado: A rectangularchannelcut acrossthe grain of a workpiece. Doweft Wood pin usedto reinforce certaintypesof joints. Edge-gluing:Bonding boardstogether edge-to-edgeto form a panel. Extensiontable: An accessorywork surfaceusedto expandthe working areaof a stationarymachine. Face-gluing:Similar to edge-gluing, exceptthat boardsarebonded face-to-face. Faceplateturning: Turning circular or cylindrical workpiecessuchas bowls on the faceplateof a lathe. Featherboard:A board with thin "feathers" fingersor along one end, clampedto the fenceor table of a stationarytool to hold a workpiecesecurely. Fence:An adjustableguide to keep the edgeof a workpiecea setdistance from the cutting edgeof a tool. Fixture Shop-madedeviceattached to a stationary or portable power tool to increaseits capacityor efficiency.
Collet The sleeveof a router that holds the bit shank.
140
Frame-and-panel joinery: A method of assemblingboardsinto rectangular frames;groovesalongthe inside edgesof the frame enclosea panel. Furring strip: A thin board that is nailed to a wall or ceiling to provide a flat or level surface;normally used for securingdrywall or paneling. Groove A cut along the grain of a workpiece,forming a channel;frequently decorative,but sometimes part of a joint. HeadstoclcThe spindle attachedto the motor of a lathe;holds work for spindle-turning in conjunction with the tail stock,or usedalonefor turning with a faceplate.Seetailstock. l-K-L-M-N-O-P-Q fig: Devicefor guiding a tool or holding a workpiecein position. fointing: Cutting thin shavings from the surfaceof a workpiece until it is flat and perpendicularto the adjoining surface. Joist A horizontal support for a floor; analogousto the raftersof a roof. Kerf: The cut madeby a sawblade. Kickback The tendenry of a workpieceto be thrown back toward the operatorof a machineor tool. Lap joint A joint in which matching dadoesor rabbetsoverlapto connecttwo boards. Miter cufi A cut that anglesacross the faceof a workpiece.
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Miter gauge A devicethat slidesin a slot on the sawtable,providing support for the stockasit moves pastthe blade for crosscuts;its angle can be adjustedfor miter cuts. Mortise: A rectangular,round, or oval hole cut to accommodate a tenon. Mortise-and-tenon joint A joinery techniquein which a projecting tenon on one board fits into a cavity-the mortise-in another. Pilot bearing: A cylindrical metal collar aboveor below the cutting edgethat guidesa router bit along the workpieceor a template. Pilot hole: A hole bored into a workpieceto accommodatea nail shaft or the threadedpart of a screw;usually slightly smallerthan the shaft or threadedsectionof the screw. The hole guidesthe fastenerand preventssplitting. Platejoint A method ofjoining wood in which oval wafersof compressedwood fit into slotscut in mating boards. Pockethole: An angledclearance hole that allowsa screwheadto be recessedbelow the surface;often usedwhen joining rails to a tabletop. Push block or stick: A deviceused to feeda workpieceinto the blade, cutter, or bit of a tool to protect the operator'sfingers.
Quill stroke The length of travel of the quiil of a drill press. R-S Rabbet A step-likecut in the edge or end of a board; usuallyforms part of a joint. Radius:The distancefrom the center of a circleto its outsideedge;onehalf the diameter. Rait The horizontal member of a frame-and-panelassembly.Seestile. Raisedpanet A pieceof wood that forms the centerof a frame-andpanel assembly.Bevelingthe edges of the panel createsthe illusion that the centralportion is raised. Releasecut A preliminary incision from the edgeof a workpiece to a line about to be cut; enablesa band sawor sabersawto cut tighter curvesby facilitating the removal of wastewood. Rip cufi A cut that follows the grain of a workpiece-usually made along its length.
Spindle turning: Turning cylindrical workpiecesheld betweenthe headstockand tailstockof a lathe. Square:Adjoining surfacesthat meet at an angleof 90o. Stilq The vertical member of a fr ame-and-panelassembly.Seerail. T-U-V-W-X-Y-Z Tirilstock The adjustablespindle on a lathe; usedin conjunction with the headstockto hold work for spindle turning. Seeheadstock. Thpercut An angledcut along the length of a workpiecethat reduces its width or thicknessat one end. Tearout The raggededgesproducedwhen a bladeor cutter tears the wood fibers rather than cutting them cleanly.
Shooting board: A jig for holding the end grain of a workpiecesquare to the soleof a plane.
Template A pattern, typically made of plywood or hardboard,usedwith a power tool to produce multiple copiesof an original.
Sizing board: A jig usedto cut workpiecesto length, typically with a handsaw.
Tenon:A protrusion from the end ofa board: cut to fit into a mortise.
Snipe A concavecut createdby a jointer or planer at the end of a workpiece,the result of improper pressureor table height.
Wall stud: A vertical framing member forming wallsand supporting the framework of a building.
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Spindle: The threadedarbor on a lathe that holds the headstockor faceplate;alsothe threadedarbor on a drill pressor shaperthat holds cutters,bits, and other accessories.
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INDEX Pagereferencesin irallcsindicate an illustration of subject matter.
A-B-C Band saws: Circle-cutting jigs, j7, 44-45 Extension tables,102, 104, 110 Miter jigs, j8,47 Taper jigs, j8,47 Wedge-making jigs, 38, 46 Bar clamos: Crossbirs for edge gldng, 80,82 Glue racks, 8O 8l wall-mounted, 80,85 Storage mobile storageracks,ll6, 118-119 storing clamps in a can (Shop Tip),119 Beeken,Bruce, 10-11 Belt sanders.SeeSanders Benchdogs,79,91-92 Lamp supports,123,137 Bench grinders: Gouge-sharpeningjigs, 69, 72 Benchslaves,104,112 Biscuit joints. SeePlate joiners Boxjoints, 12 Carcases: Carcase-squaringblocks, 79, 89 Chiselracks,ll5 Circles: Centerfinders, 124,132 Circle-cuttingjigs band saws,37,44-45 rotters, 15,20 sabersaws,37,43 shapers,15,31 Circle-sanding jigs, 95, 96-97 Faceplate-centeringjigs for lathes,69, 71 Scribing jigs compassjigs, 124,133 router compassjigs, 15,20 trammel points, 124, 133 Circular saws: Bladestoragebox, 115,117 Kerfsplitters,38, 42 Miter and crosscutguide,37,41 Straightedgegtides, 38,42 Clamps,79 Framing clamps,78, 80,87 figs for clamping thin stock, 8O 84 Miter clamping blocks, 79, 88 Rope clamps for carving (Shop Tip), 88 Storageracks,114,116,118-119 Wedged clamping bars, 8Q 83 SeealsoBarclamps; Pipe clamps; Vises Curved cuts: Routers corner-rounding jigs, 14, 2j Sanding,98 Seealso Circles
D-E.F
G-H-r-J-K
Dadoes: Routers adjustabledadoingjigs, 15, I9 jigs for evenly spaceddadoes,J3, I7 quick-setup dadoing jigs, .15,l8 T-squarejigs,15, 16 T-squarerouting guides(ShopTip), 16 De Cristoforo,R.J.,6-7 Dovetail joints: Sliding dovetail router jigs, 14,26 Dowels: Inserting dowels with a depth gauge (ShopTip), 62 Drawers: Drawer-slidepositioningjigs (ShopTip), 138 Drill oresses: Cuiting rosetteson the drill press (ShopTip), 67 Deep hole-drilling jigs, 67 Depth guides (Shop Tip), 65 Extensiontables,104, 111 |ig for drilling equally spacedholes, 60,61,64 Making wooden plugs (Shop Tip), 64 Pocket hole jigs, 61, 66 Sandingdrums (ShopTip),97 Tables auxiliary sanding tables,95, 98 tilting tablejigs, 61,63 V-block jigs, 61,6s Drills. SeeDrill presses;Electric drills Drum sanders: Drill presses(ShopTip), 97 Lathes,70,77 Electric drills: Center-drilling jigs, 61, 62 Depth guides(ShopTip), 65 Removablepower tool tables,104, 108-109 Extension stands: Yises,104,112 Extension tables, 103 Band saws,102,104, 110 Drill presses,104, 111 Routers attachedto saw tables (ShopTip), 107 SeealsoTables Fasteners,/ron t endpaper Featherboards, I 5, 32, 12i, 125-126 Beveled,123,127 Extended shaperfeatherboards, 15,32 Shimmed,123,127 Vacuum jigs, 34 Finishes: Controlling finish on brushes, J35 Drying supports,124, 135 Sprayingturntables, 122, 124, 136-137 Stackinghandles, 124, 135 Fuller,Ted,8-9
Glue racks, 80, 8l Wall-mounted, 80,85 Har dw are, fr ont endpaper Hinge mortises: Router jrgs, 14,22 Jigs: Planning,l0 Seealso namesof specifictools Joinery: Routers box joints, 12 corner half-lap jointjigs, 14,27 sliding dovetail roter jigs, 14, 26 Table saws tenoningjigs, 39, 57-59 SeealsoDadoes;Mortises; Plate joiners Jointers: V-block jigs for chamfers, 124, 132 Jointing: Routers, 2l
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L-M-N-O Lathes: Center-finding jigs, 69, 71 Column fluters, 70, 75- 76 Faceplate-centering jrgs,69, 71 Gauges bowl depth gatges,70, 77 diameter gauges,69,73 Gouge-sharpening jrgs,69, 72 Sandingdrums,70,77 Spindleturning centering a spindle blank (ShopTip), 70 faster turning with preset calipers (ShopTip), 73 layott jigs, 69, 73 Preservlngsquarecorners (ShopTip), 74 Tailstocks for hollowed-out work, 68,70,74 Lumber: Sizes,backendpaper Storageracks,ll6, 120,121 Truing uneven boards, 39, 53 Mortises: Routers adjustablemortising jigs, i4, 28 hinge-mortisin g jrgs, 14, 22 movable-jaw mortising jigs, .14,29
P-Q-R Panels,raised: Routerjigs,8-9,14,24 Table sawjigs, 3t 52 Parsons,Jeff,l0- I 1 Pipe clamps: Crossbarsfor edge gluing,80,82 Extenders,80, 86 doubling up pipe clamps (ShopTip), 86
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Storage mobile storageracks,118-119 storing clamps in a can (ShopTip), lJ9 wall racks, 1.16 Planes: Clamping long workpieces, 128 Honing jigs (ShopTip), 139 Planing jigs for thin stock, 124, lj1 Running guides for short stock, J30 Shootingboards,124,134 Plate joiners: Stands,103,105 Plywood: Carriers,123,130 Storageracks, 116,120 Push blocks, 123, 125 Push sticks,123, 125,126 Radial arm saws: Auxiliary fence and table molding fixtve,39,54 Sanding jigs, 95, 99 Taper jigs,48 Roller stands, 103 Adiustable,104,113 Temporary (Shop Tip), 113 Rosettes: Cutting rosetteson the drill press (Shop Tip), 67 Routers: Adjustableedgeguides,15,25 Auxiliary sub-bases(Shop Tip), 13,21 Bit storagerack, I 15 Circles adjustable circle-cutting jigs, 15,20 compassjigs, 15,20 Column flrters, 70, 75-76 Corner-rounding jigs, 14, 23 Dadoes adjustabledadoingjigs, 15, l9 jigs for evenly spaceddadoes, 13,17 quick-setupdadoingjigs, 15, l8 T-squarejigs,15,16 _ Jolnery box joints, 12 corner halfJap jointjigs, 14,27 sliding dovetail jigs, 14,26 Mortises adjustablemortising jigs, 14,28 hinge-mortising jigs, U, 22 movable-jawmortising jigs, 14,29 Panel-raisingjigs,8-9, 14,24 Tables removable power tool tables, 104 108-109 table/cabinets,10i, 106-107 tablesattached to the table saw (ShopTip), r07 Vacuum templates,35
S-T-U Sabersaws: Circle-cutting jigs, 37, 43 Edge guides miter and crosscut gtide, 37,41 Removablepower tool tables, 104. 108-109 Safetydevices, 13,32, 33, 123, 125-127 Sanders: Circle-sanding jigs, 95,9G97 Gang sanding, 96 Sanding: Blocks. 94 contoured, 95,100-101 wood sanding blocks (Shop Tip), 100 Drill oresses auxiliary sanding tables,95 98 sanding drums (Shop Tip), 97 Folding sandpaper(Shop Tip), l0l Lathe sanding drums, 70, 77 Radial arm saws sandingjigs, 95, 99 Thin stock, 99 SeealsoSanders Sandpaper: Folding sandpaper(ShopTip), I0I Sawhorses,124, 128-129 Padding sawhorses(Shop Tip), 129 Saws: Back saws sizing boards for crosscuts,3Z 40 Handsawholders, 116,117 SeealsoBand saws;Circular saws; Radial arm saws;Saber saws:Table saws Shapers: Circle-cutting jigs, 15,31 Featherboards,15,32 Guards,13,33 Shop Tips: Clamps, 86, 88,92, 119 Drilling, 62,64,65,67 Lathes,70,73,74 Planes,139 Routers,16,2l Sanding,97,100,101 Sawhorses,129 Tablesand stands,107, 113 Table saws,49, 53, 55,59 Tools. i36 Square: Checking,backendpaper Tables,103 Band saws extension tables,102, 104, 110 Drill presses auxiliary sanding tables,95, 98 extension tables,104, 111 ti-lting table jigs, 67, 63 V-block jigs, 61,65 Electric drills removable tables, 104, 108-109 Plateioiner stands,103,105
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Routers attachedto saw tables (ShopTip), 107 removable power tool tables, I04, 108-109 table/cabinets,103, 106-107 Sabersaws removable tables,104, 108-109 Table saws routers attached, (Shop Tip), 107 shop-made inserts (Shop Tip), a9 Seea/soWorkbenches Table saws: Blade height gauges,8, 49 Bladestoragebox, 115,117 Board-straighteningjigs, 39, 53 Cove-cutting jigs, j9, 56 Crosscutjigs, 36, 38, 50-51 Crosscuttingwide panels (Shop Tip), 53 Miter gauges angle-settingjigs (Shop Tip), 59 extensions(Shop Tip), 55 Miter jigs, 39, 50 Raisedpanel jigs, 39, 52 Routers attachedto saw tables (ShopTip), 107 Shop-madetableinserts(Shop Tip), 49 Switches auxiliary switches,123, 131 Tables routers attachedto saw tables (ShopTip), ]07 shop-made inserts (Shop Tifl, a9 Taper jigs,48 Tenoning jigs, 39,57, 58-59 SeealsoFeatherboards:Push sticks Templates: Vacuum templates,35 Tools, backendpaper Lubricatingtools (ShopTip), 136 Storage,I 15 chiselracks,ll5 handsawholders, 716,117 tool trays, l.l5 Seealso Clamps;Drill presses;Electric drills; Jointers; Lathes;Planes;Plate joiners; Routers; Sanders;Saws; Shapers Turning tools: Gouge-sharpening jigs, 69, 72
V-W-X-Y-Z Vacuum jigs, 34-35 Vacuum screeningramps, 124, 137 Vises: Extension stands,104, 112 Wood-carver's vises,8O 9J Wood. SeeLumber; Plywood Workbenches: Bench stops, 29, 90 Gripping thin stock (Shop Tip),92 Lamp supports, 123, 137 SeealsoBenchdogs;Tables
ACKNOWLEDGMENTS Theeditorswishto thank thefollowing ROUTING AND SHAPING IIGS AdjustableClampCo.,Chicago,IL; AmericanTool Cos.,Lincoln,NE; Black& Decker/EluPowerTools,Towson,MD; DeltaInternationalMachinery/Porter-Cable, Troy, Ml/WainbeeLtd.,Montreal,Que.; Guelph,Ont.; De-Sta-Co, FreudWestmoreTools,Ltd.,Mississauga, Ont.; LeeValleyToolsLtd.,Ottawa,Ont.; Sears,Roebuckand Co.,Chicago,IL; Shopsmith,Inc.,Montreal,Que.;PatrickSpielman(jig on pp. 34-35), FishCreek,WI; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY CUTTINGJIGS AdjustableClampCo.,Chicago,IL; DeltaInternationalMachinery/Porter-Cable, Guelph,Ont.; De-Sta-Co, Troy, Ml/WainbeeLtd.,Montreal,Que.;FisherHill Products,Inc.,Fitzwilliam,NH; FreudWestmoreTools,Ltd., Mississauga, Ont.; HitachiPowerToolsU.S.A.Ltd.,Norcross,GA; FrankKlausz(jig on pp. 58-59), Frank'sCabinetShop,Inc.,Pluckemin,NJ; SandvikSawsand ToolsCo.,Scranton,PA; DaveSawyerand JoanSawyer(jig on p. 46), SouthWoodbury,VT and RanchoSantaFe,CA; Sears,Roebuckand Co.,Chicago,IL; Shopsmith,Inc.,Montreal,Que.;Skil PowerToolsCanada, Markham,Ont.;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY DRILLINGIIGS AdjustableClampCo.,Chicago,IL; DeltaInternationalMachinery/Porter-Cable, Guelph,Ont.; Sears, Roebuckand Co.,Chicago,IL; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY TURNINGIIGS AdjustableClampCo.,Chicago,IL; DeltaInternationalMachinery/Porter-Cable, Guelph,Ont.; LeeValleyToolsLtd.,Ottawa,Ont.;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
(jigonp.8s),H".:1,,X:)glil?,rc"t#t:tJS,Iirc,sr,,r.*t'u BiltBivona collins(jigonp.84), LostMountainEditions,Ltd.,Sequim,WA; LeeValleyToolsLtd.,Ottawa,Ont. SANDINGIIGS AmericanTool Cos.,Lincoln,NE; Black& Decker/EluPowerTools,Towson,MD; DeltaInternational Machinery/Porter-Cable, Guelph,Ont.;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY TOOL EXTENSIONSAND TABLES AdjustableClampCo.,Chicago,IL; AmericanTool Cos.,Lincoln,NE; DeltaInternationalMachinery/Porter-Cable, Guelph,Ont.; Hitachi PowerToolsU.S.A.Ltd.,Norcross,GA; LeeValleyToolsLtd.,Ottawa,Ont.; Steiner-Lamello A.G. Switzerland/Colonial SawCo.,Kingston,MA; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY STORAGEDEVICES AdjustableClampCo.,Chicago,IL; AmericanTool Cos.,Lincoln,NE; GreatNeckSawMfrs. Inc. (BuckBros.Division),Millbury, MA; LeonardLee(rackon p. l2l), LeeValleyToolsLtd., Ottawa,Ont.; SandvikSaws and ToolsCo.,Scranton,PA;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY SHOPAIDS AdjustableClampCo.,Chicago,IL; CampbellHausfeld,Harrison,OH; DeltaInternationalMachinery/Porter-Cable, Guelph,Ont.; Hitachi PowerToolsU.S.A.Ltd.,Norcross,GA; TaylorDesignGroup,Inc.,Dallas,TX; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY Thefollowingpersonsalsoassisted in thepreparationof this book: LorraineDor6,R€jeanGarand(Atelierd'Eb6nisterie R6jeanGarandEnr.,St-Rdmi,Que.),GraphorConsultation, ClaudeMartel,GeneviiveMonette,Alain Morcel (LesR6alisations Loeven-Morcel, Montreal,Que.)
PICTURECREDITS Cover RobertChartier 6,7 RobertHolmes 8,9 MichaelMorissette 10,ll Ron Levine
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WORKSHO GPU I D E INVENTORY OFMEASURING TOOLS ANDDEVICES Utility knife tharpenedLipacoree lineaon woodmore preciseiy _-<--b
Combination 6quare For checkin4or markinq 45' or 90" an4lea;detachable blade doublee ae ruler or
izi:f67
For checktn7or meaeunn690' an4lee on a flat surface; can aleo be ueed ae a ol,ratqhLedqe
Uaeful for eetLtnq an4leeof machtne
etraiqhtedqe, one pointt eervea aa the pivot and the other acilbee a circle or an.arc around it.
9traightedge For precieion markin1 of etrai4hL ltneeand checkinqflat eurfacea. Thick metal ed4ee are machtnedetrai4ht;
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TIPS()NWORKING WITH PTYWOOD ANDSHEET MATERIATS
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. Whenusingplylvood, layouttheelements of yourprojectonthe sheetfor economy and bestappearance of grainpattern.
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o Tocutsheetmaterials, usecarbide{ipped blades withat least10 teethperinch.
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oAlways cut plywood withthegoodface up to avoidtearout.
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r Whenfastening edgesof sheetmaterials, usescrews that areno largerin diameter thanone-quarter of the sheet'sth ickness, Drillpilotholesto prevent splitting. . Storesheetmaterials flat or wellsuooorted vertically: do notstorethemat an angle.
9liding bevel Adjuet e to copy any an7le, then 1;otranefer or mea7ure i[. 7lade al;oree tn handle
French curue For drawing curved linea on a workptece
C H E C K I NAGS O U A R E Deforeuornqa cquare,makeeure iL ia accurate. Workinqon a large sheet of paper,draw a baaelineueinqa eLraiqhLedqe. (For a combinatton or t ry zquare,uee the perfecLlyetratqht edqeof a board ae the baeelrne.)Flace Lhe equare wtth one arm flueh wit;hLhe ltne,and draw anoLherlinealonqthe outetdeof Lheother arm. Fltpl;heaquare over,keepinqLhe eame arm flueh on the baeeltneand repeal;,Thbtwo lineeyoujuet. drew ehouldbe per-fecLly parallel.To true a carpenlter'e equareugea cenlierpunchta tap Lhe gquare on iLa outeide corner Lo move the arme cloeer toqether, or on iLe inoide corner to move
the arme aparL.TeaLa4ain, and repeat until the arme are perfecLlyequare.
NOMINAL ANDACTUAL SIZES OFSOLID WOOD STANDARD THICKNESS FORSURFACED HARDWOOD NOMINAL (rough)
N()MINAL ANDACTUAL SIZES FOR SOFTW()OD LUMBER
ACTUAL (surfaced twosides)
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ACTUAL (rNcHES)
NOMINAL 0NcHES)
Surfaced dry I-by-2 1-by-3
3h-by-7t/z
Surfaced dry
3h-by-2r/z
Z-by-2 2-by-4
1-by-4 1-by-6
3h-by-3r/z
2-by-6
3h-by-5r/z
1-by-8
3h-by-7rh
1-by-10 I-by-12
3/q-by-9r/a
Z-by-8 2-by-I O 2-by-12 4-by-4
3h-by-l|rh
ACTUAL flNCHES) It/z-by-Ir/z It/z-by-3r/z Ir/z-by-5r/z It/z-by-7rh It/z-by-9rh I\/z-bY-IIrh 3r/z-by-3t/z
