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a ‘va © | WORKSTATION? @ Simple To Build, Nan el ey ‘ if | Contents , Features ream shop project Carved.Lid Tool Chest__ ES 14 ‘Discover an al new joer ectrique — “eurvos? box ania Wei saw you now 0 ‘rsa an assem ther er a perec it nealoeie Better Box Joints DEE Lawn hei ge deacon acouraeomite fenkecene tie ery wcrc bec os tier Benchtop Miter Saw Fence KEES 25 Tur any surface into precision miter saw \warkstanon Al you need are 3 couse of Saas Fold-up Worktable. Departments Readers’ Tips 4 pees) Routing Grooves on the Router Table _8 ast ete pe nd enon eee Sa peereey he tr Barve Knock-Down Fasteners. 10 Looking for fast and wasy assembly wih ‘sol esuls? We have te arsiver tandeontecnique Using Contact Cement 2 Tips ad techniquos to make your nex give Ln go ogeineauick ana 2655. Shop Short Cuts __4 ‘Stop tosied tie ana techniques to hole you ‘solve your wocawarkng rabions, o ‘ShopNotes No. 98 rae) inthe shop 7 Must-Have Files. a2 Welt show you the fools you need to get super ‘smoot shapes nal atria root wie 5'Small-Shop Finishing Tips 4“ ackipe ad ca rag Ria ove xpath saving taal sow Resawing on the Table Saw. 4 erin scp as ease ao Soran bat rane ou a grt gu at: New Leigh Dovetail Jig (ee en eee ean Fe Trac Gots acd coro bot aan Q2A 50 Sources _ St won ShopNotes com Lee viens fo bung rast or ep eee oth Bu hats cy what we etd or the Wb aed om ge 3 Ae Pee a i, eee ace er “Ebay fh eg ties oe minal ‘ih ightw ates i py rel eee Nee ee ee ereyeg ae Cea ce Then al ee ger Cs Fath Ser Pt aig) rind eg rneraste erie tie hes sro remove nog tera mae Wie wht ang in Wal wended up witha ops le ing thle sapped by ur Ugg Pion Pinan te poet sain abi oer 15 Ceili butt sudo ctr cal oa Wo caet IS al lorena eer t= on lo ite photo sbowe} Now mrt oing fo mem ha os ee eee eee ale seem rao ietvohess an —— ‘nto ot wn Sopot com a - While building. a TY wall unit, hd to find 0 way to accurately snachine flats i log clus. ‘The lating jg shown hee ia my arawer What ike about the igs thatiemakesitexy eo routstaight, moot fists ang the leg of the workpiece Its worked 0 Well Router Fluting Jig ‘in my chop, I ako use i © rout roves ae dacoes “The ig made rom "Bale bik plywood and cass oF a ‘ise and two siding fences These fens butt against he ges he ‘workpies ehh keep the cite rice and sight Balding the fg stats by euting snextng worpce o ith [Next cit the grooves fr the henna runner then cut the two ens fs rom the Bank. "ou can we your router's base plate o mark an dl he moun fg holes and it opening in the ‘hee, Used the ror able to rout the wo lt fo acting the fenoas A canteline dean across the top face and two edges Peps poston thei curing use, "Nexteome the 9 fences Fist the hardboard runners are ghia fnto grooves Aol, washer, and ob ae teed 10 tighten dove the fenes. The thre counter Ford oles allow the fences to bo adjusted to it a wise range af workpiece widths A litle paste wax helps ther slide smoothly slong thebase “This has proven very handy and Tharp finding mere and more seesforitintheshop, ‘Sony Varia Yelm ‘Cone Springs, Flora Shop Notes No. 98 Cam Clamping Table Clamping small and ode-shuped paces “radius isaghnat the projet Ths way, Js somelines 2 challange Bul Tve as youtunthedisk itsam action ight found an effective yt simple clamping ens against the projet. The great hing method involves using crcular cams aboct this that you can postion the ba deatsonapiywoow bse ‘aright where you eed hem, ‘As you can see inthe phote teow, 1 Forsmall ame ke you sea below, 1 eed Fain plywood deka dried a fasten wo cleats atrightangs, Youn | “sill hoe sed fora WS screw that was _netle ane comer of the fre aginst ‘ct abot’ fom the centr ofthe the clas ard se the cams 9 apply Sk: This offer hoe i wht tars amping prea fan easy tern {be dino acam forcamping acon. tha’ prevented a oto ruseation, "To use the cams, | just fasten them ey Grant toa piece of plywood 50 the shortest agua, Masacusets ‘Submit Your Tips Hf yu have an original shop tip we would ike to hear from you and consider publishing your tip In one oF more of our publications. Just go online 0 fur wab so at w.ShopNoteacom and clk onthe ink, “SUBMT A TP.” ‘ryeucan mai your te: ShopNotes Tips forYourShop, 2200 Grand Aven, Des Moines, IA 50312, Plane include your name, adders, 40d daytime hone number in caso wo hae any austin ‘We wl pe up to S200 we publ Your tp Pees eens { ‘ing 9 sown on te ponte page. Reames Sas eee Senet ‘router, out eet 98 Marctvpi 2008 cn nes {si Rr ay Camco Srey cm soner enue De Sor eENN Soe Ca Seah bic ae “qacuccbacr seat noche oer 1 Gade yas mag emai 1 stone yar aber eee iseloe Seren serve” ees ee eke cat ee 5 ‘Keeping all my camps organized andemalyaccosble sa chalonge, Butte simple cmp rack shown akove helps beep ther within any reach in my ner ar, “Apethe thing Fike about ths nck i that is versatile enough to hold all types of clamps And t Conduit Clamp Rack did't bak the bank buying dhe prt Ie ost 9 couple of 6 ong Paces of inexpensive dia EMT onda ew od laps ‘mounted or wood suppers. T stated by seal) attaching the supports to my shop wale Afr that i was jt a mate of sitaching theconduillampa tothe Suppo and adding the lengths of eon fo storing the damp ‘Mike Real Dogs Kanes Wire Shelf Bin Rack 1k yng mal pastie storage bins keep things cngized in the shop. Butt doesnt ake long bsfow: S erehtops and workaurfces are veriowing with them his andy storage rack wes «simple fs foe set thu ost the way. “The ac just wie lost shel fastened to sips of wood (or exposed stds) on the workshop wail (ou have tout off the font po the shal ist) ‘When you ag the el ithe wie nig bois zara the plas ip onthe back o the storage is fe ver der perfec. Dries hing about i tom sot thebins an the hes comin vary ‘sizes — so there's bound tn hea combination fe jnstabout every sorage need Charey Scerson Set Pal, Mista Vac Accessory Rack hte ar what my op wel te eee ee eet car uel ifr stim one nigra Siiantciny endeociacevonans ee ieee eery ae mv bheuer caqretatia st veace Sind toe Then tech sane ePIC ripe Sheba winger Te P¥C ine fore foes RS tu metre ok rae eacecte es nee eiemeracaan ete yak Peeniceis inte siucentew te eee lia cert ib Lon Leconte Vihar pists BY EMAIL rf ae enon See sete eae e I) Merci cee Thc Sa ed at 470 protect ns fingers. Randy Wotle of You can use a Tut m9 block of \ Owensboro, Kentucky uses Caben sel wood asa simple guile ora hand tap. ‘achorent wrap tom 3M. He also wrans tI ko@ps things square when tapping “around Nis chisels fo protect ter cating holes, as Paul Fossey of Wesiicid, ‘kgs wile tho raver Massachusots aecoveted. _worw Shop Notes com 7 secrets for Perfect Grooves ge meerce 860 ‘nen it comes io making snugfting grooves, [only have two, requirments: Tho groove must be sized acutally ae he eges Should be crip and square: Mary tes, tun to the veut ble to gt tho jb dane. The main rsson i even an ordinary sah biti gv you erp, fat bottomed zone, ‘On ts pgp, youl one the setup seas well a sone essen tips for sting top roten results, And onthe fest page, youl find techniques for cater and cee Custom Grooves Youtl find the stup ips on the ‘ppt page wil give you gest ‘ls for routing just shout any ‘ypeotgoove: However ereare a few spect stations tht call Toralitle more xplnatn. Wider Grooves, Making a groove wider seems like «simple fas All you noe todo is adjest ‘he force and make anor pes, right Wel alms. “There's a eneh, You want to make suet atthe fence the ight crecton. A good mle ot ‘humbistoalway kp the mate ‘haya’ routing othe outside of thebitand ene, Yuin sce what “imeanin the upper pots. “To widen a groove, be sue t9 move the ence ay fom he Bt ‘This way, youl fed the woke iw no the aati ofthe bt “When the fences moved dose to the bit the waste is trapped Teton the bitand fence, which ‘beclaouting operation. And the sth me foe set naar he bt ‘bit wl try to pall dhe workpiace utofyour hands. ‘Cenlered Grooves, Another contom cit (often fn myst making is « ceed groove, 1 {eed to try and mess fo got ‘it perfect centered on the werk ane But the results were never A Avoid Trapped Cuts. Move | CustomStzed Grooves. To mia a gicove the fence away fm the bt io wider than your bi, start by making @ single pase increase io siz ofthe groove in to or mare passes, ute aca. Thalys reser ony tot ome ware essing al fw oas eae Ss ack aere hc, yout wh ats eee ee oe pala ithe poor yr met fo make Nesgpesun de feces tab lightly off center. Then simply fol- | ioc ati enews ee meas | Boe ere see Se ears Tele ape adam wt CSnmcsbup on ease shee fg Tats al es ogee, ih pores ret PP ee Hardware great knock-down | Any cscusion of knock-down hardware almest {mediately conjures up images of venere, press ‘board future iva bo ros he hme enter Ad ‘ts te that many ofthe fasteners shown here are {uiteohn seen that contest. “he’s a goo remem manblatoren ey these fasteners They‘ ey to ital and they‘ stron Thisllows them told nexpemsive fan tre ming. a Weak mater Hho pata and sill povice supesingy strong parts ‘But they’ not ie to particebord ite ‘You ean take advantage of thse great uals ‘nd put them to work in your shop as well. Many ofthe jigs benches, and worksurfaces that you ese ‘very day can alo be coasirted using knockdown ‘asters for more converses ven heavy-duty pieces that wort be disasem: bio ke the workbench shown above an bei from the strength and eave of we knockdown fas twee offer Sometimes the bt arse “The following common examples of knock own hngware may Spur your creativity to come up wth some ides, Thee are othr types, as wel bu! these roth onc we make sure kaep on nd CSS TT TS YY Cross-Dowel. Crosedowelfastoers and bench with considerable fore This to be put to the test under Iara Forbut jens nat dea bolts av an easy way 10 makesthemanescllnchokc for frees (ike had planing large ‘wan? be under connect to pices that meet ata makinganend rin connection, _workpiewe mounted on 2 bench). Afotol stain a tightange The ilustration below Crosedowelbelisaregreatiora The age ft can be ighlened cross-dowel cot showshow they both employ the varieiyoffuriturebuilding tasks, eal to hep the bench slid. werk very well same prinaple — ace or bot pecially atachingastrecherto a The ne fing about tis design ‘reads into bometshoped nut le. The devesldets that the heeds theese of use. To prepare your embeded In a hole In the cos ofthe belt emains vise (W you project pieces for bench bls, stat necting piece By tightening the coverit with plug, you won't be bylaying outtheline forthe shank Trl the two able tighten tate) hole fr the bl. Then, dill hole pecsae Asthoramelmplisbanchbots on thelne foe tho bara. The Bar pulled are ideal for eswy-dutyapplica- elshavea sot foraerewdriverto fogether tans where the jnery & Hkely help align the hole with the al # = Draw Bott Forheayay “appicaions, Dbenen araw bol proviso leny of ‘rangi \SConnator bls area great che CONNECTOR BOLTS m ‘when comes to attaching face ‘yon can ose thom even in places ‘whee theyll be vibe Inthe lst and photo a ‘ight you can se that connector it is ed wit a matching ap clamp the parte you antl jie The other thing to be aeave of ‘ut. you's shopping fr thon together Than della holethrough is that these fasteners rut an elie beste to oer both parts both pieas You can even counter- Alken wrench to tight and the “Ty'oltencokd separately. bore thule you wane the ad si is wally metic YOU ind Unt conneccr Bol Dulin’ tobefish withthe satice Fira, dht mast eanrector ols rye te simpler All you need to do just screw the bot inthe cap not. either nox Sm wrench TITS Traded mans are ne of the cays or removal (ape Al ou nef do ie dl ole ros uf ples of Panwine eal yo went owe rab rine wre. Th lo ed ‘Sevier Doesthlsnundite sdjstten) these le wonders cn the hee ales yo se Sones? Wall maybe a area malsaer them if the tle vt ew Uttebutwtnticonmstomaking The rice Wing abo hexded driver. But whenever pose, 1 figs oaything eke tot ute ens howeay uy aro ie, ey delprestomake nthe Sv ta tat ft be inst IS ft he bead. Then ‘Send to aut aed the rset on then fhe ba ond gen he rie agate incr. Now fst Iount he Rl in he chk od Fem tio he hol ming fhe Sick nd Using ths me Sou wat ea opt st be ead you based our T-NUTS fe “Taulsaresinatovendedinses Jn tat dhoy/re dina w accem ‘mexate a mating bolo cove But ‘athe than eying on thes or the ouside, Tras ar anchored ‘lange onthe apps feof inser but theyre a bit cheaper (hout halt the pice) So, sethacrews Etheway.heyseon"t Fac some ppheations, you may inadiion future, Tutsawea tum ssyou ighen the bolt. wart tse the flange as To do ‘woh feshop appliaion. —Insemneharder woods, thebarbs this fst dil a shallow courte. ‘As the photo at Aght shows, can bend break orsplitthe work borondiesurface winga Forster some Fruts have batts tat dig pice. fitlooks ike thas thecace, bit Thon drill dhe trouser tint the werkpiee, ethers atach THLusotheserew-on ype of Fut the shaft the rat ‘we ShopNotes.com a cr sorews prevent the nut hem ar ing as you tighten ‘amatcning bat *~ top-notch results with Contact Cement. | Less waiting, instant bond — contact cement takes the hassle out of gluing up large assemblies. BE | Ter’s no qustion ut plain old ithusalong working imeancyou Several Types Therwareseveal yellow glusis number one in my dot read to mess around with types of contact cement avalable Shop. But there ae ms when ft lmps Sineit'sso diferent from The most common type sslvent- It won't wk In tee es yelow gl using onc cement eB oul ako find ay tne of the cer adhesive tat may neem intimating, Although and wstersnaed versions ie a iate oer wea eae wes yao cal ena of the main reasons contact complkated Andaneyougetthe thebox onthe opposite page ‘cet aks ge glueups hang of youl be wching for No mater which ype you use, ss ‘ontactecment mareotenton. i will ony bond s another ayer a Soo ‘TREE-PART PROCESS “nd septa rek down the process of using contact cement Into ie stages: application scembly, and sting, Ard there cag ea fe things wane point out = Fghtol tebat youre werking sh seventies te ‘ShopNotes No. 98 appropiate repirstor to pret ‘Sounel fom Ue tang fame “Application, mented aor shar eanact cement will ely bond to-anather ayer of cement, So the thing to doe apy a oat ‘ich pete you be banding. ‘Contact coment can get tacky fas so you want 1 work quick to get it spread evenly I star by ‘cating in” the edges with ‘brush a you can ae inthe main photo on the previous page. Then {pour asl paddle of cement in the middle and speed it aroun with plastic scape: The sraper ‘wll eave thick speaks. But you ‘on sce the ot im 9 gk pass with ri rller "Second Coa. Th ist contris in about 15.2 inate (Tknow when is dy tke a Took at the photos onthe baton ofthe ecing age) ind hiscoat usally sks fn thesurtce avg oly thin, patchy fm This often reals fo ‘weak band. So i's gd ie to ‘apply a sscond cont ‘The same process wad 10 apply the vend coat You notice {scoot will goon loteasier and vont ruin as mich cement. Working Time. When the scx ‘nu cot 16 dy, you's rey to ‘semble the two plese. But you ‘dont need tobe na hry In nt, the cement hes working tne of 12 hors. Sa you have plenty of tinea ge things done. And dot ‘wore Hf you can ge boc tothe task Youcan ctv the cernent by rang ona thin skim oat. “Assembly. thers any part of sg eta coment tats chal lenge the asembly. The re sr the cement sticks intonily Gad sly as som ay if touches nother cemented pice Soto getthe plecvalgned. use spacers ke the hardbead strips yo seein the photo above, When cverthing is lined up pall oxt the epicure one at time, work Ing fom the centr out AS you remove them press the pieces teeter Bly Setting the Cement The last stage of the press sting the fmt coment tenure 4 good ona You cn do this with hard ruber roller Get pho above) Low-Odor Alternatives: Spray or Water “The fumes given offby solvent based conte cement are prety song. you wank a small shop, his might nok beyourbestoption Trankflly you hve some choices. ‘Witerbased Cement. One option 10 use water Ise contact cement (polo aight I has wally ‘no oxor anes applied ist eis solvent-ased coun Best ofall clap require just coop and water, ‘Spray. An ewen quiche allemative is spray contct ‘coment fright photo). After spraying thin lyr on fexchmuting piece youcnly need eat aminate rte ‘cement ody I's pert or small projets or oesional ‘we And ve found it's joss songs the ype. sworaShop Notes com ‘A Assemble ‘and Rll. tor removing be spacers use ‘aruboer aioe to guarartee « strong bond, 1 asd to think this step ony for ling cut ac bubbles and Jumps. Bt theresa more impor ‘unt purpose: Contact eament oly develops fal sength after pres ‘sure hs been applet the it ‘And be sure to give the edges ‘xtra stent This lp seal he ‘edges 0 avoid the possi of the piers dlaminating later on. ‘The itn joint tog and resistant fo Both het and water Pas, youca hep working on te asset without wing fort tn ‘cure That's reson enguh five contact cement ry a 1 | Teitonally bo ints are used o make bores with Classic box joints and a sagt sides and amet. $0 how do you make coopered lid combine to create | stim ‘seminpe tert iam a stylish home for your tools. Sg eeioarei oe eee cae oe (eeu tye ie lest weree iDindotaseualvoe “ ‘ShopNotes No. 98 ee box-jointed Case “The ay to bling the tol chet fs hing an acura, repeatable setup for cuting box joints. The rile on page 25 wil help you Sviththes And there aea few other ‘hinge Lwantto po out. ‘Accurate Joints. The fis thing 1 want to mento is hata lot of ‘he dimensions. shown on the rowings ave Based on the size Materials & Hardware and spacing of the box it pins And sows. You can see what ean in Figure la This maans you en tse the dimensions shown in the -awings asa guideline but you [pt the eat ll i you ene the pins and sos efeenc point Don’ worry if your dimensions aren't exact As lng a5 the box Jit fi egeter, yu be fine ‘And there's another reson fr having an accurate setup. Cut ting and iting box joints on nar- row workpiece ike the drawers yon bud ater) doesn take aot Y amare Bm 0) Ath Hy W Uy Dror Frnt /Bax(2) 2M X Lepedrawer sides) Yen 1 ipe raver orem) $4411 2 wr Drawer froct Bak) 43 ‘As Lover rer sides} 18 Lowe Dine! Brim) 04 -V Pt Ce Laren) Yasin, Lda 2) 854 HE Lad Wecpes (6) ath FF Lastea) Wa +19 96092 th Woodsoens Styles Prades S1s6 115 Pe voodirems ewer Boyde) Han sHg2h, + 10)4847 Fh Wedron Sal Drawer Fon/ack@) Yonth-4%