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19785068 UNPDF

Shop-Built Workbench

.Raised Panel Routing Jig

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EDITOR Douglas L. Hicks

MANACINC EDITOR Terry J. Strohman

ISSOCI~TE EDITOR Richard S. Peters

ASSISTANTEDITOR Tim Robertson

coNmleunnc EDITOR Phillip A. Totten

heard, "that's the way it has

always been done."

All to often woodworkers get "bogged

down" thinking about the way things

should be done, and we don't think about

the way things could be done.

WORKBENCH. A perfect example of

this is the Workbench featured in this

issue. Paditionally the top of a work-

bench is glued up kom several pieces to

form a large, thick slab.

This requires a large amount of wood

(which can be expensive). And a good

deal of time and effort.

What we wanted was the look of a

traditional bench without the work.

Kent Welsh (our Designer) came up

with a different approach. The top of

the bench starts with a plywood foun-

dation. Then thin hardwood strips are

glued on. Less wood, less effort.

PUBLISHER'S STATEMENT. You've

probably noticed that a good portion of

this page is taken up by a rather official

looking document. It's called a Publish-

er's Statement. Once a year the Post

Office requires us to print this. Basically

it lets everyone know how many issues

are printed, and how they're distributed.

Now, I'll admit that I sometimes

loose track of time, but when Phyllis

Jessen (our Subscription Manager) re-

minded me to included the Publisher's

Statement in this issue, I was shocked.

Having to fill out the the Publisher's

Statement was like getting a birthday

card. It reminded me that one year had

passed since ShopNotes was '%om."

The past year has been very exciting

(and very husy) for all of us. The re-

sponse to ShopNotes has been better

than we hoped. We now have over

165,000 paid subscribers.

I want to thank all of you for helping

us through the first year. And to let you

know that we have lots of great pro-

CRUTEVE DIRECTOR Ted Kralieek

ART DIRECTOR Gary Christensen

SENIOR ILLUMTOR K~l't Sch~lt2

Iwusmrrons Will Niskanen

Roger Reiland

Mark Higdon

PHOTOGRAPHER Crayola England

DESICW DIRECTOR Ken Munkel

SENIOR DESIGNER Jan Hale Svee

DESlCNEa Kent Welsh

SHOP YLN~CER Steve Curtis

Mamger: PhyULF Jessen . Cir&tim Analyst

Rod Cain- Newsstand Sales: Kent A BneMon

WBLISHIm SUIVICES

Aasoeiola Edito?:Gordon C. Gape. S7 Graphic

Desip: Robert H. Whitmer

COR-TEIERYICEI

Conhu1lw:Paul E. Gray. Aecm%biw Linda O'

Rourke - Bookkeeping: Julianne Spears -Z*fo.

Sewices Manager. Joy- Moore . Netwnrk

Admi*: Douglas M. Lidster . Administrative

As&.: Cheryl Scott, Jdja Fish Receptimist

Jeanne Johnson . Bldg. M&t:Ken Gath

STATEMENT OF OWNERSHIP, MANAGEMENT AND CIRCULATION

(Requjredby 39 U.S.C. 3685)

1. Title of Publication: ShapNotes. la. Publication No.: 10629696.2. Date of Filing: September

24.1992.3. Freauencvafissue: Bimonthlv. 3a. No. ofissues~ublishedannuailv: 6 (six). 3b.Annual

subscription pri&: $16.95.4. Complete mkingaddress af&own Mee ofpubkcatim: 2200 Grand

Avenue, Des Moines, (Polk County), Iowa 50312~5306.5. Complete miling address of the

Laura MeNelly . Prqled Supplies: Linda Jones

.Technical Supp&:JeffJanes .Systems apara-

tor: Linda Momow nReeeptionist Keri Lea

CUSTOYU IERVlCE

Sde Supemisor Jennie Enos = Customer

Sovice Rep7esentative.s Jennifer Murphy, Joy

Johnson, Sara Kono, Ami Blanshan,AnnaCox,

Chris Lo

Managing Editor: Terry J. Stmhman, 2200 Grand Avenue, Des Moines, Iowa 50312.7. owner;

9. (Does not a<pl~..) 10. Extent and nature of circulation:

. -

SWIPPlNG mPMYEHT

Su~:JenVCarson-Fu1~moU:GI~liaShee-

ha.h Mcvex Chuek~m,

"

to filing date

Sylvia Csrey

A. Total no. copies orinted (net orem run) ................. 184.400

199,000

ShopNotee (ImN 162-9696> is pubbhed bimonthly

(Jaw, &h, May, July, Septetebebe,Nwemherl by

Woodsmith Cornorstlo". 2200 Grand Ave.. Des Moinea

i~~o~i~.~tiniedrn

B. Paid andio&eqiested c&&tion:

O.S.A.

ShopNoteekatrademk of Woodsrmth Corporation.

eopylight 1993 by WoodsmithCorporation. All

d%.h,.? ,".se",pd

D. Free distributionby mail, carrier or other means. samples,

complimentary, and other free copies.. ............ .: ........ 26

E. Total distribution.. .................................. 151,306

F. Copies not distributed

1. Office use, left aver, unaccounted, spoiled after printing 20,849

2. Retmsfrom newsagents.. ........................ 12,245

G.Tatal. .............................................. 184,400

11. I certifv that the statements made bv me above are mmd and comolete.

(signed) Donald B. Peschke, ~ublishLri~ditor

p;idddt Des Males, lA and

at additional offices.

PostmS.de.: Send change of address to ShopNotes,

Box 11204. Dm Moines, 1A50340-1204

Subseriptioa Buestioas? Cau 1-800-333-5854,

8am

ShopNotes

No. 7

Illllp=--

ssue 7 January 1993

EDITOR Donald B. Pesehke

EXSCUTIVE

H ow many times have you

omcuunow

Cimdatim hdar: LizBredem-Su6srriptzOn

-Em IUPPUL6

Marketing Di7ector. Robert Muny .ArtD(rec-

tor Cindy Jackon . Customer Sewice MF:

8-nd ~1.2~oshpe

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ISSUE NUMBER SEVEN

--

I

Contents

fbised enel Jig 4

Rout a perfect ra~sedpanel door or drawer usfng a

route< a strafght b~t,and this shop-madejig

Raised Panel Jig

Block Plane 7ips 8

From planin; end and edge grain to trimming small

pieces, here's a few tips that will provide crisp, clean

cuts every time.

Sanding a 5urface Flat 10

2 it takes to produce a perfectly flat surface is a belt

sander and four simple steps.

Rust Removal 12

Practical solutions for removing rust and restoring tools

to a usable condition.

Keyless Chucks

14

B)

Changing drill bits without a chuck key is quick and easy

wfth this handy accessory for your portable drill.

Workbench 16

This workbenchfeatures a solid base that knocks down

easily and a top that's built up of plywood and thin

hardwood strips.

Shop-Made Kse 23

A massive wood face, iron guide rods, and a manufac-

tured vise screw combine to provide even clamping

pressure that holds a workpiece tight.

I

Four shop-tested tips: Dowel Cutting Jig, Shop-Made

Bench Clamp, Rip Fence Alignment Gauge,anda Glue

Brush Tip.

Board Footage 30

Calculating board feet takes the guesswork out of de-

termining the cost of a project.

Sources 31

Hardware, project supplies, and mail order sources for

the projects in this issue.

Shop-Made Vise

Page 23

3

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All that's needed to make a raised

panel is a router, ano~dinary

stmight bit, and this simplejig.

S ometimes a jig works out

-.-

even better than expected.

We originally designed this

raised panel jig to rout square or

rectangular pieces. But after

working on it, we found that a

simple modification allows you to panel is passed under the router.

rout curved raised panels as well. This creates an angled border .,.

principle of the jig is the same. that "raises" a field in the center. . .:

.

The router is held at an angle BASE. I began work by making -

over the workpiece. Then the the plywood base (A), see Fig. I.

Thebase can be asbig as you like.

It just needs to he large enough - ..

to support the workpiece. (In my , :: ~.

case, the base is 24" square.)

~-

FENCE. Once the base is cut to

la. When routing a curved panel, e

the fence is replaced with a "pin."

(For more on making curved

raised panels, refer to page 7.)

assembly.This assembly suspends .a': -

the router at an angle over the

workpieee. Since the router is .;-

tilted, an ordinaxy straight bit can " . .~

he used to rout the angled border.

GUIDE RODS. The router is held ..-?*

at an angleby a pair of guide rods,

see Fig. 1. These rods are 16"

lengths of 1A"dia. steel rod that I

hought at the hardware store.

(There's also a source on page 3 1

ROD BLOCK

.)

GUIDE ROD BLOCK The rods

are supported by a guide rod block

(GI. This is two 3A"-thick pieces of

hardwood glued together, see Fig.

2. Then two holes are drilled to

accept the ends of the guide rods.

The trick is to tilt the rods at a 8

slight angle. This angle eventu-

ally determines the angle of the

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Regardless of the shape, the around the edges of the panel 7;

size, a hardwood fence is in-

stalled.Thefence (B) is serewedin

a shallow dado in the base, see Fig.

The heart of the jig is the &age

..

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!

@ border on the raised panel. To

create theangle, the bottomedge

of theblock is beveled before glu-

ing and screwing it to the base,

see Fig. 2a. Then the rods are

epoxied in the holes.

sLmmG PLATFORM. With the

rods in place, the next step is to

add a sliding platform. The plat-

ROUTER ON MOUNTING

PLATE TO TRANSFER

SCREW HOLES AND

-

- . forth on the guide rods to in-

. ..

.~..

crease the width of the border. It

& consists of three parts: a mount-

--.~ ing plate, a pair of rails, and a

. finger guard, see Figs. 3 and 6.

MOUNTING PLATE. The moU%t-

-. ivqplate (D) is a piece of V4" Ma-

sonite that replaces the original

base of the router, see Fig. 3. (I

used the original base as a tem-

- plate to locatethe mounting holes

and the opening for the bit.)

WS. After marking and drill-

. ing the holes, a pair of hardwood

rails (E) is added, see Fig. 3.

Holes at each end of the rails fit

over the guide rods and allow the

platform to slide back and forth.

To keep the platformhm bind-

ing, the holes need to align with

the guiderodsand with each other.

To do this, I taped the rails to-

gether with double-sided tape and

thencenteredthe holes 71ht'apart,

see Fig. 4. Note. Sand these holes

MASONITE)

1

rail adsas part of a clamping sys-

tem that locks the platform in

place. After cuttingthe kerfs,the

rails are glued and screwed to the

mounting plate, refer to Fig. 3.

CLAMP. NOW

the bolts, the kerfed ends of the

rail pinch against the guide rods

and lock the platform in place.

FINGER GUARD. The last step

is to add a finger guard. The

guard is a piece of V4" plexiglas

that's screwed loosely to the hnt

rail,seeFig. 6. Two slotsand abev-

eled bottomcornerallowthe guard

to "rideup"ontop of the workpiece

as it's passed under the muter.

Slip a thin piece of

wood in the kerf to

prevent the drill bit

from binding.

-

the clamp can he

completed. What makes the clamp

work is two carriage bolts that

pass through holes drilled in the

ends of the kerfed rail, see Fig.

3a. By tightening wing nuts on

lightly so the rails slide easily.

Before attaching the rails,

there's one more thing to do. And

that's to cut a kerf at each end of

Hardwan

-

om rail, see Fig. 5a. Later, this

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RAISE BLADE TO

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OF ONE RAIL ONLY

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No. 7

ShopNotes

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