ShopNotes_007.pdf
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Shop-Built Workbench
.Raised Panel Routing
Jig
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
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
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
.
;
..
ShopNotes
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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
..
. .
.,.
.~
. ~~..
.
..
.
,
!
@
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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MAXIMUM HEIGHT
OF ONE RAIL ONLY
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No.
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ShopNotes
.
.
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I-;{iil.
,
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fonn carries the router back and
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