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HEAVY-DUTY # -

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1'.

Cutoffs

W~USHER Do~ald B. Peschke

EWTOR R~ehard 5. Peters

ms-ocm~~

;

I '11 never forget my first workshop. It

mrroar Tun Robertson

Phil Totten

was the second bedroom of a "single

wide" mobile home. Eight foot by ten

foot. Although it was small, I still man-

aged to build a houseful of furniture.

And alongthe way, I learned some valu-

able lessons.

Like making sure a project fits

through the door of the shop after it's

finished. (It's amazing how narrow

some doors are in a mobile home.) And

maybe iust asimuortant. Ilearned

There he was in a cloud of dust, power

sanding on his lathe.

With the helmet on, I couldn't tell if

he looked more like Darth Vader or one

of Jacques Cousteau's scuba divers.

Nevertheless, he talked me into giving

it a try. The helmet took a little getting

used to, but it was surprisingly com-

fortable. And it worked great.

CHANGES. Just as we try new things

in the shop and make changes to the

way we work wood, so it is in the

Mark Higdon

EREIIIVE RmURCES

1

ea.nnv.ma.srom 'I'cd lirdicek

UTC.MV=

nweer OESI~NLUREETO~ Ken Mdel

ROJECT WIQNSR KentWelsh

snap Steve Curtis

:IIFIWM SteveJohnson

rwluplrEa Crayola England

=c-onnr wsrls~ure Douglas NZ Lidster

~-macearpwlw Chris Glowaoki

c.ec.coumuulcrnow Gordon 0. Gaippe

ausnucrn~lrr CherylL. Gynor

emom l)uuglus I.. Hick,

" "

the value of containing

trolling sawdust.

A SNOWSTORM. In such a

small shop, a few minutes

-

CIRCUUTIOU

Waonphon Mwmagm. Sandy Baum, Tmy

Dowell, Pslge Rogers .Asszstant Suhsenphwa

Mamg-. Julie Grewlee ~N~wsstand

Because we're growing

working with a router or

and trying new things

Malzager:

ripping stock on the table

(such as the launch of our

Kent k Buckton

sawwasaUittookto!3ltheair

new gardening magazine,

WIITh SBIYICE5

Plan Dzreet~1.JonMacarthy.C~%ho11~)1Robm

Huhhkmn-SenmvAoct LauraBo--BFp'

HoUy Lucas-Pmduchomh.GeorgeChnuelan:

.PrwL My.. Carol hano .Prof: Develqxnnz*

Joyce MOOR. Net Adm. Nlck'kden.&t%

As&..

(and my lungs) with dust.

Gardm Gate), we've changed

And the worst part was

our company name to

this dust hung in the air

like the snow inside a glass

paperweight, see photo.

Well, they say necessity

Chew1 Sea Juha FL4h - Remp?m&t

Je~nneJohnson.Buddin~Mant. KenGrdEth

UllL DRDER

Opewhons Divectm. Bob Baker -tL-t fhvsdm

Cindy Jaekson Mbls My., Mark MathtJsi

4ustmwS~Mp:Jennie

try new things in the

is the mother of invention.

'%ow-to" area - like addi-

I quickly set out to find s

ways to control sawdust and keep it out

of my lungs. From fans with filters to

vacuum attachments for my tools. (For

more on containing dust in the shop, see

the article on page 12 and the sanding

tableffilter system on page 4.)

DUST MASKS. But that still didn't re-

move all the fine dust floating around

the shop. So I got in the habit of wear-

ing a dust mask. It's one of the most

effective ways I've found to keep dust

out of my lungs.

Still,even though I was used to wear-

ing a mask, I have to admit I was a bit

skeptical when a friend of mine sug-

gested I try out his new full-face dust

helmet (for a photo, see page 13).

So I took him up on his offer and

stoppedby his workshop oneafternoon.

Enoa*Worehrmnk

The only change here at ShopNotes

is Don is now the publisher (a role he

has been moving towards for some time

now), and I've picked up the responsi-

bilities of editor.

But nothing is going to change that

much. As always, we will continue to

bring you practical and uniquejigs, pro-

jects, tips, and techniquestomake your

time in the shop more enjoyable.

If you have the time, drop me a line

and let me know how things are going

in your shop. Send a photo of your

workshop or latest project. Or share a

tip, story, or anecdote. I always enjoy

hearing from other woodworkers who

know what it's like to scratch their

heads and wonder how they're going to

get that project through the shop door. bh

Johnson. &yo. JaditJones

laonin. Teohnical Support. David Stone

9zmtonzer Smee Reps : Jentufer Murphy,

Same, Sam Km, Anna Cox, Adam Best,

;ti Andrews . Warehouse. Gloria Sheeh,

ckCarhn.SviviaCarev.LmPdne

iaws), $19 85 nFo years C12 issoes), WS 95 Can-

,mku,add$5Mpu~esr

-nd Class Postaee Paid &toes MomIA an&

cow, )a 9s ~

n

~

~

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b

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Supvlor. Nq

;rip@- sm$e

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Projects & Techniques

Sanding Table & Air Filter Sy5tem 4

Solve two problems at once w~th

thls mob~lesand~ng

table It collects the dust produced when sandrng And

it filters fine dust particles out of the ai,:

Sanding Table

PW 6

bttern Cutting on a Band Saw 8

You can cut identical curved pieces quickly and accu-

rately on the band saw by using this simple technique.

Arvhed-Top Clock 10

Its hard to stop after makrng]ust one of these arched-top

clocks We offer several tricks to get "production" roll~ng.

Heavy-Duty Workbench 16

You won't spend a lot of tlme or money building thls sturdy

Arched-Tq Clock page 10

workbench Made from ordlnary constructionmaterials, ~ts

large work surface provides several clamping options.

Departments

mSit1a1 Shqa

Sawdust in the Small Shop 12

Two strategies for dealing wiih dust. Contah as much

as possrble at the tool that produces the dust And use

filters to keep the fine dust particles out of your lungs.

14

From mak~nga center marker to drawrng arcs, here's a

collection of quick trps for getting accurate layouts.

22

Confusedabout the bestband saw to buy?Our threeman

team puts SIX medrum-duty saws to the test and offers

aracttcal suaoestions on which one to choose.

the d~fferentgrades of softwood plywood w11l

he$ you select the best materral for the prolect at hand.

Fin* Roan

5pecialLy Finishes 31

Two specal finishes wiih a twlst One creafes the lookand

Band Saws

page Z2

feel of grante. The other gives the appearance of marble

No. 24

ShopNotes

3

Our readers offer their own shop-tested solutions to some

of the most common woodworkina amblems.

mberyard

5&wood Plywood

Know~ng

I

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sn- Ifu J

Table

& Air Filter System

0 n the outside, this sandingtable and air filter

systemlookslike an ordinary cabinet. It'snot

until you open the door and look inside that you

start to appreciate how it really works.

BLOWER~MOTOR.A~

the center of the system is

a blower/motor that pulls air down through a per-

forated top, see the drawing below. This way, the

A This shop-built sanding table pulls in the

fine dust that's produced when sanding is drawn

dust that's produced when sanding And it

znszde the cabinet instead of

the air in the shop.

doubles as an afr filter system for your shop

But there's more to this project than just a sand-

ing table. Even when you're not sanding,it doubles below. These filters screen dust particles out of the

as an air filter system for the shop.

air before it's returned to the shop.

Note: We used a i/s hp motorhlower that moves

FILTERS.~~~~

makes this work is the air passes

through a series of three standard fumaeefilters - 465 cubic feet of air per minute (dm). For a complete

two above the blower and one below, see drawing hardware kit that includes the blower, seelist below.

INCOMINGAIR AND Durn

PAKllCLES ARE WWN

THROUGH PERFORATED mP

FURNACE

FILTERS

SCREEN

Case

e

DUST

-ARTICLES

I started on the sanding table by the case are made from 3/4"-thick

making the case, see Fig. 1. In MDF (but plywood would also

addition to supporting the top, it work), see Fig. 1. These pieces

houses the air filter system. To are held together with a rabbet

provide anexhaustfor the air from and groove joint. To ensure a

the blower, the bottom of the case tight fit, it's best to cut the groove

is open. And the front is left open intbe sides first,seeFig. la. Then

for a door that's added later. cut rabbets in the back to form a

The sides (A) and back (B) of tongue that fits the groove.

(A) Sides (2)

26y4wx 32" - 3/4" MDF

(1) 465 cfm Squiml Cage Blower

(0) Back (1)

(2)3"-dla. Fixed Casters

/4" x 174" - 16'/2"

(2) 3"-dla. Swivel Casters (Locking)

(D) Btm. %&hers (2) 74" x 3" - 16Yz"

(16) #14 x %" Panhead Screw5

. (18) #12xY4"Fh Sheet. Metal Screw

lt/q8' - 18"

(16) V4" Flat Washers

(12) #8 x 1" Fh Woodscrews

(E) Trim %rip (1)

18"x2T - Y4" hboa*

(F) Top (I)

l8"x 3O1fi6" - %" MDF

(1) 1yZ8lx30" piano HI^^^ w/~cmw

(6) Door (1)

V4"x 19/4" - 25%"

(H) Tray Sides (6)

(12) #8 x 2" Fh Wuod5orews

(I) Tray FrtsJBks. (6) %"x 1%"- 16"

(30)#5 x lY4" Fh Sheet. Metal Screw6

16Wx25W - 74" MDF

(J) Sliding Shelf (1)

(6) #lox %" Panhead Screw

~ RETURNED TO SHOP

(Kj Cleat6 (2)

3/4"x f3/4"- 25'/2"

(1) @/4" Door Pull (Maple)

(2) Roller Catches wI5crew

* (5)l" x 16" - 26" Air Filters

To order a complete haraware krh call Shop-

Notes Project 5upplm at 1-500-444-7527

(25 feet.) Y4"x '/2" Weatherstrip

524-652P150 ...................................... $9. (17feet) Y4"x 3/a" Weatherstrip

4

ShopNotes

No. 24

7yx32" - MDF

(C) Top %re&her (1)

3/4"~

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To increase

airflow, first

enlarge the holes.

in the top. Then

chamfer the edges

with a countersink.

TRIM STRIP AND

STRETCHERS

ARE %" STOCK

STRETCHERS. To add rigidity,

three hardwood stretchers span

*the case. A narrow top stretehar

(G) runs across the front of the

case and helps support the top.

And two wider bottom stretchers

(D) double as mounting plat-

forms for casters (added later).

ASSEMBLY. After dry assem-

bling the case and cutting the

stretchers to fit, you can glue the

sides and back together. Then

just screwthe stretchersin place,

see Figs. 1 and lb.

TOP. Thenext stepis to add the

top of the sandingtable. It's sup-

ported by the case and a hard-

wood trim strip (E) that's glued

to the top stretcher (C).

To draw dust down into the

case, the top (F) is made from a

piece of 14"-thickpegboard that's

cut to fit flush with the case. But

before attaching the top, there

are a couple of things to do.

To improvethe airflow,enlarge

each opening in the pegboard by

drilling a s/s" diameter hole, see

Fig. lb. Then, after countersink-

DOOR TO provide easy access

to the air filter system, the next

step is to add a door (G), see Fig.

2. It's a piece of 3/4" MDF that's cut

to the samewidth as the case (18").

But to provide clearance when

opening and closing the door, it's

1/16" less than the distance he-

tween the trim strip and the hot-

tom of the case (3011/16"). After

attaching the door with a piano

hinge, I added a wood pull and a

pair of roller catches.

CASTERS. NOWall that's left is

to screw casters to the bottom

stretchers. To make the table easy

to roll (yet still provide a stable

work surface),I used two locking

swivel casters in front and fixed

casters in back, see Figs. 2 and 2b.

.

ing the holes (seemargin), simply

screw the top in place and rout a

small chamfer around the edges.

CHAMFERS ON

OUTSIDE EWE6

OF DOOR

No. 24

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