ShopNotes_055.pdf

Issue 55 1

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our router tab,

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PUBLISHER Donald B. Pesehke I

EDITOR Tim RobertSon

A~~OCIATE

EDITOR Bryan Nelson

conraleurlne EDITOR JoelHess

rnr DlnEcron Cary Christensen

SR. GRAPHIC DESIGNER K& Seh~lt~

SENIOR ILLUSTRATORS Roger Reiland

Mark Higdon

C an't you leave well enough alone?

Chip Separator - To avoid having to

empty the bag as often, the chip separatov

captureslarge chips before they get to the

dust collector. These chips are deposited

in atrash can which is quicker and easier

to empty than the dust collectnr hag.

Control Bnx - The second project is

a dust control box. It provides a way to

connect three tools to the dust collector

at the same time. So there's no need to

constantly switch the dust hose from

It seems like I've heard that ques-

tion as long as I can remember. To be

honest, the answer is no, I can't. Come

to thii of it, most woodworkers I know

can't either.Which isn't really a had thing.

It's one reason we're always looking

for a way to improve the quality of what

we do. Making a joint that fits a bit

tighter and looks a lot better. Applying a

smoother finish. Or building a jig to

Johnson - SetimPhd~ppher Cccy~I~E~gland

SPECIAL puemnotm

Ezemtive Edih Douglas L. Hicks . St Gmphic

Nguyen, April W Janning . Ass<. Editors: %g

Ruegsegger,Joei A Hess

GIUCULATION

make atricky cut safer

one tool to another.

Most woodworkers I

or more accurate.

know can't leave

Instead, there are

NOW don't get me

three blast gates that

well enough alone . . .

Amlystg Kris schlemmer, Paula DeMatteis . Reneul1

ML,"ngsr Psi@ Rogers. Sr Gmphie DePignars: Mak

h s

wrong. The goal

control the flow of air

which isn't a bad thing. me,, ,, ,,,

to come up with the

at each individual tool.

Hayes, Robin Dodeli . Billing & Colleetiow Mp:

Reh-Chgham-Pmm

technique or to build a perfect project.

It's the puoces of starting with some-

thii that already works and then

making it even better.

Dust Collection Upgrade -The dust

collection upgrade featured in this issue

is a good example.The idea for this pre

jed startedwith a portable dust collector

we bought for the shop awhile back It's

a small, roll-around unit, the type thafs

designedto conned to one tool ata time.

Well the dust collectorworks fine. But

to he honest, I get lazy sometimes, and I

don't always connect the dust collector

before using a tool, especially if I only

need to make one or two cuts. So I end

up sweepingup chips or breathing dusty

air anyway.

A bigger problem is the bag itself. It

ills up fast, and it's a dusty chore to

empty Plus, putting it back on is a real

juggling act that requires three hands.

The point of all this is that even

though the dust collector does its job,

there's room for improvement. That's

where the dust collector upgrade comes

in. It consists of two separate projects: a

chip separator and a dust control boz.

oerfed woodworkine

. &

blast gate, it's like flipping a switch that

allows chips and dust produced by the

tool to he pulled through the control box

and out to the dust collector.

LowTech, Hi&-Performance -Just

one more note. You won't have to invest

a lot of money in material to build these

Mp:Ri&J&

projects. Made of plywood and plastic,

they're a low-tech solution for a high-

performance dust collection system.

More Improvements - Of course,

striving to make improvements doesn't

applyjust to woodworking. It's a big part

of woodworking magazines as well.

We're hys

Dmey M Rap: John Audette . Cat. Sm.Rep:

Anna Cor, Tammy Menbmd,Deborah Rich Apd

Pxrav~mry,~skmm

W~~S~lvia~y.

loolringfor ways to make

ShopNotes a better magazine. One way

to do that is to find out what you like (or

don't like) about this issue of ShopNotes.

We'd also like to find out more about the

type of projects and techniques you'd

like to see in upcoming issues.

To accomplish that, we've posted a

short questionnaire on our web site. By

visiting us at www.ShopNotes.com and

filling out the questionnaire, you'll help

us make a good thing better. (Youll also

have a chance of winnii a free router.)

I look forward to hearing from you.

DanSpidle, Sh~IlKn~%

AlV~ipt

Manngm:DaveLarson .Sa1a~Sto~Wwd~uStttttJim

Bmett, Kathy Smith, Lmy Mamison, Hamld

Cdmmn, Tun Thelen, Gregory Kawkieh, Mark

Johnson,JoeKum. OfiifiifiiM~nng@?VI"ldEdvmi8

by August ~omi

Puhiishmg,2200 Grand, Des Momes, IA 50312.

GhooNotes@iFareeisteredtiademark of AmstHame

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Publishing. Allrightsres~wed.

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PRINTED IN U.5.A

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ShopNotes

No. 55

Cnl!Amn~UDCrn

Craativa &rector: Ted Kdieek Project Developsr

KenMunkd. hj#d Codiitor:KentWelsh Shop

Mannger Steve Curtis . Shop Cmftsman: Steve

Designrr Chris G1owaeld . Gmphic Des*~:

S-

iXmdm Srmdy Barn. NBW

&sines Drr: Wade QmW. Czdtimtim Mmedng

.,.,I om-

OpoatiaM Lhmdor: Bob Baker. Custom S&e

Johnson. Buyer kda Jones . Admi,,. Asst Nm'y

Manngm: Jenaie En- - Wmhouse Swpr: Nancy

(.Jan:, Mar& May, July, Sept.;~&)

Contents

Features

Two-Handled Push Block 6

Two handles, two clamps, and two replaceable backer

boards - together they make a handy push block for the

router table that elim~natesend-gram chipout

Push Bloclc

HVLP spray 5ystems 10

A high-volume, low-pressure (HVLP) system makes it quick

and easy to spray on a glass-smoothfinish. Is it right for you?

To find out, we take a look at two types of HVLPsystems.

spraying a Flawless Finish 12

There's more to spraying a perfect finish than squeez~ng

the trigger on a spray gun. We show you practical t~ps

and

techn~ques

to ensure a professional-looking f~nlsh

Dust Collector Upgrade 16

Take a good th~ngand make it better That's the ~dea

beh~nd

these two shop-bu~ltpmjects des~gned

to improve

the performance of a portable dust collector:

In-Line Chip Separator

the bag -on your dust collector

that is. This separator captures the large chips produced by

your tools and deposits them In a trash can.

3-7001 Dust Control Box 21

Tired of switching a dust hose from one tool to another?

Build a control box and connect three tools at once.

Roll-Around %om-All 24

It's like having a lumber yard In your shop Storage for long

boards, short cutoffs,andsheetmaterial.Also, an optional

guide for culting large panels into manageable-sizedp~eces.

Dust Colkctor Up&

page 16

Readers' Tips

Shop-tested t~ps

to solve common woodwork~ngproblems

Too1 Talk

Tw~stb~ts

dull? Get them sharper than new with Drlll Doctor.

5ources

Sources and supplies for build~ng

the prolects ~nth~s

Issue

Don? get caught hold~ng

-- -

TIPS & TECHNlOUES

' Tips

Rule Guide

rately lay out a line. You simply align

the end of the block with the desired

increment on the rule. Then mark

the line, using the block as a guide.

To allow the rule guide to slt flat

on a workpiece, the bottom edge is

rabbeted to fit over the metal rule

@t more wood-

mKmg tip$ free.

W A metal rule is great for meas

uring, but it can be difficult to use for

layout work. The problem is the

thickness of the rule itself. It creates a

"step" between the surfaceof the rule

and the workpiece that can make

transferring amarkless than accurate.

My solution is the simple rule

guide shown above. Ksa small wood

block that makes it easy to accu-

I also added a small magnet to

hold the rule guide in place, yet still

allow it to slide along the metal rule.

The magnetfitsma hole that's drilled

in the rabbeted edge of the strip.

After cutting the rule guide to

length, it's just a matter of sanding a

bevel on each end to ease the sharp

edges and then gluing in the

magnet (I

Colorado Springs, Colorado

a =rntiPam4

Replaceable Fence Insert

email every week.

I couldn't be more pleased with table saw. To reduce chipout, I even fits into a dovetail-shaped recess

the Adjustable Miter Gauge Fence added a hardboard fence insert that near the end of the fence (Figure 2).

featured in ShopNofes No. 53. It defi- can be easily replaced when it gets Note: To accommodate the insert I

nitely helps me make quick, accu- chewed up Fire1).

To make the insert redaceable. it alms called for.

All thafs needed to cut the recess

is a dovetail bit and a tablemounted

router (Figure 2a). After removing

all of the waste material it's just a

matter of cutting an insert to fit

(While you're at it, you may want to

make several extm inserts.)

To make the inserts, start with a

long strip of hardboard that's about

l/ql wider than needed. Then use the

same dovetail bitto bevel both edges

of the strip, sneaking up on the Ed

width to create a smooth, sliding fit.

Finally, cut each insert to length toe

match the height of the fence.

Rich Wagner

Hadlq, Massachusetts

made my fence 3" longer than the

used epoxy)

Richard Hoffma1z

Si up to receive

rate setupswhen crosscuthu on the

controlthearnouni ofmo~emmt way, all I have to do is "tweak" the

To make a more amrate axljust- sgem to raise or lower the table in

ment, I install a Tnat and a sokt preciseincremmts.

head&mewinthetable over each

%el& Tomhip, Michkan

01at Bimb

Plans Hanger

w To keep woodworking plans and toolmanualsin reach

I made a hanger that fitsinto a bracket under my bench.

The hangw consists of a metal ring assembly from an

old threeringbinder tkats mounted to a strip of '/a1' hard

board with machime mews. (See drawing and detail.)

To hold the hanger, it fits into a T-shaped slot that's

formed by a twolpart bracket. Each part of the bracket is

a rabbeted wood strip that's screwed to the bench.

Marty Burger

Northfield,Minnesota

Quick Tip

'A . ,r,rll CI L(",V.\ "Yay LU aCa,a,,

open tube of caulk so it won't dry

out. Jim Labyak of Kenmore, WA

pushes the tip into a wax ring.

tipping, Chuckpierce of Lugoff, SC

puts a weight in it. A string lets him

puii out the weight before emptying.

If yvu have a unique shoptip, wdd 1%

to considerfea- itinoi&rmore of

OUE print or electronicpubh~ations.

We'R pay yp to $200 fm @p we pub-

lish. Just mite down therip and maiLit

k~ SMNotes, A%.: Readers' Tips, 2200

Grand he., Des Mohes, IA 50312. Or

PAX ittn.515-282.6741, or s,endus in

e~aail at shopnotea@shopnoteacom.

Please. include your namd, dddrefjs'

anddaytimephpne number in casewe*

haveany questions.

No. 55

eo~ner of the metal saw base. llis

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