ShopNotes #88 2006-07-01

July 2006
Issue 88

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Table of Contents

Readers' Tips4

5-Step Router Tune-Up8

Been neglecting your router lately? All it takes is a quick "once over" to keep your router on the job.

New European Hinges10

Learn more about a few European-style hinges that can come in handy for tricky situations.

European hinges, like those on page 10 of ShopNotes No. 88, can help solve difficult problems. You’ll find many of these hinges readily available from hardware and woodworking suppliers. I found the inset and 270° wraparound hinges at McFeely’s. The face frame and zero protrusion hinges came from the Woodsmith Store. The Silent Close hinges came from Wood Technology. Clip-mount options are available for most types.

Patternmaker's Vise12

Is a patternmaker's vise the ultimate workbench accessory? Learn all about it and then you decide.

A patternmaker’s vise like the one featured in the article on page 12 of ShopNotes No. 88 can really add versatility to your workbench. You’ll find these vises available from a number of manufacturers. The vise (168040) we used came from Highland Hardware.

Shop Short Cuts14

  • Page 15: Text
    Clarification: We did not specify a depth for the recess in the saw base. For most saws, 1/4" should be fine. But if the saw has raised edges at the front and back end, the recess may need to be deeper.

Sliding Carriage Panel Saw16

The secret to this panel saw is the unique sliding carriage for your circular saw that allows you to accurately cut full-size sheet goods -- whether you're crosscutting or ripping a sheet to size.

  • Page 21: Figure 5b
    Three corrections: (1) The two holes used to fasten the Lock to the Carriage at the upper right have the correct spacing, but we need to add a 7/8” dimension to locate them from the top edge of the Lock. (2) The 45° callout and associated arrows should not be on the illustration. (3) The dimension of 2-7/8" along the left edge should be 3".
  • Page 15: Shop Short Cut
    Clarification: In the "Shop Short Cut" on page 15 of this issue, we did not specify a depth for the recess in the saw base. For most saws, 1/4" should be fine. But if the saw has raised edges at the front and back end, the recess may need to be deeper.
  • Page 21: Materials list
    Two corrections: (1) Item E (horizontal grid rails) should be a quantity of 4. (2) The list calls for a 5/16" Cam lever with washer, but it should be a 1/4" Cam lever with washer.
  • Page 24: Figure 8
    The two lag screws that are used to attach the patio door roller and cable at the upper right of the saw guide were not located vertically. The first one starts 1/2" down from the top edge and they are space 1-1/2" apart.
  • Page 21: Figure 5, detail a
    Figure 5a is missing a dimension. Please note that the distance from the lower left corner of the lock to the edge of where the waste ends is 1", i.e. it's a 1/4" in from where we show the 1-1/4" to the centerline of the hole.
  • Page 51: Panel Saw sources
    The SKU for the Starrett tape is incorrect. The correct SKU for the left-to-right tape is 273740.

Online Extras

  • The Ultimate Shop-Built Panel Saw
    In ShopNotes issue 88, we've re-thought the panel saw to make it fit into a small shop. This design requires only 10 feet of wall space instead of almost 18 feet that a traditional panel saw would require.

You’ll be able to get almost everything needed to build the panel saw on page 16 at your local hardware store or lumberyard. But there are a few pieces of hardware you’ll probably need to order to complete the project. The 48" T-track (21753), the 5/16" cam clamp (58244), the 5/16" x 1" T-bolts (33965), and the 5/16" x 1" knobs (34121) came from Rockler.

The toggle clamps (213-U) and the 4' (331276) and 12' (331272) selfadhesive tape measures came from the Woodsmith Store. Similar tapes are available from Starrett.

Open Floating Tenons26

You can create rock-solid mortise and tenon joints on your router table -- with nothing more than a straight bit.

Online Extras

  • Open Floating Tenon Joinery
    When you need to make a lot of mortise and tenon joints, you might want to consider a floating tenon joint as shown in issue 88 of ShopNotes magazine.

Stacking Storage Totes28

It's difficult to combine quick and easy hardware storage with portability. These stacking hardware totes give you both.

The wood and hardware you need to build the shop totes on page 28 of ShopNotes No. 88 can be found at your local hardware store or home improvement center. But you’ll need bins to go inside the totes to organize and store various items. The bins I used were small storage bins (Model 30210) made by Akro-Mils. These bins are also available from the Woodsmith Store.

Metal Jeweling30

Adding a decorative touch to metal surfaces is easy with this simple technique.

Using the metal jeweling technique on page 30 of ShopNotes No. 88 adds a customized look to the metal parts of any project. The 3/8" x 6" medium grit cratex rod that was used to make the pattern shown on the plane in the article came from Tool Crib.

You can also get an “engine turning kit” (080-558-101) that includes many of the items you need. The kit I used came from Brownells. You’ll find ordering information below.

Dovetailed Shoulder Plane32

The heirloom-quality of this shoulder plane is easily seen in the solid brass sides dovetailed to the steel sole. But it's the micro-adjustable depth of cut that will have you using it again and again to fine-tune the joinery on your projects.

  • Page 33: Materials & Hardware
    If a 1" Brass Lamp Shade Riser cannot be found or is not available, you can instead use a section of 1/2"-dia. brass rod then drill and tap it for the threaded rod. Then turn it to shape on the drill press as explained in the article on page 37.

A shoulder plane you build yourself, like the one on page 32 of ShopNotes No. 88, will become an heirloom and a great addition to your shop. To build the plane, you’ll need some hardware and metalworking tools.

First, you’ll need low-carbon steel (9517K16), brass sheet material (8956K44), and a small brass rod (8859K155). You’ll also need a scribe, layout dye to mark the lines on the metal, and metal files to work the material. I was able to order all of these items from McMaster-Carr. The #410 Clifton plane iron I used came from Highland Hardware. The brass lamp shade extender I used for the adjustment knob was picked up at a local hardware store.

Metalworking Tips & Techniques40

Working with metal isn't all that difficult. These tips and techniques will get you started.

Workbench Location44

What's the perfect location for a workbench? Find out what to consider before you decide.

Bending Plywood46

We'll show you a simple table saw technique for bending plywood into a smooth curve.

Hearing Protection48

Protecting your hearing is a must. Here's what you need to know to do it right.

  • Page 51: Headphones source
    Web site of noise cancellation headphones should be: www.protechcommunications.com. notice the "s" at the end. Not listed was the website for the headphones: www.noisebuster.net.

Hearing protection devices, like those on page 48 of ShopNotes No. 88, are a safety requirement in any shop. You’ll find many types of ear plugs available at most home centers. The foam ear plugs (25R01.01), Express plugs (22R17.05), and the Airsoft Plugs (22R72.50) all came from Lee Valley.

To get the ZEM hearing protection unit (Z01RE0100) you’ll need to order it directly from SensGard. You can find contact information below.

I was able to order the Noisebuster electronic, noise-cancelling ear muff (Model PA4000) from Pro Tech Communications. You can use the contact information below to order these hearing protectors.

Q&A50

Scenes from the Shop52