ShopNotes #93 2007-05-01

May 2007
Issue 93

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Table of Contents

Readers' Tips4

Top 10 Hand-Held Router Accessories8

Get more out of your hand-held router with a few simple, inexpensive accessories.

Just about every woodworking store or mail-order source carries the hand-held router accessories (or similar items) shown on pages 10 to 13 of ShopNotes No. 93. The item numbers for those accessories available from the Woodsmith Store are:

  • Router Mat (265652)
  • Depth Gauge (338218)
  • Vacuum Attach. (216900)
  • Offset Baseplate (226581)
  • Guide Bushing Set (226230)
  • Circle-Cutting Jig (226540)

Some items, like edge guides or alternate bases, may be specific to the brand of router. In those cases, it's best to check with the manufacturer for accessory items available for their specific router models.

The Spin on Lazy Susans12

A lazy Susan is a versatile piece of hardware that allows you to make better use of limited shop space.

The lazy Susan bearings shown on page 12 of ShopNotes No. 93 are available at most hardware stores and home centers. But if you want a specific size or style, sources are listed below.

Getting the Most Out of a Plug Cutter14

Learn how to choose and use a plug cutter to make wood plugs that are nearly invisible.

A woodworking store or mailorder source is your best bet for locating plug cutters like the ones shown on page 14 of ShopNotes No. 93. Sources appear below.

5 Plywood Shop Projects16

It won't take a lot of time, effort, or material to improve your shop with these handy plywood projects. Each one can be built from a single sheet of inexpensive plywood.

  • Page 23: Hardware List
    Six pieces of dowel are needed for the project, not 15 as originally printed.
  • Page 25: Figure 2
    Based on the layout of parts on the cutting diagram, the shelf in Figure 2 should be shown as (19 3/8 x 6).
  • Page 27: Hardware list
    The hardware list should include eight (8) 1/4" shelf support pins.
  • Page 18: Figure 1
    The dimensions of the shelf plate should be 6 x 14-1/2 not 16 x 14-1/2.
  • Page 23: Cutting Diagram
    The top cleat and lower cleat are reversed in the diagram.

You'll find very little hardware is needed to build any of the plywood projects starting on page 16 of ShopNotes No. 93. So you may be able to find everything you need locally. The 2" window locks for the assembly table came from Home Depot.

If you can't find some of the items locally, Rockler (see below) may have what you need. For the roll-around cart, I used a set of 5" locking swivel casters from Rockler (31845). Rockler also carries the L-shaped shelf pins (33860), the corner braces (33605), and the piano hinge (30085).

Shop Short Cuts28

Shop-tested tips and techniques to solve your woodworking problems.

Table Saw Outfeed Support30

Ripping long workpieces on your table saw can be a struggle. This easy-to-build outfeed support gives you an extra hand when you need it -- and it stores easily when you don't.

The table saw outfeed support on page 30 of ShopNotes No. 93 is a handy project for any workshop. And the nice thing is it doesn't take long to build and won't set you back much for the required materials and hardware.

I was able to pick up the hinges, woodscrews, and plastic laminate (WilsonArt D90-60) at a local home center. You should be able to pick up the steel flat stock for making brackets for a tube-style fence there as well. Finally, I ordered the leveling feet (62805K33) and threaded inserts (90016A030) from McMaster-Carr. Their contact information is listed below.

Tips & Tricks for Great Dovetails34

A dovetail jig is just the start of great looking half-blind dovetails. For top-notch results, try out these shop-tested tips and techniques.

Dovetail Jig Workcenter36

This workcenter is a handy addition to any shop. It's loaded with features that provide storage for the jig and accessories, improved accuracy, and added comfort as you work.

  • Page 40: Figure 4
    Three callouts in Figure 4 refer to round knobs with 1" studs. The stud length needs to be changed to 3/4" to match the correction in the materials & hardware list on page 39.
  • Page 40: Figure 4 detail
    Two corrections: (1) The detail to the right of the main drawing should be changed to 'd.' (There were two details labeled 'b' when the issue was originally printed.) No corrections are required in the text. (2) The detail 'd' should show a shorter stud in a 1" deep hole.
  • Page 40: Figure 4
    The dimensions of piece K (Front Stop Bar) should be 1" x 20 1/2".
  • Page 39: Materials & Hardware List
    Four corrections: (1) The list indicates that 8 Round Knobs with 1/4" -20 x 1" stud are needed; however the stud length should be 3/4". (2) The dimensions of piece K (Front Stop Bar) should be 1" x 20 1/2" - 1/2" ply. (3) Similar to the Online Extra, Parts A-F, I, and J are listed as being wider than they are long (see correction on p.36). To make everything consistent, the numbers should be reversed so that they match the cutting diagram from the Online Extra. (4) The following Note should be present: Grain direction on some parts may differ from project images shown.
  • Page 36: Online Extra
    The materials list included with the online extra cutting diagram is not correct. The part numbers section should be ignored. The cutting diagram portion is correct. The Sides (A), Tray Spacers (F), Handle Blocks (I), and Handle Spacers (J) are listed as being wider than they are long based on the Materials list. In the Cutting Diagram they are shown as being longer than they are wide, which is correct. Simply reverse the numbers so that they match the cutting diagram.
  • Page 38: Figure 1
    (1) Side (A) lists the measurement to be 14 x 8 1/2, this should be reversed to 8 1/2 x 14. (2) Front (D) lists the measurements to be 23 1/2 x 8 1/4. This too should be reversed to read 8 1/4 x 23 1/2.

Online Extras

  • Dovetail Jig Workcenter
    The dovetail jig gets a lot of use in my shop. But there are a few things that can be an inconvenience when using it. My biggest complaint is that I have to stoop over to see what I'm doing as I work. Another problem is keeping the workpieces clamped square. And finally, when I'm done for the day, I have to find a place to store the jig and accessories. This handy workcenter solves all these problems.

Building the dovetail workcenter shown on page 36 of ShopNotes No. 93 will take a bit of hardware. You should be able to find the washers, woodscrews, threaded inserts, handles, and piano hinges at just about any hardware store.

For the two different-length knobs (1373T57, 1373T58), I turned to McMaster-Carr (see below). And Lee Valley has all the magnet hardware. The part numbers for the 3/8" magnets are 99K3203 (magnet), 99K3252 (cup), and 99K3262 (washer). The item numbers for the 1/2" size are 99K3103, 99K3253, and 99K3263, respectively.

Note: If you want to center the baseplate and bushing on your router, the Woodsmith Store carries the Bosch centering cone (269068).

Maintenance for Your Saw Blades42

Better results and longer life -- it's simply a matter of taking good care of your saw blades.

Quick & Easy Clamp Storage44

Here are a few simple ways to get a growing collection of clamps under control.

The Secret to Locking Rabbets46

A locking rabbet joint is a great choice for sturdy drawers. And all you need is a table saw.

Add-On Digital Readouts48

Bringing digital accuracy to your shop isn't as hard or expensive as you might think.

The digital add-ons featured on page 48 of ShopNotes No. 93 are all made by Wixey (below). The digital readout for the rip fence (WR700, $150) works best with T-square style fences, but can be adapted to tube-style models.

The planer gauge (WR500, $60) works on a wide range of models. And finally, the angle gauge (WR300, $40) isn't specific to a tool, so it's handy for the table saw, miter saw, jointer, or band saw.

Q&A50

Scenes from the Shop52