ShopNotes #97 2008-01-01

January 2008
Issue 97

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Table of Contents

From our Readers4

Tuning Up Your Router Table8

All it takes are a few simple steps to guarantee success at your router table.

Router Insert Plate
Kreg Tool: PRS 3030; Woodsmith Store: 618062

Router Insert Plate Levelers
Kreg Tool: PRS 3040; Woodsmith Store: 618063

Bit Safety Guard
Rockler: 67157

Dust Collection Port
Rockler: 35317

Safety Power Tool Switch
Rockler: 20915; Woodsmith Store: 456549

Heavy-Duty Lifting Levelers
Rockler: 81239; Woodsmith Store: 454430

All About Circular Saw Blades12

Learn what to look for when shopping for a saw blade for this important shop tool.

Woodworker II 7¼″ Saw Blade
Forrest: WW07Q307100; Woodsmith Store: 222404

Sanding Drum Tips & Tricks14

Learn the techniques, must-have tips, and simple tricks to help you get smooth curves and square edges with your sanding drums.

Online Extras

  • Sanding an Edge Straight
    An oscillating spindle sander is a great help for smoothing contours. But I came up with a way to use mine to "joint" or smooth the edge of a straight workpiece. (Note: this tip works well with a drill press as well. See the video.) The simple key is a jointing fence.

Drum Sanding Kit
Rockler : 20859

Before & After Shop Upgrade16

With a few sheets of plywood, MDF, some 2x4s, and common hardware, you can build this complete storage system and workcenter. It's designed for maximum utility in a minimum amount of space. Plus, you can customize it to suit your needs and shop layout.

  • Page 22: Figure 5b
    The part labeled (P) should be (Q) and the part labeled (Q) should be (P).
  • Page 16: Online Extra - Cutting Diagram
    Three corrections: (1) The online extra cutting diagram indicates only one part T (Tower Back) but there should be two. (2) The six Cart Shelf Front/Back Pieces (JJ) are shown getting cut from a 5 1/2"-wide board. At 2" wide, these can’t come from the board as shown; a wider board is needed. (3) The 40 mounting block pieces (O) are shown as being cut from one board. There isn't quite enough room so you may need to cut several of them from a different board.
  • Page 21: Angle of bevel cuts
    The instructions for making the posts do not indicate the angle of the bevel. The blade tilt angle is 45 degrees.
  • Page 25: Figure 9b, Bottom View
    A part is mislabeled. The part labeled NN should be KK (Caster Plate).
  • Page 25: Figure 9a, Front Section View
    Two parts are mislabeled. 1: The part labeled OO should be PP (Cart Top). 2: The part labeled NN should be KK (Caster Plate).
  • Page 20: Illustration
    The diameter of the carriage bolt and washer should be 3/8" x 5", not 1/2" x 5" as originally printed. The materials list on page 27 is subject to the same correction.
  • Page 27: Materials & Hardware
    The diameter of carriage bolts, washers, and nuts used to assemble the components to the posts is 3/8", not 1/2" as originally printed. The list should indicate: (76) 3/8" x 5" Carriage Bolts ; (76) 3/8" Flat Washers ; (76) 3/8" Hex Nuts. (The illustration on page 20 is subject to the same correction.)

Online Extras

  • Before & After Shop Upgrade
    With a few sheets of plywood, MDF, some 2x4s, and common hardware, you can build this complete storage system and workcenter. It's designed for maximum utility in a minimum amount of space. Plus, you can customize it to suit your needs and shop layout.
  • Before & After Shop Upgrade
    Organization is the key to making any shop work well, no matter what the size. And if your shop is like most, it could use some additional storage space. (I know mine could.) That's where this shop system comes in. It's obvious there's a lot of storage space packed into this wall system. What's not so apparent is its easy-to-build design. Each unit is assembled from standardized components. And it's made from inexpensive, easy-to-find construction lumber, MDF, and plywood.

#8 x 1¾″ Washerhead Screws
McFeely’s: 0816-WAL-C; Woodworker’s Supply: 146-030

Plastic Handles
Reid Supply: KHO-10

20″ Full-Extension Drawer Slides (Accuride)
Rockler: 32508; Woodsmith Store: 455560; Woodcraft: 27D16

5″ Swivel Casters
Rockler: 31845; Woodsmith Store: 454398

Easy-Mount Hinges
Woodworker’s Hardware: LAXX1; Rockler: 32407

Shop Short Cuts28

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

Precision Beam Compass30

You can build this classic, precision layout tool in a weekend. Its simple construction and durability means it will last a lifetime.

Online Extras

  • Using a Beam Compass
    Using a beam compass like this one from ShopNotes No. 97 can help with a wide variety of layout tasks in the shop. This beam compass has a fixed head at one end and a sliding head that moves along the beam.

¼″-thick Anodized Aluminum Bar Stock for Beam
McMaster-Carr: 6023K14

1/8″-thick Anodized Aluminum Bar Stock for Heads
McMaster-Carr: 6023K27

10-32 x 3/8″ Aluminum Knurled Thumbscrews
McMaster-Carr: 94567A390

Easy, Accurate Tenons with a Router34

Cutting a tenon on the end of a long workpiece can be tricky. A simple jig and a router is all you need to get great results.

½″ Spiral Downcut Bit
Woodsmith Store: 271526; Woodcraft: 822963

Shop Stool36

Sit in comfort at your workbench on this adjustable-height stool. Curved legs and metal footrests add good looks and stability.

Piano Stool Hardware
Lee Valley: 01K71.01

½″-13 x 1¾″ Squarehead Bolts
McMaster-Carr: 91465A164

½″-13 Square Nuts
McMaster-Carr: 90043A055

Choosing & Using Compact Drivers42

Find out why you need and when to use this new breed of small drivers in your shop.

Top 10 Drill Bits for Your Shop44

Choosing the right bit for the job at hand can be a challenge. Here's what to look for.

Weldon Countersink Bits
DK Hardware: DB18; Woodcraft: 145636

Self-Centering Bits
Woodcraft: 16140; Rockler: 69053

Plug Cutters
Woodcraft: 146723; Lee Valley: 05J05.10

Circle Cutter
General Tools: 06; Lee Valley: 99K09.01

Hassle-Free, Precision Crosscuts46

With the proper setup and the right techniques, you'll get perfect crosscuts every time.

Online Extras

  • Making a Zero-Clearance Insert
    While an auxiliary fence prevents tearout along the back edge of a workpiece, it doesn't help along the bottom face. As the blade exits the bottom of the workpiece, the teeth can cause tearout -- especially with the wide opening in most table saw inserts. If you need a clean cut along both faces of a workpiece, the solution is a zero-clearance insert.

Super-Sharp, Super-Fast48

Find out how the WorkSharp WS3000 can breathe new life into your edge tools.

Work Sharp WS3000
Woodsmith Store: 206018; Amazon: B000PVHIMW

Versatile Shop Solvents50

Scenes from the Shop52