Shopnotes #104 2009-03-01

March 2009
Issue 104

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Table of Contents

Readers' Tips4

Choosing & Using Guide Bushings8

Get more mileage out of your router by learning how to use these handy accessories.

  • Rockler
    Brass Guide Bushings59031
  • Woodcraft
    Steel Guide Bushings04F52

Selecting Continuous Hinges10

Find out how to select the right hinges for lids and doors to ensure a lifetime of service.

In addition to the sources listed below, McMaster-Carr also carries a wide variety of continuous hinges with and without predrilled holes.

  • Rockler
    1½″ x 36″ Brass Plated19283
    1½″ x 36″ Stainless Steel36843
    1½″ x 36″ Charcoal Gray34938
    1½″ x 36″ Nickel30085
    1½″ x 36″ Rubbed Bronze23709
    Single Wrap-Around19423
    Full Wrap-Around19431
  • Lee Valley
    Small Box Hinge00D80.04
    Small Brass Hinge00D80.62
    Small Brass Hinge00D80.69
    Brass Piano Hinge00D52.25
    1¼″ x 3′ Brass Hinge00N01.05
    ¾″ x 8″ Piano Hinge00E28.08

Accurate Assembly Aids12

These clamping aids lend you a hand when it comes time to assemble your project.

  • Lee Valley
    Right-Angle Assembly Clamp50K38.01
  • McFeely’s
    FastCap Assembly BlocksFSC-0055
  • Rockler
    Clamp-It Assembly Square29190
    5″ Clamp-It Bar Clamps61003
    8″ Clamp-It Bar Clamps35335
  • Woodpeckers
    Box ClampBC4
    Precision Clamping SquareCS6075
    Phenolic Clamping SquareCS6075PHEN

Tapering on the Jointer14

Get smooth, straight tapers from your jointer using this shop-proven technique.

Project Workcenter16

Featuring an adjustable jaw, this strong and stable shop tool makes it a snap to clamp a workpiece or assemble a project.

  • Page 20: Figure 5
    Three corrections: (1) In Detail 'a', the diameter of the through hole in the anchor block was omitted. It should be 7/8". (2) The diameter of the through hole in the traveler block is incorrect. It should be 3/4". (3) The diameter of the counterbores in the traveler block should be 1 1/8”.

Online Extras

  • Project Workcenter Animation
    You’ve probably seen or used one of those folding, portable project centers. They feature adjustable, clamping tops that come in handy for light-duty work. But I’ve never found them suitable for more demanding woodworking. This version solves that problem. It features a rock-solid base with a large shelf for storing your tools while you’re working. And with the top’s array of dog holes, notches, and grooves, you won’t have any trouble clamping just about any workpiece. It’s a project that’s sure to earn a permanent spot in your shop.
  • Project Workcenter Model
    You’ve probably seen or used one of those folding, portable project centers. They feature adjustable, clamping tops that come in handy for light-duty work. But I’ve never found them suitable for more demanding woodworking. This version solves that problem. It features a rock-solid base with a large shelf for storing your tools while you’re working. And with the top’s array of dog holes, notches, and grooves, you won’t have any trouble clamping just about any workpiece. It’s a project that’s sure to earn a permanent spot in your shop.
  • Project Workcenter
    You’ve probably seen or used one of those folding, portable project centers. They feature adjustable, clamping tops that come in handy for light-duty work. But I’ve never found them suitable for more demanding woodworking. This version solves that problem. It features a rock-solid base with a large shelf for storing your tools while you’re working. And with the top’s array of dog holes, notches, and grooves, you won’t have any trouble clamping just about any workpiece. It’s a project that’s sure to earn a permanent spot in your shop.
  • McMaster-Carr
    Spherical Washer Sets91131A080
    5/8″ Acme Nuts94815A108
    5/8″ Acme Rods98935A829
    5/8″ Washers98029A035
    3″ Fixed Casters2724T45
  • Reid Supply
    Socket LevelerL-1
    ½″-13 Plastic KnobDK-94
    Crank HandlesJCL-1285
    Thread LockLOC-37684
  • Benjamin Moore Paints
    Regal Eggshell “Raspberry Truffle”… 2080-10

Shop Short Cuts22

Try out these shop-tested tips and techniques to solve your woodworking problems.

Table Saw Workstation24

This mobile station gives your benchtop table saw extra capacity to accurately cut large workpieces easily and safely.

Online Extras

  • Table Saw Workstation
    Benchtop table saws are designed for rough-and-tumble work at a jobsite. But their compact size and low price make them attractive for woodworkers, too. (I’ve used one for years.) Still, they do have some limitations. The small size of the saw table makes it nearly impossible to cut large workpieces — like plywood and MDF. And finding a place to put the saw can be a challenge. That’s where this station comes in. It provides a feature-packed home for your saw. As you can see in the photo, it extends to create a large work area to tackle almost any size workpiece. To top it off, the whole thing folds up into a compact package you can store in any corner of the garage or shop.
  • Workstation Accessories
    Improve accuracy and increase rip capacity with these handy accessories for the Table Saw Workstation.
  • Rockler
    5/16″-18 Knobs w/Insert23812
    ¼″-20 Knobs w/1″ Stud23838
    Piano Hinges37750
    5″ Locking Swivel Casters31845
    20″ Full-Extension Slides21897

Drilling Shelf Pin Holes34

Increase the accuracy and take the challenge out of this common woodworking task.

Wall-Mounted Tool Rack36

Put your empty wall space to use and keep frequently used tools within easy reach with this easy-to-build storage solution.

  • Page 41: Materials and Hardware
    The dimensions of part B (Upper & Lower Rails) should be 3/4" x 3 1/2" - 60". (The online extra materials list is correct.)

Online Extras

  • Wall-Mounted Tool Rack
    An easy way to make better use of any shop space is to organize where and how your most-used hand tools are stored. This compact, wall-mounted tool rack does just that. Best of all, the design offers flexibility to customize it for your own needs.

Our Favorite Shop Materials42

Learn what materials to use for building jigs and projects -- and why.

Simple Workbench Upgrades44

Make your workbench even more useful with these easy-to-build, shop-made accessories.

Cutting Perfect Circles46

With just a shop-built jig, you can cut a circle with your table saw -- and sand it, too.

Online Extras

  • Circle Cutting Jig Model
    A table saw isn’t a tool you think of when it comes to cutting a workpiece into a circle. But with a shop-built jig, cutting a circle up to 40" in diameter is quick, easy, and accurate. And it results in a surprisingly smooth, even edge.
  • Circle Cutting Jig Animation
    A table saw isn’t a tool you think of when it comes to cutting a workpiece into a circle. But with a shop-built jig, cutting a circle up to 40" in diameter is quick, easy, and accurate. And it results in a surprisingly smooth, even edge.
  • Rockler
    5-Star Knob w/Insert23812
    6′ Measuring Tape (R to L)69124
    Hold-Down Clamp Kit21912
  • Woodsmith Store
    Freud Calibration Disk… 222512

Useful & Handy New Products48

Here you'll find a few new products that caught our attention and deserve a look.

  • Woodpeckers
    12″ Woodworking RuleWWR12
    24″ T-SquareTS-24-2
    12″ Precision TrianglePTR12
  • Woodsmith Store
    Work Sharp Wide Blade Attachment… 206026
    Kreg Quick-Change Kit… 415596

Q&A50

Scenes from the Shop52