Handheld Woodworking Power Tools

An introduction to in the woodshop

Ka-Loon Tung

Instructors

Overview• Nova Labs• Tools• What is it? • What is it used for?• Capabilities• Anatomy• Operation• Accessories• Safety• Techniques• References and Resources

Nova LabsWhat is Nova Labs?

• A non-profit Makerspace

What is a Makerspace? (per Wikipedia)• A Makerspace is a physical location supporting a collaborative

environment and community. • A maker's facility usually provides access to community tools and

people with a wealth of knowledge. • Given access to these resources, community members are able to

learn and complete projects, which would otherwise be out of their capability.

How is the space funded?• Through classes like this, membership dues and donations

How do I become a member?• Find a subject that interests you and get a member to sponsor you.• First Step - Find a Sponsor!

Tools• Drill/Driver• Circular Saw• Jig Saw• Router• Random Orbit Sander

Drill Driver

So, what is it?

a hand tool, power tool, or machine with a rotating cutting tip or reciprocating hammer or chisel, used for making holes.

- Google

https://www.google.com/search?q=what+is+a+drill

What is it used for?

CapabilitiesSpin a bit to drill or drive• Drill a hole when using some variant of a cutting bit• Drive in fastener when using some variant of a driving bit• Useful all around tool for any home owner, renter, maker, etc• Stationary counterpart is the drill press

Variants include• Drill/Driver – 2 speed machine with a clutch• Impact Driver – Variant with a hammer that induces additional

turning force• Hammer Drill – Variant with a hammer that induces additional

forward momentum

Anatomy

Chuck

Trigger

Power Source

Clutch Gear selector

Direction selector

Operation

• Set the Gear

• Set the clutch

• Select your drill bit

• Insert the appropriate bit in the chuck

• Position your drill bit and drill through

http://www.diynetwork.com/home-improvement/the-different-types-of-drill-bits/pictures/index.html

AccessoriesMust-haves• The appropriate drill bit

Helpful• Hex quick-release bits

Neat, but not really required• Drilling guide• More drill guides

SafetyFingers and other body parts

• Keep hands clear of bits• Keep your material secure so that it doesn’t move unexpectedly

Start and Stop• Position the tool• Slowly start the tool• Wait until the tool to come to a complete stop• Clear out chips and/or debris to prevent overheating

TechniquesSetup• Hold the bit and chuck to use the drill to tighten the chuck

jaws

Drilling• Use an awl to mark the center point for drilling• Start slow and gradually speed up the bit• Slow down your speed when drilling larger holes• Clear chips often to prevent overheating of a bit

TechniquesDriving• Prevent splitting a board by pre-drill a clearance hole that is

slightly smaller than the threads of the screw you will be using

• Back up your holes to prevent blowout• Drill a countersink for flat head screws• Set the clutch to the lowest speed to avoid stripping the bit• Gradually raise the clutch when needed• Use a good quality screw• Waxing the screw to lubricate the threads if necessary• Consider using a handheld screwdriver for delicate work

Circular Saw

So, what is it?

a power saw with a rapidly rotating toothed disk.- Google

https://www.google.com/search?q=what+is+a+circular+saw

What is it used for?

CapabilitiesMake cuts! • Stationary counterpart is the Table Saw• Specialty circular saw variant is the track saw

Types of cuts• Rip cut• Crosscut• Bevel cut• Miter cut• Compound cut

AnatomyPower Trigger Handle

Bevel Adjustment

Arbor LockDepth Adjustment

Power Cord

Blade Guard

Shoe

Arbor Lock

Front Handle

Operation

• Direction of spin/rotation

• Types of blades• Tooth count• Tooth Pattern

• Depth of cut for the blade

• Direction to install the blade• Carbide into the direction of the cut

• Use the guard!

http://www.woodworkingchat.com/blogs/tips-for-picking-table-saw-blades/4919-tips-for-picking-saw-blades

AccessoriesMust-haves• The right blade• Squares

Helpful• Straight edges • Home-made jigs

Neat, but not really required• After market Rip Guides• Specialty clamping straight edges

SafetyEyes and ears

• Safety glasses• Ear protection

Fingers and other body parts• Keep hands clear of blade• Keep both hands on handles• Unplug for adjustments

Start and Stop• Start the tool before contacting the material• Stop the tool after the guard is fully

retracted• Maintain control of the tool until it comes

to a complete stop

SafetyFeed Direction• Only push the saw forward, don’t back up• Keep the saw moving in a straight line• Use a guide of some sort

Material Support• Support your material on both sides of the cut (keeper and off-

cut), so that the blade will not get pinched by the material after the cut

• Secure your material on the keeper side• Keep the good face of your work down to prevent splintering• Back up your cut with tape and/or sacrificial backer pieces

SafetyKickback• Kickback occurs when the teeth of blade is unable to slice

through the material, and the momentum of the blade pushes it back towards you

• This can happen for many reasons, such as dull blades, pinched blades, or an improper feed rate

TechniquesSetup• Blade – Follow the circular saw instructions and install the

right blade• Depth – Set the depth of cut to about 1-2 tooth more than the

thickness of your cut• Bevel – Set and lock the appropriate bevel angleWith a Guide• Setup your guide• Account for the off-set of your saw

(if applicable)• Make your cut, keeping the saw tight

against the guide or guide tight against your material

TechniquesFreehand use of a circular saw carries a greater risk. Consider using some sort of guide if possible• Mark your line• Use two hands

- One on the handle + trigger- One on either the front handle or

the wide part of the shoe

• Follow the line slowly with the saw• Stop the saw when you complete your cut and/or the blade

clears your material• Hold the saw stationary until it comes to a complete stop and

ensure the blade guard is fully retracted

TechniquesPlunge-cutting with a circular saw requires you start the blade exposed. • Set your depth of cut• Pivot the saw off your cut line from the front of the saw• Retract the guide and start the saw• Pivot your saw down to plunge the saw blade into the

material• Allow your shoe to make full contact with the material• Proceed with your cut• Stop the saw when you complete your cut and/or the blade

clears your material• Hold the saw stationary until it comes to a complete stop and

ensure the blade guard is fully retracted

Jig Saw

So, what is it?

a machine saw with a fine blade enabling it to cut curved lines in a sheet of wood, metal, or plastic.

- Google

http://www.google.com/search?q=what+is+a+jigsaw

What is it used for?

CapabilitiesMake cuts! • Hand-held counterpart of the Band Saw

Types of cuts• Rip cut• Crosscut• Bevel cut• Miter cut• Compound cut• Curved cuts• Cuts in the middle of the material

Anatomy

http://www.designsponge.com/2011/03/diy-101-building-your-toolbox-saws-part-i.html

Operation• Movement of the blade• Types of blades – size tooth pattern/count

o Different blade type for different materialso Less teeth = faster aggressive cuto More teeth = slower finer cut

• Speed controlo Slow down to prevent overheating

AccessoriesMust-haves• The right blade

Helpful• Home-made jigs• Dust Collection

Neat, but not really required• Squares• Straight edges • Rip Guides• Specialty clamping straight edges

SafetyEyes and ears

• Safety glasses• Ear protection

Fingers and other body parts• Keep hands clear of blade• Keep both hands on handles• Unplug for adjustments

Start and Stop• Start the tool before contacting the material• Maintain control of the tool until it comes

to a complete stop

SafetyFeed Direction• Only push the saw forward, don’t back up• Keep the saw moving in a straight line• Don’t push the jigsaw too aggressively – let the blade do the

work and dictate feed rate

Material Support• Support your material on both sides of the cut, so that the

blade will not get pinched by the material after the cut• Secure your material on the keeper side• Ensure there is clearance for blade travel below the material

SafetyKickback• Kickback occurs when the teeth of blade is unable to slice

through the material, and the momentum of the blade pushes it back towards you

• This can happen for many reasons, such as dull blades, pinched blades, or an over-aggressive feed rate

TechniquesSetup• Blade – Follow the jigsaw’s instructions and install the right

blade• Bevel – Set and lock the appropriate bevel angle

Freehand• Mark your line• Use two hands

- One on the handle + trigger- One on either to the front of the handle

or on the shoe

• Follow the line slowly with the saw

TechniquesWith a Guide• Setup your guide• Account for the off-set of your saw (if applicable)• Make your cut, keeping the saw tight against the guide or

guide tight against your material

Cuts in the middle of the work• Mark your cut lines• Drill clearance holes so that the blade can enter• Insert your jigsaw blade into the hole• Start the jigsaw and proceed with your cut

Router

So, what is it?

A router is a motor that spins a bit at an extremely high speed. -Steve Ramsey (Woodworking for Mere Mortals)

WWMM

What can you do with it?

CapabilitiesMaybe one of the most versatile tools you can own.Out of the box, a handheld router works well for:o Creating edge profileso Laminate trimmingo Free hand - cut profile, sign letteringo Enlarging inner profiles and reducing outer profiles

Different bits, jigs and accessories allow more complex work:o Joints - dovetail, mortise and tenon, tongue and groove, dado, rabbet,

scarf and otherso Sign letteringo Cabinet door panelso Template routing - profiles, drilling shelf pin holes, Inlayso Jointing rough edgeso Carvingo Surfacing

AnatomyTypes of routerso Plungeo Fixed Base

Knob D-Handle

o Palm / Laminate Trimmer

Variantso RotoZipo Dremel

Speedso Single - usually between 24K and 30K RPMo Variable - ranges vary, as low as 12K and as high as 35K RPM

Different size collets - ½”, ¼”, ⅛”

AnatomyPartso Baseo Handleo Universal Motor

On/off switch Speed Control

o Collet & Nuto Height Adjustment

Height Lock Depth Adjuster Turret on plunge routers

o Spindle Lock

Variable Speed Control

On/Off switch

Turret

Depth Stop

Base

Collet and Nut

Spindle Lock

Depth Stop

Adjuster

Height Lock

Lever on Back

Frequently included accessories• Wrench• Collet shank size adapter• Edge Guide• Dust Collection• Template bushings

Anatomy

BitsCarbide vs High Speed Steel (HSS)

o Hard and durable vs. inexpensive

Must-have bitso Straight Bit - ¼”, ½”, ¾”o Roundover - ⅛”, ¼”, ½”o Roman Ogee - ¼o Flush trim - ½”o Rabbeting - ½” with multiple bearingso Downcut bit - ½”o Upcut bit - ¼” & ½”o Chamfer bit

Not all bits are made equal, but most get the job done well enough. Start off with a 15-30 piece low cost set, preferably with a decent case. Replace frequently used, dull bits with good quality ones.

BitsThe right bit speed is importanto It’s primarily a safety issue: 24K:<1”, 22K:1”, 18K:2” 12K:3.5”o Bits usually have two cutting edges, which means 48K cuts per

minute at 24K RPMo High RPMs can burn woods like Cherry and Mapleo Slow down a little below maximum to cut down on heat

SafetyEyes and earso Safety glasses - routers throw chipso Ear protection - loud

Fingers and other body partso Keep hands clear of bit when runningo Keep both hands on handleso Turn off to make adjustmentso Allow to stop before moving router off work pieceo Unplug for bit changes

SafetyDusto Routers usually produce more chips than dust, but a face mask

may be required for some dusty materials like MDF.

Speedo Slow down the router speed for bits larger than 1”.

Correct cutting directiono Don’t climb-cut with a handheld router.

You could damage your workpiece. Worse, the router could run away from you. There are a few caveats, like cutting around corners

AccessoriesMust-haveo Height gaugeo Straightedge

Doesn’t have to be fancy, just straight

Helpfulo Router table

Really, it’s just a board with hole in it Opens up a lot of options

o Sub-base Better control, especially around corners

Neat, but not really requiredo Bench cookieso Expensive Jigs

Operation - SetupInserting bit

o Lock spindleo Insert bit to tips of fluteso Don’t insert all the way to bits with larger heads

Pull back out about ⅛”.

Setting heighto Don’t measure if you don’t have to

Use height gauge, setup block or stock itself Once dialed in, save a cutoff as a setup block for future setups

Operation - Cutting• Bit spins clockwise (right hand rule)

o Go clockwise on inside profileso Go counter-clockwise on outside

profileso When using guide, bit should pull

router into guide, guide on left of cut

• Cut end grain first to avoid chipout• Keep router base flat on the work

surface - gouges• Don’t cut too deeply, cut in stages• A quick moving, shallow final pass

takes off burn marks

Operation - Pitfalls• Inserting bit too far - bit can slip out of collet• Base plate not flat to surface - causes gouges• Cutting too much or too deep

o Can cause rough cuts, gouges, splintering and control problems

o Do multiple passes with one shallow final pass• Moving too slowly

o Causes burningo You may be moving the router at the right speed, but the bit

may be too fast for the wood (cherry, maple and others)• Bit speed too fast

o Similar issues to moving router too slow• Don’t measure more than necessary to avoid most human error

Operation - TechniquesEdgeso Three goals

Keep the bearing against the wood Keep the router base flat against the surface Keep moving

Operation - TechniquesTemplateso Collars - cut template larger than final pieceo Template bits - cut template exact to sizeo Needs to be smooth - imperfections with telegraph to work

Operation - TechniquesSetup Blockso Can be used to

Set height for certain bits or profiles Set distance from straight edge for dado or rabbet

o Some interlocking bits are very sensitive to height Glue Joint Bit Lock-miter bit.

Operation - TechniquesFreehand drawing or letteringo Best done with smaller/lighter router for better controlo Print or draw template and attach to stock with spray adhesive

Spray on paper, wait a minute, then applyo Select the appropriate bit, usually a 60 or 90 degree vee bito Take it slow and watch your lines

Random Orbit Sander

So, what is it?

also called Dual-Action or D.A. sanders (referring to the rotation of the disk and the head) are hand-held power sanders where

the action is a random orbit- Wikipedia

http://en.wikipedia.org/wiki/Random_orbital_sander

What is it used for?

CapabilitiesPower assisted sanding to create scratch patterns• Primarily for finish sanding, not for aggressive stock removal

Sand with two power assisted actions:• Rotation of the disc• Orbit of the disc

Sanding with two actions creates a scratch pattern that if done right, is not easily visible to the human eye

Origins from the from the automotive industry

Anatomy

http://visual.merriam-webster.com/house/do-it-yourself/carpentry-shaping-tools/random-orbit-sander.php

Operation• Sanding through grits

• Don’t skip grits, go up ~50% of the previous grit

Description Grit Use

Coarse 40 – 60 Distressing, heavy stock removal, or initial sanding of rough (unsurfaced) wood

Medium 80 – 120 Initial sanding of flattened or surfaced wood

Fine 150 - 220 Final sanding grits for most wood surfaces

Extra Fine 240+ Extra fine sanding or polishing of finishes/top coats

https://generalfinishes.com/retail-products/finishing-design-center/preparation-sanding

AccessoriesMust-haves• Sandpaper• Personal safety equipment

Helpful• Active dust extraction (connected vacuum system)

Neat, but not really required• Multiple sanders• Accessory sanding or polishing pads

SafetyEyes, ears, and lungs

• Safety glasses• Ear protection• Dust mask or respirator

Start and Stop• Make sure the material is secured and will

not move during the sanding operation• Start the tool on the material• Stop the tool off the material• Maintain control of the tool until it comes

to a complete stop

TechniquesSetup• Installing hook and loop sand paper• Align the dust extraction holes• Connecting dust extraction tools• Setting up your speed control• Securing your work piece• Pencil marks on your work piece

Operation• Start the sander on the work piece, stop the sander off the

work piece• Move slowly at a steady pace (~1 inch per second)• Keep the sander flat (don’t tilt the sander)

References and ResourcesGeneral• About Woodworking - http://woodworking.about.com/• The Wood Whisperer – Low Entertainment Center Series built with handheld power tools

o https://www.youtube.com/playlist?list=PL8616E2DC65E41C81

Drill/Driver • Articles

• Popular Woodworking: Screws are Screws – Aren’t They?o http://www.popularwoodworking.com/article/screws-screws-arent

• Wood Screws: Best Uses for the Best Typeso http://www.motherearthnews.com/diy/wood-screws-types-washers.aspx

• Videos• Skil Tools - How to use a cordless drill

o https://www.youtube.com/watch?v=grnoi528kCY• Wood Work Web – All About Wood Drill Bits

o https://www.youtube.com/watch?v=L53FQrXOgVE

References and ResourcesCircular Saw• Videos

• This Old House – How to choose a circular sawo https://www.youtube.com/watch?v=1APf46AhM4g

• This Old House – How to make a Circular Saw Guideo https://www.youtube.com/watch?v=qIeIZdrbz-Y

• Howcast – How to use a jigsawo https://www.youtube.com/watch?v=WUyL92r20UA

• Skil Tools - How to use a circular sawo https://www.youtube.com/watch?v=jU3k5D5n5xo

• Jon Peters – How to make a “rip fence jig” for a circular sawo https://www.youtube.com/watch?v=mwcOKX7PaRg

References and ResourcesJigsaw• Videos

• Howcast – How to use a jigsawo https://www.youtube.com/watch?v=WUyL92r20UA

• Skil Tools – How to use a jigsawo https://www.youtube.com/watch?v=5P38s_Yj_kM

• Lowes – How to use a jigsawo https://www.youtube.com/watch?v=FNoNeOswCt8

• Home Addition Plus – Jigsaw and Jigsaw Bladeso https://www.youtube.com/watch?v=jQfDlTNyAlE

References and ResourcesRouter• Informational Sites

• Router Forums - http://www.routerforums.com/• Router Workshop - Info and TV show DVDs for sale - http://routerworkshop.com/

• Videos• Woodworking for Mere Mortals

o http://www.youtube.com/channel/UCBB7sYb14uBtk8UqSQYc9-wo Router 101 - http://www.youtube.com/watch?v=8Vl8Jbw3cSk

• Wood Whisperero http://www.youtube.com/channel/UCKp44bWWZIiOPShPN_ytShw

• Routers, Parts and Supplieso Rockler - http://rockler.como Woodcraft - http://woodcraft.com, local stores in Springfield and Leesburgo MLCS Woodworking - http://www.mlcswoodworking.com/o Amazon - http://amazon.como Lowes / Home Depot has smaller selectiono Might be others, let me know if you find a good resource

References and ResourcesSanders• Articles

• Fine Woodworking Tool Test – Sanding Diskso http://www.finewoodworking.com/tool-guide/article/tool-test-sanding-disks.aspx

• Videos• Woodworking for Mere Mortals – Sanding for absolute beginning woodworkers

o https://www.youtube.com/watch?v=69hXo44i0Ms• Wood Whisperer – Episode 161 Sanding Efficiency

o https://www.youtube.com/watch?v=XtkIuWcW3cE• THISisCarpentry – Swirl-Free Sanding with Larry Smith from Festool

o https://www.youtube.com/watch?v=rZZyypf-Qqk• Sanding Supplies

• Home Depot has a selection of Freud/Diablo sandpaper with a universal hole pattern• Lowes has a selection of Gator/ShopSmith sandpaper with two different hole patterns (5” x

5 or 5” x 8)• Klingspor VD900 sandpaper received the Fine Woodworking award for Best Overall and

Valueo https://www.woodworkingshop.com/