vol.05 - home workshop

8/10/2019 Vol.05 - Home Workshop

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THEARTOFWOODWORKING

HOMEWORI HOP



MEASURINGND

MARKINGOOTS

.

Tapemeasure

. Steeluler

.

Try quare

.

Combinat ionquare

.

Carpenter 'square

.

Straightedge

.

Level

.

C ha l k

i ne

.

Slidinsevel

ry

:::'ff:::'a

.

Trammel

oints

o

Marking

auge

. Cuttingauge

.

Mortise

auge

.

Aw l

.

Dovetailquare

SAWS

.

Handsaws

rip,

rosscut,

backsaw,oping,ompass, _-

flush-cutter)

ref-

.

Miter box

['i'.'

''r]'ttP

with ntegral aw

.

Hacksaw

.

Ci rcu laraw

.

Saber aw

CUTTINGOOLS

. Chiselsparing,irmer,

butt,

mortise)

.

Sharpening

tone

o

Honing

u ide

.

Gouges

wood

arving

et )

.

Routerndbits

. U t i r i t y kn i f e

@

.

HODDYKNIIC

.

Single-edgeazor lade

.

Scissors

.

Wire utters

.

Tin nips

BASICW()ODWORKINGO()TS I{DACCESSORIES

BORINGOOLS

.

P ush r i l l

. Hand r i l l

.

Brace

.

Gimlet rscrew tarter

.

Electricri l l

cordless

and orded)

SUPPTIES

r

Nai ls

f

n ish ing,

common,ox,

ring-shank)

.

Brads

. Screwsflat,

round,

ndoval

head)

r

Sandpaper

.

Pumice

tone

.

Steelwool

.

Glues

woodworker's,

white, ontact ement,

epoxy,nstant)

.

Wood

putty

.

Maskingape

.

Penci ls ndmarkers

.

Woodin ishes nd

appropriateolvents

.

Householdi l

o

Penetrat ingil

.

Sponges

o

Reoq

SMOOTHINGOOTS

.

Hand

lanes

block,

jack,

ointer)

.

Scrapers

.

Fi les

f

at,half-round,

round,

riangular)

.

Rasps

patternmaker's)

.

Sandinglocks

flat

and ontoured)

:3:l l ' : : f f : ,#

.

Orbitalander

F'4 4

'sF

STRIKING

OOLS

.

Wooden

mallets

square

and ound eads)

.

Rubber

al let

.

Claw ammer

r

Nai l

ets

.

Uti l i ty ar

r

Tackhammer

v\

-Y

FlNlSHlNc00LS

1+

.

Foam

rushes

.

Lint-freeloths

.

HVLP

prayer

.

Paint craper

.

Moldingcraper

.

Putty nife

FASTEI{INGOOLS

.

Screwdrivers

offset,

stubby,abinetmaker's

n

flat-, hi l l ips-

nd quare-

t ipvariet ies)

o

Nutdrivers

r

Pl iers

standard

l ip-

joint

ype)

r

I n n o - n n q p n l i o r c

.

Locking

l iers

.

Channel-joint

l iers

.

Wrenches

adj

stable,

open-end)

:TT,fu

w

.

Tr igger

lamps

v

.

Quick-act ion

arc lamos

.

Bar

lamps

.

Pipe

lamps

.

Springlamps

o

Web lamps

.

Handscrews

WORKSHOPGUIDE



THEARTOFWOODWORKING

HOMEWORI$HOP



THE ART OF WOODVV'ORKING

HOMEWORI$HOP

TIME-LIFE

OOKS

ALEXANDRIA,

IRGINIA

ST.

REMYPRESS

MONTREAL.

EWYORK



PUBLISHER

PRESIDENT

Series ditor

Series rt Director

SeniorEditors

Art

Directors

Designers

Researchditor

PictureEditor

Writers

Con r but ng Ilust hto s

Administrator

Production

Manager

System

Coordinator

Photographer

Kenneth

Winchester

PierreLdveill6

PierreHome-Douglas

FrancineLemieux

Marc

Cassini

Text)

HeatherMills

(Research)

Normand Boudreault,Luc

Germain,

Solange aberge

Jean-Guy

oiron, Michel

Gigudre

Iim

McRae

Christopher

Jackson

Andrew

Jones,

Rob

Lutes

GillesBeauchemin, ollandBergera,

Jean-Pierre

ourgeois,

Michel Blais,

Nicole Chartier,

Ronald

Durepos,

Philippe Gauvreau,

G€rard

Mariscalchi,

Jacques

errault,

RobertPaquet,

Iames

Thdrien

Natalie

Watanabe

MichelleTurbide

Iean-LucRov

RobertChariier

THECONSULTANTS

Jon

Arno is a consultant,

abinetmaker nd

freelance riter who

lives n Tioy, Michigan.

He

alsoconducts eminars

n wood dentifica-

tion

and earlyAmerican urniture design.

GilesMiller-Mead taught advanced

abinet-

rnaking

at

Montreal

echnical chools or

more

than ten

years.

A native

ofNew Zealand,he has

worked

asa restorer

f antique urniture.

foseph

Truini is

SeniorEditor of Hone

Mechanixmagazine.

former

Shopand Tools

Editor

of

Popular

Mechanics,e hasworked

as

a cabinetmaker, ome mprovement

contractor

andcarpenter.

Home Workshop

p.

cm.-(The Art

of

Woodworking)

Includes ndex.

ISBN0-8094-9920-7

(trade\

ISBN

0-8094-992-s

oib)

1.Woodshops.

2.

Woodwork--Equipment

nd supplies.

I. Time-Life

Books. II. Series

TTI52.H6 1993

684' 08-dc20

92-682r

CIP

For nformation

about any Time-Life

book,

please

all l-800-621-7026,

r

write:

Reader nformation

Time-Life

CustomerService

P.O.BoxC-32068

Richmond,Virginia

2326t-2068

@1993 ime-Life

Books nc.

All rights reserved.

No part

of this book may

be

reproduced

n

any orm

or by any electronic

or

mechanical

means, ncluding nformation

storage nd

retrievaldevices r systems, ithout prior

written permissionrom thepublisher,except

that briefpassages ay

be

quoted

or reviews.

First

printing.

Printed n

U.S.A.

Published

imultaneouslyn Canada.

TIME-LIFE s

a trademarkof Time Warner

Inc. U.S.A.

THE ART

OF

WOODWORKING

was

produced

by

ST.

REMY

PRESS

Time-Life Books s

a division of Time-Life nc.,

a wholly owned

subsidiary f

THE TIME

INC. BOOK COMPANY

TIME-LIFEBOOKS

President

Vice-President

Editor-in-Chief

Director

of

Editorial

Resources

Marketing

Director

EditorialDirector

Consulting ditor

Production

Manager

lohn

D. Hall

NancyK.

Jones

Thomas

H. Flaherty

EliseD. futter-Clough

ReginaHall

LeeHassig

John

R. Sullivan

MarleneZack



CONTENTS

6

INTRODUCTION

Accident

prevention

Working

with safe

inishes

6

Firesafety

17

Electrical

afety

18

Personal

afety

gear

First aid

TAYOUT

Workshop

planning

2

Planning

or stationary

ools

36

Shop

organization

Electrical

ower

3

Lishtins

44

FlSors,

"a[s,

and

ceilings

45

Heating

and

ventilation

46 WORKBENCH

48

Anatomv

of a

workbench

50

Building

he base

53

Building

he

top

56

Vises

and accessories

62

Benchdogs

and

hold downs

68 SHOP

ACCESSORIES

70 A storeof shopaccessories

72

Air compressors

74

Portable

generators

76

Bench

grinders

78

Dust collection

85

Portable

dust collection

88

STORAGE

90

Storing

wood

94 Storing oolsandsupplies

IIO WORKSURFACES

LL2

Work tables

118 Sawhorses

I25 Work

supports

I29 Extension

ables

I34

Tool stands

and tables

I4O GLOSSARY

I42

INDEX

I44

ACKNOWTEDGMENTS



INTRODUCTION

Peter

Axtell

talksabout

planning

his

DREAIVI

WORKSHOP

f

startedwoodworking

round1974nEngland,

where was

playing

ockmusic

I andneeded hobby

o helpmeunwind rom

herigorsof the oad.My

shopat

the

imewas

ust

big enoughor a workbench,

radialarmsaw

and

not

muchelse.

I remember

onstantlybumping

hings

nto

the ow ceiling.

Whenmywifeand moved ack oAmericawasoffered ob n a ocalwood-

shop

un

by a friend

of

mine. t

was here hat

begano acquire feel or how

a shopshould

e

aid

out.After a fewyears

ith

my

friend left

andsetup my

ownshop n

our three-car aruge.I

oon

earned

hatworked

ndwhatdidn'g

When t

cameime o

plan

a

shop

rom

scratch,I ought

ut

mylocalwoodwqrft-

ing

organization, hich urned

out to bea fountain

of

nformation.

studi/d ots

of shopsn my area nd

asked

undreds

f

questions

boutwhat

people

iked

and

what heywanted

o changen their ownshops.

I saw ne

place

n

particular

hat

seemedhebest orjry needs nd

settled n hat

asmy model.My

budgetallowedme 1,500

qlrgtt.feet,

o hat wasone imit set.

Light-both

natural ndartificial-was

a maiorconsideration.

placed

mybuilding

and

plannedthe

indowso

take

maximum

dvantage

fthe abundant unlightn

northernCalifornia.was lsodeterminedo have wood loor. quicklyoundout

thata hardwoodloorwould

be oo expensive

o used%-inch ongue-and-groove

plywood

ndepory

paint,

whichhave eldup very

wellover he astnineyears.

I figured

out he loor

plan

on graph

paper

andcut out

scale rawings f all my

machines

swell asareasor

plywood

torage, ffice

space, nda spray ooth. t

is mportant

o allowenough

pace round

our

machines,

o spent onsiderable

time movings

hingsaround

and estingdifferent

cenarios.

The

crawl pace

nder

myshop

hasextra

learanceecausechose

o

run

my

dustcollection

ipe

under he loor,whichhas

allowedme o keep

hewhole eiling

space lear nd

airy.Oneof thebest nvestments

madewas n

super-insulating

thewhole

shop-floors,walls, nd

ceiling,whichhasmadet

easiero keep

he

placewarm n winterandcool n summer.

I

put

a

ot

of thought

and

esearch

nto my

shopand here srt'tmuch

would

change xceptor one

hing: wish hadbuilt t

bigger. ut hat s

a common om-

plaint.

t seemshatyou

cannever aveoo much

space.

Peter

xtellbuilik

ine urniture

at

his

shopn SonomaCounty,alifornin.



a -- - - -- -

o cnotrsrrxT'cAf€

cttEz'tAllpsE

- - { - F

INTRODUCTION

Martha Collins

discusses

SHOPSTORAGE

I

make

ewelry

rom exotic

woodand

dy.d ulne.r.

Some

ieces ave smany

I as800bits

of wood

n them,combining

he colors

and extures

f various

rarewoodswith

brightly

huedveneers.

eingable o

find someoffbeat

crew

or

fastener

hen need

t,

or

knowing

where o retrieve

hat wonderful mall

chunk

of rosewood

hat

've

been

aving

or 10

years

srlt a

uxury; t's a

necessity.

Throughheyears, haveearnedhat he strenghof a workshop epends n

proPer

rganization

nd

storage.

I have

our distinct

storage

areas"

n my shop. he

nfeed ndoutfeedables

f

my adialarmsaw

oldscrap

oodand

essrequentlysedools

My

ewelry

torage

bench

oldsall he

machined nd

milledexotic

woods nddyed

eneers.

he4-by-

8 outfeed

ableon the

ablesaw

ouses varietyof

items:work

n

progress,

xotic

lumber, urniture

pads,

nd eftovers

rom he

ewelry-making

rocess.

Themost

mportantstorage rea

s n the

mainworkbench

nd ool chest rea.

This s heheart f

myshop.

keepwerything

romscrewsndscrewdrivers

o

planes

andhinges

n cabinetslose

o thebench.

ll of the

hand

and

power

ools

hat use

regularly

rekept

n my mainchest,

hich s eatured

n the

photograph.

Thechest

s6 eet

ighand4 eetwide.

n theupper ection,

storewerything

rom

hammersndonesetof chiselsn theeft-hand oor o files, crewdrivers,ndplanes

in the ight-hand

ection.

he ivedrawers

n

the

center re

illedwith wrenches

nd

bitsof all

kindrspurs,

twists, nd

Forstners.assembled

hedrawers

ith dovetail

joints,

a satisfring

ffort hat

onlyadds

o the

pleasure

f

putting

hings

away.

The eft-hand

oor

n

the

bottomsection

f thechest

oldsall my

measuring

and

marking ools;

he

ight-hand oor

houses setof

pliers

along

with

my hand-

saws.

hecubbyholes

rehome o

my

portable

ower

ools-circular

saws, aber

saws,

outer, ander,

ordlessrills,

pneumatic

ools,

ndsoon.

The

ools

n my chest

ave hanged ver

he

years. ifteen

ears

go

hadonly

one

cordlesd,rill;

now

havehree.But

my

chest

as een ble o

adapt ndaccom-

modate

ll the

new ools-each

with its ownspecific

lace.

Martha Collins

esigns

nd makes

ine

ewelry

and

furninne

in

her worhshop

earSequim,

Washington.

Her husband,uthier

RichardSchneider,

orlcs

n

an adjoiningshop.



INTRODUCTION

Leonard

Leeon

THE\ALUEOF

AWORKBENCH

worlshop

canbeanywhere

oucan

it

a solid

surface.

retired

arverriend

built

a superb

orlshop

n the

inendoset f

hisaparhnent.

eonly

had o

gpel

the closet

oo5

pull

out a stool,

and

go o work.

Everything

e needed

as itted

into a space

fless

han

0

square

eet.

I built thesmall herry enchn thephotographo fit an awkward lcoven

Leonard

ee s the

president

f Veritas

Tools nd

LeeValley

Toolsn

Ottawa,

Canada,

manufacturers

nd

retailers f

ine

woodworking

hand

tools.

He is also

he

publisher

and executive

ditor

ofWoodcuts,

a magazine

hat

ocuses

n the history

and techniques

f woodworking.

my office hat

measures

nly

23 by 37

nches. or

years hadbeen

using

my

deskas

a makeshift

workbench

nd

was

rustrated y

both the

ack of any

decent

lamping

ystem nd

enough

lear

work surface.

he desk

s oftenas

cluttered

s hebookcase

n thebackground.

With the

workbench

n

place,

can

now clamp

wood or testing

aws, hisels,

bits,

andsoon,

without

knocking

coffee up

o the

loor or spilling

papers

very-

where.

hebench

s also

ust

he

right h.tght

for usingan

nspection

microscope,

an

nvaluableool

for analyzngfailures

ndsuccesses

n the

world of sharp

edges.

Thebench

occupies

n otherwise

nusable

pace

ext o a doorway.

ince

he

floor space

ext o

it canbe used

only

or foot traffic,

he bench

only adds

9

the

usibility

of my office;

t does

ot detract

nything.

ncidentally

he bench

waspulledout of thealcoveor thisphoto.

More mportant

han

ts utility,

my bench

addsa

wonderfully

elaxing nd

humanizing

lement.

ike

many

people, tire

quickly

of administrative

etail.

With a workbench

andy, can

get

up

from my desk,

wanderover

o the bench

and

inkerwith

tools

or

a

while.

t is ike a

mini-vacation

n the

middleof theday.

Thehumanizing

art

comes

rom surrounding

ourself ith things

ou ike.

I like everything

boutwoodworking.

My office

s filled with

old toolsas

well as

books bout

hiir

historyand

use.

To adda workbench

o the

general

lutter

s

just

another

ayer o

the cocoon.

heworld

ools

muchbetter

whenviewed

rom

an

officewith

a workbench

n

it.



or most

woodworkers,hehome

sa

peacefirl

efuge, here

gives

hapeo creative

deas.t is

he

placewhere

ccidents

ayoccur,

verynature f theactivity.

ikelihood f mishap anbe

few

simple

recautions.

an nformedwoodworker

s a safe

he owner's

manu-

supplied

with all

your

ools.

Before

ob,

make ure

ou

know

how

safety ccessories

hat are

o

protectyou from injury

workingwith a ool.

Most

accidents

re he esultof care-

r

inattention-failure o usea

uardwhencuttinga boardon a

saw,aceointingstockwith bare

rather

han

with a

push

block),

SAFETY

Personal afety

ear

s one nsurance

againstnjury. Here,a

woodworkerouts

a

groove

n a dra"wer

ront,

wearing afe-

ty gJasses,dustmaslgand earmuffs.

effects f somewoodspecies. afety

goggles,

ubber

gloves,

nda

rubber

apron re

good

tandard ttire or any

finishing

ob,

especially

f

you

are

spraying

inish

or

mixingandapply-

ing caustic hemicals.

Fire s another hop

hazard.

Smoke

detectorsre

an nvaluableefence,

ro-

vidingvaluableime or

you

o control

theblaze

page

6).Keep fire extin-

guisher atedABC n your shopand

knowhow o use

t.

Oneof the

eading

causesffire

s mproperwiring.

hether

you

arebuildinga shop

rom scratch r

revamping n existing pace,

lectrical

safety hould ea

priority

(page

7).

No shop hould ewithout he

per-

sonal afetyearllustratednpage 8.

You aneasilymakeome afetydevices,

routerwithoutsafety

oggles.efero thesafetyips

page

4 or ways f avoiding ome f

themorecommon

n the

shop.

Although hebig

stationary achines

eceive ostof

attentionromsafety-conscious

oodworkers,here

re

potential

ourcesfdanger

hat, hough

ess

pparent,

be gnored.

Many inishing

products, articularly

olvents,anbe oxic,although

heireffects

onlybecome

pparent fter

ears

f

prolonged

xpo-

ure.Certain pecies

f woodcancause llergic r

toxic

eactionsn some eople. age 5presentsnformation n

hoosing afe

inishing

roducts

ndon he

possible

ealth

such

s

push

ticks,

ush

blocls,and

eatherboards

page

0).

But

do

not

become

omplacentbout hesecurity

heywill

provide.

ll

thesafety

quipmentn theworldcannot

make

shopaccidentfree. afety

s foremost matterof attitude-a

confidence

n

using he

machinesombined ith a healthy

respector he

power

heseools

wield.

Evenwith the besteffortsat

prevention,

ccidentstill

occur.

Bitsmaybreak, oards plit,shavings

ly

andall oo

often

ind

a

victim.Being

repared

nd aking

prompt

action

canhelpminimize urtherdamage.

ake irst-aid ourse,

keep well-stockedirst-aid it on hand n theshop page3)

andbe eadyo administer

medical idwhennecessary.

Thereare manysafety

deviceshat can minimize the

risk of using

power

took.

The

ablesan

in this

photo

features

a

plnstic

shield

hat covershe

blade; hesplitter

and theanti-kickback

anl protect

gainst indingand

kickback.A hold-downdevice

resses

he workpiece

lat

on the able

and

against he

ence.

A

push

stick

allows he woodnorker o

eed

he

stock nto the blndewhile keeping

ingers

well anay

rom

the cutting edge.

t 3



ACCIDENTPREVENTION

GENERAL

r Make ureworkshopightingnd enti-

lation readequate.

r

Keep hildren,nlookers,nd

pets

way

from

he

work

rea.

.

Concentraten he

ob;

do not ush r

take hortcuts. ever ork

when

ou

are

tired, tressed,r have een rinking

alcoholrusingmedicationshat nduce

qrowstness.

.

Finda comfortabletance: void ver-

reaching.

r Keep ourwork rea lean nd idy;

clutter an ead

o

accidents.

HAND OOTS

o

Use heappropriateool or he

ob;

do not ry o make tooldosomething

forwhich t wasnotdesigned.

r

When

ossible,

utawayrom

our-

self atherhan oward

our

ody.

.

Keepools lean ndsharp.

SAFETYIPS

POWEROOTS

oWear ppropriateafety ear: afety

glasses

r ace hield ndhearing

rotec-

tion.

f

there

s no

dust ollectionystem,

wear dustmask. orallergenicoods,

such sebony, se

respirator.

.

Read

our

wner's anualarefully

before peratingny ool.

.

Tieback onghairandavoidoose-fit-

tingclothing. emoveings ndother

jewelry

hatcancatch

n moving

arts.

.

Unplug toolbefore

erforming

etup

or nstalation perations.

r

Whenever

ossible,

lamp ownhe

workpiece,eaving othhandsree o

perform

noperation.

.

Keep

our

ands ellawayroma turn-

ingblade rbit.

.

Turn ff a tool f it oroducesn unfa-

miliar ibration

rnoise: avehe ool

servicedeforeesumingperations.

o

Do

notusea ool f any

part

of

it

is

worn r damaged.

FINISHING

. Donoteai,drink, rsmoke hen sing

finishing

roducts.

r

Avoid

xposureo organicolventsf

you

are

pregnant

r breast-feeding.

.

Install t east

ne moke etectorn

theceiling f

your

hop bove

otential

firehazards;

eep ully hargedBC

fire

extinguisherearby.

r

Never tore olventsr chemicalsn

unmarked

ontainers.hemicalolutions

should lways estoredn dark

lass

ars

to shieldhem rom ight,

hichmay

changeheir omposition.

o

Store

inishing

roducts

n a locked

cabi et.

oTo

revent

ye

njury, ear

afety

og-

gles,

nd on ubber

loves

hen orking

with

austicr oxic inishing

roducts.

.

Donot

lush

used olventsownhe

drain. onsulthe

Yellow

ageso ind

outwho andleshemical

isoosal

n

your

rea, rcheck ith

our

ocalire

deoartment.

"fl|"ff'lll""1{l"lll"'llll'1lll'lII

ill lll'llll'll|llll ltilll lll rllllIl

1HO?

TI?

Disabling

powertool

To

prevent

unaulhorized se

of a

?ow-

er ool,

olip

he boll of a

mini-Vadlock

throuqhoneof the tinee

n

he

power

keye

out of vhe

way n

a cupboard r

draw-

er thal

can

be

locked.

cordpluq.The ockwillmake t im?o6-

sible o

plu6

n

rhe rool.lf

ou

are

ueinq keyedlock, lorelhe

t

t4



WORKING

WITH

SAFE

FINISHES

I

lthougha numberof

high-quality

inishes ave ecome

ecently,

olvent-based

inish-

products

are still

widely used,and

uperior or someapplica-

Thuswoodworkers

must earn o

hemselvesgainst he

health

ssociated

ith organicsolvents.

solvents

anhavea numberof

effects. hort-term

se an esult

anging

rom headachesnd

o skin and eye rritation.

With

oLvENTs

extended se,manysolvents re

known

to damage

he centralnervoussystem

or

respiratoryract.

Some

glycol

ethers

aresuspectedfcausing

irth defects,

while othersolvents,likemethylenehlo-

ride,have een inkedwith cardiac rrest.

Solvents

an be absorbednto the

bloodstream

n a numberof ways: fter

being

nhaled, r ingested longwith

food

eft n

the shop,absorbed

hrough

the skin,or swallowed

henvapors

et-

tle n saliva. ostsolvent-based

inish-

esareunlikely o cause

armwhen

used

occasionally,nd areonly

poisonous

f

swallowed.

ut you

still

need

o be aware

of the combination ndconcentration

of organic olventsn a

particular

inish

if you

plan

to use he

product

n large

quantities

r overan extended

eriod

of

time.Thechart below

ists

he solvents

containedn a varietyof finishing

prod-

uctsand assesseshe relative oxicityof

each

ne.

Besure o choosehe safest

product

or

the

ob

at

hand.

FINISHINGRODUCT

Woodiller

paste

nd iquid)

Stains

aniline,

iping, GR,

el

nd

laz-

ing

tains;

olor

igments)

Shellacs

white

nd range)

Lacquers

spray

ndbrush, andingealers)

Lacquerhinner

Rubbingils

Danish

il,

antiqueil )

Dryingils

boiled

inseedil,

polymerized

ung il)

Varnishes

tung

ilvarnish,par arnish,arnishtain)

Polyurethanes

poly

arnish,

rethanetains)

Laco er/varn

sh emovers

Waxes

paste

ax,urniture ax)

SOLVENT

Petroleumaphtha,*ineralpirits,*cetone,**ethyl thyl etone,** ethyl

isopropanol,

*

isobutyletone***

Ethanol,*ineralpirits,*oluene,***

ylene,*** ethanol,***

lycol

thers***

Ethanol,*ethanol***

Acetone,**ethylthyl etone,**sopropanol,**ethanol,***ylene,***

lycol

thers***

Acetone,**ethylthyl etone,**sopropanol,**

lycol

thers,***oluene***

VM&P

aphtha,*

urpentine,**oluene***

Mineralpirits,*urpentine**

Mineralpirits,*

M&P aphtha*

Mineralpirits,*oluene***

Acetone,**ylene,*** ethanol,***

ethylsobutyletone,***

oluene***

Petroleumaphtha,*urpentine**

*

Safest

roduct

*

Mildly azardous

roduct

**

Producto beavoidedf

possible

As

anyone

hohas ufferedhrough

anallergic r

rritatingeactiono

wood ustwill estify, orking ith

certa in oods anoose erious

health isks, hedust

rommany

species,ikeblack herry, ouglas-

fir,

and

pine,

s known

o

causeespi-

ratory

ilmentsuch

s hinitis

or

nasalnf lammat ion)ndasthma.

Other

oods,ncluding

ak,

sh, nd

birch, an rritateheskinandeyes.

Toxtc

00Ds

Some pecies,

ike

ebony, outh

American ahogany,ndWestern

red edar,ontainoxic hemicals

thatcan

be

nhaled,ngested,r

absorbedhrough utsandscratch-

es.Althoughhechemicalsre

pre-

sent n minute

uantit ies,

heymay

cause

roblems

angingromhead-

acheso inegular eartbeat.

Protect

ourself

romdirect xposure

to

wood

ust

bykeeping

our

hop

clean nd

wel l ent i la ted. ear

dustmaskorcut t ing perat ions.

When andlingspecies hich ou

know rsuspect ay rigger naller-

gic

eaction,pread barrierream

on

your

kin

r

wear

rotectiveear,

including

loves,

afety

lasses,

nd

long

leevesnd

pants.

Refer

o the

back ndpaperora chart isting

variety f oxicwoods nd heir

pos-

sible ealth ffects.

1 5



FIRE

SAFETY

/a onsiderinshe

number

f

lamma-

\-, Ut.

ut.ri"ul,

nd

potentialgnition

sources

n

a

woodworking

hop,

irepre-

vention hould eoneofyour

oremost

safety oncerns. awdust, ood,paint,

and

hinners end o accumulatelften

theyare

near

ools

hatproduce parks

and

heat. he

combinat ionanorove

volat i le:Whenvaporizedn

a imal l

enough oncentraiion f air,a small

quantity

of lacquerhinner, or exam-

ple,

canbe

gnited

by

a spark rom a ool

andcause

ife-threatening

xplosion.

The irst step n fire safetys preven-

tion.

All finishing roducts nd

solvents,

for

example,hould estored way

rom

heat

sources

n

airtight

glass

r

metal

containers,referablyn a ireproofcab-

inet

(page

9).Hang ags oaked ith

flammable hemicalso dry outdoors,

or soak hem n waterandstore hem n

sealed

metalcontainers.Whenworkine

with inishing roducts,eepwindowi

openand he shopwell

ventilated.

Be

prepared

o dealwitha fireeffec-

tively. nstalla smokedetector n the

shop eiling r a

wall,

and

keep

nABC

fire

extinguisher

earby.Design

fire

evacuation

lan

hat

maps

out two

pos-

sibleescape

outes

rom each oom of

thebuilding n which heshop s ocat-

ed. fthe fire nvolves n electric

ool,a

power ord,or an

electricalutlet, hut

offthe

power.

Call he

ire

department

immediately,nform

themof thenature

of the

ire,

and ry to extinguishheblaze

yourself.

ut f the lames annot econ-

tained, r the ire s

coming

rom nside

a wall

or ceiling, vacuatehebuilding.

PREPARINGGAINSTIRE

Installingsmokeetector

Openhecover f hedetector,old hebase n he

cei l ingrwal l , ndmarkhe crew oles. ore hole

fora screw nchort eachmark. ao heanchorsnto

the

holes nd, oldinghedetectorn

posit ion,

r ive

a screwntoeach nchoro securehebase

right).

Install battery ndclosehedetectorover.

est

he

device nce very onth. irst,

ress

he estbutton.

Then, low uta l i t match rcandle elow vent,

letting

mokenter

t. Replacehebatteryf healarm

does ot oundorboth ests-or f it emits chirping

sound,

ndicat ing

hebattery

sweak.

Controllingire

Toext inguishsmal l , ontainedre, se nABC-rat-

eddry-chemicalreext inguisher,hichseffect ive

againstll hreemajor lassesf ires: urning ood

r

other ombustibles

Class

),oil-

or

grease-fed

lames

(Class

),

and lectricallazes

Class

).Position

our-

self safe istanceromhe irewith our acko he

nearest

xi t .

Holding

heext inguisherpr ight ,

ul l

he

lock

in

outof hehandle

insef)and

im henozzlet

thebase f he lames.queezehehandlend pray

rna

quick,

ide{o-sideotion

/eff)

ntil he

re s

out.

Watchor

f

lashback,"r ekindl ing,

nd e

prepared

tospray gain.

f

the i re preads,eavehebui lding.

Dispose

f burned asteollowingheadvice f he re

department.f ter se, aveheext inguisher

rofes-

sionallyecharged;eplacet if it is non-rechargeable.

T6



ELECTRICAL AFETY

lectricity

lays

major ole n the

modernwoodworkinghop,

ow-

machinesnd ools,

ighting ix-

nd amps, ndheating ystems.

ocommonplacehat t isall

easy

o forgets

potential

or danger.

electricalhock,

ven ne hatcan

elt,canbedeadly.

or his ea-

on, heelectricalystem

s

strictly

eg-

lated ycodes ndstandards

esigned

o

protect

ou rom ireandshock.

Livingsafely

with

electricity

lso

equires

ollowing

asic

recautions

designedo

preventmishaps.nspect

lugs

or cracks nd

power

ords

or

frayrng, nd eplacenywornor dam-

aged artbefore singa tool.Never

replaceblown use

with

one

of ahigh-

eramperage.o

not

plug

a hree-prong

plug

nto a wo-slot utlet y

remov-

ing he

grounding rong

roma hree-

prongplug.

nstead,eplaceheoutlet

ithaGFCI

WA.

Before ndertaking

repair,

hut

off

theoower t heserviceanel.

owork

on

hesystem, ear ubber

loves

nd,

here

ossible,

se nlyonehand,

eep-

ingyour ree and ehind

our

back.

MINIMUM IRE AUGE

(|REXTENSION

ORDS

PLUGGING

N

SAFELY

Using FGIutlets

TheU.S.National lectricalodeequireshatany

new

utlet

n

a

garage

or unfinishedasementust e

protected

ya

ground-fault

ircuit

nter-

rupter

GFCI).

GFCI

rotects

circuit-and

ou-by

monitoring

he

low f

electricityassinghrought and rippingnstantlyhent detects leako

ground.

f

you

need

o

replacenoutletn

your

hop,nstall GFCI,uch s

theone hown bove,ollowingthe

anufacturer's

irections,r

have

quali-

f ied

electrician

o hework. estheoutlet nce very

onth

y

pushing

he

TEST

utton;

heRESETutton hould

op

ut. f it does ot,haveheoutlet

serviced.

o eactivateheoutlet,

ress

heRESETutton.

AMPERAGI

RATII{G F OOL

o-2.0

18

2,1-3.4

18

3.5-5.0 18

5.1-7 .0 18

7. I -12,0

18

1 2 . 1 -1 6 . 0

1 6

MINIMUMAUGE

(lR

DIFFERE}ITENGTHORDS

25' 50'

18

1 8

1 8

1 6

T4

I 2

Choosing

wirewith

he

proper auge

Using nextensionordwith he

wrong

auge

an

cause dropn ine oltage,esultingn oss fpow-

er.excessive

eat. nd oolburnout. efero he

chart t eft o determineheminimum ire

auge

for he ool nd ask t

hand.f, or nstance,

our

toolhas 7

amp

motor nd

youlre

using

75{oot

extensionord,heminimum

auge

houlde

14.

Choosenly ound-jacketedxtensionordsisted

byUnderwritersaboratory

UL).

75 '

1 8

1 8

1 6

t4

T 2

1 0

t 7



PERSONAL

AFETYGEAR

-f

h.

personal

afetyquipmenthown

I

below an

go

a ongway oward

shieldingyourommostdangersn the

workshop.

utcarrying n nventory

of safety ears notenough;he tems

must

be

properly

sedo

protect

ou

from njury.

Theneedor

sometemsmaynot

be

readily

pparent,lthoughhedangers

are ery eal. ew

woodworkerseedo

be

reminded

f thecutting

power

f a

spinning aw lade r

ointer

utterhead.

Less

ellknown re he ong-term

ffects

ofbeing xposedo hesound enerated

by

power

ools.

The

charton thenext

page

ists

a

variety

f

power

ools long

with

theirapproximateoiseevelsn

decibels.

he

chartalso ndicates

he

Iongest

ecommendedime

that an

unprotected

erson

canbe exposedo

various

evels

efore

iskingpermanent

hearing oss.

Remember,oo, hat even hort-term

exposureo somenoise,while t may

not lead

o hearing oss,

can dull the

sensesnd cause woodworker's

lert-

ness o flag-a

setup

or

an accident.

A PAI{OPIYFSAFETYOUIPMENT

5afety

gogglee

Flexible,

molded

plaati"

f,:

6o6qleo

protect

eyee.

lli

Typewith perforated vani \

holeaehielda

aqainat

impact

injury and sawduat; type with

baffled vents

protecto

a7ainot

ahemi al apl ehea: nonvent d

qoq7lea

lbo available.

Faae

shield

Clear

plaatic

ahield

pro-

tecta

a4ainat.

lyinq

debria

and eplaahea; eaturea

adjuetable head

4ear

Work

gloves

For

handlinq ouqh

lumben

ypically fea-

turee leatheror thick

fabrio

palmo

and

finqer-

tipe with elaaticized

or

knitted wrists

for

one-time-uoe

protec-

tion aqainet inhaiation

of

duat

or

miaX

featurea

a

cotton

or

fiber

shield with

an adjuotable head

atrap

and a metal noee

olip

Rubberglovea

Houaehold

ubber

gloveo

or dieposable

vinyl

qloveo

protect

aqainot mild

chemicals

or finishea;neoprene ub-

ber

alovea

shield akin

from

cauetic finiahinq

Producto

Ear muffs

Cuahionedmuffa with

adiuetable

plaatic

head

eirap

protbct hearinq

againot hi1h

intenaity

noiae

rom power

oola

Dua

-

aa tri dg e re s

pi

rato r

Frotecta

aqainet fumeawhenworkin4

with chemicala

or aprayinqa finiah.

lnterchanqeable

iltera

and chemical

cartridqee ehield

aqainat opecific haz-

ards;

filter

prevents

nhalation

of dust.

Cartridqea

purify

air and

expel

oxina

th rough exhalation

valve

Ear plugs with neakband

Reuaableduat mask

Features

a neoprene ubber

or aoft

plaatii

frame with

an adjubtable head etrap

and

a

replaceable

otton

fiber

or

7auzefiltec

protecte

againet duet

and

misL

Detachable oam-rubberpluqa

compreooed

and inaerted into ear

canals

provide

hearinq

protection

from

high-inteneity

power ool

noiae;plaatic neckband its

around neck

2afetyglaeeee

j

I

?;f:lT,if'tr:;i::fT:f

leneeeproteot

eyeb

rom

flyinq

wood

chipo

and other debris:

t.ypically eature aide

ahielda

t 8



SAFETY

MACHII{EOUND

EVELS

1%-Hf outer

1 1 5

112

I09

2-HF circulareaw

l-HP router

%.-HP adial arm

%-HP

oi

%-HF

outer

%-HPband

2-HF

ahaper

2-HP table aaw

%-HFdrill preao

*

Higheet

decibel

rating

while

cutting

hardwood

Occupational

afety a

n

d

Healih Adminiat.rat'ion

(OAHA)

atandarda

for

permiaoible

n

oiae exp eu

e

witho

ut

h

ea

i n4

p

otec'tio

n

Sound evel

in

decibela

Maximum

oafe expooure

per day

(hr)

EVELS

R(IDUCEDYPOWER

(|(ILS

rill

press

s unlikelyo damage

our

earing-unless

ou

un

he

machinellda y

long-unprotectedxposureo thenoise roducedya 1 %-horsepowerouter anbedangerousfter nly

he bove

hart howspproximate

oiseevels

roduced

ya varietyf

power

ools.

eepn

mind hat ools ithdull uttersrblades

enerate

ore oisehan hose

ithwell-sharpenedutting dges.

RESPIRATOR

hecking

or

air

eaks

respirator

s

only s

good

s tsseal gainst

our

ace.No

eal, o

protection.

o

est

our

espirator,

lace

t over

ou r

ace, ettinghe opstrap verhecrown

f

your

ead. djust

side traps

ora snugit.

To

est he

espirator,overhe

utlet alve ith our and ndbreatheutgently

right).There

hould e

no

air

eakageroundhe acepiece.

f

air

eaks ut

f he espirator,

eadjusthestrapsora tighter

it. Replace

he acepiecehen ecessary

ollowinghemanufacturer's

instructions,r eplacehe

espirator.se heappropriateil-

ers

or he

ob

at hand.

lf

you

have beard,

se full-face

mask

ith orced-airentiation.)

,.+s\N\\

,$ ;

{

f

\ /

I 9



SAFETY

A VARIETY

)F

PUSH

TICKDESIGNS

12"

-

12"

'

PUSH

TICKS

Push ticksor eeding

tock cross

stationary

ool ables anbe

pur-

chasedeady-made,

ut heyare

easyo maken theshop sing%-

inch

plywood

craps nda band

aw

orsaber aw. he ariations

hown

aboveanserve s ough

uides,

ut

noone hapes deal

orevery itua-

tion.Design

push

tick hat scom-

fortable

o

hold

andsuitedo he

machine

ndooerationt hand. he

long

ase f a rectangular

ush

tick

(above,

eft)or shoe-shaped

odel

(above,

ight)allows

ou

o apply

firm

downward

ressure

na work-

piece. i ther esign i l lef fect ively

keep

our

ands

wayrom

a blade

or cutterwhile

ushing

arrow

tock

across saw able.

For

most utson

a table aw, esign

a

push

tickwith

a

45'

angle etween

the handle

nd he base

above,

en-

fer.).

push

tick eaturing

smaller

angle, i th

hehandleloser

o he

table,works etterorripping ood

ona radial rm

saw.Whateveresign

you

choose,henotch n he bottom

edgemustbedeep nough

o support

theworkpiece,ut

shal lownough

not o contacthemachineable. ou

canalso hamfer

heedges f he

handleor

a more omfortable

rip.

Keep

our ush

ticks lose t hand,

ready

o feed tockwhen ecessary.

Touse

push

t ick na radial

rm

saw

below),

et t against

he rail-

ing

endof heworkpiece

nd eed

it into

heblade; t he

sameime,

apply ome ide ressureo keep

thestocklush gainst

he ence.

Whenhecut s

completed,etract

the

push

t ick areful lyo

prevent

i t f rom

atchingn he

blade.

20



SAFETY

PUSHBTOCK

LOCKOR

ACEOINTING

ide ase f

he

push

lock

s deal

orsurfacinghe

f a board

na

ointer.

lthough

push

locks

orsuch

obs

re vailable

ou

aneasi ly

ashion

your

wn.

Refero the

llustration

or

suggested

imensions,

ut ai lor

he

design

o suit

our

wn eeds.

Cut he

pieces

o size,

hen

lue

he

lip o he

underside

f hebase,

lush

withone

nd.Screwhe

handleo

he

top,

positioning

t so he

back seven

with heend

of hebase.

r ivehe

screwsrom he

undersidef he

base;

besure

o countersink

he

astenerso

avoid

marringhe

workpiece

hen

ou

feed t acrosshe

ointer

nives.

ore

hole

earhe rontend

of he base

o

you

an

hanghe

push

lock n he

wal lwhen

t isnot n use.

Touse he

push

lock, et

hework-

piece

n he

ointer 's

nfeedable

few nches

rom

he

knives,ut t ing

itsedge

gainsthe

ence. hen

ay

the

push

lock

quarelyn op

of he

stock, entered

etween

ts

sides,

ith

the

ipoverhe

rai l ingnd f he

workpiece.ith

our

eading

and

on he

ront ndof he

stock nd

our

thumb

racedgainst

he

push

lock,

slowly

eed heworkpiece

crosshe

knives

/efil. For

tockhinner

ha n

3/a

inch, se nly

he

push

lock.)

pply

downward

ressure

o keephestock

flaton he ables

nd ateral

ressure

to keep

t butted gainst

he ence.

2 I



SAFETY

FEATHERBOARDS

Featherboards,

lso nown

s in-

gerboards,

reused

o keep tock

pressed

nugly gainst

he ence

r

table

f a stationary

ool. hey

lso

serve santi-kickback

evices,

ince

the ingers

l low workpiece

o

moven

only nedirection-toward

the

blade rbit.Two

asic esigns

are

hown tright.

hemiter-slot

featherboard

s

attached

o a bar

that sclampedn hemiter lot f

a woodworking

achine

able. he

standard

eatherboard

sclamped

directlyo he

able r ence.

To

make ither

ype, ut

a %-inch-

thick oard

to 4 inches ide

nd

long

nough

osuit he

ob

at hand.

Cuta 30"-

o 45o-miter

t heend

of he

board,hen

mark

parallel

ine

about inchesrom

hemitered

nd.

Cuta series

f X-inch-wide

lotso

themarkedine bout

l

inch oart,

creatingrow

f

pliable

ingers.

or

the

miter-slotype,

outa slot

down

themiddle

f heboard ide

nough

for

a machine

crew;

lso uta wood

bar he ength

ndwidth

f he

able's

miter

lot,Bore hole

or he

screw

throughhebar, ountersinkingt so

the

screw ead

anbe ecessed

n

FEATHERB()ARDS

9tandard

featherboard

theunderside

f

hebar.

A

carriage

bolt

r

lat-head

achine

crew

ill

work

well.) o

setup he eatherboard,

slip hescrew

hrough

hebar, it

the

bar n he

ablemiter

lot, nd

use

washerndwing ut o astenhe

featherboard

ightly

o hebar

o ts

f ngers old

heworkpiece

gainst

the ence.

lamp

hemiter

ar n

place

t he ront

r

back f he

able.

For

hestandardeatherboard,

ut

a notch

utof one

edgeo

accom-

modate

support

oard. o

use he

device

n he

able aw

/eftl,

lamp

one eatherboard

o he ence

bove

theblade,

nd

lace

second

ne

halfway

etween

heblade

nd he

front f he able. lamp support

board

erpendicular

o he eather-

boardor

extra

ressure

o

prevent

i t f rom

reeping

utof

place.

or

thecut

shown,eed

heworkpiece

into

he

blade ntil

our

railing

in-

gers

each

he eatherboards.

hen,

with

hesaw

till

unning,

oveo

the

back f

he able nd

pul l

he

workpiece

ast

heblade.

r, use

a

push

tick

o complete

hecut.

22



FIRSTAID

ost

woodworking

accidents

rise

from the

mproperuse

of tools

guards,

nsafe

work

habits,

mishandling

azardous

aterials.

to setup properly or a

gatheringogetherhe

ools,equip-

materials

ou

need.Always

he appropriate

afety

ear.Work

ever urry hrough

a

ob.

Beespecially

arefrrl-or

stopworking-

ifyouare

atigued.

Accidents

anbefall ven

he

most

carefirl

oodworker.

oardsplit,

blades

nick,andiquids plash. anyinishing

products

ontain hemicals

hat

emit

ioxic umes,

ausingizziness

r

nau-

sea. eep

n mind he

potential azards

of anv ool

or material

ou

use. tore

first-aid it, stocked

ith hebasic up-

plies

hown

elow,

n

aneasily

ccessible

spot

n yourshop.n theevent

fanacci-

dent,

ouwill wantanyoneo

beableo

find t quicklyo administerirstaid.

Keep mergency

elephone

umbers

handy.

echniques

or handling ome

common

hopmishaps

reshown n

the

ollowing

ages.

FIRST.AIDUPPTIES

Tweezera

Rubbingalaohol

Alao known a

iaopropylalcohol:

aterilizea tweezero

and other

firat'

aid

equipment

Adheaive bandagea

)terile

4auze

dreeeinqo

with adheaive

atripa

for

protecting acratchea

or

minorcuta. Availablen a

widevariety of

sizes and

ahapes:

gquare,

ectan'

qutAr,

ouid, butterfty,

and

finaerbip

Oauze

roller bandage

Otedle roll oecurea

qauze

dreoa-

inga;

aotened with medical

tape

or aafety

pin,

or by knottinq.

Avail-

able

n lenqtha of 5

to 10

yardo

and widtha of 1 o 4 inchea

Medical tape

)ecurea

qauze

dreeein7a,

auze

roller bandaqes

or eyepada:

hypo-

aller4enic

or aenaitive

akin.

Avail'

able

n

lenqthaof 2 % o

10

yarda

and in widths of

%to 5

inches

Extract eplintera

or other

emall

objecto

lod7ed n

akin. Made of

etainlese steel in a variety of

ohapee

and aizea;

lat-tipped

type 41/z

nchea on7

e

common

Ipeaaa eyrup

For inducin7

vomitinq

in a

poiaoningvictim.

Caution:Administer

only

f

advieed

by a

phyeician

or

poiaon

control center

Triangular bandage

Multipurpoee

cotton banda7e

can be

folded to make alin4,pad,

or bandaqe;

meaeurea 5

incheaacroeo baoeand

36 to 40

incheaalonaeach

aide

Eye

irrigator

Filled with water and

ueed o fluah foreiqn

particleo

from eye

Hydrogen

peroxide

For cleaninq

wounds

before applyinq

adheoive

banda7ee,1auze

reaa'

inga,or

qauze

roiler

bandaqea; ommonly

available

n 3%

aolution

Gauze

dreeaing

)terile

pad

for

coverin7

a

wound; ecured

with medical

tape or

qauze

oller bandaqe.

Available

n aizes of 2-by-2,

3-W-3

and

4-by-4 inchea

r\r\

\ \ \ )

Eye

pada

\-'l

)terile

pado

taped

over eyee

to protect

them and

pre-

vent

movement:aelf-aane-

oive

patchea

alao available

23



SAFETY

PROVIDING

INORIRST

ID

Clearing

pailicle

rom heeye

Hold

our

affected ye penwith

he orefinger

nd humb

f

onehand.

Slowlyotate

our

eye, f necessary,

o helpexpose

the

particle.

ently ipe

wayhe

particle

sing

he wisted

endof a tissuemoistened

ithwater

above,

eft).

Or, ill an

eye rrigator

ith

coolwater nd

use t to flushout

he

particle.

Lean orward ithbotheyes losed ndpresshe rim of the

irrigator

gainstheaffected

ye, nd

ilt back

our

head.Open

your

yes

above,

ight)

andblink

everalimes

o flushout

he

particle.

f

you

annotemove

he

particle,

eekmedical

elp

immediately.

aution: onot

emove

particle

hat s

on he

cornea,s

embedded,rhas

dhered

o heeye.

/ /

J

Flushing

chemical

iom he

eye

Holding

heeyelids f the

affected ye

apart,lush

heeye horoughly

orat east

15 minutes

nder

gentle

lowof

cool

waterrom

a faucet

right)

r

pitcher;

il t

your

eado one ide

o

prevent

he

chem-

ical

rom eing ashed

nto he

uninjured

eye. f

you

areoutdoors,lush

heeye

using

garden

ose.

ently over oth

eyes itheyepads rsterile auze ress-

ings

nd eekmedical

elp mmediately.

24



SAFETY

uta splinter

he

skin round

hesol inter

i th

water.

A

metal plinter,

ven

you

are

able o

removet, may

equire

or etanus;eekmedicalelp,)

o

emovehesplinter,

terilize

needle

ith

ubbinglcohol.

ase

end

of hesplinter

ut romunder

he

heneedle,

hen

ull

t out

with

right).

Clean

he skinagain

oap nd

water.f thesplinter

annot

e

emoved.eek

medicalttention.

Treatingcut

Wraphewound

n a clean loth nd

apply irect ressureith our ando

stop ny

bleeding;eephe

wound levat-

ed. f thecloth

ecomeslood-soaked,

wrap notherloth

vert. lf bleeding

er-

sists r he

wounds deep r

gaping,

eek

medicalelp.Otherwise,

ashhewound

withsoap ndwater,hen

bandaget;

or

a narrow,

hallow ound,

rawtsedges

closed

with

a

butterfly andage

left).

25



SAFETY

CONTROTLING

LEEDING

Applying

irect

ressure

ostop

leeding

Tohelp

top

rofuse

r rapid

leeding,

pply irect

ressure

o

thewound

ith

a

gauze

ressing

ra clean

loth nd, f

possi-

ble, levatehe njuryabove,eft).DiecIpressurehould top

the low f blood

ndal lowt

to c lot . f

thedressing

ecomes

blood-soaked,

ddanother

verhe irst

ne; void

i f t inghe

dressingo nspect

hewound.

t wi l l

beeasier

o maintain

steady

ressure

f

you

wrap

hewound

itha roller

andage

(above,ight)oradded irectpressure.f youcannot top

thebleeding,

al l ormedical

elp.

4 = ,

@ \

HANDTING

SH(ICKICTIM

Treating

shock ictim

Some

egreefshock-ei ther

mmediate

r

delayed-accompanies

ny njury.

hock

anbe

provoked

y oss

f blood,

ain,

ran

al lergic

reaction.

igns f shocknclude

nxiety

rconfu-

sion; old rclammykin;weak,regular reath.

ingor

pulse;

nd oss

f consciousness.

f

you

suspect

n njury ictim

ssuffering

rom

hock,

immediately

all or

emergencyelp.

f thevictim

is

conscious,

lace

imonhis

back i th

is eet

propped

p

8 to 12 nches

bovehe evel

f his

head

right).

oosenhevictim's

lothing

round

theneck,

hest, ndwaist.

eep

hevictim arm

with blanket,

utavoid

verheating.

onot

give

thevictim

nything

o eatordrink.

26



SAFETY

VICTIMOF

ELECTRICALHOCK

victimrom

ive urrent

person

ho ontacts

live urrent

ay

nly

mild ingl ing

ensat ion.

owever,hevict im's us-

nvoluntar i ly

round

he

onot ouch

hevict im r

he

ource.

nstead,mmediately

ow f e lectr ic i ty

n hecircui t

t

a wal l witch

r heservice

anel.

f

e lectr ic i ty

annote

hut f f

mmedi-

drywood

mplement,uch

s

andle,o knock

he ict imree

electrical

ource

right).

all or

e lpmmedia te ly ,

hen heck

vict im'sreathing

nd

ulse.

f here

nobreathing,

ive

mouth-to-mouth

esus-

f heres

no

pulse,

ive

ardiopul-

esuscitatton

CPR)

nly f

you

re

ed.

f he ic t im

s

breath ing

nd

neck r

backnjury,

lace

im n

ecovery

osit ion

below).

t l t he

d ack

aceodraw

is ongue

rom is hroat

nd eepheair-

eephe

v ic t im a lm n t i l

27



t"tr,,,

{ -

r.

" \

. . \

; r f ,

''a*6*"'n'

\

,9

. G

i



s they

gain

experience

and accumulate

ools.

ine

for

place

o

heir skills.

n

their

he workshop s an

with a sub-

workbench and an

of stationarv

machines

portable

ools.

The eality

woodworkers,

ow-

s much more modest.

neverseems

have nough

ight,

power,

r

Fewhomes

ave

pace

pecif-

esigned sa

workshop

As a result, ettingup a

demands reativity

and lexibility; he taskoften

onverting

n arcaoriginally

ntended or someoth-

purpose.With careful

lanning

and

orethought, owever,

might appear nsuitable anbe urned

nto an

lace

o work.

Althoughsize

s

often he

irst consideration,everal ther

maybe

more mportant.For example, ituating

n a spareoomon the

main loor of a homemay

provide

argeworkingarea, ut noiseand dust

rom toolswould

ther

members

f

the amily.To suit

needs ithout ntruding oo

muchon the

people

with,woodworkersommonlylocateomeshopsn

SHOPIAOI-]T

Even n spacious hops, ools occasionally

eed o be

movedaround;

in

small

shopl reassigning

floor

space

may

be a

part

of

every

project.

A wheeledbasecan

make a 10-

inch tablesaw,

ike the one

pictured

here,easy o

reposition.

thebasement r a

garage. ach

has ts

pros

and cons.

A

base-

ment ii apt to be damp and

mayneed o have ts wiring and

heatingupgraded; ccessan

behamperedynarrowdoors,

tight stairways,

nd ow ceil-

ings;and

ventilationmay

be

inadequateor finishing asks.

A

garage,

n the otherhand,

s

apt o be cold; t may equire

wiring andheating. hewood-

workermayendup

ostling

or

space

ith

a caror two.

Still,

with a bit of

planning

and the

proper

ayout, even

theseocations anbe turned

to your advantage: basement

can eheatednd

powered ore asilyhana garage. n he

other

and,

garage

as arger oor hrough

hich o move

lumber

ndsheet

aterialsike

plpvood,

tsair

s ess umid,

and hedinof

power

ools nd umes f inishingan e

so-

lated rom iving

spaces.

This hapter utlinesome asic

rinciples

o followwhen

designingnew hop r upgradingn

existingne.Topics

include

lannng

pages

0and3l);allowingdequatepace

or

tools

pages

2-40);

nd

providing

or necessities

ikeheat,

light,

andelectrical

ower

pages

1-45).y isting

our

objec-

tives ndclosely xamining

ourwork,

you

canapply hese

principleso create ayouthatsuits ourownneeds.

hourspent

lanning

shop ayout

ays

dividendsater

on.

Tb

determine

hebestway o arrangehe ools

lanned

for

theshop,e woodworker

laces

verhead-viewilhouettes

of the oolson a scale

rawingof thespace.

29



WORKSHOP

LANNING

I

t

is ar

easiero shuffle

aper

utouts

I of vour ools n a emplatehan

t is

o

draga able aw alfwayicrossheshop.

Time spent

planning

he ayoutof your

shopwill bemore han amply ewarded

in reducedrustration nd ncreasedffi-

ciency

whenyou go o work.

Designing

shop

nvolves

uggling

many nterdependentariables,rom

localhumidity

and he

qpe

of

work you

do to the heightof the ceiling nd he

costof

wiring. To help

sort

hem

out,

ask

ourselfa

etofquestions,

ike hose

in

the checklist n

page

31, o

help

determinehe kind of shoo

most

suit-

able or yourneeds nd emind ouof

factors that may affect its design.

Remember,oo, a basic

rinciple

or

T()OIPLACEMENTNDWORK LOW

anyshop,

llustrated

elow,hat he

um-

bershould akea

relatively

traight

ath

as t is

processed-almost

s hough he

shoowere nassemblvine.

A multipurpose statio ary

power

tool can help

you

make

the most

of

a

cramped

work-

space.

he machine

at

right

is

an all-in-one tablesew,drill

press,

isk sander, nd lathe.

Acces

ory

attachments

also

allow it to

serve

as a

band

saw,

igsaw,

and

ointer.

Refer o the llustratednventory

f

stationary achinesnd ables

tarting

on

page

2asa

guide

o space

nd

ight-

ingrequirements.hebestway

o design

Designingshop round

thewoodworking

rocess

Formax imum

ff

c iency ,

ayOuthe

too ls

n

your

hop o hat he umber

follows

f aily direct outerom ough

stocko nishedieces.he iagramt

lef t l lustrates

logical ork ow or

a

medium-sizeorkshop.t

heupper

lef t -handorners he

entrance

here

lumbers

storedn

acks.

o he ights

thestock

reparation

rea, evoted

o he

table aw

or

adralrm aw),

ointer,

nd

p laner ;

t h is ta t ion ,umbers

cut o

roughength nd urfaced.heheart

f

thenextwork rea, ear

hebottomight-

hand ornerf

hedrawing,s hework-

bench. adiatingutwardrom hebench

are heshop's ther tationaryools-in

this ase, drill

press,

athe,outer

able

(or

haper),nd and

aw. ool abinet

isnearby.oving

lockwise,he nalwork

areasset

aside

or

assemblynd nish-

ing. his

tationeatures ableor

gluing

up

pieces

nd helvesordryingnd

tor-

ing. he pray oothsclose

y,but

solat-

ed rom heshop ywalls

n h ree ides.

Lumber

gtoraqe

Dandsaw

lxH

€_-J

Wi,ft

Izil,",t

30



SHOP

LAYOUT

ayout s o experiment

ith

arrang-

photocopies

f

scale rawings f

page

5)

on a sheet fgraph

emember

hata ool should e

o hatan accessoor svis-

from it. In addition,a

workpiece

back rom the tool should

not

able o strikesomeoneworking at

Consider edicating

paces

or

spe-

A finishingarea

ooth requires

riority n

plan-

because

f ight, emperature,nd

needs.

Depending

n

the extentof

your

shop

ocalzoning ndbuildingcodes,

ou

need o obtainpermits; onsult

building

nspection

ffice.

illl llt|ltlll

jrllll lll lllllj lll lrllll lll lll llj lll lll

ll1

1HO?

Tt?

Atable eawon

wheels

Decause

I is Lhe arqeot,nd

he

viesl

w

oo

workin No l

in manyohopo, Iable

oaw

uoually

taye

pul,

which

an

be

a

drawbackin

a emall

ohopwhere pace e

at,a

premium.

y mounting

il

on

wheels, owever,

ou

can

eaeily hifl

your

6aw

out of

the

waywhen t is not in uee.lf

your

sawdid

nol

come

witha wheeled aee,

measure

lhe baseof

the moNor

oueinq

nd

have melalworkin4hop

build

rollinq aoe o

your

epecificaf,ions,

ormaximuftlrlafitau-

verability,

he baseehould avehree

wheels,ncludinq

ne haL

pivoNe.

eephe saw rom moving r tiVpingwhen

N e n

ueeby

wedqinqwo Irianqularwoodehimeunder he

wheels

l

lhe

front

of

the baee.

TOGATION

o

Which

vailable

reasn andaround

your

ome re ppropriateora shop?

o

How asys heaccesso these reas?

.

ls

heelectric

iring dequateor

pow-

ering

our

ools nd ighting?

.

Howwell re heareas eated,nsulat-

ed,and entilated?

r

Will hop oise isturb ther reas?

.

lf

the

ocationsa basement,i l l he

shop esharingpace itha urnace

room r

aundryoom?

.

l f the ocat ionsanoutbui ld ing

r

garage,

ow

much pace

s aken pby

cars, icycles,

awnmowers,nd oon?

.

Does

he

buildingr

garage

ave ny

heating,lectricity,r

plumbing?

o

How ecures he building r

garage

from heft?

A SHOP AYOUT HECKLIST

TYPE FWORK

.

Whatype f woodworking

rojects

il l

you

be

doing?

o

What

ize re

he materials

ou

will

needo movenand utof heshop?

'

Howmuch pace il l bedevotedo

storing

umber ndwork-in-progress?

r

What tationaryachines,

odableow-

er ools, ndhandools

ill

ou

eed?

.

Are here noughlectricalircuitso

supply

our ower

eeds?

o

Howmany

ightingixtures

oes

ou r

work eouire?

.

Howmany

workbenches,ssembly

tables, ndaccessories

ike ool abinets,

scrap ins, nd awhorsesill

you

need?

.

Will ocal easonalemperaturesnd

humidity

ffect

our

work?

.

Will

ou

edoing

ot

of

nishingork?

WORK ABITS

r

What

oomemperature

ill

you

need

to

work

omfortably?

.

What

ypeof

light

do

youprefer

forworking?

r

Wil l

ou

be

workingur ing ayl ight

hours,rwi l l

you

beusingheshop

at night?

o

Whichools o

you

expecto use

mostoften?

.

Will

ou

eworkinglonen he hop, r

will t beused yanother orker? ould

that

person

ave asy ccesso heshop?

o

Will

ou

need

o

ock heshop rkeep

it off-limitso childrenr

pets?

o

Howmany ours

er

daydo

you

expect

to spendn heshop?

r

ls he loor ing ade f a materialha t

iscomfortableo stand n

or ong

eri-

ods f ime?

31



TABTE

sAw

PLANNING

FOR

STIIfIONARYTOOLS

LIOHTING

Naeda iqht from

above, to the laft

of

and behindblade

CLEARANCE

Needa enouqh

clear-

ancearound able for

lon6

boarde;keep ine

of

work

clear. Best loca-

tion ia

center of ahop

CLEARANCE

LIGHNNA

Neede iqht.

rom

aboveand to

the riqht

of

blade;

porLable

clamp-on i7ht

can be uaed

RADIAT

ARM AW

No

clearance

eeded

on

throat-

column aide; requirea4

feet of

clearanceon

other aidee or lonq

boarda.

Keep ine of work

alear.

Can be

poeitioned

aqainat

a

wallor in a

corner

LIOHTINO

Needa i7ht

from

aides,

front

and

above

ROUTER

TABTE

LIOHTING

Needa iqht

from front

and both

aides

CLEARANCE

CLEARANCE

Na clearanae need-

ed behind

ool;

qood

location a againat

wall.Allow

about 12

feet

of clearance

on either eide or

long

boarde

Relatively ortable.Allow

at

leaat

6 fert

of clearance

in front

and to the aides

when n

operation;needo

no

clearancebehind able.

Good ocation e

aqainet

wall: keep ine

of

work

clear so that

a

kiaked

back workpiecewould

not.atrike

another worker

32



DRITL

PRESS

iqht

muat

focua

bit

clamp-on

Iiqht can

be uaed

CLEARANCE

No clearance

needed

behind

oob

qood

oca'

tion ia aqainetwall,

AIIow3

feet

of

clear-

ance on either

aide,

and enou4h learance

in front for wide

work

LIGHTINO

Needa

iqht

from lefL

and

rear

of

tool

CLEARANCE

Allow3 feet of clearance

n front

of

tablea and enouqh

learance n

both aidea

or long boarde;

keep

lineof

workclear.

Dest location

e

behindor to

[ef,

of

table eaw

SHOP

LAYOUT

SHAPER

LIGHTING

Needa

ight from

fronL and

aidea

CLEARANCE

Allow

at

leaat 6

feet

of alear-

ance

n front and

to the sides:

no

clearance

needed

behind ool.

Good

ocation

s aqainat

wall;

keep ineof

workclear ao that

a

workpiece

hat

ie

kicked

back

will

not atr ike another

worker

JOINTEUPTANER

LIOHTINO

Needa ightfrom

above

and

front

of tablea

CLEARANCE

Allow3 to

4 feet

of

clearance

on

aidea,

more or lonqboarde;

keep

ine

of

workclear. Good

location ta near

umberatoraqe

rack for eaey aurfacin4of

atock

TATHE

LIOHTING

)verhead

li4ht

muat

focua

directly on

work

CLEARANCE

Leave

feet of clearance

n front:

can

be

poaitioned

7ainet a wall

aince

work s containedbv

tool

JOINTER

33



SHOP

LAYOUT

BENCH RINDER

Deet. ocation a near

lathe

aince he cutting

toola

ueed

with it require

frequenL i

ndinq. Need

clearance nd

li4ht

on

front

only;

porEable

clamp-on ight

can be aimed

directly

at

whee[

ASSEMBLYND

FINISHINGABTE

LIGHTING

Neede iqht from

above

and

aidea:nat-

ural i4ht preferable

CLEARANCE

Minimal

clearance

needed;

qood

oaa-

tion ie near window

STATIONARY

BEtTSANDER

scR0lt Aw

LIOHTINO

Neede

iqht from

front

and

left

of tool

CLEARANCE

Allow5 to 6 feet of clearance o

bhe aidea or lon4 work; eave

3 to 4

feet in front

of and

to

either side of

diak aander. Keep ine

of

work

clear

LIOHTINO

Li4ht needed

to the riqht.

of

blade;

portable

clamp-on

ight

can be

uoed to

ehinedirectly

on work

WORKBENCH

CLEARANCE

Needa 5 feet

of

clearance

at

front

and eidea;no

alear-

ance

needed

behind

tool.

Oood

ocation

ie a4ainot wall

LIGHTING

Needa i4ht

from

above,

parLicularly

over viaeo

CLEARANCE

Allow

3

feet

of clearance

around

viaea;

can be placed

a4ainet wall f neceoear,

34



SHOP

LAYOUT

RAWINGSFSTATIOI{ARY

OOTS

a wodtshopn

papel

llustrationsbove re

overhead

iews f a dozenypical

tationaryools

rawn t a scale f

V+ nch

foot.To acilitatehe

askof arranging

our

ools n he

shop loor, ketch

our

workshoppace

n

similarlycaled

raph

aper.

hen

hotocopy

his

page,

utout he ools

ou

need, ndarrange

cutouts

n he

grid

o determine

hebest

ayoutor

your

hop.

Considerhe

space nd ight

equire-

ents f the ools

pages

2-34)

when ssigning

paceo each ne.

Also actor

n

your

hop's lectrical

ighting eeds

pages

1-43).

Use hesample

ayouts f a small-,

medium-, nd

arge-sizehop

beginning

n

page

6 as

guidelines

o

getyou

started.

35



SHOP

ORGANIZATION

LAYOUT

F SMALLH()P

Laying

ut he hop

The l lustrat ion

elowhowsneway

f makingf f ic ientse

f

thespacen a smal l hop-in his ase, ne-halffa wo-car

garage.

he

hree tationaryachineshosen

re ssentialor

most

rojects:

he able aw,he

ointer,

nd heband aw. he

saw nd

ointer

re

mounted

ncasterso hey

anbemovedf

necessary.

i th hebench nd able

here

s

ample paceor

hand

ooland

portableower

ool

work.

he toragepace-

perforated

ardboardnd

helving-isocatedlong

he

walls;

a lumber ack s

positioned

earhe

garage

oor. ny xposed

atock atoraqe

thelvinq

e

Work

able

Ferforated

hard-

board wall

etoraqe

Dand aaw

e

Jointer

f raming

n he e i l ing

ou ld l so eusedo ho ld

tock . e fer

to hekey n hebottomight-handorner f he l lustrat ion

for he

ype nd

ocat ion

felectr ical

ut letsnd ight ixtures.

Note

hat heresanoverheadaster

wrtch

near

hebench's

ta i l i se)

hat ont ro lsl l h reemachines .

t ten t ions

a lso

paid

o eed irect ion

f eachmachine

represented

y he

arrowheadn hekey);he

accessoor o he

shop salways

in heuser 'sield

f

v is ion.

aut ion:f

your

hop harespace

withmotorized

quipment

ou

wil lnot

beableosprayinishes.

KEY

24O V

outlet

12OV

outlet

Incandescent iqht

fixtu re

F

uoreecent

iqht

firtu re

Overheadewitch for

power

oole

Direction of feed

11 '

r-)t

\ _ / 1 .

r c

scrap

I

bin

I

\ strort

d b d b

( a )

l l l l v

l l l l

)awhoreee

q_F _F

T

t t

| |

t,mu",

| |

racr

tJ

o

0

o

o

o

o

. .y':,"-n":

-?r:

36



SHOP

LAYOUT

tlltlll

illlll

fi

lll lll

lll lll

lll lll

lll lli

lltlll

lll lll

lll

1HO?TI?

A s af e att'enti

o

n

g

et

t

e

lf the door

o t 'heehop

s

outside

yourf ie ld

fvie ionwhenyou

reaI

a

machine,lhere

e he

r iek hat '

oomeone

iqhl

enLer

he ehoV,t'ap

you

on he

ehoulder,

nd

etarLle

ou,

Io avoid ccident'caueinq

urprioee,

mounf,

liqhtbulb

I eye

evel

ea r

the

t

ooland

wireNhe wiLch

No

he

door

rameeo

haLthe

bulb

iqhto

whenlhe

oor

s oVened,Wirinq

ano|her

bulb o

the bell

ircuiL f

Nhe

relephoneansolvehe problem f

mis in oho e calle:

Ea h

t' im

th e

bell inio,rhe

bulb

will iqht.

I

\._.2

A SHOP

OLTY

Towheelworkpiecesr arge rojects

around

heshop,

se he

shop-built

dol lv hown

elow.

tart

with he

base

ndcorner

locks,

ut t ing

them rom3/q-inchlywoodo a size

that

sui ts

our

eeds, crew

he

corner

locks

n

place,

hen

asten

a caster

nto

eachblock

abovd.

Tobui ld

heshelved

ect ion,

ut

theskir ts

nd he

eight

ieces

or

the

egs

rom1-by-3

tock;he

shelf

from%-inch lywood;nd he oP

from

%-inch

lywood.

he egs hould

be

ong nough

or he op

o sit

at

a comfortable

eight. crew

he eg

pieces

ogether,

hen

at tach

he

skirtso

he egs'

nsideaces.

asten

theshelf nd

he op

o heskir ts.

Secure

he

egs o he

base i th

angle

rackets.

37



SHOP AYOUT

SAVING PACE

Settingpa

shopn he

attic

Attic

hops

ave everal

trikes

gainst

them: hey reoften ninsulatednd

their oors

re ot

designed

o support

heavy

eight .n

addit ion,

eadroom

s

limited

ndaccess

an

presentroblems,

espec ia l l yf

you

rework ing

i th

ong

planks

r ull

sheets

f

plywood.

ut

or

a uthier,

arver,rwoodworker

ho pe-

cial izes

n smal l

rojects,

nat t ic

an

be

an deal

pot ora shop.

sshown

n

the l lustrat ion

t ef t ,

ai l ing

heetsf

sheathing-grade

lywood

o he

oists

ill

produce

floor

hat s

sufficiently

turdy

to hold pa workbenchnd ne f he

lighter

tationary

achines,ike

he

band

saw, he paces

etween

hestuds

nd

rafters

nd

down ear

heeaves-where

the oof

ndattic oor

meet-are

deal

forstor ing

umber,

ools, nd

uppl ies.

Positioning

tationary

achines

ina

confinedpace

lf

your

workshop

scramped

ou

may

have

o orego

n deal

lacement

f

stat ionary

achines

o al low

ou

o

make

hemost

f

your

imited

pace.

Consider

hedesignf

your

machines

and

he eed irect ion

ou

eed

o

use;

ou

may

eable o

place

wo

machines

lose

ogetherf

hey re

matched

roperly.

he igh

able f

a

band aw

nd he eed

irectionor-

mal ly

sed i th

hemachine,or

example,

akest

an dealmatch

rna

ight pace ith

ointer

right).

The

wocanbe

placed

lose

ogeth-

e rw h i l e

t i l l

p r o v i d i n g

d e q u a t e

spaceo operate

achmachine

t

separateimes.

38



SHOP

LAYOUT

F

MEDIUM-SIZE

H()P

Setting pa

basementho p

hemedium-size

hop epresented

elow

sharesmany f the eatures f thesmal l

shop

page

6): he able

sawand

ointer-

olaner re

on casters:

master witch

thls

t ime

nearhedoor) ontrols

l l he

machines;

the machines

re

posi t ioned

o users

i l l

see

he door

near he bench;

erforated

hardboardndshelves

or storage

ine he

per imeter

f heshop

suppl ies

analso

be

stored nder

he stairs) ;

nd he umber

rack s

ocated ear he

mainaccess oor t

the ootof hestairs.With heextra pace,

this

shop as

oom ora lathe, dr i l l

press,

anda

dust ol lector.

work able

or

glue-

up and

nishing

s

posi t ioned

t a window

withan

exhaustan.

The ocal

oint

f th is

shop s he able

aw; t

is

equidistant

rom

the

stock

preparat ion

rea

n frontof i t ,

the

workbencho one

side, nd he

work

tab le eh rnd

t .

KEY

:l

24O

V

ouLlet

rl'

12O

V

outlet

A lncandeacenL

t4hL txl;ure

O FluoreecenL

tqhL ixt.ure

@

Overhead

wtLch

or

power

oolo

@ Dtrectton f

feed

20'

e

thelvee

e

Sawhoreea

o

Drill

prena

e

?erforated

hardboard

Duai;collector

ilt

Lathe

thelvea

Lumber ack

o

e

Eand saw

- :o:*".n*-

- -? ofr.Er

Jointer/

grrrl[)

39

Window

an



SHOP

LAYOUT

LAYOUTFA LARGEH()P

Convertingtwo-car

arage

Sett ingpa shop

ith l l the eatureshownelow

al lsora

large pace,ikea two-cararage.his hop asmany f he

character ist icsf he mal lerhops

xaminedarl ier,i th ddi-

t ionalools nd onveniences

hatal lowt to handle wider

range f

projects.

t one orner

sa spaciousinishingoom,

part i t ioned

rom he est f heshop ndequipped

ithan

explosion-proof

an o exhaustumes. he hop

ncludesbath-

room i th s ink nd

toi let .naddit iono he

machinesea-

tured arlier,hishas

radial

rm

aw, haper,nd

planer.

he

shop oastshree eparate

ork urfaces:ne n he inishing

room, ne orglue-upearhedri l lpress,nd workbench

beside

he able aw. shop f his ize

ould eed

n

nde-

pendent

lectricalervice

anel

o

power

ll he ools.

okeep

the

wiring

ut

of heway, alf he loor scovereditha

raised

3/rinch

lywood

loor; sshown n

page

4,an understructure

of 1-by-2s

s aid n heconcreteloor n 12-inchentersnd

the

plywood

snai ledo heboards.

i res

re

un n

conduits

underhe

plywood

etweenhe1-by-2s.

Work

(-

v

Taorc

Explooion'

proof

fan

w -

T- F-t

Mobite

l-l -l

ctamp

I rl Fr I

rACK

flt--------t

u: ul

ork'

" I l l

u^"n

li I ll

l ' ' l l l

lH l l

IH

tr|

I ^

(]

FINI'HINOROOM

6'x|O'

$-;

AI9ED

lllll,*,"*-

FLOOR

o

0

0

o

o

o

e,

CONCRETE

FLOOR

Radial

Ferforated'

hardboard

Drill

Pree6

?lywood

stora4e

Sawhorees

ilil

Disk/belt

aander

o

Aeeembly

table

) -

v

zcraP

ptn

/-\ .----.....--..-.r

O

\_/ |

snetves

lpfl

trb*l

I U F \ I

-f--l \ Lu"h"O

\J-gtuor

KEY

24O V outlet

12OV outlet

In

ca

n

d

eacent I qht fixtu

re

F

uoreacent iqht fixbure

Eleatriaal ae vice oub-pa

nel

Direction of

feed

40



ELE,CTRICAL

OWER

lectric

ower equirement

hould

e

;

considered

arly

n the

processf

a shop's

ayout.

Allow

for

Then,as

you add

new ools

and

fixtures, ouwill avoidheheadaches

nadequate

ystem:

epeated

rip-

of

circuitbreakers

r

blowing

of fus-

andoctopus

dapters

unneling

everal

cords

nto

oneoutlet.

If

you

plan

o

wire

your

shop

o

your

main

service

anel,

e

sure hat

electrical

upply

asenough

ddi-

power.You can

geta rough

dea

how

manyamperes

our shop

will

rom the system

y

totaling

he

f all he

ools

you

plan

o use

dividing he result n half. f your

s barely

able

to

handle the

eing'placed

n

it by

your

ou

probablywill

need o

our service

ntrance-in

oth-

words,

ncrease

henumber

of amps

service

anel an

draw

rom theutil-

f the shop

will be

some

rom the

main service

anel, t

good dea o

installa 50-amp

ub-

panel

dedicated

o the

shop.

Another

point to remember:

ny

woodworking

machinehat

drawsmore

hansixamps

should

be on a separate

dedicated)

ir-

cuit,unless

he ool's

motor

s

shielded.

Refero

the llustration

n

page 2 as

a

guide

o

planning he electrical

ayout

of

your

shop.

As

you

plan,

emember

that even

simple

electrical

obs,

ike

extending

circuit

or replacing

n out-

let, canbe

dangerous.

heycan

also

cause

fairamount

of damage-ranging

from burned-out

ool

motors o a

house

fire-if

theyarecarried

out

mproperly.

Unless ou

are

cualified

nd

comfort-

able

wiih the

idea

of

wiring

your shop

to theelectrical ystem,ave qualified

electrician

o

the

ob.

Theworkbench

s

a natural

work

surface

or

using

ortable

ower

tools.Mounting

power

tripon

one

ofthe egs

nd

pluggingt into

an outlet

liminates

he

need

or

a

separate xtension

ord

or

every

ool.

r

When

lanning

he

electrical

ayoutor

your

hop,make

ure hatoutlets

or

power

ools nd

ighting

ixtures re

on

seDarate

ircuits.

o

Unless

our

hop

as right

indows

or

your

ights re

equipped

ithbattery

backups,

nclude t

leastwoseparate

lighting

ircuits

n

your

lectrical

ayout.

In he

event ne

ircuit

sdisabled,he

lights

lugged

nto he

other ircuit

il l

stil l

work.

r

Place utlets

loseo

theeventual

oca-

tionof

he ools

heywill

power;

istrib-

uteoutlets

l laroundhe

shooo

allow

for uture

ool cquisitions.

.

Avoidocating

utlets

n he loor;

he y

willeventually

ecome

illed

with aw-

dust

ndbea

irehazard.

.

Avoid

lugging

ools

nto ne utlet

using noctopus

dapter;

his an

over-

load

our

lectrical

ystem,

nd s a sign

ETECTRICAT

AYOUT

IPS

that he

wiring f

your

hop

s nade-

quate.

Upgrade

hesystem

y nstalling

new utlets

ndwiring

hem o a sepa-

rate ircuit n he

service

anel.

o

Protect nynew utlet

n a

garage

r

basement

y

nstalling

ground-fault

circuit

ntenupter

GFCI).

.

Never ork

n hewiring

f heservice

panel;

ntrance

ires

may emain

ive

even

when

ower

s shutoff at

hemain

circuit

reaker

r

use

lock.

.

Make ertainhat

any ew

ircuitsr

serviceub-panels

nstalledn

your

ome

oroutbuilding

re

rounded

o he

main

service

anel.

ndividualutlets

ust

also e

grounded.

.

Donot ake

ff hecover

f heservice

oane

.

o

Never

ork n

your

wiring

n

damp

r

wet onditions.

.

Do

not ouch

metalaucet,

ipe,

appliance,

rother

bject

hen orking

on

your

iring.

.

Never plice

power

ord

r anexten-

sion ord,

r emovehe

grounding

rong

from hree-prong

lug.

.

Use nextension

ord o supply lec-

tricity

o anarea nly

emporarily-not

as

permanenl

rnng.

.

Neveruna oower

ord r an

exten-

sion ord nder rug,mat, rcarpet;

do not

astenhecord

usingacks,

ins,

orstaples.

.

Never

eplace

blownuse

withone f

higher mperage;

onotuse

penny,

washer,r

oilasa substitute

or

a

fuse.

o

lf a circuit

reakerrips

ra use lows

repeatedly,

heck

ora short ircuit,

nd

determine

hetherhecircuit

sover-

loaded.

4 I



SHOPLAYOUT

ETECTRICAT

AYOUTOR

MEDIUM.SIZE

H(IP

24O V

outlet

12OV

outlet

In

ca

nd

eecent iqhti

nq firtu

re

F

uo eacent

qhtinq ixtu

e

Direction

of

feed

Wiring

heshop

The

llustration

t eft

shows

neelectri-

cal ayoutora medium-sizehop. he

shop as

ixseparate

lectrical

ircuits:

four or

ools

nd wo or

ighting.

he

basic

rinciple

o keepn

mind

s hatno

circuit

sing

2-gauge

ire

hould

arry

more

han

80

percent

f its

capacity;or

20-amp

ircuits,

hismeans

hecom-

bined

mperage

f the

ools

n hesame

circuit

lus

5

percent

f he ating

f

he

largest

otor

must

notexceed

6 amps.

n

thisshop,

he able

aw nd

ointer

re

orfseparate

40 V

circuits;

heir

power

cords resuspendedrom heceiling ith

twist-type

utlets,

hich

eep

he

plugs

in

place,

With

combined

oad

f 15

amps,

theband

aw nd

hedrill

press

re

on

thesame

20V

circuit;

he athe

s on

another.

dditional

utlets

n

he120V

circuits

an

beusedor

portable

ools. he

incandescent

nd luorescent

ighting

circuits

re eparate

o hat

f one ails

theother

will

stil lwork.

rh

v

0

o

t

o

KEY

42



LIGHTING

f you ind

yourselfutting

ff ineor

cannot

roper ly

xamine

f in ish

ou ake

ourwork outside,

he

n your

workshop

mayneed n

t best, poorly it shopwill

on atigue;

tworst,

t

can

o sloppy,

mprecise

ork and

Fluorescent

ightsare he

most

pop-

of workshop

ighting

fixture.

cast

a relatively hadowless

ight,

ubes re

ong-lasting,nd

heyuse

o 30

percentess lectricity

ncandescent

ightsof the

same

any

woodworkers

ind that

much luorescent

ightcan

esultn

headaches,owever,ndpre-

warmth of

incandescentnd

ights,

At a minimum,

a shopbigger

han

120scuare

eet

needs wattsof

incan-

ight or

3/q,

walt of fluorescent

per

square

oot,As n the electri-

ayout

llustrated n

page

2,shop

shouldbe

circuits eparate

rom

your

ools.

deally,he

ight fixtures

will

bedivided

etweenvvo

eDarateircuits.

Asa

rule

of

humb, o

notexceed

600

watts n one

20-amp ircuit.

Also,dis-

tribute ighting ixtures round heshop;

mountinga single

ixture n the

middle

of the ceiling

will

make t difficult to

illu-

minate he

shadowy

reas t the

edges

ofthe shoo.

If

possible,make he

mostof natural

Iight; heres

no

better

ubstitute,

spe-

cially

or hand-tool

work and

inishing.

Trying o evaluate

laning, anding, nd

finishing

obs

underartificial

ight can

be

frustrating.

Both

fluorescent nd

incandescent

ight end o distort

or dis-

guise he surfaceextureof naturaland

finished

wood surfaces.

atural

ight,

particularlyrom the

north,hasa soft,

non-glare

uality.f

your

shop

asa

win-

dow

hat

faces orth,

place our work-

bench

nder

t.

Keep n mind that

upgrading

he

lighting

n your shop

neednot entail

purchasing expensive

ixtures and

rewiring he system. imply

aintinga

concrete

loor a

ight

color

or covering

the ceiling

with white

ileswill allow

these urfaces

o reflect

ight, ather han

absorbt.

IllIlltlll illII ill illlll lll llllll ]I1llllll lll llllll lll

1HO?

Tt?

A clamp-onampcanshed ll the ight

you

need

o worksafely t

a tool.

Mountedon a drill

press,

his amp's

flexible

eck ims

a 4)-wattbulb

directly

t themachine's

ork able.

A benah'dog

1,,, , , \

lamo oupport

l'lllt'+qil'\'-.

" l - - -A " . a \

r

Fora movable

ource f

, /

-

- t \

- '

: - - : \

liqhl aI

your

workbench,

/ \

."r:r' i

a i tach

A desklamp

No

{- ' -

* --" ' " '

oneof

the bench

oqe.Dore

a

holeNhe ame iameNer

as

the ehafLof

Lhe amp

into the headof

a

w

ood

en

.d

o,q

+:==::::=--::R-::::-..--=.:

(pa4e62).The

--

-------=:* :

li,ahr,anLhen

-:]

b:e

oeitioned

*.

al any

of

the

-

*-<<*.*t3-

ja-.

_;

doqholeo

lonq

-__--

the bench.

43



FLOORS,

WALLS, ND

CEILINGS

Q

i":.

most workshops

re set

up

\,,

In

basementsr garages,

oncrete

floors

area common eature.Yet or

anyonewho has o

spend

much

ime

standing n concrete r sweepingt

clean, he

material

can

prove

both

uncomfortable nd nconvenient.he

hard

surfaces

particularly

ough

on

tools hat aredroppedaccidentally.

Simply

painting

a

concrete

loor

with

a

paint

made

pecificallyor the

pulpose

will keep

down the dust and make

he

surface asiero clean.Adhesive inyl

floor tile canbe aid

down aswell.Yet

manywoodworkers

refer

he comfort

of a raisedwooden loor.A simole loor

can

be constructed

rom

sheeis f %-

inch

plyruood

aid

atopa

grid

of 1-by-

2s

on 12-inch enters. ot

only

s

this

qpe

of flooreasier n the eet,

ut

wiring

for stationary

ower

ools

canbe

rout-

edunderneath

he

aised

urfacen %-

inch

olastic r steel onduit.

Unlike hewalls f mosthomes,

hose

ofseparate orkshopseldom

re

nsu-

Iated.

f you ive n

a

northern

limate,

you can ncrease

he hermalefficiency

of your shop

by coveringts wallswith

wood

paneling

r sheetmaterial, nd

filling the gap n between tudswith

insulation.

ood

paneling

n particular

createswarm,comfortable

tmosphere.

Interior

wall coveringwill

makeyour

shop

quieter

oo,

since he wallswill

absorb

omeof the din of

vour Dower

tools. u a bonus, oucanconceal iring

behind he walls.Make

sure he base-

mentwallsdo not eak

before overing

themwith nsulation

nd

paneling.

To hide

he exposed

oists,

ducts,

and wiringabove our head, onsider

installing

ceiling. suspended

ile ceil-

ing, n

which he iles

sit

n

a

framework

of supports anging rom

the

oists,

s

one

popular

option.

n

a arge hop,a

dropped

eiling uch s hiswill

also

elp

retainheat.

Acoustical eiling

ilesare

an

nexpensive

lternative;

he tiles are

attachedo

furring strips hat arenailed

to the

oists.

tanding n one

place

for

hours

on

a concrete

floor

can

strain

your

feet

and legs.An old

piece

of carpetor a

commercialanti-fatiguemat pro-

videsa cushion

hat can be easily

movedabout

theshop.

lll1jll lt illll1lli lllirllullllll llllIIlll lll ll1iullt

9HO7

Tt?

Making

he transition to a raieed loor

lf

parl

of

your

ehophaoa raised loor,you

an make smoolh

lransilion rom

Nhe ower oncrete loorwith

eeveral eveled

2-by-6o aid

end-No-end.ut

a

rabbeNn

oneedqe

of each

2-W-6lo

accommodatehe

plywood

loor

and he 1-by-2

qrid

undernealh, hen evelhe

oppoeite dqe,orminq ram?

lo f

acilitate

movinq

t ems romone loor o the oLher. ailor

screw

he

plywoodto

he 2-by-Oe.

\

*ri.

44



HEATING

AND

VENTILATION

eating

sa necessiry

or most hops

I in North America. ome

wood-

t;

gluingand in-

particular equire steady

eating our shopalso

t more comfortable

nd safe;

fingers nvite accidents.

If

your

shop

s somedistance

rom

home's urnace,

separate

eating

ill be

needed.Many

wood-

swear

y wood

heaq t

has

he

enefit f

consuming crap

ieces.

his means

requently

eeding he

ndcleaninghe

chimney;

nsur-

against

ire canalsobe

a

Electric aseboard

nits are

convenient,ut cancontributeo

bills and

frequentlyare

ith sawdust.

Portable erosene

nd

propane

urn-

should

be avoided

n the shop, ince

an

oDen

lameand emit toxic

exhaust. oil-type

electric

eaters re

alsoa fire hazard.

Whichever

heating system

you

choose,

eep he area

round t

free

of

sawdust ndplacet awayrom the in-

ishingand

wood storage

reas. nd

remember, nysystem

ill be

mproved

by

goodventilation.

Consider

our need o control

humid-

ity. In

shops

n

humid climates, oo

much

moisturemeans

n nvestment

in a dehumidifier

o keep

wood dry

and

ools rom

rusting.Shops

n more

arid climates

ace he opposite

ilem-

ma and

may equirea

humidifier.

Finally, very hop

equires dequate

ventilation.Airbornesawdust nd oxic

finishing

vaporsmaynot be as

visiblea

danger

skickback n

a tablesawbut

the hreat

hey

pose s

ust

as eal.

While

fire

or explosions

ue o

high concen-

trations f sawdust

r

finishing apors

are

are,heycanbedevastating.

good

ventilation ystem

hangeshe air often

enough o

maintainsafe evels f air-

bornedustand

umes. t should nclude

dustcollection quipment t each ta-

tionary

power

ool that

produces

aw-

dust

(page

7B), and a

general

exhaust

setup

below)

o remove he dust

and

fumes hat

remain.

Whilewindow

ans

or

bathroom-tlpe

ventmodels re

ine or general xhaust

purposes, finishing ooth or spray

room

requiressomethingdifferent:

An explosion-proof

ube-axialan

s

recommended.

ansare atedby the

amount

of air that hey

move,measured

in cubic eetperminute cfm).Divide

thecubic

olume fyour shop

its

ength

times tswidth imes

tsheight) y 6 to

find the

ratingneededo changehe air

10 imes

perhour-the minimum ev-

el or safe entilation.

SHOP

Installing

general

xhaustetup

lf

your

hop oes

othave indowsr

doorso

provideroper

ross-ventilation,

insta l lnexhaustetup

ocleanheair .

The ystemhown t

eft sa simple ne,

consist ing

fanair ntaketone nd f

theshop onnected

o heoutdoorsr

your

ome'si r

ducts, nd nexplosion-

proof

anmounted

n

he

wal lat he

oooosite

nd. he

ntakescoveredith

a urnace

ra i r -cond i t ion ing

l te r o

cleanhe

ncomingir. he xhaust

an

is

placed

igherhan

he ntake,ausing

theair hat iseso be

drawn utof he

shop. or est esults,rientheexhaust

setup long

he ongestxis f

your

hop.

45



heworkbench

s

thecorner-

stone

f thewoodshop,

ith

history

lmost

sold as

wood-

tself.Examplesf

primi-

workbenches

ave eenound

morehan2,000ears.

n ancient

Rome

hebasic

esign, evising

ith simplestops hat

hem o

secure

ieces

f

Until that ime,

craftsmen

orcedo

hold

heir

work,cut-

or

shaping

t

with one

hand

chopping

r

planing

with he

urthermprovementsame

WORKBENCH

The

makers f

thisworkbenchapitalized

on the classic

inesof a centuries-old esign,

creating scaled-downench

hat doubles

asa living room able.

nd

viseswereonlyadded enturies

ater.

With each

efinementhe workbench asassumed n

ndispensableole n theworkshop.t is ittlesur-

hatmany all heworkbench

hemostmportantoola

an

own.

A goodworkbenchoes ot ake nactive

ole n thewood-

rocess-it

does

ot cutwoodor shape

t-but the

nd ts accoutrements

erform

nother ssential

ask:

our

hands nd

position

heworkso

you

cancut,

nd inishefficiently.

n the

past,

venhemost-

aveallen hortof he

deal.With tsmassive,in-

op, heRoubo

Bench f the

18th

Century

was

hroughout

urope,

et

t hadno tail

vise

or bench

o holdaworkpiece;

nstead,

he

askwas one ya sys-

of ron holdfastsndanoptionalegvise.Onehundred

ater,

he

American hakers

mproved

n

theRoubo.

Their

bench

was arge ffair hat

sported

aminatedop,a system

ofbench ogholes,

nL-shapedtail

vise,and a

legvise.The

Shaker

benchwas

not

too different

rom

themodern abinetmaker'sench

pictured

n

page

6.

Thedesign fthe

workbenchas

changed

ittle

since

heearly19th

Century; nly

ts

accessoriesnd

mannerof assembly

ave

been

altered.n fact, ome laim hat he

only true

innovation as been

inventor on

Hickman'sbiquitous

Workmaterv. eveloped

n

the

1960s,he

Workmatervevolutionizedheway

many

eople

Iookatworksurfaces,ecause

t

provided

ome f heclamp-

ingabilities f a sandard orkbench ith a collapsible,ortable

design.

Although

he

Workmaterruas ounda

nichen worlshops

around he

world,manywoodworkers-both mateur nd

professional-still

pt

or nothingesshana solidmaple r

beech ench. ften hey hoose

o

build

heirown,believing

that hecare ndattention

aid

n

crafting uch

benchwill

be

reflectedn their ater

work.The

chapter

hat ollows

shows

ow

o

assemblemodern abinetmaker's

orkbench,

andhow o

nstall

he

vises ndaccessorieseededo turn an

ordinarybenchnto a

more lexible ork

station.

Thedesign f heworkbenchhown n he

ollowing

ages,

andmany f hedrawingsnd echniques,re asednaplan

thatappeared

n Wodsmithmagazine.

its origins ooted n an era without

ools,hestandard

abinetmaker's

now ncorporates

ises esigned

usewith both

power

and

hand ools.

47



ANTATOMY

F

AWORKBENCH

T

h. workbench hownat right is

I

patterned

afteratraditionalcabi-

netmaker'sench,and s crafted rom

solid

maple. hebendrncorporateswo

vises onsideredo be standard quip-

ment a ace iseon he

ront, eft-hand

endof thebench, nda tail visewith

a slidingdog block mountedon the

opposite

nd.

You

anbuildsuc,h

workbenchrom

aht suppliedwith

aterialsnd nstruc-

tions.Youcanbuythe

lans

or abench

and

order

hematerials

ourself.

r,

you

can

ollowthe nstructions

resented

n

this

chapter

nd constructa bench o

suityourneeds.Whicheverouteyou

take, workbench

s

assembled

n

three

distinct

hases:

hebase

page

0);the

top

(page

3);andthedampingacces

sories-vises

page

6),benchdogs,nd

hold-downs

page62).

The

op surface f

most

benches

s

generallybetriveen

3and36

nchahigh.

The height hat s best or

you

canbe

determined y

measuringhe distance

betweenhe

loor

and he

nside

fyour

wristwhileyoustand

pright

with

your

armsatyoursides.

Finish ur

workbenchith wocoats

of a

penetrating

il-basedproduct,uch

as ung oil. Not only do these

roducts

penetrate

he surface nd

protect

he

woo4

but the

inish

canbe

efurbished

simplyby scrubbing

t with

steel

wool

and

ecoating.

Faae viee

Alao knownaa front

vioe;

aw

aecures work

a4ainot bench

Eottom ed6e ia

"relieved"

with

a

recesa for

better

aontact

with floory

ordinar-

ily

attached

to the le4 with

mortiae-and

tenon

iointa

Bench

dog

hole

Holda a bench doq

for

oecurinqwork

on benchtop

Arm

Supporta top; top

edqe of

arm atface-viae end reliev

in

aame manner as feet.

Uauallyattached to le6a

Wmortiae-and-tenon iointa

5tretcher

Frovideaaf,eralatability

to

bench;

ttached

to the leg6

in oneof aeveralwayo

paqea

50 and 51)

Attaching he endcapsof a worl&ench o the

apronscalls

or

a strongand attradive

oinery

methodThe

ingu

joint

(also

nownas hebox

joint)

and he

dovetail

oint

shownatw are

traditional avorita.

48



WORKBENCH

aminal;ed

rom

a

hard

woodauchae maple r

hat makeup

top

be

aelected,

repared,

nd

up carefully o provtde

e

-f

ctly

flat Eu f a ce

Tool

ray

)

/ , ,

Aenah

dog

Uaed

with tarl or

face vise o

clampeLock;

made

of

metal or

wood.

Teneionoprinq keepadoq

aL deeired

heiqht;afLer uae,

dog o pueheddownbelow ur-

face

of

benchtop

Theworkbench t left

improved

hestandard

design y ncorporat-

ing a tilting toolchest

under he op.

Sliding dog bloak

ConnecLed

o Lhe ail vieeecrew,

Lhts

movable lock ontatnaa

bench

dog that. eecuree

work

on

the benchtop

tes

-\

End cap

L l e n a r a t e

n i e r e r n t t -

era end

grain

of top

piece

and eupporte

tatl vtseacrew

Moveeelidin7do1 blockLo

adjueL

clamptn4 apaciLx

to

len7th

of

work

49



BUILDINGTHE BASE

"f

h. base f a workbench ypically

J-

consists f

two rectangularrames

connected y a

pair

ofstretchers.

he

frames

areessentially

dentical,

ach

with

a foot,an arm,and wo egs. hearm of

the eft-hand rame s sometimes bout

3 nchesonger han heotherarm o

pro-

videadditional

upport

or the ace ise.

For

a bench

ike

he one shownon

pages

8 and,49,use maple

l%

inch-

es hick aftersurfacing). he eet,arms

and legsare made rom two boards

apiece ace-gluedogether, nd then

reducedo the

proper

hickness

n

the

jointer

and

planer.

f you wish

o build

the base

with mortise-and-tenons,

ut

four-shouldered

enons t heendofthe

legsand rout matchingmortises n the

feetand arms.Tenons realsocut at

the endsof the

stretchers

ith mortises

required n the legs.The illustration

REINF(|RCING

N(ICKD(IWN(|INERY

Usingruss

ods

Insteadf usingmort ise-and-tenon

joints

o bui ld hebase, se ut t

oints

reinforcedy russ ods, sshown t

r ight . vai lablen ki ts, he ods anbe

loosenedr ightenedfter ssembly

to compensate

orwoodmovement

s

a

resu l t

f changesn humid i t y .out

grooves

or he ods nto heedges f

thestretchersnd he nside dges f

the egs;hedepth ndwidth f he

channelshou ldoua lhe od 's iame-

ter.

Test-assemble

he base nd

mark

the

groove

ocat ions

n he egs nd

arms. hen ore hole t eachmark,

mak inghed iameterqua lo hat f

the ods; ountersinkheholes

o

you

candrivehenuts ushwith hewood

surface.ssemblehebase, t t inghe

rods nto

he

grooves

nd

holes,

nd

t ighteningheconnect ionsi thwashers

and

nuts.

overhe

grooves

ith ol id

woodnlayf

you

wish o concealhe ods.

below hows knockdown lternative

to

assembling

he

base

ith mortise-

and-tenons.

The

oints

etrveenhestretchersnd

the egs eedo besolid, etsufficient-

ly flexibleo be aken part hould ou

want o move

hebench.Consequently,

knockdownhardware

esignedor the

purpose

s

oftenused o

oin

thestretch-

ers o the

egs.The pages

hat follow

detailsomeothermethodsof reinforc-

ine knockdown onnections.

Bun

oints

connectinghe egs

of a workbencho thestretch-

erscanbe

einforced

ith

hardwood nockdow

inings.

The

fittings

are

nserted

nto

mortises

ut

nto

theends

of thestretchers; atching

machine oltsand nutsare

thenused o securehe

oint.

@ 8

50



WORKBENCH

machineolts nd

wood locks

heconnection

etweenhe

stretchers,

lue

a wood lock

same

hicknesss

hestock o

edge f the stretchers.heblocks

he contact

reabetween

stretchers

nd he

egs.Once

he

s dry,cut a tenon

t heendof

each

nda matching

ortisen he

Fit he

pieces

ogether

ndbore wo

or machine

olts hrough

he eg

enonn he

blocks;ountersink

holes.Make heconnection

astby

bolts nto he

holes, lipping

washersnd

ighteninghe

nuts

right).

Usingagscrews

nddowels

Another

ay

o

stren$hen mortise-and-

tenon

oint

betweenhe

stretchersnd

legs

s

shown

t left.Cuta

1-inch-diame-

ter hardwood

owelo a

length

qual

to the hickness

f the stretcher.

hen

bore 1-inch-diameterole hroughhe

stretcher

boullVz

nchesrom ts end.

Alsobore hole

or

a

lagscrewhrough

the

eg, toppinghedrillwhen he

bit

reacheshe

hole n hestretcher:oun-

tersinkhe

hole o he screw ead

will

sit lushwith hesurface.

it hestretcher

tenonnto he eg

mortise,ap hedowel

into

place

n hestretcher,nd

drive he

screw. hoose

screwthat

s ongenough

to bite hrough

hedowe,.

5 1



WORKBENCH

PREPARINGHEFEET

Relieving

he eet

Once

ou

re at isfedwith

he t of he

parts

f hebase, isassemblehestretch-

ers

nd

egs

nd elievehe eet n

he

oin-

ter.

nstall

clamp n he

ointer's

nfeed

tableo hold

he

guard

utof heway

ur-

ing

heoperation.etboth

he

nfeed

nd

outfeedablesora %o-inch

epth fcut,

and lamp top

lockso both ableso

guide

hebeginningndendof he

cut.

To

make

he irst

pass,

ower

he

oot

onto he

knives,eepingt f lush

gainsthe ence

and hestopblock

n he

nfeed

able. eed

the ootacross

he

knives

/efil

until t con-

tacts hestopblock n heoutfeedable.

Keep

oth

hands

ellabovehe

cutterhead.

Make

smany

asses

snecessary

o com-

plete

he ecess,owering

he ables%o nch

at a ime, nd eadjusting

hestop locks

asnecessary.

Installingdjustableevelers

To evel workbench

nanunevenhop

f oor,nstal l

djustableevelersn he

feet .Eacheveler

onsistsf a T-nut

anda threaded

ortion

itha

plastic

ip

0nsel.

Borewoholesnto

he bottom f

the ootnear ach

nd.

Make

hehole's

diameteroualo hat

of he

T-nut

nd

its en$h

lightly

onger

han he hreaded

section.ao

he

T-nuts

nto heholes nd

screw n

the

evelers

right).

Once

he

bench

s

assembled,djusthe evelers

unt i l hebenchtoos evel.

52



BUILDINGTHETOP

neof he

most

mportant

eatures

of a

workbench

s a

perfectlylat

At one ime,

a benchtop

ould

be

solid

maple r

beech oards

ideand2 incheshick.But

lanks redifficult

o come

andbenchtop

labs

rebuilt

up

rom

ayers

f

ply,vood and-

etween

trips

of

hardwood,

lywood trips heathed

owever,

dge

luing

wood

boards

ogether

utcher-

s

hownbelow

s he ime-

method.

Cut

rom %

stock,

heboards

re

irst, hen

he

slab

s

length.To minimizewarping,

he

pieceso hat

heend

grain

lsomake

urehe

acegran

of all

heboards

uns

n the same

irec-

are bolted

to the

slab and

joined

to

tion.

Thiswill

make

t

easier

o

plane

he

the aprons

by

means of dovetail

or

top surface

f the

slab mooth.

finger

oints.

After

gluing

p

heslab,

reparehe

dogblocks. heyaregluedup from

a

ength f%

stock

ndoneof%

stock

with hebench

oles

adoed ut

of the

thicker

oard.

he

sliding og

block

for the ail

vise s sawn

ff before

he

front

rail and

ixedblock

are

glued

together

page

a).

Next,

heslab,

ixed

dogblock,

nd

ear ail are

glued p

(page

5);

hardwood

eysand

ply-

wood

splines

reused

o strengthen

theconnections.

After hesliding

ogblock,

ool

ray,

andaprons renstalled,he inalstep

involves

ttaching

heend

capso the

top.

Two onnections

re

used:

hecaps

Once

he op

of a bench

s nstalled

on thebase, straightedgeeldon

edge

crosshe

surface an

beused

to check

t

for Jlatness.

ANATOMY

lF

A BENCHT(|P

9lidin4

do7

block

Front

rail

End cap

53



WORKBENCH

PREPARING

HE

IXED (|G

TOCK

Gutting

hebench og oles

Bench

ogs re abricated

rom

woboards,

so t ssimpleocut hedog olesn he

thicker

iece

efore

lue-up.

wo

teps

are nvolved.

irst , ut

a row f

evenly

spaced

adoeside

nougho

accept

thedogs;

nglehe

ixed-block

adoes

sl ight ly

owardhe

ai lv ise,

nd hesl id-

ing-block

adoeswayrom

he ailvise

so hat

hedogs ill

grip

hework

irmly

when lamping

ressure

sappl ied.

ext ,

c lamp

heboard

o a work

urface

nd

use

chiselo notch

he

opof each

dado

o accept

hedogheads

lefl.fhat

way,hedogs anbepushedownlush

with he

bench urface

henhey

renot

in use.

Now he

wo

parts

anbe

glued

up

o

orm

he inished

locks.

tsench

oq hole

@tsenchdo4

A

JIGFOR RIttIl{G

BENCH OG

OTES

lf

youplan

o use ound

ench

dogs,

ou

canuse heshop-made

jig

shown

elowo

boreheirholes

after

ouglue

up

he bench

op.

The

ig

should e

about 0 nches

long;

he ip s

cut rom

a

l-by-2

Kound

bench

dog

and he baserom

a 1-by-4,

fter

screwing

hem ogether,

ore

uide

ho les

bout inches

par t nd

3 inches

rom

he ip,Theholes

should ccommodate

hedogs

ou

wi l l

use.

Touse

he

ig,

clampt

to he ight

endof he

dogblock

o he ip s

against

he rontedge

nd he ight-

hand

uide

ole s

overhe

position

of

he

irst

og ole.

sing

he

guide

holes, orehe rst woholesn

thebench. or

ach ubsequent

ole,

remove

heclamp nd

lide

he

ig

to he eft

until he ight-hand

uide

hole s

al igned i th

he ast

hole

bored. l ipa

bench og

hrough

theholes,

lamphe

ig

andbore

the eft-hand

ole

right).

Repeat

he

process

ntil

ou

re inished

oring

al l heholes,

54



WORKBENCH

HE

ENCHTOP

' l

Gluing

p he op

I

First ,

lue

p he

op lab.

efore

lu-

up he

benchtop,

out

rooves

nboth

f he

dog

locksnd

ront

ai l , n

ace

f he

ront pron

nd

back

ai l ,

long

heedges

nd

nds f

he op

ut

matching

eys nd

pl ines.

efer

drawing

n

page

3

or he

size

placement

f he

grooves,

eys,nd

f

you

wanto

ncorporate

ool

n

your

ench,

ut

r/z-inch

rabbets

into hebottom

dgesf

heback

ailand

pron;

atern he

assembly

rocess

ou

ill

t

a

piece

f

r/z-inch

lywood

o

orm

he ray.

et side

hesl id ing

og

lock

(with

he

hardwood

eys

lued

n

place)

and

ront nd

back prons,

pread

lue

onall

mating

urfaces,

ndclamp

right),

alternating

he

bar r

p ipe

lamps

n h e

tooand

bottom

f he

work.

r)

Attachinghe

end aps

L

m" end aps an

eapp l red

h i le

the ai l

isesbeing

nstal led

page

7).

Whenhat

sdone,

nvert

he

benchtop

and

out T-shaped

ecessteach nd,

centeredetween

heedges.

ut wo

ec -

tangular

ttingsrom crap

ardwoodo

that

hey

it in hebase feach

ecess.

Notch ne ide feach

ittingoaccept

a 7e- inch

ut, nd

lace

it t ing nd

ut

ineach

ecess.et he

end aps

n

oosi-

t ion

and

markwherehey ontact

he

recesses.

t

each

mark ore

holeora

%- inch o l t , ounterbor ing

o he

bo l t

headsre lush.

out

groove

n

each

end ap

o accepthe

p lywood

pl ine ,

and

outa

r/z-inch

rabbet n hebottom

insidedge f hebackai l o accepthe

tool ray.

nsta l lhe a i l

vise n he

ight-

hand nd

cap

page

/).

Spread

lue

n

the ontacting

urfaces,

i t

he

end aps

(\efl,

and olt hem

n

place

inseil.

inally,

f i t

he

ront nd

ear pronsnd ool

ray

an0 ramp.

55



VISES

AND

ACCESSORIES

\ /

ises

re he ools

hat ransform

V the

workbench

rom a

simple,lat

surfacento a versatile

ork

station. he

modern

woodworking

bench ncorpo-

rates vo lpes of vise:he ace ise hat

secures

ork to the ront

edge

fthe

bench, nd he

ail

vise

hatuses ood

or

metal

benchdogs

o secure ork

on the

top of the bench.The pages

hat follow

examineways

of installing

both the ail

vise

(page

7) and facevise

(page

58).

Face ises

made

entirely

of

wood

are

rare.

However, wooden

vise s

prefer-

able o a metal

ypebecause ooden

jaws

an

grip

work without

marring

ts

surface. good

compromise

an

be

reached

y buying

he

hardware

or

a

metalvise

andmounting

wooden

ace

blocks.You

canextend he

capacitv

f

ANATOMY

FA TAIIVISE

a

face

ise

by boringholes n

thebench-

top and

securing ork

between

bench

dog n

the

vise's

aws

and one nserted

in one

of theholes.

Thil

vises

areavailablen

two

types:

an

enclosed odel

hat ncorporates

slidingdog

block

(below

nd

page

57)

and one

that features

n L-shaped

block,as n thephotoat left.Someail

vises

xtend cross

he entire

end ofa

workbench

and have

wo

screws;

hese

areknown

as

endvises, nd

hey

extend

the

utility

ofan already ersatile

ool.

Some ail vises,

ike he

oneshown

at eft, ncorporaten L-shapedhoul-

derblock.

Theblock

llowswork

o be

clamped

etween

he ear

aw

of the

vise

nd he

endof the

bench.

Fixed

doq

block

Apron

Viee lanqe

Viae

ollar

56

-



WORKBENCH

TAIL

ISE

Installing

he

ise ardware

To ns ta l l a i l

i se na bench

i th

og lock,

osi t ion

he

vise o l-

againsthe ight-handide nd ap

he

holeor he

vtse crew.

a support

oard n he

drill

press

nd

lampheend

ap n

opof

t .

dr i l l

ress

i th spade

its l ight ly

han he

vise crew

ndbore

hole

he end cap

near

ight),Screw

vise

ol laro he

end ap

o he wo

ine p.

Next,ecure

he l id ing

og

nd-up

nhandscrews

nd lamp

he

o a work

urface.

osi t ion

vise ange

n heblock

nd

mark

screw

o les .

ore

p i lo t

o le t

mark,

hen crew

he

langeo he

far

ight).

r)

Assembling

he ise

L

f ttthe lidingog

lock

n

he

bench

so he

hardwood

eysn heblock

un

in he

grooves

n hes ides

f he

a i l .

Threadhe

vise crewhrough

hevise

col lar ,

est- f i the

end ap n he

bench-

topand

ockhebal l

o int

n heend

f

thescrewnto hevise lange. et he

front pron

n

posit ion

gainsthedog

blocks

/eff)

nd est he

movementf

the ise y urning

he crew.

f he l id-

ing

lock

inds ,

emoveheend

ap,

apron,

nd l id ing

og lock , nd

ase

the

t

by

par ing

he

keys i tha chisel .

Once

ou

re a t is f

edwi th he

v ise ' s

movement,t tach

heaprons,

nd aps,

and

rays

ol lowinghe

procedures

ut-

l i n o d n n n e o p 5 5

57



WORKBENCH

ANATOMY

FA FACE

ISE

fixea ,,',------l

doq block

Apron

Faceplate

Face

block

INSTALTING

FACE

ISE

1

Preparing

he ace

lock

I

Cutan 18-inch-long

/a-by-31/z

inch

hardwood

upport

lock nd

crewt in

place

nderhe ront

ef tcorner

f he

bench, f ter

or ing row

f c learance

ho lesor

hebench ogs .

ex t , u i ld

up he ace

lock y

gluing

wo

pieces

f

7ahardwoodogether;ut t to a finalsize

of

5-by-18nches.o

mark nd

borehe

holes

or hevise

crew nd

guide

ods,

mark

l ineacross

he ace

f he ace

block; ffset

he ine rom

he opedge

y

the hickness

f hebenchtop

lab

not

he

front

pron epth). ow

se hecarriage

as

a template: enter

ts opedge

n

the ine

anduse brad-point

it

o accu-

rately

mark he

posit ion

f he

hree

holes

right)

ndborehem.

58



WORKBENCH

)

Preparing

hebench

heholes

ave een r i l led

he

ace lock,

ransferhetr

o he

workbench

pron. et he

ndbenchtopnsawhorses

use

ar lamps

o holdhe

blockn

gainsthe

apron;

rotect

he

wood

ads.

Make urehe

op

f he

blocks

ush i th hebench-

and tsend

s ush

ith heend ap.

arkhe

hole

ocationsn he

apron sing

brad-poinI

i I

( r ight) .

emove

he

ndborehe

ho leshrough

apron nd

bench og

lock,

Mountinghe

ise

Attachhevise ssembly-

he

ace-

plate, crew,ndguideods-to he ace

b lock .

urnhebenchtoppside

own,

p lace

he ise a r r iage

n hebench 's

underside,

nd

eed he ise crew nd

guide

odshroughhe

holesn heapron

and

nto hecarr iage.

ake

i lot

oles

on heunderside

f hebench

nd asten

thecarr iage

n

place.

ext ,

astenhe

guide

od ushings

o heapron:

emove

the

ise ssemb ly ,

t thebush ingsn

the

ods,emountheassembly,

nd

outlinehebushings'

ocation

n heapron.

Then emovehevise ssemblygain nd

securehebenchtop

o heapron

s ac-

ingup.With

router nd traightit,

cut

recesses

or hebushings

ith inheout-

lines

left).

Screwhe bushings

o the

recesses

n heaoron ndattach

hevise

to hebench.

owheworkbench

op s

readyo be

attachedo hebase.

ay he

topupside own

n he oor,

lace

he

base

n

posit ion,

nd

dr iveag crews

through

hearms

nto he op.

59



WORKBENCH

JIGS ORRON.JAWEDENCH

ISES

Eaeia auxiliary aw

Tapered

vieejaw

V-grooveviae

aw

Fitting oodennserts

o metal

aws

lf

your

enchsequippedith

metal-

jawed

ise ike he

one hown t he op

of

page

1, i t t ingnterchangeable

ux-

i l iary

aws

an

xtendhevise'sersat i l -

ity.Thewooden

nsertshown bove ill

notonly

e

ess

amagingo workpieces

thanmetal

aws,

ut hey

analso e

custom-madeorspecial

obs.

achnsert

is made rom

/z-inch-thick

solid tock

witha rabbeted-by-1

lock

lued

t

each nd o hug

heends f hev ise

jaw.

A l though

pai r

s equ i red,

n ly

one

f each amples l lus t ra ted.

he

basic

aw (above,

eft)will

do most tan-

dard lamping

obs .The

apered

aw

(above,

enter)eatures

wedge-shaped

strip orholding

aperedtock fficiently.

TheV-groove

aw above,

ghf) ncludes

a stripwrth

groove

utdowntsmiddle

forsecuring

yl indr icalork.

plywood.

oin

he

\

fill illll}lll

ill illlll lllll}llt

lll litlll

lll ill llllll

tll

5HO?TI?

A

quiak-owitahvise

lf

you

are reluclanlto

boll

your

bench ioe

onlo

your

workbench,t lach i t

ineheadto

T-shaoed

base

made

of

5/+-inch

twopieceeofthebase

to7etherwith

a dado

ioint

and 5crew6.

ecure

Lheverlical

parl

of Nhe

base n

e iNherhe

a i lo r

faceviee

of the bench.

60



WORKBENCH

ASLIDINGENCHTOP

lf

your

workbench"

is

a

standard

tablewitha bench ise

astenedo

one dge,he

ig

and ence hown

t

right an

end t some

ersatility.ut

theaux i l ia ry

ise

aws

rom

- inch

stock

nd he

pieces

f he

T-shaped

vise

ig

rom%-inch

ood. ouwill

needwo

pieces

or he

ig:

a op

an d

a ip.

Rout dado crossne uxiliary

jaw

o accommodate

he ipof he

vise

jig

andanothern he

undersidef

the ig op.Screwheauxiliaryaws

to he

vise

aws,

making cut

or he

vise crew

f necessary,hen

glue

and

screwhe

ip

o

he opof he

ig.

Cut hesl id ing

encerom

/z- inch-

th ickstock nd

cut wostopped

grooves

hrough

t for Yq-incharriage

bolts.

omounthe ence, ore

wo

holeshrough

he able

or

he

bolts,

feed hebolts

hroughheholes nd

the

grooves

nd

astenhemwith

washersnd

wing uts. ouse he

ig

and ence,l idehe

ip nto heauxi l -

iary

aw,

djusthesl id ing

enceo

holdheworkpiecenuglynd lamp

it in

place

y ighteninghevise

aw

andwing

u ts .

Auxiliary

viae

aw

PREVENTING

ISERACKING

Using

steppedlock

When ecur ing

workpiecetone nd

ofa ace

ise,

he

other nd f he ise

is i ke lyo rack-o r i l t oward

he

bench-andausehe

work

osl ip.

o

prevent

acking,se steppedardwood

b locko

keep

he

aws

quare .u ta

ser iesfsteps

none ace f heblock,

spacinghem tequal

ntervals,uch s

r/z

inch.Placeheblock

n heopen

end f hevise t hesameime

ou

re

secur ing

heworkpieceo hat he

ise

is

parallel

o

heedge f hebench

/eft).

6 l



BENCH

DOGSAND

HOLD DOVNS

p

ench

dogs reas

mportantasvises

Ll in maximizinghe

flexibility nd

utility of a

well-designed orkbench.

setof bench

dogsworks ike a second

pairof hands o secure orkpiecesor

planing,

hiseling,

ortising, arving,

or other

woodworking asks.

Although he benchdog

ooks ike a

deceptively imple

peg, t incorporates

design

eatureshat enable

t

to

hold a

workpiece

irmly without slipping n

its hole.

One

eatureusually

s a thin

metal

spring

attachedo oneside

hat

presses

gainsthe

nsidewallof the dog

hole

n

the

workbench. ohelpstrength-

en the grip of benchdogs, he holes

arealsoangled oward he

viseat 4o.

Benchdogscan be either

round

or square.

Rounddogsareeasier

o

incoroorate

n a bench hat does

ot

yethJvedog

holes;t is simpler o bore

holes han to

make

square

og holes.

Since

ound dogs can

swivel, heir

notched, lat headsenable hem to

clamp stock

n

practically

any direc-

tion. Thiscanbea

disadvantage:ome

woodworkers

laim that round dogs

tend o slio n theirholesmore han

square

ogi,whichcannot

otate.

Bench ogs anbe

madeof either

metal

or

wood.Metaldogs

have weight,

strength, ndstiffiress

hatwooden nes

cannot

match.Yetwoodendogs

have

their advantages-as

nywoodworker

who hasnickeda

plane

blade

on a met-

al

dogwill attest.

Benchdogsarenot the only

method

ofsecuring tock; ench

ooks, arving

hooks,wedges,ndhold downsarealso

useful or

keeping

tock

n

place. he

following

pagesllustrate numberof

commercial

ndshop-madeptions

o

keepworkpieces

ut while you work.

This benchdog

features

a threadedscrew hat converts

it into a miniature tail

vise.

Used

n conjunction with

other benchdogs, t excek

at clamping small or irregu-

lar

work, like the

panel

shown above.

BENCH OGS

Makingwoodenench og

Bench ogs anbecraftedromhardwood

stock;heone hownt

eftuses nangled

woodenongue sa spring. ut he

dog o

f i t heholesn

your

orkbench,hen his-

el outa dado

rom hemiddle f hedog.

Saw short

erf nto

he

ower orner f

thedado, ngl inghe

cutso he ongue

wil lextendeyondheedge f hedado,

Cut he onguerom ardwood,

akingt

about

s ong s hedado, swide s he

dog, nd

s h ick s heker f . luehe

tonguen he

kerf.

62



WORKBENCH

Makingspring-loaded

enchog

A woodenench og an

bemadeo it snugly

byequipping

t witha metal pring ut

rom

anoldband aw r

hacksawlade. ut

our

dog o size,

hen hisel uta smal l

ecessor

thespring.

hewidth nddepth f he

ecess

should oualhe

width nd hicknessf he

spring, ut ts

ength hould eslightlyhorter

than hatof hespr ing.

resshespr ing

nto

the

ecess;hemetal

will bow utward,old-

ing hedog

irmlyn tshole.

SHOP-MADE

DGEOGS

Edge ogs ike hose

hown t right

are

deal orsecur ing

workpiece

alongheedge f

your

ench. hey

feature rou nd owel t oneend

thatdrops

ntoa bench og

hole

andangled

eads

hat

buttupagainst

theedge f h ebench

ndhold

thework.

Startby cutting he

dogs rom

hardwoodtock.Both

eft-handnd

right-hand

ogs reneeded,

i th

theheads ngled

n opposingirec-

tions.Bore

t/z-inch-diameter

hole

through

heends, nddrive

3-inch

length

f

dowel

n

each

ole. hen

inserthe

doweln a bench og

hole

ndangle

hedog o

t

extends

beyondheedge

f he able.

Mark

a 90' notch

or hehead

erpen-

dicularo heedge f he

bench nd

cut t out.Tohold he

edge og n

p lace

hen lamping

ressure

s

appl ied,

aw %-inch-sl iceff he

bottom

f the dog,except

or

he

head. his

rovides

ip hatwillbutt

againsthe edge f

the bench

/eff).

Touse heedge

ogs,

lace

he

lef t -handog na hole n he xed

dog lock

nd he ight-hand

ne n

thesl id ing

og lock f he a i l

v ise.

Tightenhe

vise ntil heworkpiece

is held

n

he

notches

below).

3/+"x21/+"x8"

63



WORKBENCH

Making ndsetting pcarving ogs

Using standardench ogasa model,

you

can ashion

pair

of customizedogs

thatwillgripa carved r urnedwork-

piece,

rsecurerregular-sizedork, uch

as

mitered olding. o

makehese

accessories,ut bevels n either ideof

the head f a standard ench ogand

drive small crew r nail nto hecen-

ter of the head; nipoff the astener's

head

o

form

a sharp

oint.

To

use he

devices,

lace

nedog

n

a dog

hole

of

thebench'sixed ogblock nd heother

in he ailvise ra sliding og lock ole

(above).

ightenhevise crew ntil

the

points

ontacthe ends f thework-

piece

ndhold t securely.

64



WORKBENCH

NDBENCHTOPS

Using

hold-downlamp

Commercia l

o ld-downlampsanbeused

lone rwithbench ogso

secure

workpiece

n

place

nywherena

workbench.he ype hown

eaturesnadjustable

holding olt

which its n a counterbored

ole hroughhebenchtop

insef).

ouse

theclamp,aisehebolthead nd lidet hroughhenotch t hebase f heclamp.

Set theworkp ieceunder thec lamp

awandt igh tenthescrew

above) .ln the i l lust ra-

tion,

wood

ad

sbeing sedo

apply qual

ressure

o both

iiles f a doorrame.)

To emoveheclamprom hebench,

lide t off hebolt

head

nd

et hebolt rop

belowhe

surfacef he op.

Makingnd sing emporary

enchto p

A clamped-onench top ut

rom

7a-

inch

plywood

illsecure

workpiece

o

thebenchtop

ithouthehelp fbench

dogs. ut he

bench top o size,hen

mark uta r iangularedge,ypical ly

incheshorterhan hestoo. ut

out he

wedgend et

t

aside.

ouse hebench

stop, lampt o hebenchtopnd l ide

the

workpiecento henotch, utti ng ne

side gainsthe

straightdge f henoich.

Securehe

piece

ith hewedge,apping

it t ightly

n

place

itha mallet

/eff).

65



WORKBENCH

Installingwedge top

A wedge

top analsobe used o secure

stock

n a benchtop

left).The

top on-

sists f a

fixed ail

anda movableail

thataresecured ydowelsestingna

doubleowof holes orednto

he

work-

bench. ogether ith

a triangular

edge,

the ails eep workpiecerom

moving.

Cut he ails nd hewedgerom%-inch

plywood.

You

anchoosehicker tock

for he ails, ependingn he hickness

of

your

workpiece.)ore

wo

L/z-inch-

diameter

olesn

each ail, hen

lue

2-inch-longoweln each ole.Bore

two ows f %-inch-diameterolesn the

workbenchor he dowels. o use he

stop,

place

he

ixed ail

at oneendof

the

ow

of

holes

nd hemovableail he

appropriateistance way o hewedge,

when

ositioned

etweenhe ails,will

keep heworkpieceteady.

Making bench ook

The hop-built

ig

shown t rightwill

ensure

that

hecrosscuts

ou

make

n he

work-

bench ill besquare.

se

/a-inch

lywood

for he base ndstripsof 2-by-2 tock or

the ips.Makehe base t least s ong

as hewidth f

your

workpiecendwide

enougho supportt. Screwhe ips o

the

guide,

t tachingne

o each

ace.

To use he

ig,

but tone

ip

againsthe

edge f the bench nd

press

he

work-

piece

irmly

againstheother. lign he

cuttinginewith heedge f he base nd

makehe cut(inset).

66



WORKBENCH

l ip-upto p

top hown t

right

ro-

ay o make

uick u ided

na

workbench.ut he

wo

f hestop romhardwood.crew

pieces

o heendof he

benchtop;n

bench

hown,he

nner dge f he

iece

s ined p

with

he

edge

he ool ray o

provide

convenient

ine

or

squaring

pa crosscut.

hestat ionary

iece

n

place

ith

nd he lip-up

iece

ithone

t can

pivot.

When ot

n use,he

iece

hould

ieonedge top

stationary

iece.

ouse hestop,

l ip

p

he

pivotingiece,

utt heworkpiece

t, andmake our rosscut.

Makingnd sing miter enchook

Customize

standardench

ooko

make

5"angle i ter uts yaddrng

kerfsoone f he

ios.Build bench

hook

page

6), hen

usea backsaw

to cut wokerfs

n

he

ipat opposing

45'angles ndoneat 90"

(/eff).

se

the

miter ench ook s

you

would

a standardench

ook,in ing p he

cut t ing

ine

n

heworkp iece

i th

thedesirederf.

67



* \ .

t

{ :

r



SHOPACCE,SSOruES

ii-r- r:ne3'jr

,-n3

:,jrl?tt

I'l

'ill

- I

L uur-'r''Lrrlq

rrLdur

rr@ rLu

Lv urL

:i

lWw'jffi

;ilH:.t.:i:,::ii::?,

youwill

find severi

work safer

n

or safety

nd

*ore smoothly

hin

with

Most f the

wood hips

nd

sawdust

enerated

shortness

f breath,

nddizziness.

abrush.Butwiththeadventofsuch

bythisl0-inchtablesawarecapturedbya

Recent tudies

ave hown

hat

tools

as

pneumatic ailers, om-

portable

ust

ollection

ystem. fien

eglected

long-term

nhalation fwood

dust

pr.rrotr r. foundmore requent- in thepast,ust ollectionas ecomecentral is at east contributingactorn

iy,

u.n

in small

home

workshops.

tort"i,

of many

afety-conscious

oodworkers

cancers

f the ongue,

onsils'

ung,

Air-powered

ools

are discussid

in

planningthelayoutf heir hops.

*9

b.fnt'

starting

npage72.

When

ou

ad{

1o

he equation

Geniratorsltoo,

re

indinga

place,

specially

mong

hose

the

ire riskand he

hazard f

a dust-covered.lhop

loor, here

woodworkers

ho ake

heir rait

away

romhomeand

pow- arecompelling

easons

or installing ome

ind of

dust

col-

er

ines. heyare

explored

npageTl'.

-

lection ystem

n

yo_urhop.

ages8 o 87.

rovide ou

with

Grinders,

f course,

an peed

oolsharpening.

ore

mpor-

information

ou

will

needo setup_

nd-maintain

oth

central

tantly, s

ou

will see

n

page

6, heycanpermit

ou

o

mod- and

portable

ystems.

emember.that

esigning

central ys-

ifi'toolsand

eclaim ariraged

utting

dges.

temrequires

arefrrlattentionlo

{etail

an{Precisealculation

'

Airbornedust

once

wasionsidered

nunavoidable

onse-

ofyourspecific

equirements.

obesafe, heckyour

lans

nd

quence fworking

with

wood.But he

ncreased

mphasis

n

figureswith

anengineer

efore

nstallinghe

system.

shingwork-to

applylacquer

and

-72:i*.ii;*''{

r"-rqrffi

of ailments,

inclt'ding dermatitis,

Hooked

up to a compressor,

his

air-powered

ander

is

compact nough

hold

n one

hand.

et t smooths

wood

as

ficiently

asan

electric ander.

69



A

STORE

OF

SHOPACCESSORIES

High-volume, ow-preaeure(HVLP)epray syltem

Planers

ancreate

substantial

mound

of sawdustn

shortorder.

A

portable

ust

collector ill

keep

most

of thedust

from

this

and

other

power

ools

offthe

shop

Jloor

and out

of theair.

For

applyingataina

and finishee.

FeaLuree

electric

tur-

bine hat

aupplieaaraeamount of air at lownreaartreuppliea ar4e

amount

of air

at low preaeure

ir

hoge o

aprav aun:comoared io conven-

hrouqh

air hoae o

epray

7un;

compared

o ionven-

tional,

compressed-air

ype eyateme,

HVLF

allowa

ional,

compressed-air

ype eyateme,

HVLF

allowa

hiqher

percenta1e of fi niah

to contact

workpiece

Multitester

Aleo

known

a volt-ohmmeter,

or

VOM.

satte

ry-

p

owe

ed

to

ol

uaed n troubleahootina

nd

repairing

electric

deviceZ:

mea-

eures reeiatance

and AC

or DC

voltaqe

in

a circuit

Air

compreaoor

Suppliea

atream

of

high

preeeure

air

throuqh hoae

o power

a variety

of

air-operated

toola, auch

aa aandere,

epray

qune,

and drilla;

coneumer-

4rade

modele

anqe froml/a

to 5

nor9ePower

nd

can

qenerate

uP o

2OO

pounda p€r oquare

nch

(pei)

of

air

preeaure

and O.3

to 15

cubic feet

of air per minute (cfm).



SHOP

ACCESSORIES

Generator

Typic lly

g

a aoli

n

e' powered,

eatu ri n

q

uo to four 12O-and 24O-volt out-

leta. Motors on

congumer'qrade

qeneratoro ranqe batween

3 and

B

horaapower

and produce

5OO to

4OOO

watto of

output;

moet modela

weiqh

leaathanlSO

poundo

and can

befit-

ted

with

wheela or eaay

portabili$

thop

vacuum

Cleana

p duat

and

liq-

uid apills;hoae can be

attached

to individual

tools to collect

duat as

it

ia produced.

Typically

featurea

1%- o

2%-inch'

diameter

collection

hoae

and

5- to

1O'qallon ank;

some

modelecan double

aa

portable

blower

grlnder

wheel

left)

6quarea,

aharpena,

and

bladeaand

bits; cloth

wheel

ri4ht)

and cleana.

Features

a

1/+-

tol/z'

electric

moton

eye ahielda,

tool

resta, and

wheel

uarda

most

modela,Benchtop

ueually

bolted

to

work aurface

Wheeldreeeer

Used

to true or

reehapabench

4rinderwheel.

gtar-wheel

dresaer

(above) ueea

uP to

four

ota

r-

ohaped

wheela; iamond-point

dreaser

(below)

iatureal/+'carat

diamond

aet

in

bronze

ip and

metal shaft

7T



AIR

COMPRESSORS

A

n

air compressor

anbe ittedwith

A

a

arse

umber

f tools nd

attach-

ments,

iaking it

a convenient

hop

accessory.n some

hops, compressor

can represent n alternativeo some

electric

ools.Forothers,t

canbea valu-

able

upplement.

Air-powered

oolswork

best t a

specific

ressure

ndicated

n the

owner's

manual

for

the

particular

tool.

Before tarting

a

ob,

the

com-

pressor's

ir

regulator

houldbe

adjusted

o the

proper

settingfor

the ask

t hand.

Pneumatic

rills,grinders,

anders,

andwrenches

erform

at east s

effec-

tively

as heir lectric-powered

oun-

terparts.

Some

ools, ike sprayers,

nailers, ndabrasiveleaners, reclear-

ly superior

o the alternatives.

Compressorsnd

the tools

they

drive

are nherently

imple:The

air

is

drawn n,

pressurized

y a diaphragm

or one or more

pistons,

and

usually

storedn a

ank.When

he riggeron

an

air-driven

ool s

pressed,

he air

travels

through

a hose o

power

he ool.

Because

hey

containno heavy

lec-

tric motor, most

air tools

are

ighter,

cheaper, nd

easiero repair

han their

cousins. hey

cannot

overheat, nd here

is no

danger felectrical

hock.

Compressed-airower

does

have

some

drawbacks,

hiefly he

costof the

compressortself

andmaintenance.

ir

drills and he ike

must

be oileddaily.

Andyouwill invest everal undreddol-

lars n

a compressor

hat s

capable f

driving

ypical

shop ools.

Some ir-powered

ools equire

siz-

able olume

of air,usually

measuredn

cubic eet

per

minute

cfm);

others eed

a minimum

level

of air

pressure

n

pounds

per

squarench

(psi).

When

choosing compressor,

onsider

he

cfrn

or

psi

requirements

f the air-powered

toolsyou

plan

o use

and buy

a com-

pressor

ith

slightlymorepower.

You

never know

when you

will

want to

expand our

tool nventory.

AIR-POWERED

OOTS

ND CCESSORIES

Jitterbug

sander

)rbital eander

capable

of

pro-

ducina 25OO atrokes

oer

minute:

weigho eas

than 5

pounda.Keauirea .5 cfm at'9O

pai; muat

be uaed with

tank-

mounted

compreeaor

with

at leaat

3

horaepower

3/a-inch

drill that

turna bita

at 25OO

rpm; wei4he

only

2 %pounde.Kequirea5

cfm at

90 pei; muet

be

ueedwith tank-mounted

compresoor

with

at leaat

'l

horeepower

Drill

9pray

gun

Heavy-duty

aprayer

with

adjuatable

luid

and air

controle.

Kequiree5.5

cfm

at

40

pai;

can be uaed with

any compreoaor

with more

than t horeepower

72



SHOP

ACCESSORIES

o

Read

our

wner's

anual

arefully

before

perating

compressorr any

air-poweredool.

r

Donot eset ny witches

rvalves

n

thecompressor;

hey

have een

reset

at safe

evels t he

actory.

.

Checkhe

hoses,

lugs,

ires,

ipes,

and ubes

f thecompressor,

nd

he

tool

air nlets efore

ach se.

Donot

use hecompressor

r ool

f any

part

isworn r

damaged.

o

Wear afety

lasses

nd

hearing

ro-

tection

hen sing

ir-poweredools.

.

Do

notexceedhe

pressure

ating

of anair oolor accessory.

C(|MPRESSOR

AFETY

IPS

.

Always

lug

a compressor

ntoa

grounded

utlet

f theappropriate

amperage.

r

Relieve

ressure

lowly hen epres-

surizinghe

ank.

o

Donot

press

he rigger f

anair ool

when onnecting

t to an

airhose.

r

Donot emove

he belt

guard

f a belt-

driven omoressor

hen he

machine

is operating.

.

Turn he

compressorff

f it

produces

anunfamiliar

oise rvibration,

ro -

ducesnsufficient

ir

pressure,

rcon-

sumes

xcessiveil;

havehe

machine

servicedeforeesumingperations.

.

Allowhe

compressoro

coolbefore

performing

ny

maintenance;ear

gloves

o disconnectny

parts

hatare

still

hot.

r

Turn hecompressor

ff before

ovingt.

o

Donot ouchhe

compressor

hile

using

t

or

mmediatelyfter;he

machine

canbecome

ery ot.

r

Drain nymoisture

rom he ank

after

each se

o

prevent

ust; ank

pressure

should eno

higherhan10

psi

when

draining

t.

.

Replacehe ank

f it has ny

in

holes,ust pots, r

weak

pots

atwelds.

Brad ffniahing

nailer

Nail

qun

for drivinq

3/u-

to

1%-inch

No.1B inishin7

naila:

wei1ha

eas han 3

pounda.

Narrow

nose eets

naile with'

out.

marrinq

workpiece:

ma4a-

zine

holds

up

to

11O

aila.

Requireo

2b

cfm

at 90

paito

drive 10 naileper minute; muet

be used

with compreaaor

with

at

leaetl/z

horaepower

Router

%-inchdirect-drive

router that

turns

bits

at 2O,OOO

pm; wei1ha

uat

over

1pound.

Featuree neoprene

ubber

qrip

to

reduce vibration, Requiree

90

poi;

will unction with

most

compreoaore

j:i,2";:#:fi;"",.

ww

resgor

Or Connect?

two len4thaof com'

preeeor

hooe oqether

Quiak

coupler

Uaed with

hoae connectora

to

attach air

tools to compreeeor

hose

or

to

join

lenqthaof com-

preooorhoee oqether;

auto'

matically ahuta off air

when

uncoupled

rom

compreeeor

73



PORTABLE

ENERATORS

,|

heaverageome

nd

shopssowell

I equippedwith

lectricixtures,

ut-

lets,

andextension

ordshat t is

easy

to take or granted

heessentialole

hat

electricitylaysn our ives. etapow-

er outage an

quickly

emindyou

of

that ole.At

such ime,

a

portable

C

generator

ecomes

n

ndispensable

accessoryor your

home, our

shop,

r

in

a

remote

abinwhere ower

ines

o

not reach.

AC,

or alternating

urrent)

enera-

tors ypically

eature gasoline

otor

that

drivesan alternator.

Models

are

availablewith

otors

angingrom

3 to

8horsepower,roducing 00 o 4000

wattsof

power.

There

areseveralactors

o consider

when

electing

generator,

nd

hechart

on

page

5canhelpgurde ou.

Thegen-

eratormust

produce

nough

ower

o

startand un the oolsandanyother

electrical

evices

ouplug

nto t. The

wattageatings

isted

on thechart

are

typical.You

should efer

o the

actual

rating

of

your

ool,

which s

usually

printed

on the

oolbody. fnot, you

cancalculate

he rating

by multiplying

the

ool'samperageating

by thevolt-

age.

For

example,

3-amp ool

oper-

atingon 120 olts

wouldhave

wattage

rating

f 360.)

Thewattageatingof a generator

refers

o ts

continuousunningwattage.

Although

all models

eature

surge

r

maximum

ating

asmuch

as25

percent

higher

han

the running

value,

you

should ely

on he unning

wattage

at-

ingwhen hoosing generator.gen-

erator

with more

power

hanyou

need

will

run more

smoothly

or longer

stretchesnd equire

ess

maintenance.

Mostgenerators

reequipped

ith

one o four

120-volt

utlets.Many

mod-

elsalso

ave 240-volt

utlet

anda12-

volt

DC

output or charging

atteries.

Make

urehatanygeneratoryoubuy

is equipped

ith an

effective uffler.

Alsocheck

hesize

f the uel

ank.The

generatorhould eable o run for at

least

0minutes

n a frrll ank.

Portable enerators

re

a handy

source

f elec-

tricity

during

power

out-

ages r in locations

here

a conventional

lectrical

supply

s unavailable.

Ratedat

3500watts,

his

model

s able o drive

vir-

tually

any electric

work-

shop oolor appliance.

74



SHOP

ACCESSORIES

TYPICAT

OWEROOL

ATTAGEATINGS

Choosing

generator

ith

a suitable aftage

ating

All

electric

ools equire

ore

ower

o

start p han

orcontinuous

unning.he

chart t leftgivesypical owerequire-

mentsora

numberf ools.Whenelect-

inga

generator,

ake uretswattage

at-

ing s higherhan he

start-up attage

of

your

most

owerful

ool.

Adda safety

margin f

about 0

percent

o hecom-

binedunning

attagef a l l ools

ou

wil l

p lug

nto hedevicend

peratet

thesame

ime.

Tool

Aircompressor%-hp)

Table aw

10")

Saber aw

Circular

aw

7%")

Circular

aw

6%")

Belt ander

Bench

rinder

't-hp)

Orbital ander

Router

Electricrill

%" )

Electr icr i l l %")

Power

lane

Electric

rill

%" )

Random-orbitander

HVLP pray

ystem

Watts

Start-up)

4000

4000

2500

2500

2200

1500

1500

900

900

800

600

600

500

500

400

Watts

Running)

2000

1500

1200

1200

1000

600

r200

360

700

600

350

450

250

360

240

.

Read

our

wner's

anual arefully

before peratinggeneratot.

o

Neveruna

generator

ndoors;

ike

any

internalombustion

ngine,t

produces

carbon

onoxideumeshat

aredeadly

ina confined

pace.

.

Donot ill the

generator's

uel ank

whilehemotors

unningrhot.

r

Add uel o he uel ank

at east 0

eet

from

our

work rea

ndany ourcesf

heat r

lames. onot ill the ank

ight o

thebrim;

he uel an xpand

hd verflow.

.

Donot moke

hileill inghe

uel ank.

o

Clean pany

as

roilspills

mmedi-

ately,

iping p hearea

witha clean

cloth,

rsoakingt up

withanabsorbent

materialuch

scat itter r

vermiculite;

avoid sing

awdust,

hichscom-

bustible. lace

uel-soakedagsn sealed

metal ontainers

nddispose

f hem ol-

lowingocal nvironmental

egulations.

r

Donot emove nysafety

uards,

ov-

ers, r screens

rom he

generator

hile

the

machinesoperating.

GENERATOR

AFETY

IPS

e

Keep

as

nd

ilonly ncontainers

designedpecificallyor uelstorage

and

learly arked

UEL. eephe

containers

wayromsourcesf

heat

and

lames.

r

Checkheengine

il evel achime

you

efuelhe

generator.

.

Checkhe

generator's

uel

ines nd

connectionsegularly;

f

you

notice ny

leakage,urn

hemachineffand

have

it serviced

eforeesumingperations.

o

Never se

generator

itha

aulty

or damaged

xhaustystem

. Groundhegeneratorollowinghe

manufacturer's

nstructions;his

will

divert ny tray

urrentroma shott ir-

cuit o

ground,

educinghe

iskof elec-

trical

hock.

.

Do

not

connect

240-voltool

orappli-

ance

o a 120-volt

eceptacle.

.

Donotoverloadhe

generator

y

plug-

ging

n

power

ools r

appliancesith

higher attageatingshan hat

of he

generar0r.

.

Never

ire he

generator

o heelectri-

calsystemfyour ome rshopn an

attempto

provideower

uring nout-

age.

his

practice,

nown s

backfeed-

ing," sunlav'rfulnsome reas,

s t

poses

risk o anyone

orkingn he

electricalystem.

.

Keep

our

ands nd ace wayrom

carburetor

heneverheaircleaner

as

been

emoved;sudden

ackfire--or

explosionf

uel nanengineylinder-

can ause

eriousurns.

.

Donot ouch he

generator

ngine r

exhaust

iping

hilehemachine

s un-

ning r mmediatelyfter urning

t off;

these arts anbecomeery ot.Allow

the

generator

o coolbefore

erforming

anymatnlenance.

r

Turn he

generator

ff

before

erforming

anymaintenancen

t; also isconnect

thespark

lug

wire nd hebatteryo

pre-

vent ccidentaltartup f

hemotor.

r

Generator

se s

regulatedy ederal

and tate egislation

n some reas;on-

tact heappropriate

uthorities

n

your

communityorany pplicable

aws.

7 \



BENCH

GRINDERS

f,

rom dressing

ndshapingmetalto

I

squaring ndsharpening

its,

plane

irons,

and chiselblades,

he bench

grinder s

an nvaluableworlshop

main-

tenance ool. Grindersare classified

accordingo

their

wheel

diameter. he

5-

to 7-inch

benchtopmodels,with

%- o

%-horsepowermotors,are

he

most

popular

home

workshop

izes.

hey

can

be

mounted

on a work

surface r fas-

tened o

a seoaratetand.

Grindingwheels ome n manygrits

and

compositions. edium

36- and

60-grit aluminum

oxide

wheels

will

handle

most tasksadequately,

ut

you

may

need a finer wheel,with either

100or 120 grit, for

delicate

harp-

ening

obs.

Buffing

wheelsor

polish-

ing metal,

and wire wheels or remov-

ing rust

and cleaningmetal,

are also

worth owning.

Most grinders

operate t one speed,

or allow

a choiceof two speeds-typi-

DRESSING

GRINDERHEEL

Truinghewheel

To

ruea

grinder

heel

nd quarets

edges, sea star-wheel

resserra dia-

mond-pointresser.

or hestar-wheel

dresser,ove

he

grinder's

ool est

way

from

hewheel.With

he

guard

n

posi-

t ion, witch n he

grinder

ndbutt he

tip of hedresser

gainsthewheel. hen,

with

our

ndexinger

estinggainst

he

tool est,move

hedresseride-to-side

across

hewheel

right).

or

hediamond-

point

resser,old

hedevice etween

the ndexinger nd humb fone and,

set t on he ool est ,

ndadvancet

toward

he

wheel

nt i l

our

ndexinger

contacts

he ool est

inset).

lidehe ip

of

hedressercross

he

wheel,

ressing

l ight ly

hi le eeping

our

nger n

he

tool est. or

ither resser,ontinue

ntil

theedges

f hewheel re quare

nd

you

have xoosedresh

brasive.

cally 950 nd

3600

pm.

Some ewer

models

ffer

ariable

peeds,

particu-

larly

aluable

ption or

polishing

nd

A grinder

s thebest ool

for

restoring

the

correct evel ngle

on a nicked r

out-of-squarehisel

lade.The ip of

theblademust

contacthe

grinder

wheel t

an angleof 25" to

30".

cleaning, nd or grinding

with

speeds

low enough

o maintain

he temperof

a steel

ool.

No grinder

should

be usedwithout

loweringheguardmountedabove ach

wheel; he

tool should

also come

equippedwith

adjustableool rests

nd

wheel

overs heathing 5percent

o 80

percent

of the wheels.More

expensive

grinders

mayhave

other eatures,

uchas

sparkarresters,

water ray or

cooling

tool

tips,and exhaust

utlets.

Check

your grinder

wheels egu-

larly

for fractures

and, as the wheel

wears, djust he

distance etween

he

tool restand hegrindingwheel o aboutr/tinch.

A grinding

wheelwill

eventual-

ly become

ull and clogged

with metal

particles,

nd ts

edgesmay

go

out-of-

square. s shown

below,a wheel

dress-

er s a special

ool that s used

o true

the working ace

of a grinding

wheel

and

square

ts

edges.

76



SHOP

ACCESSORIES

U^

GOUGE.SHARPENINGIG

The

ig

shown t

right

guarantees

that

he ip of a

gouge

i l lcontact

thewheel

f

your

rinder

t hecor-

rectangleo

restorehe

bevel n he

cut t ing

dge.

he imensions

n

the

l lustrat ioni l laccommodate

mosr

ouges.

Cut he base

nd he

guide

ro m

%-inch

lywood.

crewhe

guide

together

nd

astent to the

base

withscrewsountersunk

romunder-

neath.

ake ure he

openingre-

ated y he

guide

s arge

nougho

allowhearm

o slidehrough

reely.

Cut hearm

rom1-by-2 tock

and

he ool upport

rom%-inch

plywood.

crewhe wo

parts

f the

tool

supportogether,

hen asten

thebottom

o hearm,

lushwith

one nd.

For

he

V block, ut

a small

wood locko

size nd aw 90"

wedgeutof one ide.

Glueheblock

to

he ool uppo rt.

Touse he

ig,

secure

t to a work

surfaceo he

arm ines p

direct ly

underhe

gr inding

heel. eat

he

gouge

andle

n heV block nd

lide

the

arm o hebeveled

dge f he

gouge

its laton he

grinding

heel.

Clamp

hearm n

place.

hen, i th

the

gouge

lear

f hewheel,witch

on he

grinder

nd epositionhe ool

in he

ig .

Ho ld inghe

gouge

i th

bothhands,

otatet fromside-to-

side

o hebeveleddge

uns cross

the

wheel

left).

Check

hecutting

edge

eriodically

nd top

rinding

whenhebevel

orms.

Tool9upport

(back) '1"x2"x2 '1"

(bot tom)%"x1%"x2 ' /o"

Ouide

( r o p ) % " x 1 % " x 9 "

(a tdee) ' h "x1u /a "x9"

77



DUST

COLLECTION

A

dust ollectionystem as

neaim:

A

to capturemosiof hewood

dust

created t eachofyour woodworking

machines nd

prevent

t from

ending p

on the shop loor,or, worseyet, n the

air.There

rea series fvariablesn

every

system hat must be coordinated

o

ensure strong nough low

ofair: the

power

f thecollector;theocation

nd

requirements

f the

machines

n the

shop;and he ype,size, nd ayout

of

the duct work.

Thedesign fa

central ystem egins

with a simple

bird's-eye

iew

sketch

f

your shop, ike

the one shownbelow,

arranging

hemachines ndcollectorn

theirpreferred

ocations. hen,

raw n

a

main ine

running rom

the collector

through he

shop.Sketchn branch ines

as needed

o accommodate ach

machine nd

anyobstructions-joists,

beams, r fixtures-that mayrequire

specialouting.For he

bestair

flow,

keep

he main ine and

branch inesas

shortand

straight s

possible,

ndposi-

tion

the

machines

hat

produce

he

most

dust

closesto the coilector. oumay

chooseo run ducting

along he ceil-

ing of the shop,or, to increasehe

efficiency

f the system, t machine-

tableheight

along he walls.

Since

n most

homeshops

nly one

woodworking

achine ill

be

produc-

ing

dustat a time,4-

or 5-inch-diame-

ter duct s sufficient or

both the main

and

branch

ines.

Thereare

several uit-

able

ypesofduct availableor

dustcol-

lection

systems.he

best hoices metal

duct designedpecificallyor

dustcol-

lection.However,many

woodworkers

opt for

plastic

pipe,

ypicallyPVC

or

ABS. t is

easiero seal ndassemble

and

disassembleor

cleaning),ess xpen-

sive, nd more eadily

available.

Because

lastic

s

an

nsulator,

ow-

ever, tatic

build-up nside he

pipe

can

reach angerousevels

uring se-pos-

siblyhigh

nougho gnite

hedust

pass-

ing through t. To prevent

his, ground

all

plastic

ucts y running

a bare opper

ground

wire rom

each ool, nside

he

duct,

o an electrical round.

As a safety

precaution, ave he system hecked

by an electrician.

mooth-wallubber

hoseand lexible lastic

ose, requent-

ly used

as branchducts o

connect

machines

o themain ine,

areotherduct

options or thehome

shop.Mostof these

producs

also equire

lectrical

rounding.

A

centraldust collection

system

requires

selection

ffittings o route

and

oin

lenghsof

ductanddusthoods.

The nventory

on page

9

llustrates

he

elements

f

a

qpical

dustcollection

ys-

tem. f you run

themain ine

along he

ceiling, ou

cansecuret in place

with

wire

strapsnailed

o furring

strips

mounted

etweenhe

oists.

Fittings irectly

ffect he efficiency

of thesystem,

ochoosehem

carefully.

As a rule,gentle

urves re

better han

sharp urns,souseY fittings

nstead f

DESIGNING

SHOP

Laying uta

shop

F()REFFICIENTUST

C()LTECTION

Thediagram

t

right

llustraies ypical ome

hop

layout.he

power

ools nddust

ollectionystem

have

een rrangedormaximum

ust ollection

ff

-

c iency. i th heexcept ion

f he able aw,

l l he

machinesre ituated

n he

perimeter

f hework

rea.

The uctingor

hecentral ust ollection

ystemuns

closeo hewal ls.

espiteequir ingrelat ively

ong

mainine,

h is es ignl lowsor

shor t ranchines

andminimal i rect ional

hanges-bothf f ic ient

arrangements.he

paceaken pby

hedust ol lec-

t ion ystemsminimizedyplacinghe ol lectorut

of hewayn

a cornerf heshop. he

planer,roba-

bly he heaviestust

producer,

s

positioned

losest

to he

collectoro reducetrain

n hesvstem.

78



SHOP

ACCESSORIES

or branch

onnections,herever

blast

ate

hould

e ocated

each ranch utlet

o seal ucts hen

arenotbeing sed,hereby

ncreas-

flow to the machine

n

use.

hether ommercially

ade

r

hould e

positioned

s lose

possible

o thesource

f thedust.

Youhave choice f

methodsor

uctwork.

any

ducts

nd

canbe

riction it andsecured

ose lamps. uct ape

canalso ffectively

oin

plastic ipe,

ut

it is

unsightly

ndwill decay ver ime.

A high-qualityiliconeealant

s

proba-

blyabetter hoice

or a

permanent

ys-

tem.Toensure mooth ir

flow metal

ducts hould e

oined

with rivets,ather

thanscrewsr bolts.

Once

ou

have ompletedhe

ayout

ofyoursystem

ndselectedhe ypeof

duct

youwill

use,

t is ime o calculate

your

dustcollection

eeds

ndselect

collector.

his nvolvesetermininghe

requirements f the

heaviest

ust col-

lection askvour svstem

must handle.

This usually'willbi the sum of system

losses nd he air volumedemanded y

the machine

most

distant

from the

collector.

Purchase

collector

with

slightlymore capacity. ystem

osses

are caused y such

nefficiencies

s

bends

n the ine,corrugated ucting,

leaks,

and

hoods without flanges.

Use hecharts nd

nformation

n

page

80 o sizeand select collector.

ETEMENTS

lF

A DUST OTTECTIONYSTEM

Reduaer

Metal duct

)tanda rd duat aollection

pipe;

available

n wide anqe

'of

diametera

Connecta

duct of different

diametere; alao used to

increaeeauction

in oyatem or

ioin

a branah

ine to hood

Corrugated

fl exible hoae

Kibbed

plaatic

hose uaed

or ahort

runs or to connect machinea ,o

main duct: smooth-aided

rubber

Elaet'

gate

?ipe fittin7 with

alidin7

qate

which

ia openedor cloaed

to direat.duat col-

lection air

flow to

a

partiaular

machine

Splice

For oinin6 two

len4tha

of

duct

Hood

Duat-

c

apt u in4 devicepoai'

tioned cloee o aource and

connected o branch

ine

or

plaatic

varietiea

aloo available

ffi

\--J

_

I'

Hoee alamp

9lotted

metal

band

T

aonneator

and

acrew

ueed

o

Connecte wo ducte

join

two len4the of

at 90" anqle

duct or hoae

PVC

pipe

Plastic

pipe

for emall ehop

duat, collection

system6;

available n different diame-

tere and wall hiakneasea

Elbow Y conneator

Att,achee o duc-t'

Joina

two ducte at

to chan1edirec-

3Ooor 45" an6le

tion of

line

Adaptere

Joina

non-atandard

hose

and duat

to atandard dust

colleotion

hoae:also uaed

to abtach collection

hoae

to facto

ry-

neta

ll

ed

po

te

on etationarv

maohines

Floor aweep

Attached to branch duct of central

eyetem to

vacuum

duat off ahop

loor

79



SHOPACCESSORIES

CATCUTATINGUST

(|LTECTI(|N

EEDS

Determiningtatic

ressure

oss

Dust ollectorsre atedby heirability

o

(1)

EOU|VAIEI{TENGTHFSYSTEMIEMENTS

move certain umber fcubic eetof air

per

Duct rFifting Equivalentengh,n Feet

minute

cfm)

gainstspecifc stat ic

res-

sure. hemost mportantariableo keepn

Smooth-wall

ipe

Actualength

mindwhen hoosingdust ollectoror

your

Corrugated

ipe

r hose

1.5

x actualen$h

shopsstatic

ressure

oss, hich sa mea-

Unflangeduct, ose, r hood onnections

10

sure f he riction irencounters

s t

passes

90" sharp lbow

20

throughduct.

he onger

heductingnd he

more umeroushesystemosses,he

greater

90ocurved lbow

10

thestatic

Dressure

oss. odetermine

he

90" hose end

10

size f collector

ou

need,

alculatehestatic

45' curved lbow

5

pressure

ossor

he

heaviest

ollectionask

45" hose

end

5

in

heshop.

n

hediagramn

page

8, t is

the ointer. he ol lowingalculat ionsre Sideeg f90"T 20

basedn t. For

our

wn hop,

ou

mayneed

Side egof 45" Y

5

to do hecalculat ionsora fewmachines-

those

arthestrom

hecollectorndat he

endof branchines-and hoose collector

based n hehighestesult

ou

btain.

(2)

AIREXHAUST0LUMEE0UIREMENTS

OR ACHINES

Startwithchart1

(right,

op) o calculate

Machine

Cubic

eet

er

Minute

CFM)

theequivalentength f heductingunning

to he

machine.n

ourexample,here re

Jointer

-r2' )

300

45

straighteetof smooth -inch-diameter

Disc ander

up

o 12") 300

ductand wo90'curved lbows.he quiv-

Vertical

elt ander

up

o 6") 350

alentengthherefores:45 feet+ 20 feet

=

Band aw up o 2" blade) 400

65 feet.Then se hart2

middle)

o deter-

mrneneexnausreourremenrsncTm Trne

Table aw

up

o 16") 300

machine;or he

ointer,

t is

300

cfm.

Radial rm aw

350

Finally,

se hart

(bottom)to

etermine

Planer

up

o

20")

400

static

ressure

ossordust ollectiont he

machine.hooserom itherhe hird r ourth

Shaper

%"

spindle)

300

column f hechart

ependingn

whether

Shaper

1"

pindle) 500

themachines

oined

o a main- l ine

uct

Lathe

500

(3500

eet

per

minute

fair

velocity,

r pm)

Floor weep

350

ora branchine

4000

pm). n hisexample,

Drill

press

3OO

a 300-cfmmachineonnectedo a 4- inch-

diameter ain inehas static ressureoss Jigsaw 300

of .05 nches

er

oot. hushestatic

res-

sure ossor

his

ointer

s:

65

feet .05

inches/foot3.25 nches. dd wo nches

for

unmeasuredossesikeair eaks nd he

(3)

STATIC

RESSURE(ISS ER

00T FDUCTT3500Al{D

1000

PM

value iseso 5.25 nches.

he hop n

page

CFM

Duct

diameter 3500 pm 4000 pm

78 would eed col lectori tha 300

cfm

rating t 5.25 nches f static

ressure.

300

4' '05 n/ft '07 n/ft

system 0

percent

arger ould

llow

or

350

4u '05

n/ft .07 n/ft

future xpansion.

400

4'

,05 n/ft .06 n/ft

500

5u .04 n/ft

.06 n/ft

80



SHOP

ACCESSORIES

COLTECTORS

llltlll lll

lt1ll lll

lll lll ll ll

IllJlll lll lil

lll lll lil llJ

1HO?

TI?

Electrioal ewee?6

lor riqht-angle

ointo

lf

you

uee?VC

ipe

or

your

duet collec-

Lion6yoNem,

ubstit'uhe O" electrical

ewee?o

far

riqht) for convenlional

0"

elbowe near iqht) to reducericLion

and

ncrease

he efficiencyf

your

oye-

tem.

Available

l

elecNrical

upply oue'

ee,Nhese

it t in4e

eaNure 24-inch

radius urve,

which

e much

qent' ler

than Ihe 5-

to |O-inch adius urve

f

etandard lbowe,

Choosingetweeningle-

and wo-stage

ollectors

Two asicypes

f dust o l lectors

re

availableor

home orkshops:tngle-nd

two-stageachines.

nsingle-stageol -

leclors

above,

eff), ebris-

nddust-

laden i r sdrawnhrough

n mpel le r ,

where yclone

ct ion eposits

eavy

dust nd ebris

nto hewasteontain-

erbelow hilehe

ighterust iseso

the

dust ag. ing le-s tage

o l lec to rs

are e la t i ve lyoud nd hedust nd

debr isend

o wear u t hebag nd

impel ler

u ickly.

n wo-stageol lectors

(above,

ight),Ihe

mpellers ocated

abovehe n le t uct

o heheavier

pa r t i c les

rop n to he

waste onta in-

er before

nyair

passes

hrough

he

impe l le rnd

ag . h is

s

qu ie ter ,

nd

reduces

ear n he mpellernd ust

bag. wo-stageollectors

re omewhat

more i f fcul t o clean.

8 1



SHOP

ACCESSORIES

DUST

HOODS

Connecting

dust ollectionystemo ools ith ust

orts

Use

commercialdapteroat tach col lect ionoseo a

machineust ort . he dapterhould esizedo r ict ion-

f i t w i th

he o l lec t ionose tone nd nd l io verhe

Hooking

planer

p o he ystem

A hoodike heone hown t r ight an

becustom-bui l to caoture ost f

he

dust

enerated

y

your laner.

ake

he

hoodrom

alvanized

heet

etal ,

ut-

ting

he

pieces

ith

insnips. eaveabs

where

he

pieces

verlapo hey anbe

pop

ivetedogether.akelanges

n

thesideso moroveheseal nda hole

in hebackor hedust

ol lect ionose;

you

wil l

also eedo create ipalong

the op o

connecto he

edge

f he

planer 's

hip ischargehute. se n

adaptero

o in

hehoodo hehose,

insedingne nd n

he

holen

he

hood

and heother nd n

he

hose;e in-

force heconnectionith

a

hose

lamo.

Fasten

he

ip

of hehoodo he

planer

with

heet

metal

crews.

dust

port

at

heother, sshown n heband aw

above,

eft).

For he adial rm aw, hose lamps usedor einforce-

menl

(above,

ight).

Adapter

CollecLion

hoae

82



SHOP

ACCESSORIES

fitlllllll lt llllll lll lll lll llllll iIllll llllll lll ]I1lll

1HO?

TI?

Adapt nq st andard

sheet'

metal ducts as dust,hoode

Commercialheet-met

l duc|'scan

bemodified

Lo eerve e eff icient

hoode

or

your

ohop'e

duet,

ollecLion

yofem.Someexamplea re

shownhere.Uee

Lin snios 'o cuNNhe ucL

'o

a eh ape haN

ouit6 he tool aI

hand.The

ducN

shoulAi1; nuqly roundhe chipdiocharqeVort

or

dusN poutof

the machine.crew

L n

Vlace

Connectingcollection

hoodoa routerable

A hood ttached

o he ence f a router

table i l lco l lect ost f hedust

ro-

duced

y he ool.Cut he

hoodrom

l/z-inch

lywood,

izingt so hesides

hug heoutside

dges f he ence's

support rackets.

hebottom dge f

thebacklangehould

est n he able;

the op

lange hou ldi ton

he op

edge f he

ence. eforessemblinghe

pieces

f he

hood, uta holehrough

theback or hecol lect ion

ose. lso

bore olesorscrewshroughhesides

and

crew ngleronso he

back o

that

heirnsidedgesre lush

with

he

opening

or hehose. crewhe

hood

together,hen

it

the

col lect ionose

in heback. se

hose lampo secure

thehoseo heangle

rons nd

position

thehood n he

ence

bove).

crewhe

sides

f hehoodo he

ence

rackets.

wibheheet

melal screwe.

B3



SHOP

ACCESSORIES

Setting

pa shop-madeandingtation

To educe

heamount

f dust

enerated

by

power

anding,ui ld

portable

tal l

that

its

ona a ble r

workbench.ut he

back,op,andsidesrom%-or%-inch

plywood.

aperhe opedgesf hesides

to

create comfortable,penworking

space,

ike

heone hown

bove. utan

outletn heback f hestationora dust

collectionose rbranchuct.

ssemble

thestation ith crews.

osition

hesand-

ingstation ecurelyn

your

work

urface;

at tachhecol lectoroseo heout let .

Turn

n he

col lectorefore

ou

begin

a sandingperat ion.

1HO?

TI?

Shop-madeblaot

gate

To aohion

an

inexpeneivelael

qabe

or a

Vlael ic ucl , sawhalfwayhrouqh he Vipe.

Cut a

4aIe

from

plywood

r hardboardo

fii

in

he kerf . )aw

a eemicirc len onehalfof

llll l|tlll l11]il

llrlll iilll1llrlll ll}|lllll lr lll ll ril

the

qate

he sameeizeas lhe

ineide

diamet

r

of

Nhe

iVe;

he olher hal t

shouldorolrude rom the kefr

Lo orm a handle. oeeal he

slol when he machine

e n

use,cuLa eleeve

rom

lhe

eamesizeof

pipe

wi lh

a d iaqona l l iL o a l low

iL o elideoverNhekefr.

84



SHOPACCESSORIES

CONTROLLING

IRBORNE

UST

setting p

positive-pressure

entilation

Tomaintain

lear i r n

a shop hen

ou

are

enerating

great eal fairborneust

orchemicalumes,

etup

a

positive-pres-

sure entilation

PPV)

ystem.

pen ll

he

windows

n he

shop nd

position

an

out-

side he

door sshown

t

right

o hat

he

airflowt

produces

ill

envelophe

door-

way. he

tream

f airwill ollow

he

path

of least esistance-through

hedoor

nd

shop,

ndout hewindows,

learing

ir-

borne

ust nd umes

uickly.

PV

as

someimitations,

owever.

he

ystem ill

only unction

roperly

f thewindow

pen-

ings re argenougho handlesufficient

volume

f

air.Also,he est

f

your

ome

must ewell

ealed

ff rom he

shoo.

more

ermanent

lternative

o PPV

anbe

fashioned

ymounting

nexplosion-proof

exhaust

an n

a shop indow.

etup o

pul l

airout

of he oom,

he anwi l lcre-

atenegat ive

ressure,

xpel l ing

umes

and

dust n argerolumes

han s

possi-

blewith

PPV.

filllll lt'llt

lt'lll-llll

II

ltt'IxlIt

lt l|l'lllt

ll

il'fiI'l||l

1HO?TI?

Vaauum

areeningamp

For

cleaninq

ust off Xheohop

loor, uild

a wedqe-

a L ^ a ^ - ) z r q a ^ q i a ^ - ^ * ^ t - ^ ^ 1 / ^ i - - r ^ 1 . , , , , ^ ^ - J

ehaped

creenin7

amV roml/z-inch

lywood.

Oefore eeemblinqhe piecee,ut an

inlet

porl

in he

backto fit

a dust

collection

ose

and ive rowe

of 2-in

h diameLerh

oles

lhrouqh

he Iop.When

dust

andchiVo

re6we\

u?

onbo he ramp,

maller

parliclee

will

all hrouqh

lhe holee

nd

conNinuen

Io the

colleclor.Larger

efuse

will emain

on bhe ramo

or

eaey

diopoeal.

86



SHOP

ACCESSORIES

l|Il

lll lll

lll ll lli

lll lll

lll lll

lll lll lll

lll lll

ltllll

]l}

1HO?

Tt?

?anty

hoee ahop

vacuum

tlt'er

Uoedpanty

hoee an

oerve o

an

inexpeneivelt'ernaLive

o replace-

able

shop

vacuum ust'

ilNero.

it

the waieL

andaround

he

loam

filf,ersleeve n

Lhe undereide

f

lhe molor

houein4 f

the

vacuum

and

knot

he lege. lide

the

ret'ain-

inq inqaround

he

panty

hose 'o

aecure

N n

place.

Filteringhop

ir

Another

uick

nd

easy ethod

f td-

ding he

hop fairborne

ust ses

ur -

naceilter

n heback

f a

podable

oom

fan

above).

henhe

an s urned n,

suct ion

i l l

holdhe i l ter

n

place

nd

draw

ust utof

heair .

The ustwi l l

remain

n he ilter,

hich an hen

e

brushedff

outsider

vacuumed.

87



STORAGE,

n'd'ub'laccumula'fesliffi#

frfi*[T"i ,{if.#

stonishing

ate: umber

saws,

aw

lades,

rills

planes,lamps,

hisels,

ilt

conveniently

vailable

henneed-

Flammable

roductslikelacquers,

hellacs,

market, ut

you

can

build

a tool

ed-and

out

of the

waywhen

ot.

and

paint

hinners

equire

ltecial

ttention.

cabinet

ustomized

o-

ourneeds

Add o these

he

umber craps,

Storiig

hese

tems

n a-doubfe-lined,

xplosion-

easily nd

nexpensively

p^qT:

? )

locks,

inges,

crews,

ails,

pire

priof

steet

abinet

sone

ensible

olution.

Thedesignshown

n

page

8

fills

pars,'andontainers

aHill of

in

two needs

n one:

a storage

abinet

isher-all sureo be nvaluableome ay erysoon-andyou that oldsdownandservessa-sturdyorksurface.ardware

mayhave

he

makings f

a monumental

toiage

roblem.

-

canbe

sorted

n drawers,

ubdivided

nto separate

ompart-

Adequate

orkh6p

storage

hould

accomilish

wo

goalg:

mentsor,

for

greateri:t lt

y, n

glass

ontainers.

or

ools

fooh

and

materialsliould

bi

kept

within

eaiy

each feach

likeclamps

hatare

used ll

over he

shop, onsider

wheeled

operation,

ndthe

torage

evices

houldencroachaslittleas

ack(page

05)..

pbssiblenwork

space.

io

matterwhat

our

particular eeds,

No matter

what

devices

nd echniques

. u choose,

ou

youshould

inda

number

f storage

deas

hit conserve

pace

may

ind that

proper

torage

ot only

providesmorespace

in thischapter.

-

andconrrenience,

ut

conveys

sensef

order

and.

urpose

tn evaluating

ourownstorage

ptions

egin

y aklg

two

that

ryill

make

ourshop

aneven

more

pleasant

nd

produc-

inventories:

ni'of

your

oolsand

materials nd

he other

of

tive

place

o

work.

h * d * d p o * . ' t o o l s t h a t m u s t b e c o m m e r c i a l s t o r a g e d e v i c e s ' o n t h e

. l

Whatever

tssize, tool

chest

anserve

sa cabinetmak-

er's

callingcard.

This

portablecarver's

hest eeps

ools

organized"

afe

rom

damage,

nd within

easy

each.

89



STORINGWOOD

p

roperly

storedumber

and

plyr,vood

I.

are ot

onlykeptout

fthewaybut

straight

and dry,

oo.

For

most

shops,

this nvolves

toring umber

n racls

that

hold the wood off the floor. Wood

shrinksand

expands ccording

o the

amount

of humidity

to which it is

exposed.

wet floor

canwarp umber

and

delaminate

ome

plywoods.

The

lumber

acks eatured

n this

section re

easyand inexpensive

o

build;

you

should

be able o find

a suitable

esign

and

adapt t to

your

needs.

Ifyou

have

he space, ou

cansetup

an end-loadinglumber

acklike

heone

shownon

page

1.Sucha systems rel-

atively asy

o construct

ut

you

will need

a wall

wice he engh

of

your

umber

o

allow or oading

ndunloading.f

space

in your

shop s

at a

premium,

consider

front-loading

ack

ike

he oneshown

below. f versatility

s needed,

xamine

A LUMBER

ACK

Storing

lanks

nd

oards

The torageack t right eaturesertical

supportscrewed

o wall tuds.

ut rom

2-by-4

tock,

hesupports

uttresshop-

made

ood

rackets,hich

old p he

lumber.ou

wi l lneed

ne upport

teach

end

f he ack , i t h

nadd i t iona l

ne

every

2 inches

longhewall.After

olt-

ing

hesupports

o he

studs,

repare

he

bracketsy

cuttinghe

sidesrom%-inch

plywood

nd hemiddle

helf

iece

rom

2-by-4

tock % nches

horter

han he

brackets.

ngle

he opedge

f hesides

byabout 'so he

bracketsi l l

i l tup

slightly

inset)and

prevent

he umber

from al l ing

f f he

rack.

crewhemid-

dle hel f

iece

o

thesides,hen

crew

thebracket

o the

verticalupports.

the ack

on

page

2,which

allows ou

o

storeboards

oth horizontally

ndver-

tically. void

usingZ-shaped

rackets;

theywaste

oo much

space.

The ypicalshopcanstockhundreds

of

pounds

f lumbet

so

t is

crucial

o

anchoryour rack

firmly-to

at

least

every econd

wall stud

or floor

oist.

Make

he most

of spaces

hat

you

would not

ordinarily

consider

s

prime

storage reas.If our

ceilings

unfin-

ished, ail

urring strips

across

he

oists

for handy

shelving

o store

short stock

and

dowels.

Everytem n a workshop emands

itsown storage

method.The

dowel

rack

at left,

built

rom

3/t-inch

ply-

wood, -by-4

tock

nd6-inch-diam-

eter

cardboardubes,

orts

ffirent

sizes

f dowels hile

aking

up a min-

imum of

floor

space.

o

o

o

o

o

o

90



STORAGE

A

TUMBER-AND.PTYWOOD

ACK

Designed

o accommodate

ot h

boards

nd

plywoodanels,

he ack

shown

ests n he

shop loor

nd

at taches

o

oists

n hecei l ing.

Lumbers

oadednto he

ai ls

from

heend,while

lywood

an

be

stacked

n he rough

t he

ront

and

held

n

place

y he

hingedar.

Refero the

cutting

ist orsuggest-

eddimensions.

Tobuildhe ack,irst ut he ails

and tiles

rom -by-4

tock,he n

notchhem

ogether

rnsef):

tarting

24 nches

rom hebottom

ndof he

stiles,uta

seriesf3%-inch-wide,

1%-inch-deep

adoes

very

4 nch-

es.Cut

abbetst both

nds f

each

rail o match

hedadoes

n hestiles.

Screw

he ails

nd tilesogether,

then

bolt he op

ends f he

stiles

to every

hird

oist,

makinghem

8

inchespart. ncehegrid s ixedo

the

ceiling

oists,

crew

hecrossbars

to

he ront tiles,

enteringhem

between

he ails.

Assemble

he

plywood

rough

ith

screws efore

astening

t to he bot-

tom

of he

ront tiles.

inally,ttach

thehinged

ar o he

roughip

with

a butt

hinge, nd ut wo

notches

n

the reeend

of hebar

ora looped

cord o hold he

barupright.

CUTflNO LI5T

Rails

(9): 1

1/2"

x 31/2" 36"

?tilea

(6):

'l

1/2"

x 31/2"

x

96"

Croeebars

(2)t

3,/+"

x 3t/2"

x 1OB"

Trough

-

back

1"x B" x

1OB"

-

bottomt

1"

x

10" x 1OB"

-

lip:

1"

x 3"

x 1OB"

Hinged bar:

3/c"

x 3

1/2"

x 65"

9 l



STORAGE

ADJUSTABTE

UMBERACKS

Building

nadjustable

ipe

ack

The ack

hown bove, ade

f4-by-4 tock

nd teel

ipe,

s

at tachedo wal l

tuds. he teel

ipes

hould e oughly

4

inches

ong nd

%

inch

n diameter.hey

anbe nserted

nto

anyof he holes

r i l lednto hevert ical

upports

rcross-

pieces,

llowingumber

o be

piled

n he

pipes

r

stackedn

endbetween

hem.Begin y

cuttingheuprights

o ength nd

mark ach

oint

n hemwhere

ou

want

o locate cross-

piece. utdadoesn hesides f heuprightso accommodate

thecrosspieces

inset),

aking

ure l l

hecrosspieces

n

the

same orizontalow

willbeat he

sameevel. ore

oles

in to

heupr ights

nd rossp iecesor

he

p ipes ;

r i l l he

holes

inches eep

nd6 inches

part , ngl ing

hem y

about ' so he

pipes

i l l i l t upsl ight ly.

ol t he

uprights

to hestuds,

hen ut hecrosspieces

o length

nd ap

them n between

heupr ights

i th mal le t .

i x hem n

place ithglue r bydriv ingnscrewstanangle.

92



STORAGE

i l i l l i l t i l i t t l i l t r r l i i i t i i i l l i t r l i l i l l l i l i l l l l i l l

l i r

l l l

ili i$ llt ii.l ul

i$ iil d.u

$ {iJ t$ tti

{ti l$ i$

iti i$ i.U

1HO?

TI?

Anahoring umber

raaka

n

aonarete

einceordinary

woodor

eheet

melal ecrewe o

noN

hold

well n concrele,

ou

will

need,

,ifferenf'

aetenere

Nhan

ou

woulduee

or wood. ead, nchore

top)com-

bined

ith aqbolloare

deal

or

anchorin7

'o

concrel'e.

lneertednto a hole rilledn 'heconcreLe,he nchor

Settingpadjustable

umberhelves

A commercia lumbertorage

ystem

like heone

hown boveonsists

f

metal trapping

ndbracketshat

t

into

olesn hestrapping.

he ack

issimi laro he

woodenne n

page

90,butbecause

t ismetal,h is

ack

can ypical ly

upport

eavieroads.

Bolt hestrapping

irect lyo he

wal l

studs, r o

verticalupportsastened

to non-exposedtuds.

Make ure he

s t rapsre l igneda te ra l l yo a l low

you

o

position

ach

ow

f

bracketst

the

same eight. or

most pplications,

attachhebrackets

o hestrapping

about 4 o 36

inchespart

ertically.

exVands

e Nhe oll

o driven

in lo t ,

qr ippinqtrhe

ideeof

the

hole iqhNly.

nother

oVtion

e

he

eell-LaVpin4

on -

crele

ocrew

bottom),lle

eer-

rated hreade

hold

fasL n concreNe.

93



STORING

TOOLS

AND

SUPPLIES

Shelvesrean deal oolstorage

ption.

This

shop-built

unit

eatures

rooves

nd cleats ustom-cuto hang

a

panoply

of

took

n

full

viewoyera workbench.

((

[

place

or

everything

nd every-

A

thing n its

place."

hat ime-

worn

adages especially

ppropriateor

the homeworkshop.From

shelves

nd

racks o tool chests nd partitioned

drawers,many

devices ill

eliminate

clutter

whilekeeping

oolsand supplies

easilyaccessible. few methods

are

shown n the followingpages.

For certain

ools,

particularly

tems

that arevaluable

r dangerous

nough o

be out of the reach

of children,wall-

mounted

boxesike

hose hown

below

are deal.For

a

more

raditional

system

ofenclosed

torage,

ou

can

build a ool

cabinet

or cupboard n the shop

(page

96).Butnot every

torage evice eeds

to beelaborate.s

shown n

page

0l,

suspending

tool from a fastener

ri-

ven nto

a

wall

canwork

just

ine.

WALL

TORAGE

Installing

ortable

abinets

The

box t right anbehung

ecure-

ly

ona shopwallandeasilymoved

f

necessary.uild t from

Z-inch

ly-

wood itha hinged

op.

Tohang

he

cabinetn

he

wal l ,

uta 45' angle

bevel own

he

middle

f a 1-by-6,

then rosscuthe wo

pieces

lightly

less

han hewidth f

hebox. crew

one f he

oieces

o

he

wall

sa bat-

ten,with hebevel

oint ing

pand

fac inghewal l ;

nchor smany

of

he

asteners

s

oossible

n wal l

studs. crewheother

ieceo the

back f heboxwith ts

atedge

butting gainsthe ipand hebevel

point ing

own

nd acingheback.

The

wo

pieces

nter lockhen

he

box s hung

n hewal l

inset).

SIDEVIEW

Wall

tsalten

94



STORAGE

Adaptingrawersohold malltems

Theaddit ion

f some implerays

anmake rawers

uch

more f f ic ient

toragenits, specia l ly

orsmal ltems

ike

screwsnd

washers,hich anbeeasily

ost. he

ar

organizer

shown bove eeps ifferent-sized

ars

n

order.

he helf ais-

es

hesmaller

ars

o

makehemmore ccessib le.

egin y

col lect ing

he

ars:

ind omeargernes

early

he

same

height s hedrawernd ome

mallernes bout

al f hat

height.

akehedividery r imming

piece

f 7z- inch

ly-

woodo

t insidehedrawer.

ay

ut

he

ars

n he

plywood

andmarkheiroositions.

se hole aw o cut

holesor he

jars

l ight ly

argerhan heir ctual iameters.

o ldhedivider

and heshelf

n

place

itha

pair

f

plywood

upports

above).

Anotherseful

rawerrganizers heslidingray

inseil.

he

tray sa basic ox hat

its nsidehedrawer.hedividersre

notchedogethernd hen ecured

ith inishing

ails. ttach

a

pair

f slides

o hedrawerideso support

he ray.

95



STORAGE

A TOOI-UPBOARD

The upboard

boveeatureswin

doors

orstoringmall,

ight oolsike

chisels

nd crewdrivers,s

well sa

large

main ompartment

or

bigger

tools. ut hecomponentsrom

32-

inch

lywood

r

umbero heappro-

priaie

ize, epending

n henumber

of

ools

ou

wn;hecupboard

hown

above

s48 inc hes ouare

nd5

incheseep

ith3-inch-deepoors.

Next, ssemblehe

cupboardsing

the

oinery

ethodf

your

hoice.

through

ovetai l

o int

sone f he

strongest

ndmost

isually

leasing

opt ions.

ut

you

ould hoose

methodssimple

scounterbored

screwsoncealednder

ood

lugs,

asshown

bove.

Tohelp

ou

nstal lheshelves,

lay hecupboard

n tsback nd

olacehe oolso be

storedn heir

designatedpots.

ositionheshelves

accordingly

nd crewhem

n

place.

Tokeep uppliesrom ol l ing

f fa

shelf r he

bottom f hedoors,

g lue

ledge long

he

ront

dge.

l f

you

want o

subd iv ideshe l f

screw

-by-1 leats cross

t or

insta l l er t ica l iv idersetween

theshe lves .

Equip ne rboth oors

ith lot-

tedshelves

o hold oolsike hisels

andscrewdrivers.

ore series f

holes l ight lymal ler

han he ool

handles,hen aw

kerf rom he

edge

f heshelf o he

hole o

enab le

ou

o s l ip

n

heb lade.

Screwhe

shelveso hedoor.

Hanghedoors

n hecupboard

w i thbut tor

p iano

inges. se

three ut th inges

er

oor.

Mount

the

cupboardo he

wall

bove

ou r

workbench,f desired,yscrewing

it

to he

wall tuds.

97



STORAGE

A FOLD-DOWNORKBENCH

AND OOL

ABINET

ldealor

small

workshops,

he

storage

cabinethown elow ndopposite

ea-

tures door hatservesouble-dutys

a sturdy ork urfacehat oldsupout

of hewaywhen t is notneeded.

Mountedna framehat sanchored

to

wal l tuds,heunit sbui l twi th n

adjustable

helf nda

perforated

hardboard

ack

ororganizing

nd

hangingools swellasa work able

supportedy oldingegs. hecabinet-

bench an be made ntirely f %-inch

plywood,

xceptor he egsand eg ail,

whicharecut f rom 2-by-4

stock; he

1-by-3rame;

he

1-by-4

ingebrace

assembly;nd he hardboardack.

Frame

Fiano

hinge

o o o o o o o o o o

o o o o o o o o o

o o o o o o o o o o

o o o o o

o o o o a

o o o o o o o o o o

o o o o o o o o o o

11

o

o

o

o

o

o

o

o o o o " " " : :

CUTTING I9T

Frame

-

Raile

2):3,/+"x

1/2" 48"

-

Stilee

(2):3/+"x

1/2" 24"

Cabinet

-

Back:1/a" 24" x 48"

-

Top:3,/+"10"x 48"

-

Eottom:3,/+" 10"x 48"

-

1ides

(2):3,/+"

10"x 221,/2"

-

Divider:3,/q"10"x 221,/2"

-

thelf

3/+"

x

10"

x 3O1/2"

Workbenah

-

Top:3,/+" 23

1,/+"

x 48"

-

Eenchtop ail:3/+" 4" x 48"

-

Bencht'op tileo:

(2):3/+"

4" x 221/2"

-

Hinge

brace ails

(2):3/+"

31/2" 461/2"

-

Hinge

bracestilea

(2):3,/+"

31/2" 16"

-

Lege

2):

1

1/2"

x

31/2" 34"

-

Leg ail: 1

1/2"

x

3

1/2"

x 461/2"

9B



STORAGE

Build

heunit n hree

teps, tart-

ingwith he

rame,hen

makinghe

cabinetect ion,

nd

inal ly ut t ing

and ttaching

heworkable

nd egs.

Referringo thecutting

ist

orsug-

gested

imensions,

ut

abbetsn he

frame

ai ls nd t i les,

hen

lue

nd

screwhem

ogether.

exi, crewhe

frameo hestuds

n

your

hop. e

sure

o

position

he

rame o

hat he

work urface

illbeata comfortable

height,ypicallybout

6 inches ff

the

loor.Now uild he

cabinetec-

tion,

uttinghe

parts

o size. efore

assembling

he

pieces,

orewo

paral-

lel ows f

holes n he

nsideace f

one ide

anel

nd heopposing

ace

of hedivider. ril l

heholes t

-inch

intervalsbout

inchesn

rom he

edges

f he

panels.

y nsertingom-

mercia l ly

vai lablehelf

upportsn

theholes,he

height f he

shelf an

be

adjustedo

suit

our art icu lar

needs. ith heexception

f he

shelf,

screw

he

parts

ogether,

hen ut he

hardboard

o size nd

nai l t to he

cabinet .

it heunit

gainsthe

rame

anduse

crewso attach

hecabinet

to he

rame.

Saw he

parts

f heworkbench

o

size,hen crewhe

hinge race

ails

and tiles

nd hebenchtop

ailand

stiles

o heunderside

f hebench-

top

(above,

ight). Altach he

bench-

too o hebottomf hecabinetection

with

piano

inge, akingure

he

twoedges

re

perfectly

ligned.

With heworkbench

olded own

and

held

aral le l

o he

loor,mea-

sure hed is tance

rom he

h inge

bracea i l o

he loor nd u t

he

legs o f i t .

At tachhe egs o the

rai lwithhinges,hen

crewevelers

to hebottom

f he egs nd

adjust

them snecessary

o evelhe

bench-

top.Add olding

etal raceo each

leg

oradded upport,

crewinghe

f lat

end

of hebrace

o thehinge

brace t i le

nd heother

nd o he

outsidedge

f he eg.

Also

ut

a

leg ail o t between

he egs nd

screw

t in

p lace .

ina l l y ,ns ta l l

haspock, crewing

ne

part

o he

topof he

cabinet nd he

other

art

to he benchtop

ai l .

99



STORAGE

STORINGAWS

NDBLADES

Buildinghandsaw

torageack

Thehandsaw

torageack hown

t

eft

savespace ystoringaws pright.he

handlesit on

oiecesf

wood

hesame

shape

s he

holen

hehandle.he locks

aremountedo a holder

hatsl idesn

grooves

ut

n

he opandbottom f he

box.Cut he

parts

f hebox o size,hen

equip

our

able awwith

%-inch ado

blade. o

accommodateheoutsideaw

holders,

ut %-inch-deep

rooves

%

inches

rom ach ndof he op

andbot-

tom.Saw nother

roove

n

each

iece

centeredetween

he

irst

wo

or

he hird

saw older. crewhe opandbottomo

the ides,

hen ack hebackn

place.

Trace

heout l inef heholen

each aw

handle

na block fwood nd

utout he

piece.

lue nd crewt

o hesaw old-

er, hen crew

pivotingiece

f woodo

the ooof

heblockoservesa urnbuck-

le

hat

willkeep

hesaw n

place

hent

is being tored. se

saber aw ra band

saw o cuthandlesn

he

holders

o make

it easiero

slidehesawsn andoutof he

box. lacehem t staggeredeightso

they onot nterfereith

ach ther. he

dimensionshown illmake box

hat

canhold aw hree aws.f

you

want

o

storemore

aws,implymakehe opand

bottom ider

nd pace dditional

grooves

%

nches part.

Baak

1/+"

x 9" x 29

3/+u

5aw

holder

1/+"x10"x291/2"

3 /+ "x8 "x29 "

Turnbuakle

/

.J- /

re

I00



STORAGE

A HANDSAW

OTDER

Build

wall-mounted

ackor

hand-

saws

witha

fewwood

craps,

ow-

eling, nd

ome

ubber

ose. ut

the base

rom

/z-inch

lywood

and he

dividersrom

4-by-4

tock;

the

dividershould

e

10 nches

long.

uta aper

t he

endof each

4-by-4,

sshown

t right.

crew

2-by4alongone

dge f he

base,

thenscrew

hedividers

n

place,

leaving Vz-inch

ap

between

them.

he toppers

re

ut rom

4-

inch

engths f

l/z-inch

dowel

nd

slightly

arger

ubber ose;

se

hose ith

idgesather

hansmooth

garden

ose.

lipa

saw nto he

rack

rombelow,

hen ug

down

n

the

handle.he

topper

ill

pinch

the blade

n

place.

Markhe

dow-

el's

position

nd crew

t to the

base.

fiIlllj

ll ll

ll]lll

lll lll

lll lll lll

lll

lll

)HO?

TI?

Hangingportable

?ower

oole

from the

wall

A eim?le

uV aoily

verlooked

olution

o

t'he

problem

f elorinq

Nools

where

hey can

be

eeen e Nohangbhem rom Nhe hopwall.

Drive

nail,ecrew,

r

lhreadedeye

hook

into he

wall,makinq

ure

N s

anchored

'o

a elud.

Loopa

lenqlhof

nylon

opearound

Nhe ool

handle,lhen

an6

'he ope rom

Ihe

faslener,

Leave'he

ope

hanqinq

rom

Lhe

wallwhen

ou

are uoinq

'he ool

ae a

reminder o

elurn

t to it 'e iqhtful

place

when

ou

are

iniehed.

Illl

ttlllt

ltlt

1 0 1



STORAGE

0rganizing

ircularaw lades

Keepour ircularaw ladesis ible

and

protected

n a custom-made

tor-

age

ox ike heone

bove.ui ldhe

box rom

/z-inch

lywood,

uttingt

a few nchesarger

han

our

argest

blade ndwide

nough

o

hold

ll

your

blades. ake

hedivrders

utof

t/q-

inch

lywood;

rst

ut

ectangles

inch ess

han he

size f hesides,

then awhemn ha l f

iagona l l y .

Screwhe rame

ogether,

hen

lue

and ai l hediv iderso hebottom

andback. eavel/q

nch

betweenhe

dividers.o

keephe

bladesrom olling

outof hebox, ut

a battenrom crap

stock

nd ai l t

o hediv idersear

thebottom

f hebox.

llltllrll ltllltll1llllt lll lllllt llljlt lllllt lllltl

lll

9HO7

Tt?

A

aircular aw

blade

aarrier

To

avoid

damaqin4

our

circular

eawblades,

r

nickin4

our-

eelfwhen he

blades re

beinq tored

or Nranoporl-

ed,use

a commercial

lade

carrier. hemodel

hown

accommodahee

p o 10

bladee,

rotecNinq

he

cuN-

t inq

edqee

wiNh

plaoLic

r im

whi leeavinq

hebladee

vieible.When

Norinq everal

bladesal

once,oeparate

Nhemwilh

cardboard ?acere

lo

prevenl

he

Neeth rom

makinq

onlacN.

r02



STORAGE

OOLSRGANIZED

Adding

ool-trayividers

To

protect

ooledges

n storagerawers,

aw

2-by-4o a

length

qualo hespace

etween

hedrawerides.

hen ut

dadoescross

ne ide f

heboardo

hold he ools-in

his

case,

arrow

adoeso accommodate

ile blades

above).

Storing

andools

The ool

ray hown bove

eeps ifferent

ools part nd

sim-

ilar nesogether,

elping

o

protect

hem

whilemaking

need-

ed

tem asyo

ocate.he ray

as headditional

dvantagef

being

uspended

rom verhead

oists

o hat

t

akes

pno

valu-

able

work pace. tart

yboltingwo

2-by-4so

oists,

pacing

them o accommodate

he

ray.Cutoff he

bottom nds f

he

Z-by-4st a

convenient

eight. ext, uild

he ray, utting

thesides

rom%-inch tock,

nd hebottom nd

hedividers

from +-inchlywood.utdadoesor hedividersccordingo

how

ou

wish o

group

our

ools,hen

crewhesides

ogether

and o he

bottom. lue

hedividers

n hedadoesnd

crew

thesideso

he2-by-4s.

crewheback o

wall tuds, r,

using

ead nchors,

o a concrete

all. f

youplan

o nstall

the

ray tanangle,

sshown,

rivehescrews

hrough ood

wedges

laced

etween

he ray nd

hewall.

103



STORAGE

Using Lazy

usan{ypetorage

upboard

l f

your

workshop

as

n unusedorner

-an

area

nder counter,

orexam-

ple,

nstal l

commercial

azy

usan-

type

upboardo

storeworkshop

ools

andsupplies.he

esignf he

device

makes

ny tem n he

rays asilycces-

sible. he

model hown

boveeatures

a carousel

i th wo

rayshat evolve

around metal haft.

sing%-inch

ly-

wood,

uild

cabinetike heone

hown

above

o house

hecarouselnd

upport

themetal haft

t both he

ooandbot-

tom.Assemble

hecarousel

ollowing

he

man facturer's

nstructions.

flIl ll1

llj lll

u lll lll

lll iIjiIl

illllj lll

ll jll

jll lll llr

1HO?Tt?

Amagnetictool

mck

KeepmelalNoolo

or4anized

nd

accessible

n a

commercial

aqnel-

ic

Nool ack.The

model hown ea-

Eures

a

heavy-duLy

barmaqneNlhaLwi l l

holA

ny ron-based

ool

eecurely-from

screwdrivers,

chieels,

nd

hammero

o Lry equaree

nd ocieeors.

o

mount ,he ack,

crew

NhemaqneN

o a wood

etrip and

anchorLheotrip

Nowall

e|uds

above

our

workbehch,

t04



STORAGE

A MOBITELAMPACK

Clamos

anbea

nuisanceo

store.

The heer

umber

ccumulated

n

most hoos-and

heir

awkward

size

ndshape--can

tretch

ven

he

most

rganizedtorage

ystem

o he

l imit . hemobi lelampack hown

belowtores

wide

arietyfclamps.

With asters

ounted

nderhe

base,

he

ack anbe

ol ledo any

part

f heshop

here

lamps re

needed,

hen tored

gatnst

hewall,

Refero thecuttingist orsuggest-

eddimensions.

Start

ycutting

he ails, t iles,

nd

crosspieces

o size

rom2-by-4 tock.

Then

oin

he

pieces

ogethersing

lap

oints

nd

notches.

o

prepare

he

rails

or he

oinery,

out nd

abbets

that

wi l l t in to he

notchesnd

dadoesut

nto hestiles.

he abbets

shou ld e

1 /znches

ide nd

4

inch eep.

ext, otchhe op

endof

each

t i le n hree

ides sshown,

then outback-to-backadoesea r

thebot tom

ndand

midd le f he

st i les; ake

hedadoes

% inches

wideand

3/q

inchdeep. lso

ut a

nolch t/z nches

ide nd7q

nch

deeo

rom hebottom

feach tile.

When

ou

ssemble

he ai ls nd

stiles, lignhe

wohalvesf each

ai l

face-to-facendassemble

ith he

stile.Screw

he

pieces

ogether,ri-

ving he

astenershrough

he

oints,

To

oin

hecrosspieces

o he

ack,

cut3%-inch-wide

adoes

n

he

mid-

dleof each nd

crewhem

n

place.

Themiddlerosspieces

i l l

est n

the

medianai l .

he

op

pieces

i l l

rest n he

outsidehoulders

f he

notchedopof

each tile.

F in ishhe

ack ycut t inghe

four

pieces

or he

skir t rom

2-by-

4 stock

nd he base

rom

/rinch

plywood.

aw

wonotches

n he

base

nd kir t

o accommodate

he

str les,

abbet

heends f he

skir i

p ieces,

nd crewhem

ogethero

form

a

box.Use

crewso attach

theskir t o

hebase.

inal ly,t tach

casterso he

undersidef he

skir t

at

each orner f he

ack nd

asien

thebase

o hestiles

ndbottom

rai l , r iv ing

hescrews

romunder-

neathhe

base.

CUTTINO

LIST

-Raile

(top,

bottom, and

median)

(6): t

3/+"

x 31/'2"

231/2"

-gtilee

(2):

1

/

"

x

3

/

"

x

44

/

"

-Croaspiecea

(3):11,/2" 3t/2"

x 23t/z

-Eaeai/+"

x 23

1/2"

x 23'/2"

-1kirt

piecea

(4):1/2" x

3t/2"

x 23

i/2"

105



STORAGE

A

SHETFOR TAMPS

Built

rom

/z-inch

lywood,

he

shelf

hown t right eatures

series f notches

orsupporting

barand

pipe

lamps long shop

wal l .

Cut heshelf

bout 0

inches

ide nd

as ong s

you

needor henumber

f clamps

you

wish

o store. ut henotch-

es

at 3- inchntervalsi th

a

saber

aw ndmake

hemwide

enoughor heclamp ars r

pipes;

7+nches

sabout ight

for most

lamos, hen

crew

shelf

bracketso the

underside

of

heshelf , enter ing

hem

betweenhe notches. asten

he

shelf o a backing

oard f Vz-

inch

plywood,

henanchor

he

board

o hewall tuds.

llll Il lt'filt

Il ll'ffi

Il ll

lll llt it'IllilIt

ilt

lll ltt

lll

)HO? TI?

?toring

alampe n

a oan

Atraeh

canfilhedwith

a ehoo-

made

id

eeryelas a

conveniertl

way o sLore

small

bar or pipe

clampe.Cul a oiece f 1/z-inchlv-

wooA nto

a ciicle oliqhtly

emaiti,

lhan the

diameLer

f he can'o im.

Then

cribe

a series

of concenlric

circles

on rhe

plywoodo

help

you

locale he holes

or

the clamp

bare,

1Vacetrhe

ircles

boutb inchee

apart

and markpoinLe

very inch-

ee alonq

hem,Bore

a f-inch-

iame-

ter hole

hrouqheach

p

oint, it,

he

piece f

plywood

n he

can and

drop

the clamos

hrouah he holes.

106



STORAGE

WALI

RACKSOR LAMPS

Makingndnstallinghe acks

Shopwalls

makedeal torage

reasor

bar

and

pipe

lamps.

orbar lamps

(above,

eft),nail wo

cleats crosshe

wall tuds.

ositionhe

upper leat-

made f

plywood-high

nough

o keep

theclamps ff

he loor;make

he ower

one rom wo

2-by-4s ailedogether

o

that he lamps

ill i lt towardhe

wall.

For

pipe

clamps

above,

ight),nail

cleats f

3/q-inch

lywood

o the studs

andscrew

room

rippers

o hecleats.

Positionhecleab n hewall o heclamps

will est bout

inchoff he loor.

Then

cut

hebaserom

1-by-4 tock,

and

bore

a rowof holes

nto t at hesame

interval s

he

grippers.

astenhe

base longhe

loor o he

holesine

upwith heclamps.

t07



STORAGE

STORING

MALL

TEMS

Mountinglassarsunder shelf

Screws,

ails, ndbolts

anbestored

in

a

varietyf containers,

ncluding

tennis

all anisters,

ason

ars,

r

pill

bottles.

ountinghecontainers

under shelf

above)

ill keep he

items ut

n

he

ooenwithout lutter-

inga work urface.

astenhe con-

tainer

id o heshelf.hen

crewhe

container

o he id.

108



STORAGE

A SCRAPBOX

Use scrapbox

o keep

rom

lut-

teringheshop

loorwithcut-offs,

shavings,nd

other efuse.

he

design hown t

eftcanbe built

quickly

rom%-inch

lywood;

ast-

ers llowheunit

o be

olled here

it is needed nd

moved utof he

waywhen t is

not.

Saw

hesides

andbottom

o a size ppropriate

o

your

eeds,hencut

ourcorner

blocks

rom2-by-2 tock.Screw

the oursidesogether,rivinghe

screwsnto hecorner

locks.

urn

thebox ver

ndnail hebottom

o

thecorner locks

ndsides.

dd

a

liparound

he op o hidehe

ply-

wood dges.

inally,

crew

asters

to

each ottom orner

nd

a

pull

handle

t

oneend.

f'{'

Some

torage evices,

articularly

those

esigned

or

small

tems, re

lessrouble

o buy han o build.

Thesystem hown

at left

eatures

open

lastic

bins

hat canbe ined

up or

stacked. hebins

aresus-

pended

from

plastic

trips hat

are

screwedo the

wall.

109



::}tu

-itffi

f"

n{;i4

w

.:.|::

' 1

l

a

r

<at

.

.

lre

s

+.""{hi*.

v'

H

b+

' - -*}*

q

3

.f,

,

_'

ffiSdg**ffft



WORKSreS

t

is

a ruism

hatno worlshop

s

arge

nough;

t is equally

verhas

ables, enches,

awhorses,

props

o support

work

progress.he raditionalwork-

owever seful r

necessary

supage

6),is nlythe

eginning.

uses,

t is

too

high, oo

too mmobileo be

helpfuL

When t is ime o markthe

le-

a

oint

or assemblehe

pieces

f a chair,

solidwork

ike the ibrary-style

able

page

13, an erve

s he

enter f

your

shop,

he

ocus f many per-

hisdesigneatures spa-

work surface

and sturdy

heonlvdrawback

size: ne

wouldneed

fairly arge hop o accommodate

Fora smaller hopwith cramped

uarters,

onsid-

olding able eatured n

page

15.

Offering

lmost s

surface rea s

he ibrary-style ersion,

t canbe old-

out of thewayagainst

hewallwhen

t is not needed. he

able llustrated n

page

l7 offers

et

another

onflict etween

pace ndconve-

oth

heneed or a substantial

orking ur-

andease f storage.

esting n sawhorses,his

plywood

abletop anbesetupwhenever lat surfaces equired,

bedismantled

nd

put

awaywhen

ourprojectmoves

n

hase.

Better

control

produca

better esults,

Securedo aband

smr's riginal able,

shop-made xtensionable ceeps large

hardboard heetleveluringa

curved ut.

With its myriaduses,he saw-

horses also heworkhorse f the

shop.

A

sawhorse

an serve sa set

of

legs or

a

fold-downwork able

(page

16) r a simple

rop

or

saw-

ing stock.With a fewnotchesut

into

their

crosspieces,orses an

form

part

of the

rame or a

shop-

made

lue ack

page

a).Clamped

to a2-bv-4 ttachedo a

commer-

cialroller,a sawhorseecomes

custom-built

ollerstand.

Outfeedables

nd ollerstands

that hold unwieldy

anels

r long

planks

ignificantlyxpandhe

ver-

satility f tools ike able aws, and

saws, nd

drill

presses.

etup at

thesameevelasa machine'sable,

or

fractionallybelowt, these

rops

canbeaswelcome sa secondet

of hands, nhancing

tool'scapacityo handle

argework-

pieces

fficiently ndsafely.

Worksurfacesaneven e

iggedo compensateor a ack

of firll-size

tationary achines.

he

stand hown

n

page

34

is

designed

o et youmounta benchtopool at a comfortable

workingheight.

The

hree-in-one

ool able eatured n

page

136

can

ransform

router,

aber aw

andelectric rill into

mini-stationaryools.

Given

need nda ew

pieces

fwood,werywoodworker

ill

deviseomewaytomprove isor her ools. heexampleshat

followaremere uggestions,

or t is mposibleto

imitthe mag-

inationwhen he

need

rises

or mprovingheworlshop.

The door of this storage abinet

olds

down

rom

a shop

wall

to become sturdywork surface.

Supported y solid

lumber egs,t

is an ideal work table

or

light-duty opera-

tionssuchas

gluingup and assemblingmall

carcases.

For detailson how to built

this unit, see

age

98.

l 1 l



WORKTABLES

{", '

or manyightwoodworking

hores,

l"

frour narkins

ut

oints

o asseln-

blingpieces

f

furniture,

simplework

table its

hebill aswellasa traditional

woodworker'sench. hissectionea-

tures everalable

esigns.ll arequick,

easy,nd nexpensive

o build.The able

shown pposites

sufficientlyarge nd

sturdyornlost

obsi

fspacesat

a

pre-

mium,

a

good

compromise ould

be

oneof the old-up ersions

hown n

pages

15and 16.You

canalso onserve

space

y

ncorporating

torage

helves,

drawers,r cabinetsn your

design. or

assemblingarcasesnd

other

pieces

f

furniture.

ou

mav ind

he ow-to-the-

ground

able

n

page

4 handier han

a standard-heightork

surface.

Whichever

esign ou

choose, e

careful f thenailsor

screwsouuse o

construct able-particularly

when as-

tening he abletop

o the frame.Thke

the ime o countersink

r counterbore

screw

eads

ndsetnail heads

elow

thesurfaceo

prevent

he

asteners

rom

marring ourwork.

Alnrostas strongasa traditional

workbench,his commercial

work table s

a

versatile

workhorse, specially hen

paired

with a woodworker's ise.The cabinetand

drawers

rovide

storage pace, nd can

be

ocked

o secLtrealuoble ools.

Despite ts ightweight,

onlpoct esign, heBlack

d*

Decker Workntate'-

can support oads up to

550

pounds.

It oko

folds

virtually

Jlat or

easy torage.

A special

pivot

designallows the vise

aws

to be

tmgled,

for

sectn"ing orkpieces

ike the tapered

Iegshown n the

photo.

Thisparticular

Workmate'''

features

a storage ray and a top that

Jlips

up

for

vertical

clamping.The

WorkntatetM

asa long,

colorfulhistory. y 1968, he

prototype,

featuring

a

patented

folding

H-frante,

had been ejectedby

everymajor tool

manufacturer n Britain. Four

years ater,

he nventorof the Workmate'*,

Ron

Hickmon, persuaded

Black 6 Decker n

England

o mass

roduce

his nvention.

nter-

national distribution rightswere

negotiated

the

following

year.Popular

success

for

the

Worknnte'n' was

olntost nmrcdiate:World-

wide

sales f the tableare close o 20

milli on un ts-an d

coun in

g.

rt2



WORK

SURFACES

A LIBRARY-TYPEORKABLE

The ll-purposeable

hown elows

bui l twitha combination

f umber

and

plywood.

efero hedimen-

sions

n he l lusirat ion

ora work

surfacehat

s 5 feet ong, feet

wide, nd feet igh.

Saw

he egs o length

rom4-by-

4

stock,hen

prepare

hem

or

he

rails:

ut

a two-shoulderedenon

t

the opend

of eachegwithshoul-

ders

/a

inchwide

inset).

ext, ut

the ails, tretchers,ndbraceso

lengthrom2-by-4s. aw

miters

t

both nds f hebraceso hat

on e

end i ts

ush gainsthe nside

edge f he

egs nd heother nd

butts gainsthebottom f

he ails.

Preparehe

ront, ack, nd ide

rails

or

assembly

ybevelingheir

ends nd utting

abbetso accom-

modatehe

eg

enons

insef).

crew

the

stretcherso the

ails, pread

glue

n hecontact ingurfaces

f

the egs nd ai ls,i t thepieces

together,nd crewhe

ailso he

legs. ext, ttachhe

braceso he

legs nd ailswithscrews.

Cut he abletoorom

Z-inch

plywood

nd

crewt to he ai ls.

Finally,uta

piece

f %-inch

ard-

board

o hesame imensionss

the opand

nail t to he

plywood

asa

replaceable

rotective

over.

Besureo set he

nailheads elow

thesurface.

Tabletop

% " x 3 6 " x 6 0 "

Brace

'l

%" 5%" 12"

Front rail

'l

%" 3%"x 60"

9ide

rail

11 /2 "x3%"x36"

Leo

3 %" x5 %" x3 6 "

1 1 3



WORKSURFACES

Front and back

aila

11 /2 "x51 /2 "x29 "

. , /

% \

Erales

%

-

-

1

1/2"

x

31/2"

x

'16"

Side

rails

11/2"31/2" '19"

3 1 / 2 " x 3 1 / 2 " x 2 5 "

Building ow ssemblyable

For

perations

hatareawkwardo

perform

na standard-height

able,

use nassemblyable

ike

heone

shownt ef t . dealor

obs

ike

lu-

ingupcarcases,he able anbe

bui l t asi ly

n heshop i th smal l

amountfwood. efero hedimen-

sionsn he l lustrat ion

or

a

work

sur facehat sabout 2 nches

lowerhan s tandardab le . aw

the egs rom4-by-4 tock nd he

rai ls

ndbraces

rom -by-4s;ut

miters t heends f hebraceso

they ut tagainsthe egs nd i t

f lush ith he ooof he ails. crew

the

ai ls

o he

egs,hen astenhe

braceso the

egs nd ails

inset).

Next , aw he abletop

rom

%-inch

plywood;

t wi l loverhanghe ai ls y

about inches nal ls ides. crew

the op

o he ai ls, ountersinking

the

asteners.

uta

replaceableov-

er rom

/q-inch

hardboardnd

nail

i t o he abletop;et he

nai l eads

belowhesurfacef hecover.

I I4



WORKSURFACES

ORKABLES

Making nd nstallingfold-downorkable

The able hown

bovencorporateslarge ndsturdy

ork ur-

face, utstillconserves

pace y olding p against

wallwhen

it is not n use. hedimensions

n he llustration

ield

work

surface

easuring0 by48

inches.

ut

hebracing,egs,ails,

and

stretchersrom2-by-4 tock ndscrewhe

bracing etween

thewallstuds

insef);

here hould eonebrace

or

every

air

of

studs longhe able's

ength. astenhe

ront egso theside

railsusing arriageolts

nd ocknuts;

lace

washersn both

sides f he egs. eavehebolts

ust

oose nougho allowhe

legso

pivot

whenhe able

s olded p.Tocompletehe rame,

attachhe ront

ails

o he

side ails. dda 45-inch-longop

rear ailand

asten

wo

7-inch-long tretchersetweenhe rear

railand he op ront ail o

provide

dded upport

or

he

op.

Next, crewhe op

o the ails, ountersinkinghe asteners.

Toallowhe able

o olddownwithout inding,crew himso

theends f he bottom ide

ails,henattachhe able o he

bracing ithbutt

hinges;

se

wohingesoreach utside race,

Finally,rive neye olt

nto

hebottom

ront ailanda catch

into hewall o securehe ablewhen

t is olded

p.

1 1 5



WORKSURFACES

Suppoilingfold-down ork

urface nsawhorses

Rather

hanbuilding frameworkora fold-down ork ur-

face,

ou

canusea

panel

f %-inch

plywood

inged

o the

wall

andsupportedysawhorses.he urface

anbeof any

size.Begin ysettinghe

panel

n wo

sawhorses;needge

of he

panel

hould e

lush

gainsthewall.Mark

point

on he

panel

t

every

all

tud, hen nstall utthinges,

screwing

ne

eaf

of each ingeo a studand he

other

eaf

to

he

panel

t a

pencil

mark. osecurehe

panel

hent is

folded

p,screw notched

iece

f 2-by-4to

hestudclos-

est o hemiddle f he

panel

t a

height

hatwillallowhe

notched nd o slipover heedge f hepanel inset).

1 1 6



WORK

SURFACES

Setting p

a temporary

olksurface

Consisting

f

wosawhorses,

ix

2-by-4s

anda plywoodanel,he unitshown

above

s nexpensive

nd

easyo

pu t

together,

et

t

provtdes

large ndsta-

ble

work

urfacehat

canbeset

upand

disassembled

uickly.

tart y

itt ing

the

sawhorses

ithcrosspieces

ut

rom

2-by-6

tock,hen

cut he

2-by-4so

thesame

ength

s he

panel.

n hree

of heboards,

uta

notch bout

inch-

es

rom ach

nd; he

notches

hould

beabout

inches eep

ndas

wideas

the hickness

f

hecrosspieces.

ut

matchingotchesn he opedges f

thecrosspieces.

enter

he unnotched

edge f the

notched

oards long

he

faceof the

other2-by-4s

ndscrew

them

ogether

o form hree

T-shaped

tabletop

upports.

he

awhorseup-

ports

an

beused

o holda

large heet

of

plywood

or

ripping, r

a

permanent

topcanbe

screwed

o the

2-by-4s.

rt7



SAWHORSES

Q

awhorses

ave

ountlesssesn the

rJ woodworking

hop, rom table egs

to tool stands.Occasionallyt

seems

that heiroriginal

urpose-to

support

boards or sawing-is only an after-

thought. t is

easyo see

why

sawhorses

are

consideredo

versatile,or

heircom-

pact

design

makes

hemespeciallyse-

ful in

shops

with limited

floor space.

Some ommercial

models,

ike heonesn

the

photo

at right,canbeadjustedo dif-

ferent eights nd olded

p

or

easy tor-

age.Wth commercial

rackets

.below),

you

can slzesawnorseso sult

your

needs. he

shon-made

orses

eatured

on

page119

anbe disassemblednd

put

awayafteruse.

Differentoperationsequirediffer-

ent-sized awhorses.or

supporting

stock or handsawing

r

holding arge

workpieces

t a comfortable

eight,

smallhorsesbout

18 nches

iehare

ideal.Taller

awhorsesreneededif hey

are o beused o holdup a work

surface

MAKING

AWHORSES

Usingommercial

awhorserackets

A

pair

f metal

awhorserackets

an

help

ou

ransformcouple f 2-by-4s

and

1-by-3s

nto sturdy

awhorse,ike

theone hown t right.

awhe egs nd

crosspiecerom -by-4s,

hen uta bevel

at hebottom

f he

egs

o heywill

si t

f lat

on he loor. it

he

egs

nto hebot-

tomof he

brackets,nserthecrosspiece

and pread

he egs;hebracketsill

grip

the rossp iece

nd tab i l i ze

hehorse.

Screwhebracketso he egs nd ross-

piece.

or dded tabi l i ty,

ddbraces

anda stretcher.he

bracesre ut rom

1-by-3s

nd crewedo

he

egs,

making

surehat heends re lush

ith heout-

side aces f

he

egs.

or hestretcher,

cuta 1-by-3

o size nd crewt

between

thebraces.

or as

outfeed upportsor a table

saw

Theyshould

eabout% nch ower

han

the

saw able.

Whatever

he

dimensions

of

your

sawhorses,evermake

hem

taller

han heir ength, s heywill

tend

to beunstable.

This sawhorse

features

eg extensions

that can

be adjusted o

a variety

of

heights.

The egs etract

nto the

cross-

piece,

making he

unit compact

and

portable.

A

pair

of these lender

metal

horses an

supportone on

of material.

1 1 8



WORKSURFACES

Buildingknock-downawhorse

With nly small

mount

f umber nd

plywood

nda

fewminutes'ime,

ou

can

make sturdy,

nock-downawhorse

like heone

hown bove.

ut he

egs

from +inch

lywood,

hen

aw 3-inch-

deep

otch

n hemiddle

f he opof

both

ieces.

ext, ut he

crosspiece

from

1-by-6 tock nd

saw

1%-inch-

deep lot8

inches

n romeither nd

o

fit into he

egs. nglehe

slots oughly

5o

rom he

vertical o he

egs pread

slightly utward.oradded tability,

screw

-inch-long

-by-2 leats

o the

crossoiece

n each

ideof heslots.

1 1 9



WORK

SURFACES

Assembling

rame-and-foot

awhorse

Lightweight ,

om

act

ame-and-foot

sawhorsesike

heone hown

t eftcan

bebuilt rom -by-4

tock.

tart ycut-

t ing he egsoa sui tableeight ,hen

prepare

hem o

oin

o heother

arts

f

theunit:Cut

enons t hebottom

nds,

rout

hrough ort ises

alfway

p he

faces,nd

aw - inch-deep

otchesn

themiddle

f he opends.

ut he eet

to ength

nd, or

added tabi l i ty,

ut

recesses

long

heirbottom

dges,eav-

ing

2-inch

ad

teach nd.

Routmor-

tises

hroughhemiddle

f he eet or

the eg

enons. ext,

aw hestretcher

o

f i t between

he egs

nd ut enons

t

both nds. ut

hecrosspiece

nd aw

notch inchesrom

ither

nd hatwi l l

f it into

henotch t he

opof he egs.

To einforce

hemortise-and-tenon

oints,

saw

pair

f kerfsn

heendof

each

tenon ndmake edges

o t into

he

kerts

inset).

ap

hewedgesn

o expand

the enon hen

he

oint

sassembled.

I]lllI]llr

itllltllt

lll llt itl

?adding

awhorses

Toprevenla sawhorserom

marrinq

our

work,

over ls

croeeViece ilh

a ebrip

of old

carpeN.

old

he

caroet

over

theNopedqe

f lhe cross-

piece

nd ocrew t,to

th e

eidee. or

a smoolherour-

face,

usean

oldNowelr

blanket, ralherthan

i

. ^ r ^ ^ ^ - c

i

piece

f car?et.

WEDGED

MORTISE-

A1{D-TENON

JOINT

u

u

llillll

9HO?

illllllt

TI?

llll

l t l

ilt

llt

llil

ui

lll

r20



WORK

SURFACES

Making

heavy-duty

awhorse

Reinforced

ya

stretcher,

races,

ndsimple

oinery,

he

sawhorse

hown

bove

ill

endure

or

years

s

a sturdy

ork

surface.

aw

he crosspiece

o

length

roma2-by-6

nd

cut

dadoes

n he

edges bout

inchesrom

either

nd o accom-

modate

he

egs. ngle

hedadoes

oughly

Oo

rom he

verti-

cal.

Next, aw

he2-by-4

egso

length

ndcut

1%-inch-deep

angled

otches

nto heir

outside

dgeso

househe

braces.

The op

of each race

hould

est bout

%

nches elowthe

tops

of the

egs.

Also ut bevels

t both

ends

f the

egs o

they

willsit

laton he

loor nd

ie lush

with hecrosspiece.

The tretcher

s a

2-by-4 ut

o the

sameength

s he cross-

piece;

ut

a notch

n each nd

o ineup

with he

brace,

eav-

inga lL/z-inch

houlder.

aw

he braces

rom

2-by-6 tock,

mrteringhe

ends o

be lush

with heoutside

aces

f he

legs nd awing

2-inch eep

otchn he

middle

f he op

edge

or hestretcher.

inally,

lue

up hesawhorse,

trength-

ening

he

oints

between

he egs,

rosspieces,

ndbraces

withscrews.

r2r



WORK

SURFACES

Top

ailo

3 /o "x5% "x36 "

Corner half-lap

joint

(fl

W

half-lap

oint.

a

IW

a\)

3A"x5%"x54"

Hinged

cro66brace

3 /^ "x5% "x16 "

Building olding

awhorse

Made ntirelyrom1-by-6tock, ith

a hinged

rossbrace

nd op, his ight-

weight

awhorseolds

lat o

store asily

in

evenhemost

rampedorkshop.

ut

the egs nd ai ls

o ength.

hen, ut

notchesn

he

pieces

or

half-lap

oints.

Use type

half-laps

inset,

ottom)to

join

he egso he

bottomails,

nd or-

nerhalf-laps

inset,

op) o

oin

he op

rai ls

o he egs.

ssemble

nd

lue

he

two ections

f hehorse,

nd einforce

the

oints

i th crews.

henhe

glue

has

ured,

oin

he wo ect ions

t he

top ai ls

i th cont inuous

iano

inge.

Final ly,

ut he

crossbrace;

esuret

is ong

nough

owhenhehorseegs

spread,he

piano

inges

ecessed

between

he op ails.

aw hecross-

bracen half

nd onnect

he

pieces

with

piano

inge,

akingure

hat he

hinges nstalled

o hebrace ill

pivot

upwards.

hen,asten

he

crossbrace

o

both ide ai ls,

gain s ing

iano

inges.

1HO?TI?

Seouringworkpieaeo

edge-up

n sawhorses

Clamp

andscrewe

n lhe

croee-

piecee

f Iwo sawhoreee

o eup-

port

work

edqe-up

hen

bench

vise e

not,

vailable.

l]llll1ll]llllll llllltriull1iltit]lll ll1lll l11ltl ilJill

To

prevenl lhehand-

screwl rom pivoNinq,

aecure

achwithlwo

C clampe s shown.

Uoe

o

many

sawhorses

nd

handscrews

s

neededNo

de-

quabe,ly

u??ort

I

Tne

?ECe,

I

r22



WORK SURFACES

Notched

wood block

1 % " x 3 % " x 4 "

anel

upport

rame

arge

anels,

roper

upport

sneededo

keep

work

rom uckl ingnd

binding

n heblade

s he ut

s

stop hecutoff

rom

alling way s he

cut

s in-

oaccommodate

hese

umbersome

obs,

onstruct

hi s

upport

rame,

hich

s

easi ly

eld

n

place

ith

ood locks.

ut wo

4-foot nd

wo8-foot

engths

or heends

nd ides

f he rame.

utdadoes

ix

rom heends

f he4joot

ensthsnd

18 nches

rom

the

ends f he

S{oot engths

or hecross

alf-lap

oints

hat

hold he rameogether

sshown.

hen ut

wo4-inch-long

blocks

rom2-by-4

ndsaw

two-inch-deep

otch,

ide

enougho

it over

%-by-I%-incheep

otches

n hemiddle

of hecrosspieces

f

hesawhorses

ou

plan

o

use. crew

theblockso

hebottom f

heend

pieces

ndassemble

nd

glue

p he

rame. ecure

he rameo he

sawhorses

ymat-

ing henotches

n heblocks

i th hose

n hecrosspieces.

r23



WORKSURFACES

A VARIABLE.HEIGHT

ORKURFACE

Building

hebox

Constructingboxwith

different

idth,

lengh, nd eightimensionsill

pro-

vide

ou

with

a work urfacehatcanbe

used t

hree

evels.

he oosurfacef

thebox hown t right,orexample,

an

beeither 4,30,or36 nchesigh.

aw

all he

pieces

rom1-by-4 tock,making

eight oards

6

inches

ong, ight oards

23tla nchesong,

our hatare 0 inches

long,

nd

our

more 9tl+nchesong.

Using alf-lap

oints lnset)

ssemble

theboardsnto ix rames:womeasuring

30 by36 inches,womeasuring3Ll+

y

29tlqnches,nd

wo

more 3%

by36

inches.

ncehe ramesre ssembled,

cut

a

s/e-by-3/e-inch

abbet long ll our

edges feach f hesix rames.

se

lightweight

oodike

pine

o

make

he

box asily

ortable.

f

you

hooseo

reinforcehe

oinery

t hecornersith

screws,

esureo countersinkhe

screw

eads.

24"

I

I

t

?HO?

TI?

A ehop-made

glue

raak

A rack made rom two mef,-

al-bracket yp e

eawhoreee

Vrovideo

coinvenienN

ay

to

hold

barclampo or

qlu-

inq

up

panele.To

ui ldlhe

ji6,

replace

he crooepiece

of

your

sawhorseswilh

oubstitutea thal are at

leaetao lonqao he boards

t'o be

6lued

o6ether.

Notch

oneed6eof each

crooopiece

at,6-inch nlerv

lo,

m

Akinq

bhecuts wide

nouqhto

hold

a

bar

clampenu6ly

and deep nou7hlohold

the

barlevelwith

he top

of t'he croeepiece.

r24



WORK

SUPPORTS

upporling

ong

plank and

arge

an-

as hev

are

edacross saw

able

asoneof

the

mostcumbersome

n the

woodworking

hop,Outfeed

beattachedo mostsaws,ut

o takeup

a ot offloor

space.

side

supports

readded

o your

our shop

maybecome

n

ourse.

Commercial

ollerstands,

ike heone

n the

photoat right,

make et-

of shop

space;

heycan

alsobe

o

where heyare

needed

adjustedo

whatever

eight

s

suit-

The shop-made

tands

escribed

andorthe

following

age

hare

advantagesfthestore-boughtari-

with theadditional

enefit

f being

nd

nexpensive

o build.

They

also e dismantled

nd

stored

when

There re therwork-supportigs

thatmake

ifeeasier

n

he

shop.

he ise

extension

tand

hown n

page

27,

or

example,

olveshe

problem

f

keeping

long oards

dge-up

n abench

ise.

A commercialoller tand upports

board

eing ipped n

a radialarm

saw.Thestand

hould

ypically eset

l,/t-inch

below

he evelof

thesaw able

and

positionedwo

eet rom

itsedge.

SHOP.MADE

OLLERTANDS

Setting

pa temporarytand

With nly sawhorse,

woC

clamps,nd

a

commercia l

o l ler ,

ou

an

make sim-

ple

oller tand

ike heone hown

t eft.

Make T-shaped

astor he

ollerha t

is ong nougho

ho ldt a ta su i tab le

height. crew

he ollero

hehorizontal

part

f he

mast. dd braceo

heside

of hehorse

orclampinghe

mast

n

place:

uta I -by-4

o spanhe

egs

between

hesawhorse

racketnd he

original

race nd crew

t to he egs.

Cut 1-by-2

o spanhe wo

bracesnd

screw

t in

place

sa vert ical

u ide

or

the

mast. osecure

he oller tand

o

the

sawhorse,lamp

hemasto he

braces,

akinguret

s ush gainst

the

guide.

r25



WORK

SURFACES

Buildingn

adjustableoller tand

To

build he oller tand hown

t

right,

start yconstructinghe rame

or he

roller,

uttinghe our

pieces

rom

-by-4

stock. luehe rameogetherithbutt

joints,

ddingcrewso reinforce

hecon-

nect ions.

hen ore holen

he

middle

of

each ide f he rameor

a

t/t-inch-

diameterarriageolt.Locate

hehole

3 inchesrom hebottom

f h e rame.

Insertheboltsrom

he nside f he

frame

nd crewhe oller

o he oo.As

well

s hecommercialoller

hown,wo

variat ionshat

permit ou

o eed he

workpiecerom

ny irectionre hown

below. ut

he

emaining

ieces

f he

standrom1-by-6

tock,eferring

o he

dimensions

rovided,

hen out

r/q-inch-

wide lotdown

he

middle

f he wo

uprights;heslot

hould eabout 4

inchesong.

crewhecrosspiece

o he

uprights,l igning

he opof he

piece

with he

bottom f heslot.Fasten

he

uprights

nd ai ls

o he

eet.

o

guide

the

ol ler

rame, ai l1-by-1

leatso

he

uprightsboull/qnch

n rom

heedges.

Tosetup

hestand,

osi t ion

he

ol ler

f rame etweenheuprights,i t t inghe

carriage

oltsnto heslots.

lipwashers

on hebolts nd ighten

he

wing

uts o

set heheisht f

he

oller.

Plate-mounted

aaatere

/ ^ rnaan ie ra

3 / + " x 5 1 / z " x 1 9 "

t26



WORKSURFACES

XTENSIOI{

TAND

usinghestand

nown s

a bench lave,

viseextension

tand s used

o

he

ree ndof

a long oard lamped

n heshoulder

f a workbench,

efero

hedimensions

n he

llustration

a stand

hatworks

ellwith

mostworkbenches.

Tobuild

hestand,

ut he

uprighto ength

nd, tarting

nches

rom he bottom,

aw ngled

otchest2L/z-inch

nler-

along

ts ength.

ut he notches

bout

inch ongand

/z

inchwide.

Then aw he

eet o

length ndcut recesses

long

bottom

dges.oin

he eetwith

a crossap

oint:

Cuta

lap n he op

edge f one

ootand n he bottom

dge f he

other

oot.

Glue

he wo eet ogether. nceheadhesive

s dry,

screw

he uprighto the eet.Cut hesupport

iece

ndswivel

bars, nglinghe

opof hesupport

iece

bout

10"

(inset).

o

join

hesupport

iece

o he

swivel ars, ore olesor%-inch-

diameterowelshrough

he

piece

ndnearheends f he

bars, nd lip hedowels

nto heholes;

lue

hem n

place.

o

use

hestand,nserthedowel

t he opendof heswivel ars

in heappropriate

lot n heupright

or heheight

ou

need

and

prop our

workpiecen hesupport

iece.

t27



WORKSURFACES

CUTTING

ARGEANELS

lN

THEBAND

AW

Makingnd singhe

ig

Formakingircularutsoutof arge

anels

n heband aw, se

a

ig

ike heone hown bove. uildhe

ig

rom

/q-inch

lywood,

cuttinghe

pieces

o he opof he

ig

s evel ith hesaw able

when

he eetare crewedrclampedo a work able.Before

assemblinghe

ig,

drive IV+-inch-longcrew sa

pivot oint

throughhecenter f he op

piece

o he ip of hescrew

ro-

jects

rom hesurface yaboutVz nch

inset).

hen crewhe

topand eet o hesides f

he

ig,

andattachhe riangular-

shapedupport racketso he opandsides; esure o counter-

sink

he

asteners.efore

etting p he

ig,

markhecenter

nd

circumferencef hecircle n heworkpiece.hen

ut

rom

he

edge f he

piece

o hemarkedircumference

ndback o he

edge, reatingstarting

oint

or

hecircularut,Now etup he

jig:

Attacht

oa able nd

place

heworkpiecen he

ig

so

he

markedenter f

hecircle ontactshe

pivot oint.

Positionhe

table o heblade utts gainsthemarkedircle nd he

pivot

point

saligned ith hecenter f heblade

nd he

machine's

centerine.Cut hecircle y otatingheworkpiecento heblade.

t28



EXTENSION

ABLES

tationary

achines

ike

able

aws,

band

aws, nddrill

presses

ome

manufacturerquipped

ith

hatare

adequateor

most ou-

ut therearesome

ong

planls

or

pan-

on

the able aw,

erforming

ong

on

thebandsaw, ndsmoothing

ieces

itha sandingrum

on he

press-that

can

be awkward r

dangerouso

attemptwithout

hesize f the

machine'sable.

hesolution

reates

new

prob-

however,

ecausencreasing

he

f a stationary

achine i th a

per-

ancrowd venhe

The ollowing

agesllustrate vari-

or extendinghe

work

of woodworking

achines.

l-

easyo build

anduse, ach

ig

designed

o be emovedr

olded ut

way.

An extensionable

reatly impli-

fies

he

askof crosscuttingwide

panels

n

the able aw.Thiscom-

mercialmodel

more han doubles

thesaw able's urface rea. t also

features

a specially esigned

ip

fence

hat canbemoved o any

position

across

he able.

1HO?TI?

Double-duty

workNable

To

qet

maximum ee

rom

lhe

worktable

n

your

ohop,

bui ld

t oo he too

ie

althe

oameheiqht, r eli7hr,ly

ower

than lhe level f

your

able

oaw. lnaddit r ion o beinq

a

handyworkeufiace

tor light

obo,

he

lable can butt

againot

he

saw able to

eerve 5

an

outfeed

up'

port. l f neaee'

oary,modify

the able o

male liqhtly

with

you?

ea w

by cutlinq a

nolch in he

top to clear he

blade

uard

o ' oth er obsl,rucIi o

ns.

r29



WORKSURFACES

EXTENSIONABTES

Buildingnextensionable ora radial rm aw

Made ntirelyrom2-by-4 nd1-by-3 tock,

heextension

table hown bove anbeattachedo the

outfeed r

nfeed

ends f a radial

rmsaw able.Using -by-4s,ut he egs,

rails, nd

stretcherso suit hedimensionsf

your

aw,mak-

ing

he

ength

f the egs qual o thedistance etween

he

topof hesaw able nd heshop loor,ess

he hicknessf

thestretchers.ttachhe railstretchers

o hat heir opsare

flushwith he ail 's

opedges.

ttach

he egstretcherso

the egs,hen crewhe egs

o he

nside

dges f he ails.

Make ertain

heoutside

ail

stretchers butted gainsthe

topsof the

egs.

Cut he bracesrom1-by-3so reachrom

the bottom f thesecondailstretchero the nside dges f

the egs,Miter heends f the

braces ndscrewhem n

place.

o astenheextension

able o hesaw able hown,

cut wowood trips nd

screw neendof each

piece

o

the

underside

f he

nside

ailstretcher,et heextension

able

flush

againsthesaw able nd asten

heother ndof he

stripso theundersidef

he able, sing hims r spacers

asneeded.f

youprefer

o

span he able'sailswith ollers

(inset),

ather

han

wood

tretchers,ut he rail stretchers

longenough

o

fasten

hem o the bottom dge f the rails.

Then

crew ommercialollerso the opsof

thestretchers,

placing

hims nderhe ollers,f necessary,

o set hem ev-

el with he ooof hesaw able.

130



WORK

SURFACES

table aw

witha fold-downutfeed

able

o

your

aw able

or

cutt ing

ong tock,he

ig

shown

bove wings own ut

of hewaywhen

it is not needed. tar tby cutt ing

he op,sides, ndsupport

brackets

rom%-inch

lywood,

iz ing he

pieces

o sui t

your

needs.

hen aw he braces ndcleat

rom1-by-2 tock, dding

n angled otchat

the bottom ndof both

braces. crewhe

ides o the op,countersinking

he asteners.

ext,

et

eadyo

ttachhe

igto

hesaw

housing. i rst , t tach n

angleron o

ach ideof both upport rackets.hen, ave helper old

he op

againsthesaw able,

making ure he wosurfacesre

level ;eave

sl ight

ap

betweenhe op

andsaw able o he

ig

wi l l o lddown

without

amming

gainsthe able.

Now eter-

mine he

position

f hesupport

racketsy butting ach

gainst

he

nsideace f a s ide

iece.

ark heholesn heangle

rons

on he

sawhousing. r i l la

hole ora machine crew t each

mark nd astenheangle

ronso thehousing. eposi t ion

he

jig

againsthe

saw ableandbore

holesora carriageolt hrough

thesides ndsuooort

rackets. se

washersnderhe nutsan d

boltheads, ndbetween

hesides ndbrackets.

t tachhe

braceso the sides

with bolts paced bout inches

ro m

the

bracket ol ts. eave l l he

bol ts oose nough

or

he

sides ndbraces

o

pivot.

hen,

oldinghe

ig

evel gain,

swinghe braces

owardhesaw

housing. ark he

points

wherehe braces

ontacthe housing ndscrew cleat

o

the housing o he

cleat 'sopsurface l igns

i th he wo

points.

oset he

ig

n

position,

est he braces n he cleat.

To old he abledown

insef),

aise he op slightly,move

the braces

ff hecleat ndswinghe

ig

down.

1 3 1



WORK

SURFACES

Buildingnextension

ableora band aw

A na u x i l i a r y

a n d a w a b l e i l l s i g n i f i c a n t l y

n c r e a s eh e

machine 'sersat i l i t y .he x tens ionab le hown boves

espec ia l l yandyorcut t ingong

r

w ide

ieces .

s ing a-

inch

lywood,

u t he

opof he

ig

o a su i tab leiameter .

Cutout hecenter nd

heedgeo i t he oparound

hesaw

table nd hroat

olumn.aw 1%-inch-wide

hanneletween

thecutoutso he opcanbe nstal ledi thoutemoving

he

blade. ext ,

repare

wo leats

hat

wi l l

beusedo at tachhe

saw ableo he

ig

op.For

hese,wo1-by-3should e

cuta

few nchesongerhan

hesaw able. hen

osit ion

ach ne

in

urnagainstheside

f hesaw able i th hreadedoles,

so hat heyare

3/q

inch

belowhe able urface, ith

at east

t /q

inch f

stock boveheholes.

Make

ure

our

machine

has hese oles; ost and aws avehem ormount ingn

accessoryip ence.)

ependingn he

posit ion

f he hread-

edholes nyour aw able, oumay aveo posrt ionhe op

of hecleatsloserhan

/t

inch

o hemachineabletop.n

that ase

ou

wil lhave

o

rout

rooves

or he

cleats n he

unders idef he op

o a l lowhe ab le topo

s i t

lush

i th

themachine's

able

inset ,

ef t ) .Mark

hehole ocat ions

on

hecleats, ore hole t each

pot, nd astenhecleats

to hesaw ablewith he

screws

rovided

or he ip ence.

Then

lace

he abletopn

hecleats nd crewt in

place

(inset,

ight); esure

o countersinkhescrews.he

opshould

sit evel ith he aw

able.

ou

may eedocut

clearanceotch-

esso hat

you

an

each

hemachinecrews

ncehe

ig

s

completed.o emove

he

ig,

oosen

nly hemachine

crews,

leavinghecleats t tachedo he oppermanent ly.

t32



WORK SURFACES

Fitting drill

press

ithanextension

able

The mal l tab le

yp ica l

f most r i l l

p resses

i l lno tade-

quatelyupport anyarge orkpieces.customizedxten-

sion

able or he

oolwi l lenable

ou

o

keep workpiece

level

s

you

eed t in to n

accessory

ike sandingrum

(above).

tart ycutting

piece

f 7+-inch

lywood

nto

a

square

i thdimensions

hat u i t

our

eeds.

henmark

l inedownhe

middle f

he

piece

nd

drawwo irc les

en-

tered

n he ine.

ocatene

bout

inchesrom he

back

edge,

iz ing

t to i t snugly round

hedri l l

press

olumn.

Locate

hesecond

ole nderhe

chuck;

maketsdiameter

about

/z

inch

greater

han he

argestccessory

ou

plan

o

insertnto

hechuck.

ohelp

oupinpoint

hecenter

f hole,

insta l l b i t

n he huck

ndmeasure

hedistance

rom he

columno hebit .Prepareo nsta l l theigon hedr i l lpress

table

ycutting

wo ecesseslong

ts back dge,

eaving

rectangular

ear"

that

protrudes

ehindhe

back ole. hen

bore

hole hrough

heear ora Vq-inch-diameter

arriage

bolt .

Next, aw he

ig

n woalonghe

center l inend

ut

out he wo

ircles. ou

may eedo

make ther uts

o clear

protrusions

n

your

articular

rill

press.

n

themodel hown,

a

notch as

eededor he

able eight djustment

ack.

Finally,

crew butt

hingeo he

ront dge f he

ig

o

oin

the wo

halvesogether

inset).

he

arriage

olt

andwing

nutw i l l l amp

he ab le

n

p lace.

t33



TOOL

STANDSAND

TABLES

standor table

can transforma

portable ower

ool into a reason-

able acsimile

f a

full-size

tationary

machine.

What

heyconceden power

to their arger ousins,ench-mounted

tools

compensateith portability,

ase

of

storage,nd owerprice.

There

are commercial

tands

or

benchtopools,

but

you

can

easily uild

a stand ike

he oneshown

below.Storase

shelves

nddrawers an

beaddedo cui-

tomize

hebasic

esign. here s

one

requirement,

owever:

nsure

hestand's

surface rea s large

enough or

your

needs

nd

hat

t

supports

he tool at a

comfortable

eight. he

extensionouter

table

shown

opposite ot only

converts

a router

nto

a

mini-shaper,

ut can

be

easilyemoved hen

t ii not

needed,

moreelaborate,ut versatile ption s

illustrated

n

page

36. he

hree-in-one

portable

power

tool table features

replaceable

nsertsor

a router,

nelectric

drill, and a saber

aw.

Because

f

its

central ole

n wood-

working,

he routermerits

a dedicated

table n

most

shops. he

shop-built

benchtop ersionllustrated

n

page

139

allows ou

to takeadvantage

f this

ool's

great

ersatility.

HeId

upsidedown in

q

commercial able,

a router

becomes

stationary tool.

Here, t is

cutting a

groove

for

a sliding dovetail

joint.

Many woodworkers

onsider he router

table to be the

singlemost

mportant accessoryou

can add

to

your

tool.

SUPPORTS()R

ORTABTEOWER

OOLS

Building

benchtop

ool tand

The tand

hown t right s

constructed

from -by-4

nd -by-4umber

nd

ply-

wood.

aw he egsrom -by-4s

nd he

rai lsrom

-by-4s,iz ing

he

pieces

o

suit

our

eeds. otch

he egs t he

op

and6 inches

ownrom he

op o i t

the ails,hen

utmatchingabbets

t he

ends fal l

he

ai ls

inset).

lue p he

legs nd ails,

dding

ountersunkcrews

to reinforce

he

oints.

ut he op rom

3/o-inch

lywood.

f

youplan

o

place

table aw n

hestand, aw

square

hole utof

hecenter f

the opasshowno allow

sawdust

o all hrough;

place

box nderneath

o

catch

he

waste.

inally,

screwhe op o

he

egs

and a i l s , ga in

oun-

tersinking

he

asteners.

When sing

tool n

thestand,

ecuret o he

topwith

crewsrclamps.

Top ail

134



WORK SURFACES

Makingndmounting

removable

outerable

Attachedo a

workbenchr able,he

extensionable hown

above

ervessa compact

outerablehat an

bestored hen

it isnot

needed.izehe

parts

ccordingo

your

eeds.tart

bycut t inghe

op rom

/a - inch

lywood,

nd he

a i l s nd

braces

rom

-by-4tock. awhe

ai ls inchesongerhan

thewidth f he op o hey xtendnderhe opand an e

fastenedo heunderside

f hebench

sing uts nd

anger

bolts.

he ingedraces

hould e ong nough

o reachrom

theunderside

f he

ai ls

o

a eg ai l n hebench.

ut bevel

at he opend

of hebracesndan

angled otch t he

bottom

end. he outer

sat tachedo he op

with squareub-base

made f

/q-inch

clear

crylic. everal

teps renecessaryo

it

the

baseo he abletop

nd hen o he

outer. i rst ,

ay

he

square

ub-base

n

he

enterf he ab le , lamp

t n

p lace,

and

marktsedges

ith

penci l .

arkhe enter

f he ub-

base nd

r i l la

pi lot

ole ompletelythr oughhe

base nd he

tabletop.

emovehesub-basend urn

our

t tent iono

the abletop.se

our

outero

plow

7a-inch-deep

ecess

with inhe

penci l

ut l inef he ub-base.

hen, singhe

pi lot

hole s

a center nd

our

outer sa emplate,uta

round

holehrough

he abletophesize f

your

outer 'standard

base, he abletopsnow eady.n he ub-base,r i l l hole

in hecenterhat

ssl ight lyargerhan

our

argestouter i t ,

and crewhebaseo

he outer,s ing ountersunk

achine

screws.

ay hesub-base

n he able ecessnd crew

t

down, ountersinki ng

hewood crews.

l lsurfaceshould

be

lush. or fence, ut wo

pieces

f

3/rinch

lywood

nd

screwhem ogether

nanL shape. aw

notch utof he

fence'sottom

dgeo accommodate

our

argestt t , hen

screw n our ence upports

oraddedtabi l i ty.

t tach

clear

emicircular

last icuard

i th h ingeo al low

t

o

be

raisedutof he

way

inset) .

he encesclamped

n

place.

1 3 5



WORK

SURFACES

PORTABTE

OWEROOI ABLE

Easy

nd

nexpensive

o

build,hever-

satile

able hown elow llows

ou

o

converthree ifferent

ortableower

tools nto tationarv

ools:heelectric

dr i l l , he outer,

nd hesaber aw.

The ableeatures

soacious

able-

top,

anadjustableence, storage

shelf ,

nda convenient lyocated

On/off

witch. he abletooncludes

a rectangular

utouto accept

cus-

tom-madensert

oreach f

he hree

power

ools.

Use

Z-inch

lywood

or

he able-

top,

heshelf,hecleats,

he

nserts

Eottom

rail

Le4

CUTflNG LIST

-

Tabletop:'1"

x 25" x 40"

-

Lega

4):

1%"

31/z x

30"

-

Suppott bracketa

(6):1/+

"

x 9" x 9"

-

Front

and back rails

(4):5/o"

2'/2"x 40"

-

1lde

raila (4):

5A"

x

2 %"x 25"

-

thelfr

"/o"

x 25" x

33"

-

Cleats

(2):

%" x 3" x

I

%"

-

Cleate

(2):

%"

x 5" x 16"

-

Inserte

(3):

3A"

x 121/2" 14%"

r36



WORK

SURFACES

he ence; 4- inchlywoodor

support

rackets;

nd

ol id

um-

or he other

parts

2-by-4s

or

egs nd

1-by-3sor

he ai ls) .

o

hecutting

ist

orsuggested

Start

uilding

he

able y

prepar-

ing he

abletop

or he ool

nserts.

a

rectangular

ole ut

of tscenter

same

ize s

he

nserts.

hen

screwhecleatso theundersidef

the op,

orming

ledgeo

whichhe

inserts

anbe

astened

below).

Before ssembling

he

able,

outa %-

inch-deepado

cross

he able

bout

12

nches

rom he

eft-handnd

o

accommodate

miter

auge.

hen

screwhe

parts

f he

able

ogether.

Use

ap

oints

or he

op

ails

placed

flat), hen

crewhis

rame nto

he

topof he egs. crewhebottomails

(p laced

n

edge)o the

egs,

hen

attach

heshelf.

ou an

either oun-

tersink

he

astenersr counterbore

the

holes, nd hen

oncealhe

screw

heads

ithwood

lugs.

Next, aw

he hree

ool nserts,

iz -

ing hem

o

t

precisely

n

he

hole

n

the abletop,

repare

he

outer

nsert

as

you

wouldhe op

of he

emovable

t37



WORKSURFACES

routerable hown n

page

35.To

mount he nsertn

the able, et

it in

place

n

he cleats nd

bore

a hole hrough

he

nsert

nd he

cleats t each orner;

he

holes

should ecountersunk.crewhe

inserto thecleats.

For he

electric

ril l nsert,

ore

a hole hrough

he center f the

insert

hat

s

slightly iderhan he

largest ccessory

ou

plan

o use.

Then crew commercialrillguide

to heundersidef he nsert o he

drillchuckwill

becenteredn he

hole.

You

may

eed

o drillholes

throughhebase f hedrill

guide

to

fasten

t in

place.)

hebit or

accessoryn hedrillchuck hould

protrude

rom he opof

he

nsert

without

hechuck eing is ible.

Place ooden ashers

nderhe

guide

ods f hedri l l

guide

o

adjust

heheight f hedrill, f nec-

essary

@bovel

For hesaber aw nsert,

osition

the ool's

ase

late

o heblade

will

be

n

hecenter. ake

plunge

cut o

pass

he bladehrough

he

insert,henscrew

he saw's ase

plate

o the nsert

left).

t

thereare

fewer

han

our

screw olesn the

base

late,

ril ladditionaloles.

Mounthedrillandsaber aw

insertso thecleats s

you

would

the outernsert.

Make

he

ence

hesame ay

ou

wouldor

he

outer

able n

page

135,

andattacht in thedesired

position

ithclamps,

138



WORK SURFACES

benchtop

outerable

benchtoo

able hown

bove

sa ull-size

outerable

ith

eaturesf hemanufacturedersion,ncluding

pivotrng,uickly

djustable

ence. egin y

cut t inghe

op

%-inch

lywood,

ized

osuit

our

eeds;he

able

l lus-

measures

4 by36

inches.

he our op

ai ls hould

ext e

cut rom

1-by-2 tock

ndscrewed

n

place

counter-

llscrews,

ere nd

n uture teps),

nd he

entireop

ecovered

itha

piece

f

/q-inch

lastic

aminate,

t

heedges.

urn he

able ver o

you

an crew

round

he

nside dgesnd

ttachhe

egso he

rails nd

op.The

upports,

egs, nd

eet anbeconstructed

f%-inch

lywood;

he

inal imensions

i l lbedetermined

y

size f

your

able.

Make ure

he egs re

t east

ong

enougho urnishmpleoomoryourouter.opreparehe

abletop

or he outer,r i l l

a hole

bout

inchesrom he

front enter;

aket slightly

arger

han

our

argestouter it.

On he

underside

f he op,

enterhe

outer ver

hehole nd

trace

tsout l ine. se

he outer

o

plow

%-inchecess

ith in

theoutline

o accommodate

our

outer ase

late

or,

make n

acryl icub-base

nd

mountt as

hownn

page

37).

Markhe

locat ionf

hebase

late

crew

oles,r i l l

ounterbore

oles,

and

ou

wil lbe eadyo

astenhe

outern

place.

ext , on-

struct

he ence

about

inches

ongerhan he op)

outof wo

pieces

f 1-by-3

tock crewed

ogether

n he

ormof an L.

Throughhe

base f he

L, drilla

hole ora

t/q-inch

carrtage

bolt bout ix

nches

rom ne nd.

Now enterhe

ence

about inches

rom he

ear f he op,

markhe

posit ion

of hehole, nd r i l l or he arr iageolt , l ip bolt hrough

the

hole; singhat

asa

pivot ,

wing

he ight

ndof he

fenceorward.

henhe ence

eacheshe

hole

ou

ut or

the outer

it,markhe

hole's

osition

n he ence.

hat s

where

ou

wil l u ta clearance

otcho accommodate

our

largest

outeri t .Make

guard

hat

shingedo

twi l lswing

out

of heway

ike heone hown

n

page

36.Screw

our

routero he op

and ssemble

he ence y

nsertinghecar-

riage

olt rom he

bottom, sing

ashersnd

wing uts o

tighten

t.Adjusthe

enceorany

width fwork

y

ptvoting

it nto

lace

nd ecuringthe

ree nd

with Cclamp.

r39



GLOSSARY

A.B-C

Bench

dog: A round

or squarepeg

of

metal

or wood

that fits into a hole

in

a workbench

to

grip

and hold

a

workpiece n place.

Bevel

cut:

A

cut at an angle rom

face

o face

along the length

or width

of a workpiece.

Box

oint:

Identical nterlocking

fingers

hat mesh

o

form

a corner

oint.

Butt

joinery:

A method

of

joining

wood in which

the end or

edgeof

one board s setsquarely gainst

the face

or edgeofanother.

Carcase:

A box-like

construction

that

constitutes he

body of a piece

of

furniture.

Cheek The face

of the

projecting

tenon in a mortise-and-tenon

oint.

Circuit:

Continuous path for

electri-

cal current;

from the main

service

panel n ahouseor garage, branch

circuit runs

to a series

of outlets,

wall

switches,and light fixtures,

and

returns

to the

panel.

Counterbore: To

drill a hole

that

permits

the head

of a screw

or bolt

to sit below

a wood surface

so t can

be concealed

y a wood plug.

Countersink:

To drill a hole

so that

the head

of a screw

or bolt will lie

flush with

or slightly

below the sur-

face

of a workpiece.

Crosscut A saw

cut across he

wood

grain

of a workpiece.

D-E-F

Dado:

A rectangular

channel

cut

into a workpiece.

Decibeh

The standard

measuring

unit

of sound ntensity;

he decibel

(db)

scaleextends rom

0 to

about

130,

with 0 representing

arely

perceptible oundsand 130delin-

eating he

average

ain

level.

Dedicated

circuifi An

electrical

cir-

cuit to which

only one

tool or fixture

is connected.

Dovetail

joinery:

A method

of

joining

wood at

corners

by

means

of interlocking pins

and

tails; he

name s derived

rom the

distinc-

tive shape

cut

into

the

endsof

the joining boards.

Dowek A

wood

pin

used o rein-

force

certain ypes

of wood

joints.

End

cap:A

piece

ofwood that

covers

eachend of the

top slab of

a work-

bench; bolted

to the slab

and

glued

to the aprons

by means

of dovetail

or finger

oints.

Facegluing:

Bonding

several

boards ogether ace-to-faceo

form

a thicker workpiece.

Face

ointing:

Using a

ointer

to

cut

shavings rom

the face

ofa

workpiece

until it is

flat and

square

with

the edge.

Face

iss A vise

hat holds

work

against

he

front

apron

of a work-

bench.

Featherboard:

A piece

ofwood

cut

with

thin fingers

or

"feathers"

at one

end;

used n

conjunctionwith

clamps

to hold a workpiece

secure

against

the fence

or table of a power

tool.

Fence:

An

adjustableguide

designed

to keep he edgeor faceof a work-

piece

a

fixed

distance

rom

the cut-

ting

edgeof a tool.

Furring

strip: A

thin

board that is

nailed

o a wall

or ceiling

o

provide

a

flat

or level

surface or

securing

drywall

or

paneling.

G-H-r-J

Ground-fault

circuit interrupter

(GFCI):

A tFpe

of electrical

outlet

that trips instantly when it detects

a

short-circuit leak

n current.

Hanger

bolt

A bolt with

no head;

one end

of the bolt has

screw

threads

while the

other end fea-

tures machine

hreads.

Inlay: A

decorative

strip

of metal,

hardwood,

or marquetry

that is glued

in

a

groove

cut

into

a workpiece.

Joist:A horizontal support for

a floor.

140



GLOSSARY

L

A cut

made n wood bythe

of a sawblade.

A metal device hat

kerf slightly

open during

a

cut to

prevent

he

blade

rom

The tendency

of a work-

be thrown

back

n the direc-

the operator

of a

power tool.

fitting: A

piece

of

that accepts

a screw

or

allowing the

quick assembly

f

a workbench

oint

A typ" ofjoint

in which

or rabbets

overlap

wo

boards.

A type of

fitting that

nto a

hole in concrete

expands

o hold a screw

A vise hat secures

tock

left-hand eg of a work-

cut A cut that

anglesacross

faceof a workpiece.

A rectangular,

ound,

hole cut

into a

piece

Mortise-and-tenon:

A

joint

in

which a

projecting

enon

on one

board

fits into a mortise

on another.

Push block or stick A deviceused

to

feed a workpiece

nto the

blade,

cutterhead,

or

bit ofa tool to

protect

the

operator's

ingers.

Rabbet

A step-like

cut

in

the

edge

or end of

a workpiece;

usually

orms

part

of a

oint.

RaiL A board

running along

he

bottom edge

of a tabletop

o which

the legsofa table

can be attached.

Serviceentrance: A box contain-

ing circuit

breakers

or fuses,

rom

which

power s distributed

to

house

branch circuits.

Shoulder:

In a mortise-and-tenon

joint,

the

part of the tenon

that is

perpendicular

o the cheek.

Shouldervisq

A fixed type offace

vise with a

aw

that

moYes o clamp

a workpiece

against

he front apron

ofa workbench.

Sliding

dogbloclc

A wood block,

part

of the tail

vise of a

workbench,

that applies

he clamping

face o hold

a

workpiecebetween

he bench

dogs.

Static

pressurs A measureof

the

friction

encountered

by air as

t

moves

hrough a duct;

often

expressed

n inches

per foot.

Stretcher:

A board running between

the legsof

a workbench to

provide

additional support.

Stud:A verticalmember orming

walls and supporting

the framework

of

a building.

T.U-V-W-X-Y-Z

Tirilvise: A screw-type

ise on the

right-hand

end of a

workbench

incorporating

a slidingdog block

to securestock

on the top surface

ofthe bench.

Tenon:A

protrusion from the end

of a board that

fits into a mortise.

Truing:

Squaring

he end

of a blade

or the

working surfaceof a

grinder

wheel so hat

it conforms to

its orig-

inal shape.

Truss od:

A

type

of threaded

metal

rod

used

o reinforce

the legsand

stretchers

of a workbench.

Wheel dresser:

A star-wheel

or dia-

mond-point

deviceused

o true the

working surfaceof a grinding wheel

and expose

resh abrasive

articles.

t4r



INDEX

Page eferencesn

ltalics ndicate

an llustration of

subject

matter.

Page eferences

n bold indicate

a Build It Yourself

project.

A B C

Air

compressors, 9, 70, 72, 73

Air-powered

ooIs, 68,72-73

Attics:

Workshop ayout,

38

Axtell, Peter,

6-7

Band

saws:

Curvedcuts

circle-cuttingsupport

igs,

128

Dust

collectionsystems, 2, 85

Extension ables,111,132

Workshop

IayouI-,

2,

38

Bar clamps:

Shop-made lue acks

Shop

Tip), 12a

Storage, 06, 107

storing clamps n a

garbage

an

(Shop

Tip), 106

Basements:

Workshop ayout,39

Bench dogs,

62-63

Carving dogs,64

Edgedogs,63

Holes,54,54

Bench

rinders,71,76

Gouge-sharpeing

jrgs,

77

Workshop

ayout, 34

Bench

slaves. 22

Black

&

DeckerWorkmater",47,

112

Build

It Yourself:

Benchgrinders

gouge-sharpening

igs,

77

Safety quipment

featherboards,

2

push

sticks,20-21

Shop ayout

shop dollies,

37

Storage

fold-down workbench

and tool

cabinet,98-99, 10

handsaw

olders,101

lumber-and-plywood

acks,91

mobile clamp racks,

105

scrapboxes, 09

shelvesor clamps,106

tool cabinets,95

tool cupboards,96

Workbenches

benchdog

holes,

54

edgedogs,

3

slidingbenchstops,

l

Work

surfaces

Iibrary-type

work tables,113

portable ower

ool tables, 36-138

Carving dogs,64

Circular saws:

BIades

circular sawblade

carriers

Shop

Tip),

102

storage, 02

Clamps:

Storage, O5,106, 07

Storinghandscrews

Shop

Tip), 107

Collins,Martha,

8-9

Compressed-airools.

See

ir-powered

tools

D E

Doors:

Opened-door ignals

safe

attention

getters

Shop

Tip),

37

Dowel racks,

90

Drill presses:

Extension

ables, 133

Workshop ayout,33

Drills:

Nr-powered,,72

See lso

Electric

drills

Dust collection

systems, 9, 70, 78-81

Dust

hoods,82-84

adaptingstandard heetmetal

ducts

asdusthoods

Shop

Tip),

83

Electrical weepsor right-angle

oints

(Shop

Tip), 81

Portable,85,87

shop acuums,

1,85, 7

Shop-made

last

gates

Shop

Tip),

84

Vacuum

screeningamps

ShopTip),

6

Electrical

ystems:

Electricalshock,27

Portablegenerators,

1, 74-75

Power

ordcovers

Shop

Tip),42

Power ool ratings,

75

Safetyprecautions,Z

Shop ayout,41-42,44

Electric

drills:

Tables, 36-138

Emergency rocedures:

Fire,16

See lsoFirst

aid; Safety

recautions

Extension

ords, 7

F G H I I

Fasteners:

Anchoring umber racks

n concrete

(Shop

Tip), 93

Storage,

08,109

Featherboards,

2

Finishes:

Safety

recautions,

4,15

Fire,13,16

Fire

extinguishers, 6

Fftstaid.23-27

Eyes,24

Shock,26

electrical,27

Wounds,25-26

Garages:

Workshop ayo:ut,

6,40

Generators,1,74-75

GIue

acks:

Shop-made lue

acks

Shop

Tip),

124

Ground-faultcircuit interrupters

(GFCIs) ,17

Handsaws:

Storage, 00,101

Hand

tools,

ront

endpaper

Safety

recautions,

14

Hearing

protection,

18, 9

Heating ystems,45

Hickman,

Ron,47,112

High-volume,

ow-pressure

HVLP)

,.

spray

systems, 0

J

gs:

Band

saws

circular

cuts, 128

Bench ogholes, 4

Benchgrinders

gouge-sharpening

igs,

77

Vises

stepped

locks o

prevent

racking,

6.1

Workbenches

benchstops, 1,65-67

carving

dogs,64

edgedogs,63

wooden

nserts or metal-jawed

vises,

60

Iointer/planers:

Workshop ayout,

33

Iointers:

Push

blocks.

2l

Workshop ayout,33, 38

K L M N O

Lathes:

Workshop ayout,

33

Lee, eonard,

0-ll

Lighting:

Bench-dogamp

support

Shop

Tip), a3

Shop

Layout,

43

Lumber:

Sizes, ack

endpaper

Lumber

racks,

94 9l

Adjustable,

92-9j

Anchoring umber racks n concrete

(Shop

Tip),

93

Multitesters,

T0

Nail guns:

Air-powered,73

Outfeed ables, 25, 29-

33

P Q R

Pipeclamps:

Storage, 06, 107

storing clamps n

a

garbage

an

(Shop

Tip),

106

Planers:

Dusthoods.

82

t42



Storage

acks,91

Hanging

portable

power

ools

rom

the

wall

(Shop

Tip),

l0.l

Multipurpose,30

Safety

recautions,14

disabling

a

power

ool

(Shop

Tip), 14

featherboards,

2

noise

evels, 19

push

sticks,20-21

Wattage atings,75

Workshop

placement, 0

space nd

ight requirements, 2-34

See

lsoLir-powered ools

13, 18- 9

sticks,

20-21

arm

saws:

Dust hoods,82

Extension ables,130

Workshop

ayout,

2

8,19

stands,125-

26

Air-powered,73

Tables, 34, 36-

37,139

dust

hoods,

83

removable outer tables,

135

workshop layout, 32

Tables,36-f38

recautions,13

Anti-fatigue mats,44

Compressed

ir, 73

Door-openedsignals

safeattention-getters

Shop

Tip), 37

Electricalsystems, 2

Finishes, 4, 5

Flammable

roducts,

89

Generators,

5

Hand ools.14

Power ools,

14

disabling

a

power

ool

(Shop

Tip), 14

Protective lothing,

13, 18- 9

Tool storage,94

See lso

Toxic substances

Air-powered,68, 72

Sandingstations,

84

Storing

anding isks

Shop

Tip), 108

Workshop ayout, 34

18-120

FoIding,

122

Heavy-dfiy, 121

Padding awhorses

Shop

Tip),

120

Panel

support

frames,

123

Securing

workpieces dge-up

on

sawhorses

Shop

Tip), 122

Shop-made

lue acks

Shop

Tip), 124

Stacking

awhorses

Shop

Tip), lI9

Scrapboxes,

09

Scroll

saws:

Workshop

ayott,34

Shapers:

Workshop ayout, 33

Shopdollies,37

Shop

Tips:

Dust collection ystems,

1,83, 4,

86,87

Safety

recautions,

4

Storage

ystems, 3,

101,102,104,

106,

107,108

Workbenches,

0, 64

Workshop

ayout, 37,

42, 43,44

Work surfaces,

17,119, 20,722,

124,

12 9

Shop

acuums, 1,85

Panty-hose hop

vacuum ilters

(Shop

Tip),87

Smokedetectors,6

Solvents,

5

Spray

guns:

Ait-powered,72

Storage ystems,

-9, 89

Flammable

roducts,

89

Tool chests, 8

TooIs,94-95,96,

97, 103- 04

clamp acks, 05,

106

fold-down

workbenchand ool

cabinet,98-99,

110

handsaw

acks,104 101

hanging

portablepower ools rom

the

wall

(Shop

Tip), JOI

magnetic

ool racks

Shop

Tip), 104

SeealsoLtmberracks

Tables,ll,112

Assembly

nd inishing ables,34

Extension

tables, 129- 133

double-dutywork tables

Shop

Tip),129

Library-typework tables,

113

Low assemblyables,

114

Stow-away

ables,

11

5-

116

Temporary, 17

stabilizing

a temporary

work

surface

Shop

Tip), 117

See lsoWorkbenches

Tablesaws:

Extension ables,129

double-dutywork tables

Shop

Tip),

129

fold-down outfeed ables,

3-l

Safety

evices,

2

Wheelbases,29

tablesawon

wheels

Shop

Tip),

3i

Workshop ayout,29, 31, 32

Telephones:

Visual

ringing

signals,

7

Toxic

substances:

rlnrsnes. 5

Woods, backendpaper,

3, 15

Ventilation systems,

5

Positive-pressureentilation, 86

See

lsoDust collectionsystems

Vises:

Extensionslands,127

Workbenches, 6

facevises,56, 58-59,60, 61

quick-switchvises

Shop

Tip), 60

tail

vises, 6-57,60, 62

wooden

nserts or metal

aws,

60

W X Y Z

Wheel ressers,71,76

Wide

panels:

Circle-cuttingsupport

igs,

128

Support

rames,123

Tablesaws,129

Wood:

Toxic

effects,

ackendpaper,

3, 15

See

alsoLumber

Workbenches,

0-ll, 46-49

Bases, 0-52

Benchhooks,66, 67

Bench tops, 5-67

sliding benchstops,

61

Black&

DeckerWorkmater',4T,

112

Carvingscrews

Shop

Tip),64

Fold-downworkbenchand

ool

cabinet,98-99,

110

Hold-downs,65

Tops,43-55

Vises, 6

face

ises,

56,

58-59, 0,61

tail

vises, 6-57,60, 62

wooden nserts

or metal

aws,

60

Workshop

layo:ut,

4

See lsoBenchdogs

Workshop ayout,29-31

Dust collectionsystems,

8

Electrical ystems,

1-42,44

Floorc,44

Largespaces, 0

Lighting,

43

Medium-sizedspaces, 9,

42

Scale

rawings,28, 30, 36,39,

40, 42

tools,35

Smallspaces, 6-39

Workshops:

Ceilings,44

Floors,44

making he

transition o a raised

floor

(Shop

Tip),44

power

cord covers

Shop

Tip),42

Heatingsystems,

5

Planning,6

Ventilation systems, 5, 86

Walls,44

See lso

Dust

collection

systems;

Workshop ayout

Work surfaces:

Tool

stands,

34,135,136-138,139

Variable-height

work strfaces,1

24

S

eealsoT ables;Workbenches

r43



ACKNOWLEDGMENTS

Theeditorswish o thank he

following

SAFETY

Adjustable

lampCo.,Chicago,

L; Black

&

Decker/Elu owerTools,

Towson,MD; Delta nternational

Machinery/Porter

able,Guelph,Ont.;FisherHill Products,nc.,Fitzwilliam,NH; FreudWestmore ools,

Ltd.,

Mississauga,

nt.;

LeeValley

ToolsLtd.,Ottawa,Ont.;Sears, oebuck nd

Co.,Chicago,

L;

VermontAmerican

Corp.,

Lincolnton,NC

and

Louisville,

Y

SHOPLAYOUT

Black& DeckerPowerTools,Towson,MD; Delta nternational

Machinery/Porter able,

Guelph,Ont.;

HitachiPowerToolsU.S.A. td.,Norcross,

GA;

LeeValleyToolsLtd.,

Ottawa,Ont.;Sears, oebuck nd

Co.,

Chicago,L; Thoroughbred awhorsesndEquipment,Division

of the

vy

Group, nc.,Valparaiso,N

WORKBENCH

Adjustable

lampCo.,Chicago,

L; Black

&

Decker/Elu owerTools,Towson,

MD; Delta nternationalMachinery/Porter

Cable,Guelph,Ont.; FreudWestmore ools,Ltd.,Mississauga,nt.;

Great

Neck

Saw

Mfrs. nc.

(Buck

Bros.Division),

Millbury, MA; HitachiPowerTools

U.S.A.

td.,

Norcross,GA;TheWorkbenchBook

(Taunton

Press, 987)

y ScottLandis;

LeeValleyTools Ltd., Ottawa,Ont.; RecordTools nc., Pickering,Ont.; RobertLarsonCompann nc.,SanFrancisco, A;

SandvikSaws nd ToolsCo.,Scranton, A;

Sears,

oebuck nd

Co.,Chicago,

L; Thoroughbred

Sawhorses

and

Equipment,Division

of the ry Group, nc.,Valparaiso,N; VermontAmerican

Corp.,

Lincolnton,

NC

and

Louisville,

Y; Woodsmirh,2200 randAve.,DesMoines,1A50312

SHOPACCESSORIES

Campbell

Hausfeld,

arrison,OH; Delta nternationalMachinery/Porter

able,Guelph,Ont.;

Dewalt

ndustrial

Tool

Co.,

Hampstead, D;

Great

Neck

Saw

Mfrs. nc.

(Buck

Bros.Division),Millbury, MA; Ingersoll-Rand

Canadanc.,Rexdale, nt.; Sears, oebuck nd

Co.,Chicago,

L; Wagner

Spray echCorp.,Minneapolis,MN

STORAGE

Adjustable

lampCo.,Chicago,

L; AmericanTool

Cos.,

incoln,

NE; FreudWestmore ools,Ltd.,Mississauga,

nt.;

HitachiPowerTools

U.S.A.

td.,Norcross,

GA;

The

WorkshopBook

(Taunton

Press, 991)

y Scott

Landis;

Lee

Valley

ToolsLtd.,

Ottawa,Ont.;RobertSorby td.,Sheffield,

.K./Busy

eeMachineTools,

Concord,Ont.;

SandvikSaws ndToolsCo., Scranton,PA; Stanley ools, Division of the StanleyWorks, New Britain,CT;

VermontAmerican

Corp.,

Lincolnton,

NC and Louisville, Y

WORKSURFACES

Adjustable

lampCo.,Chicago,

L; Black

&

DeckerPower

Tools,Towson,MD; Delta nternationalMachinery/Porter

able,

Guelph,Ont.; FreudWestmore ools,Ltd.,Mississauga,

nt.;

HitachiPower

ToolsU.S.A. td.,Norcross,

GA;

The

WorkshopBook

(Taunton

Press, 991) y ScottLandis; eeValleyToolsLtd.,

Ottawa,Ont.;Record ools nc.,Pickering,

Ont.;

SandvikSaws nd

Tools

Co.,Scranton, A;Sears, oebuck ndCo.,Chicago,L;

Shopsmith,

nc.,

Montreal,

Que.;

Stanley

ools,

Divisionof the StanleyWorks,New Britain,

CT;

Thoroughbred

awhorsesnd Equipment,Division

of the

vy

Group, nc.,

Valparaiso,N; Tru-AlignManufacturingnc.,Tempe,AZ; VermontAmerican

Corp.,Lincolnton,NC

and

Louisville,

Y

The

ollowing

persons

lsoassistedn the

preparation

of this book:

Ren6

Bertrand,

lizabeth ameron,DonnaCurtis,LorraineDor€,

RdjeanGarand,GraphorConsultation,

Irene Huang,CarolynJackson, eonardLee,GeneviEve onette

PICTURE

CREDITS

Cover RobertChartier

6,7

Robert

Holmes

8,9 Raymond

Gendreau

10, l RonLevine

30 Courtesy hopsmith,nc.

47

CourtesySjcibergs f Sweden

49 CourtesyWoodcraft

SupplyCorp.

70 CourtesyMakitaCanada td.

89

Courtesy

ustrite

Manufacturing

Co.

l12 (upper)Courtesy hureManufacturing orp.

t44



WORKSHOP

UIDE

Toxtc 00Ds

Protecting

ourself

romoxic pecies

The

dust

rommany

ood peciesan

pose

ealth

risks angingrom espiratoryilmentsoskinanc

eye rritations.ome

oodsontain

hemicalsha t

can auseoxic

ffects

page

0. The ha rt elow

l ists number

fspeciesnd heir

ossible

ealth

effects.

o educe irect xposure

o dust

rom

woodhat

may rigger nallergic

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Ash

Black herry

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Black oruce

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Boxwood

R S

California

edwood

R S T

Cashew

Chestnut

R S

Cocobolo

R S

Douglas-fir

R S

Ebony

R S T

Europeanarch

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EUrOpeanpruce

R S

lmbuia

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lroko

R S

Lacewood

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Mahogany,

frican

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Mahogany,outh

merican

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Pine

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Red edar

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Rosewood.razilian

Rosewood,ast ndian

Satinwood,

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Teak

Walnut

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Wenge

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Westernedcedar

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White edar

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vol.05 - home workshop

Documents