Mnopqrs

Mortise A rectangular, round, or oval-shaped hole cut into a piece of wood. Mortise-and-tenon A joint in which a projecting tenon on one board fits into a mortise on another. Push block or stick A device used to feed a workpiece into the blade, cutterhead, or bit of a tool to protect the operator's fingers. Rabbet A step-like cut in the edge or end of a workpiece usually forms part of a joint. Rail A board running along the bottom edge of a tabletop to which the legs of a table can be attached....

The Value Of A Workbench

A workshop can be anywhere you can fit a solid surface. A retired carver friend built a superb workshop in the linen closet of his apartment. He only had to open the closet door, pull out a stool, and go to work. Everything he needed was fitted into a space of less than 10 square feet. I built the small cherry bench in the photograph to fit an awkward alcove in my office that measures only 23 by 37 inches. For years I had been using my desk as a makeshift workbench and I was frustrated by both...

Sawhorse panel support frame

When sawing large panels, proper support Is needed to keep the work from buckling and binding on the blade as the cut is made, and to stop the cutoff from falling away as the cut is finished. To accommodate these cumbersome jobs, construct this 4-by-8-foot support frame, which is easily held in place with notched wood blocks. Cut two 4-foot and two 8-foot lengths of 2-by-4 for the ends and sides of the frame. Cut dadoes six inches from the ends of the 4-foot lengths and 18 inches from the ends...

Making a heavyduty sawhorse

Reinforced by a stretcher, braces, and simple joinery, the sawhorse shown above will endure for years as a sturdy work surface. Saw the crosspiece to length from a 2-by-6 and cut dadoes in the edges about 4 inches from either end to accommodate the legs. Angle the dadoes roughly 10 from the vertical. Next, saw the 2-by-4 legs to length and cut 1 Winch-deep angled notches into their outside edges to house the braces. The top of each brace should rest about IV2 inches below the tops of the legs....

Work Tables

Almost as strong as a traditional workbench, this commercial work table is a versatile workhorse, especially when paired with a woodworker's vise. The cabinet and drawers provide storage space, and can be locked to secure valuable tools. For many light woodworking chores, from marking out joints to assembling pieces of furniture, a simple work table fits the bill as well as a traditional woodworker's bench. This section features several table designs. All are quick, easy, and inexpensive to...

Making a bench hook

The shop-built jig shown at right will ensure that the crosscuts you make on the workbench will be square. Use -inch plywood for the base and strips of 2-by-2 stock for the lips. Make the base at least as long as the width of your workpiece and wide enough to support it. Screw the lips to the guide, attaching one to each face. To use the jig, butt one lip against the edge of the bench and press the work-piece firmly against the other. Align the cutting line with the edge of the base and make...

Building an extension table for a radial arm saw

Made entirely from 2-by-4 and l-by-3 stock, the extension table shown above can be attached to the outfeed or infeed ends of a radial arm saw table. Using 2-by-4s, cut the legs, rails, and stretchers to suit the dimensions of your saw, making the length of the legs equal to the distance between the top of the saw table and the shop floor, less the thickness of the stretchers. Attach the rail stretchers so that their tops are flush with the rail's top edges. Attach the leg stretchers to the...

Building a knockdown sawhorse

With only a small amount of lumber and plywood and a few minutes' time, you can make a sturdy, knock-down sawhorse like the one shown above. Cut the legs from 3 4-inch plywood, then saw a 3-inch-deep notch in the middle of the top of both pieces. Next, cut the crosspiece from l-by-6 stock and saw a 1 -inch-deep slot 8 inches in from either end to fit into the legs. Angle the slots roughly 5 from the vertical so the legs spread slightly outward. For added stability, screw 4-inch-long l-by-2...

Jigs For Ironjawed Bench Vises

Fitting wooden inserts to metal jaws If your bench Is equipped with a metal-jawed vise like the one shown at the top of page 61, fitting interchangeable auxiliary jaws can extend the vise's versatility. The wooden inserts shown above will not only be less damaging to workpieces than metal jaws, but they can also be custom-made for special jobs. Each insert is made from -inch-thick solid stock with a rabbeted 1 -by-1 block glued at each end to hug the ends of the vise jaw. Although a pair is...

Fitting a drill press with an extension table

The small table typical of most drill presses will not adequately support many large workpieces. A customized extension table for the tool will enable you to keep a workpiece level as you feed it into an accessory like a sanding drum (above). Start by cutting a piece of 3A-inch plywood into a square with dimensions that suit your needs. Then mark a line down the middle of the piece and draw two circles centered on the line. Locate one about 4 inches from the back edge, sizing it to fit snugly...

Vacuum screening ramp

For cleaning dust off the shop floor, build a wedge-shaped screening ramp from 2-Inch plywood. Before assembling the pieces, cut an inlet port in the back to fit a dust collection hose and five rows of 2-inch-diameter holes through the top. When dust and chips are swept up onto the ramp, smaller particles will fall through the holes and continue on to the collector. Larger refuse will remain on the ramp for easy disposal.

Hooking a planer up to the system

Dust Chute Backflow Seal

A hood like the one shown at right can be custom-built to capture most of the dust generated by your planer. Make the hood from galvanized sheet metal, cutting the pieces with tin snips. Leave tabs where the pieces overlap so they can be pop riveted together. Make flanges on the sides to improve the seal and a hole in the back for the dust collection hose you will also need to create a lip along the top to connect to the ledge of the planer's chip discharge chute. Use an adapter to join the...

Tool Stands And Tables

Held upside down in a commercial table, a router becomes a stationary tool. Here, it is cutting a groove for a sliding dovetail joint. Many woodworkers consider the router table to be the single most important accessory you can add to your tool. A stand or table can transform a portable power tool into a reasonable facsimile of a full-size stationary machine. What they concede in power to their larger cousins, bench-mounted tools compensate with portability, ease of storage, and lower price....

Accident Prevention

Make sure workshop lighting and ventilation are adequate. Keep children, onlookers, and pets away from the work area. Concentrateon the job do not rush or take shortcuts. Never work when you are tired, stressed, or have been drinking alcohol or using medications that induce drowsiness. Find a comfortable stance avoid overreaching. Keep your work area clean and tidy clutter can lead to accidents. Use the appropriate tool for the job do not try to make a tool do something for which it was not...

Making a springloaded bench dog

A wooden bench dog can be made to fit snugly by equipping it with a metal spring cut from an old band saw or hacksaw blade. Cut your dog to size, then chisel out a small recess for the spring. The width and depth of the recess should equal the width and thickness of the spring, but its length should be slightly shorter than that of the spring. Press the spring into the recess the metal will bow outward, holding the dog firmly in its hole. bottom of the dog, except for the head. This provides a...

Providing Minor First

Hold your affected eye open with the forefinger and thumb of - one hand. Slowly rotate your eye, if necessary, to help expose i the particle. Gently wipe away the particle usingthe twisted end of a tissue moistened with water (above, left). Or, fill an eye irrigator with cool water and use it to flush out the particle Lean forward with both eyes closed and press the rim of the irrigator against the affected eye, and tilt back your head. Open your eyes (above, right) and blink several times to...

Shopstorage

Imake jewelry from exotic wood and dyed veneer. Some pieces have as many as 800 bits of wood in them, combining the colors and textures of various rare woods with brightly huedtWr-5 Being able to find some offbeat screw or fastener when I need it, or knowing here to retrieve that wonderful small chunk of rosewood that I've been saving for 10years isn't a luxury it's a necessity. Through the years, I have learned that the strength of a workshop depends on . l per organization and storage. I have...

Sawhorses

Sawhorses have countless uses in the woodworking shop, from table legs to tool stands. Occasionally it seems that their original purpose to support boards for sawing is only an afterthought. It is easy to see why sawhorses are considered so versatile, for their compact design makes them especially useful in shops with limited floor space. Some commercial models, like the ones in the photo at right, can be adjusted to different heights and folded up for easy storage. With commercial brackets...

Installing A Face Vise

Cut an 18-inch-long -by-3V2 inch hardwood support block and screw it in place under the front left corner of the bench, after boring a row of clearance holes for the bench dogs. Next, build up the face block by gluing two pieces of hardwood together cut it to a final size of 5-by-18 inches. To mark and bore the holes for the vise screw and guide rods, mark a line across the face of the face block offset the line from the top edge by the thickness of the benchtop slab (not the front apron...

Setting up a shopmade sanding station

To reduce the amount of dust generated by power sanding, build a portable stall that fits on a table or workbench. Cut the back, top, and sides from or -inch plywood. Taper the top edges of the sides to create a comfortable, open working space, like the one shown above. Cut an outlet in the back of the station for a dust collection hose or branch duct. Assemble the station with screws. Position the sanding station securely on your work surface attach the collector hose to the outlet. Turn on...

Designing A Shop For Efficient Dust Collection

Plastic Ductwork For Dust Collector

The diagram at right illustrates a typical home shop layout. The power tools and dust collection system have been arranged for maximum dust collection efficiency. With the exception of the table saw, all the machines are situated on the perimeter of the work area. The ducting for the central dust collection system runs close to the walls. Despite requiring a relatively long main line, this design allows for short branch lines and minimal directional changes both efficient arrangements. The...

Shopmade Edge Dogs

Edge dogs like those shown at right are ideal for securing a workpiece along the edge of your bench. They feature a round dowel at one end that drops into a bench dog hole and angled heads that butt up against the edge of the bench and hold the work. Start by cutting the dogs from hardwood stock. Both left-hand and right-hand dogs are needed, with the heads angled in opposing directions. Bore a Vi-inch-diameter hole through the ends, and drive a 3-inch length of dowel in each hole. Then insert...

Making and mounting a removable router table

Removable Router

Attached to a workbench or table, the extension table shown above serves as a compact router table that can be stored when it is not needed. Size the parts according to your needs. Start by cutting the top from -inch plywood, and the rails and braces from 2-by-4 stock. Saw the rails 6 inches longer than the width of the top so they extend under the top and can be fastened to the underside of the bench using nuts and hanger bolts. The hinged braces should be long enough to reach from the...

Making a wooden bench dog

Bench dogs can be crafted from hardwood stock the one shown at left uses an angled wooden tongue as a spring. Cut the dog to fit the holes in your workbench, then chisel out a dado from the middle of the dog. Saw a short kerf Into the lower corner of the dado, angling the cut so the tongue will extend beyond the edge of the dado. Cut the tongue from hardwood, making it about as long as the dado, as wide as the dog, and as thick as the kerf. Glue the tongue in the kerf.

Using commercial sawhorse brackets

A pair of metal sawhorse brackets can help you transform a couple of 2-by-4s and l-by-3s into a sturdy sawhorse, like the one shown at right. Saw the legs and crosspiece from 2-by-4s, then cut a bevel at the bottom of the legs so they will sit flat on the floor. Fit the legs into the bottom of the brackets, insert the crosspiece and spread the legs the brackets will grip the crosspiece and stabilize the horse. Screw the brackets to the legs and cross-piece. For added stability, add braces and a...

Setting up a temporary work surface

Above is inexpensive and easy to put together, yet it provides a large and stable work surface that can be set up and disassembled quickly. Start by fitting the sawhorses with crosspieces cut from 2-by-6 stock, then cut the 2-by-4s to the same length as the panel. In three of the boards, cut a notch about 8 inches from each end the notches should be about 2 inches deep and as wide as the thickness of the crosspieces. Cut matching notches in the top edges of the crosspieces. Center the unnotched...

Making a flipup stop

The flip-up bench stop shown at right provides another way to make quick guided crosscuts on a workbench. Cut the two pieces of the stop from hardwood. Screw the pieces to the end of the benchtop on the bench shown, the inner edge of the pivoting piece is lined up with the edge of the tool tray to provide a convenient reference line for squaring up a crosscut. Screw the stationary piece in place with two screws, and the flip-up piece with one so that it can pivot. When not in use, the pivoting...

Anatomy Of A Workbench

The workbench shown at right is patterned after a traditional cabinetmaker's bench, and is crafted from solid maple. The bench incorporates two vises considered to be standard equipment a face vise on the front, left-hand end of the bench, and a tail vise with a sliding dog block mounted on the opposite end. You can build such a workbench from a kit supplied with materials and instructions. You can buy the plans for a bench and order the materials yourself. Or, you can follow the instructions...

Expanding a dust collectors capacity

You can more than double the capacity of your portable dust collector or shop vacuum by attaching a 55-gallon drum or a large plastic barrel as a mid-stage collector. Install plastic intake and exhaust ports on the drum as shown at left and mount a hose to the intake port on the drum to collect wood dust and chips. The 90 elbow on the intake port will create a cyclone effect inside the barrel, forcing chips and heavier sawdust against the walls of the barrel. Lighter dust will be drawn through...

Building a folding sawhorse

Made entirely from l-by-6 stock, with a hinged crossbrace and top, this lightweight sawhorse folds flat to store easily in even the most cramped workshop. Cut the legs and rails to length. Then, cut notches in the pieces for half-lap joints. Use T-type half-laps (inset, bottom) to join the legs to the bottom rails, and corner half-laps (inset, top) to join the top rails to the legs. Assemble and glue the two sections of the horse, and reinforce the joints with screws. When the glue has cured,...

Workbench

The workbench is the cornerstone of the woodshop, with a history almost as old as woodworking itself. Examples of primitive workbenches have been found dating back more than 2,000 years. Woodworkers in ancient Rome advanced the basic design, devising benches with simple stops that allowed them to secure pieces of wood. Until that time, craftsmen were forced to hold their work, cutting or shaping it with one hand while chopping or planing with the other. Further improvements came slowly,...

Lumber Rack

Bench Dog Placement

The storage rack at right features vertical supports screwed to wall studs. Cut from 2-by-4 stock, the supports buttress shopmade wood brackets, which hold up the lumber. You will need one support at each end of the rack, with an additional one every 32 inches along the wall. After bolting the supports to the studs, prepare the brackets by cutting the sides from 3A-inch plywood and the middle shelf piece from 2-by-4 stock lVz inches shorter than the brackets. Angle the top edge of the sides by...

Scale Drawings Of Stationary Tools

The illustrations above are overhead views of a dozen typical stationary tools drawn at a scale of Vi inch to 1 foot. To facilitate the task of arranging your tools on the shop floor, sketch your workshop space on a sheet of similarly scaled graph paper. Then photocopy this page, cut out the tools you need, and arrange the cutouts on the grid to determine the best layout for your shop. Consider the space and light requirements of the tools (pages 32-34) when assigning space to each one. Also...

Installing A Tail Vise

To install a tail vise on a bench with a sliding dog block, position the vise collar against the right-hand side end cap and outline the hole for the vise screw. Then set a support board on the drill press table and clamp the end cap on top of it. Fit the drill press with a spade bit slightly larger than the vise screw and bore a hole through the end cap (near right). Screw the vise collar to the end cap so the two holes line up. Next, secure the sliding dog block end-up in handscrews and clamp...

Air Compressors

Air-powered tools work best at a specific pressure indicated in the owner's manual for the particular tool. Before starting a job, the compressor's air regulator shoidd be adjusted to the proper setting for the task at hand. An air compressor can be fitted with a large number of tools and attachments, making it a convenient shop accessory. In some shops, a compressor can represent an alternative to some electric tools. For others, it can be a valuable supplement. Air-powered tools work best at...

Tool Placement And Work Flow

Designing a shop around the woodworking process For maximum efficiency, lay f> ut the tools in your shop so that the lumber follows a fairly direct route from rough stock to finished pieces. The diagram at left illustrates a logical work flow for a medium-size workshop. At the upper left-hand corner is the entrance where lumber is stored on racks. To the right is the stock preparation area, devoted to the table saw (or radial arm saw), jointer, and planer at this station, lumber is cut to...

Reinforcing Knockdown Joinery

Joinery Fittings

Instead of using mortise-and-tenon joints to build the base, use butt joints reinforced by truss rods, as shown at right. Available in kits, the rods can be loosened or tightened after assembly to compensate for wood movement as a result of changes in humidity. Rout grooves for the rods into the edges of the stretchers and the inside edges of the legs the depth and width of the channels should equal the rod's diameter. Test-assemble the base and mark the groove locations on the legs and arms....

Making and using a miter bench hook

Customize a standard bench hook to make 45 angle miter cuts by adding kerfs to one of the lips. Build a bench hook (page 66), then use a backsaw to cut two kerfs in the lip at opposing 45 angles and one at 90 (left). Use the miter bench hook as you would a standard bench hook, lining up the cutting line on the workpiece with the desired kerf.

Building a handsaw storage rack

Hand Saw Handle

The handsaw storage rack shown at left saves space by storing saws upright. The handles fit on pieces of wood the same shape as the hole in the handle. The blocks are mounted to a holder that slides in grooves cut in the top and bottom of the box. Cut the parts of the box to size, then equip your table saw with a Vi-inch dado blade. To accommodate the outside saw holders, cut Vi-inch-deep grooves 2lA inches from each end of the top and bottom. Saw another groove on each piece centered between...

Heating And Ventilation

Out Door Wall Air Intake Vents

Heating is a necessity for most shops in North America. Some woodworking tasks demand it gluing and finishing in particular require steady temperatures. Heating your shop also makes it more comfortable and safe numb fingers invite accidents. If your shop is some distance from your home's furnace, a separate heating system will be needed. Many woodworkers swear by wood heat it has the added benefit of consuming scrap pieces. Yet this means frequently feeding the stove and cleaning the chimney...

Home Workshop

TIME-LIFE BOOKS ALEXANDRIA, VIRGINIA THE ART OF WOODWORKING was produced by ST. REMY PRESS PUBLISHER Kenneth Winchester PRESIDENT Pierre L veill Series Editor Series Art Director Senior Editors Designers Research Editor Picture Editor Writers Administrator ProductionManager System Coordinator Photographer Pierre Home-Douglas Francine Lemieux Marc Cassini Text Heather Mills Research Normand Boudreault, Luc Germain, Solange Laberge Philippe Gauvreau, G rardMariscalchi, Time-Life Books is a...

Folddown Workbench And Tool Cabinet

Power Tool Storage Cabinets

Ideal for small workshops, the storage cabinet shown below and opposite features a door that serves double-duty as a sturdy work surface that folds up out of the way when it is not needed. Mounted on a frame that is anchored to wall studs, the unit is built with an adjustable shelf and a perforated hardboard back for organizing and hanging tools as well as a work table supported by folding legs. The cabinet-bench can be made entirely of -inch plywood, except for the legs and leg rail, which are...

Shop Layout

Even in spacious shops, tools occasionally need to be moved around in small shops, reassigning floor space may be a part of every project. A wheeled base can make a 10-inch table saw, like the one pictured here, easy to reposition. As they gain experience and accumulate tools, most woodworkers pine for their own special place to practice their skills. In their fantasies, the workshop is an airy space equipped with a substantial workbench and an array of stationary machines and portable tools....

Shop Organization

Shop Organization

The illustration below shows one way of making efficient use of the space in a small shop in this case, one-half of a two-car garage. The three stationary machines chosen are essential for most projects the table saw, the jointer, and the band saw. The saw and jointer are mounted on casters so they can be moved if necessary. With the bench and table there is ample space for hand tool and portable power tool work. The storage space perforated hardboard and shelving is located along the walls a...

Bench Dogs And Hold Downs

Tail Vise Wood

Bench dogs are as important as vises in maximizing the flexibility and utility of a well-designed workbench. A set of bench dogs works like a second pair of hands to secure workpieces for planing, chiseling, mortising, carving, or other woodworking tasks. Although the bench dog looks like a deceptively simple peg, it incorporates design features that enable it to hold a workpiece firmly without slipping in its hole. One feature usually is a thin metal spring attached to one side that presses...