ShopNotes_012.pdf
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.ps
on Using Dado Blades
.
Changing
Jointer Knives
--
-
-
I-~truilt
Disk
Sm
:sight-Edge
Ciutting
Guide
-
EDIIOI
Donald B. Pesehke
I
S
electing hardware is an impor-
This guide features a complete index
to all of the projects and articles that
have appeared in the past issues of
Sl~opNotes.And it includes descrip-
tions of all the hardware
kits
that are
available to huild the projects.
Projects, Plans,
&
Techniques also
contains an index of all the projects
and articles that have appeared
in
Woodsmith magazine (issues
1-
89).
To receive your free copy of Projects,
Plans,
&
Techniques, all you have to do
uuurol~a
Ernma
Teny
J.
Strohmar
ISSOC117ESDITOR
Richard S. Peters
ustmr
E~TOR
Tim Robertson
c~~nnnrnwc~aro~
Philip
A.
Totten
1
tant part of every project that we
design and huild. Whenever pos-
sible we try to use hardware that is
readily available. But every now and
then we design a project around a spe-
cial piece of hardware. One example is
the Disk Sander in this issue.
DISK SANDER.
Fromthebeginning, I
wanted to build a professional-quality
disk sander. So I started with an extra-
large metal sanding disk and built the
project around it. The sanding disk
works great, but we've only been able
to find one mail-order source. (For
more on this, see Sources on page
31.)
FOOT
PEDAL.
Anotherproject in this
issue that startedwith auniquepiece of
"hardware" is the Drill Press Foot
Pedal on page 8. This time we found
what we needed at a local bicycle shop
-a length of brake cable sleeve.
But enough about the projects, I
want to bring you up to date on some of
the other things that have been hap-
pening around here.
THE
FLOOD.
In the last issue (Shop-
Notes No.
ll),
I
mentioned some of the
problems we had encountered due to
flooding. Well I'm happy to report that
the flood waters have receded. Clean-
up and repairs are complete. And
things are finally back to normal.
It
was impressive to watch such a big
job get done so quickly. But what really
impressed me were the letters and
phone calls we received from our read-
ers. Your concern and understanding
was appreciated by everyone here.
While the flood is something I'll
never forget, I'd rather tell you about
some ofthe other things thathave been
going on.
NEW
INDEX
Over the last few weeks
we've been putting the finishing
touches on a project that I'm very ex-
cited about.
It's
a new reference guide
called Projects, Plans,
&
Techniques.
cr~rnvs
mawxoa
Ted
Kralieek
A*T DIRECTOR
Cary Christensen
rsnom
rwsruroR
Kurt Sehultz
ILLVSRIIORI
W111 Niskanen
Roger Reiland
Mark
Higdon
WOTOORIPH=R
Crayola England
I
is mail in the order card that's bound in
this issue. If the order card is missing,
DESIC~~REOOR
Ken
Munkel
SEIIIOR
DBIIOMER
Jan Hale Svee
D~~NER
Kent
Welsh
SWOP
YANAOER
Steve Curth
swo~
you can also get a copy by writing to:
ShopNotes, P.O. Box
842,
Des Moines,
IA,
50304-9961.
LUNCH WITH
NORM.
About a month
ago Kent Buckton (Newsstand Sales)
told me that Norm Abram was coming
to town for a woodworking show. Sev-
rmm.mCtnnEo
Steve Johnson
Cimlation
Diractm
Liz Bredeson
.
Subscnp
hnManage~:PhylbJessennCirculationAy
lyst Bod
Cain
.
Newsstand
Sales
Kent
A,-
Buckton
Associate
Editm
Gordon
C.
Gaippe
.
%
GraphicDesigner:Robert
H.Whitmer-GnzpM.
A*t
Cheryl
L.
C~or
CORWRITE (IWICES
Ace0unnng:LauraThomss-
6wkkesping:Julie
Greenlee.
Info.
Seruieea
Manager: Joyce
Moos.
era1people here (myself included) have
been watching Norm on public televi-
sion for years. (Norm Abram is fea-
tured on The New Yankee Workshop
and This Old House.)
PUDLIUIIMG
(IEnYICES
-
EktmmzCPub.
Cod-:
Well, Kent wanted to invite Norm
over to meet everyone. I thought it
sounded like a great idea. But I told
Kent not to get his hopes up. After all,
Norm was only going to be in town for
one day, and he had a lot of things to do.
Several days went by and I forgot
about the whole thing. But Kent didn't.
After making dozens of phone calls, he
&ally arranged for Nonn tocome over
for lunch and a short tour.
Now I was in a bit of a panic. I didn't
have a clue about what to do for lunch.
Luckily,Julia Fish (Administrative As-
sistant) came to my rescue. She took
care of all the details and we all had a
great time.
ADDITIONS.
Since the last issue of
ShopNotes we've added a couple of new
faces. SteveJohnson will be helping out
in
the shop. And Cheryl Cwor has
-
Admin~mtiveAsSistante:CherylSmtt,Jdb
Fish-
Receptionist
Jeanne
Johnson.
Building
Maintenance:
Ken Gflth
Douglas
M.
Lids&
Direetm Cindy Jahn
.
Catalog Prod4
Manayer: Bob
Baker.Project
Supplies:
Lin&
Jones
-
Technical Suprport: Jeff
Janes
.System
Operator
LindaMmw
WSTOYSR
SERVICE
Mamger:Valerie
Wlese.
Suyiem.sar:Jennie
En08
.
Customer
Seniee
Rap7esentetiuer: Jennifer
Murphy,Jay
Jahnson,SaraKono,AmiBlanshan,
Anna
Cm,
Chris
Lo
SlllPPlND
DEPIRlYElT
S%pem%m:
Jew
Carson .Fulflllmat.
GI&
Sheehm,
DmMeVey,
ChuckCarlson,SylUiaCsny
Sept.
Noul
by
Woodsmith
Cor-
poration,22W Grand Ave.,Der Moinea, IA 60312.
ShupNotes ~ss&+ed~dolW~Cmp.
Wopyright 1993
by
Woodsmith
Corpmatioh
AN
Zghtsreserved.
Iubsdptions: SinBle Copy,
84.95.
One
year
subs&
ion
(6issues1, $19.96.
I\uo
years
(12
issues).
$35.95.C
adeoreign, add
84,OO
per
YYY.
S-ndclass pwtage Paid at Des Moina, IAand
at additi0rn1
offices.
Postmaster;
Send changeof address
toSMpNotes,
Bm
112M,
DeaMoines, IA
60340.1204
8ubsoription Quetions?Call 1-800-3335854,
Sam
5pm. Centrslllme,wee*daya.
PRWTED
IN
U.S.A.
No.
12
ClREUUnOl
PIOJECT
SOPPLIU
Mark&&
Diveetor:
Robert
MurrymCataEog+$
IhopNotea
D
iESN
lWP6961
is
published
bimonthly
(Ja~.&h,
w,iy,J@,
Contents
%might-Edge Cutting Guide
4
A unique clamp~ngsystem makes it easy to gulde your
crrcular saw for strarght and accurate cuts
Drill hssFoot Pedal
8
This foot pedal frees up your hands so that you can
accurately posltlon a workpiece for drill~ng.
Dado Blades
10
A
look at the different types of dado blades. Plus some
new variations on traditional blades.
rips
on Using Dado Blades
12
Tips and techniques to make clean and accurate cuts
with a dado blade.
Changing JdinWr Knives
14
All it takes to change and adjust the knives on your
jointer is
a
straightedge and a little patience.
Disk Sander
16
Get professional quality results with this shop-built
bench-top disk sander. It features a large, flat table that
tilts for angled sanding, and a built-in vacuum port.
Disk Sander Stand
25
This standprovides a stable foundation forthe disk sande,:
A hollow column can be filed withsandorbricksto "anchor"
the stand in place and reduce vibration.
Dado Blades
Page
10
Shop Solutions
28
Six Shop-Tested
TIPS
Knock-Down Sawhorse, Alter-
nate Bench Wse, Clamp Pad, Allen Wrench Organrzer;
TIP
for CuMng Metal Threads, and a Leather Strop Tip
Theseinexpensive knock-downfasteners holdapro,,,,
together securely without stripping out And best of all,
they're readily available at most hardware stores.
.
.>
. . .
.
... .
Hardware, project supplies, and mail order sources for
31
1
~.
I
Disk Sander
page
16
e;":..
'~
..
.
the projects in this issue.
1
..
.
I
:;.
No.
12
ShopNotes
5out~e5
a
r
r
Straight, accurate cuts
with
a circular
saw.
.
.
as the strips are added.
To provide room for the
clamping system and still be
able to crosscut a full sheet of
a piece of plywood to get a that's handy about this guide is plywood, each strip is 56" long,
straight cut with a circular saw. it's designed sothe
edge
servesas seeDetail in Exploded View. Af-
The fence guides the saw for a the cutoff line for your circular ter cutting the stnps to length,
a
straight cut, but the clamps
al-
saw blade. This way, all you need theyre glued togetherwith con-
ways seem to get in the way. So to do is ahgn the edge with your tact cement so you don't have to
you end up having to stop and layout line, tighten the clamp, use a lot of clamps.
reposition them to complete the
andmake the cut, seeinset photo.
The only problem is it's hard to
keep the edges flush and square.
ting guide mth a built-in clamp- As a result, when it's time to cut
ing system, see photo.
I started work by malnng the the grooves that form the T-slot,
CLAMPING SYSTEM.
The unique
base (A),
see Exploded View. It's there's no reliable edge to
run
thing about
this
system
is
that it built up of three long strips of against the rip fence.
runs in a T-slot that's
underneath
i/q"-thick Mam~te.This allows
REFERENCE EDGE.
The solu-
the guide, see Exploded V~ew
you to cut each part of the T-slot t~onis
BASE
Fh
Woodscrews
to establish the edge of one
(lo) #B
x
1"
Fh
Wwdscrsws
(1)5/16"~4"
Hex
Bolt
(2)
=/16"
Lock
Nuts
(1)
5/16"
X
16
Threaded In6ert
(1) 5/r6"
Plastic
%Knob
(1)
5/16''
x
13/4"
I
Wing Not
I
4
ShopNotes
No. 12
cut. To prevent this, I made a cut-
SANDPAPER
WING
NU
PLASTIC
T-KNOB
.
.
.
-
..
.
BLOCK
I
Z
strip as a refereace. This way,
you can use it against the rip
fence when cutting each part of
the T-slot and when trimming
the base to width later.
To create thisreference edge,I
glued the bottom and middle
strips together
so
there's about
?4"
overhang, see Fig.
1.
Then I
used the edge of the middle piece
as
a reference to cut the groove
that forms the top
part
of the T-
slot, see Fig.
la.
TOPSTIUP.
The next step is
to
glue on the top strip. Here again,
the idea is to offset
this
strip
about
4/4"
so you maintain the
same reference edge, see Fig.
2.
Now
it's
just a matter of cutting
another groovefor the lower part
of the T-slot in the bottom layer,
see Fig.
2a.
TRW
WAFPE.
After completing
the T-slot, you'll need to use the
reference edge one more time
-
to trim the base to rough width,
see Fig. 3a. To provide plenty of
room for the base of
my
eircular
saw, I trimmed it to a width of
7".
This produces a square edge to
work off when adding the fence
later, see Fig.
3.
FENCE
With the waste trimmed off, the
next step
is
to add thefence
(B).
This is a straight piece of hard-
wood (maple) that's
cut
to the
same length as the base, see de-
tailin ExplodedViewand Fig.4a.
The fenee ensures a straight
cut by guiding the base of the
circular saw. To attach the fence,
I
cut a rabbet in the edge of the
base, see Eg.4. Then*afiercham-
fering the top edges of the fenee,
it's glued and screwed in place,
see Figs. 4 and
4a.
No.
12
ShopNotes
5
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