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Shop-Built Panel Saw
Thickness
Si
Hinge Mortising Jig
Sharpenin
EDITOR
Donald B. Pesehke
Y
ou can imagine my sur-
hinges are misaligned.
Correctly positioning the
hinge in the first place remains
thekey. Then an accuratemortise
is cut tomatch the hinge. Thekey
word is
accurate.
If the mortise is
off, you've got problems.
That's where this jig comes in.
We devised an adjustablejig that
let's you set the size of the mor-
tise to match exactly the size of
the hinge.
All
you need is a router and a
patfmx
bit
to rout perfect hinge
mortises. (A pattern bit is a
straight bit with a guide bearing
on the
shank,
instead of on the
end, like a flush trim bit.)
sHAR~E~G.
DIRECTOR
Douglae L H~eks
'
MANAGING EDITOR
Terry J. Strohman
ASSISTANT EDITORS
Rlch~d
prise at the cost of the
panel saw we were look-
ing at purchasing for the shop
-
over $1000. It's a nice piece of
equipment, but that's a lot of
money to spend.
Panel saws are used to cut
sheet goods (plywood,
ete.)
down
to manageable size. It's one of
those tools that you don't think
you need
. . .
until you have the
chance to use one. Then it sure
would be nice
to
have in the shop.
The biggest benefit is that you
can easily cut 4x8 sheets down to
size
-
by yourself.
The cost of this type of saw
usually puts it out of range for
most home shops.
In
almost
every instance like this, my first
thought is, "Okay, let's save
money by building one ourselves."
It
took about five weeks to
work out the design details for
the Panel Saw. Hardware turned
out to be one of the key elements
in the design.
It
wasn't that we needed spe-
cial, hard-to-find hardware. The
tricky part was coming up with
ways of using common hardware
in rather uncommon applications.
In the end
it
worked out great
-
we got the panel saw we
wanted for the shop. And only
spent about $250 ($100 for mate-
rials and $150 on hardware).
HINGE
MORTI5ES.
While the
panel saw is an impressive piece
of equipment, it may be too large
for some workshops. On a smaller
scale is the hinge mortise jig in
this issue.
Setting hinges is one of the fi-
nal critical parts of cabinetmak-
ing. It can break a project if the
8. Petem
nm
Robertson
I
CREATIVE DIRECTOR
Ted Kralieek
ART
DIRECTOR
Cary Christensen
,
Iuusrruroas
Kurt Sehultz
Will Niskanen
Roger Redand
DESIGN
DIRECTOR
Ken Mvnkel
DESIGNER
Jan Hale Svee
PHOTWRAPMER
Crayola England
SHOP MANAGER
Steve Curtis
CIRCUUT~ON DIRECTOR
Liz Bredeson
SUBSCRIPTION MANAGER
Phyllis Jessen
C~RCULA~ON
Sometimes the
idea for an article comes in a
rather round-about way. Re-
cently, I brought a couple of old
hand saws into the shop to
sharpen. (Oneof them appears on
the back cover.)
The sound of filing the saw
teeth brought severalpeopleinto
the shop.
Their reaction seemed
to
be
the same -wouldn't it be easier
and faster to take the saw to
a
commercial saw sharpening shop?
Easier perhaps, but not faster.
To
prove the point,
I
gave a
quick demonstration on how to
sharpen a handsaw.
All you need is a few simple
tools and a little patience. The
trick is to let the saw
be
your
guide. And to let the triangular
saw file do all the work.
Over the next few days our
workshop was fdl of people
bringing their dull saws back to
lie. The result of all this activity
is the saw sharpening article on
Dane 12.
CONTROLLER
Paul
E.
Gray
ACCOUNTING
Linda O'Rourke
BOOKKEEPING
Jul~anneSpears
NETWORK ADMIN.
Domglae
M.
Lidster
MARKETING DIRECTOR
Robert Murry
ix
SHOP
SUPPLIES
ART
DIR.
Cindy Jackson
CUSTOMER SERVlCE MGR.
Laura MeNeUy
PROJECT SUPPLIES
Leslie Ann Gearhart
~-
Linda Jones
TECMNICIL SUPPORT
Jonathan Garbison
svsrEvs OPERATOR
Linda Morrow
RECEPTIONIST
Ken Lee
CUSTOMER SERVICE
Jennie Enos (Supr.), Jeff Janes, Joy
.'
ShopNotes
No.
EDITORI~~
ANALVS~
Jlm
Woodson
NEWSSTAND
SALES
Kent
A.
Buektou
.
ADWINIS~ATIVE
~ssrs.
Cheryl Scott
Julia Fish
~UILDINQ MA~~ENANCE
Ken Griffith
:
Johnson, Sara Johnson, Ami Blanshan
§HWPINQ
DEPARTMENT
Jerry
Camon (Supr.), Glolia Sheehan,
Ronald Long, Don McVey, Chuck Carlson
Hinge Mortising Jig
4
All it takes to make perfect hinge mortises is a router
and this simple jig.
Thickness Sanding Jig
8
Sanding thin wood so it's smooth and uniform in thick-
ness is easy with this jig for your drill press.
Shop-Made Drum Sander
11
A bolt, some toy wheels, and a piece of PVC pipe are
all you need to make your own drum sander
Sharpening Hand Saws
12
There's nothing mysterious to sharpening a hand saw.
AN
it takes is a few simple tools and a little practice.
Thickness Sanding Jig page
8
Rnel Saw
16
This shop-built panel saw allows one person to easily
crosscut or rip a full sheet of plywood or Masonite It's
made with common materials and hardware
Rnel5aw Tune-up
24
Tips on adjusting the panel saw to make precise cuts
every time.
Motor Wbmtion
26
Some quick tips to reduce troublesome vibration in
belt-driven machines.
Sharpening Saws
Page
12
Shop 5olutions
28
Five shop-tested tips: Saw Blade Storage Rack, Edge
Jointing Tip, Installing Threaded Inserts, Clamping Ir-
regular Shapes, and File Handles.
Combination 5crews
30
A
unique thread design and recess in the head make
these screws the perfect choice for the shop.
@
Sources
31
Hardware, project supplies, and mail order sources for
the projects in this issue.
Panel Saw
No.
4
I
your router and this mortising
As
the bearing tracks along
jig. The key to making this jig
these guides, the bit cuts a
per-
BASE
work is the router hit that's used
feet
mortise, refer to photo on
1
started work on the hinge mor-
to cut the mortises
-
a pattern page
7.
Note: When used with a
tising jig
by
making a base
(A).
bit, see box below.
mortises every time using to use this jig, see page
7.)
ranging in length from
l/2"
to
4".
PATTERN
BIT.
A
pattern bit is
similar to a flush trim bit except
the bearing is mounted on the
shaft
rather than the end of the
bit (for sources of pattern bits,
see page
31).
With thebearing up
on the shaft like this, the bit can
'/z"
l~atternbit. the end mides
It's
iust a "U"-shawed niece of
EXPLODED
VIEW
=Ae,'
1"
MACHINE
SCREW
54,''.
2V2"
MACHINE
SCREW
END
GUIDE
be plunged into the workpiece
-
perfect for cutting mortises.
ADJUSIABLE
GUIDES.
When a
pattern bit is used with this jig,
the bearing rides against a set of
guides that are adjusted tomatch
the
exact
dimensions of your
hinge, see Exploded View. (For
mounted up
on
the shaft instead
of
w
below
the
cutting
edgo
nf
fha
bit.
4
I
4
ShopNotes
No.
4
Y
ou can rout perfect hinge step-by-step instructions on how
can be adjusted to cut mortises
3Ae',~
the guides, see Fig.
1.
The
"U"
is
formed by cutting
a
notch in one
side. This notch is the openingfor
the pattern bit.
BACK
GUIDE.
After the notch
is cut, the next step is to cut a
back
guule
(B)
from 3/4"-thick
hardwood, see Fig. 1.
This backguide provides a sur-
face for the bearing of the pattern
bit to ride against as it cuts the
back of the mortise. And it helps
align the end guides (which are
installed later).
Once the back guide is cut, cen-
FLUSH WITH BACK
EDGE OF NOTCH
terit on the base and glue it flush
along the back edge of the notch,
see Fig. 1.
LOWER
STOP.
After gluing the
back guide
in
place, I added a
lower
stop
(CI,
refer to Fig. 3.
Once this stop is cut to size, it's
attached to the base withapair of
machine screws and T-nuts. The
screws are mounted in slots to
allow you to position the back
guide for different width hinges,
see Fig.
2.
To make the slots, first drill
start and stop holes. Then clean
out the waste on the router table,
see Figs. 2 and 2a.
After the slots are cut
in
the
base, locatethe screwholes in the
stop for the T-nuts. To do this, Inuse, thestopisclampedto the
center the base on the lower stop workpiece. Then the screws are
and make a mark, see Fig. 3a. loosened and the base is adjusted
Then drill holes and insert the so the back guide aligns with lay-
T-nuts, see Fig. 3b. Finally, screw
out lines for the
hinge
mortise.
the lower stop to the base.
(For more on this, see page
7.)
ARK
LOCAllO
OF SLOT ON
OTH ENDS
OF
LOWER STOP
LOWER
5TOP
(J/~"-THCK STOCK)
i
3Ae3'-
T-NUT
No.
4
ShopNotes
5
1/2
-th~ckplywood that supports
*
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