ShopNotes_047.pdf
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Dado Blade Storage.
Tips
on
Br
h
Router Collet
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Issue
47
puauonen
Donald B.
Peschke
eDlmR
Tim
Robertson
ASSOCIAT~EDI~~
TomBegnal
ras~oraslr
EmmR
Bryan
Nelson
I
I
power tool. Itwas a multi-purpose tool
11
never forget my first stationary
Now I suppose I could have bought a
commercial mortising machine to cut
these mortises. They work great But
EDIT~RIALINTERN
Wyatt Myers
ART
DIREOTOR
Cary Christensen
an.
ommlc
~ESI~NEII
Kurt Schulta
SENIOR ILLUSTRATORS
Roger
Reiland
DdarkHigdon
that served as a table saw,
drill
press,
and several other tools all rolled
into
one. Well
I
bought the tool second-hand,
and to be honest,
I
was pretty pleased
with my new purchase. Especially since
severalaccessories had come
with
it
MORTISING
AmcHMENT.
One of
these accessories was amortisingattach-
ment for the drill press. It was designed
to use a special hollow chisel bit to
drill
a
sqwe hole.
(Ibis
is a
drill
bit sur-
rounded by a square, thin-walledchisel)
As
YOU
lowered the
quill,
the bit
they're expensive
-
$300 and up.
SHOP-MADE
=ON.
SOinstead of
buying a mortising machine, I took a
"back door" approach. I challenged Ken
(our project developer) to build a shop-
made
venion of a mortising machine.
Not long &er that, he showed up car-
rying
an armful of parts: a long piece of
aluminum channel, a couple of metal
rods, and a hand crank (the kind used
to tighten apipe clamp, only larger).
At first, this odd assortment of parts
QIUTIYL
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JayKmm
removed the bulk of
had me scratch'i
the waste, and the
my bead. But when
chisel squared up
Using the mortising
I wAed into the
the sides at the same
machine
k
a smooth,
shop a few
days
time.
At
least that
00mnuwKn
CdmZiar.
Bobin
Eut&in@on
SIAccounto~t:Lam
Thome. Aem&
PavdIe:
Ivlq
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Acrm~~ts
Ekhanic
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Bieghler.
Nezu Madio Mp:
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0.
Gaippt
MultiR.dinArth%:Ey~~n~Peders84~E-C~
process. And it
later, it all started to
was the theory.
In
make more sense.
oractice. it
was
a
dif-
cuts a crisp, clean mortise
n,
cd was
ferent story
that's dead-on accurate.
attached to the top
I had to apply colz- of a
tall,
vertical
siderable downward pressure to get the tower. Turning the
crank
raised and low-
bit to cut Then, as it dug into the wood,
ered a carriagethat served as aplatform
the bit began to smoke, and the chisel for a router. This carriage was sus
turned blue. To make matters worse, pended over a sliding table that held the
when I raised the quill to pull the bit out workpiece. By moving a handle back
of the mortise, it lifted the workpiece off and forth, the table (and workpiece) slid
the table and tore out a
bii
splinter.
from side to side under the router bit
Needless to say, I
was
pretty
frus-
It looked like a mat idea, and I
trated with the whole
thing.
I went back couldn't wait to try it out So I grabbed a
to making mortises by
driUing
a series chunk of wood, clamped it to the table,
of holes with a Forstner bit then and flipped the switch on the router. As1
cleaning out the waste with a chisel by turned the
crank
to lower the carriage,
hand.As forthe mortising attachment, it the tip of the bit plunged into the wood.
ended up on a shelf gathering dust.
Then, as I grasped the handle and slid
That's too bad really Amortising tool the table to the side, the bit carved a
that reallyworked would he agreataddi- crisp, clean slot in the wood.
tion to a shop.
In
fact,
it would be ideal The entire process was smooth and
for a project I'd been planning to build effortless.And the mortise was dead-on
just recently. The project
was
a
garden accurate. In
fact,
the mortising machine
bench that required cutting over a hun- worked so well, we decided to feature it
dred mortises. mat's a lot of
driUing
in this issue. In the meantime, I guess
and chiseling.)
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su~uiptionQuestio~~?Writeto:
it's time to build that garden bench.
ShqNote8
Gastomer
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ShopNotes@#hopnot88.mm
Internet:http:lMahopnott~.~orn
PRINTED
IN
U.S.A.
Rconnted ZOO2
2
No.
47
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Sho~Not&@
Home
Publishing
OCopyrlghL
1999
by
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Contents
Features
-
Dado Blade Case
Dado Blade Storage Case
6
The "hanging files" in this storage case hold the chippers
and blades of a stacked dado set. Thisprovides easy access
to the individual pieces and protects them from damage.
Restoring a Bench Plane
10
Turn an old rusty bench plane ~ntoa hard-workingtool that
looks great too Also, we include step-by-step lnstruct~ons
on making a new handle or front knob.
Tuning
Up
a Bench Plane
14
A bench plane is a precision tool
-
when it's tuned up
properly Here are some simple tips and techniques to
help you get the most out of your bench plane.
e
Mortising
Machine
16
lets you rout perfect
mortises every time. With a router carriage that moves up
and down and a table that slides In two directions,you can
set up the machine and cut a mortise ~n
less than a minute.
Brush Basics
26
One of the secrets to getting a smooth, even finish is the
quality of the brush. We offer practical suggestions on
selecting brushes, applying a finish, and some clean-up tips.
I
Departments
Mortising Mackzne
r
Readers' Tips
A
Our readers offer their own shop-tested tips dealing wit1
some of the most common woodworking problems
I
Tool Talk
In this ~ssue,we take a look at an Innovatwe new router
(
collet that doesn't require a wrench to tighten the b~t
5ources
31
4
Information and mail-order sources for the hardware and
supplies used to build the projects in this issue.
Brushes
No.
47
ShopNotes
.:
This shop-bolt mortis~ngrnach~ne
page
16
3,'XlW'
Readers'
Tips
a
3"
x
lW
REDUCER
REDUCER
\
Vacuum Muffler
(CUT
OFF)
Shop vacuums are great
tools, but they sure make a
lot of noise. My dog !mows.
As
soon as I flip the switch,
he bolts out of the shop.
To reduce the noise,
I
made
a
simple muffler
using inexpensive
WC
pipe
and pipe fittings, see photo.
As
it turned out,the mufiler
cut the noise level
in
half
EditoJs
Note:
This
mufner
requires the shop vacuum
to have an exhaust port
that allows you to attach the
hose and use it as a blower.
The basic concept of this
mufiler is simple.
Air
from
the vauccum is exhausted
through a layer of foam
tl
-
1
REDUCER
lat
fib
There's also
a reducer on the
between an
inner
and
outerpipe,
see
drawing
at left ihefoam dampens
the sound as the
air
passes through.
(Foam is avabilable at most uphol-
stery shops.)
To direct
air into
the foam, youll
need to
drill
a number of holes
in
the
inner pipe and glue a
cap
on the top
end.
(I
used
WC
cement to attach
the cap.) Tnis forcesthe
air
through
the holes, into the foam, and out of a
reducer
that's glued
to
the top end of
the outer pipe.
bottom end of
the
muffler. But
to
allow the inner pipe to
fit
through
this
reducer, youll need to file off the lip
that's on the inside of the fitting.
To fit the muffler in the exhaust
port on my shop
vacuum,
I added
another reducer to the bottom end of
the inner pipe. But 6rst I cut offthe
expanded part of the reducer. Note:
Don't file the lip on this reducer. It
keeps the pipe from sliding through.
Chris Glowacki
West
Des Moines,
Iowa
Wood
Plug
Trim
5a
w
H
Cutting
wood
plugs is a snap with
this simple
trim
saw,
see
photo. It
just a curved wood block that holds
a
cutoff
hacksaw
blade,
see
drawing.
To avoid marring the workpiect
the blade is recessedin agroove,se
detail. misleaves anubstickingup,
but it's easily sanded flush.) Also, a
notch provides clearance asyou saw.
Chris Forgam
North Benton,
Ohio
I
EPOXY
J
xi-,
)
ShopNotes
No.
47
\
3"xlW
CLEARANCE
W
WheneverI use a scroll saw,
I
hd With the tape in place, it practically
that some types of wood are just
eliminates the burn marks on the
about impossible to cut without edges, see photos in margin.
burning the edges. (Cherry seems What makes the tape work? I'm
to be the worst culprit of
all.)
And the not sure,but my guess is it lubricates
problem gets progressively worse as the blade just enough to reduce the
the blade gets dull.
heat thafs produced.
As
a result, I
Fortunately, there's an easy solu- end up with a nice clean edge that
tion.
I
just cover the cutting line with requires little (if any)
sanding.
a strip of cellophane tape, see inset
Rick Hutcheson
photo.
(I
use 2"-wide packing tape.)
Crimes,
Iowa
Knock-Down Work Support
Thafsbecause the stretchersfit onto
it in place. Also, you'll need to
drill
a
a metal pin in each hanger that counterbore near the end of each
'locks" them in place. The pin is just stretcherto
fit
over the bolt
a bolt that passes through a hole
John
Mappus
drilled in the joist hanger, see
Charleston, South Carolina
When cutting sheet goods or
assembling a large project, an
extra
worksurface sure comes in handy.
But
I
don't have room
in
my shopfor
a permanent "fixture."
detail. Tightening a nut on the
end of each bolt holds
a
So instead, I use a worksurface
STRETCHERS
that "knocks down"
in
seconds. The
key is a pair of metal joist hangers
attached to
each
of my sawhorses,
see photo above. Uoist hangers are
available at most home centers.)
The hangers act
as
"pockets" that
hold a couple of
2x4
stretchers, see
drawing. Fitting the ends of the
stretchersdown into thejoist hangers
creates a sturdywork support
With the stretchers
in
place, you
don't have to worry about them acci-
dentally slipping out of the hangers.
Sanding Disk Organizer
H
Here's a simple way to organize
the sanding disks for your random
orbit sander. Ifs a plywood tray with
three separate'%bays"to hold the disks.
Each bay (one for each grit size) is
formed bvthree dowelsthatsurround
I
a stack
if
disks. Placing a round,
hardwood plate on each stack keeps
the edges of the disks from curling.
Robert Page
Rochesterj New York
ShopNotes
5
*
Scroll Saw Tip
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ShopNotes_135.pdf
(15677 KB)
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(8722 KB)
ShopNotes_062.pdf
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ShopNotes_031.pdf
(7457 KB)
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