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le 30 November 1996

PUBLISHER Donald B. Peschke

EDITOR Tim Robertson

ASSOCIATE EDITOR Phil Totten

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Cutoffs

A s a kid, one of my favorite toys

vides a number of different clamping

options that many workbenches just

don't have -regardless of their size.

ASSEMBLY TABLE. Moving parts are

also the key to the assembly table on

page 4. To hold most any size project at

a comfortable working height, you can

raise and lower the table. And to

create a larger work surface, two

extension wings flip up.

TOOL TRAY. There's one last pro-

EzMUiva Edrtor Douglas L. Hicks . Art Di~icfm.

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motor that made it easy to forget that m

ject where a simple moving

my steam shovel 4

bart makes all the-difference.

It's a tool tray with a drop-

Sude Rider - &. Gmphic~:Che~IL.

was just a toy.

down lid, see page 24.

While it's my

Simp~o~

# P; FIRSTBOOK For years,

son who's doing

most of the

building with d

the erector r

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people have asked me,

'When is ShopNotes

or Woodsmith going

.%led Pzcb.: Douglas M. Lidater . Pmd. Ainst- Jrm

Snyder. Pic-has Imoe Soec.: Tmy Clark. Eled

c&m. Cod:Gordon C. Gaipp .Net Admin; Ai

I to publish a good

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Johm,SherylBibbey. BIdg.M~iit.:KenG~th

these days, I still

•

have that same fasci-

wocdworldng book?"

nation with moving

I finally have an

parts. Which is why I'm

. Ma~~Mm:M~kMattititisi.

the projects in this issue. Each one

depends on a unique system of moving

parts to make it work.

VISES. For example, the small work-

bench featured on page 16 has two dif-

ferent vises that are made from

"scratch." One opens and closes the top

of the workbench. And the other uses a

long, vertical arm that works like a

giant lever to apply pressure.

Now you'd think that building your

own vise would require a lot of compli-

cated hardware. But that's not the

case. Except for the handles (which we

had to order by mail), each vise is

made from parts we picked up at the

local hardware store.

But why not just buy a store-bought

vise and bolt it to the bench? First of

all, it's considerably less expensive to

make your own. But even more impor-

tant, incorporating these shop-built

vises into the rl~signof the bench pro-

About a year ago, Doug Hicks (a

long-time editor here at August Home

Publishing), started working on some

book ideas. And just a couple of weeks

ago he told me that the frat book was

about ready to go to the printer.

After looking at some of the early

pages, I'm pretty excited about seeing

the finished product. The first book

(with more to come soon) is called

Bookcases and Shelves, and it includes

some of the best projects we've ever

published. They're all done in our typ-

ical step-by-step, illustrated style.

Doug also found a special binding

process that allows the book to open

flat without flapping shut when youlay

it on a bench. It's perfect for use in a shop.

The book should he ready for

delivery by the holiday season. We're

offering a special early discount for

ShwpNotes subscribers at $17.95. If you'd

like to order one, call 800444-7002.

Jeanie Enos Nat'i. Soles Mgr: Kent A. Buckton .

Warnhaushaus Sup.: NhauswJ~hhh. B%ym:Linda Jones

. Sys.Op.:~yAldini-TeamhaderKarlaE*cr

Cust Sm'caMgr:

. Tech Suppmt Dave Stme. m.

Petma . W~mhousc Chuck Carlsm, Sylvia Caey.

LarryPrinprin,S~~tt mm

mw: $4.99. One YY ~bw&p+irn

(6issueal. $24.95. CanadaiPoreiguddlSp"ye~.

PeriodiodilsPatage Paid at Des Moines, IA and at sddi-

ti~nd~offices.

Postmaster: Send changed addreas to ShapNolns, PO.

Box37103, Boone, IA 5W7-2103.

SuheriptionQuestions? Write to:ShopNotea Customer

Service,P.O.Boa842,Des&~es,lAS03(14-9961.Or 4

l-oa09356W, 800 am t~ 5.W pn,Central k,

w-k-

days.FAX515-B3-OM?

E-Mall. Sh~pNp~otes@wl.iom

Internet: httpiI~.~uguguthththth.mm

PRINTED 1NU.S.A

No. 30

EDITOR Bryan Nelson

ART DIREGTO~ Cary Chistensen

SENIOR ILLUS~ATORJ Kurt Schultz

Roger Reiland

Mark Higdon

was an erector set. I'd spend

hours assembling the metal parts with

tiny nuts and bolts. Tightening each

connection with "real" wrenches.

But something else about it intrigued

me even more - some of the parts

actually moved. Gears meshed together

perfectly. Pulleys guided heavy-duty

steel cables (okay, it was only strong

thread). There was even an electric

. . " ."

Die: Lark Giimer. Sr PbtogmpRm: Crayola England

WOlCT

MAIL ORDER

Dperaths Dir:Bob Baker. iUfi.: Cindy Sqino

Srruiee Em:

Je&r Mulph~, Anna cox, KMti Andrem, Margo

ShopNotes@ OSSN 1062-9696) is pubwed bimbimbimthiy

(Jan., Mar* May, sub, Sept., NO".) by August nome

Publishing, 2200 Gland, Dee Makes, IA 5C012.

ShopNotos@k amglakre6 wemark of August Home

Publishing QCopyribht 1996 by August Home

Publuhine. Ail rizhtaYeseeed.

SU&O~~:

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Projects

Assembly Table 4

No matter what size project you're building, this

assembly table makes it easy to put it together: Raise or

lower the table to holdprojects at a comfortable working

height And flip up two wings to expand the worksurface.

5rnall Workbench 16

Don't let its small size fool you. This sturdy workbench

features two shop-made vises that provide rnore clamping

options than many benches twice its size. There3 even

an optional cabinet for storing tools and supplies.

Drop-Down Too1 Tray 24

You can take advantage of the unused space under

your bench with this handy tool tray The lid drops down

to provide quick access to your tools And a set of

unique tool holders keeps everything safely m place

page 10

Departments

Selecting Tools

Plunge Routers 10

ShopNotesputs eight heavy-duty plunge routers to the

test. Which one is best?And what are the key things to

look for when you're buying a plunge router?

Readers' Tips

Shop 5olutions

Our readers offer their own shoo-tested tias Lockina

Small Workbench

paw 16

Tool Base, Band Saw Shelf, Box Joint Tip, a shop-

Vacuum Handle, plus three quick tips.

Lumberyard

Wood Moieture 30

Using wood with the right moisture content can make or

the amount of moisture

affects everything from the fit of the joints to the finish.

@ Spray Painting a Finish

There3 rnore to applying a spray-painted finish than

Finish Room

lust shaking up a can of paint Especially if you want to

produce a durable finish that looks good too.

break a project. ~hat'sbecause

Table

This assembly table has it all -

a tqthat adjzLsts in height, an

expandable work su@ce, plus

room for storage.

w hard to find just the right place. The top of

table is you don't need a helper to do it. That's

because each end can be raised (or lowered) sepa-

rately, see photos below left.

WINGS. And making the work surface bigger

when assembling large projects is just as easy.

That's because there's an extension wing that flips

up on each side of the table. To hold the wings and

theweight of the project, a sturdy support pulls out

my bench can be too high up off the floor (or too

small) to handle some projects. And assembling a

project on the floor is hard on my knees and back.

That's why I built this assembly table, see photo

above. To hold a project at a comfortable working

height, I just raise or lower the table. And for big

projects, I can make the work surface larger.

ADJUSTABLE HEIGHT. To adjust the height of the

assembly table, each leg has a post that slides

inside a sleeve, see photo above. A series of holes

in each post lets you raise the table up to 30", or

lower it down to 21" off the floor.

The nice thing about adjusting the height of the

from underneath the table, see photos below right.

STORAGE. Another thing I like about this project

is its storage shelf. It's a perfect place for glue,

clamps, and parts that are going to be assembled,

refer to the photos on the back cover.

PAhPr. Finally, you can finish the table with spray

paint as shown here. Or just apply severalcoats of oil.

A Adjustable Height. It's easy for one person to adlust the A Expandable Work Surface. An extension wing on each e

height of the table. Lift one end and pin it in plaie (left). side of the table also lets you eniarge the work surface.

Then raise the other end and install the other pins (right). Just raise the wing (left) and pull out a support (right).

hen it comes to assembling a project, it's

""'*

EXPLODED nm

OYERALL DIMENBION6:

WH X W'Wx86.D

(FULLY RAISER WINGS UP)

15/q x 30% - 'f4 MDF

(8) 88 x I" Fh Woods~ews

(4) #5 xt'/hm Fh Woodscrews

(4) #8 x 2" Rh Woodsorews

x 14% - '/4 MDF Q hi15 (2)

C Lower SC&hers (2) 4 x 331/, -% MDF

Z1/2

35% x 36% - '14 MDF

. (4) 3" Locking Swivel Casters

4 x 25l/* - % MDF

5 Wings (2)

- 30 ft.

(4) 1%"-Dia. x '/$'Thick Wheel6

4x 28% MDF

T Trim

(with 1/4''-dJa. hole)

J Shelf Suppor& (2)

2Z1/4 x 26 - =/4 MDF

MDF

For a complste hardwm kit, call

5ho Notes PruJecC 5up~i1e~

Note: You'll need 1'/2 ohm& of Medium-Density Fiberbod (MDF), appmximace(y4 bd. ft. of

808-347-5105.

........,.... $87.95

3/+"-thick hardwood 3 ft. of l"dia, dowel and 1 ft, of'/4n-dla. dowlfor this pmject.

KK No. 6830-100

No. 30

ShopNotes

=" 7'

v (5) 2"Confirmat 5crswe

* (161 @/4" Confirmat 56mwe

111/+ x 3% - % MDF

R Top (1)

t x 26

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