ShopNotes_016.pdf
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Handy
Circular
SQTW
Cut-Off
Jig Fledle
Veneer
on*r
Daald B.Pdke
raaam
.wna
DBugfas
L Hiclrs
vureso
rsrol
RieM
S.
Petem
6
Tim
Roberhn
A..IOURTlpnBn
PhilTotllen
o~looarr
QUT~
Mark
A
Wiiliarns
aamn
mcrm
Ted l€ralkek
rar-
Cq
Chri8tensen
swm~anuroa
Ku&%huKz
wmwmm
WN
Niskanen
Roger
Reihd
Mark
Higdcm
torage. It's one of the first things next to your drill press to keep all of
I notice whenever I visit a shop. your bits in one central location
-
and
Of course the tools also catch my right at your fingertips.
eye. But it's the shop-made tool cabinet NOISE
IN
THE SHOP. In addition to
or unusual built-in that I wander over
getting organized, there's something
to first. I'll open a door and peek at the else you can do tomake your timein the
oontents. Or slide a drawer out of a tool shop more enjoyable
-
reduce the
stand to see how things are organized.
noise level. Not only does this make it
Why such a fascination with storage?
more comfortable (and safer) for you.
First of all, I think that you can learn a It's also easier on family, friends, and
lot about a woodworker by how his shop
nearby neighbors.
is organized.
Reducing the noise level in your shop
Second, over the years I've visited a takes a concerted effort. I've foundthat
lot of well-organized shops
-
some
it's the little things that add up. Using
huge, some tiny. And there's a common
a variable speed tool at a slower speed.
string that ties Or using a rubber
,
them all together.
YOU
don't have to buy new
mat to help reduce
-
vibration and noise.
~'
Crayola
England
RW-
Ken
Mmkd
auoncessms
Jan
Hale
Sveo
Kent
Welsh
--am
Steve
Curtis
nunAraaUillme
Steve
Johnsen
~~~~~naroe
O1ROUXIIIU(
C+&fi~v~~thrIjzBlpde8~.&bsni~
M:
ItB
that
they
use
tools to make your shop
In
issue,
.:
every square inch
of space.
.-
more enjoyable to work
in.
you~~findthe~irst
Ph*
d-n
r
Cimlation
Amtyst:
Rod
Ck&.
NemeIB.ladMm:
Kmt
A.
BueMan
.I*LDMII.fMIUE
Mwtage:
Wn
Granted, each of
in a two-part se-
these shop owners said they could use
ries onnoiseinthe shop-reducing tool
more space. But I've discovered that noise. Sbnple things that you can do to
C.
Csipge.
Sari07
hpliic
lksw:
Robert
H.
Whft-
their secret was they tookadvantage of stop noise at the source. Next issue
a'
the limited space they had. Sometimes
we'll look at what you can do to your
filling in every nook and cranny. shop itself (walls, ceiling, doors, etc.).
The point is you can do this too. You SOME CHANGES. There have been
don't have to go and buy all new tools
some changes here atShopNotes. Terry
*
hpliic
Asdisf:
Chew1
L.
Cynor
ooIuI).IR
LMI(I1a
JQ&~S
.ELGP%~.
M.
Lidster
.
&.
SpmzJbt
Linda
Mm.
~&W*N&T$ieken.rn.&k.
brats:
Chi
S&t,
Julia
Fi&.
R&:
J-e
Joh~.Buihiiw&&t.:
Ken
Wth
Cam*~ahrr;~&&
to make your shop more organized
-
Strohman, a driving force behind
and more enjoyable to work in. Some- ShopNotes &om the very start, has
times all it takes is a new tool stand, or moved to become the Managing Editor
a simple cabinet for your accessories. of our other magazine, Woodsmith. I'm
RADIAL
ARM
STAND. Take the Radial happy to announce that Rick Peters
Arm
Saw Stand in this issue for exam- will take over the reins as Managing
" ~~.
ple (page
16).
It effectivelyorganizes all Editor of ShopNotes.
your cutoffs. No more stacks or piles of In addition,
Tim
Robertson has been
scraps cluttering up the floor. promoted to Associate Editor. AndPhil
And best of
all,
it doesn't require any Totten has come over from Woodsmith
additional room. It replaces your old
as an Assistant Editor.
~&er.~~jea&&i&:Lirds
~OnesS~eEh%iCQi
JefPJanrs.
keep&:
Cynthia
Kerman
EUs,Il*R.MISE
&grz
Jed
En-.
%st.
Swu. Rep:
Jennifer
Marphy,
Joy
&awe,
%m
Kme,
hna
Cox,
Xlis6i
hdtews,
Lxmie
LonnLe-
&la Cronin
metal stand. And takes advantage of an
A couplenew faces: Mark Williams is
611BRc.
-TM6iT
3%~~;
areathat'snotoriousforwastingspace- our new Contributing Editor. Nick
under your saw. Thielen, Support Assistant, keeps the
DRILL
BIT
CABINET.BU~
YOU
don't computer system from acting up (most
have
to
build a tool stand to help organ- of the time). And Lonnie Algreen and
Jeny CarSon
.FuY?lEm:
GI-
Sheek,
h
?&eve%
C3n&CsrLaon,Sy1visCarey
md&b CGI-
PD&,
at4
Gmd
Are.,
!&
m,
IA
SFBt?.
ize your shop. You can make something Karla Cronin are full-time Customer
simple. Like the Drill Bit Cab'met Service Representatives. Now, if1 can
-.twsisme-a(-
IS34
bj
WmdarmtB
CnporaLian
AU
.e.-
.
--
MetiwwSmsk
Copy.8485
One
year%bslly
tm
(B
b&,
$29
%'
.
*i*+<*n-lt
shown on page
12.
Itmounts on the wall just remember all these new names.
,
gue
Qi
n
1
,
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Cm.
addPq,sbd
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w-P-PnMaibeDlomes,lAnd
at
adhid
omcsa
'RINTED
IN
U3.A.
ShopNotes
No.
16
S
w:
8hometesQ
,IWN
yWm,is
publkhed bibioattdy
iJ=a.Msd%
Mou,24y,~sast,N~v.)by
s
Rua
wa(
Circular 5aw Cut-OFFJig
4
This shop-built accessory allows you to use your port-
,;-..%.
,
.>>
<
-
able circular saw to make perfectly straight or angled
.
.
.
.
cuts with dead-on accuracy
~. .
I.
..
FCexible Veneer
8
I.
A close-up look at the different types of flexible veneer:
Also, step-by-step instructions for applying and finish-
ing flexible veneer toproduceprofessional-lookingresults.
Drill
Bit
Cabinet
12
Organizeyour drill bits andaccessories with this compact
.
.
,
_i
cabinet.It features storage trays thattiltout foreasyaccess
..
~
.
.
.
.
to your bits, and an optional drawer for accessories.
.
-
Radial Arm 5aw Stand
16
This modular system is more than lust a stand for your
rad~alarm saw By taklng advantage of the unused
space under your saw, lt makes it easy to organ~ze
cutoffs, sheet goods, and scrap p~ecesof wood
.
.
Reducing
7001
Noise
24
-
The noise your tools generate doesn't have to driveyour
family (or neighbors) out of the house. Here are some
.
..
...
.
simple tips for putting a damper on the worst offenders.
:
:;?
;;,
. ..
.I
8
~
Shop 5olutions
.,,,,.
:.$z.
.
.
28
Six Shop-Tested Tips: Band Saw Fence, Adjustable
Runner for Miter Gauge Slot, Putty Shield, "Window" for
your Dust Collector;plus two Quick Tips.
a
Medium-Density Fiberboard
30
Because it's flat, smooth, and dimensionally stable,
medium-density fiberboard (MDF) is an ideal material
for many projects.
50um
31
Hardware, project supplies, and mail order sources for
the projects in this issue.
No.
16
ShopNotes
1
Cut-Off Jig
Circular
Saw
You
can turn your portable circular
saw into a precision tool with
this shop-built accessory.
ter saw) for making a c~osscuton
a longboard. But
if
you don't have
one of these tools, this can be a
real challenge.
Even though
a
table saw has
the advantage of built-in accu-
racy, using it to cut a long work-
piece is awkward at best. And if
you make the cut with a portable
circular saw, the results are often
less than perfect.
To combine the accuracy of a
table saw with the portability of
a circular saw, I made a simple
cut-off jig, see the photos above.
This jig solves one of the hig-
gest problems of using a circn-
lar saw
-
getting a perfectly
straightcut that follows the
lay-
out line exactly.
REFERENCE.
What makes it
work is the edge of the jig serves
as arefmnce to indicate the path
of the saw blade. As a result,
there's no guesswork when set-
ting up.
Just mark the board, position
the edge
of
the jig on the line,
and make the cut. (For more on
using the jig, refer to the boxes
on page
7.)
ANGLED
CUTS.
Although I use
the jig most often to make
90"
cuts, it's designed to make angled
cuts as well, see inset photo. In
fact, this makes the jig so handy
that it recently disappeared for
several days when one of the
guys needed to miter the ends of
the constmction lumber he was
using to build a deck.
CONSTRUCnON
Basically, the cut-off jig consists
of four parts: a base for the sawto
ride on, a fence that guides the
saw, and a curved arm and edge
guide that work together tomake
the jig adjustable, see the
Ex-
ploded View below.
BASE.
I began work by making
the base
(A)
from a piece of
i/s"
Masanite, see
Fig.
1.
Since
I
wanted
the jig to span a
2x12
when cut-
ting a 45" miter, I made the base
22W
long. And since
the first cut is
EXPLODED VIEW
(6) #@xPFh
Woodscrews
(l)
l/q*
x
13/4''Fh
Machine Sfirew
(25
V4"
Washerti
(1)
V4"
Lock Nut
(1)
V4.I
x 1w
Carriage Bolt
(?I
V4"
Hex
Nut
(2)
V4"x 1V4"
Fender Washerti
(1) 1/4'Plastic
Wing
Nut
WOODSCREW
4
ShopNotes
No.
16
.
.
*
the onethat creates thereference
edge, it's
wider
than the distance
from the edge of the saw base to
I
i
the blade.
(I
started with a
10"-
wide piece.)
NOTCH.
After cutting the base
to rough size, the next step is to
cut
a
notch in one edge, see Fig.
1. This notch provides arecess for
the
arm
that's added later.
ENDS ARE FLUSH
FENCE.
Once the notch is Cut,
you can add the
fmce
(B),
see
Fig. 1. This is a piece of %"-thick
hardwood that guidesthe base of
the saw during a cut.
To
cover the notch in the base,
the fence is 3" wide. And it's cut
to match the length of the base
(22W).
After gluing the fence to
2
SECOND:
the base so the edges and ends
FIRST:
LAY OUT CURVES FOR
are flush, I drilled a countersunk
cur
Y~/~"-THICK
AND CUTTO SHAPE
shank hole for a machine screw
MASONITE BLANK
that's added later, see End View
in Fig. 1.
@
ADJUSTMENT SYSTEM
The most unique thing about this
cut-off jig is a system that allows
you toadjust ittomake either90"
or angled cuts. This systemis made
up of two parts: the cnrved
arm,
and the edge guide that's added
later, refer to Exploded View.
ARM.
Basically, the arm acts as
a "pressure plate" for a clamp
that
will
be used to lock the edge
guidein place. The armis nothing
more thana piece of l/s"-thickMa-
sonite that's cut
in
the shape of a
me,see Fig.
2.
Note: There's a
short (lW-long) '%at9'dong the
edges of one end of the arm.
ATTACH
ARM.
Now it's simply
a matter of fastening the arm
into the notch that was cut ear-
lier. To allow the clamp to apply
EDGES OF ARM ON THIS
ND HAVE 1W-LONG "FLAT"
!
pressure at any point along the
arm, you'll need to orient the
"flat" section so
it
extends away
GLUE AND SCREW
from the jig, see Fig. 3.
ARM IN PLACE
The opposite endis buttedinto
the corner of the notch, see Fig.
3a. Then it's just glued and
screwedto the fence. (For a com-
plete hardware kit, see page 31.)
No.
16
ShopNotes
5
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