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All
Nevl
Drill
Pres:
Belt
Sa
EDITOR'S NOTE
-IR
a
Issue
72
Nov./Dec.
2003
Cutoffs
PUBLISHER
Donald B. Peschke
EDITOR
Teny
J.
Strohman
A~SO~IATE
0
EDITORS
Bryan Nelson
Vincent Ancona
CONTRI~UTING EDITOR
Phil Huber
ART DIRECTOR
Cary
Christensen
SENIOR
ILLUSTRATORS
Roger Reiland
Mark Higdon
kay, I admit it. I've always
dreamed of having alarge, spa-
cious workshop with lots of room for
benches, tools, and accessories.
But the reality for many wood-
workers
(myself
included) is that shop
space is apreciouscommodity. There
just never seems to he enough.
So what do you do?Well, it seems
to me the key
is
to make the best pos
sibleuse of the spacethat you do have.
So in this issue, we've put together
three projects that will help get the
most out of your shop space.
Workstation
-
For starters, there's
the threepart folddownworkstation
shown on the front cover. It features
a rock-solid workbench, a wall-
mounted tool rack, and an overhead
storagecab'iet Itsmade up of three
parts.
You can build one or
aU
three
-
the choice is up to you.
The wall-hugging design of the
workstation takes up a minimal
amount of floor space. But when you
need to get
to
work,
all
you have to
do is
lift
the bench top, swing out the
legs, and you're ready to go.
The second part of the station is a
wall-mounted tool rack that lets you
keep your favorite hand tools organ-
ized, visible, and within reach.
Finally, we added an upper cabinet
that
can
hold everythingekeyou need
close at hand
-
from power tools and
accessoriesto project hardware. It
all
starts on page 22.
Table
Saw
Outfeed
System
-
Another project that makes the most
of available space is the table saw
outfeed system on page
16.
It con-
sists of individual, snap-together
units.
Grouped together, they make
a solid outfeed table that doesn't take
up much space. But you can also
take the units apart and arrange
them to offer support where you
need it
-
like when you're ripping
large sheets of plywood.
Belt Sander -The final project
takes onetool and addsanother func-
tion to it.
If
you already have a
drill
press, here's an inexpensive way
to
Sr
Gmphk
Dssignm
Chris
GlowaAi
.
Graphic
Desw~m
Jonathan Eike S7 Ediior
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Rueg%eggu
Assoc.
Edtior
Joel
A.
Hesa
SPECIAL
WBUGATIONS
J.
KLimhell
.
SCmtsgic Business Anolysls: Krk SM-er,
V.P.
of
Finawe:
Msry
R. Seheve
.
Catmll*7-Robin K.
Hutchimn.
%.Acct.:
LauraJ.Thomas
.Acets.Payoble:MaryJ.
COllPOlUTE
SFllYlCES
SEhultz
.
Accts
Recdzabk Miwgo
Petm
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Pmd. Dic:
Gwrge
Cmmz
.
EieUwnic
m.
Dir.:
ooug1ag
M. Lidsteste.
psiem
Admin:
Cria
Schuonebsck. PCMaid. Tech.:RobertD.
Cook.
&.Re.%
Iwe
Spcs.:
Roy
Ckk,
MimietteJohnson.
Asaoc.
akDi~,:RebeeeaC~.NwMd~Mp:mmC.Gaippe
MultrmediaArtDi7:EugenePederyn.
WdSer~nAdmiz:Cml
0
moeppler
-Web
Contsnt
Mgr: David Briggs
.
MzUti-dza
Lkkmex
Rara
Blessing
-Research
Codinator:
Niholss A.
Jaeger
.
Pmf
DBODi?.:
Miehal
Slgd
-
R.Asat:
KirstenKoele
add a belt sander. It features an
adjustable table, tracking control, and
a miter slot Check it out on page 6.
.
Ofie
Mgr:
Natalie Lonsdde
.
Failitips Mgr:
Kurt
Johnson.
AdmaRrrUm:J-edo~~MailhClerkLmWebber
I
WWOIYlnl
STORE
ShopNote&(SSSN1OG2;96liip~bUnhedbUnonthIy
(Jaa.,M~eh,
May, July,
Sept.,
Nay.)
by August Home
PubBshing.2m
Grand,
Des
Moines, IASo312.
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PRINTED
IN
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ShopNotes
No. 72
Cow.
VP:
Doughs
L.
Hicks. Ad Director
Douglas
A.
Flit
-
ClDCUUTlOY
Clrc.
m.LXrecfolr
Sandy Baum. Ci%.Morheli%gDir:
Wayde
img offices.
Pw~~~SendchulpdaddresstoShopN~kte,P.O.Box3710(1,
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Suh~eription
Questions?
Write
to:
ShopNola8
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Service,
PO. Box
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IA
50304-8961.
Or
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Contents
Features
Drill Press Belt Sander
Getmoreout of your drillpress by making it work harder: This
shop-madeaccessory turnq your drill press into a belt sander
that works every bit as well as a floor model.
Removing Rust
with
Electrolysis
Removing rust from tools can be a big hassle. With a little
'bower"you can make quick work of it We'll show you how
to do It with ease using our step-by-step instructions.
Modular OuMeed System
16
Make it easier to handle large or long stock safely on the
table saw This handy outfeed system can be configured
in
a
number of ways to support long stock, large sheet
goods, or anything in between.
SI
Building a Laminated Benchtop
20
Nothing says solidand heavy duly like a laminated benchfop.
But making one without spending a lot of time geffing it flatand
smooth seems almost impossible. Check out the procedure
we use that results in a perfectly flat top in no time at all.
I
Fold- Down Workstation
22
A
heavy-duty woodworking bench that takes up a little over
four square feet of floor space when its stored? You bet.Add
some storage
-
an easy-accesstool rack and a wall-mounted
cabinet
-
and turn ~tInto a full-fledged workstat~on.
Departments
r
page
16
Readers' lips
4
Shop-tested tips to solve common woodworkingproblems.
loo1 Chest
32
Most sharpening systems can't do it all. But the one we use
every day comes as close as
YOU
can get.
Shop Talk
34
Have a great woodworking invention and want to protect it?
Here's what you need to know aboutpatents.
Maii-order sources and supplies to help you complete the
projects featured in this issue.
Fold-Down Wo~kstatim~
page
:
No.
72
ShopNotes
3
Readers'
Tips
Big Dogs That
W
When clamping a workpiece in
my workbench vise with bench
dogs, Ihd that the small, metal
dogsleave marks on the edges of the
piece that are tough to sand out
So, to solve this problem, I made
some
big,
plywood hench dogs
that slip over the reg-
ular dogs, as
shown in the
photo at right
The henetit is
that the wide
surface makes it
-
easytogetaiirmgripon
I
noLE
IN
Do6
the
material being worked
YOUR METAL
DOG
-
-
The
big dogs are made from
a wide, shallow rabbet along the the workpiece in the rabbets to raise
squares of 3/a"plywood,as illustrated front edge of each dog.
As
you can it above the dogs.
in the drawing at left
A
hole cut in
see in the photo,
this
allows you to
overthemetal bench dog. Then
I
cut workoiece. Or vou can even clamn
Holfm
(0
the middle of each dog is sized to fit work right up to the edge of the
Houston, Texas
Dial
Indicator Depth Gauge
Planing
stock to an
exact
thick-
ness usually involves alot of
trial
and
error (and measuring) to get it right.
The problem is, the thickness scale
on the planer just isn't accurate
enough to show how much material
I
have left to remove.
But I've come up
with
a simple
dial indicator gauge that takes the
guess work out of adjusting the
planer. Now I
can
measure once and
then dial in the perfect setting the
ht
to the thickness indicator. It
acts
as a
contactpoint for the dial indicator.
Here's how the gauge works.
Start by planing your stock slightly
oversize in thickness.Then measure
the stock with calipers or a tape
measure, making note of how much
material is left to plane of£
Next, without changing the cut-
ting height of the planer, attach the
gauge. Mount it so that the point of
the dial indicator stays in contact
with the Lhracket as the cutterhead
(and thickness indicator) is lowered.
After setting the dial indicator to
the amount that needs to he
removed, as in the insetphoto, lower
the cutterhead (making several light
cuts)
until the dialindicatorregisters
-
at "zero." Now your stock is planed
@
to perfectthickness.
John
Gwen
Royal Oak, Michigan
4
ShopNotes
No.
72
\
SVED
TO
FIT
without leaving a mark.
JOE
time. This savesme alot of time,
trouble, and frustration.
As
you can see in the photo at left,
the
main
part of the gauge consists
of a dial indicator mounted to a hard-
wood block The block has a rabbet
on the back and a couple of screws
and washers hold it
hnly
in place
above the scale on the planer.
The second part of the gauge is a
small, aluminum Lhracket fastened
&
i-
.
_
.. .-
-
. . ...
iips
A
Richard
Beal
of Fort Polk,
L.
.
I
inexpensive, plasticsprayboffles
screwdriver, Eric
Johnson
of keeps the lids from his fastener make a great applicator for
Todd
Edgewood,
KY
uses his grinding boxes in his storage bins to help
Kmp
of Gig Harbo,: WA to spray
wheel to touch up the edges.
him remember the type and size.
sealer on his outdoor projects.
Laminating Spacers
-
w
When gluing plastic laminate to a substrate with con-
tact cement, I always used wood spacers
or
dowels to
position the laminate. The problem was
ftndii
(or
making)
enough spacers to do thejob.
To get around this,
I
started using plastic slats from
wmdow mini blinds, as shown
in
the photo at tight. The
Handy Tote for Sheet Goode-
w
After reading through the article hangers to either side. A metal
on working with plywood in drawer pull screwed to the
2x6
ShogNotes
No. 71,
I
wanted to share
makes a greathandle.
my version of a plywood tote that I've
Dana
Cmig
I
our print or electronic publications.
I
to
ShopNotes,
Attn.:
Readers' Tips,
2200
Grand Ave., Des Moines,
IA
50312. Or
FAX
it to 5152826741, or send us an
email at shopnotes@shopnotes.com.
Please include your name, address,
and daytimephone number in case we
have any questions.
.-----
No.
72
ShopNotes
5
a'
curved shape of
the
slats easily holds the laminateoffthe
substrate.And best of
all,
they're lightweight and can be
stackedout of the way until I need them
again.
Tom
Brodle
St.
Louis
Park, Minmsota
-
The secret to my
tote
is a pair of
wc
pipe hangers, like those shown
in
the insetphotobelow. You
can
buy
them at any hardware store or home
improvement center. I cut a piece of
2x6
long enough to make it comfort-
able
to
grip and then nailed the pipe
been usinefor the last few years.
I
to considerfeaturingitinone or more of
@
We'll pay up to $200 for a tip we pub-
lish. Just write down the tip and mail it
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