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The Gate. The gate is sized to place, and the whole assembly This stage of the process is a fit inside the pocket and seal off can be screwed to the bottom of good time to cut mortises for the large opening in the lower the lower divider, as in Figure 2.
If you turn to page divider. You can use the drawing 32, you can see the jig I used to at right to guide you while cut- support a hand-held router and ting it to shape. The two horns at the back of 1"-DIA. This involves making the drifts into the gate pocket to CL assembly that seals off the bot- the narrow slot that you cut in tom of the hopper.
The first part the plate. Below A Chute. The rear baffle is the first and I used a table saw to make this simplest to make and install. The hole in the lower divider a bevel cut along each edge.
But Closing In. The front of the allows most of the dust and chips in order for them to fit seamlessly hopper is sealed with a plywood inside the hopper to fall into the against the rear piece, they need panel. A small glass window in bag. To direct all the dust and compound miters cut at the back the panel lets you see when to chips toward the hole, I installed ends. T Shelves.
They rest on adjustable shelf supports. Upper Doors. The upper a. A coat of primer is the next The Cyclone. The final step is step. I like to sand the primer to install the cyclone unit.
Use the vacuum and tools to the collec- coat to make sure the surfaces holes in the cyclone to drill mount- tor. To minimize air leaks, wrap are smooth. The ish, you can fill it and re-prime ures 5 and 5b. For the tightest seal, ers and the cyclone with foil tape design of the that section.
This prep work sets apply a thin bead of kitchen and lower right photo. Two coats of cyclone before attaching it. Follow these steps for perfect parts, tight-fitting joints, and flush, smooth surfaces on your projects.
And grain. These tough fibers are dif- workpiece directly from the proj- it can often mean the difference ficult to cut smoothly without ect.
Most often, I use one of reliable tools and techniques to two tools to get the job done. My first choice is the table saw. Cut to Length. The simplest The photo above shows how it task is cutting a workpiece to works.
The miter gauge guides length. More often than not, this the workpiece past the blade. To shorten a Use the blade plate as a guide piece, I just back out the screw in for taking light cuts at the miter small increments after each pass saw to sneak up on precise project parts. In this And actually, the adjustable stop.
Skew the block plane and sander increases your control over the workpiece. Take light plane toward the center from each side of the joint. I also moisten the the table saw. By inserting This softens the wood and makes use. This is shown in the lower a few playing cards, I can tweak it easier to slice.
Finally, move the left photos on the facing page. To close up a when to stop when you start to saw plate.
Hold the piece in posi- joint with a gap at the heel, slip the see long-grain shavings appear. The amount you trim is to the sander upper left photo. This joint with a gap at the point. But tip to stop Trimming the length of square there are times when I delib- parts is a walk in the park.
There are a few other tasks where the erately make parts a little lon- ger than necessary to ensure Tearout degree of difficulty increases. Fine-Tune Miters. One of Through dovetails and box joints those tasks is trimming miters. So with the mating part. I use a disc sander to take off Since the parts are glued up, controlled amounts of material.
There are a few things freehand, I find a miter gauge that can make that a certainty. First, set the plane for a fine cut. One sure-fire way to prevent But rather than fussing to set the This reduces the amount of force tearout when trimming the end of a workpiece is to miter gauge to the exact angle, I you need to use and helps to score all the edges with a marking knife.
Each mortise should be sized accu- BASE 3! The space between the bases defines the length of the mortise. Below the bases, a pair of fences sandwich the workpiece and back a. Drill a hole in each shows the completed stop. Then you can cut blank cut to final width.
In Fig- the waste free at the band saw, as ure 1, you can see how to cut the illustrated in Figure 2. After cut-! Test the fit of the key in each end, as shown at right. Tapped Wood Shop-Made Handwheels Hardwoods like maple can be Making the handwheels for the planer sled levelers threaded with a screw tap. For page 23 is simple. Starting with a hardwood blank, added durability after tapping first drill a counterbore to fit the T-nut flange.
Using the the threads, soak them with thin center of the counterbore as a guide, you can cut out cyanoacrylate glue. Clean up the the wheels with a hole saw. Use spurless process after the glue dries. T-nuts or file off the spurs because they can split the wood when pressed in. Add the hardware shown in 1 Figures 3 and 4, and then chuck it into the drill press. A little hand work with a file takes care of the rest. And just like the old screws. The top planks are held lumber.
On any given day you bench from my childhood, it can with washer-head screws. The woodworking is super mower repair to woodworking But the best part is, you can easy. Upgrade this basic bench with a rail system that incorporates bench dogs and clamping accessories. It was featured in ShopNotes No. Crosscutting long 2x4s building a strong together. The box at the bottom at the table saw can be a chore.
Start by cutting the 4x4 legs to The two top rails need to be The beauty of this workbench their final length, as illustrated drilled with five pairs of holes. After laying out the These are used for securing cross Notched legs form the joinery location for the notches for the rails that support the benchtop. Sturdy Legs. I used 4x4 legs gauge. A Adjust the height of the After the holes are drilled, you for the workbench. Just make sure using for the rails.
Once the notches are cut, I The notches help by aligning the used a hahand-held router to round rails as you fasten them.
While the glue match th the radius on the edges dries, you can cut the six short of the ra rails. You can also do this cross rails that fit between the with a li little sanding. This extra legs Figure 1. These short cross step crea creates a more finished look rails join the front and back after the rails are attached. The only things you need Time for Assembly. The short Lumber. I used the holes in the.
Use a drill bit to mark the ends of the cross rails through the holes in the legs. To install all of the lag screws, you can use a ratcheting socket wrench. With the 8! They fit front and back rails. The overall dimensions for the 3! The glue joint is oriented toward the ends of the bench. With this change, the shelf slats will be 1" shorter. Finally, the heavy- Installing Screws.
Washer-head screws Floating Shelf. The shelf is secure the planks for the made up of 1x6 boards. The slats benchtop. So the first order of business is installing cleats on the inside of the lower front and legs, I used a countersink bit to attached to the fence of your back rails. A com- to the same length a snap. But the rail. The cleats are 1" wide and cut the screws to fasten the cleats.
The 1" face sup- Shelf Slats. After cutting the Figure 4 that there are 16 shelf the legs. I started by cutting and cleats to length to fit between the slats. This used in the photo at the top of the means that the last two slats you opposite page. The large washer add at each end will likely need head provides additional bear- 1 TOP PLANK to be ripped to width to fit the ing surface to help prevent the remaining space.
As I mentioned planks from warping. The screw hole is oversized to contraction. If you find over time allow for movement.
I did this Adding the Top. If boards. I staggered applying a finish. To finish the time to position the workbench ting the rails and to avoid the lag bench, I wiped on a couple coats in your shop and put it to good screws that secure each cross rail.
Few woodworkers would iden- shop vacuums are more powerful features, some can be extremely tify a shop vacuum as their favor- and have a much larger capacity effective at removing the finest, ite power tool. But ask me to give to hold debris. Their larger hoses and most hazardous dust. And most aftermarket add-ons make them shopvacuumsapartfromordinary can handle both wet and dry extremely versatile and able to household vacuums.
For a start,, pickups. Shop Vacuums. High-efficiency These are powerful, erful, vacuums are portable, and have stable, compact, large capacity tanks. These work for quick cleanup of small messes. This model shares the battery with other tools of the brand. Dust extrac- The two most common types of tor shop vacuums represent a big shop vacuums available are gen- step up in features, the size of the eral purpose and high efficiency, dust particles they can trap, and also called dust extractors.
A gen- page. They usually have High eral purpose shop vacuum can Efficiency Particulate Air HEPA be used for a wide variety of filters which make them the best cleanup chores. They are reason- choice for attaching to fine dust ably priced, and they hold up producers like sanders. See the well under constant daily use box below on HEPA filtration. High-efficiency vacuums also Special Purpose.
Usually You can plug a tool into the vac- cial uses. They also have power mounted vacuum photo above. Many are adjustments that help keep They come with extra-long hoses a wall-mounted capable of picking up liquids attached tools and nozzles from for extended reach. And they Cordless mini-vacs are another extended reach and the paper filter. Some shop are quieter than general purpose type of vacuum that I use in my hose, is an option. All these features shop photo above left.
Being that attaches to a garden hose, come at a higher price, however. Power sanding is. But particles between wear a dust mask which provides. These are. Vacuums that use dis- A sturdy switch in an accessible posable paper bags deposit spot will save you the annoyance the debris in the bag instead of of an awkward reach every time directly into the tank. The bags you turn the vacuum on and off. In addition, they contain A good system of managing the dust when you empty the the cord and hose is another fea- vacuum tank.
If you opt to use ture I look for. A well tank opening, so you can easily while the vacuum is stored. Because shop vacu- keep tools organized and close. Some tank, they tend to be top-heavy cloth filters. They cost more but vacuums have better hose and when empty. A large footprint last longer than paper, and some attachment storage systems and a hose that attaches to the are washable. If you use these fil- than others photo at right.
Dust Separators. But by If you can only afford a basic adding a dust separator at left shop vacuum, you can still cus- you can extend the cleaning tomize it to suit your needs and interval considerably. The dust requirements with a few accesso- separator is placed between the ries see Sources on page HEPA Filters.
As the box larger particles to drop out into a removes large on page 41 illustrates, HEPA filters separate container. They are sur- particles before they get to the filter. Several manufacturers. I make up my own wn hose using parts available from om spe- cialty woodworking sources.
Shop vacuums Electrical Controls. The he auto are noisy, but an switches on high-efficiency cy vacu- aftermarket muffler helps ums are also available as an after- to reduce some of the market accessory. You can read noise from the exhaust. An inexpensive speed control Filter Cleaning. Banging a some of the noise. Your vacuum m can be used if your vacuum is reusable filter against the side needs to have an exhaust port to so powerful that you have diffi- of the trash can sends clouds of attach them photos above.
I like to move the up attachment sticking to the to contain right back into the air. You can You could simply throw the filter shop vacuum to blow dust from also purchase fittings that adjust away or use a second shop vac- crevices and motors. Not all vac- the airflow with a sliding gate. Apart from Another option is the Tornado a feature I look for.
It cleans the dirty filter by Shop-Made Accessories. You can make a number of accesso- Any of these dust from the vacuum tank. I just just put your round, canister- ries to suit your shop vacuum upgraded hoses place an ordinary trash bag in the style filter in the Tornado Vac, that will make it more effective will make your tank and drape the opening over chuck the shaft in a drill, and give and easier to use.
Check out the shop vacuum the side. But until it fills, the trash it a quick spin. The dust cake dis- dust collector station on page 24 easier to use. Bag Sack is a device that posed of in the trash later. Already an indispensable tool you place inside the trash bag to Noise Supression.
General in the shop, the right selection of keep it open. Once the bag is full, purpose shop vacuums are any- features or accessories allow you I simply pull out the Bag Sack, tie thing but quiet. Aftermarket muf- to own a shop vacuum that suits up the bag, and dispose of it.
Auto Switch The vacuum is powered up when the tool is switched on. Whenever I attached my sander and one or more for the vacuum to the shop vacuum, I had to and another accessory. There is usually a These have one outlet fo for the tool programmed delay when the tool is sswitched off to clear Tool the vacuum va hose of all outlet dust and a debris. Since Sinc they rely on a current detection circuit to activate the vacuum, some low Vacuum power tools tool may not work with and accessory them.
In addition, a you have to receptacles be careful c not to exceed the th switch rating when both b the tool and the vacuum v are plugged in. Following the old workshop with a few editors around here to Where You Need Them. No matter how many clamps choose a solution or two that can For example, associate editor you have, the right kind of stor- work in your shop. While each Dennis Perkins has a dedicated age system can help keep proj- situation is unique, I want to assembly area between his work- ect assembly less hectic.
I talked touch on a few common themes. These are used more Look overhead for out-of-the- right where he needs them. In often while working at the bench. This easy-to-build cart has space for plywood, long boards, and all of your cutoffs too.
Pull up a seat, put on your thinking cap, and start the timer. This elegant chess set is the perfect way to hone your mind, and your woodworking skills. This versatile sea chest is just at home in your shop packed with tools as it is in a bedroom storing an extra set of linens. This grandfather clock takes design cues from the Prairie style of architecture.
Most hall benches live a quiet life of service, which is fine. But as you see here, that service doesn't have to be lived without style.
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