ShopNotes_013.pdf

mter Bit Storage Cabinet . Scroll Saw I

md Saw Blade Set-UD

SDROR Donald B. Peschke

~acurav~

metal parts, I was a bit apprehensive.

(I should have paid more attention in

my eighth grade metal shop class.)

SHEETMETAL. But armed with a

pair of tin snips and a pair of gloves, I

decided to try it once again. I soon

found that working with sheet metal

wasn't difficult. In fact, much of it was

similar towoodworking. Careful layout

andplanning.Anda bitofpatience when

cutting. That's all it takes regardless of

the material - metal or wood.

PUBLISHER'S STATEMENT. AS VOU

cided to design a smaller shop-built ver- may have noticed, the bottom half of

sion of aprofessional system. (Formore this page isfilledwith anofficiallooking

on this, seepage 14.) Like aprofessional

system, our version uses a special can-

ister (cyclone) to separate the large

chips from the fine dust.

But instead of buying an expensive

all-metal cyclone, we built our own. It's

a hybrid -part wood, part metal. The

woodworking part was easy. However

when it came time to making the sheet

EDITOR Terry J. Strohman

IIIMCI~IE

EDlmR Richard S. Peters

ustrrrwr rmmR Tim Robertson

co*mnaunwa sonmn Philip A. Totten

nlaEemn Ted Kralieek

run DIRE~OR Cary Christensen

ernttol trrurrarmm Kurt Schultz

aurmmmms Will Niskanen

Roger Reiland

Mark Higdon

~lom-n~a Crayola England

Ken Munkel

YIIIOR-IOWERI Jan Hale Svee

Kent Welsh

SWOPYI-ER Steve Curtis

mor rswmwmmn SteveJohnson

document. Every year the post office

requires we print a Publisher's State-

ment. It lets them know the number of

issues we send out and where they go.

The good news is that we're still

growing. The average single issue cir-

culation is up 129,000 from last year

Thank von. Without your supuort this

CI~UU1ION

PU.LISHIIIC IERYIEa

Associafa Editor Godon C. GaippepeS1: Graphic

Desip: Robert H. Whitmer. whit A1Cist.

Cheryl L. Cynor

COIPOIUT6 SEWICES

Conholk:RobinHu~on.Ae~~mting:

Thomas Bookkeqing: Julie Greenlee - Info.

Seruices MmUger:Joyee Morn. EM Pub. Go-

Laura

di&: Douglas M Lister - Adminin. Assis-

tants: Cheryl Scott, Julia Fish . Receptionist

Jeanne Johnson. Building Maint.: Ken GriBth

STATEMENT OF OWNERSHIP, MANAGEMENTAND CIRCULATION

(Required by 39 U.S.C. 3685)

1. Title of Publication: ShopNotes. la. Publieation No.: 10629696.2. Date of Filing: September 22,

1993.3. Frequency of issue: Bimonthly. 3s. No. of issues published annually: 6 (sin).3b. Annual

subscription price: $19.95.4. Complete mailing address of known office of publieation: 2200 Grand

Avenue, Des Moines, (Polk County), Iowa 503125306. 5. Complete mailing address of the

headquarters of general business offices of the publisher: 2200 Grand Avenue, Des Moines, Iowa

503125306.6. Full names and complete mailing address of publisher, editor,and managingeditor.

Publwher and Editor: Donald B. Peschke,2200 Grand Avenue,Des Moines, Iowa50312; Managing

Editor: Teny J. Stmhman,2200 Grand Avenue, Des Moines, Iowa 50312.7. Owner: Woodsmith

Corporation, 2200 Grand Avenue, Des Moines, Iowa 50312; Donald B. Peschke, 2200 Grand

Avenue, Des Moines, Iowa 50312.8. Known bondholders,mortgagees, and othersenulty holders

owning 1percent or more oftotalamount of bonds, mortgages orathersenulties: None. 9. (Does

not apply.) 10. Extent and nature of circulation:

Supervisor-JennieEnas. CustazarServiceRep-

reswziatiues: Jennifer Murphy, Joy Johnson,

Sara Kono, Ami Blanshan, Anna Cox, Tammi

Aldini, &ti Andrews, StephanieHagen

IlllPPlWG DEPlRlYEllT

Supervisor Jerry Carson .Fulfillmest; Gloria

Sheehsn, DonMeVey,Chuek Gahn, SylvkCarey

Average no. copies Average no. copies

eaehissue during of singleissue

preceding 12 months published nearest

to filing date

A. Total no. copies printed (net press run) .................. 279,983

B. Paid andlor requested ci~lation: .

1. Sales thmugh dealers,street vendors and counter sales . 14,745

305,000

2. Mail subscriptions (paid andfor requested) ............ 239,640

272,490

C. Total paid andiorrequested Ck~lati~n

.................. 254,345

294,Ml

oC;Pyasht l~bj

Wrndsmith Ct~~ti00.

All

by mail, carrier or other means, samples,

complimentary,adother 6ee copies. ........................ 25

rightlreserved.

Subrsiptions: SlgIe Copy, $4.95. One year subasrip-

tion (6issues).$18.95. ?b*o yeaml12 issues),S595 Can-

adaiForeign, add f5.W per yeap.

Second Clasll Postage Paidat Des Mcines, IA and

at addithnslokices.

E. Total distribution.. .................................. .254.370

294.661

F. Copies not distributed

1. Office use,left over, unaceomted, spoiled aRer printing . 13,941

2. Returns hm news agents.. ......................... 11,672

9,467

872

G. Total.. .............................................. 279.983

305.000

11. I eert* that the statements made by me above are mmtand complete

(signed) Donald B. Peschke, Puhlisher/Editor

ShopNotes

No. 13

S awdust. It's a problem for every

rolm Douglas L. Hi&

M~U~IN~

woodworker I know. It can cause

health problems. It clogs up ma-

chinery. And it eventually covers every-

thing in the shop (and often the rest

of the house) with a fine layer of dust.

For years, professional woodwork-

ing shops have used specially designed

collection systems to deal with saw-

dust. Unfortunately, these systems are

too large and too expensive for most

home workshops.

DUSTCOJAECITONSYSTEM. SOwe de-

cwrnv~

DESI~H ~tlrr~ro~

22,151

D. Free dis~bution

. .

Contents

Router Bit Storage Cabinet 4

You can both protect and organize your router bits by

building this handy storage cabinet.

5crolI Saw Blades 8

A look at the different types, styles, and sizes of blades

that give the best results when using a scroll saw

Band Saw Set-Up 10

changing the bladi onabandsaw is easy when you follow

these step by step instructions. We'll take you through

tracking, tensioning, and adjusting the blade guides.

Dust co//ectionsystem 14

This shop-made dust collector features a two-stage

system. The first stage removes large chips. And the

second stage filters out fine dust particles.

Cyclone

Plywood and metal flashing combine to make the first

stage of the dust collector - a cyclone that funnels

large chips into a roll-around chip bin.

Filter Box 22

By wrapping an inexpensive fabric around a simple

frame, you can form the second stage of the dust

collection system which filters out fine dust particles.

Pipe & Hook-Ups 24

All lt takes to connect your power tools to our dust collector

or your exfst~ngcollector 1s a system of pfpes and these

shop-built hook-ups

Shop 50lutions 28

Six Shop-Tested Tips: Toggle Clamp Stop Block, Shop-

Made Utility Knife, Measurement Tip, a Tip for Rubbing

Out a Finish, Sawhorse with Insert, and a Tip for lnstall-

ing a Strike Plate.

P/ywood Veneers 30

The appearance and cost of a sheet of plywood can

vary greatly depending on how the face veneer 1s cut.

50uRX5 31

Hardware, project supplies, and mail order sources for

the projects in this issue.

Dust Collector

page 14

No. 13

Protect and organize your router bits with this

sturdy storage cabinet. It features a unique bit

holding system and a handy pull-out drawm.

.IS--

s&t%a.

. ~.

This cabinet also has a door to joints are cut, dadoes are cut in

keep the bits clean and free from the sidesfor the shelves that hold

dust and dirt. And I added a pull- the bits, see Fig. 1. These dadoes

p-;.

out drawer inside the cabinet to are %''-wide and cut across the

store and protect large bits, full width (depth) of the sides.

. . . - wrenches, and other accessories.

.<;,: ~;$ .'$:?..

, ..-:.'

BACR. Next, to sealupthe rear

of the cabinet,I added a back (C),

see Fig. 1. It's just a piece of W-

ith the price of routerbits I started work on the Storage thick plywood that fits into 1/4" x

' 3

THE CASE

U these days, it just makes Cabinet by makhg the case. It's Y4" grooves cut in the sides and

sense to invest the time to pro- just a shallow box consisting of topbottom pieces, see Fig. lb.

ted them. This Storage Cabinet two sides (A) and a toplbottom ASSEMBLY. With the back cut

is designedto protect yourbits- (B), see Fig. 1. I cut these pieces to size, the case can be glued and

and keep them organized too. from ?$-thick stock and used box clamped together. When the glue

To keep from nicking sharp joints to hold them together, see dries, you'll need to plug the

cutting edges, the bits are spaced Figs. 1 and la. (If you haven't small square holes in the top and

apart and held upright in a pair of made box joints before, you can bottom of the cabinet left from e,

shelves, seephoto. There's even a find information and plans for a jig eutting the grooves in the sides.

unique system to hold the bits. in ShquNotes No. 8.)

(For more on this, see page 5.)

SHELF DADOES. Once the box to do this, see page 6.)

(Fordetailed instructionson how

DADOES FOR

SIDE

-----

TOPIBOiTOM AND SIDE5 ARE

ShopNotes

No. 13

CUT FROM Ye"-THICK STOCK

Shelves

After the case is assembled, the

next step is to make the shelves

that hold the router bits. These

shelvesfit intothe dadoesyou cut

earlier in the case sides.

m n, FPT. Theshelves (D) are

cut to length from 34"-thick stock

to fit between the sides. As for

the width, trim them so they end

up flush with the front edge, see

Fig. 2. (In my case, they're 33M

wide and 992 long.)

BIT HOLES. After cutting the

shelves to size, the holes for the

router bits can be laid out, see

Fig. 2b. But there's a problem

here. If you just drill holes in the

shelves and insert a bit, you may

not be able to get it out. That's

because humidity can cause the

wood to swell and 'locknitin place.

SLEEVES. TOprevent this from

happening, I used nylon sleeves,

see photo below. They're just ny-

lon spacers I found ata localhard- The size of each hole is deter- need. (A hardware kit is avail-

ware store. Since the nylon mined by the shank size of the able, see Sources on page 31.)

doesn't swell up like wood does, router bit, see Fig. 2a. ASSEMBLY. Once the holes are

your router bits will always slip If you have W-shank bits, drilled, the next step is to glue in

in and out easily. you'll need to drill $5'-dia holes, the nylon sleeves. To do this, I

TWO SIZES. Although the lay- see Fig. 2a. If they're $5'-shank squirt "instant" glue in each hole

out for the holes in the shelves is bits, drill S/s"-dia. holes. Note: Be- and insert a sleeve. Then to com-

the same (see Fig. 2b), the diame- fore you drill, it's a good idea to plete the case, glue and clamp the

ter of the holes may be different. first buy the nylon sleeves you'll shelves flush with the kont edge.

LOCATlONB ARE BAME

Materials

A Side5 (2) 1/zx441/q-13

B Top/Bottom (2) 1/2 x 41/4 - 10

C Back (1)

91/2 x 12% - 1/4 pl~od

D Shelves (2)

E Drawer Ft,/Bk. (2) 1/4 x 2% - 815/r6

P Drawer Sides (2) 1/4 x 222 - 3%

G Drawer Bottom (1) 3V2 x 81fi6 - 1/4 plywood

H Door Stiles (2)

x l1/z - 7?/4

I Door Rails (2)

J Door Panel (1) 7?/4 x l@/4 - V4 plywood

K Cabinet Cleat (1) 1/4 x 222 - 9

L Wall Cleat (t) 1/4 x 2% - 8I5/r6

(1) 3/4''-dia. Wood Knob w/screw

(1) %6"-dla. Magnetic Catch w/sorew

(2) ll/zl'x l1/4"Braes Hinges w/screws

h" ID, @"-long Nylon Spacers

%"ID, M1'-longNylon Spacers

To make it easy to slip bits in and out, nylon

sleeves fif into holes drilledin each shelf. This

way when the humidity changes, the wood

can't swell and "lock" the bits in place.

No. 13

9/4 x 374 - 9h

2)z x 11/2 - 13

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