ShopNotes_052.pdf

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Issue 52

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Cutoffs

hen you think of a work-

bench, what often comes to

pususnw Donald B. Pesehke

EDIT^ Tim Robertson

ASSOCIATE EDITOR Begnal

ASSISTANT Eonon Brym Nelson

ART DlnEcroR Cary Christensen

SR. GRAPMIC DESlaNER Kurt SehLllt2

SENIOR lrrusrrumns Roger Reiland

Mark Higdon

anawfully long "wish list," and at one

point I began to wonder ifit was even

feasible. But when I mentioned the

idea to our designers, they had lots of

good suggestionsto make it work.

Knock-Down Workbench - If you

look at the front cover, you'll see how

our knock-down workbench turned

out. It's made from a single sheet of

3/41! plywood which reduces the cost

considerably. And the holes and slots

peppered across the benchtop pm

vide a number of

pennanentfixtwe A bench in a box. . . and a different clamping

in my shop for

Cmtih Diredm Ted Kralicek . Pmjsd Dmelope?-

Ken Munkel I Senim Pmjjt Desipr: Kevin Boylee

CREATIVE REIOUIICES

Prejat Coo7dinator: Kent Welsh . Shq Mmgw:

SteueCurtis.Shop CmRsmarSteveJohnson-Ssniw

Photopaphe? CrayolaEnghd

SPEUU WBUWITmNS

Eweutlus Edi2m: Doughs L. Hicks . Sr Oraphic

Nguye". Apd W. Janning, staeey L. Krull . Asst.

Edit.

"*: Joe kwh, Crak Rueg$qgez Joel A. Hesa

CIIICULAIION

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CIic Mdsiing Ad@ Kris Schlemer. Creative

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Mp: RebecesCunningham Pronz Mp: Rick Jm.

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WRPORITE IBYYICES

CmlmUw:Eabin Hutchson- Sr Accozmnta1U: Lam

Thomas *Accolints Payable: Mary Schultz. Acem&tr

R8cauo6le:MargoPetm.hodL)1~)1,:G~)1~)1rgeChmielarr

can remember.) hand tool. TWOsimple down" and stored

That's okay as So&iomfiOm in a box that YOU

longas I neverhave carry like a suit-

to move it around. But sometimes I'd ease. (Think of it as a bench in a box.)

like to be able to use a workbench Is it Sturdy? That sounds great.

outside the shop. Of course, dragging But is a knock-dew)?, bench sturdy

a massive bench out to the garage or enough? To find out, we conducted a

hack yard isn't very practical. So I highly scientific test - two of the

usually set up a couple of sawhorses guys climbed on top and stood on it.

to use as a makeshift worksurface. Fortunately, the bench was as solid

The only problem is there never and sure-footed as a mountain goat.

seems to be a good way to clamp Saw Handle - Another project in

things in place. So I often end up bal- this issue that provided aninteresting

aneing a workpiece precariously on challenge is making a replacement

the sawhorses, holding it with one handle for a carpenter's hand saw. I

hand, and mahga less than perfect bought the saw at a second-hand

cut with the other. store,and since thehandlewasinrough

What I needed was a small,portable shape, I decided to make a new one.

workbench - one that had a lot of I wanted it to look liea traditional

the same clamping features I'd come saw handle with a graceful, curved

to appreciate on my full-size bench. shape. That sounded simple enough.

Besides being portable, there were I'd just cut a chunk of wood to shape

a number of other requirements for and stick in the saw blade.

the bench. It had to be inexpensive But there was a eateh. The blade

and easy to build. Plus I wanted a fit into a very thin slot in the old

strong, stable bench that wouldn't tip handle that must have been cut by a

over. Then I added one last item to specialized tool (one I certainly didn't

my list. It had to "hock down" for have). So as it turns out, I took a

storage to makeit easyto canyaround. rather unorthodox approach to make

Well, it was starting to sound like a traditional looking handle.

options. Finally, it

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ShopNotes@I nSSN 10629696) is published blmonthly

(Jan., Maroh, May, July, Sept., Nor) by August Home

Publishine. 2MO G-d. Des Moines. IA 50312.

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PRINTED IN U.S.A.

ShopNotes

No. 52

mind is a classic, European-style

bench. Chances are it has a sturdy

base with lots of storage, a thick,

hardwood slab for a top, and heavy-

duty vises to clamp work in place.

There's no doubt about it. This

type of bench is a great addition to a

woodworking shop. But let's face it.

It's big and heavy, so it sits in one

place most of the time. (My work-

bench has been a

Designar Chris Glowacki . Oraphic Des-6: Vu

more years than I new twist to a traditional ,

Mmnognogr Jennie Enos . Wnog,mI~me Sup: Nancy

Opamtlas Dlreem Bob Baker - CusmS-CB

-~~~~~

PeriodicalsPostage Paid st Des Main-, 1.4 and ataddi-

tional maiiineof5ees.

~astmaster:-Sendchangeof address to ShqNofss, PO.

Bor3Tl03, Boone. IA 5W3T-2103.

subsrriptionQnastions7 Writeto:ShopNotesCustomw.

Setvice. P.O. Box842, Des Moines, IA603M-9961. Or call

1-8~333.5854, S:W am to 6:00pm, Curtrai ~ime, week-

davs FAX 515-283-0447

Features

Adjustable Miter Jig

This shop-madejig makes it easy to cut perfect 45'miters

on a radial arm saw It features a short and a long pair of

fences for different length workpieces, an adjustable stop

for consistent results, anda hold-down to make cuts safely

Radial

Arm Saw Tune-up 12

All it takes to improve the performance of your radial arm

saw is a simple tune-up. We show you seven quick steps

to producing smooth, accurate cuts.

Knock- Down Workbench 16

Whether you use this plywood bench to builda woodworking

Knock-Dawn Worlcbench page 16

projectora deck in the backyard, its three different clamping

options are sure to come in handy. Once you complete ajob,

~- ,

*.. :"

it only takes a minute to 'knock down" the bench for storage.

. -a

Cherry Saw Handle

The graceful curves and the carved wheat pattern of this

cherry saw handle resemble a traditional design. But to

simpliv the construction, we've taken a unique approach ,

to fitting the saw blade into the handle.

Chip Carving 28

You can add an old-fashioned accent to your saw handle

by using a chip carving knife to make stems of wheat. With

a little bit of practice and a few helpful hints, you'll be chip

carving like a pro in no time.

Departments

Readers' Tips

Our readers offer their own shop-tested tips dealing with

some of the most common woodwork~ngproblems

5ources 3 1

Mail-order sources and supplies to help you build the prqects

featured in ths issue

Chip Caning

No. 52

ShopNotes

A set of sawhorsesalways comes

#B x 1W' Fh

in handy - until you put them away.

Then they're a nuisance. The legs

snlav out thedre hard to stack and

&&take hpvaidespace.

(3%" x 56")

0% CLEAT"

So recently, I built a pair of

sawhorses that "knock down" for

storaxe. Besides savim space, these

sawhks can be a&&bled

BRACE

(sYZns

x l@h")

THICKNESS OF

STRETCHER

(or

$;;xgwr

- w

NOTE; ALL PIECES ARE

taken apart) in just a few seconds.

MADEFROM 1x4PINE

LEG

Jfyou look at the dra*

at right,

(5W x 55" rgh.)

I /

parts of this

sawhorse prevent It

from racklng. Plus

they prov~dea way

to knock down the

sawhorse for

compact storage

ifs easy to wehow this works, Each

sawhorse consists of a long stretcher

that fits down into a notch in two A-

shaped supports. (I used 1x4 pine.)

To prevent the sawhorse from

racking, there are four small cl~aats

near each end of the stretcher (two

on each side). These cleats are

spaced fa enough apart to form a

channel that fits down over the sup

ports and "locks" the stretcher in

place. (You can see this interlocking

connection in the photo above.) Both ends of the legs and braces to set a square on the angled end of

Once the cleats are glued and are mitered at a 15" angle. Also, to the leg andmark alinethafs equalin

screwed in place, ifsjust a matter of form the notch that accepts the length to the width of the stretcher.

making the two supports. Each sup stretcher, you'll need to trim the top After .brimming off the waste, just

port consists of two angled legs that inside corner of each leg at an angle, glue and screwthesupportstogether.

are held together with four braces (a as shown in the detail above.

LONG BRACE

(3W x 21")

long and short brace on each side).

An easywayto lay outthis angle is

Great Falls, Montana

Quick Tipe

shop. Adolph Peschke of Des Moines, caster is locked or not So P. A. Jones Terrence McGinty of Sums Bay, MI ()

IA cuts a scrap PVC pipe down its of Seattle, WA paints the "lock" lever removes the bottom from a plastic bottle

length and glues the halves together

difficult to tell If a A To make a 'fio1ster"foracordless drill,

red and the "release" lever green.

and screws the container to his bench.

ShopNotes

No. 52

x 5th %?)

K R Richardson

A Here's a simple pencil tray far your A At a Q

installing Hing

Installing the binges on a small

BQX used to be a hassle. I could

attach one leaf of the hinge to the

box eady enough. But locating the

mounijng holes for the other leaf on

the bottom of the lid was a pain.

One solution is to use hot glue to I

temporady fasten the hingeeO the

lid. The only problem isthe glue often

dries before you can align the lid on

the box. So I use a simple trick to

quickly and accurateiypositionthelid

and tu lay out the bolesfor the h'ie.

Start by mewing one leaf of the

binge to the box Then use hot glue

to attach small scrap blocks to the

frontand sidesof the lid, as shownin

the drawing. Note:These scrapblocks a dab of hot glue (detail 'a3 Then the mounting holes (detail 'b') . Note:

should stick down past the lid so quickly fit the blocks on the lid down &r removing the scrap blocks,

they fit snugly around the box. overthe box When you open the lid, sand any excessglue off the lid.

After shimming the leaf of the the leaf of the hinge is stuck in its

hingewith apiece of cardboard, apply proper location, so it's easy to mark

Joe B. Drane

Plastic Runner

Many of the jigs used on a table

saw have a runner that slides in the miter

gauge slot 7h,ia, these runners are made of

hardwood. But recenfiy I started using another typ

of material I like even better - plastic.

One nice thing about a plastic runner (like the one

shown at left) is it won't swell or shrink with changes in

humid& So %Slide6 sm1mIf1lywithout~11ding.

Finishing Fix -

Send iaYmr Sap Tip$

If you have a unique shop tip, we'd like

to considerfeaturingit in one or more of

our print or electronicpublications.

Well pay up to $200 for a tip we pub

lish. Just write down the tip and mail it

to ShopNotes, Attn.: Readers' Tips, 2200

Grand Ave., Des Moines, IA 50312. Or

FAX it to 515-282-6741, or send us an

e-mail at shopnotes@sbopnotes.com.

Please include your name, address

and daytime phone number in case we

It's easy to repair a small nick or

a scratch in a piece of furniture

that's already had a finish applied.

All it takes is a brown (or black)

permanentmarker.

After choosing a marker that most

closelymatches the color of thewood,

scribble the marker across the nick

andwipeoffthe excess. Note:There'z

no need to touch up the finish.

George Reici

Dayton, Ohio

Yqo, Guam

Plus,plastic

is readily available. Asyou can see in the photo atright, I

just cut a narrow stripfrom a plasticcuttingboard.

Jeny Lon&?

SZverhke. W&cmMZSZn

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