Professional Documents
Culture Documents
A Simple
Solution for
Straight, Flat Stock
A Better Way
to Buy Sheet Goods
Precise Dadoes
Clever Tips & Tricks
Clear The Air
Great Dust Collection Options
Departments
Readers’ Tips _____________________ 4
router workshop
Tip & Tricks for Precise Dadoes ________ 8
Learn the key details for routing accurate
dadoes at your router table.
Trim End Grain page 30 jigs & accessories
Rockler T-Track Tabletop _____________ 10
Every shop needs a great worksurface. This new
system from Rockler has a lot of great features.
materials & hardware
Better Way to Buy Sheet Goods _______ 12
When it comes to working with sheet goods,
small project panels are a great solution.
hands-on technique
5 Keys to Trim End Grain _____________ 30
Follow these sure-fire tips for making accurate
cuts and fine-tune end grain surfaces.
ShopNotes.com 3
Tips for
Your Shop
Cutoff Storage Bin
I used to spend too much time searching for the
right dowel or cutoff. To solve the problem, I came
up with the storage system you see here. Using
4"- dia. thinwall, sewer and drain pipe available at
THE the home center, this bin provides compartmented
WINN storage for cut-off strips of differing lengths down
ER!
to 12". The design allows me to quickly and easily
find whatever piece I’m looking for.
Cut & Assemble the Tubes. To make the stor-
age system, you will need five 10' lengths of 4"-dia.
pipe. Start with the longest length first (48") and
then cut each length 2" shorter than the previous
one. (The last length will be 12".) This produces 19
individual tubes. Then use a band saw or a recipro-
cating
c g saw too cut the tops at a 45o angle.
The 48" long pipe
is the center tube.
Each progressively
NOTE: CUT TOPS
OF TUBES AT 45˚ shorter length is
fastened to it or the
adjacent tube with
1 Make a Base. Cut a piece of 3⁄4" plywood to the
⁄2" panhead sheet
#8 x !/2" Ph metal screws, in a dimensions shown for the hexagonal base and six
SCREW
spiral configuration pieces of 3⁄4" plywood for the base sides. Screw the
somewhat like a sides to the base using woodscrews and set the tube
spiral staircase. assembly inside. Drive screws through the sides into
4" SEWER & the tubes to hold the
DRAIN PIPE
assembly together.
1 Finally, mount cast-
BASE SIDES 12@!/32 ers on each corner
#8 x 1" Fh (2#/4" x 11!#/16" - #/4" Ply.)
WOODSCREW
for mobility.
Now I can place
BASE 22!/2 each cutoff in the
(25!%/16" x 22!/2" - #8 x 1!/2" Fh
#/4" Ply.) WOODSCREW appropriate tube
so each piece is vis-
ible. And I spend a
lot less time finding
60+ exactly what I need.
2" CASTERS ON #8 x 1!/2" Fh Keith Weston
EACH
EAC H CORN
CORNER
ER WOODSCREW
25!%/16
Beverly, MA
to the clamp body PAD NOTE: SIZE Single copy: $4.95 U.S. / $6.95 CDN
(1"-DIA. DOWEL CLAMP ARM LENGTH Canada Post Agreement Number 40038201.
with a nail. CUT IN HALF) TO SUIT PROJECT Send change of address information and blocks of undeliverable copies to:
P.O. Box 881, Station Main
Markham, ON L3P 8M6
Canada BN 84597 5473 RT
Periodicals Postage Paid at Des Moines, IA and at additional mailing offices.
ShopNotes.com 5
1#/4
!/4"- WIDE x TOP
!/4"- DEEP WASHER FRONT #/8
RABBETS SIZE HOLE
SIDE #/8 TO FIT HOSE
#8 x 1" Fh
WOODSCREW
SIDE BOTTOM
(6" x 6" - #/4" Ply.) (6" x 6" - !/4" Hdbd.) Quick Tips
FREE TIPS
BY EMAIL
Now you can have the
best time-saving secrets,
solutions, and techniques
sent directly to your email
inbox. Just go to
ShopNotes.com
and click on
“Sign Up for Free eTips” { Charles Lerner of Indianapolis, Indiana, places his random-
You’ll receive a new tip by orbit sander on a bag of sand to keep it from vibrating all over
email each week. his workbench while it spins down. The bag can also be used
to stabilize other odd-shaped items.
!/2
1!/8
4!/2
{ By using chalk to mark the last grit used on the piece he just { Jeff Csisek of Renton, Washington,
ngton,
finished sanding, Stephen Carroll of Covington, Washington, keeps cleans out used, individual serving
erving
track of where he is in the sanding progression in case he gets coffee cups, removes the bottom,, and uses them to
interrupted. Chalk sands off much easier than pencil. filter small quantities of dyes, stains,
ains,
i and
d finishes.
fi i h
ShopNotes.com 7
the router table fence. The other may not be able to position the measure and clamp a stop block
option is to use a miter gauge, fence far enough from the bit. in place. The stop block should
if your router table is equipped Using a miter gauge is another be positioned on the right side
with a miter gauge slot. option to consider, as in the of the miter gauge fence. Here,
The simpler of the two is using photo below. I like to attach a the rotation of the bit pushes the
the fence. The main photo on long auxiliary fence to provide workpiece against the stop block.
the facing page shows the setup. support and give me a place to Making Cuts. Careful setup
The location of the dado is deter- attach stop blocks for identical goes a long way toward get-
mined by the distance from the cuts. The fence also backs up the ting smooth, accurate dadoes.
fence to the edge of the bit. workpiece to control tearout. But once you’re ready to hit the
You’ll notice I’m using a wide, Setting Up. Each of these power switch, there are still a few
MDF push block. This helps keep options influences how you set pointers to keep in mind.
the workpiece square to the fence up for making a cut. The upper Start Easy. To prevent the bit
and also prevents tearout. left photo shows how to use a from causing chipout at entry,
Using the fence to rout dadoes workpiece as a setup gauge. ease the workpiece iece into the bit.
in the middle of a long workpiece With a miter gauge, setup is You can speed up the feed rate
can be problematic. As the dis- more straightforward. You start once the bit is engaged.
ngaged.
tance from the bit increases, it’s by cutting a notch in the auxiliary Cutting Depth. h. Resistance
much harder to guide the work- fence with the bit you plan to use. from the bit can n cause the
piece along the fence. And you Now you can use the notch to workpiece to ride de up caus-
ing an inconsistent
stent depth
of cut. Firm downward d
pressure helps get the best
results. Making a “cleanup” ”
pass (without changing any y
settings) smoothss out the dado.
After the Cut. Resist the urge to
pull the workpiece ce back across the { Clea
Clean
Cl
lea
ean Cuts.
Cuts
Cuts
ts.
bit. Any subtle shift
hift in the work- Follow some
piece can lead to o a miscut or the simple steps and
workpiece grabbing.
bing. Instead, get you can count on
in the habit of sliding
liding the work- creating smooth
piece away from the push block dadoes every time.
or miter gauge once the cut is
complete. Then retract the guide.
If necessary, reposition the work-
piece for a cleanup pass.
It won’t take long to master cut-
{ Use the Miter Gauge. A miter gauge is an effective tool for ting dadoes on the router table.
guiding a workpiece when cutting dadoes. A long auxiliary fence And I’m sure it’s an approach
provides tearout control and increases workpiece support. you’ll turn to time and again.
ShopNotes.com 9
versatile
T-Track System
Take a look at the ultimate system for clamping
and assembling your projects.
T-track has countless uses in the From there, they offer a whole all-around woodworking but it’s
shop. It’s a quick and easy way host of accessories. And the even more useful for clamping
to complement a worksurface or beauty is, you can still make your and assembly.
shop jig by providing a method own jigs and fixtures to fit the The tabletop is a full 11⁄8" thick
for attaching clamps and other system using readily available with a melamine coating on both
fixtures. So when Rockler came T-track hardware. sides. This helps to keep glue
out with the T-track system you T-Track Tabletop. As shown from sticking to the surface when
see above, I had to take a look. above, the T-track tabletop is gluing up a project. The top is
The Rockler system capitalizes everything the name suggests. banded with vinyl edging.
on the usefulness of T-track. The It makes a great worksurface for The top measures 28" x 40"
foundation of the system is the with three
th long T-tracks and two
T-track tabletop.
etop. Push rod short ones
o recessed into the top.
It’s easy to mount it to Rockler’s
Shop Stand
St or build your own
stand for
fo it. You can also place it
Handle on your benchtop as needed.
> Adjustable.
The
e Auto-Lock Tension
ACCESSORIES
Clamp
amp makes adjustment As I m mentioned, a range of
securing a accessories
accessori (sold separately) are
workpiece
ce a snap. designed with the T-track table in
Locking knob mind. Th
The most innovative one is
Clamp head the clamp shown at left.
Flange Bench
bolt Cookie
Riser
{ Elevating. The Bench Cookie Plus includes a threaded insert { Mounting Plate. For an endless variety of clamping
that allows you to fix the Bench Cookie on top of a 2"-high riser. The options, the versatile mounting plate you see here
risers include the bolt used for fastening to a T-track. allows you to use a toggle clamp on a T-track.
ShopNotes.com 11
tips for
buying
Sheet
Goods
Versatile panel options eliminate one of
the back-breaking hassles of plywood.
4'x8'
(Full size) Using plywood for building cabinets the shop, you’re faced with the task
and other furniture is a great way to of breaking it down into project parts.
create strong, good-looking projects. That’s easier said than done.
Lumberyards and home centers are Besides the added expense of buying
stocked with sheets of plywood in full sheets, storing the leftover pieces
a range of wood species. What they can be a challenge in a small shop. It’s
don’t have in stock, they can often all too easy for the plywood to get dam-
2'x8'
order. And using sheet goods is usually aged before you need to use it again.
much less expensive than building the I’ve found a few alternatives to
entire project out of hardwood. buying and handling full sheets of
Those are all big pluses. But the catch plywood and other sheet goods. And
is you’re usually limited to buying full that’s good news for my back.
4'x4'
sheets at a time — even if the project Project Panels. One new solution
doesn’t call for that much material. to this problem is offered by Colum-
A 4'x8' sheet of plywood is heavy bia Forest Products. Working with
2'x4' and awkward to transport. Once in Home Depot, they offer Project Panels.
Poplar
< Sizes.
Project Panels Maple Walnut Cherry White Oak Red Oak
come in four handy sizes.
ShopNotes.com 13
View
ew D
Details
al FOR CLARITY SIZED FOR A KREG K5
POCKET HOLE JIG
OVERALL
VERALL
A DIMENSIONS:
M O
33⁄8"W
13 W x 131⁄2"D x 1113⁄16"H (STORED)
R STOP POSITIONS
3111⁄2"W
W x 131⁄2"D x 71⁄2"H (IN
N USE)
E WORKPIECE FOR
ACCURATE, REPEATABLE
DRILLING
SLIDING INSERT
PROVIDES ADDITIONAL
WINGS FOLD OUT DURING WORKPIECE SUPPORT
USE THEN FOLD UP FOR
EASE OF TRANSPORT AND
STORAGE (INSET PHOTO, WINGS SECURED TO
OPPOSITE PAGE) BASE WITH KNOBS LOCK
CONTINUOUS HINGES SLIDING INSERT
IN POSITION
HANDLE LOCKS
DRAWERS AND
WINGS IN PLACE FOR
EASY TRANSPORT
MACHINE
SCREWS ACT AS
DRAWER STOPS
DRAWERS
ASSEMBLED
WITH SIMPLE
RABBET JOINTS
ShopNotes.com 15
CASE !/4
BACK
CL
A
TOP
VIEW CASE
SIDE
CASE
BOTTOM
B
CASE BOTTOM
(12" x 9!/2" - !/2" Ply.) c. CASE
CL TOP
NOTE: THREADED INSERTS MAY
NEED TO BE FILED FLUSH WITH A !/4"-20
SURFACE AFTER INSTALLATION CASE SIDE !/8 THREADED
(12" x 2!/2" - !/2" Ply.) INSERT
CL
b. #/8 CL SIDE
VIEW CASE FRONT
CASE 2 #/8
SIDE VIEW
TOP
CASE
CASE SIDE BOTTOM
building the storage as you’re drilling pocket holes. and the one side of the case that
Wings
Plus, the stops help you consis- faces toward the outside. I’ll talk
tently locate the holes on mul- more about the inserts later.
tiple workpieces. There’s one more task: The
Two Cases. Figure 1 will get case back fits into dadoes cut
The workstation consists of a pair you started on the cases. They’re into the case sides, top, and bot-
of folding wings, each of which identical, so you can cut and tom, as shown in Figure 1a. Then
is nothing more than a case that assemble all of the parts for both assemble each case with glue.
surrounds a small drawer. The cases at the same time. Simple Base. Connecting the
drawers are convenient for stor- I cut all of the parts to size first. two cases is a plywood base (Fig-
ing screws and other items you’ll As you can see in Figures 1 and ure 2). I cut a pair of dadoes for
want to keep on hand. On top of 1b, the top has a wide groove for the hardwood risers that support
each wing is a sliding stop assem- the sliding stop assembly. Before the Kreg K5 pocket hole jig.
bly. It serves two purposes. First, assembly, it’s a good idea to to To attach the cases to the base,
it helps support the workpiece install threaded inserts in the top I used a continuous hinge, as
a. FRONT VIEW
FIGURE
2 #/4
b. SIDE VIEW c. FRONT
VIEW
CL CASE #6 x #/8" Fh
BASE WOODSCREW
!/8 #/16 #/32
LEVELER
CONTINUOUS SHANK HOLE AND BLOCK
CONTERSINK FOR #8 BASE
HINGE
(1!/2" x 12") WOODSCREW BASE
45°
CHAMFER
#/32" #/4
CHAMFER
d.
E
LEVELER
3&/8 BLOCK !/2
D !/4"-20 x !/2"
BASE
Fh MACHINE
SCREW
FRONT VIEW
(12" x 12!/2" - !/2" Ply.) LEVELER BLOCK
(&/16" x 1" - 2")
16 E ShopNotes No. 137
DRAWER
CL BACK
DRAWER BOTTOM !/8
(7&/8" x 10#/4" - !/4" Hdbd.) 1
H F CL
G
3%/8
G
%/16"-DIA. G
F DRAWER FRONT/BACK POSITION
DRAWER DRAWER SIDE (!/2" x 2!/4" - 8#/8") DIVIDERS AS
PULL (!/2" x 2!/4" - 11) NEEDED
b. SIDE VIEW d.
LONG DIVIDER
1!/2"-DIA. ROSE
!/4
KNOB WITH !/4"-20 x 1!/2"
CAP SCREW
TOP VIEW
CL
3!/2
illustrated in Figure 2c. I set compartments when the wings The short dividers span the width
up the table saw to cut a shal- are folded up for storage. of the drawers. The long divid-
low rabbet on one side of the The sides of the drawers fit ers fit front to back. Test the fit of
case opposite the side with the into rabbets in the fronts and each piece in the drawers before
threaded insert. This provides backs. And don’t forget to cut cutting the notches for the joinery
a mounting surface for one leaf a groove in each piece for the that interlock the dividers.
of the hinge. With the same saw drawer bottom. A dado blade in the table saw
setup, it’s easy to cut a rabbet on You can see in Figure 3 that the makes quick work of cutting the
opposite edges of the base. drawers have removable divid- notches in the dividers (Figure
After attaching the two cases ers. So you’ll need to cut dadoes 3). And by stacking like parts
to the base with the continu- in the drawer pieces for them. together, you’re guaranteed
ous hinges, add a simple leveler Before assembling the draw- that all of the notches will align.
block on the outer, bottom face ers, drill a couple of holes in the
of each case. This helps keep the drawer front for the drawer pull.
case tops parallel when using the On the back, a pair of flathead
workstation (Figure 2b). machine screws act as stops to
The leveler blocks are made flush out the drawer with the
from hardwood, drilled and front of the case. Drill and tap for
tapped for a machine screw, as the screws, as before (Figure 3a).
in Figures 2b and 2d. A metal tap A studded knob through the
works great to cut the threads. threaded insert in the case side
After gluing a block to each case, engages a hole in each drawer
install the screws. to lock it in place. To make the
Drawers. As I mentioned, a drawers interchangeable, slide
small drawer fits into each case each drawer into both cases. Levelers. A
(Figure 3). The woodworking Mark the hole locations on both flathead screw
to make the drawers is pretty sides of each drawer with a drill levels the wing to sit level
standard fare. I sized the drawer bit through the threaded insert. on the benchtop. To make the
sides, front, and back for a Dividers. The hardboard threads, refer to Shop Short
snug, but sliding fit in the case. dividers are easy to make. The Cuts on page 33.
This helps keep screws in their first step is to cut them to size.
ShopNotes.com 17
STOP
(%/8" x 1#/4" - 5") !/4" CHAMFER
L ON ENDS
NOTE: REFER TO
SHOP SHORT CUTS
a.
ON PAGE 32 FOR #/32" CL KREG
MAKING STOPS CHAMFER MINI-TRAK
!/8
STOP
FENDER
WASHER
!(/64 SLIDING
NOTE: SLIDING INSERT
INSERT SETS
SLIGHTLY PROUD
OF CASE TOP SIDE VIEW
K
SIDE VIEW b.
SLIDING INSERT !/4"-20 x 1"
(#/4" x 4" - 9!/2") HEX BOLT
!/4" x 1!/2" O.D.
FENDER STOP
WASHER
@#/64 #/8 1
adding the final SLIDING
INSERT
Details #6 x !/2" Fh
WOODSCREW
CL
#/8 CASE TOP
The last things to add to the Each insert is a wide, upside- just a tad above the surface of
workstation include a sliding down T-shape made from hard- the case. This guarantees that the
stop system, knobs, washers, wood. I made both inserts from locking knobs and fender wash-
and a handle. Finally, you’ll cap one long blank. ers engage the insert to lock it in
it off by adding the pocket hole After planing it to thickness, place during use and for storage.
jig. You’ll build the pair of sliding you can begin shaping it. Cutting After installing the T-track,
inserts and stops first. the rabbets is easy to do with a chamfer each end of the insert
Sliding Inserts. The sliding dado blade. That’s how I also cut and install it with knobs and
inserts fit into the wide grooves a centered groove for the T-track. fender washers. It should slide
in the top of each case. You can The bottom of the wide rab- smoothly in the case’s recess.
see how they work in Figure 4. bets along each edge should sit A Pair of Stops. The two hard-
wood stops come next. They
FIGURE
5 each feature a key on the bottom
that prevents them from rotat-
#7 x 1!/4"
POCKET HOLE NOTE: MOUNT JIG TO ing in the T-track when installed.
SCREW RISERS WITH #7 x 1!/4"
POCKET HOLE SCREWS Because the key is so narrow, I
1!/2" BACK FROM
KREG K5
FRONT EDGE had to come up with a way to
POCKET HOLE make the stops safely at the table
JIG
saw. Shop Short Cuts on page 32
1&/8 will give you the details.
45°
In a nutshell, you’ll form the
a. two keys from one blank that’s
NOTE: JIG SHOULD extra wide and long. After shap-
M BE FLUSH WITH TOP ing them, drill holes for the hex
45° OF SLIDING INSERT
bolts and install them onto the
T-track on the sliding inserts, as
1 #8 x 1!/4" Fh
WOODSCREW shown in Figure 4b.
RISER Risers. You’re finally to the
M FRONT point where you’re ready to
RISER VIEW mount the Kreg jig. It’s attached
(#/4" x 2#/8" - 12")
to a pair of hardwood risers that
ShopNotes.com 19
Salvage your
warped boards
with this no-fuss
planer sled. { Plane Thin Stock. Though its primary purpose is planing warped
boards, you can remove the levelers to plane thin stock as well.
It would be wonderful if every run it through the planer. How- In the past, I’ve solved this
board we bought was perfectly ever, if the board is too wide for problem by building a sled and
straight and flat, and stayed the jointer, the first inclination stabilizing the board with shims
that way. Unfortunately, warped might be to just run it through and hot glue or screws. This
boards are a challenge wood- the planer. If you do, you’ll end proved to be a tedious and time-
workers encounter all too often. up with a smooth board that’s consuming process, so I came up
But if the board isn‘t warped too still warped. That’s because the with this planer sled.
badly, it can usually be salvaged. pressure rollers on a planer will Sled Features. The sled sup-
Generally the first step when flatten the board while it’s going ports the board so it doesn’t flex
preparing a board is to flatten through, and the board will just under the pressure of the feed
one face on the jointer, and then spring back after it’s been planed. rollers. Mine is sized to fit a 12"
EASE CORNERS
FIGURE
1 NOTE: SPACE SHORT FILLER STRIPS
EVENLY ALONG THE BOTTOM
WITH SANDPAPER
TOP
(9!/4" x 48" - !/4" Hdbd.)
D SHORT FILLER
(#/4" x 1#/4" - 5!/4")
C
B C
C
C
C B
LONG FILLER
C (#/4" x 1#/4" - 48")
C
C
NOTE: SIZE
THE BOTTOM
TO FIT YOUR
PLANER
A
BOTTOM
(12#/8" x 48" - !/4" Hdbd.)
!/4 TOP
END VIEW
BOTTOM
1!#/16 LONG LONG
FILLER SHORT FILLER FILLER
ShopNotes.com 21
Levelers
(3" x 11#⁄4" - !⁄4" Ply.)
F
SLIDE BLOCK
(1" x 1!⁄2" - 3")
E
The leveler assemblies provide
the flexibility to use the sled with
almost any board that will fit WAXED
PAPER
your planer. Each assembly con-
sists of a sliding base that can be
positioned anywhere under the
!⁄4"-20 x 1!⁄2"
board, a leveler bar to support Ph NYLON
THUMBSCREW
the board side-to-side, and two
NOTE: EASE
handwheels to adjust the height ALL CORNERS
WITH SANDPAPER DRILL AND TAP FOR
of the bar at each end. The leveler !⁄4"-20 x 1!⁄2" Ph
assemblies simply slide onto the NYLON THUMBSCREW
NOTE: REFER TO
SHOP SHORT CUTS SLIDE
TO MAKE HANDWHEELS BLOCK
SECURE SCREW IN
SLIDE BLOCK SLIDE BLOCK WITH EPOXY
Planer Sled
ALL LEVELER BARS
DOWN TO BASEPLATE
ShopNotes.com 23
EASY-ACCESS UPPER
COMPARTMENT ADDS
EXTRA STORAGE
TO YOUR SHOP
WEATHER
STRIPPING ANGLED
BAFFLES DIRECT
DEBRIS INTO
FRONT PANEL YARD WASTE BAG
SECURED WITH
SCREWS FOR
EASY REMOVAL SMALL WINDOW
LETS YOU KNOW
WHEN TO EMPTY
HOPPER
SHOP VACUUM
FILTER STAYS
CLEAN AND
RUNS MORE
EFFICIENTLY
A FULLY
ENCLOSED
CABINET
SLIDING GATE ELIMINATES
LETS DUST DUST CLOUDS
AND CHIPS WHEN
FALL INTO BAG EMPTYING
HOPPER
To download a
cutting diagram for
the dust collector, YARD WASTE
go to: BAG MAKES FOR
EASY DISPOSAL
ShopNotes.com OF SAWDUST
ShopNotes.com 25
Cabinet
sized to hold a commonly avail- cut at the table saw.)
able yard waste bag. You can A hand-held router and a
empty the hopper into the bag straightedge guide make a good
without raising a cloud of dust. combination for cutting the dado
One of the nice things about this Figure 1 shows the general joints. It’s a good idea to measure
system is that everything is con- structure of the cabinet. You can the plywood to find a bit that
tained in a space-saving cabinet. see that it goes together with matches the thickness.
The cabinet is divided into four fairly simple dado and rabbet The rabbet along the back edge
compartments. Up top, you’ll joints. What makes things a little of the sides requires a different
find the cyclone unit behind the out of the ordinary is that the approach, as shown in Figure
right door. The left door covers sides and back are pretty long. 1c. Here, you can use a bearing-
a storage compartment for vac- So instead of taking the parts to guided rabbeting bit to do the job.
uum accessories or other items. the table saw like I usually do, I A Few Details. I want to take
The middle compartment in turned to portable power tools to a moment to look at a few details
the cabinet is the collection hop- handle most of the work. in some of the cabinet pieces. First
per. The chips and other debris I used a circular saw to cut the off, the top, bottom, and dividers
fall from the cyclone into this sides and back to size. (The top, are all the same size. Except for
sealed chamber. bottom, dividers, partition, and the bottom, the other panels need
some additional work.
FIGURE NOTE: HOLES
1 ARE 3"-DIA. The top and upper divider
have a centered dado to hold
the partition, as in Figures 1 and
B CL
5!/4 1a. You also need to drill some
TOP
(13#/4" x 23") 5!!/16 large holes. These accommodate
the connections for the cyclone.
B UPPER DIVIDER
(13#/4" x 23") I used a hole saw and a heavy-
duty hand drill.
NOTE: BACK C 8!!/16
IS !/4" PLYWOOD.
PARTITION
ALL OTHER
PARTS ARE #/4" (13#/4" x 14!/2") CL a. !/4
PLYWOOD
5!!/16 A TOP #/4
CL
SIDE
(14" x 72")
PARTITION
LOWER DIVIDER !/4 SIDE
3!/4 (13#/4" x 23")
B
SIDE VIEW TOP FRONT
VIEW
3#/8
NOTE: DRILL
14#/4
SHELF PIN HOLES
AFTER GLUING UP
THE CASE
b. !/4
#/16
LOWER DIVIDER
1
1#/4 2
2
2
SIDE A E SIDE
BACK FRONT VIEW
(23!/2" x 68#/4")
1!/2 2 BACK
4 1!/2
2
NOTE: CENTER
DIVIDER MORTISE ON MORTISE
LOWER FOR HINGE
COMPARTMENT
OPENING
35#/4
c. PARTITION !/4
B
BOTTOM
(13#/4" x 23")
!/4
BACK
D TOP
TOE KICK VIEW SIDE
(3!/4" x 22!/2")
2
3!/4
I
GATE
(24" x 15!/2")
CHUTE SIDE
(3" x 10!/4") c. SIDE VIEW
L B G
F
NOTE: PLATE IS CHUTE SIDE
#/4" PLYWOOD.
GATE AND STRIPS 2
ARE !/4" PLYWOOD
K
1
CHUTE BACK !/4"
(4!/2" x 17#/4") L #/8 CHAMFERS
#8 x 1!/2" Fh
a. WOODSCREW
J !/4 CHUTE
PLATE CHUTE BACK
CHUTE FRONT FRONT
CHUTE (3" x 17#/4")
GATE SIDE
2#/4
CHUTE
BACK b. BACK TOP VIEW 3!/8
ShopNotes.com 27
enclosing the
Cabinet
a set of angled baffles on three angle of the rear baffle and the
sides of the opening. angle of the side baffles.
The rear baffle is the first and I used a table saw to make this
simplest to make and install. cut. Figure 3b helps you set the
Just a bit of work is left on the It has a 45° bevel along each miter gauge and blade angle.
hopper before you can close it in. edge, as you can see in Figure 3. After cutting the miter, tilt the
After that, building a few doors Clamping this piece would be a blade back to 90° and trim the
wraps up the woodworking. challenge, so I used brads to fix baffle to final length. For the other
Then you’ll be ready for install- its position while the glue dried. side baffle, you need to set the
ing the cyclone and making the The side baffle pieces start out miter gauge to the opposite angle
airflow connections. the same as the rear piece, with and use the other miter gauge slot.
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. This takes into account the empty the hopper — once the
dust gets halfway up the win-
4 LOCK RAIL
(1#/16" x 17#/4") a.
dow is a good time. The glass is
set in a rabbet and held in place
R
with L-shaped glass stop, as illus-
PAPER 2
trated in Figure 3c.
YARD WASTE
BAG In case I need to open up the
4
3!/8 hopper at some point to clear a
4#/4" HANDLE LOWER clog, I didn’t glue the front panel
DRAW LATCH W/SCREWS DOOR
W/SCREWS in place. Instead it’s held with
screws. To maintain a good seal, I
Q
LOWER wrapped the edge with adhesive-
NOTE: DOOR DOOR backed weatherstripping.
IS MADE FROM (24" x 32!/4")
#/4" PLYWOOD. SIDE Lower Door. The three doors
LOCK RAIL IS
MADE FROM VIEW on this project are all pretty
#/4"-THICK straightforward “slab” doors.
HARDWOOD
b. LOWER
But there are still a few things
about each one that deserve some
!/4 DOOR
attention. On the inside face of
SIDE LOCK
the lower door, there’s a rail with
VIEW !/4
RAIL a tongue cut on one edge (Fig-
ure 4b). As I mentioned earlier,
this works with the groove in
LOCK RAIL PRESSES
BAG INTO GROOVE IN
CHUTE FRONT
28 ShopNotes No. 137
6 2" PVC
(LONG SWEEP) 2" PVC a. WALL
STREET ELBOW (LONG SWEEP)
ELBOW
2" TO 1.5" PVC
REDUCER #/4" x 8" TOP TO
HANGER VIEW TOOL
STRAP
NOTE: ANGLE
TOOL INLET PIPE
2" PVC PIPE TO RUN
(3" LONG) AGAINST WALL
#8 x !/2" Rh
WOODSCREW
2" PVC
45° ELBOW
VACUUM
HOSE
ShopNotes.com 29
5
Trimming End Grain
tips for
block works just as well here as on use shims to fine-tune the joint. control tearout. I also moisten the
the table saw. But there’s another In the example above, I set the end grain with mineral spirits.
simple but effective technique I miter gauge to 45°. 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. the angle of the workpiece. plane so that the wood is sup-
You start by lowering the blade Where you place the shims ported on the back side, as you
(without turning on the saw) and depends on where you need to can see in the photo. You’ll know
butting the workpiece against the remove material. 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.
tion as you raise the blade back up. shims between the miter gauge Cutting across end grain can
Now make a slow and steady and workpiece on the side closest be tricky, but it doesn’t have to
cut. The amount you trim is to the sander (upper left photo). trip you up. I’m sure that one or
equal to the amount that the teeth Place the cards on the opposite more of these tips is sure to make
extend past the saw plate, as you end of the workpiece to close a it onto your list of techniques for
can see in the inset photo. This joint with a gap at the point. tackling tough cuts.
method provides a built-in limit, Glued Joints. I prefer to trim
so you can’t remove more than individual parts before they’re
just a hair with each cut. glued into larger assemblies. 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. that joints come together fully.
Fine-Tune Miters. One of Through dovetails and box joints
those tasks is trimming miters. (like the ones shown in the upper
In this case, your goal isn’t nec- right photo) are good examples.
essarily to shorten the length of When it comes to make the sur-
a workpiece as it is to adjust the faces flush, it’s too easy to round
angle so that the piece fits well over the joints with a sander. So
with the mating part. instead, I use a small block plane.
I use a disc sander to take off Since the parts are glued up,
controlled amounts of material. getting a clean cut is my main
Although you could hold the part concern. There are a few things
freehand, I find a miter gauge that can make that a certainty.
gives me more consistent results. First, set the plane for a fine cut. { Score the Edges. 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.
ShopNotes.com 31
Shop
Short Cuts
Hinge NOTE: JIG PARTS
Mortise Jig #8 x 1!/2" Fh
ARE MADE FROM
#/4" MDF
WOODSCREW
Cutting several mortises for GAP MATCHES
THICKNESS OF
hinges, like those on the dust col- WORKPIECE
lector station (shown on page 24), BASE
(3!/2" x 12")
involves several aspects. Each
mortise should be sized accu- BASE
(3!/2" x 12")
rately, cut cleanly, and located
consistently on the project.
While there are a number of SPACE BETWEEN LONG FENCE
BASES EQUALS (3" x 8!/2")
ways to get the job done, the jig
LENGTH OF HINGE
shown here does all these things SHORT FENCE
without being too complicated. (3" x 5!/2")
Creating the keys on the stops for the sliding insert on the pocket KEY FITS INTO
T-TRACK TO
the pocket hole workstation (page hole workstation’s T-track. PREVENT ROTATION
14) involves a couple of steps. The Next, lay out the length of each
STOP
drawings below highlights the key on the blank, accounting for (1#/4" x 5")
T-TRACK
process while the right drawing the saw kerf. Drill a hole in each
shows the completed stop. stop for the bolt used to fasten it !/4"
CHAMFER
You start with an extra-long to the T-track. 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-
!/4"-20 x 1"
key on one side of the blank at the ting the keys to length, chamfer HEX BOLT
DRILL table saw. Test the fit of the key in each end, as shown at right. SLIDING
AND TAP INSERT
THREADS
1 NOTE: DRILL
COUNTERBORE
PUSH
TO DEPTH AND
2
RIP FENCE BLOCK NOTE: USE A
DIAMETER
OF T-NUT 2" HOLE SAW
FLANGE TO CUT THE
FILE OFF KEY 2!/4 WHEEL
T-NUT
SPURS
STOP
ENLARGE
HOLE TO FIT
2 3 4
T-NUT BARREL
NOTE: EPOXY
T-NUT INTO
HOLE AFTER
SOAK THREADS T-NUT SCUFFING
WITH THIN !/4"-20
BARREL BOLT
CYANOACRYLATE
GLUE
JAM
NUT NOTE:
ENLARGE USE A FILE
HOLE TO FIT !/16" CHAMFER TO CREATE
T-NUT BARREL CHAMFERS
ShopNotes.com 33 !/4"-20
BOLT
weekend workshop
heavy-duty
Workbench
A basic, stable workbench is a must for every shop.
Building this bench won’t break the bank, either.
I remember walking into my The bench you see here is just readily available construction-
grandfather’s garage as a child. like my grandfather’s. It’s strong grade lumber. And the wood-
There, along one wall, was a enough for any task you can working couldn’t be simpler. The
heavy-duty bench with 4x4 legs throw at it and will last for gen- base assembly involves a few lag
and a top made from “two-by” erations. 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.
could see everything from lawn really take a beating. The woodworking is super
mower repair to woodworking But the best part is, you can easy. And in the end, you’ll have
being done on that workbench. build it in a weekend using a bench that lasts for decades.
LAG SCREWS
SECURE RAILS
TO LEGS
SHELF SLATS
(1x6) REST
ON CLEATS
Materials
& Hardware
RAILS FIT INTO A Legs (6) 31⁄2 x 31⁄2 - 321⁄2
NOTCHES FOR A B Front/Back Rails (4) 11⁄2 x 31⁄2 - 93
STURDY CONNECTION
C Short Cross Rails (6) 11⁄2 x 31⁄2 - 19
D Long Cross Rails (2) 11⁄2 x 31⁄2 - 23
E Cleats (4) 3⁄ x 1 - 41
4
LEGS MADE F Shelf Slats (16) 3⁄ x 51⁄ - 23
4 2
FROM 4x4 POSTS
G Top Planks (4) 11⁄2 x 71⁄4 - 96
ShopNotes.com 35
1!/2
A A
B A
!/8" 3!/2
a. FRONT/BACK
RAILS
ROUNDOVER
END B
VIEW FRONT/BACK RAIL
(1!/2" x 3!/2" - 93")
8!/2
%/16"-
DIA.
Base
of the opposite page explains find that a miter saw is a better
the modifications you’ll need to choice when cutting long parts
make to some dimensions. like this to length.
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.
is its simplicity of construction. in Figure 1. 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.
for the long front and back rails. rails, I set up the table saw with The bottom rails are only drilled
Cross rails are joined with lag a wide d dado blade and attached where they fasten at the legs, as
screws through the long rails. an auxil
auxiliary fence to the miter shown in Figure 1.
Sturdy Legs. I used 4x4 legs gauge. A Adjust the height of the After the holes are drilled, you
for the workbench. If you are dado blablade to match the thick- can glue the long rails into the
having trouble finding ness of the 2x4 stock you’ll be notches in the legs. Just make sure
using for the rails. to keep the assemblies square.
Once the notches are cut, I The notches help by aligning the
used a hahand-held router to round rails as you fasten them.
over the edges of the notches to Cross Rails. 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. assemblies. I set up a stop block
Front & Back Assemblies. on an auxiliary fence of the miter
Long 2x4 rails join the legs to cre- saw to ensure each of the cross
ate a fron
front and back frame assem- rails were the same length.
{ Construction bly. The only things you need Time for Assembly. The short
Lumber. You’ll find to do arare make sure they’re all cross rails are joined to the front
the lumber to build the identical length. You’ll also need and back assemblies with 5"-long
workbench at home centers. to drill hholes for the lags screws lag screws. I used the holes in the
ShopNotes.com 37
SHELF SLAT
(#/4" x 5!/2" - 23")
F a.
#8 x 1#/4" Fh
WOODSCREW
SHELF SLAT
SIDE
E
RAIL VIEW
CLEAT
E LEG
CLEAT
(#/4" x 1" - 41")
NOTE: SHELF SLATS
REST ON CLEATS
NOTE: SLATS
NEXT TO LEGS ARE
NOTCHED FOR A
CUSTOM FIT
#10 x 2#/4"
WASHER-HEAD
WOODSCREW
EASE EDGES
G
AFTER G
ASSEMBLY G
CL
FRONT VIEW
1!/2
a. !/2"-DIA. x !/8"-DEEP
COUNTERBORE SIDE VIEW 1!/2
TOP
PLANK
SHORT AND
LONG CROSS
RAILS
LEG
b.
FRONT
LEG RAIL
TOP VIEW
2!/4
of the bench and worked out- You can see the type of screw I TOP PLANK
ward toward each end. 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.
before, they’re also notched to fit To accommodate the washer
around the legs. head and allow the fastener to sit !/2 TOP PLANK
When laying the slats in place, below the surface of the bench-
I made sure to leave a little room top, I counterbored all of the
(about 1⁄16") between them to screws, as illustrated in Figure 1 TOP PLANK
allow for seasonal expansion and 5a. The screw hole is oversized to
contraction. If you find over time allow for movement.
that the slats are fitting too tight, Final Details. After all of the 3
25#/8
all you need to do is trim the end top planks are in place, ease the
slats for a looser fit. edges at the cut ends. I did this
Adding the Top. All that’s with a sanding block to form a This durable finish helps protect
left to do now is add the bench- slight radius on the ends of the the bench from dirt and grime.
top. It’s made up of four 2x8s. If boards. Using a random-orbiting Plus it’s an easy finish to refresh
you take a look at the top view sander, go over the whole bench periodically as the benchtop
at right, you’ll see how to lay out with 150-grit sandpaper before wears over time.
the screw locations. I staggered applying a finish. With the finishing done, it’s
the screws to help prevent split- Simple 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. of an oil/polyurethane blend. use on your next project.
ShopNotes.com 39
the importance of
HEPA Filters HUMAN HAIR
100 MICRONS
.0039 INCH
.1 MM
I always thought I was keeping cause scarring of the lung tissue.
my shop pretty clean because And HEPA filters remove 99.97% of
I didn’t see much dust collect particles to .3 microns in size.
on my benches and tools. But I Almost every power tool that
found out it’s not the dust you creates sawdust creates “HEPA
.9 MICRON
see that’s the problem. size” particles. Power sanding is .00000354 INCH
Forty microns is the smallest the biggest culprit, so I hook up a .0009 MM
ShopNotes.com 41
THIRD:
SMALL
PARTICLES
AND FINE
DUST EXIT
TO VACUUM
SECOND:
LARGE
PARTICLES
SWIRL
AROUND
AND
SEPARATE
FROM THE { ClearStream. Aftermarket
AIRSTREAM HEPA fil
filters trap 99
99.97%
97% off
fine dust particles.
Auto Switch
The vacuum is powered
up when the tool is
switched on.
ShopNotes.com 43
STORING
CLAMPS
ON YOUR
WORKBENCH
ADDS WEIGHT
AND STABILITY
practical shop
Clamp Storage
Take a look at a few of the ways you can organize
and store the clamps you have in your shop.
Following the old workshop with a few editors around here to Where You Need Them. On
proverb, “You can never have too learn their strategies for storing the surface, keeping all your
many clamps” means you’re pre- and organizing clamps. clamps in one place makes sense.
pared for any type of assembly The drawing above serves as a However, just because they’re
challenge. But you’re also faced gallery of their ideas. The advan- all clamps doesn’t mean you use
with storing all those clamps. tage here is you can pick and them the same way.
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. bench and workshop machines.
CLAMP BARS
ARE HELD IN
PVC TUBES
METAL SHELF IN WALL RACK
STANDARDS AND
BRACKETS CAN BE
USED TO CREATE A
QUICK AND
VERSATILE CLAMP
STORAGE SYSTEM
ShopNotes.com 45
splined
Compound Miters
Create this strong, attractive joint with a few simple
Crea
setup tips and step-by-step techniques.
Creating trays or picture frames sides of the finished project. With you’ll want to rip your proj-
with angled
ang sides can, at first, be this information, you can use an ect pieces to rough width and
a head-scratcher.
head-s How do you cut online calculator to determine length. Sometimes it helps to
{ Finished. those com
compound angles so every- these two angle settings (refer to label the parts to keep the orien-
The completed thing fitts together? It all boils Sources, page 51). tation straight as you go along.
miter joint is down to the table saw setup. Using the calculated angles, Stack the parts nearby, and
strong and Three Angles. Cutting a com- it’s easy to make a setup gauge then use the setup gauge to set
attractive. pound m miter joint requires the for your table saw. The box on the miter gauge and blade angle.
blade and
an the miter gauge to be the opposite page goes into detail You’ll keep these settings to cut
set to specifi
sp c angles. But before on how to do this. all of the miter joints.
you can do that, you need to The Process. Before setting Angled Cuts. Install an auxil-
know the
th angle you want for the the blade and miter gauge angle, iary fence on the miter gauge to
1 2
AUXILIARY
FENCE
CARRIER BOARD
(#/4" Ply.)
WORKPIECE
a.
FLIP WORK-
WORKPIECE PIECE
TO CUT SLOT IN
AUXILIARY
FENCE
a. OPPOSITE END
DOWEL
WORKPIECE
WORKPIECE 1/2" DOWEL
SUPPORTS
WORKPIECE
DESIRED ANGLE
table saw OF SIDES
15o
Cutting compound miters at the table saw To use the gauge, see the drawings below.
SAW
is easy with a setup gauge. I used a piece of I find it easier to set the angle of the miter ANGLE 431/4o
hardboard with the miter gauge angle cut at gauge before tilting the blade.
one end and the blade angle at the opposite
end, as shown at right. (The settings I used SETUP
GAUGE
are in the chart on the upper right). BLADE
After determining the angle settings, use
a protractor to set your bevel gauge. You’ll
use the bevel gauge to set the miter gauge
angle to make each of the two cuts on the SETUP
GAUGE
hardboard. Labeling the gauge as shown BLADE
MITER
GAUGE
helps with setup. Keep the setup gauge
handy for resetting the angles as needed.
ShopNotes.com 47
choosing a
Faceshield
For added protection
against flying debris,
a faceshield is a
must-have safety
accessory.
As woodworkers, it’s been drilled for very long, you’ve no doubt Safety Standards. The first
into our heads that we should experienced particles and chips thing to know about faceshields
always wear safety glasses to hitting you in the face and neck. is that there are standards that
protect our eyes. But if you’ve And when using the table saw or govern their use. For opti-
used a grinder or lathe
lat router, there’s always the risk of mum protection, make sure the
a carbide tooth breaking or wood faceshield complies with the
< Infinity. This chips flying toward the face. Z87.1-2010 ANSI standard. This
faceshield from This is where faceshields come means the product has been
Infinity Tools is in. They take over where safety tested for impact resistance and
worn like a pair glasses leave off, protecting your other safety properties. You’ll
of eyeglasses. face and neck as well as your eyes. find a “Z87” label on the product.
I ordered a few faceshields to Comfort. When it comes to
try out. These include a full-face buying a faceshield, comfort
shield from Infinity (left photo) should be the next consideration.
and 3M Tekk (main photo). I also Some faceshields are worn like
looked at the Turner’s Select from a pair of glasses, like the Infin-
Craft Supplies, Professional face ity model shown at left. For
shield from Lee Valley, and the short, intermittent use, this type
Trend Airshield Pro. These three is lightweight and comfortable,
are shown on the opposite page. even over glasses.
Most faceshields, however, include a knob on the back of the Association, the sponsoring orga-
are attached to headgear. The headgear that ratchets to adjust nization for the Z87 standard.
shield is attached to a housing the tightness of the strap. The She explained that the stan-
that allows you to flip the shield adjustment is quick and easy. dards were developed as occupa-
up out of the way when it’s not The 3M Tekk adjusts with a tional and industrial guidelines.
needed (upper photos). series of holes in the strap. It’s The selection of appropriate eye
Look for headgear that is com- simple but not as convenient. and face protection should be
fortable to wear for extended Replaceable Shields. All of based on an evaluation of haz-
periods. I prefer headbands that the models I looked at (except the ards such as impact, splash, dust,
are padded. The Lee Valley model Infinity) have replaceable shields. and fine particles.
has cloth padding on the front When the old shield becomes For significant impact hazards,
and back bands. The Turner’s scratched or cloudy with use, a safety glasses should also be
Select model is padded only at the new one easily snaps into place. used. In my shop, I’m also going
front. The 3M Tekk model has a Glasses Required? When I to wear safety glasses.
thin foam pad on the front band. received the faceshields, I was Your Choice. All of the shields
I found the lack of a pad on the surprised to find the instructions shown here range in cost from
back to be a bit uncomfortable. state that they are to be used about $20 to $50. Sources on page
Adjustable. In addition to with safety glasses or goggles. 51 lists where you can buy them.
comfort, the headband should be This seemed redundant to me, (But for the optimum in pro-
easy to adjust for different head so I contacted Cristine Fargo at tection from dust and impacts,
sizes. The models shown above the International Safety Equipment check out the box below.)
trend
Airshield Pro
Standard faceshields are a great sec- protection in the form of optional,
ond defense against impacts. But clip-on ear muffs.
they don’t provide any protection The system looks awkward to
from airborne dust. And if you suf- wear, but it’s not as heavy as it
fer from allergies to wood dust, this looks and is well-balanced. A small
is a serious concern. fan and battery pack in the helmet
The Airshield Pro powered portion draw air through a pair of
faceshield from Trend provides a filter bags. A shroud fits around the
healthy solution for keeping you face to keep out unfiltered air. It’s
{ Powered Protection. A quiet fan draws from breathing harmful dust while designed to be worn with the fan
filtered air through the face shield to provide protecting your face and neck from running at all times. At around $400,
the ultimate protection from wood dust. flying debris. It also offers hearing it’s an investment in your health.
ShopNotes.com 49
sourcing
3⁄ "
Hardboard
16
hardboard
You specify 1⁄4" hardboard in a hardboard is sold and should Baltic Birch Plywood. While
lot of your projects. All I can be labeled by its manufactured more expensive than hardboard,
find is 3⁄16" thickness. Is there thickness of 3⁄16" or 1⁄4". in most cases you can substitute
some other material I can use? On most projects, you could 1
⁄4" Baltic birch plywood for hard-
Bill Smith substitute 3⁄16" hardboard. For board. It’s flat, strong, and stable
Norton, Ohio drawer bottoms on small draw- for use in most any project.
ers or for cabinet backs, 3⁄16" hard- Project Dimensions. There’s
I like to use 1⁄4" tempered hard- board would work just fine. But one thing to point out if you sub-
3
⁄16" board. The type I use is smooth for the bottoms of larger drawers stitute a 3⁄16"-thick product where
melamine on both faces. It’s economical, and shop jigs, I prefer the stiff- 1
⁄4" is called for. You’ll need to
but more importantly, flat and ness of 1⁄4" hardboard. take this change of thickness into
strong enough for a lot of appli- Other Options. While some account and modify any perti-
cations like templates for routing, of the home centers I shopped nent dimensions on your project
jigs, and project parts. didn’t carry 1⁄4" hardboard, they parts. For example, the grooves
Finding It. As it turns out, in did carry some other sheet goods for drawer bottoms would need
some parts of the country, 1⁄4" that you could substitute. One to be adjusted, as well as rabbets
hardboard is not as easy to find of the products I found was 1⁄4" for cabinet backs.
as it once was. I checked with MDF. This would be fine to use as The Bottom Line. When it
1⁄ " MDF
4 several local “big box” stores and a replacement for hardboard. It’s comes down to it, finding 1⁄4"
home centers in my area. a consistent thickness and flat. hardboard may take a little leg-
A few retailers sell 3⁄16" hard- Melamine. Another great work. You might need to make
board but label it as 1⁄4". This product to use is melamine a few phone calls to retailers
conflicts with standards estab- board. I like it because the and lumber distributors in your
lished by the American Hardboard melamine provides a finished neighborhood. When you find
Association. According to them, surface. It’s perfect for cabinet the right material, do what I do
backs and drawer bottoms. And — buy a few extra sheets to have
< Substitutes. In most cases, the non-stick surface makes it on hand. You’d be surprised how
these products can be used ideal for shop jigs. You’ll find it often you’ll find a use for it on
1⁄ " Baltic
4 instead of 1⁄4" hardboard. in 3⁄16" and 1⁄4" thicknesses. many of your shop projects.
birch plywood
50 ShopNotes No. 137
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