Am:RICAN

WOOlIII'OR KER.

JIGS, FIXTURES, AND TRICKS TO

UNLEASH YOUR ROUTER'S
POTENTIAL

BILL HYLTON
Coauthor of WOODWORKING WITH THE ROUTER

More than 140,000 Sold!

JIGS, FIXTURES, AND TRICKS

ro

UNLEASH YOUR ROUTER'S

FULL POTENTIAL

Bill Hylton
Mitch Mandel
", .. " .. i.", b, Bili Hylton and Frank Rohrbach
Photog",h. b,

TI'~

lEADors DlGIiST MSOCIATlON . INe.

Um il now, il's gone witho ul 5:1)'ing.

To J udi. Alwa)'lo lO jud i.

Copyrig'u C 1996 by ne R~adc:r'$ Oi,<:$! """,,,".ion 'lOC.

COf')Ti&hI C 1996 by ne Roador~ Digesl AMOciaIioa (c.n.da) ud
AU n"'l> rncr"\"Cd. N" pa" "r.bi. publicaI""'may be n:pruduccd
-.,,1Itd III 011)' r<>ml OI" II)' la)" means. ......".",'" III" nlOcllaniclol.
"",h.,,!;,,, pOOIocapy. ~i .... Of ...,. OIhet
SI<ngc
an<! ""n.,...1 ')"'Iom. " 'uhoul oM
prnn;ss;on "r thc ""bholocr.
OI"

....nllm

inr"""".;.,..

""'.on

"The IU'hor ond

who comp,l~ .h .. book have IneCI la make
ali of doe COIIImU U _urale and lIS lXIrT<:CI u I"JSISI*. I'lans.
ilh.....alioftl, phoIost;lj)los. and ..... h.a,.., aII beo> ..... fully o"edcd
Ind cross-dxdcd. II""""",,". due la doe vanabilily of Ioal coodi.iona,
~_1IWcnaIJ. po:rs.ooaI sIol"- :n;Itoon. Mllher ,1Ie IU'hor

_ R"od<.~ D'g." 'f.SUIMS""y rcsponsib,h,y fo. any inJ""'"

wlfcn:d or for damIga: Of othCI" Iosses IIIcurrcd .ho ..,..,1. rrom m.
.... '.,.;11 p='cd hmc .... AU lI\SIn>ctIOnS and 1'1.... should be
ca.efUlly on.dM:d """ cal)" lRIcn400d bof"", J>e:&omon& ........a_.

lIylton, Sili.
Route, /lUlgic

""'..-eI,

JIP.
and .ne.... o unleash)'OU, n:.."","
full poIe"""] I n~llIyIuI : ~ by M,tdo M>ndcl
illUSU3l""" by tiin I/yllooo and Fran~ RoIubach.

c....

p.

ISIlN 1).7(.2I..(lISS' (~ k)
1 R""""" (TooI.)
2. Wood",,",

1. JIII Ind fiAru= .

TI'le:.
1T203') 1/<).1

1999

684 .IlS} <1<21

9924915

R F.... ,IUS OKII:ST IlllJS"n.AHD REH.ADICH IlooI:s

li:dllo .... ln-C ..kf Chnsoopber c.""l\(I.u,,"

An m ......... .Iooa Mazreo

~ .... ~ ,\Iu.~r Wilham

J. Cassody

Addrns any comltlCl1l$ .bouI R _ A,.... Ia:

Readcr~

I>ogc>l

Edil..,........chief. Ulustraltd R"rtomec 800k.

Ro:adc.~

I},&O>I Ro.d

1'1<1I<anl .. llt. /'IV

I~ 70

ROIIdcr~ 0."", an<! ,loc: ""&AIUI .... "'" n:gist=d ondcrna,1<s

of doe Roador 's Oi,aI A.wIcw ...... . ...

Amtncan W,-".J>W<1<cr
Publica .." ..... 1""

Vi,il our _bMIC II .

Pnnltd In thc:

Wl[lIt

Uru~

"910164

i I ~ .~

1'A'k....ljI-est gM

S...," or i\1nImCI

of RD

Contents
I~

Offset &aseplate Trid-~ "'sic

SORING

LUSH-TRINMINC

Croull"ir Bastplalt

Slotte<! Pilot Templalt

80rlng Templatts
Shelf Support Template

ROUler Dupllcator

FlushTrimmlng B.lseplate Trlct'lajI ....le

"'

Mortising jig Tnct ..... "'sic

124

Shop'Bulit Siot Mortlser

Ili

Template-Mortising

14'

12

19

CIRCLE CUTTINC
Tr<lmmel Baseplalt Trlck-&lg B<lJIc"
Vacuum Trammel

vacuum (lamplng

19

C!.Islam Rouler Table Top

15'

44

Unil/usal Router Mountln.g Pliue

163
173

'O

CUSTOM BASEPLATES
The Generlc Basl!plate

6l

8it Ope";"g 'nserts

Rouler Crank

177

Tabll! Saw Extensian Rouler Table

183

Horl:lontal Rouler Table

191

knch-rop Rouler Tablt

203

Floor'Slanding Rouler Table

212

Splll Fenct

217

Sltds

246
256

264

T-Squue Trlc.-1IJg &tIsic

69

FtalhuDoards

ROl.lll"9 St ralg'"edge

75
81
8S

Surfacing Baseplalt Trki'8Qg IJtJsic

FfillCllonil1ing Baseplate Trlct~ B/JsiC

Centtr'finding Baseplalt

DOWEl: JOINERY
Dowellll9 Ji9

"'

URHIHC

"

Router La l ht

269

Jig-MakJng Maurials and Hardwart

298

UKJHG
Dowel-Making Fh(ture

Oowel-Turnlng Ji9

97
102

...._._!!
JN!!!D~
EX _ _..

308

DRAWER MAKIN
Slot<utter Drawer Jolnery

112

III

Introduction
11'1 mapd
KJnd of a hiICl<rqnl <bitt, ion', II? It ,.,.,mro JfOOd .,.
l.;uncd ,hi> book projt. 1kII as I coIlt<.'<l :uK! n::finc<llho:
kka ..... pbM r"r.he jig:! md ru .....,:and p.crn.,,; In this
boGIe, I ht1nl """ry put_n .nd jibr and
to 'I,c
.1Icmoc rould ........
'WOO<>!
gic.
llu1 .. "'" booIc nn ... rompkllofl, .hc: .iIornIt ... Ui .....-b
ror ..... Whm I FI In.o 'M >hup :tnd ' l1' 001 ""'" .." lief
111"'''0 1\'<: 1tU<k-..... It WOIlKSI_ .... ~U. ,hen:: b. ~
Ab",~.. ,bMI

!OIl.,.

I'' .....

'lJWI'.

""""" me, b:K1< <kxw. ItId h",po hi> roul1ll ~a",

And rou ""Y. ' /low'" he do tN"" ..... '"" .......... )'011. il b ..
,rid If )'OIIknuw the ' rick. )'OII
any JPtttlI >kIll_
' 0 rq>IbIe 1hr; perform""", In thb ...rtkubr C2>C:. )'lilt
.........:l ~ <'qulpmml.. twIn.-.
WIw ,'"" put In IlOUI#r M"Ji.k '" .ttk:1Iy ,-.y And
01 rou ...... IM point b III IdI )'IJtr CUClIy "'Nt lhe pmmlck
i>. Whl'" I do w.lIll rou 10 he du:>kd, I :tbo W:L/It (0)'011 "'Y.
- Hey' I """ do .Iull!'

tIan, """

JlOUtff MuXk b whok IDg 111 ..... Irkl<.$ for doing

"~1Ing [0 II.

"," .he "m'!II<:" lho:nlc W>D b<-~ &clf.....b/kd

Itt!ing .. hen I a'OfIlplbh >Omfth,"- In .he >hop. II
xb.",,1t:<lgo Ih:n I "" 0111><'
aU ""[ll:'ric""",,
in ~ ,,"em I_ frum
'MIL
llIn't "'" thlft' kIn<b of m.tdc. 1n "'f mind.

"uc.""ooa .....

It_oj.., ""

liU"""'"
2. oJridl.41w>d
~ .rkkry

" '00,1''''00'''1111 LbinJI _ ..... ,...., Irs for the buoy pmIOO who
.......... '0 k"".... ,he 'rkks 50 II<: C2fl CUt "' tbr: _
. ... she:
can III't .."",.., done In los Il"'" h'~ lor Iho: _ e r
who .~ Iw a oout .... and !>lUi and tI!ld 'h<1n ~
In his ,,,. lin ~ "'" Ilw" .... ilI''$k b at.o lor lhe
woodWOfk.... who h:b III<: miller Ilnllljl on a shc:lf ...hlk ....
"",I", fur il 10 show otr "" m ...1H.... lru ,ttSOIUioy 1f)'Ollllo
tllb I."'er .......,tlpliod. this b 1M book lN111 l1. m rou InCO
.. ",,"<:f

1II... lon is ,"",pI)' ,..., IUfI$kIft. It'" hocus-pocus. Wl\al

you UI; :scd"" is ,101 wtlat'. I'l2lIy happenl"". Al .he r."nlly

picnic. Unck Ilud .hso~"'dy U_7 .he tiltloo kid> by p<dllng
off hi$ thumb III' ",omcn,..nly, ,horn pun~ ~ back I"~ lUll'
in "'" "'3)' ""' hold> hl. h:otu.b. "'c <>klcr kkb rnlitt
ll>c...5 110M of this ~"'''' ... heft, """"'...., ,."..,
kepl.he III"*"'> OUI of ROil"'" !II'IJi'c. It 'lluot 1IOO"i.... ~

co..,. ",,~ ...... nh. procI~l" ",oodworldnS

",1LtnJ

1f)'Oll ~'" Juot ...."1011 out. for cnmplc. )'OII m:ly ""'"'
to Mup '" me, !IA! and fIxt""", nurkal ... [Ih the 1"tldr1IaJI
BNc' .,-mhoI,Thc: ",,",hoi idmtifics 1hr; """",. ~
thot ""'~ rolle:lgua and I ~ ... the: .......
........ul lOr ,he ~,~ """""',,"'er to N'..... In M b:qj 0'

,n,""" trid<.~

"""II "

roilier

SIclsh. -o(hand b ~~""_ In 'OO'OQd"'Qr1<inll- To n",.

>kiIlh.4./wld is 1wId11"ll wtlns.lnt,kau, Up<T., k)n 10
quickly and fluid!t' lh>l 11_..,..,. I,'s h:on<Ulng.he I:bk
in. ""3J
pruwko ,h., ' lfQw'd br: do Ih;o,l/'
'J'b< ~:oo::ornt .....oowurl.= chop OU, oo...,ails quWflCl ...

,Iu.

""pun""

1c'8l"""-~'
'J'b< "",eh ..'IIh ""=iKh,.o(IwHl.o."d ,"" IftIiOn I...... "''''
I, OUt 01 /rut. ,~ ,1IdJ:1c, b ,hi, II ~ 0", 01 dt:dIo:1Kd,
aim"", .>I!!I<:Mi..., pnctIco:. 1f rou'd IwHl cu' <Iuwulb fur a
1WC.... m:n dr.!"""",",,-,,), ......n1na Iby lOr 2S or)l) yan>.
bcconK' adroit ~, II.

,....d

Trickery I, ",hi, IIIb book Is all ""-ot. Tridell' I!i

>Imply a.....-utinv ~ ""cll-<k"Ybcd .. "',.,.,..,., put~ 111m,
mldL '0 'to<IR. on:oklnjl. u:;o, "f 1'....:1:.01 <kvin' or Ippo.r;LIUI .
Thi' i> lhe: found.uiooo 01 boIh 111"" nt>gIc:and"n' . . . -

-..."..

I~ ' rid. lhe: 110ft

vi>ioo

rou"" ...,," pc:rtOnncd on ,do:>

bf """ n.mboyanl ~nun or ."'~h<:r. lle lfUOoIeI

up Ill. )'IKl'IJj, """''''''-, puu lin In .. .....oo.lt-" ~r.'., . ,hen

hoi..., In.,,

pu:>I'IU II oIf th~

,Ilt! m ..... below '" ,"e ...... Ied<>oo "'..... 1hr; ct:IIC.' 6mo pun. up. The """,'m"" ILln-.

I"

Trick' Bllg Bilsic

'00.

lIoute,

~IC

kaflluou#llhe book and We .. 100II '" lhex ~

'\",'lllnd lh<:tn rdoll.-dy qWd< ;onoJ n.;y L<, build, ohm 01
)\M> :obndy N"" In )'ULlf . hop. 1.<::, "iC
11<:", IN t Ih15 G not no.- ,11"84' /i,... ''''' It Is NOT - _
Stulf yuu ""n do Willi thi! iDf;:rediblc .....Ier frum _nothn
sa!Hyl' 'bur ...n<bnJ """.... will do ju5I lim for """'" of

ocr.""

,hac "".

""'fIIwoi'"

If """ .......n: IIItou@JI [lie hooIl uod >Iud: )'OW' 1>;<11 o

l'01IIer ,rid> wUh "'.. tllOC' b;uiia. )'0..11 bqr;In ... appno-

dac~

chc ,,,,,,,clJicy <A )'Our rouc" . U.itIg che "Trid;.1Iq

co ~ I >iflnlflcanl
'""'" or upc .... UOl.
Whh ~II" lik~ chc T-&j....a 1U>d chc Ft;JCclon:ollnjt
II.t>q)b'f,)'OU1I RJUI. ",~l) po$ilinncd 1U>d ~'.l ...... dn<:o.
~ond ~bbn:s.."'" muhlJ>Urpo!Ie Smt.ocll1lllWq>bl~
<qIIIr- ,.,.... lOUIer lOr pbtIJr\jIlumbc:r. funnl"ll "'P"", n.:n
C1IIllrIa cin;:k:J ond oIu.p!nM C'dl!<' . ..' Icllooc Lhc ..,ipo nll:>Cd
br boIlbIc> and ti~ or Ihc: n)uCer. Thc ~lU5h-Tri ......inI!:
J:i5c'pla1" wl1l hdp )'OU , ,, pltC plup ond IhfOU&lllCnOll!l
:tOO 'o Irim ~ndin8.
J ""f'"blly lik.. chc Tl2llImd 1bKpLu~ btt:o_ 1, Is
ju6t 6UdI I P'f'I' ulmmd. W"J1h 1' , )'OU 0;":11' cuC dbb (or
hoIts) r.onaInI! in <lbmeter from , Inch .. p 10 lbooc 11
loIchc:f. Bel,"" n",. Ihll II a ,-cry h.ndy r.nstc. espttially on
Ibc: __ .. nd. Cutll"ll el",l"" b OI'" 01 chc: Ihl"8' Ih:lC
routCT> do best,1'hl, 1. I ",bli''''1y sm;oU projec1-1D11da1c
...ou..! of
illJ , "nly ,..... "''' .... _ .... ~ ...iU h:ln: I>ig
Im~ un tUllr woodw!l<tJng.
Anothcr 01 mr uick-Ntl r....:.ma II thc: M,,"bllIjl Jig.
1I>!Ic"~, )'DU1I "" ~bIc

m.,...

Mort .... II 0i0I'I>Clhir Iha' pI\Ir1W """"'" do ~

__ ThD jig .. gnI btt:o...., ~ I!< '1uile simple 10 III.1ke. 11 I!<
JOIid and dw:lble .... "" M",-""
Gib.-.ltu.1U>d 1. '" c:osr 10
_ . l'>l<c r_ .....= mlnu."" 10 "" 1, "p.!hen )'OU an _

or

""' . cnon-'mlnUl". And ~ mort""...;a "" thc: """",,

I\o::yond 'h" .,\ick-llo3 &.Jo,," 1'0"11 Iind doot<:n OI'
"""'" >OIld ~ Uw ftUIbko
~I

1'0" .0 ltIC !ha. ""'Ier In

WIClIpCl"1~"",

w;oy5. ",., lriek. ruu

pomn..-horiIl,g hoIes. lOr cnmplc. Of n"i"ll dowd. 1U>d
_.,. join...-..ill mlkr iC Clt-M CO Imi JUOl how "o: ..... 'ik
ihc ltlUCer an !)r, ""'" "" )"OU ,ad<k: cha;c opcn.\(I<U;, your
,.,...,. _ _ _ wCU t"""""" mo", .,.n".ncrd.

Ind <:rmlnly

!lui III.1t...... )"OU reci )"OU" '" aln:;r.dy _ani thc """er,
...,ma .... yuu al~ ..... tuu. "",'c:r lOr .hc klnlh 01 opct:>.
lloo.. 1\., din!. ' >un'I puI'hc boot ......n )<OI, ro. 1'0,1 ~kc CO

thlnk '''''1 C\<Ofl 1!ICUOfI<'d wood .."O<kcr wlU dill<:<,.... r n.....

critb ond Ic:chniqueo In tm..'w ,II"Il/c.
~ ....,. I pietII'" Ihlt booIt .... nujlk" ~ . a
....... ro. lmidcD. an opportunl!y tur !hf ~ .0
~ Infunn:llion .nd kk......, wllh an audinK'or 0I1hcIr
11""" V..... know, tllc",', .... betI .... I~ ro. ....pc
locr nugi<:Wls. s..n:,. thc .....;IicIcr w\y tnow I
lot
, 1Ie1<>:and ..iU "" abk kl pld: .pan I p."fum ..,.cr
10 fIguc<O OUl 1"" "'hcr tricb. 80......gIcbn>-like woOO'
""<lfUn-~ ~ un .hc Iookout k" new IWb:!., ~h,1e
Impmemrn ... and cspedally In ........ Uon .
In Ihi> liglll, a wuod","Urkc, w;U 1""" al ;;. O< liItu'"
_ Of h,.,., 1U>d .......... Ie II . '1 .. II bc:en ....,.. """"'1 J)oa;
MWOIlK?" II ...,.,Uy lJ<'f,m Or """ difkTcnl> l.Jocs it
liOrDt." ncxihlli'y, or In: il> appt;el'i(Ins ..",. opc:ciIkl I!! i,
"""",hing '0 I<ttp In mindl Or ~111II Co M huill

.,.,... .""n ,..

of,,,,,

h:I,..,

OIr.lght:tw3y?

l'ou apnit:ntl """"''''''''ers

:Ihookl "ud)' nch j~

..... Il ......, In!hl:l bouk wl.h. crltiCII) CI" I ~ruInt). h...,.

h,,,,,

mr .....,.,.jworklnJC roIl""gDQ,
Tbt: kk:;Io r.... I",*, 1111", n~tun::s.1U>d . - CUftX' fton\
1 nrlnr of ...... ,.,.".. My juli ro..hc ..... )"Cal" tw bc:cn 10
lInt1 o:k:>dop. Iesi. Ind fillMun(' ,hale dt:rio::u. I "'" ""Iy
>nOI ...

lc:Jul<cd In boob .nd IItlIjCnIncI for ~ 1 "",1lICtC'd ....x.J.

wot!<e", f. r aI1<I ..i<k. 100I<I..... lOr onti"" ~ :and
bul'S'~. Thr bat 01 lha;c projc<.u. I chink . .....,n: .,....,"'IctJ
hr om.Jl cirde 0I ..~ eollcaguocl hen: al 1I<><b1e
....... rd 03)' ' " 1 rrlc:nd. "Wh>1 It l"'" wan.n! 10 III<' thc
1OUIc:r ,,, . r And ....,'d turn c"" kIc". Orullnd ",,0,1 .... 11 II "..."..
and Idk U chin and "lek II' butI . ... ""'C il a ~"k and
chaor II ."",nd chc bloek. rd ""~1ch I plan ond bulld and try
it . OOetl. 1'0,1
I ~pcc!C'd "'~ 1" oomc lIP ..ith.
J>n>I"'ypc. 1l>cn: w.:'" rolbbor:lllonf, ,.,....,.., ""'" """"'"
would bolid I bule 1'- and othcn would oITrr ~Ion~
for implU'lnncn ........ ~ .. ll)om)"..-W ......1>asI>cdIy. "IlItf<O ~ .a/\c:r aU. k-w kIc:a:t th:I. 'hc wn """"'1 alJndy

:0.'"

--

In .hc cnd. I ... I sw<:U roIlttlion of ma~ Ippar.ilLl>

ond /OUtc:r lrickf.. Ukc I 11<100 nla8iC ........ tm..w M aaic Is
.... lxI"'" 01 bIs'" 'rlcb ond !Om( unusual .. unu 1 oprnly
Idmh . !I<JIttC of ti ... jlp hcftin ..."... oId:lUA\lUdt. 'tUoJ"U
ligo Ind u1cks hen: lhal 1'O"'n:......" rbcwl>c", 11 ..1 1
'hlnl< l""'11 cmbrac:c 'hc ...,.......:ba ""'cn hen:: they an:
iOIid ond ~. I"'" IWIi<lrd oen:wt' 'l! up I II'lJOIlIiB
,.... ro. Ihc Altr 01 m:Wn.R h linie tllffrn:m.
ThI!o ... pan of.hc
cn .p~ OII l"undlmcnw.. To
puii oItlhc 10,1'4"""" lriekl, l"'" ha,.., .0 h.", I _.".,. 01
'hc b;uicJ, So he'" .nd Ihen: In .hc bouk ~ chapl~ lhat
cnminc furutu..etlW ""'..... jJs ~"'""" CoC1Ic1k ~
pl~'c " 10 ~ good ",,,.ml*-- About dmIm of Ihc romcr
fullun::s ;" chl!< boot Inoo/vc nulei", I n:pl;tc~mcnc 1>2......
pll.~ lOr )'OUr 1O\.I,c:r. Tbc joi> ;" ""'1)', bUl ~Idom "" CI>)''''
"""'" ,,""""'v<i<llljl 1>0<>1<. III.1kr le ....,m. "'""" CoC1Ic1k
1Wq>b ' ~ " <kuilo OOW ", [110 .l)Ouc .h lo acn.iiI """""-And
..tocn I .al' It dul"III how 10 do le. 1 """'" k JIivct l"'"
,"" l"''''lcul~'''.
Il"uln MURk...,., lUcuo,Q OII """,tfllpot'Mf III.1.CfU]o
",,0,1 'dInoIogk:oo. KnowIl1II abouc !IloOl.km """mls Ind
lutd.... ", ( anoJ ,,hcft .0 FI thctn) 10 imponant
""'3imn. I'IIC1IOlIc pb>tk , .'oIOf ThAAk wm ..... 1'.:a.')'OfI~hc.
hands pb>tic knol.And knowln,obout unusual ccdJnolo:>.
pe.""
wl!hln th" "",ch or . "" orttalkbop ~
.nd ,bc hobby woOOworko:r " Importlnl . 1"". Utloa
vxuum fur d.mplng. Usini 1i:In:kU. Oow 'o Iifi: ",utr onoJ
""Ip )"OU """'" II
Wich ,U,,,,, il""" on fundomcncal5 ond .... Iml~.nd
lechnolofn', duo 'I ,hink .hii! S .. oo,w .. urr. In .,...~..,. lI'lJOIl
_
, """".. II Inot ""'" ""1I'.... lIIn"" II .. , poN,""'1y mU:.
tIown. And I'n: ... Ih..,., urfour<A 'c:m In ~
looI< ., ,"" nlth """peer, " 11001'" l>Uplia'or." M2)"br
)'DU"'" ..,.,n ";mib, tlocvlca In wootl ..ortdnSt ntaJoss. Tbt:
kb 1. c" c..... 'e an objc:ct In wootl-a nn'in,J. ....... td1owC'd """1. 1 .....11ow JIb'~ ur t>o..1-1ht<JUSh thc par.llk:1
mO~cn .. of 'hc dupllau ...... "'-... """"'" AI )'00' "II:ICC'"
'hrc:codlmcnoion:ol ~""rn wi.h ilyl"" """,nlC'd on """
bc:am, "'" lOIId hom duplk'oc"", Chc """.."".,n1S of ltoc
n.... o ....., chc """er llIO\,m~"", on i, 10 ",plOduce: thc
objt bclnt ,r.oo;:W.I,',. whl"",,,,"lI lriel<.
AIMI ,,, n.. k" II bt.,,~ r, tbc Rou!c:r M"Itic dupl"."aor .... 1
I"'1'I""l un [";III, ' >r """",'ed Of! tund. It ij,cnlly noo. .. ()n
air. 11.., lS ""'III"!

.e"

bo,,"',

..u

'u"

,,'"

,.,... """*'

Inu odYWGn

Now fOU ClII buy a .... pIia'or I( 1"'01 Iu .,

""""'IdI

DKJnq, or fOI' ....An mUC' <IX' 1touIc:r M.>.lPC tlupl"''OI'" lOr- a

mnarbbty n~ """""'I of ...........,. :and >hop t1nl~ , .....
orith all <IX' ~ I.. ROUln ,I/'IJIIc, lhe pions lOr bulldlfl.ll
:and """'K lhe .... plialor :lit: IkWIN :and "",cd.
(1n me n.,II' """,nth" 'lnlly 11131 .11 of 1M f""Icct
dI' plcn indIldoo a II.a of lhe p:o"~ :and the IPn.tw2n: )'0\'
".,.,;.J tor huik1in8 tho:: il"'" In ql>C>tioo. The rorutNCtlon
dltol<:llun.,; .n: R><thodicaI :and lhorough. L<IU of dn ... ~
:and photos of po11nml pmo:Uun:o "'" induda111.., III..,.,.
tIooac fur usin.g <3Ch I\Il: or flJ<tUR: "'" liIt..w"" IhoruuJlh :and
""'I...... tIal..l don'llb/". roo ...... 110 ........
I'Dak:oJ o.kull b
dwxt,m,uc 01 R","","
,11('81<" Ft MCtlktl by "'1' coIlcaJ!uo fur IIcing Ion~
will<kd,:and I :lIII, Hut " m ttyinJ( tv m.al<C''''''' .'" npbined
me, full Inl ...."XIcs 01 no:h pnojca (")Aen. when I ,..,...;l
II"II'Wl!J1 _><ho."Qlltlng boob, I 11"1 {"""r.u"" by 1M mh;o..
~ "k:ccs oIlnform;JUOn- !hoooe viul dL.... i/s and .subtk
nuant'n 0( Itth niq"" tlu! _
,,'" dIIT",,,,,"cC' 1'<'1.......,..
~ ond (ru>lr.uion '''' trinl I., ftx:uj NO'll.... "" 'JIit' ...
tbC' !!rillY lImlils ,lut m,ke IhC' """ illCl"C'rn>a:..)
ponIon 0( NQIII.... ,1I<k is IIiYm .... c:r '0 mute.
lablet :and routn Iahk ~.1hIt is :lII ''''It:I.~
01 ~ ubklI :and "'"",,",rio., ~ fn)m IWU di/.
("""U ..." ... _
hori-.c:ol :and one: ..",k:a/- t ...........,
lhe ..,...,n 10 I"" table _ . tllrough v.lrktr of sIC'do and
"'"-th<11>o......, to nlfIy bcndHOfllUUtc:r ",hi!:.
Let me talk ,">me: _bout \be" Jknch.Top Ho",~'111hk.
WbIk b lUiy not ~"'P tho:: ........ ,.. )'OU, II ~ ,urn OUt b Ier
I.. h;n.,
lOr you. ln omoJl .tIop, 1hIIi ..,...cr ..' " I,
~ ben ...... II is ronlp:ocl Inti doon', ""'-"'Pr lUi OWn
"Ic 011"" fluor Set on wuo1<bcndt.II "dcftICd oboI,.,
II>c standartl ~ hdI!h'. pull ing ,"" X'I!on dooiorr 10
)''.>It II" ""'Y JIOfUIlk, ..., I..... ~;m arTY II 10. maodcIinA
>ile ..... b;w:kyANI Job I """ irlcOi POI"''''' thttt ~"
apc::rtinp In . he: """'" 10 nWtc If a." 10 nIT)' (or 10 1wIg ....

..-iaJ

. . "'*"

_n "

.."'" ruD tor "'OIIJI<').

IIut 111m;: <Iaojtll t<::o,Uf"Q IIW<C' lhis router I. IIk 8""""

-'"
FInI, II's dcsigncd ..,...ntl ,...;aU, Ib",","",

mulC'r,
...hlctl lot of hobby ...""" .... .,n."'" b ...,.
S-ond. Y"" 011 inMall .IIOJ ""rr,., 1M routc:r &om ,he
"'hie In ,en itC'QOds. In od.,.,.
,he router .... 1 1ioN

......u..

\Ii

Rou,,,, ..... 91c:

"p . .... lM:n II'. In ,Itls routo:t ullk, .... hid< .. Inv.ltbhlr II>c
"'""" ....... other routo:t lal* ~(M JVU knoov. you ... ,~
:0.11)" """" 10 """',.,... Ibm;: or four sano.... """""c . he
r(>UIo:t &om ."" mountln\! pI.11C. ohm rdrua1I 1M owck
""'"'pbl'" !If ~ I"""" II""" or four "'.......,. 'P.d<a
I hn."'C-' 10 II>.... min ..
and a """-",,tlri""",)A
of I<JI!SIc
damP>' hold lhe ..,....". uttoekrnnth Ihls nlU" ',. IWk',1Op
)'au <ion '1 "",n """"'" tho:: 5101.'11 b;uqlbu, '" tnOtIIU .he
routo:t uod<:r Ibe ubk:top.
ThiRi. a UfHop fral"'" mako it ~ 10 tru ~ e bll
~ and bi.1\dgh1 atlj .... mno ... Thi> . . . mill..,
UNIQUIlIO ~11 router 1:thIes,
'fhc """ """'.... opp<1-'
Magk ..... lI.he fabu.
kIttS ~~~ ROUtcrnbk. 11 ~ the Iifi-top .... IUIC'
.hop.mode rout"" adju>lmcnl cr..mk. rouler 1>11 OIOfaW!,dlt!.I
moJ chip coIkction. and """".
AU In aJl. 1h<:tc "'" unIqut rouu:r t:tbIa. YOu ...... 't buy

I<'"

<'OU"""

1/,,,,,.,.-

IUcc them "'I'o'YWlttltE!

"'</OIw............. Iuo 10 he 1M Rouler U lhC'.

Ir.th ,II. >hop-bt'lll tnh;t"Ism, you an !V.IICum" p05IS
and Icp and opInLlIcII and fin""" wl, h rt.np and C'U"a and
..pen 11m Ito """ opn:Dhy i< ~plt:lt., whldt arc
lhe
~"IIp:ohIlhlat of <-"'DIlhe . - ""PCmIYC 10'00 and 1M _
.Id lktl lu rnc:"," You _
CUI ,...,.., ltlnc.b of . umlRfll' on a
tlcvi like 1111:0. or y.... "....., Ihc:cn by 1wMl.
~

"""unci

If you "'On' ,0 buy OPe 01 IhQc: <IniceI, you h:" ., I .....

cholcc5--an Iocl"'C-'dihly
induoubl m.rnlnc or.
d>o~ one. Our n>llfer Whc is quile no;r '0 build
u.>in!I !OIDC bK'yd<: ISProdi:ns and _
, """" oIJ~1f
hnti... oncI ~ ond oomc plywood." " tl...-.:. fk:dbk.
.'U1d u<Uq"". No " .., """ pubIi>-hc:d pI>. ... lOr ....:t. ~
You .... y .....". build """, bul II ..'III be .... '" 10 v>b,......
aU""I"''''.
If n.,r .IIe"" ......... RiOl. ......... hlz rouler glm>o,
Ihlo i< II

""""mi.,

""*'

IIri>n: lumlng you

In lhe ohop, I<:! me o;oy tII;1I II",
Rnl 5Icp 10 bomi"ll" cc"if"'" IOUI"" ..'b:2nI .. '" ... that
ruwc:roft'lbt !bdf. Tltocn you'" got 10 fill that IL1lt O' lOUIn
1mb You an buy. lot 01 IP""'" out of ~ btIIlM
oM'O<1C"$' . _
fu1/lUa.. ,rid::< "'" til.- }"" c~lc yound/
So taC' 11m book 1n10 the ohop ond IIiCI buoy.

Crosshair
Baseplate

.,-g'.

(.;lI1ch 'ayout muks in your

roulers c:ross ha irs 10

phlftge-bore on-li1I rg t t holu.

CI

IIoujh

It ",III n("CI' rq>btt tbc: dtill and dnU

p,..".,

roulC, \!1 an acdk'nl borI"JI 1001 . Sun"

;I 1'11111" Ind I'kltll>ill.y "'" """"""M' !Imlt"". 1>1"
Ihrn."...., .......... ppllcaIlOl" in ",hle" II ""Ipnmrm$ .InUl.
AneI il you Il00 ', "'ve driU p~ I an kImeIlmcs bc.
WOfbbk 5Ubsti'u'e
Tbo: ~ oIUI<' plurtjll: tQUtn ~ !he pun.lI'"
d\ftc dt'Ill,of COlIIlI<'. Is !lutlt borr.
th:lIs pnfn:tly
~ 10!!It...onr ."rfacr. A"" altbou&h It <:an ', hore.
dftp hok: . it an hore 10 ~ dcpth.
This.spial ~,,: can nuIi:( il n,;rr 10 ..,...." " CIy
pIa<'t tM - ) ' O U horc 'NIth. plun"" rotI.n. Whm ... Ing
""""'" !'OUl ...., il ', diff\cul! 10 cyd>all lhe aan 1001100 o(
thr hok. Tbo bit docsn ', ha'-" a cnunpoim 10 line upoo .
m.uI<.>Zld lbc bulk o r ,/le MOI'" nulIa; it imp<>!6ibk: tn oIWI'
~ OI> IM bit ,."" ~YUoiSIul, '-!>bIr hei"" ""' ....u.""
hb pn.obkm. I aU It Ilie ~Ir bo>q>btr Ixa""" II 1.
llimply pK 01 da.. pLuti<: ";th crooo.hairJ dclina. lnH
thc: ccmcrpoinl oIlhc bit.
Tu . . Ihc ~pll.. c. )'0" mUSl!zy.,.. hok loc,"ion> .."
~ ........pittt ~ t""" Un~ ~.I nghI Inp... Set
'hc: """ft" on thc: wori<, and II"" "p thc h;i.""pbU" 5
.hc:

plUI'IJI(:

"'*

~"".."

tI><:

"'* wlU Ilo:: lu "

"')'<lUI. tUd< on ,.... I'OUIct:ond plun""

wlH:n;: )'OU w:ont II.

ThIo t-plalc ... orb opbIIy ....,U ",ilh l~
$MIdI rouIcn. Il< .. thc lIo!Idl pI~ ..hlch allow }'OI' 10
....iKh u.., ruuICT un ami ,Jif 1"" ......Y ,.... """'""'-1 drill.
TlI(

Making the Basep late

II >hould "" omious Ihal }"OU must U$C :o dcu p/ulic lOr
<hc ba$q>Wt. You nil US<:
~ Olt p<.>/yUrt>on:IIC.
I......J Xf}11c.
n~ on "",,",ing Ih"mH'''''''lnfI. pUMa OII bol: '0"00 In
l/le appcndill:.

ci,,,,,,

1. eul thc: bbn k. Cu, *1 ....... oIl1!ht1r """'"' Uun

pI""l.II"'"
~plal". Mili ""~
bbnk ..
1nlly"'llW"<" t.n.-.: tIK" P"I'<"' focIng "" 1"" bbnk.
)"OUl"

rotiI"'.

1""

2. MOlIDt It o n 1"" rouln". ~ lhe rotI''''

aod. tI5ing <loublt<kkkd !apt, bond h
t/w..

b:uq>b'"

'o

bbnk. Gulokd I>r II>c moumlng.,;clni hoIc>; in ,m, OIock

ba...-pbtc. >dcct ,II<: appropri' le;;i~ drill:u.:l bono hoks in

CIt~HAllt

IASEPLATE LAYO!JT

Iu.e~~e bl~nk

CI'
C

.-.
CI

III

Is slzed 10 fk 'OUIUS but,

Olmple cenle. of 1>io'~le

wlIlI V"9,oovlnll bit wllen
I>ioffpl~te 15 "loKhed to
tlle 'OUtt .

Sui'" c.oss .... lrf tll.ough

tlle centtf_rk u,ln.g
~ ,c'~lch IWI.

Plung<'bo.e ~he bilopltnln.g

aflu scribing (fOI.... I.
Ofili hol" for
mounllng SCrewt.

Cunlng Ust
Qty,

Dlmenslons

Material

Ilie: !>lan" Swllch 10 3 counlenink. 300 cOllm~rslnk Ihc

holal 110 Ihc n.thod ~ )'OU t$: wiU JCI bdo... Ihc
~1<'

...n:oo......

SCJt.>r:>I( Ihc bUnk front Ihe Slock l>ucpblc. 1"hc

PA)l.,..,.;v" ""IX" wiU ptQb;lbIy jlttl off 'hc bbnIi: """h Ihc
arpct tap<'; 11w', oby )loum Ilie blank on Ilie ""'1(',
3. Muk tIM: bit o".,nlng ~ntcrpolm, fiI v'

......ins I>it in Ilie roul~'. I'I",lSIC Ihc bir ~ Ihc bbnk.

1)on 'I ~ plog 'hc roule. in: jusI luro Ihc hit. r..... timts
by 1wId,.oror!IIJ! ~ ct:nlcrowlc InlO Ihc bbnI<.
!te"""", Ihe !>bnk (rom Ilie rtlUler. (In thc drill pn:so,
drlii Ilie .....1IoI-diam<1er ""'" )'OU .,.., Ih""4h Ilie bIank
.1 Ilie: ""nlcrm.rk.
4. Scribc the Cf"OMhaln. ""'" thc proIC<.1lve

rrom II", blam: (lf II ....llIrndy ...",..,...,.j). U"ng .

'''''',KW"C

D,IIII"" !h..,mos.." ln!! pluti, .~ulfts a hlgll

(huCk sj)Hd ~nd ..
I n~nd-OU1 feed ~ctlon . fHd
the bit ..... p/y fo< ""Iy ~ moment, then ft tflet II c~'"
of Ihe pl .. nle. fftd .hirply I9"ln, bUl onl.,. b.lefly.
Rtlratl
bit. Thl. In ~nd-oul actlon kup. IM bit
cool tnough Ih ..1 It won' mellihe pllSlk,

,"p;d

m.

""per

!oq"''''

and JC ..,dI
Ihc ~ on the bQI1On1 oIthc
N.nk AJIPIr dattr..colon:d palnl to ,he """mi Iln .....ltb.
fi"" bnOO. tIIC1I ""'pc: Ilie """""laiC ck"". "Th<: palnl wiIl
dinfI 10 thc """,lehD, hljVllif!;htlnlt !lte Iincs. <N an a1tcm:o.
ti"",)'OU an 1')' 1bI"II fine.flppro .... rkn- to color and
hishlighl Ihc """,lchI ,,""""""'1, lina.)
5 . 8on: Ihe bit openln", Vou an lxR Ihi> hok ""
thc driII pn:ss with a ufJIC'<IloJI\CIer I:0Il. Or mnount l!>oo

....... I:worplatc OII Ilie .....,1 ..... anei

~I"I!.

pI~

,1Ie bi'

",ith. bfJjll>mctcr .. ~t bit.

Using the Baseplate

b Ihi< an """Y Of'<'rAllun? y"" "'" l' b . Sd up ,1Ie ""'I~r
with tho: cro:I6hair I:tasepl'uc ond Ilie contt1 bit. lhen k1
tho: <:On"ttI p/w>J!" <k Il' h.
",., >ltc o( """f)" hule mu.... lIe Iakl ou, with CI"I-"'OC<I
byout ~nea. Set tlle routcr...-a tlle marb, anei /ll=t tbc bascplat.... cnmcd ~ dl'~:11y tM."r thc byout nwb. s."jlch
Ilie NUl .... "" and plunJIC Ihc bit.

TO c, ..... .... c ..... ' " .ln. wo,k In 1I00d lilIlI. wrell"
sqUIrl! and se".'" awl Hop). Un~ IIP'~ ~uarl! 00 k
bln,t. t"" tony ,.ntenNrk hole. Thoen draw t"" ilwI
n,mly alo"llthoe ~""rl!'J blJldt, "o'lng 1"" plU11(: as
OHply as po5olb~. Aft~, botll IIn~. are se'.tehtd into
t.... lNupi.Jte. lIighlight 1""'''' with dar~-<oIortd p;llnt
(boltom). U~ li Ilny an.!,I'J b, u,h 10 apply .. bud of
polnll!ong tlle
~"f'. Wipe Ihe uceu from
t .... plUllc, IUvl"ll JU" a Ih'ud of It In the "".ICheO.

1I"s 101"110 '"' a bull"s~d Yau c",,\ look dll"tCIIy

down on thoe em..""in ind SH wi,h""t dlslonlon
how \hey line up ""'Ih Ihe IJlVOUt llnes . BUllhe
cm h"l .. of thlo b.lupl"tt .... ke It d,.matkally
usie, 10 line up Ihe route' fOt plunoeborlng.

,,"'te""eI

c .....""" ,,"uplate

&'
...-.

"

IlO

Siotted Pilot
Tem plate
Now pilot

-~.'".
c

s/ol~

lire

usy 10 make as
pilot holu .

buiIdin (umil",,",

,~ atr: timei "'Mn )'OU na'd 10

palid Uw eNRIJO" ..1dth >nOOnally or fa>l~" a

pand .11:>. ~ width 10 >INel"", ,h;t\ doc>.fI. If
you ...... " ~ any :alk;no~ lot this [[)('cn",n,. SUtface
buckk _
joInuI_, doon ......,", 01"-''' and tirA"'''''' ",m.
Ir IIM: rnrmbc'r Uw """"";.- lastcncd 'O the rlXro membcr
"",.11 ",'""'" ,..., ~ :Ih2ru: :and held ,lIouId sIklr: in an
dorIpInI c:hannd OI" >lot.
'IlII:.rk1c 10: ho)w 10 m.:tkc .hc ...:ry ""mlW sIots .1\.:0. an:
~ Try <lrlUi". ~vCft.I holcs In I linc, esflial/r usIng
~rrblf. 1I doon', woriI ,bccalOK tI><: bit "'' '''b
10 ~"ct C>IJ tII<: .... <1< In,o ,lIe p""'~r tlrillal hok.
Ile"'. thc n\lop::ol ouIuilon; Ihc: plu "&l' ""'''' ' , It il; ,""
ldnI iOOI 10 cui I~ ..... f . AII )"'" , ..,.,.j It I
pLIlc 10 jlukk thc nuchlnc.

iim.,...

Im>-

Making the Template

'IlII: ,,, .... plate Il ~"Y 'u " ..ke. l!dtJR, bcglnnln& ,Ix
.cUlly ."'" '''",plo,e ""roti! .ho"" In IIM: oi ... " Ina.

....n:.

1. Cu h e ,,,mplal" blank. Muc ,..., ' CfJlpWc OUl

...--ro.

of .1/0. OI \I.lnd'I~hld< pIywood . ...

o. acryllc.
PIy .."UOd .. prub;ahly thc _
pn<'IbI . r kk<: tu Jut ...... '"
:md Iayoul matb 00 ...... pb ..... aod I Ilnd It dUlkul1 ro:ICC
..,. rnarb nude 0<1 ~ I'Q6ilIonIfll; an ..:ryIlc: ,cmplate b t:3Sf bcca...., k i> drar, ..... Ilo: amul ... ,.11 d " m"",
M:.,.uc con Ix broUn.
Tbt
$hoUkl tot lr200 ""Itt "" Ionjj ... , ""
da ...... .". 01 your """... ""'" and I Y.t ti""", wkln". n..,
u:mpblc >I'oowo'n In ,IM: .nwI"II'> b lalll'"l" 'h.:In , Iw. /Iu' 1,
p~ plen!)' oi d.bn.,..,.IiUtb. II) )'OU ntI c..... p 1, ,O
, .... worl; "'ilhoolln,nfn"i1lJl .."IIh rouIn" """""'''''''

''''''JIU,e

2 . ScrIbr the cr"OI!\/;h:Hno. \"QU ntI lncorpoor:a'" 'hOl<:

hd pfill aIijtnmmf inO only If )'OU "'" maldllj( ytMlr l~m
uf dnr pb!.I:ic. rnci>;c
llnes wlth ~ u,jli, ) k .. lr~
"'" IK"tMch _1 :anii "$'IU2lt. Cut rigii. 'h"-"'fIh ,.... nuskiIIA
paprr !hal pnM"':b ,IM: pb.stks >urf:1ce.

pb'" _

1""

3 . RoUl ttoc: s lol!J. GuidillJl }'OUr n:lU'"," opinst ~

... lgIM ..... mu, " oIot In , .... ttn'n" of ,he ,empla,e wilh "
'!i..inct>-di>""""," M",IIjll' hit
m:uch ~ 't.lnck-<Ii>mc:'.:r
pokIeboln&

'o

thc tempLoce O>'CT thc byoul mari< ro. IhI: >lut l\J!;iuon tht
clam!'" wh,,~ thcy _ ', in.crfc"" whh Iht "",Iu

SlOTTEO 'ILOT TEN'LA TE LA YOUT

Scri!>e crou~rs !>efort 'wUng ctmpl.ue sloti

rr. ,.""*L
J

f- ... '>.

'i.

"

1-1\-(. ::

IOW

"Yt:l:fs'1'W-101o9
pilot slot

7J1\.----I

3. Roul tJ>t .,....ntemon:, Olud: ct.. ~ bit In

Ilie routCL Sd thc ""tin", depth &lOp ro ~. ind> hcyo)nd Ilie
.hlcll"c. 01 thc Icmpl;o'C . Sl1 ,Ile rouI.". Of! thc ''''''pb,t,
""'" thc: gui<k In thc: Icmpto.c" $101. Swildt Of! thc ""',."..

"-

pltIfIIIIC cite cun."., and mul.

Yltld)oW'. Ibr::
polo! siot

1.....-- 7\o\"----:l

17\1i"
\, y,'thkk acry lIe
ood

p""'"

Of

N,dbo.ud

4. Rom tJ>e SIoL Swildt 10 thc """lin bI,. RC5Cl Iht

CUt';"II <lq>th "op 10 thc ,hicknao 01 tht wtOftpktt pl ...
th:11 oIcht .empL. ..:. Reu thc ....
NI you CUI, ",n .. nlbr:, Uw. you "'" U!oInit toIIy fr>iJ bit.
,. '" veI')' ca>J to ohcar o/f thc CUllinil ilp 011 h.indt OI' t\o..
Incll blI. Sa - . , I Jftb 01"'1' ~Iow cu\.!<'u """ Ille oIot.

CUlti", Ust
Qly.

D l menJlon s

M;Uer!;J,1

WlC IOWlC 17\1i'

"~""

Using the Template

n., C)'JII<'aI 'oj,.Inch suKJ<: bushing Itas I roIW ."'. .. """ Ind!
1orc.1Icfon: you non """ c....." b ct chlnntr .1wI .haI _ ~nd

....... ,,ha. 1\'0: dim:1td )'OU co m:U:c-you ncnIlO gnnd

dooo'1l thc toIbt.

l. Sc:t up ti", rOllCer. To rom I $101, )'OU'I ncnI a

pIuow: rouIU. .. noe c..... plaCt ""Ido ( Ilie loiHncb-O.D. oile).
bi.o----aoe il>r thc: ct>lUlccrbo.><c for clle
"""'" hc:td and I !IiIl'CrmI onr "'" tht...,""'" sIunI< sloi. For
- \O "",ntlhtad "",",". ..,;e Jt.inch-dbm~lu bil 10 CUI Ilie
counlc~.nd I ~"te1 hl. ~ .. . hc ~ sloi.
For. <08 or -6..,..,... """ cht *'-"inch bll for tM rounttftI<IK
...... !.ind> bit ro. thc: 6hanlt ~c

_ .""" "raW>'

2. Oamp Ibc 'empbtc 10 tho: ...orkplc:.

u... up

II.OUI s lolled pllOH In thlt d .... H Ihit you uSt In

i tliehlng i tabitcOp 10 IIM !eg-andipron lSstmblv.
Tht onew. d,l ~n th<O\l9h tlle cleat Into Ihe tlbltlOp
thus will bt Iblt 10 mov.. I Iiltit 10 ,ht top u.""n<Is
Ind cont"'Cll.

TEMI'lATE CUTAWAY

'- .,~.. l\6" .Iot.

'-..." .," ,~,,,. bit

ca
~

caS'

Boring
Templates
Roullng hatu m .. y be hori",.
but wlth ueh of thue templatu,
"OU Ciln gel soml! preuy Ueili",
raults: difftre"' slzes. through
or blind holes, fiiiI or Itepped
bottoms. evtn drc:.. lar grooves.

b<J.red wj. h """'Ule. !>Ils.

hole "W'. ~nd flycuuc .., y"" can usc: ro.Ucr and

aflllNlian,,,,~r hol~ '"

Ir,omrucJ (anII ,.."kly,.ve 1>;".., coup~ of lI""'l .nm

"",1> i n ,hl' I>00I<).

Of """""".""1' l>ooinJI

opcr&'''''''''''' limit;>,1on

tmlpbte gukk
OI" IWO

1'0< c:nrn,*,'

a hand-h""l titlU, nuklng 5<0'" lhc hQk: iii

*I~ 10 ,h~ surfocc b LI'" p"",*m
. y"" ",,"' 1 ",.". flycunc. In. h:lf>li.hcld driU.
. l~bmc'er ~nc:r hitJ
C06IIy, I>OO2dJusubk.
anei ~"",",". SU II ~_ 101 to ......., ""'" 01
~

""" .".,afic

W,,,,....,,.

_ Nclthcr _
.""..,

$1'" . -

ny" "w:r ..-an

(tel'"

Thc Ibt couId JO O<l ,(lt l 'd ..... Uy . hink .Ilc>u' "). HIn
r.,I\cr,han bdabot II, le, m~ ...y ,h.,. rou''''' and ,erupb'"
an pt(KIu l.:org<... .II.m"'.". IIo!lk
)'OU ..'horn <>chef
opp""'d"", an:: M)'mk<l by thcit Ilmlu.k,.."

ro..

u..

fOUkr

thtouIth

u.. C\L If)'OU

Rd

th.roush

hoIc. IuSt kttp cutd"ll dper untU ,t", dbk 01

....... c iscu' fttt 01 ,Ile wurkpic<oc. lh 6'Oppcd holc Is ",ha,
)"OU need. roti, :uuund ,1Ie ",,<lule,er of thc ,emplll' e

1"*

'o

f,..... u..: driU prcu.)'CU iim: !le .bIe 10 pe!d! Ilie

"""" an "'" madlin<:'. ~"k oahk. U thc wor1<pk....., il<
100 bif; ar un_kIy. 1f IM hoit !$n '1 ",tlfl''''1y d""" ,n
,lor wotkpic<:c NtF.hc "rill p"""" ~.. n" ..... th~ joh.
'I)'tIU

,tmp!>,.,.

5ohown t.rn. ..., I bo' d! 01

wilh II<>IQ <.'VI in
'hc:m.1b rout ma,d!,"#1 hoIc. )"OII ..... pty damp ,~ Imtpbte 'o tb(, ""00"II. fit I p""cm bi' in your ro,"n. arid ici ,~

unIII youVc: CUI 10 Ihe nml lk'peh . tllm wort b3d 200 lOnh
,,, Cl<C>'''''c aU 'hc ....~ .
Now <Ion', ,hlnJ< )'OU ...., tirru,td ,o <q>roducInjj ,...,

hole In 'hc ''''''pble . It)"Oll....,. ~ bu>hlng. " 'hkh 0/1"

bit rrom tb(, 'empl&le cdF. ,..., hoIc 5itt It tNuccd.
'00 CWl ...., _
:onr ~ bi' wi,h pokk
buohing.1Iy "';11.\1 diIJCrm' lUidc ~.-.lght bi' rom.
bi ...,iooo. )OU C<UI ...., CIoCh ''''''pble hoIc 10 roti,
lea>!
tnm differm, i .... of hoIc If)'OU usc I ~..tnch bi' ",1,1t
/luIdr bushlng wl,h In ou'>kk dl>.n,<~~r of l-< incit . It
mI...co thc dlamc,er of 'I\e 'empl.>'c hoIc by \0'0 Ind!
T11c ,a!)le .,....... pb'c Si 1I2Jlw::>t" <)fi pali<' I I ..,.. 0lIl
,11e 5p11k!i for )\MI. " 11>1> the Ji>:a 01
that C<UI ""
....IItd ""'ng u.. 'cmpl;uu. anei It b kJnt.. fiu, 'o cut aU n
ni , h~ hoIc ~. )'OII nttd an.,. th ..... gui<Ie ~ :&nd
four bi .....U COIIImon ......
One b>t
~
roundC"d
!ieU ' Ile

a,

"'*"

'h'"

oi,,,,, ,,,,,,pIa,,,,, ho,..,

<:OtnCtS.llIosc C"mL"'" "",,"', .oUJ><kd

it-L"- (or

I"ol".~

Making the Templates

' hey

iti.. I PUl"J"lll"'. ( b mp I ''''''plll,e a, , L....".,r o(somdh~

!ike , ..bk'op, "mi )'OI' ain momi Ihc romcr USilljl ro"r
lOIIta:u>d p:ll1Cnl bil. No s;ow ,""ro 10 sond ;ow;ty, no lip"
pin or Ibl ' 1"',"", Usc: 'hc .am.: ,<:mpblc ., cach cu.....,r un
lhr toblftop, ro.. """mple, Ind yo" <OUl round lhe~ ...
woothly and consislcn'ly.
Thc tcmpW.cs ~ )'OU romcr-round glli<lc> >Wting 2' I
t..Jnch r.odi ... :u>d funlp/ng In Y..mdl1ncrnnm1S 3 In<:he:!..
1"0 "",kc il I linie C<lSicr 10 poSi'OI1 ,hc com<:I'
rounding 'cn'pl.,,,,,, 1 m.atk: linie plll..,. lc OIUP; ,''''' )'ou
.<tach 'o ,hc ~ of ,,,., 'emplll'r5. llIc Ido " II.. , )'OU
makc IWO, ,hen a .. ach Ihcm Of! Cleh .ide of whichc:vcr
comer """cm )'Ou an: "'Ing. Wht:n )'OU usc " d ifkn:n,
..w"" comer, jtJ>l m",,, 'hc ...~ n", n",un'ing ":IC1t:WS'
iti.., pIa:lllC lmob5 1"'" n.. kc Il casy.

TIt .. " a Simple ntaner.Tcmplau. 1"fOIl1S""" sIlown In u..,

d... wil\jl.. You ca .. ""'~c Indi'idual 'cmpl:ncs-""" ro.. odI
si"" o( bok_hu. g>ngltlj; <ilc omaJk. holcs gl,-es)'Oll JpaCedtkirnl dampltlj; UC'A wi,houl ""'"'-lng '"",plllte ..od: Imi
with"u, "",kinllll>c Icmpbl~ unwiddy.

,O

Cutting List
P.rt

Q<y.

Templale 1
Templale 2- 5
5,ops

Dimensions

Material

Y.t"><6'>< 18'

""
""

W>< 12" >< 1.'

l-t"><2"x3"

Plastic

Hardware
2 hu nUIS, \<i"
2 knurled plaStIC knobs,
Ihread~d

in",":

'[)1(-]2 from Reld Tool Supply Co, (800-253'0421)

4 Hathud wood .erew.,'6

><~"

elReLE TEMPLATE LAYOUT5

.-

3Y,"

"':as,

2. Orill o . toul,h., boles, )ou ",n "",ke ehe hoIes

In S<-"Vt.T.at ""2fl'. 1 uscd a <x>upk. 1 uscd I'onlner b'15 In , dril1
ptnll tu ~ thc IOur,;m:ol1eSl. holcs. fur 'hc 1arJ!t-"t U<>Q. 1
uscd ~ router "'Iulp"",", w1,h ,ile Tr.ltunlCl 8aS<:p"l~ on
""l!C 3'. You <OUl ~Iso t.t6C fI)"euuer In a drilJ prc6O, or
holc "'''''',
lay out ,h~ CC1\ICrp<>lnts on l!te varlou:;
Ilo'"
II100se 1""1 )'OU " '" rnaJtinJI wi,h FotSllK'r bits. . flyculler. OI"
hol<: ... ws. ML..U,.... bc no, ,1Ie hol<:s mu>< he pn:.:i:s<:1y ./zed
bul ntII p...-dscly ""-",ffi.
for elto5c eh., wilJ bc routed, locate :mII IIrll! 1IHnchhule>. Sel up 'he tOI"er ami 'r:tmmel, "mi
IIl1mctcr
rout 'hc ""Ies. J fuunIl i, hcnt:fld:t.l 'U "'-"' up <il., mo'e' :uwJ
make ~ .CSl p:I"" OI' scnp tt) en5UJ"'-" , "", .he Ir.unmel """In~
WU ~Iy WM' J nttdcd.

C\""

''''''pili''''

3. Ro"nd 1"" COrno:nl. 1'wo ~pproach"" corn,' 10

mimi he",. 1 "S! 'hc: ' ... mmel. bltI }'OU L;tn abu .imply ""mi
~ com<'f5 10 I 1')"0"1 line. TIte lru,h ... i, 's ,ough 10 con>pk1ely
difqling ,he etlgic> \tIhen routll\jl. .he comcn,
, - Hanglng.up hoit

'J~",;,;,:;,,:,;,,.,., 2Y," rad .

5" dia.

"

L w

rad.
_

3" rad .
H.i1ngingup hoit

Q;o 1
,,.

Hangingup
hOle ' - . _

IWrad.

.g

.,"Oid

3"

wood, n=lium-dcnoity fihcrboard (MOf), OI" pank:leboard. ...,

Thc "oek shoukl b<; ..
~ ineh <ilick. It)"OU,...., :p ro- lIudng ,I>c trn,pb'c -'Ct .1I"wtI In 'hc Il ... wlng C/rrk
Templule w)'oulS. cut thc: bbnb 'o Ilie .. ~s specIfie<J by
.h<: ("ning [... .

[>i'''''

1"'"""2 ha"'ll~r bolt., 14" >< 2"

," dia, with \4"

1. Cul , he blanks. Tcmplll,,,,,an;: usu:dl)' m:t<k:o(ply-

,W rad.

6" doa .

".

IIoring Ttmpla,ts

STOP' OETAJL

........ t

PlAT[ l,AyOlJf

,_"""e Il0l6 _ u_lII. When

usl/I9 I " .......... 11\ wonk In. tn;IUbIo 10 .... kt ~ ltSI
CUl In sa.p Ind _lSurt M btfotl! cU!tJng ItIt 'tmplillt.
","cu~'''r .I~M

... ......., .. ndI~ 1. IftC>'iI;>bk. , 'uu do Dd .mooth. nJck

(n:c "<ljoef ......"" 'rtI.pbtc> tu "".......nh ....,

4. UriI! 1o""lIholl 00""'. 1f yuu I'l:on 10 "'~ tlK"""pUt.,. by h.n!li""

1If>. hy:all nll:a ... onaI<c I bok iti
nch opln~'al1y ..... thal, """, lwtjllnjI h,,'" Innriably II"b
nk,,":rnd <knlf from tloc .... nk o( I"" ... U from ""hk:h It
h.:onp. You d<Jn 't ...... ' ,~ Injutks inI1lct~ on tllI: ,,,,,..
pb.c bok. hrn...., ,....,.11 tr..."," to tn.: 1><010 TU"!OUl.

\oi' X , 'pilot hoit

,,'"

t""..

, . M.. kc Ilo" "IOp pl .. leli. Wk .. fU" nd.",

t_

l x .H ".. k pIoecC" o( "",np I u>Cd pLuck 10:1\ """r (tOm

..... k'~ tMoepbln "",,U!IC 1 lLad il anii It Iook. cooI, _
p/f'"'oooI .....".ud .... rI< ...cU. as ... >UId thin I\:onJ..-ood
~

'

""'" .."" pblt Iwi IWO poInb on nch Mic o( I

hok. ""'" l<)lnt5 ditt ...... 1ht ocmplaoc _

tlll< - - . . . . . ,......... llI\hImnl,.....
JIOp
fNml_ ....
Cool ohio ..",.,," '1' ..u.. cl\:omrcr ,"" . . . . on
1"011\"" WIk, ,bm ..,. OUl 'hio hoIn. u ...... In thc
<IRoI.i nl Slop V.1idL T1k ttfI .,.. huk _
I"oold< dcar2I>Ce
,in4! knub, 00 It
bIjqto:. , .....
,"'" ,krndrtllC<'lOon o( thc oNnt. nrtll pliou lOt 1"" ' WO
.......U....~

1""""" ,""

t""

lOr."" .......

"""'*' ""

>hl..-w~b

DrM ,"" """'"'" Inl .. 1ht Ionc< IWO hoIo.

6. 1ns&aU thc MOJ*. 1b mount lhc- MOpO. I ",",,".((110
1..,.., I 10(,"" . . ltlt pbstk: k....... (MI It. No unc (.1.., I """'-'
o( ) m.n I ..1IOl<kd pi:t>l.k knob wIth Ulf'C"rN thmod. So
I ......J I 1..1lJICI" bt~, .. hlctt Iwi rnacI1lnc thrnd on OM
cnd. I III'Cf"<l thrnd un ,1Ie OI"". 1um I nUl on ,""
ohInk. 'hc:n ,"" u.ob pm .hc mtl
.hc 1u1ob.
!Ion: ,"" pllUI I"I<oi<:> Imo .hc teftlpLotc cdgc> fur lhc0iI"",.1b """,n, ,. OiIOj'. hokI ~ In po$Itlon. in....,n ,"" ~
.... nk intu tlle hok. lnd tlW>.en.1\( ",n:w

op''''''

Monbl", SIOPS m~k", It MI,/, tO pos~oon

t'"

COfn", ..

..,.,ndln9 templaCtf. A ',..,,_: madt up of a hange,

bok and I planle kr>Oll. is , .... ""'" tir hand InlO I pllo!

hoit In che edgt of Ilie templat",. " " oehlng tlle pI.stlC
stop. Tht stOp. Ultelt un th tdgt' of tllt wOfkplec"
ens",lng IIIaI tM lempll" 15 Illgntd ""sh .

Using the Templates

'ia/I'

'e'''pIa'c. K&:rp thc coUu

'~fISl ' II" 'cn,p""" rugc ...
wotk. 1'1""8'" liltk .sn:pc. for thc l<'COnd rc-voIullon,
anei 110 10 Ihc: fuU dIrpIh ro.- ,hc: ,hIN ..... nd.
If ,..,.. 2n;: n>ady lOUIinJI;. m:uot. kltlng thc <kp<h o(

)'OII

Tho:: bsic 'L'Chnlquc I 0I ...1alnlbno.-.ud: C1amp It.. .c:mpbl"

10 lh<: """"1'1,' ..:", ....1 up . IM: " ".U<'1".:md IOUI.

1'''''

""""'" Ihc: wod:pi'r, and M .. a b;g hok. CuI ... nwar

dItou(I:II tI>e .....-.rl;pIa..." and
:> 1IfOO''' OI' m.~
...,.,.., 'o..",lnll 1>1....111> p",rtlc-. ",,",ho~ bI . tOt
~. OI' p/unftInf!; l'OIIII<kr."I' hi, _.oo )'OU an furm

eu .. pn:tty imp<lO'Ull'. l'IurW 10 ,Iw Ikplh and """

:lroIInd .hc: l""'pI1IC:. Thm ....,..., IIM: fOlIl<'1" bac:k anii
furth, dori"8 thc ,.,utc rrom 'hc: mkl<lc o( tI'III: m:uot.'Tht:
,nnp""" and gu;dc hushlna _
~ .... , )'OU <Ionl
.....:...d", .... , o( thc: ddlned am (......"hl\llllw 5 no)' 10 do

~ buI'~"" OI" ....."UeI..

when ftrchandinll

Wbm rou du 'h'"

11'-1 :> tin:k_ QJ, <:Omplel:tiy

1.',

u.e

1. Clamp tll.. . " m p la.r '0 .hc ... o .. k"iI'....'.

!lrpnI<fi1l8 "poli ""-'n: ,hr cUnIbr <."\II mllM "" ......... any
01. - r ni cbmpflK ,~ ""'f br in onkr. I( ,IM:
loc:uion II dolic 'o an
an ..... ptr cbmp w.emWUf'kp\'r If i, .. bqond. cbmp. onch . .....
<:2I'fICI "pc , ... I>,,(md' gluc:.
Untns! up ' hc ,,,mp""" r..... " cu, ,Iw mllll "" plxnl
~Iy I. Uulc 'rieky. V"" c:ln octihc " ......... 1... on ,hr
,oompI:t'c. th"n.I'}"o align ,hem
sl ml"' ..
"n ,1><:
...:npl". v" .. an .tso ..,ribo::" dtel", on ,11e "'Qf\:pi,"",,
\lut il ,""
the '''nlpI:Il'' upc:nlng. Un", up thc:
IftIIpIaIc""'1M: circk

ruw::.}'011

pU'" ",.IM:

",i,"

ni,"'''

_..,:<1 ""

2. Sd .. p ,Il" rouln". Du yuur PUII>. OI" coruul. thr

..., tabk .... P"JIII' 1 1. Stl.ce ,hr hil .n11 ,hr JUi<Ic hushlnll
romhln;o,ion nccdcd lOr ,1><: sitt bok -,ou an:: JD<>inII ' o ftJUl ,
Oll.o:k ,IM: bu In .Ioc coIk:1. and r" thc """"Ina 10 thc ~
pUlc. kI .tIc plUIljlIe Ikplh

"''''''1'''''

3. Ro .. "Joc hule. Sn .hc

,IM: ,rmpla,e "';Ih
Iht roIb .. ,iglu agaln..;! ' he ~. .. Swhch OII d le
~ ,tir
"nd !i';cd ' he ",.IIe' d od:wbc: """'nd tI>e

hi'.

"""CI'.

~).

~.

Roundlng Corners

liG

1. Altacb lhr alo"" 10 Ibr irmplalc, PId: thr

Innpla,e <:OmrI" ,ha, tw. Ihr l3dIus )'OU ......., 10 1l'iC.
l Mop OII "adi &kk 01 thc: CQn"ICt, lrtKrt ,""
"",.. n'ing .'..n ...... 'I>roualI thc hok: In IIM: >lop. and r....i It
Imo ,h~ pilot hol~ In Ihe lempl:o,c cdtIc: .u)'OU I~I"" IIM:

"'lid>

te,..,...

se,..,.... Ihc:
poInts on cam .idc: 01 .1><: tnO\ltI~
""~ ,..ill ,II" Inl... . hc: I~mpl:o,e nJsi;<: 10 kttp , IM: ><op
from rotOllng.
2, Cbn,p . hI: l emplale 10 tbc wo ..k"lccr. TIM:
.wp:!i ma](" pIIl"Il""""8 Ihc: ."mpbte """l'. Set 'OC ,cnlpla,r
OII lheo ..-odplcc" and slid<: It di:igon2lIy 0010 ti.., RUf:o
umil bOII> owpo ""III"'" .hc: ....... OII cam _
o( ,he

n.m apply a couplc

inlcrfi:n: ..-ith 'heo fOlI,n.

<:Omrr.

o(

elam", .... ""'" tht.-y .........

3, Set up lhr 1'OU1lef'. Ib noI<:d. fOII "'"' a ",1Int! bit

' h. '>pcra'ion. l"hc CUIlIna c<W doQn' , """'" .0 ""
lonl!Cr ,han ,"" oIod:
but ,tic br2nng OI .... hc In
~...... 'OICI w l,1! ' hc 'c"'plale OR C'\'ery ........ So in adi .... i""" 'heo
",,'dnll t.lcp 'h . )'I,1t ,,:aUy ha..., ' ... :<imply .""nwl ' hc hi' tulIy,
"" u.e, oIwIkmoun,"" "'-"'ring'" ClIpos<'d:md nn con!:....

,IM:

,hlcIuIoo.

Ic:mpl:"~

4. Roul .br oorlKT .......y, Whal I usu:tUy do '" .ak"

.......... cuu bac:k and btll. nlhbli"ll away al .bc comcr of
'bc """"pi'r .11La>T thc: ",""pl1'c Ila' OR 'heo 'cmpt:&t.e, bu'
tI>e bo:2ri ....
q:a; .... thc Icn>pbtt; tI>e bI. l> OUl OI thc
c<W o( ,hc: worI!pIca. 1b Ibc comcr o fOlI.<:d ....7)'. 'bc
bo:2ri"8 ",,".1 ,,-", OII thc ,nnpl1' c, and a ftn:al """" aIonII
,he ''''''1'''''' ....... pIeI:'" Ihc: eu.
Now. boo, bil Imgth. Ir)'Oll ha.", a ..."em bit ..itI> a
1lnch cltu in" k:O\SI'h. )'OU ha,.., '0 mal<r. ful l-<kpth eu; )'OU
<:an', e"-,,,p <iown 10 fuU <kp<h In incrnn""l> . ..'hk:h 1. lhe
......1 ro... lnll ap-pro:>eh . W'jlh a ohon
as dcrp as }'OII
m.... un ,"" li"" pus, 'hcn rcmovc u.e, 'cmp""" Ind gui<k
'loc >tt'<ond co, by ridI"3 thc """rinA on tlle Wgc ruuled ""
,he tlrst ........

Ion..,

hi'."'"

bllsh;ng . Tt>e bo,l", ,emplales Cin tlrlp yoo produce

tltrough hol" SltPf)rd hoIoc., 'Keur . II''''''''''. Ind
Iru. In oU .om of profilel .

'Tht: ......., ,cmpl1'cs <:an I>c: UK'<l ,,, ruund o/J ti... o:omrn 01
ubk:I<l>S, COW1''''''. and OIl>c:t 1"'""""'" lrutcad ,,' usi~ a
guide btMin& ,..... ...., a I"lttnt! hII, wlllch Ilas a ,h:tnk
mountcd ~.Iw rkIcI .... hc ..:mpl:o'" 10 gltidc ,hc: clOl .

r. ...

Th. ruoles " ... "n)'Chlnl 10," boring , but youv.:

go. to b<e Imlgl"",I\I" In yoo, dIoices of bils Ind gllid"

ca

V""
can """

cat! ronflnc 1"'"

wm 'o 'bc "'-"'1' ~........".. Ot )'QU

r""" $Iop 10 "'01', whlcI! wW help bknll .IM: r.u.ll...

Into ,hc: fbu

Iorl", T~mp"itS

How It Works

.-.

al

To IIM! you tt.e Idei of how IISInIi IheH t~mptalt.

.. orks, t.ere\ a lo"lng of the gul"eJblt combl/\Itlon.
ust<!, wlIl> the differenllil bet .. Hn t~ outslde "iilmeter of tht glll"e Ind tt.e ",,-mete. of 1~ bit. Whiltl
IIm ulling t,", "dlff~'tnt .. l" OS Iw>ce I~ o{fur, Wlltn
\I"rog il p.ortlCul.. gu.o./b<t comblNuon Wlth il CIf'CIe
tempLue, you Cin Cllcu~te Ilie sin of Ilie ~ YOII'II
Cut bv subt'ictinglh. d,fft,enllo1l from Ihe "lo1mettr of
the hoit ,n tht lempl'lt
You ..,II note Ihal NO combl ..... toon g!w,s \10\1 il
\-I.lncl> d,ff.ren,,"I. Ciln~ b~ "o.... Wllh ouldt bush
Ings; tlle coIl.o. ....as 10 hlve SmN wMllh..:kMSS, The
co"..,quenct. whoeh you wtll NIl. '" 1,," Ulfilpolilttd
Llblt. 'TtfllpI.o.', Siu RoIngn: 1. thli \"DU Unnot rou.
thl: ~. Inch Ind '\oI.-,nch Incre.-.an!S. lui VOu Cln tiV
thlS: 8uy il w,,nch-1.0. x ~lnch-O_O. bellln; .n" jIut

It OII the shank of. MHnd'I straIgIM bit. Use the

911" bushlftg .
(bgla AIneIb stockI bWtng of thIs slu: aWog
nurnber 196--0620. caii aoo-an2511 .)

bearInt 10 911" tIM Olt. mtMr !hin

.....
...
...

(OlIlde I ..shln, "I~' DlI'feiuIM'

0.0.
JlO.O.
\\. 0.0.
~" 0.0.
~" 0.0,
y,- 0.0.
~" 0.0.
)1,'

W'

l>'

....,.

".
.....
'

",

".

HOW ITWORkS
j,r,"-o.O.guidt .. 'th
M" stlJ,lght bil

Offsel" 14"

\t--o.O.gulOt ..ilh
M" strlighl bit

OffStl" ~."

\t".o.O. ould<! w ith

loto m .. ighl bll

O ffs~t

.. .,...

-"'\t".o.O. ould<! wlth

W .mllghl bll

Yl' patttrn bit

1O

ROUler /lUg1C

Offset .. 101&

Templale Size Ranges

TemplUt
Guide
Bit
HoIt
Olamettr Bushlng 0.0. O;;lmett r Oiamdtr
l' IIolt

,.
W

w
~.

W
~.

1y,' hoit

W
~.

W
W

2' hoit

~.

W
W
W
W

"

lYl' hoit

~.

W
W

w
)' hoit

k'

W
W
W
W

~.

"

1l1' hoit

,.
~.

,.
,.

",.
",.

....
~.

..

",

....

",.

.
W

,.

,'

......
~.

,.

",.

.
,.

",

..

,W

21'0'

l 'y,.

,.
,..

",

,y,,'

",.

,"'.
'W

SW hOit

,W

,.. '"
,.. '""

l'I<!t'

",.

l'y,.'

,..
,.

",

",.

".
.....

....

4'\oW.'

",.

4'\0'00'

~.

'1'0'

..

5 y,,'
5""

O'

",

,..

",

~.

",.

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Ol",meltr Bushing 0.0. Oiamtter Oiilmeltr

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INCREMENTAL lOR ING IAS(PLATE

Cuttlni list

"rt

Q'Y. Dime nslo ns

Material

",""",
Ha,dwood dowel

8uepl.ote

11"

10"x 10"

Indul"lil pin

W dla.xl"

lempllit

~" xI4"x32"

Fe"'.

l"x3" x30"

~~~~~!'l~ of ~')

",.",.,

........

,~

,. /

Hardware

,1

......

.//ii~~'.~::~:~
,hls

h~.

.~

.
r

1 !>ru, thrNdfll in""u. ~" I 6

1 pluti<: knob, wilh \-te.1 ,"ud" 'tI"16 x 1\oIt";

JOI(97 f,om IItt<! TooI SUpply eo. (800-lU-(l421)

2 10000It cLJmps (OtSU.(o ne 107U)

2 .porod~s, )10"18 x 2\o\t";

tTC225203 r,om IItid 1001 Supply Co.
t ~n~'d se't..., "

x ." (fo, mo ... n\lnO Ilie eLJmp.)

2 huhnd bolt<, ),6" x 1W (' o se"'e n

....,"0 plns)

_$ ."""

tktn 00 "'" d lill """",.11,1. b (:t.>I y"" an 11<1 III<' lo0Io

in. iu.iAhl
)'OU ... n 11<"1 , .... fi .... anei bit boIQ
<SaCtIy 24
11-1" ,he >fU<.i "" '" hoIco be,.....,.,n
.... ,.". Ind bsf ean \":1'1'.1".1 'f'3cl.. lnoon!il>lmcr can
bolI<> ''Prt. ","ling shd\e.llh,n~.
Sa I"m rrconutIt'ndin~ ,11:1, )'OU m:ok ~ anei uw a opIal
baoqobIc .... hk:h , ~-.JI ,II<: jll.:n: ......"taI hnring ha>c:pb,c

.....,.;tnd

,W
Rtler.n,. tdg.
loo ...., Il 'o lIukIc .11<' ruwn " 'hm h<ltInJ( ...... leh'p".e
~ Ir c l'l'(M" Crttpj ' ....0 ."" m:ok~ 011"" b:;tscp"'~. 11
"'--"t 'T ""',,,,, (In n' <>plnlon). ha.-auso; ,Ix hul<: ,,,,,,,Inll
00"1<' tc",p"'C ... 111 hc rorubtcn. """, hl,eh b du. ItlC n ....
:tnd b$llcmpllolc hoIef; ""'y hc mor.: ar lct:I INn N lI'k"hcs

,"00 " ,,,.., cun",b,"'" c ........

11e",' . n clClmplt- lf. In hc

'p;u1;

o,''''''''. ro", b;o..o.epl"c

Shelf SuppOf1 Templ."

13

CM' "1' .... ~ IM t ..."pl'lI~ tlOk-; C<"'''''cndr ' . Indo

ap;l" t""",,~ of 1 I..d, ap;ln, )'OU< tcmplale ",iti ~ li
inchc> rrom nn! hok 10 u..., nol 21 In<:h~, 1don 't ,i<-w this
as o prollk"m.
tIK ....... o~ op:.oct"tl ~"""-,I,,,,ntly. aod
ttl.: tcmpbtc ,"a" Ix ~tio<tal tu ","end llK .... nlt- of
ho)k,j "Thc 1""", .. """,,1 ,.ucIn" ";11 ..., """"""cnl. Ih""llh
t"', ,",,,"ubti"e Sfcin)( tn:q' ..... IK dD<k>rI_ So don', Ix

bt-a,,,,,,

at ~

.-.".
~

Millking the Baseplate

'I k p;lft> fu< .10" ~''''R: bll:ludc<J un ,..., CLn.~ U .. .
...en It ..... h. ........ t .... 'cmpbtc!5 b"II,. )'UU """' 1 nud IM

b>SCpUI .. an)'''''''''

'h" hI'

1. Cu, Ihc ""-""'1'13'" Jl"lI'lS."Thc 1),;0"'1'1'''" is. fIlt'

",-000 !i<.j .... R:, 1:&1'JjtL... lhlon 1"'" 1'1.... 1'Qll ,~. '. b>oc. On 1""
t.UtlinJt 1bt. 1 "I"'c'd II as a Io-lnd! "'1"""'. " -loII,, ,IK;
s/w,,,," It as. 7-1nch sq1DR:_ '>lan ",'I!h IM 10-lnctt !i<.j .... "' :
:Uter IM
hoIt;o .., hon:d and It... ~ pin 1,
1n".IIo:d . cut il do..-" to Ih" ~.jnch"",,""'" ohc. (Of c","""" . 1f
)'OU' rol....., 1\IUt'" h:u b'll"r boopn ..... bf aii m.,,,,,,,

d"'''' '1lI!

""""""'f)'

Inctr.<oe Ihc 1lnWw.-d ."" of Ihis b:lsrpbl",) "Thc ind':"'"11

pIn is a ... ~ pic <O( tHnch~ Iwtlwood

mut".

4. Cornpl,,'" thc ba,;cpbtc. (,h ... th" pin In tho

<I..... d

2. Mounl Ih" ba<ocpl:ne bl~nk " " Iho: rouler.

Ilc"""", .t..;, r.",01'} t.a.cpbtc rrom }'OU, pl"nll" ""'ta. and

""'8htt

3. I'lu f1tI'=br::rrt' Ih" bll opcnlng antI pin hok.. 11r

bwic:pW., tus 1"" , ~ hob In k. 1 Ind! .patI.
""" '" Ihe hit. lhe ,~hcT fOr IM indaintl pin Th<: hule" mUII
Ix thc """" disurK.'C fmm """ cdII<" oIthr: bl1cpLile.
10 ~ Ilie hll ",,,,n"'l!, >imP'!' III "J.Inch 01. .... 1):111 bi,
inlO tlle ..... tCT C<>llct . nd pl,,~ the hok 1Iori"ll tt.:
1n<kJJ"l!: pin 1>01< 10.1>;, n""", in...... 'Cd
Ilo Ihit Iirot fiI tIK C'<Igc )(0 ..... tn 1"" rout.,... ;urd ...,.
1. oI' 08>1..,. ''''' pIt'WOOd I"""I)U'" U.. ng Ihc nJtIr: ~
""II "II>lIn:: ,ha, Ihc pin hok ... tu bc lhe same <Ii"urro;, fruno
lhal etll\"" tIK hll "",,","II
No>\' 1'0' ",re"""", "',.." OrI ,1Ie hast'pL:Ile_ '" "'"
know how ( III """'" Ihc l\IUter ' " Ilie pin t~rIc ,""Il t..
1 inch 1nIfl1
opcntlJ..llun. ruh:: ltJIlrln>1 lhe ""'1'"
baoc, """ n..'" 1 jn<:h (rom Ihc baoc OrI 'hc b>o<'pb'"
Nat. .............. lhc ~pl;tl .. lron'lhe n>Ula Ind oond rt
101 b"", """'1' damp.:d ,,, ,Iu; wor1<bcnch. l1<o: ,,"<pc' .. pc
to ............ IM ~pl:tlc
H...IIy. ~ tiu; pin lKric Se, 1....
on 'IK .,..,..
pblC Sn"B ilS ccls<: guIr.k: IIjcJIt 0Rl1"" 'he ba;cpbte '~ c<I(It.
~Ildc tire rouIa lu Ihc ""u" p<~K1k:d un It.: ha.\epLlt .. Su...wilch un tbc: t"OUIU;lr!t\ p1u~ '''e 1>01<_

w~..

mountu'~"",-__

il in It..;, h.....pLu" bb .. k Tr."'(er 1111:

1'><'"'IK"". (l\Joililln .IK

IIK ""'1'" ... 111 he

pI~

""",minti hol"" ...

(Iri,:n,,,<! ",'hen you

,"" haIe:t In .11<" 'CltIpl;l ....) 1>nU ,...,
~...,mr,,",,""

'~ ... nK.'.... k

.IKm. ond ~Iuch IIK

p10ce nf tIK .. ock """"pu,,,

.~

hok,.

bb.n~

U> "'" .....Ia In

"'.w:

do.>l1 Ilie '-PUt.. III n.. n'lI<"Ibit

de, 'hl~ . ... ak" ''CI su~ thal Ihc ~rcm'ICC L"<ig<$
(IIC'C' tht ~pb'c dt:twing) tr::miIIfI pat1IIcl .0 llK Unc
""'.....'''n 1.... bit opcni"ll.nd II", pin, 'oo .... n .."" y<>tJl><1f
Illlk A...~
,",'hen )'\10 horto 'hc W;o hok In tht
'cmpbl" , II l'OU nW:c 1""'" etlljct "'IuklbDnt frum 1.... biI
II yotl w:tJII . c"l

A"OII

1;"""

--'

tlold otr "" ",...."."I"l1 U'" """'pl.. e on tht ...... '"

unIII ~ftcr tIK Il .... I""'pbt" hok 1> I-..d.

Millking the Templillte

~b'e complctnl. you

Il1lh the .pcci.l

.... n nuw ,um '0

'bc: ,cmpblC 1,,,,11

1.. CUI II.., lemp lalO: bbnk.. A> ""kh ,"" )pI:d2l
haoq>bk. ltI.: templ.:n~ bL:r.nl< .......1d ...,. bit O\.....w:u. ln
Ihis a"'. lhc tcallOn ha> 1<' du ",I'h jjO.",ull/I ,"" cdreS >Q\W'C
'U ,ht: ""n,~ oi tht ,cmpl:&'" ltu"". Se" tlo;pit:..
tbt
'(Io ..
Pf,an 1"""" ........Injl JUIQICSI~. ~ul lhe lempLu" 10
tIK JI~ Jpttmcd hy ,..., CLnun~ I.bt,

""ha,

""",,!

2. Ro", Ih., n"'l h" Ie.. O\tt. 'he d...wlng. lhen Ioy
of lhc ....... ~HndHIia...."cr hole In .t.:
C<>lumn Seri"" It", cent""i",, 01 lhe <VIun,.. of""""J;tI )'OU
do Ihl>. llcmcmh.:r ,1 .., )'OU11 cut do.>-n 'hc ,CltIpb' " . r,,,,
_~rc
b)' OUll .... 1Int 1>01< Ind Ihc ccnau
Imlne KCOnJritlld) Set Ihc n,,,',,, "'",. 1"" bolt Io.-.Iion
.ncl plu~ i,. (Il><: en:r."lt;ur 1Ia<q>l:t'" cart hclp )""
1oo.... le Ihl> ........ ~:ly. 1IC'C' pat:<' 1.)
out thc Iocltl,un

1""

...,I"lIlh. Indui nll pin holll i, usy II you pion

.heod. Befot-t rtmov.ng tht b"tplOlt I,om 1"" 'OUte'.
s" Iht ~ gulde agaln~1 Iht INtwpl,lte ed9". Thot
will tnsurt that both hOltS wlll be the UITlt d'Slince
I,om 1"" tdge. NUl, ~ncll an allgnmenl m.o,k lor Iht
'Oute, 00 thf: _ond hoit! wlll bt I Inch lfOI'I'Ilhe IlrSI.
i i shown, ~ unsc~w Ihe ba,eplate and pn>c:H<llo
bort Ihe hole .
1.

Route, MagIC

" "-. ,.,

3. C' OllDP Ihc rcncc In plao:. ,\"(JU.I mount ,lut

I"""'Rlmlai hoti1ll! ba"""lt Ofl II", "".ner s..~ Ilie n>lU",
OrI ,"" hlank ... nd ....1"" 'hc pin In tht fusl holc. 5,..1"11 thc

TtMI'lAT E PLAN VIEWS

TQPVlEW

".

Flrs. hol~
2"
al nc~ end _-l-l_
I~ \(," dia.

h" 16

~II$.

V.d~. typ.

ooooooooo oooooboooo oooooo"

.'"_.

b.n~

th.uded Insen

'""

EOGEVlEW

fNOVlEW - - - - -

WTTQM VI(W

at;gn ,"" bit o\u ,,,,, <Xfll~runc

Sli""
r~""" uf' 'o tIM: ~b'~. Wf!:t'. and dam!'
k 'o ,1>< ..'Uri;pi<'cc ,."., kncr WouId bt 1'>...1"'110 th~
cmtt'rli""
l'OUI(1' ' "

t""

4 . Plungebon: lhe boles.

s.. itdl OII Iht """<1' and

~.hc_-.:rnd_.lbr~"'>houIdhc.pi ....

iIxIainfI pon .JtouId "" apoUR'd n Ihc

line !de)'l>U bared. lkt.....-t I.hc bit :and >hift ,I>t n)UI<1' opin.

II-., lmec. and 'l>r

,,,,, "mi hok:f.. s ...1tch 10 ~ 'HndlnN al ,..., ' '''0 '+lneh boIcI . ..ith ,""
b. ", .tght og>l"", th~ fCn<.'C and II>< ;~i. . tril
tn
.h~ b ", hloch hole:
To hol"C ,.,e ...""",<1 ' .Ind. hok.)'OU lDIf lJCC'd 'o ohift
d ... r~",-'c ' Ullh tly. UrfKI,<lIRSl upon II>< "",ci>K>n ot yuur
1""",.. ,,,,,.-.1 bori'1JIlns<:pl.lc. l\Qth '.Ineh huk> mNSlIw
5.

Ph'n~r;:bo""

dW"<1~r hiL Ilo'" ,IM:

"""",

,.

Us i"" t he In crem e n.a l borlng bau pla'e'

Thls cuotom boISceplate ha. a pl .. pmj~c.ing (,om
II ,short distan<:~ Imm tlle bil opening (rliiItO
W'Flh 1""1 Indulng pin C,ptu,~d In a hoit lIe
mute. is essenU;,Il.,. on I trammel Ind un ani.,.
swing In In In;: .mund th,. hol... Brrng I lenee
.glllm tM 'OUIt, 11.10... anII you I.. blhlr
exa"ly wh~,~ th .. n~ ~. h.... wlll be bo,ed.
Shelf Support Templ ,

15

SEcnoN VIEW Of' PIN INDEXINC; AN D ROUTER PI.UNC;[80RINC;

CII
C

.-...

.
O

"""

1..'rfC~' 1r .lillnt:d u" .1Ie <:c".~rli"" """mi by .11 II)<, .... I><:r
holc5 ,\nd 10 ~
hok, )'OU 1..... 'o !IIm Ilie
">I"C' 1/10 "'W"'c',1<l '"e In<lainjc pin 10 "" '"e opposhc
.wcul'.hel>ll
It """d 1.." en."", . IL," lhc fcncc: ;" PfOI'N'rIy aliW><'<I .....
,~ LblI'toIr br fh,t,,1I. ,il<' '-.,.,,,,,11 hol. In .1Ie """n oncn.
1Ie ""'le' "" 1,
hc ,,'Ioen hori"!!.
bst ~ \l1111 ,1><:
"""e. ,umnI of/. plun..... Ihe Il" 000 nI II 1n' 0 ~ hok. " ill!
,1Ie ~ pin 6nrn,. ifl.o .he >1<1;:.0....... " t" ,*" It)'<>ll ,.,.., do
.Iut, ;u>tI 'hc: ~....."" S 'J!.h1 ' 1I,.mR , 1><: b.>CJ'b'c ,)oOJ "'" >CI..

,Iu, ..'"

,Iu,

",iI!

Ilut 1( 'Ile """" .. UIJ'

ohfl i' 50 i.

01 p<l!oi'lUn In ~nr Wol)', u"d.mp l.

.lIe "",'cp ..... md tt:cbmp k .

i:<'iI!h'/Y '1I"i"'"

(I;ow ~..~,dI bad: 'o ,"" ' ..Inch bI' ~nd ~ II", I>SI hok.

""",.h;' 10 101 of btlSf"'IIriI lIu! you oo/y luI"" 10 do 1.

OOCc .0 11'1 Ilie 'empb'" ...,.., I\nd h.>vinfc 'hc '"",pule
riW" will """'''' tlut)'<>ll ..,c ",..e ........., lImc you ~ l hc:
.cnlpl.. ~

6 . TrlRl 'he ' <"mpb'e. ~ undampillll thc: 1Cncc,

Slri~c a pencU Ilne.k>nI. ,1$ edgc:. Re"'....." 'IH: kntt . nd
""" 'Ile I"-.....IJ IInc_wh",h par2lkb ,1Ie .,.",I.'ftinc of . "e
.m'III:"" hol.".-Iu ,rim.hc ."",,,1011" ,n Iu; tI ...l .

Making the Fence

Tht.-I:N

p;o.n." mllkc b.hc " .">Ce

II pmll loos ' hc: 'cmp!>' c

'he ""-",, lOr 'hc '''8I!k d :' ru"",
...hidl "".:,.'" Ihc ,,,mpU'" 00 "," ,...,rit.

01\ , .......'llrilptC """ ..

1 . Iake 1100: reneo: b bnk.. CUl ,...., "rlp> o, ', ... ~"",
l' iywQod ' 0 'hc.' d'lI><:I!>ion> op1llcd by'~ ( ;unl"1I. Il>!.
Gluc ' h,.... b<'1: 'o bec 'o fotm ,1Ie 1I""h~hld:. bI. nk ftlt
'loc (en"" .

2. Cu, Ihe adJU~UllCnt . 1oot!I. TlIt: kncc 1_ IIIrtt

2-inch """" n>u,,'" In 1.. .... 11 """ bc """'..... up ' o ~ Inc .....
Th .... 1hc """'" 1" hdr "'de """ bc ........ioot:d :ulf"''''''"'
","",'ttn 1 """ j!ncoo (.om ' loc .uk') ~.
l'robabIy 'hc hcSt
10 rout 'hc.' hoks b ....,'" Iwtdhc:1t! plu .... ruulcr. I"lt.k:d .10"11 r.,n<'C dampN a<'rU6Io
, ..... .,;oritpicce 1"5 a jIlJOd Ideo ,n d .. n>p .<a:ojb ~Iot,!t cod!
stdr oI'hc .....tplo: .n "nw'de "IO'" b,:arl"l.1 lOr ,""
ruu'~r And n:1I\CnIbcr 'O >Iidc scnll unokm"",tt, 'hc....."..,.
pIc "" )"OtI ""n , ""'" Inco .1Ie brnclt IOp
1'.kc , ..... >lot Ioc;oIOn> rrom 'hc 'lltmpl"t~ , .." .... Ikl""
d"wI"lI, and 'noukr ,bem 'o thc wurl<pic.11",n )t.~ up

".r

""" rout L1>1.' >lot .

3. Altaeh the ","le Cbml'8. ! .-ti !)o:.So;Co

cbmp". ' hough <IIh~.. In",,", lnciudiItJI ni ..."""" ~nod
olTs, "'" sokI br a numhc:r 0I,...;k>t'dcr w:ndoo'$.TlIt: modd
I _
ha:! a h:m"k ~nd a lonM 1 _ fur ,"'" >f'IndIc: Tbt
lJ.b:o. cunfigu ..Uon aUo,... )'011 'o ''lU")" Ilie ~noJk pmltion.
Tht.- modI o( 'hc TCo:ZU7 ""rIo pruridt::l jIOOd fkllibtliIy III
cIaJt>ping. In f:Ilrty 'YP""" ""'''1', thc .plntIk J>I'C"<'UR' b
.ppIIcd "" Ilie br.'iit:k o( ,1Ie ICP1pll,c lloId. :dlbough w..

TEMPlAT[ FEHCE DETAII.

,.r
L
16

Roultt MagIC

~I"fIdw~.l

l i

voddl'S 1IM1S

"nn'

~I"fIdW~1 alIl
(I! pa'101' sdw.p
dNS 'l\>ONI MII UO ~1.lCIw~1 MII uOlI'wd ~IOII
PUI 1'11 'I6nOl'l 1 jMOOOlp IpOq 6u'.~ ,It p<I' nU~J
~'I.ldwil ~1 'II uo 'I""~I MII .....
'd pa
"3U~"JOM
IIlullu"l""o
~'II

11"'"
.t<t".OM ."1 "IIM

."1

.>Ili pu. ;)1""'=1

"'l""" .."", ""'1"

'rql O< pu.'p..>lI<lp dftlS

"'III~p ~'I' '"'1' ,.... ""'Il'utd< "'l' .... "'" OI :>lUP "'II ...,'0lIl

."""" NU "'1' UO ;)Iqdw), ""1 13$ roo,l "y ~ "'"

110 ;)Iqd=' :)<ll Ptotllrq .......1 ~~ "'lI'" .... WIp......,.
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1\11 I'U'. l>UiJ 'III IPII' UalIl '110<1 'In, I'ultti.
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. ,,1 liS

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JO ....... ~ 3lpJ'>S 14111111 00..

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,-

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>Uj ....

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SlJO<l "'I' JO ~IIO """'! 'u.>do sd'l/q;> :>ql 1P'..lI. '~
"'II 110 ;"qd=, "'lI JC> """",,>tI "'lI <Il ""'11 .... ,11: < '''''''''''''
~ ".pI 'IX pu~ p~l>"'Ip"
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'S~"'''' 'III." W"'l' U31'~ ' PUI
<>nu gq "'" I '"",'0:0,1<1<1. '1'11 111
p:oII",,,,ud JU flOI,I.:>Il
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4Iln".... -'I''IiI'l W""II1":I OI fUrq S. ~
llIij
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~
"'LI. ~1Ik. ''''''''''''' s;L\IIOO o:T'~'-'O ....1!P1ua] ilU

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"I",,)ds :)<II '1""1 *""<q> IL""A 11.'11 JOj 11>0 Iplo.1\ .1!0<1
3'''''''''''' UO -'lP:o.rtP _1" .>Il In" s;Llpmdr :IIi' 'olIll~!II!
"""'" 3 ,qdW;)l :>q. tuCUj R,j ft P5 :UU~J :><fI 4'1"" 3(dlll'<D
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Im>pl.oI~

....."1I IIM: ...'Ultpiooa" ",,'il IIM: balVpuI cunuot"l>

th< ...'UIt 'up ~. Chn* Ih>t lhc: rn- \o l'bI "IP''''''' 'IM:
""' .... (Iin..., 80Ih 1/.., ~ """ LIK OOIL _
hc: -"'"'
th< ........ 10 pooidot'I II
.\OUp ,IK ........, dam ... duon1

6 . ( .. poo ....... ) Shlfl li"" kmpbt~ ......lIlon

6,entl the non o r holao. If lhc: llIor of huIo;:o mlbl Ilo
k>ntJc< ,,,",,, N ~hcc" ,..... _.., IIw 'C1I>pIlt,~ T1Lc
Indc:Do(I pin ...11 rmu ... tha 'IK ~ of _ _

."..-conoo_
Opcn "'"

4. Sf;,t up thr rouln. lka_ ,II<" Ltlllpb,r tu.

CIt L...tnch lIoIco in II. IM rouIa """ 10 IK oei up ",'uh a ...lncl>C dU ......" . (O 1) ) .empbu: ",ilk.fuu nn ..,.. ...,. ..", NI ,1.. ,
III
InIU 'hhI
holl Ihc.ac Ih>t u....1Iy u>alll
O ~,Ind, Uomp IIM: c11o,;m bil In . tw coIkt. ;uI(I l ru,~ 1I ltw
. . ' ... I,...,h ..........
Nu ... oei th< <kplh ""'P un Ih<- pIunjJI: nMlla Set IIM:
"",In 0f1 IIK InDpI;I.'c. Wilh lhc: j(UiLk In ~
110"0<11 lhc:
bo' lJId lud ,11<" .........
Drup tIK _&fi rod .....

'c ..

n,

..,Iok.

'c_......

..,.:""n""".

""*

'''IIIIk

da"'...

l'uII "p IIK bol!

m:.-

!loc

hok "" you r .. n _

lhc: l~mpl':l1~ d<"'"11 !loc
"""'poe Line up ,1'1<: k'>da hok ,....,.. ..'" I:.o>t bok_
bor'N. and pu..h ,1", _ do:.>om
'he: Inda
and ont
1n10 llor hoIc In 11'1<: ......n.1'"" ~ ..... th<: r......,.. t....
apinst lhe: WOtl<pIn'C cdII<. """ do;)(dam ....
Now k' cp borillJl .
;~

In".

""*

,"c: "'tQI'"

, .... It,""". Ihen ..... ill. 1""'" (u...........,..<kpIh J1"' ......

,IK huIo;:o 10 br"). l.ud< lhc: rod""" unIock ,h<- poI ....... _
1lM: l'ULIIa 10 >Ct.
I ItoonIL ~ ....,...h a>cn~ LIw. a llJ)Od ......" kl __
, _-O . Ilh Ihb loJ: b I [IIun:gr toIIICT wIth ~ IrigI:r ...tdL
.,,1 ......
kpI"lI tIM: lUUIa """,1"11 "" )"OU _ _ ~
'KIrI LO r-ion. )"OU OII lum 1. OII and uit... ,.,..
......... ~ driU If)"OU ....,." drill~ a !<Crin oi 10,,10. lIoKh ..
lhc: onl)" m~kcr I <"alo lhlnlt 01 .... 00 m.1<D . ~cII
J>l""'II" ",..nc,..
anIMII

,""n
'rom .......
s.

1'lul1"'. OO..., thr 00""'. 1'Il.LjC In tIM: """ft" aJld

..... 1(1 ......... ' "'"' tIK rouIft" on Ilx- l <mpl,,~ ..Ilh il> "",,Ilic
C-":II,,ntlIOIi 10>\0 lhc: ...... pbtc Ilo'" ~wllm on ,II<"
'01" plu,,, IktIX\ Ilie 1>1. o.od "..,.... ' M """ft" 10 lhe:

""'1<,,

no:>:l hu,,"
Tcdlo.Iu>'

""'"""'r>

Ikot difflcull! ~

[ ....,ndl .. 11 ......... of su,pofl .,I.. 1001" ts UlY. AII

\"OU do il ntposil_.M .empli'e To.1ogro ~ in .eLl
.oon 10 'M II",~~ hoks. In,," 1 bolt ,hlO\>llll
tIM .empLo.e\ ~ndu"'ll hoit Ind Imo tIM LI" pin
_,ed In Ilie workplHe. II stlown .

r:d"!"'~"::~;

A"r pI .. n~ .000t ca .. p.odllC heltol fii tM

p'oper bll.nd Ir"kIt 10 the 'OUl". Ind Jet It.. dfplh
IIOP Ioring eac:h p;n hoIe Is I mlnf' of d.opplnllihe
IlU'M InlO 1 lempllit hole. l urnl!19 Of! tht 'OIIle'. IMn
plu!l9'1Ig Ilie bit In.o Ihe wo.k .

7 . S ..ltch I h" '''''' pll't.. 10 thc back

....... kp~. y"" .hlft 'o ,..., Iu<.... nlw= br li
,Ilo.: I"mplltle and ""lkln!!l....... ntlIO IIK OI"". >ldc
IIK indo!:x pin f""" 'H", ' ..Inch bok '''' t ........ he:r.
fn>c:t "",.Intr. """"In. ,1.......... . aOO tIM: p..~ltlon,,~ ....
ti .... ."...... ,1Ie" s.:tnIC"

Router Duplicator
AJ;I klnd of wooc:lworking Xeros mll(hine,
Iilis d. vk. helps you duplicate shallow

0,..,1"1. ilnd (urved moldin",s, hollowtil

ella l, SUII , iIInd even signs. And 11 does alt
'h l. whU. floiuing on

il

Ihin (ushlon of ill

'hmlla""',

""
~"'II
,hi, ....... k:~ b ..... h<, ...
""... ~1' II 0;, II \on~ ,1Ie ....,....".,. uI 'IOIAT.axll).1t
IS. 'IIo'h;M "''1'> ,.... n f< ...... uxb ls,hI . II "",~."
n28:l ,,.. bn.-iooI ~ ",",..-..:r.l\! II bon', .>fI
..1xdo .... ~ 1, 00) _1111 Oft ........tI, oIiek ....t:aa

II IoIItndy tl.OATII'o(' 0/10 AUI'

OI ('QUI'>C, " " " ,..,.. . , . !')Ur br2an muocd.)' ... UO

__ ou k:nuw ..... ",,,", ,..." .....,.....,. ~ .. TlIc _
.....
... II il. ohop-buiII ruuIft" lIIIpIoc;ut.- I()'OII ho,~. ,t.rn, _~ '*'tn". fora;;llJlplc 5/UIknI' oni"" ,.... ""'"

ro:- 0rI..-. wp)" ............ <biet

Thr dupa .... C'OfI"'-"'~ <>1, ..... "",bon,.1 bnm. Ind

,..., ...,ninl ...... um ......11 joincd.o an 'tr'-rklU'~"" pblCIl
TV uppcr bnm ha> .wylus IDOUn,~'<l al .... frun, ",10.1....
1rItW,"'cight !:Imi...." ,tim...." .. "",.. med In IIM' C","""
>p>ndin_ JXIO'IIion "" 1"" 10,,(, bc:>n, A rrmr. 1col"m ...
risInII: rrom Ilie pl>lcn .00 ;o;nro 10 IM l:M.c~rm 111""'1111
ball.r1nll 1'1>'01', iup por',; "", II ""an" A ..,cond

C<)IU"U', .t1><,l>cd " '1111 1'1"01' 10 .h" rnd. of th<- two

hr~m., kcc(t'o d'rm p. r"1(1 ~~ ' hey "h " p "n<l <I"wn Thc
pb 'en .llow. the <1,<.'1 ,",- to 1>0.' "",,',-..1 'U ."d f... (I\'cr a
o,,>OOO.h, Ih, s" rf.ce
U......, ,"" dupl";.,OO", ,"" unl"'" (Ot' ...... em).:moJ ,Ix!
WU<\1"lI >Iod .'" ...1 up, ""1'41<.-.,,,,. k> . ...:m Cf of.~
0>..... C"'ct)' ...,h "f , 1>0.- '>riII'""h """""" .. " II ,Ix! ... }....... ""
!'OU do ,iii>, tIM.('lOn'iIlIl_' tIupIOc>oc.
Thb .. rw-a ..... ...,."...., ti ... tin'..,., hoId. ,..., otl_
Rnu dilil;an din'l'llj' ' ..... r ,Ix! hI, (t1>r dI.unc-r ,. ~
:odjU!t'bk durinjc ...., ................" ...... p II 00IIIpk1nl. .....
<Il" ,"""" b ft-) nw, >1)"" ..... b;I an ~ .... Id, bul
"...,. <10.) )O ,,*,,,hcr ..1<1 ,....} .I,,'a)" ..nar., ,"" __ :u..

"""C1" ,.. ..

TIu', ,"" """1Ik

""UI'' '

of ,IIe
~1Id<otwnn tkooipI
"", pLo ." .Ik",'. U", dUpOCa' QI"'U ....inIl....,.,.u ..........
,,, :1,.. ,,,,,, .nd "",..,... /In II> ~u""lon of alr bul t h c _
and<o!,unn >lru.,un:
Whi", ,IIe

III;Itnt~ln)

,tte III) ttu4ltt Ulii

</j'n..,,'" .of , ..., ...~ntCI..." .. 11_10:1)' .....

rou';,._

kOUT(R DUPlICATOR PLAN VI[WS

TOPVl(W

.-'">

-.J

-.

,..

510E Vl[W

..

~,..

...,..

19)t

lY>...J

1 9 ~'

\10'

--1,....

,
T _;.

nit."

...

8()nOMVl(W

EI.

.::.-:::
....... . ..

.. I

..11. oi1,..

Cutting Ll st

Put

Qtv

Pivot blh

~.m

sldts

Beam wtbs
Column "du
~

Plllfn 'mGUnl eolumo "du

Pllltn

r~

Plattn

~urf,ct

AUIcnmtnt blcKk

Mounun; 1>0,

"
",
,
,
,

Olmensio n s

Materia l

~W

H. ,dwood

1i')C 2 ' )C

,w,')C 2\o1')C C8'

\I,')C S,w,')C 191t

H.,dwood

"p"""

1I')C2')C 12"

lQ.dwood

,w,')C 2 ' )C 4'

Hlfdwood

'" )C 15 ' )C 20'

PIVWood

~ f')C16' )C21'

PlaStiC I.Im,n.tf

"')C 11i')C 2'

lQ,dwood

\Io')C 114" )C

sit'

ROUTEIl DUPI.ICATOR PLAN VIEWS- COHTIHUED

ILACKVlEW

...

,w

Hardware
a ~ ben...g . W bo/'t x

ao-ring.

0,0,

x ~"Ioog

d~.

dryw~ ~,t"'., ~)<

1 'nlll,

I~"

1"

w.-. 18
x I"W
,18 x 18"

1 th't.d~ rod. ~':18

1 thrNd~ ,od, ~.

4 htx r>uIS, )o!."18

1 11f'd

~r, lji"

X 1" X 5 !t"

1 boii. d.a 10 m.td! roUltt bit, 3- long

1 .... "" nUl. ,in 10 maicII bolt OR 2 lIu nutl, ,Ile 10 I'Nlch bol\
~ IIW , ..tum"

, .... _

plo''''''''''''~1 >I"m~

,,.,., ., 1","" pk(t' '-4' x r

x ]0' ~. IHKnH" lot , .... , ..,

Routt. Oupllu,tor

2I

ROUTER DUPLICATOR EXPLODED ."IEW

P,\IOt block

/ - - P!.ten

I""",,-'[>i<:uou!l I'I'C'llIlIJIuLlr b<uc rrurr "", u;tllj' bc

tlK ,",oM (...:Inatin8 ",n 01 tbc <IuplrAt<lr It dl>trihu.o ~
OI>h"'" 01 lir br:r..'""", tbc i>lI ~"d thc ,;urfacc: , ... , II,
I"''''-cd on. 'in ""II)' dlrrti""';1\1\ oII rrictlon.lbIs .Ik..." ,1 ...
.... nCT;mol il>,.,.'mx-.d ..,-1", tu n.....'C" ...-~h.1K gn:.t~5t of
~-:&>c In a borizo",.1 pilul<" TI..- """ "'" ;" , ... , 'bc .1.
~"U"blon .... II.> origln. In .IK
01 a >hop '.lCUum
,~.u pr.. h;r.1>/r don hlnk 01 )....... ohop , ~ "" .ou..,.,
of "".. '1"<: alt no... lIur 0.11 ,"" alt 1, ",... ... , In Ius to ""
>omcwb~", OO
>Ofl1.CWhc", 1, ....1 Ih~ ah.''''"....
Gonntt"l ,IM: hc:>st
C)lh."" pon , .nd r""
alt
M"",ml.,. om o( it C"nn~c. the r..,., cnd of lhr ~ . "
tl>c pU'en, whkh dlMrihule. 'hc 0.1. ar;;n>SS a suri. ce with
t>r>C .ior hole i><"
Ind! . n.c ai. ~ushl"l1 .h"... gIt
tlK", hob It<os enou'" IOn:c to ni"" th~ pl.len .00
."I1>'c,c, s "'1011"1"" 1. It <Ioc.n', ... 1", It b._DU)W ' ..
<lent, tl>e

tu..,.-

t"',

,,,.I>e

oq""'"

22

loutt. tMQtc

"'n

ndl_l>u' ,h , enouKh 'o m,.,."" It r"""", IC"".' 111.1.

...,...,.h liuri.ce
l l>c: ""plrAtOf i> tbc 1"UU1. ..h col!. bor.ttion br:r .........

FrC<l M L:Idr.,

""""i'",, ma,..,o ..r ,lte Rod..alc Pn:,;o ~

SI><", . OO lIoh Monn IO."OOdworltlnll "'riter anei edItor. '

u'llJ'd f~ 'u ~"Umc: up ... I. h """" duplinlor 'o pru>III">. COPY oimpl~ carvl"5> . neI hoIIow ou, ><">.. fur
.cool. Of d ........ I h;r.d copico 01 phot.... 01 ~ommcl"C"bl
tluplic:u ..... Ind anld",
'''''rtI do. arni "'..,..
",,"c In(ormat"'"
>hop-hulll dupllo.or r""" I

</,"'"

.bou' ........
.bou

1,.I.l-h 1000".

Nal ~ 1 UM:w. F"", b.d pI"Uf"'l"I'C ~

kccp;nlllht
"'hh whlch)"OU .~"C 'bc ~ot ",ucm . OO 'bc
.".11 .... hit .... hlch cu.s"""", ......."'...... II"" 'hc >1)'1'" il!It>ws. In perfr...., ol!snfIl("fll. bulh at......y~ In Ibc" gnl<" uD-

rTOnl ,II<" ""'" ccilillfl.l 11<" k<")'. hc c<plalncd. b

..'1....

I~

,"" ... pcDltUCl"'" from ,""

ttitin8

Building the Duplicator

","""ni. bu'

.-ked Ihor hooizom.:Il "''''''' o( r"" okvic-o-.

II h ' WI"S L.uCT.~ ,,-orI<i~ ptUlOfYpC of ,..., dupliC"~"'..
)"011> "" ... "-as tuI~"g I>ad: ~nd funII tin ~ "",",""nell
\III nnoonW! "'h<~b rhar ....,mnllO "" JIOitlJl In .,
n. 111_ d,lfcn:nl duttolons OI OOCe. E>"<:nlll:III)', lIob
mocml ,hl. p;onlcubt pietUIT a"" ,""",ribu,~d ,lIe idt.....
for IIM- IIK"u>hIon pl~l~n a. , ITpl"""n~n, for ,'''' canoon
...web. lIe 100 eon,ri"",cd Ilie kIc:l of a>6Cmblin~ ,"<"
~ >nd Ilie c()l umru ... itll .IIIT~ rutJs Ind n""
" . . ~mblnl . ,"" ...""N"""U", . . . knockoo ... n uni.
Irotnt do, ..'n Imo hc:>m~ ,mI c"I"mns .nd pL:ouc" . ,11<"
~,or Js far "',"'. 'n
nu_ column nd .... n~

.si,,""

....., on """ In.kk ,h~ h .""n,.

0L0y. )'''U ""l;k', mllIy "'~~ . 1"" ,,11:11 (W"....,kaJ l1OOO Js k'
RopruoJucitlJl can'illjl>. '\'e mcn, joncd. If )'Ou Il"
Ifttt1"4lld-nun",r.1 >1 ... ,,<"11 . you ~",n m.kc .!glt>. \!lU ~.... n
~""'" <.... n ''-"'' an"v"r cun',-"" "KokllllJ(!l. ~'''u ""'n hollo,,"
OUl du" . nd ""nch loCI <5. Ilh:tllu ... 00..-1, . nd the I,b"
,\OfthInJI,Il:I' "",n Ix-" vk."wed as ""-"",I,d c:>.n,ng 1. ~od<kr
for ,hor ""pllc"~'''''
Thc <lk:''''''.ry dcline,; I.... ,..,tld oculplu",l ",bcf in
"'I\kh ,"" Irn;>j=lon ftQm ,h..... urruundln" OURK" ... Iigh.
lIId 110 ""n "f ,"" m'><I<.-k...... ~'"" 1. un<kn:UI " In 1111> "'....""
Ilie .IIKh' " .. >/11< .... .. lI",jlCII tu. CUIlplc of indIa.OO
<hc pmocrip,ton ajl2lrl>l un<kfCllU C2JI onI!' Ix-" riobl<"tI 'u
<!It ~iJIlU<>l <kw"n-" by u .... " haU miU In 1"" '''Uler ond
CIJmStI'''''''ng "riu>.
If ,h;' ,,""'-" ("",Of)' (It ptO~-!0h09 dupllotot
..'ilh fuul' or Ih'<'IlSt''''' pricr 'lIjI. II "'OUkl hr In",,.,,.,,,,,
10 rod .boul Itoo\. il ..'Orb. T1M: ,*"""nl o<,,,.;.c ;,. lhal
Ihis hom<'bulh <luplk..... 'or tIuco1 ...11:.. ,"" commcrrlal
<'QUIpmm1 dono. Indu.b ,"" oopIIIldcaled ,1.<V:>hIoo
~ (yOu """,,', fond
on 'I\oo;c C'On'm<:n:bI modrl
Iu <Ior:on't root ncarty ........ p u _ wplio,or ... IU ..
Thb <iuplinw. t. hulll 01 ron.monptt 1w\lOIo'UOd
Iumhrr and plp.ood. U5C'$ of1~1Ic>obc-1f bori"", ...d hanj..
......... _ ""'1";..,, a >hop ,.,.,.nd" l:tmln:I1 ... ,ri.......,.. n~
oItop ,.,., mll:>l ha,... " """'bIon for conn\lt\jIth< hooc
Ihc ah;oust port. antJ ....... v;>O 00. ' "ou 110,,'/ "',,''' II><'
~ _
JlO"'"CrluI '''''.l'hc LlmUw" ,rimnoct .,. noI
","oppi"" 11"-"'1 pai .... >IO)..a...doJc. RIUl ...... ""', you ..iti
......... k 10 bc. ,.Cf) pr.o<1lcaJ roul .... ....,ful (or.1l ..,.,~ 01
~ routirlfl.
'OII clon', ......."tI O<ldh:t.U. hard ,,~flnd .""',,. Il,,> Ari
~'of ~........oo~ (ur fO"ndn<>600) Iritl.V1Cf<}O\'ct"S ",1

.b<l.

~"ncrr

In Ihl.. "II b nu ...."hl ... k.... ''-"'' tlull ",Inl .. g1 ....

nlO", of lI.and " (ouplc o( Ii,mtded
t('lIctll\-"'. Maf'1")1nll 1:>;111 bori"". . ..ttid\ .....
normali)' .,...
wl,h ""-1.1
I \\'UO!kn
.. ruc'UIT (s '-""~.)' and .. r~4th,ron."rd ""'. ""'I~!oOnM."
and cune .. 1..... YOU n<2)" nor ...., ... )p<"dJ"loJI)'. )'UIJ'I nccd
<lrill bit ,h .. cuI. " d,:.n ""..... 1iii ~ In db""-1er III ......
Ihe "'""..... <>, ,"" ItaII hcarilltlS. and pI"8 Of 1'-""""
..."'". Ih., cu,", u."1M)Il> "",h p;ol":llld Ioidcs (POt .opnn!J '1 ..,..
10<:11 In <li.nw:1cr ,O n, r"" In"'-"1" raeo
.,
lIc"sin I>uikl,<'IJt ,"" <luplio, .... .,. ....1.....1Ie t:>ox bc;um
,1 .., brm ,1", 'OJI and bo"om 0( ..... ~. lnduduljl; ~
The

and .<-"~.
rod; 'k li",

""""wu r".

m,

rei.,,

""""ructlOll>. 'o

"'ti

c"

_.

<

,,,," p;'''01 ~'" Thm m.>.kc .....

lkIt:t"""

coIumns tIw
"""11do .......... 1lIc .11'
~"ll>hiun pLI, .... roma nc<, . l>b1.i .... , .... pbt"" S. lOmpk
""'".,.. o( routinll wid of IIfUO'ft In I pka of JIII...'OO1I.
"I'"l)ing pb<tloo l:tm"ute 0'I'eI" 'hr 111"'''''0.. and drilijng .Iny
"""'" thl'<JU8h ..... lamina,., 1",,, 'hr 1IfUIJ"...., AlIX"tI 1","
(unn

.hor ,,-"1nlI.iniDII skIo

pLI, ....

,o .....

o( """

rouIer >nd 5l)1 ....

panIIdojv......

:and."" duplio'O!" i,>CII b

1IXlUnt

th<."

C'<""pk"~~1

Making Ihe Beam-and-Column Assembly

TI.-

"'titbly b ,1Ie

,"u"',,,,, ,ha, lI"kl>

thc mutCI" and thc Sl}1u<,1<ccpins unc po:rIi."CIly oI.ignc\lln ,..,ta.... ... oM otIM:r. 0c!.pi1<-" .... Iook.>.. it b ,~ .ur')\Ic <O huikl
I')OU tak J....... tim< and.'l<1 up cxh oper..1on an."fully,

1 . Cui Ihc ph...:>t b locks.. I"d 1"t"COD1",,,,kI p"'pulntt

pic o( >1r;tigh'1I"'!ncd ...... k
.1", Ihk~"""".nd
"'idth SpO:<:ified by ,"" C.. ,,1IlS! UsI lOr .lIe plV<)! 1II....' 1u; It
.>bouId br COlII'''' offttt 1on!I. C.........'" ,1"." ho;ortl intu n, ...
pic<:a "'t i""""" k'DII. "T1IC
pic,:... ..-itI . lIu,,"")'OO, III\-"
lu"u.,. o( ruin,"t! on ... wllctt -S<-",""~ up for cunin" '''''

'o

>insle

ex"-"

'eftOfU

OII

th<." ends.

'o

",>-

,~I>i<s-((IrtImOIIpbcc

all_'Nil1 ~c". YOII ,k, n~",-"01

u. . .:.n" ""

for ~"""h iii, )"OlI

)'IIU IPln ""1"<'
rinI. }'OU'1l flnd 1.... ,l"U lI>e _',-""d bll~ OII
Prof<'c1
,"ou" >IMI ,... 1," r:.;rty l:ttgc.;:HlImc" " "" '" ck'" 11.". ,,,-".
- . , ~ corN:>olf ,<> RIUJIh 0'" Im.:., ."d ~ ' -dncr 10
odinr .""",-,, Il....... and c,ch In nil<." o.k. ~ 11
'bu JUSt mighl find ,hc duplb'o' U>dul In ronl""'-'''''''
..1th tund 'ooIs.To "'pn:.><l"'-"" d lr '"--~ ,~, fu. cxtmplc:. )'OU
an It!<" r"" duplic-' lOr n1'>l 10 cuI" >crio o.. jlaul(ln"
JI'OO"e'. Thco )'ou can II"U"", oU. Ilie .".. .. c "'Ih ,"" <lupii ..
~or, ..... ruu~'
'hin~ OUl 'NI,II >(I0I0:01'1.,..... ,.
.. _

>l)11Oj

""""'Il

",,-w.....Ind .b",si'",.

,-"a"'.

./
Thlt pivoi bloc" Iltnon s e tu. wlth. plug {uliu
thutked In .,.ou. ori" pn!". Sotnln9 IflKn.o ReUn!
,he wort.piltcn 1$ ilie pt!nnUJ"9 ""n . ~ tuue.
ItselllNke-s Ilie
fo<mlng ....... k fooIprool

,f""".

Roule. O<tpiKilOl"

II

CII

2 . Form ~ ""....."" 00. ~ 1'1...,.. b klocb. """"""'"

,Iu.. ;,. ~ driI """" """....Ion. ....... IRi..

""'It

;oI

w.k ...." >CI \Il' .1",.

madlinC" Thc
hIoock ha> ... bt- aIiJUM"l ...'I,h ,IM- ni. "f
tht d>oct<. (:hu<1t ~ Jm>,u~ .....~ ..-r hit ')f ~ ...-n'crilljC pin In
"'" liriii """'" l>r.ow di:lIfJ"'IlS ,..,..... ,........-nt.I nf. ('>Im,
bIodr 10 linii , ...... .......u.".. AIqcn ,tu. P"'" bIodr ulMkr 11..
drIlI . .. .. ~ ,...... '1I11OC 10 ttnI.". ,,,,, piec .. pnfeC'Ilt 1bm
cbmp
II", <iri. """"
tu f">dI _
pbcN in ,............. JIOI',<ln.
t-_ ct> ....1o, III".
OI" ' ..
in . hor 0011
ptno..
JtOIIljC
C'"
I"non
n, .hc:
In...". .""'" oi ~ b:dl t..-. rilljC (""d noe I'I~ ' 0 bttntt a ht:lk).
)UU do)n "1<'" ,,, ...... ('>1"11 cun .... 1"'" ..... ~ . .. ~ pb~
l ....Ioc .......,
oi ('>1 ..... CU"", u... pnlllucn
~ ..irh pa ...1d ........ ."..,.... 01 "'" .........,. 1'1.." .enon,
__ ..,.............,..". '<t ,loc <iri. "...... d"'fllh ""'" "" "'"
...... ,.". MA CUI ... In'."11 In.o .hc: ....... ", 1"" bkK .... 1:. . . lC!oO
, ......... , ... II ... "", ... 1",'OCobIooek hLInI< IQ chi: .h.. >CIlirltl

""*

"ne.,. ...

a
M"".. 'l"''"

CUI",,.
10

con ...,

""n nil'''''
"""Kl
10

n .....,..,.JO/W 'n""

\\'ilh lhc ( .........:UoeM of IIM- ..~"p ., ... Ilnnc:d ru,

1"_ " (MI hnl " ~.I<b 01 aU lhc: 101".1<., (lncl~ 1.... ,,">t
bkKk). U II... ", Io ... y l<'lKkn.., M ' hc 1l'adI> ........... or
.. I""'le .. h;"'""" ........" 1II1II .1Ie I.....,..,.damp II.... 10 "'"
,.."".,. Thh. '" MI !'i'o:' fOII ........ het """ ...., prc<'l><"
.......... ,h;u .... MI 1\1 Inco ,loc lIo::wInp lor"."..

3. Trin. Ihc 1'1.-0' bkt<:ko .... hod. fln:o.l ~h;r.pc.

1bi> b "'... donc "," h omooIlI,(, ... ln_ ~ "JM('" bIatIc un
'hc: ... hk ..... lo'ridc . ............ pIn...., ..ith ci", ",il.". III ..... ' 1,
>huukI h:.. o:- an ""dlary b<:ilIIt for ,,... <If'<'r.I'ioa
Ad;u. .hor hUck ~ 10 ' . 1oIdI, or - , _ _
lcf6 (l'ht hbI.k ~ lCIdI 1"" ...........iim ..... bkKk
OII .:tW, .... "'" ...... '"'.. Il .) To '-'''0'' .hc 11100.:1> lOr
,ht-< lfim CUI .. dImp a "Of' hkx~ 10 ,lot mii", .,......
fadnll cno.~1t' 1'. 11I<11G r""", , .... hI.odc: \"l~ ....... tor ... ",

h"'.-l i. "' .... it""'"

'" ,..., -...

,......'". "",.:tlC") '1 .....""

l.......~. Il It

on/J' "'"

hIod." ..W lIe ~ ..hm,..

II" 10 ",'" 'h" ..,."...,.. end ula bIuck

II Ih. plUJI (uII"r , III. a nun ....

lCfUUI'~

aruund Ihr

11>0.: ,rim CUI. IMI ..... ,.., 1~,1r nuIIIIoIm al __

!oU ...... "" JU>nI :lf'OUnd Qlil lC'nllI\ TlInr can IX' ..........
"oIh. dIi....
"~"K1.

le""'''

o.nn.

~. ' ruitaIJ
o.rinp. n.r
CNo.lfIOO IM
. ...1) III<' lnnrr ........ ",.IX' l>o:2tIr1J <"OIIUO> , .... povoI '*'<1
1'hio is impolfl.nl
PIVOT Iloex OETAll

TOPvtEW

m==~
'" :::;::;:t..

,.

Lc::-;,;..-:.~

EIIO vt['N

{;
L

YCTION VlEW

t 1'0"-<1 11.. bar., .." clHp ,

bou .... QUlt' ,~. of bun"!!.

OfI'IIe. llelf "'-Il bu" "!!' .

'fi" ba.e, t l1l" 0 .0 ., " " Iong

Rubbe. O.I"!! ,hlmi be",nglway

I,om .houlder 01 piVOt block.

Trim tllil sllo.ddlln of th. p lvot bloo;k III"O"S OII

tho I.llbll! 1.1"', Wnh ~ nap block ,~m~ 10 , .... mII
Of (utoff bo~ faclng, ..... blOCk, a aUlomatl
cally po,itiontd 10' tht cu ... NOlt Ihal ,he (UI' au
~e ... ith Ilie blocks standlng an tdge .

gauge

,,,o d". bar., It" 119,

P'OVK;U ,lI!a'~rKe 101
I n~. raU 01 blll",,!!

1'111". tub lenon" It

Ion!!. fu ba" of bU,;,,!!

Consul. ,h" d",wl"~ 1'1,." I/In<:. Or,,,I~ You1l 5tt ''''u

,,-ou.1d p,,-,h 'he hc.rin", ali thc "'21' ""'" 'hc
1<tMXb. 'hc OUI~. = 0 "'ould rob on .hc
lru.lod of
1....... flttl)' 1'11<: ><>1"lion tO IhiS probInn io 10 "il' a
~tcr nrin~ on to c.d! 'enon i><"furr ImulUng
dIt bnrinp.n.., ().nntll".,.IIk.. Ih .. nttUnl cI..:...JM.... . ...
"",,'a in Ihc d",willll .
..... cl'li:al"" .I,,,n..
,lIe O-rlntt> b pka of .. OUI
0lt1Oll ronl (ah" ... t ', .. locI! dl;,"..,t~r) ...'eued ,,ltI. sl ....
..."", ~ ""'""00 thc 1>:0,., tii '1 ... t""'lf\. "'" hokI k In Jlb
_'dl dw: bt'<>rirlfl. ,,'hi.., ''''' iti"" drk..

"""*"

jf)'OU

,i,,, '"

s.

l)riU lite n " , ... m lnlt rod I",I~ throllgh thr

P/>OI bloc..". l'hn<' ... I""h hoit'!> ."" tor Ihc th~
rolo INI help Iw.tIoJ tIM' riIt "'11'-"1"'" 1'hc hol<: mUSl hc In thc
ttr'IItT of.hc hIorl. '~ '''''e
noo the L"cntcrpoint. dr:o...
di:lpal1inn:K1U 'hc ph'ot hl",,~ f:>
IU 1'''' dld in ..,"1"11 "1' ,,, eu, 'he 'enon, Iign Ilie
p;.... hlod ,,_, d'iIl
'hen d.hl!' fentt>' 10 tlle
driU plftS bIe-.o bold Ihc bIock ,.,..u"" whne,..... drill
ThC><' fcnca "'ill .1><> ",ne !O pu.i,i"n Ihe "Ihet" bl<>cb
lor drilling."" ~ ..nI}' h ..... ,,, I.y "u, ,,,e cen'e' of
fll'>l bloci,.
UrilI 'h<- hoIc>

1,.

!>i'.

t""

.,'1'.00

6. Cu. che beam p;o.rt.... Thc ...... m~.re lhe

bot."", (""'ICI>Iy hon<oot:il) mo:mI":I~ <!f ti", p;t.~.lId"w.n,
t/tu """1'> ..... 1'OlII .... '" _ ...nh ."" ..1.1 .... 1' ", hc.n. okks
iI<M<: ,.... ' ........ _ ... ,tit"" ...... rin~ . Thc "'d'" "c 'hc
p.oI" of .. de, 'UII<"'II::'. "",.11" tIM- t..-.m.
Ch~ ti ... di .............. "Jl"'dflCd I>y iii<" C"" "'lII.bI for
,10: bc'ltm >i<ll:> .. 00 ",en.. hnnnll ;n mind ,1 .., tIM: tiot 1''''"
)(111) t .... n...1 tltn"'n"""" of 1"""" p;t.n . "'-IIi", , .... "..,'"
ultlm:lIdy "ill hc ~"';nchc; "'-ido:. J9U'U il"I .. no:2la ~'" ir
,fim ,1", ""cbs n"", ..ith
~ 'lfI'" .."",,".bI)'.
lhnriore, Ih I><'l'L"r 1" cuI thc-... 'SI; 'nd"", wldc ~, , hl.
jdnt ",., ";<Ies. un , .... 0100 11>00. ........ loc .;:.lI tu 'hei.
liIW :IilC nu..'

t"'"

roo

7. 80re thc bt;oorl,,1I, ~ 1" ttot ~w.",. 'I1lc.'"

.'" ~<:ppc<I-<:ow"ertto<nl. In dJc... _ ... Ih",.-II
boIolI .... Ix"~finl1llj:hll}' ""I....,.iIk dc-;o",,,,,,, lOr 1"" mne.
noct n... " ule , h., Ik......... tIM: hcarinl1 '" ,'~ i""""" in di:l",.
<In:and \j,. lnd. ok.... p "11:: d"",.....,.. .....~ .. """"">Iri<:: It
10 '. Ind> d .. AK"'n ~nd '", in<'II tkq>.
IIqcln 'he ... ori< hr ' 'lnl1 "Ul .hc c"",Ie,," m , .... 1"'"
lntintI rece .."" th.t n"",t "" 1>0..-.:<1 in ..~h , i!,le 11'e
Ioatlom ''''' ~ho",n In 'he Mu 11.... 01
dr:owmR
b'", /J"fIl1r",,,r I'/m, 11"",... Thc """'" .re een,,,,,-'tI
beI"',"n Ihe edl1~' of ,he ~kkJ . Thi. . . ~..,.,,-cnicnt
1troI_ i. ""'OI" ,h.. ,he fQu, p'ttC':! """ kIcn,lc:olr:o,"",
tIwt "Yrnmctri<":ll Y,," dun', h.'" In ~~." tr.ocll m al""",,,hoH:! .... p:o'1>.
\)nI ,"" ltto.stS on UII:: drill """" UJi~' , '..""...
.......... Foro<n<"r hit CI.mp. k ........ o Ihc- 0011 "",", .. bk
IOpo>iUon 1"'" ",,",pir..-.:UI nd .dlu.. lhe ,It..p'h "'''1' "" 1""
~

'n

t""

"'*" ...m ... C1X'I)' 10 ind, ok.-q> c:lM:dI ."./ ronllnn ,IM:
cIrpIh .op !tr'1111'11 I>y

P~';1lj{

bcJrilljl inlo

(~

hoIc

,,<,,'

,
-:-;;f'-,Y
'i

of

".
.', - -~

"Y-"!

UM . fIlM_ to 10CiU. Ih wotkplecH. aud bonng ~

.. ~ hoIe. for ,IM! l>earl1191 0 0 _ Ni.... Iod! haIH
_ an llot """'" uls. T.k~ I~ 11"""0 ~ ~ ~t ~
........ SO I~ hoIel are ctnltred across I~ beam >idft.
Then drl' an the be ... ing l>oI~s. Aft~r s....ching bils. dnll
d the <J.a.on<t hoIH. ;os .hown M-r~.

,...., bnrinK ~1Id .... n",h "Ith UII::

l ll::"~'"

""'" .. ben k .

fulIy _ n i iA tIM: Iw.>k

MIc. Uri'ltng an IhI. bt."Orlnl1 hol"", ",;,d! biI. and <lriU
,iM: nnc:t"f1la dca",,,,,,, "'-..:n.....,..])On' l """... 1"" Jcnct-: ~
;n thc
putitiun'" J"c)'OU ck-.,..n<... ~
ronccntJic ..ith ,"" """rlnll I>ok:o. U.... ... 'odo Fontnn
hi. y"" "'''' I nn:d 10 ....
of n"'len.1 ""nem"""
J"" "" Ind! b tkq> ...... JU!1I.

'ho' .....

nwn

"""'C. ""

M. A-~"'n>bk: II..: ht.:~",_~. ">...."'blr ~p'un:t ,""

......fi""" and pi>'Ol bIocl:. .... )'OU \\".'" U, 11'" ,IM: unit
"""",,"'II_hlr hcforc .... ~;nll.hb I....""'...... 'k'" pc.....
"'or 'hls ~ I $l1fII!i"'I' )'Ou ''''' A,hle ' hc bel ....
",lth "" .......~ ""1)' Afl.., ti", dlll'lk"O'o, 1> ~"Ompk"c:1y
. >S<"mhlt:d and tNlc:d. hul hcforc ro" put It 10 h""l' """.
~I"" . hc ....1.00 ,nm l""m.Ta do ,h~. "'nlO"" "ne .... t:b
.. ~ Ih..,;, . pp/j' .......... . 00 rcdri,.., ,,,,,. ;c"'....~ In ''''' "''''''
h~ Thi~ c:nStan:$ th:>' Ihc .. ch i< ""'inl! rcturn~-.l ,n il>
",,;oct . ,e"cd<lnd-f>ro'\",n positiun. MIc, .11 ,""
th,., I"'rtn.ncntly lixcd. ""'" '","er " 'jlh flII'h-1rin,mllIII
hl' '0 ........ tIM: wri n'C'll ",';'h tbc >kk> (Y'''' CII' t""
1111'" "' kk. "",,,,mba')
IlUI I'm 11'1"1III'1w..-.I uf ""
OeWn .It........ n'hIj ... ,><iI: h) f>"t'I!'I"" Iw..-.nn" fI,lIy
InlO """h ~ In 1.... lInm""'" M .~e......, lh..')'~ .... nu,.,
.. I.h tit .. ,"rfat', .M,hI. ...... m lii<ItcI '00 Ih,1 Ibc In"", r. C<1I
'recly
Now InS1~1I Ihc f',-oe 1>Io)d, Cha.1< tl>:o, )'OUr o.ri,,!!,
{'" 1tl'''',I-<-~JRl "'" ...., "., in pb (lf\ ,h(' ,~. \Vilh OI ...
u( ,IM: "'-le,
fl:tt un tIM: hcnd! rop, iruorn pi\'01 bloci<
In'o <'2<h of 1.. h""rinjo:>_Sel ."'"...,.. ><k 'n [lba. "".1i1lJ1

,,,..n,

""'Ilo .""

....,hs.

'urn

,.,<1

CII

.-"i!:
~

;II " " ' ' ' ' doun't ,ull.,. requ,'e Ih'" O'
ro". ".nd . LI.,.. Jide On Ihe wOIkbornc:h . nd in_eri

An'.... bll"l1

bunl'l9s In I"e ~ctsse._ p~ss a P'VOI block InlO tadl

burtng. fII a'Hond .Ide. W'uh i.s bu,lngsln pun.
_o Ihe pivot bloch. IUghllht lnembl.,., and lpp/V 1
<lamp Qver tacll ",VOI bhxk. as skown htn. 10 l>oId
Ihe .uemlll'!' whl ~ VOu .crtw ItIt wtbs In place.
thisoilk' bn .. nj' ",n OM ~
bloc .... ,\t.~c SUR' tM.""""", 11'1 _II th.:

."n"n. "" IIK' pi_

""y ".." ,..., In..",

r....,. of ,"" ~ .... IIM: o-rinWO ~vnlXt hol"
,e"o"
oJlOIlkkn:tnd ,I'H: """rlJljllnllt'r r.>Ccs.
~, .1Ie ,..".,..,hly,and 1iP>'1t' dunp .he si<l~. '.,.,nhtt,
~ ."e " b m"" dlm:tly """'1" IIK' b,.. rillg. 'TlIi'I ..iU
cruun: IMI .here '" abo<>lOldy "O
pby. 1'bcr \wO
oi th<: wdJs OI> ' Ik .....,ml'>ly.,.,. "''''''_" In II'" SkItII1",,', and
"'1t'W Ibm> In pbct' U,.. l.mm ~......"I
Turn OM

t''''

.kk-I..........,
.,:r',"',.

n,..,... anII "",",' tir orhtt ,,.'" wdl!o In pUa .Tbc

pn"Ol hl...,k, 51>01,1<.1 turn
In the hn~ ..1><:n """
an: don., onod ha,,, """"..w Ilie d.mfl'-. (lf,tK-1' <Ion t, db,...'.:mbk "'" bc2m OI .... II)' "1I"In. 1111> II "'hy )"" dOn ', gI""
~

,""'It'

"", ..m. In pbcc,)

M.$nI.bk .1><: SttOnd bean' In .h.:

"'u,'" ,""2)'

Lar Iloa bl!a m ~ and <ol.. m .. ~ .... Ihe. wo(I<IM .. .,1o 10

... ~mble th~m. Li", up t"".~ subuiemblies. Inun
Ihe Ihruded rods. an(! Ilgh'e" Ih~ nuts r.~"'lghl.
Af.~, lhus lying t.ht! parti '''II''lh~ .
ahgn
men, of ''''' pans aS nKes~ty. I""n d.1ve scrtws
th... ugh .1110 plvo. bkxks Im.. t.ht! eolu mns.

",n",.""

<,III" .hc p;rca IO\oI<1ha. '"",,ing a "'''IIk 1H..ioa

",>lun," Thc: dn ..in~ O""',,,, ~ I)rtltll <thowJ llot
~""'lIJII"IK"n, o( the
1f)"OO, fioo it ""'"' """,m""" .n ~ .1><: p><tI
.~I><:r ,' .. n '0 cbmp .""'" " 'hlle: tM fii"" <Irio. nul:<
.......... 1><: K~ ",,,,.Iie In.hc pUh oI.hc ~ ..... )'Ol,'l1 mUt
In .hc .."'.. ""1'

p'''''.

10. Cu"he <."01 .. nuL' '0 ."ogl1l. When tM""" il

,,<}'. Iri", <MIC" nod oi."" lo,"~ <"Ultlmn ......."'. thm ..... ~
i..ro '''-0 l-tndl1onjI [>It:S &nd '''''' 4<o<1t.k>n1l rti~
"'ti.:" m.>~ 'hoc cu'>. maIo:..,......, )UU( bUck il fXf'
pmoJ;';lIbr ta '11" '"" ...;obk and ,11" Y''''' mba ""..., rmc.
l< petp<ookulu'o .lte "'tlc( pUII" har, bttoux yuu ....'"
.t", ctrui to hc Oi "'1""'" '0 .It<" ni> o( II.... """'n.n :Il YOU
QIl

lI<"t Ihcnt.

9. M..u a .,olunu. bl;o"k. ...... ~, ,hen::lA: Ih"",

MIi."t'<11' coItlmn.' In IIM.' ~"""".bIy.1t .. ,"lbint II, 111 .... UfI Of><:
kIn3 coI"mn. ,l><:n Cn"""'" it inlu tI><: .ltn,".: Plt.-.;a: ntttktl.
Ik:lIln lty milhlljC ..... rippiflJj ti."", p;n.'D of .. r.olp".
ll"Iin~ol IuonJ .... ><>tl .. ock .<> .It<" ,hi<;~1><:S5 ,,00 ... id.1I
,pct;il""'" by lhe Cu."n~ 1.1> . E:odI ,,(,Itt:$ 1'............" .h<>ukI hc
~ ", j(l.lnd. ""'Il.It.
26

Rotile, M.1I1K

II . A.o;,;entbk thc:

bc-~rn.' ~ nd

WJU"IIl5. ASsum'lIjI

tiu, J">u bc:Jugh j6.!nch lc"IPtI o( ,h ....:-aokd rod ... w ~

in.o OM .,.,.,., ,", IncI>t... k>nIl &nd '''''' III loc""" .....
AefIIbIc .lte ho.o; 1>0..,...... coItlmn.'. '00 ,lt,,-..kd rods.
:thQwn In '"e KOtll,." IJuplkatOf" F..~plodnI l """ ,

You II ha""

II> m.>~c "n~

dePlIn ..", rrum " '11.'

}"OII

tOLUMH AS$EMILY DETAI L

$_.

PiVOI bIoc:k

OI

III

PivOI bloc:k w llll

bu,lnO OtIlenOn

..., in I h~ E.~pI""kfJ 1 1~,," 11><: kJnllt"' rod c~n ' l K",w

iIIo!b< Tn"l un ..., pl ~ n hn"... "",, lO" h "'~" ' 1 m ~ d~
iIIooor pan~ ~ J.... Ih,n" ~n ",UrA nu. ""'''' Ihe ru<I fu,
dIt Ilme be,nl.
.-lth ."" n .... <In ."" ,h ..... dc.J ru<I ~nu~ al"'ln" Ih ..
p/1'I)I bloc ... bul noi ....'crly U!lhl. "r .he """mhlf on 1..
..., on. Ilo' ... rbc ... likc ,.ou, _ I~hlc . Now nWII".rnJ
"'C) ,IN; ~ .. m... In,,, <'li"'" 1><""'IoeI. nit""" On ,ht
pIY01 bIocl<J """ noi I"""hlnll
bo~ br.on" Wllcn yuu
lu>T IlN;m IUSI riJl/Il. Ilt,hten 1"'" nut:; tO l>oIIJ IlIem
JK\IIdy In 1'11. ,""" liriII pilo1 boks Ind K",'" Ihe
pinii bIocb 10 Ihe roIulIIm lM !I{'ft'\\ will kl'('[) 1111'
IIum ... (rom ''''i>l11lA an Ihe 1'1..... bIoeb. thll> "",In

t"'"

"JnIIl1l t lle .cc" .....,.. o( Ihe III. ...lIi.., Ilie I....... okd rod
w,lI kccp the ,;,:",w5 (rom lN;;ng pullcd oul o(
~ nd
1I",ln oI Ihe column .
)'<It, .In """ IJI"" and Ios Iuru....", if }'uu 1iI<~ . bul Ibcn
j'Q\' w(>n' , I>C' ahle to dL.......,mhle , ..... d"pllc:ltor for .. on~.

t"'"

Making the Platen

YtIu . ", . h< .... , t" CQflSlI'\lCl Ih.1 magi<" C;1O."... upon "'hch
Ihe IIUpliC;1O'or Jlo;al$,TlIJ5 l!i n::ally tllc m,,,,, rrugic::>lpa" o(
Ihi> lill. IJke m"'l 'ppa"uus ~ bJ' m>.glcbru. it .. ci...
II"nlly "mpi<:
In llll' COltfW o(ju.~ few 1IICfl5. )'OIJ lransform I p;ea
, o( .....Iru.ry pIp\'OQd in,,, In'i,",i"" d<:>ia: by "",'ing
R"ut~r

Duplluto,

27

PLATEN DETAIL

,.

AI. supply port

1. After bo.lng

lh~

al ,

~upply

POM a"l ~"wid". Y,"d~ep

2. ROUl Ho" wlde. Wdeep

!I'DOV~~.

9'<>O\IU bi'~Cll n9 the port

Ind ~.all~lIng the platen',
edgeo .

11"""."" in it. "",-.:ri~ thc fOO\"" "ith

plasll" bntln., ...

tMn rlddliJts: th .. I.min ........ Ith hol.".. You ha"c to Ix >..>I<lng
)'Qu,.,.,lf. <Ioa somtthln!,l thi._ simple =lIy ,,"OrI<1
' c s. it <Jocs. JUSt)"OO.> ",..it ...

1. Cut thc pblCn bbnk. As 1 ..id. Iloc pbl .. tl I!;

pl<-cr of t. ~tlch plyw<>od. TO ......,rI< Pf'OP"rll. tM pbten must
Ix <kad nal. $O ~"'ct )'OUt plJ-....ood .,.. ....ofully. CUI II '" Ihc
din,e,,~\S 'pedfk-d by Ihc Cuttitlj! IlsI.
2. Hore the air ~upply poM. TI-.e al. il! :rupplic<J b)'
)'QUI.hop '"K"Uum. I'or th" .1. to ~ InlO Ihc pa>."""'" l!\:ol
)'Qu will "" rotlllng inlO lh .. pl.l<"n in Ih<: n= )ter. )'Ou
ha'.., 10 bot<" I hole in Ihc pl.OI"n th.,., big enoug.h for Ihc
;hop , .. ,,', hose. &..........., the ""n"""lor a" CXI"OO onl}'
}j, In"h i",o thc pl.,en.ll '. impon"m Ih:ollhc port d<>!;e1J'
m,,,ch tM "omlccIOl"". d i.:l.meu:r.
I\c"jr.in b)' <ktennining huw blg Ihe hole muM IX"
M... ,u", thc uUI<ldc dlan-.elc, of Ihc ronnCCt<:>, on Ihc
It"'" " '1111 p. i. of c;oliper5. 8(1", a te>! hole "" ith a
fOr5lnc. Of multl. pur bit ""' do~ as I"'... ibk 10 Ihc n,ca
sun:d .i>.c or Ilie "onncelor. A 1. 1"JIC' Imsc mjtltI fCquin;
Ih., IU" US<c a holc """'.
II Ihe hOle I~ ~ligt"lf tDO .m" I, IUU on Ilie III.",,,.
,,ith. b.lfround .... p . l f It '5 ' 00 1.'1I<'. )'QU ""n wr. p I'pe
28

Rout~r

Magic

3. t.ay aulth! al. holu on Ih!

plUlic lamlnate. a rfanglng
th!m an. 1" 9"d. O.illihe
hal~s wltlt a hI" bit. Apply
th! plaslic I,minate ta Ih!
plat ~ n .0 th~ hol~s line up
ove. Iht g'oovts.

.rounoj Ihc cnd nf Ibc cu nnceCO,. n,., h<>.se "'''SI fii rc-...
"","'tblr aiNlgl".
Ah", )'Q""'" dt.-.::ld"d on th, hil 1'",,11 USC. 1.) DUII ....
cenh" of Ih.c al, ""ppl)' pon . f<>!ln"'itlj! Ihc dr:twing Pliltfl/
DeI"II. l1>en bon: the ron. \ 'ou .,..0 00'" rompl<t...,.
thtoug.h th~ pl'len .
3. lay out a nd roUI t"e alr pas,;all""'. Thc alr Is dUP"~ aC"fO:S:i Ihc p-I'M' Ihruutch gr;.J of ll""D''''' I"OU!N
InIO Ilte pl"",, ', bonom.ll", Ii.."'ing Plale" De/aII shrn>1
Ihc:sc al. p.,..,gt:<. Note 111:>1 tM'" II hincb"~ ~

IU""''''

\'Hnch-d.,.,p per\n,e,,,,
.00 " .lmll .ty .sizcd ono
CXt<:nJ.ing from .I<k 10 . I<k thnlll)(h ,he ai< ... pplJ poli
Complctltlj! Ihc !!rid . '" a 007.en ,-"inchwide)( )j,.;nch-dcql
gnx "'cs ""'h:d rrom cnd ' o cod. NO/k o( tl~ gro<lV"".aI
Ct>u",",. """'ks IIt~ Ihc eJl!" of Ihe pbte".
11"", )"Ou produce Ihc groO\"CS ma)" tu,.., a bearinK OII
how )'0" b )' lhcm O", . It b ..,;dul. late. on , tO know who:ot
the gro",'CS ""'.SO )"Ou <10 .....", m. rI< Ihc 1!f1>O''' """Icrti....
on .he pblc" cdJlC!l. Roul thc WOO''CS wilh plllllllC 1"O\Itcr
cquippcd ",ilh an cdgo: gui<k. Of ,>Il ,hc rou,,,. ",bie.
Rnu, the bl)tC al. culumRll fir><. U... a *-incit strupI
hil.Adlusl the <kp1h Slop ro. a \oHncb-d .... p CUI. Scllhc cd!Ie
g"Idc "" Ihe ""nl<"11",e of tlte CUI '" 1 incit (romllte SlQCltl
cdJ\c, Roul ' he perimL~C1" oi, paso;:I!I<'. l>on1 {orgct ltul thc

opcn up ""'" pon. S..i,dI 'o I ch:unkring bil :and

rrW:e anoth<"I" pa'lO :around ..... pcrunn""
pla'cn. """'"

0i0)"OU C2JI

01.""

1...11ng ..... otwp lamilWc cdw

5. DriII the air bokt; In the p ..... lk 1:un1""'1". TIM:

nwoy hok:s in IM pLun>'. pl.a>l:ic 1amI.... ~ b"u"", n' .... be
driIIcd ~ il I ~PPIiCd. If ,.,.. liriii lIM:m ~ft"" II It
Ipptinl aii tIM: dUSI and d>ip> C""~lcd ,..W coU\ In .1"><: l i.
""........ :and Ibry rmy 101",,1 alt """"
N<n!.' ! know ,"" uouaI ~pp"""'" tu bmln.!~ "''"' 1, 1"
CUt .hc bmln>: ~ .nd "pply Il to 'hc sublil ..... c whh .,"""'" ..."riwlg "rotind allibor etI)IClJ. In Ihl' n>l' Ullply . ,
pbn 10 ~~ OM etlge of 1"" I.ml...lc fl,~'iIl ,,, ti.., >u",",r:.. c C
W8C. """ ha," .he OII<:riwlg onlr
",he,
cd/lct.
CuI ,1"><: plWlc lam!mllC 10 tII~ dlmcn.wn. ~ by Ilie . .
Culll"ll USI 11tcsc dimcrui0n5 provklc ..,.,..... ,. lOr fOI' 10
Irlm Il Oosj. aher II It lI1<:n.oo In place
GI"cn Ihe .ppllcltlon .pproodI. )'OU Ilmply h...... 0 Iay
oUl II.., hok:s. ,,-MnII from ..... "O\dJt " cdw A. tl><:.n..-w.,
P"kHe" J)ellIl/ sJ>crn- . IM: ai, """'" .... drilltd OII !!rid of 1
Ind!
tind.hc ttnle' midpoIn. ~ "'" fl .... cdjIt,
and Iar oul 1"" grid fn:m Uw poinI. u.., pcncil :and li
(nmutjl St!""'" 10 atenti ~oct
.1><: bm"",.c TIM:n
, .. m .1><: lam;.... e 90 dqjttt:JI:and pn>dIIllnn rrom lIi<k" 'o
>kIc. IOrmI. . ~ grid " ,II! Ih "'luara. AI ndI iV>d Inl.".
>caion, )"OU m ..... driU hoIc ~ tIM: bml"'I<:
lIodt lip lhc iamin:"" ..ith .. c:Ic-:In. ><>Jid pic<:e 01
ocnp-pI)......oo OI" mcdIum-dcn.si.y tlbcrboani. Orill Ihor
~. ~,...Ioch l,,"ilil-<lrlU bil in .. po ..... bk tlrlll. 1"hc
don'l nd 10 hc loOI.etI "'llh absolUl~ p""'Won. 1.
bon<1 hani.!IIM IcdiolD..

OII .""

ii"

1"=

11<1"'' '

UH a hand h.ld roul. , will. a n IMIII. IIllide. 10 (UI

~ l irpu,"!f" II""""". ~I Ihe edjje lIuide 10 roul Ihe
peflmder grooves fir.1. Don~ ru" wilh .IOP bkxb: JU.I
III' 0111 the In.H:lt cornt" of Ih~.e 11_", Ihen roul
flllm n"II, k 10 mllrl<. To .11In: Ilie (UI. lip Ilie roule o
Ilie bit 1. clelr or the work. liS .hown hfo~. TMn ~1I,n
advMIC1nlllhe fOlII~r II VOI' Iow"," il lnlo the WO<tc Ihe~
I IIm pull l"ll lhe fOule, IOWlltd me).

'"Of! >han of u.. ~ of ""'" ..od:. l"oll1l flnd k

mioI 10 I"0Il1 Ihc:x 1IfOO'""O In Ih= or mon: p<tS6CS 01
~

~dq)lh .

Rc;jn thc alti< JIlMk, :and ...,.. ""'" aii" ~ !ha.

bo.b' thc alt" ... ppIy pori lIout ..,...... 1"" "illlh of ./lr
piltai. frOCIIlhc: pcrilnctcr JIfUO''' ~ <:>ne "'-k ' 0 Ihc: OM
....... othtrokk
Sow fOIII ."" ~ zif (O/umns. S"'i.ch '0 ~ \j.lneh
Anrf&hl bIt. and ma Ilie tlq>lh .. Of! 10 pmduc~ ~ *'"lnch
dtq) f\II. Sc:t .IIe cdp= lukk ~. Ion 10 rou. Ihc lwo
1'9<1'"'" d.,..,.. \Q II.., pl:u~n ooli!n- Wh.:II
do 1. mullwo

,'OU

IfOO'"d.OM rden:ndngnch ' . "r.hc pbtcn.Thcn rt:Scl

thI/
Ind ""'1 IW" moIT
Kttp rnttlin8
lIId fOU1I"i .. "UI an ti.., gn)O>'''' h.." httn cut.
./U>< .."....",ba: OON"r bIT.k Ihrough 1"" cdgcs. You

""ido::

WQO""'.

.."iJl1 :tir e"""pinll .....Iy IhnlUJIh Ihe Un)' hok:s )"OU "iU bc
driIlin~

Ihrough . he Ilh>< k "'mhu .,)'OU wiU bc .Pf'I!inll

4. Apply I I", pl:.l$'lk l",mlmOiC to Ihc pl:llc n '"

IOp. A) 1 m<:nIM"...:d , tI.., plalen m ..... bc !loIIO wort. and it
,.,., "",..... ,,"Iy Ilie boII_ ",rt.tt:.: ..itll Ioml""~ , tlM- pbtcn
il:dmolt ttr1:lJf1 ' 0 rup. S<> "'" ...., J'ia of lamiru.c 10
thI/ <Iin>m>I<>n> .".,.,11kd by Ihc: C"I1~ u.... ~ OM

no. ""1>-

lor oM
AppIy "O,It:>Ct ttmcnt .0 ,1Ie 1am1n>le """ 10 thc '011 01
\bC plai"". WhaI .1><: ccntonI, 10 dry. oppIy ""'" lamln:"" 10

.... ploI"". IJ""nh

and flu:!olHrlmmlnjl bit. trlm Ilie

.........., ..."CIh>ng. onu li hoIc: Ihl'\.>llllh Ilie 1am1 ...IC """"
.,.q ti>< zIf ... ppty pun. and 1....," .1><: 1>1, .hruugh tii., hale
li " " "....

"""'*'

"'*"
"'*"

6. Ap p ly Ih ., p las tic laminate 10 I hc OOllonL

Dnpilc Ilie lII"OO'"d 50bsu.,c and IIM: po.."tforalcd bml... IC.
.hb '" ....... 11y a IiIr~18h'forw. ni job. Set up tint. Umlp
r...Igh'nlgc .h.t"J .hkk""
.hc pLltcn .0 oM ,,'OrI<
beneh ""'''"Cen you .nd IIl<: pbl"". Pull IM plalen 1'8l"
ag:.olrm 1. ntl .....rt Ihc: cealcr 01 """ OI" ......... oir ~ an
.Ilc 1..,.., of ti.., fcncr. l"oll .... POIII'O ...... tho<: nur10i 'o
alipt tIIc t.mlmuc. and }'OU .... lJOing 10 .... Il>c lami... lc.
O\dJt edW: ,,I.h .his fcn, ......... c ~ JOU tu", .....
pt..en tJr1cn'cd apptt>pna.tlt
Sow .ppIy Ihc: Ct>nIXI mcnl Ao JOU >prnd l un Ihc
~ pl:I\"". II,. 10 .-00 lIC"inJ 100 m""" <100>.... In 1110:
~,..het<- It mJW" uIt~ .....
ol:alt. llIbl!;n',
dlll'1.:..II. What b tric.y if .wIt"inll thc .........1 to Ihc I:Im~
""e, You tu.... 10 ltifMI of paill! >!ripa; of oM m<:n'
""',,""" ,"" h.oka. y"" \Ion ', """" ~ film oi ccmcn. j!.um
mi. . up Il>c ... I>0I0. 1 found IMI. dJ:opos;lbk briOlk: bru."J,
..."OI"b:d juIlllnc: b" applylnljl"" cemenl in tIIis ""nicub.
si .... llon . Allow."" ccmcn o dry ) uffldcn,ly.
.......... appl)' ti.., !;anli... ,., 'o ,III." plolen. Stand i fl"""
cdgc: on 1110: pili"". IWtI all"in'l Ihe rence, an'" rrW:c 6Un:
lhc appropna.e OIr1np oi "Ir h.,lc~ ..... ligncd "itll )'OUl"
. Iill',meol m"rb on l/lr r"nec. fior 1110: Iamin ., "" II
. 00 gnd... Uy Iar It OntO Ihe plllcn ""m"'" II do ...n ",lh
JroUer ot Ihc: hed of y.,.,r hand
Sel up )'OIIr I>ml ... 'e Irlmn .......... roti."" ..ilh li fi""'-

.haJ,

now

bo\O".

hkM:k ... ill'l gmo'

ttII,,,,

;" "'"

~.

...n:aa.

Mut< .Ioc
01 thc pl>len
f'tug th<: :oIr "'Inlu the
)UPP/)' port New pbtt thc ~1n3 +ir>dI
!lC<.'l1on o( colu","
'he .rudttncnt bk>d:. :md .....
'Ion ,1>0: tw<) OI Of " " ' " thc ccn,l:1"tI1afk. Thc face 01 thc

.1.
hIock ",1,1'1 t""

:uouoo

'f.nut >hooW hc dawn.

ttII,....

AdjllM ti", coIum" ~nd bIock """"'1 ""'" thc

01
the p";nen. it~. '" cn,,,.n: 1""1 ,he :aIr " ' - """"1
Inl~rfc~ ,,111t thc """",,,,,,nt of tIK """rM.AS )'OU ati II
from 'hc f'rom l1ew 01 thc: Nou',,," lh<pllc"",~ 1'/"" 1.,....."
Ilie colllmn shollkl hc OI k:-_ I ~ Ind,.,. a"..y fl'Oll' 1","
1""" cunnn1or. Whc:n )........, happy wllh ,hc Io<."allon.
"",ti< II. Thcn l!l"" .nd "'t"C'W Ihe ot1,..,hm~nt blnck 'li
pl>1o:n " c""ple of 1lnch dryw:dl ","1:W, .., >u(OcIt,u.
Iongcr """-....s u... """ )'tiu'", qulle ccn.ln thcy """,'t
"" pcnctt:lUIIJI "" ai. """""8" In th~ pbtcn.'lw.' roIlI"'n li11on. b)' ,IK ...... y. ",mains Wl>1t,..,hcd.

t""

"'"OioJ

Assembling the Duplicator

Adnncil plannlng 15 11'111 ker 10 s",un,,,I..,. ~I.
n~ling Ihe pIolen. TlM! gricl o, ... hol.s m"SI be laICI
out '.om ~ """sh' edte. lhen dnlled Ih~ Ilie liml
""le. TlM! cdll" of lhe plalen cor~spond'ng 10 lhe
'lIush' ed\le of Illt Iaml""le muSl be buUed igilnst i
'cocc. Align ..... nl m;I,ks muSl be serlbed OII the ftnee
n<t tlle !.iml""le (on the m"klng tlpt:). The l.imlniltt
Cin Ihen be "rolred'" do ... n 0f110 Itle plllen. IS sl\oWn.
... ith tne I.ml .... \e~
hoIel .lIgned ove'lht plllen~
il. pa.ss.gu.

.1.

I<,,,,,,,lnll bOI. and "'''' ,h" I~mln",<: <'Olgo filM ...;,h tM

plon"n <"<l~"" Swltcl, hll.> anJ ruut a n:01'TOW tx....1 aruunJ
th" a41<-'" to nnl>!, otTth~ joi)

Thb 1> ........ tIK llllIIl1trtc mIII' con'IC$ t""""her. 11:>_

IM major ""I. thc: lx:>m-an<koIumn asscmblJ'. hu ~
beat """""""ro.)'OU 11>,,, >eru<: 01 ",h.at thc dupllc:otl)l'
b 1!OJI"8 III Iouk Ilke OUl now )..... arc 110"'11 to ",..unt It ' ..
Ille pbt"". MQII thc
and thc ..1.1.... and rndy ~ lOr
ils "",ioJcn ,~ ""..- )"0'" workbcnctt .

I'UIJ'' '

1. Join t.he beli.....and-eolunt" ~mbly 10 ~

pl;il" .... Thc5c tot", lIUf<>< cIcmcnb; ...., dnd1coJ
...IIh thc ~ ruoJ tiu, =cndo 'hntuWt thc "",In
coIumn .

'.'''t.

7. T~kc ~ t.,,;\ drlve wlth )'011' pl .. l" n . Thl. 1. a

d<.'\iarKlfl front P"'P'" &I~p-I)y...ccp oJc.:on,m, I admit. Ilu'
th", b "" cool !"'" nd ro rry 1
. 'IU' rll!il' .w.y. Aud nu ...
,"". 1"" tp,c 111<: ai. h<Jk:) drilkU.'..... ~"aJ111<'1 lt:aJlo>t OII a
CU>hIoo 0/ .Ir.
So >l1ck un" <:...:1 ofltl(" hoK In .he
,~ ' . Cl\h.lJ!it
p<><t. 111<: 00>er Ut thc: . It )Uppty p<><t "" ,hc III.i'cn. Thm ""
,..., ,~ .00 """ _
nk...,ty Ihor puten floal ... PiIr """''' '''0(,
on il .nd >C<' how it I"C'KIII. CoJI the "mity '.'hc:r;L/ld
..00..' It nil" it"J.~, tri<:k.
Obr. brnI< . <M:f. lIact< ,n .."0<1<

.tu..,

8 . Malle aod

."S"'".. lhc a Hacl"""" 1 block. Cut

'o "_n......

'hor hIock
'hor
opcdflctl bf 'hc: CUIlInft u.t
Wry UII' ,h<: ....... for Ihc moci...... rod N<X~. In th<:
d....1njj C.llum .. ~ 0rI,,1I. tlle w:ncrolloc:otlon of
tl'lb hok. 1. S ~uidt!un, r...... thc cn<h anii I Iocl'l bacil:
OM nIfIP=. ". 'h:M .,.... . driU rou"l .......... jUSi deq>

rrom

~-nough

lu =<' ,h<: ~ on T-nut 1"I",n bon: 'hnJUg/>

'h<: lJIod< for tlle body of lho: l:"u' 1101' thc T.... on iruo thc
hok. and chcck 1" m.>kc ,...., 111>1 no pati 01;1 Pf"''<"<'\'
01>0\'" 1"" (..,., o( ,h<: bIod:
Thm ltu- pUten O>"tt (50 tlle oidc: " 'i'h the b"'Uwe
Is down) nd ,,'UI'It <><11 'he bnI ........,10<1 ror ,~ .nxl>n",n, I>Iock '11" kK.. . 'k>n 1.0 In.pon.nl , bul po>illonlllJl,h<:
30

~oule. ~ .glc

To mounl ,h .. bu.mand..:olwmn w.. h On the pl.il~n.

VOU ",uSi .e..-e t"'" botlom "III ..... ,''''' etnte'
coIu",n's th.ndtd 'od. (The sere ... s w,1I hoId ,"'" unit
t~the. when you do thls.) Torn IIIe.od Into Itle
~ttIChmenl block on tlle p1i,en IS fi' U It wlllllO
Holdlng tht rod wlth Iocklng-g.ip pll~fS." 5hown.
tlghl~n Itle tOll ... 111'0 secu~ lhe Iswmbly.

1bc ~l'SIlhini' It, 00 i< '" pl:K:e ltu, .110n coIlIIlln >tlon bl<1: 2ruUJllllhe ."""hmel1l block on Ihe pblro. Oon 1
gI.. l' lt"",-dofl'l f. >len il in anr "7Y.
Ncxt. 1'CI1IQ'" 'IM: 1>0"0"""'00 nu' frum 'he 1/1.ln<:h
Ihn:>dr:tl fUd, Thm ,11~ lop.cno.! nu, OUl ne .. Ihe eno.! of lltc
roxL Ili8hI ,Itc bnlD<lrnkolumn ~mblr. ano.! st."o.! il On
Ihc ,hor. column 'han un ,h~ pU'''''.Th n:1<l ,IM: n>tl
.uo IIIe:Toflu, In ,IM: . u. ehme" , blo.:k.
ro 'igh'en lip ,he __ ",bly. )'O" tu,,,, 10 Ilghl<"1\ Ihe "'"
OII ,1Ie: rod', 10f' eno.! down ag,oinSl Ihe oppcr pi,ve hlOl'k.
Ikfon' doi"ll 'hi~. d""'-"k ,11 .. 'he .hon <'Ulumn ., ,~" pl'l1<:n
Il ,-"e,.ncm! on 'he lower pIvot blod: ano.!lh~1 lltc btam ... "'"
roIunul ....,mbIy worl:s f=I)' When . 1I ~ oliW>e<l. tlgh'<"1\
tht nUl "" Ilie: '''Il of 'IM: ,h",o<l.:d rod, cla"'pln!! !Ilo: tKc~111
""'-""""'! 'o ,IM: pl.'en. You m. )" n~ 10 hoId Ihe rod ",llh
pIkn ")\lU 'i8hlcn ,he nul.

""'li

2. Mak" Ihe roule r moumlnlt pla le .

II<lled al
tlJdqiDninK of thi:! etllplcr, Ilie bal rolll", for I~ jl)! iSl
laminale llimm",. In fact . bccaus.; Ihe [UUt<:r ;s mountetl
t>m<..,.." Ihc bnm .>i<k:s.)"Otl ""n', """ an)"lhing hu UI11I
""te: IrUrmer bccousc 1. w",,'1 Ill.
To nH)Un1 lloe trim",er. )"" ",.k ... hal anl<>UmS to .n
.,...,r>izcd bascpl.te and S<!n"',, t'UI 10 'he bouom etil!'-"" of
tht bt2n sid<:s. M.ke ,lIe n\Oltmi"S plat" rrom. se,..p of
\l.inch po'p"uod. Cut II to the dimensions speclfoed br tbc
Cultlng Ust.
Rem", Ihc bctor}' 1u"--pl.:tIC {n,m tI><: !:uni,...,e 1<ll11nl<:1",
:md bond II. 'o IIM: moontlng pble bbnk usinJl ""rpc1 I>pc'.
.\bk "'UJ' dTon 10 lli(tl1 tIM: b:l>epb,~ '1 bil opening","Cr 'hc
ttnlapoint o( II'" moun'lnJI p"',e. Lf)'Oll \IonI. )'OllU tu,.... a
ll1fII lIt>< :aLignlng "'" bil In Ihe n~"cr dl ...:ctly undcr ti",
..,...... Yw an ftoo II".. for wng Ihi< in Ihe duplCf "l1M::
Gmmc II>s<pl1tc" un P"g<! 6}. U.., d'e ba<o:pLa'~ au gui<k in
driIIiJlg moun,;ng-.crew hok...
a bll 01',:ni"8.

c.x""",

\\"iU ,,;n'ply projecl oI' from lhe mowlIinll l:r.

5 . Make Ihe ~Irlu.~. Sun 111' ,,","'ing 'he he'.uJ 0,1",

hol, \\"i. h a hacb:lw.
Noa. chllck ,'''' Ih,..,adcd cod of Ihe boiI in )'Oll' dnll
~ . Sine.: )'()u 'lI nced 'o run nut< <Iown tl1Csc 'h ..:,b
wIM:n )'''u J""all Il'" >I)lus. you wa n. 10 .."Oid o.!;"'ortll1!l ti..,
thmttls "'1l h accsM'''' lightC!llng of Ihe cbw:k. /\ eollple of
bJ"C1"S of m>sklfll!
O<l III< 'h,,-"OtJ!; p"",itI<: SOtl1C In"",,
.nee o.g:Iil1Sl ti;",,, ..,,,,,.
Now file II><: md of,hc boiI 'o Ihc $luI'" of)"tIlI' roulcr
bil. nu. il;. ";mple. il 5OmC""<>"tul tetlious. 1>Sl. St.~ tIM: llrill . ,
pn.:ss -"f>CCd quite sJow. ~wJ"I! II><: I:IhIc ou. of tlle wal. :uwJ
rtlc
,1.., roI.:Illon of II.., boiI will Ilat n,W me \1'hilc
)"Ou'", oot hand-tooling P"" 10 5pacc-ajIC lolcr.onec:!l. ~ In G
mind ttut ,1><: mOIt-" "'---cw-. tclj)"" "-1>">tI""e II.., ,,,,,'er bit'.
p,,,file.
mute :occur~lely )'OIl' dupliC"O.lOI" w!ll dupllc,,,,,.

1:1""

<
:i'

"Pi''''

,1..,

As

6. Mak", thc ~ty lWl mOllntlng bar. lltis Iw l.. a , Ii.

1ncJ>.long >lrlp of .. ",,1 wilh a hole drilk:d llIrough II fOr Ilie
.. )' .... The ",idlh of lhe h>.r i>"01 cti'kal: .n)1hi~ :. inch
Of mort: in wkllh will do fine. tiut 1.,. 10 ~nd o pkcc " k_
Ilo inch thick. /\ ",,,unling bOf IIU! fk:>:c:!I wil1 gI,." )'Ou o.!i>,
Inn<-d dUplle,,,C5, ",hieb ls C5pCCblly '"CXinjr; if )"OU'"" 1'1';11JI
10 n:produce fon<" dc:1~il.
Cut tI><: .. rip \O 'he .ppropriate Iength. III<"n 1:01' OUl """
liriII Ihe hoIe for II.., >1)'1.... Ek-gin ",ith \to-Inch-<liamc-tcr
pil'" hllle . !hm m)~flIC!Ile !Ic ""illt Ilie 'Pl'roprialc-sl =l
l\\"isl-driU bit. 1lc
10 cb.mp 'he b:., 10 tIM: liriII P"'OS l:lblt::
whllc 1Ir1l1ln~." ,he drill bII """"1 )"Onk 1, "''' of)"", h:>nd .
Whil<" )'Oll .'" ., 'he liriII [>"' .... ia)' Oul ~nd tlrlil Ihe t",."

s",..,

",,"Il"UM

",Ill

3. InslaU Ihe m Olan,;"" plaI". Scn:w II'" pia'" \O

tht !>ollem <:dges of,he beam sides. os ,"""wn in III< I?orller
/}u!Ifrntrw 1IxpIode</ l'k'u' Scn:wlns. but ...,. gluinl!,. Ilie
plat~ In piace .Uo\\". )...... II.., Option of ",me>'in!!. Of
rrpbcing 1, OI a futu,.., tinle. Gluin!: 1111(1hl makl' Ih~
onounl~ a.....,., bil m"", ligld. bUl 11 1.n, CMcnlial.
4. 0>0:>06/: a stylUII conflguratlon . Qnc of Ihc: kq-s
10 '('cur.,, ~ duplin,ion '" 'o ~ ")'Ios of Ih<' .. mc .Ize
aod -!IlaI'" .... ,'''' ro,,'~r bi . Thc 001 roule" hi, 10 """
~ o n whe'h(' }'Ou''''' ",""",,'ing "'rgc .n"",n1S of
>IOd< OI" ICprodudn~ fUte d<UII. A ~nch """,-hox bI . ..........
goOO joi:> of """,,,i ng ..... SlC .... hilc a ,"Cinlng. V1!""",ing .
... >lg<H!l.klng bit ""ill dupli""'e fine' & .. il. [f J"OUr wori:
~rt:t:,.xh "",emi,,,, w)Ck 1'Cn1O\":ll .nd nn~ delan. ]'OU '!I
\\02111 '" "'" boI:h kloos ofbil and ",ill n.'.'<.I. "'-"P"""c >!rlu.
:md """,ntlng l:' for cad' bi, .
f.ach SI)lus ;, .....de fro." a bol . C""""" <>ne wl,h an
~ $lunk dianu" er OI lcasl .. )ll'C"AI aS t~ ",ax
Imum cu:tlng <li;IIn<"l<"r "nI><: bll.111e ICIIgth OI Ihc boiI. nor
indudin~ ,Ile hcad ho uld bc., le .... os ~I O!i ,11C ()\"Cr. 1I
Icng!h ollh" rou,e, bi,.
Ieng'b 1. n", a prohl<m - Ihc

Ex,,..

Sha .... Ihe st'l'lu~ bv fil i "!lth~ ~nd of a boiI whilt lne
0011 lurnS in tlle drlll P<l!SS. Hold tht! mI! 19a1nSllne bolt
I!nd. lnd ~ It l round aS ree~ssary 10 shape tht! 0011
end 10 malrn tht! "companion"
bit~ CO\1\Ou'.

""" t,

Rout!!,Ouplieato,

31

A 5tock-andPattern Table
Thl~ Iwo-tlered liule ,,,bie I~;I liery ImpOttall,
"djunct to t~ ...,uter dupiluIOI_ II hold~ both the
partem (lI,c ObjKI belllg copledl and Ine workpltct
(I~ woocl InlO .... hlch the !amlnale Itlmmet i~ Cu,
ling). U~e of Ine table makes II qui<;k and UIY 10
po.ltlon and IJign , hele Iwo pIetei," nOI Incon .. d.,
Ibli! .. ch't\feme~l.
TIte Ih,"9 i, ,hl' for ItIt "upllutor ta do Iti .... ork.
both the p;itlerll tO be dllpllCated Ind ttlt stQ(:k 10 I>e
rou ,~ mus, I>e held rig.dly. Nli , her mus, IM able 10
wlgglt Of
Tht IIPpe. I~ff.. cu of tlle two mUII IM
12~ inche. aput. "nd the p;itlem mu," IM dlrectly
lbow: Ihe stock. MO.-i!'OV<!r. lhe "ztll~d Ihlpe, 0 1 the
workP'KU .," unc!oubledly liVV ~rtil ly from proJee!
to PI'Ojt'Ct
TII" .tock.nd lli\uun ,~t deslgned b~ F"d
Ml, lilck Ind Bob Mo . ..n ,. il .,mp~ "lpoMe to tlle
need_ 8euuse Ilie cIt,lg., Is 10 "mpJoe, It '. "d"ptable
10. liantly of 'peClflC Mtd . Th, d"'.,ng S' ad:"nd
I'iIrrurI roble PlllrlS ~how. Ilie de'II!. of IM I.. ble_
Notlu Ihlt t"'o dllft"nt leg ;ar"ngementt ." shawn.

."'fI.

STOCKAHO PArrERH TABU

Cuttlnl Ust

dog./Wtd~tI

Wxl"xI4'

..,..,.,
..,.""
..,..,.,

Do_ls

li' dli_ x lW

Hlfdwood

""

QI)'.

~"x

TlIbltlop.

.~.'

Leg

SI ~llIhl dog.
TlIpe.

Dl menslons

~-

16" x 20"

2~'

Mllllr'.'

x 13W IW<lwood

Wx IWx 14"

Hardware
drywilll wewl,, x 1~"

'IN ,....

'TII, It:..,,!t l,..ti{l.i/ 1,

1'-1'1ewU
",bit: 'Of" ,/te 1oftg-It:Hd "''''''''. _ .

.,.",,'" "'tit.

".. It:, lida rs ""'Ilo' Ionf.

(C'''''''''M,II

TIM stodNlnd,.nvlI
and eaw to use .

32

MOUltr MagIC

~bl.

1.

il

good way 10 hoId boIh Iht palle,n ind t!'le WO<\ng s,ock. (1. tiI.y tO

mak~

STOCK,ANDPATTERN TABlE PLAN5

ENOVIEW

FRONTVIEW

:J 2"'"r

,.L

,'

TI...

I .

'_~~=WL,Jl

'

'.~

__ ._i

' ____ 1 $

TOPVlEW

1- Iyp.

r -t--j'

,.

1
..-

000

Roule, Dupllcllor

33

A Stoc.k-andPattern Table--Continued
DOG-AND-WEOGE DETAIL
~WlNG

TDPVlEW

-t"iIII

.-c~

,..

"

1. StieI< ono plece 10 Ihe ollle,

".lItll double . ld.d I.pe, U
hown IIt.t . 10 s.w Iht fi ..1
dog .nd wtd<)e.

newlV Cut wod<)e 10 the Hloe

01 lh. uncul plolo YW Ih

second dov .nd

- *. ")

L.~-,'
t'" ."
3"-

5.iw hett wilh IlIls NIIe

g.in>l tlle tablt .. w fen" .

5.iw Ile.e wlth thl. Hlg.

"o.ln<1 Ih. 1;Ibl. I-IW fene .

Oowel nd hain
In I.ble angl. 1:6.

Tht sho.\-1099td ~rsion Iccommodalts Illlclte. stock

.nd palltrns Ind 1. usier 10 el.mp 10' lable o.
wof ltbtnch_ The long-I~Otd "."ion .110",. you tO
.ep.oduce sh.llow
wltll mo ... prlSlOn
bec.u.., Ihl Mim. 01 the dupl".lo. "'dJ rem;"n mort
nu.rty pa"lIel 10 Ilie .urfact. Dt lhe 1N111.n.nd lhe
Slock. \1 rou .nII(IINI neHl for bcKII " ..slOl"l .
m.lk. Ilie ,hon. OM Ind. ",hen you <!eHI Ih. 1.11
.......Ion. block II up off lhe wQ.kbn<h
n.. d w,ng o.o.,,md WMgc Ofr<lll show. on"
muns 01 ellmplng tlle pan_rn .nd Ine "ocl< 10 Ih.
I.bles. lI<I!uust II doesn' proJI'bovt 1he SU.tlU 0 1

C''''''no.

J"

2. Thtn Slk:k th. edOt of Ilie

,.

ENO V1EW

THf WEOGES

Roul" "'91(:

Ih 10(1t. Ihl~ clamp'ng .y.tem dot.n~ Inle~ "',Ih

III. duphcilOI. II your :uoc~ Ind p.>llern Ifl' .'Onl[o
unlly ilI~t l/wIn Ilie 'CI~ u ...... d nu, you Un uS<!
Just .bou!.ny <1.mp."f"Iu w.nt. AneI ,f rou'rejuSI
.nxlOllS 10 .un tllt dupllalOllhrovgh 'IS pac
","hout I.klng Ilie lImt 10 m.lte you. OWn (I.mping
~"" stitI< III. p.n n and SIOCIt tO Iholr fl'.ptW~
(.blu wlIII doublt-"ded 1;Ipe_

1. Cut th. U1blf! pans. Tht I.bletops. dogs.

wMgtl'" plywood; Ihelegs. h.lifdwood CUI thest
paru 10 lhe d,,-nensoons SPt<lfIed bv lhe CU1I'ng li$L

Ind

2. Assemble the le9!J;. Clue anei n.~ O< Krt ..

thf ''ilhi leg plKes InlO fou. leg" ~. shown ,n t ....
dr .... ,ng S,t...,ndPanun rabie P/4O".,
3. Lay out .nd chiU the dog holu. Tht
IOU."OIU ~rt shown in t .... d ...... ,"9 Sroct"ndl'" nu"
,..... Itf_ 'fO" elmt the IIole . ho ... e"er. naliee In
lfot
Oot/'QfId'WUQt ()fftlil Imi Ilie 1Io~~ enltr
N . Ioclt lI.n Inglt Ind Imi 1.... se' of hole. an one
j.iIIf mu" angle in Gnt d " Kllon ... h,le the 1I0in an
lfot OI""" lICIt lIl9l' in th' oppome dlflcllon. Thui
il'9t1 ,nlUrt thiot tlle cIovs Il'mlJn down liglll agl,nSl
tM ub~ ....... n tlle ... edlle i. IIpped In to place and
thlt t"'" ... on, crup up ... lIHe you'tt rouu ng .. cnpy
,nw some .... ,..,. t ~ ptns ..... Slock.
n.. ;a(tual,n91~ of tlle 1101" is nOI ""ieal. The
1,6 .ptC,flC'''on ,. Ihere onlr 10 liNe vou In idu 01
roughly ho ... mucll ,nglt is approprlltt In USI YOU
,~) ' ,m, I,,, ... Ith wo.k .... ncll <log., It js Imponlnt
thil ali t .... 1101,. III .... Ihe ume lIngle ind lhiol 1....
do ... t t halu In tlle dogs IlIemstMtS hllve III,. 1.1_
"'IlIe, It 1. I lso Importlnt thit th' ho~1 ,n e;Kh Pili'
!It ,qu ldlstant,
'OIe Wily la dntl theM ho~s IS nOI .. uh .. dflll
prus but w,tll ~ hiondlleld dtill . \'ou U,"," SImple jog
ta!ll'ldt t.... b't and pos+uon tlle h61ts,
MIl<I you'sell III" J'g gu,~ tiv dflll,1'III two hoIts
Ihrough.2 ,""' . q .... '" p'Ke 01 hio,dwood. Tht hoIes
must tie 1 iMhu IIp.l1n. Thtn btvtl.n edg;e of the
llirdwood SIIlP ... ,tll 1.... table 1.1.... bI.eIe IIlted la Il
<legrttS W,th the bevelfll fKe ",,"ng on t ....... ort..
poete. tlle Jog .... '" nit tht onll bit tO Ilie prope. lInglt
Ion"'" hoIts you .. ,n\ to bOte. """ I""Jog w,ll ,n,u"
tIwollll
hoit. ,n eKh p.lIlr w,1I be equ,dlSllnt.

.'''''l'1li

t"blt ind legI UP"lIhl on the bench wilh tlle lells

.t."delllng tlle "cond ta ble, Chetk thal tlle dlnaMe
Irwn OM t.bltlop 10 the othtt Is 12" Inclles. lhen
gllli ond screw the SKond flblt In plin.

5. Make the dogs and wfilgn. Tht IOIlIt

01 tlle weoge. nH6s to mllt ll the Inglt 01 Ilie llpelld
dOg' ~ultf 'C<II"lely. To .chit'" tllis .. ,tIlOllt undue
lun tl<1 .. ,tI! twO P'Uts of stock 1 'Mile, ... ,oe fo<
botl! the wtdges ono tlle I.pelld oOgs /Ind lWO p,ec"
1111/ th'l wlelth for ttle IInlipereel de>gl. lIIy OIIt Ind
bore tlle 1I0ies fa .
dowi!ls l/lt Si"" ,,'y you bOtecl
the 00g 1I0lei ,n tlle "'blts.
Now n p the l,nd! ..1de plKfS Into .. ~. Ind
dog. wnh . lipering jog an tlle tlblf: Uw ti VOtI clon'
hi .... I tapenng j'g. StK~ _
plKe tO tlle othtf IIlKe
..,th u.pet tlpot'.
shgv,n ,n tlle d ...... '''!1 Oot/ ... ,...
wu,. ()ft",', TMn mUt the (UIS
Clut Ilie dowel. ,nto tlle hoit. In Ilie cIog 'nd
you.e dant
Wtll. .,......1 doM, VOI/'U prOb.Ibly flnd thiot the
dawtls MflII b'l of slU~'1'III ,n onIt. 10 fii UI'1y InlO
Ilie 60g I>oIts in Ilie lobi".

1"""

1,

1"'"

4 . CI..... nd !J;cre. Ih. Uoblu to the leg!J;.

hlI~n) Itepl 1f;K1t oI ..II,(h ,"rf;K~' 01 Ilie
W>lts 1'1 1'" tOpS, ml.k I""m I\Ow, TIIe tOPI Ire Ilie

II 'f"OI.'

1""

wrf~es """'re
two ,nM.mOSI p.lIIIS of holu .re
dow.t '09tt .... r; lhiol
t!>te hoIts fI,re o~t It t"'"
bonom hh t .... leg. al samt I.blei,
"""ce Gnt of Ilie IIbles 10pOown on your .. o, k
bendI.11!d S1.1ld !he leg. on end It tht /OU. CO.M" .
Pl>'illOntd .. shawn tn tlle o,awlngl. Note that Ilie
nIe sode. of tlle leII! \10 On th, tnd! 01 tht I. blt
... ",re!hot nulOW sld,l 01 Ilie legs go an the f.onl and
blck. TIII, g''''. the lower belm oI tlle duplKltO. tII'
,rw " mum,sl l ' o wlndow 10 .. o.k III.ough. Clut Ino
serew the !tII' In pl. ".
NQW pla<e!he re""' ,n,ng table tOP'IIP on VOtIr
... orkbtnch, II you've mllele Iht lellilo the Iong eltmen
SIOn shawn. p.op tlle table liP I Y" ,ncllu on. tOllPIt
Ihlcknt"" 01 j(,lnclltll,ck .tlt, PI.ce tlle lInemblld

,s.

_ ' 5 IIM HlIIP for drlllhti 111I91ec1 60tI holll .

Tlle workpiKe 1. 1I11I"!1 an I K"P plKe of pIy.
.. DOd . T"" hlrdwood dnll gl/iele is climped.1 Gnt
tno. Ilelo r.rmly IIt the o!het. Tht m Iu"!1tlpe fll!1
an t .... dnll bit ii' deplh g.1Igt limed II p"'V<!ntl"9
dlmoge la Ilie btnch tap. Whtn Ilie flig ''''"''PlIIIe
surflCe of the guode . Ilie b,1 hio. pot'Mlflted the
... orkpiKt (but noi Ilie K"'" beMath it).

Iloultr Dupllc.IO<

35

..

STYLU~

Using the Duplicator

AND MOUNTINC BAR DETAI L

\Vln;nlltto

,c'

~
____...

fii bo lt

' Oul duplica'u, b buil . n", btt,j","c lrin,n".. 1; mow1IN

" Ihe ~nd of ,1><- Io",tt beam. ,'ou',~ 110' a bos-rdkf """1n8
j-UU " ... nl 'o ""py, And n"",)'Ou p>.usc.
Lool: ., II. It ce".inly luoks ,.. gawky ., IclbotJ
C" m" .11 dbo", nd knce . 15 ,hi. sucke, re,ll)" goruu
",,,ri<1 )"U uk )'Oursdf, "ou"" gO' tim ... and moncy lkt1
"1" In It,"" il betie .
I lhink i, "ill. 1t did for Fre<J . od Ilob.And It did for me.
Wh.t)'Ou h .." \<.> do i. llle s:>mc 'hi"l! )"t)\I (O ,,ith:ll!
'ht."St: m.jj.Ic:Il. (1)">tic:oJ ",u'ing ",,"chlno: Experimen,.
,"ou
10 I.... m Ihrough upcnencc: ",h.. i, !li like 10
"""",,u'-c. lhi5 un!!"inl)" <lcvice. ,"ou h .." 'o
Ihis ."OOd
",i. h 111>1 lht: '"'l lus, and ,. . d 'h" ,uS:ltld
,N
b)ltltc ..-....Ie.-. ctlergy ."d 'Ile forec of l he spinnlnll-C1JllinJ!
bi,. StI", it's ""lII". ...erul, bu, 11 iS Ulcr.dly FLOATISG ON AlR~
The I S. ." 2\).p.mnd dt....u )"Qu lifl un'" 'hc "",rt.hcndt
.lteds:tll ,h., ""ighl ... soon .... )'Ou nici: on the ,hop.-ac.
whopplng good lrick l
Su now )"" ""'u, 'o go 'o wo rt.. llcre'$ how lU SCt up
aod ""',. copy ofa bos-",Iic( .........'ing.

h.,"

!
Ma~e Sty1I1S

from bolt of same

,hank di~me te , a, ,oute, bi!',

cutt,n; diamete'.

moumIJl'scn:w

holc:i. os .hown In the <,I ... wlng ~)"I"s ,,,,d

MQ,mll"g &" l klull.

If)'OU wan . if}'o" .hln!.: it wiU n' ...." It ..,,1.,.. ro usc.)'OU

.-an tol' ,II<- SI}'llI' hoIc. 11w ''""o)" )"OU .-an simply ,"m ,he
"liUS ilS<:lf '" :uJj"'" ;l~ 1cn!!lh ro m:uch 'hc ..,.ner bil sc"ing.
1"0 Jock

in positlon.)'OU

;am ~ wing nm ,h.,s~n IlJJ"I"Inl

om" II>< >1)1u" ~g:linst lhc ,""unllng bar. , 'ou <In IIO!. how
",cr. h.:t'" tu "'p thc hok. IItSICld.)'OU ("JJl <lriU ,il<: m"""tl"l!
bAr ,,> ti>< "" ..... ~ iliiul ........ ofth" 0<)'1'" and """,nI ,"" ")"1 ...
wi.h ,wo n u... 0It~
,h~ Mr.nd """ bdow.
In cithe.
"""em"", , ..... )"U mII>' . 1",,)... m.!"h
'he Str'''' ""I"n>ion 'o 'hc """er bit ""Ie~ . Rcm~n~r
. ISI)
)'OU n""'" a <li/k",n, mounlin~ N' for <"Vcl"}' <lif
f""'nI dbm<"lC' of OI)'lu" )"Qu ust:.

C""".

.00-."

,1,

7, IruIt:tIJ ilie m""ntlng ba. an<l st}'Jus. M lonJt

)'OUr ",ou" 1, oeeu,,"!"1y ""'un" .... In 'he <..,nte, of lhc
maun'ing pl:.i'c. :as .......u In 'hc dr.t.winAA 'he "li",
nlOun'ing bM', <Vf"I"CCt nlOun,IOJ! P""itlon .. 1 lneh ..." from
II><- ,,cl>..,. .huwn In ,ho: SI"" 11<~1I d,.~wi"l! . If fu, >Om<"
,..,.".,., )Oll\'e <,Iunc IhingS <lifJc~ntly. IfI.1kc SII'" 1"'" II><
"'llU$ I1.ounl$ dittt'l)" ~ ,lIe mu'e' bit. Se"", Ilie
moumlng bol 'o ,lte lItt<krskk- o( ,1>< hoox Il,,:am stdes. If)'Ou
.ntlelp>'" f"'"<l, ... n' l} ch,nging .h" """'"""11 h,. ,n '~C '~
nlO.!>,e , "llllS of a dilkrenl d i.>m ... ,e' ,consldcr lISing sn,:ill
hJ."fI<" balos . lId wi~ nuos Ins, ... :Kl of serew .
You, duplica' "" is now cumplc..:. Why
)"u h~
1, up 1<, ~'" !-hOl" ' ''c and l:aI<e i,
'pin up:ltld do",n Ilie
",o!1<l>Cr.chl

f"".

tIun,

"te,."

""'' t2nCc ". . .

It', .

1. Chousc }'U... " 'o rk s u rfatt, lhc dupl;c;,tOl'

"",ui"", SOlouth, fLt,. Ic\..... .\iWfR"C; """-,,,,h and ru, >O ti><
pl,""n n"",e; .!>oul frn:ly " 'm",u, h:onglnl! up Olt irrq,;uw.
'lies In lh .. surf.ce. I.. ,-cl SI) il doesn', Ictld 10 "Ildt otr
oo",nhiJl, ( lIc01cmbcr. ,1><", Is 'inu,ll)' nO ftictiOll t>cl"'ttn
'he pl.len ond thc SUrf'L" It, "<ling un l>fK" y"" 'utn ...
,hc .Ir.) II ",dl"",Jm:dned '.mrt.i>cnch "",k ..., . good w<>ri;
surf:><:e. A fl.>1 m. ofpl)'wQOd Ot~. Iousy wol"ti>cnch OI'
"bI....1so wun:" fine.
2 . Ikdd ... bow 10 s tage Ih c work p ieces. Wht"tl
Ilie dupli""''''', )"OU It,,,,-c ,wo -""OI."\;p;"",,,- )"OU :att
:Kl<Jrcs.";IltI ."nmiran."'usly. On~ is
patl~m.
oche,;'
Ihe ~ock bdng ""'Ied.
,\ In ,emp"',e-...,..'Hti\ o~ . l"n,. '''''y pa<ticulat "''''
'ion"'ip mUSl ..... m.ln,.ln."<I i>c,,,..,.,n 'he p."~m . nd ,I>c
wuri<l"l! ,",,,,,k. IJuI unlikc Ihc lCl1lpblC "",,"'l<><l. "'here ,I>c
ICII'P"'IC and ,lIe "ock ~ .... _d,,"lched 'QIIt1het; ,1Ie ''''0
wort.-plcccs must hc ..,p.... ,ed lOr ,1Ie dupllanor, Worklng
oul. , idr ""1' oI!"",i'i"n,ng an<J """utn~ Ihc !"Item ond
Ihc wort<ing s'ocl <:an Ix ""';or chltlIe"S'-", An<! tIIiS i:!t ,ruc
when usinll an)' "'u"'. duplicalO'. IlO! JU:il ,hl. unt.
Wlth Ihl; dupli""''''', ,hc ch.lkngc 1" .... mp<lUntied by
Ihe !:te'
'hc 1"'"<"1"11 n'"" Ix ....peodC<l d iJ"Cet1)" aba<..
Ihc Stod: lO bc ",m,-"d. Th,-" <lW.ncc I:>c'''.....,n ,"" ,wo
" 'uri<l ng ,u!fac"", mllM bc 12'1 ine""'"
Ona: In whiic. Ihc w orkpictt!i Icnd 'h"'...... I,' c 10
soroc ~ $1"-!ting tiu. ("JJl bc cobblcd up "' .... ppon
lhe ""Ul11l ~oo-.~' ,"" wurkl"l! swck. lIu! """" oft .... lhan
"'~ . ~ . ;'Iy .,,<1 ~Ihk , ,,,,,.I~,-.-I '''t>lr ;. ..-h>t }"" 0....-.1 I ..,.....
orun""'" tlUI )'Ou spend 'hc "me righl now,lxfon, )"OU rc:illy
do any puf"Jl"lSdul dupllal'lnll ,,"OI."\;, tu bulld thc auxill:r.'1'
projcct. ' II Slock"""d-I'"~n..,." lloblt:: prcscntl-d Olt p>.gc 32.
Ilob ""d Frcd <:nlllhoo .... led on 11$ design. and It Ju work<'tl
weH for ' hc job\. 'h., '"1.-c ,.cldC<l willl thc dUplica"".
)"OU lIS<:

,h"

,1.

1""

TIte dogl nd .... edg. Uh'P rnlIke. II en,/, 10 clamp

bolh Ihe p;>lle.n an<! the wo.k 10 tM table. Lay the
potlern on Ihe uppe' tablelop. tlght 19a1ns\ ,he
lu,lght dog. Set It.. lape",d dog into set of hole.
dose 10 1..... workp,e"s edgt. 1hen tap Ihe w'dO' InlO
t/Ie tAP ~ween Ihe dog and "'" worlc.

""'" 1"" 'ahle ,," ,il<" """'bo:-ndl. bu' <It",., cbmi' "'lf"

.... jos }"ft.n,~ ..,IUP ""lui"" a Ilnl~ , rW :u>d cm>I". """

~ an fICt jiule ru..y To ......1<)n It ... ,..<.>tI<. 1..... nenJ In
h;t..-

th<o '"'uplintOf" ..... up ..ith ,t ... bit .nd

st).,.... ",,;ng

Ihal.}'OUU bc .bIe ...,.,U"" .nd ,,"Ctl(lll" 1"" p"ucrn ,,><1

tIt< ..-ortt 'o ,IM: """" Thrn

}"OU

can run ,hruuwt tlte Il",i..

.... """""",ni 111:1, ..UI t.. n~. :and """ 1t)'OU n ro<tlpk"I~ "'" n>uI~"1I ,,[><r.t1C)l"1 .."ith IIM: I>1lI." In ''''''
p..,.;tloo.So...

3. 1'Ic.k ro'" bll (and com pie n"."nla..,. ~trl .... ).

TIU. JOOd . long.ludgmnll,,1 looIt "1 Ihc p;tllcm n~e Ihc
bitJ lIId Mflu ....""
p.l1I"""'. and """ ..hieh I>it. h 1>0,,,,
.. '""" 'u cupy II'" I""<"n1. If)"OU 11>.'c a (c)I 01 nl~l~rbJ (4)
boJ "-ay. (Ib'iOU>ly 1"tJU ...... n' 10 ..an "';,h " 1>111 hit. To
tn<"t Ihe delal1>. )"OU nd " ,,,,,,lkI"'nlC1Cr hil n,.)", .

'u ,""

~OfaV1POO' CT

Ib,lng ",Itffi tIM: 1I1t. chud< II In III< ~.ml" 'I~

mmlMf". R........" It.... molor rrom ,t.... ba....,. IItch'en Ihe bil
iti ,(,., <.'OIlet. and ",",um 'he n""OI" Iu Ihc ~ .

,h.,

.\IoUn' " .. "')111>

gocs .. ~h."" ~h<"",,, loiI"" 'IM:
duplic:u.", Thb Ukdr nlcans 1..... _
"""'... a nllMl .... ln(t
. . .ith ,il<" approprtll" .. )'111> 10 ,"" uppcr "'~m
4. Go .. nCCf Ihc alr !iUpp1r."'e .Ir '":11 fIoab 1"'-"
dttpIIntor como fn>m Y""r >hop ,. c . ... 1\" ""'" re....,..'
Ntr y"" .... ,'~ tu h:n.., a '"K ' ....1 h.) an ""....... port ln10
wbidt 1"'-" ~ CM1 M in5ct1~-d_ .\1""1 <lo ~ nul ,11.
Plug In Ihc 1"K and po;.I, .... , 1, IIOIok ,,,,-" .......... "'''''-h.
"""'Sh 00' 01 "'" .....,. 01 )'Ul1r n""""..1\I. . . much ..' ",...
-'1'IU1!1 """ cRlI n{ 'il<" ,,.,..,. ,n." "'" aru.U>I pun. "'"
0lh<T inlO ..... dupl""'I.,... al.
pun . It .hol1kJ ...-A

"'pp!)

Adj 'UI Ihe bl, and s "llI s senlngs u.lng Ilie SI<Kk
Ind IM p;luem Ilie. IheyVe bun dooged 10 , .....
Ublt. AdjuS\ Ihe bit, Ind po.lllon
dupl'Qlor.o
, ..... bit ",SIs on 1"" Slock. U I hown. The devtce~ luil
anet Is wclI thalit wih seule onlO Ih, b~: yOIJ don,
kavt 10 hold II. Then IdjuSI Ilie Stylu. so II 1. In con
laCI wlth IlIt UPI)t' ublelop.

'II,

'ltth,1y ..i,bout n!1~ritlJl Ihe pun more lhan ';. Inch "
,urn ur 1..... or m;ISl<l"lI ta"" """""" 'hc cun""","" >ItoouId
'1W"n! ~ lip If It g<>cs in ' '''' far.
I"*' OII 10 Ilie d upiicalOf" ,,-,'II ~ .... nd, ..tlile 1"OU
,um OII .hc .-..;, If CH')"I1Dr11: io "",",1"tI ... 1, -IhouId. 1hc
0111) "",,,",,".blc ~"'.,..,.. 10 It.... ii!!. >llditljlaround .UI bc
It.... dr~g&inp. ""d fIo<ing of "'" ,-acuUOl hoJt If)"nU tJD.
C(J>'CT. ,,lI<:n )"tIU >,.."ch "" II",
lha, Ihc ,",uplicatur It
>Udo.k:nly .. ud< 1oOIidI). 10 ,hc; wm" ....-btt. Y"" .... ~un
I'Ilnl It 'O 1.... '"K"s otK"tl"" """.

,-ac.

5. llootIlM p,n",,, anei Sloc:k In p""'"'. Wh~n<"'"

fl"'S>lbk. ma~e """,p 0.'1 hr makll1ll "'" >locIt ,'''' """'"
>i~ .. It.... p.I'fC1n ,.11:1, "OI)", Y"" c-an ~ ,hc p"ttern ""
i" 13bk. 11Im ..... Ihe d uplicalOf" Itl<df Iu pOOl'lon 'Ile ..ud:
OII ,hc .. oxk tabk.
l 'siOjl [hl. ll"chniq"'" 10 p<HJllon Ihc ..<.>tI<pies
dodn I rommil)<>U 10 ""'~ 'hc ..lIIc In. ~Ion
'100 You a.., aIi~ ,t.. p""cm . nd .. od " "h """
,noe""r. ... lIich il> CO&nllioJ. ~ tl>c)' 21"1" aIignnI a""
",'~'<IgnI 'o Iii<" tabk, '''''r a.., ..,1. \"00 can da. ,"" I.III~
rrom ,'''' "'-orkbmdI .nd cJo oomcthin c:umpklCIy tIIf
re"'nI ..
bo.ck Iu Ihc bench , ..... "'"ttb b.le . IJld
,to<: )'II .. ut bc propCTIy .IJwlCd ,,I,h """ :anuth~r.
So hcn:-"s 00... 10
It. Wilh It.... l'OOJ'(1" 'umnl olt, """'"

\i"'" ,,,,,,"

"'li

,Ion ,,,,-" >Iod! .... 'bc roUICT bit oJldn .1ona1""0 of I~ edgco
",hll<- It.... "'ylu. ls olidilljt ........"" ("or"",~
nIjlD of , .... p.,,~m . Thc:n cbmp ,he >Iod In ....,.,. ,"ou
clonl nn-d 10 ""
pruiK in ,h;" ",,,,'lonil1J-nobody
i likdy 'o nOIi<..., If.IM: potition oI a <.. ~ In ' hc ... od 1.
uIT by "",.u f~tI"" of .." I". h.

,,,'U

0\..,""

Now Ihe " ........ pi"'....,~,

ROUle. o..pltUlot

)1

7 . C lamp the s lock.and.paltcnl lable. Il1rh

>hop ''X runnll8 and II><' dupllc:otor Ihl .. mobile. bul 'It
Ihc "'.".... SOT ",nnln.,.. 1r.>C<' ~round Ihe pauem 10
how hal \O oritn he stud, .. nd-plllcm ubk. You do,,..
ntttI .0 il<:
~"" , .Incc )'tIU an """.., thc ulok
willooul ne,,(Iinll'" ,.,..Ii .... II>< bli and Ol)'l ... onllllJlf antl
wll"'"" .K"Cdlrljl 1" rcalign Iil<: p;luctn ..... Ihc >tudt, 1Iut
Ulll" otperl_"u"tI now ~ ""'" ~
ar.

,0<,

sItifu;

8.
b

Here'" the o\/e 11 utup.

Th~

noxk and'p;altfffllllbie

IS clamped allhf fGQf o I IIM! wO(kbMcll. an IIM! far

sld~ Ollhf IlIblt. oxc"O'fIng IIM! Ctnt" of IlIt worlt
btlKh, i. IIM! d"plicaIO(. TM shop \/ac,,"m b 10 IIM!
s~ . TM """fiilo(. SUII~ 0111 wilh tar muffs. ultlY
!I"SSfS. ~ .. uisanc:t dust muk. Is Hattd by IIM! work,

6. AdJus l eJ<le"slo n of tlte bit and 1' ''' j;1)lus. II

boIh II><' p;lllem ..111111<: """,pic:<:e ~re IIK .,.,.., Ihickr>C55.
)'1"100 m.kc lhis >dlllSlnlCfll .... "lC d", 1abIct"P' t i

"*"

coCe lJ("n,s. 1Iu, .il<: bnl """) .0 du i. i< aiic. "",\e ~

IK p;lLtcm :&IId .."Or1tp;tto: '0 tbctr resprt"tl':( .ablnopo.
Elcl~"" Ihc bit u far .. II all 1><' ""lcndcd. lhcll ",,;t It
"" Ilie ..."Or1tpi""", l'o ....... ll>O>'c 1"" duplk-.olo ' arou"d 50
lhc >l)'lus IUSi '()\ICI><:> II><.' hlllh<~ pot. un 'he p;ltttt1L
Adi"'" .tt.c .. )'luS ""."nslu" .... tha. ,
1"" ")'Iu.. i<
touchin" ti!>. hl~h painl . hc hil b rnt~ " " 1"" ,,"Or1t.
plcce ,1"0 :IOO,pJI>h Ihl>. II ....Y hc M'C~ ' 1<> "",,IU"
Ih,,!)il ulcn>ion .

"he"

'''''0

aRc. )'OU JId ..""ni.

R OUL

Anual otp<:ricn~" It b)' f.r Ihe bc5t

1'''''. 1

Uing Ilti> tJj(. Slncc 'II<' jig m.. ln,.In. ,1><' """liaI n;WJon.

>1111' 1I,,,,,..,.,n II ....1)'1 ... an<! Ilie ""'I~. bit. )'OU an 8u1do
Ilie cui. by hokllllJlllIe SI)'lu ...... 11>0'11,. it ar b)' 1ddq
Ihe <outCl" .,111 "",,'!nit k .vIU'" ""Ichintt ..'hen: 1.... l1)ill>
Is goIng.
"", IoltCl" .~ J'fO"Ido much boi' tr ("nlrul ,
li.., both ha ...... Grip Ihe dupl;",,,o. On d'hcr .Ide of 1""
bmhul~ lrimmcr,bui ..",.cIt Ilie '1)'llIs,GuiIk II by mO>~
. hc ""'Ief. Don 't ru.lI, ~~ )"(Jur ,1.,.., YOII ...-.on, .0 ,rIm
'''':1)' Ih~ wood 1111'" OI ti ..... , I':>.1hc:. lhan bu .......lac
Int!> II GI.ndns .11"" .Iock ocasionall)' ..-ilI moS5Un:)'OU
lha' .heduplk-..llooo iii P~"3:>S nlcnd<:d, It ponb:ohly
wlll ....,n] rrom ti.,..,.o .inx tiu. )'OU"" mltd O" .m_
JU>I kttp .1 It un.il Ih~ .. )iu. ~ " .... ~d aII
In:! .00
<l<Ib
.il<: .... ltem
"", <luic~e'l et",'inllS '" dupliet'e are lhuo;c IIUI
n:.aln ,he "'''''cr' ~ urllllrulll<>"JlO' mOrb. IIt' 1$1ljI' N' .....
"')'Iu_ Ih. 1 cl".dy m:uch II><' cu",.., 01"11><' a"''''''1 fIOUlII'
)"u an fullow rigIIl ..".'n Ihe CUl~S MrokN ...-ilh lhoc
>tIlu . n:ptOdueng D<:h of 1"" oriJtinaI SOUII<: n rb in
" ...... duplln.e,
Il". CUl'I"l! has bttn ",.KkJlt ...'tl OUl,)'IMJ can u>u>11)'
n>tIIIh OUl ,hc dllpllcale wnh con:-/)ux hllS, lhocn _ h
....., th""""JIOOI/IC' m,n.. wl.h ....1" ano:! obr.o;i,-n, ~
'bI)' Ilie "'-.I)' Iil<:
dId tlle urigI ......

,h"

o,

l':l"'''''

woO..
.......:f and
feeI

K"p )'OU. ")'H Of!

Ihe .... uer .. as 'fOu

Wilh prut.k~ you'lI gain confidfnc~

COIllfo.tlblt uslng ,~e duplicitar

f~n

. ._ _

31

lIoUl" Mi\gJC

,hOllllh Vau can', ste bolh Iht .,oxk

and thf paut,n at. t. h~ .. m~ IIm<! . Eve.y

"'''''C'''~'U uf Ilie
wlll Dt "pilUle<!
lIy t.he 'OUler (,igh O.

>1'('"'

Trammel Sase
(ve...,. router magician's basle bag

Iricks has li trammel in il. Here's

grui ane ror yo"r bag o' trcks .
ti'

_.

;;

II

:::"_.

"

IlO

or n .... tin~ """,Uish d~ :and hok$. ~ (rom

[-incI! dimlt,tt up lO:abtJut 16 ~ In ~C1". tlll,

"' tlK idc~1 u:lmm..... ~h:it Ili~r """" b 1" .1>Il~)' '''
cu",-,he [- .nd
~ lbc
fxI
It's !lOt /IOOd r:mlt" l>eyond Is .....",Iy. pol ...
~ pI'OlOl)'PC i> In 'he u_fn1( lulf ni "'" ROIbIr
'OQX/v.vd;lng 'hor .lhe h,d( " 'M", Plril Gchm 5f'C1'dS oeh
<lIy building furni",",;md lchol (h~, nhlocu ond pru..:n

do tho:K

,h;o,

."",11..!;,,,,,,,,,,.

2.onct\

<Ilnl.' p!i<>ns, indlJ5.ln.1 di>pla)' 00 ..... hok "" _

. ,."u
~ and nude ,ho" "rlgln.) .r,",,,,,,' lor 110 Pun""

CM* 100. 1'""

""m......,.,(I. Innulloenllk ,jmG;~ ~ ..~

IK>rs<:powe. ftlu'e' 1.
I'<'.emll, InKk

lI~e

ctlntnl"';'"

lo.... n In

Making the Baseplate

11... bo.,cpb .c 'ho.... " I.... pp"" 1'Iy. ...1tk:1t rd dwx.crUc ...
an,l,mcric:o"...utk ''Cl'!'io" "r ""ltic Klrch pl}'wuod It h1< II
pile> ...,,,.:.. ,1.." II", 7 plic 'lpk.':ll 01 tq!ub .\'. .Inch bircIt
M ...~IOIl . 11... >li<k i. ""'~1U1 ilanl"-..,, ,1Cnk:d Inclll<lo I
T-nu . a .humbscrcw or ~tI""ie,J pWlic knob. a" Iki
cnm""", n:oil. ""Li C~ I r. kM1g ",uuming ""rr..~ oJi corn-

monpb ..urr

EVC1llu;llly I ",:&41<: my O"'", 1lt\1~ [, ' 0 ' ~U _ I I

flbllI" muIe'.
n.., tr. n""d i> rouW>lr ,nnl,,,p'''''''pol '-'PUte
_
01 \.j ""h pt)'W<J<Kl. A " ~IndJ.k"'ll T~ . atcndillll
/rom ~ "" opoonlnjl, ou. 1<, .11 ..
d"'~n, ctl#,IKJUSc>.
oIIdt ..-1.11 1"'.......... 11 drh'c" Ihroul.lh ""'" eno!. Moo'c thr
!IIdt In or OUt '" 0"1"'"' .lIe r.d,u, oI.h" CUI. 11lm fi>< il>
~on h)" lghlcolnl.l 'Ile k>cki!lJl, knob.
II _II Nu,,,, ,,"Uri<. bc,l on 'Ile , ... mmel, ond o
pioInjIr ...,u'''' tu.,~ ahlll.y 10 inUI.,e: and <k"<'P<'1l a cu,
....". n..r....11) I nUcd mr .r. n,mcl bo.KpL>.C tu' SIn.11
~ rotI.a 1'0 mc. roll.i"lI 1'~I""h dL,k> .... i.h o j'..,.

""*

1. .... y ou hc: bascpb'c. The gool i. tu tu,':

6 ' Hnch!oJWl from ,1><' !:>i, ub 'o ,loc ,aii ""d of ,hc: I>;osc.
pUte lbc' Ict\gIh of _]>bIe ntt<k:d 'o achie\'c
pi
c~ In proponlon to Ihc: d .. nte ..... of.hc: rou,er ba...,
lJqcln by l'CII1O\i", ,Ite: 1it<1Gr)' Juscpbu, fn"" ,II<:

.Iti.

routa fO'I'II u>c: OII I~ , ......mei. .\I<-"..'u"" IL' r>oJlll>. :rnd

add 6~, indM:> ,O ti ..,. Cu, hlank 11", widlll ~u;d, tt ...
di:lm<1a of th<: m.... nd ,II<: ~lllIlh f".h ,!te """ .. r.o.<Jht>

pI ... 6'" incl1a.

Uoc <'U'P<' .. pc

1<1 ."lod! I~ r...,tory """'I'lalc 'u ,1",

bI:rn.k.'" """..'Il in ,1><" tlra'N1nJt /J,(.S<'pJ"'~ UlJ'Um. WI.h

39

Cuning USI
PiUt

Qty. Dlmtnslons

Sase
Sildt

)1,'

x 6)f")( 911"

M" lell' )( S'

IASEPLA TE LA YOUT

Millerlal
Plywood
I-lJ'dwood

T-,Ioi
etnte.llne

HArdw.re
I T'nul, )4",20

.-'"

-'Z

I thumbserfw, \4',20

c:

:s

-.-

x,"

1 utr;t!ong moun!",!!

K~w 5

(sin rol!'e<ltd wlU

1.._"_"_'.,.".d
_"_"'. _..'.O.'"'"~_'_._')_____..J

To lIuilk Ilie 1I"llIng of moun\I"V"screw hoit. Jnd

il

bit opt:nl

'tic. Ilie faClory bJ.nplatt 10 lhe blank wllh UrlH'llape.

TRAMMEL l,o\SfPlATE PlAN VIEW5
SECTION AA

ENOVlEW

Fl9

EDGE V1{W

IOlTOM V1EW~_ _ ~~

SLIDHOCK OETAll

o
O
g'y,."-

ROUIM I4l1lc

l OUTlHG TH E T SLOT

,.

.,.

')"-."'"
A. With a y,' str~ighl bit
In a uble' MOUnled
..,.,Itr. plow" IIroow
}t.. o.ep.

B. SWllch 10 /1 }t.. keyhole bit . Ilalst IIM! bil

flush wlth t.he bonom of Ihe IIroove.
AdJusllhe lenee ~ tIM! bil [UIS li IIOIth
in t.he $Idtw/lii farthesi ftom Ilie fenet.
""-ke Ilie Cui 1"'0 both sic!ew;l.Us.

2. Drill lhe """'" fo r the ",Uler.

UsinM ItIc hoks

iri III< factory b:ast-pI.,~ .. drili ~",do , driU """'"

I\:.>r

thr DIOIIIllinl; !iCTC""S. ~Iark 1.... Ioallon of It.. bit ....... I~

knIo>t th<: factory tu>cplalc (rom It.. bbnk. Thcn roun<moW;. th< """,ntln~'

_ <l boUI ~ IrIchCll)

for

"""".an<! ""'" a ~n

Ih~ M

.."..nlng..

C. lower Ihe bn Vi.' Ind

make" second pus on
u c h Sldt. Intrusing
Ihe htight of Iht nOlCh .

]. Root lhe T -tlkX. Thlll Is " jIOOd router I.ble """ ...
lllon. 1Iq,tIn by I\IUIlrtjll ~o-Indl.""kk X ~.lnc~p ",.""
II It.. pooIllon ........ n In It..
d ......illjl. S" 'IIch 1Q
dthcr T~ bil or. ~ ke)"tH.>k: hll Mlju>t ,il<: rcncc
110 1hI. bit "il! hc cunlnl! lrIto Ihc ouui<k oJdcw".<I1 of ,t..
P'OO'"C (Ihc .......... n f..,ht-SI rrom It.. rcne'). ' .... ,..... 01
'his bil lIhouId bot nt.M " 'Ith Ihc ",,,,,..,.. >i<\t:1t... II . IlO II>
.."inft an np llot T .'o!. ke I ("Ul Inl<) nctI ""-.<11 of thc
JPOO'"C 1lIc propcT I"ccd di...ction. by lhe "-.y. b rigIII Iu
Idl For """ lIi<k. pIow rrom cnd 10 bit opnHng tor the
othn. rrom bit OfIC'n~ 10 nlF.

101)"'"

notw.

4. I>rill fo r I ..d h.,;.t:ill ti.., T_nUI. M

lhe
"ilk b fIxcd In """'Ilon by I 'hum""" ...:.... IMI ', run
IhlUUllh ..... "U1. Thc lip 01 lhe K"n."W p<aon _Iruc lhe
.. idt:, j:amminM; II '""" ........ 10 drilll pilot lor lheT"'ul. plu>
rounlnbot"C for lheT..,,,, f'IlnF.. ,,"'" \"CI}' an:fuUy. liI>tt
you don'. ~>'\' mudl IhlckncM ..itll " 'hId! 10 WOfk..
Set 1"" N!q>btc on the driU pttM l;abk. ,,ith ItIc >lot
up AliBn il lOr drtlH"lI 1"" T..,,,, l'ikll. and cbmp it 10 the
",bie Urill 11'1<" apPfOprialcly 5i:eed pilot
S" 'kd! 1<1 1
-1>1 ....... """"""'" bIt, an<! driU a roumetbon:: t.kqI ~ lOr
thc Tnul fI:m8" Tot ,he drpth by scnilljl llot T..,,,, In,o it.
u~ oo..'n nd 5cdng II thc n. ... 1> n..... " 'hh thc
hult,,", 01 t"" JIot.
1'.p Ih~T..,U1 camull) ''''0 pbn:: "fum 1"" Ihum~'
i",o lilcT..,ut .

"'*

T-Slide Tester Tip

TIItt T,.ul for I h. alld ..lock ,ilS In

counlerbored

hoit Chi lltd In Ilie butplalt nUr IIM! IJII end of Iht

tJot. To INI tIM! TnUI's prong' . Ihrelld" boiI InlO Ihe

TfIUI. as shown. and lap an Ihe boiI head wllh.

. "'"

I\lmrner. {Hote

t~111M!

IItCUSilry hOit Is larg" Ihin

To h~lp III ,h~ sl~, (U, .. T~1ot In ilII '_Ira

piete of Ihe buepl~l~ Slock ""~h thl~ Iesle. U you
'OUl Ihe Tslol In Ilie bau. USIII\I Iht Silme w'IUpS.
As \'OU rtll~t Ilie lUdt, theck how 1\ fiu '" ,hls
tell~r WMn yOU ~lIn p41U the llidt, thrQugh the
lesler's SlOI, 11'5 JUcty.o UU In Ilie ba>tplale.

n
_.

;:

It

:::_.
C

..."

S . Cuii"" bqrpbk 10 ~ h~p" .."h iNT..... nil

iN IIIkk lod: 1mI*'1)"OU <"lin Irlm 1"" ~ ~ I f t '
lIIInn, ~'"" 10 1"" ~ ,.:-.,tlmp oI\;opc Thlt .. tIonc
'lWckly :anii noi/J' Of! ,..., ban<!!IIIW II yuu <Ion"! ....'" t.nd
""W. ...... oaIxT _
Thm sand Ihc nlIIo """".....ith hdt

_.

~nd

tipi 01 tIM: Il> ......... ~ ro ,.... It tO !It.

Whm II Ou pnfc:cI.Iy. driI:u>d ~vum~ tM hoit
for the piml
1\> OI1llke tl IC
ClAIhc .h.onk IfI)nl'" 8d """""'"
noii . Ic-~ ";'" h abouf 'Inch Ionjj ...."..
"~
hoIr, :u>d slip IIM: ob;k Into Ibt baocplatc

""'OI.,

6. Makc . 00 AI Ihe ~ lIde. Thc Niok > formo:d 11)'

bbns ."0 ... nIW 01 I _"00<1 .,Ip,
al furmlnl' ' 0fIIIUt """"...."n I""m for afct) 'u,k, tu 0JICf'
C "~>n ihould bc pc<f,,,,.n"'" n n a w'>l'kpoC , ....', 2 Inchn
. _ .... 1DOft' '<riIlIr AII ... <"UIlln" 1"" nal!hor .... _
'M fie uliM
: : ' 0fI8\IC" In ,tir oIrndr<Ul T..... " It h ...... , lIt 1""
"'""~

-.-

Ihc r:obbI:u bir ..-..

iM r:Ibbtn ... , .........

tt ~ ls ' 00 ........, ....

*",

00.."., "'""iIII

II

..-..m ' M lOIIjlUC fi .. 1"" ob . np IM Jhok (rom IIM:

.."OfI.:~ Sn "fi ,Ix rippina CUI ... ,..., .... wll f.U tu

tIM: ouuit)r 01 IIM: bb<Ior. fii 1"" >lkk 10 ItIr T-tIot ~Ih ~
bloci< pWk. ""'....... , ... ~ing; (ron, 'Ix s1loJ, .. """" Ind the

NA"'ING TH[ SU OI:

A.

the

t<!gel of I

1"-wodto

Using the Baseplate

!OUl'" ,. ." ..

::1

t""

_kplt<" /o<m'''91 u~..glle

1. Ch uck y bit 1" ,Il" colk."I. \ly 1mI1'"~~:::~~'~

>lr:IlgIw-bl! In>!\.' tlut)'OO nl:l)' "" root",-. 'l
ftk ..ith an ....piIotcd p<Utllc! 0 011.". 50 cboooor)'OlIr

..al.,.

fii il iri iN """...

II" JUO ..., rooIl, . ........ OI"
I dbL 1"<1
mcnd I oponI upcut tJ;t. Ii ... ~I .... cookr beci...., ~
ro ....... Ibt cbip up and 001 0/ iN CUI.

U'hiIc )'00 ..., .'<lll"l.l up Ihc ,.,....".. adi"'" ,hc .~';

(kptb II,..,.. a.." WIJljl plunsc """... 1t)'OO :an:: .,
<'<Im{1Id~1f Ihrouah tl>c "ock. "'"
dcpth 10
<oWd. lhidinnf ph .. nu moft' Ihoo "'" Inch.

t"" .......

1. ChKk Itle fIt of lhe 10ftgUe '" lhe

T.Iot . Re-rwlltle ~1S 10
,Hluc:., 'onglle wldlh. SUn ....... '
il Ilo, longue 1"00 """OW.

2 . ~ lhe JlkIe poo;tIioQ fOf" lhe dal.n:d M"..

..&l....

~n

1""

Ih~.

""'~

Tunglle
100M"OW

Ihc .....,

' ....n. 1"" Ih"mb.cn."W

I~'I ~ hc.." rou IttOUnI lot thc: oJ~ of,hl' hll
CUlt ... . dl.k, ,.....,/"''''
I>It frum
r:ldl ... , ""'''''''''' r....
1"" """'.". of 'Ix p>u 10 iM cIoIot pOio!l "" IIM: I>It II CUI,

t""

100 wlde

t""

JUSI.iglll

C. Rip ttle sllCIe r,om tht .. orItpl-eu

O. Fii Itle .Ikk 10 Itle T" 101 by pllnlng top Ind

edOl' of Ilie Ibnges _ 1111. bloc~ pIIne.
Plo ... tht tOgn of tlle f i I .
tO reduCt OYeQH W'kIIh
ofltle iWe
PiIne bac:k to reduc:t
Ihl(kneSi of fll"9".

S.I Ilie cOIIII ... rldl., by ","tU,lng lrom btllO

pivot. Uu I ""'1.1 "'IH 10< Ihlt . Tu," 1'" btl by ""nd
10 ensure 1""1
mtlllu.'lng Ilom Itle (Ulling

'r'OII."

edge. and IlOl the boctv 01 the bll . Mutult I.om 1""
cenifl of Itle pivot

I
I

1iIIII"1I<.>k.1"..I"'I~ It... hll In Ih, rad'u. m,,.,,"'" f .."" Ih,

pMK cm l~r 10 ti", ,".. h.,,, p"IOI or II,.. 1111 Sc:c II,.. ....Jwilltl
StltI'W lIN CulII" lI NfUI/",.
For ~ X1,.'tlI'K')',"'" mCI~ 1 n,IC', ra,t...'r 'h"" I I~I'"
~, 'O"" 'hc "jl<k

SlTTING THE CUTTING RADIUS

WANT HjE 0lSK1

<kt~T11Ilnc thc bcsI ....,nU(: <JI a.ttadt. n", nuy bc: ~bk to
.wi. ctt OII 'hc """or wiel,.hc bil R:1....,.n1 wttlltn <hc """',
'Mn """"'" III<: lod; mh>nlsm , pI~ tII<: hit inlO III<:
wor1<, and .w.lrn It... Iod<. Doe!n', wor1< lOr)'OUl Trr XI
unII Ilie
<kpch .o:./)()O. 1. lndI, .hen nlchirlft otw:
p; ..... in il> hok ... hi'" Irttpin8 otw: ",..1,,. ba.... tIppnl tip
from Ihe """"flie 50 tIM: bil 5 ck:u <JI."" wor1<. ~wiI<:h
on 'hc .. >Ule' and ~ it ""'10 ,"" worl<, p~ tbc: 00.

"""ing

Stlll unrum{o,ubld tkR:'. a .hiRl option: [lrlU .."R,"I.(

hok .11<: sune diametcr as otw: bil Set
<io::ptJI al" ~'tJI.
po!Iitioo>
mut .... "itI> ."" pi>vo in ils pilot :ond the bot in
IL' ...... i"l.( hok. Now ",.,.;Idt un thc .....cr.
W,II> .hor CUI >!arin!. it b .unpIe IIYU.". 1" ...... ing 1"'"

1""

MUS<lrt from 1"" pivol

10 lke ne;t' cU\llng
td~ of Ilie bit.

MeUU<e f,om . he pivot

10 .... f;tr cunln;
t<Ig<t of 1'" bll.

3. DriU . hc p h 'oc hule 1" lhc ~or"pk. "ou

aal., .......00 """"""s I pl>vt hok: In 'hc ...'0111. 1, <Ioco;n
Iftd 10 "" ,Ot>

<kct>, oincr "'"

",..I.".-(W...,..,...kx:kuv.. S 1"" <:OnttI kcd diotttlon.I>n,.... I """'plete ";r<:k, tf>Cft:2Sc tbc: cun". <kpth, md
,;ok anothcr bp. t;rq> it tip, md 1""1' gt1 """",

[li''''

b lm'" """" lhan a

drib bi., and bot<' 001)' ... Ind! dcq>
I:tq> thr driII perpcno.licubr 10 ,"" ..........

~ ~ '1Mnd\

1( )'OII ~~ 1'011111\11
Ilie ..~>rI< ~rwJ " t....
.... rime. pn"CC1 1"" ~rfaa: ~.h II MOIt.'U\lcr, )'OII
okfinj'dr (Ion '1 "":"'1 .h~ pl ..... pol'" 'o nlO"~ >5 )"0"
~ Ihor",,,.
What 10 "o, Slido: pic of ""pcnohbk " ..,,,,,01. 1_
'Wdt I'I)'...-ood, for cnmp"'_u n<kr ti,.. wol1<l*.Th" 'II
~ """ wortd>mch ""","J lh Itw. """"fK<'CC. 1'0 Im n
l:Iililr "'" pkcc: 1"'" "'ill hc ~," fn."C. bon<l il '" . lIe 1);K'kup
IIIII <.'afJ>C' 1:11"'. W"h .his d(>n", d''''I) . h" ..'ol1<plo: . mI
;"bod<up ' 0 ,"" worI<bench , po>lIionltl)l Ih<' e b n1VS ...""'"
....,. """,', Inlem..., " 'jlh 1"" I",mmcl ', lra"d .

oi. Clam p the ,,o r"pl.,.,.,.

\IIr<IIIP bok, )'OII nd 10 """",n:

5. S<:t !J,C roUle r In p lace. " ",1 ro"t. Wllh

.,....,ry-

!bing ~ " p,..,1 Ihe roUle r iln Ih.., ...."rI<. and ..~ ..... ,"" pl" ..
kU<> tht: pi,.... h"le.

w".,.

plutlJl"

t .... ~..i .~hinR

n)U'' ',".., Ofl"""'ion In.vl'"" '''' n"""

un .h., rout."., ph'tl)Ilnll Ilie bil In,o ,IM:

wott. and .""lngil111 ,1Ie moch'nc an",nd .1Ie pi,',,,,

FI . coJ.b:1>c 1'OlI'eU :In: a bit n..".., prollIe1n>lk. """ 1""
lII.ty

1""

pffi! 'o ,""""ri"'ent bi, "'Ith Ihe

"",1<,. )'OII h,.."C 10

.,/
A .... rfect ci rc' . il tne e nd r n u'l . Whelhe. vou
...anl a dtsk Of a hOle, Ihe ttammel b;tseplale will seNe
The effec, lViI range of Ihe Jig 15 evldenl: The
gfGOve Is Iht lal~st ITC '(OI> Cin produce, whlle Ihe
disk and hole ,ep,esenl the smaltUI.
'(OI>,

n
_.

/1

-_.

Vacuum Trammel
Rou! dn;le without lu.vlng ;il mark ;U the
pivot polnl. Vacuum pte ssure holds Ihls

.-'"c:
U"
.-~
w
w

.-U

A
t(

l"""""'. pUl" ......,er "" "' ....p" .... .....noI 01

oImply drA"'ing ara and drdc . II """blo )"" 10

V... "uum l'roducU.. ..00 Inlrod ....w

"'Cuum cbmping. (Sec ,h~

OI/thcm.

1""" 'IO.)1lM: ClGImp~ of'-.cullm =n,ntdl

'''''' r .... ".:.:n """" a ...wli>ll p"." [>IOIe "ith a riScht~

)'OU"..,

bttn wor1o:lnll wood and mdlnN

.bou.

wQOO.!w..... ' ng fQt. coupl~ of ~'I'S. }..... -v.: ...",ty .......,n I

OICOI'C of ' ... n,mc:1 odU",. O .. ,he ....., o:nII of thc , ... ",mel
...Jc .. Ih" ~lri p oll<+<nch ply....
,,-;,h I
~
al OI><" cnd ~nd .. 1'Oll..... CI~I .'.pcd 10 IIM.- othcr. 1'he

".>tl

.,..'01

,,,,"\1,,,,1 """",,pl' l<: """,,'n ;nlhc: p",">ou, clup'C1" Os MKnc:......"., in IIM: middk of ,IK ......"'. II hc'Il!irully madtloM!

111 flnL..t.cd COn1mc",lal n"m"",llikc ~icro-F<:n<:e '& cird!'

IiI! /tu'o rq>f'OOn he hi"" "nU.
T1IC ~I
M'" b "nk:1k- fb.""- .. ~.
8""<l "",omd-l""f'OM' ' .... mmd. bul il ', ~"I bn,.usc il
;llIu"", l"'" 'o..,.. dnok wil""'" m2ltl.... 1'1\'01 hol.. al'.. h"", In thC' """"pica (Il ' 1"" .pccIaI bcousc Il occds
"..xuum ",->tem .o ..'011< ""lUI! 'dveruxd.)
n.... crtUc2l dmomI ""'" lII.tIr pj>U. I!". """""'" liIl;
............ sud;! it 10 1ht ..'OII<. YOu fIO'i.ioo II>< pr..:. ~ . pulI
"XU&InI, ,",,,, It 11W111y Jnbo thoo .."011< and """"'1 ici k JIO.
y.,., lw1!. ,"" ,....."md ... Ihc: piYoc. XI tllo: r ........... an<! - . ,

I'"".,metl

Ih< <;Ia. "Ibm )'OIJ "'" d .. ''3oCUIIm,W IN;, ptvur bct;;r in>UnCJy
'CkA-a (,,,"u II .. ".",~ . N<> r...... " u " ... 1<>, 'M'
rnIduc.
I ..-as >j>Uf1"nI'O _~ ,h. fix,,,,,, by f.d F...-ri of Qu:lm}'

'''''''r

"a'

"""

10 ''''' mim

c"'p'~r.

"\'::UUII

Cl:tmpn~: 011

""Ihc:oi "

wcuum P<)/'[. "h~ ....,...,m "'- ""..

lIulrlft 10
'br e<W of ,lte pi_ hc. makinll ,he 'X\jum hoK
oI:>lu<"k I( yuu do '"'"",'''', hoK wlti.., maklnsc cu.)'OI01
1.- ,..,... 1'1_ jn>tamly. and '"CTY """"'t>ly hoId> dIC CII!
.rId lhc ItIo'OtItpctt.Thu. b
wood ... f>I1r.: ....
n""". I fiI!un: lhc... ,,"" c"""llh ~ In ,r.mmd
"""ing. "" why Introduce ."",hcr OII 'hc pn.~CI' of
_in8 thc prottM ~
Se> I an .... up ..;,,, a dcsi!V""'" """ ,"" IIIIln.tI In ,Ilo
ttII'c, of ,'''' pi"'" 1uclf. "I1>r ,....,.. an hr dn;oppnI
from ",,,rhc:uJ (....I'ft'd M from hop """hooI<) .... ,ha
,.,.. """ ..,,,,,'" i,. ""''CI' In ,hc ,,~.
1ItolL'lC
"nd ,xuum cw..plng ,.... conlem ......
13".. ..'OOd"'uldnl( mClI'lo!h. j, K'CIRlI riy)1t 'o """ that tht

",,,,,*,,

doeJn,

<1,,,,,.

II,

\'2CUUnl

"'''''''li:
tnrIlrl"ICl "" n,."" ,,It" C'OfItelltp<>t"'I) m.,MRI>_

onJr bi, of ...,"od In ,hOl

fix'u"" b "-"'IIhIr an Inch sq~ _ ~ in<:M long."I1>r ,..,..
of 1"" ,r.mmd b """.1 .nd 1'1>..<1 1<:. 1lM: onJr sluc used b"
. pp.....nc...,u a co"!ic<,u.:.'ott. ,,,,,

h4<"'1"':h ~uc lIJrmul1t~ 5J>1IicaUy '''' l>OOod (1"''''13'<

kln<b of pWlc.

Nn.,.,t....",", wIth It.... ncq>tlon of CUllilljll~ ,t....

md It.... looU UKd "IT con,,,,,.iQn2I

~ ~pplicd

"""""''<If1tins leduUquo md loob.

Iki:>n:: ~ Ilooo' 10 _~ md ..... tM ''X'UIIIIl
_ 1. I ohoukI empha>ilc WI )'OU nd oomc optti2I
<qOIipm<nl 10 anl~ IIM: ''''''''''''' lh>t l'IOIoJs , '''' pnu "'"'"
10 tIM: ...m. DcWb 0<1 Ihls an:: In ..., ncx. dupl..... ' \'xuum
~' OII ...., 50. Ir )'OU . . . 1 N'~ a l'X\IWIl sysICfll.
......, . nu po\nl In nukilljllhls Ir.trnmd.

Making the Trammel

t'. ironic. 1 Ihlnk. WI ..~ N'~ .his ~ woodlI'OfI<iIIjI/iJ;[un:: hcn;:. md it Iw> alJnoo;[ no ..'00<1 In il Ir. a
,:IOd <:nmpk 01 __ h~niI malrrbls """ IC'dIniqucs
.... bumllljl """" ~. Cl'CP 10 thc: ho/:Jbr wood-

......ur. You
pWclt:

(;IQ ~Iy subN:"UI~

put>

In lhh

r.~IUR:-"""

..'OUd r.... aImooI. aii IM

in bct. )'OU mighl mat"

6(>IJ>Clhing qw.t llandsornc. """" SOl1ltlhinll in .hc lr.dl.1on

o( cighlctfl.h<cnl ury ~ arod nbIJKunakC1'1l.
Bul wouIdn 'l Ibm IX' ironk1 II ,ul"""~l\co;on ruulcr

nM,umcd II'

li h il!lH~'Ch

v.tCUu ....d.mped ' I':I.mmd kn'lnitlr

h:an(Io2ficd uf ~ ..vuds.

1 . Cu i Iht pivot oolbr. Thc: I<cy "'.... pcJftcn, l, thc

ohort p;n:c 0(1'\'( pili<' 11u. ,.,.....". "" Ilie pl .... CQIbr. ~
dr:awings anii CWIilljl UsI "'" lOr 11':I.Il"""" bulii around
I I'Hnch-tD, pili<'. Th IX' 1Ionc>.I. IM Il':I.mmcl stx""n In thc:
.....,."" Iw> a -z.<nch.U). plp" .. 1.. colb.-. ~. nI ......
!iiH: pili<' ~1Iu11f)... do UW Ilie 1afJICr~ .... pili<'.
)'OU mlN ""ItN tht: dimnuIoM of . 11 Ilie JWU.
CuI Ihc: pipe: 10 IcnMth. :and <:kan .1Ie I>um {tom Ilie
cd!Ir:S. ~ il corduIIy wilh c:alill<'''. <kIC'1"II1IninJc booh
tht: _
and 0Ull0id0r dWnctCf1l.

2. CuI thr: pl\'OC . . ,. I nude

tht: lu.Jt ftOlll pM-

Comp. tsslon l[)ring

USI
Material

Qly. Oim e nsions

~\f01 ba$~

h"x S' )( 5'

PI.l.I.i(.

~\f01 plal~

h"x 5" )( 5'

PI.u li,

~uW1!nl b~,

loIo'xl\(,'xS'

~,dwood

p"'l~

:y.' )(lM')(6'

Plull,'

T,"nsillon

(OMtel.,..

H.rdw....
I "C PVC "1",,. 2' dlll. \nominal) x 1!1'

r b.~n b.1rbtd

hO$~ (onn~tlor.

male

2 \h.e~fd InSf'U. \01.'20

1 !)Ia.tlc: kfIQb. wllh W20 x l ' Slud!:
~~6 rrom Reld Tool S... ""ly CI'. (8002530421)

2 cGmpresslon sprin;s. W 1.0. x W Ion;

3 fI.ltlhead wood sc:.tws. '6 x 1"

2 Sltel tOds. !1" dll.. )( 36'
2 Sltel .ods. Sll'IIt dlL as fOII'tr'. tdgt';l,Ilde
rod.
4"

x.""rox,

_ _ .. ...1 ~_. . . .

II

"_.
=
III

r ""'""~ wllh ll Ud

Part

"

V",CUUM TIlAMMEL UPLOOEO VIEW

Cunl

_.

,..,...._.wd.

V" ... um la""

.lu}oIor

li .., , , " " ' _

Vic ... um Tfl,mmtl

4S

noi"' ~ a bur m:ocIe rrom dor po/)-arbona.~ OI"

mlsl" Ix nsicr
ea. tIM: pi>'Ol ba$o:: '() .h<o
~ optdfotd "" .bc Cu.ting u.e. y"" """' 0 bc
.bI<: '0 "'" 'M " .. ,ltrs of .hr ba.... .0 :align il on pi"l1

.0 .,.,....,...

:OC1'}""

al

(IIIIn. markcd (wil h ~f5) OiI a ..vrkpittc.ThIl5, ~

mu Sl "'" ruln m. hc b<bc ;,; ............ hul .b()
tIM:
"'er of.Iit ... ""'" 10 markN. (If)"OU an. ...... p<>IyarI>on~ OI" KI'}I,e. "'ne .hc p""'ccm"C ~ pal""" OiI il
an .......Itt aII 'hc lat""" nuri<> un il. AppI)" ..rip of ~
"1'" '() 'ht plltnolic.:ond mal:~ tIit mari< on Il) Card"ully

"rill. ~ndHll. mct~r hok-.I!rough.hc pllue a.

.m.

-"

.-

1.1

.!!:!
~

.-1.1

,ha. (l1li'"

}. Nou h e circular gro<n'" for the 1""01 ooUar.

u.., .hcTDn,md ~pl .. e on p.ge 39 on. p lulijtC nlU.er

for .hb """... 'ion. lls<: bi. ,ru" m.,do", ' he w:oU .h~
I'\'C p i"" .. ckN:/y "" """,'h'e. 1 u>cd. l.'""h bit.
&1 up.Iit u"n,n",1 ba5<'p1.uc by ,,"unill/o: 'eSl rinjlS ,n ":"'1'

,71.""

.... 'o;riol hcn fitling.!>c: I'\"C pipe In,<> .hem. Whcn )'0.,\..,
tIM: gru<n'C In.hc pl ..... twc.
tIit ""'" dnIkd In Uit
)'OUl" pl."O(. M. kc lhc 8"""'"
nnly III indo dcct>. iUSt ~ 1<> cuch 'hc pipe ..... """'"
... =><nUl. ' " tIM: sptt;aJ gI... """ .... 11 hon<I Ihc pI"" to
"'" pbte

:ocllionnl. JUOd

rit."""

Cftl,,,, ..

'''"''lC

fIO" I:>y m.I.llIInll 'he nte. hol<: (,"" on<:)"OU ~ 1JIItd.

plvor). o.,.ennu", "It .W:: of hok nttdcd
lhc ,~
ron""'-101" j .......111 ,,~ (1 u>cd braM b:..bcd """" ~
,,,,,:lor .... ith 10-1",,1>-11:1 NI'T "",le: th ....... un ;I).an<l driU (U
thc hoIc: .0
l1ICn " 1' .tIC hol<: fOr ,hc ron<ltt1Or
NQ<e "".. i'o',nlolul Pipe Th ..... d (1"1'1) is 51gnlfiCltntlj' <iii'

ro..

'ho' ,,'c

.h....,....

kRn. r""" .h<o N..ion:lI Cootsc

an f.lstcncn,!oO "'"
' M ~ tip. Sa tIM: Stttion ""Cut';ng l 'hn;:ao.b" In tht
.",......
S . Coluc

w ...... IO.M pivot b<aK. 1 apt'rimm.(,j

"'kh se>'ft'>l gIucI ....,."., .....1lin8 on 1kv!."UfI', I'b>tk

"'dder ...1o\ch 1~. :Il W Ioc::ll """"'.,.~.wn: Mlx tht

gJ...,'. , _ consoi"..,,~ and ~ . in
cin:ubr 8/00"0
In ,"" pi>'Ol ~. Set tIM: coIbr InIO pI:o<.'o;. lis<: ........
dtom... er """,.,,1 .0 buiJd up a Iillet of p"" iIfOUfId .hc in>Idr
anei outskk of tIM: culbr. ' o n:inbcc .bc joim
S<:t ."" asscn,bIy asi<k ,,'hilc: ,tIC SI'" cura. No
cb n.pIIjI ii 1I<"CCS.'iaI'}".

1""

6. CUl .he pl~'(){ pla.e. Thii b ,"" pIa.e """ Ou OI'Q"

,he pivot poM. 'yinJ
rou ..... '" ,"" pi"". Il "". b pb>tIt
In my [KOIOI}"pC. thoollt)"O\I rolll<l m>~c il oi pi)"><'oud.

t""

7. Shapc: .hc: p""(){ p la." ..... Y 00. thc

.ha.... oi !br

VACUUM TItAMMEL 'LAN VIEWS

TOPVlEW

StOE VlEW
"lc~um

f
,I

'---.../

hose

rlVOT lASE PLAN

TOF YlEW

,-

''h.

henoli,

m-

,-

_.

EDGE YlEW

i:::;,

n
c

~;;l", """",~e(onneC!O'

:::

--"

GI"e Ilie coli .... 10 Ilie IMs e uslng a special Iwopan

Qlue calltd ()eV<;GII\ Plastic Welder. Pu,lIing a plunger
on Ilie package di,pe.,se, .qual amOunts of Ihe two
(onstl!Uems. whlch muSI be mi.ed. Sp",ad Ihe lho,
ougllly mlxed glue on Ih~ Dollom fdge of Ihe colla'
and In Ihe groove In Ihe base. Thtn press Ilie Iwo
pans IOQelher.

'"

,.-- .---~

PIVOT PLATE PLAN

SECT10N VIEW

J
1

.-

Plasuc knob wllh

14" 20 X '"stulstud
pilI... ,"""'n In Ihc d ....wing P/nJlPlt"" 1'Ia". Thc h=k
in III<: ring illo,,",)'Utl \O fi, Ih~ , .... mmcl on Ihe pivo. h2sc
1JjItr" I\"$ ba... '-:oc""moScl on II><: W()rtp~."'" .101 Il!
_
cnoogh for ,h.... cu"m hQS<: 10 p""" Ihrough.
On I>bck phcnoIic,you ."",., golng ,,, Ix .hl<: 10 """ . nr
bI)wI ~. So .pplj. OIrips of m""'ing "'pc: 10 'h" p~ic
I:ri.>r<" doing Ihc Ia)"'">"t "'"011<."" :o),enutl,... ilI \" 'prll' ~
"""""' q( 1"1""" 10 th. plbtlc "'lth .nhl.. "f'RY :1<.1001, .
DriU IIMnch-dWnetcr ""le >t Ihe 1"1"" pOi,,! IrKlic>lw
in tht Bonom l'reu' of,he 1'1,.,'1'1",,, PI"" d",wlng.
l.1y oul 11",.rc ond 11", ,.~n," . h.:u "",end fro n. ,''''
"'" 10 III<: comcn; of the adlu"'mcm bor. CUI Ih. "fl8Cn~:
tht band",,'" \li i<I~.,1 ror Ihi,. Ihout,h ,,,her '001< ",itI! do

""

compre.:::-l
sp"ng,
...---...
14" 1.0. x ~ . long _

ENOVIEW

Th,eaded lnsen .
~'.20 _________ ~. pllOI hole
for insen

Phenollc pluol plale

",,-

NoI u><: <:;lrJX1 "PC ,,, bon<! Ihc plaI<" In h;u; ~up
"",",p III:.,,, iii)! et\Otlgh '" hc cI. mpcd ..,.. <k>8!Icd '" ,1Ie
.."QIkbr ........(I"i' mor"""'" .n Irvnlc .ppneh . inec ,,c...,
ulklng .1">0"1 ""cuum-el.mpcd jilj.. Ilui Ihc ,""h is.
....:uum d1mp;"lI <Ioc>n1 """' In c'",,,,, .i,,,",lon . nd ,his
II (lOC In ",hleh i, ",,,".,., wort.)
tblJlII. Ihc I...unn",1 lxucpl.>'c, rou, ,1><: .re ....Icr. fkr
)'OU ..... 1Cp='cd Ihe pl.,,, from tll<" ":'"1". tUU con file ....
!>nd tht cdJ!<' lu r. lr .nd '''''Mllh II><: 'I"'nsi';o" {rom.re 'o

BOTTOM VIEW

J. r

... -

114"

I~ ,ad. - . x , .1
vacuum T'3mmel

47

LlI'IJI"III. and to "OI" op the .pf'<"DtIC~ of tiI<' r>bt~'s ~

For ".,....
ti .. plate ~""k
the $0"2.1'.

k'"''

'"

8.

Kout th<: pivot hol<:. U"., tI .. pI""'lI< ..,.,tc' "nt'(!

....,th the tram"",1 haoIrpl:ttc for thls <>!",I\ltiolt "" )'OU dld
..,1 ..... rout~ thc """"" In ti .. pI ... ba$. m2lic tc<t CUt)
In
to adtu.'oI tlle router and tr.unmcl You ...""" a hlrty
tJcht fit 01 t"" poo;I In t"" hok," bit 01 ~rI ... thc:
pbtc turn' on thc:
ISOl't pru/llem. but >Iorl .. lf t""
C plate C2II r~ttk. bit on mc P'l'l , JOU ....,11 noe 11"1 !i;tti5b<:C t"'1' cuts Il>i~
t",mmd. Sa m:d<c >un: thc: t",mmd
._ adllUtmcnt III just rigllt bdo," nukil'l8 thc: CUt in thc: plate,
;:
AtI"" rouIq the hule. ,...par-ne the: pht~ from t""
.. ~""r~p Culthr~lItoIonthrband .."'t>o>
U with ..an """. Ale tlw: c:orncr> oi thls lItoI 10 """"" thcm.
and...- thc
to s,,.~ a.:.n thco
ctiIP ofl"" pl:ttc USinjt fi"" lCUld""pcr OI' .\Cr.t~

"""'1'

1'''''

t""

-.-

t"""""" rro"''''''

~
U

9.

M.ke th ... at/I " s l men' bar. Cm the lurllwood

r uscd ... tu:..,., but ",.nf Qttu:, hlnJ ...vot/S..,irI do
finr.
J.o)' out ""ti tlriU tho: hoks for tt.; tr:an\nld rud<,:0!1 ..,eU
:of for ,tu: k>ddng kn,lI>!o. Opcing for ",unIincso;. I "....u h
1_ rod> 1 boftd '~lnch4Wno:''''' looIcs for lhe'" In 'he
:ulf""n>enI bo, To lod thc
plate In rx-Itlon Ofl
rod, I uscd snt:tll pw.ic krtobs with \o.lndl~. 1
lnchIoIlll14 ..... IUmed Inw Ih"",<kd i .........
I>riU ,"" ~ hok . usins tltc tlrill ~ opttifkd ,." ,""

tn

J",

1"'"

1""

1''''''

i......n. rOl" ""'.om" II><: Insnu.

10. Mounlll.., bar "n Ihc pivot p~llc. O:uup the
palt. ,QfICtlIcr. J.or nu, . drIII oo countenink p11ol5 b' ,Ilo:
1I>"umlnw ""~
Ihr se""" .

Ori,,,

._'fftbI)'

I I . ,.... ak ... 11>0: rod$.",., I~

tu. t .....,
". of rod:!. 0rM: ...... Is ti", 1'"1' of tr~",n..,1 rod:! tiu,
<:>'tcnd (rom thc: ,...,.siliun plate tO thc pi\'Ot plate. 1 uscd ' ..
Inch ~ttl rod> for thJ:o P"'1"'"<': )'OU an ttrulnly """"k....,
>mallcr..... "'cter rodo. The Ib""''1It: UI spedfict ;,(i.incn.
Ion~ . . . Yoo can nukc tiI<'''' JonaI:r or .hore",.... )'OU

dc:sir<'. (Il<<0l ..... thc:'" roWI nn M IIn,e.."''''' from ,II<' tru.

sitlon pbtc "" aoiIy "" tbcy.~ """",'al in,o 1', rou ".

nt:t~ ~ I"'1r of.non rod> to ... pplm>mt 'hc: ~"":""~'

1ltc liCCOO<l "'" of roWI wn.,.,.;u ,hc lrommd '0 '''''

fOtt'''''. lltc """"ln~..1JOfI> 0/ tMx ruuter roWI <kpcnd upoII
thc: """"" . Somc nl:Ichlnc>, sud> .. ti", I'rn>d, Ilj,.chi. arod
R)""" n""~rs."""I"I"l:IflI'NJi><t1Ctc. rodo. Thc \).hanoAn!
~"I<i ... usa ontr onc rod, and i' ~ ~")' hcfty
IkwaJt . :md oth<.... brm<b and modrb .....
rod>, ....
thc: .~ :uwJ nxI WRocter '''"'Y. So UliC )'OU, !OUt ...
guoioX II<''''
T1Ic
rodo shoukln', "" '''', Iong. You'lI jjI<I tbr
minimum [ks In ,II<' OI"""tun: If III<' tnn>itiolt I'tlt~ Cln bo
soulll!lni >pin.. ,Itc l'QUIer ba$, ~:rso . tii<' rod< neo:d onJy bo
Ionll c"""l!h 10 rnclt rrom tII<' t""\SIt1on pb,e tn an Inch ...
"" bcyood tII<' ",.."", ', k..
se ..... or knoI:N.
MI ... sekcli"ll antl cuttin8 tII<' " .......... oi . . . to
1(rISI'h ...... dk 1" cut thn:odJ on nnc cod of ""'" ""'SIn tII<' lt'~n.l1lnn pI:lt~ b 0111)' IfI lnch thk:". l"" neo:d onI)'
tlt""'d ""1nch"'11 ...alon 01 cad> rod.

t_

""'t""

,,,ins

12. Mak", 1.... lr:IHsltiQn pb l~. lltc InIISitkm pbtt

h.. 'o "" c"""""ud t" ,,,... :. ... omodalc
fOtttu n...
1""'" lOr thc .~~",rncl rod5 Cln II<' bId OUl and <lriIIcd ba>c'd
on tiI<' tir.".... 'f'm .ult_ ,..,<U~ l.nJ_t. Dut U.., """'" '"
thc: "",te. rut/< tu..".u be: Wd out frnon)'<lUr """Ier
Afler.II<' """'" ""'T bun Wd out.drtU and '~p II ......

t"""

13. "",""",bie Ihc ,nommeL Thrn Ihc t.. m<t1C1 to<lt

""" ..,."",. n..b Into ti", t .. nsI,1on pllte: !>Iio.k ,tu: t~
rod5 "'tu 1"" :adjU>tmcnt t-. Orop a ;m;o.U rom~
"JIIIIlI " "cr the ~ud oi cad> Ioek mob. and
tbr
",ut/s into thc: iMefU in thc adjuscmcnt bor ('lltc JlUIJI'D'C'
01 'hco >pri<Ip i> ' " prncn'
lod<lnJj I<nobo frum
ribr.o.hng looIoe during ...... ) Tlgllt"" thc:m dooo'n 011 thr
n..b. loctirtfIthd' ~
TUrn tll<""""""" ftnlll.ll inlO Ihc: thc: """""m pOrI In thr
phUl Itasot. "PPII' Ihc: ''XUtln, "'1'<' ' o thc bo""", ...mc.: <J

tiu,,,.,,

t""

traIM,,'

tbc "'''''' r-c,

~..... "'" ...~ 10 """ dn:ksl

TUNSITION PLAT E LAYOUT

FRONTVlEW

SECT!ONVIEW

, - - - - -,. _ - - - - ,

I ~
Lr-

Hoit for ""'t~r ,od:

d,amel~,.nd Ip;lclng
v..... , wllh 1.... 'out~, u,Pd

Hoit for y,-dl .

uammel rod

hote;
h"le

... hh .1'>"13I.p.

l...
J

lo\~"

II

Using the Vacuum Trammel

\'OU am _

lr.lmn",1 with 1Ix~ ..... I~r, bUl dn:k

CUI1I", 15 )Irn<'r.I11y cosicr ""illl ~ pl"nll<' <QIJlc' Vou dnn 'l
haw: LO Ilo md I,..ISI tl>e Ir.. mmcl In kcc:" 'he bil fn:.: oi
111< ..."", as you SI"" Ilie rou,er. Vou ,Io.n II.,~ dlmeul.y
~ thc b;, 10 .10" ,lIceu'. -'nd c h..>nlliJ\jl . hc """ '" oi
<III bm>.tto p2SSC$ I!; nsk. ". ,.,.".". "",,11>1', 111<>. s... 1\1 n:co.mtn<l. plun"" ..... 'e.
th~

h.o.' .

1. l.Ioy OUL thc C;UL Hcc;tLOiC ' he Ir.mmd

<>C"alIy
~e<
_ , 1", dam Iw"d " ..... It... cutrlnjl
_
...... 1:11'<' ~. ~OU nccd lobyoul an.",ot thc
......., CUI. on Ihc pi1vc b;uc. -.nd "';just Ihc t ...unmcl 10
pooirion thc rourc un thc byouI ~nc. ,"ou dan ', tu,,, 'o do
Ik......, ....... jusL tnOU(III of an :uc 10 .... uP u.e, 1r.unmt1
Sa rmrk Ihc cmlcr oIlhc :uc. ""hkiI ,,m "" tlle """"
poiDt. :IlId.s<:ri:><:' brt of Ihc CUl:UC.

fii'''''

\\1th Ihc r.ocuum hoec OII 1"" ~ 'f """""" /i11 .... _
Ihc b;uc """",rtr .11gnnI. pull.hc .-.cu..... ""'" ""'" wil bc

fim,'" n.nI'" pla<~

4. AdJ"';1 Ihe CULt/LIS r,odi ..... oI.djustmcnl oi thc wl

.I"lI r ..... lu, '" ...." ..mpli."""'" by ~jJ\jl .1Ie Iocklnf< klloObo
"n II", .dltIMn,ml har. Thm Ihc ""'I~r c:uI bc """'ni in
"nd ..... , In rduioo tO 1"" piY<lC.
I I""k ,II<.: piruI ploiI: <M:r .hc ha:;c'. pi .. ", ~<>!Llr. Plunl!l"

Ilie bil 'o IlLe

.un.~e

oI lh" worl<picce (wi lll ,t... .....,e<

Looscn Ilie Ioding klloObo .nd
rn<.nC . IM: """(' In .... "'" "-'i ~ 'o allgn It "n Ihc LtkIOltl .'"
donc. tigILlm " '" lockJng knob<, plUJ! In Ih~
...... Ie -.nd you arc rndy 10 cui.
.... ;Iehcd off. of

oou~).

"'.1

2. Set up Ihc: roulc:r. "fu do Ihls . ..,kct ,hr bit lOr

tbt I<>b -.nd IiJlhlrn I in Ihc ...... ,cr"~ eo/ln. Nnl . .... Ihr
pIurw: dcptll. Fin>JIy. <."<lnn' Ilie n>utc. ' 0 thc 1...,..lIKl
, ..... an roughly ""tllM .hc cull~ ndluo.

3.

Set thc pivot "'-:.

Hcc;tLOiC

1"" fIi_ Iloi>x it

""""', il CaR hc pooiIionN xcur"d)' OII a pivot: poinL 0\11

"'" line todo Is ok61K">Ic 1"" poInt ...iTh (.....mir> pmdk:d

<:ou"'"'

""'1

"" "'" ...-ortpit- (.nd 01

thcy ........ "" It
onp:s
lOoxIJ lIlhcr). A1iJll thc Il,." ... cach ltn<1" iii on 2 crossIuir
~.Thc: pi_
wiU hc """"'Iy on thc deoIrcd pI1vc poInI.

;ur"

TO mounl lht Ir~mmtl on Ih, pivot ~s,. hook

tll~ pivol plate a.ound tlle vacuum hc>~,
shown,
and .eule il Onl O Ihe pivot collar.

a,

S. ROlll the arc. S..i,eh "" ,II<.: ..,Ulcr. plunll<"hc hit

about li indo Inoo ""'
f"",-, the """e. eoulll" ..
dod; .......,. If)'OU .'" culling rompl(I(1y IlInlUjlI, III~ WOfk.
plu""" Ihc bil dccpcr a. 'he (nil of lIM: fitSl IIp . and n.. kc
~ IIp. AlwIys rcc.t thc ..,,,,,,, counR..' ..."kJd<w....,

......n:,""'"

To set , Il, p ivOI IMse. scrlbt etOsshlol.s

OI'

tlle

,"01t"1!,,. ma.klngille ~slred Pivot poInt. Un<! up

1"" COrnerl of th-e blose on tlle IInn . s sllown .

.. hoeh ..111 place tllt .~Is of Iht ""'0I coliil dlreclLy
...... Ihe dtllrtd ""'OlllOlnl . Tu.nln g th val", on
ncuum pum" wlll puII tht vacuum . sucklng IlIt
bile 10 Ihe wo.k .

1""

_.

;:;

II

Vacuum Clamping
Clillmps in the Wit)' of )'our routin,,7 Here's how
)'ou Citn U$t ilttmospheric prtssure to dlsplitu
those d;,.,-,~! ciur it path for )'our .oute.

!
DI

.-"

ou -"". II"d in junior Iugh od>o!>I. "'c"",, ', ro,,?

Con", 0<1, :ulmi. 1 In OM nfntrtl. )",,'<1 Imprno
)'OUT fricO<b lor .uddllll ~ <lrinkinJt rup ""'0 )'001"
btt . You 'd bokll. "'." yuw- chin:mtl mou\h.no! Mrl.U
,IK ai. ""'. an<! 11'<1 1"" hang .h.,...,. Oh. nun! O".,., "'"
n:mo:mI:>a """. im~...t .lK-y.1I ,...""',

'O/I<'lh.... II.... ..,..,.".. . . . . d.,... ~hW3Y ro do ils wurt. 1oQ

Ihl- "-"prd . ....;uwn d;omP'nll .. in ''''' >C"!'1c of U>ltlJ! "'rpcI
I.pc:. bu, [, <k~ ', MI""" )'OU ro pry tho: pio:<:a apa" wilh
dili;cl wh.:o 1"" .n: tlont.-. and k .... ,-.:s no tdd<y ""kluc:
Consid<:. ,~ pOS>ibiIi'ict: You....., m.1lu:

WdI . ........ )'OU nil Impltl'> )'J'U' ".w,,"U<Io:injl (rin'Id$

wi.h. ",mibr biI 01 majlk. U... ' .. ,,"'''" p""""'" 10 hoIII.
worI<ptc .'hile )VU ruut 1,

0G, ,\Ir. ",bard," )'>II ',", ",,)ing 1""

!rjd?"

. "

f1<J,,", - " ." " , .

IM

'u hokl ,,"Urtf'k" :" in pbcc on bcnch (on III<

mu'

T~ ... n:

~tI.dl<':!o

be.,..."""

.. 'k""

,h.,

"1'1""'"

'''''0

'o ,......

lud(
'Oftt " '!l1nII
mct:honlcal damps:
fc:>tltonbootrds .nd OIh". hoId.uo,.n. ,ha!
KI,'o almtJo;.t lrI.... n' ly , """,,,,, ubIc: (ar arba'
1"'"

""",,,,,.(Qtrut.~lnll

N... uickcry.l......... plc: 5ekn. l1te "WJd>11Of> prin

dplc Inm"'-nI b It............ ....., ' ~l p"-.... IIe<J In 'he junior
hl,,11 cafete"'. Ilcmo-'1: IM ai. Ix,"'ce" Ihe wurkpi<'
('h.' CUI') :uld , ......vr1<bn>d\ {your flcd . nd Ihe}' ",-111
Mlck 10 nd. OIher k'I.1x oI .M:qI b>ck
.Ioc twO.
and 'hc"y !oI:JI.:I""c In .Ioc ~ conl~'X1, 11". """tly
~
",.cuum C'bmpln".
I..<>ok >1 .ht' moe;C "DJlhtfor>o.-.n.l \'Xullm<Ltmplnll
<kvi. hc VOCuwtl plote TlM: p!:ou" io. ,hle. bwnJ ,,'llh.
hoIc drilk'tl 'Ilro~ IL A '"X'UUdI " ' - b I~ro In,,,
hoIc 1l>m Sf'<.'d.II''''' 1.
around Ilie pn\nlC1cr uf
"'" I>cwtl, forming 'U)' .tulklw n:<:a&. \ '0 0 I:or Ilie .."Ori<.
pic"': on lOJI o( Ih.. pin... romplt'tdl' """nInJI ,"" "-"""""
an<! luminI!, 11 lote' ~ ' "h ~",bcr,' Sud< , .... :tir OUl ull ....
dwnbcr. and 1, bn~,m<'" ,,,,-'1mm dl;omba.,\lbhbnml
'J"M _"OfkpK.oo Ih" 1'1.." wlll "" .. ud< ",..:.ba
l\cC2u;c: )'<'" 00<\', ntl edamps or hooo """""', Of "",.
othct .....,.,.nk,aI d:u"p> 'n k'-'<:p ,IM::
pitt'c$ boo<.InI

5.

pb'~

hott2:ont.:ll o. ,'cnicll) .., l""" eon

tbdoa Of
IVI""',," [nlu Ihe .un.ce:. or l'OlII proIiIc un tho: c<ltIC':

............~out

.,txII . -

wort.'.I~") :

_' ~

P"'UI .".ch.,. 10 , .......'OtI< "itlnll

...iIa, ...........~ <It' Sllcl<y "pc::
. I""'pbto
Id: ftrmly tu ,1><- _pitt<: OI" !hot
hoId ,It(: .."00'1< 'Wtt Il> " Ixnt:h. 1c:J."IIIJIIh<" cdJIc5 IIRID
'I3mmd

,ho, ..

... ""',.....

1'"... , hIod.oo IltaI pidt: "I' .nd hol" ""Ofkp""''' ....,.

yt)Il '''' n:adr Il> kt gu ulll.
Thi, b a pr<11}' into xiollnjl ...rkty of ... cllum .... l>.n'J>I"I
lip,
I "'pc::" 'hol 1"" orgJ,;c ,h"", l''''nlClr. <'\lSlomlling
,I",m 'u rom jub.l'OW" ''''''''. ro- ..."'" hot>l'" ........ do ho,,,,
te, hc ",-"lcctl'''' o"'"" , .... malniab ""' ...... lOr tht: jlto.and
tOtI do h:",: 'u hur......., "I'<"COI cquipmnu ''ou .,.n, n,.kc
, .... dc:vic.. ,1"" prudu<'c:> Ihc: lX'I>Um . .... o::I.mpk'". you hol"
,,, h<>y 1< '"UII n~"'" to bo.,. ' plum~ ' ,o IlfIk ,IM: ....;uum

An"

I"o....,rful ncu um damp. un HCU"

\'OII' work 10 J bl!nch o. I lemplJ,e 'o
Ihe .. orle. Each 1. cUSlomm .
.... Ing
comm o ~ woodwo.klf19 m.1Lle.i.lL.s.

vuuum tapt, Ind

......" '" III<- jlIl. And 10

.,...."C. . Ih"

......,uum prod~

~, }"OI' b:n.., 'O h.." an alt "'''''~ Quilc fnnkly. 1

dori', thlnk }"OI' an ju:stlty ,hc OIJU>y n~ry ro. bo.h lhc:
...,..1Im "t.... ""'....J an ~ir roonp1U."" "1n.:.ty u" l!te t....io
r1iL>dArJI..,..... npmi~'icI unlc.... )"OU ano. ptO. 1Iut Ifyou
aIrndf baYc an oi. romprnso }"" 5houkl Ioot cbocly al
tbo dom"",,, ....... ic,.,. )/](m'n in tII<- ~""'"in, l'iII<'l a n<!
~

".,."..... in"".. I~ in ,II<-

.xuum

)'OU Nn I
nn~ ~ U,

Vacuum Hardware

Ihc 'OICUWII pon. 1b

pn:oo>I

"","""' .n<! con-

,..wd'....

Ih;o, 1'"'"

-'UdtnlIn,o Ilie! )1II"'" rrom ~ Lhc: ....." , toIl1" 'Y"ftLlf

indutIc fib~.. Qohrn...., n>iIy <119' milled""" dnncd.
Alth 1JW\uL.:tun:n orkr =8" oi
'""""um c\:lmptng. Lhc: oxu"m """,uri , ..1"",, Is Llle Uy COOl-

"'"SI""'" ro.

ponem in .11 01 'hcnl A, tc"M one manuf><:turcr.

of Gonconl. ,\ bssactI ......""

Q,,:al,ty \'AKuum

Prod""".

:lIk,,''-' f'J'U ' 0 InoUr up (rum Ilie! Ifw,..,...

VACUUM SYSTEM SCHEMATIC

Tht Qlotn,iaI ~ here b """ ,hal ... W "..,.te -.cu"",

fOII ran lum.", an<! ,,"OI ,,iU. You
.1...,.<It h.., rc:ad
Of hcM\l.hou, dttuic ."aC\IUftI pumpo, ... hil:t1 an:n', <kpco>-

mor

\l<nl on ... alr rom~. ll>c:sc: <kvlca .'"

vacuum fiUing.

rb-"Ic ' M.., rrom )'OIII" daopi>

(80(1.~~ .S48-f>.

pooduc\rtJ cqulp",,,nl.

ro.

~
."C1lttr cb.m('irls "'100 UW1 the 1l'P" o( cbmpiOlJl ~
iQ """<1 "",,-...nIng. Wh:1I )'DU ntt<l fur cbmplOlJl op<1>
2tOII> ", I pnno INI " o,,,,,m ... ,,,,,,,, of cumJlft'SM"d:tir

, ,
Worltpieu

inIo a.-..:uum. And "" , i, \sn' , magic ('hooJ&h i , ....., Ottftl>

..... M ..).
~

criLic2I componcn, b c:dlc<l I

.~wn

"""' uri

ni..., Somc manuf,c,u..., .. nil i , '"acu"m pun,p.

~ 1... called. 11"5 n:ally dIunk of .Iumlnum (u,
pboric) ..iLh liul<: gauJ'Ol' .. ud< <)OI k.1, ~ thn:c [I<><t>l. ' WO

. - tOr W-inch or Jo.lndl NPT ("''''tk>n.I I~p'' l"hrnd)

1In1<ljlS.1n.'kIc it< I ,,...,'uri. ""hl<h Is "",,,,'i;llIy I funnd. "
om'utl ..,.,.,.... up:lt111ow; and In
,I<..
'he al, no.. ..
mtc"d by th" ract IN' ,II<- oi... ;d...,..ttly undcr p","",,"'.
"""" il ". comina frum ",,,,,pn:sso,. h tuShn thruugh ,II<-

,h" "k...,.

AI upply from comp~n or

...,,00 $O r.~ ti ... "" h ..... '" p;l>I ,ht- adja<:n1' '"XUURI
1Q1. M oudts Ilie! a ii" righl <>ul uf Ih" pon. ' hus coeI'i",," '
~ p;LO 'he ,. cuum pon, thc 01. h;,;,;c" ou,
tbo aba"'" pon. ,,'" hl ...... " hc mUr ..."",'ing, by II",

,_.I0.Il'"

......

....,.. and """"' ,-.Cuu", ....1>..,' -""1 noe aU - i""O<JlOr1'"

Tb l:IItc ;0.1\"""'11" of Ihc

,...:ouon cmo1"" 1' (1.., ,-.h..,.

Vacuum Clamp,ng

SI

A vacuu m .... n.u'l va lve 1, Ihe hult

vICuum cl.lmp,fIO} SVSltm s. Tht
al. tnle., Ihl, vahlt Of! ..... leit;

!.

pncN o)','cm,crcdillnll tvu for IM i!licia! <:()M of,he \,,,,"c

~ 1 1Io.-. bf2t iI\ mind ,ttU .. )..... movr oI', yuu mq Aa'd n>(lfr
. 1. comf"'C'UOl" 10 um... lhc ''XU''",
~
The ,..",., mllM I>c _dlnl,u ' hc . 1, corn~. ",.
pOt" tlO\'e rinll .tQ\U1d S 100, )'OU CltI S'" a ..h.., , ... , wW
con'nI dlr 1 OI" 2 <~Ibk r.,.,. per """III" (drn) of.lr no,,
produeed br' ~horscpown c<'mpn:MOr
>'O')' .-hIc
II "",-~,,,m . A. tvu fIitIln> mulHpkd;omp .ppllatlom anei.
new 10 ("'mI' ~ ..... ai;I.b. yuu l>CCd ~cm
........"'lI OII" dm OI" 1T1On'. 1. wcs a t lt. .u 2-hotwI'O"'c,
C'OftI.,...........'O ,...,..nIC an.! S"M.ln Ih>. YDIumc al al. I1ow.
__1 Who, f1;q>pcno it ,c ..am"", ~y..em ndt rnon: . .
1
Ilow .tun .1Ir CtJmI'f"MO' prod~ Yoo <Ion ', )iei ~
gOOd ''''-"\Ium , """nI"lI (1", hoIdins fun:c S mJ ....<cd. 11 lud
lun!lC' (bf a ....."". of 2 OI" j ....:un<lo) .... ...."X\I:It<" ,"" .1.
frum )il.. anei lhe ty>.Icm """ Ina .billl)' 10 t'CR."OmC .lr
It::1ks. lf ,"" rni>m;o.dI bnwo:nl
\".1.., """:aIr rom-

o:
A

0)"""'"

In,,,.

t:i

....,...un,

p""l(>U,oced, )'00 ,,;mplr

'""""m 10 """,;o'e IlIc don,!"
ptr><IOI" ..

on:t)' '101 g<.~

e,1OtIgII

Jigmolking Basies
.\bJ<ing ,'.u,."umd.mpinll jijl; in",*,'d """'ldwur1<ln/l f2miI.
w- liU $OIId woOO. pl~"""'. arid pb>clc l:aml""'c. ",Id
IOm" acqu.1iRlmca tite acrylic. po/t'Orboo;o.c. and pile!IOJk p l>. .. k::&. !lut W':ltI!IL'f'S m .... "" invulve<J, 100: ''n}1
....... . b>r11C<J h""" ronnecf0f5:and .... Lo'cd tlnll~. """ >pedoi
lape
I)on I ...."". 100 ",,,cII .booJI r"" ..."..mlbr >uppIIc>
you ~ ''hrn JVU buy a
')"'cm . j'QU1l undoubI
nlly 11"1 roUu( \'anIum
nuJl _
.... men. of fi in",
ond. knJ!1h oI ...,u!>k _ . "fl.". j'QU ...., m:o.k. fcw ~K> .
j'QU on buy _
rrom .~ ori!Ji ...1 ,..,.,...,. ~;"Ings
.rMl _
, .... C2I\ prob>bIy lIu)' fur _
rn<IoMf "' I loaJ
11:11'<1"...., or .u... parU SI ...... JUSI ""'Ich IIK >t,,")'OU gol
in tIM: (lrilflnal ru~
Tbt f:&mill>.rs Ind '''''1u;rJn r:anco ....., . - lOr .hc III(
bo.>cs. ThIS II " 'hen: I~ issuc u( pon>Sry C1.lRIQ "1'. 11>
e mtc I ...:reu ....... j'QU ...... t .U UIC .lr ou. ol tI'" VXlMIRI
~-Nmbc . Tu malm.ln Ihc: """"""". JOII ,II) 'W(> thin~ ooc.
~ oi. &om kq'Hng M<.:k lA. 'OO r....,. cuminuc 10 ""'W
it OUl, Tu 1"'"""" oi. rrom .occplng r-i: in ... 1"" \'anIum

"olt......
n.. ....- ...

krrm Ihe \'anIum ch>.mbcr an: pbsrio-acTylic.

I>onar~ . ~ . t>-"ftI

pb>tic bmilu.,,-

" ....mode ..."00<1 pn>ducts Illc I'"lticlebo;ord and mcdo_

dcnsIry fihc:rbo;:oftl (,\101'). In bcr ...~ OIC rroIid ,,"00<1 ~

....-o.

UnprOmplo:<l. JVU m;ry nvt .hl.. k 0(.......,..J .. 1Kirlg P'f'

tlruWly pot\l'IIfi 1 ttJUinl)' <Ion' .. ,"ou i<now. wJld
llut ronskk. wood's
and tllm . .....,11. 11 <IocS nlaU
,..,...., .har It ...'tJUkI bc po ...... ,SO ..1lcn
think 0(. "'OOG

lot"""""'.

".....r

..;.~:;~~~~~;~~~
,"O.>d.you C21\OCC''''''''1,
I/W'I

"nK"Iu,", ... ,xuum

.hc

1'1115 dotsn 'r _

)'OU C21\'t ...., wO)()l/: 1. IUSI _
lRa. M
idnI. y,... 5houId ...,.1 It ... ith ..,...,.,.; cart. 0(.
film ftn~ . ~o:c "",Ibc. polrun:liunc. O< point. <II' CO\'<T k
Mrh pi2>lic IamlrWc. l'I)"NOQ<l ,hould II<: ~. AppIr
PIy and 1W. 1c IIlrdr pIywuod OIC "<11' JIOQd. 'hougIr Iaon
p/ywtlo<III m .... hc: Iftkd orrdWIy_ Ik ~ "'iPlani
>bouIlibinll'-okb In thc: NIIO-Ir).... \lOr p:rnicicl>o;oftl . ....
I ""'~ '"2Iicty,
A final n<MC on thc: "'"'" "",.<"tIaI. For ''X1.Iurn Jig, re-

".1'1

"""",,m

,;oe,."."
"'P"'.'

'"P'"

eh"",bcr. rhc ch:ombcr'& ~ muSl bc n<lfIpotOUS. Thut.1he

bcSl m:"",Nh .u ...., lOr rbIloc p;utS 01. c"''''pinll ~" ,har

S2

Rou. tr

~IC

Se&1 wooden vu uum Ji8 S w i.h .....IIac. polV'

"'fl~ne. o' some olher foim flnl.h , TII ... ,uled. JIIIS

miU!_ 01 ",Iid wood and manmade wood p<od"" ...

whlch IlIltnd 10 bt poI'OUS 10 Somt dell'H. wlll bt
Ins likelv 10 luk II . Awtv IW<I Of Ih,u ",,,.. 10 bt
su.e Iht jig 1. suit<!.

foI'

1JaI;c. So6d ..,.,.,.. ~ ~ 0rI<I [(O .. i,h

In ICm.,.......U", o.nd humidily. A ""- boanJ m"Y
OI' wup For thlJ rn>On. you ohouId tI>'(,.. ply"Ood <It

-.1

cap

-..w~

MI)!' 01" ""nlcld>omllU ........ n hasc.

Tho ~ oI'hc ''aCU'"'' .~ :dso p,,"}') a . . . hen:
"'"'" Z01 maint:UnlrlJl vacuum, :.tI..... 11 . 1> con,lnul,. 'o
drawOUl .... lf you' ",h", nI<>O'C> a lot o( >T-lf>d 'h"" ....11,
.... 01 n<U"m-l"'" an ....,.....,11 ... lIh ~ Iu, porou~
..m.b. Th n.. kc txoc ..... 0( . . . .""n .~."'. lho1l1lh. )""
.ut 'u "" ~ :ahout uslnl.l nonpot\IU> ..... 'C .... " in
~ )'OW" ii!!>.

In oddilioft."'" won.pI'" i>. OSII mcmhc'. I, rurm. twl

~tt...1XWfII .......... bcr. n:mcmhcr. Yoo
'o"""
11.1)( ~ It> "'" higlHuI""'" vaii.., It. plus .... hen
.\l1)f :and odln'''''''''m;odc.o """,'.-1;01,
'ro Iorm IIM: 1'W:Ca.s m.t. ",'hen II', WOttp;c It !>ill
0I'Ct Il, bcmmcf 'hor .,..:.. , ... ch:Imbtr. you oull!"" ~n am
oflhc bo:t!<: uslnS'"XUUIIl Ilpc. Tt/It i>. h~sI')' ",IaIiw ~ foam __
"tlppiflg. "' ~h ...hld. )"OU
_"" famlliar. 1)"pi<':IJ1y. '':K'UURI .apt' It !o i.n<:h ,hkk """
~ ind> "iIlt 1. """ jlf'tSMI~.i"" ~,.., (I'S.!.) <iti " " "
... Tho ~II-lhk:" .. pc Ii.hc hol on-.... ",oo """;" tlw.:

doo. "',,"

......u..
01

"OU ....,

A''''''

VACUUfOIl'OlIT AlTEllNATIVES

....

TltA()U(;H PORT

,onnt<;"'.; ~ '':':~_-

",.ndJnJ "[lCOUJ>I1IinI ,,'I,h nlOSl ''3CUUm"''Y'''Cft'~ .

,"M' "'''l' Gnd t ap<" ,lIu ', 14 Inch ,hid:.; ...... c ~I'>
pft"(cr thl> "" IU ""'li" "'urI<, ~"'-"" ~ brioJl!iC5 mi ...... ""'l'"
.,... inqt:ubririo hc:tter. !lut >t...... dnr of""J' thidcr UPC:.
Si"'" ~ nn .Ik,w lal~11li """'..,....,." hc:" ..,.,., IIM: dw'pltIJI
iitt lf>d IIM: ",-"",pIL-rr
t "",ntiOflcd tha' 'xllum "PC 1 imllar ,<> elu:oetkdl
wm ...... 'IIe. "rippi.... Y<>u "" li><" 'hc ..,,:ulte,
pin,. b,,' 1, ;,n', ~. lnilk-n. ~' ....,uum .apc. and II """"1
Ix ,. k'"IIl.u"n~ M'i..,.. " h..,. ~ """'.. m<nt.bcd """'"
......1 Hmc~. " "3)" cru>hC<l anii doon ', ",oound "'hen ,""
I''''SSUIT b ...""",.,.0,1. Sa <:mploy " fOr liml,cd-u$c: '''''''
p!>'''' bu, 001 fOr ~I~"'plns plat.,. aRd OIhc. jlg> '~' .... III
le<" ~ lot 01 IL"".
10 appl)' ,lte "Il<". )'OU .. mpl)' I"-"CI 'bc "'Uf ",pcr ofJ
"'" I'S.!. b:Kkinlt :and ..,.,.,. IIM: '~pc '0 Lhc (K.IkIl) tu",
Oboiou!-ly. rllc "PC m .... con'plr,el)' ~ ,Ix ..-",-""URI
"""'. and .ny IoIn .. bct"ttfl pk"ttS of "'Pc
Ix buncd
ju>I "" 'ilIJI'ly'" p<.>SOoillk. V.... "\1 _ , In i00i<;''11 at 'hc jigs
>hown In .11<' ....,." kw patIO. " .. t I ,ty IU ~n,:I""" Ill<"
..... ~'UUm a ........... i'h" "n!ll<". <'O<I.inuou!i
J tta.,.. ooty
OIM' _il juInl. II iMI ', al,,'"),> pul1lk. o( counc: .~.
)'OUU ..... , ('UrJpk' of , ...""""'" " 'Ix,,, the '0lIl 2J'a la "'''"
IlIIonot:d Im" """"', ...IIIL bmt.. In ,he ",nilion .. rips. A
>tril' 01 'Ix I~pc la ~ioncd III ,..,"'" "" " _1I'Ite; )'OU
'-""- "'" II"le ' o ''''''' rll<" ~m ,,( tll<" ''aCUum,opcn ,Il<" gat"
10 ato:nd it.

"ri.,.

m""

"rip.""

Making a

Self-Tapping Fitting
Iore o ~ .h.ough the face 01 tM t.r. ....

file ~ I\OIC" Icro .. It.. m d, of. brus ha...

fi"",O. liS shown tn It.. pIIoto, and It w,n cUI.n Own
th.eods In ,h. ""tuum 11Oft. It wilt tII"n cui th,,~dl

!n,o li .... ooden base

"'t

ar.U" sah, W 'M nOl{h II tuy 10 mllh.

onc:e Ihe "110<>9 iS IfIstalled. ltavt 1, In jJl.ic. The
notch w,1I cUi ut" lIme YOU lurn IllnlO Ilie hoIe.
RemOlnno lInd ln51IIIo"1/ IIM! fu,,"Il tOO m."y "",.OS
w,11 ~IU~ In" Joon fi, (and" .... cu .. m luk.l.

Sor, a .topped ~ Into thc b.u,. cdge.

So" hoil:' In'o the 1>'1$." Ixe. juli dtcp
el'HlUl/h 10 inltffecl ,he fiffl hOil:'.

''0'"

Sore.1IoIe Ih,ouOh ,1Ie laet 01 Ilie bl,e,

&ore.1IoIe Inlo Ihe tdge. d.illl!'lg Jus, dHP
ellOUgh 'o In,elste' 'M Ihrough hole.
Vileuum Climpl!l!l

53

ti

ii'
S

il

rI!

Iii

I
..

"Iltt: final

""1' ;" 10 plumh Ih" ~ ~ 'loc ' ........"m ,-.h'(

cat! ......,.,.1<: ~ ai.

'-_~.

frun. II'" ''X ....... ch>m""". 1010l, yuu

h...., 10 driU ',,",uum
""le ,11>, ""Imob frum .11<"
.:,,,crio< uf ,loc NI imo ,hal ...Cuum ch>mbcr. Thc: pb<...,.
"",n, oi 'hc: hol< bn', ernk'al. i, 111>1 ,,,._, '" ....-rlIR>o<k .1Ie
ch.:tmber n.,..,., .h.,....,i"" !lp<tng 10 ml'KI. an<! 'hcy :an:
"",,,,'n in ,"" dr' ...m,; llocuum I'tJrl AII~r",lIlt.w.
MI.". I><,ling .h. pori ,han 'l'I"'tpttI, ~ fur tiI<" jijc.)'OU
i....ull 3 6111"S ........ Iy barbcd _
00II""'-1 ..... T"" (>I:Istic
' quldl-diK<)rU'In:t- fluing> tha' ' )'pk'a1I)o OOIItc wi, h ,hc
klt. mUSl "" sai....! InlO III<' port ...i.h a oIlk."OI'"

1'''''.'

'''''''uni

TYPICAl VACUU... SySTE ... FITTlNG5

, ... ullr. f .... abu ll!lCd .hrn<.k'tl brA"" iU>d ")'100 fiulng>, lIot
.~p oi .tIc 3pproptU.C .hl"<'a<l ." cu htnds In 'he
.h~ .. 1""311.he IIUI"ll.
"1"0 nIT)" .Ioe ai, frum ,hc ji!l'O .i", \'"...,uum .... h..,
",mo ." ,he ai, rrom lhe dumhc. ,o "",>le .hc "~~oJ
",,,,,,mhc,). " ... any rubber. 'in)'I. or pl ,lc h"", !bit
cn<>Ujjh 10 ",Jth:;t:tn(l -.c ....... " I.",,u' coli.
.".., ho>c ... pplle<l w;,h .he .)'>otcm 1....," 'I\6.I""h.;",
tlI;unclc . ''''''lnch-<lu,.idc-<lbm<"'C1" clnr .inyl t......
.."O<b pcr1cctly ... 1.10 'he 't"ICk-dlsconncct fiuiflp, U ..
~ . ..;.h .hc _
.IMI n)'lon fiu"OSC" And lhe ......1
..,,"" "on:: h .. y:o.u. uf 11", ,,"me h<>5<' fur luI( .. Iu,

..".u

...,"1''''''1' makcr ""'1'JIIl'*

Plutic T-con ..... lo'

If )"01' ch"""" ,n u>c Ihc qukk.tf&onn"'-1 nlunp,

plug . ",. Ie fill;"II inlO ,tic lis iU>d. fcn"lc Inl" 'hc lDe
'""'" )'UU 1"" III"""''''''''' ~ _
fron. """ ItIt .,'"
nl i, ,O ."",he . \\on.., J\.., found b 111>1 'he _
onw b;afb(d nuUlJl> C".lSiIy,iU>d h ..... bo:' n:nwwe<l frum
ju>I "" ebIIy 1>O)'OU n n ....... hc ............ h "" ........
d~ iItI> whethcr)'OU
,hc .. uid<-dI!iconnl OI'
n.1<ubr Cn.1np.

\1""

PJaSlI~

+ .... ,

V..cuum Testing Routines

conneeto.

In 'hoo<y. perf",,' '"K\IUm OI sa 1e,..,1 will InUl' In

""""'I'he"" pn:uuI"C "" ,hot "",",picc~ of .houI I
pounds po:' "'-!um: Ind! (poi), In re:tliry. t>ow<:\'c,. J'O"
'o fxtor in ",.,~ti.1 f"'roiIilf. 1""
o( nn~

1J3II'-

Math in a Vacuum
""Il lip

'o

,~~aM

hoit.

l,au .... 'Ioed

hos~ ~onneelo,

bUl

n ippl."

m.I., / mal ~

lrau ~owplln"
ma le/ma l.,

11\ usefultO clIlc~la,. Ilie lo"e hoId."lI \'OU.

wo,kpjee., ~SPK"11y when you fi'si SIIM wor1ung
wl, h VllCuum clamp,"9. II w,1l hei, you dt ..... ~
sOme v.cuum ~ .. ~ li .. o,kp'~Ct Un IM
securt(! .. aII a g~n piltt; how sm.lIl" plale you
Cin m.. ke INU .. ,II Silli wor1<; .....1 \'OU h:lve 10 do
'o seCu", p;t,dcl~bo"d .nd NOf ... ",kp,eetJ; lnd

" ""'
" tl>e fOllew,ng fo,mul,,: D,vtde ,1Ie VaCuUm
Use

l,a u 90'
.,Ibo ... , f e ma ll

l,au 90" .,Ibo... ,

mall/ f.,ma l

........1 (,h, I""l>et of ""'reury indlc.Jtt(! ,n Ilie ",,<>gel

by 2. Ind mulllPIy 'M quo,ltnl by tl>e numIM. of
squ.,e Inche. endosed by ,h~ ~uum "I"t.... ., m"k: It Ihe ""ugt ,udl 22 .m;Ms 01
me'eu...,. lInd IM "I"t endeseSln 8 l< O-incI! 1fl!1.
tl>e holdl"", fo<c,', 880 poIInds OII the enU,. wo,kp!Ke_ Tha!". figu,1MI 22 ,2 .. 11, Tl\en 8 l< 10 .. 80,
~80l<tl

I,us Slop coc"

B,.ss nop coc"

(closeei .

(o~n '

.. 880_

The ~uum I.. vel wlll tell \'OU s"'""'h.ng lIboul

lhe POIos'lf of lhe .. o.tplece_ You Cin leslll>e
c!.1mp'ng pille and get li ba.elt~ v;ocuumlevel
,ead'ng Thtn rte:btck lht vaCuum le ..... ' wllen u""11
tlle pilite ..."" d,fferen\ wo,tp,eees. Youlll~e.'"
v.cuum level Vlry hom ..... m.lt".I,o "nOlhe"
lnUme 11'1". lhe hoId'ng foret wlll bt Ihe urne
w,lh li glven
",gud"'u of 1'" m".'''1 be,ng
WOfked. TI'Ia. Iln\ lrue. Ind 11'1111111'" eompu""on

Oc,,'

WI~ II<CMi 1\

1'1,,,.

.... .,., ~ ,.... ,""",",'2].,,,', "m"lrncy. Th" . )'OU11 <loI1hl

lcJo <tId .....itb
IuIr ,h~ ,h<.,<>""I<.-. 1 1'............"'. fiu'

.bou,

....u .iII ......... h;d'~' ... o( 1'''''''''''' f'I" !!qwn: fOOl

.' ""'" idn ... "'" a quiek '''''' QII

..u 1kR-'. "'"""

"""f)' """. jill )'OU

1. a..dr tIK '-.cuum .'2],-.: hy C<Jnnlin~ i, 'u 'Ile """"

~ air line. Thm OII ..... ai<. and "Ol'" , Il~ oc,"k., ~
,~ pon ""Jlh )'OU, ronll""". Th<' PUII<' ""'ul<.l n::uJ
2610 28 _
o( ""'-"""1}' (For ~ 1000 ftt,
In bd. MIbt ...... I iodJ of m=urr.) I f '"c ,,--.<ll"~
iIII~ in 'his .......,. MII,..., [lUmI' "",k<'1i n,,"cri,,~
w adllbl cii<' II..... p.."..un: up tJr
l.CaInt"<t d.r p,. 10 ..... '';11>-.: " 'ilh III<: '~uu "' ... -"'"
DaI. 'Ibm OII ,hc .-ah-.:. ' PIllli",' ,,,,, ,...,tmn, CA"'erll",
iii) """""" p<.>rl "';lh ""'" fi....,.., If ' Il" ,,,,,,eriot 1.
anii lhe pump .... 1000C<.I prot><'rlt". )'"''
!booIId ~ 21 Ind>o . ... mcn:ul}' OI' """e. If t''''
oo.c JDOt k. lhen:: b lc:lbJc: In ,..., ~'),,,m ; Ulh., che
~ Inh M 'hc ~ n.. ,nUI 10 ponm. T.,
~ tIM: ~ \'X'Uum """'1 """",11* .1'1' 10 I.,b,c
_
<'Of1'KI chc probIcm. Otk IIM: roulnp. on<.l n"'ke:
""" ctq an: """,ni
anii ,.,.. pn.>p<'ft)' A['ply .1~
lctInc! nuD< 'o ,IM: b;ubs Of 'hln<b 10 Imp""" C"" '>nI.
... 1!1t but Is I """"" producI. lppIy lI<kIillorW ro.:tts of
trakr 10 le

.bo,..,

1IOIIt.,..,.. """"

<.10,,-".

"'r--

'-.cu"m POl" :dk..... lt'" ' o pu1l tbc alr OUl of ,""

"""nn" ,"" _ 'o,..., pIa''''

cIum"",.

This b a ..'1I0I0.' I<>c ht'Tc.... ,,"'). ,<> ~ ""<>dplc:ces rllt"

mullng open.1un> ,han u>ing 'hoK
p.1<ls. o.,., blj\
ad'';In\>l1l< b chal ,ho: ...'Od. is deva,ed al><:Nc,..., "",,",""""h
by ,"" pb,e 'hit:~ . ... ,..,.. h,,,.., a Huie clan""" tor 1
pik>l """ring ,,-hen doi",~ CU1S. (lM h~y. don '
muC lhn"'llh 'ho: \'X'Uum "'*1)
lbc: cLamp pUle: doQ nrnl "-' ho: anchor-.:<.Iw work
hcndl in ......... "'If ,,,.,..,...... Il 'ron, pw.hlng '''''y rrom
)","., ..... ~.... <.IotI1l.' " o:unpIc You an lu..:h ;, 'o 1 ,,'Q<'\<
""oeh w;lh ~' l. 1, doan', ......, 'u bc: ....... n,ed un 'Il
hori:eonl>I.
." '..."ed on ,1Ie """ o( I ......u..,nch .

!OU'"

ri,,,,,,.

ROUTEJI TAIll. CLAM P PUT I. PLAN

ia

T04' VlEW

Mo"lhk k Krylic. poPyurbonilt .

phenolk pllSlK

Of

II~ '

tA

fi.....,.

il
OI

'"

The Clamp Plate

"""'io;"

Tb< ptinury ohopma<lc .,.,.."mdampl",

b wl .. , I
cal damp plate:. "" I ......... o:u1tT. it 1$ .simply boatd
0/

pbotic pand ..ith .-.cu,,", ..""' ""'1inIn1l 1 '...",,,m

d\amtN:t (Of ~ o( contIfiIed ""'mbc:n) un ono: ><k_A

VKllum poti
Vacllum ,ape ipplled "'olllld pe'lmtltf of t"" plole

EDGE VlEW

8rus fitun.g Ih'uded

1"10 pllO' In pilite

ROUTERTAILE CLAMP PLATE

Cunln,
Pu t

LiS!

OIm,," slons

Qt y.

",,'

~ ' 1(8' xll'"

Hardware.

VilCllllm tape. \6' x \6'. apPf(lx. 42"

a.mp plalU can be made In a.mosl ....... llu . n

thlU ~..mples demonslflle . Ioth the ...... llnl piile
MICI Ilie mtdlym' slnd one are huv,1y pO/yure,hln~
llIIoc 111l plywOOd . Ih~ IJr9tSlIS lWO pleCts of MOf'.
gIuM f.ctIOflct I nd c~'ed ..-llh pluli< IIm,"ate.

-.

,n
IilI

8,au VICllllm fil1;n\!. mile

""'!'Ii(. ~ar_
tltl, /IfIfIIK"'",,,.

QmI 1iM<lQ/i( lIn "II '1lI'''1oIc {II'

Vaellum Cllmplng

SS

MINI.pLATI: PlAN

n,."""
MINI -PLATE

Cuttln. Llst
P,I..I

..."

19-sq An

Diml!"~io"s

<l<"

IIo-"

s-" S"

_0<1

Vold fl'ft . .

Hardware

Yileuum I~PI!. It""

Quk:k~,s.cOl'lnt

vICuum chamw

SECTION VlEW

Qukl< dls(onnKI
filtlng. mile _ _/ "

Joi" ~ppro)(. 42"

fitllng . ..we

"

tonOUVlEW

"

" ' $CI.ln.

v.c:u"," (~t

'O'

~~rly aOsqAn.
wt~~m ehlmbf:r

SlCTlON VIEW
Qllkk-dls.conn1

MIDI-PLATE
_~_~C;:u:::
nln. Llsi
Pilrt

Qty.

::::"'::":':'"'="::":':':1-'o'

nUl"!!. m;l!tc

~"

.onow YIEW

Dlmen ~lo n ~

'O,"

aw" 1'"

)1.""

YoId"'1!I! pI ....... ood

Hardware

ptywood

'

Millf""_

~",

lIKuurn tape, it- x

appro. O'

Quoc:k-dIKOI'In,,1 "I",,!!, ..w. _ _ _ _.I

... L..;;:;;;;;;;;;;;;;;;;.;;;;;:;.;;;;;.
MAlCIPlATE PlAH
TOI' VlEW

VlCVUm tapot

V.c:~"m d\ilmbf:r
01'1 I~ 0II1y

MAXIPLATE
cunln, Llsi
PiI.1

Q1:y.

Dlrnl!n ston s
IIo-" Il'" la"

Hardware
2 pn, plastic

Wn'~le.

111-" 12W

2 PCS, plastIC IIm,Nlf. 12W" laW

VICII","

l.pe,;4- x 1<1-.

apprOK

Qu,ek-dls.conn' filUng. m;lle

1114"
II \4"

,.1..

...

Mille,lill

IOnowVlEW

' ...... di.I.

II'
V.c:wm POtI

"

I---...,--_.J
-VICII"'," \.lpf

'"
S6

1101.019< ~'"

dwioj>ii", pIoIcc ('2tI " " " " ... a VO<:IIum .i"". JlISI .eal r.,..
......,.,.rr,ith Jilkone Clulk"" al, doon ', ",.. k arouod.h<m

In&o tbc .-.cuum cllambcr.

Thc truJ~" o( .h" ..acuum..:Wnp pIlo.", ot <'<I<InC. is
)'OU <2l1 .....IIM \'OC1Ium ~ on both bco 01 lh<:
pbOL Thm. by ""0' al'pon. )OU ('2tI oimullmcously sud<
Iloo woot: ' o """ pIlo.e ond """ pblc 'o."" bo:ndl .
H<w OK pbno anii euUinI! ti5U; for (u." >lltlh.1y dit
....". rumson."" cbmpillJlpbu, ro"" .
Thc ~f9 is . pll.c
",pile"" .lIe moun'IIJI libIc In
1>Ic:. ~I' 'he rom", ou. o( . lIe ....... <1'" table anii
dnJop Ihlt 1'1:1(" 1'''0 h. pl.>cc II wiJl hokl ...mpittc so

.1Ia.

.1Ia.

fOII'' ' ..

,ou OU ,.,... around ,he ~ . """

s.",,,,,,,,,,,

t,.AM.NATIN(; SEQUEHCIE
I Apply la"'I....I~ 10

.1Ia.

flushtrlmmlng bll
'-.J

_o.

ra.:u.

'e

2. Apply laml .... 10 1

Of>pOfllt td9f:s.

lrim

Making a Clamp Plate

~ an:

u..

botlom. ,,"" " ,'" Ihe

I<ImiN.'e n"slt.

p""".. , and daIi<oa.

lOIld il, and perfona .... MI" """,".ions

appty only
"""""..ni or b'cral Jon:a.. It )'OU lift .lIe ",,,ri<plccc. he
plai" will. o( o:oursc. puii up OU' .". .he " .... e abl" .1"hc
,,*(1" u.bIc cbmp pb." is "'" a holtJ.dowlI.
Thc
.hrcc [>1 ,,_ arc 'he """" hu. fur ,hei< fttI
al ",.,eml5. J 1""
'o <kmonso:r,"" U.e r1lIII" '"
... ,ttUb ' lui ~.... n loc uscd . ",<:II ... thc conIJau ... 1om
.... , aR' flO>oIJble. ll>c mlnl-pIlotc anei tI><' ",u ~ pblc h:,,~
tanamt dumbcn (III bolh
whlk ."" midiplJlCC bas
,"KUWtI dl:lmhc, "" onc oI<k only To USC' 11. )'011 O\ll
doR ~ '0 .......... hcn<:h.

na;'

Dnaikd InlOnmtlon OII 'pp/)-~ pIaotic: brru ...., .. <':10

.... fotJnd in 'M dvpI;cr -CoMo.n Roulcr ,...,." lbp- 011
1'<'11<" I~. FoIIow 'M """"fl~ t.u",jmllj,1JI.
as )'O<t
'pp/J' and uim.tIt plulle laml""'''.
Of ~ . 1t)'O<t . ' " ... Ing pWtle lQr Ihc b;,,;.,. )'OU ('2tI
,;.kjp ..... igh. '0 S.cp 3

;It""

.t.. laml .... le 1I0sh.

,1Ie l>asle ...... 10 m:d:illJl a dam[> pIlote of 2"Y oile

lIId :ttry ntI.cri2l.

1. Cu. ti.."

~.

Sckct J'OW" ",.,,,rial. 'lcmembc.

. . pJutia are ""'" bea...., '''cy OK fb. and non
potWl. M........ tle .tt.t good.
IIUI "'1"")' In ,hcl,
po!06iIy an<! ",il! und<,uh,C(ily nced l<, bc o<:llC(i. For
".., oppli"""oo . ,,,lld wood i. okay. 'ooupo It <Jooj ,,,00
LO ",up amIII ",III IIccd 10 bc /ialcd.
Otfl'C"dinjt upun ,hc mlI..crial anii lh<: .sIY'" <II ''aCUUm
p;II'l.tbc plai" """ bc aolhln as lIi. indt bul ~ Mftl.o tic
dIId: .. 'II Inch. AnII .0 hooot lloc helghl <II11oc work
..... tbt wod< surbtt. JUlI .... y ..'aii' .0 .... kc ,lIe ~
_ _ k indt .ltlek. To:K/tk1lc u.~'SC grc>,c, hclghlS.
,... prob>bIy wlll nd 10 ftI",,l.:tmlo'le 1....0 OI' " " " " b)'Cn.
Gh'en d"~ par.lr1."'c .... . <k'e~ how ~ )'OUl' ~
tIiII tIc. :lOd eu. u", t...c (or ~ pIico). GIue-lamina ... 1""
kr<ro It neca.<al1". lhco lrim ,loc edac> 0QU<Ift" '00 noI

,."SII( l.iml.... le

a.., n.,

2. $nil tJ>t base. I()'OU OK """'II pIywood. 110 ""',

....... carduIIy. fIlUIIJI In any 11"1"> tx:t ..ccn plia whlt
lI"OOd pu"y or .sa.lcr.
"""" 000 plywood ""O loc ~al"" salisbaorily ..il h a
iim ftnl>h. !luI don'l Il<'
or hapluurd; gIeI 1"" baoc
dIrouPdr ....'"IlIcd. Slocllac drko qukldy. so )'OU ClO apply
..... .,.. lhrec C'OIU In fairly .oon or<In. ._
poIyurctlw>es
alt 1210 24 Il00 ... 10 dry txno........ ~ La.u paio. dtk:s
foidy qllkSJy .... omy Iea.~ roIon:d
on .."1>I1<pIc<."'"
MDI':onoJ panldmo.nI """" loc CO\-"n\."<l ",ilh pl.stic:
.......-IOp. bOI1O<11 . and cdp. 1"1115 ean loc donc fulcr,
IIbirJIt.lIwI ~ll:ocklnl' or paln""II. 'OO 1. "mure< lhI' ...,
pblr ",II relll.lo Ihl. "otll' fftlJJy .... /s l loc pIloI".

:::;~".'1.

fl" l hI,lmmlng bll

AP9iY l;itml .... le 10 lhe 2

,e"""oi-ng edges. ind
Irlm Ihe lamlolole

n,,"h.

4. ApplV I.ml .... te 10 lhe 101'

,,,,.Iact, and bewHtlm

Ihe 11....1..... e.

"astr

'o

15'25'

bewllri"' .... ,11!1 bit

""tJf.

3. DriU

tJ>t vacuum

dtlII. <II.,.,..,.,.,
)'OU lI.iII

pon." u.1'OUIIh p<ln", cu)".o

"fI&ht"llJlk

port or

T.pon <kmands .lul

'nI" lloc ~ o( II><: t...c 10 lrucct hok drilled

VKuum Clamp,<'>g

57

ot''''''IIh.IM: surb<:e , ........ 'el>.IM: diamaa oI,IM: hok.o

.h~
and Kf'" ol.IM: ftuinfl )"OI ..i11 bc ~.

!'i'"

4. I.,-~Iall ti ... >"X.",m connet)r. '" pIuli< qui<k

~bcorultt"t r,1II"l1" a ro: R. In tbo:: ptOpCf-MttU bok. Ta
...-.r ,1><- c<>mltt"tlon 1><1""11.1><- flt'infI and """ pIa,,,_ano!
' . _ . , 'o 10<>001 .h" nul"l! ' o ,1><- pIa.,,_applr a diKTcl~ amoum oi

Iillcoo<' .,.. ~Il< .0 " '" " nnS' NIt>!; ~ thru;ti"8 k ln'l>
,IM:
pan.
A ,hrc.kd fiulrlll is gOOd """"""-"lOf ' O..,., n pb>Iic
tft ~ ,;in."e ~"u Cln cu, ,10"""'" in ,IM: p!:I:IIi< .mh ...p
"l"Ilotigh }"()U <OIn' <..., 'h......Js in ..."0001 ..."ilh.
~ rnodify ,IM: fiuiOI\S 'hn:ad..o lolion 10 Il ..m cu' Il> .,......
_
thrnds. (Stt -M:dting a kl(1lt pr>!rllI ~1'''''lI' on ~ 5}l 10
I . . ". <05<" hin "",,"nll- of sllk:on., ..... Ltn' un lhc ' hmol!.
"in ooIkIifr ,IM: xal.

'""""m

,.p.,..,.. ......

!!!
t;;

CIt
"'I'
"'p".
ii; ........

5. Oudi".,

d.~

The Vacuum Push 810ck

i,.

11""'lt1' I"n, ""111"1\ ,hl p"",, bIod:.

lT1iI)'
P"'"l""K 111\. ",,,01 ,h.. > ",II .. I I,kc abuut II.
,"ou .,.. " ,~ l' u . p",hcr. p......kkd thr """"J"C'CT .
wi<k cnou~h ' o 1''''''1''''
tO tbc
11".......,fI'l l"
,,"OI'kpc:t,
pk<.-",;
t an:
bu, '"",11cr ,"" .. )"OU w:om 'o """",,U''CI' oround.
,,'1,10 fOII' finll<" .... Su"k ,"", wuri<piea 'o 'bc
fOII CI" wurk aii a n ..."" ,...,
..-i,1I j"()'" h;ond
1l1li' hand.." up aw:o, fron, ,iM: "un " .
lIut ... bcn: h '~ n:aily ....,ful is "IlI mpcd 1" ,'be.
i, ........,., ,.. ......., clarnpi"ll plate.

"""n,,,",.

",,,.,,1"11

""'OJI .

'w" ..,.,
I

<*.

vacu "", chamhcr WI ,h V:>CU"m

On snuU plate , ,..,..'11 "".'" only a .iOglc li"" <>..

um '"f'<'. On ""lI" pI;I.e. fOI' n.. y ch"""" 'o oolli.....
-,""Cnl """...... " ... "" ,IM: pb'e <OI" IM: u>nl ..,;,10 ...Wl.
Int'di..... or Iarttc ..." ,npk<.'C!i. (Stt "'" &>1/(,,,, I'Wu> 01 ,Il<"

.. dn"~ "'<Lrf""It.. "",,,.)

u.., '''''' ....Ie""m t:lpr t>n a ~"mp pl.te.Incc 1, Is clei,int'<I ,1> bc LO!oC'tl f~ ... ntly M:dte sun:.hc sun.c" 1. dCln
"""'" :&ppi}inIIlht upt. ~1:Ik sun: ,b., c:no.b bun tightly
p","I1..., ..m IeU alr

",.... ,...,...,hcr- ""

.-

Usin9 il. Clil.mp Plate

,."., bask

proc~

hu bn:n nutlined "",..,r.'

tlm~.,.

pIa'" 10 ,IM: '"XUUm .)"'cm. "".10 .""

pb'" ori a non.,.,..,.... .....t..a-a WU<t.

C on"",", ,IM:
' iM:

'~ um off. ~

. ......a

U""" oop, i

~.Cft<>p. C\....

Iht

fIu<J<. ' ~

,.'" ......n.pk<..., ., 'Of> oI.bc pIa."

'~um .)":11 ......

:mod puii 'bc Ya<"tlWA. TIM:

,,"Of!< ..iU bc """"..o '0 tbo:: ....... ~e .". 'bc chmp pb,e
tI"n: an: >OmC corn""""""", IlUMldincs
l\tm on Ibc

. ""'" u,,<kroi<k ."aCUum dwrtbtt "'.... bc ~ """'"

p1t1dy I>y 'M ..-ori< surfatt (nlCaRinll; ,"", )"OU "",.,
b .." tIM: plate ",".cnding hcyon<l ' hc bcnctl'<>P c:d/II:)'
.11"
.o~ .~um dwnber ~k.,...;"" m.... bc
compl ~1clt CQ\..,rnll>y ,iM: workple
. y"" h:l,'~ tu " .. I"ul" tbc vacuum t~ )"OUl"

t''''

fQUUnS opt""k!n ," ... ha......."u". II> ,;oon "" ,..,.. pIndI
of!' 'M >-.cuLln, II"" or
olT Ibc '~un, pwnp. lhc

,iim

hoIdI"lI fo ......, "l"'ppe~,." .

~.o)oJ ... ,.., 10 no~'"'.',, 'he Inl<w"ilr.tI 'bc ,~um dwn-11<-",. 1( }"OII plu"lI" 'h"'''l\h ' hc worlo;plea. fur
cnmpk. JIU" ~'1I1""M plu"ll" tlol"OlJllh i. i" to tbc :om
"","'"ring tit" cl~ mp pLt,~. or .hc ,~um v.ill bc
bmoctocd. ano! ,10" lookIinll (u ......, "'III dl.. ppcar.

Il1lh ........ ""pe""""". fO'l1I <.."..,Iop. se",", of ..""t

,..,.. "'" ."" CI" " do. y"" "", ', ape.:, ,,, huIoJ 1a')III:
WU<tp;ecc 'IOi'h nuU pIa'~. for "",,"'pk. ur tu w<r<t '''''
~"'If ..... pk<.'" IM:kl hy I'OU plll,e.

PilI. hl ndl. On yl>lI. W1IriIpMc:. by us!'19 ,IN!

~~cuum pUlh blo<.k . Here rm prolillng ~h faur ed9tS
of ~ small bw,d on 'M fOII,t, ub.e. With ' M vuuum
pUlh bl<>e. , I ~"t (omplel! con, rol of ,IN! wort<. r/e"

10 ,lIe Ultn, of "f,lng 1, ciur of ,"" 1.bltlop. AneI my

h~"d Is ~Iw~ys wtll clu, of Ilie bit.

Making the Push 810ck

I ~ thl.'l pusll bloci< Ilurlj' blJlll'- Tha! '. Il",,>d rur IL' >Ce'
aar:bry 'fl1'Ik:llIoo-ao a , 'isN1dd c:bmp pIa'e_ b Ul I admit
IIoI>it> lhc jill', llIili'f .. a pu>ber. A namJW b:t.;.c_or

....... '"JC'Uum ch:lmooon 'hc """" b:t.sc:- mIW'I 1............,

.. ....rutncss. M}'OU pin apui","'e ..'ilh _"Uum _,
J'OIIllkvl:lop " ><-'11><' 01 how ...wI )"" can mak.. a pw.hcT
. . >titl Io;o,~ C'I1QlQIh l>oIdonI btt 'o do ...<:ful ,,'Ori<,

2, Shapc tlK h and grip . To h<" truthful, I wpe<l

pmtotypc bmdlc b)' bondillJl: .,.per ~, 10 bIod; of
wood " i ru pr:ty :M1l"",I.... and Ihm a..lio(il it on lhc boruJ
..... Tbm r ",n<kd to 'hc p;llIem'. MIIC!I "" an ooeill:ning
SpiooJIc sandcr. And 10;0,-1,. done Ihat. 1 rould confum .tul
thc _
""211 pt\lP<-"r!y JIl<.'d lot rny l>:InoJ and " ... ~........
fonobk 10 grip . Hul . .......
IIY, Ih.. hand!<'
lIhouId l1.c 1:1.11,-"". ... It h II1.c hand ltf'Ip a _
, '", ...... ,h;on a

""''-"'' 11'' ' '

~"

1. CIII Ih e p;aru. For Ihl. litc. 1 u>ul Applc PIr

btalllC 01 I~ fJII'''uoO "~b anod i,s low po<O>ity. It Ius
1.,..' RWr!' ' hIo pI"-"- _ ..... _
.YOII OI" ....ke IM b;ax
01 pb!IiC. and """ a ..-.;>od Io;onoJle, Or t"'''' CIIn rnak ~

........ IiI ol..-.;>od.

<l>ooIIr)"OUl"

_nUl.and

nil Ibc poM$ lu IM 0I;",m..

""'" opcdIit:d br lh<" CUUtng USI_ Radi... II1.c ~ 01 ~

but.ril/X:.- br l't>IIlinl! 'hcm usi"g Ilte 1<-"1"plaIO lIoatIxd
.. m. ciupi ... . ""';"", T..."pblcs 00 pogc 6 or br WId ....
Ihna OII a bd' oandcr,

To makc lOC handle 00 Ihc pusi> hIoo.1: sht",-" In ,IN:

phot..,.
"",Ic:r " '!th.

rnadt:"

''''''[>b'e In lwdboanJ and u>ul JlllUlJIt

'~mpblc

"u. *

ii

_ i4-lnch bI, 'O'ilh I ~.l) htt.hlng

~ bil ",ilh a ~. l). httshlng
_loHnch bi' ,.ith I 1....cf1.<tl). ...... hl~

VACUUM 'USH ILOCK ' LAN

ToPVI(W

'"

l '"

'""

,"

I'l' rad

sa .,.

,.1."

~ua ..

l'orm Ihc h:ond-grip op:ning In .he .cmpb'~ I>y drinill8

soatc ..uning ....,., thnt CIII "", Ih~ ...asI.. ",ith a Ah<"r
.."'. Cut
D<li on
IOJ> corn'". "iru Ih<" ..00 ......
'00, Tbm ~r"", I~ Wpc and ,mOOth ' OC ~ ..i th foles
an<! Wldp;lpn".
li) cui Ihc la.rwJlc M~II". hond Ihe blank 10 a btp:: p;ca
o( ":'"1' ,hau ~ OI' cb"'))C\I 'u III<-" ~_ IJM
carpcllapc for Ihb.and 10 boi,,! Ih<: ' cmpbl r 10 Ilie ....... "
StI up'~ tOIIIc:r ",itb 'hc: hi, and bu>J11n"and lUI,Il " ' " lhc
lwM1lo. l'ry
Icmpblc of( 1"" handIc , Swlleh 10 IM
1"OI.lfId<J<= bit. and r.ldilb ,1Ie cx~ co.!aO oIlhc IYndlc
l'ry it fiom thc scnp. , um It """r, and rodiu> 'hc: ~ on
,lIe othcr >ido. Sand Ilie finl-.haJ hand ....

u...

u..

u..

_ \4.

3, Ils8nnbIe tbc: p us h blocI<. GIuc: 1"" h;andk 10

lOC buc.1>til1 pilot hoIai and oIr;'.., ...,-..--.u sao:w, 'hroU(d1
thc: ........ tnl<> 'hc h:lndk.To prt\"nI' aIr ~apply' U.1k
oIlic'Onc 10..... 10 , .... se""", ~ drMllJllhcm.

4, [)riU Ih .. "ac llum VOn, '"'"'

loc:alN al Ilie end ,,(.1Ie IYndk

"'au barbm ho.~ eonnKlor

IOTTOM VlEW

Olt)

II _

''XII''",

poM III

', hc In lOC ""0)'

VACUUM PUSH ILOCK

Cuttlng Ust

,."----,

Qty.

Oi m l!nsion s
]1,." 1'"

,.

n
i'

lIuidc 10 f"<>lIgh oul Ih ... h.1><'

li) rnokc .hc ,Ctnpbrc. o:nIug<: and .pply Ihe p. nem 10 !!I
,1Ie .cmpl.." ..ock. M )"OU du thlo. ""U Ihc
Id;
h. Incit '" aJlow for Ilie o/fxl t.n..-a:n Ihe lIuidc bush'ng ~
and ,II<-" blt. IliIIRuide bushinJt: combi",,,io,,-' Iha. will)idd
h. Inch 01 o",,", IndlMlr (buI.~ not IimlINlo);
CI

W" 3"" 6

Hand!!

2 dtyW~1I iCf~"'i. _6 IC
Br~n

t.~.

,.."

Applc
Apple

PIV
PIV

li

barbed!>olt eonnector,

Vltcuum

8W

"'htl~ rlil l

m.!~

~., ~ppfO~.

24"

Vltcu um (1l mPlng

59

i
IA

" '!om ,hr """" bIoct b ebmpcd br iu I\;ondlc In 1 ,';,c.

Oncm~ lho< t,Ii2mc:I .... ol lho< pilol h<>k: ntnkd for 'hr /1,.
Ilnf!; !'O.I'U u,;t. anei <!nU thtotagh tM m.c.

--'
r

6. 1rn; .... U Il,,, v,,",,"um oonnec,Or, li )'OU ...... I

pWllc '1uld..tl>COn't! nninll. """ ,'''' male. AppIy I hit
o( 51lioonc i!nkr "> ,"" twboo. arid p<a.s t/M: liuIII!. imo

'hr

~ a hno.s ronn<'CWf. ..hicb Iwo tIvadcd botI)' '0

~ I .urn into tM pon. File notcll

l1:li

113 'o

5 . SeaI ,'''' j\a. lho: ohellac 01'"' ''UT1i!-h .0 l!aJ 'h<:

<:rKitc jia Apply ' ...... OI'" tlU'tt ro,,,... Whilc it'5 guod ' (1 .ry
ro >OJ tM In".... ...rf:ool.hr '-.cu"m pon ,)'ou"""" ..... m
10 dotl 'hr pon

lift

t;;

Wllen .... ng .hc: YlCuum p...her. "",~e 1, tuhi.

,/te ..."Ut1t he(un, bcg1nnlnll ,tu: CU" '""""
.umlllll on !he roti,.".. Aoo lfr"u ..... n ~ffo"'!
u"",. [1<'d:tI..a ... ,cd ,"",""um pump.
ti..,

the ' htcIds ilO ,"" III,

'ing o:an CUI lta ......... 'h~ anei .urn "'" littintt iIlto ,"'"
port. " bot 01 tili<'ont ~ "" tbt Ilundo ",in ,,"""'" I
I!I""'I >ni,
a(nlOiS

7. Ap p ly .h., vacuun ape.

,..,.,.a.

on ,"'" bouom

oi,,,,, l1li.

~ oul ,h", ...cu"m " "'"

Ind .pply VKUum

'"p<' . row>d ,h"

Usio9 the Vacuum Push Block

To ...... ,"" \o"Ku"m I'..,h hk"'k.)...... JQ,,,, 'o .uiuot )'OU,

worI: h. biu 5o",ewJQ, Yuu C'On', ~"" CUt. ~ In tIlC'
_ _ 1'10'1><0 ant/ CQn1plt1" ."" cu' Qac:tIy ,hr W3'f )'OU con witII

... <If'ilinary pu>h >lkII:, 1f)'OU ,ulI"h .1Ie puoher 'o Ihe ..-urlr
ant/ pull ."" ......... um In m<k1.ll. )'OU m:or j(:fk .1Ie ",,,,*
cn()UjI.h 'o botdl tM cu' (dc:P"ndllIS <>ti """ .. ha, fIW>I'IC'
'" cu, )'OU ,..., maldn&), _ w, the aci '" puUing thc
' ....... um ,,-m ~ )'OU from 'he ~ 01 """'ing
,"'" CUI iI')'OU ,..., U$intt
cod: ot pInch damp 'o open

>1""

Thls le ,.emplue fo. I flI.boud bend, 1$ uud

wlth I ,ou.t. Stt up wlth ~ pattern bit. I c!lImp ,ht WOI'k
10 I wOlkbench wlth il el;lmp pll'e. ,hen s\lCk Iht 'em
pilit 10 Ihe work. WI,h IM hou. txtendlng IWIV ,.om
,ne 101' ed9t of Ihe""""'. il. sllown ht .... I cln tOtII
bOII'> s!de con.ours ind ,ht foot C"'OII, ln OIle pau.
60

ROIIter "'iOIc

The Vacuum Template

/fflJp4l1~

":~~:~~::;~::':

<bal _
..II "Iop
/bit .....,..., T1Ic ",'OrI<pM:a' must
~ In ..,."., "7)'. AII ,..., ,cn'pIJlc doft II

A. A

."" cu'

8 , A Irmpk"t! lbal d o"bks 111 1' ,,,"',,.. pilite, Thll;

01 ''''''pbtc is pbcctI 0'.-." ' ....... um po-n. "<~' I
plr:ce Il bld on 1"". The ,-.cuum Ilo pullcd. .ucld"!!1Iro
'c",plo'''' and ,he ..-ori< '0 Il.., I>cnch. Tht:n )'OU
Cu, .... ns a pllOIcd hi' ("";'h "'" piIoo: rkIinII: OrI
,,,n'pl':lIc, 01 """"").
C A "'",/II<I1f lbal dmibla ..... sini M f1wbn;
mut.". 1abIc:. 'hls
II 101 Iitoc ,""

,t""

,,....p!.:o,,,,

fotm. <:XttJIC that

tI ~.......,

oon 0I1wt<k OC

aId in martan-crW,. II arowtd thc bM.

In nch rorm. 'he JIUI"I'O"C ol Ih<: ,cmpb'''' II wha!

<:xpccI_l(I o:nabk""'!O~., dupllc:l.c parltI wIth
:olh", ca... 10 ullr II, )"OU cquip )'OUl" rou,~, ""llh
bu!ohIng. ""hk:h ridc aIong "'" cd(IIC oI'h<- !
the bi' dupLlc'a' .......... ry cun.., .nd con,e . .... It
..'OfItpl<. Or )'OU chuck pilolcd bit of""",,,
1l....... rimm'Oj!; bit . Ot' . pUo.cd proftk Iti!. o,.

A. templa'e thll doublu as e!.mp pll.e mi ....

mln he vlcu"m plplng ilnd Ihui much of ,!te h;asolo..
In ,ht setul' being uH-d ht .... lM ~uum ""1"0 /lis
bn In.erl..:! In _ of ,"" bench\ dog hoit . while
!ht other dog IIoIf:s h.ltve been cove<ed w;. h COm,",,"
packl"O ,~pe. ""lIinO tht vacuum cllmps Iht work 10
the lempl~l~ Ind Iht t.mpll'e 10 the bench. Tht
~s a ... clu . Ind I cln ron. nUlhu lmm'ng bn
complt'ely around Iht perlme'tI wl'houl "oppi"O .

VACUUM TEMPLATI: FORMS

"- lDIPLATE MOUNTS "TOP THE WORKP1ECE Ta

CUIOE THE RO!JTER.

Roul~'

II

tnh"",~ ~a

L TUlPLAH OOU8lES AS A VACUUM ClAMP PLATE.

Ta mpl l ' . rolldn" Dn Ihe ...... ' e . ,"bl . Is

If
yo"I"1It v"euum ellmplng tqulpmenl. Here Iht fdllt
""
Ind fn.d of" bQf..d are be,ng 5hl~ wilh I plllern bit.
Tht Itmpllit Is 1"" bln of Iht slcd Ih"l holds Ihe
..
wOfkp,tct . T"" wo,k Is sel on Ihe lempille, Il\)hl
~
11I"lnSII"" baek.n.d ~nd SlO!>" Ind IM vuuum
..
pullf1d. The sltd an bt mOl/td
lI,ound Ih. bit ,

:J

1."

con.ou.

WOf1tbe",h

(. TIMP1.ATE OOUBLES AS A SUD OR PUSHER.

SI~d

fenee

]
ROUlt. IlibIt

..;m.o/WlI<."""""n1 bt:IrifIg_in)'OUI'
be>rq ride!. oloon$l llK
1Ii<..nplro:.

l"mpblC '~

roulcr'~ roIkI .~

cdgc. Ruidinll 'hc C\I1 in

1t)'OU"'" <Ionc I""'pilile WOA:. )'Ou know Ih,' 'cmpbl"

.-.uma n",~ bc belween Ihe rou":' I .. d Ihe WOA:.
0Ibtr IIaKs. II "'''',. bc Of) Ih .. oppOW'c side 0/ ,"" work
_Ilie n:O\lIcr lhc ronncr J>I"""ailii ,... I>m )'01' "'"' H"lde
. . . . . 01. p;>lI"m bi' . 'hc loII"" ....I>m)'OU ............. "ud
JIbcd bII (lDd,,"'''II nU>h-trimming biu ond p;klle<! p .....
..... Im). IIilIh >'anWJIl cWnpinll "'" ,empb.'c 10 II",
wort.)\III caii Id,.., il boIb "''2)'3'
I <'011'1 li'''' )'O" pbn~ lor p"MCob.. ,,,cuom lem
pIN. lIa! ";1( Id..,
ic>'zn 10 )'OU. obO'kMb'Y
TIItI'C...., coupk o:nmpks >bown In ..,.. . .... hkh ~'o."'''y

:an,. ...

IIK ""11<"1'1' 1IkI. 11>ou&h The CSXDCt" oIlhc joi> i, Ihl.

Mlkill.Jl I neollm I"mplale is :o.Imo6t c:nctly ILke nul.:!n,
damp pll'e, (Sn: "lhc ClanIp PbIC ' OII p;>jtC 55.) Thc
onJr ti,""..,,,,,,, 1> ,hc
<It .tu"" 01 "'" pllle . 'T't...
""O Illai apply 10 m.ki"ll "Ilmp pllio .pplr 1" muln,
vacu"m lempla.".
F<It Ihc lempble. ""'" n<>np<lfOlb .... letW. Pbotlc il
k1n1. Itllf,lHju.l"r pl)-ood ;, gOOd. ,\IDf anii p;>nldc11<... '" 1.., only r.lr .00 mu:<, bc .... ell ...aktl ... lth
n""I"'rou~ IIIm flnl.h.
Th" minimum lhlek...,.. of Ihc lcmpble <kJl"tKI.
upon Ihc ""rface arc" of lhe ''''''I,ble. upon Ih.o 'cmpble
n"'l"ti .. >!lf(nCH, atKI upon ohe tin" oI .... cu .. m po" )'OU
~ ... u.iJI8. \l1th 511" pb1;Ik:. a ...""Ullm..,bc" Icmplale, ln"
'h~ 1"'f1. )'O" can gc:1 by ""I!h ),;.inchlhk:k >!uff In
pl)"""'-"', '1 iAdl il "'" minimum , 100 .. Of '" lnch b
brun. MOlII 6tunp Iu,c b'll<' lil""" .. I.o. of 1:1 lneh. ~
l~ 10 fn Ihcm ;nlo Ihc cdgc of. \,-inch-thk'k ."mpb.e
b ""ti""'"
Mue thc ''XOUm .empblc 11oc ....... ..... y "",'d mao'
lcmplole. 11 "'" an: ""'"" Il \O UK " 'ilh I lJUi<k:
bu>hina. hc mindful 01 o/bcI. ill aii ~ , malle lhc alp:$lIS
'mooth as Pf"I'iI*.Poy IlIcnUon .0 minim .... r:odII of Iruidc
romcn.. AlI IMI I...... pbl .. ~uff.
Ap[>ly Ihc vacuun' tlJI". Thu ;" " 'MI
an on.lillM)'
le",pbl" In,o ~ VICtlt1ln .empb.c. If 1'''' ,,,,"c an)" htoofIh
ho~_ monl... ""1000 .... , h.nJ.tuip "UlOUl ~, Ind IIK ~o" bc
Sun: 10 ..,""mllllhcm w;.h lM l ~pc . l1lhc .e",p"'" 1,1" fii
hel ..,,,,,n llK ..-ori:. an" ,he beneh IOP, .pply Ihe lapc IQ
boIh fKCS..
Ik'n: 'lud hul usdulllp: If , 1\(: ''lI<.'\lum "hombe. i.
,. " lo'J I tp><>d k/c:110 6POt liule: p;>lcha 01 "'pc 1\(:.., 000
lhcl'C' ... "'" illl~ '0 :ICI . . plllan., p""""I1n8 "'" lem
""'le (<It I thin ...mpkce) from 1Joooo,1"lt undcr ''KIlum . ln

a..,.

' 'rAS

Vlcuom Olmpn.g

61

IA

a'..,."., .ln""Ions, hln l<,n,pla.~ (O< ","Orl;pica) an colIIJ'io<' omo Ilie """uum pon. I>=klng ltu: ..
1", ..,
untu.ppy ~ for ,""
!'lan Wad In J>O>Itlonlnll ."" ' -.ocuum pori. If ~ "
Ih"""" porI. )'OU "'".., 10"'''''. WiII,rn: nning Ind """""'"
l>O>e bc: In IM "'"y o( Ilie rQUlW II il Is , right 2rogIc Of
Ti"'" , )'OU tu"", 10 ...., \t"~1 ,"" bir hl, ,"" Onlnjj:l

"'00"""0""" .

. ._ _~

~
al

.-c:

,.:,,,.Ol.

A Vacuum Manifold

Using a Vacuum Template

Wb>t con Ilcll)'UU abou1 "';"lI '"""uum .cn'pl.,o lhal
tu""",'1 ,0lil )'OOl 2ln2dy! No Jlruggllng ",ith <"nk>ao!
bat dam ... ond edmIps. Conna-t lil, "",piu, 10 )'OI'
.~rnt ~Ii...n it an lM "",It, Ind pun ..
Tbcn p:t h",,) wilh )'aU' muie,. It'. , .... 1l1li
simple.

''XlI''"'
''XlI'''''.

pans In fbgnmenl Is I needless fr"str-a"on, j,h

flndin<;l tl>t S"'lIchon-a-(o,d. The """ .. m mfmfold,
mounled ne.1 10 Ihe v""um ""mp OM VOU, work
beneh or !OUlf. lable. Is al wiVS Illere. Use 1\ f
IIIlf-doun I,mes, and )'Du'll Ilnd )'OII.stlf ,nch!MO
ou._"htwt evf" iook,ng-and lumlno' "flve to pul
~feu"m_
Tht nlee III,no .bout Ihe manlfold Is Ihflll's
assembled fron-r stoci< (jwn<;lS 1 bO"<;Ikl It Ilie loc.1
Ilit'dW1Irt "o~ (wh'cll IS IIQ House o' "'~Insl, I sptnl
r<>ughlv $10 fo, a Iwohnt mantfold, .nd I (In upand
li for aboln S 10 pe. line, AIII"-t filllngs ore fOf lIoincll
pipe: III ,re ""dt of bross. Vou Ju~t it"w IlIem
tOO'fll>tr and !tllhten 'tm ""tII '" ",rtnell. Mounl the
""n,lold besidt tllt v.cuum pump. Run I vrnyl host
1.0fI'l lhe pump 10 Ilie 'pprOprlatt birbed connK'Ol',
R"n I!osu Iram Ih, otht' conne-ctots to tlle Pl.",cuLu
1"0

00 yo~ hh il .""Itlo on ,ile limp rll'l~rt? OI OII

' ". larnp co.d, some"'h' .... belwten IIM: Ilmp i,self
Ind Ihe plug? 00 VO~ Ilkt fumbll"'llin IIM: IM,t.
findll'lg Iht co,d, then 'u"",lng yo~r 1l"9f'S'1o!Ig IIM:
tord ~ntlllhltV com, ~pon tht ~""tch?
Vul!, l ltlo:, Ilie S""l~h an Ih. Lamp belltr, 100. II~
II",aV' ,here On Iht I.mp, and know,ng whert Ihe
Ilmp Is. I know wh .... Ihl s"'ttch 's. No "'mblln9_ I
don~ tven
10 look diretllv It Iha! Lamp 10 lind
tht ~wneh and HiCk an the ItghL
The vacuum min,lold is the S<It"'" wly. My
vl'~um manlfold, shown In Ilie dr,... ,ng, gl\lts me
~"erll vac~um circuIt!. f,Kh w,th In on/off ~ ..tv. (or
.tOp cock), I Can ~t il ....n of J!!lS, OM by ane,
becluse the manlfold provlde-s .. setNf1l1e on/off valw
for each j'g.
SUit, p",~h t\..mps on vacuum I~ do lhe "me
.hl"<;I. Su,e lhey',e d"'iP, luI findong Ihem 10 open a
~acuum lin' when)'OU ITI! CorKtm "ng OII kHP!"II

1"..,.

J'Il~

t>f,1ng ~sed
Tht vac'p"mp and mani fold are ~onsLln" In_
sYS1em, whlle Ihe jl<;lS Cln be Chll"'lled os necns.ary_

MANIFOLD AS5EMILY

li~ .........~

CannKIDf - - - - ;

Turn hiftdle
90" 10 open
brlncll.

AddltloNl bfllnelM!s

Cin be Iddtd .s needed.

O"

Hose "om

The Generic Baseplate

hule, Ji9 millli"1I arte" Involves filbricOiling il SUbSllluu! (or
ilie flctory bueplilte. So milki"; il precision plille should be
l'IIII1in~

Here's Ih"

.C
3
.'"
.
li

~.
O

"'"
W

10

"'1'''''''' )'OUT fOtl!~r'.

ID

~ )'OU

...... n. >OI""I"lng 111:11'. dnr .

yo" an ....,
loc wor1< bt-ucr. M~J'hc il'. a b'll<'r b;oscpl>'c )00
n .lIItr, Of """ .... I'h k"'l'. St"~l cdsc '" ritll- aJunll
bct.. ln ...,. C'aX, It ", a bol'q>tl'" ,h'l p"""ide. a runetk>n
.... IK faclory baKpbl~ <ioa "'~
8aKpIa'Q '""' ~ 10 maI<c. 1J1(l fu.- SOlI'" applk::>'ions,
J'IItd"On doon', .... ner. ' \MI b<.: RIOUIIling""" W h<>ID,
,..boft ... CJpmlnR lOr Ihc bII. Auad! II
rxtory~ l('ttWI, and )'OU ..-.: md)'
I'OUl
!lui 106 ..,."., applk:o' loftj. ~ <Ion roti ...
D:lmplel:' ......pl:lt~ ro.. ..., ..,;u, , ..... plalc tUiok<. OI" Ihe
CroIioII>ir IWq>blc lin (>OIjIO 1. ""1>:>1 ...., ,hc clur.lc'lms.1a
It. ~ I>o.scpLltd

'o

"'lh.""

oThc bit ~i ng mu;! "'" p,,:cbc:ty silcU.

I Thc: bh <Jp<"ninl mu.'>t hc concentric ... i,h.1><" bit u"
'!bt ~ptllC " '".. "oeI,k H1IO .lIe ",m~ I""'llk>n "n Lt",
MolIa neh dn", 1. 1. In... Jkd

AChin'in/I tlli> p~ is nor diffl<Ul IIUI )"" "" h ..c

.. t.corpomc ttnaln prtncipks In )"OUr <k>lgn. A"" o(
........ ,.... mllM _"Ori< eamully
lei., matc ....,....,
ith I iii, opc n lnj'l\a.
................., on "'" bit :uIs ...uy l i .... o..c..., tuU' ~
......,., .!It cnft 01 fillillll >Udl1 bo,:.,>IoI" 10 )'OUl" 1'O\IIft".
!W1I bol: abk w"""", ,hc >IUII whcn m;I!<iroa (IIM CUMOftI
*pul(:! In <hb huok. Ik:lr in miod w, .......,. nu IJOC
broo ....,. 10 do M, II .... ,;0 x-conJ;roa 'o ,hc ,001. )'OU h:"..,

h<u<pI:a"" ..

II

'O

II
~
ID

10 wort< "'ilh. )'OUt in'mdoou. anii thc >IIill>. ,""'...., oln:ody

m:iM~n.<L J'U ""plain thc cI>oIce. ,h:lI " 'UI 1'ft>I"1I' thcm.
~h'Cll;u

J"l" ......t; m:tkc ,h" ChokH ,1\;1, ... iU wnrII 1Or)'OU.

Design Keys
'fll;""

I .th"'J7 II", JW ,iJ<,Iul SC"'''~ 10 allmb 100 "M..

v<1'Y ""dy. your A)tl,cr h.~ p;u1 1",..1
.....,,,ring
II><' t.a..cp13lc Th .. woriI ..... llh II", 1>c1"'1' ba.,"'V"" C
bcca...., .1\;11 baK'pb.c hu bllCflr.ll klc:a.inll plllll.hOl Il.

"'n;"'

cu. In,o <hc bat<: 1!>C1t TIu. ~'"

IM ba:.e onJr....,., ..~ ~ 1C1'C"'''
don', pooilion ,"" b>.!oI:pb.e: 'hcy ""'"'Ir k.... p;' rrom
f.lIhlll olt.
.,.. "ilh ~ ~ """'pb'e. 1hc 1l<'fnI'S mU>l
pooiIion 1"" bascpbl" t i weII :as 5U'UIt' " A.......Jhnd
o,. panhcad scn:w. " .1Uo:h hu nu upcr Inct>fJlOf"lnl
InlO i~ hcad Ikstgn. """, ', p<Wo.lon. bascpb,e ~
,cmlr .n<.l :K<:u"",,cly Uflles.> Ihc hoIe In ,1><' bucpb,e
"".ct ly m ches .he K...,.. .I\;InkJ <.I1;&""'ler-.OO
... ",, ', wtlt.A f1,,,h,,,<.1 K"-..... O" 1"" OI' ''''' hand . lus '
'",ad ,"", t:lp"'" In,o III<' .h.nk. !( II", hoIe tor i, ;"
" I"'"-"<I . ",,..,..,w ,,m C<'nlcr J'Klf
1. ""u'a)'" ...., IM ro"'.... 111#/ la kxul" l/xt hli V/"'''' ''II'1
~"'npol"t Tu 00 .h .... . uxh .1", h:uepL11c 'o ,h"
A)tl,CI' "'ilh II><' moun, IAA I<:......... ,hm po1<"k II wi,h
"1I"JO"Ir,g bit. lf Ihc b;uqlb lc tiu founll il> cen~ an
thc A)tl,CI' .ia <hc fb ,i>cJoIkcft-'w mounlinl!:. lhm ' hc
poin, o( IM ,., "';11 m:on: ,""
o( tM bit :am.
""0 holl(r.o'S

~ ..i111l anlo

....-nt",

"

Making a Baseplate

,loci. """'" ....1. S<-rond, )'OU ~ "",n, 'o jI(:I . . . . ,~I

l1OOO Iong k><>k .. r-- """Cf, illl ~ , :ond llk

mountinll .."."... b d~ .un1nJl poIm. Th.11 infllrm> "'"

hod~.. <>1 tl>o: "''l1l''I' ~.!iCI I'''' ...... n ('Qfl. inucc

lhc facIory ba:lCpJ.'c
1l1c- Olooa 'CunlngThn:;ods' ln tlle . ppt-ndix , ....
, .... Infomu.ion an drilling :ond bpf>i"lll>olcs.

:>boul Ihc ",,'~n' o(lhc JOI) A}'OU 0111y ",.klJlll,' b<IlItpbtt,

or"",,)'011 """ ..... "lJI..,..,., ...""" an Ihc ru11l", b;o;cl1brn
)"" .....,.,. lhc n," '~ri> 1 :ond n:al1y ]ICI 00.-... 10 nw.:n,

<Ii".

1. E.... , .... t(: thc: b;I!>Cpl.. tc-moounLing l1C.-c:w". \'00>

m.y wcU no:-t'd 'o ~~ 'hcm. a.cct. 1hc!CttW. "" 'he
""""' , and <ko."-,ru,,., ,,'he,he. OI' noi Ihory ..ia ~ for
"'" new b:L"'p",,~'
_ Arc 'hel' fl>, hcadl
_ A Ihory Iong cnough ' ... ..,., "";,h 'hkkcr

.!! -Arc 'hcy MURI)' cnough'

il
:=1l'O"''''

:al..,...,.

basqIb''''

"unJr.

lf f011' """<1'
h.. Ioog,
tLo'hn<1,.,,,.:.....
0<:1. 1f noe. COfI>kk, , ..... ,op<iont;

OI

"

_ 0nJcr a >CI <>I1onjjo:r "'...,.., for )'OUI' mula from m. il

on,kr ""n<lor, lik~ \\'oodh.1~cn (80().~4~-6657)

OI'

Ea[dc

A........,.(~H~ II ).

_ru" f011' 10"'''' 'o ' M

Iocallunl",... rc .. <>re and

1\1Id

tLoll>ead :lCn".,.,hu fii.

_ UI'I!'* )'OUl'

"",,<1' by

driJbns OUl :ond ,.ppin, Ihc

"'"'" ' O:l<;'apl "''ljl''.d'''''","cr ~

Tho: Iinio 1..'0 opt ...... arc c:lSy. lf}'OU ""....i"" ,1Ie ,hin!
opIion, I..,rc arc muplr <>1 .11"'. l'i~. " '11m }'OU rctlrill,he
~ hoIcs. bon: ali lhc .....,. .hl'UUjlh thc ~ Ibnjjo: Th.11
~,.,., WOfI ' , <lIsro<on ,lut
b011om .... ~

,1.., ..,rcw.

UPfj,ad. y .......... ten banplat. m .... ntl"1il

K,,,wl, 1 ,~pl~eed th,s "",ters 11nV serews tlloe bJ.d
_sI wlth \Hn(he'~. To cIo It, I d.IIINl new hale,
tll""'9h Ihe ro ut~r bau. close bulde Ihe o.j,glnal
mountlnq-screwl\olts. ~n' cut tII.tJds In tht ntW
hale. u.lng tM p.opu tJp.

, ... NHEAO SCAEW VS, FlATHEAO SCREW

1I"'SEl'tAl( I'tlEC'SEL Y "'UCNED

fauory baY'pI;!le wlth

for KreW .... d

(o"n'~,bo.~

SCRrW STAATED

'~nhud K'~W

l1a1e In b.. tpl~!e Is

oIj,ghtlV I..gt. tllJn
Kftw sIIJn".

al-

The

'Cf~W

SNnlt I""elln ,he

an lloe left, lea~in9 J
~p an Ihe rj,ghl. The b;r"epl~tt 1,
off'C:tnte' .
b."'tpl~te

The b;anp!Jtt Is
offnnt~ .

SClEW HALfWAY

The .. nde'slde of Iht ",.tw he~

toucllts '"t b~sepq,e an 'M
left,bll1 lloe,e', ~ Q~P On ,he right.
The b;anpl;!tt Is s1111 o ffcent ~ .

SCIIEW SEA.TEO

AStM leftw i, doiven lunht . tloe

baHpl.te 1, pulled lefl, ckHlng
tIIt ~p on the . Ighl. Tht
ba.. pJa,. " b.... pull.d , ~'o

~
I ~ll

Inuplate 1$
oflcente'.

~lIgnml!n l .

..... ~ 1001 WIJcts_ More InlO......uooOI >boul

.... ond othtr appropNlC nw"'- an bc Iound In tM

...

Sila: ~ .... Nknll a go:nai<- ba!iq'>b.c hn't:. ""', al

"-.-.: ~ do:'u. 00 's ati Improl'nlk'flt "'..., ,!It belory

3-CuIW bbnk. AImooo: >ti)' riPI pIa>I"'. ftO<Q a~

_10" xryIk u. a phmoIk. an !It "In OII ,..,...,. lahk
_ . 1Iti\ a caohIde-tlpped combiflllilon OI" ",,-..," hLolk
~ wilb lui 01 .""'h).1l>e bond ..... ru .. pl.t;.liCf "'cU.
a,<doII) II" rll1rd orr.ith meukuUiII, bb<k" MeI don
. . . . W """"'. I!><m '0 CUI .!It ba"'" bbnk. JUlI OUl lhC a
MOI >lDi3h' bit. guidcd tor TILUn' OI" othtr
_

ti . _

AcryIict ud JIOI!'afbotuo:o; 3ft thft1DopIaoOIb . ... hIm

_ thrJ aR" .......u.~ ta bal. Gmrn", ............ lin.
~ thaa. and lbcy1I ...... up .IUI wwk. I Iu>\:
-.o" !IOd poOkw In .... rq;anJ ... Iht WIic.-- ()ft ...,
. . . . . . dw
01 ...., . , . . kccps il .....,. (In MIdI_l1li< ............ .,.. ckan ehi.,.. ..d . producq "ft"J'

..,.h

-"'-'
4. DrUI W mo..ont.lng
Ihoo tbI: iJ

1>0""'". 1"ht: .ridiol p.on 01

""'inII Ihc I>oIcIIn thc

C<>n'ttt ~.1lIc:_

. . - opproadl b 10 bon<! 'I>r be .,..,. buo:pb.c '" 'ho:

\IIOIIi: ....".,.mlr ""Itll ~ .ape ( ..hkh b >l1dy OII hoth

fidet).Thal )"OU an "'" Ihc """,nlinjj: hoIai In k ~

lIriw JOll do 1R)-1hinll doc..,1m; ti", bit. l'"'" bldd !hal
.-om ~. hIl._ wori< jtbI fiM for drilli,. In ......Ic
tor ilie ~ I>a!q>b.c 10 d>oo:tI4' tht cntn'CI hII .tor
Now tt.cr.. .... . wo .....
oon . . abwt .-Itionlr1l

,,)"OU

,..., f.tocwoy b:;u.qIWc an Ihr bbnIr 'Ii1th ,,,", .,......, dar

bbepblC _ .n:: NkiI1C. JUU Q/l"mply pfunlt ....., ....., b0:I.,..,. p.vt 1II)""'t.rn:: OII 1,,", bbnk. (...,.,".0011,. JUU"I trim thc
CU:'ilom lloM"pbtc W dupIio:"Ile thc

bel.,..,. OM."" thc bit

'-'P<'n .... wla mii "1' ccnll:n::d In 1,,", pbtc

A//gHI.., lIN ~,. f'" .. 1J>aI.. s..pPOK" Ihn't:
lIOtH>IJ ............. try JUlI Il;...e 10 .,.,."e. thc belory ba<cpI:alc
.....,.. paniculo. poInl on Ihe bI.ulk Thc: f."."10" plate """
1 bil opcnil1Jlllul sudtk:nty 0 .... h'-'lll< OO II """ no li11($

'l> Mlp)'OU 11111" H OII" poInl

N_ ",h 1

, ..,. 11Ib..

With ,!It laelory !'bIe on Ihc: ""'"", . nd .. 'CI")' ... ",U

dian ....." b.. In ."" coIIet . .. n::tdl
.ap(" (n'tt .hc bit
oprnl,.. Thm OII Ilie ..... Ier md bon:: a ....... In thc "'pc:. &:
(1"lIh b
I 1>1.... l"OUIef. mon:: prublcrn>tJc "'ll> I VI
~ AMer. In
l;atter Jit-.on, da.mp thc lVUlcr O~
_
III I ~ .... ""-tI thc 1kptI>o(<IIl 1d/uStc:r. NQw

tm>Idr1,

casr ...;...

1""

.unI OrI thc _ I n d """"" thc drpth odfuoter ro makc thc

hok->1lIc: trkt, vi COU1"K. 11110 bon:: I c:bn b;)k ..ithout
I~ thc upc.. You ....,. nd ' 0 IppIr K"O"CfII lIfcnI 01
upc..Qr uor duct upc..
Rcmowc thc pbtc rroa. ,"'" muter Sip' ~ thc
.... 111 thc apt._ n:ntcr thc hok on thc bb.nII:s ttnter",*,1 Thu mar...,. thb h 1m.. IIIc:.:md .o......., dqn::c la
III. lIut
f)'OU 1.rJ iI. ,.,..'I IlnoI l ...ut. ..d!.
11_~11 /JOII'Io<II,., ,.,p.. "1th ........ <."U:MOm I:mc-pbtcs.
)'OU ..~. 10 ,-,""n. thc ..... 'er Iwwllcs I ~Icubr "'ZJ' 1"ht:
orim ...1on oi,,,", Iwodlcs II noi aIw3ys nidcno ..ben ,.,..
Iook ., Iu!ot thc bel.,..,. ba>q">bIc In tho!.c oIIo.atlont.cb<d:
bxII: and lOnh bc ... <UI thc fOUItt. ~ory
bbnk JO tlvt ......... you an:: .. dont . ....., lVUlcr bancID ....
bc orimtcd .1Ie ...,. )'OU ......... han.

""lnk

batcpb'<._

ni( Pl.UNK METHOD

A. U!.e INwpl.o.lt '0 ,tlf<'

proptt dtll! bit fOI" llot

.""

_"'9"10"<1'" hoIeli.

. Sllck U'~I tf,~ to Ilie b.utpC"t

C. UsI"9 tlle bot~plll<l 1l.!I\>Id<!.

d"III11e mounll ... K f n j hoIH
In the bl.ln"-

Ind plu"k II IM."t down OII Ilie

pl.lnk bl.l"k.

~~:::!':~~'i~":':ilk bl."k
1Ii!'"

for

b."pl.,e

0rI11bit
P1ulk blank

faetory
iluck
.0

o With. Hber ww. \fim the

1ItI... 10 wi.hIn 141" oI.1Ie
faclOlV buepl.o.lt..

flll.OIV bU<lpLllIt
uuo;k llilt 60wn
.obtio!o; _ __

lN.~epl~le

'.'<1 down

blank

L Ttim tlot ne'" lN.~pblt

tlush with IM faaoty
p!alt with a 1Iu,1tlri...... ing bit.

=::

"
_

!
"
VI

THE HOLEINTAPE MEllIOO

IQouI

/-tf':::?~Ca,pellape

A. "Pply 2 Of 3 laye..
of maskln!! ,ape

;oC,on 11>1 tJ;J

_nlng an ,he
fu,OfV bnepli.It.
Plungebort I ~
In th~
wI.h I
sma!ld",m"e' bl .

Mnklng tape
(2 o.r 3 laY"")

'"pt!

HoIe boted

'--'''''--''-_wl.h \oi" brl

1/ J bat ...

buupIatd

If

""'''II-'' '"

no paum
!'bn D 11"1 ain worl
)'OU ha,'t

IN, )"OU ."" rontforubk

fIlhC".l>U1 i. 1. prtti>c" md I does ha .., "1'1'"'.~ "" no:ed_
a~1:>k: '"" o( """,n,;"3 tcn:o>"S . .. ..-tU .. a ctnIl"riJII
pin 10 chuck In ,ht ",tller ",~k:t. 000 non buy. ~"""
pin fn>n> 0.1'1" l "oo1s (1IO().~3 1 S~S9). HaJlk" Arnmc:. (8008722S I 1), aod other bit .nll muie, . cCCSO<>'Y >'CA<k>r$. Tht
pin does ha.", <><hor ...... ; Y'''' woo 'l br YI-"'~'~ S~."..1t
on. lOull!i'XJ'llOr onIy one JIfUI.-t<J,,,,,)
CuI tho: bnds 0/1" 'IM: ,,;:..,..... md Ale <li" griod " lIOiIl
......,.", tho: _
"1>. Thtod ,IM: .tIC..,....
,1>< .~
hoIo In II>< fOUK1""S b:o>t. Ylilh aii IIM: poinI. prolfudin,_
fIlI2l
Otud< IIM: ttmcrinJ!: pin in IIM: cnIkI.

"'!O

OI

;-

...

.
3:

II

8. CUI tht [\lSlom r------"".~ D,a~ls

ba.tpll.t blllnk
" d,awn
'0 lO\I!!h .Izt.
on blank
Wilh " peACU Ind
/"
for euuom
"'"ighltdgt.
." "
baStP~lt
d ..... dil!jo... ls
10 """k the
etnltr of Ihe
desl.t<! bl,

"""""'1.

/',< -.""...,
\

openlng.

-"
O

OI C. Apj)Iy p,lIlelles of I""------~"

e_'lipe10 ,
butplate. ind
rtm_1I f.om
,he roule . Align
Ihll>ole In ,he
tape ave. lhe
eemt,ma.k by
tYt. Thtn p,e..
tht biltpl.te
fI.mly tO
,ht bllnk.

Align hole

"."

ctn'e.ma.k
fU. polnts .... hudl'L" sere .... on Ih. d,iII

",en. Ane. eutt lng .1Ie lleads /rom Iongshlnked

u.e

K<t~ of Iht sllme slzl IS

tw.sep"1tmovnl>n~
Krews, ehud' one In IM drill preS>. as shown. Wlth
IN drill press ru!>nlng II I kIw spetd. hoId I fiiI rllt
agaln" Ihe Up. A ctn.ered paint ... iIt qulclr!y develop.
Do Ihe rest of 1"" sut ... s. In .u.n. in Iht Slme woay.

THE I'OKE MEllIOO

A. Cu . ,he hNds f.om e"""
b'lSeplaltmounllng sertWs . file
o. g.lnd polnts On Iht Shllnks .
Uot l ' o. long~r sntw.

11
c. St. Ihe fOUI an .he
euSlom bl.Stplltl b~nk.
P.u. down on .ht .Oult
0 mark ,ht blank .

'1'"","'" ,r""
- Poln!t<!IC.tw
I

shank

c\

FIle Iht C\I' tnd to" poln .

Ctntlr Ilie painl an
,he shank.

D. The pain!> an ,1Ie H.t ... shlnh

and!1ot cen!e.lng pin ...111 dimple
Ilie b .... ~ . TM ma.h lift Iht
cenltrpoin!> OI.M mounlll\!1
".e... hoIu and IM bit Opening.

Bit openln; cente.poI"1

Moun!,ng screw IOCi1Uons

66

Roul " Mag ic

Urle up II.. cm.ni"3 fIIn OII . IK doiplatcd spot OII

dor bImk, and !o(:t .he mul .... IIt'mlr OII .IM: bbn~ n,.,."
,..., .......,. lw\I on ."'" touttr '0 dimpk .IK bhnk wi.h ~II
. . poIMs--tM n.nilljt pin ', poIn. ~> ....,11 '" tv<:ty """'"
oftht 1C1no.... ( A >idc bencfl, ." 'hls approach 15 .ha. you

->

QI[

orIm< tM ""'..... 1"" IM ""'y you " ... n.

bI.ln cunl"" ... "h tllc basorpLlIe,.nd .urn lht: bit. t'Oupk
",vnlu.lon. ",-1.11 your h,,,,d.

o(

7 . Ro", tire hh opcnlng. 111= optlo... for doinfl

.hls ~~""" l() mlnd.

on.1Ie neW

/!Ion IM Itto.mll"g""'" boJk'.. &o<k up ,1Ie ,,'0<1<,

po<.oittI a dc2n ho:o"',:<nd j( J'l<l cl:unp ',
r",,,,
1ht: dunp ;r..11 wr,h . n",her wuod oer.p Sc:1 .hc drIJl'.
lIftd 10 bct",,,..n SOI} .oo , ,(JOU rpm I'ttd lhc bll In.o ,IM:
_\JIIt 5Iow1y .nd .....a..lily W' .. n "wt<11Ijt w,h a ,hcnIlO'
f!b>tk,- lhe bi, ou. oI'1cn.o cInt . hc ehi.,. Uoo ', >lOC>
dor bIIln ."'" ho~; it m:oy ]ICI ..ud:: ."""' ...... t.. tip .....ro
1ht: bInI;,hrough point. _
thc bit e>'C11 ~
Afu:r txwtng lhc huk$,
juot: enough
.... thr mount.i1l8 M:fn" ,,m bC' bdooo 'hc ....&0.. A .undIrd countCTSlnt ...'><b jUSI fi"", In pb>Iic

1h:I,'.

ruut,.,.."'"

I U.., .t", Y-fI"!O"ing bI.

altt2dJ' In thr
plunlJlO'h<>r<' "Il" k.
1 , 00ud: dllk"",. bit in .bc IOUI ...... ond plwwM><><~ a
..,~ hol< lOt
particular ....
3 JI~_ ,tir ..... ~ rrom Ihc """'.... and drill hit

[lI'''''''' 1.

.h;a,

- """

n
c:

...,..,.CQiIW. ,.......

S' Trim Ihc blank tO fiu:, lIow }..... do ,hl5

"pon 'hc final
If.IK b,t"",
plat' to"'''' .... king Oi indccd IIt'neri<:, 1. prob>bly will
*'f!Iit:I'" tM >luI"" o( thc (.e.ot')' ['b'e . If . h~t',.1Ie ""'"',
r.... ,"" factOl')' pI>lC "uek." ,hc new pl.,C Pul. p,"em
lIk 01/. n",lHrim",lng h i, In }'''u' route', Orient 'h. ,....,
)'In. smdwlch >1,
pil'" ....rIng rida on IIK f.K1ory
""'.,."" Ulm Ilie nrw pb.e .
Ifl"" nrw pblC "ill bc """'" oh>pc OIheT ,h2n.bat o(
dor ti(oory ba>cpl>'e" " il}'OU ,...,.,. , uoinj! ."'" bnoty ......
D I P"1""', .ho..... rim t.hc /1CW bucpbte on 'hc o"'" ....
OI'
,,'ith sabr:r _
(Jt' """rt.5n: .Ix ~.
b _ "!""dlk tipi OII C'lllIi"3 'hc m,,,"""1 )'OU """ u:sInjj,

*t>md> 10"""", C<lcn'

:1

....

:'

>h."".

.h.

buIII,..,.. ....

6, toca.o: .ho: bit o pcnl"g. ~; Y1IfOO>'In" bI. In

tIIIr """""'0 coIkt Moun, """ nev.' bo..cpl" "_>l1I1 wI.lIou.
bit opm ..... -on .1Ic rou'er. O<.>o', c,'cn plull .hc "'".."
.. ThilIs . 1u,nd-f><>"....mJ npc.... ion_IlrinA .hc ti p or , lIc

Ali,n'nll". bl.nk "ndIU 1". driU perfecti)' i.

.SStnt~ 1. W"rth li Ctntt,lnQ pin In .1Ie ehuel<, Iow /Ind
lock 'M qulll Ju" li hah" 1"'" of the worltpiue. SilIti
Ilie workpIKt wnlil you' Clnttrm;\r~ II dl,e.:. 1y unde.
IM pln~ polII' , a, !le , CI"mp ,he wo,ltplt<:t to .ne
driU po-ess .,ble . Tlle" unlock tht quill. changt 10 .lIe
app'oprlalt bit. ind d'lllihe hoit ,

A Zero-Clearance
Opening for a Piloted Bit
Bo't 1'" hollln .... 0 Ilepl, for" bo<t .. clurlnct
hole f(Jt'.1Ie p,lo\ bonn, wilh oi !i-,nch bl" Thtn
,wrld! 10 Ihc plloted bIt TIIe ~anng PUltl
Ih.ough 1"" firs. hole. U shoYon, ind IM bit's CII'1lt'19 rdOes uiWld Itle 091"'''9 J"II tnough 10 PUI
'hl'OU9h. It\ a rtro-tleara"u Opt""'9.

~ 5:::,:i,::o~n
Itr~p
I , The mo.Of

UIt

Ix 'Jind and

Iugtf .".. IQh'

~rtd,

In .
Tlle Centtlc hstpllOlt

-li
.
II

67

lIy "","l'd<11I1I. ~;. hcr o( the n .... ' Iwo ""lIon> . )....,

wlll

~1bU'"

.h..;ot

'he bit .,.,.,ni,.. 1,

" c n ,,::~

pcrfc<:tly. If

,.., .. U5C . heV1IfOO"lng bll, Il wlU iii"" )~'" a r~ ir1r b~

diam<:tc. opcninSl.
~n tM ,.."In b pIunJ!c mo<Id. bonng W
il' 61 ... 4I/I1furw;>.nl JUSt se. lho: ""n~ r Ull .11 apcn<bblc
"""p of ..."OOd. anii ruut. Of C'OUI"oOt, you don ', warl' "'" bit
10 "..
IIKlr in ., tM IIo.scpblc, IlO t:oor.. Ilie oprnlng In
If"IC1'nDI: ...... I'Iw'8< .nIi fr.:tl W 'l' 't' fur
then mraeo "'" bit .nd . l\ow Ihc: "'Ori< 10 cool .......,.,...
wil)'. 'n "", "'. . . 'II'lin. E..."n,ualIy "",'U hnoll~.
When tM rouIa IS Iln~ rnodd. "'" wof'k .. a
linl .. RIOJft: "O<I\pli"'II!cd, 1t onIy be,,",uljC tho: _ hine Isn ',
do.lw1.... ro..
plungc CUII.Y"" hol.., 10 el.mp lM

-ci".

.!

."

S
u

1IoubIc-in>""'.

''''Y

II

!:

OI"'' 'n"

f'UU""

Makin9 a Baseplate
for Template Work
Ve ..

-,~
In Ilie

II dam ""ni 10

milk cllstom b ..cplltc th.at'lIlICcom

mod.\t sundard ttmpl.lt ljIuldt buSh'''IIs. To bo<t the
lbM!tel bn OlM'n;ng. use 1"'0 Foutntr bUl
Ta ."sure \1\;111"'" aponlll\ll! cOf>Ctnlfk W'll> Ilie
b.t "'1. mounl lhe bW>k on Ihe !"OUI"."CI IIU. VgfOO'Vl"9 b,. tO JUSt mIrle Ilie Ctntc. of the olM'lIlog .

1114' b.oupla\t r'om I~ _Ier_

Clluck I Unltl1r>g pin In I ~ d"n p'as. ~I tM
b~~pI~lt on Iht uble. Ind paSI",," IlS etnterm.,k
prtc'~1y bo!nutll t~ eenle'in9 pin', POInl. (Lomp IlIt
""<epl..It In pliKt

ch\ICktd In t!lt dnll p'US. Ckmp IlIt

plite <o II cloutl't movt wllUt \'OU
eNnQt blts md

""0--_

'"
. Chlnge Irom tht "nit ring pilI.o. 1\10"
Forslnt. bit. IIo<t I .tcu. ""'" dttp.
LuY<l! , ht pilit cl.imped In pllce.

C. Ch.nge 10. 1\11 ForSl n" bll. 8ool!

complettlv !I>rough l he pLolt. Tht
re"u!lls .. I \II" o~ning .u.toIJndecl

bv Y,'"' wide )( JI\>" -deep rabbet.

,..,.,t """

ttrodcs......cc opcning. Bul chmp Ihe modtinc 0UIdy.

:and IIM: 01'"'" "-'" wlU worI< floc.
I>rim n~ Ilie opmlng on IIM: driU "...,.... IJ ..,
.pproach. It pm:ts.r cc:nlttlng is a pL "'" ccnlcri~ ~
Of smoJl-diantctcr bll 10 llelp you pooIllon IIM: _pilor
"""ur"cly _
IIM: bll. 1I<: fU"" J'OU ~ " mp IIM:...-or1<P<tr
oncc II 1, po:Wlloncd. '!'Mn dullll<' 10 Ilie- bil nttdrd
"","IC thc pn>p<:r.ti>:rd 1Iook. ....... driU,

acuon. drm Ilie counterboni_ It JUni you dan' bare lD

l!>e Way Ihrougll Ilie plalt, bUl do bare dup tnough
IIYltlle busII'ng); nlngoe wI)I!>e flush ""III Of btlow

Ilie "urf.et.
Cornpltit.M hOit w'lh. I "tnch f OfS\M' bot.
Oon't movt """ workP'tCt, 01 count. Just ni"""'" ~
I 1II"ncll bn lrom Ilie cll\>Ck nd nipllu It WIIII IlIt
I "'ineh bn. When dtlU"'g.!te<! IlIt bot III.d for ..
<"ond. tllen ~k II compltte-!y OUl of Ilie wGrlc. FHd
. I n btltllv. llIen b.idt OUl. Repe., IIIIS In-.!Id""'!
Iwan unlll Ihe b'\ completelV pt"'I~IU lhe pllISlk.

A. U... up plalt for borlng Iov ~Jlgn,ng I~

Ctnlt-m\il,k on II unclt, ~ etnterlng p,n

fOr

Chuck I I "~ndl FOfstntt bn ,n 1!It duH prtss.

niplating Iht etm'ung 1)11. W"h an In'ind'OUI fHd

<~n

~tmovt

by 11.0 motO<,:and wodc tIM: ba<c up an<! OO"'n OII

IIM: dcpclHlf..nrl
o f tIM:
W2SI1 't

, ""'''''"' pin
c..nle.lNlrI<

m~d,

Iov v g.OOYing bit

T-Square
~

...st Ihe scralt-board fencl!.

MIoke yauuelf '" squilrl! 10
._ide those CiIIsework dildoes .

T"'I~

15 nuok 01 twO ~ t-cnnI ......hcr 10

fom1 a T. ], ', ~ basic, b:L>ic NUl....
\001.
~e l'oundf""" Bol;"'c mc. )'OUlIjICt 1 o..- 0(11.
And it 1. kind or ....... RlC;lJ lIow casr k bttumo::>
up
lobdo CUI TIle T.qw.", "" ...... "",up .1"", "..,.. iti bIf!
~. y"" <k>n', h.. , ,<, 10 ""'"' It.. fuli knItIh
~. m.n palml.k11lllly Illgn ~nd cbmp I Mr.dWunlp: 1"
Pli: Ilie muIe,. \l:11h T.qUlU'C , !\insle .ido IIW'I< ....aIy
.tIident ,Su k"'3;aS the T.qU1J1: " kn OI ~
II il> aoOa'. )'OU ('On be ...u~ ,h"" ,he: dadu "';U Ix

""""""'IlrIIln8
'o .....

of.""

lq.W't ' "

,hc .,..,

la Jddillon, thc cro>...t ... acI.;aS' br~ , ollowing 1"" 10

........ ,"" ' H>tC:l1 T-6qw.n: "'ilh IliIlJ!k cL:tnlp lf f!JU ....,'"

"IIIi* I fOII,n:ak>ng In un.u.>med hoorcl fcllCC ~

....... *lIk mmp. th., cb.mp "")l,1d becon,., pi....,., With
.. aarot.r but.cd nnnly "lI"ilW
"",""OII' h>ppm.

wurkpiL- ct4F.

"'al

Jo/..ItIOIjI I T<JqIW1O. 01 COlI ...... .. =Uy IOlIgb. (Wink,

__>YOII ha,.,

,o

,'''o .....

si"" arni ~.
;ght-af'I<""'ruc
...... ~.,. -1'00I\:I1><'_vnc p;ctt, c:uktl .ne Cftl:<>Dar
...... hnod.
lpi.... 'hc: . . . , of Ilie "'''",plC<:<'; .nd

"",tf

"'" "'Mr, ca&d ,'''' ~c or ,1>0: guide or Ilie bbdc. a;<o:nds

'". rigII.;uW<: ac..,,;o tIM: "'''ri<pN:<:C~.
TIr
TI"""'--dIi: OUl Ihe dnw!ng- h:o>
~ Mf'O<ftfl 30 and 36 hlChc!; Ioog arni ~ hm<un
II Ind 12 In<+a ...... I'<>r nim)w ","(!r\,;, a $IIUlk1 JIllI<k il
moR: ~ , lf )'OU do lot o{ eobioc1 """"', nWc~ a
n:3D)' b;{I:T~"""',an<! ctA both ca><: skb.1 """ II"",

.,-p;c.I

A lot 01 ~ m>kc IhckT~u:lmllikC copilll

T... ""hlch is 10 uy wilhout C:XICflSio"", My Tii<!"""""
fcnca llul atcnd j 10 6 indici ~d Ihe c",,",,", ta
:IC<*!y thc """,er ... It aib I cut, Thlo 10 p;1nkul.rly "",,'ul
",ith b;g ..... ,en; an<! ,,'ilh lhoo1o: "~Ih otralghl~'d u, <"'CI'oUed Iwq>blcs.
Onc<: ,..... ... into lhc h:tb[I 01 ......11 TI""'" tQr
~ .-.." an<! WOO'ft. )'OU m>y ~ln 10 dmom .boul
,..-akq lheT........, 10 "",kc It C>'CfI
10 \1.'0( TIu, ')
...'ha 1 did. aooJ lhe ~tli an: lndudcd "","" An.! 1 . <Idnl
cbmp _ l i l < t """" UIiN ..... IQUtC, .ubk kocc. No
fl1()ft fuml>lln;jl " i th
d:tmp;.. ,"""'. :aI'Ic, 1Il0l hook.,,;l
an ,xuwn c'""'pU>g. I ....uc .,..""'" T........,.,
tiut kt'. ~;u . .; '11 pWn .,..,111. T.tquan:

tu,..,

c;I.,""'"

""'*

"

TSQUAIU PLANS

TOf'VlEW

'r~~~:';.~

,

______________-,~~______~;;;:::==:J

ll_________ IL-1~Sbl'

EOCEVlEW

Making the

-Square

BASIC T-SQUA.Rf

Cunlng USI
Pout

Qty. Dimensions

Material

fence

/01-)[ 3)',' )[ 30'

Plywood

Cronbio ,

/OI' x 2Y>" x

9 ~'

Hardwood

Hardw.are

'o ""',

Whl'" II h cuier
'ht: """ In Ilie fcncr tNfott
,""",ml>llnl' ,..., T"""""", 11",,,,'. "" rnoon wh ~ )'OU . .'1
n:trotll ebm"" 10 an okJ T-sq .......

Making the Cla mps

2. "",,mble lne r"-IKT and CI"OIjOOr. G...., an<!
elamp IIx' ""'"" logcIllcr. an<! chcd:; 10 bc &un: lhey arc
c;C:In/y ,;q ... "" An oUl-<lf~ ... n:T M 'I a jI& 1('511""1' Whcn
Ih~ 8fuc' <bioti. drill pilot l>oIoN ~nd iim.., 111= o, Ii:lu,
"-~'S el ~ apprupri;olc 1tn{:'J\ 'o I'dnft>ttt ,1Ie g11lt: Joi ....

Adding Clamps
lbcT"'l."""' it cb$sic JIjI. It ha> unIy 'wO jWU, nci,hcr of
,hem """. ~ II tu... slf13Ub' pll'P""" 1..... il (ulmls f,"IIk..-..sIr. lbc 0<1(" ,,~ )'OU can
II i> 10 a<kI ,,"'mfl>

Intp""'"

SQ I did.

lbc elamp hIock ronfil\Lr~ion " bum>".~.,j r""" ,1Ie

optil "net Two an: 1lSC<l, '" you C'a<I ..,.,. One, ' fur.... damp,
b k:>o::l, .... (i;",cdr uodc, Ibc Inlcnn-tion o( 1"" b>tt and
~~ TlIc:<'Ql\ll cbmp"""nln ...... """,nllo 'Ile
""""'- To _lhltT....... "",you ""1 ,'''' ~f'""Iy~I""
'hc ~ 01 ~ _
. and IiIlthIOl ,lIe ft~nI damp. 1"h~n yuu

.w. Ihc """""d eJ.,mp 1n10 f"O"iIkln and 1"""" IL

\I:'Iolk you don ', ncnI muell Stuck tu makc thc ,,1anIp
blo"..... It .;hould hc .hieL II l"Otl OOn' ...., an 11,14 (~
q......".) lIan.lwood iri !'OU' ..:np bin, then j\I~
lIIin"", .cod!. You c:an en'n ..... ~.

1. CuI a ncl .. hapc thc dam p blocks.. TlIc ron'OIC

.00 dimcn>ions o( tbc damp blocI<> an:
In thr
dr'''''ing aa",p 1),'luU. NOtt tIu., ,lIe '''"'' damp blocI<> Olt
oJljlhlly ditr~""nt.
TlIc daJ1\j>S arc ~ ,,, !Onn "ilh 11011<1 ","w _
...
ci<Jn:ary ... nder. ' ''''' an e,,"'1]IC Ilie: paITem , tr.ruSa II 10.
singI~ b<Jard of chc CorrtCI cIIk1<n<:M, Ihcn _
""c rn.
bIocks. Thc l<U>Iltr wtll make quldr ,..an: 01 """""""~ .....
hkn<!i"l!: clIe fdp,
Alterna,I,..,.) Y"" C'a<I ..... "'" cII<' dlmp bIocb " 'I,h I
t:tl)k.mouncct! .. bc1 __ y"" ~= ..,...,. clle:m ouc "" thr
cablc .. w; Ihc <kt:I1b oi <kIInlC Chis ..... n:blnl !ro Ilie: dift<..
tioJm for m:okl"ll thc Split I'entt ""...., H7

"""""n

~nl>h ,;hapinjl chc cbmp """'It> hy .. ndinll ". mi,.

n ......... (bt at Il", jaw '~ tip 1"h('n ..... n<i-o""" lhr

HQUARE WITH CLAMP$

TOPVlEW

,.-- - - - "., -----..,

I "dla.

".
Yo "w,de slOI, centered an Ihe blade

EDCEVIEW

FI~t{I

elamp

2. 0rilI thc holes in lhe b locks. The elamp block

... """",,,,d ta 'h .. T""Iuare with l4-inch "'''';;'11<' balls . ....1i
il! ,bat, thc I>Iocks
~Iy t "' ;~ OI,t oI posi. ion, ",h;"h
...... be P"-~IY :"".o}'ln,,, when you ~n:: t"l'ln", 10 Ori .he
""",.,.. b:h eWlIp hlodt Ihen::fon:: h .. ati .Ugnm..." pin
~fronl t .... tOp. On Ihe Ilxed elamp,' .... pitl isoc"
...,.. p;tnhc2d "'''''' ', This ,.",,,,, prujt....u int(u hol" In t ....
~, ~.,.,plng tI>!: hIock from twbhng, On the mo,,'. l>Ic
cbmp.th< pin is. MOri pictt li[ !4.in~h dc'> ... ci llul pr(Jjc<:U
Ioto lh<~ ,
1b pr<l'i<k .. Hu'" pl~l' for ti", ",alin UnII bolt,,-< ba",
""""h hok (for one bolt) throush cach 1>I".. k. ,,-~ ""'wn in
Iht Ur;n.';"g CJ<m,p De/aii.
DrilI. pilot hole for lhe "1Illnmem ....,,'W In lhe tiu..!
ellmp bIodc. t""n "rh.., p""hcad sen::w im" 11. .. ,hown
In III< oowl,,&- Lc:t"c Ihc he." pI't>lrudlng al"'UI h. iru:h.
0rilI .. pilor hol<' for tlte oJignmm' pin In [.'" m",'Obk

TSQUARE WITH CLAMP5

Cutting Llst

_101"

ruMP DETAll

Qty.

Dimenslon s

Materlill

I~"

Hardwood

IW x

Allgnment pin

)4'

x 3)',"

dia. )( 1)4"

Do ... el

Hilrdwilre
Pi'llhud sere"', <1"8 x l '
1 carrlage boii. "',20)( 3W
1 urrlage bolt. "20)( 4"
1 compressloll sprlng 14 1.0.

le

1" long

2 Hal ... uhers. 14" 1,0.

2 plastic "ing nuts ... llh " ' 20 threaded loserts

PATIERNS

]1
I

I square _ Yo"

~~1.
C:::::::'=w;:
,w===:iIJ

FIXED CLAMP
TSqua~

71

damp bIoel<.ll><:n fii"" ~ ohon pka of do.....,llnlo Il. Ion ..,

Ih" do ....d p"'''''<ling abmn )t Inch .

3. """1'31"1.: the T -<JUllre. n... sloi """ il<' rottlcd ""

II'" "'<net .abk Of .... llh I nliF II\lkk-C<julppcd pon~hk
mut... And}"" """ do It a(,~ tIc T~ i$ """,,,"bkd.
Tho: opccifics of lhc sloi an;: 1f><rot,'1I In 1"" dnMng TSqua ....
lI."ltb

i --,
-

f
>

z:.

"'

at.,.,~

l-1y out Ind drillltlc """"" ......... ' hok n ,tic CI"<"lOObu
tljtrr thcT~ is -.nbkd. T..... pur2I"IIy InstaII tI><: lI~cd
'o llIiIt. ,1><: locuion of 1"" alljtnn>m,~ hoIc In
ItIc cnJMDar. Jus, """" Ihc cbmp tunl aplnst Ihc: ""","""r.
",,<llhe: 6Clt"W hc:ad will de", II", .."UU<l Wh<:rr 1""" nee<!lo
<lrill ,!te I>ok.

dam"

I><~ts

4. M" ont th", c:bmp!l. 1n.'iCrt ,he

In Ilie hoks In
,hc cbmp bloel<5:u1d 5(":11 ,"" /t(->(b ... I,h I"wnmcr bI<:rw
Slip ,"" bol .. IllfUI.Igh "'" TJ ..."'. drop I fbI W2Wt "'..".
lhc oIwtI< of ~. :uId lurn 1"" winII nulS 00'0 IIM: boIts.
Allgn.tIc ......... Ind pin 10 ..... thc: bIoc:b.
Ta pop lhc dompo &cr 01 tIM: ~ , oIIp rompI"Q-.... aptq "'.... "'" _ Id:orc: knlIIw ~ Into thc: TJlI'lI".
n... 5ftriI1I ..iIl puoh thc: bIock _.,.,. f..... 'he:T-fqU:l/C.

Using the T-5quare

Hen'~ ho ... II ",o.k,. Hook the l-<lu~'e oye' Ihe
",o.kpltee 00 that the 1.... of Ihe tind clamp II
"galnSI tbe bollom surfiCl. Uit VO<l' o!fsel ~~
10 POslHon the Sq .... ,t. KHp lhe c.oSSbl' ;lV,UnSI
the ",O<Itpitee~. TIghttn IM fi.ed c~",p.
Sllde tllo! ntO\I3ble dlmp toglu ~'ft!IIM ~k
tdge, tben t'9hten tbe ""ng nut. The ,l'I ..... tt 10
Ioc:kecl In pLMt . eady 10 gude tM 1GU1!',
You un Set llullh-t .. O<Itpoec:e m~SI be su~
patled In,. W""V th.t ptOYldeS "USI lor tl>e clamps.
Ht.rt Ihc ...0 10 dogl/ed 10 the ",o,kbench,

~tlllIl iln illrudyuse mbled Tsq~u... Cin be

Oo<!e an Ihe .outer table. Gulde the "'0' lon9 1
le nee Ihll\ Ihln..." than the squltt\ bllde. Ma.k lIto
cente. 01 the bit on the fence. Iod the ends of the sloi
on 1he ,q ulfe blade. Lo ... e. the wo.k onlO IIt. bit,
Ind .oul untilthe bit marie ~nd Ihe el'ld "'ltk llign.
then tip the ... ork up off the bll. Tike t"'o o. th_
p;ttnts to 'OUIIM !lot.

Vacuum T-5quare
\\K"uum pfCMUn.' is a grc:U ....,.,. 1., hoId I
.........peQ: "" "'"

T~n:

..

n:tu' grooo'C Of <bdo.

C2fI

~ ~"OmmonT~lW"C hak~'.':.~~:~~~:~:1

"","n~ both
....... h an<l 1"" worIcpic
Mi ......., nc.;d> '" "" cWnpnl at bolh

!III

pooIlk>tt. ~,,<l 11"'1 ""O

il<' probknt.>11c ... hen 1""" ""'"

12lnchwl<k worIc~ """Ing on 14-1r>ch..-1dc
heneh. I!>"" ,..ilh the 1'",........ ",illl nt<llfll elamps
'bo>'~}, "'" tu .., ,,,
accaos "' ..... IInlkmotll

!la,..,

.."""'~ ed!Iteo.

NoI >O """h a ......... T~. J""'.., "'". . . . ,

pbtt an<l appIy "'" V3CU ..... Rom )"OUt datkJ.
'XlI""'- """'.., "'" """"'" 10 lhc ...",1 ..,.... an<l
. ., '

1"" YlCUlIm . Obotiou>\y. )"OU nc.-ed a .-:aalum",;"~;";N;'1

Get lhe: .xtlllm <k<o.ib n 'he: dtaplet -,:..:uun< . .
~"",,,,

Milklng Ihe Vilcuum

-5quilr.

,;qu.:o.", ,II"..... In I
""nle<! .. tlle bqtInnlnll 01 Ih .. dt.>ptc . FoIIOw

c:un;:'~"':""'~~""~~~~;~'~:=1

MilW"C. ror Nr
lhc ""'"
w<ntlon.
roItJ.l"rtt pIywootl ro.. lhe:
~ }"OU
""Ol1Idn1 apptr I ftnbIt to IlIr T~"",,, UfIdct nomW
cum>l~ )'OU ough! 'o b! tlu> Jlu>'Ion. ILISI ,., M."2I
JW"f;K'.:s and ~ , 11r la"'.
Whm Ih:1I b donc:. ln".lllhe '"X\Jum 1CCnIlOt"ic>.

72

Roule. MIgIC

VACUUM TSQUARE PLANS

Qukk..!iKonnKI fitllng (miile)

llCTlON VlEW

,------\-- -, .L

30"' - - - - - - - - - -

,.-

".

!IOTTOM VlEW

,.

f-

,W

Fenct " . plywood

,.

Sit

'W

"'""""
('oub""

P$A,.bilektd ..... cuum t.a.poe

flow !pt~utel>ll VilCllum ItlU .Iong
fellCe by ' openlnO' brnk In t.pe.

,,,,,taU

1.
tho: vacuum pon. DrW I huk for thc
Iiaq f"OI.I8hIy ...,""", ihoa'n In IIK <lnwlng.Applr In.,.,...
..0:::.1 beId of iiIIioono:: ~ 10 lhc twb t<l .,.... of thc
lIIIc finUt'- ..... in<cn il In thc hoI<..

VACUUM T"SQUARE

Cunlnll Ust

P,n

Qly. Diml!nsions
\<1" )( 3101")( 30"

fence
2. Apply tho: ' '3C'Hlm tip<:. As )'''U """ >iCc f...... , ....
_ ..... tM YXUUm ......, '" divklc<l into four ctwnbtn..
AfIPI' tho .-xuum IOpe 10 'IK bou om 01 tht kn<'t. Yoo Of!
.... tItt (Of"fta1 can:fully, "" ~"""n in thc dnwinJI.or )'OU
..... I COOIIn ....... run of th~ I~pc . bc:nding 1tf"OlIf>d tlle
<anoon.On)'OU tu.." lhc "nlin: pcrirn<:lcr IOpcd. ldd thc
........ - ' ..... ctoo.un:.wIp" ("'hIch I caJI flow 1PI0" 0fI

"_.

for 06- 10 l t~""h wkk

_ onIy thc fint

lncreun.)'OU opcn """"

wv<l<pM:c~ .

oftlor eh.",bc:tJ 10 Ilie .... CUum.

Using the Vacuum T-Square

~. if)'OU ;o.n: usInSc ''aCUUQI lOr dalllpI.... """

'e

.. lbt ncuum pump roft"""lmlly IoCItlnl ... )'OUl" worIr

.... iIOd """"cd up 10 1"'" aU romprc!6Ot" Snllnl up

"Joqwn:, thcn. 15 nothin3 more !han $WitchlntI <he hoo<:

... -1i8 to anothcr_1ikt ""'iIm .... bIu In)'OU. muIe.

"*

Qomp Ilie wori<pic to thc bo:nch ()"OU can

'" i, .....,.,., 5Ii<Io ..... y f ......
)'IIIL FoIJtlon Ihc Ttuart In n:bOon 10 ttlt byoul li""", for
. . tul (lISillJl an oI'l'>c:t 11"..,.). "uD I ,"I<;UUJJt . ..... )"OU.rt

..aun tu do Ihis. uf~)

l!Odf'o mw.
don~

t~ .t

.uc" , JUJI aboul .nywhe.. ti you

tuvt tO fun 11>11 fi ....ole 10 'l"llhe workplece

posijlooed wht't thtft~ room for '" eOllplt of tlilmp._

tht workplece.
o!:IW\letion 1. lIS
vocuum hose. ;ond
flulble e nougl! 10 bt
dlrected OUl of )'Ou, WIy 11>11 Ilie rouler's palI!.
~"1Im 'lKk, 1111. Ts.qUl,e IlQhl tO
OrICe ij~ ;Netd. the T s.qUl~~ Oftly

th., "

9 ~~" -.....~"'~.....
~"'\

Hardware
4 drywall

SC~WI.

Hi)( 1\<1

vacuum lape. ".)(

)6".

IPpro . 36

QuIcI<disconMCI fil\lnll. m.1e

........ k> thc wurkplc .... kllll

Appl y

Jl" )( 2101")(

Cronbar

M.leri",1

Offset Gauge
A 6 10 12-iMIl-loog S,tlp 01 ..... 1~ri.1 is .UII is. BUl
offsel goo"ge ,,11ow. you 10 P<>511101'11 T-l.quare
s,",ed,1y and .u'.I~Iv, U511\9 1 rnark fu< tlle dado\
~. . . 1 staninll pO'"!. The III"ge's I"'k .. thb: It is
~><K1 1y IM"_ width u the dl .... nu from tlte blt's
<uII'''9 edge 10 Ilte to;,,,,pliJ.te\ ed!le_
To "'.... t ..... }I. (I"mp" len(e nu. tM~. of
I ",oo1tbelKh. BUl! tM 9-"u-g<:' stock 10 Ilie fenee, Ind
UCk It do ... n .... ,tlt a eoup!fc 01 bnds o.- suc. It down
""Iit urpCt t""". Cuide IM rflUle, lloog tlle fenct,
(UIIo"9 Ilt,ouOlllM lIock_ Pry up IM \IoIuge. l'Ou now
llaw a "'ay to j>OS.hOI'l you' T",u e wlM-n "s,ngIM
routc..nd-bll (gmbinillUOI'I "sed 10 ..... ~e IM 9-""IIe
Mall< Ilie II'IU(Ie Inde~bly ",,,h lhe b'l and rwtt,
used. Ilokt 10 d.dl ....."11'''11 ....... In Ilie J'II, 100.
To .. se
}I., musure Ind nuri< OIle edllt of
ttle d.Jdo. You clon' Mve 10 "luare a II... Icron Ilie

11'1

f"..

You don~ hl"e to ma'. bolII .. dgtJ. Just I

tltk m"k~, dado 1,.11 vou netd.
Nlon one fdlle of tlle offsel gluge ...hlt Ilie miltt,
and bUIIIM T-sqUIlf Igilnst the otlle. edO'. The tSquII'\ <rouIM. en,u,,,, th.t 1"- len't 11 sCluI.e 10
the edoe TII .. offs" O"UOf ensu'u Ihll Ihe fenee Is
tM PIO,",' dlsun(e from tht dldo loc"l,on,
Quoek. s,mple, Ind d'rt<I.
If '(OU f~llok. b~'ng pl(kv. make ,,,,e VOU hilVf I
d,ltl'enl Jig fo, taeh dado-cuItIIIII bit In yo~, (ollt(
liOn. Th,s doltSn' mfin Simplv one fo, ..leII Jlz. brt
VOU """ ... bul 0"* 10' tVf'Y indwlillllli st,"'ghl. VOU,
~In(hslt.l'lk ~Ineh itra'ghl mlY IC\Ullly bt 5ltohlr,.
d,ffe~nl ,1'1 eulling d'ilmtlff thiln vou' J4-'Mh-sh,nk
b~ 01 tht .. mt ,IZt_ And II shoukl \10 ... ,llIoul
sayoftg-b\It 1'11 ~V h InywilV-tNU you CilI'I\ IISf I
g.UIJf CUl ...1110 ont ,outer 10 sel Ilie T-sqUlre fo' USt
wuh il dlfferel'l! rwtt._
slng~

,O oHs. , lI.e Tsq ... r.. 7

ofof
In(hes
I,om the
~~:~:~~~~,;~~(1"(ouple
S('.p
hl,db41,d
o, Ih,n
S(fIP to I"e ben(1t tOp wllh
I II0hi 'oalnsllhe fenu. Run

:;::~.~:~ ;~~:::,,~::.fen,e.
(utIlnll throug" tlte
SC'"p.
stock 1. Ilte o'htt gauge.

wo,~plece_

Usln" Ilie oH.el 11I"le Is u simple U 110111'1 1119

One 01 ,U tdges ... lth tlte I.IYOUI muk. Ilten butung
tlte SClu". IlIaln>llh. 0110., t<lge , Tl>e T-squa,e's
(rossba, ... ,11 en sure 11111 Ilie lenee Is Squl'~ 10
tlle .. dOt.

Routing Straightedge
De<eptlvely usy 10 USI!, this self'dilmping
,tnlghledge SilVU time in senin" up ilnd
. .kl"9 51rilighl-line roUI". CUIS .

'<>'

8""'" thc ruu(~ r wh~n m.klllll "",lllhl .,,,,,.

hom:'.......ighlc:d1lC "'ilh bull' ln d.n,p . Thc
ebmps "inetl n <.>n ,1><: cdJco.:o of ,1", ",orl<pkcc.
lit'COIIioa tht I>lr:aif(h,edj(c ... )'OU ~-an .Ii"" tloe roul~ r .I"ns

1:

".., Ihln Cl\OI'gh 'hol I on .. ~h It

~1Hh1d< .."01'1<.
p/c 11",1', IylnJl 11;" on ItlC Ilcnch IQP. It Is nsr ta ~

For yan. I ,,'(H'\<cd .."'II Tq"""" o. whll,~..'"r

lIIllIlM I(:f:Ip I lud . , 1wMl.> a ~"'mpon r~nc~ . II ..,emc:d
.. ~~. thl"tl la do. bul il "'b/1', .1 ..... ).. 110 I(

huy. And 'ilO' onc)'Q1I bllY It d.m jlr.1nd . 811' ......,,,. tlmc 1
look In my ",.. II~I . ' .r.>y tu my,,<:Ir."M.n, i, SUn.- is em,,'y in
Ihe",. So n.'"I;"'Y, " m ... 'n' ln""l' y ... ruj!gling 'o m.kc my
w'Ml<lworkln~ doll.l ... 8" futlllet. (Sou"" b m Ul.ltl)
One .... y to do Ih., 1. IU ma"" !iOIl1C . "....,.,.,..rid. 1
non', m.kc .. N,,'a bi, o,. ~w M. de. bUl 1 non n.. kc.
"'am"."n llilide ror 51""8h' N .. tU CUl . In" .... d of
In\'c'>i'Rj!"O ' n . commcrd.1 unii. 1 put ab"", $12 into
C<Nl,n,on h.,d"",,,, .nd a co .. "lc ur comfurt;.ohle pl . SI;"

-...

........ plccc ...;os ruln'OW. tot c:nmpk, (110"1"11 I dlmp

..... cnd 01 ftI)' Slr:ai&l"~ cuuld Il<' d .. llenJ<'. rol

"'-P ont ~nd . 1Mn ..,.,11,e r ~"OUkln't I'neh IIM: 0111". cnd
-td.. damp. So 1'01 undo 1"" firsl (!>mp .nd ","n "".... Ing
....uit 2IId thc ln;p.tCtJII'= ItQund un tIM: bcn~lI 1"1'
MPt il. K!O>'S. ~ No Pu.h II funhe . \0 Ilie n>dl
- . ....)N E'"nlLu:ony 101 IICI it donc
Sol Ihb ~ is ....'ORdcr1\l1 ,~,~. 1><'11 ar
....., ti>( _por ". "," I>Cnch "'1'. Ihcn ~-wnp tIM:
"'"""'. . 10 ,hc: worl;pIca n ... cbmp bIocb Of ;.....

wor1rpolc-a
redom" , he work"ic II.'iC:lt.

(oMn "I:Ia 10 l)!acr Q"

Qulte r... nkly, 'hl. ,. a

wlthout

ruulln~ ~ry

ha,illJl 10

,h., YQIJ an

knon.. The ....... 1<1 nome fmo' mr O<J<It.an<.knd$ eoIlcctWn.

, .pcnt >boul twQ hau", m.k111J1 the Jil TI><, maney 1
a"fn', _pc"" OII ,hl' lIul<Ic I dlll .,.,nll un ,,,ul, ,lta, I
ClIn' , makc

7S

ROIlTlHC Jn.AICHT[OGE U'LOOEO VIEW

!..

tM~

bloc

Making the Straightedge

c ..nlng Ust

"',.

Dlmensl on s

Millerl~1

/I'X4"x44"

.""",

II' x 2')(."
lI"x 11',')(4"
1\11" IC 4'1(4'

..."'.....
Itiudwood

H.lrclwood

p/yto'ood~""",,~~:,,;
..
~:~; ;~:~::
ebal""'
"

Tbif
N: Il sinlpl)' I
home-bn."""",
In <XiI,,_.,.,I".

1Ik~

bk><.'ks 0I1OId!cd 10
I .

JIIP' '" ...... br ,"" ptywood Iimu AI OM ~nd b

hod ....,.. A Ihmodc<l rod c:umd> t"""-wh '1Ih
bk>cI<. ""'"' rod hal
bkx:1r. Of! OM mei"
tho: ha. Thrn tho:

tianlw....
1 brus th/'uded

,n~n,

11'-16

1 Ut~ boii. N', 16 x 51t"

2

"ylol",,,,,," nop nUl'. "',16

1 "ut~ pLaStIC Imob. 2)1." dl.l ""tII 11'-16 blond

b<n. thrudoed In...n; 'D~l fTOm bod TooI
S4.0pply Co.I800-2H04211

6rywd ~ ..s,'6)( "'l

urr'ag. bolt, 11.'

"'nd8 _OM', II" '.0.

16

x 2"

"a...

.... UIt OJI9O$Itc md

biocl!. il :uuct...d 10 !Ix iii .". I oInP: boii tn.
tbtou!Ih I ~ adjIlM_ -'<II In "'" lma ' - t i
knob ... Wt bolt ..... JOU caii
IIM:

oi.

bthoatho:~
I

tho:liI8,~II ~_~:~?:~~:~~~

pipe'
TO ....
duop. MIM: tho:...

..-ort.:and Oft II. T1Io:II .....

hnd md."" pinch ,"" wod;pkcc tWollr

"""'s ~ >boul Ihb It !ha, .""

'"IOJ-' rrwdwtlom
bok. MOJ' nulS. Ind 'twudo:<Iln>tn 1. ..
_

an<! ( hnp. And Ibr 1I1fiIwlJ....

,,,III' .haI.

wor1<:>!

ulM/', ". 1.0.

I "...,~ plnlk .noO, 2)(0" ci .. , "",.11 "',16111""'9"

br.Iu I hrf!~ Innni 'OK 12 1 'rom RtKl Toci
SIIpp,,", Co

1. Colka
lheIx"'"'
hanJ~.
1,..Vbu
r~~'~'E~~~
Ilo,..,...
ohoppInH
JOO Iqm
_
ci 'hc
In "....r.oh<>p
hlI<\Iwat1:

... tu, ' 0"

don,

ha..., "I"IK local tu<\l ....'" .. III

.ho: ~noI>o . ....... ,...... """ .....,. n...J

.ub!.ti'lIla. ,......,

e"""'Y'''I,. "'"

16

Itouttt Mlgoc

kOUTING STRAIGHTl:DGE PLAN VIEWS

.,.-

TOPVIEW

[OCE VlEW

IOTIQMVlFN

II }'OII'" mind 10. II" ;d>ead :md m;tJu, }"lU' own

W<IO'l<b knobo. lluppetl 'o lil<c""" biR
knob:l
., bortIII1II <I>Ot"' ond ..,."., rom""", In woodwor1dng
....... Tbry..., <lur.thk. pro>idc Rft'" le>'<:r.IjC ro:: ca!>)"
~. wd ..., " ". :tU du, ""1",,,,1,'''''

pU,"'"

,1La,

2. 101:01: the fe " "". I "",,<1 .IwJ>1Cl"dc blrch rIr-><>d.

. ro:: '*-'y. h"t I'd rttOmm.tnd tomc !fI'" uI ~
"""" ~ It ., .. ~bk :md ..........
CuI fOUI' "..,mol,,, ,IK dimnuions ,,>if...d I>y 'hc
Oaairts U6I , ..... an . uI """""'. m;tJu, ,IK ~ 1o;Jrqp.,..
1IIontt. 1t }'OIImake il alIo;u )6 lndIO 1on&. ..... 'U IK ablr
~ . . "'" linbbtd gui<k IICRM mnd:onkl;oed Jhcct ~
picco.)1JU ....,. fiod IIK ou'" k.~h a
- - . :. 1'hc l'lnI!I< uI 'hc guitlot <hown ... 6' Ind",> "1' 'o
w... ~u,1ons

.-

""'oaulIrr ......
_

lhc sIof "",". 1 did Ihis <III , he ".,\I1e.

lMocto Mn\Rh' hoil, SerilK Ii!'lel "'mss

,.1lIe ..i,1>

,1.., .. r~IW"cd#.

...... ...., "Alb o f Ilie Mot On m:w<ing '~I'" .ppllcd 10

.... mute...ilie frn. ""',. lhc w;,j,h <:>f'~ rou.cr b .. Un...
'" ''''' IJ'Pf'OPl'iol'" m:oob. plWI#' tht ...... on.o ....., bI',
_ lIntlI "'" cmI nwb IiM "I'. thcn III' , .......... "1' 01(
.., biI lkpa' , .... prt'lCn>o. makl. . in<:tannIl""" dec"",
CII> umil ...., oIot .. romf>lctcd.

j . (optional) Apply "'m;n.;lIe 10 It., edgal,

I~ ...

olly usN my stndgh'cdll<' fu. quilc IOn'" IIn>c beii""

Mdding 10 I.ml ..., ... , .... cdp-IO

....., okld . ... 10

"f'<".k. Thc laml""e <lrct.'ln "1' , IK pIj.,."UOd ~ 100.

SlnIpIy t:O<Il ,IK ctljp aitb contan ttmmt. ond appIf ~
10 ,IK hode> uI ....., pbotic IamiN", ..np.. ruo. Whm ,....
cm ..... Ia dry .ud: ....., larnkwe to ....., pIrwood. bumbh M
..ith a}rolkr. ,hen ,n... ....., cdp:!. Ilu!oh Mth fIu>h.
trirnnImR boL Do "'" cntIs lIr$L Atit< IIKyW !I(:cn ,nmnlcd.
appIy ....., lamnole ' 0 1.... lonR ~ 'Th>t "'''f. ,1K Ion!l ......
....... strip5 ..ilI 0>'Crl0p thc cn<b o( the!horl l>rni....... st"fI".
4. C UI li", c bmp!n& blocks. U,., ""nlwood . houjl/1
1, <lucst1' , .... tI.... ""nlcub..,. "'''''1 tunJwood. I nu..It ,...,
h~ ar>tl p..,.."n: "">cI<!; rrom o.>l<. For 'hc 1211 bIodI . l ..,...
cucd. popi", "rrell' rrom ,h., ..:nI' bin bcatlSC' h .... juSI
,hc rigln ,hldrncM ond Ielll9h Cutlhc50: ~ 10 , .... dirn('n.
,;ions J{>ttificd I>y ,..., CUr.I. . LisL Nore !bc pn dirn.'l1on.
5. Form 11101; lipi..., 00 Ihc: tail bk>d<. Tbos bIodI
t- 3 rid,.: (It lfIU'IC ,"", li" Into !bc ~,"""'. >lot ,,,

k.,..,. thc '""" front ....b(1ng.

"''O ...

10 lOrm 1'" 5pIne. 1 """

bhct> on ,I><! .2b1c _
\li'IIh a bod<sno'. I Inmrn.,d tI><! SfJioc baei! on OI><' crttl
In~ it j .... IInt1ct 2 in<:heo lOtl{!. So .hal Ihc splne: wuulll
IIC'lIfIe 1"10 Ih., " KJOON etld of Ilie !JoI.1
lOC from
cnd oltl>c ~pioc wI. h . file.

"',,1\lIcd

Th rldge I,,'t "'IW"n Iwo ... bbl!'u Iocks InlO tn ..

1I""glll~'s "ot. kupl"'llIM tail bIock alig*. Cut
th .. r~bb..u 0tI the tabl, uw. Alt ... mikl"ll IM s ..... lIow
shouldto. n.u. ",i ., thl blad .. and adjult IM .Ip fllKe
for the bis .. cu\!. Cut so the w;o.ste f"lIs tO Ih........si6t
of th.. blid ....atM. tIMn IM!i"'ll trapped !>ttw.. .,n Ilie
blade iod the f.. lKe (whieh would I"'d to klc~b .. ck).
6. Insta.ll tile tail blucl!.. Thc bIoxk '"

I_~JI ~~~~:~~~~~]~:~:. ,. . .

o(

"'''L~ .

"dd in pbcc ... Ith "

hol' hole:. OII Iho: badt of ,t>rc
bIoL.... loc.".. "'" tJ<k'I ttnk1" of 1"" pitct.
'~h
I'ors'n~. hit. drill .. ~I>dp eoun rbon: 10 tho' 1""
bolt he"" will bc ~. Sw;.eh ." " 'Io.lndI bot,
.nd LIriII Ih" .h.nk nolc.11I" hol<: ohooIJ
IIM:
_
end o( thc sploc. 1'0 ~eadt .IM: ...".l<pIt whilc )"Ou
drill ...... il irlto IIM: "' Iltlght<"<lgt 0loi and pul hoch JWU on
.t>e <lrin praf ubk
Ori>'<: "'" arriaflt bolt in." .t>e _ . thtn inoct k
.hrotl)th 1"" >tr.d;g/>lcdp: Drop
lalll<' I"m<la.~
lII<:n .hre.d 1"" I<nob onto ,t>e c:nd

""NU'"

Improu Ih .. <ymp's irip wlth .... nd~per. Tht ""'"

coml"'ll of Ihe jig\ compress\oll ,;,mp,ng systtm i. 1IIe
laek of ... ctlon OtI...-h wood surfae." To 1<<<0 tht
~wl 'rom shppi"O OUl of pos~"", an t~t S!rl,g~I\~.
and to imp,ov. Iht j.lw. g.lp ... Iht wo<kpitct. glu.
Sind~( 10 Ihe tl>t! j.lws. IS shown.

\Vo'" "

""'' /'li<' ..

()fl"'"

8 . Nocch lhc: bloc ..... Ikllh bI<><b m...c bc:

JlR"ido etnnna lor pon. of.M ~ . . . ._

"" )'OU nIl 0iCC r""" """""bIJ' IN/" II. l'itMd' .t>rc hc:Id
10

bloc..,.. ,\>"""",,0 in tht dr.IwinllltU<lnt!l9'

IN/aU. lhe bol. Ih>I pro'icb Ihc """""'" olClIIll .hn>Ujjh

for Ilie >lap nut . an<! "'" prc:>SU'" bIock for III" bolt
TIM: _eha'rI'.t>e _
" 'iLlt/t bul <Ii""rc", dep,hs.
I CUI .he n"t~h"" on tht l2bk ..... StI II..: bbdc
10 .... Icll IM dqllh (lr I h~ """dt . St2nd Ilie: hI<>d: an
and (lui<k " '""n>SS ltu: bl>dc ",i lh II><: mia ~'.'"
re"""laI CUb 10 cint thc ...-...t"

hoIt drilkd ~ .t>e n,iddk o( "'" /JIo.Jd<t, n.., had

bIol.. tta ......... pon lI<Ik' TII" fItSIlncII b l>IltnI ,.. pilot
hole: for 1.... Ih~ Insc:n. " 'hlle III<: mll.inl"" Imgth ilo
bof't<I ., da......,., hok: ro.. "'" hoh. 11Ic hoit In ot>e prn'urc bIock .. . cInron ......, lor
bolt.
Tu cn."rc .t>e hoIai .ill bc propaty oJlgnC'd. oei up,
k:nrc and 0I0fI hluck an "'" drIII """" lIbk tO poohlon and
hoId IIM: bIock bcil1l!l <lrilkd.
1>0 It>e _
bIc)ek fi"" a ...d: It>rc bit for IIM: Inscn
pilot 00Ic In ot>e driU prt...
of bit to ...., ohouILl bc
opi1k(I on Ilie: in.cn llIt ",",nell i......... 1 """ ...q,~n:

9 . Iklve tbe Ihreaded ' .....,n. 11115 15, ;',~::;:

dkry """rotk"" bea""" 1,,",", .. hul Inln
Ihc: pilot hoIc and It>e ,;u.btt of Ihco bloo.1 ".~ C",,"
<lOII ,h'I\ w:IlI wJtj", LI'h'lnS "'" iII>en.
For ilih'cr. uS< >hon hoit .ith two ""b un
oJwtt.. Tbn:-..... ,1Ie: b<~I. \\'ith .t>rc .wo nulJ oIrndf on '
IIM: I"""'.)am onc nul "Pln>l Ilie: Irucn, lhen
nu. -.p;rt>I '1Ie: ~ Qomp Ilie:
tO lum .he In..,n an<! boiI , anLl "r1~" It Into Ilie:
Wh cn It 15 fully <Iri,..,., ....;.m Ilie: nul .... Ihr boiI

7. I>rtlllh.. :rdj""lmc:ntboh holC!< in Ihc: h e:rd

",,,d

p"""'''''''

ti,,,

(11,,, "',.,

78

Routt. l14"gl(

ASS04lLY DETAIL

'""

~")(

lKIundcd M1tboul

TaJlbIock

SI'>" curiage boiI

It" )(

2" canillgt boiI

bac"'"" It..: In,.,.. "U l of It..: hIud:.

10. AoI8emble the prc:!lS .. ..., o"",ha nbm. n... kk:I

0010 /mat Ibo< boiI Ihrouglt ,t..: P"'U'" bloci: and lrAp ,t..:
bIodt ""'~ oM bolt lw::Id.mI " ;top nUI.1lM: bolt m.....
lor& 10.".. In It..: bIock. ,.., rou ean ll>rn It..: oul opirts<

.....

1 . - l I .....rbtIC boii

,<>..,.,

h~",

' 0 .110 ... Ihc- bol'

fIIed 01( It..: CUt'1><O'"' o( Ilie !>oiI ' ,;quan: ""'blind."
fAII\pat'c" I lonK 1Icc.hc-'.... huli "'"h I arriaJlc boii <>III><:
.-, ntath.You1I .!i Ih:i' Ihe: hO" boiI h.u onIy uhon ......,.

.....,..1

_ of \hmod!; . .. hlle II><: a rrl>1I" hol... Ihro.kd "'sh' up

bnd. 1lM: t pplk... rlon I"njulm. mort" Ihlnlh lhan Ilte
... bolt ""'""'. Ikn<:c:. Ihe dJOi <>1 orriaJj< bolt.
lDm Ibo< boiI. and ' 11 ........ Ihc- ."'''' n... , .. k. A
IIOP'" ...., nyIon In,.,n 111:11 p..."""I. k rrom 1o:>oKninjr..
~. a ;top nu l is h:inllo Ih~()nco: 11w:;o,;"..,.,
....... III<" bolt"" '11 ..... <1$, )"U ,,",..,
II wllh
you can, do II ...lI h rotlr fil18Cf"S.
fii Ih<" hc;od t>k><;k onlu <h<: bol. ""'" Acid a ....,on<l
IIOP "',Ilten 1"" pl11c !<nob. Thm Ihc- knob onto thc 1..,,1t
. n ........Thcn b:Kk Ihe",,,,, nUl "1'10 Ihc knob.anll j1rn
I opln;Ill><: b loh.

,<>

""*"';

'o ,um

II . Momit Ihe h c ad bk>ck "o r.I>ec SIr:a1Ilhlwg<".

\bu CJ<'I )d\lC . nd "",..,... ,Iw: hnoJ bIock 10 IIw: ..... Ijt.h,~ .
1.... 1I<tt:"W> only.:utd Ih2l . IM-m ""tI~loty
""'Idon Ihe he-ad bIodr.. as """"'n In ,1Ie drAwl" l!>
s....... ~ ..I,h I damp wtlil<:,.,.. driA pIIo! _:utd d,h..,
ok)'nII ~.I d"",.., 1" ......,..,...., IIuou/Ih Ihc bIoek 1"'0
.... !l ... ighlodll<. thcn flipPC"d Ihc mt;, "'..". .nIl <In,,c ,,,...

Using the Straightedge

n...

rou. lnll ;tr. lglllwge I~ c.:osr " , ""' I<Q(I61 clcpIhdr>o.You .dj uSl lhe il bIod: ~Iy lor Ihc wkllh of
.t..: """'piece . ..,1 , 1Ie !igln place. lhco til!.hteo Ihc p"""
...n: hl<><:k.
Rul )"Ou do "",,. .0 meaMIn: anei 1' oul !t:i p".ltlun
vM-vtt Ilie 10",..100 <>I1hc- IOlrnckd cut. Tbe ..... ighIC(lIl"
It "QI a 1'><1"' '''' 1\ """" ., )el iucIf ~uan: '0 'M nllI" of
Ihe
Mo"""..".. Ihc ..idlh <>1 Ibo< cut ;md Ihc sitt of 1)><0
fOI>ler baliC en,.". Inlo .hc oetup. "'" as t!Yy do w;lh . "f.
or <>Ihcr """CI" gukk 11=..., In) "'v ~II"",,~

_pk<.'"

"'l""'"

" p /rQ'" I/.W "",.... II... I>{"'" rul Thl. IJ ~';r to

do Ir Ihe t.a...- wmcler o( your !OILtC\" 1 01 ruund
n" rnbcr_lil<e 6 india ".. ~ 1""""'. You h"&l1o:. Ihe cut".
uoler Ilnt. IMn """""' ~ Inchn ".. ~ "', Incllfi or ..h.,
~';cr 10 rn>", Ihc >tr.ti:ghtcdrlc lQo. ioII . R~ll" nJlCSII of
It..: widlh cllht eY.. 1ht olfSf't fn.>m thc cenlcr line ..
al .... ).. Iht samoo.
IUlalIl> ~ G"ugt$. An oIllct Pili!<' i I pM: 01 !wtJ.
bo<mJ .... Ihc 1ik.m ..idlh .. Iht """"'III .hc- "rA!jhI""
hcolllct from Ibo<~ rlIhtCUI.\'''' ~"nc""
0/ 'hc PLlf!lC . . . "" Ibo< b:youl lin(, for Iht Cd.. Iha!
lloriJW tht: ~Icdp: up ." Iht Othcr ~ 0/ tht: PLllll'
C"'~ ..... as)' \O a ....... ;...., " ()ff"o.1 ( "",. "" P"4!IC' j

". ~t

ro""

LA""'I OII' IIM 'IlO posl15oto ,eq ... rn VOI! 10

mUSII,., ,nd ~ OUIIhe (III. 1Ir.... 1Ka..w 1.... IitRlgoht
fdge
5q<U'" kHIt. VOI! nHd 10 Ulend 1.... linn
Krosl 1.... workplec:t. Theft vou nHd 10 O,,", from
III, (III 'nd ...... k 1'" ,,11(1 pOloltlon. WMn c~mpi",
III. 1I"lgIIled9f IN! 1_ 10 "!!In bolii itI .nd, ... ltlt 1....

won'

IIVOI!I """k,.

80

ItooJt~

Mo9k

Senina 1'" slRltlhledp .lIh '" offsel ........

elimin;lleS IM need 10 (~Lllt Ind IIItUlire the
ofI'HI lrom tht CIII.. kll VOU 11111 mllSI LIy oul tht ''"''
KrosS the workplec.e. lJJe the 9a .... al botll tnds of
IM SI"!!IlttedOt btfo,., ll"hltn"'9 t~t ,Iamp.

'-.ncn.
l
~

$<1"""', but lhb ~p""<: b a

lfict.t T11<:
fmm ,'''' ulooflh<' bit t" ndI ""'''' .... ur
booophtc coJw;$ " difkn:n. W"h .Iri> I:>:;uo:pb'e. ,'OU
<lfW"I tbo CUlIIIjt wId,lI o( anr ...",ipll bit In )'OU. c0l!ibi, MoI ,.,..,""te roon;c:1f tho: abiIiry 10 produce a gmllct
..,,1DUItaI """8C" o( cu",
Thio """'" bakpb.e ..... ~Iopcd br NicIc Enjder, a
proIik
of .."QO(/'<,'OfItlnJ; booIto.
!Im:'. Ilo'" II ..."OC1tS: U6c Slt:l'iP" hit and """"C p"'"
.... Ilie I>iascpIaIc' .,.".... ",de "lI"l1Ul thc: Iim<:c. TIlcn 'uni
III< ....ur .. I ~ ' . Il- !lIk l; olj3illlll ,hc "'nec. ot>d mai<t'
ltOOI\ol ~ Tbc: :odditlo.....1 !II ind> bel","", Ihc bit and lhco
net MIdI
10 II'" wkltll 01 ,,'" "'" OII",. oi<k:o o( tho:
bootpI;u odd \oM inch and & nd1lo thc le.... CUl.

"m, ...

'- Incb

nu.... \_!>il couId produec Yz-Inch._ da<k>c;,

-......:t..0I'idc ~
kk dadoes, and '\>o.lnch
riI< ~. " .. "" "mple "" 'umidtl ."" ..... 'c. ' 0
~. diII'ftrn, ~ lIgOIllUIlhc 8ukk "'nec.
l"w.. 'Hn<tI tii, wlth .his ~ iP"'" )'OU <.bdo> widtll>
ti ~ lDdl, ,~ Inci., " Ind!. and ''1\0 incI! A \'. .tnrn bol. lio'''''
nIIb> oi I, indl. .,.,. In<:h,.\t. inch. and ':.\o, inch

.......,I\-...

re}'Oll"" n!tIIIy dc\'cr, )'OU'U xc 1hI. NIci". kko '" an

.... u..... 'o undcn>i'tC<! pIp"OOd. Onr o( th<~ <1 pIywood, <Sj>a:tolly h2nhoIuod >lui!', Is
~

.Iu,

~ .. ypir:2IIy. 64,h O' a j2nd \IIldIenW:d . ...... 11I>UnCC.~ ..

inch ~ ilo moRe liI;dy "h.z lndI or '"" 1nch. 1... ttlQIln
thc <b<lo J'O" "'" ~ ... II "ilh )'OUl" ",-Inch >ir.tishl .\ lMImlns.
One :iOIu.\on ilo 'u buy Sf>C'd:II d:IdoinS !>ils 1Iu.. ,,"' I~...
Inch. !JUI k:so COOIIy !oOIueion I~ It.> ~ ,"Ct>ion of Ihl>

frocllooutU!& twqIb,c t/ul'U <allow)'OU 10 m..tI<c ,"""" uH

~led <bdoco in ,,'O p;lMC!I
~ Of '>I.Inch biI.

","11

Making the Baseplate

w"'"

In III .. sltu.ulor! '""'Y accutlUe

i> oonII..i;;d. 1IK:IlJ>iC II
b lough '0 "'" lhe Iwq>blc lrimrncd tJe:od..oo wilh )'OUr
n.... ...""'..... 1'"" 1ndU<kd tiP'" OII flnunlnfj IIx: ~pb"'.

1. Cui ",nd n lOUnl It"" bbnk. Cu. a sq....., of

xrytic OI" poIyaut>on>IC. makl"3 li . boul an Ind! ar ..,
Iart!tt
III(: f:octory b<aocpblC. I.ca,.., IIx: pn>I~", p.pcr
bonded 10 IM pbslic for now. Drili mounting~, ,",Ing
IM &ctory buq)bIC"OS '" lemplalC. For th<: """,,plalc to hc

""'o

OII ,Ix: mut.". but, ,..., itI.c tO mounl k

11.1"3 nalhcal >Cn:w'. (Sec Ihc """pl.,,. CcnIt1'~ind;'"
~ . OII ~ 8~->"'i> b<ascpLtIC Qpc<:bUy t1a'ds to
bc ""1I'-<:,",lIcri"3.'" COWM,"""nlr IM moun""3 hoIoeo.

.,lf-n terin&

MouoI 'Ile

~ hLtnlr

an III(: rQlUI:t.

FRACTlOHATlHC USEPLATE LAYOUT

For, hljlwl ukee .ou l ~.
(wrtl! I 61'1.'.(11..
1

0"

3\11.'

3. Trim lne baKpbtc. Rcm<m::.hc bbnk (rotii tii<

Me"'uro: rrom thc: anlcrpoinl In I~ Il.,. >idc: . .
nuri< It for lr1n.ntlng.( H.,,<= m.. Ix tht: ttn;> 1Itk.) 1 foond i
hdpful. n layin3 OUl II.., c<m. ,o ""ncli JII'fJl'Cfl'licl.lrs (ad
di>gQfuILs) lhrouIh ,1Ie anterpolm. In addidon, l found th:t!
~ OM Jidc and nlmli:ltd l' CUltln& ,ha! :!idt __
mllcd conft$on..,." "'" ttim a .I<k, n.. '" "'hid! oido i ..
(::l'Q, .. I.j .. ,nd "" iOnh). 1 m:odc II.., ... CU'" on ' hc l3I:Lk _
When Ihc ,rim cutS:&IT (Io:)M . 1'1 Ihc pnH""'n,<= popa'
horn thc ~pl.:tlc. As )"" do 1O. I... n!okr Ihc bhcb mpo",,' 10 Ihc pl' ''k" IbcIf 10. permanenl nu"'''', INdt ..
SanfonJ ', SIw'pk ....!II do lhc: Iob.
ruutc1.

t""

F--'."-+f-'f---"

4. Bore: 11)e: bll ol"' .. lng. Wl,h Ihc:

0 "

o ~

,"

~%o

Qty.

,"

~I.

' hc: bll opc:nlnR. ,"o.. an d.. ,hi> .mit I

I .~i'mdc, 1>11 on Ihc: driU pro:" or by "''''''''''IiIf:
Ihe b.sc:p"'c ond pI~nll " 'Irh " 1.1"JIC""<I1."".ta
'<r.Iighl bit.
Irlmmcd.

5. Tati lilc basepblc. "fh<o

proof~)"OUr

,,"ol'k b irr

LIIC IbdoInR. DO Ihe follo,,lnll. Oamp .T~""'" 10" 6-10

8-Ineh..1<Ic SOOftp. (Sa T~ ...", on pagoo 6<1
p/ani.)
WlI h .he "(Cru . . . . fi<Il"lllhl~ fenec. l'QU\ d>do :ocmoo ""

ro.

~%o

Dimenslons

MAteriAl

14')(T)(T

Plastic'

boanl. 1\rm."" 1OlJI<1' '" ro:ft:tcntt lhc: """" ...ith ""

.. 11,' .si<k. and l'QI,JI .bouL ~u:trtcn ui lhe ,,~ lICIW
thc: boaRI, " 'idcnlnM \he dodo. ltcpc:al .... llh lloc -..
lIOing .boul lu lr>o.~ F"uWI!', rotii .bour qu:rn", or,~ _'OI

It -.

w;!h ""' .. .,.>lde.

Se! \he ""lIe. asi<k . nd ""'" (':lfd"LLlIy m<2SLI'" thr

..;mM
Mur difkn:1l1 on:tiun>. DW caii""", ...m!d~
)'UU' ,,.,,. a("<'Uftle ID<'a.'>W'CDK'nI . lf)'OU h;llhc incf'CMClltl
on 'he """", p.u JOUr$df on lloc "'d. lIut i( " ' " mlooood
1ltem. do liu lt rlflNuni ....

01''''''

_ _

2. Mark lhc a:ntcrpnl"L 1010'"'' 'hc: I);loc,pbLC

bl.nk 00 L~ n)lUCI" O"..,k \'.W'"...ing bli In ' hc: lOlJIe

1.0_'" Ihc bu ,~it ,0IId>n 1"" bLmk. Thm Ihe bu ~ fcw

.Imn br luoo. marklllJl 'hc: ccuC<JlOl.nt 1'<.11" LI.., saU ~
xcurxy. kccp Ihc rrwI< as JRu.II .. ~hk.

hI.rk ti, .. baseplal" bl ... k's ""'"lerpOl", by Iow

"Ing. Vi]>OY"IiI bll 10 t he blank, Ihen lu."lng it by
hlnd. Vou ~I\~' need l>Of wlnl I Ilrlile mark. so
don~ ove.do il.

TII, proof of )'0'" lNooeplale's aU"'lICY lIes In

acl.w .111 . He.e. I'm meullLing li test .ul mlde 11$;119
eacll eclge of the b.aseplalt, and I'm joll;n\! down l/It
me.. u~menlS 00 I .In ;usen the needNl flnelunlng .
TM ZItfO edge . ..t wil! equ.llhe bll dl.mele., MI
m'lt~. wlllll. It S 'n incI! lIere . Bolh rlle .. !ILo and .. '"
edgn lre ~ Inch unde., If th ... ~ . td~ i. 1Iiso ~
Inch und,., onl)' thoc zero ed~ will lIave 10 be joInled.

....,

Fine-Tuning the Baseplate

rtATi fAllltlCAllOH SEQUlNCE

OI'

MiPwuee
IOUltI
_______
. ,_ _--.I.Mount.n
OY1!.slzfi! MlU"~
of iii" Of It uryhc
plastic 10 the

roult' NSt. (In

IIIls CUt., 7'
sqUol'" 1. used In

plac, of a 6" dl'.

5Iock bl.sepLott.1
Ike fLltM,d
I<",WS lor thols
~,d~n of 1""
style us.td 10
.Iuch It. .uxk

tuo"pl'lt.
_ _ _,.,._..,..-.., 2. Wlth the bl~k
'U.ched 10 the
.",
"",Iti but, ,"StiU
"
V-t'OOVIng billn

,"" roultl. Tum

OII 1M .oute< ....:j
adJllillhe C\ltUf'IQ
Mpt!\ MI IM M .
j"ll touchn 1""

".

--,. ______
,
t

b;tst~lt.

"

.,..~I

tlnterPOlnl.

(rom tht roule<.

Ind tfim II. uy
OUl and (ul tM
.o-~

fini

MeUI>f<! (rom

the

,.."f,poinl.
Uimmlng \oi" ffom

.:.

on:r.,.,.. ....

'ruftI ."..,.,

)",,,. lhc ~ an your .....('r talIk.

2. ~ up thc rou,tt tab le: for jolm.lng. u.: ...,

Splk I'mce p<nCIUo:<I
plIf<
'0 ~ thc <-'UU To

an

__ -

(tbc' Irft haW) .. 1\lIc ~ .Ioc inb:d

01I0Il (.t.. riIIhI haW) l<tO<'d. I ~ ~'ttd thIdt
.......o 01
paptt _
..,. dia! caliptn. .......

. . oile.

_~

~ ~ 10 ..........

(1""". ..hal , !-o.d 'o""'~

u..

llOIll'cftl ~iOn II. Inch

.."...,.. \.;. ndI fn)m an ""'"

,,, ""'"' k .0 pcrf<nloo. I applio:d "*'O ~ 01 nWoUt\Jc

IIpc 'o lhc Inl'tt<l hali oIlhc
II """"0:<1.)
'-1Ih ' hc knu: fKlnJp ~. ""Iust.""
fI'JOiIt~'" In
""",100 ,0 lloc
~
,ho;: 00tk<d >rt"I1on ollhc
"""'" '" WlI!I""l ,a t"" ~ <>fu.. bit .

"nco:

3.

nJw:. Tbc: _ ..................... rdlablt

your.......,.. il 10 ..... ~.1th tho;: ba...-- I_'"

Trlm lIwe

..~ ... _

pUte ..... thc:n _

... lh",n. 'IUttt

ono:

;"' 0 pcrfI

."'" .. a 1imIe.,\obkJe ,,,,. cut, - . - . , ."" cut .'1<11.11. """

trlm ,..., ttlW .. ~ Tbc:n tn:tl< I ta< c .. , rnn>UtO: 1""
cut wtdth, .....
u.. o:dJIt: ..
Il S "'pc1ltl\.... j'<"'I.
;ond

a N"It:

t"'"

t"""""'.

,,,,,,,,,,do

Trim 'M <Mite.

~. In IM

t"'"
ume "shion.
Tilkf \oU' ',om ,""
_ond~.W

!rom IM Ih"d
edge:. vid 0tI1y
~.Iromthe

foun". tabtol tho

""

~'

......

.,'

.,..

.....

zr

joinI ..-idI1bos ",,"-, ,..,.. ....... 10 thim ..... thc

1""
1..aIMI
,/\jo,~.
e0ge "O"

t""

bi'.In"'" ""

). - - Ilie bIAnIc

ro- ,~ an<!

1. Aslic:soI
~hu3tIon . ~n ..,. jon~ ......... oile
..'\dtlts ollhr dadu ><W"""u and """"""'''8 .hf ......., 01 oile
n,nl"ll,,,"r. ncedcd. 1':aU IIIC: ........ ,....
pIy
lI<"C'd 10 *iIII IIWcrbI
0 1 ' - ........ Bul II OM
Of ~ " - ' )'OII _
10 Itim Ihr """' cdF fInI _
....1ono I ~ .... mei MnI. r. ~ ~ """" ......
a 16th. Ibthcr.I'. ~ j2noil mei 6-kht. Sud! aQ..., , _ - .
...... 1Inoe 10 bc"'- an tbc' Iabk _
""'J"IiC,JiUII'e.. b ......
pbmotk ..., 011 IIIuNrr OII ~ knna. $o W'h:>I: 1<> ~

"nco:

INIrklng ,""

Th05 15 .hf 1~ pha>t oIlhr '"'Oft:. bkc

.."O<to; mnhol1icaD)'.

edges. IS sl'lown .
Joln.lnll On the rolitU Ulbi. II tIM ben W'~.,. tO

mJkt the fine (un n.eOt-d 'o fine-tune "!'Ou' bilKpI.tt

NOtt th~t wlth 1.. knobl 'tmowd. Iht b,a le un bt lift
on .ht b"tpl~le Whllt lht }oIntlnQ II dane .

1f)'OU:an wud.Ing wl,h ~ n.nl-b;uc rou'n", and If , h..

l ............ "" ~)'UU .huuldn ',
relJlO"-e ,1Ie
!w;o,pbtc ffUIJI thc __ 'O ulm k , JU! puii "'" __ (rum
,hr 1QUtn" """...,
Mie< ,hr first cdIIC b juot """' , , .. rn 10 'hr KCOnd nil!<'
\Ind 'W'IC i, in ' hr $O""" ""'t' tlml.", do "'" lhinl ' pIu> ~.

h,"" 'U

Using the Baseplate

Onc~

)'0 .. -,,' .. ' .... .-..1 ~nd n ...." ut>Cd II... ba..-pb'''' )"U know
how 'o U5C: il. Bul. '" n::J>nI. ro" m.~c <:ul . IIt1k1intt II...

..__, """a

r-

i
-r

ren, l1>cn )'UU tu rn tI><:

\III

lII""''' tI><: rcnc.:. anei .......

W"'" ""'y no, "" .... RI~n' 1. , h., n","er 0/ fn:d 1Iiftt
,Ion If)'UU mUc tlle n"" p;lSII .... I,h ,h~ "",.. cdj;lO >(IIIimt
II><: kIK", ,1><: S<>nd pas;lI :sIIou1d II.: f<:tl In .1>0: oppolitt
~ . TIw '. """'~, ... 'hc: dnw l"3 f'effl OIrwtIoo
s...~". aWto clcar. "'" ~ p;bO ,,"'OU1d "" eUI1Injj ..
,"" .'li<It: ul .hc: dodo oppo!oitc' 'hc: r~.
If,.....
nWtc bocit ~ In "'" """" Ilin::nltool.
bc:
)'OU ma~.. ,hc cut wl,h thc " .. . . . first. M>h .,
~"Ut .... i.h ,Ilo: !Om) cd!I< second. T1u.
toc ..........
tiI<: cu, .uwanI.1><: kne.-, ... ~ .Jun ''''>1 frum ti><: 1;t>Ct.

"'n::

""211' ,..

'"Y.,.......

FEED DIRECTION SAAVY

SECOND PA5S

FIRSTAASS
j

.. ....,

~I

ti

rout~r 5Q

(cren, baoc"pl.tc t"d1lC bc:t11o

1iC<.'Ulld cut.

'z ~,..

"'~,

FHd dl(fl:\;on

.dge Is ;tg;oins, ,100

("d dlree'lon ..

l~fI

f~lKe .

'o ngh'.

Fud d''''C100<t

'+" edg' 1. agilnst ,he fonce.

fud dlrec'lon 1. rlgh. 'o I~ft.

-,'

.'"

Fud dnK,ion ,...,.

Thls Is ~ ellmb CuI. Tht: bll winll

'o puii tho rolJI.r Ihrough ,tit cu,.
SECOND PA.SS

FIRST PASS
",.

.'~,

~d dlr~ctlon .04~

'+" KllIe s ;tg~ln~1

11It

fenee .

Fud dl",aloo Is lefl,o rlgh"

fHd dirKIion . . . . .

"Zero" edoe il a!lt,nsl,tIt 'enee.

FH<I direeuoo i. lofl 10 ri!ilhL

Cente.... Finding Baseplate

~1c.lJ

Ihou"h It seems, <II simple g.eometric

";.cip'ell the seuel be.h lnd Ihl$ fllture .
WIth It, Itle bit un usily be eent!!.ed ilCroSI
ilie workpiea.

~._.

'"II
1:"1

!._.

ID

mu:rins hule o mortis<: ~ iV"O''C ti" .he cdJlC

o{ wortpittc- ...1.... , .. 'ough. ~ .00
..mbi"8 "'yo.u Iinoi NI"' 1'01",("'" Scttin8 uP
Pk' n,n Ix ."...,..,-.".. '00 an gel thc: CUI t * - '0
mMt. tu it \o oddom rnIIJ' (JfI ttt"."..
Htlu. >implr baM'pbfc , ... , can Ix nwk In a .IMIrt
. . AnII il _in alm<loI ....pcally CUlta. CUI an ,,'on:
pi<'. TII< baoepIalC """ ,"'0 pin pl'()jc<:tln~ r""" 1. Y....,
"' .... "",,,,, .!Op ,he won:pka. with pin un oeh ;kk
T9'hI ,!te rouln 10 hri"ll bolII plns In COI1uet ,",'i' h ,,..
d , Ilie bit ",'m
ccn,crnI un 'hc:
1hr lrIck b >limpk ~ry n..:, pi"" m.... Ix rqouIolb..
. . /rom , ... bit lXiI mo.l
Ix OII :llDight ti"" ,"",
JlMtjIhrou!ll> tho: bit :lX, Tk bII ,,"il! .z...~,. Ix ~,

.u,oou'k'>lIy'"
m"'"

won:.

'rom ...

... ........ ~ oi tho: ""!II<'

hk"h )'OU nlaM'''''
,.. In :oll ""'Ilie. pn:<:ision .pparmos US<:<l ",I'h ",cii
jnCIiII JkUI ;, thc kcy 10 ~t>Ca'S:lI_ In makJng ,1", ty,u,;.

1**,1'1" mll>l

Ix: p=lo;" , LIIy OUl an'" drill aU 'hc:

.., hoIo <'1",'"U), IIdo", ",,jng 'hc: ........ p""c on JI'I<XI

wodc. ~k:c Usc 01 oile Iuoocpb'c ""lui"'" ~nc:s..
b fltml)' . IIXhN 10 Ilie """er. bul .. don.n
h .... mulro to IM """"pic' Kct;II"lI'hc: IUIlla "'I0J;In:
ehI',.'Oft and thc pin< In COtII;Io(.'I witlltlM: ..'<>It ~ Ihf

"., fU"""

.,-u"....job,

r',,. ocm

lhis .!lOt! of I>cpb'" fiII"" tu ~ fixc<l.b.oM:

but tb..., RIQR: ~, 11hInk. In UWl8 it OII a plWIlJI!
1Ollln. ''ou C21\'1 tmk~.
cUi ..,i!h il.5imply!>ta....,
bodl pios mllM bc in COr>\:ICI ,.'ill> IIM: \\I'OIk. lk"pc",Unl
up>n IIM: pin pbttm<.-nl.)"" nlll)! btWn an<! cnd ""y CUI 1
routef,

"''''''III'

IO} i,....:I"'" fA"" Ihe eII<l of IIM: .......t. Stof'""d "'"' like thc.or
ore Ihe Mulf of IIM: "'ulljIC """ a",1\<11 IIM: ftxed.b;uc rout~

Maklng the Baseplate

bdIpon ... rnlIy a okno:: M bu$hi,.. 0'VCt' bol Tlw: bol.
Into. hok In thc pI.,c. 1 klalN tIM: pim 0I11>i<k
tIM: pcrin>C"l"" of IIM: !OUl.... buc:, whk:h f"'O"idcs "'i<k'
~

"'O

ti .... ~ ~",br.; but <Ioc:,.;n 'l le. tW !OUl

dooic ...
c",l. of lh~ wortcpkc", lf )'0" ,.'O", ' 0, rou n" ....1">"
."ion .hc h<>Id clo!icr 10 .IM: 1.11 (M driU :arod "1' ~
~

,h~

p:oits of """"'),

If critlol ..,.., pin ...... m"" bc cDC\I)'

from .hc bit axif. and Ihry m.... hc (>C'<p<'ndJc.

Ac<'U/'Xy
~;>M

ubt tu iho<

J'b'"' MUbtt.

l. CO U~"C1 Ih" hardware fo r 'hc III"., ,"ou ."" !1"1

by ,,"'II t\(Iw.:ls as vins. IIuI I ~ AIIJ\~ bil's pilot :b
p .... d i!(ln; I bc.rit1jj_not 0I0IkI pIn - b pn:try much thc

"

CENTERflND'NG IAUPLATE LAYOUT

for Bosch p'unge rouler

OUII ine of rou Ie, base

.;.;.;.:.:.;.:..:..:.:. .:..:.]~t~l

-i!.:~.:.'..:.:..'.:..:.-.:.:.;..;.;..;.:..;.;.:.=i'i~:.~.~

..........,

Sc:ribe dlamele,. and

lay out pin holes
equldisL1lnt f,om
Ihe eenle,.

---f-f:..--cL-~-----

'

,
,

,.

,
Mouminllscrew holes

-;;--~.;--

3 !Il"

.. ... /
'

Q. . . . . . . . . ~.~;;:;;:
. . . ?:
......:":::
......::::::
......::::J
......='--..,

uy Oul baseplale on 8' square of acrylic.

Ihen !rim 10 Sdia. ci,tle.

Orill ' Jt..dia. hole, and eUllh,ud. fo,

pin boII wlth a W20 tap.

Cutting List
ParI

Qty.

Baseplale

PIN AS5EM81Y DETA'1.

Dimensions

Malerial

\010" )(8' )(8 '

Aerylk

Hoit. tapped

IO'~'::::::':'.:i

Hardware
2 roundhead SlOve bol ... "'20
2 hu nulS.

HU nul _ _ _ _ _ _-

2'

~ 20

2 plastic slee"... , W 1.0.

~.

0.0.

x l' lonll

Plastic sluve
!(' 1.0. X W 0.0. X l ' long

Sland:onJ lh"'" d.)"S. Sa I rn:tde plM wllh ' ,~.., b<-:Iril\jl$;

....'i"l! uddmen.. rrom 'hc local hanJw.1"C SlO"'.
o..y .. ~"(luplc o( ruundh~.. d "O\'e bollS w;,11 nul r....
"""".n.e ..,-.,,; an ~ brun"" b",hi'~ Of 'in,plc pl."lc
'P>Ccr5.lIcl"C an: Ih rcc 01'110=

1'' '>1''

I. U..- a '+lnchI.D. X Y>-iO>Ch-O.D. X Hnd.-Iong

sk<:<.., ilS ,he bc"~ril1jl. . 0.>$1 : .bou, ~'O cefii' each.
2.IJsc '4-In<:h-1.I1 X h-inch-O.ll . X 1.lnch-lon~ h,oro>.<:
I>lI>hl"l!. 0.>$1 . boul $1.20 nch,
3.U..- .. l'rinchI.D. X 'iHnch-O.D. x 1;nch-ionJI brom:"

hushing In<ido: .. Ifo.lndlU). X h .jndl.(), I>. X l ~ndI1onjc

brun"" hu _;hln~ . Co:st: .b",,, S3.W ror .,.....il palr.

2. M.. ke the baseplate. Itdi:t 10 thc eruai>1cr "'11>(:

Gcn<1ic lIa.cptllc

86

UrI p2go::

Rouler MagIC

63 for 'hc dc,aHs ur huw 'o

'W'_-----

!4" 20 X
roundhud SlOve boii

OIIlUNI; SEQUEN(.E

1. StI Ilop blOdl 101lnl' bo,h .,elou of blank. "",h bol

haIoP dirtcrly under Iht drll! brt.

1. Aflt. d,lIlinO ,rammtl.plvot hoit II blthOlt lociUon.

,It.,

movt
,Iohlhlnd stOp block. Inltn il 3'1>"",ldt
Ip;lctr ilQllnst Ihe blilnk. and 'Utl Ihe $IOP block
aoalnlll1.

liIy out hoit, on

xryIlc bli!nk'5

.owlmg piper.

Bil'hcW locillion

1. SIliti blil.nk iIgiIirlII tht righiliop bIoc:k. MId drHllM

In, pin hoit.

4. Rttu,n IIM blan. 10 11111an100 POllIOn. and reui

IIM rIolIt ~IOP. Mov. IIM Itfl ,IOp ind UM IIM lPilCe'

10 'Util!. Sl>lfI IIM bll.n. 10 IIM Itfl. i9illnSI 'M

~Iop. ind drIU IIM second PIn hcW.

Pin hoit

--_.
OI

OD
_

....

00 )'Jur """er .".j nt:.IrI< ,II(, hi'

;, One "r 'h<>sc b:lscp .... 'CIi titlu tu> '" ~<cn'cr
Dd' 00 tii<: bit u.l:i
tlo", il .. InM;dkd. '" "'" n", In
lI!iIIS 0lIl and .JriJUIllI Ihc "",,,mlnll""''''w hoIca. AI Ihe:
... 1inI<.ur 10 oriem the rou'~'" OI() 'he: plotlC ut Il", "",..
<IIs.;o bc par;tlk:I .....n nit;!: of 'h<: $<1 .... '" I);a;;<p.... lt b""'k.
AfIn' )'OU"" m:trl:c<I Ih.: <'CfIler o( Ilte bit "I",nlnll. b"1
lItPw ""'\T bo<o:d !o<'rihc: .Jilrmet"r.... ,h,,"'n In ilIe
~ (\r;N,inI!:.TIlis dio.f1\CItt m.. " hc: p" ... Utl 'o an t<;IjI<'
~ an<! mari< ,IIC pin tonlkN ... M.ke: ""'" tlle pin, an.'
~p"',e

optIIIIII!. ThIs

"'''''1'

TIlmd ntn onro ,loc: boii. bul eIon 'l lam il apinsI 1"" _ _
~. whk:h wouId ~ .hf Iknt fn:>rn ....... In&llunlJ 1"" boii !nro "'" hok. lbm "'" _
un!ll il olrnu><
!leal.>. ,hen Ilghtffl Ihc: nUf >pl~ lloc baxpbtr 'I'lk boii
o/1ou.kI !le 'Ighl. but Ihc: tJtcvc mUOl rQUlC httly

Using the Baseplate

i,.

npdi!WIl from the bit

0tiII an<! cop ,IIC holc:< ro. ,he pin>. Thc: d ..~winll
/lPtItlo $Nf......nr ...... """. jjOOd .....Y " ....lrlU Ihe: 1>0"'- .nd

___ ..... IMy "'" propcrty posI,io;mc,d. 10 cut th",.ds In

usc~h '.ioch20 lap TlIC pU'" 1><,Ic '"r lhj~
lip CItI hc 1"" Inch In dilrmne . 1\0; O:I",md)' CIlft:rul ,,,
~ tbt cop 1"'f'P01\d1c.. lar u )'OU bcKIn 10 " ul 1""
trodo.ThIo il .. he ... )'OU 8'" ,hc: hoic OUl (>/'
Tk ~ Is cod:cd pon. ,,'hkh botchcs 'he 'ccuto(')' ur

* pili boIcs. 1

.I"'"",n'

,,~~

MIM an,cr ot the ""..,pla,e. drilJ It.I""h-di."",'cr

UJ.inll ro"lc' Ind ,.. mmd.
. . "'" _pla'c .n In 1I.!ncIMJ""",.cr c lrde TIlen
. . - .... bit _for tht b'll"Sl hit ,..,.. .... likely In ......
_ilie ba>cpblc

"* lor. 1.. """,,1 piYOl

11", bastplale: ... n bc ""'" .... pl1lllgc.butr: bol<$. ro CU{ mut

lba.and 10 plu,", lI""""'". Tht upc.,il"3 ptioople!;.", 1""
"n", ror .11 .h..,.,
diITn..""", Is In ...1lc:lhcr OI"
"'.. to act ....11y ftt\I ,he n)U' cr b,,, ... IIy, and 1f)'OU do. 00'"
r". lI~",. ho", 10 do II. >lep b}' ..:ep.

dIO""'."'"

I . S":1 up tJ,~ routcr. N.", .. IIy.)'OU ncc<l '" InsuII lhc

ba5<:pl>.le. ScIo "'" bl' )'OU ",:ro 'u u,;c n<! chuek il in Ihe:
""'Icr. Set
plu. >lup.

t""

.tu.

2. LlLy o ul il", cu . M~llICmh<:r

lh" ck>oc,. )'OU
CIU1 rotii 10 Ihe "",,",p1ccc'5 cnd .. aboul 3 \'. 1nchc5. Mari<
lhr hcglnnlng .nd end o( IIoc: dc>Im:I cui. If ,IIC cui I~
.simple hok. nu.rI< i. wilh an 'X'(lamp "'" ........p;t In ..".,., .....,. tiu, p"",idCIi wtoI>>lnoctcd """'""" 10 both"""""",, lha! lloc pins mUSl n:kn:ncc.
j. Makc l1>c cut. Set lhc rou.cr In plK'C.'I'wt.t 1,

}. InsWI Ibc: plru.. SlIp '''''

*",,,,

"""r "'"

hoit.

''''' pili>

ctII1k

OI)

inlo Ilrm contacl wi,h Ihr wodp;t. Align

Ctntt,- F,nd,OO llutpbt.t

17

,Ix bit "'." .... ~31'1 .". .... ""'. S"iod! (In 'hc: ,,"", .... pI. . .
'M hII.. and m:r.kc .... cut.
Troubk4boatfng: If)<>ll <Jioroo>"r ....1 fO'" pI.I'~ ""kq
...,...,', '"' ac.:"r.II" .. )"" wouId Il:....: ~k~'tl. ;lntl ,..,... ('OI
bon'l pcrfcaly ""ntcrnl.)<>II CUI sah"!!" ,IIc "'orI<~. 1'ht
<.U wilIlx ..iI,kr ,tun "'" bit., "'" 1, ,,'m Ix "",,,~ral.
Uit ,..., ""'",. an<! "-"P""llion i, ... pim a", "" "'"
'''PJI'O<'ltc lIiIln .". 'he "'ori;-pktt ,h." 'hc~ "'cA: Ix.."..
omI ute a 5CCQr1d p>...s. Nu .... do.>', .In,ply ""'....... lIr
..u""",,1on In ... hlctl Y"u t""ISlcd the fOOlcr. lf )'tIU do """
,Ix pin, ,,111 n:m.ln On It>e $Omc sidc's"" 'ho::
~OO the bit ", llI stiU bc ofr<cn tct
Uw:.."", ~. s.
,h .. """, ', ""ori<.
, .. "~Al m).,..,lf. )'''' hltvc lu ItKI"C Ilie p..
thq' Iff.
~r<:n<:e ,Hf(cn:nt .i<Io:>"" thc: ",ootp;c:cc in ,..., orcond p-.
,II." tllC)' ilitl io "'" fin;L lluI b :aU It ~ lIuI 10 lU'titf Ib:
prublcm ~ ilie Ioog lam. """'~ )~ ~ """. ~
J"" work a linle mon: can:fully ' hc: >ttOnd timt lky. l "
,n nw.:" miM ...itt. ... _ . fttI 'ou bad if)"" do too.

'0"-.'"

"''''''pira.

t>'"

ed,.

Cot.II eIIU Of! an

clon' I'H!N i kK of "lUp fI(!
dling. Whelhef the (ut Is i hoIe. I monlse. Of i slot. Iht
nnt,, Rndlng ""nplll' w,1I positlon l equld'stant from
lhe ."'StS of Ilie WOf~plKt. Tht tride behind lhi~ magI(
is th.t Ilie posltlonlng plns il~htd 10 Ihe I>oseplil. ;1.,.
lhemHlW!s equldisl.nl'rom Ihe bil uls.
CUT 5CHU4I11TIC
Twlsl ,OUlet '"IIOTH p,ns
conli>Ct workpIK . HoId plns
Rrmly ~ lnSI tlle workpiece
as vou fHd Ihe .out., Ind
mite Ilie CUI.

!4 w,d. Cut 1 quldlsUl'"

I,om Ilie workp'.,,s edges.

'.

.'

......../ ...

'.
""

Doweling Jig
&ori"g dowel joinery

be il fulfilling
uperience. Use your plunge router with
dlis prtc:ision jlg. The jig m;aku it hud
1;....

tel 110 Wfong .

..._.
O

"."
O

join~ory """ """ of thc tl'unp IIricd cutr in

my ,,"Ol>(h<.ul'ki"l' cq><,It"Ct:. Wh,.. I bad ..~ cal'
pe"'1)' ,00I:I: but r W3:i m:akln& a ,,,,,,;'y,and I ..."",cd
1/ t:*' Ihe "'II> ~1l<J >tilc> '" a bec .... " .. l)(;no'd joWll5
_ _ h~~ Ilie ""y 1<1,11(> for mc-Iu>t buy a """"'1irlII1ill
IOd IIK Ihe pon:ahl<: UrlJI ~nd .wbt hit.; 1 aIrn", ~ .
......1. dI",ppolnl",~nlt M.)'IK It _
mc nd ",,",'bc It
...,,"" j8. bul I fl(V<"r <lld 1\l.>SIcr uuwd ,,~ncry ",i'lI driU
001. oo..'rlinjl. jis_ It 1"'" nev<:. wor1<cd for "'" 'bc W2J' I
6o:qbI ~ 5/l<.MJkl. n.c, looIQ In IIM: r~U) IU(iI woukl ,..,...,.
_ ... .,.'1111 ,h~ hoIa In IlIc SI"es,"hcy'd bc. bl! 100 far

'"" 01"100 dooIc 1<'>fI!l.~iu:'r. And Ilg o .. "''', "I~I """ of lh<c
k*> fI'(IUId bc cocl<cd .
To.mty)ftf'!l Ia.er. I'm ""01jC plun)IC roti'e< w'1I mr
ti doo<",UIIfj. rl~ ...'lth far l>c1.cr n:>l'ltS. "(ieu bil o(
...... J an kn<JCk ou. whok: oei' '" oow<:I'loh"cd ro

*'

....". willI aii ,1 ... _

.....-..u, fIOMIlOocd.

21i~Oi<IU:O"' OO fl"n~ly.nd

le:m,,"'"

",. trick II
Iha, h .. &<:"" .... 1 hol", bored
...'""'..-ori<pkttJ ...... cbmped t>enc:uh IIM:: .emp''' ''.
. . UIt I plu"jIf' routcr flun! wltll [tukk ""'.hlng In
.... _"Ci hok>. An adi_abi.. wonpi .. "OI'
cach ~piccC' ... m Ix cL.m~ in ,ho: ",..n"
,...... a.>d ,o:mp"'" odjUSl<:" help )'OU (jnoN .."" , hC'
.,..,....... 'hC' 1toIo.", dnd-anl'" on ,hC' wor1Ipkce.
1')'011""' main8' tlldil10nal fr.unC' ...ilh r2i15.....;1 Stib.

_,ha,

,I>c: StiItf ..., damjK<l hori>:ontalJy bmc h .ho.' ,crnp1.",,; 'hc

l3iIo. ,....,1aIIy A '''I!8k damp ....1<0 w""'pIce .. dlalljl<'Q\-u
fo!C md

nJf.,..,. II. hokIs .hC' work

a paei

,Iu, nuI<a k

"C'I')' 0"\11'<"1),

.0

~.o

An 1........ww: lOt"", ",.hb Ji;g. ....","ioo.I'II by frnl

M.a'bd< '" RocWc:. l)c::sjpl Sbop. S .b'" ;odjuoublc: WU<i:.
piftt "op 1 """"\ono:d. YOll """'" It {rom ono: <:nil '" II><
JiR 'O ,...,
~ upon ...11Idl mii '" (ram ..
""""bC'r b bdfI8 " ...... mQnc" adjllMN br. job. )'OI' .... kc
...... oi ,hC' 5:ImC 5cI,inI!; a' both p06IOfIS.
"Thc: lis is not InfUlitdy \'aI"iIbIc:. "Thc: , ..... pIa.<: tu. fow"
""""Ir >pacnI hoIes. II )'OU al'<" ~ I \ :.-Inch-..-i<kbr eumpk. you wouId ....,
01 ,..., hok:!I. Ind

"'bn.

..odr..

"''O
xcommocl:I'"

)'OU, <lQ..,'d hok$ ..'OUId br: 1'. ind! "pu'I (CCft'<:~"").

I{."" ~ .. odI ............ :and an
.hI'C"C'
hok::i on .hC' I'..u.rn cnu.....w-cm,,,,. ~. Ihcn t......,J ......

,hm: oi" ,..., ',-"IOpIlo'" "'*'<. and J<) ono

,."0,'' ' ' ' '

Ru. "'" Ps an:and m .... Ix ,unnj

A h!teh wltll ati)' "'""" cJoooodIltI! liII b tiu. )'OII an',
ofiC'm III<' wor1<pIcco J<) ,"" oamc btt '" nch ]o IpruI
,Iw: jis. It r.... pIatt .Iw: .m~ fa<:C' '" .I>c: Mila! In
(ag>.1ru.t .ho: Jig), ,1"", ,II" ...,,-., ......... fatt '" tIIC' raU. ....... Ix
OI".'"lm .lu",
y It
Ilg m.... bc adj'l>Iahk In

,hc: ......

->

l bc elamp . .

"'Iti ohe '-ilImp.

posIion 10 accommoda' .. cIIIkn:n, oi>:<:o '" workpit>.

II;

".s...hc:

,'lIC" ......y .h.. 'h" dowd holn Cln bc pIa<:c\l prttbdy.

ArMl ' hls IIjj 1< ,1"" .dl..... bIe:

DOWEUN(; J I(; EXPt.ODED VIEW

F ac~

Q/

.-...,o
C

-:t

Q/

1bc u.-rnpLale <-.an 1><: ohi/icd In .......... un '1 ... 11....1)'. ond
LrroRlft:Jlrd,_ 1nIInI'c$n;al ~
_
Q/Iho: ''''''f'ble.TM .wnr li uu.. Q/Ihc wortpi1: >1"1'.
..1II<h .. ..,ro ro """,Ion II><: ~ It b ~
MII"",....
~ adjU>tctS all"w

".:n:w

Making the Jig

1bc do",ell"l.l lItc Is " n'lx......nedi. anlion 1 w.aJ piulic
..... ..,.=1 of Ilte p"m.n.c dcar pI ....ic w.cd ~ ... 'he ,."...
pb.e lct6 )'OU SIX .Il<' wort, whI<:h .... ke< "",up muci!
c:as;cr; llIc pb>tic <MljU>ter pble< OII loc thtcaded. >O yuu

dan', ~"IO fl<kllc wi.lt1'nu15 OI' Imcm.

0."",11. 1 .hink lhe phscic ~ It 1. ,hc rillh' >tuff Ibr
,his appli<;:o'lon. antl 1, lt>uIl5 oIid:. ~bu nil ...'Ori< . he .. uIT
wltll YUU' WUO(I"''''1''''1I tool< n ....ppcndllt ha> """",...1
Informatlon <>fi buylng an<! """"'In thc pb>Ilco ti"" an:
...it:tblo: ..... 'hl~ jlll.

1. Makoc .h" bod y. r

""Ulli

madc thc jljc bOOy by I. n,~

,'"' O 12)""" o( \ ..Inclt 11,11,;,: 1lin.1l p ll'....ood. ",hlell

odd .. p'O a IhlclmcM j ......nda I ~, ~.''hl. nu.k""

unl. """'" .t.bIe .... n If I hali ....:d a doi .......,., ..........

ami J!.1\lcl.ml"'ll~ pl)'WOOd lOr ilie: f.uc. 11_.
'op . hen ttim 'Item 10 the ~ )MXifi ..... br
CUtlinlt 1.bI
Gl"" up th~ p.n:l. as Indic:oted br thr EnJ I1I'W 0/
f'Ia .. l'fat" dr;twlflll;>' Chcck thc: ..-mbly ~1)':tS
damp i' 10 cnsurtc
it i:s ~..an:. Mi.,.. thc: [41""
"""""''' thc: damps an<! """""" oIl' ""Y "'I1>tt".t.N>Ut
,...., cn<b:. an<! .and ' he top omoodt and
to tI><
Uy ou. ""d roUl tll<' dMIoc5 ...... he """"'pic
...,... Itlc:oIIy. yuu .h"ukl do 'ltb un a .......:r ,.bk. but
.< .... Cu.

,tu,

"'1""'"

caii ...., l't)U,e. rqulppc<l 1'1'1,11 ... edftr II~ You n<I
"op 'o bc rquklblant {rom thc: ttntc:r o( tll<' ~g. "'II"
of...nld1 md 1. Is Ofl. "" yuu mlbt poNtlon thr dod"",
cmun: .IIM It ,,mIx.

.inalIy. I:ry

OU' and drill ,"'" _

lOr mount.in8

wtXtpkttolOp .mltl",.~ d.mp. Doa kw p",lIm

hoIo ......... hen :adtJ Olite.... dict:ued br .hr ...
.ions lha. """'" up.

DOWlUH(; JI(; PLAN VIEWS

1'------;

' . . / Tomplate adJuSter

'-1

~.I==:=;:::::;;;::====;i=~
,l

,-

h" dear aerylk:

FROHTVlfW

.O

ENOV1EW

,,-

:E

--."
O

o o

o'-o--JJc

"

T09!II~

...-

Qty. Dimension5

x 9" x 16"
x 3" x 16'

IW

"",

-.tinO ~d

IW

<"-mp 0..5Ia<0 ,tTC22HI

&altle: Bireh plywood

x 6" x 16"

Jqo>lff pilit

Il" x

2~'

li" x

1~'x8lo1'

,.,Iy<Q""".", OM

'Ao)ol/<.
IM ojOll/k.t"",

Baltic: Blrel'l plywood

H.rdwood

M' x 1W" 211" hlti< lire" plywood

Il'

~te

Hardware
Material

1" x 211" x]"

!""!)LItt

Stop

...

H~

Cutting Ust

'

..

x 16"

C~a'

i>CryllC

PI.ostl<"

Threaeled rod.

1 tiu nUl .

x IZ"

~"20

1 pb.,II, knobs, W dia. with \(,"20 In,en; Ilem

,tOK 42I,om Reld Tool Supply Co. (800'253~21)
3 compresslon sprlngs, \(,"1.0.)( !"Ion;

8 oanl'lud scre"',. _6 x)"

1 carriage botu. W-20 X ]"
2 flal wasll"" iii" 1.0.
2

.... ." ...., _ {M

~"20

wl~

nUIS. \(,"'20

TO'l!jI. 'tamp, DtSta'Co ITC22SU

4 panhud se,",,,,,, _8 X j(,"

TUIPLATl LAYOUT

"._ - - - - - - - - - ,

,.

Mounting se.t"
slot; lIt.m1"
Idjullmtnt of
Itmpl." ~~

IT:
1 4~. 4'

,.

..-t
C

-.
~
C

........

.. .
._......._...:._.. :':::::000
. .

L:~I~~'"~.,.,.~~~~[r
.. .

2. Cui and by oul ltIe tempble. Clnr X'lYIC il;

tlle be>t nut<:rtll for <he lemplal~. ' ''''' "'" """ l/>roudllt
'o llelp l""'ncl( alipi aMp;cca. YOlO ~ nch ..itP'I.........
Ur>eS n it "ith .. se",.d! aw1 ot a LIIili.y blIfr And M Ioab
$Iwp. ldnd:a ltJ&IH'"<:h CUI Ilie le",pbl~ bIanIc 10 si.., an Ilie
ubk ",,'"
~ 0101 Ilie Iu>es~" in tlle n",',,",I~ ~ d"'''''l1lI
right on tlle nuskbtg popct .... t proICCU Ihor ocryIic.
Prtti>ion
l. ,itai..11lr allwunmt line and ItIc <:allcrtinc
mUSl hc p"".UC'l. lhc cro6Slulrl
'M 1>010:> n 'cnJy spoo.'1I<I.
'M,h .. S<'r.Itch . "', or ",m'r knlfc. LICUr<: dlC ~ roIlln$!
riglll .hruugh Ihe n,Nlnjl. ""per .n<! etchllll IIM: pl.:Lstic.

""r<:

ro.

AIso nu", tIM: Ioc;LtiOn:l oI ' M mountlnjl.""'~ """",

U".5 .Iched '''10 Ih. l.mpl. l. hllp yOU .~, up Ind

uoe IIM J;.g. lIKlus. I""y li' KO~ In.o 1"" su.f"t.
t.1\nl!le wom 0' Kufftd otl. USI. sou....nd.
ullllty kn ife 10 K.ibe .IM IIMI. II lhown. cUltlng rlght
hrough tIM pro!ltClM! mUk'ng ~ptr.

t"'"

_ _ _ __ _ _~.::::~ce"tt'I''''''
of Itmplllt hoIn

Unt. Kortd Into ICrylk

3 . Ron: Ihc: tK>ks. Set up ,..,... driU

.hJ.

rmo

fencc .0 dn th.., and ~c .tIc Iimc 10 "'"

fint hok
t'olt' ~ _
Ihor bit bffltr; bortn8 It.

To msute ttw Ilie

>paCe'" MiU. Jlri!> oi ~ Jlock.
.hltt pleca. Uno: up thc .~.e

aviIuC .hc:

'

rmce. B"" 1"" thIft

".

bIanIc .....". o.g>lnM ti",

Re.....,.,. anothcr >p;><:eI'. """

Ihor Ihln! hoIe Itcm<ft'c thc ,..., >JI"Ctt. ano! sliock thc
...."'" ..pin>< ttlc ",up bIud<. l>riIl the l)unh hoIe.

80rln, th. I~mplll~ holn should be done On .itt

d.ill prIn, usi", il feoci Ind snetr blocks 10 tUm~
nl'e v,,'ablts ," pl.ctment of tlte holu. Tlte fenee
InSu"S tltil IUtite holu wlll bl an equJI dlst~nCt
lrom Ilte lempelate td,e. Tlte block . un in I.ont.
PO.itton tlte template in "I.dcn
tit. stop block .

'o

.o.ojUSTER DETAILS
IDIPlATE AOjUST(R PlATI

,.

....(oile

OIi. 'ko6I,. hok , ne! I'p for \01;"20 tll. ud .

\.

- ,. -

"~o.

...

r ....

Olill moullung 'Klliw "<>Ie I .

".

AOJIlIST AII.( WORKPlK E STOI'

AOjU5TER AS5Et.18LV (typ.)

Ofin '14.0.-<1.... hok. ' nd

liP for \01; 20 III.tad.

....
~.

ml>UnulIgboh

]J.
,. t-O

0 .1 11 mountlng.
K'~W holu.

0+-,

...

."

1" h..dwood

_....

... Ibt Sk>Ilcd I~IOI '''mpl.", "" 1"'8" .. 10 !ou' 'IM:

10 d!tso "p ,ne ~l'f'Cl'r~11CI: o( Ihc ,.. mp""". "",n,fe.

.. !barp ~ Qr1 'hc ro",,,", lIbk. nw.1l ...., ablnct
...... to mno<I" ...... m ...... ForWJr. fbmc.poIi>h Ih"""
..... 'IiIlbcy MI""

4. Mm tJ>t. ..q1lS1er plai", Any n"""""of dI""",nl

acNb ao bc ......J lOr ilie adju>Ia plai" "rnaIC"riaIlIw
... an CUI Ihrn\J!. nto ils beii. ,,'hidl mnno yuu C2J1 ~
'1Irinr ~ pLw:b Of mtt2b. If )'OU ...., ""'" comfon~bIt
""" .."01)(1, ."... <h~ 1mcrU. 1 ......J ~ phmoIlc
(.uI tlt" 1'1.>1" 10 :li4". and br oul Ihc ....... mlna hokI
.-1 thr boIcs fur 'h .. ~dl"'lcrs. as """"'n In ,1Ie dl"2Wintc
htpI<oIr ~II'. lIorc 'hc lIoIcr.
"ni> "'" JdjU>la hale!; """'1 .1"11<: [m ......",.,. l_ <kuilcd in
.. _
"Culling Th"",dsln It..: ~r>[1Cndj" .
ro...nu.tt ilie .ppeat2J>C<: o( ,1.., ~It , If )"uu won, II ,,,
.... ~. ddmfcr ,1Ic ~ JIbI m<>lIfIh 10 ... fle" IMir
""bine! ....... p...- 10 """"'" ..,.. ""'",5.

..,..,...t:ot

S. M2U tJ>t. ,,"Orkplecc SlOP. 111'-' il ......,00 ",,<1

~""""""'lh3Il> boIlcd 10 It..: liJI body ~ mUillJl
bf dIrdina out 1"" byoul dr...Inr.. Cui 1"" pbsIk plat ..

1""

ot>d
1wU......,oo bkw:::k 10 Ihc di~ spc:c:on..d by Ihc
ColII"" Ust.
Lar out antl drill ilie _
In rlw:tto pulS.1k adJU>I,,",
hale In ilie pIale
bc t:appc:d 1O'/Ih 14-;ncft.20 lhrcad .
"lIuJr Ihc cdga of Ihc WJP pIa'". ''' 1"'" did ilie ~ of
'hc 'cmllll'c ot>d ,1Ie adlU'l.a pilIt, br ~ .....
cdp ot>d ocr.IpIng oIf 5;lw nwb.
Sc,", Ih .. stop p llic 10 Ihe "'OJI IJIoc:k.

Dt"'"

6. "-"-""tnblc ti ... Ils- Thb b Wst=1J" m:lUa of

.O\"'inlllIIe , ..........
ot>d ~1>I1c!! 10 Ihc ii!! body.
Mount ilie IO'I1pl:.. c ot>d adjUSlcr pL>lt On 'hc li~ body
..-;,n pallhatl ~ 1nluU ,t>c worI<pio:o::
f.~
by fiui"ll ilie ...... pIa,t In,o ilie d:ulo. lhcn boIlIlJIlh., stop
bod)' ' o 'hc PIlI body. (IlIt ..op mU>l bc: ......""" 2nd ",,,,,,,w
olt"": yuu ....... 10 Uk a "'""- "III OI" o ..UIIdrtl pb>tlt
knolllMl<:Od 010" .. ..., k doQn'l tatr ........,.,m 10 mounl
.nd di.>n1OWl1 II.)
No'" "",ke up 1..... odjllMe. ocrn.""5. Cut \hn't: pic>. of
14-1.-.;h 'hrndcd rod. 1"-0 ,lui. ..-.: 2', ir>dIcI ..... lOr tlle
'''OIpt:ue ><Ij..,;I .. ..,. """ ,h .. ilo ~ h lnchc:!I ..... lOr ilie ...-ortr.
pic .. o[> ><I1,,"cr. U.....cry!-m>lI fi1c. li" 2n o"lfC"bil
rtk:. '0 ",n""'C hum rrom Ihe Cut cr\<I:j of,hc th~.l\Im
a hC1! " '" and pt."ic I<.nob 011'0 01"1<: eoo o( nclt rod. !In!

""ru

"'''1' ,,, ,.....

Oo,,"e l,ng jlg

93

TOG&lE

CLA~P ~OUNTIHG ~AO

LAYOlTT

I'iloU ro< tovgle (timp

mounU"II sc:reW5 ~~ff

".
,

.-....,

..

". plywood - -

OI

,..

"'" knob, .lM:n lam .h~ nUL '1P' 1n>l Il \'ft'}" lshlly 10 kcq> il
W>tlu'c:>dinr.,
JI\SblI thco;~:an<I "'rmon >fIrinp ""'" mk-0I .1M:
~ b lO keo>p IIM: """"". r",m nmlln, nu. ,>fllle 1""'d",.. )'OU >CI_\ 1>iI ,he
>lor.: aod ~ 'hf\loLl&h "'"
..,..,.,...",,, 01 com~ .pri l1jlO "" 1~ )'OU IInd :i M)ir
.h:i.'~ IIM: c:om:c:I In>kk dbme"_', ,IM: C<l<nx, kn,gLh, _
>fi
ar.p.."pri.'c >liff_

C rrom

-il
OI

Iunl"'.""

.0.

7 . Mounl the ,oggIe d aJ'lp, A$ fI{)I<:d, thc '<#k

damp ;, Oludltd
plod. .. hIdl 1. In LUm I>ol'<:d <O oM ~ .
TIII> ........ ljII<fI.".lL _ . " ... <O "],in Ihe 10AAk' cbmp pooilJ011 mon: o:<ISily Wn if 1 lud <O .... i.hdto.,, :ind d ,h.., lOwMO""'inS .."..,..,.". I ...ro lk-S",-eo cbmp-thc _
1
IIUllokr .. In thc 1bRtw:ttc lliI-... ILh :i
01.""", 2
10 21'> inc:hcs.1b mc. ICIdl ... 1M: disunc~ from.he cbm,,'.
rtIOUII'UIg f1angr.o oM cnd 0I,IM: b.:IrlO ... lIlm IIM: opIlkIk

...,...od1.

l5 :i1 tac11ftl " ... don', ...":UIt.o 1I!C,00 ~m.lI" domp, 1f)'OU
do"'" ..idc: (........,.. LI>(" " IatjIo:r o;tamp. and ohm IIM: k.ln.Ions oIthc in>cruo.., IIM: damp <Ioon'l m llflkl ,,I.h 1....
lcnl]ltile
1.)'00' d .. wInJt
CUI 'hc '-'10 thc tIupc """"'n In
Ck. n up IIM: cdjto.. .s.:...,... .he damp '0 .he pod . hen
nK)unl 'he.OIIIIk OII ,IM:,..

'"e

TIlc liS! J. ""act).

ro..

J<)R1oe

Th. 1""111. dlmp 1, ulr 10 poslllon .. MI rtpo.

lIuon lH!uuse II 15 screwed 10. 5..... 11 pood lhal ~
~P,""Le rrom .ht jlg. Cltcll tlle pood~ mountln\l .Iot
on .. elIrrlaOt boli Insened Ihrouo" lht :l.pproprl.llit
hoit. In tllt )10 bodV. then tigllltn tlle wlng "'" to
!Kurt Iht cI:l.mp. Orltnt lM c~mp $O IlS spiMiIt
"p~lts prtssurt dlre<:tlV on Iht worI<pit<:t, just IH!Iow
IIIt Itmpl .. lt MlltS.

1. Set up Ihc JIg. Clamp IL 10thc ......... bmdt 10~.

Noa !Ict Ilte IC1Ilpl.ue. l<x<:n III( >CI '""'"'-o AIqcp III<
o:td>o:d ~"" Olt ,empl.' ... ,,'JIII IIM: b ....... 01 jIJI. Lhm
1'CIi&hL<'I1 IIK:
Sel the ... ju ........ lIpln>t tIM: C<JsI: vi
.1Ie .cmpLue.
\ Ioun, thc 1"IijIk Cl.",p """1. Thc",', onc fI'l"/LD
lhan ",1iI2hk~ .. l'IoLh .. li ",181110, fI""'idnI Ih<"y "",,'1
100 ..idc:. lf f'ltl . ,., Wt>I"kJ"tI job ,,"11 f......., mnnlIn> tIuI
'"'" } lnchd wklor, )'Qtl wlll probIbIy h;.,... 10 .....i lrn III<
touk d,mp />;ock.nd ~l rl h hct"'t'CI12 puo;.ion 'lui , , _
for ,1Ie ,.ik:f:ind ono: 1Il0l' ..'orl<s for ,he ..u..(1'Iw: ....iu:toin(!
il M111ctomc during ."" CU,", bul ""'" .....-hen )'OU "'"

li'''''''''.

thc ""'u:Jl job,)

FinalIy. mowtt lt... worI<ple stop.

dowelmg,

2. Set up the router. 1& jit:;s ~ 'o bc UJrd

Using the Jig

Tlle IiM I.n' . difllcult ' o 1I!C.1>uL i. rruy ,.ke hit of tim.10 tun" ,"" OiCt .. p,QPIIJ1r Lhc: r".,.. . lm~)'Ou o"" It. 801
lf)'Ou" "" do"'d inS:l. bolch o(bec r.. InClo, tlle.pd :ind
:iceu .."1 "'ilh " 'hieh j"OU nil plunllC"bO"" ,h" dO"'el
hoks m.k~'S this c .... """1' ti_ a ",0n.1I " 1I11,, In"''''' I'
men,. lf )'0" u... Ilie J13 prlnurilr for \4.incll >lock, alld If
)'O" worl< ,..;,11 COIU" ... n'lr lhl(I<no:Mo:d m.." . I.1. ,tocn
~ ,he IIB 1 ...,' up, ''''' adl"""""'1 rrom ~Ih 1" )<Ib wlll
"" n.lnln,.1

....ith. h-Inch """pI:i'~ tLuKk, ... in",.11 tll,n tLukIr I>u:>hlni

on thc l'OlI'et". Sclc<:t It... co ~ blI Jiu for thc den"el> )'OII
"'" ~ ond elIUd: it In thc rolle, .

A...llp,cl thc: plO"ll" ""pl h.11, .... 1111>, cbmp ~ 0C"'f'

In .hc II!;, ~ thc I'OlIIU on .he Iil!, :ind bouQnt Ihc: biL
:lfI;linsI ..... """p Orop ''''' &rop nxI omo ,IM: '''ITCL, d~"
..1,.., II <Il ..."""" cqualL<> tIM: tkpIII of.1M: "'...'d hok l"'"
.... nI ' o bo:Jn, .... ' J'pk:&I ""plh 1> 1 ll'l(h ,

'Ql' """"".

3. Makc
y"" necd <O ,..url< .... ;.11 OCT:a[l> vi
'he "",u;oI .............. -Mod:. 01 C~ nd )'OU m .... m:C'

on llnI .....,_

joiJIl JO ,.,.. <2n a" albit I ;uId l<"2hu1c thr

'O . . . of IM p>ru:.
Uf OUl II.., 1"" pics ~nd ....1\ ..''''"''' thr ' ni!' inI.".
iim 1"" ' 5I,Ie' IIc2ri"ll In .....,.. 'M Icmpbl,,'. hoIc
~L>y0\ll 'hc dowd po$k1onJ on
piQ Fb\;Il/y.
MI< III<' ",re",n.,., rau of boIh pIt<u (u.., ..,~ I!o
ln'Ilhr 0I>r Ih.I '5 UP")'OO' "'y ""1 LI.., ,,*,1),
Cbmp II.., LeM ' Mile' In I hc ~ori"mlnlll"""'~
lKt OOIl:o\li&II thc Iryoo' "",010: ....lt h ,"" U..... nchro Imo
.. ......., Thm opin IiM: ......tI....'" 8Iljuot"" ..... U 10
~- 1aL> ~ lhc nil!
' M l ot pica

""ti.

<.,

Xl W

!'OUl ... on

minorfInNlIftIng "ilt hI: _

1""

..,"iCon

- Il thr hoIar '"'" doocf 10 thr

txt, llv lnIIo
pbc.. ~ 'o hc pooIwd 1dI:,
If lhty '"'" doIn" 'o ,Iv ldI: (;on,. 1hc ICDIplalf .... UM hc
puoho<d ro...-.nI,

""')'OU ..

':'."~':"::.:.:-~....: and C\'lIlIuat" Iht Ir'fl, jolnL .....,..

jllur. 0I ClIU<"C.'- 1nlo thr lot ........ _ ,.,..,mbIr
oIbolh ...,.,. ~ hc up,
~ thr joiJIl, /U'f ,,,,,-, '"""" Ouoh1 Do thc a!6O.-d
~ ....... n:. ....-bct1ll Il ...'tft.'. compl<1e bec ll'2mt,
.oLlotr ......... "'OUkl'hal ba: rn...., "" /laI>/U'f thr "'..
lKt
IIlNl!gnNI /U'f Ihc nIItc> propaty aIignc'(ll

7k ~ _111... wp,' l ltc woricpic MOJI ....... hc

adjIJ ..n!1n

...,. ,m,,,,,..., ,.,."

"*"

" f1nc.IUnc lhe JIa M.'tup. Oi' """""'-'. 11' thr

"""', ... Ihlo llr5I u.,., P'" JUUf'Odf on thr had; anii . ,
" ... Ihrml .. ortp;c(Q ~ """"' m..lil<dr;apc:d.dI)'

OI' OUl.

If thc cdF oi thr r.>II ~ ,hc moi 01 thr M", ,hr

odjtbIc .."...... """" hc "-"fI\CIN,
Il Ilie >IJlco <Wrrlu"8' Ihc r.tdI. 'hc ad/U5I'" ~ _
hc "",,"'''''N,

runc.

.u "'"

"""1_,

,"" l""'pIrI'" " 'lIh ." 8'~ hushltl(lia

_ellbr ltoIo. PI~ IM """'-'. ~ ..... " ,"" f'OlMC1' 10

.. ~ Idr, >nd plWIfII'-"bo'" ~ hok ~p 1011'\8 unt~ aii
ill hc h<>rillll an: donC'
""","';'d! teg p;.:.;c:J,l l1l, . 1..." , oric:m Ih" ,de",,,,,,,
IKt. IM' \M cnd 0I111c ICIi! ' nllI ' IKjUil"'I)' .gainot tlle
......" ~ lIIdr Il Icft un'il ll ~""'L""'~ lhc "op,CWllP II,
... dor JIo6n"

,l'oll aur

ha"" ,,, ......... IIM: ''''''ploI'' in OI' IlOII, OI' adjUII tM ..m ,
pion: "op ''011 nun 'hco<' adjuMmmu buc'd ''" r anaty,it 01 IIM: JoIn. ~t In trlIlion
""'y In
..-tridt Ihc pati, "''tft.' cb./IIpN In
IIg.
n.. "'"' Il,.. . . .-...t,' n.., I"n.plale 15 I."OCk<'CI SIIKIy
'hc hoIar In 11Ie."SI pittn. tJelcmlinc ....1Ii<.il <>ne l. olt ilie
anii od;u.t 'hc appropri1,e cnd oi 'hI: 'cn'I''''lf
n.. fi-s _ 1 JI- 'Ibu ncftI 10 ....,..., 'h<' cnU",
.~ in 00' OUL lo<* Ilw 'eM pio .. tMy .. 'tft.'
dampnlln IM JC.

,II.

".nI

''''''paie

Iknu,"" ...f

.'"

dn.Iil'\8 ,,'lIh lwo .."""~, ,1..,

lm~,

01 ach ' C'D'IpQle """"""'-'1 ...;U bc.' ....... "Ied, TIIu'!

In _
lIi'UiI'I(Jf\< ,"U "";11 " .. n I It) mO\'c tIIc ,empl~,,, ~
""'''' frx'Ilun 0I2111ndo, ..'bIdt lnruJ.al<:> In LO' """'" lnoe-

,rI. 'UnI

,Ion
"1,h ,hI: lO-tJunob..,.....lndt (l!>l adIU.IC ....
q ..................'iI! - . .... Ihc tip
Inch
n.., ""_ .. truc oi Ilw """""pic .op \'"Y ,;mall
odi...cmca~ 01 thc",-"",,, aiI)idd .... tiIIc .... ..tw/b 01 'hr

01,,,,,..,..,... ...

....,-..

6 , Rou. thc do....,1 hokIIln Ihc WOt'iIp~ lbu

<:an MIow " 'ha,"",, /IIlIIM '" _
productM.' III' <'<Jmr
fo .. ~,*
~ 'hc dr........ I>oo.>rllltff!iftw~ A.
,he Ilie """" b 0Cl up. rou '-"'II " " ' " 'hc ....'d hoko In.....,
cnd of nc.il ,,!lor >nd ~ I r 'fu do Ihr OIIIn molo, S'IOitdllhc
"''O<'I<pktt _op ' 0 thr OI"'" poMIlOR ~ 01 oo1torft
Ihc "m,*"" !otOp 10 pooItiOl'M'd. ,toc ....., _ orknIcd ......
b",,,,~1Iy ..ilh Ihcir """"""'" ~ OUl, IIM: raih \'C1tkaIy

ro.. ,.....,

..'hit

,Iod. """""""'".,." In

""'cr

tIR, lIId Ilie comp.uslon IP""'91 kHP Ilie Krellll's

even wlli!n lhe roult. Vlbflles Ihl Ji9,

""""9.

..-...
:E

AII "j,1;>tr (WQt ..,' I)n! .... "h 1"" problcm5 OrI<:
,i"", O
Sq ...", Ihc lempl.le ti .... , I"C" 11'-" II adlLlSlnl In ." "'"', ; '
F1NIIy. odjtbIlhc wuriirk"-'<-' 'Iop
tD
Tu adj"" thc ,cmp"'e. )"" mLLOl finl Ioooicn IM .,
""""'WIfI "-"""'" 01 """"'" Tu """,'(' il. bad, l "" Il00(1< '<
boIh ~"'" -'3)' rrom Ihc r<W 0I1hc.' tnnpbIc .. cqual
_
, ' bm puth IhI: ,cmplate: ldI: ~ ,hMl, 11>
"""'"' I font,'atd. )'OII
hulh ~cn l<> 'heT pn.<h

........ Ilw

. . . tll .... 1'" ' .... pl." poeIlllon Il usy w!th thfl4,
"""' adjuUlrs, Thf!o JJI;IsUc knobs ~ .oIY Of! tM Iln'

cO

:rJI Ihc """'5 al 'hc endo of tM ......tpKca ~

ltoc ....""pIc<\" Mop"")'011 <2n <10
.hc mi oIlhc !<>Ina Th<:>c have la "" aUtpICd WIdn' IIM:
.......,. ,..... <:an "'1tIOW'

,em pLale h<~o bre)'c 11"1 If Ihe La).....1 m."'Jon Ilie "m
pia:o .", I>C(Ul'>le , )'OU ohouldn 1 I\;&,'C "Il)' diflkulty

aowtling jog

95

DOWEL ING stQUENCE

./OintAO I

- Stllt C

Stllf A

./OInt CI

.
......
-

>'1lT'''''':''''''--

OI

Stolel
for jolnu AO Ind CB
510p on Ilie left
Rtft~nee face OUT

FUI .... orkpiec. h"'ndUng III mi,/or benefir of lire

roul" dOINeling jig. A raills pcHllloned vertlcally. OI)
the holes eln be bored Inlo Ihe end It Is IJ'9ned by
squlflng Ihe bUII encl agll",r rh, under.lde oltlle
lemplat then sUd Ing il &l}IIln" the .... "'kplece .top.
T'" IC9IIlt e~mp Snljli horne 10 hold 11 In p"ce.

OI

it

O
Q

StUtS
lor jolnU AB and CD
5top On right
Rtferenu face OUT

A 11. b , pos l.loned hOt"I.r.o"urlly benn"' .....

template. Wh,Jt Ihe elamp wlll "cure mosi sud!

very long sUI mlV ~ a tempJllt
IlMIge, tO suppO rt Ihem. 1. shown he't. AII vov nttd
1. il thln block cllmlMd 10 Ihe jlg bodV. where II ....111
.uppon t .... wo,kpltce wlthout Interfnlng wlt1"l
wO<l<pIt(:e neN"",t.
wOfkpl~e

Raii,
for jOin!s AD Ind CI
Stop on tlle leit
Referenu face IN

bils
for jo,nt, AB and CO
StOP on Ihe rlghr
Referenu lace IN

96

Routtr MIg ic

NOI .very do ..... 1 joi". 1. iti Iht end of 1.... "Ime

member. To ba .... Ihose dowel holts, VOV have.o
"mov, the .... o'kplece .rop Ind ""Ign ..... workplect
unde. rhe tem pilit holu u.lng IIV""t ma,h Ind Iht
liMs tlched In Ilie template. Tlle logglt e~mp Cln bt
rtpcHitioned II INr helps hole! tlle wO'kpleet.

Dowelnis simple, shop-m.de

.~r.lltus . de ftly 1"."
lIy il rouler ma gicia n

)"<HIn. turns

squ a", blank5

tnla round s . Yu, il's ,. tfiek ,

IMII ;"'.iI ,.ick ,."11 [iln

".rl'.,

<\

:~;,;""~;n~.~:,~,. .
:;::i~i:~,
It.,

11 th il
g!zmu?
1oQuM<:
~Ick
In,o

ou. ,""

hooIt in ,. Wb!:1I
COfIInI
Md hq1 .. .. noi a r:.ocy...rnltl.1.l1Cf
ltJd: <:1 ~ pWtJc OI" Dollc 8;l/tic 8irdl rll........:xl.
t"o ~ >II onJina<y tunt .."OOd bIod.
So ..tu. d!(, (2JI il 1)0:, _ ..,....., of lhal rouIn" .... gIcl
OII, I I<wt Ihn flxtu"" jUOl bc<::o ...... il /f SO oIm ..... SO
prxIIaI..o dh"tlvc le i> wtw ~ ~ A ..... pk- pk'<:r <il
war>!us, dd\1y ~puL1lo:d bf practIccd maJdebn 10
~..,
~IU>ion. And )-nh. It OI a
! 'm
~ 10 ,.U ,ou "'MIII b .
Tbc trick 1. ,hol ,he hokb In ,IIe 'ppa",us .'" 1"'"
<iIIr'piu;.,l and p"'cl,dy plxtd In ",I:otion 10 <>ne lfIQIhc
0I>t OI tbt Inf.,.,d I>ok Il .11"'''5 WlOy 10 ,he ou,f<ll><J.lr.
.l1li inlCf'>"fI"ll "1OC ,wQ " tlle bi' hole. (Q( COlI"""

adIeo )lele,

tOII1UI!

".,..1tln8

.rid!.

dom',. rooMr' 1n,'QIw:dI)

0IIIdI

m. approp,tllc bit -whcn

.I>c: ti"", con\(:>, "O

0JIIIIIa wbat bII b .pp...pl'tllc ,and "m goinll '" 11"1 ." wh:11

III il >ppiOjH ;:'le in mlnUlt_1n ...........1OUD'cd

~,.ou ta

m. 6~.Uft "'..". tbr bil

roti,.,..

arni cbmp k. Set thc

bllIdIIho ju>I 00, 01 rounc. s.,itd! on Ihc: ......
and poIo:c
. . lIid In tIM: lnJttd h<>k
Lct . . uplaln bow ,,, nW<C lM fWwc,thm 111 dcuil
lIoor 10 \Il1O: II """ how 10 ad!~ tl>c bat ~

,et.

f"""

lk'l I>t:~ 1 do. 1ct. IIK """"..".

quodon. "XI
""" 1"""" own do""", wl>t:n )'UU 0<:n1 w.olnut """'"da. OI"
o:.ok .Jov.' ~"'. or chcny (Iu,>.. ~ V".. r",," 1"""" ()Wn """'n
C""'OM"'pbcc bin:h d ...wo:b. n:oll:lbk: lOr dlCal' oi :any Iwn- IL.._~
l>cry2td """ m:any hlInJw;' R: >1 ........ "",,,,'t do. And <>n)'UU
~ how cur ~ i 10 MJ1 )'OUr own,!"XI n",y ~ 10
pm;um, thb !;Iti< on>g:io< an ................ )'UU ~ a 00..."'.

M.klng the JIII

Tb< iii consi>u ol a ba.>iC and a bIod:. V.... lK:Cd 10 make o
dLfkn....1 bIod: lOr nch di~I diamncr uI do:wo'" }'OU
" ....11 .........' V.... _
tho:
lOr aii ,I>c bIocb.T"
d"'nw: rrom """ ~ t" a""",,"- just undo tM f.btcrorn
,1"" ....... . '" "'" bIod: <XI 'loc _ . an.J "wilch bIoc~

son>t""'"

1. l'kk lloe hole "Izes. A> 1 MId.th<."n: "'" Ih"", l>oIa

In .hc bIocIt. Two . n:." Slonc t imple tu "i<C . Th~ ..... tfoft/ bok
nm>l M Ih" .. noe dianoe,cr as 'he do,,'cl Y"" ..-anI 10 .......
d""". n.c bit boIe is RO

mot!."

lIwt

lIt bllIII'"

In dun"'I"..

Ihm ,10<" bO'}"'" wilI....,.

111<." thln.I _
'" tloc
bok. hs ..... m... ler mU$<
""'tell tM dUgO<UI ~ ... nl 01 u..,
.......,1
bbnIt. Fur <:nmplc. 1f Y""
10 rotii a \'HnclHltlmcler
\Io'fI,,1. Y""'d elA a bbnk 1""1". ~. Inch ,;q....,.., ( ooo ~.

,"fted

"""t

o;q""'"

"

OOWElMAKIN(; FIXTURE EXPLODED \/IEW

V---Wing nul

....

!
Cunlng Llsi
Part

Qty.

..

81ock'
~

Oime nsion s

Malerlill

I " . )( 3" )( 6'

H1.dwood

Wx]"x36" j

"~..,

Hardware
1 f1atl.ud "o"" bQlts.

~.

)( 2"

..... 1I~r ' ~bk 101' (from sWc 10 sl~). CUI Ih~ JIIt'.."OOd lhI
""mc "'kJlh '" thc hk,d,. :Ind CIOS$CU! il 10 n\:tldllbr
I'OU1cr 101~~ ..'id'h.
3. Drlll thc f~-.:d hoks. n.c",..:. hoIc:s mllM ~b<m
on ,lIe ."llIe
sIIown In thc dr.wirtg Do:>oofo'.ll....,
Fumrw I,aJ'Oms. Ifs \n,ponaR' tO drW tM>c I>0Io bdort ..
bl, holc..., lh;J.t thc bit 00'1 ddlcac:d br Ilie biI hoIe.
Hy 011 mnru.. driU thc hok an ttM: </riU prUI$.Sa lip do<

".us. '"

2 washers. ". 1.0.

2 wlog

nUl~. j,I"

Cu. """ ..",It blod! for ...,It

""f/'" a.

""" ,.,1." ,,. """

lAII .. riie N'O

dlf(u.~'

d,,""f'.. o( _1

""raUl')' 'o fi. ""'" ""'t... '8&10 .

_ _ >l<:osh ",,:r th:u). IIm

)"OU ....oukln ', "" .bIe to ''''''' ,I\;It

srick ,n,o ~Mnd,.(li>m~".r hok. Iuld 111.'.
be<... ust, mn";,"",, OII d dIafton:al from COfII<O' 10 ~r.
;t's 1, ind! XTOS6. So 1/K infced ""'" mU!>l "'*<:il ,"" d<l(lO<U! rnc-.surnn<:n' 01 ,1><: bI:lnI<.

"'lu~n::

Rdo:r 10 ,"" "()oy,..,J lIIant.II'n.'d nllk Sizin(t" dw1 on

dnnmine how bqI: 'he iorenl :Ind IIUIknl
hoIes sbouloJ Ix.
p>jIr 100 10

2. Cut It... p<>rU. n... fixtun:: C'Ofbbb 01. Il>nJwood

bIod: . .....idl bas tbc ,,=,, hoIo. and plp"'OOd bax
..'hIdI pooiIiooo< :u>d $C<.'W't:$ tI'w: bIod: on 'he ..,..,." "'bie:.
'Il'hlk )'OU an ..,., """" aR)' ,","'od. Ilanl . . 00II. lOr .hotbloc. , ""1\100-.-1 ,,-iU bc more dur.obk in (/", 10"8 run.
1\' ~ maI<~ ""'~ l:>IodlI tigh. fTom .1><: j1:C11t<).
... )'OU an _
more Uun """ ...., of _ ' doSun wlth
61~ (ou'<!lWt ....) Iw"d.....oo boud :UIou1 18 in<hes lung
fbnrn """ 1:><:0: on thc jomta , 5qU:U'<' .., cdI!I" 10
r:..:.:,
... d piafIc oM boonl ' " !hc tIlId:nos spcrilil by t h ....
CutUIIjC u.. 1bm cmMCUt tbr boanl Imo ,h..,.. blocI<:<.
~h .bouI 6 illC!>o lOfltt.
Fur the p/)', ,,,ood btio:. ~,.., 111.0: width of )'Uur

,110,

Drilllnii Iwo holu On Ih. SilIm. ul, 11 U,IV witll

eorrKI IfIUP, USI a fenee on Ihe d'lII press 10
Cenler I~ workpleee unde. 1111 bll. Crank up Ilie Llblo
i i close 10 t~ bll i i \'OU can befOff m ,mng !O drll!:
vau need 10 USI n mllcb llroke a$ VO"' d.1I1 pren n.u
10 bore a 3lncbdeep holl. Bun a stOp bloek agoln.!
Ihll"d of Ihl wo,kp,tCf. and clamp It 10 !he fenct.
D'llllhl Infud segmenl of Ihe hole IIm. OO,lnll ab'M
."" Inc~s detp. To chinge bit!. (emove Ilie work
frnm !h~ d.1I1 p,." The "CIP block and fenel ""III
en~blt vou rl"',n il 10 u aCllv t he Urne poll tion for
contlnulng tht hoit wllll tht smalltrdlamt!tr bit.
I~

DOWtlNAKIHC; FUfTURE LAYOUTS

TCW'VItW, BlOCK

,.I

,- ", 'b
,ii
"
<.\
-,
)- 1

I
o

r(W
r~""""T"'--j
,.-

BaTTOM

!4"-dia.

for

lIol~

mo~nlll'9

bolt

c-1

f~OHTVlEW

InfHd hok ')

to~

VlEW. SASE

,,- ,,-

1 W-dla. bit _nlng

for

m"" .. tJ"5I boiI

y,- plywood

~ """ ""'" ond .. ofl bIock .0 pooillon ,h" ,,"Olt.

pktt DriIIIhc: ~I~n>ct .... hok: ~. ht .... fljI allC<u 1h

....,. d<qo.lbC1I swl'ch b,ts arid fini'" .,'" hok "",,h th<
II"" mi of tllc ,,~ thlOU(lh
_I:b:l. Tbt fcnL"c and ,",op bIock ollo,,' )'OU 10 ~ th<
"'lfoke< 001 ofl~ ".,.,. ... het! yoo cll~n,," bi .... }"el rMI, ....
. . ,.,.. nn ""um h tO COctIJ' th~ Slmc poaOtion.l "h>' 1,
....w It "'" """o _ "'" 10 .1",,,, iti<" .."'" ui<.

_<lilmct.... bit. bQri"ll

oi. s.,kct. b ll a OO bon.' thc b it hok. Yoo

tlt"ctl

'0

dcn tii< bII I>OW. ..""" II ",IIM fllth< bOI hol<. In t~ hIoc:k
ilbOUI rIc:I... "",,_
\ou an ..... a bl'JlC-<lI~mc:tct"~" (o. round""",,)
1It.. ~g hl. , a I1\tIf"tbr1!l bl! , ...... doo """u

*""" ...

""

1'"" ~ Ihem au. arid r h:"",, '1 lIiKuncd mlKh <liffe~

in Ihc ftow...d prod ........ ~ICSII o( w bit ..... d. I'd qgol you . , 'III"Ith ""ble""""r o( Ihoc" bit.- you tu...,.
TI>c biI hoIc Is ""pped hok. as you C"~n :c fn"" lhc
dr......m.g. It il th< ~n'" dlanlt"tct" ... "'" hi, }'lIl> ...iI ..,.,
1'1""'1100 thc ""'" ,..
10 Che d.-.w;ng, arid boIT jlbl
<kq) a>outCh .0 b"'ak "'1OU(Ih 'he .... LI uf the outkcd hok.

""""'n

""'ctId

Routing Dowels

1 t~ ..... kifljl oo...'d o OUl o( oaIo:. aob. d>ct"1y. :ooft RL:l.I''''.

poplar. ..... ln.n nd~. Alllhcx """"'<lsrun ,h"'-"'tlh
the oo...cI'ma!dna Iixt~ wlt houl a hIIeb. "" lon{I: "-" the

bbnk Is "'toJtchCPncd. Any t...;.c~ dlpo.. OI" ....." . . le3d 10

<."hlf><JU1 arid ."Ilntnlng. F.nminc your .."ck co.""fuLly. and
M ,.,lecth-c lor bol "" ... Ies

1. Cui che 00.-..,1 hlanluo. Cheek theoo...-clchan ror

you ....,,1. Ril' a IeSI hbnk 10 IM
~ )1"-"CiJk-d ror 'ht d<;jln:d dowd dWnc1er_No""
chcd! M. ni In lhe I ..fred boIc. It nl\l,., hc """8- buc not..,
""'-'II tha'}"" C2J1"t
by hand.
f/ II Is 100 1/gbI. "'""1' U", blank . .... k!1lIJ 1 Iltehcl)
&mo.Ikr.
lhc

>peC5 o( th~ ~' d

.um"

l'H 1.. llrlKt lon of th, fI.t .. r,' , IhrU holl'

(JII bt '>HII ,",r . Tlle bll 1I01~ should Ju", bruk Inlo
.... oulleed hole. Vou dan' nud 10 dflU any dNPI'
..... 11111.

J:

...
II

S. Mounl Ihc: hlocl< an th c has<. Uy OUl I~ bIock ; '

pa.llion OI' tit<- ~. and <nrukr .m. Iocauon o( tit<- block 's CI
bk hok la thc b:o>c: . At lha, .pot. boft, :an ~1.1 hnIc ""
th< bi. C2JI
llI"""l1h th" ~ iluo w bIock.
Drill mouruiflttbol' II""'". .. """"'" In IIt<- bJ"Ul
d ... ",ln", in bQth thc hlod< and th< ...... Counlero.ink Ihc
1>1.>1.,. In thc """" IIl.!ct"t flalhnd...,..., bolts .hrough 1""" 1_..1
""'c. iiI .hc bIock 0I"ct" tllcnt, add wWM:n, and lhet! thn::ad

f/ II

Is 100 _

. r1p "OOIher bIaok. m:tklnj: It )lIghU)'

I, <!F'".
DoooelM tng FIKlu,e

99

DOWEl BLANI(/ FEEO HOlE SIZING DIAGRAM

OoW~O;iagonal

dia. +Yu"

1-.

......) Oowel
dia . +Yl.."

SLANK DIMENSIONS

OOWH

Dowel Blank/ FeecI Hole Sizing

Dowel
Size
Wdla.

Bl ill nk

Infeed

Outfeed

Size

Hole
'y,," dia.

Hole

1,\" dia.

""'" "1.
' ~," "1 .

,.," dia.

\'. " dia.

~"

dia.

1,\" dia.

'~",q.

dia.

~"

' ~,"

I ~ ."

..
,
..-...
Cl\:..dl.

al

W d'a.

.q.

dia.

dia.

~" dla.

:." dia.

J4" dia.

W dla.

,"",," .q.

I y"," dia.

W dia.

1" dia.

sq.

Iv.." dia .

1" dia .

II

:r

II

~
O

Whc:n }"uu "..., c;lll bl ;"h ~-d ,he.,.,..,..,." bI>nk .i>:<: , tip ali
111<: blanks y.... n""..... plus . fcw "fW"'S, <O th .. .>1..,. H'1lJj: on
10 Ihc: COI"I"eClly.>ll.ed Iesi bI.nk, '00. 50 )"OU <"lin lISC il 10
'une . nIl r.nc:tune the fix'urt Sctup.
I!c: )Cn.<!hle ,'''''', Ilie kllJj:lh of II'" bl.lnb. t ""\It them
~ 'u 6 lneh", M'l>I<'< II .. " ....'h.' 1 . hsol"'dy nee.!. n",...,">
us".I!,.. an .. n"sable seaion
en.J tiut J!Cl5 chud<e.! In
Ilie "puv;cr fttdo::r." 11 .. , I 000 c""""'-""" 'o kttp Ihem as
1M>rt,., pu>Slble. n,'lng ,u rolll .. )C,,,r.lruutlo"lI \\.-ltlch
di.mc,.'f dowd i. OV<:m<achi n~ .

.,'hc:

2 . Se1 up Ih c fu"un:, ChLld: <hc bll In (1", ,ablemoumcd "","e<. and r;t1)C i, JlISl cnou!lh ' o <"lIP'u"" ,he

INFEED HOLE DIAMITER

..

~.

OUTFE(D HOLE DlAMrnlI

,,,,,<

(1", bit, CC11lCf ll."

clamp 1, 'o Ihc: rou' ....
" djU>! 'OC bi, bcigh, by sigII,i,,!! Ihrougb 'bc ()Ijl/tll
1>uIc. I12isc thc: bit un<ll IlS <Ip '" nU>.h ,..Ith tbc bonOQl_
r.cr of lhe oUltd bok.

11001""" on li. Noa , ... t 'hc: fixlu",

,.bk-

3. Fln" 'une Ih" <!IC'tUp. Rom a SCCt~'" 01 ~ l1li

bl. llk 'o chn:k Ihe bit bcigh' "'Uing. Swilch un ,"" l'OIII
. nd r<:ed ,Ile blmk Into the rue,,, ..,. 1\5)'OU <lu 'hiS,
blank by lurul. \'ou'U find tiu, il "lhn::tds" t"",1f Ih~ ta
fix,u...,. In utller ..... ords, )'OU """', 1"" ,, tO pU>l' i" twa.
"")"01> lUm Ihc blank , 1t will fd i,sdf.
\l'hcn ,he k:ldin~ cnd of Ihe bw.k cm<:rgt:S!rom
o",rn:d hok , ~w;td> off thc mula. PuII tbc hI.lnk 0lII ei
Ilx,u..,. Don ', bc <n'~' ~"""""mcd "';,h ,h" ,"'" doood'I
fiolsh ~, ,his [>Oio', sinee ~ lund-rcd duwd 1cnd5 ro ~
rou!!-h. 11;1.111<:1", focus un huw II fits Ille outf~"C<J 1Mlk. llI:
ligii"" ,he <luw,,!'s fiI In Ihc outfcctJ hok, the bct.....
flni,h }'ou"lIget.
'/ /be bkmk 1:,,,, '/ be fr<1/bro" /;b /be
bll is ' 00 Iuw. II ;"n', fnILK'1ng Ihc bb""', dbmetct la <qII
tlui of II'" oulro:cd hulc.
1/11x> bk"'k bl"d 1" IIx> o"tfte</ boIe, ,Ile bi, is
IIIw. ~ the bit
.Iighlly. ( Rcmcmbcr, the",
bUng dT~"Ct ~, " ... rk heI"<'. lr )'<Iu ni>c ,he bi, ~ 11l1i1,,..
fnIucc ,he duw cl's dume,,,, bl' L,.. ineb.)
1/11x> douw 1, Ins /h<m '''ug In //)e .."tfr<'d b<o/P, dor
bll Is ''''' hl!ll>. 1, Is ..,fDIl\lng '00 mll<h n""erW. A
dh;p;r.rity bcrv."cn 'he dowd "s ;md ,Ile hoIc's ,,~W

"n.

fix/'''''''' ""' ...

'''1)'

TUNING THE SETUP

BIT TOO lOW

The bit 15 not removlng
malerlal rrom the blan~;
the blan ~ un"t Ollmo
,he ou,feO<! hole.

100

Rou'" Magic

BITTOO HIGH
The bit Is removlng '00
much ma terial; ,he dowel
Is smalle, than Ihe
outfeed hole.

PERfECT SETUP
The bit Is removlng JuSl
,he rlghl amoun, 01
materoal, sa the dowel
is Ihe samt diameler;li
,he outleed hole .

......,.", ti>< do.....,. j,Uru '1) duucr an<! .... bI". "".. JPit:I.I
_
01 ti>< 00.", ', .....&ce lI"l' IDOl'<' roaN<" " ,,.....
dItct> .... ~, ....-cr llte bi'
k<dt 'he >ctup. An(! kttp 'CStinB an<! odju>IiIlJl UPt~
fOI'" ~ .h:lI II ...., fI'IOII "" )'OU an rm"" II. AIkl
..."1 ftd " """"n lhe lOl'tllp II lil!bl.lbc bI1nk "'II ..,..",
.dWppa.r In.n 'hc: fi~ ' u"'. 1>0 ch:lun, ,...., hirl<ling

oi, kt up thc powc:r feedc:r." 1'hc: bbl finbl, 1.

--..d br 'nc:",~...'n8 'he:.pced IIJ.tI lhe """k IIIrn. "" II
- . . pUt tht: hit. lbc ...,. '0 do lhis .. tu cttuct. Iht bI.nk
.pln MII 600 10 800 rpoI.
I ...., \-).Ind! porubk: Ihill lOr this. 11 p""kJcoo, n....
_eliud< npxll) an<! IlS opcal is ~""'nl-.'w,,JiIlll'O
.. 'P<'" pUt" Oft Il- I O HOO rpoI. SmaII 110....<""1 bI1n~- > fiI
"""......, tht: dtudr. IMII" """" mU>l he ,,-hiu"'" do ...." 10
.. You onlj' nn"J 10 ,,-III"'" shon 5ttIion un ,>fi<' mtl ol
lbobbnk. AfIc. '"e 00.-.:1 i51Onnnl. )'OI.I ltin, ,,.... 1" off.

. ' jIIN"tt driII, anei

R",, ' just tht . .. cI btfO<t chuck,ng tlle blank In vou.

powu 1Hd.,: You'l lIIen bt .ble 10 gft \tie dOwtl
... nfil mon .. Si .... II \'OII Shape juSt about t!lt ""9lh
shown M,e . Tu.n 1!It bl.lnk by ~nd 10 do II>IS.

,. Roul II.., do..-c:l, Il gon qllkkly,<.>n<:<: )"" 1J.t,,~ IIt"

laIft ICI up
fine-Iuncd. Il"",, '"" tl.iI! ;

an"

f....

A.0aId:. _ I n lhe driII.

1.S.'cb OII Ilte mut ....
C.IMM ti>< md ol ' he _
in.u ,.... Infd 1,,*
n Squtt..., , .... lItiII ' ..... :and >imuitann.>U>ly I'enllhe
hIml< into lhe hule.
l'l"hm )'00\'" fnl as mudt of 'hc bIank IIIIWtIh .he
ftl,U11: as )'Ou CUI, CU' .he !,O""c. '0 .he
,hen '"

li:

fI)U,,,r.

""~

f f.IllXl the do,,-d rrom Ihc-

fi~",,,,

::1

G. rut " .><,. of tIIc (/riU cll""k an" fi new blllnk In",
"'" dt\ldt. Rnum tuA.
Thc 1Ut\lJl: ol'hl5 !OulI"" ilo sud! d~. b:M~..-lIc1t IH>
. . ......,. 10 bir. pI ..... Vou gtl ' M driII ..ilh "'" bbnk aii
Dto.IbnI "tJI .... tb< pc<bl. AneI..tom)'OII alt' md)' 10
ni tbc powc:r, )'OU don 'l 1J.t,.., 10 ici 110 olthe driU h.. do it.

CI
v.s, '1'5 magld Swltch On Ihe !Ouler, Ind In.tM Ihe
bl.nk\ tip In
Infetd hole , Q"'ckly I"gge. Ihe d.llilo
.pln t'" blank, .nd .lmultlneou.1y pUlh the bl.nk inlo
Ilie hoit. Wilh I I~tle experience, you'lI dtvtlop I ftel

1'"

for tht

bUl

fef<! ,.'e.

TlN fl n"re's powu reed e . Is vou. elec"'c d,'II .

SpiMI"iI,IIe dow.1 blo.nk with Ihe drill U Ihe bll CulS
'l'"'Iduo'~< , h.. M<I finl.h nn the dowtl , To fit . '''<;Ie
dowtI blilnk In Ilie drill <huek, VOI> h ..... 10 whlllle

......

To ketp . lo nll, s lt nde . dowel 'ro m wh lpping,

fud its On,shed end Inlo I SIUdy "SI bJock cI.mped
10 Ihe IHck of lht fOul., IIble tOp. The tleady rul 1.
no mOn l~n. bJock with I hole ,he dilmtter of Ihe
dowtl drillfil Ihrough It

Here's " turn"bout an the woodworkl",

c:onvention. Turn Ihe wo.kpiec:e by h.M
in Ihis jig while using your ,oule. q
sh.pe It .ound ilnd smOOl1l.

:U do....ds. 5implc roun<.l "'pc.,;, .nd c,..,n nM>tk""Y

, _-'

om. men,<:d spi ndl"" co" t>c I'n><l'K'<"! ",',h fOI,R.,.

.nd 1111. priml*~ "'the. li OI "mplc !<, m,kc (as ,11
good jil\S arc). p,t it tus. lui uf pOlenti.!.
,.,.., e>Jlcd il a {/""",I-tuml"l' jl!! l>eco"-",, ,har. ,,ltal ,II<woodworl<~r

",ho told "'"

,1>0;"

it ust:d ;, f<)f';

oper.",,,,

m. ~in !l

dow&. ArnJ Il /s. wminll

,"nu Imn 'he spindk
t.t.nk as 'hc Culler mu,',,", olon~ i~< uis ll,~, ma~~. II
ruund Af,e. I rn:uk LI'" 1'!i1O II) "ul,1 n,.lilt~IIh;l1 il cOI,1d
"" cUSlomlzcd for 5I>mC ol he. Ol><""''';on>'' "''eli.
This jig J!OI IlS >1= ",hen Sa" .. r.'I<."!....,.' ""k><lwotl:r
Yrung Olan n=k1.l a 4-lnclHll:onlC1<1" """"d for. !Oble b:oS<'
~"'" hc coulc.I,n nnd ,,'11:0, ".. "".:.10.-.1 ...-Ml}' .... <k. anoJ
bcc;o">c hc didn', h:"" .. I:ithe.Oun tunlCtl '" hi> mut<1'. 11,~
....-nion of Ilie jig >hown is IU)' Im~'1>"'I.tlo" of CII.,,", lig.
In brid. ",h.1 he <lid
l<> ...-n:w ,,,,,.;thn fI,ur_
sid"d (>1)-..'00<1 b<>~. ln ,I>c ""nte' "r c.d. c"d. Ch ." drl1ln1
.. I,,"h hule. lle moun'ed hl"n~ for tllo dowcl 'n"d"
.h~ box b)' drlvi"" I"n~'hs of Ih",.d,' ~ ro<! .hro,,~h 'Ile
Ilolcs an<llmo Ilie ends of 'Ile bI.nk , II,' .1,., ",,,,,n.ed.n
imp",,'i"-'tI handl" on OlIe ro<! so II.. ~~'uld .um II", bI.n~ .
11,,,,, Chon m.<k a new plp"'>OtJ bas<'pl.'" for IIi.
1'OU1<'l', One ,,-Id .... nough 10 sp." Ihe ",id.h of 'Ile bo" .

w>.

,.,

'1'0 fix .lIe rum". owr .h..

'bI."k. Il ...11_
lI."i<.l<" >lrlpS ro Ih" plywood l.~l'l,''''
l I> lurn .he dow"; . aII h .. lud 10 <10 ".." .s<1 up tbl
ruu'e' ,,'i.h. Slr.igh' bil . .....,.eh it on, .n<1 ' -c' r >10,,'1)' """
It alon~ III<' top of the box ,,-hllc h... Im<ll,.noou.ty ~
'he hbnk .ru"nd .nd ' '001''1.
Chan'. iis, i, "-,,,nlS. '" JoI><;pcdfle oolu. lon .0 an _
d;"e l'n.>lllcm , Ilul " holds ~ ..ml.1 lOr a """,~' h., . . .
floibk' iig, <.>r>C 111>" , a Jiule Icss imp""iscd,one tIu!"1
kccjX' Af,c' nooll1inlC wi.1l .11<' basic doign ond U)ing'
("", kka,; ,h., dldn ', 1"'" OU" J ""nI<' 10 tiI<' c:oncluslon 1Iw
)"'<1 ...
=111' dcMWl" do.... ck"rning i'l!.
" ill ~
mOtb,,, '-"''t:ry jo/>. \"" an: goinB
h..." .0 """.., lhc ...
piece> '" ......'UIl'mow.. " diffcl't:fll >{limite lcng.hS, YOII d
"';' nI la dril1ll>c e!lod plcs opcc:iflC>Jty ro. l>pcring job4.
In mile. ,..unls. keep
lig, hUl fi!!"",, on doinS a Iitdr
""" ,nI!. drillililC .<Iopt II la tiI<' tob" hand,

n,

o,

'0

'o

,ba,

.h"

Bulldlng the Jig

it,..

111<' ;111 I'''-'>enlt:d h"", ",ill t>kc:o. bl.:mk "1' la ~2 inda

long, Jf )'OU "'ani' iig ,h w;U do .kJ<1w::t bI;onk, o.

know .h., 32 Inchn b ",uch .00 ~>nl! for .hl: nttds)tll

DOwnTURN ING J IG U PlOI)(O VIEW

~.
.,.,... {It

llle:n m<llIil)" tlle: tlint~n"""" nuk,nst t"" jIg

.ohonn.

CuUinG List

,,"

1. Cut ltot p;lrtJI. I n..de onY!lA mooolf rrom plp'"OOII

""""'"-Tht ditnorn:Iions of .hc
.pirocd 1' ,1><"
ClIaas UsI. Cu! thc bu<:. !<i<k:i. an<! cnd, lOt .hc: bo . >
5dI.Ik.....,pIa.c fo, . h~ mu.e. 1 ........ pItu "'''''11'lk
lot .... baoq>IaIc

Oim en si on s
" . X 6" X 44"

(XI""'''''

2. Bon: .hc ~p l od Jc hoJes 10 .he c:n4I. :)(utly 'hc

...... 0.. ... il,).,,,I. IIJI>tI<' eoch cnd p..: ..... h. ",rie>
....... "'="" 110 ' lut "",.." ..1<llfk""". di'm<"Ic",,.( "",,,,,'1
aa lot """"""'" IIIIlthlM ~If ~i"", .1Ie cnd
poM>.l'or tIM; Ilg tn ,.-o rl< pl'QP<'ffy, thc: ull of c..rn h..", In
_ .... pIt mtIM "",.cIt Ihc: .110 of Ilie: ........." I"'''''I;nll
" " ia Ihc Olttc:. ""ti piccr
t.zr OUt <hc _ . an<! tIriIl . _ OII 1"" drill pn'''.

Qty.
2

SidH

,,,,"

3:

W X6" x34

_.

II

~ X6"x6

:" x6xI !t"

lU.eplltte

H dwocxl ~

(lant pI.lte

\1" dl . X~ "

C.~nk ~ndle

Cuodt SI"P5

'lfjxltix6

Oowel

It" dl . X 2'

Oowel

locklng'p,n shank

:"dt. X2"

Oowel

Hardware
3. M5c:n.bk Ihc ben:. This;" as >imp"'~' Iln'OJt up
.. pam.tlriUiIIlj piloo _
. an<! dti>i llll ...-rcw . I .1l;lchcd

21-.- drywall St' .... s. '6 X 2

.. ""'" '" Ih~ ~. lhen final Ihc: cnds bc:"H-':" .iI...... \1;1.1:. su"" II><" i(Ia: :and ftMb .'" nu,h .round

I ""n\lt' boiI, ~20 X )"

.. _.

,hol.

4. Muc the cnnk. SlutIy Ihc: drAwl"l! c,,"'. 1.4)""'-

T"ttr mru: pbl~ II ' oOndt har\I.., ><JtI. II I~ bo-<k'.IIr ~ .

lItough Ihc ...'idlh of.1Ie
koo: .,.." .1Ie: <I/.It. .
<iti 01 "'" drdo.- I NIIlcU. Thc ...... "k .. mll"nt"" OII ' ..
m K ~ ""'w:r boii usU>1I' 'f.nu. ~nd
op nUl>.

""'.p , ......, "'...

t"'''' ..

Ta lOCOItltIIOd:I.c both Ihc c ..... k pt.:tIC . nd t ...'U n,,11 "" 1....

~ >tlon of tI><" h:oltJtC'. b.,lt . "'" h:o-,,,, tu
tii. ' iHn<'I>dcqI <'UWIICfbo<c. "" "",-""" '" .hc """"'1 '111.
ArId suiubI< ""'p. al>otl. 4', 1,1dIcs wi<lc . and .........
.. murpoInI "'"" HncIt 1'ur~.t\C1" bit. <lri1l <hc coun-

1<,.

~ (101 thc ttfI.trpQlnl. S...1.cll

'.-Incit bi. and drill
. . . . W ""'"''''''..... m:tklntc "I.'IX hoIc: l.;Jy "", and

2 IIOp nun.

~20

I TnuI. " ,20

~ 5<ft'w. ~.

Xr

4-8 flal w.shus. ".

II..... II><" ' .. lnch-d"'m(1<'r ""'" for thc cr."k t.. n""'.
Set "1' tll"Tnn,md IIbcpbl" (~II" ~9) to eul. 2 \ ..
Inc hr.dtu> .n.- :.ct th .. Iram_r. pi''''' In the ~..,n.c . 1>oIc,
.mI ."U' tiI<' 'Mf'<' uf .hc: <nnIt: pl.,~ . llo"lnS """'" III ...
",01,111 .h.. ph'Ol """" ,,,. ... Ineh dl.n'''tc. 10 .omrr>od ~ tc th,,'f.nu. Il.hc 'hc T-nu. In pl. c ~ . Ghtc Ihe h.ndlc
In ploce

Oowel-Tum">oJill

CI

H.It,dwood .\

Lock.J"9-1)1n gtip

:o

10)

~_ _

DOWEl-TURNINC:; JIC:; PLAN VIEWS

SECTIQN

TOPVlEW

Hanging-up hole
ENDVlEW

ENO V1EW

SIOE VIEW

c:J

.-...

Maximum dimen, lons for a blank

6"

--- -

--- ------- -

...

5"

Tiil end

-----

}4"

al

Crank .ocI

IIOTrOM V1EW

II

L -_ _

~~

_ __ _ _ _ _ _

Il

~.

CRAHK LAYOUT

FRONTVIEW

BACK VIEW

SECTION VIEW

)4" o1la . X ~ d" p counterbo

durance hol.

,-~-:'-20

stop nut

,,;;;;;;;;;;;;;r-;;;~ Handl.
........., W -dTa. x

104

Router Magic

4' dO"-.1

IASlI'l.A TE tAVOllT
I Wdia. bit hol~

''''I'-__ Culdt mlp

Hlrdwood -~

Sow boiI t:>""Y'lti"ll I~ Thtnd a .1001' nUl 0'''0

!I'd.....,. bolt. )",,'U .~ 10 I"P llK- 1>011 In wpal. o( VbcGIip anei lum llK- nul ... illt a ~h . 1\tm .IK- nUl ... &r
8 ...iII 110. Now .um thc cnnk ..... 0 thc 1>011 lahtmlna 1.
...... """ "OI' ou. Add llK-lOI1d otop nUII.

S. Make ilie bastl ) I:I1~. TlIc I>asq>Wc iti ~ for

Il!' tIM<:t ..1Ih b...qlboc di;y,lder unda 7 Incho. .. hldt
U'''f,dIm norftW}'rou.er. lt ~ Ihc """eron .....
"'" cdIa 01 tbc 00.. ..iri, Ihc bit dirlJy " , t t tbo:: bbnI<'t
DiI- Tbt JIIidc>' 81u.td W ..., bo>q>b.r ....ap lM I:wcptac.
PinlllU be.;tid rrom moi 10 md but oot ..... 10 .....
Cu! lhc b:ucpb!r rrom \o.indI _<:tiaI. I ..sed a p;ttt
t/1ICI'J1k': ... I coukl _ lbt bll "'.........,1). n>iIy, but pIywwd
WOIIld>bo bc 5Ultablc. (I don'l thlflit k'l ncc~.o bur.
piott d 0I<T)1ic ~ for 'Ilis "ppllc::1l1on ")'OU
""'II' d pIJ...'OQd.} U"", lhc ..........n fIctory b:ucpbLc as
,...... for driIIina lhc mounUng~ hoIct ond 11", bI.
. . . . . AlIK1> thc bucpIlI.c 10 "'" tOIl.er
1<1 posibon tho:: g<k Oltips. ,,'Iuch an bc t...hloncd

Iu,.., """*

"!CnP

rippiotgS. dlud: "......tkIiaJncter Slr.tigh! bI. ar

f1fOD'irlI bir in lhc ooIIn. So:l .hc: rQUIler .... tho:: pg,_
lip it dim:tIr mc...., "'" _
in ...... mei. AppIy ~n""
"101ht 1IJIcIr:I.:aod .ppIy thcm 10 thc ~ of lM
~.1Igh. :qpinsl .hc: ~ 0/ "'" bo>1. Oamp ,I1Cm

......... dornp. {To oruch tho:: >ll"ipo m my Kf)'11c t....cf-r.1 dn;n.., _

~ Ihrou(!h llK- buc-platc Inl" 1""
.... Ilripo.}

Using the Jig

",..,una1O thc $pCrifi<:$ of n>ul.er.. uming " du,.d. le!

.......... 11'5raj:Qdllc:!.
Tht liI..no..lI in 111C pb .....ill OCCO<nn>od:;J1c, bw.k

tha! 1I.t indtc:o "'I1W"1f. Unda Utc: bot rondltlonl;. lhls ... in
)"idIl " ~

cIo<o."d. Ir )"OU .tim bUnI< '0 ;In

ocup I>dl:>rt R>OUIlI'1n/!: It in !It<: 118. )'OU an prOOllC"C
_"Ci .round ~ lnocho In d~m"'er. max. (Of rounoc. )'U'U
an mb.., tho: 118 If )"OU nea! an c''''' la..,. round.)
To , ....... OIrIIaIIcrdl.1.mcl dowd. )"OU 5houId ..
urnlno!I ...... ll1C bir an 'l "" Dtcn<kd ''''ry r bclow thc
ba>cpLl1c; 10 thc doK. 'O ,bc 11(1'- 'OJI ~ ll1c bbnk I~.
."" ""tler A IelJ()rI.lObk tulc o( .humb 15 luIf ,1><: dbgon:ol
u1.!lIc "'1""'" bI:anI<.and dtup rhc 10C>d and ...iI ."indlc looko
llut: di..una: rrom 1"" lup .,..., of ,1><: en"->.
TlIc lonIIOI bLanit .11C ~ wiU accommod;!lC 15 j2
ind!Q. By o..cndlng thc I'i<k!l (and, lf ~ry. thc

be:.""

bonom). )'OU an n..... n 1on@I"T IIbnk. of COI'rIC To

1uno.IIc ~er bbnk ( ,..try .um mOl'e ./LJn )"Ou nd1).
lI"I<IVI:.hc.>.II rnll do!cr'o lI,t c ..... k cnd. AII)'Vu
10
do b puIllh 1CTt'W.'>10 r= 111C rntI plc. "'1IICn>bcr
llcar In minii
)'OU ClI/1 '. ruu he emil'<" Icng.h. lf)9U
....00 doK 10 II><: blall"', tneb. roo oUl< goojtlnll.I><: JiIC'1
md piccn. So you wIll II ....,. bit of "......'1c 10 ulm rrom 11><:

Iu,."

.Iu.

complelcd dowci.
1. Set u p . h c 11g. 1"ht: dlam~"'r ami ""ng1h of 11><:
<k>vo"d roo '""". mus. 1><: ronsi<krcd 1><: '!<Usa.
,1><: J:inh ami Icng.1I or .1", bbnk n=IN. IklCrmInc lhc
MoI """I'1on for lhc ~plndlc holes In lh~ ~R' I mtl pIccco.
Oomp 11><: JIII.o.1><: ,,urkh<:n<:h .l"ht: JII! _ ~
... lth ;In o ....loog ~ sptelnc:ally for ciamplrta. M:d<r 0UI"t
."" dan,p .. Il", cr.nk ~nd doa;n', Im~oi~.., Mth 'bc a;onk.
Ir IICCai6;Iry. n"nu'~ tit" cntl pleca ond drill \+.ind>d.i:.omcte< spintllc
Sandwldt .1><: cn<b _
dI"iIl tJw:
Iook:o in boIh .. onc dmc.
Il~ tbc wds. lf lhI: bbnk wiII bo; .v.oncr !han ~
lndIcs.oh.ift thI: llIlI mtl doocr 10 "'" cranIt tnd., 0fJPI'0IWIlI"

Cokul:o."

""Ia.

Oow~I .Tl.l m, ng

J'II

105

_.

:::1

I __~

ROUTEIITURN INC A DOWEL

1. Turn tlte "~nk (wlllcitever d,rectlon you prdtr)

10 spln lhe bl~ n k .
slo",..,. rrom Ont end of rlte j 'g 10
Ilie olher.
1. Tht brt,..;11 eul Ilte sqlJl.re bl.onk. transform,ng It
10 II rwnd .

2. Cut a nd mount the blank. e .. <ht bbnk(.) 10

sizc loo c<", "".., sorn~ tuming ,im<.- to,. ripr>inllthc bIanII
10 .n OC'~I!OIl . lIut fr;tnklf. you'U tus> tot ttaWng tiRIt OII
On~ m:ICh;n~ ro, time on anothtr. sult you...,lf. Tht "".,
n:uon fur doing .III:! Is 10
S' l"iMh "'1""""0 IIM: NI
Scrib<: <Ilo~ on thc bbnk's mds. """ <!riU ~
dia",,,,,,,, pIIob ;"'0 'hc OKI:! fur ,IM: ",,,,,,uing >pindit .
1'hc IDO'" """,,""e"" you <:an aJitIn u.n.. hoIor'.It.. 00,.,..
I lIli" ,,-..;ho:n; 'o oIt"'t LIM: bbnk from IIM: lilr;', crn.b.
Slkk Iho: ~T~nk >Pi ..... k: ,hl'O&'Sh 'IM: hol<: in 'hc lil!'s cnd,

fi,.

IWIJI ...'llShCr an ,t.. ~ 'il'. ,hen fi' thc bIank .

ri<lrI. TUrn It.. (nnlI: anei d,h.., ,t.. tpondk inIo ,hc
Ihc bW>k. 0riYr ,hc b~ KInI' ,~ 'M 1iI!' "' ....
lnIo thccnd of 'hc hbnk.

,.U

Adjusi 1"" jl, 10 KCOmmocll.." Iht blank. To rDYtll smaJlod'lImelef dowel or splndlt, as l t lefl. Ilie bl.onk mun
pOShlontd " 'gh in tlle! jlg , A IlIlrly "-roeodlll""ler bIlnk ... ,11 be SUSP'!'ndrd lrom the m,ddle of ttlt enO p,e{t!. fOf /1
!hotI bIaIIk, tlle .. ~ end elin slmply be m~ c~er 10 Ihe Clllnk end. n ~I rtght.

106

louter ,,"goc

pup..dieul .. ,o ,m, bit n j ~ Ca> oppoKd to one p . ... lld

lIu, ' Ile CU tlin" nllI<"S U e ... ~iu."<Cd .,
tIonr mmniu"" ... 'he horlwn,.1 . u rf:u.: ~ of ,1.., cu,
lIIa>do inLo ,"" ,,,nl<."l. .... II." tlun ,""IJR ~ ~ h.rp. "ilhi'
..... du,.. In ~ . 'h.is bi, Kem) 'o 1e. ,"C smoo. ht:t.
.... " .... surf:>tt.
~ or ~ bi .... st ... igh' bi ... bonom
drairC ~:IAd tnOt"ti!oing bi .. an aii bc oKd. I n."Com
..... tIw )"OU .,. ..i1ic:t1c>..". 01 ,hcs<: hilS yuu ,,"'"C. I( 1.....
~ """" :oLuy Ihcm alL T1I<1I usc .he <>ne II",. J>ro<lucn
II tbo bi, nis).

",_...uc...

"""''ci

1"" ..""'- R c""'~ ttw }'OU ,.,.,

""II." of Ihc:
'hen l"OU al, ..... "" bi,
cx,clUio<>. Thc: dlam." .... II t..-l Ib. ...al.... 11M: tlWnc:t.".
of 'hc
" iU hc ml""nI by lu-lff tho; ol..an }'OU
",o"" 'hr 1>1 ..
Ta n ........ ..,
<lWncIer of 'hc:
,,-hile It b >tiU In
tlle diirnc .,.. of

clwtWl\I< ,""

"""''ci ..

"""''ci

u...

.).., 1111. ~ cal/pers.

Wht:n }"U .n:

"""''ci

olt_. """", '~ lhc ol<J,.d rfOlll .... jijI,

1"00'''''

..-td! Iltc biI n , .... n>UtCT. 5<1 ,""

un ' .... Iill and

tlIc biI almsion. 1b Start. turn ."" b1.nk .... fu ........

!tu il up. :;.:. thc """.". In poo;itIorI ond u'e,1d ,1... bl. 'U1
I botIt::mo an thc bbnk. At ,his ..... "llJI.l"OU' li,,", po.s.< ...ill
iot ..-.y ,"" o:omns oi. "" hbnk.

4. Rou, .M bbnk.. Thc flIll ,.....

'*'

)"OU
,hr Iil\.
01 ,"" opc13'ion. Cnnk Ilie
lIIaoI< ",xhile ond koI .hc: """.". II> lhc: Id\ T1I<1I f<.l
I to th< riah<- Tbm cranl< ,t... bbnI< <'OUfI.crdocl<..-bt; Ind
f,l dIt """rr from rljtIM to Ic,. and Irft 'o r\chU'",,'1 pIl...
II' Olt . 'bm tt... l"OO,a b ..dfkoNing. ...hidt """ , <bItahie
\...,- Iltc n,r 01 )"ti"!" ~, ,..,... cIoc:s Ihc: ipd o(
iIn~""''''' ~ and ~ o(.hc: ~....
l\1If;II .\Ir upnlcncc b ,h;o, ,"" r.c~, 1"" cranl< hr

upc_.' to drvdop

..mIC

.....

-""'", .....<ba
I ....t flUm 'hr ....'
.hc: Idi, aonIi:lng ....
iIInIc dod...;,c.To b<tdn, tip .... """era l"tIe.., Ihc: bit '"
<bI o...... ......n:. S"'~ch II ono,ht.... "'-1 M b;ock on '''''

,o.."'"

'III.

!wt CIIIIklnt! ,hc: hlank. """ >tadi", """.., 1""

1"00'''''., "OU

...., fIC<"d 10 """" .... l'OUter ""'Y.

M C1 )"OU'" ck:IlM'<I 'hc: C'Of1I<n from .1Ie bbn
fIIIIII!inIl il tii. roun<!. ""1..... hc: biI ato:mion ,o :ochii:>"

A"'" fini pUI wlll clun off ,he cornen of the

~ u '/OU Un
Mt,fYrn round .

iti .

1. won ~ nKenarll y produce a

The finl.hfll doweJ's surface m~y no, bo Pl'rfK'.

f ... ,h~ bo... urf~c~ fin/sh pOu/b le. ma ke a ve..,. IIgh'

Cui on ,tit finill PilSS. movlng Ihe (oultr Clul.e slowly

but ,,,,nklng th~ bl.nk fur!>U.ly. A IIgh. und,ng
should clun off ItIt mlnu,e ridges and ImPl'rlKlIons.
(Of cou'.e, ,tit ch.. ocler of Ihe wood you Uit wlll
""~ a 101'0 do wlth ,h~ qUlli'y of , he final'urflct.)

Sand Ihe dowel . A IU'M' .... nd. hi. lurned .pindle

whil<! il ....111 moun,td In ,tit li'tIt. Ind r found Ih;o,
I .... 'S ttlt taS"," WIY to .... nd a .......... , '00. HoId ..
.... ndlng bIo<k aglin .. ttlt ~I. and , um ItIt ,,"nk. k
worJts wlth .. PIlI .... nOe lhough a beII .... ntitr II 100
crude aOO a random-orb" ......0.. i. 100 err~.ic .

TAPERING
TAPEIIl)I,yotJT

: ~.
RotJTINC TAPER
SKtOn vWW

Cflnk Is mllunt.d
Of! s_lld l"mfW
lnd of tht WOrl<piKf.

SPlndlt! ""'" is d rilled

on ,ngl~ Wt~n from Ioyout.

-...
:1
-

Tapering

RouI!n& I tapc1'<'d splndk" attOnlplishcd ~unply by likm.

Ihc u;,s of thc bIanI< In thc Iii>Onc CAd i> hiflh, thc Olhtr
Iow. T1M: ...... ,~ r """..". baeI; and fonb In thc - . . k\"d
p!>.ne, but Ma..... Ihc bIanIc i> :mgIW. Ihc ro.uh Ilo
tapercd .pindlc.
TIlI, Is noi<: ... h~..., you nttd to ",,",oml.., Ihc n><l
pi~ for the pro/<'<:I for thc blank '" bc roI.ted whhoul
bindi"S Or jiAAlill3.lhc r>ivot
In II><: lill e"<b muuld Ix
~ngJcd . So:o ImI Ih~ cnnk ~ ' I bind Orllhc cnd plc , ~
;,. bcol lo I.. ,~ il an Ilie hlgh end of the bLutk .... ..J1U",n In
thc d"",1113 TtI{J<'rl'IJl.
. ._ . .
On plIpcr Of 1\(",1' boonJ. dr\lw thc 1'11"" full~wl

"'*'

10101101109 <II bl,o~ for uperl09 requl.es the I~I

slIlndlt! 'o "" hlQhe. In IlS IIQ 'nd ' .... n ,"" u,nl;
slllndlt!. The splndlt hoIts In 1"" bl"nk .ft stlllloc~ltd
dud"<fnlff. boWl!"'o'ff.

SII"'ch In thc rIIA an<! Ihc tpIndk boIu. Dctnminr

frorn thc top ~ '" Ihc "- cnd510 II", p;YOII
IfIIIIr oIlhc: opindlcs.M)"OU ........ out t
Ihc
oIlhc ~ bIanIc In
bIanIc Of! tbc tablr _ or joInln bd::, ",

li3. )"OU1I .. ~"""",

....u 1_) pai", 01 ph"01

<>ne CAd '" ,1><: bbnk Slkkin up OUl
..,u"" moi b II tbc lIrnIts 01 thc
h<>Id Illows you 10 ""'SIt. tbc blank 10
KCO<Id X1 '" hoIo:t ""JIO'il\on$ Ihc
redU<! 10 IInbhr<l 01 ....
1<)

)"OU

bit.

In Inr cu.. by OUl 1"" ""~:~ ''''.~'':~''''''

."hc propc:r IIlglc,Thm Iruull thc md5 In "'" jiI..

)4ouru "'" bIan~ In

Ihc: jig, >C1

""

Iht ""III ...., anii IUUI

"'1fIindk as )01.1 would in makRg a >!""glll oo.."C'I.

Simple Turning

0In )'OUw IIIa>InN Ihc proceoo 0I1IIminI!. blanh in>

..... and tapao:d rounds. you'U Iitt Ih:d, .,.;u, 1"" . . . .1
_ JVU (;1.11 pn;;><Iucc _
""'limn"Ml' nnbdll>luntnt>.
~ rinp arod 00'.....
la...... !.han rq>Ol a loc oIlnform,a,;"" . In mc: ",k.
_10 lht dupl .... OI> _ing arod .... ng "'" It(..n~.
(jIIIr 169). That. <lot. Ia l<I more tn."OIvcd ,o build and " 'IIJ
. . .h lIII:ft oophiS!ialcd lumingl;. bul ,"" bilS arod
..,. ollhc: KdlnIQue!l I.*d .:an bt Cltficd OVe. 10 "'..

U,""

.......pk;;w.

Fluting
_lut> round, )OII nccd an Ind<:xlng whccJ.This is a disk
..ud otr In rqub. IocrtmclllS. whieh )'OU .. \Xh 10 tbt
bIoJIt!ol pU 01 "'~ er.lnk. Thc iR<k:1l whttl allowli )'OU
_
lhc: bLonk a Spcclnc nun>oo of d<'ltl"C"$. ,hen iod< il.
bt an lhal m..kc a SU". IJ;h' CUII"" kngth 01
bIanl<.
1t)'OU UIIC " Slr.llJIhl. mvnbling, Of botton><k2ning bit .
)!OU <"Olt ""'''e """.. gun.I , hal8O'w. Of """'JO'W bilkt .
"-ah ron:-box, )",u ..... n mul uadillonal, dp n u to:$ in..,
lpbJlI: Wilh <:O\'lnll bit, )OII '''''' etnIe bro<od, >IWJow
...... With plun~-poInl """"""U hil, )"tIU OII roul
lnIo "';"'('1 "",",.11' lhc liJ is kI up lOr u pc:t'in&,}"tIU <211
raiIy porfornt thQ<: CU" OI> ..po:rcd pitI<Iko.

'o

Indor", nwb.bu! >implo. II hc:U..... IO mr mind, rd m:oo..

mcnd makirt ....'htd wilh ontr tbo nurt<s yuo'lJ nt:nI fur
11>0: job :oi hand. \\ben" new ptojcct <kman<b IUffen:nt ""It
"",tIt:Il;"". hn:k_rn:Ike a II<"W " 'httl.lt ~n 'l l:lke Iort!!.

1. Lay 0tJ 1 Ihe ",hcdo U.., -Inch plywood ti<

mnIIIIIlHIcruilY lIbtmu.ro ( MI)F); ro. 1. )'OU1 pUI"J>OI'CS,.. an
,,1. h a 12lnch .... ......, Locale Ihc Cenle. of ~ he oquarc; \bin~
a rum~. sctibc 6-lnch-di.mC1cr ci""" ,
You.:an dlvklc up lhc ci""" In" , .. li<1y 0I"'.. ys. [)on't
II"~ orrfcd ~way .00 ma'" 100 many
though. PicI<
rn ..t ....... lIII"men l and folkrw ,b( "pproptWc OCUC1KC
lhown In II'" d ra",1np. Oncc )'OU'"" >!cppcd oIf Iht ""'lI"
men'", I.bel IlKm " 'Il h <k-gn...,.. """, Iabk OI> Iim pIiIIe
convcu IIK n .. moo of JCjU11CfIlJ In!o dcgn:u for )'OU.

KgmcrI".

2. ROUI OUl Ihc dt~k. Wllh lhc byout ...'Ori! done.

\ot.Inch ph'Ull hoIc: OI> W call cnn:ut. St1 "1'1 }.,..
""" .... and tranuncI. and NI 1"" dbk.

driU a

t""

Ml.king the Inde;1ling Wheel

.... b lhc: bige>I pan 01 tbt job. """, .....ing Indu

IIJffI Utyovl l'Hc: ......-u how 10 ...... cornpoo 10 ~
_ tbr _+ood ,.. )'OU ...,. h OUl. I ....,.,.- )'OU coukI U5C
(IIOUItIOr and 111)' ..... ,,htd with a lvupk 01 dottn

. . . . . of

...-

Setm.nu

S ~ments
,

~mfn\S

72' fi;" ;.....

60' Uell

~ments

45 ' uell

12

)0' uch

~mfnls

"=',----,

24 U9t!'fnts

15' eO

r'

"'" .....

f\

Th e Ind ... ln, w heel r.pl:lus tlll ",.nk for fllll ing
Ind bUdlnQ. Thls one Is IlIld OUl with 12 posillons.
tach with I locklngpln hule. Iv Ins.nlng 1'" kxklng
pin Ihmugh a hult In lne whte lln~o li hale lft lne JIojI
.nd. liS shown. you lock the bbnk.

INOUWHEEl LAYOUT

SIIi"dIA,

-It-l\4"'20 ilOp nul

HlInger bolt

1oi"20 X)"
C,ank pl:ue
Dowel-Turnlng )Ig

109

INDEX WMEH LAYOOT TRICKS

:'--1 '

."

"'
SI,O

6112 segment.

"9m~nt~

@
A. O.IW ~

clrcl~

and ,wo

A.. Scribe a titei". ilHI! the

dlame''''';1( rlghl anglu to

compus set to tlle cllcte'.

uell 01M., rind Ilie mldpolnt

of a ... d l\ll, n shown .. , M.

,"d lus lh,oulll>oul Ilie IIVaU!

pfocen.

.-...r
fi

8. Set i compus 10 radlus AM.

Wlth the compo.u polnt on M.
wih an arc. local11\O P.

8.

Maf~

a polnhllny polnt-on Ilie

ci.,,,m',,.,,n,,,. t.aboel it II. Siep

off fi~ mOte polnts ",.ound tlle
eircumf"."nce .

A. Slart wltll il squa.e.

~<ttf

II.

Illen scrlbe dla!jOnills, A , ..de

scribed In tlle squa ... w,1I how
II! c"cumfe.enct divide<! InlO
elllht equal seo~nls,

8. To get 16 .'gmenlS. S~tl

compa .. 10 lIalf Ilie leroglll of
a d'agonaL Settht comp;ilSS
00 uch coro~, arod m k t~h
ad]ololng slde .

C. ReStlln" corn"".. 10 radiu. AP.

Stati al A. ind slep off fout

addnlonal polnls a.oum:! Ine

circi,,', ci,cumfe,elKe.

C. SpIn Ihe a" t.t. l w~.m Iwo

poIOIS. WlIII Ilie compus 00
poIol II 1, strlke In I.e oulslde
Ilie cl.cle. !.!ave Ilie comp.ou 10
poInl '2 , Ind slflkt iln il"
I(fOU Ilie fi.51 . Uu.
str.lllllttdlJlllO eoonltlle
Ircs'lolersKllon 10 III, ci.cI,'s
cente.pOinl.

C. Br tllis p.ocen, each Sldt ... ~

lIel tWO new m.rh, brlnlllr'lg
Ilie 101"lto 16.

$'
O. Ta dOllbl" tne number of

polnt., set tne compo.ss on Z.

whkh evenlv dIvide. one of the

five segment . Siep off fou.

addl tlonll poinu around tlle
(Irtle', elrcumference. uuend a
radiui "om the cente' to eaell
mark an Ilie perlmett .

an pO'nlll7.
.nd SlIp off fi~
pO,nts
a.aun<! Ilie c'fCumfe~oce. rau
un now scnlH! d,; f.om Ilie
eMIt. 10 IlIt 12 d"umftf~ntial
m,uk$.

O, !'ulille comp;ilSS

mo.,

O. Scflbe il cl.cle. hltn'; a rad lUI

from tlle cenl~. 10 eacl! ma,k.

IPQI>.' drtllN a !.Hnrn hok .1vuugh u.. dI>k

I abo drlIlnl
Idr la ."" Pl', md pIooa " ......"C1 .h..... Ihrutoah d~
"III Ihir "bed Imo ' hc md 1'1"" Ihc ,,'bed and prn.:n..

........inIl .. ......

IlriIIhir ~ OII ..., dnD PftS. Cb.mp ""'~I' 10 "'"

~ 0..:. Ihc ......."'" LaIc hit In ~ p.,..;N ......
... k 1'1' Ihc WI< bt thc drilllnt!: oi IM
hok. n."n
_ .."..... u.n....p. ,"" dj,k'5 pA'OC hoIr "'10 ..., """~p
~ 0rilI1t.. finot hok Thm ,tic ... hcd .0 line up ,hc'
eal
and driQ ~ . Kcql lJ>UlII un, U oii 1"" hooIeJ .""

. . pooo

ar..

"'*.

4. MUe the klocklng p In . 1 ..... pin ...,;o, " . . frum

' " pi<"tt> oi """d I driIIrd ...0J>IIrd ...... In,o 1"" mii
fii ~Mnch ......d Ibm JIucd ..,.,.. fii ..........
'*-1 IIIO thC'
I uimoocd Ihc Jpip .... I Ind! ......h.

""1nIi!Ilb

"'*

............ 10' I~ 1I:r\pII.

, . Mounl . he _ h H I. 'tbC' Indo:h Mri
- . 1 thc ....... -'IIf u .h(: ~ OfilI .Iw ~
~. MII """" up Ihc ......a ...- loo6e for IIw

lw1Fr boii.
A.lomIbk Iltc h;mI...... ,..,.,.. did Ih(: cnnt 1\;lnk'atC".
-.1 ...... il In ,"" ... bed.
~

Usng Ihe IndeJtng Whefll

kbt )UU a('IUllly "'" ,t.. 1'8 lut n"'lna. )'W ""'" 10
. .<it OUl """". , IM: flnl.t..d pu1 ohould Iuok Illcc 1......

'*

manr .wocolb! '&'hal "II JOIi ....,1 1...,.. dftp"""'*l

tIM: aM bel 'I1th thctc 1Il*k1l"" In hmd. ,.... .,., .... lip
ano,!

'*' ,"" ~

1. IotOUnl the bbnJt In tho: Ils- ThcICt:hnlq ... i51hr

....., ... b mo..ne'll3' !!bn. b
fIIlltc
cranI<. _ lbe Indesl"ll " 'ho:d.
, '011 do 10..", 10 drul Ihc ~. p1n hol!:: In tM III',

..,...,.,....Insteod

enll. 1"" p".111on ofllol> hoIc ~OII It.. hci8ht fIIthc

bLlnk In Ihe JilI,. 1k51 appmaclo; ,\Iuunl Ihc bbn hen w;c:
ono: of III" Io<:klnHpln 10"",. In L1,,-" ...11""-"1 :os lJu klc In
drillln8 IIM: c:nd.OII"\ousIy. tlle h olc: .hol>ld roIncldc ... itll an
.ppn",""te allSllIne,.. poIIIl ()f'I . he md
2 . Sec "1' the rou .er. Mount thc b>t<'J)blc on .hc
"""cr Sdea ~ ~ppn:If'filo.c III. for .tIc cut )'<>lI ...,ne 10
make<- ~ li:wn..~foroampk). -' dllI(i; il in
tbr rvutcr. AdjlBc rhc
OI<rn1on. CllIllon ~ OUl 01'

'*

Ioojluk"", Ma 4S k~ tbc: fini . - cuu ohaIIow

AIIa JOIi lIa.... kd ilo" tIM: OjIU ...... ,.... proIbIy an FI
Iht drplh fii cu .... COi ond)' al Iht ......... ano,! _
""""

cu In ....... ~

f'OU'' '

3. Mue thc finit p-. TIp tbr

uP ... Iht biI.
Itdnrflllht W<Wtpkct TryIJppinR il ...... ltIc IlXiool'thc
tob ....... "'hul )"OU 11>-..". It, 'hc bil ..-\lI F<I"CqI Into .hc <.'Ul
... Iii<: CO<'f'tCt 1Ine. "thcr .Iult ""i'OiIf i ,
Swttch on thc """.". """ Iowrr thc '*- SIkk rhc """'.".
u,.. thc 118. m:tkInc thc aM. M ,.... mod! .hc mod fii rhc
"", ... ilch <JIf thc rouIcr arod lift tIM: bit dnr fii thc W<Wt.
pkn. 5cl1hc """"" dnt 01 tIM: _VtI<.
PuII IIM: lodinfI; pin. """ NWc .toc ""hed to IIM: Dat
p<Wi1nn. lcimm ltoc pln.1ockirII tllc b1W. PIrI thc l"OUICr
tack Of! Ihr II8.IQ bit dnt 01' tbc WOtlplttc SoriI~ il ....
ud totii. Kcql ttpe:2lint thio ~ ... 1l1)'OU""_~
flN.-.. on """" qmcnt 01.110: ......

4. Makc adelldona! paoiIIaI. A-...h(: ~ fii

thr ,,"Ori<pie. [( )'CIUr iim cu .. ""0'1: .mao..., odjlbI ttlc
RIUl.".', deplll o( cut. localC .tIc l>IoInlI .0 .hc Mut ..... ""'III
~nd lod: It In P""1, jon ... 1111 1"" pin. M;ik~ a occon<!. and If
n<:C'OI>ary Lhinl .... m of p""""'" In II~ ",noe ",:",n~ r ali tloc
fi"" ~
Sqll~ring

1u;.olr.lrlF u

an Irregular Workplece

iI~'

"OiI

""'"''*"

'unt..

".out nullS or bucls hoto sph.dl., UH lhe

_>1/111 wt.t,1 to dlwtbutt tt.. cut, """ty. wtM.,

""'It.

\O ttle workplKI . fHCI th<!

from onl 'ud O,
'III JI\I .0 , ... otht m.kln.g tII, cu,. Hote the ilO!'
~ 10 tlle 'Id, of tii, J~.

.hI,

sean, )'OU CIIIlbo """

",mllllllijf
10 pbnc! n:oo-l Oi" inqubr
flat ond MI~.
Ikf,r' an cxampIe:
III"' ,..,.., .......... ......., ~
oM'""VI" .... tiu! )'<>U "'.,.... to .um Into Iumbcr
1Jm,'1 how- J'OU do il. DftII JCIIn* ~ la thc 1otI.
~ II. In Ihr dowck....... "" bul lud II. ... It
1km<I'''' Ihr lJUidr . . frooa ltoc """'.". bouq>blr 00
duc )'OU can """'" thc ..,...". ..... 10 oioit OU Ihr jIl .. ....,.
OI md ." c:nd. RouI a fht ~ on ,toc ....
llnlud; Ihc WOtlpoe ano,! ruIatr 90 ~ Itdod;
il Now """ a 5ccoO>d fb o ... 1..... woc1<pku. Ih .. """ al ~
tipi. ~ 10 .ne ...... tlfll>/l "1' ,ne .....
""m::dnlnfl tWO _
In the o:amc iIWI.....

_o

Dy . . -....

oile:

r~

-...
::1

el

Joinery
drilwer j o ints with one set"p of_
, "",. Two simple jigs help y~' ."

T::~:'~~~'~~;~:::~=S~
in!!,

,",.,.".

","'h I'>!nc:II $Iod:. YOIl can

llM' Ihld<cr >locI; fur

Ihc ~

bul Ilie oIdo mU>l hc ~.-Inch lhict,no..-., IOd no 1a6.~

pn:wJuca. nU>h tIn,,'a" Ir)'OU

"""':m ",,-nbppiQ(lm..

tri.:d ..... ' - ' IL

11'1 ~ >lron,IC joIn! bc>c'''1M: the cwo pan.. Int~nock. n...
<1 ....",,. ffOl" Is gi>'Cn a I':lbbd willl a Jink 1~UC: w\ Ilts
In", . >loc in Iho: dr>.",t .kk. UnIiI<c. pbin nI:II:w:I joInl . ~

faJ.c from m .... thc dra..-.;r uz,3 _

,....,mbInl. 0tI u.. 1..... .>I<k,,..,.. .... """ "'~ .~...;..~ I
ctlc Ick ~rId Mda. ......,U al bcf..,..,.... ctlc r",m :ond iIIb.

p;ut ....... """"N IOFIM' mcch.:inlally, "'"C1l """'" you

Maklng the Jiu'

Uu.L

you\'~ IK'I ....

dri,'c n:1ib ..... bnds im<> Ihc join . le <!oeon '1

Iook...,. bcu....

tl'Ic fron, o( Ut:>"",,,r (/un ..... bbn joi"'. Tbt

dr.l,,-b:tck lor _ ha> 1l"'2)'S bn
II ~ to
lot oi 50"1'5.
TIIn! 00I"rIc0<1C $hoovnI "'" an .pproach 11' 5Uddcnly
made ,,~ dN,",'" Iod toin' _ _ o. .....,.., .."'ac",,,,l'h:ol's bcc>~ ..;,11 lhi> ...rup. it is. "'''''''' loc r:l>kr.noI
.... "'''''''' OI

"""".1.

in,.,!."

bstn- tQ ..w.:c_
T'hoo joInny .. CUI w1th "Hoch...,. """.,... ""ud.... In
uI:>INnounlcd RIUl ..... ''ou 5CI 1"'" bII, poMIlon tl'Ic rn.c.,.
anii bw<t thcm. l'.adl joint S CUI n bar p;WoC$.aU willl thc
boi' and ""'" in Ihc: """" po<>iuon. Tu nW:c tl'Ic )""'"
"'"",, )'OU nccd ,....., ClI~1y .unpk ji8>. an .uxlliuy
f.ocill.ll lOr thc ..:Ma table knI:e :u>d " booM .... okd.
AIlhough ,""
lod: foin, nil bc CUSI(>mi:tt<l ' "
work ..'1111 aU IOIU 0/ ..od: lhlcI<tIos<:s an<! <ir.I.."r conrlfl'

dra,.,,,,

ur.,,,n., tllis p:UtCUbr 5ClUP <loc!; ha,,,, llml'a'loni. II ,,'Ofb

112

)'OII ..'"'.., 10 add "

0nIy. lCw "'-""'IlS 01 ..-ood ond 00<nc coonmonpbtt

wvc: b Dftdnl 'o buikl "'" CWO ~ jIp. N>d .
...udy ,tic dr:owlnR:>.,..,.. Im)" find W3)"S !O .... ,pUfy cht
evm IOIOI"C Uun I ha,,,.

~:::::

hmI
-ood:and
hcdnalI
' o ctlc
Uot. ..
Glucc
IIIC' dimcrulons
hcd 10 ciM: Jpedt\<"d
..:>Ic. using
(Stt u.. drawi"ll /JQoI1" SIN I'fan.) M;d;c
~K MUlk nWlh . 1iO ch<y """,, c tlr.ojj Ofl ctlc "'Ulcr
... hen ctlc likd CI hci"ll uscd..

,~ bk

10051"[1. ruD PLAN

IOOSTtR SlED

...

Cunlng lisl
Qty Dlmenslons
~")(

""

~.,

)1,")(

M;II"rl .. 1

8" )( 10"

Hardboilrd

2Y.t" )( 10"

H~rdwood

Hardware
1" brads

IM: obout" ind!c5 10 (ro." I h~ ~ ..... an<! .bou! ~ tnch up

(rom ,IM: bouom nlgc . hl.>ugh ,Ilo: 5piIIc tocu"-",,,...., 11<>1
alt that Unpo<Ul\!. Drh.., ,.,., T........ 1"11tead !hc <":Irriolt"
boIb,....,.j .. ct.mp bolb,In!O 'MT........ lll1.,.tt.I. h~.. nu'
on e>ch boll . hcn a pbo6oc _
el, thc knob. Ih~n jam
,ht helI nu, .gaJ.... !hc tnob. Pfn""'1ng II (rom Ioooorn,p.rr.younn

re.I;Iw

>Ioel< an ,"" table !Ilw.

'(> !hc <Iimc:ruIoou ~>cd

inlIlo 'ISC.

. . -.I~' ,1", pan5

~ .... CIIning UoI.

3. l".taU thc cbmp ~1U<b.. lbc damping "Y..nn b

...." In !hc: Ikwt
dn ...... AuxllI",,. Fe"CfI ffld'W

oi,,,,,

"""- 0riII bob ibr!hc T-nuu In !hc b;oek.ll><= hok:s.t>ould

lne

4. Asscmbtc
f~ fadn8- lbc ~ and !hc
bad<...., gIu<d anr..l ~~ to ,.,., o:<l8cI ol!hc lOp. aslho-orn
In Awdl/ary _
Fad''JIl'Ian. ~ ...... 10 .......... rninII !hc
.ano... 00 lMy WOO'I Impcdc ,M......-cmem 01 ,.,., dn"'cr
~ aIor>8 thc I\::nce whm )'OU .., CUIll1!! ti>< jointry.

ii:

.
::Ii

.....IUAI. ... rENCE FACINe PLAN

It

_.

tie_ nul

"

AUXIUARY FENCE FACINe;;

CUnlng ~L~I'~';...-:~-:~
p,"

Q",. Dimenslons

*" x.11" X 20"

fllCl1I\I

ClAMP A55EMIl'" OfTAiL

'"

."

... ili/Y ~l"Kt ('(lng.

",. X 2" )( 20'

lif,rdwood

",. X 3W X 20"

Hl.dwood

Hilrdwilre
2 TnulS. \4"20
~

11I'ud bo~ In,o Tnu'

llfORE lSl-tmbllng 1'"

M;ateri...

.. nu,

~.~

J'1uuc knob wilh

blind Inun
(bld fOK.2)

2 curll9l! boIIs. \10"20 X ]"

2 hu nuls. \10'20

d".

2 knurled plnlk ltnobs. ",.

wl,h \10',20 X )1,'
blInd bran InSUl; fDK.2 from Rtld Tool SuPpl"f
Co. (8OQ..2S10.21)

Drywall scn.ws. #6 X l '

'"

Cutting a Drawer Lock Joint

.. oM prtnctp;al appnl 01 lJU.j<>inI 1"" """" ..... tI .. hictl ~

b . . . .1 Or b I 1"" Mrawh 01 "'" _mbkd joIm1 "''h1k

,...., . - ..","*-}'OU" bc' pkawd .. how '1u1dly 1........ ..t<
po .... ..-.. !lui ~ "'" 0. "",.- ___ ....., 1""'1 ""
iII\pftMcd ...tI "'- otrotoa Ihq.- :00 ,..,..,.. ~ bolii.
1. SrI "I' .M "",Ier I<lble. 01,,<;1. ,"" ',..j""h .....
e,,"er In ,"" tai*'
roulcr. lodj_ 'M biI u.n>......... thr lOJI ..... oI'M
,mh It ' illnch:aboo..-

1l0000NG SEQtJEN(.E

arr ,.
MU~ IM Ii,s. p,illSS ... uh ,he
ci."... " fron' n'l 00 Ih. 'OUl"
l.lbIe IOp. Tl!e ... orkplec.
,tf<!'ef'lCtS Ilie fenet. P,US!nQ
belo ... lhe a""mary "'nce.

""ed

.......,.

cut,...,

Or ....., "001

lIrIrlII ItIr Jmcc into """"... ;uQund ,hot: (uU.". ""'"

typlnl ..... ""'la m;dtQ' ';tnch4ttp oIooI, ..twm b " 'N '
,....,.--. 50 potirIon oM fr1t,c., 00 It ....in JIC"l""ii thi> ...".tI
,,~

2. 1..,u.U the aUIillary r:.dnIJ u n lhe rence. 1)Iup

ttw: :atUJIluy

~ "'..... 1.... I'cnn"'J ,=101

btt llIc p.p

,.bkwp

""'....,.,.. 1.... f..dnlf' "'........ ct4tr= and tlk

iii
,"'...,....",. It "'.... "" ~ 10 " inch ltI""I.". 'Nn , .... lhi<tc
".,.. oi 1.... dr.,..er fronl . 0In IIM: fronl "''''' fU"" bcno:2lIt
'1 00 1"" Il"" IW<' pitSllO, "<>lI <':In ~ ,"" ~
.,. ,,I,tI. n'Icr.<>tcl>hhk "Iu COlII'''' ofopxeno In eIIht:r~.
C odlU>l ,.'" tlot..1' ljI; ~11on . ,'" IljjJllrn Ih~ cWnpS 10 ~
._ "'" ."xlhuy r.clOljl

.;
.

3. Col ' h" J<>lnt. IU oho..", In 'hc d ... ..;nll Roull-W

s,,1,..mu. e.>Ch joIn! 1. cut In four ~.llIc dr:Iwcr front
b ... 111 Il".. , ...... Ihm: ~.- ""1'*"<1 ' u rompin ... u..
~ry ..... ......., e"" l. OII ..... A>unb ...... ItIr dr."..... >ido: b
..... lrd_ l~ ~ ItIr faur JWOOI:
I 'llh 1"" olr.o""" f...... tl:at on ,,,", NUIa ...... I<>p. ils
n~ fiIcr up. """ ,1 ........
l. 10 ....... ''''' 0I'Uftpitn" fur on'O<MI r-s. .... it on ,""
000M(1' oIc'd. lhe OI'knuUon ~ u.. Am<' Thit
r- wiII wIdrn ,.... >lot 10 " 1ndI.
) :!Ia 1"" okd ..... """ ound ,"" 0I'Uftpi<" on md ",ith
thc np<M\l rac.. <lUI. Qidr u.. wort ........ :alonjt ,tir
aux-,. bclnjLand um ItIr >lot 1 ..... TlIisco->pIw:$
u.. ..",....... i'Tonl.
" SIot "'" ..",....... >ido: ~ ,"" ............... on nod. and
fted It ....... u.. IIWIiuy Irnce 10 IlUkr ,hb cu_

--

,un
Place Ilie ci" .." fron, OII lop
of lhe h1,dboIo,cI boott< sltd
and ...... lhe _ond ~'U.
-'91''''. IM wor1cp,.u IS
Igllnsl lM ftnce. btto.. Ilie
aUJI,lilry ftnc .

0<.1"''' "ont

arr , .
Stand ,1Ie drl_' ',om OII
end. and.1Ick II M>ng It..
au"ihry "'nc Onc. boIh
ends of 'M _rkple<t irI
tUI. ,III! "om (s tomplo'ed.

Or.I_, "<>nl

"'lIm ........... fW\' ."" ................ ,..,.. ......, I d .......".

"'tom m"l<l.... ClIK I\JU 01 d ....."'.... It 1, """" ""1""lI'

10 rn>kc ,tic fi ... piO on btMh cnd> o( n<:h dr;o"""

ftun, (a ..... h..,:. ) Thcn ..... ' lor .In! OII II", I.N..Op and
n...1c , .... ...cond put on ~II ,IM' pl..... :>ci ,tir okd :a.ick
...... comple'e oi", ftunt, (.nd
s,,'IMm ~-'dc Ind do
'OUIi

,"" .....
""
TlII. >l'f"'OKh

"""k

~ .... po

IM ..'OII< ano.! ItIr """Ine

~.

nil..!. and n,lnl",,~ Ilie num"", o( Iln\O 1"'" ""d! ...... ,....
..""" '''''-''<-'ti

CUT .
SIot IM dr,,", sld. wlIh tlot
WOf\.pleu: on end Ind ",,,.
lhe all"ililry

.""Ing

f,,,,, .

Offset Baseplate
Are yau on tha "ge7 Tens. ilRd
10001.1ing. teeteri .. " . slipp lnlll'

1'1111 oUlrigger Inse.pliue milkes

tdge-rouling mo~ troublefree
Iry htlplng you mai"laln il
router's Dlanu.

...
",

III

"
.s .

'Y rou,cr """r~,1uru, In ........., shapin,j( :In cdg<:.

\"ou I'<'fdIlhc mldtl"" 'on Ilie: ..."(Id;. but ""'"' Ih:l"
lWf 0111 b Wl>Uppo<tcd. Oby. lIU!'bo; )"" kC<'p ,Ilo:
1taIIa:obgJ>ro ,,-hll ,he rol!" ul ,"" CUC 11m ~. olicR .. not.
""'W FI ..... h.ndl" "'..". lhc ..'Oft . ,lIe Q1h,,, .,.. rnc,.., in
lerrilOl')". Il', a ""1:md!1Jl.1KI
So e i1.""y "'OI1<1<1')'OU occaion;>lly boIlbIc. llppin" tI><:
. . . ond ,nlP!"lI II,.. cd:iP:l
,In 0"", ~tc IIkc ,hit cm hei!, yuu pl'CV<'nt
...... boIlbIa. II. obIofltl .11>1"" dtm.,. a rou td~ b.:ow.a
_ bas.1Idty tnoII "' 1.. W1bc;.t ot:>dJ , 8(J )'OU an ou,

.. ; ,ed

~,Mbobblc.

1lIr ~1.o1c is f.oIoty 5mpk fl'Oit. I( )'OU .n: 001

... pa'tlrubrol>oul lhc ......l1Ing.)"tJU an c .. ro ,1Ie dla>c.
~ of p",""k IQ 5h2pc, driU ,he nn:n"'Y b<JIo,"'" mounl " OII YOU' """e . 8uI ,,, prod,,",

.""pIy "'"

prodsion oII>ct boa!q)I. tc. onc )'OU an u"" for 'n"pb1 ...
..,m. lot aampk. }'Ou >I>ould out" ,. '''",p'',e, ,hen mak"
.. ...."..c from Ihc ' cmpl:.nc.
A bmdi, of ,IIe:
.pproarn b
)'OU an
cdI!' ..kc mon: clan onc b;o""pl>!c ''ou an .... kc .......

'=p':n"

Iootpb"

ronfIscwN w

,r..,

thto\.ofth tll" tcmplal,,;t.ppro;ICh. 1( l..... c:I>oo>c to oIcip.hr

" ''''I>I:uc. IlO ngtM ohod.J"" 10). OUt tbc t:o:ucpbtc drtttIJ"
on tll" p1u15C'5 ItPSkInll p::lpc1". and """'" fn.on, Ih"", 11)"00
.""'~ rompIt1dY"'R: oltbc 1"""'ftI""",.1 wouId ~I!I'
)"OU '0 rad .hlUU8h thr dup "Thc Gmcrit: l\a!qltttc
OII 1"'# 63. II pn.nidc> a fIIOtc .I>OIOU/Ih and 1k..11cd
~ lOr mh1l anei lIuing ~ 10 a routa
llIc d """Ing> """'" tWO <.Ill'f<:ttnt <i:.oI:s o( (lff"" bak(>b.e . FJtoo ooc <.":In Ix- m.uk rrom tbc nomln,l fooo->qtAt1'
p~ .... plu:1c (:IC1)'lIc, poIycubon:ttc, and pI.......:>tic)
.'" ",..ibhk rrom moik>rdrr ,,'OOd ....'OI'k:i1lJl """~ llIc
"""'" bticplalC )"00 ~ OUt 011 a dl:qjonaJ. 1IS }'OU <""~n occ In
IhrllmYintl. w hlk Ihc omaIkr OM 1< O<tmt<d OII.he_
pic from .si<k tO otkIo:

.Iu.

Make the Baseplate

iIJ.h<>usb

insI:alllnl( ,'''' b>Ob b .he t..SI .hln& )'Oll 00

ordt"ri"llit '" ti", ''''ry II... !h1n,)'OII)houId do. Wllh Ihc
""n./w;I", n hand.,.,.. """ mok" anei eumpktc th" off>Ct
h1wpbtc In J....... _ r Of ',,"D.

a.,<-"" ,,, lempl;n" lIul<lc . an(!

..c..r tO Xttpt falrlt' 1a'1lC"<l1.uncl proflk bilt.

iII lIIc foI~ Slcp-by-Q"p, III quk:k'r 111~ )"OU

1. C UI I lie .e m p La.e b l:.o" L I """" ">nIlw _ .... 'J

fib<:rboln:l (.'.11)1') tor .he .cm(>b.e t..:..... ",.,. h ' ..",oo!h an<!

'"

Ei

_.

~
~

._~

OFFSET ..... SEI't..ATE LAYOUT VERSKHt 1.0

bid ''''1'8-6 pW,ic: knob

EDCEVlEW

...

BDTTOM VIEW

,
,
,

-----,

\."

Tw,' bit open 'ng ,.bbtttd for templiltt guldtl

CUllla, Llst

fb . . ..11h o ronsistC1U. vo;a.frtt COft: ond o rcloti,..:1y Iow

prict' ,,"" an ..... pl}'wood. !IO Iong .. 1. III frtt o( voids.
Of P;lrtldcbootrd, Cut ,iM: bbnk III ,iM: illrn<ru!on; .plfled
..,. ,iM: Cut'lng Lbt ,

Pl rt
Templl't
BOIep l.,e

2. L:ay out tho: ~plat" on the bbnk. 1'0110",

Ihc: oppruptUtc O/f$d ~If Uzyoul dr:twin.I!: . ,,1'J'f'Q"
.,.u.c mea/'" u.e, ,"nlIion t O '" ,iM: ......Ucr ~p L:"c.

Olmt nslons
W X

MiltlriaI

.'"

14W

PIIStlc'

h' Xll }j,' X I I}j,'

Hardware

,.......... 1.0 '" IiM: b..,....

\Ii "Il ~"""p.1SS. 5Crihc ~ndKIi.mclcr d,dc ;LI " " "
C1Id o( W bbnIo:. o i -inch-di2mncr circk ., ,iM: uthcr nJd.
Uk Slr.ligl"",*
luide
""rthlnl o( W1gIrnI> con"""""1 ,iM: ...... cin:ks. Ik >u'" !"" clt:lrt) mari< IiM:
c...nC1'Jl<'ln'" vi w drdc:s.

'o

Qt)'.

I mush,oom-5Nptd DllIstlc knob.

dl._ .. I,h ",. thruded in,,";

'1011'8-6 f,om II:tld Tool SUPDly Co. (80025) 04ln
2~, '

'o

I fT"hud SIOVi! bolt. It d ...

Ar,.,w, /II1IJIC~_", _

X~

"""""",,,"~<III ,~Ir_

LA YOUT OPTIOHS

.".

.. ..

SmaU

b.~ ~pl&UL

"

...

'"

"
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",

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116

ROU,t,

M~lc

..

,"

CWfS(f IASEPl..ATE LAYOUT VERSIOM 2.0

x~

flilhud SlCM! boii

.......
o

....
3. C",t UtIl II", ""mp"'I.,. U600

~ $1 ....

or hilnd

MAMDLE ORIEHTATtOM

.... 10 ("III .... tbc: baxptllt JIul)(

I\lr IK bat I ppn ... ....., of II,., flnbhcd basc-pbl~ , tbc:
DfIIut......" mUSt bc srnooth ...... bir. l"w roun.J IIut
..adi IDo It ..... fill In flir1n3 Ihc: ~ . II ponIbk: bel.

. . , B hII 1(!IVQ6i'" IOd B'fficull 1" romrollor oomc... ~ thi:i.llhInk. buL

M~ 10"}' 1f )"OlJ ""aM, Micr liIint
. . . . . _h.ho:m ..llh. r.,M.k:In><><bit OI" pod .. n<kr.

sn-.:

4. IIore d ><e
Io*l,IIft tbc:

II

1.-

boia!. T... lor oul 1"" """,nU,,"oK"'''

routt,. b"-,,,pllo.c Stkk .wo Dt

,h~....,.. 1

0/ Orpe! "P" on Ihc mul.,.... fx ....rr ~pI>'r

. . .., (iri ..., Icmpblc . lhaI pn::so It Rnniy In pIlocr It
_
bt cool, of CO ....... , .0
.1 .., bIt ..... i> .... Ic h <hc
.-.poin. of
ci",.., . hltllh>l .Iiwlmcnl .... r bc
Iti lIlRI 10 achlc>.., In .hc Itll " "Ork1,
m ..,h Is

1"" 10,.,.-

ha..,

.ha.

- . i. 1.
" "ilai iI~' .. Ihc otknt.>uo n oI"lM mu.e' , It.:an.... lbr dDwlnjj fla ,,,/", Oritomatk;m .tIow. .t.. 1......
prIIcipoI......,.",u 1 like .hc:'''fI """. bul )"OU suit ,..,......
!III.)8t iIIiIIn Ih<- "'.. plnc ... tbc: len.p!;"" "" Ilie lw"L<Ic>
"\I(..-ben:}'Uu .."", Ihcm.
DIa """'" for thc moonolnJl ""..,-ws,MIrkIrd 17)' 'M bas<:,... Coonlcnink Ihoc hoIo. Orill " ' ~cr hole
tbt ("tdt<"tpDin. 01 tbc: ~H ""'. Thls Ij lot .1Ie kn.ob.

_....

s. u y ou. !Ind bute the bit o pc:nlng. A \'.

poooi:lI bit in tbc: ""'tcr', coIkl. Moun. tlo., IcmpblC 0tI
.. ...". Dan't c'..... "',. "'" mutcr in. IIrin8 "'" .ip ul
.. Iti in )nt3(.1 .... ith "'" bclxpbtc. 3nd lum l!tc hit
......., 01
kll JOII' hiI"" 10 nuI<c .!tc C1;ntc< of
bit mact IKa:mcrpoinl .
kJrt,oo.., l!tc rempl:ttc frum .!tc n)Utn". arni bon:
I~n" hoIc though IiM: tm>pblc Ik >li'" ,t..
W. il <mteml OII .hc ..... rit nude I>y thc bil .

",""utions ..

Dffsel

~sep~le

111

6. Makc rJ>t ~pla~. IM co"""" "'1'" 'u bon" ,1 ...

"'1""" 01 (JIa>ri<" ,..,..., .....kx!<-.l ~". ,""

,rm"l:ll~ tu ,""

ha,..pLlle. (fl>c" '1'f'M'I"JI~ Il;&> ~'''''' un 'k ""Il.hl<plelio 'h:u rmr ""II' ,..,.. <kdok "hKh h> ..... )
UrW "'" _
fini. 00 ,"" _ ' ...""''"'
ono,!
,"" k ... Jb.mounlll'ls hoit
Cnun,~""k 011 ,"" ho>lno.
_ , ''''' hI' ~ -... a ........... bit """ I"mpI;o'"
JILIItk TII " .. kr a bit ~ b" tuIW1u\I I\wt......uIIIM'l'"
!COOIpb'"
I 1' ........
,ltn..... ,t....
"""""~ pb'r, ...... I ' Hnd! ...... ho' PI> ' .. in<IH.).I>
InIIplotr I"klr "Thm JWilch 10 I ~..- ..n.,jIh' .... In "'"
......... templotc , ...... ano! r.obbr1 , ........ \\<":bun"
n..., lin Sukk hu.hi,.. ano! ..... , .... _
'lui <kpth.
It. ~1Ir'1touI 'Il \ndI, 1u rhtrt.
II,..,.. .... RI I bII opmInJt 01. <lofkrnot ..................ith
OI"'" 1IIt/btJ>h1"ll """,Iton:o,..-. 'Ibu (":In _
....",. u
bent "ZCS 01 hola . ...,;i,.. INot I ',.onm
In LI ... ,rm","I"

..,."iow. ....... is In """"'" nIII<s." "'~o:<J . I I M _

k.,.,..
a"xJIiaoy tnob "'..". Ihr
h>nd .... It .. J"U .............". ''''' rouIc-r

t""

"'*'

"'*

"'* . . . . . .

,,,kb., .....

1""

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oU

jL:lIi<k"

FifWI); .... IljII. pa1l,,", hi' .... nlhlHtIo,,,,,,, .. bot In )'UtIl"

......,... Imn 1"" ....
pU,r 10...". I"r) , ........ pbI .. anol
tit(" ~ pU'" 0p"n . 1,,11 lI .. hm ti ............ p.>per
roIIOO otrl"" """'tnl' nll ptol" " , ....,., tlle- pbI .. 'OI , ........... .".

>UII,,'"

. . ._ ,

..

T'Gub!llr. . 1td<;l,",utl"<;1 h whl' Ihr Glfnt b",.,pl~le vln,,"11v \IUA1."'HL /UlIlllIJht,ouch OII ,III!
INLSlpl~,e\ knob CG"nlerleU 1'" fOIIltr'lltndlntYlO

tappll afl Iltl worl< .

Offset Baseplate on a
O-Hand led Router

r-

If yo" are PJon,,1 tOI O-hltlelltd routlfl . ., 1..may appreCIIl' th,~ 1011" I'P. MII'" '" 01f,,1
pIote wilhaul'n ,,,.,Ii.lry knob. h,~nd ,1Ie 0111..,
"nder fhl o.h.uldll. lI's I t"A"""'~ ....,.j,IOUIiOA
Ihe roIIlt. In moll "F"mILlnUI-'YOU jul' dori)
)'OU

'UlIU iI\ 1h1'.

lut "'hin you lIftd Wt 1.'" ..,~""...... ,.;
,,,nply ,h,1i. \~.
of 'ile _If. PlAI'''iI1III

!IO""""

VIU .. s"rf". whlre

Usi ... a ,_pLala aIIow~ you 10 m'~1 mulupill

quOC:kl'f itiel
Sto<k IM INLII~II II\I.lffliJ 101 Ihe
IIIIIfIIIII. anei fHd le lround I n",htrlmmlng bit OII
1'" _ f f abIoI. You U/1 ltW"n IdlPlI Ilmpllll 10
II\OA! Ihin _
model of fOIIl". Ind 101 bcxh opall .....

,..,IIy.

...cIdur_~ .

7. IMWIIM

o~

knoh. 1 ... irt"l.n1 ..._

l1li)"\0" ",""k btob (rom "'" Idd Toul ~"rM ""....1br

""""" rumlorubIy """"""
jrip (n .... oile- ~e An)'
n .......... 01 .."",
..-.,..Id ,,'Ot'I<. Ind >uit.bir .. ,"10 .....

_,iD 1""

COA""""

Ix Ii>ond In......,. ~ ...",,1)

""'" pMtlcubr knob I mo...- """ ' .. ind1 'b..-k<!
in..,n .... 1"" knob io ",...,hn1 ... "It o ' ,.in"'~NIj( flIlhncl
.. OI........ '

Using the Offset Baseplate

, ..... prublhl) ........, ha .... I

\10" 1 "f !.l,flkul,y fiMurilljll

"''' 1...... In ...... ,....... """,.., m:a<lr ,oIT""l 11;0""1'1'1' 1lK ""'''''

III

lI.ou,,, 1011<;10<

II; w~1

do

t'" _t lJOOd

Flush-Trimming
Baseplate
lllUe In old stilndilrd OUl
_temporary. h igh-IKh
IIIlIril ls. 11'5; ulr.. s li ck .
utl'1 lough.

-,..
."

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Is

bule

Iixt~

In

o' u\d;, ",..[ )'OII ...., b ............olullut ..ry ,,,....'

1hIgn, hul CUfl''''''P''''rr
or ... 'okl .un.... , ~ 1\,< Ik>nc b ...nkw ,h~ """WO ro CXI~nd , ho;

,-cnioo,

ado ot tt... rouIa" hit an<! u.-aI high-qu:d il}' m;II,""" llw
....... lin"", ~r.nlnlt .ntl Ioolg-b '''I\j!;
n.rn,..., fIWIY 'ppruKh<'" 10 nu>lHrimmin{c foboo. hul
.. 1ta!<pbIc il 1110' ICncr.d -pu""",," lixIu ... 1Joo:oa..... II

'1',

_ Ibt ...ma uporl whkh h n:>ioI

tbc _pLu" I
... for =mploo. Ia lrim ""O<lOIkn ~nW"" OI" 1,lull'
....... ~ 11>(, <kIgn >II;"'" "'f'C'CU11y briW"1y
_1IOIIklf! In", nJI'I'"-b:ln<kd~ . ...""... <lIher n",,,"
......~ """",,,Ilr fali..,.
TlIt Irld: " ,h(, , ~~ <lcsIjvI. 111e ruu'<T Is
-tIttl W III<- uppa 1;0)""', " 'hlch I aII'.... SOl" A"..rnnr
D Ih< """",
5U~ S 5I>ortn bl""', ..-hk:h I 011
acbtd.Tht 1Ift! ....." "'" " ....,n '. ind!
...,..., ~ C3n dn. """ru,lom,111" bit
1'>I1IwIac 1OI.Uf. ... ju>I da. uf lhe ...ori< >Wbtt. ..-~ it
..... tlIooir~ nJ .he.r> , _ ",r.IIra..... "'"
lai I..,p;d b:>d:: ....rpl}, In"" thc bit. l"" . . """ II" n",
_
M )'DU "'"Ori:. the IY ..
OrI oi..,., ""10 ,II<'
""rfK<' . nd )'OU a.,""" II"" lrimn"'" ...,.

hoI",,"

,110\., ,1.., .."",

"",mU.

_......

"""1IIIIl1ICd

pLa'"

la'" d,f';;",,,, 1>;I....,pLalc ........... "",,","TI. Qn., 10 ~ ....

lamm:.o." 'rin'mtr, clIC "' heT lOr. ~ Ii.cd-"",", n>ue~.,.

Maklng the Baseplate

Ahl" '''lIh ehe e".., tusq>bfa ar<: Nljln!) d!fftrme in conf....
ur.,Ion . "" nu ,~-rUb ...col:u>d .IIC C<)JI!IIruct<>n k"Quo:nce
~nd pnK"nluon "'" ""'" ""'''' for bQlh .

p"",.,,..

my._

1. Cu, e"" hcd and ,..,Ie

I ma<k
n ...... 'rimml... """"pU.... (00<" fOr. bmlnl>'e enm....".. """
lOr full.oUnl ....... C1") of

p~k .

for .IIe bmiruee Inn>",Cr

""..-pbtr. l .....d e"" 1.)"", o( '"Hnch pbtnoIlI: 1kaU!<' uf

' Ile

<bitIn nf ."" ,rin.nl<Ts ....... uoing dnr X'lll<: ""' ''''1

"""ng 10 1'A"Id. .n)'

moft

vi.a.llny. (kM aC"f).1I<: <lua1PI"Q-

un eh<: fui ........., rou.C1"'. fl>scopb.c.oo 1

ditl "'" i. for ,"" ook pIlI'e for elu' 1"OU1C1"
fl1h", """"pl..... o( ..........,. nn "" """'" U>iJt1l- oerflic
,1< "'>I)...... rhon.>.ec. it
~ fO'J' "",r.:...,,,,,e. ar C"\"C1I pir......" d. n....... ''''''......Il,.;,) Ilbnbu;aru (MIl!'). ar 1wtI>o>nl.
If )"0\1
mnd "'..... il1ll
,II '11''''810 o( .""
pl.:l1<: "'0<1<. C" , ...... pKCn ,"" ...,,'" oi~ . '~ ~
di" ............ o( ,IIe .,,'" pl ..... An) of ,"" nu,rriab d,n! nn
bo: cu' "" ,"" ul>lc ,," ... Tu lrim ehe "..,... oi ,"" beci pIlI.e.
, .j"k """" 'bi bill,)'

.tu,

oi",,,

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3

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FlUSH-TRIMMIHG IASEttLATE FOR LAMINATE TRIMMER

LAMINATE TRIMMER BASEPLATE

Cunlnl USI

EOCE Vlrw

M... I'I.oo"H.'(It knob

''p ~~;
80nOM VlEW

".

PlI.rt

110")( lW)( Il

Hetlpl.te

Hr.")(3W)(IO~

Millerlill

..."....;;;;,~ I
I'hellolic

HArdwAre
(; flltI.ud machlttt SCftws. IO-l4 x)l'

1 m.. sl'lroomstyle plasUc knob.

2S'J,' d,a. wnh ~. I h,u~ instrt;
'Mf>B-(; from R~1d Tool Suwl'f Co. (800-lH-()4llj

e . ]"
KffcWS

Dlmenslons

SoIe plate

Knob moun!lr>g boiI

.l

Baseplal~ mountlr>g

Qly.

2 pI.oslIC opact . W 0.0. )(

~.

1.0. )(

101. thld<

1 fhlhtead JlO'It bolt. h dl .. )( I W

A.. ~mblv sc.ews

PLATE LAyoun FOR lAMINATE TRIMMER

SOl[ PLATE

HUL PlATE

MOUnlln!l' ICftW I'IOIu:

un f'ttory 1uo,.pll"

PlIuern .

.-'"
C

-....

clu.,"" hoIts
for

~. ph~nollc

E
.-E

..,~.

Counttnunk \<1

u~mbly

o.nw,

..,--, ,..

10 ~

,,,,o

AsStmbty.K'tw
holts. tIpped
for 10-24
mK~lnt .c,tW

Counltrsunk k hoit
lor knobmoumlr>g boiI

"""II<'

"'"' II'I.,.;....~ mite,

10 1"" .1lJdor opn:rocd In ,'''' b)"OO1
dr.rwInjp'. an.d "". " 10 .h<: krlgtll """""n.

2. Mouot IIM: !IOto: On thc router ba!ic.

~

nu. ...

dclllilnl in thc """pter""" Coftlc1'ic lla.;q>bte:

,,1I1e1l ~ on p. ge 61. Bosically. roo ..... Ih<: (aelOl")'

b;uorpble ." a ""Ilem (or dliJUIljI mo..m;~ hoIa r1
thc bbnk lor th<: new b.:I,;ep"'u". Ir.t :aii po:>SIoibIc, o fut
_
5Cft"Wll ro .t""'" th~ new ~. t e 10 thc rotIler.
, 'ou ~ ..... m 10 .lim the pbtc 10 <:OrIfonrt to thot stup'"
01 thc rotile' ~. The om.1I plne "..a. madc lor. tk\\~11
lamlna'e 1J1Inmcr. wllleh ha.'! ""uare Iw.c; ,"" pbn rrlkct.
conr",w:.tion.l1lc
pb.e _.........xd tO .......:h

,hal

Il""".

.he ",,"pc 01. lle\t'alt I)W 610 lixeclba.., rotita". To shapo

J"'" """"plate. roo (211 radiu it ..,;th
and ..........t
or u im 1. witb ~ n...tHtmmi~ bi .. .... Ing th" faaory .......
pl:o." a.'! a pallem.
y"" (211 moun. thc lIOk [>bte on th" .outer ~
chcc:k your worl<.but thm mnoYC tIH: pble from liH: t-.
\'ou c;m driU .he bil opcning now. or ""'It until tlle: lintI
"""P. ,,'hich b " ......1 I dif.1 il rou do it 11OW. }'OU wiU b'e''''''''
'o .rtn'lhot tip front ..., hcd [>bIe

n)U'' '

3. !.ar ou, .ocl drlll ohc IlS>ICmbly.sc:n:... ho ....

,,,'" Is kq SlCfI .'lina' .hot , .... pb.c5 an: IoIncd 0I'Id0
nuchlnc
drIll thc hok< ('i<l
wtll lin<: ..

"",..,.....10

'''''r

flUSHTRIMMIN(; 'AS(PLAT( fOR FUllSIZ(O ROUT(R

FlXEI).BASE ROUTER BASEPLATE

Cuning List
I'ln

Qty.

looIt pl.ot~

Oimensions
)6'

X 6' X II W

SIOE VlEW

Cle<ir uryl"

)6' X 6' X 'Ilo'

Htd pl,tlf

,,-

Millterlilll
f'Mnol"

BOnOM VlEW

.-1

Hiillrdwiillre
, I'IIr"uod mKlurw KrI!WS. 10-24 X ~.

1 ...... h,ooIfHrylt plasl'c knob.

lI\,' d~ \.,,111 ", Ihrt.dI!d InStrt;

ft1P1-6 from Rtld TooI Supply CD. (800-253-0421)

1 pWIK SPI<trs. y,.- 0.0. x

li' 1.0.

I ~j!I\ud Slove bolt. lot ci.,. X

)( }! .. thkk

I~'

e,

"-ATE lAYOUTS FOR FUllSIZ(O ROUTEI!.

--3~
"TI

seu PLATE

HEEl Pl.ATE

eo."ws~nk ~ .' IIDln

IDflfKlunl;ng Seft"'S

In

:r

,lot clufAR<I hoII

faf mountlng Sefi'"
COUnlfrlUnk ~~. holn
for I . .~mbtv .,,...,,,.

<>j --

-,
h

,......,,-

~ o
o

''''1''' IIDIes.

llWtd lor

10-24 """dllrw KII .....

...

p~nollc

'""

pnftttly

for~. j " "

m ..... driU IlIem in boch pblD

Stk:k."" I"~' 1''''''''' "'I!,.'.I"" ... llh a (OIJpk
>ntlIl1 ",...,," '" nrpct I~""
Uy oul Ihc ioooIlun. u( Ihe IOCIT'W lIola. If )'UIl an:
usinl! hbd: phcnoIlc. ntUIt ,hI; ~~ ,mll;l puneh or . ... i.
f)riU ,"" lIoInI wjU>. -15 drill. wllkh i> Ihe COrtn"l.ac for
, applnc Il).l4 ,1Irn<h OrIUI"" hol.,. "" ,1Ie driU p~ ti<)
'hcy ... 111 II<: ><iU:O'"
lr IhI: hcc:1 pLue CO>~ H1J' MOW1Iing~"I'CW _
In
Ihc !iOk pLtIC. }'O<l wjl nttd to dnU ck~r."'Cl" hoic" Ihro"w.
Ilie hed
b 1"" ti ..... 10 Ioc::ole ' ho:sc lIoIc<. Guiokd
by ,h" ",uuntltlJt>Crcw hoks in loc """' pb'c. drill 'hmugh
IhI: ,,,,,,1 plale
oimul~.

O:unp Ihc pLt,e on .op of "'-""1'. S... itch "" .... 10111.... II1II
...::d: the "",,,Ins """'II ""1U>tn,e,u nltwliMn 10 p/unfIr
and rrtnCI.hc bit .IIIUS "",,,,,,,,,Ilie opnti ....
An alI""'"I;...... pp~ , Iln" 1"'" 1 ....:d. b 10 bon: tbt
upcnillll ..ilh. Fon.Iroc. hit <1" IKIk "" ...

1'''''''' _

4 . Ta p tII", boieo> In t h",!I<)1c pl:ll"'- lac. I ()'l~ 1.1'

proc~u",. il )"QU\" " .......:r doo>c ' Ilu ~ . Is <k1:IJkd
In "'" r.,..cun: "Cuning11unds" in the appcndu: Omd: 1""
tap in.
n:n,,11 App!)' the appropriale lubri.:anl 10 Ilie
"'1'. ut.<cn . h", tap ', 'II' In Ilie bok. and turn Ilie "'-lnIClllo

n.c,

"1' ...

MarI

II\c Ihmd:i. ",;u;e.un: thc Up b

q~

19'hcc

pIl'".

E:och coujllc or lums. ~k .tIe "1' up. qwnet' '0 lWf~um

10 b<nk up Ihe (1111" .1111' .U <il .tIe -.-mbIy hoIo In IIle'
,;ok: pblc

t""

S. Roo riU a nd counlc .... lnk the bok:3 ln

h ,..,1
pl:lte. n.c, hol"" In .Ilc h~'Cl pbol'" ..... too ......u for Ihc
aoocmbIr iICrI."O"". [)rin IlIem witll , ho bit. lhm COI.U1lCnink
'hem. 1Ic OII'" 10 hore II", countcrsinh ""O Ihc surf.occ u(
.hc plate Ih......,.. aposcd ,,"hen j'UIJ olrilkd ,II<: hoIo In
C SI''P ~ .(lrJOU ""'~e Ihc roun.en;lnb In Ihe .......... lIidc. thc
Ilok:s p<t>babIy ...unt line up "'hen)'UIJ Iry to.-mbk Ihc
f>b'es.) Iloo: ,"" rou"w~n~, ....'CI' c"""l;lt 11..1 Ihc JCIT'W
hnd, ..iU,..,.... hdow 1"" pLtlc sutfocc.
._
lf l'OU hue ~c Ilok:s 'o dJiU fur fUU'C"","'lIIllns
t.. ""n:..-. do
'1.,...,.., 1"" oeI'CW h"..u. and hore
.hglllly Ltrgct hok '" Ihc hc'Cl pbte

c:n

E
E

-.'".."

bie.

Using the Baseplate

.11>, ........ .

t:"

.c

Ot"us up th ough .... uplat. RgU . llound Ihe

$qua~ cQ,nt'~ wlth a round~, bit in 1 , .. bie
mounted ,Ouler. StIInd Ihe bllsepliue Ofl edgo. IInd
II up ..."h 1 ScrllP pushe'. To make 1100 cut. fetd
11 llonglM renet and Icron Ihe bit .

6.

A.'i/lCmblc Ibe baKpbu:.. lllb b ....",pic .. dn.

,'Ins fo:y; ".,...,.... Pbcc 1"" lwo pl.le._ log<:lhcr. ,nsen
' .. I"d'1onJI 1().24 fb,hcad m.chine !CIC,," I"w ".ch
~on~IC'"
and lighlC1l it wj' h """",,dri>"c1"..

10.,..,.

7. Mou n t tM k.noh. 1 . - . mU>hroon.~.pcd knob

... i,lt. '.Inch l"""n. It OI mounled ,,"Ihc b3s<:pb'" ... i,lI.
' ''nch-dl.n,no:r. I ~Hnch-Ion:tI: f b _ .."'" hol. To e"'
.,.te Ihe knob frutn tlte pblt . I lbftl eouplc of
'1 ...lnch-thick plastic ~ bouJd>l .. tbc Ioall""u"... 1C

..o'"

[)riU thl; moomln",-boIt h<>k. lhen ('OWIl<n</Ik 11. A

'>o-inch ot",,, boii It... Ibm big hnd..... a ... counl...... nk
is n-quirct1 \u..o n.. y bc- abk 10 IoIIbotllllle a wtIc V"fIIOO'ill3

bit in , plw'JIC fUIlte r tor thl> job. AlPin. tIM: rounlcninl<

m .... IN: <kcp """"!Ih tlt'l Ihc boh hnd 5C3U bdow 'hc

f>bte ..,rbcc
8. 80,.., thc bit n pclllllg. o"P'""tlill.ll <>II thc fUIl,o:r,
an . ...lth caUIIOI"I. bon: ,1Ie bit 0(lC"rliI\lI "";lh iL ehud:
Ihc bolt In 1"" NUICT. then k'rcw .hc pl:lle lu tM fUIlICT.

)"OU

I ZZ

lloule.

""~'C

\\"hktI ba>qob,e '" ti,,", 11", un,' 1""1 ro" )'OUl" ,."..,ff. o(
cout>C. 1IW iI)'UU
laml ... te lrimmcr. l d ~
1""1 """er lUr ,ltis "..,.,.. It 113h' and nt:llYU\.... rabk. Eil ....
,,~.1atJ!o= or _
. 11 ... b;oocpblN an: u>CU In 1"" .."'" "'"1'.

h.'.....

1 . Set IIp Ihe: r<>tlle r. 1!cIl\O\'C t he f.n<>ry b3s<:pI;IIc.

and replocc: 1, "ilh the nlJl.h~ri m mlng buc:pb~
xlo:cl ... Ippn;opri>'t
and chuck II In 1"" rouIcr.
o.:""ndllI3 upon 1"" "",t.... )"OU <= usc: a botl~
boli . " <lod<H:""'nup bit disii ""'tler. Of' muni'lns bi, . ....
of
arc daip>cd fur ohnring thc 5uruce "' thc birt
III" You <= abo U>C ot~1 bIl.
Adi .... 'bc cutlin8 drpth br botlomltg Ilie hl. OII
.>I1Cl"I .,1' p;tpn'. Th;ot mcant j"OUt biI ...ill bc: re ... ,looo
smd,h.. sby <il ,1Ie "'OAin!I>tIrbcc. (M1' dW nllpc:rs Idl "'"
'beci of ')'p;a/ copIc:r ,,",pc:t" Is o.~ Ineh 'hkk.l
111", ""Ui"l.l ...ill ~ecp thc bit rrom _~ Of " . ..,,(IIn~,
>llgh'ly w,e'"C1l .urbe<:. ~ aI_ i , 10 p;ttc ,"" =1 1'1'01""
...000.. ,\f!cr fU" lrim ... ilh .h..... up, ' h~ ...uh . . . ndn>houkl bJinsll ...... r(""" dnd flu.Jo.

bi,.

1""""

1"'" "

2. Trino II. e n onn",h stutr. Ik""-' ....jjchlng ""

IIle' "'''ICT. take n.... e of 'Ile nud\inc'. balancc:. "Il>oup

.... pbsIic

bascpb~c:5

Sttm ~o

bc prntr ",eli b;oL1rw:;w

.. lI<fICRI tcn<Icrw:y witl> "...,.. 1u>cpl1..cs l. for "'"

~ 'o lip 011'<> "'" biI. . .\1)' p<>In. iim:' I:i II"" )'OU n~
III ~ tlK mUie. LLpriAht br plOllilljl 00..'11 OII Ih, 1>:0....,.
plllti 0/1'''''' k....... 0I1L<:rwbc:. ,iL<: !>it ...iII 11"\.119" ,IL<:

.......

"-uh OM iund p"",,,lnjt (kno'n QoI "'" knoh. 5WI.eh QoI

.\1"'''' Ihe rome ......u d the protru.kln

.. lI)<"""'

I)qJendmg upon wh'l ",-'<'ds 10 IL<: 'rirruJlC'd.)'OU ""'f >iiUc

and b.''''pi;L.c .<IdnI"'l'" ot)'OU ~ ju!.t .-..vin
IK I'OIMItI' in In In:: around .IK knob Ib!lic'all)', )"" """n, 10
" ......" 1"" """n~"""'. off
...m~ 1)00', .tk,w ,""
bit 1" <t>o",U
k"'tl1n ~nr <InC "PIC
"'L1h a linie pnak:c. )0011 ""''dop a ~ and. Ii.:el
lOt "'" mIIIunc:n.. ,lut ct~L1t1bu1c 10 ~ and tcaN>UI.
" ' " ...... 1tI'

'o"

,Ioc

_Ith Ih. flu5h' lrlmmlnlil bau'""'t.. ..

......" trirnme. '~n work pl~,es Ih~, piloled Oush
_"'\1 biL , .. n' ruell. TII .. ,'5 becauS4! Ihe m.. ,hlne
tih OII I~ wo.klngIU""" ... nd IU bit pa.u away
~ ho]h ~pao:s ar .16gu. T1I11 5. wllen Iflmmlng edCJf:'
bItId.cl8. u shown. II un '''linia bolII InslOl! and

ouuo6e tomI!'S.

"TI

~1weoI

To aYold 1I011111nll Ih , work, vou mUSI hoId II><!

routtr uprigll! by p.uslng down firmty wllh OIle h,tnd
al Ilie elld of ,I><! bastplatt nlens~n. Use YOU' Olher
lIand 10 slldt Iht I'Olllt' atong Ihe rld~t of mauffi"llo
bt .0"Led aw~,

III

:r

~
_.

3
3

_.

:s

'"

Monising Jig
Monlsln" wlth rOUler JUli
"0I il whole 101 euler. Tllil
jl" seu up qulckly, holds
the work St(urely, .. noi
ensures Ih .. t mortlsu .. ,..
consislently .nd .ccur.lely
siz~ .nd positio ned.

j
c:

OI

'~ biggc>.I .l"lIIe dJ>Jlcnge in moniMrIf!; wlth a

I'lungc !'OUl'" is hokIi"II tbc w ortpk ,",'hIk ilmu\.
~ )Upportlng and guldlllJl thc: mutcr. l'hs JI,
mttt> the tehillO<!W' ha<J.,on. Il 1> ,;.impl<: '" nuJr.c, cur ,O

T:

CI

up,lnd a sn.p ta u<:,

1.

woodwofiodrlf!; 'l """m~1

ar<' 1I<llng tu W''''' ..,. a
woodworkcr and <.I",-.;Iop y..... .kill., you 11:1,'<: 10 maoIrr
tlle "",kiog of tlle munbe4n<kcnOll toln .
ll>e "'"* ",",,,,,,n I.,., ,he monlS<'. which is . I>ok:round. "'lua~ . OI" l1""lI-"ur- :ukl ,"" .enon, wllk:h 1
cut on file" C"tI of . lIe joinlnJl " .. m"". 10 Al It",
1II<H1~ ()rItt ,..,.,mbk<l wllh g1..., ar """" , he ",0"1..,...1\<1,enon
mi.,i .11 rour I)"pa ul "rn.~_ 'cn,;lon.
romp~. shcu. and r.od:i~ An<I 1. doc:;It. ~tcr II.. "
am" OIhcr typ<: 0/ joim.
ll'oc nuln ad''3JlI'geo of II><' roule< for monl"lnll
inci..&. ,he stDOOIhncso of ilo finl>h.td ~'U~. and .hc xc ...
De)' of ~nl arni oWfIJI
pobIbk ,,'" 001)"
dis:KIv1tIugr .11.. cornel .0 mlnd '" tI><: lin,hro rr:och <>1' .hc
mu .,.,. bit. A rwrow. decp moni>c:-'Ii Ind! wkk X 114
inchc:5 OI" mon: det:p. ro.. cnmplc-itI probkn ... k for
routcr. l'h<" ~ caii do It, bu. It eullrn on'l. (GI,,,"
thc: >Umph 01
1IIuct.."""""".",,,,,,,,, tuJluw m<>t'
u.e """"0 SI!'O<Ijj joi"",) A pllII1JI"
I >piN!
Slr.tlgh. !>il. and an ~ Ilui<k 'NiII h:...dk """" ull"" ITIOI'
tisins}'OUl! ft.'" ...~ I 1<,I do
111" "I<>nlsc.nd'cnon

fr:>m<: join. , )'OU Imow So if )'OU

'''''8''"'

joi"'

,!W'.

""""'m

'"

mu.".,

or

1'0 rouI a ~,Ihc II ... Ihl,.}'OU m .... do b cdlhIt

up a ll10Itbing ils 10 hokllhc """'1*'
l bc orltllnal vcnlon o( .hlt II$! ..~ c~ ....
buU. by """ Bun"", " , """ o( Rod.llc: '. """""..........
booIr cdltOf'J. "",," lItI h... ha. mI~""Orid Iook - 11"5....x
of !oC"'P .. 00<1. Il0l nnl<lulI IlUICI'b.L 1. h:u Iou of "'...
hule), .he ro:min,Jc ... 0(, ,,~ otl",. ,hlng>. $1."1"> tluI
1>:1,,, bn ",poMlloncd. Thcn: aro: ~ .......;"3' iti

rrom pl'()jt> p:>S'

My dUpt;co.IC , ~...,. In tho: pOOIoo,b a tlrtlc: dIff<n: .... prittWtly In ,"" lwtJwuc and 1"" qu:illly 0111>0 malmalllnCd..
(Wc "'... n'lhc!oc III!:'I IO ~>OIr ""'" "" " 'd 011 ..."0111 IlIupt'l).)
Thc lltt ~ ""~ t/Ilnst>. It

_ hol<ls onc ....... r1<fIka al " Ilmc

ml'.cd;
- holtls ,he won:pk.:e

loO

"""'''''''Y'''

Iw>dll,. is mini-

1, <1000' 1 mo"c:al

)'OI' I'OUI ,

- . lk>W5 )'tiu 'o $W1.ch wor1<p;a qulel<ly, ~,~

.hcm con5l1lcm ly;
- pn.wt<kt- .<ktj.t:ltC b.:.rln[t WrfOlCC, ... "" Cu , Is C<><ft.
proml..cd b)' ..,..te. lip o. wobblc;
- cnahle!t)'tIU ' o jlOSi,iQn ,"" cu' W<\S1:stcft11y (tom mot
. 1", to monl",,;

_controh Ihc ICllJllh of Ilie cuI

IICMIT1SIHC JIC UPlODED VIEW

....

Cuuing Llsi

Building the Jig

"rt

~ lmlIIdtr 10 coIlttI alllhe

nCCdoS:lr)' I\lInlw:trc bdurc )'0\1

Iqjo il, 10 ...." aJW8)lI appropriJ.lc. Sollle of . Ile l",nlw~",
111110 pidco<d uP "' Ihc local I\lInlw:tn:",Of<' 1It, lte 1111
_ , WCIIt wlthoul tllc.(IfCgk c\amps. and It Is II~dy )'Ou
.. ltntIOOIdttobtm. !ll1M _
tlmc:. <M\k'r Ilie pIa>Ik'
..... 'l'hm IM .. utr arm-o. l!I"t to ...0lIl Of! 1"" li&-

1. C\Ic Ihe body parts. Tbc: iiIts body. iInncd oI.11c

1f,1Ioct, lIId ~, Ilo lIUodc of Ihlct It:ardwood. """ uocd
I~ .... pIc;I.1Oed l !.-!nch popbr. u.., " '1In )'OU ha,,, OI"
1II1",oor hand!; OII c:ronomk:>ll)' Whik 'Ile nlllcriaJ you
Iboukl 1)( """""'ben: in 'he I ~. 10 I ~ n:aIm, Uw: spt-

'*

tIIkkn$ of II>c parts b rcl;ollvcly unlmpo."Unl . ( 1IU1

--.... to odjWlI dimcmions It
<1<> tIe .... IC flnm llIc
l\iIdo t/IId<J>c:I.s 1lIhoo>... In "'" ."Uiou!o dr~wln~.)
..... Ind Ihicknooo IV~ (rlghl-quutcr) IIInl ...'OOd 10
1'<I . . . . 1lIp anei ClUllllJCUI tM body'. componmb ' O II",
"'"Mil..-;fkd .". tllc Cunn8 u...

j""

Dime ns io ns

Qty.

'"

Mlteri'l '

1"" X 4J'," X 1SW HI.dwood

F~,~

1"" x6" x

1""X3"X t5W Haldwood

I"X3~"X

Horlzonl,,1 worbeil
Vt<t,,~1

worlc,eil

SIId'''9 Slops

15W Hlfllwood

10Y.!" HI.dwood

I"X2WX7"

HI.dwood

""x ' "Xg"

HIt.clwood

Hardware
2 P~Sh' knobs, I~" dll. W'IIt Jl-16 x I y," Sltel SlucI;

101(-29 I.om ReIci Too1 Supply Co. (!QO..25HM2 1)

4 b.-ss IhreadecllnulU.

~"16

2 piulic knobs. 1~" dil. wltlt \("20 x 1 Yt"

.01::20 from Rtld Tool Supply Co .

$~,~I

SI"";

2 brll.. IhrN>d~ In"'t}. \(-20

2. GIue up thc Ils body. J..... II"" 1.... lOf> 10 IM

Ii tbc btt. Ind gI"" thc boOl"'" 10 II>c td; oIlbe
a..MIndIcw:d In thcc " ....... ing
I~ lhcr<: . n: ne)
.,maJ _
1\0:"" but do 11)' 10 kttp 1.... body "1 ...'" a:.
.. 1ppIf Ilie , I;oml'".
AIIu "'" iJuc hu ~ .nd .he d.mf>' III"" bccn
~ tcft!'" olf ""y <ltiW "IUft,_c'<:JUI . Then joinl 0110:
la lI!d 1"1' 10 .... kc 0IICSC" . urllK:o absoIllIely
10
.other Thi!! is cril~.

,.f,,,,

"'1"' '''

1 log;le tl.lmp

(Oe'S~~<o

4 p;o.nltud SCfews, .8 x

~"hud

M>lt~

nc 21 5U)

Jo',"

boIts. \(" XI\("

ou", Ilie front antI

b;Kk ~

0/ Uw: lap

""",lId 1ltl, 100 '" crillC":l.l . Il nnSary, lip 1....

10 """'It. 1. p. r. IJ(,1.

td; """"

MOftlsln; Jig

125

J:
:1
O

-.-.

PLAN VIEWS

TQP'JlEW

Plutlc knQb .. ith

~ -20X l !4" slUd
(Reid ,OK20)

1 - - - - lSY.r" - - - - , L -

~=!I,f"

,."
,

L,
"

low" - -_ I

SIDE VIEW

FRDNTVlEW

IW-dla , knob

DeStaCa "C""'

1"991~

damp

FRONTVIEW
~t

Up for End Mortling

.-."

III

'f
O

::lE

~~0---J

Plastic knobo .. iln

1i"16xl "'"stud

De-Sta-Co flC-215-U

(Rtld ,tOK 29)

\Ifhik i!'s noi csscn.i.aJ, )'()tJ nur w.ml 10 seu", cen,c!'

.._ .... line .c...... ,h.. lUp. I r.n<I lhe C<:1l'<"fIlno< hd~ In .euln! IIp
,h~ jig" Ihe ~nninI; of exil moni5ill!l: projcct.Juso """'.
su'" 71. Ind~ frtHTI dtllU alti uf thc ii~.tI<I
line
ac""", ,h" tup. 1
ulili'y knlfc 10 seu", lullovo' V
gro<l''''. Ihe" Inked In Ihe Iim: ,.!ith . n finc-tippcd n:d

usc.'"

"'1"""'.

ma"'e .

3. IIlSIaU Ilie I,hrcadcd inserts. uyoml<X>I;on5 of

lhrca<k<l inscns In the f.Jcc..,,(I top, '" ,,'cli as the '''''0
hulcs fur 'he slKling.... op 10",..i"l\ pin,;. 11Ie .potS "'" .110","

1~

in li'" tl .."injl.

ft,rl~ [,uJ'OWs.

II "'tiple of ," Wr<lU: In "".,. IIl<: slWinli OIop!I sl\ooJld

12&

RoU ler Magic

_____
IO~lt

cli mp

,h"

edllC1!-ukk rods. II is good !da 10 set ) _

plufl,IIC rouler-flual wi'h ilS alge guide-on 'hc 1is.:tIII;l
sec lf )'0<1 need 'o
yuur lis '" an... mmod:ne )"OUI
ruUl~r. [f II ... roW; "",n'l Iong """ugh. )'Ou will "",m 10 <1>
ti ... ilg tOp 10 m:oke it """"""CI', "nd Ir.1>o: !<Iiding $top$,
:os po:;f.iunnl In 'he pt..n" 'uu<:h ti ... fUule' ,,"het tIwI
sqOJ:l.rely comactinll.h" rods.)'Ou will ""'ni 10 nlO\.., lbem.
TIt" \oc".lingl'in hol.,. ~re ~ Inch in di.mcter. UriI
romaei

',lk>r

th~m

.bot"

I Ineh <kcp.
(>rin pilots for Ihe ,ttn.-".<lnI ~"" nal. In 'h~'''1''''
LI", tWO 1""''''' fur tl>o: oIidlng "'o~ In ,h" (.ee, there ...
tWO hoks r..... thc hOriWOlai ,,'on:n.'g :>nd
for ,"'o
t(.'2.1 "'011<""' . If)'OU don ', knuw Wh.l di:lmc<n hok

,"''O

". 1

,.un LAyoun

'"

SlJOINC STOP
\4"-d;". x )li" dttp
hoit for Ioc.., jll(l pin

\4"20 'hruckd Instn

, j
VERTICAL WORKREST

."

,.
1r

2.

HOII;IZONTI\l WORKREST

.... L - + _'O

1" _

TI

r ; . S\4"-

. Urt---'-,----,rl

t: . ... ;;rl

}-.-.,

1.---"--- 1O~" ---<

R lor Iht ~ mc:lSU"" ."" """ o:IUm!:tt'r ci (J<I(C . .i.h

611 abpcn.. (Ibe moi diamct~r It ,"" d!amc:ta ci thc
. . . 1MIok Ihc 'Iuods.) Note ,tu. '''''"' a"" ' ..odiff...."..

_ 01 iIIonu mzuim,l.

~ Ihc hoIn ."" born1, drh-r ,"" iMIon . l\H' du.fI

opm5h-r rucn .001; usc: a nul ~Mi h"II .nd a

.-:II. Thm .1", nu' OniO ,II" boII, ,1I~n ooJd Ihf 1""""".
"'" thr nUl down .g;ohlSl 1"" Inso.n , aMi >IlOn lumlng
... imn 'he pilot holc:, Ontt)'OU lt1
In!;cn swtC'd.
., thr .. f'fdoCh OII du: md ' 0 turn ."" Ocmb/f.
,...j . .

t""

t""

.. Makc Il..: ...orkresls. Tht.- Cun. . Lbl 0Ip0Ci/lc>

~ ~ .ho:

t""

..'Or'I<n:5o!;:Il I1dI: ~ .hcm tllidn .,..

. . . . . . )'013 ..1011. !lut In any ~ , Iht oIoor In
hori.......... a>iot IOruui. 1 think, I')'UU worIc ""itI> a wi<Jr
10IId r.ICbo:r tIun (J<I(C
~ riPf>".l '" fini>hW wkl'h.
lip I boInI '0 ...idlh uI :aboUI 6 1no:tIt~, and C~lIt
10'1-Inch "'nlllh. Uty oul boIh tI><! hori"""t,I .Mi ,..,...
... rntJi OII 1., Mou, Ih" .k>ts ", i.h pluf\jjC: ro"'",,
~ ,,i.1> an nlfI<' guldc. Ro", ti", hoInr In , t.. ,=101
al. ' " ''''' IWO ...... rrom t"" boanl, and ~t tt.. '"ft'

t""

,tuc'.

Iahat 10 ""'glh.

S. tnsu.U Ihe

toAAk c bmps, Uty oul tlle poooItlon uI

_qp; cWrIp OII codl ral.llorin polot _

and (..,;tw a
. . 10 r:ICh ft"I\ lII"ilh ruur JCR:'W1l"o. )"OU dorI'I realI)"
aci IWD daJop.. )"OU nn a:siJ)' wort- ,,'itI> onc: cl:lmp.

Un yotar d.1II ",... 10 dri ... Ih...,d" ldurts .

Wolh Iht Instn th<faded onto , bolt. and tht bolt
c h lKk~ In .. dfill IIffU , II Is usy ta d ...... tht Instn
squaff 10 tlle fact of ItIt jIg. OON'T turn tl>t cI,llI Pff U
on; lu.n "'" chuck by tund as YOII advanct IM qulil.
TI.. n twO tIt~ nul' onl O Iht boll .. oo l!ghleo ont
agajnst tht other, J"mm ,nll th~m $0 ntltlle. wlillu.n .
Tu.n IM 10$tn into Iht boit nt~I . The jam nulS p.t
venttht Insert rrom worklng Iii WJY up Iht bolt J~
you lu.n th~ drlll ~hu ~ k.

1 0 la )" oul . o1<)n""'o ~ a liCf&P 01 thc ~

>Iod. and (>Uliu.. .t.. mortJl;C o:octly wl>crr II. iri ' 0 bo; . .
M.'" Ihc ~'(o ..:fil"" lCnlol4.hc mon!se.

2 . CI.. mp thc Ils 10 a ,,-orkbntch. Sn rbc ii8. rbr

"';Ih a """pir de

w., oIlh.. wor\hencholod damp ~

cbmfl!"'" quld<-a<:lion bar d~rnpo;.

}o Set I'OC work""", an<! toggIt: clamp. Ad, .... tbt

""",t plea w ill l1e n""h M lb.1>c lop 0I1br
"II. It )'OU a", ""1nJt , IIe h<JrI4>ntal "'"', m.o.ke .."'" 1, i PM'
oJld .., .he 'Of>oIf)"OO an: Uiln!l thc: "CMk:aI ..,.., m.o.kc ""'"
It', pcrpcnUlcuLtr tu ,hc 10f>,
,,'ork~

""'''c

Mlj.... "'" $ndk un the '0SI!k darnp OS ~. Tho

..... mp.'ihoullJ Sn:Ip .",anly >JId bold "'" workpKa xeun:tr.

40 Clamp thc .....rkpkt-t 10 IM Ilg.. Se! thc ,est pKu

on u.. .....ond line lip thc ccn,crtiIY 01 rhe monisc wlrh rht
CCtItCrlo"" >ocon:d laOII6 thc Jitg. Sn>p Ihc "'I!;gIc elam" dooni

The s lo" 10 th .. ho,I.l.Oo\," ... orbest an IN!

,0ul..:l w ilh. plunge roule, ... ilh an Nlgt' !ilulde ...
IhoWR. Work ... Ith 1 w lder bo.ird tllan nudHI . 10 Ihe
rout~r w lll be ldequllelv IUPPGMfd. lheo ,Ip 1\10 Ihe
final width.

r-...

an<ldling il 10 ... hiehe,"". ~ )'OU In: ""1"3. lIc:ar In minii.

'00, lh.o.' )'OU mor nco:d 10 tlltifr ,he v<i'ion of ti", '''IIIk
dilmp. ...""ndin' upon . t... wkl. h of . he ......tpkcc brtnJI
mon;,ro. 1O In opinllk doesn 'l Intco*n: wlth tt... .... 11 ....
1':lntocM.l.5C1'tWS Io:nII . M)'IiIh ap"",,,no.ncc 10 the Iil!: (.ntl 1
Iblcd rhmt !n .he Il>"'.....~n: u .. ). h Ul 1.....,h tlryw:t11 ""n:w~
...., more n:al-....".j,J.

6 . Makc: thc ,.1id1n8 ,.10,... ILS wlth Il'" ...."' lte

ilops:an:""" made rrom I "",,",pIea Illat ', ~ t""" thc

finished ilop. 1#y out 5Wp oJotI nch cdJI<: 01 I .. Of' s. . _ , , _ bo:wtlo an<! damp II. U) 'loc """"'hendt .., 'hc
_
iln:2:i 10 bc .Iounl extcnd oIJ 1).., bo:ndt cdF. Wllh
plu..., tvUlcr C<julppcd ... ~h ni.,. guIdc. cut t .... sloi.
O
Croacul thc boln.IlO 1n1Ith. ~ fip .1Ie ...,....,

1:

::lE

7 . Imcau ltM: " 'orkrc51 . nd thc

.,uched

~tops.

Exh

S
10 'hc ji8 bodJ' ""lth ",...;Idcd pb.>!k
kno\)oc lumed !nIO .1Ie "ppropNl(: Ihmdtd Inscru

WOI'I< .....

>1.,....

n.. .udi"3
:an: >lmibrly txhaL 'Ib ....." nch
stop ~ . , \.IK'd hct-hcld bolt .... Joo:;uinl pu>.
I"",n lng 1, Ih rot>gh 'hc >lot !n10 the .ppropnole hok In the
' - _ , Iil!: .op. ""n u.ed 00"""" ror Ih l> pufJX* bul lhen ~ued
IItem !nIO Ihc holaI. Lc:a>1l3 .hc pitllo- " 'hclhcr boItli Of'
<luwc1$-1oo!Ic: allowa )'OU 10 SUKI Of joint the ji!! ,up 1<>
""r""", II... ,urf.oao.(1'or Ihc: .. te of)'OU' jOinlcr kni'"o'
.... kc "''''' Iile In)CM' an: sunk ..",U hclow thc 5Urtloa
bdo"" tloI"\{ Ihl,,)

Using the Jig

'J'hr

li!! b real". qul.e """y ro >ct up ..111 ",.,. [)an'l bc Pu'

o by IIM: ""mIleT ohtcps. 101.........c but .. mOfflcn, oflwo

10 oa:oonpllsh

121

Rau'" MagI(

S. SclIhc pluoll" dcpIh scop. Chuel< "'" .pprOl.....

bit in your pIurw: ...... t t Zcro<>UI Ihc dq:IdI ocale, Ihco ...
,1>0: dq>tll )l\0J> ror Ihc dq:IdI 01 rnonisc .,ou in1Cnd .0 lOll.
6 0 Adj"'" the edge guide. AI thc cdF guid<: 10 rIx
" ......... Set ,"'" ruut .... Olt tbc: iii!. witb Ihc: Juidc n:ft ,eoocq;
,hc baek . . . 01 thc ropof'hinIII' rhe bi' -wlh rbc roo:.n
HnplIlggN. 01 rounc-Io rbc wurl<pIctt. WIth rhc ....
guidc: Ioo!;c Olt il> rods. ;odjuo.t LI>c posirion 01 thc router ..
.ile: hit;,; <'(n'cred ""ltll.", thc rDOI1ltC' b}'OUllioQ.1\Im Iho
bll by mod. and ~"'" "'" cu'ung flu .,. 10 CIbUI'l" rJur l
n::>tly is CCOIl"n:d.. Slkk II>c guidc: up apinst thc ",o, t.ct
<.... It<'. a ..... "j{h,~ n ,"" lc:><:Idng knobs .
~ "'" ruuu:r from _
to _
._
thc Jl*k IIN>/J'
>PIn>! II>c ils. n.. bit ~ n:maln ccnlrmi wiIhIn Lho
",,,,,lsc 1..... 'li""'. 1f it doc:s OOI . !IOmCII\InjIirI out 0I ,,hac1
Elther "'" cdfp o( rhc jIj( 'OJ> :an: 001 pMolId. Ot rhe &tu 01
"'" lot plece arc noi p>JlI1ld.or thc nlOf1lsc byout b

_o:wnt

7 . Adj .... thc ~11d'n8 ~IOps.. Thc b ' tftl """"""""

0I11>c tvUln' i :at1'C>ltd wh"n Ihe: ~ lIuk1c rods conu.a
rbc ~ >lope.M.,..., Ihc: tvUle. k: ~ Ot fij{hl lo ~'Ioo 1""
bit ar rhc >tty c:nd 01 thc <rIOl'USC. SIkIt II>c $IOP o.p.IlUI m.
rod on tha, ....." . ...... IghLcn 1" "" ob.
SIidc tIM: roul .... 10 II>c bit is pobN 11 ."" othcr cnd 01
the monisc.
thc "'09 :aplnst ,mI :oidc:'J rod, I/>Il

.,....,uidc

1Itin,

~.cn ""'~
8. ROU1 thc ..,..1 mo"*,o WIlh ,I>c """"'pOt
dampnlln the fix' .. "". ond ,,ltll u.. tvU'n' au ~ upol'Olll
tbcmonix.
i'lW1fII:'O" 'hc cndJ 01 tbc """"bc: II ..... Doina tlIb
thc cndo o( ,hc monisc ...01 IlO' wnlcal. n...
tvUl oul u.. wutc het"""", .IM: cndlln a Jcric:I 01 p;w;co.
Wl><:n)'OU t"UI , bc 1Ut1:)'OU Ittd.hc ,.,..' ..... In ,he ....
d,n:ction . , 1><: an" ,m, .. ,.." , 1><: /OKc oIlhc bit roution ..
p"U thc: lIuide apl"" Ihc: wuri< 'Ib 00 III ... )'OU"", JOI 111
n:'.-.cI thc hIt het"""," cuni ... pusa. WoIII 1).., . . .

"""""'" ,m,

SETTlNG UP ROUTER AND $TOP

L Sol Ih. workp,eee on III.

worl<reu, hning up Ihe
(.nlerlin.on II w,lh Ihe
<.nlerlln. On Ih. JIO ,

2.

~vo:'

Ihe roule, 10 posllkm Ih.

bk tuclly belween Ihe lavouI
IInu for III. monise Ihen lock
down Ih. o<Ig. guid.,

1, Movt Ilie r(lule, 10 posillon Ihe

bkJu'lln.lde Ih.l~youllln. al
ono .nd of Ihe monl...nd
"djusllh. sliding SIOP agaln"
lho e<lgt ouldt's rod,

f~_.

4, Movt Ih. roul., 10 poSilion Ih. bil

Jus, inslde Ih. I"yout lin. allhe
Olht.r .nd of Ihe monlse and adjus,
lho Olht.r .Iidl ng stop iga,nsl lhe
.dge \!uid.'s MII .. rod.

_.

VI

:s

III

IIIII:T1SE RDUTING SEQUENCE

1. Plunoebore one
end of Ihe
monlstloth.
full deplh.

2. !'Iung.bo,e Ih.
olh.r tnd 10 tl>e
full deplh.

1. Roul lhe wi srt

from belwun Ih.
IWO hol , nibbllng
aboul \4" detper
willl ueh pass.

4. Continue 1111.
proc.ss u"lillll.
monist Is
eompleted.

glri<k <>ppo<l.e )""'. riWng .k>ng .tIc jig 'Op'S b. ck cdl/:<'.

you DU~~ .hor euu!ntt p ... by moving ,lIe "',u'e' rigII' .,
Icf<-l')M,n n::tnct 'hor bit clnr o( .II~ wor1r .nd ~lide ,lIe
......,n back 10 ,tic rigln_ Then "'plun"" 'hc bi, fo r .noth~r
eunnJI p;as>.

9 . hncll poe; itloning nurb On tit"

t-

tht

ii8. ","umlng

rigll! . )'U\l tu>"c onc mOn:

.xltJi"3 .tIc octwJ _
.
poctt<. y"" nccd 'o dcri<k ,,-tu, ~ .... 00 you wlll .....
0 ...... _
tht ....,.,.".,;00 o( " 'Qr1rpkccs bcing m.onixd.
mort;"" ,nI '''"''' <>UI
$CfUP t:i.OI< ., complet" bd()r"

y"" 00 NOf nttd W romplc1cly ..,. OUl

....,.,1".,1

~.

,.

"'"CI")'

.,

''''' ,,'" nuri< ,1>(- ttI1.erlonc o(..,.,;:h

1. n"'Y 11" nsicr .0 L.t) .......Il<' mii:>

you con ~Wn::ond nuri< ~ ...-nr1rrWtt"""

""'m ~nd .1\tI\lkr "'" nwtJ ..ith 1qUU"<" ...., pmcI.

GI.cn .hl. ~ppru:lch. )'OU nttd .o lillhtly pmdI OII

moni~. S.. bdorc ~='~~.:,:

.,od J)t'nctI '0 ""'~" II

IiI! wp 'hc "nds of.1l<'

monl"' . ...., >q ... n:
nur'" on .he 1111 .Of' .

,
The eUflIlu,1 100)'0011 mark 1, 1"" Uni,. (Ifom Ind 10
endl of
mort,se. Tht,e~ a unle.m.I,k on 11>0 Ji9.
and yOI.Ili~ up the ... )'OUt ""rlt on "', WOtkplece .. ,tii
it. Beciuse of 1\ow)'QU"" se. up 11>0 Jig and 1"" rau",.
Ilie morti" ... 111 be pe'fect'" POSitioned.

1""

Loos.." non jOi"" are ... lIitlhe venlul W<),mSI ~

tor. To mak, a Iooseltnon Joln1. you rou' mo"IJtIIo
both raii Ind stllt, Illen Inlen Iltpa,ale plece as ltot
ttlIOII w~n Ilie Jo,m Ilusembled. Typlcally. tllt
p<obItm 1, haldlng tllt ,aU SO ~ monlse c~n be fOOloC
InlO Ils tnd. As 1hown here. Ilie vt",c~1 ...o,k,nt
iOIw. 1111.1 p'obl~m .

ROUllnll a monl.e ulls for 1 it,,,"s of Itgll. cu".

Plungtbo'e tlle Iwo end! fI.st 10 ts.abl,sll 11>0 par1t.
m"t .. of .lIe flnl.llfd monlu. TiMn plunge Ilie b'l
about \4 Incll Ind makt a PUI. (unlng from ont end
10 .lIe o.lIt . Rttra<1 .~ bll tree of Ilie work. and
.ttutn 10 .lIe l.a"lno pOln . PlunOt a IInlt du"". 10<
tllt nUl P<l11. Rtpt~1 IIIIs 'ouune unllllM mool~ I~
<ulIO III final depIII.

110

Router Magic

Shop-Built Siot Mortiser

Irrth Illis flnure, rou a.n un your
plunge rouler 10 CUI monisu_

nd
10 rOOI lenonl, S1015, .nd groo\les,
(Ve" 10 (UI moldings ilnd riIIislI!
IMlttls. II'S il Milrvelous Milchlne.

nd .1lII ,'''' ntt<J ." "'" hund~ 01 mortisa. Hol>

Monn .."mi obopping for 3 .....miM 10 do Ilie job. It.:
~. "" s;,ys, " had ncI.hc:r tIM: ~ nor lhe
opn l<If a CO<nnICItialIy madc
moniM:," Ati .... thinkint;
00.... """ Ibllng IIIs l'C<julrcmrnl:f anei <loirn. Bob A<"
lRd WI hc ""uld hener .;;,,~. 1110 nCftb br 5imply
....,..,. ond buikling his uwn ..", monoo.
lkIb b\IiII hb !lxu....: around 1'1.. ,,11" n.>U'L.... n.c, mute'
_ _ni hortzo'''illf ori. 1'1>1" tII rido hac~ .oo fonh
.tbW ftuod 10 . bcndt. /I.S 111_
a pbin in dcuil ,lhcn:
.. 1tm'OI ~IS yotI an nul<r 10 control ti><: <kpth,
. . . IOd poMIlon of mori;'" 10 C'Ut ............. fOII
.., . . Mlfkpic 10 II><' worio:1>mch. thm p/uQ8c tM
.... and loIid<" il "1\ong 'hc: moniJolr'l Wftf.
In ..., ,cii J'O". mb b OM . k.worl<inll ~. TI>t
_md It>moum rol! cffunk'!l&ly I:r.od: and fonh on 11><*
. . .Thr l'\rJc atIjUS1l"cn", posslhl" an: Wpc<'p!ttS<' . ItU"ll
iIf rod oII "fI't>I1<bc:nch '" Ilie b>dt 01 ""'ta
_
doton1 lakc "I' v:1I~,* .hop spacc. 'fhc roUle'
CII tir ......,..... '1uiddr . nd usW lOr 0100 Iobs.
II llIt maur
>ina Bob d<:fOp1ed and hulit hb
......... Mort ....... it Il. . "",,,"ni it...., 10 bc
...... """"'1('. and eon ...;nlcnl li ~n bnt5 thr COfI>o
..mal OMI .vII,," ",o"i&l n~ 1~~ , ullwicldy >tock

*"

,.hIc,,""

,"t2N

"",,,,..,.,ty

b:ouo< Ihc

~ock

iO$d( is Il.cd durillil manl.inll.

lItot <II oU, io ;", ., a o:>nc-fob Ib:lun:, li <:MI function III
l'YCfJ" "Of lh3I. a hoo"ilk>tM3l l\>1li .... tlbk ~ . Yoo ~ rut
Ocn0n5 OII io "01.1 ~ rout ~"Cf :and oIoIs. 1"" ~ _
pantlJ, ,..,.. CUI

rollO

maIdirIp.

"

de""","",

a """ lI",n~. n<Jo: 00 bc abk '" """.., Of"

bc adfu>tcd In Ih= dltk.rnl dl...,.,lionJ:
1 In:anll 0lIl

_.._.
O

CO

How It Works
11> ~

li:

rur Ih<: okpoh <II rut :

2. oIdc: 10 ..Iok lOr Ih<: imath <II euo .

~. up .noI dor.-" lOr 1"" hci8ht <II CUI

..-..,.,...,1

Bob lksIsncd hI:! JIoI mo........ wo1'" lhoor

III mlnol .
'" und Oz. I:"ThI: Ut-and-UUI ..-"t:ffiCfl1 is pc-rformcd hy
111<" plunglng :&<:tlo" of III<" "".Ie'. Monl<c: <kpth Os con
IroIlcd by IIlr bil D<lC"'lon. whlch 1. lI"'......,cd hy II><:
fOUIcr"S """Il <kpth .."""
Skk 10 $"", """, ..,..,on fI>O\"Cf from sidc 00 sidc by
.....ano o(!hrtt ~ 1lIr.of'"""ion pilk>w bioo:I<.
oIldc ;do':qp; "'"o pn"ci!.Ioo-ground >Ied sIWU. "'" 1'11""'"

1"'''

'"

..o". .... ...

~OUlt.

ellllul.

moun!lng pilit

s;d~

Sl..OT WORTlS(1t (XI'LOOEO VIEW

oi,,,,,

~ ...., lI>OUn!cd on ."" JkIo

lInnnII pIa'~.
Ind Ilie ""'1'" rnountirlA I>o;wd 10 allac:b<-d 10 thr fnInI 01
lha. ploI., n.c: ohW ...., """""td wilhln m....a .haI 10
huna /)(...,..,11 a wOftc .....t.oce
SkJe.cQ4kk ....'tI It wx1y Iimitcd by ,lor rna..o
Imum moftl .. Io:n(rth UM.,; h abuuI .. ~

lndoQ (cna Im&th abo b atfeacd by tlle bi. <IWnc1cr).

I fine ~ 01 !oI""" lt:I>'d "'lhin .hol _
b p">"
. . otdtd by ocopo .... tlundftI rod lIw. aI"!Ido froon IIM:
_
~ pIaIe 11'1 ........ hoIc:o In .""
l'*IcnI

>i<b.'''''' ......

chuooiI...,.

1:: _mm, lWls """"'" thr .....,

,IM" ~h:aoob.o.k.
O lIy odjuollnw ,"" ..opo In ..... oul on "'" tOd.)'UU ronuul
2 lIcnw far Ihc ro."'" In"'" rrom loIdr ... Jkk "" ootinll botII
CXInPCb

'''nW .........

OIopo; 'plnJr .lIc chuIIb !Iidd. )'OU ~I

menI compl<1dy.
Thc: >"'1 . '" 'fM'Cb1 dbk.ffi<., nub, ofiCII calkd cht
nuu b\' 1lUd'l1IIi5u. 1IlIU$C ItIt ~"'Imrol rod .... 16
iti"""" prr Ind\. ,"" adj...unm. can "" "" RrIe .. '" Inch
(,\ fuIIuom ~
nUl \\o inch.., a <(lW1C"'''''' """""
I-_~ II .....,. 1t.. 1ndI ) P\lclkW twO dIk nUll tOfllrlhrr alImn )'OU

!""

10

jomont . . . . . Ihor _

10

hokI ,.,.....

IIp..w 0 -.... \'nUaI ~ oIthr """'''''' b ClIt2blWwO br ..... pcMlo:In o( thr I00I.............. board In
mallon to Ibr bnfinII ~'"'" ............ board II--...w
10 ."" pbIc .. lIh ll'Ioft pbAX knobo; ..-.th 1n..,.aJ lu.d ."Tht
........ Qlcnd lh""'llh """ n thr txwd !nIo ~ In Ibr

plale 1" ...." rou.c:

"",*""'01 oI,he rvtIIrr,

"""""''''II

Ioooien IIM: knobt.nt.1 ~~ OI" _ ..... he

hootd.
fin<' """I<.-..IlIdjllSt",,,ot "made lhe """'"' ....y 1I1""'~
er,,,,.,,1 .dj1lllC.... n. Ilo. A <htn<ktl rod porojl' rrom Ih~
hono...
bnrInfl pa.e. ... chcdl...", "'''''' 00 Ihe rod

"",hc:

.... oodI ,,,,, 01"" w .... ';~~::;:t

mounllng kftObs Ind Ilhing lhit -lInII:.1
roul~. rrom Ilie ehlonJ. , " - of Ilie ..... nltal Of IIln
s.m;"gs lre !osl wllen wou do 1h11, tI.UIIH WOU dOIn
hol ..... 10 Ulmpe. wlth Ilie ehed: null 10 do 11;, Wilh
tlle~ !Un. .e_d, Ilie monb" no ~ IntrvcIK
In the WO.k1j11C" TIIe ehlnl. b o'" 01 Ilie w.V
b~n~.lh Ihe heneh lOII,

CIur 1'" _

"""om

. . WUUt

$Iot,e<! pLlK >C1'tWe<! ,O ,""

01.".,
..... moonUnlj 1'10.". 'T\orning .bo: chede mII (.fle. 'bo:
bIobo_ ""*"'<:d) dtbc:r ~' Ilk nlQllmlrlJj 11<)0'" up ....
.."., k \O <lc!a'nd hllS o.I;USCing 'h<: helgh' of 'h<: nxo.
.ln<:tnnnIlJ .. ftnt: ,., ~ Inci>.

Why It Works
I h rnd ahou' Ma.. ,,', M. .....,Iou .'olan;..,. In ,h~
, . . of A ... ~,iC<m lJ(x><Iu",,"'" When I ... n cll ""rce"

"ptOjt. fo, .h ls

co U ~c' lon . It " ;~> on~ of ,hc O.. ,

N' .... me 'o mi"lI. "-fie, ",,"" in~ (>Ve. Ilob', origin al , I
"" a!Io<u m.klng my O"'''. CKep. ,II., I fei. I could
'ilprove""
Wh had rod,~11 ilie .bou' ,II~ .\" ,,,doll' Morti...,
If ,..., COSt oI ' bc p. n5,1'he panleu'" pillu ... bk><ob
MICI ,,11at!> lIob ..,Icc.ed h. d <:051 hi m
t , SO back
II tbt '~ ( Of WUrK eo", ,,u:",,.1 sluot "",,",1..,. eOS' &
M y " lmprov"m~n, " wou,d bc. "1"""
_~ llKWtisc:t; m. lle "r J,.nd1nl bitdl ply""ood anII

.boou,

"'6,1Inn '".")

bron1e bu.hlngs In pl.ce of ,he pll low 1>kN:k.s.

1111' ,,-hen comp lelell, ,he poor n,.n ', veuion ","
no lmp",,~men . Whllc " .:0.., ."n lflc,,,,,lr le05. It look
mon: ,'me and con>ider:ably mo", p""," ee<l . kill. 10
bullll , .nd ,h~n It lIidn', ..-oril: ( which or "Ou""' .." bc
",. 1 kilkr)
11,;.1 Ionll....,. .ruunll ,o""y lwo ' hlns>
l TII" o ri8iJ>a1 monl.." 1. " 'cll
2 ,"ou gel ""ha, yuu p' r

1'",.

~e<l

\lob c h~ 'hc m",eri.l nll IunJ .... n: fur ' l,ilie

q".II. I"" and "h'r:>C,~ri .. 1a Thc hI8"-<1u.'llr plywood
U>C<l ( '-"5'S more .h.n oundartl blreh 1''''''''0011 ...11 i. 1.,..,
wkldy ..... II.bl". but i, """ .hc .. ,rr"e "ceded.o coun'
c, 'he lI!ffcrc:n. ton:: ..... ppllcd 10 'ile <lev",c durons u ...
S'a" d. nJ hlN:h pl)'wood lactl ,h .. ~"IT.. cs . 00 when
ruu .uh>ll,,,,c i l for ,"" "'het. 'ile mort,..:r)'Otl c oo up
""ilh ;.n' , rilld . OO ,hc "U'5;1 ..... ta.~ noi CCU
""e i n ai i ~"ua,IOR'

Cutting list

" rt
t\ou,t, moun"11j;I

Qty.
~

pIIe$

CII.I$Sk sklt pll".

Ch.Iun Net ply

CMssls blle k ply
,

8ul1n~

pla,e pI,u

MOun' ino bloc.!ts

Vt,,;cllllIdjus~nl

pilite

TOYllle'<:!lImp [>Jocls
,

,
,
,
,
,
,
,

Dl men slons

Milter lill

W)( 8")( 1814"

8ihk blN:h plywooel

W)( S")( la"

hltlc blN:h plywooel

W)( ,2")( 10"

SaliI( blN:h r>/)t'o!ood

\1" x 014" x la"

hhk: blN:h plywooel

\1"X5"XO"

Salile b,rtII pIywoo(t

10\" x Joi" x 2"

H.1tdwood

\\'x2")(2W

Alum,""m

iii" x 1\1" x 2}\

Salile blN:h plywood

Il, fi&! ..nllers,"" 1.0.

l i nuts. )\,"
Ulu

I blurled "uli, 4\",16;

I 'i..N.1 1!<)tI> Reld TooI Supply Co. (800'253-0421)

"

drrwllii senews,'6)( l)t"

18

~nhelld

senews, U X,"

16 [>Jonheid sm~ws,'8 x "..

Iwudtd I"se"s, '!oI'"'18;

11121' from Rt'Id Tool SupplV Co_

1 plutle knobs w,1h studl. 101,"1 8;

'OK, 27 !rom Reici TooI Supply Co.
2 100000le e!ilm," (0.,.51.1",0 Hl,23S'U)
2 'OlIIIIe e!ilm," (o.,$I;ICo ,n22SUl

1 Ibruded rod, "-. 16)( 614"

1 dus "l" lI'OIJnd ""el .lultl, )'.. )( 1 2";
KIS jt'll2 Irom Thomson IndUJlfIeI, Inc_
lIQG-SH.... 66 for .... _ 01 li dulel)

I:

I L'" "'" 01<0 ~&l1I/s ""',. frr>m /6"i<'''fIC Jiul. ~'""'" <W l'IHoc~ fIIr*o<>d. <W ..... ~
ShOp-8uiil 510t Montser

a._.

10

JoI"

4 [>Jonllelld serews, ~ )(

OI

3 IlnUf-beilr'"", p,'low blocks;

'SP8 12 lrom Thomson Indll",les

IchKk nuli. "",16; .V4 lrom R,,'d TooI Supplv Co.

1tloIuded rod, " -. 16 X l!r

Hardware

",,,(-I'ud boill. )'1,")( 3y,"

I . lD ","s, 14",20

1]]

lJk ....,I"... thc piJlow bIod<:s Bob .sc1lC'd ...., ~..

<:.llly ddiIIfIt'd
Thcy 1>3\" ~w.,;

ro. 11_" _

1>:111 ""..1n",. 1>01 ~ lbty ...." df\dml du>I ..,.1;.

"'hleh 1.. Inll'Ofum In a woodo<~ ",,..;ronnomt Tl>cy
I><'rf<:CI1r nl",d >Ctl 10 thc pn.", iI~ , Iw'<k......
""d ~ .sckc:.e<l l es, th"y ~'" CIIMIy Uh ..... bIock~ and
t...., .tiUft,! COlII lIS $ 170 In I."c 19')S), hUl lhq . ... 'Iroisnnl
lOr ""'*'11r lloc klnd 01 .."..., Iltcy .'" doIn~ , i\nd icI n,,, .,,11
)'OU . .. onc .... 1>0 1<00.... (rom ""I><'"",n",,-,
lhoey III
oNtI~con>I~1oo .. 8 ......'1]' oIm[>lillc<l

.n:

1Irc:t,,,.,

1""

II >ekctlon 01 >pWitt'd 1wdvo'2n: Is mpdrW 'u .... iId 'ho::

n1OC'li5<:t !It) ,"" II .... "cp in ron!oltU<'tlOo'l thouId bt thc purchulnjt. You <:.ln cn<kn'Or 10 OlblIltutc lOr 'M J"I'U I
>pil'y Of) thc 1I.Ith<"re UsI (,,'hieh II
my cohnru
"mii Irktll"" IIro tim<: around). or )'OU caii ,..''')'<ltIf'ldr
_
tNuhle an<J !u>' bUl' ...110' 1',,, put on ' '''' II...
1'c1cJ>l>Onc'<lnk'
p"'-<t1c knohs ",llh "'uds and 1110:
t_ klntls ur chni.: nuu &un> R<:kI '!bol SUllllIy. I()"OU "",, ',
I'lnd r:w-- t1ttn<kd In:;cru; Iocolly,onkr , hem rrom Kdd,IOO.

,,'1\;1,

,h"

,....,

a"""",..,

Condon

Cl I 4~6-4 1 1 1)

Making Ihe Chassis

Building the Fixture

,'"Uow Pasa ro. """"'e>' ,,, bc':onn,ll5; , hen

O>cck Ihc

booI<? <;aJI ,li<: DWlubeturer, ~

(8OO.Ss-oI-8-i66), for Ihc ""II><' ofa n=bydealtt
Thc rc:rnau>doI' of thr ha"' ..... '" "" tII<: 1i5t shouId tir
.. od<ctl b)"", lot':>I ~ ..""'.
Arul!)', hu)' a .,.,.... ur ~"'nch lWIic DiIdI or AppIr ..,
M ...."'OO 10 USC' lOr ti", ..vudm M~un: of ,II<: rnorti!n:lI
!DU>! ";luaU""" tl~ ""'lcrbI .. opcciaI-onkr, buo II . . . .
bc '2i"'bIc. Ir)'OU .re tfuo;t for
)"OU an _ 1
b)' " ",Il (rom lIuullc. ''Iy<o~'''''' (6J"-!S66-1}4O) nr III. L
In Ihc u,kp/'K>n<:

c:alI and ' " if lhq "od; or caii Of\k1ll1<: "",ulmi pili"'"
bloci and oIWIs. OUt loC2I -""""'"" hali tMK puU In hand
..i lhln ....-"rl: ur onkfVlg.hem lOr .... Can', IInd. K>Un:f

1lllh tho:: m>lcrlaIs and l..nI ...-.", in fund, 8<t ~ in tbr

.oo,>.1IuiJd ,II<: d ~ !\ni, th"" ,li<: rou ..... moon.lng boord.

1. Cu t
.."UO)d

10

(;., 1""

..., oii

,~ ,

nlrx ........, fi ...,) ArId 1

""k.(....., Thc roult ... ..iIi:r rnalcrial.lloc:

..........,.. In ",,",binl",
Ur><:aMI><.\Ilon . I

lIoh bullt
Ltmin.tlnll (our

",~ n~ h

cornpon""IIS 5ItdI
"'''''' >hafi, wtoh a

plrtC>l

(urm

'Q

CHASSIS PLAN VIEWS

loIo" 16 x 19'
Ih.e~

.-

rod

SIDE VIEW

SlDE VlEW

'1

-o

~.

l't']f ""

OI

1:
2

,.

FRONTVIEW

'1

r i C h " " s b~ck

Knu.led nul

~~~boh:l.

'""I

,,,,o

S'

,~
'6X ~.
iNnhud Kl'4!w

134

Rout er MJglc

""
O

.,

x l I':!'

~tIt<:. nul
Ch.iuis side
kirl~ pI~tt

""L .........,
"

rU

11.

}"

1oIo16x6'4'
Ih.uded rod

COIIIpOII<IIt!. In ""'kin~ 'hc puor n>.n~ ,'C1'Non. We u.<ai

OIditw}' birch pl)'WUOII, 0011: of Ihe no,.ble f.ili.>g> of II,,
poor man',,"Cf>iofl " 'aS Ihc fla:lbihlY of the
and 'he
_1Ill! boanJ, For our filUl """"Ion, >hown In ltoc ..-~riou>

""'' ' si!!-

pbotos. l lI>Cd App~ l'Iy and n,,::oplU...<J 'he riJlkli'y of Bob',

mon;.cr.
Set. rrom lhe propc:r plywood. CUi Ihc pl;",. ~>r thl:
lM6is p:>rtS 'u 'hc <Ilrne",,""'" sprtiIInJ by Ihc Cuul/tj!. lliI.
Gr\inaI

2. GIuC,'o1an>i " ~tl: th" c h :!.';Olb; 81""" a n d bcarln !,t

plai<. Tho: b(,.ting ploi" ;,. "",d" up of 'W<> pile;; """h
dwIi> oiIk. of
lIriH'e gI~mi ..;"lng 'he chaMi5 .ilk:s. )'011 m",1 ,;,10.
ib< .,Wk pllcJ rur Ihe moun'ln~ hol"", "" sllown In ,II ..
....'I/Ig 0Jtls</s ~'I<I" UlJ'QUI. Thl5 an hc dom- on Ilie
..... .. bleor OII lhe b. oo saw. Th., l5Iots an: .uppos<:d lu
doody a<:commo<lal., ~inclt h<:J<./1L-.d hol ..; do.,., cu.
D '00 b.ooIc.l1l., hol' heod,; .hould hc Of"knt<'<l lIS .hown
io .... AsstomlN)' ()(!/{I1/ o( Ih .. dr.wing, w;,h
51ldifljl
iIIto 1110 noIchc5 . nd "~11t pOntS ptOjc<:1ing ou, of Ihe ply
!It <adi $(k. Whcn ,lIe plies .n:: I>,"'inol"". 11105<' poi .. ",
... diB btw !M ou'er 1'1<"", helpbljl 10 Iock Iltem sa Ihc

Il".,...

jb,.

hoit. " '0 ,1'1 Iwisl. (Such Iwi5ting would hc db.ina

probkn> ,,-hL'fl )'Ou ins,.11 'h.' clwo>b bcn<... h " wurI;,
hen""'.) Tht: ~h.nk uf """It hol I>oold p,,*,-~ I ~. Indt""
hc)-ond Ihc opcn end o( Il, ,;,10.. Whcn Ihc corupk1cd
chasoi. is moUn!L'd undcr" I I'.r'incll~hid hcn,,1t 101', 'hc
boI'-'I "i11 hc n::ttSS<--.J "boUl \It 1" -)1, i""h.
Wlth thc"""" CUI. )'O<l Cl/I SI"" u p ti", lwo ch:LssIs
Spr<""" 1II"'" un ti", . pproprt:rlc f....... uf Ih., plio, Slip Ilie
tnOUmlng bol... in 'hc sJot,and nndwich thc paru togcthcr_
Ikc.tllie o( ,II.. bol"',)'OU wo.I', 1", .bI<: 'o
'II<' 'op edges
o(l/I<' c:hos6is .1de:5.oo ~ ,II<' ,h= pli..s "ny =fuUy. ''00
Cl/I. o( romsc. ,Ne III<' 0100 !ltrcc Igo::5 aher Ihc 1Ll"'" seu.
Gh,.,.u.min.,., thc .....0 "lies furmlng th., bc-~rin8 1'1>" ...

.1<" ..

,rin.

".rIS

3. D rilllhc c h assb s idCli. ".., m06l cri.ical

tlul )'Ou11 bc ""'king """ 'hc ~ sidc:s.l1lcy cns"", thJ.'
,he sh;Uts "'" """,,Iu'el}' pr.UcI and 111>1 Ihe 1'1;111., of ,h~
"""ri"ll pbl~ is pcrpmd;cul.r 10 Ihe ~nclt lop.1b
,he nccrkd "OCUr.lC}. m~rk 'hc inncr bccs. and !:lpc or
""""",hc";de> 'otI"lI.~r. inner face IU inne. f.ce, Th>1
)'Otl ..... n work oolhcm OS O"" uni, .
Wi,1I Ihc side5 ",pcd OI' serc..'cd 'OjjC1hct. ltim then 'o

adl"""

"-.r.

C!lASSIS SlOE LAYOUT

ASSEM8LY OETAIL

"'"~
CIUf up 1 plie . to
form n,~ (ha"I, .; .....

Inse" mounUno bal! In

,10' In Innu ply, Ihtn
sandwkh IL bt.w~~n
tht ou.e. pliu.

,
I

_.

OI
INNER PLY LAYOUT
J<j"dla . hale
for 5haf,

l,.
,..

'-

"

SlOI for moumin9 boiI

Yl"' dia. ~I~

for adju5'm~nt

,,'
,L

le

2r'"2i

".

,.

"

",
'?Il>'1lf

,.

I
Shop8ullt Stot MO";5t.

135

IEARING PLATE LAYOUT

FRONT VI

'"

~"r
r-

,.'
T

"

-rl

~." 20

//

Ihreadod i

'11

tJ
9'

preelslon of th~ e hassls sldu 1. cl llle,1 10 Ihe

a(eu"cy of Ihl. fixlu",. To en.ure Ihallhe hole. for
Ihe .hafu and Ihe laleral lravel adjuslmem rod align
petfeetlv, lape Ilie sidH logelhe. ,nd bore IlIne hole.
in bOlh piece. al Ihe .ame Ilme. And do Ihe borlng on
a drill press.

..

Th~

1---,

Icngtl. and wld.h, 'hen lay oul Ihe ho~ IDown in Cb<us/s
SI<k lAyo"(
IIcIi>o<: boring tlle hol",. d>ttk tu '"'''"''' th;tl )'OU. drill
P""" .. bie I:! ""rpmdlcuLtr 10 thc drill, ;md usc fa>cr
... hen boring Ihe shafI hoIc5 CO kc<:p tllem Ihe s:.mc d~c
from ti><: edllC.1"" $IUfu; shuuld fit <nugl}' In tI>ci. hol.,;.
' ''''n ""p","~tC the oi<kll.

4.

Insl2.ll Ihc Inscrt In Ihc bearing l,lale. lltc

rotl'C1" mounting pLote is ""amed It, the fixlu", with rllrcc
"'-odd<.-d knob.< th:Il Ium InlO Ihrco<kd Inso::ns in Ihe ~ring
pble. Trtm Ihe bcari1lll pLole 10 It< firctl slxe. squ.oting It In
the p~ 1ltcn <ltill and In>tall .hc ;11S<:"S.
UI
Sa:.1Ie d""'ing Heurlng f'klle 18)'0"1 for Ihc 'f"'dnc
loartiom of thc- in5crU.~OUI and 00'" tlle pilol hoIcs. usillll
thc dllin<:1c-t of bit i-f><;dfocd for .he
.-rul )'OU an: using (a
)i6-loch in>cn """,,,Uy ""'lui"". I'>1ndHli:unelC1" piloI "'*).
,"OU""" boR: the holcs complelely Ihrou~ tlle pble.
InSlali Ihc inscns """'-"- pcci:l.l "''''nch """ bc pur
ehuc<l tO dri,"" 111S<:"", hut che-.p soIullon bi u..,
hcx-hcad hoit of th" approprl.ol"
chucled In a drill
p~. Sec the plloto on p.ge 127 for d"""ils.
1Ido", ,;cninS thc bc.-ari"S pbte
tlrill Ill<." hok fOr
, , _ - ' the ""nl~-.J.tr...d .djustntcn1 rod. uy oul lhe holc auha"'n
In n.-aring 1'I"le Layo"I. Ihcn driiiit ,,1Ih. \-'o-inch hit.

.-.
i!

i",

:1

si,..,
..,iclc.

5. As5crnhk the s haro.. pillow biock5. a nd

e bassis s idcs. Unpack Ihe slufts ID<I11tc pili"", blocb. M
)"OU do s<:doc"-. in mind th tlle pillo", blocI<> ,,'" sc".ltl\""
tO du;.< and din. ~
<:."<cdl<'nt dtiSt seaIs. whleh wlJl
keep out din ,,"Ce IIKy.", mounled Ofl Ih~ .holU. lluI)'OU
h..~ !O Jrc<:p Ihcm ci""" 1xifI.J.. thcr :orc mounted on thc
~. $o c\can up JUllr won: .rca bef"", yuu 0f'C11 Ihe
~. An!! ilS 500II 25 }"OU un .... r:tp ~ plllow bloclr.5l1p II
Ofllo a "'ah. ll"s .., slmpl<' as ch'l.

ha,'"

1 36

Roule. Magic

. , r~

1,

::

8QTIQM VlEW

~,

_" ,J
'"

Clue up Iwo !Il" pliU Co

Sund Ihc chusis slda Olt ~hci. baek Wp.
lns1.>l1 'he """er shafI fiM. SIKk the shafi InIO
hol<' In """ of 'Ilc slda. fll plllow bIocIr ...
"'ah, lhen ,Iide Ihc >haR imo Ilie lo,,"c' hole in Ilie odIIr
sidc. M"'.... thc ,wo sides os ncccssary 10 po;iitlon thc: !bII
nusll " ilh tllelr .... Ier f.ces.
I'o:>kc k-I nch.Jong -6 pan ltclrd sc""" 1010 Ilie ...
het ...""" II><: "'<Iod ID<I th" ~<:c1 sluft. Dr;..... thc ~
het........,., .he ,,""" and ..ed; it wUl bind tii., . _
logeIha. In Ihe ......, fashioo. dri .., screw 10 lod do.otha clussis sidI: O" thi.. fir$< shafl.
Thc oct."ond shafI Is Instotlled In ClCIctly tM ...... ""
cxcq>l Ih., tIIi. shaft-Ihc upp"r 0fIC-II>., lwo piI<rIo
bIocks 00 It.
0""" a ocrcw h2S bttn dli'..,.., at <:acll end ni
>hafls. youU ftml 1""1 lhe chas.o;is enlls stay In pooition al
OUla enlls of Ihe shafls.

""'=

10"*

6. Mount the pillo'" blocb 00 thc

plate. Set Ihc bcaring plate rac<: """." on the "-ortd:>ood
(Ilie face h.., the insc.-rul i" it).
Set thc cha>sis ..... mbt) "'..". ti...- ptlle.AUgn the ph
bIocb Ofl thc pI .. c.as "'",,n In Ihc SecNon 11.....<1: ",.,
piikow bIocb sht>ukI hc S~ aport ID<I p<><Sit1oncd >1
at thc cdge< o( thc pU.e. Thc Iowcr pilJow bIodr. _
a-nlncd. Thnc .sha" ld hc an ""ual amounl o( opatt
!hot upper ~ 1r1d bclo.... thc Iocn\-.:r bIoI:k. M05t Im
" f .11. tI><: pbtc...,....1d hc squarc 10 thc IX<=> o( thc o/WQ.

l.kkl.g Ilie s ha f1 1" Ih. chauis sid. 10 KCom

...... w d,iwn ;"10 lhe ... am belWftn .he
TM ~ takes UP enough Spoict 10
)IlOl !/It l"'-fI In Ihe hoIe, but II an"!. iri any way ..... ,
_Iwtdonecl "HI of IM INft.

lIii/Itd ..... h a
1*1'."

."""'n.

lkeIuK tht bclring pWc .. J>fOOd 01 tht cIwoW oI<b.

rror. ~ .... ""'"" paru ohould lor balancftI aboul
III lIdI 011" It.. bm<:h lap.
Drt", a .:ouple 01 sc,."...,., !n.o codI piIIow bi<>dt 10
kIId lIIrit poruun. . 11Icn ;.Iitlc
ch.a_ back and forth
JIU """ tht lnMr r.ca
ctw6i5 si(la; an: pa.-.Jlel
..... ctl!IcS of 'Ile bc2rin1! pute. If ...". =n l, II thc:

t""
01,,,,,

"ollnllllg Ih. plllow blocks II a " ..,glu'orwa,d

Krew-dfllllll9 pffKUS. Wi,lIlhe bea'lng plile OII anat
OUrfK', .... tt.. tha 1$ au,mbly In plac;. , line up the
pillow biks. drill pilot lIoIu. Ind drive IM SCftws.
chas.sb iii "-"tly rodrcd OIIIM plai" . ...khd ....... 1"" ~
Ind molljpt 'h~ 11>c:n m:Irt<t: thc: xn:ws-run ,hml lmo
dJlkn:nt hoIc:$ an lhlt ~ Iry_antI d>cdt ."" a1itJ:n"""'1 apIn.
Whcn 1,"" alotcrunm' b lt:>Cctl and pruYm conttl,
''''tell
.t.. ""'"'" hooItIin thc- bIod<:f. I)rivt :tnd , . . . _ ,

_n

'I&hten thc: """ .... Iht """""'"

SECT10H VIEW5

st:CTIOH 11

V:CTION AA

J:
:l

Thomson 'SI'112
Nnearbeafll'l9
plllow blockl

_._.

" " l 12

,.
VI

CO

.",, ' . plate

MOU NTING BLOCK DETAll

Bea,l"g """., /

Shop-Bulil SloI Mom ... ,

117

ROUTEJI MOUHTINC IOARD LAYOUT

FRONT VIEW

RO"1 Yt-dtep

C."ono.fll d.e adj .. ,lmeoHod _011"9 .Io<h

10 Ittt mortioer as ti wn '''-'Pe. Wilh 1'" rod roughly
t_ered w. tht ehassls""" ltoIeo. olide tht bonom
....., MIM bloci, under tht rod. as 'I\owo . ., II _ ,
fii, thIve the bonom wiltl bloc. pI,o... ~a It fiu.
HI Ittt lop ....., la pa,.c, .l1li se..-. the bIeK. ,o 1'"
burtng pI,o,e

,.ten fu<
' OIIlt. bu.

7 ""tali Ihc b", ... I.tn ...:1 IOdllblmcnt rod.

V;;tbooo ~ 'Ix dwob ........ hIy.>IlIk ,1trtJvt-...saI rod
wiU ~.., It ~ b'a2k ... ,-.:! odj\G!mml rod lhtuuiIIh
.Ix l><IIa la IIx ch:t_:oklQ ......, _1tna'1! oi rod ohauld
o,tfId l>c1'OOO 'Ix plaI .. OII aeI! ..6Ik. oi """'"'" 11110 rod II
fMlmrd 10 thC' bC'2tIrIII pLoI .. wilh ..........Ina bIod.>
Cut ,Ix ~ bIo<to ' 1) ~ WJIC' , and tIriI ,Ix
piloo ~ rar tItc ....,..". ... ..,""'... !lut don' tIriI lho:
bob r.. tItc ~ rod ..... ,.., IIx ~ ..... )'ti .
..... nd, ....,.. tItc a d j I _ rod JO le II ........,. .....
~ iri tItr bob In ItIc ~ ....., ~ Wn b dlM ItIc
..... ~ _ bta _ .",h In I t - .........ithouut
mlrtnIoo ..bm tItr _~ " ia ltfC' ~ m.a ,tic
plat .. 'o 'Ix c:cnt" fIIltIc rod
~ hc in ,tic Ikft<bb<w
hood oi ..... 1rtdI) by _ ,tic CCfllnpolell'" tItc ~"*
bIoeb. Ind drtII ~ hok" lhtoufll\ ndI. Thm wkh
hal"b:l,,. .... ntdt bIod: In ....." llaIvina Iim hoIC'
SlIp IIx huu...., p;1ft> flltItc I*ldr.. undrr ,Ix ....... 1<>0,...
Ihmt . 1 IIx OUl" rdfp 01 ............... .. >I\ow.... In IIx SKrkHf
110'11'1. Sa ,Ix OIOUlII"w bIodr. tOPt In plac ... ..... iim.., thc
""........ ~ ,""'" ~ II><' rod 'o thr bnt1ntI pLtt ..

'ho'

.-.

CIt
C

-i

r.

__J 8 . Malle .nd InstaU Ihc bac... lAc" Ihor mot oIthr
..'OIXlnI "'fU, 1hC' bo II aluNamillMftI fn:Im 101'0 pleca
I
0I1Hnd! pI)..."OOd..F<ttthc
fk.1e. hc:oc ... _
..... this

IOTTOMVlEW

ADJUSTMmT PlATE DETAlL

r - - , .. _ - ,

~6- ...t ... hol. for

mounl,ng screw

poIot In ,.... pro;en to eu. ~ 101'0 pin

Mc'_ thc chz>o,h, CInt pir . . ,,,,~,
t("O tItc ~
oItIct. .. I!IIC' thC' >'OOd pIy....m.y.. than. ln'" n..... ..iIII
IlK'irOUlct bee..Cut thC' p;1ft> ... thcconttl ",-dtm p.r
,h...m be .. 'o btt. A h:df'<lolea WIWI IWI> driYm I~
1"'-' plio ",'IU hoId t"'-'m in :oLogruncnI .. hiIr ,Ix aIuo: I'I-'U.and
JIC'""lt )'OLL 10 COfIlplnC' thC' asomtbIy ..... ' ''''7t
lK." 1"" b.lCk In pl:lCC' and ICTCW II fut. U"...,. """
"'K"~-1lO 1d~ -~11Qw) 1'OU Iti rt'IIIO\T tIM: bxt 3t 3 blO:r
(b1 .....b''''I.. li !>n.o,uC' n,.., ... ,."",,),.
131

Ro ..

't. MagIC

,.
f-'<--,,!J

L}to-JjoI.-L

U16 -

1t-' 1hkk um.....m

...... bot, ..'hict! ..'oukl r~ OJ, 11110 ,IM: hok ano! ~uin
_cposy.
If,..,..,cpoxy i> ,he 'hkk. JM"'y kJnd.dIilI a....,U ......
bok in> ,IM: t.ouom of ,tIC' ~ud hok. and SrncI, hoIh 'IM:
iI!i6< oI'w ."'d hokt. ~nd ,he R,.j cnd with thc pasl", OJKl
""" puIh " in Wip<' tip
ne .....
LrI ,1Ie q'lOxy cun: a, insi 21 hours befun: diS1urblnll

,h"

. . aso<mbIy. Ep<>xy do,onn ', ""lui", ar' kind of d.",pi0ll.

... ralIy docs late IIWI)' houN eurc
AfItt ,1Ie: q>oxy cu..".,
,hc f>"t$ 01 >piaJ nub ""
. . ~ 1'Of.b. borb:o<tl2l u ..'dt as ,~ioI . Thm 'ile
'-"" II1II "" ,IIC' rod Il .... ,hen Ihc ct..d: otll. I.n taW. )'OU
... m. odju:stmm, ";,h Ihc kourlcd OUl , Ibm la'" 'hr
ebed nuI:opInot il
hukJ.hc ptn:ix .... 'inc.

,um

.0

'o

Mitking the Router Mounting BOiilrd

lboll'lOUll,'nK ",..nl >hown '" >i,al 10 0001""""11" ,hc
bQI:SI FJu <It [1I:~'.Ilt plurI,IIC "'u'e'. It .. Wd "", wi,h ,hc
.. nil ,~ Ind," (rom .1Ie '0I' altle.~ .dltlSt"'''''' """'"
"..u jusI "'..". ~ Incho of \'cnk':IJ ,ro"..,1. ,( """'"'~'tl
- . . 1~hid< """""'bIe,'hc bit
l'1fljjC> I'Ullghlr
. . .~ iod.., I)do}w ,..., ... bIe ...rbcc 10 ~UII lnctItJ
...., m. rabir ",..f.w.:r , Ser 'hr dr.o..-m,; Imkdlli"''l'
,"ou ...,. ......:d OI' .."", 10 aher SOfnC' oI,hc oll"""""",,"
OIX' .. , ..... ,,, I difkrm. tuuler OI' I "'der ...'OI'Io:1abk:.
,' ........1 """"" Lhb Ib"...., w ~'hln8 tu. ,han I ~.
.tie:! lhidc.) Fo, a l~ndHhidt ,,'OI'Io:tOp, kor
add
\-) iIrlI Ut ,IM: mou.... l'lII bo:onI Icngth, ano! aUd Ihc ~
lItIwttn ,IM: oIo<lIi .nd 'he bit opcni'lll' n .., .., l:ry O\JI ,ho;
"" br .........,ring up (rom Ih"
of IIM: boonl. ..

u"

cum""',

boc,,,,,,

Jhoo<ll in '1Ie: otrnrulg 1i_N!r oII'W"'/~ &>uni LU)'O"I, and

l:ry "", Ihc bil opm;n, bt' ~ 00-.-.. (rom tIM: t"l".
Imglh "'il r:.u wtM;,,,, ~ ohuuI<l

'""" o,,,,

1. Cui thc p lywood. Ukc !tIC' dI.ossi> sidef, and

"'-," ring pla,,,, thc: ""',...
bo:onI" . . - fmm t .....

""""'''lrIjI

plc<:es of h-in<:h Applc

CUt 'hc pktt!i IOtlghty

PIr

pIyomod. bmiou,al '..........

'o 'hc d,mco!olon. >peciftoed by Ihc

UItII"l\ ti>!.

2 . Cu. thc n.'CeIiIi ()f' tl~ rou toer, SInoce Ihc m:co;5'J
\kpth "'luai.'! ,IM: "'i<.'I<J>oi!i of onc: M~'OOd ~=, It Is ~
'o CUI Ihc <>pminB bdott Iamlnlrlinfllhc mountin8 h<wt1

Uy ""llhc cm,erpolnl ofl"" bit OJX-'nitIg. Grnler.1M:

C'>'C't tIM: ........ arid ..:rillC' arounrJ ,"" ba>c Cut 'IM:
"""nins. for a s/upt ILke th>t 01 ,IM: Elu and Drw..I,
rotlle.-s, rotii .hc ... nJlthl """"ion, ...m, a c:b.mpcd-on
knce ,o lIukk Ilie: rolll",.11>cn "'" up W rotiI ... "ilh a
, ,,,mmd , and rou' 'h<o .", fl'Qf!1 onc: eOO of 'h<o "",ilhI
gn>!, ..... 10 . 1M> OIh ....

rout",

3 . Laml",.." tI~ p lles. Wl.h ,he op<:ning fOc- thc

complete<!. ~PI'1y 11''''' 'u ,1Ie: bceo oi , 1Ie ,,..'-' ",ncl,;
and cbmp ,bem 'OIIC'hcr
Whcn tbr:: ,,1.11: ...... """"', Irin, ,IM: mounling board
blinll il 10 it> final dimc.'1Uions an(! ' o ~1Wr ~

rotii ...

'o

nu.

4. Retu, . bc adjustmcm ~1ot5.

can bt 00....
wItIt fii......, ........" .-quippt'(l wItIt :an .,.. JJU!id<' :and I
h6-lnch ><raiIh1 bit. t.ry OUl' ,ho; tIou an(! rotii 'hem

VElTlCAl RA NC E
loI!~lMUIo!

VERTiCAL

~NC

MAXIMUM VER1'ICAl Sdr'NC

,=- -t;fj.

""Is of bit

J:

Ll

,..

CI

WorklOp

a._.
OI

"

ICI

ShopButll Slo, Monisel

139

,. Makc and InstaU tftc, ''a1icaladjustmc:n l

p ble. On 1I<>b', ~naJ. Ihill I'I~IC is li-inclHhick alumin..... T1lc ~ oIl1w. m31ctIaI >iCcftt> I<l h..!o .., ben!
tunctlon 01 ""~'Y For tIM; job M JK,b" ... I~ plale
could """ ... ca!oiIy Ix -.Se 01 I~UIIt' acel. %ici> or
\'Hnc:h pI}...-ood. or ~ pbc1'I<>Iic. iI)'<>U ......, ihn. I dId
~

,,",.., _

jIhcnoIK::.

:10

I ....,.. lIw.

ori

,1Ie .....

monilcr :oho\oo'n in Ilie phoI ....

If )'<>U ..,.., pIywood OI" phcnoIiooc. IOUI Ilie sloi ori Ihc
n)Uler W>k:. It )'<>U ..,., mccaI. drIU ~ _ .
lhen cut Inl" lloc hoit ..ilh. hxkgw.1onning thc sIoI. CuI
,~ plate 10 oile. DriIl I~ hoks for mouming ~'S. F'.!c:
any

fO\IId1

OI' sh.1tp~.os

nca:ssuy. M'- Ihc pIo.e 10

01."" ,"o'.!ling p"OIe:lO II", .hln<kd md fits

In!o 1"" .......
'loc bonom

6. ,,,,,taU .hc ro Ule r. I!crn<:m:.hc ~5 hucpb.e

Set .. Inwlhc "'""" In

u.. """""InS boaId.:aneI ..... it .os

p;oucm 10 driU hoks lOr IIIc

~."", ~

Coo,m.Cr$ink ,"" hok$.""'n rnoun "" f\lUlCf OII Ihc boIltd.

Slncc Ihc router 01'''''11'''' In , horizorK:tl poSiUon. lloc
",Ium "fKInI!;S """ bc a nuis;Lncc.
1oI1ov.'Cd 1Iob'. k:>d

"'O'

in ~'hc!ll.
If !hc
}'OU ..... ori Ihc rnortacr ha> a ~
Ioadcd ",unii'" 1od<.}'OU ha ..,. dcci.oon
~c.To I\ob..hc
"fl'!i1lll'1oadcd plunge lod< ori tus Ou ....... nul!olncc: . " hc
di$;lblcd 11. 1Iu! he "'aS ~ his mort;"'r lor nKK1b1n(1. only
If )'OU ...... n. )""'" ..." monlscr 10 doubk u horilOmoJ
"",Ier lable. )'OU ""~I nd 10 """ .Ioc plunge Ind. '0 So:t .""
bil Q;;:nsion . TIm rou (>ft>b.>.b/y ,..",, ', ..... n, 10 di>:ablc
cven a spnng.1oadcd plWlp' Iock.
1t)'OIl <lcckk 10 ""TlO'''' .1Ie "'UnII" Sf>rit>lP an<! .""
pl"nll<' Iod . .;hcd< ,ttc plttS dilIgrmI ro.. )'OUl' "",.er 10
fiII"'" oul how 10 IlO aboUl i., Rcmming ,~ p;ut. <Ionon',
nlClln 'ha.)'OIl con ilO ~r u,",,)'OW' rouler >cpu.. c from
Ihi5 r"'UlR'.1'he p. n s 1$"")'
oirnpk .0 "'I'!xc ...
Ihg' arc ., remo''C .

"""a

r--I

-.
f

1:
O
::lE

.0 ....

= ...

Outflttlng the Work table

1110' shx rnoniS<or i. usck:M untll it i. rnoun'N .0 ."" un<k: ..

~
"'urtly worl<l.bIe. Sine .. rou ",i ll bc ",,>hl~ and
l'ulli<18 <In Ihe ro ... a and IIK fUI."'" il i. anachc<l IO.IIK
wor1n;oblc shoo.ld bc rigid and hen}'_
You """ """ a worI<bo:ndI or a ~1laI rou1a t:lhIe .,
"'" worIo:t:lbIc for w oIoc mOrlM. fIIn A:m"rnhC"r Ihlol )""
il:...., 10 driU and ooumabon: ITI<)Undn" h/>Ici.......,11 "" h/>ID
L I for I~ ~ You wiII :;urdy ....n..... CIclI' wt<I ~"o
ilie t:lhoICIop !Il fxWut .. "'"'"ps.11 ..... >dd "1' 10 >I'<:nlk>ns
)"" 1113)' noi '....m 10 ma"" 10 a goOd .."O<\chcnd1 o.. " ..." ,..
I>bIc. If ,..., h...c >fUtt b k , and If )'OU wUI "'" ~ ofI~n
cnough,)'OU Olt 01"',")"1 buikI a ""1""'I~ worI<.aI* ro.. ,1Ie >101
morthcr.
)'OU choooc 10 deal ... ilil thl!. m>uer............
hoa' 10 aulAI Ihc "'~.Ih ... c:nrnplctU'ig ilie A"."",

01.

II"""'.....

1. Mou n! Ihe mo n l!lCr '0 .hc .....,.. I.... h l.;. "

couplc of poin .. hcforc .hc ;IoCIuai ..'Q['\( ~n>
1ir):I. ilie
'0 ""hIdl )'OU mo"", .hc nlOrtbt'r
ohouId ""OI loM. I \'li _
thIck, and ~ >hould hC" It....ith

""""lOp

."" Ind booo<n SUtb<:cs p;or:oIld. It it Isn ', thidt ~*

mountirog I)uh,j ""il pn::>lruIk 0l)000>;: !hc ....ucc.lftht sudica
....... . fla, and I""'.nd. boIlirtg d ... ",.,.,.,..,. l~hUy '" ~
..TO<"k Ihc ~ tIJro."ing )OIIr IICW """'''' OUl oftilltr.
lbc serond poin. tw. '" do .... i.h Ihc golI' bctwt<1Ir
<:Iu.>si>'~ Inding . . . . and .IM: n""""i<4I b<wd. Tht: . .
..iU bc .boul I!.. inch. and )'OU probo.bIy don~ "'.... lIrot
rnud! 6pa bnwttn Ihc mounting '-tU .nd Ihc ~
'Thcrri>rc. U"l' .0 ,;n Ihc dtasoi> bad: rrom ilie "'"<b:f
cd8" 'boul h> inch.
1 bu>d 1.... ~ ....,. 10 by "Ul .IK hob b . .
"""",.iiIt! boko ..... 'o maltc a ''''''pl...... rtom "'" _
Cur a 5)( 124nch pica: 01 ~ndI f'II'WOOd kt k "" "",,,
Ihc """In ng boIu.:aneI allgn li Oush ""i!h IIx: fronI . .
oIlhc ~,...."" (HokI .........aIp: opin .. thc dIatoIi.
an<! sllIk Ihc f ' I I - ''''''plal'' lip 2pIJUI h.) T.lp OII fir
,.,..,plale a. cxfl boIt, dmtlllll'hc Irmplole. t'lp k
driD ~ hoIc ccn.cn:!I In ad'o dcnL
l2y Ihc .,.., .... '" .... Ihc worI<'Op.:aneI :oIi,p M,Tho,.
0I1hc lemplole "'jHdC""1hc (ron. ~ 0I1hcm.ir., ..
)'OU ""'n!
tel
hac" ahi . ..,. dril~ ......Incb hob
Ihc ~ ....,..,....,. ...,..., )'OU " ' " roundf just liI*
room for odju>tnw: ..... SO line up Ihc .an..... e ..... ..,. ..
1l1th tIIil or _1. tJWt.: Ihtou!!h lloc ."mpl...., 00 ..

om;"

.0 .h,,,

II

-...

R~.hc .mspb.... o driD a 1-lndHtlamclct, ~

dftp rounltrtoon:.. een.cn:d OrI nch marii. s.,1Idi bIIt. ..
drill '...IndHII:>rncta Ih ........ hoIc> for.""
')rup ......."".1.1). rw ..~ In ., t:>d> <:OUIIIa'boot
........100 .hc ~ ...un- thc worI<'op. and p.ao ..
""""'I;na boIu "1' Ih""'Ah Ihc .......... TUrn nUl onto adi
bol and 1'Ih''r'''' nch llUUU Ihc InOUnlin1:Io:IoW."
adjlt!ol .IK ~ pooIoon undtr .hc worI:lOp You ...... fIr
fXc <Il Ihc rnuunt"'ll boIltd.o bc p;or:oIld 10''''' _ . ..
cdg<- When Ihc: mortb<: IJ Jo) >liSnC'd.up""" Ibc ........ fIr

""""""-1taII.

t1\()U1\.inl boIIJ

2. FIne-tu ne lhc rn<>un Unx- Oncc )'<>U _ _ ..

rUl'u",. 1'1<1 ncaI.o chcdr; It for ali&nme", . ~ iftl-'
,..:1)__

1. <:>n bc mi>:aLif1t>c4

"""0"

I Th.; ul, ollhc:

hi. ean hc 00. 01 p;orallc1 ...
."" bcnch 10f'
2 111e .....<1<18 .hatb ean bc ou. of ",,"""1 witIt fir
hcnch 101'.
Any rnlsalJgnn ... n. m .... bc: rorrcct~d by 1111;"11
het"'""n Ihc cha..... L. and Ihe,,~ 011"" bo:nd! lOp.
11... oIl!11\"""''' """ bc "bcd<td by dlucltinjj
.sv....,1 pin ttn.c:ri"ll ",n,OI" <....,A a ""'I~r bit In.o thc
( ..lth Ihc IUIllcr "n"'.'IlJII"d) and ~ Ibc """"" d
d..w .... pin ~I>,"'C ."" t>cnd1 101' ""hlt a do:jHh . ';;'_~
",mkr ur oJl>J caUPC<ll,''''' hd.{d1'. ,",'hen .hc
i>:tI.
"';1}' 10 ."" 1d'I.
hc: 0".W:tJY Ihc tn ... ." "hen 1. 1..1
"'';I}. ... thc ritth'.Ih<: hc4tIll n"l>1 bc Ihe .a",,, whel"'"
plurt,IIC1J Of fuDy ",.roctCtl. If ......., . tJWt.: .hc rortIC1'S d
eh>M w ......... 1"" n.... Wren ...'.. b hlgh. """""" Ilte
hokli"ll Ilie chaWl . nd 1""," p;opc:r >hin" 10 ohIm

".u;!

"""'a

TOGGlE ClAMPPAD LAYOUT

."
(Lo_""'-1

Pilols for 1099le

mounllng 'CfeWI _
~"

p!ywood

1100 ooonlnr mounlln" II p'aperl)' . ' Ign" If

-..rttnents laken al Ilie lim iU oltlle mon 'se,'$ LlI '
"_I;ond wlth Ilie ,lMIle, boIh ',,11y plU"~ and
.., mrKltd .re ,U euetly Ilie nme , TlIke 1'" mn
th. bit to
Uobletw u~lng .. pa" of
dtI:IIh-l1Ifa~url"!l dlal u.lipers . as shown .

tf"

1'"

1IIrtJ\lt"" "om

. . . ....11 OI. ,"" "urkcd ~ "Ibm Li8ht"" " lip .....

dltd;th< ~.apln. RqInt ... ""'" , .,. .. tU .....
............ :II

:aII1bur "","1> b 'hc lOaml'.

}. Gri<! tbe """""lOp. tJsinJj ..... fIlt,u",

1""

1""

m:ju1re5

l<CIIr>Id)' poeI.lonlng
_plece on
baK:h an<!
~ ~ IIM=." '"" '" ~ 1if\CS pennanrntly
t<ritrd!n 1"" hend110f! lis uscl'ul.,"ou .,.., OlIjml ..... latmll
IMI iICtOtdIng 10 ,h(:$ U"""-:Il ..'dI :Il pooitIon tbe .........
,...,.10 Ihtm. I >U~ ,~, .1 flr>I ,..... ..... pIy U5C penciI
ltrtt1. ()nco )'00 kno .... ,..h," kioo 01 a gnd .."""" boli b
TWlTOP LAYOUT
HoIt

:=:::;:_tj)

e
C

Mountin" .. tOllgl. eIamp '0 tII. workUobl.

,,"qUU1'S only' ""Ille bolt turned InlO a nui !n Ilie
,..orI<top. You un IW'ng Ihe P<ldm"unttd damp
.."und Itle bolt. orienllng II lor Ilie best conliOct w!lh
Ilie wO<1<. 8ig eLlmp. III'" a Iongft ,,"ull and ipp!V
mo,," pl'6'''''" Ihin .mall "ntl. BUl boII! un tie uled
productively.

'OI mountif\9 logg.!e wmp;

nU I

on undentde o f loble.

i
o
~ofUobleloP

,
C;rld "MI ." Incremenll

O
--.1

"

CI

Crld Ilnu 1/;" Inc'tmfnt~

1
.-"_.

fOIIr P"IJ"l'i'ia, """liCit ,h .. lillC'J In ,,'i,1t a .\It. 'l' _I..nd fiII

'lo<, ..:r~'(""" ... I.h a 'LlrI< """,,,1 mlt-r,
1,., Iml"'l'Ur1t '" lIe ablc '" """I,I"n d:u"p> on <hc:
,,"Qrt<plr :t.\ ..1aer ,.. posoIbk '0 ''''' mon~. n.c lllOM
~..,.,'... nk,,, ..... y 'u "':.mp IS ,,-i. h lt'!Q!.k: cbmpS. Hu' of
~o"""" )'<"' "",,,', ..... n' 'o clutler ,,,,,, "'O/'I:It,,, ",i.h 'OfO!I<:
Clilmp"

,,,.. ,,...1,,,,...11'1:",,, l..y """0 "" ,1"" ,,'0/'1:,"1', ( Ilun:

hol ... 1t""'lIh ' he .. hklOp and " p 'he T... o' In", 'loc
un<kl')i<k.) '\' ""n, I rottplc 0I1i1~ ."II8k elilm",,~1 ....,
lk<S,a.Q>', ''CZ,W_on ;Ja"nl JWlS al:Jdc o( ' +-Ind! pir"'''''''. Turn "'~I 1010 .Ioc T... ", . and o,dt il In ,hc !ilo! ci
ltc "lIlIIie ebmp'o
T1gh'cn 'loc "'~'. Ind you'vo:: g<>t
'olQllc da."!, f.... ...-1",,,,, fOU '>ccd 1, ...... 'hc Juba, hand You
on """ 'M T,,,ul> dI=t1r <It" vb. ,OIQIk dunp 10 iU'"
pooltloni". st"P'
proWcIlon tunS.
,\> ,,'lI h ti", JII'kI, II'li pn.tb;:tbty !)d'ef .0 <
'''dor> ........,
lQr
T-nul) ...., ..... tuI, r.thcr tlwt poet ,"" ..mIop
",hit 'hcm haph;tunlly"'" /oyt .. ~ 1 """ ." ~ In <hc:

p''''.

rar

"'loc'"

1IM*IQ{I

Lu)vut (/r:twi ....

Using the Fixture

r-..

""" _
'loc D>O<I>('r"It 01 .rulh b uport ,.. You"" Imblnl
In """""""" fliIn) bu, """'" onIy ........ pk- 01 ",'<'fIitljlS
pullln8'M monl!io:r,~ 11."....;11 II ......... ,
Only kw min",,,, ...., nttdrd '" ~ <hc: mort..... up b
eu" ,<.> damp I ."'" pic In pooItlon, anii 'Mn 10 ~tully
moke
cut And 'M 'ruth ..i ll hc In <hc: '""'''''''-

,ha,

Mortising
Tho ou.. joii b .. hich Ihc fb'u"' ...... ~ 1'aclll".
,his opcn,ioo ..m""poM' fOU '" oii ."" ...-orI<mp 01 ,,,,, n.,:.
CIt
'o adi.... :dI tltrtt ua 01 .......~nt
( tIucu>ocd., ,""
o( .hb ehopttt). , ..... ha .., 'o
,,"0.11 thc ,.hk-lop grId Ind "'" 'ogk cbmp>- , ..... """c
,_ do I/x mon~ (bncc

c:

'Vi
t:
O
::lE

......

,'-= ,..... ha",

II<'&IM'' '

'ti

1. Lay ou"he mot1l-.e. Thb b " 'hen: h hq;1" "Qn

picctminll stact. pnl<'il u4f ,Jx, """,itc }'OU
" 'hen:)"QU
it. \VIU it lQIlow thr MIIk oITh1nb-,
"">ing. "idtlt <'<jUli
ltlnl'hc Sloct ~ .ltlckncMl Will
Mbe <:en,nnl ~ ,Jx, Slock .hicknoo? Ilo ..' IooM ...1111,
bel U..... dpl Yow- byou' >IIould ons..."r 'loc nI')! ,",,",
'I"""'OrlS. ",., .........,r ,a ,"" ""'nit 'I1ICSI1oo ... 111 ""
""nlcd In """11lJI up lloc roU'ef

,,-m.,

oi,,,,, . . ,,-m.

'o ........

2. Set tIp ti.., rou' e r. 'lliS b a ,101 mOMI..,...n,,,ln8

monlsct ,,, bat:k ~nd ronlt ~ ,. gh.,n 1c,-d.'ll"",lhc
"i",h oI,hc nwnlsc: dleta'6
"/.1",c, of . he bl.
Thc r" .,,,,,,,,,., wbtlom I~ ,ha,
,,[>Cu, bir. "'"
tic" tor mon lsing. and ,h.". 'ruc, lIu. )U" nccd nOI rcd

'he

.p'''''

H' ....,

.ha,, .Ioc- 01,1)" st)'le ar h', )'0" can ,,!le. I\'e ...""'" Slr. ittll'

hlt$ of (''ef}' s'ylc-"r.t.iglu fluc. Shc., fluc, lngle ;ln<.l

<!oubl .. fiu."

Eq""lIy Imponam u 'he " nx'er 1 he IC"M111 or ,Ire

hit To .he <Jcsln:d monl!le <.Ie!,'h)"QU m"". ",,<.1 h Int:h tor
,tic ,hlcknC)S or 'he n'u"n,lng bo:.tnl. m.)'!)c, .. Lnch 01

splec bct,,"ecn ,he moumilljli boonland 'M coIIct

al Ieut '1.1 i,,~h uhhank 'u Ix p;ppcd by thc cuIIo:t
bi, ncnI:i <O be~, ml,,'mum 1\. Indxs Ionwr'
nwnbc dcpth.
Givcn ,hale MuiddtnC$,~ your .,"',~ _ _

:_~:!.:~,~~~~:~~~;

Na... >CI u... plWIJ!t'

Ind ti!ll<'cn it int<> ,""
tkpth . To do ti .... )'t>lI
witlMKn ,Ix .sprin8S. it ,...;u

it-artd.........., tI1C

"""Ion

mouOlirtg boord.PI~:i'~"~-~~~=;(:~~~~:

ci bi' is exposcd. tItt:n >CI ,

puU tht: """tt """t.
antI rndy ti", mxhInc ro. u.. ""'" ""'up MCp

~ ,IIe "'''''' of.h" bit "1I"1n>l ,1Ie monl"" I:r)"'"

..,. Ii k ...aru appropri ..". kx>I!c:" II", knob(.) and lurn
.. cbod n... '0 tabe Of "'wc. 'hc bit When }'OU . re <XIPl.
"uit ,"" """h'lto '1)Ih''''' aU .11= i<nob. :and j:lm
.. otrond dleck
:tg:Iln.. ,1Ie

"""*

n",

n..,..

4. Set the IlUn"3.I.lr~vd IIml"'. Tlll$ ,,>ti IX' donc

...... bkk>u' morti"" Of ,IM: grId on ,he
~'C.T

l_os"'. nor),,...

""""''''1'.

....,iI' ,tit St0I'S !lx ,1", noonif< ""'!II1t 1$ (2$j' 'o do

... thr tuW on Ilie bcnch '''I', Plck OIOl ,IIe jUI<Ill"'"
lqIIl'>tIIL ,tit ol",n,111o of ,hc monbe Wltll 'hc bit

,Iu,

~.bJk down "" ' Ile grid ..... aii", ,IM: bit., "'1'1 . .
..... II.. Unc "'prco:n'lnlllh( 1I>(N1!K', kfi ~ nd, !kt ,""
. , OII ,II< adju"mcn, rod', IerI ." p ....." nl IIM: mu,cr fron,
....,..;,q:...,. f.nlle. 10 " "" .11":" " 0 0 . SIkk .1", 1'OUI tT 'o 'IM:
..... ~ ,t.., blo'.
" 'i,1I ,IM: llIIe "'J>flX"'1nJc
ri/Ih' en<! . So..1 ,IIe rilthl >!Of>.

.. _lot',

rtjI.h,.,.

S' .....11100 Ilo., w..,rk. n ", Ax, ..", tu. bttn

lin

'o

ru 0(. Sf'Cd1k Letljllh ,.".. ,UkJi ...,.. a", to pbcr

.. ....npi<" "" ,tit monl><: ..'III loc " 'hac ).... ""UI' ~ .
&10 pol6,Lon . 'OU'" rttmp '" lod< u.., "'Of'I:,*"" do .....
....... root!ng Of><TO'Lon.
f'IJoItionll\Sl , ........ot'kplctt i, moller of oI'snillll .....
II""" ..itll 'hc .pprupri:t,., pid bt'tC&. For
pr\IIhIctloo fWI. It ... '..,. 'ilM II')'OU cbntp a "Of> bIoct .0
klntr It.. """"J>icccs ... ,,,,,,,,.lcaJly. TIM: "'''1' CIIn bc:
<iIItpnI wAA . Cdamp ur ,,;'h OfI8k cbmp
Thr '''I!!!''' cbmp doigtu'N 'o bold "'" _pINt
III'J\<"

>1>001.1 hc pooItion<d ... tiu, it> spindk applit:>'

"'" ,...on: .. dooc to W _
as

""'"""*

~'" tu

6. Rotit a ..,.t morti!IC. W"1lh .,."a)'thng set, k>d:

do".. n , .... 101 1'1""" and ruuI .... mori;'" 1lM:n """mIM
and .,.001 .... ., Il", mon!C ~ i. 0.. ..,. adj .... mrn..
nccd ' 0 toc madclls it ttntercd in thc cdf:r=1 b il "'" CQrrttt
Img:Ihl n.. .,........" <kpIh!
Ir ~. adj .... "'" oct,lnp.
7, Ilou. tbc ,,ork.. Whcn oii Is fi8ht. II"" ." .."Ork on
'Ile JOOd otock.
A ....:>nI OI" , _ abouI 'ccbniquc is In ordcr har.1 (Ir1oSp
,1Ie """cr', I<nob$,.,..., 111..bul loct ...,. ,ltumbl
...1..... 'M n>Ulcr mounU"8 boanl 'oull prub;t/>It. tind . ... 1
dld.1h>I }'OU lIwt: _heT control oIlhc plut1jtC oaOll f
fOII .ppIy """'""'"' ..itll )'I.IW' bo<Ir r:tW' tlwt ..'itlt yuur
hanob. n..
.hc
nl ...........
u.;, ~ c:on'mIIitl@.tlleoat.,andlleptho(plUfltICWhh
JPinl Upnll bitt. il 11"'" ~. 'o ~ """ .....lI ta,t...uy
In onc con,;_
modon . r.' ......h:ul ptungL"tI fi..,.. .n"
.hen cutt" l3 IMcr:olly } .... bc ... '" )'OU don'l Ibrtt bll .
csp<:daIly lJOIid caro;..k onc

ha"".

,h....."" .... ap''''''

"""""'IIII",..

1'"

_10)"'"

End mortllu are ni)' 10 'ou, "'lth ,he sloi mo.,

T... n tM "'orkpli!'Ce la III Ind conf.on" Ilie bll.
r.nht. Ih"n 1" t idt. ThouOh .. sloole .oogle cllImp ",III
hoId Iht "'orkplece In pl.ce "'hlle the morl,!e Is
rou'ed ... >tap block loc.'CI II for Ihe t ul &U'Ofnilkl llv.
li~er.

FixedPosilion Rouling
1oIliItt.1Ie flOPI for ,II. _rtlse leolltll Is done
tU\' uslng Ilie b.:onchtop g.it!. look down on IM
pl. A'td .lign Ihe bit ",nit Orit! lines 11\;11 ""prl senl
.. ft'I:Il o/' tM morIlse . W-IIh tM bi. a, """ m"nlsc
.-1 .... rtIon, spin Iht chi!'Ck nul on !hit sidt uniti i,
It.m ao;Iln" Ilie cllaul, 'ldt. 1.1_ Uit bIIto Ilie
... rml6on, ;aneI set Ilie Slop on tll. l .idt.

Undorr IlIb hnditlJj: 1coIi"!.U ,II""" lIori""",:tlrouICM.bk

op<'r:t'iom )'OIl an do ,..ilh .lIc ...... monlscr. 1h<.,... ~
""I'Id'I 01 tltem: tcnonioll . Io"ing . "" wunvll\jj, tal>bctl ....
rou"1\jj mt>kIlngs. r:t.I";"ll pan~b; .
In ndt of.beM: opcr1tiOlU. IIM: WOIk ilo fi."(l irita nr "''Cr
Iht: bit. Sa !O ><.1 Up Ilie Mot rt1Ol'I!d' lOr eht:m. )'OIJ lin ,1Ie bl
."...d-tr.,'d .. tip< agaln.... ,IM: du._ skk:o., Iod:Ing II", rou,~rlll
ShOp8ull, Slo. MonlSt.

'43

""'" pooiIlon.l"ho:n you": iI'X a horizom~ rouIn- l:ObIe.

Th ro.. a IV"""., witll a .."..;gh. boit. J'UU ~ dlUSl Ihc bit
atcnoion anii .hc .,.,1eaI poo:i.lon. TUm un 'hc """e., ond
rttd .Ioc "'""'"' ;oaOM tM bit. It you a~ <Io!ntt. an m<i-f,lr,ln
CUI, ai In 'rnonins. lIS<: a pusto.bIod< sk<l 10 kc<l and bad
up .hc ........,wcc.
~ )'OU ctnbrxe II..... op<1".tlon>. )'t>U . h""l<I
... ~ thc: 1mJU'-1 <JIthcDI Of! 'loc bmdt undcr whkh Ilie
lIloOI1i>c1 i> mountcd.ln aii thc: mortising """""oo$, lhc bi'
/s aboo.., thc: labktop. " ~ ......... 'he lobk.op. llul for
ncarty ali thc: fu:cd.po$itlon <>pa:I'iOnJ. Ibc bit S p;tftl;olly
burInf in thc: tabInop,
So tM qLX:Slion Io:Do I ..~, a boit CUWllI in thc: _Of)?

II you do tcoOnina only, thcn 1"" Injury > Ihc .~l>k1op

b
1II<JLk3o.." 'IM_wido:. 1" 0 I ~""- !oIoI. If)'UU
t3Iot pands OI" rouI. moIdinog>.. 1"" "'''''''op ",iU _lup a
,;igni6can1 """ice lhal', "" Ind! OI' ""'"' ..."ido: and ""'"
~. 1 , hin!< tItioI f a oo.."JUiok.
n..",., ~ at'c ~ ~Oor <kdok ,,'hcI11cr
'hcy at'c od>isable

fU""

10 , OUI a 8'00". ",111\ Ih . s lOI mor'lls, <, lock Ihf

tOUltt In PQ$ltlon, then fud the wo,kplece pu\ I., I'!M
PQs,uon Dthind IM roule' _ku the fud a<tloo OiI
ft~nllhln wlth I '''JIul .. 'OUlet t.blt .

Loose-Tenon Joints
Th~ mon's~-~I'ld-ttl>Oft

JO,nl ts I good JOInl

II PI'"",d~1 ~Iat'~~'" Ia~ a,~a. 01 141
lIralll<!d 1I1uI0JI surlau_ It 's thtot lal'fle. 1la1"'9,alr>td
beClU~

surfaeu Ihat ,"",k~ It supe'l(N 10. do ..,IjOIni

T'" lI.-.al futu~ 01 I dow<ol joIm. wNc:h ~ ~;al1v
JUst I sJ)ill,ud 1l>O"'J.<!and-tel>Oft jOom... Ihil tlot
rounde<! hoit It'" monls..1 un be qUICk.., Ind eUl'"
bored Ind
do .. ~1 tlhe .mon) (lin be ,"",,..produce<!
W"h ,n efflelf:nl .Iot mOflIs..r. Thot ..av..nt'Jlf:' of
th, mOftllt Ind Itnon Jo,nl ean be eomblnt'll ",th 1'"
adv&ntlgu of t'" do ..,1 joInl_ Tho eombl"i!'1on ,"
JOlnery unlquely suited tO the small s~ prOdU(lng
on~-of-a-tlnd Ot hm,,<"d-poodu{!lon IU'nltuIl' Of hlllh
~nd (lb,n~try.
TradlTlonally. mortlil'S Wi"f tht hard IllIft Ind
tenon ...... ell! the tUV Pi"_ Tod.y. It .. more efr,u'nl
(Ind JUlt iUOO\l) to (UII""'O momsel and uSf. SfP"alt ,tnOn The mOrllSU IIl! quIC"'" Ind letu,.te'"
CuI wlt~ Ihe 510' ll>O'tlstt. ind Iht tenon. It, easl""
mass'p,oduetd OUl oI ",,.p Of IflfXpen"\Ie wood ,n
.. h<oTever S,Ztl the woodwO,ktr "teds.
Mak100 up bi."h of tenon stock 15 ",~htforw.rd

t'"

.-1:-.
iii

c:

:lE

Illp a Itnglll of rough ~toc:k 10 tht ,ougll wldlh of

the lenon
2_ IItlaw 10 JUli Gve' the desi,", thk~neSl_
3. Su,fue 10 the desl,t'II thkkMU.
4. jo<nt 0I\t !!"dgt
S. Il,p 10 "tUr." wldtll
6. Iloundov~, Ihe !!"dlltl on IM 'OlIte, ... b~.
Ont Idvlnlage oI k>ou-Itnon jOI"ts 15 Ih'l pariS
110 Ion!lf:' nH<I tO Dt "zed.o include an int"ll",1

- -

Template-Monisi
c;wId~

templul! 10
an IMse h"rdto-pOshlon montses.
your rOUler ..... llh

il

""me-

"''''pbIc

oina
10 guidc IIlO<IISUljI; CUI io
,imn tI'o= ....... co,,...,nkn ,..:' . .. 131~. aOO &1"'"
W2Y 10 WOtII You ,,~tfi, )'OU. punp: .".lIc. " 'ilh
. . ",""",,-:and >lrllll.l1l bi' , 1htn . - 1, wi,h a lempbIc
_ dw: 0JI0<tisc

n.- hT

ii

noi

,IK .....,..... ptt se. but

tii<: " ,"',.....,. ,.

laDpbtc. Uk~ .ny "'hcr ''''''pl<"c, an "" lRI<k oi

liIIi:I:IoW, mn!;UJtt.<k ..... y fIbtrt>o;o .... ( ,\II)F), ~ . or
an "" joIpcci1Ic 1ilI, n,:,,1o;
.....d for .he
JIIIICIIbt .ppllc:.. lon .1 tund. 'hen ,~ . ar I an Ix
'wtptr, OIle' JOII .... ~, .""r . gaIn>I ti.., oby "'" n<'rtI 10
lllitlh>l...,.,. _
.goln
1...........kc Icmpl..c for monbi"Jj <k>O<' r..... """
fKr '11IlIIC$; but rr.nkly. ! III> li monislng wor1r 1oi do
... _ 01 'he Olt.." monioUl!l lil(S p<t:scn.cd in
'10&10 _ . Ihe ........ od... r wood"'<ln:ln"
<O
otIdI dw: .",nl""" ,cmpb'" b beUCT 5ujtW ....... y In
.... It.. trmpbtr b ,"'" onJy ... Imlon. Lct "'" 6" SO"te

.0"'"

'-"'/1

'"I>

"'U>'1oru

9'rlk lpplic:lllon .
'tK~

I'I>Ottbc In . p;u>d.sudI:as tii<: m"I'1I.... In

ono Of ca..e 1lIi<k:

" 1IIroICh

monisc in

''C'I')'

tllid;

""''''pIc, ..mlch

""'*"'}'OU 10 wol1< r...... boIh loid<:> or the ..

"'II.

M CDlDplC '" ...,.1>ud:

...,n>hIy Iha ha>
*'-Ch monbc for .... rnd>c'r.
..nbo In 1"" bo...., oh ~1: 1 W.1o.
,h..
ao', b< dmlpnI in lhc ) Ionising Jill <In
124 OI"

""'"'1"<'Ct'
pa""

lloc Shop-Hulll SloI Mon"",," OII P"8" 1'1 1.,.,.,., "'J>t'Od""etI a rourllry ch<:sc o( d"" "<:f$ In ",-hkh lloc r.....,
r.tIlJ "..,~ mortitftI !n1O tM >'kb To cut lhc m..rtl..........
t ~ a lnnpbte.
- . dtflkuII~ ... po<itlon moni>c, 1Udl as onc in n>und.
on~ CUI !nlO Ilie arris 0(. kr- onc ClU Inlo an . Irody-.m.pnI pan, OI" one 10 bc rut l i .n . rIj/;Ic. In lhcoc _.
sjluarions, lhc ..,... o( a lnnpblc allow. )'OU 10 nul<t". Ift
rnMIk br thc ",'OtI:rMI ;ond stiU pn:wklc fbl, 1IOUnd ; ~ ... "ace b" lhc rotIler. U.<Ing tcmpb.e ftttJ CI
)'OU of.hc n=;!10 J"'l"Itk suidc Sl.IIfaoc b" an c<IF
lIuklr OI" thc 1IaIq>b'" . . ..

J:

::1.

W1u1l'm lIUinI!: 10 <10 hc~ b ttpbln, stq> by Mq>, hoow

10 nake ;ond w.c bask monising lnnplalC ,,,.. b thc ......
<>f .empialC ~ In .tlc /lrst a:omplc &,v<:n ~oo.- ~ th~
morti ... In a bmch !ICOll 'rhrn 111 >how )'OU lhc t""'plal" ~_....
~ In Ihc OIhcr ~oe jobs (;Ie<! '00'-".

Maklng a Ceneric
Monising Template
noe cxm.ioc horn: b 10 m.kc I roU''')'<lIJ\e o.-Nxwtl bmdI.
nx, bmdI -. Iqp D<h tu .., ."'., .CDO<If a kWlS ... lhc ..... b
thlck. n.c... tmons cxtmd !nIo mortloo::I an lhroLtr;h Ihc K"
hoaftl. nx, 1~..rnmwidc )( l~...indl--lonJI mortioo m: ruuletI
...ith aJuido bo.hIng~ ptw>g<: ""',.,.
tcmplatc

_:>

'"

(;IENIEltIC MDIITISlN(O TE MPi..ATE LAVOUT

T~mplale wlndow 15
rou. ed wi\h " " bit;
COrnel ,.diu. 1. h ""

I It" X 2M" mon'H

..... ,ed ullng 'em~e

wi.t. \Ii" bit.nd MO"
0 . 0 . guide busl'lIng

Cuttlng Llsl
Pa r,

Qty"

~" X

Ttmpla't

ali

,-.
'f

I r)( 16"

Mate ria l
Bireh plywoo<!

11><: '''",pb't 1,,,,,., b a pkc<: <>1 \ ..ind> or h"inCh hin:t.

oct IM Itn 'pblt OII II ... worI<pi" ( ..'hidI
""" .' o.' a pie
sc:np) and applr a coupk <>1 cbmps.
...:cur/nit II... Itmp""<: '" IM ,,"01'1< :ano.! IM .........., In lM
W'()Itbench "rIItn rotiI
Ilo:""" muln", 'M '~mpb'r . )'OU "''''' 10 .... kc fUncb..
....:n,al \lo:dsioru ab<HJ tIc l>ushln" ;u>d ,tic bII )'OU ..i U
..,., . You "'''' 10 mUc I~ ~ up (1001, I:>faUliC

M''"''>Od . l"ol.

c:

Ol me nslon l

Or

CHOOSIN(; A (OUIDIE IUSH IN(O FOII TIEMPLATIE .. MDIITISING

COLLAR LENClli

Wi.h n.ilndud !lU"'" bu.hing ... t ....

coli., Ifl>gIII 1nUl'".e. H the col'"
d l.ilmttt' inc~.ilSu .

The longH the col"',. the thkh, the

.::J

'emp!.illt malerloill mu .. be, and 1....

!oi." 0 . 0 ..

!eIS dHP .lIe bit ulel\(ling Ihroogh

1. Un ~",h .

CHIP CLEAAANCE

SlIme \Ii"-<lII .. bit In

K"-dia" bu.hlng

\Ii""dla. bli In
h" -dil" bushll\g

Tlgh. durlnee
betwHn 1....

,aiia,

Ind 1.... bi. , _. rlcll

Ilie p.IIs~ of dllp.
f,om Ihe cu, .

i::::'l

Ample clurllnee be'Wffn

'he coliI< Ind lhe bI.
promotei p.oiuge of chlpi
OUl of ,lIe cui..

_ _ _ _ _ _ _ _ __ ,

~bmo:tn bil. U)'OU """'li ~.id<: n....,l$c!. "'"

I~. 01
' M mor

roti..,..

"Hn<tI~n bit. In lhl.

'*' 10

Itl tit 1I0I0 in<r..:, wid<:. lnd ~ '. unlil;dy )'OU ho...,
,.,.... bir 01 'hol <H. m....n . 1lK brJIc,;l"~
col-

In...,.

louiorI D I In<h in dimlc1tt

IM ...ilh l"",pI:o l~. )'OU an ...asUy ...., hinch .,..
"'-to biI 10 ~ lhlo .......,ise.ThiS l txo...., lh~ I~
pitit ........ . , . guiIX. coolfQlll "'" nn. 1.... cad of n" kina
!U1l1k .... Igh.linc CUI. )'OU " " " """,nd l M In"".
~01"'" " ,mpblc. thm fQUI baei< .nd tUnh OI" md
10...:110 rtftO(WC lM Im"""" " .... c
A ~t <;'OfttI .....""" in ch<,M:t,ilng bit l lhe:
...., 1100 bil diom ... cr to.o. on lh~ 11><JItbc', rornns. A
~l"" bil
OUl , h(: " ';I.'IIc quiddy bul "'.....os
MIounlbl ,,"" oi """"c 10 bc " .""""" ..~h chisel U)'OU
11< . Ii/IIlIkIi1IlW:n tlu_r. a '~Indt bil-d.., ,...<:1> 01
...... i> m...iI ...... tI"f, nn"'" ""'"' ra>llf "'mo......d .
1110: 60uI (Ur\!ilcknllon.lnd ~ ,1 ",1 ' '''''. b IM biI .
oormI ~ . TlIUy 101' ,1", nttds:. minimum oi h indo In
_ooIfl ~ IIM: <Oulcr """" .hk:k""",, + IIM: tIoid<noIl 01 "'"
......... + ,he tk:sirnl .......,Ic: "'I"h. lO ........hro....
_
in ~~ (fi'~) .. ,><:1< ....... hineh I~m pblc
.... III< bit n'u$l1M:: " minimum 01 2 Iod'>c lung
In thls 1"",",,". 1 .... I...:IN ' rindHll:lmt."1Cf bit.

"'*'

2. Choose .hc .cmplllic gul<k bush lng. In

. . . . tlIor JUidc bu ........ lhcr..- . rc fWO tattu ' hol m"'1
lor , ......,N Ihc colbr dWnctc 00 llIc cobr I(,'Mlh

""m.~ oboiOo.l:!oly. Ihc IrWde di2tntICf of .hr roIbr

mUSl bc aa.,.... ~naugh 10 acc:ommodalC Ibc bit llul )"OU
.h"uld .au coojkk.,. dllp cIcat:ln<'t U,i"ll ~,""Icr
Muidc - " ' l I whh ~, hl1 p"".1dc:l plen.,. of
do""",,, ro...hc chip" lNt "'.... U ..... I ni ' h<: CUI. It you CUI
nwu.., il. :0.110'" al kaot .... Inch btlwa."n ,"" bi, ~nd "'"
1....... of.lle _
. which Ol(.""" " lhol lhe: 1n.Wk' dlamt."1n 01
1"" oo.oJ\,"tI obouId be ho lnell bl'Jl<."'" ohan 'he bl' dlamc1n
An """"'pir. For a ~+Inch-diarnncr bit. USI: a \~IndI-O. I).
b,ulti"", ..."Ieh typk:olly .... I ' ......Indl In>Ne: diamntf.
In _ . ~ I ~ ...i.lI. ohon coAar ... )'~'
an """ I thln 1""'f'btt. Tbt roIbr.'" )'O.>U pn.lbabIy tn" ....
_
bo jus< I ~""" le Ih:ln Ih<: templ:olC IhIck"""",. AnII
Iht tlll..."""", 01 tht
bc o:ubtncoN from Ihc
"",~in'"m moch oi tht bil al fuU
th ... llmlllng .....
dtpth oI lht ~ ""'1 ."arI ht rour.cd. lf)'O.>Ur rnoni!oc _
bo rnon: ""'" 1 lndI dp;ond ,.,... ''''''pLlI<." 1:> ", Indt thlck
)Ull arc fiPin810 MCtl an -fuIr Iong bI ""va')' fr.to:tion olan
ind'! )'O.>U >100.., oIf ' h<: , ...... pblc ~ th<: moniM." dccJ"'t.
1lw:: ltilcll . 01 """""'. It .hal la~ lIlIidc t>o.t.n.
ing< .eOO lu ho'.... ~ colb .... A vI,,;1 10 "'" benc" grindC1"
can CUllh<." coIIar <Iown.o ............ ~ k:nglh.
1'0. Ilie _1:>In8 Icmplalc """".... ..,.. l'..Ind>O D.
~ukk
an(! makc SUn! ,toc ""'-la. 1, 110 """"' lhan ~.

",,,,,,,,,c .... ,,,

pI..,....

buohi,..

'"""

} . Sc:ka and cu. Il.... tcm platc..rock. 1lw:: I ...... plalc

Sl ..... k . ... nOIW carlicr. an loc banJboan!. MOf. pIywoocI. OI"

r--I

OIOO5IN(; A.IT FOII TEMPLATEIoIIOIITISl NC

.(l.D. busttJng
.. "

Ed\le of monise
(

Edge

Edl}tOflemPble

~=""~='"'_
:-

~ .... ,'~"'"

"r monl.t

Edl}t of ttmpll!lt
Sm.U-dlamtte, bit

wlIf-diameler bir

c!tJrs IlIt monlst

mO,",
p;lues 10 dtlO'
Iht monlse. JOO
~ul,",.

qulc~lv. JOO luves

... ide rlOdlus cornol!'.

IU"tS tlght,lOdius
(<>mers.

WilSlt slUIIO bf! 'Ou led '''''Y

Pon ion 01 bit In r",ner collM

TtmplJle Ihk:kness

Wo,t pltce Ihkknen

Stup

.,

11:
O
::1

_._.
.
VI

ta

TU4PLATEMORTISlH(; SCHEMATIC

To Ihe IonQth (or wldtll) of tlle mo<l'~ .ckllwke

Ihe offfellO determine how Iong (or,.;\de) 1""
olM!nl"g In Ihe lempiile mUSI bit.

Tempi.le

ROUling It.. Iim plat..... lrl-do ... Ii ~ slrillghtforwortl

OIM!'<lIOn. Th~ y,,Ir><II1hlck tempa,le _,etIIlll
Off,el
pb>lk:, 111111 IIM: k:nJtIh of thc gulde b ... l~ng'. cui!.>. In
rnlod. d'Icdt 'Ile !iC"~p bin Jur a us:.bk: pin:e. F:iUing 11te..."
lUt Ille _
n~ oI!hoc """crU!> fu. }'OU' lempl>!e.
Thb b npodalIy ~ iftlle ,en,pI..1'" wil! bc jotM;pccific_
,bat It. rrudo Joc- Ihb p;utICula' job lIMl """'incd lOr 'he
,.,...p bIn ... hen
job 1< romplclW .
. ._ . .
For Ille ~ templ..1lc Wldcf considcnlion I>rn:, 1
..sed 'o-indIbird'l plpood. II's. m.JlaW I ~ an hand,
and It 1< I""~ on bfuu' lincJ show up mly. M DF
(mNl~r /lbcrt:luanJ) In a ',..Ind> <X ~ IlIick
nc>o It ... o .....1lcnI m:olm:d.:II Is .ny goo<kpWi<y p/)"W<I<Jd
'" cilht, oIllIoo$c thIdoc:ooa. U.....u..:.:.na ....... bIc. bul I
ftn<llt nat 10 ImpoMlblc 10 ..,.. b)'O<a Iinol dn .... n an iI.1IO
1 JCOCf1liIy .mid II for oppti<'3Iklo> Iikc Ihio..
lloughIy II< thc 1<HIpbIe 1IUICri:JI.....tq il btl!I' .........
Itw cIIInps an bc :oppIird .."ho<tt thq ...,..., inIcrkn: ..;u,

,Iu,

c:

OI

1-__1

' hc l'IlUICT"J """........... """"'" thc 1aIlpbI" .."indoJow. l1lc

CUninl u.o op<rif"" Itw ,hit lCnlpblc Ix: Il X 161ndoo.
uy OUl Ihc win(\o"no' o n lhc IcmpblC ~""' ....
l1lc guidc: "'1..00..' il Ilie <>penins inlO " .Irit.... IIM: SUidC
bu>hlng fii . 1l11h Ihc I>u>hins ,... ppcd in
irotIow. Ihc
""" le"5 """..,menl i'I UmllW In "",en,."". II """ """"" from
Of\c elld 01 Ilte ,,~n~' 10 Ihe othc:r. rrom ..... oIdc 10 il",
OIh.", Rea..,., the bI' 1< in>1<k: 'Ile bu>hlng. ill .....,.. of
nlO"en"'111 , 100, h lin,hcd.
ll'IC .:1.>1< now is 10 design and Iar oul IM >'loc ...,.,.,..
' u r I<l produce II><: <ksi~ rnoni,.,. To illn. ","c IIM:
wldlh ."d Icng' " of It .... dc>ircd monl,., (In . 111< I",,~ .
1hoir>< lIwkk, l " .. incllk><ljc OIle), l'ou'", al.."..)y ct.o.;o,n a
', .. ineh-<.llarnc,e ....... lgII. bl. 'nd h lnCII-O.D gul<le
~Ing Cornp"'e ,he off"'I, ",hleh b <k'e,n,InW by ",1)'J':ICting Ilie bit diamC1e' r""m Ihr """"1"3 di<lrnc.C1" Ind
w'iding by 2. In 'hl, <::0,;0;,.1><: ofr!lC1 b ~, In~h .
Ite..., ', how.u 1".'1>10'" , lIe dlnlcn<lon. of 'ht <lcslrcd
rnorti>c ntO .1Ie dlmen~ktm rO. III<: """""""r Icmpl.lC
>lot ,,<101 ,wlcc <h<:: off,.,. 10 'Ilc Qwnbc k lll!'",;oS ~hown
in ,Ite dr.",lng n-"'llIal"'lfartl$l"lI Scbemallc.11.u5. lhe

4.

'Iu, ..

c,",mpe!! 10 scr<lp. ,.... windoWs ~ngth II controkcl

bV IM stop, ct<lmped 10 Ihe 'tm~te .... , ....1. Tht
rou!fr"s elIgt gulM poslt lonl Ilie wlnclow.
,~mpl'''' .tot m~ Ix: 1"0 inchcs "'idc and j ' , lndIn lttIl

o;;;,;;

Follo", Ihe d ......1nll (jto",rle Mortis'",

Scribc II><: ccnl~t1I"" of thc 0l0i, thtrt
ct()&/Uir a he nddpoim Rea""" I ~ II
agaln a od :qIln 10 po;tfi,Jon ."" <'<)mplctN
workpleCC5. Ihe II".". ,,",.ukl bc <Ir."", with I
line n.. rkC1",ll>c'n Lor Ou' Ihe " Ind..,,, rrom I
}'OU
lrotlbl~ .....,111,11
. I"",f' I
b<'lllt'\I. ll>c'n
ti Iln~.. on'M

'''9"..1,

Iu,..,

""" ,Iu..t n:.>tJ' .h/UUW' 111c "pc,)

S. Motii tI'e ... Indo ... In Ihe 1<,,,,pJ:ale
to etil .Il<: ~uklc

' '''ry .,......,. an<! accunle

"';111

"'lth

.n cdSI<"

~"

oii 1

tooac~ofthc

...,rcwncC'd rrom.t..

To bqln, d<ltI
IICr.lp
""n'."h . l""" ctamp .1Ie ,,,nlpl..11e ' o 1, . "'1T~ngc 1
!lO
you ",m ""kn."nct wiUt IIM: fOUIn,
iltJidc projttt. bcy<-t Ilie """'P" nIlI<' ,"ou " ... nllO
cntt Ihc ' C1I>p!a'( ~ ndtlslt-dy ",i,h It..
( l'ou o:ouId II.., ""....... ,IM: lCa'pI..1lt ta thc """'P:
'httt hok:s In i, ........, Inlerfc"" ..illl .1Ie ...., <1
''''''pla..".)
""-"Ien .....IAh' bit In

1"" .....

".p'

dcP"'~'~~;~::~.::::;::;;,:~: :::-::.::::

plW'l(l:lt"
InMllII 11

t10Il

.,..., wp: of

" indow, "'.. Ia\'lnil "'"

1Icfun: "",11ng,)C1 up, poi. of ..op ..~ . , . ,,,;,.~. ~

rrom Q\"Cf'IohQotlng dlhcr cnd 01 IIM: .tot.
'tl'llh Ilie bIocb JCI, """ ,"" r.... sloi. Se< "'"

!il""
po..... ..

:~~2:~~:

.1Ie ' empblC ....llcb it 00, pt""",

tQ il"" il(:l;Ct IIM: ~ guidc. 1"""
klcn llll! Ilie W\ndow
Ilie
",Ind<>.. b con'pkIW.
00

Re""",

,,(>cu. hit Ij

11'I<)S(

ur'en I'n'(lnu,ocn<k<! for

n,unl~nll.

'Il...,.,

it> tlcs.iw> 1> C'OIlctll.:tl~ 10 heip ~'llII'r d.11"I tIp ou, oI.hc cut
If )"0\1"'" 110' 5UCh bit Ind II I~ In"g. hy .11 rne.ns ....41;; 1, !Iu.
",...... 11 Icn!llh is "fien I rn"r<: sill"lflC'Oln. >ttSi\k ... tlon In
..-....nH. 1l1c lnnjCOl ' .....ch hl,. 1'..., III't-I><Kh fn,rn
An ..... ~.,.., noi "f'I...I. U". L~ an: 'hc bit> I ...... nlO5t
ofInI lOr rnonlslng

.l ...tty. "'" 'hc plunll" dcl"h.

Combining Templates
SoIVI"O Itmpl/llU lrom

proJecl c/ln make II

f"lu~ .
.... , ~'ng I",mpl,..,. Cln ~llO If:ad 10 otOf~
"'oes. If everything yO<I ttWtf .tqu'~s lWO Of III,u
Of fou, ttmplolt . '1 ... oro\ bot 100 Iong before Ilie
KC .. m .. I~11OfI push.,s OUl of liS "lllf: co"'" .nd
crowds Y'D'I ,nlO Itle <>PIH"C 0tH' .
~llokt ltfO( live-boird beIKh
lnWIvt-d IhrH 1ell\pbIH-O'le for shllotn!l ~ legs,
another for ~n(j Ihe ~ MdI.. anei /1 lII"d for
1tIUl'''IiIIM lIIOfIJl.tS. Bul gllfts wIIIt' .... th~e I~
pl.11H (it' be OM. Che<k DUC ttle pIIoIo. The leg s/w.pe
OCCUpoH ... tnd .md a sode of Itle I~I~ bI ...... n..
_Ih;tpc oct...... Ihe oehH oeMf sidt anei end.
The w,ndow for 1/1t moru.u li ln IhI moOdlt
/1

euy 10 'tprod"'", Illil pro].,ct ,n Itle

CIH .... lrs

_.

~Uo ...

)'0" 10 pOsllion 1.... I",mplat'"

..;chouIIi)lin; 0\11 I~ monil<' complelelv OII Itle wor1t.

)$11\' 0II11he unlerl' Mi Otngth and wkhh) of th.,
.wtIM.. 'IMn /lllOn the Cf05s/1.1irs OII Ihe Itmplole wIIh
lIItM Iints, ~s s"own. 1l>t mon,l<' ... ,11 bot perfectlv

Usi ng the Mortising Template

II .... IIDOI\bins Imlpblc sucttSo1ully, il .. imporum 10
_ ~ hidI bil :md Jui<k buslUng Iu ..,.., wilh It.V"" WOfI'1
"'dlfflcuI<y MIh 'hl:! ""hen)'OU ...... t~ lempblc lJnmco.
"-'Y ofIer h..ing """'" II>c lemp!:".,. But _ oboul a
,..,Ia!m Or Ih-.: l~ laletl
I lhm1 ~ is C$SetIIi2! 10 ""........,e IM tnl'pIales lha ...,

,. """'*

,...,ol)o:~.

JIlSI ... l1le Io.giblyon II>c lempblc"'luI.

roo,bin't'on Os su~ ,,, bc usa! ...lIh It.
_.u }Ql' p"'ran= 'o muc .nothcr I,,~ bcnch.
1'* !!fi O\f\ t!le tcn'pt"c. then l'etcll tlle C<:>rTtt1 h<t>hl"tl
III bit from ... he", Lhcy .r<: kcpl In yuur )hop.
~Ib/J.

1. Set up II", rouL", . SlOn by

fln~.

J:

_.._.
O

' .. lnch suloJc

::1

lto!Iunr: il1lo LlK bit Of"'nltljl ln thc mute. b>.>cpl~LC .

NaI, LlgIttell' ~.. Inch ..... ighL hit In ,he coIle, A ~pir.1

la

"" <_""'Ied mon ls .. il clf:in ind neU'il"'lv

ond posiliotltd .

"*

Thtft It mplales In on", mak.,s for caSy "ora!!".

OII tht 12 X I SInt:h p~u 01 \','int:h plywood
(nm,nq on II><! botnch)
Iht JMUtms for alllht
Itmpl;lIeilu!ded CUIS .....d., In eonSltIKl,ng Ih" livt
boHtrd bcnt:h.

",t

TMl p!.o leMom , in\l

1 04 9

2.

1..:1)'

oul Ih e o>on lse 0 0 ti.., work plece. Thl'

<!onn' , mean )'O .. muS! dnw l't'CI~ngks on ,h"

won.:

plr. ddlor.rilljl <'Xh moni~ '0 I>c rou,,,d lI .. h",. I!

you .hauld Kribtc Ihc centerli"e and m idpoi' l! of
c.e h mon;!iC un 'h" workpic<-.., . ... )"'u OI n line up ,he
,empl:llc . If
made ,I>c .em pl " wllh 1'=1.10" . on<l
)...u r 1. )...... III>C'S an: .ecu""e . Ihe monlsc. ",iti hc prop.
crly 1' JC:Jr'cd
man~

yau',..,

lO<k '" 1IiIk. nihl>ling ~ "'-.y ,1", ...... c het",,,,," m. tnd bom.
1"hc nkc {hlnll ~bo<I' usIn~ a 1<'1I, p l:lI~ for thb
{h~1 fced dln:clk>n <... nfll.""" is elimi "","". u..altlC
hll)lIhllC is , ~.ppc<l In ,h ~ ,e"'pb .., $lot. 'Ile CUI
( vct1 1f)'O<l fced wltlt ,1", bit
~~ .~.
' !9h-.l II (Do .h ",-hen llui<lilljl " monbitq CUI
lIukk: . an<! .hc cu, ~ , ...-.:r oIJ Ihe c ..mcrlinc_)

_""(r.

""",Ion

A Base-C:;uiding
Mortising Template

3. f'o!IUlo n Ihe Ic m p b 'e. u y.hc wori<pIr<...., on ..,

.1[> ''''''

o:><peno,bhk: pktt u, "'

""m back 1. up. dlmuu.UlJi:
dllP'O'l' "" Il'" wl<l<:n.itk vi Ihe .... or1<p;n:c and prutn:tJng
rt", I>cnch rop. Sc1.hc .em"t!!e on.hc work. and.IJgn.1Ie
ml<lpolm "",rit "" .I>e 'mljIb.c ";Ih Ihc ~
.... "" nil 'hc _
. AppIy a rou[>lc vlcWrtps._h.,.,hc
, ..... pIa.c. """"p;n:c. and badtup >enp 10 Ihe """"bmdI

An ahe .... ';..., ,,, .1Ie lempQ'c u5N Wlh ~.".". .,..~~.
thl5 .cmpl;Ite. ,,'Iuch lncuol,ou,a r.:na:s , h;rt PI'
"""cr b.uc: \ . .... lIon' "",.., .u . - a gui<k bu>ItIn& ...... l
'i)U

"""'! rven "",.., ,,, IIK a plUtlll<" rouIn1

4.

,,,,,,pbtr "",,', ""ve: 10 " ...... " ..10 .

'he. mortle.. Sc1,1or ......cr on 'lor

"nh Ihe """'inlln ,hc 0l0i. S..itdI an Ihe fUIIlcr. pIurtw .hc
bII nd fUUl Ihe .....ru... n... ...... inc I ~. lbIIow b to
",," .oo.r lhe r;:urnen; 0I1he lhQrt5(; II) fui do:p!b 2IId Ihcn
""'". ~ 01 ~", .. ~ dttpcr pa-. badt ond bitI>.
MOlii

Choking O" Chips

Spor ... l u!)Cul

.-.-..
i::E

I,~ ..

ab<>uc tllis tempLu( ii tiut ""

'cmpl:o'c .."in<ItJw tIw'l
laJ"fII'I" lhan 1"" moftir Thc w lndow is Olactly tIM: _
Icn8th and ,,klth as lhe moni!;c So '" posi.On tIM: ...
me",1y It,n", ,,, >CI I, an lhc b)'OIJ' liNs pt"II(ioI
on the workple<"c

Whol I p;trtirubrly

b"~

no,w,lhlUlnd,ng. chilii e... nand doi-dO; Ilie 'fmpille SlOI wllen VOU lrf
mOM'''ng_ TM ,uul! elin be " unden'Zfd mOrl,se
... <lh Unfllen ... ,,11s
Wh". IIIppen~ 11111 chlPI well up In Ilie cut ;lAd
pusll up ,nlO 1"" .empl e ilo'. A. IlIf guide bu.hlng
moves IlIroulIlI ,Ile slo,. II paeks chlp~ a~lnSI Ilie
ends. In .ffeel. Ilie "IO'lItl\ shOM.r. The "'SIlit ls ~
Slfpped monlse- One ,II ~ IlIf COrrfel Ifll<jlh nfa,
,he lurbec. bu' '00 SIIOM ,hree'Qu"Mers of ,hc way
down tow"rd
bouom_
Th. problem II moSI p,on""ncO<l. in mv ""m.
Iion. wnll wlde. 'hroulllI moMISts. whlell ",qul",
slde-.o-slde Cul\llIII u well U flld-Io-tlld C.... ling.

'h.

""'(.)'OU

Wha. 10 d01

The beSi ",lul'OIl I~ a rou'ff-m""nlfd chip

nll.Cilon '~IUp. Somc mlnul."u,en. not.obly
OeWal, ind 801(1t. offe, sucit accenonCI. 1VpiIIIt.
plutlc Ihroud ..... Ith "viCUllm-hOSt COIl .... ClIOII II
mounltd InJld. Iht b.!'!_ The sltmud "urr""n.h the
bit. Thf vl<u"m pulls .lte chip. oul or the cut.ncI
th,ough Ihe bit open'ng In
bue. Mn sucks
"w"v 10 lne IhOll ViC.
Thf "lttrNllvt " 10 SlOp work Ind Vkuum the
clI,ps ou, or 'lte cu,. OII lOn1t CIt'OMS. uSUll1y
wlttn v.o<k'nll plAt. I'yt /IMI 10 lin" K",wd"vtr la
d"n tht ledgt belwn IM {tmpl"lt 1101 Ind tht
monlse 10 CnSUrf .1111 ,ltt lIuodc bush'"" could,..
In.o tllt co.fItrl of.he \emplitt Slol _

,It.

.'.
,

.,

Wh. n chip. dog th. CUI , the re~ult,nll mor. ,se Is

St ldom ."urn. USllaIlV. Ihls muns you hlvt 10
S1 0P Ind vacuum Ihe ehlps OUl of Ihe CUI Bul w lt~
a v. cuum pkkup """ehed to 'ht : ;;~.;;;:~;; ;;;',. . ,
suc k Illose Chlps ou. or Ilie Cut as
duce~

1 50

Ro ule, "'"Ilie

. hfm.

IASl-GUIDI NG MORTISI NG TEMPLATf

~~

Making the Template

Cuuing List
Port

Qty.

Ttmplalt

,_o

..

""'

f.n<t

Dim~n s lons

M;"~ril. l

Ioi'XIS'XI5"

St,ell pIyv;ood

)j,'X IWx 15'

fbrd ..ood

)j,'X IWX 15"

Hi,d .. ood

)j,' X IWX 15"

Hird .. ood

Hardware

Imlpbl~ il; pmr,' mtK'tt

U!C" 2JI oIbct gaup:. ,,'IIid> il; _

""" 'I-mb.5 pn>fIOOoI", ...........Ij' ......,.)

MDIIfI!. Ihc

1100. You

in IXl'itloninB "'n;ghl""" fOr ruuri"" <Iadot>o :mii IIJ'OO'"Q.

NoI onIy wlD thi.'ll...rnniqur""'" brthls jla.1I 'laboa ~
~ 10 gu;dc a rouICT ,,'hen """nfI ...onbi"ll " 'in<kno.'> In
Innpbt"" inl~ndnI ro k ......,.) "ith guid< ~
,._.,
1 . M:akc .... offijd

:md bll }'OU "i11

gaU(IC. Cut 1....

lIliin3

Ik mulCT

'*' wllII "'" onortisi. . """pl:d~ that l"'" ....,

mn... Sn up "'" rQtIIn". _ CUI 6- 10 Il-inctIkIIl3 "'lip fA "'.joell 10 l'Hnch pIywuod, MDI' OI" l",nJboani.
rippin!! it :d:>oul f 10 5 Incb<:s wkk. Thb Is _
bbnIc.
(]::unp f<:n<:,: ~ ttw: cdJo: 01. ""OO1LIxnch. tlul! ttw:
11"l1li" bbnk 10 ttw: Ilo"",,; txk II <I<'.... n ...illl ('\lOJpk ot
bl3ds. or stkk il down wilh ofPCI "'pt'. Gukk 11>c: rouIn""
oI< l<lg Ih e fcncc.am lng IhMl(!h 11>c: >to.:k. Pry up Ihc ~UJC
'ou nu .. II. ""
IU poo:I,JOI1 )'OUl" ICltlp"" " r"""Q.
oI)oul 10

Drywall ,cre.." _6 X) '

'WIII~ 1, Dp"......'''Q'. C~"Q (1, ..h,~ ....I"""r Q,UI>I -

M".. ,.... ""'PIIo,..

"-' y

2. Cui tbc ,...ns. V.-..., n<"CtI pict:c of [l1).....OO<I;Ib.:)U!

15 ilIdte> "I~ lOr Il",

I~m [ll'u". an<!

.1><." '1 4 fecl of . X

..g_._.

I l;.inch haRlwood ilcrl for IIlr frncn.

3. Lay oul thc wlndow on tb c IcmpL~t~. Ury a

drop--Inf IIi".... mn-c,1 up, In Ihc ccttln" o f II", pI)'WOOd and
I"""'..round il ..ith a Wrp pcndl,
11>c: c,,"lcr1lnc 01
11'1<: llinW pin. 100, CIII~ tIIil! ~nc ...cll 1>c:)'OrId 'hco OUl
~nc 01 Ibt hirIF.

"'.tI:

4. Sd thc tcmpbl"', r~~. u ... IM off>ct ~*

for this. as .no...n in d>t dt:a""Inl! ~Mf"S" .. S#<I ....1t'L Ury
,hc ~ ... ., ...... C'dtJI" Iu>t CO\"Cn onc ,,, IIlr pt'fI<:1I II"""
outlinionK thc morthc oa"'P Ik
10 tM ImlpW<'
_
. ,hen buu a >lnp 01 tIM: fcnco: llloei< 10 iu 0()f'0tiI~
~ Sc..,.... thc rma 10 thc ,nnpbtc bbnk (10 boc. 01
COONc:. If,.,.. .tm.., thc S<:..:wI 'hrough Ihc I~mpblc OIcrl

P"

Abu. . uldlnll m orllsl nll lllm plaiil 1, .imp'" 10

... ~ IrId ",. TII. w.........trn rl ..... rracllrd ro rll. tom
pili. mllorl.11 guld. Ihe 'OUler ;'-I il CUI! Ibt "Indo..
~ Iho lomplll', Ind al.o as II CuI. rh. morti", lutlf.

inlO 1"" tDJc.: ~

Now U!C" Ihc ~"II" in "'" _

"'2)'

10 po$illon IIoIICQ

Ttm~ltMonli,"g

1 SI

"'_oi

monisc ;$100 laI"/\<' 0 " 00 omaU djUSt thc fcnce: poN'iom

FENCINGIN SEQUENCE

FIRST fEN(!

SECOND FENCE

.nd fCpc:l111Ie 1<:>1 p.-ocnJ,,'"

Using the BaseGuiding Templilte

""" -~:3,

Offm

gauge-l-v
~-cr--i

Mo"".

layout

Templlt. ~

W;,h Ihc ,,,mpl.,,, matk: and U<.:ccssfully 1C>tcd. nJI.OitI

n\Onl"", I.s f>.rlly sin'pk "'""er. This ten'pl:lte l:i """ ..
Ihc sante ""'Y Ihc n:xular1cmpblc Il. ","cept IhOl )'OU doat
neal a guidc buo.hing on)"Our ",uler.
QmUnc tlte "",I'ti:;c OI"! tit" wort<pit'CC. t/tcn:aIign .....
1C1l'pl:llc ",~. II. 1Iea~ Ihc Icmplale'. will<low Iw .....
s.mc din>crtSions as thc n>Ot"'Iisc. alignmcnt ,,'ltIt thc 10)...
Unei i,,: """y. C:lamp tlte tempb'~ U. 'ltc worl: , ontJ t'UIIl.
Ifyvu
m., .. " fN''''gp rou/<'r. Ihl; b:ut ~
.... y lu rotii 11","00. You "houkl bc: . bIt: 10 lip t"" NUIlr
I<:k couul:h tu han, thc bit cI= of ,1Ie "'...... )'CI Slill t....
tit" muter ,r.ppe<J behn..,n tbc fcn . l1lc fCOC<."llIhco 1'1'>
,i <k cnotl~' oomrolth. 1 t""' ... u lum un tlle ntUlcr, .....
bi. Into ,he wOl"'k. and rou, Ihc monis<:.Al'ter thiII ....
1"'-"" .",ilm uf( tIM: ""'tcr . nd lift i, el"". o( ti><: """'11ll'R:"aSC Il,., bit
ond ..".,... t It,., ~ 1<> mii i
liuk dccpcr. ","'( Of (our qel'" likc . hi$ lII>ould maI*
)"Ou to mut 1ll{Jf1isc OI Ic:lst an lnch Ii=p.

,fOI",

THIRD FEN( E

FQURTH FfNCE

,h"

c:;

a'''''''ton.

CU! down offset gauge

oi c""" mii o( II><: jig, I( 1KCC$!o:OT}; trim thc ofIiK:' gaugc ' o
fi. beI"'<:CR.he . _ end fcnL'eS, ond ...., It tt> po.;;tlon ,1><:
. ,_ _, (ounh arni las! (elia,

5.

T<:>jl Ihe

JIg. Tu do this. on.

picce of \'.. inch pl)'

",00<1 o r h. robo.m to IUSI tlrop in,idc Ihc (elKCll. U""

II'" cllOSCI1 router .nd bit 10 cUI a .hallow monisc in Ihis
te'" """'p , ( 1:) 0"' 1 c ut into ti'" tcmpbtc
)<'1.) ~t.,...u",

,...,.,1<

.-.c:

GIi

tl><: monb:c. 1f it 1, thc cu"",,", din'eru""". roul Ihrough the

tco'pLiue. (urmll!{( tI><: window. On thc OIhcr h,,,,d. If Ihc

A Template-Mortising Sam pler

Tcmpbtcmonising Is . vcry ''<:rNltilc "l"",cm .Thc JF!ICil'
monisil1jl. Icmpl:>l'" )"OU ' ,~ IUSI rad >boul - .nd
lricd , J hopc_ :uc JuSt an ;nlrod"""ion.llH:n: an: otft(r 10
ali<tns in whieh ,,,n'plate.monJ:.ing i,,: .J>,;olutcly 1"" la
' l"l~m . At II,., bcginning of tiris chaplc" [ lIS1cd ... ,-m
lhosc oppliCl"iOns. In ach . llte nIOnlsc "'x>uld be diftictIk
il.1Ot In'pn<Siblc, lo ",,,t withoul a template.
",., Il"",, uf 000..,... has bem <kalt wtl h by thc JI!'O"II
JlKH"tlsinf!, !empLI1<:s. lIul what " boul ,hosc: Olhcr "=
applk-.ot'o" s?
SAWIUCK LEG ASSEMBLY

Slretche.
T"' ough mon.1t

TiP.mplalemonlslng wllh a 'heclbue rotner 1,

possible it)'OU uSe a biSoegu ldt!lg template , With th.
l'O\ll.' tlpped sti th. bit i. elta. of th. wo.k, bra". Ih.
roUt.r's ba agatnst th emplal.~ fences. Switeh on
the roole . thon Iower tho bit into th. wo.k, Th. lenee.
contine tbe rooter. p.eve nling it from eultlng ounid.
th. mon' ''''.
152

Rou!o. Magic

The Deep Through Mortise

SAWIUCK LEe; MOIlTISl Ne; TEM ' I,ATE

oa..anIr.'

'"mugh ..."nl"" ... " Il<: mu,~ ~!iinll ,Il<: al'"

. . - llr:octiIlnI ah,,,,,,. II.. , <:'.""1' OI"'" In whlk. ,Il<:
* - l i 01. mon"", ,110 Ixyond ,Ix meh <li c\" .. lh<'
.... of """'" bilS. The righ' "_.... pl c ....~ uf' <.':In """e"",

Mllcll IlIoek .... ss of

lempl.ote.o Itnglh
of lempl.ott

guidt col~,.

,..""" ..... onch.

,."

"" cample ... ~k<Iown ,..wbu.ck .a"'" I ma<k

..... of,....... ;ofIO.ll>c ul><lapln..l'W' ' ..." " ''' 'C) "",wbuck
... ' . .... , joInctI .". "'",'chcr. ~h pal. ullqt> "''al
...... """"'f'.A ,,:non on ,,,,, ",,,,,cht. pu&N '1lto\IfIh
__
In d .. 1cII;f Ind _ Iock.,d In pI>tt wi.h . "''''''"'"

';-5

""""" or kq. "" ." ""'... In 'h<' t1r. willl!l Si."tJ,1dr. Utti
_~ Sin lIw: ~ ....".., 2" , Incho t/lIdt . h<' .t1rou~1
. . . ... I:q"ond ,Il<: ~ 01 my loI1fII'>I bit..

ar filllna

.IIe ' empb' e ""I,h

klmlk.~1

T,immtd
pOsltloning

. ...

""

"'K'

".".

Morllsing wlndo"," '

f'lI'lU""lng

........ hvth ho:eo. I "'-u .t>Ic 10 do .bo:: monlsc 111c

Wb prOOIo:GI J>cn:, ,,~, II, In Ihlfi"'3 'bo:: .("..

,.. r.o. .... "..,., <lIIIIe "'''''' ' 0 ,he othcr. )'O<l .urn "''''
.. -t< Of ,....1""' ....".."" .cmpb.e . h<' .cmpl3l" Ilkely
"OI br IIIIIalfloN. W1"D. ,...,.. t.a>" '0 do .. mO"VC .bo::

.em-

,... ~ ~ ~ "'31' pIa)~ otd,...,.. "'..,.., moo.ing

'0 .""

. . dlt lOp <li ."" Ikdc

bonom. Af/t:r" ,...,.. """.,
- " lIIIl rcdampN'h<' .cmpb.e urn.bo:: ",1loIc ...""'"
_.0)00011

oomim.. ~

IIII'dc: Ihc" ~ IC1IIpaa, .. .,........" in liIc dnwing

......, iii .tI_ng r~te. I !>iI! otIl and eu. lbo::
....... In .hc <:m ..... 0I1hc tanpb.e stOd-. pM:tt 01 \It.
badt p/)'WOOd. "ilie rnortbc _ _ o:caIcd 10
""'" nil. h-inch bil/)Io.;ndI gW<k bu>hin8 com~.

.".,. .hc ' .... paa'e "'"'" rndy. I I3Id "'" .he cnottu.. on
,., Iq ~. Nal I CUI ..."0 ~ ",*,iooI~
li:d:I 00 6, in.o 'bo:: ctOIch <li clic kp, ll&h' opirut bolii
.... );ow I "'31 ln<Iy. I cm'tml Ihe .cmpLue .....,. ,he

Ctnle, Itm pl.'t (lVe, ~YOIII "nes fOf mortl1t,.nd

tI.mp it 10 , he legs. Then bult t,~ngul.r pOsition!ng
block agllnst Ihe Itgs and fasttn It 10 Ihe tImpii It.
b)ou nd dompcd 1. ,(1 'h<' "'" asoemhly I 110' 6 I""'i-"
.Ionlng bloci< IInnly ~1"'1n." . he k"p . hen d""e ~ . ._~
<I\tulIBh ,"" .cmpb.( in'o ,IIIs bIo!:k. I tllft1Cd the ,,,,,,pI.o'c
0VC1"" .nd '"Kh~ lbo:: liQtKl bIock, ""'Y cardully alignlng
II ... lIh . 1Ie II .... polIllonlng hIock l~n I .rlm""-",, ."" ti""
otr lhe hI<>cb In p",,'kk dnr.mee fOr 'h<' .ou ......
\\"ItI! .1.. plUl1fl" !"OUt(1" Iltto:<.t with Ihe . ppl"'tJ9ri>le bit
.00 II"kk , I.uned rollllng . IM: n","' se. Afkr <'lItll"l
''''''''.'nwcly half...,.,. Ihmugh .ht ....-.rn>bly. r uocbmpcd
ohe tanplate. 1Iohi1\t"d ~ li' thc OIhct 51dc of .hc __ mblr
IIlI"flO'd liIc lqj.......,bIy and ,e m pb.c 0\"1:', an" "-"<Olamp'-'d
the tc:mpto .~ AII1IIy. I romplctnl thc nll>Ml ...
ThIs ;tpproKh """,,', ..-orI! fOr e''''"}" al",""ely dcq> OI
""'""" J'OU m"", l"Od.. l bc: pf'Ojc(.'I: mllSl pt'<:SCl1" <"Ouplc
01 te"'u," """" dw..,..;u C'tUbIc)OlJ to swi.ch .t.. len~ :1
pb.e from onc fxc ' 0 lhe 0100 .00 maim " prop<"1"
aIignmcnt.ArId if II docs.lhis appn>ach ""'Y
)'Ou. ""r.

f:l_.

_.

!il""

A Mortise in the Panel's Face

Any ,imc J'OU '-". n:oomsc .. Ibe fiott 01. pand,)OU Ilo,,,
aiI.mion in ..iI;dI moni!:ing <cnpiau: an bt hmdItt."IlIe
diIlkuIIy, :Il [ _
.. Ibe 0IlbCl <lI1hIo chapkr. iti tIw )OIJ . ._~

""""". pand ia lbel)-pinliiIt; duit!:<K<i to hoId MIlcI

"""ti<itc. Out """'. ""'plate. Ibe pand CUI he
<l<ItI#<I II> .........uxncb onIl Ibe ' cmpWc cbmpnllO II. n.c
tnnpI;Ut controIo .t.. pooItlon :ond lc1!jIIh qI u.. ..-t'-'
My CPmplc ho= Is dtOI <JI "'--cn I ~ b
thc boaI< C-"try Pi,., (lIlklaIc ~ Im).ll", pic Itad
ils fxc raib monlonJ Into u.. ntC ltidQ ( :ond dn\t,..". .........
an~

"" p

....'-8.
,h 'Ollll h mOtll,_ t.llo 10" mo,
. . . ttmp!.lle wlth pOoi.ionin\l blotk. on bo.h face .
T\t IWO bIoc.b .110"," VOU 10 rele,ellCe Ihe nmt edgt~
lllhe ~t fu, PO$ItIon when movlng ..,. .em
. . fnIm """ f.ce oflM usembly 10 Ihe 0I1Ie . Here I
IIM IOUItd u detp AS I un In, o ne....... Hnch'lhltk
III ~ ,.... lempblt design .lIow. mt 10 move il
............ IhoI Issembly. kHp,ng its Ofi.en.a.oon essen
.,. ..-ocNngtd. Then I Uln Ilim Iht whoIt wo,h o"",,,
_ _ ""'" , '''' _ond .idi>!O complele Ihe monlse.

and roiIs b

morti:Ied In.o

ote"""'"

u..

t.ckl qI 'h<' mlo) 'I1ocft ....,.., no

>ti"""

rrom ,op ta boulIm ... in the lypicaI r.,., fnmc. 1,

....,uId Ilo"., Il" j)OO61bIc 10 ...., an ttW: ....- onIl fttodw>d.

rou. Lt.. mon,""" In .he """"", bul I _ pili ofJ from "'..

CHEST OF DRAWEItS JOINEltY DETAIL

.ppro:;ICh by ,hc po6Sibility WI J'd iNd>1:ncm/y _100.

~ muo'ti1o: 100 k>fI3. 10><c0d I """" ,.",."... .....

ci''''' ..........

wouloJ Cf1.>U/1: ,"",cur.lI" oIzI. . """ pbammI

The
I uocd hod .;,,00... in k lor ,"" IM 011\
~.
II
1hNplI,tr. Ikcausc Ihc

,cmpb'"

,1Ii<:t<nc>;o """""

prim<'

diortInn r;ui<k bushin!! :ond '

lI>e
"""'Y 10 ...... I _

''''''pIa'''

>ln;gh'

up lI>e lI>OftWnI

panUd ,o ono: C'dIP< ...,. cd:tat cd!I:c. 1bac I >l1IdoN .

lIrntt 10 lI>e ,cmpblc 10 k>cII~ i, In ",a.ion 10 "'. ~,
thc "",,",pImr.
To ...., thc I,...,pl:no:. I Ioid nul cad! mon ....
....,ncpl<. fi~ , I 5<:ril>ed ~ fro<n md 10'"
~ Ind! r""" thc pand'. [""" c<W.l1>cn I IIWtcd 1lIt.-

Olt"

~~~;~~;'r~::~; I

poInl
()( cad!
ono<tlx.lloid
thc:
ck:oc
b..uC'd.pnsI
'hc .fro<M
,cmplatc ~ ......"..hc Io)'ow. ttnt",.;ng il. by tf<'.1

0..1_' runM'

thc: Im>pIole ....:urdy, ~ ohc rotIlCr on Ihc Icmpbct .tit

,toc guidc); <:OIbr in 'hc 'pp""",""e ~ w~'".
tOO,n . pI..yd 'hc hoit, and . . . - thc ""'.

'"

Template-Mortising Frame Members

.OI

EO
:E

'MI. you un USt I lemplolt 10 _1 mortl'16 ,n lhe

" ' 1 of IUIe. (anei ,,"I.) lor fK~ hme. /Ind door
fiii ...... TvPICII/lV. 1 Clell ~ KlltWKI 10 Ilie templ<ltt par
;alltllo lI\e mon ..,ng IIoC Tht l~plaCt an llIen t>. ,ti
on the wor~plt'(t Wlth U~ de.1 IIQItt ~;"n.t Ilie work
poKt fa<t. Clamp. a"'-lppI~.
lhe lempi,ll! 10
tht ,,"ori<. Tllen VOI! fO<Il tht morlIH.
l/1.111g il Illon Itmpl,nt wlch il clNl WOI'ks wellin Ihl~
1"....1I0n. bulthrel,). 101 01 bu.yw-ork In (lamp'ng Ilie
work Ind then poI<UO'''''9 1h4r templilt on l' Ind
Clamptl'lll Iha . To /I'IO\Ie Ilie lempljol~ 10. new lpol, VOI!
.. , ....11.,. a1so
10 ~'toon Ille wor1t In rhe VlH. Su, "
VOU un vS4! Ihd,tf IfmpLolf lIock. lOI.,. ~,nch Of mort.
VOU an ~uc:t Ihf bu'l"'"or~ Ind ..~ Ilmt.
Wl\lIl VOU do 1, mah the Itmpl;or. I;o'gt enough 10
elamp 10 I wo",!>tneh. w,lh IM mon .. ,ng slOi 300 lhe
eltal clmiltvt.ed off Iht btnel!. TII!n VOU mt"IV haV1!
10 pUlh Ilie work 19l1lnlllht ciUI.nd Iht bonom Of
lhe -mpllle..oo lhen <llmp II 10 the <ltat. To 'OUl il
...eoo<lOl Ih'rd mllfl'''' In Iht ume plect , you llmplV
hilVf; 10 _
IlIt wo,k. not lke work QnrJ Ihe l,mplilCt.
Al; I 11111 !>t~. chl. (. tht Ion of rotIl!,mon .. ,njl wo.k
lhol an be dOl\e efficlentl.,. uSlng On' of 'ht ocher mo',
Ils,"O Jlgl,
BUl. "illlanl of lhll wOlk. il "",ilnl ,n which IMi:
ItmplalfmonlSlng ;approaeh p<ov~ Its ..onh. c;amt up
in bUlkhng Iht ,tp.odUC:llon chtsl of d'lw"s b'ltfly
dtsWbtd vndt' 'A MO'III! In cht Pilnelj; Filct- on Plge
1 5 3 TIlt d wt. fUnn ... Wef' mOr1ls~ InlO IM flce
.alls and tht CUt', back boI..d~. ThtH mOl'llltl ..,,,,~ inel! squart.

_v''''9

c..ve

1 54

IlOUltf

M~lc

NOw If IIwl med 10 .....1them u .. ng the 1I0I0"'' ' 11

JIO on ~e 114.1 eltlle. wOIJld have h.ad 10 ser~e ro.
~,nch-dla_ref ,o .. nd mort'ltl or I would llave ~ ~
fO<IC chem u .. ng IWO Iltffe~nl edge'oul,", !wngl. Tr>lt
.bolll bu.ywo,k!
lJul "nee I UI~ IMI""! w.ndow in ll\eJO,nery_
1'11-1. mi,", for Ihe)Ob Ind I Y..jnch bll. lhe mortiSt.
c... n~ OIJClqUllt w,lh .adu,sed (ome" . ArId by
SCftW'ng' cleal w.lh 1 pOs'lIonlng IIOp unde. Ilie r.....
plai!. I wu ablt 10 Illp lhOI! ralllin plllct. f'O\IliM
moMlle. Ind ef!\(jenlly (hlnge OVl:'f 10 the ne~1 r.ul,

n" t"mplat" Un hold ,h. wOrlrp/ec:" for mor

IISing If It ls st ... rdy tllOlt\lh, Altaeh 1 cleat 'o Ilie
botlom of Ilie I.mpl.ole 10 peKlllon IM wor1r:pleu b
morti.lng. Clamp Ilie work to Ilie Clul. as sl\own.
IMn rotit tht mo<tlK.

jOINERY UMPLATE
Use ~

,emplilt guldt Ind

~.

stra lght bit.

".

----,,---""1

rlr"--F"='~---F"~'----~'F"~'----i'='~"---c~~'H'~--l1

,.:=1"""""'
......\:"... .......... . ............. ........... ... ..... ..........:. . . n

,on .......

6 ...... ...0 .. ....... 6

..........

0.

".

'----1'--

- - - - - - - '.J

SC:rt w iI"'" )( I y,. CIf'IIIO tlte undtBidt! oflM !t",plale.

~ Iii<- ...1Up

ro.. ,"" noa 111<>/1""' .....

oImpk'

fIociro!Ithc d a",p". 6Ildiflllll.., tcmpb\!: lu IIM: ncu

mor-

.. Iocolk>n. II", .. ...:Wnph'l( It. lire",,*, "'" doi _

!O "'" >lois. 1Il<' "",nlses "'..,.., .11 r.",.lld u> 1""

"'*'

"'s front cdgc.

A Difficuh-to-Poslion Mortise
Iloutinr; 1 moniK In a round po5t. 11110 Ilie: arris 01 a &qUln:c
biUn. ""o atI)' pon 011 >h:&pnl pktt. CUI hc voIng. U..,
ICmpbtr hoth Il> ouppon lhc .......... "'I""1'r
moniK
aI1d 10 control Ilie: widlh lfld k'tlgIh o( tbe mon~
WhaI }'OII m .... do In ,"""" lIIkuation>' b tu bulld v
bloci< or Olt..... cnok to
ttlr wor1rplca: and ttlrn
oon.trua <:<Jmplc""",wy ouppon br thc tcmplatc

to.""

"'*'

... ...niSH III lhe f ..... of il piine! ..1,11" Itm..... Iim. tlle temp ... 't is c~mped 10 ,"" sidt! of 1""
dIlSI of d,"wers. W!lh " d""1 d.lm~ 10 . "" bonom
''Il10 1.....,1.11.. , ifs
10 slide Ilie t.,mplatt . 1oftG

ei,.,.

m. 'ene..

lIt~e from mo" i~ 10 monl~.

~ !hot aii .. il! boo tlte U rne di.tanc ..

.. f.

' , om tlte

........,\ tdge. L1ning up thot .101. for tlwe Ih, ~ dtf

monJus ",,"k... i, n.~r 10 raul thom In tit ..
Inl pIoc.. mei usier illso 10 rOtII Itle mon ise

Mortls lng a turnlngls a t . mplat. Job. Here,

turneei leg Is cllmped betwttn twO m lps 01 plywood
In , vise. The mortis Ing templ". 10 allgned ove. ,he
monioe lout lon, then lltUMd to the plywood o" lps
with drywall screw s.

Templ:.lIeMo<tlSlftg

I55

Custom Router
Table Top
II must be " Olt. strong. a nd stU6l,
must both withstand OI .. d da",...
vlbr.lIIio n, a nd must hau a ~
tough , s lidr. surface. He re's hOll.
nuoke the idul 'ouler uble"",

-....
\II

... T:

{!
~

~"

lablctop IS ,tIc d1n<:c f\oot

(>l thc """ .......n"n'a1

perfum"" an do a <lao OrI

madc:, 'hcy

an::

n.., and thcy "'" tn.o<>IUb/f pncnI

"'hr 00

",,"".

nrlh woukI ,.,., I>uy ".... "'-.. po.

maI<c J"lU' '""" pc:JlIOfW. ~ UbInop lot
moncy! It II; not dlfflcult. Il J"lU ClIII ~ ""'"
l..,.ma. J"lU ClIII .... kc a bmlnal~ """CI"!>bIr
(Comc "" _ , an:: }'OU a W'(ltI(Iovort<n- ar a ("OIk(oor

""Of1<l~

runlctl 10<>1:11)

cilhcr au>:",,,. an" e'vy .,}"Ie In "",,,-''''" , foor own I"'f'

sorW <hncc wiU bc mOOl fulflUing on a pbtIorm of )'OUl"
"""" """'ItJon .Oh,)"OU """ rur., tajlC' .and In,.,.11 you cv.:<
...... )'Qu'U bc h:>PVf cnough

Whm J"lU makc)'OUt '""" t>bktop. J"lU 00n~""

!iClllc ilr lhe ~~tl"H>t~<>(-MOF w,c,. V.... _
it
U". 10 ft. hcnn- In .shop t!w..,
ro.. spaa . '00 ClIII makc II: bIjqIcr, "'"ni bIa mooop
xcomnlOtb.c ""'"' ./wI !lingk: """'n-. V"", OII . .
Ihld<cr or Ihin"CI". '00.
Wtw.n J"lU nw<~ your ""'" I:>bI,,"op. ,.,.. <WI . .
choIa ci ,dl!.lI1gs- pbsI k: l'mokIln~)'O. bul .....
bmlruuc . ... 0i0I1oJ.WU<>IJ ~If" In _~
c<J><l6C<.I ~)'k. ,"ou nil .rlm ,. wt.h <Wc ar ..~'" ac; f

wOrbhop. A [liftn!

".bIe

any :;oM of fIoor. Bul an , $l1'Oflg.

Jlbltonn.
wllh , ", ""OIh lm<l frictionlcss ,;urbec.)'OU can ..,.~tIy
$o wh ..'s your plns,",,? 00 )'OU "",rfonn .."OOdbollet? Or .rc )'Ou I"SI , Jownhomc: (kJsi!<:'t' I'ot

Rut

try " swf:ltt """,ooHallorNl 10 your XI. I( )"011

,,'211' il Iust rigii you h,,,..,!O bulld it )'0"..."'1. 1l>cn )'Ou'll

h:!,.., " Wllq ..... IlObIc1op. 0<1C tiut
bc p"rduscd, noi aL

"""'log.

(.';ln"

(rom any
1'11" indu.")' . n nd.rd for" roule. t.bl~ IOp >ttm. 10
hc " I Yo-Inch~hlck X U;nchwldc X 32III"h.11)I11\ "'p.
Sizcd 10 get oi,; rrom a ~ X H .hcct. Mcdlun"'Jcn.lly fU,c,
1:>0.>.... (MI>F) co", ",I.h p"'stlc l.mll1>le OII bolh ol<k .
011)' ,"OI"C. /lOt

Tougt> poIr~. h~l~n~ l'moldlnll wlllnll .he lOt>. " .... lIahk
" ',Ih OI" ","hoUI moun"nll p'>te "pcnlnll an"
ac ,.;,MU' a mi ., 10. 111",", ro",.,r I.ble 11'"' .rc ...dl

,..It"

'"

llul

110<"""''''' .....

"""'. bubinp.
"'hen )"OU m:okc f'l'U' """11 ul>klop. ,.,.. OII iim
coIot ot p,"""rn oItan,Uulc OII 1. J"lU ..-an. IIbck! \'ilO
IL. 1\'''1001''''' ,"O" JIOIlI. Gr>nllCP 1'b.oIf.1l\Jod1
~o"

..... "'1 "ou buy

h.)'OU.f1fIIr It.

The Custom Tabletop

1',)"",.,.,.1".

"'" cii' ...... lOr a (!iOOd.~"U>lOm 1'OtII........1* 'op. 1,

_ Ilo fbI. OI""'JI. :aneI .;tabI.,. 1, mUSI both ..itJuo:ond lI>d
-.,ea ~ion..l, III .........,"" a h.>.nI.lOU8h, 5tid; ~.
lk ....,.. in ..1Uch .."OOd .."Ori: ..... fuIfilI lhQc cii' ......
~ '"""-l "'..,.. "'" )nD. Ibd ).... bttn lOIlowo'in!I _
0lIlUaI pcrlodIc:;Ih ' O .... I S ynrs ~"". 1"OU .."UUld .....,..,

....... for

~ bcnrtIlO(I uni .... mudl ~kc

>hcct produr"I COIllf"*d I'f1'l"'I1Iy o( _.....". an<! gI ..... h ha>

"" Pol wu;:t..-.:.,;o II bcb
Mfm8lh. II ' m>de In
'"2rY!J" o( p;ratb Ibr > '"2rY!J" of putpO<!($. b<c Il ...
common 1OIIIIIln1~ 6gor ~ kiId1cn """'..
1'tJ... ......t; In my book. b "'" ldnI "",,*,,"10. Ila ..... It>
~ >'CtItttS ""'" lIf"In dirt-aion ;Ind Jlm>glh. ;Ind
bea...., dono:: ~ ........... in"'~ p/ywuo<l .... IV<"~1
Mfm8lh lhal 'hc othtt ~ .,,00. """.,. Thc "'" .>boncornintI oIp1ywood b tha' II !5n ', ....."ll)"S pnfectI). fbt .You <:an
compmW<: 6gor lhis, hoo>'t\T 1I you lIfu<: up 5UbsIr.<c fru'"
IWO picca 01 thc pIywoot.l. You wlU probahIy "" thi>.>lncc In
I~ you'! "".,,1 a lahletop .. !oM I Inch .hkk.

lhc

.......Yop Ilouttt"bbk: an ~ 203 TJ"(>icaIIy. lI"d ~ ~

.... ooidcd pIj ..."OOd box .... a >WMI ..ith .non Iegt. li
~ b.nT a '..mch p/y1o"OOd l2"""OP. Oflen. "'" mu, ....
...... ~ from "'" tablctop_yuu'd rout fNQ5 in
.. pIywaocl. ....,""" \. OI" 'II Inch 01 nw.ml (rom " 'hlch
!"Id ltanI ~ mu ...... Or )"(N'd eu, a hoIc in .hc p/)...."OOd.
tQIIICf rrom a pk(:~ 0I1unIb<><ttd ..... ith whlch
!"I _-.mI.hc et"g-., tal*.op (Thc ,~mpercd Iunlbo;tnl
"'*1 nWc!lx.surtKc $lkkcr ' ..... n pl.:tin plp'"OO(I.)
AI _
point. a fru,;:;.ol ..'<I()d"I\'I;>I1c"r modifM;d a
-.p.trduonl mc..p a, tii<: IocaIlumhcryanl.tk Clplurnl
.. lII<:kno ll1d duT.obiIi'y o( pWIic I.:tminalc tor his ""'Ia
"'IOP "ilhouI ......1nfc 'o do ""y Imltl:.llC .....orl<.
loIoore ~d)". .....,.,....,wt.;,.,r:s 1"".., bttn appl)ing pb>tIc
_
tu bolII >i<b o( a pIy .."OOd. panlclrboard. or MOP
cIluing o hok in i, ond 5U!ipCndin,; Ihc. lOUleJ
_, -..mInJI pb'~ o( ">Cf)tic. po/).CItbQfwc:. "" ~....,.. pht-

lin...,. "'"

"nit

""""'.lhcn

"' ....~

In ~ "" ~ ... blelop. 'hc sbop<n;Iodc CUSlOln

onc ntttb 'Q " " " ..ilh "'" RWntm.. I, m_
!It _
01 faltIy ro.nmon~ m;lImab. 01"lOI II"" an hc
poodInod '" omaU "",."" ...-..- AmI<ri<:;o ond , ...... an hc
0\IIttd In "'" I)pIcoIllonw; ,,"<>Oda~ ohop.
SUn ..illI "'" tlni.hcd ourfao..., .1l"c...., """..,.. ~~. from
. . wood lnd wnnd ..i,h ~ IIIm flnl'" ""...., "",,"COl :;n\l3)'
... ~ ,,hidl. thou!Ih l\2nI """ 5tid;. is ntlht"r
_ _ dtnbk. \\1lh "'" """,""'rdaI ncqxiooo......,....,
_
""3)' fiom
as wcll. I'\a.U lami~ KCm!i 10
..". liI<:Ic <:rlI<:r\II. II" h.>.ro :and duroble "lI1d ~ .. Is
lfJIoI* twf),.-t.rn.. It", roIIy t25Y ro 'III'OCI<.
TIIm JOII ,hlnl< abou! " 'hal mu..l lIn<krlk plastic
-"C 1bc ~ an ~ con,;tnICln! 01 ,tu-.:c diff~,
~ IlhInlt

",1.

'"'*

Keeping the Top Flat

ti"", llWly tllt>C1I 1Ilt"" )"U ""J'M'rlcncc<llhb al IM lumbtt,.-ud! ~Uu puii "'" 1"1> oIlCCI rAH" the S1Xk 01 pIy"t.OUtl ....
p;>nidd>cunl. n,,, apoo;cd
t.... pkkcd lip n>Qi;t.....,
from 'hc 0 l"'n .... ",hll<" ,,,," 0I1t .... f.ocr. ,,""Ing bttn ,In ...
:tIly !iC:t1c.J ' jpln,;t 'hc .hce' brnc_,h haJ ,;tO)"'" ~ dry.
1, Ihis shccl tb\1 Th<><W! .." 'hln.l< oIshcct lIOQdIl :LI bcing
fim. ,,c aU know from expcricntt 'h<y atn1~. Onc faa !FI>
damp. ,1Ie nt/Jc1" "'l}"I< drr Thc shcct aops.
HUl you """". I'lAT IIbIr<op. lI"", 'o lIt' il! Stan wllh
a tb, !ohcct, oI CO\U1C, 1)On'1 xapl that bo-.,d .ohcd. Thcn
)'OU lIt' 1"," "",.criaI Imo )'IJO" !hop and jIve ,. dayo ....
""""" <O .celi"".. " ' o "'" !hop', ",mpcn' UI"!: and humldky
~ ......tding II Whcn you lamln:u" """ tayrn.. aIwa)"S
oricn' an)' Qo1\.... ng in. ".,., bointI; al""" b)w ..il coun'era<:lUw 0("", .......... .... ~ you ..ilh ....., Pb/Inop.,.,..,. _ _
Thrn 2pp1y plutI<: laminal" \0 IIOTI' ,;.io:s 01 'hil! .,.,..,.
and ..... an)' opmcd edsa o( 1"," .,.".,. Ir JOII apply l:Ifni.
tI2l<: 10 OI"IC llIido: o( pIywotwJ .... ponldc:boonl .... "'IOn M[)f.
YOU ,.,.., !CI1lng il lip 6gor a......-p "I""M I2miIulnl ..... wW IU)'
dry. but Ihc unbmlnalcd ...... an pic. up moioI......,. 1bc
pmclll; OUl o( ~ Tbe tbnIpn 5kIc ..iU npand. 'bc ~

f...,,,

1'.

mcl'"

"""...
JIl)II

1IbmJo.rd) b tp><>d .,.,.., ""'I~

.. Dmot. 1l iJ rrIIIlk lip

o( '"<'r)' fine

panido. II ..

e"

...-~
ID
OI

'"Cf)"

.......... ..,.,. n.'.!IuI.;" ...,. op"'*"<:':. Illsn', a rtMIiIy

"""'*. biR:h pIt"W<)Od. 1I you 11:1,..,

aaft!' \Il h. 1I you IIk~

Hul bm ....IC bolb;l(lco 'o "",Intaln I~ fbt
MI! ob:c "'" ~ llodOf: >Pfllt~ nIjjr-ban<li4 To

..... '* II

_
" ' . tptOd \hin COOl o( ...hll~ .... ydl<Jw SI"" ......" tii<:
...... In II dryThrn)"" <:an !li"" O<lllle nIt!e-bond!ng..
1la,*,"""",n:I II!; ptObobly oby a > .,.,.., for YOU'
1IiIlIop WhIk I0Il'" ...,.....". .."OOd .."Ottc,,", " ,.:.,,,,,",,,,,, pan ~
ddooMI brthlt ....,.OIhcnccoolrn<l.1I:I1 II dblnRW"'" rrom
........ iomo oi> IOl.II<:'. My I"JCSS Is '11:11 a ~hcmo,h """eJ
-.1. d1r:lp panIdd>o<Ittl n.. k<" 1"""" partncr:shlp. For an
atianakJor tal* e'l'~PIX"tI " 'Ith a n,ttHil.OlRIIIIn; parti<kboord II pn>I>:>hIy ob)\ "',.. h... 'il) t.bnIl;tbk ";Ih bII
l*I; 1) 10 pIj...ood . .... )00 n.. y mvw. p;>n1c1cboanJ ...

Th .. uobl .. lop "0... Un blINd<! of

H"W,~I

dltfertn'

ml,elil.ls. \'ou un U~ MOf (Io,!. ~nlc~d (eVI/oU"

r"Pl. pIvwood (n"r~r bar/am). OI" IUIIK lirdt plywood
(&oI/om).

( "$1om Ro"'tI Tlble

T~

' S7

ANATOMY OF AROUTIEIl<_T:M:":T:O:':::::"",-------~'Squi'e the SubSt'ite

ind glut llardwood
edge'b;ondJ"II to It.

PliSlIe

~mlnite

Plutlc limlnitt 1. banat!!

to in tdgtb.ndtd cor ..
kvtH"m tlle lim.nilt.

Plywood ~rs ire

bondf:d w.th yellow gluI.

W X IW hl.rdwood

f'OO'' '

pmel will ClIp. In (omou . )'UUI'

"iU "'" in" subIk
Ite",,', wlta, 'O do 'o ~ n , thu,

Cultlng Ust
.. n
COft pll..

t:d9t

bilnds

Edgt bilnds
TOI) su,I;oee

8onom SUrfi"

Qty.

,
,

Dimensions

.sallC~ r.

Material

"'" x 21"'" X 36" Sirell plywood J

II" x 114" X J7W
H.rdwood
II" XI""

x 2Sa"

Itlrdwood

lf," X26"X38" PI.sUc: limlnitt

lf," X 26" X 38"

hck,r

.-...

1.1mJ""1' boch llK:o 10 ctnlc: a babnccd JW>C'I'hat ...

SI"t' 11;11.

. S<2J Ihc n.IfI!::J "" _1. If JOII Ippty Iwdwood ~

1wI<lin&>nl1t
~-UUPIe '"
nnWl
Pain! OI" oc"""',"," .....1 Ilie. ~ o( Iht moundns"f'btt

""'h,,

<ni" '"

Sl<ip tho: miler pup: oIot in II", ~"". 1,. UI'IIO

oary, and il brtacho Iht .......

My Ideal Ta.blelop
My ideal W>lctop Iw; " \ . 10 \ ~tHhk..k "Ip"ood """
"';'h pb>tic IamlfUlt on bocI> ><.b. Thc <li"""""""", 01" il.

..

oo:hcr rtwIlbe ~att: pn:tty much Itn:kvan'. I,

bt
!InDII mouN! (J.3y. 16 X 20 ~) 10 lIe. for "tnd,,"P
mu'er .. bie, or luAc ~ (Ay. jO X 48 Inchc!;) 10 ......
lbo :o.; a ... bIe .,,' ""tkcd (00" :as " mul.i"""CI" ,,'Ort:sutioolJ,.
for :any mnfOjtlllll.IIon, "'" IIUItIUbi uscd and "'" nlClhod d
constructlon n:maln Iht SUl"'.

""'"3'1> anii 1, hu rilIkli'y. A 1 'h-inclHhlct

~
~

:s

1 lik., Ihc "Iywood

o::

CUR:

bIooousc" it tw .. """"'"

,,""''0(1(\

,ablc1op dot!on' l n<I ~ f ..n"",,'<In.- 10 .. Ufcn 1"'1 ""On'1 ""Mr "",Ier lal*s tend 10 bc auxlliary WO<kbcn<:hd.!oO theoo:

c:oruider..,ions h.", .."nlllonc~

Thc ,ahk1op

ed!taI ""n "" Anb;htd

~crol ~ l\:III

.""I)"Inst ,!It bml......

an """,fUll)' "'lu. '" ,1", Nil<"> hef"",

lhen
laml ... ,,, 'o 'he ntp: ..... "'..:II ....

a",,1)'

Tht tibletop Itdgu Un !le finished severa! WIYS.

You Cln ci'etul .... sqUi"e tht rOI) befOfe il)l)lyl"ll tlle
~mhw.tt. thtn ~mhw.tt lho flIgu iS wtll '"' tllt IMe.
(,,,,,. Vou un "ppl,!, the !;oml""tt. then OIuI on ~ to

1lnchlhlck . . . .bind'ng cut Iram miple, oak, or

ottltr duriblt llard~ (ume". o. you cln f:dgt
bilnd tht plywood ind 'lin tht ~mIRlU' out to IlIt
edge 01 thh nsem~ COft (IIc>rrom).

t""

b<:u.. Thilil
known a5 '1Ie. " 1It1f~" In ""n", w:I.}1>, '''III .. ,1><: ~
<ahklop ' o ""11d. A' Ilie. oppooJ,c a,,,,,,,,,,, )"OU <"ati ....
exf'O'Cd edgc.h:II\iling. Sq ... rr IIM: ~ ..,.. """.,. ~
1" 1"" 10f' .nd ""nom.TIt"n gI.... on Y.. 10 "'nctHhidt ~
bandin" cu, rrom .....
oak, OI" othcr dut:i\bIe: ~
10 rom""',, , hl .... hk1op. )"OU m.... flul,h.,nm ,!It ~
banding ;ulIl
a nnW. 10 k. The ,"IRI optlo.. It _
tdllC"hlnd Iht con: ~ af'l'llint thc bmj_c. ,o proclua:

"It.

.",,1)'

... mk:on<:cak<J ~n<J;ng. 'Il"hm """

i. OU. ~ IIM: ~"II.
lbI><rim abo bruln.l.~ . abon /"OUl a I:lcvo:I ......-d abo c<lfID.
Il0l.01 roursoe. IppIy. IInbh 10 Ih<- rxJlOli'"d .........J
1bo l:a!I optiotI b my b>Vril~ Hc",'s how 10 80 >boul
WIIqa: """ l2bInop.lbt o..\lna lAt """"" wtd. "",,'d
. . . booId <hr <abIctop r..ar Ih" t~"di"llltou.~r TJI*
""" 212. ~ <hr dimcn>lom 10 >Ui. your CUMom
lIbIc10p ..11h

lJIPIr ltIc Wn''''''c. run

......... ..,. 011

mo=.\.

iNDn, .hc III"" and 11'" .hc ''''0 pic:CC$ mlly ~'tXk
l"II"thcr. Si""", ycl1uw 81"" >cI> ul' P"'''Y fa ... don . dilly.
eblly Align thc cdlt(S.
la4 )"OU apply .h<: ct.mps :UunH one cdjjc dU"1lII gI..,.,.
UP h<: 0Ih<: .. ",!II ,cnd.o opcn up E\..,n.w.Uy. '1u: cbn1p!1
... 111 cklllC .hc lI"p5.and .Iu: bowinI; wiU ~p..,"" .hc
,."....., .he cntl..: 5UtUcc .l"hc gluc bond "'UI tic .ha, mucb
l>c11<:r """".11
lct , he si"" Cun:
"';Ih th<- cbmpo in pbl""r

p""""'"

"'"CI"Tli#l'

Building the Tabletop

fII<t 'fi' tIM: ,,~cp dI=t""'" ro.. buiI<l!n3 ubkrop klr
.,dtha:: """... W>Ics In .his book OI" r..ar ""t' th:a. )"" C1"C2I'"
1oIow"!tIe 51(f' '0 ber, ... tohlcaop ' h:m )'OU an buy

'*"""

1. CUlllle b)en . CUI ",. ...

01 pI)...."'1d, p.anlda:boIrd. Of .\lI>F 'o ,.;re. I JtI:1'ICT.lDr """ bln:h p/).,.-ood
_ _ in &cea are >IIK>fIlhcr lIwI lIUndanI fir pIy'OOd.
iIrr ....... &ce 01 pic coukl mii up "" u." """'" ....,.
II. lxIth bea 01 C3dI pic 5IIookl h<- .. ""lOOIh and
tthr-bft., p<>!->ibk .
.uoo. .h<- pIc:I ro.. <:n>Wntml .nd r.,., 'fnaliry. l lk:
...-.1 bcr o( exh pic-~1'\I1~"" of Ib '1""llty_ bC"
'0 .h<: InsioJc ... h"n )'OU I!luc .hC1ll
~"'" Is ho"')"0\1 em.c a n.. . blLanctd tup. Irbolh

orkn.""

)I"<C"'" n.u .hm oncflt thc best I\IC<.$ OI"

2. Gluc up the 5ub!i1rale. Sp..,ad )..,Ilo ... I!luc ""

, bot)'OO...., .. lcctcd ... 1Ie ....11ng fxd Get on I 'hln
bot IIIoroa.agh co:>.inll. >v.,idin& dry
Whcn both ... , .
im .... "'adf. !.ar ...,., C2J"tfully "op 'hc <Mhcr. SIiek ,he
... poo an">U!Ml on 'hc bot'om plrtt fu... 1I11le 10

'pOb.

Is rour plywood .Ullhllr bowedl Don1 WOtry.

OrIen' ,he ~nel .... lth .ht erowned faet. In . A~ you
~pplV Ihe elamp. Ilong one edOe du.lno Olueup. 'M
olhus wlll ttnd 100Ptn up. Eventuall .... the cilmp. wlll
elose Ihe giP'. alld Ihe bowlng ... 111 spreael ,1Ie p.n
,ule ~c,o .. IIIt tntl .. sutflte . The glue bond ... ,11 bot
,h.. much blnel owrall. and Ihe bowing of Otte shut
... 111 tounte, atl Ihal of IM o,ht . Inving rou with a
labletop eo ...

fi.,

3. PrcP""" ).,.u NF"bandUI8 ilOC:k. I. . . .kl hc

a hard . .. n4tht-gr.dnct.l hanhrood Mkc mapk. :Wa. 00. or
I);n;h.. l' shouId bc ..idc: CfIOllSh .0 .. and bit proud o( 'hc
pIywood CfIfto <MI boo:h !Ii<kf.. ond >bou. }. in<:h .hiook. Milae
It about 1'" Inchni for.1Ie 1 ~h c""'.

'"

4. Apply thc cdgc.ban dlng. Item",,,, .he e!om"" III

rrom <hor cO"'.Trim 1. '0 moke 1, "'lu:a.., .nd 10 clC21I ond

.nac: .h<: cdgal.

Cu he ~din1! .0 n. mi.t:tIllj! j. a, u." rom"",.

CI"" It In plicc Ik ... re 10;> aUgn oda pIttc ofu." ~
!iO 1. SI.:mds proud of .hc CfIfto " " boo:h lop ond bot .,..,.
~ ' ..... ~d IIlu. OII Ih. Ilbl elop
,... 0'It' 1he surfate. Ihen sp .... ad

Ilrer I dtibble
II ound ... I,h a
.. uble .Ippln~ horn ,he serip bln. Tht INktsh,h
~I~. I goo<l jotI of thlnly e~ling lhe tnli .... Sut
Ioet. -'rid when ' hl job's dO"". 'he ""tip IJOH bKk In
.lCllp blll . A roIlet OI brush .p'ud. gl..e .. eli. bUl
-tunv 11 OUl when 'he job 1. done i nlly """ou.

S. Flush 1rim tht edlJ""bandl,.. Afan u." si"" ha.

drk<l ond )""'''' """"",-.,d Ihc dam",. """ """" tnm thc
~ n u>b ""irh thc ,op ond bot."", surbccs of thc
1IUbot"'C.M ,,'iIh "'"n)" UIoI: In WOQd",on:l"lI 1Ie", .." ""'.
croi ..... ,., da .bis.
If )"OU M~ ~gIt'''''righl tou.er :111(1 ~ nle:lns 10
0u"'1y damp <hor I1b1<1op Of! cdJlC' . )"OU Cln """ flu......

'o

Custom Rouler Table TOI)

1 59

,-':;~~~::-~"'~;~~:':~:';:':":'~'E:;~:

aamp 'hc t

TcmpLll...OII ~6
lem bit In Ihc ....,Ie<. anii .... thc
sh. nkmoun,ed bearinS
p",w sqlW'rly In,,, ,"" w.Sl c. l"hc~ '
, IlIc ca""". 10 ~""""'. !O nibblc al II
p;t.SOC5 al thc rout~r.
wilh thc ,cmpLt'c. "'" bi' ... 111 Slor

Jlap

Wllen .. slng a flllslltrlmml"ill bit 10 Irlm ~n

edge"blndlng. yO\O I\ffd a steady hand. It\ IIf,SlIf vou
Un ctamp Ilie lablelop on edge HI thil g'avlty l\elps
vou hold Ilie IOUle. on Ilie na'IOW edg Tak. v .....
.hallow CUIO. f ... dlng In Ihe co"",1 direction . Any Je.k
o' wobble of Ilie .oute. wllileleg",ph InlO Ilie rOUltd
su.flce In Ihe form of 1 90uge Ihal yOu'lI lIf, .....d
p,.., ..ed 10 ,.mOvt Or concul.

100.

Itc:pcJt 11016 pRlCCS5 al c:teh ~"O, ~~,., . . . .

tcmpLl'c.
, ..... ..w "",.., waSlc 10 ",,,,,,,c. al a>u..,.. (uru..
Il:".., 3 paucm bit ..ith 1 hlr>dJ.1ons cuttinll
this ,,~ cit. using "'" just_'ed cdF5
~
,.,.."

bIt ~

100',,,,, .,

belrifIS.
,hc lamln:atr :aRd

to,fuU '
,"" i"..,....,tsibk

)"OU "";11 Irtm "'" ~

eli""

'toi'"
"'~.~,.~=~'~""~""'~
. ~"~a~,.~....
~~"",~~_~

You <.":an

.nyway.lts
wi'" casbI<k

procc ... UM'

,""'" 10
It"s "",,cr.l.

6,..,

'

l:mIiru,e

Un'Iin;I,c

OUt

miI" an:

5afely~!

.-.
...
(1

...

.~
!!l

Contxt n'en, .. WMI h<>ntb II>c: Ltml ..... c 1<l

......tc. 1", . ""I'hb'''''''ed robt><1'
,oo."~,,
I~ m:III"i pIer anr.l Icot"c 1" ,irI' Whcn )'OU
dric<! canmt Ofl IIM: I:Imi".,e tO Ihc
$Ub!tf:l'c. tlKy
m<1'il: be :Kt."UrAlcly olljtnt'11
li tiin ""
toudt IIM: ... h!tif:llc

"""',,."

Wilh <1 n ... hCrlmm lng "lIIeplate , edoeb.ind

ttlmmlnols Ins dlcey bUl laku mOfe tlme. The
lablelOP nOI only can. bUl musI . UI nIl on Ihe
wo.kbench. as shown , Wilh mort,SI,,!! o' bonOM"
clunlnO b,l In thl IOUltr Ind Ih. bluptale nal on
Ihe subSl.lle, wo.k bltk Ind fOflh IlonOlhe
blndlno, nlbbllng II flush .
Irtmmlr\jj bit Iu do It"" job quld<ly, '"" 1Iho..... In "'" ~o .,
tap 1",1 ........ ca" dan'l' ,I>c: t:lbklop nil.anii hokI "'" rotJtn-

horiroolt.lty ti) 00 Ihls. bUl I thlnk II>c: 6keHhood el

.."IJbbk: I"",'U MOUljlC I lie Wsc Inc~ dnma'ic:rJIy.
TI"" OI"'" obvIotIs opti .... .. 10 UM Ihe flusb-uimming
"""'plale anii. rnonlsl"i or boIlomd""nlng bil. WlIII ,III.
",""up,)"OU C2n. '"" obown In ,"" photo at bOtlom Icft, OO tII<:
job ..ith ,"" tabI<1op """ln8 fLI, an ,I>c: won:bench. TlIc
~ elll>c: I'QUICf )'OU I\:l..., II Lcss el. facto 100. Pl.n, tor
tl>c: F1 ......Trimmlnl 1b>cp11\c: an: 1Iho""I> Qn p>1<= 1 III.

6. (opt iona l) Round lhe tablelop Com"'l"!! .

Rounllinllll>c: comc.s eI)'OUI" fOUla" t:J.bIc: tap .....
)'IJu
_
p2lnIuIl!rui\:4 Vou doI'\ 'l rtftd 10 !li) thls. litrI 1f)'UU
~ 10. IhlIlll ,I>c: U- 10 00 It.

$"'''

160

louttr """gle

he""'"

''''' 'WO

Sprnd thc~, Ofl

IWC m:ako I lI"""l trowcf.Ukc

pift.,.;:::,:;:::

~.

but

Backer
YOl.l (In "'VI! IOITII ~ " you ce""nl
.... Ckf ... 10 Iht bt>!tOM,w;It of 1.... I
is umi .... te w,thout tht colO< I
dtslgned
1
1,
counlt.s
knr/q.. pe:. bl"OlOn Ind
rt<,IULt. lam,nillt. blrcke. nonf,htltSS .... $ 1"" ~
molslu.e.eSlslilnt q\lilllllu, ........... thf U _
Ind 1. bande!! .... IIh 1.... ",me cont""t temenI.
An .dvlnlig.e baeke. l\i.s oye'
I
.. n1 l i sllppe:ry. C",mps Ciln IItl
(In II. Thuli.1 dilmpeddo",n leMe Is 1iOIl>eWI!.lt
mo.e IIkelv 10 slly PUt II Ihe lable,OJI's '"',,""
buk" 'Jlh" Ihiln lamlnillt.

"'il'"

s,nM conlacl ceme ," OII uch of Ilie pleees 10 be

"..,t." s.c:np of ~"'lInlile miku II good trowel-like
tpI'Udt< ro. ~nlbasPd ce ....."I. bUl vou un use.
lIIIdt bru,h or ooIle. for wile.b.ued cement.
~ COlII the sU"iees /Ind walt fo, Ihe Umenl
IId1y. Do thls In /1 weH.... ntJl.oted /I'U.

Io"d lh. I/lml"a l. tiv po.illi"V tlle SIWc:e,s OM tiv one

IInd preul"V the ~ml ...te fI,mlv onlO Ilie sulmrate.
It"s common to 1111" In the mlddlt, II ha ..... he~, and
wo,k oo;t towllrd Ilie .nd. Alw/lY' \NOri< lrom the
bondcd irU 00;1 SO voo; dan, "IP I pockel of /Ii,
betwe .. n tht I.. mlnllt! Ind the substrale. When ~I the
sp,ce.. lire remowd. selille bon<! tiv prenin!! the
lamlnal! n,mlv 10 Ilie subSl",,, with tlle ~ of YOU'
h,nd o' II Jroller.

Making a Tabletop with E"posed Edge'Banding

The pnxPdu~ lor ........ "V Ih stv't of tab~op Ire nO d,ff,r,nt tlliin tnost dtl .. Ued 'n Ih .. ellllplO .... Sltp-by'
l\tll. TMv .'mp,", IIrt po,formed 1" /1 d,"erenl SfQuenu.

1. LI",'''''lt Ilie IWO ~Y'f" 10 form the C~. 'nd prtPII"" lhe edgebamhng (Slep. 1 111'011011 3 on Pillf' 159).
2. AAtr .qu.,,"!1 tlle cort. IIP9Iv Ihe plISU<- WI'''''lIlt la"
J rrom 1110 limln.att flu.1I w,tll tlle tdllf" 01 IIIt co,,_
II, Na ... apply tlle td'it-bJmhnll_
1. rom It flusll ...,111 tlle 10p Ind bottom ,""IICU 011"" t&bItlOjI. then apply /1 !ult.1I 10 '1

'"
O

C
~
ID

.,

...-~
ID

1/1

.",m

laminate
flusll wlllt edlle
of S.. tlntlll'.

Nlllu,,1

b";';'k bru-.l' <lr Olbct applK2t""_ ~ COO'

fx~ :Ind " .. i' lOr ,""

,I",~,..

cnnm' 'o dry. ~ II")'OU ~

ooh"en'-boscd o:m"",. do .tus in ....d ....t"f\.!Wcd .......

AfIcr lhc: ~'t:rnem tu.. <Irkd. db<tiI:>uIt "'" ~
....'n lbc ...tNr.'e.The..---m. an Ix 00....,.. ... ....".,..."1'"
~ rrom l/le 5Cnp bin. 1'oM1on lbc bmin:I,., 001 lbc ......,."...

"'' ' 1Iy

""" a:mcr It .....". Ibc fUboor.ac. l'uI lbc opxtt> ...... bf onc.
_ bond lhc IamIn.ne I "",..u,. otan in It.. mid<k.,.... onc
sp.:cr and ~ lbc Ia.mi"",,, duwn onw "'" llIIINr:alc.
Thcn I wurIt (M 1(>W.anJ Il", ...,.. AfIcr lbc lamimIc 15 >tud:
10 Iho: lIlIhoIr.llo:. II-' .....". 1""
"itb J-roIIa. J>lCSSinI!:
''''"1' hard ' o ........" lIw. lhc Wnln:o'c b dllll'Ollgl1ly Il<ln<kd ta
lhc: suIIo<Dlc _Or """ l3p a IICr.lp of wood "ilh Iwnmcr ..
"'" """~ It ....-tt. _ mclho<.li<:>.lIy ~ ,!le lIlIffIIctc
fUI' Iho: """"''''' ....... r, """
<Il" p~ t(I oppty
Lim,fU'" OI" '-ilcr tu lbe "Iber >l<le.

.,,,rtocc

..,pca.

8 . Trlm . nd bevel .h"

1' lrimm'lIjI l!le

edgc of 'hc lamifU'e :uMl .".,

U..., a !le"d-.rimmlng bil In)'OUr ro.ller
1
~'" 10 .boul \to inch. " 'hich b abou' ,,,,1 ,Jt.c
of 'he Iamin .." . W"nh .he
OII II><: 1.> ... 1"",<
and tllc II;,". pllol rkIl"8 Ihc ~ndlnjl , """
,hc l.blc,op.Tum Ihc 101" cn..,r .ud lrim 'hc .,~ . ."
I.>mln,,,,, .
I~hklop

1"00'' '

9. Apply n"b; h 10 ...Ioe,.".poocd ~

>llIb~ thc I:IlXtop, Lhc ...... wood of dIC

,*",Ir

bandinjlm .....
,

nWI~1

lbc

~'4I,

whlk

10 lbc

mr.. ... .

ablllIy 10 t.lkc OII :tnd

Making a Tabletop with a Self-Edge

This ~,yle of ~I"" donn', ... qu"e vou 10 p,ep."e Ind .pply sohd"Wood edg<l!~nd'n\l. bUl 'M pnxus al
applyin\l ,rid '''mm'''II'he ~s"c Llml,,",e ii more In"o!ved. Yelthe Ih.liq",u fo. OOln\llhl. i'e I1Olhlfe<ttll
Iha" Iho.e delliled "'Ih,. clupt," Slep-bynep.
1. Lamllll,e.he IwO "yen lo!ofm Ihe core (S,ep. I ind 2 OrI poI\le 159).
Alter 5QUi,ln\lllli' core. IPPIy 11!e piI"", lam.nale 10
oppo ....
}. T"m .111. lamlnlle flUlh ~II voullll.

,..o

2.

....
.!!

J.

4 Apply IMlOtlC Ilm"',,!e 10 Ihe Iwo ,~ .... ""ng fd\lU

5. r"m thli lI-mlN,e nu.h III voullll. The end. of I/lese ""ps ",,(1 ..... e'llp Ilie end ~ of 1IIi' nm .wo m;"
ilppl,td Ind ",mmed.
li APIMV Ihe pla.tlc I"mlna,e 10 Ihe tOP 1l1li bonom .ud.let. Ollhe uble,op.
7. W,lh bevel'frlrnmlng bll. frlm IM edgeo of IM Llml,,"le. Sel Ihe Culle, 00 II bevel5 .1Ie edye. of III.
bollom su,-faces WHIIOUI Cutt'n\l inlO Ilie taces of Ihe "m,nile on III. Ilbl.loP edqe .

II

"'''WQ

"''''''

15"-2 5" be""t-"Immln\l bit

Flusll ,rlmmln\l bil

~"

LamiRile

~
Bo""I-Uim Ilie
counl.<lOP
limlna .

Ttlm self-.ed\le
flush wllh sunlCe
of SUbllr.lle .

.... minl.e

",
,
II>e botlom.

o, ba<ku.

~lou.IV

,pplled Ind , rimmed Ilush

.... mi""'e o, bide<

'---'

Universal Router
Mounting Plate
Wotk from scriiltch to make yourself a

_nlinll plate thilt'S fitted preclsely

101011' routoer a nd roulU lable.
.;,..~,..--------------------,

'"
O

'taeh Ilie roUl.". dirrctly 10 pin'" o( "lp... ~>Ii. 1lI;o,

uwd ro be thc l1"pical ~ppruach ,<> CI't"O'''\jI;'
!2I)k, ond , """ ,"", ...'Orb. NOI aJ wdl a. OIh~r.
. . o:onttmpurary approacl>es. /luI It wor1c.

"",,~.... o( C'OUlX' 1Ic-

fI.\U""

00n>m<>n

"'-ar 10 ffiOUI1'

..... in a W>k li; ";,h moun.UlJI; pWc, whlch .. lIuk

~ ~pI>'" A ",hbc:ccd <>pm11l8 b
CII ~ thr 'ablet"". lhc: opcnln~ " I>ilc ~ ,o
_ do< !OUl.". Il> <hop thtullj!ll. bul ,..., ploI" !oi (':Illgtu

.. "'"" ..,

"JIIPPOf't:d by ,"" r:obbn. "'" plate..oo. up nu>h wIIh

.. .-.op. n... Iftlgh. 01 ' M mul.". kcq ..., pb.c In
,....,... A propcr fii. mon> l~ ~ "" JidtpIay, IIO ."" pWc

__, sIlim...,. .......nIl In ,..., "'*

~ Ihc !'bl.. il >q>'M ,.bIe :Ind IlOl f,...rnro .x.-1I. t -and ,""
bo 0l0I1y mn<m:d froon the Wlletop.
'I'ha .. Im,,",,~ (n~ Ihc oId appt\Jlldl! ,"ou O"
'" do< ......... OUl .0 dwljlr l1li0 AnII bea ...... hor ~ b

_--nil

.. rrom

......,. _''''" luJf tIM: IIlIck _ 0(. pIrwood ullklop.

"'" an ,,-ri!lll gml'cr <kpd' 01 alt
)'OU ......",.
<lbriou<Iy, .be !'bl.. rrom whlch .m, muter h;m8> b
<riIbI rom""",,", 1. h .. ro be (1;11 ""
)'OUr c lI15 a""
C\IIIIiIIm, 1. hu 10 ..., ..cn"", ~ 10 ",ppon .I\!:

rrom

,1\;1,

mul(r And bcaus<: wc'n: "" OrI """'" klnd oi budfIrt,

1, ean', 00"""00 <kar.
Vou can bur a mClUntng pl1.c , of COli"" . Comm<:rdaJ
moun!inM pl>!C!I . bound . Mos. hit ""II~ .. h e .h~m In thdr
c:u.k>gs. "" do fulllinc 1001 de:l1c ... n ..,,,,, pb!~ .., ".,.
bad, !t<'n~raJly.
Il.n mr .nj.udc i5: Whr hur moun<JnJj 1'1:"" il )'OU

."o}
C
ID

-...

rrulI" onc1 ~Iy il 1"'" arc 1 hobby wood .....,rka. tD

nul<i"JI 1 moun'lng pb,,, an introduce)UU !t> .eehn lqUCA VI
an<! J'f'OI"'d~
wiU cnIun<:c ) ...... "'11 ,,"OO(/WQtI:1njJ.
Ano:! 1. con W>" )'OU .... mc<hlng you probably <Ion ', lO"t
cnough ~ pracUct .1-10,"",,"'. ,..0"'1ng from .;.c",'ch ,,'111
Si'" )'OU moun.1ng pIoIc lhot .. litlw J'fn'bcly 10 )'UlII'
routa; """ bit opcnlng ..'i11 toc cenl=<l OII thc bit axl . Ind
th;ot' . """",tiai. 1...;O sJ'" 1"'" I mounlln& pIa,e ,hal p""
m.:1y fii> ttoc ub6etop.
ln ,he ~ __ ~ 1'0 .n.- )'OU. ""P by ""P
""'" to nun I moonw.,; pIa,e y"" CiI1 rrulI.. M..... ar as
>II12ll ... )'OU like, rrom
("I'J'ft'I'ria,..) """criaI "'"
~ , :aotach wtw ....... tOlIIC1' )'OU ha\"C. an<! nWtc ltoc hit
opmins >Ii hit!: CI 0inUII ,." you _
1"1 aba expllill how
10 ...., thc """"'~ pIa.e 10 eu, ,he labktop opmln& for it.
CiI1

,ho.

"'ho,,,,,,,,,

'"

UNIV[RSAl IoIIOUHTlNG JOLATE LAYOUT

___ 11,.,-_____-,

[_____

~-4----:--,-...,

Mou~llng scre ...

hole, <ountt.,unk

IJlo"dla.

'"

,rlIo',\hkk wylk,
poIya.,~tt.

O<

plltnolic plalUC

Sti"lngpln hole

Making the Mounting Plate

Tbt .pproach ..."., ..'i11 Ix tu mat., plywoGd (W mcdiumlktUity fIbrrboard ( 1oI0f) lm>pbIe or J>3lIn'n, lhen .... ""',
." maI<c ,"" pbsric ~ ""'le.. 1l>cn: "'" oe>'CT.lI In""" lOt .1>1>.

Qty.

Plrt
Templ"l'

W X 8' )( 11\4'

JoIDf

Mounllng pI"le

]oj;' )( 8' )( 1 1!oIo'

Plullt'

]oj;'

- ""..."00<1 anii MOF .~ eukr 10 ......., llwI plastic."""'"

WU!I ' mdl, fufo::nmpk, lfyousand;m cdIIc IOO~

VI
OI

-...
~

...

!!

"
O

'"

Dlmenslons

dll. )( Ii"

0010.1

oi""lf
. Il0l11 ,,'OOd (l'IOduru

1IO'Jl. )'OU

."",'1

OO!I

les. liw1 plwlc, .. 1l)'OU

510 10 $15 ~.., of

,,"riti", otr.

""'lerl.l .
_ Il0l11 prodUCI5 pR>'idc
You """ joi dirttllQnS

lP>d .... rface<

fOr noIc

tald"".

ro. LtSiIlj;'hc tempLu.. l'ight on II

wan,."

'n II", fUI""', "'hen)"OI.I

nul:c. dupeo ulyour
nlOuntillJt plate. )\lU wm Ix ",",'n<led of ... h:1t bit> and

- Mr}.1k abo .. nsy 10"-ortr ...lth ......oo~

:lrId '" n:adily ~""'bl>lc: M pb,;ri<;oo R0n::5 and t
....Ii-<lonkr ~ IUppIkn. IL ........
aIM a> poIyarboll~tc . but II 1. more npI.
.iJKh -ihio:k pH:tt ... m ouppon a SCreo.millll I

....- M~-::i:.::"~'~O'~-.:-:':;:'~-:::::;:;;:

_ Phenollc
;1It dif6cull

1(Ui<k b,,'l\lngs 10 USC.

fim )'OI' nccd 1>01 make le",pl:l'.. If)'OU don 'j ...~nl
''', TO nukc ~ rnountiOl,ll pl:u ... follow ,"" """""""", ,
bul work with thc m"umln~ plate bbnk imlo:-ad of. tem

pIIcn .....,. pftft. II .. 'W)" MtOft8. '""'Y

~"ndHhld: plece 0/ Ilie ....1 paOo ",iU ouppon
18-pouo<k-t. 1-11""11 t:bok~

pl.lIe btlnk.
.\Ion:

1.. Sclea thc n><>Unl1ni p"'l" ",,,wrl,lI. The nu'<:n.b .......uy lI:ICd 1",""", Ib).. an: pl:t>tk:: ,cl'}'l lc. poty.
C2r'I)QQ:otc, :u>d phcnolic. In th= nut6hcllJ:

PoI)"Cafbo ..a lc .. """Y 10 work wllll woodworkl"l1

tooI!; :lOd ;s n:<>dlly .... iblJk .1 pbsllCII
.1IlI
lhruugh nwkJnkr ~ 'upplk'rl, Vln ... uy
unbrnbblo , k ... wl IkxIIJk_if
r.,hn" Uun

!oi""'"

fii'''''

Ioh:IUns-:md nay 5;l811111kr Ilie weighl of 1 NMmoIh

tt>utCr;

TbtnJ dK>Ia.

InlOmutlon .bouI Ilie ""'InWo :lrId >boia

""-1""" lOr ....-or1<lnfIthcrn Is In thc oppcndi1.

2. SelI.k:

Of>

dimenaioN lor Ihc

.h<>ukl L'~ . .." '~' J.'

,~.., ~, 00 , . .~ -'00";
10 "" .No:: 10 <Irop ti", .......". tbrough thc '-op
..l lhoLI!
. '""'''''''~ , ......."'" 10
.. loc Il", NU'"," '" 1
01 CUI
thc Iwl<llc:o bonom opIn>I thc
1UI11crS Umil. IIUl )"011 "':tnl Ilie 1!1~lt M snu.U t i
updmum illm<."R>k>n> Ihuli n~ ';ll"J. (rom IOIJICT ro lI'lIIIU.

JmlNG PLATE ANO TABLE OPENINC TO ROUTER

A. PORTrR-CASLf: "690 I VIHP FIXED8ASE ROUTER

Ut(lt. 'becl ""ndlts

wiN1I._nll he
rwter f.om droplling
Inlo pliu.

Plemy of duranet
btlWeen Ihe lable Ind
tlle hancUet. Rouler wlll
ell1l'v elear Ilie lableloll
D~n l ng.

Milh tilSV (IUfilroce

for tM handlu by
orient",!! t~m OII il
d~1 ilCrosS
I~ mounling IIlalt.

D. HITACHI,M Ilv

3~' HP

PLUNCE ROUTtR

HandltllOlKh
lilblelOP just
btfOM! rauler's
mulmum plun;dtplh 1. M!ached.

An USV .oIutlon?
Removt Ilie
hlndlu. A Iingle
screw secu"s
tacit one .
Rtmoval of IIte
'Outt. 1. now
tilsy. loo.

EV!n al mulmum IIlunge delllh,

lhere', plenly of d u raMe
tM-lween table ind hind lu.
IIlI lIau.e of hanelle design.
tht fOUler w,lI nOI ei.11y dur Ilie c.penU"l9.

;J>

".

C
..... pr.w:licol ""'IIa-, thougl1 , it ouy ~ ~.. 10 pkk up
.... rrom 11105<: maU-ol"tkr c:l.laJop.. 1 dI~cd jC>'Ct"1I:
~ ~IC< "",,,n:d nnfII'd from. sm:ill of . \, )( 10 '1
.ma ... 10 \arse of 9 )( 12 lndlO. lin. In minii 1IW
_ 0I2I0p offer ' U;I.bIe pbstlCllln ..om/"," 1QoI-sqU3ft
JIf<U. mc;ltl;nH !luI IhC}''''''' l i VI InchH
ar II ~,
a1a IIQUII"".
$o - . . . , thr 1U01Ier )""" \'" .,.......wIo:cd b u.., n;llIIer
......,... u.., ~ rrom Iundk 10 handk1 Whal's 1110:
. . . , . (rom thc bouom of u.., lWKllc 10 Ihc: 00.1"," r.:J 1110:
~. plun!!" n .... er.1x ~ 10 bOllom
... "'"~ ~.) 1I)'l1J II" ..1,h tI)( 11 '1 iJIcho"
Ia,w lfUkc k ......"v,nr LObklop oprnlnll (",,~1ud1f11!. ,1Ie
Itm) 1I'0I*l ~ obouI 7~ )( II 111<.:110. TII;' b Ilie &1" I
~"' bdna an "f'I'I'OPI"iJ1~ romproml'iC bct"'ttn Ilte !IIlC
~""IOUInII)"J'IOIIy uscd In n:>uler tobIo ond Ilte tIl",II",,1
lIIHpr< piooitic pWef lnOIII ronlntonly .'-:tlbbk.

...

...-.~

"1"''''

1/1

....or,.... '"'"

j. Cui Ihc pble l empblC.

~"'ke

,he

l ~mp b ' ~

OUl

tr. putk\dloltd. MDIl OI' p""WO<.Kl . U.., ""'1cr1.llh~t'.

. U thIct.

'ro...

5mootll mIII marlls

tII" I" mlllill" eclgH. Attv
nicb o. wa.hbo;lfd!ike fiOgeS wlllitleilraph OnlO Ihe
plulic mou~ti"Q pl~tt's edgt~. 51roce 11's tilslt< 10 file
or Sind Ihtm from MOF IItiln from Kt"/'Ilc O< phtnolk,
do thls co.mtllc wo<k on Iht lempllll .

MANEUVER ING ROUTER THROUC;;H OPENING

Whllun ....Iong

openl,,!! wlll
KCommod,Ut
mo!.l blg .0Ult.S. It
will NOT offt. usy
p.lSS.~ 10' ~I.
Ryobl' s RE-600.
I 2'A"

lor "'Implt. NS
lIulldind hilndlH
tll.t WOII'I P.iOSS,
dilQOn.llI.

even on I

an Ilie

, ~bk

..... CUC tlle m,.. elial tu Ihc dlmcmm

)'0\1\" iIC, \k(I onlOr the ,no,mlhlj( pl ne

RounrJ the ':0'''''''' ,"",,,,,. I pr>Cunl ""...... lOr thiI:
'1', elllii<:r ,.. ""'1 Ilie lohkt.'P "penrng i( 'hc apen...:.
emne", ."" radi"","",. SqIW'lnSl 'ht: rome", ha. \1) " " . . , .
wllh a ehi... , n........t 01 roundlna .he l~ m pLole romtn
ean bc dof>c (N'I >Colloo:uy S>n<lc bUl Iilke W u'"" I ..,.
pl.le 10 Rulr,le I ...... e "" p'" uem bil (Se<: "1Iorq
Temp lo,"," OII p.1JIC 6 for """" Inrorm . u"" OII rof'1It:I<ou n<llnJ ,enlp1"",,)

4. D rl lllhC moumin8'~ hok:5. You w.... III

bc . 1I1e \1) U$ Ibc Icmpl;uc ' o lIUi<Ic the: dlilllllJl. 01 tt..
mounU~rcw
and 'he: """ing 01 ,"" bi. optttq.
Usc Ihe ",u,cr', belory boucpbtc '" ""Ilem ~,.. tt..

""Ia

moun.ing;ocrcw hoIcs.
R""""" Ilie ~pl"c from Iht: f<I<IIe. lJiIC 1 ., I ~
g;r.Ujt(' tO scleet 'hc prof>Cf'6ir.cd bit 10 drilll"" nlOunlin8SCf'<"N 11<.>1",. Wi .1I tbc drilI idttIcd, ~k:k Ibc: bascplolc 10
Ihc ICnlpbte . Althoul#l tbc bII opmI"II
I>c lbooIu .. .,.
concentric wl'h 'he bi' uis It 1"" ....... , ,o ...., 'e"'p"lr
1I"kl<;< .JU.."..r" IIy. I. dQc)n , Il... e 10 hc cind cen.e. <)II "'"
pIole l'hcrcrorc. fU" can c)'d>aU Ihc rout.,.IoaUon ou thr
pIl'c: Apply ""1"pCI '-"PC w thc bo:Iorylr>$pb'c:. pOiIItiolt ~
.... Ihc 'empLole,
It 0tmIy tu.hc <cmpbtc.
ru~ Ihc !cmpl.! ~ .nd driU bil 10 Ihc driU 1'f'C'lO. anii
b<w .hc moun.l"lI"""'rcw lIoIci rue OUr <imc; fICI Iho
hoIes ""ffcclly JIO"llloo>e<l 1'<)' oM ba,,;q>Io' e otr 'hc ....
plate 1'hen. sr"'lI!I<";r.S it ""'Y """",. counl~ Ihc ""*" il
oM ''''''Pb'e.

m"'"

."<1 1""'"'

WhIIIO do1

Un Ihe fOUltt try Iht

mounlOng pilIt. Ind
man,uyt. on, p' unll'l
fOd Into a tO"'ff.

Tip

l~t <Oult.
so lllt opposllt
hlndlt tiu ..
t~ tablttop.

5.

LocaIC a n d bon: t!le b i t opc:n lnjl.. Now """""

' hc rourtt ....,If "" thc ." mplo' e. TIri. io " -hy "'" cvurrtcfsunk tbc !Crn>' holo. t''''' nn.J 10 II<" the SCf'<"NlI ....

ctIOII8h 10 puii tM t(mplale Imn

pooi'' ' ' 00)'0\1 an ......

..Idy m:uII the bit opc:"ln~ . C:cn'ef.

a",d; I v1!:"""1ng bll In oM roulcr'. roII<t. IJon1 ...

'" thc n><MC'f. hul "'I~c:r '"m Ihe hil hy hand. 111"1 bourl!'
....."'1"11 oM ,cmplotc .
RcmtJ,,, Ihc .....1.,. In,," tlle lem plole.and hnd bact III
.1", driU j'If<:H. Il..: a c""Ielin ~ pin ar malJ.di:amc1c:r bot ia
lhc driU prcIO dludr: 10 111;11' tlle wo",plt ro. 1Ioring ....
hit 0"""1",,. 'Inrcn ' 1Ie: cenl.,. pin pOim iJ righl Ofl IM a .
.ermln:. clamp Ilie won:pltte . TIten .wi,dt ' o ~
I hlncl>diltmctn
btt OI' hole saw and boI'C thc: biI
opc-n11'l3 1n thc t""'plate.
1kpcn!IinfI .... Ihc bit an<! ,cmpb.c guidc rombiru~
" ' " WIC. tiu. ~ Imlpble apenlng ""n bc lumed 1n\O I
mounllngplatc tii! apcn!ng rmging rrom .... Inch diamcIa
up 10 futt I I'> Ind!cs.

TMn movt Ilie routeo

biltk .1000g tllt d,altO/lal,
so Ihe hlndlt Is
.bovt the lablttop .

Font"".

6. Locale a n d drill IM ~l2rt1"s pln h" le. n..

... nln8 pin iJ callcd _ _ NI"II pin benu,", It hcl~ 1. Ihr
beglnnlnll 011 CUI lr ruknun ro. the "'''"'Illcec " .......
)'0\1 ,,'" rou' 1ng _b piloted bit bu' no Icnee You bta
tlle
nr~ "pin" tlte pin . tlten "leve. II Imo ,1", bll
Comrnonty. ' Slarll. . pin il" ~n ""~ .... mc:tll Of
pl~.1e pin p,,*,,"1ntt: rrocn the ll'OOUIl,intI pLole 2 .0 ~ Indl"

w,,"'

Rigllt tlle ""'ttl. "h.ng tM

second lIandlt tiu .

... tbc bit. Thc posltion I n:Inlmcnd '" shown in Ihc

pili< Irfout dn",ing . ~I.r1< Ihc loc,,,,ion on lhc ",mpl>lc, Ind
*il tht

'Mnc1Hli>mcla bol~.

7. Mnc thc mountlng pla lc. (Joc a ""uplc o( >lnp>

0/ """'"' taP<' IQ bolid lh~ u:mplalc 10 lbc p/llMlc rOI'-'"
odmtd """ Ih. mowlIhlj.l pl.:/le (( Ih~ p1:L>lk 1. prow.:tctJ
b!"....tin3 p.opct. k:lvc . he p.opc:< in placc.
/oJ. tbc dliU p..."... <lriU Ihe noountlns .....
hoIes. Ik
arduIlO <:mI ... III<" <lriU bil In II>c Icrnp1.11C5 ~ukk hoIco
")'\lI f:tt II>c bob in Ilie pl>le pcrfcctly pO<Silioncd an<l
_ tI))"OU <Ion', cn><k Ihe gui<k hul<: .
DriII tlIc >lm!ngl'ln hole.
XI lip ~ur roula 10 ",ul thc hit opcning. lIe,,", .rc'
"~lnS "'-""bilUlit.>ns u.> cho<>o;c r",m;

"'w

. Iilr +.-iDeh opc:nillll. """ ~ind, >lr. illln bil in 1

ilctKlbmc'cr lIul<k hushing .

l~nch Qfk'nlng. usc ~ch str:Iighl hll In
~i>mc1C1" guidc bushilljl.
.fo.>r. 1\4-lnch QJlCnilljl , """ ""ncll "' ....;w., hi, in
\~...,."cr gui<k hushlng.
for. 1~ ..... h Qfk'''inlt. usc a p.on~m mi .

fo.>r.

U)'OU W>nt .0 mac. hi, upenlng ,,,", will use ,cm

pilt<gu;dc:o conrlJ!ure<l un .he I\>nel'Cohlc >I.ndar<!. 00'"
'I ......... h hale clcar through Ihe moumini\ plate. Thrn
.ndI tO * lMh M... igh' hi, in Ihc ~nch Hulde

IotIImB, ... d ... blkL 'Ile huk . .\le",ure It..:, naf1!lC on

.... bu>ltlng nd mul Ihe ... blkl IhOi dcplh. 11"5 um. Ur
DIat Ij, Inci!. but cl>i(.

Router-Mounting Screws
Make Suie you h~ve reuonibly becfy serews
1I01d.ng the route, ta Ihe mount.ng pl"e . Many
olde, fOule,S had only IlI,u 832 !new, hold"'g the
baseplate CHI. Tha! was fine for Ihe use Inlended.
but when \'Ou hang the 'out.r rrom Ihe plale, you're
bono. off et\l>", dnlhng oul and tapp,nglhO'" holu
10" blgge, StZC o, drtlllrtQ and tapping .n1lfely n.w
holes The PonetCable bchemOlh used In the
Rodale DUlgn ShOpl route. tabl. nas fou. "';nch
.crew! hold tng 11 10 th. plate.
By aII mnns. use Oalhead screws "nd COunlo,
sink tnem sa Ihat Ihey are Just barely reccssed.
(Rec."ing 100 mLKh noI only weaken. Ilie plate. ti
Cre"les li coll.etiOn poInl fo, chip. th"l wtllinvarl
ably tatel> youl work and 'Uln your CUI. I( nOI you,
fin!/f's.) Flathcads !I'v. th. but Ioad-sp.eadlnggrip
and are 1...1 hkely 10 crack llu! plalo and puII
Ihrough. Oon1 USt roundhead SefeWS; Ihey requ". a
nalbottomed eoun'erbo.. Iha\ ean se.IoLlsly com
p,omt'" the mentllh of tne plai . The eoonle,bo.o
eollecl a 101 of ehlps. 100.
Th. StluallQf1 mOSI IIkely 10 IeSI the s'rengll> of
Ih. plai. and mounllntl< '5 when you make" mis'
take In fud dtrecllon. A 3horsepowe, ,Out.,
sucklng a "-Incl> plece of Qilk In,o il Y,-;neh space
IMolwun Ihe culte, and th. fonee can ereate an
amazlnll arlWunl of prenu,e. If you, ,ouler Is
securely mounted. II>. rene. should IIM! enoullh 10
allo ..... the Slock to be plueked fram \'Ou' linge.s ~nd
Ihmwn a"'<lSS th. ,ilaI'. I( IIu! muie, moun" gl""
fi'st, you could end up wilh an ang,y 'OUl.' eomLng
out from unde, IIu! table afler YOLl_

. ..

-.'

\ "r. .:...
"

1:"'''''

... J\.~ "" .....

OiRennt eomblnations of tem plate "uldes iln d

bll~ enable you to Iransfo.m Ihe tcmplat'l
IIHn<h-di.lmcle. bit o~ning Imo Ont of a smalle,
ozo .. hen maklng I mounting plalc. Vau can cven 'OUl
i~ .d bll opening Ihat will accept templale
..S<I.iS s~own htre. Mtt' routing complcttly
!iWouIJ~ Ilie mOL/nUng plate wlth one blt/gulde bu~hlng
<'!btno.tion. \'Ou swhch bllS 10 ,oullhe .abbe!.
IIrllght

A duplicate of t he mountlng plate te mplale 15

p,odue.d In I ,ingle circuit w1tn li roul., and nush
trlmmlng bit Bond moun!lnll-plat. male,lalto Ihe
lempl~l. wlth ea'pet tape. Wltn the blt\ pl!ot 'idlng on
th@ t~mpla!t. zlp around th@ undwich. trlmming the
mounting plale ~ush wilh the l.mplaLe. as shown.
Universa l Roul. , Mounung Plate

167

~1nalI)', .... 11II a pancm bit OI" nU>IHrimmlnli bit In l"",r

..,....".. lrim
""""'Iinti plal( .0 !ii4. Pry "'" ItI"plIlt and
1"" mount __ plale 1pat\: thIt le " ......, Ihor m:o'll<ing ""pcr
COft>Q olf "'" moonllnll pI.1I" ",,,xii 1"" plale lu thc: """.,,.

1""

8 . Mat<.. lhc: tartlna pin. M. notnll'f"'iooilly. II>c

tommL>fIlIWIIbtadon oIthor ..;ut!na pin b ',,><>den
""" ou """:al .... pWtC pin. for Iru. plal". 1 usnI a I \<..incto.
Icnph ul '-o4nch Iwdwood 00"''''.
CUt 1"" pin 10 ...... h . 'Ll11h ueilky kni~ . J<:On: ,"" pin
dct'pIy '. Inc:h r...... <)ti<: moi. WIIit.k: 11'11: pin r...... thc: moi
10 11'11: "'~. mludllll 11'11: dIamn.". md lQrrnInw ohaM:.
I\:tiOdIolly ."'" ' M AI ul lM iIwU: In tbe ..... nIHM hok
In LI ... lmIpblt.

1. Tnce lhc: mounlinJ!; pble on tbe lempblt

stock. Mall" 1"" framcU kc lemplolc frum I-W>ch p!yto.'1lOd
.... I.-..lbo:oni, lor lhc IIIOUnllng pIa,e on 'bc .""'.,..
srod<. ~n<l ,""'( "ruun<l i, .,..;.h a .twp pendI. II' "'" pIar
tu. fOllJ.dnI comc-n;, lIS<'. <lr.dt ..... n's rin:k l"",pI.1It 10
locale
ccnt<:rflOn1 of cadl oomer'. radj",.

1""

Installing the Mounting Plate

2. 8um p up lhe .cmp lalC oulllrn:. You nced ..

n.. kc thc 'c",pille Opcnillll WJ!cr liwI Ihc pIo'c 10 X1XJUII
for ,"" hl.'iC of lhc ron' ..... )'''u 11"'"' ti) ~'U. \hc WlInop. OrA'
l!nes on Ihc tn1'ptlte >Iod! pa II,,1 ' 0 IIIooc: 1"""'" from "'"
lIIOWl'irlII pblc. ~ diSlancc .way rrom Ihc pLtlc uac:q
dw )"'-' po51On lhac n",,' ~nes is II>c <h/I'1:-n:""" bcnI._
thc: bIl', 1':I.di....... <I lhc b;o,;cpLt'c <liU>, ...

""""'nIn "'"

<JraW'1lII Roulf~ Tublelop Ope,,/~ u:llh /lase<.uldl"l

T""'pl.ufc If "'" C<>mCrs an: round~ "'" a comJUl'6 III
&Ctlbc thc:m. plWll1n1l on ,II<: corn .... ccn''-'''J>OIn ...

,."."..,'. "" q"""'lon .lpl,1'II: _ ling plai" m .... AI prop.

eri)' In thc LObIelop. 1L ha>. '" "" dn.J/l1Ub " ilh "'" LObk:lop
""d.ct >li ...0<1< doo;n 'l 11<'1 hong up li ,"" plale S hgh Of
Iow. IM~" ... . , . . ~'hat: ' 0 ",.eb and >lop ""'"
hd"tl kd """""" 1. IL ha!i 10 "" !iahl In Ihor 0JlCfIn8. It in
kxc, III<' pp bc'I ...."..., plalt Ind lablelop filI5 ..;th dust
Ind dJlpo, hln<k:ring 1.... smoodI 1IIO>'Onnl1 01 thc .........
pcriupoi 'hrowlng uff """"..... "'''''''''''''', ' ......., pbu: an
>bIr, pooltlon .... hen ,hc rt>Uln' '" i"ilchN ono ag;oin
Ihrov.illll off. prisc 5cIUp. If ' hc li. is .oo Ilght. )'OU 1n3t'
nOI e'''''' lIiCl ,.,., pwc In,o thc upctIng. ' f yuu 00, thc pIa'"
m'r bc dlslOncd.
So lhe mlI quodon is:11ow do I ochit:t" 1"- ~i'ld" 611
Thc ........ Uot: ,.,., rnounrIng pb1c u:m.pIatt (OI' "'"' "'"
I1l<KD1'I"J; p':lIe) ." malle .......... . "",pI:l1t. Thm ..... II~ .........
"'mpil,,, 10 rou' tht I>blclop opming. n......, ~ 1"":>
>Jl'f"I'J*''''"'' tI"" "';1I "vrk. In "'" tir$! " ' IJ"",""h, )'OII ru:aI<c.

rcmpb'c "",""", ..._

"'" """ ..... ~ ....... In "'" !U'OfId,

1-"" nw:c a ,,:mp""t ~I"" whidl ''''''f'bIc lIuloil' ridc!I

, lik" Ihc second app!O>Ch, but mII doo;n ', """"')'OU
"'il!. To me, h~ . dt.. n':lg<: S
)Vtl ..... . 11<' nlOUnting plale
i"dl' 10 gui<k thc ro",.". os l' cu .. 1"" l..... pillC 1lKn:' .n:
110 pcndlily""". no rl\lMrallng eom 10 100'" 10 1I0e. Yoo
just ltUidc II>c rou'C' . rou"'" .h( m""n' lng pill~: 1. cuI> ,""
perf"'" tempLt'" 11",1'11 prod""" Ihe ""'""'" iii.
Tht firsl 'PPro.1ch S not wllll01l1 adt.. m.gc5. of
cou~. It >110"'5 Ihc !Ou,,,, u-, ride tll""',1)' on ,I>c tabk,op
surf""" os Il cu .. lhe ol"'nlng.ThI fforWi Iht I>oc .uppon
and xcwxy of CulLlltJl deplh . lt can iJc duoc ",;'h any
roul~r and .. ",ighl bi . )'0<' <.Ion '. n,,(<1 an uoon"",nl uf
I(nlp!o'c guilkll and """,,,,,,1 dlffcn:nl >lrA!tth1 bl15. II Ic:o>
oIwi<>u> al"","""!!" b .h.1 ,ht IcmpLtle nccdo', Ix OMI)'
1inWInI. ~ bt1I<' radl .... of 'bc ro\I1C' 1...., can ride:
".""1)'
nlgc ",itl.oUl l",n."II"l1 "'''''Y Illlle .. w m.rI<
In'o lhc cu,

,1.

,"''''cd

Using

il

BilStI-Guiding Template

11ti>.ppruach an bc """" ",III! ~ny rouler. O"Nb;oscd o.

piu"""",. It "'" ""'" bc """" ,,'llh a laml ... ,c ,rim",c. In
bct, ,"" ,rirnmtt", tmallt. baoc:pillc ",Inimi""" Ihc .b.l' of

IC'rtIpIa'" nccdctllO ~ukk II>c cut.

16a

R.... I~' ""'9'"

l..Jtylng .... 1 I bltsl'l u ld lng tlmplatl alls for ..MII

IloNI dflfting looIs, lik, I comp;lSS, d"ftsman's clre'ttmplllts, Ind. rul<! . Aher lr.c lng """,nd IIM!
""",nllng plAle on the lempl", "ock, 'r'OU .... ve 10
d"w CUI I,net, offHt from the Ir.ce<! IInel . To "",ne!
Ihe lemplalt\ eOfne,S P<OPerly. 'fOII m"st
the
COmp;lSi on the CtftlerPOIIt 01 Ilie mouming plate'l
c",ne' lre' , U 'hown.

''''ing

3. Cut OUllbe Icmpbtt. U"", a Pbrr _Whlk,..

.,.,;.1

I CUI liw " .. I>ik:n, ~1Ik: rippld and !'OUJIIr

......... ro .'lhouldn't l ... nskr 10 III<: rout.". cut (!houh 'II<)'
woukllf}ou ....,.., n:*~ a '<=pIa,t . . - o,pIRu: ....
,,,",pI>tt .... bc. ""'" .11<' rout.... lw;q>latt).
wanl ' 0

4. TC!lt ti"" I""'pble. U"" a J>Itft ul ptywood "'"

51: of ,II<' ' "",plll" ~'Ion ttoc I""'plale on "'" 1051 pand
.00 ,,"'mp Il V... 11><' ro." ..... and a .I.onm str.tlgh! bit 10 CUI
WOO'"<: l.a) III<: """"'ling pLt'e ....."'" ,1><: 'CSl
il>.,...
sI<k nlllI" >houkI ju>< line lip ..11h 'he ouuI<k nI8' ul ....
llro"" ,, I( III<: 1.... COl' de""""''''I'''' ,1t;Q II><: ...... platc is WO
blH " .. ",,' ~m.JI,
,II<: " 'hok: JIf'O<'D'< ,,, mai:e and ....
new lcn'pLt'~

<U,

"'1''''''

lOUTlNG TABlETOP OPENING ... ilh hse-G .. idinv Tem,late

B. BU MP UP THE MOUNTlNC PlATE TRACINC.

A. DETERMI NE THE OfFSET.

8a1~pl at e r~diui

Round corne"
witl> compa .

- hil radiui _ off'~I

In Ihl. example.
r -:y,." _ 2' l'oo"

JIi. " hit rad.

Line !ra<~d from

mountlng plMt
Scrlbe IIn~,
parallello
traced line.

-,,<""__,

.'

l' bil~plat~ rad. -

> .

Templatt
stock

Offset

Centt,polnt.located from traced line

",Ing drah,,,,,,n's clrcle t~mplate
Off.et
C. USE fINI$HED TIMPLATI' TO ROUT lliE CROOVE IN THE 1:ABLETOP.

' ' fi

Tablelop

"tLJ
..

f'.---_fi

D. S!<W OUT THE WASTE.

t- Tablelop

1__"':::::;;~~....~ ~".,jli.

hole

S. CuI thc "'hk:lop openlng. Do th!li 0Il1y :ll't~ r th~

Ili sll.C1l ~It'. of
"""'" PosilOn Ilie Icmpblc 0Il .Ile t:lblct<>p. ebmp II
u:jC lhc ro",,,, 10 ~ Ilie I.bietop. Thb
pO(II'r "'Clluwly bct:om"" Ih~ r.lbbct Ih;1l suppons tlK
tii <IcrnonoIrlt .. th.l th~ Imlpbl~

.....mr.:u>d

......ungpbl~.

Cu! 0111 'hc "'Ulc 10 eomplctc Ihe opcning. li"" ... hcr
... wlguitk II """'!! II'" Inn~r ""!!<' of 1"" gt'OO'.... To "an
.. CUl.drill pilot h<:>1c for 1"" JOlber p w b~ . W"",,, yuu
.. donc.lhco PUt( lhoultJ JUSt fil .Afier 011 .
ldU:d It.

}')Il"'"

CiIIkI.I .... rouler againsllhe le mplille's inner ed\le

IIIg_11M' lablelop. The C"t Iln't 100 heavv for ;ll laml
lIIIt trlmmu. If VOU have one. Tlle " Imme'" small Ilze 1.
l~ ... filln

Ihl. ';tuatlan b&aule tlle lemplate doesn't

10 III' ,o bog. Her~. Ille g,oove " belng routed in a
~ ~w eXlOn,lon "'bltlop.
_

Universal Roule, MoumlnQ Plate

169

Using

ilo

(;uideBushing Template

I likt 111.1$ '"1'<'031:11. , ''' I said, bea....., IM",. bo opp<>nunlly M-em..-IO e=p In. lfyou "utc "".nul'r. JUlI ""'.....,
lIiCt pnfcc. rit.

'o

1. Jtout NI intunal tempble ""lde<! by the

n.u...,Li"K ploi... u.e. pictt 0/ ~ ~. MOP'<>r
~ lOr ,..., ttruplo'''. n.a.,'. IlO l:ryQut worI< 10
"",bm, but......., .,...-po....ion is~,
J;n;t bono.I thc: n..,..,.ing plate ... thc 1Ctnpllle .I<:x:k ... ,.h
carpn t:ap<', ~ thc: carpcI bpt' abo .0 bon<! thc l~mJlbt"
srodt- pank:ul;u1y .h,,!IeClion !>mo.1I .hc "",,""11lII pb.r.... ilittc ,,(
m:o.cNl, 1)0 this C>O:'n "'n.'Ijh )'OU
""""JI ,IIe '"",pb.,, .. ud< '0 .hc ~TIIC apc:ndabIc
"",.mal "roI~'C" 'hc IOI~ 'op, TIIC ClUJ>C'I topoo
bet"''CCIl II ..... thc tcmpble u.:p. thc: "'..... c. ,,'hidI jUIpOIU
thc: fIJUIn, ftum ohiftl1(l . . II is.,.. frtt 01 ilie """JIIa<~,
Qu,A. 1'1...,., "",' n "itll t..tnct..o.O tempbtc
Iluidc ond ~nch ... raight bit ,Sa lhc pIungc dqoth
lhc bit ",iII, ..'iim bouomnI apASl 'hc swp, juM bn;:aI<
.hrough.IX' "'mplo't.wcIL Inl".IIe """"''' """""III..
t:cq,ins.hc u:mpl>." ",kIc liglU "II"'IISt.t>c m""n,ln8
plate, """ :oround i' in IIM: dirtttion IndIc.led In 'hc
drI"'1nfI !loulf", t/}k1Of> 0/111"/''1( wllb G"f<fe.U"sl1/,'l
TnorpIal~. ,,",,,ke """"'".. ~, plLUlSlllll Utllc: Ik:cpc' 11.."""II d",ui', LUl,il 'he """"'~ 15 OI' frtt. Undamp lhc W<)rIL.
pIc. Pry lhe ,,1011<' fronl ,h" "-'bIe.

"""""""'*

p>n nwnhcr ~2021 (You an aIMt 1IK' ~ .......;., bol

in. i1nch-O.D tc:mpl:l'c jltJo<k T1ti> combu1:l'k>ft ,o/wiouII)',

ticld ............." 8""""" )

Sa 'hc plunllC deplh carcfully.Th~ dct>Ih o( ,"" WOO"<'
)"" ~'" Ibou. 10 ,oUl Iohoukl t:nCIly nu,m ti", ,hid<nQo li
Ilie moumllL,Ll " I;ne. YUll .1 .... m~>I occounl lOr .he ,~
of.IIe IcmpblC.l0 du Iltl., ..:1 Ilie rout<'I"lHl .IIe .cmplm.
~nd go.:ntly bou .... ' 'he bil ~'Ithc WO<'I<p,ccc. _
....
con",. oI lht n"",,,.ing pble (>It thc 'um:'\, and drop . .
dep.h rod <>ntU II. I,>ei< ."" rod. You .'" rnt/y W <OUl
Kcq>i"8 "'" ,empa,e ilulck tl/tht 192insI thc tctnpbI<.
mut around .hc inncr pc:rimc:tcr III .hc dltc:<"llon Indlr:lLui
in .hc ~ M.u OIC:VCnl pa>OC>, pNllIPnlI: ~nJc: dftp<f
lOt <:adi d"-'Uit,
'hc: muimun> dqoth is arnJc:y(d
Undarnp "'" Icmplolt, "'" d .... riie dtipo (rom ,1Ie lfR"M.
"iIl

""'il

""P'"

Use Ihe mounlillg pl.11 10 sel the phlnge SIOp.

Ant' bouom,ng IM bil .\I.llI>t the wo,k ($t.lld Iht
rau ... , OII .h tmpl ..... nd plunge II ~II .1Ie bil
louchu .h. l.bl Oj Ind I",kl"ll the "'unge, hold Iht
pl"t btIW II .h. raUl ..... IUfltl ,"d 1'" IHpth $'OP
rod, U $howII. Wilh tIw:- ,,1.1t agllll$' U.e ""....1. nIl
Ih, rod OII .h. """t Ind Iodt It. Now.1Ie mu'v wiI
t UI I
1$ dtt" 1 h, ptaltls Ih't k.

..{!...
OI

\1'_

.!

mlOlI .. lOguide-bushlne I_plale, use Ilie

~" TornounUng
pl.te It$eII as. Ifmp!ilf , Bond M 10 tIw:- I.m

S'''''''

pIo ...
and rout counleo-ciotkwi...."",nd II, Il
lhown 1Ie.... . Kttp tlle Itmpi,o.e \lulele 110"1 ag,JIIIll Ilie
_ mlng pl bK.au ... 1he "mpl.te will "" ,uilled il
Ilie \IiIide drifts aWIY from Ihe pl.le .

2. Ro,,' Ihe: platC,s LOI.pon rab DeI In 'he:

IIIblc:top. 1U.i<lon <ilc .cmpl.' e OII thc """n ubk '''P.
Camp 1 bclng 5u", 10 posIllon .hc ebmpo whcK .h.,.
Inlcrf~", .vilh 'he """CI' ... ,..... fc..d It :.uound 'hc
In~lde cdgo: of th<: .emp!;"e:
Ow!ge Ilie plUIIIIC """CI' ""'''p. Ono
bit Ut lhc <:<>I1n. :ano! in>talI. I ~1nd>O.O. """plate
lIuidc In <hc: ~pIo,e: I'onCl'-CabIc """'''' thd 1\Ikk: i ."

_f,

......inch

"rai!Ih'
I 70

ROU't' Mag,c

Groo..lng Ihl ULbItc"" is I I..u ICk~lh 0f>Ml!i01l tNn

rouung Ilie l .. mpQie. StI ."'" n>UlH OII u.e ... mpLII.,
with Ihe gulde <oIIiI, tight ~ill>l u.e leo-npl;ale~ \lulding
tdge. 1'1.... Ilie bit,;;Ind \Iuide Ilie _IU dockwlH . 1f
'/'OU do iei Ilie .ou.... drift .way rrom Ilie \lulding edge,
'/'OU'I mf:rely "" CU!llng 111.0 .h .. was .........

ROUTINC TABLETOP OPENINC Wilh CuldeBu5hlni Templale

A. MAKE AN INTERNAl TEMPLATE.
Templale blank

JoI."-o.o. g" ld~ bu.hlng

T~mpl a t e

..,ounllno plate

Sc.ap 10 p,oleCI
wo,k su,lace

Moun"ng plale

B. ROtIT THE f>LATESUPPORT AABBIT.

Tablelop - - - - - .
I !4"O.O. lemplale

ould~

~ ...... .

.
,.::
:

: 0

... "
"

Te mplatt

C. CUT nit INTERNAl WASTE FREE.

_~_~

waue j

l
5aber saw blade

___ r-

..-

Tabletop

II

Tablelop
J4"dja. hoit

Un;V<!rsal Rouler Mountino Plale

171

3. an tfM.o ..-asI" ou' of tho: ""'letOJl <'>J1Cl"~ U..,

a .. ha _ . br ,his ~.CUlting n.><lIIy ...... oM Innrr
lohouIder of oM IIJO'I''I:. V..,lI..,. oM dr:uIOI jQb
drilI
~er ........ "' nch comc-r. .. "",",'n In ,...,
dr.Ning and phoco. 1ltis ...,.,.. JtlU .,..., in>o:n .1>0: bb<k In,o
oM
and make a .. f3!&ht ...... f...... ooc concr 'u "lOIh.".
""'" ptocUlklK of W " " " cut wi/I da""", ... how " ' Ik
oM pb'HUpJIQ<I robIxI it_lI ,.... do cu' ..... ' :II ,1Ie: 1I"'J<""lI
ohouIdo:r. 1hc r1I:ob<1 will Ilo: J.... u",d", ~" \neh wiIk. whleh
k. N. mud! A fPKI width lOr Ihc r.o.bbet ~ '. i~II_
Ti,b ,"" ..-ut" ro:m(r\-.;d. 'hc: """,n,lnS ,,""e ol't""kl n.
p<Tft1)', ..1'okb is .0 gy, JI1>t bit han!. Vou wlU "" .bIe 'o
so:t i. \n,o""" OJI"IIing, bul )'QU'U probably "",.., to ~n .. ck It
,,-itb )'OUt" f..c to .... t ie.

j(,....

"'*

Using the Mounting Plate

No """leub. ,<kk '" im"OI,', in usins ,..., mOUtiutljj

1'''''' You ~mply dri,,,, 'he m""n, lng ..,R:WII,o,,*,, Iht

.pp"-'J'l'Litle holo: InlO ,lIe """e, ~ ,\I.ncu'-U' ,'''' rout ..
Ih'''''8/o .h" ,"hIe,np n".,nln/t. Ind scaI Ilie pble Iii Iht
r~,*",' Chuek bit In ,hc colici, plug in ' hc: ruu,er, ono! )UI
.", ""dy fur "",,,:r ,.bie: ......n:
,,,,, "-dljhl "r,h" roulU' ...iU kcq> ,he pb'c: in pbtt.
A hig O<h .. nLojie ./Ils mounWlll pbt~ lk5ig:n lI2!l OO"tl' t:he
oi<! bol.<:<J.t1>-t1\c.tabk.10J1 """,nllnll """"""'" >tIfbco:!; .oM
t'O'" n'tl 'o <itanll'" bi, . Ti,h Ilie roula lOOUI'l'cd ( _ /)1
....... pcm",""",Iy) hU"Ie>,b 'Ile W:lIo:IOJI.)'OU t>a>-.; ' o SlJ\If!I!Ir
'<1 d"""ll" btu-. Qttm, )'OU C'af"j ' ..n: ...haL )'OU '"'" <l<q.
"""",.... 'hr IOhlrtop P""'~ no ",indow to ,lor """a.
dc;lr pI;<.<t1c mounling pIl'c, ''OU QII iiI:t
Ihto<o&h 'lor pLa'~ 'o II """"'" )'OU,., ... u.. ...~
~""" bc'ftrr, )'OU an puU.1Io: tuUi.n up out 0/ tllo: ubktop
anei lJI'" )'OUndf cur Xtt56 lOr bit cl\an,Jtl:s.
Ilcmnnbrr ' o puii 'lor pI"II A..'O' .~ )'OU dun8o<- loii>.
I C'af"j', 'blnlt of. >inp. lmunc:o: in ..-hk:h fm:1wId
OII ,..., rou.rr ~ il .ppr-opri;o'~' In co-rry optrolIort tha. ('Om(:) 'o minii, )'00 """ dthU" "",..Ing pin Of
I'ntcc:. r\.,., ~" tunplltc lukk, Of .n O\-nfInd pin, '"
hdp )'OU lJlIido: and C'<><tlrol.1Ie "'Mplccc
I'c:n<:<$ ,lut caii bc ~ '"'" CO\"C~ In otl>U' e""", .,.
"llIl1* s...
1toI .".1'~bic:- un ....11'" 183.1Jcndo.
TOJI Ilou,rr 1\ooble' OII ""'" 2Oj. floor.St.ndltlJl Ro\ot
TIbk' OII ~ l12. Ind ' SpUI Fnw;:c ' (NI P'JI1' 2371bt
JIOIn' """" It. ,Ilo:
pin )'QU nl:l<k W'lIcnco.,r)'tllI'"
rou'lfIJI ..itI! I pllotcd blt 1"" no fcncc , u'"" ,"", .u"l"8 pin.
~ 'hc: ..'Ofk aljOiilSl ,Ilo: pin , ,hen ' Ic:,-.:,"1\ In,o 1/1(, tol<.
""'" pin Oi Iixo:<l, "" )'OU can br.oe" 'he \0"0'" IJVOln>l k
-""""""1)' MOI't'<n"Cr, ,Ilo: pin lIi,CS "'u Ic: .., ..."", multlpl).....
.110: 5C1nlf{t1l of yuur lIold on ,ioc: " '<JUd .M damJl"nIng tItt
Clt1tc:r's en~'ln_ (1f)'Ol"'" "MinII \O"ltlll"" 1 >!'''!ni pItt.
.hen ,1Ie spllllling bj, b )'' '''' fukrum,)
Oo.,e 'hrcng.:tp:d
W()t\< .. In nrm!'Oll!act \O"i.h .hr pilot , , he pin li 51'Jl"ri1L1Ol". It """,., bun ..
kp'hc ''-o'" og:o;n;. 1 hrouKh<>u'''' much of e"" cut
pOSSible, hUl )'Ou e",', al .... ),. I<c:cp 'hc: """"':t.pInsI bodt
'hr pin .M .1.., cullcr. '0011 proI>oblr IInd
Ir)'OU!'OII",ra,c ()fl kplnll ,lor ......n: 1jOI'n>' ,1Ie pin .h~
.1Ie cu, , )-ou11 <:o'2Sion>llj' lc:I 1, JtCl ' '''2f from ,"" pikit.
k::I\';ng "" unllnlsbcd f..... .1Ie cut

"OI' wi,h ,...,

""'' 1\11

"",=>ion

""""Ing

..{!..
OI

...

:o
O
a:

"Ull(."

C UI Oul Ih4! bl oc I< of '"'ilSlI "'tll il Sl~r so". "

you elrltl Llfge' clllmeeer IIole I I uell cor ner, IS

iM .. n, ~ou slmplv ""ve 10 mlke SCtill;II, eu,s ftom

COrner 10 (Orne.. CUiele Ilie Si" ;alon; Ilie Inntr eclge
of Ilie g.oow 50;a 'ilb~, Is Itf, 10 IUppott ,lIe
mounling pilIt .

1 72

Roult ' Magic

.00l ,1..,

,ha,

'o

Bit Opening Inserts

ln ltrehanguble inserls sale the
..ounlin" pl"'le'5 bil ope"i"" to
wh,l Iever sili! bit I'0u are usi ng
10 keep rou rouli"" sdely.
IIow 10 make them for your

roule. ubl".

'"

is ,;a1c!y as much ... $I'''''Y. You

bl! opo:nlu,ll 10 .h", mounl ~'~ pl.;U~ ck>locd 00"'0
.ruu.....
bil ImI .. c k...,Iy .... f"OI"lbk.Thi. p""

T:

~
ii

,t'"

...... 1"" "'''"'I'k:<:< rrom (11" 1'1011 111'" II><' bl. Ofl<'nlng,
",,"",1I1h<c <'tIp:, m'l'h<: ~t~JII~ ,h .. cut.
Ir )'00 ....., "PI'nnl up II,., bil hok 1<1 a.:c:um,"o<!;uc a j.iIdI (OI" la","" ""11<'1.",1>1011 hoil, oon', .ht!11 O, \'o.lnch
.....mI bil .,.. \<..lncb m ..;gttl bit In .tu: roUIC. I nd upo:ct
10 """ tp'UO\'" ... ilhou. h....:anl OI" h."lIup.
" l'OI'>ibl~ fOIUIK>n. """""laiI)' 1t}'O\I
a mountirtg"
pilit' l"",pblr. l~ \0 knock oul 5e>'Cr>1
nch ...."h
diIIm:nI >Itt ol biI opc:nl"4l.
!lui :an Int""""'1Ijl :UlnTUln.., '" 10 lI\alee a 5~
~ plaI" " 'lth a oct al bit opefIlnj! ut5<:m. TII<:
............ uc ~' n In ,"" d ... wlng IlII Ofwt'fna Inu-rI
11:1<*4. I maok tI>(, ..... _ . . , In 1"" phoIo rrom ~och
_ XT)'Ilc '"'" NoOo." 1111 opmlng In dl<: """"n';r\f!. pL>tc i>
)'1Inchc> In diamClc:r. blJ:lC" cno<$h 1" accummocb, .. u..
lIrp plIId-n;,.,. In aJrt' bit coIlectIon. II lwI a Io-indt_ido: X ~ .-.btxt arouOO i,. "Thc in5o:ru :an: 4
. . , '" diamctcr ;ond ~ Jirnibrly .... bIx1<'<1 K> tM Inooen
1II .... 't.. iii. opw,,"- onoJ ~> flu.h. "'" biI opwinp in
.. ift>a1. :an: nu,chnl 10 1Iifkrm conunonI).. uscd ni,
_~. I~nch. I ' .Inch. ;ond 10 OII. ,.,.., J!Ol """
kIIod DU! and ... bbc1<'<11i)t ,(1tIpLo'~ IIIlklD.
BoIh ,t.. MOIJn,ing pQ", . bI. opminB aOO .hc lIUCI1S

il
IT

-.

h;t,..,

pb"".

1haI.

It

Thi5 mi5ma.ch of bit 10 bl. opentng II trollbl .

W;,h" smllll bil In" I"ge o""nlng. IM wo.k un Cllch
It.. b . sH:le ollhe bit openlng Ind gel hung up. Even
worse. 1, could liP 1"'0 It.. "old . II you "" Iuckv. II
will only ruin Ihe WOfkpiKt. BUl .. olng In Inse" clolu
down" hole blg enough for I poonel ."lse. 10 pfO\fldt
nUrZero dUflr>Ct for li !oIlnd! CO'o't bit (lnJ,I) .

:an:

rut US"8

,t.. s:lfIK ,n"pLolr

In fKl. )'OU can lOC<><<>-

...'" tbc.- rcquirCd ""roc<: In,u ,hol: ftMMHItlnil"pI:o'" ,nupl:o,r.

mus si... ~ityinl! "'" nw,,,," <Ji ~ ,h:II ,hc bit <lfXnl"ll
is <'C<lottI"I,,;,, wlth 'M bi. nil.

'"

tiT OPE"' I".G I".SEIIT LAYOUTS

SECTION VlEW
812 flalhead
ma(hlne

Inotn

K~ ',1.".....)"1.1
.'

'.

Mo"'I~k

lerylie.
pOlYUlbonalt.
OI phenoUe pl,Ule

'"

\....
3Y!" dl'.

Mounllng' strew hofes,eoUnltlSUnk

1It" dill .

II'" d~ .

~"dla . (IYP .)

Making Bit Opening Inserts

..
-.(!..
OI

"
a:
O

CUlting Usi

lI"' iOj! 'hc .""""' . doc:!> ro" .... 8O',.j "n~ )UU lh<> ho'"
"""""1"11 pl;Il",.... uP ,,,
,hen. S<I nuI Jh(
pla'" al ,hr ",nlC It""" )...... nuk" ,hr Inocn..; ,.,., do ...., Ihor
"'rne Icn'pb'" IIc"'........ " ...... kc ~ plaI" ~nd.n Inocn

Put

:Itt'On.rnod.a,,,

1. M3k" lloc mo""lIng.plal" I"mpla le . 1 do

nnw=r

P\;a,,,

Rou,rr Moonlinl!
Qn p;ow 16) FoIk>w Ilie ~
oull,,>C'\I ' hcl'<' lOr "",ti"" Ilie IC'mpbl"
Whcn )'OU bort ,!tc iii, opcnlnr. In Ilie leTIlpblC. nul<e
ItlC
4i \1 1nchc::o In diamnrr, "'" 1 \1 1ndoa To eIA
ltoIo: Ihlo b rw: and h.n,., It ccnlcrN pt:fftxIly. ...... """er
and Il"MrImd (1Ile TI"lfnI1IC'IIb>cpb'c .no..."
39 Ilo
Ilfn' lOr 1hIo """""llon) Of do It ar. thr drtI ....,.. ..1111 ny.
",lItrr OF hoIc ;,,,.

""""'' II

lin.,....,

2. Make Ihe moumlng plale. _

lbt diI'l'cIJon
In Ilie "Un"TnIl 1l00lrr Mounlllll
du",rr on .,....,
16) lOr using 'hc ' '''''pbte ,,, makc IhoI: """"'Ii"" pblc I)rill
:and countcf:.lnk ' hc .....-u~ ......, lOr thr ...,..ler.
.nd nU>IHrim Ibt plaI" 10 dupllalc Ilie lempolale
lIut >lUp Ihc dirn-tions In lhat. ch:qMer on IOUI~ ,hol: hi1

P\;a,,,'

""'"'"

I ....cad . ... ud)' thr

}f;" )(

m-inII "'ating 81, Upming l _

AS ..,.,..... lhen: n """ A. ...... I lo-<ncbO.ll.lClnpbIc iI*k"

~ """ I..tnm suoighI biI 'o ..... tho:: ~ """"h

Matul,1

8" )( I 1)t" Cfe acrylk I

lI")( 12")( 12" Clu. "rylkl

Hardware

ho,,,

10 do Ihlo 1" )'OU. bul

",,",p )00'
~I Ih" ......
an<! ,um 'o ' hc ~'cp-by-6l..., 'elIl !)II nul<inII Ihor u..;,-.,n;aI

Qty. Dlmenslons

2 b.us flalMlId IIIKhine K.ews. 8}2)( \Il"

\bol JIoouIj/ ,CI " _ _ ~ , ..... I"HrIJ (rom " iIIo>d

,III< wc
I ~"""" " lJI$o _,~.

lhc

-Ins pb.e. Not~ 1"" ftd dln:alon opmfio:d.

Thm swl' ..... '" %-inth M... lglll hi1 In 1"" oan", la.
pU' e jIIIIdc 10 ...,..1 ,/)f ~p ...
.no.m I!
...n II of lhr w-i"8.
i\.1 .hh poi"'. JUU .... n I"T .... n 1"" le",pl;l1~ .....

bb<:'."

moumln:jl p!>'(

3. OI I Ihc huer bl:o. .. k. 1lM: inxn mUM bc rnaIr

rrom Ibt.tall>C' m>lu2I U Ilie mounlUlg pl:l\e. 0b>i0usIy:
you .... n' ~lIxh 'he I~mplale 10 a omaU "1 ....'" ..'orl<pka;
.., ~"I :os .......,. i....,..~ "" you "'.nl rrom o"", ia'll" ...-.n.
pK<:t . 1IofKI lbt 'cn.pb .c ' o .h<: ..'Orl<picc~ ... ith c:o.~
lapt", ~J you dld ........ klOj! Ih<: maun, lng pl.,,,. Uc !ltt
"'pc ta hood Ihc "'",",pin'" 10 .".ne ""rAp Thc "''''p "il
ptOII tbt wOtl\ ..,tf:ICC llIpinljlhc w"rI<pie . 1III loCllp

IOII<1h.,. k""r Ilie ,,,"".. bb,,~ fl"O<l> ~hing "-, l' I:! cu,
~; If II wuIIIll ~"Ifi , 'he "",tct bit wuuld g<>II# It. and
tII~ "'''' l '

1IeI "I' ,he ,,,,,',,r "';, h ~Htlctl-O.I). ,,,mpt,,,, ~ukk

lIId a IIo.lnd, ..... Igh,

1)1,

ICttpblj( ,"~ '~"'pl"'~ JIUld<" 'lsht aplIOIll>!; in""" WlI"

oi the tenlpl, ". r<'>U' OUl ,I>!; Iruen bIadl<. n.., plas!k~ 'yp~

c:dIj' uM:d for """,,,.inil pll' .... '"'" aU ''t"I'J hanl. A """,,,,,"
1ltOigh, Irit '" ,hin .n<! ronliaIUC"''Y I",U. So 1lllI"
!IuJIow C"". Of' !...... rilok hrnkIn& 'he bit

"try

II J'Uu an:: nukng noon:: !han OrI<' irucn-and )tJn:1y )">II

""-pry up II>!; ''''''1',"1'''00 n::p<.>6IUI1 1. ,,, cui 1"" " "',,
""'" n.., carpc1 .. pc: al"7f5 s=ftt> tO stlek 10 1"" WI'OnIl
pul nd " '''en i, d<.oco, !'OU an'! ~Iy pcd It "I' an<l
It1pply It 10 Iht riJlh' put. So you 6huukI r.gun: " 01 uoln&
"'-"" ",np> ,rI "'pc: ..... nch ll<'W imoM.
4. Kahhe.lI ... Insert blall.k" Ud1 iru.c:n muSi bc tabbriO'<! ... Il ,,-iIll>CSI in' o 'bc """,n.lng p"'le. n,( \kplh of
th< """"" .. cmlcal. >In you ..-;mI 11l( InS<:f1 "";,h<:r
IUndlng pmud o( thc plall: . - IICI'tlj( f1.'" ",,,,,d . Iim"", bc

Jl<IftttIy nU>h

TO hold .h.. I"sen bl."k for rJ,bbeUnll, . n,d, iI .o

1 2-inch"Squl"e poSl w l l~ C,.ptl tlpt . Cbmp It.. po"
In, V'Ie , ,nd you h,vt un'tstncttd .cu u 10 Iht
bLonk\ tdgo. kaust of IlS comPOl" I Zt , ' l.m'OIlt
lrimrnt. II. dlndV rou'.,'o u for ,hil job. Ust 1
... ~!lnv bi. of COurlt.

MAKING IIT OPEHING INSEItTS

A.. CUT THE BIT 0PEH11oIC IN THE MOUNTINC PlATE.

~ dll.

bll

1\4"0 .0.
gu~ bushi"g

. ROUT THE ItABBET AROUND THE oPENlloIC.

I \11"0. 0 " guld~ bushlnll

!IIo"II"," bit
1\4""0 ,0.
lIuiOI' bUlhlnv

____.l---with

Ttmpb't

Ruu~

SUI" 10 protK' wa.k ,,,,"Ct

" Y,"" dil..

1, .

]!h"III hoIe

c. CUT TH[ INSERT BLANK.

..

y..-o.O. guid. bushlng

~ ."-du"

rlbbe.

Templl.f wII~ 1
41'>"d ll. port
4" dll . c,.-clt, wh,ch r itlds
a \4" rlbbtt betwttn 4" d;"
CUI.nd lY,"" d ... cui

\1."-o.O. ou'dt bush1nv

..,
""1:___

Se'lI>'o P'OI.CI wo.k .urfatt

Ttmplltt w1th
' 41'>"'111'" port

4""d l disk

SI\opmldt tdlle
lIuldt II bondtd
'0 bllt~lt. wllh

In.trt bLonk

Ci'1)I!1 taPI! .

~" .abbedno b"

Se,ap tllmptd In vise

(bond In.trt 10 """P
wilh earpel tlpt)

(
Inn'l

W rlbbt.lnO bil

'" Opt"lnOln ru

'"
.,"ii:
O

';}

-....
ti

IIOTTOM VlEW

1'1dli. bi,

"(
~nk l \.
l'I. " mllghl b,l

\IIwldt)(

MountJnv
plalt

O. 1tA88ET THE INS(RT 1lANK.

"

WUlt

Se.. P 'o prolt"

wo,k ,urfact

175

QlUd, I ",bb<-tilll:!:>il In IIM: rouIcr ..... k" ... "')'t1U hI,."

'M 'J>proprbIC [>1100 bcarinl! ~ .. mal;11lII I 1oHn<......io.k
... bbc:I, Set ,"" cullillll <kptll, uoiIII: ~ fl>(lUn'iIlII pbtc',
",bb<-t, Set lhc mounlln& plate on ItIr ~IC . ..... 11 1""
~ rt>nned 1' 1"" ... bbc:I ha;io.k tIM: hit,,, shov<n, Set tIM:
hcigh. oflhc "u 'ocnnlt' .... UIl .IM: ~oltbt na..,.
1()'tIU "'''''''' "'" , ....1I1cIm<:Y from Ilie Irutcn.1t ,.;u not

n...t. inlo tM mount"'ll pbt~

lb: dao<in .......... I ~ ftljp: paI<It: MLId< '0 ,""
"""cr's ~e nu. ba1 n.omtlll, bul )'OU m;/)' l'InII It
hdpfuI in k~ Ihc" routa Mady un tlle wun.J>ica Thc
irbcn bbnI< .. .smaILarId J"IU hI,." ,,, ...'Uf'k il>
~. To
~ I.bcbbnk)'CI rninlrrIiz,eu.", 1wwlIInII.:IIlek It 101 bk>d<
01 Knp ..'OOd ...ith CIf1X"I Dpor You am 1m(>l'U'l""hc hund
Il J"IU ......,.,... ,"" bbnI< ." !hc I>l00.... mornenwilj', U>lng
Qbi<'k-Grip clamp . ~ Improo,-nJ boold, 01 cout!iI', n'l':U\S Ihe
Imc:n ",in hc lurdcr 10 1"1' otr u.", "''OOd ..' h~TI d~ routlllllls
donc.) ClamJ> u.", ""OOd In ~ >"I)IO, . rId ro," thc ... I.lC\ an>UJ>ll
'Ile Imc:n.

"".iI\:

5. DrUl ~'O .. nlt:tSlnk. ami "'1' tiv: nu.lnIUII

1iC1"t-..... 00"". kt:l.:lining <i<''''''''' an:: nftdnl 1.0 kttp d.e

.
-....
.,.
II

lrucn in pu.:.,. Si"",", Ihc",'. "" .-dgtll on It, u th<n: Is OII

tM n"",ndng J>ble, th<' routcT& .ibr.>tion!o ..ill 1"""'1" It ."
pop OU' of pbcc_ n:2l disosI.cr.
1111.: ...,"'''''' "'" local .... In thc- ......., beN..,.,.. tll<' plate
:I"d thc Ins<!n. '" >hown in tII. dr.rAing HII Oprn/"II J..-t
LuJ<ftllI. M )"OU (2II ~. thc mOUl"irl@ pb." has ~
llOk:!c, ......i'" "'" Inscn., hin, onI!' 1.... cmocmIWpn!
noIcho on tIM:.,.... Alt an:: iliShtlt' countenunk..
ttcousc thc- hoIcs in thc .......... ing pbIc '"'" tlppcd (!I()
tbt JCR;'A'S Ihmd Into Ihcm), .hcir daIrlCICT t... 10 br .,.,..,.
",,,,,a! ..11" IIM: tip 10 hc lO!I<d. 0ICCIc tbt I:IJI; Ihc sIIc 01
tIM: hit tO UK" ...in hc md:>os!itd OII il. li)..... ..., LtSir1t! Sj2
tcn:"WJ, u.;c "'...s c:al1rd I -29 bil . (Yoo an bir)" 1Il<' tip or>d
U.e hit 31 """" hI~ 51 ..... .)
Tho: t"aliIc!Il "111)' 10 bon:: tll<' hoIcs Is an tlle dfW pm;.s. fi'
II> inIcn into u.", 1I>OUI1""fI: pbIc, ond p<lIitlon ,bOi ..un;.
on 1"" dr1lI 1"'"""' tWlo: DrilI thc t...'O hoIcs, lhen
tl""" .......... thcm 1tcnIo>.., t"" iMeA . Top ,Iv: hoIc> In ,iM:

~ '*"'"

II

~ pb'"

1_

on mnI!

"'1' "'" 10und

In tht

CI

""

t""

Ippmdis. in
brun: "Cuningll"""d. un 1"'1" l
lJx ,"" Imc:n tt... ', hccn drillr-d .... I"'''Ctn lOr mi ....
.Jimil:lt ..... chc> in "")' Olhcr Iru<-ru J"IU "'" n....:ln~ lttlT',
tiM: ,,'u:oUon: TIIc h:oIf-holo: DO" .....mIII tiM: 1......,
p....
.ido c~ for Iho: SCn:w
ll>c >Cn:..- """" nc-nb.
.!okoI\h 01 ,-"",,!XI. 'o lIokt
Inscn down. IIm prccito: III.
~' I lh:tIlmporUnt~. Now il'! dam"'ro to ""'" Iul"I
holc. 1t J'ontner btt ,,;11 do it, 00' t"" ...on ', nntl -l9
~. II ,..... ru ... cll Inscn lnlO ,IIC n>uun~ pLII.t 0<Id
tirUl .11 of ,lH=m, )""U dislon th~ n>OIlIl"~""'I~ hob,
m.Jdt>M. II>cm 1n>J>06Slble 10 "'p. So
""'. A ~It'" "OIt
"';'11 Ihc ~'()ml'" 01. m" >houkI do tlIC trieI!,

""''''It'

""aru:.
,"e

t"',',

..

6, ~ th" bit opcn.ing in the Insen. lllc lIN .."It"

..,.n. . ..

1<) 1""" t"" lJ;t opcnings is ..;rn I.hc

TIn. ..-ill proo,idt
truc ~n.>eICannCC l>oIt In thc irIonu.. ,",OUlII. tbt pbtc ..
tlIC row ...... 0. ....1< tbc: lJ;1 ) ..... "-.ni to u>c in t ...... n>bI<T'.
CbIkt. ~"it 2fI. in>cn in,,, pbcc- IOd dri'" in ,1Ie ~
..,..,..... turn on "'" rout ..... arid [>I~ throujth 1IIt
Iruom. lIc:ntIoc ,..... """ borinI! pllstic.,..... necd 10 ......, il
~ ~ IOd mnctin8 u.", biI. :opIn IOd . .

....'u <hc inJcn is J>I""'lI'I'n1.

Rq>nl lhis
J"IU doi",
For ,.".,.

proce!i ..ith 0100

b""" opomirtf!:l, I>oo"c

biti arid Imens, II

lhc """'" un ,IIe df'iI

1''''''' DO" ..it.... rout ..... ond 1.........,1 To mart t .... lrI!n1 C<"D~ nd tO do k>r riliM:. "f thdc
In$WI it in ,IIe rnountir>g pbt".ll>cn u>c y.

'crpoln' . ..... lell

.~ ,

~ bII., churla! In tbc: """er 00' lUmN by h,nd, to

dimp!c tiM: m.cn
I( )'OU ' - thc drill 1'''''''' u.>t l'<>roIncr bit Of ny.
cun..... w bon:: thc _
10 bcgIn.churt:l ",cring pin OI."
>n\:I..Ikli:unc..... lJ;t III tloc ch ....1<, and lod 1hc q .. i!llw.t """'~
"'" ln6m II<IIf;ocf. Unc up tlle buen', CC"tcrpoint ~
l1IKkr thc 1>1. uIs, <hen cbmp tlII.: loucn. UIlk,rl: tlIC quiI.
ontl_ltch 10 IiM: b!1 10 I!c usa! tO hore th<' bllopcning.

I( J"IU "''''" tu " .. ~c ." I"""n for ..., npbtc guidc:>. 1hiI il
t"" appro:adl to ....,. AfI ..... tiM: """'n .. aligtICd on tiM: driI
1''''''' I:lhk, """" . \'J.HndHlcq. rountm.ort: for 1"" lan.,..,.
IUitlc: f4nw: ~n(( I Ih l""h !'om.,..... bot. Thcn ...i<dl 1<).
l!<Hnch ~ b1. '0 horc COIl1P""~1t' "'rtJt.I8h I.hc imm.
I()'OU u.... 3 mut.,.. outd lnUnmCl. )"tIU -'liIlsboWd ....
~ drill pn:so; lu .,.,." a hok In I.hc ino<n b ."" pm:.. pul. For
.IIC ' ..... u'ld 10 j(Ui<k ~.,. tI>I! '~ COfK"CfUfic ...iIh thc cmI<1poInt , Ihc p/YoI
l>CCds 10 "" pnpmdIruI:or 10 t"" imm.
fat.'C. A drilt pro::a; ,..;u ~ lIUdt a hoit ~. driIl pra!,
u>c driD cquIppcd ..
rw-<II18k gt>I<Ic
Wilh t ...... "'"" hoItdribed.hond I.hc in>cn w. &irIr liwF
;cnp. ... hi<:h CUI toc danpa!1O
1UI.'bcc, Sincc tIIc
pi"'" b in tbt...--r, )'tIU IM'ftllO moun: ..... 1< """,,'1 _
b CUI coonpIcIdr flft 01 "'" Imc:n. And. fi
COUtIif. )"tIU dan', ....,.,t u.", lnKn 10 ....,..", citoo,

""k

i,"

t"" """'"

""""" t"" _",,""

AdjuOl thc 'nmmd

C.N'I co"n ll lnll .re In ,,,," In.l" u.ing.

fO"nd nle . Ml.rk Ilie loc.tlOfls of Ilie nHdHl countt'
,Inh- Iwo In ueh In"n. A cObplt of 'Wl.pt, wu" Ilie
ni. wlll fOf'" tlle profili! needed.
I 76

ROUIer Ml.llk:

....11",.....

""mi W ,,.,.

~ )"tIU

1.0 ,,,,, ~

raditJt., IOd ....... lIIr

routln!! l1J>bc:lC'l.l op<:ninJl for

1uJIr1-<l"""""" d n :Ie

talt

Iiflf.
C"((in!! l",.. inch <lccp. 1"hcn ..,.A<ljuot t"" t""",",,-"I to n ..... thr
pblc

>houtd ....... tbt

~""upaUnw..

Router Crank
Adj us 11he plun"", rOUl e, ' n . . . ._ _ - . . . .- . - ,..~
ro ur rouler la bl e Ih e u me
Wil)' rou a dju s i Ihl! bla d e
hel ght In yo ur u ble nw:
by turn l" g il c. a nk . !t's
fU I , s moolh , precisI!. And
when )'OU mak e rour o wn .
Irs economi a !.

f i i ~ ~ ....

clldw'. '"'" p.d -~ i.s 11131.

_""u In a 111*. I he plul1gc """a pl'O'lidcs 1"" mnns

alju>l bit "l<nslon '''''Y pl"'dli<'!t' and "'n_ tIM:
.Iu., plaJ!:"'" m""y
""'I..n.n.. bad

I<l

1lx~b:lsoo

_~

il dat, lIIollmcd In l ~ hlc, ,hc plunw: "',,";, can bc: ...TiSI

OIcad>t:. In adl_.
10 "".e"", ,lIe bi, lQr cut, )"" IMY nccd 1<> ",-isi )'<>UI"
WTi5I >boul 20 ,o iO tim"". Th"" H) ,,",'CI" thc: ro.otc' """"IIh
10 ~ .tIc colicI SO }'OU an ~ bib. )'OU h>,... 10
.... UtIl '.... ri.1 .nod~r 30 la 40 timcs in thc 0I1M:r dilTC_ . 1( build",g fo<'<2nns lil<c ~ ._ I!I ....., 01 )"'"

tlci"J" .
+"1\<"1 knoh ,1>;0, ""'" _ _ _ ..... un ' , blo._ted plungc ruule ... lrulnd 01 JCl'in!!. )'OU k""" 10
ltI'bI. lh~ <k,~ !!I"""" )"QU c ... nk 10 .."""" Sud<knty, "'",in~
ond """'cl'injj )"011' ...1)k.moun,n1 ..,...,.'. bj, .. as >implc: as
...,.". ar """'ring ro"'"
blodc.
1ll1>
01 ~ CUI""pU """'s obrioul ond sirnl~".l

,"bk _ ".

KtU>Iy_"

Ioo.l~"

...-n

obouI k, ,..,.l _
',
h ,.uukI ...
1 h;od dwlC<' w uy <U row:r laIJIr: huilt b)' l\l<ISIer
1O)(Joly,, ~ Nk:" &'IJtt Nidt. """er ...,.. ftnnl ..-hll cr~"k
euctI)' III<r
,"o.-n """", ....J 1, " ",,'ni ,h.,
_

*"""

u.. """

...... >lkk ,.. cuo*l bc: Oh .",., .,,..... aIm<l!it 1IUjIIc:d,

'wo ......l'O' un ,bls. "'" can .... kc ~ tia

eo.sr.

,,,,,,ro

oaciIbry 1JOill'. h",',"~, it . [( noi . 'ry Ihi> IPlmO

lf I>op-mad~ , ..">!ion 0<1 thc bmiliir

"<lOC

Now)"OU can JIO

'u'" quickly .noJ 1..... 11 ~ on )'OUt ...... 'er, lUW1 i, ... iU ........
ob)' bul ''''''''' os >Ild: as Skil'. , OII. )..... ClOn mUc. ft~'u",
,,-i,1I =c, . nd, bdon: 1nsullin8], OrI thc: "","er, )"" ~.... ,
.... pl:f~unc 'he "",,<1"'5 adi.........., mh:atLi.vns n.m yau'll
tuve .omctlll"ll. Bullhe bel o(lhe .... 11 .... !I.tu"he ",ule.
Iu<:lt l5 lhc linchpirt. It thc: pI..-.w= """"'""~ Is .. K:lty . OO
.11" <lc l" h..stop rod II mloaJigncd, no Itnob OI" cr.mk ,,;$1 bc:
mhle 10 n",~e iii. adlusuneflls
Sa .."', ~.", IlQd.nno.. dichiI' ,.,Inds oii 11", " .. y
'hrough.n." JIOOd """'"' Is. fOII' bit odju>tmm roublcs an:
Thc ... nc-1I b. fOU P'" 'UD( 'hl'
of r"" ....

"",'e'

Uslng the Flxture

Whlle 1, Is simple In CO<Kl'pI. ttlls RXlu.., ncl:<b 'u bc: nllN
prct,y pn:riK1y 10 thc: rQuler i(j, l5 'O _
... lk:k ... )'OU
" "'111 il ,0 . l'm goinB ' o flIp-1lop tIM: 11$1",1 choplc. IOtm>I In
,IIi> Inst:lna, bcauoc Ilhink 1<:11inl rou bow Ibc: b'un:
..."Orl;s ",;ll m:d:c i , casie< lOt ,.,.. w u n ~c<>tand why )'OU
~ ' " m:akc

1. ilie ""'1' I <l<::scriI>c b"'o....

...1 lhe cnnk i.s i> ..."<><I<icn roIum" bom:I 10 Il! (JO'n Ihc
l1IU\er', bc:ijd"It..stop rod. A nut 1$ epoxinllnlO Ihc cnd ci ,bc:
co1wnn. AnII uI cuonc """"'. 11101 c ... nk al"" thc: coIum ...

'"

::a
O

c:

;
...
~

AI

CT

I'D

""

ROUTEII. CRAHK
EX~OOEO VIEW

Cunln, List
Q t y,

Part

Column plin
C"nk plale

Dime n sions

Ma l erlal

Ifo'x IWX Il'

~" X I~' x 414-

IQtdwood

Ha,dwood

H~ rdw~re
I <oupllng nUl (th'ud 'o milCh , .... , of router'S
he'\Ih"J1op rod)

I plulle kllOb. ,I-t" dlol. X ~"hlgh wnh 14-,20 Inse",

ifRO ....4 r.om Rtld TooI SuOPlv Co. (800-1H 0421)

S.ove bolt

I n,'head 510111 bolt. 14'-20 X 114'

Column

Ihc: nKl umilit .';c,.\., ~l!'Iln .. ,1Ie )l>kc: "" Ilie motor Now.
)'011 c r.onk, ,1", ",oto. " '111 bc Il,hen IIown II'N: "''''''''' rodo.
1, ', )11>' lik<: ,1Ie c:om.mc:n:til :adju,unc:nl fUlI"",, ,'OII an
""r, ""c:q>I ,11'1 )'011 .'" cr.onklng. 1'IOI. '''i>I,rts,Cool. l\Uh?
!lon' , ,h<: COffimc:n:i>1 ~
a c:nnI:
uw.rn 01 a lotob, )'tIu . sk? WeU. t>.kc: Iook al 00..' thq- ....
eomIlUClcd Thc 1)'pk". 1 uniI ~ I>om:k/Upc:d pluric
,1I..,.oKkd In"," !oI1I<.:k IMIII an .Iuminum tubc:. Whcn
,umed 0<l10 ,I>c hc,g!tl ....", rod. ,hc- onIy IhiRJI keq>lrtKlM
.ubc: "" IiM: Ame axls ... hc rod i> 111:1. p .... k Inscrt. Put
c:nnk OII lap
whe,n )'Ou .. an !Vind,,,!!, Ihc ,ubc:' !tLJinI
1O ..."Obbk:.nd " 'hlp ami evenu Uy p;>p rigii. Od.. ln>tf\,
So he, ..... the ><'<-",," '1> ~T.nki'lJI "ti,:"."., n", .-.:ut.l:
rolumn has 10 bc dusc:1)' flllro 'n Ihol hci:gh'-6Iap rod. MoI
thc lonJI<'r ,11:11 rod ",Utc betler .1", UniI ",m ...orlt. Ika,,,,,,

ha."

Whr

it,

Couplln\l nu'

',1Ii,

Tu """ .1", fi ..'"... ,,..... ~" thc ...", "ut>. OI ;am nod"
rrom )'OUI' I'OI"""'S hdlCh'~"" NIl, ju>I as )'UU Ilo " 'hm )'011
nttd 10 puii .I'N: molor of( .I'N:
rods. Orop ~ /1;01
w... h~r o.'cr Ihc rod, and ,,,rn ,"" 6:.. u",'s no. 0010 thc
Ih ......1kd rod. SUn cr:tnltJng. 'urnInJ! thc
_"11",,10

"'una<'

n........

oIlhi>.)"" .....y

"'Ul' ", ~..,."'oJer "'1'''''-"l1JI ,hc ..ucle n.td

"iIh a ~ OIlc:, Ihou!d1 )'OU """'1 Ilo this un :alI f'/utIII<'

rotiI""'. (lf)'OII "",,', rond meuil: ' hrndctl rod In)'UlU' Io<:ak,
!'OII CIUI onJer il rrom 1l,-" dTu<>! Mll'l'ly Cu .. i!OO-2Sj4!l I l
...00 if ,..... an: IIO'JljI 10 ... pl.cc Ih .. rod, whr noi.
rq>bcor il wlth a ... nctt rod, whlch ... itI h~,-c 16 ,II~. pc,
ind!.. 1lK 16 1'" Ilo ml/y handy oIncc II mea"" In (MI' t'Oluel

\ahi<: appliC3lion, ,h., cacll full ",.'011111,," l>f II'" cr.utle

1\ h.If~"m m,"-.::s ,IM: hl,
~" lndu, qua"CNllm tnO\'tS II '4< 1"'-"11. Such pm:15,ool
1'""" ..."m In IXkk III" roti,,,, modllklt,lon, ",a'" ,he
r.:", utt: ' Rc:pbdllf! ,hc111",adc:d Rod ' "" p;!J!C-' 1111

dlanfIoi .IM: hit ctl~ k. incll

Making the Fixture

o" Ulbl.mo ll"te d rOIlI. r, ,he c.ank u~itu bll'

ulenslo" adlu~,men" , No mOle w.ls. W!l!ndll"ll. I,"s
....w IS UIY IS adJusung VOU. lable nw"s bl.d. , Ju"
'u,n , .... , e nk Ind wa.eh lhe bn move .

178

Roul" "" g,e

1lK nitic::al c:knIc:n. It .lutl roIum" lr ,..... ..'C """ Ia,hc- .nd
IM :q>fWOI)fble 1<rw:rw-how, )'OU C2rI ..... kc: ,IM: erant rolum~
hr bori... II""-"'><Ji> .......cr o.kn>.-.:I on .11:11 nuehlne. llul r m
I'lOl. a .umc:r. '" I had In find iII1 all"""",I." 'PfIro;o.cb. Yoo
mIjtht 'hinI<, ... J diIl 'Iii Ilrkd il. lh:o, ,hc liriII p"'" is ,Ite
righl .001 for bori"fll .hc roIumn. llul in>Icad. _
Ihc
aPf'l'Ch I ....,Ied on alt .... a c:ouplc o( false .nru. II', a llil
of 11ut. tOIJI'" ",,"pC, I !hink.
~. )'OU ,.,.. gruoo...,. in , ..... pitt<:s of ...'0<)(1. Ihm
glue ,Ilem ..... hcr. n.. ~..,. combine 10 form a dwtnd
for thc hciJlhHlop rod .nd a rc:oto6 k>r thc nUl 10 makc ,IK

.00000R CRANK LAVOUTS

fRONTVlE\\'

ENO VIE\\'

SEcnoNVlEW

1"

CRANK Pl..ATE LAYotlT

'"-.dll. x ~"-deep
!>ole for column
C ~nn~1

for

helghNtOll roci

Y,"'"d.

EpoxV n\ll In 'uess,

to.." -.di&. mouml"9 hoIe

for crank hlnd~ (ouniersunk
fa, "av.boIt Mod

cOlun,n fII """ mut"", J'O" rtp k down ...... ch:amkt ur ruun<J.
O>'C'

'''''~,

1. Start b )' meuurlng y<>u ....... c r, TI'e wlumn

m.... "" Iong ~ '0 citat ."" ,op 0I.11e .....,.or an<! tlle
IXI"'W mi, il l pn;tjf;W OUl of IIK lop o( ,IK nlQolO<' ( 1' ,""
aank hl,.: """ P'1""" ,RJ Qn """'" l'OIotlon , 1, ....w "" ..
ne"l""""" 'o u>c as o ,,'n.t00;l1"3 knob.) Thc coIumn
n,,1SI ' o ~ tu acrummo<btc """ . hrn<ktl lOd. and .1Ie
di. rnct"" oIlhe hole
mat<:h lhe dbmct"" 01 """ lOd.
(AS I cxplaincd nttkt, It this hok is lou m..:ll ~, ' han
'hc !'Od.1"" wllok rnutk ..mwubbIc wt.m )'DU turn II.)
PI",*" Ilie routct un.~ thc mocor bOllOOU an , "" b,ue,
and lod, II Thcn ma:;urr fron. Ilie yotr dtrough whlch "'"
thrnd<:d lOd p,IS5C$ to .he highc!it projn'tion On Ihe l'0I.II''''
Thls IS ,'''' minimum Icngth 01,,,,, coIumn A"" .....-,'"
from ,1Ie yote ,,, Ihc lOp 01 "'" rod. Thl~ is , '''' minimum
dcpIh 01 Ihc dcaf':l1KC hok ...., ... uot hc _
In .hc
coIumn. fnilly. USC di.ol .,..lIpom. 10 m~", ' hc dl>.rnct"" o(

m""

,'''' 'hlndnJ rod.

2 . 8u)'" COl. pling nul. Tltls" ... extra.!oog nu, ,h;o,.,

.......ur u..:d 'o ronnl "''O 1'0<10 ,h;o, h:t,.., ,"" "'RK tJore.l
I

Mus .... VO ... ro .. '.r for Ih. ('&nk . Plunge ;IU fI,
.. ~ wlll g<>. and musu,e ,he ,od from Ihe yoke 10 IlS
ond, n sl>oWft, A1.0 mu.ure from Ihe yoke la IM ,op
oflhe mKhlM .

'*"'etI 'o u>c thb ~, nut 10 hdp domlna'e "'ObbI<

,"ou, \ocaI bani .....'" .>1 .. ", wil1 ...doubtcdly h....,.:oupllrlJl nu .. in 'hc Ihe Not1Qn;o1 Cou1e . h"",d ",con !lut Il10>'
phmlF roulel'J.-"" n~,<:abk 10 lhe ane cx~1on r ean
,h lnk of- h;o,.., met"" hci&ht ;oo)jus'mCflI rods. "")'OU ncetl

Raul., Cntnk

1 79

"
O
C

.,,.

p}

-...,.
'"

COlUMN ROUTIHG SEQlJ ENCE

FIIIST CUT
SECOND

CUT~::::::::~~;~~
CUI lenglll _ I<!ngth of nul

iiI eI'-tt" _

fI.,,,...n,,, ellmt",lo" of

COUPlJNC NUl"

THIIIO CUT

nul

HElCHHToP ROD

FI.,t ..."",
drmtnsron
of nul
CII1 1<!1'I9!.h - "'!\(III! of nul

""

.
~ V-9_il'l9 bli
CUI

d~ptll

_ Y,

ouU Id~ dl~-'~'

of nUl

Ou~ldt

dlamet" of nu,

a m~"ic rou pl ~nUl . Can IIlnd ......, Ioc:aUy? T'1' R6d Tooi
Supply Co .pln. "'h"" I ""'m '1 Iookcd al .....,.,. plUllJll'
n"'I~', I con Icli )'''' ' lui ,tic: Ililachl lot 12V ,ak"". n MoS
111 ..... ,1. Ih~ Itl"Obl " I!(i()o ... lot 10
0lId ,..., biil

''''''>d,

1><:w..11 plunJlll" an M Illtuod.

nlC poi"1 11eft: ls ...... pIy tIut}"OU m ....

h.md bd"'..,

}"OU

tu.,.., Ihc: nuc in

nuk.. Ilie ""'UD"'.

1"'''

3. Cm th~ colum" pUc:.. SUn "'ith

pktts ~ X
I h X 12 incllC5. Good. lihl"l"'inc<I hardwood Uk.. clle...,.
OI'" ..... plc:. Ahcrthc coIumn S ~, Pucd up. and rippnl
""" ...... tt:<! tu ilS final "diamnn; )'OU an ctOOfCUI 1, 10 "'"
prupn lenltlh for)'Olt' ...... Ier.

He re" good flt of Ine rod and "111 In Ilie column

ply.
,oei 1111 eloHlv In It, g'~, n don IlIt (OU
phl'l9 "ul. When bolII column plles If' glued up. llot

n..

nul wUl IN If~Pped .nd un.bl, 10 ro!.llit In III uvlty,

tve" withoUI INlrI(I epCI ~l ed .
I 80

Roule, M.iOIC

4. ROll! the 1l1"OO>''''' fo r thc rod. Ilo !.hb OII 'br

...,.lIe' .. bit. U.... )lrai!lht OI'" ~. bOt tiut iJ tlle .......
lItt"""er .. Ihe rod. OI" :a do:,.., ' o tlIC -.net ... you C2Il
cumt:. Se.-! thc dcl"h <li rut 10 hal( Ilie rod '~ lIttmnet. h '~
bat 10 etttp up OII ,II<: ~ dq>th ci CUI. Grou>'<: both
pIa:n. tII .. " Ilokl tiI<:'" 10jIct1ler and _ II Uw: rod fi",""o
Ilie dunnet. If ItlC dunl\("l i ~ tOO om:olI. nu~ ... oond JWf
OII n..1l pk """ cllCd: lh .. fi, :apu>. II lhc: mannd b tOO
I>i& soon ovcr.
In nuJr.ing .Itt........

~"U1S. ~

tlw: """er lObk: """'" ~

t'"

f:IOO'~

AnII

,..., .. dooo: ta Ihc ('O>la ~ lhe )lOCk '" pOS<;ibk

ona: .... ,
Il.., b"", in II.., ..."", ~ lOr aU ou/).

k:I."

JOqunKCU~

Thc:sc: inilW gn:x ....,. C2n bo<

rout~

IIlrouIlh. OI" tht'y

<:an "" >loppnl.

5. ROllI 1"" groo'u for Ihe n"l. ThI5 Uw"I...!S

""""'itlf! thc fi"" I '" 1". Incht
IIJ'OO''C ,,'i<!rn :tnd
dttpm 1,
:occ:ornrtlO<1o,,' II ... co""llnll n" l. R~""",, ""'".
!Ion'1 choI<>gc Ihc li:ncr p<>Si1~'" rrom Ihc pn:Yiou5 cut:

of.""

,n

""",,~. d"'ngc tii,,". ;\1.,-........, .ht "'''

,n

(ron' /l:It

tO f1n. ond .....

I >tr.dght bit who!c di:un<1r. n"Irnc..1'11<' "'fll h '" CUt

........ kl hc I\:I.lf Ihc bit d!:un"'''''. ROI" boIh plcr~'

To rlnj~h 0(( Ihc gn~,,'C, fur thC nu. . . . I S<rutU
dian ...", V1If"'l'1nB hll. Rotit a V-grt>O'"" . '" "''''''.. In tltr
d,.. wlnB C<>I",,,,, 1(",,/1"1/ :wq"e"ce
0 >1< ho ... ItIC nul ~u. " ou ouy nccd tu CUt Ihc
btt dfII'1'.or "'..,., .wllCh b:oct. tu tltr ... r>iIdu bit
10 cu' , liule dpcr 'n... pJ" t" get tII<' nut tW>!lf"nnJ

""W'>"'""

to thc <'<>iwnn

6, Gh>e up ,hot: oo' umn. u... up tII<' J!:fOO'"CS" rou

dam"You.11<'don',
'..-o CtJIumn

gI","

h;lI>U. An<l

ono( !oQ~t.o

doo',

O>~

Ihc

bloci< ,II<' chan""b,

Replacing the Threaded Rod

R~pla(;ng

tM

,.ve,.1 ~""fjts .

Htt~ht

NllV, hcH}hHtOP rod "'tlh. Jj;tnt:tI-d,,,,,.te. rod "'tth 16 ,tlruds

~r

Inctl (tpl) ylckls

The moSI obvJous, pttrNPS , i5 IMI MI)USITtW!nIS can be iNttSed In Incrtmenu Ih ..1 are f.. mUia. to ","ulc.. n
"'oodWOfkttS- 16Ihs, 12nd~ , tven 64Ih~ . Slxlun tpl b.uh down 10 \II . lneh per I"U revolutlon. FOUI lums Ihus
1. )01. ""h, ",h.l. I QUMtenu.n 15 \oLo In<:h.
llulllle "-Ineh rod Is ..150 heavie. lhin Itle H,I.chl"s Jlock 6-mllllm01" 'od, whteh m.1t~es It 16' IpllO fin. Arod
1I'r'011 f"f~e tM rod, you ,.n use. 1on9t' ptec~, whleh helps .I!gn 'r'OII' rOUlt< Cflnk.nd kftpltfromwobbl,ng
Can yo<I ",pllC~ Iht rods On Olhe, ,oule,,? Som~ vou un, yu , bul nOI .U. VOI' h.ve 10 _.1 .....1. lhe rod m.1~
0t'I vo,,, .0111.. and decide whtlhe' 11 'lin tit rtplllced ltnd ",hethe. It should tie .eplued
On Ihe Hllachl, ,epllteemen\ ls .. m.uer of drllhr>g oul .nd .tt.. pp,n" the I>o~ for the.od In Ilie roule' bueo
The dellll, /lf Ihls prorus lrfe Ilid 0111 In Ihe futuf"f "Culltn; Th",'d~" in Ihe ltppend.x. Se(N'llt Ille motor
f.om Ihe base 10 do Ihls . Then Ihe yoke on Iht motor hous,n!! mull ~ opentd up 11I1<:(omll>Od.olt lhe 14t'9l!"
d meter rod. Vou Citn do \hl. u~,ly w,\h. ,.u.. ,1 file. TM yoke j~ formed of .. ~oft. USlIy 1,led miTe.lallhal"s
oflen ealled POl melal."
Tu.n li couplt of joIm nUiS on!O lhe new rod, lhen turn 1\ '''''' lhe hoit tn tht boItse. Tu.n Ihe nulS down Ilie rod .
Iim Ilie fim ~insllhe Ns.!.nd 1'" lKOtICI ~n'llhe fitiL RtlASI.U the molOt on tM NIt. Turn \'Ou. new roult.
efOnk on tht rod, JAd you "'" ",aoty 10 h.ong tM m.1tch_ '" \/'OU. mut ... lob!..

,.
O

."

~
aii'

.
T.... dlffenonce II ob .. loul. The Hllaehl 'O UI"~
SIOC' 6'm\lllmeter rod 15 clta.lv ,malle. Ihan il li
ineh 'od. Tht I.n., rod m . ~u il eUle. 10 adJu\t bli
ultnsion In p,edlClablt incremenll.

Inll.mn" Ihe ..... rod II 1 mlntr of dtlUIr>g 0111

ind rellpplr>g Ihe moun, l"9 hoIe In Ihe , ouler's
b.I~t . Som. model. h.ove. mounl'''9''' Ih'l
Ultnds lIUltle "'IV Ihrou!!h Ilie Nit , 10 VOU Clln
WOfk lrom the boltom, " _"""'n . Tht "POI
used fDt" mOll b.lses is very .olt; ~ l/f:nl ~ . I brol<e
out plece of It !!elting the lip ~W1ed ,

met.,.

ROIIler

C, .n ~

18 1

'''''!It

9. Altaeh II.., " ......,k 10 th<: <'Ulumn. O>cct<

of .hc: roIumn In 'bc """'- tr n.,a"",,), ",nd <Jow,'n
~""umn ~ .'10 It ,,'111 61 In Ihc: .,.. Appty stuc 10 'hc:
Moppc(l hoIc in 'hc pb'c . .moJ IUCr1I11e coIumn.

t""

10. Epol<}' the nm In p lace. !.n''C thc nut , .... 'ht

rod AppIy a wn:dI """""" 01 c-poIf 10 .hc nut, then oIitk tht
rod :uId nut hom<:. (1ltc tQd Itdpt; kap thc nul :dJgrto:d ..1Uk
thc qJUxy >Ctlo.) I ld'I. thc nut pro''''d,,'8 ju.>t a "'...... '" ....
nut :uId IlO! ......""""" cot""", .."OUld rub .... thc )""e.
(./t.<"IU1IIy, l2lhcr tiut> ~-.: mcul conl3<1ng mcul. I UKd
n)'1on ,,'a>IIn"
thc cohImn.. OUl anii thc ) .... e.)
Ik <lbc""'" In .ppl)''''1'1 Ilie cpoX). If)"OU ..,., .00
m""h OI put It ill ,"" " .1'Ofll! placa, Ilie aCC,", can oou
In'o .hc ""an",,1 lOr .hc rud . ,,'hich ... ilJ ,nn.!lorm ,""
pk In,o """'p
AIIer thc c-poxy drico.. """"'... Ihor rod rrom Ihc n .. :uId
n:ill>t>JI ~ on Ilie mutCT. 1hcn ilUlall ,"" <T.Ulk on thc routeT.

"""""cnI

Super--Tuning Ihe Roucer

EpOl" Ilo .. ....1 1"'0 Ilo .. (01"", .. , MI~" Vtry 1",,,11
"",ounl of houlehold tPO~v ilc(o.dlnIlIO Ihe dire( '
Imn> OII Ilo, pl.(~il9Inll. O;,b il on nlultd fI"l of ,lot
nUl, II Ihown, ind Ih,uSI ,Ilt nul InlO Ihe (Olu"'II, le
dIS(~tI, If yOll ilpply 100 "'uch tpo.y, It wlll well lnlO
iI"'U wlot'" ro .. don \ wanllt, bOlch,ng Ihe job.

7, Chamfer Or lurn tll" oolumn, On ITIO>I roul~""

Ihe helgh ..... op rod 1 ...,.,Ied q llll~ elaM- 10 lM roul~r
mOlor. Obviously. ~ 1 Y.inclqw.", C'OImn" ..;u IlO! ..,.... "
In such dosc qmne,.,;,'" II mUSl hc lrim~ down.
R1p 1"" eolum!> do"",, 10 .bOI.1I 1 'nd> oqw...,. or sm..Ik:r
iril Is possibk. )led"ce 'Ile K<.'!Kln funhcr br dumkting or
rouroling<n'C,. .lIe ~ .
f lnally,crmocut .hecolumn 'O'M final length . , .... rmy
"';"'110 iqw"" Ilie ""d o(lhc coIllmn 'lu.llhc "" fil$ no.
bul toc sur.: )'JU do,,', In...n'C ..",,<Iy cur. o.hc ""'Do< for
,"" nUl '1'>1)"'-' _ed"" diUgm ., 10 crnl~ .

OI

8. Mal! the cr .."k. u.e: ~ pKcc of ltoc cuIumrt Mock.

.-...
OI

\.ar ",,' '11<: .lupe, as .......n In R"",w C,..mll La)VU"- 50 ...

:o ,1",
cr. nk .0 " .. pe on ti", band A"', ond Iand Ihor edtI:n-lf

..:

)'OU _nl ,)'OU ,-""n chaml'ct-or rot ...........f f 'hc: edacf..

I>riU'II" 0010, a '10"""" hok for.hor cr.nk Iundk, a
Sl<>ppctl h<,lc fur Ihc: ~oIun'" o".nmlM ,"" dLlmnn- 01
''''' holc ror ,1", coIWJln by 1IIC'.asw1nJI Ihc: coI"",n.
1 u><"ll reti pb."11c knob ..... lu.ndk. Tht: pankubr
knol> 1 ""k<:ted Iu.o il "1o-lnch-<kcp irbcn. " l ' Hnc:h-IoolII
moun,lnll bol' ,"", prm"llks ~ 01 cnoHo-ftOd pI3y, conlributl~ 'o Ihc: lu.ndl~ . r..,.,..,." nf "",...,mcrll

182

lOUltr Magoc:

1b """ IM bnf OUl 01 ,"" m"'er CT.Ink.)'OU ncro I routeT

'hal pI .....,." """,,"hl)' tiut 11Ia>'CI'I', usnI '00 1"IUrI)' pI'-"'#
routCTll ,hal worted tipi,
OUt o( ,"" box, l"ou ......
nttd 10 buIf 'cm I bule u ,mlIt
Rnno>'C 1"" motor from ,"" baS<'. Thlf ... n.. tt~r 01
"""'-"'inIt 'hc nUlS r""" thc: hcll!h'<itop ...... and pulllnil 'ht
motDt
Ihor ph.,. pooo, .)CI Ihc JIlrt/l)l> :akk
_
poli'" ,,,,- pO.b. If tbc """ef'o plullJl" actlon
ha. bcftI .'CI')" .lId,y, )'OU m;I)' ...
10 ute finc--wit cmCT)'
papcr Oftlmcs. )'OU an Imprm-.: lhc aaKln <lmply h)' polishin:g thc poM> ..; , h tomClhinI liI<c Scotchl:>ri,( p.d. I

It""""',

al.,.

-an.

"..." up t"" 1"""'" until 1""," IItcr.l11y sI.l"" (" Il1U tIIb
buffIn. ;ofka .hc Iltl' )'011 uk."Un I unknowlllJd)' ro:mo>...
thousandth or 1'01'0 of mcul rtont ' Ile posu:lnd nu~c . 1Iem
100 Ioooc In thc bu.hln(l:l''-' fuoetlon pruJlCTlY1" 1l1cy "'"
<JIIC"I.IOm I a4:ed, 1C'I "'" .ctl )'OU Thc .......""1 apcn 5 I 11'1.
sukcd -.m:I "'" It .."OUlIJ I>~C bo"TS o( bum~ ">'l'h
cmcry ""per,,, """"'" I ,,,,,,,,,,,,,",h orr <hc rud>. PuIl.hb1K
Ihcm ..1II1u..'C only a POS;tn'C dTect on tl>clr pcrfonn,,,,,,,.)
ll"or1c on Ihc bwhrIJIS tru" thc: pll1/If!IC poostS fii Imo. RoD
'hc cmcry p.apcr in.o a ' .. bc. :uId buff .hc buY1lngs ... ith ~.
Il"ipe thc poM> and bu>hinjs c .... " . ,I>cn ,... x ,he poM>
mll)' " .....
Whcn 1"" rnsscmblc ,"" '....ncr. )"0'-' mar w:ln, 'o
'hh !rid<: louuII <>nty ,1Ie .pnng ,,,,,.-. on 'hc ,;klt hy 'ht
1>ciWM-MOp tQd. llcre. thc r:tIlloo",tc.n ", """er b Iksll/,llCd
'o plullJlC' smoothly"'hen fon:c is appUcd '0 11C1T1l 1u.ndlCI.
Whcn )'OU """ ' hc: ( .. nk ("r an)" ""I.... men ' knob). l"'" "'"
In dkct 'ppI)in8 ,"" ron:r '" ""1)' onr han"I<:, "'hich
III ....... Ihc .}... "", out or b:L1."", YOLL ..... n ~'on: tI'<' baJ.
ana by lc:n1ng "ut ,1", unc -'Pf!Ojj,

tI,

Table Saw Extension

Router Table
Goli"

il

rouler lol.blC whhout sa( rlfldng

precious "hop

s~(e'

Inltgn.le

il

router

"'Il<:<' moon:d 'o Lh lnch<ll:lmc'cr r.l11s. ,(

5Iand>n1 tip
)"" h:....: l><Ch"

,1\(

rwry ",.. oonary

addt'd ~" I
~ lilll<opKt' from all.hc OIIK,.,..
H~ . I 5OIU1ion . lmcw;o", tM ro" U:r into Ilie ubk .. ,.,
~. J'U Ix" thc" !\ni 10 admi, w, 1 ..,.."cd ,hls
:If'PI'I.l'K'h !lui ""'i ns finalI)' hulit an o,............."IIjt mu,er
uIW. , an ..,.:ommmd 1\ lOr smalt 5hop$-:as an n<y-<obuiI,J lInt ro..I<:' Iibk: Of U """""''''''' _dar)' ro",,,..
_

(wtIid> . ,...

"* in my """"" ..oopl.

n.c ;od\':I"'''8''> 01 dois arn".-mmt """ 5c'O.:nJ

~ Ilie li". ......,.. in'..".",,,,,, of _
nny
..-....1r.".. ,., fOII ...., ... """ In ,.,..... >hop (o. )'OU ""'
. I><>uI 10 Ft ond),
Thc !>.bIe ...... Os good .nd hc~. :and Ils n_ ...w hdp
d:lmpcn ,ibfttlon ond odoI,o ,"'" ""',,,.,. tabk ~ >t:obllily
n.c bro;><l ap:on... 01 ,Ix .."" tabk: """'~ lVU"-': ... a
hqI muIe. t.bIe:
Tl><: abi<: """".,. rlp renc., an dotIbk a, Ilie bul. for

/1. W:>k _

ruole. l3Ne
Thi~

~.

proieCt i::I bascd ..... 'he ruule, ,.bI., IOP I ,n.:I<k fur

lIIf Rock .... dl (nu", Oei ) ronnxtor" ""W, <'q.ripp<"<l ..'ltlt

comra<t""'. SI .... Ihc

~if...,.

pra<:m....t

here .hollld ,.m!ti for )oor SI...... lr 1"OY tu\~ I diffclTnl

"'"' nod.)"0\1 fIU}'
10 m.kc ......., ".l IrBllon> And ar,.Inly a dlfli:n:n. rlp-fi:ncc " lUUIlllnll ........ 1<1 abu prvbab1r
:alIC,,"'1otu 'o ,IIC' ""',.". 'abk 1Of> or II>
moun, lnjt .ppro;och
,\ Ir _ I l ~, k>ncd In ni)' >hop ... ,Il... I <100', h:o,~ 'o
~ thc ""',.". "'bie: rrom 1110: f ..... , 01 ,Ilo: P'N. 1 SI~p
:around thc ,..... 'o """ np., and """" .. ,Ilo: mii 01 tM

n.."

'"c
O

...,.,uiR: ........

;;

""'<'fi""
ubk
I...:tu.kd ..'it" '"ls

...-.~

Os. 1>oJ;1iI:~ t:octns lOr ,"" rip

le,,". ,\Ir
"",,~r . - 01 1.... .". oon
nno ... '" from mr for 01 1~""'rn'ly """i. . tM UM
I'cnc<! . C".,a rbld,,dppnl ","'IOn "' ~I "'" ..ruminum bul not
Sle<:I, s.. ..'h~n 1 ~ thc: """'" Ilodn.J.. I .....s.: ~ j' , indic:>
wllk, JO 1 ............
burl horIwnUl ~
" 'lhou, rncru:.ocN.. on ,"" fma'. >ted.
1\. piua
lCn doill'l b Ih:o' i , kn"c:l >li a ~"
lOr d~ and dtipe. 1 Jwt piUI! thc """" ''KUIlm '. """'" inm
'he lIok: a' 'he ~nd
fma, Ind muci!
rout ......
""....... ,o:U 1k1Jri. b pulkd '1"....lIh 'he I"o:t>cr Oprning ...."r
r..... ' , Jy boi'. AdmlucdIy, 'hen:'. I lot
cnds up "" my
pan,und .no." .IRI on ,1.., fIoor. III1! ""-nr Unle bi' 01 duSI
~

"bM"'" "bou'
"bou,

oi,,,,,

oi,,,,,

oi,,,,,

'ho'

~'Olk.:,1oo

1..,1"".

'"

'"

TAUE SAW EXTEHSION ROIJ'TER TAUE EXPlOOEO \/IEW

,"

"

Threaded Inseru -"-________

)

.-...
OI

.,.

(!

)"01'

""Ing cunillll ....orlc . ",,,I""lt your ,al'k <:IW

"'In"

on:l\1ll)' ,"ou an: at>ou, 'o nukt an "Icl\SIon

for
U Wh .. ,1I"uk! 'M dlmen,l"n, 01 1, be' (It )'OU Iu. .. t "
Mock,,dJ/lkll . comranor". !::LW, ItIr dln ... uon. 'l"'Oflrd
t>c.., wl1l ""O'" pcrfe"II)',) ClLn II t>c nlOUnlcd 10 ttlr,.....
.h""m in 'he d"'w"l!"l l{n.... h" ... an Y'>U . uaeh Ihc new
extc",;!oo wlnlL 'o LI ... -",w'

1. Makc Ihe tablelo ..,. CU, IW" plCCCli o( ' ~i""h

pl)'",,,od to the din,,,n';!on, .pttllicd hy thc CLll tin8 U ...
Glur-I:lmln"c Utcm (:Le<" 10 (~ . ~""re haRlWQO<l .,......
Indinll "'hlle thc "'L1e <'u"'~ ''hen , he d.m p ~.re o/J thc
plywuud '~hlelOp con:, Lrlm II to ><lu. re .hc e"n: .nd
dc." up IlIc cd~ . TI ... n aplll)" the cdlt<'b.ndIn8. Fluj./t.
, rim Ihe cdllC'"l>aodln8.
IIppl)" thc pl;l).lc I.mln.te next . TIle .op . urfacc
.llOUkl ~t pko o( ."' OQIIL, 1;lIh...,-"oI u~ . un.ltcmcd
I.mlna,e . ln mI' opinl"" ( 1 u,;cd a plece of Illk"hl~
!>mln.o.e I ("und In the Ruwl le ~""i' 1>.,.ll/n SII"p . n'" It
mOlch",," 'lle color of .he
" Iecl)" .nd "'''''co "'cII
mh.nlc:olly HUl II ', '00 d..... for lOc 'o n .lIl' ..,C tllc
""'LlP li""" I ."mc, ln'e~ (>Cndl ''" Ihc ,.hlelop) Appll'
hackcr .o thc bo""m .ul'fi Trim tlLe "miNie w l. 1I a 'ISo
~ clu.mfcriltJl bit . ("r mltlJl tlIC hc,'eI .",und thc
tahle.o p at the """",. Ilmc
I( ,h;, b your firM ,'cn.u", ,,1 .hl. ,." n urn l<l Ihe
dup'cr "Cu.lom 1I0UL~r ""bl~ Top" on p:l.Jl:t 1)6 (or mo",
lkullcd Inform:.. lon O" m.kl"M I t.blctop.

OI

O
OI:

""w

Subslrl,e

-----fi

Making and Installing

the Tabletop
""'(o..,

.'

cun.,. u

"n

Qty.

,
,
,

Subu",,,
E~wnds

unas

Dlmensions
)6')(

1")(

16')( 2S"
1 ~"X

Il"

Milleriill

"'"

1")( 1\\.')( 2r

00>
00>

Hardware
I'InhC: Ilm,n'.I. 19" X 28"
BJ,cker, 19" x 28"
] brtss Ih ..udtd Insens. loI&"18
1 he~-Mld boIu .. ,.11 n.u "Uhfrl. loI&"18 )( 1"

2 brlsi ,h",icltd Insens. 4'0"16

2 CIP bolu. )\"16

x 1 y,o

A(ryllc pllstk mOUnllng p!.alf. ,"" X 10)4"

2. !.ay Ou, t h e m<luml"g holu. I anachcd ,tit

,Ou',,, table"'P .he "".....'lth bol" drL-n. thl'OUJlh tI><

'Q

",,)Olron P ..... bIe . ...... ,"" rip fcncc nilf.Th do '/li . I loot:
..1,;on'>tIC of ",,1.. lntI h"l.", In the _
.. bk.nd 'he nUs.
On Ihc Mo<.,,'elVOelta "" .... lhe Mand:lRl Mlm~
.. cel
In", 'R" mounlcd
.h= "'indt
boII> ron throlll(h UIC " 'Inllln,,, 'hrndcd I>QIcJ In 'M P'W
tallie 11)" usln~ ',.. ineh bolb. l eould In..,n them Ihrough
tht ""W ,abi,, ', hok . dri"inll ,hem Inlo ,hR"a<kd Insc"" In
rlLe fQtller t.hle ' <>1'. Utln~ ,Il" ' RlJllet batu cvcn provi<lnl

",,,,,,Ion ...

""'fljI.

TUUTOI' I"\.AN VIEWS

"".'"

TOP YlEW (Substrate wllh tdOt tIoonds applied)

,.

~ JrIQ

poInt
10 lip fmct raii

R,p le net
bar

...

gUde

+-, ,,. _~

".
h")( h"
'Ibbtl fo,
mounllng plate

Rip fenee

~~~~~U""".
ENO VIW.

expo~d

edgt

""ls of 10uler

1...../

1~ :J:=

".

\11

.,'

Il l'>" _ _

= 10...n
~j' \ : ' 1o'\' ""8th'Udtdin

6'c

.
-....
~

....u """"u"" oI.<lIUMabilily. ..., I <:QI.I/d C'tISUn:: IN' thc

IIbk tOJl ",ould Ix flush ,,'i.h thc sn-' ':oble:
In addillon . he o<. en!-lon " 'ntt i> a.txkd . 0 och
ncc: r;dl ..'i,h ingle bol . To ruG",," .bc ......." r t.bk
qt.1 ~ ""1' bolt. In..,ntd tII""""" tht r.ol ....... and
twntd inlo IIIn:.ded nscru.
To 10)' nu. 'h" II""'" for ,bc fi..., th"".dtd insorn ... I
dwaptd """,e .... ppot"t>l.o . bc ,.bl~""w ( .flc, """,",,'illl!
.. a~""lon " lnJ!.. of COUNC:). n.cn I "'" .bc tablctop in
,.. ... d ohlnu"ed 1':lS nco;,CSSi>1')' '" li"", k 1I":lnd lK"IrIjI
I flIIIh wlth ,he """" ,ahi" U.... OI~lJlhtnlR<' 10 dtc<:k
. . flt pmcU tltroll~h ,h .. appropriale
an<! .... rIt
fOI&<I'

hol"".

.tb<~ .ndlnl! .

l ',"taU the th....,"d.:<1 Inscm. o'Ioc .11 thrcodc:d

""""..., .like, oo chk '" dMe,mi"", tbc "",ulm.! sI ror
.. piIoI hoIc:. 1Iorc tlle r>ik .. bolal . ..,b'll driIl or pI"'W

driv" ,he In"" I>. II.., boiI (of tbc appropri;ole

* ) 1I11h ''''0 mtlS IOl1lmtd 100001h on l' as 001.
li)

ThI""l;2d 'hc illSC1't on,n 'hc hol . 'Igh' "I' .0 .lte n",~. Gel
.hc ill>Cn ",.ncd In,o Ih" woocl ncJ IlIm tlte bolt with.

...n::nch. Th~ hanl ~n ls k.,.,.,inll tbc hoIl [l('rpendic"l.r

", .bc ..Ufkpico;,e. Wlw;:n .bc I"""n b ful1f In.u lk<J . "..,
."'" ... ...".,.,110; tu un~ 'Il" n .. " , .nd IUm ,h" boII oll! of
.bc In..,n
II
4. Moun. ti", Ulblttop o n the ,,"w. Se. ,lte tobk:top
UJIfIOf't . 11bC1't tII.. bol .. IUMJ IljIh'''''
1hnn. I>bU .......... hc t:lhlctop ;' flu>h " 'Ith tlle!Q'" ,~t>lc
Ndt: an thc

''''''.-.rY

s.

Cut o u, li.. n '''<lntlol/. ,,1:..... " f"' n Jn lf,- W],h III<'

I:I"'OP In pIIer. ,t"o In ras}" man"" to ~"'UI 'ht: openl.... for
tbc """ont~ pbl~. from "'hk:h .bc ...... ' .. r honll'. R;t'h
. hln n::pc:u _hRl' o ~ . 5pd1ed OUl
hy 'k:uJled
.... p on paIIf 168. I .........,,""'''''' )'QIJ o"m 10 tha. d ."p... r,
UnI\'ct'>oOI ~ .. r Mounll''8 1'1:.01.. n.c .... )'QIJ1J ""'m bow
10 11LOkc.ht: plai" md It"" oht: .......
h. A",t "",iU tt
"""" j"OU CIO LIS(: k o" /(Ui<k 'ht: nI"iatt nI.1Ie """er pun

"'' 1'

"".0

i n 'hc 12I:tIdop.

.... ltln" a small bolt throtlgh a la .g e hole pro

vldes .. musu,e of ~Ju.u.bihlV. II is p,euy dimCul!
~t tha th.udld
9O.lllo"ed
th~ tabletop
edg, wlTh absolute precl.lo". So the adjuSlablhry
f"cto' .1I0w. )'Ou 10 mo"e Ih, tablttop .lIghtly 10
.lIg" It pe.flctly wlth tlle ."w t.blt,

1",1",

1"

,..,..,,1"\ ......

10

11'5 noI p lly, bUl II il o.derly. Tht

dl!. w!ra in Ihe wllY. Th,y'd jllm IIglll",1 Ihe bollom
of Ihe Ilbltlop. IImlllng II>! dtplll of <ul ""d_
Vi!nung ma f,om j ..., hfung Ihe roule' and piile OUl fii
1.... !.IhttlOp. So I ... mOVl!d Ihem. The power tOfd cIw>gle<! OII the floo. Ind mlde k hlro 10 'WHP up. Sa I
rolled II 1"'0 il coli iIIId tied It. To lift 'I>! I'0<Il" OUl 01
Ihe !.Ible, I unpluv 11. TI>! Slrlp m~nel holll! Iht c...
wrel\Ch oUl of ,he wilY bUl close III hind.

Making and Installing

the Rip Fence Facing
Though ,his rip """"" bdng 10 hillcd "" C>fl'ional.l ..."OUIdo1
do "ithout I. As;1 IIM lumnI ..... 1 """ Ihb ruutcT
101. And m., WIk "' .... rlp ,."",., 10 a mi pI ... I """ ~ ..
poMtion qulcIdy ......, ....I!h """ t...nd
Uf<l lip . .
tIM: kDtt ",ouleln', 1><" qulc "" ..... toI ..ilhaut , .... Iwa

'"'*.

.-...
~

.
~

."
w

CI

oc"""'.....

>iCction """'"

C.UI. _
. su"lng 10 s uppOr'! the uobl.nop
wt" le \'OU ml,k tht Instrt 10Ullon A plec' of p/y.
,"'ood ellmped 10 IIM! unde"ido! of IIM! 'IW\ fenn
'l'" .upt)Oflld my ubietOl' just aboul nu.h wlth tht
SlW Ilbl . A tOUP'- pal .. of bulldm shim. W~ "II 1
nHdflI lo .. lst IIM! Ilbletop Inlo parleel po.ltlon .

6. ~r\u; )'o ur routu Ulbl<o, l.InIiko: m.,.,.,.,...

~ I\00I,,,, 'ru*: "" I"'W" 212. thb """ lu:5 no.,.,....
J'lIl"_ ut dro,"~
bila :ond QI\lI:'r ~ g.uIf. AIIer
~ IN ul*a ..".......,.I~ IN ....... _
conoumlnJI p:ort 01 >dUP ..."" Ilndi"ll IIM: . .ns .... ~h. Sa
I sc,....'n! ohon "rip ""'lI"C' 10 11\1: bOIIO"" oidc: 01 'IM:
Wlk, ..... lOr ,IM: """'ndI.
I .ba """'d my>clf NMIn,: "" ",,'cn>lon con! "'~
Iim<: I .....",nI 'u "'"" ,IM: ...... 'e. "'hoit: , So I 5prm, fu< 'IM:
~ dtttri<'al supJ1'l"" 10 011111, 11\1: uhk .... lth a
....~Ichnl out ..... '"" """"n In IIM: ""cllmpan)'I"lI ~IU"',
' I'rno'c. ", 'IM: 1l<1I.1Ier n,hoIt:' 00 po"" 190. I lIIOWl,nI ,1\1:
" " " ori ,IM: untkni<k of ,1\1: u"'" "'..... and 1 bundkd ,hc
cabIc ..ilh ,IM: l~bIc !IO .....~
c"nI "" ,IM: nun,1>c:r o(
ohk:i on;a.kln,:w.:fUOO Ihc ~""(",,e sh" " t100r b m l"In>I~.

ro.

p<'''''''

1 86

ROUla' Mlgk

fadng.

1 . Cui thc partii. lbc: ""k il .simp!c """"'" lhII ""

aii .1\1: pati> ~I oIf tIM: NI. Jol'" .nIl tllitUno
thI: lumbct, Ihrn Tip aud croMCUI IIM: paru 10 IIM: _
.sioN ....(ir>td by ,II<" Cuttiflg Ust
1 llSnI popIat for thI: """'" patul y.... eould .,., ""
""nho.'OOd. bu< In n:troo.pccl. 1 1II1nk p/y'JI-'OOd " .....Id Il\'.
...,.,. ~ ehoicr. Whi!c III<" Icndcncy miJ!.h1 IM: lu 111<.
(2JS ......

",U,,}' material, )'OU <Iu lItt\I

'o "'" ""'bie, .. r.lgllI"*,""",

..od:.., ih>, thI:,."",.,.uy.; " ... jdlI aud 1"'"

2. Cui thc Jolncry. Y"" roukl eu, ,hc tongunOIII
1""1 join il.., fn>eo:: bo~ an ti.., rouler l.bIt. b,"f
COUI"X you don 'l
onc.'bu m .. <Iu Ihc joi} wilh . ~
IM:Iel touter. bu< (..... Idt. I,.s C'aSil::r 10 do it an tII<" .. bk ...
Cui thI: gro<l"'" fll'>1. Sel II.., I~:uk Iw.ijchl , . nd pooii:II
Iitc frnce ~.'nd! rrom Ihc hbdc . .\.I.kc. fi ... p..sort exil
of tI><: (our grooo....". Itcp<ltlon 'he rip
ontl mal:< ,
" . 0.><1 pa..", un och gro<l'''', If nn."t':S>Otry, nlltl<c > Ihinl pol
10 COIIlplc1C IIM: gtUO'"C!i
car> bc lUnned in mueh thc """'" fa<lIiol
Dun 'l eh"""" "'C !>I.d<: hci{dll scnlnJ!. Ilt'pooilloo
hown In Ihc d"''''nl/.. 10 "..~c Ihe >huoMIr
cad> I'ittc. Then m......... 'hc fcntt doIct.
thc bbtk. """ . tim t>ff ,tic ttroaining :;Il,.... of wa"c.
gtUO'''''

Ilo,..,

k,...,....

"'e '''''li''''"

"'ne<'....
(..,,-/ou. ""

tht.

1I ~

FEHCE FACING EXPLODED V I[W

RIP FENCE FACINe

Cutting lis.
p. n

Thrud~d InS~rl )

...
.
_

~,

Qty.

,
,
,

From/lla,k

...

/~

Oim ensio n s

Mate ri al

Ito"X4"X27"

Ha,dwood

M" X2M" X 21"

liardwood

Ito" x lY.."

Hardwood

X~"

Hardware

le

Plaslic Iamin_te. S" x 28'

8 ovalhead wood screws. /116 x M' Ilor .nd cap,)
4 thruded In,en,.

....

'

heM head bolt .

~ 20

~ 20

X 2Y.."

_ _ From

Bonom
5AWlNG ff:NCl JO IN ERY

CUITlNC THE CROOVES

Rlp '.nce 'adng

L..
Front/back

."

""

."
,

1. Sl'tth.

blad~ height. Pa,1tlon

the Itnet. n shown. Makt ~
fim pu. On ueh !jroove.

I
2. MoV<! the lenee the thickne 01
Ihe blade 10 Ihe right. Make_
.eeond pas. un eaeh g'oove. II
the groove li not 1"'1 w1<l ""ogh.
move the lenee il ,eeond tlme and
make addiUonal paue,.

~
iD

3. The complete<!, proptrly

dlmensloned groove .

...D1

CUTTINC THE TONCUES

Rlp lenee
fadng

'''' '1-.
bon'e-

."

"'1

th~ same bl~de h~lght. Sut

reposUion the lenee lor Iht
,houlde, eUl. a hown. Makt
1W0 p~ .... on ch . dg" 'o
dtfint ai i 100' tongues_

1. Kup

tD

Rlp lence
faclng
Topi
bonom

- f-- 'I

."

\.10":-

2. Move the lene. clo.e, 10 Ihe

blade 10 Irlm olf the ~m.lnlng
waSlt .

3. The eompleled, pmpedy

dlmensioned longoe.

Table Saw EMtenslon Route' Table

187

lUP FENCE fAC ING

,,- - - - - ---1

fRONTVlEW ~

ENO VlEW

r---- Il'h"

,.

~
3'h"

' L..!
I'h"

I !iti" di .

L..

,.-

$EcnON VIEW

1>-1

BonOM VlEW

ll1t",ad.;)

lY

",~ ~nd caps "'" ... bbc.ed 0<1 . 11 !'our nlgQ. Whik 1I, i)
"'"Ould >lI"in tic RfJOd '''tJl~f .able "petallon. il C<ln fo, Ilib
prtlj1 bc .... bl~ SI'" proccdu.." s", .he bI.dc: hcigl" 10 j.l.

ind,. ond po;;.ion .II~ fcnc~ Y. ind! (ro'" .Ile bbdc:. s .. nt1
III~ cap On end. U.~k 1. up wi. h a go<>tkI~ """'p. n<!
p",,11 i, .h""'&h II'" bbdc: wlLli .k """'p. Rcpca he
proo....".,; to cu 1", ~ olaU.1le ... bbcts 0<1 botll ca[>$<
'fu .... ke .Ile IDouIde:. n",. I(no,'cr.he bWk: ..... "'po;st.
,ion .hc fcncc.~bkc II", ~.... '" with
col' ilaI O<I.hc
"'w, f'-"<:<ling 'hc WOfkpiccc wi.h push Slkk. To ..'Oi<!
1I:"ing .1Ie "" t, kkk back the tl;o,dikc "':lS'c ~,tiPi. po,;i.ion
.he (cnce !iO .ru" .Il(: .......<Stc wil! rau .0 dt~ kfl of tM hbdc:.
Thl. "'''"''''' )\MI M'''' ,11.0 e:<lrA M~p of "'J'OS.ioning ,he
fmcc ofter
CUts 0<1 boIh col"'.

,t..,

.-...

,.bIt

"'.kin.tl.\\!"

3. Cu.the bit opcnffi.ll. Thls il! fonncd by cuning an

arc In dte bonom boan!. and > ,,,,,,e:ued uimgk: in dte
OI f""" . tll ,h., ."'" pom .ugcthcr.o "'y Ou, dte cu . U"" a
saOC' !law,u nulte 'hc n u"".

~
~

."
CI

27~

80",. I >lHnch-dWnCl"" hoIc In ,he c ... ntcr of one ""1'

TItIs is Ihe """,ning fOO" 'he $hop , .. c ho. !':Is,... n
Cip
ov.:r noe cnd 01.1>c "'nec. Cho<N: dtc cnd dt .. ,uilO )'011.
F",.en .hc ooIld cop "'.." Ihe OIhcr cnd. 1t Is bcs. nOI '0]1) ...
thc cot>' in place. In ...,..,. 1hc con! 01 tM honcc <an W'
impaCtCd \\;dt chit>'.
,,'hen a """" va<: !s 1iI"'''in3
dtrough ~.~ ""',.., )'IlUt"'Clf II.;" ckan-<JtI. "",Ion . U.., S<'f<"\\'
'U.>CCtlR-' tl", ca",.

,Iu,

el"'"

7 . !'repare .he roUler tence tor OlO""'ing. o..

ruf I:IbIc -"'w. dte rip kncc """ four r.inciHJi.mcter ~
In It. OOIcnslblr for Ins<alUng foclng. It !s. si"'ple """,,'r
' 0 inst:lll 'hl'C:3dcd irlS<'rtS in thc baek of thc rou,~r~.
. hen In",," hoIts dtroush 1"" rip f~ne,,'. hol"" and inlo Ihr
ro'" CI" knce.
JIul
TItc f:bunc. hNtb ... ill protrudc: 00
.h~ ~ oppo;;,e 'he roul~r knc.... TItus,lo hol,., Ilie ""',..
fenec """""ncn,1y a"xtted 10 Ilie tip fcncc's r!ghl skle.)'OU
nttd .00 10 Iu,.., bcing u ched '0 ,he ldi ,"de:. "T"I'II,

'he"'" Iti."",

W:OY.)\MI con ruun,,,,,,,lnlt Of ~'OUn .... rbo", .I>c fosten". hc-a<b

4.

Aso;cmbk tii<: fcnce box. TItis i p"'''y ~imple

m.ner. j\.pply ghl(: '" ,ho: ,ong""" a,..1 gro",..,., and fit thc
pons '''S<''her.
up an)' ld"" "<IlIzcout promp1ly.
Cheek .hc """"",bl)' wi.h 51, ....'" 0$ 1"" 'pply dtc ctamps.
'0 ""5U", ,10... hc 00 .. ;" sq"","". ( Don't In".11 Ihe cnd caps
untll ofte he pl2>lk;" .pplk<J.)

Wi""

"I"".e. ,,'"

S. Apply ,h" pla.o;llc 1.:..

pUI'J'OS"
of 'he plastic tamilUlc b 'o m:tl;c thc fi>tt >l1dt. dt .... ntaking it
c:lSiC1" to ftt<l ,,'Of1t along 'OC kncc. It onty nc:Ws 10 bc
..
_
..
.
pplled.o.1le (ace. [fu ,"mplc job.
1
Cut 'Ile lami ... ,,, abou< 1 Indllong.oo , ineh widc:r.han
Il'" r... ncc I'x". Apply contact ccmcn' .0 bnth . he bmilU,c
..... tM ren.:., r..cc. MIow.1le <;C1IICfI' .u tlry. Afler It is dricd.
~pply 'Ile Wttin;,o,~
!he ~ ..... bumi>l' It dot>'fl ""'II .}
roIkr. Widt nu;h--tr\mn,inp. bit In > <OUlc:r.lrim thc r:dlItC$ 01
tlll." 1:unln>1~ . Ik """' .., nm ,1Ie ,rimmc:r in", tM bil openlng.

'u

6. (optional) InstaU tI>t:: end caps. trutolJ .hcsc if)"oo

I'Lln 10 """ tM fl"lK'C core 0$ d,annd lOr (1,-", roIk<tIon.

188

ROUI." M ~g lc

Into dtc f.tcing.

So whcn 1 m.de: .1Ie r'O,UCI" kncc. [ aJso nude: tip

(acin!!, For ,..M, it"s "'l>nh. 'l> tttake tM faclng, 1 gI ....
"'",i .... ,cd lWO pice"", of I-l-!nch blrch plytt."OOd. lhen
.pplled plostic "'",in"e ' 0 Of>(: $kIe. (Sincc 'Ile pl}""'ood iii
\, In~h scan, of 1-> Inch 'hld: . 'he pla.>lk: bmln'lc l>rinto
tM facIng .ltl<:l:mss 'o cxactJy 1 lrtdL A!; Iong a.! I remcmoo
10 """''''' ..... IC b)' IMt 1 ineh.l <an usc 'he rule e.ehed int~
.1Ie tip (ence .... b.o SCI thc fcncc.)
'fu ",.",fe, .k hole Ioat. io", from tl", tip fcncc .0 .hr
foclng.OO."., rouler fena:,c"'mp.1le pom-noe "'"
of COUI"SC-'O 'Ile rip fi:ncc. '!l>cn in;o:" a hol' .h""'&h thc
hIl.[c ..... "'1' i, ... i,h , ham""' .., dcnllng .1Ie W\>otl. "1 Ihr
de:nt.<, dtil! tM appropriatcly ";led hok. O,;" C thc . h .... dcd
ln ....ru. Coumc.oo", Ilie ril' facIn.!!.
fcn~c

"m(.

8. l""lal1 thc rouler fentt. TIti... ,all!Cly" .... ,""

of dnvlng dte bolt> ,M. h<>1d 'Ile pom ,000000~t. Hu' thc
f.tt:e of .he rou'''r fi:ncc . ht>o.Jld hc "'1"""" .0 .hc rou.er I:IN<
'op, AfIc. OOhlng thc fencc in pbce,dtcck wi,h. sq .... '"

II ,IIe: kncc b

0UI""'~....,.., . 1ooKn

,IIe: kntt Ind In.cn

..... bct...ttQ "'" tip Ii:tltt ond tho::......,. ~ ~

...... how far OUI,IIe: Ii:tltt b,~""'" bycDol~ tip"
.arni'" ,IIe: mlsalignmmt. RCligII,C1\ ,"" bolt> and nrlIrdr;

.......

1, " I ~ PfO""""IM "',,:., ""'''''' 1<> ,"" tlbktop.

~~,

il .... <iI J'OU Iu."

'"'" rrna io lwxIy bcaux 1... ri8h'

10 I>ddk w\tII. An<! " """,,', ohlft .... <il posirioll. cithc:r

Thc ~ 01 uoInJ! u.. "",w'f rmc., crop< lip

" 'hen )'OU ....., ....itching baei< and mh hcI-..'tt!I u.. """el"
tabk and u.. oabI< _ ,

Makinf!:

lJsIAA ,hhi nllUr, uoblr IMn a wholr 101 diffc",m Ihan IIMnS
"yOlhc',

Ikn~ <il ,"" 1oc:I.k>n of "'" """eI" and .1.. oricn",

tlon <il "'" "'...... rena, J'OU mosi freqll.,mly Ipproad11M
lOW:f l<Ibk: from ... ho, is Ihe "",,'s rigIIl reu romcr 1lIe
_ 'irqt FH.IlJirrd ..... o....co 'hb ckat. v""........ 'o ~ttp
.... :un.round ,1Ie ....,'. fiPl. md ckat MI J'OU an """'"
uound and manc:u>..". I ...'Od;piotte.

il good aampk. To nuIIc 1Ut1'O-..'

W3.D' 10 mut ,IIe: profIic Olt

"ido hoard. ,hcn

rtp 1"" sdck rrom tho:: b<>lrd.
rolll ,1Ie proflk an ,1Ie ,..'"
"""'. tlICn np i. from "'" bo<ud, To do 'hls. }'O\llu." '0 kccp
.hll'll"8 llIc rn.cc back ~nd t<lnh . LcI o .. leU)'OO fron, O"perknce.I' Udm-c J'OU 011111.
In th<:>Ic ~ 11'10 btIlff 10 ~ SC"V"t.."
""'--c for the mutel" labIc. 00 )'OU ~....,
mu.er
WJk ....cup "1Uk u5in/I IIM: rip Ii:nct" ro.. IIM: ..... OJICI"'ltlooS.
In odltt ~ wd1 .. ~ biu. IIeIlirqt bit
~ and ronuoIIing Ihr ......... P>'<'. do wilh ..., n)UleI"
WJk .. )'OU ...'OUId "ith :ati)' othcr !OUIeI" uIX
mokJi"ll".)'OU

Using the Router Table

,,,,-,,,, "" .IIe: .....

' 'ou DO oIidc" it U>Io .,.,...ion quickly and....c il. 1'010 dam ...

t"""

1"">'<' ' ' .""

FUO Oi llECTION
ROl/it. toble fff<! dlre<:lion

When u~ln'il Ihe t~ble nw's nI>

lenee 10 'illlide a 'Olll!' cut,
!M Iff<! direction Is uatllv oppo.ite
.hol fo r a nw CUI. So Ihe OPt,mal
Post 10< a <OUle' woodworh, is
f.cing Ilie righ. eM of Ilie w w.

,.
1;)

Tlble

$lIw

C
fi

.,"

fHd direction

-....
fi

Wnh IIM splil 'enet P<>1t1iont<l

0lIl1>0;0,01 of the blt. !M Iff<!
dlreellotl mlm"i lho\ of a uw

(ul, SUnd In f,onl 01 Ihe Siw

and push Ilie wo,k, jU.I., In
m.lkln'il ~ s~w t\ll .

Whe<t IIslng bit'. piIoIlo \llIlCIe

a Cllt. you' wo<klng post 1. mo,,"
flulble . Tht feed d,reetlotl
"rotltes" clc<kwlse .round
Ihe bll.

A Iong IIr.1lghltdge can be

aCn;lU IIM SlW table 10

d.m~

'ilUldt a CUI In VI uptd.'"" Ion\l

O< wldt wo<kpl~e . Thl.
.pp,o.oth p'oYldu Ihe bel!
suppat! 10' the Wil,kpl~e,
Posltion the len" "behlnd"" Ihe
blt . nd Id lrom Ihe saw',
,i'ilhl 10 Its leit,
T.blt

s..w [xttnilon Raul" Table

189

Power to the Router Table

II you a'e le,loUI .I>out mUI~' tabl. "'o"', you
nud. UIUP tllatlncorporale> a S"'rlcheel rtptacl .
TII. adVllntagei are several. PosluOll Ilie oUllel
nt~1 to Ilie mutt" mal"ng il conven'tnt to unplug
",lItn cllang,ng b'tI. me ma,n reUon woodworktls
fa,l lo lal<t 1111$ simple ~fety Slto 's Illai ,t's IMO"Vt
"lent.) You Ciln poslllon.n on'Off ~wolell ",,,",re 11'1
U~Y 10 flnd mls .. tsptC'ally appullng "'Mn you
nHd 10 ~1I111Ie ,Oule, fim_) Vou un .dd an OUIIet for
sometl!l"g IIM a dUSI colleccor OI a shop vacuum.
maltlng Il S",llcll..;on\rolltd: Whtn Ilie , OUler IJOH OII.
.0 does Ihe dU~1 collector_
",orks "you. raul...
hu Ilie soft-start- fUlule, or II bolh roul..-.nd duSI
COIlIOI ar. rdluvely lo"'ampe~ . IlIrIIW1l 111911.
.mpt!f1ot mOlor.-ny,' 14.mp roul.... nd. 12-.mo
duSI co!leclor--klcltlng OII .tlhe ~.lnSlallt CilII
O'IIttload a 20-~mp t l.tU'I, Iflpping 1"" ~ak"-.I
To sl,n, otl som. elect'''''1 suool,.s, W'II! Ilie
wlung d,,,g m, 111.... '1 I 1111 of 1"" sluff I us-td_
E>tery1h,ng skould bt .v"lIble at you' loca' bu,ld'ng
supplo.. empOnum-... 'lh Ilie U<tOIOOll of 1"" Ihrough
box, wltoch \'OU un get II .n elecu",,1 suppiy hou5t_
llegl" tov lltacll'''11 the receptaele box 10 the
'ou le. "bl., In.I,lIlh. oIug OII OII. entl of Ilie .pp!i-

rn".

.""te"

ance cab"'. and ,,, n !he OI"". Ind ;"10 1""

box, w"e Ilie s.... "e/\ follcno,ngille w!t]"9 d~"m,
.nd illstall tIM! sW"eh ol~ ... UhWlIe. Wtfe ~ receptoti! a"d Inslall!he 'tptiK'" plale.
Plug ..... rycll'''9 III. Ind you .... 'udy 10 IlO

Hardware
th'ougll rec,ptael. box
I conntC'or
I slngle-pole SWltell
1 "ulil)- s"'itell pLate
I duplt .. rec'ptiKle
I

ul~ity

receptael, plate

l' Romu

tab~.

12n ""th grouncl

I g'ouncl,"9 clip or Krew

I etimo 'ing (for ground

cond\ICt~)

IIr 10 20' eO<"d, 1612 IVpe SJ

,".,

WIRIHG DlAGRAM
(onnKl b,J,e (ground)

conduclor 10 1iI,.. n
(groundlngl KreW,

Black (hoO conductor f.om

swlltll 10 .t<~ptade

' ...--1, 81aek (1101)

COndUClO'
f,om Ineom,ng
power table.

COIInecl blKk (hot)

Con!lU(l .... from s",ilcll 10
b,~ss..;oIorHi ' .. m' .... ls.

I 90

louler MagIC

I"comlng paw" (Un cable)

Horizontal
Router Tab
Turn the traditlon .. 1 rOUle r table on
its ur. Un II 10 CUI le"OnS, rilise
panels , and edge'1lroo'tl" bouds.

lltU~ i. li" 1"'~roIloljI _ _ ~'inf.

turn on tII<' 0101 horbofllal """CI' uble lda.
MoumllQl ......ner,;o Ihc bol'~ oxio i> ~I , ... "
o.wI: ,;urf;oo:c b II'" ~ &nul' ,...,. n"y op<'t3llon ,""
~ ..... "" un./i,W'l' IUIIla I:oIbk. ..."OUkl rcquirc JOII
10 bob...,.. 1/1(' """""pIctt OII ~ ,

hh

_ CUIlIng ' '''''''''

. CunI!A wi<k nlll>cu
. ~1"", Ilie cdi!:tc> oI .. ~ , fb, lIo:.lclNf
p;llIds wtth ''allal bll
RoulilIII oudlilNr,I. ~ ,,'1\11 tlll fa..
moIIInA bit<
- Cul'DA <IovnaiI 1'1....
doYnalb

.Ibisi""

for..u.nn.

11K "",riuont.I.......,nolO\Jl k1c. Isn ', p."k .. l.tly new,

01 reuD<: ROIII'" "'apelan.
I><'cn Olbbllnlllhcn, up
lor ro"". II ... wh.cn Phil Gchrc. and Roh YDlkt, IW" of

Iu,-.,

. , ..-ood ..l>t1I.inl collclalln, flDl nlOlImN " roU1~ r On

dIr ornd of" table ....... Ihc ~ .. c",l ,"el iot) w,,-, C",HJJI
Irbal Q ~_ . , Id_
I'\g:)~" ~t:I.I 1'OUtC'l'

""'''1' OII .he labk""w

"""'"fl<K'I' In Ihc ""'P.T1It roule. b ....... "100 II Ihc Iert

<ftd o( tM WIk _ lliuaIlr. )'OU koxp Ihc: ,,"'" ."",mI tlul
cad dnr 50 )'OU c= CtO!iSCUt .. boo.n.1 ,h .. ~ ~ r .11,,,, 2
Ion. Kcq)ing th:I.l am cint ....,.,.. !t ', lkad sp;>cc. l h l'

"

,Iw _

" au. It
""
it> _ 'n noo..!pXC; It". wri"llllK I..bk oaw'.

n.- ~'C. 11K

,wjllll an" pi"'lU UI' whc:n )'QU w;>nt ,o

r.llK p.tnd OI" CUI
but tlro"" "',,"'L'rlkn tlr ou. of
'he wzy ... hen Il Lv", In ll>C U. """"""'" ~'I Im[>ing<'
.,.,.,.00 woodwori<l"fI opcntiON.
Tbc $Ctup ukes jIOOd od\':lJ1t2.jlt: of tlle s:t w '~ nw;.,;. and
Il mak!Ii ""alkn, ...., of ,t.." ...... .~
tahk,OfI ,o..
<Ion ', """,d a " llIhpowCK<J muter for 1. ; It ', on<: >c1up ,n

a,,,n.,.,

i>ro;od."".

:o
O
c

.,.

...-~

any mu.t. ",m won: (w hid. 1. ~mp lu'icall)' NOT

"'8ul~. ,,,,,,,, , hk~). As doIgne<J. trus horil.Ollw I'D
rou'~r moun,l"fI ",'cn.".",,,,. a fun<bmen':oJ short(()rTtn$ of Ion

....I<:h

."'" of

"""" 1\ori1.<""al mo"miltJi': fine adlu:;une",.

TIte doollin 1. clca"",,ut A plf"'uod .uppon 1"'",,1 1.
au..,h <'Il .0 ,t.." rin. of ,lte ..",'1 a,en""", winll. and it"lI
~rKhOt'C d
. ltc ,",'" ho,.,;inll ~ It 1, pnfn."tly pcrpcndicul. , to ,he .. .., I~bl~ lloht:>tl '" ,he """""" I"'nd 1." ,hlck
..... Inll ~rm . whkh hokb 'he ""u' er. As 1.. ... me Implic>
Ihl, un' , ... In!!, "n " bolt. ral~"SI and krto'Crinll thc: toUtc'
a"" hit , l'Inc . dlu,'n,,,n'3 tu Ihe eul""g <kpt h .'" madc
tltroltllh ~ I~"bcn."w. whkh can """'C tiu. owl"Sl .rm
. Imus' Inllnl ,,,.l n.. l 'moun.s. You .djutt 'he hot lK:ight
cmro<ly. hy """SUfinll 'he hl1 poMllon ...' )'OU """.., ,he
am, wlth )'ti'" h.nd l ""'n )'OU """.., tIM: " ck~' lIIidc
" lPln .. . lte
Turnlnll thc jock~' m<I\..,. 'hc a ..... In

.<,

.I'n\.

'"

HORllOHTAl ROUTEIt TABU EXl"LODED V1EW

$wing ;r"m b.ise ply

000
000

o o o

o o

Pbsllc knobs

.......q ..
Swln!iJ i,m lop

Slidt bonom

pI~

Slicle lop

~,

--Cunlng Ust
Pout

..- r

Qty. Dlmenslons

~~_g a,m ba,~

OI

-."

Y,," x 18Y,," x 2r B",h ptywooel

ply

2 plfKtS plUIi(: Jimlnalt. ueh 20' x 28"

t jacksc.tw. *"16; IAj55oo from Rtld TooI
Sl/ppIy Co. (8OQ.2Sl0421J

1 V, x 18y"" x 27'

SypPQrI

1 V," x zr X ny,'

SPiCe'

IWx2Wx27'

Hi'dwood

Shdt lop

I~'X 1~'X4W

HUd~

y,"X IWX IV,"

H",rdw~

3 fiI/Ied pI",stlc knobs ... ilh h'16 X 1Y,," slui

Sluds; '01(-6 from Reld Toot Supply Co.

{! r
OI

Muerl .. 1

Swlng i,m 10p ply

. ti
~

Ha rdware

Sildt bonom
Shlf

BI~h

plvwood

BI~h plywood

1 ...r~ x11"x2 ' Y.

such Ilnr V.<hlk>ns II.., )'<'U h. ,.., 10

pncd~c

n,,!~tC

Ihe eul 'o

8 Tnul$, JoIo"16
ht~hud

bolu wlth wuht.s. *"16 X Z"

1 flultd plulle knob wilh y."ZO Ihrudtd

Inun: ,01(59 from Rtld Tool Supply Co.
1 c",rrlagt boII. Yo" X 2'
2 caHlagt bo115. h" X 111'

IM diffcl'On .

Eq...1Iy ""poft.m.l"" rig an "" ronMructru .00 boIl~

10 al"","" .nr ""'-""din, l2bIc _ In malle. u( bou...
T11c o<<:Mk 1tanJW2n: I,,'.n, ...., ,.. do6/: as )'UUr 'ck phonc

6 drywi ll

scr~W$.

2" long

2 ht~ nUIS, h"

arid "",1110"

Thluctup li "'" ..,h&lilule tOr,.. muIe. l.bIe ItalhcT II',

,.. romplcmc:r.. '0 1"" mute,. uble. In Ilact, 1',.., IlOl ,.. mula

ntth,-

h""fl unda ,""

e,,,mMon winj] u( my ubl<: ""w
(,."., 1"" photo on f"lIII' 18}). I """ ,"" !"OUl'" ,able ..,IIm...a,- lkM '..-.:wf<~ 1I\.>OCU'-a:abitiIY" \1 key M In nry
<kd$ioft ,~ li 1 hzvI: 10 ~
on cdfIi': 10
nuchw II OII 1"" mula 'able. 111 _bch ' Ol ,"" hotizonlal
.nup ... 1can by II rbt.

WQI\o:.,.,.,.,

192

ROUlt.!Qg1C

Building the Horizontal

Router Table
Wi, h a bI' u( catt:fu1 b)'<'UI won:, thi:; ris wiU <"OnI<
l<J8I"1hcT n>lly. Ikbte )"Ou Slan. nl>ke sun: )'OI' h.:...., .lI 01
Ihe malcriab spccificd by Ihc Culling U51. cspccially Ihc

IIO'UlONTAL ROUTER TABLE PLAN VIEWS

""~

ENDVIEW

fRONTVIEW

Suppon shelf

'---t-:~

Suppon .,anei

--1-7

Suppon
shelf

Suppon .,anei

'--bolt

"NG ARMLAYOUT

Pivot hole
pli ~ s. and apply
the pl~Sl lc I~mlnate. Then
lay out three key elements
on the ~wl n9 arm blank:
I BV," , . The pivot hole Iocation
2. The angled bonom ~ge
3. The end line for the
curved ~Iot

g, Glue up the

A. With route, and

Irlmmtl baseplate,
make an opening tlle
sin of your route'"
base In Ihe thkker ply
of th swlng a,m.
Posltlon fi a. shown.
19W

1W rad. -

""""

-..! End of curved slot

r--:::------:,:;:------;:---<

l W rad./

I g" rad , ~_ _

C. With router and

trammel, roul the
curved slot and Ilie
arm's curvO!'(! fronl
edge . Cut Ilie afm's
angled bonom edge.

Horlzon lal Rouler Table

193

h;mj".. rc.AI I~I O<>e of Ihe h~rd".. ,-c,

;ICms, Ilie ~bc""".

unllkely 10 flnd In yuur 1<.><:11 h.rd ..... n: ~Oft ()nkr
Ihc oddl>;oll 1"" fronl Ih" =oru"",n<lc<l "",,,,,, nd " 'I",n
)"01,11;0,,, "'"CI"},hlng In h:lnd. ~ 10 won..

)"QU ~n:

Building the Swing Arm

Sean by bulldin", II>c swlng Uni Doing Il nI">! IIJ.1ko II "':d~
bIe for U5C in b)ing oul and building II>c JUpport >.!KmbIy

1. Culllle 1"'0 layen 10 slu. 1"0 m:lkc lloc:wm a.'

.ciff:as ""","bie. yuu lOnn II from 1_ bycn of bOn:h pirwood. On<: is '1 Ind!.. .1\0; OIhcr \, indI. CUI.hc nO'\> ~
1<.> .hc dl""""""",, .pa.irocd by .hc Cultinl! u...

I""'e o .. e. Ihc: ''''inll .m. You 11"1 001)" onc c ...""" ., ,!ID_
llIc."",, wrf:oC'f$ Sllck IIghI OCK."C".1Ie)'
confllC1 'IfbnI
\1.., Ioml"".c is oJown . hu,nisll 'hc: ...rbtt .iJlDRlU>lT orid!
a J-tOIIc.
Rcpn. Ihr procrM 00 lhc ~.. 5Idc
Trim 'hc lamllUlc Ouoh ... ilh Ihc eti!P o( Ihc bbIIiI
...."". n>lMe' and n...tHrlnlmlnjj hI. Th opcn up lhc ..,.,.,.

..,.1:"

fOr II", r"O\ltef. dtW a hoIc 'hn>llIIh lhc bmInal" omn......

In 'hc mWlc o( Ihr ..,...".. ~ Ihc """............. Ihc 1K>Ic. .......
Ihc

",,",ndi,. 'hruugh It. s...leh

OII lhc rouon - ' kt-d

lhc pr:rim<1a of lhc m:uo-, IIrIIH """ hc.:orin& C2ICftro
lhc ~.lbcn "'"' fOUl:uuund Ihr Inncr niF oI"!hc "'"""
hII

t~

5. Jtou, Ilie adJU'!iID>ClI1 slot. lllis b :.n<.>Ihcf """(ro

2. R(KlI Iloc opc:ning rOf" tht I"QUlcr. 10 II.., wmplctcd ami. thc routn SCl:i inw ~ ......tncIMIttp trCO& and ..
bo!lcd 10 Ibr rnnaining nwcrW oflbr arm. 1lx C21lIoI"'"3)"
"",".t .. II>c ""'OI> > 10 cut oomplclcl}" ~ Ihc llUekn
pty.ono<l lzy<:T """'" """
si_ 'Q8Clhcf
Si""" I _
" I'onn-C>bIc 690 rouIn. " 'hlch ~ "
round t.oooc.. CUlliojI lloc opm~ "'""" " simple .... lIn 01
rouling trith a I"OUlcr and IhcT~ Ha>cpbl" OII .... ""
}Il La)" <ItI1 Ihc .,nUl pai ... frum thc d .....q
Su1ng ... .....
WyoUI. and driII pilot hoIc fOr !hc ,,,,,,,meI"s pi .... Ta
kp Ihc ..._ " disk fTOcn s/tiIiflll ">li Ihc !OUlcr j)" I)md:,
l"""-wh Ihc: ....orl<piett. usc 0l1J'CI .. pc '" bon<I Ihc: ."'" 10
bot..-cd.o " ...." baclr.up.
If)..... ....,. routn ...ith albI cd!Ic. .... cc Ihc b:ttc 00 Ihc:

'o

1_ b:J""" _

.....,t<pioctt.lbcn cbmp'

~'cdp:.o

Jtuidt lhc fUUIln as }OU rouo Ihc

lhc ""Ull:piL=.o

II

..

3. Co lor: upllle pU"",. lllis 1>. gI~p lho. n:tJ" I"'"

" k>l of cbmj , _
I l mcdlum-slzal ""mi """""s,
"""""II thcm blrfy C'YnIy around the pcriphcry of .hc
a._bly.AdjuSl thc damps bcbrclund,""" lhcy .re ""'<1)' '''
,"ppl)" ... I\hooll k>I o( fumblittg.
Exltml"" Ihc lwu pin..,. of pl)"WOO<.I . Thcy >houkl be
Ibt. hut if "h he. piccc or ""'h piccc::> an: bo.... ed, orien, .he
CU.,,"'" f:ocs) In .
U.., }c llo ... !Il""". appl)1nll bc. ds la Ihe m. tlnll facc~
of bolh plie>. U.... bru,h o, sc ... pwood $prc'dc. '0
~ pn: .d ,hl~ IIluc OU, , >(, Ilie cnlln: surf""e h. . . ,hin
cOOIl1lJl oflt Lor on~ plece >lOp Ih .. Olh.. r. nd .Iilk Ihcm
around a bit ' O!IC' a gt><>d. ,u.,tI,,,,y bnnd.Thcn . ligI> 'he
edgo . nll 'I~n .pplylnll lhe clanlps. ln nlY ""pc:rlc""c.lf
,"u IC'" Ilie cdgo e l.nlpctl ... "U. ,hc In.erlor of Ihe glucU)) . ",hen: It '~ dlm .. "I 0 apply ."y cI.mpinlI p<cs>un: .
... 111 .~ ke ...... n: of Ilsclf.

-"
II

ar:

4. Appl)' Ihc: plal!ltlc lamin"'c. , ou nccd 10 """a

hulh "Ido "/lhe _inl! ... m wllh pl:astic bminatc. Cut twO
plece> o( "'mi"",c '" '1Ie)' >Iipllly "'''~ lhc cdfp 01
lhc """lr'll

.rm bl:Ink.

In ",dh"n.lb.cd ain. hrush a .hin b)-er 01 con~

Cemenl OrI ..,"" JIdr: oI.hc s""1njj arm hbltk and 00 """ 01
pin 01
"'hen lhe cm..,m 10 lIry ( n::uI lhe
Iobel for propcr dryIntj IIn1d). an:fully lor .hc pbstic lam-

"le

194

Wul"",..

Rou r~

UJl<""Mk>n, hul II'" ' .... """'1

dooal
...." Ihc """'" fOr Ihb job.Youli fu .. ""'... 10 10'0<1< .linlr
~ mqk. " 'hlch b " 'h;u I did.
lb bqr;in. you nccd '0 by ..... 'hc 1_
hujc "'hile 1""
.rc al 11. lor ou, lhc bqelnninjl and cnd JIOlnlJi ollhc ~
adjO>lmcn. >101. '" >hoto"Tl In .hc (I"''''i''ll .'1"./,,, ...""
Uzyoul. OriU """ pi.-o< usi". "" Ol.:llchcd 10 'hc plVOll 01
your tt2DImd In my C"aW, thJo: ,,"' .. Inch (thr fIm]:oIzc: 01
Ihc hoIc).
Set up YOU' I"""md. and ..... IIlJIII ftom Ihc: arm ', pi",",
,.. 001", . l"hc ....... l>Wtl< >houkI bot cwnpcd ' 101' "'-""t
"""'1' ,11;0. ,,;U b:lck up.hc <"\II mII' prot'kk pro!CClIon il>!
.hc hcnch '''p. lktIl" ..",tl"l.l Ihc .1'>1 hy plur\llC"b<>ri .... I
hol<: al cach cnd of Ihc: sloi. ( lf)"Ou lI;o .. c 10 .....,1'1: wl,h.
fixcd.b:lsc ruu.a , driU Ihc,", hoks.) Naw rOll! Ih~ >Iol

Ib. ~nl of Ihc ~

lbm ~ileh . 0 ,hr 1.. 0""" aRd .....1 lhc <"\II"'>::d ~t .

.-...

i>;oxpLI."

~,

6. cu, .Ile .rm 10 slrapc. The fi I">! Slcp In thl>

pnxr:ss I\)IIOW$ "",'u"'lI)' (rom 'hc pn:vlow opc ... ,i<Irl.
R<:>:cf .hc , ... mn.d tor. Inngcr-.... dlll~.rc lhlng , h c _
polnl. """ Ihe.r<: on ,h .. rrom ed,tlc oi Ihc ~rm .
(If nccr.l bc. )"OU con _
dtill 'hc: pi .... hok 10 tlIc
n.-quln."<I kMndt-d~lc, 01;: .)
N..... Ior..,ld and cui thc """'1 anak<l ""'Iom.,.... 10
mc . he bot app ....... h il 1" damp " ", ... (ght~ .lI tii<
""". and fOUI " " , iu;, "'3.ole. I"m 8'>1""0 """ thc
10
ruUlllllhc ~m"5 sh.i&rp comc: ... """1 . "" I ""'Y ~ ....~p ..... k
fOI" Iilb CUI. IDO
, u:lCd COfRCr'-ruuRdflll " 'mplotr::.l .0 oh>pc 'hc corrocra.
(Stt.heo cho",c.IIorIngT~mpl:uo an l"'ilI" 6.)
ollhc comc ... "..., ..."y "" "'Iuon:. you ean 11<';0[1 Mor __
nr:rs <IQnc, """lly "IVi. h Ihc .onpla'o. Sc:i'! ' hc: ,~mpb<r
"IVi.h ,IM: appropr:llc ..Mli .... :ono! aJign It 00 lhc wort<pin-L
Tbm trim Ihr arm nU!oh u>int<. ""'ln.o<I rithcr. pallml
bit OI" " nuID-lr1mmifql bOl.
Whcn ,hc: .... pIns il.1I ........,. ehud<. bc>"Ckttm"*'l
bj, in your ..... In and run 1....... nIl Ihc nItIc>-holh
bccs-o(.t... ....... You" rond 1"" "'I~' pIuuc baii... 'c r:<lgr::f ...., lenillly sIutp; J:tnd.lrlmmirlfl lhc:m ""'.,
cdp: o/f
jO>l ""'Y "", .., }"OU an an"")i,. cut.

pl''''

"""a

'fboudl'_

'h'"

"00

7. Drill holes ror tbr:: I"QUIn moumh" "".........

1Mo il casr mot.I[II\. Drop IhI: mutcr's ~" Intn ti..
il ... guIdc 10 dIiIIlhc """"""'IC.. ........... hob.

n:cc;s._ .....

"fum thc """ oo-er :and COIOnlcninlt thc hoIcs.

_.

"'" IM .mI :t>ide. :md Cum ro llor mi of llor

Buildin9 the SuppOr1 Assembly

""'loJi,.

Thb "'''li'" ,","01"0 br'nII. OUl aRd

llor ""ppo"
p;tIl<'L. llluilljl. 1"" ..-u '0 io hen bolti,. ' h<: _mhIy ro
yuur "'bie: _ . This is tIM: ""'III< il( wlLldl .Ior ...11 tnlly
l~k~'5 f<>rm .

1. CUI thr: ... uppon panel Tbt ouppon It CUI from

\, Inch bn:1I plywuod. 1"o ..ronomIze "illloul Dcrillclnll
>cru':lur,dly. yuu .... " use: lI~dc Ilr pIrwt>Ud. lIJ1..v;t<Ic: lua
smood,. finislK<l ',<:<>c<."t OrI hoch......,. hu' <Joc,.n ', n'O
Slrlly Ioot gOOd.
In.'>OfllC .ll wttJon" )'011 n.. ,. W"~"II " ~h.nll" Ih" knllih
of Ih<: "'pport ~I 10 m>tdl 'he hclW" or)'OUt sa"'. M)'
ohop fl<xIr is c<>oc ....c-.
bu<:"'~"1 sll"",lon - to 1
ean', libtcn .Joc p:trI<'I 10 II", .hop Iloor 1 dc>Jjolal Ih"
""IOd 10 cnd abaul I ind! >hon of l hc O...... 11 1. poIr.cd on
1.....0 *-ind! ~ boIts, 'hf'<"O<ktlInIOT.f1"" '" Ihe p.anc! ',

,ypK.'"

bonom . , .. whid! ""'"'" ..

""'~Icn.

Mcasurc ,...... ...... ao&eS$ YUU' >hop

.1, ...,,,,". and CuI

Ihc p;md.

2. ~y OUl aud. drill th" Iockln(tluW>b holes.

Study tIM: d .....in&SMppon 1'P1Id 1#)'00'1, and ""''' tIM: locaIOOS of halci Iilt Ihc pivoo _
IactiQa-mob T.f11J1J llIr
"""" 0CC\InIIc ~ 0 Iaf OUl lbesor
It 10 I"'n.-kr Ihcm
rrom Ilie .,.ing ami. y"" ought la driD 1"" <:<>UIllabom
fInI. :tnd ' hcy an;: OrI ' hc p:trI<'I '. _
.
Wilh il F"""""" b1' . \IrUl ,"" 1'.lnd><IWncte. )oi
)u.incl><lccp rounl<'fbora b>" Ilie 1\n1ll 0....,. al lheoe
5f>OIs. .. ~"'n In ,I'M: dr.twin" TlIcn dorill II'M: ''''''nchdWt!cta ht.>Ia tor Ilie T.f1U' """'""'. ccnLC!"tng Ilie h<lIa
"'in8 Ih<: ma"'" leII by Ilie
bit . ttnla ""'"
1111' 1"" T.f1ul$ InlO p!xc

""*"

Font"".

-.
luk .. Icks IISed 1" ,0Iltl"1I Ihlt m's s haPit
..ciudt t,ilmmel \Iulded. fenct ... ulded. and templ.ut-

"oded eul . Roulln\l the ar(ed ed~ Involw. the use

oIi11ummel (tap) . To Cut the iln\lled bottom edge

u../dltl. elilml> a Slfll'lht fenee 10 the a,m ilnd f.ed a
lOIIIe' Ilong II. Complete the .,m ~ slllpe by ,oundlng
ilie come'5. usl"1I il templale (110110m).

tita bollhol. Ioatlo"s o" , ... SlIppOrt

pan.l. lIM up tlle vm on Ilie boc. of Ilie JUpport
P;O"'1. In ...n ~ l6kKh bolt In Ilie JIiyot ~ mii lill> it
wilh 1 hamme ... The bolt W!II _,k Ilie P;OM'l. Inse" the
boiI In I~e adJu$lment $I~ II thc lap. Ind liP III9ilin.
Th~n work OUl Ilie Iocli lon of IM JKond Iocki"1l ~nob
IlonO the slo!. Insell the bolt ' MIt. V\d lIP It.
,.,.~.k

Homonlal ROUIH

Tlb~

195

SU'POIIT I'AHElLAYOUT
[NO VIEW

O(T.t.JlOf COUNTER8O!IE FOR. TNUl

I W dl.o. )( ~'. ~p eOUnltn.or..

".

F"-,

-,'-

O"

,~!

1
"(

19".3<1_

21 1'1"

'0' Tn"" II,.

Tnlll

'0' swlng ".m

[timp knob

,,"

lEVElER. OETAIL
SuppOn
~~O _/

II '

I
O

loIo" X , y,'

&

elim. . . ., , - ,

"12","

3 . Lay oul td roul thc ~Ioc tor ti.., sUok. T1M:

Iocol lon ~"n hc I>ken (rom,het b)'OUl ~
UK
roulcrand a !?-inch 51nltlht bil 10 rout file
...... Set "1' ti", ""'"" (k.cnnlnc .Ik d;....nc~ 'l!ukk r.:,...,.,
mu.t bc """,,, (rom .1Ie !JoI "J Cft\1~ ~ lhaC
wookj Ilo: ,.... 11IKIi,,~ of 'he ho..... pb.,.. ). Oamp a 'U;uglllcdF
'0 lhet W>( 1 , ~ ,o .hc (mI"""" of lbc
<Ilbct
.IM: ~ry dbc"""".
Ikgin rvull"lI br ~II.II Ih""'llh fhc potnd
1,,", bc'Ic:inrtinJ 2Ild <"'Il of ,ne ....Tbct ..... , "'" lbc ...~
bon...""'" lbc
boIr:J.

[li""""

!iIac._

6 . l.oc.Ite It... mounllnlt bolt hoks. M shown In

lltUIll, 'ht so~ OMf'mbIy ..
10 It.. 1~1>Ic 0;0'" "' ~h "'.1' Ih .. ,..M Ih...,..tl
_ ,n ' ht _ ...bk an(! Ihmtd InloT-nuu In Iht~.
Sintt ...., particIIWs of _
W>kf vary ftom btand 'o
bn.nd, rou "'In 113,.., 10 00......""" 1"" ~ tpOI' for "'"

,"" tIn"inS 11_"9'

~nxhcd

mounl"'boI~

My

R ~1I/Ddl.;I

COOlno;.1uO ..... lut oumpnklcd

atm5lon " ings. rad! of ..-hich

tu>

I!vn;,

oI:lIonJl,

,,1:1"" r">nl

wKk moun,ing-boIt hoIcs In IU rinu;. , ......., 1_ of llIex

hok:s, buL """ 'lIe: lhird. "OC<" il il dnd<cnle . rlJdu ... hen:
Ii>e fOUln" bil doD iU ""'"'-. (0b\'Iou$Iy. rou mull'l Ix l'Oll'
niWlI of Ih<- ullim.lI" ioallon of Ihe rotile. bll . <ion '. pilI'
hol' wbm:: Lhc hit ... iUhit i' Ihc: lint ln1c )'OU u>c Ihc "'l ui".
menI . TbaJ wuukl <hmfl<'" )"OIl,c,"hllSiaom . ........ Ido . III)
In 50mc """"'. rou n.. y nttd 10 d riU I>ok:< for ,,,,, bol"
'hrough Ihc " m of)"OU' Aw lable. 'r.Ikc a cut: 'rom Ih<Dd", dc;ign. and ""'kc . he holcJ blAAer Ih:tn 1'''' "'li" Th:;J1
... m h"'p )'Oll 2djlbL 1"" .up""n . ...."mhly fi....., wlth .""
J:Iw u l>k: during in5l ~ ll:ulon .
In any
",rur", 'hc holc ioa. 1oru rrom Ihc .....
13bk 10 Ihe
O:.tmp " ,o Ilie: p,w ubk rlm. llcxIt
Ihrougb II>c holes w;lh a pmdl, n",ridng 1"" boIt1tok Iuntions ori thc sp;>ct: Unclamp 'hc opooec

pl.",,, Ihe
>lock 10 lhe "Jl'C"'11k<I wkhh . r><Ilh kkn."., "",,~Ing 'lI'" ,""
raecs an: p;o ... lId '0 .... d> (>\h ... antl ,;qu:tn: 'o .lIe ctIjcs.
en-,III II 10 Ilie: k n!t,h )p<.xilktl by tlle C;u,,~ u.e.

7. 6on::md c ounlerOOn: .t... .5pa<:cf". A> ....111 thc

holes for . hc "f.n" " in t.hc ... ~ """,,1. Ihc counl~
O'ho<IId I>c driIkd Ii,,"-. ,bm .I>c m..nt 1IoIcs. A&iliL.
a

'.'0

4. lmotall thc T ,\U~ rur II"" no::le ..... 1be 10:>...1<:1'$,

bQIt <ha. , Ivnd Into T..,,,,,.
",., Ioallon n: """"'n In Ihor dr.ownIl Suppon PaMi
lMyoul. lIo)n, Ihc dcan.nc:c
lor ~nch T."ul., driIJ1!8
dtq> enoup. lOt lbc boii ....nla,
Orim tIr T.fllll. ntriuUy
)'OU d'1\"" lhml 11110
~ 1111 bc oo.'Iou. hlIl . Ioc fbnp ar<" J!:<>Od bit bl'JlC'l"
than Ilie plywood Is l hick. l oric:nlcd Ihc .nuI> 110
pun woukl b"e InlO ,Ile wood. and t i... Iwi Pro\~ JOlb-

.. noocd :alrndy. aR" Qni:a"..

11<"""

""ro."

.,. ..,

.wo "r.he

S. Cuc II"" liP""""',

Tht

' PXft .110ultl loc

h. n1wood I,kc d ",,..,... ,,u. o. ",. ple. JoInl

196

R.OUlt. Miglc

"'"<:n'
.pac"'.

~nd

'*

ASSlMIlY IXTAIL

I !otdi;l.X

"_~,,,~,,,,,bo"

( Plas'k

)amlna,e

,--"',.-Q, ,..,'","" wing

~w(f~stens

S"PI'O" !Hilel
10 sPKe,)

Suppon !Hilel
fI:I'><IItt bII 1<.> driII I~ ("OWII~~. ~1kt ,,,,,- ("OWI'~
tIIIm 1, ind:I Ilcq> 1"hm <!rib Ihor \fo.lndHlbm<"l .... boli
WoIhNug/> ihc lif""tt<"
lJI>cn ihc T-nu~ In thc: COUI\tUbO'C3, lIn4l .,.,.", 'hr:m.
1b "" _)'OU nn 'hrrad a bol' In,o 'M 1:"'"" Ih"" "'1'
.. boii wl,h a h:un1TlC1'" 10 drl"" Ihc: prunII" o( IM flI"8C

~""8. ~mblr Ihc 5.,...".r "00 .hc Mlppon pa""L

I'if: paOO il iti""" :ami :",....-...1 .0 W >paCft".. Sprnd I!I....
al damp the po."8 10000OO. ...."hJk 'M etam", :ut StiU
"""lI! III< pati driU .... d rountcrlnk ",100 hok:> b :z..
~ 1Ir)....
u... abota a h:aIf-doun ...-.rwJ,

...u ..,..,...,.

rwmIJ ~

'M pand. J"'" bot: ,.,'" 10 <MIid Ihc

who:"" .t... bit wiU bc <:\I1Ims.
""'("tII... cbrn",:m urf,oand thc: IOP~ "'ihc palid
01"'" topofihc "f"IC""'!mOOIh:aml nu:.h. ~' ~ic
........ ~ ...-.oss lhis surbcc.:amI 'rim ill1ush olt aruund.
>Cr055

1".,

"""Ii,w hile Iun</t' tur I . _ W ~ III " ... (1)" an

olignmrn. do:..k ."" . It kc",," II ... sul'fK"1 pand rrom gortllnS

~ In Iu..-anllhi; $;ilO' hOllSlnR OI" l>ullcd;<W;ly rrom it.
Wi'h. frami"l1 !Iq""n;. lin .. up ,1Ie:
Mcasun:: fn>m
,m, """"r. In"", r"", 'o 'h" .kk o( ,"" . . w housillg ., thc:
..,...,1 )"" ,....'" 10 pUa: ,..., ""'Ir. (A.'i )'OU nn > rrom ,IM:
~my $;IW'. . .:md il! ~ bi' widcr ,/un 1111< $O'" houslng,
"" Ihc:n:. a Icds<: un "'hich IIt<: >he" R:SlS. n .. , Icdg<: ilie ___,
u.e, ..... would bc.)
CuI''''' .rn.lcrrom t..inch 1'11'...00II. Th" shdfwiU im~
kn: ...ith thc:
of ,1Ie: .li<k. "" )'OU'II h.o~" 10 rIOIch
it. Hold Ilie: ....., In pooi'lort.1lId nuri.: Ilie: ... id,h llId <kpth
0/ thc: ootdo. CuI il on II><- t:tbk ...... 00 ,IM: b~lId $;iW, OI"
..ith. $lbcr $;IW.
:00

1>"""'.

1'

",ed ,...""",

"""cmcn,

<mICI" ..aion.

9, Mou'" thc assembly 00 thc !law tabk. "tbrnd

""" Ilo: nul:! {)fi neh of 'M ....., ."".., ....... atri;qoo bol ....
~ , ....... up '0 ,..., ~ Thn::od .hc boii:! In,o 'hc T_In tlII< j'WI<l 's boI,om ~ .
PlOp 'hc """,n,blr ~ ,IM: . , . 01.111< A '" I:lbk:. tiI
I .~ at>d I spli. ,,",,>ha" {)fi neh ........ nlu. bolt. 1,,",,"
... tDOUn,IJIg boIts .hn>ugh 'hc hoI,c,j In ihc ubIc"!o tim, IOd
M:od thi:m UIIO , h~ Tnu .... '" )'OU,Ijth,,,,, u.e, bol .... 'ry 10
o( ,h~ JI'PJIOI1 .-mbly nU!oh whh
....... lObi<: sud><...,.
~ ,IM:
as ,,~ 'o puo.h ,III< ~
. . ptOp<f alljInrmn, ..1,h th.e ",W lable. ~n Ihc
..mbIy iii I~ IlI'" thc Il"" hcx n,,' on exh
..... ""'Tn..,. I nd j:>m Iho: K1:OIl(I "lP111SI 1., Iod<init ,hi;
Itodtt" f'il'Illon .

,..
C

'il

IT

.... "",."" ""rt.t""

I<:,"'k'"

k>"c",

10. CuI " ",d nI Iho: ~hclf. nlC r...:o: o( .IIC ... ppun
,... ...... "" """"'''tHcul>r 'o 'h~ surl'acc ""1Ie: "... ..bie

' "Pf'OM

pan.' aU, nm. "1 Is crltlca l, Th~

paMl's face muS, be ~pendicul~f 10 .ht Slw liblt.
~nd tht surliKe of tht sPKe, must be flllsh w~h tht
ww ubloo. Mon~or ,ht .... ~h9nmenu. wilh ~ f,~m l ng
iqlR.re IS you MljuSllht lewlers ;Ind pusit"", ,1Ie
!H",IIO musure for Ule shelf.
no.

HorizonUI loule,

T~

197

,
II . 1.....'aU Ihe lihdr and "'1.... ..., Ihe as...,mbl y.
1'0 bokIlbr >heI( In "",,"Ilon ...'bile Y'''' drill pI ....., and drl>..,
, "" moun~ Ktf:WlI, dlmp ,_ lIand JCtnI., ' Q ,"" p>nd
...... ~ ,"",Jx,1f on 111<.'10. t'lI>'~n ,""
ro 'b~ 'Mlf
AIl"""sh 1"" """If appe... ,<1 1>1: ""pp..ned br 'he ","W
.und. II i. It5lcn<':d ". Ilie ,,",W .... i' h """".. 1 '1>..,.",
p''''''r I)riU dr:>r.ln 1101<1: ' hroujlh ,1", ta ... h(lll:<ll'1't ror
,1>1: .M:rcw ~noI <lrivc IlIem lbn,u"," ,1Ie h... ,;Jng Inl" rIIe

p"''''

>bc'1fi III<'

Maklng Ihe Slide

Thr . . . "lmuUed In ,,'" """ ""'led InlO IM >uppol'l ["<IMI.
II ......ides rlflC odjusoo"",' o( IM swlllSl ....., p<,,;I'1on 1' .....y
01 a !iptd:d ~ 01 lunJ ..... "" .,.... ....., o
Aft~ ",ugtll)' "'-"II.". 11", om. f"I'I'lon. )" U """"'O II",
ICIclIng koob 00 'hc sIkk: ...... IIK"": 1, up ,11e .-lot umil i. con.
lac:t5 m,; cdp: oI 'M Inn . "IfI,1ucn .he b>Qb. 11",n IooKn ,....
Ihrtt """"" ><'CIlrlng ,11e am, 11.1...., Ilie .",11.. n~lr"d fr.l<'
ri0n5 hr Illm l,. 'M jao;:1<-..._ .11", j30;:k...:rcw h:o.. 16 IhJeMb<
per rldI. 110 'uminll It!' krlurl ..... nUl I ol"llk m"OIu,Io;,,, ... w
........., ,h,,,,m, !I.o. lnd,. A 'lu:oncl'tun, n""...... u.., Inn It. 1,,,:11.
""1'011"" wj""'mm'. Anyw;ty...'hen )'<"I'vc I!''' IUSI I""!ICI'
til\jl, )"0<' "'~!11. 'wum lhe l<noIIe 00 ilie S><~ .rm

j:I<*""".....

Il .",,, Ilo... 10 nuJtc Iht: oIkk.

1. Cut Ilie " Iidc: body. IIcCoWC ,Ile '"V p~

funninll ,he ,lido:: 1,.., m;>jU,', a ..,.,nII i<In ' o do "'" ...,.,..,.
1tIl.'hlning un I ol"tdc C"'blhdy) b'll" pIecr. ,hen ""fI"r.'c
the p>IU and u lm lh"n, ro fi",,(!Ihc R<1I""Uno oI ..-lut tbr

CUt/1n1l U.. spuilla for rhesc

p'''''.

2. OJt tlte I"dbhcL. th3t rorm tlle tong........ Siott

)'n<" '" woo1<ing .... i' h a olnglc woo1<pirc~. JVIl occd '"

bm
only o,,,, ,o"~",, . 1, b "askso 'o do ,hl. 00 ,Ile ",bie: ...... Sto
'he hlWc hdllhl
Incll. an<! posilion rlle rip fcnce ro cut
11I" .Ides ..{ 'he '0011"" . 111<:n cr.nk up ,"" hUde 10 \'.o incb.
.noI ""posilio" ,11<: fiI' r"nec. CUt "" tlle ..'aSI" fiu.. 10 t!lt
OUlj k!<: 01 1"" bb<k:. Ih", lYOi<Jlns Iu.ins rf1c,jc wakn
kkkcoJ Ilack Il 1''''.

'o '.

3. OrUi the hok:!i fo r the jacksc....- and w

Ind:I .. " 0011. tl<l 1.... '~lodHIi:;m"" .... h<>k k>o" t!lt
1..,l<><:rc.... n.... lIon:: 10,.. tin<: "noi 01 <ho: >ikk bWtk, 1""'<'"
.r.rIt'llIIlSl "'..". 2 IodtCll. "' .hown In ti", SlI," iJfotttlL
No._ CIII
bbnk
pIr-ca. 0". p<"tt ohould Ix
,1' , 1nchc. 1ont!:: ,b i> i> ,IIe !IIkk '0f>.111<: >Ii<k: toc::.lOnI ";1 tot
tal<cn fton, ,IIe "",Wn<Icr. iju, drUI a ~....".
lOr tlle Iockln", boii ncxI. Set up a firncr and stop bkJri: ""
,IM: <lriU ptcSIl ..hm y"u liriii ,hal!: "'....., 'hc: tWO rans
wlU "Iiwt ...hen boItcd ,~. 0tW a hoit In .... !IIido< "'"
ll1d """ In thc: >Iiok II..-t""'. :li ohown In m., SI"" o.t.alL

t""

in,,, ''''''

"'*

oi. eo'"plclc a.." t.."tallr.hc .Ii<k. WIlh a """"""",,,

CUI.

a '. le 2!-.-1nclt I<nob clraraloct tlOIcII In "'" _

R~id

FROWTVlEW

lOIt59 knob ,

OI
'"
-...

{J.

...OI

-"

HoI~

for ll\i.nk

of j.ltcluc:.~w

1 98

ROUlf.

M~lC

SIO( VlFN

'op,aI

""""'" In Ilie $IIM Orfoll1l>m trlm ''''' >Ii<k: bon"", 10

fin;&J IcnJlh.

SUOE OETAll
BOTTOM VlEW

I'd rccommc:nd

...ninll ..1,h a .I ngk pl""~ or ItlInJ ..vud I Y.t loehe> SI/""'"

Illd 8 inchcit 1ooJI.

TOI' VlEW

'Dp ~ T-nUl intO ils hok:, an" turn 'hc ~ into

pIItf. ""'" "'" C'UtbW= bult !Ilrough UM: .Ikk bonom. an"
......, I/oc >Ikk in 1... sIoc In 1hc wpport.

Instiiiling the Router

'l1li !iii ....... nlllrdy md). la 'ry OU. )"OUI"

IIC"W

1IoI"imnl:l1

- . _~ You 10;".., '0 moun "" roon.". and al ... cu.

!lor ... lot , .... b/l in 1hc .... ppun p2IId :IOd 1hc ~poccr. 1
",b..,d "'" lin.". opon' ion wi.h 1hc !"OUl"'.
!oIounI ,"" rou'", n.... lit it wi.h ..... bfIIII'SI..Jiamc:Icr
..,. bol YOU Mt ltclraa ' hc b/l imo t .... 100'''' ~
51* lIIt ...... d<nm .. Iow '"' I,:U lIP.
UM: _ I l
_ """'" """"IIh IN')"OU caii 1110\" 1hc arm, bul <Ion,

1r.I,,,

~lho:um~
SIri<dI OII 1hc routcf, p/ungI:

1hc bit _ _

ind! in,u

!lor iUppOfI pand.and lod: ."" ~h Thtn lift ."" :um and
_ 0loi up th""'3h thc 5p:>Cef. ~"Cf 1.hc- a na. UnIocl<
!lor """'" ond plunp:: a link dttpn-. ~ and lovi..".

-...

t""

Kp lq>Ming ,"" proccsac umil1.hc-...." il; IOUIcd 10

. . llUlPum dtpth th:a' fOW" lOO11cr aod Ihc: b/l ;an:
~ of. If YOU CVft" J!I<I a lar!I<' b/l. II.. o oimpk """"'10
....,. Ihc bM ...." In 'hc .aJI1C ~ .

Horizontal Routing
(lbo.1O )QUVe bulll ,hi> nifty rom.". moumilljJ. Now ... ho,
"'" !"" do with it1 Ibm nt."1J" onythin8 }'OU <2to du ..ilh
tqI1Iat "",,~r tlbIc on<l fcn<..". I
!Il'" .>dUP '"'
for a "", .". I~bk . J sec II . . . compkm<n. 10 .

_tU

don' ..,.,

~_ .

JM 1IItn: Or"<:

....,...ror QI1

rcw """...., Iuru ,1\;1., "'"

donc: bene.,

Ihe hortwnlaJ ....... p . n..".., "'" It.., opcn

..... ","1 QI1thc rcgt.lbr ro",cr t,hle ""n:fI Ihc workpic
. . . o\MQnjI !Ilem "'" ... lsIn" pancl. . .Ith ",nkal
~ b/l :IOd profillng It", r:.cc ~~ (~ btoad
pIm:o-ba>cboaRb . .,..ings. ""'''"'''", .nd OIhcr moklin"".

AII HeeJlUlI "'.)' 10 nJR ....... ts 1. 10 ute a V1! nlc~1

bit In Ihll ...... tI u~. ~ft k~1 Pll .... I.
'alslng biti are ...... ller lhan wl "ll ~ j)I.....rl lslng
blll, IMy COlt ~n l hin the bigge' bit ~nd they an
be po_red by mldolzed 'OIIt~ . Set "p tht ...... Ie' Ind
bit J.... J.J I'0Il WOf.OId for <U"1ng a lenon Of (()UIIII9 a
moIding. AdJust the bli Vllen~ Then .cIJu.. Ilie
swlng arm KI IM bIt\ <unin9 tdgf: II ... reIy u~
a~ the uble. M.lke fine adj"stmenn 10 Ilie llelgtu of
'M bit by 'QUlllng ,hot jiKbcrtw. F... bt.. reoults . "pe'
<il.I"" In "'-rdwoods . fllH j)VIeh In 1"'0 j)lUU.
pll .... I "" I~l ng

Making a Slip Joint

"oc

Thc: bnI >InfIIc UIUIiI... tJOll o(

horI.....' aJ """'" _.
(.;Ip1hi!itla II 10 mat .. a oIlp I<t'nt
Thc: oIlp jobIt " slmpk nriation OII tbc mort>C.'<lf>d.
Im<)fl. II, rnlJy a oIot4ftd..cnon 1OJnI, """",,1...., caUcd ...
"""n n..... iK-antkmon . hriI1k 1<>In1. a _
joilw. .-. a

"""" Jul .. t ...... oImpk "">(Jf rn.mc:s.1iKc r........."..and lhc IIk..

Il """" _
AI"" am ttwt ,...,. 0I11Cr joir!t you couId 5Ub>lltule. Al'il> 10. '" truly <2>)' 10 ""' up:mll CUI. Tu do II OII

lhe horlmnw n >U1c:rul>Ic, all)"OU nccd Ilo a 01......,

'* and a

01<'(1. Laj'tlUL ........-1< II as !Lionpk as ~ "..,.. caii c-..". be.

Thc: ptQ<"<:'l!o o( """1nJt ,"" ...... '" a .,....~ Joc" ...... Ifl/I
thc ~ ur lontI.....1<1<: hoItnb.lbr ..... tI"" "",,"<:Un ........ :IOd
rOf ",he. !fImliar "",,~~tio<lJ. M:W1lJI Ihc tenon for tbc oIip
j<.>!n. " ni) t1lffe"",1 from ""kin~ 1("JIQrt Joc" a mortiK4nd-

:<J
O

C
~
ID

...-~
ID

1/1

. . . ,o,"i", a br_d arehhec:tural moldl""

I.ttft Iht IfOOttplect 141 OII the l~blt. IV l,~nd i"ll
beboIIdlht I""ng a,m at thol <..."et 0 1
ub~. you
bold 'M lI".. ' O.lnlt 'M s""no .,m
II"'" MeI it iKroU thot ( .. IIt<. Of (OUlUi . a ( Oliple 01
~rdl . a" M lp, 100.

... """" .'"iIy

t'"

Th lIp jolnl 1. t _lec:h and 1'"5)' 10 o; .. t, espe

cil.lly OII Ihe horlzonlal 'Olile r lable. In th,. limple
varla"'l of Ilie mon lUiandlenon. Ilie monl.. 1. a slOI
InlO ",1>I( h lhot tenon Sl,pl.
Horizonui Roule, Table

199

lCnOn joi...

bctJI..lJId

Thl5 proccM ;, paradigrn for ruu'ing ...idc ni).

fur ~ mokIilllP lJId r:u.iIIf! pand

nul

1. SeC u p 10 cui th<:,;1ot.. In Ihc khl--and probobly

_
_ "",up. II><: .IiIoo. i> cx:actIy Ihc " 'idlh of Ihc
cu"n. 1f)"OU:ItIbI!cribo '0 ,t... Rulc oi"Thlnis, u.e. h lnch

.'ltr.lltlh. hitlbr ....kllll! W join. in ~"nch <lock.

W ellC1"Il oi" Ihc b)"'" _
.On sampk of ,t...
>Iod<. ~ ...., rrwb.divioJintl.lhc ~ lnto 1hInb. 1.
ha.-".o bc: pcrfta; u.e a rukr f I comfurts you.o
do 0i0.Se! ..... pKa: un tbe ,..... t2bk. 2nd SC1 up ,I'N; fOUIn.
fii "'" hit in "'" _
._
"'" ~....
ana """"I.d"< ....,
lhc hit > up ...bc:tt you an ....., I. "'djuoIlt... bI. o,moion
Il,,;!. Pu. tho: pktt 01 $Iod< agonsI tbe $OOina "'"". ond
adi_ "'" """n,., Ihc bI. pru;n:tJun b. ,. halr pn,n !han
. t... ...'idlh oi" .t... .. net<. No ... adj .... 'Ile- hit hdtIh' hy
....:nin,g 'hc swins :ornl. Se! Ilie $Iod< bcMlc .1Ie hit 00
Ilcno '

docsn.

eu. lwitt .0 rorm .be .enon (3Od kttp i, C<:11'n'W).

I-""'"."n ."" Iocklng Itnobo: an<I mm ."" jacbcrtw.
llghlt:111h~ knob>. Cu, ~ nc""01 Ic:non
fini
onc f i. WU.OU ,ltick).T",c .lIe iii In ,1Ie oItlt . If~.
"<.Ii..... . IM: hit hdgh' "-J!'Iin .nd eu, a ,hinl .o< p;cn.

), ""'''' ,...

prod,....,.

6. CUI lhe Ic:nnn~. Wh~n 'hc: 5<:1111\3

'CrH)I\ .h.. IIUI 'hc: , IVUI po:nc:c,ly. c... 'el"lOlU OII tht
worklng >loek.

i""

:oI1gn (I'N; bi' btI.."ccfI

,...,

boj"om .... rIoJ.

2 . C ui a tel. ,;Iot anei line-tune th<: Klup. Ur 'hc

.. ud< fht un ,"" ...... _
, iI!i mii """ni :opiruf ,"" Win,g
.m>. llrin,g Ilie >Ied up bchloo h. ,hen badt ,"" ",ud< cnd
.t... $OO"Illl um. You
.,.,0 I q out ,I'N;
fuJl<lcp<h .sIot in " Ioingk V-.

ohouItln,

'''''f rrom

S",I.ch OII ,1Ie rouL~ 00 cu, .t... """. ,""", ,t... .ani
"'I ...... ty .I!'lin>t ,t... _11tI!. ana . ~.t... _
Imo W hit.
"""ing" $lut
f. ind> dcq>. PuU ,..., $In! ..... worI<
I>;ock and .t"ft (I'N; ",""",
1<0 I..,:h cii ...... '0 ,1Ie :um.
_ _ Mu" ..:cond p;bI. puu botck. ""in ,h~ ........ owanl ,I'N;
am>. and make " ,hlrt! p;bI_Con,in"" , .... tI)Utu>(: urI'U Ihc

.bou.

.101

.II

.a
(!

.!

II:

.bou,

rtlchcd full <Il:pth_

Now roIl ,I'N; "",rI<pk:o: 0Ytf an.! .... kc IUII-drplh
p<l.-.s. TItlo< will proh.ohly ...1den .hc toInI. but 1. dt:f\ttldy ril
C<:11.n 1, un .he ....O<tpktt..
Swl,ch o
"""e. ImI """mi"" Y'''Of ettl .... Ion!! ..
,I'N; sloi .... 110< aro:: h. In<:h ,hiek Of benn. YOU'""'''fI I oby
ha;

li,,,

R_II .. ,11..... lIp jOlnfi 1101 [IfOducu SlnOOlh.

sq~ . e ~urfKU . Bk Ul) Ihe .. o.kpleee .. ilh II'N; ~Ied.
Cui Ihe sloi. In Ih," Of 'ou. p,os",S. HoId Ille ..ork
plKe INd: from ,he ~wl"9
ilO Ihe fim 'ul l~ ""Iv
It .o It Inch deep. ~ ,Ile ...-arkpieu ,Iooe. 10 'he
.. m on ,he u,<ond l"ilSS. aS shown hert. and bun It
lI\llllnst thc m fat the ,hlr(! ~ SJ. Thcn 1011 ,hc: work
plece DVI" . and. wilh me W<lfltpleee buUed to tlte
s wi"9
make It fi".1 [NU 'o ctnte hc SloI.

li''''.

:li"'.

proccd"'"

,. C u. Ihe ~Io,",. U.lng Ihe mulU""",,,

deo<:ribcd In S.e" 2. Cu, Ihe 6Iot In .11 .he ....orl<"io .

4. R""j,.., IRc "':IUP ' 0 cu It" 1" .." ...... Unlock lhc
an<! tmo.'W .1Ie hI . [.;ry "
plece hoiioJc .hc hit
and vi5u;llly:diin .1>0; eu,tln!I ~ 0/ ,1Ie bit .... hh "'" oItlt _ .
'00 ""'" It> """'". alllll," .....""", 1~ w;tl1 511l1dt........
Do NOT :oI'n 'he 1>1. OIt:11>lon.

""".nI

""";",,"mI

'"non

,. CUI . It$!
~nd "nc:.l un" Ih" ""'h.p. CUI
a ,enon """ ~ 1.".. pIa..... of 'h" ,"..,rI<lnll .. , .... k. On.:n hc:
&Iod( ond .ani .. you did for c:u,,1nJt ,1Ic: """ . Ftt<! 'Ile worI<
In II'N;
Cut """ oItIr hen roillhc: &loek ovt: nd
cut ,Ite oce<>nd
Tot.1te Ik uf.1te .enon In a """ .

IWIM."....,.

- /f II /.r lo"w. you m.... Jowcr Ihc bl .

- /f Nil '/fIbI. Y'MJ m.... ro.lsc 'hc: bI,.
II '" IMI 51mpk U!Ie ,~ ~ br Ihdt: .dlnS!
menI) Rcmctnbtr ,lui. thc <:Iun"" b d ..ublcd lIC"<::I.usc )'OU

The Iyplul lenon Ciln be rouled q"id,1y an ,Ite

horl~onl.1 tOIIle. Ulbie. fie amounl of mI,erial bting
.emoved i. modUl . ..,. singie pa.. un compIMe a
cheek.ndsboulde. CUI_ For" slip 101"1. 1"'0 ~ues
complelu Ihe 'tnon. Fo." mortioe.ndltnon IDim
Itnon can bt compleled In foul ~Ut!S. speed Ih.al
malch .. any olh"" ap.,mach. Tht chHk. will bit
smool h. Ihe shouldtrs ."ua",.

li

Horizontal Savvy
WIIII III OOlf'\ o".m'loon (h~~gtd hom "",",,"I
to """lOrllal, Ilie mel hod~ for flMe'lunl~g .,ou< tul
mull c~rlge "8<1 htlghl- betOfl1.ela tonlu~'rIg lo,m
'lot$ II ref..-Io an o1<Ijull_nl made on Ilie I'OIJlor, I I le
<Iotl *I>tn work,ng It a '~ular I'OIJltr lable? 0< don "
Itle. eo In adJullmtne madt b~ mOVlrlg Ilie IWlng a.ml
ro "le. Ihf .dJu!lmem VQU _k. on III. I'OIJ'"
~,tIt II for 1111 tJlltm/on, It gOW!,nl Ilo ..... far oue /rom
!tie I"'~ Iim l/le b<t ulondl. SII I>t/{lhl. wMn ,"'ro
t.lIil~ .boUI Ih. hO"IonlallO\llt< lable ... ltll 10
tIIo Mog~U of IM bot in 1.lillon 10 Ih. pliM of 11>1:
ubltlOfl
wnon I'QU beg,~ 10 rOUI, ~ou haw 10 dell w'lh
ftod d"wlo~, II~ d,fftrent: Voo feHl from Itft 10 roght
Io! "',\ 1101 gel Ihud of or.l'lelvel 00 tht idj"ll
...1111 f"ll
'u-uIMSIlm #djwJr_m EIIIV 10 do, Vou U~
I1lod bolid. Ihe ro"ter ind fook I\filoghl dov>~ on Iht
Dt MoItOW!r, you don~ hlw 10 worry aboul !oslng
1'" ",utru bll Mtght Utllng ..... hen Voo Iooltn Ine
,~"'~ _urirlg Ilie motor I~ II' Nle. You i.en\
r.gh""11 g',1VUV In th" adjuUmtnl,
HoId I ,ule nut tO Ihe bit and mow IlIt .OOltr.

SOl'M.ghl "")Ulf"""": Tht I"""ng ~m\ fi ....

lodjUIt.menl Ifll .....
gre.ltl.
To gel il eOl'~ 101t'rIg. Iooson \1'0 Iocking knobs

........u

and lift Ih. 1..... lng ..... , Whon tho ,etl'ng Ioob riglll,
togll,en 1110 knobs (~",eulllrly the ,,",O on lhe ,010;).
T,,"n bnng tho ,lide up 10 eho IIO~ of 1'" 1JCU"o"'"
10Ut"', Ih. ,,,,,,'ng arm, ... !Ult Iht 1JCUtrt..... i l aboul
hilfwiVOU! !hOl Ofilultllllal VOU Cin Iowo, the i ....
u ..... dl U fiOR ,IlO f'nelu .... 11>1: bot he'llhl
MUo 11011 tUI and musu", ehe tul!t50If. To
dtt~n lhe '0.1. ~IR tlle i"'l. To
les. dup.
Iowor Ih. iim. In bolII "llIiItoonl. IOOSffllht lotkl"ll
\v>oIn-romombt<. e~ ..... won~ movo ..... hon VOU do
Ih'I "~ ,urfI Iht j1ekK ....... eloc ...... 'lt!o '"lie Ilie
.,m. eounlfrtlotk ... ,u 10 10..... It.
If VOU .... lI"k"'. yOU'H
10 r..... mbtr tl\;ll
Ilie fitkK<t ..... 1Ia, 16 I~ id. ~. Incll, OM complete
<tVOIuloon ... ,1 aft .. 1\1 hf!ghl >1. !nth, SUI yOU ilso
neocl to know tllallht po'o"OIlfIg KllOII of 1110 1..... ,n9 iim
Ind Ilie local"'" of tlle boe u,s ..... ,11 haM tllat Mlghl
ellange JIIM b'l TUf~ 11>0 .IiItkK<t ..... J complttt ,evo
lut_. and Ilie btt lIo'9hl '""" tllangt >1. Inch.

"""u"

""'.11\

IIT EXTEHSION

,,,,,!,~.,"~

,,,

10 ..... Iden Ih. tUI .

Ho.lzonlal Route. Tiblo

201

Horizontal Savvy--continued
That IS flne-tunin!!.
ftul d'rufil)n' A~ I ,.,,,d, It '5 f,om left ta "ghl,
unlok~ on a ,egulM route, table. Thi. i. bKaur.e YOU'ff
using what would be. an a ~ula' ,oule, table, tne
~ck of Ilie hit,
It\ eaoy to figu,. Oul. l<>ok &t the bit U II u ttnd.
Into tI\/! tabletop bit openlng. Look at lhe cutUng
edge. Ooes ,t remind you of Ihe cuuen on a Joonl~f,

Ine way Ihey a 'e pllch"" InlO the cu!? It dou me. I
look al that ",utu hil and I <an ju.t ~ It\ (lo'ng to
.pm toward the left--<ounte'cIDekw'St.
Arod becau.t \'Ou always fttd QgQ/nsf the CUlIt'
fOlallon, I know I'm 9",ng 10 feed Ihe SIDek Irom leit
10 rlghl. In p raetlu l lerms: Feed Irom Ilie from 01
tne nw table \0 Ine haek, JUSt as you would when "pplng o. Uo ..cullinll

IT ELEVATION

RAI51NG THE BIT ELEVATION

Turn IhtJackscrew
ta Ihe flghl. ..

.
-.{!"..
.!

10 raise
lhe swlng i.m .

LOWERING THE BIT ELEVATION

toasen
Ih. IDeking knob .

~"

Tum Ine jackscrew

10 Ine left .. ,

202

Roule. Magit

ta lower
Ine .wony arm.

Bench-Top Router Table

'(ou.

l'(Iuter ","on'! be lied up in this

IWtu table, Removing it i5 U usy

(IIOpp/1IfI il [ollpl", of log"l", clamps.

illIi

or Ilie .... ,.U ,001', fo, ,hc ",mO'" joi> ""0:, Qt "" .n
o,n In bu'y >hop, ,III,; lIule IKnclHop muler bIt
i> j .... 'II" ,'cka . Il h"". buneI! orpIXllal r<":lllllOO,

....oI>I~ l h~ bol b lloc .Iml"e mUlcr-nl<lU", lng )' ..cm

I know 101 of l'I<obbf woodwurl<c"" ''''''( Qn/y ......,
actt;and tht:y <ion ', "'''''' 10 mOllm II In ,.bk bc<....... 11
. . . to bt I)illjl it "1'. 1'h<' appro:.och ,,":...:n'~-.l hen:
..... ~ tir up )"OI>r
i'>I:c".us<: ml-'t.1nll
'''IlIIk
~ f<ttll 'hc fUme' from Ilie 1.1~(. lOC1Uy <n<lt' '" Il""'
I:r _ k l won:.
JulI iMc:n thc rouler (,.,ilh , he h~<q>I .. c ",lIIlrIS"'Jled)
!Ilo: rtt<:S> for il bcnc:.. h thc ,ahle,ol'. and ' ''"1' 1...0
.... dlmps dooc<l . I, '. ul(lIln"" J, c' ''Y >S Ih.l! N'<l thc
Ilan<l-lIckl pro<:cdun:;1 1'uJ> ''f'''n Ilie .. ~ and
ti fm: 01 'hc t.hk ond mdy '0 11". No IkIdUr\3
.......... ,1njI """""'"S to "'nlO\"<,' fTIOI""injI platc ."" ".Jn.
.. 1bt1wql1'1<". bc:au... lhc ""''''[lI>1<" ha> t><:cn In 1,1><,<,

tOt""',

''''ti

-.ilr.

"!VUIa"

....... 'inoc.

,"'rfum.

JoIllint lhi>' liu'" opcn.lio<l (.-cn oc.l$lc' h>

1
..... fto= ( ,,Ibch ,1110 !"ou.., . oahk "" ........... 1011 ,t",
.... Aoor-St:tndi"ll lt"u I <:1" I ~hk p=;cnoa! on J>.iIjC<: 2UJ
nor o.obktop .. hlnw<l , ...... il oHIb up In (.....,1, 1..... ohouo
)'OU IM "",,~r IIc:aIJK" It Is.., ~.."y 10 .10. )UU 1I
.. - . , "'" lUllocr 10 d ...""" I">io,..

'"

E<Ju.aJIy Im~ It how ta$)" bIt..".,~1Uion adfu5o.

n..,," MC"",,, """,, Ihlt I.Iltoiop mo"", \l"Ith lhe W*l;op O
lilicd. l"'" an oIgho """"'" ohe ",1* JUrt.a: 00 It.. blo C
wJ,I>ouO he ..... ing oc 5to>oplnt..l"bc: kr1c~ dooc... o no:cd 10 bc
"",,"ni 10 OUO ot.. I.bktop Th ... )"OU nn malIc I 00( CUI ,
"..,.,.,"" OM cut k... lr....... ~ft ohe tobIctop 10 adi ..... 0IM: blo
,,hllou' IIlsIn, )"OU. (c!>Ce JeIUp. va.. C"iln UN: ~h ~
10 :adiLlOl. ..., IUlllcr. bccaU$" c~ Ild .. ar kttpo
II .. o.blctop In ollc lihcd-up p<idon unUI you.n: ..... d)"
", ck>K 10.
tD
OI
Wi.1I " bcn<:tt.op unlo , .'" "'"OIVin3.surbcr i d"""oa!
<:Iosa to )"OU lhan ,,hh o l"loor...t:uldI"'I! unii. Thl> ... ">pecIoUy "'lpfl~. 1 'tti"k . .... hen dcaH"'I ,,hll ~u WO<topia. 1
'c ..... Ou lIuncll 0>"C1" ", kp" doJC C")'C: OII ohf opa-ooion.
whlch In o prottoctN ~ .. 'Iuik II.nolIy o pal" In o...,
"",,-". S<> 1Or.....,1I _kw.I, , oftCII ",..",h ... hlle 10 puU out
,h""illic o~'~c . kll' on IlIc wol"l<bcnch (<>fOII" $hopm>oc),
"" d (I>.mp 1. 00.."11
",,, uni!"' fvotprlnl Is ""oU. lu>l 16 X 28 1"".... n..
"'''tom e><ocnds wdJIlc)"OfId ,t.. "'"",In, 00 tM 1ikLo;md
al tll<:~ .!10 10 i. Jlahk ""ti ,,cll u;oetl Ou clampin, ou'
""o",bc" "II. 11,e ha,., l. o pl}wood lI..x .... lth hutl~ It
l' palma!.
Ahn.." .., 'n of,cnhou!du.J fOU'W o 11.> .....

...-';}

""1' .."",,;,,11.
'0'

, ~ tJ>c,

bol'()OI on ~ Ioiok 01 thc ho}u~"II Ind ~hlrol

makr 11 n>)" 10 carT)' lhe . . .

..,u. ~ IwKIaripo

II ,., ..

iU'UUD<l, and O"" .... """,,," In'~ ~ U' ~

hok ' luna il oYcr (bi&l1Ull '0 "'Oft k .
T1I~ ul)k,"P Ilo lWO
of ~...lnch pIrwood "" Itll
ual< cd~ndl .... le b ro..., ..,.j nn 'Of> ...ilh rJuli<: l.lJIIi.
... te; an Ilie bou..... . ... itll Net,a. ll>e III,.. Ic'o"", _

la,..,..

mot.

...ilh hothcad ~ ~ ..., u...... .~ 11111&" """

A.ltl>ouSth
lablnop doew! ', occm In lumI' OI" IIg
durllIII ....,. I InsuJled coupk oI tOgk ""ICha 10 lod< ;.

t""

down.TluI ~ Ihc: ubktop 1I<'*fI' (~,,' horn II ', bdni

l'n<WI .bou
A ('Oft)IL&ry oIthe I~ mp """"'Ii"", oppmodl il
tlw. tbcn:'I no mounIlna plalt. Tbis I ....,.,try o( _
bcoWiC ,1>0: bit ~ > ,. hok in ,"" L:lbktO(>, "nd ....
doQ ba..., dr.rwb;ock. 1. b Iha1 0fICC )'OII """' OUl Iho
"""nlnc ..Ith a bIj! l1li. 11 ..iD oI..'OIt" !le: opmed "'rt up. oU
a con.oeqlllrnCC. )UU mor ......1 10 l;"'il yuur1o<:lf ' o lI>in8 rda'i ..",y vrWl bb-,,*!", undoa I Inch In diamd.".-In lhiI
W:W. II .... 1 >Ullcd 10 pat>d l1Ii>inII "").....,..
1 ...."Ied Ihc bmclHOP
ubk lOr SI"IWI. fiud.
ba>< fOUt(:f. I UK I'\)tt~ 690 In It. but 1 IlIink
Dcw2l' OW610 Iot lIooch 1606. '00 C\"m Saf"!; modo:Ii
wouId wortr. PlUIljlC rout~n ... ;U bc 100 ];l)1.1O jl"Iu..' ......
)OU .... goc. bc ...-.n: llul J'Oll'U nd 'o rQilt "'" ~ .....

..,.,'tr

rou\,.,

10 accornmo<l>'c )'OUr n"",II~.

-rtw;, pbn. ,luI ~Iow .t.o", "ery bo5k fcncc. 11 OI.
olmplc "' .... lghle<4Pe ... ;.11 Im("gr"o/ clam"",. 1Iut _
timc IQ
.lme. )"OU moy Rnd i. lx""rlCi:l.l 10 II'...., """" daho,., ..
r.:ntt '0 1Ut. <>ne ",i. 1I ,..,nlcll faclngs and "'"m <Iu!oc
p ickup. For ,III )'OU >hould "" a ble 10 ad>pt lIN: Spli.
>hown on p.1ge 237 10 1i1.hi5 l'QU,er ... bIe.
Thl, i, dondy linie unl' , ......,n lf I do ""y ... m)'''''.
If y<lu hlI,., alI Ih., h.n1 ....,.re In hand. t'Oll can bulld 1. In.
prodUCI;'"(: "'-kcOO. "Pply llot finbh (n'e' .lIt nc,,, fnI"
~"tniflJ!S, aml pUl II [O Wlll1; Iht: fullo ..'lng wcekend.

""o

-...
.
III
OI

Building the Router Table

1..... bn>I<en <hIs proj<'CI oo""n InlO IIuft romponrnll.t"adI

of ""hich )'OU buiJd in lum: llot b:osc. Iltc lablc:1"p. anii.
!!cocc. In act ...", doing lIN: ..."rI<. )'OIl' U prob>hIy l>outItt
b;K:k and l'onh b<:\ ..-n ,lot baJ;e and ,he tabldop . ~
tho:: ~ """in8 1Oro.">J"d on OM from ",IIIIe.1Ie gluco 11
dr)1ng "" Ihc 0100. Thc fcncc pmbahly >houkl bII: buili \(1
fii Ilie to.l:Jktop.

"

O
OI:

Building the Bue

HO. )'011'

roon", Is 1101 pOn"necl , nO\

bu",..,..

by Il1ls

'oUI ~' tlbl~ .

To rftlll", lhe rOlu.,' 'or I lu.ndheld

po-oceclurt (0' slmp"" 10 chang .. a bitl. Ju n I,fllhe
"bl.,top untit Ihe hd m,~ loc ks ( raP) , G.oosp the
.outt, .. itll one "'iOnel, and POl> OI"''' the lwo '099le
cI,mpl 0011'" the OIM' {unt..". Tlle ..olite. \li.lul' ....

faU. oul of ilS mou",lno ri!'Ceu. N01t that lu "oek

b.utplatt Is uUlIII
(bollom) .

pI""

A b..... is lillle mon: ,Jun pl)"wood """ I angIN 'ht

baek ond ,1Ie fron . ..iln <O gl'''' lhe unII Ihc appc:a,.,,,,,,,
of bclng broadl)' Iwoscd.nII '-ar slable And 'hc
~kc .. lcmcnt5 ... rel) do >nlribu,.. ,,, ,1Ie 1).1...: unln
rigidily.
1 plannl (rom ,he .. an 10 ~Inl Ilie uniI .o I
glucd lOIid-wood cdgo:-O;>nllinl 10 anf c_pooW pl)"'"OOd
cdt!n. 111;'; prottS5 <loc> add 10 .1Ie C'OfI.. ructlon '1_.
II", p"""'lII)' no ...."" . 1I.n an hour.
You an makc thc ba>< uniI .... rn >lmplcr Ih;ln It Is.lf

IUIOHO, ROUTER TABLE U'LODED V1EW

T~bletop

pile.

Edgebandlng

"''' - - _/
Edgebanding

Cutting lIst
Port

Qty.

""~

.,.

W,

Dimen$lon$
~"x

1411: x 26W

2 y.- X IOv.- x 10!n'

Hardware
Material

,...,'"
Plywood

PlyWQOd

lur bU1!res~s 2

Y," x 2l4" x W

Front sllle!

.y,' x II " X4 '

' dgobanding

Y." X W X 12"

",...,
",...,
Poplar

6d finlsll na,ls
2 drywall screws, Ifi x 114'

he~l>ead

2 OlUS t09gle I~tche.; 'DTl.802A rrom Reld Tool

Supply Co. (S00-2530421)

Popla,

Y." xY,x2S"

Popla,

y.- x 16" x 20'

Edgthanding

I"XWX l1W

~hand;nQ

,. , .

o.k

y,." x 16' x 20" Plastic laminate

Top lunac.

!<V. x 16' x 20' Lamlnale b.o.cke'

y. ~ I XI2Y,

rOMe
Clunp blocks

IWXI!n" X)Y.!"

O.,
o.k
O.,

.,
ii
...
ID

Y." x Y,"X 16"

"""""
O

4 Rat washers, ],1" I.D.

Edg.bandlng

lag K.ew., ],1' x 2'

2 Dzu. miku; WTLgoo.g rrom ReI(! TooI

Supply Co.

fdgebanding

;O

4 drywal1 serews. <1"6 x l!t

~nhud

ID
VI

wood 5Cff1W5. Ifi X~"

2 I09gl. tlaml>'. o..-SI.<O ITC-21 SU

a panh d K"'WS. IS xl "
1 folding lid .uy wlth mountlng seff1WS. rlght-sld.
mount
1 lende' washe'. ],1" 1.0.
2 carriage bo115. ,.'20 X)"
2 plastic

~nobs,

IJoi" dia. wlth " --20 through Inse";

'OK-S4 rrom Reld Tool Supply Co.

2 Pi'l\heild K'ews,

#(i

8enchTop Roule, Tab le

,,,

IENCHTOP ROUTER TABLE PLAN VIEWS

BOTTDM VIEW

TOPVIEW

21 y,-

=
o

""'--___----'!1
FRONTVIEW

ENDVIEW

BACK VIEW

Use a Dzus ,DTL802A loqgle

III(h wilh a ,OTl8009 mlke
tllock tabletop.
qUd<-<ln<kJirty il; )'OU. 'f}k. Ihen fo<ogo Ihe cd!,lC"-b.nding
<><1 the butt:s.s-Jike Sliles . n<! Ick. A pl.in pl)"'00<1 I>ox
wiIl dt> !"-', fll1t.

the f.>ccs oft hc b>.ck .nd Stilc,."tltis sua casiJy if}'01l lI$<'
RJU.CI :lI1d 'hc fl",,1\-Trinmlog """,pl3le on [>2# I 19.

1. CUI Ih c: parts. Allihe 1'1)",00<1 pari> acept Ilie

cod, >re IgclwJded tu runccal .Ioe pllc. 1 llS<'<I bireh
1'11""'00<1, bUl )"UU can u.., Illl-g""le fir plywood .Ince Ih ..
1.,., 1> p. imcd. Fu. III<: aiw:-b. "dinN. I """.1 P"1>I.> . impl)"
ripping a fcw Slkk~ 'u Ihe ,hi~kne"", "nd wld.h .pcclfocd
b)" .he COltlng USI .
To <klerminc Ihe bunrcso ang.k: Of! Ihe b>.ck . un Ihe
""" bun~ . 1\1.1 un Ihe fronl sriks. 1 I.>id "'" ,he ~.
11tu J set. 'liding T""",,"1 rrom Ilie la}'01ll:lltd uscd il 10
adjU>llhe lable SOI'" mlte' 1t'I'*".
1'0 s;<fcJy cu' "", the srllcs and butt~ 1.>)" Ihem ou,
",i,h Ilie b>.d< on a pI)....""" piccc II X 37 Irtdt"". La)" oul
OIle >tllc OII c.eh cod uflhe piccc.CUt tlle- .n!;la. thcn n:s<"t
Ihc .. her pUI!<" >q".re 10 erosscul thc srllcs f""" .he O>"CI"
slttd bl:mk. RCpc:l.1 'hc plUC<:5<.o cu. 11><0 rulR:SS<:> rrom
.hc bIank.n ..... cui tIIc angl.,. un Ihe b. ck.

cntls and ~ on inlo h -ind>-widr: X ~+incl>-<lttp <lador:o

RJutcd Into ,he ~ . Tbe dr"JwlnlllJmtu'" u'yum sho9.~
,.,he .... l o cUl tI><" tbdoc5.

3. 0;>(10 Ihe bonom fo r Ihc cntls and back. TII<

2. Edgcband Ihe SIli"", bUllressclli. and bae k.

Cu, .nd sluc strips or wuod IU .he eXf'O'"'d cdgc:i of
Ihc stil"" and I.ck. You can .,oid aII Ilie frust ... tion of
cb"'pin8 'he anglai p.rtS If 1"u n.il .he edb"e-banding as
,,clI as glue It. USC 6tJ nnbn nallli. OJ.<l couOlcrsm ~ meni
and pun)" OVCl" tI.c hoM.
.>,,'It. tii<" g1"" luJ sel . lrim the ctli/l---bm<.ling flush wi,h
206

Route, Magic

Cuide a rouler along Ihe Rouling Sifitlghledie (sfl'

page 7SJ 10 cut Ihe d a~s In the bottom. Especlally
,.,itn a Ot)andltd roote~ It I ~ a qukk 0p""'llon . Hoit! the
"",rit with on. hand. and 9UIM Ihe ,Outer wlth Ilie othor.

1OTT0f0t LAYOUT
SECTION VlEW

,i-

- ~.

''ri."

.
1,r-

"3"'"

,,IO V>"

--

.~

,r

8OTTOM LAYOt!T

r- 5\01....,

y,-

1
.wid~

'-

=
I

X "'"deep dado

14 1'1"

jII"sq. edgeba"dlo!l
(Cu, to fiI and apply

btfore nsembllng

l ,.. _

~, .)

'"

26 '","

"" W',

Ed~band Ih" basc. Whll" 1,

>C~1lI .,.......
'PJII!' ,hls ~ndin" ~ftcr
t>:tsc b ~_hk<J , )"tI
oiIlhro flod tiut n ",J"'rin,mi"ll"'" ~ndlnll b o",ne
... ptobl<m;o,Ic. Tbc >tIin wll1 "" In Ihc ....,.y. So
~11ll)' I mund ,"" bonom, mC;l.'iuri n". n>nIOg ntl
...... .oon 51<i [>5 <H ""o"d In thc ptywOO<l cdgC!l.
lIcguI by sunding II'" >Iii"" b' poo;lIlon ~nd !ICI1b1tlJ1.
_*"'3...rn cdjje OII tli<'~. X.u.u tI><: In... bctw",,"
...... "" ~ndinH ,,';11 hc: .""Iied he t<:.
AppIy >lrip:l ""I'USII ,t ... cn<\oi of ,Ile bo!"om 6n1 .111C>'C'
. . . ..., ... ,=<1 on both nuts. M.,..lSUr<', mll ..... and . pply

4.

'h"

""rI<

n,-

_ You C2<I damp thnn ,,-hilc 'he lliuc: >CU. o. I"" .... d
..... n-' l\nhiII ...Ilo; " . o;ccurr!hem Ne:.t "''''""Of'<", mi' .....
. . """". >bon p;tas ",,",""Il ,Ii<' rrom rumeni Ind .h"
.... marb OII ,hoo nI!It'. II il. beu<:r ' u h .." t he><: a .:1 1<~\3

*- "".. thcm Ix .00 ohorI. "llIoey OI" hc (W'N b,,~k ... lth
,dOId for . pnfcct fi. Rnall)'. cut
'"pl)' ,1Ie: .. nI' ,h..

"".j

li"""...", .... , ......Hla

lIMr ilie p..c Iw ><t. lrim lhc ~Il nu~h. ChI<
.... lh< Ilik:s lIt. If~, 1"""' back d.. elUl> of II..

5. H()ullhe h a ndgrlp ope n ln&" In t h e: bouom. tD

,\t.kc " Icmpb.c: ", lIulde ,hi> t;Ut U )' ()IJt ,..., op:nblll on '"
Ihc ""nle' of. ~hKh.wkk X 16.I,,,,h.101lJl p"'~e oi h"No ~
boonl o . plp..... 'OO lIorc: H...:h-dl1mcte. hook al ClICh 1
cnd. 'he:n ""'" OU' thc tem.lnl", ..... SIC "'.h ,,bc:\' 1<1'" 1:1'"
SanII Ilie cllll" or Ihe: opcnln_ ' moo<h.
_
1'0 rou' Ihc: <>pcnlng In IIM: houom . cbmp Ilie le.... tD
pl .. c '0 Ihc ",,'Urllplc, ~lt pl unjIC !'O<Jlc..... I\h " VI
', ... Inch.o l>. Icmpl e lIul <k .nll" 1,lnd, .. nlgh. III .
Rolll ou, .he ""'.... Afle. III~ ol"'nlnH 1. CUI . roumkn.".
Ilie cd~~ un hUlh .ltIn of 11", " 'orllple wllh . ...... Ine ...
..,unll",'" hll .

6. A......fI\blc Ihe: Ixa!lc unit. GIIK ond ruiI .1Ie p.uU

"'II"lhc" SIon wllh lloec cn<U. (il.., dlan lnto 1I>e <.bdon.
TlIeD fi, Ilie ~k In".. p ~ .GI"" :lOd ruiI k ro III< bOllom ond
III< ~....... , (;111< 01111 n.1I II", bolii..".,.", an,J >1110 In place bol.
('.t, ''''O' thc li.."' . ...... counlcr!link . 11 Ihc n:olls: thcn mi
Itlc ho lC$.s;. nll Ihe ~ . AJ'k .. I.. ''''''~~op ..... httn nned_
""" Step 4 W><lc:. "lIul"'lo/l the l1Ib1etop: bdow - .ppty
prima. ttleD ('< . .1 o.. tw<, III' p;tlnt Inskk: . 00 OUt
kochTOp RO\lltr TJ,bl,

207

TA8LETOP OETAIL
TOPVIEW

SOTTOM VlEW

,"

21 I/l"

r ,..
3lt"

17\1>"

,------,1:
,'

FRONT VlEW

L":'o'

Building the Tabletop

The '~bIeI<>p iS pmlY mudl min",u'" of lbe eu.,om

Rou"" T'Jble Tol'. n ", """p",r of ,,,,", ""n",. which beglns
OrI P"l!<" 156, de ..ili III" how 'o ronSIruc, Sloch bic'!)p.
1. CU! a hole I n o..., ply for ilie

roti""".

LJke th"

*,ncr1c ,abiel,,!,. Ihl. I.hk """ 3 .wo-pl)' con;,. n", bl" ....
OO"""e\"Cr", ~ pl)...."00<1 (no. t .-in<."h). 1he rIXUer
mOIU"ltS dlfi't.l) 10 !ti<: Ubkwp_then::'li no mounting p"It":

II

Slrike for tOgglf latch:

~sllion 10 Ilt.
IOW

.... ,
~

1
J

,"'

f'mition 10 fi!.

'2W

Auach te

,,.......

b.~ .

lOt"

J z"L

DtSta Co 'TeZI SU J ommerCial

tO!lgle cl.lmp
fOldlnglld Slav

"PC or packlOj;:!>pc (or wi,1l carpct "PC bc,,,,"CC1l 'hmI).

Lo)' ou, Ihe Ilingc-pin hole ."d tlle stup<: of Ille blngcS OII
Iho: "'" wortple.
I)rlll Ihe hole for ,1><- hinl!<' pin .
\Vi'h 11>0: ''''"O Itinges .. iIl.apo:d logetllu. milerthc cnds.
os .h"",n In 'hc t\r." i ng.'hen cu, Illo:.....,in upc'. Th i< Lost
Cu, 1. """" ""'" ca.";!y on Ihe 100
bul I d id i,
lable""w "sin8 ' 'apcrinll JIg. 1'1 off the ",,,,. lnlng IOpe.
""p.<:ating Ih" pulS. ""d ~ d Illem. softcning Ihe WgcS.

""w.

"".11<

tl~

,nlo \;.loch-dttp ...,.,.".. In ,h" undcr>lde. Now )',,<1

' Ile =ess . I'ler usembll"1l ,hc Ilblelop, but 1!"5
httk of. "" ~r ' o .imply ""'1 hQic in on" ply. !hen
gtue-la",u\;I,e!tl<: .,.,...,.
U)' ou, !hc CC1l,cr of ,hc hok. driJl p'"OI hoIc. and U>e
tl", li:l/llmel lb.Scpb'e (ke I"!!IC 39) on plungc """"" 'O
CUI !ho: opcni"J!. fiI lhc IIp<'ning Ilghtl) 'o "'" ro", ... )'Iltl will
bc usj"ll in 'hc rou' ''' .. bie.

...'" ",,,,,,,.,'e

2 . Make Ih e lable lop . foU"w,nt< ,he detolk<.l

lnstructlOlls for ""ki"tI <Ile Cu"om Rou, ... 1':Iblo: Top un
I""e 156. m. "( ,hc "ble'op shown in ,hc d ... ,,;ngS. The
Instructlons Ihere basic:tlly lndU<k 1"""" .'cp.:
" GIIIt' "1' Ihe plia.
" Trim this COI"C 'o ~lW'e 'h" L-dgol.
.. Apply oaIt ctl~Idl"ll . Trim il n ... h. lap "mi hQlIOIn.
.. Applypbslkbmin .. e'o bo'"'Of> .nd bonom.Tlim .he
b min1te, ,,,,d .. pcn up Ilie """er
On Ihc ""'Iom .
.. IIc'.d 1h<: c<lj;<:> o( 11", table,op.

="""

3, Cu. and s h .pc Ihc hiup, I made , he hinga of

oal<.cU!1inll ,h= 'o Ihc 'h"pc >II"",n In ,h e d ... wiOj;: I/I"ge
la)"''''.

(;", 'he 'wo oaIt worl<pies ' o ' he <lin'l(:n,ions Speci.

fled by 'hc CU!1lnll lliI.. 1':Ipc ,"em 1ogt1hcr .... ith masklng

CuUlng the hlnge Ul pe . Cin be done safflv on the

table ,. w using I 'urry b<>ard: Wl,h Ihe Iwo hlnge
laped 100elllt'. tlamp Ihe", 10 a $Crap of pl vwood
wilh a l"!Igle clamp, as .ho .... n. The cu' line .hould be
aligntd dir1!ctly ove, th. plywood', tdge. Fud Ilte iig
along the rlp fence. Cult Ing off tlte wute.
4. FII Ihe h lngcs 10 Ihe b asc uniI. iii.. of ti\(
"'ust bc pa"'d ...... 10 allow Ihe hlnlP
'o nesll/; squ:....:ty . g>'nSt 'Il( bUc'! cndS. 1l0J(l hinw:
' lI"ins, (lne ~i<k and .....,rk aJont< iu; lower <:d/l" 00 ,Ile bUl'
back' buu~"

.,.r

HIN(;[ LAYOUT

It"dla . hoit for IlIg,scrl!W hlnge pin

12\6"

~-II--------..
, I-- ,..

.... "'-~b I boo:k $O'" anei dI~~ orim IIM:

. . pro(.'Q> <li! thc otbcr _

but,,,.,..,1t<t'C'"

thc btJnmli anei ttm". ~ OM nutnial lhal

tit ",,,,,,,'ni. ti"," pa'" II Iw:lY

5. MIXh OM h lo ll"" 10 Iru, lablrop. StI thc

...... 01' {)fi Ihc: Mo.t, .nd c:arrlully :llian .... 10 ....mung;... bo>t a:xtly IIM: ""Y YOU "'-;ulI It 10. Tl>cn oe<iIM: ......
dor buo nJd5 OrI Ilie ",bie",., In 'urn. hokI c:och h lnac: In
pbcc. 2I1d ""ritM: .k>RJj " ....
<)ti IIM: ,,"""'nkk oi ohc:

,,\d.

-OI'

- - - -- - -+_
,hc pikIt for it. Ori...,.hc ....11:W5 " 'th. wn:nch .

ClIoodI: I ~nch bit In II ponablc dril. /Iokl hlnflc In

".... opIn:M ohC' lu5o< unii. Guldcd br .hc: hok In thc
1IiIF. driII pilot b thc ~ hll\JlO' pin 0riU thc
~ I\illfl"'1lin hok.
Tompor.u;ly IDOIIfll clic hlnllcS <)ti tIM: baM: unit Try
II lift tIM: /l1n1!lC'. Ind yuu'n > thc: ... >tiU 'rltCOfc.toKC"
_

------'--------,

'"r

Wt 1"" 101' off IIM: ba",.nd

It (H\)"OUf ...'OII<bcnch.
lottOIII "1'. Xl ,h~ hl~ ...... ohe '~bl"'QfI bou. \'It ln<:h

Naiok oIlttr Un.... UriU .,111 cou",c/'li'nl( 1'1101 _

8 , IlI.'ItaU the 51a)', Afit. o.perimnung " 'jth ~,..-nJ

dlfkftn. hIImnna<k prop> liJr .hc t:IbInop, I ""nled on ~
t'O<I\JItCfdaI 1OkIi". bd t:If. llte fuIdins ""'Y ~"OSI mc 001)'
n , and II kttpo: Ihc o~hI<1 op up .... Iil 1 am ronsdous/y
mWr 10 10....,.. it.
To ~ I lhe t:If, )'OU ...'ill ha..., 00 "'pc-rirncn0 flOd
,"" ...,.. Ioatlon.llte dfn,'[ng Ud SUIy (RUlU 1''''''IIks
~ Idn 01 ..~ 10 Ioate It

9. [mt2.11 tt... loggIc btcheo. Qnc, logk t"ch b

""""'Ied on nch front :Iti.... llte >lri~es .'" 1ruI:>llnI an
,he undcro.l<k 01 the "'blnop.
UD STAY DETAIL

SEC"TlON VlEW

, and

'*'"
''1.ln<:h dryw,d l " :"'''''. Ihroullh 11>0: hlf13C5 Inlo IIM:
tIbkIop. l hrc.:
In ,",cII Illogc 1. cnQugl!.

'"
O

."
...-.

IiC"'W~

6. InStaU the logle elam"" 'n ., opllm,l ros1clon

_lIIt """ togglc el.m"" will ..",)' (rotII rouler 10 rouler.

1k kK:a'1on!. .nol otkn..,lon IJlown In Ihe df\lwlng

rtNtt(J{J DrliJII ......... ",i, lI. Pon.,..c"blc 690 """er. hUl
...,. Il10)" noi " ';oh I difkn:n, model Of Imnd. Whh lloc
lIbkIop Miii OII IIM: W<H'Io:hc:ncll, 5cI )'OUl' rout~, in plxe,
III! b"J' "'" ebmps In diff~",nt Ioall""", l)un', be con'tn,
.a.d llpOI ' lut ...'011<~ If ,"" dom"" .'" doscd.. "ou
. - t 'lIedimp.o ~nsu", .luo .hc JPindk: docsn ', lun,,"
" ... tIIc bo<l)' '" oile bate IX otl<- <kpt/wvfllrol Icoob or
- ' 0lIIn" ptOIUtl<-IItIKC on ,lIt rotI't.,
'Ibm ,..,.."", dcl~rmI""" obe bot Ioatiorul for ,h~
......ud! <3dI.o \hol: "'bktop ...ilh four ~ X l .fndl

OI

1Ia,..,

-~
Adju:>I thc >pIndk: 01 euh cbm" "" thc rouOcr b hcld
...,. in pbce Tltcn "''''''''''' 'hc rotttcr anii 5cI it :I.>idc:
..... rou.cr "'bie: Is compk1w,

7, MOO"' I Ih t tabletop on It... baK unlL Set 'hc

"'*"JP ..op ..... ~ ....i' ~I' Il" """'>hen on Ihc ha
lIt:td ba ac..,..,., anii lnocr1 OI><" ,hl'OlJ8h <3dI hlngor 1010
BenchT",,"OI.ltr Table

209

FEN CE PLAN

2714"

TQPVlEW

:<}

lWdi~.

r--;,
-~

PIUtie knob (le,d 101(54)

fRONT V1EW

BOTIOM

CutClut for bit

V1EW

..,.1.'

, " tbrougb ""le

fClr elJmp bolt

( 114" bl1nd hol

fCl' Jl,gnmen t KttW

\ .";

VI-I

- 17 t'"
2i\"

(LAMP DETAll

.'
E==:",~,":="~~I...l
1
,

Building the Fence

.,
1/1

Z>

.,.

~
~

:s

II rou, .... ",bie 00' complc1<" ..;,bou, ~ rma l1M: lene ..

shown;" n::al buk _ _ ..lIh ohop-mad< ebmpS 1, tus

cu,ou, for I 1>11. T"hb h3>k ~ b mi """'~ : I1l1"b

kM ci u...

1. Cui and

sh.~

Ih .. d am p block..,.""'" ronlOI.Ir

3. ~pa"" II.., f<,.!. I..ut th .. (~nc~ tn th.. "ln>Cl\oIon> opcdIkIi by It... Cullin~ Ll&t Th" CUIOltl for 'h .. 1>1,

ond dinln1>ol<!m ci ,"" elamp bIod~ .'" ""''''n In 1""

d ... winll !'e,l(t I'f(l".
11Ic dllmpo,.,., ca.O< 'o brm ..lIh" b;:anll _
Ind.
.uUon' l"}" .. ndc:r. Enbl'Jlll' ,t... (XI1I~m. I"'n.""," It 'o " >lngk
of ,t... conttt 'hiekncA. ond ,hen ..... 0lU ,t... bIods
TlIe ... n<kr ... iII.."ootb anll bk:nd , IM:~.
A.' .n .II ....... U..... )'OU an ..... "'" ,t... mmp hIocb

CIIn Ix e"" .. ft! ... I,h 1 ~""h I'unt""r h l!. ,.,,~ <:<:n' .... of
tt... hoIc shoolkl Ix f. lnctI (fUrII ,t...
nlgc Mtt<
drlWllJllhiI OJ'C'nin4I.
ou' an<! tlrill 'II" ctomp-boll tlOln.

,,;,h a ,.lJIe.moumnl ... her SI'" Or)OO CItI """'Sh ,hcfn 0<01
a n the toble ",w: tt... d<"I.ib of doillJl'hi> .'" "'lxnl In ,""
dl"""I0". for malcln" ,IM: SpUI I<t"na. on ""II" U~
In onr C',,"'.)"OII .hould compla .. II... (bonp bloc"" hr
..ntlinll Of filinll'
flo, ., ,t... jow"1 ' ip. Thm roun<J.

Slip It... hohs 'hflJ<l8h It... knct:. ti""" ~ /b, ,,-.shcr ,,",'(r It.r
oIwlIt. and ,um Ihf: ~k ~ ""'0 tt... bul"'. AUwt thc:
......,.,. In ,IM: .lQInmm, hoIcI. and rhr fa><:<: Is mody .a

O """ni

a::

10 pn ..... '" 1I11k: pl:lr (o. ,IM: m<)"nU"l! boiI'" ~ '>10Inch """"" thn:J<lllh t"Xh bI<lI:k."" _ n In lloc .....""fII.
!Uso drilI piIoI: hale: and ti""", ,"" olllUl", .. n, ,ocn:w In'" It.
1.<"2\'<' ,t... hod protrudlfIJI ~bou' ~ In<;b

""I'ft)""

",,:r ,he """"'"'""' ~ .."lIb ..ndpaflC'" Of. fii<".

2. Orilllhc 1><:>les In Ilo .. b loc"". ""'" dan,p bloc ...
an: ",,,umed ' o ,t...
I,h I.-Ind! CIIrrIIW bo lo ... !'.adI
I>Io<:k Iw o ponhcad Kn:w prutrudlllll frum ,t... t<>p. ,t...
5<:Tf:". P~ '$ in,o. h<Jk In ,h.. (<'fi. ~IIJI thc bIod

r..:,,,,,, ...

rrom '""blln,,.

210

ROUI!r Migic

!:ar

rcn.:".

.1....,.. NUl a m.mf<:r "" an ,IM: ~

4. Moum lhc dam"". I,*" ,1.., bolt:! in 'hc: tt.oIQ In

,t... mInJI ~.nd!ln' rt.r IM::ut. wI,h 2 hammcr bIow

>Ikk OOICO ,t... ..

hiel""

Using the Router Table

11.,..1' n)UI~r~! 1,, o ......u OM 'o Ix ,;un: . Hu, OII
il. )'OU CIIn do 111>1 abouo ~",'hInK )'OU can 00 ""l' fIoor.

,;unding .......,.. uI>Ic: II"... ,t... tlrin

1. Clan,p IM unii 10 _ ...o rk bc:m::h . Tbe ntttl <O

...... tabk ...... t...... t i iipI0n00..""""" 'ht ..."""

. . . . u:sIw:ly 1n10 tlv bit, and)'OU LB3f fiDd :UI unkt
...... t.wr . . . . nnr r__ you 'loc JII)Od. Sa damp it

.... you rl&mp "'" ...... Ia ... n ..."., "...., a wun..

12bk. rrom a p<flr ni """" 'mlies 'o a

. . . tii w

,,Iu. "'"

....... ~ Ik' ... <dU1 alx>u'

d""""" \n.II._
'W"Mi'" _.illll. )'OU nuy flnd a bjI.h''''~ _ wob-

_1IppInc.__iIIa-A """"'' ' nd! ..

ltll.

... _ ..n,ha ...;11. 12bk ......

.. _

ma!iO

"'' OfI',

II 5100p''''''':,'''1I. ilJ

;and rubbcty ....... ptO'I1ck:s a ...... basc:. Of

r
ua"

u."

A
fllft
Is UIV la 'ffJ"IJI l' \'OU m.kI
1_ m.tu for t'" btflcJ'I-IOp rouIotr table, ...... of tht!1n
wlth J IItfllc.ll f.K>IIIJ_ Ta ('nit J 'rIJI fe<\Ce. vou
~pIy ","0I1on lht Iow m.c. pU;tJ1tl tO lht wnicll
fet'Ia! TlIe 'rlP fe<\C. UItH .IM bonom of lht WO<\
pje from lf;d,ng 'QV ftOf'll , ...
ltId
!hul t'" IMI. Try II. You'lllnd tlllll n UlkH SU<PriS"'91v
II",t prusu .. 10 k"p
WOf~pIKt aoalllst .... \It.
II(~ ffn(t nd thlt tvef'I I 411'It"hIgoh wnic_1 ',,<\Ce
1, plt"' ''' "igll .0 SUPCXl'11 UlII wott.l)lett.

_.1

t'"

r.nc.

CUU_.In _
A""Ir Cflm'onabl .. worlLllIlJ h.llJh' II ...... a l 1'"
pfIdti of. bt!ndHOp !'OU.t. "bie . Tho.,gh lu work

.n.:e Is ~I. Ih~ rou'f' t;I.bIt il )U".~ for ~I

_ of Opfflliom, C~mp II la Ilie

.. MI 1tiC!y for work.

WOf~biI'<\Ch

,,""

-'><>Po. '!Lc htftdHop l'UULtt IlIbk _ ht

up pntIlIIAC:mlr ... "" IUlillaty tabk. " 'h1k In oaWJndr<u.......nca, i, ,,'iI .,., ItOftd In III out .....~he-ony lIplt
Ind "'" ........,. ....hn! Il It PILLII la ht IIK<L

>ori

2 . Cbomp ,hc: "",tel' undc1' tl'tc- lablnop. ClIud:

III<: .... '" ...... nu joi:> )'OU"'" ........ In .IM: ~ <'OIIn,
un IIM: IlII*<Op. fi ht ft)U,a in,u b .......,...,:ond .nap .,~
'OW!lf dom ... c1L...cd No MCd 10 mno>'C Ihc: h:uoc>
P"'f. " , _ h a 1I'lIda l'\IIc: a' Ilie bit, 1Uld:ad/u>< Iht bOI
<,I/OUI Iowtr .1Ie IIhkrop,

''''U

""'=>Ion.

.,

3. Srt thc fc:1K-'c: <W ~ntl pin. 0bri0u>IJ' ,..,..

naod"""", ......... 01 . . . . . and~tht ........
picct" II ,..,.. .... doi"" aIF "'.......it" a pilot.,.. bit. ""'" "'"
.... nlf\J pln ,()lhctwbc" oIkk 1"'"
otIlO "'"
'aI*iOp . .... illO pooi ...... and .""'."" tht dam,,"

opp<uptia." """"

4. Muu' . Plug '"'' to" It;f In

n...''lI aU II",,,, It 'o II
111c 11m1t.. 1oM

Ioecr.-,.....

"''IIl'

~""
On Ilie: Otha han.d. l"vc al,.. ~cd ....1 illl,;.nmi oi,...
and 11:1 dnlllC'd .KlIIIU'" ( wtM:n cLampnl
"",kc il

>II

O"

ID

'"

01,,,,, ..ni. will bcromc dor.o)'OU .. __-4

probably _ , In ~....od milIi"II var totw ........

.. n"", .... _
pan<:b. 111c IlII)1clOp ;.n', olI , .... ~

"ou'lI

ID

)"';to: h i, 0<'1. Row

)'OU Il!<: ~ ...."., ...... ""'"' I\'C aln:::3dy ""IIII""cd. lOr

OlIm pk:, , ... , ~ .... ., kInl ' " rahi"ll ....-. primIriIf
dan'.
' 0 ""'." , .... bit op<:h"", 100 bis-

.. _ ...... bI boultl .... whltovl "s.ani"" pl".

... NI~' _,," II Mtds la be. pioI'Illuck In J
!de ..... ht! ublttOp. With mv be<\Ch-IOP 10000tr ... ble.
1... , tlllIII/Ulu Krap dlmptd .0 IIMI tablttoj) II a
'tW1""11 pin: U lhow" .....,

"c:

,""""iim, d """"

tu

tor .m. 11 ""n.,

a bcoch LIIp)

Floo....Standing
Router Table
I .. Ud

vo"r Own personaUJ:~d

rouler
from a m~nu of Innovallve
and practical featur~s : a lift 10p
for ~as,. rout~r adJustm~nu,
I_ 'stag~ dun colleellon , bil
norage, ilnd a 101 more.

tabl~

1"," I 11<.1 oul 10 gel ~ """"",andln~ <UU'"", table 1

.- W
{!
.
II

.Q

"
O

..:

"" """1', I mcn...lIy ~,,",,'Cd thc m,,,ne""",*,

.."'"jIt.... .00 ~ of II","" 1\1 ..,.", and
......J. An<! DO..,. 1"" YO". n-e oct:n and '*"'<l qultc a n"mller
of oJifkn,m ........ n ubks. hoth """P-rmdr: and rom"""'."'I.
Jljgh. 01( I I<ntw ''''1 ['ti buiki, .. tha ,han buy, "'"
rout"T table.
1.001< a, wtw', .,2ibblo: lhf'OUllh _wooting co~

1ottJ: ptbIlC l<unifUlC-oM:n"d ubk:t<;lJlS m,,"IUt<! OII lR:><k

or ~"""'.pron k1C 3MmlbIiO.. U=.OO .hen: )..... '0 >Ce
tahlctop m",mlnl

<.>Il

cobion. Tlle: .. hle."...

tu,,,, 1"'"

lOOW1'inl!I-pL:nc hnle k>CIk.J <k:u.ke"'er.and . mi,.". gaullr'

>k.>I, .......w rrom """ moJ la Ihc ",h,,.. "'" lhac u bleo "",II
""""'1 ""'Ilie must p;lr1.5Un:. TlM: klI~Nk. """ .tjlhtly
joirIC'd an<! ~ tigkl n.. Cllbincl:i :lR: "",,,'d. o(
<'COROmIn1 ronMructlon. <Ibp/a) 1"11 cNrxtct" In......1 o(
lumlxT)..rd kitct.cn abincu. TlM: ~ ...., 011. Tl>o:
m1i1 pOc'" 1I"ncrill)' :li'<: ~bk'
llul I kn<-w lh2I If 1\1 Wic Lhc """"1' and iIn..,. ~ In

"UI'' ' ' " ~>r. !ou''''

\>.bIe,1 coukJ build mud! bellcr ",ba.

,Iun 1 <'(IUkI hU)'. 1 ~""I d IrICOtJ)<)"'atc
iim >Uitcd _ .
...."" It t/..,y ouIted "u on ~ eN. So ,,'h>! dld I

r.:... .......

""',,?

_ NI ClCp1rt>j,c W>ktOp ",Itll 'hc ''''''er 0"<,, IOW;&n.1

,"" r..- edgr. FbI and 1r4ry. No hoIcs or o.Iob In Ihe

W>klop t..,rin'lI" co>'Cri"ll 'bc:

1ontI,"'nl'.

212

"".In: 'Op surfxc: fur

_ A >I~',1l'\Oe I'cuce. onc " -kh 3 JIOOd dusi pickup"""

mal1lc cvco adjU>Uhk r...np.1 doJn', want 10 hnI: 10
ipM:
damp . . - ~
lC:na. J
"":,",ed ' " "" ~bk 10 dar ,"" I'cntt fmm 1"" labIt
'lulckl)', " iI...... ' undoinp; boIlJ, IOIcy.d damps 'hul
woukI bt """,nIW.
_ M.,..ody :tCCCOS 10 ,he roul~r, "" I o:ould du,nil" bi ..
quicl<ly ond t:lSiIy ;md muc :I<li..... rnco~. ~'1.K>'''nicnlly
I'm 1I"";ng 10() okI fut ,"" >toopinM an<ll:nttlinM,
_ "".... I ..'lllKCd a hc:I..,. plen' INI ..'OUId dunpm III<
.'ibr.uions 01 :> 1'O"-.:rfuI """"'" _ins
CUlS.'
9>lid .,,"",,"" lI\ao WQuIdn ', drift Of dantt _~ m:-

u..

,o ,1..,

an'''''' "'"

ha..,.

me 10 mItkut.

_,,,,,>ti dust coIlcction Whybp<ping thcohopoobur

Ikmomc! 1. isn', lIanI """",, bu' 1 N'" It. So 1 ..-an,t'd
10 .... plu"" Ilie roUl""ll"nc"UOO maun ;n 01 ...... and
elllpS 1Hft>rc II 1101'(1 .lIe 11<0<> .
_ Orde,lr. 1 0~lcol bil .IO .... M" , 1'," 10" .oil mlJpllced ""o,es or blu, IUII"ly btcau.c I tlon I
kno'" ...h.1 I ' ve 1101 u.d ""II"..., w p u t 1, wh"n II

,,,ti

I.n ', in ,II., 'o .. ,,,,'. "oU." A r,,,q,,,,ntly ..

rou'''' , .ble hu ' '''0 (1' IlIree d ........ cu ro. '/)-loc II
sll.nk bits, I coupl" or 0111".. ro. ~~In"h .. h.nk
bl'J . lookl nll ro. :> ',...Ioch roundove. bU l YOOI
"nd up opcn lng and "l"lng aII , II" d ....... ero 1
w~n'''d 10 o'lI"o lU n,)' hi", ma kinll :> p"llcula.
>pot for ucll bl l , '" 1 don ', II .,., ' o look 'hroull

'"em

....... oU 10 fInd JUOI OQC. ArId ~Il

by 1''''"
lIt mall... a \01; mon: 5cMC: 'o """ th1n S<.wq:I,irtg
....... by shank !Ii>:c. (Do )"OU """'" ......., lrtit:tbUl'y Olt

..

~.

. Con,,""n' "''''''lIC for fc:.u/"la1xl<lnl$. ~ ond OIlle,

lip ;ond ~ usnl ""'" thc: Nu'''' ,abk
~ Qtltkt:. "" l>otIt ,hot rol." .... ond ,1Ie dust li_
coulII be po;m:d "I' a, ,h<: sune ,imc.

'h'"

1"hi. i:i an celcell" mI), of (".tu..., . 1 m.k" "" !>ono

.bo.. , IL.
borrowcd bra~~nly f",", hunc:h of . ......,
dc~illne"'. S[1CCln<."".II~. 'he . ",nd arul uPP'" """,0<"1 ~
d r. ws hnvlly on ro\lt~r .. hI, do"n"" h) F.1Ii,
W\olcntlnc and Andl Ibe WOI>dwot1o:.lfQI ... ri,e, Nlct
d . im, c~i, fn, ,he IIft,ap conc ~ pt , .nd IIi. "OU Ihc 1111>1
wot1o:.Jnll model I CYC , """. Woc>dwut1o:.", Fn:d ~h'bd< """.
ges'<:d lew ui'''''e ,wok. and fulo thl"Ollllhoul lne
dcYClopnocm pruca.>.

1",..,

rnwcr

I ("OQIC up wlth lIoign

""po<>ds 'O neh of ,IlCSC
..:cb OI" u..!mo. Fcw of ,1Ie Indivklwl !IOIu'ioIU ot'C ponJc.
*'f oriPUI. I admit. bu' In OJ!.SI"S",e , . h")" yldd
...... pk 01 WOO\bhop (urni,,,,,,. And the bcot of
...., blltC>.", u"'q"" to >hop-n,.<\e toblcs. l!e",s """1

"P
I I'>-i""h~hk:k . pl >..1e I>m ln.'c -ro."(~ labletop
"'""" 01 hl"'" plywood wltlt semloon.k<! ""nlwood
~fQI:

.. II/hop ("",u", tII., .110 .... )"OU '" oJJWoI ,1Ie rot.t, .... and
<hanll" III .. wi,ht"" Ilendlna. ~oopl n~ ,;quln'lng,

kll11nI. >rul o"IC .....,~ -"'1'1"""" '''11:

dam]XIn f~...,.,_wlllI ,.. own buUHn dam;--11w
di;t<$n'1 Inlede", wllll 'hc lift~1IfI kalUft:
. .....""'. hanh."U<>d, IIO$IAIlnd-ltPron Iqj 'Nm1b1y ,o ... ppun li>< tobl<"lop:
. , ..-plIn'e ""hlncI Inscn .0 l1ouc ,IIC rot.t ..... and 10 ptO.-Ido ..,....., for bI.., ...n:ncha;, an<! OI"""~,
du., ..-oI' NCIl Ion-1I puII. chip' off ll ile
_op 'h.roIogh (en/:C-fnOl.onlcd pId;up an<! fiotrt thc
roo.ur companm<:nl bomc.th
I:tbktup-~
trr. cornn"", ~ '"X\Jum;
. "...".,... dnwcr for .......,:
OcIMrielI oullcu Inlikk 'hc rot.tl.... COtnW!mcnt :tnd Olt
tht: ~ bold: cuntnJlkd by I .w;'dl.

.,_1",

,h.,

Th. ,., .. , . , u.bl.'s upper abi " ", enwJops the

router (when 1"" tabletop is IDweJl!dJ. CJptu""II 101
of 'IS din.~ mufflin.g Ils noi .... In .ddttion. II fur
n!shes or~r1y 1I00.ge for bin.~ otlle, essenli.,
plripMm.lIh... rlgh! l i )'OII' IIfI9t"ips

;J>

O
C

II ;;;
.,
~

.-

IZ

Iim th.t tabletap .;lled up , it Is surp,lslngly e~SV

.dwIgo bitI ~~ ~djust Ihe bit h~lght. The rouler 1.
ws;atdtd .\. very convenient lIelghl. ind \'Ou can
,. bolii Iw.nds 10 Ioasen Ind Ilghlen Ilie collel.
f\OO<St.ondin!l Roule, Table

211

FLOORSTANDING ROUTER TABLE

EJfPLODED VtEW

Maunl;ng

PI'I~

,,,,,. d"m, block

/ - ,,,,.,,,,

hlng~

Upper cablnel
Bil drawer

"

-..'.."

SIOr .,. dr.wer

...

II m.y nOI ~ Ihc mosi bc:un!fuJ roul~ lable )'Ou ..."

ro... h:o.u.wortdng piece:

uf .hop fUmi'u", ..\1 1' pllln ",.,. ,,, make !Il" """e. ... ble ""'.

c\'" 5n. hul It

1""'1 J:>:W.looklng

n.blr a""'cU,". wlllloul g""lng tn]O u.lng ",ally

~" ....p",mium
h:ordwOO<l&. Fu, Ihc sund ""d Ilie elIbinCl f. s. 1
uSCtl ook .n<l .ppliN. cln, finish (polyul"'<:1lu""). Fur 'hc
eli""''''''. I uSCtl plrwood ",,<1 popl:lr. ""d I p;oinle<l 1hcm.
Thc compl<"led l.bIe-. tincd OUl 05 sllown In IIK- photos.
;, sWnly. rigid. ;Ind h"",1'. It docsn 'l wobblc or "w'y. i,
<locsn', "lb,:ne, l, doe:;.,,., shlmmy or Ilunbog. l exp'l II '0
"""e n.... ~, lung 'In ....
" grea! bcncfi. of 'he modu!>, design ia tiu. j"OU elin
build 'hc: ro""" ble In ''''8<''. On.."c )'Ou Il.:...., thc <lltnd
. nd It... I'hlctop hulll . )'Ou..-an pUI Ihe roulcr !>lIle 10 """
WhCfl )"OU get IlnlC. buil<l the fencc.1lt.1t"lI g l,c j"OU plcnl)"
o( rou ter t"ble: rou nul' nner ,ake .he projt:e nr funber.
Bm f tl =on.mcnd )"Ou >dd Ihe elIse Ih" houscs Ihe
rouler .00 P""""i<Ics SIU",# for bits .00 attcS5DIiCS. StiU

ZI'"

ROUlt. MagIC

I'h,r. )"" can tinbh 001 .lIe uni, It)" buililing . he big stu ... gc
10 tiU It... bOllom of It... OI""". Thls 15 )"OU1 CUSlom
""'ter "bIe-. 60 rrulkc it scn" )'OUr rw:c<Is.
1, !Ill:! IIte ul.im"" rou.e, ... ble! Hn1:. no. ClClli,,,
"vodwon.crs .'" "iIl noodHng :uound oul Ihc'" In Ihc
"",rI<shOps uf AmeriCll .nd thc ,,"Ooid bc}"ontl. New ~.
",,<1 conf'llur.. k"''' and aecc:"""";cs
bound 10 ctOp up.
10 mj" n.ind. Ihe..., tIC""r wli ~ "" - ultlnulc" rotIler bk.
For now. lbough. IIlI:! Oflc ia p",n)" dam good .

<1"",,,,

Building the Router Table

This I:! modum- Sh"p fUmit"",. mode up of si" SCJr.Ilc
con.ponelllS. A. ntlnimum, }OOJ nttd .0 build '''"o of tt...m_
Ihe >land .ntl Ihe tobklop - In onkr 10 tI>"" worllirtg
rou'e' t.ble.O""" .tu:sc "'"o ..., buih.j"Ou ctn USC Ihe ",bie.
whcllK-r II bc for )'Ou, ""," .. lar ... oodworl<ing ar \O complete
Ihe olt...rcom~ls.

flOOttSTANDINC ROUTI:R TAaLl PLAN VIEWS

TOf' VlEW OF ST"-ND

TOI' VlEW

18 "'

" .-

,,-

;i

-1
37 W

FlONT VlEW

S!D VlEW

,-,

"IW

..

,I

3l ".

,.-

,-,
-

- " ,,--".-= - 0'-

(5
'4l>'1"

,-I

.<2

L~~.:~-I
r-r

'11," mln.

,.--i

ftOOlSTANDINC ROUTER TABLE SECTION VIEWS

FRONT SECTION VIEW

.-

II

Building the Stand

"""CI"

uble \s Ih<: .. ~ntl . "" li m.k ...

I!uiltlll fiM. TII ... >lantl \s .lr." hlf"""'Ud, 1.... 4
1oJi.nd 10 nib, bul II U; OI.ronll ami rIjd<I Wl1h ""n:w
~ 1mWIN. li c:tn toc set >lluan: ...... 1e""1,.,....,n .M' .n

l\r blllilatJon of II><"

,..,.."ily

I><"n: In a.'oIcm ' 'l:nn'r'.=b.

a.-:olbblc fn>rlI loc:&I
"",,mill ... 1"hc """,II I.s an o>p<:n JI.n<lllul, III;llvy ~rlOUIIh ' 0
>I'Y pUl . t,..", uJKlC1" .1\( !II,"" 01 """" pmty v\jI<>n>m

. . . . U)

rou'~o~'k>nS .

m.IatinIl fIoor.

1. CUI II", .... ru. u.., .JIr..tlW,,""W"IRttI. <kfrct.f..,.

'Iock fo r II..,
MIII !oIock 10 Ihlekno.."", of' ~ IndIC'"
.. " ',," loch . Rlp ..." crosM:ul 11.., Iqp ......... lls 10 Ih<:

I UIit"d (I;lI.: tOr II><" ,....,"'III)'. 11 II !oI1"OIIJI, . unell>.., . ""

$1'"''

FloorSt~ndlnllll.oult.

Tlble

215

lEC:; AHD ItAll JOINElty

STAND

FIIONT LIG

Curtin. Ust
rt

Q!y.

SOdt rJJIs

,."

~k

rl,ls

Dimen,lon,

",;neri.i

IJI,"X 1 JI," X 12W

14"X2WX2'W

""
""
""O.,
O.,

JI," X " " X 20\11"

Ook

"" x,." X 2S"

o.k

111"

r.r,"

X 3" X 28~""

liI" X

F'OIIt ,aII
801l0m f'O~1 ", I

I"/Mntrs
( le,1IS

3" X 20W'

2" X 28W'

IACKllG

)l".<~

\oi" (tyJJ .)

\oI",wIcIe II
" "dftp
",bbtu

Hardware
drywlll SClt ... S, #fi X 1 \Ii"
4 T"uts, y","'I'

4 adJUitlble \IJklu: ."'-50 from Rtid TooI

Supply Co, (8()O.251.(M21J

dl"~n.lon~ apcdfled hy ,IK Cunllljt U,;t. R~p and

cn....:u' ","",,,m, 10 fonn ,IK runno:n ond dnts

2. lto UI lbe monl,..". 10 Ihe Ic-p. T.lke IM

mon"., ... ..,. :and Io<.'alkl<l. from tM dn~
l~ '<lui tt.. 11 JOI""? II\d Iq OUt u.., "",.Irp NoIc tb><1
aU tM monktn "'"'
h.cII wi<k 'TlM: ....,..,1oQ for u..
"de' "'II. "'"' oIf-.el '. Inch
.IM: 1f\oI(k~ . ... hlle
.hooot r... Ihr r""'1 Ind bod< ",ils "'"' oIJ)Ct ' ,1Kh rrom
III Ihr oulOOlk ~
II
1 ....... t'd aii In..... ....n>CO """"" ~ routtt .....
,lor .\ton ..... Jii "" ..... 124 M<>ot 01 u.. monko.",
2' , irK'ha~, Sn up ..... ,. ..... do tbox nI!II'U$a 1locn
ma .,.., lillior llor ohoncr """'bo ond do _
lk:'IU. 01

'* 'rom

-.{!..
.!
"
'"
O

3.

Ik>re Ihe

bo~

-'lUlt.~ ~1Ik.< """~

ro.

thc adjUli le .... 'TlM:

you 10 Ic:vcl tlor n,,"c' I. ble OII on

noor !lut Ihcy 01,;0 .1_ !'O" 10 ",t.e Ihr nlll",

t>l* "" Int:h ar ... 'TlM: aIidQ Ihcm..,h-eI Ilo...: \o-Inc:'"
dtlmc1cr ohanb ..... ..., Ihrnded Into T-n\Q, "'" nn:d h.
dnI \ ~ XI',.....,., piIo<> for Ihc T-n .... Ind
otJfu:>Icr oho.nb ......... CCftcr 01 och ...... foot cnd
~ lIoko CM br drilIcd ... It.. tiri. ~ .... Ihc joi>
CM >ba lor donor "*'III ..... pI........"" _11or mon ......
lIIt.- l""'w ........ lilI .... II(! :and Ihc ~ bit Pl .hc
unn'm

...... (ii...: il

It)',

_"C1
""",....:ut'

4. Mound-<wer
u.... ~
Phk (but

.....u

thc c:a:pojCd
01 ac h q.
bit. nu. ....... Id br tU)' un I n>Ulrr
build;"g. to'"'''' hk, II fU>!

""r

bc I"'I)'OU don', ..."" OM).

Ta ~ IM joii ""Ib ~ ... n<l-hrld n>UIC', doi! I 1<11 10 Ihr
~ Oplurilljllhr crllh o(
kJI.oo )'OU ~.. n makc

1""

216

louttr MiO"

TO ba Ih. MljU51" hol. . OII 1110 monl,l"1I J....

w up IM J'O\ ..Ofbul fOI roullnO ,nd monJOH. 5o:t
up ,1Ii! fOiItt"" flIOII OUlcM 10 umer Ilie hoIes. ,nd
pO,1t1on tht SlOPS ' O pltvenl Iht route. f...... meM"II
IIltlln.,.. One bv o .... ,,,mp ' M 1e0' IlI tM ~ Ind
plungebOIt Ilie hoIel.

8.

OrI.., m., i"~",,, tQr th.; t:<bktop h l,,8'" boII'!.

moununj_ 1n d'hcr lIt<: 11fI-wp OI" lIxc:tkup

runllg ..... IIon- ...., hoIl> 11111 ...,...,,"'Ie 11", kw' ~nd lurn
imo 11uc..xd imcm ImtalIrtI In l!te ~. In Ihe IIfHOP con6gu","Jon, IIt<: ,J/unk \t(lkS """ 1""""" "'" In l!te had: 1'-11'
onl)' In tItc: IIxnkop fonn. aU r......~, mu,", It<: o.IrillN
Whil<' It wouId Ix ca!)" la dlilJ
ho la be(o",
.-",bly, tItc: holes ...,..."...., thc IOP r.til 'e"""'. $O t'<'u
111...,.0 ".,.;, un.1I afler Ihe llide t.... ....,. .'" glut:d up t" n,.ke
Ihc: hoIes. 'Jbc: a;oom,bIcd !>Idc t..n"", .", .wk..... rd 10 .......
10 driU tlle
lion 00 IIt<: driU prea. but IlIi! "' IIt<: bc\
~ 1lt<: _
""""'" Ix pcrpt:ndicul.r to ,It<: kg ni .
AI neh >pot. Will tltc "neh.<Jbn'~le . :1"'n~h-<kc:p
pilof fur thr In!OM. 1ltr:n ~'itc" hlt~ .nd dritl the: 'M nehdWrt<:tn ~ hole on thc ~t: ""b. Uri>", Ihe In",,,,,,

TIt<: _OI'

1""""

war

9. l' lnish assc:mhllnll tm: stand. "pplr ilh..: to The

mortisrs Ind ICn\IflS, and jQin thc front "nd Ick r.lIs 10 'hc

_,",""Ve<" O"' edilI. of each leg . AllOICh a thunk

~tht ~

stoc. 10 Ih. rouler ba~pl"le ",,;Ih arpel

Tht rou,er wmlhen be , upported s.qu,,~IV by
!IIt leg .nd 1"" . cr.p , m.klng It U'Y la perla,," 1""
\lpI!.

""M....

Kcu~lely.

1""" ,,-ilhou,

_ cdtI< 0/ ndI q .

int~ Roun~-a

only

S. Cullhc ..,ROM on Im: nou.~. Whll<' the hciJ!ht o(

............. rics ~- ""'. thq an: consiSlently ~i>",cd,
otIl I ItngI:h of I ind> ~II<I \t.!nctI.,.,kIc ./I"u ..... r :tii
tIIMId. ~ oM r.H .oeI: "..s n>llled la a ""miSlcm
IOd omnlc t.< ....llthlckncu. )QU Oftly
ta "->nn t""
*"'dcT Jlr1lPCrIy and Ihc: te ........... "" ,.,m be rorrn1..
IIrn:'S ilOOthc:r lOt> ,1... , rould .,., dofle qulckly on
-"ubIc, lI)\MI " .... OM. lt)"" do ""''C lCCC>o> tu a ",uler
..... 1nIkc tcnonlng Jlc:d (sec Ihc cl1lplcr "S1ctl." ... ' lUlI'=
lt611f1d IUUI Ihc: len ...... OII 'h" tno.l'I o( 'hc: ",H~.
OLIt<rwbc, ~"I
tet""" on Ilie t.ble ,,"w. lI>lnll
lIIIINn< tmonlng lig.
Ilourtd Ilie cdirP "r ",,,,,II len"n ""illl a file , .nd 'OI hn,.,
ndI tcnon n\J IlS morti..,.

It,,,,,,,

,1..,

r........,

cu" "c,,,
"'1""'"

:bSt:mbliD. If tIt~ joIncry

d<tnc ICCU""cly, l!te unit >hould COllie: tOll"llt<:r "'Iw", .nd In,..,. bul
_ n : di.:l.gon>b Ind chcck "ilh.
10 "" $Il"'.
Wlt<:n ,!te gluc tu> ... ' :utd Ihe cbn,p' "", uff Ibc """"',
1"",.11 tlle fUnn"", .nd elalS. GI"" tit<: fUn""r 10 IIt<: ",It..
bul nOI th., 1cJIS.,"ou Cln dri>'c IWQ or Ih..,., dryw;oU x"",,,
duou!!.h c:adJ ",nnet OI"
in,o Ih" r.ai" .

sid<:

et",,,

10. InstaU thc adjustml. Upc:nd 'he ... nd and

dri>'C T-nul Into """" q ,1\tm thc: odjU>lltbk glidQ inlO
IheT-nulS.

Building the Tabletop

TIt<: ,,"Olt. pbtfomt tor this roul". Ilbie ... tItlct.. broad. LI ....
InItN:O>"'rcd t.blctop.
pn:fcttncrs mar ...... }'OU la
tu."" C11l"JOCd ~ing or to c<M:r ,!te ~ ~ wclI a
,It<: lUp. wlth 1am1nl1".TIt<: 101' I dt<x;t 'o nuk., """..,..,,~
concnkd ook ~ndina . 1b "",. tltis b l!te moot <lur:lblc
<""f'Ku .... IIoo . ... ncc Ihc lami .....,.,.".<:<$ "'" ~
as "'cU .. II><: OU""'r:lI,,.
n.., I '+lndHhld: ublctop .. <:eruinly hcaV\cr 1""" a
14nch-lhlck 0t>C. which mcans il g;'u g<n1C1' mass 10 ,1>0::
mIi", W>Ir. 1t _nu """" subountial.

''''It

-.

6. Ibbhet the noi"'. TItc upper ilie. r:all ( " '''lell Is

...,. a/:IooM mldk",,!) b r:lbbctctl alo'LJI lt, Irulc. ~ to
I('(QItlmQdJ.e .nd/ar ,uPl"'rt tlle c.blncu (Sec thc
"IIILrg ulld N,,// .I<>/"cry.) TIte ",bite", an: "'" '" Ind>
Ietp 1n\O Ilie Inner t><:c o( ,It<: raii .11<1 .", ~ Inch ... idc .
-..mI ffOO1 ,he ctl"" .
OII 1'" r.tbbc1s"" Ihc: t.hk 5;0 .... Or ' ou' ,hem ... I,h.
llaad-hold rouler 1.pc: supp<t" blo.:t. 'o ,tt<: fl,lUler 1:..,..
!>tlp Sln<1f ,.'" nuchl"" durtm; thc op<'r:lIIoo . ..
)'OII \II<l1n I'QIlndlnl('<>'"<" the Icw>.

1. Mak"" the: labldop. Lct mc dirttl }'OU 10 the

chopcC1' "("-""om 1I<)Ulnl'1ble Tup" on p2It" 156. lltrtc }'OU IA
",iti fi"" dn2Ikd . .. ~C'(I dI...ct1om lOr stuIns up l!te
....bstr:ll., . wttirts l!te pWiic laminalc. and 100 00. TIt<:
tabktop dao;rihcd In tl1l, mapccr "' ,!te w::ry _OI' .-d
.... ,IIi> """er tablr. (1 _
}'OUlI r..... that ,!te "'blrtop ' _ _
...alon o( Ihc Cutting UoI """" "'*dtes thc CunillJl UoI
11tcn:. " '5thc samr "'bletup.)

7. Ann"b!c Ih ., ,Idc r.... n..".. "pply gluc la l!te

lIOI'ti!o:I; :Ind IC""IU Ind joIn Ilie partS, Io,j )\MI cbmp thc!ic:
.....wcs. ehcc. Ihem ,,'I'h a ~uuc . and m~un:: dlajpIII!' front ltaoJ , o I'oot ' u cnou'" ltu, Ihcy arc ,,!uuc ,And

2, Mlkc: ilie h1nlJC'l, Ibl!te. 1""" ruoh :ahcId and cut

11>0:: mountiflg pble 0f>CT1\n.8. liItt ,!te tabIcwp \nSI:llIcd 00
,!te 1!UfId. TItnt ,!te 'OI' wili bc .... pponcd whcn 1.... do cut
"'" ~ n.., fin;! >tcp in """""1n8 ,1>0:: ubkrop .. 10
.... ke II><: hln~
'Jbc: ............ ~ :q"Jp<'O>Ch gi>-a; }'OU Ihc 6"" 01 l!te

*. .

,..1<1

. . ....., I ....

y.'" fi,,,,lOII ,

-1

TABLETOP CONSTRUCTION ANO MOUNTING

HINCE CLEAT LAVOUT

TA8lETOP LAVER5

23 Y.!'

Plas , ic
,,",V. led

""

I.minat~ }

W bireh plywood

edge

r - r - - - - - - - '"-'"-4Jr
2 '10\.'

H,oge "

Solt ,

Mitored ends
"Backtr"' lamlnate

Hardwood edgeband lng

AS5EM8LV OETAIL

Thruded Insen .........

ii
~",ha.

Flat WUhU!

I,:4iY":.,",:., ., ':,eL
~n~.:~
'w,,"

X !i. " pilei fer inun

Wdlll. X 211>" bolt

Wdia. hole for bushlng

~' dlll.

'"

shank hole fo, bolt

TABLETOP

Cuttlna lIst

Part

Qly.

Core pile,

~.

,
,

Edge band,
Edge band.

Dimenslons

x llW X 36"

Material
Blreh plywood

WX1Yo' X37 W

wx

IYo'X25~'

SUffue covering

y..' x 26" x lS"

Plastic lamlnate

Souom surlace eove,lng

y,,' x 26" X 3S"

Ba{ker

Moun,ing plate

WXS " XII~ '

Phenoflc plasllc

W x IY.." X 21Yl"

O"

Hlnges

Hardware (for Attaching Tabletop to Stand)

4 brass

Ihr.ad~ in~en~.

!4"20; ,[212 from Reld Tool Supply Co. (SOO2S30421)

4 h.. hud bolt,. \<1"20 X 2Y.."

2 bronze bu,hlngs. !4" LD. X 'ro" 0.0. X l' long; '01880 rrom Re,d Tool Supply Co.
8 H/Ii wUhers, ~.' 1.0.
drywall screws, '6 X 2'
drywall screws, #6 X 2W
2 DlUS ID!lgie latcl>u; ,OnS02A from

R~jo

Tool Supply Co.

2 DlUS strikes; 'OTLSOO9 from Reld Toal Supply Co.

S panhud screws.1fi X l' (for laIChts ano sttlkes)
I fOld,oglld Slay wlth moun\lng

sc~ws.

'6"1' D J1QY I<>Nkd fO' 1"J1DIID'/cII "" III<

.l1<li ~ _nr.

2 18

Route, Magic

lelthand mount'

~f'. c~~

tlJough II ",III ". 1~"Dllod O" ,1>< rlg~' .I<h of 'N rD/rI

I~'

/dI..h<r'lll ~'Dr Is

- . tmk;6 lII2flJ' choic:c1 0rM: opIOO S thc liti ..Op

~ Thc: <Ilhct Is lhc fu:C1HOp opIion 0rM: <Ioa

001 prttl_ ,IM: 0<IM:. Thc: constructlon diff"mlc"

m-.m "'" opIioos Is IWU lO!Qdc b ..:hcs ortwo boI~an<!
M:odod i _ Th<..- hn ', Slcq>. an<! ,"" _
hn' ,
0","',;1... Muc" a litI "'1'. 1f)"OU ...." i', uk~ off ","
..... 1aI~ and irualIlhc al'" ....., bolii.
C. ."" Iunw: dn". '0 thc di"""'sIon> Spo<i6cd by .hc

0IIIIirtI1ht. Slut><" lhc cnds of lhc ck:>. ...... .r.o..", '" thc
- - . 1IIbI<!fo{> l'.onsIruetlon u"" .1I00mlf"s.
1"0 b::;u" ."" h""""",,, IIo<>IQ.cWn[> dw: h",., ck:>.lS '0
.. 0I:WId.1n>cn a Kn' ch _1 "'........"" h<>k> In .hc ~
. . owtt tht
lOr Llw: ~ """'" In ,,,,,

""n,on

..... DrilI thr hoIH "" "'" driU fI"'SI.

]. 1nHa.U .hot: hlo'lIft. llw: bot ,...:al 'o p<l>O'on LI'"

-.: _
Il '0 III .hnIt '" "'" Sland an<! .ablctOp.
lIqIn by boI"/lI! .11<' h",w: clcal . in pbcr If)'OU 0[>1""
I>boft: hok:s n oii lOur Io:p. 1"'" bol' ,1Ie ck:>.lS 10 ,II<: Iqpl.
It """ ln;WI thr bu>I'llIjl:i. and thc (b,
ti ...
..... :ar<' axtIr l i 'hcr ,,m II<' In Ilie IinW>cd [>rod'..:t. If
"'" 0f1'("(1 lOr 'h<: MI .. Op c:onfigu n.on. i"".11 ,1Ie ci""".
.... thc hnltlC" bol .., ,""n damp thc frtt m<b '0 thc SW\d's

LO

"'bM"''''

......

~ liCI

Ill<" uhlaOp "" 'hc tin .. and align 1. ''''ry

(lamp .h<: dcolS 'o thc
,"OU """ er~wl
..... bmn,h thc ... nd. driUi/ll! 1'1101 hoIa an<! drhillj!
Kffft, Kl joIn ,hc elcalS 000 uhletOp, lI,u 1. ia cuk:. 10
.abmd ,IM: bol!.> (and "n<:lnnp.h<: d ""lS fn:>nl l hc ~),
a I _ 'hc uhlc,op ,n)"OU. ,...orI<hcnch. s.:. i, .. i,h ,1Ie
.... drm; ul', of roti...., OrIU
piloti. dl1 ..,
xrews,
al thc III.."., ,,mIM: """,n.ed.

,.bIe

~,

.h"

.h"

4. Moun l II><: tabklop 00 .hc: b'l.:Ind. On( '~sIc

"""""II> """"" hoI."JI: ,1Ie ublclOp ,n placc-. lf)'OU waJ1' ' Q

'<>1"

IK abk IQ lift .IM: ublclOp. )"OU h,... " IQ radi ... Ihc:
of
.hc: back Ic!r;s.. A ",,"able IKlt under nukeo qulck w<n" of
,his dc:l:lt.I.
Now .....1Ie: ubk1<>p in pili"" Ind imlall thc boIt~
Inst;d! ,hc:
I,uchcs 1Ia'. ~,erml"" IIM: p<>S1ton
of caci> br 1IoIdi"JI: .hc ,,"in, Ioop up and 5liclng 'hc b,eh u[>
lhc ks until thc 1001' 'ou.chc. thc untkrsi<k of 11., .<>!'. lIokl
,Il<" b,eh in .... , 'p<Il whlle )'OU lin ,he ~"'eh ~nd m,rIt
.hrough thc 5C1'CW h<>Ies <l<l 'h" leg. OriU pilou and "'rew
,"" b'dIcs in 1'''''''. ..",.,Ion .11<: Stril<cs and ",,,:,., 'hem '"
,1Ie undcrside of "'" 1<11'.
AllxII ,he Ild M:1): nu. i!i .. t:tdt.<-d
th" 1<11';1<1" r.U
and "'" ublcl<>p.l 'bc d ... wi"lI 1i,bklUP C", ..tmdlo" ,mtl
"'01"'11"11 pnwilk:> spn:illc k"",.1on Yuu ""'l" wan, .0
experiment. m. '11 determine .hc <lplinuun 1oc-"IDn for "'"
oUY)"QU bu): In any n"Cn . bC" >urc )"QU urient ,1", ... ). .., i,
IOkls 10 .hc ftun. of thc ubk; o.he,w$, i' rrut) c<>U.ipSc

''''*'''

'o

i.wh",n~n'!)'

5. Make I he mnumlng plale. Afie.complc'inst and

""",n,'ng ,hc Ublt'<>!" turn 1<1 ,he: ch.>p'e. 'Unl'",,,,,1
It",ucr Mount;nst !'Ia'c on ~!l<' 16~. In .ha' eh'[>Ier a",
dc ikd dltttllon. for maklng ,hc nI<>Un.inst [>I:olc UsN In
,hi. """e' uble .

6. ln~1.:I1I Ih" " ...."nllns pblc, St")' "i.h "'"

",,,un.lns plo.e eh.>p.e. lOr 'hc dirtttorb QI1 ",,"Inst thc
"""nlng In ,1Ie ,ablcoop for'lIe mounllnS p""e." rouplc 01
.lIgh'!)' dl" .... m .ppro.:lChc> ..... <k.alled ,he",. El.1>cr """
.... ill worlt.

..II

....... ,1 ... labl' lop squartly on .h. "and by stI

lWj
IlIbltlOP (bottom '$lde up) on )'Ou. wo.kbench
ni up"fndlng the stand. wllh Ihe hlngn /lullched, on
t Thls WIY,)'OU an tlsUy allgn lhe ".nd on Ihe
tllH!op. Then clllmp .he hlnges 10 the .abltlop. I l
Ihown. d~lI pilOt hOles, Ind ci ....., sc~ws Ihro~h .he
br\tfs ""o ,he 'lIbleIOp.

1'"

To fiI Ih, 5U1)' Mlween ,hot.op fiii of the SiliM I"d

,he hlnge, 1 ntflIed '11 rout II "h., Inlo Ih. hirtII'. 10
do .hls. I mode a templa't of IHnch pIvwood. I bored
''''0 semk:ltdes In lhot templ~1t ~ wuh I FO'S'n"
bit. lhotn (U. IIW~Y the w~ste lrom bet_ lhotm. '
cl.lmped lhot templJlte .0 ,/'le ~'lIafld I'tn9l! IM
used Itmplate gulde Inci l4'lnch ...:aigh. bit '0 .... k.
.he ~lIef (u . 1$ $hown.

Ildore you cdch""e, brca.kOUl' <.'."In 0(1\nbh an<! ~

tob.\"rnbh lhc: np<$'d ","QOd- thc
and Il", ~ Iruidt tlle CUlOIJ' for t"" """"'lina plai"
Of COUD<', j( ,hb Slcp 7 Is bul a >l"" on )'OUt ~
}'OU nu,' ...'an' , ,, hoId o "" ,IM: fttIbhirw >lqo "",ij ,.... ...
sot ,"" fenct and cal>lnml huill, ' Mn nr..II """" . . . 111(
samc" ,Imr.

~ '" pUa ,"" mounll"!! plat~ i> for you to d~.

1""'" are my thou!Ihts for you 'o ,,"cigh os rUll ded d"
T1lc pIMIs. 121<"" rrom "".: ruu,~. Iabk: ,"""wn In 'hls
bit ",,1, 8 Inches from d,~ rron'
~ o( ,"" ,~bletOJl. Thil! il! ~l1e . ,hon 'he n,r:illcx:>,i(>n
th.1l b "" ~t . I"d bct 'ho' 75 j1CI"CCJ1' o( 1""" ro,na
tab!<: ....... uwul,,,,, . hon, n.rruw ...,rtpin. (lltls I:i
~'" !N' ....... 11 IKnch~op roltla ,abIe!; . ", 50 scniaoohIc: .) I.oco'in~ Ilie
re!>';,,,/y elose: 'o ti><:
cdgc
m.o.kd ,t t Ur 1() ~ ((}t th llt 75 lW'~nl 01 f"OO' \./odt.
Whe" )'Utl h3''' 1.'l.t" P'~1
roUI. 51 "1' 10 ,1Ie n:;o.. o(
tlle t.ble and . <kI1"tSS the !)Il rrom 'here. You hau. n<:2t!t.
lnch'wkIc .urlloet bc:,,,, ."e n 'he ~~ ~ and ti><: bit
UlII Mth ''''' route.
whidt b. wotk surfxc !N,lI
.ruppott . IUG ",,~l. h '~ "10'" ,"'ppon 'han 1'0011 JIC1 rrom
table wlth 'ht roUlt:. In lhe cen,raI
In ",""r .. ottl<. ,he n,raI RIU'a """'tlon b. eoat"..,.
mi .... b<uf comprnm l~ for mos! o( your ..."O<k,1t Is tOO tu. ""'r fn,,,, "'IIe,,, you ha,,, 10 Km<1 Nod ..'hen you have:
biA ","Ortpi".", I, ' '00 doo:c 'O III 'he tdjp:. fH"\""llng thc
....... ,.hlctnp fo,." ""Ing u.~ 'O )"'" ...:1''''''''11<" in SlIppOnlllll 'he wotk

dtap'''''' p""'....."""" ,""

,.bk:',

""",t.

Building and Installing

the Ballast Box

'o

If!"OU Iruend 10 lnrotponIe lhc: IIII->p (o,urc Imo,.,...

0"",.

"",'a 1ltbIt:, )VII ~ 'o controm ,he tlp-<7"Ct 'l-..drome.

Th<: bct is. ' his ,""",eT t2bk. Iil<" III
'"'*'.

.....,.'ion.

I"u, 'he moun'lrtg pIa,e ... here you ",i D. l

,he O:<et 1oa,Ion _1><""0 10 ,"" pb ~

cd#'-""""""

pkt" ' h"

OI"'" "",'''''

"'dIIh'

" t ~"l' """" o( ,""

I!I 1" ,lIe tabk:<op :and "'"
routcr, DOI thc SOIId. 1\II IIlr 1ltbIcfop. and Ilie ...'d!Vt' li
~ and rru-o.-", ,~ ,"" bodt. In ",;,; a'Il'U<k , 1I ttIIn
a

''O"f'''''''' pusi> 'o l<>Jl'I'k lhc: """'~. tabk. lbd"""'"

BALLAST BOX
Cunl,. Ust

rn:ontI1I<1>d

Pon

Dime n Sion s

,,",

,
,

Ji," X. ' X 19'110"

k~

I-\,"XI9W)(ZS~"

From/b.Ick

,. Ap ply tb" n"bh. k1no' ,"" mounllng pbK to

)'011' IOIIte . nd dmp It In pbct: In ,he ",biet"". ,ou,.........
JIOl I"OlIta ",Ne 1"" <.'."In ..... If ,hb "OU )'OUt tkstination,
you \'~ rnchN 1"

Qty.

j,I," X 4")( 261-\"

M;tl e rh.1

"",
Pop"r

"""" I

IA!.lAST 10X COfrfSTIIUCTION

..l!!,.

TorVl(W

JOINERY DrTAi L

C_

OI

Z.

,lele"

,.

26 )10"

'orbouom
"""ltll In
front, Ind ~k .

2~W
' -~

.,;
20,,"

O
OI:

18""

W plywood bouom

FRQNT VIEW

SII)( Vl fW

li
-

-lot"

C;

20W
19k"

....

[1

~l

OII LM IImch-ll., Rouu,r11oblr. clic .rndrom.. 1> .,.,..,..

IrmIbr chc tia.... <bIgn.Thc ph.... 1'....... io IOtwoatd ni ~

ltIdi tdF ni ..... ~. S. J'OU "'mc co bc: abIC' 10 odiJrb.
. . ~ 1t"",."llobIt rrom chc bxIc <XClI>oIona1ir
1'111\ dx poInt ni otf>CI11ng chc
.....",.lotI. 1f
.hc bxIc po5I$. fK 5C2b 00
r.:... , )'O'I'U ...,
. . . . . ~ .Item Ihc: ...... unproplc!ouS n.om",""
,.,. ....Ion io balJ;w; boL Ih "",hi... ""'"' cl\;ul a
beii dA...". ~ rrom thc: k>wcr raib, VO<I I\;I\,<,
.oocao c... thh bol< onJy ""hc:n "'.. ..onll" dr~",..,.. 1
.....wd. Wha. J'OU 00 b AII II
bdiul' ..:np lron ,. ""II

lIOOUn'InI!1>lo'"

"(MI

donjp.""

,,-i'"

""."'=

co.:mc, ~ . . . ..
yo.. "'" romc: "1' .01.11.
.... dIc:op anei hc;o,"y YOIt ncnI '""'- JO 10 SO poun<b

1. Cut IM box p;on.s. Thc bolt it. .... vlhlInlwood

.... ftotor . ano! .It. MII ~ pe,...'OOd boIlom.
" - It il ' o bo: palntfti, J'OU >hould ........... lhac "
- . , Iroa~ aM !ha! Wet p;w1l ..... .
c;. Ihc: parb 10 thc diwc.diotb ... >cei3td bf cIM:

_....
......-

2. Ilou' Ihe oo.~ils. Tbc fro<>< anei boodI _

joincd

II clIt licia orich 1OUI(1'<uI haIf-blind ~ . IIC'I lIP ...,

4tJo<naiI jla and ..... ..,..n, anei makoI: 011 Ilie 'OII nob lWCfto

.., 10 ... ",-.:IIo"'C"" duo"".; ... Thm

!'OUl

Ilie 00.-..01/0 ....

3. Roul Ihc groov .. ro .. Ihc OOtloon..... """"'-n In

IK Ihwing H.oJ',m Ha>r eo .........,;o... 1"" boClom 15
liIIDIo!d In 'l).irIct1,,1Oe x ~-dttp &fOOI-T Thc: .,.,.,....,
I'! lftdI rrom ."" bo"..... ...." of tM 1IiIJoo, t .....c. and
Itd.I madc Ilie W"""" In 1"" t.....1 and baeI< OI"""""
..,.,.. 00 k wuuIdn , ..,.".. In """ aoocmbInl boli. Tbc: .t\IIh
a.1Iown'tr. tlut ,"" ..,..." tlbk', kp con<'UI thc: joinc. In
.., ~ bolt,,", ,. ... dorI'l ...,.,.. 10 "" ' 00 panlculor abouc
.., lftII"'O fTIlm ... Ippnr;tfltt 5I:lrIdp<lim I ~ ItIc:
,...,..,. 0II11w IOUIcr .:aI)k. Onc .nUl' """'" aU ,.,..,. p;Itt>,
4. AM<eonllk IM b;oJla,;t box. It '. pruckm CU
........ IM boJl ... i,OOuI Jtluc 10 el>cdc how ,hc palU fie
qnbn; ~ )'OU co rnn.. adj .... mm .. It ~.
n.. k (IDt:Ii l.,.,c""" r-4>ily ,,l1.houl .."". "'" OUl Ih.... "",
.... ....., dam!"" anei li<:! J'OU" OIuh dotoe al 11. ...... ,
AppIy 11:1.... 'o ,"" tai ... and ~ .1Ie box. AII""
_ _ .... Il> """',., dwio """""bir, hul dorI 'I ....... k
..., a.ap lho: _mbIy ...Iil thr """" >cu, and
III II> wIpc "" ...,. ..., oq~ bd3rt " _ ,

'*' ...""

S. kftw

IM ~ 10 IM Maod. Thr

boa._,........

..., P<**d out. ..... ,"'" bo" .... el ."'" ..-s. .......
_clItlio::low(1' ...... 11 ...... u~ "'" boii .... ofthrdncJ

.ord le> tM lo0>'OI .MOr

ma.

Ac !lor bo:loz lInI k ..,. """ 10 boe ""*d fK pbncd 10

IIIIcn>m\ lht Itp. .."." )\IlO ,.... It 10 Ik. dIftIp It .. pbl'r
_doM ~ "'........ ~ Intu bolh Ihr front anii bod: DIIs.
AfI ... FI'1na k mouncfti, 1'1..:1< ..... Ilie ~... l1l<I
- . , ....., bol< ro, pauI.i .... ' 'ou Qd mouua II II\n botll
bo.I """
~ ba\'<' bn flnbhrd.

c"" .. . . .

,
elam, t"'lNolh.st boa 10 t," stand wll,~ you d,m
pilot ....s for IM mounung S<:~ then d ....... tM

. ,nst

K,eW$. II fIU bet_ Ilie legi, up

tM ClelllS
Iowat s,~ ,.W . An .. mlng VOIIIwI~e
mo ... unu lhan' do, .,.oull do lhe Job <omfon
,bie WOflting he;g.l!t by Kttl"9 tlle Slind OII fOIi'
JtUoched 10 IM

worl<beflch .

Building the Fence

... fUUtC\'" table: ion' eomplolM "'-it ....... timu- Tlaio
I\u lhttt bn~ ........ b wtina .......

al\lOOd ..... pidup

Inlevol, lIdjI.tIubI<: damps
a 1>fuJd, (b. b;ox

-.k;"
c......,

Tlc .. d"'" pictup Oi

a ~"JC\>"'" """", anII
1, ~~.h(: ho<o<::os
Co "'~ labiC'lop.tl1ff:ca ...
W1... I'\,<, lbund Oi ch.c d ...... ndchlps Imd c.. I'n.. up.c.ny
II~ OI" lcd(!IC bc.wcen Ilie u blclO~ and ,lIe l106C IlflC'nlnJ. So
I ~HonUuled
lip by ..,nlng ,IIC hO>C tJf'<'nlng 10... a.....
ongIlnJ h I....... td clle ... bletop ... tf'>a
Vou Qd ..... lhis p;d<up "';.h
diIttC I'rom )'OU ..
>hop ,--ac. fK)'O'I <:an
~ m,o c"" tatw. ...1<k d""
('(IkcIor bf .... nIn& >bon ..... 11. of " ' - tfOIII tM kna:
pekup 10 Ihc: ......... companoncnl
Thc: brood ~ anii Ihc: ,",...,al dantpt _
,~
10 Pf'l'I""IIr -'">IId dlmpina. ~ vi...., timu- ortcnu
t10n flnC of aii. iri ..... pDinI .... Ilie do-~ around """
..... pboIic "'inlndS th:at ....m ~ do16Ip hIorb apirtot
""" ~ t i ..... - . . . . AII 100 oftnI on c_>ct<bJ
Ihoe knobo ................. ~
kntt bdnIJ:
'J1#lIm Ilie knob, ;ood J'OU tcT.lfI" ,our l<nuckIo .... tM
fadna. Nor. "ith ..... ""'-'r.
T1>c rn.c.. <'III bo: q..1ckly ~"" ,rom Uor tablr ~..,..,.
pkc~Iy, )wI loaIcn Ilie cbmp knobo lItId .Ude 1"" kno;: ..

""""bir.

.Iu.

inrorpor:I'"

rrnco.

.;
.-"
C

"'*'

1""

;;

CI'

FEN CE PLANS
ToPVIEW

CLAMP 8LOCK OETAIL

".

fNOVIEW

Wrad.

I
'W

moun!in!! optlon.1 f.dn!!s

BOTTOM VlEW
W di . hol\ for elamp boII

'']
'1.

CLAMP BLOCK PATTERN

1 sQu,,'e _ W

I
2W

EI""Iffi

...J 2~-'- ~" rad.

FENCE
Cuttlno L1s1
Part

Qty.

Oimensions

'm
Fac,no

.-'"..
OI

Plckup

,
,
,
,
,

Clamp blocks

OI

Spllt faclng plles (optional)

Splll racln\! laminale (oplional)
Spllt facln\! back,nll (optlo.nal)
spin radng slldes (oplional)

4 brass roundhead

I" X4"X43"

1" x 4W x 43"

0"
0"

W x 21'1" x 2Yl"

1<1" x 3" x 3W

Pickup top

"

s~es

Pickup back

O
II<

Material

SC,",WS.

16 X

,.

lot" x

2~"

x 4"""

Clea, acryllc

2Wx2Yl"x4"

0"

*xS" X21"

Balt" Blrch plywood

1'0." x SYl" x 22"

Plastic lamlnate

," x 5\1." x U"

* " xYl"XIS"

Hardware

2 panhud ",.... wI.,8 X 1"

Z u",.ge 0011$.

~"X

4Yl"

2 nal washers, W 1.0.

2 plastic wing knobs; .85Jg4 f,om Wood"aft Supply (80022S 11 S 3)
4 plastic knobs, 1*" dia. with

222

Rou!e( Magic

I~ "

",uds; lOK20 from Reid Tool Supply Co. (8002S30421)

Bachr
Phenolic plullc

"1IIt

W*~.., ..,,,, '1 bc any k>O'iC p;u\.' 10 """1 "'1110.

...... 1ho: dam~ ~nd kn0h:5 "'u)' cQn!>ttle<! 10 Ihc tenee.
_tInb<t ilie 10:,," It (>fi tII<'
off

,,,bie .".

1. UlIIM plIl1!I. t.ook ""~r!he p.nund Ihci. dimcro-

_ '" JPIIlcd by 'loc (.un!njj U,.. Mr in"", <Icslgne.

UtIl ..~rin" '" mc:U... 00. :10 1, m.,el..,. "'e ><and .,Kl
"'-! bclng>: 50 r .......-.1 ""k fur the ..uodcn p;<n. of Ihe

'*' aooo.hc'r wood, o' rou ""n ~ut:

lI!'tfI 01 ~h pI)"W()Od 10 fum, 'he II ..", and f.ldng

Imtt. You car1

',,'O

"0<.

Sc..., dty. OI",rJlih.1l-'"Alnell. Ilcfecl r..,~

for .hc
... :Ind fxil\ll. '"Ou _n' ,hen' 'o a.ar rt>, .nll
",'ct
_IonA lI.ml . }oIn,. pl."" . tip . n" e.o.:,,1 Ihe ..od: 10
.. dImot>Ion. >p""rnC\l IIr Ihe Cutii"!! USI. Eoch damp
.....k ilo f<>rmcd IIr (.c~ulnll "nU br<rs of )Hnch 1I>nJ.
1l'IIO<I M k.
Jbdj ... ,Il<- I>Kk ~''"''' .. of Ihe ha...., and .hc 1"" COl'
.." oI ,lIe: &clnl!.. ,., ,<I"_n In 'loc 11,.....,1\11 /hI~ I'IaItl..
Ot}'OU car1
pe"""",
fiiii can lIe: doN'e OII tloe 1..1kl
lIM(t ..ith dU", ,,,,mmd OI" co""' .. rotIndlnll .cmpb .,.

,tu"

IIiI"'.

III r.tdILllthc>c

'*'

cuMcno.

cont"".

2. etil IIM: damp bloc"" 10 shapc. Th<al dintmsIon.> of ' he ~bmp hk>eb an: """"'n In 1""
0."", lUo>d 1t,1I,,", oft"" d ... wlnll N-Nor PL,ItI..
TII< cbnlpo'''' ca>lo! to Ion" ..~,h ,. b:lnd "'... and .. a
.."..". Andcr \'ou can ~Ia'll" ,iM: pal.~ . trm,;kr it ,,, ,""
~ damp tJIod<.>" then "" ... OUl 'hc: hIoo;:b, T1>c:...oocr
d flW;C quld: ..uri< of ..,lOOIh"" and mundln8

1""

.... (1"0 make 1"" bloc.. d"plica',,". aU ,...... havc: 1" do b

Slid Ihnll 100000hcr ,,;,11

samc limc ,)

arp<11~pc

)1kl1Omd

boIh~,

Ihc:

M .n ~ltemalh'l:: . )'O" caii ..... "'" IM c:b.n.p bIoo:b

,,;th I'~"'cd saoo SlW Or "'" can 101""" Ihcm ""1
00 'he eoblc sa"", thc dcub of doo"ll ,IIi>. ln: orlalcd In IM
olil'l::Cllons fur maI:ng "'" SpIi' Fcntt <>n p;iF H
tlnlsh .... pIng; thc: darul" bIockt~ SIlldiIljl'" fllilljl
~ n'lTOw n a hc: i:n..., "I'. Tl>('n roun<J.ovcr .iM:
cxpoo;nl ctlp "" )'O"t new rotIte ."bIe Ik ""'" t<I ....,
,h~ ...nlng pin

3. DrilJ thc hole. In thc blocb. Thc damp bIoct>

.., hwog <>n IM Iw;c wIIh 'liHnch atri3# boIllO.1b kccp il
rrom
OUl oi pooiIion. ncb bIoo:k 1<>5 "" :Uignmcnl
K1'I::W ptO<rudina front IM "'P Thi$ ~ onno' pru.
ja"b InlO hoIr: drilkd lor II In the m.c.
UriIIM lIHnch hoks lor Ibc damp bb:Ic5. ~ indicale<!
In 'M C1.amp llIodt Ib"..,." of 1""
Pra1J$ dr_\ns .
llk", driJI ) piIoI hol!:: fur IM allgnmcn' .<en:W. and o:lr;....,
"'" X I~nch >CI'CW Inl" il
IM """"",. protnJdinl:'OOuI

""Ulm.

_O/)

... .

In,,..

4. Ofili Iilc hole. In thc f=.<:e ~. follo w!1ljI

thc: dr.noonjl ~ Pforu. by ou. bolII .hc bob ILoks and
thc ~_nl_ hoks "" thc: ft:,," btic 1
tu
....,.". :ahout MJdt ....ft .., I ..... thc """"" I>,o,;c, "" thc
roti.", Iabk lOJI ' o conlimt Iba "" hoIc Ioc>lions wcrc
....... 1 ...an'e<! 'o "Iklw lin'" $idN~ ....I..... mcn. of
Ihc rcnc., )'CI gu:.nnlec ,h.1 'hc cbmp hIock p"'" """"W
hc: In conl ..... ..,j,h tl1c eol>lclop. ~ of,lIe oIdc-I.,.
..ode .,.,..tiuoif141.
l>rtI ,iM: bolt ......... IbIng >1o-1ncll l>II. l"Mn "rlii
IM all(ulmcnl-pln hoks ... ilh bit :IOmewlLa. 1a'1l'" 'h""
'hc IO<:W htao!', di;omctcr. '(Qu wm. ,iM:
'o kccp ,h~
bk>cL> f...... ' piVUIIIljl UlJI of pooiliuo. bul yau dan 'l " .. nt
thcm 10 lam In .hc 00In..

,.,nd

!C"'''''

,. C", Iilc bll noteh"" In .he: b asc: . "d rad"g.

11>c ",,"cl>Cs, "'hlch .'" olimcn!ilOflaI fn. )")u In .he
dn... ll\II. Iwlusc Ilie bit. lay oul .hc: oo.ch",. NO\leo: ' hat
tx:IrIfI., notch """'. ~nctt.r""l.,. .n:, wlliell .. form<"<I by
1:>orinjI. I '+IndHIbmcte. hoIc . On 'he b:.olkl s:,ow <>r wlth ~
,;aher ...... ,,"w in rrom IILe racbl/l "d/IC .0 ' hc hok. ln~ .....
u"r milion. lhc: notcIL in II>e ba!C 1. "'""'-"<1 by bor1ng
*lnctHlbmcle. h<~c.I a. ll>e cornc ... th"n ""'illtlln rrom
.iM: <:tIp:>;.".hc Ilo"" "nd rl'Ol1l hule 'o hole.

6. AsllCnlhlc Ih e r" "tt. UM: id"" on/y tic ,..",. JM'C""

dlsc . nd hc .... .., the f.e" u a;q .... rc:.o ,Il<: I ~, .....lcubrlf
dtedt II,., ou .. l<k
wi,h a e;q ......,.(ScI ' hc cbn,p biodL>
asltlc for now.l
Af,c' ,hc ~ut: It>s !iCt ~Ikl ."" dltn'P> ..., o tloc ft:ntt.
""'~pc of( ""Y 1<1"" a;q.....,,,,,,,,t an" joIn, 'loc boii""' .....
bec 10 cn..... '" 11La. it ls pc:tfoxtly e;q".", ' o ,"" f.ocIns .

f."""

~i .. I ~pe. Iloyo ... 10 lhe cli mp block Is su..,1y

., usitsl "'ay 10 IIlIn,f", ,he J>Ouem 10 Ihe wOfk
IIIKC. EnWvo: 1"" J>Oue.n Olt jHpot and make a copy
bNdl
you pli n 10 eul. Use spra~ adhni,... on

bloc.

lfM bbnI: Mod IM ~Pfcr. Wh!n the. idhesivt hu d.itd.

lor 1100 PiPl' Olt IM block and burnlsh it do",n.

7. CUI and ~.ta<:h Iilc dUSI pkk"p ~1detJ. n",

pickup sillo: ~'" snIOlU .,nod IheI. nIgd.oould bc ""'drd 10
fi, pr(>pcrly 'lPi"" thc fcncc and IiM: bo>ck. ~
FloorSloJnd",g Roult<' Tiblo!

223

.ID

appropri:ue (:Iu,Oon io euul"1t .hesc 1"(15 011 tII<! table pw,

Ir yuu h.,.., a chop""w Of Ikli"ll eomp.,,'"d mlter .. w,
..... It 10 cuI tI~ p. MS.
lkItIn bj. rippl"1t a rOOlkmg pleee Q/" j,jlocllllt<ICk tO
.1Ie wkl.h )pedlk .1 bl tlle CUttlnl( I..lst fur'lIe tkkJ.
u..- >lkll"lI T~", ..,I 10 ClIP'''''' .1",
of II", ,1OKh
1" tlle b;tsc '0 the .. "f~ of .tl<! I\oclnll. TIII tlle t.~w
bbdc tu tlli>' . n!!le . n<! Croe5<:ut tllo: boanJ in
M."ko: ono:
txvclcd ~rosocut un .,.",,11 pIC. 11l~ txvclcd "nd btttU
'iI"lo" Ilte "dntl.
To eut th<: baek cnds of the SIdcs. J"lu h,"'" 10 m;U.;o:
~"OIt1puund mitC1. So.'o: thc tJ.bIc _
.. Mvd aOjtlc. antl
5"'1nt; tho: mU". iI""II<' Iu 22 1t dcgrtt>. y,.., ...,.,.j >er.p
facing anxhcd to tIM: mitC1 11'1. to >Upport tIM: ,,'OrI<.
pic!! '"" yuu .... ko: tru. eut, '"" Im >un; yuu 'U ,"" lIdurc
)'OU nuI:c IlIeeu .... nurtt. thc Mdo ...
mlxlhnn up
antll!Cl thc angIcS JOInlI thc "''''''II ""2)'. (1bc
on ,""
coo. of c:t<:h pic nI ..... bc ""...ud}.
Gluc ,1Ie >idol in pbco:.

'"g'''
,'' <).

,,,,,<Iun.'
""'..,b

8, CuI and ;attach tIw: d ..... , pldtup back. Thc: baek

.. ""'"c:1cd '''1' an<! bu"om .... it on Inn
thc tndJ of
thc oIdr.; 1"'- stilI makc fuII. n:1I ronlXt wItIt thc b:a>ll" an<!
P"'5Cnt " tbt ....nac., ro. ,II<! picltup 1Op. Thc """" ....p: II;
thc _
as thc "';'0:0- ""I!k (In tlle: tndJ of tlle: lIidc5.
u,;., !he .. idln5 T-k'I'eI Ul opt"'" thc qIc and ..... up
tII<! tllt of thc lIbIe ..... bbdc Rip t"" badt: Mode ,,idlh.
txvcling both o:tlp:$ as fOII do 10. Mita .Il00: cnds OS shown
In tlle drn<1nfI: _
Pra_
GI"" .he bad: In ~ AppIy. cbmp .0 grlp .Il00: b:od:

.,1""

'o

.u tII" b;tsc. T1I<: cbmp> apphnJ .a hoId tIM: b:od: t(> tho:
sI<kt n<J .1Ie ",roJtollaped CII .... W><kr thcir "'..,.

9. M"kt .ho: 1......, port.. Aher.1Ie: dam", an; olI". UI<

bolt "'" ... in a lund-lle:kJ elec.ric dtlu." m;U.;0: thc port Sot
II", "'IUP".-Xll"'''......,. I boI.ttII"1 bok .. w..,..,., timc ...
>1""'11Ic:t.IIy iii fIl:Iko: port> Sot .hc ~ l1000:, antl ..... II
not .1Ie: n..,. tlrrM: ...... ....,.,. i . 1. """eI>Q .1Ie ~t
diamner, 110 II!CI " aood li. 1.
COOl much. antl I thInI:

didn'

k ..... 1 ....,..,11...111'" InYClitmcnl .

T1I<: ...... b .... ~ Ilie bok r""" ........ tho: du!t
pldt.up, !hen eomptt.e ~ by ......In rrom .1Ie ottl>oidc. lbt
.hlduIoo In Ix- pcnctn,cd b 'OII 11""" lOr 1 bolt "'"'" 10 CUI
tII""""" III>k:Iy frura onc oIdc OI" tlle othcr.
1 )Urtcd.1Ioo: bolt rrom l..,kk.1Ie pickup hc:o.""" thb
11'1.... III<' lIn.cr control ovn tllt JJtttIc antl JlO"IUon ar 'M
bolt. I "'" "ycbllk:d tIM: uqck anii CJMJn,-on:d 10 minimi~c.1Ie lip lin .." " .ho: '-.om S<trf.Kc "'tIM: '=0 and
.Ix- hooit pon. II
C>I,tnd .IM: hoit ....... pilot hit
... it on do ~s job. ,,hldt t..o hclp )'OU "1n :and
Ilie: lIu1e
U.
.hc: hok" ... w bouomo. 11 tlle: pilot tu. cmcrp;d
throufth ,Il00: plcltup's md:. )'OU nn ,,"".., 1n>WId:and __
front ,hc ottL-Idt: 1( it hasn't. ehUd out IIO<II<! of tht- " ....t
:and roti"" .........1l1li (rom tlloo: Insl<k untll.1Ie: PIlot 1>11 doct
"""''li''- Tbtn fOII nn Jhi{. your <>pcr:I.Oon .0 .hc otttsid<
anii complc:1 ~ .hc ""*'-

poM''''''.

.nso

"".U

1 O. Apply fl n b h . I .ppIlcd .ho: """'" poIyuf'<1h2nt

......J an .hc '"'>t
1OIl."r "'bIc

""lIc

.
-.{!..
.:!
II

~"

Si'"

To eIamp Ih .. plo:kup sldu to Ih .. '""0:,,, vou t>eed

I couplt of cI~mps ~nd I jWh of wf<lge .h~ped c~ul .
Apply ~ elamp 'o ,he .,de's 'OI' edgt Ind ,ht blst
bOltom. I I shown. Then ... t I Clili Iglln .. the baek
edge of tlle ,Ide Ind .pplv In idditlonal cl,)mp.
!-quttzlng ,lIe ,ide 19IJn,( ,ht ftnet fi clng .

CUI Ilie vac .... m lIose port wJ,1I il hoIe

In il
ponlble d.1l1. Tu.n tht ftnet Uptldt down ~ tl,)"'9
;1. as silo",,,,. it il comtr of tht wo<kb<!nc:II . The trkk
1, gtttlng .lIt hole stlltf<l ln just 'h.t! .IgII' ,pol
wi(hout hiving tht hoit n", skip nff 1"" mirt.. 1 found
,hll)'OU Cln beQln lt iln Inglt Iow tnougll for ,'''''
pilot bit to b,tt In.o
Iktn. btfo~ you ge, In 100
dHp. chinge lht inglt of ,'''' hoit by r.llting ,'''' drlll

"'00<1.

i S)'OU

Si"'.

II . Cut a nd atl;ach Ihc dUlI plckup IOp. ~ top

~. ~ <Ii dear ac')'liC, I usro ~hldt Sluff. slntt 1
bo4 terapii o( 1, Idt from 111~~ing Ihc """",,'inll pl.>,t :and

Othrr IIg4nd-futluK projn"u. \ ...... "'" U><: IhlnMr m;utrtll

WlhII', "'hal )'QU h:n'c. Cu, the IOp to .lup". Sc ... pr and
dIamkr 'Ile cdgcl,and bulT ',,/li for ..,mo: .I>"rklc> lhcn d,llI
pI;I hoItli and ' \lach Ilie top ,,';'h fuur ruund~ ""K""
Ott!td In.. 5CKWS tO
,he <>ther turd""""'l.

nw""

12. InstalIlbe darup bloc""'. Slip a -lIH"':h ~"rrull"

lbrouJIb cad! cl.>mp bIod:_ ~;, Ihc boii tltrotl!lh ti ...
.trop an 1 fl:I, ,,"a>hcr; and ,um
pb>I k- " 'ing knob
_lhtbolL lillhl~!hc I:noblimtlf ' 0 lat t"" boII"lI ... t>bolt

t""

k:od irlto tlK bIodI.

I.ooom thc knobs. ond >Ikk lhc __ kncc..",... II ...
I1i*Iop.T1IIftIcn lhc

dam""

10 lod It in poal,lon.

13. (Optional) "tiaU and InstaU IllOnbk" fac

. . Tb< b:>!k knc" il< gnt. lIw
3 I>o-rIrfit fur ceruln
ijiCI ........ ro "" abk to ........,
kncc bcingS. puUi..
. . . III da!or 10
bit. TII .. i< 3 primo: .... uo:c 01 tbc SpIi'
"-"(>tt ~ 237). ...... youan h:...., ..ithout boIldl. . an
..ni!' __ frncc. A 101 oItips"" COWIruetllll tlle ~
cal tit I!kancd fron, tMt cNplC'<.
In blid. """,', how 10 mal<c: 'hac opdonal fadnp:
Qn and gluc-lamlrul'e lWO plrco oIl1alUc 8in:h pir"'lO<I (or tlK ~ ... rkty. AWk PIy) 10 furm
(rl "",,'2.I>IC: facing. ('ia;. !'<>lI nccd '''''' fadn,p.) ~ llnII
<I<IIOC\II tho: bcin~ ,,, " Im .nd "'Iu:L'" tlld, .,.... 10
jIftIdt>Ix '0UJIh. !oIlek worldn!!" ..,rfacc . ppty pI:.aslk-

It,

t""

1""

1IDiM'~ .

Raul aT..o In lhe boct 01 cadI bdns- u... >lfaI&hI bit

'o ~ exIL ~ . ,hen _k"" ou. U)'hoIc biI orT4ot

bi' 10 convcn "'" 1IfOO'''' InlO lhe T4ot.
Tu motOnl lhe ~. drilI Iour \ ~1ndI _
lhe

knc~ '.

flo<:c Locale 'he hoIo:o OS _

'h""-'Wt

'n In !hc dr:Iwinx

"""COl 1>4>".
Now eu,

twu I s-Incll"lon!! >!tip> <M ~h phcnoIi<".

c""I"lI thtm Ilie lilIJ1lC: ..-idlh '" lhcT4Jl.s In II... facln&>.
Ibbbct ''''0 toJII'" of 'hc phenoli<: 10 fonn T.. Ildcs. Tnt th<n, of ,h"", ,Iidc> In lhe ....... in "'" f.tcings..1lnII1IOInd ,hem
tor. omoothiiliding fiI. Now oJrill and tip I"*,,
In Ih" iilk1c5 lOr ,he >l1I<ld<,.1 pl ... ,c I<ttoho. [Men the knobI
In Ih" hok:l ln Iht
""d
U..,m ImO 'ht slideli
aboul ,h..,., turn ... Slip tlle fodng omo Iht phcnulic ~Il<lc ,
.dl.... II. pooIllon .iw-vis Ilie bil opcn:i!1Jl, and 'tgllL"n 'h"
1utobs 10 lod< 'hc bc."InJI.

.. """""""t)"

r.:""".

..,"'W

Building the Upper Cabinet

TIM'

ntXI

k'1' compone", !hc UPl""'" <'2.bina. huw;ca II ...

aplurinI! lot <M lhe noosc: and ch.il'> il F"'''''''' In

It prtwidc5 ordcrfr """'/1'= for bll... coIlct.. .nd

1'OlII."..

OSC

ro.-

.."cooch<s. An<! il Inrorpor.IICS ~,.;cchN rettplocks

lhe
"""".". and I >hop ''X OI" <lIN c:oUc:aoo-.
Allhoush in Jma.d 1"" h>d:o ncg>'i.-.: tqptd fur doort
"" rou\O'COffiparun",u". 1 pw ...... "" IhIs<'2.bina ~h 1""
lifI.. op katllft, tlK door OO' I:vI inmln bclrrio:r 1<> """,.".
X'C">oo. Now it) bclrrio:r 10 cI1P61ln11 nobc. ARd ~ b."..,...
tiai fur dUSI roIlcctlon.
ClJmpltmcnlin3 u... door b:o JWId r ali thruhold. 1t
ptc.-.:n .. ""11'> fron, ,;pI1Iin& out 01 thc: """'.". OOftIpom
ment. t'..,., ..'hen lhe door Oi <>pcn. Tbc: door .. hin#<! 10
this pancl.so i' con dtop opcn.1Mi th ... out <Mlhe.....,.
TII" abln", h two wtlJ.like otOf'O.F biRt for
"""...:h"". colk:ls .1Mi <>ch.". usd'ld 1001. arul "upplic:ll!ke
dusI bn~h and " S<.'<>lm.IIr1,,, ""II Thc bI"" an hc
acceM<!1I only when 'ht top 10 lifl"d fkca,l!iC 'hc:y an:
flXN 1>111.O. l h"I, COnt"n15 ean ', be dumped lnuJvcn",uty
The bin Of! Ilie rillh ' .1", hous." ,1.., n... tal elc:ctrklll box
for Ilie switch am.l """..,. ali tlte eh. "" fur Ilie "l<:cl rkAI
L.. bk ,h:tt conn.,ctS , loc ~wilc h 10 Ihe 1.llk ~ .wo doplu

:JJ

.,I I

o}

...-

rn:tpt.cla.
In Ilte Spacc ""Rea,h ""'Il axtd bln 1, abil >!orAj!C
d,.......,r. whlch is . ,ooilion:tI II...",,,. oct On I,~ ~id<:. To noe:. ID

llot Op110"31 mo"abl. fael ngs for tlle f~lK~ ar~

IIOUI'tt!'d on T.hdU m;ad~ kom phelKllk: pl,a,SIk:.
fI1mnv IWO pln!!c knobs tl!lhl~ns Ilie sl~ agalnSI
Iht fente. seo:U,ln!llh, fac i,,!!. Loounl,,!!ln. knobs

ht. tht f"lng 10 be mowd or ttmOllfll. NOI' thal

ilo f,(lngs h,!Ve piaUIe "'mlnatt on th, fronli. and
IIIckt' an Ihe bat<.

Ihc: d........,.. mUd betI.". """ 01 'Ile ~ ..... ll.>bl<: If If. on.
mlc:d IM -r- Eact! dr:I"",r lwL wootI .. nI'", c.och ",I,h "
line <M ~.". boia for hokllng lhe bI ...n." .. rips
:aIm ha .., gt'OO"-.:s fur bbcJI; .., I ("an I2bcI c-ao.:h bil Call mc
..w.malti>"'O: it you "':an'. _ It k~ ,"" bib OIlPni!.Cd.
and I CU> ill",ulfy """ oile 01 exIL bll. 1 k....... aaaly ..heK
10 IJO fur "II)' bit. IOO, 1inc:c ach hali a ,;pc:ciroc pb
Thc c:;tb;nc-t b 3 pIya'O(ld .,..., ""'II o.aIt fx'r p;uud .....O' f-.b. IhrDhoIol, :ond dQor". TIM' ... bbct joInb
bet,..tt:n u... Mdcs and b:td; ..., conccaIcd by tk Iq>. 1
pIanno<d fJ"om th< 0UI0ct 10 ~ 'h<: eate, 0i0 I lLII'"d bin:h
pIywuod. _
w,,<:> paint "ri.0tl>cr ,.,00 chok:<:> fur III;'
ron:.tt\oCtJOO ..'OlIId

"" mcdoum-dcnlioly _

(MOI')

..... mcdium-dmsity .,..,-rby ( MUO), both 01 ..'hidI w""

.,.

.--oi

U~~EII

CA IINET

~LAN

VIEWS

fACE FROHT VlEW

CA$[ fRom VlEW

,

.~ll ''"' 1

26h

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o

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l'

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r-

.'II
I

2Sfllo
26Jot"

TOPVlEW

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...

t tfll"

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t"

12t1, 0

II '10'1,"

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16

1.,

BAC,; VlEW
Por! fOt

v~,uum ho~

from tM lence pkkup

,,lSJ.t,'

..!
.:

26Y1
ROUTtR COMPAlITr.lENT OOOR OETAJl

II

{!

liN fROf<IT DETAJL

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Cutting lis!

" rt
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b"

1/0' x 15' x

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811 holde (bonoml
8'1 holde. (middle)
iii hoIOers (tOp)

15~0

B"cll plI'Wood

2r.~0

81,,;:1. plywood

1/0' x 15"X 19J\'

Io.eh ptywood

",. x 14"'0 X 19J\'

S;rc:h plywood

19~'

B,rch plywood

Wx 14'X 15l1o"

8irch plI'Wood

..... X 2110' X S~

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Hardware
6d fon.sh >laii.
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2 magnellt C.1tches and
I Pf b.lISs hlnges. 2"

sl'l~u

.... llh mOun\"'9 serews (fo. 'oul!' tompartmenl

Ooor!

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2 bnn tllrud.d insert . \4-

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10. dIoi<'<: Mrd ..""" plywood fur ' hc ....... If }'QU do lhls.
k1lft )'OU cut thc: p. n$ ... lhc: V_In dln:ction i5 oricntnl
a.ioIcntll' (and JogicalIy) l h ~ thc: C2SeWUf1I .

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10
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-,.
II

Wltb Vbloc:k illlilned undu tlle bi, ind cl.lmjll'd

. 0 Ilie d'lII p,tSS I"ble. d,"l1ng tlle aogled IIole. In the
bll holde .. Is tlsy. LoV oUllhe hole poltlons on Ilie
holde,. Ind sel II In.1Ie Vblk. Orlllllle fim hole.
Ihen .Ilde Ilie holde,. Illgnlno tlle ohl mlfk under tit!
bit . 0 , 111 11. Ketp It up unllllll lhe lIolu,,~ flni,lIed.

230

Route, Mi""

Qu"rte .. I"{IISII,,,'k blts flt \'.tln{1I holes If VOt! I/Of

sl"ve. ml de from lenglll, or )Hnch dowel , To drllllllt
dowels. hold Ihem In .. sllopm i dt plnc:1I cl"mp sK l/'od
10 Ilie d'llI p'u, I"ble . Clamp tlle Itn" 10 Ilie lible.
Ind d,ill" !flnt ll hoit IIIIt b~"ks Ihe edge . ~I ItIt
cJ.owel ln 1111, hole ind Jim It w;lh i plvot;no JiW. a s
sllown. whlle VOI' d,lIIl )II ' Inc:1I IIolt thlO'-'Oh II .

l EZ

illq'J. 'ill!>OlI II"'P\I"SJOOIJ

imi' J.>\I...... '" \PI'I .... ' I""'J UN~' ""I ,nl),l ""'U\ .~~"" ~
:IIl1 10 XII;! ~UI :IIl1 ,,"UltIIE 11flI11 111'Ill11lp3." JO !lUldwtp
'd~
'1U:IIl' dn ~ <>d~, ~D '1'1 ..... ~ ' ''Id w~' ~'II
~ ur" n.o,( ' ""r,,~, "1 ""I,,<>do ~'I ' H"I'nlU U ~IM,I.

"Il-_

~,

'''''''lI .""""

""1< ~1'ldUl.l' .>li' d,~ '''''!nl),l .>I!Im,d dn '''S

'I1OOIU!I1bIIiU .>pl<"! ~'I' "1'-'1 ........ ""''''' ~ '1'1," "1'''1"'

'!UXUOO "'1' "1 ""''''' 4""1"", 1I)l(1 ~,qd

""'" WOJJ _

""'1'

"""1 "'lI ,"" 111;) ~"I".xlo "'lI '1lOJ 0' ~lqdw~, p.>,.,dwoo
"'l' 'III." "Plnll ~l"ld,,,~, (I'o-IP"I~ '1 ' 10" '1<1 IP"I""l
""", ' P!<.lI" IP\'I-"Ii ~I ' I'l.l '<PO'"I\ ui PJ ,,"odwoo. 4'1-'"
II ""' ''''" ...,.." """ '~"Id,,,~, ~4' UO xoq
~
~"d ..... ~ (I)~ q~", "1 .1') )~d . UI ~,qdw~,. ~~'N
' ~11lOJ .o11lOJ
"'" ~~II 1 "iti ..... ""'l"" 'III," !!luI".xlo.Mj' "'" UD no.(
""I""d no.( JI P'" '1Iu,,,~do ~<>d p.>;>u ' ,IlO!'
~,"'"
-tU)1 .lI"!," II" "''''II p.>"wu I .,......J "1'1 """"'I!lIIl.Mj11lJ lS"l
"'1' P"" ~W"" !Snl' ."ll "1 .>UO ' ~ "'1' JO ~,..., "'l' UJ .>UO
' lIu;.q <lJuIU;)(\O ='1' ''''1' ~I"I.I UOill':JlnUJ lJ'1l :><u.
(" "~Q1<1 'IIUI~~:>\I' """ "",oqwd nI-'" ~
r.llnWl< iI"IU'" ""1101" ...... , '''''''''"''''110 :31n,,,,,,, , U'I!&ijOII.
"'1' I:nl ullllU :>\l' )1 """O q.a ..... qlUJ 'dn .~ .>Ol!
1' 1>1Ip "41 pul "",nUl "41 'I~'" """ ., ......) PIIj<fI!.) "'II ""
' P l!."" ~41 'I~"n,1 ""l!IO" ,.n p.>O x.. dOI/'" ..., '" ,xq
"""qr" "'" "1 PI''''' "'1' "'!'I .... ',plllO.l "'11 ""'J", "",,qo "'lI

.,,,,,Kb.J

:ii
(!

..!

.l!"

no.,

r ~l l
~

.,"1. :'
'1',

, 1

.>pfj"1'"I''''' .>I\J..~"'" ""1

"Y.~

""il'"

JIUI_"od....., ' - , .

........... 1Iu)l\Jl\OUl .'nnd "'" ,,..,,OWUl<U;>O: OI ""'PlOII 1I0OI

,.. "f'U'> "'1' "1 ""'PIOU """" <Il ~ ;oq b~'" .OfqoqooI
'1 ~"'"""'1' \XI lU"fItOIl :>:U41 "'" nru Jl lI"{l "!os ~
"'1' "1 u......... "' p.><n I \Iupod< ""U. 'J.>JIIOII 'IX-" JOI ""'"

.""'-"'" :>:U1lL "l\"""I JIUl """IO<! "'" l(ilnruq, ~ ~

.\q ... """"" "". "1 ~ 3K ""'PI"'I "'lI. ........ap ,.
III OI .......,..,.. "'II "'!'J. ' ~0lI I!q :M.[I " "1 ~VI 11

('I!Q l!A-UOP q~

Vu!Sn

~ 0.", II!

"-""'Ji ...
"'II ~~ .... UC """ ' I!Q 1!Ol"-"'I' ~ "'"' ' 1 1.""1' no.i Jl
"UJIIO'II!<I q:>u JO ~
"'lIlIuo\I: """""" en>o'lP'
Il1O.l JIUI'.>;JU.>j "'1' PS '<pUI "I 1I>Oq" , ..::>!<""I'C qq "'P I>S
IIQ ~Q"-"'I' 'P"I", 4),!." ~" .... )IIOI "'" dn h'S '.(gaJy

''''''J

("du).JU<l

JUJ

1O!!d r.rw .......

'-uD'" """1"1,

q,!-" QUlop ".... """.,. UD "".\ ~

....... IN ~ ,nd OI n.o,( ~""'11" ~ .p....,., 'P"t<i
JO Afd IIuot<Put l ,.. ....1U.U "'" UJ 'DII"I ~
ltlJO 'OIJq ~ JOI. u~. ."..... 1 ""'1 "1 .1:1._
.>q, ' 1pUI "; 3K ptOq "'I1 1f1'
~ 3K
"Ul!d1: QPUJ !i1 01'_
""I0Il .... ' ~ J.>IIIO "'1' UI '<JII1'fI"I'l." "'!<l.u"""",,,"Jr;>Ihq

.u.""

.~ r \U
..~,I/l ' l
~"":' /':

\XI

,)1'1'J1I1 Q1XI(b.J ~lOIluo.xpl!...s 1fI~" p.1J~" ti ~

""'dn "'ti s8l1!u:>do x<>q IIOf-IP;''P ~ 100"II 'lI

"""ro

r \iI -'

... . 1

-.l.'11
.u

)1O(Il~

.~Ol

liJ
M3lf1 NOI01S

M31A NOI.t:>3S

.,.K-...l

'~I"n"' IJiIU~).'A L

'SitG'I " IP '.'A

N
'S~IOIi

lOIS oU)'

](U5 .u!:ltlI

'IYllO 1I10l0H.ut


Ihe lemfll ". you ",111 h;a,"c '" ""ntl ,1Ie wortflic '" '"'<""fi
.ntl ... rround It ",i.h hlodrlnjt 'o hdfl"'l'pon ,he 'emfll'1<~.
'J'wo tirW roughin job5: UriU a hule ,hrQugh ,1><: """'"
b:ock (o, 'hc flO"'er cord: . nd tlrill I>uk: tI,rough 'h" fiIII"
parti'iu .. tur .he: a.1>k ti"" ru,," from Ilo" _I,eh 10 ,h" 0\1,'
kls. Locatloo. an: "'AA"",ed 10 lho:: d ... " ings, . hOlIgh cnct
Ioa.tioml.n: "p '0 )"Ou. Si>.c: th" hoIo;:s tn acmrnrn.od:otc the
",bie you lJS<:.

""<lched Ihe f~tlcc opcn'tI"" iS 10 Ihc bi, rontour.'hc bt:1ln

,he fencc wil! b;tck up 'ho:: cu, and m ioimi~-i f 11<"1, <:Ompk'c~' clirnln .. c_d.;pping .hnd of Ihc CUlter. U.ing tt..
SplOl F........, (O P'lI<' 237) ",.k"" ,his eu, " o .crom[llish.
,"ou simp/)" sIlih ,he IWO fCltcc elcmcnts 'owaN rhe bi. umil
,hcy ncarly touch " , then k>d , hem <kt",n.
Set couple of fcatt",rbo. nIo .0 k""l' . 1", won: tlSh' to
Ih~ fmc~ .

Whcn ",,,,,.,h' nll sccms '" bc,..., up prupcrly. CUt tho

profik ond gnx...e In th~ insitlc nIge< of lbe MU", . nd r>ib.
0 ' '" pass oJ.oold Ix....rtlclc:nt 10 complele """h cut .

I S. Col'" , he e nd.!< of I.h" ralls. TItIs opcr..1on "

l>e>I done
mi.er 51N. pl."" fur "'Ilkh an: In tbt
ch.plcr . $115; whlcll bcgns 00 P'II<' 246. Wi,h 'hc skd
pbus an; Mq"h)'>lep dir,:ccions fur m.kinl! iii" ~... pc WtS,
Thrn '" tII ... ch:tpla and toIlo .... ilS di=,;on. ln roplng tht
cnds of thc door ... ils.

""ng .

16. Iblsc Ihe pan el [)o . hl, on ItI<" router 'able. oI

C",""". Aflcr 'rimmlng ,he p;>nt:1
Ihc r"",1 din ..............
fonn .11 rour .:dp " ith p;>nd .... isirtjl. hit. Cu. :tctO$I t/l(
cnds . hen .'u"8 th" .i<ic>. Malt" sIt. llow passes,
"p ,.,., flfUl c .. t tkJ>th

.0

.-.
.a
(!

Ro.u;.." an oP<l! nln" In ,he bin fron, for ,he "Iectrlcal

bo~ i.

usier Ihan trying

.0.aw It. betaule of Ihe

part"s ,mall .Ile. U.inQ .crap . make il tixiU.e \0 hold

,he bln front, Ihen damp ,he ,empla,e on top and rou,
Ihe openl"g. I u,ed the lemplate shown 'o ,Oul open
In9' In ,he use back and ,he dUSI baffle aS well.

.!
=

13. CUI Ihe door palU. TIt" muler romp.nmem

door 1. aMcmblcd ... ith ropc-and-s"ek "'in.,, 1 U!ICd. ~
pand. IhOllgh }"<IU coultl e2;ii l)' ",~it u te h>nJ .... >O<l
p~'",ood pan<:l."" ","co ele.. pa"" of ""'1'11e OI polya.r
bon"e.
Njp .nd crosso" tlle nil. and stilcs fur tll<: doot tn tl><:
tIi"",,,,,io,," .pccifoed hy 'he CUttin!l Us! .11", .-tlks ~.. n run
lillie Iong, hut ,he ... 11. nll~ Ix Cltl pn:ciscly 10 len):th . Citi
Ihc I"",el. OI gl"e "p sux:k 'o funn tI\(: p'""".

Hi. Rom Ihe sticking o n ,i><: s tiLes and ..dis.

TItiS b . mu'a .. bIe opcr.t'ion.11ghtcn .he S1iddng!:>it in
the _ter cotlet. and adlUSl the bit', heillllt '" CUt tiI<"
<Iesim! pmfil.,. n.e objcel l"" In setU"lI ,he !:>i, ho::lgh' 1> to
posi,ion Ihc profile for IlS l>e>I 'ppc:>r.tncc wi,ho"I IftC1 ,ing
Ihe gro(>\"c '00 d o,.; '" thc b:ldt: \I;~th 'h" );..jr>dl >Iod
helng worI.:nI. thi, ""ouldo' , bc tOO difficull. M .k~ I~.>I CUi'
as nec""""'1' to .sl.bli"" 'hc optl",,, m bil hclJlh .
For. safe oper.ttloo. "". lip thc h..... cc sn thc bit .. """"1}'
buried In the r~nc~ antl tM gulding nllI<' of.ho:: rencc 1.
c>~tI wi,h Ih" cd~ of ,he hit'. bcarilljl. TIte more do5c~.

"''''''inlI

17. As""mblc .lIe door.

...i. . ..

11.1

Ucfurt: lIIuing thc ........&

>ti"'" .<JtlClher. }uu .hould .....,mhle It "'11i1ou. gllIt

'o chcek tll:o, e'"C1")1hlng f,tS.llIen .ppl)" gluc to 'h<>;oints.

lqin 'U ..s<:mhk th.~ ...1'" and Stilc<. SlitI<" th" p:>nd inlo
thc f...... e !>dure fitting the .sc:cund Mile in pl.ce, cl<IsinS
tiI<" f...."'c.
l.;ty OI" thc toearions of tho:: hl n ~ th.t mUunt thc door
'u tll<:
Caf<,fuUy P"'" mon~ fw tlle hinl!<"' DriU
pllol. for ,"" moumlng ocn:"-'5.
t.r uul Ilte t",,,," fuT ,he wi", pulr. moun'ittll .............
t)rill,hcsc hu"," and inSt.U thc pull.

,11."""""<1

18. ASs-emb le tlle ah ine . face . MOSI c..uy

inM. lled "'" 'lIc: hit dr. ....as; sirnply oIitlc . hem intu thdr
contpartmen ...
alrinl.t~

"PoeeD . n: gluc<i 10 ,1Ie ,hmbold

w hieh in '"m is gluc<i t1ircClly ,o tlle nit
lIc:twecn tI><: b;t dr.""c,,,.
The tlm:shoId .00 Ihe leflh>nd bin fron, >re Inst:illed
wi,h hIass
pI.1td. H. th<:sc """ p:utS in place. Usc a
pl:.lrc . s" guidc: tO ilIl' UlJt tii<" muuntlng.o:om:w hule!.. DriII th<
('Ik"", and In>tall 'II<" p!:l1 .... -"'CUrinJI tii<" 1"'"" to Ihc C1\C.
1,.., rillhlh>nd !:>in fmnt i,!lC(."Ured hy .he rttept>d<
ho~ . Ht tlle 00" Inru .he front,and ..... do il wi,h. tiny c rntl
dri,..,n throUflJ. the oo,, '~ n.nge'l. Se, Ihi, unit in pi""" i<I
the a5C: l,hlnk )"OU11 nnd )"Ou nced ,o ~hisc l recnocs in
tiu: hin boiI"'" ro, .... rio'"" """"''':lnd nuhl:>ins on tll<: ....
side uf iii" bn~. [)o wh.t",er i:i ncccssary ou """ " ", 00.
and ,he bin front propcrly. 1l>cn >ce"", Ihc wooo hy <Iri~Inlll *'n<:h-Iong s<;n.-w.; .hmugh ' lIc: appn>priatc hul", in
' hc bn ~ intn tI><: .....IX
On ,he threshold. lay 00' Ihc monl5cS nee<k<I for '''''
door's h;<IJI.C"!'. "~n: Ih.csc: moniscs . nd mOuot thc doot
TIt" 1""0

ed!lC4ndi~ g.

'nW"

Dttemtifl<' 'hc appruprilue """"jo",, fur 'he lIUl.<J1e'jc

~ ...... mounllhem
\fllh ,'''' pon. aU "",unlro. ~hc<.1; Ihe opcr~lk>n of the
door mtl ,"" ti,.."",,,;. OK-'d< 'he fi, oi thc cabino:t In tlle
IWId.lf C>'<1),hlng ;,. cup;tectlc, ,""" It aII .port ("""ep' Ihe
thre>hoId nJ~"ding . of rour.;o,).

19 . Flnlsh the uppcr cab Inel. W"h .he tlrJ"'''''

..... thc door and aU Ihe frunt. remO\'Cd. prim<' antl poinl
,... p~...'\XId <OSe. ~ ;ll;k <>IT thc .hn:shold ~-..b:tndinJl S<>
J'OII dooI ', get p:nnt Of] i,. Jlcmu.", thc puJls .ntl utile. I\;onlnrr from thc fronl den.ents. AppIf dor OniSl> ,o.hc
1DIr. Ihe d ... "'"r and bin fronlS, and Ihc Ilu>!sltokl
'I'htn 'hc finblh is tlry. "'",,"'o. Ih~ hanJ"'>an: ""ti
~ the a.hlnd.

.,.1>1"

nce,jo ... In the dC.:trK::lI box"". A .1I0n picec of

ex,cn<15 rrom Ihe ' oll1sidc' box 'o ,he ' insidc" box. Moum i.
in ,hc "OUlSi<k" OOX, then k'Ctl it n'o ,he "insidc" box ... you
Sli<k.hc ti"" b;offic In,o pl.~c.
Follow 'he If'lrfng Sch<'l,,,uk. in c:onrtecIlnJ! Ihc cif.
eullS. 1'11.11 Ih<" eleclric fi~,u"" inw 'hc bo~<.. > d';'-e Ihe
nouun.inll ""I'CWS, "ntl i...... U ,lIe
1n.",,11 ,1Ie plug un
the cnd of th" po,,'cr cunI .

pLo'' ' '

Hardware for wlrlng case

3 steel receplade bo.es
12 rouodllud screwl, 14 X W
slngl@'pole !\<Iilcll. I S amp
s\<lileh plale

20. Wln: the cabinet. The

bo~

fur .h~ .,,itch bI

Ibt:ody IR>UlInl In...... 1I the box for Ilie "OUlSi<k" """'IN.,.,'"
il u.. C2!C b:tck. PuII Ilie duSI baffk from Ihe case .ntl
iMUD .lIe box fur Ihc "i"side' Itt<:po:>de in il.
RIlfI thl: cahks O"'tI. Ruo cahle r",m , Ile ' uutsi<k"
~ box .0 the "....;,ch box. Thls cahle .oou ld ~
~ 10 Ihc
,,'ill. a <:<>uple of metal clip' m. de fur
m. job. fttd 'I>c l>O"'",r cunI .hruuJlh ilS hoi<' in thc ~'ll>C
orw;l n<cnoJ 1, In,,, thc ' outsi<k" =epW:lt: box. Ik."", 'o
!Un' thc J>I'WC1' conl,o 'hc C;lS<'''' 11\;0, whctl )'011 ca,ch
J'OUt i0oi in ,he conl (sometl1y),)'Gu woo' , rip ,,'" tlle roM

2 duple. ,eceplllcltl. I S amp

u"llly reeeplacle plale
",,,,placl@ pla.e

3' Romex cable. 12/2 wllh ground

2 grou~di~g cllps or serew.

10' 10 20' cord, 14/3

,y~

Sj

I plug

WlRIHG SCHEMATlC
20AMP SI NCLE POLE 5WITCH

"QUTSIDE" RECEPTACLE

" INSIDE" RECEPTACU

-.
O

ID

Co~necl

o}

whilt

IT

(ntulriQ co~duClors
lo.ilvercolortd
tt,minal .

ID
OI

~20amp ,",ceplacle.

rece ptacle

rKtp,aele

TOP VIEW Of WIRINC LAYOUT

"
Floor-5landing ROUltr Table

233

Building the Storage Drawer

Thc RIUl demen , Iu

a_

nuu i> I bi3 dt:.....er lhal rnt> on Ibr

<Unfln1l >llacbcd 10 1"" bOll0fll5ido: ",ib. 1I ~

1'0"'.

CfOU5 SlOfIgC ~

for an cu .... fIMJtct ....

aua
mounting pwQ. ....... fnlho:>'boanlJ.lfId ocba """~ tal*
....~. AIIhough lhc pbn> ""'" """'. an und~idtd
",",",,"CI". il ..."UUId bc a simple: ....tler 10 partiliun tho:: ~
p<O>idu"o{I: tid}. ~ 10 ~ tho:: >l<If">#

1. Cui tboe d .....er part. Thc MOfIgC ~ h20 Q

front.nd baei< joincd 10
""iti> fOUler<ul
1"hc \o.inch-pI)"WOOIJ "'-.om .. ~ In J1'IO" ... rotile<! in

its.....,.

""'"CUib.

IM """"" pom..
n.c tron. Os CU' !'rom oolt K> i ......ehet tho:: Othcr Crom

......
..n

Qty.

.,,,~<.

h""lIIngl h. Jwltch I~ Ihe Inl Iltp In ...I"ng Ilie

.OUltr I"ble. !k'o. t you do Ih,~. )'OU "'u~1 ~tcUtt Ilie
eltel' ic,,1 bo~ 10 Ih, bln ' ronl ,nel the U~t. IlIen rough
In Ihe "bie. Luve 'boul I hlnd\ It"llih 01 ("bit
' ''Itneling "0'" Ilie bo>< J(I 'fOI' '''' wlre up Ilie
~wll(h . HOit Ih, bl'tk la~ CHIII1e ... hile (CHIe1UCIO<. I
",lnele.INn il Is hot. I"lOl "eul.'1.
STOflAGl DflAWElt COHSTIIUCTIOH

STORAC;;E DRAWER
Cutting lisl
Miil e . ;

O ime n s io n s
~"x 8'~")(

li/o" x

0.-

26r.."

8 ' ~")(

20"

Popi".

M" x 8v..")( 26r.."

F'o!>la,

IIo"XI~"X2S'l'w;'

Plvwood

Ha rdware
2 ...Ire j!<IlJs. 1".

..1

bfass~.~
W~
"~
'~';
<"
~
W~'_ _ _ _ _

TOPVlfW
26~."

EXPLODEO V1fW

19,."

,..

SIDE VlEW

20M"
,~

,1

FRONTVlEW

8' Vi."

L
'"

ROUIt<

Na9t<

-,

- ,
..

4~'

dmcnt5 o( tII<: ",,,,<:r .. ble_ Th c .i,le" and b.ck ~t't: "",,<It:

oi popW" ( ot
)'tiu al'<: "'ing as ).....r """"",ndo:"y"
.00<1). JoI",.n<! plane the: Mock tO the I'<:'1"il"<"d thiekncss.
)\</.SU .... thc ",.n<!'$ 10"""
and comp.n: )"Ou< "'CiI,
_nt:< ,a 'he plan OO 'he C"ttlng U .... ~"'ingth"
.. adju;t,,,ot. ~I'<: ".,~ed . nI' ~ntl <:rosScut the p.n. to
.... llilnensio:m pedlied by t~ Cut'lns U", CUt the
bonom rrom pir""""".

"re<I.

4. A.""'lCmble t he d l"3 ,,""'. Do dry n,n tu enSure

th:tl """I"}'thing /l,s
p"'P"f"ly and ta >C' u]"! 'M
d.mvs arni ",uls. Thcn .pply ~"e: 10 Ihc <kn..,l:lHs .n<!
""",mble thc dr.,,"e . i, 'he buuom in pbee, bul tiun ', gh..,
1, lnw ilO
uy oUl ti", Ioat;OIl.'I of lh~ hob for lh~ tl",""~r puiI>'
moumillJl5<:l"CW!I. Orm III<- holcs . nd mOUnl Ille puUs.

2. Ro u, Ihe duvCI;lIl jolnc ry. U"" an)' jil! ,lut will

yidol !>-inc:h lul(-blind <kn"t:!>il;. Se, up 'he lig an<! !"OU'er
><"<lIfdUl~ !" 'h" m.nufa~"tul'<:r's Ins1n"-"tlun . R.... l lhe

5. fll ihe dra..-e r 10 Ihe: ~l:Ind. The: dr."" , sbo,,111

fii ; you chcck~ Ihc dinlCflSlO<I. of 'hc: 'p;I<:<" fo, il bcfu",
)'ru
'hc:: p;l1U_ Hut <:ht 'hc:: fi. and set; h"", ~n'IUQ(hlj'
'lte: dnwe. 0P<'r~t.,., II n,,_I)'. "'00 ot 1'1""" 'h" .kk>
.n<l,I<>1" C<l!<d la ""Ilic:"", a good fK.

",h.,,,.,,,,

p3.

ROll!

u,e grooves fo r !he: bonom.

1)0

,h" un

tii<: """," ublc, ..>Ing. ~neh "''''I"ht bit. Se, 'hc l'<:ncc '0

pidI: rn., ,",u . nd rotJ! a l<-inctKlccp groo',<: jUS1 shy of Ihe

bonon> cdt;o: of ho'h sldc<. as ,,"eli., 'hc (tun, and !>.Id<.

'''8<''1'''.

g/"O'' ' '.

ru'

6. Apply lire fInls h. ,..drI .he: back and .i<les, and

.pply cku finl_h .n 'he fron' .l"" ..Ion ', <><:e.J ,,, IMI", 'hc
d","'~r c:d~ sincc Ibey WO<l '1 bc 5<:cn "'hen il 15 5C1 in
pl:k.., In ,II<- '''<lIer <ohIe.

The Dust Collection System

Ccllw;ng alllhe duO! and ehlps gener.oled bya
'0II"let I,ble is a eh,lIenge. Afte. aII. making dlr"\ juS\
IIIIV be !h~ on~ (hing Iha! roulers do bUl of aII. The
'''''''''"toonal .pp,oach i~ to ,nleg'lle a p<ckup Int.
I"t f.nce. Ihe Iheory tHolng Ihat sucllon la one slde of
<!le b'l ",il cap!U~ aii the thips and du$!.

w"U. It you'"" u.ed a ,outerl.ble al .11. Y<lU know

lha! Ch,ps ilO eve.ywhe,e, If YOY foul Ihe edile of il
boa.rd. a fence-mOlln!ed shop,v.>Cuum pickup wHi ~p.
tu, .tlol of Ih dtn, But if lhe 101 h;ts Ihurcuu,ng
"UI"S, ami If Ihe b'lls net fully tlevaled above lhe
\abltIOp." wlll \h,ow muth of !,t d,n l!elow \he
(c""I,~~ul

DUST COLlECTION SCHEMATIC

Chlps d'awn ofl Ihe bit via Ihe fenet's dus! plckup are earried In!o Ihe plenum bV Ihejumpe' hose ,
Ther drop to .he bOllOm of . he plenum ind " e sueked imo the stw,lvac hose.

:rl
O

DuS! pltkup
Inco,por.ned Imo lne fenee

it
...
';}

.IT
ID

ChipS thrown below the

moumlng plale fali 10
the floo, of the ,oute,
comp.anme nl and are
swepI unde. !ht baffle
,mo the shop Vie's hou.

f loo,Stand,nil Rau!.' Table

23S

The Dust Collection System-Continued

.
-.{!..
.!
II

~"

tabletop .u, face. TI>.II ftnctmounted plckup JUSI Ciln,

get II aU. vou nteO sorne 10.... of conlalnmenl unde.
tlle table. too.
WII.I\ tlll. ,outer "bie', duSI colltolan '1"lem llro
vld-t' II a two-lewlapprGltcll, " puII. duSI ilnd tIebn.
0 Ilie top of Ilie table tllrou;1I Ilie leMe.. pKkup
AnO II sucks o uSi Ind ( h,p, from tlle , Oule, com~f1'
menI u well. BolII It~el, lire cltiI.~ by one .hop
vacuum. Tlle O' ilwlng DUJI CoI/al_ SeIK_IIC ,ho..,
ho .. It II sUIIlI'tOIO wo.k.
Tlle Il"lem depends upon Ilie venlufl eflKl In 1_
placel. One II Ilie In"ke btlow Ilie III'e'hoId. Ao a" "
pu lleo \h'OU;1I Ilie naffO" . 111. lI.petdo UII. and tlll'
",.11 of al. help. I " ~II Ilie duSI .eU!I"5! OII ' II. com
p,mmenl fIoor 10Wllrd Ilie Vi>CUum POlI. TIIe du", taa~
Io.ml Ih. second ventud. a )otlnI;hlIlgh.1ot IlIrougll
wlllell aII Ilie al' In Ilie com~rt_nl " pullto by the
vacuum. SpeedI"9 up Ilie il" llellnll keep Ilie dU)lln
IUlpenSron 10 " can bt ' '''pllnIO lhe ","cuum hase.
To mlke Ilie Ivst~m wo,k II advefHI-td. you h....
10 be d,lI~nl ll\)oU' stll!.n; Ilie roul" comp;1lrtmenl.
10 111<1' al. enters t.he rout" comp;l""",nt only VlllllIe
Jumpe. hoit I<om tlle f~ntt~ duSI plCkup. tlll'O<i\lh ,1Ie
mounlln; pl.lle" bit opetIl"9. anolllrough Ilie na,ro""
Sloi benulh IlIt tII.uhold The mort f,,, lIl, In Ilie
.vstem. Ilie ~n offKlJV1! IM d,m re-tI\Ov.IIlwllI be. II
VOU ,un Ilie iVitem Willl Ilie roolt. comp;ll1menl cIoor
OIIen. Ilie ~hop ~lIe wllI be ~twhe lm~d and WOtl) be
Ible 10 caplure Ilie route"gtfMnl~ deb"s. {ven_
dUIl collIOI' .... nll 1 4lncll hose "01'1) be.bIe 10 clea.
Ilie cllipS In tlli. ~11~toon . .... t ~en ~l'tm,"91y Insi9n'"
jc~n\ Inr.llrlllron ..... 11 rob Ilie l't'$lem of effecl"'tl'lelS. If
VOU hnd Illai clllpS lInd duSI i>Ccumul.lte In \)olll.1Ie
~nce" p+<kup Ind tlle .oute. CQmp;lrtmenl, check for
~ glIp btlwetn tlle (&.~ and Ilie ublelop You iuve 10
keep Ilie 'vsltm se.led.
To tlli. end. I . , uek 10lI'Il wUIIIe. IIt1pp+ng tO Ihe
tOP t(\get of Ilie ca~" INck. duol bome. and p;lnl
lion', around Ilie cIoor. nd """ 10 Ilie lOII of Ilie
threohold. Keep Ihe Il00. clost'ci .. hen '(OU are rouI'''9.

236

" ""18

~Ic

Whlen Ilie

.~

1I0n 10 puN

vac .. _ranng. "c",ale,

the dusI and dllp, f, om the

e~h SUC

~tI

Inlo tht

1O<I1f'r corn~ l1 rnel1 ' .

h:~ a lIOOd $Yw,m.

and 1'1 Uplu,e il loc of t.he 0"1.

perfKI. If'(OU !OUl a;1'OOVe w"h il
",al;h, bit, Ilie worio:.poece
tllat f~ncemoun l~
Plckup. Whlie _';'11 ro eaplured '" IM AlUle, com
~11_nl. CII.p, blow OUI IMllroow. 100. What rm
'.yIn; l' 111.11. u'(OU bulld '(OU. lWO"level ,ouleNablt
dU'1 collKllon f't'$tem. '(OU neo-d 10 accepll h.il YOU
.....1 un' conuln and captu,t "I/ille dUSI.

r""n so. il i'n'

bloc",

Surlt'" .-"'~ ' ........ nm.nl _11 10 enlu,e

Ihll you, shOP ","Cuum 1.n\ ovt . .... helm,d by 100
much .It. Alplv loam wUlller'I,lpplng 10 Ilie 10P
~ .. 01 Ilie CllSe" bllck. p;I"ltiOnl. and duSI b~~
10 sul l"e IIolP betwun Ihe cue anolhe l~bltlOP
TIIII vre ... 110"'" Ilie III~num fo, med by Ihe dUII
baffle. lIS well U Ilie two port. In Ilie cne back.

Split Fence
Hete"

first-cllllss fence for liIny

router table. IlS separ;"" facu a djust
li

iadependt!ntly for joinling o~r;Uions

iUId for nur-zero clt,lnon,,, work .

:;:~~~~::;:
"""" a r~<:bss
w:o.ill/lt

!hal',
btlIlRl c.b.mpcd rmc."
10 tbeOM
ublc:lop.
boanI seto the ",,,linoe ...".... donc:. bul
dIIo >plic (''IIC<:
mon: llun tho: n>utin<:. TIt<! r..ntt bas
1loIII-in cLtmp'. ,,-1ti(:11 aIlQW fO'J 10 adjUA tbe Ima's posOlioII ""'haUl fumbllng ..ith it. ANO Kpant~ cbmp
... '" ,,.,0 lu.mJ.. 10 won..Willl,oor big, ~ "'in& I<nobt.
dIr IMII';" cbmps.,.., . cinch 10 US<c.
lbc: r..nc~ lin ' ''-0 fxn thal an be adjuMed i~
dmIly 0/ ~ a""lIKr. Surfaccd ....... pbstk lamlnat~. tht
bIc.T &ce; won', . dd any dr111 tU lM rI>Q>'CIlItdt oI)'OUt
- t 0C'r06:S lhe I'UU t ~r ...I>k. Mo",,,,,.,,.he
hlWI
""""'" to .uppon . ..II workple.
n.. fxt II"" ,h. faed alt: adllU hk: In ...'" pbno
..... you an c;l5ily alte. ,1><: II"P het ....""n ltw:m '0 KO,)f&
.ro.c moo:I anI' oiu hU. Il me,m_ }V<I ea" ..... fO'Jr rotIIcr
uIII< ... join,cr You11 he .ble 10 joIm """'II pom . ... hletl
............ 10 nuchlnc on . jolmcr,and j!.Iuo:-bdct111httt
".... ,,-hicb mlIy _huse: "",,1 loiruc. kni>"tt.A11 )'011 Il;""
II do 10 oI>inI o", tiK OlIlfttd fen"" (..,,,.
",..,.. I'carun:s a1onc:.", Cf1nUj!.h 'o m. kc 11t;, . wonba

,ha.

rx......,

'"'" ....t<.hop 1'f'J'iI. 1Iu1 lhc:re'J mOR'. Yoo ca" ""nm",

.. faca C<>nIpktdl'..,d ..... lhe f<:ncc wllhoul Ihem. And
.. &ca ..., ouftldmdy a.y 10 m.ke Ih>l Ihey can Ix
"JIIKnI quKl<ly and l"""peml~ly.
1rhy ..nuld Ihcy n<.l n:pl2ce"",nl.,_ u k. !lecaLlS<:
. . . . , )h~ "'" biL ... ill probabiy 8"i ehc ....:d up
""""" 10 Iotc Ihcir cff""'-I\~ If,...... LLK ...idc VlIrlcly
... __ a.- \hmL In Of) bis profik bil C110Ugll timc,.

and . lKy jusl ....... ' \ c~ In Qn ~",.II b h

)00 c:an mal<c ft:ncc: likc . bJ~ 10 AI . ny ,;~e "",ter
W>k. T1Ic: pIaM an<! dln:cIlofU Ii)Jlow~ $1\0 ... . vcnIon
.ucd 10 .bc Floo.,Su ndlnll flOtM r 1lot>k (p' ll'" 1 11) ., wcll
:os onc for my1\dlk 50... ~::'IC11si<>ft Rnllle.llIhle (p.tSCC l l1j).
Tbc: damP Of) IIx 11"(1""" ~ LQ /lrip'bc np-re"""
toiIoI ...""'r liwI "'" abktop

Maklng the Fence

";;
O
C

.,

:-t

T1Ic: ~ II cml rallo "'" cur runclloo o( Ibill rn.cc,

and)'OU _
'1 II'"' " ... r..r 1"'0 lhi5 [NO/ca bdo"" l>CCding DoI
It Whilc Ibc boIu"", common . bc pbstic ~ ,,'w tu,..,
10 Ix O<dcn:'d &om C2L2loB. I'd """""mcnd WIldng unl ~ )'OU t-r "'" tunh>'VO: In hand bcfOn: Ixgin ning.
I'D

r:r

OI

1. Cui tM parts. T1Ic: " " " fftJuin:s onJy re... 01

thcm. T1Ic: 'WO rn.cc rx.:. ""' lOnncd tor p.c.I:uniLuIng
.wo picca 01 \fHnch pIyo>UId' ''')'OU nud bir pio:: :0.110JCthcr. 5ince IIK ba:s mUS! bo fbL, ...., soo<kIu:oJi,y
!>It"""OOd (Of MDt). 1 ........ M2tMlatd birei:! pIywood T1Ic: 6tccs
""' ",LoI;' ''ty sma1l. "')'OU Lm)" bo abk 10 UX kfi..,.tt!>lt'
w<>Od from anotbcr projI .
Thc Otbcr p:trU sItoukI bo rnadt 01 ...-alghI~
harUwood. liILc oak. ""pic. bc<rll. Of "'"CII rn..ny_Apin. noi
I!t"'ll deal o( ""'Ima! i> nccdcd. but Lbc put< ..., aii dII'.
fCTC11L Ihick"""",, :an.d ..Kkhs. o..;,." "'" Iwtlw<>Od to Ihc
""'luln:d th~. and cu. "'" puu; 10 "'" liuJ 5pCCIf\nI
by . he CuLlJng lliI,

SPUT HHCE EJlPlOOED VIEW

... I;J

...l.:i

. tJ

ClI.mp

b....

fiet

In

-...
(!
OI

FlOORSTANDING ROUTER TABLE

SPLIT FENCE
Cutting L1st
e.rt
b~

liIeks

OI

F,.~ pl~5

"

C"'mp bloc..s

Qly.

,
,

Dlmenslons

Millerlill

l' x 3W)( 19'

H.rdwood

ly,'x2'Xl~'

Hardwood

W)(~W)(I7'

Plywood

11''- )( 21'>' )( 31'>"

Hardwood

Hilrdwilre

PI.o.1iC

"'mln,II!~.

2 pc,. S' )( II' tac"

4 tOllet holn, V,' X 2W

4 plaStIC knobs, 4-ptOf>g, il'<" dla_ '01.111 V," Ihrough

th",.dtd InSflU; .oK59 rrom Reld TooI Supp/y Co

I
2. tamina K' thoe r:oao plla . "Pf>Il' 81"" 10 tht
bea. and "P"""d ;, rhiftly ond ~~ OI"" tbt _

..... 111'0/1

~. I"ur tbt lItIJf>cn t~ ~nd , ... hiI thna a bit ' o ...
a good hood,Unc u p ,1..: cd/jdo and appIy cWnpl.

}. Glue thoe bx: .... 10 thc baK. ~ octuaiIJ

pbcc , driU tlx h<>IcJ fOI" tI..: totkt bolt>
lI"'t .......... t d!<O faca< ' o tI", ,-.",..., Loy OUt and drili rbr
hol." .... "'flrl/); to 'I\q ",iU Ix In thc sarM pbM, cnsuritrc
that
:I>S<.... bI); thc f.aca ,,-m loc Ic>-clllul il casr
c"oujh 10 1.1<> Ir J'1>U hOl', dtill p~ an<! .....
f"<:nN
10 poojnlon ,h ....'011:(>1,",,"'. If you doR'I II,.." I driII """"'
)'0 " CI" ,~...,. plunw: muie. t'qulppc<l wi,h.n W: luidr:
for thl~ opocr:"lon. ,"ou do.) nccd'loI'I,(I bit '" pcnct ... ,e w

!Il"'1'0/1 the hacl<5ln

ati.,

i\~lnch,,1t1ck

2 plastIC Wlng knobs '011111 1t"-16 th<t..ttd Insefl;

'85194 from Woock;,"ft Supply Co. (800-22 511 53)
2 p.lInMad K.t'OlS, '6 x l'

238

Routt. MJgIC

bacIo!

1"'}' o", the Iocatlons o( tI..: b;r.cb on thc twc: AppIr

!Iuc arul damp tho: t>acl<li 1" pb,Wirh . "''CI rog, wipc oII

.ny

!II'''' "l"""ze-ou, "d"", 1, seu

4. Mai<.. 11,.. daml' bloc ..... Stan ",Ith , ...-0 bIod5~

(800-253,0421)
2 CiI""'ge bolts, It16 )( 41'>"

'*'

..... ijdr,pnnJ IuRlwood, cu, to lIr~ ~""ron poctifiI

by tire (."u"~'!l I .bt. l1.., bo,;c cut ...... be m:ulc on tM ",,*
1h do sa, }U" muSI . n:u;tr aii ~ uxiliary facm8 ro tht
mi,er 1t""11". 1lrc faci"JI: .hOllld ""-ten<! M-j'1>n<I lire bIade.
IQIaRllcss of whiCh mlt~r ';01 lhe f'I-l"ll" .. pl.ct m.
,""kc ,IM: CU",;U ~tlown ;n ' hc d.-.w;nlt M,dd"S Da",/!
1Uat:.... Tu avoid """,fll>lon ... J'1>u wOrl<, ;, ',. kO<JII kkI <O
,",w

t~

.. t;.
'+v

;..

.. ;31
SlCTlON V1EW

fRONT VlEW

1-...., r-

""""- -,,._ --;

'"

(LAMP LAVOUT

}ro"

..

5.I.0T lAYOUT

Ei'-I ----"". IHI:J"

1511>"

Hot. for

..

-1 .

k" bolt

,.

,"IUNC; eLAM' IlOCKS

!, ..
.

f!!
~

-.

Mite.

, ."xm..

mkt< g .. uoe In Ilie Itfll\;Jnd

.kM. C~mp Ilie worklJieu 10 the
~ugt 1~lng.

,.

g.uge

:;--1--'."e'""ilary

fitdng

"~

1. M.1ke tM .......IcI" CUI wttll the

mite.

"hit,

M,le. o .. uge

..uxlhary f,e.ng

;}

...-

1. M.. ke Ihe but Cui whl! tne blade liiled S

ancl tlle m ite. IiIlugf ,n the left-h.nd 0101.
Align tlle bhx:k.o Ilie ( .. tlnte,n,u Ilie tncl
ofth.e .houlele. cui. C\;!mp.1Ie wor!<plece 10
Ilie mlle.!p~ fKlng.

II

...

~.

hole for bolt

Sand fla! on
l ip 01 J,lw.

l . M.ke tlle 10P ;1 wllh Ihe blade

Iilied Ind Ilie mite. lII'u~ In

Iht

rlghl h~nd

slOI. elimp Ihe wo.k-

plece 10 \IIe mite. 01119" lu,ng.

Sphl

("net

239

1""

ROunNG ,., TSLOT

Ihe fcn<:e pOSilloo an

I.blclop. So cach bloci< 113!0
>mall Krcw protrudins !'rom Ilie IOp. Thc: xrt"W had
e.o.cndo1lnco a rlUling l>uIc: on thc _
, kttp;,,& t h c _
!'rom IwIsIln&.
Bon: ,.,., }o..Inch I>oks ,1"Irough ...c:h bIodc. aslobawn n
Ilie <lt-.wlnf Multlng Dam" /lIocJls. lIon: fD21dUns ...."
IhrouBh thc fnw:e _ .
Drill p!klc hoIa for 1"" .lipunml JC..,..... ,Mn
panhc:od ~ 1'''0 cadI _
,"
10 1"" drn.inILea"" Ihc Itc">d proInIdina :aI)out \o. Inch.
10 locale thc hok pooilions n thc baw, DIOWII thc
bklCl" on 'Ile baJc ",ich thc bol" ;ond pLostic ""ins knobI..
lirM: .bem up. _ .Ightl:o Ihc ....... I<nobs cn<>ufIh .0 nuri;
Ilie baw wilh thc ICKW hcads Remm..,.1Ie bIocb. InIl tlriII
OIoppcd hoIes foo" .hc 5CfnI' hnd>.

L Rou! a g'oov~ 10 rougl>

oul Ihe T$loI. UK a
waight bit wP\o$f
di"mete, matclln Ilie
0011', ,I>.onk d."mel~'.

_"TI

2. To e.op Ilie T..." a

ktYl>ole bit O< ,pecl.lll
T$IOI bil.

3. In$e" Ilie

..c

.!

.l!"

boltln t h~

compl~lw

,101..

....,.,"" Ihc .... pc o( lhc finhhcd bIock on nel> WQrI;J>ktt.

Paf all .... tlon 10 1"" gnin din:'ction .n,.,
.nllll.
>O cbmp thc worItpic- 10 Ihc ml"'.-pUKt" f.tcinl! wh ....

bloc"" ...,

nuking ""'.

lWo o( .I> ~

c ..'" "'" m.<k ... i. 1I

.h~ bb d~ .1It~d

5
<kgr<-el. ~ I.bl~ SI" " lilt Ih~ arbo. ", Il>e k fi. mile ..
.0 . hc "sl>l.lll>lnk
good id~ o kttp .h~ ....;,rkpiccc
c~ '0 II>" mller &""11" 1....,1f. ",.hcr Uun hu"Jj om on
.Ile rar Mile of Ihc b!ade Sa ,,".. Uch Ihc gllu!!<' (rom on~
,,101 10 Ihe mile . as . pproprUle. 10 .eromplish Ihll.
Set. up . he ..... rrom .he shoulder cm, lnd malle U on
bOIh ...orkpiece. Then make ,he b.,., CUI> . nd fln"ny Ille
10p Cu lli.
Hobh .hapinS 1"" cl.omp bIocks br ""oding <>r /UinS I
narro ... n..1 al . he ," ... '. lip. Thcn roun<J.o.er thc ItlIpoocd
ood~ ",ilh .. ndp'l"'ror a file.

i.

S,

Drlllihe asscmbly ho le!. The elamp bloc ... a",

mounlcd 10 1"" relKC b3.\.c "ilh ~lnch carnal'" bol",. Lcfi
., Ihal.11><: bIockli " o.... d casily IwIsI OUl 01 pOSition . .. tueh
woultJ bc pro:"y ""norins "'MO }'QU "'" uylng ' 0 adjusI

<!ti,..,

6. Rout thc T ,.Iou. ~ Iiooo. Ind .1Ie sptti;aJ bolti

lha! III In thcm. "'" "'-hol ~IIOW Ihc ~ fxcs 10 lor
odfustcd In twO pbncJ ( pualld 10 Ihc buc uii Ind p<Tpcndicubr ' o .hc ~ ual n... ttoum nn hc dthcrT"""
bolt., ""ro:huOO<J rrom woodWQftlng IUppty 0UI1n, OI"
cum""", loiIe! boltit. pun:Iwicd 1111K' Ioal lwm<;o", ........
I U5N .hc toik:t bol ...
n,., tb, <:an .,., ""'Ini wIIh ..-liber 1 kq.1\ok bit <>r I
T-oJoI bII. In ..-Ilhcr aoc, .... ke "'''' tiI<' bl, proIIk- m>tchcl
Ihc bolt. I ~ I;.indt 1<C)'h<)k bll.
80Ih k(")'hok ond T-.IQt bI .. ha..., " Jkn.tlc, _
J:w,t,,-..rn Ihc oIunIc Ind 1"" """~. Thc n...,k 1. fnU anei
h<nb ea>lly if)'OU {.,.,.;I ,.,., WO<t< '00 .~lycly II good
apprwch il 10 t'OUIIh oul 'lle ..aot by roullng I sroo'''' II><
oiK 0I.1Ie bol' oIunIc w,m 1 JlnJWI. bI .1kn ",1"0 yoo
......e Ilie pUO wllh 1"" T-6Iot or ke)lIuk: bit . It b nuklnj( I
much Ilgh '~ CUI. olkYl.tllng ,he .Ira<; "" Ihe r<.c<:k.
~' alle .1Ie "".. on "",.e. "'bk.:oruJ n.(, 'be )10"1 ot1
Ihc ...-orIrplcc.,.. 111<' >lot. In Ilie r.,n.."Q , ..., tm<k "'"
..oppcd un """ end (,lIe tine CImcslIU Ilie bl1)." sh",,n
In Ihc dn"lngs.Th<")' do ha"" 10 bc uP<"0 OI tine cnd ,;o yoo
C:iU' n tl<' bul' hcooKh b,. A ke~huic bI' w iU >lluw J'UU tU
mall" .. uppc:d..aot. 1>;0"'" It Il" plunlF"'"U1t1ng bll. U1,h
lu
en<l "'Mlo~ <lfI Ihe tohlctf>('l. bold ."" WOrkplc"
IcWlnl\ end
It .. bil. PlulIJI'C II on,o .hc bll .and ftt<I III
tI.e C<;H"fttt dlfttllon , fQOlln& ' ItroYjth . O 1.... cnd.
T.. lul blls scncrally . '" n<lt plun.,...antlllJl. biu.l h .,....
h.ovlf\SllO make cUmb cm , whlch can bc dlecy. )'<>ll """
rotiI Ih" .."'" from "nil 10 "nil.

,.il

"Ilo.,..,

7, IIpp ly pb.5tk lantl""le 10 Ihe f:acc:s, ""'''''"'

."" plywQod 13cl:f by " pplrtg and el'OPClltt'n,; Ihcm to
elco... Ind "'lUI'" up Ihe cd8cs- Trim Ille pIo<ca 0/ bmln.llt
10 IM dimcnMom .pedtlcd by Ilie Cu1t11'lll UOI, whk:h wiII
mak" lhcm aboli. I Inctt Ionlll" antl wIokr .Iwt thc "'"

..,.,.,-

IIpply conl""l c......,nl 10 1"" 1am!""le ;ond Ilie r..co.

an<.! Ict Ihc CCIt\C1l. dry. Otrcf\tll)' Ippty 'h<: bmirut" MI
,"""". """'" """~ OII aii .,..." Wilh """ ..... fttTcd wIIb
a n...tHnmmins bll, Ulm Ilie lamlnale
Fio"ly "", IIM: -4~ "'""'1 ~ onc c-ntl of
c-ach face

- /ft_:r"Jlf'Pof ''' I''d1(W~beI ..."tt!I ,"" &c.:s ......

.... Ubktop. ~ ,"" ro:occ and joInI .ht MfC

... ".,.,......,.,. 10 dlml"'lc Ilie Pl'.

gup "''''' ... IIIb bcta 'n ."" ben ...... ....
,"blc1<>p, )"OU ~
toc bel, ... oIf nul<inJ!; ........ lac.".
You nccd 10 ""
oIjointin, IM ""'" 100 "un. lIur
)"()u muSl ..... rou, OWII ludgmO:OI :os 10 ."h., COIIliI~

- /f I~:r u

' U'L" "

0<)

mi"",
""r)"

IlIln;

- /f IIH fous 0IwV<'''8 '00 base. liS<: ~ n",lHrinmtlllJl 1>1,

'0 n)<J' Ihcm flU>l! wilh II ... b:ts<-'. bonom ' lII"f.tc:e
no,,., clo.hI> OI' )'OUf joInlff;'hc: p luti" Lamln"e and
..... ~...,. In ..... pIya-ood wiU ""'00 lw\I OII 1"" knh-a.

Noa' !Iw )"OU ""." I IghI fii t.et.."CCfl fencc f"""" ......
..bkt ...... :od<ltQo ..... IJIhcr :oIiw>mcn, atroCft'1\5 Holcl. IOIlJ

SlnitUtlrdR<- "" II..- beD, dM:ddng lbdr fbtn<:M fn.>m ' OI'
10 boU""'. d~ rrom COf1XT 10 COf1XT
FIMsh'lrlm Ihe fenee fun If thy o... e rh l nll Ih"
b.os.. To do thls. tI ~mp Ih~ ~ ..emblt'd felle. In ~ vls~.
II .t>Gw1l. 50'1 Ilie .oul ... OII Ihe !IKf . wllh Ihe bil'
piIcII bNnng .idl"g on l h~ I~nce bJ,s ~. Roul lrom one
f'lll of iii, ~net 10 Ilie Dther.

- /f mt,. (W Ix>Ib fi~s u ... b .. m{J<!rl"" """""1 ' QM 'hc

fenc,' . nd n,aIte. new <NK I""I '~ .....11). ILaI
- /f b<>lb fil(es ""'fim ,"', (mI o{ ulig"m""1 u'/Ib wl(b
l>Ibef: _1-It1",~ 'Q brillJl ,hcm In, o . llsn",enl. Stript of
10"" 0""'11'<1 10 IM (<Ia b:tcb.", IJ"<><I

__ '* "IiqUMe ' 0 chcd< tho...... {ucs ' ''' >CJUl'" 10

1"" tabktop

_ .111_ fI~nnn ean bc ~ ..i .b ohl .... ,

_ .l/uJw dl~11dn ........ 111 bc ~""""""'cd by db:tS- _ _~
kn.bh"ll Ihc: I"t:nc:c: .neI jeIIntl"ll Of "'1oIn11rttt .""

bosc/b>d< uniI

For a Table Saw Mounting

Shh". hce 10 11"1 11 properlr a llg ...... T~IM' 1.
900CI for lhis pu.pose. slnee II "'0'" r,lI off Ilie lene.
'you m_h he. ~dJ uttm,nlt d .. ring ..... AppIv.
lIrip-or II ,,tsUr)'. sever.' suips IIO!' _

ht.--rlghl

..,h~.e

II

n~s

fO\t'' '

1I)'Olt'" JJ1C
IwtglJlg (rom ...bit .. w UI("",," ..~.
)'Olt an Idapt III<" I-(lIit ~ ID LlX wIIb II Thc t\.tIlo"11lJI
~ ond
"itb Ihr:Tobk

..,..afic>IOII> """ "" ipI" fcnc:c:

madc 10 i!:O

s- Exlcnsion Rou,,,,,ToIX "" poJtI!' I IU

10 be 10 Icm:, Ilie f,ee

1rTI0 _lisnmenl.

"'''''1'''''''' 'o ti'" ""no",. Chcck 11115 "'ith ~n ..;:cu.

OI

la' $QIllft' ~

hoI' in]> , h~ l':au!Iln p~. I( "'-~

....,., m."., SllrUcn 10 acI> OI""," un ~ joln,.,..
loikt hoII, 10' 0 Im. >lot In """,h f<la .
'iow Inocn
_ _ ' hc btt< on II><- ~T1l1hlO:O Ihc plucie l<nob>
.. _ .... bec. rormJr qaino< .hc ~ W"I'l. 801, Ihc
...... in pbtt "ith 4 \ ~ 0""'8" boiI. aitl>
pbIILic ..ing knob>.

'wo

9. fine-Noe ,he (.. nec. Th!o D .......... 01 .....11nj(

ee Imc:c "" Ihc muIe. l.hIc:
c:bmpilljl, i. do....... :md
1, "'-"CIi 'o cfUu", 11u1Ie r:.cc. .", fl..,;,h
.. par.1I.,. 10 ach OIher .nd.", >CJ""'" 10 'he UlJktop.
Dta1 wilh Ilie klLm 00"'0 Ihe fcnc:c::md II><- .. blctop
... Thc f:IcC!L Wuuld l<lIICh Ihe IlIhlctop.

_ ,,'Iu'n''''

.o}iD
.cr

>n' of 1"" n.sclb>ck

8. .-......emblc Ihc len. Thc I..

. . mU>l

6'c

'''1'.

Splll Ferrce

241

TA BLE SAW EXTEN 510N ROUT ER TABlE

5PLrr rENCl PLAN VIEWS

,\..I~
('1
"-,.
t

'II'
1

""

".

'II'

lf;i

,I
i'""

.-

... "rt....
~
.
OI

"
CI<
O

aaeks

FlO" pliu
Climp bloc:ks
Fulerums

Qty.

Dl menslon s

M Oii t erl Oii I

l' x lY,' x jS"

~"'~"'".......

U'. xl"x 12"

Wx~YI'x

15'

1"'"x 2ti. x 3Y/"

~"'-

l' dlll. x 11','

HlOrdwood do...-el

Plulk l"mINlt. 2 pc:s. 5' x 16' fuh

loIlel bolts. \4')( 2W

4 pl"'ll( knobs. 4-j11"Onjj1. 1)1' dll. .... 'Ih )1' tIwough

Ihruded Instrts: "OKn from ReICI TooI Suppiy Co.
(800-251-00421)

'lOrrl'~

boIIS. ,.'1 6 X 4W

2 pllOstk .... ,"9 knobs IOnll *'16 III.flded InSert;

'85J94 from WQock.,.h Supply Co. (8002251 1531

242

". ---,
IW

". I ~

Hilrdw ilre

;}"

'- 1,

TABLE SAW EXTENSION

ROUTER TABLE SPLiT FENCE
Cuning Llst

OI

\.w

F1

".

'II'

IlC>l.llet loIi1ogIC

~ big <llfk...",...., bel ....,.,.. 1111> (~ncc .ntl Ihe ono

dtsIpKd for a ...... tu fOUlcr uble 15 Ihe d..nlP bkd
<kIign. /k"'. 'hI: chm.1"'" ~ 10 pinch I~ rouad
fiJ>--k1Ia raIb. lIuI. "'" """m i Icngtll of ,ili> reocc b diIkrnn. 100. 0Iedt III~ Cutll"tl U .. an<! 1'1<", Weu, d ....1rI

b" thc da';!!;

If } ..... an:: going '" .... lkI m i> :q>11. ft:ntt, Miu>< d'es'<p~'"P d~

undn Ilie I>cadlng "M.klng thc F.....

(lxwin.n;1III Olt .,.Il10 237) = 1 fur Siep s 4 ;md 5. 1.... nd.
1QlIQ,.. lIv;o.t;:

""'J'$;

1. Cui lhe b lank.s. llte ebmp> oon"" of an tIpptf jIw.

" ' _ i6 ~""" 'o .tIco un<kr"Skk of.tIco fen I"usc. :ond Iooon
jaw, .. bich 15 bull"<l .0 thc ("occ. IIoth lt1co UPI""" and ""'"
jnI. arc formed rrom slnglc bkrl oi h:ard ..-ood.b ,00..11 il
tI>C" d.-inI; Multi.., aa",p 8Iorlu.
c .... tIco

t",.. lIl,utb ""Iulrnl 10 ,tico dlrnctbi<l<l> $pijInI

by "'" CU'1iII4I LbI. Rlp h<>n plc ull~ndHJWnn<1_

In lu lr. ItIcon croooru1 ~'U 1.lnch-lrnIIlh> oilM oo-.d h1I<n.

2. So .... tlte ho lCli. 1'wo hol<:> an: homJ in t;td

cbnlp bbnk. One i. rOf tll~ r.lI. :m<I ,11~ dl>.mnn 01 dtia
hole m .. " ..... Ieh 1hal of Ih" ren.:.. r.IL. "" )'OU. 1alX...T1M: IlIeCQnd ht>Ic"
Ih~ cbmp hoIl.
1-"" fi", Iwle mu" "" boml wl.h J10QInn bit
con bn.-a th" cdll" or U.., bIlInk. ,...., Wawi~ ~.
I ~ttdl dbm~1tT, hUl bdo..: fOI' drill ,hl> ht>Ic. chcd ,..

ro..

tII_

MAKINCO CLAMP IILOCKS

)t" drill bli

../

'W~
SI~n

wlCh, bloc.k nf

ti r~lgh \ .g",; I\t'd

hirdwDOd .

WiC~ ~

Fn"IM' bit, 01,,11 ~

I Jt" di.i. hoit posltlnned
cn bn!~k through the
tdile, I l .hnwn.

C "~'b'"
.!.

OrIII, }t;"'dl" hole fo.

Itle c~mplng bolt ,

~FUlcrum
Lower jaw

~
lipiM block In CWO, m.aklnil
CM uwer Jaw)ol," thi<k it-(I).
Rip Ih. Inwtr j.lw. making le
I W \hk;k iri,ltl).

R,p a l"diJ.. dow.lln

h,Jf, Ind gl..e a pleet

cn ctle lowtr jaw as ,

fulc:rum.

>:lw . ,.",.,., nib.Adlu>c 1"" di:ornc"\ft"

d1hll1IoIc It nct:QS;I.I"JI. LIy I.IUI th< ~en tcrpo;n, o(lht hok
OII <adi bbnk. Posilloo nelt bl:ink <"",fullt 00 Ihe driU

MI" )( 41'>"
C~mp

CI..e ~ uPP'l" ja .... In

\tIe fenee base. n.en
ulend Ihe MI" hoit
Ihrouglt IM fene. b.ls .

dlhocbmp-h<~1

Tlti, fcna 10 grn' h'.u.. o( lht buiI,4n e l:lmJlOi I.ooo!;cn

bi3 "'ing Imot)s ahou' a lurn. and II><: renec <'In "'" >lkl

. Ilo:

~ out IIM: Iocaelon

hok. lnd drio une ' h1Ql.lllh ndl hbnk.

3. CuI Ihe blocb. On Irn. eobloo ...... rip cite hbnb In

IW. kwmin/I: "'" uPfJo<1" and 1ooI~ jaw5. Ik-rip tlle 1ooI~
",",, ""00'" M10 cite 11,,",1 chldc...-

st.... :ulii
tt... .pllt """'"CI pKccs . .,.,hkh ~.., OS JiJknuns.
10 Iho ....cr la",... u
In tit .. dr.~ n..,n ISI"" :ulii
...... Ihor U"""," jo .... 1<1 tlte ~ o( 1"" ft-""" bo.K
'1111x:n 1"" (ti .... ~ ..,. I<kI "'"
tu.., I>ttn
........"l."Il. hor<: ci,.. ebmp-boh hok tlu"ough Chc Icnec I!;o;.c
(1< Ilo: J>OIc In tI><' UPl><" ""'" oS ~..,;,s,;,. o( rourx.
ln>n1 "-"incit )( 4 ...... lnclt nrrlaF boii tit""*" II><'
bo'<rjno.; l...... duuujlh II><: fcntt. Sun: IIlo: U$<:mbly ",i th
1arJr pb!<1c ,",1nll knob. Il j'OlJ '"'''''1 lu ~"..,.... ma. IM
""~ .... """" ,,'11Cf1 )"OU Ioo$n IIM: "''11<' plutlc ,,tnl1
bob. 61 ctJn'J)~ .prIng O"," IM bQII ~
....... R In tlte""""'.
4. ~mllic clic cbmp!l. !legln by

,.O

Using the Split Fence

~ o( j"OUl" c~1>Ic

prno.anoI hor<: the 00Ic:.

ou.et o +'oMnch bit In d>c: dtiII p,""

boii

""""'"li

dam.,.

II.. IlIbl"'-Ofl. TUrn 'hooc wtng kn<>l Net. lIId k b

~Ie cI.. ",.,. .o tumbloo ..ith . N"
" " - past.
drop an tt.. Il<)(>f ......... )"OU''''' tf}1ntc
'o boI<I o Jln::d ........11re.
" is j"" ~ o"purposc I'UIIICf . . . . If:n

dam""" JCCllrcl}'
1"0
'O MI or

Ne~ ... Zero Cle~r~nce

.'SI> IIft:OC heeo"", k CIIn t.. ""ju"rd 'u

oum .......... ~.n infinilUdc: li( bil !oItts .n<l SCllil'l/lS. 1< """,

n .. .",iC r..n..:., b

.lKolu,r ufO.Cln ... nc .. ; 1>111 in

",u,~r ",OU<Iwori<lllJl,
du>l1IJI ttro-ck.nn..., Is .... <;unOunl t" c~ unicom~
_bly }'OU,,,.>ttn _ lor romn""'-ia! lrn<n ,..;tlt
pbs<ic inscn. r..r }'OU 10 mUc uro-dconnc.. IMeru. ilul
'hlnk ahuu' huw )"OU d>uc pasticulJr .... up. ,,-Iten
..."klntc panlcub. mokIlntc prulik. 1or o:x:unpk YOll ..... up
.n<l m>ke o I~ L..... "Thcn 1"" n bc O< .,.,...,.. 'he hit haIr

'''''.11x: ,.,.,...,

"'''IHhcr
gri' J'Ul'Cd In ur OU"<. AnOIhcr 'OI.
AnIHhcr bil hcghl :><Ijusul'len<. AOOIhcf leM .
Irc\l. wi,1< ndl aIIj""'''''''', tl..- ""'''' 1$ g<.>tng out li( ,""

cIror.oncc het",'".,n Ilte: bi, an<! Ihc: .......,n

SopI,1 f fllC.

243

c
".,
II

il
...

-.
II

Adj ".t Ih e f ildnll .padnll 10 . .. lllh e bit ro ....e "linII . The ,plll len" .110 ...1,...... 10 ...1 Ilte I~M' .rotInd
1.... bit ... ilhoul hoI ... lnlOlO iKl~.ltr C~I OUl .. SPK' fo, II. ro.. un move 11t' f,nc, flCel dOle In 10 .. IIUIi bll (k(r).
lhen J>Ulllhem OUl lor .1.,11'" OM ('41'1111. !Iv ha ... I"IIlh, feM" (1010, 10 11t, bit on ,ltlte< .!dt. Iht'V Ciln provklt
~klng fo, the WOfk.

00"'''''''

8UI 01:'); )"00 "" ".,.01 tu ....., , .... pp

In>
:md bie :as much :as poo6ibIo, :u>d Ilie In>. """"hk IX-es
.. _ ""'" ' o do 'Iut.To:od;u.. , .... pp bn ..ttn 'ht fxn.j...1
""""'" It.. ,.,... kn<>bo 'h:l1 MtUrt lhtm. ~Iidot 1.... ~ In
IOO-"Ud Ilie bil ar out '''"31 rrom ;1 Tbm rttjplltn It.. ."'...

Jointing
, ...... """<1" an do. d:am !IOC'<l1ul> """""lIIlrog ~ I JoIn",.

.OI

.a

Thonk

.bouI .... l1li Ihc rouIcr if

. )..... dan'l h:I,'c

. )..... lut,,,

"'l,h "'" tplit kn,)'UU c.... Ilo 'he joii OII 'he """"'"

"""

Tu joint '''' I

"""t. ' .hIc.111)"OII h ...... 10 Ilo 1di">!I'"

>t>b' kl1oCC:. , ....., f:ot;:c:> kp.> .... ,dy. It, .-.:,",,,, . . inkcd Ind ou"

....Thc
w""""" ."" """",ti

~
ajpln>l 1.... rmet b;o(:u nd Iltc
tnllre: uni, 1"" bttn
~ ~U )'OU 10:"." W do I~ >hlm <>tii
lht 0 ...1"ttd bet li)"O" "",nI 'o ",mo,." 1110", Iw I""h el
loIock.lry 1I..;l"JI ,.,nlt """'(>li of pb"k: I:Iml,mt .. ~hl1tl) For

,tun!.

JoIn.er.

. )..... W2flllo jOim gil>Nadm m;t1e11alS tike pI}'''"OOIJ

mt"diunHltn);iry lihcrllo<wd ( ,\101'):

. 1"00 ...... , 10 join l I b<wd .... jUOd ,h:lo". ' o() hqj 10
.... n<"U'I"n" ...... n il"s l'Iondu,. Of! nIfce;
an opa:ioltr .... "' .. bIocl<j;or Ihln ........ pie.

O<

(!

...OI

-"
O

'"

Tht . plll ftOCII 1. o.y 10 SIli Itp fo,

jolo, lnll. Loo.en lhe knob. SKIt,lnglhe
Itlthand fenet lacl"II. Ind In.tr! .hlm.
be, ... ,en Ihe fene, bKk Ind lhe f;tel"ll
(~(r). The Ihic:k",ss of lhe SilIM. eq .... l. tllt
.mo,,"' of .tock IhoIl ... 111 be ftmovtd In
ane ~ss. Wllh l!"tl. OIO,fttd fl""'IiI kdftl
down. adJuS\ tit, fenet po.ltlon $O lhe OUl'
fetd fK1"II11 IlfI9I'nllo I~ bit" cunl"ll
KIgt. Cl>Kltllls ... lth I Strllllh'~. n
.hown aboYt. You Ift I~n .tI 10 JoIn!.

""""u

<>r 5c.'\~I.h~ of
nil , /"II' lIOmC >Iu_
.hc .hiel<:
_ J\IU.n: almlng for. Th", Is ,ho: n>y pm .
du.lk:nging bo ~.hc fcnn: l""'f'n"Ir
_ith tho bit."'" 0I~r...."<l h,..r 06 thc fmn: m"", hc WWfI' fO
bit $ n.nins ~ I do it lins "'.,.,.
1< ula CUI, US<: sca .... 06

nrd ..""le.

ro...

~Xf

'0

Who,', """"

*'

)111:;~ " I"QUjIh 3dj",,,,,,,m 06 .hc Ii:t>cc-, ""'"' 'lgIt.cn

..... "bn'p.
2. H<lId a >lr. gh' cdgc .pln~, .hc ou.kcd r.c.lAn....., thc ,,,.."" poN'ion by.....:wing ilS un~Wnped
md . .\di"" it .... h ~ bir, ntI'lnJI; ~ 1"'" gruc:l.1>(-

!IUO>JIh.nIp:.
~

"I1ghem .hc ..,.,.,...j cbmp

'Tttt .beo .S<."tIl"ll by nlaltlnS! " ",,"10' cu. ~ esI
'*"~ h~ .beo bit .... ill ...,..rty Sp.1I\!o tbeo tntln: r.:n""
SwI.eh otr ...... ...,.""". nd .:.mutl) cbcck " 'hdher 1. Is
"IlW"Ocly "fI.OU>SI bOIh ra.....". o6 .hc Iim. In. I~. ,..
.ndy.o ,,"nI.1Ie worl;piecc

. . ""'

TlIt idol bi' . ln .1, ...."., ~, IS blrty """'"Y bd. .... dl

Stt".tijI:ht bit. """'~""S
"Mnchwnk bit It

......

\IIIbIn(I

Thc: hllCl!C>t con>C ... ln. In ....1"8 'M rouIa lor ~~nUn8 Is
tkbi'"I cun~ 1crt8. h."Tht
St.-.!sh. hit hlI5 . 1
itdt ....... ~"" C\II~Y. wi.h lonJIrr ono a.cndinJ! .1LaI .0

'n"""

1":I _

..."h 'M bita

bit.,.... CUI bard)" hIDdk" 6{~

' .........a ) bo:tnJ

,...., rrunuf. c'uren_ Freud >ndAmana- maI<~ " ..IlI<h

bie.. ...."h Z~>-InctI culti"3 "'ngth . l"his b .he
~ .\I r.~ht bit I\'C" ,.,.,n. Cun ing JIUidoII>I). fOII

ltfJIeIIht

From S:O'''I)' SUtlHlpolllt. ,h~ rou.er lnity be tINe

"'ft.ooI fo r fUrfati"g flnitll workpl~cn. M"y'" Ilte
piec~ 11 sm"lI"nd bIoc. y. Maybe Il"o thlll. Th'fl oU,
,ht! pl"'f thlt' the joInctr .e"ds 10 jert i'O<J"d O,
demolifh. lnitt>ling )'Our nnge'f In tht! proce ... A'IOkI
.hl. Nurd-jolnt the plect O" the JOU,e, lable.

.h"

""",Id I>(-.bk .0 joi'" up.o 10/~ lItock wlth

rou ...... lI..'C it for n.anl"..u..r .. r:Ilgh.-bl.
b/t il C\II.alug numhn I 2-IJO; Am .... b 4SH-

bit Anei

jubo.'_ r..",.. ,

~
li
c

..

.cr

S91rt r tnct

245

Sleds
forteI

th~t

mite. gllullt! ;Ind Ils

nulS.lnce slotl Ust! one of Iheu
slHs i"nud.

.- W
...
OI

-"

mu''''

bcn !"OU I>uild (Of buy)'

taN<' , Ilie 'cmIcnCy
b lU chink ,..,., 1' ...... ""'" uhk~. ml.tt It'....
00 it . " , ~'t:1 I h,...., '" nulic: CUI .........11<"mI
thInk." ' ~ lIC1 tbo ~ In tI><' m~('f 1"'''11<"
ond BIIi<k Ilie eu ...111\ .1w. 1Ic>ioks. l:akndt h;,,'1: 1, '
n.r mi.a ~UIIC l. ubic SI"" acc~. ~'" It IMI .t...
!>.bIe .....' It ..... suj,cd lOr f'OUln uble wodt.
Wlto. )"'" do nd ... o.Icd Of ....... Wh" o.Icd <k><:>
.lut. mi, ... PIlJDO docsn',;, bad< up ,1Ie _
. p""..,n'lnjI
:os .hc:
""ilS ,tic """'p"cc.A oIcd doHn ',
~ui"'. >k>I in IIM: I:Ibklop ca lI"idc It. Somc!ikds tkk
:lIon& ,""
orhn$ 1u>'C. <hoc 'hlI' rkln IlonI! ,he

pal"'""""

,c;tNJoU,

""'''0<

rrn.c.-;

cdw: o(.hc ,.bklop

FQIIrro.ing .'" pbm lOr xvn:ll diffcrm. puShc'"
skds th3I _II- .....11 ,..,.... routcr tmk.

tit

Pus her
I.oob like h:mds:<w ",ndic:,<lue:.n ", ;, 1 II .hould. :>ln.,., I
.r:>d .n;>und 'hc m<N. comlOrnbl.. ""W b.rnJl" 1 ';:<>uld
linii '" >latI .he p;lu<rn lOr 'his pu.>hcr. In makirlj!: il . 1
".,.."ed IoOmC'Ihll\,/l lino. d,ff.,,,,,n, {rom .he ",ual ..,,....1 ..
..'>0<1 pu>h >lkk.
ll'lo:' 1)-pIc.LI tl~'" puID stick kes '''Out n,.., mln-

uto ca .... kc. llu <J/whkh . ",

'"

.pcn. rumm.ging Ihrough

"""""

el", Kl'ap blfllooI<inII for

ohc oigIII "lek. n", <Mhrr
.""..., "I"'" t.I1<:""OO""w DUI 1 ",."nloo IlIi~ pusli ... ",
Ilo. IMIIe ~ Ih,n o ,"'''' ... k:k doc:o.
o\.nd dearty. lhis is. " .... ro: eLo.hor"" pu>I", .
- lblnK tlle notch In ti", IOC. )'OU elin f.....J SlOCk inl" lh<
$O'" ' " roul('t 1)11.
_ Un~ .lIe hn;,1 1(> hook tlie "'<Iri< p"l~ tlle !oI>Ic: of lh<
p",ha fbl "" the wur1<pIe.""t "'Of}'OU C2I1 oppIf
<lnwnw,....J rol' al II", Pn'" tlme )"" ..., ~
1, 1Orw'.ud.l 111. 1 ""nnllc plu' on tIM: roUIcr ublo
USln!! the V'll"""'c In thc ot<>Io: a llOWI }'OU '0 hoId lh<
,,'0<1< <lnwn. hUl .Is<> fOI'' 1, .JtJIn>1 , he r.,,,,,,, .. ,.,.
ftt,J 1, . To do Ihll.)'QU lill III<' pu>hcr Ind "",m IIlc ~
o( It", ...on: In thr ]p\JU'''' 1'hc: Ilcct h<>ok> Iii<' <1111 f;(
Ihe .....,'n:.1l1l. Is 'Ile mOSI u.c:(uI lip'! '" ' hc pu1I>rt
"" .he ""'.e... bk . ~11y ""hcn "j"'pln"
o( ",l:lIh...,1y no. n,w SlI ~ k .

")fI'"

thc.

Gh-en , lie """;;III1l'y '" ,hc pU>hct. 1 ".,ntoo II ' n iod

]1000 In ,II<' hand. tu (.:ti n.mr.al u, . wuod ..., Jdcr. '''''2I1IN
il 'o hc u><-"tI. alic, .11. Su ,hc _..,..",...'" IIf1P i> perim
.\l :ll<c II'" Ih in" r""".....,1<' p"'''y "'''''''-)'Ot1'Q ncal . . .
IIWl ~ Snull lImIp. ,' m .fnkl_and IfU looIt IU)I ~ II
}.... 'r!ihop.

P1JSHER LAYOUT
1 squ'~ _ \.Ii"

rRONT V1EW

SolO(

VlEW

lou! It" dftp

mlj)pe(lv-gf'OOW

from liP I hHI.

".
15'110"

Making the Pusher

I .-v>'1 W .... ~e .hr. ~ ""ner ~ (nt""" t./Dn ~ bln.l
!>f.' projceI) 1 al>o ...arued 'o nu.ke i. """y ' o IlU/<c du""
.... , Sol I fin, ",.de. 'cmpbte. then knocked "". K\"Cr.II
jUhns from thc: tem pl. te.

1. Ma kc ,h., '~m(lI~I~. F... largc 'hc: ""Item .hown

Or tm..", 1'oL'" h:",dl<- antl atend line:!:
.... thel~1'Idlc: ' Ii ~~>nJt1 1 0 ,hc: body b)'OI" t.ken fn'n>

.. """- u.,,,,,,,.

.....

~ WI u.., pali"'" un pk of hoInlboonl ar IWncIl

"",'COd. Cut ;t nn Iht band ...... OI' ..i.1I a ..." " ... " . 1b cut
.. hatId.. (>patl ...... driU hoks .0 lOnn thc r.oilii ~, c:och md.

tltm "'" WI ,tit "'aSte 1lcr<I..,.,., , ....... ,,'kll 'ht ... ~ _

50nd an<Vor fllc.hc: ~ smooth:uxl fiii'.
!Wk' WIm r k>und. ati ..... nu.king ~ prucoc,...... pu>hcr. is
Ibaf; pu>hiltl; OII,he """ ..... WIk '" ;>Iipltly d.tJ'cm1l _
Ib>n SilI"'\nj\. If yuu mc:""1y dupllc,ne .IM: hoInd1l" p<>l<iIlon
.... tIIe ""W, ti won'l be rlid>'. ln;tad. romc .ht hoIn<1k- ""

...

~~

."

PUSHER

cunlnl Llsi
Qty.

Diml!nslons

Miuerl .. 1

l"lCS"xI6"

H"dwood

h.,c. opir.ll upcu! . lQ!ubr l+ind! bit It,..,.. <IlIn'!.:uxl

h .. lnd>O.ll. guidc I>u>tIlng, RQu .......00 and around .IM:
tcn,,,I:II", culling l""",mm,alIy dttper on (XI! drcult. You
con kttp .he bit eUII;RII eex>kr If,..,.. 0"'1> :uxl YKUUttI thc
ehi"" from ."" cII! a!'ter "''tT)' drcuh OI' ...,.

roti,,,.. lablt
ll>c sn-'" .. >I...,pW. Mcu\U"t: 11 Incheli rrom ,"" hi'.
3. llo Ul II.., Vgroov."

[l<)

. hlo OII .hc:

"';ng V1!">O'illjl Iti . ~nd 811idc .hc cui whll.h<- fcncc.

:tnd put a plece ." muldng ,ape OrI ,IM: lal>k' op. ROUl un,11
tIM:.oc 01 tIM: pw.hcr mdt.,. thc upc. <II .... l!fi .lte work

pieee "" olt tIM: bI.

2. ROUI Oul ,h., pus h .,r. ~11'>l 0. ""leCI nlce

pottt oIl1>n1"vod for tlll~ lOiiI Stkk .he .e",,,I.. e . 0 .lIe

4. GI ..... on ,loc h.,.,1 anei notch the toc. Thc hcd

;s a ~, X [ .Ind! bI. nl.hc wudtlng >Iod<. GI .... ;. in pbcc:

..... ..;.11 ""'l'C'

,hl .... nrl<picce .,," an apcnd
pittc: of p l ) _ or hanlbQ.Inl ( 10 prut"'" )'OUr

1'1>cn "'~~h thc 1"", .. ....,.....

""cii "'"w or on lht i);lnd $>"".

domII5 an .IM: bodr ..,<1 ..... ,ctl Ihc! lundk htn ~hiftctl
.. d:>lllpo; "" I cotIkI
OIi' 'hc: ~ oi ,II<" "".her.
1$ plunll" fOUltr.. 4-Indt 'Pinl Upcu! !>il il}....

r,od;"" oii ,/te edJtC>_1UOCtl t ....!nch l'OUtI<Io.'tt bot In alabkn""""C<lI'OU,~ r 1\>< ,w,..11>en sand II'" edgn and ~

.apc. x'

"'*
.-..tbnodI). and cbmp tI.o .he ..... rI<l>omch IIoa.ctl .he
1'(""

S. Kou"I1 ...."cr

th~

thc """"i ng. ...... a

edges. 1l>c

firul

.oud>cJ....., to

li>
O

;;
...

...-

.
fi

Usin g the Pusher

Th" 1. 001 complex_ If )'(Ju\'C _ .... a pu>h >illel<, yuu ~"o """
,hi> p .........." .
r w:lS JIOlnjt .o sar
i, docsn', lak~ li 10' of pr.I<:tkc.
bu' n ""yII doc. Us/0il p""he' 00 li ...1>Ic .. w Is 1"'cl1)'
o,,><:It """"od O.IU,"" fur
CIod ....ork""" bm Iha. '~ ROI
>O "O Ihe rou,crtabk On~ ~lls .hal you don '! channcl

,h;o,
m<'" ..

rou'",

,he ...uri< 1>ct,,ttO ,he Ilit :utd ,,'" fc:occ 00

lobk. 1f
jUlI JU>! pusl' tI'e ~~,d of the >loct. It 'cnW; la COIU~ .....".
rrom tloc reo.:" .no.! 'h"" .""'y rrom
bi.,
Aod 'h .... "'hen: .Ill. p","hc' P"""c> IL' .." .. h In.h m..
V-g'oo'". yuu C"~n ~pply Ih~ rO", ... ncedc-d la kcql Ilie """"
Olt Ih ... 1obIc1O\>, '11";11>1
reace aod bil. and rno>ing iIlraII ...-blle h"<-l'rnl'l j'(Jur fil\j<:t:ni ...-ell clcar u" .... n g<"t.
Wh., Ihc p""her will om do Is p""'ide Md:up tor It..
.... "ri<. Il doesn', pn:'''nI I".r-o",. I'or Ih>l
nd cit.htr
'hc p",h-hl''''k slc<I Or ,1><: mile. >Ic<I.

.Ir"

,h.

".nI.

t'"' '

Pu sh-Block 51ed
" h;g. Ihld bloci: fiucd ",ilh " Iwldgrip " firSH~'c b
fc:cdi~ ...... ,fI,; " ' " li cutler III <'Ulljunclkm ,,-I,1t Ih~ kncr.
It ha5 ataSS. 50 il > suble,

PUSHBlOCK SlED

Canini list
Qly.

Dimensions

Wi,h il Y1;[ roove In Ils sole, tllis pushe! 15 perfect

fo' roule, table wo,k. 1111 Ihe pu.he,.o .he edge of
Ihe wo,k otstlu In.o Ihe groovt. The hulllook5 the
cod aod allows you ta fee<! Ihe wo,k whlle simu ltane
ou.ly holdlng "down an Ihe tablelop ind In agalo.t
the react.

Malerial

Y< x6" x 12"

1" x 4W x

S~"

Hardwood

Hardware
2 rounr:lhead wcod

S(~ws,

1110 x I W

PU$HBLOCK SLED 'UNS

TOPVli

.-.

HANDGRIP PATTERN

'IQxlY>RHWS

...

6"

"

' lio"

I!ACK VIEW

248

Roule, Mag IC

1 sQ"are _ \oii "

ENDVIE'W

"'ha,

l"ou """ do
1did.or 1"" can.calc "I' lhc: hanllpip
pati.,..... L:ly out II><: grlp on a bIock .... 1-VK:h-tbid. hard,.. >Otl.~" Ilie ptl dircaion.
c.., OUl IIM: Vip on Ih<' band ,....' .... "~III a ~ _
San<.l lIN: c lll ~ A "001"11 drum chuckctl In 'hor dri.Il
ptU!l C"An .nlO\l'h IIM: Iruidc mii. \l11h a W-inctt or lHnch
'"u"du,,:. bi, in 1~1Jk.""""'lctl ",..ti.". machi"" ,1><" nIso
of .h~ han<J!Iflp.

3.

MOllnllh~

,Iu: b'Ii<'; )'<JU

h a n dllrip. Don 'I gluc

Ib~

h=dgrip tu

"'=, 10 "" _bie ." """" h 10 "

ne ... ~

IIOmc<1oy U..., lwo _1 0)1 1h -t""'" mundh ... d wood K\'t:VI"',

1oC1t1~"ll .., >I,own In Ihc: dr.!wlnll/'rlSb-Bloc. S/etI Plu,1&.
It'li il Hrious IHoc:k of wood. bUl lhe!\lnd llrip
UmU ij ;"10 a roult. lablt .IIN!. fI.ocklng up.n ~d
11"_ cut. il bcMII ItlN!. the wofIt. kHP!ng It MlUI.t 10
tIIt fflIet. anei bach it up. prtventin", Itlf>OUl.
lbi> ~ >In! p""i<ks 1I0O<I _ 1 '
_ \ FlIQNIU\ n 1h<' ..'OftpKtt lIcousc of

.., you

,,,,,.oricn-

lXIOn 01 tbc

Iuno:If!:rip. you actuaJly ha."(C ''''0 .,...,. you (:lJI

1""

For C\IIS ...11,,,,,

wo<It Ilo on md. nI< ~ .""
btt.1 tmd 10...., ""'5hon ed., ""hm lhor......t< b n.. nn
o.. tabktop :md I ....111 1"" *<l 10 hdp .cql Il
10
!tit 1<ntt, I usc .1Ie k>ng .,...,
a.a...., ~ i> roulind) nlbbkd by ",II:"....,.. cun"", )'OlI
<'1(.

"'IW"C

,..In

""""--.:<1 "1'. WtM'n IC1MlU' ouru 0 .....

Ilie ,,'Ori<. i. ~ limc u, r"",,,,,,, "1' Ih<' *<l Sunply_
d!. "'" <lanugc<I .ro un .1", U!lk ilO ..... cx~ a r"'>h.
"l"l'" .urf.cr {h~ tlrnc. of """rSt'. 11I1s .,.,..,o 1"" oJftl ...

..... Im. 5kd 1!iC1~

-U II"I

uld"6 . Wl><:n

1. d",,", m:okc """,11CfI

Making the PushBlock Sied

lIaUng lIN: handgrlp l' .IM: ,I"..,..,"n."mll\l( p:>rt uf 1111>
P"*<1.IIu' ,ha, 'o ,IM: p:>n ,ha,. ",.~., '1m<-. I!iCUI ' ......ferml
(rom """ Iw;t 10 lOOIIN: s Ihc: 1xI.... I!iCI d l<"w~d "1' In lIN:
~ of)"OU' ..."OrI<. Spc-nd 1..", .. Ilme un 'hal !Iflp "" lhll
il fiI>)"O\II" Iand eomro.ubly.

1 cockcd lJoe Io;tndp;rip "" Ih'" pushinl1 OU 1, ..." .. Id

""'"all<'<' ,lIe oJnl bul wuulo.l abu ~""'p 11 1(I:"insI IIM: fcn,
Using t he PushBlock Sied

1'11" I'kd b .1W3)"J U!<d with ."" fcncc. bccI.t ."" fe"""
JIlIkIrs bolh 11 :uod Ihor wt>rI<. wtllli lhc >IN b ~ \o

pWohIng Ihc wM. kccping l qllllrc 10 Ille fcntt. :uod

IIp 00 .C2t....... \o pn.....<o>,N.
'file atI!Ik ..... hc lundgrip nul;oc 1. =r 10 ~""p th.
>Ied apim.t "'" rc..cr .. il i5 ""'-anc:cd.
~ It

Miter Sied
TII. mit." loial ....."binu 'Ile roIo:s .... mlln 1"'''11<. push
bIoo:k.:uod chip brr:akn. !kca...., il _
....~ """ I:lbk
""",. 11 0000n'\ nc:cd 10 hc uscd Wt.ith lhc fmcc ....... duo ~
""1"1'" a 0l0i.
Whcn IIx okd .. ocnq,.. a chip~, thc Iti, CUt>
II\nJUgh 1"" _
and Into thc >In!'o I't-ncc. "".hc: fmcc ...
In , .. rong """"". ' cOfl.'illll1ablc It'~ '"'"Y to rcpbcc 'he- kntt
..... """" lu " .. kc .n cnlirdy ""'" okd.~)"OU C2fI " . . kt poe
dai kd,; Nr di(krcr" c""" T1>c skd >hIiwn Iw httn U>n1
O'duoh"lr lOr 1Iu: copt CIIb !TI3de in c:onlWlCllon " .jth
ro.,..,.arnkli<k """". 11 w;u tna<k of $Cr~p-hln nt.llcrbb.

1. Mall", 1"" bll!lC. CUI ,,,.., picca. of "..1""'" 1'1)...,>00

.,lbe dirn<:nsions >pc<:iflCd by ,II" J>u9t.Klud ~ c.. .. inJj
I-.GIur: thnn
ba 'o ba
AfIn" "'" cbmp> .rc off ' hor ba",. rip :md ~ul II 10
_tltc cdw:S an(! 'o ln1kc Ihc con'ICn pcrftt'lr .......,..,. It
oorncttI ...."..,', ... ....,..,. Ih<' ..'OtItptai you jtlIidc "",II 1

rr
ID

*'

OI

... bt""' .....~uan:

I ndMINIlhe- ljIht ,..". coma-of 1"" """"'. rut~ it un

.. bond _ Thb b a cut .0 otkn'lng .hc JIcd . .".....
.......hinI<i.... 1 knnw " 'hId\ ............ loc lhe- ~ """
2. Cui ti ... Iuondgrip. I ""><kkd "'Y lundltrip OII a

m,

.o}

;;

'owU"""

..... pbnc'.. handtvlp 1 """",'fii lhc p;oft 'rom """ of my

. . . . . "'..".,:lI a pan."... _
Ma .... Ilie tlf1tIIMI "'-1'1
fIU bIg ct>OOlIh ~,..
1und.1~mchcd il ~ bIt. 1 :obo clonpI(d tbc hx 'o pn.iIk pbcaI U) pul a cvupIc: of
-..u/II! "",.,.., . (!kcal"" M .. U>d'ut on aU !IOIU of
~ t nud<: ha<dh< .. t\I l.''''plal. 10 1 """ n:p<OI.Iu
6rwuitt<J grlp wh~nc:vo:t 1 " ' ''''.)

:c

Wh_ milk illil il

c_

CUI.

~lwlYS

hltw tht .111 fi.mly

.. ","",pIN! 10 lhe ,Ied . FHd II>e ,Ied p.nt Ilie bll.

INlking lhe cui. Whtll tht! cUI 15 doM. vou can !.lmplv
use Ilie !.I~ ""''''1' "om.1Ie I!'dg<! of Ilie l"bIe\OP Ind
Ihul U't IM .. Olt " .... ,,'1' trom tht! bi1 . You cIonl h:IV"f
In pu lllllt woflr. blek x.ou lhe CUUt .

NIUIl SUD I'1.ANS

ToPVllW

twtdgrlp

OeSYCo
" TC235-U
toggle dlmp

HANOCIUP PATTERN

EHDVlfW

-....

<II

!.CI"'' ' _I0I0"

MITER SLED

....

"rt

"'"

Cunlng lIsl

....

"
'"

Q ty.

Di men slo ns

Millerlill

Wx 10"')( 16W

""''''

,\'.",. 1Y.!'x t61'>" Hilrdwood

-r~nct

1\4')(3")(11"

turdwood

" )( 4lo1o' )( 510\'

Hardwood

H~rdwilr.

6 drYluli ocrnn, Iti x "

I 101M11e

~"'P. ~-SUl<o

ITC-23S-U; from boci

TooI SUpply Co. (800-253..().421)

.. p;ilnlM~ SertW5, "14 >< "
'TIM ..... """,,, _NI feN;e kttofth "'~ .. H IIdJ~"'''' <Il
...,.,_ In 'Ilo 1...... Ia IIM: II....."" .., .... ~ riN

IDNtIlfl' , . IIM ,/II !NI 0#1

250

ROUlf' !QgOC

~r

_lfnQbll. SU lur

It Jlf'lClial !ni,,", o( Ihr !oInl b rhc lQAAk dImIp. ~

ko;q:Joo 'Ix ....,o. firmly In pLoo:~. ,,"'hllc fn:ft"'8 ba<h al",.
lwKb 10 ~ "'" >ktl , .. po.hiorl b ~ 10 kp'"
C'nd <>f ,"'" ,"NIl rrom bowll\M up ....,.y r....... 'hr bit, ..'bidI
""""kll[tI\'c!'UI' "" Im'JIul:lr cm
. '0. ruplnll ...ur1<, . 1", eLtmp ,. alrno.t ",CllIW. n..
",a.'OOnl rn ""1100, ,he cOjll.'!!bI. 1, &dfftt,Jj"ll.:lOd llKq:II
,..".. .", """in" !tIC" ,,"OI'\( COUnlcr tO ."" bll". lOUlia.. i
,,'111 1"'11 Ihc ........ In,o tI,11"' ...... ti .., >lan.
ul' oI'ghlly arW<'d. Ind lllr """dIN tom .. )'OU a-. lIUf ...
' ;lIh'ly
)OU IIY)' IlOl ~ th ...........
cbmp an dmdI .Ioc wurt.: .... tll!hl cr than ,.... ca . . .

"'1......,....,-..

n.

'"""""IIh

""',.......

Milking the Miter SI"

,ha,

Thls b >lai
...nnuId loc CU!II ....6utd 10 rour . t:r.1Ik_ Thr: hotw: In panicubr 1111$ alftId ""'" ,Ior.obQc,
l lor tdIIf' o( tM b/I N_unIIy, tII:ot ~ .. w ...,. ......
"",'~r tallk 10 I'OU, .... tahIc Thr: ...... """,,'II Is 12lIom:I1IIl'"
tlout.,$undlflll R""tcrllobk <I"'JIIC 212)
Thc bkd bll rolbllllWlk, a I r1IIIN QI'\kr.1lK t.c
ond shOC' " '1II1bI Ion!!u",c. bul Ilie kn "in nctd pm

odif: "'f'b<'rn""" . t, rtW<c:,. ~ '(1 ~voId A1 .. In~

q,rtbtr. t lUed "" ........& ""cI....."'y.

'"ep. ns

1. Cut lhe pans. l1>e bIbe, ~, ono! Ioh<x: n~ ,,, bc:

fIa md "" ... re. CUI II", sbor ano! '-nce 10 ,bc: dln,eruioou
Ip&d br ,h( (.""ut'ing LiM. On '''"' """"'" '~hIe ......"UU ...
from Ibc: ubI<~op CllJIII' 10 the bil axio. thoeQ subtr~ Ibc:
DIli ... o( 'he pll... bc:ariog o( ,he bit )UU In,eml
10 _ "i,1> '''"' fkd. o\dd )1 indl,o III>' rneuumneo' (ti...
wIoJIh o( 'hc: ...1Ut in ,hc- """">. ono! rtp ,,,", ha>c 10 11>:11
wiokh.<.n-...., l' ", 'Ile 1cngIh..-;tled hr 'hc CulUog Wt.
11)'OU "'2111 IM mi,,,," .Iokd 'o .atp ~tl}' ca!lJy" m
pI;uIk lamlna,e ..) ,hr bonom owf:w:c o( ,t ... ~

2. Make aud ios la ll tbe s h oe. CUI nbbt' fOl"1><:

baS<' in 'be sh<Ie. '"' sho:nm 10 Ihe I.h.. "'inl! MII.... SInI
PIu~ Thc ...1Ut i<
Cu, 00 . he mU'er ,abk .... ,""

noi.,.

ubIo: .......

Sco IiM: twc lrMo ,1Ie nbba.and dm.~ 'hrce OI" bir ..,..
"""'-"'8h u... """"
siloe. II )'OU\~
rooanI """ >uo1..,. o( 'hr h:.o>c wllh pla.51k bminalc. bc
ur '" orient it down, 110 i, is ,1><: surbtt III>, 1'idQ on .1><:

In,,, "'"

..... JC'1'<"'IIo"

-"'*
3. Scrcw tho: relKC In 1.......,. NOIC ,II>, lbe k...:c b
pooitionaI fIu5h "ilh ,"" " ..,riliog rdJI<' o( , .... t..... and ,II>I
.~ "'" Ioh<x: hy ahOUl 4';, I~ Tho: aIn koIg'h
joi.: pro>iob futler ... ppon (".. IiM: ""OII.:pIra !le ture II 15
rida ~ 10 'he ~hoc. 1)ri'~!anI"S
ba.....,
_ ,1Ie '-nce. """p 'hem badl: follO 'bc ~ .... ""re 'Ile: hl1
--'" hiI'hem.
Sc:n:oo' 'Ile: ,OtQtk ebmp ,,, ' he knce.lbe cbmp ,pcc~

'"-.h ,....

..., il DIG. and IIltllO'<" 11 ;... il iI ..mns.

b;"" """

y,,,, cao """"joI}'

W 1,..,.1Icr d.mp. lf )'""

n.c: "".CI pool,loo of
_ dlmp It 001 !n,,,orUlII, but II><: splndle lIhoukI CO<I.OCt
_ woot qullc cIosc 'o rhe wor11lnI! ~ o( rlle: okd.

4. CuI. s hapc:, and InsuU tho: handjj;rlp.

\'ou.,.,.

caboJe 'he p;llrcm Indudcd In ..... dnwinA,OI' )"011 an C'OIlo

""" all)'uu' of)'UU<O9In ,Tho: o:DC1 )hal"" Is 1""" Im"' ...... " l
u... blter.
CuI,bc: I",od!!rip 10 Ih:>pe Olt Ihc band SIw OI' wirll o
Ilb<:t o:rw. Rou"" .1><: nl@lr:$wilh "l<>odQlcr boi. n " _
-.n,<'lI m"'a. Allxh ,IM: Fip 10 'he t>a:;c, by drivnj!."""
~ drl""U c""".... hlOl.$h .IM: ~ !1'0 lhe grip.

.... ItI nr in )'UUr hand; try 10 xhie\"

5. Trlm Ih".kd ' o n t o.., ... ble ;Ind a"pIIoUon.

Jhooukl !imi. )"0\11' IJIIC o( ,he Jkd 'o ~
putiNI.v appllc:alion. ",., oIaJ .'Ihown In II>< p""'''' b
o:ampk. t. uscd
fur lhe ""PlOi' cu .. ......", ....
"",ol~ ..."OIk.
AI IiM: bit UKd ro.
appllc:a'ion In , .... """"
F(A' bQI m.ut" . )'OU

""_.,,It'
.ha'

ro.

"""liC:"'k>n.

,"""'o

. . IIdjlut ils d<-\'21ion

II'"~
l\u"n "" u...
""" .... and nWoc ....., fW" wirll tbe .led .rnI a ....... p wort
piM" Th< "'~ edtIo: o( .he basc wil! be trim~ '"'
.al "'" md o( .1><: fcncc IIoIh wtU pffl"eeol) .....ch u...

...

-".,..

Thr oIcd b rndy

fur """'"

won:.

Th. co ....nd51kk jofnt Is. (Hnempo,ary Joln .

used prima,ily on ubl ~ dool"l. One pin Ilono the
ed~ of , he taU O< SII'" ... ilh 'Ile J 'lck lng bl. <u.s a
dKOt.,lve pronie and. 0 _ for rIIe doat plntl,
The <op,ng bi' maclllnts ,I>e tnels of , ht !lIlls. f",mlng
s.ub 'tnon anei. n~'Mt of th, dt(o'.I1~ potoflle.
The raii fnd IIIus un neSlIt snug aga Ins, Iht td~ of
. ht ..ilt ... itll Iu le_ Iockftlln tlle paoel

11_.

Using the Miter Sied

"iI""'"

("",ncnJly opnl;;l"lI . ml'er >kd b "-"'<1

,1><: """et
",bie fma The Iohooe ridiog aloog Ilie table, edtIo: guidco
Ilie Ikd. ond ,II ... 'he C\Il .Tho: bI<;d's kncc ~",p$ ' Ile ,,"OIk.
pin:o: In I""'i'Ion 0,,01 1"''''1110< ,hOl ~IHmpon.", bacI1"p ""
Ihc cu"a ~'.
f"",,, rhc "'"OII.:pka 00 mucll OI
p.u5 from it Inlo '''''
fenC'r II It ",lIen ' Ile ",,"er

'''''''''J(.
oi""

.~ . ,n.o ~

_ .. "",

'J>lInl~

,"ou .,.,. ....k" a J''''''''~' ~PurT'''''' mla <kd. ...tI k ... 0

function :as ,-0.... tabJe..SI" " mi'"," ""_ doa. n.., It., MwUI
hokl ...... ""OII.:pka"")"Ou,,,,, nul<e a C\Il 0Q\Iifrlr lIoCnIO/l
rlle cnd.1IuI il won"r pro1'ldc CUI~ bacI1up "nicio )"<>1'

3dd ... o.... ili>ry b einl!,

1kI. b C'rtuln upo:nolons. w.:c matng copt nl1$.)"Ou
mii)" "''2n, tallored .Inl. ",., ""It' diffacno:r

"".",,,,,n

'h>,

" ~PU"l>'* SIClI "n" I ~ sIcd '"

Ilie
lan.,.. '" ,,;ni ","Chk.,j,..,,, "ith panlcuW" boi .. II> ",,,,,,.
Ing """" tus hl:c" ,rimll>t'1.l wt,h IIw bit. "" Ir "'

:c

-..
It

';}

,,,,ro- ".

,~-

lIn'ausc mI' ml.er okd b UICd b cope ,,"Ori!. It "",nI>

approptialC 10 t:dk )'OU .h l'Ul.lgh .he C<>pfI8 Opc"I!KI \"o,,U
thm Ott riie
roIc and ...... opIfIa ci lIOInll1 . And I

>led.,

"""'~ foum 111;' ~"Ic"l.:!r opplJca.

llon 'o."" mure ~....,. ~ noitcr sIcd has,
The eope.-....kllck joinr il a retu""J)' new.....,. lUed
prio"'riJ)' In cabin<:t <\oo)t . 1t is rou.CII"'i,h" sJ'W toi, sa.

bclkl... )'OU'II bc: abi<: ' o

lbe .. 1I:klnli CUI. ntadr Olt llle nl8C> of 'Ile: frame mcmbcr<,

foro .. ~ d,,,~. ' he proIIle - a I>c-:ld or an OS"". for

cx:on'I>k:_ m<l :It lhc _
' _ "k..... Ihe p;lnd grou.~
TIIe ~"<>f1'I"II CUI" ~.....- II,.. "mi> of rl>< .. II,. bnl> a
nqoa. I'e
profiIc aud ~ .. ub le""o lhal rns In.o Ihc
p;lnd !If"OO'''- \lbm ...... patb ...., julnro. )'OU scn a ......"

o, . . .

.~h'

join

SIed.

251

It
OI

"'aleh Ih. (o,. bit h.l ghl og.ln$l. pltct of 1'"

$IkkHl $Iock 10 t$llbli$h I ,ou!jlh mlll\O. 111$. qulek
ond pretty ftl~bIe ...... '1 10 do " . Set th, llOCk bul'"
Ih~ bil, .$ $how<>. and .dJu" IM bit to .. lIl1n wlth it..
ChKk Ilie ltning wil h. test eUl, bUl If I"l u're u ..ful,
II $hould be righl ono

'0$11Ionln,III. woritplec. In Ilie sllHl fOI lite n'll

cu t h~l p s \'OU undenland ... ity you w.nt 10 use tM
fe~ct.$. posilionlng stop. 'iou mUSI hunker down 1\
I.blelop 1ewI,.nd slgitt OerOn the end of the ttll
wo, kpIKe. Unt UP 11$ end wllh the bea.lng O<II"t bit.

'iou U$UalIy ..ick ;oU Ihc ..mplc:cn 01'>1. Thr ~

CUI 10 lM<k an thc roula l>IbIc. ";lh the ,,""'" ~ br
Ihc ruula tabk r.:nc.o.lbrn you SW,lch LO IM copc cu"cr,
and goot oul your 1.'OfII.. okd ..

4, Sellhc roulcr table kott '"". J/Op . lb!ICI ~. ICI

thc >Ied ..mtt "'" 1C$! tull'lill dampnl 10 ~ .t """ ""'" r:ldw
UbIcIop. Brtng lM fcotcr lip 10 thr .ocr.tp. ThI: fmce ...... Ilo
pu;tIId _
Ihc fn"u cdIIe oi "'" table Of thc: S<tUp _~ Ilo

1. Adj " sl Ihc:

lOtlIPc d a mp ~plnd.)c, Thr Ucd tus .

bis lotWc d2<np. T1x: damp '" bnporun~

1>;0,,,, o l<n<knq' tu puii Ihc .......... ~ '"

Copinfj CUltcr)
IM ia;I comcr

o:r.. ~ ,1", ~ II);thc $;>m<' db::t)"" ""p<.'rio.~lCC "'hen

tUu'u)JI :an nil<: _
~ tt:.nd-hdd fOUler, . . you JII<'I tu .....
roma, you 11:1,,, IflM ''''1' c:ucful th;u. you dc:lr thc 0Jma

OI
OI

-...

",ithou' oIIppOnt: around k . II you ...., .... "" )"'" r...... ' o
hoItl tbr """'" an
lkd,)'OU mI)' not bc ahIc: W pn:>'CfIl
this kind eL 5clf.!;:t:dif1.S. Thr dunp a ll" , So..,.., k, _ ..,'"

u...

)'UUI1df """" """".

llec::l.ux .. ock lhic:l<Jlai>~' '" "'1' "';jIh1Iy from job lu
job, J'O'I <ICt'4 'U atIj..". thc >pindk 10 1K'<'ommod:lI~ m.,
tllidncs!o ,,( Ihc cun=1 run's .. ock, If you "'" """"" p;ctt
ol>lock ti .., ., dam.,.... in Ihc!kd. thc opIn<Ic 10,.. , ...1 COl'

OI

m:tIy; OIdj'''' II

..

"
~

~ So >litIc thr lIcd bacIr antI fonh, linln8 uP "'" ""'"

"'i\h thc nod o( lbc scrap.Wbcn k '" alip>o:d.loct ~ doo<rI.
'ilie i)QI O"'2"lII'''''''' " Is 10 "'" , .... Splil Fmtt ( ....
paIJI" 137 ~II' pbm) mei 10 n:rtIO\'C 1.... outked....:lloo d

"""'"'<

II~rafta.1O """"ion ~

1>;o''C

""""JIIea in tbc sIcd.)'OU....m,

'o sb<k lt aIun!I1hc6ktl, kntt uooiI k ......... apImo dw

I<:ntt.Ftip Iht lOjI;I\k 10 Iock " oo..'n.and )'OU'n: n...ty "' ....

2. Se! lhc ooping bit dcY;ltJon. Thc!>jl cb'1lion ;,

ICI In \...., 5l>p:$. Rl&h' now. you lIC<'d LO ."..,bli>h. <.'OIltSC
..... I~ .. )'OU ClfI prep;l'" thr lai eLI'" ,""up.Thm)'OU'U
mum 1<1 thc dcv:Ilion ;md fine.outlll: k IlSIr\!IlC$! CUI$. for
no .... I.... adju>I; 'bc bi' by cyc.

3. MJlkc 1"'" cu~ u.;., tbc sk<I ..... not Ihc fmcc
Uy thr lest "",",pIcu in ,... *<1 wilhuul cbmpUljj, 1
I.inc up thc rod wIlh Ihc b<atinjI an
bit. ""'" .... p
"'" '''I!IIk damp do\cd M:tkc thc CUI. A~. witll "'" ro..
"",itdlc<l "IT.~
sIo:d antI thc I~ pIo:a ..." thc bit antI
cbtdt w Ix ......, thr pie<.'<: tus bem CUI 10 Ihc full dqKh.
1~[lCftdl.. UpJn how lP)d ruur cyo: 10, you n.. y /IOIthc
pooilion 1.... !iah' an lbc n .... ..,.. But il Is mon: IIkcly lhal
)'01.1'11 lIC<'d 10 Jncak tlle .est ..mpittt <>ne W2)' Of thc
OI"'" 'o p:t "'" po:<illon o<t p~I)'.

u...

u...

252

Roult. Magic

"a

Cu tii,.. .eron eMi ,raln Is perllo ... bec: ...... the

cuttt< usu.lly lears spli"lers out .$ II ulls Ilie SIOCI(.
Tho! slHl' ' enu baeks up ,"" r. il-plt ..... nting the I~'"
OUI_Iten tlte ,.JI\ \.qualt 'dgt Is tucktd ~IMI k.
boJl Ihil' only half t"" (uls. for 1"" ol""n. inltn I
lptd plece of se'.p InlO Iht Uk: ~ Cl,t'( before
cl.1mplng IM rlllin Ilie sled. I i .hawn ""re. FGr Ilie
'ill 10 be propetly allgned In Ilte slHl, m.ke su., tlle
Icrap Is al Jo..st n Iong as tlte 11ed. fenet.

S. Rdlnc your co:o.nc b ll-cK:vallun Sdllng. 00

doolluoogh ICSI CU\JI. l~ cope eultc. is dc:signctl '0 """ a
pro/Ik Ihat 10<:'" InlO thc IItidWIg <."Ul. FI. YOU' .eat cu. 10
_oi m" <lua. Kp adjustln& IM bi, hdjtln umil II.., .lil~
Iftd ralllUrlxcf an: tlush ",.het! >lS6Cmhlcd (If 'ile e<:>pcd
pIott .. pmud ol .hc Mic:kc<l pit. """.~ hc ruu c. Ii ,h~
!Irltd pItct: .. IliWte., rob.c: Uw:: hl .)

6.

AS W.h the 5tlckifIA CU'5 . IM: ""'" CU'5 !ohoItId bc romp!c,nl in une pU$. ltcpca.ing pass (U" crtbfJC ' ile cu, and
C ....."'~. Ioooc fi .
i rope o .... ~nd of och ",orItple.1lIcn 1 booo ,hc
.u~il laty f.ocing ,o ,IM: $Ied with Olrp(t u pe: Ind copc: 'hc
'MIlcr cod.

Tenoning 51ed

Prc",,",. wp<:d backu p ~Irl p. Thc ,kd' (cr><:c

t<M:S'(I prn-.:n' II.., rutle' (ron, hI(lwlntt (\1" chip" os il

0lil: thc lIOQd .. <.>d<. llut thc!>led I'nla h .. . 5qu"" c:dgc,
.. ~ an only do ,hit "' hen ,hc fii. cdll!C o( ,hc ",II il! OW'iost
k. For half
~'I1 pe ( Ulii, y<HJ'11 Iu"" ./te .<tic:kcd ctJw=
lfIIlnst thc lk<J rCl1C~. Fu. th~ b ll~' CU". nuk . """,d....., ",ril' to """,~ n . "xili.11' fc""c f.dtlJl l 1,., .. id cd
.....,of ach ",Il w ll l nest In " ,./te L~'pcd c:dgc o( thc &doM.
I!.1tcn thc proper bit bdldn I :1<:1, CWnp Icnglh of ~
lIIdt pl)wU<MJ.o .lIc rome obl<: 'up .Ionl! ,1,., r"""" n,.,,,
fWI' cQPC "10"8 10.
of. "rip o( ,/te " ,,",1"8 >tock.
Thb .. thc .u~lIi2ry 6I<:d (ene.: r....,ln".

rou.

7. Trim Ihe ",ll~ 10 tlnlslw.! length ."'15 hu 'o Ix

dooc bclon: copI"8 ,hei. enUs. Thc wkllh 0I.hc: pro/ik Is
" M )tIU nl ust 0tt0UI1. lOr For uaruplc, 1l)'tHJ an: m>.kl"ll
l8-irtd>-wIde: door I nd l~ 11II-Inc... wIdr .. iks..1x- diJ..
tancr; bel....",n thc .. Ilo .. I ~Y:t 1n<:hc$.1\ut. 'hc ",il!< mUSt Ix

lIwll CfIOUI!.h

10 tWCttIp thc stlel<l"ll proIlk. Il 1I . l\ Ind!

wIdr (...1>Idt $CRIlI to Ix tht ..>n<hnt), Ihm ,..,.. nced
ldII ~ Ind! .0 .hc kngth 01 thc rails ( ' Inc:h for cxt. >tik .
1>' lWit:e thc .. kkh of ,hc: ptnIllc).1lM: """y ""2)" 10 n"I<2..""'"
tIIO proIIk: iii '0 .. lek ruI( In.o Ibc lIfOO"" and ...., how
tp il. il; thc dtpth of Ihc JIfOO'.... ..;U ....'rn 'hc width of

"'-

'o

A :<Iigh ' ly dilk ..... nl mi.~ . ... )1c >Ied .. OIle UI!ltd for rootlng
,~nons . in.se, . p<Ut from thc ~k
>I<:d br
\WO Ihing,o-tlle I\":ntt tiu, extcrtds far bcyond Ihc b<lsc:.
.00 .bc sepatlu: worIo:1littt ~op . (Oby, it ~' . Iu..... anr
~ of lw>dk dtbe but !har. 1rK~-:ant.)
",., l"'fl"J/'C 01 lhc rm.c., th;t., t:Jl,md> ",..,.. and
bcyond Ihc bit Is tO booek up thc rut and '<> Stlppon. potit/QnlnjJ .. op.ln thl$: Imuna Ibc cut', CQOIDW" III,.,. m..rn
horizoaul &li "MicaI, '" YOU "'"3f\I ,lut >CCtlon 0I1bc k"""
OO...... lhc bit.
I a1 .... ys ....
iIh Ibc ~ bit.,. 1\4..Inm mor
tiolinf; bit. Thc bit-Mk cdF of 'be oIcd's """" ..... cut 10)' thc
biI. ,., Ibc bosc: Nec: indieues thc cdF of Ihc cu'. ",15 S
usduIln 6ninl1 "P _
for .~IMMUnt!..
Thc .. op
' o the ...,.. """". ,"OU bll" tbc _
.
piect" aplml Ibc "09 """ makc a pas!-. ..-hich nJI.S thc
,enon cbcdt and ~ Il .hc Icno<t S Ioolgcr tIun 1II.
Indtn, Ihm you makc . _ ~ """ ",iIh Ibc _
lpin>I thc stop, OM...;u, it pullcd badr &om thc >lop.
Thc Iualc cbmp is 5tJ"k , ..... do5c:s "'"ben 1"00 """"
~ un .bcT.......... llI ... il. <:In scn...... llundgrip

mi,.,..

this...,.. ...

dam""

M<1klng Ihe Tenonlng Sied

Thi.!o '" IAOtbct 01.",- .oct:Ip-bin ptOjc<:"t .ll><::t-.:."
thc _
tIun
IM wood.

'o

moI"C

.0

8. Cope thc ..orkplcs. Wllh your ""'''P laIcd

al tht 11II!< I ftmm<:d 10 !cnath, you >ohouId bc lOdy

'o CUt.

1. CuI tht.sltd and .stop partoi. Thc <limet>sions of

thc IWU ,.,., .!'j)<:dfic<I br thc Qlt""l!i LUt.",., widlh of thc
oIcd """" m .... Ix lkIcrmincd br mcaouring rrom tlx- ,abk
cdF It> ' IM: bn uS on )"OUr routcr tlbk. To
Mc"t\l, add Ibc '1IlcIr.ncsi of tbr: """".
In ~ and pro-p;uIn& u.. hardwootl plIU. bc ........
W joill' and pbnc 1tM:>c pia squan: Ind
",ith par.
;lilci ~_ bcoo.Thc p;utlrubr wood YOU""'"
~" I U.M:d popIar.

,Iu. _ . . .

'ruc.

2 . AlIxmblo: thc: ~ and sboe. Cii"" and ""f"<:"W

oM baK 10 Ihc ohot fJtJO.
1"hc second ..... mbly ilCp I 'o trim 'he bosc " i ,h the
bllllu,
be U.M:d wilh .hc okt1 .1. )'Ou
-cunlng !>it
In Ibc tlbIt, fOIJ'c . Adj ..... he dc
to tht thJcknuo of
,"" b..e Wilh Ibc ohot 'lichI alPin" 'hc t.bIc ~ cdgc. makc
a pUS ..i lh ,1Ie 0I<:d. lrimml0l! Ibc bi l.kl< cdp: nush wi,h

"'m

"t_illl sled IMlr.es fiSl W'OfIr. of fOUle' I~blt

am,,,!!. A ""rve-dl.1m~ t ~. bonQm-c .... nl"!!

bit
... <UI a <hHk and .houlde. for IM ,yplc:~l l eno" In
OM pus. A SUljI on IM sltd's f~ncl ailiomollleally
ptIIoit_ tM wD. kpiKe for the CIII, SO ,he shoulder
wiII be ><lu ... e .. nd perft" .... ~II!1ned aII tht Wlly ~Iound
tbe ,.,;1.
11lIOI"I

isn' .....

.,,,1on

c.......

Ihc: hI,.

3. In.~ .a llt hc: fencc: and cbmp. ~'ion Ihc f<:ncc

perp(ndkula. 10 ,1,., jU>lt.<rlm mW cdll" o r the ba<c. I nd
IJCT<'W II to \t.., baK and .hoc:. I d ......... ''''"O ~ ..... ""5 'hrotlJdt
,hc "'nce Into .hc >hoc-.
,hrough thc bas<- Imo 'bc

,wu

Sleds

253

II

In

TENON'NG SUD I't..ANS

STOP ASSEIo48lY O(TAJl

PlutI< knob (Reld 'OK. 421)

0)1
Ht~ "'"

BII Cui.

I~IO

fence. _ _-;;;_

....
TOPVI[W

TENONINC SlED

CUtllng Ust

....

Qly.

PUI

Oimenslons

,.

MilIe.ial

y.- X 9 ..' X , 'W Bln:h plywood

"-

","x "X IIW

H.ntwood

Fence

,1'0" X 2"," X 18"

Hantwood

Stop pllle

W >c l" X SIro"

1in:1I plywood

"'le "le 3"

Hdwood

Stop~ws

H,irdwilre
iC~w,.'6

12 dry>o,ll

1'<I.llion stop an fente

to contmltenon length.

jJ

II\\'

"-~~~~--'-'

x,'

I tOlKl~ cll.mp, Oe--Su.(o .TC202TU: '.om Reld

TooI Supplv Co. (80002S30-421)
I spln-dle. De-5u.(0 'TC21 S2G8; '10"1 Reld TooI
Supplv Co.

r.

c.rn.

I TnuI.

boiI. y.-

FRONTVIEW

le 2W

,.

, II.. nut. Y'

v.-

, pluti< knob wltll

IlIruded lnoen: 'OK42
trom ReI(! Tool Supply Co.
11to"u ",Id!~ "'U1t" ..djwn.d.~ .... p/<JI ... d I~ ,"101'.10
d'''''''''"I'''''. IM IQI>I<'oP .d~ QfId rloc
blr",,)'OIIr 'Ou'" MbIr. SU luI.

(1'.

". _---~

OeSt,.(o
nClI 5208 ,p,ndit
(2141' DVtralilengthl

lhtx KKW5 .... pbd ,,'hen: ,he hI, an',

iii"" thc fc>tt.on lhe lllcory!ha. 1'\1
ami 10 n:pbcc il rn .... ti_ (D ti... ",. 8m ,hc ""I!ok ok<l II
~(Bc

fUIT

runu.c! 1lomI.) 1 dkln'l

'" tronOmk::ll o( RU.efiabI """

.....

Otft' ....

'QO

chcoo-~

IlO)

qukk 'g nule tiu. If k

up. I can 111>1 "'f'bCt' thc " 'ho!c

S""p II'" 10QIc clamp ~Io>nl damping lhc wurl<JIk'

(Adj"sI ."" SpOndic .., n,:"""",'Y "" 1"" cbn.p 10 Jel'I 'WH
grip 00 'hc ......ne.)
Nt>w oct 1"" >lap. ~ It OII ,,.., rcnc.,.l>ullcd apInst
Ilie cnd
wurt t>ittc. T>W>t= 1... d:omp

oi,,,,,

Mounl ,lIe u'l!llk d:anlp OII Ilie kno..., "-"'!un it..., lhc
wn~ thc workpiC(;c "'ithin ~. '" ',. Ind. o(

lJIio<k wIlI

_1"""".

4. A5Sn0bk 1"" ~IOP. 1>rtI1 . ck2nncc ""le .11..,....

011..1"1' jo ... b .heTnUI . Uri>", .""'f.n'" 1n10 Ihc """'-TUrn
Ibt ~ bolt
.1Ie T....... 1'1..... ~"" and 5<.ttW Ihc
lIOp plate (D Ilie 1"'0 "'''P j:lWJ. ArWIy.lum ''''' b<:Jl n.. an<!
_ pIaotl< knob 00'0 'hc boIl.jam. thc ..... , 'OllC'lxr 10 klOC(!
_bob frum unlhmdin&

in,,,

Using the Tenoning Sied

.... ,1Ie Mal :md Ihc rigIoI bil . enonl. . 1iI .....p an tll<. . . . table. It"",', _ 1 0 00 It, ",cp by"C'P
1. Set up 11"" rouler tab..,. TIlb iii nutler o(
ductIog thc approprL:rlc hit In Ihc fOlRer and odllnjl l""
Clllni< bit c\n':ollun. The bj, an Ix monisl"3 bit Ilo...,.
oiomrttr "'''''PII 1>1'.01' bor,~ . . bi'."'e murtl!iiIIlI
biI-..-t>idI i> dcsigncd ro,. datina
moni:lcl.n<M ....,.
.... for ,,,,,,,,,,,- and II'" bor,.,.....,hnln/l bilS:lIT dr:Jigntd
drv broad .wba. ... ~ k d e"n :md omoodi. A
...... bit iii nOI -S ....:o $Ui.cd ~w iliC but ..ilIlx rompIrwIr 1IIc<ju.:"c

hl,..

trom.""

<""'""'"

Thc hit
~Id "" rnc-Suml
lOJI 'U'"
!noi"'" >Ied'. ~ Srt lhc bl' kooh ........ ... )'OU C:l1l
-.,., 'ta <:DIS and cn:c" IIp "" ,hc just~" ""'linII.

lenon on ( aii pioea', u.., >craI'" o(

for .hc 10000.l'bt. >inJ!,k Iloyuul b"., )'OU
m:orklnS th~ 1"""" ohouIdcr. Serihc 11 2fUIIlld

Work ... d .011 is tlle ,olllln. for (Unlnl/lfnon. 00

IIM:
tlb~. Wlth tIM: worl<plect In the ""non'lI\I
!Ied. Its bon Igll"n Ihe SIOp. mike i pin. CUIII"" IIM:
b ..... d (~k. PuII the)1ed bKk. pop tlle 10{HI1e dimp.
. 011 IM workpltCt on, o IlS ~ye. hQOk .1Ie work wllh
1.... cllmp-yoli (1lI~ ",,",p k clos~ ~n Ilie wo,.k~ On
tdge-.llf'd make illOlIM:. pus. TW<I """" q .... ne ..... oll.
Ind 1"'0 mo", pa.."" complete Iht ""non.

""'t"

2. Uy OUl

worklrI.It "'adi
imi II

0IlC'

.""
r .poc.
aii JKIIIOIbIe. ll>C <lM uI ro'" mon i"", (rallxr ,Iw>
.'*"110 clo:Icrm lne."" ~ .mon .IIkk.......

J. Set IIp t.h(! slcd.

, ~."" 101

pIa'" In 1"" >Ied. :.,11$

... .... """"loc..,. line ",itI! ,"" bi,-.I<k cdp': o( lho: b;Lo;c.

4. CUI Uit! te5llenon . Turn "" lhc """c nd ~

P4f. ('Ultin. IM tiI'>( dlttk ind o/'IouIokT. 1I"1I11",,n 1""
damp ....... roll 1"" workpk:<..., "'.., /obU. pa>IO,~"'"inIL 'bc
"""ond dMrl: and >h<>uIOO.
O>ed: lho:
o( Il\b
In
nlllf1hc. Ib,,;c.,..
lo'.'er Ilie bi -S "".:as:uy. 10 refine Ilie ni. Mak anothcr

n,

.mon

om.

yuur

,o< nA ind Il, it ,o '1'" """"lor.

Whm )'OU\'C)lOl ,1Ie

""hl. "" ,Il<-!nI work .

S"'dJ

255

O
C

.,O;

...-~

II

Featherboards
Held ar mechiiniCilI c:lilmps Of
VilCuum, fUlherboilnis provide
workp;Ke 9u;dilnce on IIM.
Iilble-ilnd prevtM
kic:kbilck.

.,'"

-{J..a A
~

:s

IZ

..:.,.

,mpo.m ~ m

)'OU

probably ton"" il; a fttd

"""'e.. 1, ,. simple 10 makr. and

'U 1l>C.

rout~,

tabl<: ",un:, pankll"'rty ....""" .... u. illSl pro.

flI r~ on ~fool and longu worlc p leCh, 1'11 plan
fc:>!herbo.>.rds on .he I.ble'op. one on cach .Idc o(.hc bl
In

.,...

I't:a'herbu>rd. as
con,,:,,' .nd saJ"C1y

they'U p~ .he ..,url< _"",Infl 'hc fc::n.,.., l1Icn I'Il cbmp

a eoup'" mo", 10 Ihe re".,., 10 p""" .lIe wur1c agaln .. thc
I. ble. ln addiUon!O "",,,ring ,h.,.he _Ii< doesn ', drlft Of
00'" ....... y fl'QO\ ,he b;' . he fc.,hctho.nU """""n, . hc
...orI! rrom kkking Mck. (In ,hl. "'83"'. fC3Ihcrbo;:lnJs .'"
,crrlr"",lIy ...dul on .hc , ahle ""w.)
Wh," I .....n\ to 00 hen: 15 ~how )'W "<HJp lc ..... rtI
tions an .lIe ""'thcrbo:lnl .nd cmph .. l.c hu.., ca.)' .he)'
:an: ta m.ke and ..... , a'"" W"~nl la .I>ow )'U" YKuumd.mpc<l v.:nions of Ihc (., .. h c tbo.rd . !f )'Ou h.~c
......, .... m 5)'.,.,rn a, )'Ou, d l.pos;ol . )"011' 11
, ha, II i>
$/)

,Ii""""",

e."," a>lcr 'o oeI .lIe re he""",,," ",I. h '';ICuu m Ih.n

.. ith mh>.niCIl cumps.

Maklng

il

hslc Featherboard

" IM.., rypi<'aI b,hc:rboonlt I doub4 1I. 1bcy tu .., bn

mode In :alI >iza ....J ronllgu ... '1oIIll. r..... .'ln 2~""h wklc

'"

DnaI aod I GU'ocf>.wIdr: oroeJ. I'W. . . . . couplt 0/ 2.ft:II.

thld:.....s. ,"ou an makc youn 6 Incf>o!

Ior\s. Somc .., cu, .... IM

....-

Tlw:fT "'"

,.1* ....."""'"

Iona Of 18 lndIrI
<NI

IM t:.nd_.

n..,., ~ "'ha CUt 1!>c: I'<:oIhn's wI!II l

....mir "'ppcm If , ..., )<ItI "'" In,o oinatIoo

,t><: I'<:otherboanJ!: )<ItI'W. .....",,', ""'l<'It. On(:'uoo

W ho,

biJI. "",hn'I ,"" omaIl. CIr )'OU dan', ,,"ve mouttb bIwf.

""""".

5l>)<ItI nukc _

' o S minUlo

"""".

1, W(S. ,tip 10 '!>C: """"" birt

It "'" .....

lJin80l You

....... aDOIhcr

It)<ltl .., 1.... ~inII OU'. hc:n:' IM

)<ItI, ""1')' A....

..,.n

rnm..

"""'P OII ......

(lf"It.

1. Ikl-t board 10 ..,...,. As 1-": ..............

wld, h an<! Iclljllh 0/ bule b,hc:IboaN :ortfI' , . . . Imponan, Thc btOO' dr.owillll shows fa,hnboanI droI.
~'-to lnet"", ..'kk: ond 10inmc.ionA._ IIw'J~. (Ik
(""11"'1"11 cal"" oul nIa ond .....,., II !ha, wIdtb ""beII I
. ~ . ,,,.. 'boanl on my compu'''''. WoukI)<ItI ~ .....
rb;, .., .,..I) 1{J"'U:m: nul<J1\I!:' b~ Iur. ~
lmml.i:I' ''' Med. si>:<: II lOr "'" tob.
AS }'OU lIOr1 'h....wo lhc: 5Cr.lpt In )'OUl" bIn. 1ooIt la ~

IASIC fEATHERBOARO LAVOUT

'0 [lO<Si.lon' fcal.hc,"""",rd in a '''ry tiglll Spui.

At any rAle , m.kc )'OUr lin;( ~Ul mi",r.Scribc Ii .." , .."
.Uel 'o ,lIe ml,~ md bu, off5(" abou, 3 ' o 6 Indtcs.l'his
line "",n;s ,hc b:lsc ohh" fc>, hc1"S.
3. Cu. Ihe feathers. Son~ woodworkcB ""~r b y
,he b1nll ""'" fOr ,hJs worl<. b u, Ido" Olt thc .. l>Ie ""'" No
l.oJ'>Ut-be)....... thc b:lscl!ne_1> """"",",ry.
As )'OU mlgltl CJlpeeI, both .hc length .nd thc 'hlcknc>s
of ,ht- f~,ht-" atfceI ,hc pli>bili,y of ,he bo;tnl. SIlo"
r~.... th<-n; "re: .uff", th:U1 lung (".<hen. of lhc .. m~ <hlck"""'.
TIllck r""~' I~". loo .
",lffer th:U1 <hIn 0fICS. lf)'OU I...e 10
makc the 'boanl shon !iO i, "iti fi, o conlincd spoi. m.ke ,he
fClt,hcrs ,hin .
Set II~ rlp froo:::>bout li indt
ilie bb<k. 1Ud thc
bIank irI,o thc bb<k. cu~ .. fu" .. Ihc "-'Iinc. Pu1I "'"
..."OrI< boek. )10>":: thc Il:ntt \1; ind> ' ''7)' from 'hc bIadc. M2kc
CUI .. fu" .. thc
..-.:I puD ti", work """". 1 u.sc: pu>!t
:iIld< tu hdp "'" trIO'" thc
Id; off.1Ie bbd<:.
Kttp up .his rominc until)"OU n,n OU, of fotllerbo:..d
"'idth. [f )'OU f"I>O\'C ,he ("n"" !4 Inrn af,,,r c:ach CUl. l""u
shoukl ge' fully :S:Ilislactory "'" of fca,ht-...
AnII ,h.I", aii ,here is .0 i,."'cU. ok.y .. .)'OU c::>n modify
thc "h<xIy" o( thc 'hoan1 Round " u ff, mo)'hc .-...I.i'*'i th"
~,IIrill ""'le In " "" l""u c::>n h.ng It on ""u.v.... ~...."
cvcn put
lin ish Olt 1 lIu, =lIy. oocc ,hc f.,.,hcB :u-c
CUl, I, 's ...... dy
b<: pu,
,,"Otk.

rrom

""""i"".

...

SOft,.

'o

r.,.,hcrtxwd

'o

Making a Fealherboard wilh Thumbs

~"I.~

" fc:u h<:rI:x.rd IMn \"ery <J,kful for llot rou " ....000"""",,,er'" ''''' "' humhcd" .. }"Ie. 1t Cltn bc ptan.ctJ un. P","y
""rrow ... tUcc.liltc. rotI,er ,abIe rc:ncc. by .pplyi"ll cbmJ15
'o thc: 1 'o 2lnchwkIc Kalons 00 OfIC Qr both !-I<lctt of
thc fi.... thc1"S. '11>,,* clamplng ...rfo= .'" "'h.ot I 0011 .hc
<humbs.
,u}"OU c::>n "'" ftvm ,"" byoul dr.twlng. ,1Ie Ihumbol . ",
1ro inrn o'.so shortcr ,h.n 'hc fc.,her"S. wtollc ,he l"'nlcul.or
, crslon .bown In ,"" dr:IwIng, "'1Ih IlS ,""i....ro cornc .... '"
baItd-saw pro,icct. }"OU c::>n C2Si1y produc<: O wurbblc
n>OtI<:l un ,he table SO"'. AnII it onc ,humb i.< au )'OUr .. ppl~
catlon cart occommodo,e , one thomb wtU bc .<k<jua'e.

"'" (.yp.)

BASI( FEATHERBOARD
CUITING U5T

"rt

Qly.

Dimensions

Material

lic\.Ibr for piccc of oU or"Uh. TII"""

"""ur..Jly springy
l!Id wort w<:ll fOnhis u.sc:. Bu, ""'pic and rn..rry ~nd ""plat
........ ' 00. "" ~ gmeral rul~. you oUjlh' !O ",ea cica. of ,1Ie
OI aod ,hc bn.lle W<>Od5.

2. Mhe. thc " nd. TIle Lo)..... ' .00"'5 ~

."..... fine. Bu, l""u'li lind. O>-C' ,irm:. ,h.. !lu' anglc

~ :llbirary. '00. [( l""" .'" m:dinl; " Job-opcdfic (~,hcr

boutI, a \""ry . Il:alluw (or \"ry "'''''p) onglc m ay a1low l""u

Using Featherboards

._,

.tD

Sct'Ing . f.,.lh<-rboanl thc first ,i"", cart bc linie fn.Jstr.t,;t\jI.

1l>c go>J is 'o t-',ion thc 'board "" 'Mt it> 1bo'hcrs
f"I>O\'C JUSt linie :l:l }"OU fcctl ,1Ie wortpkcc pa>! It.
a
linie l1cxIng. 11lerc nccds 10 bc prcs.su",. but nOI $O murn
Ih.t' )"0\1
10 ",rugsle 'o ""'''"''''''' thc ,,"oR:J>ic<'c. Wh:" 1
}"OU u:rudnly don', ",an, " .. >lIp r" for ,1Ie workpitt<:
be,wcnt Ihc fence.OO Iht- ftoathcrboard.
1bc !-lip fiI . of coursc. is cur 10
It. ,he ';ght fi,
.lut)'Ou
work (or.1 ,hlnk i, """"'" ",i,h practice.
Stand . wor1<plece aga""" ,hc I't-ncc. SJklc the f.:uhcrboartl ajlOin>t il . Moncu'"C1" It 'o set ,he r.,.,he .. squ:",,1y
aga;n", ,1Ie wur1<-)..... don', "'.'u IUSI 'hc beci o, th" tt><:
}"OU ",am ,1", ",hule fQO\ prc:s.sl~ aga;n", ,h~ work. "'"""" It
50 thc f~,h= nc:.lust. linie. Now cl.omp i. AII)'OU nccd

J"'"

ha,""

""\le ,,,

odt""".

Fea.htrboards

257

rEATHERBOARD WITH THUMBS

"

,I

L " ">t- . . ---

.'

",," ," '" "" "

(
,,

""-'

Y ' y ' " {_ "

:'

:
,,

2'14"

.-".,

"

---.J
'"

.-...

FEATHERBOARD WITH THUMBS

CUTTINC lIST

OI

Part

Qty.

Dim~nsion s
Ji"X" X JO"

OI

."
w

""00..

Ili Ih"",
OM la bold ,he 'bo;InI. ,,,,"o ' o apply lhI:
d . mp. Wfutl tlStll1lly hap(l<n5. of rotI!'s... ls Ih.l )"011 " - lhI:
'CI.,ion ,il )"Ou 11'" 'he cbml'>' tlgJn-rn:d.
Hen:.", 'wo llick.. you ""n '<r. Sco, ,hc Ic:nherb<lanl
.pln51 I hc worlt 10 ".I.hU.h II~ """Uloo. ti ft t!>c wort
r",m Ihc l. hle. aruJ mO"c 'hc f""lherboonl.boul h. lncII
elose. 'o Ih" Icncc. Thcn el.mp i, . Nuw .hc ehannel i
narrowc. Ih an Iltc wor1<pleec . eoough 10 put ,he """"
unde' p ...,n un: bLlI nOI SO m""h 10 sl.1I il. 1'.....,...
The second ,tick i. 10 !IC' ,he r""hcrboonl jusl:a bit
cocked. and .pply U,e fl~, cl>.mp. Th"n ",m",'", ,he ""on:.
pi...:" and pi,",,1 'hc: f<::llhcrboartl aroLlnd Ihal fir;! d a mp.
property ~Iigning '!>c 'ips of t!>c ka'h".-s. -'pply IIl<
5O"tl cl>.mp.
Note 1""1 )"Qu n~ 1"'0 c" mps for cad! kalhaboan!.
Wi,h 0011' a slogll; damping pOIOI . Ihc kalhc:I'bO',"d \tii!
1'1''''' .ruJ sIllfl ou, of p"'itioo. TI,o: dnoplng puin .. c:an br
v;'Htally sidc by $id<". bUl .. Ionll " )"QU h:t,c 1\-\"0. 1"" 'boan!
"'00" lO<)\'e. "" sa,.". in )"OII' eltQi,co; of damps. 100. I~
fountl Ih:ll h.11t.I "" ......... ClI1
1"""" utIcltpeetcdlJ.
NKll hc popul:t, Uil!8<'f"<IC1On quldt-<:I. mps. whleh )\)U nit
o.pply ",il h Om: h''''.,I . don', ~Iw.)'l' hold secure!)' c:ilhcr.n..
pl<>lic ~ on Ilte 1>"" co.n .IKJc 00 ,he
arul <"\'t1I
"-"Or1t o/J lheir 1>""'.1 ...., 'nil. but noi for cbn'ping knc..
o.nd r.... 'hcrb<::t:on,U 10 Ql)' I'I)Uln , .. bIcs.
wt>e", ,I>oold 1t::1lhcrb<::t:ords bc SllIIioned1

,'ib"""

S.w;nl th~ fea th ~n on th~ tabl& nw ~n,,, ...,, that

vou g~t wi,ghl kerfs ~nd luther, oI a cons;'le~1
Ihkkn~". Mov~ Ih~ f~ne~ ~ Ineh ahor ueh eul. A
push Sllek can help VO" moV! ttle feathuboa,d buk
('om Ine blade.

2S8

Ro"tor Magic

,,"'11<.

In 8""cr.d tl>q !lhoukl hc: fi...., and .1\ of '''''' bil, lhough
.he s[lI'Xilia of 'hc: upcrOlIon M''t' 10 bc- IUcn ... ,.,
:roum, ['m fIO\ romfon:al* wllh ,"" kk::I of "PMiIIt "'"
r.,.Alncmoanr5 f'"'SSOr<' din:cd)' al ' ''''' hIt. ~ "'" ..."OIk
iim o.- "'" ubklop (or boIh) b ...haI fOU """" 10
tJo. Ofi..,.. ~ o.- ' ....od;ao.pallO.1le ..... ,.,.- ,_
lup 000 .,...,..... tlle ..."OIk ~1rnoI tlle",...,., .wr",.,..Othct
,imc5 fOU .."", 'Ile k;t""'lf>ooonill dampal 10 Ille ",...,.,.
p~ "'" ..."Otk de....... ""' 0 1"'" ubk ./Uld " 'ben miU'ng
Ionll mokIlngs.)"OO 01:1)' h:l,'t' 10 klllOOn bolII labklop and
fmcc wilh fc;tlh<:rboatds.
AU Ihcoo: f""lhelf>oooru. ",</ul", CI"~ of clamp$.
,"ou >1"''''' " lut tin", "'II~,. . nd f"CRI(II1ng 1"" cUm",. 101>
1'011" ....
SOfTI<.' dmC$wllIJI . 1'f"'I'IIChn;.

'O1""

U" a p lKe of lhe worklllll Ilock to lIelp you "",1 .

Ilon the futnerbGllrd. Hold It Igalnn the fence Ind
a11~ .. t~ futhe.boa.d ~o the workpiKeju~t OIIe' IaIIIIU tip_," _hown . Steure the lutherbo.o,d wlth
IWO dlmp~_

'''3.'''

A Tandem Featherboard

"''O

" sUlgIc cbmp ...,..', tJo OII' ~nJ; ,ou nced

10
k~ 1"'" tlMitt
pivo<lnjt 0lIl of poeOl\oa. ,\t ~'t'f.
~~ blhc:rboani ofIm ...,.." do dtbt:r.)"OO n.:cd . "" 10

rrom

1"'" ..-ori< in ~"".

1""""'"

n...,
k;t~ ..'..., d>.nlj"l!l and clamping
I'm<" lf~~, oImpk and .x..iOI.S lhol you'U k\ck)\>Ulli<'1f fo,
ncva h;..;,,~ Ihollghl of '1. (''cu, ~I 1ca.'<I I dkI ,,-hen I 5:1'"
""'-' (." III<.' II .... Ilmc.) lb nul<e onc. fOU simply ~. a
dc~1 10 1"" (nl hcrbo<mb.. IInkinc thc:m 10fIl"Iher (.<tt Ille
dn ... ~ Tumkm mlberl1ourdl).
One c_p ~oplio:d 10 ndo "boud In ' ''''' llOfJdcm ...ilI
ouII\t:"r Se:! a W>Ilor:m OI> "'" l2bkoup . ...1th .,..., bl~
OII exh oIdc of tIM: bit.

Vacuum Featherboards

th'""

fo ..... fealher_'" selup I~ oflt ..

_imi wlM!n routing mokllng~ tO tnSurt tI.al tll e
_ l doesn\ bow or drrfl IW'Y "olll the cultt . Thl~
""V foalUrt. a "thulIlbed" fealherbo;o,d clalllped 10
tM lee. and a couole of ba~k: lelthtrbGllrds
cUmped ' o Ilie lableloo.
A

Of"

\:.cuum 5ImpUIieI 5ClU~ dr;un;oli.:ally. ""' dorn n.:cd ;IR}'

n.n:h"nr.......r clamps .. au. Hold IIM: (calll<.'lf>ooonJ In ~'ioo
IImt/y ""h 0f\C h.",J.~nd lum I v.oI"" wilh 1"" OI"'" '['h<,
>'aCUunl .... llI ln'''mly sud: 1"" ft-.Ilh<:rl>r .. ni It> 1"'-' ubletup
OI" (enec.
ti ....... caoy '" wtl
~
~'ou do Il'd ' ';roCUum-doml'lnll C<jUlpmcnL lIcvkw Ihc:
ch:IJMn "\:.cu"", 0ampin3" OI> P"iI" 50 lOr "'" ckulb OI>
.....-uum pumpo. "nifl&'i .nd "'-s. '"X\Itlm . .' a"" OIhet
ouppIirs. You ...,..', t:dc Ihc: vxu........:bm~
n
_
'o 5CI btl>crbo<lRlo: tu. iI)'OU,,", .... IIM: ~uipmcn', I I
III
OI" JOU'", pQnnlll8 OI> 1n'"eItlIIJI1n ''Xuum ...,IUP in 1"'-'
'b~ ~ OIle oflIM: I pplieuions.
You Cln orobltbl)' con""" Ihe fe .. herbnoroJ, )'O"
.lrc:><Iy
lung .. II><: Slock used .. lIOI,poroo..."" 'Ile
bOOio .", bf8l" cnough 10 JM"O"kIc: 1"" mlnlmutrl-Slud
,';roCUuru <."h:tmbcr (II) ~U1J'r in<:hc:lI).AU you Iu,'(" 10 do is
d rill a "",-",um pori, >ni "'" f..lhnboanl, and Ino:lall 11,_
ling. lben apply "'" """"um upcli fOU "'211' 10 JPft fnrm """,,<:1\. hctt:', IMI "buK"
"""",", modIIIrd 10 'M)f\< "ilh ,-xuom.

:c

ii
;)

"'UIIjIIO

fui.....,.

h:t,.., ....

Atarodt m feathe. _... CU" down on lhe lI"""ber

dcWnol ~ulred. It
uo ... IUp. 100. bec.u ... II

.peed.

. . ~atherbo.ofd Il "",ilioned prope,ly. IIM! ncond

NwlU be.

1. ..... y OUl arod cu, ltoc. fcalhrrbn:o ...... u...,. SlOUI.

h>.nlwood ~kc nupk .... cbn"ry (E:u1K:-r 1 ..,.,.
omnrmdai ""k ."" ...-Il for (..I"",rbo;uili.. bm I""y .n::
"""pomul

F U lh U b o ~ .di

259

...-

TAHO"'" FEATHERIOAROS

I----------- Il"" -------======I~

nccdctI. If 00, opt 10 ....., bn>5 .... rryIon barbcd lIaJ,o, c-.

"'*'

TANDEM FEATHERIOARDS

r>tot,(You <:an "'"' slip oile ncuum

(7)'CI' tho: '-ti;,,"
otl>cr ('I)IlIItCIOI' iri ntt'<kd.)
I _ ~1'Md br Ihc Ida of ""vine lhc 8ttin JurIiII
"'p OUl citIM: iI:athctbooInI,JO in thc bJouI '*-..... 101...lbo: ute: of '"" dbow n!lln&.
To Imtall thtndIOd litlln& IrIto ....,.ud _
r.m..

Cultln, Ust
Q!y.
""
'utlltrbo;",ds 2

OUt

.!,. ........

(!.

)II'

x 4!t"

Milterlal

>< 10'

"'x3'xll'

H...dwood

"-nl.are

OI

II
J:I

........

Dimenslons

probk ....1k .nlh va.:uum Ilu:o...., 01.- J'OfO'Irr.) s.-k<1

3 boomllhat ~ frtt 01 ddccu. Mit .... oroor rnd 01 thc bo:wd al
abouI JO ~ l,;oy OUl Ilie Iwc 011"" CUlS thal furm tiM:

..
:

You can CUI tM klol",,"

""'"

Qn

Ilie I.Ib1c

"'w OI" an

nboan1 jIbl ilie ooteh KfOIIO lloc r,u;IIII', fini; "

Ihtt:ads.It W\II act Iikc a 5cU".gppIn& ~. cuning ils o....
Ihrtad$ in "'" WQOd. If )'OU drilk<l .1><: COI1"tCI .att piIol. J'lO
.>houId get a >lIfIIdmt1y .Jah .or:d. If)'OU do mii up ",cb
>;\cuUnl Iak. bIIck 'M nnu.. ou. ond ljlfI/y I bcId of !ti
conr: null< '0 .Ix: t.lun.,b bc:1i:>tlo m l rhing .bc: nllln8-

llK

2. Drill thc vacuum pon anei !leal thc boanL

Oncc 0.11 thr ..... Ih~ .. mI''' bn CUI. dri Ihc
pon.
TIle hok: Is ~ pilOi fOr J'O"r vacuum nu'n!/.. J<l ~>'" .he hok:

apPropN' dy.Th( b)'U\ll loho>v$' lhrough pon, bUl)'OU can,

a'J!pon If)'\>ll pn:r.....
Apply. couple o{ COOl!.> C>f. IIlm Ilnl'" 10 thc boanJ',
hody ' 0 1i<2I1. :IJIOOiIUt POro6i1y. Sc:aJ ,"" ~ '" tM .-acuum
pon ,.. w.:11.

. . . . . o(

\';!CU,,"'

roti....,. "'"

3.

' lt!Ilall tho:: vacuum nn!ng(.).

~ opIioM

,.", .v:a.ibblc ""..,. An cur ~ Is 10 tnl mak 'IuIdr..

discoonecl 1n10 thc pori .. lth IJlk:onc aulk.. If )'OU chiM
)'OUlI I)C: I.$\J mullil>oaroJ KlUp". )'OU
"11>' ' 0 cut
' - n on tM numbo:r 01 k .... quid<~ fjninp

mar ..

A ~um ' .,..111.,........... .. d .....n l _ I~ ''''' 0. ...

wilh whidl II can be lopplled 10 ,11., 11obietOP OI' ft1l(~
HoId it In p/;Itt w"l1 _ hl.nd and puII Ilie VaCuum

witll lM OIIIe .

VACUUM fEATtlEIUOARD LAYOUT

1"'"

4. App l)'
vacuum !.:Ip". Mll: Ihc vacuum
dtambn"
as b'llC os )'OU O/I. lltmnnbtr '''''1 IM l>fMcr
II", """"'''u''' ebamhc . ...n . ,hc pc>trr ,h<" damp/rt btcr
)"ULl .... III il.,.., , w.cd a <"OntnlJOW; ban<l ,,.. "'pc .n>Llf>li tM

"*

k~lh"rIJo;onJ.

Turn Into vIC""m

pan in futh~rbo;a rd .

A VQCIoI,.,m Tandem Featherboard

'-

Thc W>dcm " a <k:vic<: for gangi"ll tW1' fc:tl lt~I<);I.I\IS on

dampiJlSl pblf . T1tI.t ""2)". )'OU an ,;ct Inf<"cd .. td oLltfccd
re. 1 ~ >oImulW>CoU>ly. , ...:... 1.... 10 ...., -"',mlIaRl
~ but rit l/W:m (In :o k~ or :aIoot!. IM fronl oi
IIM: \"2fioUf ''''"C' r.abIr:.i ma<k for lhi> boot.lbb com"....

8OTTOM V1EW

"'"- -1-

--

1 . CUI Ih"

r...IMrb(rl.Rb

r""t....,rboard~

""""um

:ond

pl:U"". Thc

(n,hcrtxwU> drMYibnl
ln"""dblcly aOO,"1.'. FoDow 51q>f I and 1 on l"'l9"" 2W-l6o
1'" thc

' CI makc "'... fC".. hC"rb<rl.nJo fu< n<"h ,~ndctn

1l1c bas<: plr...r mr ptulOIJ'PCS III pltC.'noIle. " 'hid! ... a
strong, nonpo",,,. m.,~rial Ih .... Ideal ro . ""cu~m
c bmpins pQICI.ThC IOp pl .... 1,. Mrlp n' ptywuod. I .......
l"'llle lIirch for thlI. bUl YOU don', 1.. ,.., to. CU ~ pans
ta III<.' <Il""""""'" spcd/led by tbc: eun~ Ulii
2. Cut half.bpl In tht ft.>t""'tboUtb and top
pbl"- To ""n' IM rour coml"J'<W'C'IIIo: (1"'" pbt"" an<! ."'"
blhnboo.rds). 1 opIed lo cut balf-bl'" In Ih<: mll>nbouds
anii Ih<" 10f> plale.. T1to: bal<: fiL< inlO Ih<" bps In IM feJlhcrboo:ltUJ. " '1liIc IM ~ ...., k>d<cd irlto IIM: bPl' In
ItIt 1"1' pble.. n", .......-mbIy .. Rlucd l"II"ihn ...utt cpoxy.
AIII!le lap culS ,....t!le $O...., depch . To Ql;lblbh l!le cor-

""

rect wi<lths and Ihc: ronttI po6IlionJ, il Is bc$t 10

,_-1

br , _

,.bIt.

oul u>ing ItIt ",.ort~ Do II", laI'" on ""' ....... rr

u>ol"lllh" Mllrr SIcd (pag<" 249) 10 guklc IM ",,",pio.
Do thc ti::athcrl>o:>rds fl~ . UIiC Ilie bas<: 10 oct .1Ie deptl!
01" cut. llK:n "'" il 10 by 001 Ilie bp. CUI .hcm.
OI.> u.. tap plale !>al. Chcdt Ihe IIq>th u r cui apln ..
IM bppcd bthcrl>oanls. and adi_ Ih .. !>it c:ncrtSion it
ne..""""...,. I..ay ..... thc bl'" on ti", pL;ilf L1tIdt. Ihe fc:..ho:.- . .
boud:I, lhcn cut lhem.

ii

0riU tbc vacuum pon. " ni lhinII obouI. ~

noiI<" (an<! olhcr pb>da)"!hal you an lICI.UlIIy CUI dunds
In ~ w;lh a tap. n", plan hen: " 10 han: anii Ihrad a hoIc
(thc .:acuum poti) in tIM:...., "'" a nipplc ","1 ClIII.'nIb .. p
.hrotJWt 'hc 'ap pble.Tu ""c o..unO.... I" IIM: nipplc. ,hc: tap
pble nttdJ. etor.on holc Ih:ot . f.....:llon:ol1y I:qw:r tlu.n
Ihe outsklc di.omctc. oi Ihc nlppk.
Loy UUL and liriII tlle: .-a..... un. po.>rt in ilie I>ax. TllC.'n,

.,.~

.-

3.

VACUUM FEATHERBOARD
CURlng Ust
'ill1

Qly. Dimensions
". X 416" >< 10'

Hardware
lIKuum

~oe,

It x

11111 90' tlbow.

IIU5 b""btd

~'.

appmx. 2-4'

Mille rl,,'

(O)nM<;tor,

mal~

"--1

Ll>lng ,h<" 'PP""""'I" "'p-,ile " "'" Ihar. W>I Ihc oame Ihmtd as)"OUl" Ittillll-cut Ihrnds. Wi,iI phcnolle. you dun 'l
~ tap Iub<:. ~ )"OU \III ""Ih orhcr pI1""la. (Sa II'"
..,.,.,Ion -CUllinA TIttnd:o' 1n l!le :oppcndlll.)
8uK Ihc etor.ona: hoIc Mue ~ il aIlgn5 wilh thc

vacu .... port.

~~m.il~

hos~

II

4. ASsc:mbk ' hc: Il"*",- l:pOxy _ " aii towcthcr.

MllI batch oi "'" 8!1IC. applr il. and a!I5CInbIc tIM: pans.

Fu,iltrboolrds

261

VACUUM TANOEM FEATttERIOAROS PLAN

TOPVIEW

SECTlONVlEW

90" elbow
~
(rem~le/ lemale)
~

Ba,N<! hOle
( connetto,
\

I~~~~~~~~~~~~~~~~~~~"~J ~'~'~"~~"~"~'~,~~~~~"'"~~~
Phenolic bue ply

Vacuum !;IIM'

FealhubN,d

O;

~!

l "'"

Vacuum pof1

BOTTOM VIEW

'-OI"

.CI

.!

VACUUM TANDEM FEATHERBOARDS

Cutting Ust

:s

part

Qty, Dimenslons

.!llhe'boaldS

Base ply

~-PPIY

Material

J/,' x 4)6" X 10" Nonporous hardwood

Ji" >< 2" x 14"

J/,"

x 2W X

24"

Plywood

Hardware
Vacuum upe, li' x \0\", appmx . 54"
Sr.US nipple, male/male. I W 10tIg
R'ns 90 elbow, female/female
81;1.55 ba,N<! hO'lt connectOf, male
'AuylIc, pdycarbonalO, aM plHl..o/lC are aii ,~I,,,I1I<.

The tllndem vaC\lum futherhoard Is desioned 10

fot tlle ",,'mw space between the table\ edg. and ih.
mute, bit. Posit;on it so the bit is belwten Ih. leathe,

boards. as shown.
262

Roule, MagH:

sh"""

5. Inslall the , ....,uurn f1l1lng.~. Thm It... connCClur

jrU<I "'" db<>w ""d lit<hten Il. Turn the elbow onlO Ilie
nippl" . nd ~lI"lo tl'\lu"" Ihe 1>""$ "'1j!I.1hcr. ~il\ldly, lurn Ihe
nlppk imo the ''''CUurn port.

I Plumb 1"" four fctlltctbo.:tn,b. as

in II><: d",wing
CIosc oJl Ihrtt plnch damps 'ighL
2 " "'1 Ilie t:l.llktop iokal d.mp fir:ot. 11 h.1s no pmdt

6. Apply Ilie' vacuum tapc. ~Iol;e Ihe ... " "um

cII;un""r "S{ " blJlC;LS you an, bu' confine It '" Ihe b;tseo
pir (don', i"""rpor~,c ""y of ,1Ie fe,,"h..'11>o;on.l I>0Il11..,.). I
lISttI a eonlmuous hand of 'apc o",,,od 1hC' pir. keping i'
. HIo5c 'o Ihc plj"s edgcs;LS pOSSIblc.

o". fct:d fc:tI'",I'ho:JRl nClt1, Slidc il inlo

pooi,lon , ,hen opcn "'" pmch cbmp.11>c (al""rbo:oRl
.... iU bc .ncked 10 Iitc tobklop.
4. Sc1 'he ' ..m fcnce fL'It<l1L-m.rus In <I1e ""n", m""ner.
Onc "f or>t:. CSl.~"I;'h Ih" pt>:Sitlon . Ihen sud il 101h",
f~""" by opcnin,t!. Ilie plnch c bmp.

ebo,p. youll note. kl Ihe """illoo. Ihen lurn 00 II><:

'",,,uum .
j Sc:, 'he

Using a Vacuum Featherboard

"""""1'

Rqx,..;.ioninll a fnlhnbo"nJ i:<..,.sint,*, ... do.!ng Ilie

pindl d:uup 10 fn.'C' the d<-.i<'C'.TIK'1l}'OU C:lI1 o,.,." il 10. It,:",
>JIOI ~00.>O:t il by Q(lCfling th.; l"nch cUr"p (Rcp<>:SiIi<>rIin!!
""" tollkt<lp lokaI r..."",rbo:ud, <1f C<lUI'>C. ,,'OU1d n:q~
"'Iea.l:ing ali four r...1herboanJ5. "nWss )'OU pul , pinch cbmp
OII ks h"..,. 1OoJ,)
Using tIte .....'UwtI 1:md,:", fc::ul>t:rI>o>rd >implific> tl..,
plun,bing >Ub>untioJl)'. sioa }'Oll only nee<! 1..-., lincs. Sc1 "''''
tondml OII d", roulCr WlIc. p<J6ilioo1in.B it ,.;. thc bit i het""",n
Ilie r...'h<-rt><:>atds.n...... "'-" t:l.ndem on thc ClII "-"""'. :.gaIn

Fcw >C1"1'" 10 wood ...o"tinj! ar<: c"-SieT 1""" pl:tn.ing a

vacuum fc.tlherh<>.1rd.as I s;<id. \ '0" pOsi'k>I! ttH,,;c ' '''-'''''''1 In
lht: sarnc p""-'cI, )'OU J"'" doI1', h~.,,, 10 Jnlpplc wilh
"",cII:tnlc:ll ,,1:1011'" Ulii ;0 rotile. ,,"OOdwor1;ing. )"'" usu:&1IJ'
.... rv.", ro fum {c;Jlhcrl>oards ' l a 'imc, liQ ....1t:It } '0 Il ar<:
ml/y duing is tr.w"lllht: n>cch;tnlca.l ""''''ps for ,,,,,,,,,, , 00
1'11'...,. or pinch eLim"".
Seniog foUl' '-.cu"m {c;Jlherbu>rus n:quin: 'hn::c ti,
tjqgS . nd thrtt pinch elomI". as w<:ll .., 1"" vacuun, 1'''011'.
Consul, thc dr:Iwi"ll Plumb/nil a "'ullll>oord Se/up, The
~11n8 .cqurncc 15 as foUows;

poitiorllnjj 1, ,., thc bit

bdwttll "'" fc:tlhcJbo:udo.

I'lUMIUNG A AIIUlTIBOARO SETUP

Vacuum

hos~

Plastic T-nnlng

Plnch clamp _ _ _,

'"

Vatuum val""

-.;.
O

....III

To sel fitsl '~ ,d,

poli a vacuum bV
lurning on Ihe vaCuum ".Ive.
To stl lhe olher 3 'boards. puII "aCuum
10 Ihem bV open ing

Ih~

individual pinch ciamp!.

ftalherbo.tds

263

Surfacing Baseplate
Fit.l .outt. with a long , wldt Nstplalt , and II btc:omu I
hollowing muhint. tvtn a drde Clllte"

"."'
"

""
-.urfkm:s ~pbl<:. b ~,,'hl"g "r
mi"",,,,c,. n,;. "USI"'" ~ph..: \s ",.Jly "lUl,l
purI"'"". ,",'enlud f!ll''''''
Yn, .1><: prinury "'" Is lOr >urf:Jdn3 ..oo:k U", 1......
CIi 0100 U!C5 OS ",eU,MI)' jub in ....hlch Ihc
""!:il M _
~ p"ndnI .bo\'c ,..., work- hoIlowin!! .. brmd m:css, b
omIpIo-Is.",., for "'hIch 1"15 bosq)b'e \s .sul.cd, Y()U an
II hb;:I( 11 up .nd cbmp k 10 "",",""nct., .nd 1, be<:orn<:s
klnd of o';cm~'3d n ...I1 ....
IJeawe Ihc:
lut so
:::1 m",," .. .. rl'.ce .m '0 cithtr ..., 01 "'" l'QU.c,.II', aba kind
' " 01 off..... Iwlepb.e K<:poo./tIon Ihc """"" "ff<enl ..... :and I
miI)' bomcs .n offia hascpbl<!. If you o", wllU<I,IIIO driU
le .... a .... Jrok>; 'n 1' , 1. an br:. lrommd
(}uite otmpl)'. hcrc '~ ....... IM ... rf<l<:lng I>.1.",V"'<: Is: ..
",ido:. fl:t. V.., r" .... line<! ,.ilh .wtJ """.lIe !lril'" lI:nina
"""'" usW .. plywuod
llU l"ilo.1 e"","" 10 mUe 1""
""" .ho"'" """" dcu """!iiC. &po:ciall)' wllh thc: .. iffi: .........
i. i5 $U1'.bIy rigid, )'<:1 you an Stt ",~, II and """';Ior

"",.e,

"ti

't

"'''''p'''''

Ils,,,,,,

fir..=

Jvur ,,'<>fI<.

Sinec 1 flUolk il, 1"' U>cd il fur onl)" ft:w pru;au.. .....
In ",,~h caOi<: 1 ,,'"" mi3InY p l l had.1Ie
on hand
..... . "oupk 01 ''''-~.
cioc woukl do. (loc
cnmplc' 1 r>dtd ' " fl:tlt,... ..
pbnk 1"'1 ......' ....
wkIc fur my joinl.... II _
IIM: klnd of
Ihc plai" ......

_"irtjj
,,-.rpc<I

26.

""""1'''"''

,,,II

!ICI"" .....

desipc<l1Or."ori<nllike . " ....... . :and "'"

oinIpk
:and 1!Qo:.,"",n ,...,'" .... ,,'" ,"" ........ It J.IIOI bea""' , .."d!. M.....
, ... , ......ultl work. In."nd of C<JIlNiIlll up I
,,, ",.11 .. 17 10 l~ndI ... 11'0;, for
QlIJI,pIo . I JUSl drlllctl pl''OI hoIc In ,..., la. oomcr of mi>
b..lept.." :and usW II ~ ,...,
....., I _
, ..mmd

~II)'

,nmmd.
Maklng Ihe Baseplale
'"'" r..:...pb .., tloc,.,'. lat~ Iong 1<> ","". 1 opcn' ~boull""

houn 00 il. Thc l.ifJcllCl"S ,,~ flUolk Iiom cberry riPJlll1l>

"",",cd (rom mi' I~().{()O> "".." eolkction. n..
Xl'}ik: moJlhc

""*"',

.......

".n,J Id,,~ ~

1. Cui t1~ ""ru

lut ....1)'

'h"'''

<:Sptci:dl)'

ro. <hol

"''''''''tt

10 sUr. Thc wrf>dnll

part. 10 makc_, .... pLotc 1""'1(. Vllllo _

1 nwk "'y surfaclng hbq>bl~ Il10'''11 lt.i""h drar

xl)'lk:. Thc plOIC nd noi bc act'}1ic. 1\ nccd noi hc: drar.
U.., phcnolk. U.., \Wnch OI' ~ OI' ~ALl'I pl)-..ootI,
mruiun>dcn.";,y fihc:rtloanl P!DF). p:tnk:lcbo:lnJ. or banJ.
.....nJ .Thc .liffcncB wilI ancd 1"" 'cndcncr
o.hinDa

of.""

m;I.criol5 '0 $<tll_

SURFACIHG IASEPLATE LAYOUTS

EDGEVlEW

8OnOM VIEW

".

,
o

...

I V/" -

r
o

l'

..

o
Allemlliw fOUle, poslllonlumed so .... nd~s
j)lIrlllel Ilie blStpllll widlh

_It,

Cutting L1 st

".
",,'

Q t y, Dl m enslo ns

Sliffe~'s

It'

,y,' K

Millerl ill

24'

"," xl ' x21'

CIU' Krylil;
H"dwooel

Hilrdware

f.Tti,

2 t1~,ed pll.SUC kllObi . ,,' 1111. wltl> "' 16

tII~i<Ied In\.ln;
',om Reici TooI Supply Co.
(IOOo2SHM21)
2 fUtl\ud Slo-t boI\s. "'16 XI"
I

~Iheld

wood SCrtws. '6)( l'

Thc ~iIkrw: .... .,... M :any 01 ...".,

r~.

1 - - - - ... _"":::':'--1

Ihc otJfl"cn-mountlntl ocrn... "'" ' ilicit In dbmt:ter 'l'boo ..._../

1..." hoIa for l!le knob. boIt5 ""'. inctt In diarr'M:ler Ort
IlIe driU pn:ss. driU thQ<: hok:t.
You an ..... SWldlrd ~ Iw\I or bndopoIn.
<lriU NI.<; tor Ihl5. U.., 5Iow. cY<:n fccd ra.c. bKkIn& OUl 01
Ilie hol<: f""lucnlly cu "'<IUCt hc-~I b"lklup TU I'rucnl
dlll'plng as lhe bil b ..... ks IhrOl'l!.h IIK 1'13.>I1<:, 000w IIK
rd r.ue c-'Cn more as)'OU ~h oouom.M<I....,. good ' "
I>Iekul' board,
1:
N<:>:<, cinICI< a counln'Wlk In 1"'" drIU Pf'nI (1 meloJ. :::I.!I,
~ ~Ulc: OOW\lenlnk produca Ih" """' resul"
In pb!cie. b)' IIM: w:.y). Coumcnlnk ;tiI .hc hoIa. For Ihe
_
romi>ttn. rrsuI ... ...., Ihc <lrIU ptna. <kpth oIop. 1.kle
one 5CltlntI ro.. "'" bolt hoIcs "";ti.......,,,. !iefll"ll for thc

ii

~. nwnial,

but I uoni

YOU"'"

anc.,
..,lee",<1 }"OU, mau,rial .. cu. dw pana 10
lIoe "'" 5pificd by .hc C""II\(I UsI.

2. Drlll thc b:wcpbtc: holar. A. Ihb poim. by OUl

-' <lriU .hc hale> tOr.1Ie: "llfellC1-~IOU~dn" scn:ws anii thc
Dd:Hnountlnjt bol... In .he """1 .,ep}"OUl! <lc>1 wlth "'"
.....-mounUns SC'R:W. an<l IIM: Ilii """nl"3.
(In Ille m .. klnH papt, "rolttllflSl, Ilie: aerylic.1a)" O<l'
lIoeioc;td<,.,s and &1,, of .hc Kftw holc,Th<: dgbl """'" for

3. Locatc: and drilI rhe rou ....... moumlng KrC'IV

hotes. 'l'boo U5UII ~".O'cI, 1110 lOItxto lhe baxpbte CU thc
.."(N'tpit...,... carptt . . . , , - ro drtII thc ......... ~
"""" paI<Ird br thc "'-Pbt"- _
tlpoI """ llIenwnu
an he found in"Thc: Gmnk ~e' on "...63.
.._~
Sckct thc drIU bir you MII usc ~ }'OU "ici< down
"'" ~ AlIxh Ibt ~ ' 0 drc: Iop ... <fa 01 thc
filIl~ . bc!~ lloc oIlfkncB. ""...., .hc ","le II backed
"1' ",""1 "'hen you <Iri. thc boIr:a. Aner "'" """" _ drillcd,

""';.eh ro a roun.er:olnk . ...m Ilie pU'e

<M'1'.

and """"tel'

.un: thc boia. (1 .oc1 "p mr t.a..eplzrr fiShl otr thc 1>11 "'ith
Su ,faclng &&sepli lt

265

Accommodating
Template Guides
A ""de SPlt<It\lm of lempl.1te work un be dot>e
_h .. stod< ..... tu, JII"" '1 , ....... from Ihe file'
tory. An<! IMn OM tb.y. you nHd some om.IIO( The
templ.1te req\l"~ fo< a p.tr1" .. lar ~t Iu.. an
~nt"!l

tlult" ~(;K'O" IIu.n YOU' ..... Ie ....

ba ... pI.1le. So "'Mn 11\ OVe. IM middlt of IM tem
pI.1te, tIM! .000ltf won) ~ any f\.pPO<l
Vou t~ke do",n yOII' ,u,'.nnll bas.pl.le.
.nd yo .. ....udy tO """,nt IlIt .....It. IP II, when
you .ullu ... lt" nOI ,onfill ..... d 10 accept a lem
pl~le gu,de.
QtI, b .. t l' un bt! TIle model shown ,n 1"" pIIoIO
Iw..o. bit ~nlng fo< I'orle,.o(.bl,!"IVl!t templatt
gu,,:lH. Thi. mU!l5 II lui I \IIlncll"<ll.mve. hale .
... r..... nded I>ya 1I. 'ncll""de X ",,Imhdeep
r;>bbel. It 0.110 mean. Ilie ~"11Ig mllst be u.efullv
pO.,tlOr1fl1 .0 Ihlt It 1. concenlllc ","11 tIM! b'llMlS.
If yo.. ",.n' to ~etp YOU' opllOn, OPen, m.ke
yOII' .urful"" ba.eptatt ""tII. prOlN'r bll 01N'"'"1I.
Read Ilie del led d,recllon. for do,nll tII, . ",hICII
lre foun" In Ilie clu.pter "Un'ver ...1 Ro .."r MOUntl""
Plate" on ~e 163. ChooSt VO'" apP'QiKh .nd
IPply It 10 1"" f'b"Glllon of IIIIS bUtpl'''.
Someda~. vou'lI be III.d ~ou dld

CO/"1KrN :wd 1OIIllh, lIut tM fixt"l'l' ..-\11 looIt 101 betI ...
Of J"'>IIln."cOI an ""... lro m;nu'.,,; ' o bulf Iu a~
SUn al. "'" '-"""""'" Round 'M bir <'<:If'1>mI ..... a
I'OOla ond a f1wIHrimmu. OI" $tr.ol4!hl pali,,", bit. podrd

br

cOl ,...HOUnding !nnpIol<". ( $

1Iori,. TmlpbIe ..

I"'F 6.) Round 'he rornctli al. I inctt tadlus.

N..... ........ "" ,..., tdp.1kpI ..ilh abinrt ~

Ntn 01
lIC1"}"tIc In """"'"c" the _
....Iti Alta "'" ..-o.taI oi ,..., _
~
Iora

'M

~ "''CI"

1""

II.....

""""'."", ~ 'M.-djtn.
flamr.pnIiohln il a IcdlnIquc lha! IlIk", 8""'l ""'ta", 01 ,"" hc:Il ........ ' lrity ,o( aerylk pWilc ......... I
J'ft>Il'U'C 'ordI. and paS!I'hc: twnc ......,. "''CI" "'" cdt!a of
"'" pblt Thc JO.II It ,,, ~ "'" n1F1 and 1 lhiRlt}'Olll
find li tolt.,. qullt. fcw ,'ery __ ~ ...lII ..... "nI, 10
_1' ,toc ...rt'a cnoo'Sh !hol 1'" mln",,, xr:uct\cs bImd
1011 ...., "'" '<'C:1lnk/II<' down, tho:ouIb. )'l1li
...iU find IM c.lfor:!I tolt" I righl nk<" poIM.

."""""'" _n

S' h 1.!iwl ll~ .ltlft......,..... ~Il! ..... "'" <'Od!I 01 "'" !iii!""'" 211 hown In Ihc byout!I. You C2fI 1tJII!Id..o<n ....
...ptMCd t<lsCS on III<' I'OOla 13bk. It 1011 li"" r """" I
k-k>dt r>djus bjj, S:>oo Ihc $(itk",", and. It fOII aR" Jo
~1itICd , Ippty I 0;"0.>' Of , ...., oI lInUh.
W,,",n Ilie fin"'" il dry, 11Iad! III<' .clff~"" .. 10 It.. ~
.... llh .06 x 1lnch f\.:o,hcootJ ,,'00<1 5c~ CLtmp 1"," aii'
c-nc:n In pll , anll driU pilot hoIes. guitkd by 'hc hoIt ilo
the: pb'~ .l"hm drI.", lh~ ,,.,,., . ~bk~ ou .... ""'r
""10... ,1Ie pl;u~" .. uf.w:t

11'<' ' ' ' ' '

6 . "",,,m blo. Ih" '-pb,"" AU .hi, .... nuin:l1O Ix

.Jo.nr .. 1" '1btlI1i ti ... knoho (OI" h.ntIIo). 1 u:<d 4\2.1ndt-1a1

p".Hrl'"<" h.nIllC"I. 11>o1lllh. 01 COlIne, m:on)" OIh<:r OP"
a .... av.o.ibblc. T" m"un' ,h~ hindl"". 1 'umed f\.:othc-ad .II"'~
bol .. ,hrollgh .IIC pla,,, In,,, ti", bf2Sli tItre--~<kd lruc:ru In!<-

V.IN Inlo

th~01.

"'"l . h .he hal"'l.,. l",,,,!led an" '1 ... roll'", mt>",,'td OII
,1Ie pla,,, . )'Otl ..... "'ad}' ,,, '""toll a bll . nd ,.~" lh" pIltt

fo r

li""

Using the Surfacing Baseplate

"'''0 poNt"...u; ~ ... ,"" "",ta. Onc- Is ,"" <"m' r.olloa.ion. ond
hen: I ImN lip Ihc nMa 1undI'" "';,h "'" buq>Lt'" gri""

n.., oo.hrr 1oa,1on bo offi<:t.and OI Ihl> IoatJon. 1 lumed "'"

I'OOla \10 ~.)
"'al, ..1>Idt ,"" lOII'a 10 ,"" pb,~ Vou C2fI t;"i. hrr
. ._~ pI~ I bI' opcnlnjl ..ilh 'he I0Il .". ~If OI" ...., IV
lI1OO'irttI bO' d"octN In W roII01 iti mI'" 'M bll opcnnll

ccnlerpoinl I')'OU Wt "'" Iolla .pptWCh. unlDOUlll ,""

lOIIIa bdtIn' driUirlll W bit Of>C'ninf!: ..... 'hc drill pn:s>.

4, PoI~1I tII" plate ', ro8"*" nu. is I pun:Jr aQo

""P: fOII an le,,,,,, 'he <"<lfI:<:t 01 W ....'" $harp-

,II01K

266

RoUlt. MagIC

To pLtn" s,ock wllh a ",u'er. wlla. ro" need, In adtlilio!110

.tIc ... rhdng hucpb'c. "' . SlUttly ruuto:r. W"gtNliamctn
1>otlom-clnnlng OI" dish--culUng bit, ilOd 'rxks llul lIiI
"""ltlnn ItIc "",Ier and b"-"'plOl e 31>0.", Ilie SOOll
Illttwing 'hc onodIinco ., "",,c Jido; 'o
and bad: W
IOnh in I k\..,1 .......,. In I nu"IIeU . Ilie procN"'" il 10
d amp Ilie boord 10 bc ploDed bcro.=n "'''O Iroe"'. Se! tIot
f\)Ula Ott ,lIe 'r:>C1<s.
. 11<" hI' set 'O ...:tnn .., "'It.. '""" o f .. <>eI<. SlKIc . hc lOII ...... and basc ....te up"""
doIO'n "'" ,r.odo!.. mclhodicolly pLtning
iDdI
oIlh" board.

si""

0';'"

e.",.,. "'1"''''

n..,

surf:Kc soocl: In "'":1)">' ,hi ........... Of

1, an ..."",...1" a =nI. 11 C2f1 1~pcr VOIt.,.
...., IM surt.ocing baxpbl" for botll oI lhc>c .............
le! $ k>n/o
"'Igh,funo... td

joIn'''''

t(OUI."" <2i1

C2I\IIO[ ,

.'Dt,

.. ~" by

""p

a, ...

sunad""

"*

rl.ANlNG lUMIlER

Bench dog

Lumi)e.

VI" wlth PO~'u~ dog

8onom-dnnlng bit

1, Thkc slock o f lhe mlll...uJ 10 bc surfac:ed.

Gm<nlly s(ldkil1ll., Ilie mut .... ti oot Ilie proper 1001 for
pbnins lumhc., y"" <:2/1 '1 !>nI Il><o <t:iIdilion2l join......
jlbnrt_ubk ""OI' "fl><:mbk .0 drr:.o ~... boanJs,
mklnM. II", !:oc"" .. ,K>OCh. fbl. arni ponIId. Ihc aiItc>
lalOOIh,>qum: ,arnI p.>.raIkl. Kul ~ry <>fOC<' n o ..1'I;Jc; }'OUlI
0ltIfn>n. a specl..1 f"'OiC'Ct where .......".~ns b
:\' a)'bc 1111 bc tI1~'1'1<tl a ..... nd a ~..."'. nupk
boud_ beautlrul but dlfflcuh 10.surfoc:c ..itt>ou. 1CllM>U1.
l'ntIaps II'. . ....upcd plank. If k '~ ...'Otp<'<l ~ , It C'af\ bc
tbt dtvtI '0 joinl fW 10 }'OU an b'd M Ihr<.>ugh Ihc plan,.,..
So 1"" fin< """"' b 10 "'ud)' tIOC' malC'Nl md oonfinn
dIIIl k Is. indccd. .., appropriolc ~ pn:Ijt,
'Ibm l'I3ute OUl how 10 ...'Ork 1 It..... aii m.... lhe .fXb
tirI How ...UI you ~ lhc Mod!: an<! lhc I~

Imulbtion).Try 10 oei 1"" boutl ""}'OU can get a 11:1, ou ...

btt ";Ih min.m:oI Slod< 1'Cffi(>\..1. Whrn Ilte Itoonl Is ';"1 ,
pwu Ihc u..cU OI> odI!fi<k of IIt( boanl ,TlIl5 con hc Ilte
probIcm.1k pari of llIc joii.

""""pru'''.

2. Cui U'aek!t 10 ,uppon Uoe , urfaduR basepbIc. Tbc n:1J k(V 10 !!Culn. fbl >toc1l: ...irh ~ facQ
1ritIt "'" .lUtf>cins """'pbo( II oeeul'X')' In Ibc lnod . fach
Ddt ....... bc "r.lIshl ,,-~h panoild ~, and Ihc._ must
loc of kk1UicoI ~I. Tho: .r><:b m",. Il" about ' 0 6
lida 100>8<' .han.he ..."Ori<,*," "" thc hk C'af\ """.., off
,.,. . . of thc ..."Ori< ",ithout thc ... r&cIn~ bl!ql10 1 ~ lurn011" Ihc t.n<:l<.l.

w.c

3. Secu,.., lhe " 'orkplc aud

.hc .rac"". ",.,

SloeI< 10 pooIlion rar machlnll1ll. I~

..,ro ..uit Wh:I. you nd '0 do .. $CI .1Ic ..... tp<'d Sloo:k
_""'" "'~, Ind >hint thc cume.-. "" ~ so
1""",,,'1 rod< (l;ke Wtlntming c:lblnc1. 10 1c>-.:Ilhcm duri"ll
_

.~

C.p.,..1 Ihl workplec" beh.""" IrfICks, IJ lhown

here. Tlte SpiCerJ belW1!en I~ Jlock Ind 1'" trKkJ
aUow you 10 ,urfate aUIM w~ 10 IM~' wlthout
ch!wing complelely 1ht'0U9h lM IrKks.

I"'_~

4_ Sr:1 up the route . You <2>1 lIS<: atI)' 01 'h<: foi.

"'.... ing bilA k>r ,urf.dn!! ""'tom<lnn;~, "''''lBllt ,
monising. dioIH:uIUIlIf. Thr bat bit 10 lIS<: i!I IDo: lXIr )'OU
:lIrndy h>,", lho<CII clrM'ty a 1f.. indHli>mctn bou ......
dcanin~ bII. .... W do u.. joii quidrn than IHnclHli;un.,t~r
monioilljt bit
Thr bi' 1 IlJcc _
ro. ..,.{""Ulj( i!I dc:5iwJ<'d d.idtr for
buI",,",u.,; "". compatImn>" In

'1"1)". 1.-.

~'O.IIC<J d~.

nt"n. Wh>t rmkn It idt..1 ()I" ~"rf.dnltll Th~ cutting ~

.... ~UKd ., 'h<: perime'e. o(,lIe blt.ThI. III'''' 1""" nkc
ruli"" In.i<k a ""'C"". but 1, '00
1.... """., h>o..,.
ltard edse ~,w~rn .dJ.tecn' """-"" .
A' an)" ... ,c. y<>u t\(:ed 'o c huck whatcvc. bi'
an:
,,"oing 'u usc In ' h<: "",'n ,k, ,II<: tOll,n un ,"" 'ncU,
and "Sh' MI"...,n lhe Iw.oop~,~ aOO th<: ..."OdpOe tu K"I
II>c bit atenslon . !>on ', makc li'" tkep. ntl (I.c . """"

tii.""..

,'OU

,h>n .. lndI).

""1.

a. meillodlu l. Slld,n9 tbt surfacln9 bastplateequ,pped rOute, around wlllynllly Mim \lCt 1"- jctI
dont ... tventually. But you'll 9tl a lmcoth. ~I ,urlau
more qul(kly II you stan .t Orte end oi."" board ano;!
_
tlle .cule. lrom sldo! tO slde. methodically
(re~ p lrlil fo<ward a f'KIIon of an ,nth alte. fKh paSI.
AlIn a fini paM ""'CI' thc mtir<- surfxr, lItaIu Il! """'!'
lddi!ionol ~ :u nc<:"""rr to n.nrn Ihe boud.
N>turally, """ nttd 10 adiu&' tM <.kpth 01 CUI bct ..,."
pa--.1bnI makc a fIrW ,Jkim nt. 'u makc thr >llrfxr ti
omooth OS rou Cln !FI 1\ ... "h 'M routn. Sc.. ptna m;I
~ ",jU tbcn rtrn<W't ""y rtmolnlng 5irl ""'rU.

Beyond Thicknessing
alts sultable for s urfaclnll Include r~fr la rl,h/la
mor11i 1rlil bit (Inlfnd~ for roullnll hlrlile monlses). a
dlshcunif19 bll. a bonomdellnln9 bll. and li (ommon
stralght bll.

,. Surfau Ihe: wor kpl.:cc:. Thc conocnl"""'l

w,MIt"" SttmS 10 ~ lhal l'OU mu.l rml<c: )'OU, ....'cq>S in 1""

dln:c'1on 'h:al Ilie WOin ........ Tlu' """1 .he C2Jt. Unlil:c:
pbnn or JoInln.lhc: rotIln bit ', cutllnR aaion b Ilie: .. mr.
rqpn:lJc!;s of thc din:ctlon front ....hi(h ;1 addn:sso ,IM:
..""" goin. It b juIoI LIl1> =1in& _
!ha mabIa ,loc
fOU,n .0 pw.., curIt
an<! 0Ihn IwUlc:d.g;Iln .."OOtb.
So jY..ecpIrqj hotd; and b'th:ocross thc bo:u\l doon1 )"ic:1d
....,.,.... Bnb/I <ban <'OUt>OnB &om cnd 'o cnd.
Ik melhodleal, _.....",. WMihn }'OU ovork badt :ant.I
mh or~ . bc an 'uIOtn.1ton. S" ""p un unc: .~Is .
thcn clid( """r r"IOIch in . h<: othn. Sw""p, . hen cI!ck
",. . . S..."tCp. 'Mn dId<

""''*"

0<",

268

Ro .. tt. MlI9tC

"'"ff.

!ts "",11 "cp '.om ,hlck"""';ng a bo:u\l 10 1OUlirf;.

rec:n

in 1

IIJ'OU an: combublc Ir<:dtanding II. )"OU <2>1 oWInt ....

""'" tO "" ~. "Ou don"t nccd.o "" up U3Cb.Thr_
bdnf! baorpblr rtIoI:tt dltcaJy an thc ..'<ld<pi<a:. wilIt tIIc
~ ."" mosi rnimInW:omounl bmeJth iI.1b
IIM: ..,...". sa thc hiI. li pohcd .bo>'C u.. mIddlc 0/ thc:ata 10
h<: ..'OfI<C'd. T\Im lhr rourn an. and 100>",. "'" bII. 1n1O ....
...'Of!<. ;'1:0 """"" mutn ncnkd. rnlIy Ikczu:sc IM ~
Is do:M. )"OU .,.... ~ 00 ... (Io!ic: 10 thc cuning lincs j'OO iII'<
l1Iis ....... 01 worIt II"nrr.lln "" IncmIibk ornouru II
dt/pol. II 1"" Il,,,,, rotI'n th.1t ~..,. hc fiUed ",1'" . plcku". br aii mearu L10C 1 h ,",'iII koocp Ihc dU>l tJc".." ;al
,,111 nul<c II ...... , 10 ...., )'OUt ..'01'1<.
I()'OU .'" r"IOI con.lbn.bIc wor1tIng f=hand. mr 1
tcm[lbtc A'udt It 10 thc ..'OfI<. 1bnI. "';Ih a guide.""..
"""""al in "'" "'rbcin$l)ucpIotc.do lhr )o:lb ""i ......

'*

iUft."

ra.-

. . . . . . 00'

Router Lathe
Crullt elaborate piltterned lurnings indllding s plr.. ' cuts- in table legs.
bedposts, sUllr s plndles. or (olum"l!

11.... 0 k.o ",a,."."ln/i,.

lky.Ilob. llc",,'s a >UI!:IIOtOO ...... ,bc: Mo,,'n M:lgk pA>mtIoo picaln.. c:ad ar .......i"8 II", ","U"" b,h~ 11.~1f In ,..., ~.
..,.., "","" " prodUCC'II SII<;ro.' .an..

'''rni11p (illdooillg

1pir:II ........l",.,., ..,.. ' AU. lltl'SE lll1NGS WEI.~ OJT

WIDI II ROI.11'U!!!1 11...1 10 bclit:>..:? ROM'.... Moglr >howJ
li'" lIow 10 do iL'
Il0l>.
,dllljl )"U 11,.",. lumllIII' " ill ......" . IIfllb
1II<1IIiorI. An C1<P<'riencc<l "'~ m..;... )'QU dthe.
al 'PinI ' wnIt\gs
""'"1 ~k" ,hIs"")'QU ~ ......,
~.
Und.ThoM: cigl!'nlh<m'ury IIUfS....",.)d 11I"a. hoo,,,, and

"m

on

'''''m

- . In nning ,.... oI"piftl .utninp lOr >!Ome' ttiJIg lil<c a

~'k

.all elock. Wlth du. machlne (wh.' d ... nn I ali

_ \lui m><:hlne/) ,,"O<:>Ih>nn:O:'_C\'cn hobby ..-ood..:wI;tr, lOr a l & ~an knock OUl ,bc: ~ p;r>I
lIn\lng> In a C'OUpk bou .... II mlly 1. Incrcdibk " 'hen )"OU
lliIIII >boul k In lhooec It:trnS.

if,.,.. """" know how Ih~ ,.,.. JIf".l"lucftl,'h.b>ock )UUr Iks off SI:> ..."OO<hVOr1<a ,,-1\0
loQp ro. IM kno......t.ow 10 makc ."cntioo.gnbbing rurnJ.
_ ..il! pocn on'" .h!> """,hine
Oby. ""'y. '{nil , )nh, ynh. '(OU an go OUl and hU)'
fiul ~"CfI

.,ni!:

fu><

like Iim. Bul If}'OU ...,,111 10

but

OIle of th .....

<Initts, 1Iob, yuu ... "" '''''' d>oIcQ-an l~bIy a"" ...

om: IndIUlrl:d mamlne (apmsi'" Iil<c '.'0 11"'1111 pl.u """

"",,~.nd hI'~) nr. chcop-(Hhoddy OM CI m~.n chop llk

'hrcc hundrnJ buda;)'OU tnoYI"" /bul """"pl. And RO OM, I
mcan 1\'0 OM'. ...... puIlti>llcd pLm for 5UCh 1 dcvk:e
Should I poIn' ou'
'hb Is ~1bbI!' ....,u C<)II.cc.(."et! gzm& FoN M.tbd:, .... 00 l'UJ1S u.e, ~ obop,
cookcd il up. Hc: ~ onc of 'hOR chc;I~
nl:tdtlMs .bouI """ Of n,"C t"'~,., ~ horn lhc !ohop IIUf
....c"' .......ing Slunning 1.11 dod; for an tlmertc,,,, ..
\Jbod...,..... anidc. l1l.It mxhiM lud onIy OM ra,i(> of : .
llnnr 112\..,11'" '""'ulion, ...1Ildl ...... 1IJIht, 100 T~' for
lUncli,c Icgs, TIlc .hlng "'2$ shon. '<)0: '00 ohon for bcd.,.,.cs Of:any lumlng I<>ngrr ttwla .. bIt q.On .op of,ho. ,
k uocd ..... ~ .0 IIlO'I"C .hc IOU'~. arni Ihcy lcndcd 10
..,.,.ch (You 8'" ..ho. )'OU 1'"1' r.,., )'UU knuwl l
So ,,horn r ","nallhb boole projcct, I .stnl FrnJ If hc
cuuld nui<c bn.~ .,.,.,. OM ,ho n:uomh/y aklUcd
woooJ\\'1XUr coukI IIW:C And hc.., 1, Is.
11tc bcd il; -se 01 pty.."OO<i.l "hc mcchanlcals indudc
oomc ofI"-<hc.obclf bcarlnll' .... d ~ 1'10 rc:al cq>eru/>'r:
>tufi' ...... cad oIcoblt. 1Ic """d HICYC LE alAlN 1,. casy 10
!ind, d>c">p ~ ....." usc okl chiin-donn', ....."C to bc
new), onl "rong, .nd il WOfI' , ",,,,,ch, ThiI b brillWttl Tu

,Iu,

-le

..

ca

".

Hud

ch~ln

Curbox

RO UTER LATHE EXPLOO EO IIIEW

Cuttlng USI
Part

QIY,

M
Front
Mld/Tall supP<lru

Htadslo<:k end

jt"xl!6"x41'

Bi,eh plywood

~' x

5" X 11'"

Blrch plywood

)('x 12"x 17'"

81rch plywood

~" x

8irch plywood

It dia. x il"

Hardwood dowel

)(" x 3lt" x 6"

Blrch plywood

JI,"x2Wx4"

Bllch plywood

Chip sh,eld

""x3i1"x3i1"

A",yllc

Chip shleld riser

~"J(!II"x 3 W

Hardwood

Chip .hltld rstr

~"xJl " x2"'"

Hardwood

Large chuek dis k

"'" x ll " xl!"

Small ehud disk

.Ilo" x 9" x 9"

Transvern sprockel hub blank

' "x5'x 12"

""
""
Hardwood"

Qriv. sprocel hub blink

)("x5 " xl2"

Hardwoodl

Cea,boK CiSt halvu

Curba . sUPP<lrl blocks

SI.d bas.
SI.d bU5hing bloe k!
Clamp bu,hing bloc k.
Chaln d a mp ba..
Cha in damp jiW'
TallSloc k

ROUltr Maglc

IIl" x4~"

Blrch plywood

)("xrxI7~'

Birch plywood

)("x2i1" x B"

B,rch plywood

)("x 1""xB"

Blrch plywoodt

)(" " 3\01" x2\o1"

B,rch plywood

)("x2" x Ilt"

Hardwood

JI," x 3" x 1BIl"

Blrch plywood

)("x

C,..,nk plai.

'"

Blrch plywood

Il" x 3)(" x 3)("

karlng sleeves

W x Si!" x 43)('

8irch plywood

Trlan\luli\r gunels

.i=

Ma leria l

12"x IZ"

Relalne, plate Slock

.-'"C

,
,
,
,

Dlmensions

,
,
,

..... he d .. in, }'OU ..... go< .u u>c bIq'1.'k >{If'OCt~""' IIic)'Ck>

!>al......tul . . 10. Il . Ul opc<'dl; Ihcse doL).... M> for aII loo.e
>p<c<b, hi<)'cles nenl It.... of dilTt:n:n. si:oes d sprodIeu.
AIId W(I/ m.... "" .he roUln lI'!le )'''u l>uild 10 F"',h "f'l'Q
<OII tu,,, oac: hecl< o( ~ 101 of .pln ' ~'''''' .
Ob.Y. 5<> basicolly. hcre'J how It ...'01'1<., It', ruJly ,,",,1)'
>implt Vou ~""'I~r ro", .umlnl! I>bnk In Ille ehuek. Thc:
!OUL ... 10 s<re ..."c"d la a .Ied Iha' ..m ,Ikk from onc <TIt! of
dI< Lil"" ' o lhe Olhet.l l>c bi, . llc k h!'OUllh '11c .Ied """
.....m.::. Lhco luminI! I>bnk. v<>Il .um Ihc c ..."k o n Ibt ftQrl'
01 dI< lItlK. :md 1"''' lhllljj> h~PP"n >lmuh~n""",Iy. ll>c

X I \II"

dfYW~11

.crews (rime

anembl~.

e.c,)

7 lull be~,,"9s.~" bare X I h" O.D. X W 10.,...

...."" drlvrn by Lhco ~ ........ 1<. You ean turn

opintI"" "" iLhout ""intI Lhco rotIler

by hand. )'OU CUI """....hc """n ....w.oul
ha,lng.hc loIock ...... 'c, Th""""" ''Uiuus oombm:iLtion> o(

1"" cnnk

la ",ule II..:

m'''.... ,l.nt!

,h.,... IctJcxu.,)'OU

an round 01(. "luare bbnJ<, r<MII

I blcycle chlln ...""1 (or

.procht)

f," . . .,,"I), 46too.h

4 ,oundh~ad sere ... s. _4 X

1 100jI of bkycl. eha!n.

(erence (hud Chl,n)

7 IIU'Mid bob. W!I" nuu. \t"20 X 2"

'-D.

'Ppro~.

44 InCMS in cireum

I brlSS .h ....ded Insen. W-20

2 win!l nuu. "'"20

~u. 2~

tu ........ hal'f'<Tl simultaJlCOU!>ly ",., 101"" """ I"''U """", ... Ie

I blcy",e ehalnwhul (o, f, ""h I), lNooth

2 roul\dhead wood scre ..... s ~ X W

1 bewl

"""'" protI\Ic'Q tpII1lirltl ......

1111f docon'l ......... ll\inJI; One 1nd ThIrlJl TWo al",,,),,

(tr~nsw~~

I .IMI plale, \1\0" X 2" X 2"

21 fLll ....... her \II"

loIock bq;no ' " /'OUlt, Thintt Onc" And, llIi"lll'oi.'U. Lhco
IUInn hegln~ la ",,,"<"1 .x.--n II><' Lomslh o( 111c .. ock. ll>c
combu1lllk>n oll"" bbnJ<'. """,!ion :md .1..: cuucrs Ilncar

I ",undhnd JlOW boII, \4",ZO X 1W

'OOIh. Bo.lon ,lI48YC

1 be .... t IJl'lr. 12IOOIh.Io.,on 'U.SY-P

plastic knob with \(' ZO blind Ins.n;

'ROA.. /rom Reld Tool Supply (8002S30421)

1 "eel rod. 1'>" d, . X 6W

I , .... ndMad OI""" bol \4"20 X 1\4"

1 eel rod, h" dl . )( 3)1,"

2 bicycl. nuwh 1sprochts, I )-Ioo.h

1 bronn bu.h,ng. W I.D.(\'I;" O.D.)( 3\11"

I pc, Slul i"!JI., II'.!" x IW X \0'0" x 2*'

(drl .... <hlon t.n"".... r bodV)

1 br6nze buoh,"!!. }\" I,D,(II.I" O.D.( 1W

.,)( 1\II" drywall sue"', (fo, mountlng

~i'bo.)

1 b1cycle cl"ln ... hul

101 cll.ln"ng), 5Noo.h (huCk sproctel)

2 roundl\eld sta.... boIlS ... ,th nu.s, \11"20 )( 1 \II"

I roundheid SIOW bolt ..... ith nul. \11",20 XI "
Z II., ..... uher!. \Ii" I.D.
I

5 ~nhud sCfe"",s,'8)( 1"

(for mounUng chuck sprocteij

""'ng nUl,

\11"20

10 fiiI ""lshe'l. ~" I,D.

1 loop 01 btcyc"" chlln, IPPro. a4 lnehes In Cltl:um

f.,ence Id,1Ye chl,n)

a PC!. s.tel Ingle. 2Yi"X 2Yi" X ~" X loIo" (ch...:k elimf/S)

1 coldroll~ "MI sh"ft, 1" dii;.)( ]6"

fOU~dl\ead s.o~e

bolts, \11", 20 x Z" (elamp screw.)

WJ..I\e~,

ICI

I thre.ded rod. \4 "-20 x 2)1,"

'Ao- I.D. (chuck ,etlrin.,.)

) ""nh,ad le ........ o.6 x loIo" (fo, f.nd., ....... h.r.)

2 piUI" knobs ... lIh \4- -20 Ihrelded onsens;

.DK81 lrom Reld TooI Supply

1 b<au .h,uded Insut, \11",20

ni. ... &She~. \II" I.D.

I fOUndhud stow bol., \4',20 X r

p,.c Iumlnum condu1!. W

,Ih. I#<Ink

'/1 _ . 1~"~. X /" ,,,,",~. j, .." (rom

'Il00 M .. ud! ,~. ","' .. _ ""
,~

r.- .. b/o> ....

'1100 .... ,., ... w...-h. __ 1'It "'....re re cu, ""'" ,IM .,;. -tt-~ Ilie _ t i ,.,. - .

.r.

.,2_.

"
"

I brass Ihruded insen. i/i"20

16 p.anhud .trew. 8 x I \Ii"

(/I...:k clI.mp moun.lng sert ..... s)

) lende'

) b,ouze bushlngS. 1" I.D x 114" O.D x Z-

I,D,

x S"

""11 ..,,,

Rou , u.he

271

:tnd cu'..". lm<>

lh~

C)~

hl,.nk, aruJ, oi """""'......... _

1"'1'1'1"1( '1'1 ..,,,

'"')'on,, ...ho bulkb """ ",.hoc III 1IOi"ll to hr.-.: a lot
of fun ""pn1mcnUI1ll ..-1,11 Il. 1Ioh. I mean. thcy .. mpty ""..,
'" CKl"'rin"'nl ,,'1.11 Ilie jI<2t ..mos:.nd diI'fnonw. f'OIIlrf bit>
'O unk;l5l, ilS full potcn,l>.L Or IohoukI I A); "lJSI.J!ASJ/ ITS
f UI.L I'QTENTlAlJ'!r Hu< In ,hr procc:s8 hq" tie cn::>tlng
Irul)' uni<!"" lUmlnp.
Koow ..-Ilo, cbd Tlu:!
WIlI _
)VU IQ do
Ioo:NlnnjIjIAA IUrn[1Ip. ll kc bnl~ SIx fn:c laii. ..
II". mc ph'>lhfOUl!h d"...iI lh;u FmJ ~
l>UtI
,,-lIh .III!! ~
iMdtillJl 0\It """ cnd 01 ,""
Aher YOU'\IC: IUnKtl !fIoR. you ~n oM dwd: Ind
~hifr ,"" b1anlt. Now ,....."" II'" >Iod >l1el1,. out IK'IT1I
cnds 01 tM Lut... TIIm Ihc. oond 5Iion. ,hal !hIli thc
IIbRk """""'" u.."'. Now ,,,", lumlfl.ll i> ..i0ctir\8 u." .1>0:
QTIIER o:nd 01 UIt I..hc. , ..... an , /)U)' tlll> npabillly. ""h.
y"" "",ta buiId It
AneI ..... ""'"' china )'OU (;In do. RnilJlI. bob. "'"CII
tiai fl:uno: linil.ls.
01:1 man!TlIis" m'gic>I.Bob. (l know, 1 know SotTIIAT
wonl >pin.) Du. Iook .pin . . .hc: phoIo 1\.., .uxhcd.
Loo4o .' lho5c: IUm~ ..;,11 ' htir bD<b _
<V\'Q, .nd
~ Ihmc: >j>if'ab. 0Icd: out tIw linia!. Nu I;"hc "'1>
...al, "" rrul !:IoM, atI)'W2f. J""- our home-bw1. nuchlrn:

la,""

11>,,,,,,,,
la,""

"QU

I<j"''''

..,1.

md. nochln'-specW _ner.

Hc~. o;tJRIrIhinl rl><". A lot oi wou<lwur\r."", <Ion",
cI _ _ ' uml .......
ofthnn, l . dmlt. (lI .." 10
bdln.., . .... '. il!') 1 <Ion', kn<Jow ...ml il is. lUminII" an
:absfrxt ikill. loo ~t..lr;l(;l In 1:ld:1c: Ihrough book.lc:amlnl!
( l"'" llul ~ ,"" ~ klnd, l I<nn..,) 1, ju>o .aII\> li ~ ~ , umlnll11
Il<' 100 apnu;h" 10 ~ 1n10 ...itholl1 ~ lI""o;,"t"" tmn
)'OU .. l113>(~r II So..., dl00 huy the lUminII" Qr hulld litufr
...-111>00, lI'millg&.
Ahhh, hu1 ,,'I'h 0111:5 ",..ucr 1.1 ,1..,. ,IIOh, 1 n.. tIc:
WitldtoHr)'le: ..001 .... I'h nla: doubk'-bobbln ICIIJ. I'm
m&lclng a u .......~th '"m..... k'iI" NOI ~J'I .... I ~ um~"(lI 'lI>, JuSt
nla round t. pcn "'itI> cwplc of bc''',1> top and bOlloo,.
So JlJtkk'nIy, I caii do IJQII'C
~ploo'" tumlnll.
ARd h.,., 10'. ",Ith n ,}' rout~.,..
So ...'h<odtb)"lhlnkl Thi. (! tlle huoIt'. Gr. nd FUuIc:""",
omchln~ is dom casy 10 bulld. npttbJly con>itkrilljl ""h:11
I will do. NOI c'"C1)' ....o od"',on:cr wlll bllild lllK, huli""
kin<b of ..."Olic 11 prodlM."C!I ,,;11 11'""1> ""y ... <>O<I""""'CO",
allcmlon. ln '. mal: s .. ", 11 '. In Il.., ptO<llO<lon ~ , IIob.
lIut.how CI11 wluu i,'11 do.l h:a'" ...... , wllll!'""b 'CI11I

",,,..,a

m"""

"",1<:

.-"'"

."

Building the Router Lathe

Thi> projcct m"l' hnd ,..,.,.., of)'OU IIIto unfamiliar tcn1lOl')'.
1. IIIml,'"," "","c f.",UI. r nI'lcrial:5-pty..'OOd .00 h;JnI.
,,'OOd blo<:h ~nd MDF-~oo ""niliH OP<:""~r1ppin3
. 00 ("""",,"ln8o cUlli"!! 1V"<""'" .00 dadoft, """1"8 dbl<:!
.00 hol.,. U>.ing t/',u nmd.
IIll1 11""1'5 . rnI .prod::ct.l 8icyck' chainl CUlli. . and
driJllnli met:>l , Cuuinll .Junds? 011, )-':: JOd$ and linie: Ii.>hc>I
Rcux Rclax, It 1:5 au do:abIc. Tbc biq"c:k main :and
sprockcu Cll1 bc pun::~ :It ~ bIqdc ohop ''ou don',

nttd new ~bca""'}"" ""un 't bc U>lng ll",n. to prupd

I-o.pouoo Io;od "''T<~ lhc coumry!li.Jc. fu>d whilc ,...... ""'
nw.:infl )'<1lU' 1"'1'du.>c, )'OU caii P/'''''''~' I!'-~ """'" f_
poIrtlCrs un making up tIK lwo cM ln Ioopo tuu Med.
""'" bcannp and .....-.::111'""1'5 and bu>hlnll'l aII ...... ~
pun::h;I.Kd ;01 lhc la"'" pu.x;Jook In Ihe Ycllow ""p UI\d(f
tIK hndiog . bc:-artnS".'

Metal put>1Tr)" "-.::ldlng >hOp OI' m:IC h in~ ohop.

~ lhi> In mioo ,you . rc buildlng a V('ry' inapc:n!i<t
b.hc IM I "'III do~ Ihlo!!' ,"'" c,-.::n .he tnOli1 Cll~'t
>hop I:Ilhcs ~-.ut ..... tin 11 '~ wnnh a linie: troubk 10 fll1d tb<
od<IIWl JWt. }_ nco:d and 10 m;m~r Ihc- simple mnaI..'Oridll.ll s/.:ilb )'Ou nd,

Bulldlng the

Fr~me

Sl:In~ ",l1h II", rr.. mc t. ""Rlc"'1u1 ..mIr:>!'); but ~'. 111

Ipproad1 Ih., j!l"c> )'(lu sense 01 f"'OIt""'> .,...,. Oft. k
dua!n'! I~kf Ionl1 fQr II", fr.ut>C.o w<c ~"", 11''in&)'OII.
cono:;rclC kk~ 01 .... h'1I}'OU ~rc n,.ldng.
Aflcr}'OU h" Ihc rr:.."e a5>cmhkd, JUII..-an """"' ...
lhc hcatblock, Ihc jtC"Orina. Ind aii Ihc- ... j1fIOItlr"II para.
phcmalu.

1. Cut Ihc: (ram.: pafU, 'Thdc lndutlc: lhc- ftOllt lIId

back, the mid aoo !>.U supporu, !hc ~odt cod, ""
..".lnct pl:...", and thc .~bt fIUOII'"b in buildlRl! III>
orij!lnal P""01)''''', fred .....u ~ medlum-dcn>ity . . .
board (MDF) for :>II bul Ihc bacl<...-ttk:Il ....., . . . . ~
)I.;!I(:h pIj'WOOd. 10 buiIdin3 my own uniI. 1 _
lo.iDdI
I!.altlc iii"'" for au !hc fnmc po ..... Frcd. I:ItIK,oI COUIIIC,
workrtl 1_ Hnc; but I thlnk Ihc hul.icr .urrer fr.uno- is.
lmpro...:mefl1.
AlmuoI au Ihcl/: pati> r i l Iw: furtlw:r modIfit:d _
....:m11ly. bul bcgin by runintt :>II bul the- mld aOO WlIlIp
poru 10 lhe- dimm.sions ~ by !hc Cutti. . 14_
SMpin thc IWO Wppo!'U 1:5 ~ by sunln3 "ith. tInIi:k
pond 10)( 17 " Inchc:!I;:aftn making Initial :<Npin& cut~thio
pancllo cut In lWf tn ,ioold Ihc two 5<'p'U:llC suppons
Aftn
.hc thrtt squarc picco::s ~1Cd lOr tb<
JIU"""', hafo.-.:: odI-"'Iuarc on di2gonaI_lh" ;" C2IiIy .....
on Ihc hand --forntIntI tIK t~ occdc-d 10 brxt

,,..,

....

='inII

2. CuI Ihc joln~ry 00 Ihc: from aod baek. 1bt

hnd pond, thc mId MJpt>Ort. and 111<' uU pond iii imo nilbctJ or <1odoo t'Ul OCroti In thc huni and b:acII,as sho .." iri
Ihc 1bp Ilct<' of Ihc d"'''ina Roul.... (Dt,,*, I'/{II/ 11e.....
~' 0lIl .hc Ionfio.... 01 IhOO5<' rut. un lhc ftO<ll anii
b;M:k CI:Imp. T""I'W"c: Qr ",hcr 1ln.lW>tcd!lc ." .hc swck.
aud mUc Ihc cu" " 'lh ;> Stralgh! III.

3. S h apo: Ihe mkl and tall " upp<>"", I"",h >I'Ppon

'wo """'ldn:ular culOlI1$ 10

cd!Ic."

itI IOp
""",,'n iri
Ihc dn. ...in& Suppon ~t. TItc "''ACI' of .1", ,''''O o:clllldr>
dQ:. ptOVitIc:s dnt2nco: Ior.hc .ock bcl1lJllum<'ll, ..hIIt

ha.

""" ...wJcrlllK cntIIo II", >Ied ...." . Ilhln. II.., ~a.o,Icsc .."""
10 mokc lhco.c culOUlJ io 10 cuII" '" cir.:le:. In onc llrJ:<
pond. lhcn cu' i, in 1Wf, SplluiOJlllIe 001(.,

ROUTER LATHE PLAN VI EWS

TAILENO

FRONTVlfW

HEM> ENO

.,.
!.>t" OII! a cC11lcrline on 'he p. nd fu, ,hl: ,,,,,o .uppons.

CUI Ihe .... """pIece In h.:ilf. s"IIUlng Ih<: I>oks .rnI

fonolng lh<: ''''-0 suppons.
In lh<: fini>hcd Iolhe, .he 12lI ",,,port Is ~"<luil)pnJ ,,",Ih
IWO hc:Iring> Ih" aN}' . hl: IIil diSk, whieh l<usoed 1'0. cspc:- I~"
cb lly lung 'umlng>. ur ou. and bare ,he ~Inch.(lbmc":"
hoks for 'h<: h<:' ringmoun.ing 11<.>11$.

ccn,e'l"'tn .. of .h" '''''0 holo 10 ~ CUI On .h..

<O'"I:r1iM . IJo.., Ihl: sm. lIc. hol<' wil h ~ Fonsnc. hil on Ih<:
drili
)t0l" Ih<: " 'li'"
,,",.h pluI1g1' muie'
(Ulppctl .... ilh Ihe Tr-.mmd lIJ"'plue (I'"II<' 39) or """'"
}brI: "'"

"InS.

ho'"

Olhtt 1=tl1ll:1.

SUPPORT LAYOUT

....

.'

..........
",

"

-;r

.
\1,' )(
lerewed 'o b."
",
2" )( 2

"
"

,
,

ywrad.

,.

:/.:,':::"
..
......
,... " .
::'
~

'

":

"

.''''''

",

......... ..
,~.

,..2_.,.
...

"

..

II

~." n9 on ,aH
'"O POri only.

"
S~

fIIelll plalt

ofUilsuppo

"

"

I rl-\"

'

..

....
!"'"

11
- lY
' 'i
~

"

..... :),;' :,,:

Rou,e,

u,he

273

frttf). Th keep 1, iti plac<:, ,h~ ehud d i>.k \s ' .. ppo:d

bel " '"",,, ,I>e ,.,Ial"", plai" on tht h",,<l>IOCk cnd ', ou,..,.
inner f;tcc.
f.ta: Ind SC>""] "' '''p ,,-..,hen" 0Il
11'1<: fi,.,. .,ep In nuking 1111> oss<:mbly ;<10 i2t. ou.!hc
he"AW;IOCl;: cnd. Sludy lhe Ue<Ulslock ,.;"" S"Ilon
d r.rwilljl UC"<UIslock La)","". !hen duplicate ti", II)UlIt OI!
'lk h<:adstock cod :W1d . I"-"gin hr b ring Ou, ,/te Ct1ltttpoin l of lhe eIIuck di>lo: hole.l]",n >CIibing u. ~ s.lr\Ch.r.ldi","
I>ok ... illI composs. Rc5cI II", c<>mp<lS5 10 ."'ing" S' !uInch .... dius. XI Ihc P;''OI Of> ,hc hulc's ccmerpoim. <Ind
scrll>c <c<:ond ~i",lc . ll'1<: cenlcn of U.e dtu<o" 'lJppotI
bcorings ... ;U bc On Ihls circle. Marl< ,he bc:r.ring C<:flt ......
Now ~. oul 'hc I'C>I of Ihe holcs."lIe lt.1n<:tJ.diammt
hok 1> ~ ... " sprucke' >lI. f" U.e
of Y..tnch.<JWnetcr hokI
p rovt<k chaltl oJjUSln",nl . nd Ihe ~Inct..... i<k >101 :t.Iloool
oJjuslmcm of !he ch.in, Icnsion .

!""

oi"'"

.r<:

Auembl., Ih .. lath. 'ram. wlth 91" .. and drywa ll

"rew'. Join tlle mld a"d .."d ,,,ppOrtS 10 tII., bac k.
,h.,n add \11., rrom . When YO"
sere"" 1"10 the
9"""1,, il wlll pullthe ' rame into Sq ui""

d.'".,

6. !..ay

,,.'<:>

,he

sup"" .....

!U

b)' uut ,he ccntcfJ'<Jin, oi the spnxkcl opcnlnl1. S<:ribc "'"

II><: fro". ""d b,orl<. SqU.>n: .lIc

""'"''''bly. . ..... PoI"""OO sc""" .he II""""'" in

(.\U Ihe .. " . 11 "...,1 plot(' for

t""

[~iI

oUl Ilie rcraine r pbles. FoIlo" 'ing !hc

N<>u.,,," /,/",... ..,."Ion oi Ihc d"""';1ll! 1I"'' "'o<:lt La)llu,

4. Ikgln assembl ing th .. framc. Gluc . 00 sen:""

9IHndt-di>meu:r hole. ,hen :Ldd 'he mI Iln<:>; ,1... , lr,nslorm

Ihe bbnl;: inlo t ""O ~I:t.Incrs.

p","ce.

SI'ppon . "d dri]1

lWO muuntlnN'SC:~ hulcs In It. Scrno.' thc ptI'c \0 'ho: SU I""

pun in ,"" uppc:r f",m cume" whel'<: 1..... n .!mul ,neou..ty

7. Make the hcadstock boles. Thc l"rgoNli2nlClCl

l>oIes In lhe h.... d >!""k end . nd lhc "".lnc'1'lal.. bbnk CItI
bc "'Uled using" plungc rou,er cqu;ppcd wilh ,heTrammd
""",pl.le. Whcn nuki"ll ~ach nf 'hes<: eUIS . .,id: tii" ,,'Olt.
plec., 10 ""rap wl.h atpCI pt. makltlg su,., .Iut tbc
pl''OI_point
CSpcci. II}".15 S<:C\1~~' bonded 'o ![.., 5cnp.
Afle< ",uling lloe brgc opcn;ngS. 1>0", lh~ Sprod<OI
hule:tJId 'he cluln idl<:, hule~ on 1[.., dJilI p"""_l1>< dt1inlemion . djtrnmcnl >101 an [.., formed I>y drilling hok.,
.,.d, cnd and .J;!w ing Out II", "-0L5t<: bctwo:cn lhcm "'lb.

..,,,.,, ... ,he "'I.tnerforlhc >led .hafl . nd aH contoel 1'1 >1"

fo. the ch:lin tcnsioncr.

5. Lay Oul ti .., hcadstock end. n", fr. me '. h""d$Iod:-. 5utnsscmhly-.uppons tI>(, ehud< disk . nd , he

.n:.,

ch.>m-dri,c o.>scmbty. Thc l>C:Ids,ock con"st> of t he hc:ld,",ock en<!. ''''u n:~r

h:...dful of 1x>1(;j, nu,""

p.u"" """

w.shefS, sere"" , .OO IxaringS,111e chuck disk filS imo a

hole in ,IIc hcads,,,,,I;: cnd. 1, ridco 0 0 ,h mo htlrlngs .-;.
'k.>ncd HQwld u.e ho!c's p"rlmcl"', I>'hlt:h :aUo,.. 11'0 lum

..bcr,,"w.

HEAOSTOCK LAYOUTS

RETAINER PLATES

-...
CII

.cc

""',"OC,,,,, I "'"'.~w

,r",u~~~. ~ .~............ t-~-"-"~

Mountlng
for Idlu

2" rad,

<:.t

3\,,,.
-;;;;:..
. . ~.~
-'.
I W dia .

1" (typ.)

~ ".

".
, ,.

..

'---iIe=s::,".=lIJ
1 . . ._ _ _

Both (etalne!

" .~_-".

plale~

ale

CIII from, slngle blank.

274

hDI~,

Rou.er Magic

o
o

,..

f--- r

1 . . .-

..
!4"'wld~ ,10' for

I~"

chll n-ten,ion adjustment

- "

"

,,'olt ,o drlll , h~ opt n~ ~ ,"" I1nrlng> IInUI 1fIrr

lIIt md and IM

rcl ~ lnc ..

ha..., hcen ",lnN.

8. ,"""mbk tl ... Mad:srock.

~)'OII OII

oc:',wly

Iht _0<11 mii and ' M rc.ulncn ' 0\1<"100. 'M

flIIinn'opbIr bIant Iwi 10 Ix aii imo 1hc . _ ~. 1;"
,.".Iht..,.... Iin<:!o "" 1bo:: _ _ (ur ..'hh lDbrr $aW).
liIIIr _
d>mp IN lttaIIocD 1<1 .hr hnd!o1O<11 ftId. u
_

......... In .bc: bfout d ......... Ai )UU ;tppIy IN Jduie, M

cad\II,o kccp ,"" p..,
rrom 'M .,..,. oi"'" ehud<
diIII """'..... ''ou doo!', ...... ~ '0 dnI ",ilh In
.... on. bt ' M II wilinI,",*,", ..ilh.Iw Iftc rowion 01

...

_-

_';._~

"'"'*

Ihr.....,,,

4." w..n In tho ctn......

9. lIoft tM
..... ,., barinII

dry.

roo-I "'"

""p

comrn 01 IN

btariaa '"' _ _ ,'''' lIont 10

and ...... bob .... Ibc ~

_ _ _ boks. Thc: Ihrft cmI'"'J!01nU ""' Iald OUl ori ,IM:
...... fott oIlhr ~. Thc: bntInp '""' 1\ 1 _ In
......., To ......iIk~ ....... ~"".hmlln.M
_oet oIocIuId bc I lt Inchco In d;OlMlrr
!Ion: thr n:Ccao OII ,IM: drIU ptQO "'lrll r.-ncr
b;( . .... klnl ,I><:m aboli' " IAdI dttp Try 10 ~M lip IM
1Iok. pr:bl:1y AhIwJ.uPlIl ""'" >m 10 Ix alra bIIqo
wori1 . ro" mar .... n' 10 ..... a ceolc . lnll pin (II'
h 'CUKlI

Alltlnl ... IIM.ns KcUl1IleIV k HH:nlIaL The ouuKll!

tOges of 1"'" IIIrge reu.intt pilIt an bt aIigMd flush Wlt/I
lhoM of t/Ie hud tnd. k bo hc:lpful,o ~nClI posll .... ~
lround Iht SOlII reuiner pIilt durlng I dty "'" SO l!\a.
vou an posItIon it qllickly ",rw Iht gille 15 .~

HlA05TOCK ASSOlIlY

fACE
HoIts for ielle< bt.lrIng

OUTSIO(

,.....~.~- ~~

SI>I1U.diarnc'c. !>i') 'o al!An ,"" _pkn: OII II><: drtJl

JK'I!"> u.bk Whcn IIM: a Olcrpoio. 1. propcrly .UlI"flI aod

lIIt wori<pica cLtmpc:d '" IIM: u l>k. JOII CIIn swl .eh 'o II>c:
i<>NM' bl1 10 00",

, he~ .

M<l if j'UIJ u.1<c 1hb u..rt.)'OII caii I""n ~"''IId11<1' lwndI

1IiI-'" ~ .hr II1U1'MIRlC""'" ""k. Ilo .. """"",,
It..
uD ";U bc Ct>nttI'I>C' ",i,h ,lut oI'lM: ""'"1'$ """""'.
In ""t' """". ORa )'OII ..., Ilor'ftl ,hr n:""""",. bon: ,1Ie
boko.

,Iu,

_ ..,Injt-boI,

".

~+O_L-j
Ttl1slone. bt",,1ng

INSlo( FACE

Iu.".

10. Moun' ,'''' Marinp. Thc: bcItI..,.

bQne
CIf\ _ ..... "'" """""Ioa 001 .. iU'I! 14 Ind! In IM .a., di~
JlftJ'1ieI0 bk oIl1dj1buhihlr
!'mi', 1hiIIk....... ,hit: E>'m ")'001''1.)'0\1
'""Y
Ho ~
ori ohr :uio 01 ....Ti 1..,.l:1li 0I1:>do,.
..-.....ne. .... Ix """,,,ric So M driIrd lO=Indo bob In
.... bkJ 01""""'" do>o'do 10 ........ a. ~ bcl ..ttol , ....
~ _
Ihr boIu.lb adju>I: bnrtroI ...,..,~. In

nil'

""",trft!

'O

;;_.

....... 10 Iht chuck dbk. lor 1...... Iht "'""" 11;0..... II b

......., WWIy ccanlrIc. il ,,"1110 Iht baIrint; pooilIon.
So bcPI IN wuUa11oo1 0/."" hcIdocoo:t bc:atinp .".

.... - .

"

CI

~ ~

pIun 0/ "-IncIt _Ti

,hrec: hncbcoo:lI bcarlnp.lhc:n:

(ourn... "" I~.n: onIr

. . four othct pbcet 'hc: ~ ..., lOkd "" 'hc: Lt,hc: ....
,. ft&h1 .. ",..,11 _ llor ~ "" aii 0/ ....... :II ,""
. . . u..w.) Grip Ihc: <10>0..,1 In hand ..:...... '0 bold It
wWk ,.... _
OII ."" drIIl praoo. Thc: ........,1> .mIi 'o
. . .. >0 _
', fc~d 100 ~"Iy nd hc: """.,.."", fur.
1IirII' h~ fali ....., r ~ , J ....
)'0\1 only nc:cd """"n

1 y,-di .

,..,~

bu.ing

...,,,,,,...t...

Macrnhk:.1>cc 00-1. bcarlnJ, anol ' .....

",.",...tw:n

OII 'M

bo;t:." >hown In Iltc dn...-l"lI IlNUbUXlt A_HIN...

.."""

loC ' ~.detp

'KtU

Wdio.. dowtl

Conslructing the Gurboll

....u.

The gcMtlo. Is Ihc Ilnchpin 01 tIIls b ,hc$ ...

''IIm "'"
I"m th" .:rani<. the roul .... ~ oIong tIM: >kd >IuIi ...:1
" "IS Ihe spindk: chueked in ItIc bthc. lr. Ihc ~ .....
, ... ""re", ,he p<>"'er frorn Ihc craok 'o Ihc spindk:. f() !ha
I>'h,," Ilie rutl'er "",,'o. >10 <Iocs tIM: ...'OI1<pictt.
Thl il>l unit 1 .-mbled rrom an..,..", ....... olpam.
indudlng sornc pl)...'OOd coupk- 01 bto<uc btJshinp..oct
bc;."eI II<'~"'.

Do" .. try 100 lI.rd 10 u ,,,,,r III. hain In t~

t...r1ng mounllng sluves. Offu"te. hole. p<DVlde.
s"",11 mUSutf o,.dJuSl-lbih,y. Ta boff ,~m. """k
untt<POlm wilh.n .wI. T""n pllKlIl .....!ee"" In ..
IIInd SCI1!W. 'nd drllll .... 1>oIe" 1"" muIr..

u.e

ti.., boU .twtI< th""'lth u.. DIOIIIII~t hoIoo.:and ....1k

Ihc bnring ,mo lS =as. Acid ~ ...-:lSba and nu' an Ihc
bol. ~ olwIk, """ tif!:I1 .", tIM: nUl MtII a ...1"n>dI..

Il . Tempot:lrily joIn Ihe heaebnock

rrame.

T~",pomrlly

",mao..., tii" ~od<

loCC

to

Ihc

means 110 gtuo:. ,"OIJ nccd to hc obk

ta lnMalI 'hc

goeamo . But

~.

tun

10
10

Ih" fr;uno: t;tke wpc.

~i, tii" hndstoek ......""b/r Into 'hc rabbrts lOr it in 'hc

fron, 000 bad<. Drill p;1ot

Ihe ""n.

"""".:and drn.., "'""""-.

""" >led f'O<b. n.., """ieub... ollhc JI<2fboJ:

<"tI""",lc rrom II.., bc;...,1 J!t"...... n.., br.ond .ntl U"", """"""
oI,hc lII'ar5 "sed In Ihc fl"JI(M)'J'C' .'" indudcd In tho
tuRl"..", Ii<t : Ihcy aR: off-th<:-6hctf it""" a, ~ (k2lcn
(1ook In Ilie Ydlo,", P-'8'" under thc ""....ung bnring>').""
~r I!I"ir h:as . !>-I och ba",. ".-hk:ll dlctalCS thc ""' ...
~nch .tWI wlth II, whlk 'hc ,;null .... I!"".... hou ~ 1xR.
~t:lljng Ihc lI1< of a IIo-lnch ,twt OIn'ioo>Jy. II ~
ha.., bccn be" .... ifhnlh gc>1':'I h:Mllhe .. ."'" ho",. "'" Ihcy
don,.n.., lIilo 01 ,1Ie /ufi, dlct>'e Ihe site> of 'hc bushlnjtl
noocdcd. n.., bu>I!1ntt> ..... hc p""--ha>c<I rrom thc ......
dc:lIcr Ih:u "'pplie6 Ilie I!I"inl (anoJ Ilie hcaring> u.><d cbe.."h<tt in ,1>(, btIM:). Cokl-tolk-d w:d rotl "",n hc purdwaI
"'. good h:u\l,,~ .."'" tii" OI tii" hnring >1""".
n.., kcy 10 5m00t1l opoo"'llon is prccbe ...,.."rtICllon....
l'oIk>w thc din:<:tioou mnicuklu4ly an<! ,,'011< "",,,,ruUr.

1. CUI thc gc-arbox

~lOCk.

l"hc

10 .....,.,'"

2 . Jtoul Ihc bu.1 hing

ch~nnc:l~.

CURBOI CONSTRUCTJON

ASSEMBLY IXTAiL

BAU VlfW

c:
.c:
ISI

TOPVlfW

y,-d'i .
..ul rod

(!.

3W

II<I'velgur BOSlon IL148YC

Btvtlgt.r BoUo" 'lI4SYP

''_--j._ Mr'.dll.

-J

IIHI.od
1'\1\, '

FRONT VI(W

Y>'to. )( \t'O.O.
bronze boI'hing

2 76

.000Ie. Magic

11"".""'._""'...11

Io<rncd of 1"-0 5maII pia 01 plywood. CuI lh" IW() cw

hal>..,. ta tM dim"nMom'pcctfIed by ,1Ie C"ui"ll LIoI .Tokt
Clua ~ 10 CMun: thal' .... Ions """'" a", """,11d .nJ 11131
tM.-nds "-"= pcrli:aIy sq......, la 1"" 1kktI.

Thcx channdto

a,... 10 <mletc lip """,,,,",Iy

_tlrn Ihc .....'" tu".."..", """ed. 11><: ~ "">J 1<) .... It Is 00

...nI '0 .,., CU, p ......~""I). il they

,'''' """u
,.bIe.
n~ , clmck lIolnch core-OOx blc In I .. bk-moun.ed

fOU1er s.".1><- h~ n.rn,kln 10 ~.'nch . nd .Illust , hc r.:ncc

10 (lOli'in<I .hc dUMei. "" M10w" In .he <lr~"" ng Gcwrl.>o.x
(J)rulnKtlo ... OIcck u.., OC"Cl1ncy of . hc ..,.up IIr " ... klng a
!ni cuI In a """" of ocnp. Thcn rou 1><- ctc. .. nct 1.. ....,.11
haI>'D of .1Ie I""rOOx CQc.
To CUI .1Ie lI<""CQnd dw\ncI, ."" """ .... IiC"Ilip mlUl ""
_
S_1tch .0 a '+lnch corN:>o:l loii. and adjlN .1><- hit
alm""" .0 I \neh AdjIlSl ,"" kno:c ID p"..I,1oo thc WIWI
>1>0><11 in ,"" d,...,,,,*. M.>kc .taI CU" In '""P 'o
ronIIrm 'M KCt1J"XY of<hi'l .... lIp Th:1I dono<. fOUIIM ...wl
du""el "" ........ hoIh pic<: ... o(!!tocl<.

d\annd."
3.

CuI Ihc elearao: nOlC"- Al thQ (Xlin. )'OIIr" IJ'".....

ftni!ohcd bw fOr."" noIch .lul p""idcs clcanr.ce
tir Ihc- bt->"Ct
Cuac1llly Iz)' OU, Ihc " " ,ch. as .<lIo,,"n In
II>< dmoiflA. CUII. OM lhc band ..... or
t>,ad:s:l ....
I)oHlO:< 1>

w:ars.

..-1'"

Wllh lh poxy appllH and Ihc bnttl ge . $t.lfll.

and bysh'ngs pl.leed ," I gUrboK aSe Mir. ~ou mu"
~just-for .lIllm_tht muh of ,'''' bevtl gel'l.
When y(lu hlV'll! IlIem adjusted just rilIh Sel ,''''
SKond ase 11.11 10 pllCt Ind d~ Ilie .c.eIN' .
m""h hc.ulroom hc 'celh """', mcsh COflsl~rnlly. and ,he

4.

J'n:~ Ihc

bushlngs and

~II

rod5. C.., .hc

lMhioltc> :lfld &Ied rod< .,..;.h a hacbo ... ' 0 "'" kengtru
orpt"("\f.ro by 'hc Cu.tinfI u... SOIC tho. "'" Iafl!"r-diamti ....
blllhinlll> CUI .. Inch lonFr lban.hor dwcnd In "hkh II
wUI he pbccd. 'M al'" lo:tIth ")O II can olmd Ih..,.,p
...., iI<'adslock. Mak" ,"" CIIU "'I"''''Iy. ano! ,..."""" any
bum ,,1,h a fi", or cmcry' p:1pn".

M' .... hc wf,.ba,.., bem CU"" "'nglh. l!rind or fi", a

.oon. na.ro ...

0..1 a' ""etc cnd Tl\c 11""" and hll1 'hOl

R>OUI1' 011 Ih"", .l\:If.s "'" !iCC1lr<"d ... I,h
\l1.IIou.
1I1c!c n...~.'h" r\.';C""''' ,,m .lnlO>' c~n.'nly .lIp

""'""R."W>

S.

M""... ble mc gcarbox. ~ . pu,;h nch tlcvcl

P "''<'1" OM cnd r;L Iti shaI'I, Ind tJshlrn ti", 5Cl0<TCWS
<*O ."" 0...0.. Thcn .>lip .he WutiJ .hrou..,
bwhillJ;s.
Onc tpc2I note .. in 0ltIer ,.. .hb poilIt. lbc uppcr
pbow on thD ...., ..........1Ie ..... of ...... Of rltr sbon
~ 00 nch >Iu./i , OU (2n hur lo>olJ! \Ju!.hings. and )"00
1houId. If ~ ,o "'" sbon bu>hi1"Ojj!l, JrC:* lIP thc ii/Uful
10 "'" ("JlQ:<Y ""Ol\l ..ick 10 thcm. l. wurI1cd br ""'.
No ",Ix lip """'" cpo:<y. and ;pcnd II In ,"" P"'l'-.:s.
(l u;cd 1'C7. whieh Iru ilr, "","'c!lkc comlslalC'f. OS)')U
(;111 5<'( In ,hc ph010.) Don', "" ' 00 """"""'" wlth ,he
(1IOq';)'O" don . ,,-.ull sq1ltt1<'oOlIl w!",n )"Ou n,.'e .1><" cas.o
blh"".Tha. could foul.hc ,,'011< .
ScI,hc bushing:u>d rod __ mbl"" In pbcc in onc /ulf
01 ""'.,.... Whiic 'hc cuc b opn1. )')U
.0 adj ...... lre
..... .., ohc)'l1 spin >mO<"Mhly anei mnh I"opcrl) This b.
aiIiaI adju>tmco' ..... )'OU ...,,, 10 jtCI rigIt1. Ontt )')U
.do:et: "1'. "", C2>C ano! Ihor cpoxy CUfQ,thc gnrt>ox can'l
!It n::odj.... ed, " an onIy he rrcomIfUl""led. But lhc ("JlQ"Y
_ oIO"'Iy. and .ltlll )"00 ...,'" time 10 fIddk ..i.h .hc .."0<1<5
bob-c cloosing uP 'M cas.o
~. )"OU wan, b fOr .hc bt->,,' 110'" .0 ",oii )O .1><"
IndMdWll 1I1t h:l'"c 1IOme 11o<I.00m. You'U tind .1\:1, lf
,ou fon;c Ihe g'"'''' .IKI,.ly u~'her, IlIcy bind whcn )"OlI
ur.o ~pin .lIe ,hafb On ,hc OIher 11 111, il ",,,,,,'s 'O(l

.""iI"

aetion is <"ITA.i<: .nd tcrt;y W01l< wi.h .hc 11""" . nd get thcm
li<1 IIbl rll(lu
Now u.e ,hc bu>hlng posi.lons
hold Ihc JfI'.r

.0

adi_menl)"'>ll'" ~blbhcd .W"'" .hc OO.llln" ,Ion, '"e

$h2ft "" i. """"'""""""" thc bo<Iy of . 1Ie gcu. Whcn 'hC
gnn ano! bu$~ a.., .'isncd-.fC"l 'hc 0"0nd C"I>C hali" In
pbC"e Ind ~ llIc ''""0 /ul ..", 10000hcr. Set .1Ic JIIl"Irhux
asi<Ic.o c .. ..,.

6. Mount .h e (I<'&rbox on mc r~. 11><: anrboJ:

lS IrAppcd hetw....,n .1Ic hn<.htock and .1Ic n,W", Klppon.
I,'s hdd ke"(1 by ti", front arni by
'0 ,""

bloc,.., .,oachcd

Ircld... ort :lulll"" mldtlk ~uppon .

_ _~
Ikllin II><- ln.'Ialb.1on by u.ISe ..... "'ln' .he h~.d"""k
f1Ull1 .hc flUll' ,..,<1 b;I.ck. Mo>'C .I>e hc:od>.od< lusi c1>OtlJlh .0
aIIow)'OU 'o lllip ,Il(" .,...btn: .tufI .hmugh .he IIOk fur 1.

2
;;_.

It,,,,,

A ci.,. .......IU lIN! fi ...1 au.mbl)'........ "

Mlped p!IIOr1 the suppons. whiclt!\rit bten glued
to IM M.dstoc:k ancl mIII suppon. ArId II ~mo ...
$!file<! 11I.1t. pulli"9 IM hudstoc:k only lboul Y.! ;nch
from the fmM ....ould p,oYIcfe Ilie clu .... el nKIS~ry
.0
tht gur Ih.ft .h'OIIgh Iht o~nl"9 for II .

'""It

Rou.e , LaIM

277

In 'M ........ ock. Thm IIklr 'M lIn<bfock Net. InlO pbtt
UId (b"", ,"" .-mhIy
Nao, JC">' oM prt>o" QfI ,t... ~ <11 oM
ma!r(
IU'" II il ""-d, and IICIihr olonJIltJ bouom and Inna ~
on ,!te headstock and ,!te "'kldIc: .JUp....,.,. Thaio: nurb
Indk;o.., ",1IcIT Ih<: IUpport bIocl<J n,..,. !te a"adw'd.
~bk ob< ~ock md II""rOO'" <..'u, , !te lUp....,.,
bIocb 1<> ,!te dl~ .p"dflcd "r .!te
I..... hen
IIOIIch .hetll. GI"" ""d ... ..,... .toc .JUppon bkoclo:s 10 .t... he2d.IIIock md ,t... mi<l<lk OIUpport. JtooKmblc ,10.. "",rOO" arul
hnd.Iock. Compklc .hr Iru.t:olb.1oo "r tJming l _ '1'1c
..:~. , h""'8h Ih" head.!lloek Inta "'" tp:1Im..l" ~od a >i0glc
fICN;W Ihn)U~ 'M middIc "'ppon In.o "'" JtnIbo . (1
dldn, u,., BI"" In , hl. 1'"" <1I1!te ....,mbIy 1 ~"1n 01 ..-. ),
mnlM:'hc hnd.... ock arul Ih" ~~ "r " I' hd ... wlnllll,,,
:lJK1IIbIy JC~'S. Md t luSl
"1'" 'o CIunI1C II:I"r .... 11o
"""..-d;oy, ... hk:h woukl rrqull"<' "'" to ,,,. k,, ."d In,. . 11
tIl'W w::..box )
Firuolly. CUI ;tI1d lnoull Ihc ac1"}'1k: chip ... kkl ",..". Ilie
"""".To ....... ,"" .hldd ele.. o( , h" lIfJIC'r ~I """r. )"<.Iu
" 'm ha,.., 10 .pply' """pic .. Ii", o( "In<:h~ hlck >loek (Iirpins.' rrom .h" >e ... p hin. rcotllr) 10 Ihc 101' <1111", Il".rbo .
s.:, IIM:: >hi"kI on Ihc 'Iri.,.. and ,""W 1. In pto~

f....,..,.

CU","

mar ..

M;t;king the Chuck Assembly

Th,s Is Ihc 1'<'" or II", bllh"

'Iu, 1loI<b Ilie ","orltplc and

r:o""," 1, 'o "-""'" " 'h<:n

,un. ,h" er.nk.

)'t>U

CHUCK CONSTRUCTION

,,,.o,..'.......

u."",,",,

""1'<' '

mOSI dlld,,'" .....Y .u d" 1. Or )'OU aII," a II.". da'c, """'"

""nu ti", "c~ . nd makc !ha!

bxk 10 Ihl~ .....~Ion .

secund chuc:k.

Ih c proc:k""
ro r . h c " huc:k
'{.... nc:al Ir:uo: ....... Thc m..dol w.o-.n "
.,,""'. fond If)'t'" "-'0' 100 ni adJ'I"Uhility in ,.......... b.be.
1.

Coli.,."

~mbly.

Thc chuck huh c..."I.,s or ''''0 d isk.. ur .\I1)~. IP",," b ml

",,,al r>ee:
f.Ic". l"1><: hub fi.~ Inlo .hc opcnlrljl; In .1",
hr:odsoock Ind rIdc:-s on .hrcc be.rinll'l. On O"" I<,k o('M
chuck hul) ,..., mounu:<l /Our .11OjHtWIc: W ..pnI br.odcCl.>.

.0

..' hict1 ......"" """'IlS "r whkh .hr .."OIkpktt Is hckl. Ott
'he ",het >idc;" .u.chcd. 52~O<>Ih hkyclc ctwnrintt
Con.plcllllJt ,h" ch uck ...,mbl) " Ilie
"""",ka. which Is moumnJ on.he jlC">rbox .h.".MI proja:t,; ' hruugh Ihc hnd.... <><."k_Thc
spn>cke" whidt
b ab;o a ch.lnrlnll pi ... . nJ fron, a biL-yek, , ... ",ro,,., "'"
po.o.er rrom.M It<'lrbo" ' o Ih~ chuek .p"",kc, 'il!.st:uId>nl
I>kyt;k ehaln. Th<: ,!>,od", " I~l\"n In II", <.I ... wi"llS na.16
'ttlh. bu, ~ JOI.>d bkyclc >ltop wlll 1.. ,.., a ,.,Ic<."tioII ..
us:lblc cllalnrifts:o. lIy cltam:lng .hi5 "prock" . )'t>U aii """'"'
.h~ (Ii"ancc Ihc ",u'er ' ....-.:1. j><"' ..."OIkpictt ~ulio".
Cun~.",,-~Iun uf .hc ehud In .... I." . somc mclalworI<~'II, whk:h <.m hf 1k:rJ. ... i,1\ .... ~ Ilaek>:l..., )'OIO'"
<.Irill l"".... ~n<.l op lf)'Ol' <Ion '...... nt lu l:ockic il )..........t(
I, -.rul (~hcr me.:tI ~~m'p<>""nlS of.hc "",'e. I>..hc--on
Ix: fobriCl.le<J fo. )'OU br a """'1 nuchi"c snop.
lf)'OU
10 ",., )'uur ro",.". I."h" for ' W"tt!ottt es''''
k>nll won.picc ...... )"U will n""d a _ d chuci< ," kr>.., iIII
a '~llstO<." k . Tl'" 1:tIIstoek muci< tIoc:.n , nccd Ihc sprodIn.
bUl 11 1, Qlllerwlfc dUI'lIca'c of .hc head:!.ock ehud!. y,.
""" makc b".h "hucks ., .M "'m, .1"", . ...hieh is SUtcIj" "'"

)"OU

""n u""' ",'cn ""-",,. - UiI<c p..m.- <III I"'I!" l8.2 pt(>O"IIk>
bIui<: in6:xnu'1on :abQu, blcyl::1c ..".".

tome

I'or "'" chuek $f>roCka.

."

.-...'"c
C

INSIOE VlEW

278

ROUttr

nccd a S2~ooth .....

OVTSIO( VlEW

f.brluted
angll!: I.on

)'OU

,~

...

~ tu M c:l1l,~ <:NinMIL QI" a chal ...

..'bed. F<w ,"" 1ratlJ\"nW ""rockct. )"OU o=l {j).,omh
,.ar. Ind il l.';lO hc: cilhc:. l ch;unwhi ,,, a rfttwhttl. For
alditIoIuI n ' k", 01 ''''bit, loO'ln;1 jl;nl'$ tor Ihe: l",nl\..,rK
~ tlw h:I .., k"f,..". ledh 'NO 46.
'Jbc, ~)'OU ...., tor Ihc: chuck 'r>lUCkct "'III h;a,'~ 10 t""
aoodif"'" In creale: an IIn<ll>:\I""";:lcd 5 IHnch-dl.m~IC'
opmlng IIlSiok 11.1 1001111 Mit ",.,
l:uk it tu "1iC
COI:dpaN of oQmC klod la mari< .he k><.... II"... ni ItIc
"""""Ing<'lC1'CW """"" 11>:11 h...., la hc: drllll.n~ muI M
... ,1Ie <ne: d""""fe",1ICC line !fa .h;a. you l.';lO ~ ... u"' II><:
sprodIct is COO11.ric "i,h Ihc chuek. an .,.,..,nll<ol for
MIIOOth '-'1""'""'10<>. Afle. :ocribinglh.. II"",. ",duce .hc r,td;~
'" "'" rompa.o.s and .ocrihe Ihe Cu, Iinel.
Il"i.b l\3Cks;aw, cu' ,II~ wd>billjj "". or. c""ln",h1
Of' amput:"~ ,h<; mOtlnllng tob. of ch.lnnng_ Dnll II><:
lIIOWllinJI...:n:: .... holo <>n Ihc dnl! pn:!ll.

whld'l """"'" il

n....

2. Lar ou he Iwo d l_k., ror lhe c huck. 'I11oc:

"''O p>'" m: m.ao.k

nu.

ii thc ldal

of me<Jl"m-dcnsi.y fiherbo:;u'd (MOF).

ror ,his p>l"Iicuhr opplic:ulon.

m.,~n.l

CUllinIt 1. ~"CS crisp ~. which , bcco ..... 0I.hc: 01'1...

riaI's dc:ruif)'. w",, ', bc~...... hworddo.fMd byllle ~
..... which 'hc hub <i<k'.Thl> is Of1e;11St>J1tt ...!le:n: subItltUlloo ...... dl..:o""'lI"d.
fktIln b)' CUUII'lll .,,~,
of MDf la .bc dl.....,...
Iion> "f><"'lncoJ hy ,he CU ll lnllLlM. M.ri< .1Ic ccmCl" of C3ch

.".

"'1"""'"

",.. largc <Ilo&: nttds 10 ""'" indcxinllltW!<:5 :odo.kd .0

II>
llul <li,ille 1. In10 24 CII""I liCJI1I""""'. laI'" thoc
il'>da:ln(l n,."'. ' Rc u.cd ",hen rominJl. opir.d tumitlJlS and
In po&ill~ flulel or bo:odI "" a lurning.It. Ctiicit.o Iar
Ibrm 0'" n""".I.h'"'IIh )' K' Ilo", ', JKcd '" ~I l1",m.J"'"
...rI: Ihe ""11"",n", In<klll>ty. I{)'OU"'" 1tC>..". donc k, lum 10
pI$ ilO in LI'" eluple. I ""'..,~Thrnlll.ll Jis; and "'.-.It' th<:
dr.I..1nJIt","X W_t IAIJ'O"I Trlc.1. 1'hl> dr.,,1nt! olt<>w>

row-

how 10 dirilk di>!< InIO 6 or Il ~n", U>ins ' com.pa>

alUJ ruk. Hy carryIng 'bc l'fOCC'i" onc 51.,. furI""". )'O\I an
dl."kIc: ,I>c cbmpitljl disk inlo l~
kp1Io(1l1$.
To compk:l~ ,IM: Iay<>u' oi thc _
......,..,. worl:

cq..w

"'1"""'

fl'Ufll thc ttn.erpo;n, and ,;aibe

~:!i irtchcs an
>kk in thc n,er 01 IIM: pkcc. E>omluallt; this ..1U bc CUI
OUl .0 pcnn1t 1"" """"'plece 'o actu:OIIy ~ throuah ,IM:
chuek Ibdiatltw from Ihc: ce,uerp<>ln' and bhectln& odI
"r .I>c &CtIbcd ""luate', oIdcs, lD3d! lina "" ...nkh Ihc
L-brrlct, W'ilI M pI.ottd.
3. ROUI thC' e huel, d b ks. tnt a pI""lJIC "",ref
cquippctl
u-anund
thb """",.Ion.
U""8 I tiR)" drlU bir. bon: a pnut hok: .hr'O\.lgh odI
<iri th<: drIIl pou6. ThIJ " Imponan' sin ..... hok
..;U hdp )'OU /ItIlhIt ehud<
u..:mhkd ~ ekl>c
10 conC'nurk .. k "i11 bc poooIbIc ' o JIlCI rhcm, l "" ncnl
Ilie hoIIo 10 ho:
ro Ix pnpcndIcuIu .0 .hcc faca, :Ind

"",10

ro.-

"'1"""'

ton,,,,,,,,,n,,,

...,.u.

ro completdy J'<1l"'I"IIC Ihc tQuaR"

lbc lIn' oIohc _
db/I: ion ', critlcal. l{ Illum. oul
ro M an dpnh undrr OI" .,...". 'be ","""",,,, "fIC'drlCd. I!m',
no hiI!; deal. lIu1 Ihcc IaQllel" di5k Ioas .0 bc e" - n, In ,he
hok: lOt k in Ihe /M::I(b1:Qdr.I, 1113)' ho: wonh,,-hllc ro m.
!<:SI cut;! in hanb,wtI OI' Iwnch p/t...-ood 10 Sct up .h~
uammd. Do thio: Set Ihc tr.I.I1UDcI, cut I Ample di5k.lnd fi.
it ,mo ."'" hcadstod! opnUng.
,h<; ,rammcl ... nre.
~. ondcu' _het 'Ql di>.k.Whcn )'OII\" .... hc ..,tur>,

AtI"'"

...,..IhcMOE

"'utJ.

Whm CUluna IM gOOd

"'i<:k thc MI>P 'O """,p
..i lh atpCI tap<:. Thi> ..iU protttl thc ....orI:bcnc;h bcncath
thc WO<'Io:. Ind i, wIIl kttp thc pans rrom .hlftll'lll :Ind Ia"'mInjj " 'hen ,hit 1>1, ""'" through.
AfIn Ihc b"", dlsk is cut,doeck ,1$ fii in thc hc:a<Istoek,
Itcmcfnber ma. Ihc l:Ielrinp
......u m~...,.,.., of
ad",..-f)'. y"" ...aRl Ihc di>.k 10 !Olite f..,.,It, "ilhonl plar
or clutllct. It Ilie di>k b I .!woh ''''' bis, )'OU probahly con
",nil thc mmmci 5cnlfijt and 1ttU. .hcc dbk, Md of
OO<IrK, If thc dbI< 10 .00 ""'.u, ..... 1, an<l
()\ef.

lta,.., "

""1"1

4. Lar o ul Ihe P1QUnling fo r Ili e chtKk

'prockd. Thls "f'n)d:ct , whkll )'O\l p",p>rnlln SI~1' 1, il
IICl'C\Oo'C'd ' o thc ~ dbI<, 0f1 ,hc okk OfIJIOMle Ihc lnda
mar1<injp,n.c ""rock<1 m"" M os cklM: ,,, coneen,,'" wlth
Ihc dWt '" f'O"ioIbIc. SI<Itt )'OII I:ol<! OUt and drilk<llt", ljCJO . .
mounlllli-tC<t:W 1loIcs.)'OU Imow .hc .. dl". o( Ihc .K upon ~
..1tlch 'hcy an:: loo&l~.
lJIinII """ drillcd n"IIlcrpotnl '" phVl,lICribe 1 dn:1I: o( ~
t1w nrdiU!l OII.hc 'ppn:>pri>'" ~ o( ,1Ic bl"f" doudt dbk.

C-l

:a

5 , G l uc:,lamlnate Ihe chuck dl5k!1. GIIK'bc lP..u

di;.k 10 Ihc ~ onc. !>ti,'e

laylnll Oul Ihe Indulng .... rks U.kes u,e,..1 wOrk

w~h, comp;lSS , MlIklnoj )'Gur marit, on the ch1Kk hub
blank wh l!. il's ,dll lquo.e will mih lhe luk i bit
w;.,. and Ihe .esullS mort ilCCII'Ilt.

Ilnbll no.il Ihn.>U&h ''''' ""n,,,,

hule 01 ehc """II dl!ll<. 50 '"" 'Ip p!\Mrudc OII ,I>c <>thcr
sidc. "'ppIy g1uc 'o !hal .-kk ."d 0C1 .loc .n,.11 dl"" omo thc
ta"", """. ""118 Ibc ""li 10 "I~ Ihcm . lJc ... '" )'OU <Ion ',
00>..". thc tQ""'" lald oul Of! .hc OII""IJ d""" and 'NI )'OU
apM' .!le: snulI di>k 'o tho: okk of the Ia'll'" d!>k INI tta. II><:
index
0f1 IL CJan'p Ih~ dl5ks 1"II"lber Ind ~Uow
Ihc: g1"" 'o d'l'.

"""""'II'

Route. Lolhe

279

A nall a lil ns the ehuck d isks during glueup. Drlw

It t~rOu9h tlle piVOt hole In one disk. sprud the glue.
U shown. and J~n Ihem. In,enln9 Ihe rutillnlo Ihe
second disk~ pivol as yo" do.

6. Mai<c Ihe "h u e k dam "". CUI (ou, J>..inch,.,i<k

seetlun. of 2 ~ l( 2 ~ )( %-incit ",,,,,1 ~n~. Wilh """!.:sa,."
IIt .. could IOlle .ou", lime. If).... u h"..: Ihe OPlion.
lhe
~ngk: lron cuI >1 ~ m",~1 $ltop. Whttl )'Ou 1>;0,,,, 'hc faut
pi<x..", Cu, """'n onc c::ncn>ion u( cach '" I Ind>, as .hown
In "'" <lr-.,.,tng Cbrtdt ConslNlCflo ...
1'0". dnll ..,d lap 'hc iJJot1 o.nns fo< !4-ind>-20
'hn:2d, as shu",n n thc dr...... ing.Thc ,"ist-dnU hlls )'Ou "'"
fur "'OOd"'.... r1<lng ..... ;U ~Iso l><IK hoIes in mel:ll; It jusI eokcs
\onJjcr. ([)on 't ~ brAtJ.[JOim Iti ..... Ilttlugh, thcy :ut.'!l'\ h~
spccd ",""1,) A <k,aikd opl;m.o.'iun or 1>0", '" ,"p hule 1.
prtl\'\led In ,hc sectlon 'CUUing Th=d. In Ihe . ppendllt .
~1" .lIr. liriII 11'''0 ",ouminll"';:"""" holo in II", lung
otcnsions nf Ihc (lamI' h ... dtns.

h.,."

7. Com p lete Ih e " h uei<. n", iiI'>! Ihillll is 10 cuI 001

Ihe openlllj(, Ilnll. "'-'1!IiamelCf su.nillj( lIok: Insidc thc
La)'"", lincs. Wilh a .. bt:, ""'''', eu, ou, ,ltc
file "'" cuI
edgn .,. n:C5.Sar)' 10 elcon .nll sqUOI'C lhem.
Ncn. moum Ihe tu:a<l sprockel. Ve.)',
C'O",fully
:!lign th" duinrlng un 'he hUb, cen,erlng.u Ihe muunUnjj
II' hok. m'cr II><: drc'" scribed an the OUl""" of 1hC' La'll"
d;"'lI. When )'Ou\", aligned il jusc ngltl. ,"pc i' dawn ",ilh
. - ~in~ 1''''' u, nusking ,a"".., il C'On ',.hifl,.n<l drill pilot
holn. Re"""", Ilie IOpc, .n<l "')'Oll >C1'l"W Ilie sprockel in
~ p!>ce. sUp collple of
,,';l6hel'll unde< Ihc sprucket a,
cach SCI'l"W.Thc:ic "":1Shcrs will OffSC1'hc sprodtn from 'he
ehock .u provkk: ek:l".nc~ (or tlle """" ehaln.
Now mO\l1l1 lhe ehuek cI. mps . Alilln coelt cl . mp
Ono. lar""l line . d rlll pnOl hole., and au . ell II wi,h
"8 X I' ,Inch p.nhe~d ""rew,. Af' e' .11 (our el. n,p.
are mounted. lurn a roundhca<l SlOI'C bolI Inlo Ihe
Ihre.<led hole ;n ueh ebmp ,
FinotUy, in;u!l tiI< d ud In tlle h<-. .....ock.Adj_ dle ~
lnjI>: as nCOSar)' 10 e""".., goud fiI. 10 ~""P 1"" ehud in
pbcc. lSCn:w fcndcr ,,-asltcrs 1" the hcadstod, just . , thc cdgc
ofthc hok. _!ion cod, "-..tIC,",, il Ju:>o OI",rttps tlle ehud;
t/ttct' ~ lrtM:l!led In 'hill "''''l'. un" ~ ~

"'.ISI".

'''''1

c:

"OI

I-

280

Router Magic

f e nde t wu hef'$ ho ld 'he eh uc k In pl;a{l. Pesltlo"

Inem around Ihe edge of the headwx:k\ ol>l'lIlng,
roughly as shawn. NOle Ihal lhey don\ have 10 projecl
far beyond Ihe edge 10 keep \he chuek In place.

8. 0 11 ti.., . ..... u;ver.oe sprocke . h ub. Wi,h lho:

ehock irt pLau, ,1Ie ne,u e"'l1ICnl 'o nuke '" U,e Iral\".."..
sp"",kcI """"mb!)', II!J noled
Ihis sprockn is ;nl ...
cl>;ongcablc. :Il1owi1lS! )'Ou 1" ehange- lhe distance Ihe IO.UCT
mOI"", pc:r .pindlc revolutlon.TIte hul> for this sprodtn i>
<lc:signed 10 hokl lwo <liffe,clll<ilzc<l .procket . Th ~
gca,..,."" 10 Sf>C'lIk, ).... u IUSl IooKn Ihc sprockcI SC~.
puU Ihe sp1'OCket :asscmb!)' off Ihe gnrtJo~ )!ufl, flip il
arounll. ond re ....... nl II.
Thc """"mbly ren'; ... oI "''O <liff=nl bie}"':'" ...... """"
."rock"'" and a hub.n..:: hub ;. a pic of 5/4 (fi'juorl<T)
Iw\lwOQd, romcd In", ;1. 2 ~inch-l1Wnc1cr rountl ond hortd
"'ilh a ""inch CCtllcrhule. To eeoler Ilte sprock,,!>. Ilte h!b
;" .bouldefcd OII boIh sides. >O a vcry .hon ,lub ''''''''' pn:>
jcCI5 thruugh thc sprudtn 'S hor<:. A~' is ><1 O""' tht
>1 00. thcn s"..,,,,ed 10 1hC' hub.
To m>kc lhe huh.)'011 obviousJy nc:cd 'h"
sprod<u
In hand. ""o,,-ure thc hore <liamC1el') '" . h""" >f>I'I'Ckcu 10
)'Ou know wl>;ol siz< 10 ..... ke Ilie SIUM.klecl > tkernl~
plc o( 514 I>;onlwuo<.l from ",hieh )'OU wil! roul thc h!b
(big " nouglt ' o ""mfO .....blt s uppa" )'uu' l1';l.mmc:~
cqulppcd ptunge rouler). DriJI pi"", huk In IT. burin
eomplC1ely Ihroullh Ilie Slock.
TIte &tubs ar<: forrrtal h!' routln!! cirruIo, 8f00'U
arotInd thc piVOI OII boIh ",-,,,,, of lhe hob slack. Set llIt
tr.unmcl 10 cuI Ih~ t:uljos of IIx- sprockn ""..,. Set lho:
roulcr', plunJ'll' <kpth .,op 10 Ilmil thc rul tk:plh 10
thc sprockn tltlcktK5S (prohab/)' ~ Inch 10 !t. inch). Set tht
pI''''' .nd roul llx: """"'" in Ilie Slock.
Tum Ihe ",odt o,'c' ond r<:pc:11 Ilie pl'OCa6 'o fonn llIt
>e<:onll ..uh.
RaUl Ihe hub """1 . ROCI Ihe Ir.mmel 10 a JI-.lndl
t:ulius ond 'Ilc plu<lgt: dep'h "'OI> 10 l ~. ioehat (so )...... OiI
ru. oomplc.ely thro<q;h II><: Slodt). R~ .... ,lte ttamn,el pi>u
In lhe san,e pi''''' hole in Ihc OIock, ~nd p ... b)' P"'6-"""
complC1ely IhrouSh Ilie ",ack. "I1';3,lnll .hc rollnd hub.

.txw.;,.

' ' ':>

HUIDETAILS

SI~ boII

TI\ANSVERS( SPROCKET ASSEMBlY

OII_'e' of

:::ketA~
'
W-di.&. bo,e fo,

Th.uded IMeni \ :
.p,ocke. A

Pilot I\oie
for Insen

gllrbox .h.l.ft
~

Sproc:ke. A

TtNSlONER SPROCKE'T ASSEMBLY

Hub

Sjlrocke. I

l\(' d~
l,~" frH.w~HI .p.oeke.

\('-dl.&. bon
ro. moun. ln; boii

CAANK ASSEMBLY

K'odI.&.

" ' XI'

bo~

ro. gfJtbox sh.l.ft

l"'di'.@

9. CO'''plrle the ~ prock"" assembly. llIrtt ~

....wn h~""drillirJ!. out.1K ""'" "" 1"" h"b will 61 "" IIK
pbox s/Uf' . in.\ t::IlU,. .1Ie ~. and rnoun.ing th<
~ . Do 1"" I""k. In 1"'" _
.
AI Ihc driD ~. hun: I J;.<n,ch-diamCU'r hoIo Ihrough
"'" hub. cmlef'l'd Qn ,tw: pi'o'Ol. hok
Stand ,IK hul> ... edgr-)VU """ elim" 1, In I lwMI
M"~" 10 k~cp li r....... .olUng-Inu ddll a ,,1l"1 hOle
lor ,he In,.,,, . pencor'IJ'nll Ihe cdge InUl Ihe hub&
_ om-c .hc .... lnc .... 20 in.,:n lnln 1"" hok And h.,re'. ~
Iitlk ~p : Tbc: h... b a $dUIl 1'1""" uf ...'00<1. 1b _
""..u.,;

1n<tr1,.,u, h , ~ th< pilot ""It largc enougll tlw tM

Ot\m', Ihn.-adi an 'l bite '00 dttp. Apply >CI"'" cpoxy 10
.... in11, ,hen
II In,o pba.
W'hcn )"OU inmJllhc .pmd<ct """"1>Ir on "'" JII<'lmox
5h1ft. )"OU an drn" I l'Qur>tIhc'>d SI"'''' boii: [n,o th< inKn
:and tIgh,m II "fPlnSI11Ie Ihl flk<! "" ,"" ohafi. oh... 1ocIIlng
"'" 5pR><"ket "" lloc Ihaft.
Fin:l1Iy. moun 1Ie sprod<cu. A. """' ......,.. Iu Slut>. an<!
okM '" ( OOple ....... 11 """"'''' InlO lloc 5Qm bct ..cm lloc
.n.tI and th< WQOd. TUrn 1"" hul> "'''''. and moun hc
~ in th< . . - .-zy.
tht

,u"". boiI

13'100' h
frHwtlHI

.~l

'P.oc~ o
"''<''',rude<! Insen

...... In 11'" hnds!ock, I<kl )'1:1 IrIOIhcr ..~hc:t, !hen ~

mcul ..lnS <lui .
Tbc: 1dIc:. I!I. dupll","" 01 'loc I~. bul IlS ntl<: S
d;fkmu, Ind i, .. oucd only occasIonalJy 1t)"OU nd 10 """
Ilie """"Ict" gnr OII IM 1r.u>s'"CNC _proo::kcf.,....lI.n..ro...".
)OU h.." an ""cu. 01 dl:un. 'I'h .. )'O" do .. non oh<: duIn
Ionp <IV':. Ibc: Idlrr, whlcb )"OU poIoiIlon 10 tal<c: up _
01
Ilie Jbek. You IMIII U!oC thc: Icn>oIuncr 10 taI<c up IM Iast bil

......

Tbc: Idkr Il mounled In """ <>flile ~ 01......." you

drillctl Ih"""'" th< qwdr;I.nl of 'M hn<btot:k ahc:n"C 'loc
prI>o ... ~ .

d"'"

10. " UilaU tbc hrad c haln IerulIo .. c r anei Idlrr.

A tmtIoner 1 dnice 1""1 odjusu 1.hc ;bck In Ilie """In
ioop. In thl> Cb( , ,he IlCIdSIoek ' cnsioncr il '" II6-ln<:h
borIns....no.." ....... n'ln" boii passo thl'Ollgh '" .0loi.. 1'hc
eboIn pa."""" "'..". th< lxarinl., and by ad(USl11l3 Ilie lxari""
pOIIidon. J"lu an ah"" ,1Ie _
Ioop., obck.
Thc borin8 u:.cd 1, IM ~ as lbo:!c 111;01 5UPP<l" Ihc
dIudo. M ..ilh ,''''''' i)<:arings. }'OU nttd ~ ...-.:tOI.kn ~'e .
OII IIoMnch ha../lnd boIl,sw:Io fiii
th< lInring
arid 11>.... and anochcr ..-:uhcr. 1"""" ,'''' bolt IhtOU,lh 1.hc

,,-:uMr.

In.Ullllnlj t tl. hu d etllin tlkts onIv '" minute. Cateh ~

hw lin'" OII (OOi of ba'" OprtlCk.lS, lhen puii "'" c.... in
slowly 00 bottl iptOC!tets m<M!. seltiln; IIM dlIln InIO
plIn. TMn adJu .. th~ len.loM. 10 tab up Ilie ,IHI<.

Route.

la, ~t

28 1

Bike Parts
8I<\'i:1e I/Nn <Inci (ha," "!'! .s.el!el!d fOi tll,s
b!cauu IMy.", ."",Iiobt. almo11 ~hw!;
IMy .,e "'Iiouvely 'M'pensrve, tipoK .. Uy ,f pur<II.1H<!
.. s!d; IMy prtlV>l1t il ,a"Of! of lIt'at m,os; .nd tlltv.",
d",.bl . ~ onlV d" ... back to \lS'~ Ihtse P-l'lS 111:111
Un IlI,nk of 's IlIilllley are un'amlt .. r tO _
..00<1.
",o,k" .
Htre ,re tlle bules of ",hll you nd 10 ~now. Ask
Ihe mtchanle II the blke dlOP ... h"e VOit bllY the
~rts to Clifify anyth'r'Ijj VOU don' "ndtmand. upe
c'lUv u.(Uy Ilo .. 10 bruk tlle (Ilaln. Ali l'Ou nud 10
do tII,. lo.n ,nupensive d""iu call!d a e"',n 1001
Ltt mt Slin ... ,tII IM w,n. You nttd ibolll 11
fetl of" 111000etlltr. sa OM olel b,ke .. on' votld
enougll fo< Ilie p'OJe<:I. Thtre.", 10'0 birsoc .. idlhs
B"'~ al'\Cllll OM' Ind tII._spHd b'kts U~ ~Inc:h
cll.1,". TII,s IS "''''1 '*e llsed. Dtfaltleu, blku. thost
~

""th ttll spMds.f\d liP. use 1I.. ,neh ehl,n. )'ou UI~
Ils.' tJ't~, ..,d!". but m.h suti! 111.11 ,IIIM cll.1", you
g,tl is tit"", OIle Wlclth or Ilie OIhe,.
&/cy<:1.. 1uve I ~aflffl of spiockeu or oun. You
nud bolII free ... lleel oprochts, whreh .... mounted 10
Ih~ b;k,~ ",~r wh!et. ;Ind th~,n .. hHI lor th;llnnngl
sp!ocktts. wheth .", lluoehfl! to Ilie pedils.
T"" I.lhe~ Idle. Ind 'rink ~p'lXkeI5'''' b,,~le
fruwlleel oeall. On Ihe Ilnhe. bolh oflhne sprockeu
mu.t b! Ilie urne Slle. w,th Ihe urne numb.e. of
tUlh. Wt u.ed 13'lootll SP!lXkets. but freewhttl
ours .... n~e from 12 lteth up 10 34 t~elh. L.arge
d,a_ter sprockets m.y ge, In 'fOII' ".Y. $O sltek w,tII
S....
onel. 8..1 elon' fuI Ior;k!d tnlO Ilie 13tOOlh
slZe. JUOI oet 1.. 0 Ihe Urne.
~ OIhe. sprocktts "'t (hi,n ... httl, or cll.1.n
ringo. On il bocy<:le. Ih II , ... bto sprocket at lhe
petlaJs. TIIe dlffe",nee bt{wttn ,hil,nwhulo Inci
cll.1,nflfl9S sl>ould b! tllldenl from Iht Milmes: One iS a
loothed ... IIHI. Ilie olhe tootllfll MII Usuafly...
cllillnwhetl" used OM 8"'X In<! OIle' .nd tllree"pttd
b,(.,.des. wh"lI"'ve il s,ngle sp/lXketll Ihe ped.ilo.
The (h~.nrmll'" found OM blC\'i:les .. ,tII ten Or mOft
spuds. as Ihese 11.1"" two o. th'te ,p'lXkets al Ilie
Pl'dil' . The.e sp,ockets 'inge .n ttu from 24 tutll
up to 56 teelll.
Our boi'e StlUp UItO I 52'1001h!INf an Ihl!
chuek. ind. 46'IOOIh \/tu &nd il 32-t001h gur on Ilie
t.."sverse sProcktl. AU e chlo,n ... lIHlo. The ch n
... hHI used IOf It.. cII",. sprockrt hiS Ilie webbtng
Cu\ OUI.nd hlts _nllng,,,,,t... hoIto dnlltd '" 11

,Ie.

.-c'"

.
C

Ilcyde cJQllI Is eul' to "brNk. ~ If \'OU U~ Iht

n.. dIa,n is ~ liP oIlfnks I"'t lte
(onnecled 10 tiCIl ottot, wltll plaIes Ind pins. To
""b~ak . ehaln Ioop. yo<I use I eha ln tool lto,l to pusll
tht pin OUl of. hnk. bul IlOl corn""'tely 'M of llIt
pIiote Whtn dont eorrectly. Ilie pin wlO projtcl rrom
tht OUlolcle of tht pl.lt n<! you ..... 11 b! able 10 puII
tlle link fti!e (boflom). (Bt Citi!ful: It you push Ilie pin
III tht ... IY OUl, you .. 00' b! able ta gel n baek In .)
YOU'U Qulckly SU IIow usy It is 10 .dd and ",move
IInk l to make up the speeifoc lenOlh of ehaln l'Ou need .
COff'KI 1001.

212

Roul" "'.Ole

licyel.. sprodc..u ce..... I ~ m.ny olZes ind eonfigu

.... Iions. Uit ell.1innng. whk:h II.1s mounling tlbs
but not wtbll;ng (/owu Ifftl. Of il t h.ln",lIHl. wllkh
hu ... tbblng Ceelllu!. for Ilie cll",k sprockel anei for
Iht tr.~sve.se sprocktt. (AI upper lefl Is .. ell.1ln
... hul wlth Ihe wtbblng ( UI out.) Fftewheel gurs
(rill'"!) can b.e IISed for Ilie Idler an<! "ank sprlXktt.
ilO wel! u tIIe I .... nsverst Ip.ockel.

Il. lnsta.Il thc c:bain. Ao ...-i. coc Iache ~!IWI<brd

bIqck dlaill. Wh;oc JVU
do _
is n",", up a duin eluc
.:an bo- Ioopo<d around bodI ~ on cbt hn<...oct
Oon'c m>Jr~ II a cil!bc flc: JVU ~,......, >bck. ond cbt ,,",oune
oi >bod; can hc: adj.1SlCd using thc: ch;tin II:n!iIJnCf.Tk dI2iD
<In III)' b.hc: 1< obotn 44 in<"too;::s kqc.
WhnI J'U'l ""," lhe dWn m;odc up. In!t:IU k OII che
~ ,\bk~......, tII.. ch.Un lUI\!> "'"lT lUp oi clle 'cn!iIonc:r.

III""

l~nsior><-t

PIIfIclO<l 10 III'" )"OU chc: rigIIc

1IDOWIt of:N3dL l"ou do ncro JOOlC !J~ck; If toc chlln I!i 100
...... thc ~ oi chc a>ICmhIy ... \lI bc jcrk)' ~ml
~ y"" ..,.,.. thc 5prVd<ns '0 lum .w>OOt1tly and qwc~
&ttt,o.TlfIII"'" chc win8 n .. co lod< chc: ..............
.1Ie

Building Ihe Rouler Sied Assembly

ThC" I!kd ~ Ihc: ..... ,.". 1. 0I0d0 bx:I! _ tonle aIon8 "
hH.,. ~""I ..tWt mounlc:d !il .iM- f" ... oi" Ilie bCIle . .."hik foi.
Ioooi"ll" CCll1pl:OI" cbmpcd 10 clle bllle', _ .T1>c .cmpbte
(i)tI."", dku.es.ln J"Il1 , .1Ie .IoN.It oi thc "fIIIIoolk """ lOC
"""n C1IlJ . . it n""..,. fn .... OIte~"fld of chc: .pindle \O tllt
ochn". Tk )Ied S d ...1!IICd On II) ft ... rncy by " ehaln Ioop
m.c e:'cntb (n.>m chc c nnk II .Ie~ 1I,,.<h!ock lo.n klicr"1
thr caii ... ppon.
"1IiIc thc oIcd Itxl! is oill1p/y" plywood rttl"'ljllc CO
..tIidI thc: tQutn is ~ cbt .ppano.... tlw CUltI"'" i!oi
--..mmt is......,., complex'''''' ICIUibic C~IO....,. b to
......, ond iooulI COC ch;ttn <Iri,'c ~ 0iI""'. chen IJl:lkc Ihc sIcd.
iti; l'Ji<l1n<"<: f}~""' . _ cbt cbmp .."up th;>. connU le ' o
~du.Jn.

1. Ma.,,;: thc ! prockct hu bol. Thc: dm" duin .,-.cem

10. )impic ""'p. wi,lI .1Ie ehaln runninJI
1"'" ."rod:e!oi.
IIoIh thc Cr.Ink .,,1"0<.1< ... . " 'hleh ts mounlcd CO Ilie lIC~rbo" .
.al thc: kIIcr. IoeIlcd a' llee ... 11 end o( Ilte bth~ . an:: kknri<:lL 'au lXCd.wo I ~ Of I ~ooth (""""heel 'procI<"'~ .00

"'''f

'''c

''''''' Wt>O<lcn h"bI!.

1\.lnch-diltmcter huhs an: JhouI.
dtrcd to .\\:.ot .1Ie ."n>Ck<1 <:m drop .,...". a 1!.lncll
di:&m<1cr$IuI> .."d ~t :ag;>1n>!. hub body.(N04e Ih.t )'OU "\:It'

""'" co modIfy lloc iluI> 5pca tom.,,'''''''c

." """"(............ 1"

thc particulu ~ )'OU U$C.) Thc hubol ~~ CuI (rom
lI-indHhId Iw-dwwd OiIod< "ilh your 1- fam..il.i:lt
trammckqulppcd pi...., ruw.cr.
x\ccl ..
oi \urdo1"OOd C""I It bia C"nOUIh ,,, SlIpp<>rI tloc tOU,er _lramn>eI a:.)'OU wurt:. 5ttlch OUl " 'hc:n:
Ih.. huli!; wiIJ Ix CUI. tllm drill a pk"Ol hoIc IhlOOlth tM
OIock In Ihc: """' ''' o( each spoc. Stldc lOC """"" ,,, on1i>
both '0 ptol"'" tlle ..""'hc:nc:b :and 10 I<cep 1"" 11111> (rom
ohlftlnll" thc: cut \s compl<1c:d.
I\otIt Ihc: ,;cub scction f1rst . xC lloc Ir~mmc l '0 cu' a
lHnch D<lIuo,ond.." thc ruucer"' plu"!!" Ikpl h ..Of! ,n Ilmi,
thc: C\II <kptll to li 1Dch. Srt thc: pMM ...,d mut .. drrul..
8f'X/"" In the $Iod< al ndi >pOt.
Rcxt Ihc: 'nmrnd
' ",,"Inch radI ... :and.hc: plunl!l"
dC'pth ~Of! to '\o, 1Ddo. to )'OU cat! cuC COIIIpI<1c1y through
lOC $Ied. 'ou' OUt thC" .....o hubi.
FIn2lIy, """" OUt thc: p/>"OI bok In cach lIub. thc: kIcr '"
\o.inch dbm<1er. tM CftItlc hub '" ~ diam<1."

'*""'

'0"

2. Mak" ti", e .... nl<. SUn by CUlIIII3 and lIh:aping Ihc

pl3le . .. ohown In Ihc: <Ir.wtna /lublNlula . DrtD_
l..... ne,nllnk .. ~Inch 00'" ., onc cnd for mo"ncing .. knob.
_ <!riu .. ~ hoIc ac Ihc: 0100 for ' hc I!I""rbo"~
G"", thc oppruprialc: WOI)I\<1t lelll> ' o Ihe crank pb.e.
in>cr1. '-'neh bolt tllrough chc hoIc In thc Cr.Ink pl:uc:utd
Into thc 11111>'......., 10 aIiIIn Ihc 1_ partli during g\UC-Up
~ ltI'" )'OU orien. thc: hub conocnIy, .. _ n in Ihc:
........hlll.Aftcr thc: si'" ..... drinl. and "'" cdp:s.
cr~nk

NcQ. ~"11=adC1I1rucn Iorthc~. " Io,.inch

~ "'''''' bolt Is UKd for .. ~, 1iO J'U'l ...,.,... ' 0

,""' .. ;...w:h-20 m.cn. 8of'C I pilot oItoc appropn.le_
ctcr for tloe in>Crt. <lrillintllnlo thc:,;cam bCf,"CC1l chc cr.mk
pblc and thc: huli ""d ""I!i~ thc: hok In.o chc """'''' 0/
tlle hub ",-,"",. ILpp/y cPQX)" to <lte th rndcd 1n>Cr1 ... ml dm"
k Inco cioc hoIc.llocn turn Ihe sn""n::W Inlo Ilie inscn.
FirWly, ~."" p~k I<nob on tlle eranlt.

3. Epoxy the ~prockctli II) the 11111>5. The

an: bo<lIkd tO thc: lIubs "'kll cpo~y. oM", .. 5rTI:IJ1
amount oi
adhoh" and appIy k to coc ohouI<Icno oi thc
ilubf. Fi' .. SJm>dct "'..". chc ,;cubolndl hul> _ ont il In
t"" q>OX)".TryIO bo- ne>t .oICOUI"IC. Sn thc: ~:ooidI:"
>II Il"')" """, 't be <Ib.ourbe<l ...!tlk "'" CPOX)" cutft.
~

o
10uIIIII th. a prockel hubs Is il lWo-slep u5k.
Wilil a Ifimmel equ,pped plu~e "'ilie'. CuI Ilie
,mallerdlamele' cl,cle. form lng tile ~tud ""e' whkh
tht .p,ocktt Ilts. Tilen resec Iile l,amm!1 11>(\ 'OUl Ilie
diameler. (utMg the hub Irte 01 tlle Slock.

li"",

th"

k>."',

4. Mal<" ti", I" ....

body. Tbc tcmioncr It Ihcc
n"", ... for WtlIIJ! tip the ~Iack In the)led dWn. Whc:n tIM:
ccnsiO<l ti b:ockcd oIf .,..,.,.plecd y. Ihe c""ln k>op ",iti IM:
..,..,.11 <1"KIUjt/l 1""1 J'U'l ean "''''''''c it (tOm IIM: 5proc1<cu.
Tbi> """"'bIy ~ oi tlte klIcr ""rud:~C (",hk:1I It""
~. bem ....,..,). tlte ccwloncr body on whleh clle Idkr
io
pi\"oI
an adj_nt boIt.Tk body bi
" .......... Icng!h of OiIccI "ngIor.
Cut tOC Oile'" anpc \O 1"" Icng!h $pCciI"ocd
clle
lI ...dw;..~ list.

_.ed, .

boI',_

tor

1t0Ule, lat....

283

TENSIONER CONST1tUCTIOfrf

\.(,"20 wlng nul

)4"20 hu

Auembllo a nd In5l.al1 ,he si" chaln ' . n,!-on ,

wflleh polvcns on IM mounling se.ew II Ihe botlom of
its "'IIlelfO/I boeIy. Aher .he sle<! ch.ln li lnSIlIIe<!.
turn IM .dJust_nl "'''',.. (ritJoIIIl 10 .Ite. tM 'ngle of
Ilie leflslon".nd thus IM deg"" of sti"k IfI IM
,,"'-In loopo.

"o,

pivot away fn .... Ilie pble.TIghlCf\lnlj III<: ..'IRI! nUl:oplnst

tht . rnoIor\tr booIl Jocb ,li<: adJU>l1l'ocn.,r.:w p05llion.

' rL~laU the crank. '''15 Is CU)' lIadc OUl tho

10 allo:rw !hc: ~ 10 M 5Iippn! O)nlO tho
~ ~ luni......... o( lhc front o( 1"" JIIIn'bOL Unt "P
"'" ~ .....,.. 1"" fbl filcd 1N0 1"" ....11. and tW>tao

6.

lICUCn::W " " " " ' "

' Y>")( 1y>")( \oii"

1"" .cn::w

sl.,.,llIngle

I-"t' out ami drill ~ino:IH;Ii:arncte< hoIc: rut llle: p>'QC

boIl. lbc<I ..,. ..... ami dtW _
rut 'Ile: \dICf .......... 11 .... bob
anii lor rn.. -.ltoutmmr boIL Both lhot _
mll>C hor
.. ppaJ wilh 1<Hndt-20 Ihm>ds. The hok:f )'OU driU. tha'tIi>r<:. mu~ hc ' . . Inch In dlamne . Ux a up 10 C\A rn..
Ihrn<b.

CII

.-...c
C

5. Mscn>ble llnd lm;taU Ilte 1" " 5Ion<;:r . ~lrst.

irucn tht piWII bolI In." i", hoIc: in ,...,
00dy, IMn
tmen il llvoujd'l lhc moun\IIA hoIc: in 'M mu'e< b .hc
tron'. Soxun:: wlth a W";\Sher and ....... ~20 hc::o nUlS. Lod< 'hc
n.... apin>t ndI Othc<" wht:n tht .o1op bas bl"tn "",,en OUl
0("", piWII"' fii .

,,,nsIoo;>M.

Nea Dch .hc k1Icr. 1rum ~ >100'<: bolt

through thc Idkr. and t,,", ~ In." "'" aJ>ll"OPflale hoIc: In rn..
body. Srol Ilie holt. 11Im ' - i ; II uff. 1Wf~urn OI"
!ilO. alIowilllllhc kIIc:. 10 spin fn::<:Iy wllh,>UI r;kkpby.'Tl'ue>d
a har ou. " " Iu llle: hoII an<! ;am ~ "3"i ...... III<: ~ uf,"e ,,, ...
:si<>nCf body, IhUl .,..,.'t:IlIlng rn.. boiI front It>oo:rnln".
Fin:l1ly.1hn::ad metal willll nul
ItIOIhu .. "'~ hoIl.
"" shooon In "'" dr.owillll T~ Cmtslntlo,., and .urn

.cru.Ione.

-.1,....'" "'*

u"'"

1"""""""

"'" bolt Imo ,""

In "'"
body. The
boiI wW contx'I lhc ....w plate ",txhc:d 10 Ilie W1 ""P'
port. oU )'OU Iurn Il further. k ... il! Ino-tt llle: lC'rISioonc to

284

~ou\e.

Mi gle

7. Ins lall lhe e haln. ,,,,, ~ CMln b ~

bicydc cMln. M>.ke up dlaln l hal Ioops comfonabiJ'
.........,.;1 boIh .1Ie cnnk sprod<'" anii 'hc Idle . ..-i,1I , modat
amo..... ol..-. If)'OU an III le ""'" ehco ~prockns without
1DO"I... oncor "'" othcr eo ........ 1I InIopb,)'OO mar ......
a llnI: (or more) 100 nunr In Ihc 1oop. 1 1lnd lhae 1 00:110
/Il "'" chain onltl !hc: kIkr, Ihm """ I _ _cd on I " "
o( e"," cnnlt .,-.mdct anei gIvt- IiM: cnnk a e..... 10 <arry!lor
eha!n fully 0010 ebal Sf"'>Ctn. Whcn It III In pb. thtr< il
"""'" I<!adc.
tlte liled part:!I. '1"" Mcd Il6Clf b ~ pty..'OOd
15 mowt.nl on CI><: l'kO sh2fI via l>n.>rtH lkM
Inp eha! an:: U':Ipped hct~iftn ..'<>lIOkn ~ b60cb
attaehnl to ehc undrn;idc olelle okO. Aho lnpped 00.......
!hot hu6I\lnJt bIods an:: ."", othcr bu5hIn8 bIod<$ ttw :wt
I.tachnl to a damp tItvItt. 1'hiJ damp Iinb thc _

8. Cui

~ . It

.-mbly 10 ehc tIm1: dum. OIeck OUl e"," drn-ina SIN

""$1,,,,,/19':III II\i:I 15 more """pic: chan II 1IOUIlds.

!kgln nuldng "'" ...,d .-,mbly by ru'lin8 "'" J>"fQ.

,,,,, """" tu.c, ehe cbmp b;ae.and III<: hu>hlng bIocb b"'" >kd can Ix eu' 10 Ihc dln>cnslons JpCCifktJ br 1!It
c..Il1"fl u... To nt1kc It n.skr 10 """' and .... pc Ihc omalkr
oo.hin3 bIocb (u..- fur Ihc cbmp). It b best 10 CUII
>ulPc plece olJw.:h pty..'und 10 l-k Indlao by.Sly. 8to Il
inchc:f b boch bIo<:b ForulIy, .o ..w:c 1. sakt 'o ~

obt damp

barIl'M>od

""''J,yoo
la

koc:tIQ lOt bolh

$h.ould CUI IIIngic ~ oi

1I'kllh oi ~ Ilo ln<:tIo ..... a

JiI..inch

kfI8lb oi 6

10 8

lawa,

9. Orill Iilc bt.L.hlng blocks. Each bushi,. hIoc:k,

.r1>nIIott il bc: lOt .1\(: ,;,It:oJ <K for "'" daInp, /Ua lhouIdcm:I
""'-'.lbc thtoutIh lIok II 1" inchQ In dIaInnn, .... pn.wi<k
plmcy oi elco.r;l.no:e for

.1\(: 1 ~nd>di1mc:lcr

>Ied .n..tt 'M'

atntd> lhtuugh 0.11 .I ~ bIocb. I'or .wo-ohIn.Ie oi lu

\cnIlh. ca<:h ~ '" opmcd up 10 I ~ dlamctcr.
Thi5 i5 10 accommo<blC !hc: bnJn:r;c ~ ... tudt a", 'he
belrings that nw.:c ""',.,.,.",bIy.utk,;mootl1ly ..... (,"It'

... Ibc: MW'I.

lbc SIcli ~ drowing indic:uc:s """" 'bc: ' hn:<:
btMlnjp an: deployN. o.,., .. Inscmd in the kfI >k:d
btMIlI3 blod... ..... OM In "'" rl&h'.)u:oI Oltlng bmo.'ttn .hc
frtt enob o( .hac buohlnjp Os thc cbmp subo.ssernbly.
"hiel. '''''' .hc .hin! buohins lnJ'P<"d "".Wttn iu ...-0
buohlng bIoeb
In my '-'Illnlon, Ibc: _
accura'e :ond .roub!<:(rtt
.pp!"ICh tii drilllllll'hac hoIcI b 10 . btu In Ibc:
I/riU Pn::M. Wbc:n I m:adc ...,. Nod<.'. I poo;ltlnncd bIock on
tMdriU p<r:t> W*,cWnpN il oJooom, driIkd lh" ~
~cr, ~ hok. lhen ~ehal bi...nd ,:omplrtcd
dlC bon: ,..;u, thc ~ bir. AI'~ 1. In""",c otni bi'
dwIgIng.lhIs.pproxh '"""""" !ha, 'bc:
h,-*- In: con<:m'ri<:. ArId ttw'. impon:o.m. Uilllll fencc en..,,,," lhal Ibc:
~ in Iikc bIo<:l<:s ,,10 "" c:onsistcntly poooIlIor'N;d.
I'>y ~ .llentlon hcn:. You ha,oe 10 bon: ,1Ie >Ied
buoI!iniI bIo<:l<:s in ......h. "7)' IM. )'Ou cod up ",ith kfI
_ ........ NOI' ..." idcn.;cal 1>Iod<>. I ali,nc<I "'" hoIcI in
.... bIodItn rdatlon ta "'" ''-'Il ~.

foh["".

'...-o

au~m~

Shnd 1"," dwoin ckmp bas. on Mlp '0

I.
T.~ a bronu MII!ng bel""i!~n .1Ie IJ.\oshlng bIoc.ks.
applv ...1.... 10 11lei. bOllom edgu. and damp lhem 10
lhe bue. iS shown. Then dflll pilot hoIt!s aM drlve doy.
waU ~ws lhrough 1'" ~ Inlo ueh bushl..... bioo::k.
Fccd "'" Iruo:n buo thc hok. as if i, _
drill bio. . ..... 'uni
thc chucIt by band. Oncc: thc lIIscrt Is "'dI >Cancd buo .bc:
wood. ~ It from Ihe chuck and rUlbl! driyil1ll
thc;n,cn ...ilh a ... ",nch.Thcn ,,*, ...-o ... rm.d>Q 'O ""jam
lloc nUb,:and lum IiM: boii ""1 oi the In>crt..
tn.t.:dI.1oc l:IIMilla bIocb """'. Jam onc on cither cnd
oi onc oi thc I:won bu!lhin3>t. Gl"" :and 0iCfnI' "'" damp
l:Iouc: la 1"" botl""'" ar 1"" bu>ItI,. bIocb..

la..... TItt damp jn\':li ....,

plneh .bc: dlaln !hal Iti Ioopcd ......... thc bthc:
frono.lbc chaItt p;HCS '111'11Uj1:h a ~ ~ ""o.hc undcr...., ar .bc: law. Wl..,n .h~ ;o'" b. ~, ti.., chain """""
~ lhrough .bc: groovc: anei IIM: >Ied docsn', """..,. Du.
whcn ."" la'" ...1ghlCllcd., il jam> "'" chaln wtnso 'loc
cbmp ~.:u>d ti", >Ied "-"'<1I'bIy lIP<b dr.1IMO<l :tkM~ 11t"
>Ied sJWt by .1Ie dlaIn.
10 makc thc i'wa, mal<c " ...-rb oi ....... OII Ihe LOh'"
.. w . ... lng 'bc: mi,.". 11'.... 10 """Iroi IiM: cuu. Makc ,IK
CUI5 in a ~"'""" <n;;ni:r;cd ..-orI<p;.o,c.;, wltkh )'OU "'" do,,'n
'" Ihe An.aI ....,.In tho: JItOC1'>"'.
Cu. .Ioc d1aln J!tOO"l' 1inI. Set Ilie bLu.Ic heW>' 10 . ,
!1. lneb, and rnaIu: thc r..... puo ,. incit frum "'" bun cnd 01 : .
.hc ..-orI<plea ()'ou"""" ' " ~ ~ Ibc: grAln). ShlR thc ::::1
,,-orI<plea 10 tiM: right anii mal<c &econd pOM, If fICttMarT CII
'o xh""oe Ihe _........., 'lllidtll, nukc a .hln! PUJ.
I'or thc nat CUI. Iowa lloc hbdc \<, lneh . Ad{U>I Ihc:
worI<p;ca: poiSiUon, anii CUI 'ht IIhouklc:. 01 .h" doubk
12. Cui Ihc cbmp

~ 'O

10. Shap" lbc btuhlng bloc ..... WhiIc "'" :!kd'.

......... I*x:tt> could bc kR "'IlI.1,..,...,w, thC}' koo/r: beti.". il"
J'OU tol""" Of mrt.our lbc: """om cdgtao. as Indtalccl n.1Ie
drJ'NinI. lbc <:DO;t $h:IJ)C o( Ilie CO"'OUt bn'l lIw. l1li1'0"WII. Slmply by oul. 1I..., IMi CU, 10 It OII IiM: band "" ... OI"
..idI sohtr ,,",..

lbc domp bu.hlng l>Iocb LX) nccd 10 h:noe thc cxpotcd

comcrs roundcd olf. '" Indicatcd in thc "'-inl.b tho: okd

er..n..

o:> ""'" "'" ~ r:tnJ!l' of molion.

thc bIodI
...., obt ~ picco. thc:n wJ)C the ~lbc joii an bc
......, OI Ihc band _
(lor on swio<ury lOlndct.

II. Mscmblc thc ch;oin cbmp basc. lbc d.unp

pom $IU1.o bc "",de an:: Ihc ~ ..... twO p,..".
Sun wl.II ...,~ . Dtili "'" hok ro. Ihe thn:aded rod,

.......

>hown 1" .he 'Ibp \ 'koI>--<l<omp oi tiM: Skd AsHmbi)'

AfIer }'\M," oe drilk:d IIK hoIoo . ..... bcfon: )'OU undamp
dlC p:1tI In ..... bc: drill p""'" W*. """ .hc mac:hinc 10 hcip
fOII drl,~ I "-tncb.20 lhtn<kd ",""n buo "'" hok. U"" a
1I-Ir>Ch boiI "'ilh twO nul> jammccl 1....00 OII II. Thrn<l
lhc: in",..
' loc boh , rlght; up 10 .hc nu ... Chucl< .he boiI
ilI lbc: drill .,..,.... OON'T lurn Ihc mxItlno> 011, 111'" .. I lwIdpo....,rW OflC1"lion Whal Ihc onxf"tl"" <.Ioc:s b hclp )'OU
tetp .hc Inscn pnpc::ndkuW 'O "'" ",orI<plt(:c turbe"

""'u

,,-1

n""".

Now k),o.'CO' Ihc bbo.Ic " ""...,.". 'ime.1IO Ihc: CUI <.Iq>th b

ortIy " iIIdI._~ t _ Of 1lIm: ~ 10 form .1Ie ~

wldc:. ~ nbbct.
L_~
Ta eompklc thc j:lw's sh.apc. crank thc: hladc up 10"
hci8h1 oii" Incha. .... "'.., thc flp ~ 10 \\ilhln It Inch al
IiM: bbdc Stand lloc ..-orI<pic:c<: on cnd. Wlh IIK uncul ba
~

thc kntt. ~b.Iu: one p"'"

ROUler Llthto

28S

-..

Now lip Ifle .rorItpkc:t iri two. tlle-n CI'OHC\OI tht

j:o..., rrom tht WUI~. finali)'. drill a mountlnlt ""'" th ......

13. _mblc tM akd. 1)0 thc dLaift daaop

~ 1Int. 1\orn a 2~
o( tl\mldltd IOd
throutsh the ttuuelrd - . , .. II"" an eqUlloi ~ PfO"
0<1 ndI ba 01 tbr cbmp blK. AppIy. """ dropo
oIloctil .. 10 tbo: rod. thr - . , 10 "JIuc" il In 1"'*Now 6Iip damp ..... 00'a" tbo: tbmdnt rod oa ..
..... nlblf. top. add a fbI ~ "'"' rum a ongII pbotit
knob onto tbo: rod.1\orn thr _ 00'a" and ln>uII the tm:lftd

t_

formh.g Ih. dlal" damp ~'" 1 tabl ........

openotloft. AftH mlklng IleriU of crou~n kerh.
.und Ilie workplece on end and rip aWI, Ilie lut biI$
of WI.It. kaUle tlle Individual j.Iow~ aN ~maII. it I~
y~r to INke the CUt1 on an oyenlzed -'<p!e<e...t
then ttlm Ilie two j.Iow' from M.

'*"

damp ; -.
.,.... driII t .... mutcr hit ~ ......, tivtJoCh tht
>Ied bue. as .".,.... Ia thr R>p .~ o( ti>< !iIM
M$t'mbly ......~
Cut ~ lmtIIlI 01 ......... drrokId c:onduk ....
orrva ... Iht t~ 5Ao;Nt.. and driII hob .". lIIt
lIIOO.01IintII K'I'<"WL Scribt: 11.0110.., ~ thc boor. ni
........ nt Ilie- """""'" n-ntn"ftl ... !bat \lnco AmltW:
allgJuncnt iIIlmporWll.

SUD A5S[MILY

Roule. bit

"'"
SlOE VlEW
(IImp

"'''',,..
a.m,

'".
C
C

ToPVI(W

""

..

,
,-,_~
__o_,,_,._._...=Il

.,""'"
.,'

tNDVllW

SO"

0"0.'. ' 1101".o.O. XT

bfOnze bUlhlngt

'fu m:akc, M .....,. 10 IDO"'". I drilIed rouplo o( hoIo

rijchl throusb lhe rouIa b;uc:.llIa> _ Jlmpl """ ' hc mu' a
in pbtt ( wioh Ils twcpIaoc l'CTIMWnl) and d..,..., dryw:;all
"""""'" ~ lhe ba:;c l1li0 IM oIord.
Thc fini ImC )"OU insO>.Il thc IOlUa"" thc ,;.IeU tr...",.
)"OU n<!10 align il on:fully.l1M: bil <IX"' must he <kod-un
lhe Inln-:lCCllon of 'he """"'(>it-cc ttnl~rIl"" and rhe r~..,.
pau foIIoo<ows ttnl..mnc.

Maki ng the T.ili lstock

11lc I.il>l""k ... ~ 10 do ;U'" 00.'),., .11 lUme: Im"U....
SUI''''''' IIle: ..il o:mI of Ihc \lJm ins .r""k. Ir tus lh= el<-men" rh .. ncnl ro hc pooi. _
VC1"f 2<."CUIlIrcly:ll )"OU
m.kc 11. n..: ..,mlctn: lI~ r "",ch , 11.:11 fiu .,."a IIle: oIklr bar
l~ .hc n"" of Ihcn . TI!c!iolXODll S' sq.... ..., ""'do IIu, f .....
oV"t:, lht" b:>ck of Iht """cr b.hc. FiJulIy.
hoIr: lOr
Jcrrw Ih.1 OCI. :II doe< laii (::=Ia OII rrgubr I:IIM
Ori"" JC""'" lhrough .hl5 hoIr: 1010 thc ccn,cr oIlhc

,hcrt

' umJllJI; bbnk.

Completa Ih. ilssembly of lh .. 51ed by unl"O Ihe

dIIln c~'"P li .... s ave. Itlt Ih.uded siud lInd Iht drlve
thioln. Thtn ""fn Iht planle knob, Onlo Iht >lud.

:u,,'

'''''

1. Slu thc . 1Od<. CuI thc l2i15cod< bbnI: ' o .hc

diInrluioolf Jjllfkd br rhe Culring LiL

u..

Now III""
~
buohing bloc,," 10
lIfl<Ia.
Ii<k of 1"" oktJ IMx.To <.10 Ih~.1 found k hdpfullo cbmp
Ihc hase OI ,tic "Cf)' ~vrnc:r of tho:: worl:bcndI. I InotaIkd
bulhintt In ('2Ch buohl"Sl bIock and >lid lhml <NIlo tM >Ied
1IWt. 'fh(,n I applle<J si"" 10 lho:: l>Iodc5. >CI Ihcm on !tIc
baK. arni ollpKd .Item ",ith ilS ~_ Alin I dampcd
lMm.o th<c ""-', 1 ~ "'" oIW't.

2. Supe tbe MOck anei drill thc: sc=w hoit:.

OIJ. lhe .""'" cnlc':al

de"~'''lf-thc

..... nc:JIdIoo::o and Ilie

hok_.uy anfuIIr 'IlIq ..., Im""n.m 1" Iht ace ..

ner n(.hc bthc. folk>w lhe lin..;"" Tutlstoclr Wyo"~ and

liCKW

la)' OUl )'OUl" t:Oibtod:.

....... /gplnjl Ilie t:alblod:

br bor!ng 1"" "'" for ltlt

JIcd wl'l lJJc. ' ~nd.di"""'1a FonIncr billn. drill~.
1"hcn "'" Ihc Pf\lIIk 0/ lhc lliloo:k "" 1"" lxlnoJ "",W o.with ubCT _ . "" you do 10. card 'ully cu. OIJI It", nl>lch
lor ."" rr...... haei!
FuulIy,
and driU Ilie: Jc""'" hoi<" w;rh ~
dl:lmelc, dt1U bio . 11 b rsst'ltfl{jl.h .. Ihb II"'" he l""'J'CffY
Iocatcd, mnnllllllh:ol t, h:os 10 "" :alljtnnl ,,lth lhc cenla of
,1'1<: ""..d' J( 1. is hlgll Of Iow.
he .bIe ,n l'OUI flC\'"
(<'CI cyllnokn .
1'hc: beii ""y 'o nnc>(lInc Ihc ,.II.wck b 10 moun'
...... ighl. ItIr 'umlnjj bbnk In Ihc Lalho:". ttrller;' r:artfuUy.
and mtU"'" "'" d~ rrom .IIC: brndI "'" to ,1Ie bbnk.

,"" III"" h30 CUfftI."1dr lho:: sIcd shafI inlO onc

bwJllng of IiM: r.kd. tII IIM: dWn ebalp UQi. inIo "'" pp. . . . , )WO: il it uri<nt<'d (.'OIttCl/y__ rttd u.. .oIWt
tbmt.iIIh IlO bu>ll1IIp; .nd ... !n10 "'" .-:ond >Ied buohina.
ScIt'" ohaIi Imo pb on 1"" b l IM: mmc. So:c I'>oov thcslcd
_
<NI " ' " shafI. 1. ... jIOOd iIk:o '" W;U " ' " sluft, bul
AfI~r

Iar ou'

.... ~OUII.

r"" WO\l.,

14. Maunl."'" ft)U~on thc .~ 1l'oc "",,~r ustd

.. m. latl,., """"... II. fb~ ~L. n', JOI boIh !4IDeII and lHnch coIku ano!. OI I ~ liOIkpo"""'. tus oII tI><:
po.'" nttdnl b.tIt wort: bd"ll donc.
TAILSTOCX I.AYQUT

I' r
C~
,

18)10'
~.

plywood

"\

.,.. ............................................
'

, ,.

5..-

-- - -_. _- - -. _-

..

Iii" -

-1

~.

... -.1

',~.

.~ I

..................... ... ..

HoIe for Sen ....

Sqllll!

noteh

1-, .

.oule. lat""

za7

."2

"
'""

c~ruC<pOinI.\ It Ihc hndotod: and thc IlIl5ock, :lnd al<o

from tbe Iad.... badr; 10 Ihc bbnk'$ <rn<crpo"ns OI both
endIl. MI;.....br: taibood: ocn:w ",,",tIon os ,.... O1ry.

e02f\k thc: C02f\k and .... lcll Ihe ehud! lum . Vou1l pby ..i!b
thc: ehaln cbmp ""lUp.
Try il .... I,h hoth cloaln ebrup "'WJ IlghtmN.1! Iocb "FI
,m, .... h"'" WO<b. Cnnk """'., . um , nod.1nf! rumo.,
oothing n~. YOU","""""" fIIJIn,'o Ulie 111h1J ""1'
l,oo,;,rn boIh "'WJ.l "ht: c ..... k 1"m5 and ,1Ie chudr TIImJ.
hul ,II<: ok<,IlII>I iii", lhc:ft: Vou1l IIM: 1hiJ..,...., 1 Iottor "vnythln3 but routlntl spltaII.
Tlgh1C"r1 111>1 ,1Ie: lOJI la"'. WhttI )'OU
thc aw
dot:kwis<', t1~ ak<J lnOVQ Id't to Ii&ht. WhttI )'0\1 "'"'
II COWI,c:t"dtrlwbc:, Ilie Ic:d mo'.."" rfIItht to Idt.
TlKhlcn IlS Ihc bonom jow. Whm )OU ,urn Ihc aw
dod<wis<', thc,;kd """"'" fi&ht to Id't. WhttI )'0\1I11I"II
1, rounlcrdoc*wbc:. thc okd """,ou 1d'I 10 "Bftt.

tho: t:albtod: chuek suppon ~,go..

y"" lohouId ati' iim:: a lwldfuJ 01
10 imI:aIL '!beM:

3.

Itbtall

_"'"are

..., thc bnrtnp .hal""Pf'Orl1hc Udblod, dltodc - .hc onc

""'nHon& ..'O<k~.lIoIt 1110: bc2rinp

uxd ...1Im ..... tlna

.bec .,...;1 suppon.

10

'um

Using the Router Lathe

You ..., IfIO/nIItO lIn'<I a bll

o( ",.,.,In ' Imund IIme 10 gel

""'. ro.. how Ilie roo.Uer lalIM:.....ts.

You WO<\', be 01)1( tu Jump ti!lh' In.a l'OUIing splrals,of

tlnl ,.,.,,,,,, JIOI lO 11'" thc h"'K of lhe basics. Just
mount lng 1 hl.Ink will be. cb:>lIclIJIC Ilie fi rst tlmc)'OU do
li. 11""",,"", onoJ I<IPC';1IjI In: thc II'IOISI c\cmcnwy 'uming
opn-atJoru., Ind )'OU''''' JIIM 10 nl:l>ter lhem ""'IOn: )'OU an
cmlX'llb.h a 'f'lndlc wlth rillll". C<>Ya., ,md- yes- spir2ls.
AkKljl.."" .... y )'\>"11 k";Im how 10 mal:c and """ .cmplatc..
Eve"HI:IJIy, .houlll' . you'U Ic:Im 10 I'OUI .,..."Uful tumlnp
"ilh )I",lgll! ~nd Iwb ..,d n UlCi ~nd beJ,d,;.
TII" Oni! Ihl",," yuu :o...: fIIJIlliII 10 oo-""",,,, )'OU~ prtJb.
.hlr dun" 1 1I>ln and all>ln .. yuu """","hkU thc bthc-Is
<'OUQt.

wm

CIne 01 , Ilo: f'ttndamcnt2l k:Mon<

)OU .. II leI/"JI
opInIo II thc imporwx."c: 0Ibctnj!; ...",. ronodottI
oI.,hidl W;OY)'OU :o...: rumi ... ,hal c:nnk. 1nd ... hIch
tbo

)OU ~

"'-ar

sIoed il; ~ 10 ........,

Templ.ues
lhc first time )'OU !i<1 up 10 do I .urftin&, Ind C>ttJ .Imo
tbett2ftet, )'OU ...w nttd
10 B - thc: IOUItt So
yuu lDIght as wdI ~ up ori wh.1t - m IOUtcr blhc ,,,",,,,-

",mpIlt."

LAYINC; QlIT A nMPLAU:

OOUBLE80B8IN LEC PROf ILE

12 W

15 14'

1 Y,"d~ . l W dIJ . ~' d ll.

I" dl.i.
flltST To.IPlATE
)fi"
r ...............

,...

It

'MI" ",,-

It

"Con,,~nt''''''

.I ........ !. .... L ..... L ..L ... "'01-....

- r
:1
-1 --,

tI. -

t -- ,- -

i
..-.-~~ i~tr:: ~:L::::f : 5~:c:i

.-E...

w ,~ .

~.

II

rad.

~. r~d.

"ll
1

Proflle SkttChtd on ttmpllott

.. .J ......... j _ _

Tr

It- .MI.
PlOI

points on e"",ou" 1

~------------------ ,.~-----------------,.
SECONO TEIoI PlATE

..

.......................... ............ ..

..., r- \',' (typ .l

................. ...... ................. .

t.ly fl,st TtmplJlt on

~
288

~ond

Ttmpt,.\I.

"'V OUl Jnd cut Ilie notches.

",,-

______________~J

Rou,er IoIJglc

T'ilU ,he conlOUT, then

b:. wtw. ~ ~. an<! how )'OU malle """.

In lhc !iC'<jucnca .1Ia1 follow. 1'11 CI,."., baei< 10 dU.
1OjIk. Ind >how Ind 'd yuu how .0 m3<: .h~ t~mpla!e
needcd for lh:iI ""..Ia..... p""""".And Ilo... !O """ k.
I

,cmp!:ll~

NrJ tcmpla,e doC> ' 10'0 Ihlnjtf.

sled. foUo ....... olT IIl<: !:IIM back, prob<:t><'C<:Il tii<:

of ,Il<: >Ied and .hc
lWftiQa btln". V..... 0/1' 1 It:".., u", ok<l "'IIlin8 ... lhc bIan.It:
A ..... k Iifts II><:

"'>CU""

ridit1I: ck:annc<:
~

_ ', >PIn. ,.. K<:,

Sood "" tmlpbt<: SUi<I"" lhc 1'OUIn" ~ '1"11>.rtaI spi<><.lld ilie I 'empl:l,~ wilh "Uligh!. """" C1lF
1l'1n, .... ~ Uoc 00< wllh &lO'2igh' bul >Iopif'fI
undul:i'1oN.? ilie """pIa,e wltlt I lIIIdub.tlng edg<:, Nttd I
i!I'U<I"t' 10 I particula. Sf">l1111c templue ..;.It ""''''' ' 0
""p Ihc """""".
kct'ping "'" " ....,,~. In pooIllon.
Som~d""," )'OU ncntlWO '<:mpb .." ~>r I oInPc ~,
CInt b Il!<d ' 0 ~1I.r><: "'"
.hc l'OfttI ' O poo;iOOn
..., """""' ,hc rou' er lOr :oddtng JII'O">'I OI' lIn<Is Othcr

t:tI#.wao,

,1>""

,....uns.

1ioIa,)'OU .... y tind

" bdplUl,o cWnP ..apo ' o """p""e

")'OII an work I 'um" onc "",,'\Ion '" a ,ime.
A .cmp La.c i< asy 10 ........e . of ~. l!lt Itanlboanl OI'
II-Inch pIyw<nL L:ay ou, .hc profil<: anei C'Ut it un thc bmd
)aW o. whl> sabcr SIW. U!i<: file. and ...mI""rcr 'o n::finc
""'" ><nOOlh "'" .,....
Thc: trio:kr po<t , 1", by-out. llcn;:t why: 1Ica..... 01 thc
- . . . 01"", ""'.e. OII "'" skd, "'" .empl:l,e CIRt'IOt I>c
duplicate 01"'" pn'llilc )'OU ...,.."
produ. Thc: rb<: and
foii el "'" ptOfik ml1>t I>c lIOkd u p.
11=', . hrid .. q>br." OII ,~mpla'c m>I<InIJ.

'0

1. Cu, ;o p l<:cc of IftIlplatc lIIOd.. M.1J[e it oOOu' 7

10 8 b>o:hcI wide and l6 inchaliong. ..... OII ,hc ,empb,e
)tO(i:. <lnw "'" proftk: )'OU ..-an .....,."...... 011<1 l'tt\>I'dins
tbc Ddii 01 .......... fa""tU-Itigh points""" 10.... poInI1
\'ou ..i l pO: noelt of tb<:M: poin'" In I:IyIn8 ou. thc ,empIaIe'! cort'our. Stt thc <lnwlO1ll 1.11)'1"8 Oul " ~k.
wfIIctI <kJku IIow ' o malle I ......".... 'cn.pla1<: lOr 'uminSI
I dol/bIe.bobbIn dwr le&- "",,,e 11Ia. )'OU ............ 5Cribc ,1><:
uls, .hen b OUl tii<: ,,",ilie In rrlatiofIlO th:u.

.....m..

2. Locale: II><: b.rge8' .-.lJU5 In

u.e: pl'Oflte. Thi!!

''''''pIa.e,

.... bc "'" Itlflhol poin' on thc

You wUl alc:ub' e:
aII,IM: 0100 """nu .... hc '","pIa' e contOUl' In rel:l,1on 'o
thh polii' . Thi!I ra<ti"" \s 'h<: ' OO<UW'II' \n cakul:ltin8 othcr

--

........

3 . .... Y Ou, .1><: 'cmpblc pl'Onlc. Ul-ing "'" luJIn<

,he tll"'anec. IDClI>Ure from 'hc ."",pLa.e ilIC
... lICIibc tit<: ub. rnaI<ins :rute " i> ~I 'o 'hc
pbI~ edgt:. 'l'ou nc:cd both .hc IIIC :t.t>d .Itc ub line ' o
,.;Iiuo ,..

,""'o

ploi ,IM:

"""'OUI'.

Now marii: ,Il<: atrcn.ltld 01 .Il<: '..-nIn!!- ' he 1....,

....... In 0I1tcr WOO'<h. lIc<w=n thcK poin ... "",ti< .hc luDliDn

01 ' '''' 0100 "~y r.ulll.

I'klt thc con.our pointS

ncQ.

You ntl .0 do _

lIIXh: 1...., thc "'n.pI"~ .. !It)' .ocn.,eh pad tor ' ltlo..10 locale
tk pkII; poin. (X) tor a pa ..1cubr ratlius (1I) ....t>Craa

.Ita,

..... ftum Ihe rort>WI, (e;) (u..,, .hc ~ ndi... OII .Itc

'...-nIfl8. ",membcr). DMIk thc dllh: reno::

by:z. Ihc:n moi

tIpIy ,hc 'l'IOIIm' b)' ~. "" an "'1"".100. th:u ~ Itc:

X~(C- R) + 2 x 3
Ag;ain. thc <lnwil'll14)~"1 Ou, .. 7mIpII"" JI"O"IO.I<:t I
"f>I'dI\c aamp!c. No'c
' X' b noi ,Il<: r.otll .... y..... ploi
.hc polii' by Mc2>UIin& f...... thc ''''''pWc cdt!<:."""'" Ilun

'''*

."" " Ilo.

Aflu 111 ti", poOnts It:..", bn ("~",'I and p!ot'I,
connc:ct ,Itc tlols. >kctchln& a f:1l. comour

4. tsob'c nnd r",,'u ra for ;o "'p"nIlO:: tem

pb'e:. So far. thc 'crrtp!a'e bas bn con,l'ived .0 11",<1< thc
r(>UR'f as il b tIKM"tllllong Ihc: ' umlnf!:'~ uls..lIut .tCJfI'" b'U"", 01 a 'uminK ar<: produc:<:d ..,. pbn'inp. thc lOUIer In
ono: spot.Tbl:V~ In thc Iq ~n In .hc<ln9l'injj:ln:

"....,-"..

Vou ....... oomc: devltt 10 u:ap .hc "'u'u In I Ibed posithc CTIIIII: antl 'f>In 1"" 'umInI( wllh"",
""lIT)'itl8 ."". "'" l'OD'er wUI .slip OI' dri/i. OUl 01 p($l'Ion.
,It... ntinlng ,IM: ......tlplca. A ::mldrck. """ "'" !J;lJ"<'
dlametc. the foIIow<:r. CUI 11"<1 ' hc cdt!<: 01 "'" lcnlpLuc
1ion,!iO)'OD an ' um

..kk....

.Ita.

,Ita,',

11<>. if)'OD CUI

1"'0 ,Itc lcmp1:t'e
lIuki1n8 "'"
rou.er III il .. tII<MId ba<:k :t.t>d rom. aIo.>rlJI; .hc ... I'ning', n;"
II .. ~ 10 bc an ob:>IltcX.
Thc ",,"'ion" I C<>tttp!cmml:>ry
,hot: fixcd pooI'lonJ.Afln J'O" $har><: Ihe .""",,*, J'O" an
n:pbce ,Itc fiI$! ,,,,,,pLa'e...tth .Itc "",,"OOd. 1bm ""'" ,h<:

.cmpU.e."* ...... """

....,..,M_
s.

Cu, lhc tc:mpbte . ,.. lIIour. W,.h ."" .e01p1a.c

(and 1,,, .... 'e) biei ",",<:o, .IM: edjjIc on "'" Iwtd""w OI' wllh
so1:>cI' ....... Fik Ind sand "'" cdIiIC :III ~ry 'o ctimin>1e
nlbs. bumps..dlps,and ~

Roundlng a 5plnd le
1kn:'J ,Il<: """"~"" Opcr.>,Ion. Thc nI$! .. cp 10 an)' 'um/IIJI
)'00 do II ' o knort thc """"-'h ofJ )'OD' IIqUItC bbnlr. antl
malle II roo,l1<I lIere. how 10 loC1 "P antl do il.

1. Ch _

y<>u r stock .. 00 cut 1, 10 ,Izc.

Whc"""'" )'OU :In: ........ lnjt ..;.It Ion!!. tI>in so!d<Ji, )'OU nced
'o """""'" MOd: ";lh ,uIlgh' Ind .....,.. Rnin. 1'b1l..,.....,. _
..., pwpotcS. ooc practlcal and onc KSlhcde:. Se ....., 2
1I"'.olntd .......00 .. stroIIfII'I' anei ......., tQI"""" .0 Sf>Ii' .....
Th;tt'J lmponan'. You <Ion't ..,.", your opIr>oJk ' 0 brak UJ>
modway llltouW> .IM: opcntion. Iko. abo. tpindIt:!I Iool:
bet' er .. hen
profik "",., bclnll ~ I>y 'IM:
wood"' ligur-.::.Sovr: thc hIjUtly filjur-.::tl woutllOr anothc. ut<-'.
Thc
lIIhc: ril I<I1<c ..od 1 ~ Inchc:s "'1"""' and
onuUcr. An)'lhlns lIlscr ...",', n, In,o thc ehud<. A blank
....ulk:r lI..n 1 Ind! ""I... re a n bc ptUbk:matic bc<... ...., 01
i~. Oaihilily. Whcn ,IM: bit P1'C1i1iC111IplnsI ~ , 11 ";U how It
wW I>c diIBcuI, 'o "'" mootIt. ___ >f>Intlk:.
In oi ..... fl"SI . ltt lathc wlM 1"'0<1,, I 'l9-Inch-It>01II
,urnini- To .,. du Ut'ttlng. )'OU ne! libni< obou. oj(l

ce

.hc:l.

""",n

Roule, UI''''

289

Bits for Turning

"1'0<> ll~lcly I>lw b". '(OU Uln u,e wnll you. new
loII",. But de""nd".g upon tlle mu,er 111'''''''15
'(OU w~"o produce. '(OU m,y netd 10 UpaM your
collecuo...
RigIl"wIY. ~I" tllmlnlle lrom eOllsld<! 'OOfI ,"'y
bit w,th. Plic>! bun"!I.
But 100'; II Ilie OI""" b,tl YOU ~. Surelv '(OU
..,~ ""''9111 bru, I 1111_', and. co~bo" OI lWO.
W,lh It...~ b'li '(OU un produce .000nd Or t.11H'rONf
SPl"<ilH. ,"ou CMl produce 11I''''''IIS .'Ih ""ldly curwd
1ape11. Iwetpl"'1 onoltS. Ind. 01 CO<>flot. cO'o'e nd V
!lfOOYU_ ""'" doltblebobbr" le!! .ncJuOONf in tM photo
of IU''''''!I. al It... MII,"rung of III,. c".Pler.u c~
.ted with;l SII3JOII, bII:and I V1I1'OO\ter. ""'"
worltpitc:t sl>own ,.. Ilie. pl>olOO ~p<ung Ilie spII.1
IlIm,"II proCeS! w.. wo.-ked w1111. " ..oghl blt.nd
IWO Slzes of cOf~bo" bns Yo.> c.n do useM.nd
'"Jl1(11Yt 1"""lnO' w!lll. fftIlOdul bot C~I_. So \'OU
don' neecl 10 buy-!nOn! s""e"hu'd b'lI I... medilielv.
Sul when you do PfOIl"ss btyorMI I~e ""''9111
b'u. V'9~rs. Ind cor-t-bo. boII. rd <Konwnend IWO
lpec,fic p.of,~s.
The filSl "1. d,sll cuner-is IIlnd of UIOI"y bol
8tc.use " II dtllgntd 10 CIII OII tlle botl""'. It doel a
belter joii 01 rOllnd,"!I and tapt""11 sp<ndles. AItnoII
.vel"f Iu.nl"" IIslo you'lf do w"II. str''!Ihl bli w,11 be
dOM botle. by 1. disII CUn"._ Sucll b,".re ."lU(.bIt ,n
vanelV 01 SIUS, ,n bolII ~-ln(1I and 1t-lnclI s/wnlo
conn!lU",\lons_
TIIe second profile 15 rllt polnl(utt, .. " ,o,md_.
bll TIII. II Ilie bot uI.d 10 {ul rin" nd munded
slloulde". It CUIS, groo~ In whlCh bolII shouldert
.re rou"ded (lVe Tlle ,. 1\0 1\;(, belWUn Ih.
roundolle.s. DtClust III. culto"" od". cornes 10 i
PO,"I. NOI evOI"f bit m.nulleture. ma~'1 PO!nt-eu\llng
,0undowlS . .o IlIeV ar.n' e'IV 10 flnd. upt'cl.lly In
.,zes oille. Ih~ .. m,nlscul.
Here lre ,e~ ..1 good IOU'ces: O!dh .... (800-8289000); ;agk .... m1(1 (80087225! 1): WOO<!havtn
(800 HHi657); HlQhland i-U;rdw.re (SOOH 16748)
He ~ Ihe h"ch, PoInl-cuu.t>g foondo"tr b.n ato
Ulremely Irlg,lt. Tht eUlllng edgt "CI lrom !he 0<>1mut~.

.-...'"c
C

sld. edg. \0 '" Wry sllarp po,n! a! Iht b,' axll. T~.e\
no w,y 10 luppOrtlhe cartllde II ,11., polnl. so 1t;1
Wl"f prone 10 brf!i~a9t. (lIVlptClllI,s II whv Ihtre
Ift SO lew m.nufaClurer. of IlIu. b!u.1 Tlte b kage
11 mort hhly 10 Ou. ," handUng llI.1n in ule, I"d bel.
A Vl/linl of 1"" pGlnltulung .oondover 15 Ilo<!
plUf\Oe-eulllt>g ,ound_ TII" b,t produc.. I groove
".. tII. na"ow """ belween tlle quan..,.round .houl
d.". TII'II lIu.d'" b't. bUl bec.u.. oi the fl.t. Ilie
m.kts mir nor. be u -n.u.ule_
It number of SOIIn:ts .1,0 ""ve glOOllH:uW"" prol'lti IOtnut>td Il ogett .nd cI.aUIcIl: Clleck I~m
OUI.'~ UtlJogs. Ind decide fo.- yourtelf ..... ,lIe. tMy
can be IfI(orporlted In IUrnin"S_
So tlle mUia". on b,"" III,,, You un do .ome
Inle.e.ung IU''''''''" wllh b,u you It.~ .1.e.cIy. Sul
10 rullv uoUtllSh Ilie MiI"OC:. you MftIIO do IOfl\t
dIOPp,ng.

C"" "

A good bh collealon fo.- 'OIIltrI'IM work would

(nclud. co. t boK blts IIfQe and .",,11, IWO .1:.. 01
disII eUlte'l . 6O.<feg.ee Vgroove . s"",e pol"l
cultlng .o.>ndove. bit . and ewn. "roovelorrnln"
profil. culte. o. !wo .

moft"

cnd o( III<" bbnk ,11.11 ",n'l Ix 'uma!. Ijk.....i5c ... hoI tht
>ktl hlu rhc mi<! suppon, ,he bit :lJ<S . .iU "" .Ilo _
rron, 1I. An<! rrom Ih>! poInt 10 100 ch"d . 100 diMa""" il
~boul \Ilo in<:bes. Sa )'OU ... ;U ha,,,, I} inchc:s of soocl< ,Iw

1DnRt,.,..

you (:10', rum "" any spindlt bl2nk.

lIy gangioog u ..-rungs on ton.t btonlo:, fOU .,-... IN"""
Ihr O\"",,,U "-asle.
" bIanl! docI not .b,;oIu'dy ha~ ro "" ~ ono.J
.. uan-d. Ir shouJd II<' rougIlly oquan 10 begIn. bUl a bbnk
rtpped rrom rougIr 51ock-on<" ... i,h lwoorlh= rougIr ......
faca. in <>thcr .."Ords-(";On bc ccn,CTCd n:;UQruIhIy wdI .

ind>es lorljI. lIooar In mlnd. IKnoo'<"=. 111.11 ";111 Ih" tceond

ehud< >cn"inllaoc. raib.,>ek. lhe b oII<" Con
,b,,, 3

"""<>",,,,...

much i<>nFr ,h:ln 40 Inch<"t.. l"ou "'"' ~.. n' rum ..,.
o/I! IIwI abooo 19 inchcs .. OM II .....
Thc liho.-tc5t bbnk ,.,.. c:on do "')1ltlr$ ..1,1t ;,:abouI
1~ ind>es.N>d.r ,h:lo ~, ""':abouo 011,.,.. c:on do \oi n..
3)1:1'tX1ft 3bQul)1t IncI>o< rrom OM mii.
Ikn:. III<" <lea( " 'I,1t aU this
M...d ..Thc: daign 0/
,II<" ~ di(ur." """ rht:ulll 0/ rht bit
~""'" <'klott
rlwl .t it Indoo 10 III<" mid ""I'P"f1 OI" ,II<" LlI~odt. Thb
...tII ... ~. ~ 10 .tlWncft.Ionar; "8""'" :al III<" ,~
_

..-;oR".

C2f1.,

1
So 10 bqn )'QtU" ""1" li.... 'urnina. PI"'P=
>boul 2* ;""t>n oqua..,:ond "" In.chtIlonJc,

2. C<.'ntet thc:

~tocl<

bhnk

1" thc: I'Qtltoet lai"". Just :as in

st..,danI 1.011\1: ,,,ml~ . ccn'~r\njI 'he ," xii In 'he fUU(""

... "" is ~ crucl.ol "CI'. FlndlfIJIllK: """le. of 1"" botlom of
LM Iqj .ud: I:t 05y.Just Ilr.w 1l1'4jOnllllhK!l OC""'" th" md
lIDin. Th~ point .. tlen:: 1"" 111>0 Im,,1'!ICCl '" Itle cemer of
\lIc: stock. Whm 'II" ,iII1oe COlI,.,.. rou jLl>l Ilrl..., 21",,"
~
ihrouJIh thc: 1011.lock In((. t""l poInl On

...

*"'""

"""'-

emlc:rin, Ihc: top 0I 1hc: ..... od< I)c,.....,.,n 'he hol.., of

"'" dampifl& dbk Ilo 1It1,," It1odkr. 1 :IUIn "y Ilr.rw1~ a ce,..
. - aIoaa nch ba" of tIM: bLonk. Stan thc: butt 0I.hc:
""'k" Ilie lin(a """'" 2 indoa 1nnSt.
WbnI rou1" 106, tIM: bbnk In thc: b l hc:.,...,l1 Il~..,..
m.a tIM: oIrd il In Ihc: wzr v:tlh IIM: >k<I's 101.....,.. restirJM,
OII IIM: blIM: b>d<. 1hcr!: isn'l C1\OIWl room btneJlh thc" oIrd
rar. 21WndqUilT bIanIt. """" I do I:t lip 'he >In! up ~nd
P"'P il lip wi!h I Knp 01 orood.
V;;lh II", >k<I ....... 1""''IKIl OUl 01 thc: VIrf. I poeitiQn
!Ix Iq .. ud< in thc: ehud :utd 'urn Ihc damp...,......... in
(ItoI)LII1t LO OlIppt>o"1 Ihc .<>d:. T1xn 1 joump 10 lhe !aii moi
."", """"I!h 10 IIm... 1"'" ~ibtock """"" lIMo lhe bbnk',
Ctnlapoin' .Wllh 'he!<lil moi 1II0..mro. 1 can (ocuo on ccn.
l<'rinII 'hc: tind moi 01 the bLonk.
R<1um 10 IIM: ~ock an<J 1111..... 'he damp~'" ,.,
..rn le"'"" I:t un oooe o( Ihc: cmlcrlino.This is III il t:ll<C$ 10
mughl}'
Ih" bUnk. (NId ... lLh o:~ and proc.
00: , rou ~ bc obi<: to 8<1 'o Ihis poinl w1t1lou1 mar1ting
t"'*' ttm~"ln .... , ,\),,'n M.bIe 10 ryd>;lll il.)

bbnI<._

n,,,.

TI) IinNIInC thc: onLlp, ~ JCnp 01 .."<I0Il .. I "".....

on thc: tnId OlIppt>o"1 and blIIl Ib moi oplMl 1""
bbnk. Turn thc: cn.nk var
opIntIl.,. Ilie: bbnIt.
)'OU want 10 do .. hoId Ihc -P ...- ....1ouI: a comcr 01 "'"
bl:l.nk. It lhc: bbnk III cmlftN. )'OU can rum IIM: bbnIr _
Ilci! "

"""'t

"""1y.

oJI four comnI ,,111 bnosh 1"" "'.... Wh.tn ~ II oIl"<m'a.

,WO ~.......... uTi.., corncn ... ilIl>r\lsh .he "'.... hul Ihc ,JI;n;\
:lrId fQunh rumen wIlI ml... YOll 11>,.., 'o ad .... Ihc cbmp
"",..,.... tO I""'h 1""",, tomcft do5cr
Ihc ",...,.

'o

I!'s

tri:lkln(l.c:1't()r

pn>C<:!iII

,Iu, iII<1>' c;Uia Ilie: ".."...

tI""",)'OO do II

3. s"" up a ICnlplaIC. Wllh bUnk eemcmJ in 1""

bitle. it shoukl bo:: nldcn, ti"" o -'''''''pL"c- II ~,
ar<>.........,1}' "",DdIflJl. bbnk.lh~ Icmpl.t~ i. jw.t
.uip lalla 11wl1hc: bl"" back 1""1 <:;In ."ppon lh~ ~kd's
foi.."...,... Fot ' hc: usi! .. lund-rounding 11\;1, 2~In<:h
!Jq~-' 6 \;. 'o 74nd1 ...1Or, }-I(>oI.Joolll pIcct of h.nI"'-d OI" l<riDch ~ood Ilo .U l /un !Il'aJed.
c... Illis KnlpI.Itc,11'<:n sund 1,
' tle bttle ba<ok.
it< bonom ....... thc: bmch
cbmp" 10 1"" blhe.
1Icmo\.., ,1Ie: prop fiom unda tIM: >Ied. ond ....
>Ied
01110 Ilie: IcmpblC.

Wbm,...,

'01',_

,...In>t

= 1""

4. AdJU5I thc bit doeplh, aun o bk "1'JIf"I'IU'~ lOr

IIM: job a )'OlII" JIcd.molImro 1'OILta'.'lb ...... 11Ie: lok;lI bit il
~ dWI OII.ta. Bul )'OU <:an "'" a bun"""

ror

bII, I monloinll bII (~d

0II.tlnf! hin8r
monila). OI" brp:-diamc!a stnl$hl bII
Adfust Ilie: dcpIh 0I1IM: bit 10 OII. " 10 !Io ind> Ikq:> in,o
st""k AlI an Ikl UI adj .... lnfllhr bit 1kp1h,.ointpIJ Iowa
,IM: >k<I unIII Ihc bII rnu OII "'" comcr 01 1"" lum""
bUnk. and lhen .......sun:: 11>0: di1lUntt bct ....,.", 1"" Jollc>,...,..
Ind 1"" 'OI"> Wsc 01 ,II.: 'cmpb,oe. Adi"'''' III.: bit IIn\U "'" . _ .
d ... anc" rqu:oh bIU/ ' hr omoun' 01 .. ud< rou wanl 'o

dcaninfI

1""

roe......., In ,"" fini "....

S. Round II", turnln(J a",o. 11'<::tet1on wlll sccm
n",,,, lit" IIIlrfKI"fI Ih.n """"ling. Wlul rou do Ilo oiklc 1""

"",le. \);ICk .nd (,.",h (n'a ''''' SII'lon>ry bbnk. nmln.g

f..... ' "nd ' o md.TltIf .pproach 1n,"OI\.,. tlll'" er.nklng.and
1, co."pk\n ti", won: in a roen ..
""'n Tlmc.-.
SIIdr 1"" >Ied .. b. 1<> lhe hcad moi of lhe 1.l1""" I
..-ill I!!IO, S"'i,eh OII Ihc "",1<'(. an<! ......,.. Ihr :<kd un,iI 'he
iOIIown" !'nU OII ,IM: ,cmpbtc. 11'<: bil .......... mpgc Ihc:
bbnk. Gr.upi,. Ihc n>ut""'~ knob OI" 'he sJctI ilsclf. olidc it
om<>othly and Meadily 10 ''''' !aii moi 01 thc
bad:
LO thc ~ pofIIiQn.
Now gm, 1"" cr.lnk I n ..... I"m1"l1 ,"" bbnk abo!Lt 10
~. ~oe _ h a pISOI fiom thc: Itod moi 'o thc wl

",bIy

Ia'''''.!hen

--opin.
Cenlerlng sTock In Th. e huck ln\/O"'e. lrapplng It
d.~wn On Ihe >tock
MII' gel the Inltl~1 stltln\!. To flne' JUne II. d.amp I
S('IP" one eo,nu o f Ihe bl.nk. u .ho... n. AdJUSI
the screws unIII neh come. JUSI brushu the SCr;LP U
tlle s,ock rowu ,

be ....nn fo", re ..... Cenlerll .....

u.., thc: cn.nk 10 lurn 1"" bbnk :onotha 10 ~

lllm ""'" Ihc "",Ia frum moi 10 tnd _ t.>dt.
An<!
how il. is donc. YOll just ft:'P<2l and .."..,.. lhI:t
""""'"" ...IU )'00 .... l'OOIftl 1"" cmi", bi:ank_1bI:t fini pa!li
willlClwJly ""Iy ruund IIM: ~ oIlhr bbnk.lt .,.;o lItilI
pruonincQl naTII, To lIPItoe it reolIy 1OUnd,,..,.,1I 11::1"" 10
Itle
10 " ind>""" 1IW<oe:anothcr.mo

,lui"

Iu""

0:'''''''

bi':onothc:. "

Rou ... Utile

291

,.,.'2._.
'"

1.~fS

XI ... I tapet II produc... Hott ,,,,-\ Ilie corne', NVi!

been knoo;ktd 011" Ilie wa", at the foot. of the lu,nlng
$O

il.

Ilie sled C<ln PlIU _

Rou11ng a Leg

el puon, roulinK In. emi", ~. Thc:n, 1I'tCI" cncndi"ll Ilie

bil yo:t .
n , )'1U hau: 10 do il a IhiI\l tirnc (rn2)'bc C>'CIl a
ru..ru. and MII). OrI !hc /IruJ
el ~ IW1l tht bI:uU:
011!)' :aboul S <Jcwtta pet pa>I and ~ Ilie bit onIy
ko ln<:h .Thls ",ill yIdd the _hall!IUrbcc.
Whcn )'OU "'" flrtWIed, )'OU wlU ..."" a tmOOIh.,

l1>c beot w:ry 10 obow ,..... oow thi> ......... _

~ .. '"
","",il ,..... th""lgh ~ . A table Iqj li a good turnlnjj: '"

C'o'I:n round.

.tt""

Taperlng a Splndle
,

ta,....

Iplndle. \'OU netd 10 use Ilempl<lle lloal

from _ , neS tO the Dtht<. It 11 oOvIou. hen!
INI IlIt It",pllte Is mo~ "ffiL/y angltd Ih<ln lhe

To
To rollnd & splnd l., .hdt Ilie _tt. lJ.KiI Ind funII
11119 Iht bl.nk by "'-ne!, III.n l"9 Ilie blank onIy 1 few
d~'H' belwHn PlUts. y"" Un e'up llIe.1ed Ilstlf
o'. knob 011 tllt _tt, a. \'OU m_ k , MiMt tlle
malgh! It .... 1 ttmplllt cl:.Jm~ 10 Ihe I:.JtM bKk.

_ _, Roo.l"II t:lper (0110_ 0t:ICt1y IM ~ prott'\lu", :as

roundlnA. The ooly dlffctaKc I!i Ilie lempble. In"'''''''' 01
usinll st ... ;gtu , Icv<:l lIukIe ~, )'UU use a "' ~"I!hI , 1IIupcd
lIulde ctJw=.n", stttper .1", ~ . Ilie lJurpcr .n. "'pc',
.'>Iue Ih~ .(",pl>l~ tQllowl"jt'hc lIuklcUn.,.:id ou. In
Ilie ICCfIon "'cm pl~t.,. on Pl'1IC lAS,
Onc<: )'OU ..., RWk 1. , g, 'u wor\<. l\IU don ', nttd 'o
l'QIIJId Ihe bbnk 1\nC. You un u,", Ilie lopcr t""'pblt: and I
!l<!uan: bIonk. JUSI set Ilie ruu1lll!llkpth .... llh II", tQllo....".
pObcd~' ,n. dttpait poIn l e1 ' M topet SI>)'t>U WOJI'I 0V1:l'
Iood....., rou'tr.YoulI probably,JUfl .... lth 1"'If.lc"ltIh~,
. . .nd Ilie Mlal ..... .'J\CCI1oo <>fllle luminII may bc l'QIIJId bcfo",
~ )'OU """" I><'sIn I<rtocIdnIl 'he rotnc ... ol 'h~ tloueso .'J\CCIlon.
()n" prubkn. )'t>U n.. y cont"",. It
Ilie ~ .....
tapet Is., pronounc:cd . ... I)'t>U Cln'l c""" lI"l d", "f'Indlc
.uned.l1>c lIkd ""ltIa< OI1tu lhe bbnk beton: Ihe tQliowcr
..,..,.,.,. ,1Ie k>wctt poin. un ....., lempb." . wtw )'t>U tu"" 10
do il pul "f'K"n undtr .iM: Icmpblc I"".ponrily. Slan
rout1llll wjlh Ilie Icmpble e"","Ied lhe ~ amounl al
boIh cJIIb. Alier Ilie CUl'T1en arc oi( Ilie bIonk, )'OU un
..,....,.., .1Ie ~ ano! Iowcr Ilie IcmpblC.
tlul now lhe corncn 011 lhe ""rouled wastc al lhe l ;d~
stud< cnd oI thc lIIanlt wIU hll thc6kd.JUSI blOdtofflhcsc
corncn wlllI dtbd or dr.Iwknifc. II '" W3>'1c . .... kc off
."..,.... 10 alIow tht loIcd dantnc...

c:n
c:

'c
I-

''''1

292

ROUle. "'aek

.....;OS.

Tbc

pnctlo:c~ .

q,

sItown In

......... "fI JiIlW

lir

""'" dQiannl by my ~ Rob Y~. It..,...

>lsb e1th"", 1""", hc:ado al In. top, ~ tapcr.twu ~
beodf, anei iU:light foo:M. RouIJIII this lumini!. Isn't ttiftkuII
ORCI' )'OU ...,.., tht 'wu tnI1pW:Q ~. tiu! dclermInirtI
lhe conl"'" el the Anc Innpblc b. ~ttlc tridy. 1n adoIIdoe,
IIIIs tLll'Tlln3 Inuodutts J"OU 10 thc: lnuic:adcl of..:countirl!l
for Ilie bit diamcl ... In Ioyin& out the tcmpb.~

1. Lay OUl end an:o.lyu the lu.ning. Thc fint 5lq>,

of rourx, '" 'o CUI. pIcc<: of 'empb'~ lIIod: alIlI.o by ....
the lumlng proIlloo on Ih .. ",ud<.
Ibvln.tl dune lhal. analpo: the profilc: In lo:nM 01 how
cao bc n:prod~ 011 'he """ ... btht. Notc lIw. the ici'"
oqua", !lCClIon , .... hlch Io .... hen:....., aprun wIll Join IL ......
bclow Ih. 1 Is ~ 2 ~nctHonx!lqmCn1 I"'t i5 2 ~ inct>C5 ia
d ~tr, It '" cmheUisheo;I wjtll the insct bcod, N= il!
I(i"Ao.if!Ch.long tapcr. j!nduaJly rcdudng ....., turnin8 '~_
c l~r III I ~ inci ...... AI Ilie md ..... thll tapet ...., tht two
ptOtrudlllll~. wllieh ha..., a lILuimum di:uncter 011
InclM.... . 1nally, IIIe..,.,. ~ 2~ ndHong lOot that b I ~ inct>C5 lrt
d l~tr. Any",ock heyond lhat Is W7.S1e.
0\11 Ihc bads ha,,, a !4jncl.~U5 ketion, and Ihq
con'-=fg<:, .... , ...... ,han ha";"!!. (Lu bclwcc:n ,11=. You con
plan 10 rool lhe n. wllh !4--inch. po!nl<ttttlng n>Ul\doYn"
mi. Ikcaw.c: Ihcy.", /Ued elcmcnts,lhe IcmpblC "",eba
$hould he OII Ihc scn>nd ,cmplalc .
l1>c Il .... t<:lup"'lt: nttds 10 prod""" the ronl""', .... hldI
I!I prctt)" ..... Ightfurward ""CCf>1 lOr Ilie protrudlng ~ .

TAIU LE" I'ItOFllE

Squ.re SK!1on

".

l ~' d~ .

II

21'" d~.

11'" ' ''"1''"

dll.. dll.. dia..

Thc lemplale ni ..... obi<> ha", a poeilh't oIOf!I<> Ioale thc

shoukkt bct ..'CcI"l III(' lq~ :and lumed ''''ClIorul. Thlo
II:mpl:llC. "'''''' rom"", .n.-n 10 .11(' d .....,tnl! T~ fIJl
r~le LuJ_ts. .. ~ 100 Iw'd .<> ftgu", 00. ",., loicIcy
put ilo """"'lallna lloc dimcmion5.'IUu mUSl .c>un' lOr ,"'=
lhl!. ou.
Iliarncl .... ci 1"'= bir ;l5 ,ou _

Tu ac<..v un' k>o- ."" bir :iiH .w..r.tC1 lis dia""" .... f"""
"'" di1mrt~r of .he foIlowcr hen divide by 2. In thc
tlr.>wlng. '0'''' :uc ~ a 1M..IncIHlLlrn"..... d .... cult..... 1bc
fQUo"""r III 110 Inch In diamorter WJM.n .hc foIkn<~ il; :>gairut
I SlOf! he bit """t~ 10\.0 irH:h b<-yon<l thc '"Of!. So,:II
>hown in thc - . .. 'o ~ntl, ,he "'ngrh of.he cut .0 19
lncIIcs (Ihc dbtancc from Ihc "'1 ...... ~ 10 thc pn:>tntdi"ll bcadii) . thc oI<>Pl m.... 1", ItI'- incho apan.
Note thIt 1f)'OU uoc bit ..... JIc:r In dbmcI .... 1h1n .hc:
~. lhc SIop5 """,1(1 h.vc Hl "" fut""," apan tIwt ,""
Imgth ci ,ho; ournnl :om.

2. L;oy out tbe Ic mplatcs. Ilhink )'OU ean ", U<If'hc:

..,...,.. drawIn& :and figun:: ou, 'hc: ntionalc lOr """'" .hc '"NU
l<mJ>bteo . '" bkl oul. lf)'OU "'", Ihc 5>tI>C biq 1 ...ro. ""'n
"'" <211 dUflllatc Ihc ,,,,,,plat.,. o/IOWn.

lJuI it you m"St ""'" ~ 0Ibtr tIwt "'" dbh

1 uocd. )<>Il'1I h."" > mk> thc 1Ir$I." mpbte.1"h<:n::.
of roun;c. "" SI"""l.u." lOr lhc Jl<)inl<utt\njj roundoott bit
lor produci/lSl: thc beads.

Cu"....

,. Cla mp thc 6 ..." IcmplalC 1<> thc muie.- Iathc.

"Al puN.I"" the .c"'pble ... ..-c .. minimbed .

1'''''

sh<>uld
oIed .. ck>oc 1<> .hc l>eadsloek ;l5 possibk",
I nd fK'>P It "p.Sct thc
ogai"" "'" ba<.1 t :and ad j.....
IlS !aler>1 poeIlkln "" Ils MOJI III apln.'I thc thlloWCl". Oamp
'hc ''''''ploI''.
lI:iuoc )'OU 'w ... 10 IWildl''''''pl.'r. to complete a

.ude " '"

fOUlCf

"''''plalc

,umlng (:and )'OU ....., to cocnplctc I 'uml"", llocIOft,

n::mo,ing I mxn "'" 1atItt), )'OU ntt1J '" 1"""" :aIoo1It llJ mOI
on thc 1alhc.l1w ~. )'OU an pooi.1on Ihc !CCOnd 'Cfllpb!C
""."""'" thc nwb:and bc <XlOtid<:nl that "'" bcadii _ nod
up In 1_ Ihc r\IhI pb<:cJ. ('{ou migh' """'" damp OI" lC1'eW
a SI"" 10 lloc ulhc bKtr to aId In puNtlooll18 thc tDDpbtl1)

4. Cui thc q blanks. lIy walll"8 untM ...,... 10 cut

"'" bbnb.,.ou an ..", a bit un m:>lcrtal. ''l'h thc tcmpWc
In

pbocc.,..,.. an dclc:nnJnc ho,," Ion{! odI blank ....... tic

TAltlE llE" TlEMPLATIE LAYOUT5

ACCOUNTlNC; f OR IIT DlAMITER

Sf:CONO TEMPLATt

FIRST TEMPLATE

Trlm'he "u .s" ffom 'he templi!e .

t""" 6~~T 2"j

16"'"

It ~r~:}-

I ~ J~".'. ,\. ~lf[T

L- - .,- -_._.-.-._- -

F.~.~':::"JlrYl"('Y!).) 17\1"

1~" \

7101 _ ~~~

32"

".

LI.,. Ihe Fim Ttft'lplil'

the Second Tt mplate T.~t
alonlllM lOII tdQt. Transfe r Iht "bud SIOII"loaotions
Irom Iht profile sktleh on t/te FIm Tem pi,l te.

lou' " .... 'M

293

a:o

Slidc Ihe sIed 10 lhe laii end o( Ihc I~mplale . Sel Ihc I~II
Slock In J>b<:c on II", laII", . n<! mC2Sun: f,,,m II 10 Ihc
chuck.llt". I>ow Iong 1"" bl:rnk n1l'" bc:.

5. Ro ul ..,., lurnln g8 balilc p 1"Ofilc. l"hc p"""eu

""'" 1> cx:ICIly Ilkc ,hoi, In rounding or ..""ring plndlt:.
Sel Ihe bil ""lcnsioI,. lunI on th~ roul ...... aOO ma .., II",
roul.". ~Iw b;tck and forth.RuidW by Ihc lempl"~ . M)'tIu
n= , hc lumlng. root. ~olu 'lI hlI,c 10 lift Ihc sktl sll&htly 10
"" II ",",,. Ihc hump for Ihc prolnldlnS\ bcads. Afkr """h
p.US.lum Ihc bbnk a fcw ~ "'hen you\.., roulC'd baek
""d funh 'hruu&h a full "",'iun of ,hc bLtn.l:, """" 'hc /)i.
cx,cnsion ~nd..,..,.1 ,]", p~ .
,"ou do 1"".., 10 monilor yuur Progrn:l by "",""-'Urinl
,he ginh of .he lurnl"B- It 1> pO>Sibk
lum ."" bbnk
smalkr Ih:ln you ,,-,ulll1 yoo
eardul.
Whro II", bask pro6Ic b <Ionc ond Ihc luming 1> to
Ihe cum:cl d>m<.1er. I .. limc 10 ~wileh Icn1pLoI"" and
mmn !>ilS.

="1

Ta 'Oid bumlng ItIc wood ,,hen rul1!ng clcm~lll' Hk..

lhac Ixads. Fml UkCl[ 10 rI c ranking be(u", III.. f<>llowcr ha" bol"""''''' "n ,tic ,empLuc. I( you ''Y It, youU
nole lhoil Iht slcd lro'" 10 puU 10 onc skJt. whleh <"III
""USI: ' ddu",,"" L"UL,"OU hoi'"C'o Ix c...,ioU$. Ill<pc:ricn("C.
""Y" Fred, wlll ,e-Ach you which w:ay and how moe" 10
rom",,"""lc.
AII.". )'tIU"1"C roatplelcd a fi". p.u5 OII .11 Ihc bc:>ds,
readj_ 'hc bi' CXlcnslon. ,"ou >hooltI lx.bIe to eompklc
Ihc hcad:i 'OIilh thl> JSI!'. SI) )'OU """'1 10 :Klj"'" Ilie bil "",..,.
fuUy. Oo /lOl cuI 100 dp.
.\Ial<c Ihc Sd."Ond rounod oi culS 'hc ",,",e ""Zf )"UIJ did
Il'" fi"" ruund.

Routing Spirals

'0

6. Roul ti", b<-"ads. !'rol' ,Jx, "Ied up (o'<:"';..<=Iy) 0111

oC ,Jx, "-Ar.Swi,ct1 Ihc 'empb' .... bcing "".du! 10 a1ign .he

'""""" '10"'1'1'"' cnctly the ""'y ti", fi ... was.

Swllch bilJ. U"" a I\.-Inchndiu. fK>nH:ulling

roun<lo>"tr bi,. RctJ>o\Ic the prup .nod Io,,c hc "Ied. fui.
Iower 1>1110 IM I~mpbt~. AdjlLSltM bit ex,~nsion 50 il CUI!!
aboul " Inch dp.
Now m:ike firN f>3$S on car:h trAd. TII' th(: r()l1lcr up
... c'Y >l1!h'I)I. arul p<>is<: the IOlIowcr ovcr onc of 'ile -bcad
OI"",' onll", IC",p"IC.1\1I11 on lhe rouICf. nod
Ihc sIed
50 'hc fol~ 'wer drops .'i1nighl In.o ,he Slop. Cr.rnk Ihc
,urnlng 'hmuglt lWU ur Ih"'" (ull row.lon5. ( It .houId go
wllhoul ""ylnl Ihal II", ehoiln damp j."", "'" 100><
Ihrou~1 Ihis rolire luminjl. projt.) Ufllhc .olller Ju>I
cnougll Iu puls<: thc fuUu>ocr 00 'hc CCO'Cf of 'hc <>oe' bcad
""OI'. Lowcr thc mulcr .nod cra"k. UfI . hJfI . lowcr. aod ."..nk.

""'"CI"

...

.-...c
C

ror

un

Now
thc fun pact. n,., .biIl'y 'o roul opir.ob
'urninp
b f.-:tlu", unlq ..... lu Ihe roulCf lalb" . mi II rnlly ...

,,;",pIc opcr~lio" .
Spini , umlng; """ Ix u..,d as ... hle klI" or betlposu.
on doeb and nl(rror fntM . nd in ",."y othcr .pplic:l.
lions.The la'hc . llows you 10 'plr.t!lh" cuIJ dodwisc OI
rouoICR.iocI:willC, "" yuu eould """,,c "'blc .. i.1t .hc Icp
on Ihe lefl .plnllog one w-.ry and the kgs on ,he ri&hl .....
r.t!ing Ihe OIhcr ""r.,"ou ean do a lul"l1lnj! ",ilh Iht ' OU
. pir:l.Ung from.hc bonom liP in ()n(: direction and trom III<
tOf> dOf"II In Ih~ oth~. mUling In th~ nl;ddlt.Y()U <'V\ ...."tII
cuI crosslng splr.ols.
1I01l'ing opirAIs ""Ils in.o p"y:.u ,Itc !l<aD'nod ch<tim
!lu' .re in'cgr:al '" thc bthc . tk.slll". You ,um , h" e ...mJ: anii
Ilie .plndlc l un", ,,hllc the mulCr migral.,. (rom OOt cod 01
,Itc blhc 10 Iitc OIhcr.
Wl'" ,he Luhc ..... up_ Ukc .hc prolOl)1"'- wl'" 11>0
2:[ gc-.ubox ..~tIo ond Iltc ~2-{UOlh cbtrl !l<'"H:lJ1d thc 46lOOlh InllS1"CnIC [!<'aI". Ihc roul"r will mo" c [S Inch.,. :doog
'hc plndlt cxh , Ime the plndk m>kcs One eomplete~'
oIUIIon. Rdcrml lo .. O[ In [S Inchoo; Ihl> .. , !o b <kcmt
(or lable kJI- lcfllllh IlIminll> . I ~1 It n"'f he bil .......,
ro.- mortn ,,,,nlng;. ,"ou ""n Icngrhen thc 6PIr.iI br U$ing
""",11er tr~ lI"ar; . hc :lII""""" gnr oln thc pnxotypc
",hc lui 32 l<CTh ami "'0\'0 Iht roull'1" 2[ Inch .... ~
pindlc ~u.ion . W:m, an CVC1'l loosc:r spi .. l? SloI' bJ' ~
hicyclc """p ~nod buy >lilkmallcr 11""....
1f)'OU ""nI. ligii'" ~llhan I In I S lnche5.}'OU hlI'..,
1<:> huild a I!ICarbox wlh a \cs$-.In 2: 1 ,,'io.1!uy a SC1 or 1:1
hcvt:l gn .... ""d bu.ikl tKW I!ICarbox. I..... 1I 11, 'nod occ: wlUl.
.plr.il .. ,loli arc produ.:ed u.sing Ilie .prockc:1;; )"011 hoi'"C.
Aud IlO from Ihen:.
Tu 11hJ-"r.,c ,1Ie "p"n,iun. Iet 01" . _ )'OU how ' 0
mlll p; ... Ung co\..,. Imo. miklly tapcrnl opindlc .
1. Ma ke the te mpla te. s...n hr nukinl 'hc .cmp"'~
sIIo ... n In ttw.- d..... lng Splmll'd-5pltulle T"mp''''. "lbc: ,crn-

Usl n" te mp t e is ~ .. ~ntl.1 with I"~ fOUI .. I",h~ .

Ea' h afC of lhls I ~ mpl~l~ Itlal" , the (ollow~r. 1" ~fftCI
p,"klng Ihe mul~r In one .pol. 'o lIS bil mak~,. cIII
amund Ihe c!rcumference of tl>e splndlt . Wilh a polnlcu"log mundO>le' bit, Ihe I~mplale pmduc~ , Ihree fIIII
wads.
294

~OUltr

Magic

1""

pI:ole hos ~ str.Ighl lapet. boundcd by notei",". ,"ou Inp

fullowe r In a noteh 10 rou C(J1"C around lhc Spindlc.
n", 001'' '''' CUl ...i,h a ~ ~~:t bi, . SC1 of( lhe .pI.. Ied 5ct1On from Ihc fCM of Iht pindk .
In 2!ldi,i(ln 'o Ihc 'cmp"lc shown. you nccd a pIaIn
""'-"Wlgubr ,cmp"lc 10 gukk: thc munding of thc .pindlc.
,;.led.,

,..

SPIRALEo.SPINDU TEMP1..ATE

r- ,.

,..r
L

---.l .

I ~.'
~

..)1

\Ii" hi'tlbooord

3. Raul lhot ~'CIO. S" ';ldl ICI ~Inch ~. bil.

""'10\'" thc OI""" bIodr.~ Iht noochcs.

bit ext....won OI) Ilie CUI wW tit >boul It 10

~ Inch dcq>. Lift 1""
okd Jlitdl.tr. anii pobc lhc foi..
knott .00.", onc 0/ ,"" .cmplalC ",,"c hD. s.ritm "" l1M:
fUUlcr, ........,.. ,"" /'OUI.Cf, ond lum Ihc cnnt 10 roble
,"" spil>llk ,,,.., Of 111= compk1c ~iont.. Noow I,ft IM
"""tcr and ~<k It
,Ilo: .duft, lininfl il up ......"thr w.n
fIOIrn. 1.0 .....,. ,he l'OIJIa .00 cnnk 1"" 5pindk 10 CUI ,""

.,,,ner

alon.

.......,~

II no:o:c:s5>ry, odjust ,"" "",.ing dqlth ond nul<c

lImI dqMlI.

fN(M1d pas.< at och C'O\"t, aatitlfl ~ h 10 lloc

IIM: routrr liO u.., bit II fu>t cint.". u.., .....ne...... itm II on.
\oooIrr 'M llil 10 Ilie .......... _
lurn Ilie cnnk. dr.qqcing tIM:
...,....... 10 tbc (IIIbcr rod 01 u.., tu~. ~~ yuu llfI tIM:
routrr apln _ _ IIm II o/f.
a opIrai cuI
[t"I ""'l' !lui )"OU mUlil bc mindl'uI o( 1"" da",Us.
l)ffljU 1: FiJun: 0IIt how many II9Inls )'OU ........ beIOoT
cuttl,. a oI"IIk OOK. IlrtrrmiM whldt inda numhen ).... '1
usc: 10 opaCc "'" IopIrob c:vcnly around tIM: opInd"'.~ .~
2~ ln<Iot DWU ... tbc muci<. In .his ~. )'OU'U do
tuU.1iO)'OU """ c:vay IIllrd ln<Iot m:..k: th:lt It.:
9.

'bu"'" "'"

.,.,t

StI: OI' Ihe ~

10 .....,

Ihe ~plrah.. SC>'n:d

.tdjUStm<:00i h,n.., 10 "" 0IU<k.

An:<.)'OU necd 10 ...'lch 10 ~nch ~s bit. ~
10 CUI

cighI sh:lIlow coou inlo tii(, upo:mI porUoa

01 thc "Pindit ..'itb thi!I biI. aurl."" bie In l1M: ...,...,., ond
adju.I II

OI)

It wtII pmetr.llc.bouI "'" iD<:b InIO 1"" spcndIc.

To chcck Ihc dcpth, lilt Ihc rouICr $kd dtnI... !il) Ilw tbr: boi'
il rating (In Ilie !'Iod, _
tbcn ",."......, Iht ~
bnWttn IM rouo..u _ IM I=pbl~ ~ . ~ drpch 01
CUI will Ix IWIHhinh 0I11ul dist>ntt..
Ncn. fOU ....... ottI:unp !Ix ..~ .,...".,Ix "",c~. You
_ 1 "'.n' ...., iUIIoooou 'o clip In'o Ibc nocchcs..

S.

ROOI

IIK flr!;t

plnl C"<>ft.

To

tou!.

a spital. )"OU

lndc:xintI nwII ... IM muek wIIh tbc ~

UlIUon nwk OR Ibc ~ock . ~ou "'USI $<1 .bc fkd a.
d!bc:r [Il( holbIodl or Wbiodl rod, 1hC"t1 tigI"I[(n IM
1f'I"I"tl'JIN... ctulin elamp. 'IihC1l ) .... ,...., rndy to rout. lift
...... al ... an

'.6.

12. I S. 18. 21._ 24.

l*f.. u 2;TI>c: drh~ \t:lltI h:I a UuSe: pt.y In 1'. You ........ n.
to kttp IhIs pby under......,uuI by alw:t), .urn", IIM: cnnlt
In thot: _
dlltttion . lf... hen $<111l1li up. you...-cnohoot Ilie
ln<Iot nwk. dt> NOT had: up .1Ie chuck hy ~n,
thc ~ )'OU ano cranklrIa. Instod,"""" . .... chuck oll
Ilie ""'Y amund 10 Ibc .........11Ilo k .,.,p& Ih~ ~""k I ~kcn "1'.
In l<kIhion. aI..ayt cranl<1 ... In .h( s:urtc di"'"a~'" \
habit ,hot nn , ..~ you """'" WO<I< lmaaI"" rotIUn" Ihc
ci;ghlh ""rai dodt...bc aflrr roulintl llle Ar.;[ !!C\'m ro,,,,

tndockwbc

o.wU J: Ilon't ~ lhe chaJn .;1:ID'p. ~\MJ wUl bc U[lht.

roin _

pbn is

11 ~

'"
"y

4.

\10" /!yp.)

2. Muullh oul Ihe splndk, CuI IIpIndlc lbouI 2101

lnd>cI "'I""n:
.btlUl 36 1nd><:J, kInIf. Cent ... it In ,he:
muci<. ,h ~n ruund II'" turnal:* tr'IIIII"'" of It. l1tt Olraiahl.
k-vrllcmpbu: aod ..n.leva" bie )'OU f,n.... lOr Ihb O(ICnl;""
Whcn ."" .[>indlc: Is .\U'11Cd 10 2-InctI row>d ""ilch
Icmp"''''' and CUI 'he LOptI. To 1'f""'tfI' IM kd' 1bIk>oo>..".
frum dipplnjc 1010 thr noIch O! cllOO rnd 01 IM ta".,...
........1' ~ !ICr.lp t>Ioct 1, lhc >'CI'}' C'd!Po 01 och <>ne.1'hm "';'h
"'" ......., bII }'tJU 11:1.., bttn Lt<inJI. CUI ,"" apn.

s", I hc

plywood

:arul

Of

1oo:Icni1lll11le clamp "8"ln an<! "1I'I1n os you IOm

!iCriQ oi ~. C".oon.!In:tte . he dtml' )'Ou "",- oul' ar

bat.OIII_ .... th tht dittttion you turn tbc cr.nk and thc ~"
"",,s JI"ninK palitOn.
FQr c:nmplc. 1 .en<! '0 crank eoun'ctrlod:wisc:.lb mc. .,
thc ,op elamp ..,.,.,,'" C3SIcr 10 l11e. Sa [ ~ Ihor slro al thc

:!!.

CUI. '''''',

taibtod: 10 btWn """" IopIm

" ' hen 1 Ilghlcn 1"" ~
IOP elamp and lurn Ibc crank C<>Uf\.cteIocJcwi!lc . thc roulcr CI
..iD bc ~ 'o 1.... hnds",ck.
[tere'. tbc drill:

1. I.oooom .IM: elamp, an<! .1kIc II.., .I~d .0 II. >1""1l1li """'"
lion.
1.Thm .hc e..."k In .he
dim11"" .n "lign Ihc
approprl:o.c chuck Inda n\lln: ... i.h.IM: hndstod< "'It.

""<>'CIl

bl:r.llion .........

j.l igh.(n .hc e!amp .

.... ~tlk(!lI( CU!.!hal ~w;(ch of( II..,

ro~l(r.

S. Go 10 Step 1.

ROUle. U;IM

295

So . . thn:Iu!Ih thc ~ in your _

anii ""'It...
wilh llle: "Ihc:, ..ith thc: ....... cr .wiu:bed 011. Whm )'OU ~
rontkknl )'OU ~ rndy 10 maR lhe dril'f fly. ~ Ihc:
........... 11nc IIJIInda """" _j.ligInrn thc: damp, anii tuUl
lne fini spini.

6. llout thc reI ofthc spltab. With.,.,., spini CUI

un<kf , . - bdl, lhe rut ,,'ia hc: pKa 01 ak~ .
I.oooo<'n lhe dWn damp, and otidc lhe rau .... 5Io:d back
10 thc >l:lnin.(I: poooi.lon. Ctank lhe spindIc ~ il:i ..,.,....
IUlIon. ~ thc Ind<:x nwI< 006 ... llh thc: rcgbI ... Uon
maft,l,.lllm thc: rn.1n d.mp. Rout ""'00 spini.
1'hc: """1 spini ...111 !-Wt from lnda m:"k .09, an<.l 'h<:n
_12, and lhen "15-00' you ",. , hc piclu..,.11w.: WI. >pir'"
you fQUl will hc:" 1"""'" nuri< "24.

Elltended Turnings
Il "'"uld hc: a >han", If 1"" mu't, ""hc ', WlIq"" ,utnir1gs
'o hc: con/l~ 10 ,umlnll bb,,~ " .., <'<JU1d ft, hc:tWttft
thc: hnd$lock .mI l>lI>1od:.. IIIM Ihc " ,he'. unlQuc deoi&a
al ~>Wlo you lum I>Iank of a"y jmoC.tClllcrogth
h:o<.I

Won, ,n mUl a ~ Of 6-foo<.1I>fIjI Mdpoot:l y..... OUl do il!

Wuu 10 l urn couplc of post~ lVr Ilie pon:hl 11'0 hc: I lot 01
"""",,blll)'OU can d.. k, AII)'OU JICCd In .."btod:. ehod: 10
"""ch ,t", tlDlb.lod: (h""k, WIth Il In ","" thc t...-nln8_
om 1"''' throtljlh ,"" ..1I,..ock just .. Il ...... Ih~ tho
hcod5todr.You OU> h....: acouplc Jca 0I5!od:. !u'UflII_ 01
boIh m<b
bthc: ,,'I\lk: )'OU "NQf'k ,1Ie tnlddk.
n", utlblod:. ehud< il I dtlplical~ oItt.. hc:a<bI""" ono,
1houjjh)'OU <Ion '1 n<-N IIM: IndallIII m;ub".. Il In _ , Ihb
.. ~j l i1ty ehud< "mply """" <MI ,t.. .wo ... ppon b<:artnp
'o ,t.. uu ...ppon..t, ...... 1 loppIr oIf u.. bnr10p
beca_ 1, II dampnllo IIM: blank, ond 1"" hbnk in 1.... i>
c"mped 10 ,he ~od< ehud:, ..'hldt 101 K(Ul'tIy
moutu"" in thc: hc:a<bI<Xk. Gm. tlw1
1O.oeI lip III c:xlrndt:d bbnk .... ,........ ""'8hlY cmm
I in thc: t.il......,., dtu<:t: ~ . f<d thc: _
~nd throt.I!Ut tbt
_ o d r ehod:, ond ..... thc: Wboodr ehud! <MI It.. ""JIIIOfI
~_
ani .... I~ bbnIt In IItt: hc:ao.bJd: ehod:.ThIt
dont:,ldinc thc nIerirW 0Il/tt: wort< in I/tt: "iktgdt dtud<.
Tbc bIanI< cat! _ _ Ilo: 'UI'Ilon! ...... If Il ..""'" a ~ ....
To do III ClUrndt:d lumln&)'OU h...., 1" cuotomb:c: tbt
design 'oc:onccoJ \o;onsiIiDRs be,,,,,,,n 'urrtcd Oi<'ftII1"n.. YOl>
probobIy won't ......, mud! """"""" pro<.I~ a conilnUOLl>
ruundorUpa' that'slonjja I"""I~ 2? Indtn.h~ blIM:aon
wort< al 0fX tlme. Whl:n,.,... s/lili IIM: .....n.plc<:<: p' ....
J<lU ha"" 10 ~, .... Il In ''''0 ehucb, and th<: UkcUhood 01
'be 0'0IId .oeIUP """ehlllll t/tt: II"" aHlIIlmcn. 10 oUm Kl
none. Th~)'OU """",' , ltt:.bIe tO sean.lcs.<ty I>kn<.l 'w<I 0I_ 10IIC'h<:r_ So """ mII'''' lI~c heod 'Of c<}.-': ",

oi,,,,,

bul'''''

,k'o!.

--

_It

.~"
Routing 5plr~15 rflQulrts YOU 10 IN! m~ l hodlul 'Ibovt
'III else. Al"'iVS tu,n Ihe cr.nk In Ihe SIom, dl'etllon.
Align 1"" Index m.,k on Ilie chuck witl! the 'eglStrl'
lion mil,k on the headslock (rop) to Sti Ihe splndl, In
Ihe prope' "a,Ung 1)O.lllon. Wllh IM ,ouler In IlS
"irt'ng lociltlon ind IlS ctllmp tlghltned, lum Ilie
crank {b<lt lomj 10 Simullan~ud\f 'OIi1le Ihl Sptndle
ilnd d,ag the roU!tr, mlklng the Sptr.1 cui.

296

Rouler Magic

ROUllnl _ lonl workpiece c"lIs tlte i1... m".,. ehud;

In,o plily. Tht opoe:n-c:enttred chuck design "llow$ you
'o 'SItP' Ilie bl"nk .hrough."" ....... , wl)flu"9 il; sec
lion bv 'KlIon. I1f:rt t lle mld>tlon of" Ior>g post"
lN!ing rounded. E><ltnding Iht lumlng slmply fflIulrfl.
you 10 IooStn IM chut. dim", VId shih ,1Ie pos,
10w~rtI tl'M! tilISIOCk. T/'M!n ~ rtCenw the blank ind
contln~ 'OLl"ng.

Creating a Finial
A tin,al II

il clKor~tlve

lum'ng used al IM I'p of il

Ilc~plKe lu,nlng.
th.on il spmdle IU,"II'Ig. The (Of! IS turMeI 10 il po'n, ; it
ln' S& .... f1:I olt.
TlIe moSI eboborllt "n"'l, thll come 10 "'" m,nd
ate 1'" Ila._ f,n ... l. IYnda....... d for Quetn""'nf1
""iIhoboys. Whlle , ....OUtt.
_~ produce i"'Y.
Ih'ng U exqu,"tt n il ~t fin ...l, It ..... ,11 frYble YOll
10
il fin,al ind d",o"'lt II ... ,tII . pin! ~id s.
9'00\1<'0, Of (ovu.
Onet 'Ou'w miStt~ the an of ruming splndles
ind tlKonl,ng 1""'" ... ,," .,1 ma""", of spor.o.ls, you
POR 11\ U!1.<i11y (IUte<! 1$"

rit"",

Ia,,,,,

' ' !)le

mlY .... Inl 10 Up"r1mt!nt "'lth finlal,. Tht ,*,OIOS show

tIM! selup for .. Iln, ..! turned on tlle mut,. t'tlle by
f.ed IoIlO\llOCk. Tht Iurn,nll Slock 1. suppo<led by III,
thudt Uld.n .u~,hlrv suPPOrt ellmptd 10 IlIt ""o.k
b.",,,11 10 Ilie left of Ilie hud'\OCk. You ""o,k Ilie end
of Ilie .IOCI<, Ind lIN. In m,nd Ih.1 Ilie .Iock h" 10
pt'OJftI be'l"'nd \~e LoI"" f.. me~ m,ddl, support If It "
10 be ... "h'n Ilie router's 'Nch.
To IIW Ilie IWle. bit bellt' acctn tO Ilie Slock's
end. F.td sh,fted.1 10 Ilie edgt of th-e sltd lIe"eSI Iht
I>Nd'lock . Ht cUi. Itmpl"t. ""h,ell he uoed boIh 10
slll.pe the f,niallnd 10 QUode tlle roullng of spo, "1
COWS "'10 ti.

il splralect fI.lIl 1. il rovl', I,U'" t ~du'

You can ,hape il finallike Ihls on il lal"t. blll
you'" 1Ia,,! to handca"" Iht (ovn. Tlle gractfu!

1I..... llnll
sl~.

Ifmpllue clamped \0 Iht lal"t batll "',u Uled 10

bot" shape ind .pl.al 11010 flni"'l. The block clamped
to Iht It mplile ii Iht start'"!! block ror Iht spl",I

A ....... QlU ..,.... Isl>Hded 10 support Ilie

finlll bl.nk's free end. "simple bUl effeet!w one Cln
tie cobbled from K"PS and dvnptd 10 Ilie work
bench, "' sko""n.

2
;;_.

,....

Roul" LIIthe

297

Jig-Making Materials
and Hardware
loc <>1 Jip. n..fs ... ha. I"\~

KftI In lhe coww 0/

book.A LOT oI;isI. l'w buil 101
of tllem. '00. 5o<r>c fW(J OI" th= limc. n.c I>c!it 01
'bem. 01 ~, han a1rndy bttn o:kocrIbN In druiI.
Wh:a. 1 ..... nl .0 ,alk :abou, ""'" il OfI>C' 01 IIM: m:lCerb'"
u..cd .0 .... k,. ,h,. ilsS in ,hit 0001<.

de\~IopinjI;.hk

llou.n

Ji&s doR',

onc ...... 'h~

ha .., 10 hc fancy. _

"'" ma<k

al

i.,.,.......rn 311 ovhm you W2t1' .o:mach

.special Imei: OI" !.Iop .0 lhe I00I11:. wj,hout ~ .tIc

fac.Ofy twcpb"', Tht an;: th.c: jilPl )'OU pr\lbaI:IIf ..'ia
robbIc UP"""B nu.tt\aI:o rrom "'" "'nil' bin.
Th .. doon ', n.... n. oIco..,.,.,.tluo.lhnc JIa"icubr 113>'
""00 " Ix Idgh.quaJiry. II)'OU Otdiltl.tlly """'" "';,h dcft.
IJU.cri:oJs hen yuur ocnP5 wiU IN: <1,.0. , '''''. II", Ju:!I.hal
)'OU I'robabIy wW fttl leu "'8"'" a. ,ONO!ng iilI )'OU Imdc
wirh
)'OU had alrndy dcckkd ta 'OM out,
The ""'lOrity 01.1><: 1'11' I'\-c: IndU<kd In ROUlft' .1I..gk"
.'" buUt to be ....,<1 apln arwl IlJ'Iln -a nw.IHrimml..,
l5rpl>rr, for a.mplt:. (M"' Inlmmel. a mon;~l ... li,.
T-.q,,,,,,,. for.h....,. you IUM mlglu "'~I 10 In.-at In I\CW,
>P"<'i>I!.nl ",,,,,ria" .nd lurtl...."' . So al ,hIJ book ..'Ind:J

"""nU"

or.

down. I w:.." .0 p;lSl oJO"ll1Ome of'M thl"ll" Ilnmed

.bou hc!iC .peeialllsm. klng IIU'Cr!a1J "m.l Iuru""""

Sheet Goods

le"".

ru'u'"

Dcp<=ndin/l upon l'Ou, ",,~e

and 'M
01
. ._ , . he ..'QOd......n:l"JI),ou do. you ""'y bc .h<>rotqd1ly f:lmlllu
wllh 5h1 JIO(><ls. Surdy. ~''<"I'Y ""U'CI' ..~JOtJ"'u",~ r tus

" 'o",<:tI \VI,II p'r"0..d and h:utlboanl, wh k ll "'" 61<xk""

tir honl<: CCnl~1'lI os wdl luml"C'ryanl$. 1\>1' "",tl1ljl Jlp
npecbllY.)'011 ouWlI 10 ""mu", l"C'yond Ihc c"n,......, C<>nSlnIC,l"n 1ih1 guod~.

.!:lI

Plywood
1.ke pll"''00<1 ror a . mpk. I, ~. nmerial found In. (U't"
""'ny of Ihc: Ro,,,.... M"J1/( 1111'.110" aII I<now lh.. II I:!I ".bk.
,h.l, II .. ",,,,U""1y u".rr...:1.,.j by ch.lnll"" In humldlly. ll~
.ubiUIy m.te> " JIOOd n'.lerial 10 .u.e whcn )'OU w.rm a
~K 10 m.ln IlS accul'K}' (or. ""'It ,'nl<:.
IIm )'OOJ !ohouldn' ...., IUIII :ury tind of plywOO1l. You

!ohuuld WI1: hanl""OOd plp.."nd ..... cwn l"ct1 ~r. a p ....mlllff/

h...,l>o'OO<l pl)"''OOd like -'ppk PIr or I:\.OI.k III,,"'" ply\O'OO<I.
Unlikc WU1t11ClIOfl pl)'WOO1l . h.lnlwood plyWOO1l h,..
_ I I, h.lnl ne" ''nI1'S on bolII .kIc> of
r.l11
1'Ij'WOO1lI~ madc lIy glulnll ,hin I>c" ,'cnec", (I<i.o 10
'-_'" 1;. Ind!) 'o .,..... 01 wood pllc OI' comlX'""c m.lerl.lllte
pankkboanl OI' mcdlum.ucn'>lly "II<:rhoonl. V"n....:ore
(Ve) pIpo.'OOd .. Ihc .;uictr mosI c<mlmonly IWnd In

,1..,

... bon .. nu foI' I'OU''''I' JI, ",.. ti", 'UId1!Ii In ,1II1i

IilKk of f~rtv corn",,," IiMeI 9QOds . ....
li",,"""
.....kt 9QOd Jivs. bul s.om, mak, ,,...,, 1I9s.

,'1IoH

...... ,1 )il<>t>J.Thc ~ IJ madc (rom pllc5 8iUC'd 10lIl<100 In

.',c"""tl1ljl IV"in dlm;tlon!l. Tbl'! cn:.>M1n8 of "'" 8f'OUt$
III""" VC p/J'WOOd I,~ unlrom. .. mrllll and dlmm!IIonaI
... bllI'Y. li IJ ""b,I",,1y Ilgh,wcipl' .M doet a (DOOd joi> '"
hoIdl"JI fUle"""',
1ypIco11y, 11-1",,11...111"" >llce, of ve pIpo.'OO1I ....
",,"e" plln-flv".,..... pllc5 and IWO IX" "C'f>CCD.";pc..
lV.dc plywood has :1 jIteIlff numbtt 01 p6eI (l$l2lIy I) lor
'~lndHhld pand). "'hkh ""''''''' u.., (WI<:I .. iffct' .....
more ... bk.TbIll !li
In ,hc: 'ypic;d liI!;.Iri'1I hi:d>
quall!y pl)"''00<1 wch as II;o1!k lIi",,1I OI' o\ppk 1'Iy, a ....,
cdg<: con b<: ~I\<kd ""d poIbhc:d fur a dtn.>ra'h'C dfn;t.
For ......, VC pty.......w.. )'OU CI" apcct ...... u voIob In ,Ilo
( undtr Ilnch di.tmtlt:t) duo: 10 kl\od>Olcs. While o'OidI
wun ', lI"""tr aff<'Cl ,hc .. ..,"8'h of ,I"C' paRCI, e<Jsr::o _
'1ttIl 10 hc: flllco.l. or bcilt r }'CI, Iwodcd wUII 00I1d wood.
Common Ihkknc>sc:5 fur hartl....ood p/J-..vod
51
Incll. ~ Inch. :lJld 3i. inch. t:ttp in mind riu, 'hc:$ itt ...
nomln:al .
III<: par><:ll"" buJ' ,,'111 b<: thinna th:uI
,II<: "a,cd ,.~: For """mplc:. ~ pIywood b!fpinlly ~
Inch ,tlick (~ lnch ,lIl(Ia 'hc: nornin;.II ~). Al1hough pandI

'",pun"",

c<,,,,

""""r.'Iy,

...., .......,. .. " ti fttt. ~ .n.cu Iik~ B.ll,ic Ili:R:It >K

","ric y>tcm ~nd COI1>C in odd Ji><:II (<><kl ' o ,..Arncn<::utS).
1)"Nc:oI;" 1:10" 1:10 CctI,imctcn (~ S fttt ><1""'-").

Me.dium-DensiIY Fibe.rbooilrd
II .-.:rr t.IICfuI ohm l!OOd thol '~ ~........., """2ibbk

nx..Iililll-<kn>ooy fibnbu;onJ. 1, ', """" pupuIar matn"i:ll

CummonI)' a1kd -MOF,"" ~'Y Ilbnbo;onl b

u.N "'horn ....,,1...., ur !A>bstn,~ 'M"s c:r;tmncl fb, md
!inlOJ<Jth il. ~ . MI)f S nude: f.........tw. UIdI 'o bo;
~"OOMo.km.l "'-a>tc_ .."Uod chi"".1l"oc mi"", from both Iwdwood.'i an<! .ooftwood!.. arr jI:I"IIW>d in'o ~ bIornokd ..i,h

1 ......11 1rnou.. , ci "rc:> /duc md ~ ..-nes (b tn(Jf'U'" ""'i>I2ncco), ,hen bIown in,u 1 lOtming mxhl...,. A
con'ln ....... """ nncQICS from 'M ~ """"1"", an<!
posses imu hoc ~ ....Ildl 5qU"'" It fL\T wKkr
''''n\CI<!ous pl"t$SUJ"C (up ,o :10.000 pound!;). lbo:n "'"
poncll:! "ulllcd ,o a >f>iJlc ,h"'1<nc::>.. and.av.-m In >W:
Unl;~c pi}"WOOd \.IOF ,hickncssc. ~'" '"Cry pm;:i!.c, A
1'~l nch, hlck pane! ;< rigii' un 'he MOII<")". WholCO<lk
... pplie....ock "''''''' In \!Hncll. '+-Ind!.:arnI *Ind! ,hld
M>OeS. lhoupo )"0\1 m:>y noi flnd .1I1hkkncooes In a /CI,.....
mo.il o".lc'.l11c s'=o!an:l (l'Ulcl ,itt .. b lnch <J\~" kct by
8 kcI . MOf is h....,,.. 1110U1 h>lf
a rompa...bIc picee ofpi}"WOOd .
TIlc del15C. hornow:nrou ~ eI", ........ cr ci MI)P ~ 1,
p;rc:l' stabiU,y. ..... klnll II an kk>l m .. cri>l fur liS' :arni Ilx_
nun.. 1 ,hlnk 1, I:! ""nlc.. larf) o .... ror 'cmpl.:o'es. II rooInbit"s piloo:
..-on ', cumpr<: 116 dcn~ tU!on (ar (1"",
imo 1 void bo;, ,,,,,cn plic..). MI)!'"" "ni fum, ... n""" n",~.,. 10
an acclknl sumtr. 'c fur I.:omln>ln.. Routl"lllt> cdp prodoJc:d shatp. cri.!p profolcs. TIle I'ocd.n: 1m000h cOOU/d! 'o
obri:alc 'hc: nd br ~""'I"lI, bUl 'hc ~ .hoold bo;
.wt<kd Ilghlly """"" fI .. r.hl"gl .. onkr 'o ",mOV<' ... p "'(O
iLfIn macbinil13.
Cornmoo "'OOdw0<l<i113 "'''''' bornJ .... dl 'o ,he ... r&c.:
ci MOf. bu, "'" .,.,..,... edgo:o >hoo,kj he ollC<! ""toR: wulllJl
(II ,hin c,,", cI"'hllc ar 1"'1""" (duc wo'\:' fine.)
1jIu, MO~ 1J.n', ptQbk..,.r"", m.:ncri.>.I.Qnc hitch '" ,h .
lriI. .........1nI. MDf wlU .... lck up """".. '" wnd ,,,,,,Il. ,.,,,,,Inll
pcnru.nm' c~ In dI.... ruIoo II film Ani, .. nr .'urf,..;c
\"CI\ttf ...... , proIt bo.>r\b from .bliOr"b,nll n'"I .... '"
AI>Olhcr h1,m b ,Iu, ....., MI)~ p:oncb Iu'c. 'cn,kncr ' o
. . undcr Ioad. ~ WKlcr ,heir ""'n ",clllh' . bccau,;o: 'he
....crW hali IlO I'""in 'o pt'O"Idc .d{(nc. \\1,h 'hc 'I'PIcIJ
iii ur fix ....... , 'h" ....., ~m . bu, it C:U1 bc If yuu u.e
.wOF ro.
,abIe 1<>p.1b
gglnl.
lltI
oIc>ipo IIIJIPOf' WUClwt Cu>Ttn!II bo<h bec~ whh pW;c1c
Ilmin>,~ _
.utkn oM (l'Ulcl. oqc;otlllJl Its ,cndcncy tu
. . II ,hin! probIorm ol!io!it""'" f""", MIW. p:alnlc>sr>cs!.;
kvubr ..vod !lCfnl'S ..rip OUl. Ulle dcc .....htntlcd
lor ....... .,-ab. for n=
hokIInJ poa~. U'lC knock
00..... f.btc ........
~. MOF
' o poa"dct ..1Int !"OU machlnc i,. I
- . I'QWI}[JI. Thl$ il fiM du>! Ihat ljCU n"'I"}'''''~;
...... dll!it <:"OIk!ct1on Ind I ...... mN .... musts.

"8'''' .. Ilo,,. ..

Ixari",

.,......",n' ..

bn''''"

'"n

r"u

'o fiherboord 1" ,Iu, it '" m.adc: f......

1Ic""""" ,,', cun'monly .,..ibbk- in P""-

1l:udlJ<.q'" '" simibr

ground-up flbe ...

c;,;." and uniform ,lIlck"""",,,," of It I.. ch ~nil 14 lodt . Ind

btt:tu!c i, ..... bumWtro wn.ce
_1> . ..... !oIipPCI"}". tit'" r)'Pc ci ho<ud '" wcll wl,w 'o l~ iti(! R~, ..", ..'Ori<.
Sc-"ttal ~ cI .... Rlboartl .n: .... II.blc .nil tor Ji8
makinS!. ,lIe n.olc of ,ltumb 15 '"e I>.nlcr ,he bet'e.
Tcmpcm.l 1un.lIxu.td, SOMnlmc1 ",{cl'ftd 'o os MuonJ,c
("'" br.utd ... me ci In'cm;o'lon.J r.pcr Con,p."y, bo:onl).
I ~ ~,y honIboanl' ......' htto reslnlmpn:g ... 'w
:arni heI..<u~ TII'" ,cmpcring procCII5 cnlunec, 'hc
11,,",,1"> luni...... !it"'., md
n::sbtm.Th<' 'YlX' of
IunJboanl rd """""............. 'WO """"'It fa<.ti. bu, a
5C1tttlbad<W 1unIboud, ..1tiCII ~ 1 smooth bec .. nd 1
obo .v:albblc.
Tnnpcrcd lunlboanl ... JOOd c:I1oko: fOr quietlc: b2>cpLltcs ( ,boec )oIHpcIIc 0IIC5 !"OU make lot h2>le, 'horn ">S/l
Ju$o aii qulckly"). It .. quI'c uoItotm wkh no W>kb ar opn ...
~ bu, l'OU IMJ" ha.", tu lf'PIr ""'''''''' I.'OIU ci JOkr 'o
'hc: cdpcs (""" lI"t'inS! (u:cq. II !"OU nd 'o lIIuc 1,
'0 ano<hcr put, Iu ~ hHdI 10 bc rouJthcd up nr:.o

,1"'' 5

;"

amana c:oramm:iaI ~ for Ion bul unIy m:cno.Iy

hu ~ Iound it> ",....y Inoo nuilllouiIdin8 <UppIy (din;..

n,.""..

Hardboard

,n

"""""'$

"-"er

,,,,,.urni fa."

.,......'ml

(1 ZO-gI, ..""'" "",U).

p.. nicle.booilrd
l'anldcboanl 10 .... Ioldy .,..U.bIc md chel.p .... k It .u........ "'"
10 """'y ..'OOd .......... cn. Il b COtUidcm.l ~ aco:llcn' .....
for plutlc Wninatcs and tit.., la widcly l1SN for
""".. 'enopl ond cabincIIy
II" ~Iy Iro"o.ibbk In I wtIcr lICIcaIon clthidu>csocs
.han pIywood ur ,\ l0I! AlI oM aund1td thIct~ftom
!o Inch ' Q ... lnch_aK !itod<cd. ......,11 .. thidc. """,,10 Iik~
1 Incit. 1~ Inchcs. and , ''' nchcs. P:uIc.. aK I)"picdly
411 1i inches ..idc by!l(; \; I~ Iong.
00"" ~ fbkcboattl ur doIpboattl. parUcId>oattI b
madc ftom mlpo
aK compn:ooal untln" hc1I and prosu'" "l"he ""ua'ini pancll<.lil<c MI)" hca>icr t/un pIJ"'vod ....
bu' Icss "I"0<\Il ,han pIywood. UnliU MDF.1u in,cnW oJrn.
>II)' l~ Iow. o.nd ..au ",,"kc )lOF. I Iw ""'~ ~ 'M
......1' fn,m \he br@tI: mi"" UM:"d ' o makc ~. Ukc MOF.
wQrl<l"II ..i,h portlc\d:loan:l rtquIto 11""'1 du>! coIkctIon.
Thc upoJtoo; ls .It:ll ponlckbo:ortl b a pml)' poor cboico:
tor maklnJj 1... You apttbJly .t>oukl a>'Oi<l uo;ing partidebo;in:l ... Ioc", .,n:''lI'h o.nd niF quallty arr ImponanL 1,
n,.kcs ""s;olhifoctol")' 'cmpl.:ola btt:tusc """cr bit pilou aK
likcly '" <.Iig In,o ,he clI[!IIO.

"'''''c

,ha,

-'i

Plastic Laminate
lkcIusc il "'....... "..,U .... doi "'KIOIhlyon "'OOd,and;,,CI1lIIy
n~hlru.bl~.

pb!itlc "'ml... 'e iS . lI'"Ca, m:>'cri>J In U'lC In

making. roul".. ul)k an<.l ...~:lJld In nu.k"lI rooIcr
jI&$ ond costom ~p"' , a. I ' I:! R:adily ..-:li.bbk ond b =y
tu bond '" ..'OOd . (Somc of II b n-m Mlpf>O"'"'l tu looIr likc
..-<IOd. 'hou!!.h "",;011 know i, dncsn'I n ..... comc <.io5c.)
Thc n...
nu<k hr ln'p"1l""tlng ....."'nI LI)"Cn ci
knft popcr " ith phcnolic pl.soic "",io.Thc colonnd p:oUcm
.. in 1 5C",,""e sht of ""pcr.l mpn:gru.'l wi,h mdamlnc

,,,rtaJ ..

J;.g Mi ~)no

"';!'te ,!ils and Hirdwi't

299

1
M

1._'"

moot IIOJ>UW" iti .... tOr tI!;..""", Wnin:alc '" J"'II'!1onC'd MI iti
edgcs ","Cth:uljt 1....... ollix .ubsmle "'"' lllile """Ilh )"OW
rou' "," ".. ..... lnal .. trimrnet" lfKl flus/Hrirnrni"ll hll. zip
:It<lOIIOO Ihe ~ , lI"immir18 -'2)" Ihc: ClCC<SS Iambu.c ortd

makinM; "

n..... wlth IIx oubot"'... clisa- hrfu11

~'.

l ~,tlc onan: 10"~ "itll rta>tk lamlnal"

!han mal. huI. II,.. ....... <1" i> .,... kcy 1001 u""<l 'lItnllWO .... ,1 thr

proc"'" In addl'lon 1" .nmmlng Ihc: n!p 10 finul!. Wnj.

nale projoccI. ro" OIn ~bo WIC Ilie !OUle. 10 rut tIM: pIcuo
}"OU nccd r.....m ,"e Iomlnat<" ~ ,o,..n Ihc plllject.

Plastics
For jigs :Ind r"'IUOft. 1 lot .. lhit .. urr. Ckat ba:qlbICS maltt
II "" mud! ~ 10 lin: .. hal Ihe """<1" .. <IoIns .. ,.,.,
worI<. 0c2r moum .... pIl'", can m:t.ke II n>icr 10 ctu ....
bib in a W>IC"-moltn ..... """n_And ,har. fus! , hr b<:sInninl
oI.1IC" btt...flt5.
y"" ""011'1 (ind p .... tkll OI ,lIe Ioal buildif\jl centt . hul
the",, p,ol"'hIy pl;tMl.,. dC":lk. ncar )'OU. l u.... ""'>OIIwur1<I"8 power '0011 wlll CtI, and 00"" anei .napc- ~k ..
w<1I as ,II..)" do w<.lOd.

Acryllc ud Polycarbonate
Pbo5tle Ia.mlna.t .. 1, aUKhed Wltl! tontact <~m~nl ,nd
cu! with, flushtrlmmlng bit. fU USV as It is 10 applv. ~
P'O"id~s Slitk. du"ble surfitCes for "'-n:lworkl"ll rDUlt.
Jlgs and fixtu.u. The flnntd-OUl umplu.", oniy" ~
",senti!;"'" of "UIIIe IVlIlldrle toIon ind te~lures.

_ _. .
,

pb;IOC ..".." " 'hkI! ro\-n:o ,ho: .....,. ""'" .urf:K." an br

~ "ith de5ign OI" tatun: ""'" ""per bycn :o.nd 'he
pI:lstIa an:- bon<kd .... hc:r..-..kr hiWl hnl aneI~.
",., tDUlrin8 nutmal il Iwd anei dur.obk-nMly ckane<l.
1fKl-"CDl<."h- ..... ,,~t I'uor.U lhl>, I bon'l apell';'''.
In 1"" rQUI"," """'""""', plastic I;omln:"< an b<: UloL-d t<>
nrvn' an)1hlng ltul ntt<b ~ wc-..... rni>clnl .tiei<. n>iIy
cr.oncd 5Umcc ROu1cr t>1">Ie Wf"'. Feocc f.Ici"ll".You an l6C
~ 1" ..I... nt;l.g<: un til(: b;t>o: 0(. oIa.I .... lI ... """'" of. <tJSigtM..
t<Ijcr. If. ""'bk.flo, sutfx1: il nttdnI. 1I< IImln:llc >houId b<:

.ppllN W bolII ...... oft .... ....., 10

r''''" ..-:upirw.1n .......

1n>Pna:o . ~ ,.~< lOappty~ ..

.!:!
'a

10 bodI ~

bul """,,,"", """ ......&tt ...\11 b<: hiddm ltom . _. ,.,.. an

~." m<ln<"y 11)' >ppI)ing """,,1 caIlI'd t.cl.n 10 Ihe hidden
liIk l\Jd(er 10 bmin:oIc ,,i.hout Ihe IIoo-1o}""',
SokIIn :IC"O-nal gn<klt., ,lte motI romrnonly urtI il 'hC"

~ horiront>1 gr.Mk . ""hieh "' .1>0011 Il. Inch IlIick .\ lany ihttl
. . Jiu. ......... Ubk. r:onging In widlh rronl 30 loch.,. up 10
II. 60 ~hcs, and in "'nglh fro", "'0 12 fert. MOSI lumbC"r
Qi t"llM ><11 ",'cr.ol di"......'" b .... nd 00 " 'iI! h......n
4( locmllhle >MOMlnen' of I )( 2-ioch ","",pla ' 0 <:ho<:>M:
from Onkr Ihc Ct>Ior and flnbh 1"'" .... n "",kcl 1"" obttt
lI1zc. and In a...,... d:tl~-motIlikdr- ,...,' pla>tk lamlnat<"
...111 Ix ......". ro.. )"OU 10 pidt up. tled "p In Z. '0 Hoot
diamtttt roIl.
In. n ul>IxU.1he ~ ro.. ""Ofk~ " 'lI h bmInat.,.
.. CuI pit- <li pI;toIk I:mtina.< 10 ot:.c: JUSt kw fr:>etioru
01. an Indt Ww=r th:tn Ihe pIj"WOOd, MD~ OI" OI ........ """'r:otc
li it 10 <00.",.. lIond II 10 me .ubol", ... ; cOnlact ....... enl Is Ilie

L._-'

Acrytic anei pOlrc:"'bu.... c. l...... cornmon pbMia., an:- '"CI"J'

popular ro.. """'ORI 1>aocpIotes. bli ~uanJs. ond Qthcr iiiappIintIons..
AcryIic: ~ bC" mon: familiar ta )'OU OI PlaigLu, ,hr
bt2nd lIWIubttumJ "" IIoIIm and , ...... OI" OI w.,;'e. ,.,.
br.tnd .....tc "" Dul'onl Thc", ..... OIhet br.lJ1ds," ,,"cu ..
1jCItCrla.. 1ltis namc (lam<" I~ lruc oh.o of p<)I}... rbon.:ol<""
y"" =y ha,-.: hc-ard of C.cn"",1 F.kcIrk", tooon. o. Roluri
and 1I..... .1Uffak. wlll!oul know\njI borll "......, boran<b 01
poIrcarbon;olC. and ";Ihout knowi"8 lhal )"'" rouId buy I
"I!IOJKri<:" P<>tt"Cll'b and ,."., a Utile m<ln<"y
' .....h :tCf)1ic and po/yatt)on>l" pI;toIkt an: P"""Y """'"
"""'It"
nq... !IIodn! "" pb!llio do~
J">UI" l dlo.. Pap-in ohttL. In I .,..,., <li .hk:kncsscs.
~ anei oridth!.. .... )"OU can .....wl)' buy odd!t :tnd <1"I<b
lhal an: perfectI}' ouitn! ro.. b;t>o:pI.:tI.,.. mot.tntlng pI:u.,..and
ud ...... iiII ..-m.

.nd4b,......

.,.,n.bIr

""'" p.-.ttic"Ol d~ncr be,wttn Ihc IW<l 'ypo 01

p ..... kl Thc ""'1'lk 1> CI")"S ......I...., ripd . OO 'ltlll"!11""",
and .., such k ,,".. Il rcga<d<:d as a Icso-r.... 8lk gbss oubRinue.
Nn-.:nh<k. i. Is pmsIbk tu brnk. Po/tnmona .... ......
'-':I"><:Iy. Is '"CI")' hard ta bfok (II". ,Ix ",urr..aktt ~ .,..
n1llde 01'), bul II "' iesi rigid .han :tCtJ1k: Undcr II~. polrarb w111 Irod 'o gi ..... and oile OI,""> 01 "'~ al
III-pound roultt an produa ...........
""3- So nu.l
durahk . ..,lxnbble ~I'" ro.. hartol-hcId roullng rrom

"''*

poIynIh, anei rotIItr-ubk """"'ling plala 'rom :tCf)1ic.

IIoIh m:l!""'" ..... quitc ea>Ily ...,><kcd wllh carbIdtlippcd ..'<XI<l.."Ofkinll touls. ThClie f'1 .... klI . .... po-pul.:or
ptiRUrily bttau,,", Ih~' .'" . n.hlt In ("' thcclS.
Osttnlolhly. w h:l><f'btt ,n.:odc o( d.htt affon.b nnrty unob)lrutfW \'Icw o( II><: wor1c ~I Iu.nd. lIur. both pI.:o>tkt..:nod!
....oty.to :tftcr bdniI USO'd I "'1I~. 1wl-pl.I~ ~ &om lMm
bccolllt wtbbnl ...Ith ocnrdoc:!i :tnd th.. &lr1y Q(>3<JIIt.

Phenolic
Ph~noIlc pl"-'llc i! g;olnl"ll popularlt}' for cU5I"om """'1'1;01.,..
mountinsr, pb,CS, .OO othcr jig'm>i:illl\ u.O\C:S. It ', Ilie ""'tnial
th:l' th<" MOO)' b, sq,Luc:l h:I"c Ix."n m"d~ o f fur )"""',
I'h.,nolle .111 IS. , ..ni, <lmsc m:llcri:ll made 1' ' pp,)'in!!
hc:o' and [>/'Cssure tO b}"C1'5 of paJ>Cf Of doIh Imp"c'IU\."':d
wi,h .rn''''''i., "",n, The LoJ'''''' ""n I)c, ""'de of ttllulosc
paper Of conon . 'p"hctic (>brie, OI' gIa>s fJI>fic. Und~r 'he
h""l and premi/'C.' """mical mocl lon - pol}'II",riullon ',,'". r.,...... 'hc "')'~"" m1(, an iodu .....1"'''';n01,,<I 1'.....1<:.
PhcnoHc ,,"'.'" and slitln "",ren",ly "'cII, il'. hL""
re';st.nl . ....( <kpending on pani<:ular phcnolic '~ co,up<>';1100 , i' c:on Ix '-cry liJlid . nd St"mA. I' n.. chincs wdl and
doc;n', tcnd 'o mclt and Stlek li~" 'he Oti'><'r p""'~icJ
l'yplatlly, phcnollc pl:l.Slic b hlU"'n Of ",.cIr.
Th" rang<" of grades Is ",""ildering. and il'5 diftkull 'o
kno,,' "'hC1het" ""MinI"'t pk1:t: wil! I)c, suit'ble for)'tlur
purpu:;c.Try NEMA XX. ohe 10"''''';' gra<k.n.., rool o( !4.1nch
[>hcnollc In Ihi> gra<k Is comparablc 10 Ihc cost of .I""h
'eryiic, and 110 i5 ItIC "1ClSth.
n.c, [>roblcm wilh phcnol~ i , ... ibbili'y.ll>co [>I.stics
dnk'r "'ho ..,lIs }'OI' ...-raI" of acl'}'lic .nd pol}'Carb 1>
unJlkdy .0 ha,,, scraJ>S of phcnolic .round. N:w of .he
" I>oJcsak.n:,,,il dL-akrs L."cn SI""" phenolic:l.
Thcre an:, h"",c"cr re\>.' rrutiJ.<>n:lo:r '001 L-umpaniol
orferinj;l sm:oll p k<:cs of phcnolic m:I'eNI.

T h" IN nd uw cu ls pla n le wlth HS". Acryli< and

polYClllbonJle usually come wllll i p.o,ecli"e masklng
applied. so you un draw layoullines an t he papt .
The black phenolic belng Cui hut ha. ma.king tapt
applled 50 layout lin ... wlll be "Isible.

How to Work Plastic

PUseIC hu lo01ltoI: " 'onll)' us.es in "..:>Od,,'Orklng.cspl:ciaJI} In
nw:i"ll strung, p ... c'k...1 !>asep"""" and """,n,ln!, pl.' ..... ,
n'IUfall}' sllcI< rou'cN.bk sIeds, .nd vlnmlly bulle'proo(
1'OUlc..ublc bit gmrds.
'"'" plasticJ We .re toJkinl(:>bou' h= .n: ~' "~""<:tl
witll Iyplatl wood,,'OrkJnl! ,ooIJI~s;tW!., drill., S>.IIdl..,. And ,
)U, roulers.
lhcre "'" SlW bladco and driU bits .hal Icnd
tlKrns<h"" bcltC1' '" pbstle ,,'01'1< tlun <llhct:s. lIu' as ptae'leal "",u"', }'OU do.I" n=110 get '00 blhcred al>om 'fl<'d:Il
book "'lIS rnadc' ""illJl wha,
'ooIing. E\-cry plltslk NI. in
C\'Cr ,,~wo rt ing bb<k: wos In thc tabl .. SlW Qr band SI'"
., m.. lin", tlK ""u "."" madc nd wlth ."""IUlel} >WKl>.rtl
,wlst.<Jrill and For!.tocr bi ... BoIh l00ling and workpi""""
cme~ from 'hcso: O:J1C~ In sood ~pC.
ACI'}'lic.o and pol}'Carbona,,,,, are casily ""..,chc<J. For
=->. mo:st of 'hcsc plastlcs ...., ,,,,..,red 01\ both slde>;
"i.h prot1;"C "",",ing papcr.
,1Ie p. per On whik
)'Ou "'Olt. Do )'Out lltj'OulS wi,h peneU OII ..... masl:lllJl
p;lper. Af,et' )'Ou'>'" cu, 11, borcd Ille hol'-".""d scrapnllhe
edJlC5, pcd 'he p. pt'r <>fl'.

1'0'"",

'"ls

'"I>

l.e>,..,

Cutting
Almo:It an)'

riid

[>laMk. from lamlnol., 10 an acry'lk.o.

b<: Cu, OII)'Our ..bie ".,,' ... it" C2Jbidlpptd
con>biJu,iun bIlt<k.The band ..,w. fincd "i,h. nln2k.'UttillJl
bIltdc, cu .. pl,,'lcs "'cU, cspccblly CUIVCll. Of .he ponabk
po....er Sll",>,.'he Sllbct Sllw Is tb<: most ,~,ik . sine" il will
1I:In<lk. ,..n8" of cU,", fron> """'li ro curves. rr. ~
sood for cunlng 11)II11... dius cu"..... And don'l fOf)lC1 th.,
phcnolk.~"'"

h uh ma ku a s tral, ht b ll Just for cultino pl.sticl

(u'alog numN. 85611 M). 11'. a 14lnch bit wlth Iwo
1jnchlono fiute!. Tlle culter oeomet ry 01""5 a Sut
pri.lngly ,moolh fini,lI. Acco.ding la fIo"h, Ihl5
geomelry also reduces heal bulIdup, Ihus Iltlplng 'o
pJl!Vtn\ tlle bIt trom Nlng wtldtd In the cut:
"""e . I),o,th. c:ut>i<J<><lppcd bl . )"<lU nIl CUt )'OU' plaMk and
plwlJlC'bore ha""'. Equlppetl wloh clthcr ""nem hit ,>1
l1u.>IHrimmlllJl bI', )'OUl' rou,.,r will produce as many pla.>tlc
duplic'>tQ b)'OU ,,""" front. pollem,
AcI'}'1JQ """ pol}'Ca1b<Jna' "" ...., 'hermoplastiC$. whlch
mcons
scnsi'i,.., 'o hc". Gcnetale.oo rnuch hco. In
working tbem. """ 'hey'U g"m up ,11:1, "'Olt. So whcn cuI
tillJl. back oh~ bIlt<k ou, ofthe cut as """" as i. ""'fU 'o bind,
TI", length of ti", band .. w bbdo l<ps It cool, 110 ohio '" lcs.s

,hey...,

Jig-Ma~ing

Material, and tV.dW"f

301

-.
OI

G.

L_"

oia prubkrn ,",'llh Ih~ hand ""w. (In addllloo. , I1~ b:ooo 1"1'"
bIa<k cka~ chlp5 ",..,U. prodllcln", a '''ry "moOlh CUI .)

Drilling and Counterboring

Orilling hoIei In pla5tk IS ""'''' probicnulk III." culling II
lxausc of IlS lOOO<np~lhllilr. hrlulc:oe>o> . ,><V.". ~"'I
6Oft,""lng ,nnpc"r.turc. l lMo ....... aoJ.!tt II '0 U5C a IIlj1h.
>pttd ' wl>I III' 11111:. brtn rcarow>d oIljIhll}' 10 k~~p II (rom
sp~ninJ: OfaxkinJ!, Ih~ pbs!k' Thc: klc:a '" 1" ch,fItI" Ih~
cu'uog c<lp rrom :an acu'e :an~ 10 ~" . or ('I..,n an
oIMusc. angk. Wh1. usuaIJy "'""""" , ,",ilh ~Il u,~~ltcrcd bll
.. INI il a~ m" lhc plailC Uite ..,.,..,.... 131hc. Ib.n
I>ooina' boIe.
_
up lhc pI2$ll< wilh a don _
ano:! wmp II IOa
bo:nch top Of In ",,". Of ,,, 1"" drili preM table. Fcnllhc hII
nl" tho: worIt sIooo"Y and SlnolIIy:lhr
~ shor.tId M
'ioOO 'o 1.000 rpm, Ifrht: hoit: .. dttp and ,"" mllcrbl a om ...
mupIo';doc. Id! Ihc bil OUl olt,"" 10 ck'u .ht: chip" Do'"'
01"1' tho: bir In lhc hoIr. k IM)' JC1 .. ud IIIm: "" Ihr tip
"""'" ,t.: bn:akIh"""" point . ......' ,t.: hII c"'" mon:
AIIlhil1a,Mtt DOIwilh..:..~ , I\'" Iound ,Iw M2Ildud
brad-poIni bit, anei C\'l'f1 For>Incr bIb ..'Of!< ,..,.. IIM l>rill
Ihc hoit: ... illl ~n ~ ...,k", "" 1","' Ihl,.. ",",..,
duntt ' " kttp ruoI_ eool cnough, artj....'3f. 10 P""'~I .1Ie'
pIa>llc (rom mellln4l, A M:andard C'OUI1,n!oInlr >imlbrl) .........
jllSl flnco f<K coumcnilnklng m""",I"II hula; >llhouKh
>tIl!lk>Ou,c <"OUnlco;ltlk producn l<IlOOll!rr CU' ,han
mul,lnu,e OM
lIc p;tnkul.rly CIIrcfiii ",-hen ""111"11 la"", hoIo., "nu
Ihls oper. '''''' CIIn ("""tc c""""h beai 'u ><>I\cn IiM: plaMk:

doi",

.00 m.kc 1\ Ml<k l<> Ihc 1>11. A good .ppr<eh il 1" ..... lhr
lcnlplalCS <kK-riboed in Iht: chaplcr"1k>rinJ Tnnpb$' 011
p;t,I\C

6.

Joining PlastiC$
~ic ..... n Ix joincd 1" plaMic ar 10 WOO<I ot la mcuJ. u..
common mL'dt:utk::ll """~ne", like bul", """
Si"". Though I>oIh "I'I'fO"dtn arc familiar 10
9/OOdo
worlrc., Ilie", arc 50mc 1>0\..,1 I"isu in """. 111""" opp/y
10 p1aM1C .
T:.kc the f.ostcne ppro:och n"" . lIerc arc. ,""w I"1>U;

..,,,,,.,.,.Of """

('1"""

CuI lhmds ;n '-Cr}tic ac pol}nri)Qn:t'e " 'lth a 1.11'. y,,1t

,hen <:an ,um a machlnc """-..... lll"-"Ctly In.o ,hc pW<k,
clln.1!Wlns Ilie ntttl
"ul. (s.:., CuI U"Xll=""" ' \>II
~~.)
- I.IK sclf-uppifl3 sc......., dQigncd for us<: In rmu.L Wbtrt
.umed In", pIIoI hok, ~ ",lf-1.lt~ oe<cw "il! "'" II>

ro...

....... tIuads. ( R.."alc:dly ~i.." Ind UMc,"--q

lhIs flsocncr <k:$boy!I lhc: lhn:2ds,
II
onIy , .-here acmbIy \li. ~ J>f'OII'OI'IIJO)
u.e "...00 5CJno"$ ;n acr}1k:o and po/)c ;ut,on,"".
Cbmp Ihc lS>CIDblr '0fI':lhcr and tlriU a pil<ll hoit.
maI<in3 il >ti&htIY _lhan tt.:.crcw'. ~_
eter, :anII ... dttp ... Ilie ....,.".. il ioaB.";;Ih JW'OPO'I""
loodI. beat tt.: se ..... 'lil i, '5 dttp bI",,_Pwb il " .. A lhr
pilor hoIc. lbc: pbMk wiII ""'k and mnk>tm 10 oht
5cfCt\'"s .... pc. Whcn ,t.: K1'<:"W .. rooI. 1C1I>O'o'" II ..1111
se"",,-dm"", and rcpbtt il ..ith._1Cn"W

""""'\'ef, .., """

You <2fL oi rounoo::, ..... ...., nucIlInc ~ ..iIh llUb,

with 1IUlS. ~ and funili3r and pnctial and dr.cIhc. CoIIncct.
c:nmplc:. t...., picco oi pbMlc, . pic fii
pIasIic and bIod< al wootl,ot. pWlk bir. and mtUI p....

OI" bol"

ro..

u...- W2Shcrs f<K beM """,1...

Whcn;1 comes 10 bon"/'W pb.>llc 10 pbMk, wuod, ..

meuI. furtlC'- .I><! r..",ilia. SiUCS.1ltc)' proholhIy _ b\' ...
bfactory. lru.tooJ , )'OU nccd cpoxlc!l """ 'f'CCbJ ~
.nd .oI~ms .
AJlhough}'OU nur ""'..,. 11:1,,,, USC<I <:utI\ICI ccmcnt OI'
epoxy, )'OU ttrullnJy
hc:anJ of 'ltcm , 1.cH familiar, per.
It.1po, \s ","'IhC!lc rubbN aoJhc;.i"" , .. hldt ",(en tu ttoc .....
oi Clulklikc aoJhcsl,'eS Mockcd hy ('I'c')' ILonl .... rc OIon: """
buiJdlng cen.e . (SUi.oon<>I...,;cd .dltolVCI WQf'k lIen: , 'ooJ
SaI\'C"I and ""'111c ullleni arc probably DeW tu )"Ou; boIb
arc 50Id by Ilie ... "", rctaJic ..-ha ,..,llj ' he pl>.'o\lc.
O ( thc latler ''''0 h<>ndln~ '11<'0". """ 'COI ", ,,,flb
cuIcr
bul ro.. "",'~r IIfI:HnMIx,ul'<' _
. tbt
Xll1Ic ccmcnl moy",,", t>ctlC.
Thc: 1K>I~t.< clfea""'''' ..",kllhc pb.>llo 10000' lIer Tht
paru 10 bc foincd arc :osocmhled. ,hen ,II<: 1K>I'..,.,I - U>UaUy
~1crIC dlcltJoo-i- u applkd along ,hc .... "'" willl.
brush Of s,....... So ~:os tIM: foi'" III pcrfealy .... Id>od,
capillaty anlon puJh lhc: ,.,. ..,." In,o lhc 1OIn' ~ k
oofttru ,hr pbMlo.. a1IowIng ,t.:m to Intcrmlng;., and,,..
Ibc .......,." Ct":Ip(nIC$. ta fu><: I( 1"" joi'" '" DOI ~
fil.cd, thc
U1 Ix: plllkd In OII!)' ""." and 11lc"n:. """
tho: bond \riU b\' "lMHTf.

tu,,,,

.-ac

1
c

An o ....... " ulv. , - " ..... u llud IIM eblpp;n,

l,IIM hoIe d.MIt!d In Iltit JU"k IMnplile. To.vo;d
I"1s problem , tie t u'e I'0Il ~ good ~Itlng tlene.>tb
tM workpl ~, . AJ you nu. b.ukthrough, un up OII
IM fe~ fille so th.ltl Ilie bit bo<es Ihro.ogh ltM, ,''''"
P\lnclln tb'OIIgh.

.0 ......

""""cn! ...

~'ou COn drcum''1:fl' ,his """,,,,,,'h., by _klnll one p>.n

In .ru.llow I'uddk of ,he ,;oI,'~n t , ,he" I'''''';ng It to Ihe
uther p>.n . S,jU. ,... lKn ",'ng th~ .o1""nI. ;1 '5 bcst 10 h .."
l!ghtfi1tlng joinl5.
Thc ,cerlic ccm cn" un 'hc "'her hand, .."Orh bcs' In
II"pp~ loin", . Two "ons, ltucms. a ",.In . nd hanJener,
a'" ruixcd, .nd Ihc ",sulting syrupHkc Ccmen ' i$ "I'plie<j
whh srrin~ . U~""lIy, 1, will {orm o ",in(orclng mic,
.10"11 ,lIe ",om.

lIufflnl' con II" <Ion" dth~r by Ilo<><l Of llkCb>nlc.lly.

U.., o humnll rompound, ..,k:cUIIjI 00" usW for mClal.
A[l[ll)' II><" Ctlmpound 'o Ihc truffcr. ' hen huff 'hc: [lI"';"
...i,lI il. Nex" ...""h 'hc pl:'-'Ilc ... Ith _1' . <><1 ""'e" ti>
"""""" ,1><"
huffing COIll[lOUnd; .nd nOlIlj-', poIl'h
rour I:>;Jscl'late wllh paslc w;JX,

.br.l>i."

Polshing the Edges

.n: a,; mcrk:uJuus aOO'" flnl,hlng }'OUr IIg<i 000 fixaS you .'" . !>out finlshlng l'o .. r wood,,-nrk;ng
JlroJc<cts,}"OU ""Y ""anl lu .nlOOlh an<! pOlish lhc Cu' rtllIC'i
uf rour 1".,;.0.'" bal.cl'''',c. 1,', o s<:,,,rol->;rcp Pf'O$S, and ;J
l"tJU"" ~ke ",.,,}"OUU prob>bly coruproml... by"' ... ping Ihc
roupr .potnd be"clin~ lhe cdgco j ..., cnough '" dim~
mUc Iheir .ll1Il'ncss.
U"""mpromislngl Thcn ""rapc: thosc c<lgo "",xl la
",n"",,, Ih~ ""W oears, lhen bulT m d poli;!> thc cdgc5 'o
bring Ihcm la a hlgh ~~.
For the firM "~"p, US<:' "'!lui.. coblnet ""r.pc:r. CllImp
II><: pla,;lk bclW~ ""OtJdcn coul. In a 'iS<:. !'osillon II>c
sc:rap"r aCross Ihc pl;r.s{ics cdgc, ' illing It bad< , (.",.nI yuu
" an an&le of
60 <kgn:o. Pull the oerapc:r ,ow:tnl
you: nel'ff pusi! li ~w:ly. Use mode1:lle pre55U!'e ~OO long
;trokes 10 .."Okl creallns dcpn:$$ions In II>c pi.,.:". u.e: " file
lu S<nouth in'ctlor cu,ou", "'hc",, scr>p"r won 'l fi, .
Smooth<ot ra,1'> .<><1 bast.nJ<u, miii (des . '" bcsc . Rub
d,.lI< ",,,r lhc flk la kp II rrom Slkking.
I{ l"tJU

,u",~

aba",

Un ~ cabinet scraper 'o remove saw marks from

,he edges of plullc. For me Il works ben 10 drag Ihe
.crap"r ,ow~rd me. rather ,han pushino it away. ,he
usual technlque. 1, doesn~ tak~ many stroke. ta
r~mov. all,he ratehu. Thls works On phenolic and
IKIlyc.,bon3,e as w ~11 as !he acryllc shown .

(;1"'1 the edoes il final poll,h . In worklng wlu< il

buffing wheel, yoo mu~1 be cardul Ihal Ihe worl< dot'sn ~

ca!Ch In tlle wheel arni gel yanklKl from \'Ou. griSp.
Begln In ,1Ie mlddle on an IKI~. aS skown , and puII Ih~
work up, sa yau buff towanJ !1Ie botlom Oflhat IKI~.

Edges u n be ~me-poIl5 hed~ wlth your propllne

toreh, Sweep ,he name ,'owly ove' Ihe edge, and 'he
heal will mei, the plas,lc enough 10 smoolh oul 'h e
,oughntss and add a ,h etn. Whlle you don't wan, to
dw~1I an one SpoI 100 long, It doe. ,ake more Ihan
lew .econd. 10 hU'the plas'ic enough 'o polish- It.
jlg-Maklng Ma,e ,lal, and

Hardw",~

303

Cutting Threads
Taps Ir>d dleS CUI tnruds In m~I.1 and plnllc,
Tjps CUI Int~'NlIII"~ldi (,n hol~s, in olne. ..... onIll.
whll~ d,es C"t nternlllthruds (0<1 rodl .nd p<pu, for
eumple). As an enltrp"srng 'OUl" wooel ..... orker. 'fOu
juSI mllY rond II h.ndy 10 hav~ Iwo .... II,," IIUS of
IIPS a"d dlei ,n your 1001 ub,nf!.
Do 'fOu. for eumplt, Wam 10 upgra~ your
rouler'J bueplale'mount,ng screw51 ....ghl 'fOu wa"1
10 liP a hole In I pluII' moununo pl'te ar lroolhe, J'II
Pitt1 Mlgh\ you nud 10 CUI Il!ruds ori a I... mmel O<
~d\ll'\lulde rod111 VOI.I do. Ihen 'fOu nud 10 leam i
Imle .boUI tlpS Ind d,ei.
Nel!nt< ire d,flicul! 10 Ust. bUl VOI.I ouOIll 10
undustlnd som~ rud,menrs of t"read Jirgon, 1 he
bllsk dlmen.lon 01 Ihf"d~ faSlene, 15 '15 d",metet.
But the ""mbe. of Ih,elds pet Inel! Ind Ilie I"re,d
cllOU,r,nuon mav ,1j.Q bt pet1ln~nl u~r ........ cir'
cumSl.ncu, [ve. f,nd. nul 'luI ..... ouldn~ Ihrud onlo
bOII. Ihovgh II!rr' were Ilie ume d .. m~lers' Well.
'fOu had Ofli! p,ec~ Ih.e,~d in Ihe NillONI Coarst
11.ndard ,r>d one In Ihe Nat,on,al FlfIi! stindard,
Tvpleallv, the IrIln'h bolt '(OII b...,. .IIM Ioa! hard""lire S\~ wllI lI.ve 20 Ihrnds pe. Inth, whr<;h .. the
N.llo .....1COlItK INC) Sllndird for tiut .,u flstene'_
NaliOnal Fine (Nn hu 18 thrudl per ,nth.
As I pr~tK.1 mallet. 10 cullhre.cls, 'fO\I fIftd 10
IInow Ihl d"'_'et of Ihe Ih.e&d, i l well i. Ihl nu",,
btr of Ih.uds per I"ch li",). Whtlller" .. In 11>1 Ne O<
Nf "uSlfinl,O<! 's "relev.nt. Ihough II wlll bt _ O<
Ihe otht (~ lhI d ... 11 "Tap Orrft S,Ztl" on pooe 306.1
(loch tap o. dlt! 15 "'MI<~ "",th tlle Slze 01 Ilie /101,
o. shilt Ind Ilie ""mbe. ollhre.od. per ,ntl!. II Ihe
d,~_le. " ~u Ih~n iri ,neh, Ilie
15 9'''fn ,n It"...
of IT\i(hlllt,$(.'~w ~uoe" Th"5 ~ t.ap matk~ 10-H
Nf ... ,11 CUlthrelds 10 acupla 1~'Uge,....;1m>t
s,~w w,lh 2. th".ds pe. ,neh. whlCh Is Ihe N3tOO ... 1

',le

.!!

F'fIi! IlVldard. A JIr-16 HC t~p ""II cut Ih.,ad. lor a

lt--Inth bolt "'1" 16 thread. pe. lneh, '"""'" iilM
N"1oniI1 CO;IIf'it sUtndi,d
.... 'fOu ere"e I I""ade<! hoit. makt .uft vou
stan w,lh. hoit 01 ~ CO.fKI "le. CheeI< IM LlIp vou
w,11 u ... firsf, Embo..td O<! ilS "de ..... ,11 bt IM Illt of
d.iIl b'tlo u ... 10 boft ,1Ie hoit. Chk OUl Iht dull
s,zes In Ilie lip d,ill ehan. anei bt ""eleomed 10 tht
w""kV"'orld 01 machlnOlu, f~w of Ihe b,u are spec'd
bv d"m.ter, r.l.tM hty luve numbtt Ot lelltt de.lg'
"'''0115_ The stOfe ,horI has Ihe up, and d,u ... ,11 al ...
have boU ,n tht ""mbt nd ~lIU de.l9 ..... tIOnS.
YOu Un b...,. LlIps Ir>d dits IndMdua11y ar In SelS
lrom good hardW3re store., Intludlng Se... , By mall
ardt . you un buV .nd,,,rduil LlIps, d~., d.~1 blu. ind
.d'l~ i<ce ..Of~' from Reid TooI Supply Co. (8002S )-042)). A \Yl!K11 .... w,1I Indude ;o cIoun Of more
of tlle moSI common liP', m~lch,ng dlel, i tap
w"neh ".ed 10 lu.n IIM! t.ap. ind I d'tllock ustel 10
lu'" IIM! d,e. lOnd perhaps i fumer VId. thre.d
~uoe- A. I colle-eloon of pft(,sion 10010, a lip'.nd
d,~ Sti won'l bt 'fIi!xptnJive. Arul luth I stI II
undoubledly mont lhan 'fOu fIi!~d_ You c.n .. ve by
bIIV,ng NU lhe UP o. IWO yOU need. alon9 w'lh a
"mple I'P wreneh. Ihe fli!CtSury d"l! b'ls. ind I Un
of cuuo"9 001
The thltad ~uoe. by Ih~ WIV, eo_. InlO pllY
wllen yOU "inl 10 eul I"".d. 10 match. >1ock nut o.
bolt, U.e In. bllodes ,n Ilie glouge in lo ",.I-andt!fOf
proce.. 10 dttt.m'M Ihe "umbt. of Ih.uds per i",h
'1'0" must CUI. A measuremenl ..... ,'h I dlal cahper ..... il'
Itll yOU lhe d'amelec m,s 1" Iurn WIII tell 'fOU Ilie eo,respond,ng liP Ot d,~ 10 use
To lip th"aeI . cLomp Ih~ wo.k tO I workbef\(h o.
In I ~!le i l . comfollible wo"lng helghl_ Unle .. yOlt
..e CUllrng Ihruds In CISlltOn o. brUJ, 'fOU nud 10
use ,Iubflynl, Turl1tntrnt II' .u<lab~ lub.ICi"t for
iJum,"um Of coppe., Ind sOllpy .... Itr wo'ks ""111 plu
IIU. SINI requlffs In oll-bUI tub~_ You Cin buy
ou,tabl, cu",no 011 w"ere youlltl Ihe tap. Apply I few
dmp. to the tap'!. I".uds btfore 'fOu Slall. Ihen add
mort w,tl'l elch tutn. drlpp,ng 11 on Ihe liP shank J"II
.tbove Ihe hole,
Tht finI few th.ud. vou eul w,11 determ,n, Ilie
{GUrSf Iht I'P w,1I lollow.o allgn the lip ,"IIfully.
Vou don\ wantlhe 1"'Udl 10 bt cocktd. If It ... ,11 hflp,
Itt i If'( ~C!u"e btslde Ihe lip Ind line up Ihf I.p
... un Ihf vetll,,1 leg 01 Ihe ~u"rt_
Whtn Slatllng oul, I~.n Ihe wr~",h dockwlS<! wl,,~
u~rt,"g mode."te downwlrd pftnuff. Once Ilie '"'I~I
threads are CUI. Ilie P'USU'f Isn' ne-e .....ry; tht I"tuds
",,11 puII Ihe lap jnlO Iht hoit a. '(Ou lum II. Alte. fach
lurn or two of tne tap wrench, bick oH a QUlrter-Ium o.10 10 CuI off b""llnd IlIow /lI,no' 10 C~I~

If rou Uln d.lve .. KI"eW,}"<MI C.ln tlp.l hoie. 0.,11 II!oIe of I~ CO'~I lin. I~n lu.n Ilie tip Inlo INI hoIe.
The /1\1.1""\1 tlpe ...u ipplied 10 11>11 pheflOllc: m<lI,"u"II pl.lll 10 Ihe !>oI<! Ioc.,kln COl/iei bt ~ 0lI'l,

a rod ...nh" dle. VOU ",ul' (I.I",P IM

a "'Il, W'lh a", ~IIM end o, Ilie ,od, Ihtn

TO thfUd
rod '"

rn.ark ... Iw.e 10 ...... , IM th.ueb 10~. f" IM d,.

lIock _ , tlw rod. Ind IIdJUltlM
r~ 10 the
d'''' >ttel of ">t rod. ' - ' _ ,1Ie dlflrodc.l"" fIII'"
ellt IR'O" !'VI tl>t eloeilodc bac' O'YIII'" roci, IIM ""
tt>t \lu,eIe fi ......."t> lhIlop 01 m.. rod .-.d. 9"" ,"'

""ode

,Iw cenlt. of Iht dl.llock In VOl/' f,n~'I , c tlul""

lurn II O!'IIO Iht rod u"I,llhe elle "al ni' finn purch.lSf ,
TMn
IM ltindltl. anei. Ut","" do .... " ..... eI prelW~. lu.n IIw un,1 eloclt ... lH. EVi!fV OIIt o. IWO Iu.nl,
_It o" IM un" aboul" quan,'lu,n, Conl,nw ,n tlul
....... ne. unl~ you compltte IM Ilvelldl.

,,"p

THllfADlNG A 1100

Do

-'.::- Chlml,.
Cham'"

n. d I~ In CUIUII9 Ih~adl O!'II rod 11 tnlUfllIQ

Ihal Ihey ar, ~uirelO tii, rocrs 11Ids. U" IM dnll

Pltll. Tlghten IM rod 10 bt Ihre.odtd In lhe ehuck. C~mp Ih, elltllock 10 eh, drln pren tablt_ CON. lum IM
mlChine O!'I. InlltiWI. turn I"'.od ... ith IocklllQ-Q"p pllt" whUt leI",,"clng Iht qulU. OII" VOI' haVi! Ilie Ih ad-<
III""" VOI' an movt llot worl! 10 a VIle and (O!'II'I\UI 11\ I more cOIIVi!nllonal manner.

rc~u~tt~!~
~~gThreadS ~c~o~n~t~~n
~u
=e
=d~__~~~________________~~__-,.
Tap Orill Sizes

Hallo_' C. .rsil
Sin

TPO

Bit Sin

"
"

6l

"
"
,,.'"..
,,'
,.

"
"

20

"
"
"
"

National fir
TeO
Bit Sin

.
"
"
"

"
"
C'JI.o"
2S

,,'

"
"

u C''''-''

20

'lo!,.'

20

F (In'

"

"
"

21 (14,,'
14

(JI. ,'

1 (li.,'
, (I~,'

....'...

Q ('"",'

A""",.I"""~ ,Iu-i~ ......1 ,,,al '/lfM'r 1IW,,1za.

Plastic Knobs

Hardware

bQo lIP and /Ix,,,,,," do noi count "",kohlft

ihdr chanctC"riolla.lt b do=...1M:n )'OU"ud)' OIle.
thIt ti><: ...nou. potol ....,.., m:adc 10 pcOOmt .piIk fun.t.
_
.TII
0I~1 win8 n""Of WOO<lon cr.lnbb
u.. mm. 01. "",ke!hlll fiti. Sure. m:tkcshili jl!j$ usu:oll)' do
..1\:01 lhef "'ct<: CO<Itri.'<:d 10 do. fiUl If Ihc IIjj: J:j" keepn;
why noi Sl)1c It " bit .nd ",.kc It nsler 10 ......1 Why noi .ar
kool and I......,n ~n<.l ......nk whlXb Ih", pafunu aptioaoiI)' wdl .nd ,11>1
c:lSf on me Iunds ....... ",..,.1
llIcte "'" Ih"'e b;uk: ,,m of pl;os(lc kDobo. 1ho.c ..iIlI
<hreadc-d studs. lt..o.!c ,,lIh blind Insnu. and thooc ..."Itlo
through In>e/U. 'fillhln elM.... 11P<'. 1hc:n: are dottns 01 MYb.
Tk

Alm"" C'""'Y woodworklng jlJl

Of n.HI~

ha> """'"' hard-

.."'''' In '1 'Il~U. ok.)", tcmpl .. "" probobly <Ion't

butpb",,,

,._,

It""

ha,..::

hlnlw.,... and ,."r\otu positiol\ln, pup (Ion ',

hard. .. .1.(0;. lIu' cVOI """om
nd IIIOIIntl"ll.!iC1'\"Wll
JUOI II,., fi&ht pica 0/ hotnJw.m: an .....pIifr li8. makc
it ........ IInta. mon" c:ffic;nIlJy, ..."'" ~ takly. Itow III
~ rn.c.. ar ..""" Uow 10 ~ In odjllil""'"t Of
..... upll""' 10 bold tM ",'Of1t? lIow 10 cn>oJrc: KCUro<')'l
Thc 'In."'U1 10..tl tllc:so: i<II~pI 'IunlJon5 Iust mor
Ix tndiIy .vaiW;Ik bits of h;o~ , So .s"'" rrom Ilie
booIr;C"", Ind ,"" SUl"'rm>.rkct. m)" ,...,,;,'" [>1. ro.. .'oI1Op"
pin, Is II",
Slon:_ Wh<n "1'ln~ 10 ""llr!< OUl 1i8
~ " <,,, W"" """U=.I room Ilie alMe lookln8.t It...
f.".cncOIlnd nUlnll" an<! 8"""11""" Ind ...1dt!o:1... And .........
,Imn !he .n....." (, lhen::.

""rd""",

1 ......' 'hlnk I ntttl to IIsI..nob<: WI~ Ih:1I

maklnj ~p .

.!:!

306

Rou'er Magic

_ ,thc...,

miW't ~

,"ou know ahout Ind ...... d..,..... 11

..:~ machi"" ";:"""11.
boIts. <2I"I"i2jp: ~ nu
-ci tind bol..., ""JShcrs and fmdcr """""Do...". nuu,:ond "1118
1: nu.... .u)'OU txtdr tht ..nou. N: ~ In tl"lb 1IooIr.
" , )"OU'I non a<:..-thc IDo cocn .......pbtt hatd .... ~ bjlll 'Mt
Do >h"Cd prOOk.... for ""'-R}1on ...a..t"'n. pIa.SIlc 101<'<"'""".
t.roow. ~. rotIfIIltltI n ...... 1hrndcd rod. w"'pA:>o.>lon
<II( spri~ Tnuu. IhrnOcd in>au. and II><: likc
BultWO tpiaI c:ncgoric> of oscn'i:llllJjn,.kJ"J! Mru.
.... ~ a~n t J!ound In Ihe lo<."aJ h.rd"... ~ .......". Ih .. I
fm:jucnt. l" m .. Ikl"ll .boUl pl;os(ic knoh> and l<>tI/de eWnp'.
"Ill~ .'" hen" I bul' 'hruugh tI>c /lUD. Al'IKJUSth _
woodwQfklnll c:ltalog> .how as.ortmml> of t.lch. 1 buy pn.
_..1 m>rily thruugh II><: Rdd Toei Supplr c:llaIotJ. ..hleh !tu :an
1
InlO~k3ljng rangc 01 knob;l and d1mpI.. U "'o!D U IIWI)'
othtr 1n1fiJl:~ Ite",," Intmtlcd lOr mxfIinisu
.....ful In

'"CI"}"

SI"'..,

Thlt ri1Iht plas tic k .. ob un tie lM dll'ftrtnct

btlwHn $WHt"".. Ind ml$erv w,",n ullng I jlg. 50
.... ny sin. Ind styles are avaHabli!. al VOu un lte.

thlt VOU IM-uld tie ah11 to find one

.ny jlg .... king applic"lon.

Ihat~ tl4!rf~ct

for

"lJl!'nll frum Iirry knoI )'<>II ~ ......"""'n A*,#'" :and

,llUmh "1' ,o hldky h.. M.!wiI>3.1'l>cn. ....., boli >Il. pc$. football
..... p"', mll$l"o"",,". ~"VC:n ' nnlropo. Rountl knob< """ 1><:
knurlcd. nU'L'tl . ,,,. OOIh . ~ ar.' Ih,,,, ~n<.l ~~
~1a. .... rtikc pau"",,. ""'~ ~~ w!nl( knot
n.. .. uddc<l k...... "'" likc bol" ur machi ........""'"..
ti.., lfC bc ';gh' cncd by ""..<.1, Mhcr than ..ith I wn:""h
ur "","""<Ithn. n.n., ....., IIol"n. of ~pplk2lloru. fur ,;.uch
""Rl"'''",, In ji!! mUillll- " "",,Uluil """odl " 'Ullum "1' C\"t:o"}'
'hl~ frum bln~ _
wllil ~-kIrlII tI-.U ..U<h. ,,,
h',,;.ky gri"" ..i ,h Nnehlolljl.
uob.
TlM: ot/1("I" 'VI'!) 'Ype$ r.>f i<n<lb>....., ~k" nu, ~ ' o
bc Ilglllcncd by ""..<1. l1'l' h tM Ihrouf.h in""n . ...1uI"''CI"
.hr<:a<kd sluok ,1Ie knob !I 'umed ",,'o <::00 paS> romp.."dr lhto<.Igt! .Ile 1uIQb. ~"h I bllo<l 10 """, tM U\rnck'<l
s/UnllwU "bol1om" in the In>cn
Gotng bcyood r.:.-, fOII """ nnd tund " .httb, c",nU,
:and~. If}"OU h;,,~' llOund "'11>1 )'<>II M"Cd
.omplif)"
J')W" lIlI . n<l mUc i , ccuicr ou usc. fOII ptOb;obly tu,..,o ,

'o

"'1ndI ..

'o

Iooked h.:inl

Toggle Clamps
M.ny of 'hc: P8S !n 'III.' 1xIok-'hc: skd fuc ,'Oplng CUI)
>hown In ,1><: dt:I.ptcr -~" an
246, fur cumplc. OI"
,Il<' mon..u.g illl .t"""D in ,"" d ... ptcr "Monbing JIa" an
124_.", cqulpped "'il.h "'Mk eI""'I"
Thdc dan,p' .n: noi juM for l000i; Uq,endi"ll
,1><: applk:a'I, .... 'hc: 'ogk da"", ""O 1><: 1a_~"lI 'rkk ,
I pnctkaJ clan'plnJl; 001111100 . or. safcoy dor\"Itt In ...,m"
.pplk:aIlOflS, 1I IS .U ,~ .
Co",ld.... It!; ruk OII >pIo.:lkd.tOr aamplc.lf)'OU .....,
0101011 cope ruu..)"OU nd '<1 darnp lhc .."OI1<p;tte. Thc
rnoo !I
Ilun oi tiM: elm .... ,..01 puII in OII tM
wolk(licct" . II )"" allow th.:i' 10 ""ppcrquur ",,"cr "iIl act
Iil:e.
,tim""""J choppcr lOt. spti, K<'I>nd.l lta1_
Ihing _ prob>bIy I)tnk and II" t"l)i.njl .,...... III<" room . I

pa""

pa""

ti"""

,Iu, ,"" .....

'=

'''IW''

p......,n, ,hi> disasocr But

damp" ><ronll. "nlJ~
"""Iee , ... , ~ 5Upcrior 10 fil1JolCfS 'u. ,Il<' joi>
/UWJ unlikc ..,..,.....anlon
01 '"Uiow klnds, '<JMIc
clarn"" lfC r<o:OT Inco.w=icrl' OI" ,1InN:<Jon,,,mlnlilO U>C AI
'hc fi"'" 01,.,.... wris,.' 'OJISIC rump ,..111 ,oap cIooo<d Of! a
" '0f1<pk. dnehl''lII' tlllh'l)' In place. AllOIhc. Ilidr: 01 tii<"

dam""

,,"rioI pop> thc: ~ bmp Open. in5t.",1y f=iol( ,t.. .... ""plct:c
1l>gIc d.n,.",,.,.., .."2lIabk 10 four ~ 'H>n- hokJ.
dowo . .. ",lg/IIline, p"lI_tl<>o . Ind "'!ucc ....... ioo .
....,..,... In ,t.. drn.i"l! "1bJuI1~ a"'N/I J}Pt>I. TlM:'" .'"
of oIlO and ~Ies. wlth 1IOI1"""'al. '-ntk:al. and
T.Juo<llo, &traw>' :and flo"l9l' moun~ ooIkI .rId lJ.Qu
damplnj.t anno, Ind hljh . nd lDw profiIo. 'ilie fi""
'ypcs_l>nItkIo:>..n an<l .,r.U.(cht-tinc:-1fC .hc hol odopIcd
10 wuodwort<lRtl. ~llp b;tdt 'htot.l&h tii<" book; fOII'. ,.,.,
' h.:i' ,t.. Ms dut h"',, '''IfBk: cbml'" hOl'" 001II<" lOrm oi

....rlctr

,"'O

1~"J1 I)'pt::.

Sco"Cnl >p1nd1o ond . . . . ~ 1113)" Ix u:;duL ....1

rqlIott tii<" ~ SpondIc ailh ..
oIiIchtJy iooljICf ono: ,..,., "".,.. ~ lcrII\tIt ...,.".. )"W 'o
"""""""'.od.a!c a pcalcr ..., . of " ...... poctt ,1Ird<nc>se5. In
N11li11101L'i " " !IX )W ncnl m :ldjll:\l thc ~ o/trn 'o
>CC<lmmodal" ,,"OI1<r*::S oi difl"craM ~ . 1, " 'iI!
~ " .., )"01.1

bcncfi,

)"OU 10 diIcIt tii<" lIcx n"", LtO<d

10 odj_ """ loci< the

"f'Indk.11>C1 roupIcol"hcck ........... chodt "''' and,"inK

o........cad. n... _
ou' .1'Iin5 n ... """'biIu'lon aIknI., fOII
10 "'""" >p<ndIc .!j..,,"'...... "il""'" u;iIlI! wrcndlo..
FrmIIy. ........, tic pu' of'f try tii<" ~, of '0fIIdc" rum"".
RcmnnI><"r
)'<>II """ ..,., tM SUI,e clao,p OII :In)" num""r
oIl11!:o :and IIl""'.... 1, ,.ka ooly t""J1 'o fOur ..,~ 10
""""'" damp. It"> cu)" ' o bul' (JIIC damp and ...., 1, OII
..... tc...".I4I ..... ....,.An .llemall.".. .. ronW<c.1r<: loOr1 01
mouo,log pM.I _
' 0 In ,lIe d ..ptn -Sb<>p-8uih SIot

th.,

Munl,...,: " 'hk:h bqIn. OII p;IJIC 131

TOCClE

C LA"'~ TY ~ES

<Ion', a":U\l 'o "" 'h'"R: ""hen happcn,;. >IId ndlhcr do )'<>II.
Now. fOII ""'y ...... "J"OIIfI n"l9l' ..... >IId 'hc:y ....,. bt.1<0118 CflQU!Ih'o ckndI the .."OI1<piec.: oufficicn'ly ,~h,

,,,
HoId dowo typt

,:
ii
_.
il
.
TotII"l .

c:"'m p~ "'" m~d, 10 In llmon IHowild~ring

01 sjz~s lod s'\fIes. 'OIls srNli s~lectloo

nSOl1mtnt
coo~ys

.h, rlngf 01 ,/ze..

~od

1, lneludu cllmp,!'VI!'

lo ... nd usefu' In mlklog jigs lod flxlures for roult'

woodworklng.

~Ich 'a<;doo

'vpe

Index
N""~ ~

",rmmcC'5 in boldfac<o Indic:uc tabla.

A
Acrylk. See 00 Pla51C l:unln:>! ...
:1..1 rnoun,jOg p"t~,

lG4

Bi<1dc gnrs. 27l1-179. 280-281. 292

1Ii<)'dc "pl'OCkCIlI, 271:1-279. 280-281 , 282

Bit .,. .... ",100

cll.r""'er:istJo of, 300

hco" scnS1;>i1r. 65

.djustillj! " illl cr:tnk. I n-l8l

in horiwnt:ll setul', 20 I

('I01i.,hing, 266. 303

u>lng in a '-.cu,,", tramm~l. 46

,-.eunm cllunping, 52
"'u~J; willl ..'IOI-303
AdJUSI.ble 5hel"lng, 12-1t1
Ai, c"mpn:sso<. m ehi"!;: ...,,,!UrI , ...h-.: tu. S2
Alr-<.:uoJllon d... ~lc<:
maklng ro< a !'OUt", duplicotor. 27-3(1

"'ing In a rom .... dupliator. 22, 23

Air pblen . .w.. Alr-cushion ,Icvkc
Alignmcn. pmblcrru
drimng holcs.9S
monising IcmpbIC'.153
Alm"u ",inting bit. 2H

A",,,"ctm Woodll,. ,rker, 133.213.269

",,,pk]'It' PIt'WOOd
.... II:lltlc BireI! pl)wood. 39
fo, ji ~ m.kin!t.
for ~uum clamping. 52. 59

Archite<:Ulr.1 moId!ng, 199

Mriso:s. <ourWinll. 21 6-21 7

Aw<i.l1Iry r... nc ...

{.an,.. 113

B
Ibckcr. 160. ~
Iblla>! oox. 220-221
II.:IIIic m",h pl)'wu"d
..... Applc:: !'It' plp... ood. ~
fUt' jig m. kins. 291:1-299
for ' .. cuum cbnlplng, 52
\l;lsq>1.tc(s)

II

centcr.fiooing,85_118
crosohalr ~I.tc. /-3. 14
drilllng muunting holel.65-67
nU>h~rin'nl;ng, /19- / 23
f,aclion:nlng.8 / -84
gcnrnc.63_68
fu, Inc",n"'nI./ borIng, ]3-15
m. king. foc '=[>b''O "'''rk. 68
nl:lrklng ccmcrpoin" 82
m.tcti:ll (or, WO
"b<."I. /15_1/8
for surf'dnjI, 264-268
' ... "'mel boscpbtc. 39-43
ursr..... iflll. n,,,unling se"",',. 64
1Ie:tds. rou,lng, 294
Ikoch .. u[> l'QulC1' .. hle. 20)-2/ 1
bulkHng,204-ZIO
limll:llions of,2 1 ,

using.210-211
Biq'Ck cll.in . 282. 283

308

Oit flU:O.u.. 301

Rj. hel&'''. in. hurilOn .. l K'U!>, 201
Oi. opt1ling """.... . 73_176
IlitS. SefI al.., s.p/ftc I)'(>n
for """ing hule . 42
for """..,1 n",klflll., 106-107
dnwcc ro.-, 228
ro.- Ilu.s/Hrinlnllng, Il!
for flmillJl'oo bcading. /09
holdec ro.-. 23O-2} 1
for fo1n1ln1l "'lth ~ .p~t(~nc~. 24~
fur mortisiflll.. 142. 147. 149
o""ning iruo.1b (or, 173-176
pilot<'<l. lCRH,"k,~ ... ~ OJ><'ning fur,67
.Iun~ slCC:,'<=S. 230-2)1
for SUrf""lllj!, 268
fur .. pping th""do.122.306
(or IUmlng. 290
uIDJg In ""'Ier dupliClUOI'. 3/
usinjj. .... ith [Wlde bushlnll$. 100-11
Bonding plaMia, :S02-303
II<':>o,;t<:. skd. /12-1 t3
IIoring
inc",m~nI'/ bo~pl,ne fur. 13- H
plungt. / _j
templ>!", ro.- Ilolel. 6-/1

""""

bi' fur """ing pl;<;.iOl.:SO/

eI'lp<>:tr.oction .cc..".;ory. 1'iO
tri~ i.ch plung<: roU!C1'$. /11
lIottom-cl""nlng bit
pll1ll)SC: dcscribcd. 255
.... rtadng " i lh. U>8

1IouILer P1l'wood. 134

1Iridlc: join,. using .. horimn, ..1 setup fu . 199-200
8uffing pbsllOl. 303
1Iu"oo, ""n. 'r.. ll4. 125. 128

c
CaI'T)' bo:trd, IlStng. 208

('.... nlnS". n:ptULIudnl! ",ilh .. """er duplic:".,... 23

Cnucr-finding bosq>l.t'O.85-811
..... king, tl5-87
usiflll., l!7-118
c..merinst Slock 00 romer bthe. 291
c..ntcrpoin,. mlIrklng on .. buc[>b''O,82
Ow>.WunK.102

Olipbclard. 299
(;hips.S <I/sa DUM COllCC1tln
clc> ... nc'O (or. /46. 147

coun,,:r:sunk .......,"". ""d. 167

du", coJlc:clion design.213
alrK"lion do;vi<:es. 1

sa

Chuck " ...."''''bly rur" roulc< t;,Ihc. l78-ZII!

Gre'" tcmpblC b)"OU1S. I I

OlImp hlucl<s
for a n""""lOnd~ roUter l~bk. 2H
fur ho,;wnlOl roule' IOble split.(en . 242_2<13
maln!!, 210, 2;i11-240
a.mpiDJl;
hcnch.'''P ""'ter .. bie. 210-21 1
f.'''ltctbo;tnls.2508
mo>'ab!c l1>!lBk-Clo.n1p>. 141. 142
securing t"lllll:tamp .plndb, 17
''aCUllm <_\';tcuum cbmping}
CI:omp>
1>uil.ln f.... a >lf"Jlglu"dgoo, 7S- 1IO
ue-s..-Co tQAAlc, 16.94. 142
dos ... l\d.w~ , ~-3S. 37

forT-sq"'",, 70-72
CMTTools, ntcrirtg pios. 66
Cundun, M.L . 134
Cupe<lJld.5tkk joim. 25 1- 253
Cap.: cu"'. using " miter ''''''. 219
Caplng bit . 25 I
Comcr5, rouniling with a tempbt.,7.9
c...untet1>u<irtg plastlcs. 302
Com,rry' P("r. IS3
C...nk, lOr hcijjll1 adjus,m"" .. , 177- 182
CrosoJ,.lr 1.""1'1""
m:okin/l. 1_ j
usin!;, 3, 14
Cu"ing pbslko. 301
Cuuinlllh ...... <Js. ~-305. J06

D
l).oJolng. ",ing. T-sq""'" 'o S<'1 up, 69
l>CC:p !htQugh mllttblng, I H
Pe-513-Co 1"AA1c cbmps. 16. 94 . 142
1>O..,,,n. Plas,1c Wd<k,. j6
DcWa), roul=
"",c~

usl n g . 99- 101

DI,,,'d,
fixtu", fur m:okinll.97- lOl
nU";"II. 1 09_11 1

IlJI for making. 102- 11 i

s..ndiDJI,I07
,.pc:ring. IOII_I09
~~mrnlllJl II:!!, lOZ- III
maJ;lng. l02 _105
using, 10S-l I I
Onwcr joincry, 2H- 235
lis for. 10ck join. 112_ 114
jip for """etoils in liJlP"d fronts. 22<)-230
Ilrillin!! pl:tslicll. 302
Oril!in~ ,,,"o hole. on thc: some axis. ?lI
I)uplleatlng. S ROU1.,.. dupliealo,
Uui'om, 300
O"", roHcctlon. J also Ollps
designing for, 213. 221
"".1XI1un <k'icc5. 1
m:oking fur. IOUlcr ftflce. U3-225
1,,.... Ie\..,1 .pproach. 235-236

sa

E
""Sic NOcriO
~rinll' for III ... , 10
n.thc:ad SCI"CwS, 64
potn,<uunJ! round,,..c, blt.:WO
Edge-bondilljl
hcnch ....>p rt>Uu:r
207
,.bh:10p. l61
trimmllljl mlh Oush-t';mminlllnscpb,e . l23
f.<lJl<-~"".."iniC- off..... ~pb'" fur. II 5~ 118
Elt:CIric ,"XUun. pumps. suilabilll)' of, 51
El1r1c:al wiring, 190. Z33 . 2~4
End II"'ln
culling aenS fur oopo:-and.stick join.. , 252 . 253
pR:vcn'ing '''"'<lu. lu. 228
Engkr. Nld<. /ll. I n, 2 13
EuropcOJ1 bin:h pl}v.-ood. S<'<! II>hi<: lIin:h pl}"Wood
El<.cn<led 'umlngs.296

,.bk:,

fu<dtlp "",noi"" . 150

hcigh' lKIlus'men' rod fur. 180

I>-h:rndled roulor, oflsel bucpl:.t.e for, 118
Oiar. jOo- 305
l>bh< llltlrtg bi,
..,rbci"ll wi.h. 2(\S
.umlng wilh. 290
I>isk(s). m.king "ilh " tr.<mmd 1>a.s<:pl:.t'e. H -,U
llo!! .. rnl-"Wge cbmp
m.ldnll.34-35
USirtg, 37
1><>iI hules. jig fo' "'SiN.35
DOor f.un""
,;lip jo;n' ro<. 199_200
tempbt~ttlslng , 154
lXIublc>bobbin 'cmpl>tc, 2!18
1)o,"t:Uib, In liJlP"d .1 ... " ..,.. fronl', 229-230
1>O"'e1 blo.nklfd holo !-i1J"lI, 100
I><>-ling lis,89-96
"""klng. 90-94
",ing, 94 -96
IJoowdlll.l.klng fiJ[I~"'. 'f7-101
nking,97- 99

F
Face rr.<mes . lip joln, fur. 199-200
F.dngo. mo,'. bk, for. k"flcc. 225
Fo:;<ener:s
for medlum-dmsily fibcrb<:>:>rd (MO~). 299
for plasfko, 302
Fe.'hcrl>o;uds, 25<>-263
m:oking. 2S6-257
,.n<km, 259-260
uslng,257- 263
'"XUum. 259- 263
F<:c<l dirtt1IOl1
in a horizontal S<.1up. 202
",hen cullin!; monhc:. 128, 130
when using a r... ctiona.illjl Inscpl~lc. 1I4
when \lSing. ,.bI""",w.c'IIcru;lon """er toble . 111'\1

...-"
=

Fcn~"f:(s)

awrlliary f>Cin~ , 1 15
bcnchU>P ""'Ier tallIt . Z10-211
floor--.c.nding roUlcr l~blc. 221 - 225

Index

309

Faota (trMd"WfI)

___ bdrwt "",m

d-dam.,.,."'niIIhtnlF -5-80
fouhdf....,.,.,..lanpbl~. 16

opliI, zr-2H
Ii:ncc'. 21 ,
' '''Alkr ..~. 280
F.:rrt. EAl. 44

''''p

.........

""

lIinJp
for bmdHop romn tabk, lOII-:109

tor floo<>f"!it;lJl</IOJI

""'te. ta""'. 111. li \1

flitachl plllnil" rotile'

heig/l! adj,,"'mcm rod for. 180. 181

tini<llf. 171. 2'r

FiI.... .u!nI a

lIifdKknsit pOIycth)........ ncuum cbnIprlfI, S2

IlifIIlbnd 1"''''''-=. poInl<ul1in(l: lOIaodoteo t..

""",n,,"8 pu.,c r..... 16,

..,If~ 5j

....... ...., ~ un ~ 5pOII.65

tluo/Hi - .clDwpIMrloc,ll9-l2j
plw:W-O<>t.,. ..ill\. 6'" 611
.. ~~O. ~. ~
lC1n~ninII wilh.151

t1.t.kdxoltd.l99
t~. l66.j(),

''''''' driUiniI

too.'O 0<1 ."" SI .... 010. \l8

maItInfI ..."" a ,romnocl bucpI>.". 42-1j

,aapbtes b borinjL 6-11

ItorIJ<,lntaI ......... _

nWd1llJ.191 - IW
$pIit-kncc for. 24 I - U~
IIQ1bontll
L99-201

1'UUlIn,.

tbl/lelld K""""

for 3nxhir18 baoqIblt , 63

'"5. panhnd ~64

tloor~ todrt~. 212- 236

haIWt bo>: ..... 226+UI

boaI<linI Ihc JlmlUi S-1 , -

buiIdiroe tht tab&nop. 21-:'- 22O

~for. U'- :U5

rmcr loc. 221_1~

uppn-C3biMt lOt. 2~."lj'

flU>h-tfimIniAA b:ucpblr. , 19- ' l3
tluUns. 109_ 111
f<>kIing ~d M:oy, lO'J

f .....,lon.>,ing ,,-,",platr, 111 _8t

I
1dIn", l:81
IlKocuKntll

baWplatt

~lj _ 14

....... 14- 15
~

pon(t), boJI'qt tIM: hok fur,

14

ln<kltinfI ... hI, l(ll!,.. II

oIcubllona. l09
'~ru

I ,_'"6

fOr hit opmInjJ. ~

dth'irlll tll~adc:d. 127

lntrmatlonal ..."". Compari) , 199

'""Iular .."Oflple . oquann., I I I

n~""InR..IU-M

naakin&. 81 -8l
....... 111 , 84
Frnod. bit k>r jOIinI~ 24 S

G
(".co!b;,x fOr. NUia bIM. r6-rlI

o..h"'l . 1'hll, oi9, 191

0.."" ....1 Ek<:trk. ~
Q:'l(:rk ~,~, 6j-611
63
doign

""'f-.

..wc1n1L~-6H

(".I"",, .ptndln& I W

(;"In.SH Wood Knln

Gukk '-II.".

ct.oo.IntI lOr "'n,pUI~bin(I., 1-'6. 14........'illl boI'IRj( IcmplllD. 6. 10. 10. II

i-

H
Il>ndtuip(.)
bmcft.Iop ..... I~r l~bk.
""lcor oIcd. 1~. l' 1

lO~ - 2O<I . "lOi

fftI!<Obk.1.f8.l49

wl'ln8. '9

IbnItInI l>oIcs, 8. ~
Ibnblard. 199

11;1./\1.......,. ""'111

bmIn.uc lrimnIa
..wc~ ~ ~

IIrljd:M adjlllt"",n ..
"'pbd"llIM"MI br. 11I1

.... 1111 ~ ..... I(r ~ r.nk . L77- 182

110

Indo:.

nuolHr1rr........ ba!cpI.llc b

. 11 9-113

"""" in l'OUIa dupllnHW, 19. 13. j 1

bmilUtin.g sh= "."do, I S- . 1sa. 160-16.!

,.. III(: """n:.... illl a mUIa, 'l69-z<n

!.cg, m,king ",i.h ~ n",'er l;o.h" ,292-29-1

lc,"dc: .... fur. horiwtU.I rolIler "'hle. 1\1$-1%

Lex.n,XIO
ud ''''y,ln>t,tllinlj., 209. 219
I.o<>:scnon join... J30. 144
Luci' e.jOO

M
.\1. L.. Con<loo.

,}4

""orl:pi""". 192
;\-I.nlfold.ln '">cultm jigs. 62
;\-1...,.,lte.299
;\-1.'W:k, Fn:d, 22. 32 . 36.89. 213. ~. ~7
MUI! Sn Mcdiumdcn.<I~' fihct't><m\l
.\ Iedium-dcnsl.y fihcfboo.nl (MDF)
d .. rac.~'1isIia of.
.,k ... It::ablll.y of, ~2
""ing for. rou,er .. bie
1$7
.\ Ikro-fence . r.tmrncllig . .. 4
Minimum !lift ror. ,-..:"um ch.mhcr, l~
;\-Ian"u,'~",bili'y.

.op.

P.a.ln', go..d ,urf""c. for, 225-226

1";0",,15. monlsiltjl .hc bec. 15j- ,55
P.nideb'.... nJ
w.k ..... iubl1i.y of, 52. 299
U511l11 fur a mu.e' ble ' OP. 1~ 7
1'."cm. rr.an>fcl'1iflll ." ....."tI1kpKc<-,223
P...cm bi . USIng.o round <:on\Cnt. l'
l'hcnolk
dur.teteriMlo; of. 301
... mOlln,ing p"'te. 164
USIng In ~ '"aCUum .r.mmd,.f~---'l7
using .0 "",ke T-oJides, 225
'7CUum cWnplng, ~2
\'aCuum f""'herboard. 26 1
I'iUow blocks
con\merci:tJ1r O\./k, 133- 134
h. ndllng, l36
mO\lntlng. 1}7
PikJ.al hi', uro-elcar:rnce """nln3 for, 67
Pilo. !>lot>. tmking. 4-5

.\III"r pugoo. 2'16

f'jv", coll.o ..f ~

Mi.e.
241'_2Sj
.\ Iolding
usillJl,' lIori:oontal se.up fut. 199
usillJl, ft:a.llcrboorili wh"n rou.ing, 2~9
MOI":In, BOb, 22. 32. 36. 131. J3~. I}i
MonSC'<>n(kenon j<tin . ",ing' horiW<lt:l.l "". up fur.
199_200
Moniser fixtltre. 131-144
Monising
~uidlng .cmpl'ld fur. 1W - 1~2
blt selectlon . 146-1.17
dttp . hmugh, 153
SC'nerk .empb.cs fo<, 1 .(~ - I50
jig. 124_lj(I

Planlng. wl.h a .surfacing Iwq>""c. 266-268

l'I.osIic knobs. j(I6-}07
PI.osIk:: ",mina,,,
. pplyng.o. routng >l .... igh.alJIC .
b=l<er.<k>ICrihcd,IGO, jOO
ch.ractcr1"1cs of.
p. nlddx>anl ~ut>i'r.t'e.
"'Ing for a rott.e. "'bie 'op. 1~ 7
uslng In alr<usllion ooiccs.29
uslnS In , ....... unt ,r.lJt1"",I. <i~_46
\'a.,uum cI>mptng, ~2
Pw.ia
dt01".c.erbtk:.. of, 300
'">cuum cbmping. 52
,,'<>I1<lng wi.h, j(l1-j(l3
PlcxiJ!b.'l, jOO
Plumbilljl' muhiple {t:;I,hctboord SCU' p. 26j
Plungc-boring
crossh.i. lI .......pt e for. 1-3
wi,h. fIJc~ mu.~.,.,67. 68
PlunJlC<un~~ rou""""", bi . 290
Plungc rott'er. Sn- Q~ Plunge.borillJl,

,Ied.

"umlng. l~$
Mon,sln~

bl.

purposo: <k:s<:ribcd, 255

... nodng ....i.h . 2611
Mounting b.>r. fo<. >Iri .... ~I
.\louo'lng l>o!e5, drilling, 65-67
;\-lountlOj! pb.c
fut b;. opcnlng Inscn.., 173- 174
<k<:ldiltjl whcre to pl.ce . 2W
i"".. Jlinll in n""e' ... ble 'op, 168_172
for , I.:tmlo.' " 'rin,mer.31
"",.erial fur. jOO
sakly f.Ktor, 167
unl'~.163- 112

MO'''bk f.><:ings fur . fcnce, 22S

N
N ional Cou:i<: ( Nq .h",. d ""nd:lnl. 16, 3o.'i
N01ion. 1 fine (l\'f) .hre'" and:lrd . 304
N"kIn>l Pipe Thre'" (1\'1"1) stand:lrtl, 46

o
Offsc. b_p!>'c, IlS-II!!
Offsct gou},,,,, ~4. 80, 151
OldlLilm , poInt~1I1ng rolltldo>..:r bi . Z90

m-300
m

,'li. fixc<l.f>:osc roU<c1, 43. 49, 85

O\onWttg jlg fur. 124 - 130

.unlng 'he plungc mhani>O\, 1112

,""-

" pplc PIr ~ II.>ltle Rircb. 39

selcctlnn ronsl<k .... Uon., 134.298-299
U5ing fur. rou,er .. bie {op. 157
fo< ,""cuum ebmplnJl. 52
worIdng ""I'h un/kl'ltlzcd. 81
Point~ni"ll rottndo>'<:r bi . 290
PoIi>l1\ng pIw.lc, 266, 303
PoI)corbona.c. Sn- aJso l'I.osIia
dtar.tc,cristIC!l or, 164, j(IO
h.,., ..,n,ItM.y. 6 5
U5i1ljj In a '""C\IIIm ..... m""'!. 46
""",,uo, cbm.pillll. 52
....-orl:lng wi.h. 301- 303
1'o11':th)'lcne. wcuunt cl.:tmping, 52
PuI)'n,eri",.I"", j(li
1'or05l1y ;n '"aCU"m d:. mpillJl,. 52-~4
l'ur1er-Cable.off;co diarnt1er .emplo.e gul<k:. 170

Inclu

-...
.
:s

"

3 11

I'WII;I"{'....I* lOUKn
bit <:>prninfI lot

.,-

5MI<lk' toin. , .......

Sal'Cfy

lwWu ~_
1IIOlWI""

"""PiJ'c- SUIolc:> conI"lIILft'd lot.

rooJ lOr, 1"

pble lor I'lxnl"'", multn.

1M

OdIlJl for. 199- 200

bo '~'-, 1-3

p .... ll'}
l.....u. maklnll ",ItCl,~" ..... ,kt, 190. 23 1-lJo'

joinu~

"",",Juni . .

1'1-" bIodt. varu ...... ~ -60

~ """.2411_249

0iIIUl1 'NUdtp\c5. 245

"""'0'''' pIa'e. 167

....... hoI111.nt:o.l oc,,"p for. 199
Sondint! ......" .... "'"

S- n>arb, rmMWIna. ~3
s..iIuct lq mortI .... Iftnpla<r. I ~l. 153

""""

....,

br rotII~ "...t<.l~lUl
usInp; ,,, ~, 'c:;OrOuI. llll

mC\li......ocn.nr lIbnbi-.I ()I[)f), 299

1'OIJI~64, 1 6~

s..1f",pplnJ fk,1n;p, ~ "

Slunk ~'CJ " .. bIb. 2;loO. 131

S/""JI<'d poiD. monlolntl. 155
Sht:,", te<>OOs

Qwllty \:AKu.... Pruwc\>. ~. j . ~ 1

Quld...Jbconncct

n l1~. ~4

charoncrbllQ uI. l9II-29')

R
~..,;ing ' " kp "'-II bb:t<J ~.

'"

n.

RK.Mdy, 113

bfnina'I .... 157, ISo!!. 1(,o.161

Shdl !IIIIJIPOI1,rmpb'., 12- 18
lihopraa<:', 1 11
Sbop 0X'\lUIII .....,. In """~ dopIjcaor, 21, 23. "

....

.......,."Ujpot ...... l~

,,~

hoooI~. 111 _ 113

QIi,et' skd. 2 19-153

~ tkd. 148-2~9

"""' ... thc 1Iid<i. . on, Ul

'rmpb' .....M'n...... I S4

Il;tltcd "",net. lISIn!t a _ ..... ,a! OdUp br, 199

~ . cu"lnjI; "'~h a ""rf~UII ~pb'e, 268

Rddlbol Supply. 1111. 1;44, 178, UIO. 304, j()6

lip fmtt ~ 11l6-190
lodIIIc I'm<r; l)olpl Sloop, 21, 8\1, 2U
Aotul> and tiu<, :100

""""'

"""""'- 2 16-21t:Q'I'oCD, ~,9

opono;k .. 1Ih

a..,..., I;o,t,."

l89-Z92

..... 'rrcnnk, 1-- 182

Rout cttJuplic3tor.I9-~

doaIbnl, 19. 22
nWdn!&.19- 31..Yi

-,..'"

lwIcr bot,."

lor. roo,o:r bit,.,. 283- 287

'cnonI,. .......253-2"
SlcnQ., lOr hit w nb. ljCJ. 231

Slip joioI. ...... hurll!JO'a! sc:tUj) br; 19')- 200

SIoI~ lOIm, u!oI".. hortzonlaI octIIp lOr. 199- lOO

5Iot<Ul'~ _.", toinn')'. \12- 1 H

SloI AMIf1I>C1'. 131 1 H
SkIIs.ICmJIb'~ "' ..........
SIoI,cel pilot 'C'IIIpble . ~ . '

m>LIDII ..ith I """"~ .. ,~. 289-291

!'OOI~ t>pcn'd >ptO<.Ik'. 108- 109. l92
~tIC. m.ki"I
1\1 tIoI . T' - '"II
~p1"1l, ..... ,"-. l'Jot-~
!tpI~

269-297

~r2 .l$I

Imer. :U~ - 2i5

_ _ U~ - 243
ldinIJ. 24,..215

........ 288. 2?7

SUpos. ,,""''''''''''' ...... _

(l!lJIkator.36-jII
ScorUl_pin
..... bmchiop "''',,'r ",,*. 111

lIou,rr ",1*
.. atcmioro '" I DhIc """ . 1113- 190
btn<tHop, lO;J- 211
~211_1.Yi

191 - 199
....tn, ... toinler. lj1
Kooon tabk 'OII
bulkII"'I.159- 161
rrIIef'b fot. 15-, 1'MI
_ieOO~

InIlwoIry lIarwbn1, 1~

WUU ...... <:"U!oIo.I - . . . . pIa,e, 168_1 72

for. ubIc ~ 1113- 190
..... , Ing.~ , 199-.101
IIouUIl8~.

-5-110

II"'" ofThinis. \42. 200

11)'0lIl 1'1"""" rotile.
hclpn ildJu>lmen, ,,1<1 ror. 1110
IIIOlWI'flII pIl,e for.\M - I 66

)12

'0

Rod; lob:o: llmlu.-.290

.....,cr""""'tina .tCIn>... 64. 167

i-

4-'

Inele_

.............r ........ piecoc. III

~1-2

Stay, Ud. 209. 219

SokLI"lt biI. lS\

"""

.....

.......".1lK .. kkl"" on, 232

'''''pbt~~.

15i

Sood;.....u.p;umrt 101*. n.. kl .... 32 -3 5

......
-'"
-,
'

50.,.... <b\pI c:om.idmot_ l12-21 J

50nlglucdltr
IS(:lfdam""-.

usInf,. ""9-110

-'-IlO

S')' I~.

nuI<lng lOr """fr ~upl k:;o,or. 31. 36

....1\11 in ~ rouler aupllotor. j 1. ~

.. /si> jokI'in!I on ,IM: rou.er

~ l66-168.SH

""'" ,. "",.

hcnc:h..f.up rou\er t:Ibk. 2OJ. 2IJ9

rar ~ ..-.:d, 250
~.16.94, 142

,,~

Sutbcin,ll ba5<'pWc
nuklng. :l6-4-z66

u.'>I"",.l66-2611
S"'in!I :um.1br a horIlOfItoI

_..

rar JiI!; mal<inll. ~

ruukr

1:11*. 11l! - 11'4

..ithT....... ~ 141.142

......, ""',.., ~ COfIi"'" CU". 2~2

'=md

apbIution oi. 44

...mctng "'...ptuc lOr. 2601

l\I.bk(.). ~ ""o<Itt>bk
Ubk "-1!;. m:lkl"ll ,,I,h. rou,er l;uIM:. l9l-l9-I

oddI"lI a OOnl.O<l.alrou'er 1:11* 'o. 191-1\1')

IIldIng an n,en>ion !OUIer l2bk 10, 18'- 1\10

sp/i, fCt"lCC' lOt a horIzontai ruUler 131* a'cnMoa.
241_213
1'.01* A'" a,c:nsIon rou'cr Wlk. IIIJ-I\IO
T.lbIc."P Ibr ruutcr 5H lloutcr table l<Ip
l:,,><km fc"hctbocIRI5. 2~9-26j
T.p driJl >il<$. J06
n""rlnll
" 'I,h a roulcr I;IlIM:. 2')2
IQUIlnll a "fJ<'rcU spin<lk. 108-109
1~"". 3(H-306.306

ful'Olll . p",,-.;n ..,'Sl. 22l:1. 2.\0. 246. 249

l\:mpl.>.",~nll . 14}-1"
'"mpl.>'''''
.nnot.,lto~ 149
cumhln.'1on.149
hoic horin~. 6- 11
lOr instaJling ft\OUntl"tl pl.>'e. 16tI- , 2
nloklnll' ~pl;uc lOr, 6/,!
fur monioinl1
~uldltol!!.ISO-152

fr.tme mcmbcn.15'- 155

gen<.Tk, 14S-I~
lumlng. 15S
otr.." j!.uidc: lOr. 170
fur a 1"OU.er ",he
aecOWI'ing fur bit di,,,ncler, 292-293
'ruol)">ing an<! 1.I"tI OUl. 286--289
'pi",letl .pindlc. 29-<-295
fur "",cit suppOn_pin 1Iole:<. 12_18
~0I1etl pllol,4_S
,.Ne It!!.. 292-293
uSing lOr ...... klnll ~"'pt>.c.. 115. 118
,'aL.... um. 60-62

Tcnon Set! lllso MOI'1;,;ing

horiwn,.1 SC'lup for cuulng. 200
Ioooie-tcnon joi"' . 1.\0. 144
Tmonlng skd. 25j-255
lbtsioner. 28 1. UB-284
TIl=nopl.1Mia
boring.67
eUl1lng.6S

Thk:l<.nooing.267-268
ll>omson Indu,nie.;. 134
n,rndc:d Imcru. d,hing. 78. 127
".."
bi .. 1br t:lpping.I22.J06
cuning. ~-.\O5
.... ntl2td>. 46. ,04
ThrotllUl monlsin3. 153
Thumbed .... thcrboanls. 257. 2~

.-.cu..... ~4-49

T...... md~
rnakin& J9-'t2
using ;" mal<inS jqp and IC1I"Ipbto. 7. 4-.18

-...-

,"",,&42-H

T~

.,..nem 10 ~ .."Otkpic, 22'

T~kntt.211

aplaincd. /r... "

nu..JHrimminS ha>Cpb'r. 119- 12j
fractOn:>tnI! ~ 81-l14
tI>Ot1isint; iis. 1l~_ljO
off>o1 baocpblC. 115-118
5Ut"f.>cing~. 2601_2611
tf'lftlll1o<i "'-'..... c. 39-4J
T""'I""",.6'}-74
Tl""i:ggI:Mv.itd> p1unsc """eD. 18
TIXk. maklo&42,225

,-

rnakin&41

bit. ,cehniquc

rar USi

2-'0

''''~
clarnp bIods 1Or.70-72
~70-"

ptl<Ii.ioning ...ilh an ofl"SC'l ",*", 7~

UWog. 6'}. 72
Tuffak. 300
Thni"ll 1'1""",, rou .....s pIWIfIC IDCdwlISm. 18l
TUtnln&..,.;m. rout .... Jatbc.l69-297

u
Unl'~"'" ruu,~r

nlOUlttb'lI pbte. 16j-172

v
\Xuum dwnbcr. minimum >ile. :H9
\XulUU d2mping, ,.a-62
caIruIIUng thc hoIdlng fon:c. ""
fc:l1herboo.rds. 259-16j

-..."
..

~ol, ,.a

\'acuum ct:amp pla,e

dcooc"bed. 50
""'!:Ing. SS-511
..... "lI.511
Vlcuum rc..thcrbo<lnls, 2W-:z6j
V...,uumha~.~I-S2

Vacuum nl1nifilld.62
Vaeuum pori,
r.u!rtp for. S4
kln<h oi. H
V.ocu"'" l1u./! bI<:ldr. 5II 60
V.lCUum '~pc. Sj
V"""um t""'p"u:(,). 60_62

Inelu

III

\ ...:....... lo:>tlfOl; 1OUI0nD,

\'x ....... ,rommd.4~-19

_Id.... j~ _ 18

So6-"

,...Io ...ith a nlOIIer. 168

f btbnd ""'"" M
puIn<.nItlq roundoo'I::. bit. l9O
1I'Uflhmdl ~ 11lr11kt11'1<.>1c>o fi .... j~

-"

\')oc"uml'ooq .......
nul<u1,g, -1_-j
~ng,

...1lnl

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A8RACADA8RA!

Irs

MAGIC ..

S18.9S USA

Now you can leach your router to do magical tricks you

never dreamed possible, and aII you need are a handful
of standard bits and the extraordinary jigs, fixtures, and
techn iques inside th is book.

Craft nawless cope-andstick joints on your

router table, qu ickly and easily.
Spin out cuslom dowels for aII your special
proJects. from any specles of wood, in any
lenglh or dlameter.
Create spectacular f1uted splndles. amazlng
splralbeaded columns, and astonishing finials.

More than 50 new jig5 and fixtures tO save you lime,

money, and effon! Router Magic's explicit step-by-slep
instruclions show every jig and how to use the jigs and
your rouler In dozens of
new ways. Yes. it's magic.
But Router Magic makes
YOU the magician .

Bill Hylton has been writ ing about woodworking for

more than 20 years. A whiz w ith a (Ouler, he pulS his
favorite woodworking 1001 to use n both practical and
innovative ways. He is the coaulhor of
Woodworking wirh rhe Roufer - which has
sold more than 140,000 copies.

ISBN

D -7 ~2~-D~!S-7

ISBN

D-7~2~-O~!S-7