I S S U E N U M B E R

ONE

Jigs and Accessories Elu Plunge Router Crosscutting Table 5 aw Cabinet Router Table Router Table Top Router Table Fence

4
10
Elu Plunge Router

Three table saw accessories: Small-Piece Clamp, Push Block, and Table Saw Jointing.

page 10

The Elu #3338plunge router is put to the test andcomes out a real winner.

12
14

Problems involved with crosscutting on the table saw and helpful tips on solving them.

This simple cabinet mounts to the side of a table saw providing storage for blades, a rip fence, various accessories, and even a miter gauge.

16
18

This router table is loaded with options starting with a very simple base. (As a special bonus we've included a set of plans for an enclosed router cabinet.)

Crosscutting

page 12

The sandwich construction of the top provides a heaw vibration-free worksurface.Andallowsasmooth surface for the miter gauge slot and the remov&e inserf plate.

Sliding faces allow you to vary the bit opening to fit the bit you Y e using. The T-slot makes attaching accessories quick and easy

Fence Accessories

26

A bit guard, free-hand guard, aflustabte featherboard, and shop vacuum attachment make the router table safer and easier to use.
I

Table Saw Cabinet

page 14

Five shop-tested tips: A Sprlng-Loaded Sanding Block. A Woodscrew Tip. Sawhorse Tray.Pipe Clamp Rack. And a Magnetic Tool Bar.

Book Review
A look at The Worksho.~ Book by Scott Landis,

5ources

31

Hardware, project supplies, and mail order sources for the projects in this issue.

I S S U E N U M B E R

TWO

contents
Drill h s s Caddy fbdial Arm 5aw Fence Cornbustibles
How to prevent spontaneous combustion from occuring in your shop. Also, tips on safe disposal of finishing suoolies and materials. ,

This handy Drill Press Caddy provides instant access to your bits and accessories.

A versatile Radial Arm Saw Fence along with two shopmade fence accessories:a stop block and a hold-down.

Hand Scrapem

12
Hand Scrapers

Two methods for sharpening a scraper let you create a cutting burr in just a few minutes. (We've also included a burnishing jig to make it even fastec)

%rage System

16

This wall-mounted storage system features a variety of shop-made bins. The d~fferent-sized bins allow you to customize the system to meet your storage needs.

Joiner's Mallet Hand-Cut Mortises Shop 5olutions

22 26
Storage System page 16

Laminated construction is combined with lead weights to create a mallet with excellent balance and heft.

The right tools coupled with a simple technique willhave you cutting mortises by hand in no time.

28

Five shop-tested tips: A Countersink and Bit Organizer, Framing Square Stop, Finishing Stand-Offs, Radial Arm Saw Depth Stop, And an Idea for Gluing-Up.

505s Hinges 50urce5

30
31
J o i w ' s Mallet page 22

A brief histox applications, and tips on installation.

Hardware, project supplies, and mail order sources for the projects in this issue.

blip-on Auxiliary Fence Bevel Grinding Jig Router Trammel Tool Carry-All

This auxiliary fence slips over your rip fence so you can cut rabbets or support tall workpieces.

Grinding a precise, even bevel on a chisel or plane iron is easy once you've built this handy jig.

8
10
l'ool Carny-All

Cut perfect circles or arcs with your router and this shop-made trammel.

A removable tray for small jobs and a storage tray for organizing parts and hardware are just two of the features of this handy Carry-All.

II),

Plate Joinery Plate Joiners Clamping StaUon Shop Solutions

16 20 22
Plate J o i n m
page 16

Make tight-fitting joints quickly and easily by cutting matching slots and then gluing in a wood "biscuit. "

A review of four plate joiners priced for the home workshop: Ryobi, Freud, Porter-Cable, and Skil.

A flexible clamping station for gluing-up perfectly flat panels and frames.Andit doubles as an assembly area.

26

Four shop-tested tips: A Drill Press Clamp. Scraper Holder. Shop-Made Bench Vise, And a Tip for Storing your Shop Manuals.

Toggle Clamps
@
No. 3

28 31
I

A look at these versatile clamps along with tips and ideas on how to use them in your shop.

Sounces

Hardware, project supplies, and mail order sources for the projects in this issue.

Hinge Mortising Jig Thickness Sanding Jig Shop-Made Drum Sander

I

All it takes to make perfect hinge mortises is a router and this simple jig.

8
11

Sanding thin wood so it's smooth and uniform in thickness is easy with this jig for your drill press.

A bolt, some toy wheels, and a piece of PVC pipe are all you need to make your own drum sander

Sharpening Hand Saws Rnel Saw

12

There's nothing mysterious to sharpening a hand saw. A N it takes is a few simple tools and a little practice.

I
Thickness Sanding Jig
page 8

16

This shop-built panel saw allows one person to easily crosscut or rip a full sheet of plywood or Masonite It's made with common materials and hardware

Rnel5aw Tune-up Motor Wbmtion Shop 5olutions

24
26
Sharpening Saws Page 12

Tips on adjusting the panel saw to make precise cuts every time.

Some quick tips to reduce troublesome vibration in belt-driven machines.

28

Five shop-tested tips: Saw Blade Storage Rack, Edge Jointing Tip, Installing Threaded Inserts, Clamping Irregular Shapes, and File Handles.

Combination 5crews

30 31
Panel Saw

A unique thread design and recess in the head make these screws the perfect choice for the shop.

@
No. 4

Sources

Hardware, project supplies, and mail order sources for the projects in this issue.

I S S U E

N U

0
Small-Piem Miter Box SmaN Shop lip5 ,
I

4
Small-Piece Miter Box page 4

Cut tlght-f~ttmg mlters on small pleces of trlm with th~s shop-made miter box

8 10 14 16

Five space-saving tips to make your woodworking shop more comfortable and efficient.

Tool Handlee Turning Jig Roll-Around Shop Cart

Manufactured handles are designed so "one size fits all. " A custom-turned handle looks and feels bettec

You don't have to own a lathe to turn wood. This simple jig lets you turn small projects on your drill press.

Pegboard panels and pull-out trays combine to create much-needed storage space. Adding casters converts the cart into a mobile work surface.

Stub Tenon & Groove Adjueiable Setup Gauge Shop 5olutions

22 24 28

The secret to this strong and simple joint is to glue a man-made panel into the grooves of a frame.

This shop-built precision gauge ensures accurate height, depth, and distance measurements.

Five shop-tested tips: Drilling Tip, Scroll Saw Blade Organizer, A Tip for Turning, Squaring a Miter Gauge, and Pads for C-clamps.

Lumber Thicknetis SOUIY;~~

NO.5
ShopNotes

30 31
Set-Up Gauge Page 2.4

Find out why saw mills, lumber yards, and retail outlets often use different terms to designate lumber thickness.

Hardware, project supplies, and mail order sources for the projects in this issue.

7ilting Drill h s s Table Adjustable Stop Block

4
Drill Press Table

A tilting table, an adjustable fence, and a replaceable insert make it easy to drill straight or angled holes.

This stop block is ideal for making stopped cuts on a router table, band saw, or drill press. Itk "micro-adjustable8'so you can fine tune the position for an exact cut,

Fomtner Bits Shop-Built Clamps

I I )

10

Guided by its rim insteadof a centerpoint,a Forstner bit cuts near perfect flat-bottomed holes at any angle.

9
Shop-Built Clamps page 12

12

Two clamps you can build at a fraction of the cost of store-bought clamps. One for gluing up panels and the other for quick clamping jobs.

Table Saw Tenoning Jig

Precision tenons are easy with this shop-madejig for your table saw it features a unique doublestop so you can cut both sides of a tenon without flipping the workpiece.
i

7@ for Cutting Tenons

24
Tenoning Jig

From stock preparation andlayout, to cutting the cheeks and shoulders, these helpful tips will show you how to cut a tenon that fits perfectly.

Shop Solutions

28

Five shop-tested tips: Zero Clearance Insert, Depth Gauge, Cut-off Jig for a Circular Saw, Squaring a Mitered Corner, and a Tip for Mortising Hinges.

Knock-Down Fittings 50unes

NO.6
ShopNotes

30 31
Tenon Cutting Tips page 24
3

All it takes to build furniture that's easy to knock down and put back together again is the right hardware.

Hardware, project su~plies, and mail order sources for the in-this issue.

ISSUE NUMBER

SEVEN

--

Contents
fbised enel Jig
I

4
Raised Panel Jig

Rout a perfect ra~sed panel door or drawer usfng a route< a strafght b~t, and this shop-madejig

Block Plane 7ips

From planin; end and edge grain to trimming small pieces, here's a few tips that will provide crisp, clean cuts every time.
I

Sanding a 5urface Flat

sander and four simple steps.

10 2 it takes to produce a perfectly flat surface is a belt 12 14 16

Rust Removal Keyless Chucks

Practical solutions for removing rust and restoring tools to a usable condition.

B)

Changing drill bits without a chuck key is quick and easy wfth this handy accessory for your portable drill.

Workbench

This workbench features a solid base that knocks down easily and a top that's built up of plywood and thin hardwood strips.

Shop-Made Kse

23

A massive wood face, iron guide rods, and a manufactured vise screw combine to provide even clamping pressure that holds a workpiece tight.

Four shop-tested tips: Dowel Cutting Jig, Shop-Made Bench Clamp, Rip Fence Alignment Gauge, anda Glue Brush Tip.

Board Footage Sources

30 31
Shop-Made Vise Page 23
3

Calculating board feet takes the guesswork out of determining the cost of a project.

Hardware, project supplies, and mail order sources for the projects in this issue.

Contents
Router Jointer Box Joint Jig
4 6
I
All it takes to get a perfectly straight edge on a workpiece is a hand-held router and this shop-madejig.

Router Jointer

Page 4.

Thisprecision-madejig produces tight-fitting box joints. The secret is a micro-adjustment system that lets you sneak up on the perfect fit.

Makind Box Joints Sharpening Brad Point Bits Band Saw Fence System

12 14

Professional look~ng box joints are easy to make with this ample step-by-step approach.

A file and a few basrc techniques are all you need to restore the edge on your brad point bits.

BOXJoint Jig -

. .

16

Make perfectly strarght cuts on your band saw wrth thrs rock-solrd fence It features a bwlt-rn clamprng system, an adlustment for drrft, and two shop-made accessorres

Sliding Bevel Gauge

22

1
Band Saw Fence page 16

Brass and wood combine to produce a fine tool thatk both handsome and functronal Plus, some special technrques for worklng wlth brass and wood

ShI o Solutions ~
-

28

Seven Shop-Tested Tips: Dust Collector; Assembly Surface, Storing Waterstones,Auxiliary Fence Tip, Keyless Chuck Update, Drrll Bit Spacer, and a Biade Guard for Hand Saws.

Abrasive Bds

30

Create a mirror-smooth finish on your projects by using abrasive pads rn between coats.

Hardware, project supplies, and mail order sources for the projects in this issue.

Sliding Bevel Gauge

page 22

No. 8

ShopNotes
-

Contents
Jointer Push Block Vertical Raised h e 1 Jig Router Tune-up Edgebanding Plywood Portable Planer Stand
4
I

The unique design of this push block allows you to safely flatten the face of a board.

Raised Panel Jig

Page 6

6 10
12

All it takes to rout a professional-looking raised panel is this shop-madejig and a vertical raised panel bit.

A close look at router maintenance problems And tlps on keeplng your router ~ntop shape

Three different types of veneer edglng let you hlde the exposed edges on a plywood project

16

An adjustableouffeed extensionprowdes support for long boards T o make it easy to store, the extensfon 'knocks down" and the stand tilts and rolls on a set of wheels

Table Saw: Ripping

22
24
Planer Stand

Practical tips and shop-built accessories for ripping a workplece safely and accurately on the table saw

7001S m g e
Shop 5olutions

A place for everything, and everything in its place. That's the Idea behind this easy-to-build storage system for your portable power tools.

28

Five Shop-Tested Tips: Router Bit Depth Gauge, An Adjustment Block for your Router Table, Installing Threaded Inserts, Squaring-Up Large Panels, and a Cork-Bottom Sanding Block.

Lumber Gmdes

30 31

You can save money on materials fora prolect by us~ng the d~fferent grades of lumber to your advantage

Hardware, project supplies, and mail order sources for the projects in this issue.

Tool Storage

page 2.4

I S S U E NU

ER TEN

Contents
Indexing Jig
This jig for your router table lets you quickly and accurately position the fence. The fence can be moved in orecise %s" increments or fine-tuned for an exact cut.

Indexing Jig

Page 4

Drill Bit Case

Per-hect Miters Lathe Stand

10 12 16

Protect and organize your twist drill bits with this simple case made from wood salvaged from the scrap bin.

All it takes to cut perfect miters on the table saw is a few basic adjustments and our simple cutting sequence.

A heavy bench with a unique sand-filled beam virtually eliminates lathe vibration. Two drawers keep lathe accessories handy There'seven plans for an optional tool rack.

Layout Techniques

22

Practical tips and techniques to increase accuracy and simplify measuring and layout.

Sanding Products 26 A look at new sanding products. New types of abrasives. New sanding belts. Even "metal sandpaper."

Shop Solutions

28

Six Shop-Tested Tips: Pipe Clamp Edge Vise, Supports for Cutting Plywood, Auxiliary Band Saw Fence, a Tip for Rust Removal, Glue Brush Tip, and a Shop-Made Cord Tie.

Full-xtension Dmwer Slides

30

Adding a pair of full-extension slides is an easy way to increase the usable space of a drawer, tray, or shelf.

Hardware, project supplies, and mail order sources for the projects in this issue. I

Layout Techniques

, . . ,

Contents
I I

Drill h 5 5 Table Counterweight - -4

All ,I takes 1 s 1,nger pressure lo movc your drrll press table orice you've ~nscall~~d ch~s srnp~e counlcrwerghr

Randonz-Orbif Saxd

Pipe Clamp Rack Radial Arm Saw Return Random-Orbit Sanders Hand Plane

Keep yourpipe clamps organized and right at hand with this easy to build wall-mounted rack.

Make your rad~alarm saw saferto use w~th th~s accessory It returns the blade after each cut and keeps it there.

8
10
Hand Plane page 10

A look at random-orbit sanders. What makes them different, how they work, and techniques for sanding.

There's nothing complicated about making your own hand plane. Especially when you start with a special blade set and build the plane around it.

Portable Miter saw station

16

You can make yow power miter saw safer and more accurate to use with this work station. A unique design offers support for long stock, yet knocks down easily for storage.

Sharpening with Sandpaper Shop Solutions

24 28

You can ach~eve a razor sharp edge on your hand tools wlth thls qulck and mexpenave technique

Seven Shop-Tested Tips:Frame and Panel Jig, Sanding Belt Storage Rack, Tip for Clamping Edging, Plugging Mortises, Peel and Stick Veneer Tip, No-slip Waterstones, and a Guide for Power Sanding.

P b o o d Grades

30

What the various grades of hardwood plywood mean. And how to use them to your advantage

Hardware, project supplies, and mail order sources for the projects in this issue

No. 1 1

ShopNotes

Contents
%might-Edge Cutting Guide
I

A unique clamp~ng system makes it easy to gulde your crrcular saw for strarght and accurate cuts

Drill h s s Foot Pedal Dado Blades

8 10 12
14

This foot pedal frees up your hands so that you can accurately posltlon a workpiece for drill~ng.

A look at the different types of dado blades. Plus some new variations on traditional blades.

rips on Using Dado Blades

Changing JdinWr Knives Disk Sander

Tips and techniques to make clean and accurate cuts with a dado blade.

All it takes to change and adjust the knives on your jointer is a straightedge and a little patience.

16

Get professional quality results with this shop-built bench-top disk sander. It features a large, flat table that tilts for angled sanding, and a built-in vacuum port.

Disk Sander Stand

25
Dado Blades

This standprovides a stable foundation forthe disk sande,: A hollow column can be filed withsandorbricks to "anchor" the stand in place and reduce vibration.

Page 10

Shop Solutions

28

Six Shop-Tested fips Knock-Down Sawhorse, Alternate Bench Wse, Clamp Pad, Allen Wrench Organrzer; fip for CuMng Metal Threads, and a Leather Strop Tip

These inexpensive knock-down fasteners holda pro,,,, together securely without stripping out And best of all, they're readily available at most hardware stores.

.
I1
I
~.
. >

5out~e5
. . . ..

31
ShopNotes

. ...

e ; " : . .

. ; :

. .. . .

1
Disk S a n d e r

'~

Hardware, project supplies, and mail order sources for the projects in this issue.

page 16

No. 12

cI Contents
. .

Router Bit Storage Cabinet 5crolI Saw Blades Band Saw Set-Up Dust co//ectionsystem Cyclone
.

You can both protect and organize your router bits by building this handy storage cabinet.

8
10

A look at the different types, styles, and sizes of blades that give the best results when using a scroll saw

changing the bladi ona bandsaw is easy whenyou follow these step by step instructions. We'll take you through tracking, tensioning, and adjusting the blade guides.

14

This shop-made dust collector features a two-stage system. The first stage removes large chips. And the second stage filters out fine dust particles.

15

Plywood and metal flashing combine to make the first stage of the dust collector - a cyclone that funnels large chips into a roll-around chip bin.

Filter Box Pipe & Hook-Ups Shop 50lutions

22 24 28

By wrapping an inexpensive fabric around a simple frame, you can form the second stage of the dust collection system which filters out fine dust particles.

All lt takes to connect your power tools to our dust collector or your exfst~ng collector 1 s a system of pfpes and these shop-built hook-ups

Six Shop-Tested Tips: Toggle Clamp Stop Block, ShopMade Utility Knife, Measurement Tip, a Tip for Rubbing Out a Finish, Sawhorse with Insert, and a Tip for lnstalling a Strike Plate.

P/ywood Veneers 50uRX5

No. 13

30 31

The appearance and cost of a sheet of plywood can vary greatly depending on how the face veneer 1 s cut.

Hardware, project supplies, and mail order sources for the projects in this issue.

Dust Collector

page 14

Contents
Miter Gauge Fence Anti-Kickback Bits Chisel P/ane
4
Make quick and accurate cuts on the table saw with this shop-built fence for your mlter gauge An in-depth look at how anti-kickback router bits work Also, a companson of the different bits available

' I

Cleaning up hard to reach places (like the corners of a a chisel plane All I? takes to drawer or panel) is easy w~th make your own is some slmple hardware, a blade, and a scrap of wood

Chisel Plane

Stock hparation

12

The foundation of a quality project can be traced back to how carefully the stock 1 s prepared before the actual building beg~ns

Fold-Down Work Center

16

This wall-mounted work center offers plenty of built-m storage to keep your tools r~ght at hand It also features a bench that folds down to provide a solid worksurface And a f l ~ p u p d w r holds an optional shop 11ght

Drill Press Tips

24

Solutions io some of the most common driIIingproblems in the shop. Also, simple jigs you can make to increase your accuracy when working with a drill press.

Shop 5o/utions

28

Work Center

2
page 16

Five Shop-Tested TIPS Plpe Clamp Caddy, BenchMounted Belt Sander, Shop-Made Chisel Holder, Foot Pedal Modlhcation,and a TIP for Mixing Powdered Glue

Gel Stains 50ume6

No. 14
ShopNotes

30

The thicker consistency of gel stains offers a number of advantages over 11qu1d stalns

31
Drill Press Tips

Hardware, project supphes, and mail order sources for the projects in this issue

page 24.

I'

Band 5Cutting aw Circle Jig 4 perfect circles is easy with this shop-made jig for
your band saw. A built-in tape and indicator let you quickly set up to cut almost any size circle.

Band Saw C i d e Jig

page 4

Belt Sander Maintenance Shop Tote

8
10
Shop Tote page 10

All it takes to keep your belt sander running smooth and trouble-free is a routine cleaning and inspection.

A un~que deslgn prtov~des a handle for each tray of thls handy tote Then the two halves comb~ne to form one gr~p to carry parts, tools, or hardware whereveryou need them

Epoxy 5ystems

14

An in-depth look at using epoxy systems in the shop: from measuring and mixing, to tips on application. Plus step by step instructions on how to make your own filler:

5liding Table

16

If you've ever tried to crosscut a large panel on a table saw, you'll appreciate this shop-built sliding table. It features a built-in fence that slips on and off for quick and accurate set-ups.

Chisel Technique5 Shop S O / U ~ \ O ~ ~

24 28
Sliding Table page 16

Making a controlled cut with a chisel depends on using the right grip and a few simple techniques.

Five Shop-Tested Tips: C-Clamp Rack, Hole Saw Relief, Cut-Off Gauge, Pinch Blocks, and a Tip for Keeping Power Cords Out of the Way'

Spring5
'

30

Two types of springs to improve the performance of your shop-built jigs and fixtures.

soume5
No. 15
ShopNotes

31
Chisel Techniques page 24

Hardware, project supplies, and mail order sources for the projects in this issue.

Circular 5aw Cut-OFFJig

, ; . . % .

..
~. .

.>>

<

..

This shop-built accessory allows you to use your portable circular saw to make perfectly straight or angled cuts with dead-on accuracy

I.
I.

1.

..

FCexibleAVeneer 8 close-up look at the different types of flexible veneer:

Also, step-by-step instructions for applying and finishing flexible veneer toproduce professional-lookingresults.

Drill Bit Cabinet

.
. . . .

12

,.
.

_i

Organizeyour drill bits andaccessories with this compact cabinet. It features storage trays thattilt out foreasy access to your bits, and an optional drawer for accessories.

Radial Arm 5aw Stand

.. -.

16

This modular system is more than lust a stand for your rad~alarm saw By taklng advantage of the unused space under your saw, lt makes it easy to organ~ze cutoffs, sheet goods, and scrap p~eces of wood

Reducing - 7001Noise
; ; ,

24

. .,,. ... .. .
. . . .I 8

The noise your tools generate doesn't have to drive your family (or neighbors) out of the house. Here are some simple tips for putting a damper on the worst offenders.

::;?

~ Shop :.$z. . . 5olutions

28

Six Shop-Tested Tips: Band Saw Fence, Adjustable Runner for Miter Gauge Slot, Putty Shield, "Window" for your Dust Collector;plus two Quick Tips.

Medium-Density Fiberboard

30

Because it's flat, smooth, and dimensionally stable, medium-density fiberboard (MDF) is an ideal material for many projects.

a
I

50um
No. 16
ShopNotes

31

Hardware, project supplies, and mail order sources for the projects in this issue.

ISSUE NUMBER

SEVENTEEN

Contents
Jigs & Accessories
Combination Layout Tool Band Clamp

12 26

This unrque tool comblnes a mark~ng gauge to lay out lornew anda beam compass todrawlargearcsandcircles

All rt takes 1 s a few hours to bulld thrs shop-made band clamp It" /deal for clamp~ng large or odd-shapedprqects

Adjustable Sawhorse

page 4

Projects
Adjustable 5awhorse Lumber 5tomge Rack
4
A versatile sawhorse that raises up and down to handle almost anyjob. Then knocks down for compact storage.

16

This sturdy storage rack provldes easy access to all your long boards, short cutoffs, and sheet goods.

I n the Shop
Cutting Tapers on a Jointer
'

Get crisp, clean tapers on a jointer without using any special jigs or complicated layout procedures.

Containing Noise in the Shop -22

A step-by-step approach to treating ceilings and walls so noise from the shop won't slip through.

Aniline Dves I

30

Cleat bright colors that can be mixed to match an existing color make aniline dyes worth a close look.

Departments
Shop Solutions
Six shop-tested tips from our readers.

28

Sources
Hardware and supplies for projects in this issue

31
ShopNotes

Containing Noise

Page 22

No. 17

ISSUE NIIMBEB EltiHTEER

II i
I

Jigs & Accessories Dmwer Joint Jig

4
16

Work~ng on aproject w~th lots of drawers? Thisshop-made jig turns your router table into a production tool.

Drill h s s Table & Fence

Projects

Make quick, accurate setups on your dr~llpress with th~s table. It features a large work area and a built-~n fence.

Hardware Bin
There are plenty of drawers 10this compact storage bin to help organ~ze small parts and loose hardware

page 12

Dovetailed Bookcase
Strength and good looks Two reasons why dovetail jo~nts are a perfect cho~ce for thls wall-hung bookcase

In the Shop

Resawing on the Band Saw Hand-Cut Dovetails

12 22

Simple tips, jigs, and techniques you can use to make thin stock out of thick boards.

You'll be cutting dovetails by hand in no time with our step-by-step approach and a few basic tools.
I I

page 1s

Wood Filler 30 Two types of wood fillers - each with a place in your
shop. Here are the reasons why.

Departments

Five shop-tested t~ps from our readers.

5oumes
Hardware and supplies for projects in this issue

31

Hand-Cut Uovetazls

Contents
Projects & Techniques Hand Plane Jointer

4 12 14
16

This shop-built jig produces a straight, square edge on a workpiece by converting your hand plane into a jointe,:

Built-up Moldings
build up your own detailed moldings.

' A router and some ordinary bits. That's all it takes to

Wall Mirror Cutting Guide Routing Rofile5

Use our simple built-up molding technique to make this handsome wall mirror in just a few hours.

A un~que track~ng system on th~s cutt,ng gu~de lets you use your c~rcular saw orrouter toproduce straight, accurate cuts

22

a
GreatTips

Create decoratwe profiles that are smooth and cons/stent w~th a hand-held router and our step-by-step approach

Departments
8
Buying a circular saw? Our team tests eleven popular saws and offers practical suggestions on what to look for

Pipe Clamp Tips

~rdm glu;ng up flatpaneisto keep~ng clamps from marnng the work, here's a collect~on of our best plpe clamp tlps

The Small Shop

Clamp 5tomge system

Readers'Tips

24 28
30

This convenient storage system organizes all of your clamps so they're right at hand where you need them.

Shop 5olutions
Lumberyard

Our readers offer their own shop-tested solutions to common woodworking problems. Plus two quick tips.

Lumber Grain

There's more to lumber orain than aooearance. It also affects the stabil~ty and cost of a projeit.

Finish Room

Danish Oil
ShopNotes

31
Clamp Storage System

A natural-looking finish that" easy to apply And you can

repair it too. A N this makes Danish oil worth a closer look.

page 2;

No. 19

Contents
Projects & Techniques Adjustable Dado Jig 7

4 8 10 16 22

Adjustable Dado Jig

page 4.

This shop-built jig offers a quick setup and guarantees a perfect fit when routing dadoes (or rabbets).

step 5tool
Cutting Tenons on a Band Saw Oueeed Table cutting fibbets

Build this strong, sturdy stool in just a few hours with the help of our adjustable dado jig.

Accurate cuts. And a quick, easy setup. Two reasons why a band saw is an ideal tool for cutting tenons.

lhis ouffeed table makes it easy to cut large workpieces on the table saw And it folds away for compact storage.

Band S a w n Tenons

page 10

Two basic techniques for cutting rabbets on a table saw without using an expensive dado blade

Departments
GreatTips

Router Table Tips

14 20 22
Outfeed Table page 16

Ftve tips to help you get the most out of your router table

SelectingTools

Quick-Change Bits
The Small Shop

Our team tests four qock-change bit systems foryour drill And offers practical suggestions on what to look for

Overhead 5tomge

" HardT oard

At the Store

Three s~mple solutions to one of the most challenrr~nn problems in a small shop -storing lumber

26 27 28
30
ShopNotes

What it is Where to find it And how we use it

New &ducts
We test three hot new tools for your workshop

Readers'Tl

shop &lutions
Our readers offer solut~ons to woodworkingproblems

Finish Room

5urhce hpamtion
~ a r e hpreparation l is the secret to a perfect finish.

No. 20

Projects & Techniques Avoiding - Kickback

Featherboard

Safety IS no accident Here5 a close-up look at some of the causes of kickback and what you can do to prevent it

A unique design lets you adjust thls shop-made featherboard to use on many of the tools ~n your shop.

Tongue & Groove

!
Tongue & Groove

Cutting a tight-fiiting tongue and groove joint is easy when you follow our simple step-by-step approach.

Lap Desk
7hicknessing Jig

11
16

This compact lap desk provides space inside to organize pencils and paper and a large stable surface to write on.

You don't need a planer to thickness stock accurately All it takes is a hand-held router and this easy to build jig.

The Small Shop

Departments

Power Tools
Wh~ch power tools are best for the small shop?Full-slze, benchtoo or comb~nat~on tools7

-'Tips

Glue-Up Tips Table Saws

20

Thicknessing J i g

page 16

A c~llection of our best tips that includes everything from choosing the right glue to the best way to apply it.

SelectingTools

22
28

Our team tests six popular table saws and offers practical suggestions on selecting a saw that will suit your needs.

Readets'TSps

Shop 5olutions 5oftwood Grades

Shop-tested solutions from our readers on their most common woodworking problems. Plus two quick tips.

Lwnberltanl

Building a prolect out of softwood? Understanding the dffferentlumbergrades can affect ~ tcost s and appearance

FinishRoom

WaterBased Top Coats

No. 21
ShopNotes

31
page 22

A durable finlsh that's easy to use Andno messy cleanup All thls makes water-based top coats worth a close look

Contents
Projects & Techniques
Drill Press Hold-Down Sanding Table Box Joints: Router Table Wall-Mounted Tool Cabinet Tool Holders
4
It's easy to drillprecision holes on the drillpress when you use this hold-down to 'Yock your workpiece in position.

10 12 16
Box Joints page 12

Eliminate the cloud of dust produced every time you sand with this benchtop sanding table.

Perfect box joints. That's what you'llget when you cut them on the router table using our simple step-by-step approach.

Thiswall-mountedcabinetprovidesa home forallyourtools. It not onlyprotects them -but organizes them as well.

20 26

One of the simplest ways to protecta tool is to make a holder for it. We'lllookatcustomizingholders for nine different tools.

Solid Wood Edging

You can give a plywood project the appearance of solid wood by trimming the edges with hardwood. Here's how

Departments
GreatTips

Jointer 7ips
Selectin Tools

8 22
Tool Cabinet page 16

Our favorite tips to help you get the most out ofyourjointer

rape beasurn Roll-Around Tool Base Shop glutione

Six shop-tested solutions from our readers.

Which of the eight popular tape measures that we tested is best for you? Our two-man team offers suggestions.

The Small Shop

24

Moving heavy tools in the shop is no longer a wrestling match when you use this simple roll-around base.

Readers'

28 30 31
ShopNotes

Lumberyard

%rticleboard
Finish Room

A look at different grades of particleboard and their uses.

Oil Stains
No. 22

True colors that don? fade. Oil stains offer this and more.

Contents
Projects & Techniques Saw Blade Storage
Turning with a Spindle Gouge Shop-Made Mallets Sabre Saw Table Dowel Joinery
4
Saw Blade Storage Pag
Protect and organize your valuable saw blades with this handy storage cabinet.

This versatile turning tool can do it all- from roughing out spindles to shaping decorative coves and beads.

8
16 22

Two traditionally designed shop mallets that can be turned withjust a spindle gouge and a parting twl.

A simple fable and a unique adjustable arm convert your hand-held sabre saw Into a precision cutting tool.

Shop-Made Mallets

Page 8

It's easy to make strong, accurate dowel joints withjust an electric drill and one of our simpie shop-madejigs.

Thesmallshop

Departments
10

Selecting Hand Tools Random-Orbit Sanders Lumber Storage 7ips

Here's a collectron of our favorrte lumber storage trps

What are the most practical hand and portable electrrc tools for the small shop? Here's a look at our top p~cks

SelectingTaols

12

Our three-man testrng team offers suggestrons on which palm-grrp random-orbB sander is best for you

GreatTf

24 26

Finii Room

Varnish

A hard, durable ffnrsh for your specal prolects

At the Store

New Products
Readers'm

27 28 30
ShopNotes

TapeMate, VentasBrass Insert Knobs, and NobexSquares

shop 6lutions
SIXshop-tested solut~ons from our readers

Lumbeyad

Buying Lumber

A step-by-step approach to buyrng hardwood lumber

No.23

Projects & Techniques Sanding Table & Air Filter Sy5tem

4
Sanding Table

Solve two problems at once w~th thls mob~le sand~ng table It collects the dust produced when sandrng And it filters fine dust particles out of the ai,:

PW

bttern Cutting on a Band Saw Arvhed-Top Clock Heavy-Duty Workbench

You can cut identical curved pieces quickly and accurately on the band saw by using this simple technique.

10

Its hard to stop after makrng]ust one of these arched-top clocks We offer several tricks to get "production" roll~ng.

16
Arched-Tq Clock

You won't spend a lot of tlme or money building thls sturdy workbench Made from ordlnary constructionmaterials, ~ t s large work surface provides several clamping options.

p a g e 10

mSit1a1Shqa

Departments
12

Sawdust in the Small Shop

Two strategies for dealing wiih dust. Contah as much as possrble at the tool that produces the dust And use filters to keep the fine dust particles out of your lungs.

14
From mak~ng a center marker to drawrng arcs, here's a collection of quick trps for getting accurate layouts.

22
Confused about the bestband saw to buy?Our threeman team puts SIX medrum-duty saws to the test and offers aracttcal suaoestions on which one to choose.

Our readers offer their own shop-tested solutions to some of the most common woodworkina amblems.

mberyard

5&wood

Plywood
31
I

Know~ng the d~fferent grades of softwood plywood w11l he$ you select the best materral for the prolect at hand.

Fin* Roan

5pecialLy Finishes
ShopNotes

Two specal finishes wiih a twlst One creafes the lookand feel of grante. The other gives the appearance of marble

Band Saws

page Z2
3

No. 24