WORKSHO

GPU I D E
INVENTORY
OFJIGHARDWARE
Wood acrewa
Oval(below,lefL)and flat head (below,
cenLer)are ueedfor counLereinktnq;
roundhead(below,
rtqht) can be
removedeaerly.
Typtcallyavailablefrom'l Lo 6
incheelonq;common head typee
includeelotted,
Fhilipe,and equare

ffi;rfr

@@(a

Waehera
Uaedt.o helpdiaLributeload
whenueinqnuta and bolte;lock
(cenLer)and epltL(rt4hL)Lypee
deai7nedto keepnu1,from looaentnq;avatlabletn a vanety of aizeo

Toggle
clampe
Qutck-acLin4

v '

r nv n| v n) ,

at

l#t#,'w
t

applicattone

TT T7

ahle

and eaeilymachrned,plaeLice
auchaa_
acryltc,polycarbonaLe,
phenoliceheel,,
and polyeLhylene(HDFE) are often ueed
ae eee-throu7h
4uarde, Lemplateo,and
tneertplaLeefor rouLerLablee

6olta
Plaetic knobsand handlee
jiqe durin4operaFor conLrolltnq
ttona;offer comfortablegrtppin4eurface;nylonwaaherareducevibration

Cam clamp
Ueedto aecure
workpiece
injiq; Lurn
handleLo
increage
clampinq
Preaaure

Common
naile Fl
Featureqroovedll
ahankafor
ll
otrenqthand ll
h o l d i n 7 p o w e rl :l

Knockdown hardware iLem allowtnqjt7

Lo be taken aparL and reaesembled
wiLhouLeLripptng ecrew Lhreade;
threaded dowel te ineert ed in one
part of ji4 perpendtcular to bolL; bolLs
ranqe between 1and 3 inchee

Ueed wiLh nuLe for faeLenin7

wood; carria7e bolt (near rtght)
feaLurce oquare necl Lo keep bolr
from roLaLtng, hanger bolt (far
ri7ht) featuree machine fhreade
on one end and wood 1crew thread'
on Lhe o1;her;eizeo typtcally ranqe
'/,
from 1 Lo 6 tnchea rn lenqLh
and I to /, inch in diameLer

Miter bar
'/,"
Ftl,eetandard x'1" miter 4auqeelol,;
aerveoa6 foundaLtonfor a number
of ueefuljtge tncludtnq
a Lable
eaw croaacul;jig, a miter
jtg, and a feaLherPOara

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Threadedinaert
Knockdown
faatener
usedwith acrewgor
bolt;oLojoin compa-

1eneralfaetentn4of wood;etandard hexnut

(above,left) provideaeaeyacceeafor t urnrn4;
wtngnuL (above,cent,er)ta uaed wheredioaeeemblyand reaeeemblyie expecLed;T-nut
(above,riqhL) te ueed ae a knockdown
faeLener or rn ertuaLionswherebolLie no| acceeetble
after aeeembly;avatlabletn a varieLyof aizee

C,f

clampe that are faaLened to

jiqa Lo hold etock in place

iifir:'@W&
AHH

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lenathtvpicallv ll
J

r t

b e L w e e n l a n dl l

6 inchee

TT

Fl FI
Fl trI
ll
Il
ll
II
|

II

[J
" llV

tlII

E
E
E
E
E

F+
t*
>

Pneumatic
clamp
Ueeeair
nrpaat

trp

f ^

oecure workpteceer;ojiqe:
clampinqpreaeure adju.,t able from 20 to 160
pounde: varieLy of clampinq arme available for a
ran7e of applrcatlonz

S O U R C EFSO RJ I GH A R D W A R E
l
,j

",ad

M a n yh a r d w a rset o r e a
s n dw o o d w o rnkgi
supplh
y o u s eosf f e rs p e c i a l i z he ad r d w a r e
f o rs h o p - m a d
e sa n df i x t u r e sl t. i s a
lig
g o o di d e at o h a v ea s u p p loy f 1 i gh a r d -

w a r ei n a v a r i e toyf s i z e o
s n h a n di n
y o u rs h o p ,s i n c es p e n d i nt o
g om u c h
t f i t sp u r t i m em a k i n a
g j i g d e f e a tpsa r o
p o s eT. h ei t e m sa b o v e
p r o v i dae b a s i c

jig hardware:
listof essential
formorespec i f i ca p p l i c a t i ocnhse, c o
k u tb u s i n e a
s sn d
tradedirectories
aswellasmanufacturers
a n ds u p p l i eor fsi n d u s t r i p
a rl o d u c t s .

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THEARI OFWOODWORKING

SHOP-MADE
IIGSANDFDilURES

THEART OF WOODWORKING

SHOPME
FDffT'RES
IIGSAI.{D

TIME-LIFE
BOOKS
ALEXANDRIA,
VIRGINIA
ST.REMYPRESS
MONTREAL.
NEWYORK

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THE ART OF WOODWORKING was produced by
ST. REMYPRESS
PUBLISHER KennethWinchester
PRES/DENT PierreL6veill6
PierreHome-Douglas
FrancineLemieux
Marc Cassini(Text)
HeatherMills (Research)
Art Directors Normand Boudreault,Luc Germain,
SolangeLaberge
Designers Lina Desrochers,H6ldneDion,
Jean-GuyDoiron, Michel Gigudre
Research
Editor Jim McRae
PictureEditor ChristopherJackson
Writers Andrew Jones,Rob Lutes
ResearchAssistant BryanQuinn
Contr ibuting lllu strators GillesBeauchemin,RolandBergerat,
Bourgeois,
MichelBlais,Jean-Pierre
RonaldDurepos,RobertPaquet,
IamesTh6rien
Administrator NatalieWatanabe
ProductionManager MichelleTurbide
SystemCoordinator ]ean-LucRoy
Photographers RobertChartiet ChristianLevesque
Administ rativeAssistant Dominique Gagn6
Proofreader Iudith Yelon
Indexer ChristineM. Jacobs
SeriesEditor
SeriesArt Director
SeniorEditors

Time-Life Booksis a division of Time Life Inc.,

a wholly ownedsubsidiaryof
THE TIME INC. BOOK COMPANY
TIMELIFEINC.
Presidentand CEO
Editor-in-chief

JohnM. Fahey
JohnL. Papanek

TIMB-LIFEBOOKS
President JohnD. HaIl
Directorof Marketing NancyK. fones
Vice-President,
RobertaConlan
ExecutiveEditor
ExecutiveArt Director EllenRobling
ConsultingEditor
ProductionManager

lohn R. Sullivan
MarleneZack

THECONSUITANTS

and
JonArno is a consultant,cabinetmaker,
freelancewriter who livesin Troy,Michigan. He
alsoconductsseminarson wood identification
and earlyAmericanfurniture design.

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I(am Ghaffari is a freelancewriter and editor.

He hashis own businessin RhodeIsland
designingand building one-of-a-kindand limited production furniture. Kam'sbackground
alsoincludesworking professionallyin furniture reproductionand fine carpentryand
studyingwith furniture patriarchsWendell
Castleof the U.S.and England'sFredBaier.
GilesMiller-Mead taught advancedcabinetmaking at Montreal technicalschoolsfor more
than ten years.A nativeofNew Zealand,he has
worked asa restorerof antiquefurniture.
fosephTruini is SeniorEditor of Hoze
Mechanixmagazine.
A former Shopand Tools
he hasworked as
Editor of PopularMechanics,
a cabinetmaker,home improvementcontrac/
tor, and carpenter.

Shop-madejigs and fixtures

p. cm.-(The Art of Woodworking)
Includesindex.
(trade)
ISBN0-8094-9508-2
l. Jigsand fixtures.
I. Title: Shop-madejigs and fixtures.

IL Series
Tll l87.ss41993
684'.083-dc20

93-34t03
CIP

For information about any Time-Life book,

pleasecall l-800-621-7026,or write:
ReaderInformation
Time-Life CustomerService
P.O.BoxC-32068
Richmond,Virginia
23261-2068
@ 1994Time-LifeBooksInc.
All rights reserved.
No part of this book may be reproducedin
any form or by any electronicor mechanical
means,including information storageand
retrievaldevicesor systems,without prior
written permissionfrom the publisher,except
may be quoted for reviews.
that briefpassages
First printing. Printed in U.S.A.
Publishedsimultaneouslyin Canada.
TIME-LIFE is a trademarkof Time Warner
Inc. U.S.A.
R 1 0 9 8 7 6 5 4 3 2 1

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CONTENTS
6 INTRODUCTION

t 2 ROUTING AND
t6
20
2T
22
23
24
25
26
31
34

SHAPING JIGS
Dadoingjigs
Circle-cuttingjigs
Routerjointing jig
Hinge mortising jig
Corner-roundingjig
jig
Panel-raising
Adjustablerouting guide
Joint-makingjigs
Shaperjigs
Vacuumjigs

36 CUTTTNG
IrcS

40
4l
42
43
46
47

48
49
50
52
53
54
56
57
60
62
63
64

Sizingboard for crosscuts

Miter and crosscutguide
Ripping jigs
TWocircle-cuttingjigs
Wedge-makingjig
Two jigs for anglecuts
on the band saw
Thperjigs
A bladeheight gauge
Crosscutand miter jigs
Raisedpaneljig
Board-straighteningjig
Auxiliary fencesand tables
Cove-cuttingjig
TWotenoningjigs

DRIIIING JIGS
Center-drillingjig
Tilting tablejig
fig for drilling equally
spacedholes
65 V-block jig
66 Pockethole jig
67 Boring deepholes

68
7l
72
73
75
77

TURNING IIGS
TWocenteringjigs
jig
Gouge-sharpening
Spindle-turningjigs
|ig for fluting columns
figs for sandingand checkirg depth

78
81
86
89
90

GLUING AND CLAMPING JIGS

Edge-gluingjigs
jigs
Frame-clamping
jigs
Carcase-clamping
Workbenchclampingjigs

94
96
98
100

SANDING IIGS
|igs for face-and edge-sanding
Auxiliary sandingtables
Hand-sandingjigs

IO2
105
106
II2
113

TOOL EXTENSIONSAND TABTES

Plateioiner stand
Tablesfor power tools
Viseextensionstand
Adjustableroller stand

II4
II7
118
120

STORAGEDEVICES
Storingsawsand blades
Mobile clamprack
Lumber storageracks

T22
125
I28
130

SHOPAIDS
Safetvdevices
Sawhorses
Workshophelpers

I4O GLOSSARY
I42 INDEX
I44 ACKNOWLEDGMENTS

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INTRODUCTION

R. J.De Cristoforoon

DESIGNINGIIGS
J lookat anewtoolasabeginning.Onceit istakenfromitsboxor crateI readthe
I owner'smanualto learnwhatthemanufacturel
strggests
thetool cando.ThenI
standbackandthink, "Theremustbemoreto it thanthis."
Inevitably,
bysomestrange
thoughtprocess
I cantexplain,thereappears
amental
picttueof ajig, sometimes
simpleenoughto testimmediatehothertimeselaborate
enoughto requirea session
atwhatat onetimewasa drawingboard;now,I design
onmycomputer.
Thenewjigmight
enablethetoolto
dosomethingits
desigrernever
envisioned
or it mightincrease
accuracywith
minimumfuss,or it couldadda safety
factorto a routineoperation.ln anycase,
it hasto becustom-made
sinceit is rarely
available
commerciallv.
I'vedesigred
dozeniofjigsfor powerandhandtools.Still,for meit'snotanobsession:Practicality
is essential
andshoptestingmustprovethejig'sworth.Somefolla
jigs
think that areonlyfor amateurs.
If so,therearemanyprofessionals
workingin
amateurish
ways!
|igsaremeantto beused.ThosethatI designarenot madefor thesakeof a magazinestoryor abookandthenstoredor discarded.
ln a sense,
I conceive
aprojectthat
helpsmeexploitamachine,
or assists
mein workingmoreaccurately
andsafely,
and
thenI shareit with otherwoodworkers.
If I'veproventhatajig will beusefulto just
onereaderthenit hasvaluefor me.
I m fondof themasterjigsthatI havemadefor thedrill pressandbandsaw,and
especially
theunit for thetablesawshownin thephotoat left.Itsbasiccomponent
is a generous
slidingtablewith removable
insertssoit canfunctionwith a dadoing
toolaswellasasawblade.
Itsattachments
includeadjusable
guides
for accurate
crosscuttingandmiteringandamountable
unit-a jig in itself-thatallovrs
cutsliketenons
andslotsin theendof narrowstock.Thedeviceincludesa numberof essential
but
jigsandaddstheadvantages
usuallyseparate
of a slidingtableto eachof them.
There's
no doubtthatjigscanhelpanywoodworker,
but theymustbemadecarefrrlly.Thesearesituationswhereit pap to take10minutesto do a five-minutejob.
Consider
thatthejigwillbe alifetimetoolandyodllagreethatmakingit rightisthe
onlywaytogo.

R. J. De Cristoforo,author of numerous
boolcson woodworkingand othersubjeds,liva in LosAltos Hills, Californin

INTRODUCTION

Ted Fullerandhis

ROUTERIIG
\r/ earsago,I workedin an autobody shop,wherewe hand-formedbodypanels.
I Oftenweneededtwo matchingpanels-one for eachside-but weneverpro"You
ducedexactmirror images.Subtledifferences
wereeasilyexcused: can'tseeboth
sidesat thesametime."it wassaid.
In cabinetmaking,
hor.vever,
matchingpiecesmustbeexactduplicates.
Youusually
Although
masters
canseethemat thesametime.
some
canaccomplish
thisfreehand,
most of us must rely on carefullyconstructedjigs.
I wasluredto woodworkingin gradeschoolwhentheshopteacher
put meto work
props
play.
I
learned
on the
for a Christmas
earlythatthetimespenton thejig or templatemeanttime savedand consistency
gained.
Thereareplentyof jigs and fixtures'onthe marketbut, like baseballgloves,only
your own hasjust the right fit. Whenyou makeajig yourself,it is designed
for a specific
applicationandsizedto matchyour project.Bestof all,you don'thaveto changethe
projectto fit the store-boughtfixture.It's alsolessexpensive.
Making arched-topraisedpaneldoorsis one example.A manufacturedjig, and
pre-cuttemplatesthat enableyou to do thejob costseveralhundreddollars.Forthe
custompieceI amworkingon in thephotographI built a simpletemplateout of plywoodto createthe contourfor thearchedtop rail.Thisparticularjig is adjustable
for
two widthsof doors.Wideror narrowerdoorswill requireanotherjig anda re-draft
ofthe curve.
With the multitudeof top-bearingrouterbits on the market,exactcontoursare
quickandeasyto duplicate.Simplyroughout thepieceto shape,clampon thetemplate,androut to thefinishedshape.
Anotherbenefitof thisform of duplicationis
thatit doesnot leavethetool mark thatabandsaw
wouldandtherefore
reduces
sanding considerably.
Thenextstepis to run thepiecesthrougha matchedsetof rail and
stilecuttersto rout the profile on the sticksand makethe copecuts.It's a goodidea
to markthedimensions,
bit selection,
andset-upinformationon thejig sorecalculationis not recuired.
I think oneolthe mostintriguingthingsaboutwoodworkingisthatthereis always
someriggingthatwill makethework easier,
faster,andbetter.Theonlyreallimitation
is your own imagination.

TedFuller is theproductmanagerat Delta

InternationalMachinery/PorterCable(Canada)
in Guelph,Ontario.He is currentlyworkingin
newproductdevelopment
and marketingfor

woodworking tootsqnd' r"n2::

: #;":fri.

INTRODUCTION

BruceBeekenand Ieff Parsonsdiscuss

PLANNINGIIGS
p u.ry*oodworkeruses
jigsregularly.
Markinggauges,
combination
squares,
the
I-l rip fenceon a tablesaw,androuterbitswithball-bearing
pilotsarealljigsthat
aretakenfor granted.
Andwhohasn't,
atonetimeor another,
madeasimplethingamajigon thespurof themomentto helpgeta certainjob done?
In ourshop,wedesign
mostof thefurniturewemake.In developing
a newpiece,
weconsider
theesthetic
andthebuildingprocess
atthesametime.Our chairs,for
example,
havepartsthatdorit comestraightfrommachine
tables
because
welikethem
to havea certainstance
to supportthepersonsittingon themjustso.
jigsareusedin chairmaking.Thesesortsof jigsare
Someof our morecomplex
plannedfromtheoutset,tailoringtheprocess
to thedesign.
Wedevelop
themon a
full-scale
drawingasweworkoutourconcept
of thefurniturepiece.
A clearunderstanding
of thestepsandtheirsequence
notonlymakes
thewholejoblessintimidating
but oftensuggests
waysto simplifytheprocedure
andrefinethepieceitself.
Sometimes
ajig isassimpleasa wedge
to jackup a partattheproperangle.We
havealsofoundthatjigscanservemorethanonepurpose,
travelingwith apartfrom
machine
to machine.
Thehome-made
device
shownin thephoto,for example,
isused
forbothformingchairlegsontheshaper
andcuttingmortises
in themonthemortiser.
Westartby bandsawingblanksto approximate
size.Theyarethenfastened
to the
jig-in pairs,sincethejig hastwoedges.
Weshape
theinsidefaces
of thelegs.Then,
by changing
shaper
knives,shiftingthedowelpegsin thejig, andrepositioning
the
legs,wecanusethesamejig to shape
thefeet.Onceallthepartshavebeenformed,
wereturnthepegsto theface-shaping
positionandboltthejig to ourmortiser's
table.
Thejig thenholdsthelegsin theproperpositionasthemortises
arecut.
Therearetimesthat,with a littleextraeffort,ajig canbemadeto serve
a general
purpose:
for instance,
ahingedtaperjig forthetablesawor thickness
planer,
or arouter
boomfor cuttingarcs.
Theuseofjigsisinseparable
fromourunderstanding
of howto makethefurniture
wedesign.
Evenif apieceisto bemadejustonce,it islikelythatwewill develop
and
useajig somewhere
alongtheline.Whenweareproducing
abatchof several
hundred
jigsarecriticalin almosteverymovewemake.Whethersimpleor complex,
chairs,
theyserve
asthelinkbetween
drawingandtool,ensuring
precise
consistent,
results.

BruceBeekenandJeffParsons
aregraduates
of Boston
University's
Programin Artisanry.Theybuildfinefurniture
at theirshopat Shelburne
Farms,Shelburne,
Vermont.

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ROUTING
A].{DSHAPNGIIGS
earlyin the20th
Q in.. itsinvention
therouterhasbecome
one
tJ Centurv.
of themostpopularportablepower
Fewtools
tools-andwithgoodreason.
andvercanmatchitsspeed,accura6/>
satilityfor shapingwoodor cutting
joints.Butjigsarealmosta necessity;
althoughtheroutercanbeusedfreehand,mostcutsrequirea guide-particularlyrepeatcuts.
proin thischapter
Thejigsfeatured
videvariouswaysof obtainingquickand
precise
resultsfromyourrouter.Some,
jigsshownbeginning
likethedadoing
on page16,reducethesetuptimefor
likethelap
simpleprocedures.
Others,
joint jig on page27,allowthetoolto
produce
multiplecopies
of thesame
joint in a fewminutes.
new
A relatively
vacuumwoodworking
development,
(page34)elimipoweredaccessories
need
for
clamps
natethe
conventional
patterns
whenrouting
usingatemplate.
Thevacuumpumpis alsousefulfor
featherboards
to a routertable.
securing
jigsareeasyandinexpensive
All of these
to build.
Theroutertlargercousin,
theshaper,
better
canperformmanyoperations
thanthesmallertool,but it isgenerally
regarded
asoneof themostdangerous
A shoptoolsin thetypicalwoodshop.
(page
madefeatherboard
32)andguards
jj) will makeit a safertool.
(page

(lF ROUTING
A SEIECTIOI{
ANDSHAPING
JIGS
Dado-routin7 jig
(pa6e 17)
Faatenedto router
baae plate to cut
equallyopaced
dadoea

Auxiliary rout'er
aub-baae (page 21)
)ff-oquare base eecured
to router baoe plate to
enabletool to makecuta
wider than bit diameter
Freeatanding ahaper
suard (pa6e 33)
K
Trian4ularcutter \
auard with viewhole
for freehand ehaping

_---:
shaperguard (page55)
quardprotectaueerdurin4fence'
L-ehaped
Aidedbya simplejig, a table-mounted
routercutsa perfectboxjoint.

quidedehapinqoperationo;featureaviewhole

t3

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ROUTING AND SHAPING IIGS

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Corner halFlap
joint jiq (page 27)
Uaedfor routin7 corner half-lapjointa

5liding dovetail jig

(paqe 26)
Uaedwith router to cut
both parta of alidin7 dovetail joint; holda router horizontallyand eliminatea
need for router table

Hinge-mottiaing jig
(pase 22)
Clampedto edqe
of workpieceto rout
hinqemorLiaea
Movable-jaw
moftiain7 ji6 Qa6e 29)
Adjuatablejawo enaure
that cut ia centered on
the edqe of atock

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?anel-raising jig
(pase 24)
Uaed with router to
bevelpanel edqea;holda
router in horizontal
poaition, eupportinq
panel on a broad table

Adjuetable mofiiaing jig

(pase 28)
Holda workpieceed4e-up
for cuttina morLiaee

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ROUTING AND SHAPING IIGS

-\\
Extended ehaper
featherboard (paqe 32)
Clampedto ohaper fence Lo
aupporb workpieceedurin4
fence-7uidedcuta and protect uoer from cutter

Adjuatable airaleautting jig (page 2O)

Ueedwith router to cut
circlea. )crew ia fixed to center
of circle; radiua determined by
diatance betweenscrewand bit

to router baeeplate to 4uide

tool around circular cuLs

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Adjuetable routin4
guide (page 25)
Adjuatable edqe quidee
ueed with router to cut
recta nquIar qroovea;tem platea can be added to
rout patterne

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Quiak-aetup
dadoing jig (page 18)
Conaiataof two L-ehapededge4uideefor
routin7 dadoea:quideereatfluah aqainet
oppoaite ardeaof router baee plate

Shaper airale-autting jig

(pase 31)
V-ehapedjiq quideacircular
atock duringahapin4operationa

T-equarejig (paqe 16)

Clampedto workpiece,
jiq qurdearouter
through dado cute

Adjuatable dadoing jig

(pase 19)
Securesworkpieceo
of varyinqwidtha ,

for dado cuta

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DADOINGJIGS

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A T-SOUARE
JIG

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Edqe qutde

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theiig
1 Building
and
I Toroutdadoes
thatarestraight
to theedges
of yourstock,usea
square
T . s n r r airi epl i k et h eo n es h o w a
nb o v e .
"

I'b

"''"

M a k et h e j i g f r o m3 / q - i n cphl y w o o ds,i z i n gt h e p i e c e tso s u i tt h e s t o c ky o uw i l l

b e u s i n ga n d t h e d i a m e t eor f y o u rr o u t or haco nl:tp

Thp cd'sc srridp shnrrld

t inchew
s i d ea n d l o n g etrh a n
b ea b o u 4
t h ew o r k p i e c ew' si d t h :t h e f e n c e .a l s o
a b o u t4 i n c h e sw i d e ,s h o u l de x t e n do n
orthor side nf thp orrido hv ehnrri thp

. ssemble
w r d t ho f t h e r o u t e rb a s ep l a t e A
t h e 1 i gb y a t t a c h i ntgh ef e n c et o t h e e d g e
g u i d ew i t h c o u n t e r s u ns kc r e w sU. s ea
try squareto makecertainthe two pieces
o re a c ho t h e r T
. hen
a r ep e r p e n d r c u tl a
a n d ,w i t h
c l a m pt h e l i g t o a w o r ks u r f a c e
t h e b a s ep l a t ea g a i n stth e e d g eg u i d e ,
r o u ta s h o r td a d oo n e a c hs i d eo f t h e
used
fencewith yourtwo mostcommonly
bits-often r/zand3/qinch Thesedadoes
i n t h e f e n c ew i l l m i n i m i z tee a r o uwt h e n
t h e l r g r s u s e da n d h e l pa l i g nt h e l t g
w i t ht h e c u t y o uw i s ht o m a k e .

r) Routing
a dado
aligning
thedadoin thefence
L Clamp
thejigto theworkpiece,
w i t ht h eo u t l i n oe nt h es t o c kW
. h e nm a k i ntgh ec u t ,p r e stsh e
Continue
theedgeguide(above).
routerbaseplatef irmlyagainst
router.
fence
stopping
the
distance
into
the
before
thecuta short

il lll ilil,l|lllllill '[l il dliltt

NiifilxllXl,lli,lii]}1iittr
1HO?Tt?

) a '

t;t.r f

( T-equareroulinq guide
A draflingToquarecan
b e u e e dt o g u i d ey o u r
rouf,erthroughdado
culs. To cuslomize
t h e j t q f o r y o u rt o o l ,
clam?Lhe7quareto
a ocra?board,buLLinq
iLecroooViece
aqainel
the boardedqe.KideIhe
rouLerbaoeplabealonq
the arm of the oquare,
into the boardand
cuLLing
Touse
LhecroseViece.
Lrimminq
lhe jiq, clamViI Lo Nheworkpiece
wilh the cuf,edgeof NhecroooViece
aliqnedwilh Xhecu|Ninqmarkon Lhestrock.KouNthe
Ihe arm.
NhebaeeplatrebutrtedagaineN
dado,keepinq

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ROUTING AND SHAPINGIIGS

A JIGFOR
EVENLY
SPACED
DADOES
thejig
1 Assembling
I Thejig shown
at rightis idealforcuttingequally
spaced
dadoes
witha router.
Dimensions
depend
on
thesizeof theworkpiece
andthespacing
between
the
dadoes.
Beginbycuttinga pieceof lo-inchplywood
forthe base,makingit a fewinches
widerthanthe
diameter
of yourrouter's
baseplateanda fewinches
longer
thanthespacing
between
thedadoes.
Setthe
baseona worksurface
andplaceyourrouternearone
end.Markthescrewholesin therouterbaseolaieon
thebase;
alsomarka spotdirectly
below
thetool'scollet.Boreholesfor the screws
andcut a holeat the
colletmarklargeenough
fortherouterbit.Remove
the
s u b - b a sf e
r o mt h et o o l ,s c r e wt h ej i g b a s et o t h e
routerbaseplate,andinstalla straight
bitthesame
youwishto rout.Next,cuta spacwidthasthedadoes
erto fit snuglyin thedadoes,
making
it slightly
longer
thanthewidthof theworkpiece.
Screw
thespacer
to
the bottomof thejig, making
thedistance
between
youwantbetween
it andthe bii equalto thespace
dadoes.
vour

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r) Cutting
thedadoes
L Clamovour
stockto a worksurface
and
setthejig ontheworkpiece
withthespacerflushagarnst
oneendandtherouter
bit
a t o n ee d g eH
. o l dt h er o u t efri r m l ya n d
feedit across
thesurface
to routthefirst
dado,keeping
thespacer
flushagainst
the
workpiece.
Turnoff therouterandinsert
thespacer
in thedado,repositioning
the
clamps
asnecessary.
Routthenextdado,
sliding
thespacer
in thefirstdado.
Continue(lefluntilallthe
dadoes
havebeencut.
(Tovarythe location
of yourfirstdado,
guideliketheone
routit witha T-square
shown
on page16,rather
thanwiththe
jig.)
spacer

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ROUTINGAND SHAPINGiIGS

DAD()
A OUICK.SETUP
JIG
thejig
1 Assembling
I Thejig shownat leftmakesit easy
to routdadoes
withminimal
tearout.
The
device
consists
of fourstriosof %-inch
plywood
attached
to formtwoLs.Ripall
thepieces
of thejig about4 inches
wide.
Cuttheedgeguides
a fewinches
longer
t h a nt h ec u t y o ui n t e n dt o m a k eT. h e
to overlap
cleats
shouldbe longenough
theadjacent
edgeguidebyseveral
inches
whenthejig is setup.Fasten
theedge
guides
to thecleats,
making
certain
the
pieces
usefourcountersunk
aresquare;
screws
foreachconnection.

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r) Routing
a dado
L Setupthejig byclamping
thestockio a worksurface
and
against
theworkpiece
at thebeginning
and
butting
thecleats
theedgeguides,
endof thecut.Thensetyourrouterbetween
Slidetheguides
together
aligning
thebitoverthedadooutline.
u n t i lt h e yb u t ta g a i n seta c hs i d eo f t h er o u t ebr a s ep l a t e .
S e c u rteh ej i g b yc l a m p i ntgh e L st o e a c ho t h e a
r n dt o t h e
w o r k p i e cTeu. r no n t h e r o u t ear n d ,w i t ht h et o o lb e t w e e n

plunge
theedgeguides,
thebit intothecleatat thestartof the
theworkpiece
cutto formanentrydado.Guidetherouteracross
(above),
extending
thecut completely
through
thestockand
intothesecond
cleat.
Thiswillminimize
tearout
asthebitexits
theworkpiece,
lf youneedto routseveral
dadoes
of thesame
size,leave
thejig clamped
together
andaligntheentrydado
withthedadooutline
marked
onthestock.

18

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ROUTING AND SHAPINGIIGS

DAD()
JIG
ANADJUSTABLE
thejig
1 Building
j
i
g
I T h e s h o w na t r i g h ti s i d e afl o r
in widepanels.
Sizethe
routing
dadoes
pieces
theedge
sothedistance
between
guides
equals
thediameter
of yourrouter's
b a s ep l a t eT. h eg u i d e s h o u l db e l o n g
enough
to accommodate
thewidestpanel
youplanto rout.Cutthefouredgeguides,
t h et w oe n d sa, n ds p a c e rf sr o m% - i n c h
plywood
m; a k ea l l t h ep i e c e4s i n c h e s
wide.Sandwich
theendpieces
between
guides
At
andscrewthemtogether.
the
to
oneendof theframe,attachspacers
t h et o pa n db o t t o mo f t h ee n dp i e c e .
allfasteners.
CuttheclampCountersink
stock;make
ingblockfrom%-inch-thick
i t a b o u3t i n c h ew
s i d ea n dl o n g et rh a n
theendpieces.
To installthepressscrew,
b o r ea h o l ef o rt h et h r e a dtsh r o u gthh e
(right,below).
endpiecewiththespacers
Remove
theswivelheadfromthepress
screwandfastenit to themiddleof the
clamping
block.Attachthethreaded
sectionto theswivelheadandscrewthecollarto theendoiece.Usetherouter
to cut
shortreference
dadoes
in theotherend
pieceandtheclamping
block.

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r-) Cutting
a dado
Z- StlOe
theworkpiece
between
theedge
guides,
with
aligning
themarked
outline
thereference
dadoes.
Secure
theoanelin
p o s i t i owni t ht h ec l a m p i nbgl o c kC. l a m p
t h ej i g t o a w o r ks u r f a c eW. i t ht h e b i t
clearof thestock,
turnontherouter
and
startthecut at thereference
dadoin the
, a k i ncge r t a itnh er o u t eirs
e n dp i e c em
beiween
theedgeguides.
Feedthe bit
intotheworkpiece,
keeping
thebaseplate
flatontheslock(left).Tominimize
tearout,
waituntilthebitenters
thereference
dado
i n t h ec l a m p i nbgl o c kb e f o rrea i s i ntgh e
routerclearof thestock.

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I9

CIRCLE-CUTTING
JIGS
Comprisingtwo hardwooddowelsand
jig allows
a centerblock,thisadjustable
your routerto cut circlesof virtually
any diameter.The jig is assembled
by
slippingthedowelsinto theaccessory
holesin the routerbaseplate,fixing the
dowelsto theblock,and attachingthe
blockto thecenterof thecirclemarkedon
theworkpiece.
With woodcleatsholding
thestockto a worksurface,therouter
bit is alignedwith the end of the circle'smarkedradiusand thescrewsthat
clampthedowelsto the baseplate are
tightened.Thecirclecan thenberouted.

JIG
C()MPASS
Making
thejig androuting
a circle
Tocut larger
circles
thanmostcommercial
jig shown
guides
allow,usethecompass
at right.Makethe devicefromr/rinch
hardboard,
sizingit to suityourrouter.
becircuTherouter
endof thejig should
larandaboutthesizeof yourtool'sbase
plate.Makethearmat least2 inches
wide
thantheradius
of thecircle
andlonger
youwillbecutting.
Borea holein thecenendforthe routerbit.
terof the rounded
remove
To mountthejig onyourrouter,
thesub-base
andcenter
the bit overthe
clearance
hole.Markthescrewholeson
thejig,boreandcountersink
them,then
screwthejig to the router.Drawa line
downthe centerof thejig armandmark
theradius
of thecircleon it, measuring
fromtheedgeof thebit.Drilla holeat
thecentermarkandscrewthejig to the
workoiece.
Secure
thestockto thework
surface
withcleats.
Plunge
thebit into
thestockandroutthecirclein a clockwisedirection.

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ROUTERIOINTINGIIG
ROUTER
JOINTING

llljlll llllllll
llllillltlllllltjjitllllilrilllrlll}llltilllrufilllll1
5HO7Tt?
An auxiliary oubbaoelor widecuts
To makea cut,Nhat is wider
than a particularrouler bif,
youwouldnormallymakeone
Vaee,ohiftyoured6equideand

B-inchequare.Kemovelhe router's
eub-base
Andborelhe screwholeeand
Lhe
clearanceholefor the bit trhrouah
so Ihe Loolwillbe cen'
auxiliary
eub-base
Leredon the jiq. Next,cut 1/rcinchof woodfrom oneedqeof the
inchfrom an adlacenN
edqe,andl/+inchfrom a lhird
eub-baee,1/s
on eachside.ecrewthe 1iq
edqe.Markthe amounloyou removed
to trherouNerand makea ?ae6withNheuncul endfluehaqaineLthe
and makea secondpaoo,wideninqNhe
4uide.KotaLeNheeub-baee
qrooveby 1/o,1/a.
or 1/+inch,dependinq
on whichoideyou uee.

Jointing
widestock
Tosurface
boards
thataretoocumberthejointer,
usea
someto moveacross
routeralongwitha perfectly
square
edge
guide.
Thistechnique
worksbestusing
a top-piloted
straightbit withal/z-inch
shank.
Position
theedgeguideatopthe
board
to bejointedwiththeedgeof the
protruding
board
fromtheguide's
edge
b y a b o u%
t oi n c h C
. l a m pb o t ht o t h e
w o r ks u r f a c eM. a k et h e e d g eg u i d e
longerthantheworkpiece
to prevent
the
withtherouter;
clamps
frominterfering
place
a s h i mu n d etrh ec l a m pj a wt o
keeptheguidefromwobbling.
Withthe
routerflatontheguide,adjustthebit
height
soit willcuttheentireedgeof
Feedtherouterfrom
the board(inset).
oneendof theboard
to theother;the
p i l ow
t i l lr i d ea l o n tgh eg u i d ea st h e
flush(above).
cuttertrimstheworkpiece

HINGEMORTISINGIIG
theiig
1 Building
I A j i g l i k et h eo n es h o w n
a t l e f tw i l l
allowyourrouterto cut hingemortises
quicklyandaccurately.
Tomakethecuts,
youwillneedto equipyourrouter
witha
guide.Build
straight
bit anda template
froma pieceof %-inchplythetemplate
wood.Sizeit wideenough
to support
the
router.
Outline
thehingeleafonthetemplate;remember
to compensate
forthe
guideandthethickness
template
of the
fence,whichis alsomadefrom7+-inch
plywood.
Cutoutthetemplate,
thenattach
thefencewithcountersunk
screws.

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r') Routing
hinges
4 Secure
theworkpiece
edge-up
in a
vise.Markthehingeoutlineonthestock
andclampthetemplate
in position,
aligni n gt h ec u t o uw
t i t ht h eo u t l i n eo n t h e
edgeandbuttingthefenceagainst
the
innerfaceof theworkpiece.
Makethe
cuI (right)by movingthe routerin small
clockwise
circles,
thenremove
thejig
andsouare
thecorners
witha chisel.

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CORNE,R-ROUNDING
IIG
'l

Constructing
thejig
I Forcurvingthe cornersof a workpiece,
y o uc a n u s et h e s i m p l ec o r n e r - r o u n d i n g
1 i gs h o w na t r i g h t .T h ej i g c o n s i s tosf a
p l y w o o db a s ea n d t w o l i p st h a t a l i g nt h e
e d g e so f t h e j i g a n d t h e w o r k p i e c eC. u t
Formost
the basefrom7a-inchplywood.
j o b s ,a b a s ea b o u t1 0 i n c h e sw i d ea n d 1 6
i n c h e sl o n gw i l l b e a d e q u a t eD. r a wt h e
c u r v ey o u w i s ht o r o u t o n o n e c o r n e ro f
t h e b a s ea n dc u t i t w i t ha b a n ds a wo r a
sabersaw;sandthe edgesmooth.Cutthe
lipsfromsolidstockr/zinchthickand 1%
i n c h e sw i d e ,t h e n n a i lo r s c r e wt h e p i e c e s
t o t h e b a s e l, e a v i n g
a b o u t3 t o 4 i n c h e s
betweeneachlip and the roundedcorner.
T h et o p e d g eo f t h e l i p ss h o u l db e f l u s h
with the top surfaceof the base.

VIEWOF UNDERSIDE

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r) Rounding
a cornel
with
I Setvourstockon a worksurface
t h ec o r n etro b er o u n d eedx t e n d i nogf f
thetablebyseveral
inches.
Place
thejig
o n t o po f t h ew o r k p i e cs eot h el i p sa r e
buttedagainst
the edgesof thestock.
to
Useclamps
to secure
thetwopieces
theworksurface.
Tomaketherouter
cut
easier,
usea handsaw
to cutawaythebulk
of thewaste.
Then,usinga top-piloted
flush-cutting
bit in yourrouter,
startclear
o f t h ec o r n ear n de a s et h eb i t i n t ot h e
s t o c ku n t i lt h ep i l o tc o n t a c t sh ee d g e .
Pulltherouter
around
thecorner,
moving
against
bit rotation
andpressing
thepilot
flushagainst
theedgeof the1igthrough(/eff).
outtheoperation

PANE,L-RAISING
IIG
thejig
1 Building
I Featuring
a fence
andtilting
table,
the
jigshown
youto raisepanat leftenables
elsusing
without
a router
mounting
thetool
i n a t a b l eT. h ej i g i sc l a m p ei d
na b e n c h
v i s eC
. u ta l lt h ep i e c eosf t h ej i gf r o m
l-inchplywood;
thedimensions
suggested in theillustration
willworkwellwitha
typical
workbench.
Startassembling
thejig
byscrewing
thebrackets
to theunderside
of thetableat oneend,thencutadjustmentslotsthrough
thearms.Secure
the
topendsof thearmsto thebrackets
and
thebottom
endsto thefenceusinghanger
bolts,washers,
andwingnuts.Attachthe
positabletothefence
witha piano
hinge
tioned
about
6 inches
below
thetopof the
fence.
Toprepare
thefenceforyourrouter,
borea holejustabove
thetablelevelto
accommodate
thelargest
%-inch
vertical
panel-raising
bitorstraight
bityouwillbe
using.
Screw
theguardto thefenceabove
thehole.Finally,
cuta notchin thebottom
endof thefence
to cleartheworkbench's
visescrew.
lnstallthebit in therouter
and
screw
thetoolto thejigfencesothebit
fromthehole.
orotrudes

NoLch
for vrse
9CTEW

Adjuotment alot

r) Raising
a panel
L Secure
the1igfencein thevisewith
thetableat a comfortable
height.
Adjust
thebitfora shallow
cut,turnontherouter,
andmakea testcut in a scraooiece,
To
adjustthebevelangle,
turnoffthetool,
loosen
thewingnutssecuring
thearmsto
t h ef e n c ea, n dt i l tt h et a b l eu po r d o w n .
Raise
theendsof thepanelbefore
routing
thesides;
thiswillreduce
tearout.
Feed
the
panelacross
thetableface-up,
keeping
yourf ingers
wellclearof thebit.Test-f
it
thepanelandincrease
thecuttingdepth
slightlyto makea secondpass(right).Continueuntilthepanel
fitsin thegrooves.

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ROUTINGGUIDE
ADIUSTABLE

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theiig
1 Building
at leftis idealforroutI Thelig shown
pattern;
it can
in a rectangular
inggrooves
for curved
alsobef ittedwithtemplates
from1-by-2stock
cuts.Sawtheguides
%inchdeepandwide
androuta groove
edgeof eachone.Cuta
along
theinside
tenonat oneendof each
two-shouldered
guideto fit in thegrooves
andborea pilot
holeintothemiddleof eachtenonfora
bolt.Screw
the
hanger
%-inch-diameter
threadproenough
boltsin place,leaving
theadjacent
truding
to feedit through
andwingnut.
edgeguidewitha washer
through
rout%-inch-wide
mortises
Finally,
from
theguides;
startabout3%inches
t h ee n dw i t ht h et e n o na n dm a k et h e
them
4 inches
long,separating
mortises
Assemble
the
withabout%inchof wood.
jig byslipping
thetenons
andboltsthrough
andmortises
of theadjacent
thegrooves
guide
andnuts.
thewashers
andinstalling
maketemolates
likethose
Forcurves.
shown
in theillustration.

Edqe7uide

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r) Routing
thegroove
to theworkpiece.)
thetemplates
tapeto secure
Z- Outline
thepattern
onyourstockandlayit ona worksurface. (Usedouble-sided
to the
thewingnutsandclampthejig andworkpiece
it onthestocksothe Tighten
Loosen
thewingnutsofthejigandposition
thebit intothestock,makethecut in a
flatonthework- table.Afterplunging
Place
therouter
frametheoutline.
edgeguides
the
keeping
thebaseplateflushagainst
direction,
pieceandalignthebitwithoneedgeoftheoutline.Buttoneof clockwise
at all times.Forrepeatcuts,simply
on edgeguideortemplate
therouterbaseplate.Repeat
theedgeguidesflushagainst
(abovd.
androutthepattern
clampthejig to the newworkpiece
arein position.
andtemplates
theotheredges
untilallguides

25

JOINT-MAKING
IIGS

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A SLIDING
DOVETAIL
JIG
Building
thejig
1
youto routslidI Thejig shown
at leftallows
(rnset)
ingdovetails
without
a router
table.Cutthe
piecef rom%-inchplyfence,
table,andsupport
wood.Makeall the boards
16 inches
long;the
fenceandtableshould
beabout10 inches
wide
pieceabout3 inches
andthesupport
wide.Screw
thetableto thetablesupport
sotheyforman L.
Position
thetable4 inches
fromthe bottomof
thefenceandboretwoholesthrough
opposite
endsof thefenceintothetablesupport.
Usea
routerwitha straight
bit to lengthen
the holeon
theoutfeed
sideof thefenceintoa curved
slot.
Attach
thetablesupport
to thefencewithcarriage
bolts,washers,
andwingnuts.Leave
theboltat
theinfeedendloose
enough
forthetableto pivot
whentheslotted
endis raised
or lowered.
Remove
thesub-base
fromyourrouteranduseit asa templateto markthescrewholesandbit clearance
holeonthefence.Thebottom
edgeof thecleara n c eh o l es h o u l ldi n eu pw i t ht h et o po f t h ej i g
tablewhenthetableis level.

Eit clearancehole

Curved
-----=-\\\\\\\
etot

\ W
Routing
thejoint
S e c u rteh ef e n c ei n a v i s ea n dr o u t
groove
thedovetail
first,thenthematching
slide.Forthegroove,
startby installing
a
straight
bit in therouter,
attaching
thetool
to thejigfence,
andadjusting
thecutting
depth.Setthegroove
workpiece
face-down
onthetable,buttingitsedgeagainst
the
bit.Loosen
thewingnutat theslotted
end
andadjustthetableto centerthebit on
theedgeof thestock,
thentighten
thenut.
Secure
theworkpiece
withthreefeatherboards,
clamping
oneto thetableandthe
othertwoto thefenceon bothsidesof the
cutter.
Make
thestraight
cut,thencomplete
thegroove
witha dovetail
bit.Fortheslide,
setyourworkpiece
onthetableandlower
thetableto produce
a 7e-inch-wide
cut.
Makea passon bothsides,
finishing
each
(lntheilluscutwitha pushstick(right).
tration,thefeatherboard
on theoutfeed
sideof thefencehasbeenremoved
for
clarity.)
Test-f
it thejoint.lf necessary,
raise
pass
thetableslightly
andmakeanother
oneachsideof thestock

26

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ROUTING AND SHAPING IIGS

A CORNER
HAIF.LAP
JIG

Corner half-lap
End quide

Routing
thehalf-laps
and
Clampthejig to a worksurface
s l i d et h ew o r k p i e cbee t w e etnh eb a s e
pieces
untilit buttsagainst
thestopblock.
Protecting
the stockwitha woodpad,
in place.
Adjust
the
clamptheworkpiece
thestock
router's
cuttingdepthto one-half
positioned
thickness.
Then,withtherouter
inside
theguides,
turnonthetoolandlowerthebit intotheworkpiece.
Guidethe
routerin a clockwise
direction
to cutthe
edges
of thehalf-lap,
keeping
the
outside
b a s ep l a t ef l u s ha g a i n sat g u i d ea t a l l
waste,
times.Thenroutouttheremaining
thedirection
of
feeding
thetoolagainst
(right).To
bit rotation
asmuchaspossible
simplyremove
routa T orcrosshalf-lap,
thestopblocksothecutcanbemadeat
anypointalongthefaceof thestockand
clamotheworkoiece
on bothends.

27

thejig
1 Building
I Cutthetwobasepieces
andthestop
as
blockfromplywood
thesamethickness
yourstock.
Thebasepieces
shouldbewide
theedgeandend
enough
to accommodate
guides
yourrouter's
andsupport
baseplate.
Usesolidwoodstripsforthefourguides.
Next,marktheshoulder
of thehalf-lap
(inset)
one
workpiece
and
buttthebase
on
pieces
its
with
against edges theshoulnearthe middleof
dermarkpositioned
the boards.
Installa straight
bit in the
mark,
router
andalignit withtheshoulder
guide
thenmountanend
across
thebase
pieces
thetool'sbaseplate.
andagainst
to position
a guide
Repeat
theprocedure
a t t h eo p p o s i teen d .N o wa l i g nt h e b i t
withtheedges
of theworkpiece
andattach
t h ee d g eg u i d e sl ,e a v i nag s l i g h gt a p
between
therouterbaseolateandeach
youmakewill
guide.(Thef irsthalf-lap
routreference
notches
in thebasepieces.)
F i n a l l yi n, s t a tl lh es t o pb l o c ku n d eor n e
endguide,against
theendof theworkoiece.
Countersink
all fasteners.

ROUTINGAND SHAPINGIIGS

ANADJUSTABLE
MORTISING
JIG
)top block
t/o"x1%"x5"

Jiq aide
t/o"x6"x16"

Jig baee
3"x3"x16"

r) Routing
a mortise
L Settheworkpiece
onthejig'sbasewith
themortise
outlinebetween
thestopblocks
f lushagainst
thesidewith
andonesurface
Place
theblocks.
a shimunderthestockso
itstopsurface
buttsagainst
thestopblocks,
t h e nc l a m pt h ew o r k p i e tcoet h ej i ga n d
secure
thejig in a workbench
vise.Next,
install
a straight
router
bitthesamediameterasthewidthof themortise,
setthe
depthof cut,andattach
a commercial
edge
guideto therouterbaseplate.Center
the
bit overthemortise
outlineandposition
theedgeguidesoit restsflushagainst
the
opposite
sideof thejig.Adjusteachstop
blockbyaligning
thebitwiththeendofthe
mortise
outline,
butting
theblockagainst
therouter's
baseplate,
andtightening
the
w i n gn u t .O n c et h eb l o c kas r el o c k e idn
position,
turnonthetoolwiththebitclear
of theworkpiece.
Gripping
therouter
firmly,
butttheedgeguideagainst
thejig,press
the baseplateagainst
onestopblockand
plunge
thebit intotheworkpiece.
Holdthe
edgeguideagainst
thejig asyoudrawthe
routerthrough
thecut untilit contacts
the
otherstopblock(right).Cuta deepmortise
passes,
in several
increasing
thebitdepth
e a c ht i m e .

thejig
1 Making
jig
I The shown
at leftwillguideyour
router
andsecure
theworkpiece
asyoucut
a mortise.
Thedimensions
suggested
inthe
illustration
willsuitmostrouters.
Cutthe
jig sidesfrom%-inch
plywood.
Makethe
baseof laminated
solidwood.Attach
the
sidesto thebasewithcountersunk
screws,
making
surethepieces
areperfectly
square
to eachother.
Fashion
eachstooblockfrom
solidstockbycutting
a rabbet
%inchdeep
and1 inchwide,
thenrouting
a 4-inch-long
slotto accepta %-inch
hanger
bolt.Mount
thebolts3 inches
fromeachendof one
in place,
side,slipthestopblocks
andf ix
themwithwashers
andwinsnuts.

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ROUTING AND SHAPINGIIGS

A MOVABLE.JAW
MORTISING
JIG
'l

Making
theiig
youto routperfectly
I Thejig at rightallows
centered
mortises
in stockof anythickness
usinga straight
bitand
guide.Cutthejig topfrom%-inch
plywood;
a template
makethepieceabout15 inches
longandwideenough
to
acceptthethickestboardyouexpect
to mortise.
Cutthe
twojawsfrom2-by-4-inch
stockthesamelengthasthe
top.Toprepare
thetop,marka linedownitscenter
and
routa notchcentered
overthelineat oneend.Thenotch
guide
youwill
should
bethesamewidthasthetemplate
usewithyourrouterbit,andlongenough
to accommoyouexpect
datethe longest
mortise
to cut.Next,routtwo
adjustment
slotsperpendicular
to thecenterline.
Finally,
borea viewing
holebetween
thetwoslots.Toassemble
thejig,screwhanger
boltsintothejawsandfasten
the
topto thejawswithwashers
andwingnuts.

Viewin4hole

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r) Cutting
a mortise
L trttark
a linedownthe centerof the
mortise
outline
ontheworkpiece.
Loosen
thewingnutsandsecure
thestockbetween
thejawssothemortise
centerline
isaligned
withthatof thejigtop;makesurethetop
edgeof theworkpiece
is buttedagainst
theunderside
of thetop.Alsoalignone
endof themortise
outline
under
theend
of thenotch-offset
bythedistance
from
guide's
theedgeof thebitto thetemplate
edge-thentighten
thehanger
bolts.Align
theedgeof thebitwiththeotherendof
theoutline
andclampa stopblockto the
topflushagainst
therouterbaseplate.
Routthe mortise(left),slarlingthecut
guidebuttedagainst
withthetemplate
theendof thenotchandstopping
it when
thebaseplatecontacts
thestopblock
at theotherend.

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29

ROUTING AND SHAPING IIGS

JIG
A B(lXJOINT
upthejig
1 Setting
onthispageallows
I Thejig shown
youto cutthe notches
fora boxjointon
a routertablewithlittlesetuptime.lt
consists
simplyof an extension
board
gauge
f itted
to
the
miter
and
screwed
witha keythatdetermines
thespacing
Install
a straight
bitsized
of thenotches.
width
notches
and
to thedesired
of the
mounttherouterin a table.Setthedepth
of yourstock
of cutequalto thethickness
intothebitto rout
andfeedtheextension
its bottomedge.Reposia notchthrough
sothatthegapbetween
tiontheextension
thediameter
thenotchandthebitequals
of thebit,thenscrewit in place.Feedthe
intothebitagain,
cuttinga secextension
a woodkeyto
ondnotch(/eff).Fashion
f it in thefirstnotchandglueit in place
soit projects
about1 inchfromtheextensionboard.

r) Gutting
theboxjointnotches
against
L nod oneedgeof theworkpiece
themiter
the key,buttingitsfaceagainst
gaugeextension.
Turnon the routerand,
yourthumbsaround
thegauge,
hooking
slidethe boardintothe bit,cuttingthe
first notch(right).Fit the notchoverthe
cutkeyandmakea second
cut.Continue
thiswayuntilyoureachthe
tingnotches
To cut
edgeof the workpiece.
opposite
in themating
endof thenext
thenotches
fit thelastnotchof thefirstboard
board,
overthe keyandbuttoneedgeof the
matingboardagainst
thefirstboard.Move
fonruard
theentireassembly
to cutthefirst
holding
both
notchin themating
board,
pieces
flushagainst
themitergaugeextennotchsion(page12).RouItheremaining
es in thematingboardthesamewayyou
madethecutsin thef irstboard.

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SHAPERIIGS
A CIRCTE.CUTTING
JIG
theiig
1 Making
I Shaping
circular
workfreehand
onthe
isa riskyjob.Onewayto makethe
shaper
tasksaferandmoreprecise
isto usea Vblockjig liketheoneshown
at left.Build
it froma pieceof %-inchplywood
about
14 inches
wideand24 inches
long.To
customize
thejig foryourshaper,
holdit
above
thetableflushwiththebackedge
andmarkthelocation
of thespindle
on
thesurface.
Cuta right-angle
wedgeout
of thejig,locating
theapexof theangle
point.Thencuta circle
at yourmarked
outof thejig centered
ontheapex;the
holeshouldbelargeenough
to accommodatethelargest
cutteryouplanto usewith
thejig.Routtwoadjustment
slotsrntothe
backedgeof thejig oneithersideof the
h o l e - a b o u%
t i n c hw i d ea n d5 i n c h e s
long.Theymustlineupwiththeshaper's
fencelocking
handles,
ason themodel
shown.
Thejig canalsobesecured
to the
shaper
bymaking
it asIongasthetable
andclamping
it in place
at either
end.

Adjuetment alot

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r) Shaping
circular
work
Z. Position
thejig onthetable,centering
thebit in thehole.Seattheworkpiece
in
thejig,buttingit against
bothsidesof the
V,andadjust
thejig andworkpiece
until
thewidthof cut is setcorrectly.
Secure
the
jig in place.Youmaywantto makea test
cuton a scraooiecethesamethickness
anddiameter
asyourworkpiece
to becertainthatthedepthandwidthof cut are
c o r r e c tT. u r no n t h es h a p ear n db u t t
t h ew o r k p i e caeg a i n st h
t eo u t f e e sdi d e
pivotthestockintothe
of theV. Slowly
cutteruntilit restsf irmlyin thejig'sV,
moving
it against
thedirection
of cutter
(ieff).Continue
rotation
to prevent
kickback
rotating
theworkpiece
untiltheentirecircumference
hasbeenshaped,
keeping
theedgein contact
withbothsidesof
thejig throughout
thecut.

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ROUTING AND SHAPINGIIGS

FEATHERBOARD
SHAPER
ANEXTENDED
thefeatherboard
1 Making
I F o rw i d ec u t s s, u c ha ss h a p i ntgh e
feathedges
of a panel,useanextra-wide
onthispage.
erboard
liketheoneshown
the
It will bothpress
thepanelagainst
fromthecuttableandshieldyourfingers
ter.Cuta 2-by-4at leastaslongasyour
the
fence,settheboardagainst
shaper's
thelocation
of thecutfence,
andoutline
ter on it. Curvethe bottomedgeof the
featherboard
slightly
sothatonlythefingerswillcontact
theshapthepanel
during
of %-inchingoperation.
Bandsaw
a series
wideslotsat a shallow
anglewithinthe
a rowof sturdybutpltoutline,
creating
to the
ablefingers.
Screwtwospacers
sothejig
backfaceof thefeatherboard
allfaswillclearthecutter;countersink
teners(/eff).

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r) Raising
thepanel
featherboard
to thefence,
I Clampthe
overthebit,andturn
centering
thefingers
Foreachpass,useyourright
ontheshaper.
intothe
handto slowly
feedtheworkpiece
cutter;useyourlefthandto keepthe panthefence(right).
el against

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ROUTING AND SHAPINGTIGS

TWOSHAPER
GUARDS
guard
Building
a fence-mounted
guardshown
Theshaper
at rightis ideal
forfence-guided
operations.
Cutthepieces
plywood,
from%-inch
making
theguard
i n t h es h a p eo f a n a r cl a r g ee n o u gtho
f r o mt h ef e n c ea n ds h i e l dt h e
extend
c u t t e cr o m p l e t e lTyh. es u p p o rbt o a r d
shouldbewideenough
to beclamped
to
thefencewhentheguardisalmost
touchi n gt h es p i n d l eS. c r e w
t h eg u a r df l u s h
withthebottom
edgeof thesupport
board;
c o u n t e r s itnhkef a s t e n e rN
s .e x ct l a m p
tn
t h ej i g i n p o s i t i oann dm a r ka p o i n o
theguardabove
thecutter.Remove
the
j i g a n db o r ea 1 % - i n c h - d i a m e
r
h toel e
t h r o u gthh eg u a r da t t h em a r kt;h eh o l e
w i l la l l o wy o ut o v i e wt h ec u t t edr u r i n g
shaping
operations.

guard
Making
a freestanding
Forfreehand
shaping,
makea guardlike
theoneshown
at left.Sawnfrom%-inch
plywood,
it covers
thecutterfromthe
s h a p e rt 'osp ,b a c ka, n ds i d e sC. u tt h e
topabout16 inches
longandwideenough
to extend
fromthebackof thetableto
aboulIYzinchesin frontof the cutter.
Bevelthefrontendsof thesidessothey
canbe positioned
ascloseaspossible
to
thecutter.
Ripthesidessothetopwillsit
above
thebit withjustenough
clearance
you
for
to seethecutter.Holdthetopon
thetableandmarka pointon it directly
overthespindle.
Cutanoval-shaped
hole
through
thetopat themark,largeenough
t o c l e a trh es p i n d laen da l l o wy o ut o
movetheguardacross
thetableslightly
to
accommodate
different
cutters.Fasten
t h et o pt o t h es i d e sw i t hc o u n t e r s u n k
screws.
To usetheguard,position
it on
t h et a b l ew i t ht h es p i n d l pe r o j e c t i n g
t h r o u gthh et o p ,a n dw i t ht h es i d e sa s
c l o s ea s p o s s i b lt eo t h ec u t t i n ge d g e s .
Clamp
t h eg u a r di n p l a c e ,

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VACUUMIIGS
Vacuum

The heart of the vacuurrlsysten is thepump, herea1/: horsepoweroil-Iess

ntodel,which drawsair at a maximtrm of 4.5 cubicfeetper minute. The
hosefeaturesa quick couplerthat attachesto a connectorthat is screwed
into a lrcIethrough the templateor featherboard.Youwill qlsoneedto use
as a gasketto sealthe
vaatum tapeor closed-cell
foam weotherstripping
and
workpiece
or
cavity betweentemplate
featherboardand work table.

FEATHERBOARD
A VACUUM
Anchoring
a leatherboard
to a sawtable
B o r ea n o u t l eht o l et h r o u gthh ec e n t e r
Thehole's
diameter
of thefeatherboard.
should
b es l i g h t llye s st h a nt h a to f t h e
you
endof thehoseconnector
threaded
willuse.Next,applyfourstrips
of closedof the
tapeto theunderside
cellvacuum
with
forming
a quadrilateral
featherboard,
nogaps(insef).
Screwthe hoseconnector
intotheoutletholeonthetoofaceof the
oppofeatherboard;
usea wrench
asshown
jig,placethe
site.Tosetupthevacuum
onthesawtable-forthe
featherboard
t od
m o l d i ncgu ts h o w ni t, r sp o s i t i o n e
press
against
thefence.
theworkpiece
Makecertain
thetapestripsaref laton
t
a
b
l
e
S
.
n
a pt h eq u i c kc o u p l eart t h e
the
vacuum
endof the
oumohoseontothe
a
n
h o s ec o n n e c t o r dt u r no nt h ep u m p .
willanchor
thefeatherboard
Airoressure
y
o
u
f
e
e
dt h ew o r k p i e c e
t o t h et a b l ea s
(right).
throughlhe cut

n-[' h. vacuulnsystem
shownhereisan
l- excellentwav to anchorfeatherboardsto work tablesand fastentemplatesto workpieces.
Thesystemis more
thanconventional
clamping
convenient
andoffersasmuchholdingpowerwithout riskingdamageto stock.The only
must
limitationis that matingsurfaces
be flat andsmooth.
To setup a vacuumsystem,you need
thepartsshownin thephotoat left.The
to the underside
of the
taueis fastened
a cavfeitherboard
or template,
creating
ity.Thehosefrom thepump is inserted
in a holein thefeatherboard
or template.
\{hen thejig is placedon thesuifac.,
thepump suckstheair from thecavity,
producinga vacuum.Anypump ratedat
3 cubicfeetperminuteor higheris adequatefor the homeworkshop.If you
you can convertlt
own a compressor,
into a vacuumpump with a transducing pump.

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ROUTINGAND SHAPINGIIGS

VACUUM
TEMPLATE
ROUTING
thetapeandconnector
1 Installing
provides
I A vacuum
an effective
alternativeto double-sided
tapeforfastening
a plywood
template
atopa workpiece.
Once
yourtemplate
is theproper
size,traceits
patternon yourstockandcut out most
of the wastefromyourworkpiece,
leavi n ga b o u %
t i n c ho v e r h a n g itnhget e m plate.Boretheoutletholethrough
the
middleof thetemplate
andapplyvacuum
tapealong
theperimeter
of itsunderside;
makesuretherearenogapsbetween
adjacentpieces
of tape.Withthinstock,
add
twothinstripsof tapeoneithersideof the
outletholeto prevent
presthevacuum
surefrompulling
themiddle
of theworkpieceagainst
(insef).
thetemplate
Attach
thehoseconnector
to thetooof thetemplatein theoutlethole(right).

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r') Routing
thepaftern
Z- Install
a piloted
flush-trimming
bit
in a router,
mountthetoolin a table,and
adjust
thecuttingheight
sothebitwitl
shape
theentireedgeof theworkpiece.
Placethetemplate
tape-side-down
centeredontopof theworkpiece.
Attachthe
vacuum
hoseto theconnector
andswitch
o n t h ep u m pt o c l a m pt h et w ob o a r d s
together.
Turnontherouterandeasethe
stockintothebit untilthetemplate
contactsthe bit pilot(/eff).Complete
the
c u t ,k e e p i ntgh ew o r k p i e cf lea to n t h e
r o u t etra b l ea n dt h ee d g eo f t h et e m platepressed
flushagainst
thepilot;move
against
thedirection
of bit rotation.

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35

't

j
,{
,,{
..u

,f

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CUTTINGIIGS
I rom thetimeyoucut roughlumber
I to Iengthat thestartofa projector
miter trim to finish it, your powersaws
arelikelyto beyour mostandhandsaws
usedtools.Althoughmanycuttingtasks
without them,the
canbe accomplished
jigs shownin this chapterwill make
theseoperationseasier-particularly
whenthe samecut mustbe repeatedon
workpieces.
several
arms,a tablesaw
With its iniersecting
miter jig (page50)guaranteesmiter
jointsthat form perfect90"angles.
The
tenoningjigsshownon pages57and58
allowyouto cutbothpartsof openmorjointson thetablesaw.
tise-and-tenon
jigs
Some facilitatecuttingtasksthat
aretoughto performfreehand.Thecircle-cuttingjigsfor the sabersaw(page
43) andband saw(pageaa) help make
quickwork of circulartabletops.In tandemwith your tablesaw,theraisedpaneljig (page52) canproducebeveled
oanelsfor frames.
Thesejigs will saveyou time in the
shoo.An addedbenefitis that mostcan
bebuilt from scrapwood,makingthem
considerablyless costly than storeboughtcounterparts.

OFCUTTING
JIGS
A COTTECTION
Miter and croeeaut guide (page 41)
Makeamiter cuta and croaacuta
with a saber gaw or circular saw

)izing board
for aroeaauta
@a6e aO)
Ueedwith a backaaw for croggcutting; eLop block
ie adjuetable

Saber aaw airalecutting ji6 @age a3)

Attachea to eaberaaw
and pivote around center
of workpieceto cuL circlee:pivot point can be
located at any point
alonqjig arm

Eand eaw airaleautting jig

(pase 44)
Adjuetablejiq for
cutttnq circleaon
the band eaw;jiq
ia clampedto oaw
table and workpiece ie ecrewed
to alidinqbar and
rotated into blade

The crosscutjig shown at left provides a

safeand accurateway to cut long, wide,
or heavystockon the table saw.Because
it slidesin the saw table'smiter slots,
this sturdy, adjustablejig makesit easy
to hold workpiecessquareto the blade.

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CUTTING IIGS

A COLTECTION
OFCUTTING
JIGS
(continued)

Olade height gauge

Table aaw taper jig (page 4A)

For cutLin7[apero on the table aaw;quide
bar with to4qle clampa is acrewedin place to
hold workpieceat proper taper anqle.A aimilar ji4 with a handleand LheL-ehaped ,{
fence poeitioned differently can
be ueedon the radial arm
aaw (page 48)

Qasea9)

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Meaouringgauqe
for eettinq the
heiqht of a table
aaw blade

Ker-faplitter
(paqe 42)
Used with a ctrcularaaw
to prevent the blade from
btndinqin the kerf; placed
in kerf of lonq rip cuta partway Lhrou7hoperation

Mitering ji6
Qase a7)
Uaedto mtter
trim on band
eaw: ecrewe to
mttrerlauqe

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Table saw croaacutjig (page 5O)

Adjuatablejig uaedto makecroeacutg on the table eaw tn wrde,lon4,
or heavyotock

Wedge-makingjiq (paqe aO)

For cuttinq ehimaand wed4eo
on the band eaw

Band aaw taper jig

(paqe 47)
Fixed-anqleji4 for
makin7taper cute
on the band aaw

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?traightedge guide
(page 42)
For ripping wif,ha
circular aaw

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CUTTING IIGS

Radial arm saw auxiliary

fence and table (page 54)
Termtta the radial arm
qaw f,o cuT.qrooveqor
moldin4owith ito bladein
the hortzontalpoeition

Tenoningjig
(pase 57)
For cuttin4 both
parte of open mortiae-and-tenon
jointe on the Lable
aaw;rune alonq
rip fence

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nanel

aaaemhlica

Cove-cutting jig (page 56)

Uaedto eet up 4uideboardeon eaw
table for cuttin4 cove moldin4

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Raioed paneljig
(pase 52)
Attachea to the table
eaw rip fence to bevel
the edqeeof raised
panelefor frame-and'

Adjustable tenonin7 jig

(pa6e 58)
Uaedto cut openmorLiae-and'
tenone on the table aaw;adjuata
to etock of varyinq thickneaa

Table oaw miter jig (paqe 5O)

)imilar to the croaacutjiq, except
with analedarma uaedto make
matinq 45' miter cuta

Eoard -strai g hte ning ji g

(pase 53)
Uaedon the table eaw to
true the ed4eeof uneven
atock; featurea a bar that
runa in mtter alot

SIZINGBOARDFORCROSSCUTS
thejig
1 Building
I Thejig shown
it easy
at rightmakes
workpieces
to crosscut
several
to thesame
length
byhand.ltsadjustable
stopblock
canbe positioned
at varying
distances
fromthe kerfin thefence.Cutthebase
p l y w o otdo t h e
a n df e n c ef r o m% - i n c h
dimensions
suggested
in theillustration.
Usesolidwoodforthestooblockandlio.
Screw
thelipto theunderside
of thebase,
takingcareto aligntheedges
of thetwo
pieces.
Sawthefenceintotwosegments
about7 inches
fromoneendandusea
router
fittedwitha %-inch
bitto cutgrooves
t h r o u gbho t hp i e c easb o u It i n c hf r o m
theirtopedges;
stopthegrooves
about2
inches
fromtheendsof eachpiece.
Screw
thetwofencesections
to thebase,
ensuringthatthegapbetween
thetwopieces
i s w i d ee n o u gtho a c c o m m o d aatsea w
blade.
Sawa 9O' kerfacross
thesurface
o f t h e b a s ei n l i n ew i t ht h e k e r fi n t h e
fence.
Toprepare
thestopblock,
cuta 3inch-long
rabbetononefaceandborea
clearance
holethrough
itscenterfora I%inch-long,
%-inch-diameter
carriage
bolt.
F a s t etnh e b l o c kt o t h ef e n c ew i t ht h e
bolt,washer,
andwingnut.

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r) Making
a crosscut
L eufithelip against
theedgeof your
workbench,
loosen
thewingnut,andslidethe
stopblockalongthefenceto theproper
distance
fromthekerfbetween
thetwo
fencesections.
Tighten
thewingnutand
butttheendof theworkpiece
against
the
stopblock,Holdthestockf irmlyagainst
thefenceasyousaw(right).

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GUIDE
MITERAND CROSSCUT
theiig
1 Assembling
I Themultipurpose
edgeguideshown
a trri g h w
t i l la l l o wy o ut o c u te i t h e4r 5 "
witha saber
m i t , cutsor 90" crosscuts
miter
c i r c u l asr a w .M a k et h e j i g f r o m
p iie c eo f l - i n c h p l y w o o dr .e f e r r i ntgo
ao
o r s u g g e s t eddi m e n s i o n s .
t h e i l l u s t r a t i of n
e ith
C u tt h e b a s ei n t h es h a p eo f a t r i a n g lw
o n e9 0 " a n g l ea n dt w o 4 5 " a n g l e s(.T o
m a k ea ; r gf o r 3 0 " o r 6 0 " m i t e rc u t s .t h e
s i d e s h o r r lhde 1 2 1 6 a n d2 0 i n c h eos r
) c r e wt h e
a v a r i a t i o on f t h e 3 - 4 - 5 r a t i o . S
f e n c e st o t h e b a s e- o n e o n e a c hs i d e
o p p o s i toen eo f t h e 4 5 " a n g l e sT. h ef e n c e s
m u s tb e f l u s hw i t ht h ee d g eo f t h ej i g b a s e .
S A Wo r a

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r) Makinga mitercut
L t o c u ta m i t e ru s i n gt h e j i g ,s e tt h e
e i t ht h e c u t t i n g
s t o c ko n a w o r ks u r f a c w
l i n eo n t h e b o a r de x t e n d i nogf f t h e t a b l e .
A l i g nt h e c u t t i n ge d g ew i t ht h e l i n ea n d
b u t tt h e a n g l e ds i d eo f t h e j i g a g a i n stth e
s a w ' sb a s ep l a t e ,w i t h t h e f e n c eo n t h e
the edge
bottomof the guideflushagainst
o f t h ew o r k p i e cC
e l. a m pt h ej i g i n p l a c e
a n dm a k et h e c u t , k e e p i n tgh e s a wf l u s h
a g a i n stth e . 1 i tgh r o u g h o ut ht e o p e r a t i o n
(left).To makea 90" crosscut,usethe
s q u a r es i d eo f t h e j i g a sy o u rg u r d e .

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RIPPINGIIGS
TW()CIRCULAR
SAWIIGS
Using
a kerfsplitter
A kerfsplitterliketheoneshownat left
w i l lh e l pp r e v e natc i r c u l asra wb l a d e
frombinding
rnitskerfandkicking
back.
Choose
%-inch
hardboard
forthesolitter
pieceand%-inch
plywood
fortheshoulders;referto theillustration
forsuggested dimensions.
Fasten
thethreeoieces
together
withscrews.
To usethejig,start
thecut,turnoffthesaw,andinsertthe
splitterin thekerfa fewinches
behind
t h es a w B
. a c ku pt h es a ws l i g h t l yt h, e n
(left).Forparliccontinuethe operation
ularlylongcuts,advance
thekerfsplitter
periodically
to keepit nearthesaw.

Edge atrip
tl"x4"xB'

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guide
Ripping
witha straightedge
youto makeaccurate
Thejig shown
above
enables
ripcutsin
panelslikeplywood.
longmanufactured
Makethebasefrom%plywood
inchplywood;
use%-inch
fortheedgestrip.Gluethe
stripparallel
to the base,offsetting
its edgeabout4 inches
fromoneedgeof the base.Trimthebaseto its proper
widthfor
yoursawbybuttingthetool'sbaseplateagainst
thejig'sedge

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stripandcuttingalongthe lengthof the base.To usethejig,
marka cuttinglineonthepanelandclampthestockto a platformof 2-by-4s
resting
atopsawhorses.
Clamptheguideto the
panel,
aligning
thetrimmed
edgeof thebasewiththecutting
lineontheworkpiece.
Makethe cul (above),
keeping
thesaw's
baseplateflushagainst
theedgestripthroughout
theoperation.

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TWOCIRCLE-CUTTING
IIGS
CUTTING
CIRCLES
WITHTHESABER
SAW

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thejig
J Using
f- Clampdownthestockwithasmuchof theworkpiece
as
possible
extending
off thetable,usingwoodpadsto protect
thestock.Cutintothestockto bringthebladeupto theoutl i n eo f t h ec i r c l ey o uw i l lb ec u t t i n gT. h e nd r i v ea s c r e wi n t o
thejig onthepivotlineat thecenter
of thecircle.Holding
the
sawandthestockfirmly,cut outthe cicle (below),
shifting
the
clamps
andworkpiece
asnecessary.

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thejig
1 Building
I Tocutcircles
bigger
thanthecapacity of commercial
sabersawjigs,usea
guidecustomized
shop-made
foryoursaw.
Theexactsizeof thejig canvary,butthe
dimensions
suggested
in the illustration
ai leftwillyielda jig largeenough
to cut
a circleto theedges
of a 4-by-8panel.
Beginby removing
the bladefromyour
sawandoutlining
itsbaseplateona piece
plywood.
of %-inch
Reinstall
thebladeand
c u ta l o n g
t h em a r k sm, a k i ntgh es e c t i o n
thatwillbebeneath
thebaseplateslightly
larger
thantheplate.Lighten
thejig by
trimming
it to theshape
of an L, thencut
outthenotch
forthe blade.Screw
thejig
to the baseplate,
ensuring
thattheback
o f t h eb l a d ei s f l u s ha g a i n st ht eb o t t o m
of thenotch.Usea pencil
to marka pivot
l i n eo n t h ej i g t h a ti s a l i g n ew
d i t ht h e
teethof theblade.

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CUTTINGJIGS

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CUTTING
CIRCTES
ONTHEBANDSAW
thejig
1 Building
I Forcuttingperfect
circles
ontheband
jigcustom-built
saw,usea circle-cutting
for
yourioolliketheoneshown
at left.Refer
to
the illustration
forsuggested
dimensions.
Usea routerfittedwitha dovetail
bitto cut
groove
a %-inch-deep
inthemiddle
ofthejig
base.Thenusea tablesawto rip a thin,
beveled
board
thatwillslidesmoothly
in
(Setthesawbladebevel
thechannel.
angle
b y m e a s u r i nt hgea n g l eo f t h ec h a n n e l
edges.)
Cutoutthenotchonthebandsaw.
Thenposition
thejig baseonthesawtable
sothatthebladeliesin thenotchandthe
d o v e t agi lr o o vies p e r p e n d i c utloatrh e
direction
of cut. Nowscrewthe suooort
armsto theunderside
of thejig base;
the
a r m ss h o u l dh u gt h es i d e so f t h e b a n d
sawtable.Boretwoscrewholesthrough
thebottom
of thedovetail
in the
channel
jig baseroughly
1 inchand3 inches
from
theunnotched
end;alsoborethreeholes
throueh
thebar.

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Contact point

Keleaaecut

Circleoutltne

r) Preparing
theworkpiece
youptan
I ftlarX
thecircumference
andcenter
of thecircre
to cuton its underside.
Then,usethebandsawto cutoffthe
fourcorners
of theworkpiece
to keepit fromhittingtheclamps
thatwillsecure
thejig to thetableastheworkpiece
turns.Make
a release
cutfromtheedgeof theworkpiece
to themarked
cir-

cumference
andveeroff to the edge(above,
/eff).Screwthe
pivotbarto thecenterof theworkpiece
through
oneof thebar's
holes(above,
right),leavingthe
screwlooseenough
to pivotthe
point
workpiece.
Turntheworkpiece
overandmarkthecontact
where
theblade
touched
thecircumference
durinstherelease
cut.

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CUTTINGJIGS

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theworkpiece
tothejig
Q Securing
r-,f Clampthejig baseto the bandsaw
table,making
surethesupport
armsare
butted
against
thetable's
edges.
Slidethe
pivotbarintothechannel
in thebaseand
oivottheworkorece
untilthemarked
contactpointtouches
theblade.
Screw
through
oneof theholesin thejig baseto lockthe
pivotbarin place(left),

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Completing
thecircle
Turnonthesawandoivottheworkpieceintothebladein a clockwise
direction(below),
feeding
thepiecewithyour
righthanduntrlthecutis completed.

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WEDGE-MAKINGIIG
'l

9top block
'/""x1%"x4"

% "x 1 "x 1 5 % "

Kunner
'/""x%"x19"

Building
thejig
I Smallwedges
areusedforwedged
tenons,
orto shimcabinets
on uneven
f loors.
Thejig
youto makethemquickshown
at leftallows
l y o nt h eb a n ds a w (. Y o uc a na l s ou s et h e
s a m ed e v i c o
e n a t a b l es a w . R
) e f etro t h e
illustration
forsuggested
dimensions,
making
surethehardwood
runner
fitssnuglyin the
sawtablemiterslot.Screw
therunner
to the
underside
of thebasesothattherunner
extendsbeyond
thetabletop
andthebasesits
s q u a r eol ynt h et a b l ew h e nt h er u n n ei rs i n
theslot;countersink
thefasteners.
Next,screw
t h ef e n c et o t h et o po f t h eb a s ea; n g l et h e
fenceat about4oto thefrontandbackedges
of thebase.
Setthejig onthetablewiththe
r u n n ei rn t h es l o tt,u r no nt h es a wa, n dc u t
through
thebaseuntiltheblade
contacts
the
fence.
Turnoffthesaw,remove
thejig,and
cuta slotthrough
thestopblockfora machine
bolt.Attachtheblockto thebase,addinga
w a s h earn dw i n gn u t .T h eb l o c ks h o u l b
de
f lushagainst
thefencewiththetip of itsangledendaligned
withthekerf.

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r) Cutting
wedges
L for yourwedge
stock,cut a stripof
woodfromtheendof a board;
cross-grain
makeit aswideasthedesired
lengthof
t h ew e d g e sP.o s i t i ot nh ej i g o n t h es a w
tableH
. o l d i nygo u rs t o c kw i t hi t s e d g e
flushagainst
thefence
andoneendbutted
against
feedthelig across
thestopblock,
thetable.Makesureyourhands
areclear
of thebladeasyoucut eachwedge(right).
Tocreate
4" anglewedges,
square
theend
of yourstockonthetablesawbefore
each
c u t .l f y o us i m p l fyl i pt h ew o r k p i e b
ce tweencutsonthebandsaw,allthewedges
afterthef irstwillhave8' angles.
Toprowedges,
ducethicker
loosen
thewingnut
andslidethestopblockslightly
away
from
thekerf. Tighten
thewingnutandcutthe
(inset).
wedges

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TWO IIGSFORANGLECUTSON THE BAND SAW

TAPER
JIG
Making
tapercuts
jigshown
Thesimple
L-shaped
at rightwill
youto cuttapersonthebandsaw.
enable
Markthedesired
taperon theworkpiece
andplaceit on a boardwitha perfectly
square
edge,
aligning
themarked
linewith
theboard's
edge.Usethelongedgeand
theendof theworkpiece
asa straightedge
to markanangled
cutting
lineandthelip
ontheboard.
Sawalongthecuttingline,
stopping
2 inches
fromtheendof thecut
Turnthe
at the bottomendof the board.
board90" to cut outthe lip.To usethe
boardasa jig,setup the bandsaw'srip
fenceto therightof thebladeandholdthe
jig flushagainst
thefence.
Aligntheedge
of thejig'slipwiththesawblade
andlock
thefencein position.
Seattheworkpiece
against
thejig.Turnonthesawandslide
theworkpiece
andthejig together
across
the tableintothe blade(right),keeping
bothhandsclearof thecuttingedge.

Jis

MITER
JIG

Fence
%"x13A"x13"

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Guide
a69embly

Jiq body \
1%"x11"x11"

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3/n"x B" x'14"

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Mitering
trim
Usethejig shownat leftto mitertrimon
thebandsawwithout
angling
the miter
gauge.
Formthejig bodybyface-gluing
twosquarepiecesof %-inchplywood
together.
Oncetheadhesive
hasdried,cuta
45' miterfromcorner
to corner
across
the
body,forming
a ledgeonwhichtheworkpiecewillsit.Cuttwoslotsintotheface
of thebody% inchbelow
theangled
ledge
to accommodate
springclampjaws.Next,
cutthefencefromsolidstock,notchit for
theclamps,
andattachit to thejig body
sothatitstopedgeextends
%inchabove
theledge,
Screw
thejigto themitergauge
andfeedthejig intotheblade
to trimthe
lower
end.Tocuta miter,clamptheworkpieceface-down
ontheledgeandf lush
against
thefence,andfeedthejig foward
withthemitergauge(left).Besureto raise
thesaw'sguideassembly
highenough
to
avoidhitting
thejigorworkpiece.

TAPERJIGS
A taperjig for theradialarm sawcanbe
built exactlylike thetablesawjig shown
thesaw
below.with oneaddition:Because
abovethetable,the
motoris suspended
radialarm sawjig canonly befed with
onehand,makinga handlenecessary.

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A TAPER
JIGFOR
THETABTE
SAW

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a tapercut
1 Making
I Foraccurate
tapercutsonthetablesaw,buildthisjig (tnsef) of thejig basenearest
theblade.Holding
theworkpiece
securely,
from%-inchplywood.
Referto the illustration
for suggested position
theguidebaragainst
it,withthelipsnugly
against
theend
Toassemble
thejig,setthesawbladeto its maxi- of theworkpiece.
Screw
theguidebarto thebaseandpress
the
dimensions.
mumcuttingheight,
buttonesideof thejig baseagainst
the toggle
clamps
downto secure
theworkpiece
to thejig.Tomake
theothersideof the thecut,setthe bladeheightandslidethejig andworkpiece
blade
andposition
theripfenceflushagainst
handis in linewiththe
base.
Lower
thebladeandmarka cuttinglineforthetaperonthe across
thetable,making
surethatneither
(Caution:
Bladeguardremoved
for clarig.)
workpiece,
thensetit onthebase,
aligning
thelinewiththeedge blade(above).

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ABLADEHEIGHTGAUGE
(lNA TABTE
HEIGHT
SETTING
THEBLADE
SAW
gauge
a bladeheight
Using
Yourtablesaw'sbladecanbe setat a
quickly
specific
height
witha bladeheight
gauge.Makethejig fromstripsof %-or
% o - i n c h - t hhi cakr d b o aor dr s o l i dw o o d
laminated
together.
First,rip a lengthof
the stockto a widthof 3 inches.
Crosscut
withan 8thepieceintostrips,starting
inchlength.
Makeeachsuccessive
strip%
inchshorter
thantheorevious
one.Once
allthestripsarecut,gluethemtogether
face-to-face
withoneendaligned.
Touse
thejig,setit on thesawtablebeside
the bladeandrotatethe bladeheight
adjustment
crankuntiltheblade
contacts
thegaugeat thedesiredheighl(right).

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Illlllllllllllltllllllllillllltfilllllfit-l1ll"tlll-1[t'llt"lltl
llt'tlll
1HO?TI?
Shop-made
table ineerte
lf ihe table
inserLseupplied
wiih vour Nablesaw are
aL leaeN%inchthick, youcan
makeyour ownfrom woodecrape.
The inserle willminimizeNheqap
belweenlheeawbladeandNheLable
ineerLo?eninqand ?reventecrapwoodfrom \
jamminqaqaineN
the blade.UeeLhefactory-euppliedineerl ae a lemplale t o cul a blankfrom a /.7
pieceof woodof lhe eamethickneee.Tap
a finisfur(gnailinVoIhe blank'e
front enAunlil'/oinchprotrudeefrom if. (Thenailwilloerveae an anchor
CrankNheblade
pint o keeplhe ineerLin Vlacewhilethe eawie runninq.)
to ite loweet,eetlinq and eellhe newineert in place.TosilionLhe rip
fenceto etraddleNheinserl,makinqeureIhat iI is noI directlyin line
withlhe cuttinqedqe.Iurnonbheeawand crankNheblade
olowlyup
to itrohiqheotoetlinq, cutlinq a eloLNhrouqhNhewoodineerl.

49

MITERIIGS
CROSSCUTAND
The tablesaw miterjig shownat right k
similar to the crosscutjig describedbelow,
exceptthat insteadof an extensionand
safetyblockit featurestwo l2-inch-long
1-by-4 miter arms.Placedat 90" to each
other in the middle of thejig, the arms
ensurethat a workpiecemiteredalong
oneguide will form a perfect90" corner
with a boardcut along the other arm.

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SAW
A CROSSCUT
JIGFORTHETABLE
Clearplaetic
quard

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)top block
2"x4"x4"

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Kernforcinqblock
2"x2"x8"
9upporEframe
2"x3"x36"

tothebase
therunners
1 Aftaching
jig custom-made
above
is
foryourtablesawliketheoneshown
I A crosscut
to the illustrawithunwieldy
stock.Refer
valuable
if youareworking
especially
hardwood
runners
Startbycutting
two25-inch-long
dimensions.
tionforsuggested
intothe
clearance
holesforscrews
to fit yourmiterslots.Boreandcountersink
in theslots
fromeachend.Place
therunners
of therunners,
3 inches
undersides
a n ds l i d et h e mo u tt o o v e r h a nt hgeb a c ke n do f t h et a b l eb ya b o u8t i n c h e s .
itsedgeflushwiththeiroveronthewoodstrips,
Position
thejig basesquarely
andthe
to thebase(/eff).Slidetherunners
hanging
ends,andscrew
therunners
baseoffthefrontendof thetableanddrivein theothertwoscrews.

50

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CUTTING IIGS

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p
6@^
@

,@O

E=-Itr*\:/-t'r

r) Installing
thesupport
frame
andguide
I W,tntherunners
in
still themiterslots,
attach
thesupport thebasefromunderneath
thejig,making
sureyoucountersink
jig
glue
framealong
thebackedgeof the and
onthereinforcingthefasteners.
Gluethesafety
blockto theoutside
faceof the
block,centered
between
therunners.
Thenmakea cutthrough guide,
again
centered
onthekerf.Raise
thesawblade
andfinthesupport
frameandthree-quarters
of thewayacross
thebase. ishthecut,sawing
completely
through
theguidebutonlyslightTurnoffthesawandlowertheblade.Screw
a reinforcing
block ly intothesafetyblock.Mounta clearplastic
sheetoverthesaw
guide
position
guide
to the
and
the
alongthefrontedgeof the kerfasa bladeguard,
fastening
it to thereinforcing
blocks
with
jig,usinga carpenter's
square
to ensure
thatit is square
with wingnutsorscrews.
thesawkerf.Clamp
theguidein place(above)and
screwit to

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Q Crosscutting
r-,1Formaking
repeat
cutsto thesame
length,
screwan extension
to the right
sideof theguideandclampa stopblock
to it. Cuta notchin theblockto holdthe
clampin placewhenit is loosened.
Touse
thejig,fit therunners
intothemrterslots
andslidethejig toward
the backof the
tableuntiltheblade
enters
thekerf.Hold
theworkpiece
against
theguide,
slidethe
s t o pb l o c kt o t h ed e s i r epdo s i t i o na,n d
. i t ht h ew o r k p i e c e
c l a m pi t i n p l a c eW
h e l df i r m l ya g a i n st h
t eg u i d ea n dt h e
s t o pb l o c ks, l i d et h ej i g s t e a d r a
l yc r o s s
thetable(left),feeding
theworkpiece
intotheblade.

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5l

RAISEDPANELIIG

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thejig
1 Making
I Toraise
a panel
onthetablesawwithout
adlusting
theblade
jigshown
at left.Refer
totheillustration
angle,
usetheshop-built
forsuggested
dimensions.
Screw
thelipalong
thebottom
edge
fence,making
thescrews
where
of theangled
sureto position
t h e yw i l ln o ti n t e r f e rwei t ht h e b l a d eP. r o pt h ea n g l e fde n c e
against
theauxiliary
fenceat thesameangle
asthecuttingline
marked
outonthepanelto beraised.
Usea slidingbevelto transferthisangle
to triangular-shaped
supports
thatwillf it between
in
thetwofencesandcut thesupports
to fit. Fixthesupports
placewithscrews(above).

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r) Raising
a panel
thejig
L Snttttheripfenceto position
j
o
i
n
t
w
i
t
h
o nt h es a wt a b l e
the
o f t h el i p
f
e
n
c
e
a n da n g l e d
o v e trh eb l a d ee; n s u r e
thatthescrews
arewellclearof thetable
o p e n i n gT.u r no nt h es a wa n dc r a n kt h e
to cut a kerfthrough
the
bladeup slowly
l i p .N e x ts, e a t h ep a n eiln t h ej i g a n d
l sina d j u stth eh e i g hot f t h eb l a d eu n t i a
gletoothis protruding
beyond
thefrontof
thepanel.Makea testcut in a scrapboard
thesamethickness
astheoanelandihen
Adjust
the
testitsf it in theframegroove.
position
of thefenceorblade,
if necessary,
l ,e v e l i nt hgee n d
a n dc u tt h ea c t u apl a n e b
grainfust (right).

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BOARD-STRAIGHTENINGIIG

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1iililil ilil tiiilililil|il ilil|ill tiiillil illl llll llil illl llll liil llll
ili iii ill {il lti {$ {il i.Uui ul l$ ili i.ti iii iil iil ul ill

5HO7Tt?
Crosscult'ingwide panele
or you are workinq
lf yourIable oawdoeenot havean exLension,
wiNhVanelolhal are t'oo larget'o cuNwiLha mit'erqauqe,you can
crosscutlheee paneloby clampinqa equare1-by'3fencelo the
undereide
of the panel.Uoea 1-by-3Nhatis lonqert'hanthe Vanelio
wideand carefullypoeition
it, undernealhperVendicular
H

"n22"
:?
"|flV
i:o;:,"
F
Nhefenceto the

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VanelwiLhC
clampo.Guide
along
Nhefence
the ouler edge
of your eaw'e
table ao you
makethe cuN.

"
'

'.t:t--/

'

Truing
a board
on a tablesaw,
Totrueuneven
boards
jig shown
buildtheboard
straightening
a b o v eB. u i l tf r o m% - i n cphl y w o o tdh, e
jig slidesin thetablesaw'smitergauge
to bestraightened
slot,whrletheboard
i s h e l di n p l a c eb ys u p p o rbtl o c kas n d
Firstcut the basefrom
toggleclamps.
plywood;
%-inch
makeit about9 inches
wideandlonger
thanthewidthof your
s a wt a b l eC
. u ta r u n n etro f i t t h e l e f t handmitergauge
slot;makeit longer
it onthe
thanthejig baseandposition
underside
of thebasesothattheinside
thebladeby
edgeof thebaseoverlaps
%inch.Screw
therunner
to thebottom
allthescrews.
of thejig,countersinking
Next,screwtwosupportblocksto the
toggle
clamps
onthem;
baseandinstall
position
sotheworkthesupport
blocks
p i e c ei s c e n t e r eodnt h eb a s eF. i n a l l y ,
it totheend
fashion
a handle
andattach
o f t h ej i g .T o u s et h ej i g ,f i r s t r i mt h e
it across
inside
edgesquare
byrunning
to be
t h eb l a d et .h e nc l a m pt h eb o a r d
to thejig andrepeat
to true
straightened
itc odopc

(zhnvp)

AUXILIARYFENCESAND TABLES
A RADIAL
ARMSAWM()TDING
FIXTURE
Cutout
2 % "x 9 % "

LiP
'/+"abovetable

Building
andsetting
upthejig
1
I lf youwantto cutgrooves
or molding
ontheradialarmsaw
position,
withthebladein thehorizontal
tryanauxiliary
fence
andtableliketheoneshown
above.
Thebaseraises
theworkpieceto thecutter,andthefencesupports
theworkwhileprovidinga clearance
cutoutforthedadoor molding
headguard.
plyCutthefenceandthetwopieces
forthebasefrom%-inch
wood;makethe basepieces
thesamesizeasthe frontsaw
table.Screwthe basepieces
together,
offsetting
thetopslightly

to createa gapalongthefencethatwill prevent

sawdust
fromaccumulating
between
the baseandthefence.When
sawingthe
fencecutout,leave
a lipthatwillprotrude
at least
%i n c ha b o v teh eb a s ew h e nt h ej i g i s i n s t a l l eTd h. el i pw i l l
support
theworkpiece
asit ridesalong
thefenceduring
a cut.
Screw
thefenceto thebase.
Tosetupthejig,slipthefence
between
thefrontsawtableandthetablespacer,
thentightenthetableclamos
to secure
it.

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r') Cutting
a molding
L lnstalla molding
headonyoursaw,
thensecure
theworkpiece
byclamping
onefeatherboard
to theoutfeed
sideof
thefenceandanother
to thetable,braced
witha support
board,
Adjustthemolding
headfor a %-inch-deep
cut,making
cerj uds t
t a i nt h e b l a d eg u a r di s p o s i t i o n e
abovetheworkpiece.
Feedthestockinto
the cutterswithyourrighthand(right);
useyourleft handto presstheworkpiece
against
thefence.Finish
thepasswitha
pushstick.Makeasmanypasses
asnecessary,
advancing
themolding
headno
morethan%inchintotheworkpiece
at
a t i m e .O n c ey o uh a v ec u tt h ed e s i r e d
p r o f i l em, a k ea f i n a l ,v e r ys h a l l o w
pass,
f e e d i nsgl o w l ay n de v e n ltyo p r o d u cae
finish.
smooth

54

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CUTTINGIIGS

F()RTHETABLE
SAW
FENCE
ANAUXITIARY

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illtilllllillllllll llltlllllllllllllllllltillll
fillrlllllltijllfiitlll1
9HO7Tt?
A miter Oauge
extension
Io increasef,hebearinq eurfaceof your
tableeaws miler gauqe
or Nomakere?eatcrogo'
cu|s wiNhthe aid
of a eNopblock,
athach a wood
exDeneion
lo the
qau7e.The
excension
muel be lonqenouqhlo
extendbeyondthe eaw blade.)crew iNNolhe qauqeand Vuoh
off Nhesaw
NhegauqeLo cut,off the endof t'heexEension.Turn
and slideLhemiLer6auqeto Ihe fronLof Nhelable.Toeet up a
Nhedesireddis'
ehopblock,clampa woodblockloNheexEension
Foreachcut, butt' trheedqeof the work'
lance from Nheb1ade,
olop block.
andlhe enda7aineNthe
pieceaqaineNNhe
exLeneion

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55

anauxiliary
fence
Using
youusea dadoormolding
head
Anytime
withthe
onyourtablesawin conjunction
rip fence,youneedto attacha wood
the blades
fromconfenceto orevent
themetalone.Cutthefencefrom
tacting
plywood
thesamelengthasthe
%-inch
higher.
Lower
the
ripfenceandslightly
the
thesawtableandscrew
blades
below
woodfenceto theripfence.Markthe
depthof cut onthefenceandposition
fencedirectly
overthedado
theauxiliary
head,
ensuring
thatthemetalfenceis
Turnonthesawand
clearof theblade.
s l o w lcyr a n ku pt h ed a d oh e a dt o t h e
line,producing
a relief
cutin the
marked
fence.Buttthecuttinglineon
auxiliary
theouterblade
theworkpiece
against
a n dl o c kt h ef e n c ef l u s ha g a i n st ht e
like
stock.Formostcutting
operations,
in theillustration,
cutshown
therabbet
with
should
besupported
theworkpiece
at a
featherboards.
Feedtheworkpiece
steadyrate,usingbothhands(above).

COVE,.CUTTING
IIG
andusing
thejig
1 Building
I Fashion
moldins
onthetablesawwith
guideshown
thehelpof thecove--cutting
at
left.Toconstruct
thejig,fastentwo 18inch-long
l-by-2s
to two9-inch-long
1-by2 s w i t hc a r r i a gbeo l t sa n dw i n gn u t s ,
forming
twosetsof parallel
arms.
Adjust
the
jigsothedistance
between
theinside
edges
o f t h et w ol o n ga r m se q u a ltsh ew i d t ho f
thecove.Crank
thebladeto thedesired
depthof cut.Laytheguideacross
theblade
a n dr o t a t er t u n t i lt h e b l a d et,u r n e db y
hand,justtouches
theinside
edges
of the
a r m sT. h e nr u na p e n c ial l o n g
t h ei n s i d e
edges
of thelongarmsto traceguidelines
across
thetableinsert(/eft).

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r) Cutting
a cove
1 Remorethe
thebladebeneath
thetable.Outline
euideandlower
thedesired
cove
profile
ontheleaJing
endof theworkpiece,
thensetthestockonthesawtable,aligning
the
marked
outline
withtheguidelines
onthetableinsert.
Buttguideboards
against
theedges
o f t h ew o r k p i e caen dc l a m pt h e mp a r a l l e
t ol t h eg u i d e l i n euss; eb o a r dlso n ge n o u g h
t o s p a nt h es a wt a b l eC
. r a n tkh eb l a d e%i n c ha b o v teh et a b l eT. om a k e
t h ef i r s tp a s s ,
(above),
feedtheworkpiece
steadily
usingpushblocks
whenyourhandsapproach
the
blade
area.Makeasmanypasses
asnecessary,
raisingthe
blade%inchat a time,

56

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TWOTENONINGJIGS

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JIG
G
A SIM PLTEEN O N IN
thejig
1 Building
thefence-straddling
I Easy
to assemble,
j i gs h o w n
at righw
t o r k sw e l lf o rc u t t i n g
openmortise-and-tenon
two-shouldered
joints.Refer
suggested
to thedimensions
making
surethethickin theillustration,
andwidthof thebrace
nessof thespacer
your
a l l o wt h ej i gt o s l i d es m o o t hal yl o n g
r i pf e n c ew i t h o uwt o b b l i nC
g .u tt h eb o d y
plywood
andthe
andbracefrom34-inch
guideandspacer
Sawan
fromsolidwood.
of the
in onecorner
ovalholefora handle
jig bodyandattach
theguideto thebody
hole,making
in frontofthehandle
directly
s u r et h a tt h eg u i d ei s p e ref c t l yv e r t i c a l .
(Theblademaynotchthe bottomof the
guidethefirsttimeyouusethejig.)Screw
a s m a lw
l o o db l o c kt o t h e b o d yb e l o w
h t o g g l cel a m p
t h eh a n d l ae n da t t a c a
, s t e nt h es p a c e r
t o t h e b l o c kF
. i n a l l yf a
andbracein olace.

r) Cutting
a mortise
I Placetheiig astride
thefence.Butt
t h ew o r k p i e caeg a i n st h
t ej i g g u i d ea n d
c l a m pi t i n p l a c eP. o s i t i ot nh ef e n c et o
with
ontheboard
alignthecuttingmarks
thefence
theblade
andslidethejigalong
to makeIhe cuI (lefil.

CUTTING IIGS

ANADJUSTABLE
TENONING
JIG
Blade4uard

Erace
3/+"x13/+"x351/q"

Fence
3/+"x5%"x351/+"

11,/2"x51/2"x24"

Kunner

thelig
1 Assembling

I Thejig shown
above
canbeusedon
the tablesawto cut bothpartsof an
joint.Refer
openmortise-and-tenon
to
theillustration
forsuggested
dimensions.
Cutthejig fenceandbackfromthree
piecesof %-inchplywood
andsawa
45' bevelat oneendof eachboard;
the
pieces
should
bewiderthantheheight
ofyoursaw'sripfence.Fasten
twopieces
together
face-to-face
to fashionthe
back,thenusecountersunk
screws
to
attachthefenceandbacktogether
in
an L shape;
makesurethefasteners
will
pathwhenyouuse
notbein theblade's
the jig (inset).Next,cut the bracefrom
solidstock,bevelits endsandattach
i t a l o n gt h et o p e d g e so f t h e f e n c e
andback,forming
a triangle.
Cuttherunnerfromsolidwoodandattachit to the
fencesothatthejig runssmoothly
across
(Therunner
thetablewithout
wobbling.
in thisillustration
hasbeennotched
to
fit theparticular
desrgn
of thesaw'srip
fence.)
Finally,
cuta pieceof clearplastic asa bladeguardandscrewit to the
jig backflushwithitsfrontface.

r') Mounting
theeccentric
clamp
1 tttat,,e
plywood
theclampbyface-gluing
threepieces
of %-inch
andcuttingthe
assembly
intotheshape
shown.
Borea prlotholethrough
thejig backandtheclamp,
thenfastentheclampin place;wedgeoneof yourworkpieces
between
theedgeof
theclampandthefenceasyoudrivethescrew.
Offsetthefastener
sotheclampcan
(above),
(Drilladditional
pivoteccentrically
youto move
holesin thejig backto enable
theclampto accommodate
stockof varying
thicknesses.)

5B

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CUTTINGIIGS

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Cuttinga tenon

lllllllllllll]lllll illlillllllllllltlll
,lllllllljlllllllll]lllilll,ll1
1HO?TI?
A miter 4augeangle-eetlingjig
useon
Tokeeplrack of non-eLandard
angleolhalyou commonly
yourtable oaw'6miter qauqe,makea sel of anqle-eeNIinq
1iqo.
)implycut Lwo1-by-2eand clamVIhemto the miler
q a u q eo, n ea q a i n e l t h eb a ra n d o n ea q a i n o t r L h e
f a c e . 7 c r e wt h e m N o q e L h ei nr N oa n a n g l e dL
i
ohapeand markdownf,heanqlethey form
,,
o n t h e j i g , U e et h e d e v i c el i k ea o l i d i n g
t o ee| the miter
bevel
qaugequicklyLo a
opecific
angle.

S e tt h e l i g o n t h e s a wt a b l ei n f r o n t

of theblade
withtherunner
andfence
straddling
theripfence.
Secure
theworkpiecein thejig byturning
theeccentric
clamp,
andposition
theripfencesothat
t h eb l a d ei s i n l i n ew i t ha t e n o nc h e e k
Feedthe
cuttingmarkontheworkpiece.
jig intotheblade.
(Your
f irstuseof the
1 i gw i l lp r o d u caek e r fi n t h eb a c k .F) l i p
theworkpiece
in the1igandrepeat
to cut
Remove
thejig
theothercheek(above).
fromthetable,lower
thecuttingheight
t o t h el e v eol f t h es h o u l d e rasn, ds h i f t
theriofence
to cutthetenon
shoulders.

'!
',r;&c
&w

'C.''.-''..'l

!-.
weba

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DruLLINGIIGS

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rillinga holeis simple,but there

you
aretimeswhenajig cansave
when
time and frustration,especially
the hole mustbe locatedprecisely,
or at
jig,
an exactangle.The center-drilling
for example,ensuresthat doweljoint
holeswill be centeredin the edgesof
matingworkpieces.Thejig for drilling
equallyspacedholeson the drill press
virtually eliminatesthe needfor measuring andmarkingandguarantees
consistentlyaccurate
results.
The tilting tableandpocketholejigs
areboth invaluablefor boringthe angled
holesthat arecommonlyusedto attach
tabletops
andchairseatsto legsandrails.
The techniquefor drilling deepholes
shownon page67 willdoubleyour drill
press's
quill stroke,allowingyou to bore
straightthroughthick stockwithout
resortingto an extension
bit.

A SETECTI(IN
OFDRILTING
JIGS

Jig for boring

equally spaced
holes (pa6e 64)
Uaedon drill preaa

V-bloakjig (page 65)

Holde cvlindrical
stock on drill
preee table

Tilting table jig

(pase65)
Equippedwith thejig shownat left,
a drill presscanborea rowof equally
spacedholesquicklyand accurately.
Thejig is simpleto buildfrom scrap
woodanda shortdowel.

Adjuetableji4
attached to drill
preae table for borin7
anqled holea;workpiece
lies face-downon top

Cenier-drilling ji6 Qaqe 62)

Uaed with an electric drill to locate
the center of a board ed1e; dowelo
at the enda of the arm are butted
aqainet oppoeite board facea

Pocket holejig (page 66)

Clampedto drill preaa
table to bore pocket
holee;workpiece
reste edqe-down
in an4ledcradle

CENTER-DRILLING
IIG

Drilling
holes
dowel
j
i
g
T h es i m p l e s h o wanb o vw
e i l le n a b l e
youto boreholesthatarecentered
on
theedgeof a board.
Theinsetprovides
dimensions.
Markthecenter
suggested
of thetopfaceof thearm,andborea
Theholein the
holefora guidebushing.
bushing
should
bethesamesizeasthe
youplanto drill.Turnthearmover
holes
anddrawa linedownitsmiddle,
Mark
points
ontheline1 inchfromeachend.
(Check
yourmeasurements:
Thepoints
m u s tb ee q u i d i s t afnr ot mt h ec e n t e r . )
holehalfway
Thenborea %-inch-diameter
through
thearmat eachmark.Dabsome
g l u ei n t ot h eh o l e sa n di n s e rdt o w e l s .
protrude
Theyshould
byabout%inch.To
it ontheworkpiece
usethe1ig,position
opposite
sothatthedowels
buttagainst
facesof thestock.Holding
thejig wrth
o n eh a n df,i t t h ed r i l lb i t i n t ot h eb u s h ingandborethe hole(above).

ltllLiilllllll
lllillllllllilllllillIJllrlitllilltilllillll]lllljrJl
1HO?TI?
lnoertin7dowels
wilh a deprh gauqe
ToavoidNheriekof drivinq
doweletoo deeVlyand epliNIinq the board,try thie
eimpledeplhqauqe.
U e ea 6 - i n c h - l o n q
Vieceof ebock
one-hala
fe
N h i c ka e t h e
lenqlhof the

dowele.9ore
a hole
n e a ro n ee n d L h a N
i e e l i q h b l yl a r q e rL h a n l h e

doweldiameler.Then
elipthe 1igaroundeach
dowelwhenyou laV it, in Vlace.Thedowelwill
be aI Nhecorrecldepthwhenit ie fluehwith
t.heNoVof the deplh qauqe.

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TITTINGTABLEIIG
thetable
1 Making
I T o b o r ea n g l e d
h o l e sw i t h o utti l t i n g
t h ed r i l lp r e s tsa b l e u, s et h et i l t i n gj i g
shown
at right,builtfromsolidstockand
plywood.
%-inch
Refer
to theillustration
for suggested
dimensions.
Connect
the
j i g t o pt o t h eb a s eu s i n ga s t u r d yp i a n o
hinge.
Cuta %-inch-wide
slotin thesupportbrackets
andscreweachoneto the
top;secure
thebrackets
to thebasewith
wingnuts,washers,
andhanger
bolts.

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r) Drilling
angled
holes
(-, a ^Center
thejig underthedrillpress
s p i n d l ec,l a m pt h eb a s et o t h et a b l e ,
andloosen
thewingnuts.Usea protractoranda slidingbevelto setthe
angle
of thetop,thentighten
thewing
nuts.Clamp
theworkpiece
to thejig
andborethehole(below).

9upport bracket
t/o"xl %"x'lO"

IIG FORDRILLINGEQUALLYSPACEDHOLES

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thejig
1 Making
holes
spaced
a rowof equally
thetaskof boring
I Makethisjigto simplify
p
r
e
s
s
.
b
a
s
et,h e n
e
d
g
e
o
f
t
h
e
Screw
t h ef e n c ef l u s hw i t ho n e
o n t h ed r i l l
(The
hole
holder.
of thefenceasa dowel
attacha woodblockto thecenter
jig.)Tne
given
you
dimensions
usethe
forthedowelis madethefirsttime
i l ls u i tm o s dt r i l lp r e stsa b l e s .
i n t h ei l l u s t r a t iw
on

l]Illlllllllilll
llllullltiilltllrljlllllllirufiililllillll]lllllll]I1
5HO7Tt?
Making
wood plugo
eavelime
makinqwood
pluqeby uoin4a
pieceof IaVe Noremove
themfromtheirholee,
Use
a oluacull,eron the drill
Vr:"eir,o borea rowof plugeNo
Lhedepthyou require.CoverNhe
t aVe,
row wilh a eNripof maekinq
then rip Ihe pluqelo lenqthon Nhe
bandsaw and eimplypeeloff the
ta?e to removethe rowof Vluqe.

r) Boring
theholes
L S e t h e1 i go nt h ed r i l lp r e stsa b l e .
Markthe location
of thef irsttwoholes
thefence
against
andseattheworkpiece
mark
thefirstdrilling
of thejig,aligning
under
thebit.Butta guideblockagainst
t h eb a c ko f t h ej i g a n dc l a m pi t t o t h e
t a b l eB
. o r et h ef i r s th o l e s, l i d et h ej i g
along
t h eg u i d eb l o c ka, n db o r ea h o l e
t h r o u g thh ed o w ehl o l d e rF. i ta d o w e l
andintothe
through
theholeintheholder
Slidethejig until
holein theworkpiece.
markisaligned
under
thesecond
drilling
j
i
g
t
o
t
h
e
t
a
b
l
ea n d
b
i
t
.
C
l
a
m
t
p
h
e
the
T
o
d
r
t
l
l
e
a
ch
s
e
c
o
n
h
d
o
l
e
.
b o r et h e
al n d
h
o
l
e
r
,
e
t
r
a
c
t
t
h
e
d
o
w
e
remaining
jig
fence.
workpiece
along
the
slidethe
Pushthedoweldownintothelasthole
youmaoe.

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V-BLOCKIIG

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Boring
holesin cylindrical
stock
T o m a k et h es i m p l eV - b l o cjki g s h o w n
above,
marka right-angle
V on theend
o f a p i e c eo f s o l i ds t o c kt h a ti s l o n g
e n o u gtho h o l dy o u rw o r k p i e cTeh. e n ,
adjust
theblade
angle
onyourtablesaw
to 45"andalignonecutting
linewiththe
b l a d eB. u t t h er i pf e n c ea g a i n st ht e
stockandfeedtheboard
to cutthefirst
s i d eo f t h eV . R e v e r st he ep i e c ea n d
m a k et h es e c o n cdu t .T o u s et h ej i g ,
secure
it to thedrilltablesothedrillbit
t o u c h etsh ec e n t eor f t h eV w h e nt h e
quillisextended.
Holdtheworkpiece
in
t h eV , a l i g n i ntgh eb i t o v e tr h ec u t t i n g
m a r ks, e tt h ed r i l l i n d
g e p t ha, n db o r e
the hole(above).

llllilI1
lllltlllll1
llltilij]ltiluili ll11
illlllitfillilltllr1
lllll]t1
1HO?TI?
Depth guideo for drilling
I i'l
I
To borea holelo an exacL I | il
: I
q-hr".t:','*
d,epNh,
uee a maekin4t ape I
flag or a deplh orop block, I
: ll|;t
lf you are ueinqNheNape, F:;=
y
meaeure
the drillinqdepth t from the Lip of the"biv,'then ffufl-{-ffi;{.
wra?a eNriVof NaVearound
ive'ehank.
Wnnarhwlhe bit W
whenlhe NaVetouch,eethe sy1#'
s t o c k . T ou e ea b l o c k e, u b - W
tractNhedrillinadeplh from
f il
Nhelenqth
ofrhibit'Vrotrud- tT--*l
i n qf r o m l h e c h u c k C
. U La
Y
-tD'
piiceof 1-by-1
eNockNo
lhie
length,Nhenborea holeNhrouqhite middle.
)lip the bit throuqhthe blockandboreyour
holeunlilthe block t ouchee Lhe workpiece.

65

POCKETHOLEIIG
theiig
1 Making
I T o b o r eo o c k eht o l e so n t h ed r i l l
press,usethisjig madefrom%-inch
plywood
andtwosmallpieces
of solid
stock.Referto the illustration
at left
for suggested
dimensions.
Screwthe
twosidesof thecradletogether
to form
an L. Thencuta 90" anglewedge
from
eachsuooort
bracket
sothatthewide
willsit at anangleof
sideof thecradle
about20" fromthevertical.
Screw
the
brackets
to thejig baseandattachthe
cradle
to thebrackets.

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Da'ee

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r) Drilling
pocket
holes
in thecradle
with
I
Seatthe
workoiece
t h es i d et o b ed r i l l e fda c i n g
o u ta n dt h e
t o ne d p es i t t i n si n t h eV o f t h ec r a d l e .
Boretheholesin twostepswithtwodifferentbits:a Forstner
bit slightly
larger
of thescrewheads,
so
thanthediameter
theycanberecessed,
anda brad-point
b i ta l i t t l el a r g et rh a nt h es c r e w
shanks
t o a l l o wf o rw o o dm o v e m e nI n
t .s t a tl lh e
b r a d - p o ibni t i n t h ec h u c ka n dp o s i t i o n
t h ej i g o nt h ed r i l lp r e stsa b l es ot h eb i t
withthecenter
edge
alrgns
of thebottom
) .l a m p
o f t h ew o r k p i e c( ien s e t C
t h ej i g
bit
to thetableandreplace
thebrad-point
withtheForstner.
Holding
theworkpiece
firmlyin thejig,feedthebitslowly
to bore
eachholejustdeepenough
to recess
the
screwheads(ilgh|.fo complete
thepockh rea d - p o b
i ni ta n d
e t h o l e sr ,e i n s t a l l t b
borethrough
theworkpiece.

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66

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BORINGDEEPHOLES

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lllllnillltilljl]lJ
l]llillJlfllll1
ullllullllillll]illlllilllllllllll
1HO?Tt?
Cuttinq roaettes
on the drill preao
Youcan cuI decoralive
rosetNeeby modifyinga
drill oreeeflv culter wilh
a be'adinq
biadefrom a
Nablesawmoldinqhead.
NotchNhefly cuNLerarm
to accommodat
e Nhebead'
inqblade,locaLinq
LhecuLNeraboull inchfromlhe
endof the arm. Makeeureit
fite eecurely
in the notcheo il cannolehifLduringuee.borea
holethroughthe
armand ueeabolN,waeher,
and nuNLofashenNhe
bladein I,henobchwith i|s flat,lace t owardthe direcNion
of cuNter
rot ation,1eI your workpieceon a woodbaeewibhetoV blockeNo
holdit oecurely.
ClamVthe oebupto LhedrillVreeeNable,
aliqning
lhe centerof the fly culter overlhe cenherof lhe slock.Turnon
the drilland lowerthe quilluntil lhe bladeliqhtlyconlacts the
wood.Continue
cuNlinqunlilLherose|te hasLheprofileyou want.

67

quillstroke
Exceeding
a drillpress's
Themaximum
distance
thattheouillof
a d r i l lp r e scsa nb ee x t e n d ei sdc a l l e d
itsstroke.
0n mosttools,thisis nomore
than4 inches.
Todrilla deeper
hole,you
mayuseanextension
bitor,if thehole
measure
andtheworkoiece
lessthan
perform
twicethequillstroke,
theoperationin twostages
witha standard
bit.
A s i m p l jei g s o l v easn ya l i g n m e pn rt o b lems.First,clampa scrapboard
to the
d r i l lp r e stsa b l ea n db o r ea g u i d eh o l e .
Then,clamptheworkpiece
to theboard
a n db o r ei n t oi t a sd e e p layst h eq u i l l
stroke
willallow.Remove
theworkpiece,
f i t a d o w ei ln t ot h eg u i d eh o l es, l i pt h e
workpiece
overthedowel,
andfinishboringtheholefromtheotherside(above).
Thedowel
willensure
thatthetwoholes
areperfectly
aligned.

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TTIRNINGIIGS
athesenablea woodworkerto turn
blocksof woodof almostanyirregular shapeinto beautiful,roundedcreations,Woodturnersoftenspeakof how
visualtheirart is; theyseea chairleg,
bowl,or peppermill seemto growfrom
a spinningblank.Yetdespiteits visual
"feel"
for
on
elementandtheemuhasis
judgingthe progresiof a turnedworkpiece,turning alsodependson accuracy
andcarefulmeasurement.
Thejigsin thischapterwill helpyou
with precision.
Useone
turn a workpiece
of thesetupjigsshownon pages70 and
71 to mount a blankproperlyon the
lathe,evenif theworkpieceis irregularly shaped.A layoutjig (page73)isideal
outliningthe
for quicklyandaccurately
locationof the contourson a blank,
while measuringjigs like the diameter
gauge(page73)orbowl depth gauge
(page77)comein handyfor checkinga
workoiece's
dimensions.
Tlie lathecanalsobe usedfor purposesotherthanturning;seethesanding drum (page77) and the jig for
routing flutesin columns(page75).

()FTURNING
IIGS
A COLTECTION
Center-finding jig (pa6e 71)
Locateathe center of irre7ularly
ohapedworkfor faceplate turninq
Diamet'er
gauge (paqe 73)
Uaedto checkthe diameter
of a turned workpiece;ocrewo
orovidefine adiubtm ent

Faaeplate-aenteringjig (page 71)

For mountinqthe lathe faceplate
Lo the center of circular workpiecee

Gouge-sharpeningjig (page 72)

Uaedin conjunctionwith a benchqrinder
to eharpenLurnin7toola; holdatool,
bladeat the properanqlefor
qrindinqthe bevelon
the cuttin4 edqe

Mo unting h ollowed- out workpieces

on a lathe can be challenging.For
the cocobolobud vasebeingsanded
at left, a conicalbull-nosetailstock
waspositionedbetweenthe lathe's
metal tailstockand the workpiece,
allowing the vaseto be supported
snuglywithout dantage.

Layout jig (page 75)

Uaedto tranafer layout lineafrom a pattern to a f,urnrnqblank

69

TURNING JIGS

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A COTTECTION
OFTURNING
JIGS
(continued)
Tailetock for hollowedout work (paqe 74)
Conicalwoodentailatock
placed betweenmetal tailetock
of lathe and workpieceto 6uppor, openmouth workfor final turnina and finiahina

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1anding drum (page 77)

For amoothingcontoured work;aandpaper ie held in place by a hardwood etrip acrewedinto -a
a 1roove rou'ea
in the drum
blank

Column fluter
(pa6e 75)
Uaedto rout flutea in turned
columna;columnblankia mountedon lathe while
jig elideealonq the lathe bed and 4uidee router

Bowl depth gauge (page 77)

Uaedto determine the depth
of a bowldurinqturnin7

tllltll]lllllllrtlllllltlllfitttlllll11
lllllllltllllllllllilllltlltllj
1HO?TI?
Centering a epindle blank
F i n d i n q L hcee n N eorf a b l a n k
for epindle
turninqie tradiNionally
doneby markinqNwo
diagonallinesfrom cornerlo
corneron eitherend of Nhe
workpiece.
)till, for bolh
eafetyand accuracy,iNie
a
aoodideat o double-check
lhe localion of the center.
With lhe lathe swilchedof*, pooilionLhetool resLclooeto the
blankparallelto oneol ite corners.KoIaIe the blankby hand,The
qap belweenLheNoolreet and the blankshouldbe the eameat
eachcorner;adjuol lhe poeibionof the LoolreeI, if neceoeary.
Ae
an addiLional
check,ewiLchon the laLhe,placea pencilon NheIoot
resL,and ecribea circleon the endof the opinninqblank,as ehown.
Turn oft the Nool.Thecircleshouldbe centeredon Ihe endof the
blank;if not, adjuetthe tailslock and repeat,

70

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TWO CENTERING
IIGS
JIG
A FACEPLATE.CENTERING
ona workpiece
Centering
thefaceplate
yourlathe's
faceplate
ona cirTocenter
jig shown
usethehandy
cularworkpiece,
pieceof woodto
at right.Turna cylindrical
threaded
of thefaceplate's
thediameter
(Youmay
hole,tapering
theendslightly.
wishto forma handle
at thetopendof the
j i g . )D r i v ea n a i li n t ot h ec e n t eor f t h e
a ,n d
t a p e r eedn d ,c u t o f f t h e n a i l h e a d
grinda sharppoint.Tousethejig,mark
withan awl
thecenterof theworkpiece
(page132).Next,setthefaceplate
onthe
workoiece
withtheawlmarkin themidhole,insert
thejig in
dleof thethreaded
and"feel"forthemark
theholeasshown,
w i t ht h en a itl i p . H o l d i ntgh ej i g i n p l a c e ,
to theworkpiece.
screw
thefaceplate

A CENTER.FINDING
JIG

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shaped
workpiece
Attaching
thefaceplate
to anirregularly
youto centerthefaceplate
on
Thejig shown
above
wrllenable
pieces
Cut
of
Ya-inch
clear
irregularly
shaped
workpiece.
an
plastic
into12-inch-diameter
disks.
and%-inchplywood
acrylic
tapeanda screw.
Attachthetwotogether
withdouble-sided
to yourfaceplate
sotheplasticisfacingout,
Mounttheassembly
conto
cut
a
series
of eouallv
spaced,
thenusea skewchisel

lefl. Remove
theplastic
disk
centricringsintothedisk(above,
andspray
it withblackpaint.Oncethepainthasdried,peelthe
paper
Tousethejig,set
offbothsrdes
oftheplastic.
backing
iswithinoneof
it ontheworkpiece
soasmuchof it aspossible
righil.Use
the ringsandmarkthecenterwithan awl(above,
for mounting
thefaceplate.
themarkasa centerpoint

71

GOUGE-SHARPENING
IIG
thejig
1 Making
I Thejig shown
at leftguarantees
that
gouge
thetip of a turning
willcontact
the
grinder
wheelof yourbench
at thecorrect
angle
to restore
thebevelonthecutting
e d g eT, h ed i m e n s i o n
i nst h ei l l u s t r a t i o n
willaccommodate
mostgouges.
Cutthe
baseandtheguidefrom%-inchplywood;
screw
theguidetogether
andfastenit to
the basewithscrews
countersunk
f rom
underneath.
Makesuretheopening
createdbytheguideis large
enough
to allow
thearmto slidethrough
freely.
Cutthearm
from1-by-2stockandthetoolsupport
plywood.
from7z-inch
Screw
thetwoparts
of thetoolsupport
together,
thenfasten
thebottom
to thearm,flushwithoneend.
FortheV block,cut a smallwoodblock
to sizeandsawa 90'wedgeoutof one
side.Gluetheblockto thetoolsupport.

Tool aupport
(back)t/z'x 2" x 2 3/+"
(bottom) 1/2"x 1 1/2"x 2 3/+"

Guide
(top)1/2"x13/+"x9"
(eidee)1/2"x15/a"x9"

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r) Sharpening
a gouge
L Setthejig on a worksurface
sothearmlinesup directly
wheel.
under
thegrinding
Seatthegouge
handle
in theV block
andslidethearmsothebeveled
edgeof thegouge
restsflaton
t h eg r i n d i nwgh e e C
l . l a m tph ea r mi n p l a c eT. h e nw, i t ht h e

gouge
clearof thewheel,
switchonthegrinder
andreposition
the
toolin thejig.Holding
thegouge
withbothhands,
rotate
it from
sideto sidesothebeveled
edgerunsacross
thewheel(above).
periodically
Check
thecutting
edge
untilthe
isfullyformed.
bevel

72

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SPINDLE-TURNING
IIGS
A DIAMETER
GAUGE
ANDA LAYOUT
JIG

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Resemblinga tuning fork, the dismetergauge

shownabovecan be usedlike calipersto checkthe
diameter of turned workpieces.The jig is cut from
solidwood;thedistancebetweenthe armsshouldbe
slightly wider than the largestfinished diameter to
be turned. Two screwsdriven into the insideof the
anns can be adjustedto setprecisemeasuremenls.

lll llllfirlillrllllilltlllllll ilillllllllJlll llllllllllltlll llllltll

jHO? TI?

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'v:
identicalworkViecee,
adjuel,a eeNof caliperolo
e a c hf i n i s h e dd i a m e N eyro u n e e d .
t h i e w i l le l i m i n a t e
L h e n e e dt o r e a d jueLoneeeNrepeaNedly.
Uoeyour deoign
of the pieceae a quidelo sel the calipero
and a eNripof t ape lo identifythe adjuot,ment on eachone.A cheaperaltrernaLive
ie
t o m a k es e v e r adl i a m e l e rq a u q e al i k et h a T ,
ehownin the pholo above,

jig
Making
andusinga layout
forspindle
turning
T h el a y o uj ti g s h o w na b o v em a k e si t
easier
to turnmultiple
copies
of spindle
you
worksuchastablelegsbyallowing
to scribe
layout
linesin exactly
thesame
yourdesign
Trace
location
onevery
blank.
ona pieceof scrapaboutthesamelengh
asyourblanks
andwider
thantheirdiameter.Drive
a nailintotheedgeof thejig
a transitional
element
at eachoointwhere
of thedesign-such
asa beadorf illetbegins
andends.Snipoffthenailheads
points.
andgrindthenailsto sharp
Once
youhaveroughed
outa cylinder,
simply
press
thejig intothespinnrng
blank;
the
nailswillscore
thelayoutlines(above),

TURNING IIGS

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A TAITSTOCK
F(lRHOII()WED.OUT
W()RK

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r) Turning
hollowed-out
work
L Mounttheworkpiece
to a multi-purpose
chuckandsecure
thechuckto thelathe.
Turntheinside
of thework.Onceyou
areready
to turntheoutside,
insert
thetapered
endof thejig
intotheopening
in theworkand,holding
theauxiliary
tailstock
in place,
advance
themachine's
tailstock
untilit contacts
the
jigandholds
thejig andworksecurely.
Tighten
thetailstock
(above).
andfinishtheworkpiece
Making
thetailstock
1
I Tosupport
hollowed-out
workpieces
o nt h el a t h eu, s ea n a u x i l i a tray i l s t o c k
liketheoneshown
above,
Turned
from
h a r d w o otdh,i ss i m p l jei g s u p p o r t hs e
workpiece
at therimonly,androtates
preventalongwiththelathe's
tailstock,
i n gv i b r a t i oann db u r n i nogf t h ew o r k p i e c eT. o m a k et h ed e v i c ef ,i r s tt u r n
a c y l i n d ef r o ma b l a n ka b o u4t i n c h e s
i n l e n g t ht ,h e ns h a p teh ec o n ew i t ha
gouge
roughing
andusea skewchisel
to
smooth
theconeandseoarate
it from
thewaste(above).
Thesizeandtaperof
thetailstock
willvaryaccording
to the
sizeanddiameter
of theworkpiece;
a
cone3%inches
wideat thebasewitha
60"tapersuitsmostsmallwork.

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lllllltlltllutlllilltfiltlllt
5HO?TI?
?reoervin6
oquare oornere
Wheneoindle
lurnina
workpieceo th at, require
a eharpdivisionbeNween
lurnedand oquareoecNione,
euchas the
oquareVommel
at the
Lop of a chair leq,
wra?a lenqNh
of duct
or maekinq
lape around
the blankatthe lraneiNion
linebeforeturnin4trhecylinder.TheNaVewillhelpreduce
learoul and Vrovide
a visual
quideto whereyou shouldoNoVturninqlo preoeweyour oquarecornerg.

74

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COLUMNS
IIG FORFLUTING
theiig
1 Building
jigshown
at rightyou
I Withthebox-like
c a nr o u tf l u t e si n a c o l u m w
n h i l ei t i s
mounted
in thelathe,
Cuttheoartsof the
jig from%-inch
plywood,
forthetop,
except
w h i c hi s m a d ef r o m% - i n cchl e a ar c r y l i c .
R e f etro t h e i l l u s t r a t i of onrs u g g e s t e d
d i m e n s i o nt h
s ;ej i g s h o u l db e l o n ga n d
w i d ee n o u gtho s u p p o rt h
t er o u t ear n d
highenough
sothetopjustclears
thecolumnwhenthejig restsonthelathebed.
areassemOncethetop,bottom,
andsides
bled,addtwobraces
to makethelig more
r i g i d .I n s t a lal d o u b l e - b e a rpi ni lgo t e d
f l u t i n gb i t i n y o u r o u t e d
r ,r i l la b i tc l e a r anceholethrough
thejig top,andscrew
thetool'sbaseplateto thejig.Therouter
shoulb
d e p o s i t i o n seodt h eb i tw i l ll i e
n h e nt h ej i g i s
alongsid
t heec o l u m w
u s e dB
. es u r ea l l t o o l sa r eu n p l u g g e d
d u r i n sge t u p .

Dit clearancehole

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r) Preparing
thecolumn
andthelathe
Z- Toensure
thatthef lutesaresoaced
equally
around
thecolumn,
markcutting
linesforthef lutesontheblank-inthis
12 in all.Makecorresponding
example,
marks
reference
onthelathefaceolate
b yd i v i d i nigt sc i r c u m f e r e nocre3,6 0 ' ,
i n t ol 2 e q u asl e g m e nst sp a c e3d0 '
apart.
Markthelines
witha pencil
anda
(/eff).Setthejig onthe lathe
protractor
bed.mountthefaceolate
onthe lathe
sothatoneof the reference
marksis
position,
in the12 o'clock
andmount
thecolumn
soa cuttingmarkis at the
position,
3 o'clock
Tighten
a handscrew
around
the lathedriveshaftto prevent
it fromrotating
andclampstopblocks
to thelathebedto makesurethatall
fluteswillbethesamelensth.

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75

TURNING ITGS

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-) Flutine
thecolumn
<'

r - J A d j u s t h e r o u t e ' sc u t t i n gd e p t hs o t h e b r t i s
: l r o n p d r a r r l hl h o ? n ' e n r k n r r l l n o m
, ,: r- k, , .R-,-r r. t.l l.h, o, ,J r g
c
l
o
n
a p an q to n F
h l n c ki r t r no n l h e r o r r ' l e
a "n dn u s h
o n t h e s i d eo f t h e i i s t o f e e dt h e b i t i n t ot h e b l a n k ,
O n c et r r en i l n t sa r cf l r r q ia p a i n s- th es t o c ks. l i d et h e
j i g a l o n gt h e l a t h eb e du n t I i t c o n t a c ttsh e o t h e rs t o p
L ^- + ^ ^ r-..
h l o c kK
. e e nt h etns i. .l,o. - t srn. -r) cJ g-u- ^ ,o^6^o ^i l ;r^> l- +
l|c >luun d) it
(inset).
routseachflute
Turnoff the router,remove
thehandscrew
a n, d r o t a t et h e b l a n kb y h a n du n t r l
t h e n e x tr e f e r e n cmea ' ki s i n t i e l 2 o ' c l o c kp o s i t i o n
a n dt h e r e x tr ^ . r t' l rDn
l rpr" e'i s i n l h e3 o c l o c kn o s i ' i o n .
R e i n s t at lhl e h a n d s c r eawn dr e p e atth eo p e r a t i ot n
o
c u t t h e ' e n a l n r fg ' u l . e s( a b o v e ) .

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IIGSFORSANDINGAND CHECKINGDEPTH
Accuratelydeterminingdepth is
essentialtofnceplateturning:too
deepa cut can ruin a bowl.Made
from solid wood stock,the bowldepthgaugeshown at right featuresa pair of perpendicular
',4-inchdowels;the holes
for the
dowelsoverlapso that the longer
dowel can be adjustedand wedged
in place by the shorter, tapered
one.Marking depthincrementson
the long dowel will speedsetup.

A SANDING
DRUM
F()RTHELATHE

Making
andusing
a sanding
drum
u rl u m of thegroove.
T h ej i g s h o w a
n b o vw
e i l lt u r ny o u rl a t h ei n t oa p o w e r f d
Toholdthesandpaper
in place,
makea hards a n d e rS. t a r tb y r o u t i n a
g % - i n c h - w i d%e-,i n c h - d egerpo o v e woodstripto fit in thegroove
andscrewit in place(above,
alongthecenter
of onesideof a square
blankabout14 inches left).To usethesanding
drum,mountit between
the headi n l e n g t hM. o u ntth eb l a n ko nt h el a t h ea n dt u r ni t i n t oa c y l i n - stockandtailstock
of thelathe.Youcanthenusethedrum
der3%inchesin diameter.
Next,cuta sheetof sandpaper
to
to sandworkpieces
withcurved
contours,
suchasa cabriole
wraparound
thecylinder;
itsendsshould
overlap
at thebottom leg (above,right).

77

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'

fl

:*

irtk llui-t.
I ,lbi (4
'lu
$
r{

|.
{';

,li;i .<

!l_{i;
I t

Ttqi

f,tll

x-

H :

'\
?-8,

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::,li

: , ,l l
'

. l
l-

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.;'
i

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GLI.INGA]\ID
CIA4PINGIIGS
lampsand benchvisesareindispeniableto thewoodworker.Their
verysimplicitymakesthemversatile,but
the basicclampor visecanbe madeto
work betteror moreeasilvwith thehelo
of ajig. Theitemsshown'inthischaptei
will enableyou to getthe mostfrom the
clampsandvisesyoualreadyhave.Other
jigs providealternatives
to commercial
devicesthat maynot bethebesttool for
a specifictask.
Gluingboardsedgeto-edge
to assemblepanelsis a commonstepin furnituremaking.Thejigsshownstartingon page
8l providewaysof keepingyour clamping setupsflat, square,and stableasthe
adhesive
dries.Thewall-mountedglue
rack (page85) can saveconsiderable
shopspace,
whilethewedgedclamping
bar (page83)andthejig for edgegluing
thin stock (pageBa)will takethe place
of bar clamps.
For securingstockto your workbenchfor sandingor planing,makea
temporarybench stop (page90).To
fashiona handywood-carver's
vise,try
thejig on page93thatcombines
a standardpipeclampwith two woodblocks.
All thedevicesin thischapteraresimple
to build with only a fewmaterials.
The
dividendstheywill payarewell worth
the effort and expense.

A C(|TTECTION
OFGTUING
AND
CTAMPING
JIGS
Caroaae-aqua ri ng block
(pase 89)
Flaced on corner of carcase to keep it sauare
duringqlue-up

Miter clamping blocka (paqe 88)

Ueed with handacrewato clamp
mitered cornerg toqether; two
blockaat each corner are aecured
to atock with cord

Bench dog (page 92)

Hardwooddog alipo
into benchdoq holee;
anqledton7ueacte
aa a opringto hold
dog in place

Eench etop (page 9O)

For eecurinaatock
to a work aurtace
without.benchdo4
holea.Workpieceie
wed4ed betweentrianqular
piece and baae, whichia
clamped to table

Benah dog (page 91)

Cuatomizeddoqa with naile
in center of bevelledhead
for grippinqa curvedor
turned workpiece

Madefromjust afewpiecesof wood

andsomehardware,theframing
clampat left allowsyou to keepthe
cornersof a pictureframesquareand
tightlyclosedduringglue-up.

79

GLUING AND CLAMPING IIGS

Pipe clamp extender (pa6e 86)

ExLendethe clampinqcapaciLyof
ptpeclampe;jtq cleat huqa workpiece whileaemicircularnotch
accommodatesclamp iaw

Wall-mounted
glue raak (page O5)
For ed4eqluinqeLock.
Dar clampoait in notched
c rooepiecee:ba ck c roeepiece
ia anchoredto walletuda

Wood-aaruer'svise
(pase 93)
Two-parDvteefor holdtng carvrnqblanks;made
from wood blocksand
pipe clampe.Dof,tompipe
clampie mounted to
benchand Loppart ia
elippedtn place

Crosebar for edge

gluing (page 82)
Ueedwith bar or pipe
dampa f,o keepatock flat
durinqed6egluinq;panel
fita betweencrooabara,whrch
are securedwith wingnuLe
Glue rack (page 81)
9awhoraeawith notchedcroeaptecee
deeignedto hold bar clampaeteady
for edqeqluin7

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Wedqedclamping
bar (page 83)
9imtlar to edqe 7luin7
croaabar, excepLwed4eepreeaedqee
of boarde togeLher,taktnq the placeof clampe
Framing clamp (page O7)
Ueedwtth a handacrewLo
alue
uo frames wiLhmitered
-cornere:
modelahowncan
clamp framee up Lo 24
rncneoaquare

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Ji6 for clampingthin atoak
(paseO4)
Foredqegluingthin boarda;
wedqeeapply the clamp'
in6 0reogure

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EDGE-GLUING
IIGS
RACK
GLUE
theiig
1 Building
I A pairof racksmadefromtwosawhorses
liketheoneshown
at rightprovides
a convenient
wayto holdbarclamps
for
gluingupa panel.Remove
thecrosspiece
fromyoursawhorses
andcutreplacements
thesamewidthandthickness
astheorigi n a l sm
, a k i ntgh e ma t l e a sat sl o n ga s
t h eb o a r dyso uw i l lb ea s s e m b l i nCgu.t
notches
alongoneedgeof eachcrossp i e c ea t 6 - i n c hi n t e r v a lm
s ,a k i ntgh e m
wideenough
to holda barclampsnugly
anddeepenough
to holdthe barlevel
withthetopof thecrosspiece.
Youcan
alsocut notches
to accommodate
oioe
clamps,
butit is better
to usebarclamps
withthisjig sincetheywillnotrotate.

r) Gluing
upa panel
justenough
(above),
L Seatatleasttwobarclamps
in thenotches
sothattheboardstheclamps
to butttheboards
together
to begluedaresupported
every
24 to 36 inches.
Toavoidmar- thenplacea thirdclampacross
thetopof theboards,
centerringtheedges
of thepanelwhenyoutighten
theclamps,
use ingit between
theothers.
Finish
tightening
alltheclamps
until
twowoodpadsthatextend
thefull lengthof theboards.
Setthe therearenogapsbetween
theboards
anda thinbeadof adheboards
face-down
ontheclamps
andaligntheirends.Tighten sivesqueezes
fromthejoints.

81

GLUING AND CLAMPING IIGS

F(lREDGE
GTUING
CR()SSBARS
thecrossbars
1 Building
frombowing
during
I To keeppanels
pressure
glue-up
isapplied,
whenclamping
liketheoneshown
bolta oairof crossbars
Make
at leftbetween
eachpairof clamps.
wood
from
two
short
spaccrossbar
each
ersandtwostripsof 1-by-1hardwood
thanthe panstocka fewincheslonger
beslightwidth.
The
spacers
should
el's
bolts
diameter
of
the
lythicker
thanthe
place.
Glue
crossbars
in
usedto holdthe
the
ends
of
the
strips,
thespacers
between
to prewaxon thecrossbars
andspread
glue
from
adhering
to
them.
ventexcess

9pacer

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thecrossbars
O Installing
L Glueup the boards
asyouwouldon a rack(page81).fo
prevent
the barclampsfromtippingover,placetheendof
the barclamps
blockof wood.Before
eachonein a notched
centerin pairs,
install
thecrossbars
havebeenfullytightened,

in place.Insert
carriage
theclamps
already
ingthembetween
andwingnuts
slots,usingwashers
boltsthrough
thecrossbar
Then,tighten
the panel(above).
to tightenthejig snugagainst
completely.
thebarclamps

82

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GLUING AND CLAMPING TIGS

WEDGED
CTAMPING
BAR
B u i l d i ntgh el i g b o d y
1
I T h ew e d g e dc l a m p i n gb a rs h o w na t
l e f t i s a n e x c e l l e nat l t e r n a t i vt eo a b a r
c l a m pf o r e d g eg l u i n gb o a r d sb, e c a u s e
i t p r e v e n ttsh e s t o c kf r o m b o w i n gw h e n
p r e s s u r ies a p p l i e dC
. u tt h e t o p a n d b o t t o m f r o m% - i n c h - t h i cskt o c k ,m a k i n g
t h e m l o n g e trh a nt h e w i d e s tp a n e yl o u
w i l l g l u eu p . C u tt h e s p a c e rt .a i l b l o c k .
a n d w e d g e sf r o m s t o c kt h e s a m et h i c k n e s sa s t h e b o a r d tso b e g l u e d (. K e e p
setsof spacers,
tail blocks,andwedges
on handto accommodate
boardsof varyi n gt h i c k n e s sU
. )s ea m a c h i n e
b o l t ,w a s h e r ,a n dw i n gn u t a t e a c he n do f t h e j i g
t o s e c u r et h e t o p , b o t t o m a, n d s p a c e r s
together.Waxthe barsto preventadhes i v ef r o mb o n d i n tgo t h e m .

r ) P r e p a r i nt g
h ej i g f o r g l u e u p
y o u n e e dt o b o r eh o l e st h r o u g ht h e j i g t o a d j u s ti t f o r
l
. i n c ey o uw i l l b e d r i l l i n g
t h ew i d t ho f t h e p a n etlo b e g l u e d S
s t r a i g htth r o u g ht h e j i g , c l a m pa b a c k u pb o a r dt o y o u rd r i l l
p r e s st a b l ew i t h a f e n c ea l o n gt h e b a c ke d g et o e n s u r et h e
h o l e sa r ea l i g n e dI.n s t a l al b i t t h e s a m ed i a m e t ear s t h e
. u t tt h e j i g
m a c h i n eb o l ta n d p l a c et h e t a i l b l o c ki n p l a c e B
a g a i n st th ef e n c ea n dd r i l la h o l et h r o u g h
t h et o p ,t h e b o t t o m ,
a n dt h e t a i l b l o c k .B o r et h e r e m a i n i n hg o l e st h r o u g ht h e j i g
bodyat 7r/z-inchintervals(above),

gluingboards
Edge
S p r e a da d h e s i v oe n t h e e d g e so f y o u rs t o c ka n d s e tt h e
b o a r d sf a c e - d o wonn a w o r ks u r f a c eS. l i pa c l a m p i n gb a ro v e r
t h e b o a r d sa n d p o s i t i o ni t 6 t o 1 2 i n c h e sf r o mo n ee n do f t h e
assembly.
Butt the tail blockagainstthe far edgeof the boards,
u s i n g t h em a c h i n b
e o l t ,w a s h e ra,n dw i n gn u tt o f i x i t i n p l a c e .
To applyclampingpressure,
tap oneof the wedges
at the front
edgeof the panel(above)until thereare no gapsbetweenthe
b o a r d sa n da t h i n g l u eb e a ds q u e e z eosu t o f t h e j o i n t s .I n s t a l l
t h e b a r sa t 1 8 - t o 2 4 - i n c hi n t e r v a l s .

GLUING AND CLAMPING JIGS

THINST()CK
A JIGFORCLAMPING
gluing
thinstock
Edge
jig shown
you
at rightallows
Thebenchtop
pressure
for
clamping
to applythecorrect
edgegluingthinstock.Cutthebasefrom
pieces
andtheremaining
1-inchplywood
to theillustration
fromsolidstock.Refer
butbesurethe
dimensions,
forsuggested
to beglued
thantheboards
baseis longer
a n dt h es p a c eirs l o n ge n o u gtho b u t t
theentirefrontedgeof thepanel.
against
than
bethicker
stripsshould
Theedging
yourpanelstock.Screw
themalongthe
of the baseandfastentwowedges
edges
onestripwiththeirangled
f lushagainst
at right.Waxthetop
facingasshown
edges
faceof the baseto keepthe panelfrom
o i t . A p p l yg l u et o y o u rs t o c k
a d h e r i nt g
a n ds e tt h ep i e c eos n t h eb a s eb, u t t i n g
t h ef i r s tb o a r da g a i n st ht ee d g i n sgt r i p
Buttthe spacer
the wedges.
opposite
the lastboardandslidethetwo
against
andthe
thespacer
between
loosewedges
tightto
Tapthe wedges
fixedwedges.
(below).
pressure
applyclamping

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Edainaatrip
s7o';
* i '7r",'19 ttr"

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GLUING AND CLAMPING IIGS

t
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GLUERACK
A WALL.MOUNTED

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FronLpoeL

Notched
ctamP racK

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":'

.-.-/t-

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---'--

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B u i l d i ntgh er a c ka n dg l u i n gu p a p a n e l
T h el r g s h o w na b o v ea l l o w sy o ut o g l u eu p p a n e l su s i n gb a r
c l a m p sb, u t s a v e s h o ps p a c eb y b e i n gm o u n t e tdo a w a l l .F o r
c l a r i t yt,h e i l l u s t r a t i osnh o w so n l yo n ep a i ro f c l a m pr a c k sb, u t
y o uc a ni n s t a lal s m a n ya sy o ul i k ef r o mf l o o rt o c e i l i n ga t 1 2 - i n c h
s n ds a w
i n t e r v a l sC.u tt h e c l a m pr a c k sf r o mB - f o o t - l o n1g- b y - 4 a
notches
alongoneedgeof eachpieceasyouwouldfor a sawhorse
r a c k( p a g eB l ) . A t t a c ho n er a c ko f e a c hp a i r t ot h e w a l l ,d r i v i n g
two screwsintoeverywallstud;makesurethe notchesarepointi n gd o w n T
. o s u p p o rtth e f r o n tc l a m pr a c k ,c u t f l o o r - t o - c e i l i2n g
n n ed i r e c t l fya c i n ge a c hs t u da b o u t
b y - 4 sa s p o s t sa n d p o s i t i o o

8 to 10 inchesfromthe wall.Screwthe frontrackto theseposts,

p o s i t i o n i nt hge n o t c h efsa c e - u p
s o t h e yw i l l h o l dt h e c l a m p s
p
l
y
w o o ed n d p a n e l st o f i t a r o u n d
m
o
u
n
t
%
i
n
c
h
l e v e lN
. ext,
wo
j
i
g
.
N
o
t
c
h
b
o
t
t
o
m
e
n
d
o
f
t
h
e p a n e l st o f i t o v e rt h e s o l e
the
the
p l a t ea n df a s t e nt h e t o p t o t h e c e i l i n gD
. r i v es c r e wtsh r o u g ht h e
p
a
n
e
l
s
. o u s et h e
i
n
t
o
t
h
e
e
n
d
s
o
f t h e r a c k sT
s i d e so f t h e e n d
j i g t o g l u eu p a p a n e ls, l i d eb a rc l a m p st h r o u g h
t h e n o t c h e isn
, a k i n gs u r et h e e n d so f t h e c l a m p s
t h e f r o n ta n d b a c kr a c k sm
rack(rnset).
Therestof the
extendbeyondthe stud-mounted
g
l
u
i
n
g
w
i
t
h
a
n
y
o
t h e rc l a m pr a c k .
l edge
o p e r a t i oins i d e n t i c at o

FRAME-CLAMPING
JIGS
A PIPECLAMPEXTENDER

Gluing
upa largeframe
T h ej i g s h o w na b o v e
w i l le x t e n tdh e
c a p a c i toyf y o u rp i p ec l a m p sC. u tt h e
mainbodyof theextender
from1-by-6
Saw
stockandthecleatfroma 2-by-2.
a D-shaped
cutoutnearoneendof the
bodyto accommodate
thepipeclamptail
stop,thenscrew
thecleatto theopposite
pressure
Toapplyclamping
end(inset).
o n t h et o pa n db o t t o mr a i l so f a l o n g
frameliketheonein theillustration,
set
thecleatagainst
oneendof theworkp i e c ea n df i t t h ep i p ec l a m pt a i ls t o p
intothecutout.
Thentighten
theclamp
j adwi s p r e s s i n g
s ot h a tt h e h a n d l e - e n
against
theopposite
endof theworkpiece(above).
Usewoodpadsto protect
theworkpieces.

ti,.ultlilliltiilltllllrfilr]lltlllllljtlllriljlillrllilIfllll] iili
1HO?TI?
Ooubling
up
pipeclampo
Anotherway
lo exlendlhe
capaci|yof
1norter ?t?e

\.'.,r"
.

-,4;r=

u s e l h e mi n
naira

l n lt tnr -

lion as a oinqle

lonqone,)et,upLhe
(herefour
workViece
boardsto be edqeqlued)ae
you wouldon a 4luerack (pa4e
B1).Tofashiona lonqclamV,?oeition
lwo ehofLerclampeacroasNheworkjawe reet,aqainet.oVVoeile
pieceeo NhaNthe handle-end
Aeyou
edgeeandNhetaileNoVe
ofNheclamVooverlap.
Liqhhen
oneof the clampe,iNwillpullthe joinXeNoqebher.

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GLUING AND CLAMPING TIGS

CLAMP
A FRAMING

Corner block
3./+"x21/2"x21/2"

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Center block
3,/+"x21/2"x6"

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Corner block

Arm

3/+"x21/z"x19"

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87

picture
frame
Clamping
a mitered
witha handscrew,
theselfIn conjunction
a l i g n i njgi g a t l e f ti s i d e aflo rg l u i n gu p
Thedimenframes
withmitered
corners.
sions uggeste
i ndt h ei l l u s t r a t i w
o ni l l
frames
measuring
upIo 24
accommodate
inches
ona side.Cutthearmsandcenter
from1-by-3
stockandthecorner
blocks
plywood.
Drilla series
blocks
from3/q-inch
of holesdownthemiddleof thearmsfor
machine
bolts;begin
%-inch-diameter
1 inchfromoneendandsoace
theholes
a t 1 - i n c hi n t e r v a lcso, u n t e r b o r it nh ge
Also
to house
the boltheads.
underside
blocks
1 inch
drillholes
through
thecenter
thecorner
fromeachend.To DreDare
blocks,
drilltwoholesthrough
eachone:
thefirstfora machine
boltabout1 inch
holeabout
fromoneend,anda smaller
1% inches
in fromthesameend.Finish
bycuttinga 90'wedgeoutof theopposite
theapexof theangleat the
end,locating
holedrilled(inset).
center
of thesecond
jig
onecenter
Assemble
the bysecuring
washblockto eachpairof armswithbolts,
thenutsloose
ers,andwingnuts;leave
e n o u gtho a l l o wt h ea r m st o p i v o tT. o
clampa frame,
setthejig on a worksurface.Fasten
thecornerblocks
to thearms
areabout%inch
sothatthecenterblocks
withinthe
apartwhentheframeliessnugly
j i g . U s ea h a n d s c r et owp u l lt h ec e n t e r
theclampuntil
blocks
together,
tightening
jointsareclosed(/eft,below),
allthecorner

GLUING AND CLAMPING IIGS

MITER
CLAMPING
BL()CKS

Gluing
upa mitered
frame
Clampmitered
corners
usinghandscrews
a n dt h es p e c i abl l o c k s h o w na b o v e .
Youwillneedoneclampandtwoblocks
f o r e a c hc o r n e rC. u tt h e b l o c k fsr o m
stockthesamethickness
asyourworkpiece.
Referring
to theillustration
above,
shape
oneedgesothereis a 45" bearing
surface
forthehandscrew
nearoneend,
anda smallV-shaped
notchneartheothe r .T os l r e u n A c o r n e tr i et h eb l o c k s
s n r r p lt vo t h e e d p c sn f i h e f r a m ew i t h
c o r d ,s e c u r i ntgh e l o o s e n di n t h e n o t c h .
S e t t h e j a w so f t h e h a n d s c r e w
against
the 45" anglesandtightenthem (above)
u n t i lt h e r ea r en o g a p si n t h e j o i n ta n d
a t h i n b e a do f g l u es q u e e z eosu t o f i t .
T o k e e pt h e j o i n ts q u a r et.i g h t e ne a c h
h a n d s c r eawl i t t l ea t a t i m e ,c h e c k i n g
t h e c o r n ew
r i t ha s q u a r e .

lli llrllntultllllllltfiljlltJ
ljllllljlltuittllllll]ljllillJllllllt
1HO? Tl7

ii.
-i
A rope clamp for aarving
I
Carvinqoften requireefre- I I ] .....
quentrepooitioninqofthe I j
I
workpiece,
whichcan be
l,l
l
Lime-consumin7when . jl,
ueinqholddowns,clampe, \*r
and benchdoqe.VakeLhe
taek of eecurinq
carvinqeLock
moreconvenient
by ueinqa eimple
ropeclamplikeLheoneehownhere.1orelour holesthrouqh
Ihe middleof a lowcarvinqbench,Thencut a lenqthof rope
or lealher,looVit throuqhNheholeeand tie Nheendst ogether,
Theropeehouldbe lonqenouqheo Lhat the boLLom
endof
Ihe loopie no moreIhan 12 incheefrom lhe floor.Slipyour
workpiece
underlhe loopoon the tabletopand eNeV
on the
botrtomlooVNoholdIhe oLockfirmly in place.

88

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CARCASE-CLAMPING
JIGS
BLOCK
A CARCASE.SSUARING
Carcaae-squaring block

square
Keeping
a carcase
square
It canbedifficult
to keepthefoursidesof a carcase
l. carcased u r i n g l u e - uoprw h i l ei n s t a l l i nagb a c kp a n e A
willsolve
theproblem.
blockplaced
oneachcorner
squaring
of %-inchplywood.
Eachblockconsists
of an 8-inchsquare
gluesqueeze-out
frombonding
theblockto the
To prevent
holein thecenterof each
borea 2-inch-diameter
carcase,
blockwitha holesawor circlecutter.Next,installa dado

headonyourtablesaw,adjustit to thesamewidthasthe
at right
stock,andcut twogrooves
thickness
of thecarcase
intersecting
at thecenterof the block
angles
to oneanother,
(above,
thecarlefil.f o usethejig,applyglueandassemble
right),centercase,thenfit a blockovereachcorner(above,
join.Install
and
ingtheholeat thepointwhere
thetwopanels
theclamps.
tighten

TW()WEBCLAMPS

Cardboard

re
K
Wood
block

upsmallcarcases
Gluing
. s eC c l a m ptso p u l l t h e
or C t h ec o r n e rwsi t hc a r d b o a pr da d sU
outof rooeanda handscrew
Youcanmakewebclamos
lefil.A
each
other
and
clamp
thejoints(above,
two
lengths
of
blocks
toward
and
clamps.
0nedeviceusestwowoodblocks
perimeter
Wrapa
method
employs
a
single
handscrew.
second
clamping
areslightly
shorter
thanthe
ropethat,whenknotted,
your
rope
the
carcase
and
feed
the
ends
through
the
near
the
length
of
around
Boretwoholesthrough
eachblock
of
carcase.
pressing
handscrew
the
rope
against
knot
clamp.
With
the
tip
of
the
a holerneachblockand
ends,threadoneropethrough
tightenthebackscrewto pinchtheropebetween
withtheotherrope,adjusting thecarcase,
itsendsagainst
theblock.Repeat
parallel
the
back
end
of thejaws,thenclosethefrontendof thejaws
whensetonthecarthelengthsothattheblocksare
(above,
pressure
protecting
right).
clamping
thecarcase,
to apply
case.Wraptheropesandblocksaround

89

WORKBENCH
CLAMPINGIIGS
Youcan increasethe reachof a
C clampwhenyou needto apply
clampingpressure
awayfrom the
edges
of a worksurfaceby usinga
strip of woodasa clampextension.
Tosecuretheframeshownat right,
thestrip extendsacrosstheframe
and clampingpressure
is applied
overtheinteriorof theframe,
securingbothsidesat once.

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A BENCH
STOP

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Securing
a workpiece
to a worksurface
Youcanusea clamped-on
plywood
benchstopcutfrom%-inch
to secure
stockto a worksurface.
Cutthe
bench
stopto size,thenmarkouta triangular
wedge,
typically
3 inches
shorter
thanthestop.Sawoutthe
wedge
andsetit aside.
Tousethebench
stop,clampit to theworksurface
andslidetheworkpiece
intothe
notch,butting
onesideagainst
thestraight
edgeof thenotch.
Thentapthewedge
tightlyin place(above).

90

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GLUING AND CLAMPING IIGS

BENCH
DOGS

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Makingandsettingup carvingdogs
U s i n ga s t a n d a r b
d e n c hd o ga s a m o d e l ,
youcanfashiona pairof customized
dogs
t h a t w i l l g r i pa c a r v e do r t u r n e dw o r k piece,or secureirregular-sized
work,such
a s m i t e r e dm o l d i n gT. o m a k et h e s e
accessories,
cut bevelson eithersideof
t h e h e a do f a s t a n d a r d
b e n c hd o ga n d
d r i v ea s m a l ls c r e wo r n a i l i n t ot h e c e n t e r o f t h e h e a d ;s n i po f f t h e f a s t e n e r ' s
h e a dt o f o r ma s h a r oo o i n t .T o u s et h e
d e v i c e sp, l a c eo n ed o gi n a d o gh o l eo f
the bench'sfixeddogblockandthe other
i n t h et a i lv i s eo r a s l i d i n gd o gb l o c kh o l e
( a b o v e )T. i g h t e nt h e v i s es c r e wu n t i l
t h e p o i n t sc o n t a ct h e e n d so f t h e w o r k p i e c ea n d h o l di t s e c u r e l y .

lllJllttlltfil1
lllllllllllll|llllflilllllltr]lrfiIlllllilltliltIIIilil
?HO?Tt?
Carvinqgcrewo
A Vairof han4er
boltecanenableyou
Nogecurean ircequ'
lar-ehaVed
workViece,
suchas a carvinq
block,toyourbench.
ThebolNsfeature
woodecrewNhreade
on oneenaana
machine
screw
lhreadeon
the oLher.
fo securea
workpiece,
boreNwoholee
Nhrough
lhe bench-lopfor Nhebolte.ScrewNhebolls inLoIhe
carvinqblockfrom underneaNh
Nhetop and holdLheboltsto
the undereide
of the loV wilh washereand winqnuLe.

9I

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GLUINGAND CLAMPINGTIGS

A SUBSTITUTE
BENCH
VISE

Makinga benchdogwitha wooden

tongue
B e n c hd o g sc a n b e c r a f t e df r o m h a r d w o o ds t o c k ;t h e o n es h o w na b o v eu s e s
t o n g u ea s a s p r i n g
a n a n g l e dw o o d e n
t h a t p r e s s easg a i n stth e w a l lo f t h e d o g
h o l et o k e e nt h e d o s i n o o s i t i o nC. u tt h e
d o gt o f i t t h e h o l e si n y o u rw o r k b e n c h ,
t h e nc h i s eol u t a n o t c hf r o mt h e m i d d l e
o f t h e d o g .S a wa s h o r tk e r fi n t h e l o w e r
c o r n e or f t h e n o t c h a
, ngling
t h ec u t s o
t h ee d g e
t h e t o n g u ew i l l e x t e n db e y o n d
. u tt h e t o n g u ef r o mh a r d o f t h e n o t c hC
w o o d .m a k i n gi t a b o u ta s l o n ga s t h e
notcha
, s w i d ea s t h e d o g ,a n da st h i c k
a s t h e k e r f .G l u et h e t o n g u ei n t h e k e r f .

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If yow' workbenchtloestrct lnve a bettchvise,yott cnrt itrtprovises substituteusirtgreodilyovnilableshoprrcccs-soric-s.

nrrartgedns showrrnbovewill holtl
Two largehartrlscrews
of the work sttr.face.
n board upright at tlte corrrer-

ffi.jjil,llillldl,l]ljlllillllild,li iilii i l $ r " * r u * r i i

1HO?Tt?

Grippingthinstoak
on
Securinga Ihin workpiece
ed,qercuallyrequires
v i s eo r b e n c hd o q s .
lowever.you
can <
\--

faelton abench

i;-'''
II
I
]r
i
{-t

-a
' "l
a L o Vl i k eL h e o n e \ - - --ii:
shown on ?aqe 90 No
a c c o n V l i e iihh e t a s k . l n
",,ti.Lhis case, make Nheetop fr,om
r'
,
_- ' -ft'ji"
L h i c k e re t o c k - a b o u N 2 i n c h e sN h i c k
-Lo qet a bef,Leq
r r i Vo n r h e w o r V p i e c e
a n d l o c a t r et h e w e d q ec l o s e rt o L h e m i d d l e
o f N h ee l o p . C l a m pI h e 1 i qr , o I h e b e n c h t o p ,

92

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rl
ir)
i"l
il

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GLUING AND CLAMPING TIGS

VISE
A WO()D-CARVER'S
M a k i n gt h ej i g
1
I T o h o l dc a r v i n sb l a n k sa n dc u r v e d
, s ea n
w o r k p i e c east v i r t u a t tayn ya n g l e u
viselikethe oneshownat right.
adjustable
A t t a c h e dt o t h e e n d o f y o u rw o r k b e n c h ,
t h e j i g c o n s i s tos f t w o p i p e - c l a mhpe a d s ,
t w o l e n g t h so f p i p e ,a n d t w o p i v o t i n g
b l o c k sT
. h e u p p e rb l o c kg r i p st h e w o r k
, i l et h e l o w e r
a n ds w i v e l sh o r i z o n t a l lwy h
b l o c kh o l d st h e u p p e rb l o c ki n p l a c ea n d
r o t a t e vs e r t i c a l layr o u n dt h e p i p e .F a s h i o n
t h e t w o b l o c k sf r o m l a m i n a t e hd a r d w o o d
s t o c k ,r e f e r r i ntgo t h e i l l u s t r a t i ofno r s u g g e s t e dd i m e n s i o n sB.o r ea 1 - i n c h - d i a m e t e r h o l ei n t h e u p p e rb l o c k ' su n d e r s i d e
a n dg l u ei n a 2 - i n c h - l o ndgo w e lr,e i n f o r c e d
w i t h a w o o ds c r e w B
. o r ea m a t c h i n gh o l e
t h r o u g ht h e l o w e rb l o c ka n d c u t a k e r f
t h r o u g ht h e b l o c k ' sr o u n d e de d g et o t h e
hole.Next,borea holeintothe end of your
w o r k b e n cnhe a ro n ec o r n e rl,a r g ee n o u g h
t o a c c o m m o d aal e1 2 - t o 1 4 - i n c hl e n g t h
h o l et h r o u g h
the
o f p i p e .D r i l la m a t c h i n g
p
o
s
i
t
i
o
n
i
n
g
i
t
n
e
a
r
r
o
u
ndl o w e rb l o c k ,
the
F
i
n
a
l
l
y
,
a
h
o
le
e d e d g eo f t h e b l o c k .
bore
p
i
p
e
forthe
t h r o u g ht h e u p p e rb l o c k .

Upperblock
3"x3"x3%"

Lowerblock
3"x3"x4"

r) Securing
a workpiece
pipewitha pipe-clamp
headat oneendthrough
L lnsert-the
12-to l4-inch-long
pinblockandintothebench.
Fixthepipein placewitha locking
thebottom
a smallmachine
boltor large
woodscrew.
Fittheupperblockrntothelower
one
pipe-clamp
headto secure
theupperblock.Next,insert
a
andtighten
thelower
longer
length
witha pipe-clamp
headat oneendandholesdrilled
of pipe-also
pin-through
4 inches
fora locking
theholein theupperblock.Place
the
every
headasshown
below,
workpiece
against
theupperblockandthepipe-clamp's
pin,andtighten
fixthepipewiththelocking
thehead.
Toreposition
theworkpiece,
loosen
clamphead,pivotthetwoblocks,
andtrghten
thehead.
thelower

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93

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SATDINGIIGS
anding is one of woodworking's
most tedioustasks.but thereare
tools and techniquesto makethe job
easierandimproveyour results.Theuse
of a simplejig will help improvethe
speedandefficiencyof mostoperations,
and maketricky taskseasierto accomplish.Several
areshownhereandon the
loilowingpages.
A custom-made
sanding block (page100),for example,allows
you to smoothcontoursthatwouldotherwisebe difficult to reach.For sanding
the edgeof circularworkpieces,
a circlesandingjig (page96)is designed
to hold
a belt sanderon its sidewhile you feed
the stockacrossthe belt.Also usefulis
a jig for surfacingthin stock (page99)
on the radialarm saw.
For everyday
sandingtasks,usethe
auxiliarysandingtableshownon page
98 or the sandingblockon page100.
Thelatterdevice,alsoshownin thephoto at left, offersa simplewayof holding
a pieceof sandpaper
in placeagainst
a flat surface.
To savetime andsandoaper,considerthe tipson gangsanding
andfoldingsandpaper
shownon pages
96and101.

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Fittedwith 220-gritsandpaper,
a
shop-made
sandingblockis usedto
smooththesurfaceof therail joining
two tablelegs.A felt or corkpad can
begluedto thebottomfaceof theblock
toprovideevensandingpressure.

Auxiliary aanding table

(pase 9B)
Secured to drill preaa table for
aandinq oper atib ne; feat uree
clearanceholefor aandinadrum

Contoured aandin7 bloak

(pasetoo)
Cuetom-profiledaandin4 ourface for smoothinq moldin4a

Radial-arm-saw sanding
jiq (pase 99)
For eandtnqthin atock on
the radial arm saw;clearance holeaizedto accommodate aandinadrum

Circle-eandingjig (page 96)

Holda belt eander etationary
on ite aide for aandina the
edqe of circular atock

AND EDGE-SANDING
IIGSFORFACE,Youcan savetime nnd lchieve
uniform resultsby sntoothing
severalworkpiecestogether,a
"gang
techniqueknown as
sanding."If theyare thesame
width, the boardscan lte secured to a work surfacefaceto-faceand edge-up,and
sandedas though they were
a singleworkpiece.

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A CIRCLE-SANDING
JIG

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thejig
1 Building
youto
I Thejig shownat rightallows
workpiece
the
edges
of
a
circular
smooth
Thedimensions
of the
witha beltsander.
jigwilldepend
your
size
of
sander.
onthe
Makethebaseandtablewith%-inchplypoststo
woodandaddsolidwoodsupport
fit in thehandles
of thesander.
Setthetool
on itssideonthetableandsliptheposts
in place,
thenscrew
themto thetableand
Cutthepivot
screw
thetableto thebase.
from1-by-2stock,
barandsupport
boards
longer
making
theboards
thanthediameter
of yourworkpiece
andthebarlonger
than
theboards.
Screw
thesupport
boards
to the
near
basesotheywillsupport
theworkpiece
itsedge.Next,drivea screw
through
the
it to the
middleof theoivotbarandfasten
Fliptheassemunderside
of theworkpiece.
blyoverandscrewoneendof thepivotbar
to thebasemidway
between
thesupport
boards,
leaving
thescrewlooseenough
to
allowyouto pivotthebar'sotherend.

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96

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SANDING IIGS

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Sanding
a circular
workpiece
Clampthejig baseto a worksurface
andsetthesander
in placeonthetable,
fittingthetool'shandles
overthesupport
posts.
Turnonthesander
and,if necessary,
adjustthetool'stracking
mechanismto movethebeltdownto thejig
table.Lockthe On/offtriggerin theon
andmovethefreeendof the
oosition
pivotbartoward
thesander
untilthe
workpiece
edgetouches
thebelt.Clamp
thefreeendof thebarto thebase,
then
rotatethepieceagainst
thedirection
of
(above)
beltrotation
untiltheedgeis
smooth.
Keeptheworkpiece
in motion
t rm
a n dp e r i o d i c a sl lhy i f tt h e p i v o a
toward
thesander
to maintain
Dressure
against
thesanding
belt.

illlfilllltl{tIlll'IIl
tllllIlfllltlllltlllilllillltllltlllilltllll
9HO7Tt?
Drillpreseaanaingdruma
lf you needa epecialoff-sizeoandinq
drum for your drill ?rees,you can
makeyour ownfrom a dowel.Find
Ihe riqhl sizedowel,lhencut a
elrip of oandpaperae lonqae iNe
circumference.
Applya Nhincoa|
of qlueto the woodand faelen lhe
?a?erIo ft (ri7ht, top). For a flexible
eanderIhal can smooth irce4ularly
ehapedworkViecee
or enlarqeholee,
cut a elot in a doweland eliVa etrip
of abraeiveVaperinlo it (ri6hifr,bottom).

97

AUXILIARYSANDINGTABLES
TABLEFORTHEDRILLPRESS
A SANDING
Holefor aandinqdrum
3'/a"dtameter

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Jiq baoe
1%"x1%"x11"
' / o x" 2 % " x 1 1 "

thejig
1 Making
aretoolarge
I Sanding
drumslarger
than%inchin diameter
Tomakefull
tables.
to fit through
theholein mostdrillpress
builda tablelikethe
surface
of larger
drums,
useof thesanding
Usea copingsaw,a sabersaw,or anelectric
oneshownabove.

top,cendrillfittedwitha holesawto cuta holein theplywood

3 inches
fromthebackof thetable.Screw
tering
theopening
together
from1-by-3and2-by-2stock
the L-shaped
basepieces
(above,
right),thengluethemto thetable.

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r) Sanding
curved
stock
Z Clu^pthejig baseto thedrillpress
underneath
the
tablewiththeholedirectly
drumA
. d j u stth et a b l eh e i g htto b r i n g
level
the bottomof thesanding
sleeve
f irmly,
withthejig.Holding
theworkpiece
feedit at a uniform
speedin a direction
therotation
of thesanding
drum
opposite
(right).
Toavoidburning
or gouging
the
workpiece,
feedit witha smooth,
continAssegments
of thesanding
uousmotion.
rarse
table
sleeve
wearout,
thedrillpress
to brinsa freshsurface
to bear.

98

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SANDING IIGS

A RADIAL-ARM-SAW
TABLE
SANDING
thetable
1l Buildins
jig shown
I Thesimple
at rightwillenableyouto sandthinstockonyourradial
armsaw.Cutthetableandfencefrom
l - i n c hp l y w o o d
s i,z i n g
t h e p i e c etso f i t
yoursaw.Cuta slotoutof oneedgeofthe
tablelargeenough
to accommodate
the
sanding
drumyouwilluseandallowyou
to shiftthedrumforward
andbackfordifferentsizedstock.Routa %-inch-wide
groove
alongthelength
of thefence,leaving% inchof stockbelowthechannel
to
fenceslot.Insert
slipintothesawtable's
t h e s l o t t e de d g eo f t h et a b l ei n t ot h e
groove
in thefenceandscrewthetwo
nipcps

ioopihpr

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r') Smoothing
thinstock
I lnstalla sanding
drumin yoursawfollowing
themanufacinstructions.
turer's
Slipthejig fencebetween
thefrontand
reartablesof thesaw,positioning
theopening
in thebasedirectly below
thedrum,thentighten
thetableclamps
to secure
the
jig in place.
Lower
thedrumsoit isjustbelow
thetopof thejig
table;position
thedrumsothedistance
between
it andthejig
fenceis slightly
lessthanthethickness
of thestockyouwillbe

sanding.
Turnonthesawandfeedthestockslowly
andcontinuously
fromleftto right-against
therotation
of thedrum
-betweenthefenceandsanding
(Clamping
drum(above).
jig
press
a featherboard
to the tableto
thestockagainst
the
gouging.)
fencecanalsohelpprevent
Foreachsuccessive
pass,reduce
thegapbetween
thefenceandsanding
drum
bynomorethanXeinch.

99

HAND-SANDING
IIGS
BLOCK
A C()NTOURED
SANDING

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Making
theblock
youcan Laya single
of plastic
wrapovertheboxand,whilethe
thickness
I Forsmoothing
thecontours
of a pieceof molding,
sample
inloiI (above,
left)
themolding
of themolding
to shape
a sanding
blockthat filleris stillsoft,press
usea shortsample
Letthefillerharden,
thenremove
Fashioningandclampit firmlyin place.
withthesurface
of theworkpiece.
matesperfectly
rubber
to makea
t h em o l d i nsga m p lfer o mt h eb o xa n dt h en a i l sf r o mt h ee n d s .
autobodyfillerormodeling
theblockrequires
a pieceof sandpaper
Startbynailing
together
a smallboxslightly Nowsawoff bothendsof thebox.Stretch
moldof theprofile.
upacross
themolded
sideof thebox.Usethemoldmolding
andat least%inchdeeper
than abrasive-side
larger
thanthesample
partof themolding.
filler,then
to press
thepaperagainst
thehardened
Prepare
thefillerfollowing
the ingsample
thethickest
right).
theendsto thesidesof thebox(above,
manufacturer's
instructions
andf ill abouthalftheboxwithit. staple

ljllilIl
tlllllflllltfilItllJ
llllilllilllllltilllill]firlillrllllllrllll1
1HO?TI?
5andingbloak
CUNa woodblockLhatyou
can qrip comforLably.
0n ile
Nooface. saw Nwonarrow
grborruand cultwo wedgeehaVedwoodeNriVeto fit in the qapo
enuqly.ToVrovideevenoanding?reosure,
you can qluea felLor cork ?ad to Ihe bo|tom,
aroundtheblock,
WraVa Vieceof oandpaper
then t ap in
ineerllhe endsinto the qroovee,
Nhewed7eoto holdlhe VaVerin place.

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rlllilltill fitllll]Illllilllllllllilllllllilllllllllllilllllllllllllll
1HO?Tt?
Foldinqaandpaper
Toqetthe moetlrom a sheet,of oandpaper,
of rhe abrasiveeurtace
ueeonlyone-quarNer
al a lime. FoldNheVieceinto quariere,lear
the sheethalfwayalonqonefold line,and then
fold it inboa four-Vlyoandinqpad eo LhaN
no lwo of the abrasivesurfacesare in con'
tacL.Whenthe first surlaceweareouN,
refoldNheeheet,Noex?o6e

anunueed
Vly.

,/

:T

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101

r) Smoothing
themolding
I Clamp
theworkpiece
to a table,
thestock.
usinga woodpadto protect
Slidetheblockbackandforthalons
(above).
themolding

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TOOLEXTENSIONS
ATDTABLES
hejigsin thischapterwill allow
power
portable
youto transform
toolsinto smallstationarymachines
on your
and handlelargeworkpieces
stationarypowertoolsmoreeasily.The
standshownon page105,for example,
convertsa platejoinerinto a stationary
cutter,a moreconvenient
biscuit-slot
The router
setupfor someoperations.
for some
tableon page106is essential
fenceand
cuts.Featuringan adjustable
a storagecompartment,it allowsyou
to setup your routerasa mini-shaper.
In a smallshop,a removablerouter
tablecan be attachedto a tablesaw
(page107).Thethree-in-one
tool table
shownon page108can convertyour
router.sabersawandelectricdrill into
stationarytools.
Extensiontablesand roller stands
greatlyexpandtheversatilityof toolslike
Seepages
band sawsand drill presses.
I 10 and I I I for jigs that enhancethe
capacityofthesetoolsto handlelarge
feaAll theaccessories
workpieces
safely.
tured in this chaptercanbe custommadeto suityour needs,at a fractionof
versions.
thecostof commercial

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Secured
to a bandsawtable,theplytableat left morethan
woodextension
doublestheoriginal table'ssurface
area,allowingbetter
controlovera
cut-especiallywith longstock.

103

TOOL EXTENSIONSAND TABLES

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Drill presa extension
table (paqe 111)
Attached to drill preea
to extend oriqinaltable

t
Removablepower
tool table (paqe lOB)
Holds router, aaber saw,
or electric drill upaide-down
for atatonary work;attached
Lo workbenchwtth winqnuta for
eaayinetallationand removal

Vise extension
atand (page 112)
suPPorcaffee
end of lon4
board clamped
in workbench
ahouldervise

Adjuatable roller etand

(pase 113)
1et juat belowaaw table levelon
the outfeed aide to aupporL lonq
or wideworkpieceo
aa they are cut

q*..,;

Eand aaw exteneion

table (page 11O)
Fastened to band
aawtable Lo increaae
aurfacearea

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Barreleupport(top)
1%"x3'tr"x6"

Auxiliarytable
7" x 12"

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Darrel oupport
(bof,tom)
1%"x5%"x6"

Handleeuppor,
3'/r" x 12"

thejig
1 Building
above
willreduce
the
theligshown
I Paired
witha platejoiner,
in a series
of workto cutslotsforbiscuits
setuptimeneeded
plywood,
pieces.
forthebarrel
except
Buildthejigfrom%-inch
for
Refer
to theillustration
whichshould
besolidwood.
support,
support
to thebaseand
dimensions.
Screw
thehandle
suggested
themto fit yourtool.With
brackets,
spacing
attachthehandle
butt
onthehandle
support,
upside-down
theplatejoinerresting
andoutlineits
against
themotorhousing
thebarrelsupport

shape
onthestock.Borea holeforthebarrelandcutthesupportin twoacross
of thehole.Screw
itswidth,through
thecenter
thebottompartto thebaseandfit theotherhalfontop.Boreholes
then
boltsthrough
thetoponeachsideof theopening,
forhanger
Usewingnutsto
of thesupport.
drivetheboltsintothebottom
screwtheauxiliary
tableto
together.
Finally,
holdthetwohalves
to drillholes
f ixed-angle
fence.(lt maybenecessary
thejoiner's
in thefenceforthescrews.)

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r) cuttingtheslots
4 Secure
theplateloinerin thestand
andclampthejig baseto a worksurface.
height
and,
Setthefenceat thecorrect
forrepeat
cuts,clampstopblocks
to the
in
tableto center
theworkpiece
auxiliary
frontof thecutter.Foreachcut,putthe
f latonthetableandbutted
workpiece
faceplate,
thenturn
against
thejoiner's
onthetoolandpushthestockandthe
tableintotheblade//eft)

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105

TABLES
FORPOWERTOOLS
A ROUTER
TABLVCABINET
thetable
1 Assembling
I B u i l te n t i r e fl yr o m% - i n c hp l y w o o d ,
youto use
thetableshown
at leftallows
yourrouter
asa stationary
tool-a requirementof manyoperations.
lt features
a
largetopwitha slotfor a mitergauge,
anadjustable
fence,
a storage
shelf,and
cuoboards.
Startwiththe basicstructureof thetable,sizing
thebottom,
sides,
back,
shelf,
dividers,
anddoors
to suityour
needs.
Fixthesepartstogether,
usingthe
joinery
method
of yourchoice.
Thetable
jointsand
shownisassembled
withbiscuit
screws.
Borea holethrough
thebackpanel
power
to accommodate
theswitch's
cord.
pieces
plywood
Forthetop,cuttwo
of
and
useglueandscrews
to fastenthemtogether;thepieces
shouldbe largeenough
to
overhang
thesidesof thecabinet
by2 or
3 inches.
Fixthetooto thecabinet.
Finally,fastena combination
switch-receptacleto oneof thedividers,
witha power
cordlongenough
to reacha nearby
outlet.Whenyouusethetable,plugin the
routerandleaveits motoron.Usethe
table'sswitchto turnthetoolonandoff.

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r) Preparing
thetabletop
I me routeris attached
to thetoowith
a square
sub-base
of %-inchthick
clear
acrylic.
Several
stepsarenecessary
to fit
thesub-base
to thetopandthento the
router.
First,position
thesub-base
at the
center
of thetopandoutlineitsedges
with
a pencil.
Markthecenter
of thesub-base
anddrilla pilotholethrough
theacrylic
and
thetop.Remove
thesub-base
androutout
recess
withintheoutline
a %-inch-deep
(right).
Usea chiselto pareto thelineand
Then,usingthepilot
square
thecorners.
holeasa center,
cut a holethrough
the
yourrouter's
topto accommodate
base
plate.Next,usea straightedge
guideto
helpyouroutthemiterslotacross
thetop:
Clamp
theguidesquare
to thefrontedge
of thetopandbutttherouteragainst
it
asyouplowa slotthatisjustwideenough
to fit yourmitergauge
barsnugly.

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Preparing
thesub-base
larger
Drilla holethrough
thecenter
of thesub-base
slightly
to therouter
router
bit,andfasten
thesub-base
thanyourlargest
(above).
in
machine
screws
Setthesub-base
usingflat-head
drillingpilot
thetablerecess
andattachit withwoodscrews,
allfasteners.
holes
firstandcountersinkine
Making
thefence
Cut two piecesof 3/q-inchplywood

lljllllllll
llllilI1
lllrilljll11
l]llulllltllljlllllll]l]11
illtillltllJ
1HO?Tt?
A router table on the table eaw
To makethe moet,of Nheepace
in your ehoV,builda router
table intoyourNableoawo . ex\eneiontable,
RouN
a'/+-inch-deep
receeeinto a 6t j:
non-meNallic
sei-

eaw,cu| a holein the receee

Noaccommodalevour rouler'o
from Nhet.ool,ecrew'
baeeplate.Thenremovelhe eub-baee
ingthe rouf,ert o the plaeticVieceinetead.NexNecrewlhe
plaoticinto the receeoicountersinkall Nhefasteners.KeatLachIhe rouNerNoNhebaeeplaIe.A fencecan becul from
plywoodand atNachedto tie sawfencewhennecessar'l,

r07

andscrew
themtogether
in an L shape.
Sawa notchoutof thefence's
bottom
yourlargest
bit,
edgeto accommodate
andscrewfourtriangular
supports
to
the backfor addedstability(above).
plastic
guard,
Attacha clearsemicircular
witha hingeso it canbeswungoutof
theway.To usetheroutertablefor a
s t r a i g hctu t ,c l a m pt h ef e n c ei n p o s i intothebit,
tionandfeedtheworkpiece
holding
it flushagainst
thefence.

TOOLEXTENSIONS
AND TABLES

A REMOVABTE
POWER
T()()LTABLE
thetable
1 Building
I A t t a c h etdo a w o r k b e n cohr t a b l e ,
theremovable
extension
tableshown
at
youto convert
leftallows
threedifferent
portable
power
toolsintostationary
devices:
therouter,
theelectric
drill,andthesaber
saw.Sizethepartsaccording
to yourneeds.
Startbycutting
thetopfrom%-inchplywood,andtherailsandbraces
from2-by4 stock.
Sawtherailsa fewinches
longer
thanthewidthof thetopsotheycanbe
fastened
to the underside
of the bench
w i n gn u t sa n dh a n g ebro l t sT. h e
using
hinged
braces
should
belongenough
to
reach
fromtheunderside
of therailsto a
l e gs t r e t c h e
o rnt h e b e n c hC. u ta b e v e l
at thetopendof thebraces
anda rightangled
n o t c ha t t h e b o t t o mM
. o u nat n
forthetoolontheunderside
On/off
switch
o f o n eo f t h er a i l sa sy o uw o u l df o ra
(page106).
table/cabinet

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r) Preparing
thetabletop
L Cutarectansular
holeoutof thetabletop'scenter
theiamesizeastheinserts
youwillusefortheIools(page109.fhen
screwcleatsto theunderside
of thetop,
forming
a ledgeto whichthe inserts
can
(rrghf).
befastened

108

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TOOL EXTENSIONSAND TABLES

therouter
insert
Q Preparing
sizingthemprecisely
to fit rn
:.f Sawthethreetoolinserts,
t h et a b l e t ohpo l eA. na c r y l irco u t esru b - b a si sef i t t e di n t ot h e
insert
following
thedirections
fortherouter
tableonpages
106
a n d1 0 7 .T oi n s t a l l t hien s e ri tn t h et a b l es, e ti t o nt h ec l e a t s
andscrewthe insertto thecleatsat eachcorner(right).Drill
pilotholesforthescrews.
Makea fenceasyouwouldforthe
nnsirouter
tableon page107.Secure
thefencei1 l[s clesirocl
t i o nw i t hc l a m o s .

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Electric drill inaert

Preparing
drillinsert
theelectric
B o r ea h o l et h r o u gthh ec e n t eor f t h ed r i l li n s e rstl i g h t l y
you
widerthanthe largest
sanding
drumor otheraccessory
planto use.(Thestationary
drillis particularly
useful
forsandi n g .S
) crew
a c o m m e r cdi ar li l lg u i d e
t o t h eu n d e r s i o
d fet h e
(You
insertwiththedrillchuckcentered
overthehole(above).
mayneedto drillholesin thebaseof thedrillguideto fasten
i t i n p l a c e . ) T hb ei to ra c c e s s oi nr yt h ed r i l cl h u c ks h o u lpdr o without
visible.
trudefromthetopof theinsert
thechuckbeing
P l a cw
e o o d ewna s h e rusn d etrh eg u i d er o d so f t h ed r i l lg u i d e
Fasten
to adjust
theheight
of thedrill,if necessary.
the insert
to thecleats
asyoudidtherouter
insert.

Preparing
thesaber
sawinsert
f,
r,l Position
thesaw'sbaseplatesothebladewillbeinthecenterof theinsert
andmarkitslocation.
Borea holeat themark
large
enough
to cleartheblade.
Screw
thesaw's
baseplateto the
inserlhbovd lf therearefewerthanfourscrewholesin the
baseolate.
drilladditional
holes.
Mount
theinsert
to thecleats.

109

I
TOOL EXTENSIONSAND TABLES

TABLE
A BANDSAWEXTENSI()N
UNDERSIDE VIEW

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Cleat groove
(rf needed)

Building
andinstalling
a tableforthebandsaw
A n e x t e n s i otna b l eo n y o u rb a n ds a ww i l l e n a b l ey o ut o c u t l o n g
. s i n g% - i n c hp l y o r w i d ep i e c e sw i t hg r e a t eer a s ea n dc o n t r o lU
w o o d ,c u t t h e j i g t o p t o a s u i t a b l e
d i a m e t e tr h, e ns a wo u tt h e
c e n t e tro f i t a r o u n dt h e s a wt a b l ea n dt r i m a o o r t i o no f t h e b a c k
hannel
e d g et o c l e a rt h e t h r o a tc o l u m n C
. u t a i % - i n c h - w i dc e
f r o mt h e b a c ko f t h e t a b l et o t h e c u t o u ts o t h e t a b l ec a n b e
installew
d i t h o u rt e m o v i ntgh e b l a d e N
. e x t ,p r e p a rtew o c l e a t s
that will be usedto attachthe jig to the sawtable.Forthese,two
1 - b y - 3ssh o u l db e c u t a f e wi n c h e sl o n g e trh a nt h e s a wt a b l e .
P o s i t i o tnh e ma g a i n stth e s i d e so f t h e s a wt a b l es o t h a t t h e y
, i t h a t l e a s t% i n c ho f
a r e % i n c h b e l o wt h e t a b l es u r f a c ew
eas
s t o c ka b o v et h e t h r e a d e dh o l e s (. M a k es u r ey o u rm a c h i n h
an accessory
theseholes;mostbandsawshavethemfor mounting
r i pf e n c e .D
) e p e n d i nogn t h e p o s i t i o no f t h e h o l e so n y o u rs a w
t a b l e ,y o um a yh a v et o p o s i t i o tnh e t o p o f t h e c l e a t sc l o s etrh a n
% i n c ht o t h e t o p o f t h e s a wt a b l e .I n t h a t c a s ey o uw i l l h a v et o
r o u tg r o o v efso r t h e c l e a t so n t h e u n d e r s i doef t h e t o p t o a l l o w
Mark
the tabletopto sit f lushwith the machine'stable (above).
t h e h o l el o c a t i o nosn t h e c l e a t sb, o r ea h o l ea t e a c hs p o t ,a n d
f a s t e nt h e c l e a t st o t h e t a b l ew i t ht h e m a c h i n e
s c r e w sp r o v i d e d
f o r t h e r i p f e n c e( r i g h t .t o p ) .T h e np l a c et h e t a b l e t o po n t h e
cleatsand screwit in place(right,bottom);be sureto counterl i t h t h e s a wt a b l e .
s i n kt h e s c r e w sT. h et o p s h o u l ds i t l e v e w
Toremove
t h ej i g ,r e m o v e
o n l yt h e m a c h i n es c r e w sl,e a v i n tgh e
y t h e t o p . Y o um a yn e e dt o c u t
c l e a t sa t t a c h e dp e r m a n e n ttl o
n
o
t
c
h
e
s
i
n
u
n
d
ersido
e f t h e t o p s o t h a ty o uc a n
clearance
the
r e a c ht h e m a c h i n e
screws.

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110

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TOOL EXTENSIONSAND TABLES

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A DRILL
PRESS
EXTENSION
TABLE
Fitting
a drillpress
withanextension
table
Thesmalltabletypical
of mostdrillpresseswillnotadequately
largeworksupport
pieces,
especially
whenthetoolis setup
forsanding
operations.
Tobuildanextens i o nt a b l e s, t a r tb yc u t t i n ga p i e c eo f
plywood
%-inch
intoa square
withdimensions
thatsuityourneeds.
Thenmarka
linedownthemiddle
of theoiece
anddraw
t w oc i r c l e cs e n t e r eodnt h e l i n e .L o c a t e
t h ef i r s ta b o u 4t i n c h e fsr o mt h e b a c k
edge,
sizing
it to fit snugly
around
thedrill
o r e s cs o l u m nL. o c a t teh es e c o n h
do l e
under
thechuck;makeitsdiameter
about
%inchgreater
thanthelargest
accessory
youplanto use.Tohelppinpoint
thecenter
o f t h eh o l ei,n s t a al l b i t i n t h ec h u c ka n d
measure
thedistance
fromthecolumn
to
thebit.Prepare
to install
thejigonthedrill
press
tablebycutting
itsbackedge,
leaving
"ear"thatprotrudes
a rectangular
behind
thebackhole.Borea holethrough
theear
fora %-inch-diameter
carriage
bolt.Next,
sawthejig in halfalong
thecenterline
and
cutoutthetwocircles.
Youmayneedto
make
o t h e cr u t st o c l e a rp r o t r u s i oonns
y o u rm a c h i n eO. nt h em o d esl h o w na,
n o t c hw a sn e e d efdo rt h et a b l eh e i g h t
a d l u s t m etnr ta c ko n t h et h r o act o l u m n .
F i n a l l ys,c r e wa b u t th i n g et o t h ef r o n t
e d g eo f t h ej i g t o j o i nt h et w oh a l v eass
shown.
Thecarriage
boltandwingnutwill
clamp
thetablein placeon topof the

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drill nrpss t:hlo

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n1

VISEEXTENSIONSTAND
M a k i n ga n du s i n gt h es t a n d
T h ev i s ee x t e n s i osnt a n ds h o w na t r i g h ti s u s e dt o s u p p o r t
t h e f r e ee n do f a l o n gb o a r dc l a m p e di n t h e s h o u l d evri s e
T .h ed i m e n s i o ngsi v e ni n t h e i l l u s t r a t i o n
of a workbench
w i l l w o r kw e l lw i t h m o s tb e n c h e sC. u tt h e u p r i g htto l e n g t h ,
t h e n s a w a n g l e dn o t c h e sa l 2 t / z - i n c hi n t e r v a l sa l o n gi t s
. a k et h e n o t c h l e n g t hs, t a r t i n g5 i n c h e sf r o mt h e b o t t o mM
e s a b o u t1 i n c h l o n ga n d 1 , /i:n c hw i d e .T h e ns a wt h e f e e t
t o l e n g t ha n d c u t r e c e s s easl o n gt h e i rb o t t o me d g e sJ. o i n
t h e f e e tw i t h a n e d g eh a l f - l a pl o i n t :C u t h a l f - l a pisn t h e t o p
e d g eo f o n ef o o t a n d t h e b o t t o me d g eo f t h e o t h e r ,t h e n
g l u et h e t w o t o g e t h e rO. n c et h e a d h e s i v ies d r y ,u s ea l a g
s c r e wt o a t t a c ht h e u p r i g ht o t h e f e e t ;d r i v et h e s c r e wi n t o
t h e u p r i g h ft r o mu n d e r n e a t h e f e e t .C u tt h e s u p p o rpt i e c e
a n ds w i v ebl a r s ,a n g l i n gt h e t o p o f t h e s u p p o rpt i e c ea b o u t
1 0 " t o w a r dt h e u p r i g h tT. o l o i nt h e s u p p o rpt i e c et o t h e
s w i v e bl a r s ,b o r eh o l e sf o r % - i n c h - d i a m e tdeor w e l st h r o u g h
t i e c ea n d n e a rt h e e n d so f
t h e s q u a r ee n d o f t h e s u p p o r p
i
n
t ot h e h o l e sg; l u et h e d o w t
h
e
d
o
w
e
l
s
a
n
d
s
l
i
p
thebars,
. o
l
e
a
v
e
t
h
e
s
u
p
p o rpt i e c ef r e et o p i v o t T
b
u
t
e l st o t h e b a r s ,
e
n
d
o
f
t
h
e
s
w
i
v
el
a
t
t
h
e
t
o
p
d
o
w
e
l
i
n
s
e
r
t
h
e
u s et h e s t a n d ,
y
o
u
f
o
r
t
h
e
h
e
i
g
h
t
i
n
u
p
r
i
g
h
t
s
l
o
t
t
h
e
b a r si n t h e a p p r o p r i a t e
p
i
e
c
e
.
p
r
o
p
y
o
u
r
s
u
p
p
o
r
t
o
n
t
h
e
w
o
r
k
p
i
e
c
e
n e e da n d

Uprighl;
3/,"x2i/+x30'

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APIUSTABLE
ROLLE,R
STAND

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Building
thestand
Setupontheoutfeed
sideof a sawtable,
a n a d j u s t a brl o
e l l e sr t a n dl i k et h eo n e
shownat leftwillhelpyousupport
large
workpieces.
Startbyconstructing
theframe
fortheroller,cuttingthefourpieces
from
1-by-4
stock.Gluetheframetogether
with
buttjoints,adding
screws
to reinforce
the
connections.
Thenborea holein eachside
fora %-inch-diameter
carriage
bolt.Center
thehole3 inches
fromthebottomof the
frame.Screw
therollerto thetoo.Cutthe
pieces
remaining
of thestandfrom1-by-6
provided,
stock,
referring
to thedimensions
a n dr o u ta 1 4 - i n c h - l o n%g-, i n c h - w i d e
slotdownthemiddle
of thetwouprights.
S c r e wt h ec r o s s p i e tcoet h e u p r i g h t s ,
aligning
thetopof thepiece
withthebottomof theslot.Fasten
theupright
andrails
to thefeet.Toguidetheroller
frame,
nail
1-by-1
cleats
to theuprights
aboutr/t inch
in fromtheedges.
To setup thestand,
position
theframebetween
theuprights,
f ittingthecarriage
boltsintotheslots
frominside
theframe.
Slipwashers
over
theboltsandtighten
thewingnutsto set
theheight
of theroller
slightly
below
the
levelof yoursawtable.

Frame
10"x 18"

Carria4e bolt

Foot
3/+" x 5 1/2"

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rllillltfiilllltl]lJ
lll1
illtllllllltlllllltlllltlllltll]fiIjlllJlltillll
5HO7Tt?
Atemporary rollerstand
Ueinqonlya eawhoree,
LwoC clampe,
s o m ew o o d a
, n d a c o m m e r c i ar o
l ller,
you can makea eimplebuI effect,ive
eland Lo supporNt.heoutfeedfrom
anyof yourmachinee.
Makea T-ohaped
maeNfor the roller,eneurinqit io long
e n o u q hN oh o l dl h e r o l l e ra L a s u i i a b l e
heiqht.)crew Lherollerto Lhehorizontal
memberof Nhemast. Add a bracelo
oneendof Ihe horeefor clamoinalhe
maet,in place:Cul 21-by-4oto opanthe
l e g ea n d 6 c r e wl h e m l o N h e l e q e
ao
e h o w n . Tsoe c u r e t h er o l l e re N a n dl o
lhe sawhorse,clampthe maeNNotrhe
bracee,makinqsurelhe rollerie horizontal.

113

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STORAGEDEVICES
hethervour workshoois tucked
awavin a cornerof vour basement or sDreadout over a two-car
garage,
stoiingthe toolsand materials
is a persistent
thataccumulate
challenge.
Thischapterofifers
several
simplestorage
devicesthat canhelpyou win the ongoingbattleagainstclutter.Theywill
keepyourtoolsandmaterials
within easy
reachwhentheyareneeded,
andout of
thewaywhentheyarenot.
For storinghandtools,considerthe
handsaw
holder (page117)andthetool
tray,the chisel,and routerbit racks
shownopposite.As well ashelpingto
organizeyour tools,thesedeviceswill
preventdamageto cuttingedges.
An effective
systemfor storingclamps
is a must.Therackshownon page118
will accommodate
a largeselection
and,
it is mountedon casters,
the
because
rack can be movedto whereverit is
needed.Lumberand ply,voodstorage
racksareshownon pages120and12l.
Eachof the examplesshowncanhold
projectswhile
enoughstockfor several
preciousfloor space.
conserving

Clampscan be a nuisanceto store

because
of their sheernumber in the
shop.The simplerackshownat left
is madeof stripsof wood nrounted
on wall studs. Tlrc lowerstrip is
thicker, to keepthe clampsleaning
toward the wall.

A SETECTI()N
OF
ST(lRAGE
DEVICES
2aw blade otorage
box (page 117)
Keepectrcularaaw
bladeavieibleand protecLed; dividere keep
bladeafrom touchina

Chiselrack
)ecured Lo wall to keep
chiaeleor4anized.Made
from Lhreewood atrtpa;
elota for chiaelaare
dadoedalongedqeoof
middlepiece,then etdpe
are qluedtogether.

Router bit atorage rack

Holderouter btta
upright; holee
are epaced to
preventcuttin7
edgeefrom com'
tnq into contact.

Tool tray
Drawer wiLha
notched2-by-4
dividerfor houetn4
and protecLinq
filee and raope

STORAGEDEVICES

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t
Handsaw
holder
(pase 117)
Wall-mounLed
rack for holdinq
handeawe;made
from 2-by-4
atock, plywood,
dowela,and rubper noqe

Lumberatorage
rack (page 121)
FronL-loadin4rack
for lumber,with Eideloadinqarea under'
neath for etonnq
/ywood and oLher
manufacturedpanele

Vefticalplywood
rack (page 12O)
For etackin7plywooaon ena;Pan'
elE held by furrtn7
eLrip, Lhreaded
rods,and winqnuto

Mobile alamp
rack (page 118)
Uprtqhtframe
holds wrderan4e
of clampa;caetere
mounLedunderbaee
allowrack to be
movedeaeily

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STORINGSAWSAND BLADE,S
BOX
A SAWBLADE
STORAGE
Stolingcircularsawblades
O r g a n i zyeo u rc i r c u l asr a wb l a d e si n a c u s storagb
e o xl i k et h e o n es h o w n
tom-made
a t r i g h t .B u i l dt h e b o xf r o m% - i n c hp l y w o o d ,
c u t t i n gi t a f e w i n c h e sl a r g e trh a ny o u r
l a r g e sbt l a d ea n d w i d ee n o u g ht o h o l da l l
y o u rb l a d e sM
. a k et h e b o t t o ma n d b a c k
f r o mt h e s a m ep i e c e ,r o u t i n gt h e d a d o e s
f o r t h e d i v i d e r fsi r s ta n d t h e nc u t t i n gt h e
p i e c ei n t w o . T h i sw i l l e n s u r ep e r f e c t
a l i g n m e not f t h e d a d o e sC. u tt h e d a d o e s
I i n c hd e e pa n dw i d e ,s p a c e da t l / - i n c h
i n t e r v a l sM, a k et h e d i v i d e ros u t o f % - i n c h
p l y w o o do r h a r d b o a r dF. i t t h e d i v i d e r si n
t h e i rd a d o e sg, l u et h e mt o t h e b o t t o ma n d
To keep
back,then screwthe boxtogether.
t h e b l a d e sf r o mr o l l i n go u t o f t h e b o x ,c u t
a battenfromscrapstockand nail it to the
d i v i d e r sn e a rt h e b o t t o mo f t h e b o x .

HOLDER
A HANDSAW
h eh o l d e r
B u i l d i nagn dm o u n t i nt g
rackshownat left,made
Thewall-mounted
w i t h a f e w w o o ds c r a p sd, o w e l i n ga,n d
s o m er u b b e rh o s e ,u s e sf r i c t i o nt o h o l d
. u tt h e b a s ef r o m
y o u rh a n d s a wi sn p l a c eC
p
l
y
w
o
o
d
.
E a c hd i v i d eirs m a d ef r o m
%-inch
a 1 0 - i n c h - l o n g 2 - b y f-a4c e - g l u etdo a
s h o r t t, a p e r e d2 - b y - 4 .B e g i nb y s c r e w i n g
a 2 - b y - 4a t t h e l e f te n do f t h e b a s et,h e n
s e c u r et h e d i v i d e r si n p l a c e ,l e a v i n ga
' / - i n c hg a p b e t w e e nt h e m .T h e s t o p p e r s
are4-inchlenghsof l-inch dowelpressed
r ari n t os l i g h t l ys h o r t epr i e c e so f r u b b e g
den hose;usehosewith ridgesratherthan
s m o o t hh o s e .S l i p a s a wi n t ot h e r a c k
f r o mb e l o wt,h e nt u g d o w no n t h e h a n d l e .
T h es t o p p ewr i l l p i n c ht h e b l a d ei n p l a c e .
M a r kt h e d o w e l ' sp o s i t i o nb, o r ea % - i n c h h o l ei n t ot h e b a s ea t t h e
d i a m e t esrt o o o e d
, nce
m a r k t, h e ns c r e wt h e d o w eiln p l a c eO
, ount
a l l t h e s t o p p e ras r e i n p o s i t i o nm
t h e h o l d e tro t h e w a l l .

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t17

MOBILECLAMPRACK

Top rail
1 1/2"x 31/2"x 22"

Median rail
11/2"
x 31/2"x 23 1,/2"
?tile

1 1/2"x 31/2" x /yl1/2tl

Eottom rail
1 1/2"x 3 1/2"x 23 1/2"

t/2"x 23 1/2"x 231/2"

1 1/2"x 3 1/2"x 23 1/2"

r) Attaching
therailsto thestiles
L Prepare
the railsforthejoinerybycuttingendrabbets
thatwillfit intonotches
anddadoes
in thestiles.Therabbetsshouldbe 71/zinches
wideand3/qinchdeep,except
f o rt h et o pr a i l sw
, h i c hr e q u i rae r a b b eot n l y1 i n c hw i d e .
N o t c ht h et o pe n do f e a c hs t i l eo nt h r e es i d e st,h e nr o u t
back-to-back
dadoes
nearthe bottomendandmiddleof
thestiles;makethedadoes
3% inches
wideand3hinch
deep.
Alsocuta notch3% inches
wideand32inchdeep
fromthebottom
of eachstile.Whenyouassemble
therails
andstiles,
alignthetwohalves
of eachrailface-to-face
(right)and
attachit to thestileswithscrews.

thestockforthejig
1 Gutting
I T h el a r g ec o l l e c t i oonf c l a m p si n
mostshoos-andtheirawkward
sizeand
shape-canstretch
eventhemostorganizedspace
to thelimit.Themobile
clamp
rackshownat leftcanbestoredagainst
thewall,thenrolled
to anypartof theshop
where
clamps
areneeded.
Startbycuttingthe pieces
to size,referring
to the
i l l u s t r a t i of onrs u g g e s t e
dd
imensions.
Thesixrails(top,median,
andbottom)
thetwostiles,
andthreecrosspieces
are
all sawnfrom2-by-4stock.Cutthefour
skirtpiecesfroma 2-by-4andthe base
(inset).
fromr/z-inchplywood

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118

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STORAGEDEVICES

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Mounting
tothestiles
thecrosspieces

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T o l o i n t h e c r o s s p i e c et os t h e r a c k ,c u t a 3 t l z - i n c h - w i d e
d a d oi n t h e m i d d l eo f e a c hp i e c ea n d s c r e wt h e m i n p l a c e
( a b o v eT
) .h e m i d d l ec r o s s p i e cwei l l r e s to n t h e m e d i a nr a i l .
T h et o p p i e c e sw i l l r e s to n t h e o u t s i d e
s h o u l d e rosf t h e n o t c h e d

tnn nf p:r^h s,tilo

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Attaching
thestilesto the base
Finishthe rackby sawingtwo notches in the baseandskirtto accommodate
t h e s t i l e s ,r a b b e t i n og n e e n d o f e a c h
skirt piece,andscrewing
themtogether
to
form a box (page118, insef).Usescrews
t o a t t a c ht h e b a s et o t h e s k i r t .F i n a l l y , a t t a c hc a s t e r st o t h e u n d e r s i d e
of
t h e s k i r ta t e a c hc o r n eor f t h e r a c k t, h e n
s l i pt h es t i l e si n t ot h e n o t c h e si n t h e
basehbove)and secure
thestilesto the
b a s ea n ds k i r tw i t h e l u ea n ds c r e w s .

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llllilliilllljl1tlllillJlllillrlilllrlllrlllilltilllllilllliilillllllllj
1HO?TI?
1toring clampoin a can
A Lraehcan fiNNeA
wibha ehopmadelid oervegas a convenienl
waylo eNoreemallbar or pipe
clamVe.
CuNa Vieceof '/z-inchVlywoodinLo
a circleeliqhLly
emaller ',.",
NhanNhe
diamelerof Lhecan'srim. r-:
Thenscribea eeriesof concenf,ric
cirto helVyou locate
cleson LheVlywood
Lheholesfor the clamVbaro.Space
LhecircleeaboutZinchesaVarLand
markpointoevery3 inchesalon4them.
Sorea |-inch-diameter
holethrouqh
eachpoint,fit Lhepieceof plywoodin
Lhecan,anddropNheclampethrough
Nheholee.To
clampefrom
prevenNNhe
keepthe can dry aL all Nimes.
corrodinq,

119

RACKS
LUMBERSTORAGE
Commerciallumber racl<s,suchas these
cantileveredlumber shelves,are both
adaptableand strong, making them
idealfor the home workshop.Screwed
to a concretewall or to wall studs,they
can be adjusted to various heightsto
suit your particular storageneeds.

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r
PLYWOOD
RACK
A VERTICAL

Threadedrod
Furrin7 atrip

Constructing
therack
plywood
onendsaves
valuForlong-term
storage,
stacking
Therackshownat leftis builtfrom
ableshopfloorspace.
rods,andwingnuts.Startbyscrewing
furring
strips,
threaded
two1-by-3
furring
stripsto thestudsof onewall,2 and5 feet
rods4Y,feetapart
fromthefloor;first bolttwothreaded
intothetopstrip.Cuta thirdfurringstripandborea hole
it at oneendandsawa notchat theotherendto
through
. o t ho p e n i n gssh o u l d
b es l i g h t l y
l i n eu p w i t ht h er o d sB
twowoodpads
larger
thanthediameter
of therods.Place
sheets
onthefloorbetween
therodsandstacktheplywood
the
upright
onthem.Holding
thethirdfuningstripacross
faceof thelastpanel,
sliponerodthrough
theholeandthe
andwingnutsontherods
otherintotheslot.Putwashers
them,pulling
thefuningstriptightlyagainst
the
andtighten
(above).
plywood
Toremove
a sheetfromthestack,loosen
the
wingnutsandswingthefurringstripupandoutof theway.

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Woodpad
3/r"x3%"x12"

r20

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DEVICEs
STORAGE

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RACK
A LUMBER.AND.PTYW()()D
Fastening
therackto anunfinished
wall
to wall
madeentirely
oI2-by-4stock,is attached
Therackshownbelow,
joists.
is
Lumber
whileplywood
studsandceiling
canbepiledonthearms,
brackets.
Youwillneedat least8%
stacked
on edgeagainst
thesupport
panels.
feetof freespace
at oneendof therackto beableto slidein plywood
themto the
Beginbycutting
thetriangular-shaped
brackets
andscrewing
andnailthemto
Cutthefootings,
slipthemunderthebrackets
sluds(right).
andtoe-nail
theirendsto the
sawtheuprights
to length
theshopfloor.Next,
footings
Cutasmanyarmsasyouneed,
aligning
thefirstrow
andthejoists.
brackets.
Usecarriage
boltsto fasten
the
withthetapered
endof thesupport
making
surethearmsin thesameroware
armsto thestudsanduprights,
features
armsspaced
at 18-inch
intervals.
level.
Therackin theillustration

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)ole plate

11/2"x31/z"x20"
11/2"x31/z"xB"

t2l

9upport bracket
11/2"x31/2"x41/z'

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SHOPAIDS

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ostjigsthathangfromthewalls
of woodworkers'
shopstypically providea shortcutto a commontask,
from boring mortisesto edge-gluing
panels.As the previouschaptershave
shown,the mostpopularjigsarethose
that makea job easierand more accurate,or improvea tool'sperformance.
But eventhe mostmundaneof workshopchorescanbenefitfrom a helping
hand, whetheryou are moving large
sheetmaterialsarounda shopor throwing somelight on your work.
Thischaptercoversa collectionofsuch
shopaids.Somedevices,suchasfeatherboardsandpush sticks(page125),are
for everywoodworking
indispensable
for morespeshop.Othersaredesigned
cializedtasks,suchasmeasuringand
markinglargearcl"'s(page133)or preparing thin or smallstock(page130).lf iou
frequentlywork alonewith largesheet
materialssuchasplywoodandparticle(page128)
board,collapsiblesawhorses
areashandy asan extrapair ofhands,
while an auxiliaryoverheadswitchfor
your
thetablesaw(page131)wrJJmake
shop a saferplace.Evenmany of the
stickyproblemsof finishingcanbesolved
with a fewsimpledevices(page1j5).

(lFSH(IPAIDS
ANASSORTMENT
Eeveledfeatherboard
(pase127)

9tandard featherboard
(pase 125)
Aleo knownae fin4er'
board: preaeea atock
enu7lyaqainat the
table or fence of a
etationary tool

ldentical to atandard
featherboard, except the
fin4eroare beveledeo they
preoo workpieceaqaineL
both the fenceand table
of a stationary tool

thimmed featherboard

(pase12Q
A atandard featherboard
aupported b5ta ahim ao
that finqere apply preaaure
hiqher on workpiece
Push atiak (page 125)
Uaedto feed atock
acroao atationary tool table
Plywood carrier (page 13O)
Features a handleand a lip for
carryin7 large eheet materiale
Iikeplywoodand particleboard
Bench dog lamp
euppora (page 157)
Fite into benchdo7
hole;featurea a hole
to accommodate
deak lamp

A sprayingturntableallowsyou to
applyafinish evenlywithouttouching
theworkpiece
or movingaroundit;
theend tqbleshownat left restson
As shownon
four dryingsupports.
page136,the jigis easilybuiltfrom
p\nvoodanda "lazySusan"bearing.

Auxiliary table aaw switch (page 131)

For turnin7 table aaw on and off when
main awitch is out of reach; inetalled
near ceilingand wired to eaw

t23

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SHOPAIDS

Compaoe (paqe 133)

For drawin4 circlee;
awl ie fixed to ctrcle's
center and pencit
drawa circumference

V-bloakjig
(pase 132)
Clampedto
jointer table
for chamferinq a
workpiece

Planingjig for thin

atoak (page 131)
For thrckneaeplanin4
of aLockthinner than
%inch;beveledcleate
hold workpiece
in place

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Trammel

9praying
turntable (paqe 136)
Kotatin4 platform ueinqa
"lazv
)uean" bearina
Vacuumacreeningramp (page l3O)
Dust is ewept onf,oramp and falle
throu7h holes;holetn backaccepLo
duet collectionhoaeao that duaL
ia auckedinf,ocollectionavatem

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gtaaking handlee (paAe 135)

Tack-nailedLo the endaof a
board to enableboth facee

clamped to a board for

acribinglarqe circlea

to be ftniahed before piece

ie left to dry; can be

etacked for multi'
ple workpiecea

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Center finder
(pase 152)

S S S 6 S

Ueed to def,ermine
the cenLer of a ctrcular workptece

.-a"-*"'\
s s s s s \
s '-

t-s

Shooting boards (page 134)

Ueedwtth a planeto emoothend7rain.
Kiqht-an1leboard (top) ro for planinq
atraight end grain;anqledveraion
(bottom) ie ueed for milered ende

Folding sawhorae (page 129)

A hinqedaawhoraethaL
can be folded flat

Knoak-down
aawhoree (page 128)
Three-pieceaawhorae
whichcan be dieassembledquicklyand atored

t24

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SAFETYDE,VICES
BL(ICKS
PUSH
STICKS
ANDPUSH
pushsticksandpushblocks
Making
forfeeding
Pushsticksandpushblocks
power
stockacross
thetableof a stationary
plywood
or
toolcanbemadeusing%-inch
is ideal;
a wellsolidstock.
Nooneshape
pushstickshouldbecomfortable
designed
t o u s ea n ds u i t a b lfeo rt h em a c h i naen d
t a s ka t h a n d F
. o rm o s tc u t so n a t a b l e
a pushstickwitha 45' angle
saw,design
between
the handleandthe base(right,
a n g l ef o r u s e
f o p ) .R e d u cteh e h a n d l e
withtheradial
armsaw.Thenotchonthe
bottom
edgemustbedeepenough
to supporttheworkpiece,
not
butshallow
enough
thesawtable.Thelongbaseof
to contact
pushstick(right,middle)
a rectangular
youto applydownward
pressure
enables
Forsurfacing
ona workpiece.
thefaceof
a boardon a jointer,
the long,widebase
of a pushblock(right,bottom)isideal.
I t f e a t u r easl i p g l u e dt o t h eu n d e r s i d e
o f t h eb a s ef,l u s hw i t ho n ee n d .S c r e w
tothetop,positioning
it sothe
thehandle
backis evenwiththeendof thebase.

Pueh etiak
%"x5%"x12"

A STANDARD
FEATHERBOARD

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a standard
featherboard
1t Makins
I Featherboards
serve
asanti-kickback
allowtheworkdevices,
sincethef ingers
p i e c et o m o v ei n o n l yo n ed r r e c t i o n toward
a stationary
tool'sbit or blade.To
liketheoneshownat
makea featherboard
left,cuta 30"to 45" miterat oneendof
a % - i n c h - t h i3c -kt,o 4 - i n c h - w i b
do
eard;
to suit
thelengthof thejig canbevaried
t h ew o r ky o up l a nt o d o .M a r ka p a r a l l e l
fromthemitered
lineabout5 inches
end
andcut a seriesof slotsto the marked
l i n eo nt h e b a n ds a w s, p a c i ntgh ek e r f s
about%inchaoartto create
a rowof sturdybutpliable
f ingers.
Finally,
cuta notch
outof oneedgeof the featherboard
to
accommodate
a supDort
board.

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SHOPAIDS

Usingstandard
featherboards
onthetablesaw
Clamponefeatherboard
to thefenceabove
theblade,andplacea longer
onehalfway
between
the bladeandthefrontof the
table.Clampa support
boardin thenotch
perpendicular
to thehorizontal
featherboardto prevent
it fromcreeping
oui of
placeduringthecut.Fortheoperation
shownat left,feedtheworkpiece
intothe
fingers
bladeuntilyourtrailing
reach
the
featherboards.
Thenusea pushstickto
finishthecut,or moveto thebackof the
tablewiththesawstillrunning
andpull
pasttheblade.
theworkpiece

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Pushsticl<s
andfeatherboards
makean
operationlike rippingon thetablesaw
muchsaferby keepingyourhandswell
awayfrom theblade.Thepush stickis
usedtofeedthestockand keepit flat on
presses
thetable,whilethefeatherboard
theworkpiece
againstthefence.The
shownin thephotois
featherboard
secured
to thetablewith specialhardwareratherthanwith clamps.A clamping bar in themiterslotfeaturestwo
scrsusthat canbetightened,
causingthe
barto expandand locktightlyin theslot.

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SHOPAIDS

A BEVELED
FEATHERBOARD
Ripping
stockwitha beveled
featherboard
A featherboard
clamoed
to thefenceof a
page,
tablesaw,asshown
ontheprevious
cangetin thewayof a pushstickduring
a
ripcut.A featherboard
witha beveled
end
will pressa workpiece
against
boththe
fenceandsawtable,eliminating
theneed
to clampa featherboard
to thefence(rrghf).
Makethedevice
asyouwoulda standard
(page125),but cut a 45"
featherboard
bevelon its leading
endbefore
cuttingthe
f ingers
andslots.Alsomakesurethatthe
featherboard
isthicker
thanthestockvou
ara rinnina

" ' ' l i t s H " ' b

(incef)

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A SHIMMED
FEATHERBOARD
Shimming
a featherboard
Whenworking
withthickstockor runninga boardon edgeacross
a saw
table,a featherboard
clamped
directly
to thetablemayapplypressure
too
lowontheworkpiece,
causing
it to tilt
awayfromthefence.To applypressurecloser
to themiddleof thestock,
screw
thefeatherboard
to a shimand
thenclamptheshimto thetable(/eff).

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r27

SAWHORSES
SAWH()RSE
A KN()CKD()WN
B u i l d i ntgh es a w h o r s e
A s t u r d ys a w h o r slei k et h e o n es h o w na t
l mount
l e f tc a nb e m a d ew i t ho n l ya s m a l a
o f l u m b e ar n d p l y w o o da,n dt a k e na p a r t
a n d r e a s s e m b l qe ud i c k l yC. u tt h e l e g s
f r o ml - i n c h p l y w o o dt h, e ns a wa 3 - i n c h d e e pn o t c hi n t h en i d d l eo f t n et o oo f b o t h
p i e c e sN. e x t c. u t t n e c r o s s p r e cf reo m
1 - b y - 6s t o c ka n d s a wa 1 / - i n c h - d e e p
s l o t8 i n c h e si n f r o me i t h e re n dt o f i t i n t o
. n g l et h es l o t s ' o u g h5l y' f r o m
t h e l e g sA
iho vorlinal tn cnrped lho looc cliohtlv nrrl
! i

i !

i ! b J

w a r dF
. o ra d d e ds t a b i l i t ys,c r e w4 - i n c h
l o n g1 b y - 2c e a t st o t h e c r o s s p i e coe' r
e a c hs i d eo f t h e s l o t s .

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-lb
phrtc lottgworkpict'c:tt,itltottt
t l t cl t c l p o . l ' rbr t ' t r c l rv i s c ,c l t r t r t p
o ,rsr
r atttlscrcn
t l t t ' r tcr d g c - r rrpt , i t l h
ri.s-s/io ttri i
l fi t() ()t' il t o t'c -srlrr,/irl r--sc-s,

o t r i g l t t .S c c t t rtcl r cl r a r t t l s c r c tno' s
rlitlr (.' clorrrps
Io
l/rcci.rr-s-slls1-r'-s
prcIcItt thcttr .li'ort t slipp i trg.

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SHOPAIDS

A F()LDING
SAWHORSE

Top rarl
3/o"x5%"x36"

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Corner halfIapjoint

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lll1
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illllltlll rlitljljllltllltilltlll1
llitillll]|tlltlilllljll
1HO?Tt?
Taddingeawhoroes
To VrevenL
a sawhorse
from marrinqyourworK,
coverits croeepiece
with a elriV of carpeL,
an oldlowel,or a blanket,Foldthe maLerial
overf,heNoVedqe
nl

lhe

rraaaniere

andscrewor nail
it,to the eidee,

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Making
thesawhorse
M a d ee n t i r e lfyr o m1 - b y - 6
s t o c kt,h e
lightweight
sawhorse
shown
above,
featuringa hinged
topandcrossbrace,
folds
flatforeasystorage.
Cutthe legsand
r a i l st o l e n g t a
h n dl o i nt h e mt o g e t h e r ;
(inset,top)Io loin
usecornerhalf-laps
thetoprailsto thelegsandT half-laps
(inset,
bottom)
to attachthelegsto the
bottomrails.Reinforce
thejointswith
glueandscrews,
thenjointhetwosectionsat thetoprailswitha pianohinge.
Finally,
cutthecrossbrace;
besureit is
longenough
sothatwhenthe legsare
spread,
thepianohingeis recessed
below
t h et o pe d g eo f t h et o pr a i l s S
. a wt h e
crossbrace
in halfandconnect
thetwo
pieces
withthehinge.
Thenfasten
the
crossbrace
to bothsiderails,againusing
pianohinges.

WORKSHOPHELPERS

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CARRIER
A PLYW()()D
Moving
l a r g ep a n e l s
particleboard,
and hardSheetsof plywood,
to carheavy
and
awkward
boardareoften
l
e
f
t
w
i
l
l
m
a
k et h e
T
h
e
c
a
r
r
i
e
s
r
h
o
w
n
a
t
ry.
l o a de a s i e tro b e a r .R o u ta 1 - i n c h - w i d e
r a b b eat l o n go n ee d g eo f a l 2 - i n c h - l o n g
b o a r dC
. u t a n o t c ho u t o f o n ee n d o f a
pieceof plywood,
thenscrewa woodblock
acrossthe end of the notchto serveas a
h a n d l eA. t t a c ht h e o t h e re n d o f t h e p l y w o o dp i e c et o t h e r a b b e t e df a c eo f t h e
b o a r d( i n s e t )T. o u s et h e c a r r i e rs, i m p l y
h o o ki t u n d e rt h e s h e e ta n d p u l l i t u p
underyour arm (left).Somewoodworkers
f i n d i t m o r ec o m f o r t a b lteo s t a n do n t h e
c a r r i esr i d eo f t h e p a n eal n du s et h e i ro t h e r
h a n dt o s t e a d yi t .

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PLANING
SH()RT
ANDTHINSTOCK
U s i n gr u n n egr u i d e tso p l a n es h o rst t o c k
F e e d i n sgh o r tb o a r d st h r o u g ha t h i c k n e s s
p l a n ecr a nc a u s es n i p r n ag n dk i c k b a c k .
T o h o l ds h o r ts t o c ks t e a d ya s i t e n t e r s
a n de x r t st h e n l a ,n" . e, rbs., l" u et w os o l i dw o o d
s c r a pr u n n e r st o t h e e d g e so f y o u rw o r k n i p c p [ \ , 4 : kspr r r pt h p n l n n e f sa f e t h e
s a m et h i c k n e s a
s s t h e w o r k p i e caen d
e x t e n ds e v e r ai ln c h e sb e y o n db o t he n d s .
Feedthe workpiece
intothe planer(rrght),
makrng
a s e r i e so f l r g h tc u t su n t i l y o u
h a v er e a c h e tdh e d e s i r e tdh i c k n e s sT.h e n
cutofftherunners.

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SHOPAIDS

U s i n ga p l a n i n jgi g f o rt h i ns t o c k
T h i c k n e spsl a n i n g
s t o c kt h i n n e tr h a n
r/ainchoftencauseschatterand splintering of the workpiece.
To avoidtheseprob"thicker"
l e m sm a k et h i ns t o c k
w i t ht h i sj i g .
To makert,srmplygluetwo beveled
cleats
t o e i t h e re n d o f a b o a r dt h a t i s s l i g h t l y
. o
l o n g e rt h a n y o u rw o r k p i e c e( i n s e t ) T
makethe cleats,cut a 45' bevelacrossthe
m i d d l eo f a b o a r da p p r o x i m a t et h
l ye s a m e
t h i c k n e sa
s s t h e w o r k p i e c eN. e x t ,b e v e l
t h e e n d so f t h e w o r k o i e c eS. e tt h e s t o c k
o n a b a c k u pb o a r d p
, o s i t i o nt h e c l e a t s
f l u s ha g a i n st h e w o r k p i e c seo t h e b e v e l
c u t sa r ei n c o n t a c ta, n dg l u et h e c l e a t si n
p l a c et o t h e b a c k u pb o a r dR
. u nt h e1 r ga n d
, aking
w o r k p i e cteh r o u g ht h e p l a n e r m
s e v e r alli g h t p a s s e sd o w nt o t h e d e s i r e d
t h i c k n e s s( r i g h t )t,h e n c r o s s c utth e e n d s
o f t h e w o r k o i e cseo u a r e .

ANAUXILIARY
F()RTHETABLE
SWITCH
SAW

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Installing
an overhead
switch
S w i t c h i nogn a t a b l es a ww h i l eb a l a n c i n g
a l a r g ep a n eol n t h e t a b l ec a np r o v ed i f fi c u l t .T h ea d d i t i o no f a n o v e r h e asdw i t c h
w i l l e n a b l ey o ut o s t a r t h e s a ww h e nt h e
mainswitchis out of reach//eft).Locate
t h e n e ws w i t c hs o y o u c a n r e a c hi t c o m f o r t a b l yw i t h a 4 - b y - Bp a n e lo n t h e s a w
tablejust in frontof the blade;screwa tria n g u l abr r a c k etto t h e c e i l i n ga n da t t a c h
t h e s w i t c ht o t h e b r a c k eat t a s u i t a b l e
h e i g h tR
. u na l e n g t ho f n o n - m e t a l l i c
s h e a t h e ld2 - g a u g ec a b l ef r o mt h e s w i t c h
a l o n gt h ec e i l i n gd, o w nt h ew a l l ,a n da c r o s s
the floorto yoursaw.Havea licensed
elect r i c i a nw i r et h e s w i t c ht o t h e s a ws o t h a t
b o t hi t a n dt h e o r i g i n asl w i t c ha r ea b l et o
startor stopthe machine;neverdisconnect
theswitchonthesawitself.

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SHOPAIDS

V.BL()CK
IIG

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Cutting
a chamfer
Tocutchamfers
onyourjointer,
usethesimplejig shown
above.
Referto the illustration
forsuggested
dimensions.
Beginby
bevelcutting2-by-2s
fortheV section
of thejig. Position
the
twocut piecesonthe basesotheyextendbeyond
oneendby
gapbetween
witha %-inch
about12 inches,
them.Attachthe
twopieces
to the basewithcountersunk
screws
to avoidscratch-

ingthejointer
table.Tousethejig,clampit in placewithone
withthecutterhead-end
endof thebasealigned
of the infeed
table.Lower
theinfeed
tableuntiltheV section
of thejig lies
flushonthejointer's
outfeed
table.Seattheworkpiece
in the
gapof thejig,thenfeedit across
theknives
whileholding
it
firmlyin IheY (above).

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Finding the centerof a circular workpiece

is easyif you use the jig shown at right.
The simple deyice consis* of a piece of
plywood with a 90" wedgecut out of it
and a l2-inchJong 1-by-2 mountedso
that one edgebisec* the wedge.To usethe
jig, seat the workpiece in the wedgeand
draw a line acrossits diameter using the
1-by-2 as a guide. Rotate the workpiece
about 90oand draw anotherline. The nvo
will intersectat the centerof the circle.

r32

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SHOPAIDS

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FORSCRIBING
CIRCLES
TW()DEVICES
M a k i n ga n du s i n gt r a m m ebl l o c k s
Y o uc a ns c r i b ea l a r g ec i r c l eu s i n ga s e to f
t r a m m ebl l o c k sl i k et h eo n es h o w na t r i g h t .
C u tt h e p i e c e so f t h e j i g f r o ms o l i dw o o d ,
make
referring
to the insetfor dimensions;
s u r et h e b e a mi s l o n g e tr h a nt h e r a d i u s
. u ta n a n g l e dn o t c h% i n c h
o f y o u rc i r c l eC
f r o mt h e t o p o f e a c hb l o c kt o a c c o m m o d a t et h e b e a ma n da w e d g eF. o rt h e p i v o t ,
d r i v ea n a i l i n t ot h e b o t t o mo f o n eb l o c k ,
s n i p o f f t h e h e a d ,a n d f i l e i t t o a p o r n t .
Mouna
t s h a r oo e n c iiln a h o l eb o r e di n t h e
b o t t o mo f t h e o t h e rb l o c k .M a k es u r ei t s
p o i n ti s l e v e w
l i t ht h e n a i l .T o u s et h e j i g ,
l o o s e nt h e w e d g e sa n d s l i d et h e b l o c k s
a l o n gt h e b e a mu n t i lt h e g a p b e t w e etnh e
n a i l t i pa n dp e n c ipl o i n te q u a l tsh ed e s i r e d
r a d r u so f y o u rc i r c l e T
t h ew e d g e s ,
. rghten
p
i
v
o
t
p
o
i
n
t
a
h o l dt h e
steady t thecenter
l oint
r
o
t
a t et h e p e n c i p
o f t h ec i r c l ea
, nd
(right).
aroundit

Making
a n du s i n ga f i x e dc o m p a s s
C o n s i s t i nogf a n a r m ,a n a w l ,a n da p e n c i l ,
the compass
shownat leftwill allowyouto
s c r i b ea c i r c l eo f v i r t u a l layn yr a d i u sF. o r
t h e a r m ,c u t a l - b y - 2a f e w i n c h e sl o n g e r
t h a nt h e r a d i u so f y o u rc i r c l e B
. o r ea h o l e
a b o u t1 i n c hf r o mo n ee n d o f t h e a r m ,
l a r g ee n o u g h
t o h o l dt h es h a f to f t h e a w l .
M a k ea n o t h ehr o l eb i ge n o u g ht o a c c o m m o d a t et h e p e n c i lt;h e d i s t a n c b
eetween
t h e h o l e ss h o u l de o u atl h e r a d i u so f t h e
c i r c l e .F i t t h e a w l a n d s h a r o e n eode n c i l
i n t ot h e i rr e s p e c t i vheo l e sm
, a k i n gs u r e
the twoextendfromthe bottomof the arm
b y t h e s a m ea m o u n tU
. s et h e c o m p a s s
a sy o uw o u l dt r a m m ebl l o c k sh, o l d i n gt h e
t i p o f t h e a w la t t h e c e n t e ro f t h e c i r c l e
a n d r o t a t i n gt h e p e n c i la r o u n di t t o
s c r i b et h e c u c l e( l e f t ) .

SHOPAIDS

TWOSHOOTING
BOARDS
RIGHT-ANGLE
SHOOTING
BOARD
)quare etop block
1"x4"x5"

Top

t/r"x5"x19"

t/o"xB"x1B"

MiLered
atop block
'1"x5%"x12"

shooting
boards
1 Making
I T os m o o t eh n dg r a i nw i t ha p l a n e ,
usea shooting
boardlikethoseshown
at
left.Theright-angle
shooting
board(left,
above)
is for planing
straight
endgrain;
a mitered
version
canalsobe built(/eft,
below).
Cutthepieces
according
to the
dimensions
suggested
in theillustrations.
Buildthebase,
top,andmitered
stopblock
plywood;
from%-inch
usesolidwoodfor
thelipandthesquare
stopblock.
Screw
thetopto thebasewiththeendsandone
edgealigned.
Thenattachthe lip to the
b a s em
, a k i nsgu r et h a tt h el i p l i n e su p
withthe endof the base.Forthe rightangleshooting
board,
fasten
thestopblock
to thetopflushwiththeotherendof the
jig.Forthemitered
shooting
board,
centerthestopblockonthetop.

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r) Smoothing
endgrain
L to useeitherjig,hooktheliponthe
edgeof a worksurface.
Setyourworkpieceonthetop,buttingtheedgeagainst
thestopblocksothatit extends
overthe
edgeof thetop byabout%oinch.With
position
themitered
shooting
board,
the
workpiece
against
theappropriate
sideof
thestopblock.(Fora longworkpiece,
it
maybenecessary
to placea support
board
undertheopposite
endto keeptheworkpiecelevel.)
Seta plane
on itssideat one
e n do f t h ej i g a n db u t tt h es o l ea g a i n s t
theedgeof thetop.Holding
theworkpiece
guidetheplanealong
firmly,
thejigfrom
oneendto theother(rghf).

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SHOPAIDS

A cleanmetalcanwith wire strung

acrossthemouthoffersa neatand simple way to controltheJlowof stainor
varnishfrom a brush.Punchholesin
sidesof thecan neartherim,
opposite
stringa wire betweentheholesandpour
theliquid into thecontainer.After dipping thebrush,draw the bristlesacross
liquid.
thewire to wipeoff any excess

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HANDLES
ANDDRYING
SUPPORTS
STACKING

Stacking
shelves
to dry
Finishing
a shelfonesideat a timedouforthistask.Using
blesthetimeneeded
t h es i m p l es t a c k i nhga n d l essh o w na t
l e f t ,y o uc a nf i n i s hb o t hs i d e sa t o n c e .
fromsolidwoodstockand
Cutthehandles
m i l la t o n g u ei n o n ef a c eo f e a c ho n e .
t i n c hw i d e r
M a k et h eh a n d l east l e a s%
thanthethickness
of thestockyouare
finishing
D.r i v se m a lnl a i l sl o n g et h
r an
thickness
through
themand
thehandles'
gentlypress
pointsinto
the protruding
before
finishtheendsof theworkpiece
ingit. Usethehandles
to turntheboard
asyouapplyf inish;whenyouaredone,
theboards
canbestacked,
allowing
airto
circulate
freely
asthef inishdries.
When
pieceof furniture,
finishing
a larger
setthe
(inset).
pieceon a setof dryingsupporls
These2-inch-souare
woodblocks
have
s m a lnl a i l sd r i v e tnh r o u gthh e i rc e n t e r s
to support
a workpiece
at itscorners.

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r^gwn

re
\Y;--r

\L---l

135

SHOPAIDS

A SPRAYING
TURNTABLE

theturntable
1 Building
I Consisting
of a baseandtopcutfrom
plywood
%-inch
witha "lazySusan"
bearingfastened
in between,
theturntable
shownabove
allows
a pieceof furniture
with
to berotated
asit is beingsprayed
. u tt h eb a s ea n dt o ps l i g h t l y
a f i n i s hC
larger
thanthebaseof thepieceof furn i t u r teo b ef i n i s h e d
C.u ta h o l ei n t h e
centerof thebaseto allowaccess
to the
screwholesforattaching
theupperbearingto thetoponcethelowerbearing
is
secured
to thebase.Firstattachthelower bearing
to thebasewithscrews.
To
fastenthejig top,setthebaseontopof
it withthebearing
sandwiched
between
t h et w op i e c e as n df l i p t h e mu p s i d e
d o w nW
. i t ht h ee d g e o
s f t h ep i e c e s
flush,rotate
thebearing
sotheremaining
screw
holes
areexoosed.
thenscrew
the
upperbearing
to thetop (above,
right).

lllllllllllfillllllllllultllllllltlll llllilltllilllllilIllltlillll][t
5HO?Tt?
Lubricatingtoole
LighNly
oilinqa handsaw
bladeor a planeeole
beforeeNorinqiNkeepe
the Loolcleanand prevenberueN.Tooilyour
toolo neatly,ueea lubricalinq pad madefrom a
lonqoLripof burlaV,Liqhtlv rolledand oackedin a
i
smallcan as shownhere.
'.MakeeureNheeLriVie
wide enoughto exbendpael
the loo of the can.)oaklhe maNerial
in Ihin
machine
oil,andwipeyourplaneooleeand
handsawbladesoverit beloreeNorinqthe
toolo.Tiqhtly
coverlhecanwhennoNinuee.
v

r36

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SHOPAIDS

r) usingtheturntable
C- ltlahe
foursmalldryingsupports
(page135).Setthe workpiece
on the
rotate
tipsof thenails,
thenslowly
the
turntable
withonehandwhileoperating
a spraygunwiththeother(above).

BENCH
DOGLAMPSUPPORT

A movable
lightfora workbench
A desklampattached
to a benchdogas
youto position
shown
at leftwillenable
thelightat anyof thedogholesalongthe
b e n c hT. o m a k et h ej i g , b o r ea h o l e
t h es a m ed i a m e t earst h es h a f o
t fthe
l a m oi n t ot h eh e a do f a w o o d ebne n c h
dog(page92).

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SHOPAIDS

A VACUUM
RAMP
SCREENING

t
S S S 6 S
S S S Top
S S
^

S,OOS

S
\

Collecting
shopdust
Forcleaning
dustofftheshopfloor,build
a wedge-shaped
rampfrom
screening
(above).
plywood
Before
andhardboard
assembling
thepieces,
cuta holein the
backto fit a dustcollection
hose,and
borefiverowsof 1%-inch-diameter
holes
through
thetop.Whendustandwood
chipsaresweptupontotheramp,smalle rp a r t i c l ewsi l lf a l lt h r o u gthh eh o l e s
a n dc o n t i n uoen t o t h ed u s tc o l l e c t o r .
L a r g edre b r i w
n nt h er a m p
s i l lr e m a i o
foreasydisposal.

A.

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ljltllltlllllIllllllltlllllltllltllllllltl]llllljllllultlluilllllll
9HO7Tt?
A drawer-elidepoeitioningjig
pooilioncommercial
Tohelpyou correcLly
elideeon drawereidee,
uoelhe jiq shownhere.CuLa rabbet,in a ecrapboard;make
Lhedepthofthe rabbelequaltolhe deeireddielance
beLween
the slide and the botlom of Nhedrawer
,-----.-.

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'I:!:,1::"n"^--'
j,.s:fu
3:i;^':^izl"J"jil;Pii"If
lf
- - -'{
onthedrawer
sia",iili tii

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bottomedqeof thehara-

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warebuIIed a4ainot
I h e j i q .H o l d i n q N h e
s l i d ea n d L h ej i q
in place,markthe
ecrewholee,bore
pilot holee,and
ecrewthe elide
to lhe drawer.

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--'

--'

-#

o41l*

. -,i'5

,. )

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SHOPAIDS

A STEAM-BENDING
JIG

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lll1
filtrlllllltllltfinfiltllllfiltfillfilllllllllllll llllllllllllllll
1HO?Tt?
Ahoning jig
TheoimVle
1igehownherewillenableyou Nooharpenplane
honing6uide.)lip a
bladeewiNhoulthe aid of a commercial
4 - inch1 onq, 3/ s- inch-diameter car ria4e bolt throuqh th e
blade'eeloN.Faetenwaehersand wingnulo on both sidesot
etone
Nheblade.Wil'h
lhe cuLtinqedqeon lhe oharpeninq
and Nheheadof lhe bolt on your worksurface,ueea
-..-/'\,
?rotractor and a olidingbevelIo adjuoLthe winq
nuNeeo Nhatthe bladecan be slidalonalhe
oione allhe properan4le,typically
3O".
,,t-.Yat

139

Steam-bending
a workpiece
Tosteam-bend
smallworkpieces,
such
asstripsof molding,
buildtheportable
Cuta lengthof
steamer
shown
above.
ABSpipelonger
thanthewoodyouwish
to bendandaboutthesamediameter
kitchen
kettle;
asthespoutof anelectric
usea kettlewitha roundspout.Connect
oneendof thepipeto thespout,makinga tightsealwithducttape.Support
theotherendof thepipeat a slightangle
pieceof plywood
ona notched
clamped
in a bench
vise.Tousethejig,bringthe
waterto a boil,insert
theworkpiece
to
(above),
besteamed
andstuffa raginto
theopenendof thepipeto contain
the
"cook"until
steam.
Lettheworkoiece
thewoodsoftens;
asa roughguide,allow
per
t hour inchof thickness.
Refillthe
plugging
kettleasnecessary,
theendof
thetubetemporarily
to contain
thesteam.

GLOSSARY
A-B-C
Auxiliaryfencs A wooden attachment to the rip fenceof a table saw
or other machine,for the purpose
of avoiding accidentaldamageto
the metal fence.

Countersink: To drill a hole that

allowsa screwheadto lie flush with
or slightly below the surface.

Bench dog: A round or squarepeg

made of metal or wood that fits
into a hole in a workbench to hold
a workpiece in place.

Crosscut A cut made acrossthe

grain of a workpiece.

Bench stop: A jig fastenedto a work

surfaceto steadya workpiece.
Bevel cut A cut made at an angle
from faceto facethrough the thicknessof a workpiece.
Biscuit joiner: A portable power
tool usedfor cutting slotsfor wooden wafersin biscuit joinery. Also
known asa platejoiner.
Biscuit jointz Seeplatejoint.
Box joint A corner joint featuring
straight, interlocking fingers.
Carcasq The box-like body of a
pieceof furniture.
Chamfer: A bevelcut along the
edgeof a workpiece.
Chuck Adjustable jaws of a drill that
hold bits and other accessories.
Clampingcapacity: The widest span
of a clamp'sjaws.
Clearancehole: A hole bored in
a workpieceto accommodatethe
shank of a screw.

Cove:A concavedecorativeprofile
cut in wood, usuallyalong an edge.

D.E-F-G.H-I
Dado: A rectangularchannelcut
acrossthe grain of a workpiece.
Doweft Wood pin usedto reinforce
certaintypesof joints.
Edge-gluing:Bonding boardstogether edge-to-edgeto form a panel.
Extensiontable: An accessorywork
surfaceusedto expandthe working
areaof a stationarymachine.
Face-gluing:Similar to edge-gluing,
exceptthat boardsarebonded
face-to-face.
Faceplateturning: Turning circular
or cylindrical workpiecessuchas
bowls on the faceplateof a lathe.
Featherboard:A board with thin
"feathers"
fingersor
along one
end, clampedto the fenceor table
of a stationarytool to hold a workpiecesecurely.
Fence:An adjustableguide to keep
the edgeof a workpiecea setdistance
from the cutting edgeof a tool.
Fixture Shop-madedeviceattached
to a stationary or portable power tool
to increaseits capacityor efficiency.

Collet The sleeveof a router that

holds the bit shank.

140

Frame-and-panel joinery: A method

of assemblingboardsinto rectangular frames;groovesalongthe inside
edgesof the frame enclosea panel.
Furring strip: A thin board that is
nailed to a wall or ceiling to provide
a flat or level surface;normally used
for securingdrywall or paneling.
Groove A cut along the grain of a
workpiece,forming a channel;frequently decorative,but sometimes
part of a joint.
HeadstoclcThe spindle attachedto
the motor of a lathe;holds work for
spindle-turning in conjunction with
the tail stock,or usedalonefor turning with a faceplate.Seetailstock.
l-K-L-M-N-O-P-Q
fig: Devicefor guiding a tool or
holding a workpiecein position.
fointing: Cutting thin shavings
from the surfaceof a workpiece
until it is flat and perpendicularto
the adjoining surface.
Joist A horizontal support for a floor;
analogousto the raftersof a roof.
Kerf: The cut madeby a sawblade.
Kickback The tendenry of a workpieceto be thrown back toward the
operatorof a machineor tool.
Lap joint A joint in which matching dadoesor rabbetsoverlapto
connecttwo boards.
Miter cufi A cut that anglesacross
the faceof a workpiece.

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Miter gauge A devicethat slidesin

a slot on the sawtable,providing
support for the stockasit moves
pastthe blade for crosscuts;its angle
can be adjustedfor miter cuts.
Mortise: A rectangular,round,
or oval hole cut to accommodate
a tenon.
Mortise-and-tenon joint A joinery
techniquein which a projecting
tenon on one board fits into a cavity-the mortise-in another.
Pilot bearing: A cylindrical metal
collar aboveor below the cutting
edgethat guidesa router bit along
the workpieceor a template.
Pilot hole: A hole bored into a workpieceto accommodatea nail shaft
or the threadedpart of a screw;usually slightly smallerthan the shaft
or threadedsectionof the screw.
The hole guidesthe fastenerand
preventssplitting.
Platejoint A method ofjoining
wood in which oval wafersof compressedwood fit into slotscut in
mating boards.
Pockethole: An angledclearance
hole that allowsa screwheadto be
recessedbelow the surface;often
usedwhen joining rails to a tabletop.
Push block or stick: A deviceused
to feeda workpieceinto the blade,
cutter, or bit of a tool to protect the
operator'sfingers.

Quill stroke The length of travel of

the quiil of a drill press.
R-S
Rabbet A step-likecut in the edge
or end of a board; usuallyforms part
of a joint.
Radius:The distancefrom the center
of a circleto its outsideedge;onehalf the diameter.
Rait The horizontal member of a
frame-and-panelassembly.Seestile.
Raisedpanet A pieceof wood that
forms the centerof a frame-andpanel assembly.Bevelingthe edges
of the panel createsthe illusion that
the centralportion is raised.
Releasecut A preliminary incision
from the edgeof a workpiece to
a line about to be cut; enablesa
band sawor sabersawto cut tighter
curvesby facilitating the removal
of wastewood.
Rip cufi A cut that follows the grain
of a workpiece-usually made along
its length.

Spindle turning: Turning cylindrical workpiecesheld betweenthe

headstockand tailstockof a lathe.
Square:Adjoining surfacesthat
meet at an angleof 90o.
Stilq The vertical member of a
fr ame-and-panelassembly.Seerail.
T-U-V-W-X-Y-Z
Tirilstock The adjustablespindle on
a lathe; usedin conjunction with the
headstockto hold work for spindle
turning. Seeheadstock.
Thpercut An angledcut along the
length of a workpiecethat reduces
its width or thicknessat one end.
Tearout The raggededgesproducedwhen a bladeor cutter tears
the wood fibers rather than cutting
them cleanly.

Shooting board: A jig for holding

the end grain of a workpiecesquare
to the soleof a plane.

Template A pattern, typically made

of plywood or hardboard,usedwith
a power tool to produce multiple
copiesof an original.

Sizing board: A jig usedto cut workpiecesto length, typically with a

handsaw.

Tenon:A protrusion
from the end ofa board: cut to fit
into a mortise.

Snipe A concavecut createdby a

jointer or planer at the end of a
workpiece,the result of improper
pressureor table height.

Wall stud: A vertical framing member forming wallsand supporting

the framework of a building.

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Spindle: The threadedarbor on a

lathe that holds the headstockor
faceplate;alsothe threadedarbor
on a drill pressor shaperthat holds
cutters,bits, and other accessories.

L4T

INDEX
Pagereferencesin irallcsindicate
an illustration of subject matter.

A-B-C
Band saws:
Circle-cutting jigs, j7, 44-45
Extension tables,102, 104, 110
Miter jigs, j8,47
Taper jigs, j8,47
Wedge-making jigs, 38, 46
Bar clamos:
Crossbirs for edge gldng, 80,82
Glue racks, 8O 8l
wall-mounted, 80,85
Storage
mobile storageracks,ll6, 118-119
storing clamps in a can (Shop
Tip),119
Beeken,Bruce, 10-11
Belt sanders.SeeSanders
Benchdogs,79,91-92
Lamp supports,123,137
Bench grinders:
Gouge-sharpeningjigs, 69, 72
Benchslaves,104,112
Biscuit joints. SeePlate joiners
Boxjoints, 12
Carcases:
Carcase-squaringblocks, 79, 89
Chiselracks,ll5
Circles:
Centerfinders, 124,132
Circle-cuttingjigs
band saws,37,44-45
rotters, 15,20
sabersaws,37,43
shapers,15,31
Circle-sanding jigs, 95, 96-97
Faceplate-centeringjigs for lathes,69, 71
Scribing jigs
compassjigs, 124,133
router compassjigs, 15,20
trammel points, 124, 133
Circular saws:
Bladestoragebox, 115,117
Kerfsplitters,38, 42
Miter and crosscutguide,37,41
Straightedgegtides, 38,42
Clamps,79
Framing clamps,78, 80,87
figs for clamping thin stock, 8O 84
Miter clamping blocks, 79, 88
Rope clamps for carving (Shop Tip), 88
Storageracks,114,116,118-119
Wedged clamping bars, 8Q 83
SeealsoBarclamps; Pipe clamps; Vises
Curved cuts:
Routers
corner-rounding jigs, 14, 2j
Sanding,98
Seealso Circles

D-E.F

G-H-r-J-K

Dadoes:
Routers
adjustabledadoingjigs, 15, I9
jigs for evenly spaceddadoes,J3, I7
quick-setup dadoing jigs, .15,l8
T-squarejigs,15, 16
T-squarerouting guides(ShopTip), 16
De Cristoforo,R.J.,6-7
Dovetail joints:
Sliding dovetail router jigs, 14,26
Dowels:
Inserting dowels with a depth gauge
(ShopTip), 62
Drawers:
Drawer-slidepositioningjigs
(ShopTip), 138
Drill oresses:
Cuiting rosetteson the drill press
(ShopTip), 67
Deep hole-drilling jigs, 67
Depth guides (Shop Tip), 65
Extensiontables,104, 111
|ig for drilling equally spacedholes,
60,61,64
Making wooden plugs (Shop Tip), 64
Pocket hole jigs, 61, 66
Sandingdrums (ShopTip),97
Tables
auxiliary sanding tables,95, 98
tilting tablejigs, 61,63
V-block jigs, 61,6s
Drills. SeeDrill presses;Electric drills
Drum sanders:
Drill presses(ShopTip), 97
Lathes,70,77
Electric drills:
Center-drilling jigs, 61, 62
Depth guides(ShopTip), 65
Removablepower tool tables,104,
108-109
Extension stands:
Yises,104,112
Extension tables, 103
Band saws,102,104, 110
Drill presses,104, 111
Routers attachedto saw tables
(ShopTip), 107
SeealsoTables
Fasteners,/ron t endpaper
Featherboards,
I 5, 32, 12i, 125-126
Beveled,123,127
Extended shaperfeatherboards, 15,32
Shimmed,123,127
Vacuum jigs, 34
Finishes:
Controlling finish on brushes, J35
Drying supports,124, 135
Sprayingturntables, 122, 124, 136-137
Stackinghandles, 124, 135
Fuller,Ted,8-9

Glue racks, 80, 8l

Wall-mounted, 80,85
Har dw are, fr ont endpaper
Hinge mortises:
Router jrgs, 14,22
Jigs:
Planning,l0
Seealso namesof specifictools
Joinery:
Routers
box joints, 12
corner half-lap jointjigs, 14,27
sliding dovetail roter jigs, 14, 26
Table saws
tenoningjigs, 39, 57-59
SeealsoDadoes;Mortises; Plate joiners
Jointers:
V-block jigs for chamfers, 124, 132
Jointing:
Routers, 2l

r42

L-M-N-O
Lathes:
Center-finding jigs, 69, 71
Column fluters, 70, 75- 76
Faceplate-centering jrgs,69, 71
Gauges
bowl depth gatges,70, 77
diameter gauges,69,73
Gouge-sharpening jrgs,69, 72
Sandingdrums,70,77
Spindleturning
centering a spindle blank
(ShopTip), 70
faster turning with preset calipers
(ShopTip), 73
layott jigs, 69, 73
Preservlngsquarecorners
(ShopTip), 74
Tailstocks for hollowed-out work,
68,70,74
Lumber:
Sizes,backendpaper
Storageracks,ll6, 120,121
Truing uneven boards, 39, 53
Mortises:
Routers
adjustablemortising jigs, i4, 28
hinge-mortisin g jrgs, 14, 22
movable-jaw mortising jigs, .14,29

P-Q-R
Panels,raised:
Routerjigs,8-9,14,24
Table sawjigs, 3t 52
Parsons,Jeff,l0- I 1
Pipe clamps:
Crossbarsfor edge gluing,80,82
Extenders,80, 86
doubling up pipe clamps
(ShopTip), 86

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Storage
mobile storageracks,118-119
storing clamps in a can
(ShopTip), lJ9
wall racks, 1.16
Planes:
Clamping long workpieces, 128
Honing jigs (ShopTip), 139
Planing jigs for thin stock, 124, lj1
Running guides for short stock, J30
Shootingboards,124,134
Plate joiners:
Stands,103,105
Plywood:
Carriers,123,130
Storageracks, 116,120
Push blocks, 123, 125
Push sticks,123, 125,126
Radial arm saws:
Auxiliary fence and table molding
fixtve,39,54
Sanding jigs, 95, 99
Taper jigs,48
Roller stands, 103
Adiustable,104,113
Temporary (Shop Tip), 113
Rosettes:
Cutting rosetteson the drill press
(Shop Tip), 67
Routers:
Adjustableedgeguides,15,25
Auxiliary sub-bases(Shop Tip), 13,21
Bit storagerack, I 15
Circles
adjustable circle-cutting jigs, 15,20
compassjigs, 15,20
Column flrters, 70, 75-76
Corner-rounding jigs, 14, 23
Dadoes
adjustabledadoingjigs, 15, l9
jigs for evenly spaceddadoes, 13,17
quick-setupdadoingjigs, 15, l8
T-squarejigs,15,16
_
Jolnery
box joints, 12
corner halfJap jointjigs, 14,27
sliding dovetail jigs, 14,26
Mortises
adjustablemortising jigs, 14,28
hinge-mortising jigs, U, 22
movable-jawmortising jigs, 14,29
Panel-raisingjigs,8-9, 14,24
Tables
removable power tool tables, 104
108-109
table/cabinets,10i, 106-107
tablesattached to the table saw
(ShopTip), r07
Vacuum templates,35

S-T-U
Sabersaws:
Circle-cutting jigs, 37, 43
Edge guides
miter and crosscut gtide, 37,41
Removablepower tool tables,
104. 108-109
Safetydevices, 13,32, 33, 123, 125-127
Sanders:
Circle-sanding jigs, 95,9G97
Gang sanding, 96
Sanding:
Blocks. 94
contoured, 95,100-101
wood sanding blocks (Shop Tip), 100
Drill oresses
auxiliary sanding tables,95 98
sanding drums (Shop Tip), 97
Folding sandpaper(Shop Tip), l0l
Lathe sanding drums, 70, 77
Radial arm saws
sandingjigs, 95, 99
Thin stock, 99
SeealsoSanders
Sandpaper:
Folding sandpaper(ShopTip), I0I
Sawhorses,124, 128-129
Padding sawhorses(Shop Tip), 129
Saws:
Back saws
sizing boards for crosscuts,3Z 40
Handsawholders, 116,117
SeealsoBand saws;Circular saws;
Radial arm saws;Saber
saws:Table saws
Shapers:
Circle-cutting jigs, 15,31
Featherboards,15,32
Guards,13,33
Shop Tips:
Clamps, 86, 88,92, 119
Drilling, 62,64,65,67
Lathes,70,73,74
Planes,139
Routers,16,2l
Sanding,97,100,101
Sawhorses,129
Tablesand stands,107, 113
Table saws,49, 53, 55,59
Tools. i36
Square:
Checking,backendpaper
Tables,103
Band saws
extension tables,102, 104, 110
Drill presses
auxiliary sanding tables,95, 98
extension tables,104, 111
ti-lting table jigs, 67, 63
V-block jigs, 61,65
Electric drills
removable tables, 104, 108-109
Plateioiner stands,103,105

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Routers
attachedto saw tables
(ShopTip), 107
removable power tool tables, I04,
108-109
table/cabinets,103, 106-107
Sabersaws
removable tables,104, 108-109
Table saws
routers attached, (Shop Tip), 107
shop-made inserts (Shop Tip), a9
Seea/soWorkbenches
Table saws:
Blade height gauges,8, 49
Bladestoragebox, 115,117
Board-straighteningjigs, 39, 53
Cove-cutting jigs, j9, 56
Crosscutjigs, 36, 38, 50-51
Crosscuttingwide panels (Shop Tip), 53
Miter gauges
angle-settingjigs (Shop Tip), 59
extensions(Shop Tip), 55
Miter jigs, 39, 50
Raisedpanel jigs, 39, 52
Routers attachedto saw tables
(ShopTip), 107
Shop-madetableinserts(Shop Tip), 49
Switches
auxiliary switches,123, 131
Tables
routers attachedto saw tables
(ShopTip), ]07
shop-made inserts (Shop Tifl, a9
Taper jigs,48
Tenoning jigs, 39,57, 58-59
SeealsoFeatherboards:Push sticks
Templates:
Vacuum templates,35
Tools, backendpaper
Lubricatingtools (ShopTip), 136
Storage,I 15
chiselracks,ll5
handsawholders, 716,117
tool trays, l.l5
Seealso Clamps;Drill presses;Electric
drills; Jointers; Lathes;Planes;Plate
joiners; Routers; Sanders;Saws;
Shapers
Turning tools:
Gouge-sharpening jigs, 69, 72

V-W-X-Y-Z
Vacuum jigs, 34-35
Vacuum screeningramps, 124, 137
Vises:
Extension stands,104, 112
Wood-carver's vises,8O 9J
Wood. SeeLumber; Plywood
Workbenches:
Bench stops, 29, 90
Gripping thin stock (Shop Tip),92
Lamp supports, 123, 137
SeealsoBenchdogs;Tables

ACKNOWLEDGMENTS
Theeditorswishto thank thefollowing
ROUTING AND SHAPING IIGS
AdjustableClampCo.,Chicago,IL; AmericanTool Cos.,Lincoln,NE; Black& Decker/EluPowerTools,Towson,MD;
DeltaInternationalMachinery/Porter-Cable,
Troy, Ml/WainbeeLtd.,Montreal,Que.;
Guelph,Ont.; De-Sta-Co,
FreudWestmoreTools,Ltd.,Mississauga,
Ont.; LeeValleyToolsLtd.,Ottawa,Ont.;
Sears,Roebuckand Co.,Chicago,IL; Shopsmith,Inc.,Montreal,Que.;PatrickSpielman(jig on pp. 34-35),
FishCreek,WI; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
CUTTINGJIGS
AdjustableClampCo.,Chicago,IL; DeltaInternationalMachinery/Porter-Cable,
Guelph,Ont.; De-Sta-Co,
Troy, Ml/WainbeeLtd.,Montreal,Que.;FisherHill Products,Inc.,Fitzwilliam,NH; FreudWestmoreTools,Ltd.,
Mississauga,
Ont.; HitachiPowerToolsU.S.A.Ltd.,Norcross,GA; FrankKlausz(jig on pp. 58-59),
Frank'sCabinetShop,Inc.,Pluckemin,NJ; SandvikSawsand ToolsCo.,Scranton,PA;
DaveSawyerand JoanSawyer(jig on p. 46), SouthWoodbury,VT and RanchoSantaFe,CA;
Sears,Roebuckand Co.,Chicago,IL; Shopsmith,Inc.,Montreal,Que.;Skil PowerToolsCanada,
Markham,Ont.;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
DRILLINGIIGS
AdjustableClampCo.,Chicago,IL; DeltaInternationalMachinery/Porter-Cable,
Guelph,Ont.; Sears,
Roebuckand Co.,Chicago,IL; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
TURNINGIIGS
AdjustableClampCo.,Chicago,IL; DeltaInternationalMachinery/Porter-Cable,
Guelph,Ont.;
LeeValleyToolsLtd.,Ottawa,Ont.;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY

(jigonp.8s),H".:1,,X:)glil?,rc"t#t:tJS,Iirc,sr,,r.*t'u
BiltBivona
collins(jigonp.84),
LostMountainEditions,Ltd.,Sequim,WA; LeeValleyToolsLtd.,Ottawa,Ont.
SANDINGIIGS
AmericanTool Cos.,Lincoln,NE; Black& Decker/EluPowerTools,Towson,MD; DeltaInternational
Machinery/Porter-Cable,
Guelph,Ont.;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
TOOL EXTENSIONSAND TABLES
AdjustableClampCo.,Chicago,IL; AmericanTool Cos.,Lincoln,NE; DeltaInternationalMachinery/Porter-Cable,
Guelph,Ont.; Hitachi PowerToolsU.S.A.Ltd.,Norcross,GA; LeeValleyToolsLtd.,Ottawa,Ont.; Steiner-Lamello
A.G.
Switzerland/Colonial
SawCo.,Kingston,MA; VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
STORAGEDEVICES
AdjustableClampCo.,Chicago,IL; AmericanTool Cos.,Lincoln,NE; GreatNeckSawMfrs. Inc.
(BuckBros.Division),Millbury, MA; LeonardLee(rackon p. l2l), LeeValleyToolsLtd., Ottawa,Ont.; SandvikSaws
and ToolsCo.,Scranton,PA;VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
SHOPAIDS
AdjustableClampCo.,Chicago,IL; CampbellHausfeld,Harrison,OH; DeltaInternationalMachinery/Porter-Cable,
Guelph,Ont.; Hitachi PowerToolsU.S.A.Ltd.,Norcross,GA; TaylorDesignGroup,Inc.,Dallas,TX;
VermontAmericanCorp.,Lincolnton,NC and Louisville,KY
Thefollowingpersonsalsoassisted
in thepreparationof this book:
LorraineDor6,RjeanGarand(Atelierd'Eb6nisterie
R6jeanGarandEnr.,St-Rdmi,Que.),GraphorConsultation,
ClaudeMartel,GeneviiveMonette,Alain Morcel (LesR6alisations
Loeven-Morcel,
Montreal,Que.)

PICTURECREDITS
Cover RobertChartier
6,7 RobertHolmes
8,9 MichaelMorissette
10,ll Ron Levine

r44

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r
I

WORKSHO
GPU I D E
INVENTORY
OFMEASURING
TOOLS
ANDDEVICES
Utility knife
tharpenedLipacoree
lineaon woodmore
preciseiy
_-<--b

Combination 6quare
For checkin4or markinq 45' or
90" an4lea;detachable blade
doublee ae ruler or

izi:f67

For checktn7or
meaeunn690'
an4lee on a flat
surface; can aleo be
ueed ae a ol,ratqhLedqe

Uaeful for eetLtnq

an4leeof machtne

etraiqhtedqe, one pointt eervea aa

the pivot and the other acilbee a
circle or an.arc around it.

9traightedge
For precieion markin1 of etrai4hL ltneeand checkinqflat
eurfacea. Thick metal ed4ee are machtnedetrai4ht;

TIPS()NWORKING
WITH
PTYWOOD
ANDSHEET
MATERIATS

. Whenusingplylvood,
layouttheelements
of yourprojectonthe sheetfor economy
and
bestappearance
of grainpattern.

o Tocutsheetmaterials,
usecarbide{ipped
blades
withat least10 teethperinch.

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oAlways
cut plywood
withthegoodface
up to avoidtearout.

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r Whenfastening
edgesof sheetmaterials,
usescrews
that areno largerin diameter
thanone-quarter
of the sheet'sth ickness,
Drillpilotholesto prevent
splitting.
. Storesheetmaterials
flat or wellsuooorted
vertically:
do notstorethemat an angle.

9liding bevel
Adjuet e to copy any an7le,
then 1;otranefer or mea7ure
i[. 7lade al;oree tn handle

French curue
For drawing curved
linea on a workptece

C H E C K I NAGS O U A R E
Deforeuornqa cquare,makeeure iL ia accurate. Workinqon a large
sheet of paper,draw a baaelineueinqa eLraiqhLedqe.
(For a combinatton or t ry zquare,uee the perfecLlyetratqht edqeof a board ae
the baeelrne.)Flace Lhe equare wtth one arm flueh wit;hLhe ltne,and
draw anoLherlinealonqthe outetdeof Lheother arm. Fltpl;heaquare
over,keepinqLhe eame arm flueh on the baeeltneand repeal;,Thbtwo
lineeyoujuet. drew ehouldbe per-fecLly
parallel.To true a carpenlter'e
equareugea cenlierpunchta tap Lhe
gquare on iLa outeide corner Lo
move the arme cloeer toqether,
or on iLe inoide corner to move

the arme aparL.TeaLa4ain,

and repeat until the arme
are perfecLlyequare.

NOMINAL
ANDACTUAL
SIZES
OFSOLID
WOOD
STANDARD
THICKNESS
FORSURFACED
HARDWOOD
NOMINAL
(rough)

N()MINAL
ANDACTUAL
SIZES
FOR
SOFTW()OD
LUMBER

ACTUAL
(surfaced
twosides)

%'

3/rc"

t/z'

5/rc"

u/"'

7Aa"

'/o'

a' / /

t
16

3/4t or l3/rctl

LYqu

Ir/rc"

IYr"

1 q /

2u

r"/ t6

IVz"or I3/+"

N()MINAL
(INCHES)

ACTUAL
(rNcHES)

NOMINAL
0NcHES)

Surfaced
dry
I-by-2
1-by-3

3h-by-7t/z

Surfaced
dry

3h-by-2r/z

Z-by-2
2-by-4

1-by-4
1-by-6

3h-by-3r/z

2-by-6

3h-by-5r/z

1-by-8

3h-by-7rh

1-by-10
I-by-12

3/q-by-9r/a

Z-by-8
2-by-I O
2-by-12
4-by-4

3h-by-l|rh

ACTUAL
flNCHES)
It/z-by-Ir/z
It/z-by-3r/z
Ir/z-by-5r/z
It/z-by-7rh
It/z-by-9rh
I\/z-bY-IIrh
3r/z-by-3t/z