ShopNotes Magazine Issue 135

There are times when we feature a project that leaves me wondering, “Why hasn’t someone done this before?” In this issue, it happens to be the drill press table shown on the cover (the detailed plans start on page 34). At first glance, it looks like a typical drill press table with a large worksurface, an adjustable fence, and a replaceable insert — all must-have features. But the amazing part is what’s underneath the table. There you’ll find a clever solution to the main problem of adding a large table to any drill press — the hassle of reaching around to the back to make adjustments. It can be difficult to loosen the table lock and crank the handle to adjust the table height up or down without banging your…

Versatile Miter Jig Instead of a miter gauge, I prefer to use a sled for all of my crosscutting at the table saw. To avoid having to remove the sled to make mitered cuts, I came up with this simple jig. The miter jig clamps to the crosscut sled to make accurate 45° cuts. Then it’s quick to remove to use the crosscut sled for straight cuts. This jig is also versatile enough to be used by itself by running it against the table saw rip fence to make mitered cuts. NOTE: USE CLAMPS TO ATTACH JIG TO CROSSCUT SLED NOTE: BASE IS MADE FROM ¼" HARDBOARD. CLAMP SUPPORT IS ¾" PLYWOOD. FENCE IS 1"-THICK HARDWOOD NOTE: INSTALL TOGGLE CLAMPS AFTER BASE, CLAMP SUPPORT, AND FENCE ARE ASSEMBLED To build the…

Several years ago, I bought a lock miter router bit, thinking it was an ideal solution to strong, perfect-fitting miter joints. The idea behind the bit is simple and ingenious. With a single setup, the bit allows you to rout both halves of a miter joint that incorporates a tongue and groove. This aligns the joint for assembly and creates an interlocking connection that increases its overall strength. It works great for everything from boxes and cabinets to table legs. (See the box on the facing page.) A Sticking Point. The bit certainly lived up to the hype. But there’s a downside. The setup can be time-consuming. The reason is the bit height and fence setting work together and in turn, depend on the thickness of the parts being routed. You…

Box joints, with their interlocking fingers, have been a favorite of box builders for over 100 years. Factories use specialized machinery to mass-produce box joints. In the home shop, the table saw or router table does the job. But there’s a limitation in the size of the box and joinery you can create using these tools. For large casework like blanket chests, toy boxes, and tool chests, making box joints this way can be cumbersome, at best. A better solution is the Portable Box Joint Jig from Woodhaven. It’s unique in that the jig fastens to the workpiece and you use a hand-held router to cut the joinery. With this method, you’re not limited by the size of the workpiece as you might be at the router table or table…

Woodscrews are my fasteners of choice for most tasks. But every once in a while, a project comes up in my shop where I need something stronger. The tower cart on page 14, which is built to hold heavy tools and equipment, is a good example. In these situations, I’ll turn to heavy-duty fasteners like lag screws, carriage bolts, and lock nuts. All three of these choices offer a step up from standard screws and nuts in terms of strength and holding power. Here’s what you need to know to choose the right one for your project. LAG SCREWS With a pointed end and a tapered, threaded shank that pulls the fastener into wood, lag screws share similarities with woodscrews. One big difference, of course, is that lags are larger…

In my small shop, it’s a constant struggle to keep clutter at bay. It seems that every flat surface is a magnet for everything from tools to project parts to hardware. In an effort to free up the already crowded floor space, I built the tower cart you see here. The three sturdy shelves allow you to store several tools and accessories vertically. The wide base provides stability when rolling the cart on its locking casters. You can position the middle shelf to serve as an auxiliary worksurface. And each shelf includes a drawer that’s accessible from either side of the cart. All in all, this practical, easy-to-build cart is a must-have in any woodworking shop. start with the Ends The great thing about this cart is that you can…