ShopNotes Magazine Issue 137

Just like you can’t make an omelet without breaking a few eggs, you can’t do much woodworking without generating some sawdust. In the past, I’d get out my shop vacuum once a week and suck up as much as I could. It wasn’t long before I decided that a dedicated dust collection system was a shop necessity. Now, dust collection may not be the most exciting aspect of woodworking. It’s probably why so many of us focus on the more “fun” aspects and put off dealing with it for so long. But dust managment is important not only for keeping your shop clean, but also for your health. So if you’re still cleaning up your shop with a broom and dust pan, you’ll want to check out a couple of…

THE WINNER! Cutoff Storage Bin I used to spend too much time searching for the right dowel or cutoff. To solve the problem, I came up with the storage system you see here. Using 4"-dia. thinwall, sewer and drain pipe available at the home center, this bin provides compartmented storage for cut-off strips of differing lengths down to 12". The design allows me to quickly and easily find whatever piece I’m looking for. Cut & Assemble the Tubes. To make the storage system, you will need five 10' lengths of 4"-dia. pipe. Start with the longest length first (48") and then cut each length 2" shorter than the previous one. (The last length will be 12".) This produces 19 individual tubes. Then use a band saw or a reciprocating saw…

A dado joint doesn’t attract the same kind of “oohs” and “aahs” that dovetails get. But what they lack in visual appeal they make up for in everyday practicality. However, it still takes some care to get a joint that fits well and looks good, too. I’d like to take a closer look at cutting these joints at the router table. To my mind, the router table is ideal for cutting narrow dadoes in small parts like drawers, boxes, and trays. A straight-cutting router bit leaves a smooth, flat-bottomed dado for a strong glue joint. The following tips and tricks will give you an idea of the process and help you get better results. The Right Bit. For simplicity and accuracy, I like to rout dadoes that match the width…

T-track has countless uses in the shop. It’s a quick and easy way to complement a worksurface or shop jig by providing a method for attaching clamps and other fixtures. So when Rockler came out with the T-track system you see above, I had to take a look. The Rockler system capitalizes on the usefulness of T-track. The foundation of the system is the T-track tabletop. From there, they offer a whole host of accessories. And the beauty is, you can still make your own jigs and fixtures to fit the system using readily available T-track hardware. T-Track Tabletop. As shown above, the T-track tabletop is everything the name suggests. It makes a great worksurface for all-around woodworking but it’s even more useful for clamping and assembly. The tabletop is…

Using plywood for building cabinets and other furniture is a great way to create strong, good-looking projects. Lumberyards and home centers are stocked with sheets of plywood in a range of wood species. What they don’t have in stock, they can often order. And using sheet goods is usually much less expensive than building the entire project out of hardwood. Those are all big pluses. But the catch is you’re usually limited to buying full sheets at a time — even if the project doesn’t call for that much material. A 4'x8' sheet of plywood is heavy and awkward to transport. Once in the shop, you’re faced with the task of breaking it down into project parts. That’s easier said than done. Besides the added expense of buying full sheets,…

Ever since I purchased a pocket hole jig, I’ve found more and more ways to use it in my projects. But I’ve always felt I could get more use out of the jig if I had a dedicated workstation. The portable workstation you see above is the answer. First of all, the “wings” fold down to provide a wide, stable base. Each wing contains a drawer with dividers for storing screws, drill bits, and drivers. A sliding insert on the top of each wing provides support for large workpieces. And a pair of adjustable stops allow you to drill holes at the same locations on multiple workpieces. Finally, when you’re done for the day, the wings fold up for storage. The hardwood handle secures the wings and the drawers until…