im <4 Pe A. PEUS;)° IEXGLUSIVE[ONDINE ars Sire Mussina (ue ¢ Router Drill Press * Table Saw ¢ Band Saw & Much More...Tools & Jigs PLANS, TIPS, TECHNI President & Publisher: Donald Pexhke Editor: Ter ,Svohman Managing Editors: Biyan Nelion, Vincent 8. Ancona Senor Editors: Phi Huber, fed Rife ‘Assistant Editors: Mitchell Holmes, Randall A.M Dennis Perkins, Caro Bernich Editorial Interns: Abby Harvey, Kati % Executive Art Director: Tos Lambith {Ar Director: Cary Chistensen Senior lustrators: David Kieyling, Dik Vor Steey Harlan Clark, David Kallen, Peter Larson Senior Graphic Designers Jamie Dovininy Bob Zimmerman Graphic Designers: shelly Cronin Graphic Dosign Intern: Eriy Sibert. St Photographers: Crayols England, Oenns Keely Associate Style Director: Rebecca Cvsninghan Electronic image Speclalst: Alan Hulse ‘Creative Director: To Kral ‘St Project Designers: Ken Mure et Wel ‘Shop Craftsmen: Stove Cutis, stove Jolson Project Designers/Builders: Mike Dorval Dole wis Contributing Art Director: Dov) Hi Videographers: Mark Hayes, Cin | Nueguegge? ‘Single Copy Sales isa Tom, Sai Bou New Media Manager: Gown Gao “Took igs: Plans, Ty ISDN VTA OTN ie publi by As ing Company, 2200 Grand Ave, Des Moi {Cana ow Apron a0 8201 (Canad BN 94597 5173 RT [OCopyegh 2007 Asus Hoe Pubs All ahs reserved Nop ‘rsaps may te qt free Woodseih® and ShopNives® are rg ears of Ag Home Publihag Co. For sabcrpton nkrmatio bot ‘ods Shope, it oie sxatxtWondsmith.com ol (0) 335078 ‘wt ShopNokes.con oe 0) 395854 Avsust HOME Zo Gand Ave, Des oie 1A $0412 Printed in USA, HHO SAFETY 1A YOUR RiNPOMAMONITY tn tt a nal pod todo oe wand weg Web hag me hun Copy nae dead lon tele et of trata aati ow Saletan nando bch(WShoplNotes> FREE Preview Issue Voucher Ton Pa bret ens te (AYES! please send mea Free Preview Issue of ShopNotes. ike it, Il get afull yar (6 issues) for only $24.95 ~a 1696 savings off the cover price! f not Ill write “cancel” on the bill,return it and owe nothing, The Free Preview Issue is mine to keep! Make the Most of Your Home Shop! ShopNotesis packed with projects, tipsand ideas tohelp you get more ‘ut of your tools and rake your shop a better place to work, : + Hands-on techniques and shop-tested tps + Ideas for setting up your shop Payment enclosed Bill me aa Trea + digs and accessories or, ae faster more accurate cuts PEE) Access + Storage solutions for your tools h SF Allwith NO ADS! i Gy Sate Zp : Seip eaine clan Mail this voucher today & get exon rr Ca ie np fps mn | aFREE Preview Issue i of ShopNotes! MAIL TODAY! Offer subject to change. ssBasToL Try These Woodworking & Magazines e WeSaSi> FREE Preview Issue Voucher Becomaiapstts) AYES! Pease send mea Free Preview issue of of Woodsmith! MAIL TODAY! Offer subject to change. albaestos Woodworker! Woodsmith ike it, geta fll year (6 issues) for only $24 viocchmthhelpsyou buldyour —-~=~*« 8.19% SavINgs off cover price! If not, write“cancel” on PORNO TATE ry bil retum itand owe nothing, The Free Preview Issue is. 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Plus, there area few jigs you can build to turn your saw into a precision, joint-making machine. For shear versatility in the shop, it’shard tobeata router. And on page36, we'llshow you how to make the number one upgrade —assimple, inexpensive router table. Itcan even be used to power a shop-built tool, like the exige jointer you see at left While your at it be sure to check out the ceasy-to-build upgrades and add-ons for your drill press and band saw. + Techniques in Every Issue www ShopNotesSpecials.comWY Wo) fore} WY pee | fe) fe) 2 = =) a a S ass 5) 3-IN-1 SLED This cutoff sled features reversible fences that can make accurate 90° and 45° cuts 8 OUTFEED TABL| 4 TOOLS M fia Mier TsROUTER TABLE With just one sheet of plywood you can build a top-notch router table in a weekend. 36 ROUTER TABLE SLED Rout perfect-fitting joinery quickly and safely with this easy-to-build sled. 42 SHOP PLYWOOD Learn about a variety of plywood ‘options, and find one to best suit your shop project 48 THICKNESSING JIG You don't need a planer to thickness, flatten, or smooth stock accurately — just this simple jig 50 wwiShopNotesSpecials.com DRILL PRESS TABLE A large top, an adjustable fence, and handy features make this the last drill press table you'll need. 58 BAND SAW TABLE Take your band saw to the next level by adding an adjustable fence anda sturdy, extra-large table. 64 PANEL SAW This siding-carriage panel saw allows one person to cut or rip a {ull sheet of plywood with ease 72 THICKNESS SANDER Powered by your table saw, this tool will sand panels up to 16" wide so they're smooth and flat. 82 ROUTER JOINTER Turn your router into a jointer and create a smooth, straight edge that’s perfectly square. 92Top Table Saw _ Accessories _ The table saw is the heart and soul of most ‘woodworkers’ shops. Here are four must-have accessories that will help yu get more from this versatile machine BeIN-1 SLED... scsstecsres OUTFEED TABLE BOX JOINT JIG TENONING JIG.........3-In-1 Cut-Off Sled Reversible fences make this cut-off sled perfect for accurate crosscuts and miters. For even more versatility, you can build the add-on tenoning jig. Accurate Miters. Simply flip the adjustable fences on the sled around to cut perfect, 45° miters every time Want to make your table saw more versatile and ne time? The answer is in more accurate at the $3 the 3-in-1 table saw cut-off sled shown above, Whether you're cutting a small workpiece to final lengthorsquaring up theendofalargepanel, youcan be certain they're perfectly square. The construction of the jig and sliding, fences ensure th nd precision ate built into your workpiece ‘Square crosscuts aren’t the only thing accurately with this sled. Simply reverse the fences like you sce in the photo at left, and you tight-fitting 45° miters for just about any pro If perfect crosscuts and miters haven't sold you on this sled, then take a look at the third e of this project — the add-on tenoning jig. It holds a workpiece securely in place while you cut the cheeks of a tenon perfectly smooth, fou can doOVERALL DIMENSION: BOW x 24°D x 475" — ALUMINUM GUIDES Lock FENCES: WHO RERF IN BADE OF SLED — RET, EcoRADY BY GUIDING SLED. Bhatt ACKOS TABLE SAW Materials & Hardware ‘wow. ShopNotesSpecials com 910 oe NOTE: ease ano miner s.0ce NTE PAwrooe, srrenens Bnd Lkbe Novane ‘ee etbeo Urrmow ‘wo tarexe OF ences BASE ene) GTIFFENER se10NG ADuUSIASLE a MITER BAR ¢ sexx rn woobscKew so0% eh woobscrew Building the Base Building the cut-off sled isn’ta difficult task, What's important is to build accuracy into the sled as you 40. So, before you get started, it’s worthwhile to take some time up front to get the base set up well. ‘This way, using the sled will be automatic later. First, your saw’s blade, miter slots, and rip fence need to be aligned parallel to each other: It'sa good. idea to consult your owner’s manual if you need to make any adjustments, The other thing to keep in mind is that one comer of the cutoff sled’s base GENTERLINE OF SLED -must be cut at exactly a 90° angle. This way, you can rest assured that once you have completed the sled, the fences will be perfectly square to the blade. MAKE THE SLED BASE “The base of the sled starts as. rectangular piece of 5" plywood, as shown in Figure I. (I used Baltic birch.) ‘As mentioned earlier, one corner of the sled must be square, So, after cutting the base t size, I checked the comers with a framing, square and marked one cor ner to use as a reference, as illustrated in Figure 2 The next step is to cut a shallow kerf across the back edge of the base. This isshown in Figures 2and 2a, This kerf will lock the fences in place — whether ‘you are using the sled to make a 90° or a45° cut. ADD THE BASE SUPPORTS When you use the sled for the first time, you'lnearly ccut the base in two. So, the next thing you need to dois toadd supports to hold it together when you make the cut. To help position the supports, it's a ‘good idea to mark a centerline on the sled. MITER BLOCK, The first support to add is the miter block (Figure 1). This triangular piece of plywood acts as a stop to position the fences on the sled. It's important here to cut the block accurately, so that ‘once it's glued in place it’s flush along the back edge of the base and forms 45° angles on each side. Toots & fics: PLans, Ts, Teciseques