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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?
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+ Hands-on techniques and
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+ Ideas for setting up your shop
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For more than 15 years, ShopNotes has been
dedicated to helping woodworkers get the
most out of their shops. We've featured
hundreds of versatile upgrades, add-ons,
shop-built tools, and other projects. In this
book, we've gathered a few of our favorites
It all starts with the heart of the shop
— the table saw. Beginning on page 8,
you'll find projects that will make working
‘with your table saw easier, more accurate,
and safer. 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.comWY
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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 TsROUTER 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.
92Top
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 doOVERALL 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 910
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NOTE: ease ano miner s.0ce
NTE PAwrooe, srrenens
Bnd Lkbe Novane
‘ee etbeo Urrmow
‘wo tarexe OF
ences
BASE
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GTIFFENER
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ADuUSIASLE a
MITER BAR ¢
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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