DeWalt PowerShop Build #3: More Pieces, More Progress

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Blog entry by Smitty_Cabinetshop posted 04-01-2014 12:35 AM 2745 reads 0 times favorited 33 comments Add to Favorites Watch
« Part 2: A Basic Framework Part 3 of DeWalt PowerShop Build series Part 4: Uncertainty and Missteps »

I’ve managed to squeeze a few minutes’ time into the shop, which was long enough to complete a couple of sub-tasks on the PowerShop Bench (PSB). Which also made me think to do a quick update to this blog series. At this point the PSB consists entirely of five ribs and two struts and is structurally able to stand on its own. No glue or screws yet, just dry-fit; as I’ve mentioned, DW102 didn’t come with build instructions or narrative.

When the seven pieces I’ve made thus far are supposed to be fitted and permanently fixed into place, in other words, is unknown. So with that said, what next? I think it’s the two plywood bottom pieces.

I collected a used and slightly abused 5/8” sheet of plywood from inventory and laid out cuts that would avoid an area of blowout on the stock and get me both bottoms. Cuts were made with a circular saw (the Black and Decker Sawcat of the late 80s is an awesome tailed apprentice, BTW) on a pair of horses, with additional trimming done via RAS. Processing sheet goods is not my favorite activity – where have I heard that before- but with the stuff was cut to width, notches had to be cut so the bottoms could trace around each inside rib structure. Those notches were traced against a 1×6 cut-off and completed at the bench via handsaw.

At that point this first, smaller bottom was ready for fitting and it went well!

Repeat the process for the cuts on the larger carcase bottom and I’m good to go, right? Well, in theory, yes. A bunch of measuring had to be done to the elongated carcase bottom shelf in that it’s not on the drawing; that side of my build is essentially twice the width of DW102 but not exactly. The first piece was true to the drawing and progress on that one was quick. Well, the second went quick too, only it was wrong. Shouldn’t be in a hurry to make a mistake, I guess.

A Diversion
At this point, an error surfaced because I used a certain 1x cut-off to mark the notches shown in the previous pics… You see, I’m what some might call a hand tool junkie. I wouldn’t go so far as saying I’m a galoot, because I wouldn’t want to be associated with a group that would consider folks like me for membership. But I do like hand planes and have been known to grab the odd piece of scrap, clamp it up on the leg vise and take a few passes with the jack, jointer or block just to hear the “schhhh-k!” sound it makes. Well, it was just that piece of planed scrap that I used to mark the second of the two cabinet bottoms.

So when I finished the notch cuts and did a test-fit, there was a disconnect. Argh. Unaware of the true cause, I measured the distance between the ribs (front-to-back) and cut the front slot longer. AND, to make matters worse, the front extended beyond the cabinet’s intended face by the amount needed at the back. Argh again.So I pulled the piece, ripped it again and here’s what I’m left with:

I’ll glue and pin nail these before the back of the carcase is put in place; no impact and no one will ever know. Well, except for y’all. And now back to our regular program…

Back on Track

The other piece of progress was on the shelf runners. DW102 spec’d these to be ¾” stock that was cut to length and 1 ¾” wide. Well, that’s too much for shelves (I said) so mine were ripped to 1 ½” and cut to length via bench hook and backsaw as several rib components had been earlier. As a matter of fact, here is the same picture you’ve seen before of those cuts…

Next Time…
What next, then? Glad you asked, because I’ve been wondering that myself. Until then, as always, thanks for looking.

-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive --

33 comments so far

View GrandpaLen's profile


1652 posts in 2753 days

#1 posted 04-01-2014 12:47 AM

To err is human, to recover is fine woodworking.

Work Safely and have Fun. – Len

-- Mother Nature should be proud of what you've done with her tree. - Len ...just north of a stone's throw from the oHIo, river that is, in So. Indiana.

View ShaneA's profile


7084 posts in 3079 days

#2 posted 04-01-2014 12:47 AM

You seems to have an endless supply of vintage/repurposed stuff. Feels good to give them a new lease on life. Easier on the wallet too. Sheet goods can add up fast.

View Don W's profile

Don W

19314 posts in 3048 days

#3 posted 04-01-2014 01:18 AM

it’s better then the salvage dawgs!

-- - Collecting is an investment in the past, and the future.

View 489tad's profile


3638 posts in 3492 days

#4 posted 04-01-2014 01:50 AM

Good stuff.

-- Dan, Naperville IL, I.G.N.

View stefang's profile


16717 posts in 3815 days

#5 posted 04-01-2014 09:40 AM

Good work on this Smitty. When I made measuring and/or cutting mistakes in the past I thought I had ruined the piece. Now I expect this to happen (based on much actual experience) and like you I just fix it, like you did here, and move on, without a guilty conscience.

-- Mike, an American living in Norway.

View AnthonyReed's profile


10105 posts in 2921 days

#6 posted 04-01-2014 02:32 PM

Your deadman? Where is it?

Spurned, the #203s weep in their cubby….

-- ~Tony

View Smitty_Cabinetshop's profile


16186 posts in 3099 days

#7 posted 04-01-2014 03:17 PM

Slipped out of it’s track so I could work the large plywood sheets. You see, my #203s are rather snobbish and don’t appreciate being used to secure processed building products.

I guess they’re spoiled.

(the very bottom corner of the deadman can be seen in the ‘large panel’ cutting pic above, outside the bench leg)

PS: Very nice arrows, Tony!

-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive --

View AnthonyReed's profile


10105 posts in 2921 days

#8 posted 04-01-2014 03:51 PM

Got it.

Glad to hear the 203s have standards, integrity is in short supply nowadays, it seems.

-- ~Tony

View ToddJB's profile


8537 posts in 2611 days

#9 posted 04-01-2014 06:36 PM

Looking good, Smitty. Thanks for the blog.

-- I came - I sawed - I over-built

View Slyy's profile


2840 posts in 2136 days

#10 posted 04-01-2014 11:22 PM

What I’ve spent the last 3 days finding the perfect arrow processing software and now I find out someone has a circle maker too!!!!!!

Incidentally, the work continues Smitty. One of the wonderful things I’ve figured out from LJ’s is that mistakes can be hidden. I can only imagine the fine woodworker of lore who earned there craft (and came perhaps) through the ability to hide those mistakes so well, we never even know. Looking forward to part san!! (Stuck some japanese in there!)

-- Jake -- "Not only do we live among the stars, the stars live within us." - Neil Degrasse Tyson

View terryR's profile


7524 posts in 2789 days

#11 posted 04-02-2014 02:37 PM

Another great blog, Smitty, and excellent work in progress! What mistakes? I don’t see any…

Yeah, I hate cutting sheet material, too. I have a sweet Grizzly TS, but cannot cut a straight line with it! My method for ply goods:jig saw just outside the line, than handplane to the line. S L O W .

+1 to the nice arrows, brother Tony! :)

-- tr ...see one, do one, teach one...

View lysdexic's profile


5291 posts in 3103 days

#12 posted 04-03-2014 01:56 AM

-- "It's only wood. Use it." - Smitty || Instagram - out_of_focus1.618

View Dave's profile


11432 posts in 3320 days

#13 posted 04-04-2014 01:25 PM

I want that Anvil!!!!!!

-- Superdav "No matter where you go - there you are."

View Smitty_Cabinetshop's profile


16186 posts in 3099 days

#14 posted 04-04-2014 01:38 PM

Oh, it gets tons of use (not…)

-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive --

View Dave's profile


11432 posts in 3320 days

#15 posted 04-04-2014 01:41 PM

OK so go beat it a few time with a hammer so it wont feel left out.

-- Superdav "No matter where you go - there you are."

showing 1 through 15 of 33 comments

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