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391K views 607 replies 172 participants last post by  tbagby21 
#1 ·
Intro

Greetings Lumberjocks,

Two years ago I finally got a space for my own. The basement of MY own house! Later I will explain how the shop has grown, but for now, I will just say, how great it is to have a space to express my creative side. Financial limitations (child support - love and support my kids always - but VERY expensive) have plagued me for years (and still do) but I have managed to aquire a decent collection of tools of a budget.

I appreciate all the expertice found on the Lumberjocks site and I have to check EVERY day! Thanks to Martin for a great site….

Thanks for reading - the next post will have photos!
 
#240 ·
Benchtop Clamping Frames

This is one of those projects that was dreamt up in the middle of the night - I am still gluing up sections of reclaimed bowling alley lane (more of that story to follow) and it is always tricky to keep things straight and flat.

The first rev this morning yielded this….some Maple flooring scraps cut up to give an elevated clamping surface with minimal contact to the clamped boards. The tongue on the flooring was a natural…...just add some wax to keep the glue at bay:

Wood Hardwood Plank Wood stain Lumber


Wood Wood stain Plank Hardwood Varnish


Then it occurred to me that having some clamps at the ready would help shave some presious seconds off the glue up time so added the clamp holders:

Wood Wood stain Hardwood Tool Plank


To make the clamp holders, just clamped them all together to cut the slot on the TS:

Planer Wood Flooring Engineering Gas


Wood Gas Machine tool Machine Engineering


The clamps are just below the height of the tongue:

Wood Plank Hardwood Wood stain Flooring


Wood Flooring Gas Hardwood Machine


A couple shots in action:

Wood Tool Toolroom Workbench Engineering


Wood Flooring Hardwood Tool Engineering


And a final shot:

Wood Tool Wood stain Automotive exterior Hardwood


Wished I'd done something like this sooner - they work pretty good…......will post some of the results of this soon…...

Thanks for looking.

Jeff
 

Attachments

#241 ·
Benchtop Clamping Frames

This is one of those projects that was dreamt up in the middle of the night - I am still gluing up sections of reclaimed bowling alley lane (more of that story to follow) and it is always tricky to keep things straight and flat.

The first rev this morning yielded this….some Maple flooring scraps cut up to give an elevated clamping surface with minimal contact to the clamped boards. The tongue on the flooring was a natural…...just add some wax to keep the glue at bay:

Wood Hardwood Plank Wood stain Lumber


Wood Wood stain Plank Hardwood Varnish


Then it occurred to me that having some clamps at the ready would help shave some presious seconds off the glue up time so added the clamp holders:

Wood Wood stain Hardwood Tool Plank


To make the clamp holders, just clamped them all together to cut the slot on the TS:

Planer Wood Flooring Engineering Gas


Wood Gas Machine tool Machine Engineering


The clamps are just below the height of the tongue:

Wood Plank Hardwood Wood stain Flooring


Wood Flooring Gas Hardwood Machine


A couple shots in action:

Wood Tool Toolroom Workbench Engineering


Wood Flooring Hardwood Tool Engineering


And a final shot:

Wood Tool Wood stain Automotive exterior Hardwood


Wished I'd done something like this sooner - they work pretty good…......will post some of the results of this soon…...

Thanks for looking.

Jeff
Totally an ingenious way to use those scraps. This would be great for those clamps I have that have a poor foot. Great stuff Jeff.
 

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#251 ·
Birdseye Score!

I know I shouldn't have…...but man what a deal…..I can almost here Shane's post already…..

This is furniture grade birdseye and curly maple and I think maybe some curly birdseye…............:)

Bought it from a semi retired grandmother that is getting out of the furniture making business…....been stored indoors for the past 20 years. A couple of the boards are planned, otherwise all rough - I need to change the planer knives before even thinking about this stuff….

All was had for 15¢ to 25¢ on the dollar (depending on where you shop).

I guess the car stays outside for now…...lucky we got NO snow this year….:)

Wood Flooring Composite material Hardwood Wood stain


Wood Flooring Floor Hardwood Natural material


Wood Rectangle Hardwood Flooring Wood stain


The 2 piles on the right are all birdseye - the pile on the left is curly. A couple pieces of 8/4, 6/4 and 5/4 as well…...

Wood Rectangle Composite material Building material Hardwood


On a different note….here's a sneak peek of what I've been working on…a common table for the miter saw, RAS (traded with my brother) and the drum sander…...........long ways to go….....

Table Wood Electrical wiring Workbench Tool


Thanks for looking.

Jeff
 

Attachments

#252 ·
Birdseye Score!

I know I shouldn't have…...but man what a deal…..I can almost here Shane's post already…..

This is furniture grade birdseye and curly maple and I think maybe some curly birdseye…............:)

Bought it from a semi retired grandmother that is getting out of the furniture making business…....been stored indoors for the past 20 years. A couple of the boards are planned, otherwise all rough - I need to change the planer knives before even thinking about this stuff….

All was had for 15¢ to 25¢ on the dollar (depending on where you shop).

I guess the car stays outside for now…...lucky we got NO snow this year….:)

Wood Flooring Composite material Hardwood Wood stain


Wood Flooring Floor Hardwood Natural material


Wood Rectangle Hardwood Flooring Wood stain


The 2 piles on the right are all birdseye - the pile on the left is curly. A couple pieces of 8/4, 6/4 and 5/4 as well…...

Wood Rectangle Composite material Building material Hardwood


On a different note….here's a sneak peek of what I've been working on…a common table for the miter saw, RAS (traded with my brother) and the drum sander…...........long ways to go….....

Table Wood Electrical wiring Workbench Tool


Thanks for looking.

Jeff
what a good score

nice saw table too
 

Attachments

#278 ·
Like taking a picture in the mirror.....

By popular demand - I updated my shop page today here ..and since it refers back to this blog - please be careful so you don't get sucked into the vortex…....

Thanks for looking.

Jeff

Sorry - I fixed the broken link….....oops.
 
#279 ·
Nice shop Jeff. Looking at your duct collection system, I might be able to do what I need to do with mine.

The videos were very cool.

Thanks for sharing:

Tim
 
#284 ·
Copy Cat.........

I am stuck between projects again…..tons of things I want to do, but can't pull the trigger on any of them…..so a couple of little things done while my brain adjusts…

1. Router Plane

I have wanted a router plane for quite awhile and have been checking eBay here and there…...I took a chance a few days ago and bought a Stanley #71 along with a bonus #152 Stanley spokeshave…...$30 plus $8 for shipping.

Here are the before pictures:

Plane Hand tool Rebate plane Wood Scrub plane


Gas Auto part Font Wood Metal


Wood Tool Bicycle part Automotive exterior Hand tool


Building Font Wood Auto part Metal


Wood Sculpture Art Metal Tool


At this point I checked this post from SuperDave - and how cool he restored his #71. Dave also helped me identify my #71 as a Type 9, which puts it at 1916-1924. Thanks Dave.

He used metallic paint which looked nice and it turned out I had a rattle can of metallic paint on the shelf…(not sure why?) and it was meant to be…......the after shots:

Revolver Tool Bicycle part Auto part Metal


Bicycle part Auto part Tool Nickel Metal


Guitar accessory Wood Ball-peen hammer Tool String instrument


The plane is missing the front guide thing but it still works good….....And only came with the 1/4" blade.

And the #152 with a bit of scrubbing:

Bicycle handlebar Bicycle part Rim Cable Bumper


Bicycle part Tool Auto part Bicycle drivetrain part Wood


Gun accessory Metal Bracket Air gun Wood


2. Zero Clearance Insert for the Mitersaw:

I just tired of the crappy stock insert - this one is made of IPE:

Tool Bumper Automotive exterior Wood Motor vehicle


Hood Motor vehicle Vehicle Automotive tire Trunk


3. French Cleat Clamp System:

Nothing new here - just keep collecting clamps and built some simple french cleat clamp holders using dimensional lumber and some pocket screws:

Hand tool Tool Gas Bolt cutter Auto part


Wood Gas Engineering Machine Gun barrel


Wood Wood stain Automotive exterior Hardwood Machine


Thanks for looking!
 

Attachments

#285 ·
Copy Cat.........

I am stuck between projects again…..tons of things I want to do, but can't pull the trigger on any of them…..so a couple of little things done while my brain adjusts…

1. Router Plane

I have wanted a router plane for quite awhile and have been checking eBay here and there…...I took a chance a few days ago and bought a Stanley #71 along with a bonus #152 Stanley spokeshave…...$30 plus $8 for shipping.

Here are the before pictures:

Plane Hand tool Rebate plane Wood Scrub plane


Gas Auto part Font Wood Metal


Wood Tool Bicycle part Automotive exterior Hand tool


Building Font Wood Auto part Metal


Wood Sculpture Art Metal Tool


At this point I checked this post from SuperDave - and how cool he restored his #71. Dave also helped me identify my #71 as a Type 9, which puts it at 1916-1924. Thanks Dave.

He used metallic paint which looked nice and it turned out I had a rattle can of metallic paint on the shelf…(not sure why?) and it was meant to be…......the after shots:

Revolver Tool Bicycle part Auto part Metal


Bicycle part Auto part Tool Nickel Metal


Guitar accessory Wood Ball-peen hammer Tool String instrument


The plane is missing the front guide thing but it still works good….....And only came with the 1/4" blade.

And the #152 with a bit of scrubbing:

Bicycle handlebar Bicycle part Rim Cable Bumper


Bicycle part Tool Auto part Bicycle drivetrain part Wood


Gun accessory Metal Bracket Air gun Wood


2. Zero Clearance Insert for the Mitersaw:

I just tired of the crappy stock insert - this one is made of IPE:

Tool Bumper Automotive exterior Wood Motor vehicle


Hood Motor vehicle Vehicle Automotive tire Trunk


3. French Cleat Clamp System:

Nothing new here - just keep collecting clamps and built some simple french cleat clamp holders using dimensional lumber and some pocket screws:

Hand tool Tool Gas Bolt cutter Auto part


Wood Gas Engineering Machine Gun barrel


Wood Wood stain Automotive exterior Hardwood Machine


Thanks for looking!
The #71 came out great, along with the spokeshave. A great $38.00 investment!!!

The ZCI & Clamp racks came out great also. Shop upgrades are always well worth the effort.

Now you just have to find & do a project using the #71, #152, Miter saw & clamps. Eagerly awaiting the blog & project post!!!
 

Attachments

#294 ·
Dust Collector Mod

Modded the single stage collector into a dual stage collector using to the super dust deputy from Oneida - Decided to to relocate the motor and blower above the cyclone and minimize the runs…..also hard mounted the cyclone under the blower and built a riser to bring the barrel into the cyclone. The barrel was a freebie from work.

Gas Technology Machine Electrical wiring Cylinder


Worked on this all day and not much scientific data to report - but here is a video of the first run, using a bucket of super fine dust - Some dust did make it to the second bag - see photos after the video…..

Here is the dust that made it into the second bag:

Table Automotive exterior Wood Bumper Tints and shades


More than I would like but I will continue to tweak the system….

Since the cyclone is hard mounted above, I have to bring the barrel up to the cyclone:

Automotive design Wood Automotive exterior Motor vehicle Bumper


Wood Rectangle Composite material Automotive design Flooring


Wood Gas Composite material Flooring Tints and shades


The lift is hinged in the back and will lift the barrel straight up into the cyclone. Use another short 2×4 to lock the barrel tight up to the cyclone…

Some other photos from the build:

Property Gas Kitchen appliance Machine Home appliance


Cylinder Gas Machine Metal Engineering


Pipeline transport Gas Engineering Machine Shelf


Pipeline transport Plumbing Gas Engineering Industry


I'll shorten up the flex tube runs after a few days of proving the layout…..

Thanks for looking.

UPDATE - Newer photos posted here.
 

Attachments

#295 ·
Dust Collector Mod

Modded the single stage collector into a dual stage collector using to the super dust deputy from Oneida - Decided to to relocate the motor and blower above the cyclone and minimize the runs…..also hard mounted the cyclone under the blower and built a riser to bring the barrel into the cyclone. The barrel was a freebie from work.

Gas Technology Machine Electrical wiring Cylinder


Worked on this all day and not much scientific data to report - but here is a video of the first run, using a bucket of super fine dust - Some dust did make it to the second bag - see photos after the video…..

Here is the dust that made it into the second bag:

Table Automotive exterior Wood Bumper Tints and shades


More than I would like but I will continue to tweak the system….

Since the cyclone is hard mounted above, I have to bring the barrel up to the cyclone:

Automotive design Wood Automotive exterior Motor vehicle Bumper


Wood Rectangle Composite material Automotive design Flooring


Wood Gas Composite material Flooring Tints and shades


The lift is hinged in the back and will lift the barrel straight up into the cyclone. Use another short 2×4 to lock the barrel tight up to the cyclone…

Some other photos from the build:

Property Gas Kitchen appliance Machine Home appliance


Cylinder Gas Machine Metal Engineering


Pipeline transport Gas Engineering Machine Shelf


Pipeline transport Plumbing Gas Engineering Industry


I'll shorten up the flex tube runs after a few days of proving the layout…..

Thanks for looking.

UPDATE - Newer photos posted here.
Whoa Jeff, kinda has a nice but yet mad scientist look to it. Pretty cool, hopefully you can get it dialed in the way you want.
 

Attachments

#306 ·
Shop Vac - Cyclone and Cart

Always working on the dust issues in the basement…......

Automotive tire Engineering Gas Motor vehicle Wood


Love the Fein vac - Klingspor was selling the Turbo II for $100 off list a few weeks ago, so just couldn't resist and the Super Deputy is just a sweet addition. The reviews are accurate on this one - it works great.

Just hate dragging around all the hoses and crap…....you know what I mean…....

This is just a 2Ă—4, a bunch of scrap wood, and the old metal base off of the dust collector I modified recently. It looked a bit shabby - so it got a coat of paint.

The vac and cyclone just drop in with a bit of a friction fit:

Exercise machine Wood Plant Gas Automotive tire


Wood Flooring Gas Composite material Auto part


Automotive tire Automotive design Electrical wiring Audio equipment Gas


Automotive tire Motor vehicle Tire Automotive design Wheel


Thanks for looking.
 

Attachments

#307 ·
Shop Vac - Cyclone and Cart

Always working on the dust issues in the basement…......

Automotive tire Engineering Gas Motor vehicle Wood


Love the Fein vac - Klingspor was selling the Turbo II for $100 off list a few weeks ago, so just couldn't resist and the Super Deputy is just a sweet addition. The reviews are accurate on this one - it works great.

Just hate dragging around all the hoses and crap…....you know what I mean…....

This is just a 2Ă—4, a bunch of scrap wood, and the old metal base off of the dust collector I modified recently. It looked a bit shabby - so it got a coat of paint.

The vac and cyclone just drop in with a bit of a friction fit:

Exercise machine Wood Plant Gas Automotive tire


Wood Flooring Gas Composite material Auto part


Automotive tire Automotive design Electrical wiring Audio equipment Gas


Automotive tire Motor vehicle Tire Automotive design Wheel


Thanks for looking.
Nice, pretty sweet paint job too. Kinda race car looking color scheme. Your shop has to be a great place to make stuff.
 

Attachments

#317 ·
The Sander Cart......

I've been working on the old Craftsman belt sander for awhile now. Picked it up from my brother a couple of years ago. I replaced the bearings and that made a world of difference. Built a new cart recently and picked up a 12" disc sander at HF with 20% off coupon…...and the free flashlight.

Office equipment Wood Table Gas Office supplies


Automotive tire Wood Gas Engineering Machine


The motor on the old Craftsman was tired, so another HF gamble was to buy the 1/2 HP motor….of course with the 20% off…...

Automotive tire Gas Motor vehicle Machine Engineering


Gas Engineering Motor vehicle Machine Automotive wheel system


The motor is smooth and strong (so far)......previously, I could easily stop the sander with moderate pressure…..not now…..

Next issue - DUST. No dust control on the old timer…..

Sliced up some 3" PVC and modified a shop vac port and made a friction fit dust collection port…..not that pretty, but it functions well…....

Gas Audio equipment Electronic device Camera accessory Automotive tire


Cylinder Cable Font Audio equipment Spark plug


Automotive design Automotive lighting Automotive exterior Automotive tire Mesh


Next problem - no where to mount the switch for the belt sander - so engineered a bit of "plier" like mount using maple flooring scraps on the cast iron handle on the disc sander….

Automotive tire Office equipment Office supplies Desk Audio equipment


Behind the switch is a little pvc tray for the eraser….

Sewing machine Wood Machine tool Machine Engineering


And here it is it's new home - the sanding corner…...

Table Wood Desk Office supplies Gas


The old Craftsman is running better than ever - lots of power. The HF disc has yet to prove it's keep, but runs pretty smooth, lots of power (1-1/2 HP….or so they say). The table is sub-par but we'll see.

Dust collection is good on both - and that's a major issue in the basement…....

Thanks for looking.
 

Attachments

#318 ·
The Sander Cart......

I've been working on the old Craftsman belt sander for awhile now. Picked it up from my brother a couple of years ago. I replaced the bearings and that made a world of difference. Built a new cart recently and picked up a 12" disc sander at HF with 20% off coupon…...and the free flashlight.

Office equipment Wood Table Gas Office supplies


Automotive tire Wood Gas Engineering Machine


The motor on the old Craftsman was tired, so another HF gamble was to buy the 1/2 HP motor….of course with the 20% off…...

Automotive tire Gas Motor vehicle Machine Engineering


Gas Engineering Motor vehicle Machine Automotive wheel system


The motor is smooth and strong (so far)......previously, I could easily stop the sander with moderate pressure…..not now…..

Next issue - DUST. No dust control on the old timer…..

Sliced up some 3" PVC and modified a shop vac port and made a friction fit dust collection port…..not that pretty, but it functions well…....

Gas Audio equipment Electronic device Camera accessory Automotive tire


Cylinder Cable Font Audio equipment Spark plug


Automotive design Automotive lighting Automotive exterior Automotive tire Mesh


Next problem - no where to mount the switch for the belt sander - so engineered a bit of "plier" like mount using maple flooring scraps on the cast iron handle on the disc sander….

Automotive tire Office equipment Office supplies Desk Audio equipment


Behind the switch is a little pvc tray for the eraser….

Sewing machine Wood Machine tool Machine Engineering


And here it is it's new home - the sanding corner…...

Table Wood Desk Office supplies Gas


The old Craftsman is running better than ever - lots of power. The HF disc has yet to prove it's keep, but runs pretty smooth, lots of power (1-1/2 HP….or so they say). The table is sub-par but we'll see.

Dust collection is good on both - and that's a major issue in the basement…....

Thanks for looking.
Spiffy design and setup, makes the most of limited space. Finished nicely, almost too good for a workshop. Well done.
 

Attachments

#335 ·
Byrd Shelix upgrade for the DW735

I burn through planer blades like crazy so I bit the bullet and upgraded. Took about 2 hours this morning to install and cuts sweet on the very first pass. Time will tell, but should be a great upgrade.

On a side note - I use an old dust collector bag for chip collection - otherwise you fill up the dust collector or shop vac way to fast…....I think it will work anyways, just hooked that up yesterday.

Here is the difference in noise level - some say you don't need ear protection with the Shelix, but I think it's still a good idea…..



Motor vehicle Bumper Automotive exterior Yellow Gas


I've got a batch of Maple to plane up this afternoon so will see how that goes…...

UPDATE:

Milled around 80 Maple boards - jointed 2 sides first, but the finish from the jointer not so good, so surfaced all 4 sides in the planer…....the finish looks good - handles the figured stock very well….last photo is a kind of a prototype of some furniture ideas I'm kicking around with this Maple…...which I have a quantity of 20" pieces…..

Wood Rectangle Wood stain Floor Flooring


Rectangle Wood Floor Building material Flooring


Wood Floor Hardwood Flooring Plank


One thing to note - the diameter of the Shelix head seems to be smaller than the factory blades, which makes sense if you understand how this has to be installed. So will just take a bit of time to adjust to the change. So the pre-set stops will need to be tweaked, etc… I use a vernier caliper as a rule so probably not a big deal…...

Bottom line - the cut performance out of the box is impressive….as it should be…......

Thanks for looking…
 

Attachments

#336 ·
Byrd Shelix upgrade for the DW735

I burn through planer blades like crazy so I bit the bullet and upgraded. Took about 2 hours this morning to install and cuts sweet on the very first pass. Time will tell, but should be a great upgrade.

On a side note - I use an old dust collector bag for chip collection - otherwise you fill up the dust collector or shop vac way to fast…....I think it will work anyways, just hooked that up yesterday.

Here is the difference in noise level - some say you don't need ear protection with the Shelix, but I think it's still a good idea…..



Motor vehicle Bumper Automotive exterior Yellow Gas


I've got a batch of Maple to plane up this afternoon so will see how that goes…...

UPDATE:

Milled around 80 Maple boards - jointed 2 sides first, but the finish from the jointer not so good, so surfaced all 4 sides in the planer…....the finish looks good - handles the figured stock very well….last photo is a kind of a prototype of some furniture ideas I'm kicking around with this Maple…...which I have a quantity of 20" pieces…..

Wood Rectangle Wood stain Floor Flooring


Rectangle Wood Floor Building material Flooring


Wood Floor Hardwood Flooring Plank


One thing to note - the diameter of the Shelix head seems to be smaller than the factory blades, which makes sense if you understand how this has to be installed. So will just take a bit of time to adjust to the change. So the pre-set stops will need to be tweaked, etc… I use a vernier caliper as a rule so probably not a big deal…...

Bottom line - the cut performance out of the box is impressive….as it should be…......

Thanks for looking…
Do you notice any difference in quality of the cut/finish? What about weird grain, knotholes, etc?
 

Attachments

#350 ·
The Sharpening Cart.....

Not too fancy, but always trying to save a little floor space, so combined a few different gadgets on one cart:

Wood Gas Engineering Machine tool Machine


Buffing compound is stored in pvc pipe cutoffs. Using the compound on MDF discs is a trick I picked up from Stumpy Nubs:

Audio equipment Electronic instrument Gas Machine Wood


Yep - that's an old 5-1/4" Floppy case, it fits the Worksharp paper just right…...yeah, I'm an old geek:

Hood Musical instrument accessory Audio equipment Wood Electronic instrument


It sits in a piece of foam so you can get it out of the way and also have a spot to set the sharp (or dull?) stuff down:

Electronic instrument Audio equipment Gas Office equipment Machine


Used some Kaizen foam for the other supplies and extra wheels (stacked 4 high):

Wood Gas Audio equipment Trunk Machine


If you spin the cart around the variable speed grinder is on the back:

Wood Engineering Electrical wiring Gas Machine


Little supply drawer with foam again:

Machine tool Table Gas Machine Engineering


Wood Hardwood Wood stain Gas Audio equipment


Mounted the old drill on the side to run the stropping wheel:

Table Machine tool Workbench Wood Saw


Power strip on the other side so one plug does it all:

Audio equipment Telephone Electronic instrument Gas Gadget


Now I just gotta find the motivation to sharpen stuff!

Thanks for looking.

Wood Toolroom Gas Engineering Machine
 

Attachments

#351 ·
The Sharpening Cart.....

Not too fancy, but always trying to save a little floor space, so combined a few different gadgets on one cart:

Wood Gas Engineering Machine tool Machine


Buffing compound is stored in pvc pipe cutoffs. Using the compound on MDF discs is a trick I picked up from Stumpy Nubs:

Audio equipment Electronic instrument Gas Machine Wood


Yep - that's an old 5-1/4" Floppy case, it fits the Worksharp paper just right…...yeah, I'm an old geek:

Hood Musical instrument accessory Audio equipment Wood Electronic instrument


It sits in a piece of foam so you can get it out of the way and also have a spot to set the sharp (or dull?) stuff down:

Electronic instrument Audio equipment Gas Office equipment Machine


Used some Kaizen foam for the other supplies and extra wheels (stacked 4 high):

Wood Gas Audio equipment Trunk Machine


If you spin the cart around the variable speed grinder is on the back:

Wood Engineering Electrical wiring Gas Machine


Little supply drawer with foam again:

Machine tool Table Gas Machine Engineering


Wood Hardwood Wood stain Gas Audio equipment


Mounted the old drill on the side to run the stropping wheel:

Table Machine tool Workbench Wood Saw


Power strip on the other side so one plug does it all:

Audio equipment Telephone Electronic instrument Gas Gadget


Now I just gotta find the motivation to sharpen stuff!

Thanks for looking.

Wood Toolroom Gas Engineering Machine
little by little buddy

looks like a good set-up
all in one place
smart

i need to consolidate things too

way to much time spent
looking for things
 

Attachments

#371 ·
Updated Wood Shop Tour......

Haven't posted any updates to the old blog for awhile, so shot a quick video…....Sorry - it's really shakey and was done in one un-edited take…...I had just finished the morning pot of coffee before filming….....if you are prone to seizures don't watch!

 
#408 ·
Another Drum Sander Upgrade...

Hey folks….another upgrade for the old Performax ST (22×44) drum sander. This is the original drum sander that Performax made and it bolts onto a RAS.

You can see previous mods here:

http://lumberjocks.com/JL7/blog/19321

http://lumberjocks.com/JL7/blog/19348

http://lumberjocks.com/JL7/blog/21269

The sander has always worked great for me, until the other day when I tried to sand a 21Ă—36 solid Maple desk top. I don't usually use the full width of the sander. The problem was the cheesy plastic paper holding things just didn't keep there grip and the paper would overlap and burn...



(That's the photo after I drilled out the rivets holding them in….)

I called SuperMax, which is the original company that built the early Performax stuff, before Jet bought them…...and they are still in the Twin Cities, so close to home…...

The young lady was so pleasant, I called right after she shut her computer down for the day, but she processed the order anyways, from memory…...works for me.

The parts showed up today in the mail. Only gripes…..no instructions….and no counter weights….I wouldn't have even considered the counter weights until I Google'd the directions, which I found in an obscure re-scanned document not on the SuperMax site. Thankfully, it described the correct weight for the counterbalances…...

Here are the new grips:

The outbound:

Gas Rim Composite material Auto part Metal


The inbound…..this one uses some heavy spring pressure to keep the paper tight and is easy to load:

Composite material Engineering Airplane Gas Auto part


I didn't take photos, but without the counterweights, the drum was a disaster…..vibrating all over the place…...Panic ensued….

Luckily, a few day ago I bought a HF scale for weighing out finishes….....$16 with coupon. Good call, because I could weigh out enough washers to balance each end of the drum…...used super glue and hot glue to attach. Runs nice and smooth now.

Oh yea…...

Got a perfectly smooth solid Maple top (from old gym floor) on the sander….no burn:

Wood Milling Machine tool Toolroom Gas


Wood Motor vehicle Gas Automotive exterior Machine


Wood Rectangle Wood stain Hardwood Plank
 

Attachments

#409 ·
Another Drum Sander Upgrade...

Hey folks….another upgrade for the old Performax ST (22×44) drum sander. This is the original drum sander that Performax made and it bolts onto a RAS.

You can see previous mods here:

http://lumberjocks.com/JL7/blog/19321

http://lumberjocks.com/JL7/blog/19348

http://lumberjocks.com/JL7/blog/21269

The sander has always worked great for me, until the other day when I tried to sand a 21Ă—36 solid Maple desk top. I don't usually use the full width of the sander. The problem was the cheesy plastic paper holding things just didn't keep there grip and the paper would overlap and burn...

Wood Font Rectangle Electric blue Tints and shades


(That's the photo after I drilled out the rivets holding them in….)

I called SuperMax, which is the original company that built the early Performax stuff, before Jet bought them…...and they are still in the Twin Cities, so close to home…...

The young lady was so pleasant, I called right after she shut her computer down for the day, but she processed the order anyways, from memory…...works for me.

The parts showed up today in the mail. Only gripes…..no instructions….and no counter weights….I wouldn't have even considered the counter weights until I Google'd the directions, which I found in an obscure re-scanned document not on the SuperMax site. Thankfully, it described the correct weight for the counterbalances…...

Here are the new grips:

The outbound:

Gas Rim Composite material Auto part Metal


The inbound…..this one uses some heavy spring pressure to keep the paper tight and is easy to load:

Composite material Engineering Airplane Gas Auto part


I didn't take photos, but without the counterweights, the drum was a disaster…..vibrating all over the place…...Panic ensued….

Luckily, a few day ago I bought a HF scale for weighing out finishes….....$16 with coupon. Good call, because I could weigh out enough washers to balance each end of the drum…...used super glue and hot glue to attach. Runs nice and smooth now.

Oh yea…...

Got a perfectly smooth solid Maple top (from old gym floor) on the sander….no burn:

Wood Milling Machine tool Toolroom Gas


Wood Motor vehicle Gas Automotive exterior Machine


Wood Rectangle Wood stain Hardwood Plank
Great fix Jeff. The clips on both of my drum sanders are less than ideal. I have to use strapping tape on the outboard end. Noy sure I'm handy enough to do these new clips though:(
 

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#431 ·
Magnificent Wood....

A couple years back I scored a great deal on an exotic wood lot on CL and for the most part have been using those cool woods in many projects, with a couple of exceptions…....and this was the main exception. There were 4 pieces marked "Rosewood" in the lot that I just knew were something extraordinary.

The boards are roughly 5" x 36" (4/4). I should add that I did barter one of these boards for my lathe, so now it's 3. It's hard to imagine anything denser than these boards. For a couple of years now I would pass one of these boards to any shop visitors just to see the reaction…...they are heavy….

Honestly, I have cleaned up a bunch of hard wood, but was always intimated by these four.

I just sharpened the jointer knives and rotated the carbide cutters on the Shelix cutter head in the planer, so decided today was the day to see what was hiding under the rough sawn exterior of one…....

Shown with the other two boards rough:

Table Wood Shelving Wood stain Rectangle


Wood Table Musical instrument Rectangle Varnish


Brown Wood Flooring Floor Wood stain


Table Wood Flooring Floor Wood stain


Wood Rectangle Wood stain Flooring Floor


I'm color blind, but I'm seeing a bunch of different colors here. I'm thinking Cocobolo.

Not sure where to go from here, but wow…......

Thanks for looking.
 

Attachments

#432 ·
Magnificent Wood....

A couple years back I scored a great deal on an exotic wood lot on CL and for the most part have been using those cool woods in many projects, with a couple of exceptions…....and this was the main exception. There were 4 pieces marked "Rosewood" in the lot that I just knew were something extraordinary.

The boards are roughly 5" x 36" (4/4). I should add that I did barter one of these boards for my lathe, so now it's 3. It's hard to imagine anything denser than these boards. For a couple of years now I would pass one of these boards to any shop visitors just to see the reaction…...they are heavy….

Honestly, I have cleaned up a bunch of hard wood, but was always intimated by these four.

I just sharpened the jointer knives and rotated the carbide cutters on the Shelix cutter head in the planer, so decided today was the day to see what was hiding under the rough sawn exterior of one…....

Shown with the other two boards rough:

Table Wood Shelving Wood stain Rectangle


Wood Table Musical instrument Rectangle Varnish


Brown Wood Flooring Floor Wood stain


Table Wood Flooring Floor Wood stain


Wood Rectangle Wood stain Flooring Floor


I'm color blind, but I'm seeing a bunch of different colors here. I'm thinking Cocobolo.

Not sure where to go from here, but wow…......

Thanks for looking.
Oh no…bad news Jeff. That wood ain't any good. I would feel as if I let you down if I didn't offer to take it off your hands.
 

Attachments

#454 ·
The Sharpening Cart - Now with a buffing station.....

I made a few changes to the sharpening cart that I originally posted HERE.

I added a removable platform to the right of the Worksharp - thanks for the idea Stumpy….much appreciated.

Later, I decided to add the the Beall buffing setup under the the little shelf. Previously this was just mounted on a piece of plywood and I would drag it out every time I use it. Since I use it a lot, this should be useful.

Also added the "shelf" that hold the buffing wheels, buffing compound and up to eight extra Worksharp discs. The shelf is form fit to the grinder and just sits in place without fasteners or you can remove it and hang it on the side of the cart.

Here's a shot from each side of the cart:

Wood Gas Audio equipment Machine Engineering


Office equipment Wood Gas Auto part Machine


Table Desk Computer desk Writing desk Office equipment


Engineering Gas Wood Workbench Machine


There's more "stuff" in the top drawer:

Wood Gas Engineering Audio equipment Machine


The platform stays is place with 4 dowels and is easily removed:

Motor vehicle Bumper Automotive exterior Gas Auto part


The shelf:

Wood Shelving Audio equipment Electronic device Wool


Motor vehicle Bumper Automotive exterior Gas Engineering


The back of the shelf is notched to fit into the grinder:

Wood Floor Wood stain Hardwood Gas


The little Maple cleat is all that is needed to keep the shelf in place:

Wood Gas Bicycle part Auto part Machine


Optionally, the shelf can hang on the side of the cart:

Cabinetry Drawer Wood Computer desk Chest of drawers


One of these days I'm going to build these cool jigs for sharpening the lathe tools like Steve posted HERE.

Thanks for looking….......
 

Attachments

#455 ·
The Sharpening Cart - Now with a buffing station.....

I made a few changes to the sharpening cart that I originally posted HERE.

I added a removable platform to the right of the Worksharp - thanks for the idea Stumpy….much appreciated.

Later, I decided to add the the Beall buffing setup under the the little shelf. Previously this was just mounted on a piece of plywood and I would drag it out every time I use it. Since I use it a lot, this should be useful.

Also added the "shelf" that hold the buffing wheels, buffing compound and up to eight extra Worksharp discs. The shelf is form fit to the grinder and just sits in place without fasteners or you can remove it and hang it on the side of the cart.

Here's a shot from each side of the cart:

Wood Gas Audio equipment Machine Engineering


Office equipment Wood Gas Auto part Machine


Table Desk Computer desk Writing desk Office equipment


Engineering Gas Wood Workbench Machine


There's more "stuff" in the top drawer:

Wood Gas Engineering Audio equipment Machine


The platform stays is place with 4 dowels and is easily removed:

Motor vehicle Bumper Automotive exterior Gas Auto part


The shelf:

Wood Shelving Audio equipment Electronic device Wool


Motor vehicle Bumper Automotive exterior Gas Engineering


The back of the shelf is notched to fit into the grinder:

Wood Floor Wood stain Hardwood Gas


The little Maple cleat is all that is needed to keep the shelf in place:

Wood Gas Bicycle part Auto part Machine


Optionally, the shelf can hang on the side of the cart:

Cabinetry Drawer Wood Computer desk Chest of drawers


One of these days I'm going to build these cool jigs for sharpening the lathe tools like Steve posted HERE.

Thanks for looking….......
You need to send that cart to my shop. I have plenty of room for it
 

Attachments

#466 ·
A couple of workshop updates.....

I still like those little workshop improvement projects…..they are a nice diversion when you are immersed in a big project. And most of them are created out of frustration with the current state…

Anyways, none of these are pretty but here goes:

You can't have enough clamps….BUT….it's always a challenge to figure out where to put them and how to access them quickly. In the basement it's logical to store stuff in the ceiling between the floor joists, but it is a little awkward to get the clamps down, especially the longer ones….

Had some leftover Fir flooring and built these really basic parts which will work for standard F-clamps or quick clamps:

Wood Flooring Floor Wood stain Hardwood


Used some simple dowel construction and mounted them in the ceiling:

Building Cloud Sky Line Stairs


The concept is the clamps are stored at an angle which makes them much more accessible.

Fun Event Retail City Idiophone


In the photo above, the rack in the front is fixed and can hold clamps from 12"-24" long and it only hangs down 4.5", so no problems with clearance in the shop. The rack behind it is hinged and can hold up to 36". It hangs down 10" from the ceiling which doesn't cause a problem most of the time, but could be a problem if I have to move the big band saw or whatever. So it can pushed up and locked in tight to the ceiling if necessary. The photo below shows the spring loaded lock mechanism:

Motor vehicle Vehicle Automotive tire Engineering Electrical wiring


The photo below is a shot right above the workbench, which includes one of the new clamp racks, an angled shelf thing, a simple piece of sheet metal angle for tape measures, and a mag bar mounted at an angle for easier access:

Gas Retail Machine Engineering Publication


Here's the angled mag bar:

Wood Architecture Beam Line Roof


Also in front of the bench is the bench puck dispenser, which is 3" PVC cut and shaped and mounted to a piece of pine:

Wood Gas Shelving Engineering Machine


Wood Kitchen appliance Food Gas Tableware


It works like a Pez dispenser, but to be honest….by design, the pucks don't really want to slide out easily….but it still works..

I've been building my own dowels and when I setup to cut dowels, I cut a bunch….which causes the next problem…..what to do with all those dowels. It's ugly but effective, a combination of PVC and flex hose scraps and a few labels and the dowels are sorted by size, again, hanging from the ceiling:

Wood Building Ceiling Beam Machine


One more ceiling mod, and an idea I stole from my Dad, the drill and impact driver holder. which is just holes that fit the chucks:

Audio equipment Electrical wiring Gas Electronic device Machine


I have the Ryobi One+ drills and things and just got the battery charger recall…..which is scary to say the least when they can suddenly burst into flames. Either way, I've never liked to keep the chargers plugged in when not in use, but sometimes you just forget. My new solution is to mount the chargers right next the door so it's the last thing I see when leaving the shop and hopefully I remember to unplug them…..and for the record, the recalled charger is gone:

Shelf Shelving Tire Building Wood


Also beefed up the dust collection on the big band saw and the router table…..kind of ugly, but works well and both have quick dis-connect fittings:

Missile Gas Cylinder Engineering Rocket


Automotive tire Floor Flooring Wood Gas


Wood Table Machine tool Toolroom Engineering


Wood Engineering Gas Machine Metal


Now they both have 4" fittings. The band saw gets a new port right under the table and the router table has an optional 3" gate for the fence. Form follows function here…..

Lastly, got a bunch free (odd sized) chunks of 1" MDF and they make great tool holders for the French cleat system…..here's one for the drum sander:

Electrical wiring Electricity Gas Engineering Machine


Enough ramblings…...thanks for looking…..
 

Attachments

#467 ·
A couple of workshop updates.....

I still like those little workshop improvement projects…..they are a nice diversion when you are immersed in a big project. And most of them are created out of frustration with the current state…

Anyways, none of these are pretty but here goes:

You can't have enough clamps….BUT….it's always a challenge to figure out where to put them and how to access them quickly. In the basement it's logical to store stuff in the ceiling between the floor joists, but it is a little awkward to get the clamps down, especially the longer ones….

Had some leftover Fir flooring and built these really basic parts which will work for standard F-clamps or quick clamps:

Wood Flooring Floor Wood stain Hardwood


Used some simple dowel construction and mounted them in the ceiling:

Building Cloud Sky Line Stairs


The concept is the clamps are stored at an angle which makes them much more accessible.

Fun Event Retail City Idiophone


In the photo above, the rack in the front is fixed and can hold clamps from 12"-24" long and it only hangs down 4.5", so no problems with clearance in the shop. The rack behind it is hinged and can hold up to 36". It hangs down 10" from the ceiling which doesn't cause a problem most of the time, but could be a problem if I have to move the big band saw or whatever. So it can pushed up and locked in tight to the ceiling if necessary. The photo below shows the spring loaded lock mechanism:

Motor vehicle Vehicle Automotive tire Engineering Electrical wiring


The photo below is a shot right above the workbench, which includes one of the new clamp racks, an angled shelf thing, a simple piece of sheet metal angle for tape measures, and a mag bar mounted at an angle for easier access:

Gas Retail Machine Engineering Publication


Here's the angled mag bar:

Wood Architecture Beam Line Roof


Also in front of the bench is the bench puck dispenser, which is 3" PVC cut and shaped and mounted to a piece of pine:

Wood Gas Shelving Engineering Machine


Wood Kitchen appliance Food Gas Tableware


It works like a Pez dispenser, but to be honest….by design, the pucks don't really want to slide out easily….but it still works..

I've been building my own dowels and when I setup to cut dowels, I cut a bunch….which causes the next problem…..what to do with all those dowels. It's ugly but effective, a combination of PVC and flex hose scraps and a few labels and the dowels are sorted by size, again, hanging from the ceiling:

Wood Building Ceiling Beam Machine


One more ceiling mod, and an idea I stole from my Dad, the drill and impact driver holder. which is just holes that fit the chucks:

Audio equipment Electrical wiring Gas Electronic device Machine


I have the Ryobi One+ drills and things and just got the battery charger recall…..which is scary to say the least when they can suddenly burst into flames. Either way, I've never liked to keep the chargers plugged in when not in use, but sometimes you just forget. My new solution is to mount the chargers right next the door so it's the last thing I see when leaving the shop and hopefully I remember to unplug them…..and for the record, the recalled charger is gone:

Shelf Shelving Tire Building Wood


Also beefed up the dust collection on the big band saw and the router table…..kind of ugly, but works well and both have quick dis-connect fittings:

Missile Gas Cylinder Engineering Rocket


Automotive tire Floor Flooring Wood Gas


Wood Table Machine tool Toolroom Engineering


Wood Engineering Gas Machine Metal


Now they both have 4" fittings. The band saw gets a new port right under the table and the router table has an optional 3" gate for the fence. Form follows function here…..

Lastly, got a bunch free (odd sized) chunks of 1" MDF and they make great tool holders for the French cleat system…..here's one for the drum sander:

Electrical wiring Electricity Gas Engineering Machine


Enough ramblings…...thanks for looking…..
Man is your shop cool. You got stuff and places to put it all.
What a fun place to work that must be.

Steve
 

Attachments

#476 ·
Saw Blade Jackets

Basically like LP jackets…...but peg board. It did occur to me that I could have used old Rolling Stones or Jim Hendrix record jackets, but that thought was too late.

Wood Rectangle Floor Wood stain Hardwood


When I moved into this house, there was a bunch of pegboard on the walls of the little shop. Don't use much pegboard since the french cleat system went in, so it was nice to find a use for this otherwise worthless material…...

Ripped a stack of pegboard into squares:

Table Rectangle Wood Textile Tablecloth


Took a third of the stack and screwed it together so I could cut out the center section in one setup:

Rectangle Wood Flooring Pattern Beige


At some point, it occurred to me that the shortest 23 gauge pins for the nailer I had were 1/2", some I cut some thin strips for the back so the pins wouldn't go through and used a simple assembly jig - this is the assembly progression and used the pin nailer on both sides:

Wood Flooring Rectangle Font Pattern


Table Wood Rectangle Flooring Floor


Cleaned them up on the spindel and belt sanders:

Wood Gas Audio equipment Table Cuisine


Motor vehicle Vehicle Wood Gas Automotive design


The idea here is to build one for each blade and keep track of the sharpening history…....and built a simple containment in the corner of one of the shop cart drawers:

Wood Wood stain Hardwood Engineering Plywood


Wood Hardwood Wood stain Flooring Lumber


Also, one the jackets is 2x deep for the 10" sanding disc - which uses 2 of the center inserts in lieu of the thin strips - here is the comparative photo:

Wood Flooring Wood stain Floor Automotive exterior


Should be handy…...you can pull them out of the drawer and carry them around if so inclined…..

Thanks for looking.
 

Attachments

#477 ·
Saw Blade Jackets

Basically like LP jackets…...but peg board. It did occur to me that I could have used old Rolling Stones or Jim Hendrix record jackets, but that thought was too late.

Wood Rectangle Floor Wood stain Hardwood


When I moved into this house, there was a bunch of pegboard on the walls of the little shop. Don't use much pegboard since the french cleat system went in, so it was nice to find a use for this otherwise worthless material…...

Ripped a stack of pegboard into squares:

Table Rectangle Wood Textile Tablecloth


Took a third of the stack and screwed it together so I could cut out the center section in one setup:

Rectangle Wood Flooring Pattern Beige


At some point, it occurred to me that the shortest 23 gauge pins for the nailer I had were 1/2", some I cut some thin strips for the back so the pins wouldn't go through and used a simple assembly jig - this is the assembly progression and used the pin nailer on both sides:

Wood Flooring Rectangle Font Pattern


Table Wood Rectangle Flooring Floor


Cleaned them up on the spindel and belt sanders:

Wood Gas Audio equipment Table Cuisine


Motor vehicle Vehicle Wood Gas Automotive design


The idea here is to build one for each blade and keep track of the sharpening history…....and built a simple containment in the corner of one of the shop cart drawers:

Wood Wood stain Hardwood Engineering Plywood


Wood Hardwood Wood stain Flooring Lumber


Also, one the jackets is 2x deep for the 10" sanding disc - which uses 2 of the center inserts in lieu of the thin strips - here is the comparative photo:

Wood Flooring Wood stain Floor Automotive exterior


Should be handy…...you can pull them out of the drawer and carry them around if so inclined…..

Thanks for looking.
Wow Jeff.
You are one organized guy. I like the price though. And having individual jackets is a great idea.

Speaking of sharpening… where do you get your blades sharpened?

Steve
 

Attachments

#489 ·
Saw Blade Jackets

Basically like LP jackets…...but peg board. It did occur to me that I could have used old Rolling Stones or Jim Hendrix record jackets, but that thought was too late.

Wood Rectangle Floor Wood stain Hardwood


When I moved into this house, there was a bunch of pegboard on the walls of the little shop. Don't use much pegboard since the french cleat system went in, so it was nice to find a use for this otherwise worthless material…...

Ripped a stack of pegboard into squares:

Table Rectangle Wood Textile Tablecloth


Took a third of the stack and screwed it together so I could cut out the center section in one setup:

Rectangle Wood Flooring Pattern Beige


At some point, it occurred to me that the shortest 23 gauge pins for the nailer I had were 1/2", some I cut some thin strips for the back so the pins wouldn't go through and used a simple assembly jig - this is the assembly progression and used the pin nailer on both sides:

Wood Flooring Rectangle Font Pattern


Table Wood Rectangle Flooring Floor


Cleaned them up on the spindel and belt sanders:

Wood Gas Audio equipment Table Cuisine


Motor vehicle Vehicle Wood Gas Automotive design


The idea here is to build one for each blade and keep track of the sharpening history…....and built a simple containment in the corner of one of the shop cart drawers:

Wood Wood stain Hardwood Engineering Plywood


Wood Hardwood Wood stain Flooring Lumber


Also, one the jackets is 2x deep for the 10" sanding disc - which uses 2 of the center inserts in lieu of the thin strips - here is the comparative photo:

Wood Flooring Wood stain Floor Automotive exterior


Should be handy…...you can pull them out of the drawer and carry them around if so inclined…..

Thanks for looking.
great idea and build jeff.been wanting to build something to hold my blades.so if you don't mind i might borrow your plan!!!
 

Attachments

#505 ·
The Wooden Hex Nut Jig....

Or nut jig for short…....

I picked up the Beall wood threader using up some Christmas gift cards…..it's the one with inserts and taps for 3 threads (1/2", 3/4" and 1").

Office equipment Wood Engineering Gas Machine


Mr. Beall himself has some great videos available if you want to see that work.

Also picked up his book:

Motor vehicle Automotive design Automotive tire Font Audio equipment


And also this little template for making hex nuts:



Using the template still requires you to cut the nuts free (somehow) and I used the band saw and belt sander for the task. Unfortunately, I'm not that good at doing that! The one on the right (Below) is using that process and the one on the left is with the new jig:

Wood Automotive tire Gas Audio equipment Composite material


With the new jig, you can make several nuts from one long piece of stock (just like the old way) but you can cut them free with the table saw (or whatever) into squares:

Wood Table Automotive exterior Bumper Wood stain


The jig I made is setup for the RAS, but you could easily put a runner under it and use it on the table saw. It has 3 different locations on it (one for each size):

Wood Rectangle Triangle Art Indoor games and sports


Here are some shots in the saw:

Wood Floor Flooring Automotive tire Automotive exterior


Wood Gas Flooring Tool Engineering


The square blanks start an 1/8" or so oversize and are dropped onto a dowel and secured by a Bessey auto adjust toggle at a 30 degree angle. Keep rotating and cutting until you trim all six sides.

The next trick is right out of Beall's book - make an adapter for the drill press and use a ROS to soften the edge:

Milling Wood Drill presses Drilling Jig grinder


Milling Wood Machine tool Gas Machine


Wood Automotive tire Gas Tool Machine


And you get this:

Wood Cylinder Hardwood Plywood Wood stain


Keep in mind, the jig is not ultra precise, and it tends to leave the edges tapered a bit, due to the side clamping pressure, but it's pretty quick and easy to build and use. And the results look good, which is what mostly counts here.

If anyone is interested, I can put more detail in here…..

Thanks for looking.
 

Attachments

#506 ·
The Wooden Hex Nut Jig....

Or nut jig for short…....

I picked up the Beall wood threader using up some Christmas gift cards…..it's the one with inserts and taps for 3 threads (1/2", 3/4" and 1").

Office equipment Wood Engineering Gas Machine


Mr. Beall himself has some great videos available if you want to see that work.

Also picked up his book:

Motor vehicle Automotive design Automotive tire Font Audio equipment


And also this little template for making hex nuts:

Rectangle Wood Font Technology Pattern


Using the template still requires you to cut the nuts free (somehow) and I used the band saw and belt sander for the task. Unfortunately, I'm not that good at doing that! The one on the right (Below) is using that process and the one on the left is with the new jig:

Wood Automotive tire Gas Audio equipment Composite material


With the new jig, you can make several nuts from one long piece of stock (just like the old way) but you can cut them free with the table saw (or whatever) into squares:

Wood Table Automotive exterior Bumper Wood stain


The jig I made is setup for the RAS, but you could easily put a runner under it and use it on the table saw. It has 3 different locations on it (one for each size):

Wood Rectangle Triangle Art Indoor games and sports


Here are some shots in the saw:

Wood Floor Flooring Automotive tire Automotive exterior


Wood Gas Flooring Tool Engineering


The square blanks start an 1/8" or so oversize and are dropped onto a dowel and secured by a Bessey auto adjust toggle at a 30 degree angle. Keep rotating and cutting until you trim all six sides.

The next trick is right out of Beall's book - make an adapter for the drill press and use a ROS to soften the edge:

Milling Wood Drill presses Drilling Jig grinder


Milling Wood Machine tool Gas Machine


Wood Automotive tire Gas Tool Machine


And you get this:

Wood Cylinder Hardwood Plywood Wood stain


Keep in mind, the jig is not ultra precise, and it tends to leave the edges tapered a bit, due to the side clamping pressure, but it's pretty quick and easy to build and use. And the results look good, which is what mostly counts here.

If anyone is interested, I can put more detail in here…..

Thanks for looking.
Cool tutorial, Jeff. From now on, everything you make will be screw-together….right?
 

Attachments

#523 ·
New Sharpening Jigs

Made a few more updates to the sharpening cart. Last cart update is HERE.

I was inspired by Randy (DIYaholic) with his blog HERE But don't tell him that, his head is already swollen…....here's the proof:

Head Arm Smile Human body Gesture


Also got some inspiration from Joey (joeysjunk) HERE for the t-track idea.

I got a hoard of free MDF, so that seemed like the way to go for the base. 3 layers glued together with a pair of 3/4" pockets for the "wolverine" style bars to slide through:

Wood Rectangle Composite material Gas Wood stain


2 coats of red paint and it kind of looks like one thick slab:

Wood Gas Wood stain Hardwood Composite material


Added the t-track so the Veritas grinding jig can be added or removed quickly:

Sewing machine Machine tool Motor vehicle Gas Home appliance


Machine tool Office equipment Sewing machine Gas Motor vehicle


Wolverine style jig for the sharpening the roughing gouge:

Gas Engineering Machine Wood Household appliance accessory


My first attempt at an Ellsworth style jig failed (it cracked) because I didn't pay attention to the grain direction….

Jig Fail:

Rectangle Wood Floor Flooring Beige


Second attempt, I just glued up 3 hard maple shorts:

Wood Rectangle Table Tool Flooring


So far, just built one jig for the 1/2" bowl gouge, using a 5/8" through hole, a 5/16"-18 threaded insert and bolt, and piece of 5/16" metal rod. I threaded the end to accept an acorn nut for the pivot. The other little block will set the chisel projection:

Wood Office supplies Writing implement Pen Gas


The same little block will set the jig location in the grinder base:

Wood Tool Hardwood Automotive exterior Wood stain


In action:

Gas Wood Household appliance accessory Engineering Machine


Also re-located the old drill used to power the strop, just behind the grinder. There are 2 short dowels in the grinder base to locate it and you can move it quick if need be:

Cabinetry Audio equipment Drawer Electronic device Machine


Automotive tire Motor vehicle Machine tool Automotive design Gas


This was all working up to the point of attempting to turn a bowl on the lathe…....and I must say I have a new found respect for bowl turners…..it's not as easy as it looks!!

I really need to find some green wood to practice on, but had this little piece of 4" x 4" of Redheart, so started rounding from the bottom up…....I had to walk away for now, watch a few more videos, or find a class…..but no one has gotten hurt yet:

Motor vehicle Automotive tire Gas Cylinder Engineering


Thanks for looking…..
 

Attachments

#524 ·
New Sharpening Jigs

Made a few more updates to the sharpening cart. Last cart update is HERE.

I was inspired by Randy (DIYaholic) with his blog HERE But don't tell him that, his head is already swollen…....here's the proof:

Head Arm Smile Human body Gesture


Also got some inspiration from Joey (joeysjunk) HERE for the t-track idea.

I got a hoard of free MDF, so that seemed like the way to go for the base. 3 layers glued together with a pair of 3/4" pockets for the "wolverine" style bars to slide through:

Wood Rectangle Composite material Gas Wood stain


2 coats of red paint and it kind of looks like one thick slab:

Wood Gas Wood stain Hardwood Composite material


Added the t-track so the Veritas grinding jig can be added or removed quickly:

Sewing machine Machine tool Motor vehicle Gas Home appliance


Machine tool Office equipment Sewing machine Gas Motor vehicle


Wolverine style jig for the sharpening the roughing gouge:

Gas Engineering Machine Wood Household appliance accessory


My first attempt at an Ellsworth style jig failed (it cracked) because I didn't pay attention to the grain direction….

Jig Fail:

Rectangle Wood Floor Flooring Beige


Second attempt, I just glued up 3 hard maple shorts:

Wood Rectangle Table Tool Flooring


So far, just built one jig for the 1/2" bowl gouge, using a 5/8" through hole, a 5/16"-18 threaded insert and bolt, and piece of 5/16" metal rod. I threaded the end to accept an acorn nut for the pivot. The other little block will set the chisel projection:

Wood Office supplies Writing implement Pen Gas


The same little block will set the jig location in the grinder base:

Wood Tool Hardwood Automotive exterior Wood stain


In action:

Gas Wood Household appliance accessory Engineering Machine


Also re-located the old drill used to power the strop, just behind the grinder. There are 2 short dowels in the grinder base to locate it and you can move it quick if need be:

Cabinetry Audio equipment Drawer Electronic device Machine


Automotive tire Motor vehicle Machine tool Automotive design Gas


This was all working up to the point of attempting to turn a bowl on the lathe…....and I must say I have a new found respect for bowl turners…..it's not as easy as it looks!!

I really need to find some green wood to practice on, but had this little piece of 4" x 4" of Redheart, so started rounding from the bottom up…....I had to walk away for now, watch a few more videos, or find a class…..but no one has gotten hurt yet:

Motor vehicle Automotive tire Gas Cylinder Engineering


Thanks for looking…..
Pretty sharp, Jeff.
Pun intended.
I won't tell.
 

Attachments

#552 ·
Moddin' the Table Saw.....

This is another project that I've been kicking around for awhile now. Kind of time consuming but think it will be a good one for the long run:

Furniture Table Cabinetry Wood Gas


First off, this is an older Craftsman "113" contractor saw. I would much rather have a shiny new cabinet saw, but lack of power and funds are preventing that! Some of the mods were done earlier and here was the saw prior to this last round of changes. I've never cared for those sheet metal bases on those saws. Really hard to add storage, etc. Also, the router table on the left which is solid Maple, has too much movement in it and had to go:

Table Wood Engineering Machine Art


Most of the materials used are re-purposed, such as the 80/20 style aluminum channel (obtained used for free) along with all the gray and black plastic panels. The drawer slides were a garage sale find. Nearly all the hardwood used is old Maple gym floor I got cheap.

I did have to buy the casters, dust ports and 2 switches (they are about $10 on Amazon) made by Woodstock.

The frame design was largely dictated by the used material I had on hand, and tried to design with a minimum amount of cutting aluminum. It's noisy and messy..

FRAME:

Wood Automotive exterior Gas Composite material Plywood


Wood Gas Composite material Engineering Automotive exterior


Rectangle Wood Automotive design Shelving Art


The casters are the industrial ones that have the rubber pads that can be used to level the rig:

Wood Rolling Toy Gas Motor vehicle


STORAGE:

There are 8 drawers and one open compartment. 4 of the drawers have Kaizen foam in them:

Audio equipment Gas Wood Electronic device Machine


One deep drawer in the middle holds the saw blades (there is a blog on that HERE) and a tenon jig:

Wood Gas Audio equipment Hardwood Composite material


Wood Automotive exterior Flooring Gas Hardwood


Three wide drawers hold 2 miter gauges, 2 crosscut sleds and a miter sled:

Wood Rectangle Automotive exterior Flooring Machine


Wood Rectangle Flooring Recreation Machine


Wood Shelving Cabinetry Drawer Shelf


THE SAW:

I covered the front of the saw with some rubber sheet material I had laying around. Not that pretty, but it covers up some of those gaping holes. I removed the factory tilt indicator thing because it's virtually useless and requires a much bigger opening to function. The tilt scale is there mostly as a novelty. I also printed out the serial and model number of the saw (just in case) because the original plate is covered up now:

Gas Automotive tire Audio equipment Machine Shelving


In the back of the saw, I built 2 removable panels to enclose the back and use rare earth magnets to keep them on the saw. Unfortunately, they have to be removed to tilt the blade. I may build a 45 degree tilt version some day, we'll see:

Gas Wood Machine Metal Cylinder


Rectangle Circuit component Composite material Technology Pattern


I built an extra beam on the out-feed side of the saw to place 2 movable out-feed boards on. The challenges in designing out-feed for this rig is the Incra TS-LS fence rides on top of the back rail so you can't have a permanent structure on top of the rail. The other issue is the tilting motor in the back, when fully tilted comes very close to the plane of the saw table. So the rail I added is just behind the motor allowing it to tilt.

The sliding out-feed boards have plastic runners that keep them in place, but can be moved or removed quickly:

Wood Rectangle Floor Flooring Wood stain


Rectangle Wood Flooring Floor Wood stain


Wood Automotive exterior Gas Engineering Machine


Also, my downdraft table (which I had to install a lift kit on for this build!) falls just below the out-feed boards:

Wood Gas Engineering Machine Motor vehicle


ROUTER TABLES:

There is a router box on both sides of the saw. You can access the routers under the table with removable panels that are held in place with rare earth magnets. Also, both boxes are hard wired with a duplex outlet inside each box:

This is the right box (which is also the access to tilt the saw):

Cabinetry Wood Shelving Wood stain Gas


Automotive lighting Gas Machine Vehicle door Automotive exterior


And the left box which has access from the end of the frame:

Musical instrument Wood String instrument Gas Guitar


Fixture Wood Gas Machine Door


The table on this box is mounted directly to the aluminum frame and not the saw. All I can say is it is REALLY sturdy…

DUST COLLECTION:

There are three 4" dust ports on the back on the cabinet and I have to change the quick connect hose for each:

Gas Cameras & optics Machine Electrical wiring Cable


The dust box for the saw has an angled bottom and works good. Haven't tested the router boxes yet, but I'm guessing they will be marginal, but better than no dust collection:

Wood Rectangle Shelving Hardwood Plywood


The blast gate is mounted near the ceiling and at the back of the saw, which is un-reachable from the front of the saw. I attached a dowel to the blast gate so you can open and close the gate from the front. Also marked a line on the dowel so you can tell if the gate is open from across the shop, because the gate itself is hidden behind the ceiling mounted air cleaner:

Pipeline transport Gas Engineering Wood Machine


Electrical wiring Gas Engineering Electrical supply Machine


OTHER STUFF:

The saw is wired separately from the 2 router tables and these 2 cords are zip-tied above the right side of the saw. This makes it really convenient to unplug things for safety reasons and also means you can't have the both the saw and router tables plugged in at the same time….also for safety reasons. I've been known to hit the wrong switch before. Also, there is a little flashlight mounted there which makes reading the Incra scale much easier:

Wood Motor vehicle Gas Electrical wiring Machine


Hood Motor vehicle Bicycle tire Automotive tire Rim


I still intend to build several zero clearance inserts for the saw and will install splitters in them. I purchased the Leecraft (CR-1) to use as pattern. This is a really nice insert and completely adjustable for height and fit:

Wood Bumper Hardwood Wood stain Automotive exterior


Wood Floor Flooring Composite material Hardwood


Lastly, for those of you that have the Incra fence, you know that it is a space hog when the fence is opened wide. I found a spot is the shop where the fence can be open and doesn't affect any other stuff, basically it opens into an un-usable space between the dust collector and the separator:

Cabinetry Wood Drawer Table Gas


Like everything else in the shop, I'm sure there are more changes coming…....

Thanks for lookin'
 

Attachments

#553 ·
Moddin' the Table Saw.....

This is another project that I've been kicking around for awhile now. Kind of time consuming but think it will be a good one for the long run:

Furniture Table Cabinetry Wood Gas


First off, this is an older Craftsman "113" contractor saw. I would much rather have a shiny new cabinet saw, but lack of power and funds are preventing that! Some of the mods were done earlier and here was the saw prior to this last round of changes. I've never cared for those sheet metal bases on those saws. Really hard to add storage, etc. Also, the router table on the left which is solid Maple, has too much movement in it and had to go:

Table Wood Engineering Machine Art


Most of the materials used are re-purposed, such as the 80/20 style aluminum channel (obtained used for free) along with all the gray and black plastic panels. The drawer slides were a garage sale find. Nearly all the hardwood used is old Maple gym floor I got cheap.

I did have to buy the casters, dust ports and 2 switches (they are about $10 on Amazon) made by Woodstock.

The frame design was largely dictated by the used material I had on hand, and tried to design with a minimum amount of cutting aluminum. It's noisy and messy..

FRAME:

Wood Automotive exterior Gas Composite material Plywood


Wood Gas Composite material Engineering Automotive exterior


Rectangle Wood Automotive design Shelving Art


The casters are the industrial ones that have the rubber pads that can be used to level the rig:

Wood Rolling Toy Gas Motor vehicle


STORAGE:

There are 8 drawers and one open compartment. 4 of the drawers have Kaizen foam in them:

Audio equipment Gas Wood Electronic device Machine


One deep drawer in the middle holds the saw blades (there is a blog on that HERE) and a tenon jig:

Wood Gas Audio equipment Hardwood Composite material


Wood Automotive exterior Flooring Gas Hardwood


Three wide drawers hold 2 miter gauges, 2 crosscut sleds and a miter sled:

Wood Rectangle Automotive exterior Flooring Machine


Wood Rectangle Flooring Recreation Machine


Wood Shelving Cabinetry Drawer Shelf


THE SAW:

I covered the front of the saw with some rubber sheet material I had laying around. Not that pretty, but it covers up some of those gaping holes. I removed the factory tilt indicator thing because it's virtually useless and requires a much bigger opening to function. The tilt scale is there mostly as a novelty. I also printed out the serial and model number of the saw (just in case) because the original plate is covered up now:

Gas Automotive tire Audio equipment Machine Shelving


In the back of the saw, I built 2 removable panels to enclose the back and use rare earth magnets to keep them on the saw. Unfortunately, they have to be removed to tilt the blade. I may build a 45 degree tilt version some day, we'll see:

Gas Wood Machine Metal Cylinder


Rectangle Circuit component Composite material Technology Pattern


I built an extra beam on the out-feed side of the saw to place 2 movable out-feed boards on. The challenges in designing out-feed for this rig is the Incra TS-LS fence rides on top of the back rail so you can't have a permanent structure on top of the rail. The other issue is the tilting motor in the back, when fully tilted comes very close to the plane of the saw table. So the rail I added is just behind the motor allowing it to tilt.

The sliding out-feed boards have plastic runners that keep them in place, but can be moved or removed quickly:

Wood Rectangle Floor Flooring Wood stain


Rectangle Wood Flooring Floor Wood stain


Wood Automotive exterior Gas Engineering Machine


Also, my downdraft table (which I had to install a lift kit on for this build!) falls just below the out-feed boards:

Wood Gas Engineering Machine Motor vehicle


ROUTER TABLES:

There is a router box on both sides of the saw. You can access the routers under the table with removable panels that are held in place with rare earth magnets. Also, both boxes are hard wired with a duplex outlet inside each box:

This is the right box (which is also the access to tilt the saw):

Cabinetry Wood Shelving Wood stain Gas


Automotive lighting Gas Machine Vehicle door Automotive exterior


And the left box which has access from the end of the frame:

Musical instrument Wood String instrument Gas Guitar


Fixture Wood Gas Machine Door


The table on this box is mounted directly to the aluminum frame and not the saw. All I can say is it is REALLY sturdy…

DUST COLLECTION:

There are three 4" dust ports on the back on the cabinet and I have to change the quick connect hose for each:

Gas Cameras & optics Machine Electrical wiring Cable


The dust box for the saw has an angled bottom and works good. Haven't tested the router boxes yet, but I'm guessing they will be marginal, but better than no dust collection:

Wood Rectangle Shelving Hardwood Plywood


The blast gate is mounted near the ceiling and at the back of the saw, which is un-reachable from the front of the saw. I attached a dowel to the blast gate so you can open and close the gate from the front. Also marked a line on the dowel so you can tell if the gate is open from across the shop, because the gate itself is hidden behind the ceiling mounted air cleaner:

Pipeline transport Gas Engineering Wood Machine


Electrical wiring Gas Engineering Electrical supply Machine


OTHER STUFF:

The saw is wired separately from the 2 router tables and these 2 cords are zip-tied above the right side of the saw. This makes it really convenient to unplug things for safety reasons and also means you can't have the both the saw and router tables plugged in at the same time….also for safety reasons. I've been known to hit the wrong switch before. Also, there is a little flashlight mounted there which makes reading the Incra scale much easier:

Wood Motor vehicle Gas Electrical wiring Machine


Hood Motor vehicle Bicycle tire Automotive tire Rim


I still intend to build several zero clearance inserts for the saw and will install splitters in them. I purchased the Leecraft (CR-1) to use as pattern. This is a really nice insert and completely adjustable for height and fit:

Wood Bumper Hardwood Wood stain Automotive exterior


Wood Floor Flooring Composite material Hardwood


Lastly, for those of you that have the Incra fence, you know that it is a space hog when the fence is opened wide. I found a spot is the shop where the fence can be open and doesn't affect any other stuff, basically it opens into an un-usable space between the dust collector and the separator:

Cabinetry Wood Drawer Table Gas


Like everything else in the shop, I'm sure there are more changes coming…....

Thanks for lookin'
Awesome setup man! At first I thought it looked ridiculously expensive to build, but it sounds like you found everything on the cheap, and free 80/20 is just insane. Really nice work.
 

Attachments

#593 ·
Building ZCI's with a homemade pin router for the '113 TS

Tool Wood Font Gas Pipe wrench


This has been on the list for awhile now. I've built ZCI's in the past from Oak and Masonite but overtime they have issues. I got my hands on a Leecraft ZCI for my Craftsman 113 TS and was blown away at how nice it was. So all the design credit here goes to Leecraft, here's a picture:

Wood Bumper Hardwood Wood stain Automotive exterior


The Leecraft doesn't use the front hold down screw that comes standard on this saw, rather, they use 2 horizontal screws (one in front and one on the right side). You tweak these screws to get just the right fit in the opening. They also use the 4 set screws to adjust the height.

My LJ buddy William has been using Corian for different stuff and he was gracious enough to give me a stack of rough cut pieces:

Wood Rectangle Table Flooring Floor


First step was cutting the corners off and then flush trimming using the Leecraft as a template:

Automotive tire Saw Floor Flooring Tool


Audio equipment Drill Office supplies Gas Drilling


This is a REALLY messy process…..You must where a mask!! I did capture most of the dust even though the photos would suggest different…..

Next up is drilling the holes for the horizontal screws - I used 8/32" countersunk screws, so you first drill the small hole to be threaded, then follow with a larger hole so the screw head will have clearance once you machine away some material later. You may have to study the photos down the line to understand:

Wood Bumper Automotive exterior Machine tool Gas


Motor vehicle Engineering Gas Machine Machine tool


Then I drilled a tapped the 4 holes for the set screws:

Wood Tool Hardwood Workbench Wood stain


Also used a 1/2" spiral bit to carve a relief for the blade on the bottom of the insert. This also provides clearance if you run a stabilizer on your saw blade. In hindsight, not sure I would carve this deep on future versions. In order for the blade to clear the insert prior to cutting it through it, there is only about 0.060" left. That's a little thin! I would still cut the relief in the bottom, but not as deep, then use an 8" dado blade to start the cut, when cutting through…..Make sense?

Wood Gas Machine Bumper Auto part


I set up a homemade pin router on the router table. It use's a 1/2" spiral bit with a 1/2" steel pin fixed above. This allows tracing the Leecraft insert (underside) exactly:

Wood Workbench Engineering Machine tool Gas


Wood Bumper Gas Tool Composite material


A couple of things to note here - the Corian is 1/16" thinner than the Leecraft so you can't set the bit height from the Leecraft - you need to check it and make some test cuts. The dust collection works much better here from below the table. Just take it slow….takes 10-15 minutes to cut these shapes.

There is a locking feature at the back of the insert and I used a pull saw and chisel to open this up:

Wood Hardwood Wood stain Workbench Gas


Wood Automotive tire Wood stain Hardwood Automotive wheel system


Wood Drinkware Drink Alcoholic beverage Hardwood


Table Wood Grey Flooring Floor


This is a bit over the top, but used the mini CNC to carve the intended purpose in the bottom of the inserts:

Wood Font Gas Parallel Rectangle


The Corian is brittle, so I covered the entire insert with a tubafore before cutting through, and clamped it all down of course.

Wood Machine tool Hardwood Table saws Workbench


One of the problems with the 113 saws is the inserts are not really long enough to put a splitter in them safely, so I am going to have an insert (with a splitter) for cuts up to 1-1/4" and will have to switch out for an insert (without a splitter) for taller cuts.

For cutting the 1-14" insert, you need to count the number of turns when raising the blade….

I found these Grip-Tite splitters on Incra's website (Incremental.com) for really cheap ($8?) so going to give them a try. Includes both thin and full kerf in the same package:

Gadget Audio equipment Font Cable Wire


Automotive tire Wood Flooring Road surface Circle


Parting shot:

Automotive tire Wood Bumper Grey Automotive exterior


I built four of them, plus have the Leecraft, so hope they last awhile….I did read a tip online somewhere that said when the insert starts to open up from blade drift or deflection, you seal the top with tape and pour epoxy in the bottom and start over again…..I will be trying that some day.

An interesting challenge…...thanks for looking.
 

Attachments

#594 ·
Building ZCI's with a homemade pin router for the '113 TS

Tool Wood Font Gas Pipe wrench


This has been on the list for awhile now. I've built ZCI's in the past from Oak and Masonite but overtime they have issues. I got my hands on a Leecraft ZCI for my Craftsman 113 TS and was blown away at how nice it was. So all the design credit here goes to Leecraft, here's a picture:

Wood Bumper Hardwood Wood stain Automotive exterior


The Leecraft doesn't use the front hold down screw that comes standard on this saw, rather, they use 2 horizontal screws (one in front and one on the right side). You tweak these screws to get just the right fit in the opening. They also use the 4 set screws to adjust the height.

My LJ buddy William has been using Corian for different stuff and he was gracious enough to give me a stack of rough cut pieces:

Wood Rectangle Table Flooring Floor


First step was cutting the corners off and then flush trimming using the Leecraft as a template:

Automotive tire Saw Floor Flooring Tool


Audio equipment Drill Office supplies Gas Drilling


This is a REALLY messy process…..You must where a mask!! I did capture most of the dust even though the photos would suggest different…..

Next up is drilling the holes for the horizontal screws - I used 8/32" countersunk screws, so you first drill the small hole to be threaded, then follow with a larger hole so the screw head will have clearance once you machine away some material later. You may have to study the photos down the line to understand:

Wood Bumper Automotive exterior Machine tool Gas


Motor vehicle Engineering Gas Machine Machine tool


Then I drilled a tapped the 4 holes for the set screws:

Wood Tool Hardwood Workbench Wood stain


Also used a 1/2" spiral bit to carve a relief for the blade on the bottom of the insert. This also provides clearance if you run a stabilizer on your saw blade. In hindsight, not sure I would carve this deep on future versions. In order for the blade to clear the insert prior to cutting it through it, there is only about 0.060" left. That's a little thin! I would still cut the relief in the bottom, but not as deep, then use an 8" dado blade to start the cut, when cutting through…..Make sense?

Wood Gas Machine Bumper Auto part


I set up a homemade pin router on the router table. It use's a 1/2" spiral bit with a 1/2" steel pin fixed above. This allows tracing the Leecraft insert (underside) exactly:

Wood Workbench Engineering Machine tool Gas


Wood Bumper Gas Tool Composite material


A couple of things to note here - the Corian is 1/16" thinner than the Leecraft so you can't set the bit height from the Leecraft - you need to check it and make some test cuts. The dust collection works much better here from below the table. Just take it slow….takes 10-15 minutes to cut these shapes.

There is a locking feature at the back of the insert and I used a pull saw and chisel to open this up:

Wood Hardwood Wood stain Workbench Gas


Wood Automotive tire Wood stain Hardwood Automotive wheel system


Wood Drinkware Drink Alcoholic beverage Hardwood


Table Wood Grey Flooring Floor


This is a bit over the top, but used the mini CNC to carve the intended purpose in the bottom of the inserts:

Wood Font Gas Parallel Rectangle


The Corian is brittle, so I covered the entire insert with a tubafore before cutting through, and clamped it all down of course.

Wood Machine tool Hardwood Table saws Workbench


One of the problems with the 113 saws is the inserts are not really long enough to put a splitter in them safely, so I am going to have an insert (with a splitter) for cuts up to 1-1/4" and will have to switch out for an insert (without a splitter) for taller cuts.

For cutting the 1-14" insert, you need to count the number of turns when raising the blade….

I found these Grip-Tite splitters on Incra's website (Incremental.com) for really cheap ($8?) so going to give them a try. Includes both thin and full kerf in the same package:

Gadget Audio equipment Font Cable Wire


Automotive tire Wood Flooring Road surface Circle


Parting shot:

Automotive tire Wood Bumper Grey Automotive exterior


I built four of them, plus have the Leecraft, so hope they last awhile….I did read a tip online somewhere that said when the insert starts to open up from blade drift or deflection, you seal the top with tape and pour epoxy in the bottom and start over again…..I will be trying that some day.

An interesting challenge…...thanks for looking.
Great Job Jeff!

I have been looking for corian locally to make template out of it but not luck. Maybe I did not look hard enough.

I love the blog. Very Detailed as you always do.

And that home made pin router, I am stealing the idea.

Thanks for sharing.
 

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