Accuracy in the shop is easier with the right setup tools at your fingertips

Three set up blocks can be stacked together to get the right measurement for the task at hand. Brass set-up blocks are commonly available in 2V2 and 4 lengths. Power tools are great when it comes to consistent accurate results. But every power tool requires some sort of setup to get those results. A square and a ruler are often all you need. But it's easy to misread a ruler when you're setting up tools, bits, and blades. To get around these problems, I rely on almost foolproof machinist's...

Make the Cable Cutouts

A sanding drum on the drill press (matching the radius of the curve) makes cleaning up the plywood edge of the cutout a snap. Start with a Jig Saw. After laying out the shape of the cutouts, use a jig saw to cut the curved shape. A fine-tooth blade makes a clean cut in the plywood. Finish with a Sanding Drum. A sanding drum on the drill press (matching the radius of the curve) makes cleaning up the plywood edge of the cutout a snap. NOTE Clamp workpiece to bench so...

Stackmg Featherboards

A featherboard is a great accessory for supporting a workpiece when cutting on the table saw. But if you're cutting a work-piece on edge, most featherboards aren't thick enough to provide adequate support. That's why I built this stacking featherboard. It has a full height of21 4, high enough to hold most tall pieces firmly against the fence. And if you're working with a flat work-piece, you can reduce the height by removing one or two layers. The three layers for the featherboard can be cut...

Add A Sliding

After making cuts with the tail fence, you can probably imagine how vertical cutting techniques can be applied to joinery. You'll find that making a sliding jig for cutting tenons and splined miters is also a great addition to your table saw. REVERSIBLE JIG. The sliding jig shown in the illustration at right is similar to the tall fence you made earlier. But in this case, the jig slides on your rip fence instead of remaining stationary. You'll also notice a cleat on either side of the jig. A 90...

Shutter Index

Assembling movable, lou-vered shutters can be a challenge. But one thing that make this go smoothly is an assembly jig, like the one shown in the photo below. Evenly spaced slots in the sides of the jig hold the louvers while you assemble the frame. To make building the jig a little easier, I put together a quick indexing jig, as you can see in the drawing and photo above. The jig is made of two parts. The first is an auxiliary fence for the miter gauge. It's made from a piece of 3A plywood....

Protruding Hinge Strews

The lower doors on the dropfront desk are mounted with no-mortise hinges. Although these hinges are easy to install, I came across one catch the heads of the screws stand proud of the hinge just enough to prevent the doors from closing properly. In order to solve this problem, I simply enlarged each screwhole with a countersink bit. Then I used a permanent marker to camouflage the bright steel rim of the hole. E5 Screw heads stand proud of hinge and don't allow door to close fully Screw heads...

Leg Taper jig

Tapering the legs for the coffee table on page 22 presents a challenge. Because each leg is glued up as a mitered assembly, you can't use the same jig setup to taper both edges. Instead of making two separate jigs, I made one with a movable fence, as shown in the photo. As you can see in the drawing at right, the jig is just a plywood base with a narrow fence. A small block of plywood is glued to one edge of the fence, flush with the end, to serve as a stop. This L-shaped fence will cradle the...

Hinge Mortises

The drop-front lid on the desk on page 32 pivots on three, brass card table hinges. These hinges are recessed into both the lid and the upper case of the desk. Creating the hinge mortise is a two-step process. First, a shallow mortise is routed for the leaves of the hinge. Then, a deeper mortise is created for the hinge knuckle. All it takes to do this is a router and a shop-made template. TEMPLATE. The template is simply a piece of Vi' plywood with an opening sized to match the hinge. You can...