Making a Self Tapping Fitting

File a notch across the threads of a brass hose fitting, as shown in the photo, and it will cut its own threads in the vacuum port. It will even cut threads into a wooden base. Brass is soft, and the notch is easy to make. But once the fitting is installed, leave it in place. The notch will cut each time you turn it into the hole. Removing and reinstalling the fitting too many times will result in a loose fit (and a vacuum leak). The final step is to plumb the jig. so the vacuum valve can...

Router Mounting Screws

Make sure you have reasonably beefy screws holding the router to the mounting plate. Many older routers had only three 8-32 screws holding the baseplate on. That was fine for the use intended, but when you hang the router from the plate, you're better off either drilling out and tapping those holes to a bigger size or drilling and tapping entirely new holes. The Porter-Cable behemoth used in the Rodale Design Shop's router table has four 5-inch screws holding it to the plate. By all means, use...

Base Guiding Mortising Template

An alternative to the template used with a guide hushing Is I this template, which incorporates fences that guide the router base.You don't have to use a guide bushing withil You don't even have to use- a plunge router What 1 particularly like about this template is that you don't have to work with a template window that's much larger than the mortise. The window is exacdy the same length and width as the mortise. So to position the template, you merely have to set it on the layout lines...

Template Mortising

Guide your router with a template to cut those hard-to-position mortises. Using a template to guide a mortising cut is sometimes die most convenient, accurate, and effective way to work. You outfit your plunge router with a gukk bushing and a straight bit, then use it with a template lo rout the mortise. Hie key is not the router, per sc. but the template. A mortising template, like any other template, can be made of board, medium-density fiberboard (MDF), plywood, or plastic. It can be a...

Outfitting the Worktable

The slot mortiser is useless until it is mounted to the underside of a sturdy worktable. Since you will be pushing and pulling on the router and the fixture it is attached to, the worktable should be rigid and heavy. You can use a workbench or a substantial router table as the worktable for the slot mortiser. But remember that you have to drill and countcrborc mounting holes,as well as holes for threaded inserts. You will surely want to etch a grid into the tabletop to facilitate setups. These...

Using the

As I mentioned, the template is easier to use than it is to make. Set the fence square set the router. Then pop the template on the workpiccc, and bore away. Here, step by step, is how to do it. 1. Lay out one side. Layout is primarily a matter of deciding How far from die workpiece edges you want the holes How far from the top edge the holes should begin. How close to the bottom edge they should end. You might scribe a couple of lines on one of the shelf or cabinet sides to help you set up the...

For a Table Saw Mounting

Shiming Tablesaw Fence

If you've got a router hanging from a tabic saw extension wing, you can adapt the split fence to use with it. The following C directions and specifications arc for a split fence made to go with the Table Saw Extension Router Table on page 183. table saw extension router table split fence plan views TABLE SAW EXTENSION ROUTER TABLE SPLIT FENCE Cutting List Plastic laminate. 2 pes. 5x 16 each 4 toilet bolts. 'A x2Ji 4 plastic knobs. 4-prong, 154 dia. with J4 through threaded inserts DK-59 from...

Making the Baseplate

5 The parts for this baseplate are included on the Cutting List, g even though, once the template is built, you don't need the baseplate anymore. 1. Cut the baseplate parts. The baseplate is a plywood square, larger than your plunge router's base. On the Cutting List, I spee'd it as a 10-inch square, while the drawing i shows it as a 7-inch square. Start with the 10-inch square after the necessary holes are bored and the indexing pin is installed, cut it down to the 7-inch-square size. (Of...

Building the Swing

Doing it first makes it available for use in laying out and building the support assembly. 1. Cut the two layers to size. To make the arm as stiff as possible, you form it from two layers of birch plywood. One is ' j inch, the other inch. Cut the two pieces to the dimensions specified by the Cutting List. 2. Rout the opening for the router. In the completed arm, the router sets into a h-inch-deep recess and is bolted to the remaining material of die arm. The...

Why It Works

I first read about Moran's Marvelous Moniscr in the pages of American Woodworker. When 1 started screening projects for this collection, it was one of the first that came to mind. After pawing over Bob's original, I set about making my own, except that I felt I could 'improve it. What had rocked me about the Marvelous Mortiser was the cost of the parts. The particular pillow blocks and shafts Bub selected had cost him about 150 back in the '80s. (Of course, a commercial slot mortiser costs...

How It Works

To be effective, a slot mortiser needs to be able to move or l> e adjusted in three different directions 1. in and out for the depth of cut 2. side to side for the length of cut 3- up and down for the height of cut. Bob designed his slot mortiser with these movements in mind. In and Out The in-and-out movement is performed by the plunging action of the router. Mortise depth is controlled by the bit extension, which is governed by the router's own depth stops. Side to Side The router moves...

Using the Jig

The jig is really quite easy to set up and use. Don't be put off by the number of steps. Most take but a moment or two to accomplish. 1. Lay out a mortise. Use a scrap of the working stock, and outline the mortise exactly where it is to be cut Mark the centcdine across the mortise. 2. Clamp the jig to a workbench. Set the jig at the edge of the workbench, and clamp it with a couple of G clamps or quick-action bar clamps. 3- Set the workrest and toggle clamp. Adjust the workrest so the workpiece...

Jigs For Turning Spindle Dowel Ends

The jig presented here will take a blank up to 32 incho long. If you want a jig that will do a longer blank, or if you know that 32 inches is much too long for the needs yuu anticipate, then modify the dimensions, making the jig. longer or shorter. 1. Cut the parts. I made my jig mostly from plywood leftovers.The dimensions of the part.s are specified by the Cutting last. Cut the base, sides, and ends for the box. as well as the baseplate for the router. 1 used a piece of acrylic for the...

Using the Vacuum Trammel

You can use the trammel with a fixed-base router, but circle cutting is generally easier with a plunge router You don't have to flex and twist the trammel to keep the bit free of the work as you start the router. You don't have difficulty plunging die bit to start the cut. And changing the depth of cut between passes is easier to accomplish, too. So I'd recommend a plunge router. 1. Lay out the cut. Because the trammel has a nearly 2-inch-diameter pivot hole, it's dam hard to set the cutting...

Making the Jigs

Installing Rip Fence Table Saw

Only a few scraps of wood and some commonplace lunl-ware is needed to build the two necessary jigs. And if you study the drawings, you may find ways to simplify the jigs even more than I have. 1. Make the sled. Cut the hardboard sole and the hardwood heel to the dimensions specified by the Cutting List. Glue and nail the heel to the sole, using 1-inch brads Sec the drawing Booster Sled Plan. Make sure the bnuk are sunk flush, so they won't drag on the router table top when the sled is being...

Fixed Position Routing

Horizontal Tenoning

Under this heading I collect all those horizontal-routcr-tablc operations you can do with the slot mortiser. There's a bunch of them tenoning, slotting ar.d grooving, rabbeting, muting moldings, raising panels. In each of these operations, the work is fed into or over the bit. So to set up the slot mortiser fur them, you set the Iat-eral-travel stops against the chassis sides, locking the router in one position. Then you've got a horizontal router table. To cut a groove with a straight bit, you...

Routing Dowels

Router And Drill Dowel Making Jig

I tried making dowels out of oak. ash, cherry, soft maple, poplar, walnut.and mahogany. All these woods run through the dowel-making fixture without a hitch, so long as the blank is straight-grained. Any twists, dips, or waves lead to chip-out and splintering. Examine your stock carefully, and l e selective for best results. 1. Cut the dowel blanks. Check the dowel chart for the specs of the dowel you want. Rip a test blank to the dimensions specified for the desired dowel diameter. Now check...

Shop Built Slot Mortiser

Furniture Made With Plunge Router

With this fixture, you can use your plunge router to cut mortises and to rout tenons, slots, and grooves, even to cut moldings and raise panels. It's a Marvelous Machine. Faced with the need to cut hundreds of mortises, Boh Moran went shopping for a machine to do the job. He discovered, he says, I had neither the money nor the space for a commercially made slot mortiser. After thinking 3 all over and listing his requirements and desires. Bob realized that he could better satisfy his needs by...

Building the Horizontal Router Table

Horizontal Router Table

With a bit of careful layout work, this rig will come together easily. Before you start, make sure you have all of the materials specified by the Cutting List, especially the A. With router and trammel baseplate, make an opening the size of your router's base in the thicker ply of the swing arm. Position it as shown. Clue up the plies, and apply the plastic laminate. Then lay out three key elements on the swing arm blank 3. The end line for the curved slot With router and trammel, rout the...

Using the Baseplate

The baseplate can be used to plunge-bore holes, to cut mortises, and to plow grooves. The operating principles are the same for all three chores. The difference is in whether or not to actually feed the router laterally, and if you do. how far. Here's how to do it, step by step. 1. Set up the router. Naturally, you need to install the baseplate. Select the bit you need to use, and chuck it in the router. Set the plunge stop. 2. Lay out the cut. Remember that the closest you can rout to the...

Trammel Baseplate

Every router magician's basic bag o' tricks has a trammel in it. Here's a great one for your bag o' tricks. To guide the drilling of mounting-screw holes and a bit openini stick the factory baseplate to the blank with carpet tape. I T-nut, J4-20 I thumbscrew, 4-20 x 1 I common nail, 8d 3 extra-long mounting screws size needed will vary by brand and model of router

Table Saw Extension Router Table

Delta Saw Extension

Gain a router table without sacrificing precious shop space Integrate a router mounting into your table saw. the standard rip fence moored to 1 ' -inch-diameter rails. If you have a Delta contractor's saw. the specifics presented here should work for your saw. If you have a different brand, you may have to make some alterations. And certainly a different rip-fence mounting would also probably require some alterations to the router tabic top or its mounting approach. My saw is positioned in my...

The Generic Baseplate

How Make Boat Template

Router jig making often involves fabricating a substitute for the factory baseplate. So making a precision plate should be routine. Here's the essential savvy. to work with, your intentions, and the skills you've already mastered. I'll explain the choices that will present themselves as you work make the choices that will work for you.

Using the Router Table

Using this router table isn't a whole lot different than using any other. Because of the location of the router and the orientation of the saw's fence, you most frequently approach the router table from what is the saw's right rear corner. 'Hie drawing Feed Direction makes this clear. You've got to keep the area around the saw's right end clear so you can move around and maneuver a workpiccc. The fence is handy because it's right there on the saw. You can slide it into position quickly and set...

Transition Plate Layout

Because these rods can be unscrewed from the transition plate as easily as they are screwed into it, you can make a pair of short rods to supplement the rods specified. The second set of rods connects the trammel to the router. The specifications of these router rods depend upon the router. Some machines, such as the Freud, Hitachi, and Ryobi routers, use quite large-diameter rods. The D-handled Makita uses only one rod, and it's pretty hefty. Porter-Cable, DeWalt, and other brands and...

Making the Template

Making the template is pretty much a can't-miss proposition. You use an offset gauge, which is most commonly used in positioning straightedges for routing dadoes and grooves. Not only will this technique work for this jig. it's also a good way to guide a router when routing mortising windows in templates intended to be used with guide bushings. 1. Make an offset gauge. Cut this using the router and bit you will use with the mortising template that you are about to make. Set up the router. Now...

Using a Base Guiding Template

This approach can be used with any muter, fixed-based or plunger. It can even be used with a laminate trimmer. In fact, the trimmer's smaller baseplate minimizes the size of template needed to guide the cut. 1. Trace the mounting plate on the template stock. Make the framclikc template from 14-inch plywood or hardboard. Lay the mounting plate on the template stock, and trace around it with a sharp pencil. If the plate has rounded comers, use a draftsman's circle template to locate the...

Building the Storage Drawer

Installing the switch is the last step in wiring the router table. Before you do this, you must secure the electrical box to the bin front and the case, then rough in the cable. Leave about a hand's length of cable extending from the box so you can wire up the switch. Note the black tape on the white conductor, a reminder that it is hot. not neutral. The final element to make is a big drawer that rests on the runners attached to the bottom side rails. It provides a generous storage space for an...

Vacuum Clamping

Vacuum Clamp Routing Template

Clamps in the way of your routing Here's how you can use atmospheric pressure to displace those clamps and clear a path for your router. Powerful vacuum clamps can secure your work to a bench or a template to the work. Each is custom-made using common woodworking materials, vacuum tape, and a vacuum fitting. valve to the jig. And to power the vacuum-producing device, you have to have an air compressor. Quite frankly, I don't think you can justify the outlay ncccssary for both the vacuum system...

Router Crank

Tambour Door Crank

Adjust the plunge router in your router table the same way you adjust the blade height in your table saw by turning a crank. It's fast, smooth, precise. And when you make your own, it's economical. It's a good-news, bad-news clich .The good news is that, mounted in a table, the plunge router provides the means to adjust bit extension very precisely and without the sideplay that plagues many fixed-base routers.The bad news is that, mounted in a table, the plunge router can be a wrist wrenchcr to...

Assembling the Duplicator

Duplicators Router

This is when the machine really comes together. Because the major unit, the beam-and-column assembly, has already been constructed, you have a sense of what the duplicator is going to look like. But now you are going to mount it on the platen, install the router and the stylus, and ready it for its maiden voyage across your workbench. 1. Join the beam-and-column assembly to the platen. These two major elements are cinched together with the threaded rod that extends through the main column. To...

Horizontal Router Tabl

Horizontal Router Table

__________w____________ extends only a foot beyond the end of the saw table that's all. It isn't an extra stand that needs its own floor space it's sharing the table saw's floor space. The swing arm pivots up when you want to raise a panel or cut a tenon but drops conveniently out of the way when it isn't in use. Its presence doesn't impinge-on other woodworking operations. The setup takes good advantage of the saw's mass, and it makes excellent use of the saw's broad, flat tabletop.You don't...

Bowl Making With Router

Router Bowl Making Jigs

Before getting to the specifics of router-turning a dowel, let ox- mention the jig's capacities. The jig shown in the plans will accommodate a blank that is 4 inches square. Under the best conditions, this will yield a 4-inch-diameter dowel. If you trim a blank to an oc agon before mounting it in the jig. you can produce a dowel around 5, a inches in diameter, max. Of course, you can enlarge the jig if you need an even larger round. To turn a smaller-diameter dowel, you should raise the turning...

Power to the Router Table

Wooden Fishing Lure Templates

If you are serious about router table work, you need a setup that incorporates a switched receptacle. The advantages are several. Position the outlet next to the router, making it convenient to unplug when changing bits. The main reason woodworkers fail to take this simple safety step is that it's inconvenient. You can position an on-off switch where it's easy to find. This is especially appealing when you need to kill the router fast. You can add an outlet for something like a dust collector...

The Deep Through Mortise

Ordinarily, a through mortise can be routed using the approach described above. But every once in a while, the demands of a mortise go beyond the reach of even the longest of router bits.Thc right template setup can extend rour router's reach. An example is a knockdown sawbuck tabic I made a couple of years ago.'ITic underpinnings were two sawbuck leg assemblies joined by a stretcher. Each pair of legs was joined in a crosslap.A tenon on the stretcher passed through a mortise in the legs and...

Crosshair Baseplate Layout

Baseplate blank is sized to fit router's base. Dimple center of baseplate with V-grooving bit when Daseplate is attached to the router. Scribe crosshairs through the centermark using a scratch awl. Plunge-bore the bit opening after scribing crosshairs. Dimple center of baseplate with V-grooving bit when Daseplate is attached to the router. Scribe crosshairs through the centermark using a scratch awl. Plunge-bore the bit opening after scribing crosshairs.

Making a Slip Joint

The best single illustration of the horizontal router table's capabilities is to make a slip joint. The slip joint is a simple variation on the mortise-and-tenon it's really a slot-and tenon joint, sometimes called an open mortise-and-tenon, a bridle joint, a saddle joint. It's a good joint for simple door frames, face frames, and the like. It offers more glue area than any other joint you could substitute. AND it is truly easy to set up and cut. To do it on the horizontal muter table, all you...

Building the Duplicator

The joinery in this rig is not sophisticated. Butt joints, glue, and screws account for most of it. and a couple of threaded rods tie the rest together. Marrying ball bearings, which we normally associate with metal constructions, to a wooden structure is easy and straightforward but requires some bits and cutters that you may not have. Specifically, you'll need a drill bit that cuts a clean hole I inches in diameter to seat the outer race of the ball bearings, and a plug or tenon cutter that...

Router Duplicator Exploded View

Carving Duplicator Machine Wood

Dent, the inconspicuous rectangular base may actually be die most fascinating part of the duplicator. It distributes a cushion of air between tlx jig and the surface that it's parked on. virtually eliminating all friction.Tills allows the router and its overhead stylus to move with the greatest of ease in a horizontal plane. The best part is that the air cushion has its origins in the lungs of a shop vacuum. You probably don't think of your shop vac as a source of positive air flow. But all the...

T

2 tapered plastic knobs, 4J4 tall, with H-16 threaded insert BTH-8 from Reid Tool Supply Co. 800-253-0421 2 flathead stove bolts, amp -16 x 1 8 flathead wood screws, 6 x 1 The stiffeners can be any of these materials, but 1 used cherry. Once you've selected your materials, cut the pans to the sizes specified by the Cutting List. 2. Drill the baseplate holes. At this point, lay out ind drill the holes for the stiffener-mounting screws and the knob-mounting bolts. In the next step you'll deal...

Routing Straightedge

Straightedge Used For

Deceptively easy to use, this self-clamping To guide the router when making straight cuts, here's a straightedge with built-in damps. The clamps pinch in on the edges of the workpiece, securing the straightedge so you can slide the router along the edge. For years, I worked with a T-square or whatever straight scrap 1 had at hand as a clamp-on fence. It seemed the quick-and-casy thing to do, but it wasn't always so. If the workpiece was narrow, for example, getting a clamp on each end of my...

Making the Fixture

Crank Hat Makeing Machine

If you've got a lathe and the appropriate know-how, you can make the crank column by boring a 1-inch-diameter dowel on that machine. But I'm not a turner, so 1 had to find an alternative approach. You might think, as I did 'til I tried it. that the drill press is the right tool for boring the column. But instead, use the approach I settled on after a couple of false starts. It's a bit of that router magic, I think. Basically, you rout grooves in two pieces...

Fluting

How Make Index Wheel Layout

To flute a round, you need an indexing wheel.This is a disk marked off in regular increments, which you attach to the blank in place of the crank.The index wheel allows you to rotate the blank a specific number of degrees, then lock it. You can then make a straight cut the length of the blank. If you use a straight, mortising, or bottom-cleaning bit, ihi can create pentagonal, hexagonal, or octagonal billets. With a core-box, you can rout traditional, deep flutes into a spindle. With a coving...

Building the

Dowel Jig Homemade Togle

A reminder to collect all the ncccssary hardware before you begin is, to me, always appropriate. Some of the hardware-can be picked up at the local hardware store. But the jig won't work without the toggle clamps, and it is likely you will have to order them. At the same time, order the plastic-knobs. When the stuff arrives, get to work on the jig. 1. Cut the body parts. The jig's body, formed of the cop. face, and base, is made of thick hardwood. Ken used i gt inch maple I used 1 Vt-inch...

Making a Tabletop with Exposed Edge Banding

Countertop Edge Router

The procedures for making this style of tabletop are no different than those detailed in this chapter's step-by-step. They simply are performed in a different sequence. 1. Laminate the two layers to form the core, and prepare the edge-banding Steps I through 3 on page 1 59 . 2. After squaring the core, apply the plastic laminate to it. 3. Trim the laminate flush with the edges of the core. 5. Trim it flush with the top and bottom surfaces of the tabletop. then apply a finish to it. Trim...

Making the Mounting Plate

Router Table Lifting

The approach here will be to make a plywood or medium-density fibcrboard MDF template or pattern, then use that to make the plastic mounting plate. There arc several reasons for this. Plywood and MDF are easier to work than plastic.They won't melt, for example, if you sand an edge too aggressively. Both wood products cost less than plastic, so if you goof, you aren't writing off a 10 to 15 square of material. Both products provide good surfaces for note taking. You can jot directions for using...

Building the Upper Cabinet

The next key component, the upper cabinet, houses the router, capturing a lot of the noise and chips it generates in use. It provides orderly storage for bits, collets, and wrenches. And it incorporates switched receptacles for the router and a shop vac or dust collector. Although in general I've had a negative regard for doors on router compartments, I put one on this cabinet. With the lift-top feature, the door isn't an irritating barrier to router access. Now it's a barrier to chips and...

Shelf Support Template

A shop-made template, a guide bushing, and a plunge router are all you need to bore clean, accurate, precisely placed support-pin holes for adjustable shelving. Here's a jig to make boring ranks of holes for adjustable shelving a whole lot easier and more accurate. It's a template that clamps to the work-piece. You use a plunge router with a ' 2-inch template guide and a ' -inch straight bit to actually bore the holes. With this shelf adjustment approach, of course, you have sets of four holes,...

Universal Router Mounting Plate

Universal Router Base Plate

Work from scratch to make yourself a mounting plate that's fitted precisely to your router and router table. Attach the router directly to a piece of plywood. That used to be the typical approach to creating a router table, and it's one that works. Not as well as other, more contemporary approaches. But it works. Nowadays, of course, the most common way to mount j router in a table is with a mounting plate, which is little more than an oversized baseplate. A rabbeted opening is cut through the...

Dowel Joinery Using Plunge Router

Router Doweling Jig

Boring dowel joinery can be a fulfilling experience. Use your plunge router with this precision jig. The jig makes it hard to go wrong. Dowel joinery was one of the things I tried early in my woodworking experience. What I had were carpentry tools but I was making a vanity, and I wanted to join the rails and stiles of a face frame. Dowel joints seemed like the way to go for me just buy a doweling jig and use the portable drill and twist bits I already had. What a disappointment Maybe it was me,...