The ridge left between two rabbets locks into the 03 straightedge's slot, keeping the tail block aligned. Cut the rabbets on the table saw. After making the shallow Ql shoulder cuts, raise the blade and adjust the rip fence S for the base cuts. Cut so the waste falls to the outside 'ST of the blade, rather than being trapped between the
® blade and the fence (which would lead to kickback). ^
O 6. Install the tail block. The block is. of course, fitted into the straightedge slot, then held in place with a carriage bolt and plastic knob.
Counterbore and drill the bolt hole. On the back of the block, locate the exact center of the piece. With a ftnnch Forstner bit. drill a Winch-deep counterbore so that the carriage bolt head will be recessed. Switch to a ?H-inch bit, and drill the shank hole. This hole should emerge at the back end of the spine. To steady the workpiece while you drill, set it into the straightedge slot and put both parts on the drill press table.
Drive the carriage bolt into the hole, then insert it through the straightedge. Drop on the large fender washer, then thread the knob onto the end.
Plastic knob with blind threaded insert
Vs" X 5'/2h carriage bolt
Plastic knob with through threaded insert
Corners filed off square subhead of bolt
W X 2" carriage bolt unthreaded without backing the insert out of the block.
10. Assemble the pressure mechanism. Hie idea is to insert the bolt through the pressure block and trap the block between the bolt head and a stop nut.The bolt mast be free to spin in the block, so you can't jam the nut against the block.
I used a carriage bolt here. To allow the bolt to spin freely, I filed off the corners of the bolt's square "subhead." Compare a long hex-head bolt with a carriage bolt of the same Icngth.YouIl see that the hex bolt has only a short section of threads, while the carriage bolt is threaded right up to the head. The application requires more threads than the hex holt offers. Hence, the choice of carriage bolt.
Inser. the bolt, and thread the stop nut onto it. A stop nut has a nylon insert that prevents it from loosening. Consequently, a stop nut is hard to thread. Once the insert engages the bolt's threads, you have to turn it with a wrench; you can't do it with your fingers.
Fit the head block onto the bolt next. Add a second stop nut, then the plastic knob. 'Aim the knob onto the bolt until it scats.Then back the stop nut up to the knob, and jam it against the knob.
11. Mount the head block on the straightedge.
You can glue and screw the head block to the straightedge. I used screws only, and that's been satisfactory.
Position the head block, as shown in the drawings. Secure it with a clamp while you drill pilot holes and drive drywall screws. I drove two screws through die block into the straightedge, then flipped the unit over and drove two more screws through the straightedge into the block.
To finish, I glued sandpaper to the working edge of the pressure block, just as I did to the tail block.
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There are a lot of things that either needs to be repaired, or put together when youre a homeowner. If youre a new homeowner, and have just gotten out of apartment style living, you might want to take this list with you to the hardware store. From remolding jobs to putting together furniture you can use these 5 power tools to get your stuff together. Dont forget too that youll need a few extra tools for other jobs around the house.