Cutting the roof miters. To cut an angled roof piece, the author clamps it to either the side or the end of a right-angled block that slides in his tablesaw's miter gauge slot.
Drill the pivot holes. The author's jig ensures accurately positioned pivot holes. A clamping arm presses the work-piece against the jig's fence.
Rout the lid mortises. A shop-made template clamped in a vise makes routing the lid mortises fast and accurate.
Assemble the case. Slip the second case side onto the pivot rods by working from one end of the case to the other.
lid blocks from two strips of stock dressed to l3/8 in. by 2 in. by 27 in. Shape one edge of each strip on the router table, using a 1-in. radius round-over bit. Before routing, saw away most of the waste on a tablesaw set for a 45° bevel cut. Sand the rounded edges smooth, then crosscut the lid blocks to final length.
Drilling the 'Z^-in.-dia. holes for the pivot rods is next. I like to use a brad-point drill bit for this because it won't wander. However, I don't have a in.-dia. brad-point bit, so 1 bore each hole first with a l^-in.-dia. brad-
point bit, then I enlarge it with a in.-dia. standard twist drill bit. Make a drill-press-fence jig like the one shown in the top right photo above to position and hold the blocks for boring.
Next, on the underside of each block, cut a round mortise that will tightly hold a jar lid without glue. I prefer not to glue the lids into their mortises 011 the finished spice rack because unglued lids make for easier 14label-forward" jar switching later on.
I crcatcd pcrfcctly fitting mortises by template-routing them. The process is simple: You make a template with a hole the exact size of the mortise, then rout the mortise with a flush-cutting router bit. (See bottom left photo, above.)
Make your template from ^j-in.-thick medium-density fiberboard (MDF). Cut the template hole on the drill press using an adjustable circle cutter, which allows for fine adjustment of hole size. When the lid fits tightly into the template hole, attach a pair of side rails and an end block to the underside of the template to position each lid block securely when routing it. (See Fig. 2.)
Before routing the mortises, 1 drilled out most of the waste on the drill press, using a l-in.-dia. Forstner bit.
To set up for routing, clamp the lid block against the template's end stop, dien clamp the template and block in a workbench vise as shown in the lower left photo on the opposite page. For this type of template routing, I use a mortising bit widi a top-mounted bearing (#116-1215, available from Eagle America, 800-872-2511), which will cut flush to the walls of a template. Cut the mortises just a bit shallower than the jar lid height.
When all the lid blocks are mortised, you're almost ready for assembly. But first, apply finish to the lid blocks and the inside surfaces of the case. I spray on a few coats of lacquer, but any finish is fine.
Dry-assemble the case and pivoting mechanisms to be sure everything fits well before glue-up. Begin by pre-assembling the pivoting mechanisms, inserting V^-in. washers between the lid blocks and a washer and spring at each end of the rod.
Next, clamp one case side to your bcnchtop and insert that end of each pivot rod into its hole. Then attach the opposite case side, working from one end to the other, jiggling each of the pivot rods into its opposite hole. (See bottom right photo, opposite page.) When everything fits well, glue the joints, clamp up the assembly, and check the case for square by measuring its diagonals. Don't attach the back or stop strip yet.
Assemble the gable roof, gluing it to the top of the case. Use a couple of 25' wedge scraps as clamping blocks, gluing sandpaper to their edges so they won't slip off the roof during clamping.
When the glue is dry, sand the unfinished surfaces of the case and finish them. Attach the stop strips by nailing them on through the case back. Then nail the back into its case rabbets.
Press the jar lids into their mortises, making sure the label on each jar faces forward when screwed fully into the lid. Glue the lids in the mortises with a dab of silicone glue only if necessary. A
SANDOR NAGYSZALANCZY, a frequent contributor to AW, a ho cooks a mean goulash.
FIG. 3: PIVOTING MECHANISM
Springs at the ends of a pivot rod press the lid blocks together, so they will stay pivoted out for easy jar replacement.
LID BLOCK LID BLOCKS CASE SIDE
LID BLOCK LID BLOCKS CASE SIDE
FIG. 2: LID BLOCK MORTISING TEMPLATE
To use this template, clamp the lid block to the stop, then clamp the rails in a vise. Rout the lid mortise using a mortising bit with a top-mounted bearing.
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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.