® WOOD MAGAZINE’ S Great Projects for Your Shop 2 3 Shop-tested benches, racks, organizers, and more... Right-angle router-table push pad p. 10 Proven plans by the editors of WOOD Supplement to WOOD® Magazine WOOD Magazine's Great Projects for Your Shop Contents 1 Mobile utility bench P.4 2 Folding assembly table 3 Multilayered lumber rack and sheet-goods holder 4 Rolling storage cart 5 Easy, attractive drill-bit cabinet 6 Benchtop sanding-disc caddy P.6 7 Built-to-fit sandpaper holder 8 Tablesaw tapering jig 9 Exact-width dado jig 10 Right-angle router-table push pad 11 Zero-clearance cutoff guide 12 At-the-ready router rest 13 Hang-and-go lathe-tool holder P.1 14 Easy-access router-bit storage 15 Round and ready drill-bit carousel 16 Workshop drawer organizer 17 Movable task-light support 18 Wall-hung tape dispensers P.10 19 Portable glue/towel center P.13 20 Edge-protecting chisel rack 20 pencil box with sharpener support 21 Handy hardware bin P.17 21 Hanging glue box ©Copyright Meredith Corporation 2010. All rights reserved. Great Projects for Your Shop Mobile utility bench The perfect size for smaller tasks, this handy bench rolls—and then stays— wherever you need it most. or a shop with limited space, or when you need some additional work- F surface for a project, this small bench fills the bill. With casters on one end only, you can easily move it like a wheelbarrow, yet the bench is rock-solid when lifted off the caster with the load leveler. The bench shown here features alder sides, exterior- grade ¾" medium-density overlay (MDO) for the carcase, and construction-salvage oak 2×4s for the benchtop. Laminating the top with 2×4s makes for a more stable than a solid slab. Project design: Dale Faulstich, Sequim, Wash. 18" 54" 3½" 2x4s ⁄" lag screw 36" #17 x 1½" brad 2½" long #17 x 1½" brad 14½" 1½ x 3 x 24" caster cleat 1½ x 3 x 30" leveler board 27" 3" 34½" Plywood 27" 3" 1½" Solid stock 3" locking swivel caster 5½" Load Solid stock leveler 6" 1½" 24" 1½" 4" 1 Great Projects for Your Shop I talked with Mr. Faulstich a few times to get info on his bench, he told me all he used was a brad nailer to put it all together, 100505676.ai he explained he was going for speed and ease of assembly, 2-09 he said he used no screws FILENAME : FaulstPrj1_#100505676.eps Filename: Faulstich bench Date: 11-07 R LeMoine Lorna J . 11-6-07 Folding assembly table ¼" Baltic birch plywood covered with laminate Use it. Fold it. Then Table leaf levelers store this table in a 24" TOP minimum of space. 84" his versatile table with a removable worksurface allows Jeff Tobert some Lattice T additional space to assemble projects, 1¼" frame and gives him a larger outfeed space when ¾" aligned with the regular outfeed table on his tablesaw. Continuous hinges allow the 4" SIDE folding end assemblies to collapse for easy ASSEMBLY storage. Each leaf of the tabletop consists of two plywood skins over lattice frames, 30" Pocket-hole screws covered with plastic laminate. Install cabinet levelers at each corner so you can adjust 60" ¼" dowels with mating holes in top the table to match just about any uneven 52" surface inside—or outside—your shop. 4" 4" Heavy-duty 17¼" NOTE: Jeff used continuous (piano) hinges cabinet leveler for his table, but to save money, consider END ASSEMBLY using less-expensive butt hinges. Project design: Jeff Tobert, Spruce Grove, Alta. Continuous hinges 30" long joining side assemblies 30" Continuous hinge to end assemblies 30" long joining both halves of 4" end assembly 2 Great Projects for Your Shop 100505693.ai Filename: Tobert knockdownTBL 2-09 R LeMoine 1-3-07 KNOCK-DOWN COLLAPSIBLE WORKTABLE FILENAME:TobertPj1_#100505693.eps Filename: Tobert knockdownTBL Date: 10-07 R LeMoine Lorna J . 10-30-07 Multilayered lumber rack and sheet-goods holder 1½" rabbet #8 x 1½" F.H. wood screw Pack lots of wood in a ¾" deep 72" minimum of space. 1½" dado ¾" deep ¾" hole 3" deep his wood-storage system keeps sheet drilled at a 87° ¼" lag screw goods and boards close at hand but 3° angle 6" long Toccupies minimal space. The upright component stores long lumber. It mea- sures 8' high × 6' wide. Attach 2×4s to the ¾" pipe 16" long wall and drill ¾" holes 3" deep angled upward about 3° into the 2×4s. Then insert 2x4s 16"-long pieces of ¾" black pipe. Fasten a 1×4 horizontally along the rack face toward 1½ x 5½ (2x6) x 48" the bottom, creating a small cavity between the vertical members where you can store flat stock, dowels, and scraps of fine woods. 96" The second component is a swinging 4" hinges sheet-goods holder. Make a frame of one vertical and one horizontal 2×6, faced on each side with a 4×4' sheet of plywood cut on the diagonal. The vertical frame piece attaches to the 2×4 on the wall with hinges. A 3" swivel caster attached near the end of ½ x 48 x 48" the horizontal frame piece allows the unit plywood to swing out easily, providing ready access to materials stored behind. Project design: Dale Heisinger, Orcas Island, Wash. 1½ x 5½ (2x6) x 46½" ¾ x 3½ (1x4) x 72" 3" swivel caster 3½" notch ¾" deep 3 Great Projects for Your Shop WOOD ST ORA GE WALL SYSTEM (1x4) 100205901.ai Date: 3-09 FILENAME:Tip2_#100205901.eps Date: 7-06 Lorna J . Filename: Heisingershop tip 1 R LeMoine 6-21-06 Rolling storage cart This shop helper brings order to chaos. he design of this unit revolves around goods usage. Rout a 1/8" round-over along plastic storage tubs like those sold in the one exposed edge of each 11/2×11/2" Thome centers and large discount cleat and along the top edge of each 3/4×3/4" stores. Our version houses Rubbermaid cleat where shown. (The round-over on the Roughneck Storage Tote 3-gallon/11.3-liter interior cleats allows the tubs to slide easier.) containers, but just about any kind will do. Then, drill the countersunk mounting holes Just be sure to adjust the project dimensions through all parts where noted. Glue and to fit the tubs you select. screw the dividers between the two sides. The entire project, minus the optional Next, attach the top, bottom, center parti- shelves and cleats, is built from two sheets tions, and cleats. Mount the interiorCutting support Diagra m of medium-density fiberboard (MDF), but cleats, allowing about an inch or two of 3/4" birch plywood would also work well. clearance, from top to bottom, between Start by cutting the parts to size as noted in containers. Attach the casters. Drawing 1. See Drawing 2 for optimal sheet- Project design: Bernard Monneau, Calgary, Alta. 1 EXPLODED VIEW *26¼" Center partition Divider TOP #8 x 2" #8 x 2" F.H. CLEAT Cutting Diagra m F.H. wood *21¾" wood screw 1½ x 1½ x 32¾" Side screw Top/bottom 1" *10½" DIVIDER 16" ¾" ⁄" round-over ¾ x 49 x 97" Medium-density berboard 7¼" (MDF) (2 needed) SIDE ¾" SUPPORT CLEATS 21 CUTTING DIAGRAM ¾ x ¾ x 16" 7¼" (48 needed) SIDE *Dimension Center partition Divider will depend upon the size of your tubs. ⁄" round- 68" Side overs Top/bottom #8 x 1¼" F.H. 32¾" CENTER 16" wood screw #8 x 2" F.H. PARTITION wood screw 16" ¾ x 49 x 97" Medium-density berboard (MDF) (2 needed) 4" DIVIDER CLEAT Outside cleats swivel caster 1½ x 1½ x 32¾" 1½ x 3½ x 72" Pine (4 bd. ft.) Inside cleats BOTTOM 32¾" ⁄" round-over ¾ x 5½ x 96" Pine (4 bd. ft.) *26¼" Inside cleats 4" xed caster #8 x 2" F.H. wood screws ¾ x 3½ x 96" Pine (2.7 bd. ft.) Outside cleats 1½ x 3½ x 72" Pine (4 bd. ft.) 4 GreatInside Projects cleats for Your Shop ¾ x 5½ x 96" Pine (4 bd. ft.) Inside cleats 100.ai ¾ x 3½ x 96" Pine (2.7 bd. ft.) Date: 5-09 FILENAME:166GIFY StorageCD.eps 100 Date: 7-05 Date: 5-09 Lorna J. FILENAME:166GIFY Storage1.eps Date: 7-05 Lorna J. 100.ai Date: 5-09 FILENAME:166GIFY StorageCD.eps Date: 7-05 Lorna J. Easy, attractive drill-bit cabinet Here’s a great way to keep everything you need for drilling tasks in one place. f you’ve ever discovered that you had wasted money by buying the same drill Ibit more than once, you may need a cabinet for organizing all your bits and accessories. With everything in its own spot, taking inventory of your drill bits takes only a glance. This cabinet is made of Baltic birch ply- wood (drawer fronts plus side, back, and door panels); pine (drawers and door trays); and walnut (drawer handles) for an attractive appearance. But use whatever materials suit your tastes. Likewise, make as many or as few shelf-holding dadoes as you need to match the number and sizes of the bits you own. Putting a few extra dadoes in the sides of the doors at the time of construction allows you to change 8⁄" 8½" the internal shelf arrangement as your 16¾" needs change. Project design: Tom Whalley, Urbandale, Iowa ¼" dadoes 24⁄" ¼" deep 15¼" ¾" plywood 4¾" 1¼ x 1½" ¼" hardboard 24⁄" 7¼" ¼" plywood ¼" groove ¼" deep 16¾" Magnetic 4½" catch ¼" rabbet ¼" deep 1½" 10" ¼ x ½ x 9⁄ " drawer guides 15⁄" ½" groove ⁄" deep 5 Great Projects for Your Shop Filename: WHALLEY projects 1 100505696.ai R LeMoine Date: 5-09 1-3-07 FILENAME : Whalle yPj1_#100505696.eps Date: 10-07 Filename: WHALLEY projects 1 Lorna J.