Sawdust Session #24: September 13, 2008 Topics: Replacing and repairing the major parts and sub-assemblies of the quill and quill feed inf an older Mark V headstock, making a finger plane, tips and techniques for biscuit joinery, and how to set up you Shopsmith for shaping.. Plus Drew's interludes (naturally). 1. Rebuilding the 2. Making a Finger Quill and Quill Plane -- Many of Feed -- In Part 4 of you have asked Shopsmith Reborn, about Nick's "violin Nick shows how to plane" -- a handy replace the quill tool if ever there and the quill feed, was on. how to replace or Unfortunately, there re-attach the quill are hard to find and spring, and how to ridiculously re-tension the quill expensive when feed. you do. But here's how to make your own. FREE PLANS! 3. Setting Up the 3. Drew's Shaper -- You Interludes -- never knew you Besides being an had so many accomplished shaping choices. woodworker, Drew You can shape with is also a very the Mark V capable machinist, horizontal or and he offers some vertical, with our sound advice for without a speed working with metals increaser, using a -- Marking on split fence or rub Metals and Drilling collars to guide Sheet Metal your work. We Safely. demo all the options. Sawdust Session #23: August 9, 2008 Topics: Replacing the major parts and sub-assemblies of the drive train in an older Mark V headstock, band sawing and air-drying your own lumber, digitally measuring the quill feed, and a simple storage system for small tools and parts. Plus Drew' gives advice on preventing insect damage when drying wood and protecting cutting edges when storing tools. 1. Rebuilding the 2. Band Saw Drive Train -- In Lumbering-- You Part 3 of Shopsmith can use you Band Reborn, Nick shows Saw to turn bolts of how to replace and wood that might adjust the belts, otherwise go for how to remove the firewood into usable shafts, and how to lumber, provide you perform a high- stack it properly to speed adjustment. dry and monitor its moisture content as it does so. 3. Digital Drilling -- 4. Egg Carton With an ordinary Storage -- A quick, digital caliper and easy, and some hardware, inexpensive idea for you can achieve organizing the extra-ordinary drawers in a tool accuracy when chest, workbench, drilling holes, or any piece of gauging their depth shop furniture. to one thousandth Keeps small tools of an inch as you and part separated, drill. FREE PLANS easy to find, and for this super easy to reach. simple jig. Drew's Interludes: 1. Preventing Insect Damage -- All your hard work band saw lumbering and air drying can be for naught if a few insects invade you wood stack. Drew has some advice for how to avoid this disappointment. 2. Protecting Cutting Edges in Storage -- Storing chisels, planes, files, rasps, and other hand tools in a drawer can be hard on the cutting edges unless take a few precautions. Sawdust Session #22: June 28, 2008 Topics: Cutting coves and making moldings on a table saw, an ingenious technique for cutting irregular shapes easily and accurately, how to set up and use the pneumatic drum sander, and what to look for when shopping for a used Shopsmith Mark V. Plus Drew gives some good advice on sanding coves and gluing mitered joints. 1. Working with 2. Truing the Table Wood Composites to the Drill Chuck - -- If you're looking - For most drilling to make your ops, the table must outdoor projects be square to the last, the longest- axis of the chuck – lived material front-to-back and available is wood side-to-side. The fiber and plastic equipment needed composites. can be made from a Includes FREE carriage bolt and PLANS for a scrap wood. composite Adirondack Chair. 3. Cleaning and 4. Drew's Inspection -- In Interludes -- First, Part 2 of Shopsmith Drew shows us how Reborn, we tear to to use winding down the headstock sticks to gauge if a of our 1964 goldie, drawer is flat or clean each part and twisted. Second, sub-assembly, and he takes advantage decide which parts of the propensity for must be replaced wood and glue to before the Mark V "creep" under will run safely. pressure to straighten the twisted drawer. Sawdust Session #21: June 14, 2008 Topics: Cutting coves and making moldings on a table saw, an ingenious technique for cutting irregular shapes easily and accurately, how to set up and use the pneumatic drum sander, and what to look for when shopping for a used Shopsmith Mark V. Plus Drew gives some good advice on sanding coves and gluing mitered joints. 1. Making Cove 2. Cutting Moldings -- Using Irregular Shapes -- nothing more than a Another time-saver saw blade and a from Nick the little ingenuity, you Jigmaster -- cut odd can create elegant angles and shapes cove moldings for quickly and furniture and finish accurately in both carpentry. large and small workpieces using the dead-simple jig. FREE plans (of course). 3. Pneumatic 4. Finding a Drum Sander -- Bargain -- In Part 1 This little-known of our series Shopsmith sanding Shopsmith Reborn, accessory is worth we go hunting for a it's weight in gold used Mark V. when you need to Here's what to look "blend" curved for so you get surfaces or sand yourself a bargain three-dimensional and not a basket shapes. case. Drew's Interludes: 1. Gluing Miters and End Grain -- The weakest glue joint you can make is to glue end grain to end grain, as in a miter joint. The end grains suck up all the glue and "starve" the joint. Drew has a way to prevent that. 2. Pneumatic Cove Sander -- The Drewster shows a brand new application for the pneumatic drum sander. Sawdust Session #20: May 24, 2008 Topics: How to rip bevels along the length of a board, including FREE plans for an adaption of the Shopsmith Outfeed Table that raises, lowers, and tilts with the main table. Plus how to assemble and clamp unusual shapes, joining complex project one half at a time, setting the thickness planer knives, and Drew's Interludes. 1. Ripping Bevels 2. Clamping Oddly with a Tilted Table Shaped -- When ripping a Assemblies -- bevel on you Assembling the Shopsmith, you diamond-shaped must support two shadow box that we boards as the work introduced in leaves the saw -- Sawdust Session the upper part and #19 presents an the lower part. You entire series of can adapt the clamping Shopsmith Outfeed challenges -- but Table to do just that nothing we couldn't -- FREE plans. handle 3. Joining Mitered 4. Setting Planer Assemblies -- Knives -- Changing When putting and setting the together a complex knives in the frame where all the Thickness Planer is parts have to mate surprisingly simple perfectly, it and straightforward sometimes helps to once you know a assemble one half few secrets. at a time. Sawdust Session #19: May 10, 2008 Topics: ALL about sawing and dadoing with a table tilted. Nick shows how to rip bevels along the length of a board, how to make bevel-miters across a board, how to make compound miters, and how to make angled dadoes. Includes FREE plans for (1) an "Anti-Gravity Uphill Miter Jig" that makes tilted table operations simple and safe; (2) a miter gauge extension"; and (3) a unique, elegant diamond-shaped shadow box. Plus a FREE Compound Miter Calculator and Drew's Interludes. 1. Cutting Bevel- 2. Making Angled Miters -- You make Dadoes -- Cutting a a "bevel-miter" by dado, groove, or cutting a bevel in rabbet at an angle the end of board in a board requires with the table tilted. the you tilt the table Here's a unique jig and, on occasion, that defies gravity make a special and keeps your cut- table insert. offs from sliding downhill. 3. Making 4. Drew's Compound Miters Interludes -- First, -- To make a the Drewmeister compound miter, shows us how to you must tilt the extend the table and angle the Shopsmith's miter gauge. You capabilities and cut can find the angles beveled miters needed with our smaller than 45 FREE Compound degrees. Second, Miter Calculator. he reveals two tricks to keep stock from blowing out when using a dado cutter. Sawdust Session #18: April 26, 2008 Topics: Making a Laptop Desk with a "breadboard" lid, routing finger joints with a shopmade jig, and how to rout stopped or "blind" joints using a little planning and some simple geometry to feel your way. Plus Drew's Interludes. 1. Making 2. Routing Breadboard Finger Joints -- Joints -- The lap The sides of the desk is a lap desk are timeless keep-all joined with with some interlocking special joinery. tenons or "finger" The bread-board joints. These joints in the lid strong, keeps the decorative joints unsupported are cut on a board from router table with cupping. Includes a special jig. FREE plans for Includes FREE the desk! plans for the jig. 3. Routing 4. Drew's Stopped Joints Interludes -In -- The bottom of Interlude 1, our the lap desk musical friend rests in stopped waxes laconic or "blind" about "upcut" grooves. Routing and "downcut" blind joints router bits. In requires a Interlude 2, he special setup on shows how to the router table make and use an and a special absurdly simple way of laying out "push board" for the joint. cross-grain work on a router table. Sawdust Session #17: April 12, 2008 Topics: Making turnings with the Ringmaster that curve in and out, how to make basic mortises and tenons and several variations on that theme, making "stopped or blind" joinery on the Overarm Router, and replacing the Mark V Speed Control.