Rail Bit

Ihls $ame
BallBit Stile Bit
allowsior
Sttb&
Exlandd
Tenons
For Stile Guts

Rail Bit

For Making
Stub Tenon
Guts on Rails
Raised Panel Bit

For Making
Raised
Panel Guts

Fdonsr.aoa.\

Now you Gan Grcab Beatffitl, r" rrua'1

Gushnizcdllmrc wtUtSUottgJoints. tEl
1t \".'tL'J
Imagine the Possibilities,,,
lnshrctional
Thanks to Freud'spatented innovation,you now have DUIIIncluded
the abilityto make door joints with preciselyfit tenons
of any length.Use the bits right out of the box for high
qualitystub tenons,or by simply removingthe top of Bit Sets Available:
the Rail bit, createextendedtenons (for strongerjoints) Two Piece Bit Sets Available: . RoundoverProfilewith Bevel
. RoundoverProfile(#99-267) RaisePanelBit (#98-300)
at all four critical corners of your door. Combine with . Ogee Profile(#99-268) . RoundoverProfilewith Cove
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you can create unique interior doors with any design
or wood species. These router bits come set up for
1-3/4"height(forentrydoors)and can easilybe adjustfor
'1-3/8"height(for interiordoors).
ffi'
Preciselythe best.
 Better Homes and Gardenso

Best-Ever
HomeShopldeas2A09
woodmagazine.com

Editor-in-ChiefBILLKRIER
ManagingEditor MARLENKEMMET
Deputy Editor DAVECAMPBELL
PublicationWriter CARLVOSS
Techniques Editor BOBWILSON
Tool & TechniquesEditor BOB HUNTER
MultimediaEditor LUCASPETERS
MultimediaEditor CRAIGRUEGSEGGER
ProjectEditor LARRYIOHNSTON
SeniorDesignEditor KEVIN BOYTE
DesignEditor fEFFMERTZ
Production/OfficeManager MARGARETCLOSNER
AdministrativeAssistantSHERYLMUNYON
Photographers MARTYBALDWIN,IASONDONNELLY,
DEANSCHOEPPNER, IAYWTLDE
ContributinglllustratorsTIM CAHILL LORNA|OHNSON,
ROXANNELeMOINE
Contributing Craftsman llM HEAVEY
Contributing ProofreaderIRA LACHER
Art Director KARLEHLERS
ProjectArt Director fOHN GEARHEART
AssociateArt Director GREGSELLERS
AssistantArt Director CHERYLA. CIBUIA
SUBSCRIBER SERVICE
Co to woodmagazine,com/help
or write to WOODmagazine,P.O.Box 37439,
After moving carsoutside,this homeownerrolls out cabinetsto form Boone,lA 50037-0439
a worksurfacein his garage.To learnmore, seepage 22.
PublisherMARK L. HAGEN

Frombkay'to'wow!' ADVERTISING
AND MARKETING
CHICAGO:333 N. MichiganAve.,Suite1500,
Chicago,lL 60601
MarketingManager AMANDA SALHOOT
few months ago, I spent a good portion of a week AdvertisingManager fACK CHRISTIANSEN
watching the transformation of a ho-hum ZYz-car Account ExecutiveRYANINTERLAND
garageinto an incredible car buff's backyard escape. Direct Response
AdvertisingRepresentative
LISAGREENWOOD
(For a closer look at the shop, seepage36.)
AssistantsGAYLECHEIN,NIA WILLIAMS
What a difference five days made. And believe me, the ATLANTA:NavigateMedia
"wow' factor doesn't fade: A revisit months later still took DETROITRPMAssociates
away my breath when the garage door rolled up. But who BusinessManager IEFFSTILES
wouldn't be green with envy gazing at a sparkling epoxy AssociateConsumerMarketing Director DAN HOLLAND
AssociateDirectorof Marketing-NewsstandTOM DEERINC
floor? No oil stains would dare linger!
ProductionManager SANDYWIILIAMS
That garageis a multitask spacedesigned and organized AdvertisingOperationsManager llM NELSON
as many of us imagine our shops.Car-careproducts, previ- E-CommerceManager MATTSNYDER
ously shuffled around in cardboard boxes, are now neatly Vice President/CroupPublisherTOM DAVIS
organized behind a pair of doors. The adjoining cabinet MEREDITH PUBLISHING GROUP
holds a season'sworth of yard and garden remedies. Paint- PresidentfACKGRIFFIN
brushes and hand tools, neatly lined up like soldiers, beg to ExecutiveVice PresidentDOUGOLSON
be picked up from smooth-rolling drawers. Chief RevenueOfficer TOM HARTY
Finance& AdministrationMIKERIGGS
The recent visit to the shop gave me pause. No more Manufacturing BRUCEHESTON
excuses:I got the jolt to jump-start and overhaul my own ConsumerMarketing DAVIDBALL
shop. I referredto the planning articles in this issueto lead CorporateSalesMICHAELBROWNSTEIN
me every step along the way. Meredith3600 IACKBAMBERGER
How 'bout you? Just picking up this magazine affirms InteractiveMedia LAURENWIENER
CorporateMarketing NANCYWEBER
that there's a garage or shop redo on the horizon at your ResearchBRITTAWARE
home. So get going! Break the work into bite-size tasks, and Chief TechnologyOfficer TINA STEIL
you'll be there quicker than you think. New Media MarketingServicesANDYWILSON
.lUleredlth

m^l^fu
I conponlrror

Presidentand Chief ExecutiveOfficer STEPHEN M. LACY

Chairmanof the Board WILLIAM T. KERR
In Memoriam - E.T.Meredith lll (1933-2003)
@CopyrightMeredith Corporation 2008. All rights reserved.Printed in the U.S.A.
Marlen Kemmet RetailSalesRetailerscan order copiesof WOODfor resale
by e-mailing jennifer.buser@meredith.com.
WOOD@MagazineManagingEditor
H,o'O
 No Helper?No Problem
Overcomethe challengesof accomplishing
strenuoustaskswithout a helper.

To Buyor Not to Buy?

Beforepurchasinga new tool, weigh
your rentaloptions.

PIan Your Shop

12 It'sTimeto Act on Your
DreamShop
Timespentdesigningyour new-
work room will pay huge dividends.

16 PackMoreWorkshop
Into LessSpace
Makethe most of everysquarefoot
in your new shop.

20 FlooringOptions
You'llfindplentyof choiceswhen you
considerupgradesto your shop floor.

22 WorkshopCabinetry
Feastyour eyeson all the options for
storingtools behinddoors.

26 WallSystems
lf you want efficiency,you'll plan
for hangerspaceon your shopwalls.

28 GetWired Prepare Your Shop

A top-notch electricalplan allowsfor
changesin shop layout.
36 GarageMakeover
Join usfor a journeyinto an upgraded
30 BrightenYourShop garagethat! now a pleasureto work in.
Don't be left in the darkwhen reading
project plansand setting up tools.
38 Tips& Toolsfor Applying
an EpoxyFloor
32 EnergyEfficiencyfor YourShop See how professionalsprepare a homeowner's .
How to reduceyour energy bill and reap garage for an industrial-quality epoxy floor.
dividendsfor yearsto come.

42 How to UnstuffYourGarage
34 KeepYourShopand LungsClean in 2 Days
Beforeyou start building projects,be Learnhow one DlYerspent lessthan
sureto includea systemto gather dust. S1,000to injectorder into hisshop.

Best-Ever Home Shop ldeas 2009

Build Your Shop 90 Orbital-SanderRest 122 TheUltimateCheapGuy's
Takethe swirl out of sanding. Workshop
50 One-DayWorkbench Savvyshopownerssqueezethe most into
A solid bench becomesthe keyfeatureof 91 SheetsGoodsMover/Lifter everytool purchase.
your long-anticipated
shop upgrade. Insteadof strainingyour back,work
smarter when you carry sheet goods. 126 SaveBigBuckson Tools
56 ToolCarousel Fourteentips will help you shopsmartlyfor
Reduceclutterin your shopafteryou build Equip Your Shop your next tool purchases.
and mount this storageunit on the wall.
92 GettingStarted
60 Bench-Tool
System Because fewof uscanaffordto buyallnew
A versatiletower and cabinet-both on toolsat once,it makes
sense to havea plan.
wheels-are idealfor benchtoptools.
95 Power-SawComparison
65 RollingWorkshopStorage Allsawscut,butchoosing
thebestonefor
Savea lot of stepswhen you wheel a tower thejob canbea challenge.
of materialsto your work area.
98 SuccessWith
66 ShopCart M itersaws & Accessories
In a weekend,you can build a convenient Mitersawsareperfectlydesigned
for cutting
shop cart from one 4x8' sheetof plywood. moldinganda wholelot more.

70 ToolCabinet 100 Drills:Compared and Contrasted

A tidy wall-mountcabinetpacksa wallop Besureyoureadthisarticleabouthand,
with amazingswing-outspacefor tools. battery-powered,
floor,andtabletopdrills.

75 Stool& ToolToteCombo 102 Random-OrbitSanders

Thisstraightforwardtool carrierdoublesas Thesetoolssaveyouhoursof sanding
by
a convenientstoolfor DIYprojects. leaving
scratch-free
finishes.

76 Tablesaw
Workbench 104 Portable Tool Storage
Makethe most of a combination Carttoolsto yournextprojectin a bucket,
workbenchand outfeedtable. box,or sturdyfabricroll.

82 MobileStorage 106 Ready,Set, Roll DrillComparisons

100
lf you'verun out of spacesolutions,build yourtoolswithportable
Corral cabinetsand
this project for a quick fix. portable
cheststhatwilllasta lifetime.

84 Mobile Tool Cabinet 108 AirTools and CompressorSystems

Customizestoragefor tools, hardware,and You'llbeamazedat howpractical
finishingsuppliesin a smallfootprint. isforjobsaroundthehouse.
a compressor

110 Lasersfor the Home

Harness foryournext
lasertechnology
project.
household

112 DigitalToolsUnder 5100

Intoday's market,you'llfindanaffordable
forhomeprojects.
arrayof digitaltools

114 Clampsfor the Home

Besureyouhavetherightclampforthejob.

116 Understanding Tool Batteries

Technology advances openthedoorfor
lighterbatteries quickly.
thatrecharge

118 Eking PrecisionFrom

3 Portable Power Tools
Circular
saws,jigsaws,
anddrill/drivers
arecapable jobs.
of amazing

woodmagazine.com
Best-Ever Home Shop ldeas 2009
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l l r i n l s l r r v o r r r s c l f\ .\ ' h c t l t r r r o r r r n l r i n I r s I i l . r c l .& l ) c c l i er ' ' s \ \ ' o l l i r r r . r t cr l l r r r l r ' . i l l l t ' \ i l \ l ) t ' r i r t i t t g t ' \ f r i ' f i 1 - ' 1 l r r t' ,' \ t ' l t i l r p t t
'l'hat's
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lro.rlr, r i r r r r i o t l r l o t ' l . i n ! ,r ' t t t t ' l l o 1 t t , n t ' r ' c nt I r o s ct I r a t i n c ' o r ' 1 r o r ' ., r t rt v o - r l l t r c I c o n s t r r n t l rl i g l r t i r r t t l r c c l o c l . ,t r v i r r g t o
t t t ' r r l t o n r i rn r ' u v c r i t r n t s t l t a t . tr c l t t , , t r , t l o l l v l o r l r a L r l i n ,t g
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lrLrllso ' , r s i n r p l r r t ' r l r r i r t ' t l t t ' c( ro r n t o r c ) t l r t ' j o b s i t c . b c i o r c t l r c g l r r cg r a b s .l l u v v o L r r s c lsl 'o n r t '
l r r l p i n gh u n t l s .

I r t ' r ' r i r o r l . . s l t o pn t i r t l t r o l I i t t , n . l l l t ( ' To properly support long stock,build a mitersawstand

t o r e s t o n t w o s a w h o r s e s .F o r t h e p r o j e c t p l a n , s e e
I r . r :i r : o l i t l r v o r l ' l r r n c lrt r . i 1 l t .srt r r r r l rr i r t
. Or,for an off-the-shelf
o r t t r t ) l ( ) \ r ' ( t l l c . t t t ' t t | L l t i c C t \' . t i s t 'l l ' t ' t ' : m i t e r s t a n d, s e e p a g e 9 9 .
L r pb o t I r o l r o t r r l t a n c l ss o t l i a t \ ( ) L lc i t n
n r c a \ u r r , n r . l r l . ,. r n r lc r r t r l i t l t o L r tc l u r s i n , q
r o t u ' s t o c ' 1l l.l l o r t ' r 't l r t s l r r i p .
I n . r r l c l i t i o r rr,o L r ' l l r r ' . r r r ty r l c n t r t ' l
'
c l a n r p s t o s u p p l c n t c n t \ ( ) u r l r c r r tl t ' s -"r:l i

I t o l c l i n gl ) ( ) \ \ ' rs' ,f r n r lf r i ru s s t r n l r l i r i p3 r o i -
t ' r ' t sS . t r l t t t , , li 1t 'J k r t l t e i r . t s i ti i n t ' r r 1, r l
r ' l . r r r rtp\ ,l l t s l r sr v c l l, r s . r r l r l i t i o n i, 'lr l o r -
n t , r t i o na l r o t r tl r c r r c l vt i s t ' s .
S i t t tl t o r s c s , r r l r c tl t t ' r ' l ) L ll { , r) r '
s l r o p - n t . t c l c ,i l r ' t ' i t S l ' c itl i t i t , , , ; i l l t \
'l
l t o r n cs l r o D . l r c r I t o l t l p l r r r l r i t l : i t t ' t ' t s
1 ' o r c L r t t i n g ( ) l ' s c l ' \ ' r ' i l \ t c n t l t o r ' ,r tr
l t s s c n i l r l v t t r b l c s . l r o l c l i n g s u nl t o r s t , s , ?
l i l i c t l r r o n r s s l r o n n . r t i i , 1 / l / ,r ' c r l r r i i t ,
r n i n i n u r I s t o r ' , r g sc l ) l l c c .
. \ n o t l t r r f r a t r r l ct o c o n s i c l c r s l t c i g l t t
a r l j r r s t . r b i l i t i. .\ s v o r r ' l l c l i s t ' ocr t ' ,t u i l o r -
i n g t l r r l r o r s t ' t o r o r r r s t . r t u f ci l n r i t l t t ,

woodmagazine.corn
I
1
Whenyouswitchto a gluewith longeropen
time,you'llgainclampandassemblytime.
extra assemblytime by choosing a glue
that doesn't grab as fast as ordinary yel-
low carpenter's glue. Franklin makes
a version called Extend Titebond II with
a slower set time, making it ideal for
complex assembliesor when you don't
have an assistant.
Another one-person strategy is use
pocket-screw ioinery. As shown below,
the jig guides your bit to bore an angled
hole in one workpiece, and you then
clamp the pieces to another, drill a
matching hole, and securea strong joint
with screws (no glue required). If you
make a mistake, simply back out the
screws and try again. You can craft a
wide arruy of ioints, and even build
entire face-framecabinetsand furniture
projectswith this system.
Dollies provide
moving experiences
Moving dollies are helpful ad-
ditions to any shop for a wide
range of tasks, whether you're
wheeling a new tool into your
shop,shuffling supplies,or roll-
ing out a finished project. TWo-
wheel dollies are good choices
when you're moving a stack of
boxes or a similar load that's
taller than it is wide or deep.But
reach for a four-wheel flat dolly
for cumbersomeloads or when
you want to keep a piecemobile
for an extended period of time
without lifting it repeatedly.
But why choose?Some dollies,
such as one manufactured by
FastCapat right (seeMcFeely's at Whenmovingcabinetsaroundthe shopor house,it's
mcfeelys.com),morph between hard to beat the convenienceof a dolly.This FastCap
the two configurations simply SpeedDolliesupportsup to 250 pounds.
by moving a handle. This par-
ticular model won't negotiate stairs Before you go to the lumberyard,
like a standard two-wheeler,but it does develop a cutting plan for each sheet
simplify many moving tasks in your that will reduce the panel to several
shop and home. manageablepieces. Some lumberyards
and big-box stores will make several
Gain some leverage for plywood cuts at no charge,then tack on
heavy lifting only a nominal per-cut fee after that.
Woodworking and carpentry involve A caution: The purpose of the lumber-
a lot of material-handling challenges. yard cuts is simply to make handling
Full sheetsof plywood and other panels easier,not to obtain final sizes.
can be tough to lift, and even more un- Trying to control a long piece of lum-
wieldy when you try to maneuver them ber or plywood at the tablesaw can be
at a tablesaw.But here are a few ideas dangerous. An outfeed support is an
that can help. inexpensivepurchasethat keepslumber
from taking a dive. The outfeed support
can also serveyou well at the drill press
and other tools in your shop.
A panel lifter is a big help in moving
plywood, drywall, and other sheet
goods. Most lifters fit under the panel,
and you simply center the carrier in the
length of the sheet, as shown opposite.
A quick tip: Keep your arm straight to
avoid fatigue. Another style of panel
lifter squeezesthe top of the sheet,and
you hold your hand at shoulder level.
This design frees up your other hand
and also providesbetter visibility while
you're walking.
Helplng handr
Whether you're installing crown
molding or a bank of wall cabinets,
Tt,", one tough part of the iob is holding
Pocketscrewseliminate the long and bulky item in position
"ta,
complexclampingsetups. while you drive fasteners.A strong and
\" Yousimplyclampand drive
patient assistantisn't always available,
screwsat eachstep.The
screwshold so tightly that so tool up for installation choreswith a
gluing is optional. couple of mechanical helpers.
Best-Ever Home Shop ldeas 2009

Thispanellifter from Stanleydoesa great
job of helpingyou carrysheetgoodssuch
as plywoodand drywall.
For installing cabinets and other
heavy chores, consider the Craftsman
Cabinet Support from Sears (olsovecen-
tel.lt quickly adjusts from 50" to 85",
and holds up to 400 pounds. Plastic
support pads at both ends help protect
the floor and the item being installed.
There's also a "shorty" version that
works in the 17" lo 25" range; it's ideal
for installing wall cabinets after the
baseunits are in place.
The Third Hand Tool, top rigltt,
manufactured by FastCap, excels at
lightweight holding tasks (up to 70
pounds), such asholding crown or cove
molding at the ceiling line. Each pole
has a series of ball detents (stops),
allowing for fast adjustments in a range
Tossa sheetof expandedpolystyrene
insulationonto the floor,and you bypass
the need to lift plywood onto sawhorses.
Cut notchesinto the foam to accommodate
clampsfor the cuttingguide.
woodmagazine.com
sqF
TheCraftsman Cabinet
Supportallowsyouto
usebothhandsto levelandsecure a cabinet
to th ew al l .
from 5' to I2'. Once you get close,
squeezethe handgrip to advancea Yz"
steel rod topped with 3x3" swiveling
p a d . The base al so has a textured
rubber pad to resistslipping. For extra
stability, upgrade to a 6x6" foot. See
McFeely's(mcfeelys.com)for one source.
Keep small tools and
paris within reach
People constantly invent new ways to
make good use of magnetism. One clever
idea is the magnetic wristband that grabs
onto nails, screws, and even small tools
and keeps them-quite literally-close at
hand. A variation straps around your
bicep, and is appropriately named the
Tool Band-it (toolbandit.com). With a
HJ
ffi
TheThirdHandTool(aboutS45)solves the
problemof needing threehandsandtwo
l adders
to i nstalmol
l di ng.
magnetic field strong enough to grip a
carpenter'shammer, the bicep model
enablesyou to shed your tool belt when
working in confinedareassuchasa crawl
space.Either version works when you're
scootingunder a vehicle.
A mechanic'smagnetic bowl provides
another great way of keeping ferrous
fastenersin an easilyaccessible location.
If you're the truly frugal type, you can
make your own container from a small
steelkitchen mixing bowl, and a magnet
salvagedfrom a stereospeaker.tF
Written by: Robert f. Settich
Keepfastenersaswell astoolscloseat
h a n dw i t h a m a g n e t i cb a n d . l t ' se s p e c i a l l y
handywhen you'reworkingalonebeneath
a vehicleor on a ladder.
Youprobablyhavea friendwho will seizeeventhe flimsiestexcuseasa justification
for buyinga newtool.Butsometimes, eventhe mosthard-bitten tooljunkiewill flinch
whenfacedwith purchasing an expensive,specializedproductthatwill seelimiteduse.
At thesetimes,it paysto takea seriouslookat renting.
wo top reasons to consider tool (For more about compressorsand air- the base fee, even if you return the tool
rental are limited necessity and powered tools, seepage 108). sooner. For longer rentals, you'll find
storage issues. For example, you There are no absolute rules on the weekly and even monthly rates. Some-
may use a stump grinder to pulverize an rent vs. buy calculus,but the 50-percent times, the day of the week or time of day
annoying stump, but then not need the rule is a good guideline: If the rental fee makes a difference in the rental rate.
tool for another decade or two. And a is likely to be 50 percent or more of the Again, asking questions may land you a
concretemixer may be useful 1 percent purchaseprice, buying makes sense. discount.
of the time, but during the remaining If you can visit the rental store at a slow
99 percent of its life, it merely eats up Check around for time, the employeesmay be willing to
floor spacein your garageor shed. advice and pricet discussyour proiect with you and offer
When you have a rental need on the advice that could saveyou a lot of time,
When buylng makes renJe horizon, check at severalstoresto com- money, and work. For example, you may
Let's look at another rent vs. buy sce- pare prices as well as the quality of the walk in thinking you need to rent a sand-
nario: You're laying down a prefinished equipment. If you seeoff-brand tools or blaster, but a quality pressure washer
hardwood floor, and you have all of the poorly maintained equipment, go to could be an even better tool for the job.
tools except a special flooring nailer another rental center.Most of the time,
and'an air compressor.If you're doing pricesamong the various'companieswill Popular rental tools
only one room, buying the nailer be similar, but you'll sometimes find a Most rental storesdo a brisk businessin
probably doesn't make much sense. real bargain. carpet-cleaning machines, and it's no
But perhaps buying the compressor Also askabout the rental periods avail- surprisethat there's a seasonalnature to
does because it can help you with able. There's often a minimum rental the demand. For example, some families
many other home and shop chores. period-two hours, for example-that is want to freshen their house before the

8 Best-Ever Home Shop ldeas 2009

 'l

as a result of overloading the gar- Unloadingand loadingthe equipment

bage disltosal, potrrir-rg grease can also be a real tirne-wasterif you're
d o w n t h e d r a i r - r , a n d h a v i n g a not organi zed. Get ram ps f or your
housefull of people. pi ckup truck, i f necess ar y,or ar r ange
Other tools corlmonly rented for scveral beefy buddies to help you
include a prcssure washer for hoist the equiprnent.
c l e a n i n g d e c k i l t g a n d s i c l i n g ,a i r - Efficiently organizing your work is
less paint spraycr, hardwood-floor another way to savetirne. Let'ssayyou're
sander, pavernent breakcr, post- tiling a dining rooln and needa tile saw
hole auger, and garden equipment to accuratelycut the border pieces.
such as a tiller and aerator. Cotrtirutedon page10

Planning requirements
'l'hc
old phrase about the equa-
tion of time and lnoney takes on
a sharp reality when you're rent-
ing tools ancl other equiprnent.
-l'he
clock ticks away relentlessly,
ancl votrr rnoney lt'ill disappear
qtricklv if you arcn't organized
I n d u s t r i a l - s t r e n grtehn t a le q u i p m e n ct u t sb i g j o b s ancl prcparecl.
down to size,savingyou time and effort. For starters, rlake sure you have
a l l o f \ r o l l r s L l p p l i e sa n d a u x i l i a r y
1 ' h a n k s g i v i n g a n d C h r i s t r n a s s e a s o n s , tools on hancl ltefore picking up your
so don't wait urrtil the last minutc ancl rental gear. If vou're rcnting a verti-cut
risk a lack of availability. lawn seec'ler(cuts parallel grooves in the
[ : r ' c n s e w e r s n a k e s h a v e s e a s o n a l soil), for example, buv your seed several
n . r t l r r r s . I n t h i s c a s e , t h o u g h , h o r n e - days bcfore renting, and make sllre you
o \ \ ' l t c l ' \ o l t t ' r ' r c l i s c o v c r t h a t t h e y n e e c l have spare gasolinc so yoll don't need to
A tile wet sawis a must for smoothcutsin
t h c r n a f t c r t l t t ' b i g h o l i d a y g a t h c r i n g s stop in the rniddle of vour project. s t o n e ,p o r c e l a i na, n d m a n yf l o o r t i l e s .

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 Do you need a permit?
Don't make the costly mistake of rent-
ing equipment and then learning that a
permit is required. Digging equipment
demands advance preparation so you
don't accidentally chew up buried utili-
ties. Yearsago,you had to contact each
utility company separatelyand wait for
its worker to mark the location of lines
on your property. But many areas now
simplify this procedure with a one-
call service(call8l1.com).A contractor
comesto your property and locatesthe
lines for all the utility companies with
color-coded spray paint. The service is
often free, but be sure to allow adequate
lead time-48 hours in some locations.
Local building inspectors are gener-
ally a helpful and friendly group-
unlessyou tryto build without a permit.
A coupleof hourswith a pavement breakercan
demolisha weekend's worthof whalingaway And then, fasterthan you can say "stop
with a sledgehammer. Work Order," your project screechesto
a halt. And human nature being human,
Continuedfrom page9 theseusually cooperativefolks will find
Instead of renting the equipment for a dozen other things more pressing
the entire duration of the iob, lay all the than getting your proiect restarted.
full tiles you can in the room, and let the
mortar set. Next, mark all the tiles that Know what you're doing
need to be cut. Finally, rent the tile saw, Beforeyou leavetf,e rental store,bJsure
and do all of your cutting at once. that you understand how to start, stop,
and operate a piece of equipment. Ask
about any adiustments you may need to
make such as setting the depth of cut.
Somestoresinclude a printed "tip sheet"
with frequently rented tools.
There are many potential hazards
when you're operating unfamiliar equip-
ment, so make sureyou understand each
safety rule for its operation. Also inquire
about recommended safety gear. Most
rental operations sell dust masks, hear-
ing protection, and safety glasses.
Some rental companies offer a damage
waiver for additional charge at the time
you rent. This means you won't be
responsible for equipment savefor dam-
?g€, abuse, or theft. Your credit-card
company may offer some protection
when you use its card for the rental, but
getting authoritative advice on the cover-
age may be challenging. Best tip: Check
your homeowner'sinsurancepolicy. That
may cover rental equipment, but it's best
to call your agentbeforerenting to under-
stand limitations and deductibles.
One final word of advice: Clean the
tool before returning it. This isn't merely
a matter of courtesy-most shops will
tack on a stiff penalty if you bring back
dirty equipment. i
Written by Robert f . Settlch
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I f fhen it comes to location,
ttlt there are three basic choices
f f for your shop, and each one
hasvirtues and vices.
A freestanding outbuilding can
be as small as a garden shed or as large
asa barn. This opportunity is limited for
city dwellersand most suburbanites,but
could be an appealing possibility if you
own a rural acreage.However,construc-
tion costscan be substantial,and you'll
needto carefullyconsiderwhether you'll
recover the investment when you sell
your property. In addition, monthly
operating expenses can be a genuine
concern, especially if your part of the
country requires a heating system for
comfortableuse during winter months.
A basement is often a great shop
location, especially if it has a large
ground-level entry. This permits you to
easilymove in tools and materialsand
just as easilyget finished projectsout of
12
your workspace.Shops accessibleonly
via a flight of stairs are slightly less
attractive, but still may be your best
option. Somebasementshave minimal
lighting and poor air circulation, but
these are fixable inconveniences, not
deal-breakers. The proximity of electri-
cal service and other utilities means
that poweringup your shop and getting
it comfortable is usually quite afford-
able. (Seethe article "Energy Efficiency
for Your Shop" on page32.)
A garage shop is often a good choice
because of excellent accessibility and
sturdy concretefloors to support heavy
equipment. As a bonus, many garages
havea high ceiling.This makesit easyto
handle sheetsof plywood or long pieces
of lumber. TWo potential drawbacks
involve existing clutter and vehicles.
Clutter-busting solutions including get-
ting rid of unused items and renting a
self-storageunit. The storage-unitoption
involves an ongoing expense,but it is
sometimesthe only real alternative for
an unrepentant pack rat. The vehicle
situation is potentially a more serious
issue,especiallyif your family includes
people who are under the delusion that
a three-car garageshould hold at least
one vehicle. If your shop needsto coex-
ist with a car, you'll need to employ a
range of space-savingstrategies,such as
flip-up work surfacesand mobile tool
basesto exploit every cubic foot of stor-
agespace.
It begins with a plan
But even beforewe get to the plan, let's
debunk the myth of the "ldeal Shop."
Like the EasterBunny and one-size-fits-
all clothing, it simply does not exist.
The truth is that your shop will be a
unique creation because its purpose
satisfiesthe needsof one person: you.
In addition, recognizethe fact that your
Best-Ever Home Shop ldeas 2009
 f "-'

Don't tossthe plan afteryou've

moved into your shop. You'll no
doubt refer to the drawing again
to experiment with new arrange-
ments without getting into any
heavy lifting of machinery.
However you complete your
plan, don't scrimp on storage
areas. Empty spaces fill up
quickly with lumber and tool
accessories.

shop will need to grow and adapt to
meet your evolving needs. You may
need to sharpen a mower blade on Sat-
urday morning and build a shelf in
the afternoon.
Begin with a list that includes the
size of your workbench and storage
units, as well as the primary power
tools, such as tablesaw,drill press,air
compressor,and so on. To help ensure
that your shop will be large enough,
make a list all of the major tools
you're planning to buy in the foresee-
ping, and rotating them any'whereyou ISSUeS flfSt
want. Youcan evenstackelements:put- Whenever possible, move everlthing
ting abenchtopdritl pressonto a counter, out of your shop areaso you can easily
for example.To accessthis freeplanning deal with infrastructure upgradessuch
tool, go to grizzly.com and click on as wiring, lighting, insulation, heating,
" Interactive Workshop Planner." and so on.
Erizztu Industrial i nooMLAYour
Wo-rnsnoP Planngr : bsouth'rP
m CCD CgAJ @lt
hSqqr,r,

able future-not just the ones you tdietli tml] iIn[J

currently own. Trblcbvrr

Next, draw a scalefloor plan of your lolntevr

Plmcf'
space,and createtop views of the tools thrpcrt
on little piecesof paper so that you can DuJt Collcctb|l
move them about to test various loca- 5rnd.r3
Wood Eindr|urj

ffi
tions. To help with the planning, you
DrflPrtsrcr
can download a free planning article at fl[k
woodmagazine.com/shoplayout. l/Lblf.$Gj

A more high-tech approachis design- Othr.firchln t

ing your shop layout on your computer.

The Gizzly Industrial Web site, for
example, allows you to quickly create a n t:] &
floor plan, add doors and windows, and
then drag in a wide variety of elements.
Theseinclude countertops, wall cabinets,
and tables.You can sizeeachone of them
t--*l
*l_J

**F
trn 12 -A

in L" increments. Now you can select

A virtual shop layout on your computer allowsyou to drag and drop equipment with a mouse
from virtually all of the major tools in insteadof strainingyour back.When you createyour plan, allow adequatepathsso that you
the company's catalog, dragging, drop- don't need to bob and weavebetweenthe tools. Mobile baseshelp you stow idte tools.

woodmagazine.com
13
 Good planningmadethe bestof this shop space.Windowsand A mobilecabinetdeliverstools and suppliesright whereyou need
banksof fluorescentlightsimprovedillumination.Mobilebasesare them-for auto detailingfor example.Simplyclosethe doorsat
a must for a maximum versatilityof space,and the most-usedtools the end of the project,and rollthe cabinetagainstthe wall,where
convenientlyhang abovethe generousexpanseof countertop. it's neatly tucked out of the way.

If you don't have enough coveredarea
to accommodate your shop's contents
during construction, considerrenting a
storagetrailer that a rental company can
deliver to your driveway. Somebuilding
centers act as agents for portable stor-
agecontainersas well, so that's another
option for temporary storage.
If you're finishing the walls, use fire-
rateddrywall if your localbuilding codes
require it, or consider a special grade
of impact-resistantdrywall. A wainscot
of plywood or vinyl garage liner is
another way to keep your workspace
looking sharp and minimize mainte-
nancechores.
Painting the ceiling, walls, and floors
is relatively inexpensive but makes a
-hugeimpact on the appearanceand ease
of maintenance. Renting an airless
sprayer for the ceiling and walls can
make this a quick job.
Insteadof rushing to move equipment
into your shop, exercise patience. You
may tell yourself that you'll paint later,
but the truth is that it would probably
neverhappen becausethis task generally
involves too much tool shuffling. This is
especiallytrue of prepping and painting
a floor or installing another type of floor
system.Doing this job when the shop is
empty adds only a couple of daysto your
construction schedule, but it makes a
huge difference in the appearance of
your shop. For more information, see
"Flooring Options,"page20.
Using light tones also improves the
efficiency of your shop'slighting.
Don't be a noise nuisance
If your shop is in a basementor attached
garage,you also need to be sensitiveto
issuesof noise and dust that you'll cre-
ate when working in your shop. Locat-
ing your shop in a detached building
doesn'tnecessarilysolvethe problem-it
may simply mean that you'll be irritat-
ing your neighbors as well as your fam-
ily. With some planning, though, you
can minimize the nuisancefactor.
There are a number of ways to
minimize sound transmission. Sound-
attenuating fire blankets (SAFBs)install
quickly into stud bays and between
ioists, providing better sound control
than fiberglassinsulation. You can also
consider a sound-reduction board as
the first layer that is then covered with
drywall. Homasote 440 Sound Barrier
Panel (homasote.com)shown below is
one brand.
Or, gain further improvement in
noise insulation by adding a second
layer of drywall. For general informa-
tion on insulation , seepage32. tl

n * "d,-a tu
Sound-reduction products,suchasthe
Homasotepanelsshown here,can providean
effectivebarrierto noisetransmission.

14 Best-Ever Home Shop ldeas 2009

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PackMoreWorkshop
lf clutterandcramped
floor spacedescribe
workshop,
your
fight back lt,
andwin with these
space-saving ideas. I
I
I
I
t.
L"_
obody plans to mess up the
shop; it gets messyfor lack of a
plan. If you're toiling in an
unworkableworkshop,devisean organi-
zation strategy,and take action.
Every woodworker's clutter cure is
unique, so pick and choose the ideas
shown here that suit your situation.
Whichever solutionsyou go with, you'll
first needto do three things:
I Define the boundaries of your shop
to determine how much space you
actually have. Rememberto also think .a

vertically-not just within your shop's

width and length.
I Decidewhat needsto be kept within
the shop and what could be moved
elsewhere.Then, list the tools you
currently own, and envision locations
for tools you'll own eventually.
I Make the same space hold more or
se r v e m ult iple pu rp o s e s . S e a rc h o u t
areaswith untappedstoragepotential.

Bust up the clutter

You can't organizeyour shop until you
get rid of needlessstuff, so play "moving
day."What would you keep or tossif you
had to pack everything and move next
week? Send everything that's not a
keeperto the trashor to the secondhand
store.Turn unusedtools and loosehard-
ware into someone else's clutter by
boxing them up for the next garagesale.
Then, takenearlyempty cansof paint in
Lay out spacefor flexibility
forgotten colorsto your local hazardous- When reorganizingyour workshop, plan !l Adjustable
shelvingadaptsto change
waste-disposal site. for changing equipment or different !f betterthanfixedshelving,
especially
As you sort,distinguishbetweentools woodworking interests such as wood- for storing lumber. The wire-mesh
and suppliesfor home repairsand those turning. A singleareawithin your shop shelves used here provide ventilation for
for woodworking. Box up plumbing and can serveexisting and future uses,but dimensional lumber and are readily
electrical specialty tools and fixtures only if you designit with that flexibility. available at most home centers. Run
you'll seldomuse.Then, storethem on Here are 10 ways to make smarteruse of shelves all the way to the ceiling to use
high shelvesor outsidethe shop. the spaceyou have: every cubic foot of space.

16 Best-Ever Home Shop ldeas 2009

into Lgss
1fl1Plan for equipmentyou expectto add
E/along with what you already own.
That could mean leaving a corner empty
until you can afford that bandsawyou've
been eyeing. If you're creating a new
shop, add 2ZO-voltoutlets to power step-
up machinery without the hassle of
extensioncords or rewiring.
woodmagazine.com
Space^,_k ror
nes,ec,ed
space,,
add
f\Mobility = flexibility. Even if you
Y don't haveto accommodatevehicle
parking in a garageshop,placetools and
cabinets on castersand mobile bases.
That lets you use the same floor space
for more than one task, speedscleanup,
and makesit easierto accommodatenew
equipment as your shop expands.
!t storagc.A cabineton wheelscan be
storedbeneatha tablesawextensionand
rolled out to doubleasan assemblytable.
Also, store loose parts in stacking bins
beneath jointer tables,between the legs
of a lathe, or below a drill-presstable.
G\ Add wall cleats for a more flexible
l9lhyout. Wall cleats give you the
freedom to add or rearrangewall cabi-
nets as your needs change. They also
make it easierto build or buy additional
cabinetsgradually insteadof all at once.
In addition to cabinets,cleatscan hold
specializedstoragesuch as clamp racks
and tool boards.
1|l Createspacewhere you can sit and
\37 work. Between cabinets under a
countertop,Ieavea knee spacewide and
deep enough to store a mobile storage
cabinet or scrapbin. If your countertop
stands higher than your tablesawtop,
build a rolling storage cabinet short
enough to fit easilyinto the knee space
but tall enough to double as an outfeed
support for the saw or other maior tools
around the shop.
1fi1Double-duty design uses half the
\7 space.Instead of a separaterouter
table that takes up floor space,drop a
router tableinsert plate into the tablesaw
extension. This arrangement lets you
use the samefencefor two tools.
j!\ Make a place for wood scraps.For
l9f pieces too large for the trash but
too small to store with your lumber,
build a mobile scrapbin. That way, you
create a source for small project parts,
scrapsfor testing blade or bit settings,or
just material for building jigs.
1@l Fit tall tools into corners. Use gaps
E/ between benches or cabinets and
walls to storetall, narrow tools such as a
drill press.Mobile basesmake it easyto
move tools into thesetight spaces.
!fil Replacesteel leg standswith mobile
1l9/ cabinets. This keeps accessories
closeto the tools that usethem, createsa
heftier tool basefor greaterstability, and
relieves some of the storageburden on
your other cabinetsand drawers.
17

Custom cabinets: Think inside the box
!lBump up wall-cabinet capacity by
!Ifitting them with clamshell doors.
Use the inside cavity to hang tools, or
fit it with adiustableshelvesto organize
fasteners and loose hardware. Then,
customize the outside of the door for
hanging storage.
6LAdd dimension to storage space.
\TPerforated hardboard provides
easy-to-install storage, but alternative
methods use space more efficiently.
Instead,buy or build cabinetsthat hold
more tools in lesswall space.
1lilAdd cabinets that create storage
\Twithin storage to hang hand tools
and organizeaccessories. The accordion
cabinet (page70) usestwo interior doors
with perforated hardboard for layers of
hanging storage.
/lReplace space-eating drill and router
ttbit packageswith a storagecabinet
that holds everything you need, includ-
ing wrenches,collets, and accessories.
AUse slide-out trays in basecabinets
provide accessto the contents
Vto
with less bending or kneeling (and
quicker tool retrieval). For a simpler
alternative, fit cabinets with adjustable
shelvesto keep tools and suppliesfrom
being heapedonto each other.
18
AGustomize drawer storage specifi-
\7 cally for itemssuchasplanes,chisels,
and saw blades.Allow spaceat the top of
the drawer to hold a removabletray.
fl\ Maketool- or task-specifictrays such
17 as this portable chisel tray. Create
similar trays for turning or measuring
tools that you can take to the machine.
Roclcor roll?
Mobilityonly goesso far in the shop;someitemsare bestleft with a solidfoundation.
Usetheseguidelinesto decidewhat needsto be rocksolidor readyto roll.
Wo rk b e nches.P ut bencheson w heel s
only as a lastresort.Workbenches are
best plantedin one spot for greater
stability.
Lathes.The vibrationof a lathemakesit
a poor candidatefor mobile basesand
casters.lf you need mobility,usewheels
that retractcompletelyor low,
removablerollingdollies.
@ffi
6\ Usecabinetsinsteadof open shelves
\7 to keep dust off tools and clutter
out of sight. If a cabinet-and-countertop
arrangement doesn't fit your workshop
plans, add storagecabinets beneath your
workbench for increasedweight and sta-
bility, and to keep tools close to where
you'll usethem.
Saws.On a mobilebase,a tablesawcan
be swiveledor repositioned
to rip large
panelsand tuckedout of the way when
not i n use.
Drill press.A mobile baseallowsyou to
wheelthis tool into a cornerof the shop
w hen not i n use.
Routertables. Shapinglong stockis as
easyaswheelingyour routertable into a
wide-openwork area.
f oi nters/pl aners. can be
Joi nters
mountedon baseswith retractable
wheels.Planerscan be attachedto
cabi netsw i th l ocki ngcasters.
Best-Ever Home Shop ldeas 2009
Space-stretching
tips just for
garageshops
A Nospacegoesto waste.Put that area
!7 above your garagedoor to work by
suspendinga platform beneath the ceil-
ing. It's a handy spot for lumber, tool
cases,and household items you moved
asideto make room for your shop. Just
make certain you've firmly connected
the framework to the ceiling joists.
Needtemporary storagefor a coupleof
long piecesof lumber? Restthem on the
garagefloor centeredbetweenthe wheels
of your car.Raisethe boardsoff the floor
using scrapwood supports, and cover
them to guard againstvehicleleaks.
against wall. Sheet goods
ellp .the
\T leaning againsta wall wastespace
and tend to warp. Solveboth problems
1Ql Put high walls to work. Not all
\7 storage needs to be within easy
Useevery cubic
with a simple bungee cord. Mount eye reach.Usethe high walls in your garage foot of your shop
hooks into the wall studs more than to add one additional layer of storagefor
E v e n l i t t l e c h a n g e sc a n a d d u p t o b i g
8' apart, center the panels between the items you'll use infrequently. Mount
spacesavings.Here are five more ways
hooks, and pull them tightly againstthe cabinets in the space above your car
to stretchyour shop:
wall with a pair of bungeecordshooked hood. You'll add storagewithout sacri-
at the middle. Most panelsare 4'wide or ficing parking rpuce.cF- , r i v en a i l so r p e g s
I I n b a s e m e n st h o p s d
less,leaving plenty of room for shelves into the overheadjoists to hang clamps
Written by Robert Wilson
aboveyour sheetgoods. convenientlycloseto your workbench.
l l l u s t r a t i o n sB:r i a n f e n s e n

I lf you can't foreseewhen you'll have

t i m e t o b u i l d s h o p c a b i n e t sd, o n ' t w a i t .
Get startedwith inexpensive,ready-to-
a s s e m b l ec a b i n e t sf r o m a l o c a l h o m e
center. Then, customize these basic
boxes with add-ons such as router-
b i t h o l d e r s ,t o o l r a c k s ,a n d a d d i t i o n a l
a d j u s t a b l es h e l v e s .

I Handle every incoming item only

once.Forexample,don't leavethat new
box of screwsyoujust bought restingon
y o u r w o r k b e n c hs i m p l yb e c a u s ey o u ' r e
in a hurry.Takethe extra 15 secondsto
store it now, and you'll save yourself
15 minutes of clearing accumulated
clutter later.

I Don't stop with your shop. Add or

improve storage throughout your
house to create places for items that
d o n ' t b e l o n gi n t h e w o r k s h o p .

I C r e a t ea " l i m b o " b o x f o r a l l t h o s e
interesting doodads you toss into
your shop when you think they're too
handy to pitch but haven't earned
a permanent home. When the box
f i l l s u p , i t ' sj u d g m e n t d a y :T i m e t o s o r t
t h e t r a s hf r o m t h e t r e a s u r e s .

woodmagazine.com
19
LEE-ttt
Paf;nt and eBoxy
l'aint pnx'iclcs tlic lastcst itncl r.tsicst
I l o o r L r p - t r ' , r cf o l rr '\ ' ( ) ur 'L l i r r ' . r g[c. . r t t r c o n -
c r r t r ' p . t i n t o l ' t e n c ' , r l l c t l" p o r c ' l t - a n c l -
f l o o r ' p l u n t " - o t ' l ' t r s . t r l L r i c l ' ,i n c r l t c n -
s i v c , . r r t r lc o l o l t r r l s o l r r t i o n .. \ s l o n 3 . t s
v o r r c l o n ' t p l . t n t o s l r . r I ' r\ ' ( ) r l rg , t t ' . t g st 'l r o l t
r v i t l t . r r ' . t r '( l t o t t i r r s c ' . t n r l . t n t . r g , tt l' t t
slrrl'ircto ' )r o t l r t ' r n ' i s c. t l r r r s ti't , c r t n c ' t ' c t c
l r a i n t r t i a v b c l i g , l r tl o l r o r r . [ ) r p t ' n r l i n g
o n l r r ' . r n c l ,g. a r l l o n s r l l s f o l a l r o r r tS ? o .
l : p o r r - l r i t s t ' ttl' o ; t t i n , g sr r, t r r n r c l r I t i t r t l
r v l r c nc ' L r r c c( lr,f c( l l n o n gt l t c r r r o s rt l L r l l r b l c
o p t i o n s .. \ o n c - p . r r ct p o r v c . r nl r r . r p p l i c r l
s t r a i g h t l l o r n t l r r c . u r , r i ' l r i l t 't r r o - 1 t a r t
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i s 1 0 0 p c r t ' c n t s o l i r l s( r x r f i l l c r s , r n r l
t l r t ' r ' r f o r cn o o c l o r r l r r r r n g a p p l i c l t t i o n )
( ' o n l l ) a r c cnl i t l r . t l r o L t ? t O l t c t ' r ' c n ts o l i c l s
lor tlrt' l)l\ p r o c l L r c t .I I r c i t t r l t t s t r i i t l -
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( ' l ) ( ) \ \ 'f l o o r ' .
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I { o l l t ' r cl o r c r i n g s f o l t l r c g i t f a , g ca,\ s h o t v n
i n t l r t ' / ( ) /l)) l r o t o ,i n s t i t l lt h t ' s . t n r c\ \ ' i l \ ' ( l s
i n r i o o r v i r r v l f l o o r i n g . l l L r t b c c a t r s ci t s
o \ \ ' r r r v c i g l r t . r n c l r o r si t i r t p l i t c r , \ ' o L r
a r e n ' t r c c l L r i l c r it o a c l l r c r c t l r r g i l r a . q c
r i r r v l r v i t l r . r n ; r d l r c s icr o r t a 1 r c .l { o l l c c l
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i n g a t o l t L r n l o r g i v i n gc o n c r c t ef l o o r s .
I n a p c r f c c t l v r c c t a n g u l a rg , l t n t g rcr i t l r
n o o b s t r r r c t i o n s ,r n s l . r l l . r t i o nr l o c s n ' t
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t o r o l l i t o r r ta n c l j o i r ' \l e i l n r s( . t n o l t t i o t t . t l
stclr). Iror a garil.qt n'itlt ltcrnt.utcnt
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ncrclto trirn it to fit. \lost lrorttcorvncrs
r r i l l l r i t v ct h c s l . . i l l tso i n s t i r l l .
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a n r l s i z c , r o l I c o v c r i n g s i t v c r ' . r g c$ I . 5 0
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7 \ t : i , 8 , . r r r c l( ). S o n r r n r . r n t r f a c t L l r c l ' s
l ( ' ( { ) n t t } t t , t 1 t l( ) \ ( , 1 ' l i l | | i r t l \ r ' i t l l t \ .
Best-Ever Home Shop ldeas 2009
 I
;

Interlocking tlles
Offering good cushioning, a variety of
stylesand surfaces,and a large selection
of colors and patterns, these tiles (right)
provide the most pattern options.
The tiles come in different types,
including solid, perforated, and even
drain tiles, and have embossedsurface
patterns for good traction and durability.
The most common tiles measureLZxIZ"
and 24x24", with intermediate sizesalso
available.So you may need to trim tiles
around obstacles.Most systemsinclude
beveled attachable outside pieces to Byalternatingtilepatterns,asin this Theair-gapengineered intoDRlcoretileslifts
improve the transition between tiled and DiamondTrax floor,youcancreatean the woodenportionoff the concrete,
which
unlimitedvarietyof floordesigns. creates
an insulating
layer.
non-tiled areas.
One benefit of tiles that paints and 1," thick so transition and reducing to be laid on top. You can find the tiles
roll materials don't have is breathability. strips (available at home centers) are at many national home centers (one
The seamaround each tile allows a bit of required on exposededges. brand name is DRIcore; information at
air circulation, and perforated tiles offer The tiles come only one way-bare dricore.com), where they sell for about
even more air movement-a boon to wood-but can be painted if desired. $5 each, or about $1.25lsq. ft. Only
garagefloors prone to dampness. Or, you may choose to use the tiles as a paint is lessexpensive.I
Because they simply snap together, subfloor for another flooring material Written by A.l. Hamler
homeowners can design a three-color
pattern and install the tiles with no
experience. (Race Deck shows several ' Leastexpensive
Latex palnt Dry concretea must
options at racedeck.com.)When there ' Wide varietyof colors No cushioning
are a lot of cracksin a concretefloor-too ' Makescleaningshop Requirescleaningof concrete,
many for epoxy or paint to hide-tiles
easier removalof old paint
make great alternatives. ' No seam Doesn'thide cracks,other blemishes
Tiles offer one additional benefit: Leastdurable
Should you move to a new home, or
Epoxy palnt ' High durability ' Dry concretea must
simply want to try a new color pattern
' Wide varietyof colors ' No cushioning
or tile arrangement, they can be
' Makescleaningshop ' Two-partversionscan be tricky to mix
unsnapped and rearranged, or easily
easier and apply
removed altogether for installation else- ' No seams ' Requiresextensivecleaningand
where.Expectto pay $2.25-$5.50/sq.ft.
etching of concretebeforeapplication
for tile materials. ' Doesn'thide largecracks,other
blemishes
Air-gap tiles o Short "open" (application)time
Although not pretty, air-gap wooden
Roll materlal ' Cood cushioning ' Largerollscan be unwieldy
tiles (above rtght) offer extreme breath-
' Cood traction ' Cutting necessaryfor perfectfit
ability for concrete floors prone to ' Hidescracks,other ' Somecolorsmay requirespecialorder
dampness. The oriented strand board
blemishes
(OSB)tiles, measuring24x24", have pat- ' Varietyof colors
terned plastic undersides that actually ' Removable
lift the tiles off the floor. Not only does
the created space allow the most air Interlocklng ' Cood cushioning ' Cuttingmaybe necessary for perfectfit
movement of any flooring option, but tiles ' Wide varietyof colors ' Desiredmaterials/colorsmayrequire
' Good traction special
order
minimal amounts of running water can
. Breathable ' Seams easyto spot
freely flow underneath. This solution is
' Hidescracks,other ' Dust,dirt get trappedin open-pattern
best for a basement shop or garagethat
doesn't share spacewith an auto. blemishes tiles
' Easyto remove
You may have to cut tiles to clear
obstacles, but the tongue-and-groove Air-gap tlles 'Cood cushioning ' Cutting may be necessary for perfectfit
edgesmake for fast installation. If you'll 'Cood traction ' No coloroptions
be rolling heavy equipment around, 'Breathable ' Lotsof joints
you may want to add some of the edge 'Hidescracks,other ' Can't toleratethe weight of a car or truck
tiles to the floor to prevent shifting. blemishes
' Easyto remove
Shims are availablethat fit the patterned ' Water barrier
plastic on the under-sideto level the tiles ' Inexpensive
on uneven floors. The tiles are nearly

woodmagazine.com
21

. " . - , , , , . . , . . ., - : . . , . i - ;
:U-,ir:.:::.
ffi
Ample,accessible
storageis the key
Workshop Cabinetry
or a lot of us, the farnily garage is
the rnost available space to create a
workshop. Unfortunately, it's also
the most available space for
storing yard gear and other
household iterns-and, occa-
sionally, a car-creating a lnass
of clutter not conducive to set-
ting up a shop.
Basic shelving can get stuff
up and off the floor, but offers
few options for increased
workspace, and plain shelves
in an unimproved garage are
really just vertical clutter on a
dirty concrete floor. The
perfect solution would be a
system of manageable storage
cabinets, a way to hang all of
your horne, shop, and yard
tools, as well as a ntore com-
fortable and attractive floor to
stand on and keep clean. Let's
22
ff
ffir"
;,:-rr.':...
first look at cabinetsolutions.(Seepcgc What cabinets work best in a garage
20 for floor upgrades and poge 26 for workshop? Well, consider for a mornent
wall storagesysterns.) the other most work-intensive area in
the averagehome:the kitchen.
It's a place with arnple storage
for tools and supplies, an
interconnected system of
expansive worksurfaces, doors,
and shelves to keep every-
thing contained (and hidden)
when not in use. Add to that
$ur the fact that it's also a place
where creativity is irnportant,
and it's no surprise that man-
ufacturers have taken their
cues from the kitchen to
introduce cabinetry designed
and styled with the workshop
in mind.
As in the kitchen, garage
cabinetry comes in a huge
W i t h a p p r o p r i a t e l yd e s i g n e d c a b i n e t s ,l i k e t h e s e s t e e l b a s ea n d w a l l range of sizesand styles to suit
u n i t s f r o m B a l d h e a d ,c a r sa n d t o o l s c a n c o e x i s ti n a g a r a g e w o r k s h o p . any need, with some manu-
Bert-Ever Home Shop ldeas 2009
facturers offerir-rg custorn design ser- Cabinets made from
vices. This isn't your grandrna's kitchen heavy-gauge steel are
you relnember growing up, though. Sur- extremely durable and
faces are sturdy steel, stain-fighting sturdy-unless they
larninates, and heavy-duty resin or plas- have wheels, they're
tic. Most garage cabinets sold today meant to stay in one
come in base and wall units that you spot. (Wheeled base
can arrange to fit any size garage, with cabinets are a good idea
individual components geared to your for infrequently used
storageand project needs. tools such as mitersaws
or drill presses; the
Base units entire unit can be rolled
Base units can be simple or elaborate. out of the way when not
Sorne are basic, srnall cubes with a set of in use.) For versatility,
drawers or doors. Others can be quite simple cabinets of
large and fully tricked out with doors molded resin or plastic
and shelves, and available in several panels are incredibly T h r o u g h c a r e f u la t t e n t i o n t o l a y o u t ,w a l l s t o r a g ea n d c a b i n e t r y c a n
be integrated for an attractive and efficient workshop solution.
lengths and styles.Some manufacturers, iigtrt and can be reai_
especially those on the low end of the ranged any time you want. They're also Most are sizedto match the baseunits
price scale, offer just a few options; on easyto stackto createtallerunits.Between bel ow , and some can act ually be
the upper end, some carry hundreds of those two extremes are cabinets more attachedto baseunits and arrangedin
configurations. sirnilarto typical kitchen setupsmade of modul ar groupi ngs. M at er ials and
As in the kitchen, rnany base units particleboard,MDF, or plywood. A lami- construction from each manufacturer
can be connected, while others are natesurfaceimprovesboth durabilityand tend to match thoseof the baseunits.
placed side-by-sideas needed. Most rest appearance, asshownbebw left.
on the floor, but some manufacturers Worksurfaces
design their base cabinets to attach to Wall units Many base-unit worksurfaces are made
wall brackets. These hanging base units Base units for garage systems can be of the same material as the rest of the
leave open space underneath, an irnpor- complemented with wall units hung cabinet, and may be unsuitable for tool
tant factor in garages and basements above them. Wall units can have doors use. Others have wood or MDF surfaces
prone to damp floors. or shelves, or a combination of both. that stand up to sorle abuse.

Whatever cabinets you choose, you'll need a strong,

reliable worksurface. Depending on the manufacturer, the
This 20"x20'workstation includes a backsplash for hanging frequently used tools. The options may include solid wood (as shown on the cabinets
table of the compound mitersaw is set flush with the worksurface, fully supporting long above), steel, MDF, particleboard, rubber, steel, pliable
boards. This setup makes it easy to control long boards and cut accurately. polyurethane, plywood, or molded plastic.

woodmagazine.com 23
 For more durability, choosebaseunits
from a manufacturer that offers optional
benchtops (or be prepared to make your
own). Wood is a traditional favorite, but
many homeowners prefer the low main-
tenanceof aluminum or plastic surfaces.
Cost
Generally speaking, heavier cabinets
are more expensive. Simple molded
resin cabinetsgenerallycost $110or less.
Laminated plywood, MDF, and particle-
board cabinets range from $80 to $250
for off-the-shelfunits, with custom units
pricier. Steel cabinets list from $100 to
$450,with premium units going into the
thousands. High-end, custom-designed
cabinetsmay require professionalassem-
bly and installation, which costs more.

Guide to Base and Wall Units for Your Garage

'$
J
Baldhead ST 5T
Hff
5T Yes Powdercoat
colors;
insix
custom
colors typical
for
52,000-$9,000
cabinets
Combined
setsavailable;
optional
worktopsof 11/2"
udj'
877-966-22s3
baldheadcabinets.com
available andinstallation maple
or12-ga.
steelavailable
BHNorth America MDF LPB MDF Yes* Textured per
PVClaminate 559-5149 Alledges
radiused;
optional 866-325-2339
MAXimum
component 1Yr"MDFbenchtops
available;bhnorthamerica.com/ulti-mate
Garage
wheeled
base
unitavailable
BH North America MDF LPB MDF Yes Polyurethane-coated per
579-5249 Alledges
radiused;
optional866-325-2339
Ulti-MATE Garage
doors;
textured
PVC c0mp0nent 1%"MDF
benchtops
available;bhnorthamerica.com/ulti-mate
laminate
elsewhere wheeled
base
unitavailable
BHNorthAmerica MDF LPB MDF Yes Polyurethane-coated per
599-$399 Shelves
are1";alledges 866-325-2339
Ulti-MATEPro
doors;
textured
PVC component radiused;
optional
1%"MDF bhnorthamerica.com/ulti-mate
laminate
elsewhere benchtops
available;
wheeled
base
unitavailable
CaliforniaClosets LPB MPB V Yes Melamine;
10colors for
5800-$1,500 Allcustom
components 800-274-6754
available system calclosets.com
Coleman LPB LPB R No Plastic
laminate per
$70-5198 Perforated
hardboard
hutch 800-523-3987
TD2
component available;
noworkbench colemanstorage.com
available;
metaledging
ontop
anddrawer
sides
forstrength;
metaldrawer
sides
CooperCabinet MDF MPB MPB Yes Plastic
laminate for Formerly
51,500-$2,000 Mitchell
Cabinets; 866-321-2525
Systems
typical
cabinets cabinetshangonsteel-rail coopercabi
netsystems.com
andinstallation support
system;
slatwall
tool
organizer
overworksurface
Garage Storage MDF LPB MPB No Melamine
inthree Complete butprofes- 866-414-4844
systems DIYinstallation,
Cabinets (cSC)
colors from5675-51,800sional available; garagestora
installation gecabinets.com
various
cabinetdepths
available
GarageTek PL PL W No plastic
PVC $8,000fortypical Dealer-installed
only;modular 866-664-2724
Plastic
cabinets
and components to special- garagetek.com
attach
installation izedwall-plank
system
GarageTek 5T ST W Yes Powdercoatavailable S10,000installed Dealer-installed
only; 866-664-2724
SignatureLine
infourcolors garage modular
foraverage components to garagetek.com
attach
specialized
wall-plank
system;
worksurfaces
1%"-thick
wood;
steelshelves

24 Best-Ever Home Shop ldeas 2009

Most availablecabinets are strictly do-it-
yourself, however, requiring little more
than a basic knowledge of hanging cabi-
nets. Further, if your needs change, the
entire arrangement can often be altered
or addedto with more cabinetry.
When it comesto keeping costsdown,
there's one more option. Since garage
cabinet design is based on the kitchen,
don't overlook that source. Kitchen liq-
uidators often discontinue cabinet lines
and mark them down considerably.Also,
check with local kitchen contractors-
after a new installation, many offer the
old cabinetsthey've removed for a song.
A light sanding or coat of paint may be all
they need to be transformed into a low-
cost storagesolution. JF
Written by A.f . Hamler

/^.;$.
H{d
So

{,
.ob
T
Gladiator
Q-

5T 5T MDF Yes** Powdercoat Welded:$150-5450 (ombined

setsavailable; 866-342-4089
""7
perunit. 1"solid-maple gladiatorga
optional rageworks.com
Unassembled: worksurface
available
598-5398 perunit
Lista 5T 5T W Yes Powdercoat 5739-52,466 Workbench
available; 888-897-9050
several
wheeled
cabinets listacabinets.com
available
Premier MPB MPB MDF Yes Plastic
laminate About5150perlinear Cabinets
raised
to 866-483-4272
foot minimizecleaning
and premiergarage.com
potential
reduce forwater
damage;
various
cabinet
depths
available
Redline MDF MDF Wor Yes Powdercoat fortypical
55,500 250cabinet
styles/sizes 877-624-2332
Garage Gear PP cabinets
and available; are redlinega
allcabinets ragegea
r.com
installation professional
wall-hung;
installation
only;optional
worktopsof 1V+"
mapleor
1" pliable
polyurethane
Sears 5T 5T MDF Yes Baked
enamel p9
5119-537 er (ombined
sets sears.com;
clickontools,
then
c0mp0nent available garage
& toolstorage
Slide-Lok MDF PLY LPB No Plastic
laminateavail- 5999andupfor DIYinstallation,
but 800-835-',I759
ableinfivecolors average
installs professional
installation slide-lok.com
available;
various
cabinet
depths
available
Stack-On 5T 5T MDF Yes Baked
epoxy 5100-S2s0 Workbench
andwheeled 800-323-9601
Products cabinet
available stack-on.com
Stanley AL A L & PL Yes M o l d eadl u m i n uamn d 580-5 1e0 Wall-mount
base
units; 800-782-6539
PL polypropylene plastic
sides;
various stanleyworks.com;
search
cabinet available garage
depths cabinets
Suncast PL PL PL No Plastic
resin per
550-5110 Nobenchtop
available; 800-444-3310
c0mp0nent removable
drawersslide suncaSt.c0m
intomolded
slots

MATERIAL KEY: (MPB)Melamine-coated particleboard (R)Rubbermat (.) Batt-bearing,

but%-extension
(Al)Aluminum (PL)Moldedplastic (SI) Steel 1**)Notfuil-extension
on ready-to-
(LPB)Laminated
particleboard (PLY)Plywood (V)Variety
of optionsincludewoodandLPB assemble steeldrawers
(MDF)Medium-densityfiberboard (PP)Pliablepotyurethane (w) sotidwood

woodmagazine.com
25
 ith cabinetsand worksurfaces
in place, a lot of tools and
shop paraphernalianow have
homes.But a lot of typical garage"stuff"
is too big or awkward to store in
cabinets.Unfortunately, things like rec-
reational gear, yard equipment, and
garden tools end up leaning againstthe
wall or in corners,consuming valuable
floor space.The trick here is to keepthat
stuff easily at hand, but up and out of
the way.
Baredrywall-or, in some cases,open
framing-requires that anything hung
there be anchored to a stud. However,
the typical 16" spacing of studs gives
only a limited number of vertical loca-
tions (and few, if any, horizontally) for
mounting hooks and hangers.
A number of wall solutions are avail-
able. Perforatedhardboard (commonly
called Peg-Board,a trademarkedname)
is a favorite for hanging hand tools.
However,this doesn't provide a worthy
solution for heaviertools storedin most
of today'sgarages.
26
screwmounting hooksand
brackets, or hang shelves
wherever you like. As you
update your tool inven-
tory, alterationsare just as
easy:Just unscrew mount-
ings and move them to
new positions.
Bare plywood doesn't
look that appealing, and
changing the tool layout
later leavesunsightly screw
holes. Plywood is difficult
to clean and is vulnerable
to moisture from wet yard
tools and dripping hoses.
A couple of coats of paint
Bracketsand hookscan be mountedanywhereon a slatwall
system,as in this examplefrom storeWALL. Gravityholds helps, but that's more
the bracketsin place,so they can easilybe rearrangedat any work. On the plus side,all
time accordingto changingneeds. the materialsyou need are
inexpensiveand right around the corner
Plywood at your hardware store or home center.
A quick-and-easyupgrade is to attach Betteryet, construction is simple.If your
Vz"plywood to the walls, anchoring the budget is limited, and you don't mind a
plywood solidly to the garage'sexisting bit of maintenance, this may be your
framework.After fasteningthe plywood, best ticket.
Best-Ever Home Shop ldeas 2009

Slatwall
At many of your favorite retail stores,
you've undoubtedly seen wall panels
using modified T-slotsthat acceptangled
brackets. The brackets, which slip into
the slots anywhere along their length
and are held in place by their own
weight, can be attached to a wide range
of specialized hangers-they include
simple hooks, hangers, and brackets
designed for specific tools and yard
implements; hook-on baskets and
shelves;and light fixtures. Most, but not
all, manufacturers produce interchange-
able hangers.
Slatwall has become the most popular
upgrade for today's garages,and is gen-
erally availablein panelsin many colors.
Composition is of melamine-coated
MDF or rugged heavy-duty plastic.
Panels range from large 4x8' sheets to
individual strips from 6-15' wide. The
panelscut easilywith a circular saw.TWo
8'-long panels are ideal acrossthe front
of most two-car garages.
A grid system,like these examplesfrom Schulte,supports
heavytools and shelvesand is easyto adjust to meet
changingneeds.The grid panelsare securedto wall studs.
Depending on the material and fin-
ish, slattedpanels aren't cheap (about $6
per squarefoot), whether sold individu-
ally or in packages.Hanger and acces-
sory prices vary widely, depending on
size and use. A package of six simple
hooks goesfor lessthan $5, while a rack
for 12 garden tools retails for about $25.
woodmagazlne.com
i'!
Metal grldwork
Metal grids are similar to
slatted panels in the way
they are anchored to wall
studs, but offer attach-
ment points over the
entire wall surfacecovered
by the grid. Hooks, hang-
ers, shelves, and other
accessoriessnap onto the
gridwork, and are held in
place by gravity.
Grid panels come in
severalsizes(2x4', at about
$ 1 2 -$ 14 i s the most
popular), but colors are
currently limited to white,
black,and silveror chrome.
Hangers are priced similar
to slatwall hangers.
Steel panels
A third type of panel
system consists of rigid
steelwith regularly spaced Thesesteelpanelsfrom Wall Controlare solid,colorful
perforatedhardboard.Although the company
slots or a alternativesto the panels
offers a wide variety of hooks and accessories,
combination allow the useof any third-party magnet hooks or hangers.
of slots and
holes similar to perforated Shelves,baskets, small cabinets, and a
hardboard. Plain panels variety of hangers and hooks snap into
come in brushed aluminum the vertical strips.
or galvanized steel. You'll Rails, slotted strips, brackets, and
find steelpanels in a range hooks range from $2.50 to $12. De-
of power-coatedcolors.Pan- pending on size, cabinets and shelving
els sized at 8x32" or 16x32" units matched to the rails range from
can be hung singly or com- $60 to $150..l
bined to form larger arrays, Written byA.l. Hamter
and mounting holes are a_-_
set at standard 16" intervals. )ources
pricesranserrom
$13 to $23.
"uo"t ffi1"jlllfiff;LX?*,1i1'schurtestorase'co
schuttewatt Grid:Boo-B2g-47s2,soo-66s-322s,
Accessoriesthat hang in schultestorage.com
the slots include a variety StoreWAL[ : 866-889-2502, l.com
storewal
Wall Control: 770-723-1251,
wallcontrol.com
of hooks, brackets, and
shelves, plus larger pieces
designed for specific uses
such as tool holders, parts
bins, even fluorescent-light
mounts. Smaller accesso-
ries, such as hooks, sell in
multipacks starting at about
$4; larger accessoriessell
for $7 to $24.
Rail systems
A different type of wall storage uses
rails rather than panels, but shares
traits of the other panel types. This
system uses a vertical rail mounted
A rail system,like this examplefrom Freedom
securely into wall studs, from which Rail,offers shelves,cabinets,and hangers
vertical slotted metal strips can be supported on heavy-dutyverticalmetal
hung anywhere along the rail length. stripssecuredto the wall studs.
27

New220V60A
breakerfor two
110Vshop
circuitsand one
220V circuit
220V 604 feeder
from service-
entrance
breakerpanel
110V20A
shopcircuits
220V204
tablesawcircuit
Sparecircuit
1lf hop wiring requirements can vary
\widely, depending on the type of
J proiects you tackle. If your hobby
is building radio-controlled airplanes,
you may need a single convenience
outlet for a soldering iron. But if you're
into woodworking, you'll need some
seriousamperageto simultaneously run
a tablesaw and dust-collection system.
And if cars are your passion, you may
have a large air compressorand welding
rig that demand wiring on nearly an
industrial scale.
But no matter your requirements, one
thing's for certain: You can't starve a
power tool and expect it to last. When
you don't provide a motor with enough
power, it runs inefficiently, tempting
you to push it harder to get the iob done.
That further overheats the motor, and
you're quickly way beyond the tool's
designedoperating range.
At that point, severalthings can hap-
pen, and none of them are good. If you
blow a circuit breaker,that's a dead give-
awaythat the circuit is trying to deliver
more amperage than it can handle. By
resetting the breaker, you continue
28
Ground-faultcircuit
interrupteroutlet,
. first in circuit
Sub panel
Groundwire
(requiredin
some areas)
torturing the tool for a while, but it
doesn't solvethe problem. In severe
overheating conditions, you may
burn the insulation off the motor's
windings or fry another compo-
nent. Either way, you'll have a dead
tool. If things really go wrong, /ou
could start a fire.
Flgure your power needs
The unit of electricalpower is called
the ampere, usually shortened to
amp.To figure the sizerequired for a
tool circuit, start by looking at the
motor nameplate of your most
power-hungry tool. For discussion
purposes, let's say it's a tablesaw
subpanelfor a homewood
with a 14.2-ampmotor (at llo I 720 volts). Thiselectrical
shopidentifieseachtool'scircuit.There's
also
Tools often draw a surge of power at roomto addmorecircuitslater.
startup, sowe'll figure a 25 percentallow-
ance for this by multiplying 14.2 times then add the requirements of the two
1.25. The result is 17.75,so a 20-amp tools. If the total exceeds 20 amps,
circuit is a good choice for this one tool. though, you'll usually find that the
The math remains easy even if you'll most practical solution is to run each
run more than one tool simultaneously tool on a separatecircuit.
on a circuit-say a router and dust col- Some large motors have dual-voltage
lector. Look up the nameplate amperage capability: They can be wired to run on
for each tool, figure its surge allowance, a"l,lOll20-volt circuit or on a 22Ol24O
Best-Ever Home Shop ldeas 2009
circuit. You or the motor won't notice a
particular advantage either way. That's
becausedoubling the voltage cuts the
amperage in half. In the example of
the tablesawmotor requiring 14.2 amps
at 110 volts, wiring it for 22O power
drops the amperageneededto 7.L.
Other power requirements in your
shop may be relatively minor, such as a
radio or fan, but adding an appliance,
like as a refrigeratoror spaceheater,can
createa seriousdemand on a circuit.
The circuit for the lighting should
always be separate from the power
receptacles.Otherwise, if a tool trips a
circuit breaker,you'll be in the dark.
For more details about shop wiring,
seewoodmagazine.com/stropw i ri ng.
DIY or hire an electrlcian?
If you're confident in your ability to
plan and install circuits, you may want
to take on the actual wiring yourself.
But check first with the local govern-
mental agency that issuespermits and
conducts inspections. Many locations
allow the homeowner to complete wir-
ing chores; some require that you prove
your knowledge by first passing a test.
Others absolutely prohibit the home-
owner from doing wiring unless it's
completed by a licensed electrician.
In almost all cases,electrical work
requires that you obtain a permit and
have the work inspected by a building
official. If you proceed without a per-
mit, you could have problems with your
homeowner's insurance in the event
that you need to submit a claim.
If you have doubts about your wiring
skills, hire an electrician. Skilled trades-
men don't work cheaply, but the peace
of mind that comes from having a pro
handle the iob is worth it.
ExtensionCord Recommendations
Up to 3 18 gauge
3-4 18gauge
4-5 18 gauge
'
5-6 18 gauge
6-8 1 8g a u g e
8-10 18 gauge
10-12 16 gauge
12-14 14 gauge
14-16 14 gauge
woodmagazine.com
Ground-fault protection Never walk on a cord or roll wheeled
Electrical codesmay require that your obiects over it. That can stressor break
shop's outlets have protection called the insulation or even the wire itself.
GFCI (ground-fault circuit inter- Never use an extension cord that's
rupter), particularly for installations tightty coiled on a storagereel because
in a basement or garage. GFCI is that can create an undesired electrical
designed to sense dangerous condi- field. (Think of the motor you made in
tions and shut off the power. This school by winding copper wire around
could prevent a serious or even fatal a nail.) Instead, fully unwind the cord
electrical shock. before use. I
You can achieve GFCI protection
with specially designed receptacles
or breakers.Either way, carefully fol-
low the manufacturer's installation
instructions to ensure protection.
Check the breaker or receptacle
monthly by pushing the test button.
Extensloncord cautlons
Short and fat may not describe the
ideal body type, but it's a good rule of
thumb for choosing an extension
cord. "Short" means picking a cord
that's no longer than necessary
becauselong cords can causea loss of
voltage. uEat" means wires with a
large cross section, enabling the con-
A ground-faultcircuit interrupter (GFCI)duplex
ductorto carrymore power. The gauge outlet can providevaluableprotectionagainst
numbering systemfor electrical wires electricalshock.
is counterintuitive: the smaller the
number, the larger the wire. For
example, 1O-gaugewire is substan-
tially larger than l4-gauge.
If you're doing projects outdoors,
make certain that you plug your
extension cord into an outlet with
GFCI protection. Some outdoor cords
include GFCI protection plus a multi-
ple outlet block that allows you to
have severaltools connected at once.
Seethe extension cord chart below
or refer to your tool's owner's manual
for selection advice. Here are other
cautions about extension cords: Buy high-qualityextensioncords,and protect
them from abrasionto keep your tools running
strong.This pigtail model includesa GFCI.
18 gauge 16 gauge
18 gauge 16 gauge
18 gauge 14 gauge
16 gauge 14 gauge
1 6g a u g e .12 gauge
14 gauge 12gauge
14 gauge 10 gauge
12 gauge 10gauge A fluorescentlight on a retractablereel gives
your home shop a professionallook and
12 gauge 10 gauge eliminatestangled extensioncords.
29
 trr
i
.i\
hen it comes to energy-
efficient lighting, it's tough
to beat natural daylight. Of
course, you rnay need to tnake an invest-
rnent or two to get it into your shop, but
after that, it's virtually all benefit.
If you have a garage workshop, for
exarnple, adding a window or two-or
even rnore-will make a dramatic differ-
ence. If the walls in your garage have
exposed frarning, putting in the headers
and frarning the openings for new
windows is a straightforward task,
whether you tackle it yourself or delegate
it to a contractor.
If your garage is detached frorn the
house, you needn't be finicky abottt
rnatching its style of windows to yottr
house. That opens up the cl-tcticesto
include less-expensive stock windows
frorn a home center.
Or, if you're not in a big hurry to get
your windows, contact the big-box stores
and other window suppliers in your
area, asking them to let you know when
they have bargains available. These can
include closeouts, "scratch-and-dent"
30
iterns, or custotn orders where the speci- lights give you flexibility to tailor illu-
fications got garbled. Retailers often mination alurost instantllz to tl-re chore
slash prices dratnatically on these itetns, at hand-an excellent choice if your
and you pocket the savings. shop handles a wide range of repair and
construction chores. You'll want to posi-
Task lighting is essential tion the track lights high enough so
The level of overall illurnination in a they aren't in the way, yet low enough to
shop is called "arnbient lighting," and it permit easy adjustment.
rnust provide sufficient brightness to
enable you to rlove about safely and
perfonn a range of tasks.
But when it comes to close work-
tight-tolerance lneasuring and rnarking,
for exarnple-you need to purnp up the
arnount of light to give yourself a better
view. This type is lighting is called "task
lighting." You'll want to permanently
irrstall task lights at some locations and
also have portable sources,both for shop
and on-location use.
A workbench is one logical location
for fixed task lighting. You can position
a fluorescent or halogen-strip fixture
above your bench for illuminating the
entire area.Or install a canister fixture
at a critical location: above a frequently a m pi s a n i n e x p e n s i v e
A n a r t i c u l a t e d - a r lm
'frack
used bench vise, for exatnple. a n d h a n d yt a s k - l i g h t i n sgo u r c ef o r y o u r s h o p .
Best-Ever Home Shop ldeas 2009

Halogenwork lampson standsare versatile
in your shopaswell at remodelingsites.
Dedicated and movable
task-lighting choices
Some workshop tools tend to block
ambient light that providesa clearview
of your work. So it makes senseto pur-
chase accessorylighting fixtures and
install them at the machine. A drill
press and bandsaw are two popular
tools that fit into this category. A
grinder and scrollsawalso would ben-
efit from this specialtreatment.
Movable task lighting offers another
solution. This can include a goose-
necked desk lamp (from office-supply
stores) that you can mount on your
bench to drench sharpening chores
with light or as "raking" light (grazing
a project at a low angle) to inspect the
surfacewhile you apply a finish.
Another useful movable lighting
choice is an articulated-arm fixture
(opposite;think drafting-table lamp).
This type, also readily available at
office-supply stores,usually includes a
clamp-on base. However, by drilling
mounting holes in work surfaces
throughout your shop,you make it easy
to move the lamp wherever needed.
Many of these fixtures use standard-
base lightbulbs, making it simple to
switch to a CFL (compact fluorescent
lamps) and enioy energy savings.
Some articulated lamps instead uti-
lize circular fluorescent lamps and
incorporate magnifying lenses that
improve your view of tiny assemblies.
If you're into detailed work, you'll
find this combination a convenience.
woodmagazine.com
Haloqen lamps solve
biggEr problbms
Halogen lamps provide power-
ful lighting within your shop as s
fr
well as throughout your home il
I *
during remodeling projects. You i,tt aq
&,-ry,"
can purchase an individual '-
E
lamp with an integral stand, or
buy one or more lamps mounted --
on stands, as shown left. (Many
include adjustabletripod bases.)
c&
Some lamps have dual-level
tlt
lighting: Click once for 500 watts :
of power,and click again to boost l l
G t
!
to 1,000 watts. i-
,-
il...
Paint makes a -
difference %lF*
Dark colors on walls' ceilings' compactfruorescent ramps(CFLs)save moneyin a
and other surfacescan seem to varietyoffixturetypes.
suck all of the light from your
shop. You'll make your work area technology. As a result, the lamps stay
brighter-and even seem larger-by cooler and consume only about one-
choosing white or other light-reflective fourth the energy of incandescentsof
tones whenever possible. It's best to the same light level. As an added bene-
avoid glossy finishes, though, because fit, the lamps last about 10 times longer,
the glare can be distracting and cause slashingreplacementexpenseaswell as
eyestrain. the annoyance of changing them.
Brightening your floor with a durable The new T8 style of fluorescent tube
coating is another way to maximize the has a smaller diameter than the T12,
light in your shop, provided that you which will be phased out of production.
stay with the lighter tones. Seepage20 The T8 fixture is also more energy effi-
for more information about choosing cient, so choosethis style if you're in the
and applying a floor finish. market for new tubular fluorescents.
CFLs,in the curlicue configuration or
Energy-efficient lamps another shape, allow you to re-lamp
Incandescentlamps have changedlittle existing fixtures and enioy considerable
in the past 100 years,but the systemis energy and cost savings. If you have
not efficient. (A considerableamount of recessedceiling canistersin your shop,
energy is wasted as heat.) Fluorescent look for CFLs in a style that closely
lamps utilize more energy-efficient resemblesstandardreflector lamps. cP
When your handsare full, groping for a light switch
with your elbow is a definitenuisance.That'swhere
a motion-sensorlight switch helps: lt "sees" your
motion and turns on the lightsfor you. Evenbetter,
when the sensorfails to detect motion for a time, it
turns off the power. (You set the length of the time
delayby adjustinga screwhidden under a panelon
the switch.)
This type of switch isn't recommendedas a control
for the main lightingin your shop becauseit would be
inconvenientand dangerousfor the lightsto go out
while power tools are whirring. But it's perfect for
stepsand hallwaysleadingto your shop, as well as
storageclosets.
A motion switchturns out
Read the specificationsof the switch carefully the lights automatically,a
beforeyou buy it. Many will handleboth fluorescent usefulfeaturewhen your
and incandescent lampsbut not compactfluorescents. handsarefull.
31
EnergyEfficiency When installedover a concrete
floor, a modular air-gapsystem
createsa vapor barrier and
insulatingair gap. The 2x2'
DRlCorepanels slide together.

for YourShop
aking a shop warm is a rela- vapor barrier and insulating air gap
The inset image aboveshows
the air gaps.

The panels have an impressive load

tively straightforward task, above the concrete surface.As an added rating of 5,000 pounds per squarefoot,
and you have bushels of bonus, the new resilient floor reduces and have a low retail price of about
choices: from portable electric heatersto leg fatigue. As a result, you'll discover $1.50 per square foot. For more details
stoves that burn wood, biomass pellets, that your shop time is far lesstiring. about air-gap flooring, seepage20.
or even corn. (No, it doesn't pop.) The 2x2' tongue-and-groove panels are
But making a shop into the comfort- easyto transport and simple to install. You Choosethe rloht tvre and
able and inviting retreat that you want can cut and drill the panelswith power and amount of iniulatioh
requires more than raw Btus. To make hand tools. Place %" spacers along the Whether you're building from scratch
your energy dollars more efficient, you'll perimeter of the room and around fixed or want to upgrade the energy efficiency
want to make sure that your shop has obstructions, then tap the panel edges of your existing shop, you need to know
well-insulated sidewalls. And if your together using a hammer and block of the recommended levels of insulation
shop is in a garageor freestandingbuild- wood. For maximum strengtfi stagger.the for your part of the country. Energy Star
ing, be certain that the attic spaceabove .joints between rows in a brick-bond pat- is a joint program of the United States
it has adequate insulation. In addition, tem. At low spots,usethe company's plastic Environmental Protection Agency and
you'll also need to plan for air move- shims to level an uneven shop floor. the Department of Energy.The prograrn
ment within your shop. For shop use, you can leave the goal is to help people save money and
oriented-strand-board (OSB) surface as protect the environment through
Transform concrete lnto a is, or apply a stain, sealer, or paint. If energy-efficient practices and products.
warm and reslllent surface you ever convert the spaceinto a living Energy Star estimates that a knowl-
If standing on a cold concrete slab area, the system serves as an excellent edgeablehomeowner or contractor can
keeps you out of your shop or garage,a subfloor for carpet, or "floating" installa- saveup to 2Oo/oon annual heating and
modular air-gap system, such as DRI- tions such as laminate or engineered cooling costs while enjoying additional
Core, above,quickly and easily createsa wood flooring. comfort as well as the savings. For more

32 Best-Ever Home Shop ldeas 2009

 (such as the Gulf Coast),the paper faces
lnsulation Recommendationsfor Existing outdoors. Check with your building-
Wood-Frame Houses regulation official for which orientation
is appropriatefor your location.
You'll also find expanded polystyrene
(Styrofoam is one brand) in sheet thick-
nessesat your local home center. The
material easily cuts with a handsaw. If
you need to glue these panels in place,
select an adhesive specifically approved
for the application.

You'll be a fan of this ldea

|zo,.;r h-t"d."l Unlessyour shop has an air-circulation
^ | Hawaii,Cuam, I
C
I PuertoRico,and I
system, the area will probably suffer
the Virginlslands from hot and cold spots, air that settles
I I
into temperature layers, and moisture-
Wall Insulation: laden air that collects in corners and
Whenever exterior siding is removed on an
uninsulated wood-frame wall:
other dead areas.Stale air can produce
. Drill holes in the sheathing and blow a musty smell or even bloom into a
Add Insulatl,on to Attlc insulationinto the empty wall cavity before serious mold infestation. Moving the
Uninsulated Existinq3-4 inches i n s t a l l i n gt h e n e w s i d i n g .
Zone Attic of iisulation Floor o Zones 3-4: Add R5 insulativewall sheathing
air helps solve those problems, and it
1 R30to R49 R25to R30 Rl3 beneath the new siding. can also relieve a claustrophobic feeling
2 R30to R60 R25to R38 R'13to R19 o Zones 5-8: Add R5 to R6 insulativewall in small shops.
3 R30to R60 R25to R38 Rl9 to R25 sheathing beneath the new siding.
Insulated wood-frame wall: If your shop has a high ceiling, con-
4 R38to R60 R38 R25to R30
r For Zones 4-8: Add R5 insulativewall sider a ceiling fan. Manufacturers'Web
5to8 R49to R60 R38to R49 R25to R30 sheathing beneath the new siding. sites will help match your shop's vol-
ume with the recommended number of
details, visit the Energy Star Web site purpose sealing, but purchase the low- fans, their blade diameters, and mount-
(energystar.gov). expansion formulation for improvements ing heights. In warm weather, you run
Insulation amounts are specified by around the frames of doors and win- the fan so that it blows downward
R-value, which is a measure of the dows. That's because the standard on you, creating a cooling evaporative
insulation's ability to resist the move- formulation can expand too aggressively "wind chill" effect. Reverse the fan's
ment of heat traveling though it. The in these applications, and could even rotation in cold weather to harvest
larger the R-value, the greater the bow the iambs, making it difficult to warm air from the top of the room and
insulating ability of the material. Refer operateyour windows and doors. guide it down the walls without creat-
to the USA map and chart above for Duct sealing is another important ing a draft. Both ways, you'll be more
recommended R-valuesin your climate step. If your home's ductwork is accessi- comfortable. |F
region of the country. ble (in an attic, basement,or crawl space,
for example), seal the joints with a spe-
Start by sealing air leahs cial duct sealer(also called duct mastic)
Most air leaks are easyto find because to help eliminate the loss of heated or
you'll feel them as cold drafts in the cooled air. Don't rely on ordinary duct
wintertime. A stick of incenseis another tape becauseit simply doesn't have the
way to help you find an air leak. You'll sealing ability to deliver the energy-
see the gentle smoke trail deflected by saving resultsyou want.
even the tiniest air leak. Likely locations
to begin your investigation include Fiberqlass and other
windows and outside doors, as well as insuliting choices
electrical switchplatesand sockets. Fiberglassoffers an affordableand widely
Seal leaks around electrical devices available form of insulation. You'll find
with inexpensive closed-cellfoam seal- it in 1-6"or 24" widths suitable for studs
ers. (Shop in the weather-stripping aisle or ioists that are spacedon center. Some
of your hardware store or home center.) batts come factory-cut for standard stud-
Around doors, examine weather- bay lengths so that you don't need to
stripping at the top and sides of the trim each batt; other fiberglassproducts
This Hunterfan, designedto hang from a
door. Don't neglect the seal and sweep come as a continuous roll. ceilingjoist, circulatesthe air in your shop
at the bottom of the door. As a final consideration, choose without subtractingfloor space.
For tight spaces,aerosolfoam sealant whether you want the fiberglassto have
performs well. (Great Stuff and DAP a kraft paper facing. In most areasof the hurces
DRlCore: dricore.com;B66-976-6374
products are distributed nationwide.) United States,the paper facesthe living Energy Star: energystar.gov
Use the ordinary variety for general- space.However,in some humid locations Hunter: hunterfan.com; 888-830{326

woodmagazlne.com
33

our dust-control strategy should
ideally consistof severalelements:
a central or portable dust collec-
tor, a portable shop vacuum or dust
extractor, an exhaust f.an, a ceiling-
mounted air-filtration unit, and a respi-
rator. When you look at the price tagson
dust-control equipment, you may be
tempted to avoid these purchases and
simply let the chips fall where they may.
Don't be penny-wise and pound-foolish:
You can't buy much health care for the
price of effective dust control.
Small dust particles carry more poten-
tial danger than large chunks. For exam-
ple, somedust collectorscaptureparticles
down to 30 microns in size.This sounds
fairly impressivebecausea micron is one-
millionth of a meter. But larger particles
simply drop harmlessly to the floor, so
the real health risksstart at the 3O-micron
and smaller size.
34
This N95 half maskrespiratorby AO Safetyweighs lessthan 5 ounces,
hasdual exhalationvalves,and usesreplaceable filter elements.The
soft rubber body sealswellwithout chafing.
Air YouBreathe
Keeplbur
Shopand
LungsClean
Youprobably knowthatdustcontrolis
already
animportanthealthissue: Inhaling
extremely
fineparticles problems.
canleadto respiratory
The front llne of
dust defense
The best starting place for dust collec-
tion is at the source: at your tablesaw,
router, sander, or other tool. Many of
these already have dust ports, simplify-
ing the connection to a dust collector or A dust collector
shop vacuum. may use a cloth
Installing a central dust-collection bag or canister
filter. Many have
system can be an excellent strategy
heavy plasticbags
that's convenient to use. But properly for chip collection,
designing and sizing your system
involves a host of variables:the range of
simplifying
disposal.
F
F
tools you own, your shop's size and lay-
out, and even the types of hoses and
I
ductwork you'll use. listing of articles that walk you through
We can't coverthat breadth in a couple the design process, provide product
of pages, but we can guide you to an reviews of dust collectors, and open up
excellent resource. Visit the WOOD@ additional resources.If you don't have a
magazine online searchable index back-issue collection, /ou can easily
(tt,ootlrtiaglrzinr,conr/irrcler),
and enter download many of the articles for a
the words "dust collection." You'll find a nominal fee.
Best-Ever Home Shop ldeas 2009

Cleanair in the shop isn't
a matter of being finicky-it's vitalto good
health.A ceiling-mountedcleaner,likethis
JDSmodel, can deliver excellentresults.
Dlsposeof alrborne dust
In addition to a dust-collection system,
invest in an air-filtration system that
continually pulls those floating dust
particles out of the air before they reach
your lungs. A ceiling-mounted unit is a
great solution if your shop has adequate
headroom. The one pictured abovehas
multiple filtration stagesto remove 99olo
of dust particles down to 5 microns in
size, and even 91oloof particles down to
1 micron.
A number of manufacturers produce
these air-filtrations systemsin a range of
sizesto suit your shop'sneeds.One multi-
tasking model from Delta incorporatesa
work light into the bottom of the unit.
Hanging it above a tablesaw,which is
usually in the middle of a shop, enhances
both sight and breathing.
Instead of scrubbing and recirculating
the air within your shop, |ou may want
to simply export the problem outdoors
by opening your garagedoors or adding
an exhaust fan. (Forgetabout the kind
of fan that's usually installed in bath-
rooms-it simply won't move enough
air to be effective.)
Pop rivetssecurea fan framework made from
standardaluminumextrusionsavailableat
most hardwarestores.
woodmagazlne.com
For a simple, low-tech solu-
tion, secure a window or box-
type fan in an open window in
your shop. (To purchase plans
for the setup shown below left,
seewoodmagazine.com
/fa n.)
If possible, choose a totally
enclosed motor because it will
survive well in a dusty location. An
even better alternative-though sub-
stantially more expensive-is a motor
that carries an explosion-proof rating.
This type helps provide valuable insur-
ance against accidental ignition due to
dust and solvents.
A portable dust
extractortames
dust-collection
problemsin your
shop aswell
as at job sites
throughout
your home.
Portable shop vacuum
vs. dust extrictor
Hooking up a tool to an ordinary
shop vacuum helps prevent a cloud of
dust from filling up your shop. But
attaching that sametool to a dust extrac-
tor can make a healthy difference. For
example, the HEPA-rateddust extractor
abovetraps particlesdown to 0.3 microns. Sourcer
(HEPA means High Efficiency Particle AO Safety:aearo.com
Attenuation.) An extractor generally has Fein: 800-441
a smaller footprint than a shop vacuum. I DS: 800-480-726t
Of course, performance like that f et : 800-274-6848,
carries a price tag (about $350 retail)
substantially higher than ordinary shop
vacuums (about $125). If you're not
quite ready to invest in a dust extractor,
at least searchout a more effective after- lf metalworkingis part of your shop,
market filter for your shop vacuum than
the one shipped as standard equipment.
The resplrator: Your
last lind of defense
Some woodworking operations gener-
ate so much fine dust-machining
medium-density fiberboard (MDF) or
sanding on the lathe, for example-that
it's nearly impossible to capture enough
of it through standard collection meth-
ods. In those cases,wear a respirator
over your nose and mouth.
i
Choosea disposable
respiratorwith the
N95 designation
for good protection
againstairborne
wood dust.
A single-strapnuisance
maskprovideslittle
protectionfrom
airbornedust. r
If you want a disposable respirator,
look for one that meets the NIOSH 95
standard (often abbreviatedas N95), for
particlesdown to 0.3 microns. (Seephoto
fop.) Most of these respiratorshave the
shell style similar to a "nuisance dust
mask," above,but the N95 is far more
effective than the one-strap model.
A respirator with an exhalation valve
makesit easierto breathe.You'llalso find
a pleated design that claims even easier
breathing and improved visibility.
A half-mask single- or dual-cartridge
respirator (shown opposite)offers even
more protection. A dual-cartridge model
protects your lungs from the solventsand
particles of sprayed finishes. Choose the
proper pre-filters and cartridge elements
to match the material you're using. Q
-9878,
feinus.com
jdstools.com
jettools.com
you need to protectyourselffrom
fine particlesgeneratedby sawing,
grinding,and other operations. The
'.
fumes produced by welding add
another levelof concerns.Check
with mail-ordersourcesor a local
safetysuppiierto ensurethat your
defensivestrategiesare appropriate
for the metalsyou work and the
procedures you use.
35
fiarage
Makeover
Burgundy cabinets and organized
walls transform an ordinary garage here are garagesand then there
are garages.If you baby every-
into an extension of a car guy't home, thing from your car or pickup
truck to your favorite 2r/2"-widePurdy
Theepoxyfloorwaspeeling upinflakes,
open wereadistracting
shelves clutter, paintbrush, there's good reason to
andgarden toolswerechainedto thewallto prevent onefallingontothe
another invest in a garage upgrade. In fact,
organizing a garage may be the last
hood allinthepastafterthishomeowner
ofa car.Butthat's upgraded hisgarage. frontier in home-improvement projects
Doeseverytoolhaveitsplace?Youbet! for many households.

36 Best-Ever Home Shop ldeas 2009

lf you can see it, These wall systems have also
you can find it become popular with sports-
Don't you hate it when you can't find a minded families desperatefor a
shovel among your jumble of garden solution to a mountain of golf
tools? Or when that darned string trim- bags,tennis racquets,basketballs,
mer falls off the wall and smashesonto and whateverelsegetspiled up in
your car hood? an active family's garage.
If that sounds like your garage,it's Before you begin hanging any-
time to restore order with a wall sys- thing on the wall, Todd Walker,
tem. (For a more complete look at wall owner of a garage and storage
systems,seepage26.) store, suggests removing every-
One inexpensive option is a single thing from the garageand assess-
strip of hooks and hangers that fits ing what you really value. He
many garden tools. Although inexpen- provides a 24' trailer for custom-
sive,this solution doesn'tmake the best ers to temporarily store garage
use of space. contents while the garagefloor is
Wall systems, like the storeWALL being prepared. This usually
units shown at right, allow more flexi- means calling a family summit
bility than a traditional linear strip of to claim all the tools and sports
hangers provides. Most manufacturers equipment worth keeping. What
offer just about any hook under the sun doesn't find a home in the "new"
for odd-shaped equipment, including garageshould be donated to char-
Eight-footlong sectionsof an interlockingtrack
leaf blowers, string trimmers, wheel- ity or hauled away. system(abovelby storeWALLattach quickly to line
barrows, and garden hose. Written by Carl Voss one wall of the garage.

Afterse(uing andlevelingthe top andbottom2'Lwidesteelrails,JoeM<Guirefitsthe notchedcabinetendpieceagainstthe wall(teft).Onceallthe

framesareassembled,Jake Berhowbeginshangingthe doors(certer). Doubleball-bearing holes(frght).
drawerslidesscrewintofactory-drilled

Cabinets: What you A new 6'-long workbench be-

need to stash avlay neath a garage window provides
It's ideal to placeyard and garden tools the homeowner with the spacehe
on hooks acrossthe front or along the needs to spread out his proiects.
side of a garage.However, lots of other He chose a bench surfacecoated
garage items belong behind doors or with black urethane (the same
in drawers. In this homeowner's case, tough material asa spray-ontruck-
he selectedburgundy cabinets for his bed liner) that should withstand
car-care products (below right), garden even the most powerful solvent in
sprays, and do-it-yourself supplies. A his cleaning arsenal.
two-man crew installed 16 lineal feet The homeowner loaded most of
of cabinets and drawersin five hours. his auto-mechanic'stools into a
The Redline Garage Gear cabinets mobile tool chest (see other
(redlinegaragegear.com) are powder- examples on page 106) and found
coated MDF and should provide years a home for home improvement
of service.Becausethe basecabinets are tools in his new drawers beneath
mounted on the wall and not resting on the workbench.
the floor, homeowners can hose down The dovetailed drawers in this
the garage floor and not worry about system are constructed from 9-ply
damaging the cabinetry or contents. hardwood plywood, and travel
(Many of the companies listed on pages smoothly on double ball-bearing
24-25 also offer wall-hanging cabinets.) full-extensiondrawerslides.i

woodmagazlne.com
Learn from these professional applicators as they share
their secrets for putting down a high-quality epoxy floor.

Stirring
upa batchoftwo-partepoxyistheeasypartofapplyinga newgarage-floor
covering.
Thehard partisavoiding
thetemptationtotakeshortcuts
intherecommendedpreparation
steps. aretipsfromprofessionals
Here your
thatwillkeep floorlooking
asgood twodecades fromnowasit does onDay 0ne.

1f, ccording to Todd Walker, owner of Absolute Garage in Des Moines, Iowa,
tl about 50 percent of his businessis applying epoxy floors to home garages. No shortcuts
u l"Concrete wasn't made to be coated,"Todd explains. "So to get it right, you A long-lasting epoxy floor requires
have to trick the concrete."That means properly preparing the concrete to bond proper preparation of the concrete
with the epoxy. In the caseof this car buff's garage,his builder passedalong incor- surface.First, remove every bit of the
rect advice about new concrete not needing preparation before the first coat of three layers of epoxy previously
epoxy. The homeowner's attempt to fix the.first application with two additional applied by the homeowner. A power
coats of epoxy compounded the problem; the epoxy began peeling off in chunks. scraper above (available from rental
That's when the homeowner threw in the towel and called in the pros. Removing storesat about $60 a duy), peels up
the old epoxy proved to be a 32-man-houriob. The new floor?Just 10 man-hours. the layersof epoxy.

38 Best-Ever Home Shop ldeas 2009

 *
:.,..,1
Y,.
w

. 4r4
4i{iiSlitj!il

Establishing a good bond between the

cpoxy and conctete requires opelting
the pores of the concrete.
true even with new concrete (a step
'l'his
holds
f:lrirfil
ry'-*ffi
civerlookedby some homeowners). Etch-
ing with muriatic acid is an option
w i t h n e w c o n c r e t e . I n t h i s c t a s ea
, n B"-
diarneter grinder (available at rental
storcs) rernoves any stubborn epoxy
and prepares the concrete for proper
adhesion. The shot blaster, a specialty
rnachine, obot,e,pounds the surface with
tiny pellets. The photos r1glrfshow two
stagesof the shot-blasted floor prepara- A h a m m e ra n d c h i s e rl e m o v et h e t o p l a y e ro f
caulkA . r i g h t - a n g lg
e r i n d e rr e m o v e st h e c a u l k
tion and the finished surface.
down to about 72".(Grinderguard removed
for clarity.)
'l'hc
rnost colrtnon preparation is
, \ n ' e l l - p r c p a r c . de p o x y g a r a g e f l o o r i s a with rnuriatic acid (available at hornc
sight to behold. Unfortunatelv, sorre centers ancl paint stores) or Quikrete
honreowners who apply epoxy them- (lleaner. You'll see the acid bubbling
selves eithel receirre incornpletc ;rdvice away on the concrete and srnell the
or rusl-r through tl-rc. stcps tl-rat will effects of something sin-rilar to rotten
e n s L r r ea l o n g - l a s t i n g f l o o r . cggs. Be strre to ventilate your basement
If an epoxy floor seel.nsright for you, or garage properly, and thoroughly
kcep in rnind that thcr'e are several water-rinse tl're acid. Wait at least 24
grades of epoxy. (For rnore details, see hours before applying epoxy to be sure
ltogc20.) Top epoxy grades contain rrore the concrete is cornpletely dry.
solids-the good stuff you want on youl If you rnust rclnove old paint or epoxy
'lbdd,
floor. the applicator frorn Des before applying a new coat, follow the r+*i-,mq*'iw*.-*uiw
M o i n e s , u s e si n d u s t r i a l - q u a l i t y p r o d u c t s t i p s d e s c r i b e d o n t h e s e p a g e s .I f y o u ' r e
whether he's working on a two-car doing this yourself, plan for two days of
garageor a sprawling airplanc hangar. preparation for a two-car garage. ,d
The top products are kinder to the nctsc Your floor will have a srnoother
during curing, too.
f"
appearance if you take tirne to fill cracks
Regardless of your epox\/ buclgct, and the concrete saw cuts, as shown at
'-t
make the rnost of your invcstrncnt by ri3lrt. Although solnc homeowners are
following recomlnended prcltaration satisfied with premiurn-quality caulk-

tu
'i.\

steps. A good tootl-r (boncl)-opening 'lbdd -,

--4.

-,.
ing, prefers a slurry of patching I.

up the concrete pores so the cpoxy has epoxy corrlpound. "The problern with
sornething to grab on to-is what drivcs caulk is that eventually it will crack dur-
thorough preparation. Witl-rout a good ing expansion and contraction. Then
tooth, you are apt to see the coating your eycs go right to the crackl If the I
t
1
bubble up. This is especially evident if garage is on stable ground, I'vc found
A slurryof patchingepoxy compound replaces
you drive a ctar with hot tires onto a t h a t e p o x y i s l e s sp r o n e t o c r a c k i n g . J u s t c a u l k a n d h o l d s u p w e l l t o s e a s o n a le x p a n s i o n
poorly preppcd floor. take your tirre, and do a good job." and contraction of the floor.

woodmagazine.com
39
 To establish a crisp edge of epoxy
at the garage door, Todd rolls out
Z"-wide painter's tape directly below
the garage door. Then a second layer
of tape goes on top of the first. To
make sure the tape is sealed well,
Todd suggestsrunning a putty knife
or drywall tool over the tape; this
will prevent the epoxy from creep-
ing beneath the tape.
To stand up against wear from at the
garage door, Todd creates extra-deep
trough of epoxy using a right-angle
grinder and a diamond wheel, as
shown at rigltt.
With the floor back to Square One, To createadditionaldepth for the epoxy coat beneaththe overheaddoor),removeabout l/to"of
the fun begins. And what could be concretewith a right-anglegrinderand a diamondwheel.Two layersof 2"-wideblue painter's
more fun than a rose-colored floor? tape createa crispedgeto the epoxy.
Cut in the edges of the floor with a
brush (page 3B), then roll on the
epoxy with a 3/a" nap cover. Profes-
sionals use an 18"-wide roller (twice
the width of the standard roller).
Most epoxy applications require two
coats to cover.
While the first coat of 2-part epoxy
is still wet, Todd and his crew sprinkle
a custom rose-colored quartz (sand)
over the entire 500-square-foot floor
to provide additional traction. (What
quartz doesn't stick gets swept up and
sprinkled later over the second coat
of wet epoxy.) After the final epoxy
Joespreadsthe first coatof red epoxy with a 24"-widesqueegee.Whilethe epoxy is stillwet, he
coat cures, a coat of satin polyure-
usesan 18"-wideroller(twicethe standardwidth)to eventhe coat.Strap-oncleats(similarto a
thane tops off the project. al golf shoepattern)makewalkingeasieron the wet epoxy.
Writtenbv Carl Voss

Whilethe first coatof epoxy is still wet, After the first coatcuresovernight,Todd Finally,Joe spreadsa thin coatof clear
JoeMcGuireduststhe entiregaragefloor with Walkersweepsup the looserose-colored polyurethaneoverthe secondcoatof cured
rose-colored quartz. quartzthat wasn'tembeddedin the epoxy. epoxy.The polyurethaneaddsluster.

40 Best-EverHome Shop ldeas 2009

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Howto Unstuffa
in 2 Drys
Garage
Froma shambles to
shipshape-weuseda
modestbudgetanda
boatloadof greatideas
to restoreorderto a
readertdisastrously
-/-
unorganized garage
shop.Adaptthesesame
ideasin yourshopto
createan orderlyspace
with ampleroomto
movearound.

he mission: Demonstrate that

your dream workshop may be
closer,and more affordable,than
you think. To prove it's possible, we
visited the shop of WOOD@magazine
reader and Seattle woodworker Mark
Lea.Upon first inspection, his one-car
garageshop looked more like a storage
locker (seethe photo aboverrsht)than a
functioning workshop. But after a sin-
gle weekend,and for lessthan $1,000,
we transformed Mark's shop into a
model of efficiency that even he barely
recognized.To accomplish this feat, the
five basic organizational principles
(oppositepage)were used to put things
in order. NoW equipped with the ideas
found here, you can do the same.

42 Best-Ever Home Shoo ldeas 2009

 '1

5 basic principles of
workshop organization
Mobillty-This makesa smallshop work like a largeone. To create
mobility, mobile baseswere added to Mark'stablesaw 8" jointer,
and 14" bandsaw.(The router,belt/discsander,and planer already
had wheels.)When the countertops and mitersaw station along
one wall were added, resulting recessesserved to house Mark's
largejointer and roll-aroundcabinets.After two days,his shop had
only three wheellesstools (the workbench, mitersawstation,and
drill press).

Flexibility-Needs change from project to project and

with each new tool purchase. The "Versa-cab" (see page 46)
offers the maximum in flexibility. Shelves and drawers can
be quickly relocatedto meet changing storage needs.The Triton
lumber-rack system (page 45) has movable arms. The large tool
recessin the corner accommodateseither Mark'smobile jointer or
his mobile tablesaw.

Accessibility-Organization means little if you can't get to things

easily.To createaccessibility,we opened up Mark'sfloor spaceby
creatingsensiblehomes for all the largetools. (Seethe shop floor
plan on page44.)The open floor spacedramaticallyimproveswork-
flow, providing obstruction-freeaccessto all parts of Mark'sshop.

Durability-There's no point to doing the work if it's not going

to last. For the shop's worksurfaces,birch plywood was used with
hardwood edge strips; for the cabinetty, 3/+"MDF with heavy-
duty hardware.Mobile bases,made of welded steelfor maximum
strength and durability, made moving large, heavy tools easy.
For protection of the bare wood surfaces of Mark's countertops
and cabinets,he'll need to apply at least two coats of oil-based
polyurethaneto ensurelastingmaterialstability.

Affordability-ln addition to making sure that the shop com-

ponents last, purchasingthem at a low or reasonableprice also
proved important. (See"Where the money went" on page 49.) ln
Mark'sshop,all the materialsfor the cabinetryand countertopcost
lesstlran 5440for five cabinets,multiple drawersand shelving,and
more than 32 squarefeet of countertop.Lessthan S40was spent on
the plywood holder.

Fora grid and tooltemplatesto begin planningyour shop,see

woodmagazine.com/shoplayout.

woodmagazine.com
43
 5'iffi!*AFiFFFjF*ie5.-tr,,.*

\{
,---.'4ilr\'-i t:
t!
'ffit
slrst, &ffidlvervi€try
srf tfue sh*;* trverh;I#fi
To best show you the improvements to Mark's
shop,her e' sa diagr a m o f th e fl o o r p l a n , p l u s *(- .ftfi
phot os t hat s ay it a l l . U s e th e p ro j e c t d ra w -
ings shown throughout this article to build
t*1
the key components.
L-1

tu
lLr
L
\.

\w
E
f!L,-

'!]N
"|N
{*::lQi

Project l: vf;ftss-f&rt sv$T*ru*
This customizablecabinetsystem,dubbedthe
"Versa-cab"(seepage46 for the plan), works
as a wall or basecabinet. The cabinet's15%"-
deeptop servesas a shelf for tool cases.
K
Proiect 2l Mrr[ft$AWwonxsrArtrlr*r
More than 32 square feet of countertop, not including the
mitersaw platform, were added to Mark's shop. As you can
seefrom the photos, none of the space,either above or below
the countertop, is wasted. Most mitersawsbenefit when they
have permanent homes with plenty of work support on ei-
ther side. Our mitersaw platform, supported by neigh-
boring "Versa-cab" base cabinets, is deceptively simple to
build, and effective in function. (Seepage47 for the plan.)

t
1 Jli.Y li
Mobile
belUdisc
sander

Versa-cab
Project 3: sm*.r.r
ccs#s KA{K
A long but shallow rack allows Mark to store
full-size and partial sheet goods in spite of Sheet-goodsrack
the shop's limited ceiling height of 7' 9". (See
page 48 for the plan.) It includes a hinged con-
tainment stretcher for easy material removal. Dowelstorage
We even threw in extra storage for dowel rods Mitersaw
that come in the form of two spaced sections Mobile FLOOR PLAN station
of heavy-duty carpet tubing. tool
cabinet
Lumber
rack

Mobilerouter
tableunder
Mobile bench
bandsaw

Mobiletool cabinet
underbench
,*/ \
ll/\ \ Drill
ry ) /oress
MOBILEBASES ThreeHTCmobilebasesaddedto the \f
largerpowertools significantlyimprovedMark's Overheaddoor
workshopmobility.(chwilke.com or call 7'17-764-5000)

44 Best-Ever Home Shop ldeas 2009

 d;

Project
Two sirnple wall cabinets perchecl above the counter-
tops rnake a htrge difference in tl-re sntall shop's
a v a i l a b l e s t o r a g es p a c e . B e c a t r s es u r f a c c - r n o u n t e dc o n c l u i t
preventecl us frorn r-r-rountingthe caltinets togcther, we
u s e d t h e o p p o r t u n i t y t o a d c i a d j t r s t a b l es h e l v i n g b e t w e e r - r
t h e t r v o . A s a f i n a l t o u c l - r ,s h o p b r u s l - r e s( n o t s e c . ni n t h i s
plroto) find a hancly home on thc cabinet sicle'.(Seepo;gc19
f o r c o n s t r u c t i o n d e t a i l s .)
f f,;,
T
ei*.'.**'F! -l

i*
rl
FTL 'qh#..;

I ii_
I

il t
r*1

\
\

I ;
I
*-

I
L U M B E RR A C KT r i t o n ' ss t u r d y l u m b e r r a c k , m o u n t e d a b o v e t h e
countertop, leavesMark plenty of room for "current project"
m a t e r i a l ,a n d t h o s e s p e c i a lb o a r d s s e t a s i d e f o r a n h e i r l o o m t o
L A R G EP O W E R - T O O L
\
\.
R E C E S SL e a v i n g s p a c e u n d e r n e a t h t h e
countertops allowed us to store and protect Mark's 8" jointer.
T h e s p a c ei s l a r g e e n o u g h t o a l t e r n a t ea s a t e m p o r a r y h o m e f o r
come. (Visit rockler.com or call 800-279-4441.\ the tablesawaswell.

to rne to have an organized shop. And Mark recently moved into a new
Of all the features shown herc, Mark I've kept it that wav!" horre, with a Zl/z-cardetached garage
Lea was rnost appreciative of his new Mark's shop also includes a 2-stage that serves as his shop. All of the
bench that incorporated a rnitersaw Delta dust collector on wheels that he benches and fixtures shown on these
station. "lt was really nice to have a rloves from machine to rnachine. Mark pages moved to Mark's new space.
full-length bench along the wall. But 'l-he
also has a pancake cotnpressor to run a only rnaior upgrade in his new
overall, I can't tell you l-row it meant varietv of nailers. shop is a glearning epoxy floor.

woodmagazine.com
45
 I vrnsn-cAB 1/q"groove 7e" deep 3/q"trom back edge

s/q"rabbel Te"deep

41/2"

81/2"
3 t/a" dadoes
th" deep 121/z'

7+"dadoes
Project I: "vERsA-cAB" Te"deep
TOO T . CA B I NE T SY ST E M
This simple cabinet design (Drawing1)
offers the ultimate in versatility; hence s/o'\
the name. It accommodates multiple s/q" rabbel
Ta" deep
drawers,shelves,or vertical dividers- 1/q"groove 7e" deep
or a mix of all three. Placeit vertically
as a basecabinet on the floor, or mount 7+"rabbets
it vertically or horizontally on the wall.
Becausethe dividers lay looselyin their
slots,the layout of each cabinet can be \
quickly reconfigured to meet changing t/+" groove a/a"deep
needs.The cabinet sizemakesoptimum 3/q"trom back edge
use of a sheetof medium-density fiber-
board (MDF). The spacingbetween the
dividers proves ideal for medium-size
drawers and many smaller tools, tool grooves for the cabinet backs and
cases,and other items. drawer bottoms. make certain the L/+"
Overall, the cabinet measures hardboard fits somewhat loosely into
(when vertical) 15%" deep, 13LA'wide, the grooves. If the fit is too tight, the A sides 3/+u 153/q" 381/t" MDF 2
and 381/+"high. At its most basic, it remaining lip may split away from top andbottom 3/q" 153/c" "l2yz' MDF 2
has three equal compartments of the MDF. As you assemblethe cabinet centerdividers 3/4" 143/+"
'121h"
MDF 2
ll3/+x7I3Ax743/E" . The individua I spaces, carcase and the drawer boxes, glue D back t/i' 121/2" 371/2" HB
with dividers installed, are 33/+"wide. the r/+"hardboard into the grooves to partitions t/q" '123/ro"143/l' HB 6
When routing thre V+"wide, 3/a"deep provide extra strength.
drawerfront 3/4n 311/.t6" "l1s/e" MDF
We found that once all the parts are Fx 2
andback
cut and routed, and assumingyou have G* drawersides 3/l' 311/16" 14" MDF 2
a finish nailer, each cabinet, including Hx drawerbottoms 1/q' 107/e" 14' HB
three drawer boxes, can be assembled * foronedrawer.
Quantity
in about an hour. Materials
key:MDF-medium-densityfiberboard,
HB-hardboard.

Assemblethe Versa-cabby giuing and

fitting the centerdividers (C)and the cabinet
back(D)into the sides(A).Glueand nailthe
dividersand cabinetends,squarethe
cabinet,and then nail through the backinto
the dividersto stiffen the cabinet.
For wall installation,add a horizontalcleat insidethe cabinetand to its back,securingit to the
sides.Then drive screwsthrough the cleatand backand into the wall studs. To increise the
versatilityof the partitions,add a dowel for storing circular-sawbladesof 10" or less.

46 Best-Ever Home Shop ldeas 2009

 # 8 x 1 t / 2 "F . H .wood BENCH
p nltrrERsAW
woRKsrATtoN
(
\ ? 7- 27"/o'
I

1-:
#8 x 3" F.H.
wood screw 6d finishnail

26va" -
t
21/a"
|
PLATFORMASSEMBLY
W
6d finishnail

4"
END SUPPORT
-{l
3/z'\--

VERSA-CAB

Materials List

B frontedging 3/c" 21/au 72" PO1

C sideedging 3/+u 2Y4' 273/c" PO 2

D wallcleat 3/+u 2Y4' 72" POl

As basecabinetssupportingthe mitersawworkstation,
the flexibleVersa-cabs accommodatemultipledrawers,
shelves,and verticaldividers.The divisionof space
+,r Ft'
mitersaw
platform
Platform
suppons
3/+" 261A" 26"

3/c" 31h" 26Y4' BP 2

G platformedging 3/q" 21/q" 27y2" PO

within the cabinetsallowsfor storageof smaller
toolsand other items.The spacebehindthe cabinets H* topcleas 1Y2" 2" 153/+" P
providesroom to run the dust-collectorhoseout of the l* bottomcleats 1Y2" "l1A^ 153/+" P
way and to the jointer.
J* frontbasetrim 3/+" 1y2" "143/q" P
K* sidebasetrim 3/+" 11h" 153/q" P

Project 2z
MITERSAW WORKSTATION
As with most workshops, the mitersaw
serves as one of the busiest tools in
Mark's shop, and it neededa permanent
home. Mark needed additional work
surfaceand storagecapacity.Theseneeds
were met by installing a mitersaw work-
station along the 18' right-hand wall
(looking in from the garagedoorway).
The mitersaw workstation was centered
on the wall to allow maximum cutting
length to the left or right.
TWo Versa-cabs(Drawing1) installed
as base cabinets support the counter-
tops on either side of the mitersaw.
Wall cleats(D) were screwedinto studs
endsupport
crossrails
3/c" 31/2" 26'
3/c" 3Y2"
M outerlegs 41'
to support the outside end of the left N longlegfillers 3/q" 3Y2' 30'
countertop and the countertop back. If O shortlegfillers 3/+' 31h" 4"
you don't carry the countertop all the * foronecabinet.
Quantity
way to the corner, build the end sup-
I3y4-4',depending
onmitersaw
tableheight,
port (Drawing2). Either solution will
Materials plywood,
key:BP-birch P-pine,P0-poplar.
provide firm support.
Mark's shop had an uneven and sloped
concretefloor that required a little extra underneath the countertop (Drawing 2).
effort when setting the base cabinets. Next, a 4S"-long level line was drawn
To solve the problem, the position of from this mark. We lengthened the level
the base cabinets was located, and then line acrossthe entire wall with a chalk
measured up from the highest spot on line, and used the mark to install the
the floor. The top of the wall cleat was wall cleats. Becauseof this floor varia-
positioned 41" from this high spot to tion, the height of the end supportswas
allow the Versa-cabbase cabinets to fit adiusteduntil level with the line.

woodmagazine.com
47
 With the countertops installed but
not attached to the base cabinets, the
base cabinets were positioned and
leveled to maintain 2712"between the
sidesof the cabinets.This spacing left
a 3/+"gap between the side of the base
cabinet and the countertop side edging
(C). The gap left spaceto maneuver the
mitersaw platform supports (F) into
the correct position. We then attached
the countertops to the base cabinets
through the top cleats(H).
We placed a long straightedgeacross
both countertops to act as a guide
while leveling and plumbing the base
cabinets. For Mark's shop, one of the
bottom cleats (I) was shaved, and we To align the top surfaceof the mitersaw Setthe depth of the front of the mitersaw
added cedar shims where needed to with the countertop,we useda combination platform first by slidingthe platform supports
even up cabinets. Nails were driven squareand measureddown from Mark's (F)behindthe countertopedging (C).Clamp
through the cabinet bottom to hold mitersawtable. We then trimmed the the platform supportsto the neighboring
width of the platform supports (F)to cabinet sides.Setthe depth of the platform's
the shims and cleats in place. We se- that measurement,less7+",to provide back,and screwit in placeat that location.
cured the bottom of the cabinetsto the adjustabilityfor the platform positioning Returnto the front, recheckthe depth, and
floor by applying concrete-compatible without sacrificingstrength. finish screwingthe platform in place.Add the
silicone to the trim parts (J, K) before mitersaw,and recheckthe height.
nailing them in place. The end result:
a perfectly level countertop.

p snerr-GooDs
RAcK

6" strap
3 A ax 1 1 / z 'F . H . hinge
boltsand nuts.
#8 x 3" F.H.wood screws
R=3" centeredover wall studs
(
71/a"
#12 x s/e"
Door hook and eye screw F.H.screw

The lower (containment)stretcher(B)of

the sheet-goodsrack is held in placeby a 6"
strap hinge bolted to the rack'sside and a
hook and eye at the other end.
#8 x 1t/2"F
Project 3: sHEEr-GooDs
RACK
Every shop needs a place to store sheet
goods, including sheet-good scraps. Ss/a' 314
Mark's shop is no exception. However,
the limited ceiling height (7' 9") of
sides 3/l' 48'
Mark's garageshop required some spe- we designed a "swing-out" contain-
cial considerations.To meet that need,' B stretchers 3/c"
ment stretcher (B) that improves the 31h" 99"
we built a rack for horizontal storage accessibilityof the rack. C bottom 3/q" 53/q" 97Y2" P
with enough spaceinside for 97"-long The trough at the bottom of the
Materialkey:
P-pine.
sheetsof MDF (Drawing3). rack contains the materials in a de-
Becausethe wall-mounted Versa-Cab fined and generous space. The rear sections of heavy-duty cardboard
above the rack prevents placing full stretcher at the top allows you to firmly carpet tubing (shown in the photo on
sheets in the holder by lifting them mount the rack to wall studs. For added page44 and at left) to the sidefor contain-
over the lower containment stretcher, versatility, we also mounted two short ing dowelsand other thin-strip material.

48 Best-Ever Home Shop ldeas 2009

 s/q"rabbet 7e"deep
Wallstud 1/q"groove Roller-catch
strike
3/8"deep
#8 x 3" F.H. 3/q"from
wood screws back edge

@ wnu cABINET Roller

catches
30"
Roller-catch
strike

/e" round-overalong
outsideedges
Shelfpin

223/e"
II
1/q"groove
s/e"deep
3/q"trom
back edge
l
Full-overlay
hinge

231/q'

sides 12"
B top and bottom 3/+" '12" 23y4" MDF 2
Proicct 4: wnll cABlNEr C back th" 231/a" 291h" HB
D doors 3/4" 1115/$tt 30"
Most shops require at least some MDF 2
degree of protected storagewhere dust E* shelves 3/+' 101/+" 223/e" MDF 2
can't enter.This wall cabinet meetsthat F* shelf edging 3/q" 1y2" 223/a" PO 2
need simply, affordably, and quickly. G wallcleat 3/c" 4" 221h" PO 1
Cut the parts shown in Drawing4to - Optional
shelf
andshelf quantity,
edging depending
onneed.
size.If you're making a pair of cabinets
Two wall cabinetswere mounted 18"above W*a MDF-med
ium-density
fiberboard,
that support shelving in between, first
the countertop besidethe mitersawwork- HB-hardboard,
P0-poplar.
determine which cabinet sides will
station. The 18" spacebetweenthe cabinets
allowsthem to supportadjustableshelving support the shelving. On these sides, way, the holes can house a shelf pin on
for added storage. drill the holes for the shelf pins all either side.Next, drill /t" holes 7s"deep
the way through, where shown. This on the interior faces of the opposing
cabinet sides.
Assemble the cabinet carcase and
Where the money went dry-fit th'e Y+"back in place to ensure
All in all, the workover at Mark'sworkshop was limited to a budget of 51,000, that it's not so tight as to risk splitting
makingthe changesaffordable.Therewasevencashleft over.Here'swhat had to off the lip behind. Then, glue the 7e"
be purchased to put thingsin order: backing into the /e" grooves, and glue
and nail the sides, top, and bottom
Bandsawmobile base s106 together. To ease assembly and hang-
Jointermobile base 106
ing, align and predrill the hinge holes
for the doors, but don't mount the
Tablesawmobile base 80 doors until after hanging the cabinet.
32"medium-densityfiberboard(MDF)(5 sheets) 142 Install the cleat on the cabinet by using
7+"hardboard (4 sheets) 47
glue and nailing into the ends of the
3/q"birch plywood (3 sheets) cleat and into the cabinet sides.
108 Using 3" deck screws,we installed the
7+"poplarand pine 76 cabinets to wall studs, where shown,
Tritonlumber rack 82 checking for level. Il
Assortedhardware 84 Written by Mike Satterwhlte
Profectdesigns:Kevin Boyle
TOTAL Ssgt lllustrations:Roxanne LeMoine; Lorna fohnson
Photographs:Richard McNamee

woodmagazine.com
49
 cheap as dirt, solid as a rock
Best-Ever Home Shop ldeas 2009
50
 Corner or straight bench:
itt your choice
Thisarticle
shows youhowtomake thecornerbenchshown
youprefer
opposite.lf astraight
bench(shown atleft),follow
the
same instructions,
butmake tworightbases(A),twoends (C),and
thelongtop(D).
0mitthebiscuit slots (D).
in Use thecutouts from
(A)tomake
therightbases twolongbase shelves(F).Fityour
straight
benchwithoptionalshelvesateachendbymaking thelong
(H,l) andthelongandshortshelves
andshortcleats (J,K)fromthe
extraparticleboard.

Forthe itemsneededto build this project,see

the MaterialsListand Cutting Diagramon poge 55.

Cut out the bench parts
! femporarily fasten 4-tong 2x4
I extensions to a pair of sawhorses,
and lay a sheet of 3/+"particleboard
across them. The extensions will
support both the workbench parts
and the cutoffs as you work. Referring
to the Materials List, mark the width
of the right base (A) on the sheet.
! Measure the distance from the
-right edge of your circular saw's
shoe to the right side of the blade.
Lay a second sheet of particleboard
ontothe first, offsetting it from the A
marked width on Part A by the
distance you measured on your
circular saw. Clamp the second sheet
to the first, and cut part A to width.
I Using the cutoff from the first part
J A as a straightedge,clamp it to the
other sheets(PhotoA), offsetting it your
measured distance from the Darts'
dimensions.Cut the rest of the puttt A,
B, C, D, and E to size.
Afuy out the end and center cutouts
'lon the right bases(A) and left bases
(B) (Drawing1). Drill blade-start holes
and jigsaw the cutouts, or seethe Shop
Tip on page 55 for making inside cuts
with your circular saw.
(frue up one edge of the four base
dcenter cutouts. Cut the upper and
lower long base shelves (F) out of the
cutouts from the right bases(A), and the
upper and lower short base shelves(G)
Usingthe edgeof a secondsheetto guideyour
out of the cutouts from the left bases(B) saw,cut the first part A to width. Savethe cutoff
(Drawing1). asa straightedgefor cuttingthe other parts.

Form interlocking slots Rout, drill, slot,

With the slot template (painted green for
clarity in this photo) guiding the flush-trim
bit's pilot bearing, rout the slot in the end (C).
I Vat<ethe slot template (Drawingt)
I from leftover particleboard. To cut
the slot as accurately as possible,use a
iigsaw and straightedge.Mark the out-
side corner, where shown.
f Retrieveone of the ends (C), and
Sclamp the template to it, aligning
the template's marked corner with
one of the part's corners. Chuck a 72"
flush-trim bit into your handheld
router, and rout the l%o"-wide slot
(Photo B). In the same manner, rout
the other three slots (Drawing1), flip-
ping the template as needed.
I Using the slottedend (C) as a tem-
rJplate, clamp it in turn to the other
part C and the two left bases(B), and
rout the slots into those parts, where
dimensioned (Drawing1).
finish, and assemble
Chuck a le' round-over bit into
!
I your handheld router, and rout all
edgesof parts A, B, C, R and G. On the
long top (D) and short top (E), rout all
the edges except where the two tops
butt together, where indicated (Draw-
ings1 and 2).
S/sz"countersunk shank holes
fnriU
Sinto parts D, E, R and G (Drawing1).
I nOlust your biscuit cutter to center
J a slot in the thickness of the par-
ticleboard. Plunge mating slots into
parts D and E, where shown. To keep
the tops aligned, insert #20 biscuits
without glue into the slots.
protect the bench from
Al"
Tmoisture and grime, apply two
coats of finish to all the parts before
assembly.Apply a third coat to the top

woodmagazlne.com
51
 Iennrs vrEW

rI Note: Alledgeshave
38" I
26',
t/e"round-overs,except
where indicatedon o
END
parts@ and @.
(2 needed)
II
L
6"

I tglr6'.
StsAa' )"/'tu"
l-+1
, I,s
lr - [f-toYr"--1 -l
._l t- 37/a"

t I o
I
26"
25" LONG BASE SHELF
(2 needed)

II L /-i 37/e"

i1
I-i 96

96"
5/32 shankhole,countersunk i\ 1.-t
\ lll

II 37/a"

25', @
SHORTBASESHELF
I (2 needed)
I
L -l
37/8'

*lrt 8" | 8" | 8" l{15,

:-l No round-over
for30"1j

No round-overon this end

13/.16" 51s/ra"
I
I
-]t t r-f
3"
8"

8"
I
24',

8"
l_
-+1 10" F-
SLOT TEMPLATE

Best-Ever llome Shop ldeas 2009

52
 t

flexeloDEDvrEW

No round-overs
*==_ #8x2" F.H.wood screws

4-#20biscuitsfor
- countersunk
tiign;erii
(Donotglue.)
^r/s"round-overs

%------lleooes

#8 x 11/2F
" .H.
wood screw
7
23Y4' t/a"round-overs
alongalledges

# 8 x 1 1 / q 'F . H .
#8 x 2" F.H.
wood screw
wood screws

/e" round-oversalongall edges

t/e"round-overson front edges only

after assembly.To keep the cost down, /ou can use any house paint or
finish. (We used satin polyurethane.)
(Witfr the finish dry, enlist a helper and assemblethe bench (Draw-
J ing 2) and in the four photos on page 54.Take care in handling the
bases(A, B).The 6"-wide "rails" are somewhat fragile until the basesare
interlocked and supported by the ends (C) and shelves(R G). Using the
previously drilled shank holes in parts D, E, R and'G as guides,drill
pilot holes into their mating parts, and drive in the screws.

Add the optional shelves

I fo add shetvesto the ends of your workbench (Drawing2 andPhoto
I C), cut the long and short cleats(H, I) and shelves(J, K) to size.
ya"round-overs onto the front edgesof the shelves.DrilI s/zz"
lnout
lcountersunk shank holes through the cleats.Locate the holes L" in
from both ends of each cleat,then evenly spacetwo more holesbetween
those. Apply two coatsof finish to the shelvesand cleats.
I Using the shank holes in the cleatsas guides, drilt pilot holes into
rf the bases(A, B), and screw the cleats in place. Position the long
cleats so the long shelvesare flush with the bottom of the bases'end
cutouts. Position the short cleats to accommodate the height of the
items you plan to store. You may want to make more than one short
shelf for each end. Lay the long shelvesonto the long cleats.Drill pilot
and countersunk shank holes,and screwthe long shelvesto their cleats. After assembly,
installoptionalshelvesto
Lay the short shelvesinto place. Jl furtherexpandstoragespace.

woodmagazine.com 53
 I n t e r l o c kt h e s l o t s i n t h e l e f t b a s e s( B )w i t h t h e r i g h t b a s e s( A ) . I n t e r l o c kt h e s l o t s i n t h e e n d s ( C )w i t h t h e b a s e s .A d d t h e l o w e r b a s e
s h e l v e s( F ,G ) .

D r i l l p i l o t h o l e s ,a n d s c r e wt h e u p p e r b a s es h e l v e s( F ,G ) P o s i t i o nt h e l o n g a n d s h o r t t o p s ( D , E ) .D r i l l p i l o t h o l e s ,a n d s c r e w
in place. them in place.

Meet the designers

fa Chad Veach, far left, a professionalengineer, and

Carneron Campbell, an architect teaching at Iowa
StateUniversity,collaboratedon this entry for Best
Original Workbench Design in WOOD@magazine's
GreatAmericanWorkshopsContest.

,ffiffi
ru
By replacinglegswith interlockingpanels,their
design elirninated the problem of making rigid
connections between the benchtop and legs. In
the corner configuration, each section reinforces
the other, which increasesworkbench stability.
Chad and Carneron also included a continuous
T* overhanging edge for clamping and shelvesdeep
enough to storelargetools or shop materials.

ff d
Usingonly a circularsaw,drill, and jigsaw(altern-
ative to a router),they built the original bench in
half a day.

54 Best-Ever Home Shop ldeas 2009

 1

Cutting Diagram

s/qx 48 x 96" Particleboard

(2 needed) 3/+x 48 x 96" Particleboard

@ @

s/qx 48 x 96" Particleboard

(2 needed) s/qx 48 x 96" Particleboard

3/+x 48 x 96" Particleboard

Materials List
Making inside cuts
with a circular saw
A rightbases 3/+u
To get arrow-straightedges when
B leftbases 3/qu 38"
m ak ingins idec u ts ,l i k eth e o n e sn e e d e d
to removethe cutoutsin the workbench C ends 3/qu

D longtop 3/q' 30"

bases,useyour circularsary a straight-
edge, and a t ec h n i q u ec a l l e dp l u n g e - E shorttop '/4
66',
cutting.Here'show. F lonqbaseshelves 3/i' 25' 477/e"
Measurethe offset from the edge G shortbaseshelves 3/+' 25" 417/e" P
of your circularsaw'sshoe to the side H longcleats Tc' 11/z" 231/+' P
of the blade.Clamp a straightedgeto saw, and lower the blade through the I shortcleats 3/qu 11/2" 161/2" P
the part, offsettingit that distancefrom part, asshownin the photo above. J longshelves 3/+' 161/z' 23t/i' P
the cutout'slayoutline.With the saw's Keepingthe saw'sshoe againstthe K shortshelves 3/q' 161/z' 161/2" P
depth adjustmentloose,raisethe blade straightedge,continueyourcut,stopping
Material keyl P-particleboard.
abovethe part'ssurface.Startingat one at the next corner'sintersectinglayout
ins idec or ner ,h o l d th e s h o e a g a i n s t line.Repeatwith the otherthreesidesof 5upplies:#8x1%"
flathead
woodscrews,
#8x1h"flathead
woodscrews,
#8x2'flathead
woodscrews,
#20biscuits.
the straightedge, and swivelthe blade the cutout.Finishthe cutsat the corners
guard out of the way. Switch on the Bits: %"flush-trim,
%"round-over
routerbits.
with a handsaw.

woodmagazlne.com
55
 ^il::l}ffi?:Tb0l
Carousel
We packedall thesetoolsand bits-l35 piecestotal-into
storageunit that takesup just 2x2'ofwall
an instant-access
Thinkof how it will helporganize
space. yourshop!

Rlec
ects Editor

"# Ftr#-*fr**
E-odb_-\"
f. Eb{&.!t

-*,WLt-rqil &t ft:,$:

g E 111
t - b--?-t I 7

,-'*+\;r&*ffi
- {h-* --rd+}Fa*'
. a
{
|}
s

{orHff'f'T!11111\ t
fr

fl
' l 1;' tTt'vtl i
# l d/ #t d$$#d
,Jg g s t $ }uu1
4-l*
d 't fl
q*

, dts ,/l-
i

Spinthe entirecarouselto accesseach ...and rotate eachwing to accessboth

of its six tool-holdingwings ... of its sidesand the centercolumn.

56 Best-EverHome Shopldeas 2009

flroe ANDBorroM

63/q
181/2"
7sz"shankhole,countersunk
*'fr*"'\
s/ez"shank hole.

I
# 8 x 1 1 / z 'F . H .
wood screw
I cnnousEl
-

l-
#8 x 11/qR

T:o
' .H.
screw
on,topof @ and bottomof@

l
16"
7/a+"pilol
1" deep

IF
t/aq"pilol hole, centered

7se"shankholein
parts@and@,
Locatibnof parts@
l 'Til
1il.

tll
Forthe itemsneeded
redrill tzlo+"hole to build this project,
in part@ seethe MaterialsList
and Cutting Diagram

l_u
t/q" hole
on poges58 ond 59. g/a"deep
centered
on part@
rfhis handy shop helper is the brainchild of reader
I Jim Maw of Kleinburg, Ontario. His ingenious
I design earned the prize for WOODo magazine's # 8 x 1 1 / z 'F . H .
wood screw
"Best Storage Solution or Organizer for Power Tool t/q" dowel
z/a" long
Accessories"in our Great American Workshops Contest.
We liked Jim's organizer so much that we obtained the 1/q"flal washer
design rights from him, then built one ourselvesso we
can presentthe plans here.

Start with the carousel

I fo make the top (A) and bottom (B), stick together two
I Yzx76x787z" piecesof plywood with double-facedtape.
Mark the top one "A" and the bottom one "B." Referringto
Drawing1,lay out the hexagonalshapeand location of the
holes on the top (A). Bandsawcloseto the line, then sand
the top and bottom to shape.
fi,iJ.',1;,,j;'-l ri 7ez"shankhole,
countersunkon
bottomface

lOritt the six 7rz"holes around the perimeter,and the

jfour 7sz"holes around the center through both parts.
With the indexing
Countersink the center holes on the top surfaceof part A markson the top (A)
and the bottom surfaceof part B. Drill the 1" hole at the and bottom (B)facing
center.Make indexing marks acrossone edgeof the joined upward, use spacers
parts for later reference.Separatethe parts. Enlarge the to positionthe core
paralleltotwo sides.
perimeter holes in the bottom (B) to tzk+".
Measurein from the
Q Cut the core sides (C) to the size given on the Ma- points,centering
rJ terialsList. Glue and clamp the core together in the the core.
configuration shown on Drawing2. Make surethe ends are
flush. Drill pilot and countersunk shank holes where
shown, and drive in the screws.Removethe clamps.
Ato position the core between the top (A) and bottom
"l1f;, cut two 3/tx5lzx73Vz" spacers.Make the spacers
from poplar. [You can rip them later to 5" wide for the
brackets(G).1Clamp the corebetweenthe top and bottom
(PhotoA). Using the countersunk shank holes in the top
and bottom as guides,drill pilot holes into the ends of the
core, and drive in the screws.

woodmagazine.com
57
 #B x3/q" F.H. wood screw ---\

'1#:A
T s z "s h a n k h o l e , c o u n t e r s u n k = - i

6rR
A t t a c ha n a u x i l i a r y
extensionto your
m i t e rg a u g e ,c l a m p
on a stopblock,and
cut the notchesinto
the back(F),making
severalpasses.
p exeloDED
vrEW
# Bx 2 " F . H .
wooo screw

Y
Add rotating panels 7sz"shankhole,
countersunk
I from 7+"tempered hardboard, cut the six panels (D) to 21/zu
I the size listed.
)Cut the panel cleats (E) to the size listed. Mark, '-tloa"
pilot holei
tbandsaw,and sand the r/2"radrr on their ends (Drawing2).
For the six upper cleats, dtlll 7/o+"holes, centered on the
length and the 72"thickness, where shown. For the six lower
cleats, drill centeredT/q"holes 7a" deep. Cut six Vl" dowelsT/s"
long, and glue them into the holes in the lower cleats.
and clamp the cleats (E) to the panels (D), where jtl+" lag scre
QCtue
rJshown. Set the panels aside. i 3%" long

)
Make the wall bracket
I
Laminate two .t/+x51/qx22r/2" board.s for the back (F). \41/a"tlat
I With the glue dry, joint one edge and rip and crosscut it washer
to size. Install a 3/+"dado blade in your tablesaw, and form
the notches for the brackets (G), where dimensioned on
Drawing3, as shown in Photo B.
fRetrieve the boards used earlier for spacers, and cut the
B
Sbrackets (G) to the size listed. Mark the angled cuts, I
where dimensioned on Drawing3. Bandsaw, and sand to the
-*-*b
penciled lines.
the lower arm (H) and upper arm (l) to size. Using a 1" hole 1/2"deeo
QCut
JForstner bit, drill the 1" hole 1/2"deep into the lower arm,
and the 1" hole in the upper arm (Drawing3). The holes are # 8 x 1 1 / 2F
" .H.
wooo screw
centered on the widths of parts H and L
lllCtue and clamp the brackets (G) to the back (F). Drill
'Tpilot
and countersunk shank holes, and drive in the
screws. Remove the clamps. In similar fashion, glue, clamp, z/J+'pilot
ire (
and screw into place the lower arm (H) and upper arm (l). s/q" deee 7/aq"pilol hole 7+" deep
) sAz"shankhole,
#8 x 11/z'F.H.wood screw
countersunk
Finish and mount
the carousel
! Sand all the parts to 220 grit, easing Cutting Diagram
I the edgeswith a sandingblock. Apply
the finish of your choice.We brushed on
two coatsof satin polyurethane, sanding
lightly with Z2O-gritsandpaperbetween
coats. You can also prime and paint to
match existing cabinetry.
r/+x3r/+x37/+"
) Cut tw o h ardboard blan ks
jfor the washers(J).Marktheir centers, t/zx 24 x 48" Birchplywood 1/qx 24 x 48" Hardboard
and draw 3"-diametercircles.Drill cen-
tered 1" holes,and bandsawthe washers
to shape.
QCut the cover plate (K) to size.Drill
3/qx 51/zx 96" Poolar
rJcountersunk shank holes at the four
corners(Drawing3). @ [@ @ @ @
3 / q x 5 1 / zx 9 6 " P o p l a r

58 Best-Ever Home Shoo ldeas 2009

 lwitn the finish dry, drill 7+"holes
'tthrough the wall-bracket back (F). Adding your tools and bits
Transfer these locations to the wall at a
stud location. Drill pilot holes into the
stud. Now, fasten the wall bracket with
V+"Iag screws3lz" Iong.
(Cut a 773/+"-long piece of 1" dowel.
JPlace the carouselbetweenthe upper
and lower arms. Slidethe washers(J) into
placebetween the carouseland the arms.
Drop the dowel in from the top, seatingit
into the hole in the lower arm (H). Center
the cover plate (K) over the upper arm's
dowel hole. Using the shank holes in the
cover plate as guides, drill pilot holes, Arrangeon the panelsthe bits or tools
and drive in the screws. you wish to store in the carousel.Leave
enough clearancebetween itemsto allow
1lArcange your tools on the panels, for easyhandling.
lfand make the holders. For the
mounting methods we used, see the
sidebar,right.
JWittr the holders now attached to
J the panels, slip washers over the
bottom cleats' 7+" dowels, and tip the
panels into place, seating the bottom
cleat dowelsinto the holesin the carou-
sel'sbottom (B). Slide a #8 flat washer
between the top cleat and the carousel
top (A), where shown on Drawing2. ow many of the hundred-plus
Securethe panels to the top (A) with flat small items that clog the
washersand roundhead screws.Attach drawersin your shop can you
the tools and bits. .l fit onto your carousel? To plan the After fasteningspring-cliptool holders
to the panelwith machinescrewsand
Written by f an Svec with Chuck Hedlund arrangement of your tools and bits, nuts, snapthe tools into place.
Projectdesign:f im Maw; Kevin Boyle place the panels (D/E) on your work-
lllustrations:Roxanne LeMolne; Lorna fohnson bench, and position the items, as
shown in PhotoC. You can store items
Materials List on both sidesof each panel, and also
on the core.
Note: For the panels to rotate, there
B bottom l/^t
must be clearancebetween each panel
16" 181/2"
3/4'
and the core.No bit, tool, or tool holder
C coresides 41/q" 15"
1/q'
may protrude beyondan imaginary 8'-
D panels 71/c' 147/d,
diametercylindeq centeredon the pqnel.
E panelcleats 1/
f2
ll
vi' 7y4' 12 Items storedon the coremust not inter-
F* back 11/2' 5u 221/c' LP
ferewith thepanels' rotation.
G brackets 5u 131h" For tools that can hang from pegs,
H lowerarm 5u 13Y2" mark the locations, and drill holes Toavoidhavingto makeintricate
I upper
arm 3An J tf through the panels. Insert machine parts,
holdersfor smallor odd-shaped
J* washers Y4' 3"diam, screws,and thread on nuts, as shown mounta magnetic toolholderwitha
on Drawing4. machine screwandnut.
K coverplate Y4' 3" 3u
*Parts
For drill bits and other tools that fit If some of your tools have their
initially
cutoversize.
Seetheinstructions.
into round holes, measure the bit or own small casesor holders, you may
plywood,
Materlals key: BP-birch P-poplar,
H-tempered tool center-to-center distances, and wish to mount them to panels. To
hardboard, poplar.
LP-laminated
transfer these dimensions to blocks of permanently attach the case, drill
Supplies:#8x7i'flatheadwoodscrews (4),#8x1%" flathead
(32),
wood. Drill holes slightly larger than holes through it and the panel, and
woodscrews #8x2"flathead woodscrews (3),#8x'17c"
roundhead
woodscrews (i2),'/i'flat
(6),#8flatwashers the bit-shank or tool diameters. fasten with machine screwsand nuts.
(6),1/t"
washers lagscrews 3%"long(2),7a"
dowel,1"dowel. Clamp the holders to the panels.Drill For removable attachment, adhere
Bladesand bits: Stack
dadoset,1"Forstner
bit. pilot and countersunk shank holes Velcro tape to the case and panel.
from the opposite side, and drive in Other easymounting methods are to
Source screws.(We didn't glue the holders in use spring clips, as shown in PhotoD,
Tool Holders:Lookforspring-clip
toolholders
andmag-
atyourlocalhardware
netictoolholders store,
homecenter, place, just in case we ever need to and magnetic tool holders, as shown
orwoodworking specialty
store. rearrangeour panel layout.) in PhotoE.li

woodmagazlne.com 59
60
 I
3" rabbet
s/q"deep
3" rabbet Isrus
I Overalldimensions: s/+"deep
Toolcabinet,273/+u wide x 253/te"deep
x 852e"high.
Toolbase,2"17/s" widex 2213/te"
deep
x 367h"high. t/+"holes
I Inexpensive materialsareeasyon the s/a"deep,
wallet.One-stopshoppingfor most centered
partsand simpleconstruction make
thisa greatweekendprofect.
I Benchtop toolsbolt to traysthatfit 3/ro"groove
overthe top of the tool base.For 3/8"deep
storage,lift the tool andtrayoff the 3/a"trom
base,andslidethem intothe cabinet. outside face
I Rollthe cabinets out to work,awayfor
storage.Dual-locking provide
casters
both mobilityandstability.SeeSource
on page64.
Skill Builder
I Makea simplejig to cut rabbetsfor TOOL-BASESTILE
(Leftfront insideface shown)
half-lapjointsin multipleoversize
parts
at once.
3/ro"groove
s/e"deep
3/q"tfom
Make the case sides outside
I Setect straight 2x4s with as few face
I knots aspossiblefor the tool-cabinet
stiles (A), rails (B), and stretchers(C),
and the tool-base stiles (M), rails (N),
and stretchers (O). Clean up the 2x4
faceswith a random-orbit sander.Then,
rip and ioint both edges to the 3" fin-
ished width. NoW cut the parts to the
finished lengths (MaterialsLtst,page64).
afuy out the stiles(A, M), rails 18,N;,
Sand stretchers(C, O) in the arrange-
ments shown (Drawings2 and 3). Then
mark the locations of the rabbets,
notches,and grooves(Drawings1, 2, 2a,
and 3). Cut the rabbetsand notches. Set
the stretchers aside. Now, making two
passesover the tablesaw blade, cut 3/ra" Markholelocationson maskingtape appliedto
3" F--
grooves7a"deep in the stilesand rails for a perforatedhardboardstrip.Usingthe stripas
a guide,drillthe holesinto the stiles(A). TOOL-CABINETSTILE
the panels (D, P). (Leftfront insideface shown)
Note: We used%c"perforatedhardboardfor
the panels (D, P). For /e" perforatedhard-
board, cut the groovesin one pass with a
dado blade.
let wood screws
I Cut the panels (D, P) to size. Dry- do the clamplng
J assemblethe sides(A/B/D and M/N/
P) to check the fit. Make any necessary Here'sa way to cut down on the
adiustments. Then, glue and clamp the c l a m pi ng ti me and number . of @,@
sideswith the smooth face of the panels clampsneededto glue up the sides
facing out. Check the sides for square. (Al Bl D and M/N /P ). A ftercl ampi ng
To speed the side glue-up process, see up the first side and checkingfor
the ShopTip at rtght. square,drill a screw hole centered
fWitn the sides assembled, drill y+" in each half-lapjoint. Then, drive
Tholes through the tool-cabinet screws, as shown at right, remove
stiles (A), and /r" holes 7a" deep in the the clamps, and set the assembly
inside faces of the tool-base stiles (M) aside.NoW your clampsand bench
(Drawings1,2, and 3, PhotoA). The photo space are free for assemblingthe
shows drilling the holes into the tool- next side.
cabinet stiles.

woodmagazlne.com
61
 #8x3/c"F.H.woodscrew--1
b-

Countersunk
shankhole -

3/ro"grooves 7e" deep

3/+"ffom outside face

lCut the tops (E, Q) to size, and rout

2t/q" rabbets 3le' round-overs along the edges
z/q" deep (Drawings2 and 3). Then, clamp the tops
to the cases,drill screw holes, and drive
the screws.Align the tool-cabinet top (E)
flush with the back stretcher(C), centered
#8 x 11/z'F.H.
side-to-side and overhanging the front
I
/ wood screw stretcher. Align the tool-base top (a)
t./ flush with the caseall around.
I
1/e"
Q Cut the bottoms (F, R) to size. [Make
round-over
rJthe necessaryadjustment for Ve"per-
forated hardboard panels (D, P).1 Draw
the corner notches (Drawings2 and 3),
and cut them out (PhotosC and D). Rout
round-overs, where shown. Apply glue to
the top edgesof the lower stretchers (C,
1tl2"rabbets O), and clamp the bottoms in place.Drill
3/4" deep screw holes, and drive the screws.
Afuy the casesfacedown. Cut the caster
Tblocks (G, S) to size, and glue and
clamp them in place (Drawings2 and 3).
3/ro"grooves (Cut the backs (H, T) to size. Center
wood screw 2t/q"rabbels7+"deep 7e"deeP3/+"trom rrthe backs side-to-sideon the cases,
outsideface and clamp them in place. Then, drill
3/+
x 3"notch
Assemble the cases screw holes and drive the screws.
I Retrievethe stretchers(C) and tool- brace, see wocldmagazine.cr>rn/brace.)
I basestretchers(O). Usingright-angle Then with the four cabinet stretchers Add trays, shelf, and door
braces to align the stretchers, attached to the first side,add the second I for the tool cabinet, cut the tray
glue and screwthem to one side (A/B/D side (PhotoB), and glue and screw it in I panels (I) to size, and for the tool
and M/N/P) (Drawings2 and 3). (To place. The photo shows adding the base,cut the shelf panel (U) to size.Then,
dbwnload a free plan for a right-angle second side to the tool cabinet. cut the short edging (J), long edging (K),

t,
&
t
t
-*
@,@ .*-/
Handsaw

Long cut made

with a portable
circularsaw

With the stretchers (C)attached to the first side
(AlBlDl, apply glue to the stretcher rabbets,
and position the second side.
@,@
E square
To makethe long cuts,adheresandpaperto a
speedsquareto keepit from slipping.Thenuse
it to guideyour portablecircularsaw.
E
After makingthe long cutswith a portable
circularsaw,finishcuttingthe notcheswith a
fine-toothhandsaw.

62 Best-Ever Home Shop ldeas 2OO9

...1 -!

I
#8 x 11/z'F.H. wood screw--\t
217/a" .s_______-_

ka----

#8 x3/c"F.H.wood screw
t/e"round-over
\
cAsE
ftrool-BAsE
2lq" rabbet s/+"deep

-1
# 8 x 1 1 / z 'F . H .
wood screw

3/ro"grooves 31"

I
s/a"deep 3/+"tlom
1/2" rabbets7+"deep
outsideface

I
I / tt)
2/c" rabbel 3" rabbet
s/q"deep s/+"deep
<-#8 x 2" F.H.wood screw )
-3/q x 3" notch

!flrnnv suPPoRrs AssEMBLY

@roor cABTNET

and shelf edging (V) to size. (We ripped the hinges and handle (Drawing5). Now,
these parts from the edge of 2x stock. lay the tool base on its back, and fasten
You also can cut them from %"-thick the door to the case(PhotoE).
stock.) First, glue and clamp the short
edging to the trays, flush at the top and Apply finish and assemble
ends, and then add the long edging I Removethe door from the tool base,
fDrawing ). Now, glue and clamp the I and the hinges and handle from the
shelf edging to the shelf panel (Drawing door. Removethe castersfrom both cases.
5). Rout ys" round-overs along the top Examine all the parts and assemblies,
edgesof the trays and shelf, and finish- and finish-sand where needed. Then.
sand them. s/ro"hole,centered
3/+"-widestrips from a 2x4, and.
?ntp
Scut the tray supports (L) to size.
Then, drill a %0"hole at each end (Draw-
ing 4a). Finish-sandthe supports. 't/q"
carriage bolt 2r/2" long --"
r
2 my the tool-cabinet and tool-base t
rJcases on their backs.Then, position *l*asher
the casterplates Yq"from the caseedges, t/+"wing nut
and using the holes in the plates as
guides, drill screwholes. NoW screwthe
castersin place.
fCut the tool base door (W) to size,
Tand rout %" round-overs along the
front edges.Then, drill holes and attach

woodmagazine.com
 Rehang the door. Now insert shelf sup- Materials List
ports into the tool-base-stile(M) holes,
and install the shelf (U/V).
stiles 11/z'
! ltace each benchtop tool on a tray, '11/z'
.Jgenerally centered side-to-side,and B rails 3' 221/z' P
as close to the front edge as the tool C stretchers 11h' 3u 27',
allows. Then, using the bolt holes in the D panels 3hc' 183/+ 743/i' PH 2
tool as guides, mark the hole locations E top 3/i' 25' 273/q' MDF 1
on the tray. Remove the tool and drill 3/d'
F bottom 24' 251/e^ MDF 1
the holes, countersinking them on the
G caster
block 11/z' 3u
bottom face of the tray. Fastenthe tool
H back 3AC' 261/z' 80'
with flathead bolts, washers,and nuts.
Position the tray supports (L) in the I traypanels 3/l' 221/q' 22W' MDF 4
/
'ftool
Position the door 27/a"lrom the stretcher (O)
cabinet, spaced vertically as J shortedging 3/i' 11/2. 221A' P
bottom edge and centered side-to-side. Screw needed, and fasten them with carriage K longedging 3/i, 11/z' 233/4' P
the hinges to the stile (M). bolts, washers,and wing nuts (Drawing traysupports 3/i' 11/2"
4). NoW slide the trays, with tools
ease any sharp edges with a sanding attached, onto the supports.I
stiles 1t/l' 3u 31"
block. Now apply a clear finish. (We
applied two coats of Minwax Antique Written by fan Svec with f eff Mertz N rails 11/z' 3u 203/e" P
Projectdesign:Kevln Boyle
Oil Finish, sanding lightly with 220-grit 0 stretchers 11h" 3" 217/a"
lllustrations:RoxanneLeMolne; Lorna fohnson
sandpaperbetween coats.) P panels 3/ti, 16s/a" 253/c, PH 2

lneinstall the castersand the hard- O top 3/cn 217/s" 21t/e' MDF 1
3ware on the tool-base door (W). R bottom 3/l' 20" 217/s' MDF 1

Tray from tool cabinet 5 casterblocks 11/2" 3u 4',

T back 3/i'213/s" 31"
Broor BAsE
AssEMBLY Self-closingoverlayhinge
U shelfpanel 3/i' 183/c" 195/s' MDF 1
V shelfedging 3/l' 1t/2" 193/i'
t/e"round-overalongoutsideedges 3/i'
W door 193/c" 253/s" MDF 1

3" wire handle -----[ Materialskey:P-pine, PH-perforated MDF-

hardboard,
medium-densityfiberboard,
H-tempered hardboard.

"fl
Suppfies: #8x3/i',
#8x1V2",
#8x2"flathead #12x1"
woodscrews;
panhead (32);
screws nuts(12);
7l''wing (12);
%"flatwashers

,,j
t/rx2l/t' bohs(12);
carriage self-closing
overlay (2);3"
hinges wire
handle;%" supports
shelf (4).
round-over
Bits:7a" router
bit.%"and%C'drill
bits.
Source
18%"- r/a"round-over Casters:4"dual-lockng plate
swivel castersno.36992,510.49
J ea.Hartville
Tool. orgoto hartvilletool.com.
Call800-345-2396,
#8x2" F.H.woodscrewJ

#12 x 1" panheadscrew- r/

x 120"Pine(2x4x10')(4 needed)
11/zx3Vz

1/zx3t/z x 120"Pine(2x4x10')(4 needed)

Pine (2x4x8')(2 needed)

sAax 48 x 96" Hardboard

e/qx48x48"
s/tax 48 x 96" Perforatedhardboard 3/qx 48 x 96" Medium-densityfiberboard Medium-density f iberboard

64 Best-Ever Home Shop ldeas 2009

 ,.

Rolling
.-*F
*

aa
Workshop
Storage
J J unit was designedand built
Arhis
to bring order out of the chaos
I
I in my workshop," explained
reader Bernard Monneau of Calgary,
Alberta, in his letter to us. We liked his
idea of mixing plastic tubs and shelves
so much, we built one for the WOOD@
magazine shop, and invite you to con-
struct one for your work area as well.
The design revolves around plastic
storage tubs of the type sold in home
centers and large discount stores. Our
unit houses Rubbermaid Roughneck
StorageTote 3-gallon/11.3-litercontaih-
ers.Adjust the project dimensionsaccor-
dingly if you use a different-sizetub.
The entire workshop project, minus
the optional shelvesand cleats,is built
out of two sheets of MDF G/q"birch
plywood would also work well). See
the Cutting Diagrambelowright for opti-
mal sheet-goodsusage.
To build the project, cut the parts to
the sizes noted in the drawing below.
Rout a 7e" round-over along the one
exposed edge of each lr/zxlr/2" cleat
and along the top edge of each 3/tx3/+"
cleat, where shown. (The round-overs
on the interior cleat allow the tubs
to slide easier.)Then, drill the counter-
sunk mounting holes through all parts,
where noted. Glue and screw the two
dividers between the two sides. Next,
attach the top, bottom, centerpartitions,
and cleats. Mount the interior support
cleats, allowing just an inch or two
of clearance, top to bottom, between \
containers.Attach the casters.||

1Vzx11/2x323/a"
#8x2" F.H.woodscrew cleat

\
\"

I 16"
"

\-zt
-T-1/I
I b---- As an option, use
l0Vzxl6" shelvesin
placeof some or
all of the tubs.

.l
3/qx3/qx16" +4/i
7 1 / a "l l
llll

rrh' l l I
I
t/e"round-over

#8 x 2" F.H.
wood screw

*Dimension
supportcleats
(48 needed) rJ/I Cuttinq
willdepend
uponthe size Diagrafrr
of your tubs. t/e"round-overs

#8 x 11/+'F.H.
wood screw # Bx 2 " F . H .
CENTER wood screw
PARTITIONS

1 1 / 2 x 1 1 / 2 x 3 2 3 / a " e/+x 49 x 97" Medium-densityfiberboard

cleat (MDF)(2 needed)
outside creats
. - * . r

" i n e( 4 b d .f t . )
1 t / z x 3 t / 2 x 7 2P
lnsidecleats

t/e"round-over 3 / q x 5 1 / zx 9 6 " P i n e ( 4 b d . f t . )
*261/+".

4" fixed caster

r Inside cleats

3 / t x 3 1 / zx 9 6 " P i n e ( 2 . 7 b d . f t . )
woodmagazine.com 65

#8 x 1Y4'F.H. 1" hole
I exnloDED
vrEW
13h"
3/qu
3/a"
\-J
13t/z'
3" rigid.".t..---f,|
*rooir"uit---l"--,(l\fF":r^9,'?::r:#;#."0
2lz"(
I Overalldimensions:21"wide x 383/q"
long x 331/c"
high.
I Forthe itemsneededto buildthis
project,seepage69.
ior about $85 and from just one 4x8'
Isheet of 3/+"plywood, you can build
I this sturdy shop accessory.With
biscuit-ioined side and end frames and
simple rabbet-and-groove joinery, you
can easily complete it in a weekend. We
used birch plywood that cost less than
$40 a sheet at a local home center. Sur-
prisingly, that plywood came closeto the
quality of pricier Baltic birch plywood,
having the same number of plies (13)
and few voids for smooth, finished edges.
As a cost-saving option, you can make
the cart from medium-density fiberboard
(MDF), which runs about $20 a sheet.
Start with the
side and end frames
from 3/+"plywood or MDR cut the spacersbetween the bottom and center
I
I sidestiles(A), siderails (B), end stiles siderails, as shown in PhotoA.
woodmagazine.com
s/e"deep
wood screw 1/2"
-diam.self-adhesiverubberbumper
19Y2'
R = 1 1 / 2 " 1"-diam.dowel
2ot/q",long
7az"shank hole,
countersunk
# 8 x 1 1 / q 'F . H .
wood screw
3" swivelcaster
t/q"hole,Jyi l
countersunk +fr lq_20x 11/q,
F.H.
machinescrew
i l3:--'t/q" tlalwasher
Note: Use holesin castersto locatehole
centerpointson bottomof part @.
ftl cnsrERLocATtoN
DETAIL
(Bottom view)
(C), and end rails (D) for the frame
assemblies,shown on Drawing1, to the
sizeslisted in the MaterialsList.To ensure
you'll get all of the cart parts from one
4x8' sheet,refer to the Cutting Diagram,
page 69.
mark centerlinesfor #10 biscuit
arc
lslots on the stiles and rails, where
dimensioned on Drawing 2, page 68, Iay
With the centersiderail (B)positionedin the
out on a flat surface two side stiles (A)
framewith spacers,markthe centerlinesfor
and three siderails (B)in the arrangement biscuitslotson the sidestiles(A)and rails.
shown. To position the center side rail in
the frame where dimensioned, cut two Mark the biscuit-slot centerlines across
Ixl0lz" spacersfrom 3/+"sctap. Place the the stile/rail joints, as shown. Also, iden-
tify the bottom rail to ensure correct
frame orientation later. NoW repeat the
67
 I

E sroe ANDENDFRAME
ASSEMBLTES

#10 biscuit-slot
centerline
I
13/a' I
2%',
I

2e/q"for part@
2t/q"tor part @

1 0 /21/ l l

@
o
291/a'

F
14"forpart I
2,,t/z"torpa

10

Glue and clamp a side frame (A/B),end frame (C/D),and the bottom shelf (E)
together, making sure you close the frame corner joint by drawing the end
frame tightly into the rabbet in the sideframe.

marking processfor the remaining side holes for 3" castersthrough the bottom Next, glue the top shelf in place. Now,
stiles(A), siderails (B), end stiles(C), and shelf, where shown on Drawing1, posi- glue and clamp the remaining side
end rails (D), keeping the parts for each tion a caster on the bottom face of the and end frames to the assembly.
frame together. shelf,where dimensionedon Drawing1a.
I na;ust the fence on your biscuit (We found the rigid and swivel casters
Jioiner to center the blade on the with brakesat a local home center.)Mark
p ennrs vrEW
plywood thickness. Then, with the parts the centers of the mounting
clamped to your workbench for safety, holes. Repeatat each corner of HANDLE SUPPORT
(Outsidefaceshown)
plunge slotsfor #10 biscuitsinto the rails the shelf. Then, drill Yt" holes
and stilesat the marked centerlines.Now, through the shelf at the marked s/e"deep on insideface
glue,biscuit,and clamp the partstogether centerpoints, and countersink 7a,,-_1" hole
to form the frames, again using the the holes on the top face so t_r
spacersto position the centerrail in each the heads of Vq-2ox|l+"flathead
frame assembly. machine screws will sit flush
f fit your tablesaw with a dado blade with the shelf surface.
-fthat matches your material thick- !Sand the side
ness. Then, cut T+"-deepgrooves along jframes (A/B), end
the length of the sideand end frameson frames (C/D), and LONGAND SHORTLID PANELS
317/a"
the inside face, where dimensioned on shelves (E) to 150 1/t\ -7r1.u
j411^,,
Drawing1. Keep the bottom edgesof the grit. Then, to assem-
frames firmly against the fence when ble the cart, glue
cutting the bottom and center grooves, and clamp a side --
After jigsawing3" hole, ii
and the top edgesagainst the fence when frame, end frame, crosscutblank here to li
separatelid panels., ii r/z" blade
cutting the top groove. and the bottom shelf
\i start hole
(Rttach an auxiliary fenceto your rip together, as shown
rf fence. Then, cut a 3/+"tabbetY+"deep in PhotoB. (To mini-
along the outside edge of the side stiles mize the number of
191/2"
(A) on the insideface,where shown. clamps needed, we
assembled the cart
Add the shelves and in four stages.)When
assemble the cart the glue dries, glue
! Cut the three shelves(E) to l8lzx3l". and clamp the center
I To locate and drill the mounting shelf in position.

68
Best-Ever Home Shop ldeas 2009
 dimensioned on Drawing1. Then, glue Finish up and get ready to roll
and clamp a handle support to a top rail, Removethe casters,long and short lid
I
aligning the support with the marked I panels (I, J), and hinges. Sand any
Iine. Drive the screws.Repeatto mount areasof the cart that need it to 150 grit,
the remaining support,making sureyou and remove the dust.
capture the handle (H) between the
anpply two coats of a clear finish. (We
supportsin the 1" counterbores. &used VarathaneDiamond Water-Based
1lCut a l9r/2x317/e"plywood blank to Polyurethane,sanding to 220-grit smooth-
lfform the long and short lid panels nessbetween coats.)
(I, J). Draw a circle for a 3" hole (for fin- remount the castersand lid
lFinally,
ger access)on the blank, where dimen- rJpanels. Open the lid panels and
sioned on Drawing3. Drill a r/2"blade install a pair of r/2"-diameterself-adhesive
start hole iust inside the circle. Then, rubber bumpers on each top side rail (B),
iigsaw the 3" hole to shape and sand where shown on Drawing'1.Now, clear off
smooth. Next, position your tablesaw your workbench, load the cart with your
fence 7Y+ufrom the inside face of a' tools and supplies, and start motoring
7s"-kerfblade. Now crosscut the blank around the shop. I
through the center, of the hole to sepa- Written by Owen Duvall
rate the lid panels. Prolectdesign:feff Mertz
mount four 27O" overlay hinges lllustrations:Roxanne LeMoine; Lorna fohnson
7fo
J for the lids, where shown on Draw-
ing 1,position a hinge on a top end rail
(D), tight againsta siderail (B),asshown
in PhotoC. Mark the mounting holes on sidestiles
the inside face and top edge of the end B side
rails tAl 23A' 261/z'
rail. Using a 3" bit extender or magnetic C endstiles 3hu 2V+' 291A'
With a 270'overlay hinge positioned on a top
e n d r a i l ( D ) ,t i g h t l y a g a i n s t a s i d e r a i l ( B ) ,d r i l l drive guide for chuck clearance,drill the D endrails 3h' 23A', 14',
t h e m o u n t i n g h o l e s ,a n d d r i v e t h e s c r e w s . holes. Then, drive the screws supplied 3hn 18Y2'
E shelves
with the hinges. Repeat to mount the
Mount the casters, and remaining hinges. F top+helfdivider 3/cu 13/cu 18"
complete the cart flPosition the long and short lid pan-
G handlesupports 3Au 21/q' 14Y2'

1 to mount two 3" rigid casters and lJels (1,J) on the cart with the finger- H handle 1"diam. 20Y4"
I two 3" swivel casterswith brakes to access hole straddling the top-shelf l* longlidpanel 3hn 191h,, 241/z'
the bottom shelf (E), where shown divider (F). With the panels tight against J* shortlidpanel 3A', 191h" 71/+',
on Drawing1, position the cart with an the hinges and the edgesflush with the *Parts
initially
cutoversize.
5eetheinstructions.
end frame on the floor. Now, attach outside faces of the side rails (B), drill
the casters using r/+-2ox7r/+" Materlalskey:P-plywood, B-birch dowel.
flathead mounting holes centered in the slots of
machine screws, r/+" flat washers, and each hinge into the edges of the lids. Suppller: (24),3"
#10biscuits (2),3"
rigidcasters swivelcasters
withbrakes(2),
%-20xVc"flatheadmachine screws(16),1/l'flat
Y+"lock nuts. Set the cart on the casters. (Note that the hinges offset each panel (16),
washers %"locknuts(16),
#8x17c"flathead
woodscrews (8),
)Cut the top-shelf divider (F) to the Yra"towatd the center, leaving a Ya"gap %'Ldiameterself-adhesive
rubberbumpers (4).
jsize listed. Then, glue and clamp between the panels.) Drive the screws. Bladeand bits:Dado-blade se!l" Forstner
bit,3"
bitextender
the divider to the top shelf (E), where Then, open the lids and drill mounting ormagneticdriveguide.
dimensioned. holes centered in the hinge holes and Source
I Cut the handle supports (G) to size. slots into the bottom faces of the lids. Hinges:270'overlay hinges
no.15455, pr.(2pr.).
58.29
JOn the outsideface of the supports, Drive the remaining screws. CallorclickRocflsy,gQQ{l
i4441;rockler.com.
mark centerpoints for four countersunk
shank holes, where dimensioned on
Drawing 3. Also, mark Yz" radii, where
shown. Next, on the inside face of the
supports, mark a centerpoint for a
1" hole, where dimensioned. Drill the
countersunk shank holes. Then, using fl
[l.
a Forstner bit in your drill press, bore
the 1" hole 3/e"deep. NoW bandsaw
and sand the radii to shape.
Itrcm a l"-diameter birch dowel 36"
lil
a
'tlong,
cut a Zor/+"-longpiece for the
handle (H).
(fo mount the handle supports (G),
rJdraw alignment lines on the top
side rails (B) 1/+'from the top edge and
U
1"-diam.
Birchdowel
extending 73/+"ftom the ends, where e/+x 48 x 96" Plywood 36" long

woodmagazine.com
69
 Tool Cabinet
shop-in-a-bo*

Keep tools,
hardware,andsuppliesorganized
inthisspace-saving
4-door
cabinet.
Thoughit occupies
littlemorethan7squarefeetofwallarea,
it offers
afull26square
feetofstorage ontheperforated-hardboard
panelsalone!

bE
ooking for an easy-to-buildproject Becausethe thicknessof plywood varies,
that makes a really big impact you may need to slightly adjust the sizes
on reducing shop clutter and of some parts and the mating dadoes
improving work efficiency? Here it is. and rabbets.
With identical caseand door construction lVark centerpoints for Y{ holes
using simple rabbet-and-groove joinery, 33/e' deep for shelf supports on the
you can makethis cabinet in a few evenings inside faces of the sides (A), where
or a weekend.For materials,you need only dimensioned on Drawing1. Drill the
a 4x8 sheet each of /+" perforated hard- holes using a brad-point bit in your
plywood, plus a quarter-sheet
board and3/+" drill press. Adjust the depth stop for
of V+"hardboard. consistentdrilling depth.
2 ti, your tablesawwith an auxiliary
Start with the case rJ fence and dado blade that matches
3/+"plywood, cut the sides (A) the thickness of your 3/r"plywood. Then,
I from
I and top and bottom (B) to the sizes cut a 7a"-deeprabbet across the inside
List.(We used Baltic faces of the sides (A) at each end, as
listed in the Materials
birch plywood, which we found at a local shown in PhotoA.
home center,and applied a clear finish. If lCut aY+"groove7r" deep in the sides
you plan to paint the unit, you can use 'ttn) and top and bottom (B) to fit Though the case measuresju st'l2s/e"deep, it
less-expensivetype AC or BC plywood.) your Yn"perforated hardboard for the h o u s e sa l l f o u r d o o r s w h e n c l o s e d .

70 Best-Ever Home Shop ldeas 2009

 tr CASESIDE
(lnsideface of leftsideshown)
s/a"rabbet e/s"deep ,11/2"
21/a'\ t
7-

t/r" hinge
clearance
321/z'
Locationof
outer-door
continuous
hinge i
1/q"hole
Locationof Te" deep
Inside inner-door
continuous
hinge
K e e p i n ga s i d e ( A )t i g h t a g a i n s ta n a u x i l i a r y With the shelf (D) on 51/2"-tallspacersand
fence and miter-gauge extension, cut a rabbet /+" groove
t i g h t a g a i n s t t h e b a c k ( C ) ,d r i l l m o u n t i n g h o l e s g/e"deep
acrosseach end on the insideface. through the sides (A) into the shelf. 3/+"'from
41/a"- back edge
back (C), where dimensioned on Draw-
'/a . Location
ings1 and 2. To do this,first switch to a @cLEAT MouNlNcDETATL of part
standard ya"-kerfblade in your tablesaw. Tse"shank
Position the fence 3/t"from the inside of holes,
the blade. Then, cut a groove along the countersunk
on outside
back edgesof the sides,top, and bottom face
on the insidefaces.Now, reposition the
fence, as needed,and cut the groovesto Ta"rabbet=*i
final width to snugly fit the hardboard. 7a"deep
Sandthe parts smooth to 180 grit.
(from r/a"perf.oratedhardboard, cut a Note: Rightside@is a mirrorimage.
{373/+"-square piece for the back (C).
Then, dry-assemblethe sides(A), top and
bottom (B), and back, and check that the
parts fit together correctly. Make any
needed adiustments. NoW glue and
clamp the case together, measuring for
p cnse
equal diagonals to verify square. Drill 1/+"groove-3la"deep
1/q"groove /a" deep 3h" trom back edge
mounting holes through the sides and 3/+"Irom back edge
into the top and bottom, where shown #8 x 3" F.H.
wood screw 7o+"pilothole
on Drawing2,and drive the screws. s/q" rabbel3/8" deep driveninto 17e"deep
(nrom 3/+"birch plywood, cut the wallstud
Locationsof

!
lfshelf (D) to size. Then, from your continuous
Yt"perforated-hardboardcutoffs, cut two hinges #8 x 2" F.H.
11/2" wood screw
4x5/2" spacers.Position the shelf in the
case on the S/2"-tall spacers,as shown
in PhotoB. Drill the mounting holes, +1
NI
where dimensioned on Drawing1, and 3t7s'-< T'l
drive the screws.
lnroms/+" plywood, cut the mounting
#8 x s/q"F.H.
wood screw i/
J cleats (E) and spacer (F) to lVzx3l',.
3O7/e'.
i/
r/
Bevel-rip one edge of each cleat at
45", leaving aVs" flat, where shown on Shelfsupport 321/z'
Drawing2a.
51/z'
flPosition the case on your work-
tlfbench with the back (C) up. Then,
s/c"rabbel
glue and clamp a mounting cleat (E) in 3/8"deep
place on the back, tight against the top
(B), in the orientation shown on Drawing #8 xe/+"F.H.
wood screw
2a. From inside the case, drill holes Magneticcatches
(centeredin the holes in the perforated- #8x3" '/2
< / t l

wood screw driven into wall stud

hardboard back, into the mounting
V+"groove7a"deep 3/q"trom back edge
cleat, where shown on Drawing2, and
12Y8"
drive the #8x%" flatheadwood screwsto
r
woodmagazine.com
 -1

Align the inner-door hinge with the marked Position a hinge on an inner-door side (J),with Clamp the spacer to the door, flush with the
l i n e s ,a n d p r e s st h e t a p e d h i n g e i n t o p l a c e . a /a" overhang. Measure from the back to the b a c k e d g e . W i t h t h e h i n g e t i g h t a g a i n s tt h e
Then,drillthe mounting holes. hinge to find the spacer width. spacer,drill the mounting holes.

further stlengthen the attachment. In the

sameway, glue and screwthe spacer(F) to p ooon
the back, tight against the bottom (B). (Leftdoorshown,viewedfrom back)
r/+"hardboard, cut a /2x31" strip 1tl2"continuoushinge
Qfrom 7/aq"pilolhofe 17e" 0""\ 307a"longfor outerdoor
J for the bin stop (G). Glue and clamp 241/2"long for inner door
the stop to the bottom (B), 4L/+'from the
\_--
front edge,dimensioned on Drawing2. 7sz"shankhole. 4%<
I o i,llT#il#:"1
:il:ffilH1".' countersunk

Now, build the doors

I fo ensure that the outer and inner
I doors fit into the casewith 7a"clear-
#8 x 2" F.H.
ance at the top and bottom, where shown wood screw
on Drawing 1, measure the openings
between the top and bottom (B) for the e
outer doors and the top and shelf (D) for
the inner doors. Then, from 3/+"plywood,
cut the outer-door sides (I) and inner-
3OVc'for part c
door sides (J) to the sizes listed and
lengths equal to your measuredopenings
24t/2"for part o
minus /+". (Out sides measured 303/n"for
the outer doors and 24/2" for the inner
doors.)Also, cut the tops and bottoms (K)
fo-rthe outer and inner doors to size.
lfrom /a"perforatedhardboard,cut the
3 outer- and inner-door panels (L, M) /+" grooves
s/s"degp
to the sizeslisted. Locationof
plate
a dado blade in your tablesaw, strike
Q using 3/+"
rJcut a tabbet 3/e"deep across the
onpartc
51/e'
1 a/q" rabbet
g/e"deep

ends of each outer- and inner-door side

(I, J) on the insideface, where shown on
t/n"groovess/e"deep
Drawing3.
Ato crttVq"grooves%" deep in the door parte
rTsides (I, J) and tops and bottoms (K),
where dimensioned on Drawing3a,switch (Sand the door sides(I, J), tops and bot-
to a standard ys"-kerfblade. Position the rf toms (K), and panels (L, M) to 180 grit. f,fl DooRGRoovE DETATL
fence llz" from the inside of the blade. Then, glue and clamp each door together,
Then, cut a pair of grooves along the checking for square. Drill mounting holes
1/^t,
insideface of each part, rotating the part through the sidesand into the tops and bot-
end-to-end between cuts. Now, move the toms, where shown on Drawing3, and drive
3/a"
,t' /tvz ', -l L
fence awayfrom the blade as needed,and the screws.For easein mounting the hinges 3/t'

cut the parts again to widen the grooves and installing the doors later, identify the
and achieve a snug fit with your perfo- top (K) of each door and the side (I, J) that
rated-hardboardpanels (L, M). you'll hinge-mount to the case.
I
72 Best-Ever Home Shop ldeas 2009
 !l erru

6/a'
(
3/qu

D
P o s i t i o nt h e r i g h t i n n e r d o o r i n t h e c a s e , Align the mounting flange of the magnetic
a l i g n i n g t h e h i n g e w i t h t h e p r e v i o u s l yd r i l l e d catch with the marked centerline on the shelfATo mount the hinges onto the doors,
t'Jwhere
mounting holes. Drive the screws. (D). Mark the centers of the slots. shown on Drawing5, place a
hinge for an inner door along the
Add the easy-to-make bins outer-door hinge and r/s" from the top front edge of the side (J) identified for
! from 3/+"plyiood, cut the fronts (N) and shelf (D) for the inner-door hinge to hinge-mounting to the case. With the
I and backs (O) for the eight bins to center the hinges top-to-bottom. Then, hinge leaves positioned at 90o, the top
the sizeslisted.Then, from r/+"hardboard, position the barrel of the inner-door of the hinge at the top of the door, and
cut the sides(P) and bottoms (Q) to size. hinge ys" from the front of the shelf so the ends flush, align the hinge so that
afuy out the angled edge on a side the door closesflush with the shelf. To the barrel overhangsthe edgeby t4".
3(P), where dimensioned on Drawing do this, adjust a combination square to Measurefrom the back of the door to
4. Bandsaw or scrollsaw to the marked the distance from the front edge of the the hinge for a spacer,as shown in Photo
line, and sand smooth. Using this piece side to the shelf, less 7s". (We set our D. (We measured 33/eu.) Then, f.rom Ve"
as a template, mark the angle on the square to 4r/s".)NoW mark intersecting hardboard, cut a 2O"-longpiece to your
remaining sidepieces,and cut and sand lines using the square. measuredwidth. NoW clamp the spacer
them to shape. 2 fo mount the inner-door hinge, apply to the door, and mount the hinge, as
I Sandthe fronts (N), backs(O), sides J a few small pieces of cloth-backed shown in Photo E, driving all of the
r, (P), and bottoms (Q) to 180 grit. double-facedtape to the case-sidehinge screws.Repeatfor the other doors.
Then, glue and clamp the parts together leaf. With the hinge leavespositioned at (Position the case on the right side
in the configuration shown. 90o,and the marked top end of the hinge r, (A), and screw-mountthe right inner
correctly oriented, align the hinge with door, as shown in PhotoF.Raisethe door
54nd, then apply the finish the marks, as shown in Photo C, and to the closed position. Then, mount the
1 ff needed, fill any voids in the ply- pressit into place. Using a self-centering right outer door. Using a helper, reposi-
I wood edgeswith a paintable wood bit, drill the mounting holes.Then, drive tion the caseon the left side.Mount the
putty, and sand smooth when dry. Then, the screws(suppliedwith the hinge) into remaining doors.
sandany areasof the case,doors,shelves, the two top and
and bins that need it to 180 grit, and bottom holes to pre- Icnerruer
easeany sharp edges.Removethe dust. thread them for
a\ppty two coats of a clear finish, easier mounting of 1tl2"continuoushinge 24-1/2" long
&sanding between coats.(We applied the cabinet door.
Varathane Diamond Water-BasedPoly- Remove the screws,
urethane, satin finish, sanding to 32O hinge, and tape.
grit between coats.) In the same way,
mount the outer-door
Complete the assembly hinge, except posi-
I Vdasrrre the lengths of th6 outer- tion it so that the
I and inner-door sides (I, J). Then, barrel overhangs the
from two lVzx48"continuous hinges for front edgeof the case
the outer doors and two llzx3o" hinges by Ye".Use a combi-
for the inner doors, hacksaw the pieces nation square or a
to the measured lengths. To maintain z/+"-widestrip of %"
the correct orientation of the hinges hardboard as an
during assembly, mark the manufac- alignment aid to set
tured (uncut) ends "top." the hinge overhang.
afo position the hinges on the case NoW reposition the
Ssides (A), where dimensioned on caseon the right side
Drawing1, placethe caseon the left side. (A), and repeat the
Draw alignment lines on masking tape hinge-marking and
1/e"from the top and bottom (B) for the mounting process. Note: Rightouterdoor removedfor clarity.

woodmagazlne.com 73
(t" mount magnetic catchesto hold
tlfthe doors closed, where shown on
Drawing2, position the strike plates on
the back edgesof the inside door sides
(I, J), where dimensioned on Drawing3,
noting the different locations for the
outer and inner doors. Drill the pilot
holes, and drive the screws supplied
with the catches.
Next, mark the center of the shelf (D)
on a piece of masking tape positioned
behind the inner doors, as shown in
PhotoG. Mate a catch to the strike plate
on the left inner door. Holding the front
of the door and shelf flush, align the
catch with the centerline, as shown.
Mark the centersof the mounting slots.
Drill the holes, remove the tape, and
screw-mount the catch. In the same
way, mount the catch for the right inner
door, tight against the left-door catch.
Then, mark the center of the shelf (D)
on the bottom face at the front edge.
Now, mount the catches for the outer
doors, aligning the catches with the
centerline.
mount the unit, hold the remain-
7to
J ing mounting cleat (E) level on your
wall, with the beveled edge positioned
where shown on Drawings 2 and 2a. Drill
countersunk mounting holes through
Cutting Diagram
Lock hooks to perforated
hardboard in d snap
Here'sa simpleand inexpensive way to secure
standard, nonlocking hooks to perforated
hardboardsotheywon't comeout. Strapthem in
placewith M-stylehook holders.Justcentera
holderoverthe hookshank,and pressthe barbed
endsinto an adjacentpairof holes,asshown.You
easilycan releasethe holdersto repositionthe
hooks. The holdersfit standard9-gauge and
heavy-dutyS-gaugehooks used in Va"and 1/c"
hardboardwith %0"or e/tz"holesspaced1" apart.
A bag of 50 clips,no. 1169485,
costs$11.89from
McMaster- Carr,404-346 -7000,mcmaster.com.
the cleat into the wall studs, and fasten Hang shop items on the perforated-
with #8xZVz" flathead wood screws. hardboard panels using suitable Vt'
Using a helper, hang the unit. Then, metal hooks, available at your local
from inside the cabinet, drill mounting home center or hardware store. For a
holes,centeredin holes in the back (C), simple way to keep hooks securely in
through the casemounting cleat (E) and place,t.. ih. shopiip, above.*
spacer (F) into the studs to anchor the Written by Owen Duvall
assemblyto the wall. Projectdesign:feff Mertz
(f Finally,install the shelves(H) where l l l u s t r a t i o n sR: o x a n n e L e M o i n e ; L o r n a f o h n s o n
(Oyo.t wish, using %" shelf supports.
Placethe bins in the cabinet behind the
bin stop (G), where shown on Drawing
5. Tidy up your shop by filling the cabi-
net with tools, hardware, and supplies. sides 125/s' 32lz^
B too andbottom 3/i' 125/a' 313/i'
C back yi' 3tth' 313h'

D shelf 3/q' 73/s' 31" BP

E cleats 3/i'
mounting lyi'
F spacer 3/qn 11/z' 31" BP
G binstop Vi' t/zu 31.
shelves vi' 3vd' 307/t'

I outer-door
sides 4t/s' 303/i'
J inner-door
sides 3/i' 4Va' 24lz'
topsand t/i'
* 4t/s' 14Yi'
ooltoms
3/qx 48 x 96" Baltic birch plywood 1/qx24 x 48"
Hardboard outer-door
', panels
1/q' 141/t' 30" PH

M inner-door
paners
1/i' 14Vi 233/c',

fronts 3/c' 13/q' 3yi'

0 backs 3/i' 3Vc' 4Vl'
P sides Yi' 4Vc' 63/i'
0 bottoms Yi' 33/i' 63/q' H 8
birchplywood,PH-perforated
Materlals key: BP-Baltic
hardboard,
H-hardboard.
l/qx 48 x 96" Perforatedhardboard (6);#8x2"flathead
Supplies: #8x%"flathead woodscrews
Findmorefreeshopproiectplansat: woodscrews (48);#8x21/2"
flatheadwoodscrews (2);#8x3"
woodmagazine.com/freeplans flathead
woodscrews (4);cloth-backed
double-faced tape;
11/2x48"
continuous hinges(2)andI %x30"continuous hinges
(2);paintable
woodputty;magnetic (4);7i'shelf
catches
supports(8);7+'perforated-hardboard
hooks.
Blade and blt: Dado-blade
set,%"brad-point
bit.

74 Best-Ever Home Shop ldeas 2009

 j'
"
,..
; \ ' : , . 1 ' .. . . , '
.. , -,.,. I
i', ,'. .. ,'!.. .: . i.

rt*,,;'i.-ltl.;i,
ii$,t.. :. .'r.,, .ir
'''.r::' 1 Ii.-
i

Stool&
Tool-Tote
Combo
Thissimple carnerrsa
stepup for odd jobs
aroundthe home.
tand it upright, and you've got a
sturdy stool for reachingthe top of
your lumber rack or doing house-
hold chores. Flip the stool over, fill it
with tools, and you're ready to tackle a
repair anywhere on your property.
To cut the pieces to size and shape, use
'l t/2"
the dimensions on the drawing. Miter- slot St/q"long, centered
cut both ends of the legs at 15'. Use r/2" #B x2" F.H.woodscrew--\i
plywood for the top, sides, and ends. For
23/q"
the legs and handle, cut 2x4 stock to size.
Cut a Vz" groove Vz" deep, centered along
C23/q'
4)7
15"
the inside face of each leg. Mark the slot, Countersunk
shankhole
drill a blade-start hole, and cut the handle /8" round-overs
opening in the top to shape. Cut the arcs 1/2"groove
j/2" deep
in the ends. Rout 7a" round-overs along
the handle opening and on the remain-
ing parts, where shown at right. Glue,
clamp, and screw the project together in
7a"round-
the configuration shown. Sand smooth, 15' OVETS 1V2"1
and add a finish. CF # B x 1 1 / zF
' .H. miter
wood screw
\
Project
design:
LynnLawrenz,Algoma,Wis,
v'
Findmoreshopprojectplansat:
Countersunk 1"
,:iiri!-iiji'i;.)ii,r-i " .: i . . .: - . - , .,1 i-i':
" shankhole
7a"round-over 7e"round-overs(

Try a "greeJr" version of the stool

We designed this stool and tool-tote
com bos oy ou c anb u i l di tfro m c o mmo n l y
a v ailablem at er ia l sl .f y o u h a v ea c c e s sto
constructiondebris,repurposethat waste
by building the project from it. That's
how the stool'sdesigner,Lynn Lawrenz,
constructsthem. "The raw materialsare
headedf or t he la n d fi l l u , n ti l I s n a gth e m
for stools,"saysLawrenz."l've given away
dozensof them, alwaysin pairs,because
p e o p l el i keto set a pl ankon top of the
s to o lsw hen spreadapartfor pai nti ngand
o th e rchores."
ln his version(seephoto right),the end
p a n el s/l egs are scrapsof 12" engi neered
l -j o i s ts,the cross brace/handl ej oi ni ng
them is a 2x2" cutoff,the top is discarded
ro o f sheathi ng(typi cal l yori ented-strand
b o a rd), and the si de panel sare cut to
shapefrom sparel/2"cabinetplywood.

woodmagazine.com 75
 rable'#Tirdlflfr.?[tr'
Attention,
small-shopandgarage-shop
woodworkers:
Here's aprojectdesigned
withyouinmind.lt'sacombination
workbenchandoutfeed table.Plus,for
thespace-starved
shop, it stores
inthe

g same asyour
footprint tablesaw.

Watcha FREE
two-minutevideoof the
TablesawWorkbench in actionat:
woodnragazine.com/videos

Useit as I Overaldil mensi ons:61Vz"widex

an outfeed 321/a" deepx 393/td"
high (castersin
't''table... the downposition).
I Youcancustomize the workbench to
fit anytypeof tablesaw.Thework-
benchshownat leftfits a contractor's
modelwith a 30"fence.
I Levelers letyouadjustthe benchto
matchyourtablesaw heightfor useas
an outfeedtable.
I To renewtheworksurface, simplyflip
or replace the3A"plywoodtop panel.
I Forthe itemsneededto buildthis
project,seeoppositepoge.You'llfind
the Suppliesat homecenters. For
the casters,seeSource.
Skill Builder
I Learnhowto formlargedadoesand
rabbetsusingyourtablesaw
fenceas
a workpiece
stop.

l\lote: To position the workbenchoveryour

tablesaw,removethe bladeguard, rip fence,
and miter gauge. The bench dimensions
allow L" clearance at the top of the tablesaw
and 1" clearanceat eachside. Thereis no
front-to-back clearance.With thewo*bench
positionedover the tablesaw,the back-fence
rail touchesthe insideof the upper-backrail
assembly (F) [Drawing 4], and the back of the front-
fencerail restsagainstthe front legs(C).

Best Ever Home Shop ldeas 2009

Measure your tablesaw
No matter the type of tablesawyou own, or how tr
it's accessorized,you can customize this proiect -
to fit your needs.
Length
T-
I Veasure your tablesaw [ ], and enter the (291h')
I dimensions in the empty brackets. (Our
tl
sampletablesawdimensionsare shown in paren-
theses.)If by chanceyour saw dimensionsmatch
those of the sample tablesaw,stop here. Simply Length: Measurefrom the back
use the part dimensions for the sampletablesaw of the front-fencerailto the
shown on the MaterialsListat bottom. back edge of the back-
fence rail.
lfor dimensions in bracketslarger or smaller
jthan the ones in parentheses(Drawingt), Height: Measurefrom the
here'show to sizethe workbench to your tablesaw. floorto the top of the
saw table.
(Don't let the following lengthy explanation
scareyou off. The processis really quite simple.) Width: Measurethe maximum
dimension, including the saw
I Subtract the smaller lengthdimension from the table,wings,extensions, !
larger one. Enter the difference in the L column and 6ack-Tence rail. I
under the CALCULATEheading on the Materials
List for parts A, D, E, H, J, and K, and in the W Note: Our tablesawdimensionsare shown in parentheses.
column for part N. Precedewith a plus symbol (+)
for a length in brackets larger than the one in
parentheses,and a minus symbol (-) for a length EXAMPLE' ]}.iI.J
3 /2"_291/ a,'=11/4,,
O1
in bracketssmallerthan the one in parentheses.
I Subtract the smaller heightdimension from the
larger one. First, enter the difference in the L
column under the CALCULATEheading for part
C, and in the W column for part E. Precedewith
a plus symbol for a height in bracketslarger than Step4 Step2 Step3
the one in parentheses,and a minus symbol for Crossout The length in 233/q"+11/t"=25"
a height in brackets smaller than the one in the obsolete bracketsis larger
parentheses. dimension. than the lengthin
parentheses.
I Subtract the smaller width dimension from the
larger one. Enter the differencein the L column
under the CALCULATEheading for parts F, G, I,
and N. Precedewith a plus symbol for a width in
bracketslargerthan the one in parentheses,and a
minus symbol for a width in brackets smaller
than the one in parentheses.
I Divide the width dimension difference (deter-
mined in the previous step) by 4. Record the
dividend in the L column under the CALCULATE
heading for parts L and M. Precedewith a plus or
minus symbol, as directed above.
I For awidth dimension in bracketssmallerthan
the one in parentheses,divide the dimension
differenceby 2.Enter the dividend in the L col-
umn under the CALCULATEheading for part B. I front/ backtrim 3/i' 2Y2' 611/2"
Precededwith a minus symbol. (Do not make
part B longerthan the length listed for the sample
tablesaw.)
I Now add the numbers in the W and L columns
under the CALCULATE headingto, or subtractthem
from, the W and L dimensionsunder the SAMPLE
TABLESAWheading. Enter the new dimensions in *Partsinitially
cutoversize,
Seetheinstructions.
the W and L columns under the YOURTABLESAW Materials key: LM-laminated maple,M-maple, LP-laminated pine,P-pine,BP-birchplywood.
heading. Then, to avoid confusion, cross out the Supplies:#8x1th",#8x11/2",#8x2",#8x21/z"flatheadwoodscrews;%"levelerswithT-nuts(4);1/4x11/2"
hexhead
obsoleteSAMPLETABLESAW dimensions. bolts(6);7+x2"hexhead bolts(24);
%"washers (52);
7i' locknuts(32);%x2" eyebolts(2);Ts" (6);
washers
NoW for example, let's say your tablesaw mea- 7sx%x36" steelbar;/rx36"
schedule 40steelpipe(2).
sures3OYzu long, and you've entered this number Bladecand bits: Stack dadoset;%"round-over and45"chamfer routerbits.
on Drawing1 in the bracketsunder Length.In this
Source
case,completethe row in the MaterialsListasshown Catters:4"swivelcaster withbrakeno,36992, 51039 ea.(4).CallHartville
Tool,800-345-2396,
orgoto
(Exampf e, right center). hartvilletool.com.

woodmagazine.com
77
 7e"drill bit
lR.

@
%" bolt -
insertedto T
-.keep thepipe-/

/ @
With 3%"of pipe protrudingfrom one end of the pivot block(A),drill With washers,a spacer,and the leverassemblyin place,markthe pipe
holesthrough the blockand pipe at the markedhole centers. lengthand leverattachmentbolt-holelocation.

Build the pivot assemblies

I for the pivot blocks (A), cut four3/t"- l/q x 2"
I thick pieces of stock to the width bott p ervorASSEMBLY
and length listed. (We used maple. If
you've adiustedthe length of part A, be 1/zu
r/q" hole l/q x 11/2"hexhead bolt
sure to use the new length.) Then, mak- schedule \
40 steel -- \ F 1/ax 3/qx 9" steel bar
ing two passeswith a dado blade, cut pipe
centeredgroovesin eachpiece(Drawings 31tle"long
2 and 2a). Clamp the piecestogether in
the arrangementshown, and verify that
72"schedule 40 steel pipe slips through
the square hole. Now, glue and clamp
the pieces,keeping the ends and edges t/+"washgr
flush.
2tuy out the hole centerson the bot-
tZ" stoppedround-overs
Itom face of each pivot block (A)
(Drawing2a). (Use the caster plates to
locate the caster-mountingholes.) Drill
only the caster-mountingholes.
(B) to size. Rout
Q Cut two levers
J stoppedround-oversalong the edges
(Drawing2). Then, from a1/ex3/+x36" steel
bar, cut four 9"-long pieces.Drill holes *Sizedto acceptt/z"schedule40 f[ervor BLocK
where shown. Now, position a bar on
each lever, with the bar protruding 1" *7/a"groove z/ta" deep,

beyond the end of the lever. Using the
holes in the bar as guides, mark hole
positions on each lever. Also, mark the
hole center at the opposite end of each
lever. Drill the holes using your drill
press.Bolt the bars to the levers.
1/2"schedule
;f StiOea 36"-longpieceof
'l+O
steel pipe into each pivot block
(A), letting the pipe protrude 37e"at one
end. Then, drill the four 7a"holesthat go
through both the pivot block and pipe,
where previously marked (PhotoA). To
keep the pipe from shifting in the pivot
block, insert bolts into the holes as you
drill them.
centered on inside face
T3"
I
Use the holesin a casterplate
to locatethe mountingholes.
E fo cut the pipes to finished length, pipe. With the lever (B) and pivot block
rJ first cut a 3"-long spacer from 2x4 aligned horizontally, mark the finished
scrap. [The spacer representsthe thick- length and the bolt-hole location (Photo
nessof a leg (C).1Drill a centered7/e"hole B). Repeatwith the other assembly.NoW
through the 3" dimension. Then, slide mark the pipes and pivot blocks for reas-
two washersand the spaceronto the long sembly, remove the pipes, and cut them
protruding pipe end of one pivot block to length. Using a V-block on your drill
(A) assembly.Apply masking tape to the press,drill the bolt holes.

78 Best Ever Home Shop ldeas 2009

p eruoAssEMBLY f[uvelER DETATL
(BACKLEGSHOWN)
t"11;."
3" dado #B x 11/z'F.H.
1t/2"deep wOOdSCrew

) 2i/q,
,/
#B x 21/2"F.H. \ ) a"/o"
wood screw

\r
//tr
-'-'rl | -

341/z'

S" rabbet
s/q"deep

BACK LEG

z/e"washer

s/e"leveler
6

Assemble the endt

I for the legs (C), cut eight 2x4 and adiust it to cut lVz" deep. To estab- four legs. Now, make repeat cuts to
I pieces Vz"Ionger than listed. Lami- lish one edgeof the dadoes,position the remove the waste.
nate them in pairs to form four 3x3Vz" fence 5" from the right side of the blade, 2fo form the 8"-wide rabbets at the
blanks.Then, joint one edgesmooth, rip and attach an extension to the miter rJtop and bottom of the back legs(C)
the opposite edgeto width, and crosscut gaugeto back the cuts. Then, using the (Drawings3 and 3a), leZrvethe tablesaw
the legs to length. To avoid problems fence as a stop, cut a dado at both ends set up as in the previous step, but lower
when building proiects from construc- on the inside face of each leg. Next, to the blade to cut 3/+"deep.Then, making
tion lumber, seethe ShopTip, below. establish the other edge of the dadoes, sure you will have mirror-image parts,
arc form 3"-widedadoesin the inside reposition the fence 8" from the /eff side cut dadoesat both ends of the back face
ifaces of the legs (C) (Drawing3), of the blade. Again using the fence as a of the back legs.NoW make repeat cuts
install a3/+"dado blade in your tablesaw, stop, cut a seconddado at each end of all to remove the waste from the dadoesto
the ends of the legs.
iloritt zs holes for the pivot assembly
'Tpipes
at the bottom of each leg
Hory to keep constructlon (Drawing3a). Then, drill a hole for the
lumber straight leveler T-nut.
Constructionlumber (2x4s,2x6s, etc.) (Cut the end rails (D) to size. Glue
has a high moisture content. When { and clamp them into the leg (C)
brought into a shop, the lumber dries dadoes,with the rail ends flush with the
out, causing it to shrink and often front surface of the front legs and the
twist. Of course,lour project will go rabbeted surfaceof the back legs (Draw-
together easierwith straight lumber. ing 3). Check the assembliesfor square.
Her e' sa s im ples o l u ti o n . Then, drill holes, and drive the screws.
First, select lumber that does not (For #8 screws in softwood, drill 7r2".
include the center (pith) of the tree. shank holes and3/sz"pilot holes.)
Cut the parts to rough length as soon return them to the bag until you are (C"t the end panels (E) to size. Glue
as you bring the lumber home. Then, readyto assemblethem. After building lfand clamp the panels to the end
placethe partsin a trashbag, asshown the project, the wood dries, but now rails (D), a with the top of each panel
aI right, and close it with a twist tie. twisting of any one part is restrainedby flush with the top of the upper rail. Drill
Removethe parts for machining,and the other parts. screwholes, and drive the screws.

woodmagazine.com 79
 Countersunk
shankhole

11/2"

t/q"hole 1" deep,

drilled after assembly
t'T
|8"
J
Complete the base
I Cut the back rails (F)to size.DnllT/a"
I holes for the pipe in the lower rail
(Drawing4). Join the end assemblies
(ClDlE) with the back rails (F),and glue
and screw the rails in place (Drawing4
and PhotoC).
l/q x 2" eyebolts tZ" washers
Note: Locatethe screwholesin the back
rails (F) so they don't interpre with the
screwsthat fosten the end rails (D) to the Positionof @with the castersup
kgs (C). To avoid interferingwith the leg #8
;il;;&'' x2t/2"
F.H.wood screw
levelers,usea 7/2"-longscrewat the lower
outsidecornersof the bottom backrail.
a Apptya finish to the pivot blocks (A) the pipe holes, and bolt the pipes in tape to the upper back rail at the loca-
jand levers(B). (For an easy-to-apply place(Drawing2). Now, slip a washerand tions of the lever ends when the casters
and easy-to-repair finish, we appliedtwo a lever (B) assemblyonto each pipe, and are in the up position. Mark lines on the
coats of Minwax Antique Oil Finish.) bolt the leversin place (Drawing4). tape lYz"from the endsof the rail. Rotate
Attach the castersto the pivot blocks
1l Aanere masking tape to the lower the levers so the castersare in the up
(Dra wing 2) . Tback rail (F) at the location of the position, and drill 1"-deepholesthrough
Q ltace the base upside down on the lever (B) ends when the castersare in the the rail and into the legs(C).
J floor, and slide the pipes through down position. Draw a line on the tape ( furn the baseright side up. Cut the
the legs (C), washers, pivot-block (A) 73A"from the bottom edge of the rail. J rcIl stiffener (G) to size, and glue
assemblies, and lower backrail (F) (Draw- Drill holes in the rail for the eyebolt and clamp it to the top edgeof the lower
ing 3). Align the pivot-block holes with lever pins (Drawing4, Photo D). Apply backrail (F) (Drawing4).

ffir'gwr*.*-
-'-'-&.-""g_.*
.
.E+!-
E tr JbF
Glueand clampthe backrails(F)into the end assemblyleg (C) Usingthe hole in the lever(B)as a guide,alignthe drill bit with the
rabbets.Checkfor square,drill screwholes,and drivethe screws. markedline,and drilla lever-pinholethrough the rail (F).

80 Best Ever Home Shop ldeas 2009

 edge of the trim protruding 3/+"beyond
the tops of the legs (Drawing 5). (Use a
scrap of 3/q"plywood for a gauge.) Drill
screw holes and drive the screws.(For #B
screws in hardwood, drill 5/32"shank Clearance
notch,cut
holesand7/e+" pilot holes.) afterassembly
lCut the top supports (J), end
s/o" chamfer
Acleats (K), outer
routed after
cleats (L), and inner -,,,,..,,,-3ll"ro'u
cleats (M) to size. #Bx 2" F.H. Yi
Then, clamp the parts wooo screw
r rrvrr/

in place,with the top

€/I
/ '-;4)
3/su o--
edges below the -'
,/ '/
top edges of the end . / #Bx2"
trim (H) and front \ / r.H.wood
trim (l), and with the top screw
edges of the top supports L
#8 x 11/qF
" .H.
flush with the top edge of the
wood screws
upperbackrail (F)(Drawing5). Now
drill screwholesand drive the screws.
Retrievethe back trim, and clamp it to
the upper back rail. Drill screw holes,
and drive the screws. Iroe
(N) to size.Clamp it in
Q Cut the top
rJ place,resting on the upper back rail
(F),top supports(J),and cleats(K, L, M).
Drill screw holes, and drive the screws.
Rout a %0"chamfer along the outer edges aTap the T-nuts into the holes in the position the bench over your
Af"
of the trirn (H, I). Zbottoms o f t h e l e g s( C ) , a n d s c r e w i n
3tablesaw, first remove the blade
APosition the workbench over your the levelers. Insert eyebolts into the lever
guard, miter gauge, and rip fence from
Ttablesaw. On the inside face of the (B) end holes, and secure them with the tablesaw. Then, withdraw the eye-
upper back rail (F),mark the location of washers and lock nuts (Drawing ). bolts from the holes in the upper back
any part of the tablesawthat protrudes rail (F). Rotate the levers (B) to the hori-
beyondthe back-fencerail and interferes Using the workbench zontal position (casters down), and
with the upper back rail. Then, transfer to use the bench as a tablesaw insert the eyebolts into the holes in the
1
the marks to the outside face of the I outfeedsupport,rotatethe levers(B) lower back rail (F). Now, roll the bench
upper back rail. Now, lay out a notch, to the verticalposition (castersup), and into place, and depress the caster locks
adding 1" of clearanceall around the insert the protruding ends of the eye- with your foot. .F
obstruction.Jigsawand sandthe notch. bolts into the holes in the upper back
Written by f an Svec with Chuck Hedlund
rail (F).Adjust the levelersso the bench Projectdesign: feff Norris, Delta, B.C.
Apply finish and hardware height matchesyour tablesawheight. l l l u s t r a t i o n s :R o x a n n e L e M o i n e ; Lorna fohnson

! tnspectthe bench, and finish-sand,

I whereneeded.Easeany sharpedges
with a sandingblock.Apply the finish. 3 / q x 5 1 / zx 9 6 " M a p l e ( 4 b d . f t . )

Cutting Diagram
3 / q x 5 1 / zx 9 6 " M a p l e ( 4 b d . f t . )

3 / qx 7 1 / qx 9 6 " M a p l e ( 5 . 3 b d . f t . )

1 1 / 2 x 3 1 / zx 1 2 0 " P i n e ( 2 x 4 ) ( 2 n e e d e d )

1 1 / 2 x 3 1 /xz 9 6 " P i n e ( 2 x 4 )

1 1 / 2 x 3 1 /xz 1 2 0 " P i n e ( 2 x 4 )

s/qx 48 x 96" Birchplywood

woodmagazine.com
 f ustaswith clamps,you never
seemto haveenoughstorage.
Thiseasilybuiltprojectwill serve
yourstorageneedsin spades.
Useit for lumberor asa catchall
in the garageor basement. Plus,
1/2"
using plywoodand 2x4sfor
you'llfind this
its construction,
projectveryaffordable.
Note: Our unit measures 99" long and slight round-overs to break the sharp
restson four castersfor mobility. Size edges along the top edges of the r/2"
the unit to suit your needs,and omit the plywood shelves.
castersif mobility is not a requirement. lCtue and screw the four uprights
-f(D) to what will be the bottom shelf
! Cut the 2x4, plywood,and perfo- assembly(A, B, C). Usea framing square
I ratedhardboardparts A,B,C,D,E,Fto ensure squarenessand plumb of the
to the sizeslisted in the MaterialsList. uprights to the shelf assembly.
a flat surface,drill countersunk (Scre* the bottom four vertical
2O"
Amounting holes,and screwthe shelf Jsupports (E) to the inside faces of
supports (A, B) together to form four the uprights(D).
rectangular 2x4 frames. Note that the /Position the next shelf assemblyon
bottom frame uses four Bs, and the tlftop of the vertical supports, as
other framesuse just two. shown in PhotoA.
QCtue and screw the four plywood /nepeat Steps5 and 6 to secureall
rJshelves (C) to the 2x4 frames. f the supportsand shelf assembliesto
Check each for square. Sand or rout the uprights. Before screwing the top

'l

!--
- ; rQuiqh-and-easy
- -(f

l+rL

-t
.-
v

82 Best-Ever Home Shop ldeas 2009

 #B x 1 1/2"F.H. wood screw

Note: Attach@to end supports@

w i t h# 1 2x 1 " panheadscrews.

207/e'
OptionaltZ" pedorated
hardboardfor hangingtools

7 17/a'

#B x 3" F.H.woodscrew 1 / s z "p i l o t h o l e

#8 x 21/2"F.H.wood screw

four supports (E) in place, make sure

the top of the top shelfsitsflush with the
Materials List
top endsof the uprights (D). If necessary,
trim the top four vertical supports.
A horiz.front&
O Cut the perforated hardboard end backsupports 1Vz' 3Vi' 96', C
(CDpanel(F)io fit betweentwo
uprights B endsupports 11/2" 3yi' 207/a' C 10
(D) for additional storageon one or both 1/z' 237/s' 96'
C shelves PL
ends of the unit. Add hooks for hanging
D uprights 11/2" 3yz* 717/ar C
tools, accessories,or supplies.
E verticalsupporrs1yi' 3yi' l}yd' C 12
OLuy the unit on its side and attach
t 4u heavy-duty swivel-lock casters F endpanel Vi' 16Ue'71Ua" PH 1

to the bottom, if desired. Paint the Materials key: C-choice of pineorfir2x4,Pl-plywood,

PH-perforatedhardboard.
time, glue and screwthe 2x4
completedproject, if desired.rF
Supplies:%"lagscrews 17r'long(16),4"
heavy-duty
verticalsupports(E)into position,and add a swivel-lock (4),#12x1
casters " panheadscrews,
#8x3"
shelfassembly.Continuethe processto the Projectdesign: Chuck Hedlund flatheadwoodscrews, #8x2%" flathead
woodscrews,
top of the project. lllustration:Roxanne LeMoine; Lorna fohnson #8xl1l"flathead
woodscrews.

woodmagazine.com
 'l

I
I
t

J
fl ooon EXPLoDED
vrEW
(2doorsneeded)
#6xs/a" F.H. wood screw s / + "r a b b e l s 6 " d e e o
# 5x % ' F . H .
# Bx 1 " F . H . wood screw
wood screw

%0"pilot hole
s/e"deep on
back face

2" continuous
hinge6
, 0 "l o n g

# 1 8 x s / q "b r a d s
1/2"dado 7e" deep
s/q" rabbel
1/a' 7a" deep

1/4"carriage bolI11/a" long -1

t/2" rabbel Ta" deep
43/q" 4' caster
3/a"
s/q"rabbel3/a" deep
4" caster
withbrake

Note: Foro turturol-woodlookand void-free

edges,we usedBaltic birclt plywoodfor our
cabinet, and applied a clear firtislt. Bttt, I Ctue and assemblea door's sides, / Brush or spray the inside and out-
as ct lessexpensive alternative,you alsocan Jtop, bottom, and shelves,as shown lfside of the doors with a finish of
use typeAC or BC plywood,partictrlarlyif in PhotoA, using squaringbracesto keep your choice. (We brushed on three coats
youplan to paint the cabinet. the assemblysquare.With the glue dry, of Minwax satin polyurethane, sanding
sandthe door frame'ssurfacesand edges to 220 grit between coats.)
Start with the doors to 22Ogrit. Repeatto assemblethe other f Cut the perforated hardboard panels
frorn 3/+"plywood, cut the door sides door frame. f (G) to size. Screw them to each
!
t (A) and tops and bottoms (B) to the ffromr/2" plywood,cut the backs(D) door's spacers,where shown.
-Tto
sizes listecl in the Materials List. I.rom size.Sand thern to 220 grit, and
Vz"plywood, cut the shelves (C) to size. rernovethe dust. Glue a back in the rab-
?O" the inside face of the side pieces, beted opening in each door frame, and
&rout r/2" dadoes 7a" deep to receive clarnpit securelyall around the frame.
the shelves, where dimensioned on ( From 1/2"plywood, cut the vertical
Drawing 1. Then, rout3/+"rabbets %" deep Jspacers (E) and horizontal spacers
acrossthe ends of the sidesto accept the (F) to size. Then, glue and nail the
tops and bottoms. Now, rout a Vz"rabbet spacersinsideeachdoor to the back (D),
7a"deep along the back edge of the sides, whereshown on Drawing1.
tops, and bottorns to receive the back (D).
Alote: Becauseactual plywood thicknesses
Note: To rout the /2" and 3/s"rabbets snd vary from their nominal dimensions,
dadoes in this project, we used 3/8"and /2" measureall insidedimensionsof the tool
With the edgesof the door-frame members
straigltt bits, respectively,making two passes cabinet.Cttt the spocers,
and later the upper
f l u s h , c l a m p t h e a s s e m b l yt o g e t h e r w i t h
to size the joirtts exactly to fit the mating and lower shelves(L, M) and shelf edging s q u a r i n g b r a c e s .Y o u c a n m a k e s i m p l e b r a c e s
plywood parts. (N), to the necessarylength for the bestfit. from scrap 32" plywood.

woodmagazine.com 85
 @
* e*&q**..

A d j u s t y o u r r o u t e r ' se d g e g u i d e t o c e n t e rt h e b i t w i t h i n t h e w i d t h o f C l a m p s c r a p 3 / t "p l y w o o d s p a c e r sf l u s h t o t h e e d g e s o f e a c h s i d e ( H ) .
a side (H),and rout a 3/c"groove from the bottom to the dado for the P o s i t i o nt h e s h e l f s t a n d a r d a g a i n s t t h e s p a c e r s ,a n d m a r k t h e s c r e w
c e n t e r s h e l f ( l ) . M a k e t w o o r m o r e p a s s e st o r e a c h t h e 3 / a d " epth. h o l e sw i t h a n a w ! .

Build the center cabinet 3O"-longsteelshelf standards,hacksaw Hinge the doors to

3/+"plywood, cut the sides(H),
I from eight piecesto length to fit the bottom the cabinet
I bottom and centershelf (I), top (J), openingsand four piecesto length to fit Using a hacksaw, cut two 2x72"
and divider (K) to size. On the inside the top opening. I
I continuous hinges to a length of
face of the sides, rout 3/+"rabbets 7a" zl Position the four standardsfor the 60". Align the doors and the center
deep to receive the bottom shelf and .ltop opening on the sides(H), and cabinet on a flat surfacewith the back
top and rout a 3/q"dado %" deep to mark the mounting-screw hole loca- sidefacing up, and clamp them together.
accept the center shelf, where dimen- tions, as shown in PhotoC. Then, drill (Seethe ShopTip, belowleft.)
sionedon Drawing2. Rout a centered%" Yte"pllot holes 7/rc"deep at the marked
groove 7s"deep into the sidesto accept locations,and screwthe standardto the the hinges along the door/
lCenter
the divider, as shown in PhotoB. Using sides. Following the same process, lcenter-cabinet joints. Drill lre" pilot
the same setup, rout the mating mount the four outer standardsinto the holes 7s" deep into the centers of the
grooves for the divider in the bottom bottom openings. Then, mount the hinge screwholes,and drive the screws.
and center shelf. four inner standardsto the sides,using NoW set the tool cabinet upright on
)Sand the parts to 220 grit, dry- the 3/+"
spacersto position them parallel the casters.
aassemble them, and verify they fit to the divider (K).
correctly. Then, glue and clamp the (Position 4" casterson the bottoms Add the shelves
parts together, again using squaring J (8, I), where dimensioned on
I From t/+" plywood, cut the upper
braces to keep the assembly square. Drawing 3. Mark the centers of the I shelves(L), lower shelves(M), and
When the glue dries,apply the finish. casters'mounting-bolt holes, and drill edging (N) to size. (Again, it's a good
I V.uture the openingsbetweenthe /a" holes through the bottoms at the idea to measurethe inside width of the
rJbottom and center shelf (I) and marked locations. Bolt the casters to cabinet, both between the sides(H) for
between the center shelf and top (J). the bottoms, as shown, making sure the edging and the shelf standardsfor
(Our openings measwed 28V2"for the to locate the casters with brakes the shelving, and cut the parts to the
bottom and 29r/+"for the top.) From where shown. exact length for a snug fit.)
)C tue and clam p t he
-edging to the upper and
lower shelves, where shown
How to install continuous hinges on Drawings2 and 4. Center
the edging so it overhangs
When attaching doors with continuoushinges,
the shelves by l/eu at each
such as for the tool cabinet, leaveal/'rc"gap between end. When the glue has dried,
the membersto be hinged.The gap will prevent sand the shelves to 22O grit,
p o t e n t i a lh i n g e b i n d i n g d u e t o w o o d m o v e m e n t ,
trim to length, and apply the
which could keep the partsfrom closingtogether finish. With the finish dty,
tightly.To establishthe gap, place %0"-thickwood
clip the shelf supports in the
spacersbetween the parts as needed,and then
standardsat the desired loca-
clamp the parts together.
tions, and install the shelves
on the supports.

86 Best-Ever Home Shop ldeas 2009

I cerurER
cABINET @ sneruNc DETATL
EXPLODED
VIEW
%o" pilot hole tAa" d e e p
%" rabbet 3/a"deeo T O PV I E W
Steel shelf standard -Ut
s/s"F.H.
\ -#5 x 4l7ru Ss/a'
\ wooo screw
%a"pilot hole
7e"deep %0"pilot hole
7a" deep on
# 4 x s / e "F . H . back face
#6 x 7e"F.H. draw latch
wood screw
, , , E N Dv l E W
, - { 1 1 - . .t'/8
wood screw i''l-lll

ri'#6 2" continuous

hinge,60" long

s/q" dado
il) 4\,/""1So"
T O PV I E W

3/'ta"
I
ll % groove
Te" deep 101/2'

holes
lL"W' 3/a"
}ftova
a/s"deep
L\ E N DV I E W
I
s/q" rabbel
ffi;1,/a',
;!;;),=v,
F!-
\ Te" deep
# 1 0x 1 " \578"
R.H.
wood
SCTEW

* Note: f,ll cnrvr

DETATL
=
Location
to wire pull Notch filed
55/a'
and lock In cam
cam screws
3/q"groove I rocr rNsrALLATtoN
s/a"deep (Viewed
fromtop) 7 % +p" i l o t h o l e
t/2" deep
Disctumbler # 1 0x 1 " R . H .
1/4"carriage bolt 231/a" 4" caster cam lock wood screw
1t/q"long with brake Left door
1/q" hole side
t/q" flat washer
4" casterwithbrake ----@-;/4'
t/a"lock nut

s/+"hole
frorit Centercabinet
p cnsruRPLAcEMENT
(Viewed
fromthe bottom)
2 " . c o n t i n u o uhsi n g e lnstall the locks and handles
4" casters O" the front of each door, mark the centerpoint for a3/+"hole to
1
I receive a disc tumbler cam lock, where dimensioned on Draw-
ings 1 and 5. (Note that the two lock installations are mirror images
of one another.)
lUsing a 3/+" Forstner bit, and a backer board to prevent
4" caster 3tear-out, drill the lock holes through the doors. Remove the
with brake screw attaching the cam to the back of each lock, and then remove

c the cam. Install the locks in the holes as directed in the manufac-
turer's instructions. File a notch in each cam where dimensioned on
/4" carriagebolt Drawing 5a. Then, screw the cams to the locks.
1tl+"longwith
/4" washerand On the back of the center cabinet's front side (H), mark the
t/+"lock nut 2
Jcenterpoints for #10x1" roundhead wood screws that engage
with the locks' cams, where dimensioned on Drawings2 and 5. Drill
7/a+"pllot holes r/2"deep at the centerpoints. Then, drive in the #10x1"
roundhead wood screws to the depth shown.
AO" the front of the doors and center cabinet, mark the screw-
tfhole
locations for attaching the wire pulls, where shown on
4" casterswith brake
Drawings 1 and 2. Drill %0"holes at the marked locations, and mount
the pulls using the supplied screws.

woodmagazine.com
87
 rr

@ onnw LATCH
rNsrALLATroN
Tool-hanging and storage-bin options
'il ':
ii I llooks. To ensurethat your
#6 xs/e" Lockable tools' hooksstaysecurelyin
F.H.wood draw placeon the perforated
screw latch
hardboard,uselocking-type
i r r\
\iI nylon hooksfor rock-solid
@ attachment,as shown at right.
The hookscome in a variety
of shapes,so you can mount
Front virtuallyany tool or accessory.
the doors snug against the center cabinet at the We usedTalonperfboardhooks
(Ctamp
for our project,availablefrom E a c hl o c k i n g h o o k h a s a d u a l -
rffront. Engage the lockable draw latches in the mating
McFeely's. Cal| 800-443-7937, purpose pin that you push in to
clips, and position the pieceson top of the tool cabinet, where or go to mcfeelys.com. l o c k t h e h o o k i n p l a c ea n d
shown on Drawing6. While holding a latch and clip against unscrew to remove it.
the cabinet, carefully releasethe latch lever, and mark the I Storage Bins. To keepbulk
mounting-screw hole locations in each piece. Repeatfor the hardwareitemsorganized,
other latch. Then, drill 7o+"pilot holes 7e"deep at the marked identified,and easilyaccessible,
spots,and screwthe piecesto the top. it's hard to beat storagebins.
We placedbins,alsoavailable
NoW to mount your tools and organize hardware in the
from McFeely's(Web address
cabinet, seethe iidebut, at right, foi ideas.I and telephoneabove),on the
Written by Owen Duvall lower shelvesof the doors,as
Projectdesign:Burdette Heikens, shown in the photo on page84.
Carefree, Arizona, with feff Mertz The binshook onto a support
l l l u s t r a t i o n sL:o r n a f o h n s o n strip, as shown at right. Packs Thesupportstrip,which mounts
Materials List of six bins,no. BINS-6000R
(red),BINS-6000Y
to the cabinetbackwith #8x3/8"
(yellow),or panheadscrews,keepsthe
BINS-6000G (green),include binsfrom slidingaroundwhen
yt the supportstrip. movingthe cabinet.
sides 6"60"
B toosandbottoms 3/l' 6'231/i'BB Materials hey: BB-Balticbirch
C shelves t/z' 5t/2" 23Vt' BB plywood,
PH-perforated
hardboa rd,
D backs t/z' 23Yi 59Yi' BB SuppIies: #18x3/c" br ads;#4xs/e",
E vertical
spacers 7/' 172" 45" BB 6 #5x5ls",and#8x1"flatheadwood
screws; %" carriagebolts11/c" long
sDacers1/zu 1Vz' 22Vz' BB
F horizontal 4 (24);1/4'flatwashers(24);%" lock
nuts(24);4"casterswith brake
(4);4"casterswithoutbrakes(2);
steelshelf standards 30"long(12);
60"
steeI shelf sup ports(24);2x72"
I bottomand
3/q' continuous hinges(2);disctumbler
center
shelf 12" 23yi' BB tZx30x60"
camlocks(2);#10x1" roundhead
J top 1/q' 12' 23yi' BB wood screws(2);33/+" (96mm)wire Balticbirchplywood
K divider 3/l' 23yi' 2gyi' BB pullswith#8-32x1" machinescrews
3/i' 10Yi (3);lockabledrawlatches(2)with
L uppershelves 221/s' BB
#6x7s"flatheadwood screws.
M lowershelves 3/i, 41/a' 221/s' BB 4
Bladesand bits:1/q"andl/2"
N edqinq 3/i' 11/a' 22Vi' BB 12 straightrouterbits,3/"Forstnerbit.
1/qx 48 x 48" Perforatedhardboard

3/+x60x 60" Balticbirchplywood 1/zx60 x 60" Balticbirchplywood g/qx 6Ox 60" Balticbirchplywood

88 Best-Ever Home Shop ldeas 2OO9

 fiomtheeditors
ofW00lTragazine rywilmti!frff

Benchtop
RouterTable Go-Anywhere
ToolGaddy ShopCail/Workbench
PlanDP-00151
$7.95 PlanDP-00426
$6.95 PlanDP-00592a
$4.95

Roll-Around
ToolBase RollingWorkshop
Storage Flip-TopWorkCenter MobileMitersawGenter Full-Service
Workbench
PlanDP-00061$6.95 PlanDP-00488a$2.95 PlanDP-00239 $5.95 PlanDP-00098 $7.95 Plan,Part1,DP-00058
$8.95

FiveGreat
Glamp BasicWorkbench and Simple'N'Sturdy Mobile
Sawing Full-Seruice
Workbench
0rganizers 6 Waysto Beefit Up ToolStand & Routing
Genter Lift-UpRouter& ToolTable
PlanDP-00230
$6.95 PlanDP-00456$7.95 PlanDP-00577$4.95 PlanDP-00271
$8.95 Plan,Paft2,DP-00059$8.95

UniversalWall
Cabinet Space-Saving
WorkGenter Get'r-Done
ShopGart LumberStorage
Rack CycloneDustGollector
PlanDP-00140$8.95 PlanDP-00168
$6.95 PlanDP-00486a
$4.95 PlanDP-00135$7.95 PlanDP-00068$10.95

Download
anyofthese plans
woodworking fortheprices
listed,
orviewa larger atwmdmagazine.COm/plans
image,
Tohavepaperplansmailed to you(add$3perplanS+H),
directly cailtoll-free l -888-636-4478.
Pleasehaveyourcreditcardavailable.
BEHSI09
0rbital-
Sander
Rest
Customize the basic
designto support
yoursander.

or Chuck Hedlund, WOODo

magazine's Master Craftsman, The optionalsupport
time is always of the essence. atrightworks wellfor
Even the precious few seconds he the vacuum hoseto
wastes holding a 5" random-orbital rest on, preventing
the sanderfrom
sander until its pad quits spinning tipping over.
add up. And even if you're not in a
rush, isn't it a pain waiting for that
pad to stop twirling around?
To remedy this situation, Chuck
designed and built this benchtop
sander rest. After turning off his
sander, he immediately places it in
the rest. After much t/z"solid stock
testing in the WOOD OPTIONALSUPPORT(Forvacuum-hosemodels)
I
magazine shop, Chuck Heightsutficientto J-
chamfered the bottom supportvacuum hose
edgeof the hole in the top
to trap the sander in the 7/u" pilot hole t/2"deep
opening. Then, he added Diameterof hole centered,
th" largerthan the diameter
an upright to catch the of the sander base
sander's dust port and s/sz"shank hole
keep the sander from
spinning. For sanders lc" chamter along
with a vacuum attach- bottom edge
ment (seesmaller photo), Note: Allstock t/2"plywood
s/sz"
shank hole, (exceptsupport)
add the optional support. 10"
countersunk
This holds up the vacuum on bottom faoe UPR!GHT
hose while keeping the
sander from tipping over.
Use the L" hole in the
base to hang the rest 3"
when not in rie. ai \

Projectdesign:Chuck Hedlund
lllustration: Roxanne LeMolne I nt x 1/2"F.H.woodscrew
fr--

90 Best-Ever llome Shop ldeas 2009

 Easy-Does-lt
Sheet
Goods
Mover/Lifter
F.* shop choresrival the awkward-
I ness of moving large sheet goods
I by yourself.And it's nigh impossi-
ble to get them up onto sawhorses
without help (or the horses skittering
acrossthe floor). You'll neveragain have
to cafolereluctant family membersinto 7 e z "s h a n k h o l e ,
helping if you use this system,designed c o u n t e r s u n ko n b a c k
by WOOD@ magazinereaderJim Forney.
Build the dolly from 3/+"plywood or
medium-density fiberboard (MDF), and
# 8 x 1 t / q 'F . H .
wood screw
11/2x21/2x24"
1
12',
solid stock,as shown in the drawings at I x 11/zx 11/2"
right. Carefully position the castersso
they run parallel to one another- l" angleiron
24" long
otherwise,the dolly can shimmy like a
bad shoppingcart.
E ac hs heetlif t er c o n s i s tso f a p a i r o f
z%+"
pilothole
1t/q" deep J
hi n ged 2x 4s . O ne a tta c h e ste m p o ra r-
ily to the top of your sawhorse;the
other guides the stock from vertical to 1t/z x 24"
hor iz ont al. n o n - s l i pt a p e
''akt
To work the system, slide the angle- 1t/2" rabbei
iron of the dolly under the edge of the t/a" deep
countersunk \
sheetyou want to move. (It works best if 1/a"F.H. machine screw
1" long
you storeyour sheetgoods standing on
their long edge,raisedup on 2x stick-
ers.)Grab the top of the sheet,and tip it
toward you. This lifts the material off
the stickers,and shifts its weight to the
31/2"neavy-dutyhinge
dolly. Now, wheel the sheetto your work
area, steeringit by tilting and pivoting 2 x 4 , 1 "l o n g etrh a n
ight of sawhorse
the dolly on one caster. 2 x 4 , 6 "l o n g e tr h a n
sawhorsebase
To lay the sheet on sawhorses,roll it
# B x 1 1 / qF
" .Hl
into position over the angle iron of the wood screw
lifters, and tip the sheettoward the saw-
horsesto free the dolly. (The sheetshould
be resting only on the lifters.) Pull the
dolly awaft and set it aside.Finally,raise
the material by tilting the top toward the 1/eX11/2X11/2"
sawhorses-the lifters will drop down to angleiron
31/2"long
the floor oncethe weight of the sheethas
transl'erredto the hories.ll 7 ,/-,,/, xi./,,,
:@*^::;s'iotaoe
P r o j e c dt e s i g n :f i m F o r n e y 1t/2" dado t/a" deep
1/q"hole, machine screw
l l l u s t r a t i o nR: o x a n n e L e M o i n e
countersunk 1 7 + "l o n o

woodmagazine.com
-:
hen you have a hardworking
and organized shop, routine
repairs and special proiects
becorne a pleasure, not a chore.
The first step toward equipping a shop:
Designate an area that you can call your
own. It doesn't need to be a huge space,
but it should be comfortable, well-lighted,
and have adeqr.rate electrical service.
Individual articles within this rnagazine
give you the details on how to create a
workspace that's inviting and efficient.
You'll also find valuable advice on choos-
ing individual tools.
Next, set up a workbench. Make sure
it's sturdy and free of clutter. If the bench-
top is piled high with tools and supplics,
it's only acting as a shelf, not a bench.
Clear the deck, and keep it clcan.
Add a vise or two, and yor,r'll ntake
lnany of your projects consic'leraltlveas-
ier by elirninating the effort of rnanually
irnnrobilizing a workpiecc. Work orr
your bench, but not itrto it. Stray holes
in your workbench, as well as spilled
paint and oil, quickly downgrade your
shop's appearance.Protect or renew your
benchtop with a replaceable layer of
plywood or hardboard.
92
of power tools-the type that lequires
An efficient home shop has plcnty of an electric cord. But every well-equipped
storage area for tools and supplies, with shop also has plenty of hand tools. These
the most-needed iterns always at arrn's basic implements include wrenches,
reach. If you find that you're continu- saws, files, chisels, striking tools, and
ally walking across your shop for an rneasuring and rnarking tools.
iter-n, relocate it closer to
your workbench or other
area where it's used.
You'll need a variety of
storage options: sturdy
shelves for' tools and bulk
supplies, drawers for preci-
sion tools, bins or snap-top
containers for fasteners and
srnall tools, hanging storage
for everyday tools, and out-
of-the-way storage for items
you need only occasionally.
But even the best storage
products won't do you any
good unless you're rnethodi-
cal about putting away tools
and supplies.
W h e t h e ry o u b u i l d i t y o u r s e l o
f r b u y a n da s s e m b l e ,
Mention "tools," and tnost a sturdyworkbenchis one of the top necessities for
people irnrnediately think s e t t i n gu p y o u r h o m es h o p .
Best-Ever Home Shop ldeas 2009
Investin high-qualityhandtools,and they
Precision
will lasta lifetime.You'llusethem on many accurately,
projectsaswell asfor machineryadjustments. by buyingcheaprulesandsquares.
As you begin to build your tool collec-
tion, bewareof bargain bins. Thesetools
often provide attractive price tags but
little in the way of quality. In fact, you
may discover that poorly designed or
poorly made (or both) tools will frus-
trate your best efforts. High-quality
products usually aren't cheap,but hav-
ing good tools removes a significant
barrier in your quest to produce first-
rate results.
Several brands of hand tools offer
lifetime guarantees,such as Craftsman
(Sears),Husky (The Home Depot), and
Kobalt (Lowe's).The initial investment
may be higher than brands that don't
offer liberal replacement policies, but
an active do-it-yourselferwill enjoy the
Unlessyou've recentlywon a lottery or
a big poker tournament,you probably
aren'tgoing to buy a shop full of tools
on a single visit to the home center.
The following categoriesrepresenta
startinglistof basicshop toolsto tackle
a wide range of home repair and
improvement projects. They don't
includeall the tools requiredof trades
suchas painting,drywall,electrical,and
s o on.
Primary shop
1 6- ounc ec law h a m m e r,a p a i r o f 1 2 "
o ne- handedbar c l a mp s ,a 1 0 " p a i r o f
locking-grippliers,6" and 10"adjustable
wrenches,sawhorses,battery-powered
drill-driver,a set of drill bits, shop fire
extinguisher,safety glasses,hearing
protection, respirator, drive-bit set
(whichcanalsobe usedwith a magnetic-
tip screwdriver),flexible and stiff 1/+"
woodmagazine.com
layouttoolsenableyouto work
sodon'tshortchangeyourresults
benefit of never struggling with a dam-
aged tool. The warranty covers a wide
spectrum of hand tools, such as pliers,
wrenchesand screwdrivers,but excludes
power tools.
Don't spend more
than ydu have to
Retailers often provide generous dis-
counts on lawn and garden gear in the
spring, and even more dramatic mark-
downs at the end of the summer. when
the equipment will otherwisebe returned
to the warehouse. Other outdoor tools
follow similar cycles: for example,
you'll usually get the best deal on a
snowblower when the weather begins to
warm. The storeswill alsohave salesdur-
putty knives,a set of wood chisels,chalk
line, line level,ball of nylon mason'sline,
utility knife and spare blades,slip-joint
pliers,tape measure, torpedoand 2' levels,
combinationsquare,framingsquare,caulk
gun, handsaw,sandpaperin a varietyof
grits,smallpry bar,6'stepladder, compass,
varietyof tapes(masking,duct, electrical),
nailsets,scratchawl.
Secondary shop
Cordedelectricdrill,setof spade-type drill
bits, 25' extension cord (14-gauge is
adequate;12-gaugepreferred),tool belt,
hacksawwith spareblades,plumb bob,
bevel gauge, coping saw, circular saw,
jigsaw,set of Allen wrenches(hex keys),
socket-wrench set in both SAEand metric
sizes,mitersaw,sander,sharpeningstones
and honing guide, block plane,crowbar,
strap wrench, tongue-and-groovepliers
(C h a n nel l ocki s one brand), stapl er,
additionto yourshop
A routerisa versatile
thatcancutcabinet joineryaswellasshape
decorativeedgeson a widerangeof products.
ing the year when you'll enioy substan-
tial discounts-even 50 percent off-on
selected hand or power tools. You can
build or upgrade your tool collection
more quickly when you watch for these
deep discounts.
Closeoutsand reconditioneditems are
other money-saving opportunities, and
these tools often carry full warranty
protection. Storeswith rental operations
often offer low prices on used tools that
are top-quality and professional grade.
In this case,though, you'll probably buy
the tool "as is," without any warranty. It
may work for 10 minutes or L0 years,but
it's yours either way.
Another opportunity is the "brown-
bag sale" that retailers sometimes
3-pound dri l l i ng hammer , 8- pound
sledgehammer,wood rasps, grinder,
dead-blowmallet,4' level,needle-nose
pliers,wire stripperand cutter, center
punch, neon electricaltester,electrical
continuity tester, cat's-paw nail puller,
pipewrenches.
Advanced shop
Shop vacuum, constructioncalculator,
laserlevel,dialcalipers,micrometer,full-
face shield, precision screwdriverset,
router, high-speedrotary tool (RotoZip
type), reciprocatingsaw,propanetorch,
air compressorand pneumatictools,
tablesaw,welding rig, tap-and-dieset,
bandsaw, solderingiron,coldchisels,
drill
press,tin snips,electricalmultimeter(AC
and DC volts,ammeter,ohms),heatgun,
metal-cuttingchop saw, impact driver,
central dust collector, overhead air-
filtrationsystem.
93

A 2' level,alongwitha torpedolevel,ispartof
yourbasictool kit.A 4-footerprovides even
betteraccuracy for big projects.
conduct, offering a percentagediscount
on all the items you can stuff into a
brown paper (grocery)bag. This can be a
good way to save on some hand tools,
such as measuring and marking equip-
ment, that are often not discounted.
Make a list, and
check it twice
The sidebar on page 93 lists primary,
secondary, and advanced homeowner
tools can serveas a generalguideline to
prioritize your wish lists. But bear in
mind, however, that building a work-
shop is a long-term proiect, not a one-
time event.
It's easy to get carried away
when buying tools, so set a
budget to keep things under
control. That way, you can
add to your shop every month
without undue strain on the
finances. In general, you'll
buy power tools as your
projects iustify them, but
you'll probably be pleasantly
surprised how quickly they
pay for themselves when
compared with the fees
charged by a contractor. For
example, the installation
price that you'd pay for an
entry door will go a long way
Buyinga tablesawis your passportto the world of
toward buying the mitersaw precisionwoodworking.You'll build great projects
you'll need for the trimwork. for insideyour home and outdoors.
94
Stoclcplle supplies
When you get into your
proiects around the home,
you'll save time and trips
to the hardware store by
stockpiling nonperishable
supplies such as wire nuts,
sandpaper, fasteners, and
other products. But be
cautious about buying
giant bottles of glue and
other products that have
limited shelf lives.
It's also wise to keep
volatile liquids (fuels and
solvents, for example) in
limited quantities. When-
ever possible, store com-
bustible liquids in a shed
or garage that's detached
from your home.
Of course, having sup-
plies on hand is only part
of the challenge-finding
them when needed is the real key.
Organize your fasteners in neatly
labeled standardizedtransparent con-
tainers. (Seepage 105 for one option.)
Maintaln your tools
When you spend your hard-earned
money for tools, you'll be motivated
to take care of them. Scrape soil off
gardening tools before storage (see
more details in the sidebar at right),
and buy canvastool rolls so that your
woodworking chisels don't bang each
other on the cutting edges.
Learn how to sharpen basic edges,
such as plane irons and chisels, or
sendyour tools to a sharpening service
to keep them in prime condition. ll
Equipmentarticleswritten by Robert f . Settlch
Protect Your
Tool Investment
Buyingnew toolsfor your shopcan be an
enjoyableexperience.But replacingstolen
or neglected equipment can be both
painfuland expensive.With a bit of care,
though,you can minimizeyour risk.
For starters,conduct an inventory of
your shop.Thiswill be helpful if you ever
need to file an insuranceclaim because
your.toolswere stolenor suckedup into a
tornado'sfunnel cloud. Recordthe tools'
makes,models,serialnumbers,dates of
acquisition, and purchase prices.Shooting
photos or video is a quick way to prove
ownershipof small tools that would be
too tedious to list individually.Storethe
inventory in your safe-depositbox or at
anotheroff-sitelocation.
Next, contact your insuranceagent to
discusswhether itemsof substantialvalue
shouldbe specifically mentionedin your
coverage.You'll also want to find out
whether your policy provides full re-
placementvalueor would pay only on a
depreciated basis. Coverage at the
depreciatedamount is lessexpensive,but
it mayalsoprovideonly a smallfractionof
the tab for retooling your shop. The
differencewould comeout of your pocket.
Ask for a quote on switching to full
replacementcoverage,and you may find
that it's quite affordablecomparedwith
bearingthe riskyourself.
It's also a good idea to keep valuable
tools under lock and key.Make surethat
your shop has a sturdy door with dead-
bolt, and even lock tools up again in a
wall cabinetor mobilestorageunit. (See
"Ready,Set,Roll" on page 106.)
Securityis a specialissueif your shop is
in an attached garage. Professional
burglarsoften approachtargetsvirtually
empty-handed,relyingon a quickkickto
a weakdoor to get into the garage.From
there, they often use the homeowner's
own tools to gain entry to the house.
Keepyour toolr clean and dry
Theft is a quick way of losingtools. Rust
and corrosionwork more slowly,but can
niake your tools just as useless.Scrape
loosesoil from garden tools to keep rust
and corrosion at bay. For off-season
storage,blastthe toolscleanwith a garden
hose, air-dry,and then give each one a
spritz of oil. lf you have a tablesawor
other equipment with cast-iron tops;
protect them with coats of automotive
paste wax. Catalogs for wood- and
metalworkersalsooffer spraysand wipe-
on finishesthat banishrust and corrgsion
from small tools. (BoeshieldT-9 is one
product.) You can also invest in
dehumidification blocksthat keepthe air
dry insidea tool box.
Best-Ever Home Shop ldeas 2009
 {}L}\ ,\!
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You'll find a wide range of choices

within the circular-saw category, but
A circular saw allows you to take n-rost of the tools fit into two basic A c o r d e dc i r c u l a sr a w ,s u c ha st h i s S k i l s a w
s e r i o t r sc u t t i n g p o w e r t o t h e i o b , a n c l clesigns:the sidewinder and tl-re\ /onn model above,providessteadypowerfor
t h e r e a r c p l e n t v o f t a s k s i t c a n h a n c l l c : clrive. Each saw style defines itself by evenyour most ambitiousconstruction
projects.The Skil77 worm drive has
crosscr,rttingsttrds for a roonr aclclitior-r, the position of the rnotor relative to
exceptionalpowerand a narrowprofile.
c u t t i n g d e c k b o a r c l st o l e n g t h , n o t c h i n g the blade.
tirnbers for a backyard play set, cutting l-he worrn-clrive design places the
'l'his
4x8' sheet goods to sizc, and ntuch long axis of the lnotor parallel to setup gives the saw a narrow pro-
more. Install an abrasive lnasonry the saw blade, as shown at ri,glrt. file side to sidc, but stretches the body
wheel, and you can score concrete The rnotor transfcrs the power to the of the worrn-drive saw, adding reach
blocks or paving stones for your patio blade tl-rrotrgh a serics of pir-rions that's often handy on long sar,vcuts.
(You'll need a cold chisel to finish the and gears. A worm-gear assernbly that However, the real benefit of the worm-
iob.) Substitute a rnetal-cutting wheel, gives the design its name turns the drive design is exceptional torque (rota-
and you'll power through conduit. rotary rnotion 90" at the saw arbor. tional power). That rneans you will

woodmagazine.com 95
rarely find a situation where you'll bog
down the blade. On the negative side,
the gearing and powerful motor
translateto additional weight.
With a sidewinder saq you
mount the blade directly to the
motor's shaft. With some saws,the
blade is on the right (iudged from
your operating position), but others
place it on the left. Some manufac-
turers produce both models: blade-
left and blade-right. In theory, a right-
hander should find a blade-left saw
more convenient because you don't
need to look over the saw to see the
blade. But if you're a righty already
accustomedto ablade-rightsaw,switch-
ing to a blade-leftcan be a disorienting
experience.
With a little practice, you can follow
a line freehand to make cuts straight
enough for most proiects. For more
accuracy,usea purchasedor shop-made
clamp-on straightedgeguide with your
circular saw.
Enter a recilr saw into
the demolition derby
If you do occasionalhome repairs,you
probably own a tool belt. If you're a
serious remodeler, you'll definitely
own a reciprocating saw. Fans of this
tool nickname it the recip saw, and
after the first time you use one, you'll
be a fan, too. With a recip saw, many
operators actually look forward to the
demolition phase of each proiect
instead of dreading it.
The saw getsits name from the back-
and-forth action of the blade. You rest
the foot plate of the saw on the piece
you're cutting, and squeezea variable-
speed trigger with one hand while
your other hand steadiesthe body of
the saw. It's a tool built for speed and
power, not pretty cuts.
Cutting through old decking, lum-
ber, and plywood is no problem, even
if it's riddled with nails and screws.
Need to slice through rebar or old
pipes? No sweat-simply pop in a
metal-cutting blade. The recip saw
with a coarse blade lets you cut up
downed tree limbs with nearly the
speedof a chain saw,but with a lot less
noise and zero fumes.
Most corded recip saws have plenty
of power to cut big iobs down to size.
But if you're willing to sacrifice power
for the advantage of going cordless,
you'll find battery-powered saws that
won't tether you to electrical outlets.
96
Next to a friendly bankerwith a low interestrate,
a reciprocatingsaw is the remodeler'sbest friend.
This model usesan 18Vrechargeablebattery.
figsaw: Cutting corners
accurately
While a reciprocating sawmoves a blade
forward and back, a jigsaw moves it up
and down. And unlike a recip saq a
iigsaw is capable of accurate and intri-
cate cuts. You can craft holiday yard
decorations from plywood, cut through
a laminate countertop to install a sink,
or shape smooth curves in decorative
deck brackets.
Choosethe right metal-cutting blade,
and you'll zip through sheet metal,
steel, and copper pipe. With a fine ply-
wood blade, you'll negotiate hairpin
turns in 1/+"stock. With a medium- to
coarse-woodblade,you'll sculpt smooth
curves in outdoor projects such as %"-
thick fence pickets or |Yz"-thick cedar or
redwood beams.
You'll find that most iigsaws offer
variable-speedcontrol, where your fin-
ger pressureon the switch has the same
effect asyour foot on your car'saccelera-
tor pedal. Many sawsalso allow you to
control the orbiting action of the saw-
a motion that powers the blade forward
and back while it's alsotraveling up and
down. The greater the orbit, the more
A jigsaw cuts smooth curvesin a wide
rangeof materials,from thin plywood to
dimensionallumber.
aggressivethe cut, which also means a
rougher-cut edge.Dial down the orbital
action, and you'll get improved control
and a smoother (but slower) cut.
When shopping for a jigsaw, you'll
notice that most have horizontal grips
that parallel the motor housing. Others
may have you grabbing the housing
itself, a position that could uncomfort-
ably warm your hand during an
extended cutting session.Check how
the saw fits your hand, and whether the
grip is comfortable or seems strained
when you pull the trigger.
Tablesaw: First choice for
straight cutting
With the saws we've discussedso far,
the lumber is stationary and you move
the tool to make the cut. A tablesaw
reversesthe dynamics: It sits still while
you advancethe material pastthe blade.
When you're working on piecessmaller
than full sheet goods, you'll find that
this makes it easy to achieve accurate
results. In addition, the blade-tilt fea-
ture enablesyou to cut bevels with or
acrossthe grain. The miter gaugeand
rip fence make it easy to crank out a
stackof identical parts within minutes.
If you'll cut only a few long boards,you
may need to recruit a helper to assist
you in balancing the lumber. But an
outfeed stand is an inexpensive alter-
native that doesn't get impatient.
Even with a helper and an outfeed
stand or two, you'll find that manhan-
dling a full sheet of plywood over a
tablesawcan quickly turn into a wres-
tling match. Whenever possible, use
a circular saw to break the sheet
into manageable pieces before going
to the tablesaw. How big a piece fits
the definition of "manageable"depends
somewhat on you and the size of
your saw
Best-Ever Home Shop ldeas 2009

A tablesaw caneasilytrumptheaccuracy
of alltheotherhand-guided sawsin your
arsenal of powertools.
The smallest-and therefore most
portable-tablesaws are often labeled
as benchtop tools, though many have
optional legsset to improve their versa-
tility. Low price is the prime motivator
behind these saw designs, so you'll
typically find a stamped-steeltabletop,
and a universal motor that directly
drives the blade. Follow the setup
instructions carefully, and you'll get
decent results from this type of saw,
but don't expect glass-smooth cuts or
extreme precision.
The next step up is a jobsite saw,
which usually includes a folding stand
that doublesas a dolly for easyportabil-
ity. You'll seea significant boost in the
price tag, but you'll receive substantial
upgradesin the quality of materials as
- well as improved precision and power.
The next level is called a contractor-
style saw, but you'll see far more of
these in home workshops than on con-
struction sites.The contractor-stylesaw
has a cast-iron top that's machined flat,
and an induction motor rated about
1.5 horsepower. A V-belt connects the
motor to the saw'sarbor. This category
represents such a large share of the
tablesaw market that there's an abun-
dance of aftermarket accessories.So
you can bolt on upgrades for accuracy
and convenience. For example, you'll
find beefed-uprip fences,superaccurate
miter gauges,and a host of jigs. A care-
fully tuned saw is typically more than
capableof furniture-quality cuts.
Take one more step upward, and
you're looking a at cabinet-style saw, a
true industrial machine with a 3-(or
woodmagazlne.com
more) horsepower, ZZo-volt motor. It's
all about cast iron, with heavy-duty
everything, including the price tag.
Bandsaw: Cuts curves
and thiclc stock easily
Add a bandsaw to your shop, and you'll
open new possibilities that are difficult
to achieve with any other tool. You can
make straight or curved cuts in thick
wood with accuracy.Compound cuts-
where you slice through two adiacent
facesof the stock-are not merely pos-
sible but downright fun to do.
This tool also excelsat resawing lum-
ber, which means slicing it on-edge.
This allows you to open up a piece of
wood to create a book-matched panel
for a stunning cabinet door. Even
benchtop bandsawsoffer decent resaw-
ing capability, and a mid-priced saw
with a riser block can resawthrough 12"
slabsof hardwood.
A bandsawis simpleenoughforthe
beginnerbut capableenoughfor the
advancedwoodworker.
F
'
i
The defining dimension of bandsaw
capacity is the distance from the blade
to the column. Some benchtop units
utilize a third wheel to improve the
capacity of the saw without trpscaling
the major components. However, most
sawsfeature a two-wheel design.
Although the vast majority of band-
sawsare intended for cutting wood, you
can also purchasemodels that cut metal.
In this case, though, the pulleys are
sized to slow down the cutting speedto
a rate that's more appropriate for metal-
cutting blades.
A scrollsawhandlesa wide range of
precision and creative cutting tasks in
wood and metal.
Scrollsaw: the one-tool
habit-forming hobby
Scrollsaws should have some sort of
warning label attached, becauseusing
one can definitely become an addictive
experience. Some users start out in-
nocently enough, crafting nameplates
and simple plaques.But then, they find
themselveshooked on complex designs
and other advancedtechniques.
Most scrollsaws have variable-speed
controls that allow you to tailor the
cutting approach to the material you're
crafting, whether it's wood or metal.
Equipped with the appropriate ieweler's
blade, the scrollsaw can craft exquisite
detail in a variety of metals.
The up-and-down motion of a scroll-
saw reminds some woodworkers of a
sewing machine.
One key tlp: changeto a new scrollsaw
blade whenever you notice the cutting
action slowing.A new blade helps you
finish sooner,and increases
the life of the
saw by reducingstrainon the motor.i'
Sources
Bosch: 8772672499,boschtools.com
Craftsman: 800-549-4505, craftsman.com
DeWalt : 800-433-9258, dewalt.com
Hltachl : 800-829-4752,hitachi.com/powertools
jettools.com
f et : 800-274-6848,
M Ifwau keez262-7 81-3600, milwaukeetool.com
Skllz877-754-5999,skil.com
97
 With
Success
& Accessories
Mitersaws diameter, of course, translates into
Whetheryou need tochop a4x4deck postor I I ost mitersaws on the mar-
I!1fI ket today are the com- greater cutting capacity. A sliding
slice
adelicatemolding forajewelrybox,a I U I pound style, which means mechanism is another way to boost
the blade can bevel and miter simul- the tool's effective cutting range.Saw
mitersaw Togetthemost
isthetoolofchoice. taneously. This enables you to cut manufacturersgenerallylist the maxi-
crown molding flat on the saw's mum thickness and width of cut at
fromthistool,though,thinkabout thescale
of deck. Most compound mitersaws two positions: the zero-degreecross'-
workand thematerialyou're These
cutting. bevel in only one direction, but a cut and at a 45" miter.
few can bevel both ways-a feature Make sure that the saw you choose
considerations
willhelpyouchoose both
the that's occasionally handy but not will handle the largest stock you
job.lfinstalling necessaryfor most DIY iobs. need to cut. There's always the
saw andtheblades forthe In today's market, saws have initial burning temptation to buy
moldingisyour firstgoal,
you'll
need awayto either a 10" or L2" blade, though the biggest saw in the store, but
you'll find a few sawsthat usesmaller looking at the price tag often cools
measureandcutmiterangles, too. or larger blades. A larger blade that passion.

98 Best-Ever Home Shop ldeas 2009


Chose your blade
Matching the blade to the iob is a criti-
cal part of cutting success.For decking
and other'framing chores, a 10" blade
with 24 carbide teeth will produce fast
cuts and eject chips efficiently. For
smooth cuts in moldings, choose a
quality blade with 60 or more carbide
teeth. If you'll cut plastic molding,
you'll need to search out a company
that makesspecialtybladeswhich mini-
mize melting. (ForrestManufacturing is
one source.)
Working all the angles
One of the key steps toward virtually
seamlessmolding joints is knowing the
precise angle you need to cut. You'll
get the best results by using a protrac-
tor with legs long enough to span the
humps typical of outside drywall cor-
ners. An 18" plastic protractor from
Quint Industries is an affordable and
accuratetool. If you don't mind parting
with more money, you'll find
digital protractors that will
calculate the bevel and
miter anglesfor you, as
t ,L\. shown below.
ffir
qT-
A digitalangle
finder eliminates '\ €
guesswork \ of the two types. On the downside,
when you're installingcrown molding.
Capture the crown
Wrapping a room with crown molding
motivates many people to purchase a
compound mitersaw, but the instruc-
tions included with the saw often fall
short of even basic training. For more
help, consult a book such as Crown
Molding and TTim: InstaII It Like a Pro
from Quint Industries. The book is
available at many home centers,or you
can order online (compoundmiter.com).
For a handy video of cutting molding,
seewoodmagazine.corn/rnold ingvideo.
It's time to take a stand
A mitersaw can be extremely handy in
the shop, but making the tool easily
portable multiplies its usefulness.That
way, yori can take it to the backyard to
woodmagazine.com
*
hold long piecesof lumber or molding.
Typically, you use a built-in screwclamp
to match the support's height to the
saw'sdeck. Some supports even include
a provision for a stopblock setup, a real
plus when you need to cut a batch of
parts to identicat length. lF
lf metalworkingis a part of your shop
activities, you'll appreciate a big-
When choosinga stand,look for stability
as well asthe ability to support long capacitychop saw. Despitetheir size,
workpieces.Thisdolly-type standfrom thesesawsare surprisinglyaffordable
Hitachilets you transport the saw and its
support systemin a singletrip.
and can cut a wide varietyof ferrous
and nonferrousmaterials.By using
a specialcarbide blade, the model
install a new deck rail or near the living pictured below can cut significantly
room to install crown molding, a chair fasterthan either a mitersawwith an
rail, or both. abrasivewheelor a portablebandsaw.
You can put the saw onto a piece of The bladeproducesvirtuallyburr-free
plywood between sawhorses,or set up a cuts,reducingthe needfor grinding.
portable workstation such as Black & A quick-acting viseholdsthe material
Decker'sWorkmate. If you choose either firmly, and a 45" fencepositionsstock
of these alternatives, it's a great idea to for accurateand
clamp the saw firmly to the stand so it repeatable results.*
won't slide when you're making the cut.
For real convenience, though, take a
look at a dedicated mitersaw stand.
(Somecan even double as a platform for
a planer or other tool.) You'llfind a vari-
ety of designs among manufacturers.
There are two categories:a stand that
travels independently of the saw and a
There'splenty
to like in a metal-
cutting saw:
huge capacity,
high power,and
stand with wheels (above),serving as uncomplicated
a dolly to transport itself and the operation.
saw at the sametime.
The independent stand is the more
plentiful and generally the lower-priced
though, you'll always make at least two
trips with this variety: one for the
stand and another for the saw.
The dolly-type stand is a sweetheart
because it cuts your commute in half,
and it also eliminates the strain of carry-
ing the saw. Typically, the stand even
includes a gas-charged cylinder that
helps you overcome gravity during
setup. If you'll move the saw up and
down stairs, look for large-diameter
wheels. If you'll travel over soft ground,
wide wheels will keep you on a roll.
Somestandsrequire the sawto be bolted
on, while others have a quick-release
mechanism.Detaching the tool is a plus Sources
if you need to load the stand and saw Bosch: 877-2672499,boschtools.com
into a truck. Most dolly stands store on Craftsman: 800-549-4505; craftsma
n.com
DeWalt: 800-433-9258,dewalt.com
end, reducing their footprint. Forrest:800-733-71
11,forrestblades.com
Both types of stands usually incorpo- Hitachi : 800-829-4752,
hitachi.com
rate outrigger work supports that help Quint Industrles:866-544-2016, compoundmiter.com
99
 *r"-
t-:L t*I*.
, ,a
E,

r , ou have three potential power sources for a drill: battery pack, electrical cord,
:,:r:'
and compressed air. Batteries give your drill the most portability, an advantage
:;r' that's important when your potential household work sites range from the roof
to a cramped crawl space. Dragging along a cord adds a degree of difficulty to many of
these iobs, and it seems that the plug always pops loose just when you're ready to pull
the trigger.
But corded drills definitely have their advantages.When you're faced with heavy-duty
tasks-drilling large-diameter holes in wood, for example, or simply boring a lot of
holes-you'll benefit frorn the dependable power that flows through the cord. You can
work all day without the bother of swapping power packs or waiting fbr a recharge.
If your shop has a compressor rated at rnore than 4 SCFM, consider a pneumatic (air-
powered) drill. It's not a good choice as your only drill, of course, becauseyou're tethered
by an air hose. But the simple no-motor construction of an air tool gives it light weight, A n a n g l ed r i l lp e r f o r m sw e l l i n t i g h t
excellent dependability, and low maintenance. Many pneumatic drills lack the refine- spaces.A cordedversionletsyou
q u i c k l yd r i l l h o l e st h r o u g hs t u d st o
tnents of corded and battery drill-drivers: no clutch settings and no variable speeds.Some
r u n w i r i n go r p l u m b i n g .
units even lack reversing features. (For more about air tools, seeprl.ge108.)

100 Best-Ever Home Shop ldeas 2009


Cordlessdrill-drivers
Battery power gives your drill-driver a
highly portable and dependable power
source.No wonder it's one of the most
popular of home-shoptools.
A drill-driver with a power sourceof
10.8 to 14.4 volts is usually plenty for
routine drilling of pilot holes and driv-
ing screws.But if you need additional
power for more demanding tasks, such
as spinning spade bits, look for more
voltage. However, the high-voltage bat-
teries also impose substantialpenalties
in both price and weight.
When you're shopping for a drill, don't
merely look at price tags. Instead,check
the tool's balance (with the battery in
place,of course).Also, learn whether you
can easily reach and operate all of the
switches-such as the reversing con-
trol-without straining or fumbling.
To understand more about batteries
and chargers-including the new
lithium-ion technology-
check out
page116.
Severalman ufacturers offer
14.4-voltdrill-drivers(shown
with a rechargeablelight).
The drill press
The operationalprinciple of a drill press on buying vs. renting on page8.)
is extremely simple:The tool that bores
truly vertical holes to a precisedepth-
something that's difficult to do with a modes: rotation only, hammer only, or
handheld drill. For precision work in
both metal and wood, a drill pressrates
as a virtual necessityfor your shop.
The size rating of a drill press can
be confusing becauseit representsthe
maximum diameter of a workpiece in
which you can drill a center. For exam-
ple, you could drill the axle hole in a
16V2"-diameter wood wheel with a L6y2'
drill press. Manufacturers like using
this size system becauseit makes the
tool seem twice as big as describing its
chuck-centerpoint-to-post dimension
as 8V+".
The other size consideration in drill
presses is whether you prefer a floor
model or can utilize a benchtop unit. In
terms of precision, you can get excellent
woodmagazine.com
results at either end
of the sizespectrum.
Most drill presses
have slower speeds
that match up well
for drilling metal.
T h ed r i l l p r e s s , l i k e
this benchtopmodel,
is a must-havetool for
precisionwork. lt can
alsospin a wire wheelfor
removing rust,or a buff
for polishingboth
wood and metal.
The hammer drill and
rotary hammer
The hammer drill combines rotation
with a forward-and-backhammer action
that the drill generates mechanically.
The combination of these two forces-
when teamed with specially hardened
drill bits-quickly pulverizes concrete,
brick, and stone. In addition to RPM
(revolutions per minute) ratings, ham-
mer drills also have BPM (beats per
minute) specifications.
A similar tool, the rotary hammer,
derives its percussive power with an
on-board hydraulic mechanism. This
system delivers more energy to the bit
than a rotary drill. It's iust the kind
of tool you need if you're drilling a lot
of holes in concrete; for anchors or a
termite treatment, for example. But it's
also quite pricey, so you may want to
consider renting instead of buying if
your need is short term. (Seethe article
Hammer drills and rotary hammers
usually let you select among three
hammer plus rotation.
A rotary hammer will saveyou a lot of
time and effort when drilling holesin
concreteor stone.
I
l
The impact driver
Impact drivers have long been com-
mon pneumatic tools: You've heard
their distinctive wails in pit rows and
the neighborhood tire shop. Corded
impact drivers have also been relatively
common. Until recently,though, impact
drivers were virtually unknown in a
battery-poweredformat.
But several manufacturers now pro-
duce compact versions of the impact
driver. They are promoting the tool as a
real problem-solver for tough construc-
tion and renovation tasks'around your
home. If you're finishing a basement,for
example, you can use an impact driver
to drill holes in concrete and then drive
TapconrMor similar fasteners.If you're
building a deck, an impact driver will
drill pilot holes and
then spin in lag
screwswith a
powerful ham-
mering action. |l
A new generationof
battery-poweredimpact
driversprovidesthe muscle
that takesthe hard work out
of tough fasteningjobs.
The sizeof a drill is usuallyrated by
the maximum diameterof bit shank
that will fit into its chuck.The most
common size for both corded and
battery drills is 3/e".Heavy-dutydrills
feature72"chucks.
A clutch is a handy featureon a
drill-driverbecauseit allowsyou to
set the maximum torque you want
to apply to a fastener.This helps
prevent overdrivingscrewsor strip-
pi ng thei r heads.
Somedrill-drivershavedual speed
range switchesthat help you tailor
the tool to the task.ln the low range,
the bit spins more slowly, but you
have additionaltorque and control.
In the high range,you trade torque
for greater rotational speed-great'
for fastdrillingresults.
Sources
Bosch : 877-267
-2499,boschtools,com
Delta: 800-438-2486,deltaportercable.com
DeWalt: 800-433-9258, dewalt.com
Gri zzlyz800-523-4777,grizzly.com
Porter-(able : 800-487-8665, deltaporterca
ble.com
Ryobi: 800-5252579, ryobitools.com
101
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h.-
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[veryone thefeelandappearan(e
enjoys 0fa random-orbit sander excels. It's also a
silky-smooth butnobody
surface, wantst0 good choice for general finish prepara-
tion (sandinga bookshelf,for example).
spendhours t0getthatsmoothness.
sanding An inexpensiveaccessory likethis (520
You want to pull the dust away from or less)activatesyour shopvacuumwhen
Arandom-orbitsanderminimizes
thatchore, the surfaceso that you're constantly cut- you switch on your sander.Turn off the
sander,and the vacuumrunsfor three
makingit avaluable toyour
addition shop. ting fresh wood, not merely rearranging more secondsto clearout the hose.
the dust on the board. Most random-
ff$sfl*u*mr$
efuqt*ss&fue orbit sandershave on-board dust collec-
$pgsgsmrxe*F $*q#ffiB{}w**; tion or the even better alternative of you to use either five- or eight-hole disks
A random-orbit sander combines the easyattachment to a shop vacuum. The on the pad. Some people may say that
rotary motion of a disk sander accessoryshown sboveright provides an it's not the ideal situation, but it works.
with the orbital action of a finishing easy way to turn on the shop vacuum
sander. As a result, it cuts quickly, and sandersimultaneously. #me- and tw*-hnnd versf,*ms
like a belt or disk sander,but with the If you typically use a random-orbit
control and cross-graincapability of a k**$*r",y seftdpftpe$"f sander for extended periods of time,
finishing sander.This means that you Some sandershave five dust-collection you'll probably find the two-hand-grip
can move the tool in many different holesin the pad while othershave eight. version less fatiguing because you're
directions-even at right angles to the Although it may initially seem strange splitting the effort among more muscle
grain direction-without producing an to pay good money for sandpaperthat groups.For accessinto tight areasor for
objectionablescratchpattern. looks like Swisscheese,it makes a great working on small pieces,though, you
As a result, you can quickly level sensefrom a dust-collectionstandpoint. may find a single-handmodel easierto
slightlymisalignedwoodworkingjoints. Some five-hole pads also incorporate maneuveracrossprojects.
Cabinet face frames and rail-and-frame slotsextending from eachhole, asshown Whichevertype you choose,resiststhe
doors are two examples where the opposite.This clever arrangement allows urgeto pressdown on the sanderto speed

102 Best-Ever Home Shop ldeas 2009

Ir
The Boschsander(left) requiresa two-handed grip, while the Porter-Cable(right) leaves
one hand free to repositionthe stockas you work. Both sandershavevariablelpeeds.
the smoothing process.In fact, it usually they find that PSAstarts to lose its grip
has the opposite effect; plus, you make after a few times on and off the sander.
the job much harder on yourself. If you have a pneumatic random-orbit
sander-it's often called "dual-action"
Keep sandpaper attached when powered by air-you may find
H&L is shorthand for hook-and-loop, that PSA is your best choice. That's
the generic term for the temporary because these sanders often operate at
fastening system known by the brand very high rotational speeds:10,000 RPM
name Velcro. PSA stands for pressure- is common. Friction at that speed can
sensitiveadhesive,another way to hold melt the plastics used in the hook-and-
abrasivedisks to a random-orbit sander. loop system,so it's not a practical choice.
Most woodworkers prefer the hook-
and-loop system becauseit provides a A quiclc course in sanding
fast and easy way to swap grits, even Here are the basicson how to get sanding
before the disc is worn out. By contrast, over as quickly as possible.The grits rec-
ommended are a suggestionthat you'll
need to adapt, depending on the aggres-
siveness of your sander and personal
preferencesin surface quality. Another
variableis the smoothnessof your proiect
before you begin sanding. For example,
furniture-quality hardwood plywood
arrivesin the lumberracksalreadysanded
to 180 grit or finer.
Begin sanding dimensional hardwood
.,m[ with a coarse abrasive (80 grit). After
sanding, inspect the surface to make
When the sanderbasehas slots (left),you can sure that you've removed all the stock
useeither five- or eight-holepaper. needed.From that point forward, it then
becomessimply a matter of each succes-
sively finer grit removing the scratches
of the one before it.
Use a vacuum, cloth, or bench-
dusting brush to remove the 8O-grit
particles and dust, and move to 100,
l2O, and 150 grit. Between each grit,
brush or wipe to ensure that you're
starting with a clean surface. With
wood, sanding much beyond 150 grit
usually isn't necessary,and it can even
cause problems, especially if you're
applying a stain. That's becausefiner
grits can burnish the wood's surface,
The SanderSittereliminatesthe nuisanceof preventing it from absorbing stain.
waiting for the sanderto coastto a full stop Don't skip grits-leapfrogging con-
before you can set it on your workbench. sumes more time and leave scratches.
woodmagazlne.com
How to ge.t a g.rip on
your sanolng cnotces
As with many tools, you'll find that
random-orbit sanders cover a wide
price spectrum, with the more expen-
sive models ($165) easily costing twice
as much as low-price leaders($70). So
what do you get as you invest more of
your hard-earneddollars?
Sanders that are more expensive
usually have more robust internal
components, such as metal instead
of plastic gears, improved bearings
and electronic refinements, including
dustproof switchesand speed controls.
The way the sander fits in your hand
is another consideration. Test-grip a
number of sandersat the home center
or hardware store before making your
final choice.I
Sources
Bosch : 877 -267-2499,boschtools.com
Porter Cabf e : 800-487-8665,
deltaportercable.com
Sander Sltter and switched outlet
a v a i l a b l ei n m a n y w o o d w o r k i n g c a t a l o g ss u c ha s
Rockler.comand LeeValley.com.
Other sander options
A belt sander aggressively removes
stock,but its linearscratchpattern means
you can only use it with the grain of
wood. Cross-grainscratches(at mitered
or butt corners,for example)are asvisible
as beaconsand difficult to remove.
A finish sander overcomes this
problem by moving a pad in a tight
circularmotion so you can sand with or
across the grain. The small scratches
usually aren't conspicuous, and the
sander is easy to control. On the
downside, though, it's a slow worker.
Most finish sanders have square pads
that usequartersheetsof sandpaper,but
you'll also find rectangular half-sheet
versions. You may see these sanders
categorized with orbital models, but a
squareor rectangularpad meansthat it's
not random orbit. Pneumatic (air-
powered) sanders with orbital motion
are often called "jitterbugs."
Disk sanders have big appetites,and
they aren'tpickyeaters.In the blink of an
eye, the rim of the spinning disk can
easilytake a nastybite out of your project.
And unfortunately, it's difficult to teach
good table mannersto a disksander.
Of course,many of thesesandersspray
dust everywhere, making the sanding
chore more unpleasant and even
hazardousto your health.(See"KeepYour
Shop and LungsClean" on page 34.)
103
PortableTbol Stqrage
You can take it with you-
aybe installing a new dimmer
switch in the dining room isn't
exactly like an astronaut's
repair of a solar panel on the Interna-
tional SpaceStation. But in both cases,
the repairman needs a way to get tools
and suppliesto the worksite. Fortunately,
you can get all the tools you need to the
site of your earthbound chores with
readily available portable tool storage
that falls into five generalcategories:
Toolboxes: Thesecan rangefrom palm-
sized soft-sidedbags to metal monsters
big enough to dislocate your shoulder
even beforeyou load any tools.
Mobile storage: Essentially,toolboxes
with wheels, though some of these
units pack multiple functions.
Wearable rtorage: This includes
aprons, tool belts, and related accesso-
ries.Your tools and suppliesgo wherever
you do.
Organizers: These storage units keep
fasteners, drill bits, and other small
parts neatly corralled.
104
On-site storage: This burgeoning Put your MP3 playerin the zippered
categoryincludes a wide range-from compartment,then plug the CraftsmanTunes
and ToolsBag into any outlet at your jobsite.
plastic file cratesto toolboxesfor your The built-inamplifierand speakerslet you
pickup truck. do more than whistlewhile you work. Almost
forgot-it also carriestools.
Buckets and boxes
full of tools
Sure, you can still find rectangular
metal toolboxes, but they are only
the start of your portable storage
options. You'll also find cloth and
plastic carriers, and each material One of the
has its advantages and drawbacks. advantages
Plastic boxes generally cost less of a 5-gallon
than metal carriers, are lightweight, bucket-
storage
and dent-resistent, but scuff easily systemis you
and may become brittle and crack in canquickly
cold weather. locatethe
Metal does a great iob of shielding toolyou
valuable tools and has traditional need-no
needto
appeal. Aluminum boxes weigh less rattle
than steel and don't rust. On the around in the bottom of a bulky box. This
downside, they dent more readily. version is from CustomLeathercraft.You can
Newer surfaces, such as diamond organizeanother bucketwith drop-in plastic
compartmentsfor bulk fasteners.
treadplate,give a modern look.
Best-Ever Home Shop ldeas 2009

This 14"-fabric
bag from Huskyopens
wide for easyaccessto tools.
Fabric bags are tough
and versatile carrlers
You'll find severaldesignsfor cloth car-
rying bags,with battery-poweredcombo
kits and individual tools such ascircular
saws. You can also purchase bags to
serve as totes for specific tools or as a
general carrier (above).The tough fabric
can't dent, of course,and you can squish
the bag to reduceits volume. That feat is
impossible with rigid materials such as
metal and plastic.
A number of manufacturers produce
cloth organizers for S-gallon buckets
(opposite).Pocketsboth inside and out
provide high-visibility storage that
makes it easy to find and grab the tool
you need. Snap strapslassorolls of tape,
and you can use the volume inside the
bucket to transport suppliesto the iob-
site. To avoid the hassleof continuallv
putting away tools, simply place
the loaded organizer right on
your bench. That way, you
can grab and go on a
moment's notice.
Thismobile
work station
from Stanley
features 7"
wheelsfor easy
rolling,even
over unevenground.
The cavernouslower bin
holds largetools,and parts bins organize
fastenersand tool accessories.A generous
toolbox at top holds even more tools.
Make storage .
a moving eiperience
Putting wheels under a toolbox is a
great idea, especially if you need to
transport items that are heavy, bulky,
or both. When you're shopping for one
of these units, make sure that it will
accommodate the stuff you need to
move. If you'll be hauling large tools,
woodmagazlne.com
for example, measure carefully to involves maneuvering around in a crawl
ensure that they will fit. Another space.Also check that the fastenerpouch
consideration is ease of retrieval. A doesn't have exposed rivets with edges
big bin may offer generous volume, that can dive under your fingernail as
but if you fill it with small items, you reach for a fastener.
you may need to completely unpack
it to find the one tool you need.
Also consider whether a mobile
toolbox includes storage for fasten-
ers and other small items that you'll
need at the worksite, like the model
below. Of course, you can always opt
for separatesmall-item storage,but that
means one more thing to carry. Look
for a telescoping handle that stores
out of the way but extends to give you
a leverage advantage when you're on a
roll. Large wheels are better than small A traditionaltool belt (thismodel is from
ones on uneven terrain; wide wheels Duluth Trading)is set up for generalcarpentry.
help resistsinking into soft surfaces.
Everything in its place
The walking workshop Every hardware store and big-box home
A well-stocked tool belt surrounds you center will offer a good selection of
with your most-needed tools and sup- small-part organizers. But don't stop
plies, while a shop apron trades away there. Also look at tackle organizers at
most of the tool-toting ability to keep the sporting-goodsstore as well as stor-
you clean. The general guideline is that age accessoriesat the local crafts store.
an apron is for shop use, but you wear a Most organizers include dividers that
tool belt on the jobsite. let you split up the space to suit your
There are two general approaches needs. Some include a set of modular
toward tool belts. The first is purchasing insert cups so you remove the fasteners
a one-piecerig that has a hammer loop, you need and snap the lid on the rest, as
a seriesof pockets, a tape-measurewell, shown below.
and assortedtool slots(aboveright).lt's a If you have a significant volume of
good solution for carpentry and fastenersor supplies,look at the compart-
general-purpose tasks, but mented plastic storage units that stack
some models have draw- inside a S-gallon bucket. Adding a pad-
backs. A left-hander will ded lid to the bucket helps prevent spills
immediately notice that the ham- and also gives you a place to sit. al
mer hook is usually located
opposite his dominant hand,
requiring double-handling each
time the hammer's drawn or
returned. In addition, there
will be times where a job
requiresonly a few tools instead
of the full capacity of the tool belt. That's
why many people prefer the modular Laythis
approach: a leather or web belt to which Stanley
organizerflat,
you can easilyadd or subtract accessories open the lid, and lift
such as a fastener pouch, drill holster, out one of the storagecups-there are
utility-knife sheath, and so on. That three different sizes-for easyaccessto
way, you can customize your tool rig to the fastenersor parts you need.The extra-
wide handleopening providesa .
the iob. suregrip, even if you're wearing bulky
You'll find modular and one-piece gloves.They stackon the shelf,too.
tool belts in both leather and fabric. But
no matter which approach you take,
carefully examine each item before you Sources
(raftsman : 800-549-4505,craftsman.com
buy it to ensurethat it meetsyour needs. Custom Leather(raft
: clccustomleathercraft.com
For example, an open tape measurewell Duluth Trading : duluthtrading.com
might do okay most of the time, but Husky: homedepot.com
look for a strap to secureit if your work Stanley: stanleytools.com
105
MobileCabinets
& Carts

Readry,
Set,Roll
rF here are two types of home-shop enthusiasts:
I those who already own a mobile tool cabinet
I and those who want one. Even if you're part of
the first group, read on becauseyou'll discoveruseful
accessoriesthat boost the storage capacity of your
cabinet, both inside and out. You'll also learn about a
smart way to createcustom drawer labels so you can
instantly put your hand on the right tool.
In addition, you'll seehow a mobile shop cart can
help you get the most enjoyment and productivity
from your time in the shop.

Think inside the drawer
When you start looking at mobile tool
cabinets,you'll seean incrediblevariety
of drawer configurations: shallow or
deep, narrow or wide, and even doors
on some units. The setup that will work
best for you depends on the type of
work you do becausethat in turn deter-
mines the size of your tools. If you're a
machinist, for example, you'll probably
want a chest that has mostly shallow
drawersto organizedrills, taps,and cut-
ters. If you thrive on engine work, you'll
need shallow drawers for wrenches and
screwdrivers, but also some deeper
drawersfor larger tools and accessories.
Doors open wide to accommodate
bulky items. But if a shelf is near the
floor, you may need to get down onto
your kneesto retrievetools and supplies.
You'll make the space more accessible
by installing a pull-out shelf. You can
make one yourself or find one in the
kitchen-organization section of your
local home center.
Havinga great tool collectiondoesn't do you much good if you can't find the one
you need.Thiscabinetfrom Kobaltfeaturesa flip-top lid and an add-on shelf.
Try before you buy
Even with your eyes closed, you'd be
able to distinguish between a home-
owner-gradecabinet and a professional
model. The entry-level version won't
have individual drawer latches, and
you'll feel and hear metal-to-metal con-
tact as the drawer scrapes-rather than
slides-open. When you close the
drawer,you'll need to make certain that
it doesn't bounce back or stop short. YK
As you move up the price ladder,you'll Divideand conquerwasa winning strategyfor
find doors with individual lift latches. Romanlegions,and it's a good way to organizeyour
tool cabinet,too. Dividersand trays(thesearefrom
This is a great feature becauseit ensures
WaterlooIndustries)are a good start,but you'll also
positive closing and also keepsthe draw- want to recruitspecializedorganizersfor sockets
ers from sailing open when you move and other tools.
your cabinet. With non-locking draw-
ers,you'll need to put the entire cabinet drawer's weight rating. Inexpensive
in lock-down mode before moving it. slides can complain loudly as you load
Better chests also use ball-bearing the drawer, but ball-bearing slides seem
drawer slides. These operate smoothly to thrive on the work by operating more
and quietly, and also help boost the smoothly under an increased load.

106 Best-Ever Home Shop ldeas 2009

 Plug into your tool chest
A power strip on your tool chest can be
something that you pop on with a few
minutes' work or a factory-supplied
accessory.Either way, it will add conve-
nience and reduce your dependenceon
long extensioncords.
You can buy an intermediate chest
(sitsatop the rolling cabinet) from Sears.
It's wired as a charging station for your
battery-operated tools aswell aspersonal
devicessuch as your mobile phone and
MP3 player.
The CraftsmanAXS systemfrom Sears
takes electronic convenience (and a few
gadgets)to the next level.Your tool chest
can have under-frame downlighting, Craftsman labelsmakeit easyto
magnetized
two slide-out LED task lights, backlit findyourtools.
nameplates,a 12-volt power outlet (auto-
motive style), six-outlet power strip, and models let you choosefrom severaltype
even a USBport. A built-in messagecen- stylesand sizes.Unlike the old-fashioned
ter delivers data on duy, date, time, embossingmachines,thesenew models
indoor and outside temperature (via producecrisp type.
remote sensor),timer, and alarm func-
tions. The matching portable tool box Put a shop cart into your
shopping cart
l o l
(seepage 104) includes a dock for your
With the introduction of the CraftsmanAXS
system,Searslaunchedmobiletool storage
MP3 player,and amplified speakers. Once you start using a shop cart, you'll
into the electronicsage.Somepeoplemay wonder how you survived without it.
considera few featuresgimmicky,but this Go ahead: Pick a color, Many models have generous drawer
cabinetwill still be the coolestplaceyou ever any color (almost) volume to keep your most-used tools
parkeda wrench.
Years ago, a brown-wrinkle finish was instantly available. Use the top to stack
virtually the only color choice for tool parts as you move them among various
Casters,lochs, and cables chests,and some old-schoolmachinists workstations or to hold supplies.dF
Castersput the motion into your mobile still adhere to that tradition. But now,
tool cabinet,so they deservesomeatten- you havea wide paletteof color choices,
tion. The usual setupfeaturestwo casters and can even order drawer fronts
that swivel and two with fixed axles- emblazoned with bright graphics in
similar to the setupyour automobile.As themes ranging from NASCARto NFL
a result, positioning a cabinet against a to patriotic. At least one maker pro-
wall is similar to parallelparking, requir- duces cabinets in a forest camouflage
ing additional space at each end to pattern that pleasessome people but
permit maneuvering.If you want to push leavesothers scratchingtheir heads.
a cabinetstraightbackinto a fitted space, You can also buy a cabinet in stain-
four swivel castersare a better option. lesssteel,and it can look very sharp if
Although castersare a real blessingin you're willing to invest the time in
moving a fully loadedcabinet,they also polishing it and avoiding fingerprints.
enablethievesto make your cabinet dis- Also be aware that stainlessis softer
appear.To help keep your tool collection than regular steel, so it could dent
secure,invest in a heavy-duty security more easilyif the manufacturerdoesn't
cable that tethers your cabinet to an compensateby using a thicker gauge.
anchor point solidly imbedded in the
Solvethe problem of a clutteredworkbench
floor or wall. Label the contents by purchasinga rollingtool cartand
Forthe lockson the cabinetitself,look Some manufacturers produce drawer offloadingthe basicnecessities into the
for pick-resistanttubular keys. If the labels so you don't have to remember drawers.The top of this Grizzlycart provides
cabinet you buy doesn't have this type, whether the crow's-foot wrenches are in a surfaceon which to placecomponentsof a '
simply remove the stock lock and take it the fourth or fifth drawer. But the work in progress.
a local locksmith. The shop will be able printed labels (some are magnetized
to provide a more securereplacementat sets)can't anticipate all of your needs, Sources
a price lower than replacing even one so you may need to resort to hand- Craftsman: 800-549-4505; craftsman.com
Grizzlyz800-829-4752,grizzly.com
quality tool. A locksmith can also help scrawlingon masking tape. Kobaft Tools: 262-781-3600, lowes.com
you if your upper and lower cabinets are Avoid both those alternatives with Waterf oo I ndustries : 714-522-8088;
keyed differently. a hand-held labeling machine. Most waterlooind ustries.com

woodmagazine.com 107
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Best-Ever Home Shop ldeas 2009
 You'll also find nailers that get their have developed some ingenious so-
power by igniting gas from an onboard lutions. For example, product engineers
fuel cell. This system eliminates the shed the weight of a cast-iron compres-
necessityof a compressorand air hoses, sor block, and substitute steel sleeves
as shown bottom left. inside an aluminum block. Many also
abandon the oil-filled crankcase and
Big jobs for station ary substitute Teflon piston rings and a
compressors cooling fan. In fact, an oil-free compres-
From the standpoints of depend- sor requires less maintenance than the
ability and performance, bigger really oil version.
is better when it comes to air com-
Don'tletthe smallsizeof theJacPac refillable pressors. For starters, a large motor Choose from a wide
carbondioxidecylinderfoolyou.lt has (sometimes requiring Z{o-volt power range of air tools
powerto shoot500fasteners. Includingthe for the serious DIYer or auto mech- You'll use a compressor for much more
regulator, it weighsaboutfivepounds.
anic) squeezes the air to a higher than simply filling tires and inflating
One simple method involves adding an pressure.A two-stage compressor,for pool toys. An impact wrench (what
air regulator to a portable tank. Simply example, typically achieves a maxi- auto shops use to remove lug nuts)
fill the tank with air at a gasstation, then mum pressureof 175 PSI compared takes the hard work out of
use that compressedair. It's a good alter- with 125 PSI for a small many vehicle maintenance
native to lugging a portable compressor compressor.That's signifi- chores.A word of caution:
up to a second-floor room to install a few cant, because it means Be sure to invest in a set
piecesof baseboard. that a comparably-sized of impact sockets.An ordi-
One recent innovation in the air- tank holds 40 percent nary socket could shatter
powered arenais a high-pressurecarbon- more air at 175 PSI than when subiected to an
dioxide cylinder teamedwith a regulator. at I25 PSI. A 30-gallon impact tool. But impact-rated
The combination mounts on your belt, tank, for example, acts as if sockets (usually black in
and therefore needs only a short hose it had a 4Z-gallon capacity. color) have beefier walls to
to connect the tool, as shown above. A large tank helps ensure stand up to the strain. You
The carbon dioxide is stored in a liq- that you'll never deplete the can use standard sockets,
uid state, but quickly converts to a gas pressure below the tool's though, with an air ratchet.
when it passesthrough the regulator. working requirement, even For wood construction, you
The cylinder maintains pressureas you when you run it wide open for can drive a rangeof air-powered
use up the carbon dioxide, so you get an extended period. Second, fasteners,from framing nails to
full power down to the last fastener. a big tank means that your finishing nails, brads, and
You can have a cylinder recharged compressor will power on staples.-lF
at any paintball supply company for less often, extending the
about $5, and that should be enough to life of the motor and the
shoot about 500 fasteners.You can also compressor's components.
do a cylinder exchange at stores that Virtually all compressors This 28-galloncompressordeliversthe
sell the system. are rated at a maximum ser- power to run a wide rangeof pneumatictools
vice rate of 50 percent, which means for jobs in woodworking, metalworking,and
auto mechanics.
that the motor should run no more
frequently than half the time.
(Standard
SCFM CubicFeetperMinute)
required
at90Psl*
Small compressors Finish
nailer,
bradnailer 3SCFM
are hard workers
Stapler 3 SCFM
Mid- to small-size compressors with
Airratchet 4 SCFM
4- to 6-gallon tanks lack some of the
meatier specificationsof their big broth- Drill6mall) 4 SCFM
ers, but they make up for it by being Airhammer 6 SCFM
tough competitors. If you match. the lmpactwrench(72") 8 SCFM
compressorto the tool, you'llnever out- Straightline
sander 9 SCFM
work it. Many of the contractor-style (medium)
Sandblaster 10scFM
compressors have twin quick-connect *Manyof thesetoolsdon'tactuallyrequirean operating
hose outlets becausethey have enough pressurethat high,but tool manufacturers
convertto
that pressure
to makecomparisons easy.Valueslisted
muscle to keep two workers busy. Even a arerepresentativeof the categoryandmayvaryamong
small compressor,such as a 150-PSIunit manufacturers.
with a 5-ga11onpancake-shapedtank,
has enough capability to keep a carpen- Sources
Cordless(and hose-free)nailersreducesetup Campbell-Hausfeld: 800-543-6400, chpower.com
time for projects.Choosefrom a framing ter with nail guns working hard. DeWalt : 800-433-9258,
dewalt.com
nailer,suchasthis model,or a rangeof finish To achievebig performance in a small supplierpipel
f acPac: 800-567-0864, ine.com
nailersand driversfor bradsand staples. and portable package, manufacturers Parfode : 847-634-7
048,paslode.com

woodmagazlne.com 109
 Lasersfor
the Home
The straightstory
on straightlines
ffi1
li #a
\ * .. \
,':,\
. . l \ t s ' .

;ilkryt#itool, shownaboveprojectinghorizontal
andverticallines,isa realmultitasker.
Other functions includeelectronicstud sensor,sonicdistancemeasureand a continuous-read
featurethat lettyeu measureas you walk. lt retailsfor about 570.
_\r/

he first time many of us saw the
power of a laser was when arch-
villain Auric Goldfingeradvanced
the high-energy beam toward a captive
JamesBond. When that film debutedin
7964, few people could have imagined
that lasers would eventually become
practicaltools in home workshops.
There are three main uses for laser
productsthat you'll find helpful:
I a beam indicateslayout lines
for a project (tile installation,
for example),
. a lasershowsthe spot or line
where a tool will cut
(a drill pressis one use),and
. a laserservesas a
referencepoint to show
where a measuringfunction
is occurring (aswith an
ultrasonic measuringtool).
Laseruthat point
Some ultrasonic measuring tools
display distancewith iust the push
of a button. A model from Calcu-
lated Industries, right, projects a
laserbeam to indicate the target,
Thislaserfrom
eliminating guesswork.It claims Calculatedlndustries volume of rooms, a key piece
a 99 percentaccuracyrating over readsdistances.
its 2- to S0-foot range, and is useful in
calculatingmaterialsfor a number of proj-
ectsthroughout your home.
Peoplewho do appraisalsor other real
estate work find a laser/ultrasonic tool
especially handy. More-expensive mea-
suring devices have built-in calculators.
The devicesusuallytoggleeasilybetween
the inch/foot systemand metric.
Stanley has a line of Tru-Lasertools
that utilize the laser beam itself for
linear measurement,a technology that
the company says offers
superioraccuracycompared
with ultrasonic.
Linear measurementsare
easy, of course, but team
laser deviceswith an inch-
foot calculator (seepage112
for the Construction Master
5) and you can quickly esti-
mate areas for flooring,
drywall, paint, wallpaper,
and more. These two tools
also speedily figure perime-
ters, as when you're buying
crown molding or other
millwork. Or, calculate the
of information when you're
sizing the capacity of an air-conditioner
or humidifier.
Another example in this categoryis a
no-contact infrared thermometer that
includes a laser for targeting of surfaces
that can be out of reach or dangerously
hot. You can usean infrared thermometer
to find hot spotsin electricalpanels,mov-
ing parts, or in automotive applications.
Lasersthat show the path
Tool companies often refer to this cate-
gory as "laser-guided"tools, although
the laser doesn't actually take over the
steering or positioning of the tool. It's
more correct to say that these are tools
with laser guides, showing you where
the blade will cut or the hole will be
drilled. These guides can slash tedious
setup time, promote better work habits,
and provide more-accurateresults.
One example is the drill pressopposite
that utilizes twin criss-crossing laser
beams to pinpoint exactly where the bit
will enter your stock. You find this fea-
ture on somenew drill presses.Or, retrofit
your existing tool-benchtop or floor
model-with an easy-to-install after-
market unit. For the best results, be
patient when you adjust the aim of the

110 Best-Ever Home Shop ldeas 2009

 Onegreatadvantage of thisDeWaltlaser
systemisthatyoucanswitchon the laser
whilethebladeisstationary.
Thissimplifies
setupsandproduces more-accurateresults.
beams so that the cross mark exactly
matchesthe drill's centerpoint. It's also
a good idea to periodically verify the
setup, especially if your drill is on a
mobile base,becausethe vibration and
shocksof repeatedmoving may compro-
mise accuracy.
You also can equip your mitersaw with
a laserto indicate exactly where the blade
will cut, as shown above.There are two
basicways of doing this. Somesawshave
factory-installed systems that indicate
the cutlines, and the beam can be
switchedon even with the blade station-
ary. The other technology involves a
Twin lasersgeneratea crosshairtarget that showsthe
centerof your bit, promoting fasterand more-accurate turn on the beam whenever you
results.Newgl drill pressesbuild in this technology,but want to inspect your progress,as
it's alsoavailableasan add-on for someolder models.
woodmagazine.com
Equipyourmitersawwith anaftermarket
laserfromlrwin,andyou'llincrease
your
accuracy.Thebeamswitches on whenthe
bladespins.
laser-equipped saw-blade washer that
replaced the factory-supplied washer,
as shown above.When you switch on
the blade, the centrifugal force caused
by the rotation closes the electrical
contactsinside the housing, turning on
the laser.This affordableretroflt^adapts
to a wide range of saw makes and
models. Bearin mind though that both
of these systemsusually show only one
side of a saw's kerf, so you'll need to
consistentlyposition your stock so that
the wastesideof the line is to your right
(asyou face the saw).
You'll also find circular saws that
proiect a laser line ahead of the
I UtaOe like the model aboveright.
Simply match the laser projec-
tion with your marked cutline
and keep them aligned while
you cut. This also trains you
to aim the saw by looking
at where it will go instead of
focusing on where the blade is
currently cutting.
Lasers that find level
Lasersexcel at establishing lay-
out lines because the line is
dependably straight and you
don't need to fuss with erasing
preliminary marks. In addition,
you won't cover up your layout
lines as the work progresses.For
example, the old-fashioned way
of marking out a start line for a
ceramic flooring installation has
you place the marks directly on
the backer board, where they're
quickly lost under the first appli-
cation of thinset mortar. With a
laser layout though, fou simply
shown opposite.
Somecircular sawshavea laser(thismodel
hastwo)that projectsa beamontoyour
workpiece. Matchthe lightto the marked
cutlinefor results
thatarerighton thebeam.
Securemounting is one of the keys for
successin using a laser.With lightweight
units, usespecialadhesivestripsto tempo-
rarily secureit to the wall or floor and
then remove the device without leaving
any residue. Larger units offer different
mounting options such as a tripod, as
shown below,or a specialbasethat permits
temporary attachment to a stud or that
even clips on to a suspendedceiling grid.
In addition to the ceramic floors and
suspendedceiling proiectsalreadymen-
tioned, you can use a laser for layout
lines for a wide range of other projects.
These include hardwood and laminate
floors, vinyl floor tiles, ceramic tile on
walls, wallpaper,embossedceiling pan-
els, hanging pictures, installing shelves,
nailing on outlet and switchboxes,install-
ing cabinets or a chair rail, and many
more proiectsaround the home. lF
Acculine'smanualrotary-headlaser(lessthan
S100)quicklyfinds horizontaland vertical.
planes-ideal for tasksfrom buildingwalls
and installingcabinetsto hangingwallpaper.
Sources
Acculine: 262-242-1161;
acculinepro.com
CalculatedIndustries:800-854-8075;
calculated.com
Craftsman: 800-549-4505;
craftsman.com
DeWalt: 800-433-9258,
dewalt.com
lrwin: irwin.com
Skil: skil.com
Ryobi: 800-525-2579;
ryobitools.com
111
DigitalToolsUnder$100
Value-packed racy devices
deliveraccu
igital technology touches nearly
every aspectof modern life: tele-
phones, TVs, and computers,of
course.But digital is alsosteadilybecom-
ing a part of home workshops. Some
shop tools, such as tablesawsand drill
presses,are beginning to sprout digital
readouts.But in this article we're focus-
ing on tools under $100.
The dlgital imclinom*t**"
two-step
The built-in blade-bevelscaleof a table-
sawwill usually get you into the general
neighborhood of an angle. But to bring
real accuracy home, try a digital incli-
nometer (or tilt box)-a cleverlittle tool
that quickly comparesthe angular dif-
ferencebetween two surfaces(above,the
sawtable and the blade).
To calibrate the tool, first stick it onto
your tablesaw'stop with the rare-earth
112
magnets built into the bottom of the
case.Push a button to zero out the set-
ting. Next, use the magnetson the side
of the case to adhere it onto the saw
blade. (It works with saws that tilt the
blade either right or left.) Now you can
crank the blade to the exact angle you
need. The digital readout displays in
increments of 0.05 degrees, but the
statedaccuracyis 0.2 degrees.
A calculated way to
irnprove ac{uraty
Most fifth-graders are proficient at
working with fractions. But it's often
tough to find a fifth-grader when you're
in the middle of a project. In that
case, you'll find it helpful to buy a
calculator that works in feet, inches,
lf you want to quicklybreezethroughestimating
and fractions. and project-planning chores,get yourselfa math
The Construction Master 5 Calcula- wizardsuchasthe ConstructionMaster5 from
tor, shown at right, can easily add, CalculatedIndustries.
Best-Ever Home Shop ldeas 2009
 subtract, multiplt and divide all of their rigid storagecaseafter use to avoid
those dimensions and metric values, damagefrom abrasionand impact.
too. You can easily toggle between
English metric systemsor even include Laser and digital tape
both systemswithin a string of calcula- measurements
tions. But those capabilitiesmerely hint Some tools work hard, but others are
at the full power of this handheld math multitasking overachievers. The Bulls-
whiz. You can calculate squareyards of Eye laser level (boftom) from Black &
carpet, cubic feet of room volume for Decker combines an auto-leveling laser
sizing a dehumidifier, cubic yards of (with three lines) and a digital tape mea-
concrete for a driveway repair, figure sure. The self-leveling feature is a real
rafter lengths for a new shedor riser and timesaver because vou don't need to
tread sizesfor a set of deck stairs,evenly fiddle with tedious alignment
spacebalusterson a balcony or pictures adiustments.
along a wall, and much more. New devices,such as the
The calculator is intuitive to Digital calipers(about 540) remove
uncertaintyfrom precisionmeasuring
ScaleMaster from Calcu-
use: You merely push the keys in the chores.lf you're a left-hander,look for a lated Industries at right
same sequenceas speaking the math model with a reversedconfiguration. speeds the translation
operation. But don't worry if you get of plans and Faps
into a tough situation such as figuring Measurinq without the drawn to scale. rF
the length of edging for a circular French acient
planting bed around a tree.The calcula- Calipers and many other measuring
tor includes onboard storage for its instruments have long had a supplemen-
pocket reference guide, so you can tal scale that was developed by Pierre The ScaleMaster
quickly look up the exact procedure Vernier in 1631. (Interestingly, Vernier's from Calculated
lndustries
you need. name wasn't widely associatedwith the measuresscales
scale until the early 19th century.) The in drawings
Doing your level best Vernier scaleis easyto understand and and maps.
Reading the vials of an standard level use, but it involves the ability to clearly Sources
Black & Decker:
can be a dispiriting task. The result seesmall markings.
800-733-71 11,
- depends on how you hold Digital calipers overcome that short- blackanddecker.com
your head, and getting any coming with a bold readout (above)that CalculatedIndustries:
accuracyat all in cramped or can displayin fractions,decimal inches, 800-854-8075; calculated.com
dimly lit areas is a tough or the metric system. A 6" measuring Craftsman: 800-549-4505,
craftsman.com
assignment. But the technol- range should handle most home-shop Grizzly : 800-523-4777,grizzly.com
ogy built into digital levels chores.Calipers have the Wixey: wixey.com
removes any uncertainty. ability to take inside and
The bright display is easy to outside measurementsas
read (Ieft),but there's also an well as depth and step
audible beep at O, 45, and 90 measurements. You can
degrees, so you could even combine inside and out-
operate the tool with your side measurement capa-
eyes closed. If the surface bilities to directly read
you're measuring isn't per- the difference between
fectly level or plumb, you can two components such as
read the angle to an accuracy a shaft and a hole. If your
of an amazing one-tenth of calipers' manual doesn't
a degree. cover all of these proce-
The inclinometer function dures, spend a few min-
can also switch to read a slope utes on the Internet, and
percentage or a pitch. This you'll discover plenty of
is useful for surfaces that helpful advice.
require an elevation change And although the tool
to drain properly. You'll find is easy to use, it's not
it handy when you're build- idiotproof. So it's worth
ing a deck, installing gutters, developing good work
or setting up forms to pour a habits such as holding it
patio or sidewalk. squareto the object you're
measuring. Even a slight
ThisCraftsman24"digital levelincludesa A digitaltape measurein Black& Decker'sBullsEyelaser
laserreferencebeam.You'llalsofind this tool angledefeatsthe accuracy level
brings your DIYprojectsinto the 21stcentury.The
in a torpedo versionthat easilyfits into your built into the tool. Be sure built-in auto-levelinglaserprojectsverticaland horizontal
toolbox, or in a 48" size. to return the calipers to lines,so you finish projectsfasterand more accurately.

woodmagazlne.com
113
 :l :,:.*'{i,::l : : : : : : : : ; : : : : : : : : : : : : : : il: :::
: : : : : : : :: :: : : : : : : : :: : ] i l l : : :
::i::::;r:;;:;:::::::il:::

Clampsfor the Home

Get a grip on your work and budget
IFhere's an old saying that you
I can't have too many clamps. And Five Favorlte Clamps
I while that's accurate,it's only half for DlYers
the truth, because it's not simply the
number of clamps; you also must have
the right type.
- We'll take a quick look at a wide One-handed
range of clamps that will make your bar clamp
time in the shop easier,safer,and more
productive.
S l i d i n g - b acrl a m p
Work-holding clamps
At the drill press,/ou can use ordinary
C-clamps to attach a plywood basethat
keeps you from drilling into the metal
table and prevents chipout when the bit
breaksthrough the wood. A fence-also
held in place with a C-clamp-helps
immobilize the edge of your stock so
that the bit can't grab and spin it. (This
is a common source of shop injuries.)
Alternatively, you can use a drill-press
hold-down that fits into one of the slots Springclamp
milled through the drill-press table.

'114
Best-Ever Home Shop ldeas 2OO9

ThisVarioClippixby Besseyis a clever
variationon the standardspringclampwith
infinitely adjustablejaws up to 4".
Assembly and
disasseniUly clamps
There'sa wide arsenalof clamp typesthat
can help when you're assembling proi-
ects.Spring clamps are among the least
expensive and easiestto use, but each
size has a fairLylimited clamping range
and only a single pressuresetting. And
when you use them to hold glued parts,
they sometimesmake the parts slide out
of position. A new style of ratcheting
spring clamp (the BesseyVarioClippix,
above,is one example) overcomesmany
of theseshortcomingsby allowing you to
adiust the opening, the clamping angle,
and the amount of clamp force.
If you get into repairing and reassem-
bling furniture, you'll need some large-
scaleclamps.Pipe clamps are one of the
leastexpensivealternativesand also one
of the mostversatile.The length of clamp
you can make is limited only by the
length of pipe you have. If all of your
pipe sectionsare threaded at both ends,
you can expand clamping capacity by A four-wayclamp providessteadypressure
ioining them with pipe couplers.By the and cornersthat help squarethe project. lt's
way, we recommend the fixtures that use idealfor assemblingboxesand frames.
t/+"pipe becausethe Vz"version doesn't
have enough muscle for big iobs.
Barclampspullthe boardstogetheredgeto
edgewhile the springsclampskeepthe board assembling drawers or a large cabinet.
facesflush.To balanceclampingpressure,
Alternatebar clampsoverand undera panel. top right, is one example.
woodmagazlne.com
Another type of bar clamp uses
fixed lengths of steel, aluminum, or
composite material. In similar lengths,
these types generally weigh less than a
pipe clamp. However,you can't combine
two clamps to make one that's longer.
Sliding-bar clamps are a long-time
favorite in the shop. The one-handed
bar clamp has becomepopular in recent
years becauseit's fast and easy to use,
and keepsone hand free to adjust project
parts (not an easytask using sliding-bar
With this clampand one hand,you can snug
clamps). As an added feature for one- up miters,butt joints, and evenT-joints.The
handed clamps,you can reversethe jaws
clamp self-adjuststo piecesof differentwidths.
to use it as spreader.This is handy in
disassemblyoperations (taking apart a Clamps for round and
chair, for example)or in caseswhere you irregirlar shapes
need to apply outward pressure. When you need to apply pressure all
At the top end of the bar clamp around a circular form, a nylon band
category are those with large parallel clamp may be iust the solution you need.
jaws and impressive clamping force. To use it, Iassothe parts you're ioining,
Although a number of manufacturers pull the clamp snug, then tighten the
now produce a similar design,the Bessey ratchet mechanism with a wrench. The
K-Body and Jet clamps are often consid- small version of this clamp is 15' long
ered the premier examplesof this type. and usually includes four metal corner
brackets so that you can conveniently
use it when assemblingpicture frames.
In a pinch, /ou can also use a ratchet-
ing tie-down strapasa band clamp. You'll
find that these are quite inexpensive at
hardware storesand the home centers.
If you get into a really big proiect,
make a supersizedband clamp using a
trucker's tie-down strap. Don't get too
carried away with the pressure,though,
or you could crush your project. ll
Sources
Bessey:800-828-1
004,besseytools.com
f orgensen: 312-666-0640,
adjustableclamp.com
-8158,leevalley.com
Veritas:800-871
Woodcraft: 800-225-1153.woodcraft.com
More a$sembly clamps
For smaller-scaleassemblies such as
picture framesand boxes, try a clamping
system such as the Veritas 4-Way Speed
Clamp, shown above.One handy feature
is the quick-releasenut that can slide
along the threaded rod until it's nearly
in position. You then engageit on the
rod and tighten.
Another handy assembly clamp
securely holds corners or T-assemblies
square to each other, even when their
thicknesses are different. This clamp
considerably simplifies and speeds the
construction process, whether you're A band clamp works great on rectangular
projects,but reallyshowsits value on odd jobs:
multi-sided,circular,and other toughies.The
The Jorgensen"Pony" 90"-angle clamp, largetrigger on this modelfrom Woodcraft
tightensthe straplikea one-handedbar clamp.
115
Understanding
TbolBatteries

hen woodworkers talked about batteriesand chargers.In addition, these chemistry uses no heavy metal, unlike
battery-powered tools a few two technologieshave been around lon- NiCd. TWo drawbacks: NiMH batteries
years ago, the discussion was ger than Li-ion, so their characteristics cost 35oloto 4oo/omore than NiCd, and
almost always about drills. But tool- are well established. they typically exhibit drops in voltage as
makers have now hitched batteries to a NiCd batteries, which debuted in the battery discharges. You'll often
wide afiay of power tools, including 1946, charge rapidly and efficiently, notice this as a distinct loss of power
reciprocating saws, impact drivers, and don't require critical control of while you're using the tool.
flashlights, angle grinders, sanders,iig- charging conditions. (That means
saws,staplers,hedge trimmers, jobsite they're more tolerant of heat and cold
radios with amplified speakersfor your than other chemistries.)They produce
MP3 player, and many more. A number a steady voltage when discharging
of tool manufacturersbundle severalof (while powering your tools), and
the most popular tools along with a the system has lower internal resistance
charger and two batteries to keep you than NiMH. This means the NiCd
working strong all day. batteries achieve a higher maximum
discharge rate. On the negative side,
The battles of NiCd batteries are the heaviest of the
battery technology three systems, a disadvantage if you're
A battery-powered tool will likely have using the tool for long periods, or over-
one of three battery chemical systems: head. And, cadmium is a heavy metal,
nickel-cadmium (NiCd), lithium-ion which is dangerousto discard.
(Li-ion), or nickel-metal-hydride(NiMH). NiMH batteries store more charge
At present,Li-ion grabsmost of the head- (think of them as larger fuel tanks), and
lines becauseit's the relative newcomer. that translates into longer run times
But iust becauseLi-ion has a better press than NiCd. The unit that describesthe
agent doesn't mean that the other tech- amount of storedchargeis the amp-hour
nologies are going to quickly or quietly (abbreviatedAh). NiCd batteries offer a It takes 15 cells,each rated at 1.2volts,to
disappear. After all, millions of home maximum of 2.4 Ah, but NiMH maxes producethe long run times of this 18-volt
shops have tools with NiCd and NiMH out at 3.5 Ah. As another plus, NiMH nickel-metal-hydridebattery pack.

116 Best-Ever Home Shop ldeas 2009

 Enter Lithium-ion
! Although some accounts would have
iT you believe that Li-ion is a brand-new
technology, it's really only new to power
tools. Li-ion is the battery chemistry
I found in portable electronic devices
such as cell phones, personal digital
assistants, and laptop computers. It's
also the technology that makes cardiac
pacemakerspossible,and it remains the
power source of choice for implantable
medical devices.To understand why Li-
ion batteries are causing such a stir, you
need to know a little about the internal
construction of a tool's battery pack. If
you took the housing off a pack, you'd
discover that it's composed of a seriesof
individual cells, as shown previouspage
bottom.With NiCd and NiMH chemis-
try, each cell produces 1.2 volts. The
manufacturer then wires a number of
cells together in series to produce the
desiredvoltage. (By connecting 10 cells,
the manufacturer produces a l2-volt
battery.) So it's easy to seehow increas-
ing a battery pack's voltage quickly
makes it larger and heavier.
On the other hand, each Li-ion cell
produces 3.6 volts, so it requires only
three cellsto make 10.8volts. The effect
on tool size is dramatic: Bosch's 10.8-
volt Litheon drill-driver weighs only 4
ouncesmore than just the battery from
a competitor's l2-volt NiMH drill. If
you're lugging around a drill all day, the
weight savings makes a big difference.
Somemanufacturersnow selltools, batteries,
and charge.rs
ir la carte.You can add to the
systemlater-and savemoney-by purchasing
additionaltools without a battery or charger.
woodmagazlne.com
Li-ionpowerdoesn'tfade,sothere'sno
warningof a lowcharge.MostLi-iontools
havefuelgaugeson thetoolor battery.
Another advantageof Li-ion is that it
holds its charge better than NiCd in
storage: a distinct advantage to people
who enioy working with tools but don't
do it every day, or even every week (for
example, DIYers).
Of course, tool manufacturers are
utilizing Li-ion technology to produce
batteries comparable in size and weight
to the traditional units, but with volt-
ages higher than practical only a few
years ago. So, there's a growing number
of 24- and even 36-volt tools on the
market. With these muscular battery
packs, a whole new range of tools has
become practical. Now, you can have a
rotary hammer with legitimate power.
And a circular sawwith a 36-volt battery
pack is an unmistakably serioustool.
A chargerwith a built-in fan, like this Ridgid
model, coolsthe battery before and during
charging,which prolongs battery life.
Batteries and chargers
are getting smartel
Old-style chargers reenergized depleted
batteries, but they sometimes also
helped the battery to an early grave.
That's becausethey couldn't recognize
conditions that produced problems dur-
ing the charging process.If you put an
overheatedbattery onto the charger,for
example, the unit would try to force the
battery to take a charge that it was in no
condition to accept.Some chargersnow
include refinements such asbuilt-in fans
to dissipate damaging heat. (Seephoto
top rrght.)
Now, an intelligent battery pack (com-
monly availableon Li-ion units) includes
a computer chip that helps regulate
the incoming charging current as well
as the work-producing output. The chip
tracks charge and discharge patterns,
and recordsthe first date of use for war-
ranty purposes.Somebattery packseven
have easy-to-read"fuel gauges"that tell
you how much of the charge remains
i. ,eserrr..(Seephoto top te1t.".ll
Sources
Ryobi: 800-525)579,
ryobitools.com
Rldgid:homedepot,com
81-3600,
Milwaukee : 262-7 milwaukeetool.com
Even the best rechargeable battery has
a limited lifespan,and after a while will
refuseto accepta wor,kablecharge.Instead
of trashing your old battery, take it to' a
retailer that servesas a collection point '
for the RechargeableBattery Recycling
Corporation(RBRC).Some of the better-
known retailersincludeThe Home Depot,
Best Buy, Target, Circuit City, and others.
To find the drop-off location nearestto
you, contact RBRCby calling 800-822-8837
or visitingits Web site:RBRC.org.
117
EkingPrycision
*o*u*ol-ffom 3 POftablg POWef TOOIS
l ru'v,"u,o,,"e
see the tools above as the
rough-work trio, not to be
mentioned in the same breath with
Discovershop-proven strategies to elevateyourcircsaw,
the word "precision." Typically, jigsaw,and portabledrill to the stratosphereof performance.
woodworkers rough-size wood mate-
rials with a circ saw and finish-cut
them on a tablesaw; or they rely on But what if you don't own a tablesaw,bandsaw,or drill press?What if you don't have
their bandsaw to cut curved parts, the extra jack to buy these stationary power tools? Can you perform high-quality
fearing they'd hack up workpieces woodworking with the much-maligned trio? The answer: Absolutely! With the right
with a jigsaw;or they view their cord- accessories,bits, blades,and a shop-made helper or two, improved-if not flawless-
lessdrill asa convenience-not nearly precision is well within your grasp. Here's how to turn these "go-away" tools into
as preciseas a drill press. "go-to" superstars.

Crosscutting,ripcutting, and Carbide saw-blade savvy

bevel-cutting along a
straight line sum up the fO ff youlre cutting softwood, softwood plywood,
circ saw's role. To ensure and MDF or ripcutting hardwood, a standardor thin-
s u c c e s se, q u i p t h e t o o l w i t h kerf 24-tooth,7l+" combination blade will deliver a
a q u a l i t y b l a d e ,m a t c h i n g i t respectablecut. It hasqn aggressive20o tooth hook
with the material and type and costsabout $tS. g For a fine-finishing blade to
of cut (see right), and cut hardwood and hardwood veneer plywood, pay a
adjusting the blade depth few bucks more for a 40-tooth, hard-body thin-kef-blade. Costing around $30, its 12" tooth
'lzs"
below the work. angle cuts lessaggressively,leaving few splinters. Q)A standard-kerf4O-tooth blade, with its
20" tooth hook, deliversthe cleanestcut, only at a slowerrate. Price:about $45.

118 Best-Ever Home Shop ldeas 2009

 Troubleshaating prohlerns
Alignment woes. Do a two-step to tune up your saw
for spot-on accuracy.First, squarethe saw'sbaseplate
to the blade. With the tool upside down (and
unplugged), loosen the blade-depth lock. Lower the
blade, and lock it into place. Then, retract the blade
guard. Fit a squaresnugly againstthe blade body and
baseplatesole (PhotoA).Adjust and lock the baseplate Measureat front
to square. back of blade, from
Also, using an adjustablesquare,check whether the Fdge of baseplate.
baseplateedgeis parallel to the blade (PhotoB). If you
detect a difference from the front to back, adjust the
baseplate.If you can't adjustthe baseplate,add a shop- t
made zero-clearancesubbasediscussedunder Splinter-
ingandtear-outbelow.
Finally, using a drafting triangle, check the calibra- /",
tions on the blade-anglescaleat 30" and 45". If your
scale is off, incise these intersections with a sharp
blade or nail for speedyreferencelater.

Kickback and wavering cuts. It's scarywhen a circ

saw iumps back during a cut. You fear injury and
chewing up the workpiece.Many factorslead to kick-
back:a lack of stocksupport,which causesthe material
surrounding the saw to bind the blade; a forced feed
rate; or a hung-up cord. As shown (PhotoC),it pays to
equally support material on both sidesof the cutline
and-if needed-clamp the workpiece down to pre-
vent it from moving when sawing. Using sawhorses
and sacrificial 2x2s under the workpiece provide a
cheap solution. Also, don't force the saw; you'll know
when the motor slows.Drape the cord over your shoul-
der so it doesn'tcatchand yank the sawoff course.
To correct wavering or binding freehand cuts, make
a straightedgeguide customizedto your saw,like the
one at rigltt. Another option: Buy a clamp-on tool
guide with a circ saw subbase,as shown previottspage,
top left. Such systems prevent the tool from straying
from the cutline. (Seeother helpful shop guides from
WOODt magazineat rr,oorl rrr;r,q;
rz i nt'.t'<lrrr
/ toolg tridrs.)

Splintering and tear-out. Unlike a tablesawblade,

the teeth of a circ-sawblade cut from the bottom up,
so it's the top face of a workpiece where splintering
typically occurs.For this reason,placethe good faceof
your workpiecedown. Tear-outoccurswhen the blade
exits the edgeof the workpiece,creatinglargesplinters.
Severalstrategiescan eliminate theseproblems (photo
D).Beyondadding a sharpblade,they include pressing
masking tape over the cutline; securinga scrapbacker
block where the saw blade exits the work; and attach-
ing a zero-clearance,Z+"-thickhardboard subbaseto
the saw'ssole,ensuring that the subbaseedgesparallel
the blade.
Painter's
When sizing the subbase,make it the samelength as maskin!lape
your tool's sole,but make the width betweenthe blade on both filrgs
a\
and subbaseedge a whole number, such as 6',, and. and end
you'll savetime setting up for a cut by not having to
deal with fractions. Once you've cut the subbase,
secureit with countersunk screws,washers,and nuts, Backer block
or cloth-backeddouble-facedtape. Another strategy: clamped to
Scorethe cutline with a knife (photoE). tr edge

woodmagazine.com
119
 Guide roller
N:r,ryt
Controlguide
You can't make a good cut with a cheap,
down-and-dirty jigsaw, regardlessof blade
style or quality. A good tool features guide
rollers behind the blade to provide support
and keep it from deflecting. Some Bosch
jigsaws (see above) also include precision
control guides that contain the blade along
both sides.A lock-on button, sawdust blower,
variable speed, and straight/orbital cutting
options also help deliver a quality cut when
matched with the workpiece thickness and
material.(The lessorbital cutting action, the
cleanerthe cut.) Still one more feature is an
anti-splinterinsert in the baseplate,servingas
a zero-clearance subbase.
tr
120
When selectingblades,chooseone
basedon the material you intend to
cut, its thickness, and the type of
cut. The teeth per inch (tpi) of a
wood or plywood jigsaw blade
rangesfrom 6 tpi (coarse)to 20 tpi
(fine), with 6-tpi bladesbeing fast
and aggressive.Ground, close-set
teeth yield clean, precision cuts,
while narrow blades excel at turn-
ing sharp corners. As the name
implies, rely on plunge-tip (and not
tapered-tip blades)for plunge cuts.
Also, expect to find two stylesof
upper-bladeends: T-shank and U- T-shank U-shank
shank. This describesthe part that
f!
inserts into the tool. Of these,the
T-shankbladeshold more securely
in iigsawsthat acceptthem.
Bestblade choices
(| o tpi for fast,coarsecuts;@ t0 tpifor straight,fine cuts;i s\to tpi reverse-tooth
for straight,splinter-freecuts on the surfacewhere the blade exits the workpiece;t4,)
glogressive-toothwith graduatingtpifor fqs-t,cleancuts in thick and thin material;--
( S)tZ tpi for narrow,curved cuts in woods;( A) ZOtpi for fine, narrow curved cuts in
fr'oodsand plastics.
Trou bleshooting problems
Blade deflection and saw marks. Deflection occurswhen
the blade bends to the right or left of the cutline [Photo
Al, leaving an unsquare edgeand, in severecases,ruining
the workpiece. Saw marks leave rough edges. Choosing
the right tool and blade are part of the solution, as well as
using a straightedgeto guide the sawalong for straight cuts.
When cutting curves, stayYte"outside the cutline. Clean up
curved cuts with a drill-press-mountedsandingdrum (con-
cave cuts) or with a disc sander (convex cuts). Or, make a
hardboard template of the cut edgeand use it, along with a
router and flush-trim bit, to true the edge.
Splintering and tear-out. Cure these with the same
techniques described on the previouspage used to reduce
splintering and tear-out with a circ saw.Scoreand/or tape
cutlines, employ backing materials,and use a zero-clear-
ance subbaseor anti-splinter insert.
Kickback. Culprits here: binding due to a lack of stock
support, wrong blade speed and feed rate, a bent blade, or
a hung-up cord. Make practice cuts in scrap to determine
the ideal blade speedand feed rate.Then, use the circ saw
tips on the previouspage.
Rough field cuts. Simple solutions apply when you cut
out an opening in the middle of a workpiece. For fast
plunge cuts, insert a plunge-tip blade into the iigsaw,
turn on the tool, and slowly tilt the blade into the waste
side of the workpiece (PhotoB). For more precision, drill
blade-startholes at the opening corners to accommodate
the jigsaw blade. Next, clamp a straightedge into place,
insert the blade into a hole, and begin cutting (PhotoC).
Best-Ever Home Shop ldeas 2009
 For project building, a lightweight,
cordless12- or 14.4-volt variable-speed
drill with a keylesschuck provides all
the torque and freedom you'll need.
Having two is better, allowing you to
drill pilot holes with one and drive
screwswith the other without the fuss
of changing bits.
Although twist bits win the popularity
contest in most shops,you can achieve
splinter-free results, greater accuracy,
and more versatility with the four
choices shown at right. Note, too, that
vary, McFeely's, -7937,or mcfeelys.com).
to maximize control, the larger the bit,
the slower the speed.

Troubleshooting problems
Unintentionally angled holes. To err is human, and
nothing proves the point more than when trying to
drill a hole at a right angle into a workpiece with a
handheld drill. You can, however, reach perfection
with a handheld drill using these two strategies.The
simple shop-made iig (PhotoA) offers a clear view of
the hole location while guiding the bit through the
vertical hole in the iig's center. (You may need a drill
press to drill the 90" guide hole through the jig.)
Or, buy an inexpensive adiustable drill guide (photo
B)(no. DG-3637, about $53 at McFeely's).Attached to
the chuck, it lets you drill 90o or angled holes and,
stopped holes, as well as centeredholes in dowels and
board edges(PhotosA and C).Just be sure to have a firm
grip on the guide's handle before aligning the bit
and drilling holes.
Break-out. There's not a single good thing you can
say about splinters. They're a thorn in a wood-
worker's...let's not go there. Speaking of backsides,
backing a planned drill hole proves an effective deter-
rent here. To stop break-out both where the bit enters
and exits, make a sandwich using scrap (photoD).

Inconristent hole depthr, Many people use masking

tape to achieve repeatable-depth holes in wood.
And although this puts you in the ballpark, it doesn't
knock it out of the park if your goal is dead-on
accuracy.Unfortunately, masking tape slips. Your best
bet: no-mar stop collars (PhotoE). (Order 908-298, set
of 6,Ye"-V2",
about $22 Woodworker'sSupply,800-645-
9292, or woodworker.com.)Theseaccessories secureto
the bit using an Allen wrench. A polymer boot at the
base of the stainless-steelcollar prevents burning or
burnishing the wood.

Bit clogglng, Drilling deep holes often causessaw-

dust to iam the channels in a brad-point or twist bit.
Carefully dig the dust iam out with a nail tip to avoid
burning and polishing the hole sides, which makes
them less than ideal for gluing plugs or dowels. I

Written by flm Harrold with Kevln Boyle and feff Mertz

woodmagazine.com
121
 1, ,n^rr*.g(n- qBr
-/
{t
f:
stl (i{tlt'( - r'1i- 1.6${

@:r
'
9ltl autRN )i tiJ 'l(.-r.l

Properly stored
l u m b e r p r o v e s e a s yt o
"Cheap" l o c a t ew h e n y o u n e e d
woodworker it thanks to labelingof
s m i l e sw h i l e s p e c i e s ,d i m e n s i o n s ,
dreaming and board footage
up more on one edge of each
Inexpensive board.
money-saving
plastickitchen
schemes. Inexpensive
containers Sanding brackets /^\\
hold screws drum kit p r o v r c l es e c u r e
and hardware. gets double lumber storage.
duty from
drillpress.
Portableplaner shaves
d o w n l u m b e r c o s t sb y
Wallet
Benchtopdrill allowing you to buy
remains
pressoffers more economical
securely
in pocket. enough capacity rough-sawn stock
for most jobs. a n ds u r f a c e
it yourself.

Shop , : : r '

'
Low-cost
vacuum .,.:i-
scrapwood
,,li
provides stand supports
low-buck the planer.
d u s tp i c k u p .

iI
i:i[*f
-.'l * *J

Portablebench
offers versatile
workspace.
Two 24"-wide,30"-
tall wall cabinets
placed back to back
t*
create a tool base
with storage.

o t t v i i t t c c lt l t . t t r o t t I r . t r t ' t o s p t ' l t i l i r r r c s t . r l ' c r r l r r r c ' 1 .S s .t . t r l t t v i t vl t ' o t t i t t l i r , t -

lrig lrttci.s on Iorr'-rnclIrrnclrtop \a\\'s (1trit'ccl l'()ltt
i n t i t r s i r i . r l - t l L r . r l i i r \ \ ' o o r l r ro r l . t ' r ' so 1 ' t t ' nr l c I t i t t t r v l tr c l t t t i o l s
g a c l g ; c t s; t n c l s l t o l r 1 ' t t t . t t i s l t r n gt so t o l r r r r r v h c n s t ' t t i n g r r p s l r o l t .i l c r t ' s o t t r . r l r o r r tS 1 0 0 t o 5 2 ( X ) ) . i l t c r ' o t f c l l i t t l c
',llt'lt
gct grtltt ltstrlts/ IItinl' it!:r t i r l \ ro l r p r i o r i t r z i i r g\ o L l r [' ) u r c ' l r . t s cIsl t. c l ) o \ \ ' c ro r ' p r c c is i o n .
\ ' () L l n r i l k c s i l , r l t c l r o i c t ' s , r ' .ln l i s t i n c l r r t l t ss t , r t i o n l i r vr n r t c l r i n c sl,t o t ' - . \ t r i r i r i i n r L r r ltttr, r r ' , ltt , t s i tc' t t n t r . t t ' t o t . sl ti 'r
otttlit r ottt'sltolt on .t sltot's r , q t ' t . t . r l r l rt o o l s , . r r r t lo t l r t ' r c s s r r r t i . t l st \. \ ' t " l l s i l \ \ ' o r ' . r i r i g l r - c t t c ll t c n c l t t O i t t t l O c l t l i O t '
I l t e s c c t ' t ' t :l l L r r , , r ' l l t I r r ) r ' ., i t t l t t ' t t . l \ \ L Il l r c \ o u i rI r t ' , t t l vl r . t v ct ' o r t 'nt t o t t t r t o l s S-l(X)to 5700. I'lrtr ofl'c't'rt.tsoltill)lcl)o\\'(-'r'
v o L t t t c c r l i t , , t n r l r l o n t \ l ) r ' l l ( rr n ( ) n ( ' \ ( ) l t s r r c l ra s r t c o r r l l c s sr l r i l l , . t i i g s i t t r i,t t i c l, t lrnci ,tccttnic'r, .tntl .lcccl)titc'ctssorics.
illltccessitrr' lttrttt'its. I,tkt',t lool' .tt li s l r o p v l t c r - l L l n) t . I r p t l r t ' a n t c t o . rr x r n t l S 1, 0 ( X) , i tn t l
i)l'o's n ' o o r l r v o r l i i n g s l r o p i I r o L r r r l t n t \ o L l ' r c i t r C i t l t i n c t - s . t tcr 0 t t t l l r r ' , ( ) l ) l ) o . \ i l (
ploof. l lrcrt', cvcf v tool Ir.rs to cirln its A n c h o r y o u r s h o p w i t h a t a b l e s a w . I o 1 t .( ) r , l i r r t l r a t \ i l l n t n t o l l c \ , g c t i t
'l
lt'cp. l{t'ari on to st't' lrorr r otr ('al'r nrill\r' l r i s r c r s . t i i l ct o o l s i l s i t t t l t t ' l t t ' . t t t o t c r ; n t r i t c t o r ' s' sa \ \ t r l i r i p p t ' t lr l i t l t . t 1 . 5 - l t 1 l ,
\ ' ( ) i l f s d o t l t c s a n l r , i t n c l I r o r r t o s r l r r t ' t ' z t ' n r o s ts l r o p s I. t r i p sa n r l c r o s s c r r Itsl ;, t r l o t s , l 2 O / 2 - 1 0 - o r l t n r o t o r ' , u n c l i l . ) r ( r "l . t ' t t t t ' .
tltt r r r o s t i r o r t t c v r r ' \ t t ' r t t r r i t I r o L r t r i r l r l r c t s ,c r r t s t r n o n s , . tn t l t l o t ' s t t t L t c l t . \ s . r r rr r r c i t l r c r o l ' t l r c s cc ' i t t c g o r i t t' tst . i r l t c
s c r i r n p i n , qo n t l L r , ti lt t . n l ( ) r ' ( ' .l i t ' r ' i t t t s tt l t i : i : \ ( ) L l r L ( ) l ' r 't o o l , t l t t ' o n l v o n t ' i ' o t t ' l I t r t t ' l r t t r .

122 Best-Ever Home Shop ldeas 2009


Tablesawbargains
aboundat severalprice
levels.Asan example,
lessthan 51,000buys
this GrizzlyGl0235L,
a sawwe've tested
and admire.lt hasa
240-volt,3-hpmotor,
an accuratefence,and
cast-ironwings.
An accurate rip fence is worth its
weight in gold, so make sure you get a
good one.
When you set your saw budget, allow
at least$50 for a high-quality 40- to 60-
tooth combination blade. Doing this
means you won't sacrificewood to chip-
out and burns.
After you get that saw, sink a router-
table insert into its extension table. By
doing this, you eliminate the cost of a
separatestand, and savefloor space.You
can even get double duty from your
tablesawrip fence by building a slip-on
router-tablefence.
y'ult-base routers play many roles. or a simple shop-built bench, such as
The router is one of the most versatile the one shown below.
shop tools. And today, you get more
router for your money than ever, as
shown below.
A router is uselessalone,of course,but
you can buy bits in batches to save
money. If you use a bargain-price bit
enough to wear it out, replace it with
a higher-dollar version that will yield
longer service.
y'euy out for layout tools.
You can only cut as accurately as you
mark, so devote a few dollars to good-
5175to 5250buysa full-featuredrouterwith
multiple bases(fixed,plunge,and, in some
kits,a D-handlebase).Table-mountone base,
and usethe othersfor freehandwork.Add a
bargainbit set-this 66-piecepackcostsless
than S200-and you'rereadyto rout.
woodmagazine.com
Youcantacklemostlayoutchoreswitha tape
measure, combinationsquare,6"steelrule,
compass, anda mechanical pencil.Tohandle
toughertasks,adda slidingbevelgauge,
protractor,
caliper, anda 45otriangle.
quality measuring and marking tools.
Many elaborate gadgetsexist, but skip
them. The few basics,above,will suffice.
y'Worl<out a worksurface.
Now that you can transform lumber
into project parts, you need a place to
work with them. A full-blown cabinet-
maker's bench would be ideal, but you
can do a lot with a folding work station;
a solid-core door thrown on sawhorses;
A workbench mustbeflat,sturdy,andstable. though, a jointer is
Tomakeyoursmoreuseful,incorporate a
viseandbench-dog holesthateaseholding
chores.Purchase plansforthiseasy-to-build
benchat woodmagazine.com/workbench.
y'e"ta
grip on good clamps.
A woodworker can never have enough andgap-free
clamps, but just a few will get you
started. Bar or pipe clamps still rule
for versatility, and are the favorite for
gluing panels.Build an inexpensivebut
expandableset by getting a half dozen
pipe-clamp heads, plus some 24" sec-
tions of pipe and pipe couplers. That
way, you can arrange the clamps'
lengths to suit your needs.
One-handed clamps are handy, too,
so augment your collection with a few
of these in the 12'-24' range. As your
budget allows, pick up more clamps to
fill your set.
y'suil
into smooth sanding.
If you can only have one sanderin your
shop, make it a random-orbit model,
right. Fit it with coarsepaper
to removestockury.11,_
sively,and with fine-grit {
paper to leavesmooth,
scratch-freefinishes. You
can pick one up for as
little as $35.
The pad on a random-orbit
sanderrotatesand movesin
an orbital motion to blend
the scratchesinto a hard-
to-see pattern.
l/ndrill pressGomesnext.
Modern hand drills are wonders of
power and versatility, but for ultimate
accuracy and control, you need a drill
press.For 90 percentof proiects,a bench-
top model will do, which can save$100or
more over buying a floor model.
Devote those savings to a set of twist
bits, imported Forstner-style bits, and
a sanding drum kit. You can even get a
mortising attachment that bolts on
when you need it.
y'next pointer, get a jointer.
You may think you need a jointer, below,
only if you purchase rough stock. Or
you might be tempted to buy one of
those gadgets that's supposed to joint
edgesusing your router. But a jointer is
no luxury item. With one you can
remove saw-blade burn marks, dress
edgesfor perfect glue-ups,and, on many
models, cut rabbets. Most important,
the only tool that can
reliably flatten the faceof a board.
Evenif youdon'ttakefull advantage of a
jointer'sabilities,
you'llappreciatehow
quicklyit prepares boardsfor perfectripping
glue-ups.
 Still ready to spend? Now with all of these
consider these'contenders tools and machineson
With the tools on the previous pages, hand, you'll be set for Obviously,many more toolsand accessories
plus your jigsaw and drill, you have all most tasks. Now, you woodworkingeasier,
you need to build most projects.Eventu- can add specialized securingthe toolscoveredin this article,buy thesenext:
ally, though, you'll want two additional tools as your budget
Hand tools:
power tools. permits and projects Benchchisels
require. Read "The B l o c kp l a n e
y'nunfor a ptaner. next wavei' right, to see Dead-blowmallet
A planer, below,savesmoney on lumber what you may want to Japanese-style
becauseyou can buy rough-sawnboards, purchasenext. handsaw
then mill them to finished dimension. Cabinetscraper
Plus, owning one allows you to work Time to get
with lumber thicknessesunavailable at Organized Portable power tools:
Biscuit joiner
your home center. Getting the most from B e l ts a n d e r
Be aware that a planer will create a any workshop requires
Handheldcircularsaw
huge messof flying chips. Some newer keeping it clean by Secondrouter
models offer built-in chip collectors creating placesto stash
that will saveyou the expenseof invest- all your stuff. But don't
ing in a dust collector until your shop assumethat storagehas
budget allows for it. to be fancy or costly to be effective. Try
thesepointers.
y'srrornge up some cabinets.
You can create great storage without
spending a dime if you keep your eyes
open for discarded kitchen cabinets.
Neighbors, friends, and contractors
working on a remodeling project are
often happy to get rid of them.
Once you get the cabinets in the
shop, use them creatively. The drill
press in the photo on page 722, for
A portableplaneroffersamplepowerand example, sits on two wall cabinets.
(u s u a l l1y2 -1 3 " )to
enoughwidt hc apac i ty They position the drill pressat working
handleallofyourlumber-surfacing needs. height and provide about 8 cubic feet
Thism odelc ollecits
tso w nc h i p si n a b a g . of enclosed,dust-freestorage.Kitchen
base cabinets servewell as workbench
€No*, bring on a bandsaw. basesin the shop.
Not all woodworking involves making Make the cabinetsmore functional
straight cuts. A handheld jigsaw can for shop use by building in cubbiesor
' negotiatemany curves,but, eventually,
extra shelving, or adding perforated
you'll want a bandsaw, below.In our hardboard to the insidesof the doors.
opinion, a 74" model offers the most Throw on a coat of glosspaint to lend
bang for your buck to handle home-
shop needs.
a finished appearanceto tattered or
mismatchedcabinets.
l/f..pyour lumber in line.
Lumber leanedagainstwalls or stacked
underfoot quickly becomes disorga-
nized or falls victim to damage.Store
thoseboardsright by mounting simple
metal shelf brackets,as shown on page
122.(We purchasedours at a hardware
storefor a meager75 cents each.)Each
shelf will easily support six to eight
boards. Use four or five metal brack-
ets-screwed into the wall studs-for
A bandsawshinesat cutting curves,and can eachshelf,and spacethe shelvesabout
alsorip, resarycut circles,and evenmill short, 8" apart. Finally, lay, particleboard
small-diameter logs into lumber. over the brackets.
124
existto makeyour
faster,and more refined.After
Stationary tools:
Dustcollectorand air filter
Compoundmitersaw
Belt/discsander
O s c i l l a t i nsgp i n d l es a n d e r
Scrollsaw
Lathe
Accessories:
Mobiletool bases'
Rollerstand/outfeedsupport
jig
Pocket-hole
Dovetailjig
M a r k i n gg a u g e
These short stacks prove easy to sort
through when you need a board, espe-
cially if you mark the stacks(page122).
lVloreways to squef;zeths
nr$$t frem yonr budget
€suue some coin on clamps.
Want to reduceyour need for clamps?
Try securing glued-up assemblieswith
a few air-nailedbrads,below.
You can get a compressor and brad
nailer kit for under $200,the price of just
a few decent-qualitybar clamps. If you
already have a compressor,the invest-
ment for a nailer may be aslittle as $40.
i
t
A pneumaticair nailerdrivesa brad into
I
joints without splittingthe wood, and holds
the assemblywhile the glue sets.
y'naa lumber purchasingpower.
Buying lumber doesn't qualify, strictly
speaking, as part of shop setup. But
building anything in a shop proves
pretty tough without boards. Why not
make them lessexpensiveby purchasing
in lots of 100, 25O, or even 500 board
feet?Pros do it, and so can you, by get-
ting a group of friends or club members
together.You may be ableto mix species
and still earn discounts.li
Written by David Stone
Best-Ever Home Shop ldeas 2009
 fromtheeditors
orW00ll'ragazine
-lsffi }A p.- F"
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pF'

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) F'

Entry-Area Home/Shop MissionBookcase Entertainment

Genter Arb & GraftsBookcase All-in-order
Bench& Shelf Storage
Cart planDp-00563$8.95 PlanDP-00092
$9.95 PlanDP-00080 $10.95 StorageBins
PhnqP0Q0e_$5.e5PlanDP-00561a
$6.95 PlanDP-00558a $5.95

FantasticFutonBed FutonTable Heirloom

HopeGhest Hideaway Gompact Towering
Tomes
PlanDP-00025 $8.95 PtanDp-00026$8.95 PlanDP-00190
$7.9S Computer
Desk Entertainment
Genter Bookcase
PlanDP-00192
$9.9b PlanDP-00474
$9.95 PtanDp-0010S
$8.9S

Country-fresh
Bed County-freshDresser Five-Drawer
Chest Eight-Drawer
Dresser Armoire/TU

rumru
PlanDP-00081 StackableBins
$8.95 PlanDP-00008 $8.95 planDp-00010
$8.95 PlanDP-00172
$9.95 Center planDp-00547a
Entertainment g3.ZS
PlanDP-00171$9.95
lffi|
ll'ffifI
I [*"J" I

MissionBed
PlanDP-00424$9.95
MissionDresser
ptanDp-002t40
MissionBlanketGhest MissionNighbtand
$9.95 ptanDp-00446$s.95 PlanDP-00433
Gedar-lined
BtanketGhest
@
Heirloom
Gorner
$7.9S Cabinet
PlanDP-00534$7.95 PlanDP-00527
$9.95

I i-l
I t4
3-in-1Bedfor AllAges
t l,'l
I
-
,i- -' ' -:- -.I

WineCabinet Heirloom
Bookcase ChinaCabinet Shelvesfor Show Ghimney
Cupboard
PlanDP-00524 $9.9b ptanDp-00517
$S.9S PlanDP-00513
$11.95 PlanDP-00502
$12.95 PlanDP-00540 $8.95 PlanDP-00494
$7.95

Download
anyofthese
woodwolking
plansfortheprices
listed,
orviewa targer
image, aturuoffrnagnzlna.iln/dant
Tohavepaperprans
maired royou(add$3perptans+tt;,cattlur[fioo togg&o-{a7s
direcfly
Please
haveyourcreditcardavailable.
BEHSIOg
 gurks
bnhd$
7g
Youdon't needto be rich to outfit a smartshop-you iust needto
shopsmart.Hereare 14money-saving strategies
to help you getthe most
bang (and whirr, and hummm, and buzzz)for your tool-buyingbuck.
Recognize good deals may be a why-bother tool next year.
You also may find that the price of
a Do your researchbefore you buy. a newly introduced tool drops after
I Watch Sunday newspaper ads, the newness has worn off or when
study tool catalogs,and make mental the manufacturer replacesit with an
notes as you peruse tool stores and updated model.
home centersso you can identify a real
bargain when it comes along. Don't be AOp t for mul ti functi on tool s or
fooled by comparisons to "list prices," &bonus accessories. A drill pressthat
which are sometimesas much as twice comes with a mortising attachment,
the normal selling price. And have for example,will saveyou from buying
patience: Today's gotta-have gadget a dedicated mortiser, at least for a
126
while; likewise, a tablesawthat comes
with a high-quality blade. A hammer
drill can be used for ordinary drilling,
too, and doesn't cost much more
than a non-hammer drill. Somewise-
buy tools do more than one job equally
well. For instance, Shop Fox (shopfox.
biz) sells a benchtop drill press that
doubles as an oscillating spindle
sander;Ridgid's(ridgid.com) edge-belt/
spindle sander works equally well on
both flat and curved edges.
Best-Ever Home Shop ldeas 2009
 ? ?p
Q Checkmail-order sources.Becausethey lack a dis-
Jtributor network, manufacturers that sell directly ,?'
to consumersusually can offer tools at lower prices.But I'
r;
I

make sure you're dealing with a reputablefirm. Some

companies,such as Grizzly (grizzly.com),will provide
you with customerreferencesupon request.

\\]

')tt
ABuy the best you can atford, and
ttthe cheapest you can find. You'll
only cry once when you buy a top-grade
tool. On the other hand, a cheaplybuilt
tool may not cut or hold its accuracy
well, and your ioy over the initial sav-
ings may give way to tearsof frustration
each time you use it.
But be realistic-you don't always
need to buy the best. If you think a
pneumatic brad nailer will come in
handy, purchasea$2O model, and useit
up. Even if it lasts for only a handful of
projects, you can buy five inexpensive
brad nailers before you outspend a
$100nailer.
r'
( Replacethe tool, not iust the bat-
Jtery. The first thing to fail on most
cordlesstools is the battery, but a pair of
new batteriescan set you back almost as
much asa new tool. And that new model
may have more featuresor higher volt-
age,so it's like a low-cost upgrade.
That strategydoesn't apply to cordless
kits with severaltools sharing one or two
battery packs; but you can economize
here as well. Beforeyou buy such a kit,
considerthe voltageand style that fits all
the cordless tools you may eventuallv
want to buv.

Must you buy new?

tVuy reconditioned tools with a full
lfwarranty. Manufacturers can't sell
returned tools as nery even if they're
unused but lacking their original pack-
aging. So,if necessary,they replaceany
bad or broken parts with new ones,
repackagethe tool, and then resell it as
"reconditioned." You risk little because
manufacturerstypically honor the full
factory warranty on these tools, and
unlike new-in-the-boxtools, reconsget
a complete and thorough test at the
servicecenter before they're repackaged
and resold.

lfind a demo. An exhibitor at a

f woodworking show will sometimes
sell a stationary tool off the show floor,
rather than pay to ship it back. Ask
whether you can take it off his or her
hands for a discounted price when the QBuy f rom a private owner. your local shops, though: Sometimes these tool's
show is over. You may get a good deal , {Onewspaper classifiedadvertisingsec- are overpriced for their quality and
on a tool that's already assembled,and , tion is a good source for used tools. condition. Don't overlook searchmeth-
saveshipping costs.Also, watch for spe- , Besidesscanning the "Tools" classifica- ods of finding online used tools-
cial scratch-and-dent and tent sales i tion, pore over the garagesalesand auc- classifieds, such as those at WOOD
from some manufacturers. In many : tion notices. Often, sellersdon't know Online@ (r,r,ooclrrrag.tz i rrc.ctI rn / c Iassi t iecls),
cases,the damageis cosmetic,and you ; (or don't care) what they have and Craig's List (craigslist.com), and
can pick up a perfectly functioning tool , underestimate its value. Beware of virtual shop-tool auctions such as eBay
at a deep discount. , buying used power tools from pawn (ebay.com).

woodmagazine.com
127
 Better Homes and Gardenso

Best-Ever
HomeShopldeas2009
woodmagazine.com

Editor-in-ChiefBILLKRTER
ManagingEditor MARIEN KEMMET
Deputy Editor DAVECAMPBELL
PublicationWriter CARLVOSS
Techniques Editor BOBWTLSON
Tool & TechniquesEditor BOB HUNTER
Multimedia Editor LUCASPETERS
MultimediaEditor CRA|GRUEGSEGGER
ProjectEditor LARRYIOHNSTON
SeniorDesignEditor KEVINBOYLE
DesignEditor fEFFMERTZ
Production/OfficeManager MARGARETCLOSNER
AdministrativeAssistantSHERYLMUNYON
Photographers MARTYBALDW|N,fASONDONNEtty,
DEANSCHOEPPNER, IAYWTLDE
ContributinglllustratorsTtM CAHtLI-LORNAfOHNSON,
ROXANNELeMOINE
Contributing Crafuman llM HEAVEY
Contributing ProofreaderlRA LACHER
ArtDirector rnnlrnlF
ProjectArt Director IOHN GEARHEART
AssociateArt Director GREGSETLERS
AssistantArt Director CHERYLA. CTBULA
SUBSCRIBER SERVICE
Go to wosdmagazine.com/help
After moving carsoutside,this homeownerrolls out cabinetsto form or write to WOODmagazine,P.O.Box 37439,
Boone,lA 50037-0439
a worksurfacein his garage.To learnmore, seepage 22.
PublisherMARK L. HAGEN

From'okry'
to'wow!' ADVERTISING AND MARKETING
CHICACO:333 N. MichiganAve.,Suite1500,
Chicago,lL 60501
few months ago,I spent a good portion of a week MarketingManager AMANDA SALHOOT
1f, AdvertisingManager fACK CHRISTTANSEN

AH'.'l'lf,i::l'#::TT"::??,xl,l"T;i:*
(For a closer look at the shop, seepage36.)
2Yz-cat
garageinto an incredible car buff,s backyard escape.
Account ExecutiveRYANINTERLAND
Direct Response
LISAGREENWOOD
AdvertisingRepresentative

AssistantsGAYLECHEfN, NtA WTLUAMS

What a difference five days made. And believe me, the ATLANTA:NavigateMedia
'wow'factor doesn't
fade: A revisit months later still took DETROIT: RPMAssociates
away my breath when the garage door rolled ,rp. But who BusinessManager fEFFSTILES
wouldn't be green with envy gazing at a sparkling epoxy AssociateConsumerMarketing Director DAN HOIIAND
floor? No oil stains would dare linger! AssociateDirectorof Marketing-NewsstandTOM DEERING
ProductionManager SANDYWtLL|AMS
That garageiS a multitask spacedesigned and organized
AdvertisingOperationsManager llM NELSON
as many of us imagine our shops. Car-care products, previ- E-CommerceManager MATTSNYDER
-ously
shuffled around in cardboard boxes, are now neatly
VicePrerident/Crorffi
organized behind a pair of doors. The adioining cabinet
MEREDITH PUBLISHINGffi
holds a season'sworth of yard and garden remedies. paint- PresidentfACKcRlFFlN
brushes and hand tools, neatly lined up like soldiers, beg to ExecutiveVice PresidentDOUGOTSON
be picked up from smooth-rolling drawers. Chief RevenueOfficer TOM HARTY
The recent visit to the shop gave me pause. No more Finance& AdministrationM|KERIGGS
Manufacturing BRUCEHESTON
excuses:I got the iolt to iump-start and overhaul my own ConsumerMarketing DAVIDBALI
shop. I referredto the planning articles in this issueto lead CorporateSalesMICHAELBROWNSTETN
me every step along the way. Meredith 360" fACK BAMBERGER
'bout you? lnteractiveMedia LAURENWTENER
, How Just picking up this magazine affirms
CorporateMarketing NANCYWEBER
that there's a garage or shop redo on the horizon at your
ResearchBRITTAWARE
home. So get going! Break the work into bite-size tasks, and Chief TechnologyOfficer T|NA STETL
you'll be there quicker than you think. New Media MarketingServicesANDYWILSON
/tUlerdtlh

fn^X^fu
I conpo"o'o"

Presidentand Chief ExecutiveOfficer STEPHEN M. LACY

Chuir.un of th"
ln n4"-or
Marlen Kemmet @Copyright V"r U.S.n.
RetailSales
Retailers
canordercopiesof WOOD
for resale
WOOD@MagazineManagingEditor bye-mailingjennifer.buser@meredith.com.
llttrr
-t - ,/\r
-'t tf tdE \
 il
l
l l
rl
I
I
I
I
I

-
w
IKry
re'
G* qe'
S,
I n 2007,we published thefirst V
! issueof HomeShopldeas,and
Ifrom yourletters ande-mails, it
appears youlovedit.You're holdingissue 2.
NoWwe'dliketo knowhowyouusedourideas,
or yourown,to create or upgrade yourownhomeshop.We'reon
thelookout for alltypesof shops: basements, garages,
outbuildings, smallspaces, andevengarden-shed shops.
Besides searching for great-looking
shops, we'realsolookingfor
projects, organizers, storage cabinets,or workbenches you'vecreated
foryourshop.
lf you'dlikeyourshop,or a friend's, to beconsidered for national expo-
surein oneof ourmagazines, sendussomephotosanda shortwrite-up
of whatyoudidto makeyourshoplookbetterandworkharder. lf you've
got some"before"and"after"photos,thosewouldbeexcellent, too!

Sendyoursubmissions
to:
Home Shopldeas
WOODoMagozine
l7l6 Locust
Street,
LS-221
DesMoinellA 50309-3023

Or e-mailyoursubmissions
to homeworkshops@meredith.com.
ThedeadlineisJune1, 2009.Submissions
cannotbe returned.
Please
includeyourdaytime telephone
number,
mailingaddress,and
e-mailaddress,
if youhaveone.
 Pinnacle@
DrillPressTable
148369

Pinnacleisdefined
byWebster's pointofdevelopment
asthe highest latestofferingof
orachievement.The
drillpresstablesystems thatbearthePinnacle@
anda varietyof accessories namehavecerlainly
livedup
EverydetailofthesePinnacle@
tothisdefinition. withonethingin mind:to provide
toolswasengineered
withtoolsthatempower
woodworkers them.
Pinnacle@
toolsareavailable atWoodcraft.
exclusively