Workshop Shortcuts for Woodworkers

by McCulloch, Graham

• ISBN13: 9780806993959
• ISBN10: 0806993952
• Format: Paperback
• Copyright: 2003-10-01
• Publisher: Sterling

Summary

For warmth, versatility and sheer beauty, few materials can match the appeal of wood, and few hobbies are as satisfying as woodworking. The multitude of tools and machines offered, however, can be daunting, and learning proper techniques can be an expensive, time-consuming process. Now the learning curve can be dramatically reduced with the proven advice offered here. You'll get strategies for determining electrical needs, tips for lighting, ventilation and dust control, and maximizing storage. Other topics covered include choosing the right hand tools and machines that match both your skill level and projects, using epoxies and other adhesives, special techniques for nailing, cutting and staining lumber, workshop safety, and more. The hundreds of tips featured here are sure to help any woodworker get more out of every minute spent enjoying this wonderful lifelong hobby.

Table of Contents

Introduction	p. 16
Planning a Basic Workshop	p. 18
The Two-Car-Garage Workshop	p. 21
Floors and Ceilings	p. 21
Lighting	p. 21
Electrical System	p. 22
Ventilation and Sawdust Collection	p. 23
Lumber Storage	p. 24
Tool Storage	p. 25
Safety Guidelines	p. 26
Telephone	p. 26
Shop Aids, Jigs, and Helpful Woodworking Techniques	p. 28
Abrasives	p. 29
Sander Pads	p. 29
Replacing Sander Pads (#1)	p. 29
Replacing Sander Pads (#2)	p. 29
Sanding Discs	p. 30
Hook-and-Loop Sanding Discs	p. 30
Maintaining Sanding Discs and Belts	p. 30
Perforating Sanding Discs	p. 30
Removing Sanding Discs	p. 30
Storing Sanding Discs	p. 31
Sandpaper	p. 32
Close-Coat and Open-Coat Abrasives	p. 32
Grades of Sandpaper	p. 32
Jigs for Cutting Sandpaper	p. 33
Sandpaper Workshop Guidelines	p. 33
Types of Sandpaper and General Applications	p. 33
Used-Sandpaper Applications	p. 33
Sandpaper Belts and Drums	p. 33
Cleaning Sandpaper Belts	p. 33
Maintaining Sandpaper Belts and Drum Tubes	p. 34
Purchasing Sandpaper Belts and Drum Tubes	p. 34
Storing Sandpaper Belts and Drum Tubes	p. 34
Sandpaper Sheets	p. 34
Purchasing Sandpaper Sheets	p. 35
Storing Sandpaper Sheets (#1)	p. 35
Storing Sandpaper Sheets (#2)	p. 35
Steel Wool	p. 35
Removing Specks from Steel Wool	p. 35
Using Steel Wool	p. 35
Synthetic Abrasives	p. 36
Adhesives	p. 37
Applying Adhesives	p. 39
Applying Adhesives (#2)	p. 39
Cleaning Glue Squeeze-Out	p. 39
Extending Adhesive Effectiveness	p. 40
Getting Adhesives into Workpiece Cracks	p. 40
Laminating with Contact Cement	p. 40
Laminating with Contact Cement (#2)	p. 41
Small Glue-Up Jobs	p. 41
Spray-On Adhesives	p. 41
Spreading Adhesives	p. 42
Air Compressors	p. 42
Air Compressor Mobility	p. 43
Air Nailer Maintenance	p. 43
Allen Keys	p. 44
Aluminum (Grinding and Filing)	p. 44
Angles	p. 45
Angle Jigs	p. 45
Drawing Angles	p. 45
Drawing Angles (#2)	p. 45
Finding the Centers of Angles	p. 46
Auger Bits	p. 46
Awl	p. 47
Backsaw	p. 47
Band Saw	p. 47
Auxiliary Tables for a Band Saw	p. 48
Backtracking with a Band Saw	p. 48
Band Saw Blade-Cutting Limitations	p. 49
Band Saw Blade Types	p. 49
Band Saw Rip Fence	p. 50
Bevel-Cutting with a Band Saw	p. 50
Crosscutting Dowels with a Band Saw	p. 50
Cutting Accurately with a Band Saw	p. 51
Cutting Circles with a Band Saw	p. 52
Cutting Dowels with a Band Saw	p. 53
Cutting Spiraling Dowels with a Band Saw	p. 53
Guide Blocks for the Band Saw	p. 54
Installing Band-Saw Blades	p. 54
Making Long Crosscuts with a Band Saw	p. 55
Relief Cutting with a Band Saw	p. 56
Resawing with a Band Saw	p. 56
Rounding Band-Saw Blades	p. 56
Safe and Accurate Cutting Techniques	p. 57
Scoring for a Straight Line	p. 57
Tensioning Band-Saw Blades	p. 58
Bar Clamps (Gripping)	p. 58
Belt Sander	p. 59
Safety Guard for Belt Sanders	p. 59
Using the Belts	p. 60
Bench Dogs	p. 60
Bench Vise	p. 60
Biscuit Joiners	p. 60
Blades	p. 61
Brace	p. 61
Brads	p. 61
Brass (Removing Tarnish From)	p. 61
Buffing	p. 61
Caulk	p. 62
Caulking Around a Bathtub, etc.	p. 63
Preventing Caulk from Drying Out	p. 63
Preventing Caulking Tubes from "Running On"	p. 63
Center-Finding Jig	p. 63
Centers (Drawing)	p. 64
Chair and Table Legs (Fitting)	p. 64
Chalk Line	p. 65
Chipboard	p. 65
Chisels (Maintaining)	p. 65
Circles	p. 66
Drawing Circles	p. 66
Patterns for Circles	p. 66
Circular Saw (Portable)	p. 67
Plywood-Cutting Jig for a Circular Saw	p. 67
Proper Circular Saw Cutting Techniques	p. 67
Using a Straightedge	p. 68
Circular Saw Blades	p. 68
Buying Circular Saw Blades	p. 68
Cleaning Circular Saw Blades	p. 69
Containers for Circular Saw Blades	p. 69
Determining the Sharpness of Circular Saw Blades	p. 69
Fitting Circular Saw Blades	p. 70
Safety Techniques for Circular Saw Blades	p. 70
Storing Circular Saw Blades	p. 70
Clamps	p. 70
Clamping Aids	p. 71
Clamping Odd Shapes	p. 71
Clamp Storage	p. 71
Clamp Storage (#2)	p. 71
Clothespins as Clamps	p. 72
Emergency Clamps	p. 73
Pipe Clamps	p. 73
Protecting Workpieces from Clamps	p. 73
Protecting Workpieces from Clamps (#2)	p. 73
Shop-Made Framing Clamps	p. 74
Shop-Made Framing Clamps (#2)	p. 74
Shop-Made Rubberband Clamps	p. 74
Strap Clamps	p. 75
Tie Wraps as Clamps	p. 75
Compass Cutter	p. 75
Compasses	p. 75
Shop-Made Compass	p. 76
Shop-Made Compass (#2)	p. 76
Coping Saw Jig (Shop-Made)	p. 76
Copper Pipe (Resoldering)	p. 77
Countersinking	p. 77
Covered Boxes	p. 78
Cutting Technique	p. 78
Cutting Technique (#2)	p. 78
Curves	p. 78
Duplicating Curves	p. 78
Making Freehand Curves	p. 79
Depth Gauge (Shop-Made)	p. 79
Dimples (Removing)	p. 79
Door Edges (Sanding and Planing)	p. 80
Doors	p. 80
Installing Locksets and Deadbolts on Doors	p. 80
Installing Striker Plates on Doors	p. 80
Dowels	p. 81
Dowel Joints	p. 81
Dowel Joints (#2)	p. 81
Finding the Centers of Dowels	p. 81
Fluting Dowels	p. 82
Plugs	p. 82
Rounding Off Dowel Ends	p. 82
Storing Dowels	p. 83
Drafting Pencils	p. 83
Drawers	p. 83
Childproofing Drawers	p. 83
Childproofing Drawers (#2)	p. 84
Drawer Handle Jig	p. 84
Drawer Handle Jig (#2)	p. 84
Drill Bits	p. 85
Cleaning Drill Bits	p. 86
"Truing" Drill Bits	p. 86
Drilling Techniques	p. 86
Depth Stop	p. 86
Depth Stop (#2)	p. 86
Depth Stop (#3)	p. 87
Drilling Perpendicular Holes	p. 87
Making Repeat Holes with a Portable Drill	p. 88
"Parking" Portable Drills	p. 88
Drill Press	p. 88
Angle Jigs for the Drill Press	p. 89
Chuck Keys	p. 89
Circle-Cutter Safety	p. 90
Drilling into Dowels with a Drill Press	p. 90
Drilling the Ends of Dowels with a Drill Press	p. 90
Drill Press Auxiliary Table and Fence	p. 91
Drilling into Spheres with a Drill Press	p. 91
Drill Press as a Lathe	p. 91
Sanding Wheels with a Drill Press	p. 92
Setting Angles on a Drill-Press Table	p. 93
Tightening Bits in a Drill Press	p. 93
Truing-Up a Drill-Press Table	p. 93
Drywall	p. 93
Epoxy Glue	p. 94
Mixing Epoxy Glue	p. 94
Retarding Epoxy Glue Setup	p. 94
Extension Cords	p. 94
Selecting Extension Cords	p. 94
Storing Extension Cords	p. 95
Extension Ladder	p. 96
Carrying an Extension Ladder	p. 96
Carrying an Extension Ladder (#2)	p. 96
Clamps for Paint Cans	p. 96
Transporting an Extension Ladder	p. 96
Wall Protection	p. 96
Files	p. 97
Cleaning Files	p. 97
Making File Handles	p. 97
Filters (Disposable)	p. 98
Finishing Wood	p. 98
Fly Cutter	p. 98
Foam (Cutting)	p. 99
Fretsaw	p. 99
Funnels (Making)	p. 99
Furniture Height	p. 100
Garden Tools (Storing)	p. 100
Geometry	p. 101
Glue	p. 101
Gluing Racks	p. 101
Protecting the Finish from Glue	p. 101
Removing Glue	p. 102
Spreading Glue	p. 102
Hammer Handles (Renewing)	p. 103
Handsaw	p. 103
Japanese Handsaw	p. 103
Shop-Made Handsaw	p. 103
Hand Tools	p. 104
Cleaning Hand Tools	p. 104
Covers for Hand Tools	p. 104
Mending Hand-Tool Handles	p. 105
Preserving Hand Tools	p. 105
Protecting Hand-Plane Blades	p. 105
Protecting Hand-Tool Edges	p. 106
Protecting Hand Tools	p. 106
Sharpening Hand Tools	p. 106
Hardwood Lumber Sizes Hardwood	p. 107
Hardwood Board Foot Chart	p. 108
Hardwood Designations	p. 108
Grades and Cutting Requirements	p. 108
Cutting Sizes	p. 109
Moisture Content	p. 109
Standard Grades and Cutting Requirements	p. 110
Hardwood Lumber Sizes	p. 111
Holes (Enlarging)	p. 111
Hole Saw	p. 112
Enlarging Holes Made By a Hole Saw	p. 112
Increasing Hole Saw Cutting Depth	p. 112
Releasing Drilled-Out Plugs	p. 112
Using Hole Saws to Make Rings	p. 114
Jigsaw Blade Storage	p. 114
Jointer Knives	p. 115
Joints (Identifying)	p. 115
Labels (Removing)	p. 115
Laminating	p. 115
Lathe	p. 116
Description and Use	p. 116
Prolonging the Life of a Lathe	p. 119
Sanding with the Lathe	p. 119
Shop-Made Lathe Sanding Drums	p. 119
Leveling Scribe	p. 120
Lumber	p. 120
Storing Lumber	p. 122
Magnets	p. 123
Masking Tape	p. 123
Measuring Techniques	p. 124
Mini-Power Tools	p. 124
Miter Gauge	p. 124
Fitting a Miter Gauge	p. 124
Gripping a Workpiece with a Miter Gauge	p. 125
Squaring a Miter Gauge	p. 125
Miters (Hand-Cutting)	p. 126
Molding Head	p. 126
Nailing Techniques	p. 126
Correct Nail Sizing	p. 126
Nailing Close to the Edges	p. 126
Nailing in Close Quarters	p. 126
Nailing the Correct Way	p. 127
Nailing into Finished Wood	p. 127
Nailing Guards	p. 128
Nail Sets	p. 128
Nailing Thumb Savers	p. 128
Removing Nails	p. 128
Removing Nails (#2)	p. 129
Toenailing Technique	p. 129
Nails	p. 129
Brads	p. 129
Common Nails	p. 130
Octagons	p. 130
Paint	p. 131
Cleaning Paintbrushes	p. 131
Cleaning Paintbrushes (#2)	p. 132
Cleaning Paintbrushes (#3)	p. 132
Cleaning Paint Roller Trays	p. 132
Cleaning Paint Spray Cans	p. 133
Dust-Free Paint Drying	p. 133
Estimating the Amount of Paint	p. 133
Filtering Paint	p. 134
Going Up a Ladder with Paint	p. 134
Keeping Paint Cans Clean	p. 134
Mixing Paint	p. 135
Mixing Paint (#2)	p. 135
Mixing Paint (#3)	p. 136
Painting Drawer Handles	p. 136
Painting Steps	p. 136
Pouring Paint	p. 137
Preserving Paintbrushes	p. 137
Preventing Paint Rollers from Sliding	p. 137
Removing Paint	p. 137
Shop-Made Spray Booth	p. 138
Spray Paint Aid	p. 138
Storing Paint	p. 138
Using Old Paintbrushes	p. 139
Paint Thinner (Recycling)	p. 139
Patterns	p. 139
Drawing Patterns	p. 139
Enlarging Patterns	p. 140
Transferring Patterns	p. 140
Transferring Patterns (#2)	p. 141
Pegboard	p. 141
Securing Hooks on Pegboard	p. 142
Using Pegboard on Stationary Power Tools	p. 142
Pencils (Sharpening)	p. 142
Picture Frames	p. 143
Plastics	p. 143
Bending Plastics	p. 143
Cutting Techniques	p. 143
Safety Techniques	p. 143
Types of Plastic	p. 144
Plexiglas	p. 144
Welding Plexiglas	p. 145
Plywood	p. 146
Adding Edging to Plywood	p. 146
Bending Plywood	p. 147
Clamps for Carrying Plywood	p. 147
Jig for Carrying Plywood	p. 147
Preventing Tear-Out in Plywood	p. 148
Polygons	p. 148
Pulleys (Sizing)	p. 149
Radial Arm Saw	p. 149
Adjusting the Depth of Cut on a Radial Arm Saw	p. 150
Checking a Radial Arm Saw for Square	p. 150
Cutting Circles with a Radial Arm Saw	p. 151
Extension Table for a Radial Arm Saw	p. 151
Stop Block	p. 152
Rafter Angles	p. 152
Random Orbital Sanders	p. 153
Setting Orbital Sanders Down	p. 154
Rasp (Shop-Made)	p. 154
Refinishing Furniture	p. 154
Refinishing Techniques	p. 154
Removing Old Glue from Furniture	p. 157
Stripping Spindles	p. 157
Routers	p. 157
Auxiliary Base	p. 159
Measuring Router-Base Radius	p. 159
Measuring Router Cutting Radius	p. 159
Molding Jig	p. 160
Router Bit Storage	p. 160
Router Tables	p. 160
Testing Router Bits	p. 160
Rubber Cement	p. 161
Rust (Preventing)	p. 161
Rust Check	p. 162
Safety Glasses	p. 162
Importance of Safety Glasses	p. 162
Types of Safety Glasses	p. 163
Sanders	p. 163
Sanding Techniques	p. 163
Preventing Marks When Sanding	p. 163
Sanding Concave Surfaces	p. 164
Sanding Drywall Joints	p. 164
Sanding Small Parts	p. 164
Sawdust	p. 165
Air Cleaners	p. 165
Clearning Sawdust Blockage	p. 166
Down-Draft Collection	p. 166
Dust Collection with Portable Tools	p. 166
Installing Dust-Collection Systems	p. 167
Metal Straps on Dust Collectors	p. 167
Preventing Sawdust Blockage	p. 167
Removing Sawdust	p. 168
Sawdust Static	p. 169
Static Control	p. 169
Treating Sawdust in the Eyes	p. 169
Sawhorses	p. 169
Folding Sawhorses	p. 170
Folding Sawhorses (#2)	p. 170
Padding Sawhorses	p. 170
Scrapers (Honing)	p. 170
Scratch Awl	p. 171
Screwdrivers (Reusing)	p. 171
Screws	p. 171
Broken Screws	p. 172
Countersink Covers	p. 172
Driving Screws into Hardwood	p. 173
Driving Screws into Wood in Tight Spots	p. 173
Lubricating Wood Screws	p. 173
Measuring Screws	p. 174
Pocket-Hole Jig for Screws	p. 174
Purchasing Screws	p. 174
Removing Broken Screws	p. 175
Repairing Broken Screws	p. 175
Screw "Covers"	p. 175
Selecting Screws	p. 176
Tightening Screws	p. 177
Scroll Saw	p. 177
Extending Blade Usage	p. 177
Scroll-Sawing Thin Material	p. 178
Storing Scroll-Saw Blades	p. 178
Seat (Shop-Made)	p. 178
Shaper Head	p. 179
Crosscutting with a Shaper Head	p. 179
Sharpening Shaper-Head Blades	p. 180
Shelf Brackets (Making)	p. 180
Shelves	p. 181
Making Shelves	p. 181
Painting and Finishing Shelves	p. 181
Signing Your Work	p. 181
Small Items	p. 182
Spray-Painting Small Parts	p. 182
Storing Small Items	p. 182
Storing Small Items (#2)	p. 182
Socket Wrenches	p. 183
Softwood	p. 183
Checking Checks in Drying Softwood	p. 183
Softwood Buying Guidelines	p. 183
Solvents (Disposing of)	p. 184
Spade Bits	p. 184
Spirals (Making)	p. 184
Squaring Project Corners	p. 185
Squeegee	p. 186
Stains (Applying)	p. 186
Steel Square	p. 186
Steel Wool	p. 187
Table Saw	p. 187
Changing Blades	p. 188
Changing Blades (#2)	p. 188
Dust Collection	p. 188
Ensuring Accurate Angles When Using a Table Saw	p. 189
Link Belts	p. 189
Miter Gauge	p. 189
Adjusting the Miter Gauge	p. 189
Preventing Miter-Gauge "Catch"	p. 190
Smoothing the Edges of Miter-Gauge Slots	p. 190
Repairing Miter Gauges	p. 190
Out-Feed Roller	p. 191
Out-Feed Table	p. 192
Zero-Clearance Insert	p. 192
Zero-Clearance Insert (#2)	p. 193
Tape (Double-Faced)	p. 193
Backing "Leader"	p. 193
Tape (Sticky)	p. 194
Tape Measure	p. 194
Ensuring Tape-Measure Accuracy	p. 194
Making Precise Inside Measurements with a Tape Measure	p. 194
Stick-On Tape Measures	p. 194
Using Tape Measures As a "Compass"	p. 195
Tenons (Making Round)	p. 195
Thickness Planer	p. 195
Knife Repair	p. 195
Planing Small Pieces	p. 196
Tool Kit	p. 196
Toothbrushes in the Workshop	p. 196
Vacuum in the Workshop	p. 197
Veneer	p. 197
Applying Veneer	p. 203
Cutting Veneer	p. 204
Gluing Veneer	p. 204
Repairing Veneer	p. 205
Vise	p. 205
Determining Workpiece Thickness with a Vise	p. 205
Vertical Planing Vise	p. 205
Wall-Cabinet Brackets	p. 205
Water Stains	p. 207
Removing Water Stains on Finished Wood	p. 207
Removing Water Stains on Unfinished Wood	p. 207
Wheels (Shop-Made)	p. 207
Wire Wheels (Extending the Lives of)	p. 208
Wood	p. 208
Storing Wood	p. 208
Transporting Wood	p. 208
Wood Filler (Applying)	p. 209
Wood Finishing	p. 209
"Aging" Wood	p. 210
Ensuring a Smooth Finish	p. 210
Filling Spray Guns	p. 210
Finishing Long Workpieces	p. 211
Hiding Knots	p. 212
Preventing Hardened Residue on Cans	p. 212
Safety Procedures When Using Finishing Materials	p. 212
Spray Finishing and Painting	p. 213
Wood Stains	p. 213
Applying Wood Stains	p. 213
Water-Soluble Wood Stains	p. 213
Workbench	p. 214
Bench Hooks	p. 214
Expanding the Surface of a Workbench	p. 215
Light for a Workbench	p. 215
Workbench Dogs	p. 215
Workmate Portable Project Center	p. 216
Extenders for Workmate	p. 216
Extenders for Workmate (#2)	p. 216
Nail Support Bin for the Workmate	p. 217
Tool Rack for the Workmate	p. 218
Workshop Cleaning	p. 218
Cleaning a Workshop	p. 218
Cleaning a Workshop (#2)	p. 218
Metric Equivalency Chart	p. 220
Weights and Measures Chart	p. 221
Glossary	p. 222
Index	p. 238
About the Author	p. 256
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