Archive for the ‘Articles’ Category

Having a workshop and spending a lot of time in it can eventually lead to some health issues if you cut a lot of wood.  For a while I was cutting a lot of MDF and as most people know the MDF creates small little fibers that float around.  These can be irritating if you breathe them in over a long period of time. I was using the MDF because I had a nice run of production on some children’s tables and the MDF was ideally suited for the job.  However after a while I noticed that just wearing a respirator was not going to cut it.

I also used a dust collection system to my shop and still had a lot of airborne dust.  I thought about adding the overhead units that Jet and Grizzly make just for the purpose of catching dust.  Those units did not really work for me and the cost was somewhat prohibitive.  I considered some dedicated air purifiers that I found online.  The XL tower professional air purifer seemed like a pretty good option, plenty powerful and had some good reviews, but maybe a tad to pricey for what I had in mind.  Plus I am not sure if the workshop would do more damage to the unit than it would do in helping my problem.

Finally I did choose a Proshield Plus Air purifier by Orek.  The Orek brand seems reputable and it seemed like it would be a good unit.  However I did not stick it in my shop, I ended up putting it in the living room.  After a lot of head scratching I figured that I could make my own Air filtration unit system from an old furnace fan that I had and some heavy duty filters, this way I could change out the filters and my fan only cost me twenty bucks.  It was a pretty good decision and it hangs from the shop ceiling.  The best part is I only hit my head on it once.

This is the model Air Filtration unit that I copied and used for my design.  I made mine with scrap 1/2″ plywood.

Most woodworkers are on a budget, so going out and buying all the tools for your dream shop is not a reality.  Sometimes buying used tools can be a great option for increasing your shops offerings.  I love to find stuff at garage sales and on craigslist.  When I am at garage sales I find that finding a decent tool usually falls into two categories.  It’s a decent tool at a great price because the seller usually has no idea what it is or they have good tools and are priced really high.  Occasionally you can find someone that is moving and just wants to clear everything out, but that is not usually the case.  Look at the seller, if you feel comfortable with the tool brand and the fact that it may not look that beat up, take a chance.

I occasionally buy tools on craigslist.  These tend to be a bit higher since the sellers are not as desperate as garage sale sellers.  I have found some pretty cool stuff over the years and the offerings are always changing, which makes looking for them fun.

The one place I do not buy is from pawn shops.  The tools that are for sale in most pawn shops are so beat up that I can never see myself paying for one.  Another factor is pawn shops always seem to want some crazy price for the tool.  Most of the time I could buy the same tool brand new, for the same price.  I know they want to add some haggle room, but I prefer not to have to go through that.

I have done an interesting study and have answered a lot of phone calls.  A lot of them include the question of what brand is this router table, or router bits or accessory?  This seems to be an important question for some and others really could care less.  I decided to post a very short poll to find out from you, our readers what you think is most important when considering a tool purchase.

A lot of independent companies or sellers online have developed their own brands.  They do this by approaching a manufacturing company that makes a “universal” or generic tool have have them brand it with their name.  This is very very common and if you look closely at a lot of tools you can tell the only difference is in the label.  A good example of this is the Bosch Tool company who makes their own great router line.  They also make a few models for Craftsman, with the craftsman name for sale at Sears (of course).  Great tool and both have a good reputation.  But what about smaller or lesser known brands?  Are they just as important?

I think the answer comes in reputation.  If a company has a reputation for cheap quality tools, it could have a negative effect.  If it is unknown, its a crap shoot for the buyer.  Now a days tools have really improved in quality and sellers have to sell quality if they want to stay in business.  What do you think?

By now you have seen these, they are pretty much available in most woodworking catalogs.  At first I did not think to much of them until I held one in my hand.  I thought I could just do what I have always done and use a piece of scrap wood.  Sure enough these things work, and they work well.  For $12 its not too bad and they will find a lot of use in your shop.  Here is an interesting factoid, do you know what the difference is between the Rockler bench cookie and the Bench Dog Bench cookie is?  The answer is, nothing.  Rockler owns Bench Dog and the only difference is the color.

• Rout, sand, cut and carve without using clamps
• Raise up workpieces for easy edge finishing
• Support projects without leaving marks
• Assemble projects on a stable, non-slip base
• Set up quickly for any application

Some feedback for the Rockler side

Simple and Strait forward,

Very useful,

So Far, So Good,

Good Stuff

From the Bench Dog side:

Works Great!

Nothing but awesome!,

shipping and tax free alternative to Rockler cookies

Bench Dog Cookies Great Shop Item

Doggone Good

And Just for fun….

Bench Dog Cookies,  get them here

Rockler Bench cookies, get them here

I have been doing quite a bit of work on the router review section of the site and have come across a really good reference.  It is so good that its hard to pass up.  have you have  ever bought a router and needed a part?  Of course you have, or at least I have.  If you know anything about small routers or woodworking tools its that even though the manufacturer warranties the parts and the operation, it is still up to you to take it to a service location.  I don’t know about you, but this is as about as much fun as going to the dentist.

Service Centers

Although this is a good idea from a business point of view, it really is quite painful.  I think if someone from Delta or DeWalt actually went to the service center, they might figure out that it is indeed a pain for the customer.  However that is most likely not going to happen so we are stuck with it.  That is the reason for this post.  Most Service departments or storefronts are expensive.  Cost per hour of service is that of the auto industry caliber.  I just don’t think that small motor repair should be as expensive as it is, but that is my opinion.  Most woodworkers are fairly well skilled and could fix it themselves if they could find the part.

Parts online

I really like this company since they supply the parts and actually have a website that functions (huge in my opinon)  And just so you know, this is a random unpaid recommendation.  http://www.ereplacementparts.com

Check out the diagrams:

They also carry just about every brand of router and small woodworking tool you can think of.  Who would of thought that you could find a part for Rigid right along side Porter Cable?  A while back I lost the thumb knob to my Porter Cable 7529 router, it vibrated off, fell on the floor and vanished forever.  Try going to Porter Cable/Delta to get a new one, it’s not easy.

This is the latest from Wood Magazine, they put all 195 back issues on one DVD.  I spent a good hour cleaning out my closet trying to figure out which issues I wanted to keep and which ones I wanted to throw away.  I am going with this, its easier and I have what I need at my fingertips.  I usually just try to keep the issues with router table and router stuff, but you never know when you need something you saw a while back and cannot figure out where it went.

This content is straight from Wood Magazine:

Readers told us they wanted all 195 back issues on one disc, with a single, comprehensive, searchable index. So we did just that, while maintaining the super-high-quality, 300-dpi resolution, ensuring you crystal-clear illustrations and photos. 

High resolution PDFs make for easy, enjoyable reading.
View every photo, drawing, and detail in digitally reproduced, crystal clarity. Zoom in for a closer look, or print articles for use in the shop with the handy “Print this article” button.

Free up shelf space in your home and shop:
The disc and protective case fits 195 issues into the space of a slim paperback.

Save hundreds of dollars versus buying back issues.
In fact, many of the most sought-after issues on this disc have been out of print for years and are no longer available in any other format.

Compatible with PC and Mac.
If you don’t already have it, Adobe Reader is included on the disc for viewing.

Cuttting Dados on the Router or Tablesaw

So your project calls for some precise dados to be cut.  Some are through dados and some are stop dados.  Having never cut one before, which tool do you reach for?

 The thought process:

Router:

Never having done this before, you will have to thing about what you need.  If you use the router, you already have one (assumption).  A straight bit will do the trick for the cutting portion.  What about a dado jig?  How will you guide the router?  Do you need to buy a jig or make it?  Do you have time to make one?

Once you have or make one, you need to practice using it.

 Tablesaw:

Do you have a Dado blade?  Can you afford one?  What is the best brand?  Is your saw big enough to hold one? (check your arbor length, a bench saw arbor are sometimes shorter)  How do I cut the stop dado on the saw?

 These are good questions.  Its better and easier when you already know the answers.  Deciding the first time is what takes all the research and time.  After that when you have the tools, you can easier figure out how you want to tackle the dado proposition on your project.  One of the things I like about the tablesaw, is that it is fast.  I can cut a groove or dado quite quickly.  But I love using my Router Table, and any chance to tweak or improve its capabilities is fun.

The last thought is of course budget.  If you think that you are going to cut a lot of dado’s then the dado blade on your table saw would most likely make the most sense.  If you are budget minded and the only project you may need it on is the one you are working on then the router may suffice.

It has been an interesting week in reference to router table insert plates.  Lots of questions and lots of comments on different types of plates.  One of the biggest comments has been why are router plates all different sizes?

I think the best way to describe it is money.  If a manufacture can make their shape conducive to their own brand they will keep you locked in as a customer.  What I mean is this, say you buy a router plate from Bench Dog and later on you want to upgrade to a router lift.  If you made your table, or bought a Bench Dog table, you would have to buy a Bench Dog Lift because nothing else will fit.  Its that simple.  Most guys will not start over.  It is similiar to computers.  I am a PC, but  I would really love a Mac.  Why, well to be honest PC’s kind of suck.  They are bloated with a pig of a operating system, they crash a lot, have all kinds of problems and are always being exploited by hackers.  But I am “all in” because of the software I need and use is not available on a Mac and starting over from scratch seems more of a pain than its worth.  There is also the money.  The Mac costs more than the PC and there you have it.  Back to the plates, is one any better than the other?  Nope.  Just know you may be committing yourself to a brand in the name of budget and time.

Last thought.  There has been a lot of questions abot aluminum verses phenolic or acrylic.  Aluminum plates are very expensive so does that mean they are better?  Not necessarily.  You will always have the guys that have to have the very best of everything so aluminum is great for them.  But what you really need to look at is what size router are you hanging from the insert.  You should never store your router on the insert in the table.  Most of us do and that is where the problems start.  After a while the gravity bandit comes and your insert is now not flat (acrylic or phenolic).  To complicate the matter, some people thing they need the big 3 1/2 HP router in their table. (cause bigger is better right..uh no) So they buy this monster 23lb thing and hang it on a phenolic insert and let it sit in the table for a year.  You guessed it, bad news for the insert plate.  Why in the world do you need a 3 1/2 HP router in a router table in the first place is beyond me.  You still can only shave off so much in a single pass unless you love the smell of burnt wood and dull router bits.  If power is your game, buy a shaper.

About four years ago I built this loft for my son.  He had the smallest room in the house and it has given him a lot more room.  Its kind of a cross from a giant tree fort and a stilt home built near beaches.

If you have a small bedroom and want to maximize your space, building a loft in your child’s room can be a great project. They are surprisingly easy to do and can be completed in a weekend. You will be amazed at the ton of room that you gain by not having a bed on the floor plan. Didn’t have one in college? Then the key to building one is planning. I am not talking about a glorified bunkbed, I am talking about a room defining space that will change your child’s bedroom

The key to preparation is looking at your room and figuring out what you have to work with. Do you have high ceilings? Is your closet internal or external?

High Ceiling Homes

Obviously, the higher your ceilings are the better your loft possibilities are. Standard 8 foot ceiling rooms are not conducive to building lofts. However in today’s building market 10′ and 12′ ceilings are becoming more and more common.

Closets

 A room with a bumped out or external closet looks like this. It creates a natural ledge on the top of it and has some room from the ceiling. An internal closet is just that, it fits inside the internal dimensions of the room. The closet is a great point to use for stabilizing your loft, we will discuss that later. The example shown here is with an external closet, in my opinion it is just as easy to build one for both examples.

In the last part of the preparation phase you want to note the closet style so that you can plan your posts. In this example two of the main posts actually attach to the wall next to the closet. Internal closets loft styles are free standing.

Preperation

The first step in building the loft is building the posts. Posts are easy to build and can be very simple in construction. If you have experience in woodworking, it will be even easier. All four posts can be built from two pieces of ply wood. You will want to rip the plywood into four even strips of wood to build a hollow box. The diameter is up to you, but the bigger the posts the more stable the loft will be. I kept my posts fairly big around 8 inches square. Do yourself a favor and buy the cabinet grade plywood at Home Depot or Lowes. This grade costs about $40 per sheet but it is worth it when you go to finish the project. You will use simple butt joints and you can screw them together. Make sure you counter sink the holes and then fill in the screws with either a plug or with wood filler. Take your time here, and sand them up real nice and clean. These posts are multifunctional, they will hold the electrical work that you run inside for the lights that shine up on the ceiling. When you are done with the posts paint them to your desired finish.

Loft Post

Bring the posts into the bedroom and put them in the approximate spots the will go to. You will then need to cut the two long support beams that connect to the posts. You can use any time of wood you like. If you are going for a rustic look, you can use 2″x6″ lumber. Make sure you do not get the pressure treated variety. When you have the supports cut, sand them, and then finish them with paint. Bring the supports into the room and get ready to install them to the posts.

Supports

This is really the trickiest part of the assembly since you will need some help holding the support up against the post. Use carriage bolts to bolt the support to the post. You may have to reach down into the post with your arm to attach the nut to the bolt. Once you have the main two supports bolted on, repeat the process with the two cross supports. You are basically building a big box, or something similar to a deck that would be outside your house.

Support

While the unit is still movable move the loft into the desired position. If you are going to attach it to the wall through a closet you would do that next. For mine I went and bought 14″ carriage bolts and ran them through the loft post, through the wall and through a homemade washer. (A piece of wood)

Add the rest of the cross bar supports. As you add the supports the unit will get more stable. (and heavier) If your loft is free standing, use this time in the framing stage to access its stability. The bigger the posts are the more stable the loft. If it is not stable, add whatever bracing you need. (keep in mind the floor will add a lot of stability) The loft I made was 8 feet by 8 feet, so it was very stable because of the materials and the size of the unit.

Floor

Adding the floor to the loft is next. Simple sheets of plywood attach to the top of the supports. You can substitute MDF for the plywood. It is a much smoother surface and costs less than the ply. You won’t have to do any sanding on MDF either. When you add the floor, make sure you countersink the screws so that they do not stick up. The floor will add considerable strength and stability to the unit.

Ladder

Next build a custom ladder that you can paint to match the loft. Again the type of wood is your choice. We made ours out of 2 x 4′s and custom cut it to fit the space we had. The strength of the ladder can easily hold an adult if you build it right.

Railings

Don’t let any kids go up until you build the railing. The railing is very important and your wife won’t probably let you build this project without one. Other parents will appreciate the railing too since their kids are going to be in the loft as well. These lofts are kid magnets, so make them safe. I made my railing a bit fancier since I had access to a router table. I ran the flat spindles on the router table with a roundover bit to make them round. This softens up the unit and makes it look more furniture like.  Keep this in mind, the railing is not designed to be leaned on, swung from or to be some sort of super stable safety device.  My son was 9 when I built this and he pretty much knows that the railing is there as a reminder where the edge is.  It also adds a nice finishing touch the the loft so I took the time to edge profile each one on the router table.

Loft Railing

Finishing Touches

We put carpet up on the loft floor; it was quick and easy and cost about $25. Next we hoisted up the mattress. There is no need for a box spring, since the wood gives more than adequate support. If you have an external closet, you will have a natural ledge in which you can install a bookshelf or even a TV set. Ours had a TV and Xbox for our son and all his friends were in the loft.

Loft Bottom

The bottom of the floor is the perfect opportunity to finish off with some plywood to make a mini ceiling. In the ceiling you can recess some lights. This makes if more functional for the room and less dark.

Loft Options

I choose to use the hollow post design for running two light fixtures near the top of the loft to shine upwards onto the ceiling. Use the newer “green” Eco friendly light bulbs and you will not have to worry about excess heat from ordinary standard bulbs. You can run regular extension cord up from the bottom of the post by drilling a hole at the bottom and pulling the wire through.

loft carpet and bed

Hiding Spots

I like to take the other two posts and put caps on them with a hinge on the inside. If you put a shelf in the inside while assembling the posts, it makes a great hiding place for kid things. From the outside it looks like an ordinary cap, kids love it.

Have Fun

You will find different customizations for your loft. All of them are super fun for the kids and a real accent to your home. If you use good quality materials you are really making furniture. Take your time and you will be glad you did. Young boys will think you are the best parent in the world for taking this project on!

Electrical runs down hollow posts