Smart workshop solutions : building workstations, jigs, and accessories to improve your shop

178 Pages·2003·16.75 MB·English

by  Paul Anthony

CRAFTS & HOBBIES
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The right fixtures and accessories can M
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mean a big difference in how well your
R
T
workshop works for you
. W
O
In this book, Paul Anthony has collected some of the
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best ideas for shop accessories, workstations, jigs, and
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Smart Workshop
storage solutions.With the help of the detailed drawings S
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and step-by-step instructions and photos, you can build
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and install these ingenious shop additions.The result
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will be a more efficient workshop and woodworking

S S O L U T I O N S
that’s safer and easier.
O
L
U
CLAMP RACKS Building Workstations, Jigs, and Accessories to Improve Your Shop
T
I Paul Anthony
WOOD STORAGE SOLUTIONS
O
N
DRILLING STATIONS
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TABLESAW STATIONS
ROUTER TABLES
TOOL CABINETS
AND MUCH MORE . . .
About the Author
Paul Anthony
has been a professional woodworker for
almost 30 years and is a past president of the Sonoma County
Woodworkers Association.He has built hundreds of projects,ranging
from furniture to turnings and musical instruments.A former editor
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for American Woodworker magazine,he is also the author of Home
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Storage Projects.He lives in Riegelsville,Pennsylvania. t
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Visit our website at www.taunton.com. Cover photos by:Paul Anthony o
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Cover design by:Howard Grossman/12E Design
y
The Taunton Press also publishes Fine Woodworking
magazine,the single best source of woodworking
ideas and information anywhere.
US $19.95 T
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$19.95U.S. ISBN 978-1-56158-578-6 u
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9 FnL1 00 0000 781561 585786 S
Taunton Product #070695
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W
ORKSHOP
solutions
Building Workstations, Jigs, and Accessories
to Improve Your Shop
PAUL ANTHONY
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Text © 2003 by Paul Anthony
Photographs © 2003 by The Taunton Press,Inc.
Illustrations © 2003 by The Taunton Press,Inc.
All rights reserved.
pP
The Taunton Press,Inc.,63 South Main Street,PO Box 5506,Newtown,CT 06470-5506
e-mail:[email protected]
EDITOR:Stefanie Ramp
COVERDESIGN:Howard Grossman
INTERIORDESIGN:Lori Wendin
LAYOUT:Marta Strait
ILLUSTRATOR:Melanie Powell
PHOTOGRAPHER:Paul Anthony
Library ofCongress Cataloging-in-Publication Data
Anthony,Paul,1954-
Smart workshop solutions :building workstations,jigs,and
accessories to improve your shop / Paul Anthony.
p.cm.
ISBN-13:78-1-56158-578-6
ISBN-10:1-56158-578-5
1. Workshops--Equipment and supplies--Design and construction. I.
Title.
TT153.A58 2003
684'.08--dc21
2003007857
Printed in the United States ofAmerica
10 9 8 7 6 5 4
The following manufacturers/names appearing in Smart Workshop Solutionsare trademarks:Accuride®,
Adjust-A-Bench,Delta®,Fast Trak,Makita®,Masonite®,Melamine®,Porter Cable®,Rockler®,and
Woodcraft®.
WORKING WITH WOOD IS INHERENTLY DANGEROUS.Using hand or power tools improperly
or ignoring safety practices can lead to permanent injury or even death. Don’t try to perform
operations you learn about here (or elsewhere) unless you’re certain they are safe for you. If
something about an operation doesn’t feel right, don’t do it. Look for another way. We want you
to enjoy the craft, so please keep safety foremost in your mind whenever you’re in the shop.
To Mom and Dad, for all your love and support throughout the years
ACKNOWLEDGMENTS
T
HANKS TO THE STAFF AT THE TAUNTON PRESS for their good work throughout the creation
of this book.I don’t know how she does it,but Executive Editor Helen Albert always manages to work
through difficulties with creativity and grace.Her editorial assistant,Jenny Peters,is as reliable as they come,
and Managing Editor Carolyn Mandarano is always a pleasure to deal with.A special debt of gratitude goes
to my editor,Stefanie Ramp,for her patience and meticulous work,as well as her humor and determination
during the incessant eleventh-hour computer glitches and crashes.
This book would not be a reality without the help of all of the woodworkers who contributed their
time and designs to it.It was a blast to visit the shops and homes of such a good-hearted,gracious bunch
of folks.Thanks to Ken Burton,Craig Bentzley,Brian Boggs,Mike Callihan,Bill Hylton,Fred Matlack,
Tony O’Malley,Andy Rae,Larry Seachrist,Walt Segl,Don Weber,and Bob Whitley.Special thanks to Ric
Hanisch,Andy,and Fred for behind-the-scenes consultation and to Craig for going the extra mile when
help was needed.
Last,but certainly not least,I couldn’t have done this without the help and encouragement of my
lovely wife,Jeanie.
CONTENTS
Introduction Wood Racks
2 36
Smart Workshop Solutions Table-Saw Station
4 48
Clamp Racks Drilling Stations
16 68
Lathe Stations Mobile Tool Cabinet
86 142
Chopsaw Cabinet with Assembly Table
Extension Tables 160
100
Sources
Router Table 172
122

INTRODUCTION
T
IME SPENTin the young acrobat capable of tra-
workshop is the most versing your overstuffed shop
enjoyable part of the day with only minor injuries.
for many woodworkers, Whatever the case,there
whether amateur or profes- is no shortage of good shop-
sional.In fact,many of us improvement projects to
have a sort of ongoing love minimize your wrestling bouts
affair with the shop because it’s our place of creativi- with tools and stock.To that end,this book offers
ty and refuge.It’s where we make these beautiful, designs for shop accessories such as lumber racks,
useful things that last for generations and where clamp racks,outfeed and assembly tables,and tool-
we go to recharge ourselves,surrounded by wood, storage solutions.What’s more,you’ll find designs
projects,and tools. for various shop workstations dedicated to particular
If you’re a woodworker,it’s a good bet you love woodworking processes.Workstations are not only
tools.That’s a good reason to have your shop in the best approach to efficient production,but they
shape,as it’s the biggest tool you have.It pays to keep also make woodworking more enjoyable and safe.
it fine-tuned and operating as efficiently as your Whether a workstation is dedicated to sharpening,
saws and planes.An unruly shop can cause you grief drilling,sawing,assembling,or sanding,it includes
as you hunt for that bit for the third time or screw all of the tools,supplies,and space you’ll need to
up a cut because your quick-’n’-easy outfeed support perform a particular process.For example,a sharp-
fell over again.A well-tuned shop allows you to glide ening station usually includes a grinder and honing
from one process to another,getting much more stones placed at the appropriate working height,
done and enjoying it more. with a wheel dresser,water for cooling,and any
Chances are that no matter how well your shop is grinding and honing jigs nearby.No matter how it
organized,you’ve got improvements floating around is configured,a workstation that provides a ready-
in your head as you work.Maybe the thought of a to-go work platform with all of the necessary tools
new lumber rack sprung to mind when you tripped and supplies close at hand will pay off big dividends
over that pile of boards last week.Perhaps that in efficiency and quality of work.
recent back twinge from hoisting your “portable” So have at it.I think you’ll find that the projects
planer is triggering the “tool-stand design”cortex of in this book will make your time in the shop more
your woodworker brain.Or maybe you’re just finally productive and enjoyable.Just don’t forget to step
reaching the sad conclusion that you’re no longer the outside for some sunshine once in a while.
✦ 3
Craig Bentzley’s shop is a model of compact efficiency.
Thoughtfully designed storage and carefully positioned
machines create an environment for smooth production
of woodworking projects.
SMART WORKSHOP
SOLUTIONS
WHETHERYOURWORKSHOPis in There are a number ofapproaches to
a garage,a basement,or a increasing efficiency in the shop,but the
warehouse,organization and most important involves thoughtful shop
efficiency matter.And they layout and appropriate fixtures and work-
matter to both professionals and recreational stations.The way your machines and other
woodworkers alike,because a well-organized, tools are placed in relation to each other can
properly outfitted shop pays offbig divi- save a lot ofwasted steps and aggravation
dends in terms ofboth productivity and throughout the workday.Well-designed fix-
enjoyment. tures such as wood racks and clamp racks
The whole idea oforganization and effi- can ease access to materials and tools,saving
ciency is to make life in the shop easier and you a lot oftime during project layout and
more fun.Woodworking is challenging assembly.Carefully conceived workstations
enough without building difficulties into the condense into one area almost everything
process by poorly arranging tools and using you need for a process,maximizing your
shoddy shop fixtures and accessories.It’s time and energy.
funny—I’ve spoken to hobbyist wood- Small shops benefit especially from orga-
workers who seem to think that efficiency nization because space is at such a premium.
only matters to professionals who are trying When every tool has its place,work goes
to crank work out the door.But efficiency more smoothly.Keep in mind that an orga-
matters to everyone.Woodworking tends to nized shop doesn’t have to be uncomfortably
be labor intensive,and ifyou’re going to get neat.I’ve visited countless shops over the
projects done,you can’t waste a lot oftime years,and every one has a style ofits own.
diddling with your machines and searching Clearly,a shop doesn’t have to be pretty to
fruitlessly for misplaced tools and supplies. produce beautiful work.I’ve seen plenty of
After all,ifyou’re going to get points for amazing work emerge from some crude-
that “honey-do”cabinet for the spouse, looking shops,but the more productive of
you have to actually hand over the goods those shops were organized in their own way
sometime. and carefully tailored to the nature ofthe
work produced there.
✦ 5