T 1 P S • T 0 0 1 L S • T E C H N 1 1 Q U ES, □ Building Raised Panel Doors □ Torpedo Level ■ Frame and Panel Jig □ Using Stile and Rail Bits I T 0 R ' S NOTE Cutoffs • lliilteteB. Issue 35 September 1997 publisher Donald B. Peschke editor Tim Robertson associate editor Phil Totten assistant editor Bryan Nelson art director Cary Christensen SR. GRAPHIC DESIGNER Kurt Schultz senior illustrators Roger Reiland Mark Higdon CREATIVE resources Creative Director: Ted Kralicek • Project Developer: Ken Munkel • Project Designers: Ted Wong, Kevin Boyle • Project Coordinator. Kent Welsh • Shop Mgr.: Steve Curtis • Shop Craftsman: Steve Johnson • Photography Director: Lark Smothermon • Sr. Photographer: Crayola England BOOKS Executive Editor: Douglas L. Hicks • Art Director: Linda F. Vermie • Sr. Graphic Designer: Chris Glowacki CIRCULATION Sub. Sen\ Dir.: Sandy Baum • Neiv Bus. Dir.: Glenda Battles • Renewal Myr: Paige Rogers • Billing Mgr.: Rebecca Cunningham • Asst Sub. Mgr.: Joy Krause • Promotion Asst.: Rick Junkins • Single Copy Mgr.: Todd L. Bierle • Assoc. Graphic Design Dir.: Susie Rider • Sr. Graphic Designer: Cheryl L. Simpson CORPORATE SERVICES Vice Pres, of Planning & Finance: Jon Macarthy • Controller: Robin Hutchinson • Sr. Acct: Laura Thomas • Accts. Payable Clerk: Mary Schultz • Prod. Dir.: George Chmielarz* Elect. Pub.: Douglas M. Lidster • Prod. Asst.: Susan Dickman • Prod. Artist: Jon Snyder * Pre-Press Image Specs Troy Clark • New Media Mg:: Gordon C. Gaippe • Multimedia Aid Dir.: Eugene Pedersen • Net. Admin.: A1 Barnes • I.S. Support Asst.: Chris Harrison* H. R. Dir.: Joyce Moore • H. R. Asst.: Kirsten Koele • Admin. Asst.: Julia Fish • Recept.: Jeanne Johnson, Sheryl Ribbey* Bldg. Maint: Ken Griffith • Special Proj. Dir.: Saville H. Inman MAIL ORDER Operations Dir.: Bob Balter • MaCls Mgr.: Mark Mattiussi • Oust. SeiviceMgrM enmeEnos • WarefmtseSupeivisor Nancy Johnson • Buyer: Linda Jones • Op. Asst.: Tammy Aldini • Team Leader: Karla Eslinger • Tech. Rep.: Matthew TfeRonde* Cz 7 /& 3 / 4 x 1 / 2 -2 Note: To build this project, you'll need 2 V 2 sheets of% n -thick Medium-Density Fiberboard (MDF), a half sheet of % n hard board, and approximately 10 bd. ft. of 3 7 4 -thick hardwood. No. 35 ShopNotes 17 FEATURE PROJECT Mounting a number of roller bearings to the top and bottom of the tool station allow the carousel and turntable to spin easily. NOTE: TOP, BOTTOM, SIDES, AND BACKS ARE %“ MDF; RAILS, MOUNTING BLOCKS, AND FEET ARE %“-THICK HARDWOOD Base I began work on the tool station by making an open, L-shaped base cabinet, see drawing. The shape of the base will provide easy access to the turntable that's added later. And it pro- vides leg room when working at the tools on the carousel. SIDES & BACKS. The base starts out as two sides (A) and a right (B) and left back (C) piece, see Fig. 1. (I used 3 / 4 " MDF, but ply- wood would work just as well.) These pieces are held together with simple butt joints. So to allow for the joinery in the back comer, the right back is wider (33 3 / 4 ") than the left back (33"). After cutting the pieces to size, there's one more thing to do before moving on to the top and bottom. That's to cut a dado in each piece for the bottom of the base, see Fig. la. TOP & bottom. Besides holding the case together, the top and bottom provide a surface for mounting a number of roller bearings, see margin. The roller bearings on the bottom make it easy to spin the turntable around, while those on top allow you to rotate the carousel. Both the top (D) and bottom (E) start out as a square piece of %" MDF, see Fig 2. But to create an overhang, the top is larger than the bottom. NOTCH. With the pieces cut to size, the next step is to cut a large notch in each one so they don't extend into the opening in front of the base. While you're at it, rout a small (Vs") chamfer on the top and bottom edges of the top and the exposed edges of the bottom. ATTACH ROLLERS. Now you're ready to attach the rollers to the top and bottom. After spacing the rollers evenly around the perimeter of a large circle, they're screwed in place, see Fig. 2. Note: To provide plenty of support near the edge of the carousel, the circle on top has a larger radius (16") than the one on the bottom (13"). 18 ShopNotes No. 35 FEATURE PROJECT Before assembling the base it's easiest to drill several large holes. There’s a hole in the top for an iron pipe that serves as a pivot point for the turntable and carousel, see Fig. 2. Also, five holes in the bottom will be used when levelers are added later. ASSEMBLY. At this point, you can begin assembling the base. I started by gluing up a U-shaped assembly consisting of one side and the two back pieces. Then I slipped the bottom in place and added the other side. Reinforcing each joint with screws helps strengthen the base. RAILS. To add even more rigidity, I installed two hard- wood rails under the top and bottom, see Figs. 3 and 4. A long rail (F) spans from one side to the left back. And a short rail ( G) connects the long one to the opposite side. ATTACH TOR All that’s left to F complete the base is to attach the top. It’s simply glued and screwed in place, see Fig. 4. Levelers To compensate for an uneven floor, I added five levelers. They allow each outside corner of the base to be leveled independently. Basically, each leveler consists of two parts: a thick mounting block that attaches to the bottom of the base and an adjustable foot, see Fig. 5. By turning a bolt that passes through the center of each part, you can raise or lower the foot, see margin. MOUNTING BLOCK. To provide plenty of strength, each mounting block (H) is made by gluing up two pieces of 3 / 4 "-thick hardwood (maple), see Fig 5. Before gluing and screwing the mounting block ^to the bottom of the base, you’ll need to drill a counterbored shank hole for a T-nut that accepts the adjustment bolt, see Fig. 5a. FOOT. Once the block is in place, you can add the foot (I). It’s a piece of 3 / 4 n -thick hardwood that’s captured on the end of the bolt by a pair of lock nuts. One nut rests in a counter- bored shank hole drilled in the bottom of the foot. The other tightens against the top of the foot to lock it in place. To raise or lower a leveler, simply turn the adjustment bolt with a socket wrench. No. 35 ShopNotes 19 A length of iron pipe threaded into a pipe flange works as a simple pivot for the turntable. Turntable FEATURE PROJECT a. IRON PIPE CROSS SECTION CATCH ^ COLLAR BLOCK ^ ] pr~ «