TIPS11

SEASON

COLLECTION

© 2017 Cruz Bay Publishing, Inc.

Episode 1101
Swivel Storage Rack
Like a lot of woodworkers, I have lim-
ited storage space in my small shop. So
taking advantage of the space I do have
is very important. To that end, I came up
with this swivel storage rack.
CONVENIENT DESIGN. At the heart of the
storage rack are some 8-oz. clear plas-
tic jars with screw-on lids. These jars
are available online from Amazon
(B00YQBYQ7W) and are the perfect
size for organizing a vast array of small
items and hardware.
SIMPLE BUILD. With the exception of the
dowel and the PVC spacers, the storage
rack parts are all made from plywood.
I made the top, bottom, and back first.
A shallow hole in the top and bottom
holds the dowel, and a couple rabbets
are needed at the ends of the back.
Next, cut the arms to size. Drill a hole in
each arm for the dowel to pass through
and use a couple screws to secure three
lids to the underside of each arm.
ASSEMBLE THE PARTS. Screw the bottom to
the back first and glue one end of the
dowel into the hole.Then it’s just a matter
of stacking the rest of the pieces in place,
alternating between spacers and arms
until you reach the short spacer at the
top. Finally, secure the top to the back.
Ernie Perez
#/4" hardwood TOP
Key West, Florida dowel
NOTE: Top and
bottom are identical
a. 1
SECTION VIEW
!/4
1#/4

1!/2
NOTE: Top, bottom, ARMS
#/4"-dia. back, and arms are 4
hole made from #/4" plywood
Arm
16#/4
16
!/2 BACK

NOTE: Attach #/4" PVC pipe 4

#/4 spacers
lids to arm
13 with screws
Countersunk
Container mounting
lid holes

#/4 4
ARM
#8 x #/4" Ph
sheet metal
screws
#/8 NOTE: Dowel is glued 1!/2 #8 x 1!/2"
into shallow holes 3!/2 Fh woodscrew
in top and bottom
3!/2
8-oz. plastic #/4"-dia. hole,
jars with lids #/8"deep 3!/2 BOTTOM

1 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
 NOTE: Location of #/4" through hole
for dowel depends on position of
dog holes in workbench
4
9!/2
MOUNT

13#/8

BASE
%/8
4
#/8
4
Episode 1101 Pocket Hole Jig Base #/4"dowel CLEAT 1!/2

Lately, I’ve been making a lot of projects piece is the base. It supports the mount NOTE: Dowel 5!/4
is hardwood.
using pocket-hole joinery. I don’t have that the platform is attached to. A dowel All other parts 2
the space to dedicate to a permanent locks it to the workbench (shown in the are #/4" plywood
3
setup. But clamping and unclamping the inset photo above). A cleat screwed to
#8 x 1#/4"
jig on my workbench was getting old. the base from underneath prevents the Fh woodscrew
My answer was a simple portable plat- whole unit from spinning while in use.
form. Just three pieces of plywood and a Jim Moorehead
dowel are all that’s required. The largest Barrigada, Guam

Episode 1102 Pipe Cut-Off Guide

Recently, I installed some 4"-dia. PVC (You could also use a jigsaw to rough the guide block and clamped the pipe
drain pipe in my shop for a dust collec- out the hole, then file and sand it to in place on the top of my workbench,
tion system. To get tight-fitting joints, I its final shape.) the inset photo shows this.
needed to cut the pipe ends squarely. I BLOCK BASICS. As you see above, I made I use a hack saw to cut the pipe, keep-
came up with a simple idea to do this the blocks from two pieces of plywood ing the saw blade flush with the guide
that works with pipe of all sizes. glued together. I made two of these block. You can also use a Japanese
A SIMPLE SETUP. Using my drill press blocks — one to support the far end Ryoba saw. It will also ride against the
and a wing cutter, I cut a hole in a of the pipe, and the other to guide my guide block and leave a smooth cut.
block the same size as the diameter saw blade while making the cut. To get Francis Herzing, Jr.
of the pipe that I was going to use. a good grip on the pipe, I cut a slot in Lincolnton, North Carolina

2 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
 Episode 1102
Biscuit Painter Points
I came up with a simple way of creating some
stand-off blocks for the stack of cabinet doors
that I needed to apply finish. Using a length of
scrap plywood, I cut multiple biscuit slots along
it, glued biscuits in the slots, and cut the blocks
free at the miter saw. The blocks can be any
length to suit the task at hand.
John Doyle
Ankeny, Iowa

Episode 1103
Multipurpose Supports
When adding finish to a completed
project, I always run into the same
problem. How do I finish opposite sides
without scratching or marring a finished
surface. Applying stain and varnish to a
project takes long enough as it is, so the
last thing I want to do is chase my tail
by fixing sawhorse marks or dings on a
surface that’s already done.
To curtail this problem, I made NOTE: Riser and base
two stands that look like an upside- are made from #/4" pipe
NOTE: Riser #/4" plywood insulation
down ‘T.’ They sit temporarily on is glued to base
32
my sawhorses while finishing and
once done, can be stowed away
!/2"-rad.
when not needed. Just clamp the
stands to the sawhorses.
A SOFT LANDING. I used four pieces 34
RISER #/4
of plywood that are slightly
shorter than my sawhorses. To
join them, I cut a centered groove !/2"-rad.
in the base piece that holds a ver-
2!/4 34
tical riser. I put a bullnose on the
top of the riser with my router a. END VIEW
and a roundover bit. Around this !/2"bullnose
riser I wrapped a piece of #/4" pipe
BASE
insulation. This is the pre-sliced
type that you can get at your local 4 NOTE: !/4"-deep
groove is centered
hardware store or home center. on base
Wallace Swindells
Chandler, Arizona

3 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
 Episode 1104
Carving Tool Caddy
Storing carving tools in a tool roll
is a good solution for protecting the
delicate cutting edges. But when I
go to use them, I typically have to
pull several out of the tool roll until
I find the right one. In order to pro-
tect my carving tools, and make the
cutting profile visible, I designed
this carving tool caddy.
CLEAR VIEW. What sets this tool caddy
apart are the two acrylic side panels
that provide a clear view of the busi-
ness end of my carving tools. Not
only that, but I was also able to cut
the slots in the block to exact size to
match the individual carving tools in
my set. And a couple of finger holes
in each end make it easy to move
around my shop.
PLYWOOD CONSTRUCTION. With the excep-
tion of the acrylic sides, the entire
caddy is made from plywood and is
held together with glue and screws.
Glue up the material to make the
block first. You can then lay out and
cut the slots for your carving tools.
To soften the rough edges, I cham-
fered the base and ends (including
the finger holes).
Hermie Tolerba
Sugar Land, Texas

a.
NOTE: Size grooves in End
block to accommodate
your carving tools
!/2 7!/2
1!/2"-rad. #/4 END %/8 1&/8
!/4 %/8
!/4
SIDE
Block 4
1#/8
1!/2
Base
1%/8
#8 x 1!/2" 1!/2 SIDE 2 SIDE SECTION VIEW
BLOCK
Fh woodscrew (!/4" acrylic)

#8 x #/4"
6!/2 Fh woodscrew b.
END 2!/4 1"-dia.

9#/4
3 BASE End END
6!/2 VIEW
#8 x 1!/2"
Fh woodscrew 5
3!/4
NOTE: All
3#/4 chamfers
NOTE: Base and ends are #/4 are #/32"
made from #/4" plywood.
Block is glued up from Base
three layers of #/4" plywood

4 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
 Episode 1105 Quick Whiteboard
Tired of searching for notes jotted on scraps of paper,
Bob Schultz of Saint Charlottesville, VA, turned some
of his shop doors into big note pads. Vinyl peel-and-
stick whiteboard decals found online can be cut to fit
inside the door panel.

Episode 1105
Simple Saddle Square
There are many commercial saddle squares available that
allow you to mark three adjacent faces of a workpiece with-
out moving the square, but they’re rather expensive. What I
wanted was a three-sided saddle square that wouldn’t break
the bank. What I came up with is the simple square you see
above and in the drawing below.
PLYWOOD PARTS. This saddle square is made from four plywood
parts and some common hardware items. The fixed jaw has two
guides glued in notches at the top corners. I cut the notches at the Episode 1106 Bucket Recycling
band saw. The rear, sliding jaw gets a threaded insert installed as Seeing an opportunity, James Bradley of Oceanside,
shown below. A cap screw and small spring hold the sliding jaw CA, made use of an old five-gallon bucket for different
in position. Depending on the spring’s tension, this square will tasks. Cutting just below the top structural rib leaves the
adjust to accommodate workpieces from !/4" to 1!/4" thick. bucket and handle intact. The remaining lid and cut sec-
DeLayne Peck tion can be used as a basin to clean saw blades.
3 Lincoln, Nebraska
1
GUIDE
GUIDE

NOTE: All parts

are made from
#/4" plywood

!/4"-20
threaded
insert

SLIDING JAW #/4

#/8 !/4" I.D. x
1"-long spring

%/16"-dia.
hole Episode 1107 Waterstone Storage
2!/4 Steve Kralicek of Omaha, NE, uses waterstones daily in
FIXED JAW his shop. So instead of drying and storing them away,
he leaves them in water in a plastic bin that has a lid. He
3
!/4"-20 x 2!/2" adds a capful of bleach to the water to prevent any mold
cap screw
buildup between water changes.

5 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
 Episode 1109 Precise Epoxy Mixing
Episode 1108 Pet Collar Cord Keeper Phil Huber of Urbandale, IA, uses graph paper to measure
To keep all his unruly extension cords in order, Dana Myers his epoxy. Matching the volume of resin and hardener is
of Des Moines, IA, decided to employ an item rarely found in just a matter of matching the size of the puddles of each.
the shop, an old pet collar. As his puppy outgrew its collars, The graph paper gives a good visual reference. To mix up
he used them as a binder and hanger for the extension cords. another batch, simply tear off another sheet.

NOTE: Scrap
pieces must be
at least as
thick as
workpiece

Scrap Scrap
piece piece

Workpiece 14"
min.

NOTE: Snipe
ends up on scrap
pieces, not
workpiece

Episode 1109
Planing Short Boards
I can never bring myself to throw away causing it to lift off the planer bed. At pieces span both feed rollers, so the
the short hardwood pieces left over from best, this causes severe snipe (a deeper board stays flat on the bed of the planer.
a project, especially if they’re exotic or cut near the end of a board). At worst, The result is a planed surface that’s
expensive. They’re often ideal for small the board can get chewed up, damaging mirror smooth. If there’s any snipe, it
projects. But they typically have to be the cutterhead in the process. ends up on the scrap pieces, not the
planed to thickness before I can use them. To prevent ruining the board (or my board. Once the board is planed to the
The problem is that running a board planer), I glue long, narrow scrap pieces desired thickness, just cut off the narrow
less than 12" long through some planers to each edge of the piece I want to plane scrap pieces at the table saw.
isn’t recommended. It can get caught (upper right drawing). Inexpensive Roland Romito
between the infeed and outfeed rollers, pine or fir works well here. These scrap Broadview Hts., Ohio

6 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
 Episode 1111 Precise Epoxy Mixing
Bill Wells of Olympia, WA, uses a pair of dedicated large vol-
ume syringes (purchased from a local medical supply house)
for storing his epoxy resin and hardener. The graduations on
the sides of the syringes gives him precise control over the
amount of hardener and resin needed for each job.
In addition to making the epoxy easy to dispense, the
syringes also keep things tidy during use. So you don’t end
up with stray drips. They also keep air out and this helps the
epoxy stay fresh and ready for future use.

Quick
Link
Snap Link

Episode 1112 Overhead Storage Tray

My small shop doesn’t have much release the snap links and gently lower
room for storage. Especially when it the tray until it’s supported by the chains.
comes to delicate sheets of veneer and Jeffrey Martel
various lightweight items. To solve this Seattle, Washington
storage problem, I made this shallow
!/4" snap END
tray that’s mounted to the rafters in the link NOTE: Sides and SIDE NOTE: Size chain
ends are made lengths so tray
ceiling. You can see how the tray goes !/4" eye contents do not
bolt from "two-by"
together in the drawing at right. stock fall out when
lowered
Creative mounting system. What’s #/4
unique about this tray is the system for 1!/2

raising and lowering it. Each corner of !/4" deep rabbet

the tray features eye bolts and snap
1#/4 NOTE: Bottom is made
links that match up with eye bolts from !/4" plywood
on the rafters. Connecting the snap 48
#8 x 2!/2"
BOTTOM
links with the rafter-mounted eye Fh woodscrew
24
bolts holds the tray closed. 49!/2 SIDE
Both front corners of the tray also 24
3!/2 NOTE: Use two lengths
have a short length of chain that’s END of chain with !/4" quick
connected between the eye bolts #/4 #/4
#8 x 1"
links at each end to
attach tray to rafters
with quick links. To access the tray, Fh woodscrew

7 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
 Episode 1113
Small Parts Keeper
Howard Moody, of Upper Jay, NY, often
finds it necessary to disassemble a tool
or appliance in the workshop. It may be
extremely important to identify the loca-
tion and sequence in which the parts were
removed. He found that a piece of heavy
paper or light cardboard can be most
helpful when doing these projects. Fold
the paper in an accordion style and place
it on the bench where you’re working.
Now the parts can be placed in the val-
leys as they are removed, thus prevent-
ing them from becoming mixed together.
Episode 1112 This, of course, makes reassembly much
easier and faster.
Marking Gauge
Philip Brazier of Bristol, England, took
a piece of 1!/2"-thick hardwood and
made a marking gauge with fixed set-
tings at the dimensions he uses most
often in the shop: #/8", !/2", #/4", and 1".
He cut all the rabbets !/2" deep, using
the dado blade in his table saw. For
safety, he did all the machining on a
12" length of stock, then cut the gauge
free as the final step.

Episode 1113
Double-Duty Drawers
a. TOP VIEW
Large, deep drawers in cabinets seem to
waste a lot of space. In the past, I would !/4
just dump loosely associated tools into !/4
one of these drawers, only to spend time
rooting around in the drawer looking for
Notch in drawer side
the item I needed later. It occurred to me Drawer slide provides clearance for
that I could reclaim some of this dead tray and slides
space by adding a pair of slide-out trays
TRAY SIDE TRAY
to the top of the existing drawer. This is BACK
done by flipping the direction of these Base drawer
additional trays and slides.
I started by cutting a pair of notches
b. SIDE VIEW
in the sides of the drawer and sanding
TRAY Size the tray to
the opening smooth. Then, as the draw- BOTTOM allow for drawer slide
ings show, I built a pair of trays that open
to the sides. This gives you maximum
control over the space you have avail- TRAY Drawer slide
FRONT
able. When sizing the parts of each tray,
NOTE: Tray #/4"-rad.
remember to account for the thickness of bottom is !/4"
the drawer slides. hardboard. Other
parts are #/4" plywood NOTE: Tray width and depth
Fred Adams will vary depending upon
TRAY SIDE your needs and space available
Henderson, New York

8 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
Episode 1113
I end up trying to keep the board from Before attaching the two blocks, it’s a
Sawhorse Flip Stops sliding across the sawhorse. To solve good idea to bevel the end of the flip stop.
One of the cardinal rules of using a cir- this problem, I installed two flip stops on This makes for a handy finger recess.
cular saw is to make sure your board is each of my sawhorses. The stops hold a There are a couple of things to keep in
secure before making a cut. But to be board in place without clamps. mind when locating the flip stop. First,
honest, I don’t always follow that rule. EASY CONSTRUCTION. Each flip stop consists when it’s in the down position, it must
So instead of concentrating on the cut, of two wood blocks. The flip stop itself be below the top of the sawhorse (inset
can be pivoted up when you photo, below). This way, it won’t be in
want to use it. A cleat mounted the way when you’re not using it. Also,
underneath holds the flip check to make sure it will pivot without
Flip stop stop in the upright position. binding against the cleat.
on opposite Cynthia McGaha
side keeps
workpiece from Russell Springs, Kentucky
pivoting
!/2" washer

#/4
FLIP STOP

CLEAT

a. FRONT VIEW !/4 #/4

3
Sawhorse
45˚ bevel Flip #/4
stop 3
#/4
#/4 1!/2 #8 x 1!/2"
Fh woodscrew NOTE: Position
flip stop so it's
below sawhorse
Cleat surface when folded

a. b.
END SECTION VIEW TOP VIEW Episode 1113
2%/8 !!/16
Chamfer Sander
1!/4 Sanding a chamfer is a
!/2
#/16 quick way to soften the
Block
1!/8
sharp edge of a workpiece,
Block
1 1!/2 but it takes some careful
Fixed
runner 45˚ 45˚ !/4 sanding to keep the angle
#/4
and width of the chamfer
Adjustable runner !/2
uniform. To make the task
easier, I built a chamfer
sanding block that has
NOTE: Glue fixed !/4" washer
runner to block two runners to guide it along
the edge. This way, the angle
FIXED stays at a consistent 45°.
RUNNER QUICK BUILD. I made the two runners by ripping a piece of plywood
Adhesive-backed with the blade tilted to 45° and then cutting them to length. One
4!/2 sandpaper
of the runners is glued to the block, but the other can be moved
in and out to adjust the width of the chamfer. To make this runner
adjustable, I routed stopped slots in the top face of the block and
!/4"-20 installed threaded inserts in the adjustable runner. The parts are
threaded
insert !/4"-20 x #/4" then held together with machine screws.
Rh machine USING THE SANDER. I attach a strip of 1!/2" wide, 180-grit adhesive-
screw
1!/2 backed sandpaper to the flat portion of the block, as shown in the
BLOCK drawing. Installing the adjustable runner helps hold the sandpa-
per in place. When the desired chamfer width is set, tighten down
NOTE: Fixed and adjustable the screws and start sanding. Stop sanding when both runners
ADJUSTABLE runners are made from
RUNNER #/4" plywood. Block is make contact with the workpiece.
made from !/2" plywood
Robert Foss
Des Moines, Iowa

9 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
 a. 1!/4"-rad.
Handle
!/2 !/8"
roundover
END #/8
VIEW &/8"-rad.
(/16
Base

HANDLE
NOTE: Handle 6
#/8
made from #/4"
plywood. Base 5#/4
!/2
is "two-by"
lumber !/2 !/2
7!/2
5#/4

2!/4
BASE

1!/2
Episode 1113 Improved Push Block
!/4
1!/2

Having a push block close at hand is hold them together. The handle echoes
always a smart move. I decided to take a the comfortable grip of a handsaw han- b. 1%/8 SIDE VIEW
little time to design one that fits the bill of dle. I made several replaceable bases
comfort and long life. I landed on a push and centered a dovetail groove in them 1%/8
block with two parts: a simple handle (drawing at right). Then I fashioned the 1#/4
5!/2
with a replaceable base. handle. When it came to creating the
A sliding dovetail joins the two dovetail, I snuck up on a perfect fit at 3
together. The groove is in the top of the the router table (see detail ‘a’). 1!/4"-dia.
base, and the dovetail is on the bottom John Gosner
!/4
of the handle, with a spot of hot glue to Grand Rapids, Michigan

%/16"-18 through
knob & washer
7!/2
24

BASE
#/4"-rad. 1

24
BED
FILLER

1!/2

24

a. 2#/8
SIDE CLEAT
SECTION
VIEW %/16"-18 x 2!/2"
carriage bolt
Base

Bed filler NOTE: Base and cleat

Cleat !/4 are made from
#/4" plywood.
Bed filler is made
#/4 from !/2" plywood
Episode 1113 Space-Saving Tool Platform
My lathe and dovetail jig are tools that I I started with a plywood base that Your lathe bed opening might require
don’t use every day. But I would never is slightly longer than my dovetail jig. a different thickness.
dream of giving either one of them up. Then, to secure it to the lathe, I made The cleat ties it all to the bed of the
So, for the sake of shop space, I found a a bed filler and a cleat. For my setup, lathe. The drawing above shows the size
way to make double-duty use of the lathe a !/2" piece of plywood worked nicely of hardware I used to clamp it in place.
footprint. All it took was a base for my as the bed filler (the piece that fits Thomas Lamb
dovetail jig that slips into the lathe bed. between the rails of the lathe bed). Waupaca, Wisconsin

10 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
 MAIL Project Sources
ORDER
SOURCES Manufacturers and retailers will
periodically redesign or discon-
Essentra Components
800-847-0486 tinue some of their items. So you’ll
essentracomponents.com want to gather all the hardware,
supplies, and tools you need before
Lee Valley you get started. It’s easy to adjust
800-871-8158
leevalley.com dimensions or drill different-sized
holes to suit your hardware.
McMaster-Carr
630-600-3600
mcmaster.com

Shopsmith
800-543-7586
shopsmith.com

Woodworker’s Supply
800-645-9292
woodworker.com

11 WoodsmithPlans.com TIPS-SEASON11 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.