46 - Utility Workbench, страница 29

46 - Utility Workbench, страница 29

TIPS & TECHNIQUES

CUTTING & SAND' JG CIRCLES

Cutting the seat and collar for the ^^Shop Stool (page 6) is easy. All it takes is a banc! saw and a simple jig, see top photo at right. As an added benefit, you can use the same jig to sand the disks smooth on a disk sander, see lower photo.

JIG. The jig consists of four parts: a base made from MDF, a hardwood runner, a short dowel used as a pivot pin, and a small screw that acts as a stop, see Fig. I.

To fit the runner, I cut a groove along one side of the base. Cutting the groove to one side allows you to flip the base around later to accommodate the larger radius of the seat.

With the groove complete, I added a W'-long screw a few inches from one end of the groove. This screw acts as a stop for the runner.

Finally, drill a hole at one end of the runner. Then glue in a short V4"-dia. dowel to act as a pivot pin for the workpiece.

SETUP. Setting up the jig is a fl^imple process. The first step is to position the jig on the band saw table. To do this, set the runner in the groove and slide it against the stop. Then carpet-tape the base to the table so the center of the pivot pin is directly across from the leading edge of the blade, see Figs. 1 and la. Note: The distance from the centerpoint of the pivot pin to the saw blade equals the desired radius of the disk.

CUT COLLAR. With the jig in place, pull the runner back and set

the hole in the collar over the pin. Then hold the blank securely as you slide the runner forward. When the runner contacts the stop, rotate the blank clockwise to cut the collar to final size. Once you've come full circle, slide the runner back and remove the collar.

CUT SEAT. To make the seat, simply repeat the process. Here, you'll need to turn the base around.

This places the groove farther from the blade of the band saw. This way, you can still carpet tape the base to the table of the band saw and allow for the larger radius of the seat. Note: You'll also need to move the screw to the other end of the groove.

Once you've turned the base around and carpet-taped it to the table, set the hole in the blank for the seat over the pivot pin and repeat the process.

SAND DISKS. After cutting both the seat and collar to size, you'll need to sand the edges smooth. To make quick work of this (and to end up with perfectly round workpieces), I used the same jig.

Setting up the jig to sand the edges is similar to cutting them to size on the band saw. Only you won't

need a stop for the runner. Instead, the base of the jig is carpet taped to the table of the disk sander so the front edge is Vie" away from the sanding disk, see photo above.

Then simply fit the workpiece over the pivot pin and slide the runner forward until the edge just contacts the spinning disk. At this point, clamp the runner in place and sand the disk by rotating it in a clockwise direction, see photo above.

STOP

(#6x1/2"Fh WOODSCREW)

FIRST:

POSITION JIG 50 CENTER OF PIN ALIGNS WITH FRONT EDGE OF BLADE

PIVOT PIN

FIRST: FIT

WORKPIECE OVER PIVOT PIN AND SLIDE RUNNER INTO STOP

SECONP:

ROTATE WORKPIECE CLOCKWISE TO CUT DISK

SECONP: CARPET TAPE JIG TO TABLE

#6x1/2"Fh WOODSCREW

No. 46

ShopNotes

29

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