46 - Utility Workbench, страница 7
SHOP PROJECT Because of the curved legs, I wasn't ^ible to use a router or table saw. But a handsaw worked fine, at least to establish the shoulders of the notches. To ensure that the shoulders align, start by clamping the legs together so the ends are flush, see Fig. 2. (A scrap block supports the curved ends of the legs.) Then extend the layout lines for the notches from the sides of the legs across the inside faces. Now you're ready to cut the shoulders. The goal here is to end up with a clean, square-shouldered cut. So to prevent the saw blade from tilting at an angle, I made a U-shaped guide from scrap and clamped it to the legs, see Figs. 2 and 2a. After cutting the shoulders, you can unclamp the legs and remove the bulk of the waste with a band saw, see Fig. 2b. This leaves a rough surface at the bottom of the notch. So to create a smooth, flat surface, I routed the rest of the waste — but not with a router. | DRILL PRESS ROUTING. The idea "here is to use a straight bit mounted in the drill press to clean up the notch, see Fig. 3. Granted, it's a bit unusual. But it works great. To produce a clean cut, adjust the speed of your drill press to its maximum setting. Also, since the metal table of my drill press is quite small, I attached an auxiliary table to provide support for the legs. As before, clamp the three legs together and carpet-tape the scrap block underneath. The depth of cut is established by lowering the quill and locking it in place. (At most, remove only W of material.) Now flip the switch on the drill press and get a firm grip on the legs. As you slide the legs across the table, the bit should just shave the bottom of the notch, see Fig. 3a. DRILL HOLES. After cleaning up all the notches, the legs are almost complete. But to mount them to the supports later on, you'll need to drill two counterbored shank holes in }each leg, see Figs. 4 and 4a. Fitting scraps in the notches keeps the leg level. Plus they prevent splintering as the bit breaks through. carpet tape location OF notch notch band saw NOTE: carpet-tape scrap under legs for support straight bit scrap block aux. table router bit scrap block NOTE: holes are centered on notches SECOND drill %" shank hole scrap No. 46 ShopNotes 7 |
