The Woodshop Shed

adventures in woodworking and home maintenance, from my shop in an oversized backyard shed

May 2020
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UnderSawStop StorageCcart

Furnished content.
(from Lumberjocks.com)


UnderSawStop StorageCcartI'm taking an online course from Woodworking For Mere Mortals right now that focuses on shop organization and improvement. This is the Handicart from that course, but modified to fit under my table saw and also hold my miter sled. It's made using half lap joints. I was able to make it all from materials already in the shop too, which was a nice bonus. I might modify another one into a bandsaw outfeed table.



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posted at: 12:00am on 17-May-2020
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Shop Mallet

Furnished content.
(from Lumberjocks.com)


Shop MalletI've been wanting a nice mallet to replace my old store bought one, so I finally built it. It's made from walnut and maple, my favorite wood combination. The head is made from 3 layers, with the middle maple layer made from 2 pieces cut at a 2 degree angle to form a tapered mortise. Both maple pieces have a 1 1/4 hole to accommodate steel BB's for added weight.The maple handle has a wedged tenon, which combines with the tapered mortise for a very strong joint. The contours of the handle were shaped with a belt sander on my homemade jig which holds the sander perpendicular to a small shelf, and also a round-over bit in the router table. Followed of course with lots of sanding.Since you are fellow woodworkers, I have to disclose 2 mistakes, and my remedies to fix them. The first is the middle maple layer in the head, which is slightly wider on the bottom than the top. Since I don't own a band saw in my small garage shop, I had to resaw a small piece on my table saw, and it apparently tilted slightly when ripping and I didn't notice it in time. I considered scrapping the head and starting over once I noticed the mistake after the head was glued up, but after some thought I decided to see if I could still make it work. Which I did by offsetting the tenon on the handle in order to center it.The second mistake happened when I was rounding over the handle with the router. A large chunk chipped out on the end. Instead of tossing it and starting over, I decided to cut off the handle a bit and add a walnut accent on the end. Since it's an end grain joint, I strengthened it with a dowel.Now I have a proper mallet, with a couple of reminders that all is not lost when mistakes are made.



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posted at: 12:00am on 17-May-2020
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May 2020
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