My Birthday Belt Sander

I had a birthday on Friday and here is what I got!



It's a Craftsman 3" x 21" belt sander!!! Here is what the other side looks like.



I really wanted this as opposed to a palm sander because it can chew through some really heavy work that a palm sander would take a long time on and also because I already have a palm sander.

I also wanted the 3"x21" because it is the most common size. I did consider the new Porter Cable mini sander. (Click here to see it.) but decided that the 2-1/2"x 14" belt was just not everywhere unlike the old 3"x21".

Not everyone will need one of these, but they do so much from smoothing out scratched wood floors to distressing old furniture to making a badly fit joint smooth as it should be. You will see this again in future entries.

At Long Last ... The A/C Project.

It has been quite some time sine I wrote in here and here is where I left off.



Above, you can see the storm windows that I have are higher at the bottom, than the window sill. This causes the air conditioner unit to slope into the house which is bad for water drainage. (It's also bad for the electronic parts and wood floors.)

Here is a photo that demonstrates this idea.



I am holding a steel ruler with a torpedo level on it. The end furthest from my hand is sitting on the storm window sill. I have lifted the rear of it up until the level reads level (about 1/2") to which I decided to add 1/4" so I have an easy, outward slope.

Because there will be so much open area between the storm window and the window sill, especially on the sides of the A/C unit, I decided to add a scrap of 1/4" plywood 7-1/4" deep and 27" wide. This will create a new "window sill" that is flat and solid across the whole bottom of the opening. Because of the shape of the track and the narrower opening of the storm window, I had to cut several notches to make it fit into the space, but in the end, it will keep more bugs out.

With the plywood cut to size and shape, I nailed a 3/4" thick strip of scrap wood under the back of the plywood and then a 1" strip of pine across the entire back to hide the edge of the plywood and give a finished look.

With this whole piece in place, I don't have to screw the bottom of the A/C into the window sill saving that damage and I have eliminated the bug problem.

Here is a photo of the finished project.



Because this is the south-facing side of the house where the sun beats on it all day long, I covered the side "wings" of the unit with some insulating styrofoam to help reflect the suns heat and keep the cool in. I also put a strip under the entire front of the unit as bugs may still be able to find a way through there. Finally, because it only has to last 3-4 months tops, I sealed all of the edges up with clear packing tape.

Tomorrow I'll be going over my latest addition to the tool cabinet ... my new Birthday Belt Sander!!! I'll also, finally get to the lumber thinmg I was talking about.

Sorry for the Delay

I have had some computer troubles and should be posting soon. Sorry.

Things Just Keep Coming Up.

I had hoped to write about the different kinds of lumber and stock I keep on hand and how to get it at little or no cost, but a couple of side projects came up.
The first is an extension of my garden. I love having these kinds of problems. A neighbor gave me more plants than I had room for, so I am pushing the garden 6' longer by hand. That means, I am the roto-tiller and it's hard work. I'll be extending the fence down there too, so that is at least another day's work.

The second will be a post or two in here. The house I live in has storm windows with an opening that is higher at the bottom than the window sill. Higher by a good 1-1/2" - 2" which makes it difficult to install air conditioners in them. I will be designing and building lifts that will bring up the level of the window sill for the A/C.

Look for that in the next day or two.

The Bench Saw Project III

Okay. I finally got this project pretty much wrapped up. First, here is what the saw looks like as a stand alone. Please note that I added a small dolly on the bottom to make moving it easier.



Using some 3/4"x3"x6' pine, I created a frame by centering and bolting them to each side being sure that the were flush to the top of the table and centered on the middle bolt hole on both sides.

I left several inches of space between the saw table and both table extensions to allow the blade guard and rip fence to function. The fence is a tight squeeze, but it works fine. for different saws you will have to play it by trial and error. In my case I measured off some space and used masking tape between the side beams to ensure I had enough clearance.

To that measurement I added the width of the table extensions (15-1/4") and the thickness of the end board - 3/4". I then subtracted 1/4" because I wanted to cut a rabbet for the table extensions to sit in and help keep them from sagging.

I unbolted both side pieces and made the cuts for length and cut 1/4" dado's in the ends to receive the end pieces to the frame. Then I cut the end pieces to fit and clamped all 4 together to check that I had cut everything square and they fit well. As it's often said, "Measure twice and cut once since we're all out of board stretchers."

Since everything fit and I was able to square the frame up with a framing square inside the clamps, I began cutting the rabbets. first, 3/4" deep using the rip fence and another board clamped to the saw table to keep the boards from moving. Then I cut them all to a depth of 1/4" and chiseled out the corners where the saw couldn't cut through.

Finally, I cut the table extensions to size. These came from the lumber store marked as shelves. I don't drive an SUV or pick-up to save gas money so I have to get my lumber in manageable pieces that fit in the car with the back seats down.

With the table all cut and dry fit, I drilled pilot holes and screwed everything together and bolted it to the saw. Here's the photo:



Here is another view from on top of a 6' ladder right above it:



Next, I thought legs in the corners would be great, so I took an 8' 2"x4" with few knots in it, and ripped it down into (2) 1-1/4"x8' boards. Using a 4' level (a 2' would work as well) I lifted the table until it was level and measured from the ground to the bottom of the frame. This 36" height worked well because I in my box of hardware last weekend, I had 4 bolts and t-nuts to use as feet. A t-nut is like a thin walled nut with a washer on the end which can be pounded into a hole so a bolt can be screwed in. Here is a link to what they look like.

I drilled the holes in the ends of the legs, pounded in the t-nuts and screwed in the bolts. Finally I lifted the legs up to the bottom of the table deck (the MDF shelf boards) and screwed the legs to the corners of the table top with wood screws on both the side and end pieces of the frame. Using the level, I was able to level the entire table by adjusting the bolts in the t-nuts.

Here is what the whole thing looks like now:



When I get to discussing routers, bits and how to get the most out of them, I'll cut the slot into the table deck additions for the miter gage.

At some point I should add some spreaders to the legs, but for the moment this will work for what I'm doing and I have other projects to work on.

Next up: Lumber - Where to get it cheap or free and storage in the shop.

The Bench Saw Project II

I am back in the shop and getting this project finished today. The object is to take an inexpensive bench saw and make it more like an expensive, full-sized, table saw by extending the tabletop with an in-feed and out-feed addition. This will allow me to cut longer pieces of stock more accurately and safely.

Once the project is complete, I will post photos which will make the directions make sense. Also, feel free to post questions in comments or e-mail for clarity on any steps.

I started last weekend with a rough drawing with no measurements on it. I decided that the best way to approach this project was on-the-fly and expecting changes as I go.

Last Tuesday, I outlined the beginning of the project and a couple of mistakes I made (Click here to read it).

The side pieces got bolt holes drilled in them to mount to the stock holes that came on the saw. If you have a saw with no holes, they can be drilled (and tapped if you have the means) to mount the frame. Once I got those mounted I measured from the table saw 3" to the front to accommodate the fence and saw guard, and 5" to the rear to accommodate the fence latch. I added the 17-1/2" from the two, 3/4" thick MDF (particleboard) table surfaces to both ends. These were intended to be shelves, but this project has repurposed them.

Now, with the table frame cut to size I cut dado's in the ends of the side pieces to receive the two end pieces. Finally, I will be putting a 1/4" wide groove, 3/4" deep in the frame where the MDF will sit to make it more stable.

Following that, I will rip an 8' 2"x4' length wise to make legs and use the router to cut groves for the miter gauge.

If all goes well, I'll post photos next. If it goes badly, I'll document that too.

Back In The Shop Tomorrow.

My short week at work is over and tomorrow I'll be back in the shop hopefully, wrapping up my current project.

In the mean time I think it's best to lay down a few rules for this blog.

The most important one it that every idea is good. They may not work, but building or trying to fix something and failing at it is still valuable in that you now know a way that won't work and can rule it out. Share your ideas and seek help and advice through the comments.

If you have a better way, please offer it, but I'll be deleting negative and inflammatory comments.

Don't expect to see your high school wood shop here. If you have the means for a set-up like that I am happy for you, but my goal is to help folks with portable and hand tools which are what most folks (like me!!!) have.

I definitely like discussing tools, brands and what will work best for a situation, I would appreciate it if "my DeWalt drill is better than your Makita" conversations take place somewhere else.

Those seem pretty simple, easy and fair.

Tomorrow I should be finishing the bench saw table expansion and will start using it to mill down some rough lumber. Come back tomorrow afternoon for that.