1. Adjustable-Height Sawhorses
Every shop needs
horsepower. These adjustable horses are easy to build from construction-grade
1x4s and 2x4s. Add the adjustable-height jig and these horses will hold
projects at the perfect working height. Use a pair of them as a stand for
portable or bench-top power tools, or make a temporary workbench by throwing a
piece of plywood on top.
Cutting List
|
KEY
|
PCS.
|
SIZE &
DESCRIPTION
|
|
A
|
2
|
1-1/2" x 3-1/2" x 25" legs
|
|
B
|
2
|
1-1/2" x 3-1/2" x 18"
footers
|
|
C
|
2
|
3/4" x 3-1/2" x 36" top
rails
|
|
D
|
1
|
1-1/2" x 3-1/2" x 13" spacer
block
|
|
E
|
2
|
1-1/2" x 3-1/2" x 21"
adjustable slides; drill 1/2" dowel holes 2" apart
|
|
F
|
1
|
3/4" x 3-1/2" x 20" slide
support
|
|
G
|
1
|
1-1/2" x 3-1/2" x 40" work
rail
|
2. Muffler for Your Shop Vacuum
Avoiding clouds of
sawdust is a must in a small shop, but a dust collector eats up valuable space
and money. A shop vacuum makes a good substitute, but because the decibel level
of most shop vacuums rivals that of a jet engine, build this box to muffle the
noise. Put casters on it and it’ll follow along as you connect it to various
power tools.
Build the box from a 4 x
8-ft. sheet of 3/4-in. plywood or MDF (medium-density fiberboard; $30). Glue in
wood battens at vertical corners for additional strength. Fasten with 2-in.
screws. We lined ours with carpet scraps for extra muffling. Cut them to size
and glue them to the box with construction adhesive. Use strap hinges on the
door so the screws drive through the face of the door and box side. Avoid butt
hinges because there’s little holding power for screws driven into the edge of
plywood or MDF.
Click image to enlarge.
Click image to enlarge.
Shopping List
|
ITEM
|
QTY.
|
|
4' x 8' sheet of 3/4" MDF (or
plywood)
|
1
|
|
Solid wood battens, 3/4" x 3/4" x
30"
Carpet scraps to line the
interior
|
4
|
Cutting List For MDF
|
PCS.
|
SIZE &
DESCRIPTION
|
|
4
|
23" x 30" sides and door
|
|
2
|
23-3/4" x 23-3/4" top and
bottom
|
|
1
|
7" x 7" reinforcement plate
|
Hardware
- One pair of 6" strap hinges
- One 4" slide bolt
- Four 2-1/2" swivel casters
- 16" of 3" PVC plumbing pipe
- Two 3" PVC elbows
- 2" drywall or deck screws
3. Flip-Through Storage Rack
Unless you live in an
art gallery, wall space is always at a premium. Build this book-like storage
rack, and expand your wall space exponentially. Grabbing a tool is as easy as
flipping through a magazine.
Mount two parallel 2x4s on the wall spaced 24
in. apart. Cut the leaves from 3/4-in. plywood and hang them from the 2x4s with
3-in. door hinges. Fur out the hinges with 3/4-in. plywood blocks so the pages
can pivot without binding. Mount the leaves at least 4 in. apart to allow room
for them to fold back. Let your imagination run wild creating holders for your
various tools.
For you Peg-Board fans,
sandwich a 1x3 frame between two pieces of Peg-Board. Now your collection of
hooks and holders will work with this tool storage system.
Click image to enlarge.
4. Workbench With Built-In
Storage
At the heart of
every small shop is a multipurpose workbench. Build this workbench with tons of
storage space underneath. While ours is configured for lumber storage, you can
put cabinet doors on the front and store tools and materials. For our 8-ft.
long bench, we built four 2x4 frames; that left about 27 in. between them. This
spacing provides plenty of support for the double 3/4-in. plywood top and long
lengths of lumber underneath.
5. Full-Feature Miter Saw Stand
If dedicating 8 ft. of
wall space to your miter box is just another fantasy, build this portable stand
for your miter saw that provides all the features of a permanent miter saw
table. When it’s not in use, lean it against the wall or hang it from the
ceiling.
While you can build this
from an 8-ft. 2x12, it’ll be challenging to find a straight one. A good
alternative is to glue together two layers of 3/4-in. AC plywood. Cut a 3/4-in.
wide by 1/2-in. deep groove for the T-track with a dado blade on a table saw or
with several passes with a router. Build the sliding supports out of 3/4-in.
pine or plywood.
CAUTION:
Screw or clamp your stand to the sawhorses to prevent tipping.
Click image to enlarge.
Shopping List
|
ITEM
|
QTY.
|
|
4' aluminum T-track, No.
21753
|
2
|
|
2" T-knobs for 5/16"-18, No.
71514
|
4
|
|
T-slot bolts, 1-1/2" x 5/16"-18, No.
83311
|
4
|
All the above items are
available from Rockler Woodworking and Hardware, (800) 233-9359.
www.rockler.com
