Plans N O W                                 ®
w w w. p l a n s n o w. c o m
                                                                                          TOOLS & TECHNIQUES SERIES
                                                        Everything You Need to Know About Buying Router Bits
                                                                  Router Bit Basics
                                                                                                       A colored Teflon or oxide coating
            O     nce you get hooked on routers
                  and what you can do with them,
            you’ll find no shortage of other tools
                                                        find today are carefully engineered
                                                        for safety and performance. And while
                                                        some indicators of quality can be seen
                                                                                                    on the bit body is a nice bonus.
                                                                                                    Manufacturers rely on them for brand
            designed to put all of that potential to    only through a microscope (see              recognition, but the key function is to
            good use. Dovetail jigs, edge guides,       Understanding Carbide), a low-tech          stem the buildup of wood pitch.
            router tables — all of these acces-         visual inspection can still reveal a lot
            sories can open up new woodworking          about a bit’s pedigree.
            techniques for you, but none can lay           Details, as always, speak volumes.
            claim to being the essential router         A smooth, highly polished surface on
            companion. That role belongs to the         the shank and on the carbide tips
            cutters.                                    reflects careful machining that will
               Like saw blades and shaper cutters,      result in a better collet fit and longer-
            router bits are typically made with tool    lasting cutting edges. Carbide
            steel bodies and tungsten-carbide cut-      quantity should be gen-
            ting tips, but their inherent design dif-   erous (about 3/32" to 1/8"
            ference (a support shank that’s per-        thick) to allow multiple
            pendicular to the cutting force) and        sharpenings — many “dis-
            higher operating speeds (up to 25,000       count” bits skimp here. Also, the
            rpm) means they’re sometimes sub-           braze (the alloy weld that bonds the
            jected to greater stresses. Still, virtu-   carbide tip to the tool body) should
            ally all of the name-brand bits you’ll      be free of voids.
                                                                                                              Continued on next page...
                                                        Plus: Bonus Article                                       See Page 5
                                                        Step-by-step plans for building your own
                                                        Router Cabinet
                                                        Store everything you need for routing in one place with this easy-to-build
                                                        storage cabinet. It includes a sturdy platform for making bit changes and router
                                                        adjustments. A convenient cut-away shelf lets you store your router in an
                                                        upright position without removing the bit! See page 5 for details.
From Workbench Magazine                                             page 1                                © August Home Publishing Co.
                         Starter Bits                     Today’s Cutter Designs Are Safer
             Recognizing cues to a router bit’s
             quality takes some practice, but it’s           Once the exception, now the rule, anti-kickback cutter designs (left)
             much harder deciding which cutter              have largely replaced the open gullet tool bodies of yesteryear (right).
             profiles to buy. Router bits are the                              Also called chip-limiting, this bit style restricts the
             Lay’s potato chip of woodworking                                        bite of the cutting edge by reducing its expo-
             tools — nobody can stop with just                                                                   sure, making over-
             one. Get used to the idea of spending                                                                 feeding and kick-
             more money on bits than you will on                                                                     back much less
             most any router.                                                                                         likely. Careful,
                If you’re just putting a shop                                                                        though — they
             together and haven’t figured out                                                                         still aren’t any
             exactly what kind of woodworking                                                                     friendlier to flesh.
             you’ll be doing most, you can get
             plenty of versatility from a basic
             starter set of a dozen or so cutters.        door frames for a partial overlay fit.                Basic Bit Care
                Straight bits specialize in cutting       Sets with multiple bearing sizes are        Whatever individual cutters you buy,
             dadoes and grooves, but they can             especially useful, allowing you to          get carbide-tipped bits, and expect
             also cut other joinery details. I use        change the rabbet width quickly. A          to spend about $150-$200 on a decent
             the 3/8", 1/2", and 3/4" sizes most often.   chamfer bit, also guided by a bearing,      starter set. Some vendors still offer
             If you work a lot in plywood, try the        cuts a 45° bevel on a board’s edge.         high-speed steel cutters, but their
             undersize bits ( 31/64" and 23/32" )         Roundover bits turn sharp square            edge life is much shorter than car-
             designed for those reduced panel             edges into soft radiused contours,          bide. Engineered wood composites,
             thicknesses. Straight bits with guide        making them friendlier to the touch.        such as plywood and particleboard,
             bearings above or below the cutting          Radius sizes range all the way from         contain glue lines and binder resins
                                                          1
             flutes will trim an edge flush with a         /8" to 11/2", but 3/8" is a good starter   that are tough on tool edges, and
             template or guide board — great for          bit because it can put a half-round         they’ll dull a steel cutter before you
             curved work or for trimming plastic          bullnose on 3/4"-thick lumber.              can say “burn my edges.” By the time
             laminate.                                       Another suggestion: bit shanks are       you figure in the need for constant
                A rabbeting bit makes quick work          typically either 1/4" or 1/2" in diam-      resharpening, the lower purchase
             of milling square ledges along the           eter. For midsize or larger cutters,        price of a high-speed steel bit is no
             edges of boards, or around cabinet           buy the 1/2"-shank versions.                bargain.
                                                                                                         One exception to this rule in my
Flush-trim
             Basic Set                                                                                shop is a spiral-flute milling cutter
                                                                             45° Chamfer              that I use for mortising. The only
                   Straight                                Rabbeting                                  alternative to high-speed steel here
                                     3
                                      /8" Roundover                                                   is a very expensive solid carbide bit,
                                                                                                      but this is a joinery cutter that I don’t
                                                                                                      use on wood composites. The steel
                                                                                                      edges hold up well in most hard-
                                                                                                      woods, and resharpening costs less
                                                                                                      than it does for carbide.
                                                                                                         With the relatively recent avail-
                                                                                                      ability of small diamond sharpening
                                                                                                      hones, you can tune up some car-
                                                                                                      bide edges in your shop, but I still
Reversible        Finger-joint
                                         Joiner y Set                                                 send mine out to be professionally
glue-joint                                                                                            ground and polished. If you decide to
                                         Lock miter                             Drawer-lock           sharpen your bits yourself, dress only
                                                            Dovetail               joint              the flat face of each cutting flute,
                                                                                                      never the outside edge.
                                                                                                         It’s equally important to keep bits
                                                                                                      clean — the cutting flutes, the bit
                                                                                                      body, and also any guide bearings.
                                                                                                      Accumulated wood pitch creates
                                                                                                      excess heat that will dull cutting
                                                                                                      edges and burn your workpiece.
From Workbench Magazine                                                page 2                               © August Home Publishing Co.
“Component” Bits Provide Versatility                                                                               SOURCE LIST
Some router bits feature interchangeable components that let                                Major Router Bit Manufacturers
them do the work of several cutters. Seven different guide bearings                     ■ Amana Tool Corp. (800) 445-0077
let this rabbeting bit (left) cut six rabbet depths                                     ■ American Tool/Irwin (800) 866-5740
or double as a flush-                                                                   ■ Bosch/S-B Power Tool (800) 815-8665
trim bit. The slot-cutter                                                               ■ CMT USA (888) 268-2487
set (right) swaps the                                                                   ■ DeWalt (800) 433-9258
cutting bodies to create                                                                ■ Eagle America (800) 872-2511
varied slot widths.                                                                     ■ Freud USA (800) 472-7307
                                                                                        ■ Grizzly/S-Y (800) 523-4777
                                                                                        ■ Jesada Tools (800) 531-5559
                                                                                        ■ MLCS (800) 533-9298
                                                                                        ■ Ocemco/P.R. Carbide (800) 237-8613
                                                                                        ■ Oldham/Viper (800) 828-9000
                                                                                        ■ Porter-Cable Corp. (800) 487-8665
                                                                                        ■ Vermont American (800) 626-2834
                                                                                        ■ Whiteside Machine Co. (800) 225-3982
House-hold ammonia,                                                                     C o l o r e d s q u a r e s i n d i c a t e m a n u f a c t u r e r ’s b i t c o l o r
Formula 409, and oven cleaner will
remove pitch, but I like to use non-
toxic products such as Simple Green         shapers typically run at only 7,000 -     more about form than function.
or some of the new citrus-based              12,000 rpm — one-third to half the       Designed to produce decorative
cleaners.                                   speed of most routers — because the       details, these include multi-form
                                            large cutter diameters create dan-        bits, molding cutters, round-nose
        Specialty Cutters                   gerous rim speeds at higher rpm           and V-groove bits for fluting and
 For moving beyond the basics, my           levels. If you want to use a big bit in   bead routing, and many others. Like
 favorites are specialty profiles for       a router table, the router motor          joinery bits, many of the larger sizes
 cutting joinery. These bits do fast        should have a speed reduction fea-        are for router table use only.
 and precise work, creating self-           ture. Other specialty cutters are
 aligning joints that make glue-up
 much easier. Examples include a
 reversible glue joint, a lock miter, a
                                               One Theme: Five Variations
 drawer lock joint, a slot cutter set, a       These five flush-trim bits work the same
 dovetail bit, and a finger-joint cutter.      way, but the small laminate trimming
    Because joinery cutters usually            bit on the left can’t handle the
 remove most or all of the board’s             thicker stock and heavy cuts
original edge, nearly all of them are          its siblings are built for. Bits
designed for use in a table-mounted            with larger shanks and/or
router only, and must be used with             spiral flutes are better at
a guide fence. If you limit yourself           pattern-routing wood.
to freehand routing, you’ll have to
live without help from these cut-
ters. I don’t think the trade-off is
worth it. Even a relatively simple
router table (see our portable                         Decorative Bits                                       Multi-form                                              Molding
design in the Februar y 1998
Workbench) will let you machine pre-                                  Table-edge
                                                                                        1/
cise joinery quickly and accurately.                                                      2"Core-box
                                                    3/8"   Cove
   With the wide range of router bits                                                   (Round-nose)
now offered, router tables also mimic
the role that used to belong exclu-
sively to spindle shapers. Panel-
raising bits (like the one shown on
page 1) and stile-and-rail cutter sets
let you produce custom cabinet doors
just like the pros do. One warning:
 From Workbench Magazine                                                page 3                                              © August Home Publishing Co.
                                          Understanding Carbide
                                                 When Bigger Isn’t Better
            U    nlike tool steels, which are forged in a molten state
                 and machined into drill bits and edge tools such as
            chisels and plane irons, tungsten-carbide is what’s known
            as a sintered metal. It is formed by mixing fine grains of
                                                                         Photos Courtesy of: Freud U.S.A.
            carbon with powdered tungsten, then consolidating the
            mixture under intense pressure and heat. Developed first
            for the metalworking industry, carbides also contain
            cobalt (about 6-10 percent in woodworking grades), which
            helps bind the carbide particles together and allows the
            otherwise brittle blank to be brazed (welded) with silver                                       Coarse grain
            alloy to a tool body.
               Carbides don’t have the fine crystalline structure of
            high-speed steel. Their edge-holding capability is a func-
            tion of their grain size and how well the binder prevents
            edge-fractures and resists chemical erosion — two of the
            three culprits responsible for most carbide wear (the
            other is heat). The best grades are “micrograin,” with an
            average particle size of one micron (a millionth of a
            meter). Larger grains mean bigger voids and more binder,
            producing a softer compound and a rough, dull edge as
            grains break off during use.
                                                                                                            Micrograin
From Workbench Magazine                                     page 4                                                         © August Home Publishing Co.
                                                                                      Complete Step-by-Step Plans
                                                 Router Cabinet
     O     f the dozen or so power tools
           that have taken up permanent
   residence in my shop, only two get pref-
                                                absurd devotion I can feel for a fire-
                                                breathing 21/2 -hp plunge router.Confess
                                                this to a normal person and they’ll make
                                                                                           a precision inlay, shaping the edge of a
                                                                                           board, or machining joinery details,
                                                                                           routers earn their keep like no other
   erential treatment. Both are routers.        a mental note to sit near someone else     portable power tool.
   My various drills, saws, and sanders         next time. But tell a fellow woodworker,      By itself, though, a router is just power
   all do their jobs without fail, and I rely   and he’ll just nod his head and smile.     and potential. What makes it sing are
   on each one, but none inspires the             Whether they’re cutting a recess for     specialized cutters, edge guides, jigs,
                                                                                           and other accessories. These things give
                                                                                           the tool amazing versatility, but in my
                                                                                           shop they also tend to get scattered in
                                                                                           odd places while I work. I decided to
                                                                                           remedy the problem with this dedicated
                                                                                           storage cabinet.
                                                                                              Aside from a storage bay for my dove-
                                                                                           tail jig and a pair of drawers to hold
                                                                                           accessories and oversize cutters, this
                                                                                           cabinet offers other bonuses. The doors
                                                                                           provide room for up to 40 bits, all held
                                                                                           in place so the cutting edges don’t collide
                                                                                           with each other. Also, clearance holes
                                                                                           in the shelf let me store the routers
                                                                                           standing up without removing or
                                                                                           backing off the bit.
                                                                                              The drop-front lower door, though, is
                                                                                           my favorite feature. I use it as a tray to
                                                                                           change bits, install an edge guide, or
                                                                                           just fine-tune adjustments. My tools don’t
                                                                                           stray like they used to, and the door
                                                                                           frame acts as a rim to keep bits and bear-
                                                                                           ings from rolling off.
                                                                                                 Use Strong Materials
                                                                                           I wanted this cabinet to be stout but
                                                                                           simple, so I used just two sizes of Baltic
                                                                                           Birch plywood for all the components.
                                                                                           Most suppliers label these panels as frac-
                                                                                           tional inch sizes (1/4" and 3/4" for the
                                                                                           panels I used), but they’re made to
                                                                                           metric dimensions (6mm and 18mm
                                                                                           thick, respectively). The thicker panel
                                                                                           actually checks in at 11/16'', so that’s what
                                                                                                                           (continued )
From Workbench Magazine                                           page 5                             © August Home Publishing Co.
             OVERALL SIZE: 361/4"H× 24!/8"W× 13"D          Router Cabinet Construction View
                                                                                Cut List: 18mm Panel
                                                                                A Carcase side panels (2)
                                                                                  10" × 361/4"
                                                                                B Carcase top/bottom (2)
                                                                                  101/4" × 231/8"
      WORKBENCH PROJECT SUPPLIES                                                C Shelves (2)
                                                                                  91/4" × 231/8"
    Router Cabinet                                                              D Drop-front door panel (1)
    A kit has been assembled for this
    project that includes the hinges, braces,                                     11" × 231/8"
                                                    Plywood Cutting Diagram
    50 nylon bit bushings (25 in each size),                                    E Upper door stiles (4)
    and all fasteners. Order No. 3305100                                          21/2" × 241/8"
    To order call Workbench Project Supplies                                    F Upper door rails (4)
            1-800-311-3994                                                        21/2" × 11"
                                                                                G Drop-front door rails (2)
  I used to plan my joinery design
                                                                                  21/2" × 231/8"
  (Router Cabinet Construction
                                                                                H Drop-front door stiles (2)
  View). Also, it comes in sheets 60"
                                                                                  21/2" × 12"
  square. I cut the panel into sections
                                                                                I Door shelf inserts (8)
  (red lines) for batches of various
                                                                                  2" × 105/8''
  parts
                                                                                J Drawer bottoms (2)
  (Plywood Cutting Diagram). Most
                                                                                  77/8" × 103/8"
  of the joinery details will be easier
                                                                                K Drawer fronts/backs (4)
  to machine on these larger pieces,
                                                                                  53/8" × 107/8"
  then you can cut the individual parts
                                                                                L Door shelf lips (2)
  later (black lines). Make sure your                                             3
                                                                                   /4" × 10"
  rough sizes allow for the blade kerfs.
                                                                                M Divider (1)
  Each cut will mean a loss of up to
  1/ " of material.
                                                                                  6" × 91/4"
    8
From Workbench Magazine                                    page 6             © August Home Publishing Co.
Carcase Assembly View
                                                                            Side Panel Detail                              Shelf Detail
                                                                                       (Inside View)                                  (Top View)
                                                                                                                 While I still had the wide dado
                                                                                                              blade set up, I also cut a groove in
                                                                                                              the drop-front door rails and stiles
                                                                                                              for housing an 11/16"-thick panel (see
                                                                                                              page 10). This door doubles as a
                                                                                                              work tray, and I didn’t think the 1/4"
                                                                                                              plywood I bought for the other door
                                                                                                              panels would provide the rigid sup-
                                                                                                              port I wanted. A 1/2"-thick panel
                                                                                                              would have been plenty, but to keep
                                                                                                              my materials list simple I just opted
                                                                                                              for the thicker plywood I had on hand
                                                                                                              for the carcase sides.
                                                                                                                 Next, switch to a 1/4" dado blade
                                                                                                              and cut the grooves that hold the cab-
                        Cutting the Joinery                        After I machined these joints I got        inet back panel (Figure 2). When
                 Once I’d shimmed my dado blade to              ready to change the dado setup, but           you cut this detail in the carcase
                 match the plywood thickness, the               realized I might as well cut all the          pieces, keep in mind that the top and
                 carcase joinery was simple — rabbet            door frame rabbets while I was at it          bottom panels are 1/4" wider than the
                 joints at the corners, and dadoes for          (see the door assembly views pages            side panels and will be offset at the
                 the shelves and shelf divider                  58-59). Consolidating these steps             rear edge. (This offset simplifies the
                 (Carcase Assembly View and Side                required a little labeling work to keep       mounting system I used for the cab-
                 Panel Detail). I managed it with just          all the parts organized, but it did save      inet, a feature I’ll explain later.) One
                 the table saw and a dado blade (Pro            me from making a few blade                    fence setting will do the grooves in all
                 Tip and Figure 1).                             changes.                                      four carcase panels, if you guide each
                                                                                                              panel with its front edge against the
                                                                                                              fence.
                                               PRO TIP                                                           The upper door frame rails and
 For odd plywood thicknesses, lose the habit of measuring joint depth.                                        stiles also need a 1/4" groove to accept
                                                                                                              their panels.
 Plywood thicknesses used to be reliable, but with today’s undersize and metric
                                                                                                                 One other detail I added was a pair
 panels the resulting odd fractions create headaches, especially when cutting joints
                                                                                                              of holes in the upper shelf to make it
 that affect the overall dimensions of a project. Avoid mistakes by designating the
                                                                                                              easier to store my routers (Shelf
 thickness of the remaining material, not the joint depth, as your working dimension.
                                                                                                              Detail). These holes, cut with a 21/8"-
                                                                                                              dia. hole saw I’d bought to install a
                                                                                                              lockset, allow me to set the routers
                                                                                                              directly on the shelf and leave the
                                                                                                              cutter settings intact.
                                                                                                                Assembling the Carcase
                                                                                                              At this point you can assemble the
                                                                                                              carcase and let the glue set up while
                                                                                                              you cut some of the remaining parts
                                                                                                              for the cabinet. I did take one slight
                                                                                                              detour before reaching for the glue,
 1                                                                2                                           though. I drilled and countersunk
Keep matched parts together for machining the joinery, then     When you switch to a 1/4" dado for the nar-   holes in the side panels so I could
cut them apart later. Fine-tune the dado width with shims if    rower panel grooves, keep the front edge of   screw the carcase together. It’s faster
necessary, and adjust depth of cut to leave 1/2" of material.   each piece against the fence.
From Workbench Magazine                                                      page 7                                 © August Home Publishing Co.
    3                                                                       4
   Fit the cabinet’s shelves and divider together first, then glue and   After gluing and fastening the bottom carcase panel to the sides,
   fasten the carcase side panels. All front edges should be down.       slide the 1/4" back panel in, then add the top carcase panel.
   than putting the assembly together               drawers. With only rabbet and butt             Start the drawer assembly
   with clamps, and this is a shop cab-             joints, these assemblies are even sim-      sequence by gluing and clamping
   inet, so I don’t mind having the fas-            pler to build than the others (Drawer       the front and back faces to the ends
   teners show.                                     Assembly View). The drawer fronts           of the drawer bottom. You’ll need to
      Start the assembly by gluing and              and backs are identical down to the         use some 3/4"-thick clamping cauls to
   fitting the vertical divider between             half-round cutout pulls. This feature       keep the pressure from “folding” the
   the two shelves. Then spread a bead              isn’t intended to make the drawers          faces inward (Figure 6). Gluing the
   of glue in the dadoes in the side                reversible (although they are).             drawer sides in place will also help
   panels, fit the shelf assembly in place,         Instead it’s to provide clearance in        keep things aligned. A glued-only
   and put a clamp on to steady every-              the back for any bits that extend           joint would likely hold up fine here,
   thing while you’re driving the screws            down through the shelf above. I cut         but I drove brads into each corner
   (Figure 3).                                      these with the same hole saw I used         for extra strength.
      The cabinet’s top and bottom                  earlier on the shelf, drilling into the
   panels are next, but don’t install both          center of two larger pieces that I cut
   pieces at once or you’ll lose access for         in half later.
   inserting the back panel into its                   Because the rabbets in the drawer
   groove. I glued and screwed the                  fronts and backs are so shallow (1/4"),
   bottom panel in its rabbets, then                I didn’t bother reinstalling my dado
   nudged the assembly square and slid              blade. I just set my rip fence so the
   the back panel in from the top end of            left side of the blade was cutting at
   the cabinet (Figure 4). Then I                   the 1/4" mark, set the blade height,
   installed the top panel to close up the          and made one pass on each edge to
   carcase.                                         define the shoulders of the rabbets.
                                                    (Figure 5). Then I just scooted the           5
        Building the Drawers                        board away from the fence and made          Cut the drawer rabbets on double-wide
   While the glue was setting up in the             a cleanup pass guided by the miter          blanks, then rip the pieces in half to get a
   carcase joints, I went back to the               gauge. With the rabbets done, I cut         drawer front and back from each one.
   table saw to cut all the parts for the           the face blanks in half.
   Drawer Assembly View
                                                                                                  6
                                                                                                Cauls direct clamping pressure to the bottom of the
                                                                                                drawer assembly. Align the front and back first, then
                                                                                                glue in the sides. For more strength, I secured the
                                                                                                rabbet joint with brads.
From Workbench Magazine                                                   page 8                                   © August Home Publishing Co.
Upper Door Assembly View
                                                                                Stile Details                         Rail Details              (End View)
                                                                                      (End View)
                                                                                                                     (Inside View)
                                                                                                             holes spaced every 2", enough to
                                                                                                             spread a heavy load out across their
                                                                                        (Inside              full length.
                                                                                         View)                  Under most circumstances, I’ll
                                                                                                             install hinges on doors first, then
                                                                                                             the cabinet. But with this design, I
                                                                        Door Assembly View, Stile            fastened the hinges first to the front
                                                                        Details, and Rail Details).          edges of the cabinet — one on each
                                                                        You have to insert the panel         side and one across the bottom
                                                                        before you close up each             (Figure 8). I clamped one leaf of
                                                                        frame, and the assemblies            each hinge to the cabinet (its edge
                                                                        must be flat and square to           flush with the inside face of the
                                                                        ensure a good fit against the        panel), then drove a few screws to
                                                                        carcase. I glued up one end of       hold it in place. (The hinges have
                                                                        each frame, fit the panel, then      no adjustment feature, so I waited
                                                                        clamped each door to my              until all three doors were aligned
                                                                        workbench (Figure 7). I              before driving all the screws.)
                                                                        drove the screws immediately            When I was ready to fasten the
                                                                        but left the clamps on for an        hinges to the doors, I set the cab-
                                                                        hour while the glue set.             inet upright and clamped support
                                       Note: Cut rabbets in the
                                                                                                             blocks on each side, letting the
                    stiles only. On the upper doors, these are
             the longer frame pieces; on the drop-front door             Fitting the Doors                   doors rest on them (Figure 9). I
         (facing page), the stiles are the short frame pieces.    The door designs for this cabinet pro-     used more clamps to hold each
                                                                  vide built-in bit storage and a con-       hinge to a door edge, and drove only
                  Assembling the Doors                            venient work surface, but these fea-       four screws into each door frame —
             With no integral shelves or fixed                    tures come at a price — extra weight.      just enough to keep everything con-
             dividers to worry about, the door                    To make sure the mounting hard-            nected. After I mounted all the
             assemblies fit together quickly, with                ware was up to the strain, I used a        doors, I shut them and checked for
             just a captive panel and rabbet joints               24"-long continuous hinge (some-           a uniform 1/8" gap between, then
             at the corners (Upper Door                           times called a piano hinge) to mount       sent screws through the remaining
             Assembly View, Drop-Front                            each door. These hinges have screw         holes in each hinge.
 7                                                                                8
With one end of each door frame assembled, insert the panel, install the        To ensure accurate placement, clamp each hinge in place — flush with
other rail, and clamp the door flat before driving the other screws.            the inside edges of the carcase panels — then drive just a few screws.
From Workbench Magazine                                                          page 9                                 © August Home Publishing Co.
                 Rail Details                                                       Drop-Front Door Assembly View
    (End View)
                          (Inside View)
                 Stile Details
             (End View)
                                 (Edge View)
                                                These braces are marked for left-
                                                hand and right-hand installation, and
            (Inside
             View)                              feature positive-locking and a release
                                                button for closing them. I screwed         place, but when I started the layout
                                                the lower end of each support arm          marking it became obvious that the
                                                directly to the inside face of the door    dadoes would interfere with the
                                                frame stile (backed by several 3/16"       panel grooves and corner joints.
     The doors also need some other             flat washers), but the offset at the       Besides, I’ve found with other proj-
   hardware. I drilled screw holes in           top end requires a double layer of         ects that over-customized storage
   the panels to install the pull knobs,        1/ " plywood to serve as a mounting        gets obsolete in a hurry (anyone
                                                  4
   and in the cabinet edges so I could          block on the inside of the carcase         remember eight-track tapes?). My
   press-fit the magnetic catches               panel (Drop-Front Door Support             router bit inventory has grown a lot
   (Figure 9).                                  Detail). I opted to run longer pieces      over time, and I wanted a storage
     The drop-front door also requires          and use them as supports for a loose       system that could evolve with it.
   a pair of hinged support arms. For           shelf made from scrap plywood. I use          The simplest solution proved to
   extra heft here, I ended up using a          this spot to keep router manuals and       be a series of eight interchangeable
   pair of folding table leg braces from        the instruction booklet for my dove-       shelf inserts, four for each door. The
   The Stanley Works (#446 -1/2- 2C).           tail jig.                                  inserts stack inside the door recesses
                                                                                           with help from thin plywood spacers,
                                                          Door Shelf Inserts               the last pair of which gets screwed in
                                                       Building router bit storage         place to secure everything below. I
                                                       into the upper doors really         kept all the inserts the same size to
                                                       exploits the usable storage         streamline the cutting chores.
                                                       space in this cabinet. At first I
                                                       thought I would simply cut
                                                       dadoes in the door frames and
                                                       glue permanent shelves in
                                                          Drop-Front Door
                                                          Support Detail
                                                          (Cross Section View)
    9
   With each upper door resting on a support block,
   clamp its top end to the hinge before fastening.
From Workbench Magazine                                                   page 10                           © August Home Publishing Co.
Shelf Inserts Assembly View
                                                      10                                             11
                                                      Using a notched push block, cut the end        As you work your way up the door, each
                                                      rabbets for the shelf inserts on an oversize   shelf insert locks the spacers below in
                                                      blank, then rip it to the required sizes.      place. Fasten the top spacers with screws.
                                                       spacers captive without fasteners or
                                                       glue. Just as I did with the joinery
                                                                                                            Mounting Detail
                                                       details on the carcase sides, I
                                                       machined these rabbets on larger
                                                       pieces (two 81/2"-wide × 105/8"-long
                                                       panels), as shown in Figure 10.
                                                       Then I ripped them to the required
                                                       size. This process is faster than cut-
                                                      ting the joints piecemeal, and it
                  Shelf Insert Details                makes the stock easier to handle.
                                                          After all the inserts are cut, you
                                                      can drill holes for the nylon bush-
                                                      ings that hold the router bit shanks.
                                                      These bushings are just plastic                rails — one screwed to the cabinet
                                                      sleeves with either a 1/4" or 1/2" bore.       back and one to the wall studs
                                                      They make it easier to get the bits            (Mounting Detail).
                                                      in and out, and you can drill different            Five minutes after the cabinet was
                I cut a pair of shallow rabbets on    hole patterns to accommodate the               on the wall, I had my routers nesting
              the ends of each insert (Shelf Insert   space requirements of your various             on the upper shelf and both doors
              Details). These create a self-locking   cutters.                                       filled with router bits. I also added a
              feature by holding the vertical             I cut 20 shelf spacers from 1/4" ply-      few screw hooks to hold the router
                                                      wood and drilled 3/16"-dia. screw              cords up and hang edge guides.
                                                      holes in the center of four of them            I figured
             What You’ll Need                         — the rest simply press-fit in. After I        that’s prob-
                   Lumber                             set the first two spacers at the bottom        ably enough.
   (1) sheet 18mm (11/16") × 60" × 60" Baltic         of each door recess, I glued a narrow          If I get any
       Birch plywood or equivalent                    strip of 11/16" plywood to the bottom          more organized,
   (1) sheet 6mm (1/4" ) × 60" × 60" Baltic           frame rail. This keeps the spacers             it’ll be a crime.
       Birch plywood or equivalent                    seated and creates a pocket for
                                                      storing small items such as extra col-
                    Hardware*                         lets and guide bearings.
  (76) #6 × 1/2" flat-head wood screws                    The shelf inserts stack in place,
   (3) 24"L × 11/2"W continuous hinges                locking the spacers as you work
   (1) pr. table leg braces (Stanley 446-1/2 -2C)     your way up (Figure 11). As soon
  (48) #6 × 11/4" drywall screws                      as I had them all fitted, I drove
   (8) #10 × 1" pan-head sheet metal screws           screws to hold the top spacers
   (6) 2" L-hooks with screw thread                   snugly in place.
   (8) 3/16" flat washers                                 I hung the cabinet using a pair of
   (4) 7/16" round magnetic catches                   3/
                                                         4"-thick bevel-edged mounting
   (3) 11/4"-dia. wood knobs
  (50) nylon bit bushings (25 ea. 1/4" and 1/2")
                                                               Any hobby can be easier to
  *(Workbench kit available; see page 6)                       manage with this cabinet!
From Workbench Magazine                                            page 11                                 © August Home Publishing Co.