LRyIrue LnuINATEI USS CoruSrIruTION SNIM I ... - Wood Tools

End Cap Details
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Right end cap (Face View)
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Support rail cutouts
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corner to corner and release the long blank first, then cutting it into fin wax along the inside corners
waste part (Figure 4). Remember, individual blocks (Figure 5). Drill where the rails travel (Figure 6).
these cutouts allow the support two screw holes through each This will help them slide a little
rails to slide back and forth
through the platform, so make
block, just below the rabbet. Add a
countersink. too - the screw
easier. Then feed the rails through
the cutouts in the end caps and fas-
sure there's plenty of clearance at heads won't compress the hard ten the guide blocks in place -
those corners. Then drill and plastic the way they do wood. one in the center and one at each
countersink the screw holes, Three guide blocks along each corner (Figure 7). Don't apply a
spread glue on each end of the
plafform assembly, and fasten the
support rail turned out to be plenty,
and I found it easier to position
lot of pressure to the guide blocks
or overtighten the screws - it
end caps. Once they're secure, them with the rails in place. To doesn't add any critical precision,
slide the pegboard tray bottom in install the blocks, flip the plafform and anything more than a snug fit
and fasten the front beam in place. upside-down and rub some paraf- will make the rail travel stubborn.
Fitting the Support Rqils
At this stage you've still got the
riser blocks and other accessories
to make, but detour for a few minutes
to cut and install the plastic
guide blocks for the support rails
(Guide Block DetaiD. I chose a
high-density polyethylene called
UHN/ilV (for ultra-high molecular
weight) because it slides so easily
against other smooth surfaces.
Though it's denser than most Use a jig saw to cut between the three
woods, it cuts well with regular holes and free the waste piece. Prccision
carbide blades. Besides cutting isn't critical - just leave clearance room.
the blocks to size, the only
machining required is adding a
shallow rabbet on one face, where
the aluminum rail will nest. I felt
safer machining this rabbet on a
Guide Block Detail
Wih the wood platftrm upsidedown, rub
some paraffin wax along the inside cornen
wherc the supprt rails will track.
center to center
Cut the shallow rabbet on a 20"+ piece of
UHMW plastic first, then cut it into shorter
lenghs tor the individual guide blocls.
Let the guide blocls rcst naturally in place
as you fasten them to the beams. Too
much prcssure will bind the rail action.
\Torkbench r December 1997 +>
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