And, I apologize for the poor video quality. Limited bandwidth options where I live makes broadcasts challenging. Next time I’ll try another connection method.

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On Sunday July 19th, I held a Live Sunday Workshop via Zoom. The topic was about the parametric plywood bench that was featured in the December 2019 issue of Popular Woodworking magazine. I showed how to vary the design and several methods to construct it. Speaking of which, above is a link to the recording on my YouTube Channel.

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So, the topic of this weeks workshop was Getting the Most From Your Small CNC. In the workshop I made two key suggestions. First, set up your machine for pass throughs by using pin registration on your CNC bed. Second, with small CNCs being somewhat slow, use your machines to make patterns for your projects. Pattern shaping can often by much faster than making parts directly on a small machine. Combined with the first suggestion, you bypass small CNC size limitations.

Next, I suggested that you build and use my shaper jig. Rather than dedicated shaper jigs for every part, my jig adapts to the pattern and parts you are making. To make the jig you need to reference my July/August 2014 article in Fine Woodworking Magazine. Here’s a link to the article and an introductory video on the project. Because the base jig is built on a grid, the dimensions are critical. If you keep to them, then you can make all kinds of different bases for special uses: longer jigs, bent jigs for dining chairs, jigs for cutting curved parts, etc.

Also, the specific Bessey Self Adjusting Clamps are important as the jig is dimensioned around them. The clamps are model STC-HH20

The fastest way to make these jigs is to use my master template on your CNC. Once you have the template you can double stick tape it onto your blank tops and bases and use a router with 5/8″ bushing plus 3/8 bit and a machinist 1/4″ center punch to mark positions for machining out jig tops and bottoms. Jig construction goes very fast if you use this technique.

The DXF file for making the jig making template are available for free on the password-protected downloads page. To access the files and other project files, just add your name to our mailing list and we’ll send the link and your password.

Use 1/2″ MDF or Baltic Birch Ply and a .250″ bit to make the template on your small CNC. As always, make sure you mic the actual diameter of your cutting bit first and enter it into your CAM program. Otherwise you might be a little tight on the slots you’ll cut with your router.

Here is a link to the video of the April 19 Sunday Workshop. It will be available for two weeks.

Next workshop will be May 3 at 1 pm PDT

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Anyway, I created a display for holiday cards by using a tree I designed a few years ago and coming up with a simple base to plant the trees and hold greeting cards. The trees were cut out of 1/8″ plywood with a laser cutter, but you should be able to get just as good results on a CNC with a 1/8″ bit. To access this and my other project files, just join our mailing list and we’ll send you a link to the download area. Here’s a project preview from my YouTube channel…

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This Festool Systainer tool tote is designed with a focus on hand tools and includes space for a set of chisels, block plane, saw, mallet, screwdrivers, pliers, folding rule and much more. I’ve included an alternate layout that adds space for measuring calipers, but you can design your own layout, too.

Every woodworker has at least one toolbox. Many of us have several. But, when it comes time to take your tools to a woodworking class or a job site a regular toolbox isn’t as good as an open tool tote designed to display, organize and protect your tools. Several years ago, I designed a tool tote insert for a Festool/Tanos #4 Systainer. Your tools are protected during transportation and when you need them you pull out the tote for easy tool access.

This project is designed to be machined on any size CNC and for that, I’ve included Rhino3D files and DXF files. It is possible to make one without a CNC, but it’ll be challenging to accurate cut the pass-through slots. I’ve included a 1/10th scale PDF file if you want to give it a try. Speaking of which, the secret to the project is finding the perfect fit for the slots. I suggest using my Plywood Thickness Gauge or digital calipers to find the gap needed. Armed with the needed thickness, change the width of the slots on the CAD file.

The Systainer Tool Tote was designed to be made from 9mm Baltic Birch Plywood. If you develop your own tool layout, send me a picture and if you’re open to sharing your tool layout with others send me your new DXF file and I’ll post it. Before you know it, we’ll have library of knock-down Systainer Tool Totes.

To download the Systainer Tool Tote files, head to the Store

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