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Get Woodworking Day 2 or Setting up Shop?

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Last night found me in the shop for a few hours. I had hoped to be able to jump into getting the top and bottoms for the latest box milled up but no such luck.

When I began squaring up the cherry sides the other night I ran into some trouble at the table saw. No matter how long I futzed with the factory throat insert I couldn't get the damned thing to sit flush. As such when I ran the sides through to cut them down to size, the piece would get trapped against the slightest lip, forcing the stock into the blade and we all know where that leads...kick back city...Thankfully I recognized the problem quick enough and was able to avert disaster but it made it absolutely clear that I needed to take some time and get my router station back up and running...and then make some inserts.

Well over a year ago I picked up a PRL lift system from Woodpeckers tools on closeout. I never got around to installing it; kicking it around the shop for far to long. But in this case I'm kind of happy that I procrastinated its install or it would have gone to the junk pile with so many of my other tools after Niagara Falls visited the shop. So out came the new toy and I got to work.

[caption id="attachment_161" align="alignleft" width="600"] It\'s all bling bling in gold like that[/caption]

I have to admit that I actually paid $15 for the template...I often scoff at the idea of buying an installation template, but this is one time I'm thrilled that I did so. Where my free time is at an all time low these days, every second is precious and if I had to kerputz around trying to get the opening for the plate just right I would probably still be there.

I did find that a support rail under the table top ran smack dab through the middle of my soon to be opening, but the lovely thing about MDF is that it's no match for a dead blow hammer. Actually judging by the way the included extension table of the Grizzly G1023RLX table saw is built I have little doubt that I will be building my own...more likely sooner than later, but I'm sure that's an entirely different post all together.

[caption id="attachment_162" align="alignleft" width="448"] No more MDF[/caption]

I also have my doubts about the Formica top as it was far too easy to drill through which makes me wonder how long it's going to put up with the use and abuse that is sure to be thrown its way.

[caption id="attachment_156" align="alignleft" width="448"] 4 holes makes a square?[/caption]

So with the rough size of the opening cut into the top it was time to apply the template and route it down to final sizing. So out came the handheld with a flush trim bit and bingo bango bongo the opening was done. Again...I really can't believe I paid for the template, but man oh man did it save me a ton of time in getting the opening laid out, roughed and to final dimensions.

[caption id="attachment_157" align="alignleft" width="600"] Templatastic...[/caption]

Next came the undertable support for the insert. I cut a rough opening in some ply I had in the scrap bin and screwed it to the bottom and edges of the table. Not the best solution but for now it's serving its purpose and should hold together until I can get a new table built (again, another post). Once that was finished up all that was left was to drop in the lift and level it with the top.

[caption id="attachment_159" align="alignleft" width="600"] Support me...[/caption]

[caption id="attachment_160" align="alignleft" width="600"] It\'s so pretty against that grey laminate...ok...both are kinda ugly[/caption]

With all that done it was time to fire up the router and give the entire thing a test run and make some zero cleranace table saw throat inserts. I'm a fan of the phenolic DIY insert kits that you can pick up from Rockler, they're not the cheapest item out ther but I really like the phenolic and think it defelcts less than a wooden shop made insert. Either way I'm now set to get back to making safe and burn/mark free cuts on the table saw.

[caption id="attachment_158" align="alignright" width="600"] Mmmmm tastes like mint, freshly minted that is...[/caption]

I do have to say that the Woodpeckers PRL system is nice, however I am having some trouble with it. I'm not certain that this has to do with anything on their part and very well could be of my own making. I'm using Hitachi 12MVC 2.25 horse routers in the shop because they're cheap and I've had good luck with them. When I placed my order with Woodpecker I was instructed that their adaptor collar for Makita brand motors would work for my Hitachi. However I don't know if this is exactly true as that collar fit like an OJ Simpson glove...it took some convincing to get it on and it fought me the whole way. But I prevailed and got it installed and the entire assembly into the lift. The problem I believe is that the collar spread out of round due to the poor fit over the Hitachi and as such is putting pressure on the lift assembly, essentially spreading the lift bars/guides to the point that they're binding. The lift still operates but not as smooth, nor as easily as I would like. So I'm left with more than likely pulling the motor and either buying a Porter Cable 75182 motor (which honestly I probably should have done from the get go due to its heft and power) or cobbling together a less snug collar and giving the Hitachi a second go. Either way I think I'm going to give a few days to think it over and get back to making the bobbin box.


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