Cabinetmakers are probably more familiar with layup tables
than carpenters and remodelers are. Layup tables allow you to
make cuts without damaging the underlying surface; they're also
great for assembly work. For example, when assembling a face
frame, you can raise it on the layup table so the work surface
below doesn't interfere with the clamps. On site, I use layup
tables for edge banding and cutting plywood.
There are many designs, but layup tables generally use evenly
spaced supports screwed to a sheet of plywood or some other
panel product. I made mine from a 4-foot-by-5-foot piece of
plywood with 1x4 cleats screwed to it on edge every 16 inches
or so. It's still not quite big enough for a good-sized face
frame, but I didn't want to build it any bigger — I
wouldn't have room to store it, and it's already too big for my
van. So, when I need a layup table on site, I usually cobble
one together from whatever is lying around.
The Smart Table
Now, however, with the expandable layup table from Eurekazone
(732/259-9984, www.eurekazone.com), I no longer have to
worry about any of that. Called the Smart Table, it's sold in a
kit that includes everything you need to build a sturdy,
compact layup table. Unlike the permanently mounted cleats on
most layup tables, the Smart Table's sliding cleats allow you
to expand the table to 4 feet by 8 feet and then collapse it
for easy storage and transport. The kit includes bolts, bottom
tracks, guides, and even the drywall screws you need for
assembly.
Simple setup. To assemble the table, you start
with a 2-foot-by-4-foot piece of plywood — but rather
than screwing cleats directly to it, you bolt the kit's plastic
tracks to the plywood. The tracks receive mating plastic slides
that attach to the 1-by support cleats. The sliding supports
are the key to the table's small footprint and large capacity.
To improve flexibility, the two end tracks are each secured
with a single bolt so they'll pivot. When the end cleats are
perpendicular to the side cleats, the table expands to 4 feet
by 8 feet and can support a large face frame or a full sheet of
plywood (see Figure 1).
Figure 1.Thanks to sliding supports, the Smart
Table can support a full sheet of plywood (top) or a large face
frame (middle) and then collapse to a 2-foot-by-4-foot size for
transport and storage. The plastic slides attach to 1-by
support cleats and ride in corresponding plastic tracks; since
the end cleats are secured with a single bolt, they can be
positioned as needed (bottom).
I cut my cleats 3 inches tall, but you could make them shorter
or taller. The instructions recommend fastening the end tracks
so they butt into each other, but with 24-inch cleats, you'd
have to remove one set of cleats to store the table. Since I
wanted all the cleats on the board at all times, I mounted the
end tracks so the cleats would slide by each other for smaller
projects and storage (Figure 2). The center supports use
similar hardware, but they don't pivot. You can slide a single
cleat into each track or use two cleats per track to widen the
table to 4 feet.
The instructions suggest positioning the
end supports so they butt end to end. However, by offsetting
them slightly, all four end cleats can remain on the table when
the table is at its smallest, making transport and setup
easier.
Performance. My only complaint about the Smart
Table is that when the plastic guides are extended to their
maximum reach, they tend to flex. This hasn't been a big
problem, but a metal guide would work better. I also wonder
what a system like this would be like if it were made with
heavy-duty full-extension drawer slides.
The table works well for cutting plywood and assembling face
frames. It's great because I'm able to get my vise-grip clamp
into any location. If one cleat is in the way, I just slide it
in or pivot it a little, but the frame is always
supported.
The Smart Table sells for $55 on the company's Web site.
EZ Smart Saw Guide
The Smart Table actually wasn't designed with face frames in
mind. The inventor wanted a table that would work well with his
saw guide, the EZ Smart Guide System. I've used a lot of saw
guides, from homemade plywood versions to Festool's plunge-cut
saw and guide rail, and just about everything in between. If
you're reluctant to invest in a Festool saw and guide, this
8-foot guide is a good substitute. The guide I tried is made in
two 4-foot aluminum sections, but the company also offers 50-,
150-, and 200-inch versions. Track sections can be joined
together or used singly. The sections join with dovetail
splines, creating a dependably straight cutting guide —
mine was off less than 1/16 inch over 8 feet (Figure 3).
Made from two aluminum sections, the EZ
Smart Guide provides a simple and accurate way to trim door
bottoms and cut panel products (above). Guide sections are
joined with tight-tolerance splines and set screws (bottom
left); clamps can be placed anywhere along the aluminum
extrusion (bottom right).
Mounting it. The manufacturer provides nuts and
bolts for mounting the saw to the plastic sled, but I couldn't
bring myself to drill holes in the base of my saw. Instead, I
secured it with double-sided high-strength tape. I've banged
the saw around plenty, and the tape seems to be holding very
well. One of the nice things about this guide system is that it
prevents tear-out on both sides of the blade. The guide
protects one side of the cut, and an insert in the bottom of
the sled protects the other side (Figure 4).
Figure 4.A zero-clearance insert and the guide
itself work together to ensure a splinter-free cut on both
sides of the blade. The insert snaps into the bottom of the
sled and is cut the first time the saw is lowered. The
manufacturer provides four inserts — two that work with
the guide and two for freehand cutting. The extra inserts allow
you to use a variety of blade thicknesses.
Using it. Unlike homemade shooting sticks, which
are often held in place with spring clamps, this guide will
never move. It clamps quickly and easily, and never interferes
with the operation of the saw. Even when you're using the guide
at its maximum length, the cut is always perfectly straight and
splinter-free, and the saw balances comfortably. And if you use
the guide with the Smart Table, you don't have to worry about
the drop-off breaking loose at the last second and splintering
your cut.
For $190, the EZ Smart Guide model 100 includes the two-section
track, two clamps, the sled, and four zero-clearance inserts
— two that work with the saw guide and two for freehand
cutting. A router attachment ($125) can also be used with the
guide and provides an accurate way to cut flutes, make tapered
columns, and cut curved trim.
Gary Katz, a finish carpenter in Reseda,
Calif., moderates the jlconline.com finish-carpentry
forum.
Landscape
Tools
by Patrick McCombeMake the Grade.
With its unique
S-shaped tooth pattern, the New England Sifter is the perfect
rake for spreading topsoil and removing small rocks before
seeding. Like the company's other aluminum rakes, the Sifter
features sturdy construction and a lightweight anodized handle.
It comes in five different widths, from 24 to 48 inches; prices
range from $45 to $60. The New England Rake Company,
203/933-1230, www.newenglandrake.com
Hole Hog.
Getting excited about
digging holes isn't easy, but maybe a cool new post-hole digger
can stir things up a little. The Fiskars Post-Hole Digger is
completely different from other models I've seen. Steel offset
handles eliminate knuckle-smashing and are less likely to break
than wooden ones. According to the manufacturer, the new tool
can dig down to 48 inches instead of the more typical 36 inches
— oh, boy! It sells for $45. Fiskars, 800/500-4849,
www.fiskars.com
Single-Track Hauler.
On my old job
sites, we'd refer to the wheelbarrow as "the poor man's dump
truck." It was one of the most widely used and abused vehicles
in the fleet. In addition to traditional landscaping tasks, we
used it for moving boxes of nails, mountains of old plaster,
and acres of stripped roofing. Since the average wheelbarrow
turned out to be no match for those materials, we eventually
graduated to more robust, steel-framed versions — like
the Union 77015. With its 6-cubic-foot capacity, cushioned
steel handles, and two-ply tire, this powerhouse is almost as
good as a real dump truck. It sells for about $90. Union Tools,
800/888-4196, www.uniontools.com
Measuring Tools
Pocket-Sized Laser Level
. To
challenge the highly regarded PLS lasers, DeWalt recently
introduced its own version of a compact laser tool with both
horizontal and vertical beams: the DW087K. According to the
manufacturer, the new laser performs better than competitive
products because the tool body features a clipped corner that
gives the unit greater vertical range, especially when it's
placed close to the wall. The tool's magnetic mounting bracket
swivels, and the controls are designed to be more intuitive
than the single-button control on PLS products. DeWalt also
offers a model — DW086K — with a horizontal line
only. Both units include a case and are accurate to 1/8 inch at
30 feet. The DW087 sells for $250 and the DW086 for $200.
DeWalt, 800/433-9258, www.dewalt.com
Low-Cost Laser Measurer.
Don't have a laser measuring
tool? You're not alone. They're great for generating estimates
and taking difficult measurements, but a $400 price tag has
deterred many contractors from getting one. However, with the
recent introduction of Stanley's $100 FatMax TLM 100, expect
laser measuring tools to become as ubiquitous as 30-foot tape.
With a range of 2 to 100 feet and accuracy of 1/4 inch at 100
feet, the TLM 100 doesn't offer as many functions as some laser
measuring devices — but it does include a square-footage
function, measurement storage, and a built-in calculator.
Stanley, 800/782-6539, www.stanleyworks.com
Crowning Achievement.
For a long
time, the Bosch angle-finder was the only tool designed
specifically to measure corners for crown-molding installation.
Lately, though, a couple of other angle-finding tools have
arrived on the scene. One of the most feature-laden is the The
Finisher Angle Calculator. Designed by a professional
carpenter, this device incorporates a chart showing the miter
and bevel settings for cutting 45- and 38-degree crown molding
on the flat, and a slotted measuring arm that allows the tool
to function like a T-bevel. The calculator comes in three other
models — Framer, Remodeler, and Basic — as well,
each with slightly different features designed for different
carpentry specialties. The Finisher, Framer, and Remodeler
calculators sell for $50; the Basic sells for $40. Mayco Tools,
877/742-7842, www.maycotools.com
A Better Protractor.
When the
original ProSite protractor was introduced a couple of years
ago, I was thrilled. Somebody had finally produced a well-made
carpenter's protractor that not only showed the angle for an
accurate miter, but also indicated the saw settings. Now
there's a new version of the tool. Like the original, it has an
easy-to-read scale and a tight-tolerance joint where the legs
meet. Unlike the original, the 7-inch 505A-7 fits in your
toolbelt. It costs about $50. The L.S. Starrett Co.,
888/674-7443, www.starrett.com