If you’ve been busy in the shop this week and haven’t had time to keep up with Toolmonger, we recommend checking out the following posts when you have a chance:

How-To: Turn an Old Tractor Seat into a Great Shop Chair
We put the chocolate of an old tractor seat with the peanut butter of a broken office chair to make a slick little roll-around for the shop.  Follow our instructions to build your own.

Preview: Milwaukee’s New V18 Cordless Line
We talked to Milwaukee about their upcoming Li-ion-powered V18 line (due in August).  The verdict: It’s a fewer-cell version on the V28, and the line’s drill is all new.  Check out the post for details.

Hurricane Preparedness Part 1: Weather Radios/Public Alert Devices
Here’s part one of our three-part hurricane preparedness series.  Weather radios have come a long way, baby.  Don’t miss out.

Save Your Fingers, Woodworker: The SawStop
Who’d have guessed it – a saw that stops in 3-5 milliseconds when you touch the spinning blade.  This looks like something we should all eventually own.

Book Review: The Field Guide to Tools
Ever wonder what that tool on the flea market table is and what you can do with it?  Need a gift for a newly-wed couple?  The ‘Guide can help.

We’ve got a lot to tell you about next week as well, including our hands-on experiences with two new low-cost Li-ion cordless screwdrivers and our first report on our new BMW airhead motorcycle project.

It’s hurricane season again, and whether you’re on the coast or inland, you’re likely to see the effects of these storms first-hand.  With that in mind, we’ve prepared a three-part series to help you get a grip on the tools that can help you weather the storm.

A month or so ago we had a close call here in North Texas with a spate of tornadoes that killed five people and destroyed a good bit of property.  While we escaped unharmed, the scary part was that the tornadoes came in the middle of the night; two of the people killed were an elderly couple who didn’t wake up until the storm hit.

To prepare for a storm, you first have to know it’s coming.  If you’re like us, the last time you heard about “alert” weather radios was back when they went off way too often — pretty much any time the weather station you’d tuned to issued a message — and eventually ended up turned off or stowed away.  Thankfully, technology has come a long way since then, and through the use of digital signals you can now receive timely, accurate alerts that actually apply to you. 

In part one of this series, we bring you up to speed on weather radios — and their new, high-tech cousins “public alert devices” – and give you an idea of how to select the best one for your situation.  (Lots more after the jump.)

(more…)

When we first heard about the SawStop, we were doubtful.  A table saw that actually stops when you get a finger caught in the blade?  Impossible. 

Well, apparently not.  The SawStop induces an electrical signal onto its special blade and then monitors that signal for changes caused by contact with the human body.  SawStop says:

The human body has a relatively large inherent electrical capacitance and conductivity which cause the signal to drop when a person contacts the blade.  Wood has a relatively small inherent capacitance and conductivity and does not cause the signal to drop.

When the SawStop detects such a drop, it sends a surge of electricity through a fuse wire, which burns and releases a spring-driven block of aluminum (a “brake pawl”) into the teeth of the blade to stop it from spinning.  Simultaneously, the system shuts off power to the motor and the saw’s angular momentum causes the blade to retract below the table. 

The result: the blade stops in 3-5 milliseconds, turning what could have been a severed finger into just a nick.

The whole brake and fuse mechanism is contained in a cartridge which must be replaced  — along with the blade — after each “emergency stop.”  Pricing for the SawStop 10” cabinet saw is $2,799, and replacement cartridges run from $60 to $89.  Sure, that’s not cheap, but compare it to a trip to the ER and possibly lost fingers.

There’s a lot more information about this system on the SawStop website (including a cool video of them simulating finger contact with the spinning saw using a hot dog), and we’ll definitely bring you more on this subject soon.

The SawStop Table Saw [SawStop]

Yesterday we mentioned Stanley’s Fat Max Tru-Laser measuring device, and today we came across another tool that’d be extremely handy in putting together job estimates: Calculated Industries’ Scale Master Classic.

You can use the Scale Master just like a pen; draw around an area on plans and it’ll give you linear distance, rectangular area, and even volume.  It converts between scales and dimensions using a number of built-in scales, or you can draw a line and enter its distance to create a custom scale (to match a faxed set of plans, for example), six of which can be stored in the Scale Master for future use.

The Scale Master Classic lists for $69.95, and we found it for as little as $52 today on the street.  To make getting learning the Scale Master easier, Calculated Industries also offers a “quick start tutorial video” for $10.  They offers a variety of other calculators and calculating tools for construction and shop purposes as well; their website is worth a look.

The Scale Master Classic [Calculated Industries]
Street Pricing [Froogle]

(Friday, June 30, 2006) We’re not suggesting that you skip going out — or doing whatever sort of thing you normally do on Friday night — but if you do choose to stay in, there’s plenty on the tube to keep you entertained. 

Tonight:

• How It’s Made: Episode 45: Brushes, Brooms, Blackboards, Smoked Salmon, and Zippers (Discovery, 6 p.m. CDT)
• While You Were Out: Fairfield: Welcome Home (TLC, 6 p.m. CDT)
• How It’s Made: Episode 20: Carpet, Drinking Water, Laser Eye Surgery, Acoustic Guitars (Discovery, 6:30 p.m. CDT)
• Building the Ultimate: Big Shot: The Art and Science of Blasting (Science Channel, 7 p.m. CDT)
• Trading Spaces: Maple Glen: Fielder Road (Discovery Home, 7 p.m. CDT)
• Formula One: US Grand Prix Practice (Speed, 7:30 p.m. CDT)
• Toolbelt Diva: Backyard Makeover (Discovery Home, 8 p.m. CDT)
• The Great American Motorcycle (Discovery HD, 8 p.m. CDT) 
• Toolbelt Diva: Work Bench (Discovery Home, 8:30 p.m. CDT)
• American Chopper: POW/MIA 3 (Military Channel, 9 p.m. CDT)
• Monster Garage: Old School Cadillac/’64 Impala (Discovery HD, 9 p.m. CDT)
• The Practical Woodworker (RFDTV, 9:30 p.m. CDT)
• Trading Spaces: Austin: Wyoming Valley Drive (Discovery Home, 10 p.m. CDT)
• American Chopper: Sunoco Bike 2 (Discovery HD, 10 p.m. CDT)
• Toolbelt Diva: Backyard Makeover (Discovery Home, 11 p.m. CDT)
• The Great American Motorcycle (Discovery HD, 11 p.m. CDT)
• Toolbelt Diva: Work Bench (Discovery Home, 11:30 p.m. CDT)
• Overhaulin’: LeMama’s Boy (TLC, midnight, CDT)
• Flip That House: Glynis’ Las Vegas Gamble (Discovery Home, midnight CDT)
• American Chopper: POW/MIA 2 (Military Channel, midnight CDT)

Our insomniac recommendation: While You Were Out at 1 a.m. and Trading Spaces at 3 a.m., both on Discovery Home.

Removing siezed bolts is a common shop task — one that we engage in all too often, it seems.  Last week we were trying to remove a well-used mower deck, and just yesterday we were trying to remove a set of obstinate motorcycle pipes.  Neither of these situations was easy on the arms, but a good liquid penetrant can significantly reduce the amount of elbow grease required.

Lately we’ve been using Blaster Chemical’s PB Penetrating Catalyst.  It does a better job than WD40 in this particular task, and it seems to evaporate less than most spray-type penetrants we’ve used, which makes it easier to work down into the seized fastener.  One concern: the PB penetrates does contain around 0.5% silicone, which can be a problem if you’re using it in an area you might later paint.  Blaster says it cleans up fine with the proper solvent, but be warned.

Whether you use PB, WD40, Liquid Wrench, or any of the other myriad of penetrants out there, you’ll definitely save your body some wear and tear over just pulling harder.  You can find PB (and others) at your local auto parts or home supply shop for around $4 a can.

PB Penetrating Catalyst [Blaster Chemical]
Street Pricing [Froogle]

(Thursday, June 29, 2006) Tonight’s loaded up with everything from window blinds to bikes to tractors, so settle in on that couch and take your pick. 

Tonight:

• How It’s Made: Episode 44: Grinding Wheels, Compost, Window Blinds, Milk (Discovery, 6 p.m. CDT)
• While You Were Out: Los Angeles: Novocaine for the Soul (TLC, 6 p.m. CDT)
• How It’s Made: Episode 19: Wooden Doors, Paintballs, Newspapers, Diamand Cutting (Discovery, 6:30 p.m. CDT)
• Classic Tractor Specials (RFDTV, 7 p.m. CDT)
• Building the Ultimate: Safety Squads (Science Channel, 7 p.m. CDT)
• Trading Spaces: New Jersey: Tall Pines Drive (Discovery Home, 7 p.m. CDT)
• Overhaulin’: LeMama’s Boy (TLC, 9 p.m. CDT)
• Flip That House: Glynis’ Las Vegas Gamble (Discovery Home, 9 p.m. CDT)
• American Chopper: POW/MIA 2 (Military Channel, 9 p.m. CDT)
• Wrecks to Riches: Pony Race (TLC, 10 p.m. CDT)
• While You Were Out: Oregon: 29th Avenue (Discovery Home, 10 p.m. CDT)
• Mythbusters: Mythbusters Outtakes (Discovery, midnight CDT)
• American Chopper: POW/MIA 1 (Military Channel, midnight CDT)

We’re really pleased with Discovery’s decision to offer two episodes of How It’s Made every day at 6 — what a fun show.   Leave it up to Speed to provide our insomniac recommendation for tonight: the Barrett-Jackson 2006 auction show runs at 3 a.m. CDT.

The last time we installed a new door lock, we had a hell of a time getting everything lined up.  A pro we were talking to last week turned us on to the easy way to do the job: a door lock installation kit like this one available from Irwin.

These kits are essentially a jig that clamps right to the door and properly positions two hole saws — one for the lock and the other for the mechanism.  Irwin also includes a slick bolt-plate template, so all you have to do is align it with the mechanism hole on the side of the door and run the included custom router bit through the slots to create a recess for the bolt plate. 

Separate kits are available for wood doors and metal doors, though Irwin now offers a kit with bi-metal blades that’ll work with either type.  Street pricing starts around $21 for the bi-metal kit, which means you can afford to pick one up even for a single door installation.  And when you’re done, you can become everyone’s best friend by loaning it out.

Metal & Wood Door Lock Installation Kit [Irwin]
Street Pricing [Irwin]

We’ve had one form or another of Black & Decker’s Workmate series work tables for, well, as long as we can remember; this is another case of us having a tool for so long that we just forgot to mention it to you.  So here’s our belated recommendation: If you’re doing any kind of project work in a small shop, you’re going to want one of these.

At its core, the Workmate is a small workbench that folds away for easy storage.  (Just click two releases and the benchtop collapses to the base.  Fold the legs in, and you’re left with a package not much larger than the benchtop and about 8″ thick.)  However, the top is actually in three pieces, and with the cranks on the front you can move the front piece back and forth to clamp work in place — adding a vice functionality to the unit.  You can clamp small items (like a 2×4) with the center piece in place, or you can remove it to clamp larger items, including tools.

A quick trip to the local retailer revealed a number of cool features Black & Decker’s added since we came across our old model:  Newer Workmates include a linkage between the two clamp cranks so they turn together and can be operated with one hand, and they also offer two height settings.

Workmates come in a variety of “flavors,” from the simplest WM125 model with just an X-frame and a two-part benchtop all the way up to the WM425 (pictured here) which can handle up to 550 lbs and includes a 6-outlet power strip.  Black & Decker also offers specialized models that incorporate a hand truck — one less tool to carry — or are purpose designed for tasks like painting.

We’ll admit that we’ve used ours for all sorts of things, like clamping wood together during gluing and even acting as an impromptu welding table.  We’re guessing that “welding table” isn’t recommended in the manual, but hey, we lost our manual years ago.

Street pricing starts around $35 for the simplest version, and we found the big-boy WM425 readily available for around $100.  At these prices, we might just have to upgrade.

Workmate Project Centers [Black & Decker]
Street Pricing [Froogle]

Carpet and flooring layers (as well as numerous other contractors) need the ability to measure a room or object quickly and painlessly in order to provide estimates.  In the past, the tool of choice for this job was an ultrasonic tape: a device that bounces sound off a remote object and times its return to calculate distance. 

As you can imagine, there are some limitations to ultrasonic tapes, specifically the fact that they need large surfaces to work correctly and can sometimes catch spurious sound reflections that degrade their accuracy.  To eliminate those concerns, Stanley’s created what they call their “Tru-Laser” distance measuring system — a system that actually measures the laser light travel distance.

To use the unit, you simply point it to place the red laser dot on the remote item you wish to measure and press the button.  It instantly displays the distance on its built-in LCD screen.  It measures from 2′ to 100′ with a +/1 1/4″ accuracy (at 100 ft), and can display units in ft/in fractions, ft/100ths, in/10ths, or metric.

Best of all, street pricing starts around $100.

The FatMax Tru-Laser Measurer [Stanley]
Street Pricing [Froogle]

(Wednesday, June 28, 2006) It’s a full night tonight, with four available episodes of How It’s Made (plus some reruns later on in the evening) and a cool outtakes episode of Mythbusters.  (We’re definitely going to check that out; some of those tests they do are bound to go awry, and that should be interesting indeed.)

Tonight:

• While You Were Out: San Francisco: Happy Ending Bedroom (TLC, 6 p.m. CDT)
• How It’s Made: Episode 43: Conga Drums, Metal Plating, Buttons (Discovery, 6 p.m. CDT)
• How It’s Made: Episode 18: Hydroponic Lettuce, Construction Wood, Finishing Flies (Discovery, 6:30 p.m. CDT)
• Chop Cut Rebuild (Speed, 6:30 p.m. CDT)
• Trading Spaces: Quakertown: Quakers Way (Discovery Home, 7 p.m. CDT)
• Mythbusters: Mythbusters Outtakes (Discovery, 8 p.m. CDT)
• How It’s Made: Episode 15: Honey, Figer Optics, Bricks, Pipe Organs (Science Channel, 8 p.m. CDT)
• How It’s Made: Episode 50: Countertop Laminate, Frozen Treats, Detergents (Science Channel, 8:30 p.m. CDT)
• Mythbusters: Jet Assisted Chevy (Discovery, 9 p.m. CDT)
• Pinks: Jonathan Adkins vs. Jeff Gilbert (Speed, 9 p.m. CDT)
• Pinks: Brian Bassone vs. Mike Boccella (Speed, 9:30 p.m. CDT)
• Unique Whips: Dead Men Walking (Speed, 10 p.m. CDT)
• How It’s Made: Episode 15: Honey, Figer Optics, Bricks, Pipe Organs (Science Channel, 11 p.m. CDT)
• Pinks: Jonathan Adkins vs. Jeff Gilbert (Speed, 11 p.m. CDT)
• How It’s Made: Episode 50: Countertop Laminate, Frozen Treats, Detergents (Science Channel, 11:30 p.m. CDT)
• Pinks: Brian Bassone vs. Mike Boccella (Speed, 11:30 p.m. CDT)

Our insomniac recommendation: The Pinks/Unique/Chop block on Speed will rerun again from 1 a.m. to 4:30 a.m. CDT tonight.

Some people dream about having their own Ferrari or villa in southern France.  We, on the other hand, dream about having our own waterjet cutting rig.  But until that lottery-wining day comes, there’s always Big Blue Saw.

Big Blue Saw offers you the ability to create a part — using any one of a number of commercial or even free CAD applications — send off the file, and receive your part cut on their waterjet in 14-21 days.  Their unit cuts with a 0.040″ stream, so that’s the smallest limit for your cuts and corners, and their automated quoting system currently offers parts made of aluminum, stainless steel, mild steel, clear polycarbonate plastic, and clear acrylic plastic.  Big Blue Saw says, however, that if you give them a call they’ll work with you to cut other materials as well.

For those not yet in the drooling-over-it-gotta-have-one know, waterjet cutting works by mixing water with an abrasive powder, then using a pump and nozzle to eject the mix at exceedingly high pressure to cut abrasively.  Since it creates very little heat — and the water carries away what heat there is — there’s no HAZ (heat-affected-zone) to warp the material or change its properties (via tempering or other processes). 

There are lots of examples of things they’ve made for customers on their site (link below).

Custom Waterjet Cutting [Big Blue Saw]

Milwaukee’s V28 line caused quite a bit of a stir in the industry last year, harnessing the power of lithium-ion, bringing it to the job site, and putting it to work in some of the most powerful cordless tools available.  In August, Milwaukee plans to bring the V28’s technology to the 18 volt crowd with the release of their new V18 cordless line. 

We spoke to Milwaukee about V18, and we’ve prepared this post to give you an idea of what to expect.  Read on past the jump for the details.  (more…)

Have you ever picked up a tool at the flea market and wondered exactly what it is and how you’d use it?  The Field Guide to Tools serves that need exactly, matching photos of tools with their names, descriptions, and uses.

The Guide is a reference book, including information about 136 commonly used tools.  Each tool receives a page or two of explanation including a general description of the tool, its “habitat” (e.g. the place where you’re likely to find it), its uses, its operating principle, and basic instructions on how to use it.

For example, the Guide has the following to say about the seam roller:

General Description: A small, wooden roller mounted in a metal bracket on the end of a short wooden handle.  The roller is about the size of your big toe.  Its working face is not flat, but slightly crowned, which allows the operator to concentrate the rolling pressure by simply tilting the roller handle.

Habitat: Home decorator’s toolbox or wallpaper trough.  Sold by hardware stores, home centers, and paint and wallpaper stores.  The crowned face distinguishes it from the veneer roller, which has a flat face but is otherwise identical.

Primary Uses: Pressing the seams of freshly pasted wallpaper tight onto the wall.  Regulating wallpaper seams.

Secondary Uses: Pressing freshly glued plastic laminate onto a counter-top.  Pushing the last bit of toothpaste out of the tube.  Flattening a glued seam of fabric while sewing.

Operating Principle: A roller can be used to exert and distribute pressure without adding any sideways sliding force.  A crowned roller can focus that pressure onto a narrow band.

A page worth of instructions follow to describe how to use the seam roller for common applications.  Photos are grouped together in the center of the Guide with numbers that tie back to specific entries.  Tools are also indexed in the back of the book so if you know the name of the tool but not the function or appearance you can reference that way.

While the Guide doesn’t provide a lot of background on the history of tools or cover the variety of unusual tools we saw in Herbert Comte’s Tools: Making Things Around the World, the Guide is a much smaller and more practical reference and does include most every tool you’re likely to see in a well-equipped home shop environment.  And because the Guide’s explanations are written in such simple and straighforward terms, it would make a great gift for a first-time homeowner, a child heading off to college, or young newlyweds.

Street pricing starts around $10.

John Kelsey. Field Guide to Tools: How to Identify and Use Virtually Every Tool at the Hardware Store. Philadephia, PA: Quirk Books, 2004 (Softcover) ISBN: 1931686793

Street Pricing [Froogle]

In this post we show you how to combine that old tractor or lawn mower seat you’ve got lying around the shop with a broken office chair to create a great, inexpensive rolling shop chair.  Why pay $30 for one from Sears — that doesn’t raise and lower pneumatically or hold your weight as well — when you can build your own for less, or even for free if you’re willing to root around a bit for parts?

Best of all, when everyone asks you, “Where’d you get that chair?” you can answer: I made it. 

Lots more, including detailed build instructions and photos, after the jump. (more…)

Milwaukee has updated their cordless caulk gun line with a new 14.4V model, released in April and now available via commercial distributors.  The new model provides the same 620 lbs. of pushing force as the older 12V gun, but increases runtime — Milwaukee claims 185 10 oz. tubes of caulk per battery charge. 

Most notable among the 14.4V gun’s new features: you can now set the speed range of the variable-speed trigger with a small dial on the back rear of the gun, dialing in the correct speed range for the job so you don’t have to half-squeeze the trigger all the time.  The battery’s also reversible to let you improve the gun’s balance with different caulk loads.

Additionally, the new gun features an all-metal gearbox, electronic overload control, a 360 degree swivelling carriage, a trigger lock (so the gun doesn’t happily caulk your toolbag on the way home), and a manual clutch release to simplify reloads.

As with the 12V, Milwaukee offers the 14.4V gun in three kits, each equipped with a different carriage.  The 6562-21 fits 10 oz. tubes, the 6562-23 handles quart sizes, and the 6562-24 is designed for sausage packs.  Street pricing starts around $220, $235, and $245 respectively.  

You can also purchase the carriages separately, so if you commonly use more than one type of tube, you can swap them out as needed.

Note: We linked to the 10 oz. kit version below, but you can find the other two easily on Milwaukee’s site.

14.4V Caulk/Adhesive Gun [Milwaukee]
Street Pricing [Froogle]

(Tuesday, June 27, 2006) Discovery offers up two back-to-back episodes of How It’s Made starting at 6.  Wrecks To Riches continues the fun at 7, and if their build gets boring you can always switch over to Pinks at 7:30 to see someone lose their ride.  And don’t forget Overhaulin’ — they’re running the LeMama’s Boy episode twice tonight at 9 and 11.

Tonight:

• How It’s Made: Episode 41: Plastic Injection Moulds, Automotive Oil Filters, Filing Cabinets, Blown Glass (Discovery, 6 p.m. CDT)
• How It’s Made: Episode 42: High-Precision Cutting Tools, Stained Glass, Semi Trailers, Recorders (Discovery, 6:30 p.m. CDT)
• While You Were Out: Bayview: A Cozzie Community (TLC, 6 p.m. CDT)
• Wrecks To Riches: Dad Stole My Car (TLC, 7 p.m. CDT)
• Trading Spaces: Wake Forest: Rodney Bay (Discovery Home, 7 p.m. CDT)
• Pinks: Jonathan Adkins vs. Jeff Gilbert (Speed, 7:30 p.m. CDT)
• Overhaulin’: Mean Anemul (TLC, 8 p.m. CDT)
• Overhaulin’: LeMama’s Boy(TLC, 9 p.m. CDT)
• Overhaulin’: LeMama’s Boy (TLC, 11 p.m.)
• Biker Build-Off: Matt Hotch v. Rick Fairless (Discovery, midnight CDT)
• Unique Whips: Blazing a Trail to NASCAR (Speed, midnight CDT)

Tonight’s insomniac recommendation (brought to you by Sean, who really should have gotten more sleep over the weekend) is Build or Bust: Massachusetts Man on Speed at 4 a.m. CDT.