General Shop safety Rules Preventing Accidents Rules for operating Equipment Table Saw Avoiding Kickback Jointer Thickness Planer Radial Arm-Saw Compound Mitre Saw Bandsaw Drill Press Router Table Belt/Disc Sander Lathe Scroll saw Mortise/Drilling Machine Framing saw / Panel saw Cordless Drill / Biscuit Joiner Orbital sander / Palm Sander Spindle sander / Jig saw Equipment Specifications 2 3 4 7 9 10 12 14 16 18 20 22 24 26 28 30 32 33 34 35 36 INDEX Created by Jeff Wilson
Loose clothing must be tucked in and shirt sleeves must be rolled up. Chains, drawstrings and necklaces must be secured. Long hair must be tied back. Do not run in the shop. No horseplay in the shop. No fighting in the shop. Do not throw objects in the shop. Report all accidents to the instructor, no matter how small. Safety glasses must be worn when using or observing the use of any power machinery. Never use a machine without the approval of the instructor. Tools and machines are not to be used until you have received instruction on them, and have satisfactorily demonstrated proper use of them. (Safety passport and/or contract.) Only one person at a time is to operate a machine. Do not approach another student or instructor while he or she is operating a machine. Work areas must be kept clean. Pick up small pieces of materials from the floor. Return all tools to their proper place when you finish with them. Return unused materials to their proper storage area. GENERAL SHOP SAFETY RULES 2 Created by Jeff Wilson
PREVENTING ACCIDENTS Accidents are caused by inattention, taking chances, bad judgement, fatigue, missing guards, unsuitable clothing, defective equipment and horseplay! A clean and organized shop is a safe shop. Do not attempt to use any tools while under the influence of medication, alcohol or drugs. PREVENTING ACCIDENTS 3 Created by Jeff Wilson
WOODWORKING TOOLS CAN BE DANGEROUS IF NOT USED PROPERLY. 1. Only use woodworking machines that you have been trained to use properly and safely. 2. Make sure you understand instructions before attempting to use any tool or machine. 3. Ask questions if you have any doubts about doing the work safely. What safety procedures/rules should you follow when using woodworking machines? 1. Always wear safety glasses or goggles. 2. Wear dust masks when required. 3. Wear hearing protection that is suitable for the level and frequency of the noise you are exposed to in the woodworking area. If you have trouble hearing someone speak from three feet away, the noise level from the machine is too high. Damage to hearing may occur. 4. Use gloves to protect hands from splinters when handling wood but do not wear them near rotating blades and other machinery parts where the gloves can catch. 5. Make sure the guard is in position, is in good working condition, and guards the machine adequately before operating any equipment or machine. Check and adjust all other safety devices. 6. Check that keys and adjusting wrenches are removed from the machine before turning on the power. SAFETY RULES FOR OPERATING WOODWORKING EQUIPMENT 4 Created by Jeff Wilson
7. Inspect stock for nails or other materials before cutting, planing, routing or carrying out similar activities. 8. Ensure that all cutting tools and blades are clean, sharp, and in good working order so that they will cut freely, not forced. 9. Turn the power off and unplug the power cord (or lock out the power source) before inspecting, changing, cleaning, adjusting or repairing a blade or a machine. Also turn the power off when discussing the work. 10. Use a "push stick" to push material into the cutting area. Jigs are also useful in keeping hands safe during cutting procedures. Keep hands out of the line of the cutting blade. 11. Clamp down and secure small work pieces when drilling or milling. 12. Ensure that the floor space around the equipment is sufficient to enable you to machine the size of work piece being processed safely without bumping into other workers or equipment. 13. Woodworking machines should be fitted with efficient and well-maintained local exhaust ventilation systems to remove sawdust or chips that are produced. 14. Electric power cords should be above head level or on the floor in such a way that they are not tripping hazards. 15. Keep work area free of clutter, clean, well swept, and well lit. Spills should be cleaned up immediately. Floor areas should be level and non-slip. Good housekeeping practices and workplace design will reduce the number of injuries and accidents from slips, trips, and falls. 16. Do not wear loose clothing, work gloves, neckties, SAFETY RULES FOR OPERATING WOODWORKING EQUIPMENT 5 Created by Jeff Wilson
rings, bracelets or other jewelry that can become entangled with moving parts. 17. Avoid awkward operations and hand positions where a sudden slip could cause your hand to move into the cutting tool or blade. 18. Do not remove sawdust or cuttings from the cutting head by hand while a machine is running. Use a stick or brush when the machine has stopped moving. 19. Do not use compressed air to remove sawdust, turnings, etc. from machines or clothing. 20. Do not leave machines running unattended (unless they are designed and intended to be operated while unattended). Do not leave a machine until the power is turned off and the machine comes to a complete stop. 21. Do not try to free a stalled blade before turning the power off. 22. Do not distract or startle an operator while he or she is using woodworking equipment. 23. Horse play will be prohibited and not tolerated. It can lead to serious injuries! SAFETY RULES FOR OPERATING WOODWORKING EQUIPMENT 6 Created by Jeff Wilson
TABLE SAW The table saw is the most often used piece of equipment in the woodworking shop. This is because of its accurateness and extreme versatility. It is capable of making all the basic woodworking cuts, rip, crosscut, miter, bevel, and even compound angle cuts. Its large table can easily handle both solid wood and sheet stock. There are special table saw procedures for cutting dadoes, tapers, rabbets, and tenons on the table saw. 7 Created by Jeff Wilson
Never use both the mitre gauge and the fence at the same time. Make sure the power is off and blade is not in free spin before making any adjustments. Always use a push stick when ripping stock less than 8 in width. Always have guards down on the table except when making specialty cuts, ie. dado cuts. Never stand directly behind the blade. Never let go of your stock once you have started your cut. Have someone assist you if your stock is longer than 48 in length. Never cut freehand. Never reach over the saw blade while in operation. Never cut warped stock. After changing or adjusting blades make sure blade is securely fastened and pointing in proper direction. Always raise the blade from 1/8 to 1/4 higher than the thickness of stock being cut. Do not force stock into the blade faster than it can cut. Never use hand to clear away scraps when saw is operating. Have qualified instructor double check/or help with specific set-ups and blade changes before starting up saw. SPECIFIC SAFETY RULES - TABLE SAWS 8 Created by Jeff Wilson
Kickback is caused when the blade catches the workpiece and violently throws it back to the rear of the saw, towards the operator. It can be thrown very hard and can injure the operator. Blade must be sharp and clean. Novices often do not recognize the importance of using a clean and sharp blade. Pitch buildup on a blade greatly increases friction and decreases the quality of the cut, causing burning. Pitch also increases the probability of kickback. Saw must be aligned. The blade must be adjusted so that it is parallel with the miter grooves and the rip fence. If the blade is out of parallel, it is possible for the workpiece to be pinched between the blade and the rip fence, which will cause violent kickback. Use the blade guard when possible. The blade guard on typical American market saws incorporates a spreader, which helps prevent the cut from closing on the back of the saw blade. Natural tension can exist in wood that causes the cut to close. Some blade guards have anti-kickback devices that allow only forward travel past the blade. Push the work piece past the blade. Do not release a work piece until it is past the blade and removed from the saw. Turn the saw off before removing small cut off pieces. Always maintain control. Do not execute a cut where you do not have complete control of the situation. Make sure there are no obstructions. Do not cut a workpiece that is too large to handle. Do not use the rip fence as a guide during crosscuts. If you need cuts, use a stop block in front of the blade so the workpiece is not in contact with the rip fence during the cut. It is easy for the workpiece to twist out of perpendicular at the end of the cut and thus get caught by the blade and thrown. Be careful about flaws in the wood. Cutting through a loose knot can be dangerous. Cutting a warped or twisted board along the rip fence is dangerous because it can get pinched between the fence and blade. AVOIDING KICKBACK 9 Created by Jeff Wilson
JOINTER The jointer s primary use is to square up stock which makes it an extremely useful tool in the woodshop. When used properly the jointer will give a flat, straight edge on stock, an edge with the smoothness, evenness and is square to adjacent surfaces that is required to ensure accurate dimensions of your work. The jointer can also be used to create rabbets, bevels and tapers. 10 Created by Jeff Wilson
Never place your hands in the path of the cutter head. Always push stock all the way through until the guard snaps back. Always use a push stick when planing the side of a piece of stock. Use a push stick to plane the edge of a piece of stock only when the stock is less in width than the height of the fence. Never plane a piece of stock less than 12-14 in length. Never plane stock that is less than 1/2 thick. Never let go of your material once you have started your cut. Always plane cup side down when planing the side of a piece of stock. Never joint the end grain. Feed stock into rotating knives firmly and at a rate that will not overload the machine. Turn off the jointer before making any adjustments. Always have the guard in place over the knives while the jointer is being operated. Always stand to the left of the jointer, never directly behind it. Do not use the jointer for cuts heavier than 1/8. Keep your hands on top of the stock and not on the ends if the operation does not require a push stick. Have qualified instructor double check/or help with specific set-ups before starting jointer. SPECIFIC SAFETY RULES - JOINTERS 11 Created by Jeff Wilson
The thickness planer is used to plane stock to a uniform thickness. It is usually used in conjunction with a jointer to dress rough lumber or create a true piece of stock. The cutterhead is mounted above the table, so only the top of a piece of stock is planed. Thickness planers are self-feeding. After stock has been fed into a thickness planer it will continue through the planer by itself. Thickness planers will NOT straighten warped stock. CROSS SECTION OF A PLANER THICKNESS PLANER 12 Created by Jeff Wilson
Never bend down and look into the machine while in operation. Do not place your fingers under your stock before it enters the machine. Never place your hands directly into the machine. Make sure that the stock is at least 2 longer than the distance between the feed rolls. 14 for stock is common. Make sure stock is free from nails, loose knots or other foreign matter. Always stand to one side when planning. Never stand directly behind the stock Only remove a maximum of 1/8 or 3mm each time a piece of stock goes through the machine. Plane a warped piece of stock only after one surface has been trued on a jointer. Never reach over the planer. Have an assistant help support long stock as it is being fed out of the planer. If a piece of stock sticks, turn off machine or disengage feed and turn off machine. Once cutterhead stops, adjust thickness planer to remove stock. Never pull on stock being planed. Support the stock, keep it level and let the rollers feed out stock. Only plane stock with the grain. Have qualified instructor double check/or help with any concerns before starting up the thickness planer. SPECIFIC SAFETY RULES -THICKNESS PLANERS 13 Created by Jeff Wilson
The Radial Arm Saw is mainly used for crosscutting operations. It is sometimes referred to as a cutoff saw. The blade of the saw is positioned on top of the stock, which makes aligning the cut very accurate since layout lines are very visible. Only light hand pressure is needed to hold stock as the action of the blade pushes the stock down and back against the fence. Radial arm saws can cut stock on mitres and bevels and can also be used to dado, rip, and shape stock using molding cutterheads. RADIAL-ARM SAW 14 Created by Jeff Wilson
Make sure the guard is always in place. Make sure all clamps and locking handles are tight before starting the motor. Make sure the blade is at full RPM before starting cut. Keep your hands out of path of blade. Keep at least a 6 inch (width of your hand) margin of safety. Hold the stock firmly against the fence for crosscutting operations. Make all adjustments with the motor off and with the blade at a dead stop. Never stop the blade by holding a piece of stock against it. Always return the saw to back of the table after finishing the cut. Never remove stock from the table until the saw is returned. Never cross your arms. Cut on the pull stroke only. If installing a different blade make sure it is sharp and pointing in the right direction. Have qualified instructor double check/or help with any concerns before starting up the Radial Arm Saw. SPECIFIC SAFETY RULES - RADIAL ARM SAWS 15 Created by Jeff Wilson
The compound mitre saw and the sliding compound mitre saw are both used for crosscutting only. They are both capable of cutting compound angles at the same time, with the mitre being cut across the side and the bevel being cut on the end. The compound mitre saw is sometimes referred to as a chop saw because of its cutting motion. Different types of sliding mechanisms allow sliding compound mitre saws to cut wider stock. The action of pushing the saw away from the operator when making a cut is also an important safety factor. COMPOUND SLIDING MITRE SAWS 16 Created by Jeff Wilson
Keep all guards in place. Keep hands out of path of saw blade. Wait until blade has completely stopped turning before raising the saw head and removing stock. Wait until the blade attains full RPM before lowering it into the stock. Make sure stock is positioned against the fence. Any gap between the fence and wood will cause the blade to bind. Make sure saw is secured to bench or table before operating. Never cross arms. Never cut with the grain. Use clamps or vice when you cannot secure the stock on the table and against the fence by hand or when your hand will be dangerously close to the blade. 6 to 8. Never cut Freehand. Never reach around or behind saw while in operation. Make sure to position hold-down clamps so that they do not interfere with operation of the saw. Make sure all clamps and locking mechanisms are secure and tight before cutting. Always support long stock to prevent stock from binding or jamming saw. Have qualified instructor double check/or help with any concerns before starting up the mitre saw. SPECIFIC SAFETY RULES - MITRE SAWS 17 Created by Jeff Wilson
BANDSAW The band saw is primarily used for cutting curves, circles and irregular shapes. It is also capable of making straight cuts, such as rip, crosscut, mitre, and even bevel and compound mitre if it has a tilting table. The band saw is an excellent tool for cutting a thick board into thinner ones. This process is known as resawing. Band saws can accurately cut a variety of materials such as wood, plastic and metals. Wider blades are required for resawing, while narrower blades are required for cutting a tighter radius. 18 Created by Jeff Wilson
Keep upper guard as close to the top of material as possible. Make sure the blade is running at full RPM before starting your cut. Plan cuts carefully and make relief cuts before making long curved cuts. Make short cuts first, so there will be a minimum of backing out. Never back out of long cuts while the saw is running. This will cause the blade to come off the drive wheel. Try to keep fingers (hands) beside or behind blade, not in front. Keep fingers at least 2 inches away. Use a push stick with small stock and to remove waste pieces. Support round stock in a V type jig. Make sure blade is sharp and in good condition. Check for proper blade tension and make sure teeth on blade are pointed downward. Hold stock flat on table. Push stock into the blade firmly and at a rate that will not overload the saw. Make sure the band saw has completely stopped before making adjustments. If you need to back out of a long cut, turn off power and let machine stop before moving stock. Have qualified instructor double check/or help with any concerns before starting up the band saw. SPECIFIC SAFETY RULES - BAND SAWS 19 Created by Jeff Wilson
DRILL PRESS The drill press is an extremely versatile machine that can be used to perform a variety of operations. It s main use is to drill holes of various diameters, depths, and at various angles. It can also be used for mortising and sanding. Drill speed can be adjusted either by a variable speed control or a step pulley system. This is essential for different operations, and when using various bits and accessories. The drill press can also be used for drilling metals and plastics. 20 Created by Jeff Wilson
Keep your hair and loose clothing away from moving parts. Place the drill or bit in the chuck straight and tighten it securely. Always remove the chuck key before starting the machine. Keep fingers at least four inches away from the rotating tool. Feed the drill or bit smoothly into the work piece. When the hole is deep, withdraw it often to clear the shavings. Make sure material to be drilled is secure. Clamps or a vice should secure smaller pieces. Always use bit with straight shank, never a square one. Know what speed you should be using. Slower for large holes, faster for smaller holes. Slow for metal. When setting up make sure bit will not drill into the table or vice. Place scrap stock under the work if needed. Clamp round stock in a V type jig. Remove chips and sawdust with brush or stick, not your fingers. On a step pulley machine, disconnect or kill power before adjusting belts. Have qualified instructor double check/or help with any concerns before starting up the drill press. SPECIFIC SAFETY RULES - DRILL PRESS 21 Created by Jeff Wilson
A router basically consists of a high speed motor fitted into a base. A cutting tool is attached to the shaft of the motor with a split collet chuck. Common uses of the router include cutting cabinet joints such as the dado, rabbet and mortise andtenon; trimming plastic laminate; shaping decorative edges; milling moldings; and carving signs and plaques. Routers can be used in a variety of methods including in a fixed base, a plunge base, mounted upside down in a work table and part of a Computer-numerical control (CNC) machine. ROUTER TABLE 22 Created by Jeff Wilson
Make sure you have proper bit or cutter for the specific job and adjust it to the proper depth. If not using a router table, secure work piece in a vice or with clamps. Keep hands clear of the rotating bit or cutter. Always feed the router or stock in the proper cutting direction. When in the router table, feed from right to left. Feed the router or the stock at the appropriate speed. Feeding too slowly will cause the bit to heat up. This will burn the bit and burn your wood. Make sure router comes to a complete stop before setting it down. Hold router firmly with both hands. Stay focused when turning router on and off. Use proper wrench or wrenches on collet nut. No vice grips or pliers! Never attempt to change a bit while the router is plugged in. unplug first or lock out switch on the router table Make sure base is secured tightly to the motor. Have qualified instructor double check/or help with any concerns before starting up the router. SPECIFIC SAFETY RULES - ROUTERS 23 Created by Jeff Wilson
The belt-and-disc sander is a very useful combination sander. Both the belt and disc have tables to rest stock on to get a very accurate finish. End grain, side grain, edges, curves, and irregular shapes can be sanded using stationary power sanders. BELT/DISC SANDER 24 Created by Jeff Wilson
Make sure both disc and belt are correctly installed or mounted. Make sure guards are secure and adjustments are made before operating. Use table, fence and guides to control the position of the work. Small pieces should be held in a hand clamp or jig. Use for sanding only, not for cutting irregular shapes or cutting stock. Do not use for removing large amounts of material. Keep stock in motion to prevent burning due to friction. Keep hands at least 2 inches away from the belt or disc. Sand on the down side and from the center to outside on the disc sander. Check the rotation of the disc. Feed the stock directly against the sanding belt. Never feed from the left or right as it could damage the belt. Do not sand the sides of thin materials. Do not sand the face side of material. This will bring fingers too close to the abrasive and will most likely result in an uneven surface. Have qualified instructor double check/or help with any concerns before starting up the belt/disc sander. SPECIFIC SAFETY RULES -BELT/DISC SANDER 25 Created by Jeff Wilson
LATHE The wood lathe is used to shape stock by a process called turning. This is a cutting operation in which the stock is revolved against a single edged tool. 26 Created by Jeff Wilson
Make sure the stock is free of checks, knots, and other defects. Remove loose or baggy clothing, tie back hair, and remove any dangling objects. All glued up stock must be dry at least 24 hours to make sure glue has set properly before turning. Use only wood turning tools when working on the lathe. Hold all turning tools in both hands. Securely lock the tail stock before starting the lathe. Check for end play by rotating the stock. Set the tool rest as close as possible to the stock being turned. Rotate the stock a few times by hand to make sure stock clears tool rest. Start all turning jobs at slowest speed until stock is roughed down to round form. Then increase to a speed suitable for the size of stock and particular turning operation. Do not adjust tool rest while lathe is operating. Always stop the lathe when checking diameters of stock. When faceplate turning, screw the faceplate securely to the wood. Avoid cutting too deeply or you might strike the screws. When sanding or polishing, remove the tool rest to prevent accidents. Have qualified instructor double check set up/or help with any concerns before starting up the lathe. SPECIFIC SAFETY RULES - LATHES 27 Created by Jeff Wilson
SCROLL SAW The main purpose of a scroll saw is to cut intricate curves in stock. The scroll saw s size is determined by the distance from the blade to the rear frame of the saw. The scroll saw is somewhat similar to a band saw but instead of a continuous loop of steel for the blade, the scroll saw has a blade similar to a copping saw and operates in a quick reciprocating up and down motion. 28 Created by Jeff Wilson
Make sure scroll saw is securely fastened to a bench or stand. Make sure blade is properly tensioned before operating saw. Make sure teeth are pointed downward toward table. Always adjust hold down foot for each new operation. The hold down foot should be set to avoid material from jumping up and down with the stroke of the blade. Do not cut material that is too small to be safely supported. Make relief cuts before cutting long curves. Always hold stock firmly against table. Do not use bent blades. Avoid awkward hand positions where a sudden shift could cause a hand to move into the blade. Do not force material into the blade. This will cause the blade to overheat and bend or break. Have qualified instructor double check/or help with any concerns before starting up the scroll saw. SPECIFIC SAFETY RULES - SCROLL SAWS 29 Created by Jeff Wilson
The mortise/drilling machine is used for drilling square or rectangular holes in stock to receive tenons. A special hollow chisel with an auger bit inside it is used to create the holes. These hollow chisels come in various sizes. MORTISE/DRILLING MACHINE 30 Created by Jeff Wilson
Do not attempt to mortise material that does not have a flat surface, unless a suitable support is used. Always clamp work piece securely to table with vise or hold down clamps to prevent lifting. Always support work piece securely against fence to prevent rotation. Be sure drill bit is sharp, not damaged and properly secured in the chuck before operating. Take care when changing bits as the chisels are extremely sharp. Make sure chuck key is removed before starting machine. Adjust depth stop to avoid drilling into table. Never place your fingers in a position where drill or cutting tool could contact them if stock should shift unexpectedly. Make sure machine is securely fastened to a supporting surface to prevent it from tipping over. Have qualified instructor double check/or help with any concerns before starting up the mortise/drilling machine. SPECIFIC SAFETY RULES - MORTISERS 31 Created by Jeff Wilson
FRAMING SAW PANEL SAW 32 Created by Jeff Wilson
CORDLESS DRILL BISCUIT JOINER 33 Created by Jeff Wilson
ORBITAL SANDERS PALM SANDERS 34 Created by Jeff Wilson
SPINDLE SANDER JIG SAW 35 Created by Jeff Wilson
PAGE 7 10 DELTA RIGHT TILTING UNISAW. MODEL 36-R31 PAGE 10 GENERAL 12 JOINTER MODEL 780 PAGE 12 KING 20 PLANER MODEL KC-520C PAGE 14 WADKIN UNIVERSAL 14 RADIAL SAW MODEL 14 BRA PAGE 16 DEWALT 12 SLIDING COMPOUND MITRE SAW MODEL DW-718 PAGE 18 WADKIN 20 BANDSAW 153 BLADE MODEL 20-BZB PAGE 20 DELTA ROCKWELL 14 DRILL PRESS MODEL DP-225 PAGE 22 BENCHDOG TABLE, DEWALT ROUTER 3.5 HP MODEL DW624 PAGE 24 WADKIN BELT/DISC 16 DISC 63 BELT MODEL BGY/3 PAGE 26 GENERAL LATHE MODEL 260 PAGE 28 DELTA 16 SCROLL SAW VARIABLE SPEED MODEL SS 350LS PAGE 30 KING 3/4 HOLLOW CHISEL MORTISE MACHINE MODEL MA-1012C PAGE 32 DEWALT 7-1/4 FRAMING SAW MODEL DW 378 MILWAUKEE 8 PANEL SAW MODEL 6480-20 PAGE 33 DEWALT 14.4 VOLT 1/2 CORDLESS DRILL MODEL DC 983 DEWALT PLATE JOINER MODEL DW 682 36 Created by Jeff Wilson
PAGE 34 DEWALT 5 RANDOM ORBITAL SANDER MODEL D26453 PORTER CABLE 5 RANDOM ORBITAL SANDER MODEL 343 DEWALT 1/4 SHEET SANDER MODEL D26441 PORTER CABLE FINISHING SANDER MODEL 340 PAGE 35 DELTA BENCH OSCILLATING SPINDLE SANDER MODEL SA350K MAKITA JIG SAW MODEL 4324 37 Created by Jeff Wilson