Early PM Shop Notes Projects

So here is the third file I made up from those early (1905 - 1930) PM Shop Notes volumes. This file is not as large (41 pages) as the other two. Pickings were slim after pulling all the Romig plans for the other file. Never the less, some of these are more interesting than practical today, but thats an opinion,some may find many of them worth challenging, like the tool box below.

To complete this little collection, click Early PM Shop Notes Projects  to download. 11 MB - pdf

So as mentioned before their is enough content on this site now, that someone looking for projects to build, should have no trouble finding something of interest here.

There is a lot of work I need to do around the place and get my hands dirty on, and I want to fit in a few good road trips this summer, so I will be posting a lot less.

First on the list is dismantling my old Cavalier. It runs fine but the suspension and body have seen better days. I could repair and resell, but used Cavaliers, 15 years old, aren't worth much. I offered it to family for "FREE" but nobody bit. Ha ha. I guess I can use some parts for my sawmill build. The motor still runs great, not sure what I will use that for yet. Hows a 142 HP lawnmower sound? lol, lol not really.

Cheers

Plans By J. V. Romig

During the early 1920's Joe V. Romig was one of the most prolific authors of plans and articles for the home diy'er, His plans and articles were published in both Popular Mechanics and Popular Science.

This 69 page file covers the majority of his work. I left some of it out, like a 8" jointer, the 2 knife square head is considered unsafe today, and a table saw, with limited adjustment (Joe was not a woodworker). I also left out some industrial sized cranes and farm equipment that were to far off topic here.

A few of his plans incorporate concrete for mass, a method developed during the first world war to get around material shortages. Since then their has been a bit of a revival with a few sites using this method to build mass in machine tools and avoid cast iron.

So I hope some will enjoy this collection of plans. Many of them are still very practical for the small hobby shop.

To download this file click Plans By J. V. Romig 15 MB - pdf

Short Plans From Pre 1930 Shop Notes

So as promised here is a 71 page collection of short plans and ideas from the pre 1930 PM Shop Notes. The 26 previous Shop Notes volumes (1905 - 1930) are widely distributed around the web and at least one company, Algrove Publishing, has reprinted them.  For this reason I did only the post 1930 uploads in my previous posts. For those who have not accessed these volumes but have some interest in what might be in them, here is a collection of short (less than 1 page) but more outstanding plans and ideas in these volumes. There are 2 more files coming with larger projects including one devoted to J. V. Romig and his plans.

To download click Short Plans From Pre 1930 Shop Notes 13 MB - pdf

Disk And Spindle Sander Plan

So I am pretty sure I included this plan in a previous Popular Mechanics post. I found this plan today in my Plans-Projects-Models file, the resolution is better than the previous file and my new software cleaned and straightened out the file nicely. This is an advanced very heavy duty machine for the larger workshop. With a good finish you would never know it, but the machine is all built from laminated plywood. The drive components are mostly hardware store stuff, bearings, shafting etc. The double shaft motor is harder to find new, but if you can find a salvaged 1 hp grinder (usually 10") that would be perfect. Failing that a regular motor with an extra idler shaft mounted above the motor will give you drive from both ends. One thing I would change is the disk to a 12" or 16" disk, it would be easier to find replacement disks for these sizes, and would be better sized for 1 hp. Size your spindles to accept standard size sleeves for easy replacement. Or another option is to order and adapt a set of spindles from a machine supplier like Busy Bee .

Shaker Chair - Engine Hoist

So I am shooting for 31 posts in 31 days, be there tomorrow ha, ha. Well the bloom is off the rose and I can check "web site" off the bucket list. I'll continue to do the occasional post of interesting info. or completed project from my "have to build" endless project list, but I need to focus my attention on other matters.

So the first of two nice projects today is a authentic Shaker swivel chair from the 1974 Mechanix Illustrated. Very nice.

The second project is something every metalworker can use, not just for lifting engines. This engine hoist is a good example (from the April 1983 Popular Mechanics magazine) of how many of these early designs are being cheaply reproduced for the import market. Most importers carry a $200 version of this hoist. You can still build it for less than $200 and have the satisfaction of building it yourself.

Solutions For The Small Hobby Shop

There are many people who would like to practice hobby interests but are often limited by the space available. Model making, toy construction, small wood and metal craft interests do not require a large shop or dedicated machines that eat up floor space and produce lots of noise and dust. Hand tools and portable power tools are more suitable for a spare room apartment shop or a small basement space or outdoor shed in a typical townhouse. So the challenge is to set up an efficient method of working with these tools in a smaller space.

I have assembled this pdf with plans from a couple of sources, (1989 Popular Mechanics Yearbook, and 2012 Fine Woodworking Tools And shops) that together make for one solution to the limited space workshop.

The set up consists of three constructions. All three are on mobile casters so they can be moved around to utilize your space or tucked off to the side when not in use. The first is a power tool table which will allow you to set up two portable power tools as stationary power tools at the same time. With the right adapter bases you can run any portable tool as a stationary tool, lots of storage, nice design, looks solid and accurate. To compliment this table is a small-parts cabinet that doubles as a out feed  support for the circular saw. Lots and lots of storage for all those small nails, screw, nuts, bolts, and parts that accumulate over time. The third piece comes from FWW’s Tools And Shops. No shop could be called a shop without a workbench, the problem is most good ones are large and heavy. This design is unique and perfectly suited for the small shop. Made from mostly sheet material it incorporates a wet dry vac. combined with a commercially available cyclone collector for dust control. A solid top with a unique inexpensive clamping system and convenient power access for your portable tools.

A small shop equipped in this manner with good quality portable tools would provide all the needs for a hobbyist to produce some nice work in a small space.  I could go on about how a band saw and a drill press would be nice but that would be getting beyond the scope of the small shop. Smaller bench top units could be easily incorporated into this set-up.

To download the pdf click Solutions For The Small Hobby Shop - 6 MB - pdf. 

Band Saw Users Guide

So from the 1989 Popular Mechanics yearbook comes this nice band saw users guide. The band saw is in most opinions the most useful machine in the shop. It can do most cuts that other machines can and much more. Crosscuts are limited by the throat depth, but there is not much else that it can't do.

There are many user guides out there, this one stands out for it's nice table extension plan  and a great circle cutting guide plan. I have seen many different circle cutting jigs, this one is easy to build, the two eccentrics make it accurate and easy to adjust.

Click to expand, click again for best view. 

PM Yearbook Projects Part 2

So here are a couple more projects and an article from the PM 75-82 yearbooks. So I will start off with a clear but too short article on Ohm's law.

The 1 HP = 746 watts statement can be deceptive and would have benefited from further explanation. This only applies to a 100% efficient system. A heating element is 100% efficient. Most other electrical equipment is not. Motors are generally 65% to 75% efficient at the shaft output. Some claim efficiencies as high as 82 or 83%.

As a general rule I look for a 10 Amp draw at 115 Volts per HP give or take a bit. This gives you 1150 watts, which equals 65% efficiency. Also be aware that starting loads can be two or three times higher. Modern breakers usually have built in time delays to compensate for this. Imports will often only include voltage and HP on their labels. Their's a very good chance they are using Ohm's law to determine HP disregarding the actual efficiency of the motor. The only motor which can approach 100% efficiency would be one constructed from superconductive materials, and superconductivity at room temperature is still many years if not decades away.

If you have a small lathe and basic welding equipment the next project is very useful around the shop. You can make quick and easy scroll work, hooks, brackets, and decorative metal work with this solid metal bender.

The next project is also very useful in the shop and around the house for producing accurate square cuts in  many different materials from glass to photo mats, and this cutting board conveniently folds up for storage.

Popular Mechanics Yearbook Projects

So as promised here is the plan for a cider press. The plan also includes a plan for a cider grinder,so if you want to make your own cider, you will be well equipped  with these plans. These are my own scans from the PM yearbooks so resolution is very good down to the material lists. If anyone wants to build any of the previous shop notes plans but finds the resolution lacking for the fine print, like that in the material lists, drop me a note and I will try to find it in my encyclopedias or yearbooks and upload a better scan.

Click images to expand and then click again for best view.

Here are a couple more interesting plans from the same 75-82 period, that I feel better about uploading, since I can control the quality of the upload. The first is a plan for a shop-built polisher. After uploading the tumbler and faceting machine plans I would be remiss if I didn't include this one. A tumbler does a good job but takes a long time, this vibratory polisher accomplishes the same in one quarter of the time. Looks complicated but it is not, an easy construction for what you get.

Here's a blast from the past. Remember spirograph, it was a popular toy from many many years ago, it came with different size plastic gears to produce a variety of designs. This plan is much more robust and will survive in the shop for, in addition to pen and paper creations, you can use a diamond point grinding wheel dresser to engrave metals for an outstanding finish.