Another New Jig (I Think)

peterm · Post by **peterm** » Thu Mar 15, 2012 2:05 pm

Has anyone tried making a ZCI out of pieces of laminate flooring? I found I had to cut away some areas on the back to get it to drop in flush but by using the plastic face of the back of the flooring as the top of the ZCI, I got a nice looking result. Warning...easy to cut yourself on the sharp exposed edge of the back plastic, don't ask me how I know this.

dusty · Post by **dusty** » Thu Mar 15, 2012 3:09 pm

prmindartmouth wrote:Has anyone tried making a ZCI out of pieces of laminate flooring? I found I had to cut away some areas on the back to get it to drop in flush but by using the plastic face of the back of the flooring as the top of the ZCI, I got a nice looking result. Warning...easy to cut yourself on the sharp exposed edge of the back plastic, don't ask me how I know this.

I've not done that but only because I don't have any plastic laminate flooring. If it is 1/2" thick and can be milled like any piece of wood or plastic I see no reason why it should not work very well.

Next time I visit the Habitat Store, I'll be on the lookout for flooring.

Changing Subjects just a bit: If you have never visited a Habit Store (Habitat for Humanities retail outlet store) you really need to do so.

The Habitat Stores get a lot of their stuff donated to them from retail outlets (over stock or damaged goods). They then re-market it at unbelievable prices. If you visit frequently and have patience to wait, I believe you could build a house without going anywhere else.

They also accept donations of just about any description from the general public. They give you a "tax deductible contribution" receipt in exchange for your donation.

pennview · Post by **pennview** » Thu Mar 15, 2012 3:43 pm

Yes, I've used plastic laminate flooring to make ZCIs, but not for the Shopsmith. They work very well and are quite strong. And, the wood glides over the smooth surface after waxing. If you make some, I'm sure will like them.

I still have a few ZCIs for the Shopsmith made out of hardboard, so I'm not likely to make any out of laminate any time soon.

gchapman · Post by **gchapman** » Thu Mar 15, 2012 10:23 pm

I made some for the Mark V out of 8mm leftover flooring that matched perfectly without shims or sanding to thickness, it was exactly the same thickness as the original insert. Cut slightly oversize on the bandsaw and used a router with a flush cut bit against the original insert to finish. Marked the holes and drilled for the hold down screws.

dusty · Post by **dusty** » Fri Mar 16, 2012 8:24 am

Without cutting the first piece of wood, I have (for the moment) abandoned this particular jig idea. This was to have been used with the belt sander which has a very small table.

To take advantage of the larger table surface (safer support of the work piece) I have switched to the flat disk sander and the Mark V. Concept has not changed but application has.

I have made many ZCI on the belt sander but they were always one or two at a time. It is when one starts pushing quantity that issues arise. I don't need self induced issues.

hjlssfor1 · Post by **hjlssfor1** » Fri Mar 16, 2012 9:19 am

Dusty, what material do you use for making your inserts?

Thanks, Hank

dusty · Post by **dusty** » Fri Mar 16, 2012 10:02 am

hjlssfor1 wrote:Dusty, what material do you use for making your inserts?

Thanks, Hank

I have been using 1/4" hard board (from Woodworkers Source) but it requires a shim. I use a black duct tape for the shim.

I have a piece of hardwood veneer (both sides) that I am about to try.

terrydowning · Post by **terrydowning** » Fri Mar 16, 2012 6:11 pm

I knew I kept the left over from my recent flooring project for a reason!!

dusty · Post by **dusty** » Fri Mar 23, 2012 7:23 am

dusty wrote:Without cutting the first piece of wood, I have (for the moment) abandoned this particular jig idea. This was to have been used with the belt sander which has a very small table.

To take advantage of the larger table surface (safer support of the work piece) I have switched to the flat disk sander and the Mark V. Concept has not changed but application has.

I have made many ZCI on the belt sander but they were always one or two at a time. It is when one starts pushing quantity that issues arise. I don't need self induced issues.

This project has been a bust even though it seems too simple to bust. The rotating disc just does not handle this task as nicely as doers the belt sander. I'll probably revert back to the belt sander for this task.

I do need the ability to turn out ZCI with little or no effort.

The biggest problem is because the force from the disk tends to relocate the jig on the table. The jig rides in a miter track and I did not include a way to lock it in place.