New Type of Woodworking System Project Complete

[Mike Goetzke]

The trouble started when I went looking for a new and better edge guide for breaking down 4’x8’ sheet goods. One of the supply houses had what looked like a robust guide rail system at a reasonable price so I ordered one. It’s made by Eurekazone and called EZ-Smart Guide System. I liked that the kit came with a plate that attaches to your circular saw to enable it to track with the heavy-duty aluminum extrusion(s). What is really handy is that you line up your cut line with the edge of the guide rail because this is where the cut will be made (no off-set calculations).

(click on images to enlarge)
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The trouble intensified as I found that Eurekazone had a web page with many unique/clever tools for woodworking. Being a hobbyist / tinkerer I was hooked.

I have incorporated the guide rail system into a precise woodcutting system called a Power Bridge Bench (PBB). By adding an ingenious pivoting bridge kit and customized extrusions, called SME (sliding module extrusion), you can quickly build yourself a compact saw system. What I liked about the system is that there is no set design. The user has the freedom to customize the PBB to his/her specific applications.

Before building my PBB I did lots of research to see other designs and even had unlimited access to asking, even the simplest, questions to the owner of the company –Dino. I quickly got information overload but gave it some time and sketched up my own PBB.

Even though the SME’s generally get fastened solidly to a base table I wanted to add flexibility and make even my extrusions movable. I did this by starting with a 2’x4’ piece of ¾” ply and cutting dados to accept some Rockler T-track that I had on-hand. I cut the dados using a product they call a smart router kit (SRK). This kit allowed me to track my router on the guide rail system. This way I got very accurate positioning of the dados. Plus, since the tracking device is captured on a rail it’s impossible for the router to want to “walk” off the cut. After cutting the dados I screwed and glued the T-track in place.

Since I cut ½” deep dados in the ¾” ply I stiffened the top by building a semi-torsion box (I haven’t enclosed the bottom yet, just in case modifications are needed). I used pocket screws and glue (and my 14 year old son to help drill the pocket holes).

http://img.photobucket.com/albums/v212/mbg/EZ%20Smart/PBB/th_IMG_1251_5_1.jpg (http://img.photobucket.com/albums/v212/mbg/EZ%20Smart/PBB/IMG_1251_5_1.jpg)
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I attached the SME’s to the base by drilling holes to accept 5/16” button head bolts and square nuts that fit nicely in the Rockler T-track. It was easy to get the drilled holes centered since the extrusions have an extruded groove in the bottom along the entire length.

http://img.photobucket.com/albums/v212/mbg/EZ%20Smart/PBB/th_IMG_1248_2_1.jpg (http://img.photobucket.com/albums/v212/mbg/EZ%20Smart/PBB/IMG_1248_2_1.jpg)
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Next I made what are called sliding modules. All they are is ¾” ply pieces rabbited on the ends so they fit and slid between the SME’s. This makes supporting of the work load very versatile

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Then I attached the bridge assemblies to the table and a section of the guide rail to the bridge assemblies to complete the PBB. I didn’t mention above but there are many accessories available that fit the extrusions or you can make your own. The sides of the SME’s accept a standard 5/16”-18 bolt head and the top accepts what are called connectors. The connectors have a double dovetail shape that self aligns in the SME. I then added a sliding fence and some squaring blocks and was in business.

http://img.photobucket.com/albums/v212/mbg/EZ%20Smart/PBB/th_IMG_1271_2_1.jpg (http://img.photobucket.com/albums/v212/mbg/EZ%20Smart/PBB/IMG_1271_2_1.jpg)
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Before making any cuts I had to square the front top SME to the guide rail by adjusting the bridge position at the front and rear. I found a 2’x3-1/2’ piece of 1/8” ply to test on the PBB. I used one clean edge as reference and cut two sides perpendicular to it. Then I cut the other side using one of the newly cut sides. Not only was the width as close as I can read on a scale with 1/32" increments but the diagonals were also as close as I can measure. I also tried it out on some smaller scraps of ¾” ply and equally impressed with not only the accuracy, splinter free cuts, but also the safety the system allows since the wood is stationary and the blade does it’s work from below the surface.

http://img.photobucket.com/albums/v212/mbg/EZ%20Smart/PBB/th_IMG_1282_5_1.jpg (http://img.photobucket.com/albums/v212/mbg/EZ%20Smart/PBB/IMG_1282_5_1.jpg)

My first project will be an aquarium stand for my son’s 55 gallon tank. My son was a big help in building the PBB. He caught on quick to the features of the PBB and actually asked me if I needed my Unisaw any more :eek: . Well it took me 20+ years to justify my Uni so I’m nowhere close to getting rid of it but I think I’ll be doing most if not all of my panel trimming on the PBB.


Mike

[Mike Spanbauer]

Wow, that has to be one of the most ingenious cutting tables I've seen. I like the Festool MFT, but I think yours is a step up. Only thing I could see myself doing is forgetting what I had set the depth of the saw blade to and on my first sheet cut cutdown, running right across the aluminum rails.

nice job!

mike

[Mike Goetzke]

Wow, that has to be one of the most ingenious cutting tables I've seen. I like the Festool MFT, but I think yours is a step up. Only thing I could see myself doing is forgetting what I had set the depth of the saw blade to and on my first sheet cut cutdown, running right across the aluminum rails. Actually the PBB is designed to cut through the SME (it's 3/4" thick so you have a 3/4" margin before cutting into the base board) but the idea is to cut it in the same place by fixing the bridge position. I will probably cut through mine but since it's brand new I'm chicken.

nice job!

mike

Thanks for the kind comments.

[Dale Sudhoff]

This is why I've gone totally EZ. This system is like no other on the market. It lets you design the system to fit your needs. Now everybody else is trying to catch-up.