Workshop Machinery

Whilst most of the work that we carry out as site carpenters happens on site with hand and power tools, a good selection of the components we use are made in a workshop. Traditionally, creating components in a workshop was an expected part of a carpenter's job description. Components such as stairs and kitchens would have been made to order and installed by the same operatives on site. In modern construction, due to the rapid efficiency associated with current technologies, site carpenters are less likely to carry out tasks in a workshop as well as on site. That being said, understanding the wide array of modern workshop machinery is still important from both a safety and manufacturing perspective. Additionally, some of these tools have been adapted into battery powered, portable site varieties that allow for more versatility on site. Without further ado, here is a rundown of the most commonly used workshop machines. 

Edge jointer

Edge jointers are a larger workshop machine that are used for jointing the edges and faces of boards to aid in the creation of square stock for joinery purposes. When creating pieces from reclaimed or pre-machined timber, the first step in transforming the timber into a usable material is to create a straight reference edge. The jointer is used to create this initial edge from which the other edges can be machined. The machine features an infeed table and an outfeed table, separated by a wide rotary cutter. The cutter typically extends across the full width of the table for maximum cutting width. A fence is located at the back edge of the table at 90 degrees to the surface of the table, forming a reference fence to push against. When the depth of the cutter is adjusted upwards from the infeed table, the outfeed table rises to the height of the cutters, to support the planed material as it exits the cutters. On modern machines, a blade guard covers the cutters, being pushed out of the way by the material to allow the cutters to touch the surface of the timber. This spring-loaded guard swings back into place once the timber is no longer covering the cutters, in order to minimise accidental exposure.  

Sharp cutters leave a nice surface finish, typically requiring minimal clean-up after the fact. Once a single straight face is created, other tools such as table saws and thickness planers can be used to create a square piece of stock.  

Band saw

The bandsaw is a relatively compact free-standing machine that boasts an incredible depth of cut. In short, the assembly of a band saw sees a continuous, long, flexible blade running around two cams. One of the cams is powered by a motor, driving the belt-like blade around in a continuous motion downwards towards a height adjustable table. The blade is a long thin length of flexible steel that features teeth, welded together to create a single looped blade. Due to the design of these saws, the maximum depth of cut is much larger than other workshop saws, in essence almost half the length of the total blade circumference. This allows very large pieces of timber to be re-sawn or ripped to width, a task that most other saws struggle with. It can also be used to make standard crosscuts or angled cuts in timber. When thinner blades are installed, the saw is also able to make cuts in tighter space than a regular circular saw blade.

Table saw

Table saws are a staple machine in a woodworking workshop, performing the bulk of the cutting tasks associated with larger component construction. The table saw features a wide flat table surface, with a circular blade that projects upwards from the table. The height of the blade in relation to the table can be adjusted through the use of a dial or handle. Most table saws feature an adjustable fence that sits parallel to the blade, acting as a guide for ripping materials to width. The table also typically features “T slot” grooves that run parallel with the blade and the fence, which can be used in conjunction with purpose-built or manufactured sleds and jigs. In most instances, the blade can also be tilted to the side to around 45 degrees, to make a range of angled cuts. Typically, the opening around the blade will be covered by a zero clearance insert, which prevents any waste from falling into the running mechanism of the saw. Behind the blade, a writhing knife is typically installed to prevent the kerf of a timber from closing around the blade due to internal forces acting within the wood. Without a writhing knife, the internal stresses of a piece of wood can cause the timber to pinch the blade, bringing the machine to a sudden stop, possibly violently pulling hands or fingers towards the blade, or hurling the timber away from the blade.  

The blade of a table saw most often runs towards the operative, pushing the workpiece downwards into the table to prevent it from lifting upwards. This does however mean that unsupported or loosely held material or offcuts can fly backwards towards the operative at speed. This is dangerous and can cause serious injuries in some scenarios. 

Blade guards with built in dust extraction have more recently become the industry standard for these machines, both in terms of respiratory safety and physical protection from the blade. 

In terms of safety, it goes without saying that one shouldn’t put hands or body parts near the blade and should never reach over an operational blade. Push sticks or rubber buffers should be used to hold the workpiece being cut and push it through the blade. By using these tools, we can maintain a safe distance for our hands away from the blade.  

Site table saws have been adapted by a few of the larger tool brands that are smaller and more portable. For general carpentry applications these tools are quite expensive and more of a luxury item. For some more specific applications though, the investment of a small table saw is worth it. An example would include a kitchen fitter having to rip end panels, infill panels, and plinths.  

In terms of machining stock from pre machined timber, the table saw is a useful tool for shaping. With a flat surface having been created through the use of an edge jointer, this reference surface can be laid on the table of the saw and pushed through against the fence to create another flat, perpendicular edge. From here, the other side of the raw timber can be cut flat before moving onto other shaping tools such as thickness planers.  

Through the use of a purpose-built clamping sled, a completely raw piece of timber can be held securely in place on the sled and fed through the saw to create the initial reference edge, in the case that an edge jointer is not available.  

Thickness Planer

Thickness planers are a workshop machine that are used to create lengths of timber and finished boards at even thicknesses. The machine features a belt or a set of rollers that pull the workpiece through the opening, and through the cutters. The cutters are similar to those found on a jointer and extend the full width of the opening capacity of the machine. The height of the opening can be adjusted in small increments to allow for precision thicknessing. The intended purpose of a thickness planer is to produce boards with an even thickness along their length, as well as producing a nice surface finish. In order for this machine to work, the board must already possess a flat face that registers against the rollers. For boards that possess a twist, or are being processed from un-planed timber, preparation of a flat surface must be carried out. This can be done on a jointer, or by temporarily stabilising the workpiece on another flat material. In this method, a piece of flat plywood is used as a base, with shims being used to stabilise the twist in a length of timber. Once this flat stable surface has been established, the material can be passed through the thickness planer to create a flat parallel surface. The length can then be flipped over and planed on the other side to create 2 planed parallel surfaces. This machine is typically used in a workshop for creating custom boards or panels and is rarely used in site applications.  

Larger machines are commonplace in mass production joinery applications. Smaller, more portable thicknessers are available for use in more bespoke applications. The larger machines feature a long outfeed and intake table. The smaller machines typically feature no table to speak of, and so longer materials that are passed through them must be adequately supported.  

Bench grinder/sharpener

Bench grinders are bench mounted rotary machines that can be used for a variety of different tasks. At its core, the bench grinder is a motor that spins 1-2 arbours, depending on the model. These arbours are standardised sizes and are capable of receiving most common bench grinder attachments. Common attachments include buffing wheels, wire wheels and grinding stones. Most grinders feature an adjustable table in front of the wheel that can be used to safely support tools and workpieces that are being worked on. Most commonly in a woodworking context, the bench grinder is used for sharpening tools such as chisels and plane blades. Whilst the general sharpening and maintenance of these tools is typically performed by hand with sharpening stones and strops, the initial setup or restoration of blades may require some more intense treatment. The grinding stone attachment can be used to remove material more rapidly in comparison to hand sharpening. The adjustable table can be tilted to present the blade to the stone at a specific angle. This can be used to create a bevel at a set angle. It's important when using a grinding wheel to regularly cool the blade in water to prevent the friction of the wheel from overheating the tool steel and ruining the temper.

The buffing wheel attachment can be used in combination with an abrasive honing compound to polish the edge of the tool up to a razor sharp, mirror finish. In terms of tool restoration, a wire wheel attachment is a great tool for rapidly removing rust from old tools. 

Drill presses/ pillar drill

A drill press is a free-standing drilling machine that is stabilised in a vertical position. A motor powers a chuck via a speed adjustable cam belt. The chuck of the drill is capable of receiving any standard drill bit. A spring-loaded depth adjuster on the side of the drill lowers the chuck towards an adjustable table attached to the stand of the drill. The table can be adjusted for height, as well as at an angle in some instances. With a workpiece secured firmly to the table, perfect and consistent holes can be drilled into the timber or metal using the drill. These drills are perfect for accurate drilling requirements in a workshop environment, though they see little to no use in a site environment.  

Lathes

Lathes are an ancient form of technology that have been adapted in modern times to an effective woodworking workshop tool. The basic premise of the lathe is a motor that drives a horizontal chuck capable of receiving wide timber stock. A tool rest parallel to the spinning workpiece can be used to safely support woodturning chisels. The spinning motion of the lathe turns the workpiece rapidly. When a woodturning tool is offered to the spinning timber and supported on the tool rest, a concentric shape is carefully created. Wood lathes are used primarily in this fashion for creating perfectly round components such as stair spindles or furniture legs. Larger lengths can be supported at the other end by an adjustable support.  

Belt and rotary sanders

These free-standing workshop sanders are larger variations of the smaller handheld styles that we looked at earlier. Both styles work in much that same way, with a rotating or belt driven sandpaper belt or disc. The machines typically feature a flat static or adjustable table directly in front of the exposed moving belt. This table is used to support workpieces as they are presented to the moving sandpaper. These static machines are more suitable for controlled precision shaping of components. In contrast to the handheld varieties, it's much easier to see what's happening at all times, as the intersection of the timber to the sandpaper is exposed to the operator. As such, it's easier to creep up to a pencil line or make fine-tuned adjustments to components.  

Router tables

Router tables are another workshop tool that are adapted from their handheld counterparts. The router table is essentially just a flat work surface that features an integrated router motor. The chuck of the router faces upwards out of the table. Typically, an adjustable fence is present that can be used to reference timber off of. The height of the router bit above the table can be adjusted via a height wheel. To use the tool, the workpiece is slowly fed into the spinning router bit. Due to the fence and large flat table, this machine is perfect for accurately routing grooves or profiles into lengths of timber.

Mortisers

Mortising machines, also known as slot mortisers are a type of woodworking machine that are used for cutting mortises. Depending on the criteria of the workpiece as well as its size, a couple of varieties of mortiser are available. For smaller components, a special mortice bit is installed in the machine. This bit features a centrally spinning drill bit that removes most of the waste. The bit is housed inside a static square tube, the end of which is sharpened on all faces. As the bit is plunged into the timber, the central bit contacts the wood first, beginning to remove the material. As the bit is plunged further into the timber, the sharpened flute contacts the timber surrounding the drilled hole, pairing downwards around the hole is a square shape. Once the correct depth is achieved and the bit is removed from the timber, a perfectly square hole is left. To create a larger mortise, the workpiece is moved in relation to the cutter, with a series of square holes being made to depth inside the layout of the mortise. In terms of an efficient workshop, this machine increases the speed and rate at which mortises are cut, without sacrificing any of the accuracy.  

In larger applications “chain mortisers” are used to cut deeper and wider mortices. As opposed to a horizontally spinning drill, a vertically spinning chainsaw blade is spun around two gears. The chain mortisers are capable of cutting deep mortises in wide beams. This variety, whilst not exactly on par with the portability of handheld tools, can be used on site for cutting mortises during post and beam procedures.