Power tools are great when it comes to consistent, accurate results. But every power tool requires some sort of setup to get those results. A square and a ruler are often all you need. But it's easy to misread a ruler when you're setting up tools, bits, and blades. To get around these problems, I rely on almost foolproof machinist's set-up blocks.
ACCURACY IN THE SHOP. Set-up blocks have been used by machinists for years. They're more commonly called gauge blocks in a machine shop. But they have a lot of uses in a woodworking shop, too.
Set-up blocks are precision blocks, usually made from brass or aluminum so they won't damage cutting edges. As you can see in the photo above, a set typically consists of five different sized blocks (1/8", 3/16", 1/4", 3/8 ", and 1/2"). For other sizes that you may need you can combine two or more blocks. The nice thing about set-up blocks is that there's no measuring involved. You simply use them as gauges to check distances and set up bits, blades, fences, and other tools.
Set-up blocks are especially handy where space is limited or the area you're working in is obstructed. If you have a job that requires precise setups even in an accessible area, I think you'll find set-up blocks a must-have.
ROUTER SETTINGS. Set-up blocks are great tools for using when setting up a router, whether it's mounted in a table or hand-held. If you need to set the distance of the router table fence from the bit, set-up blocks are pretty handy, as shown in the main photo. I like to use the long set-up blocks on the router table, so they reach across the opening in the insert. You can use the blocks to set the height of the router bit too, as shown in the photo below. I place an extra block over the top of the bit and raise the bit until it grazes the bottom of the top block.
BLADE HEIGHT. These blocks also work well for setting the height of a standard table saw blade or dado blade. You can just grab a plainly marked block or two for an exact measurement and raise or lower the blade until the highest tooth is flush with the top of the blocks. Again, if you add a block to go across the top of the blade, you can raise the blade until the teeth of the blade just graze the top block.
MORTISING MACHINE. I also use my set-up blocks to square the chisel on my mortising machine (photo below). This way, I can set the chisel square to the fence and set the distance from the fence to the chisel in one easy step. For example, if I need to cut a mortise 1/2" from the edge of a workpiece, I can use the 1/2" block to square the chisel and set the fence. Then all I need to do is place the workpiece in the machine and cut the mortise.
If you've never used set-up blocks before, I think you'll find they can be invaluable tools in the shop. Plus, they won't set you back a lot of money - you can purchase a set for less than $20.
A Step Up: Veritas Set-Up Blocks
Lee Valley offers set-up blocks made by Veritas. These anodized aluminum blocks range in size from 1/16" to 3/4". They're clearly marked on the face for easy use.
Just like the brass set-up blocks, these aluminum blocks won't dull the cutting edges of your blades and bits. Plus the anodized aluminum surface is extremely hard so the blocks are practically impossible to scratch or dent. So the blocks will maintain their accuracy for years to come. The black anodized surface also makes a good contrast when it's placed against tool edges.
In addition, the Veritas set includes a 1-2-3 block. This precision ground steel block gets its name from its dimensions: 1" x 2" x 3". The block is a machinist's tool that is also useful in the woodworking shop. Used in combination with the small blocks, you can measure up to 4 11/16" with the set.
An added convenience of the 1-2-3 block is the machined holes. Some of these holes have been drilled out to reduce the weight of the block. But other blocks have been machined to hold a cap bolt for anchoring to fixtures in the shop. I like to use this block to position multiple workpieces for repetitive drilling tasks on the drill press table. It will bolt to any steel machine table.
