Even a large piece of furniture can have a few small pieces and parts. And if you’re making small projects, those pieces can be an extra hassle to make safely. I’ve gathered up a few of my favorite tips and tricks for small-scale work. They’re all time-tested and sure to help you get the job done right the first time.
Keep It Large
The first principle in small-scale work is to keep the parts large for as long as possible. For example, start with a long or large blank when edge-routing a profile for a thinner piece (far left). Then cut the part away from the blank (left). This way, you have much better control and the piece is far less likely to be pulled from your grip by the router or saw.
Make a Sled
One of my go-to jigs is a small parts crosscutting sled. As you can see in the photo at left, this handy jig is made from cutoffs of hardboard and hardwood. The sled incorporates a fence to keep the workpiece square, a stop for repeatable-length cuts, and a brace for the fence that acts as a blade guard. With this sled, you can easily trim small pieces to length.
Small Tools
Another helpful idea for small jobs is to use a smaller tool. For me, this usually means reaching for my rotary tool and one of the many small-scale attachments available (main photo). It’s tough to match the performance of these tools and all their accessories for getting into tight spaces.
Handscrews
Unless the part is really tiny, a handscrew can usually get a bite on it and hold it securely. I often reach for one when routing a small workpiece (photo at left). The big advantage these have over other clamps is their ability to hold irregular shapes. By skewing the jaws, you can grip almost any part. For an even more secure grip, attach some adhesive-backed sandpaper to the jaws
Pencil Hold-Down
There’s nothing worse than having a small piece grabbed by a blade and shot out from the saw. It can ruin the workpiece and your day. Quite often, a shop-made jig just needs a simple hold-down to keep your fingers safely out of the way of a blade or bit. For this task, many woodworkers rely on the humble pencil eraser. The rubber tip provides plenty of friction to hold a small piece in place during a cut. Best of all, you probably already have several in your shop.
Carrier Board
When it comes to planing very thin pieces (1⁄8" thick or less), an easy and safe method is to attach the blank to a carrier board with double-sided tape. This allows you to use your planer without bottoming out the cutterhead. For the best results, make sure the plywood or MDF carrier board is completely flat.
Small Miter Box
An inexpensive tool that’s become a favorite of mine is the small miter box and saw shown in the photo at right. The box has very accurate 22.5°, 45°, and 90° slots that guarantee your joints and parts will fit perfectly. And the anodized aluminum construction is tough as nails, so it won’t easily bend or distort with use. Included is a high-quality back saw with super-fine teeth (35 TPI). The high tooth count of this saw leaves the freshly cut surface smooth as glass. The combination of the box and saw allows you to stay away from power tools when making small parts.
