Yesterday started with the bench side of the Toolwell. I glued up the back wall the night before and yesterday morning it was time to remove the clamps and rip that to the correct thickness. I decided to do it this way so I could clamp the other side to this one as a cutting guide. It worked pretty well.
A quick pass with the No 4 and it is done.
Then I trimmed up the leading edge where the dovetails will be and started on the mortise in the endcap. I used the same process as the deadman groove. The more I do this the better and faster I seem to get at it.
I was feeling good about everything until I went to fit it to the end of the bench…. I had measured the piece wrong and it turned out to be upside down! Measure twice cut once folks. This could have been a disaster but it looks like this endcap will work on the other end with some tweaking so that is ok I suppose.
So that meant starting a new endcap. Measured 3 times this time ‘round and chopped out another mortise. This resulted in a nice blister on my hammering hand and a nicely fit endcap on the correct end of the bench finally :D
At this point the transition from endcap to the bench bothered me. I decided to fix that with a gap filler between the endcap and the first leg.
I was going to stop here for the day but I got a bug up my arse and decided it was all or nothing and started on my first ever dovetail. I was pretty nervous about this but how hard could it be? It’s just cutting a few lines right? Well yes it is but different. One problem is that the bench top doesn’t fit into my Moxon vise so it had to stay horizontal throughout this process and also the tails are slightly larger than my DT saw. I had to cut holding the saw sideways on my knees and finish the cut with my flush cut saw which is the only other saw with the same kerf size. Made for an interesting couple hours (yes hours lol.)
The pins were a bit easier as they DID fit into my moxon vise unfortunately I have discovered that my fret saw is possibly the worst saw ever manufactured so removing the waste between was a lot of fun… I see a new fret saw in my near future.
Anyway.. I’ll finish this up with the usual series of pics taken during the process. The end result is a slightly loose and kinda ugly joint but I’m actually pretty proud of it considering. I just have 3 more of these joints to do before the bench is done :D The good news is.. now that this is fitted I can FINALLY start on the wagon vise. I am really wanting to get a vise on here of some sort soon to help build the rest of the bench with. Stay tuned and thanks for reading.
-- Eric - http://theidiotgaloot.com