Workbench Build #38: Final Assembly of the Top...

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Blog entry by Airframer posted 08-11-2013 05:34 AM 1852 reads 0 times favorited 9 comments Add to Favorites Watch
« Part 37: Finishing up the Toolwell... All downhill from here.. I think.. Part 38 of Workbench Build series Part 39: Stretchers and Shelf »

I couldn’t wait till tomorrow to put the top together. This did not go without it’s fair share of oh sh#t moments one of which almost had me starting the whole thing over almost.. But I’m getting ahead of myself..

I had planned to use pegs instead of bolts. I am trying to keep the number of mechanical fasteners to a minimum on this so lets have a go at it..

Marked out the location of the peg holes and drilled just the end caps..

Then fitted them and marked the hole locations on the tenons..

After they were marked I marked slightly inboard of that mark to suck the ends up nice and tight to the bench top. I drilled these out all but one hole slightly elongated to allow for expansion.. I might have f’d that away but we will see how it goes..

After that I drilled for the pegged dovetails. I chose to peg these as well as glue them because of how loose they are from my stunning handy work..

This required some specialized equipment lol..

Then cut and shaped some pegs and went to work gluing this up..

Which went fine until I was pounding the peg into the front left corner dovetail. I wasn’t paying attention to the bottom of the dovetail until I heard a crack split noise ( we all know that noise ) .. apparently something had shifted quite a bit since I drilled the hole and the bottom hole did not line up with the rest and I had beat the peg straight into the bottom pin splitting it off of the endcap.

After unleashing a flurry of profanities I quickly cut the bottom of the peg flush with the bottom tail and glued up the split before it completely let go of the endcap.

This…. I did not get pictures of but it glued up relatively seamlessly and since it is not on the wagon vise end I am not too worried about it.

So after letting my heart get back into my chest I finished up the pegs and cut some shims for the dovetails..

Just needed a few LOL!

After those dried I flush cut the dt’s with the bench and couldn’t resist trying it with the legs on.

Pretty exciting to get it to this point.

But I still have a ways to go before I am allowed to use it for anything…

Gotta keep the eyes on the prize and not get distracted lol..

-- Eric - "I'm getting proficient with these hand jobbers. - BigRedKnothead"

9 comments so far

View Tugboater78's profile


2746 posts in 2219 days

#1 posted 08-11-2013 06:30 AM

GitRdun! Glad nothing completely devastating happened.

-- "....put that handsaw to work and make it earn its keep. - summerfi" <==< JuStiN >==>=->

View Don W's profile

Don W

18754 posts in 2595 days

#2 posted 08-11-2013 11:36 AM

Its getting close now.

-- - Collecting is an investment in the past, and the future.

View Buckethead's profile


3194 posts in 1896 days

#3 posted 08-11-2013 01:25 PM

I’m highly impressed with the determination you have displayed in this build. I really don’t know how you are managing it. I’m guessing you stayed up late last night. Ant the bench looks beautiful. I am sure this had to be a very exciting night.

I think you just gave me an epiphany! A to do list!

-- Support woodworking hand models. Buy me a sawstop.

View kenn's profile


810 posts in 3747 days

#4 posted 08-11-2013 02:41 PM

The main problem I seem to have with my to do list is that crap gets added faster than I can cross stuff off! Looking good, keep at it and you’ll be making stuff soon.

-- Every cloud has a silver lining

View Airframer's profile


3043 posts in 1981 days

#5 posted 08-11-2013 04:31 PM

The list came about because I didn’t want to forget or skip an important step at this late stage in the game. I realized last night I should have waited to assemble the tool well until the base was finished so I could drawbore the beck legs in. Now I’m going to have to wedge them. Not a major setback but could have been avoided had I just thought ahead a bit.

-- Eric - "I'm getting proficient with these hand jobbers. - BigRedKnothead"

View theoldfart's profile


9743 posts in 2479 days

#6 posted 08-11-2013 04:48 PM

Eric, end in sight! And remember “follow the List, Eric” (star wars voice in your head)

-- "With every tool obtained, there is another that is needed" DonW ( Kevin )

View Mauricio's profile


7144 posts in 3179 days

#7 posted 08-12-2013 03:33 PM

Looking great Eric, the DT’s look a lot like the ones on my bench.

Great to see another splayed leg bench come to life!

-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

View Smitty_Cabinetshop's profile


15369 posts in 2646 days

#8 posted 08-12-2013 03:52 PM

I’ll say it again: that top is beautiful… And good on you for creating a punchlist and holding out for completion. Very tough to do, but I know how effective it can be to prevent an attack of “90% is good enough”...

-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive --

View sb194's profile


196 posts in 3046 days

#9 posted 08-12-2013 06:58 PM

I almost lost it when I saw the pictures with the shims. That was classic. Trust, mine will probably need the same thing done to it.

Looking forward to the finished bench.


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