In some of the other posts in this series, Bob Babcock and I were bouncing around ideas about making this bench portable. I toyed with this and after coming up with some relatively complex ways to make the top removable, the obvious (or so I think) approach dawned on me.
The simple solution is to widen the crosspiece at the top of the leg assembly by 2 inches. Widening the bottom two supports that are part of the bench top assembly is also required. This allows for 4 to 6 bolts to be used on the “flanges” that are created by doing this. The bolting is done in lieu of screwing the two assemblies together with the deck screws as called for in the design.
Here is what it would look like when the top is separated from the legs. The blue element is top of the leg assembly that is widened by 2 inches (from 3” to 5”).
Here is what it looks like assembled.
My rough bolt renderings don’t show the usage of washers but I would recommend it to avoid crushing the fibers.
A detail illustrating the “flange” created by widening the supports. The blue support is not widened, just the green one. The blue and green elements are still joined with deck screws per the original design.

The other aspect of making this a knock-down design is the easy separation of the stretcher from the legs. I didn’t modify the SU for this but it is a simple matter of using bed bolts rather than lag bolts. These can be purchased from a number of suppliers. Here is a link to the ones Lee Valley sells. (Ding! That’s an endorsement.)
I think if the bench is built this way, a person with limited room to work could move their bench around from season to season. When broken down, you have four pieces that can be easily stored (top, planing beam, and two legs). I guess it would really be 6 pieces if you count the two clamp bars the planing beam rides on.
I kinda wish I had built mine this way now. I would be much easier to move when we get a new house.
Whaddya think Bob?
-- Jeff, St. Paul, MN






















13 comments so far
Bob Babcock
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1808 posts in 978 days
posted 826 days ago
Very, very cool…..That will definitely do the trick. The only thing I might add/change is to use big wing nuts to make it quick. I will be moving it frequently. Awesome job…I hope I can make one as nice as what you’ve done…..great Sketchup work too…:)
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
Jeff
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posted 826 days ago
I didn’t think of wing nuts… Good idea. I wonder if T-knobs would be just as good and provide a better grip?
Thanks for the compliments my friend. You’re too kind.
-- Jeff, St. Paul, MN
oscorner
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4572 posts in 1203 days
posted 825 days ago
WEDGED THROUGH TENONS MIGHT BE AN EVEN FASTER WAY TO ASSEMBLE AND TAKE DOWN THE BENCH. GREAT JOB ON THE DETAILED DRAWINGS, JEFF!
-- Jesus is Lord!
Jeff
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posted 825 days ago
Thanks, Os.
You know, the wedged tenon brings up a good question. I’ve often wondered if those are meant to be wedged once and then left alone or if they were created with the intent to be used many times. My thinking is that over time with the slot or tenon will be damaged and the joint loosens. However, since it’s a wedge, you always have thicker stock with which to keep the joint tight.
Does anyone have any input?
-- Jeff, St. Paul, MN
Dick, & Barb Cain
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7034 posts in 1191 days
posted 825 days ago
Very nice Jeff, It looks to me that it should work fine.
I envy you guys with the sketch up skills.
I’m still in the dark ages, with my old drawing board.
-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1
Jeff
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posted 825 days ago
Thanks Dick. I wouldn’t knock that drawing board though. Honestly, I feel there are some things that can be done just as quick if not quicker with the old pencil.
-- Jeff, St. Paul, MN
Dorje
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1768 posts in 888 days
posted 824 days ago
I think wedged tenons could be used over and over and over; wear (or damage to the tenons – or wedges) would be pretty dependent on the hardness of the wood.
-- Dorje (pronounced "door-jay"), Seattle, WA
Jeff
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997 posts in 986 days
posted 823 days ago
I agree. I think it might be a bigger issue with this design since it calls for fir. However, the fibers don’t crush indefinitely. Thanks for the feedback Dorje. I’ve already decided that the next bench I build will be sans mechanical fasteners. Just because.
-- Jeff, St. Paul, MN
Dorje
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1768 posts in 888 days
posted 823 days ago
Yeah – Just because! That’s good enough reason!
-- Dorje (pronounced "door-jay"), Seattle, WA
gizmodyne
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1668 posts in 982 days
posted 816 days ago
Portable looks like a great idea Jeff. However, we are all doomed anyway if we have to move our shops. I would have to hire a separate truck. How do you move a jointer and bandsaw?
-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne
Jeff
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posted 809 days ago
Yeah, that will be a bitter sweet day. I worry about the transport but look forward to the need to do it.
-- Jeff, St. Paul, MN
GaryK
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9521 posts in 880 days
posted 809 days ago
Using wedges could creat one problem. If you knock them in too hard you might split the piece
you’re knocking it into along the grain.
You can prevent this by adding a couple of splines across the grain to strengthen it.
This is an exagrated version if the grain were running from left to right.
If the grain were running up and down you would run the splines perpendicular to the
way they are in the picture.
-- Gary, East TX -- The longest journey begins with a single step.
Bob Babcock
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1808 posts in 978 days
posted 809 days ago
Good stuff Gary and great use of Sketchup to illustrate. A little text and an illustration combined go a long way.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org