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Blog series by CartersWhittling updated 05-16-2012 02:25 AM 18 parts 116888 reads 185 comments total

Part 1: Design Plans

06-11-2011 03:05 PM by CartersWhittling | 8 comments »

Hello. These are the plans I have for a new workbench. I think I have decided that now is the time to build a bench I won’t need to remake. I have done lots of studing on workbench designs and could not decide between the German bench and the Roubo because of the leg vise. I had some thoughts in mind to making a double sided bench and incorporating both bench designs. I soon came across the Edwards bench. http://woodtreks.com/design-build-traditional-woodworking-workbench-tail-shoulder-...

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Part 2: Materials Obtained

07-09-2011 05:31 PM by CartersWhittling | 5 comments »

Good day. I now have the wood for my new workbench. My friend (who is also building a workbench) and I, drove to Exotic Woods in Burlingtion Ontario a few weekends ago to get the wood for our benches. I have regular hard maple at 8/4 and 12/4 thicknesses. The piece of walnut in the picture I got from a friend and I will be using it for my sliding dead man. I also want to try and aquire some walnut for the leg vise chop and the shoulder vise pad, for added visual interest. I also...

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Part 3: Milling Mostly Done

09-24-2011 02:50 AM by CartersWhittling | 1 comment »

Hello. This is another update on my bench build. I have had almost two months off working on it because my friend has been in my shop working on his bench. But just over a week ago we took his almost done bench to his house for him to do the final fitting of parts and such. After doing a little organizing and sharpening I got back to work on my bench. So right now I have the legs and parts for the top all milled to thickness and width. This is the slab for the roubo half of my bench. Its 2...

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Part 4: Top Glue Up and Dog Holes

09-29-2011 02:42 AM by CartersWhittling | 2 comments »

Hello. I have just finished joining and glueing up the two doghole strips and the top slab. First I milled the 8 3/8” wide slab top to length by crosscutting it roughly and using a router with a straight bit and straight edge to square it up nicely. With the two doghole strips I crosscut them on the table saw. I was impressed to find the saw made an almost perfect finish on the endgrain. I then marked where the threaded rod will go and marked out the position of the dog holes which a...

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Part 5: Holdfast Holes and Spacer Block

09-30-2011 02:50 AM by CartersWhittling | 0 comments »

Hello. This morning I took the clamps off the glue up assembly and scraped the glue squeeze-out off. The joint turned out nice and the top surfaces are all within a 1/32” of being flush. I then chamfered the dog holes and laid out were I wanted the holdfast holes to be. I placed all but the first and last holes, flush to the front of the dogholes, so I can place a batten across a bench dog and holdfast. They are also positioned so the holdfasts reach the edge of the b...

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Part 6: Dovetailing Endcaps

10-01-2011 02:40 AM by CartersWhittling | 3 comments »

Hello. Today I’ve been working on endcaps for the shoulder vise. I started by routing the grooves in the spacer block and in the doghole strip for the spacer block. I then squared up the end of each end cap for the shoulder vise and laid out and cut the tail on the long end cap with the bandsaw. I then transfered the tail and cut the pins with a jig on the bandsaw. And after a little fitting… I then put the rod through the top and clamped the spacer bl...

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Part 7: Top Almost Done

10-04-2011 07:09 PM by CartersWhittling | 3 comments »

Hello. I am now almost done the bench top. The tailvise still needs to be made and I need to glue the shoulder vise together, but the majority of work is done. Since my last post I finished the splines for the shoulder vise and tapped the nut for the vise, and cut the detail out. This is a 2 1/2” diamter nut with 2 tpi. I am making a video of the process of tapping the nut. I also finished the splines for the end caps and drilling the holes for the bolts. The bolts and splines ...

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Part 8: Progress Video 1

10-06-2011 10:21 PM by CartersWhittling | 6 comments »

Hello. This is a video I made to show the details and construction of my bench so far. I go over the shoulder vise construction and joinery. I hope it may be useful to those who may be contemplating bench designs. I will make a few more videos as I progress, and I will have a video or two on making wooden screws and nuts aswell.

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Part 9: Making Wooden Screws

10-08-2011 02:33 AM by CartersWhittling | 57 comments »

Hello. This is a video showing the process I go through to make wooden screws. I briefly try to explain how it is set up and show the jig making the screw. I will soon have a video on making wooden nuts aswell. I will eventually make a video showing how to make the tap and screw making jig and explain how to create the size of screw you want. I’m sure there are many other ways to make nuts and screws but this is how I do it and it works fairly well, the main downside being that I can ge...

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Part 10: Making Wooden Nuts

10-08-2011 04:35 AM by CartersWhittling | 27 comments »

Hello. In this video I show you how I make wooden nuts for my bench with a tap. I explain some of the details about the tap and show you how its used and set up. Again like I mentioned in my last blog entry, I will be making a video later showing you how to acually make the tap.

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Part 11: Tail Vise Has Begun

10-10-2011 04:59 AM by CartersWhittling | 10 comments »

Hello. Since my 7th workbench post I got the shoulder vise done and started work on the tailvise. This is a picture of the vise from underneath. I have the bench top upside down while I am working on the tailvise. I first tapped the nut in the endcap for the vise. If you look at blog post #10 you can see me making the nut for the tail vise at the end of the video. You can see the 1 inch deep notch cut above the nut which allows for the covering of the tailvise to slide over. A...

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Part 12: Bench Dogs

10-17-2011 06:16 AM by CartersWhittling | 4 comments »

Hello. This weekend had I finished up my tailvise and made the bench dogs for my bench. I am currently making up a video to show you the tailvise, so when that is done in the next day or two I will post the finished vise. I made one dog for each hole in my bench. Aswell as a special dog that fits in the first hole in the tailvise for when I need to clamp work that would be to short otherwise. I have a thin strip glued with the grain in the opposite direction to give the extension...

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Part 13: Tail Vise Is Complete

10-19-2011 01:31 AM by CartersWhittling | 20 comments »

Hello. I have now finished the tail vise, and today I had acually started work on the base. After I had got the dovetails for the tailvise fit and the pins on the guide rod I cut out the place for the pins to be inserted in the vise assembly. I then started work on getting the notches cut in the guide blocks for the sliding parts. Here you can see the guide rod in place, with the one guide block attached to the end cap with a notch for the guide rod to slide through aswell as a small notch...

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Part 14: Starting The Base

10-25-2011 12:08 AM by CartersWhittling | 1 comment »

Hello. I am now working on the base for my workbench. I have changed some of the design details since my first concept, but not by much. The main difference is that the two legs on the Roubo side of the bench have tenons that will go into the bench top. The base was going to attach to the top the way most trestle bases do with bullet dowels, but then I realized that when I use the leg vise, all the pressure will be placed on the dowels! So I redesigned the front legs so that they have a tenon...

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Part 15: Base Mortise & Tenons

10-29-2011 06:47 PM by CartersWhittling | 0 comments »

Hello. I have now finished the mortise and tenons for the base and have them all fit. Here are the two base assemblies put together. The assembly closest to view still needs a thin leg installed on its right side. You can see the tenons on top of each assembly which will be going into mortises in the bench top. Here is a view of the leg assemblies from the Roubo side of the bench, with the front legs that will be flush to the bench top side and the tenons that will be mortised into the ...

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Part 16: Base Complete

11-14-2011 02:09 AM by CartersWhittling | 2 comments »

Hello. At this point in time I have the workbench finished, but this post will be about the base. I will make a video going over the completed bench and then post my last blog entry of the bench. Shortly after the last blog post I bought the last portion of wood I needed for the bench. The first piece I worked on was for the underside of the bench top. I made a piece 4 1/2” wide and about 1 1/2” thick to glue to the back edge of the top to make the edge the same thickness as th...

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Part 17: Completion

11-22-2011 05:17 AM by CartersWhittling | 21 comments »

Hello, this is probably my last workbench blog entry, now that my bench is complete! Like I said in my last blog, the workbench has been complete a couple weeks before this post on November 12. With my last post I had wrote about completing the base. After I had the base assembled, glued up, and drawbored I placed the bench top onto the base. Previous to putting the top on the base I had put one coat of boiled linseed oil on the underside of the top. The top is removable from the base, I deci...

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Part 18: Thoughts and Changes

05-16-2012 02:25 AM by CartersWhittling | 15 comments »

Hello. Its been 6 months since I finished my bench and I have spent over 1000 hours on it. Now that I have gotten a good feel for how the bench works and its ups and downs I thought I would write an update on it. To start I’ll mention the modifications I made. The first was to add leather to the pads on the hold fasts. With leather I no longer need to place scrap wood between the work pieces and the hold fasts to prevent denting. If you have hold fasts (which you should) I would r...

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