The design called for a stretcher piece between the carved medallion and the back board that supports the belts. I thought a through tenon with a wedge on the outside of the column would look really cool. I wasn’t up for making a true through tenon between the round and tapered columns so I decided to make fake through tenons.
After I fit the stretcher to the inside of the columns I marked where the “tenons” would come through the columns and cut a mortise.
After that I fitted the “tenons” into the mortises.
Originally I was going to make the backboard out of solid 3/8” or 1/2” stock. When I resawed some stock for this it sprung and twisted so much that the wood was completely unusable!
These boards were cut from a fairly straight piece of stock. In the photos they are sitting flat on the bench! There is no way I could get a flat backboard out of them.
I ended up making some 1/16” band sawn veneer and laminating a piece of it onto each side of a 1/4” piece of plywood. I banded it with some 1/2” stock which left just enough of a recess to allow space for the velcro straps.
The photo above shows the backside of the back board and the one below is of the front side. I later trimmed the ends to exact the size needed.
Below is a photo of the base piece. I took fewer pictures around this time because I was getting into a real time crunch!
In this photo you can see the keyhole slot I cut into the top piece so we would have a good way to hang it on the wall.
I put PSA sandpaper on the offcut from bandsawing and on a board that I used for a pattern. I then used these to fair the curved pieces.
-- Adjustable Height Workbench Plans http://www.Jack-Bench.com