DocK16's Blog at LumberJocks.com

Woodworking Bench #5: Adding End Caps

DocK16 — Sun, 15 Nov 2009 03:51:00 GMT

Work on the bench continues with attchment of the endcaps. I posted this picture primarily to show this little trick on how to extend your bar clamps since most of us don’t keep 7 foot clamps around. I’m sure this is old news to most but for those who have never tried it, it’s a nice trick in a pinch.

The cherry end caps are held on with double half inch splines. Getting these to line up was a little tough.

Thanks for lookin.

Woodworking Bench #4: A Perfectly Flat Top

DocK16 — Thu, 12 Nov 2009 04:12:34 GMT

Moving along with the woodworking bench. The previous blog showed the final glue up of the laminated top. even planing the sections before gluing didn’t lead to a perfectly flat top. So that leads to the 64 million dollar question, how do we get it flat. Since I don’t have 40 inch wide planer or sander I guess we’ll have to look at other options. One method is to cross plane it with a fore plane or jointer plane (a very long bench plane). As I don’t have a bench plane larger than a #5 bench plane, I decided this might be an opportunity for a new tool. Lie-Neilson fore plane $425. Since this iis more than I’ve spent on the whole project so far I decided to pass. I’m not that good with a hand plane anyway. So I turned to the guys a Fine Woodworking.com. The answer was to make a sled for a router with a flat bottom bit. Succesive passes over the top of the table knocks off the hight spots.. Picture below shows the jig, just to the left of the jig you can see the marks from the router passes about every inch. To the left of that is the marks are gone after light sanding with and orbital sander.

You can see how the router slides bach and forth in the jig staying at a level setting while the entire jig moves left to right on rails clamped to the assembly table top and sides of the bench top.

The result is a perfectly flat top side to side and front to back.

Next week I hope to attach the top and the front and tail vises. Thanks for looking

Woodworking Bench #3: Finishing andFastening the Ttop

DocK16 — Mon, 02 Nov 2009 01:59:52 GMT

Work on the work bench continured this weekend but slowly. The top was originally glued up in 5 sections each being planed before all were glued together. A few pics of the process.

Yeah it’s real heavy top alone is close to 200 lbs and 40 board feet of lumber

Okay so here’s the kicker. When gluing up the 5 sections it is done face down on the assembly table. Unfortunately when I took the clamps off and flipped it over I big Boo Boo. I had not flipped over the one plank with the dog holes for the tail vise. You will see how the dog holes don’t line up with the others for the face vise. I was about ready to run it thru the band saw and retro fit the 3 tail vise sections but after thinking about an easier fix it came to me. Drill some 3/4 inch plugs and fill the goofs and drill some new holes. Now I just gotta find a 3/4 inch plug cutter.

I thought I was real careful when gluing up the sectons and expected the top to be dead flat; NOT. A quick check with a straight edge revealed a fair amount of planing will be needed before this top will be flat. Might be an excuse for a new jack plane and a video of the process.

Lastly the top will be applied with 4 threaded inserts into the underside of the top and bolts up thru the base.
threaded inserts

Next: flattening the top and addding the vises. (still on order)

Woodworking Bench #2: Base finished

DocK16 — Sun, 25 Oct 2009 02:22:26 GMT

I spent most of today (Saturday) working on my Woodsmith Workbench, and didin’t get very far. I was abe to finish the base and man isi it heavy. The stretchers lock in with wooden keys and even without the top the base is very sturdy.

It took two to lift ijust the base down from the assembly table

I alternated the cherry/maple wood on the lower shelf to match the top.

It may appear a little short in this picture but there are some spacers to be addded which will add a few inches to the height. I also shortent the table by 10 inches to save space. I hope that wasn’t a mistake.

Woodworking Bench #1: Maple and Cherry work bench

DocK16 — Sat, 24 Oct 2009 04:58:12 GMT

I have always used my assembly table as a work bench but after recently acquiring a truck load of hard maple from a local farmer the first thing I decided to build was a new woodworking bench. I’m using the plans from a recent issue of Woodsmith Magazine. The first picture is half the top, a mix of hard maple and cherry. the other half is standing in the background.

The base is also hard maple glued up from 4/4 stock

As it’s supposed to rain all weekend I hope to be able to post some finished pics by Sunday.

Bee Swarm

DocK16 — Mon, 06 Jul 2009 23:24:39 GMT

Some of you know I am also a bee keeper in addition to woodworker and keep numerous hives around my shop. This past spring I had numerous swams where large amounts of bees leave the hive to start a new colony. I was able to record this phenomenon last month which is difficult as it lasts for only a few minutes till they disappear out of site unless they lite close by as in this case. I know this isn’t woodworking, I offer this video to those who have never witnessed this phenomenon of nature. Make sure your sound is turned up.

Entertainment Center #7: Finished (well almost)

DocK16 — Wed, 18 Mar 2009 21:11:18 GMT

This is the last blog on my Media Center Project as taken from Woodsmith Magazine late last year (with a few changes) I’m still waiting on some back ordered hinges from Rockler. I wanted to get this into the house for the Super Bowl but I guess March Madness will do. Wifey not too hot on the spalted panels, but she may have to live with them. Final version turned out to be quite massive having to add to height and width to accomodate larger TV than original Woodsmith plans. Bring on the Madness, my recliner and I are ready.

Entertainment Center #6: "Finishing" Up

DocK16 — Wed, 11 Feb 2009 04:03:40 GMT

I can see light at the end of the tunnel with this project but still have hardware and lighting to pick out before final assembly. It has been several weeks since my last blog but a cold snap and empty propane tanks makes for slow work. Plus propane is still going up in price not like gas. Throw in a computer crash (I’ve been gettin my LJ fix on the office computer) and it really slows down the blogging and comments. I was able to start the finish work this past weekend after several samples/tests to get the final look. I will save my finish process and critique for the final blog. Here are some progress pictures.

Entertainment Center #5: Seeing Double

DocK16 — Thu, 22 Jan 2009 00:28:47 GMT

Haven’t posted any updates to this blog series due to home computer crash, so I’m borrowing my son’s laptop to post a few pics. I stated in my last blog I hoped to do something to the original plans to make this a unique piece. I’ve been saving a large piece of 8/4 spalted maple for something special and I think this is it. I was able to resaw it twice and get two bookmatched pieces for the doors and enough to finish the drawers. Other progress includes trim work assembly of the over head “bridge” piece. Still working on the crown molding and other smaller trim pieces.

Here is the spalted maple after 2 resaws.

Spated panels applied to doors and drawers

A closer view of the panels and doors.

Glue up of stacked molding including crown molding.

Case work dry fitted with bridge installed.

Original plans from Woodsmith.

Entertainment Center #4: Twin Towers

DocK16 — Tue, 06 Jan 2009 05:12:21 GMT

Casework is complete ending construction of major componets, twin towers on either side of the center console are starting to show the final form. The center piece will be fitted between the top of the towers forming a connecting bridge. Still a long way to go with most of the trim, all the finish work, hardware, glass, doors and panels remaining. I have been thinking of ways to make this piece a little unique and I hope to have a few suprises before it’s all done. Thanks for following along.