Began working on a workbench for the garage so I don’t have to keep cutting on the floor or my makeshift horses (2 bar stools and the first board I can reach). My plan is to have a laminated top out of whatever wood is available and affordable. A quick run to the local hardware store resulted in the purchase of 30 2×4x10 boards for $60.
I’ve cut and glued the legs down (36” pieces of 2×4 laminated) and spent the day today cutting tenons with a plunge router. That was interesting – and I knew it wouldn’t be as easy as using a table saw (but I can’t afford one right now).
I’d seen my grandfather cut tenons on a table saw before, but never saw anyone use a router for this task. Now I know why. :-) I had 5 boards which both ends needed tenons, making it a total of 10 tenons to cut – 1/2” deep. I wonder if cutting these by hand (with a good saw) would have been faster and easier…..
All-in-all, it took me about 5 hours to cut all 10 tenons. Using a 1/2” router bit I put the fence at 1.5”. I know… this just makes it sound like cutting by hand would have been easier, doesn’t it….
I will say I learned a few things though:
- ALWAYS use safety gear when using a router (ear plugs – I would have ended up with mounds of sawdust in my ears…, good fitting safety glasses, and a respirator)
- using the router wasn’t as scary as I thought it would be
- ALWAYS secure the piece to be cut
- you can never have enough clamps!!
I had difficulties getting the correct sizes on the tenons, but hoping that glue will make up for the difference. Tomorrow: cutting mortises and prepping the tenons for assembly.