Installed Shelf Boards
Before I started on the dogs and deaman, I installed the shelf boards. Screwed into the cleats at both ends.
On to the dogs. I followed a diagram I found on the Benchcrafted site (sorry, don’t have link), and made the body of the dogs from jatoba. Springs from ash.
The springs were easy – just sliced off the side of a piece of ash. The dogs were a bit more complex shape. Mostly done on the table saw, with one of the cuts on the bandsaw.
I was planning on glueing up a “sheet” of them at a time and then cutting fully-formed dogs. But my ash board was a different width than my jatoba board so it seemed more efficient to glue them up individually. I did make the dogs 6 at a time.
Glued them together. Because the glue joint is on the angled section I glued them up in pairs so they could act as cauls for each other.
And here they are in the bench. Each dog hole has one, with a couple left over.
They work, but I’m not 100% happy with them. They are not sized properly for the holes, which means there is too much slop when they are being used for clamping. Very easy to make, so I’ll crank out another set.
I had a chunk of walnut I wanted to use as the deadman. It was from the same board as the chop, should be a good match for color. But when I cut it to length, I found this:
Rather than find another board, I think my design can work around the crack. If it fails down the road, I guess I’ll have to make another one.
After flattening the board, I laid out a line every inch so I can get my hole spacing correct. The shape will be curvy, so better to do this now than after the curves are cut. Note the use of the white lead pencil – the layout lines show up far better than regular lead.
Then, time to lay out the curves and holes:
I did the rough layout with regular pencil and when I was happy, I put the final lines in white.
Cut it out on the bandsaw
This is better
Drilled the holes (layout was on the back, btw) and this is the first look:
There is a slot on the underside of the top to hold the top of the deadman, so I made and glued in tabs at the top. They need a bevel on the back to allow them to slide in at an angle, and they are lapped onto the deadman.
Also cut and fit the guide to sit on the bottom runner. It is biased to push the bottom of the deadman out about 1/32” from the runner – so the deadman won’t rub against the stretcher.
The guide is glued on, and at this point the deadman is functional. I still need to fair the curvy bits and round over the edges. And apply some finish.
-- Mark Kornell, Kornell Wood Design