LumberJocks

My new Roubo

  • Advertise with us
Blog series by JasonD updated 03-05-2011 09:42 AM 19 parts 36180 reads 66 comments total

Part 1: Legs...lots of sweat, lots of shavings

11-28-2010 03:57 AM by JasonD | 1 comment »

I first got into woodworking a year ago when my wife and I bought our first house. At the time, my son and I built a makeshift workbench using 2×4s, plywood, hardboard, and a $20 vise from Lowes. It’s served me well in building some cabinets for the house, but it’s seriously lacking in a lot of ways. Being a big fan Christopher Schwarz’s books, DVDs, and blogs, I’ve been wanting to build a Roubo-style bench for months. I finally got a break in my honey-do proje...

Read this entry »


Part 2: Working on the top

12-07-2010 07:38 AM by JasonD | 2 comments »

One of the things I’m most thankful for about this project is all the lessons I’m learning, relearning, and getting a new appreciation for. Dimensioning the boards for the top 100% by hand has proven to be a lot of work, but I’m loving every bit of it. Planing these boards has been a real challenge considering that they’re a foot longer than my current plywood + hardboard bench top. I’ve had to be creative and to attack that problem; finally coming up with a g...

Read this entry »


Part 3: Laminating the top (part 2)

12-19-2010 03:56 AM by JasonD | 2 comments »

Still hard at work putting the top together. I recently upgraded the blade in my vintage Stanley #7 jointer plane with an IBC Pinnacle blade / chipbreaker. This made a HUGE difference in dimensioning the boards and getting the faces flat for glue ups. I decided to glue it up in 3 sections each 8” wide. Then one final glue up of those 3 sections for a final full width of 24”. The pieces being glued up for the top top are 61”; which will be trimmed to 60” after the en...

Read this entry »


Part 4: Final glue up of the bench top

12-27-2010 02:39 AM by JasonD | 5 comments »

There were points in this process that I didn’t think I’d get this far. I took some vacation time and spent the past few days trying to get the top finished up. My goal was to have it completely glued up before the first of the year. I’m glad to say that despite a few set backs, I’m a week ahead of my goal. Not only is it a big motivational factor in a long bench building process, but it’ll also allow me to take a few days off to let my achy planing / sawing m...

Read this entry »


Part 5: A minor set back, but happy to have it

12-31-2010 07:46 AM by JasonD | 3 comments »

After getting the 3rd 8” section glued up to complete the bench top, I went to bed, letting it sit in the clamps all night. The next morning, my son and I moved the top onto my old bench so that I could start flattening it. That’s when I realized that the glue-surface face of the last section, while flat, was angled. I was in such a rush (ie: excitement) to get it clamped up that I didn’t realize the problem when I glued it up. Part of the problem was that I didn’t fla...

Read this entry »


Part 6: Beefing up the legs

01-05-2011 06:28 AM by JasonD | 1 comment »

Originally, my legs were going to be 3-3/4” x 4-3/4”. After I got my top glued up, I decided that I wanted a little more beef in the legs. I had enough lumber left over that was already acclimated to my shop. I spent a little time yesterday dressing up the legs and put in a bit of time tonight getting the new pieces planed true and ready to add to the leg laminations. Because of my limited number of clamps, I was only able to get 3 of them glued up so far. Taking a break to wat...

Read this entry »


Part 7: Continuing to work on the legs, 1 step at a time

01-08-2011 07:50 AM by JasonD | 0 comments »

This past week was very busy for me and I only managed an hour a night at best in the shop. I spent most of this early evening cutting a few sheets 3/4” plywood and putting it down as flooring in my attic over the new insulation I put down last weekend. I spent most of my shop time after climbing out of the attic cleaning up and sharpening a few plane blades (just got my first waterstones in from UPS today). I didn’t want to close up for the night without getting at least somet...

Read this entry »


Part 8: Starting on the joinery

01-18-2011 06:09 AM by JasonD | 5 comments »

Because I train and teach Gracie Jiu-Jitsu between 4 – 6 nights a week, I don’t get as much time in the shop as I’d like some times. We had a 3-day weekend this past weekend, but I wasn’t able to get any time in the shop on Saturday. Our head instructor came down from Hattiesburg for a seminar and that is an all-day affair with us all going out to eat afterwards and spending the evening hanging out around a fire in the back yard. I did get to put a good bit of time ...

Read this entry »


Part 9: Leg tenons done

01-24-2011 05:56 AM by JasonD | 3 comments »

I got the leg tenons cut throughout the week and got them trued up tonight. I don’t own a shoulder plane, but I have a Stanley rabbet plane that did the job. I’m going to start working on the stretchers tomorrow; short ones first, then the long ones. I can’t believe that I’m finally getting close to being able to assemble the main structure. Don’t know how much shop time I’ll get over this next week. One of my students has started scheduling regul...

Read this entry »


Part 10: Twisty stretchers, sore shoulder

01-29-2011 09:56 AM by JasonD | 0 comments »

After a very busy week, I finally got some time in the shop tonight to start on the stretchers. The 4 boards that make up the two short end stretchers were fairly flat to start. It didn’t take too much work to get them flattened and glued up. I injured my right shoulder early this week. So, I was pretty excited to find those boards to be flat to begin with. Well, that excitement was short lived. The boards for the long stretchers were twisted pretty bad. Not too bad to toss in the sc...

Read this entry »


Part 11: The base is COMPLETE! (with pics)

02-13-2011 07:12 AM by JasonD | 4 comments »

FINALLY!!! After several weeks of little to no shop time each day, I finally hit another major milestone. The base is complete; glued up and sitting in the clamps for the night. The past few weeks have been crazy for me: new projects at work, a battle with the flu, getting 15 of my students ready for a competition, etc. I was able to manage about 30 minutes of shop time every other night at best. It was 14 days of knocking out one little task after another until it all came to fruition. I ...

Read this entry »


Part 12: Base + top = bench

02-20-2011 07:52 AM by JasonD | 6 comments »

The day started with me cutting the vise chop into shape. I cut the straight cuts with my rip panel cut (as seen in the first pic below). Then, I cut the curved cuts and glued the chop together. I didn’t have any 8/4 stock, but I did have some 4/4 hard maple and red oak left over from previous projects. So, I hand planed them flat / square and decided to cut the shapes out before the glue up. After letting it sit in the clamps over night, I’m going to clean up the sides of the ch...

Read this entry »


Part 13: Knocked several items off the list today

02-21-2011 05:19 AM by JasonD | 1 comment »

I didn’t quite get as far as I’d hope today, but I did make some good progress. I set a goal of getting through my list up to flattening the top, but I decided to put that step off for another day; partly because I put in almost 12 hours of shop time yesterday and my body is HURTING today. My son and I flipped the bench back upside down. Then, I marked out the location of the sliding board jack trench, grabbed my drill and chisels, and got to work. It wasn’t hard, but it ...

Read this entry »


Part 14: Thankful for small victories...or how to eat an elephant one bite at a time

02-22-2011 06:50 PM by JasonD | 8 comments »

It’s funny that no matter how many hurdles I’ve tackled so far in building this bench, I still find myself “paralyzed” with fear when I come fact to face with a big new task….even if it’s a task that I’ve already accomplished in the build. My next major task for the workbench was to flatten the top. This shouldn’t be too hard. For one thing, the boards were fairly close to lined up when the top was glued up. I purposely didn’t spend tim...

Read this entry »


Part 15: Mon Roubo est complet!!!

02-23-2011 06:58 AM by JasonD | 7 comments »

What can I say…when the bug bites, it bites hard! I had about 1-1/2 hours after work before I had to be at the gym for Karate. I got busy with my “scrub” plane (heavily cambered iron in an a modern Stanley #5). I spent about 45 minutes in the shop, got the bench almost entirely roughly flattened, and still had enough time to clean up and get to the gym on time. Well, things went great at the gym (I got promoted! :) ) and came home pretty pumped up. So, I got busy with my ...

Read this entry »


Part 16: Tools used in the bench build

02-23-2011 11:18 PM by JasonD | 3 comments »

Here’s list of the main tools I used in this bench build:- a “scrub” plane (a cheap modern Stanley #5 that I heavily cambered the iron on)- a pair of cheap modern Stanley block planes (LA and regular)- a cheap modern Stanley bullnose rabbet plane- a vintage Stanley #7 Jointer plane that I bought off of eBay- a LV LA Jack plane that I got for Christmas this past year- a cheap Great Neck brand crosscut panel saw- a cheap Putsch brand rip panel saw- a cheap modern Stanley copin...

Read this entry »


Part 17: Continuing the "accessories"...

02-28-2011 08:38 AM by JasonD | 5 comments »

I spent the evening cleaning up and rearranging my shop the night that I got the top flattened and the leg vise installed. For the first time since I moved into this shop, it actually feels and looks like a work shop. Everything is actually in the proper place, as opposed to being thrown randomly some where in the hectic scramble to get our house remodeled so that we could move in last year. After getting everything cleaned up and organized, I started working on some of the remaining acces...

Read this entry »


Part 18: Completed shelf and sliding board jack track

03-03-2011 07:04 AM by JasonD | 0 comments »

Just a quick update tonight. I got the shelf completed and also made / installed the track for the sliding board jack. I chose not to nail the shelf boards down. They are joined with shiplapped rabbet joints; no glue. This way, I can easily remove the shelf to sweep it off, sweep under the bench, etc. I also decided to forgo screws to attach the track for sliding board jack. I made some v-grooved cauls with 2×4 scraps to clamp it during the glue up. I made the 45-deg chamfers on eithe...

Read this entry »


Part 19: Making the sliding board jack with hand tools only

03-05-2011 09:42 AM by JasonD | 10 comments »

I got some time in the shop tonight and was able to get the sliding board jack made and installed. To make the V-groove at the bottom, I first made two cuts down the center with a rip panel saw. Then I cut a 45-deg kerf from the front / back that met those first two cuts in the middle. Finally, I chopped out the middle section and pared it flat with a 1/4” chisel and cleaned up the slopes with a paring chisel. Here’s a picture after the first 45-deg cut: After the sec...

Read this entry »



DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics

HomeRefurbers.com

Latest Projects | Latest Blog Entries | Latest Forum Topics

GardenTenders.com :: gardening showcase