While chatting with someone here, there was some interest in what I’m doing. So, here’s what I’m doing. I’m building a workbench, out of 2×4s.
Unfortunately, I’ve only recently learned about a thing call “moisture content,” the fact that 2×4s aren’t as dry as hardwood lumber, and will therefore tend to warp as they do dry unless you do something about it, and what to do: sticker them.
The result is as you see: not a straight, flat, or square board in the picture. Not even the near pipe clamp, which is partially hidden under the workbench, but is about as straight as a banana. I can’t fully close that gap between the two sets of glued-up planks, so I’m going to screw them into the runners and hope they stay.
I found if I tried to pull the gap closed, the plank would pull up, which is why I’ve got the C-clamps there. I need them to be flat more than I need them seamless. At the end I’ll route an even channel in the voids and fill it with some more wood.
Here is the base, with holes drilled for my router’s plunge base, and a hole for the massive straight bit.
Here are two pieces that will cradle the pipes.
There aren’t any holes in them yet, because I didn’t think when I purchased the 3/4” pipe that this isn’t the diameter of the outside, which I calipered to 1 5/64”, but I’m going to purchase a 1 1/16” forstner bit.
Four pieces will be holed out to that size all together, the other two being attached to the pipe ends to keep the pipes at a constant width apart from each other.
Here is one of the pipes.
Here is my router, with the massive bit installed, and the plunge base. I like this router.
So, the pipes will span the width of the workbench, and they will ride along some extruded aluminum 80/20 that I purchased for the task. This is only one inch square, and I now realize I should have gotten something larger that doesn’t flex so easily. I’ll have to brace it somehow.