The dead man Fits between the Top and the bottom stretcher and is used to hold longer lumber so that you can work the edges comfortably. You’ll see this makes sense once you see it finished and in place…
SO Lets make it… If you remember, I offset the Cut for the big dado cut on the top 5/8 from the edge and 5/8 for the width… First you make two pieces…. A back and a front that are 21” and 22” tall ( For my table Height, you need to measure these carefully). You should Fit them so that the Taller one can easily be lifted from the back of the table to its front with out hitting the ^ front rail that is sticking up in the way…. It will never lift out as easily from the front unless its sloppy and you want it tight so that the outside face is FLUSH with the bench side face.
What I did was get them close and cut the ”^” using a Tenon Jig to cut the needed 45 degree on each side.
They are not glued up doing this unless your perfect fit is done.. I am into allot of clamps and being careful… I bought One Stick of expensive Ash to make all my appliances.. I want them to last so I carefully cut and fitted these…
OK that done we glue it up for real and then make it pretty. You need to cut a shape of some sort into the sides of the deadman so that if you get it against a leg you can get it out.. I just shaped my “Dead Lady” with a shapely figure. I then used my Oscillating Round Sander to make it pretty… Which looks like this. Used a Band Saw and a I measured 3” for top and bottom and stuck a line across her form, then used a thin bow-able scrap to make an arch 1.5” in from the middle of it. to scribe an arc. Looked like this after the cuts and fitting again after the glue up.
Now the fun! ( I am trying to be more old school and if you see above the top has been drilled.. More on that later) Anyway you want to scribe to LINES 3.5 or so from the outside edges top to bottom. and then make one about 3” from the top and on the other line add 1/2 or (what ever floats your boat). I did that and then measured 2” from each one.. on both sides and struck the intersections. What you wind up with is allot of drilling!
And then you wind up with a dead man!... You can use a hold down like the one that veritas sells of just a peg to hold your vertical work for working the edges for jointing stuff… at a comfortable “your work bench height ”.
And here she IS!
Now to the mystery of the holes appearing on the bench top!..
-- Duct Tape is the Force! It has a light side and a dark side and it Binds the Universe together!