So my 3 sheets of veneer arrive and I open them to inspect them. I opted to use 2 ply 4×8 sheets to save time vs. laying up my own veneer. Out of the 3 sheets I rejected two, one walnut sheet which was supposed to be flat cut and the maple sheet which I paid a premium for to have wider leaves. The walnut piece didn’t have any cathedraling in it at all and was made up entirely of the quartered portion of a flat cut piece of veneer. The supplier worked with me to get me replacement sheets ASAP. Honestly Joe at Veneer Supplies has to have some of the greatest customer service I have ever encountered. He totally gets it. I decide to keep one of the walnut sheets and use it for the inside of the storage case. I chalk out the sheet and cut it into pieces.
I veneer one side of each panel and clamp them up. I stack them on top of each other separating them with wax paper. I use one of the slab legs for added weight. The 75lbs comes in handy.
My replacement veneer arrives a few days later and I am able to veneer the other side of the panels that will make up the case. I also veneer the slab legs. I then attach 1/4” thick maple solids to each end of the slabs encasing them entirely in maple. I oversize the solid maple and then use my block plane to bring the edges flush with the veneer. I then use a 1/8” round over bit to soften the edges.
I then drill for the vertical dog holes in the side of the right leg.
The slab legs receive two coat of whip on poly. I will follow up with a few more coat once the base is assembled.
I next turn my attention to the construction of the case. With both sides of the top, bottom, back and fronts veneered I drill the sides for the 3/8” x 2 1/2” lag screws that will attach the case to the legs. The sides of the case are unfinished as they will not be seen. I recess the washer to be flush with the side of the case and mark the center lines for the drawer slides. 
I then use my pocket hole jig and drill for the sides of the case.
I also rabbet the back of the sides, bottom, and top to accept the 3/4” back panel.
I glue up the case and add the 1/4” solid edge to the front side using blue tape as clamps. I miter the corners. Once dried I flush the edge to the case using a flush trim bit on my router and soften the top and bottom edge.
everything gets sanded and then the case receives two coats of tung oil to bring out the grain of the walnut.
Now for the fun part, assembling the base. To aid in the assembly I make a quick riser out of mdf to set the case on. I level the glides and then attach the case with 4 lag screws into each slab. I remove the riser and test for any lateral movement. Sure enough this thing is solid!!!
!
I couldn’t resist seeing what it looked like with the top on (obviously without the apron yet). It is starting to come together. Next up the top.
-- Brian, Folsom, CA http://www.brianfullerdesigns.com
18 comments so far
PurpLev
home | projects | blog
2733 posts in 541 days
posted 212 days ago
looks great! gotta love that walnut grain, and those clean lines on this bench give it a beautiful balance.
-- When in doubt - There is no doubt - Go the safer route.
GaryK
home | projects | blog
9521 posts in 881 days
posted 212 days ago
Great looking job so far. Looks nice and clean.
-- Gary, East TX -- The longest journey begins with a single step.
EternalDesign
home | projects | blog
141 posts in 888 days
posted 212 days ago
awesome
-- Brian, Eternal Furniture & Design http://www.eternal-furniture.com Repurpose Reclaim,Stay Green
Damian Penney
home | projects | blog
1030 posts in 884 days
posted 212 days ago
Hadn’t caught this before. Really cool looking – bit flimsy though ;)
-- I am always doing that which I can not do, in order that I may learn how to do it. - Pablo Picasso
bfd
home | projects | blog
418 posts in 700 days
posted 212 days ago
Thanks guys for your comments.
-- Brian, Folsom, CA http://www.brianfullerdesigns.com
pommy
home | projects | blog
951 posts in 584 days
posted 212 days ago
thaqt looks cool can’t wait to see the finished piece
Andy
-- cut it saw it scrap it
spanky46
home | projects | blog
736 posts in 283 days
posted 212 days ago
Very nice so far!
-- spanky46 -- Never enough clamps...Never enough tools...Never enough time.
jlsmith5963
home | projects | blog
180 posts in 241 days
posted 212 days ago
bfd I have a question regarding the feet. Are they side mounted to the particleboard and if they are, are you concerned that the way they are attached will have enough holding power over time (and abuse)?
-- criticism: the art of analyzing and evaluating the quality of a artistic work...
Scott Bryan
home | projects | blog
20586 posts in 715 days
posted 212 days ago
Brian, this is looking good so far. This is going to be a nice tool when you get finished with it. It will not only be functional but it will also look good as well.
I am looking forward to seeing the next post.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
Napaman
home | projects | blog
3482 posts in 970 days
posted 212 days ago
wow…brian this is so great…i love the photos…and flimsy is not on my mind…lol…
cant wait to meet you tomorrow…!!! Bring your bag!!!
-- Matt, Napa, CA...fun is beautiful...just trying to have some fun...
bfd
home | projects | blog
418 posts in 700 days
posted 212 days ago
Hi jlsmith5963,
I am not too worried about the feet they are secured to the particle board with 6 screws. With the addition of the metal lip that laps over the bottom of the side I don’t anticipate any strain or failure over time. If that lip wasn’t there to transfer the weight I would be very worried but these glides are designed for this exact application and are rated to 1000 lbs each so they should hold.
-- Brian, Folsom, CA http://www.brianfullerdesigns.com
Moai
home | projects | blog
721 posts in 286 days
posted 212 days ago
You did a great Job Brian, the bench looks awesome, so well built in every single detail! congrats!
-- Francisco Luna, San Francisco Bay Area.
bfd
home | projects | blog
418 posts in 700 days
posted 212 days ago
Hi Matt,
Looking forward to meeting you and the others tomorrow. I learned how to build a flimsy bench from this post from Damian! lol
http://lumberjocks.com/projects/14909
Moai, Thank you! The top will be fun with hand cutting all those half blind dovetails.
-- Brian, Folsom, CA http://www.brianfullerdesigns.com
jlsmith5963
home | projects | blog
180 posts in 241 days
posted 212 days ago
bfd thanks for clearing out the fog I was in re: the feet. I am going to use the fig leaf that the picture showed the feet upside down and therefore confused me. Otherwise, I will have to admit just how silly that question was.
-- criticism: the art of analyzing and evaluating the quality of a artistic work...
Blake
home | projects | blog
2748 posts in 767 days
posted 211 days ago
Great project. I think I would be afraid to use it when it was done, its so nice. But it will reflect your business well to potential clients. Excellent design as usual.
-- Check out my new website! http://www.blakeweberwoodworking.com
Woodhacker
home | projects | blog
1145 posts in 616 days
posted 211 days ago
Brian, I’m a latecomer to this series on your workbench…I had to go back and look at your earlier posts as well. This is one sweet bench. Can’t wait to see it completed.
Thanks for posting it.
-- Martin, Kansas
Beginningwoodworker
home | projects | blog
4123 posts in 566 days
posted 91 days ago
Nice progress!
-- CJIII Future cabinetmaker
a1Jim
home | projects | blog
16683 posts in 470 days
posted 91 days ago
looks great full speed ahead
-- Jim from Heirloom Woodshop Southern Oregon