LumberJocks Woodworking Forum banner

Benchtop Bench - got tired of back pain... Blog

12K views 25 replies 21 participants last post by  mafe 
#1 ·
Benchtop Bench - got tired of back pain... Blog

Benchtop bench
got tired of back pain…

When I was sawing finger or dovetail joints on my traditional Scandinavian workbench, I always ended up standing in a bed over position sawing. Since I am retired du to a neck operation this is especially for me no good.
So when I realized I had to cut a handful for my daughters confirmation gift, I decided it was time to quit whining and do something about it.
Two ways ahead a moxon or a benchtop bench, the bench on bench would give me a general chance of a higher work surface, so that became my choice for now.
It can also be brought on location work and clamped to any table top.


This is how I usually stand.
Bad position, low control and need the work to go up high to not catch the bench and so it becomes less stabile.


I wanted it to be a use and trash version, no sensitivity after, a work top, not a art piece, so I went for thick plywood in a good quality.
First one for the work surface.


Then for the front piece and vise.


This is the plywood.


Then a couple of roof battens 38×57mm / 1,5×2,25inch are cut to length.


That's the basic parts.


Since I did not have the right length to screw from underneath, I drilled top down at the back end.


Like this I can put wood plugs in later.


Glue and screw.


For the front end the front board are put straight up, glued and then nailed in place for now.
Counter sinking nails quite deep (app half a inch).


Then the bench is turned up side down, the batten glued on two surfaces and screws added from the back side, since the top is where sharp tools will work later.


Now time to play with a tool I bought time back and never got to use.
A wood threader.
The stocks I turned on my lathe some time back and kept on the shelf.
I wax and then go for it - it's wonderfully easy in the beech wood.
Yabadabadooooo


Beautiful - yes?
I love it.


Then I test cut a thread in a piece of pine, just to see if it will work.
Again easy and a joy, cutting through the grain.


Test time.


Need a little grease and then runs as a dream.
Seems really strong.


Back to building.
Here the benchtop bench is put on the table and I cut a round hole in each end of the battens and cut down from the end to make it more elegant and so that a clamp don' need to be as high to grab a table top.
Look at later pictures, forgot to take the after photo, sorry.


So wood in the holes I made later, now the glue is dry.


Now I can drill holes for the vice.
Starting with a pilot hole all the way through.
Then for the vice front (jaw) a little larger than the threaded spindle.
And finally the right size for tap to cut thread (depending on your threader and tap size).


Now cutting the thread with the tap, please notice I am a wee bit off center (********************)...
Not a big problem, just with a long spindle it became visible after.
So yes please laugh at me now, all beginning is hard, every new tool takes some practice, a woodworker is a person that did a lot of practice, best every day 8-10 hours, us boy scout wood workers have to accept our mistakes and call it charm. ;-)


Yes!


Now I can cut holes for handles.
Using center jig.


Grease up that baby!
First a good soak of Japanese camellia oil and then bees wax.


We got a bench top workbench MaFe style.
I did it my way!
Notice how I hold it to the table with the end vice.
(Alternative is to use a clamp from under the table).


Get the picture?
Raised surface clamping right in front of you.
I can even sit on my bar stool and work comfortable in front now.


Where we want it.


Here you see the build up.
The front goes under the tabletop to secure a firm grip.
Here you also see why I drilled that hole in the side batten, so it would be lowered for clearance and beauty.
The long spindles makes it possible to clamp a drawer or other full size items.


So time for a tool for the tool… and testing the benchtop bench.
First mark up two pieces of wood.


Then score with a chisel for cutting, before sawing.
Saw.


Transfer fingers.
Thinking of my friend Bas as I so often do when using the beautiful marking knife he send me.


And we got a finger joint…
Why MaFe?


Glue them up in a straight angle.
(You are there on the side my friend Jim - the beautiful awl on the table).


Once dry a little shaping and this is what we got.


Time to do some spinning.
Since I am no athlete I will do it on the lathe, while I sit comfortable on a chair…
A old chair leg found in the street becomes useful.


Tatatatatatatataaaaaaaaaaaaa we got a handle for the new benchtop bench.
(Guess you thought I had become a lazy bustard, using that screwdriver).


It's all in the wood…


Drilling holes in the ends matching the thickness of the rod.


Glued in place with epoxy and a bamboo nail going through.
Now you see why I made the angle.


So I can set the wood straight…
What do you think of my new Italian pipe by the way, I simply love it.


Now back to work.


Ok I fast realize it needs more attention, as soon as I had sawn the fingers and needed to cut the waste I realized I needed hold for that also…
So marking up for a row of holes.


Careful MaFe.


Drilling.


Now I can use my Festool clamps and gear on it too.


Works super well.


But is it sexy…....
Not with all those nice tools all over.
It's like a green Storm Trooper had landed in a Amish movie.


So we need to invent.
A wall plug and a wing nut.


A piece of pine.
Drawing a slight curve.
(Notice the metal dogs also).


Drilling a hole in the center.


Sawing the curve.


Shaping.


Shaping.
(This was not a mistake, the text are supposed to be the same).


Contact glue and leather patches.


Magic!


That's a more sexy hold fast in my universe.
(My shop is my universe, kind of the reversed Death star - the Life star).


A fine grip when chopping out the waste now, eve it's a bit annoying to turn the wing nut each time…


Ok - use a Wedge!
Fantastic, this is fast and gives a firm grip, adjustment only needed when changing quite a bit up or down in size.
Love it.


Sexy and simple.


Gave et some extra holes, same system as the Festool, like this I can use those clamps too.


Like this.


But I need some more woody bench dogs.
I know I'm a wee bit too much, but it just makes me happy.
So cut some rod and some squares.


Drilling for the rods.


Epoxy…


- and bamboo nails.


Now back to working on that secret project, I used already too much time playing - but at the end of the day, that's what it's all about. ;-)


Here the dogs.
Wouffff.


Also added a little planning stop at the end, based on the Fibonacci numbers.


That's it.
Back to work, Mathildes confirmation is in a week and a half now.


UPDATE for the hold fast: https://www.lumberjocks.com/mafe/blog/133203

Thank you for following my little de tour.
Perhaps this can inspire others to fool around and at the same time give your body a good place to work.

best thoughts,
Mads
 
See less See more
69
#4 ·
Wonderful as usual Mads. A very useful and nice looking bench. I know what you mean about having a higher bench top. I often come in from the shop bent over. I am planning that my new bench (not built yet) will be much higher. Don't forget to post Mathildes gift when it's finished!
 
#5 ·
Great photo journey, Mads!

I noticed in several pictures there is a small , pegged piece placed between the front, movable jaw and the rear fixed top. Is that to prevent racking and assure the jaws are parallel to the work piece?
 
#20 ·
Hi all,
Serge, yes I think this is clearly a project for you, look forward to see what you come up with.
siavosh, yes I was in doubt if I should do that instead, but feel I got it all here.
Stefang, I am actually thinking of rising my bench app five cm (two inch), I will post her gift. ;-)
Lew, you are fast, it is just what it is.
Philip, these run quite smooth, but still talks.
Gibernak, I love using the holdfast, it is amazingly fast and functional.
SAS, thanks.
doordude, yes I like to sit now and that relaxes the back, so I really enjoy it.
SPalm, lol, I never claim to be a hand tool person, I have a simple princip; I can use hand tools when I am able to do it by hand. The ply was to make it fast, cheap and not be afraid to use it. But I cam agree it might have been more elegant in some hardwood and a matching color…
Sodabowski, hope you had a fine communion, we had a wonderful confirmation. Yes it will be usefull on the kitchen table also.
Bob, thanks, yes I love to work and be in the shop.
Don, smiles thanks.
freddy, at least a true child.
wolf, thanks, you will never regred making one of these holdfast, the wall plug makes it fast removable in a simple way.
Ian, yes that threader is sexy!
Topa, one day, one day… I have plans but it will not be a how to book.
llwynog, thanks. ;-)
Smiles thanks to you all,
Mads
 
#22 ·
herbritchie, yes ply is good for jigs and holds, but I think I will change the vice into a good piece of hardwood at some time, the ply is too soft and bends a little, but works fine for now.
This is the one I use:
http://www.highlandwoodworking.com/manualwoodthreader1-126tpi.aspx
As I remember it's 1,5 inch.
Bes thoughts,
Mads
 
#23 ·
Yes, the featured project is a great accomplishment, but the story takes first place. I like how you lead us from one point to the next with good photos and simple text. This was pleasing as well as informative. Many of us woodworkers love to just spend time thinking and tinkering with new ideas, its how we relax. These story/projects are another way we can do that.
Thanks for sharing with us.
 
#24 ·
Hi Andy,
Yes thinking and tinkering with ideas must be the one thing most of us share.
I personally love to follow when a fellow woodworker can make me feel like being in his thoughts, understand his way of thinking and see how he actually does the work. I also, just like you, find the big joy in the process and are actually less interested in the result. In a way the result is usually a anti climax for me. ;-)
So thanks for your kind words, I am really happy to have given you that feeling of looking over my shoulder.
Best thought,
Mads
 
#25 ·
Mads, here in my office it is almost time to call it a day. It was a very long day. My help is off this week. I am behind with processing the orders for the crew. The printer broke, so i had to hand write the orders for the guys…. I had to stop for a moment and catch my breath…. I needed to smell the wood shavings…. It started with and email, or eMag from LumberJocks… And so I ran into your blog…. Your long blog…. I forgot where i was and for a moment I caught myself with YOUR tools in MY hands… I was in Denmark for a second… I could feel the joy you had with that bench that started as a bench just a little higher up to save your back, but needed constantly more and more upgrades.
What a joy. Thanks for sharing.
PaBull
 
#26 ·
Thank you my friend, happy to give you a much needed brake, hope he will be back soon so you will get some load of your shoulders.
Happy to have you with me.
Best thoughts,
Mads
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top