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YAR! - Yet Another Roubo #3: Finishing the top & assembling bench

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Blog entry by Douglas posted 587 days ago 2029 reads 0 times favorited 13 comments Add to Favorites Watch
« Part 2: Assembling the base, milling top stock Part 3 of YAR! - Yet Another Roubo series Part 4: Finishing up »

All this past week I was able to get an hour or so each night to keep going with gluing up the 4 sub-sections of the top, getting them done by the weekend. Each section was 4 boards, and ended up being about 5 3/4” wide. I decided to do it this way for a few reasons. First, I wanted to be able to run each section over my 6” jointer, and then the planer. Second, by doing the glue up in stages, it made the final full glue up easier to manage.

Here’s one of the sections in the clamps…

And then the full top…

I left some room in the front section to accommodate the wagon vise, and, after jointing and planing, had to add a 3/4” piece on the back to get back to 24 3/8” width, to match the width of my base. I took care to try and align the grain direction to make flattening the top easier, but there were several pieces that had grain reversal that I couldn’t do anything about. I’d also tried to hide any knots inside the glue up, or on the bottom as best I could.

After the top was dry, it was time to take it out of the clamps and see how I did. Not bad, it was very flat within 1/16” – 3/32” showing a slight arch in the middle, consistent over the width. I’d also been able to keep my thickness on target: shooting for a final thickness of 4”, I started out rough milling each piece at 4 1/2”. After jointing each individual board, I was at just over 4 1/4”, and after jointing & planing each section, 4 1/8”. After the tight full glue up, I was at 4 1/16”, which was a great place to be at the flattening stage.

Here I’m using my #5 with a cambered blade to hog off the worst of the hump. I followed with my #6 & #7, then some #4 smoother plane and a touch of 220 sandpaper…

Flattening went well, and it was onto chopping the mortises for the legs. Some forstner bit and chisel work got the waste out, and only took a few tries to get the fit right. I used my skil saw and a clamped guide to even out the ends. I then proceeded to route out the groove for the sliding deadman, and the grooves around the wagon vise. I also did the drilling for the drawbore pins, with a 1/16 offset there.

With all that in place, I fit the top, and drove in the pegs. I was using store bought dowels for this, and I wish I’d used a doweling plate and made my own. 3 of 8 pegs broke during the insert, but only after going in 2/3. I was able to chase the broken dowels with another shorter one, and finish the insert. I don’t think it will affect the joint, as all 4 joints seemed to pull up nice and tight.

I was VERY excited to reach this stage, finally. I did some clean up, and got ready to add the vises, end cap, and other fixtures. That’s next time!

-- Douglas in Chicago - http://dcwwoodworks.com



13 comments so far

View blackcherry's profile

blackcherry

3156 posts in 2458 days


#1 posted 587 days ago

Big and Stout oh what fun you must be having this is a beauty of a project…ENJOY!

View grfrazee's profile

grfrazee

325 posts in 774 days


#2 posted 587 days ago

Well, your leg mortises look much neater than mine, I can tell you that much. I decided against draw-boring them so that I could disassemble and move the bench, but otherwise mine are pretty similar.

-- -=Pride is not a sin=-

View John's profile

John

341 posts in 2432 days


#3 posted 587 days ago

great bench! enjoying the series, thanks

-- John - Central PA - http://affyx.wordpress.com

View walden's profile

walden

617 posts in 657 days


#4 posted 587 days ago

This is great! You’ll love using that bench. I have yet to find a task mine can’t handle.

-- "When and if the day comes a lion is on my roof, I am hiring a realtor." ShaneA

View murch's profile

murch

1141 posts in 1259 days


#5 posted 586 days ago

Going really well. The finish line is in sight.

-- A family man has photos in his wallet where his money used to be.

View Willeh's profile

Willeh

228 posts in 974 days


#6 posted 471 days ago

Did you cut the opening for the wagon vice after the top was glued up, or did you leave that out before hand?

-- Will, Ontario Canada. "I can do fast, cheap and good, but you can only pick two... "

View Smitty_Cabinetshop's profile (online now)

Smitty_Cabinetshop

9822 posts in 1253 days


#7 posted 471 days ago

Beautiful!

-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive

View Douglas's profile

Douglas

304 posts in 1194 days


#8 posted 470 days ago

Willeh – I “left it out” during the glue up, and then routed the tracks for the wagon “ears”, then screwed in strips to support the wagon. Does that make sense? I could post a pic if you’d like.

Smitty – Thanks!

-- Douglas in Chicago - http://dcwwoodworks.com

View Willeh's profile

Willeh

228 posts in 974 days


#9 posted 465 days ago

Douglas,

Just to make sure i get what you mean: You left out the slot wide enough for the dog block, routed out the underside for more space and so it would be supported from the top, then added strips to the underside to keep it supported from below?

A pic would be awesome! Thanks

-- Will, Ontario Canada. "I can do fast, cheap and good, but you can only pick two... "

View Douglas's profile

Douglas

304 posts in 1194 days


#10 posted 465 days ago

Hi Willeh, here’s some more pix…

So, as our can see, the wagon block is one piece, cut like an inverted “T”, and then I screwed in cleats below. I left them thick to make sure they were strong. Let me know if you have any other questions.

-- Douglas in Chicago - http://dcwwoodworks.com

View Willeh's profile

Willeh

228 posts in 974 days


#11 posted 464 days ago

Brilliant! Thanks much! Appreciate it :)

-- Will, Ontario Canada. "I can do fast, cheap and good, but you can only pick two... "

View PurpLev's profile

PurpLev

8476 posts in 2283 days


#12 posted 464 days ago

looks sweet!

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View Willeh's profile

Willeh

228 posts in 974 days


#13 posted 463 days ago

Hate to be a pest, but can I ask how long your slot for the wagon vice is? I ordered the vice, but it is taking forever and I will probably get to the glue up of that section this weekend…

-- Will, Ontario Canada. "I can do fast, cheap and good, but you can only pick two... "

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