My 5 projects #10: Progress on the knock down bench, pallet crafting the whole thing. Some nice legs.

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Blog entry by derosa posted 01-13-2013 05:21 AM 2387 reads 0 times favorited 1 comment Add to Favorites Watch
« Part 9: Progress on the clamp cart, dinosaurs, and some cleaning. Part 10 of My 5 projects series Part 11: pallet crafted feet and cross supports for the workbench. »

I’ve been wanting to get going on this project for quite a while and have finally made a little more progress. I now have most of the design in my head and have managed to collect a good portion of the wood.
Last three days have been spent milling down some of the stock for the legs and making the cross members.

Each leg is 3”x2 7/16x whatever the height is, didn’t actually measure that so I don’t know. Height is based off my current table which is between 3-4 inches lower then I’d like so I just set one against the table and drew a line and cut all of them to that line. Plan is a 2.5” top and I’ll add an 1.5” pad to the feet. The width of the bench will be 28” so I’ve got the legs 24” apart so that there can be a slight overhang on on side.

The cross members on the short side will be wedged mortise and tennon, one of the two cross members needs to be remade, I experimented on making the tennons on the bandsaw and they ended up too narrow. Each tennon is 1 1/16” x3” with a 5 degree slope for the wedges. There will be a lower cross piece/foot on each one.

As you can see so far it is all solid white and red oak, to get these I had to cut up several pallets. The last two legs and the long cross pieces were from the last 2 pallets, a lot of the pallet hits the garbage can especially where there is splitting and cracking. I can live with the nail holes which you can see but not splitting. Some of the rest of these two pallets resulted in 3 pieces of cherry 36×1.125×7-10” wide finished dimensions. A couple of red oak boards and a maple board only 5” wide. As you can see I get some nice pallets.

The final pieces to be started on are these which will be the two long cross pieces once milled down. Expected dimensions on them will be 2×3x60”

As I said this will be a knock down bench so these will be designed a little differently. The plan is to make a wedged mortise and tennon but the top of the tennons will be straight and flush with the top of the cross pieces while the bottom of the tennon will be angled 5 degrees. This way a separate wedge can be driven in at the top which will wedge the cross members into the legs but can always be knocked out later. Hopefully that will follow tomorrow.

-- --Rev. Russ in NY-- A posse ad esse

1 comment so far

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15881 posts in 3356 days

#1 posted 01-13-2013 05:14 PM

You are lucky to get pallets made from such good woods.

-- Mike, an American living in Norway.

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