Weekend Bench #6: Getting a little closer to being done

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Blog entry by dsb1829 posted 01-04-2009 02:21 AM 1003 reads 0 times favorited 6 comments Add to Favorites Watch
« Part 5: Advice Part 6 of Weekend Bench series Part 7: A bit of reflection »

I had to take a couple of days off for Holiday travel. I got back at the bench yesterday for about 6 hours and batched out the dog holes and lower shelf.

I am not overly thrilled with how the dog holes worked out. In the end I used an Irwin boring bit and this jig.

I found that using just one clamp allowed the board to wiggle some as the bit drove in. Doing it this way the second and third clamps secure the board better. A backing board is necessary.

or you will get blowout at the bottom…

Overall the boring bit didn’t leave a great finish and it was constantly clogging. It also wobbled a bit due to runout. I don’t think the bit was ever intended for nice work. Forstner bits are also pretty prone to clogging. I also found the forstner very hard to keep aligned. I think if I were to do it on a nicer bench I would use the router for the top inch and then a standard brad point bit to get full depth. I went cheap. It did work out, but again it was another learning experience.

I added a temporary stretcher to reduce racking so that I could use the bench to surface the boards for the bottom shelf.

This worked fairly well. racking was there, but not so bad that it affected my work.

The shelf is constructed with but joints. Since it is captured between the legs there isn’t really a need for a stronger joint. Time will tell if that assumption was correct. As it is the bench is knock-down, so I could easily build a new shelf if it came to that.

I also had a scrap laying around that I mitered to fit on the diagonal. I don’t think it does much, but I had the scrap and extra bracing never hurt anyone.

To finish up I moved the temporary stretcher to the rear and bolted it up.

So there you have it…

Time log:24.5hr so far

Next up front twin screw construction and laminating up the front of the legs to flush them to the front apron.

-- Doug, woodworking in Alabama

6 comments so far

View SPalm's profile


5249 posts in 3306 days

#1 posted 01-04-2009 03:18 AM

Sweet. It is really looking good.

I went through the dog hole thing this summer. It can be nerve racking. I bought a 3/4” spiral upcut router bit ($$$) and it cut like butter, but did not go all the way through. So I had to finsh drill with a bit such as yours. I admit, I have not finished all of them yet.

Amamzing how the time goes, huh?


-- -- I'm no rocket surgeon

View Callum Kendall's profile

Callum Kendall

1918 posts in 3127 days

#2 posted 01-04-2009 04:38 AM

Looking good!

Thanks for the post


-- For wood working podcasts with a twist check out

View Derek Lyons's profile

Derek Lyons

584 posts in 2992 days

#3 posted 01-04-2009 07:50 AM

Twenty four hours – shoot, you’ve got a whole day left in that weekend! :) :)

-- Derek, Bremerton WA --

View Beginningwoodworker's profile


13347 posts in 3097 days

#4 posted 01-04-2009 09:25 PM

Nice progress Doug.

View Tomcat1066's profile


942 posts in 3220 days

#5 posted 01-05-2009 12:28 PM

Looks good Doug. I can’t wait to see the finished product, which can’t be to far away, can it? ;)

-- "Give me your poor tools, your tired steel, your huddled masses of rust." Yep, I ripped off the Statue of Liberty. That's how I roll!

View dsb1829's profile


367 posts in 3051 days

#6 posted 01-05-2009 05:55 PM

Hey guys, thanks for the comments. I am thinking that this bench is more like a 2 weekend project :)

Design as you go is a bit time consuming. With a plan in hand things would have gone faster. Also pre-milling all lumber to dimension would have been much less time than the mill as you go approach that I used.

Hey Steve, where did you find a 3/4in spiral upcut bit? I did a quick look at the usual suspects (rockler, woodcraft, mlcs, eagle) and didn’t stumble on anything.

-- Doug, woodworking in Alabama

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