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Weekend Bench

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Blog series by dsb1829 updated 01-11-2009 10:13 PM 12 parts 14995 reads 67 comments total

Part 1: Getting Started

12-28-2008 07:50 AM by dsb1829 | 8 comments »

Okay, I should probably preface this by stating that I started this bench about 2 months ago. I have been gathering lumber and vise hardware as economically as possible. So before anyone tries to duplicate this bench in a weekend they should seed out the lumber and acclimate it to their shop as well as purchase the vise hardware. That said, you need a bench to build a bench. Sorry, I haven’t come up with a way around this yet. To date I have a fairly well equipped shop, yet I sti...

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Part 2: Rough lumber

12-29-2008 05:54 AM by dsb1829 | 4 comments »

Rough lumberCould be worse, but without a proper bench it is pretty hard to deal with. My secret weapon (s)Cheap Harbor Freight clamp on vises. They are barely functional stock. However with a few small alterations they can work quite well. I use hard maple cauls with sand paper for better grip to make them hold to the bench better. I lined the jaws with 1/8in plywood adhered with double sided duct tape. Not going to win any awards or admiration, but these vises will do in a pinch and...

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Part 3: Aprons for the MDF top

12-29-2008 06:34 AM by dsb1829 | 7 comments »

I should refer to this entry as “more work than I had anticipated”... I put in close to an 8hr day today and about all that I have to show for it is aprons around the mdf, a bit of new knowledge, and a few mistakes. I will run through this step by step. Again for the most part this is a keep it simple bench. There are other ways of doing most everything here. I am just going to lay out my method here. The first hurdle of the day was figuring out how to deal with my rough...

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Part 4: Rounding 2nd

12-30-2008 05:51 AM by dsb1829 | 2 comments »

Okay, so another 8hr day in the books. Again I am humbled by what I can get done in a day. And again I see that a better plan would have taken a lot less time to accomplish the tasks I did today. Well, the day started with some remorse over yesterdays hasty apron glue up and lumber sizing. I had intentionally left the aprons proud of the bench to flush trim. This isn’t normally a problem on a light duty bench. But for this weekend warrior bench I have to flush trim aprons that a...

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Part 5: Advice

12-31-2008 04:31 AM by dsb1829 | 4 comments »

Okay, more like add vise. Not much doing today. I spent a good 4 hours in the garage, but only got as far as mounting the end vise and the legs. Using the predrilled holes on the legs and a transfer punch allows me to position the holes in the top. I used a block jig to keep the holes lined up. I drilled the hole in the block using the drill press. Next comes mounting the tail vise. I wavered back and forth on this. In the end I decided to just drop it into the end apron. Us...

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Part 6: Getting a little closer to being done

01-04-2009 02:21 AM by dsb1829 | 6 comments »

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 bott...

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Part 7: A bit of reflection

01-05-2009 07:11 PM by dsb1829 | 8 comments »

Okay, I am nearing completion on the bench. I am currently working on the front vise. I will save that story for the finished product. I am sitting here today having a bit of a reflective view of the project. So I am going to break it down here. Costs:$100 – about 100BF of rough 8/4 poplar (I will likely only have gone through about 40BF during this build$81 – 3 sheets of 3/4in MDF (still have over half a sheet, I could have used some of the poplar for the lower shelf ...

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Part 8: Front twin screw vise

01-07-2009 07:53 AM by dsb1829 | 9 comments »

Okay, with most of the headaches behind I figured it was time to dive into the twin screw for the front. This should be easy right. I look at the lumber pile. It is much smaller than a lot of the other jocks here, but it does have a couple of options. I had planned to use poplar, but was thinking it may just be too soft. I had picked up some 3/4in oak at the HD for a project that I haven’t gotten to yet. I figure the oak is a better choice for the vise. So I mark out and do my ...

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Part 9: Some comments on the twin screw

01-09-2009 06:09 PM by dsb1829 | 7 comments »

In my last installment I ran through my basic install criteria for the twin screw and how I chose to build the bench mount and vise chock. I left off waiting for some brad point drill bits and some longer bolts to mount the vise with. Brad point bits arrived yesterday.They are huge! Near 8in of fluted cutting capacity. Can’t wait to try these things out. First I have to clean off the cosmoline or whatever they shipped them covered in. I had already jumped the gun and mounted t...

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Part 10: Finishing Touches on the twin screw

01-11-2009 07:46 AM by dsb1829 | 1 comment »

I spent a couple more hours on the twin screw this morning. I had a few details to straighten out. I went ahead and split the vise. I decided that the front leg lamination should run top to bottom. So I pulled the vies and split the block. I mentioned slipping in my last entry. So when I remounted the blocks I used a liberal coating of 3M super77 spray adhesive. Seems to have done the trick. Now the blocks are rock solid to the bench top, yet if need be I can still remove them. N...

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Part 11: Flushing up the front legs

01-11-2009 08:08 AM by dsb1829 | 2 comments »

Okay, started the afternoon with a very rough and checked 9ft x 8in poplar board. Oh, it was cupped and warped too. Good excuse to get out some hand planes. In the end I am looking to laminate onto the front legs another vertical member that will be flush to the front apron.Kinda like this. Savvy? Nothing too noteworthy. Chop, hand plane, bandsaw to width, clean up by plane, bandsaw to thickness, clean up with hand planes. Sorry, didn’t detail that out. I kind of cover most of...

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Part 12: Stick a fork in me

01-11-2009 10:13 PM by dsb1829 | 9 comments »

Took about 3 hours this afternoon. I am going to close out this series. Yes, still have a few more items that I need to do like seal the top and drill some more dog holes. But, by in large, the bench is complete. First item of the day, hand plane the legs, vise mount, and apron flush. Minor issue, this bench is getting heavy. I managed to get it down without much strife. I went to pick the thing back up when done and failed. Took 2 more attempts to right this beast. Amazingly enoug...

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