Hullo, folks. I’ve been sneaking in a little more time on the bench and have an update. In the last entry I mentioned a snaffu with my chamfers. I got those all done in short order on the router table. I even took a chance on the leg I had already assembled. The fit with the lag bolt was of course a little looser when I reassembled the leg but nothing to get uptight about. This was pleasing.
I put the legs together and then drilled my holes for the lag bolts in the ends of the stretcher. This is where I ran into my next challenge. I brilliantly didn’t think before I drilled. I had “3/8 lag bolt” in my mind and promptly chucked up the 3/8 bit rather than the proper size for the 1/4” x 3” pilot holes I really needed… I drilled three of the four before making this discovery. Fortunately, since the stretcher is 5” I was able to relocate the holes. I still had the correctly spaced holes in the legs though (they could not be used because of the difference in spacing I had to use for the new holes). Since I only drilled 3 of the 4 in the stretcher, I wanted to use the original location for at least one of the holes thinking it might add something to the stability. In hindsight I should have just relocated all four and stuck with the pre-drilled holes in the legs. At least it would have been less unsightly. It is, however, a workbench and will definitely not be the last one I build so I can live with it. I just hope I don’t have any problems with the Fir splitting. A season will tell. If it does, the replacement cost will not be bad.
The upside is the back half of the bench top involving my salvaged conference room door went together quite well and is almost perfectly level. I’m choosing to believe the hair that it is off is due to the 50-year-old shop floor. I hope to get some time this week to assemble the pieces of the well and front rail. The particle board door was secured to its supports with Confirmat screws. These are specially developed for use with particle board. They have deeper and more closely spaced threads that reduce the occurrence of tearing apart the board or becoming loose. The Fir pieces were then joined to the leg assembly with deck screws as mentioned in the FWW article.
If you aren’t familiar with Confirmat screws, I’ll be taking more detailed shots of the well assembly for the next entry and will include some shots.
What’s most exciting is I think I picked the right height to comfortably use this bench with my had tools. Before I cleaned up for the day, I took a pretend passes with a #4 plane (with retracted blade). It felt pretty comfortable.
This was pleasing…
-- Jeff, St. Paul, MN
13 comments so far
Dorje
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1743 posts in 478 days
posted 441 days ago
Looks very satisfying! You’re making good progress…you won’t have to pretend for long! (Though that’s fun too)
-- Dorje (pronounced "door-jay"), Seattle, WA
Jeff
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964 posts in 575 days
posted 440 days ago
Thanks, Dorje. It will be nice to have a multi-functional worksurface finally.
-- Jeff, St. Paul, MN
Dorje
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1743 posts in 478 days
posted 440 days ago
What did you have before? And, what happened to it?
-- Dorje (pronounced "door-jay"), Seattle, WA
woodspar
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684 posts in 580 days
posted 440 days ago
Jeff, I’m likin’ the progress!
-- John
Jeff
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964 posts in 575 days
posted 440 days ago
Thanks, CISPOOK and John. I hope it turns out to be genuinely usable.
Dorje, I haven’t had anything other than the desk in the first photo or my table saw (not the best idea without a special cover for the top). The desk is not dead flat. The Black and Decker Workmate is also useful.
I have not really used my hand planes (other than my block planes) since I acquired them. That, I feel, is unfortunate since part of the reason for getting into WW was as much therapeutic as any other reason. I spent several weeks locating them and have a real desire to have an appropriate area to hone and use them. I truly want to build something without any electricity whatsoever. I unfortunately won’t make the summer project deadline but that won’t keep me away from the personal challenge. Lofty goals I know.
-- Jeff, St. Paul, MN
Bob Babcock
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1807 posts in 567 days
posted 440 days ago
Looking great Jeff. The more I think about what to build the more I like this. Do you see any way that this could be in two or more pieces and easily assembled when needed? My shop just can’t fit an assembled bench inside, but I was thinking it would be great to be able to set one up outside when the need arises. It’s either that or wait until I build a bigger shop.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
Karson
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12887 posts in 881 days
posted 440 days ago
Jeff:
Did you have Douglas use his trusty PhotoShop to get that Bubble right in the middle.
Or was it shims under the table. LOL
Great start.
-- Karson Southern Delaware karson_morrison@bigfoot.com
Dorje
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1743 posts in 478 days
posted 440 days ago
Jeff – not to rush you or anything: What are you going to build when you complete the bench?
-- Dorje (pronounced "door-jay"), Seattle, WA
Jeff
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964 posts in 575 days
posted 440 days ago
Karson,
Ummm, errr, no. Douglas had nothing to do with it…....... wink, wink. LOL!!!
Seriously, good idea but I’m proud to say, that has been my crowning achievement of the project thus far. I was really worried that I would get the top situated and it would be a half bubble off or something… Douglas, the good man that he is, probably would have rightfully told me to not be a weenie and go fix the situation correctly. I guess before I get to proud I should move it out to the driveway which is pretty level and take a measure there.
-- Jeff, St. Paul, MN
Jeff
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964 posts in 575 days
posted 440 days ago
Dorje,
I have two things in mind. (1) The Adirondack chairs I have been promising my “shop landlords” or (2) the frame for the mirror project have made plans for. I’m thinking the chairs will win out because that gift is long overdue. Also, that was my intended project (sans fasteners and glue) for the summer project but it simply isn’t going to happen with the time left. Such is life.
-- Jeff, St. Paul, MN
Jeff
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964 posts in 575 days
posted 440 days ago
Bob,
I can’t believe you asked that question!! Every since I started this project, I have been rolling that idea around in my noggin’. I think it is totally achievable! The downside would be the repeated line-up of the bars for the planing beam and the re-installation of the beam every time you wanted to use the bench. This said, if you only needed the beam once in a while or could plan you work accordingly, the bench is very doable as two pieces or maybe three.
The top is basically a whole assembly that rests on the leg assembly. In fact, the two are put together with nothing more than deck screws. A clever man could easily fashion a way to attach the two with a clamping/joinery system. I envision a sliding dovetail with some side rails that are ultimately clamped to just slightly pinch or clamp the leg assembly. If designed right, it would have no more lateral movement than the current design. Frankly, it might be stronger and stiffer.
To compensate for the planing beam clamp bars I have an idea but not sure. What are your off-the-cuff thoughts? Let that 3-D mind of yours flow…
-- Jeff, St. Paul, MN
Bob Babcock
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1807 posts in 567 days
posted 439 days ago
Sounds like a great modification. I was thinking 3 main pieces. What is the issue with the planing beam clamp? Seems like the pipes could be positioned as the pieces are assembled. They don’t actually clamp they just support, or am I wrong? Cut holes in the top and bottom to fit and just insert as you bolt it up.
This is such a cool bench. I think it will be one of this winters projects.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
oscorner
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4573 posts in 792 days
posted 439 days ago
Nice progress and posting.
-- Jesus is Lord!