When milling up the material for the bench at my firms workshop i created a right angled triangular rail for the deadman to slide across, a couple of opposing 45 rips followed by a 0 rip was enough to create the slide. This was cut to the shoulder length of the front slider, glued and clamped into position.
The underside of the top received a 12×20mm groove between the two front mortices created by a router and parallel fence.
I cut a birds mouth at the bottom and a tongue at the top with a tenon saw and cleaned and scraped the cuts with a chisel.
After a few height alterations the deadman ran smooth across the length of the sretcher.
I wanted to add some detail to the stretcher so i created a template from 18mm MDF, clamped the template to the deadman and cut the form using a 12mm bit in a 30 mm guide bush with a half inch router. Lots of shallow, controlled cuts left a finish that only required light sanding to clean it up.
a small rounder was applied with a router to all the edges and the deadman was complete for now, i am going to wait until purchase a deadman before i bore holes to receive it.
in all honesty im not altogether happy with the way the deadman looks, i hadn’t accounted for the offset of the bit and guide bush when creating the template and the detail just looks wrong. I can reform the edge at a later point if i decide i can’t live with it.
i have photo documented the build on instagram @joedillon