For five years now I have been making do with a 31” or so length of a 5” x 5”. We call it here in the Philippines as “YAKAL”. Very sturdy wood. Commonly used as house posts. Resistant to rot and termites wont even touch it. I found it lying around in my mother’s yard. Added the legs and the vice. A real workhorse ever since. I have used it to build everything around the house and more. My wife even uses it as a pedestal for her laundy buckets and pails.
It is very functional but the limitations are obvious. I gotta build something better…..
From a piece of 2” X 4” X 8’, I cut
1.) 25 1/2” lengths – 4 pieces for the leg uprights
2.) 14” lengths – 2 pieces for the top crosspieces
3.) 21” lengths – 2 pieces for the bottom crosspieces
I used my router to true up the edges riding the only straight edge I have around, a carpenter’s square. After routing one edge of the these eight pieces, I used the router’s edge guide to true up the opposing edges. Final width came to 3 1/2”.
After truing up the edges, I laid out the lines for the mortises. If I remember right, the mortise is about 2 1/2” X 3/4” wide X 1 1/2” deep.
I chewed most of the waste out with my US$100 drill press and a 1/2” bit….
Cleaned the jaggedness with a chisel…..
This is how it looked like after I am done with the chiseling…..
Then routed the mortise to final dimension. Eight in all. To speed up the process a little, I drilled all eight mortises first, then the chiseling, then the routing and the final step was to square up the mortises with a chisel. I did it in a three step process so as not to tax my router. It is fast becoming my favorite tool. Sorry folks, I forgot to take a picture of the finished mortises. I
I would have fabricated a jig to do the mortises. I just can’t find the right material. The router’s edge guide served the purpose. I just Flipped the workpiece to work the other side. It was tedious work and I had to be very careful so as not to allow the router to dig into the workpiece the wrong way.
Then, I also used my router to make the tenons. I again forgot to take a picture how I did it. I clamped a speedsquare on the workpiece aligned the tip of the router bit on the lay-out line and plunged away.
One of the legs assembled. Not bad eh?
More to come….
-- "Real jocks do it on a bench"