Hello again folks. Here I am in the home stretch. I say that but I know there are still a bunch of details left.
I decided to go with drawbored Mortise and Tenons with no glue. The splayed legs on this bench make it incredibly stable as is so it’s not necessary at all. I also won’t have to worry about glue not curing well in the cold weather. The idea of not watching the clock during glue up is pretty nice to, especially on an assembly his size.
The hole stress free thing is true in theory any way.
This assembly was pretty damn stressful since it was my first time drawboring anything. You’ll see the issues as we go through the pictures.
I think you are all aware of my venture into making drawbore pins. 

So now that those are done I needed to smooth all surfaces and edges. 
Then drill out the holes in the mortises. 
Transfer the holes to the tenons with a little offset. This was one of the nerve wracking parts because I was really unsure of how much offset to use in oak. I ended up using around 3/32 or so I guess. Once I got a sense for it I just went by eye. 

When I tested the fit on my fist couple (with only 1/16” offset) there was almost no offset and it wasn’t pulling the joint tight. 
So I used a tip I saw on a Peter Follansbee blog. I glued dowels back into the hole then predrilled them with more offset. 

Pretty easy and I only had to do that on 3 of the holes.
I had to adjust the fit on one or two shoulders that weren’t closing up tight on the outside face. The drawbore pin helps for checking these fits. 
The #92 was the tool of choice for cleaning up the shoulders. 
Next I cut some oak pegs. 
Then whittled a point on the end of each. 
So without further ado lets start driving some pegs. I’m almost shat myself on this part because I didn’t know what to expect. I just stopped thinking about and started pounding them in.
I was afraid my offset might be too much. Maybe the pegs wouldn’t go in? Maybe they would break off in the middle of pounding them in? I didn’t know.
I did read one tip about rubbing wax on the pegs to ease their navigation through the hole, so that’s what I did.
And I’m glad I did. Here goes the first one! 
Went in perfectly!
I went through all the joints for the stretchers first. Besides some stray hammer blows (I’ll have to steam the dents out) everything went swimmingly.

But of course nothing ever goes perfectly right?. Here is my first and only FAIL. 
Kind of looks like a surprised face ;-0
The peg broke off before I could drive the last inch in. So it did get all the way through the tenon and about 1/2” into the back wall of the mortise before it broke
Also, I guess this is the best place for this kind of failure because it will be covered up by leather for the vise chop.
So here is the assembled core of the bench. Or the wet dog as Roy Underhill called it. 

It’s amazing how the pegs hold everything together. Its Rock Friggin’ Solid. Just an incredible bit of ancient technology. There is no give in the joints at all. I’m pretty excited!
Next up:
Flatten the top again
Chamfer dog holes
Glue and bolt on the tool tray (that will be tricky)
Final small details (removing dents and such)
Apply finish
So I’m almost done!
Comments and questions are always welcome.
Thanks for the watching and for all the encouragement!
Mauricio
-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

















27 comments so far
blackcherry
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2903 posts in 1991 days
#1 posted 112 days ago
Does the phrase labor of love fall into this project, this turn out great with your spot on craftsman ship well done!
Brandon
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3746 posts in 1119 days
#2 posted 112 days ago
Wow, I can’t believe you broke that dowel. You’re gonna have to scrap the whole project now. If only you had rived your wood and made the dowels from a dowel plate. ;-)
Looks great, Mauricio. I think you’ll have quite a bench to take pride in.
-- "hold fast to that which is good"
stefang
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9455 posts in 1502 days
#3 posted 112 days ago
Looks really good Mauricio.
-- Mike, American in Norway
ShaneA
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3963 posts in 766 days
#4 posted 112 days ago
Really nice Mauricio. This is an inspirational piece. Between all these benches and tool cabinets I am seeing pop up on blogs and in projects, it puts a lot of pressure on a fella to get off the porch and run with the big dogs. Well done.
John Franklin
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321 posts in 1966 days
#5 posted 112 days ago
that is a great,solid looking bench! thanks for the info on the drawbores, i’m about to drawbore mine (in the next weekend or so) and was wondering if 1/16” was enough
-- John Franklin - Central PA - http://affyx.wordpress.com
SASmith
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1368 posts in 1155 days
#6 posted 112 days ago
Great bench.
Thanks for sharing the progress pics.
-- Scott Smith, Southern Illinois
Mauricio
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5114 posts in 1319 days
#7 posted 112 days ago
Thanks BC, definitely a labor a love I’ve been working on it for about a year and while I’m happy to almost be done I think I’ll miss the bench building journey.
Your right Brandon, I think I’ll get rid of it. You want it. Come get it….. Syke…
Thanks Stefang!
Shane, you have way more skills than me man, go make you one. It will probably only take you a week.
Thanks John, I tried to do 1/16” but I found it to be too close to the first hole I poked with my auger bit. That’s what happened when I had that one tenon that wasn’t closing up. There was not enough offset to pull it tight. I had better luck with about 3/32 – 1/8”. Just play with it and see what works for you. And be sure to rub those pegs on a candle, that’s what I did and it worked great.
-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch
Brit
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4186 posts in 1011 days
#8 posted 112 days ago
Yippee! Another convert to drawboring. Looking good Mauricio.
-- Andy -- Old Chinese proverb say: If you think something can't be done, don't interrupt man who is doing it.
Mauricio
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5114 posts in 1319 days
#9 posted 112 days ago
Thanks Smith!
Thanks Andy, yes sir, no glue or anything, I’m a convert. Cant wait to try it on furniture projects.
-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch
AnthonyReed
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1346 posts in 608 days
#10 posted 112 days ago
Yes!!! Nice work Mauricio.
-- ~Tony
Mosquito
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2765 posts in 460 days
#11 posted 112 days ago
So much awesome going on there Mauricio. Hope mine comes even half as good as yours does. I’d be happy with it.
Why not leave the battle scars in? I mean… it’s gonna happen sooner or later, right? ;-)
-- Mos - Twin Cities, MN -- Stanley #45 Evangelist - www.youtube.com/MosquitoMods
LukieB
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658 posts in 498 days
#12 posted 112 days ago
Looking good Maur…. like really good. I really like the drawboring, gonna have to try that
-- Lucas, "Someday woodworks will be my real job, until then, there's this http://www.melbrownfarmsupply.com"
Don W
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9947 posts in 735 days
#13 posted 112 days ago
Mauricio, I’d never have considered building a bench like this but I really love it. I’m still unsure how I’d like a bench with flush legs ( no overhang) but it looks great. You’ll enjoy it a long time. Thanks for sharing the journey.
-- There is nothing like the sound of a well tuned hand plane. - http://timetestedtools.wordpress.com (timetestedtools at hotmail dot c0m)
jjw5858
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987 posts in 770 days
#14 posted 112 days ago
Great stuff, I too agree those draw bores will hold more than fine. Great looking bench my friend, you will always remember making it and look back when your older and smile. Awesome!
-- "Make something you love tomorrow...and do it slowly" JLB
Smitty_Cabinetshop
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6384 posts in 786 days
#15 posted 112 days ago
Outstanding bench with near-flawless execution. Wow.
From the finished surfaces to the screws to the splayed leg design, you’ve done amazing work on this bench. You’ve built a shop partner that will last several lifetimes, without a doubt. A long way to come from your starting point: a couple of thick oak planks. :-) Congratulations, looking forward to the final project post!!!
-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive
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