A lot’s happened lately! I pegged the long stretchers. Funny story. In my mind, the pegs in Schwarz’s Roubo were 5/8”. I didn’t have a 5/8” bit, but I had a very nice 3/4” one, so I used that and made 3/4” pegs. I figure, maybe they’re a touch bigger than the ones Chris used, but hey, no biggie. Just the other day I realized: Chris used 3/8” pegs!!! Haha, oh well, the Schwarz has said that you can’t overbuild a workbench, right?
The only thing that went wrong is that I drilled the hole in the wrong spot for one of the pegs. In a show piece, that would have ruined my month. But hey, it’s just a workbench. I plugged the hole with a scrap of peg and did it again (you can see it in the front left leg).
Then I glued up my interior 12 boards, which determined the length of my short stretchers. So I glued up my cut-to-length short stretchers and pared the tenons until they fit in the leg mortises.
But here’s where I had problems. Somehow, the front and back leg mortises on the right were just misaligned enough that the stretcher was not wanting to go in all the way. I did everything. I laid the base on its back and jumped up and down on the joint. Literally, it was just like you’d picture a cartoon character jumping up and down on something, like a suitcase getting it to close. I squeezed all four of my 48” clamps on it hoping to get it in. Finally I whittled a severe one-sided taper on a peg and hoped for the best. It worked! So while that joint might not be the best, it’s pegged and not going anywhere. If I’d used 3/8” pegs, it would have never worked.
And so now I have a base! Next step is to glue the next two boards on each side of the 12 you see in the picture. Then the benchtop, as it were, will be able to sit up on the legs. You can already see on the benchtop (far left of the pic) the start of the void mortise for the planing stop.
It gets a little tricky here, as I need to figure out how to glue up the rest of the boards around the tenons. I only have 4 big clamps, and they’re not very good, so I don’t really want to just glue them up while the benchtop is in place on the base. So far I’ve been gluing up the benchtop on its side, with the newly-glued piece at the bottom, so the weight of all the other boards serves as a “5th clamp.” But this gets harder and harder as the top gets heavier and heavier, and it also involves constantly removing and replacing the benchtop on the base to check for fit.
Light at the end of the tunnel, but it still may be a while until I’m out of it! (Absolutely must be done by year’s end.)
-- Eric at http://adventuresinwoodworking.com