| Project by Doug S. | posted 573 days ago | 1924 views | 7 times favorited | 26 comments | ![]() |
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Well like everything I start, this took 5 times longer than I estimated to complete but it’s finally done (well 99% anyway).
The construction is pretty much following Sam Blasco’s bench on this thread
http://www.sawmillcreek.org/showthread.php?t=22081
Things Sam forget to mention though:
1) I make this look easy
2) You’re an idiot if you try this without a honkin big vacuum press bag like I have
3) Having a big slider TS sure beats trying to trim that top with a circular saw.
4) I make this look easy
This ended up at 28×78. The thickness was originally meant to be 4”. The top is (from the bottom up) 2 horizontal layers of 1/2” ply, 1 layer of 1” vertically laminated ply, 1 horiz. layer of 1/2” ply, then 1-1/2” of vertically laminated ply. The bottom 2 layers and top 2 layers were glued up separately, run through a wide belt sander, then those 2 slabs were glued together. The LH 2/3rds of the top ended up with a crown in the middle so more flattening with a router sled on rails was needed. That and the wide belt sanding made for a final thickness of around 3-5/8”.
The vertically laminated layers were done using yellow glue to glue 5-6 layers of ply – the most I could do and be able to cut it on the TS. Then those were cut on the TS to form sub-sections of the 2 vert. layers. After those were all formed, epoxy was used to glue those together while also glueing them down to the horizontal layer(s) beneath.
The hardwood edging, and vise jaws are purpleheart. Not the funnest stuff to work with, but I wanted something darker to contrast with the ply. Of the locally available options in 8/4, the PH ended being one of the better prices. It’s glued to the ply core with epoxy. The area around the Tucker vise also has #14-4” screws through the PH as well. It seemed prudent for supporting the 50 Lb vise weight.
The rear rail underneath is a piece of Macacuaba I pulled from my No-Kill Wood Shelter.
Noden Adjust-A-Bench leg hardware underneath which I’m already enjoying. It made for much more comfortable working heights as I completed finessing and finishing the top. The caster set rolls extremely well too. Maybe I’ll mount some masts and sails in the dogholes and take the bench for a spin around the neighborhood this summer:-))
Bison leather jaw liners for the Twinscrew picked up on eBay around 1/4” thick.
I wanted to be able to keep longer work flush with the bench front which is why the Tucker vise is mounted in that setback. An LV Surface Clamp in the dogholes on the front edge works to hold the opposite end.
Still need to finish up a couple of things but probably wont get to them for a couple of weeks.
-Finish touchup in a couple spots
-Easing the dog hole edges
-Drilling dog holes in the Twinscrew jaw
-A tiny bit more shimming underneath for the UHMW rub strips
-- Use the fence Luke































26 comments so far
Mottom
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29 posts in 798 days
posted 573 days ago
Wow,
I didn’t know that jealousy could cause me to drool this much. Darn, that’s a beaut of a bench and the cadillac hardware really complements it well. I f I had such a nice bench, I’d never get anything done because I’d be staring at it all the time.
-- New to the craft and loving every minute!
fredf
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320 posts in 605 days
posted 573 days ago
I wouldn’t DARE to use it. I wold ding it up!. You should put it in the dining room!. Sure is a mighty prutty workbench!
fred
-- Fred, Springfield, Ma
CharlieM1958
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7648 posts in 1114 days
posted 573 days ago
Great looking bench!
How good is the rigidity of that leg system?
-- Charlie M. "Woodworking - patience = firewood"
Doug S.
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306 posts in 603 days
posted 573 days ago
Charlie
With the casters adjusted down so that it’s sitting on the leg panels it feels rock solid. After I had all the work done on the underside I did a couple months worth of work on the top after I had it mounted on the legs and it wasn’t moving. Haven’t tried using it yet with the casters engaged but locked though so I may have something to report later.
Fred
I’m not sure I CAN ding it. That edge-up ply is tough as nails plus the finish is a few coats of epoxy. I actually didn’t discover my crown problem in the middle until after I had the first coat of epoxy on. So I had to sand that back off, and that was like sanding concrete. Then I initially tried flattening with handplanes. That worked but after only getting about 18” fixed over a week, I gave up and went with the router sled approach. A lot of that time was just continually having to resharpen plane irons.
-- Use the fence Luke
Scott Bryan
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20693 posts in 717 days
posted 573 days ago
Doug,
This is a gorgeous bench. I am beginning to really appreciate these “furniture” benches. I agree that it does seem a shame to beat them up like I do my cheap ones. I like the mobility of it as well.
Thanks for the post.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
stanley2
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278 posts in 691 days
posted 573 days ago
Obviously a well thought out project. I’m thinking that the quality of the bench will impact the quality of the work that comes off it. Your description indicates that great work doesn’t come easily.
-- Phil in British Columbia
GaryK
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9530 posts in 884 days
posted 573 days ago
Man, that is one nice looking bench! Very cool pattern makers vise also.
-- Gary, East TX -- The longest journey begins with a single step.
thetimberkid
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1944 posts in 599 days
posted 573 days ago
Nice looking bench!
Thanks for the post
Callum
-- For wood working podcasts with a twist check out http://thetimberkid.com/
Kevin
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294 posts in 853 days
posted 573 days ago
That is an amazingly beautiful top. I can honestly say that I have never thought of using the edge of plywood for a bench top. However, I may have to try it out after seeing yours.
No vacuum press though, so it may not be a good idea to try and tackle.
Deffinetly jealous of the vices. Those will be a great addition.
-- Kevin, Wichita, Kansas
Kipster
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1072 posts in 648 days
posted 572 days ago
That is a beautiful bench. I realize it took a lot of effort to make and I was wondering how many man hours it took to make.
Again beautiful bench
-- Kip Northern Illinois ( If you don't know where your goin any road will take you there) George Harrison
Doug S.
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306 posts in 603 days
posted 572 days ago
Kipster
That’s a tough one. Most of the work on this was confined to weekends, with a stray couple of hours during the week at night. There were also longer holiday weekends, vacation days, and my work shuts down from Christmas until after New Years, so about 10 days or so this year. But I also lost a few weeks during this to the flu, when nothing got done on it. I first bought the ply around September so this went on over a span of 8 months I guess.
-- Use the fence Luke
Dadoo
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1723 posts in 886 days
posted 572 days ago
Nice one! I really like the purpleheart trim. Might have to consider that when I redo mine.
-- Bob Vila would be so proud of you!
wpreman
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1486 posts in 608 days
posted 572 days ago
Very nice bench! I don’t know if I could bring myself to use it. Great Job!
-- Bill, Florida
SteveKorz
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2030 posts in 609 days
posted 572 days ago
I would have commented on this sooner, but my drool ruined my first keyboard!... That is awesome!!... you’ve done a fantastic job… I’m lovin’ the purpleheart.
Also, I’m having my wife paint me a sign to hang on our biggest pole barn, “No kill wood shelter.” That cracked me up… lol
-- As iron sharpens iron, so one man sharpens another. (Proverbs 27:17) †
Jon3
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439 posts in 1001 days
posted 572 days ago
Very nice. Purpleheart may be hard as nails, but it is beautiful when finished, and adds a great accent color.
How do you like the Veritas twin screw? I’m considering one myself. Does it require a lot of clearance under the bench at the end?
Doug S.
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306 posts in 603 days
posted 572 days ago
Jon
The screw spacing I ended up using (22-1/2” OC) means the screw actually straddle the Noden leg panel. So in theory I could have gone with NO clearance but I ended up putting 6” between the leg panel and back of the rear jaw. I forget the exact distance the screws protrude behind the jaw. I think that number is on LV’s catalog page instructon link, but that will shrink some too if your jaws are thicker.
-- Use the fence Luke
manilaboy
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122 posts in 831 days
posted 571 days ago
Very nice!!! I have just finished my bench. Dunno if i have the guts to post it. Hehehe
-- "Real jocks do it on a bench"
blackcherry
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730 posts in 718 days
posted 571 days ago
Massive looking bench…great work you should be proud and enjoy for many years to come..,Blkcherry
Dominic Vanacora
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504 posts in 765 days
posted 571 days ago
I have to buy one of those Tucker Vices….....Did you know how much they cost. WOW…... more than my table saw. This is a nice…no….Great Bench. You have spared nothing on this one. Great design. It looks to good to use. You have great skills.
-- Dominic, Trinity, Florida...Lets be safe out there.
Doug S.
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306 posts in 603 days
posted 571 days ago
Dominic
They weren’t cheap when I bought it either but fortunately I got mine before the big spike due to currency rates. That was a huge increase.
-- Use the fence Luke
Karson
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25802 posts in 1296 days
posted 571 days ago
A great looking bench. I’d hate myself the first time i dropped a bucket of paint on it.
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
bobdurnell
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197 posts in 792 days
posted 571 days ago
Very nice work bench. I love the purple heart and that adjusta bench stuff you used. I have seen it at some wood show. I used to cover my bench top with carpet until realized that it was a work bench and could handle the use no matter what happened. Use yours with pride.
-- bobdurnell, Santa Ana California.
mcoyfrog
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824 posts in 490 days
posted 461 days ago
Wow looks more then sturdy, way cool…
-- Wood and Glass they kick (well you know) Have a great day - Dug
mmh
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1385 posts in 618 days
posted 416 days ago
VERY NICE! I want one like this! This is nice enough to use as a dining table. Can you move it to the dining room? I have seen some really nice ones including this that are inspiring. Our current pine/plywood work benches do not compare. It looks like a lot of TLC went into this.
-- "They who dream by day are cognizant of many things which escape those who dream only by night." ~ Edgar Allan Poe
Doug S.
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306 posts in 603 days
posted 415 days ago
mmh


It’s funny you should mention that as the bench actually got moved OUT of a family room into the GaShop.
The shop isn’t heated and about halfway thru the epoxy glue-up stages it got too cold for the epoxy to cure. So I moved it inside and continued to work on it for the next 5 months or so.
-- Use the fence Luke
depictureboy
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309 posts in 538 days
posted 273 days ago
oh man ….. my wife would keeeeel me!
-- If you can't build it, code it. If you can't code it, build it. But always ALWAYS take a picture.