While I have given quite accurate dimensions in the plans, I would never recommend that you take any measurements as the final word in getting good fits. I always fit “from the work” using the measurements as a guide. I will explain this as we get into this segment.
To begin the half-lapping of the bench top framing, lay out the long pieces and clamp them as a unit. Then mark the half-lap notches on them. Mark one side of the notch from the dimensions but mark the second with a piece of your plywood as a spacer. The plywood is not actually 3/4” and you want a snug fit.
Here the first notch has been cut and a piece of plywood is fitted in it to lock the pieces together in alignment while the rest are cut. The next notch has had its edge cuts made, just inside the lines.
Then you make a few more cuts between the first two and pry the scrap out with a chisel. Follow this up by “planing” the bottom of the notch by moving the saw from side to side as you advance it through the cut. It is easier than it sounds.
This is what your fit should look like.
Here all the notches are cut.
Now begin laying out the cross pieces. There are some notches that are double width for the dog hole logs. Be sure to mark them with two pieces of plywood as a marking spacer.
Parts “R” and “O” now get a spacer, “P” on each side and then another notched in strip. Again, fit from the work. If you use measurements here the tiny differences in thickness will start to add up so use a piece of scrap to make the marks and then transfer those marks to cut the corresponding notches in part”O”.
With all these parts dry fitted, screw the corners together with some slim 2” screws. They won’t split the plywood and will hold well if you drill for them first.
Set this assembly aside and we will move on to the top and bottom of the torsion box table top.
...........but that will have to wait. I’m golfing tomorrow.
Thanks for looking in.
-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fiberglass trees. http://prmdesigns.com/