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Workbench Challenge #5: Assembling the Top

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Blog entry by shipwright posted 146 days ago 1652 reads 1 time favorited 9 comments Add to Favorites Watch
« Part 4: Fitting "from the work" and cutting the notches Part 5 of Workbench Challenge series Part 6: Assembling the Legs »

OK, I’m back from golfing and still have some photos left from yesterday. When I left off we had the inner framework of the top dry fitted. Now we can move on to the top and bottom sheeting of the torsion box.
Screw the top sheet in position, forcing the frame into square if necessary. Turn it over and then use a forstner or speedbore bit to mark the dog holes in it using the holes in the framework as a guide..

Next, mark the area where the wagon vice will go.

Then flip the whole thing over and screw the bottom on.

After removing the top repeat the marking of the holes and wagon vice location on the bottom sheet.

Now you can remove the framing and finish the holes in the top and bottom sheets.

I like to feel for the tip of the bit coming through and stop the hole. Then I finish it from the top for a cleaner hole with less chip out. If you don’t feel good about doing that, don’t. Just have a piece of scrap underneath the hole to minimize tearout.

I finished the holes with a little corner round because it is plywood and loves to splinter. If it were solid wood I wouldn’t do it.

That’s it for the top for now. We will get back to it after the legs are assembled. With a little luck that will happen tomorrow.

Thanks for looking in.

Paul

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fiberglass trees. http://prmdesigns.com/



9 comments so far

View gbear's profile

gbear

381 posts in 2605 days


#1 posted 146 days ago

Nice job…I wish I would have had this kind of tutorial when I built my first bench…or even knew about torsion boxes!

-- gbear, Carmichael, CA

View SPalm's profile

SPalm

4621 posts in 2387 days


#2 posted 146 days ago

Nice. Love the technique with the hole drilling.

I think you should glue the top and bottom to the torsion frame. And glue it to all the members including those middle strips. But maybe you need to get back inside for now, I don’t know, I guess you will for the wagon vise.

Looking really good though,
Steve

-- -- I'm no rocket surgeon

View Marco Cecala's profile

Marco Cecala

188 posts in 2539 days


#3 posted 146 days ago

Glad to see you back in Arizona. Need to plan a trip to hang with you and bask in your brilliance.

View Joe Lyddon's profile

Joe Lyddon

7454 posts in 2558 days


#4 posted 146 days ago

I think he's going to hold off with the glue until everything is done, vise / vice & all…
... then make with the glue… but, make it possible to service the vise (in the future, if req’d).

Just a Guess… will probably be wrong… BUT, I agree, things should eventually be glued…
... but if Paul doesn’t glue, he will have a good reason for it… :)

Looking good so far…

Thank you.

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View Jim Jakosh's profile

Jim Jakosh

10271 posts in 1611 days


#5 posted 146 days ago

Nice sturdy top. Paul. I do the same thing with Forstner bits every time. It prevents tear out big time!!
Cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!!

View NormG's profile

NormG

3632 posts in 1509 days


#6 posted 146 days ago

Lot of good work done here

-- Norman

View TopamaxSurvivor's profile

TopamaxSurvivor

14416 posts in 2181 days


#7 posted 146 days ago

Nice job and interesting design.

-- "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View shipwright's profile

shipwright

4670 posts in 1303 days


#8 posted 146 days ago

Steve , the bottom of the torsion box will have to be fastened to the legs first for rigidity. Then all the parts will glue up nice and strong.

.......... be patient. All will be revealed.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fiberglass trees. http://prmdesigns.com/

View stefang's profile

stefang

11826 posts in 1839 days


#9 posted 146 days ago

Good methodical approach Paul. It will be interesting to see how the legs and top go together.

-- Mike, an American living in Norway.

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