This one will be quite long but mostly photos because I want to make the process as simple to follow as I can.
To start off here are two ways to assemble the legs:
For the vice side I assembled the four sections first and then slipped the resulting finger joints together. Before this can be done there is one more operation to do and that is the cutting of the two rebates that will form the hole for he lower leg vice brace. Do these the same way as you cut the notches in the top framing and then assemble them face to face like this.
Continue to dry-assemble the leg as per the sketchup using just a few screws until the unit is together. Then, unless you are a lot better than me with a skilsaw, you will have a little clean up to do with a plane before glue-up. Once it is all cleaned up, disassemble it and re-assemble it with glue using the screw holes as a guide to accurately relocating the pieces.
Next assemble the top, bottom and back leg components in a similar fashion. If you want to shape the ends of the feet this is the time. I’m using a cheap jig saw to make the curve but just a 45 off the corner would look as good and could be done with the skilsaw. You don’t need the expensive circle marking jig, you can use a compass.
Once you have one cut, use it to mark the others, including the twelve parts “I”.
Dry fit the whole unit to check for square and look for any problems. With luck, you won’t find any.
Now you can slip the pieces apart, coat the insides of the mortises with glue and permanently assemble them with a couple of screws on each corner, both sides.
The other way you can assemble the legs is by laying up layer over layer all at once. They both work and are equally messy. First lay out one layer of the whole unit.
Then lay out the second, overlapping layer. Align them carefully and fasten with a few screws. Don’t put any screws in the areas where the verticals intersect the horizontals.
Continue with this until the unit is built up. Then slip it apart at the corners and clean up the edges with a plane.
Now mark all the pieces in the top layer “L1”, remove them and set them aside. Mark the next layer’s pieces “L2” and set them on top of the first. Mark “L3” and do the same. You don’t have to mark “L4” but I did for clarity.
Re-assemble piece by piece by first running the screws in just through the inner surface and then, after applying glue, use the screw tips to locate the piece before screwing it down tight. Once this is done you can add a few screws to get good pressure if you like. This may seem like a long way around but screwing these pieces together dry really makes alignment easier than with a layer of glue (ball bearings) in between.
As you glue up the layers, you will need to screw the corners together. Use an alternating pattern on adjacent layers to avoid hitting the screws in the layer below. I used top right / bottom left and then top left / bottom right on the next layer, then back to the first orientation.
When the dust settles you should have two leg assemblies that look like this and will support your truck.
That it for today. Sorry to be so long winded but this is supposed to be a beginner build-able bench and the details might make a difference.
Tomorrow the final assembly of the basic plywood bench. After that we will build the vices and the finish trim.
Here’s a peek.
Thanks for looking in
-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fiberglass trees. http://prmdesigns.com/