terryR's Bench Blog #1: Cutting and pasting the legs

Welcome to terryR’s Bench Build Blog…

I’m sure you know the story…I need a bench…so, let’s build one, right? Only problem is that I’m very much a beginner woodworker, so a bench can be quite intimidating when first considered.

Luckily, I recently purchased Paul Seller’s book Working Wood 1 & 2 which is full of information on using hand tools. I’ve learned quite a bit from hanging out in the forums on LJ’s…but I also love to have a good book from a recognized master for other opinions and ideas. If you are new like me, this is an awesome book…

Anyhow, Mr Sellers has a simple bench in his book on which he teaches his students. To me, it looked very simple, but at the same time, very functional. I decided to give it a try…although with a few size modifications. Here is a version of the bench I found on the web, and mine should look similar. I plan to add one face vise as shown here, and another similar vise at the tail end and tons of holes for bench dogs…

I chose Pine for the bench…cheap…available…perfect. It’s just too bad the big box store has a different standard for what they consider ‘kiln dried’ lumber. To me, that means 6-10% moisture content. So, I bought a stack of 2×10’s and stickered them in the shop to dry a bit…this photo shows about 2/3 of the pine…’premium’, huh?

In hindsight…I should’ve built a small dehumidifier-based kiln and dried the lumber for a week or so…but I was lazy and addicted to the newly acquired lathe…so put it off till never. After a couple of weeks I got the itchy trigger finger and decided it was time to cut and paste some pine! I need a bench!

All the cutting and 4-squaring of the pine took place using the miter saw, band saw, jointer, and planer…ummm…powered tools. Then, I swept the 5 1/2 over the surface to remove tool marks. Love me that 5 1/2…

If you count the number of 3”x4” legs in the photo above, you’ll notice there are FIVE. I’ve learned that trick here on LJ’s…number five is for practice. And it certainly paid off for me. This was my first attempt at a M/T joint! The first mortise was darn ugly. Here’s the second…a bit cleaner…but the haunch wasn’t laid out properly…ooops…

Lucky for me, the Book said to lay out all the mortises at the same time to avoid error…

Hmmm…good idea! Then, it was just a matter of hammering out all the pine between the lines. I actually enjoyed this part very much, and look forward to more mortises…

Well, except for ones like this…

…note to self…Do Not cut and paste lumber so knots appear exactly where joints are supposed to be placed!
But…all worked out OK in the end. Here are the 4 legs and an LN bevel edge socket chisel that survived all the 4” deep mortises with no problem. But, I can attest to the fact that the Hornbeam LN uses is harder than the Bubinga mallet I’ve been using to hammer with…just a little. Next note to self…Gotta start looking for Hornbeam!

You might also note the small deposit of O+ human red blood cells on one of the legs. For some reason, I tend to hold the chisel right on the socket section, so the sharp edges nearby kept grabbing me. I’d hate to take those edges off…guess I better get used to wearing a band-aid at the base of my forefinger!

Next, I focused my attention on the upper and lower leg rails. This is where I made a change in Sellers’ plan because his bench was only 24” deep…not enough for me. I added only 6”, but I think that will be valuable space. So, I measured and cut the rails accordingly…the lower rails are 1 1/2” longer so the tenons protrude in a pleasing manner (hopefully).

You may also note that I’m already working on a bench-like thingy. I can’t remember which LJ I stole this plan from, but I have several of these 2×4 tables in my shop. One for the miter saw, one for the lathe, and the one in use now will become my new sharpening station soon! These tables are certainly strong, but not fine woodworking in any way, shape, or form. So, on we continue, and hope for something a bit stronger, and even better looking.

trying to keep a bit of accuracy…

This is far as I have gotten to date…I marked out for the tenons, but haven’t started yet because I’ve spent all day typing this blog with my ten thumbs!

As far as the huge tool well on Sellers’ bench, I’m still undecided. Well, mine won’t be as large if I choose to keep it. But on the current table I’m using to build this bench, I have a tool well sort of. And…so far…I like it. I’ve read the LJ’s blog on well vs. no well…and I can see both sides pros and cons…

More to come as soon as I can…Comments, ideas, and free donations are always welcomed…

-- tr ...see one, do one, teach one...