Well my Friends I have been at if for some time now and felt it was time to get busy I worked on the legs first after a critical error the leg assembly had to be broken down which was a big job and then the legs were taken back one step the outer legs were re worked and the bench was put together for a test fit and to let the tops lye flat for a while to get them as flat as can be.
First we made the leg assembly this is a through mortice that is back cut and wedged together for a tight fit
Next we cut the mortice for the half lap dovetail the edges were cut with a hand saw and then the waste was removed with a router. Using the CRB7 from M-power and an extra wide base to bridge the mortice.
After Routing close to the boundary cut I cleaned up with a sharp bench chisel.
Now the Half Lap Dovetail Mortices are ready to go there are two per leg the upper and the lower
Next it was time for the dry fit no bolts just to make sure every thing is going to fit.
After the dry fit I glued the outer legs to the Leg assembly. No room for error on this so hurry up because when its 120 in the shop the glue is a fast set up less than 4 minutes and it wont budge.
The next step was letting it settle I have it set up in the shop and am letting it sit clamped flat for a couple of weeks to insure it is done moving for a while. The Old timers call this step resting the piece. I believe it helps and so I am doing it. After a week I will cut the tops to their finished length of 90 inches. I don’t have a 12 inch Sliding compound miter saw so I will make the cut with my Bora wide body clamp and my Circular saw. Then I will finish the cut with My trusty D7 Hand Saw. After that I will be time to make the tool trays they are 4 boxes that are make to sit on cleats in the gap between the tops they have a dual purpose. They are tool trays or if you flip them over they widen the flat top of the bench. I will be making mine out of Black walnut. As that is the accent wood I chose. The plan calls for locking mortice joints I feel that is a big understatement and am leaning towards dovetailed boxes. I think the Dovetails will be done on the Woodrat. I have too many to do by hand and feel the Woodrat is second best. I will be doing a prototype box first and I hope it looks as good as I see it in my plan. The next Blog entry will be on the Tool Box build so stay tuned for the next issue Cheers.