Hybrid Work Bench


Coop

Recommended Posts

I've decided to revert my work table back to a table saw and build a flat surface to pound on. Since I am more of a 110v. tool guy, I'm not going the Roubo route. I found that back in 2003, Christopher Schwarz did a "24 Hour Workbench", so with that general design, and ideas from some of the clan here, I begin.

 

Since I am halfway limited for space and the top of my bench will be made of plywood, I decided on 3/4", 5' x 5' Baltic Birch. I took 2 pcs. and cut them in half, using 3 sheets, 30" x 60". I glued 2 sheets and screwed them together until the glue set, then removed the screws and repeated the process with the 3rd sheet.

 

post-14556-0-05085600-1409089900_thumb.j

 

I then planed the top smooth

 

post-14556-0-17804400-1409089918_thumb.j

Link to comment
Share on other sites

I attached 1/4" hardboard w/ brass screws as a sacrificial surface. I'm skirting the top w/ 7/8" thick pecan using finger joints.

 

post-14556-0-95924600-1409091729_thumb.j

 

post-14556-0-50641100-1409091771_thumb.j

 

post-14556-0-08883900-1409091800_thumb.j

 

Mr. Schwarz mentioned in his build that the glue should hold the skirting to the ply edges of the top. I'm taking a little extra precaution and am adding 1/2" walnut dowels drilled 2" into the ply top

 

post-14556-0-19569000-1409091942_thumb.j

  • Like 1
Link to comment
Share on other sites

The base of the bench is a sled-foot trestle design. I am using some 80-90 year old knot free SYP that has some sentimental value (another story). I have approx. 18' of 7/4 x 11" wide boards that I planed to 1.5"

post-14556-0-45838500-1409329000_thumb.j

post-14556-0-73234300-1409329024_thumb.j

For the legs, I've ripped the 2x's to 3.5" and laminated 2 together for a total of 3" x 3.5". I did the same for the sled feet and top members and set them aside to dry.

post-14556-0-38757200-1409329616_thumb.j

post-14556-0-21388900-1409329640_thumb.j

After the glue ups had dried, I cleaned the joints up w/ my Stanley 80 and now its time to layout my mortises

post-14556-0-36705200-1409329907_thumb.j

Link to comment
Share on other sites

To attach the legs to the feet & top members, I'm using peg mortise & tenons. I drilled the holes for the thru pegs at the drill press prior to starting the mortises. Even using a backer board, I still got a little blowout on one of the holes for the peg. Again at the dp, I used a 7/8" forstner bit to remove most of the material for the 1" mortises and cleaned them up w/ chisels.

post-14556-0-25007200-1409331320_thumb.j

post-14556-0-19271300-1409331337_thumb.j

post-14556-0-08622300-1409331353_thumb.j

After the mortises and holes for the pegs were complete, I cut the thumbnail profile on the feet at the band saw.

With a sigh of relief, as this is only my second attempt at mortise and tenons, on to the tenons. Because of limited experience, I thought it best to nibble away gradually at the table saw. I found this to be a very slow but accurate process.

post-14556-0-68490600-1409332733_thumb.j

The two end sections will be connected by upper and lower stretchers, front and back, made from 6/4 poplar. I again am using mortise and tenons and will use countersunk 5/16" x 5" lag bolts thru the legs into the tenons.

So, back to the dp to start the mortises in the legs for the stretchers.

post-14556-0-34036500-1409333018_thumb.j

Link to comment
Share on other sites

With a satisfactory dry fit

 

post-14556-0-26513000-1409341915_thumb.j

 

I added glue and clamps and set the end assemblies aside to dry

 

post-14556-0-82806800-1409341969_thumb.j

 

While waiting for the glue to dry, it's back to the table saw to cut the poplar stretchers to length. I then cut the tenons, again using the stacked dado

 

post-14556-0-21456500-1409342074_thumb.j

 

With stretchers cut and end frames dry, it's time to put them all together w/ glue and clamps. After assuring everything is square, I drilled into the tenons of the stretchers from the predrilled holes in the legs and added the lag bolts.

 

post-14556-0-66792000-1409342254_thumb.j

Link to comment
Share on other sites

As an afterthought, I decided to add more stretchers, front to back for added support. So with the router , I cut the mortises in the bottom rails. This pic shows the base laying on it's back.

 

post-14556-0-59021600-1409343447_thumb.j

 

As my bench will go just inside my overhead garage door, and as the builder, unfortunately poured my driveway even w/ the garage slab, I decided to add some sacrificial pads onto the feet to keep them off of a possible damp slab. I used some pieces of teak that I had.

I also drilled thru the tenons in the legs and tapped in the 1/2" walnut dowel pegs and sanded them smooth.

 

post-14556-0-95722300-1409343749_thumb.j

 

Back in the upright position, with a coat of Arm-R-Seal. HF dust collector in background, still in box, waiting anxiously to be assembled

 

post-14556-0-27109700-1409343941_thumb.j

 

Ready now for the long weekend to start on the case and drawers

 

 

Link to comment
Share on other sites

I've always thought that a guy could never have too much fried shrimp or shop time. With my wife out of town and not having to do honey do's, I think I almost limited out in shop time these past 3 days :)

With the available space below the worktop, I figured I had 3 options. I could just add a shelf, enclose it as a cabinet for storage or add drawers. I find the trouble w/ shelves and cabinets is stuff tends to accumulate quickly so I opted for drawers. I made the case from 3/4" BB plywood using rabbet joints. Dados were cut for dividers and horizontal braces. I clamped and glued the pieces, all except the top which is left un-glued to make it easier to add the drawer glides later.

post-14556-0-44507000-1409674241_thumb.j

post-14556-0-30942200-1409674267_thumb.j

The bench top is already being put to use.

While the glue dries on the case, I planed a 4/4 piece of 10" wide poplar for the drawers.

post-14556-0-88577000-1409674462_thumb.j

After cutting the drawer sides to size, I used a Rockler box joint jig and a 3/8" spiral bit to cut the fingers. I also routed a 1/4" groove for the drawer bottoms.

post-14556-0-14746000-1409674613_thumb.j

Link to comment
Share on other sites

Drawers glued up and sanded.

 

post-14556-0-04521400-1409676699_thumb.j

 

I decided just for the heck of it, before going any further, to make sure the case will fit into the hole in the base.

 

post-14556-0-80366300-1409676833_thumb.j

 

Never a doubt :D

 

Next I applied 2 coats of Arm-R-Seal and added the drawer glides.

 

post-14556-0-38501400-1409676924_thumb.j

 

I'm glad I left the top loose as it sure made installing the glides in the case much easier.

After test fitting, I cut the walnut pieces for the face frame and assembled it w/ pocket screws. I failed to drill pocket screw holes into the sides of the case to attach the face frame so I'm betting glue alone will hold it. After 3-4 hours in clamps, clamps are removed and I'm calling it quits for the weekend.

 

post-14556-0-37953100-1409677295_thumb.j

 

 

Link to comment
Share on other sites

Ken,

You might consider not even securing the box at all.  Gravity would probably hold it fine but if you did need to, some sort of bracket underneath would hold it but also make it removable.  That way, if you ever had a problem with the drawer slides or anything else, you could just slide the box out and work on it.

Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

  • Who's Online   0 Members, 0 Anonymous, 36 Guests (See full list)

    • There are no registered users currently online
  • Forum Statistics

    31.2k
    Total Topics
    421.8k
    Total Posts
  • Member Statistics

    23,759
    Total Members
    3,644
    Most Online
    R Parekh
    Newest Member
    R Parekh
    Joined