Coop Posted August 26, 2014 Report Share Posted August 26, 2014 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. I then planed the top smooth Quote Link to comment Share on other sites More sharing options...
Coop Posted August 26, 2014 Author Report Share Posted August 26, 2014 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. 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 1 Quote Link to comment Share on other sites More sharing options...
Llama Posted August 26, 2014 Report Share Posted August 26, 2014 Nice progress! Quote Link to comment Share on other sites More sharing options...
RichardA Posted August 26, 2014 Report Share Posted August 26, 2014 Looking good and solid so far. Keep us updated. Quote Link to comment Share on other sites More sharing options...
wtnhighlander Posted August 27, 2014 Report Share Posted August 27, 2014 Should be a very solid, and not bad looking, work surface. Quote Link to comment Share on other sites More sharing options...
Coop Posted August 29, 2014 Author Report Share Posted August 29, 2014 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"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.After the glue ups had dried, I cleaned the joints up w/ my Stanley 80 and now its time to layout my mortises Quote Link to comment Share on other sites More sharing options...
..Kev Posted August 29, 2014 Report Share Posted August 29, 2014 Looking good! Quote Link to comment Share on other sites More sharing options...
Coop Posted August 29, 2014 Author Report Share Posted August 29, 2014 Thank you sir. I've been working on this for a couple of weeks and am trying to bring it up to date quickly. It seems that I got into it so much that I forgot to take pics of each step. Quote Link to comment Share on other sites More sharing options...
..Kev Posted August 29, 2014 Report Share Posted August 29, 2014 Happens to all of us. More important to have a build you're happy with than to document the progress. Quote Link to comment Share on other sites More sharing options...
Coop Posted August 29, 2014 Author Report Share Posted August 29, 2014 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.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.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. Quote Link to comment Share on other sites More sharing options...
Coop Posted August 29, 2014 Author Report Share Posted August 29, 2014 With a satisfactory dry fit I added glue and clamps and set the end assemblies aside to dry 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 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. Quote Link to comment Share on other sites More sharing options...
Coop Posted August 29, 2014 Author Report Share Posted August 29, 2014 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. 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. 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 Ready now for the long weekend to start on the case and drawers Quote Link to comment Share on other sites More sharing options...
..Kev Posted August 29, 2014 Report Share Posted August 29, 2014 Really coming together! Looks awesome! Quote Link to comment Share on other sites More sharing options...
Coop Posted August 29, 2014 Author Report Share Posted August 29, 2014 Appreciate that. With the wife out of town this weekend, I hope to bang out some drawers without interruption Quote Link to comment Share on other sites More sharing options...
Freddie Posted August 29, 2014 Report Share Posted August 29, 2014 Appreciate that. With the wife out of town this weekend, I hope to bang out some drawers without interruption Lets hope that's all you'll be banging out this weekend, or you're going to be in a lot of trouble when she gets home. Quote Link to comment Share on other sites More sharing options...
Coop Posted August 29, 2014 Author Report Share Posted August 29, 2014 I thought about the words I used just as I clicked post. Too late then As long as the drawers are on glides and not being worn I should be safe Quote Link to comment Share on other sites More sharing options...
Coop Posted September 2, 2014 Author Report Share Posted September 2, 2014 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.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.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. Quote Link to comment Share on other sites More sharing options...
..Kev Posted September 2, 2014 Report Share Posted September 2, 2014 Awesome progress! It's always nice to have some shop time! Quote Link to comment Share on other sites More sharing options...
Coop Posted September 2, 2014 Author Report Share Posted September 2, 2014 Thanks Kev. By Sunday evening I had had enough sawdust so I called my daughter and met for a couple dozen oysters and a brew or two. 1 Quote Link to comment Share on other sites More sharing options...
Coop Posted September 2, 2014 Author Report Share Posted September 2, 2014 Drawers glued up and sanded. 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. Never a doubt Next I applied 2 coats of Arm-R-Seal and added the drawer glides. 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. Quote Link to comment Share on other sites More sharing options...
..Kev Posted September 2, 2014 Report Share Posted September 2, 2014 Wow! That looks awesome! You should be ok with just the glue. 1 Quote Link to comment Share on other sites More sharing options...
TerryMcK Posted September 2, 2014 Report Share Posted September 2, 2014 Great progress so far Ken. I must have missed your first few posts. 1 Quote Link to comment Share on other sites More sharing options...
TerryMcK Posted September 2, 2014 Report Share Posted September 2, 2014 Being slightly nosey what goodies do you have in that big cardboard box with CA on the side? Quote Link to comment Share on other sites More sharing options...
Coop Posted September 2, 2014 Author Report Share Posted September 2, 2014 Thanks Terry. That is a HF dust collector that I received for father's day a couple of months ago. I just put it together and from just a small amount of usage, I really like it. 1 Quote Link to comment Share on other sites More sharing options...
tim0625 Posted September 4, 2014 Report Share Posted September 4, 2014 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. Quote Link to comment Share on other sites More sharing options...
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