/*

Workbench Build – FINISHED!

And…I’m calling it finished. Technically, there are a few more small things to do, but the projects await and the bench needs to prove its usefulness. Once the next two projects are done, I’ll take time to square up the left end of the bench, flatten everything and fine tune the bottom shelf.

After the leg vise, I added a planing stop. The stop is doug fir, about 12″ long. This was probably the most difficult mortise in the bench, and I accidentally blew out some on the underside of the bench while I was chiseling it out.

And of course, I had to enjoy some Wilshire in my handmade pipe. Recently re-buffed with Carnuba.

With a few holes drilled out and the planing stop added, it’s starting to look good.

One of the best secondary uses for me has been to support work when I am crosscutting on my miter saw. I simply raise the stop up and it keeps everything level while I cut.

Quick demonstration of the incredible leg vise. Love this thing. Here I am fine tuning some massive tenons for a bunk bed build.

And, ta-da! Had to rehang my Hornets penant closer to the bench, and tried to get my great-grandfathers tool chest in the photo. With beer just within reach in the fridge behind the bench, I think I’m really going to enjoy this setup. I use leftover SYP 2x’s to build the bottom shelf. Each is rabbeted to interlock together.

Titus is happy I’m done. Maybe one day I’ll get him to chill in the shop like this with me.

Workbench Build: Top attached, leg vise construction

Unfortunately, we got rained out while trying to camp this past weekend and had to head home early. Fortunately, that meant more workbench progress. My bench is considerably lighter than a full Roubo, but man is it heavy to keep moving the base between the bench top and the floor! Whew, glad that is done. First up, drilling/chiseling out the big mortises.

After a few test fits, all is well and the draw-boring begins. You’ll notice the legs aren’t perfectly flush with the top – each part will need a bit of cleanup after it’s assembled. I want to assemble it, let the wood settle down and then finalize it with the cleanup.

I’ve recently been going through The Fellowship of the Ring for the thousandth time. This rainy day of draw-boring and top assembly called for the audio version and a pipe. Notice the flashlight for seeing through the pin holes and the Kershaw Emerson CQC-5k for tapering down the pins.

Next up, the leg vise – the part I have been waiting for. Lined up the vise and mortised for the parallel guide.

Good fit!

And…everything lines up! You’ll notice a gap at the top – that is perfectly fine. The entire vise will hang about 1/4″ – 1/2″ off the ground, so it should fit snug against the top.

Next up, I finished shaping the leg vise and then clamped it up to the leg where I want it to sit. This gives me a test fit of everything before I attach the parallel guide and so that I can bore the hole in the right spot.

Next up, I wanted to embed the vise screw hardware into the leg. I have seen some put this on the outside of the leg, but I hate the look of that. It was tempting, since it was over an hour of additional work to chisel out the large taper and mortise. Here’s a shot about halfway through as I am tapering with a straight chisel.

Accidental selfie trying to take a pic of the finished work. Loving my Artifact Bags apron!

Finally ready to attach the parallel guide. Did this with a wedged tenon. You’ll notice the blowout on the bottom right – looks bad here but the wedges really filled it out and it’s tough to notice now.

Taking a final look before assembly. You can see the embedded hardware here – love that it is flush mount!

You’ll also notice I added a brand to the front. This is the same thing I use as a bookstamp, but with the Fangorn Workshop logo inside the head instead of ‘rybo’.

Ta-da! Everything is assembled and running smooth. I dropped a few drops of mineral oil on the vise screw and it made a tremendous difference. After opening and closing the jaws a few times, there was a noticeable improvement in the smoothness of the screw.

Overall, I love this thing. Hands down my favorite (and most satisfying) part of the workbench build. It is super strong and I spent a big part of the rest of the day just clamping random things…because I can.

Next up, holdfast holds, flattening the top and I will be done!

Workbench Build: Legs, part 2 – base complete

The base is complete! Last night I finished drawboring the side stretchers into the two sets of legs. A total of 8 mortises that I cut by hand – something I find really enjoyable. I cut the leg tenons and long stretcher tenons by hand, and the small stretcher tenons on the table saw. True hybrid woodworking!

I placed these mortise for these stretchers 1″ in from the outside of the leg. This makes the stretcher inset about half an inch. In retrospect, I should have just made them flush, but I was thinking I would beef them up if I add a deadman. Bad idea, I could have just added a top piece for the deadman. Ah well, live and learn.

Test-fit…not quite.

Got great use of my great-grandfather-in-law’s (!) brace and bit and auger bits. They were beasts, but need to be sharpened after all this. Which, I don’t know how to do.

Post draw-boring. You are looking at the back legs (I placed the laminated posts in the back). So far, so good on the draw-boring. I have yet to have a pin explode, but I suspect that a few pins have not made it all the way through their tenons into the other side. However, for each leg I’m fairly confident that one if not both pins have, so I feel good. All but one stretcher was draw-bored without glue (creature of habit when I did the first one).

Getting close! Next up will be flattening the bench, cutting the huge mortises, and attaching the base.

Workbench Build: Legs, part 1

The workbench continues. Finally got some great red and white oak from the Asheville mountains, and I’m ready to complete it.

First, need to notch out a spot for the parallel guide on one of the legs. I made the first cuts on the bandsaw, then chopped out the waste with a chisel.

 

Then the huge leg tenons that will fit into the workbench top.   

 

Then the mortises for the stretchers.

 

Which are drawbored and pinned.

And set #1 is complete! 

While working, I found this date scribbled in my great-grandfathers tool chest. 1936!

Workbench Build – Rips & Laminations

Day 2 of the workbench build happened this Saturday. A friend at work was generous enough to give me his old Ryobi 10″ table saw when he upgraded to a Rigid. I decided to break it in by ripping the surfaced boards into ~2.7″ pieces for the top.

Going in, I knew that some of the boards were a little warped, but I thought it would be easier to straighten them out when they were ripped into smaller pieces.  Most of it isn’t that bad, and can be clamped out.  The two walnut pieces I ripped are worse than the others, so I’m not sure what’s going to happen with those.

The pieces had some variance in width, so I picked the smallest and ripped it in half, then used that size to rip the remaining boards.  This means that some of the pieces are over 2.7″ – I plan to just surface that later once they are glued up.

A friend stopped by to help me with the rip cuts – after all, each board is over 6′ long and holding them level throughout the entire cut is difficult. He snapped this while acting as my outfeed table.

20131117-221737.jpg

Post-cuts.  You can see the plan for the final top – 4 laminated oak pieces, a walnut accent strip, 4 more oak, another walnut accent, 4 more oak.

20131116-224651.jpg

Clamps, clamps, clamps.  I need more clamps.  I decided to start laminating the pieces two at a time, then I’ll rough surface them, glue them into 4’s, etc etc.

20131116-224704.jpg

20131116-224726.jpg

While waiting on the glue to dry, I decided to hang some of the proposal boards that have been sitting almost two years now.

20131116-224742.jpg

And a glimpse at my new shop dog, Titus.

20131117-221709.jpg

The Workbench Build

*/