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Old 12-03-2017, 11:57 PM
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Default Yet Another Bench Thread

Hi folks,
Been a while, but I thought I would post progress on this bench that I started several years ago. I got sidetracked building the boat shop bench, and the Point Comfort 23 too, but I'm working on it again. It's a Roubo-ish thing. Pretty hefty, from solid ash. I'm working on the vises now, but I'll post some pics from the beginning. I did not document this project very well, so all the nitty gritty details are scant.


I bought this when ash was cheaper, after the market flooded with ash beetle trees that were cut all of a sudden. I dithered a little, and the price went from $2.75 to $4.00 in a week. Spent about $400.









I hear the supper bell ringing. Will pick this up later!
Cricket
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Old 12-04-2017, 01:08 AM
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Default Re: Yet Another Bench Thread

Appears you have my bandsaw.
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Old 12-04-2017, 02:02 AM
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Default Re: Yet Another Bench Thread

The Minimax. Good machine. I'll tell you though, I have a 17" Grizzly out at the boat shop, and except for the guide adjustments I like that saw as well as the MM16. Kind of heresy, but it's the truth. If anything, the Grizz is quieter and smoother. The MM has a bigger motor, but I haven't bogged the 2hp Grizzly down yet. I had some issues with the MM's fit and finish, for a pricey saw.
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Old 12-04-2017, 04:35 AM
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Default Re: Yet Another Bench Thread

I find mine kinda crude.
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Old 12-07-2017, 02:18 PM
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Default Re: Yet Another Bench Thread

Ash is a nice wood to work with. I have a pile that my wife inherited, but it has been ravaged by borers.
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Old 12-07-2017, 07:10 PM
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Default Re: Yet Another Bench Thread

" Buggy" is the hot thing here, costs extra for furnature made with it.
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Old 12-08-2017, 02:40 PM
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Default Re: Yet Another Bench Thread

I bought all 8/4 material, so the legs and stretchers were glued up. Legs finished 3-1/2" x 4-3/4".





I glued up the bench ends permanently, but attached the front and rear stretchers with bench bolts. For some reason the bolts were not long enough for my set up (the reason has been forgotten), so I bought hex drive cap screws in black from Mcmaster.



I'm going to saw out my leg vise today. More later. Thanks for looking.
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Old 01-05-2018, 11:11 PM
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Default Re: Yet Another Bench Thread

To continue- The legs and rails were glued up similarly from 2 8/4 thicknesses. I need to be able to knock this bench down into movable (barely) components, so I glued up permanently only the leg end assemblies, and used those bench bolts to connect the front and back rails to the leg ends. The legs and end rails were glued up with floating tenons, and mortises in each component.


This is not me, but this is the Felder mortiser I used for the floating tenon mortises.


That's the tenon stock which gets cut to length. Kind of like a big Domino.

For some reason, the Benchcrafted bolts weren't long enough to join my rail to leg assemblies, and I don't remember why now. But I bought these hex keyed bolts from McMaster.





I do have to tighten these up from time to time.

Anyway, I glued up the two leg assemblies, and worked a similar tenon into the front and rear rails. I bored the legs for the bench bolts on the mortiser, then clamped up the rails, and took a 10" long, 9/16" brad point bit to bore into the rail. The bench bolt nut goes into a 1" diameter hole bored ino the back of each leg. It was pretty tricky getting both holes lined up so that the bolt threads smoothly into the nut.


Murky pic, but this shows the nut in the back of the leg.

I had already glued up the final top assembly, ripped it to width, and cut it to length on the Martin. My new little personal workshop is upstairs in my Brooklyn house, in a spare bedroom. The top alone is 160 lbs. I got a friend to help me and my wife hump this, plus the legs and rails upstairs.


And here's the top.

I'll show the how the top goes onto the legs in the next post.
Cricket
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Old 01-06-2018, 01:56 PM
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Default Re: Yet Another Bench Thread

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Old 01-06-2018, 03:37 PM
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Default Re: Yet Another Bench Thread

The top is connected to the base with floating tenons, plus lag bolts from under the end rails. These bolts run through elongated slots to allow movement of the top, but the top is registered flush to the legs with the tenons. These tenons are beefy to withstand the force of the leg vise pushing against the top. They measure 1-3/4" x 2-1/4", buried 1-3/4" in the legs and top. A real tenon would be better, but I didn't have enough length on my leg stock, and I think it will be fine.





Notice one of the dog holes enters the mortise. Hard to plan everything, with conflicting requirements for various components. So I have short and log dogs.

The mortises were cut with a jig and plunge router with collet.



My wife helped me flip the top upside down, and back upright again. Not near as bad as carrying the 160# up the stairs.

Anyway, here we are with the top on.






Vises are next, stay tuned.
Cricket
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