Work In Progress (workbench build)

[randy618]

Hey folks!

After an encouraging conversation with Sir Timber, I've decided to post a thread about my first-ever work in progress. This project was conceived out of the need for a sturdy workstation that could take a beating, for the sake of sparing the other household furniture from such abuse. Needless to say, it's been a learning experience thus far.

I used a plan from YouTube. Since I can't post links yet, look for "How to Build a Workbench" by texanocalderon if you want to know what I'm talking about. I had to derive a hard-copy plan from what is shown in the video, since after several days of fruitless searching, I gave up looking for the actual plans online.

Please remember that I'm still a total rookie and bear in mind that esoteric woodworking jargon including but not limited to "tenon," "mortise," "joinery," and "dovetail" were not in my vocabulary when I started this project. Thus, the legs are held together by glue and wood screws. Now that I've done some more homework (and picked up some more tools ;) ), I plan to use tenon and mortise joinery to connect the crossbeams to the legs.

All of the dirty work is done in the parking garage of my live-in girlfriend's condo, or out on the floor in the open-air walkway just outside our front door.

For the tabletop, I was faced with a dilemma: I don't have a circular saw, and my hand-sawing skills were limited at the time of gathering the wood, so I decided to use 2x4s for the tabletop instead of plywood. Think "butcher block" meets "plank top" meets "picnic table".

Some of the 2x4s are pretty badly curved and/or have slight bowing and it took a while to arrange (i.e. flip/rotate/substitute) the 2x4s in the best possible way to minimize the gaps between them. I've only got two 32-inch F-clamps (P700 each from Fineline, Las Piñas) at my disposal, at least for now.

Now for some questions:
I've read that some folks recommend using steam or actually slightly wetting lumber to straighten warped or curved boards. Have any of you tried this? How did it work out? And what else would you suggest I do to prevent/minimize gaps between the boards?

Looking back, one of the ironies I've learned is that you kinda need a workbench to make a workbench; maybe I should have at least made a couple sawhorses and slapped a door on top of them to make this easier on my back. Looking ahead, there's gonna be a lot of sawing, sanding, planing, and heavy lifting in the near future!

It just occurred to me, now, at the time of this writing, that this workbench is going to be entirely made of 2x4s. So far.

Time for me to practice making joints on wood scraps. Pics to come (as soon as I figure this out!)

8)

[timber715]

nice Randy, we look forward to your works in progress (WIPs), 2x4's does pose a lot of work especially what we have here. getting a good source of wood is something I cherish a lot, they give me free access to all their wood to choose from and gives me less time squaring and cleaning them. choosing the wood carefully takes a bit more time but will make our work much easier.
welcome to pinoyhandyman...
cheers

[randy618]

Having a hard time posting pictures, so just check my photo album to see pics of this project. ;D

[timber715]

hope you have a photobucket account... upload your pictures there and get the link to post here... hope this helps

[randy618]

http://i1026.photobucket.com/albums/y322/randy618/Workbench%20Project/CRW_4680.jpg
http://i1026.photobucket.com/albums/y322/randy618/Workbench%20Project/CRW_4678.jpg
http://i1026.photobucket.com/albums/y322/randy618/Workbench%20Project/IMG_4681.jpg
Hope this works!

[timber715]

hehehe, edited your post, things to consider in posting pictures.
1. try to limit the size to 640x480 pixels.
2. use the lowest link in your photobucket, the one with the "IMG" link.

[randy618]

Ahh okay...I'm new to photobucket as well. Thanks timber! Advice duly noted.

[timber715]

you can actually resize the pictures from photobucket...
btw, will edit your title as well for others to search better...

[owyn]

Awesome. I kinda envy the 'just do it' mentality of other people sometimes. How many days/hours into the project are you?

(Here in my workshop, fixing the jointer is my first step to the greater goal of making a 5 foot workbench.) I can't remember who it was, but someone gave me the link to scott landis's workbench book before...

[randy618]

Hi Sir Owyn!
I'm only a couple actual work hours into the project, spread out over this past week, gathering tools and materials along the way that I've discovered I needed to complete the task, and also running into problems inherent to inexperienced rookies like me. Under ideal conditions, this project would take less than a day.

One thing I don't have (and would find handy) is a jointer. The only power tools I've got are a compound mitre saw (Ozito) and a drill (Talon). This project is mostly an exercise in using my hands. So gathering proper power tools is another thing I'm looking forward to.

Speaking of books, I've been looking around for workbench and general woodworking books, and there aren't very many I've come across. The other day I was at Fully Booked at Bonifacio High Street, and I only saw a couple books in the Hobbies and Scrapbooking section. The whole time I was checking the Art/Architecture and Design sections, where there's a wide array of books on working with plastic, iron, rubber, steel, etc. I've also tried National, Best Sellers, Powerbooks, Book Sale, and have come up empty so far.

[guad]

On workbenches, been meaning to get Workbenches (http://www.amazon.com/gp/product/1558708405/ref=ord_cart_shr?ie=UTF8&m=ATVPDKIKX0DER) by Christopher Schwarz. The first chapter is online (http://www.lostartpress.com/product/3513e08a-2f07-4616-8f2f-74017f296377.aspx) (and more if you search for and follow the books.google.com link).

Also, a previous (to the book; 2001) article is online, $175 Workbench (http://www.popularwoodworking.com/article/175_Workbench/).

[randy618]

Hey Guad! I actually read the first chapter of the Schwarz book and the article on the $175 Workbench.

I had to swap out one of the tabletop boards (the fourth or center board) since upon close examination of the pictures I took, I measured it and found it to be tapered by 1/8". I've since swapped out the tapered board with another, and now it clamps more squarely.

Now it's back on the road to fetch the materials for the assembly of a front vise!

[beebeenator]

randy , ive got a book on workbenches. i will bring it during the hafele seminar if you are coming :)

[jonathanscruz68]

randy maglalagay ka ba ng tail and face vise?san ka mag purchase ng said tools?i'm planning of working on a new workbench,gawang marino lang kasi yung sakin,very rough.thanks

[randy618]

Hi beebeenator, what book are you referring to? Looks like I'll be going to the Hafele seminar.

Hi Jonathanscruz68, I'm just adding a face vise for now. I got it at Panda hardware in Binondo, and it's HEAVY!! Budget constraints are delaying the addition of a tail vise at the moment. I might have to retrofit one later.

Timber, thanks again for educating me. I still have the dowels you showed me. I'll get them back to you the next time I run into you, sorry about that.

[beebeenator]

A workbench book. its more pics than plans though

[jonathanscruz68]

how much do you got your face vise?

[randy618]

The face vise was P3780 at Panda in Binondo.

[jonathanscruz68]

whew expensive pala.well i think i have to buy muna a set of a good handplane,next in line will be the bench vises,since i really have to build a sturdy,reliable& hardworking workbench,substitute to my gawang marino workbench.thanks for the info randy.mabuhay!

[randy618]

@jonathanscruz68: Yeah, I'll say I underestimated the enormity of the project when I first started on it. To stay on track, what I do is break it up into small, realistic tasks, as small or big, easy or difficult as you want, then go from there. It also helps to have a plan that works.

Remember, all my work is done on the floor outside the condo. including gluing and planing. In fact, I just started planing yesterday. I don't have a real bench to work on, and I don't even have a workshop or garage, but I'm trying not to let that hinder my progress or affect my performance. I also had absolutely no carpentry/woodworking experience a few weeks ago, and I'm still learning as I go.

What tools do you already have? I'd suggest getting the most reliable layout tools you can, also buy a lot of clamps (if you don't have them already)! Leave nothing to chance!

Good luck sir! Be sure to post pictures of your progress too, as you go along. Maybe I can learn a few things from you.

Cheers!

[timber715]

what we are waiting for are pictures Randy... :p of your progress... we love pictures, pls keep em coming...

[violaine]

when i wa sbuilding my wokbench i didnt foresee that eventually another tool is going to be added every so often.my workbench is 2'x6' almost filling up my 9' x10' long woodshop.

putulan ko kaya kahit 1 foot! hehe

here is an old photo taken by a cameraphone when building my wb.
got to buy a piece of solid panel door for the assembly (for those currently in the build of their own)
http://i435.photobucket.com/albums/qq76/violainesweetness/06.jpg

[violaine]

blister producing planing
http://i435.photobucket.com/albums/qq76/violainesweetness/boards.jpg

[violaine]

installation of the front vise
http://i435.photobucket.com/albums/qq76/violainesweetness/lagscrewsinplace.jpg

[violaine]

and the tail end screw vise
http://i435.photobucket.com/albums/qq76/violainesweetness/screwvise.jpg

[violaine]

and few of the last garnishes..the deep penetrating oil
http://i435.photobucket.com/albums/qq76/violainesweetness/wb1.jpg

[violaine]

done...note that my wb has a well where shavings can collect or to be used for tool and glue docking station.
http://i435.photobucket.com/albums/qq76/violainesweetness/wb.jpg

[violaine]

i used gmelina for the wb top but applying the hardwood oil made it a bit yellowish brown in time..mas gusto ko sana yung dating natural color ng wood..yun ang sabi ng mga masters, the top should be lighter in color because, the wb top can become also the staging area where you can appreciate darker colored wood projects.
:rolleyes:

[timber715]

dang Doc, thats a gorgeuos wb. the finger joints on the apron is perfect and the dogs... the dogs................ :rolleyes::rolleyes:
the tail vice installed very well... got pictures of the stages of that build?
finally we see you wb... and a stealth gloat on the ts extension from Dewalt... lol.
also is the ts the same height as the wb? seems you use the wb as an outfeed....
as for a lighter color, bleaching before finishing can bring you there...
again conratulations on the well made workbench...

[randy618]

@Violaine: That is an awesome workbench! Congratulations to you, and thanks for posting these pics. If you got your tail vise locally, where did you find it?

As for my WIP, no new pics yet, as I haven't finished planing the top. Some pieces, stick out more than 1/8" above the adjacent boards. Who wants to see pictures of a tabletop that's in the middle of the planing process? It's not a pretty sight at the moment. :p I really thought I'd be done with this part tonight, but I underestimated a few things, namely:
1. the difficulty of planing on the floor
2. my body's exercise deconditioning
3. my inability to use a plane effectively. (using a plane is another "first" for me) :)

Pics to follow in my next post!

[moji]

randy,
Its alright posting pics showing rough work..You really should build sawhorses..you may not be able to use your plane properly and your back might go which is never a good thing.

@violaine,

Post more pics of your workbench! Tapos na pala yan eh..

[violaine]

randy,
Its alright posting pics showing rough work..You really should build sawhorses..you may not be able to use your plane properly and your back might go which is never a good thing.

@violaine,

Post more pics of your workbench! Tapos na pala yan eh..

ahehe..

the wb was finished wayback since late last year..took photographs of the build but they were posted irregularly within the tipidpc forum so no one noticed its already done...ok should i have the time i will post the process and difficulties (and mistakes) i encountered so our buddies making their own wb like randy would benefit

[violaine]

dang Doc, thats a gorgeuos wb. the finger joints on the apron is perfect and the dogs... the dogs................ :rolleyes::rolleyes:
the tail vice installed very well... got pictures of the stages of that build?
finally we see you wb... and a stealth gloat on the ts extension from Dewalt... lol.
also is the ts the same height as the wb? seems you use the wb as an outfeed....
as for a lighter color, bleaching before finishing can bring you there...
again conratulations on the well made workbench...

thanks bro..but it is only actually 80% done..id still like to make drawers below the wb top but i am planning half of that space will be occupied by the 2012nb in the future..

the fingerjoints were made manually and true fitting. the fingers are 1.75 inch long but if you measure them accurately and cut slowly with the right tools then you can achieve a true fit (it took a while before i finished it..you will realise that the last board of the wb top needs to be free from the rest to make that fingerjoint apron)
i initially made the fingers stout for a tight fit and ease them bit by bit using the bastard file (but i see noticeable protrusion of the fingers last summer due to wood expansion..this i expected so no glue was applied during the build..and to date no screws are holding that apron)
i reckon i have not been able to document the process though..i think i was working on the floor and very akwardly it pained my back but pain turned into something.

what i would like to emphasize to randy and the others who would want to build their wb is that..the last piece of work to be the done i considered the trickiest is the installation of the tail vise..if you remember what i have been through when i posted my questions to you sa tipidpc...anyhow i was able to document the process step by step (which shall be seen anytime soon in this forum).

yes i am happy with my "dogs" but i still dream of the proper dogs that are commercially available (perhaps in our next big box).;)
below is the diagram of how my dogs bark err work.
http://i435.photobucket.com/albums/qq76/violainesweetness/dogdetail.jpg

the TS is about 1cm higher than the wb top...yes indeed, the wb becomes the outfeed table hahaha and also now a tool dock...hehe..i am lazy sometimes to return tools from their proper location.

@randy, your boards were glued on their narrow sides..one thing good for this move is economy..but what i fear with this is cupping of the boards in time unless you support them very well underneath.my wb top has about 16 pcs of 2 x 4 planks glued on their widest sides for strength (the exact final dimension is 1.75" x 3.5")
also id like to ask also the type of glue that you used..i am happy with elmer's carpenters glue..i have had experience with locally available glue like pioneer. weldwood etc but elmer is the best (locally ha).

but you know, this could just be your first wb..who knows you will still build the best some years soon!

btw i bought the screw vise from the store wher you got your front vise...i would have preferred the one with quick release.hehe

[violaine]

aw i posted a pic of the dog installation diagram without labels..i reformatted the harddrive i need to download again the sketch up software.

[jonathanscruz68]

just like you i have no background on woodworking or carpentry.when i became interested in this kind of hobby.to tell you the trith randy,i think i've been in this hobby for more than a year..but to know this people,the very fined tuned in woodworking like timber,& add to the circles the likes of violane,moji beebeenetor,chisel& others,i think i'm still a beginner..its good that you are starting at the right path,good think that you came in this forum,getting advice from the experts early on...the very first tool that i collect was a circular saw,then followed by jig saw(although it dont produce a good cut,it sucks)& an electric drill(hand held)of course with assortments of bits,especially spade bits,clamps from japan home.then i go on to work on my gawang marino wb,hehehe,and because i really want to test my skills& gigil na gigil na makagawa ng project,thats the reason why i build that wb.when i have finished a project ,then its the time i have to upgrade my tools.the table saw came,then the fix & plunge router,& then the drill press,marami pang kulang,dahan dahan lang,salat din sa budget.lately ko lang nalaman tong forum,which is very helpful indeed,thats why i tell you,you are at the right path.just go slow,& dont get frustrsted when you make mistakes,it is there that you learn.practise makes things perfect,goodluck sayo sir randy,mabuhay!

[randy618]

Thanks everyone (timber, jonathanscruz68, moji, violaine) for the advice, suggestions and encouragement :) . Been under the weather the past couple of days. Looks like I'm overdue for an update! Here's what's happened so far.

After my last post, I spent half of the next day planing the top (again, on the floor), then decided that this was going to end one of two ways:
1. I would do the heroic thing, eventually plane the tabletop to an unacceptable thinness, and burn about a couple thousand calories.
2. I would use common sense and call for help. This is what I ended up doing.

Of all the tasks that go into this project so far, planing is one that should not be done on the ground. I decided to save my strength (as well as the rest of the top) and take it to a local sash factory in Taytay to finish and clean up my work. I'm glad they did a good job. The top is now about 1-1/4" thick all around, level and flat. Original thickness of the 2x4s used was 1-3/8"

Next up for me is to lay out and install the vise. It's a Record 9" vise (not quick-action). After reading the Landis chapter on how to do this, it looks like I'm going to use an edge-mount. Upon measuring the vise, I'll need a thick spacer (3.25 inches) to allow the top of the vise jaws to sit 1/2" below the top of the wood cheeks. The tops of the wood cheeks will be flush with the top.

@moji: I dig the sawhorse idea, especially since I can set the bench top on them and work from there.

@violaine: Since my top is thin at 1-1/4" and I've got a vise to worry about too, I'm thinking of running several parallel 2x4s from the front of the bench to the back. These will function as support beams for the top and spacers for the vise. I'm currently using Pioneer Wood Work glue. Although I almost tried the brand at the "American Bazaar" store for P66!

Once again, I keep getting error messages when I try to attach pictures, so until I figure this out, please check out my photobucket to see them. Sorry about that, everyone!

[timber715]

just copy the IMG code and paste it to show the picture on your post...
http://i1026.photobucket.com/albums/y322/randy618/Workbench%20Project/IMG_4732-small.jpg
http://i1026.photobucket.com/albums/y322/randy618/Workbench%20Project/IMG_4741-small.jpg
looks very nice, but somehow you're cheating... hehehe :p
http://i1026.photobucket.com/albums/y322/randy618/Workbench%20Project/IMG_4726-small.jpg

[violaine]

randy,

im good at your plan to install perpendicular supports underneath the top but i suggest to encircle the whole thing with 2x4s to further strengthen them (and for aesthetics).you can punish yourself (because you cheated..hehe) by fingerjointing the four aprons..you have more than enough tools to make them..you also need to realize that you are not in a hurry to make this wb..this is not somekind of a nice piece of furniture with a time limit like let say a baby crib.we have all the patience in this world to wait for the wips.you need to enjoy the craft and we are not telling you to hurry either.

btw, i suggest as well (though this might be your plan) you bury not only the rear jaw of the front vise but also the rear cheek of the spacer..in this way..any piece of stock gripped by the vise will be flushed to the sides of the wb top..it means that only the front cheek will be butting against the front apron...i regret this is not true with mine..see photo below.
http://i435.photobucket.com/albums/qq76/violainesweetness/P1010207.jpg

i suggest you make use of stainless lag screws and stainless washers to mount the vise..with them, you dont worry about the remaining moisture in the wood to eat away the galvanized ones in time and discolor your wb top.of course they are more expensive but hey you spent a fortune on the front vise..the cost of the lag screws wont make a dent on your bank statement.hehe

and lastly, did you apply any wood protection? i wetted mine with clear solignum before gluing them...hindi naman aanayin yan but you know..you still have the bukboks to worry about..anyway, if this will force you to bring it again outdoors for the preservative application..the hardwood oil is as ok.

ok..need to snuggle now.

[randy618]

Cheated? Can't argue with that, and I'm not taking any credit for the appearance of the benchtop at this point. I just gave up on planing because I was getting tram marks and tearout everywhere, and even though I made adjustments as per the instruction manual, things kept getting worse as I continued. Planing on the floor without a table = big no-no. :P

@violaine: I'm planning to use dovetails, but should I switch to fingerjoints? As for the vise and stainless steel screws, you've just described what I'm already going to do. :) I'll probably need a router for this part. Finally, wood protection...I'll buy some tomorrow during my citywide scavenger hunt for the following:

Protractor (Panda)
Drill Guide (LYS along Recto near Arranque going to Divisoria [is that right?])
Lag Screws (forgot the name of the store, on T. Alonzo)
Dowels (To Suy)
Paste Wax (True Value? Ace? Handyman?)
Sadolin (I haven't seen this around. Where should I go?)

Thanks for all the tips. Please keep them coming!

[guad]

i suggest as well (though this might be your plan) you bury not only the rear jaw of the front vise but also the rear cheek of the spacer..in this way..any piece of stock gripped by the vise will be flushed to the sides of the wb top..it means that only the front cheek will be butting against the front apron...i regret this is not true with mine..see photo below.
http://i435.photobucket.com/albums/qq76/violainesweetness/P1010207.jpg

Not clear to me what is meant by burying 'also the rear cheek of the spacer', or what the problem is in the picture that is being regretted. I think the term 'rear cheek' is throwing me off. If cheek means 'side', then there should be a left and a right cheek, not a front or rear cheek? :confused:

[violaine]

@guad,

sorry i made you confused.

i forgot the term so for now i will refer to the wood that is screwed onto the metal jaws as the "inner" and "outer" jaw faces.

what i regret about my front vise is i completely forgot to make a deeper recess to bury both the inner metal jaw and its wooden face.
:rolleyes:

[guad]

Vise jaw liner or pad. Definitely clearer, I understand now, lack of permanent embedded liner (although on the inner jaw, debatable/depends whether you really need one).

[timber715]

if you intend to use it on wood, you definitely need one (jaw liners)... :p

[violaine]

Vise jaw liner or pad. Definitely clearer, I understand now, lack of permanent embedded liner (although on the inner jaw, debatable/depends whether you really need one).

i went back to check an old issue of woodworkers journal (summer 2008) where the arts and crafts workbench made by the master woodworker Ian Kirby was featured...most of the ideas in making my wb was lifted from that article...and true to my recollection, he refers to the wood that is attached to the opposing metal jaws as "wooden cheeks"..i added the confusing words "outer" and "inner"...btw nowhere in the article did he specify which is which.:p

technically speaking, i would have named the cheeks as "wooden lips"...and more specifically, the outer and inner wooden lips since the front vise is not vertically oriented...you are correct in saying the cheeks is either the right or left.

comments are welcome.

cheers

[violaine]

or "front" or "rear" wooden lips! hehehe

[timber715]

what you need Doc V is the dado blades... ;)

Randy, the finger joints are more forgiving to make than the dovetails, but the dovetail joint is the better option as long as you do it yourself :p...

[violaine]

i agree! with seasonal changes, i hate to see the fingers protruding.

with dovetails, it is fixed...kaya mo yan randy! ;)

below is a pic of my front vise with the "lips"..i should have buried the rear lip so that the stock will be flat against the apron..see the white arrow for that potential space...that i said i regret.
http://i435.photobucket.com/albums/qq76/violainesweetness/P1010246.jpg

[timber715]

I have the same dilemma too on my vice, that is why I wanted to replace the top for a long time already, plus work on the tail vice some more... doc V, got the build pics for the tail vice?

[violaine]

i reformatted the harddrive and transferred all old data in my portable hdd...now i cant find the proprietary usb cable...there i kept the pics of the tail vise installation.

do you remember when i was asking you about how to install the vise screw?you even sent me a sketch up plan of yours.

anyhow should i be able to open the hdd then i will post them very soon.

see you next week bro for my stuff!

i am here in nueva ecija pa kasi.

[jonathanscruz68]

nice tools to start with,where did you bought your back saw?what brand?nice marking gauge too,i think that was the same as timber?where did you buy it?good luck pa rin so woodworking project mo,i"ll make mine siguro matagal pa,cause i"m planning to build my own router table.secure ko pa mga materials,hindi pa complete,busy pa sa work.mabuhay sir.

[randy618]

Hi jonathanscruz68, the back saw is a Stanley, I got it at To Suy Hardware last month. They have a few left. The marking gauge I bought from timber himself. Good luck on your project Sir!