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workbench build

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(@joey81)
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Finally! After several years I've finally mustered enough willpower to start building my workbench. The design is a scaled-down version of the 21st Century Workbench. You can find the plans and drawings freely available around the net.

Got some rough-sawn mahogany

Cut to length

 
Posted : 11/01/2015 8:39 pm
(@joey81)
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Since I don't have a jointer, I'm just going to use the trusty old Ryobi thicknesser.

Here is the bottom view of the jointing sled

Top view. Just ignore the torn ply, recycled lang yun plywood

There is a "hook" on one end. This will prevent the stock from being pulled by the thicknesser off the sled.

Close-up of one end gives you an idea how the sled is constructed

The top doesn't have to be flat, but its better if it is. The rails at the bottom must be straight in the vertical direction.

 
Posted : 11/01/2015 8:42 pm
(@joey81)
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I find it easier if I place the stock with the cup/bow facing down

If you have a power planer, "pre-joint" the bottom side by planing out the high spots. This will allow you to get the most out of your bowed/cupped/twisted stock.

Now here is the most important part: shimming

You have to put shims under the stock in the parts that don't touch the surface of the sled. The shims will ensure that the feed rollers of the thicknesser don't push down the stock. If the rollers are able to push the stock down, the thicknesser will not be able to remove the bow from your stock. Para bang umiilag yung kahoy. :shifty:

 
Posted : 11/01/2015 8:42 pm
(@joey81)
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BTW, don't overdo the pre-jointing or the space underneath might be too small for your shims.

Next is to secure the shims with hot melt glue

You also need to secure the stock to the sled with the same glue. Forgot to take a picture of it.

The actual planing. Feed the hook end first.

First 2 passes

 
Posted : 11/01/2015 8:43 pm
(@joey81)
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3rd through 6th passes:



 
Posted : 11/01/2015 8:44 pm
(@joey81)
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Checking the result with a Woodpecker straightedge:

One down, a dozen more to go!

 
Posted : 11/01/2015 8:46 pm
rosy
 rosy
(@rosy)
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Ahha!, so you finally decided to build your own workbench, that is great and congrats bro joey. Will just be following this thread and seeing this project up to its completion. :2thumbsup:

Enjoy the build !! :clap1:

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HOBART and ESAB Welding Helmets
cloned STIHLs
MS 044 chainsaw
MS 070 chainsaw

 
Posted : 12/01/2015 7:38 pm
(@joey81)
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I had to scratch the itch. So I went to the workshop last night to work even a just bit.

Edge jointing using the Bosch track saw

Biscuits to maintain alignment during glue-up. Forgot to set the biscuit joiner fence, hence the extra slot near the edge

Applied some glue

And clamped together

 
Posted : 15/01/2015 5:55 pm
(@joey81)
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A clamping beam ensures the pieces being glued are straight

 
Posted : 15/01/2015 5:56 pm
(@joey81)
Posts: 1098
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Topic starter
 

Ahha!, so you finally decided to build your own workbench, that is great and congrats bro joey. Will just be following this thread and seeing this project up to its completion. :2thumbsup:

Enjoy the build !! :clap1:

Thanks, rosy! I hope you don't get bored as this project will take quite a while.

 
Posted : 15/01/2015 5:58 pm
(@joey81)
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BTW, this is how the bench would look like, more or less. The storage trays in the middle are removable.

Brown shade for easier visualization

 
Posted : 02/03/2015 12:41 pm
(@joey81)
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After gluing and dimensioning the rail parts, mark the ends for the tenons. I finally had a chance to use the Veritas marking gauge

Cut away most of the waste using the bandsaw

 
Posted : 02/03/2015 12:44 pm
(@joey81)
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After dimensioning the legs, used a forstner bit to remove most of the waste material

Chiseled out the rim of the mortise

And let a top-bearing straight router bit do the rest

 
Posted : 02/03/2015 12:45 pm
(@joey81)
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First pass, with the bearing riding along the lip of the mortise

After routing full-depth and cleaning out the corners

One down, 7 more to go.

 
Posted : 02/03/2015 12:47 pm
(@joey81)
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Cut the mortise for the bottom stretchers

Then the lap joint for the upper stretcher

 
Posted : 02/03/2015 12:49 pm
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