I've done machine woodworking on and off for a long time, but I finally decided I hate table saws and the dust......and I like fine handtools. My first project is the Morovian Bench by Will Myers using mostly construction lumber plus some hand maple I salvaged from an old industrial benchtop. I have a few mods I want to make also. Here is what I've learned so far in no particular order;
1. 4 1/2 " deep mortises are particularly easy to make.....seemed more like timber framing
2. Only having a 5.5 tpi rip saw to make much of the jointery teaches you a lot about chiseling and fitting.....and sawing!
3. Construction lumber is mostly pretty miserable to work with given the small knots and the swirling grain they bring.
4. A quart of Titebond isn't enough.
5. Take your time getting everything square......saves grief later.
6. It is not possible to spend too much time on layout and dry fit ups.
7. Build a saw bench before a workbench.
8. My old bench is incredibly rickety for hand woodworking and it was a plan from Fine Woodworking.
9. Chris Schwarz knows what he is talking about with benches.
10. Construction lumber can be incredibly beautiful when quartersawn and planed.
11. If you are going to glue up a number of pieces to make legs or a top, try to orient the grain between the boards to make planing easier.
12. I don't have enough clamps.
13. Vintage tools are crazy fun to find, sharpen and tune up.....my vintage refurb collection includes a Stanley 4 with a new Veritas blade and breaker (un-freakin' believeable), a Stanley #6 (nice enough, want a new blade like #4), and a Disston No. 7. There is so much history behind them and the handles are already broken in.
15. Your first joints will be embarrassing by the time you do your 20th.....and pretty joints can still make a small bench. Good thing I see it as a learning experience!
I've lurked here for a while so I figure I ought to share a bit. I'm almost ready to start glueing up my top. I think I'll use a lot of drywall screws for my glue ups and take them one board a night to avoid getting yet more clamps.
Thanks for listening -- Mark