New workbench build thread

[brian zawatsky]

I’m building a new workbench, and while I’ve had several benches this is my first attempt at building one ground up.

Started with some wide 16/4 cherry timbers that were shot thru with drying checks that I had to cut around. The guy I bought them from said his father had them milled 7 years ago and they’ve been sitting around ever since. He seemed honest enough, and they proved to be bone dry. In the end I paid $2/bdft for it and although it was a pain to cut out the splits & checks, it was still a good deal.

In the interest of full disclosure, I ripped the big heavy timbers with a worm drive circular saw to make the pieces more manageable, and spared no electrons in milling it all.

So far the top is done except for final smoothing and leveling of the tail vise. I’m on an iPhone so I’ll do my best to post pics of work so far. I hate trying to post pics here from my phone.

[brian zawatsky]

Because I’m totally impatient and like to do things the hard way, I didn’t leave space in my lamination for the tail vise. As a result I had to cut a notch out of the end where the tail vise would go. Working on stuff that’s 4 1/2” thick is challenging! Used a hand saw to cut the ends of the top square, as well as to cut the vise notch. But I’m getting ahead of myself. After squaring up the ends I flattened one side, marked all 4 edges for a reference rabbet, then flipped and cut. Great excuse to break out the new LN 10 1/4.

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[brian zawatsky]

Planed the underside of the benchtop flat. That was a hell of a workout! I should have started with a much shallower rabbet lol. Because there was some ugliness on the ends of the boards that make up the top, I decided to cap them & hide the sins. Also cut the tail vise notch after flattening the bottom side & installed the tail vise. Went with the Lie Nielsen tail vise. Wasn’t too bad to install. I used a router to cut the huge mortises needed in the bench side & vise block.

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[David Eisenhauer]

Great start brian. Thanks for throwing out a bench build for us, as we do like bench builds. Looks like you came up with some good top material, but man, you do have a deep rabbet to plane down to in some spots. That is an interesting looking panel gauge you show also. The electrons spent for ripping the top timbers was well spent in my opinion.

[brian zawatsky]

I was having so much fun breaking in the bench rabbet plane I got a little carried away. It took me forever to scrub all that material off! It seriously wore me out.
Today I started installing an Emmert turtleback. Definitely not an easy install!! I made a template of the rear jaw profile from a scrap piece of oak, and used a couple different top bearing bits to cut as far into the top as I could reach. Then I flipped it over and used a bottom bearing bit from the other side to finish the notch. Next I cut the square notch for the hinge with a tenon saw & a chisel, then chopped out the monster round notch to accommodate the hub with a big incannel gouge. Next was plowing a dado for the beam that contains the vise screw.

Sorry, no idea why some of the pics came in sideways.

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[brian zawatsky]

Flipped the bench & cut the mortise to let the hinge plate into the top. I really took my time mounting the vise, because there’s nothing worse than having to drill out off-centered screwholes and plug them, just to re drill them. Vise works great, but I need to do some more carving to allow it to rotate freely without tilting. As it is now I have to tilt it parallel with the top, then rotate & set it back down.

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[Jerry Olexa]

One of the "funest" projects: building your own bench.....You feel better about it when you've built it yourself....A labor of love...
Nice work and love those thick timbers!!!! Thanks for posting.

[Christopher Charles]

Thanks for posting. That's going to be one serious bench and great score on the Emmert vise! What are you planning for dogs?

[brian zawatsky]

Im planning on using round brass dogs, like these: http://www.leevalley.com/us/Wood/pag...27&cat=1,41637

Hopefully I'll be able to work on the base this weekend. Legs & stretchers will be made from 16/4 poplar that is currently waiting to be milled

[William Fretwell]

I see the bench you are working on has square dog holes and your new bench is to have round ones. Is it the simplicity of construction that prompted that choice?

[Dave Anderson NH]

Great job so far Brian. Mounting an Emmert with the inner jaw flush is truly a pain. Been there, done that. You will not be sorry you took the time to do the more difficult install. It adds immense extra versatility.

[brian zawatsky]

The bench that I’m currently working off of was a Craigslist find, for 150 bucks it doesn’t owe me a penny!! The ironic thing about the square dog holes is that the bench never had a tail vise, which renders them completely useless. Apparently the guy who built it just liked the look of square dog holes or something.

I chose to use round holes (which I have yet to drill) because of their simplicity and because they could also accommodate a holdfast if necessary. I feel it gives me a bit more flexibility.

[William Fretwell]

The square dog holes still act as a planing stop, so not useless. Perhaps he intended to add a captured tail vise at some point.

[brian zawatsky]

Thinking about adding a sliding deadman. Any thoughts? Pros/cons?

[David Eisenhauer]

I have one, don't use it daily but it is there when I need it. Mine can be removed from the bench if it is in the way of anything but seldom requires that. Same 3/4" holes as my holdfast holes on the benchtop.