Thread: WIP - John's "Jack-Bench"

Pipe are probably cheaper and you can always get longer pipe if longer is needed (or even a joiner)
But they can flex under pressure

I like my biggish Bessey's I got in the last group buy, but didn't get enough

see if you can borrow some

Hi John,

Sash clamps will work, but I think pipe clamps are better for this application. Also, as Sawdust Maker pointed out, pipe clamps are probably less expensive, too!

Charlie

John,
Can you tell us how many 8 x 4 plywood boards are required for a typical build, and are they 1/2" or 3/4"?? US builds usually use 3/4", not sure about this one since you mentioned 1/2" at one point.
regards
Chris

Originally Posted by Chrism3

John,
Can you tell us how many 8 x 4 plywood boards are required for a typical build, and are they 1/2" or 3/4"?? US builds usually use 3/4", not sure about this one since you mentioned 1/2" at one point.
regards
Chris

Sure. The legs are HW sandwiched between 2 pieces of 3/4", whereas the jack stand, wheel mechanism, and side thingo's are HW sandwiched between 2 pieces of 1/2".

In total the plans call for 1 sheet of 3/4" & 3 sheets of 1/2". But I'm finding Charlie to be a bit conservative with his cutting diagram. I'm pretty sure I can do it with 2 x 1/2" instead of 3.

It all seems to be working so far, except I'm making a couple of panel clamps (not sure of name, provides downwards and sidewards clamping pressure) ATM. Then, I need some pipe clamps anyway, so need to actually walk into the shop and fork over some $.

Perhaps the designer didn't use software. I use an excellent piece of software called Smart 2D Cutting, which optimises cutting from stock of any kind. It lets you choose grain direction, or to ignore it eg in case of MDF and masonite.
You can use it to plan a purchase by playing with the piece sizes to fit into a known sheet size.

Originally Posted by Chrism3

Perhaps the designer didn't use software. I use an excellent piece of software called Smart 2D Cutting, which optimises cutting from stock of any kind. It lets you choose grain direction, or to ignore it eg in case of MDF and masonite.
You can use it to plan a purchase by playing with the piece sizes to fit into a known sheet size.

The designer (Charlie) is interested in my progress also, so im sure that he will comment. I wonder if he has just allowed extra for an "idiot/mistake factor"...

How do you find the "Smart 2d cutting" software?

Hi John,

I am interested in the progress of everyone who builds a bench from my plans!

One of these days I have to add a gallery page to my website to show off benches that people have completed. My first priority is to continuously improve on the design and to help people who have purchased plans from me.

The bench requires 1 sheet of 3/4" plywood and either 2 or 2-1/2 sheets of 1/2" plywood if you add the optional face panels for hanging tools onto the side of the bench.

I did leave some extra space on the plywood layout, but not enough to require purchasing an extra sheet of plywood. That said, I laid it out so that the grain is running appropriately. If you turn some pieces sideways you might be able to save plywood, and if you do reduce the amount required then please show me how you did it!

Thanks for the tip Chrism3. I have heard of a Sketchup plugin called CutList, but Smart 2d is a new one. I should check it out.

Charlie

Here's the link for Smart 2DCutting
Cutting software for 2D panel cutting optimization

Some progress! I've managed to glue and clamp the shelf that the scissor jack sits on. It looks quite simple, but it's a lattice-work of HW sandwiched between 2 pieces of 1/2" ply. Might actually work...I suspended it between 2 saw horses & stood in the very centre without it bending. That was before glueing, so it should be stronger as 1 complete unit.



(note the home made panel clamps...I found the idea on the forum by another member. They work really well )

Oh...I ended up buying some Groz Clamp Heads from Carbatec and mounted them on pieces of 50x25x2.5mm RHS. Total cost us less than $40 per clamp...nice



I have a few days off now, hopefully the domestic duties can wait for a while - I also have a new Japanese Ryoba saw to play with. Nice...think I might be converted, plus a disposable blade!

Well...this is kinda embarrassing...

I've done another backflip on this bench. After all the valuable advice that Derek gave me, it's time for me to stand up and admit that I was wrong & he was right!

This bench is not going to suit my needs, a few reasons include not having any space underneath to store junk. Design of the thing is cool & seems strong enough, although I'm not entirely wrapped with the idea of no joinery & the whole thing being held together by butt glueing HW & sandwiching between ply. But I'm sure that the engineering is sound.

Looks like a more traditional bench. Back to sketchup plans

Originally Posted by johnredl

Well...this is kinda embarrassing...

I've done another backflip on this bench. After all the valuable advice that Derek gave me, it's time for me to stand up and admit that I was wrong & he was right!

This bench is not going to suit my needs, a few reasons include not having any space underneath to store junk. Design of the thing is cool & seems strong enough, although I'm not entirely wrapped with the idea of no joinery & the whole thing being held together by butt glueing HW & sandwiching between ply. But I'm sure that the engineering is sound.

Looks like a more traditional bench. Back to sketchup plans

Bugger!!!! Just when things looked like getting real interesting...."the best laid plans of mice and men".

Eyes will be waiting anxiously for the new WIP....all the best

Ta. Look, I'm sure this is a great bench, just the more I am working with it, the more I am realizing it is not what I am after. Better to quit now with only 4 or do metres of wood & 1/2 a sheet of ply used, than to finish it & not be happy.

Might steal a few ideas from the plan for the new bench tho!

Always handy to have 2 benches.

The adjustable one would be very handy as an assembly bench as you can vary the height to suit the job,

Then build your dedicated work bench with all the bells and whistles like Groggys.

Having 2 benches also makes for a great work surface for larger peices.

I've just received plans for the 21st Century Workbench from Popular Woodworking, and not only is it fairly easy to build, but it has loads of great features. Being a split bench you could even make one side higher.