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Rubber matting is fine for plate tools like nickel or chromium plated stuff but I agree it can make a mess of exposed iron.



It does not hold as well as rubber matting but I'm finding some...

The grand opening of Bob's New shed could be on the cards?

Sounds good !

I'm flat out over the next 6 weeks, trying to move cupboards and stuff currently on the back patio back into the shed before the rain comes back, sons wedding, and a 9 day trip to...

Wow, Derek, that's one fabbo looking bench. Sometime when I retire ie maybe next year, a new bench is on my todo list. If mine can be 1/10th of yours I reckon I'll have done OK.

Derek although I think your router method is fine, is you have concerns and get desperate then there is always this.
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I'm a big fan of barrel bolts and use them in tasks like joining metal tubing perpendicularly to flat surfaces.

An improvement on putting the barrel under the DP and hoping that perpendicular...