WIP - Groggy's Workbench

[Groggy]

Finally I am going to replace a Wobbly Old Bench (WOB) I have been using for the last...hang on, that can't be right....crikey!.....27 years. You can see it in the pic to the right.

On my other bench I have jury rigged the new frame pieces. The timber came from the Great Timber Purchase of 2006/7 (it should be in the history books by now, along with The Great Bessey Buy) and this is the last of it, though I did recently acquire a new pack, but I digress :) .

This is going to be a planing bench and suit my needs better than the WOB ever did. The new bench will be 900-910mm high, depending on the actual height of the table saw plus or minus floor imperfections where the new bench will stand. This will probably take me a while to finish.

----------------------------------------------------------
EDIT: The bench was completed in December 2011, it took three years of spare hours to complete. Since this thread has become an epic I've decided that an index is needed for those interested in just one part of the build.


http://www.woodworkforums.com/attachments/f213/187727d1321250985-wip-groggys-workbench-workbench-final-finish-008.jpg

INDEX

1. Making the bench legs (http://www.woodworkforums.com/showthread.php?t=76785&p=788761#post788761).
2. Feet design discussion (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index56.html).
3. Comments on the leg flutes (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index56.html#post802728).
4. Rail Mortises (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index55.html#post1003252).
5. Leg pegs (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index55.html#post806308).
6. Stretcher Mortises (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index54.html#post1016573).
7. Google Sketchup drawing of the base (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index54.html#post1008286).
8. Clamp Cosy. Designing (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index54.html#post1003787), mock-up (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index52.html#post1020456),
9. Dry fit of the frame and testing the clamp-cosy (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index53.html#post1017829), and a later test (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index52.html#post1029365).
10. Squares, squares, squares (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index53.html#post1018179).
11. Mobility kit idea (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index53.html#post1018604).
12. Fitting the base (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index51.html#post1036068).
13. Choosing vises - it begins (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index50.html#post1036700). Decision time (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index44.html#post1140747). They arrive (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index42.html#post1153488).
14. Intermission - Rebuilding the Wobbly Old Bench (WOB) (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index49.html#post1047085). Completed (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index48.html#post1076453).
15. What to make the top out of (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index48.html#post1111468)? Found some timber, (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index47.html#post1120494)de-nailing begins (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index47.html#post1121965).
16. Putting the top beams over the jointer (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index46.html#post1129078).
17. Using the Domino to repair nail holes. Making your own dominos (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index46.html#post1132186). Repairing nail holes and divots (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index45.html#post1134431).
18. Thicknessing the top beams (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index45.html#post1135066).
19. Beams ready to make the top (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index44.html#post1143936).
20. Discussion on jointing the top (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index43.html#post1151426).
21. The temporary top frame (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index43.html#post1151475) <- This was a great idea and worked exceptionally well. Frame (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index41.html#post1156420).
22. End Caps. Hardware (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index41.html#post1155435). Marking our attachment slots (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index31.html#post1211621).
23. Weight of the bench (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index41.html#post1157398). Weight broken down (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index36.html#post1191888).
24. Laying out the top beams (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index40.html#post1158690). Testing the bench dog location (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index40.html#post1159142).
25. Gluing the top commences (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index39.html#post1166045). A few more (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index39.html#post1168537). Third go (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index38.html#post1168956). Main top less the skirt (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index37.html#post1187856).
26. Making the deadman (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index37.html#post1184345). Finished (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index31.html#post1208727).
27. Surfacing the top with handplanes (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index36.html#post1191101).
28. Patching out (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index36.html#post1191527). End cap patches (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index16.html#post1323752).
29. Planing for the skirt (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index34.html#post1194957).
30. Top jointing video - post #500 (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index33.html#post1198914).
31. Cutting the bench top ends (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index32.html#post1202331). Slots cut for the end cap bolts (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index30.html#post1220120).
32. Wagon vise - cutout (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index30.html#post1217390). Fitting (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index19.html#post1308408). Recessing (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index18.html#post1309607).
33. End cap fitting (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index29.html#post1226625). Attaching (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index27.html#post1229511). Dovetail design in Sketchup (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index27.html#post1230355). Finessing the joint (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index26.html#post1232432). Fitted (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index21.html#post1268942).
34. Dovetail discussions. Fibonacci and the Golden Mean get a mention (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index28.html). Marking the sockets (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index22.html#post1262671). Getting big dovetails flat (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index22.html#post1263247). Start to end (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index17.html#post1321075).
35. Router blowout repair (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index25.html#post1235664).
36. Clamp slip damage whilst routing (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index23.html#post1261100).
37. Dry fitting the front skirt (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index20.html#post1272446). Gluing up the front skirt (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index19.html#post1308846).
38 The top is on (http://www.woodworkforums.com/showthread.php?t=76785&p=1221617#post1221617)
39. Dog hole drilling (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index14.html#post1332245). Partway done (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index12.html#post1334532). Done (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index11.html#post1334867).
40. The Benchcrafted Leg Vise begins (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index10.html#post1348111). Roller bracket (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index9.html#post1350996). Starting the chop (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index9.html#post1354619). Rough cut (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index8.html#post1357654). Fluting (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index7.html#post1360545). Roller housing (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index5.html#post1373090). With a finish (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index5.html#post1375871).
41. Some thoughts (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index4.html#post1384906).
42. Finish problems (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index2.html#post1394558). A second go at it (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/index2.html#post1401416).
43. Replacing the knobs with Jarrah (http://www.woodworkforums.com/f213/wip-groggys-workbench-76785/#post1407771).

[Waldo]

Sticking my ugly mug in for a poke. :2tsup:

(you should've loaded a few slabs in the yoot while Dj wasn't watching on Saturday. He'd never miss 'em, if he asked all you'd have to do was say, "didn't you burn that one?" :; )

[Cliff Rogers]

Watching. :2tsup:

I showed Gina the picks, she is impressed with how neat & clean & tidy it is, even the dog is neat & clean & tidy...

I told her the place belonged to a sick man. :D

[DJ’s Timber]

Looking good Groggy :2tsup: still need to work on Sally thought, she still looks miserable when you take a shot with her in it :doh:

As for you Waldo, I've got another brick here still :brick: :U

[RufflyRustic]

Sticking my mug in too. Shame I couldn't move DJ's bench :(or it would have come home with me, one way or another:oo::wink::)

Hey Groggy, this is a good start. Glad to hear you say it will be at least 900 high.

cheers
Wendy

[tea lady]

Watching too. Prolly need a bench soon.:rolleyes:

BTW, how do you get your dog to sit OVER THERE? Mine always sits at my feet.:doh:

[Cliff Rogers]

.... how do you get your dog to sit OVER THERE? .....
No more nails or CA. :2tsup:

[Wongo]

For a big man like you, the bench should be at least 2m high. :2tsup:

Hurry up, are we done yet??



:D

[Pops]

Hi Groggy,

Yep, we're all watching, waiting,.. watching,... waiting. :wink:

Do let us know where your design ideas may have been influenced by the workbench books. That would be interesting.

Don't forget those pictures, 'as you go' now. :D

Thanks for sharing.

Cheers
Pops

[Lignum]

So whats the WIP. Is it the thing on top of the bench, or the bench its self:?

[edit] just re-read. oops.

[Groggy]

Do let us know where your design ideas may have been influenced by the workbench books.Funny you should say that, I have the pdf plan for the Holtzapffel bench up on my other monitor as I type, and have been staring at the thing on-and-off most of the night. My previous design was going to be a 'wooden cube frame' style with upper and lower rails. Since reading a few more designs I am thinking of using just two lower rails :think:

[Waldo]

Groggy,

Don't know if it's a help or not, but load up Sketch-up>File>3D Wharehouse> Get Models and search for "Holtzapffel workbench" and you'll find a model already drawn up. :shrug:


(Holtzapffel were my Dad's mother's side from Germany - doubtful that it'd be the right mob though)

[Groggy]

So whats the WIP. Is it the thing on top of the bench, or the bench its self:?Both :rolleyes:

[Groggy]

Don't know if it's a help or not, but load up Sketch-up>File>3D Wharehouse> Get Models and search for "Holtzapffel workbench" and you'll find a model already drawn up. :shrug:Thanks Waldo, (see PM)

[artme]

Holtzapffel only dealt with lathes.:-:-

Ah! Ignorance is bliss!:D:D

[Groggy]

After doing a bit more reading I've decided I don't need stretchers at the top of the bench. If I mortise the legs into the top and dowel them there should be no movement and stretchers would add little to anti-wracking. Also, the stretchers may actually be a negative in that they would limit the clamps I could use plus they may get in the way of bench dogs and holdfasts.

So, the top stretchers were mated to the bottom to beef them up a bit. I haven't drilled the holdfast holes yet or cut the tenons, maybe next week. The legs have the edge routing complete and are waiting for the holdfast holes to be drilled.

In picture #2 you may notice a larger profile routed in the front stretcher. This is the beginning of the rail for the dead-man to slide on.

[artme]

Looking good Groggy.:2tsup: Finished item is awaited wih baited breath>

[Groggy]

This is going to take a while so you may as well get comfy. :rolleyes:

[Waldo]

I'm comfy. :2tsup:




















So are you done yet. :D





So what did you end up going down the path of, the Holtzapfel? Or a bit of a bitsa from here and there?

[Wongo]

It's going well mate. :sleep1:


:D

[Groggy]

So what did you end up going down the path of, the Holtzapfel? Or a bit of a bitsa from here and there?It is a Holtzapffel/Roubo hybrid. Mainly a Roubo but with a Holtzapffel style top and vises. It will have a deadman and leg vise, plus an end-vise of sorts (not sure yet).

[Groggy]

Had a bit of time today as it was "father's" day and SWMBO let me off other chores for the day :rolleyes:

I have now got the legs ready to tenon but won't cut those until the mortises are ready in the feet. The feet have been glued up and will be dimensioned next week I hope.

Couple of pics of the legs, the first shows the fronts, second is side and back and the third shows the drill press and home-made table used to drill the holes. What is not shown is the clamps used at either end of the legs to hold them during drilling. I used a quality forstner bit for the holes as I did not want to tear out the flutes.

The flutes serve two purposes, the first is obviously for looks, the second is to give me some purchase on a dog if it gets knocked flush with the leg; the 12mm flute is just enough to grab the tip with the fingers or and pull it out again.

The dogs in the bench legs are to give support to oversized work and to be a place to store things (like bench dogs and hold downs).

Last pic is the feet block glue-up.

[timberbits]

There is a big difference in the colors of the legs, from different trees?

[Des.K.]

Looking good. :2tsup:

I'm envious - so many parallel clamps. I ordered a few from Rockler a couple of months back, and the postage cost more than the clamps.

It's probably too late, but the latest issue of Popular Woodworking has an article on the "21st century workbench". Interesting article, and you might be able to pick up a few ideas for some last minute design modifications.

Regards

Des

[Groggy]

There is a big difference in the colors of the legs, from different trees?The timber came from a forums timber buy from QLD. The lighter colour legs are the back and darker ones for the front. I've laminated the timber so I could use up the wood that I had left, I don't want to buy timber specifically for the bench so am making do with what I have.


It's probably too late, but the latest issue of Popular Woodworking has an article on the "21st century workbench". Interesting article, and you might be able to pick up a few ideas for some last minute design modifications.Thanks Des, I haven't seen that one yet. I want the bench to be fairly traditional as it will be more for neander type activity. I have a couple of other benches better suited to electrical WWing.

[boban]

It's looking good Greg. I really like the look of the legs.

I hope it doesn't end up like my WIP Workbench. I've built the leg frames and laminated the stretchers which I completed in about 1 week. The rest as the say is history. The history being that about 12 months later, I still have no further progress. Too many other things that have priority I guess.

To be completely honest, I have 3 WIP Workbenches. Perhaps I need to focus.

[Groggy]

Thanks for that Boban, I am pretty pleased with the legs myself. I wanted to play around with flutes as practice for later jobs, and the flutes in the sides were an attempt to visually taper the legs. I like the idea of trying these things on shop furniture because it is a visual reminder of what does and does not work. Thankfully the legs worked. I have also put a flute in the stretchers, just one, to carry the lines between the legs, that didn't work as well but I'm hoping it will look better when assembled - if not, I still have a reminder not to do it again :; .

[Cliff Rogers]

It is gunna be a swish desk Groggy, bit good for woodwork. :D

[Groggy]

I should have mentioned that I learned a bit about flutes doing this. For next time I WILL be building a jig with a ramp at the end so I don't get burning in the end of the flute. Also, I found that hand guiding with the standard fence is pretty agricultural, you really need a template guide to get consistent, error free, results.

I was darn lucky that the two or three dimples I had in the flutes just so happened to match where the dog holes went (ok, so maybe the hole distances were varied ever so slightly to make them disappear :wink: )

The dog holes were cut in three steps:

forstner in DP for 3/4 way through,
spade bit till the centre point just broke through the other side, then
forstner from the back to complete the holes with no tearout. You must have a good sharp forstner when cutting across the flutes otherwise it will tear up the edges.

[Wongo]

Good work Groggy, I really like your legs, they are beautiful. :U

I am a bit like you, I don't normally go out of my way to buy more wood for a project. If it is for myself then I always use whatever I have in the shed. If it means the legs will look different then so be it. It is for me and I like it that way.:2tsup:

Why don't you drill the holes all the way through to the other end? It would be easier to remove the dogs by pushing it from the other side. Don't you think?

[Woodwould]

Nice work! :2tsup:

I really like the idea of using multiple timbers for something like a workbench. I would even like to see the legs treated differently; perhaps different period turnings to act as a reference for other turned work etc.

[Groggy]

Why don't you drill the holes all the way through to the other end? It would be easier to remove the dogs by pushing it from the other side. Don't you think?My knees prefer I don't kneel to often, so if I can make it easily removed from the front I do it. Give it a few more years, your basketballer's knees will say the same things :;

The dog holes do go all the way through btw, but if I decide to put a small cabinet underneath it may restrict access a bit.


Nice work! :2tsup:

I really like the idea of using multiple timbers for something like a workbench. I would even like to see the legs treated differently; perhaps different period turnings to act as a reference for other turned work etc.There's a thought. A Roubo eclectic bench :U

Turnings eh? :think:

[Woodwould]

Turnings eh? :think:

Go on - you know you want to!

[Groggy]

Go on - you know you want to!I want to alright, not the legs though, they need to be square as they are clamping surfaces, besides, I like columns and pilasters. I have toyed with the idea of some corbells but have no overhanging surfaces other than the very ends of the bench. The sides and legs are flush with the benchtop edge. Maybe some turned pegs for the deadman perhaps.

[Pops]

Hi Groggy,

Very nice legs there. I like the flutes too. :2tsup: Have always thought dog holes in the legs of a bench would be something worthwhile doing. :2tsup: Going to be one impressive and solid bench.

Cheers
Pops

[Groggy]

Looking for opinions or ideas here. I would like to have a low cabinet in the bench, maybe even just a low drawer unit with a tray on top. To achieve this I need the stretchers to be as low as possible beneath the top. I am planning to put them at the bottom of the legs and mortise the legs into feet, like the picture shown, or for those familiar with benches, the design is similar to Kelly Mehler's and Garrett Hack's benches.

http://www.majorpanic.com/images/woodwork/BB/bench-1.jpg

My question comes from the design of the top. The top will be flush with the legs - no overhang whatsoever. So, the feet will protrude about 100mm. Is that going to be a problem? A tripping hazard maybe? I am thinking that if it is then maybe I should put a kickboard all the way around and not have protruding feet, more like a cabinet or island-bench base.

[m2c1Iw]

Hi Groggy,
I recon this bench is going to be one flash beast. My 2c for the feet if the bench is going against a wall can you offset the feet so there is little protrusion out front, this may leave a gap at back at the wall but I guess you can fit a filler piece to fix that.
Just a thought.

Cheers
Mike

[Groggy]

Thanks Mike :2tsup:

This bench sits in the open and will be used at both ends frequently. I did some research last night looking at benches from around the world and am thinking it won't be a big issue. This is mainly because there will be a small overhang at each end. If the ends were flush they would get in the way. The main one I was concerned about is the front-left, but when I put the leg vise on it will protrude further than the foot so that negates that one. The other three should be small enough that the hip would contact the bench at the same time as the feet contact the foot, so I might just press on with the design as it is. Thanks for the comments!

[Woodwould]

Think kitchen units and toe-space. My bench didn't have protruding feet and yet I would still kick the right hand leg occasionally. As you say, the vice will divert you away from the left hand foot.

Another aspect worth considering is that if you have a stretcher at floor level, it will make brushing the floor around the bench more difficult.

[mic-d]

Hi Groggy, it's coming along nicely! I like your ideas so far so will rip them off once you've documented your build:D. There is still a bunch of rs timber laying around here waiting to turn into a bench, but when will I get time:?.

For your cabinet location, a couple of interesting downsides have been raised so have you considered just leaving the feet off?

Cheers
Michael

[Groggy]

Michael, the previous post by Woodwould has set me to thinking again (wish he'd stop doing that :U ). I am now swinging back to having the bench legs on the ground and lower stretchers instead of feet. Then I can put a removable skirt/trim board around the bench to keep the junk out from under it.

I've also had a good idea to make the bench fully mobile if necessary. More on this later.

[Alastair]

Hi Groggy,

Inclined to think along WW's lines,; If there is no possibility of tripping over it, I still will!

Your front left is probably the least concern, as I would look at incorporating it as the base of the leg-vice

my 2c worth

[Scally]

There is too much thinking when making a bench........

On my WIP workbench I went for legs without feet. The main reason was the uneven concrete floor and I think I can adjust single legs easier.

They sit inside (will) the 40mm apron.

The long stretchers are low on the legs and the end stretchers are above them.
My idea is to give me more room/height to sit two cabinets on the long stretchers.
Each cabinet would have a 20mm thick board fixed under its front and back. Set back 20plus mm so the front and back of the cabinet rests on the long stretchers.
I will leave the cabinet height 30mm less than the space between the upper and lower stretchers. This will allow the cabinets to be put in place and removed if necessary.

I hope this helps?

[zelk]

Michael, the previous post by Woodwould has set me to thinking again (wish he'd stop doing that :U ). I am now swinging back to having the bench legs on the ground and lower stretchers instead of feet. Then I can put a removable skirt/trim board around the bench to keep the junk out from under it.

I've also had a good idea to make the bench fully mobile if necessary. More on this later.


Groggy, I had similar concerns when designing my bench.

http://www.woodworkforums.com/showthread.php?t=67360&highlight=mobile+benches

As the top rail is not in contact with the table top, I placed spacers in between for support. These spacers are removable and adjustable should there be any sag over time.I plan to put storage units between the rails ie: cupboards and draws.

One day, there will also be dog holes which will naturally be accessible from under the table top

Most of the time the mobile platform is in position and one castor is locked for light hand planing. However the platform can easily and quickly be removed, should it be necessary.

Cheers,
Zelk

[Groggy]

Thanks for the comments guys, I may not answer them all but I am reading and considering them :2tsup:

For Woodwould, I got out to the lathe this evening for a bit of turning 101. Made a peg for the leg to rest longer boards on. Just mucking around but I didn't want to see the missus burn those bits (heathen woman :melod:)

Skew only got the piece once - chopped the end off though :(( . I did have a nice rounded end at one stage, oh well :shrug: I have another 8 bits of timber to practice on :U

[DJ’s Timber]

I have another 8 bits of timber to practice on :U

So we can expect to see another 8 pegs that look the same as the first one hey :whistling2:

[Groggy]

So we can expect to see another 8 pegs that look the same as the first one hey :whistling2:Individuality is much prized hereabouts :p

[Cliff Rogers]

Like it or not.... :D

The trick is to turn out a couple of dozen & pic the ones that match the closest. :wink:

[scooter]

Following this with interest, Greg. :)


Cheers....................Sean

[Woodwould]

Made a peg for the leg to rest longer boards on.

The peg is restrained, elegant and purposeful, but will probably go unnoticed by many. I really like it. :2tsup:

[Groggy]

Here are two more. Intended to be a bit beefier, these are a matched pair. The phone camera makes them look different but they are remarkably similar considering I have never tried to turn two like items before.

[Pops]

Hi Groggy,

I likes the last version of the pegs. Well done.

Cheers,
Pops

[Woodwould]

Sorry if this link has been posted before, but you may find some inspiration amongst this lot. (http://www.geocities.com/plybench/bench.html)

[Groggy]

In between painting the pergola and moving things around I got to finish the pegs, I did four the same and one flat in case I had any larger pieces.

[Cliff Rogers]

Not bad, not bad at all, you need to put 3 of them back & turn the knob down just a bit more to match the one with the smaller knob. :D

[Tex B]

How goes the workbench Groggy?

Tex

[Groggy]

How goes the workbench Groggy?

Tex :( No movement since last update. Renovations have taken priority. I have to move all furniture outside and paint the skirtings in the house so we can have slate put down. Unfortunately that has put the bench on hold. It will be a few weeks before I get to have fun again.

:kickcan:

[Groggy]

Well, I've been so flat-out procrastinating I haven't got much further than the last time I posted. However, I have got the mortises finished for the stretchers. Side stretchers will be next but I am playing with a storage idea that will hold things up a little more.

Here is a pic of the front leg assembly dry-fitted.
http://lh5.ggpht.com/_-LWpBUYGKV4/Smqd511H-cI/AAAAAAAAAd4/96L5HEinhAk/s400/20090725%20Workbench%20Mortise%20and%20Tenons%20002.JPG


http://lh4.ggpht.com/_-LWpBUYGKV4/Smqd5tm_5cI/AAAAAAAAAd0/DvG5CwHMn1g/20090725%20Workbench%20Mortise%20and%20Tenons%20001.JPG

[Burnsy]

I like it but how do you go sanding out that permanent marker or is it some other type of marking pen/pencil? - looks like creating hard work:oo:

[Groggy]

I like it but how do you go sanding out that permanent marker or is it some other type of marking pen/pencil? - looks like creating hard work:oo:
I can remove the marker with good quality 100% meths but in this case it will be cut out when I fit to the top. The legs mortise into the top in the Roubo fashion (unless I change my mind again, I'm doing a drawing in Sketchup at the moment to try some things)

[tea lady]

I can remove the marker with good quality 100% meths but in this case it will be cut out when I fit to the top. The legs mortise into the top in the Roubo fashion (unless I change my mind again, I'm doing a drawing in Sketchup at the moment to try some things) Code for procrastinating.:D

[Burnsy]

I can remove the marker with good quality 100% meths but in this case it will be cut out when I fit to the top. The legs mortise into the top in the Roubo fashion (unless I change my mind again, I'm doing a drawing in Sketchup at the moment to try some things)

Does this work for all markers and timbers? I will have to try it.

[Groggy]

Does this work for all markers and timbers? I will have to try it.I'm not sure. I know it works with the marker I am using because I tried it once before. Even so I only use it where the timber is to be cut or covered.

[Groggy]

Code for procrastinating.:DCaught me :-

I am stuck trying to figure out how to do flutes (anyone?)

[m2c1Iw]

Caught me :-

I am stuck trying to figure out how to do flutes (anyone?)

Thought you are making a bench not musical intruments.:rolleyes:

Anyway whats a flute :D

[Groggy]

Anyway whats a flute :DThe grooves in the legs and the edges. I am trying to figure out how to taper them but the flu seems to be stopping me from thinking :(

[Groggy]

I put a quick blog (http://groggy-workbench.blogspot.com/) up to show the planned 'secret' storage under the bench.


http://1.bp.blogspot.com/_-LWpBUYGKV4/SmvphnWRzdI/AAAAAAAAAfk/JxSVVr9lJtg/s320/20090726+Workbench+Clamp+Cosy+004.JPG (http://1.bp.blogspot.com/_-LWpBUYGKV4/SmvphnWRzdI/AAAAAAAAAfk/JxSVVr9lJtg/s320/20090726+Workbench+Clamp+Cosy+004.JPG)

[waikune]

112338

Here is a snap of a work bench I'm building for a mate. All material is second hand (free) and the only cost is the galvanised bolts and of course the Jet 7" vice. Top is made up of 65x19 messmate with tons of biscuites glued to two sheets of 18mm MDF. Dimensions are 2460 x 800 x 900 high with a lower shelf to hold my mates many cases of woodworking machines, drills, sanders etc.:2tsup:

[Groggy]

I've been playing with Giggle sketchup to get an idea of how it will look in the frame layout. Here is a copy if your interested.

(Ignore the dimensions, they are close but not accurate)

When you open the file click on the tabs to get the preset various views. Note the long Bessey clamp storage area.

[Groggy]

Today the side stretchers were started, glued and dimensioned, plus I started the tenons. These will be double haunched blind tenons with dowels to give some extra holding power.

The joinery for the long stretchers is now complete, including the dado for the lower shelf. Next weekend I hope to get the short stretchers finished.

[Wongo]

Don't muck around with drawings. Just do it.:U

[Scally]

Tricky things flutes.

Good looking bench Waikune.

[Groggy]

Working on the short stretcher mortise and tenons this weekend. Halfway there, tomorrow I'll finish the haunches and square up the mortise ends.

Note the choice of double tenons was partly for strength and also so I could straddle the peg hole.

[Waldo]

So that's what you've been doing all day. :2tsup:

Keep it up son.

[m2c1Iw]

Groggy I'm more than a little concerned you have not crossed the waste on your tenons a bit of pencil scrubbing is not wise. I know if I was sawing them you can be assured the middle bit will get cut out. :D

Nice joint man, love and peace :2tsup: sorry it is the 40th anniversary of Woodstock.

[Groggy]

Groggy I'm more than a little concerned you have not crossed the waste on your tenons a bit of pencil scrubbing is not wise.I couldn't find my crosshatch pencil :rolleyes: :)

[Cliff Rogers]

I couldn't find my crosshatch pencil :rolleyes: :)
You probley cut it up & binned it. :think:

[Jim Carroll]

When you slide the clamps in will there be dividers so the other clamps will not catch each other.

Nothing worse the trying to get one out and a few others follw up with a tangled mess.

[Groggy]

When you slide the clamps in will there be dividers so the other clamps will not catch each other.We think alike Jim. :2tsup:

Originally I was planning to run some hardboard dividers dado'd into both the top and bottom shelves but that is overly complicated and the grains run in different directions. At present the plan is to use some triangular guides attached to just the bottom shelf with glue (and a few brads to hold it until the glue dries :rolleyes: ) I don't want the ends constantly catching each other.

[Groggy]

It never ceases to amaze me how many tools climb onto the bench while I'm mortising.

The first end-frame is together (dry fitted) and I am very happy with it. The frame pictured is the right end of the bench, the dark leg is the front. The mortises will be draw bored when assembled.

A nice blurry shot of the twin tenons.

The frame is dead square with no 'encouraging' from me.

Now for the second one.

[Pops]

Hi Groggy,

Nice work. Nice fit. Nice square. Oh,... and that bench. Looks pretty damn tidy to me, even the floor is tidy. All those tools led to that perfect fit so I guess the more tools the better. :)

Keep the photos coming, thanks.

Cheers
Pops

[Groggy]

I just noticed in that photo that I haven't routed the edges of the side stretchers. :doh:

Job for during the week.

[Groggy]

Got them done, took no time at all really, I must be getting used to the flute cutting. Maybe an hour all told, including setup.

Ran the router flat out so I could climb cut but still got some burning, not too deep though so they should sand out with a bit of work.

[Woodwould]

They look really well. :thyel:

[Groggy]

Had a play tonight and erected the frame dry to see how it was going. Pretty pleased with the result as it sits very solidly and pushing it does very little to it, even with dry joints. Once it is glued, wedged and dowelled, then a top attached with more mortises, I doubt very much that it will move at all.

The first photo shows the general frame. The others are showing the way the clamps will be stored. The heads of the clamps will be slightly raised so any vibration will move them in rather than out of the storage area.

I have had a lot of comments from people about how difficult it will be to move the bench, in fact it will be very simple. Anyone care to hazard a guess as to how it will be done?
http://lh3.ggpht.com/_-LWpBUYGKV4/Sop9ONeoDcI/AAAAAAAAAkI/UYoP_ChjdaI/s640/Workbench%20Mortise%20and%20Tenons%20001.JPG
http://lh5.ggpht.com/_-LWpBUYGKV4/Sop9rj-k-YI/AAAAAAAAAkQ/yl5Rb2q3tCU/s640/Workbench%20Mortise%20and%20Tenons%20003.JPG
http://lh5.ggpht.com/_-LWpBUYGKV4/Sop9clnI25I/AAAAAAAAAkM/w6s4Xw_kBA8/s640/Workbench%20Mortise%20and%20Tenons%20002.JPG
http://lh6.ggpht.com/_-LWpBUYGKV4/Sop92sxV1tI/AAAAAAAAAkU/AGxaOvwokOA/s640/Workbench%20Mortise%20and%20Tenons%20004.JPG
http://lh4.ggpht.com/_-LWpBUYGKV4/Sop-B3vWR6I/AAAAAAAAAkY/mugy46WcPXQ/s640/Workbench%20Mortise%20and%20Tenons%20005.JPG

[Waldo]

How it's going to be done?

a. :yes: Much like a deadman switch on a c/saw, you'll do the same on the bench with castor wheels. (after some Buds i can't be stuffed to find a link from FWW of what I'm talking about, but if I'm on the money in any way youi know what I'm already talking abiout) :U

b. But really, it'll only ever live in one spot and you get some burly blokes to move it into place then ply the blokes with vitamins for helping move the beast.

or c. much like above, but you'll put the frame of the bench where its final resting place will be and attach the top and rest of it after it has been located in the final resting place. (make sence? :yes: clear as mud)

[Groggy]

a. No
b. No
c. No

[Waldo]

Bugger, can I buy a vowel?

[Groggy]

Bugger, can I buy a vowel?I'll have to come back tomorrow, my son has used up our bandwidth and I am on dialup speed :(

Oh well, nothing wasted this month :D

[Squirrel]

It never ceases to amaze me how many tools climb onto the bench while I'm mortising.

The frame is dead square with no 'encouraging' from me.

Groggy, Just popped into this thread to have a peak at your new bench. I haven't read all the posts but the bench looks like it will turn out very impressive.

The reason for me butting in, as I has to have a little chuckle at your "dead square" comment. I couldn't understand why it wouldn't. I had a close peak at your work bench and I could count 7 possibly 8 squares on it. I understand double checking, but 7 times, that's gotta make it perfect.

Squirrel.

PS.. the picture was the first one in post #80

[Pops]

Hi Groggy,

Looking good alright, and very solid. I likes it.

Cheers
Pops

[Groggy]

The reason for me butting in, as I has to have a little chuckle at your "dead square" comment. I couldn't understand why it wouldn't. I had a close peak at your work bench and I could count 7 possibly 8 squares on it. I understand double checking, but 7 times, that's gotta make it perfect.Squirrel, I am lucky to own a few squares but in my defence I can say they do get used. I'll try to explain why they were all out.

1. Lee Valley saddle square. Was using it to transfer markings where the haunches are.
2. LV small try square. Was using it mainly as a depth gauge to 20mm for the step in the haunch.
3. Starrett 4" try square. Used to guide the mortising chisel.
4. Chris Vesper square. Used for just about everything. It was used to check the progress of the 45 deg haunches, the start of the mortises etc.
5. Generic 8" square. Used to check larger leg assembly but also as a visual cue when mortising.
6. Colen Clenton square. This has a slightly thicker handle than most squares which allowed me to use it when the flutes in the legs were a nuisance. It also balances well.
7. Starrett 12" combination square. Note the ruler is removed. I was using it to rest the chisel on when starting and finishing the 45 deg cuts for the haunches.
8. Starrett 300mm combination square. This was being used for another job and happened to still be on the end of the bench.
9. Generic machinists square. I'd been using that one to square up the drill press table to the bit.

[Squirrel]

9. Generic machinists square. I'd been using that one to square up the drill press table to the bit.

Sorry, I don't know how but I missed this one.
Must admit, I have 1 or 2 (dozen) myself

Squirrel

[Christos]

I want to say that this looks really good on the progress.

As for the other point the Squirrel made on the squares


Sorry, I don't know how but I missed this one.
Must admit, I have 1 or 2 (dozen) myself

Squirrel

I originally had one that was not square. Cost the same as the ones that I now have that are square. :)

[Christos]

As for moving the bench. Why would you want to once it is in place.

By Hoist

[Groggy]

As for moving the bench. Why would you want to once it is in place.

By HoistI have a habit of rearranging things. I will be moving my lathe once the bench is finished and that will probably mean moving half the workshop outside to do it.

[Groggy]

If you look at the legs you will notice the dog holes are on all four legs, not just the front. This allows me to place a 19mm rod through and attach wheels to it. A simple cantilever will let me lift the bench up.

Another way I am thinking of is the dolley wheels used for trailers. If I weld two rods out the side to go into the legs I can crank the bench up. I saw some cheap ones today for about $15 each. The dog holes give me quite a few options as they are very strong lifting points.

[artme]

Its all looking very impressive Groggy. :2tsup:

[m2c1Iw]

If you look at the legs you will notice the dog holes are on all four legs, not just the front. This allows me to place a 19mm rod through and attach wheels to it. A simple cantilever will let me lift the bench up.


Ah ha......clever idea :2tsup:

Did you use a jig to do the flutes?

Mike

[Groggy]

Did you use a jig to do the flutes?The first lot on the legs I fussed around with the router and guides doing it hand held - DON'T BOTHER! In case you missed that - DON'T BOTHER!

The side stretchers were done on a RTA300 Triton router table (note to self, make that thing flat or get a new router table :~ ) and four pencil marks on the fence. No jigs at all other than the table and fence. The legs took a few hours to do, the side stretchers were done in minutes and with less risk of error.

Happy to explain further if you want.