Thread: Cheap bench build - hand tools only

Scott,
you know they never say anywhere what the most time consuming bit of a bench build is... it is the thinking about it. trying to work out all the different options with limited budget, tools, skills and confidence. the last two from my experience being the biggest stumbling blocks. I have spent the last year and half (plus some) thinking about mine, and decided I just had to do it one way and go for it. if it works, great! if not, I learnt something.

my plan for attaching the top is to have some mortice and tennon, but not all the way, but then also screwing the top rail into the top. I wasn't wanting to wedge the top in, because it means that I can then take it off in the future if I so desire. I have always liked a bench that Konrad Sauer has rehabilitated (http://www.sauerandsteiner.com/galle...?g2_itemId=885) and the associated base.

stretchers: I have legs of 90x90 and there is plenty of room for my 90x45 stretchers. I will also be putting a shelf in the bottom. one thing I am still tossing up is if I put a third leg or not in the middle (like Konrad's above). the three 90x45 should be plenty.

dog holes: the brace bit I have been using has been ripping the wood around the hole, so I was planning on using either a forstner/spade bit to start with and then finish with the brace and bit. getting them straight? I don't think it really matters if they are perfectly straight, as long as they are consistently pointing in the same direction (towards the right of the bench if you are right handed. so I was going to build something like I bench hook with a piece of pine with the correct sized hole attached, and then slide it along to all the spots I want the dog holes.
I know you don't have a brace, but I would suggest trying to get one from someone like hans brunner.

btw, where on brisbane southside are you?

Hey Greg, thanks for the advice. I've been thnking about investing in a brace but haven't taken that step yet, from looking online (particularly in the US) they seem to be everywhere but I don't really know what to look for & wouldn't know a good brace from a bad. Carbatec have new Lee Valley ones on special for $75.00 but I've read they're not as good as the old Stanley's .. sometime i research/investigate things too much & before you know it a month or more has gone past & I've achieved nothing ! Having a 9 month old makes things hard too, as I don't get much shed time these days.

The reason i say i may struggle with the laminated 90 x 45 legs is that I planned on making things easier by only having to cut a rebate (the entire width)in the middle piece of the leg prior to lamination for the 90 x 45 tenon to sit in, saving me from chopping or butchering a mortise (if that makes sense). By doing this it'll leave me room for a maximum depth of mortise for the side stretchers of 35 - 40 mm as I only have one 90 x 45 leg to utilise (which may well be enough). It's very difficult to explain in writing !! Basically I don't have to cut mortises for the side stretchers at all but will for the shorter sides (if that doesn't confuse all I don't know what will !! )

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I'm in Calamvale on the Southside Greg.

Not much can go wrong with a brace as long as the jaws are OK I wouldn't spend more than 10 dollars on a second hand one unless it was special. If the bits are tearing the wood on entry they may be ones with out the wing which are used in hardwood and for construction. If the bit has wings the entry whole should be very neat
Check Paul sellars recent not sharpening video he shows one in use.

Sent from my GT-I9100 using Tapatalk

I am watching and learning whilst you build this bench.

Ozzie,
how are things progressing?

Originally Posted by Greg_stewy

Ozzie,
how are things progressing?

Hey Greg,

Slowly ! The little fella has had a cold along with his Mum, so I've been playing the role of nursemaid/cleaner/wiper of noses. I hope to get back into the garage on the weekend.

Good news on the brace front. I borrowed one (& then bought one on gumtree). I've snuck out into the garage late at night after the infirmed have been put to bed & had a play with the brace(s). I have sharpened my 3/4 inch bit but still have tearout and after reading your last post realised that perhaps it's not about the bit not being sharp enough after all it may be the pine. I too was thinking of starting the hole with a forstner bit, the problem with this may be that I have a 3/4 inch bit but a 19mm forstner bit. Was this an issue for you ? Technically 3/4 inch is 19.05mm of which the difference is very small but may be an issue, I'm not sure yet.

Will post any progress after the weekend is done.

Managed to get the legs laminated over the weekend. Still have to tidy up the 4 legs dimension wise so they're all of equal proportions.

I have a question for anyone who comes along here: My bench top will be 1800 long (before the breadboard ends), how long should my base be, to ensure maximum rigidity ?

Ozzie,
I don't think there is a magic answer.
I believe you will get maximum rigidity if you put the legs all the way on the ends. That would give the rigidity, but you might be someone that likes to have overhang/space on either end. I think you more have to ask yourself, how much space do I want /need on the ends? how are you going to place your vices? inside or outside the legs? or on top of your leg?(leg vice).
They are my thoughts, it is more up to what how you are planning to work.
for me, my top is 2.4m long, but will be trimmed to about 2.3m. I have the legs in about 40cm from each end, and thought wiht the weight of everything, that should be fine. it lets me have clearance on either end for the vices. Putting the legs closer to the end would have given me more stability but I liked having that clearance space underneath(I can store my drill press under an end.

thats my thoughts....

Greg

Yeah, what Geg said. You would have to have a lot of overhang to make a 6' bench too tippable, unless it is a very lightweight item. You probably don't need 400mm overhang, but certainly leave enough to give you plenty of room for clamps to fit under, should you need to use them. OTH, if you want to fit a 'wagon vice' you'll probably need about 400mm clear at the end where you place it, so that the dog doesn't foul on anything

If you intend building cupboards underneath, the wider apart the legs, the more room you'll have here. So it's just a matter of juggling needs & wants.....

Cheers,

Thanks Ian & Greg. I really need to consider the hardware side of things. I know that I won't build cupboards underneath, that'll be a shelf only. I'm not sure about a leg vise at this stage. Excuse my ignorance but the legs are three @ 90 x 35 and although the legs will be flush with the bench does the leg where the leg vise will be need to be wider to maximise the gripping area ? If I do add a leg vise I will also add a sliding deadman.


Laminated legs (not yet fully dimensioned to final size/smoothness).
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And the brace i was given. After a degrease and a clean up it went from black to not too bad. Still need to sand and oil the timber parts but the brace itself is close to as good as it'll get. Still a bit of pitting that I won't bother cleaning up, but it works well

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Hey Ozzie,
how are things progressing?

Had a couple of wife & baby fee days and spent almost all of this time in the man cave.

Glued together 2 parts of the top & gave myself a good workout getting this relatively flat:

Top (kinda) flattish.

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Associated mess.

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I then had a crack at using the drawbore method to join the stretchers to the legs.

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With success.

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Then had a practice at dogholes with my "new" brace.

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Before the real thing.

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Finally, tonight I assembled the base and am ready to complete the top (hopefully tomorrow).

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I'm really happy with how this build is progressing, given my lack of experience. While it's far from perfect I'm really excited that it's (thus far) exceeded my own expectations. The next phase will be completing the top and making the tail vice, adding a front vice & finally adding a sliding deadman.

Cheers, Scott

Looking good Scott!
It is amazing what can be done when little people/wife aren't around!
I noticed in the last photo that you have a bit of a lip in the stretches. how did you do that?

Originally Posted by Greg_stewy

Looking good Scott!
It is amazing what can be done when little people/wife aren't around!
I noticed in the last photo that you have a bit of a lip in the stretches. how did you do that?

Hey Greg,

I used my rabbet plane to cut the rebates. This is where my shelf will sit eventually.

It's good to see the plan taking shape.