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Thread: Marty's Workbench rebuild.
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2nd March 2020, 12:32 AM #1Member
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Marty's Workbench rebuild.
I built this workbench when I was 15 for a high school woodworking major project. I did an okay job of it at the time, because I walked away with the school prize for woodworking that year. I think they were calling it "Industrial Arts - Wood Technics" at the time. 66x66mm Meranti/Maple trestle legs with a single longitudinal on the bottom. The original top was 12mm MDF laminated with 6mm Masonite top and bottom. It lasted 20 years, 2 of which were outdoors, under an awning, but it has had it. The front apron was made from a scrap length of what I believe to be beech and it is about 150mm wide and 28mm thick. The longitudinal is held in by two lag screws at each end directly into the end-grain. 3 out of the 4 hold well, but I have a feeling that I should drill a blind hole near each end and insert a 19mm Tasmanian Oak dowel so that the screws hold more securely.
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I was going to get rid of it, but I was all overcome with nostalgia for this bench. It survived 4 house-moves, and being used at various times as a stand for a cheap lathe and as a work-table for model-building, live steam miniature engines, bicycle parts, etc. It got all manner of chemicals, grease, etc on it over the years, including suffering from spilled methylated spirit catching fire on more than one occasion! I had used slotted steel screws to affix the apron to the top and legs. All but one came out easily. The last one had to have the head drilled out and it had to be ripped out of the leg.
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A trip to Bunnings and I was intending to get a laminated Beech worktop panel, but I was put off by the fact that it was made up mostly of short lengths all glued together. I was a bit wary of how it would stay flat given that there is no supporting framing under the bench top. But I found a 1800x600mm 25mm thick Merbau panel for a few dollars cheaper and a bit of research via google on my phone found that it is a hard-wood known for being stable, a bit oily/waxy and so rot and insect resistant, dense, heavy and very stiff. The kind staff member didn't charge me anything for the single cut to lop it to length (1530mm - yes, a slightly odd measurement) It is nice and heavy - similar in weight to the original top and it feels very stiff and solid. Underneath the bench is a wooden box I also made in high school for a project. This was always intended as a small toolbox, but I never did get around to fitting any handles. 20 years later I might actually get to it!
Just need to drill some holes for the coach bolts so I can attach it to the frame. The 20-year old originals were somewhat rusty, so either I dip them in linseed oil before fitting them, or I might replace them with some stainless steel ones rubbed liberally with beeswax so that they don't get too stuck. If I get some augers, I might recess the nuts.
Ideas/suggestions/tips/tricks/hacks or just some comments are all welcomed.
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2nd March 2020, 09:58 PM #2Member
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A few coats of Linseed oil mixed with methylated spirit, and a rubbing down with beeswax paste (I think it is mostly beeswax with some lanolin and coconut oil) and now it is all disassembled and stored against the wall in the garage again. I have to do some work on the top - drilling holes, fitting coach bolts, etc. I think I will go for stainless this time around. I also need some 1" beech to make some vice jaws. Anyone got a couple of off-cuts of 6"x1" about 8 or 9 inches long? I originally used the front apron as the fixed jaw, but I have cut out a hole so that the fixed jaw will be flush with the apron. I noted on one of Paul Seller's videos that he preferred it this way so that he didn't trap his fingers when putting small pieces into the vice. I am thinking of putting in some holes for bench dogs for clamping wide boards and bowls when I get my lathe back up and running.
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23rd March 2020, 12:43 AM #3Member
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Workbench is back in the garage. All the steel screws and bolts have been removed. I upgraded to M10 Stainless Steel coach bolts (with the dome head) to hold the apron to the legs, and I got rid of the lag screws which held the single bottom stretcher to the legs. I took a 25mm tri-flute auger to the stretcher and made a through hole for the nuts. I had intended to use dowel nuts, but couldn't get them at Bunnings, and I would have wanted M10 stainless anyway. The Merbau top isn't bolted down yet. I discovered that the holes I drilled back in high school were all sorts of strange measurements, so I plan to drill out new holes for the new bolts.
I will also run some stainless screws to attach the apron to the top. Yes, the garage is a mess, but I will get it cleaned up. The way that current events have worked out, my next appointment of any sort is not until the 4th of May!
Grandfather's Disston saw on right-hand side of the bench with handle re-attached.
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23rd March 2020, 03:26 PM #4Member
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All bolts sorted. I used 50mm stainless steel decking screws with Torx heads to attach the apron to the top. For a bench without angled braces, it is surprisingly rigid. It will slide along the floor before it will rack or twist. Speaking of which, I really need to find some rubber pads I can use as feet!
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28th March 2020, 12:26 AM #5Member
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20200327_224946[3100].jpg
Installed a 7" cabinet-maker's vice, but I have decided that I don't really like it on this bench. Looking around for an old Dawn Vice now.
I increased the height of the bench by putting some half-pavers under each leg. This raises it 50mm to a more comfortable height for me.
I also installed a shelf where I can now store tools under the bench. 18mm thick Merbau panel from Bunnings, finished with raw linseed oil mixed equal parts with mineral turps.
Starting to think about a couple of shelves and tool racks above the bench to hang my saws and other items.
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29th March 2020, 11:10 PM #6Member
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Dawn_Vice_Fitted.jpg
Found myself a nice Dawn No. 225 (formerly No.9) without the quick-release. Paid a reasonable sum for it via facebook marketplace. Jaw liners are 250w x 110h x19d Tasmanian Oak. Held in place from below with some pine packing blocks and M10 stainless lag screws. From above there are now 8x 50mm stainless steel Decking screws holding the block in place.
I originally mounted it in such a manner that the front apron was the fixed jaw liner, but I found that this gave me issues with trapping my fingers. So I added the second piece of Tasmanian oak which now allows me to better grip the work-piece when opening and closing the vice. I added some rubber O-rings to the handle just to lesson the high-pitched "clink" when dropping the handle and it is now a slightly dampened and lower-pitched "clunk" - that should keep other members of the household happy.
I also tossed in a dash of eucalyptus oil with the linseed and turps finish for the vice jaws and the result is a more pleasing room note left behind when finishing.
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30th March 2020, 01:06 PM #7
Nice. You will never ware that out.
Regards
John
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31st March 2020, 12:19 AM #8Member
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When I was in high school the ones we had were at least 30 years old and were regularly abused by students, but seemed to be just about indestructible. I do remember quite a few students who would torque down lumps of timber to the point of crushing it and then grab a 1" chisel and absolutely pound down on them. I vividly remember one student managed to put a crack in the bench somehow!
I am pretty sure these cast iron bench vices will outlast most workers, even when thoroughly abused.
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31st March 2020, 02:45 AM #9Member
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Shelf added above bench. Rulers and a small saw hanging from nails in the plasterboard.
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1st April 2020, 12:21 AM #10Member
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Opportunity taken to add a small tool rack under the shelf using a scrap of 42x19 pine, brass hooks and a few dowels. Note the small brush on the end of the shelf and the large red dustpan and brush. These were items until recently sorely lacking in the workshop - note the reduced amount of sawdust and wood shavings on the floor. The black bin is also an important item of workshop equipment.
I have a pair of little 3-draw cabinets. I plan to put one either side of the bench for storing miscellaneous small items the plan is to put things I use regularly on the shelf and rack and everything else in drawers.
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Also got myself a 6" bench grinder. At the moment I am keeping this attacked to the tail end of the bench, though normally clamped toward the rear. Needs a new wheel or some serious dressing work on this one. This picture is just showing that I am ready to get my plane irons and chisels sharpened again.
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17th April 2020, 11:11 PM #11Member
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93412199_10157936812911251_5574972154136494080_o.jpg
Installed this gizmo today.
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19th April 2020, 07:16 PM #12Member
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93504429_10157944723661251_6157174534685327360_o.jpg
Made myself a bench hook today out of a scrap of 285x19mm pine and some odd lengths of 42x19mm pine. If memory serves, I got these from the off-cuts bin at Bunnings and paid all of $2 for the timber to make this.
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