WIP - Downunder HolzWerken Workbench and Garage Makeover

**Elill** · 24th February 2013, 09:10 PM

Alrighty guys and gals, I've been stewing on this since I first saw zee German wersion a few months back (ok, I promise that'll be the end of the accents

).

Was diese Bank so alles kann! / Maschinen / HolzWerkenTV - Holzwerken

I ordered the two magazines (which are excellent and I wish they did it in English). He (the German guy) builds the top first and then the frame.

Originally I was going to build a slightly longer one (2400 instead of 2000) and put a Festool CMS insert for my TS75, using the incra fence for this as well as the router. I changed my mind however as its another 400 I'll loose on that wall which I can use for another tool (a bandsaw and thicknesser are on the cards at some point in the next 50 years

. Some context. At some point we'll have two cars and this is the only space I have to play with, so as recently discussed in another thread on these benches it works for me because it's a Festool MFT, router table and workbench all in one. I am going to have this on the left of the garage where my drop saw is. I am going to make another stand for the Kapex that will be the same height and it'll sit next to this bench. Everything will be on casters (Fallshaw 75mm) all with brakes.

Some photos:

As you can kind of see, I've got a bit of a thing for the green stuff. I recently purchased a OF 2200. My first new router (I'm selling an old Hitachi and Rupes) and today was the second time ever I've used one. I am going to build a separate stand along tool chest for my hand tools etc and a big drop down assembly table on the right of the garage - on a pulley. I am going to try to figure out a way to mount my TS75 in this for cutting thin stock.

So I started today, first things first. He builds the whole thing out of out of ply (hardwood frame) with biscuits. I don't have a Domino and I hate my cheapo biscuit cutter so I considered three alternatives (1) dado butt joints (2) sliding dovetails (3) mitre lock for the edges and dados for the others. I am going to try the last option first and it that does't work I'll consider the others.

The ply I am using is 25mm thick ArmourForm from Big River Timbers. This stuff is solid hardwood and weighs 75kg per sheet......stuff me, thats 1.5 times the Mrs (whoops can I say that online?). I struggled today to lift them by myself.

First thing I had to do was figure out how to do a mitre lock without a table. Now I know there is a lot of fist waving, head shaking, finger pointing, cursing etc going on, but it is actually possible. I did it today on some 25mm chipboard. First one is easy. The vertical ones a little harder. What I did was clamped the stock to a 2x4, clamp that to a bench (horses and ply) and then I've got a nice stable means to route it.

So progress today?.....well it took until 4:00pm to figure out how to do the mitres so I only got the two long sides cut and the sheet sized (900mm wide).....here is a terrible photo.

So anyway, strap yourselves in, this is going to be a long one (we've got an 8 month old to contend with)

Oh and I dont have any of the spiffy Veritas stuff yet - am waiting until the working with wood show in the hope they're cheaper....in saying that, the vice is only $308 from Carbatec (or is that a lot?)

**Christos** · 27th February 2013, 09:30 AM

Ok I am in watching this one. No matter how long it takes.

**bsrlee** · 1st March 2013, 01:50 PM

He seems to have a serious Festool & Veritas thing, doesn't he. I just wish I had his tool budget.

**wheelinround** · 1st March 2013, 05:58 PM

I will pull up a chair also I mean any supporter of the Toon boys has got to be on the ball.

**Elill** · 1st March 2013, 06:44 PM

Originally Posted by Christos

Ok I am in watching this one. No matter how long it takes.

It'll take a while, but hopefully this thread will be of benefit once we get to the end. I figure I may as well learn on cabinets for the 'shed' before I get too deep into 'fine' stuff for the house. In saying that I did the Studya while back and its pretty alright

Originally Posted by bsrlee

He seems to have a serious Festool & Veritas thing, doesn't he. I just wish I had his tool budget.

Me or the German guy?.......ok well yes I do....I made a vow about 6 years ago not to buy a tool unless it was the 'best' I could get (this is why I dont have a table saw.....that and room). I've had too many crap tools and I dont like buying things twice. In saying that, the reason for the Festool gear is because of the "system" (and I'm fickle, I like things the same). I'd prefer a rupes sander and vac, a Makita mitre saw (the Japanese one) - but when it comes to the plunge saw and router I'm very happy (actually I'm not unhappy with any of the others except the Kapex).....ah dont get me started

Originally Posted by wheelinround

I will pull up a chair also I mean any supporter of the Toon boys has got to be on the ball.

Mum's a Georgie. That is known as "Alan" in this house.....Mrs wouldn't have him in the bedroom

. He signed it when he was here in 2008? He's going to have to move to cater for the new drop down assembly table

Probably into the stairwell between the garage and house, he'll be out of the dust more there

**wheelinround** · 1st March 2013, 08:45 PM

**Mutawintji** · 2nd March 2013, 05:18 PM

Originally Posted by Elill

Everything will be on casters (Fallshaw 75mm) all with brakes.

Hi mate, I'm not a woodworker and this is not a plug. But if you are in the Brisbane area you can get excellent heavy duty industrial casters from Wild Industries, with or without brakes, and cheap.

They are down in Cairns Cross near the Dry Docks, no shop front but go into the front office. They are a heavy engineering firm. I just bought a heavy duty set, 120 mm for $22, no brakes and $34 brakes and swivel (rubberised all terrain)

Greg

**Elill** · 3rd March 2013, 07:47 PM

I was hoping to have the frame of the top finished today.....the top mitres are done, the four sides, and the dados. I've not cut the middle rails yet. I've dry fitted the ends and sides and it works nicely - see the corner of the mitre lock.

The sides are slotted into the dados to keep them straight - works a treat

**FenceFurniture** · 8th March 2013, 01:00 AM

Fuzzie, is there a reason why you stayed with the black top? And did you get it laminated on by a third party?

**Elill** · 8th March 2013, 08:57 AM

Fuzzie?

I went with this as its hardwood ply (25mm thick) and the film is a very nice "slidey" surface

**FenceFurniture** · 8th March 2013, 09:17 AM

Originally Posted by Elill

Fuzzie?

Oopsie! Sorry mate, was pretty late, so maybe I was.

**Elill** · 12th March 2013, 02:28 PM

So how was everyone's weekend? mine was swell.

.....Saturday was gluing up day.....looks like I didn't have my wheaties in the morning, because as I was lifting the top onto the saw horses I slipped (nearly slicing my hand in two) and dropped the bastard. I cant bring myself to taking a photo, but those clean cut mitres are ruined in a corner and two sides......serves me right for thinking I was smarter than a German. So I'll start again with dados and biscuits. I just have enough left for a slightly (~20mm) smaller top.

I was thinking of doing the end cap in dove tails. I'd better post a drawing at some point to show you what I mean as I don't want an even shorter bench if I stuff that too

sigh....lets hope the next few weekends bring some more love

I should have built my fold down assembly table first - that'll go together in a day or two

**Elill** · 18th March 2013, 08:47 PM

Okky doke, back into it. Routed 6mm dados, biscuits and dowels all over the show.

Just need to and the ends on and thats the main table top frame finished.

Next job is to route and cut the insert plate and decide on a method to attach the timber for the tail vice. I'd like to do two long and wide sliding dovetails? thoughts?

**FenceFurniture** · 18th March 2013, 09:11 PM

Not sure what Tail Vise you have in mind, but I'm using one of these (in a crappy bench) and they are fine. Quick to install, quick to use, and just a small knob sticking out. There's only so much pressure you can put on thin stock before it bends anyway, but they sure seem to have some holding power. I I ordered two extra dogs of 1/2" and 3/4", but didn't think at the time to order two of each

Mind you, if you're using other types of dogs on the other end then you only need one each of the different sizes.

Some have said that they look slow to operate, but I've developed a technique of running the v of my forefinger and thumb over the knob (?) and I can run the full 100mm in about 3 seconds or something. One of the things that I'm considering for my upcoming benchbuild is recessing the knob into the bench top (still with enough room to perform that rolling action) because then there'll be nothing sticking out from the bench end.

**Elill** · 18th March 2013, 09:24 PM

LOL (you know which bit

....)

Interesting, I probably should do some more research before taking the plunge

I had planned one of these:

endvice.jpg

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