Thread: Redefining the Aussie WorkBench

Thx for the feedback Ian your thoughts are always appreciated

Im not used to being comfortable or fashionable when Working id probably be more inclined to chock the Bench up maybe a sole that could go under the feet could be worth the effort?

Just a different approach........................then again I think id have to be doing long production runs of Dovetails or Tennons before the pleasure of the discomfort became unpleasurable HA

Anywaz will keep thinking how to refine the design ....................... focusing on more Benchtop Rigidity the gem from our Yarn i thinks!

Cheers Clink

Gidday

Have been thinking a lot about how I work N past experience working on Benchtops

Even as a Boilermaker 95% OF Thrashing and Bashing with Sledge HAmmers MAsh Hammers N Such Occured on the Floor in Unfixed Positions.....................Seriously IF im really gonna Belt something im not going to do it on a WorkBench ................Nothing like really winding up a sledgehammer and letting rip...................humbling to see what your belting hardly move.....................Satisfying when you get the resullts your after

The results im after from a Bench ..........A Flat surface..........Multiple Fixing options..............Vices capable of providing light medium heavy clamping duties................A stable worktop! however if it did move a tenth of a mm or 2 in use BUT returned to acceptable flatness tolerances would it really matter? would i even notice? Would the structure of the BEnch be compromised? most likely for most of us most of the time NO!

Mortising; Normal HAmmer work within the Range of Light to Moderate 'Bash Work' etc etc can easily be achieved on the Benchtop Design Proposed. However if a More robust options are required as suggested above you could always insert and area with Plate Steel, Hardwood or for that matter anything else that delivers the goods for the style of work you do. The bonus being Ultimately you still get to keep a mare free Benchtop (Were there is some dedicated real estate for Bashing Crashing n Mashing allocated to your Benchspace.......................Problem solved if indeed there ever was one!

I think the idea of keying in some pipe heavy dowell? Hardwood (Anything that works for you) is exciting as it potentially addresses the XY Axis movement issue (If indeed there is one?) Cheaply. Regardless I'll test it once the Bench is Completed n record my findings just in case myth n legend abounds ................rather than fact

Heres a few SketchUps of some rough ideas on how to reinforce a Benchtop made from 3 cheap laminated 18mm layers of MDF (A stable cheap dead flat Surface than never requires hand planning to adjust for seasonal movement)

Regards Lou

Also heres a few storage ideas and an Anti Racking Pin for the front vice (Inspired by DarthC, At this stage is made from large dowell I have a huge piece of round that may also be useful)

Am really curious if anyone has any ideas on how to locate it under the bench and best way to make X (horizontal Axis movement work Well (Could thread the Dowell? Attach it to a metal locator & thread? Etc etc etc)

Any other thoughts ideas really appreciated on this one. The speck being the idea is incorporated into the BEnchdesign..................

Regards Lou

Originally Posted by NewLou

Have been thinking a lot about how I work N past experience working on Benchtops

Even as a Boilermaker 95% OF Thrashing and Bashing with Sledge HAmmers MAsh Hammers N Such Occured on the Floor in Unfixed Positions.....................Seriously IF im really gonna Belt something im not going to do it on a WorkBench ................Nothing like really winding up a sledgehammer and letting rip...................humbling to see what your belting hardly move.....................Satisfying when you get the resullts your after

but a concrete floor doesn't really move, meaning that most of the energy in your sledge hammer's "thrash and bash" ended up in the piece being bashed

Originally Posted by NewLou

The results im after from a Bench ..........A Flat surface..........Multiple Fixing options..............Vices capable of providing light medium heavy clamping duties................A stable worktop! however if it did move a tenth of a mm or 2 in use BUT returned to acceptable flatness tolerances would it really matter? would i even notice? Would the structure of the BEnch be compromised? most likely for most of us most of the time NO!

when chopping a mortice, if the bench top does deflect under a hammer or mallet blow, even if it's only a mm or two, too much of the energy on your striking gioes into making teh bench move and not enough into actually cutting wood fibres.

It's not a structural thing. Think in terms of using an anvil.
If the anvil is sitting on a concrete block, the energy in a hammer blow deforms whatever's on the anvil.

but if the anvil is sitting on a beam, much of the energy in the hammer blow goes into making the beam bounce and it takes a lot of blows to deform the metal.

Curious observations Ian thx for the commentary

Im not sure I agree with your notions of physics or the mechanics of how force works with tools and the materials worked on ................even large heavy objects move when hit with a sledge hammer!

Regardless

Ive worked in puddles sand on plastic tin on Railway haulers under machine lines n all manner of other surfaces mostly hot dirty n not much fun rather than a glass being half empty I tend to have a half full approach and 'make it work'.............n if i get it working i like to spread the joy u know add to the greater good all that positive nice happy bliss stuff.................you know FUN!

Secretly Im confident i can make cutting a tennon on the above design Bench work......................if not initially im sure i can tweak it to get a win!

YAY!....................................For those interested in Trestle style Workbenches check out David Marks from 'Woodworks' fame giving a good rundown on his Bench Here with the Woodwhisperer

https://www.youtube.com/watch?v=Ch8SFQJsR2E

Regards Lou

Gidday

Thought it might be fun and interesting and indeed an opportunity to tweak the Mk1 through some modelling

Heres the GO ...........................

I'll try to model any type of work piece clamping at optimal position on the Bench

Feel free to throw me some dimensions shapes (anything really) and we'll see if the design can stack up without adding additions (Like a moxon Vice) to the basic design

HAs the potential to be quite the thought provoking exercise

My current kit is a Basic Powertool setup VAriety of HAndplanes + Moving Fillister (HNT of Course)

Also Because of Space restrictions Shes going to have to Double up as a Cutting Table + Router Table

All thoughts suggestion experiments encouraged

Regards Lou

Gidday

Heres a simple setup that works a bomb for knocking down Sheet Goods......... You can even stack sheet gang cutting as required

All you need is a few sacrificial bits of scrap to cradle the sheet on ..................... a good guide rail n decent circ saw n off you go

Ive used this method on many occasions with great results often the hardest part being managing n moving the sheet before you knock it down (lots of fun making totes n using skatebords n the like moving em round )

Ive noticed endless reems of information on the NEt, Blogs, Webpages, Youtube Channels n the like great access to information these days YAY!

Big question which camp to join in regards to an optimum Bench Height The yanks have a few ideas as do the Brits Most champion setting up for how you work and the kind of work you do

I know this will be contraversal BUT i cant see the point in making a Bench that can't do 90% 95% percent of what I want it to straight off the BAT PERIOD!

this is just my point of view and im sure im in the minority but if i had to Knock up a Moxon Vice or make a Bunch of other Jigs Fixtures Additions and other adjustments then for me (And once again i know im in the monority here) Ive got the design Wrong.................Yes it needs to be modular for the future but also as close as i can get to the mark 1st time round espically if im going to invest thousands (which isnt hard) in making it.

For my Money a moxon Vice is great for those poor souls doing long production runs on Dovetails and great for those Selling wares to make one. Call me consumer resistant trend resistant and the usual (*^%$^(%&*^% BUT to me keeping away from such bells n whistles is a liberation to focus on making goodies like furniture

So back to the camp im in ..............I will need to knock down sheet goods a few times a year crook back from boiler making days so low Bench heights bring on an allergy to the Bench. Iim thinking around the 37 inch 90mm or so MArk will do. I want to use all the real estate on the top so arn't fussed about chopping over legs and all this kind a thing I'll demonstrate that I can cut bang and bash from anypart of the surface and the Bench will last generations...............In sum for the most part Im likely to be making projects that go in houses or back yards

The End Vice will be used to Hold My Router Table this significantly adds FUNK! to my Bench a strategy ive used very successfully in the past ...............

Am interested if anyone has had 'stand out' difficulties using a Bench (With a Front n Tail Vice) to fix/hold/secure any thoughts ideas really appreciated

Regards Lou

Gidday

Have been agonising about which camp to go with in regards to Dog holes and clamping options.............. Round Square Round Square T - Track I keep coming back to T-Track at one stage I was thinking of using all options!

Round dog holes for light to moderate clamping options N square Dog Holes seated in RHS keyed into the Benchtop for the Heavy Duty Stuff ................... Ultimately always something that can be revisited in the future.............

HAve also been checking out the prices of MDF n Plywood in Canberra where im now located about 75 Bucks for a sheet of 35mm MDF (Thats Ok)............... Plywood Sheets are considerably more expensive in 19mm and 25 mm Options

Ouch!..............Some of the stuff like AA Grade Marine Ply is up to 350 odd bucks a sheet of BB grade $150 for the 19mm n $220 for the 25mm slapping on 30 bucks for delivery......................sounds better!

The hard part is deciding whether to go the full el cheapo monty or A sheet of 25mm BB Grade Ply, A 19mm Sheet of BB grade ply N a Sheet a 35mm MDF Considering im willing to pay upto $500 for a Handplane around that

price I can live with ..................... If im gonna re cycle hardwood ill make furniture out of that thank you very much!.....................with sugar ontop

Further

I was playing around this morning tinkering with ideas about the best places to inlay the T-Track. I discovered that about a centre 65mm in from the front face of the Bench felt perfect for me (See the Pic) the sweet zone

I also played with different height n once again for me the sweet zone was about 90mm 37 inches High..................Due to boilies back low Bench Heights are a No Go! N as stated I want to wring out all i can from the

Benchtop Real-estate. The Bash Plate is a bit of 250 * 150* 12mm thick Mild Steel Plate the location is Perfect (once again for me specially not being shy about using a (mallet, hammer, sledge with no Bench LEg Under

it.................gasp! trust me it i'll be fine) with the added advantage of providing a Welding Point (I Tig n Suck the Heat out with A Large piece of Copper Flat sneaky huh )

so at this stage time will tell if the heat becomes an issue I'll report once I take the leap...................................but also have many workarounds

The T-Track is some heavy Duty Ally 3mm thick so should hold upwell .....................Any thoughts comments advice critic appreciated

Regards Lou

HEy

Great thing about sliding Bench Dogs is their cheap to make. I've used these with great results in the past n so far have yet to find anything they can't Handle. Advantages infinite adjustment along the X Axis through

the length of the track, low profile................if they break or get damaged you just make a new one. Also you dont really have to use fancy T-Track you can just inlay a narrow piece of flat n get close to the same

results...................possibly better. Ive seen another forum member do this but forgotten who it was

Looking good so far............................Regards Lou

Gidday

Ok time to start honing as I gear up for production just wanted to revisit modelling the Bench clamping Setup Ive come up with.

Yes she does lack the leg vice from the French bloke...............Mr R. Am wondering however if the current configuration is just as versatile ?

This Bench needs to be flexible and will be the foundation of all my needs in limited space. As mentioned earlier long heavy sheet goods can pose a few hassles and problems

How would you go about clamping a bit of sheet this BIG in position ?

Very interested in your thoughts?....................particularly those that have leg Vices??????

Regards Luke

Gidday

Keeping it all cheap and without changing the present structure of the Bench I came up with a way such a large piece of sheet could be clamped 'in position' for edge work.

The key is the leg design that can accommodate fixtures as required a good simple cheap solution significantly value adding to the flexibility of the Bench. (Lots of Jigs and Fixtures could utilise this if required)

There could be a case that the Legs are coming out to far posing a trip hazard? but in my extensive experience with large trestles, I certainly didn't find this an issue hence the design suits how I work

This considerably reduces build time and keeps it simple

I can't see myself ever if rarely attempting such a thing (Working with such a large sheet) but it is do-able n certainly what I have learned over the years is where there is a will there is a way!

Realistically if you look at the standard dimension of most furniture builds the current design will be able to handle most presentations I'll report back if there's anything I can't seem to make work!

I also have an AusBench 2000 that I bought at my very first Woodworking Show in Canberra........................I really love using this piece a kit and am trying to come up with an innovate way to incorporate it into my

Clamping options....................................

Regards Lou

Heres some great work holding ideas..............without any vices

https://www.youtube.com/watch?v=yvhn-PAfEW4

Regards Lou

Gidday

Well things are starting to get exciting sheet goods came in @ $485 from Turners in Canberra..............good mob to deal with. I was surprised by the quality of the BB Ply

Time to start refining the plans n setting up a cut-list!...... In my experience planning is Key ...................... I'll do this using Sketchup which I love playing with also helps me pick up on measurement mistakes n other little

nasties before I start ...................I'll only get one crack at getting the cuts right!

The MDF comes in at 32mm n the Ply 24mm Im thinking of tweaking the plans so that the Benchtop is 4 layers deep of MDF a total of 128mm Dam this stuff is heavy!

I struggled to move it around! Sure would make for a Dence Flat work Surface the top skin being replaceable........................anywaz time for a final Tweak of the Plans

Regards Lou