In this episode, Paul demonstrates how to measure and cut the slats of the cot. After configuring the slats and numbering each one, it’s time to fit the slats into the rails.
Paul takes you through the first stages of cutting the plywood to create sizes that are easier to manage. He then rips through the panels using the bandsaw and planes the edges. He repeats this method until he has done all of the panels. Lastly, Paul moves on to gluing up and screwing his workbench top.
Paul has come up with an alternative workbench design that matches his original for utility, stability and durability, but which can be made using a bandsaw, plywood and an ingenious approach to joinery.
After finishing the end frames of the cot, Paul moves on to create the grooves along the long pieces using the plough plane. Paul takes you through the process whilst troubleshooting a slight problem he incurs with the plane. Once the grooves have been cut, Paul moves on to cutting the tenons for the long rails which then fit into the mortise holes within the front and back frames.
In this episode Paul lays out and shapes the cambered top rail of the cot end frames. Paul has developed his own technique for cutting and fitting veneered plywood panels using hand tools that ensure a perfect fit. This episode culminates with a completed dry fit and rehearsal in readiness for the final glue up.
In this final episode Paul shows how to cut the two different types of tenons, stub tenons and through tenons. Then he shows how to round over the edges of the top pieces and the front of the shelf. The project is assembled, to test the overall fit, then taken apart and glued up. Finally Paul does some cleanup and finishes the project with shellac. This is a great beginner project as well as being a good, simple project for those with more advanced skills. We hope you will give it a try!