Reply To: Using American Construction Grade Lumber
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My guess is that by the time Paul was done planing his boards they weren’t a full 1 5/8” either. Depending on the species, I’d compensate by keeping the proportions between apron and housing.
But you could laminate a 3/4” backer to the apron and really beef it up instead of cutting the housing.
I’ve seen other people’s designs for Nicholson benches that do this.
None of this is etched in stone. Work with the materials you have.
Here’s one example.
Or here: https://blog.lostartpress.com/2014/09/08/download-free-plans-for-the-knockdown-nicholson-workbench/
( look closely at the backs of the aprons)
I’d keep Paul’s wedge system in the housings. It’s what makes his design unique.