At last started my workbench project
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9 February 2014 at 8:28 am #27489
At long last, after several months of gathering tools, learning about their use through Paul’s blog, dvds and youtube vids, and here on WWMC, I arrived at the point where action was required. This workbench will be a first for me, in joinery, hand tools, quantity of lumber (timber) involved, etc. ..I hope and expect it to turn out serviceable, not hoping for picture-perfect joints, I will be happy with a stable, straight, “third hand”.
So yesterday I picked up 16 2″x 4″ x 8′ (50 mm x 100 mm x 2.4 m) kiln-dried Douglas fir construction grade studs at a local lumberyard. It was bitter cold out, and took a while, but they let me go through a pallet of the studs they had there on the floor. I saw that many were cupped and bowed just by sighting down them. These I put back on the pile. But almost all had knots and small “hairline” cracks. I figured that at 8′ lengths I can set up the laminations so that the sections with knots or cracks get crosscut.
Though the nominal size was 2″x 4″, they actually measured 1 1/2″ (38 mm) x 3 7/16″ (87 mm).
I plan to use these for the bench top. I’m going to let them acclimate for 3 or 4 days before I begin.
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You must be logged in to view attached files.9 February 2014 at 5:04 pm #27512Hi Dave, thanks for sharing your experience. Honestly, I was not sure at all yesterday when I got them whether all the knots and splits would let me plane alright. But you have put me at ease. I suppose, worst case, the knots will just have me sharpening more often as I surface plane and then flatten?
I will certainly search on the blog for Paul’s jig for the mortises. I forgot who posted it, think maybe it was Greg, but it was commented that its critical to get the sides square. I will use the router plane for the tenons, too.
One thing I’m not sure of, is whether I should try to orient the studs according to grain direction when I go to laminate them. To ease planing. Thoughts?
While I let the wood rest there for a few days I think I will begin taking notes on Paul’s youtube videos and start a drawing of the bench in a notebook.
I probably will also see if I can retrofit the cheap alum bar clamps I picked up as Paul shows in his blog.
Will keep you posted.
Thanks a ton for your help and knowledge.
Carlos
9 February 2014 at 5:12 pm #27513Here you go Carlos…good luck on your bench build. https://woodworkingmasterclasses.com/discussions/topic/mortise-chopping-jig-reference-sheet/
All that lovely wood waiting for you to transform it into a workbench. It’s a great feeling when you start a new project isn’t it?
I’m midway through building my bench. I made a point of orienting the grain when I initially planed each piece of timber. I found it did pay dividends later on when the laminations were glued up. The planing of each section was a joy. I got one bit back to front so the grain is going the wrong way on one part though and that lamination is proofing to be a challenge to work with. Good luck and have loads of fun.[quote quote=27512]One thing I’m not sure of, is whether I should try to orient the studs according to grain direction when I go to laminate them. To ease planing. Thoughts?[/quote]
I was going to mention this very thing. I laminated a top for my sharpening bench, and totally forgot to pay attention to grain direction. When I went to flatten the top, I was rudely greeted with nasty tearout in some area. Does not have a profound effect on a bench top, but it does not look pretty.
Otherwise, I would recommend that you provide space between each those studs so they can acclimate faster.
I am eager to see your progress.
Yes make sure grain is running the same way. Treat the knots with crazy glue or epoxy, this seals them and helps with the tearout inevitable with knots. Make sure you have your sharpening skills are up to par cause you will have to sharpen a few times when planing.
I try to let new wood acclimate for at least a week if I can. Once you come to glue up, to avoid to inevitable slippery slope (twist) at the ends I usually clamp a cawl on each end to prevent this, and if long, 6 foot or more I would probably use one in the middle, use wax paper so you don’t glue the cawl to the bench top. And let it dry over night.
9 February 2014 at 6:24 pm #27528Jon, yes, it is a nice sight to behold! It’s a feeling like no other to see all that nice wood just waiting to be crafted into a project! Thanks for sharing your workbench build by the way, it’s been very instructive as I like how you organized it into a step by step progression. The close-up of the wedges in the apron area is especially helpful. Going to be a sweet bench for sure.
Scott, thank you. I will absolutely separate the studs more and create more space between each so they can acclimate faster. Did not occur to me. Also, you and Jon have convinced me try to orient according to the grain direction before laminating. Problem is, I am not that good at determining the grain direction. Need to try to plane the piece first I guess for the “cat’s fur” effect. By mere sight it looks tough since there’s no “cathedrals”. This will a good exercise for me to learn about grain regardless. Any tips you can give on how best to determine grain direction are much appreciated.
Greg, thank you for that reference sheet for the mortise chopping jig. I really admire how crystal clear it is. Superb drawing, really. For some reason I fear mortise chopping more than anything else, even dovetails. Probably because I have even less experience with chisel work than fine-toothed sawing.
Thanks again…time to roll up the sleeves.
Thank you everyone for the encouragement. Will keep you posted on the progress.
Carlos
9 February 2014 at 6:37 pm #27529Dave, great tip for dealing with the knots, thanks. Never would have occurred to me to treat them. Absolutely worth the price of a tube of crazy glue or epoxy if it “seals” them. Need to go out and get one.
18 February 2014 at 6:24 am #28004PROJECT UPDATE: Last night I surface planed the studs. I planed the surfaces of the 1st group of 8 studs that will be one section of the top. Started after sundown and went well into the evening for several hours.
I came face to face with many challenges that I had never dealt with before: planing technique (the physical body movements as well as angling it slightly either left or right makes it more effective), how to tell if blade is dull or your just fatigued, sharpening, plane adjustment (back iron, cutting iron, frog), what depth of cut is best and getting to know the play in the adjustment wheel, how plane behaves when you hit knots and difficult grain, what to do when suddenly your plane glides and slides (sharpen iron) or wood fibers clog the mouth (diassemble iron assembly, clean out wood, and re-close gap between back iron and cutting iron. Use the lateral adjustment lever to make cutting edge parallel to the sole). I learned a ton and had an absolute blast.
What pops out in my mind from this is the great feeling of assurance when I heard the high-pitched “whooooosh” sound! You know the one! It feels great to see and hear the progress in your skills from where you were just a day before. Another thing that sticks out is how relaxing it was as the aromatic scents of the wood oils filled the garage.
I used a Stanley 5 1/2 for the first 4 studs and a 4 1/2 for the last 4.
I had planned to complete this first stage of planing + glueing up by this weekend, but mid-week I came across a post on another forum that warned that you shouldn’t glue up in an unheated workspace because this causes gaps in the mating surfaces and it adversely affects strength of the bench and structural integrity. I was then advised definitely not to glue up in the cold (My garage was and currently is, well below 40 F (4.4 C). So I decided I will glue-up in the garage and then carry inside into the family room. For this I had to clear out furniture, boxes and whatnot. Still a long way to go, many challenges, but I’m having a great time.
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You must be logged in to view attached files.23 February 2014 at 11:24 pm #28240Well today I finished my first lamination of what will be the 1st section of the top. I actually didn’t finish it cos I ran out of glue after the 7th piece! I didn’t anticipate this. Just goes to show I worried needlessly about not having enough clamps. Should’ve got an extra bottle of glue instead.
Things are going slower than I expected probably cos i’m taking my time and well, never picked up a plane before this project. Also had to do glue up indoors cos the garage was/is not warm enough.
Pretty happy so far cos I’m learning so much. My main concern right now is is the stagger that I got on just one end (see pic). I tried banging it down but then the other end of the same piece would pop up causing stagger there. I decided to glue up anyway, hoping I’ll be able to plane it down later. Still a bit worried whether this stagger will create twist or any undue stresses. If anyone has had this happen i’d love to hear how you handled if you think it’ll plane out.
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You must be logged in to view attached files.Carlos, I mentioned how to alleviate the twist at the end in my last response. What you do is clamp the ends with a 2×4 on each side of the bench top, this keeps the ends flat. Use wax paper between the cawl and the bench top. Some 2×4 may have a bow in them and you’ll have to plane it out after the top is glued up.
24 February 2014 at 12:56 am #28246Dave, you’re right. I know you mentioned the cauls. Truth is, I reviewed Paul’s youtube video on laminating the top just before starting the glue-up and since he didn’t mention them I just plain forgot all about them in the garage before it was too late…so I guess I kinda blew it there. I will definitely not forget cauls on the 2nd section if I get any unevenness.
Carlos, you didn’t blow it lol you just have to deal with it using your plane. Now is the time to make yourself some winding sticks to help out getting your tops flat and twist free. They need to be wider than your bench tops and about 1 – 2 inches tall. Each stick needs to be parallel.
24 February 2014 at 1:24 am #28248Lol, well maybe not blown it, but you know what I mean..woulda shoulda coulda.Anyway, thanks for the advice about the winding sicks. This was actually my next question I going to ask since I know it has to be flattened. When you say make them parallel, do you suggest I plane them S4S? Thanks again!
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