We left off with the untrimmed legs laying on the workbench surface waiting to be mated to the tabletop. I began by assigning each leg to a corner then marking of the center of where the leg would be from the outside rail of the frame. The plan was to secure the leg to the table top with a hex bolt. I didn’t get very far when I was interrupted and had to assume other duties. While otherwise occupied (probably doing the dishes or folding laundry… some household chore), I started thinking about stability. If I only use one hex bolt, over time, that will become an axle for the legs to pivot on. Not good. I rushed to my nearest big box hardware
store and picked up four more hex bolts, eight lock-washers, and 8 locking nuts.
The next day I measured out (from my center marks) the center for each bolt. Once satisfied, I used my 1/2″ auger bit to drill out the holes. I had a little trouble with this in that my 7.2V DeWalt and 12V Ryobi cordless drills didn’t have enough juice to get the job done. I was afraid that they just didn’t have the muscle. I did as much as I could then when the batteries gave up the ghost, I switch to cutting the legs to size. Since I want the bench to be 36″ tall, I cut the legs to 34 1/2″ (tabletop is 1 1/2″ thick”). This is cake using a miter/chop saw. But it’s 11:30PM and I have children sleeping so this would have invoked an ass-beating of epic scale. Since I want my wife’s encouragement and support, I opted for the hand saw.
I really haven’t used a handsaw where it counts. I’ve used them in the past to cut stuff up but not with the level of precision that I “needed” from the miter saw. I found out, like with everything, practice is important. My cuts on the leg are not square and just off. Since its on the end grain, the plane doesn’t want any part in that. I will need to use my palm sander to get this fixed. Learning is living, aye?
The next day, I had fully charged batteries and a new attitude. This bench was going down (or up?)! I finished up drilling the holes into the rails (Yay! The drills still have some life left) and then marked each leg’s bolt hole location and then drilled all the legs separately. I thought this was going to give me trouble because I can measure twice or a hundred times and still jack up a simple hole. Well, I can tell you that I did NOT this time. However, there were some minor variations in the alignment. I think this is good since it helped lock in the legs once the bolts were fastened.
Now that the legs are drilled, I began by attaching the bolt closest to the tabletop first then moving the the upper (lower? … the table is upside down at this point) bolt. The first bolt is much easier then the second and I discovered how far my drill holes were off. I didn’t have to alter any holes but I did have to use my BF Hammer to get some of them in. Once I locked the first leg down, I pushed and pulled on it to see how stable it really was… <insert evil laugh> It was gloriously solid and whatever stability issues I might have, it won’t be due to wobbly leg joints.
I proceeded to attached the other three legs and then went around and gave each bolt a final snugging up. I still have to install the braces on the legs but I wanted to see the workbench on it’s feet. I flipped it over and set it up (this was not the easiest one-man job). I was surprised at how high it was. Yup. 36″ is pretty high. I also needed to see if it was going to be stable. Meh! This workbench design has a basic flaw in that it is long, narrow and tall. If I chopped 10 inches off the legs, that would probably help but that means it’s back to the crinkle-back, all hunched over my work. I want it this height. The other thought would be that I could add one or two more 2x10s and widen it. I think this would allow me to keep the height and give me more stability. Space is limited so I am going to stick with this design for now and try the leg braces. I can do my planing on the ends of the table which will prevent the tippiness. Since I attached the legs to the long rails of the frame, I can simply pull out the short rails and put in longer ones. I will have to do some serious disassembly but it’s something I could finish in an afternoon. Something to consider.
So, I threw my shooting board on the bench and started planing a scrap piece of wood. I definitely need to work from the ends when doing planing or chisling (where permitted). It’s a little wobbly but I still haven’t attached the braces or flattened out the feet. I am planning to surface the feet with bicycle tire tread (I saw this done while making a dog sled on “How It’s Made” on the Science Channel). Once flat, the tread should give a solid non-slip surface to keep the bench from sliding. I don’t want to permanently mount the workbench to the floor.
Tomorrow night, I plan to add the leg braces then flatten and surface the feet. If I have time, I will start planing the surface and get the MDF for top.
Oh, I almost forgot. I had to make some alterations to the dimensions. Here is the cut list. Keep in mind the following:
- 2×10 = 1 1/2″ x 9
- 2×4 = 1 1/2″ x 3 1/2″
- 1×4 = 3/4″ x 3 1/2″
- (3) 2x10x54 (table top)
- (2) 2x4x50 (long rails)
- (3) 2x4x20 3/4″ (short rails and center brace)
- (8) 2x4x34 1/2″ (legs 2 laminated together to make a 3×3 1/2 post)
- (1) 1x4x51 1/2″ (long leg brace)
- (2) 1x4x20 3/4″ (short leg brace)
I have also listed below, the hardware and tools I used:
- (8) 1/2″ x 6″ Hex Bolts
- (8) Disk Washers
- (8) Lock Washers
- (8) Lock Nuts
- 1/2″ Wrench
- 1/2″ Socket and Ratchet Wrench (long is leverage)
- 1/2″ Auger bit
- Tons of screws (I forget the specs… I’ll come back to those)
- Countersink bit
- Powerful Drill (or in my case…)
- (2) Weak-ass Drills
- BF Hammer
- Swanson 12″ Combo Carpenter’s Square (these are da BOMB!)
- Tape Measure
- Titebond Glue
- Sandpaper (60 and 120 grit)
- Sharpened Pencil
- Plenty of Diet Coke
- Plenty of Sam Adams (for after the job)
Here is the gallery of images taken since my last post.