1st Bench Build - Page 6 - Woodworking Talk - Woodworkers Forum
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post #101 of 121 Old 07-13-2018, 09:03 PM Thread Starter
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Jaw liner

Turns out, my local Menards had rolls of cork. I used Loctite industrial strength spray adhesive. Seems like it will hold, but the cork is thin. This stuff is more like 1/16" thick, so maybe I'll just double it up if I end up having to re-apply.

I didn't take a pic, but I also did a Paul Sellers retrofit on a 3 ft Harbor Freight bar clamp. I cut down a piece of furring strip to fit, then pounded it down the full length of the bar. Did some light filing to the clamps and turn screw, and finally added some pieces of thin plywood to act as padding.

Figured I should do this to at least one of my clamps and give Paul's clamp-in-vise holding method a shot. I'm uninitiated in such things, so no bias towards any particular method. I'll try them all and see what works for me.

Tomorrow...jigs! I also bought a 3/4" oak dowel, so I might make a few dogs - for the imaginary holes in my bench (auger bit shipped today).
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post #102 of 121 Old 07-14-2018, 09:52 AM
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Anthony, I used a ship boring auger bit for mine. The holes that were a little ragged were cleaned up using a 3/4" router bit in my drill. If you have a bench top drill press, you might be able to swing the head over enough to clear the base of the press (clamped to the bench) to drill at 90* to the bench.
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post #103 of 121 Old 07-14-2018, 04:16 PM Thread Starter
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Jigs!

On the left is a standard bench hook - nothing to see here, it's just 3 pieces of wood glued and screwed together.

In the vise is a shooting board. Can't remember where I found the plans, but I thought it was an interesting design. The fence has a bit of adjustment, so you're 100% sure that it's square every time. The rail of a 7" speed square rides along the edge so that you can do 45's as well.

This has been a good exercise. Definitely helping determine where holdfasts could be used.
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post #104 of 121 Old 07-16-2018, 08:13 PM Thread Starter
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Almost done!

Took a big leap forward tonight and I'm very close to wrapping up this build. Finally!

Pic 1
Waiting for the Wood Owl bit was totally worth it. This thing bores the cleanest holes I've ever seen. I made a jig to make sure the bit was at 90 degrees and created all of my dogging/holdfast holes. Went back after and added a small chamfer with the Dewalt router.

Pic 2
Here's the bench with its first coat of BLO.
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post #105 of 121 Old 07-17-2018, 09:00 AM
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Quote:
Originally Posted by AmishElectricCo View Post
Took a big leap forward tonight and I'm very close to wrapping up this build. Finally!

Pic 1
Waiting for the Wood Owl bit was totally worth it. This thing bores the cleanest holes I've ever seen. I made a jig to make sure the bit was at 90 degrees and created all of my dogging/holdfast holes. Went back after and added a small chamfer with the Dewalt router.

Pic 2
Here's the bench with its first coat of BLO.
Wow! That is ONE SWEET BENCH BUILD! I have enjoyed watching you progress through this build. Time for a short break.
I'll have to look up the "Wood Owl bit, it sure drilled a clean hole!
Cork works well to pad/grip clamps, I use contact cement.
I also have leather (from an old belt) glued to my (cheap) cast iron hold fasts, to keep them from marring my work...but I may switch to cork because the leather is kinda hard and I think cork may work better.
When using your shooting board...limit the thickness of what you plane to the thickness of the stop. If you plane wood thicker than the stop you will get tear out because it's un supported.
I bought a 4pt rip saw at an antique store for around $8.00 about a month ago, it looked like it was hardly used and was left to rust. After de rusting and sharpening I ripped some green hard rock maple logs to get billets for future mallets. I filed the teeth to the original angles and was not satisfied with how long it took to saw them. I sent an email to Paul Sellers asking how to improve the angle, and he responded back in a couple days. I did what he recommended and the saw worked much better.

What is going to be your first project on your awesome bench?
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post #106 of 121 Old 07-17-2018, 09:21 AM
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Very nice! It looks fantastic. Let us know how you like using it!
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post #107 of 121 Old 07-17-2018, 11:45 AM Thread Starter
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Wood Owl Ultra Smooth 3/4" Auger Bit

Just make sure you're looking at the "ultra smooth" and not the "nail chipper" model, which are for going through nails. These bits are made in Japan, not China. Very high quality, I was super impressed.

Time for a break, indeed! Maybe let my debit card stop smoldering for a little while! That's the best part of following a Paul Sellers build. All of the tools I bought for this bench are used with most of his other projects. I'm sure I'll eventually get out from under the Sellers umbrella and spread my wings, but for now, those tools were a good investment and should allow me to do quite a few projects.

I'm going to do Paul's Shaker-style wall clock as my first project on this bench. It's beginner-level, I have all the needed tools, and it's cheap. I'll probably use mahogany.
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post #108 of 121 Old 07-17-2018, 04:42 PM
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Nice. That looks like a fun project. I look forward to seeing how it goes!
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post #109 of 121 Old 07-17-2018, 08:08 PM Thread Starter
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Last one...

One last "official" post from me, and I'm calling this build DONE!

My dog holes are all 3" from the edges. The six holes to the right of the vise are spaced 15" apart. My holdfasts have a radius of 13", so this gives good coverage.

Pic 1
Here I have used extended dogs with Bench Cookies. This can act as a second work surface (using my front 2 holes, I can run this the full length of my bench) or just elevate a piece for sawing, finishing, etc. Rockler had a sale awhile back - the set I got has x4 cookies, cone tips, and extended dogs. Must've been something they pieced together for the sale, because I don't see it on their site now.

Pic 2
The back 4 holes are centered over the leg, which is perfect for mortising. Given the arrangement of these back 6 holes, I should be able to hold just about anything.

A note on the Gramercy holdfasts - maybe it's because the bit I used left such a smooth finish in the holes, but I had to sand my holdfasts with 80 grit so they would grab. Specs on the holdfasts say they will work with a 3 1/2" thick bench, which is what I have, but they absolutely would not hold until I sanded them. They work great now though!

Thanks for the support and help, everyone. I definitely couldn't have done this without you!
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post #110 of 121 Old 07-18-2018, 06:13 AM
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Anthony, Enjoy your break, I sure enjoyed watching your bench build, you did a wonderful job. I hope to see more of your projects in the future. You are very talented.
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post #111 of 121 Old 07-26-2018, 08:53 PM Thread Starter
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Made a modification.

If I'm being honest, I needed to do this because I drilled the hole hopelessly crooked. Dunno how. I made a jig to keep my bit at 90 degrees, and all the other holes came out perfect. For some reason, this one did not - and as you can see from its position on the bench, it was a critical hole to get right.

I considered chopping out the hole completely and use a 2x2 square dog here. I found this planing stop from Lee Valley and decided this would be easier.

The mortise for this was complicated due to the underside workings of the stop. Took me a couple hours, but I went pretty slow to make sure I got it right. The piece is cast aluminum, and there's a bow in the middle. I'll probably take it out and run it over a belt sander to get it flat.

I'm happy with it. Planed a board and the stop holds it rock solid. I bought two of them, so I may eventually replace the other dog hole as well.
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post #112 of 121 Old 07-26-2018, 09:01 PM
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The traditional way to repair damage and celebrate a defect is to insert a Dutchman. Use a contrasting wood to enhance the look.
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post #113 of 121 Old 07-26-2018, 10:40 PM Thread Starter
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The traditional way to repair damage and celebrate a defect is to insert a Dutchman. Use a contrasting wood to enhance the look.
Been there, done that. Got the t-shirt!

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post #114 of 121 Old 07-27-2018, 09:32 AM
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Love the adjustable stop. How adjustable in height is it?
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post #115 of 121 Old 07-27-2018, 10:14 AM Thread Starter
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Love the adjustable stop. How adjustable in height is it?
It will expand to about 1/2" tall. > http://www.leevalley.com/us/wood/pag...48&cat=1,41637

Funny story: If you look closely, you can see one of these in some of Paul's older videos. I always thought it was volume adjustment for his microphone or something like that.

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post #116 of 121 Old 07-27-2018, 10:15 AM
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I've been curious about those, so it's good to know they're reasonably high quality, and work.
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post #117 of 121 Old 07-27-2018, 10:25 AM Thread Starter
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I've been curious about those, so it's good to know they're reasonably high quality, and work.
Check this out: https://paulsellers.com/2015/03/addi...sh-bench-stop/

A few years old, but good pics. Here, Paul details how he installed one. You can just barely make it out in one of his pics, but only 2 screws hold this in place. It's important to get the mortise recess correct so that there is support underneath. I would imagine that too much slop and you'd end up ripping this out of your bench. I've been thinking about adding some epoxy to mine, just to make sure it stays put.
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post #118 of 121 Old 07-27-2018, 01:31 PM
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I remember in the late 60s, there were bench stops like yours...but made of steel, in my 6th grade woodshop class. Never used it though. High school wood shop never had them.
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post #119 of 121 Old 07-27-2018, 04:00 PM
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Your bench looks great!!! One day ill build my own and ive picked up quite a few things from watching your build. I do have a question for you though.
The side boards on your bench is some thing i would like to know more about. Can you tell me why they are so wide? Ive learned that every part of your bench was designed to aid in different wood working aspects but i cant figure out the reasoning behind the wide side boards.
Thanks for sharing your build with us and I look forward to seeing more of your work in the future.

Mike
Everything i build comes with a redneck warranty. If it breaks you get to keep both pieces.
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post #120 of 121 Old 07-27-2018, 06:15 PM Thread Starter
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Your bench looks great!!! One day ill build my own and ive picked up quite a few things from watching your build. I do have a question for you though.
The side boards on your bench is some thing i would like to know more about. Can you tell me why they are so wide? Ive learned that every part of your bench was designed to aid in different wood working aspects but i cant figure out the reasoning behind the wide side boards.
Thanks for sharing your build with us and I look forward to seeing more of your work in the future.
I'm no expert, but I'll give it a shot:

The side boards are called "aprons." One of the unspoken rules of a bench, especially one for hand tool work, is the heavier the better. You want a rock solid platform A) so the bench doesn't move around when you're working on it, and B) so that you have a solid foundation for things like chiseling out a mortise. The aprons add a lot of weight.

My particular bench is a Nicholson or English style. The aprons actually hold it all together. This design relies on engineering and a minimal amount of materials. Compared to a similar-sized Roubo bench, this style uses about 1/3 of the wood. Some designs have dog holes in the apron to be used in conjunction with the vise.
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