A custom workbench is designed to accommodate many woodworking needs. This one has a shelf to store wood and tools; a secure vise and a sturdy top. The mortise-and-tenon system give the legs added stability and strength. Figure A Figure B Figure C Figure D Figure E Figure F

Is your old workbench too small, unsturdy or lacking functionality? DIY Woodworking host Bruce Johnson found his to be too narrow, with a wobbly vise that needed replacing. He designs a larger workbench that includes a larger work area, a convenient bottom shelf and a new vise. He begins by selecting rock-hard maple and creating a mortise -and-tenon system that will strengthen and stabilize the legs and base.

This is an intermediate project that can be completed for $250 to $300. With high -quality materials, the workbench should last a lifetime.

Note: This workbench originally appeared in Workbench Magazine. Complete plans to build this workbench can be purchased at www.workbenchplans.com .

Materials:

Hard-rock maple, cut to desired length for legs
Additional wood for tenons, cut to desired length
Table saw with dado blade
Woodworking glue
Clamps

1. A mortise-and-tenon system (figure A) will stabilize the table by creating greater strength than glue alone. (The legs will be created by gluing together two pieces of wood that have had half of a mortise cut.)

   
   

2. Use a dado blade (figure B) -- with extra teeth in the middle -- to narrow the wood and create an opening. Cut mortises about 1/2" deep (figure C) at the top edge and about 6" from the bottom. Repeat for the opposing board.

   
   

3. To secure the pieces together, hammer a nail halfway into the board. Use pliers to snip the nailhead off and create a brad (figure D) that will work into the opposing side of the leg.

   
   

4. Apply a generous amount of woodworker's glue to the inner surface of one of the boards and use clamps to pull aligned sections together (figure E).

   
   

5. Repeat steps 3 and 4 until you have created all legs. (Tip: A damp cloth can be kept nearby to remove any excess glue while assembling legs.)

   
   

6. Cut tenons to desired length, then use dado blade to narrow the tenons on both sides to fit the mortise (figure F). Repeat process to narrow tenons for all legs .

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RESOURCES :
Workbench Vise
Model: Record 52 ED
Record Tools
Website: recordtools.com

Setting Up Shop: The Practical Guide to Designing and Building Your Dream Shop
Model: 1561585556
Author: Sandor Nagyszalanczy

Making Workbenches : Planning, Building, Outfitting
Model: 0806905352
Author: Sam Allen

The Workbench Book
Model: 1561582700
Author: Scott Landis

The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619

Workbench Magazine
How-to magazine featuring a wide variety of woodworking projects.
Workbench Magazine
Website: www.workbenchmagazine.com