DIY Network

Bench Top and Final Assembly Bench Top and Final Assembly From "Trade School" episode DTRS-102

Figure A

To conclude his final project, Tyler crafts the top portion of the workbench, which is comprised of several main components secured together with a combination of glue and steel bolts. A series of glued boards form the long middle section, or "infield," as well as the aprons, which skirt the infield lengthwise. Two breadboards bookend and bind the bench top together .... (figure A)

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Basic Tools:

Jointer
Planer
Plunge router
Jigs
Miter Saw
Band saw
Table saw
Belt sander
Chisels
Electric Drill
Wood Glue
Masking tape
Quick Action Clamps
Wood Dowels
Linseed oil

Having already squared and measured the stock for the entire bench in the previous segment, Tyler begins by crafting the holes in the aprons. These holes, affectionately called kennels, serve to house bench-dogs, or wood pegs, that when placed in the holes, help to hold work in place on the completed bench (figure B). Guided by a secured jig, Tyler uses a plunge router fitted with a bushing to rout out the shape of the kennels along one board of each apron. (figure C).

Figure B

Figure C

Because removing wood for the kennels can cause the board to warp, Tyler quickly glues the boards that make up the aprons together. Tyler applies masking tape to the inside of the routed kennels to eliminate glue build-up (figure D). Then he drills holes into the boards to insert dowels (figure E).

Figure D

Figure E

Dowels have enough inherent strength to straighten a slightly bowed board and they ensure proper alignment during glue-up. Tyler enlists the help of several classmates to ensure a quick and accurate gluing process (figure F). A series of quick action clamps keep the glued boards pressed together for one or two days until dry (figure G). Once the glue has dried, Tyler removes the clamps and scrapes off the glue build-up. Tyler crafts the infield of the bench top in the same manner as the aprons, only without creating kennels.

Figure F

Figure G

With the aprons and infield prepared, Tyler flattens and squares the surfaces with a hand plane to avoid warping problems later on. Then he carefully aligns them together with dowels and glues the components together (figure H). This requires fewer clamps than the previous glue-ups, as the material is much heavier and thicker. Once dry, Tyler removes the clamps, scrapes the glue and flattens the material again.

Next, Tyler attaches the breadboards. The breadboards serve to minimize any warping of the bench, which may occur over time. Using the router and another jig, Tyler crafts double tenons to both ends of the bench and triple tenons on the two breadboards for a snug fit (figure I).

Figure H

Figure I

Then Tyler drills two holes into each breadboard to insert steel bolts (figure J). With the top set on its side, he slides the breadboards onto the ends of the bench and then drills through the holes in the breadboards and into the aprons. A clamped straight board serves as a sightline, keeping the drilling action level (figure K).

Figure J

Figure K

Then Tyler drills larger holes into the bottom side of the aprons connecting to the ends of the previous holes (figure L). He secures the breadboards with a steel nut. To protect the wood, a piece of half dowel serves as a buffer between the nut and the apron (figure M).

Figure L

Figure M

Tyler joins the bench top to the base by first embedding four metal pins in the leg assemblies (figure N). He drills 1" holes in the base assembly to accept the pins. Then he aligns the bench top on the base and stomps on the top to create an imprint of the embedded pins (figure O). He flips the top over and drills into the imprints so that the top fits snugly on the base.

Figure N

Figure O

Next, Tyler installs the vise to the bench top. The vise mount is lined up under the apron and bolted in (figure P). Two pieces of stock glued together comprise the vise jaw. Tyler cuts curves in the jaw on the band saw and smoothes the surface on the belt sander (figure Q).

Figure P

Figure Q

Then, he traces around the vise mechanism on the jaw and drills the holes, widening them using a forstner bit (figure R). Then Tyler secures the mechanism to the jaw and attaches the assembly to the mount (figure S).

Figure R

Figure S

Figure T

Nearly finished, Tyler again levels the bench top surface with a hand plane and finishes by applying several coats of linseed oil (figure T). Tyler inaugurates the bench by using it to build drawers and doors for the base giving the bench its final appearance.

School Contact Information:

Red Rocks Community College
13300 W. 6th Ave.
Lakewood, CO 80228
303-914-6600
Website: www.rrcc.edu