Bench in a weekend

[Derek Cohen]

I decided to take a short break from the chair build - it had been quite intense for a while and it was time to chill out for a couple of weeks.


The background to this bench is that each year I get invited to demonstrate something at the Perth LN Tool Event - joint making, dovetailing, tool building, whatever. And each year it is held I wind up with a bench that suits a power tool user! One small face vice that is inaccessible, and a large flat bench without dogs. I can use clamps only, and this is not really convenient when planing mouldings, rebates, grooves, sliding dovetails, and so on. I have a Moxon vise, but what I really need is a bench. So I decided to build a small bench that I could fit in the car (I have a two-seater so it has to be small).


This is what I came up with with scraps on hand: 28" long, 15" wide, and 2 1/2" thick. Materials were Pine sandwiching a LVL core, and Jarrah for the central dog holes, wagon vise and screw.


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench1_zps46448cec.jpg


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench2_zpsb95b15f4.jpg


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench3_zps78f2b459.jpg


I agree with Chris Schwarz, who recently blogged on cutting full blind dovetails, and wrote that the through dovetail is the most difficult of all to get right. Particularly when the tail is 1 5/8" long.


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench8_zps495b431f.jpg


What I love about the brass Veritas dogs is that they are spring-loaded. They compress into the dog hole, and then pop up at a touch of the finger ..


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench4_zpscfef100f.jpg


The dogs can be re-sited for traversing ...


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench5_zpsadd18ecf.jpg


... and they may also be used with the Veritas Surface Clamp, which is the only hold down with a leg short enough for this bench ..


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench6_zps6b1ecbb6.jpg


The end of the bench has an adjustable planing stop.


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench7_zpsc6bccee8.jpg


The black dots (above) are where I shall drill holes to clamp the bench down on the "table" top.


The screw for the wagon vise was intended to be made with a kit, but it did not work (blunt blade which did not work after I sharpened it), so I turned the threads on a power router and finished with a file ..


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench9_zps768e33ac.jpg


Here are the parts ..


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench10_zps517a78f4.jpg


.. and together ...


http://i13.photobucket.com/albums/a262/Derek50/Workbench%20and%20Workshop/Mini%20Bench/Bench11_zpse4731c37.jpg


Regards from Perth


Derek

[Graham Haydon]

Very nice work as always Derek. I must confess to eyeing that router. We recently said goodbye to the same elu but with the orange buttons, a sad day indeed. The modern DeWalt replacement seems familiar in the hand but very cheaply put together.
This should make a perfect portable work surface.

[David Dalzell]

How does one "turn threads" with a router? I can't seem to fit this in my mind.

[Sean Hughto]

http://www.youtube.com/watch?v=UCLGCzOqjv8&feature=channel_page and part 2 to the right

[Chris Griggs]

Pretty cool Derek!

[Jim Koepke]

That is cool.

Down on my list of projects is a portable work bench.

Ideas and inspiration, thanks,

jtk

[Daniel Rode]

Well done, Derek. It's nicer than my "real" bench.

So if 4 minute dovetails take me 2 hours to complete, how long would it take me to make a weekend bench? :)

[Tony Wilkins]

Very nice work Derek. Will love to see how you put it two work.

[Steve Voigt]

Very nice work, Derek. If you can find the time, I would love to know a bit more about the thread making part. Did you also make the female threads?

[Dave Proper]

Derek,
A very impressive build! And completed in a weekend is even more impressive!
Dave P

[Judson Green]

Nice work! Really cool, great for the woodworker on the run!

[Derek Cohen]

How does one "turn threads" with a router? I can't seem to fit this in my mind.




I have made a few 1 1/2" screws before with a kit (tap and cutter) for moxon vises. These turned out pretty well. However, when it came to using the cutter this time, it just tore up the grain. I sharpened it, but this made no difference. The problem may lie with the wood I used (I tried a few different types, but they are all pretty dry and brittle). As a result I decided to research screw cutting with a router (since I had heard about that), and turned up the same videos as posted below. With a little trial and error, I was successful on the second attempt.



http://www.youtube.com/watch?feature=player_embedded&v=5C4p8aT7CDs (http://www.youtube.com/watch?feature=player_embedded&v=5C4p8aT7CDs)

[Brian Holcombe]

Really cool. That guy's shoulder vise is pretty sweet as well.

[Derek Cohen]

http://www.youtube.com/watch?feature=player_embedded&v=4ZmnGLpqAGI

Regards from Perth


Derek

[Dave Anderson NH]

Hi Derek,

To me, the biggest problem with small benches (if they are on legs) is the instability caused by the small footprint and the lack of weight. I demoed once on one of the small Sjoborg benches and it walked all over the place, bounced, tried to tip over, and provided me no end of aggravation. I am actually happier with a 30" x 72" folding leg table and some large wooden C clamps. The only problem there is the bounciness of the work piece while driving a chisel with a mallet. even if you work over the leg set. If you are planning to clamp your portable bench to a tabletop it should work out fine though.

[Derek Cohen]

Hi Dave

At present the bench top has rubber non-slip "feet". These do a surprisingly good job of keeping it in one spot. However I shall drill the holes I mentioned earlier on so as to clamp it down.

I have not weighed this little bench top. It feels pretty solid and quite heavy. There is enough clamping, using the wagon vise together with the planning stop, to hold down a 24" board length. With the side dog holes, there is sufficient support to use a jack plane diagonally to flatten a panel. Importantly, it is possible to hold boards close to the edge to rebate or add a bead.

Regards from Perth

Derek