New Moravian Bench build

[ken hatch]

Went by the Woodstore on the way home from work. They had some nice 12/4 Poplar sticks in the stacks. I picked up two for legs and long stretchers plus one 8/4 hunk for the short stretchers. I'm getting too old to handle 12/4 wood even if it is Poplar. A photo of breaking the 12/4 down into something I can wrestle into the shop.

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The new bench will be portable with a 380mmX1800mm slab. The slab will be laminated Beech, I figure about 15 BF @ $6 USD/BF, with waste the slab should be about $100 USD. The Poplar for the base was $275 USD and a Lake Erie 2X vise screw kit is $330 USD, $250 USD if I go for the standard screw. Add it all up and material to build is ~$700 USD. BTW, there ain't no money in building benches, it is a work of love or compulsion I'm not sure which.

ken

[Christopher Charles]

Good to see you feeding the dragon, Ken! Who/what's this one for?

Will enjoy watching.

Best,
Chris

[ken hatch]

Good to see you feeding the dragon, Ken! Who/what's this one for?

Will enjoy watching.

Best,
Chris

Christ,

Not a clue. Once finished I will figure out what to do with it. Some of the options are to replace one of older builds, sell it or give it to someone, stack it in a corner with one of the other benches, or save the screw and turn it into firewood,

ken

[ken hatch]

There are four legs and two long stretchers in that pile. After ripping them from the 12/4 slabs I'd had enough heavy lifting for the day. Tomorrow, while it is still cool, I'll cut everything to rough length and true with the machines. Once everything is true the heavy lifting for the base is done. The marking out will go pretty fast because I've done it enough times I expect little head scratching and I hope few mistakes.

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One of the nice things about this Will Myers designed Moravian bench is he stayed true to the original. When I built the first one I didn't appreciate how perfect each joint was for its intended use. There are three different type joints in each base unit, each of the joints is the simplest and easiest to make and yet do the needed job. Only after building a couple more did the light bulb turn on and I realized just how smart the design was.

ken

[ken hatch]

If you have a good imagination and squint a bit you can almost see a Moravian Bench base.

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With the milling scut work finished the rest of the base is pretty easy with little wrestling of heavy timber. Six joints plus four for the long stretchers and chopping four mortises for the keys. This bench is a sheet of cake to built.

The next heavy work is the slab, and that is to be decided as I look for wood. I can always fall back on laminating the slab out of 8/4 Beech if I can't find a 12/4 whatever that is wide enough.


Mark out of the base units is next. That may wait until tonight or tomorrow morning, the shop is getting a little hot to work in. The desert is a wonderful place to live but afternoons are best spent in the pool and/or napping.


ken

[James Pallas]

Finished mine today. It was a little work. Some touch up to do.:)
Jim

[ken hatch]

Finished mine today. It was a little work. Some touch up to do.:)
Jim

James,

It's a beast, Roubo eat your heart out :).

Beautiful bench and there ain't no way, no how that sucker will move on you.

Congrats,

ken

[James Pallas]

With all of the Moravian stuff being talked about I decided to spoof everyone a bit. The bench I pictured is only about a foot long. It's a proof of concept for me. I want to build one with a leg vise and wanted to work it out. Pictured is the hard maple in the shop ready to get started on the real thing.. A little levity never hurts, or does it?
Jim

[ken hatch]

The fun part of the build starts with marking out the base unit legs. While I've done this a few times it is always a good idea to go back and review the process. I'm making a couple of changes this time, while I've marked the legs and stretchers with chiseled Roman numerals before I've always marked on the non-show side and usually just one side. This time I'm chiseling the numbers on both edge and face sides of each leg and stretcher. When glue up time comes there should be no question where the faces are and what tenon fits which mortise.


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Depending on glue used and temperature, bench glue up can get a little frantic when working alone. Sometimes you have to learn the hard way and it is a workbench dontcha know.


The basic reference lines are marked, now it is just extending the marks around the legs and marking out the actual joints. The lower stretcher and the long stretcher joints are marked on the edge face and the middle mortise and top bridle joints are marked on the reference face. Easy to get confused when you are old and confused most of time anyway.


I was late getting to the shop this morning (honeydos) and it is already too hot to do much more. I have a late shift tomorrow so maybe tonight or early AM tomorrow I can finish marking the legs and start chopping mortises Sunday.


ken

[ken hatch]

With all of the Moravian stuff being talked about I decided to spoof everyone a bit. The bench I pictured is only about a foot long. It's a proof of concept for me. I want to build one with a leg vise and wanted to work it out. Pictured is the hard maple in the shop ready to get started on the real thing.. A little levity never hurts, or does it?
Jim

Jim,

Fooled me:o. All I can say is if built it would be a beast.

ken

[James Pallas]

Jim,

Fooled me:o. All I can say is if built it would be a beast.

ken

It will most likely be heavier in the base. I'm working out a tail vise for it. It is not intended to be portable easily. The construction part is fairly easy. They remind me very much of a saw horse. Trying to detail particulars that it is not meant to have creates the issues. Fun working it out though.
Jim

[ken hatch]

Joinery work has started, kinda. Because the mortise is angled it is easier to mark out the mortise using the angled tenon. The last of the base mark out is the long stretcher mortise. Once I have a long stretcher tenon cut I can finish the base mark out.

Small brain fart on the mark out, I had the middle stretcher marked too close to the upper stretcher. Not a biggie, the bottom mark should have been the top mark, squiggle a pencil across the top mark and mark a new bottom. If that is the biggest problem during the build I'll be in good shape.

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The tenon shoulder is angled 15 degrees which of course means all the base cuts will be angled 15 degrees. You really need a good bevel gauge with a reliable lock for this build.


Shop is getting hot, time to walk away and make a Costco run followed by a afternoon nap. After the nap it's monkey suit and a dark box for most of the night, at least the box is cool.

ken

[Phil Mueller]

Funny the difference a uniform makes. If we walked on board and saw you in shorts and a T-shirt, it would very surely makes us nervous. Safe travels.

[ken hatch]

Funny the difference a uniform makes. If we walked on board and saw you in shorts and a T-shirt, it would very surely makes us nervous. Safe travels.

Thanks Phil,

The uniform does help, most of the time to be confused with the guy that hails the taxi or handles baggage ;-). There is a great video on that aspect, if I can find it I'll PM a link.

ken

[Phil Mueller]

Ha. Love to see it. I do hope those extracurricular activities come with a good tip!
Anyway, sorry for the diversion. Back to the bench build....

[ken hatch]

Ha. Love to see it. I do hope those extracurricular activities come with a good tip!
Anyway, sorry for the diversion. Back to the bench build....

No problem, it's hot enough in the shop I need the diversion :). BTW, I finished cutting the long stretcher tenons this morning and have leg I and leg III long stretcher mortises marked. Leg II and leg iV will get marked when it cools off. Those are the critical marks, really easy to get confused and end up either re-marking or having base pairs that were not intended to be a base pair.

Video link sent.

ken

[ken hatch]

Completed the marking out, now the fun starts. As I have posted before, on the base unit there are three different joint types plus the wedged M/T long stretchers.

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The three types of joints are part of the genius of the original makers. Each of the joints is the simplest and quickest to make that is also strong enough for its job.

The top stretcher uses a brindle joint. a through mortise would add no strength and a brindle is much quicker and easier to make. The middle stretcher is a pegged through M/T with a single shoulder, again quicker and I expect stronger against racking than a double shouldered tenon. The bottom stretcher's only job is to keep the bottom of the base's legs from spreading. A lapped dovetail is perfect for that job and easier and quicker to cut than a M/T.

Tonight, tomorrow and for the next few days there will be lots of chisel and saw work and I expect a little sweat.

ken

[ken hatch]

The bench is coming along I've sawed the upper stretcher tenons.

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You gotta love bridle joints, they are quick work. After chopping the bridle joints and cutting the 15 degree bevel on the top of the leg, fitting the upper stretcher was a walk in the park.

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Just a reminder, click 'em to big 'em.

Next is finishing the other base pair upper stretcher and starting on the middle stretcher M/T joints.


ken

[ken hatch]

The top stretchers are finished and fitted. Next are the middle stretchers.

The middle stretcher uses a single shoulder, flush to the face M/T joint. Once you understand what you are trying to do the markout is easy but can cause confusion if you do not pay attention to the marking, sawing and chopping.

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The mortise gauge is set so the far pin rides on the back edge of the stretcher so it makes a single mark on the stretcher. The waste is the face side leaving a tenon on the back side of the stretcher. Marking the mortise is just normal mortise marking using the face edge to reference the fence.

Will Myers threw me a curve yesterday. He posted about a new Bench Crafted Crisscross that works with a standard portable Moravian bench. For his installation he used a BC metal screw, not necessarily a deal killer but I like the Lake Erie wood screws. Will and I have had a little back and forth about using a wood screw with the crisscross (room issues) but as I haven't ordered the vise screw yet I've decisions to make. I expect I'll wait on Will to checkout the room issue before ordering a vise screw. One of the reasons for building this bench was to try the new 2X Lake Erie screw but I want to try the BC crisscross as well.

Two possible answers; build another bench, one using the BC crisscross and one the Lake Erie 2X or just make two vises with vise backers for this bench and then A&B 'em to see which I like best.

Not a bad problem to have,


ken

[ken hatch]

Most of the time to make a mortise hole I just grab a chisel and beaver away. Not on these chip breath, Mostly because of the size, I'm drilling and paring. It is a little slower and because I didn't match the tenon to a chisel size a little easier and probably gives better results.

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The first test fit is perfect:

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The tenon needs maybe one or two swipes with a plane and it should slide home.

BTW, I just ordered the BeachCraft Classic Vise Screw with the small crisscross. It is a little cheaper than the Lake Erie Toolworks 2X wood screw. It is not as fast but is the same speed as the standard wood screw and I don't think there is room to use the crisscross with the 2X screw without some major mods to the bench. Whatever, this bench will start life with a metal screw.



ken

[ken hatch]

The upper and middle stretchers have been fitted. Next up is the bottom stretcher with a lapped dovetail joint and then drill and pare the long stretcher mortise. Other than size and the angle the long stretcher mortise is a piece of cake because it needs to be loose.

There is a very slight curve in the #IV middle stretcher shoulder causing a small gap at the top. I'm not sure if it is worth fooling with it is so slight, other than the one shoulder everything has pulled up nice and tight.

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I've the weekend off. If I can stay out of MsBubba's line of sight I might get the base units finished. Still a bit of work with a slab glue up, vise chop/backer board install and tool tray to build.

I could be waiting on the vise hardware to finish this sucker.


ken

[ken hatch]

Except for chopping the long stretcher mortises one base unit is finished and one to go. The first base pulled up square with only a couple of small gaps, fine furniture, no go without figuring out how to hide 'em, but for a workbench it looks good to me.

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I picked up 48 BF of European Beach for the slab yesterday. Once the other base is finished it will be time to rip the Beach and glue up the slab. The BenchCrafted screw and crisscross has been shipped, this sucker may be in the short rows soon.


ken

[Jake Hillestad]

I've been tossing around the idea of building a Moravian based in part on your exposing them here. I'm sure you have mentioned it somewhere, but, have you scaled the bench up compared to Will Myers plans? I'd like to use a BC Crisscross (I see they are making a 14" version targeted towards Moravians and smaller benches) but I really want to use the Lake Erie screw. In your experience do you think there is room for both assuming the bench is scaled up a bit with a height of say 38" instead of the ~33" on Myers version?

[Frederick Skelly]

Ken,
Thanks for the tutorial on the 3 joints used!
You know, I really don't need to build another bench. But every time I read about your latest, I start thinking about building one anyway........

Fred

[ken hatch]

I've been tossing around the idea of building a Moravian based in part on your exposing them here. I'm sure you have mentioned it somewhere, but, have you scaled the bench up compared to Will Myers plans? I'd like to use a BC Crisscross (I see they are making a 14" version targeted towards Moravians and smaller benches) but I really want to use the Lake Erie screw. In your experience do you think there is room for both assuming the bench is scaled up a bit with a height of say 38" instead of the ~33" on Myers version?

Jake,

Several answers to your questions. First I built a scaled up bench (full sized shop bench) about a year ago. Will linked to it on his blog during the build. So in answer to your question, yes the bench can be scaled up very easily. I'll go back to Will, he thinks the Lake Erie wood screw will work if the long stretcher is lowered or in your case the bench is built higher.

You will not regret building a Moravian, it is the easiest and quickest build of all the major types of benches and much cheaper to build when compared to the Roubo yet is every bit as stable. I have a Roubo sitting next to my shop sized Moravian, I expect the Moravian weights half as much as the Roubo yet is just as stable and is my main bench.

ken

[ken hatch]

Ken,
Thanks for the tutorial on the 3 joints used!
You know, I really don't need to build another bench. But every time I read about your latest, I start thinking about building one anyway........

Fred

Fred,

If anyone doesn't need another bench it is me, yet here I am in mid build. Go for it, you will enjoy the build and even better really enjoy working on the bench. I'm always amazed at how often I pull the one I have disassembled and stacked in a corner of the shop out, put it together where needed around the house, then when finished put it back in the corner. Just like I would do with a Workmate but it is a real bench.

ken

[ken hatch]

Smaller lapped dovetail mortises I'll take off the saw, these I figured would work better to get close to the sides with the saw and pare to fit. The first two proved that was a good decision, I hope these do as well. The only problem is it takes longer and there are more chances to screw up.

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The above dovetail and mortise fit just fine. One more to go and then on to chopping the long stretcher mortises. Once those mortises are finished I'll glue up the base and then the slab. With the vise and vise backer board install plus the tool tray the bench will be finished. If not for the day job I'd be in the short rows.

Speaking of the day job, the day job has me booked seven days in a row starting today at 1600. Work on the bench will slow a little toward the end of the seven for no other reason after four days I will be dog tired and needing a break with three more to go.

ken

[Jake Hillestad]

Jake,

Several answers to your questions. First I built a scaled up bench (full sized shop bench) about a year ago. Will linked to it on his blog during the build. So in answer to your question, yes the bench can be scaled up very easily. I'll go back to Will, he thinks the Lake Erie wood screw will work if the long stretcher is lowered or in your case the bench is built higher.

You will not regret building a Moravian, it is the easiest and quickest build of all the major types of benches and much cheaper to build when compared to the Roubo yet is every bit as stable. I have a Roubo sitting next to my shop sized Moravian, I expect the Moravian weights half as much as the Roubo yet is just as stable and is my main bench.

ken

Thanks, I went and checked out his new posts - I'll be tuned in for the rest of your build and look forward to seeing how you like the crisscross combo.

[ken hatch]

Thanks, I went and checked out his new posts - I'll be tuned in for the rest of your build and look forward to seeing how you like the crisscross combo.

Jake,

Good move.

The good news, because of the design of the bench, if for any reason I do not like the metal screw or the crisscross it is an easy job to replace the whole vise unit with either a wood screw or a parallel guide and pin. Or both.

BTW, the two base units are finished except for chopping the long stretcher mortises and then glueing those suckers together. The slab is just a lot of grunt work. The vise install, this time I don't know, it will be the first time I've used a crisscross but it should be a little less fiddly than a parallel guide. The tool tray is just a PITA because the boards are so long and only a couple of joints to hold 'em together.

ken

[Jerry Olexa]

Good progress Ken...Thanks for posting...We envy you....

[ken hatch]

The UPS girl was good to me yesterday. She delivered a set of Sukezane Oirenomi chisels from Stan and the BenchCrafted Classic vise screw with the 14" Crisscross. Xmas in June and pretty close to the Summer Solstice as well. With the vise screw in hand there will be no delay once the slab is finished.

The chisels still in the box:

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Exciting photo :o, the next is even more exciting, the BC screw also in the box it came in:

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Next up is chopping the long stretcher mortises. The mortises are marked and are ~25mm wide. I'll use a long 3/4" drill to drill out most of the waste and then clean 'em up with chisels. Because the bottom and top of the mortises are angled I'll use the tenon cheek cutoffs as a guide for the drill.

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The long stretcher mortises are the final step on the base units before glue up. A way to go yet but I can almost smell the barn.

ken

[ken hatch]

Good progress Ken...Thanks for posting...We envy you....

Thanks Jerry,

It's a fun build.

ken

[ken hatch]

We had to put our big yellow Lab, Sam the Wonder Dog, down last Friday. I'm very much missing Sam at my feet and barking for a treat but life must go on and the best way for that is to get back in the shop.

I'm not much of one for drilling and paring mortises. Every year or so I forget what a disaster the last time I tried it was. Well it's been more than a year and it is still a disaster. I'll save the leg but you will not be seeing any photos of the inside of the long stretcher mortise on at least that leg. That's the bad news, the good is what the inside of the long stretcher mortise looks like makes no never mind, it just needs to be a loose fitting mortise with intact shoulders.

It's back to chopping the mortises, a photo of getting ready to chop.

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A Narex firmer chisel with a Hornbean handle makes a pretty good wide mortise chisel, not as good as a pigsticker but it's hard to find a 25mm pigsticker :).

Once the rest of the mortises are chopped it will be time to glue up the base units. I can't see the barn but it should be over the next rise.

ken

[Patrick Whitehorn]

My condolences - losing a pet is always hard.

Patrick

[ken hatch]

My condolences - losing a pet is always hard.

Patrick

Thanks Patrick, it has been a tough couple of days. Sam was "my" dog and my best bud.

ken

[Frederick Skelly]

Ken,
I'm sorry about Sam. I know what that's like.
Fred

[James Pallas]

Very sorry about Sam. There is some very special attachment to your "shop dog".
Jim

[ken hatch]

Very sorry about Sam. There is some very special attachment to your "shop dog".
Jim

Thanks Jim. All dogs are good some are just better, Sam was better

ken


Ken,
I'm sorry about Sam. I know what that's like.
Fred

Thanks Fred. It's hard have critters in your life because you know the ending to the story going in. But then they bring so much joy and richness that is is worth the hurt.

ken

[Christopher Charles]

Hi Ken,

Also very sorry to hear of the loss of Sam. :(

Best,
Chris

[ken hatch]

Hi Ken,

Also very sorry to hear of the loss of Sam. :(

Best,
Chris

Thanks Chris.

One more mortise to chop and the base of the bench will be ready for glue up. That's the good news, the bad is, it is slow going in the heat of the day and now we are in Monsoon season and it doesn't cool off that much at night.

ken

[michael langman]

I'm Sorry to hear about Sam, Ken. It is too bad, that dogs cannot live as long as us.

Try to take it a little easier in the heat, if you can.

[ken hatch]

I'm Sorry to hear about Sam, Ken. It is too bad, that dogs cannot live as long as us.

Try to take it a little easier in the heat, if you can.

Thanks Michael. Sam was a special dog, everyone should be so lucky as to have a Sam in their life at least once.

The workbench build ran into a snag last night. I totally messed up one of the tenons on a long stretcher. After much "well if I" and maybe "this would work" I bit the bullet this morning and made a trip to the woodstore for another hunk of 12/4 Poplar.

ken