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WonrcrNan
A Imge,h"oW-d"q wail<bench dtat'seasyta buiW.
CombiningnadidcnaljoixleryandmDdemmaterialsis tfu l<ey.
At*,t}"tn*l$1""ff1,;
eightfeetlongandthee feetwide,not
well as being flat and stable,it has
the additionalbeneft of being quick
and easyto rnake (udike a top that
oPTlollAt
SIoRAGI.As great as this
workbench is to work on, you can
makeit evenbetter by addingsome
includingtle vise), ifs reallythe con- is glued up from solidwood). optional storage units underneath
struction that makes it interesting. Anothernicefeatureare the rows (see inset photo below). With the
Ifs ablendof old andnewtechnology of dogholesalongthe font andleft bank of drawers,the cupboardsat
The base is built of healy, solid side of the bench.Combinedwith a eachend, and the open shelvingat
lumbel using traditional mortise few simple accessories(which are the back, you won't be running out
and tenon joinery. Bul the top is describedon page13),thesemakeit of space anltime soon. You can
constructed primarily of MDF easyto hold a workpiecewhile rout- read the story behind these stor-
(medium-densityfiberboard).Soas ing,sanding,orplaning. age units on page 14.
I Stretchersstabilize
. long front & back rails
, l
Heavycluty"cast
iron viseis mortised" %" hardboard splines
help align top and aprans
rc.t on cleats -
Sturdybench,
LOWER
FRONTRAIL
11/2"x gla" - 96" Hard Maple (12.3 Bd. Ft.) (9 6 Bd. Ft.)
No 133 Woodsnitir
NOTE:
Leave top
eoges of teqs
square
Brse
When it comesto buildinga work-
NOTE:
bench, the base has to meet two
MORTISE requirements. It needs to be strong. I sh6"-deep
LAYOUT And it needs to be stable.I decided
to use hard maple for the base NOTE:Legs are
because of its strength and the gtueo up from
------------------
tA)
"
ToPcENTER
PIECE
@
SUPPORT
BLOCK
@
TOP
FRONT
PIECE
rop
It goes without sayingthat thc top of l l l c t o p p l e n t yr h i . k i o , . r n u n r i n g l .
and width) After it's
r !aurkhenchn-cds tu bc \trong alrl vise and for holding bench dogs.
'lb first layer,it will be h.ir
5 t u | d ] t u s k n d u p t o r l l I h e a b u . ei r rrake the top, start by cutting In addition to makir
will receive.But it aiso neerls to be the first l.)/) lolter (L) to finished
layer ovcrsized,a notc
0at.Trr.l1orrtltc tunof rny,rt,r.kberrcl. size (Fig. 6). Then before adding
cut ln one corner to
t q a r c i e r c n ( . ew l l e n a s : ( . m b l i n R i . the seconcl layer, I glued a harcl- aroutd the hardwoor
pr-ujec{ UI rlinrerr:iurring\tocL.Soit \ wooclnLplxr.t bloc:k1,41)to the cor glued to the first layer
i n r p o l t a n irl r a rt l t e t o p b e p , . r f e t t l ] ner where the visc'willget mounted.
done with a sabre s:
flat (7rd stay that way. (This bloch will give the screws saq and you don't nr
Although solid wood is a more something to bite into when you're
tussy with the fit. (M]'
traditional ciroicc for beuch tops, I mounting the vise later.) However,
larger than the block.)
decided to use Mt)!'. It's hea\.y, as you car see in Fig.6, the
top Oncc the notch is cu
tough, aucl very flat. And unlihc piece is upsidc-clownwhen you glue
layers can be glued
solid wood, you don't have to worr y this block in place. (1l.rat'swhy the
togcther I useclyel1o,
about MDt' twisting ()r warping out block is shown in the right corner)
ing glue, spreaclingit
of shapeover line. Plus as an adclerj 5t(0t{DIAYIR.
The.secowlLruler(L) surlaccswith a 3rrpailr
Hall mapleoprons bcnefit, N,ID!'is a whole lot less encls up the
sane size as the first The screws help to 1
l lrrf arolnrl three cxpensivethan solid wood. layer But trying to keep two large, layers together while
Lrrcrso/r -tFar ln order to beef up the thick- iclcntically-sizecl workpiecesaligned up. There's jusl one
lnllecr lhd hliftl, ress, I built up the top out 0f three when gluing them together can be
"layers" awarc of when you're aclding the
flat uork vcfLtce. separate of ltnF, as you tricky. So I cul the second layer screws.Later on, you'11be drilling
can see irr Fig. 5 above.1'his makes slightly ovelsize (r,/+rr in both length dog holes ir the top of the bench,
.-Afrro,i,n"i,'.
Trim second laver
Na s.rews should
SUPPORT
G\
ELOCK'J
10 trVoodstnith No 133
and you don't wiurt to accidentally
drill into a screw. So I laid out
some 'no screwzoles" to
make sure this woulcln't
be a problemfig.6). I
Once the two layers are
laminatecltogether, you can
tdnr tlle sccord layer flush with
the first using a router and a flush
trin bit (Fig. 6a).
THIRD LAYtR. If you take a look at
Fig. 7, you'll see that the thircl
"layer"
is really made up of sk sepa-
rate piecesof l,Ilp. You'Il need two
ettd pieces (N), a.fi ottt piece (O), a
back pi.er:e (P), ancl two center
pieces(Q). Once these pieces are
cut to exact size, they can be glued
ard screwedto the secondlayer
APRotlS. To protect and corceal
the edges of the MDF, the top is
wrapped with 1%'Lthick hardwood
cLptotts (R, S, I O on all four
sides. If you look closely at Fig. 8,
you'll see that each apron is a little
different. To begin with, the ends
of the right apron and one end of
the left apron are rounded over far rearjaw af vise,
(Fig. 8a). (fhis roundover will also A coupLeof cleats
be created on the face block that clampedto the top
will be added to the vise.) o;f thc benchalk'u,
"pocket"
Second,a is routed in ,\o1tto cnmP tne
the back face of the front apron to endnpronsin plocc.
accomnodate Lhe back jaw of the
bench vise (Fig. 8b). (The size of
this pocket will depend upon the
viseyou are using, see page20.)
After routilg the pocket, you can
lout a gl oove around the top of the
bench as well as on the aprons @ig.
9). These grooves will hold splines
that help align the aprons with the
top ofthe bench. A router and a slot
cutter is all you need to make the
grooves. But note that the grooves
in the aprons are stopped short of NOTE:lf end of
the exposedends (Figs.9 and 10). apron ts exposed,
stop gtoove short
SPI|NIS. Once the grooves have
been routed, you can glue Lhe
aprons to the top using splines cut
into ships fron a sheet of farr hard-
board. Clamping the front and END
back aprons in place is no prob- SECTION
VIEW
len. But clamping across the
length of the bench is a challenge,
'1/a" slot
unless you have son.reextra long
clanps. For a simple solution, see
the margin photo at right.
l
r-'l
Round.bench d.ogs.Put &tgs in the Wonder PuP . \Yith its threaAed Veritas hold.&nm. To keepyow
benchtop arl vise,ad" lyoucan cLtrnp shaft, the Pup servesas an eru).ttise work clnmpedfinnly to the bench,
warkpiecesin a lariety oJwols . that can beplacedin aq doghole. just nghtenthe l<nobon the tctP.
ow do you make a
great bench even
better?The answeris
to adda storageunit to
the base.Actually,the
designwecameupwith
features ,zro storage
units-afrontcabinet
with drawersanddoors
and an open shelving
unit in back. And if
that's not enough,you
canaddanoptionalpeg-
board storagepanelto
eachend. Build them
all,andyou'll be ableto
put a shopfuloftools at
your fingertips.
The reasonfor dividing the stor-
age spaceinto two separateunits is
only want to build the cabinet in (tilTlnSloloil.The centersection s
fronl Solefs start with that one. of the cabinetis ply'woodframework
simple. First, it allows you to have that creates the openings for the
accessiblestorageon both sidesof rRolttcallltEt drawers.You can begin by cutting
the bench.And second,it keepsthe The front cabinetis reallyjust a ply- the top andbottom(A),two uertfual
drawers in the tront cabinet at a wood box that's sizedto fit in the d;taiders(B), a hortzontal d,iuid,er
manageabledepth,so items don't spacebeneatl tle top of the work- (C), and a d,xtwer d,iuider (D) to
get lost at the back. bench.Ifs dividedup into compar! sizetom 3/arr plywood,as shownin
Of course,there's no reasonyou mentsfor the drawersandcupboard Fig. 1 on the next page.
have have to build both storage storageareas.The centersectionis The front edges of all these ply-
units.Ifyou're planningto placethe constructedfirst, andthen the sides wood panels need to be covered
bench up against a wall, you may are addedlater. with strips of %rLthick hardwood
Bank of dtawers. KeepJour hand.took Shelving Unit. U se every itlch of the bench Pegboard.End. Storage. In just a few
cleanmd arganized in thesegenerousll.sixed.b1 adding this shallowsheluingunit at the minutes, 1ou can have this optional pegboard
drawers.PIus,theJopenon full'extensrcn back. It's a perfectplacefor jigs, hardware, storagepdl1eImoratted,at eachend.of tfu
soyoucanfill themfrun frontm back. and other supplies.(Plarc start on page 19.)
slides bench.Seepage19 to finl outhow.
t4 Woodsmith No.133
I
p d g ; , , 9( E t . a s s h o w n i n F i g . L l
chose to do this before asscmbll
becauseI found it a lot easier rt,
ahach and rim the edging flu5h VERTICAL
with each panel lying flat. DIVIDER 2
NOTE:A -z
Once the edging is in pJaee.you
cansetup your dadobladelo malch
palt @xcept
]h' pfwood
1 NOTE:Cut a
t}e lhickres: of the plyvood you rr
u.ing (Fig. la). All the dadoesarr 2l ' wide; then
187/16"
the same depth and width, so when edging strips
rhe bladei\ set up. il's just a maner
of adjustingyour rip fence to posi
ljon the dadoesaccordingto Fig. 1.
With all the dadoes cut, now is a
good time to assemble the center
section.I used both glue and screws
to do this, drilling all the pilot and
shank holes beforehand(Fig. 1b). It
makes sense here to work from the
inside out, starting by assembling
the horizontal divider between the
two vertical dividers. Then you can
add the short drawer divider and
the top and bottom panels.
slDls.All you have to do now to
complete the case of the cabinet is
to add a couple of sides (Fig. 2).
Like the other panels you cut earlier,
the sides (F) are also cut from %rl
pl1.wood.But these panels are cut S H E L FP I N
l/arrwider than the other pllwood TEMPLATE
I
panels. That's because they'll be
rabbeted along the back edges later
to hold a ply-woodback.
After cutting the sides to size,
hardwood edging is added to the 12"
front edges. Then a rabbet is cut
along the ends of each side to hold l
the top and bottom (A) of the cabi-
net (Fig. 2a). Before assembling the 1946"
sidesto the rest ofthe cabinet,a /arl
wide rabbet is cut along the back t
edge of each side pieceto hold a %r' 7-
pll.wood back that will be added %'
later (Fig. 2b). Then the sides can
be glued and screwedin place.
EDGING
SHtLvIS. With the case of the liont
cabinet completed,the next step is
to add the slrcLues(G). These are
nothing more than a couple of
pieces of %" plnvood with hard-
wood edging attached to the ftont.
The shelves are supported by
brass shelf pins. To ensure that the
holes are spaced evenly and line up * A hcLtclbodrcltem-
accurately,I used a sinple drilling pl"o.te
alktwt 1ou to
template that is shown in the draw- accuratelydrill holes
ing in the mar-ginat right. fo.theshelfpins
No. 133 Woodsmith 15
SMALL
DRAWER
t '
dratrersi Plentl \,Yithheatry-dut1,
full.
ertcnsionrlrau,erslides1ou canmakegoctl
rrseof erer,r-inchof cachdrawer.
TIATERIAIS SUPPI.IES
FnorrStonlorClgrrrr . (48)#8 x 1Zz"FhWoodscrews
A Top/Bottom(2) 3/<ply - 21 x 647/s . ( 1 6 )Z r ' B r a sSs h e lP
f ins
B VerticaD viders (2) 3 h p ) y-.2 1 x 1 8 h e . (5 pr.)20' Full-Extension DrawerSlides
Wscrews
C H o r i zD v i d e r( 1 ) 3/a p|y.- 21 x 341h . (26)#6 x 1" FhWoodscrews
3h . (26)#6 Finish Washers
D D r a w eD r i v i d e( r1 ) fly. - 21 x 41/<
E Edglng ( 1 ) 3 / a x %- 4 8 l i n . f t . . (0) 4%' DoorPullsWscrews
F Sides (2) 3h -
ply. 211/'tx 197/ta . \2 pr.)2" x 11/2" BuItHinges Wscrews
G Shelves (2) 3/<ply. - 20 x 145/ta . (2)Maqnetlc Catches M5trikesandScrews
H Sm.DrawerFr./Bks. (4) 1 / 2 x 3 1 / z1_5 5 k . ( 7 6 )# 1 6x 1" W i r eB r a d s
I l\,4ed. DrawerFrlBk (2) t/2x3t/2-33
J Lg.DrawerFrlBks(4) 1 /2x43/ax33
K Sm./Med.DrawerSides(6) 1/zx 31/z- 193/q CUTTING DIAGRAM
L Lg.DrawerSides(4) 1/2x43/e-193/c
%" x 51/r"- 96" Hard Maple (3.7Bd. Ft.)
M 5m.DrawerBtms.(2) 1/a ply.- 197ha x151ha
N Lg DrawerBtms. (3) % ply - 197/ax327/ra
O Sm.DrawerFalse (2)
Fronts 3/qx35k- 161/z 3h"x 9'/a"- 96" Hard Maple (6.2ad Ft)
P IVed.DrawerFalse Front(1) 3/tx3s/e - 337/a
Q Lg DrawerFalse (2)
Fronts 3/qx 43/q- 337/s
R DoorRals (4) 3,/<x 21/z_ 1051e 1/2" -
5 DoorSties (4) 3 / q x 2 1 / z - 1 7 1 3 1 a x 7le' 96" Hard
T DoorPanels (2)
U BackEnd Panels(2)
l/t ply - 101/a x 133/t
1/tply.- 155/ax 197/te " x9%" - 96" Hard
K
K
K
K K 2
V BackCenterPanel(1)
Srrrvne Ulll
1/tply.- 343/ax197/ta
L
,%
W TopiBottom(2) 3/t ply.- 71/2x 647/a
X Sides(2) 3/<ply.-73/ax 197/ra
Y D i v i d e( r1 ) 3/t ply - 71/zx 187/ta
Z BackPanes (2) l/ap)y.- 321hex 197/ra
ALSO NEEDED:Two theels ol lz maple plwood
AAShelves (2) 3/'+ply.- 7% x 31l1/ra and two sheets of t/4" maple plwood
Woodsmith
SuopNoms
fllounting o Vise
Aclclinga visc to you have a snrooth, Insfallationof thc vise Siarf by adclinga spacer
the worl<benchou "paddecl"
face the lergth bcgins beforc' l.ou attach block under thc bench
page 6 isn't difficult. In of the bench for clal.rping. the i'onl apron. As you top.Tl.rispiccc f,lis the gap
fact, it's just a three-step The large thce block has can scc in Fig I, a pocket llelwecn the s?,pllo11
process.Irirst, a pochet is dog holes that align with is laid out and r-outedin bltr;l; (l,I) and fhc vise
cut in the front apron to thc holes in thc bcnch so thc back lace 0Ithe apron. irounting plate (l'ig. 3). I
accepttlle rear jaw oI tlle you cal sccurewiclework- Positionthis pocket so tht' routerl a.ifrr rouncloveron
vise. Thcl the vise is pieces. lt also sprcads vise will be centercd olre e(lgc so it woulcl fit
attachedto the bench.Ancl clanpilg pressurc. betwcer the dog holcs in snugly behincl lhc jaw
firally. awood faceblock is To inslall tht'vise, you'11 the beuch. Its size is r,/r,;" After the spaccr is cut to
acldedto the irontjaw. neeclto take it aparl first. wider ancl ta11erthan thc size.i1'sglued in place.
But rvhy even go to this This isn't as scary as it rear jaw of the visc. Ncxt, a selies of holes
tr-oub1e? \Vhy not just bolt sounds. B5r renoving a Once lhc pockel is neecls1o bc drilled. If you
the vise to the ftonl apron cotter kel', I was ablc to clone,thc apron can be iook at l.'i.q.2,you'll scc
ancl screw a wootl pad to seDaratethe front jaw of altachcd to the bench top 1wocounterboredhoics in
eachjaw?There are a cou ny vise (a1ongwith the anclyou ca| movc on to thc top of lhc bencl.i.
ple ofreasons.By burying 'I)rese
guide rods and threaded the seconclstcp - attach- acccpt hex head
the rear jaw in tl.teapron, shaft) [-onl the rearjaw irg the vise. bolls that pass througlr
.'.
NOTE:Remove lront
jaw (with rods) before
aftacntng rear law
.-,".l*-- ( 1 1 / a t' h i c k )
THIRD:Lay out
mountingholesin bench
tap and tront apron
z\) \{rooclsrnit lr N o .1 3 3
the vise. And hvo holes Alter gluirg the piect's jaws of the vise, f oull
through the tionl apron togelhcf,lay out an(l drill a rolicc a srtrail gap
-tl allorv access lo screws cotqrleol ciogholcs ir the bctweerl thc aprol lincl
that attach tlle rcar jaw t0 jaw so that thcy aligrl wilh the bot10[l of the facc
the bench(Fis.3b). the holes in the bench. block, like l ou sec in the
To 1a1'ou1ths ht1.. ;I Then to mounl thc face photo at right. DoLr't
the berch top, yoll wiutt to block, just usc the vise 10 lvorry. The vise jaws cant
worii out liom the center- clan4r 1he block against (tilt) in slightl]' at thc top.
line oi 1hc pocliel in the the apron lvith the top Thc reason is that as you
aprol atrl the centc,rline edges antl cnds llush cianp a worlipiece, it
of the mourting p1ate. (Figs. zla and ,1b). -l'wo lorccs the top oI thc.vise S T|r rrr1., cd.qcs pf tfit 141'srilr in sliqfirh
The ncxt thing Lo do is scrcwssecule it fo theja\a'. apart.This lilt heeps thc r,.,(.r.,r''.'. r'il.,.
to drill the accessholes lvhen you clo-se thc jarvsparal1cl.Ei rhrrrrcirilto Jr-rtrth.rl()f cdg.s4)rrrt
through the fr ol]t apron
(Fig. 2). Thcsr: holes need
to be big enough to allow
lhe screws to pass
fhrough. Her-cagain, lay
out the holes by worhing
lron the centerlinesof tl.ie
rearjaw and the pockel.
The third step is rrak
ing and nrorrnting the
wood.[rr:r,Dlocl''( l]. This
consists 0f two slabs of
1Ll,rr-thick maple gluecl
together (Fig. ,1). Before
rloin.qthat, a racliusneecis
?t to be cut on each end of
one block as you can see
in irig. 4a. I did this on thc
band saw,thelr sandcdtl]e
curvessmooth.
No.133 Wooclsmith