The holes we want to mark are the holes through which the threaded rod connecting the two legs will run. This threaded rod will run through the 3/8" groove along the bottom of the short stretchers,. The hole for the upper stretcher has to be positioned so that when the rod is running through this groove, the top of the short stretcher is even with the top of the legs. The most precise way I've found for marking the position of this hole is to use a dowel center. Fit the dowel center into the bottom groove, line up the stretcher, and bang on the end with a rubber mallet. The dowel center will leave a mark indicating the center of the hole.
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The jaw for the front vise needed to be 10" long - to span the distance from the leg to the end of the top, 1-1/2" thick - to allow for benchdog holes to be drilled in it, and 5" tall. The end vise was mounted 3/4" lower than the front vise, and the screw and guide rods were thicker, so its jaws needed to be at least 6-1/2" tall. Again, they needed to be 1-1/2" thick to allow for benchdog holes, and 23" long to span the width of the bench.
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Assemble the vises, for the final time. You'll not be taking them off again, so tighten everything down, and attach the endplate to the ends of the screw and guide rods. Then mark and drill benchdog holes in the outer jaws inline with the benchdog holes in the top. Generally, through-holes are preferred for benchdogs, so that they don't collect sawdust and gunk. With these vises, that isn't possible, there are screws and guide rods in the way. I drilled them just deep enough to hold a Veritas Bench Pony (their reduced-height benchdog), without it sinking to where I can't get a grip to remove it. Rockler sells some very inexpensive plastic benchdogs that can't be adjusted for height, and aren't as strong as metal or wooden dogs, that I intend to keep in the holes full-time, to keep sawdust from collecting in them.
Even with all of those faults my only regret is that it is too ugly. I didn’t take the time to make it more visually attractive as I was eager to get right into making beautiful furniture instead. Twenty years later the furniture is still beautiful (or not) but I go out to the shop and look at a drab uninspiring workplace. Yeah, nothing wrong with having a visually inspiring workplace in my opinion. All that shop furniture I slapped together years ago with no concern about aesthetics is getting replaced bit by bit. Why should my shop be downright ugly when it is one of my favorite places in the world to spend my time? I see no reason for that, but that’s just my opinion and as we all know everyone has their own one of those… Sadly, no one pays nor reveres me when I offer mine. bummer, I could be a rich egotistical maniac if they did coz I sure offer it enough. 😉
First, we need to drill out the holes for the screws that will hold them together. While the two layers of MDF are glued, the countertop and the MDF will only be screwed. The oak countertop, like any natural wood product, will expand and contract with humidity changes. If it were glued to the MDF, the difference in expansion of the two layers would cause the countertop to buckle and curl.
If you remember, when drilling the MDF I finished the holes from the other side using a Forstner bit. It made for a clean hole, but the positioning wasn't as precise as I really wanted. So for this, I decided to clamp a length of scrap MDF to the back side, and to drill straight through. My Forstner bits were too short, so I bought an extender. And then I found that the spade bits I was using gave a cleaner exit hole. Whooda thunk?
Drill four 5/8-in.-dia. 1/2-in.-deep holes on the large disc?inside the traced circle?then use 5/8-in. dowel centers to transfer the hole locations to the underside of the small disc. Drill four 1/2-in.-deep holes on the underside of the small disc and a 1/2-in.-deep hole in the center of the top for the dowel handle. Glue in the dowels to join the discs, and glue in the handle. We drilled a wood ball for a handle knob, but a screw-on ceramic knob also provides a comfortable, attractive grip.
After you have all the holes clean, set things up for your glue-up. You want everything on-hand before you start - drill, driver bit, glue, roller or whatever you're going to spread the glue with, and four clamps for the corners. You'll need a flat surface to do the glue-up on - I used my hollow core door on top my bench base - and another somewhat-flat surface to put the other panel on. My folding table was still holding my oak countertop, which makes a great flat surface, but I want to make sure I didn't drip glue on it so I covered it with some painters plastic that was left over from the last bedroom we painted.
A workbench needs to be heavy enough that it doesn't move under you while you're working, and stiff enough that it doesn't rack itself to pieces under the forces that will be placed upon it. It doesn't take many hours of planing a board or hammering a chisel for a worktable made of nailed 2x4s to come apart. Traditional bench designs use mortise-and-tenon joinery, which is strong and rigid, but not really suited for a novice woodworker who doesn't already have a bench.
In the "Getting Started with Woodworking" video, the holes through the 4x4's were drilled from the back. That is, they start on the side opposite the precisely-positioned mark, and drill through to hit it. If they can do this, more power to them, but I can't drill through 3-1/2" of wood to emerge at a precise mark without a drill press - and not always then.
You may even want to put yourself in the picture. If your workshop space already exists, find a large piece of cardboard, wallboard, or plywood that’s about the size of the workbench top you envision. Find a couple of stools or chairs, perhaps a few books, and turn them into stanchions to support the “benchtop.” Is it too big for the space? Is it large enough for the tasks you envision will be performed upon it?
I used the factory edge of the half-panel of hardboard as a guide for cutting the ply. I wanted to cut a 5-1/2" strip, and my saw cuts 4-1/2" from the edge of the shoe, so I wanted the edge of the hardboard 10" from the edge of the ply. So I set my combination square to 10", and used it to mechanically set the distance. Hint - if you need two things to be precisely the same length, try to avoid measuring them separately. Use some mechanical mechanism for setting the distance.
Dark colours appear heavier and create a feeling of stability, whereas light colours hold less visual weight and can appear unstable. When joining woods of dark and light colour, the visual effect of heavy and light suggest that darker woods work better when used on the bottom. A suggestion from my mentor to help getting proportions right was to spray paint mock-ups with a colour similar to the woods to be used later.
Cut off a 21-in.-long board for the shelves, rip it in the middle to make two shelves, and cut 45-degree bevels on the two long front edges with a router or table saw. Bevel the ends of the other board, cut dadoes, which are grooves cut into the wood with a router or a table saw with a dado blade, cross- wise (cut a dado on scrap and test-fit the shelves first!) and cut it into four narrower boards, two at 1-3/8 in. wide and two at 4 in.
Of course, few benches can be ideal, and this one does have some drawbacks. That being said, most of the disadvantages of this bench are minor annoyances rather than deal breakers. For instance, this bench does not include any kind of storage whatsoever. Though, it does have the option of adding numerous additional features like a storage area. Still, for the bench, you would expect a drawer at the very least, maybe a shelf below the main table area.