@cahudson42 I bored the holes in my sandwich top with a 3/4" power auger bit with the drill in a portable drill guide that kept it vertical and in a way a bit like a plunge router. The guide screw of the auger was dead easy to centre over the laid out grid points. The holes are dead straight and clean sided. The auger bit was new which probably helped. As stated I have three rows from an end vise running the length of the front as well as from the front vise and holes in the front apron to support long pieces as well.
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To develop the material, we editors asked ourselves—and dozens of top woodworkers—what’s likely to go wrong at each stage of a project. We really dug deep to make sure we didn’t just repeat the types of advice you see in the average magazine. We ended up with a list of more than 500 problems covering everything from design and layout, to stock preparation, joinery, finishing and more. Then, we reached out to top woodworkers around the country for their solutions. The result was a 320-page book filled with some of the best advice you could ever find from more than 75 master craftsmen, including Marc Adams, Mike Dunbar, Graham Blackburn, Toshio Odate, David Marks, Frank Klausz and Lonnie Bird.
Originally published at the turn of the twentieth century by an anonymous “Practical Joiner,” Woodwork Joints: How to Make and Where to Use Them remains an incredibly useful and practical guide for deciding which joints to use and how to make them the right way for carpentry, joinery, and cabinet-making. Here is the carefully illustrated source on joinery that not simply a collectible classic, but also a requisite and invaluable tool that withstands the test of time, containing more useful information than any other woodworking guide. Inside are illustrated instructions for making all kinds of joints, from simple to complex, suitable for novices and experts. The comprehensive list includes joints such as glued; halved; bridle; tongued and grooved; mortise and tenon; dowelling; scarf; hinged; shutting; dovetail and many more. Instructions specify which tools are required (i.e., planes, gauges, saws, chisels, the try square for testing purposes, etc.) and how to use them on each joint. Extensive chapters on each type of joint contain precise illustrations that make identifying joints for different purposes easy. Not a word is wasted in this short but entirely comprehensive guide, making Woodwork Joints the perfect aid for any joinery project.
Drill a pair of 3/8" holes in each end of the short stretchers, just over half of the depth of the dowels, using a brad-pointed bit. These stretchers already have a groove running their length, centered on the bottom edge. Precise placement isn't necessary, but keeping track of which part is which is. We need a hole in each end of each stretcher. Take care to keep these holes square, you don't want them running at angles.
With the shelf secure, get a couple of friends to come help, and stand the bench on its feet. I said earlier moving the top by yourself is dangerous. Trying to lift the entire bench is foolhardy. Of course, I already said I'm stubborn, so I did it myself by rigging a simple block-and-tackle using lightweight pulleys I got at the hardware store. (Not the lightest-weight pulleys, those are meant for flag poles and have a design load of something like 40 pounds. These had a design load of 420 pounds.)
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I was using 2-1/2" coarse Kreg pocket hole screws. Kreg screws are supposed to be self-tapping, but the coarse-thread screws are intended to be self-tapping in softwood, and the fine-thread screws they intend for use in hardwoods aren't available in 2-1/2" lengths. I decided to drill pilot holes in the oak. Just to make sure, I did a test hole in the scrap piece I'd cut off.
Begin by cutting off a 10-in. length of the board and setting it aside. Rip the remaining 38-in. board to 6 in. wide and cut five evenly spaced saw kerfs 5/8 in. deep along one face. Crosscut the slotted board into four 9-in. pieces and glue them into a block, being careful not to slop glue into the saw kerfs (you can clean them out with a knife before the glue dries). Saw a 15-degree angle on one end and screw the plywood piece under the angled end of the block.
Happy bench building folks. I hope you make it your own and not worry too much about what someone else thinks it should be. Use the rules as a guideline, they have validity, but make it your own in the end. If the rules fit you that’s great, if they don’t quite fit you then make it to fit yourself. It’s you using it, not some guy making a nice living off of telling you how he thinks you should do it. One size does not fit all. Never has, never will.
Woodworking Workbenches are available in a variety of styles. Open Style Wood Workbenches feature a large work surface and a lower shelf. 2-1/4" thick maple top with maple plywood lower shelf. Open Style Wood Workbenches are available as a 2-station unit (28"W) or a 4-station unit (54"W). Open Style Auxiliary Workbenches are used for placement against walls. Shelf features a rear curb to keep contents in place. Solid maple top features angle iron front edge. Plywood shelf is open for maximum functionality. Solid maple legs. Environmentally-friendly UV finish. Units measure 24"D and are available in several lengths and heights. Mitre Box Benches ensure wood pieces are kept flat while mitres are cut. Bench is made using solid maple unit with environmentally-friendly UV finish. Holds a mitre saw up to 26"W and provides a 24" square work surface on both sides. Mitre Box Benches measure 33-3/4"H. Sheet Metal Workbenches are made with a 2-1/4" thick maple top and is protected on two long edges with 2" x 2" angle iron. Solid maple legs and stringers. Plywood shelves are designed to provide open storage of 30" metal sheets. Measures 40"D x 32"H and available in widths of 60" or 96".
When the holes were complete, I flipped the legs and drilled the countersinks with a 1" Forstner bit. Trying to drill a countersink when the center was already drilled would be impossible with a spade bit or an auger, but Forstner bits are guided by their edges, not their center, so they can handle this job. On thing about Forstners, though -- they have a tendency to skitter around a bit when starting, before they bite. An easy fix for this is to drill a hole through a piece of ply, and to clamp that to your work, creating a jig that will prevent the bit from drilling in the wrong spot.
Drilling a precisely positioned, deep, wide hole isn't easy, without a drill press. So I bought a WolfCraft drill guide. After experimenting with it, and drilling some test holes, I build a jig around it. I screwed it to a scrap of MDF, and then drilled a carefully-centered 3/4" hole. The MDF can be clamped more easily than the base itself, and the 3/4" hole will keep a 3/4" Forstner bit drilling precisely where it is supposed to.
One aspect of the Windsor Design that is hit or miss is the vice. Notice we have to use the singular when describing it because this is the first workbench that we have reviewed which features only one vice. To make matters more frustrating, the vice cannot be repositioned along the bench. That said, the vice does at least have the largest capacity out of any we reviewed. At 7” capacity, the Windsor Design vice can secure any size workpiece you may have.